GE Series 90-30 PLC Hardware And Installation Manual

Download

Page 1

GE Fanuc Automation

Programmable Control Products

Series 90™-30 PLC Installation and Hardware Manual

GFK-0356Q August 2002

Page 2

Warnings, Cautions, and Notes

as Used in this Publication

Warning notices are used in this publication to emphasize that hazardous voltages, currents, temperatures, or other conditions that could cause personal injury exist in this equipment or may be associated with its use.

In situations where inattention could cause either personal injury or damage to equipment, a Warning notice is used.

Caution notices are used where equipment might be damaged if care is not taken.

Notes merely call attention to information that is especially significant to understanding and operating the equipment.

GFL-002

Warning

Caution

Note

This document is based on information available at the time of its publication. While efforts have been made to be accurate, the information contained herein does not purport to cover all details or variations in hardware or software, nor to provide for every possible contingency in connection with installation, operation, or maintenance. Features may be described herein which are not present in all hardware and software systems. GE Fanuc Automation assumes no obligation of notice to holders of this document with respect to changes subsequently made.

GE Fanuc Automation makes no representation or warranty, expressed, implied, or statutory with respect to, and assumes no responsibility for the accuracy, completeness, sufficiency, or usefulness of the information contained herein. No warranties of merchantability or fitness for purpose shall apply.

The following are trademarks of GE Fanuc Automation North America, Inc.

Alarm Master Field Control Modelmaster Series 90 CIMPLICITY GEnet Motion Mate Series One CIMPLICITY Control Genius PowerMotion Series Six CIMPLICITY PowerTRAC Genius PowerTRAC ProLoop Series Three CIMPLICITY 90–ADS Helpmat e PROMACRO VuMaster CIMSTAR Logicmaster Series Five Workmaster

Page 3

RFI Standards

The Series 90-30 PLC and its associated modules have been tested and found to meet or exceed the requirements of FCC Rule, Part 15, Subpart J. The Federal Communications Commission (FCC) requires the following note to be published according to FCC guidelines.

NOTE

This equipment generates, uses, and can radiate radio frequency energy and if not installed in accordance with this instruction manual, may cause harmful interference to radio communications. It has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of the FCC Rules, which are designed to provide reasonable protection against harmful interference when operated in a commercial environment. Operation of this equipment in a residential area is likely to cause harmful interference, in which case the user will be required to correct the interference at his own expense.

The following note is required to be published by the Canadian Department of Communications.

NOTE

This digital apparatus does not exceed the Class A limits for radio noise emissions from digital apparatus set out in the radio interference regulations of the Canadian Department of Communications.

The following statements are required to appear in the

Series 90_-30 I/O Specifications Manual

1. EQUIPMENT LABELED WITH REFERENCE TO CLASS I, GROUPS A, B, C, and D, DIV. 2 HAZARDOUS LOCATIONS IS SUITABLE FOR USE IN CLASS I, DIVISION 2, GROUPS A, B, C, D OR NON-HAZARDOUS LOCATIONS ONLY.

2. WARNING - EXPLOSION HAZARD - SUBSTITUTION OF COMPONENTS MAY IMPAIR SUITABILITY FOR CLASS I, DIVISION 2:

3. WARNING - EXPLOSION HAZARD - DO NOT DISCONNECT EQUIPMENT UNLESS POWER HAS BEEN SWITCHED OFF OR THE AREA IS KNOWN TO BE NON-HAZARDOUS.

4. ALL UNUSED SLOTS IN ALL BASEPLATES MUST BE POPULATED WITH FILLER MODULES, IC693ACC310, OR EQUIVALENT.

for Class I Div 2 Hazardous Locations.

Series 90_-30 Installation Manual

and the

GFK-0356Q iii

Page 4

Page 5

Preface

This manual describes the GE Fanuc Series 90-30 Programmable Logic Controller (PLC). It contains a description of hardware components and provides basic hardware installation procedures. The Series 90-30 PLC is a member of the Series 90_ family of Programmable Logic Controllers from GE Fanuc.

For a list of product standards, refer to data sheet GFK-0867B or later,

Standards, General Specifications

Installation instructions in this manual are provided for installations that do not require special procedures for noisy or hazardous environments. For installations that must conform to more stringent requirements (such as CE Mark), see GFK-1179,

Conformance to Standards

What’s New in This Manual

■ Added the model 374 CPU, which supports connection to an Ethernet network through two built-in 10BaseT/100BaseTx auto-negotiating full-duplex Ethernet ports. Models 364 (release

9.10 and later) and 374 are the only Series 90-30 CPUs that support Ethernet Global Data. Note that the CPU374 is supported only by the Windows®-based programmers.

■ Other corrections and clarifications as necessary.

Related Publications

For more information on Series 90-30 products, refer to these publications. (For a publication to product catalog number cross-reference refer to Appendix G):

GE Fanuc Approvals,

which lists all of the standards for GE Fanuc products.

Installation Requirements for

GFK-0255 - Series 90 PCM and Support Software User’s Manual

GFK-0256 - MegaBasic Programming Reference Manual

GFK-0293 - Series 90 -30 High Speed Counter User’s Manual

GFK-0401 - Workmaster® II PLC Programming Unit Guide to Operation

GFK-0402 - Series 90 -30 and 90-20 PLC Hand-Held Programmer User’s Manual

GFK-0412 - Genius® Communications Module User’s Manual

GFK-0466 - Logicmaster 90 Series 90 -30/20/Micro Programming Software User’s Manual

GFK-0467 - Series 90 -30/20/Micro Programmable Controllers Reference Manual

GFK-0487 - Series 90 PCM Development Software (PCOP) User’s Manual

GFK-0499 - CIMPLICITY® 90-ADS Alphanumeric Display System User’s Manual

GFK-0356Q v

Page 6

Preface

GFK-0582 - Series 90 PLC Serial Communications User’s Manual

GFK-0631 - Series 90 -30 I/O LINK Interface User’s Manual

GFK-0641 - CIMPLICITY® 90-ADS Alphanumeric Display System Reference Manual



GFK-0664 - Series 90

GFK-0685 - Series 90 Programmable Controllers Flow Computer User’s Manual

GFK-0695 - Series 90-30 Enhanced Genius) Communications Module User’s Manual

GFK-0726 - Series 90-30 PLC State Logic Processor User’s Guide

GFK-0732 - Series 90-30 PLC ECLiPS User’s Manual

GFK-0747 - Series 90-30 PLC OnTOP User’s Guide

GFK-0750 - OnTop for Series 90-30 (State Logic) Program User’s Manual

GFK-0781 - Motion Mate APM300 for Series 90-30 PLC Follower Mode User’s Manual

GFK-0823 - Series 90 -30 I/O LINK Master Module User’s Manual

-30 PLC Axis Positioning Module Programmer’s Manual

GFK-0828 - Series 90 -30 Diagnostic System User’s Manual

GFK-0840 - Motion Mate APM300 for Series 90 -30 PLC Standard Mode User’s Manual

GFK-0867 - GE Fanuc Product Agency Approvals, Standards, General Specifications

GFK-0898 - Series 90 -30 PLC I/O Module Specifications

GFK-1028 - Series 90 -30 I/O Processor Module User’s Manual

GFK-1034 - Series 90 -30 Genius® Bus Controller User’s Manual

GFK-1037 - Series 90 -30 FIP Remote I/O Scanner User’s Manual

GFK-1056 - Series 90 -30 State Logic Control System User’s Manual

GFK-1186 - TCP/IP Ethernet Communications for the Series 90_-30 PLC Station Manager Manual

GFK-1179 - Series 90 PLC Installation Requirements for Conformance to Standards

GFK-1464 - Motion Mate DSM302 for Series 90-30 PLCs User’s Manual

GFK-1466 - Temperature Control Module for the Series 90-30 PLC User’s Manual

GFK-1541 - TCP/IP Ethernet Communications for the Series 90 PLC User’s Manual

vi Series 90™-30 PLC Installation and Hardware Manual – August 2002 GFK-0356Q

Page 7

Contents

Chapter 1

Chapter 2

Overview of the Series 90-30 PLC .....................................................................1-1

The Basic Parts of a Series 90-30 PLC....................................................................... 1-1

Assembling a Basic Series 90-30 PLC System .......................................................... 1-2

What else would be needed to make this basic system functional? ...........................1-6

What if the application requires more than five modules?......................................... 1-6

What if the application requires more than ten modules? .......................................... 1-7

What is the Difference Between Expansion and Remote baseplates?........................ 1-8

What if I need to cover more than 700 feet (213 meters)? ......................................... 1-9

Installation ...........................................................................................................2-1

Receiving your Products - Visual Inspection ............................................................. 2-1

Pre-installation Check ................................................................................................ 2-1

Warranty Claims......................................................................................................... 2-1

Working with Series 90-30 Modules.......................................................................... 2-2

Module Features........................................................................................................ 2-2

Installing a Module.................................................................................................... 2-3

Removing a Module.................................................................................................. 2-4

Installing a Module’s Terminal Board ...................................................................... 2-5

Removing a Module’s Terminal Board..................................................................... 2-6

I/O Module Terminal Board Posts ............................................................................ 2-7

Installing and Removing Terminal Boards with Holding Screws ............................. 2-7

Baseplate Mounting.................................................................................................... 2-8

Mounting a Baseplate to a Panel ................................................................................ 2-8

Mounting a Baseplate to a 19" Rack .......................................................................... 2-8

Grounding Procedures ....................................................................................................2-11

System Grounding Procedures ................................................................................. 2-11

Ground Conductors ................................................................................................. 2-11

Series 90-30 PLC Equipment Grounding................................................................. 2-12

Baseplate Safety Grounding.................................................................................... 2-12

Grounding 19" Rack-Mounted Baseplates.............................................................. 2-13

Programmer Grounding........................................................................................... 2-13

Module Shield Grounding........................................................................................ 2-14

Shield Grounding Information for CPUs with External Port Connections.............. 2-14

CPU351 and 352 Shield Grounding........................................................................ 2-14

CPU363, CPU364, and CPU374 Shield Grounding................................................ 2-16

Additional Modules with Shield Grounding Requirements .................................... 2-16

General Wiring Guidelines ............................................................................................. 2-17

Discrete I/O Module Connection Methods............................................................... 2-18

Connections to I/O Module Terminal Boards .......................................................... 2-18

Terminal Block Quick Connect Installation for 16-Point Discrete Modules ........... 2-19

Installation of 32-Point Discrete, 50-Pin Connector Modules .................................2-19

Using Weidmuller #912263 Terminal Block .......................................................... 2-19

Using a Generic Terminal Block or Strip................................................................ 2-20

Direct Method ......................................................................................................... 2-20

Installation of Discrete 32-Point, Dual 24-Pin Connector Modules......................... 2-20

Using a TBQC......................................................................................................... 2-20

GFK-0356Q vii

Page 8

Contents

With a Generic Terminal Block/Strip...................................................................... 2-20

Direct Method ......................................................................................................... 2-21

General Wiring Methods for Analog Modules......................................................... 2-21

Analog Input Module Wiring Methods.................................................................... 2-21

Using a Generic Terminal Block or Strip................................................................ 2-21

Direct Method ......................................................................................................... 2-21

TBQC not Recommended for Analog Modules...................................................... 2-22

Analog Output Module Wiring ................................................................................ 2-22

General .................................................................................................................... 2-22

Using a Generic Terminal Block or Strip................................................................ 2-22

Direct Method ......................................................................................................... 2-22

TBQC not Recommended for Analog Modules...................................................... 2-22

AC Power Source Connections....................................................................................... 2-23

AC Input Wiring to AC/DC Power Supplies ........................................................... 2-23

Power Supply Overvoltage Protection Devices........................................................ 2-24

Special Installation Instructions for Floating Neutral (IT) Systems ...............................2-25

Definition of Floating Neutral Systems.................................................................... 2-25

Use These Special Installation Instructions for Floating Neutral Systems............... 2-26

DC Power Source Connections....................................................................................... 2-27

DC Input Wiring to AC/DC and DC-Only Power Supplies..................................... 2-27

+24 VDC Output (All Supplies)............................................................................... 2-27

Basic Installation Procedure ...........................................................................................2-28

Chapter 3

Baseplates .............................................................................................................3-1

Baseplate Types ................................................................................................................ 3-1

Common Baseplate Features...................................................................................... 3-1

Two Baseplate Sizes................................................................................................... 3-2

Baseplate Terms................................................................................................................ 3-3

CPU Baseplates................................................................................................................. 3-4

Embedded CPU Baseplates (Figures 3-2 and 3-3) ..................................................... 3-4

Modular CPU Baseplates (Figures 3-4 and 3-5) ........................................................3-6

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

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

I/O Bus Expansion Cables........................................................................................ 3-10

Differences Between Remote and Expansion Racks................................................ 3-11

Mixing Expansion and Remote Baseplates in a System................................................. 3-11

Termination Requirement for Expansion or Remote System ......................................... 3-12

Powering Down Individual Expansion or Remote Baseplates .......................................3-12

Series 90-30 PLC Backplane .......................................................................................... 3-12

Rack Number DIP Switch on Expansion and Remote Baseplates.................................. 3-13

Expansion and Remote Baseplates Connection Example............................................... 3-15

Baseplate Mounting Dimensions.................................................................................... 3-16

Embedded CPU (311, 313, and 323) Baseplate Dimensions ................................... 3-16

Modular CPU, Expansion, and Remote Baseplate Dimensions............................... 3-18

viii Series 90™-30 PLC Installation and Hardware Manual – August 2002 GFK-0356Q

Page 9

Load Ratings, Temperature, and Mounting Position ...................................................... 3-19

Baseplate Adapter Brackets for 19" Rack Mounting...................................................... 3-20

Baseplate Comparison Table.................................................................................... 3-22

Contents

Chapter 4

Power Supplies..................................................................................................... 4-1

Power Supply Categories.................................................................................................. 4-1

Power Supply Feature Comparison...................................................................................4-1

AC/DC Input Power Supplies........................................................................................... 4-2

IC693PWR321 Standard Power Supply, 120/240 VAC or 125 VDC Input .............. 4-2

IC693PWR330 High Capacity Power Supply, 120/240 VAC/125 VDC Input ......... 4-4

Field Wiring Connections for the AC/DC Input Power Supplies...............................4-5

Isolated 24 VDC Supply Output Connections............................................................ 4-6

DC Input Only Power Supplies......................................................................................... 4-7

IC693PWR322 Standard Power Supply, 24/48 VDC Input....................................... 4-7

Calculating Input Power Requirements for IC693PWR322............................................. 4-8

IC693PWR328 Standard Power Supply, 48 VDC Input.......................................... 4-10

Calculating Input Power Requirements for IC693PWR328.....................................4-11

Input Power/Current Calculation for IC693PWR328 Power Supply....................... 4-12

IC693PWR331 High Capacity Power Supply, 24 VDC Input................................. 4-13

Current Derating for Higher Temperatures .............................................................. 4-14

Calculating Input Power Requirements for IC693PWR331.....................................4-15

Field Wiring Connections to the DC Input-Only Power Supplies ........................... 4-15

Common Series 90-30 Power Supply Features............................................................... 4-16

Status Indicator Lights on all Power Supplies.......................................................... 4-16

Input Overvoltage Protection Devices...................................................................... 4-16

Output Voltage Connections to Backplane (All Supplies)....................................... 4-17

Overcurrent Protection (all Supplies)....................................................................... 4-18

Timing Diagram ....................................................................................................... 4-18

CPU Serial Port Connector on Power Supply (All Supplies)................................... 4-19

CPU Serial Port Information.................................................................................... 4-19

Backup Battery for RAM Memory (All Supplies)................................................... 4-20

Chapter 5

GFK-0356Q Contents ix

CPUs .....................................................................................................................5-1

CPU Types for Series 90-30 PLCs ................................................................................... 5-1

Embedded CPUs......................................................................................................... 5-1

Modular CPUs............................................................................................................ 5-2

General CPU Features................................................................................................ 5-3

Microprocessor.......................................................................................................... 5-3

CPU Serial Port (Connector on Power Supply)......................................................... 5-3

Memory Volatility..................................................................................................... 5-4

RAM Memory........................................................................................................... 5-5

RAM Memory Backup/Backup Battery Information................................................ 5-5

Programmable Read-Only Memory (PROM) Types................................................. 5-5

Uses of PROM devices in the 90-30 CPUs............................................................... 5-5

Page 10

Contents

CPU Firmware........................................................................................................... 5-6

Determining CPU Revision Levels (Versions) ......................................................... 5-7

EPROM and EEPROM User Program Storage Options................................................... 5-8

Comparing EPROM and EEPROM Features............................................................. 5-8

Procedure for Creating an EPROM............................................................................ 5-9

Flash Memory............................................................................................................. 5-9

Series 90-30 CPU Capacities....................................................................................5-10

User Memory Addresses (References)..................................................................... 5-10

Difference Between a Memory Address and a Nickname........................................5-10

User Memory Reference Types................................................................................ 5-11

Application Program Compatibility ........................................................................ 5-12

CPU Time-of-Day (TOD) Clock Accuracy............................................................. 5-12

Breakfree SNP Protocol .......................................................................................... 5-13

350–374 CPUs.......................................................................................................... 5-13

Compatibility With Hand-Held Programmer (HHP) and Memory Card................. 5-13

350–374 CPU Advanced Features........................................................................... 5-14

Details of 350 – 374 CPU Advanced Features ........................................................ 5-14

Hardware Features of the 350–364 CPUs....................................................................... 5-18

CPU350 and CPU360 Hardware Features ...............................................................5-18

CPU Firmware Upgrade.......................................................................................... 5-18

CPU351, CPU352, and CPU363 Hardware Features............................................... 5-19

CPU Firmware Upgrade.......................................................................................... 5-19

Keyswitch................................................................................................................ 5-19

Shield Ground Connection Tab............................................................................... 5-20

Serial Ports .............................................................................................................. 5-20

Serial Port Front Panel Connectors ......................................................................... 5-20

Serial Port Status LEDs........................................................................................... 5-20

Protocols Supported ................................................................................................ 5-21

Pin Assignments for CPU351, CPU352, and CPU363 Serial Ports 1 & 2.............. 5-22

CPU364 Hardware Features..................................................................................... 5-23

LED Indicators ........................................................................................................ 5-23

Ethernet Restart Pushbutton.................................................................................... 5-23

Keyswitch................................................................................................................ 5-24

Front Panel Connectors ........................................................................................... 5-24

Shield Ground Connection Tab............................................................................... 5-24

Firmware Upgrade................................................................................................... 5-24

CPU374 Hardware Features..................................................................................... 5-25

LED Indicators ........................................................................................................ 5-25

Ethernet Restart Pushbutton.................................................................................... 5-25

Keyswitch................................................................................................................ 5-26

Front Panel Connectors ........................................................................................... 5-26

Shield Ground Connection Tab............................................................................... 5-26

Firmware Upgrade................................................................................................... 5-26

CPU Data Sheets............................................................................................................. 5-27

CPU311 Catalog Number IC693CPU311 ........................................ 5-28

CPU313 Catalog Number IC693CPU313 ........................................ 5-29

CPU323 Catalog Number IC693CPU323 ........................................ 5-30

CPU331 Catalog Number IC693CPU331 ........................................ 5-31

x Series 90™-30 PLC Installation and Hardware Manual – August 2002 GFK-0356Q

Page 11

CPU340 Catalog Number IC693CPU340 ........................................ 5-32

CPU341 Catalog Number IC693CPU341 ........................................ 5-33

CPU350 Catalog Number IC693CPU350 ........................................ 5-34

CPU351 Catalog Number IC693CPU351 ........................................ 5-35

CPU352 Catalog Number IC693CPU352 ........................................ 5-36

CPU360 Catalog Number IC693CPU360 ........................................ 5-37

CPU363 Catalog Number IC693CPU363 ........................................ 5-38

CPU364 Catalog Number IC693CPU364 ........................................ 5-39

CPU374 Catalog Number IC693CPU374 ........................................ 5-40

Contents

Chapter 6

Chapter 7

Memory Backup/Battery Backup ......................................................................6-1

Backup Battery for RAM Memory (All Supplies)............................................................ 6-1

Battery Replacement Instructions ..................................................................................... 6-2

Battery Replacement/Memory Protection Factors............................................................ 6-3

The Importance of Backing up Your Program.................................................................. 6-3

Factors Affecting Battery Life .......................................................................................... 6-4

Low Battery Warning Methods.........................................................................................6-4

Operating Without a Memory Backup Battery................................................................. 6-6

RAM Memory Battery Backup Connection Path ............................................................. 6-8

Super Capacitor Memory Backup..................................................................................... 6-8

Maintaining RAM Memory During Storage or Shipment of a CPU.......................... 6-9

Modular CPUs........................................................................................................... 6-9

Embedded CPUs ....................................................................................................... 6-9

Battery Accessory Kit (IC693ACC315).................................................................... 6-9

Battery Accessory Kit Installation........................................................................... 6-10

External Battery Module (IC693ACC302)..................................................................... 6-10

Batteries in Power Supplies on Expansion or Remote Racks ......................................... 6-11

Input/Output Modules ........................................................................................ 7-1

Basic I/O Module Types ................................................................................................... 7-1

Discrete I/O Modules........................................................................................................ 7-2

Discrete I/O Module Point Density ............................................................................ 7-2

Standard Density Discrete I/O Module Features........................................................ 7-2

Wiring Standard Density (16-Point or Less) Discrete Modules................................. 7-4

Discrete Relay Output Module Protection ................................................................. 7-4

High Density (32-Point) Discrete Module Features................................................... 7-4

Wiring Methods for 32-Point Discrete I/O Modules.................................................. 7-6

Modules with Single 50-Pin Connector .................................................................... 7-6

Modules with Dual 24-Pin Connectors ..................................................................... 7-7

Analog Module Features................................................................................................... 7-8

Wiring Methods for Analog Modules ........................................................................7-9

Analog Input Module Wiring Methods..................................................................... 7-9

Analog Output Module Wiring ............................................................................... 7-10

I/O Module Power Supply Current Draw ....................................................................... 7-10

GFK-0356Q Contents xi

Page 12

Contents

I/O Module Wire Routing............................................................................................... 7-11

Grouping Modules to Keep Wires Segregated ...............................................................7-11

IC693DVM300 Digital Valve Driver Module................................................................ 7-12

Indicator LEDs ......................................................................................................... 7-12

DVM Specifications................................................................................................. 7-13

Fuses......................................................................................................................... 7-13

Chapter 8

Option Modules ...................................................................................................8-1

Third-Party Option Modules and the Accompany Program ............................................. 8-1

Option Modules Discussed in this Chapter....................................................................... 8-1

IC693CMM301 Genius Communications Module (GCM) .............................................. 8-2

Status LEDs................................................................................................................ 8-3

GCM Documentation ................................................................................................. 8-3

IC693CMM302 Enhanced Genius Communications Module (GCM+)........................... 8-4

Status LEDs................................................................................................................ 8-5

GCM+ Documentation............................................................................................... 8-5

IC693BEM331 Genius Bus Controller (GBC)................................................................. 8-6

Number of Genius Bus Controllers............................................................................ 8-7

Status LEDs................................................................................................................ 8-7

Compatibility.............................................................................................................. 8-7

Series 90-30 PLC ...................................................................................................... 8-7

Series Six PLC .......................................................................................................... 8-7

Genius Hand-Held Monitor....................................................................................... 8-8

Hand-Held Programmer ............................................................................................ 8-8

Genius I/O Blocks ..................................................................................................... 8-8

Genius Bus ................................................................................................................ 8-8

Diagnostics ................................................................................................................. 8-8

Datagrams................................................................................................................... 8-9

Global Data................................................................................................................. 8-9

Sending Global Data ................................................................................................. 8-9

Receiving Global Data .............................................................................................. 8-9

Genius Bus Controller Documentation ..................................................................... 8-9

IC693BEM340 FIP Bus Controller (FBC) Module........................................................ 8-10

Status LEDs.............................................................................................................. 8-11

Serial Port................................................................................................................. 8-11

FIP Bus Connectors.................................................................................................. 8-11

IC693BEM330 FIP Remote I/O Scanner Module.......................................................... 8-12

Features of the Remote I/O Scanner......................................................................... 8-12

FIP Bus Interface...................................................................................................... 8-13

Module Description.................................................................................................. 8-13

Connectors................................................................................................................ 8-14

LEDs......................................................................................................................... 8-14

FIP Remote I/O Scanner Documentation:................................................................ 8-14

IC693APU301/302 Motion Mate Axis Positioning Module (APM) .............................. 8-15

xii Series 90™-30 PLC Installation and Hardware Manual – August 2002 GFK-0356Q

Page 13

Contents

APM Cables ............................................................................................................. 8-16

Motion Mate APM Module Documentation ............................................................8-16

IC693DSM302 Motion Mate Digital Servo Module (DSM302).................................... 8-17

Features. ...................................................................................................................8-18

IC693DSM302 Documentation................................................................................ 8-18

IC693DSM314 Motion Mate Digital Servo Module (DSM314).................................... 8-20

Features ................................................................................................................... 8-21

IC693DSM314 Documentation............................................................................... 8-22

IC693APU300 High Speed Counter (HSC) Module ...................................................... 8-23

IC693BEM320 I/O LINK Interface (Slave) Module...................................................... 8-24

IC693BEM321 I/O LINK Master Module......................................................................8-25

Compatibility........................................................................................................... 8-26

IC693APU305 I/O Processor Module ............................................................................ 8-27

Module Features...................................................................................................... 8-28

IC693CMM321 Ethernet Interface Module.................................................................... 8-29

IC693PCM300/301/311 Programmable Coprocessor Module (PCM) ........................... 8-31

IC693CMM311 Communications Coprocessor Module (CMM)................................... 8-34

IC693ADC311 Alphanumeric Display Coprocessor (ADC).......................................... 8-35

IC693TCM302/303 Temperature Control Modules (TCM).......................................... 8-37

Connections............................................................................................................. 8-37

LED Indicators ........................................................................................................ 8-38

Internal Fuse............................................................................................................ 8-38

Automatic Data Transfers Between TCM and PLC................................................ 8-38

Comparison of TCM302 and TCM303 Modules .................................................... 8-39

IC693PTM100/101 Power Transducer (PTM) ............................................................... 8-40

Difference Between PTM100 and PTM101............................................................. 8-40

Capabilities............................................................................................................... 8-40

Operating Modes ...................................................................................................... 8-40

Automatic Data Transfers Between PTMPM and PLC............................................ 8-41

Compatibility............................................................................................................ 8-41

Dimensions............................................................................................................... 8-42

PTMPM Indicator LEDs .......................................................................................... 8-42

General Mounting Information................................................................................. 8-42

Baseplate Type and Allowable Number of PTMPM Modules................................. 8-43

Power Supply Requirement...................................................................................... 8-43

Memory Requirement............................................................................................... 8-43

Configuration............................................................................................................ 8-43

Ordering Information................................................................................................8-43

Documentation ........................................................................................................ 8-43

Chapter 9

State Logic Products............................................................................................9-1

State Logic Overview .......................................................................................................9-1

State Logic Products ......................................................................................................... 9-1

Baseplates and Power Supply, I/O, and Option Modules........................................... 9-1

GFK-0356Q Contents xiii

Page 14

Contents

AD693CMM301 State Logic Serial Communications Module (SCM)............................ 9-2

Description ................................................................................................................. 9-2

OK LED .................................................................................................................... 9-2

Reset Button.............................................................................................................. 9-2

Serial Connector........................................................................................................ 9-3

Cable Information....................................................................................................... 9-3

State Logic SCM Documentation............................................................................... 9-3

IC693SLP300 State Logic Processor Module .................................................................. 9-4

Description ................................................................................................................. 9-4

SLP Features............................................................................................................... 9-5

Memory ...................................................................................................................... 9-5

Installation.................................................................................................................. 9-5

Status Light................................................................................................................. 9-6

Pushbutton.................................................................................................................. 9-6

Battery ........................................................................................................................ 9-7

Cable Information....................................................................................................... 9-7

Hardware Specifications............................................................................................. 9-7

State Logic Processor (SLP) Documentation ............................................................. 9-7

State Logic CPUs.............................................................................................................. 9-8

Features of State Logic CPUs.....................................................................................9-8

Model CSE311, CSE313 and CSE323 Embedded CPU Baseplates .......................... 9-9

Model CSE331 and CSE340 Modular CPUs.................................................................. 9-10

CPU Serial Port Connector on Power Supply .......................................................... 9-11

Configuring the State Logic CPUs........................................................................... 9-11

State Logic CPU Firmware and PROM Configurations .......................................... 9-13

State Logic CPU Data Sheets .........................................................................................9-13

CSE311 Catalog Number IC693CSE311 ........................... 9-14

CSE313 Catalog Number IC693CSE313 ........................... 9-15

CSE323 Catalog Number IC693CSE323 ........................... 9-16

CSE331 Catalog Number IC693CSE331 ........................... 9-17

CSE340 Catalog Number IC693CSE340 ........................... 9-18

Chapter 10

Cables .................................................................................................................10-1

Cable Data Sheets ........................................................................................................... 10-7

IC647CBL704 Workstation Interface to Series 90 CPU (SNP Port) Cable ................... 10-8

Function of cable..................................................................................................... 10-8

IC690CBL701 PCM, ADC, CMM to Workmaster (PC-XT) Cable............................. 10-12

Function of cable................................................................................................... 10-12

Cable Specifications.............................................................................................. 10-12

Wiring Diagram..................................................................................................... 10-12

PCM to Programmer Cable Installation ................................................................. 10-13

IC690CBL702 PC-AT to PCM, ADC, CMM Cable .................................................... 10-14

Function of cable................................................................................................... 10-14

Cable Specifications.............................................................................................. 10-14

xiv Series 90™-30 PLC Installation and Hardware Manual – August 2002 GFK-0356Q

Page 15

Wiring Diagram..................................................................................................... 10-14

Contents

PCM to Programmer Cable Installation ................................................................. 10-15

IC690CBL705 Workmaster II (PS/2) to PCM, ADC, CMM Cable ............................. 10-16

Function of cable................................................................................................... 10-16

Cable Specifications.............................................................................................. 10-16

Wiring Diagram..................................................................................................... 10-16

PCM to Programmer Cable Installation ................................................................. 10-17

IC690CBL714A Multidrop Cable ................................................................................ 10-18

Purpose.................................................................................................................. 10-18

Specifications ........................................................................................................ 10-18

IC690CBL714A Multi-Drop Cable Wiring Diagram............................................ 10-19

Connection Diagrams for IC690CBL714A Cable.................................................. 10-20

IC693CBL300/301/302/312/313/314 I/O Bus Expansion Cables ................................ 10-22

Description ............................................................................................................ 10-22

Cable Lengths........................................................................................................ 10-22

Function of Cables ................................................................................................ 10-22

Connecting the Cables........................................................................................... 10-23

Important Notes About I/O Bus Expansion Cables............................................... 10-23

Cable Application Suggestions.............................................................................. 10-23

Using Standard Cables .......................................................................................... 10-23

Using Custom Built cables .................................................................................... 10-24

Building Custom Length I/O Bus Expansion Cables ............................................. 10-24

Two Types of Custom Built Cables ...................................................................... 10-24

Components Needed to Build Custom Length I/O Bus Expansion Cables........... 10-24

Expansion Port Pin Assignments........................................................................... 10-25

I/O Expansion Bus Termination............................................................................ 10-25

Shield Treatment ................................................................................................... 10-26

Alert for Users of Early Remote Baseplate Versions............................................ 10-26

Making a 100% Shielded Cable............................................................................ 10-27

Wiring Diagrams................................................................................................... 10-28

Application Examples ........................................................................................... 10-31

Expansion System Cable Connections.................................................................. 10-31

Remote and Expansion System Cable Connection Example................................. 10-31

IC693CBL303 Hand-Hand Programmer and Converter (IC690ACC900) Cable ........10-33

Function of cable.................................................................................................... 10-33

Cable Specifications............................................................................................... 10-33

Wiring Diagram...................................................................................................... 10-34

Connecting the Cable ............................................................................................. 10-34

IC693CBL304/305 Port Expansion (WYE) Cables for PCM, ADC, and CMM.......... 10-35

Function of cable.................................................................................................... 10-35

Cable Specifications............................................................................................... 10-35

Wiring Information.................................................................................................10-36

IC693CBL306/307 Extension Cables (50-Pin) for 32 Point Modules.......................... 10-38

Function of cable.................................................................................................... 10-38

Cable Specifications............................................................................................... 10-38

IC693CBL308/309 I/O Cables (50-Pin) for 32 Point Modules .................................... 10-40

Specifications ......................................................................................................... 10-40

Wiring Information.................................................................................................10-40

GFK-0356Q Contents xv

Page 16

Contents

IC693CBL310 I/O Interface Cable (24-Pin) for 32 Point Modules.............................. 10-42

Function of cable.................................................................................................... 10-42

Replacement/Obsolescence Information................................................................ 10-43

Connector Depth for Cable IC693CBL310........................................................... 10-43

IC693CBL311/317/319/320 I/O Interface Cables for Power Mate APM Modules......10-45

Function of cable.................................................................................................... 10-45

Specifications ......................................................................................................... 10-45

Wiring Information.................................................................................................10-46

IC693CBL315 I/O Interface Cable (24-Pin) for 32 Point Modules.............................. 10-49

Function of cable.................................................................................................... 10-49

Building Custom Length Cables for 24-Pin Connectors........................................ 10-49

Replacement/Obsolescence Information................................................................ 10-51

Connector Depth for IC693CBL315 ..................................................................... 10-51

IC693CBL316 Serial Cable, 9-Pin D-Shell to RJ-11 Connector.................................. 10-53

Description ............................................................................................................. 10-53

Typical Applications .............................................................................................. 10-53

IC693CBL321/322/323 I/O Faceplate Connector to Terminal Block Connector, 24-Pin10-54

Function of cable.................................................................................................... 10-54

Cable Specifications............................................................................................... 10-54

Connector Depth ................................................................................................... 10-55

IC693CBL327/328 I/O Interface Cables with Right Angle 24-Pin Connector ........... 10-57

Description ............................................................................................................. 10-57

Applications............................................................................................................ 10-57

Specifications ......................................................................................................... 10-58

Connector Depth for Cables IC693CBL327/328 .................................................. 10-58

Building Custom Length 24-pin Connector Cables ...............................................10-59

Connector Depth for Custom Built Cables............................................................ 10-60

Possible Uses for These Cables (Factory or Custom Built) ................................... 10-61

IC693CBL329/330/331/332/333/334 Cables 24-Pin I/O Faceplate Connector to Terminal

Block Connector ........................................................................................................... 10-62

Description ............................................................................................................. 10-62

Connector Depth ................................................................................................... 10-63

Applications............................................................................................................ 10-64

IC693CBL340/341 PTM Interface Cables ................................................................... 10-65

Documentation ....................................................................................................... 10-67

Chapter 11

xvi Series 90™-30 PLC Installation and Hardware Manual – August 2002 GFK-0356Q

Programmer Hardware Products ....................................................................11-1

Products Discussed in this Chapter................................................................................. 11-1

IC640WMI310/320 Work Station Interface Boards....................................................... 11-2

Replacing Workmaster Computers........................................................................... 11-3

IC690ACC900 RS-422/RS-485 to RS-232 Converter....................................................11-3

IC690ACC901 Miniconverter Kit .................................................................................. 11-4

IC693PRG300 Hand-Held Programmer (HHP).............................................................. 11-5

HHP Features ........................................................................................................... 11-6

Page 17

HHP Memory Card (IC693ACC303)...................................................................... 11-6

HHP Modes of Operation........................................................................................ 11-6

Documentation ........................................................................................................ 11-6

Contents

IC693PIF301/400 Personal Computer Interface (PCIF) Cards ...................................... 11-7

IC655CCM590 Isolated Repeater/Converter ........................................................... 11-8

IC690ACC903 Port Isolator..................................................................................... 11-8

Chapter 12

System Design ....................................................................................................12-1

Introduction..................................................................................................................... 12-1

Step 1: Planning Your System................................................................................. 12-1

Step 2: Determining I/O Requirements ................................................................... 12-1

Additional I/O Module Selection Factors................................................................ 12-2

Step 3: Selecting Option Modules........................................................................... 12-2

Step 4: Selecting a CPU .......................................................................................... 12-4

Step 5: Selecting Baseplates.................................................................................... 12-5

Step 6: Selecting Power Supplies............................................................................ 12-6

Reducing PLC Module Count by Using Other GE Fanuc Products ............................... 12-7

Designing For Safety ...................................................................................................... 12-8

Protection From Electrical Shock............................................................................. 12-8

Fire Prevention ......................................................................................................... 12-8

Protection From Mechanical Hazards ...................................................................... 12-8

Protection From Electrical Failure ...........................................................................12-8

Protection From Design Changes or Overrides....................................................... 12-9

Safety Documentation ........................................................................................... 12-10

Guarding Against Unauthorized Operation........................................................... 12-10

Labeling, Guarding, and Lighting Issues............................................................... 12-10

Equipment Accessibility Issues............................................................................. 12-10

Number of Modules Per Series 90-30 PLC System...................................................... 12-11

Calculating Power Supply Loading .............................................................................. 12-12

Load Requirements for Hardware Components ..................................................... 12-12

Power Supply Loading Calculation Examples...................................................... 12-14

Scan (Sweep) Time Calculation.................................................................................... 12-15

Major Design Factors Affecting Scan Time........................................................... 12-16

Where to Find Scan Time Information................................................................... 12-16

Calculating PLC Heat Dissipation................................................................................ 12-17

System Layout Guidelines............................................................................................ 12-17

Benefits of a Good Layout - Safe, Reliable, and Accessible.................................. 12-17

PLC Rack Location and Clearance Requirement................................................... 12-17

Location of Modules in the PLC Racks ................................................................. 12-18

Allowable Module Locations ................................................................................. 12-19

Series 90-30 PLC Layout Example............................................................................... 12-20

PLC Mounting Position ................................................................................................ 12-21

Recommended Upright Mounting Orientation....................................................... 12-21

Derated Horizontal Mounting Orientation .............................................................12-21

GFK-0356Q Contents xvii

Page 18

Contents

Chapter 13

Maintenance and Troubleshooting ..................................................................13-1

Troubleshooting Features of Series 90-30 Hardware......................................................13-1

Indicator Lights (LEDs) and Terminal Board .......................................................... 13-1

Module LED Indicators .................................................................................................. 13-2

Troubleshooting Features of Programming Software..................................................... 13-3

Ladder Screens ......................................................................................................... 13-3

Configuration Screens .............................................................................................. 13-3

Fault Tables .............................................................................................................. 13-3

System Status References......................................................................................... 13-3

Reference Tables ...................................................................................................... 13-4

Override feature........................................................................................................ 13-4

Sequential Event Recorder (SER), DOIO functional instruction............................. 13-4

Replacing Modules ......................................................................................................... 13-5

Series 90-30 Product Repair..................................................................................... 13-5

Module Fuse List...................................................................................................... 13-6

Spare/Replacement Parts ................................................................................................13-7

Preventive Maintenance Suggestions.............................................................................. 13-8

Getting Additional Help and Information....................................................................... 13-9

Appendix A Serial Ports and Cables...................................................................................... A-1

RS-422 Interface.............................................................................................................. A-1

Cable and Connector Specifications.......................................................................... A-2

Series 90 PLC Serial Port.......................................................................................... A-3

Workmaster Serial Port.................................................................................................... A-4

RS-232/RS-485 Converter............................................................................................... A-7

IC690ACC901 Miniconverter Kit............................................................................. A-7

IC690ACC900 Obsolete Converter........................................................................... A-7

Serial Cable Diagrams ..................................................................................................... A-8

RS-232 Point-to-Point Connections .......................................................................... A-8

RS-422 Point-to-Point Connection.......................................................................... A-10

Multidrop Connections............................................................................................ A-10

Appendix B IC690ACC900 Converter .................................................................................. B-1

Features............................................................................................................................ B-1

Functions.......................................................................................................................... B-1

Location in System .......................................................................................................... B-2

Installation........................................................................................................................ B-2

Cable Description............................................................................................................. B-3

RS-232 Interface Pin Assignments............................................................................ B-4

RS-422/RS-485 Interface Pin Assignments .............................................................. B-5

Logic Diagram ................................................................................................................. B-6

Jumper Configuration ...................................................................................................... B-7

xviii Series 90™-30 PLC Installation and Hardware Manual – August 2002 GFK-0356Q

Page 19

Example of Cable Configurations ............................................................................. B-9

Contents

Appendix C IC655CCM690 Isolated Repeater/Converter ..................................................C-1

Description of the Isolated Repeater/Converter............................................................... C-1

Logic Diagram of the Isolated Repeater/Converter ......................................................... C-3

Pin Assignments for the Isolated Repeater/Converter ..................................................... C-4

System Configurations..................................................................................................... C-5

Simple Multidrop Configuration ............................................................................... C-6

Complex Multidrop Configuration............................................................................ C-6

Rules for Using Repeater/Converters in Complex Networks.................................... C-7

Cable Diagrams................................................................................................................ C-8

Appendix D IC690ACC901 Miniconverter Kit..................................................................... D-1

Description of Miniconverter........................................................................................... D-1

Pin Assignments............................................................................................................... D-2

Pin Assignments, RS-232 Port .................................................................................. D-2

Pin Assignments, RS-422 Port .................................................................................. D-2

System Configurations..................................................................................................... D-3

Cable Diagrams (Point-To-Point).............................................................................. D-3

Appendix E IC690ACC903 Port Isolator .............................................................................. E-1

Connectors ........................................................................................................................E-2

Logic Diagram ..................................................................................................................E-3

Installation.........................................................................................................................E-4

Specifications....................................................................................................................E-7

Appendix F Calculating Series 90-30 Heat Dissipation ....................................................... F-1

Overview........................................................................................................................... F-1

Information Required........................................................................................................F-1

Procedure ..........................................................................................................................F-2

Step 1: Basic Method to Calculate Module Dissipation.............................................F-2

Step 2: Calculation for PLC Power Supplies.............................................................F-3

Step 3: Output Calculations for Discrete Output Modules........................................F-3

Step 4: Input Calculations for Discrete Input Modules ..............................................F-4

Step 5: Final Calculation ............................................................................................ F-6

Other Information Related to Enclosure Sizing................................................................F-6

Appendix G Catalog Number to Publication Cross-Reference ...........................................G-1

General System Information ............................................................................................ G-2

Analog I/O Modules ........................................................................................................ G-2

Baseplates ........................................................................................................................G-2

Communications Modules ............................................................................................... G-3

GFK-0356Q Contents xix

Page 20

Contents

CPU Modules, CPU311-CPU341.................................................................................... G-3

CPU Modules, CPU350 - CPU374.................................................................................. G-4

Digital Valve Driver Module........................................................................................... G-5

Discrete I/O Modules....................................................................................................... G-5

Genius Modules ............................................................................................................... G-6

Motion Modules............................................................................................................... G-6

Other Option Modules ..................................................................................................... G-6

Power Supply Modules.................................................................................................... G-7

Programming Device ....................................................................................................... G-7

State Logic Products ........................................................................................................ G-7

Publication Revision Letters............................................................................................ G-8

Other Sources of Information .......................................................................................... G-8

Appendix H Terminal Block Quick Connect Components ..................................................H-1

Terminal Block Quick Connect Components for 16-Point Modules............................... H-2

Terminal Blocks ........................................................................................................ H-2

Cable Current Rating................................................................................................. H-2

Cable Selection and Cross-Reference ....................................................................... H-3

I/O Face Plate for 16-Point Modules......................................................................... H-3

I/O Face Plate Installation......................................................................................... H-3

Module Wiring Information ...................................................................................... H-4

Cable Information...................................................................................................... H-4

Connector Pin Orientation and Connection to Module Terminal.............................. H-5

Terminal Block Information...................................................................................... H-5

IC693ACC329 TBQC Terminal Block.................................................................... H-6

IC693ACC330 TBQC Terminal Block.................................................................... H-7

IC693ACC331 TBQC Terminal Block.................................................................... H-8

IC693ACC332 TBQC Terminal Block.................................................................... H-9

IC693ACC333 TBQC Terminal Block .................................................................. H-10

Terminal Block Quick Connect Components for 32-Point Modules............................. H-11

Terminal Block........................................................................................................ H-12

Cable Selection and Cross-Reference ..................................................................... H-12

Cable Current Rating............................................................................................... H-12

Cable Data ............................................................................................................... H-13

Terminal Block Data ............................................................................................... H-13

IC693ACC337 TBQC Terminal Block .................................................................. H-13

Appendix I

xx Series 90™-30 PLC Installation and Hardware Manual – August 2002 GFK-0356Q

SNP Multidrop..................................................................................................... I-1

SNP Multidrop Overview ..................................................................................................I-1

Multidrop Cables.........................................................................................................I-2

Limitations...................................................................................................................I-2

Cable and Connector Specifications ..................................................................................I-2

MultiDrop Cable Wiring Diagram.....................................................................................I-3

Page 21

SNP Multidrop Examples ..................................................................................................I-4

Configuring and Connecting a Programmer to a Multidrop Network ...............................I-5

Assigning a PLC SNP ID to a PLC with Logicmaster................................................I-6

Connecting your Logicmaster Programmer to a PLC on a Multidrop System............I-6

SNP Multidrop Troubleshooting........................................................................................I-7

Contents

Appendix J

Ethernet Transceivers .........................................................................................J-1

IC649AEA102 Ethernet 10BASE-T Transceiver............................................................. J-1

Power Requirement .................................................................................................... J-1

LED Indicator Lights.................................................................................................. J-1

IC649AEA103 Ethernet 10BASE2 Transceiver............................................................... J-2

Power Requirement .................................................................................................... J-2

LED Indicator Light ................................................................................................... J-2

Appendix K Tables and Formulas..........................................................................................K-1

AWG to Metric Wire Size Conversion ..................................................................... K-2

Temperature Conversion ........................................................................................... K-3

Formulas................................................................................................................... K-3

Conversion Information................................................................................................... K-4

English and Metric Equivalents................................................................................. K-5

Appendix L 44A420084-001 EMI Line Filter........................................................................ L-1

44A720084-001 Optional EMI Line Filter .......................................................................L-1

44A720084-001 Line Filter Mounting Dimensions..........................................................L-3

GFK-0356Q Contents xxi

Page 22

Contents

Figure 1-1. Five-Slot CPU Baseplate ...........................................................................................................1-3

Figure 1-2. Power Supply Module................................................................................................................1-3

Figure 1-3. CPU Module .............................................................................................................................. 1-4

Figure 1-4. I/O Module................................................................................................................................. 1-4

Figure 1-5. Assembling the System.............................................................................................................. 1-5

Figure 1-6. A Basic System.......................................................................................................................... 1-6

Figure 1-7. Ten-Slot Rack ............................................................................................................................ 1-6

Figure 1-8. I/O Bus Expansion Cable........................................................................................................... 1-7

Figure 1-9. Connecting Expansion and Remote Baseplates.........................................................................1-8

Figure 1-10. Connecting PLCs Using GBC or CMM Modules ................................................................... 1-9

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

Figure 2-2. Installing a Module .................................................................................................................... 2-3

Figure 2-3. Removing a Module................................................................................................................... 2-4

Figure 2-4. Installing an I/O Module’s Terminal Board............................................................................... 2-5

Figure 2-5. Removing a Module’s Terminal Board .....................................................................................2-6

Figure 2-6. Terminal Board with Holding Screws ....................................................................................... 2-7

Figure 2-7. IC693ACC308 Front Mount Adapter Bracket Installation....................................................... 2-9

Figure 2-8. Dimensions for 19-inch Rack Mounting Using IC693ACC308 Adapter Bracket..................... 2-9

Figure 2-9. IC693ACC313 Recessed Mount Adapter Bracket................................................................... 2-10

Figure 2-10. Recommended System Grounding......................................................................................... 2-11

Figure 2-11. Baseplate Grounding.............................................................................................................. 2-12

Figure 2-12. CPU 351 or 352 - Attaching Shield Ground Wire ................................................................. 2-14

Figure 2-13. CPU 351 or 352 - Mounting the Shield Grounding Bracket and Wire.................................. 2-15

Figure 2-14. CPU 363, CPU364, or CPU374 - Attaching Ground Wire.................................................... 2-16

Figure 2-15. Power Supply Terminal Boards ............................................................................................. 2-24

Figure 2-16. Overvoltage Protection Devices and Jumper Strap................................................................ 2-24

Figure 3-1. Common Baseplate Features...................................................................................................... 3-2

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

Figure 3-3. Model IC693CPU323 (10-slot) Embedded CPU Baseplate ......................................................3-5

Figure 3-4. IC693CHS397 5-Slot Modular CPU Baseplate......................................................................... 3-6

Figure 3-5. IC693CHS391 10-Slot Modular CPU Baseplate....................................................................... 3-6

Figure 3-6. IC693CHS398 5-Slot Expansion Baseplate............................................................................... 3-7

Figure 3-7. IC693CHS392 10-Slot Expansion Baseplate............................................................................. 3-8

Figure 3-8. IC693CHS399 5-Slot Remote Baseplate ................................................................................... 3-9

Figure 3-9. IC693CHS393 10-Slot Remote Baseplate .................................................................................3-9

Figure 3-10. I/O Bus Expansion Cables ..................................................................................................... 3-10

xxii Series 90™-30 PLC Installation and Hardware Manual – August 2002 GFK-0356Q

Page 23

Figure 3-11. Rack Number Selection Switch (Shown with Rack 2 Selected)............................................ 3-13

Figure 3-12. Example of Connecting Expansion Baseplates...................................................................... 3-14

Figure 3-13. Example of Connecting Expansion and Remote Baseplates.................................................. 3-15

Figure 3-14. Model 311 and 313 5-Slot Baseplate Dimensions and Spacing Requirements .....................3-16

Figure 3-15. Model 323 10-Slot Baseplate Dimensions and Spacing Requirements................................. 3-17

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

Requirements..................................................................................................................... 3-18

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

Requirements..................................................................................................................... 3-18

Figure 3-18. IC693ACC308 Front Mount Adapter Bracket Installation.................................................... 3-20

Figure 3-19. Dimensions for 19” Rack Mounting Using IC693ACC308 Adapter Bracket..................... 3-21

Figure 3-20. IC693ACC313 Recessed Mount Adapter Bracket................................................................. 3-21

Figure 4-1. Standard AC/DC Input Power Supply - IC693PWR321 ........................................................... 4-2

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

Figure 4-3. Overvoltage Protection Devices and Jumper Strap....................................................................4-6

Figure 4-4. Series 90-30 24/48 VDC Input Power Supply - IC693PWR322 ............................................... 4-7

Figure 4-5. Typical Efficiency Curve for 24/48 VDC Power Supply .......................................................... 4-8

Figure 4-6. Series 90-30 48 VDC Input Power Supply - IC693PWR328 .................................................. 4-10

Figure 4-7. Typical Efficiency Curve for IC693PWR328 Power Supply ................................................. 4-11

Figure 4-8. Series 90-30 24 VDC Input High Capacity Power Supply - IC693PWR331 .......................... 4-13

Figure 4-9. 5 VDC Current Output Derating for Temperatures above 50°C (122°F) ................................4-14

Figure 4-10. Overvoltage Protection Devices and Jumper Strap................................................................ 4-17

Figure 4-11. Interconnection of Power Supplies ........................................................................................ 4-17

Figure 4-12. Timing Diagram for all Series 90-30 Power Supplies .......................................................... 4-18

Figure 4-13. Serial Port Connector ............................................................................................................. 4-19

Figure 4-14. Backup Battery for RAM Memory ........................................................................................ 4-20

Figure 5-1. Models 311 and 313 (5-Slot) Embedded CPU Baseplates......................................................... 5-2

Figure 5-2. IC693CHS397 5-Slot Modular CPU Baseplate......................................................................... 5-3

Figure 5-3. CPU Serial Port Connector on Power Supply............................................................................ 5-4

Figure 5-4. CPUs 351, 352, and 363 ..........................................................................................................5-19

Figure 6-1. Backup Battery for RAM Memory ............................................................................................ 6-1

Figure 6-2. Installing the Battery Accessory Kit ........................................................................................ 6-10

Figure 7-1. Example of Series 90-30 Standard Density Discrete Output Module........................................ 7-3

Figure 7-2. Example of 32-Point I/O Module (IC693MDL654) With Dual Connectors ............................. 7-5

Figure 7-3. Example of 32-Point I/O Module (IC693MDL653) With Single Connector ............................ 7-5

Figure 7-4. 50-PIN, 32 Point I/O Module Connection Method.................................................................... 7-6

Figure 7-5. Example of Series 90-30 Analog Current Output Module......................................................... 7-9

Figure 7-6. IC693DVM300 Digital Valve Driver Module......................................................................... 7-12

Contents

GFK-0356Q Contents xxiii

Page 24

Contents

Figure 8-1. The IC693CMM301 GCM Module ........................................................................................... 8-2

Figure 8-2. Genius Bus Wiring Schematic ................................................................................................... 8-3

Figure 8-3. Example of Genius Communications Network.......................................................................... 8-3

Figure 8-4. Enhanced Genius Communications Module..............................................................................8-4

Figure 8-5. Genius Bus Controller Module .................................................................................................. 8-6

Figure 8-6. Example of FIP I/O System Configuration.............................................................................. 8-10

Figure 8-7. Series 90-30 FIP Bus Controller.............................................................................................. 8-11

Figure 8-8. Example of FIP Remote I/O Scanner System Configuration................................................... 8-12

Figure 8-9. FIP Bus Interface Module........................................................................................................ 8-13

Figure 8-10. Motion Mate APM Module ................................................................................................... 8-15

Figure 8-11. Example of Motion Mate APM Servo System ...................................................................... 8-16

Figure 8-12. Motion Mate DSM302 Module ............................................................................................. 8-17

Figure 8-13. Motion Mate DSM314 Module ............................................................................................. 8-20

Figure 8-14. High Speed Counter (HSC) ................................................................................................... 8-23

Figure 8-15. Example of a Series 90-30 PLC in a Fanuc I/O LINK Configuration ................................... 8-24

Figure 8-16. Example of I/O LINK Master System Configuration............................................................ 8-25

Figure 8-17. I/O Processor Module ............................................................................................................ 8-27

Figure 8-18. Ethernet Interface Module .....................................................................................................8-29

Figure 8-19. Programmable Coprocessor Module (PCM)..........................................................................8-31

Figure 8-20. Communications Control Module.......................................................................................... 8-34

Figure 8-21. Alphanumeric Display Coprocessor Module (ADC)............................................................. 8-35

Figure 8-22. IC693TCM302/303 Temperature Control Module (TCM).................................................... 8-37

Figure 8-23. IC693PTM100/101 Components ..........................................................................................8-41

Figure 8-24. IC693PTM100/101 Component Mounting ............................................................................ 8-42

Figure 9-1. AD693CMM301 State Logic Serial Communications Module................................................. 9-2

Figure 9-2. IC693CBL305 WYE Cable ....................................................................................................... 9-3

Figure 9-3. IC693SLP300 State Logic Processor Module for Series 90-30................................................. 9-4

Figure 9-4. State Logic Processor Module User Details .............................................................................. 9-6

Figure 9-5. Model CSE311 or CSE313 5-Slot Embedded CPU Baseplate .................................................. 9-9

Figure 9-6. Model CSE323 10-Slot Embedded CPU Baseplate................................................................... 9-9

Figure 9-7. CPU Models CSE 331 or CSE 340.......................................................................................... 9-10

Figure 9-8. Serial Port Connector............................................................................................................... 9-11

Figure 10-1. Serial Port to Work Station Interface Board Cable Connection ............................................10-8

Figure 10-2. Series 90 PLC to Workmaster II Serial Cable .......................................................................10-9

Figure 10-3. Example of Multidrop Configuration with Converter .........................................................10-10

Figure 10-4. Series 90 PLC to Programmer 8-Wire Multidrop, Serial Data Configuration..................... 10-11

Figure 10-5. PCM, ADC, or CMM to Workmaster or PC-XT Serial Cable ............................................10-12

xxiv Series 90™-30 PLC Installation and Hardware Manual – August 2002 GFK-0356Q

Page 25

Figure 10-6. PCM to Workmaster Computer or PC-XT Personal Computer........................................... 10-13

Figure 10-7. PCM, ADC, or CMM to Workmaster or PC-AT Serial Cable ............................................10-14

Figure 10-8. PCM to PC-AT Personal Computer..................................................................................... 10-15

Figure 10-9. PCM, ADC, or CMM to Workmaster II or PS/2 Serial Cable............................................. 10-16

Figure 10-10. PCM to Workmaster II Computer or PS/2 Computer........................................................ 10-17

Figure 10-11. Connecting Diagram for Multidrop Cable IC690CBL714A..............................................10-19

Figure 10-12. Multidrop Arrangement for Series 90-30 Redundant System............................................ 10-20

Figure 10-13. Connecting CPU and APM to Programmer with IC690CBL714A Cable......................... 10-20

Figure 10-14. Multidrop Arrangement for Series 90-70 TMR Redundant System.................................. 10-21

Figure 10-15. Detail of I/O Bus Expansion Cables .................................................................................. 10-22

Figure 10-16. How to use Split-Ring Ferrules for Foil and Braided Cable Shield................................... 10-26

Figure 10-17. Point-To-Point Cable Wiring for Continuous Shield Custom Length Cables ................... 10-28

Figure 10-18. Point-To-Point Cable Wiring Diagram for Applications Requiring Less Noise Immunity10-28

Figure 10-19. Earlier Versions of Remote Baseplate Custom WYE Cable Wiring Diagram .................. 10-29

Figure 10-20. Current Remote baseplate (IC693CHS393/399) Custom Wye Cable Wiring Diagram .... 10-30

Figure 10-21. Example of Connecting Expansion Baseplates................................................................. 10-31

Figure 10-22. Example of Connecting Expansion and Remote Baseplates.............................................. 10-32

Figure 10-23. Wiring Connections for IC693CBL303 and Custom-Built Cables.................................... 10-34

Figure 10-24. Hand-Held Programmer Cable Connection to a Series 90-30 PLC................................... 10-34

Figure 10-25. Wye Cable.......................................................................................................................... 10-35

Figure 10-26. Wye Cable Connections..................................................................................................... 10-36

Figure 10-27. 32 Point I/O Module to Weidmuller Terminal Block Assembly ....................................... 10-39

Figure 10-28. IC693CBL310 Cable .........................................................................................................10-42

Figure 10-29. Dimensions for Depth of Connector in front of PLC......................................................... 10-44

Figure 10-30. I/O Connector Cable Specifications................................................................................... 10-45

Figure 10-31. IC693CBL315 Cable .........................................................................................................10-49

Figure 10-32. Dimensions for Depth of Connector in front of PLC......................................................... 10-52

Figure 10-33. IC693CBL316A Serial Cable Illustration and Connector Pinouts ....................................10-53

Figure 10-34. Connector Orientation on I/O Faceplate............................................................................ 10-55

Figure 10-35. I/O Faceplate to Terminal Block Cable ............................................................................. 10-55

Figure 10-36. Dimensions for Depth of Connector in front of PLC......................................................... 10-56

Figure 10-37. C693CBL327/328 Cables.................................................................................................. 10-57

Figure 10-38. Dimension for Depth of Connector for IC693CBL327/328 .............................................. 10-58

Figure 10-39. Dimensions for Depth of Connector in front of PLC for Custom Built Cables................. 10-61

Figure 10-40. IC693CBL329/330/331/332/333/334 Cables ....................................................................10-62

Figure 10-41. Dimension for Depth of Connector.................................................................................... 10-63

Figure 10-42. Figure IC693CBL340/341 PTM Interface Cables............................................................ 10-65

Contents

GFK-0356Q Contents xxv

Page 26

Contents

Figure 10-43. PTM Component Mounting and Cable Connection...........................................................10-65

Figure 11-1. WSI Board for the Workmaster II Computer......................................................................... 11-2

Figure 11-2. Location of WSI in a Series II 90-30 PLC System................................................................ 11-2

Figure 11-3. Example of IC690ACC900 Converter Connection................................................................11-3

Figure 11-4. IC690ACC901 Series 90 SNP Port to RS-232 Adapter......................................................... 11-4

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

Figure 11-6. Example of PCIF Interface to Series 90-30 I/O ..................................................................... 11-7

Figure 12-1. Hard-Wired MCR Circuit Example ....................................................................................... 12-9

Figure 12-2. Allowable Location of Modules .......................................................................................... 12-19

Figure 12-3. Series 90-30 Example Layout .............................................................................................. 12-20

Figure 12-4. Recommended PLC Mounting Orientation ......................................................................... 12-21

Figure 12-5. Derated PLC Mounting Orientation..................................................................................... 12-21

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

Figure A-1. Series 90 PLC, RS-422 Serial Port Connector Configuration ................................................. A-3

Figure A-2. Workmaster RS-232 Serial Port Connector Configuration...................................................... A-4

Figure A-3. IBM-AT/XT Serial Port........................................................................................................... A-5

Figure A-4. IBM-AT (compatibles) Personal Computer to Series 90 PLCs ............................................... A-9

Figure A-5. Workmaster or IBM-XT (compatibles) Personal Computer to Series 90 PLCs ...................... A-9

Figure A-6. Typical RS-422, Host to PLC Connection, with Handshaking.............................................. A-10

Figure A-7. Workmaster II/Series 90 PLC Multidrop Connection............................................................ A-11

Figure A-8. Workmaster/Series 90 PLC Multidrop Connection............................................................... A-12

Figure A-9. IBM-AT/Series 90 PLC Multidrop Connection..................................................................... A-12

Figure A-10. IBM-XT/Series 90 PLC Multidrop Connection................................................................... A-13

Figure B-1. Front and Rear View of Converter........................................................................................... B-2

Figure B-2. Typical Configuration with Series 90-70 PLC......................................................................... B-3

Figure B-3. Typical Configuration with Series 90-30 PLC......................................................................... B-4

Figure B-4. RS-422/RS-485 to RS-232 Converter Logic Diagram............................................................. B-6

Figure B-5. Location of Jumpers for User Options ..................................................................................... B-7

Figure C-1. Isolated/Repeater Converter..................................................................................................... C-2

Figure C-2. RS-422 Isolated Repeater/RS-232 Converter Logic Diagram ................................................. C-3

Figure C-3. Example RS-422 Isolated Repeater/RS-232 Converter Connection ........................................ C-5

Figure C-4. Simple System Configuration Using the Isolated Repeater/Converter .................................... C-6

Figure C-5. Complex System Configuration Using the Isolated Repeater/Converter................................. C-6

Figure C-6. Cable A; RS-232 CMM To Converter ..................................................................................... C-8

Figure C-7. Cable B; RS-422 CMM To Converter ..................................................................................... C-8

Figure C-8. Cable C; RS422 Twisted Pair................................................................................................... C-9

Figure C-9. Cable D; RS-422 Twisted Pair ............................................................................................... C-10

xxvi Series 90™-30 PLC Installation and Hardware Manual – August 2002 GFK-0356Q

Page 27

Figure C-10. Cable E; RS-232 Converter to CMM ................................................................................... C-10

Figure D-1. Series 90 SNP to RS-232 Miniconverter ................................................................................. D-1

Figure D-2. Miniconverter to PC-AT .......................................................................................................... D-3

Figure D-3. Miniconverter to Workmaster II, PC-XT, PS/2 ....................................................................... D-3

Figure D-4. Miniconverter to 9-Pin Workmaster or PC-XT Computer....................................................... D-4

Figure E-2. IC690ACC903 Block Diagram .................................................................................................E-3

Figure E-3. RS-485 Port Isolator in PLC Network.......................................................................................E-4

Figure E-4. Mounting Port Isolator to Panel ................................................................................................E-4

Figure E-5. Multidrop Configuration Connecting Devices with 15-Pin Ports and 25-Pin Ports..................E-5

Figure E-6. Cable for Supplying External Power Through the Port Isolator................................................E-6

Figure H-1. Typical TBQC Terminal Block................................................................................................ H-1

Figure H-2. TBQC Faceplate....................................................................................................................... H-5

Figure H-3. IC693ACC329 TBQC Terminal Block....................................................................................H-6

Figure H-4. IC693ACC330 TBQC Terminal Block....................................................................................H-7

Figure H-5. IC693ACC331 TBQC Terminal Block....................................................................................H-8

Figure H-6. IC693ACC332 TBQC Terminal Block....................................................................................H-9

Figure H-7. IC693ACC333 TBQC Terminal Block.................................................................................. H-10

Figure H-8. IC693MDL654 32-Point Module........................................................................................... H-11

Figure H-9. IC693ACC337 TBQC Terminal Block.................................................................................. H-13

Figure I-1. Series 90-30 Multidrop Example.................................................................................................I-1

Figure I-2. Multidrop Cable Wiring Diagram ...............................................................................................I-3

Figure I-3. Connecting CPU and APM to Programmer with IC690CBL714A Cable...................................I-4

Figure I-4. Multidrop Arrangement for Series 90-70 TMR Redundant System............................................I-4

Figure I-5. Multidrop Arrangement for Series 90-30 Redundant System .....................................................I-5

Figure J-1. IC649AEA102 Ethernet 10BASE-T Transceiver ...................................................................... J-1

Figure J-2. IC649AEA103 Ethernet 10BASE2 Transceiver ........................................................................ J-2

Figure L-1. 44A720084-001 Line Filter Connections to Series 90-30 Power Supply ...............................L-2

Figure L-2. Equivalent Circuit for 44A720084-001 Line Filter ...................................................................L-2

Figure L-3. 44A720084-001 Line Filter Mounting Dimensions..................................................................L-3

Contents

GFK-0356Q Contents xxvii

Page 28

Contents

Table 3-1. Rack Number Selection Switch Settings................................................................................... 3-13

Table 3-2. Series 90-30 Baseplate Comparison.......................................................................................... 3-22

Table 4-1. Power Supply Comparison.......................................................................................................... 4-1

Table 4-2. IC693PWR321 Power Supply Capacities ................................................................................... 4-2

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

Table 4-4. IC693PWR330 Power Supply Capacities .................................................................................. 4-4

Table 4-5. Specifications for IC693PWR330 High Capacity AC/DC Input Power Supply......................... 4-5

Table 4-6. IC693PWR322 Power Supply Capacities ................................................................................... 4-7

Table 4-7. Specifications for IC693PWR322 Power Supply........................................................................ 4-8

Table 4-8. IC693PWR328 Power Supply Capacities .................................................................................4-10

Table 4-9. Specifications for IC693PWR328 Power Supply...................................................................... 4-11

Table 4-10. IC693PWR331 Power Supply Capacities ............................................................................... 4-13

Table 4-11. Specifications for IC693PWR331 Power Supply.................................................................... 4-14

Table 5-1. CPU Firmware and PROM Configurations................................................................................. 5-6

Table 5-2. EPROM and EEPROM Catalog Numbers.................................................................................. 5-9

Table 5-3. Series 90-30 CPU Capacities ....................................................................................................5-10

Table 5-4. Range and Size of User References for CPU Models 311-341................................................. 5-11

Table 5-5. Range and Size of User References for CPU Models 350 through 374.................................... 5-12

Table 5-6. Port 1 (RS-232) ......................................................................................................................... 5-22

Table 5-7. Port 2 (RS-485) ......................................................................................................................... 5-22

Table 7-1. IC693DVM300 Specifications.................................................................................................. 7-13

Table 7-2. IC693DVM300 Connections.....................................................................................................7-14

Table 7-3. Series 90-30 Discrete I/O Modules ........................................................................................... 7-15

Table 7-4. Series 90-30 Analog I/O Modules............................................................................................. 7-16

Table 8-1. Comparison of TCM302 and TCM303.....................................................................................8-39

Table 9-1. System Specifications for Series 90-30 State Logic CPUs ....................................................... 9-12

Table 10-1. Series 90-30 Cable Cross-Reference ....................................................................................... 10-1

Table 10-2. Expansion Port Pin Assignments ..........................................................................................10-25

Table 10-3. Wire List for 32 Point I/O Cables ......................................................................................... 10-40

Table 10-4. Wire List for 24-Pin Connectors ........................................................................................... 10-43

Table 10-5. Catalog Numbers for 24-Pin Connector Kits ........................................................................ 10-46

Table 10-6. I/O Cable Wire Coding for IC693CBL311 and IC693CBL319............................................ 10-47

Table 10-7. I/O Cable Wire Coding for IC693CBL317 and IC693CBL320............................................ 10-48

Table 10-8. Catalog Numbers for 24-Pin Connector Kits ........................................................................ 10-50

Table 10-9. Wire List for 24-Pin Connectors ........................................................................................... 10-51

Table 10-10. Catalog Numbers for 24-Pin Connector Kits ...................................................................... 10-59

xxviii Series 90™-30 PLC Installation and Hardware Manual – August 2002 GFK-0356Q

Page 29

Table 10-11. Wire List for 24-Pin Connectors .........................................................................................10-60

Table 10-12. TBQC Cable Cross-Reference Table .................................................................................. 10-63

Table 11-1. Personal Computer Interface Card Comparison Table............................................................ 11-7

Table 12-1. Power Supply Feature Comparison Table............................................................................... 12-6

Table 12-2. Maximum Number of Modules Per System.......................................................................... 12-11

Table 12-3. Load Requirements (in milliamps)........................................................................................ 12-12

Table 13-1. Fuse List for Series 90-30 Modules ........................................................................................13-6

Table 13-2. Spare/Replacement Parts......................................................................................................... 13-7

Table A-1. Connector/Cable Specifications ................................................................................................ A-2

Table A-2. Series 90 PLC, RS-422 Serial Port Pin-out ............................................................................... A-4

Table A-3. Workmaster RS-232 Serial Port Pins-out.................................................................................. A-5

Table A-4. IBM-AT/XT Serial Port Pins-out.............................................................................................. A-6

Table B-1. RS-232 Interface for Converter ................................................................................................. B-4

Table B-2. RS-422/RS-485 Interface for Converter .................................................................................... B-5

Table B-3. Jumper Configuration for RS-422/RS-485 to RS-232 Converter.............................................. B-8

Table B-4. Specifications for IC690ACC900 Converter............................................................................. B-9

Table C-1. Isolated Repeater/Converter Pin Assignments .......................................................................... C-4

Table D-1. Miniconverter RS-232 Port ....................................................................................................... D-2

Table D-2. Miniconverter RS-422 Port ....................................................................................................... D-2

Table D-3. Miniconverter Specifications .................................................................................................... D-4

RS-485 Connectors........................................................................................................................................E-2

Table H-1. TBQC Terminal Block Selection Table .................................................................................... H-2

Table I-1. Connector and Cable Specifications .............................................................................................I-2

Table K-1. Standard ASCII (American Standard Code for Information Interchange) Codes ..................... K-1

Table K-2. AWG to Metric Wire Size Conversion ..................................................................................... K-2

Table K-3. Celsius to Fahrenheit Conversion.............................................................................................. K-3

Table K-4. General Conversions ................................................................................................................. K-4

Table K-5. Length Equivalents.................................................................................................................... K-5

Table K-6. Area Equivalents ....................................................................................................................... K-5

Table K-7. Volume Equivalents I................................................................................................................ K-6

Table K-8. Volume Equivalents II............................................................................................................... K-6

Contents

GFK-0356Q Contents xxix

Page 30

Chapter

Overview of the Series 90-30 PLC

The Series 90-30 Programmable Logic Controller (PLC) is a member of the GE Fanuc Series 90 PLC family.

The Basic Parts of a Series 90-30 PLC

The Series 90-30 PLC is very versatile because (1) it is programmable, and (2) it is assembled from a wide variety of modular, plug-together components. Therefore, by choosing the correct components and developing an appropriate program, the PLC can be used for an almost unlimited variety of applications. Although there are many choices of individual hardware components to use in a system, there are just a few basic categories. Each of these component categories is covered in detail in a separate chapter in this manual. They are introduced in this chapter so you can see how they fit together:

 Baseplates

 Power Supplies

 CPUs

 I/O Modules

 Option Modules

 Cables

Baseplates

The baseplates are the foundation of the PLC system because most other components mount on them. As a basic minimum, every system has at least one baseplate, which usually contains the CPU (in which case, it is referred to as “the CPU Baseplate”). Many systems require more modules than can be mounted on one baseplate, so there are also Expansion and Remote baseplates that connect together. The three categories of baseplates, CPU, Expansion, and Remote, are available in two sizes, 5-slot and 10-slot, named according to the number of modules they can hold.

Power Supply Modules

Every baseplate must have its own power supply. The power supply always mounts in a baseplate’s left-most slot. There are several power supply models available to meet a variety of requirements.

GFK-0356Q 1-1

Page 31

CPUs

The CPU is the manager of the PLC. Every PLC system must have one. A CPU uses the instructions in its firmware and application program to direct the PLC’s operation and to monitor the system to make sure there are no basic faults. Some Series 90-30 CPUs are built into baseplates, but most are contained in plug-in modules. In some cases, the CPU resides in a Personal Computer using a Personal Computer Interface Card that interfaces to Series 90-30 Input, Output, and Option modules.

Input and Output (I/O) Modules

These modules enable the PLC to interface with input and output field devices such as switches, sensors, relays, and solenoids. They are available in both discrete and analog types.

Option Modules

These modules extend the capability of the PLC beyond the basic functions. These provide such things as communications and networking options, motion control, high speed counting, temperature control, interfacing to operator interface stations, etc.

Cables

These connect the PLC components together or to other systems. Many standard prefabricated cables are available from GE Fanuc. They are primarily used to:

 Interconnect baseplates

 Connect a programmer to the CPU or to an option module

 Connect option modules to field devices or other systems.

Assembling a Basic Series 90-30 PLC System

Let’s assemble, on paper, a basic system using the following components:

 Baseplate

 Power Supply module

 CPU module

 Some I/O modules

We’ll start with the baseplate. To keep it simple, we’ll use a 5-slot size. Note that a 5-slot baseplate actually has six slots, but the power supply slot is not numbered. Note also, that this baseplate has a CPU slot, which is slot number 1, and it has an expansion connector on the right end, which is used for connecting to another baseplate if the system has more than one baseplate.

1-2 Series 90-30 PLC Installation and Hardware Manual – August 2002 GFK-0356Q

Page 32

PROGRAMMABLE

CONTROLLER

BASE 5-SLOT

USER PROGRAM

AND REGISTER VALUES MAY BE LOST IF POWER

SUPPLY IS REMOVED FOR LONGER THAN

Memory Backup Warning Label

1HOUR.

Power Supply

CPU/1 2 3 4 5

CPU Slot (Slot 1)

Figure 1-1. Five-Slot CPU Baseplate

Next, we’ll add a power supply module. It mounts in the unnumbered slot on the left end of the baseplate. This slot has a unique connector that will only fit a power supply module.

PWR

GE Fanuc

Series 90-30

HIGH CAPACITY POWER SUPPLY

PROGRAMMABLE

INPUT

100-240 VAC

50/60 HZ 100VA

125VDC, 50W

RUN

BATT

CONTROLLER

E X P A N S

I O N

I/O Bus Expansion Connector

Figure 1-2. Power Supply Module

B A T T E R Y

24 VDC

OUTPUT

0.8A MAX.

GFK-0356Q Chapter 1 Overview of the Series 90-30 PLC 1-3

Page 33

Then add a CPU module. A CPU module can only mount in baseplate slot 1, next to the power supply. Slot 1 has a unique connector that will only fit CPU or special Option modules.

CPU331

Figure 1-3. CPU Module

To finish, we will add some I/O modules to baseplate slots 2 through 5.

A1 2 3 4 5 6 7 8

B1 2 3 4 5 6 7 8

Figure 1-4. I/O Module

1-4 Series 90-30 PLC Installation and Hardware Manual – August 2002 GFK-0356Q

Page 34

PROGRAMMABLE

CONTROLLER

BASE 5-SLOT

CAUTION

USER PROGRAM

AND REGISTER VALUES MAY BE

LOST IF POWER

SUPPLY IS

REMOVED FOR

LONGER THAN

1 HOUR

a44564A

NON-CPU SLOTS

GE Fanuc Series 90-30

HIgh Capacity Power Suppl

PWR

RUN

BATT

Power Supply

POWER

SUPPLY

CPU/1

CPU331

CPU

I/O-2 I/O-3 I/O-4 I/O-5

A1 2 3 4 5 6 7 8

B1 2 3 4 5 6 7 8

A1 2 3 4 5 6 7 8

B1 2 3 4 5 6 7 8

A1 2 3 4 5 6 7 8

B1 2 3 4 5 6 7 8

A1 2 3 4 5 6 7 8

B1 2 3 4 5 6 7 8

I/O Modules

Figure 1-5. Assembling the System

GFK-0356Q Chapter 1 Overview of the Series 90-30 PLC 1-5

Page 35

When assembled, the system will look like this:

PWR

GE Fanuc

SERIES 90-30

HIGH CAPACITY POWER SUPPLY

PROGRAMMABLE CONTROLLER

INPUT

100-240 VAC

50/60HZ 100VA

125 VDC, 50W

24 VDC

OUTPUT

0.8A MAX.

B A T T E R Y

Figure 1-6. A Basic System

An assembly of baseplate and modules such as this one is called a “Rack.”

CPU

RUN

BATT

A 1 2 3 4 5 6 7 8 B 1 2 3 4 5 6 7 8

A 1 2 3 4 5 6 7 8

B 1 2 3 4 5 6 7 8

A 1 2 3 4 5 6 7 8

B 1 2 3 4 5 6 7 8

A 1 2 3 4 5 6 7 8

B 1 2 3 4 5 6 7 8

What else would be needed to make this basic system functional?

To make this basic system functional, you would need:

 Mounting. Safe, secure mounting for the PLC in a protective enclosure.

 Wiring. This includes properly installed incoming power to the power supply, as well as

wiring from the I/O modules to field devices such as switches, sensors, solenoids, relays, etc.

 Program. An application program for the PLC to run. This is developed with GE Fanuc PLC

programming software.

What if the application requires more than five modules?

You could use a 10-slot baseplate, shown in the next picture:

PWR

GE Fanuc

SERIES 90-30

HIGH CAPACITY POWER SUPPLY

PROGRAMMABLE CONTROLLER

INPUT

100-240 VAC

50/60HZ 100VA

125 VDC, 50W

24 VDC OUTPUT

0.8A MAX.

CPU

RUN

BATT

A 1 2 3 4 5 6 7 8

B 1 2 3 4 5 6 7 8

A 1 2 3 4 5 6 7 8

B 1 2 3 4 5 6 7 8

A 1 2 3 4 5 6 7 8

B 1 2 3 4 5 6 7 8

A 1 2 3 4 5 6 7 8

B 1 2 3 4 5 6 7 8

A 1 2 3 4 5 6 7 8

B 1 2 3 4 5 6 7 8

A 1 2 3 4 5 6 7 8

B 1 2 3 4 5 6 7 8

A 1 2 3 4 5 6 7 8

B 1 2 3 4 5 6 7 8

I/O Bus Expansion Connector

A 1 2 3 4 5 6 7 8

B 1 2 3 4 5 6 7 8

A 1 2 3 4 5 6 7 8

B 1 2 3 4 5 6 7 8

Figure 1-7. Ten-Slot Rack

1-6 Series 90-30 PLC Installation and Hardware Manual – August 2002 GFK-0356Q

Page 36

What if the application requires more than ten modules?

You can add one or more Expansion or Remote racks to this system. Some CPUs can support up to seven additional racks. If you added seven additional 10-slot racks, you could have 70 more modules.

Racks are interconnected in a “daisy-chain” cabling arrangement. This interconnection system is called the “I/O Expansion Bus.” The connections are made from one baseplate’s I/O Bus Expansion Connector (shown in the figure above) to the next one’s. The I/O Bus Expansion Cables, shown below, have a double connector on one end to facilitate these connections.

Female Connector

Male Connector

Figure 1-8. I/O Bus Expansion Cable

Male Connector

GFK-0356Q Chapter 1 Overview of the Series 90-30 PLC 1-7

Page 37

The next figure shows a system that has a CPU baseplate, one Expansion rack and three Remote racks. Notice that the last rack, the one at the end of the I/O Expansion Bus, must be terminated. A convenient way of terminating the bus is with an IC693ACC307 I/O Bus Terminator Plug, as shown.

CPU BASEPLATE

CPU

BASEPLATE

EXPANSION

BASEPLATE

MAXIMUM DISTANCE

FROM CPU = 50 FEET

(15 METERS)

REMOTE

BASEPLATE

C P U

EXPANSION BASEPLATE

REMOTE BASEPLATE

REMOTE

BASEPLATE

REMOTE

BASEPLATE

MAXIMUM DISTANCE

FROM CPU = 700 FEET

(213 METERS)

REMOTE BASEPLATE

Figure 1-9. Connecting Expansion and Remote Baseplates

What is the Difference Between Expansion and Remote baseplates?

The main factor to consider is distance. How far will the baseplate be from the CPU baseplate? If the cabling distance from the CPU baseplate is 50 feet (15 meters) or less, use an Expansion baseplate. The Expansion baseplate is preferable because of its higher communication speed with the CPU baseplate. However, if a baseplate must be located where it requires a cabling distance from the CPU rack in excess of 50 feet, an Expansion baseplate will not work - a Remote baseplate must be used. The limit for a Remote baseplate is a cabling distance of 700 feet (213 meters) from the CPU baseplate to the farthest Remote baseplate.

I/O BUS

TERMINATOR

PLUG

IC693ACC307

1-8 Series 90-30 PLC Installation and Hardware Manual – August 2002 GFK-0356Q

Page 38

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

You can cover much greater distances by using Series 90-30 communications option modules. For example, Genius Bus Controller Modules (GBC) can communicate at distances up to 7,500 feet (2,286 meters) over a shielded twisted-pair cable, as shown in Example 1 below. Or, serial communications with Communications Coprocessor Modules (CMM) using the RS-485 standard can cover up to 4,000 feet (1,219 meters), as shown in Example 2 below. And virtually unlimited communication distances can be attained with modems and telephone lines or radio transmitters. Also, there are numerous networking options available such as Ethernet or WorldFIP.

Example 1 - GBC Example 2 - CMM

Series 90-30 PLC

CPU GBC

Shielded, Twisted-Pair Cable, 7,500 Feet (2,286 Meters) Maximum Length

Series 90-30 PLC

CPU GBC

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

Series 90-30 PLC

CPU CMM

Series 90-30 PLC

CPU

CMM

Serial Cable , 4,000 Feet ( 1,219 Meters) Maximum Length

GFK-0356Q Chapter 1 Overview of the Series 90-30 PLC 1-9

Page 39

Chapter

Installation

This chapter discusses installation details only. Other information about the products such as hardware descriptions and specifications, is covered in the applicable chapters.

Series 90-30 PLCs must be mounted in a protective enclosure.

The installation instructions described in this chapter apply to PLC installations that do not require special procedures for noisy or hazardous environments. For installations that must conform to more stringent requirements (such as CE Mark), see GFK-1179, Installation Requirements for Conformance to

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

Receiving your Products - Visual Inspection

Important Note

When you receive your Series 90-30 PLC system, carefully inspect all shipping containers for damage that may have occurred during shipping. If any part of the system is damaged, notify the carrier immediately. The damaged shipping container should be saved as evidence for inspection by the carrier.

As the consignee, it is your responsibility to register a claim with the carrier for damage incurred during shipment. However, GE Fanuc will fully cooperate with you if such action is necessary.

Pre-installation Check

After unpacking Series 90-30 PLC racks, cables, modules, etc., record all serial numbers. Serial numbers are printed on the module packaging. Serial numbers are required to make a claim during the warranty period of the equipment. All software product registration cards should be completed and returned to GE Fanuc. See “Module Features” in this chapter for location of module serial numbers. See “Common Baseplate Features” in chapter 3 for location of baseplate serial numbers.

You should verify that all components of the system have been received and that they agree with your order. If the parts received do not agree with your order, call Programmable Control Customer Service at 1-800-432-7521. A Customer Service representative will provide further instructions.

If you require assistance with your installation, GE Fanuc’s Technical Support department offers expert help. Call the support number for your area from the list in Chapter 13, “Maintenance and Troubleshooting.” The GE Fanuc web site support address is www.gefanuc.com/support/plc.

Warranty Claims

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

GFK-0356Q 2-1

Page 40

Working with Series 90-30 Modules

Module Features

13 81

IC693CPUxxx CPU MODULE 25 MHZ

LISTED xxxxxxx 123456789

123456789

127

6 7 8 9

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

1. Pivot hook

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

3. Catalog number and description section of label (Includes MAC address for CPU374.)

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

5. Module connector - plugs into baseplate backplane connector

6. Release lever - spring loaded

7. Ventilation openings in module case (top and bottom)

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

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

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

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

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

13. Module label

14. Serial Number - used to determine module warranty status. (On some modules, the Serial

Number may be on a small tag on the back of the module.)

2-2 Series 90-30 PLC Installation and Hardware Manual – August 2002 GFK-0356Q

Page 41

Installing a Module

Warning

Do not insert or remove modules with power applied. This could cause the PLC to stop or malfunction. Injury to personnel and damage to the module or baseplate may result. Also, attempts to force a module into an improper slot type will result in damage to the module and/or the baseplate. Modules will mount in the correct slot type easily, with a minimum of force.

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

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

assigned a particular module type during configuration. A Power Supply module must be installed in the left end unnumbered slot only, and a CPU module and some special Option modules can only be installed in Slot 1 of a CPU baseplate. I/O Modules and most Option modules install in slots numbered 2 and higher.

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

away from you.

■ Align the module with the desired baseplate slot and connector. Tilt the module upwards so

that top rear pivot hook of the module engages the baseplate’s top module retainer.

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

connector, and the release lever on the bottom of the module snaps into place in the baseplate’s bottom module retainer.

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

a43055A

PIVOT HOOK

BACKPLANE CONNECTOR

BOTTOM RETAINER

RELEASE LEVER

Figure 2-2. Installing a Module

GFK-0356Q Chapter 2 Installation 2-3

Page 42

Removing a Module

Warning

Do not insert or remove modules with power applied. This could cause the PLC to stop or malfunction. Injury to personnel and damage to the module or baseplate may result. Also potentially dangerous voltages from user devices may be present on a module’s screw terminals even though power to the rack is turned off. Care must be taken any time that you are handling the module’s removable terminal board or any wires connected to it.

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

unwire the terminal board) or cables. The procedure for removing a terminal board is described later in this section.

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

module.

■ While holding the module firmly at its top and fully depressing release lever, swing (pivot) the

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

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

the baseplate.

IVOT HOO

PRESS

RELEASE LEVER

Figure 2-3. Removing a Module

a43056

Note

Modules in expansion or remote baseplates can be added, removed, or replaced while the PLC is in RUN mode if power is first removed from the expansion or remote baseplate. I/O data to/from this baseplate will not be updated while power is removed.

2-4 Series 90-30 PLC Installation and Hardware Manual – August 2002 GFK-0356Q

Page 43

Installing a Module’s Terminal Board

Note: Modules IC693MDL730F (and later) and IC693MDL731F (and later) have special terminal boards that are equipped with holding screws. For Installation and Removal instructions, please see the section “Installing and Removing Terminal Boards with Holding Screws” later in this chapter.

To install a terminal board (circled numbers refer to drawing below):

■ Hook the pivot hook

➀, located on the bottom of the terminal board, to the lower slot on the

module.

■ Push the terminal board toward the module

■ Open the terminal board cover

➂ and ensure that the latch on the module is securely holding

➁ until it snaps into place.

the terminal board in place.

Caution

Compare the module catalog number on the label on the back of the hinged door (see Figure 2-6) and the label on the side of the module (see below) to ensure that they match. If a wired terminal board is installed on the wrong module type, damage to the module may occur when the system is powered up.

Module Label

a43062

REFER TO TEXT FOR

INSTALLATION PROCEDURE

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

GFK-0356Q Chapter 2 Installation 2-5

Page 44

Removing a Module’s Terminal Board

To remove a terminal board:

■ Open the plastic terminal board cover.

■ Push up on the jacking lever to release the terminal block.

JACKING

LEVER

■ Grasp pull-tab and pull it towards you until contacts have separated from module

housing and bottom pivot hook has disengaged.

PULL

TAB

Figure 2-5. Removing a Module’s Terminal Board

a43715

2-6 Series 90-30 PLC Installation and Hardware Manual – August 2002 GFK-0356Q

Page 45

A1A

A4A

A2A

A3A

A7A

I/O Module Terminal Board Posts

The terminal board has three posts on the left side. The top and bottom posts hold the terminal board cover in place. The middle post keeps the terminal board wiring in place. If you do not require it to hold the wiring in place, the middle post can be easily snapped off. (Be careful that you do not inadvertently snap it off if you need it to keep your wiring in place.)

Installing and Removing Terminal Boards with Holding Screws

Discrete output modules IC693MDL730F (and later) and IC693MDL731F (and later) have a special terminal board that is equipped with holding screws, shown in the figure below. These screws prevent the terminal board-to-module connections from deteriorating in applications where the PLC is subjected to severe vibration .

Holding Screw

Removeable Terminal Board

Holding Screw

A1 2 3 4 5 6 7 8

B1 2 3 4 5 6 7 8

IC693MDL730F

Hinged Cove

Module Catalog Number

Figure 2-6. Terminal Board with Holding Screws

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

of the terminal board, then follow the standard removal instructions in the section “Removing an I/O Module’s Terminal Board.” The holding screws are held captive in the terminal board and do not have to be completely removed.

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

section “Installing an I/O Module’s Terminal Board,” then tighten the two holding screws to 8 to 10 inch-pounds (1 Newton-meter) of torque.

GFK-0356Q Chapter 2 Installation 2-7

Page 46

Baseplate Mounting

Be sure to follow baseplate grounding instructions in this chapter. Failure to properly ground the PLC can result in improper operation, damage to equipment, and injury to personnel.

Mounting a Baseplate to a Panel

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

Install the screws in four tapped holes. The “Baseplates” chapter has the applicable dimensions and mounting clearances. Alternately, 10-slot baseplates can be mounted in standard 19-inch racks by using the appropriate adapter. This is also discussed in the “Baseplates” chapter.

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

orientations will require derating the Power Supply current capabilities. See Chapter 12, “System Design,” for details.

Warning

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

has details.

■ The Rack Number Selection switch must be set on each Expansion or Remote baseplate. A

CPU baseplate does not require this switch. Rack numbers should be assigned by the system designer. Failure to set the Rack Number Selection switches properly will result in system malfunction. See the “Baseplates” chapter for details on setting these switches.

Mounting a Baseplate to a 19" Rack

Two optional Baseplate Adapter Brackets allow a 10-slot baseplate to be mounted in a 19 inch rack. Each baseplate installation requires only one of the adapter brackets.

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

of a 19” rack. Install the adapter bracket by inserting the tabs at the top and bottom of the adapter bracket into the corresponding slots at the top and bottom of the plastic baseplate cover. NOTE: Although Figure 2-7 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.

2-8 Series 90-30 PLC Installation and Hardware Manual – August 2002 GFK-0356Q

Page 47

■ 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 b ase unit and bracket. Tighten screws t o secure bracket to b ase unit.

Note: Baseplate is shown with cover removed for illustration purposes. It is not necessary to remove the baseplate cover to install the bracket.

Figure 2-7. IC693ACC308 Front Mount Adapter Bracket Installation

Dimensions for rack mounting a 10-slot baseplate with the IC693ACC308 Front Mount Adapter Bracket are shown in the following figure.

18.89 (480)

18.47 (469)

DIMENSIONS IN INCHES (MILLIMETERS IN PARENTHESES)

Figure 2-8. Dimensions for 19-inch Rack Mounting Using IC693ACC308 Adapter Bracket

GFK-0356Q Chapter 2 Installation 2-9

Page 48

3.540 (90)

1.630 (41.4)

0.346 (8.8) Inside

0.439 (11.2)

0.160 (4.06) dia. x 4

0.842 (21.4)

0.280 (7.1)

4.000 (101.6)

1.368 (34.7)

16.850 (428)

18.122 (460.3)

DIMENSIONS IN INCHES (MILLIMETERS IN PARENTHESES)

Figure 2-9. IC693ACC313 Recessed Mount Adapter Bracket

2-10 Series 90-30 PLC Installation and Hardware Manual – August 2002 GFK-0356Q

Page 49

Grounding Procedures

System Grounding Procedures

In addition to the following grounding information, we strongly urge that you follow all applicable codes that apply to your area. For example, in the United States, most areas have adopted the National Electrical Code standard and specify that all wiring conform to its requirements. In other countries, different codes will apply. For maximum safety to personnel and property you must follow these codes. Failure to do so can mean injury or death to personnel, damage to property, or both.

All components of a programmable logic control system and the devices it is controlling must be properly grounded. This is particularly important for the following reasons.

■ A low resistance path from all parts of a system to earth minimizes exposure to shock in the

event of short circuits or equipment malfunction.

Warning

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

Ground Conductors

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

earth ground point, shown in the figure below. This ensures that no ground conductor carries current from any other branch. This method is shown in the following figure.

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

ground cables (typically green insulation with a yellow tracer - AWG #12 (3.3 mm can be used to minimize resistance. Conductors must always be large enough to carry the maximum short circuit current of the path being considered.

PROGRAMMING

DEVICE

PLC CABINET

RACK

EARTH

GROUND

MOTOR DRIVES

AND OTHER

ELECTRICAL

CONTROL

EQUIPMENT

CENTRAL

GROUND POINT

MACHINERYSERIES 90-30

NOTE

SIGNAL AND POWER

CONNECTIONS

ARE NOT SHOWN

) or larger)

Figure 2-10. Recommended System Grounding

GFK-0356Q Chapter 2 Installation 2-11

Page 50

XPA

Series 90-30 PLC Equipment Grounding

Equipment grounding recommendations and procedures are listed below. These grounding procedures must be properly followed for safe, proper operation of your Series 90-30 PLC system.

Baseplate Safety Grounding

The following recommendations are offered, but applicable safety codes for your area or equipment type should also be consulted. The baseplate’s metal back must be grounded using a separate conductor; the baseplate mounting screws are not considered to an acceptable ground connection by themselves. Use a minimum AWG #12 (3.3 mm washer under the head of one of the baseplate’s two lower mounting holes. These two holes have openings to the side to allow connecting a wire and ring terminal under the head of a mounting screw. Connect the other end of this ground wire to a tapped hole in the panel that the baseplate is mounted to, using a machine screw, star lock washer, and flat washer. Alternately, if your panel has a ground stud, it is recommended you use a nut and star lock washer for each wire on the ground stud to ensure adequate grounding. Where connections are made to a painted panel, the paint should be removed so clean, bare metal is exposed at the connection point. Terminals and hardware used should be rated to work with the aluminum baseplate material.

) wire with a ring terminal and star lock

PROGRAMMABLE

CONTROLLER

BASE 5-SLOT

CAUTION

USER PROGRAM

AWG #12 or Larger Wire

Paint Removed From Panel Here

AND REGISTER VALUES MAY BE LOST IF POWER

SUPPLY IS

REMOVED FOR

LONGER THAN

1 HOUR

POWER SUPPLY

Screw, Star Lock washer, Flat Washer, Ring Terminal, installed in tapped hole.

Figure 2-11. Baseplate Grounding

All baseplates must be grounded to minimize electrical shock hazard. Failure to do so can result in severe personal injury.

CPU/1

Warning

NON-CPU SLOTS

I/O-2 I/O-3 I/O-4 I/O-5

Alternate location for Ground connection

N S

O N

2-12 Series 90-30 PLC Installation and Hardware Manual – August 2002 GFK-0356Q

Page 51

All baseplates grouped together in a Series 90-30 PLC system must have a common ground connection. This is especially important for baseplates that are not mounted in the same control cabinet.

Grounding 19" Rack-Mounted Baseplates

There are two Adapter Brackets used for mounting a 10-slot Series 90-30 baseplate to a 19” Rack. Regardless of which of the two Adapter Brackets is used, the 19” Rack should be grounded as per the instructions in “System Grounding Procedures,” including Figure 2-10. (For details on the Adapter Brackets, see the “Mounting a Baseplate to a 19” Rack” section earlier in this chapter.)

Nineteen-Inch Rack-mounted PLC baseplates should be grounded according to the guidelines in the “Baseplate Safety Grounding” section, using a separate ground wire from the PLC baseplate as shown in the previous figure (Fig. 2-11).

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

installed as shown in Figure 2-11 with the ground attached to the Recessed Mount Adapter Bracket. An additional ground wire connecting the Adapter Bracket to a solid chassis ground on the 19” Rack should be installed. Use the same or equivalent hardware and paint removal scheme as shown in Figure 2-11.

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

run from the baseplate as shown in Figure 2-11, to a solid chassis ground on the 19” Rack. Use the same or equivalent hardware and paint removal scheme as shown in Figure 2-11.

Programmer Grounding

For proper operation, the computer (programmer) running the PLC software must have a ground connection in common with the CPU baseplate. Normally, this common ground connection is provided by ensuring that the programmer’s power cord is connected to the same power source (with the same ground reference point) as the baseplate. If it is not possible to ensure this common ground scheme, use a port isolator (IC690ACC903) between the programmer and PLC serial connection. If the programmer ground is at a different potential than the PLC ground, a shock hazard could exist. Also, damage to the ports or converter (if used) could occur when the programmer serial cable is connected between the two.

Warning

Failure to follow programmer grounding recommendations could result in personal injury, equipment damage, or both.

GFK-0356Q Chapter 2 Installation 2-13

Page 52

Module Shield Grounding

In general, the aluminum PLC baseplate is used for module shield grounding. On some Series 90-30 modules, shield connections to the user terminal connector on the module are routed to the baseplate through the module’s backplane connector. Other modules, such as CPUs 351, 352, 363, 364, and 374 require a separate shield ground. These are discussed in the next several sections.

Shield Grounding Information for CPUs with External Port Connections

CPUs with external port connections, the 351, 352, 363, 364, and 374 must have a separate shield ground connection to provide shielding for these ports. Because the design of the ground connection for the CPU351 and 352 is different from that of the CPU363, 364, and 374, each grounding method is discussed in a separate section.

CPU351 and 352 Shield Grounding

The CPU 351 or 352 module must be connected to frame ground at the slot where it is installed. Two methods are provided for making this ground connection. Each CPU comes with an EMC Grounding Kit (44A737591-G01) that contains a ground wire, grounding bracket, and screws.

1. The connection from the CPU to frame ground can be made using the ground wire (part number 44A735970-001R01) that comes with the module in the EMC Grounding Kit. This wire has a stab-on connector on one end for connection to a mating terminal on the bottom of the CPU, and a ring terminal on the other end for connection to a grounded enclosure. Where the ring terminal contacts a painted enclosure panel, either a star lock washer can be installed between the terminal and the panel to cut through the paint, or the paint can be scraped away down to clean, bare metal to ensure a good contact. Note: The star lock washer method is

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

CPU351 or 352

#6 TAPPED HOLE

REMOVE PAINT UNDE RING TERMINAL OR INSTALL STAR LOCK WASHER BETWEEN TERMINAL AND PANEL

STAB-ON

CONNECTO

BOTTOM OF

CPU MODULE

USE 1 #6

MACHINE SCREW

44A735970-001R01

MOUNT ON

GROUNDED

ENCLOSURE

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

2-14 Series 90-30 PLC Installation and Hardware Manual – August 2002 GFK-0356Q

Page 53

2. The second method, which can be used for systems in noisy environments consists of installing the green ground wire and the optional grounding bracket (part number 44C715646-001R01). This bracket attaches to the CPU using two #4 thread-rolling screws (part number N666P9004B6) and to the grounded enclosure using two #6 thread-rolling screws (part number N666P13006B6). Two holes must be drilled in the enclosure for mounting this bracket. Also, if the bracket will be attached to a painted surface, the paint should be removed down to bare metal under the bracket to ensure good contact between the bracket and the surface. See the next figure.

CPU351 or 352

USE 2 #4

HREAD ROLLING SCREWS

(N666P9004B6)

44C715646-001R01

BRACKET

THREAD ROLLING SCREWS

(N666P13006B6

USE 2 #6

MOUNT ON

GROUNDED

ENCLOSURE

PAINT REMOVED WHERE BRACKET MOUNTS TO PANEL

Figure 2-13. CPU 351 or 352 - Mounting the Shield Grounding Bracket and Wire

Note: When the grounding bracket is used, pin 1 of the cable connector that plugs into the Port 2

connector should not be connected. A metal connector shell must be used on the cable for this port, and the cable shield must be terminated at the metal shell instead of pin 1 of the connector.

GFK-0356Q Chapter 2 Installation 2-15

Page 54

CPU363, CPU364, and CPU374 Shield Grounding

The CPU363, CPU364, and CPU374 modules must be connected to frame ground at the slot where they are installed. Each module comes with a grounding wire for this purpose. These modules do not support or require the use of a grounding bracket. If the ring terminal on the grounding wire is to be mounted to a painted surface, remove the paint under the ring terminal to ensure good contact, or place a star lock washer between the ring terminal and the painted surface. See the next figure.

Note: The star lock washer method is suitable for a shield ground, but not suitable for a safety ground.

CPU363, CPU364, or CPU374

STAB-ON

CONNECTOR

#6 TAPPED HOLE

BOTTOM

OF CPU MODULE

USE 1 #6

MACHINE SCREW

44A735970-001R01

MOUNT ON GROUNDED

ENCLOSURE

REMOVE PAINT UNDER RING TERMINAL OR INSTALL STAR LOCK WASHER BETWEEN RING TERMIN AL AND

Figure 2-14. CPU 363, CPU364, or CPU374 - Attaching Ground Wire

Additional Modules with Shield Grounding Requirements

Some of the Series 90-30 Option modules, such as the FIP Remote I/O Scanner (IC693BEM330), and DSM modules (IC693DSM302 and IC693DSM314) also have shield grounding requirements. These modules come equipped with suitable grounding hardware. Please refer to each module’s user’s manual for grounding instructions. Appendix G contains a product to publication crossreference to help you identify the correct manual.

2-16 Series 90-30 PLC Installation and Hardware Manual – August 2002 GFK-0356Q

Page 55

General Wiring Guidelines

In addition to the following wiring suggestions, we strongly urge that you follow all wiring and safety codes that apply to your area or your type of equipment. For example, in the United States, most areas have adopted the National Electrical Code standard and specify that all wiring conform to its requirements. In other countries, different codes will apply. For maximum safety to personnel and property you must follow these codes. Failure to do so can lead to personal injury or death, property damage or destruction, or both.

Color Coding Wires

These color codes are commonly used in industrial equipment manufactured in the United States. They are cited here as a reference. Where they are in conflict with codes that apply to your area or your type of equipment, you should follow your applicable codes instead. Besides satisfying code requirements, wire color coding makes testing and troubleshooting safer, faster, and easier.

Warning

■ Green or green with stripe- Ground

■ Black - Primary AC

■ Red - Secondary AC

■ Blue - DC

■ White - Common or neutral

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

personnel that there may be power present (from an external source) even if the equipment is disconnected from its main power source.

Wire Routing

To reduce noise coupling among PLC wires, it is recommended you keep electrically noisy wiring, such as AC power wiring and Discrete Output Module wiring, physically separated from low-level signal wiring such as DC and Analog Input module wiring or communications cables. This can be accomplished by grouping separately, where practical, the following categories of wiring:

■ AC power wiring. This includes the AC input to the PLC power supply, as well as other AC devices in the control cabinet.

■ Analog Input or Output Module wiring. This should be shielded to further reduce noise coupling. See the Series 90-30 I/O Module Specifications Manual, GFK-0898 for details.

■ Discrete Output Module wiring. These often switch inductive loads that produce noise spikes when switched off.

■ DC Input Module wiring. Although suppressed internally, these low-level inputs should be further protected against noise coupling by observing these wiring practices.

■ Communications Cables. Wiring such as Genius Bus or serial cables should be kept away from noise-producing wiring.

GFK-0356Q Chapter 2 Installation 2-17

Page 56

Where AC or Output wiring bundles must pass near noise-sensitive signal wiring bundles, avoid running them beside each other. Route them so that, if they have to cross, they do so at a right angle. This will minimize coupling between them.

Grouping Modules to Keep Wires Segregated

If practical, grouping similar modules together in the PLC racks can help keep wiring segregated. For example, one rack could contain only AC modules, and a different rack only DC modules, with further grouping in each rack by input and output types. For smaller systems, as an example, the left end of a rack could contain Analog modules, the middle could contain DC modules, and the right end could contain AC modules.

Discrete I/O Module Connection Methods

■ For modules with 16 points or less, the standard method is to use the removable terminal board which comes with these modules. The removable terminal board makes it easy to prewire field wiring to the user supplied input and output devices, and to replace modules in the field without disturbing existing field wiring.

■ Some discrete 16-point I/O modules can be used with an optional Terminal Block Quick Connect (TBQC) assembly. This assembly contains a module faceplate, with built-in connector, that replaces the removable terminal board. The assembly also contains a DIN-rail mounted terminal block and a cable to connect the module to the terminal block. The advantage of this method is that it saves about two hours of wiring time per module compared with hand wiring from a module’s removable terminal board to a user-supplied, panel-mounted terminal block or strip.

■ Older 32-point I/O modules have one 50-pin connector on the front of the module that is either connected by a cable with a connector on each end to a Weidmuller panel-mounted terminal block (Weidmuller catalog no. 912263), or is connected by a cable with stripped, tinned leads to a user-supplied terminal block or strip.

■ Newer 32-point I/O modules have two 24-pin connectors on the front of the module. These module may be wired in one of three ways. (1) Use a pair of cables (IC693CBL327/328 - see data sheet in “Cables” chapter) to connect the module to a user-supplied, panel-mounted terminal block or strip. These cables have a 24-pin connector on one end, and stripped, tinned leads with wire markers on the other end. (2) Use a pair of dual-connector cables to connect the module to a Terminal Block Quick Connect (TBQC) terminal block (IC693ACC377). See Appendix H for details. (3) Make your own custom cables. Instructions are found in the IC693CBL327/328 data sheet in Chapter 10.

Connections to I/O Module Terminal Boards

Series 90-30 PLC I/O terminal boards have either 10 or 20 screw terminals that will accept from two AWG #22 (0.36 mm (194°F) wire(s). Each terminal can accept solid or stranded wires, but the wires into any given terminal should be the same type (both solid or both stranded) to ensure a good connection. Wires are routed to and from the terminals out of the bottom of the terminal board cavity. The suggested torque for the I/O terminal board connection screws is from 9.6 in-lbs to 11.5 in-lbs (1.1–1.3 Newton-meters).

) to two AWG #16 (1.3 mm2), or one AWG #14 (2.1 mm2) copper 90°C

2-18 Series 90-30 PLC Installation and Hardware Manual – August 2002 GFK-0356Q

Page 57

For 24 volt DC input modules, an internal 24 volt power connection is provided on the terminal board to supply a limited number of input devices. Also, a 24 volt DC output is available on the power supply module’s terminal board to supply a limited number of output devices.

Terminal Block Quick Connect Installation for 16-Point Discrete Modules

The Terminal Block Quick Connect (TBQC) Assembly is an option for certain Series 90-30 discrete I/O modules. See Appendix H for more information.

■ Remove standard terminal board from module.

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

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

on a standard 35 mm DIN-rail.

■ Connect a TBQC cable between the TBQC faceplate connector on the module and the connector on the TBQC terminal block.

■ Wire I/O devices to the terminal block.

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

These 50-Pin modules are an older design and are not generally used on new systems, unless to fulfill standardization requirements. They are mainly used as replacements for existing installations. For new installations, we recommend the dual 24-pin connector style because they have additional features not found on the older modules (LED indicators, TBQC), and it is much easier to fabricate custom-length cables for them. Installation information is provided here for the convenience of those still using these modules.

Using Weidmuller #912263 Terminal Block

Note: The TBQC is not available for these modules, but you may purchase a Weidmuller #912263 from your electronics distributor for this application.

■ Mount the Weidmuller#912263 terminal block. It has a 50-pin connector and a terminal strip, and mounts on a standard 35 mm DIN-rail.

■ Connect an IC693CBL306/307 cable between the module’s faceplate connector and the connector on the Weidmuller terminal block. See Chapter 10 for cable data.

■ Wire I/O devices to the terminal block. See the Series 90-30 PLC I/O Module Specifications Manual, GFK-0898, for pin-out information.

GFK-0356Q Chapter 2 Installation 2-19

Page 58

Using a Generic Terminal Block or Strip

■ Mount terminal block/strip to the enclosure panel.

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

connector and wire the stripped ends of the cable to the terminal block/strip. See Chapter 10 for cable data.

■ Wire I/O devices to the terminal block/strip.

Direct Method

■ Connect an IC693CBL308 or 309 cable, or a custom made cable, to the module’s faceplate connector and wire the stripped ends of the cable directly to the field devices. See Chapter 10 for cable data. See the Series 90-30 PLC I/O Module Specifications Manual, GFK-0898, for pin-out information.

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

Using a TBQC

■ Mount two TBQC terminal blocks. Each has a 24-pin connector and a terminal strip, and mounts on a standard 35 mm DIN-rail.

■ Connect a pair of TBQC cables (IC693CBL329 - 334) between the module’s faceplate connector and the connectors on the two TBQC terminal blocks. Note that both a right side and left side cable is required. See Appendix H for a list of cables.

■ Wire I/O devices to the terminal blocks. See the Series 90-30 PLC I/O Module Specifications Manual, GFK-0898, for pin-out information.

The Terminal Block Quick Connect (TBQC) Assembly is an option for certain Series 90-30 discrete I/O modules. See Appendix H for more information.

With a Generic Terminal Block/Strip

■ Mount terminal block/strip to the enclosure panel.

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

connectors, and wire the stripped ends of the cables to the terminal block/strip. Note that both a right side and left side cable is required. See Appendix H for a list of cables. See Chapter 10 for cable data sheets.

■ Wire I/O devices to the terminal block/strip. See the Series 90-30 PLC I/O Module Specifications Manual, GFK-0898, for pin-out information.

2-20 Series 90-30 PLC Installation and Hardware Manual – August 2002 GFK-0356Q

Page 59

Direct Method

■ Connect an IC693CBL327/328 cable, or a custom made cable, to the module’s faceplate connectors, and wire the stripped ends of the cable directly to the field devices. See Chapter 10 for cable data. See the Series 90-30 PLC I/O Module Specifications Manual, GFK-0898, for pin-out information.

General Wiring Methods for Analog Modules

Twisted, shielded instrumentation cable is strongly recommended for analog module input or output signal connections. Proper grounding of the shield is also important. For maximum electrical noise suppression, the cable shield should only be grounded at one end of the cable. For Input modules, ground the end that is in the noisiest environment (which often is at the field device end). For Output modules, ground at the module end. See GFK-0898, Series 90-30 PLC I/O Module Specifications, for more shield grounding information.

Analog Input Module Wiring Methods

Correcting electrical noise problems can sometimes be a trial-and-error routine. However, in general, it is generally best to ground the cable shield as close to the source of the noise as possible, which is usually at the device end. In troubleshooting noise problems, sometimes it is beneficial to experiment with the shield grounding point location. Remember, the cable shield should be grounded at one end only. Also, it is best to keep the length of stripped cable leads as short as possible to minimize the length of unshielded conductors that will be exposed to the noisy environment. See the Series 90-30 PLC I/O Module Specifications Manual, GFK-0898 for additional details.

Using a Generic Terminal Block or Strip

■ Mount a terminal strip inside the control enclosure and run a shielded cable from the terminal strip to each input circuit on the module’s terminal board terminals.

■ Connect each cable’s shield to the metal panel next to the terminal strip. Do not connect the shields at the module end (cut shield off at module end of cable and insulate with shrink tubing).

■ Wire the field device to the terminal strip with a shielded cable, grounding the shield at the device end only (cut shield off at terminal strip end of cable and insulate with shrink tubing). Also, keep the length of exposed (outside of shield) leads at the terminal strip and device ends as short as possible.

Direct Method

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

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

GFK-0356Q Chapter 2 Installation 2-21

Page 60

■ Ground the shield at the field device end, exposing a minimum amount of conductor to the noisy environment. Do not connect the shield at the module end (cut shield off at module end of cable and insulate with shrink tubing).

TBQC not Recommended for Analog Modules

The Terminal Block Quick Connect (TBQC) Assembly is not recommended for use with analog modules due to cable shielding requirements.

Analog Output Module Wiring

General

Each output should be connected using a good quality shielded wire with the cable shield grounded at the module end. See GFK-0898, Series 90-30 PLC I/O Module Specifications, for more information.

Using a Generic Terminal Block or Strip

■ Mount a terminal strip inside the control enclosure and run a shielded cable from the terminal strip to each output circuit on the module’s terminal board terminals.

■ Ground each cable’s shield at the module end only. Do not connect the shields at the terminal strip end (cut shields off at terminal strip end of cables and insulate with shrink tubing).

■ Wire the field device to the terminal strip with shielded cables, grounding the shields at the terminal strip end only (cut shields off at field device end of cables and insulate with shrink tubing). Also, keep the length of exposed (outside of shield) leads at the terminal strip and device ends as short as possible.

Direct Method

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

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

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

noisy environment. Do not connect the shield at the device end (cut shield off at device end of cable and insulate with shrink tubing).

TBQC not Recommended for Analog Modules

The Terminal Block Quick Connect (TBQC) Assembly is not recommended for use with analog modules due to cable shielding requirements.

2-22 Series 90-30 PLC Installation and Hardware Manual – August 2002 GFK-0356Q

Page 61

AC Power Source Connections

AC Input Wiring to AC/DC Power Supplies

If the same AC power source is used to provide AC power to other baseplates in a Series 90-30 PLC System, ensure that all AC input connections are identical at each rack. Do not cross Line 1 (L1) and Line 2 (L2). A resulting difference in potential can injure personnel or cause damage to equipment. Each baseplate must be connected to a common ground.

Ensure that the protective cover is installed over all terminal boards. During normal operation with an AC power source either 120 VAC or 240 VAC is present on the AC Power Supply. The cover protects against accidental shock hazard which could cause severe or fatal injury to the operator or maintenance personnel.

Both the Standard (IC693PWR321) and High Capacity (IC693PWR330) AC/DC power supplies currently have six terminals for user connections. Early versions of some Series 90-30 power supplies had five terminals (see next figure). The wiring methods for both five-terminal and sixterminal types is similar, except that step 3 below does not apply to the five-terminal type.

The power supply terminal boards will accept one AWG #14 (2.1 mm

) copper 75_ C (167_ F) wires. Each terminal can accept solid or stranded wires, but the wires

in any given terminal should be the same type. The suggested torque for the power supply terminal board is 12 in-lbs (1.36 Newton-meters). Open the door protecting the terminal board and make the following connections from the AC power source, and ground connections (system grounding requirements are described in detail later in this chapter).

Warning

) or two AWG #16 (1.3

1. These are wide range supplies that can operate from an AC power source within the nominal range of 100 VAC to 240 VAC at 50/60 Hz. This may vary -15% to +10% for a total maximum range of 85 VAC to 264 VAC. These are auto-ranging supplies that do not require jumper or switch settings for selection of power source voltage.

2. Connect the hot and neutral wires or lines L1 and L2 to the upper two terminals on the terminal board. Connect the safety ground wire to the ground terminal, which is the third terminal from the top, and is marked with a ground symbol.

3. For power supplies with six terminals, the factory jumper between the 3rd and 4th terminals (see figure below), should be left in place for normal installations. However, this jumper must be removed and external surge suppressors installed in installations with a “Floating Neutral” input. Please see the section “Special Instructions for Floating Neutral (IT) Systems” later in this chapter for details.

4. After all connections to Power Supply terminal board have been completed, the protective cover plate should be carefully reinstalled.

GFK-0356Q Chapter 2 Installation 2-23

Page 62

INPUT

100-240 VAC

50/60HZ 90VA

Input Power

Factory Jumper

24 VDC Output

For I/O Modules

125 VDC, 50W

24 VDC OUTPUT

0.8A MAX.

Six-Terminal Board

Figure 2-15. Power Supply Terminal Boards

Power Supply Overvoltage Protection Devices

The overvoltage protection devices for this power supply are connected internally to pin 4 on the user terminal board. This pin is normally connected to frame ground (pin 3) with the supplied jumper strap which is installed at the factory. If overvoltage protection is not required or is supplied upstream, this feature can be disabled by leaving pin 4 unconnected by removing the jumper strap. Also, this jumper must be removed and external surge suppressors installed in installations with a “Floating Neutral” input, please see the following section “Special Instructions for Floating Neutral (IT) Systems” later in this chapter.

Input Power

24 VDC Output

For I/O Modules

Five-Terminal Board

INPUT

100-240 VAC

50/60HZ 90V

125 VDC, 50W

24 VDC OUTPUT

0.8A MAX.

If you want to Hi-pot test this supply, overvoltage protection must be disabled during the test by removing the terminal board strap. Re-enable overvoltage protection after testing by reinstalling the strap.

a47086

Jumper Strap Connects

Overvoltage Protection

Devices to Frame Ground

Frame Ground

Screw Terminal s

on Terminal Board

Figure 2-16. Overvoltage Protection Devices and Jumper Strap

2-24 Series 90-30 PLC Installation and Hardware Manual – August 2002 GFK-0356Q

Page 63

Special Installation Instructions for Floating Neutral (IT) Systems

When the AC input power supplies listed below are installed in a system where the Neutral line is not referenced to Protective Earth Ground, these special installation instructions must be followed to prevent damage to the power supply.

IC693PWR321S (or later version) IC693PWR330A (or later version)

Definition of Floating Neutral Systems

A Floating Neutral System is a system of power distribution wiring where Neutral and Protective Earth Ground are not tied together by a negligible impedance. In Europe this is referred to as an IT system (see IEC950). In a Floating Neutral System, voltages measured from input terminals to protective earth ground may exceed the 264 Volts AC maximum input voltage specified in the power supply specifications in Chapter 24in this manual.

Example of Floating Neutral System

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

Systems in which one leg of the power distribution wiring is tied to Protective Earth or a tap between two legs of the power distribution wiring is tied to Protective Earth are not Floating Neutral Systems.

Examples of Non-Floating Neutral System

N/PE

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

GFK-0356Q Chapter 2 Installation 2-25

Page 64

Use These Special Installation Instructions for Floating Neutral Systems

1. The input power terminals should be wired according to the instructions in the “AC Power Source Connections” section of this chapter.

2. 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.

3. 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)

The expression N-PE refers to the voltage potential between neutral and Protective Earth (PE) ground.

MAX.

For example, in a 240 Volt AC system with neutral floating 50V above earth ground, the transient protection should be rated at:

240V + 100V +50V = 390V

2-26 Series 90-30 PLC Installation and Hardware Manual – August 2002 GFK-0356Q

Page 65

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

Page 66

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.

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

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.

Warning

2. 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.

3. Mark the hole locations for the baseplate safety ground wire (see “Baseplate Safety Ground” in this chapter).

4. Mark the hole locations for module shield ground connections (if any). See “Module Shield Ground” (and accompanying sections) in this chapter for instructions.

5. 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.

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

7. 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.

8. 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

2-28 Series 90-30 PLC Installation and Hardware Manual – August 2002 GFK-0356Q

Page 67

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.

9. 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

Page 68

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

Page 69

56 1 7 8

PROGRAMMABLE

CONTROLLER

BASE 5-SLOT

CAUTION

USER PROGRAM

AND REGISTER

VALUES MAY BE

LOST IF POWE R

SUPPLY IS REMOVED FOR LONGER THAN

1 HOUR

POWER SUPPLY

CPU/1

NON-CPU SLOTS

I/O-2 I/O-3 I/O-4 I/O-5

E X P A N S I O N

1. Module retainers

2. Upper mounting holes

3. Baseplate description

4. 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.

5. Backplane connector for Power Supply

6. Serial number label (on bottom edge of baseplate)

7. 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.

8. Slot number labels

9. 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.

3-2 Series 90-30 PLC Installation and Hardware Manual – August 2002 GFK-0356Q

Page 70

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 cablefeet 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

Page 71

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

Page 72

Replaceable System (firmware) PROM

PROGRAMMABLE

Description Label Says "With CPU"

Memory Backup Warning Label

CONTROLLER

BASE 5-SLOT

WITH CPU

CAUTION

USER PROGRAM

AND REGISTER

ALUES MAY BE

LOST IF POWER

SUPPLY IS REMOVED FO LONGER THAN

1 HOU

POWE SUPPLY

SYSTEM

PROM

PROGRAM

PROM

NON-CPU SLOTS

I/O-1 I/O-2 I/O-3 I/O-4 I/O-5

Socket for Optional Program PROM

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

PROGRAM

PROGRAMMABLE

CONTROLLER

BASE 10-SLOT

WITH CPU

CAUTION

USER PROGRAM

ND REGISTER VALUES MAY BE LOST IF POWER

SUPPLY IS

REMOVED FOR

LONGER THAN

1HOUR.

POWER

SUPPLY

SYSTEM

PROM

I/O-1

PROM

NON-CPU SLOTS

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

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

GFK-0356Q Chapter 3 Baseplates 3-5

Page 73

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

USER PROGRAM

AND REGISTER

VALUES MAY BE

LOST IF POWE R

SUPPLY IS REMOVED FOR LONGER THAN

1 HOUR

POWER SUPPLY

CPU/1

I/O-2 I/O-3 I/O-4 I/O-5

NON-CPU SLOTS

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

PROGRAMMABLE

CONTROLLER

BASE 10-SLOT

CAUTION

USER PROGRA M

AND REGISTER

VALUES MAY BE

LOST IF POWER

SUPPLY IS REMOVED FOR LONGER THAN

1 HOUR

POWER SUPPLY

NON-CPU SLOTS

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-10CPU/1

NON-CPU SLOTS

E X

P A N

I O N

E X P A N S

I O N

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

3-6 Series 90-30 PLC Installation and Hardware Manual – August 2002 GFK-0356Q

Page 74

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

XXXXXXXXX

■ 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.

EXPANSION RACK #

DIP

1 2 3 4 5 6 7

PROGRAMMABLE

CONTROLLER

BASE 5-S LOT

EXPANSION

POWER SUPPLY

1 2 3

X = CLOSED

E X P

ON-CPU SLOTS

I/O- 2 I/O- 3 I/O- 4 I/ O-5I/O- 1

A N S

I O N

Figure 3-6. IC693CHS398 5-Slot Expansion Baseplate

GFK-0356Q Chapter 3 Baseplates 3-7

Page 75

EXPANSION RACK #

DIP

1 2 3 4 5 6 7

XXX

PRO GRAMMAB LE

CONTROLLER

BASE 1 0-SLOT

EXPANSION

XXX

XX X

X = CLOSED

NON-CPU SLOTS

P A N S

I O N

SUPPLY

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-10I/O-1POWER

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.

3-8 Series 90-30 PLC Installation and Hardware Manual – August 2002 GFK-0356Q

Page 76

PROGRAMMABLE

CONTROLLER

BASE 5-SLOT

REMOTE

EXPANSION RACK #

DIP

1 2 3 4 5 6

XXX

XX X

X = CLOSED

NON-CPU SLOTS

A N

I O N

POWER SUPPLY

I/O-2 I/O-3 I/O-4 I/O-5I/O-1

Figure 3-8. IC693CHS399 5-Slot Remote Baseplate

EXPANSION RACK #

DIP

1 2 3 4 5 6 7

XXX

PROGRAMMABLE

CONTROLLER

BASE 10-SLOT

REMOTE

XXX

XX X

X = CLOSED

NON-CPU SLOTS

POWER SUPPLY

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-10I/O-1

Figure 3-9. IC693CHS393 10-Slot Remote Baseplate

NON-CPU SLOTS

E X P A N S

I O N

GFK-0356Q Chapter 3 Baseplates 3-9

Page 77

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

MALE

CONNECTOR

Figure B

MALE

CONNECTOR

Catalog Number Length Figure

IC693CBL300 3 feet (1 meter), continuous shield A

IC693CBL301 6 feet (2 meters), continuous shield A

IC693CBL302 50 feet (15 meters), continuous shield with

IC693CBL312 0.5 feet (.15 meters), continuous shield A

IC693CBL313 25 feet (8 meters), continuous shield A

Figure 3-10. I/O Bus Expansion Cables

.5, 3, 6, 26 FOOT

CABLES

MALE

CONNECTOR

50 FOOT

CABLE

MALE

CONNECTOR

built in terminator (this is not a Wye cable)

Note

The 3 foot cable (IC693CBL300) can be used as a Wye adapter between custombuilt cables and Remote baseplates.

3-10 Series 90-30 PLC Installation and Hardware Manual – August 2002 GFK-0356Q

Page 78

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

Page 79

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

Page 80

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 1 2 3 4 5* 6* 7*

1 open

closed

closed closed closed

closed

open open

open

closed

open

closed closed

closed

open open

open

open open open 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.

EXPANSION RACK #

DIP

GEFanuc

SERIES 90-30

PROGRAMMABLE

CONTROLLER

BASE 10-SLOT

EXPANSION

1234

XXX

X = CLOSED

5X6X7

= 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

Page 81

Expansion Rack Connection Example

The following example shows a system that includes Expansion baseplates.

PROGRAMMER

CPU 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 termination can be done with the I/O Bus Terminator Plug (IC693ACC307), by using the 50 foot (15 meter) cable (IC693CBL302) with built-in terminat ing resistors, or by building a cable with the resistors installed

custom the connector at the end of the

in bus.

SERIAL

C P U

DISCRETE/ANALOG/OPTION

EXPANSION BASEPLATE

DISCRETE/ANALOG/OPTION

EXPANSION BASEPLATE

DISCRETE/ANALOG/OPTION

EXPANSION BASEPLATE

DISCRETE/ANALOG/OPTION

EXPANSION BASEPLATE

NOTE

TOTAL MAXIMUM DISTANCE FROM CPU BASEPLATE

TO LAST EXPANSION

BASEPLATE IS

50 FEET (15 METERS)

I/O EXPANSION CABLES

I/O BUS

TERMINATOR

PLUG (See *NOTE)

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

Page 82

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

C P U

EXPANSION

BASEPLATE

IC693CHS392/398

Maximum Cable Distance from CPU = 50 Feet

(15 meters)

REMOTE

BASEPLATE

IC693CHS393/399

REMOTE

BASEPLATE

IC693CHS393/399

REMOTE

BASEPLATE

IC693CHS393/399

Maximum Cable Distance from CPU = 700 Feet

(213 meters)

EXPANSION BASEPLATE

REMOTE BASEPLATE

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

Page 83

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

(102)

POWER

SUPPLY

3.54 (90)

.79

(20)

ALLOWANCE FOR COOLING

10.43 (265)

9.84

(250)

FRONT VIEW

8.60

(218)

4.00

(102)

.20 DIA.

(5.08)

(TYPICAL)

4.00

(102)

5.12

(130)

4.00

(102)

DIMENSIONS IN INCHES,

MILLIMETERS ARE IN PARENTHESIS

REMOVABLE

I/O

TERMINAL

BLOCK

HINGED

DOOR

5.59

(142)

SIDE VIEW

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

Page 84

4.00

(102)

POWER SUPPLY

3.54 (90)

.79

(20)

ALLOWANCE FOR CO OLING

17.44 (443)

16.85 (428)

FRONT VIEW

15.60 (396)

4.00

(102)

.20 DIA.

(5.08)

(TYPICAL )

MILLIMET ERS ARE IN PARENTHE SIS

4.00

(102)

REMOVABLE

TERMINAL

BLOCK

5.12

(130)

HINGED

DOOR

4.00

(102)

Figure 3-15. Model 323 10-Slot Baseplate Dimensions and Spacing Requirements

DIMENSIONS IN INCHES,

I/O

SIDE VIEW

5.59

(142)

GFK-0356Q Chapter 3 Baseplates 3-17

Page 85

Modular CPU, Expansion, and Remote Baseplate Dimensions

Baseplate dimensions and spacing requirements for installation for Modular CPU baseplates are shown below.

DIMENSIONS IN INCHES,

MILLIMETERS ARE IN PARENTHESIS

REMOVABLE

I/O

TERMINAL

BLOCK

HINGED

DOOR

POWER

SUPPLY

10.43 (265)

9.84

(250)

FRONT VIEW

8.60

(218)

4.00

(102)

3.54 (90)

.79

(20)

If the cable i s used, allow about 6 inch horizont al clearanc e

NOTE:

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

4.00

(102)

SEE

NOTE

.20 DIA.

(5.08)

(TYPICAL)

4.00

(102)

5.12 (130)

4.00

(102)

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

4.00

(102)

POWER

SUPPLY

3.54 (90)

17.44 (443)

16.85 (428)

15.60 (396)

4.00

(102)

SEE

NOTE

.20 DIA.

(5.08)

(TYPIC AL)

4.00

(102)

5.12

(130)

DIMENSIONS IN INCHES,

MILLIMET ERS ARE IN PARENTHESIS

REMOVABLE

I/O

TERMINAL

BLOCK

SIDE VIEW

5.59

(142)

CONNECTOR

FOR

EXPANSION

CABLE

5.59

(142)

NOTE:

.79

(20)

IF THE CABL E IS USED, ALLOW ABOUT 6 I NCH HORIZONTAL CLEARANC E

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

ALLOWANCE FOR COOLING

FRONT V IEW

HINGED

DOOR

4.00

(102)

SIDE VIEW

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

Page 86

Load Ratings, Temperature, and Mounting Position

The power supply load rating depends on the mounting position of the baseplate and the ambient temperature.

The load rating with the baseplate mounted upright on a panel is:

■ 100% at 60°C (140°F)

Power supply load ratings with the baseplate mounted horizontally are:

■ temperature at 25°C (77°F) – full load

■ temperature at 60°C (140°F) – 50% of full load

GFK-0356Q Chapter 3 Baseplates 3-19

Page 87

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

Note: Baseplate is shown with cover removed for illustration purposes. It is not necessary to remove the baseplate cover to install the bracket.

Insert two screws (1 at top; 1 at bottom) from back of base unit through base uni and bracket. Tighten screws to secure bracket to base unit.

Figure 3-18. IC693ACC308 Front Mount Adapter Bracket Installation

3-20 Series 90-30 PLC Installation and Hardware Manual – August 2002 GFK-0356Q

Page 88

Dimensions for rack mounting a 10-slot baseplate with the IC693ACC308 Front Mount Adapter Bracket are shown in the following figure.

18.89 (480)

DIMENSIONS IN INCHES (MILLIMETERS IN

Figure 3-19. Dimensions for 19” Rack Mounting Using IC693ACC308 Adapter Bracket

0.160 (4.06) dia. x 4

18.47 (469)

0.280 (7.1)

3.540 (90)

1.630 (41.4)

0.346 (8.8) Inside

0.439 (11.2)

0.842 (21.4)

16.850 (428)

18.122 (460.3)

DIMENSIONS IN INCHES (MILLIMETERS IN PARENTHESES)

Figure 3-20. IC693ACC313 Recessed Mount Adapter Bracket

4.000 (101.6)

1.368 (34.7)

GFK-0356Q Chapter 3 Baseplates 3-21

Page 89

Baseplate Comparison Table

Table 3-2. Series 90-30 Baseplate Comparison

Catalog Number Type Size (Slots)

IC693CPU311 Embedded CPU 5

IC693CPU313 Embedded CPU 5

IC693CPU323 Embedded CPU 10

IC693CHS397 Modular CPU 5

IC693CHS391 Modular CPU 10

IC693CHS398 Expansion 5

IC693CHS392 Expansion 10

IC693CHS399 Remote 5

IC693CHS393 Remote 10

Series 90-30 Baseplates

3-22 Series 90-30 PLC Installation and Hardware Manual – August 2002 GFK-0356Q

Page 90

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

Number

IC693PWR321 30 Watts 100 to 240 VAC or

IC693PWR330 30 Watts 100 to 240 VAC or

IC693PWR322 30 Watts 24 or 48 VDC +5 VDC

IC693PWR328 30 Watts 48 VDC +5 VDC

IC693PWR331 30 Watts 24 VDC +5 VDC

Total of all outputs combined cannot exceed 30 watts.

Load

Capacity

Nominal

Input Output Capacities (Voltage/Power *)

125 VDC

+5 VDC 15 watts

+5 VDC 30 watts

15 watts

30 watts

+24 VDC Isolated 20 watts

+24 VDC Relay 15 watts

GFK-0356Q 4-1

Page 91

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

Number

Load

Capacity

Nominal

Input Output Capacities (Voltage/Power *)

IC693PWR321 30 Watts 100 to 240 VAC or

125 VDC

Total of all outputs combined cannot exceed 30 watts.

IC693PWR321

CONNECTIONS

FOR

AC/DC POWER

SOURCE

INTERNAL

POWER SOURCE

FOR

MODULES REQUIRING

24VDC

LITHIUM BACK-UP BATTERY

+5 VDC 15 watts

GE Fanuc

SERIES 90-30

STANDARD

POWER SUPPLY

PROGRAMMABLE CONTROLLER

INPUT

100-240 VAC

50/60HZ 90 VA

125 VDC, 50W

24 VDC

OUTPUT

0.8A MAX.

B A T T E R Y

+24 VDC Isolated 20 watts

∼

PWR

RUN

BATT

SYSTEM STATUS INDICATORS

RS-485 COMPATIBLE SERIAL PORT

BATTERY

CONNECTORS

+24 VDC Relay 15 watts

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

Page 92

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

Nominal Rated Voltage Input Voltage Range

AC DC

Input Power (Maximum with Full Load)

Inrush Current

Output Power

Output Voltage

Protective Limits

Overvoltage: Overcurrent:

Holdup Time:

120/240 VAC or 125 VDC

85 to 264 VAC 100 to 300 VDC

90 VA with VAC Input 50 W with VDC Input

4A peak, 250 milliseconds maximum

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)

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

5 VDC output: 6.4 to 7 V 5 VDC output: 4 A maximum

20 milliseconds minimum

GFK-0356Q Chapter 4 Power Supplies 4-3

Page 93

BATTERY

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

Number

IC693PWR330 30 Watts 100 to 240 VAC or

Total of all outputs combined cannot exceed 30 watts.

Load

Capacity

125 VDC

IC693PWR330

CONNECTIONS FOR

AC/DC POWER SOURCE

Nominal

Input Output Capacities (Voltage/Power *)

+5 VDC 30 watts

PROGRAMMABL

+24 VDC Isolated 20 watts

GE Fanuc

Series 90-30

HIGH CAPACITY

POWER SUPPLY

INPUT

100-240 VAC

50/60 HZ 100VA

125VDC, 50W

PWR OK

RUN

BATT

CONTROLLER

+24 VDC Relay 15 watts

SYSTEM STATUS

INDICATORS

INTERNAL POWER SOURCE FOR

MODULES REQUIRING 24VDC

LITHIUM BACK-UP BATTERY

24 VDC

OUTPUT

0.8A MAX.

RS-485 COMPATIBLE SERIAL PORT

BATTERY

CONNECTORS

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

Page 94

Table 4-5. Specifications for IC693PWR330 High Capacity AC/DC Input Power Supply

Nominal Rated Voltage Input Voltage Range

AC DC

Input Power (Maximum with Full Load)

Inrush Current

Output Power

Output Voltage

Protective Limits

Overvoltage: Overcurrent:

Holdup Time:

120/240 VAC or 125 VDC

85 to 264 VAC

100 to 300 VDC

100 VA with VAC Input

50 W with VDC Input

4A peak, 250 ms maximum

5 VDC: 24 VDC Relay: 24 VDC Isolated:

NOTE:

5 VDC: 24 VDC Relay: 24 VDC Isolated:

5 VDC output: 5 VDC output:

20 ms minimum

30 watts maximum

15 watts maximum

20 watts maximum

30 watts maximum total (all three outputs)

5.0 VDC to 5.2 VDC (5.1 VDC nominal) 24 to 28 VDC

21.5 VDC to 28 VDC

6.4 to 7 V

7 A maximum

Field Wiring Connections for the AC/DC Input Power Supplies

The two AC/DC input power supplies have six terminals for user connections. These connections are described below.

AC Power Source Connections

The Hot, Neutral, and Ground wires from the 120 VAC power source or L1, L2, and Ground wires from the 240 VAC power source connect to the system through the top three terminals of the terminal strip on the front of the power supply.

DC Power Source Connections

Connect the + and - wires from the 125 VDC (nominal) power source to the top two terminals on the terminal connector. These connections are not polarity-sensitive on an AC/DC input power supply. (However, the DC Input-only type supplies, which are discussed later in this chapter, are polarity sensitive.)

Input Overvoltage Protection Devices

This information applies to all Series 90-30 power supplies except IC693PWR322 and IC693PWR328. The overvoltage protection devices for this power supply are

connected internally to pin 4 on the user terminal strip. This pin is normally connected to frame ground (pin 3) with the supplied jumper strap which is installed at the factory. If overvoltage protection is not required or is supplied upstream, this feature can be disabled by removing the jumper strap from pins 3 and 4.

GFK-0356Q Chapter 4 Power Supplies 4-5

Page 95

If you want to Hi-pot test this supply, overvoltage protection test by removing the terminal strip jumper strap. Re-enable overvoltage protection after testing by reinstalling the strap.

Jumper Strap Connects

Overvoltage Protection

Devices to Frame Ground

Figure 4-3. Overvoltage Protection Devices and Jumper Strap

Isolated 24 VDC Supply Output Connections

The bottom two terminals of the power supply terminal strip provide connections to the Isolated +24 volt DC output which can be used to provide power for external circuits (within power limitations of the supply).

Screw Terminal s

on Terminal Board

must be disabled

Frame Ground

during the

Caution

If the Isolated 24 VDC supply is overloaded or shorted, the Programmable Logic Controller will stop operation.

4-6 Series 90-30 PLC Installation and Hardware Manual – August 2002 GFK-0356Q

Page 96

BAT

TER

DC Input Only Power Supplies

IC693PWR322 Standard Power Supply, 24/48 VDC Input

The IC693PWR322 is a 30 watt output power supply designed for 24 VDC or 48 VDC nominal inputs. It will accept an input voltage range from 18 VDC to 56 VDC. Although it is capable of maintaining all outputs within specifications with input voltages as low as 18 VDC, it will not start with initial input voltages of less than 21 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 +24VDC, which is used internally by some modules, can also be used to provide

external power for 24VDC Input modules.

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

Table 4-6. IC693PWR322 Power Supply Capacities

Catalog

Number

IC693PWR322 30 Watts 24 or 48 VDC +5 VDC

Total of all outputs combined cannot exceed 30 watts.

Load

Capacity Input Output Capacities (Voltage/Power *)

15 watts

IC693PWR322

PROGRAMMABLE

CONTROLLER

CONNECTIONS

FOR

DC POWER

SOURCE

INTERNAL POWER

SOURCE FOR

MODULES REQUIRING

24VDC

GE Fanuc

Series 90-30

PROGRAMMABLE CONTROLLER

+24 VDC Isolated 20 watts

STANDARD

POWER SUPPLY

INPUT

24/48 VDC

50 WATT

24 VDC

OUTPUT

0.8A MAX.

PWR OK

RUN

BATT

+24 VDC Relay 15 watts

SYSTEM STATUS

INDICATORS

RS-485

COMPATIBLE

SERIAL PORT

BATTERY

LITHIUM

BACK-UP

BATTERY

CONNECTORS

Figure 4-4. Series 90-30 24/48 VDC Input Power Supply - IC693PWR322

GFK-0356Q Chapter 4 Power Supplies 4-7

Page 97

Table 4-7. Specifications for IC693PWR322 Power Supply

Nominal Rated Voltage Input Voltage Range Start Run

Input Power

Inrush Current

Output Power

Output Voltage

Protective Limits Overvoltage: Overcurrent;

Holdup Time:

Standards

24 or 48 VDC

21 to 56 VDC 18 to 56 VDC

50 watts maximum at full load

4A peak, 100 ms maximum

5 VDC: 15 watts maximum 24 VDC Relay: 15 watts maximum 24 VDC Isolated: 20 watts maximum

NOTE: 30 watts maximum total (all three outputs)

5 VDC: 5.0 VDC to 5.2 VDC (5.1 VDC nominal) 24 VDC Relay: 24 to 28 VDC 24 VDC Isolated: 21.5 VDC to 28 VDC

5 VDC output: 6.4 to 7 V 5 VDC output: 4 A maximum

14 ms minimum

Refer to data sheet, GFK-0867B, or later version for product standards, and general specifications.

Calculating Input Power Requirements for IC693PWR322

The following graph is a typical 24/48 VDC power supply efficiency curve. A basic procedure for determining efficiency of the 24/48 VDC power supply follows the figure.

45W

VERAGE

INPUT

POWER

(WATTS)

Figure 4-5. Typical Efficiency Curve for 24/48 VDC Power Supply

51015 2530

TOTAL OUTPUT POWER (WATTS)

Note

Start-up surge at full load is 4 amps for 250 milliseconds (maximum).

4-8 Series 90-30 PLC Installation and Hardware Manual – August 2002 GFK-0356Q

Page 98

Input Power/Current Calculation

■ Determine total output load from typical specifications listed for individual modules in

Chapters 2 and 3.

■ Use the graph to determine average input power.

■ Divide the input power by the operating source voltage to determine the input current

requirements.

■ Use the lowest input voltage to determine the maximum input current.

■ Allow for start-up surge current requirements.

■ Allow margins (10% to 20%) for variations.

GFK-0356Q Chapter 4 Power Supplies 4-9

Page 99

BATTERY

IC693PWR328 Standard Power Supply, 48 VDC Input

The IC693PWR328 is a 30 watt output power supply designed for 48 VDC nominal input. It will accept an input voltage range from 38 VDC to 56 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 4-8. IC693PWR328 Power Supply Capacities

Catalog

Number

Load

Capacity Input Output Capacities (Voltage/Power *)

IC693PWR328 30 Watts 48 VDC +5 VDC

15 watts

Total of all outputs combined cannot exceed 30 watts.

IC693PWR328

PROGRAMMABLE

CONTROLLER

CONNECTIONS

FOR

DC POWER

SOURCE

INTERNAL POWER

SOURCE FOR

MODULES REQUIRING

24VDC

LITHIUM BACK-UP BATTERY

GE Fanuc

PROG RAMABLE CONTRO LLER

+24 VDC Isolated 20 watts

Series 90-30

STANDARD POWER SUPPLY

INPUT

48 VDC 50 WATT

24 VDC

OUTPUT

0.8A MAX.

PWR OK

RUN

BATT

+24 VDC Relay 15 watts

SYSTEM STATUS

INDICATORS

RS-485 COMPATIBLE SERIAL PORT

BATTERY

CONNECTORS

Figure 4-6. Series 90-30 48 VDC Input Power Supply - IC693PWR328

4-10 Series 90-30 PLC Installation and Hardware Manual – August 2002 GFK-0356Q

Page 100

Table 4-9. Specifications for IC693PWR328 Power Supply

Nominal Rated Voltage Input Voltage Range

Input Power

Inrush Current

Output Power

Output Voltage

Protective Limits Overvoltage: Overcurrent;

Holdup Time:

Standards

48 VDC 38 to 56 VDC

50 watts maximum at full load

4A peak, 100 ms maximum

5 VDC: 15 watts maximum 24 VDC Relay: 15 watts maximum 24 VDC Isolated: 20 watts maximum

NOTE: 30 watts maximum total (all three outputs)

5 VDC: 5.0 VDC to 5.2 VDC (5.1 VDC nominal) 24 VDC Relay: 24 to 28 VDC 24 VDC Isolated: 21.5 VDC to 28 VDC

5 VDC output: 6.4 to 7 V 5 VDC output: 4 A maximum

14 ms minimum

Refer to data sheet, GFK-0867B, or later version for product standards, and general specifications.

Calculating Input Power Requirements for IC693PWR328

The following graph is a typical 48 VDC power supply efficiency curve. A basic procedure for determining efficiency of the 48 VDC power supply follows the figure.

45W

VERAGE

INPUT

POWER

(WATTS)

51015 2530

TOTAL OUTPUT POWER (WATTS)

Figure 4-7. Typical Efficiency Curve for IC693PWR328 Power Supply

Note

Start-up surge at full load is 4 amps for 250 milliseconds (maximum).

GFK-0356Q Chapter 4 Power Supplies 4-11