GE Series 90-30 PLC Hardware And Installation Manual

GE Fanuc Automation

Programmable Control Products

Series 90™-30 PLC
Installation and Hardware Manual

GFK-0356Q August 2002

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

©Copyright 1998—2002 GE Fanuc Automation North America, Inc.

All Rights Reserved.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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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

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

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

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

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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

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

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

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

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GFK-0356Q Contents xxv

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

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

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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

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

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Chapter

Overview of the Series 90-30 PLC

1

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.

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