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

a44564A

PROGRAMMABLE

CONTROLLER

BASE 5-SLOT

CAUTION

NON-CPU SLOTS

USER PROGRAM

AND REGISTER

VALUES MAY BE

LOST IF POWER

SUPPLY IS

REMOVED FOR

LONGER THAN

CPU

1 HOUR

CPU/1

I/O-2

I/O-3

I/O-4

I/O-5

POWER

SUPPLY

PWR

GE Fanuc

Series 90-30

RUN

CPU331

BATT

HIgh Capacity

Power Supply

A1 2 3 4 5 6 7 8

B1 2 3 4 5 6 7 8

A1 2 3 4 5 6 7 8

B1 2 3 4 5 6 7 8

A1 2 3 4 5 6 7 8

B1 2 3 4 5 6 7 8

A1 2 3 4 5 6 7 8

B1 2 3 4 5 6 7 8

Power Supply

CPU

I/O Modules

Figure 1-5. Assembling the System

GFK-0356Q

Chapter 1 Overview of the Series 90-30 PLC

1-5

When assembled, the system will look like this:

PWR

CPU

GE Fanuc

A 1 2 3 4 5 6 7 8

SERIES 90-30

RUN

B 1 2 3 4 5 6 7 8

BATT

HIGH CAPACITY

POWER SUPPLY

PROGRAMMABLE CONTROLLER

INPUT

100-240 ~C

50/60HZ 100VA

125 VDC, 50W

24 VDC

OUTPUT

0.8A MAX.

Figure 1-6. A Basic System

An assembly of baseplate and modules such as this one is called a “Rack.”

What else would be needed to make this basic system functional?

To make this basic system functional, you would need:

Mounting. Safe, secure mounting for the PLC in a protective enclosure.

Wiring. This includes properly installed incoming power to the power supply, as well as

wiring from the I/O modules to field devices such as switches, sensors, solenoids, relays, etc.

Program. An application program for the PLC to run. This is developed with GE Fanuc PLC

programming software.

What if the application requires more than five modules?

You could use a 10-slot baseplate, shown in the next picture:

PWR

CPU

GE Fanuc

A 1 2 3 4 5 6 7 8

SERIES 90-30

RUN

B 1 2 3 4 5 6 7 8

BATT

HIGH CAPACITY

POWER SUPPLY

PROGRAMMABLE CONTROLLER

INPUT

100-240 VAC

50/60HZ 100VA

125 VDC, 50W

24 VDC

OUTPUT

0.8A MAX.

I/O Bus Expansion Connector

Figure 1-7. Ten-Slot Rack

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

GFK-0356Q

What if the application requires more than ten modules?

You can add one or more Expansion or Remote racks to this system. Some CPUs can support up to

seven additional racks. If you added seven additional 10-slot racks, you could have 70 more

modules.

Racks are interconnected in a “daisy-chain” cabling arrangement. This interconnection system is

called the “I/O Expansion Bus.” The connections are made from one baseplate’s I/O Bus

Expansion Connector (shown in the figure above) to the next one’s. The I/O Bus Expansion

Cables, shown below, have a double connector on one end to facilitate these connections.

Female Connector

Male Connector

Figure 1-8. I/O Bus Expansion Cable

GFK-0356Q

Chapter 1 Overview of the Series 90-30 PLC

1-7

The next figure shows a system that has a CPU baseplate, one Expansion rack and three Remote

racks. Notice that the last rack, the one at the end of the I/O Expansion Bus, must be terminated.

A convenient way of terminating the bus is with an IC693ACC307 I/O Bus Terminator Plug, as

shown.

CPU BASEPLATE

CPU

BASEPLATE

EXPANSION

BASEPLATE

EXPANSION BASEPLATE

MAXIMUM DISTANCE

FROM CPU = 50 FEET

(15 METERS)

REMOTE BASEPLATE

REMOTE

BASEPLATE

REMOTE BASEPLATE

REMOTE

BASEPLATE

REMOTE

BASEPLATE

REMOTE BASEPLATE

I/O BUS

MAXIMUM DISTANCE

TERMINATOR

FROM CPU = 700 FEET

PLUG

IC693ACC307

(213 METERS)

Figure 1-9. Connecting Expansion and Remote Baseplates

What is the Difference Between Expansion and Remote baseplates?

The main factor to consider is distance. How far will the baseplate be from the CPU baseplate? If

the cabling distance from the CPU baseplate is 50 feet (15 meters) or less, use an Expansion

baseplate. The Expansion baseplate is preferable because of its higher communication speed with

the CPU baseplate. However, if a baseplate must be located where it requires a cabling distance

from the CPU rack in excess of 50 feet, an Expansion baseplate will not work - a Remote baseplate

must be used. The limit for a Remote baseplate is a cabling distance of 700 feet (213 meters) from

the CPU baseplate to the farthest Remote baseplate.

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

GFK-0356Q

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

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

example, Genius Bus Controller Modules (GBC) can communicate at distances up to 7,500 feet

(2,286 meters) over a shielded twisted-pair cable, as shown in Example 1 below. Or, serial

communications with Communications Coprocessor Modules (CMM) using the RS-485 standard

can cover up to 4,000 feet (1,219 meters), as shown in Example 2 below. And virtually unlimited

communication distances can be attained with modems and telephone lines or radio transmitters.

Also, there are numerous networking options available such as Ethernet or WorldFIP.

Example 1 - GBC

Example 2 - CMM

Series 90-30 PLC

CPU

GBC

CPU

CMM

Shielded, Twisted-Pair Cable, 7,500

Serial Cable, 4,000 Feet (1,219

Feet (2,286 Meters) Maximum Length

Meters) Maximum Length

Series 90-30 PLC

CPU

GBC

CPU

CMM

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

GFK-0356Q

Chapter 1 Overview of the Series 90-30 PLC

1-9

Chapter

Installation

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

hardware descriptions and specifications, is covered in the applicable chapters.

Important Note

Series 90-30 PLCs must be mounted in a protective enclosure.

The installation instructions described in this chapter apply to PLC installations

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

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

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

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

Standards, General Specifications.

Receiving your Products - Visual Inspection

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

damage that may have occurred during shipping. If any part of the system is damaged, notify the

carrier immediately. The damaged shipping container should be saved as evidence for inspection

by the carrier.

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

during shipment. However, GE Fanuc will fully cooperate with you if such action is necessary.

Pre-installation Check

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

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

the warranty period of the equipment. All software product registration cards should be completed

and returned to GE Fanuc. See “Module Features” in this chapter for location of module serial

numbers. See “Common Baseplate Features” in chapter 3 for location of baseplate serial numbers.

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

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

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

instructions.

If you require assistance with your installation, GE Fanuc’s Technical Support department offers

expert help. Call the support number for your area from the list in Chapter 13, “Maintenance and

Troubleshooting.” The GE Fanuc web site support address is www.gefanuc.com/support/plc.

Warranty Claims

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

GFK-0356Q

2-1

Working with Series 90-30 Modules

Module Features

IC693CPUxxx

CPU MODULE

25 MHZ

LISTED

xxxxxxx

123456789

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

Pivot hook

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

Catalog number and description section of label (Includes MAC address for CPU374.)

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

Module connector - plugs into baseplate backplane connector

Release lever - spring loaded

Ventilation openings in module case (top and bottom)

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

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

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

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

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

13. Module label

14. Serial Number - used to determine module warranty status. (On some modules, the Serial

Number may be on a small tag on the back of the module.)

2-2

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

GFK-0356Q

Installing a Module

Warning

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

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

or baseplate may result. Also, attempts to force a module into an improper

slot type will result in damage to the module and/or the baseplate. Modules

will mount in the correct slot type easily, with a minimum of force.

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

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

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

installed in the left end unnumbered slot only, and a CPU module and some special Option

modules can only be installed in Slot 1 of a CPU baseplate. I/O Modules and most Option

modules install in slots numbered 2 and higher.

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

away from you.

■ Align the module with the desired baseplate slot and connector. Tilt the module upwards so

that top rear pivot hook of the module engages the baseplate’s top module retainer.

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

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

baseplate’s bottom module retainer.

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

a43055A

PIVOT HOOK

BACKPLANE

CONNECTOR

RELEASE LEVER

BOTTOM RETAINER

Figure 2-2. Installing a Module

GFK-0356Q

Chapter 2 Installation

2-3

Removing a Module

Warning

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

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

or baseplate may result. Also potentially dangerous voltages from user

devices may be present on a module’s screw terminals even though power to

the rack is turned off. Care must be taken any time that you are handling

the module’s removable terminal board or any wires connected to it.

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

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

described later in this section.

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

module.

■ While holding the module firmly at its top and fully depressing release lever, swing (pivot) the

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

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

the baseplate.

a43056

PIVOT HOOK

PRESS

RELEASE LEVER

Figure 2-3. Removing a Module

Note

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

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

remote baseplate. I/O data to/from this baseplate will not be updated while

power is removed.

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

GFK-0356Q

Installing a Module’s Terminal Board

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

boards that are equipped with holding screws. For Installation and Removal instructions, please

see the section “Installing and Removing Terminal Boards with Holding Screws” later in this

chapter.

To install a terminal board (circled numbers refer to drawing below):

■ Hook the pivot hook ➀, located on the bottom of the terminal board, to the lower slot on the

module.

■ Push the terminal board toward the module ➁ until it snaps into place.

■ Open the terminal board cover ➂ and ensure that the latch on the module is securely holding

the terminal board in place.

Caution

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

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

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

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

a43062

Module

Label

REFER TO TEXT FOR

INSTALLATION PROCEDURE

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

GFK-0356Q

Chapter 2 Installation

2-5

I/O Module Terminal Board Posts

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

board cover in place. The middle post keeps the terminal board wiring in place. If you do not

require it to hold the wiring in place, the middle post can be easily snapped off. (Be careful that you

do not inadvertently snap it off if you need it to keep your wiring in place.)

Installing and Removing Terminal Boards with Holding Screws

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

special terminal board that is equipped with holding screws, shown in the figure below. These

screws prevent the terminal board-to-module connections from deteriorating in applications where

the PLC is subjected to severe vibration .

A1 2 3 4 5 6 7 8

B1 2 3 4 5 6 7 8

Hinged Cover

Holding Screw

Removeable Terminal Board

Holding Screw

IC693MDL730F

Module Catalog Number

Figure 2-6. Terminal Board with Holding Screws

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

of the terminal board, then follow the standard removal instructions in the section “Removing

an I/O Module’s Terminal Board.” The holding screws are held captive in the terminal board

and do not have to be completely removed.

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

section “Installing an I/O Module’s Terminal Board,” then tighten the two holding screws to 8

to 10 inch-pounds (1 Newton-meter) of torque.

GFK-0356Q

Chapter 2 Installation

2-7

Baseplate Mounting

Warning

Be sure to follow baseplate grounding instructions in this chapter. Failure to

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

equipment, and injury to personnel.

Mounting a Baseplate to a Panel

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

Install the screws in four tapped holes. The “Baseplates” chapter has the applicable

dimensions and mounting clearances. Alternately, 10-slot baseplates can be mounted in

standard 19-inch racks by using the appropriate adapter. This is also discussed in the

“Baseplates” chapter.

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

orientations will require derating the Power Supply current capabilities. See Chapter 12,

“System Design,” for details.

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

has details.

■ The Rack Number Selection switch must be set on each Expansion or Remote baseplate. A

CPU baseplate does not require this switch. Rack numbers should be assigned by the system

designer. Failure to set the Rack Number Selection switches properly will result in system

malfunction. See the “Baseplates” chapter for details on setting these switches.

Mounting a Baseplate to a 19" Rack

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

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

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

of a 19” rack. Install the adapter bracket by inserting the tabs at the top and bottom of the

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

cover. NOTE: Although Figure 2-7 shows the plastic baseplate cover removed, this is for

illustration purposes only. It is not necessary to remove the cover to install the bracket. With

the bracket in place, insert and tighten the two screws (included with the bracket) through the

back of the baseplate holes into the threaded holes in the bracket.

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

GFK-0356Q

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

a 19” rack. A baseplate mounts on the rear panel of this adapter bracket using four 8-32

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

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

recommended).

RIGHT SIDE OF

BASEPLATE

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

from back of base unit through base unit

and bracket. Tighten screws to secure

bracket to base unit.

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

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

Figure 2-7. IC693ACC308 Front Mount Adapter Bracket Installation

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

Bracket are shown in the following figure.

18.89

(480)

18.47

(469)

DIMENSIONS IN INCHES (MILLIMETERS IN PARENTHESES)

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

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Chapter 2 Installation

2-9

Grounding Procedures

System Grounding Procedures

Warning

In addition to the following grounding information, we strongly urge that

you follow all applicable codes that apply to your area. For example, in the

United States, most areas have adopted the National Electrical Code

standard and specify that all wiring conform to its requirements. In other

countries, different codes will apply. For maximum safety to personnel and

property you must follow these codes. Failure to do so can mean injury or

death to personnel, damage to property, or both.

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

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

■ A low resistance path from all parts of a system to earth minimizes exposure to shock in the

event of short circuits or equipment malfunction.

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

Ground Conductors

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

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

current from any other branch. This method is shown in the following figure.

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

ground cables (typically green insulation with a yellow tracer - AWG #12 (3.3 mm²) or larger)

can be used to minimize resistance. Conductors must always be large enough to carry the

maximum short circuit current of the path being considered.

SERIES 90-30

MOTOR DRIVES

MACHINERY

PLC CABINET

AND OTHER

ELECTRICAL

CONTROL

RACK

EQUIPMENT

PROGRAMMING

RACK

DEVICE

NOTE

SIGNAL AND POWER

CONNECTIONS

EARTH

CENTRAL

ARE NOT SHOWN

GROUND

GROUND POINT

Figure 2-10. Recommended System Grounding

GFK-0356Q

Chapter 2 Installation

2-11

Series 90-30 PLC Equipment Grounding

Equipment grounding recommendations and procedures are listed below. These grounding

procedures must be properly followed for safe, proper operation of your Series 90-30 PLC system.

Baseplate Safety Grounding

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

type should also be consulted. The baseplate’s metal back must be grounded using a separate

conductor; the baseplate mounting screws are not considered to an acceptable ground connection

by themselves. Use a minimum AWG #12 (3.3 mm²) wire with a ring terminal and star lock

washer under the head of one of the baseplate’s two lower mounting holes. These two holes have

openings to the side to allow connecting a wire and ring terminal under the head of a mounting

screw. Connect the other end of this ground wire to a tapped hole in the panel that the baseplate is

mounted to, using a machine screw, star lock washer, and flat washer. Alternately, if your panel

has a ground stud, it is recommended you use a nut and star lock washer for each wire on the

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

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

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

PROGRAMMABLE

CONTROLLER

BASE 5-SLOT

CAUTION

NON-CPU SLOTS

USER PROGRAM

AND REGISTER

AWG #12 or

VALUES MAY BE

LOST IF POWER

Larger Wire

SUPPLY IS

REMOVED FOR

LONGER THAN

1 HOUR

POWER

CPU/1

I/O-2

I/O-3

I/O-4

I/O-5

SUPPLY

Alternate location

for Ground connection

Screw, Star Lock washer,

Flat Washer, Ring Terminal,

installed in tapped hole.

Paint Removed

From Panel Here

Figure 2-11. Baseplate Grounding

Warning

All baseplates must be grounded to minimize electrical shock hazard.

Failure to do so can result in severe personal injury.

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

GFK-0356Q

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

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

cabinet.

Grounding 19" Rack-Mounted Baseplates

There are two Adapter Brackets used for mounting a 10-slot Series 90-30 baseplate to a 19” Rack.

Regardless of which of the two Adapter Brackets is used, the 19” Rack should be grounded as per

the instructions in “System Grounding Procedures,” including Figure 2-10. (For details on the

Adapter Brackets, see the “Mounting a Baseplate to a 19” Rack” section earlier in this chapter.)

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

the “Baseplate Safety Grounding” section, using a separate ground wire from the PLC baseplate as

shown in the previous figure (Fig. 2-11).

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

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

Bracket. An additional ground wire connecting the Adapter Bracket to a solid chassis ground

on the 19” Rack should be installed. Use the same or equivalent hardware and paint removal

scheme as shown in Figure 2-11.

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

run from the baseplate as shown in Figure 2-11, to a solid chassis ground on the 19” Rack.

Use the same or equivalent hardware and paint removal scheme as shown in Figure 2-11.

Programmer Grounding

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

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

provided by ensuring that the programmer’s power cord is connected to the same power source

(with the same ground reference point) as the baseplate. If it is not possible to ensure this common

ground scheme, use a port isolator (IC690ACC903) between the programmer and PLC serial

connection. If the programmer ground is at a different potential than the PLC ground, a shock

hazard could exist. Also, damage to the ports or converter (if used) could occur when the

programmer serial cable is connected between the two.

Warning

Failure to follow programmer grounding recommendations could result in

personal injury, equipment damage, or both.

GFK-0356Q

Chapter 2 Installation

2-13

Module Shield Grounding

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

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

baseplate through the module’s backplane connector. Other modules, such as CPUs 351, 352, 363,

364, and 374 require a separate shield ground. These are discussed in the next several sections.

Shield Grounding Information for CPUs with External Port Connections

CPUs with external port connections, the 351, 352, 363, 364, and 374 must have a separate shield

ground connection to provide shielding for these ports. Because the design of the ground

connection for the CPU351 and 352 is different from that of the CPU363, 364, and 374, each

grounding method is discussed in a separate section.

CPU351 and 352 Shield Grounding

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

Two methods are provided for making this ground connection. Each CPU comes with an EMC

Grounding Kit (44A737591-G01) that contains a ground wire, grounding bracket, and screws.

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

number 44A735970-001R01) that comes with the module in the EMC Grounding Kit. This

wire has a stab-on connector on one end for connection to a mating terminal on the bottom of

the CPU, and a ring terminal on the other end for connection to a grounded enclosure. Where

the ring terminal contacts a painted enclosure panel, either a star lock washer can be installed

between the terminal and the panel to cut through the paint, or the paint can be scraped away

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

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

CPU351 or 352

#6 TAPPED HOLE

REMOVE PAINT UNDER

BOTTOM OF

RING TERMINAL OR INSTALL

CPU MODULE

STAR LOCK WASHER BETWEEN

USE 1 #6

MACHINE SCREW

TERMINAL AND PANEL

STAB-ON

CONNECTOR

MOUNT ON

44A735970-001R01

GROUNDED

ENCLOSURE

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

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

GFK-0356Q

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

the green ground wire and the optional grounding bracket (part number 44C715646-001R01).

This bracket attaches to the CPU using two #4 thread-rolling screws (part number

N666P9004B6) and to the grounded enclosure using two #6 thread-rolling screws (part number

N666P13006B6). Two holes must be drilled in the enclosure for mounting this bracket. Also,

if the bracket will be attached to a painted surface, the paint should be removed down to bare

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

next figure.

CPU351 or 352

44C715646-001R01

BRACKET

PAINT REMOVED WHERE

BRACKET MOUNTS TO PANEL

MOUNT ON

GROUNDED

ENCLOSURE

USE 2 #4

USE 2 #6

THREAD ROLLING SCREWS

(N666P9004B6)

(N666P13006B6

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

Note: When the grounding bracket is used, pin 1 of the cable connector that plugs into the Port 2

connector should not be connected. A metal connector shell must be used on the cable for

this port, and the cable shield must be terminated at the metal shell instead of pin 1 of the

connector.

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Chapter 2 Installation

2-15

CPU363, CPU364, and CPU374 Shield Grounding

The CPU363, CPU364, and CPU374 modules must be connected to frame ground at the slot where

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

not support or require the use of a grounding bracket. If the ring terminal on the grounding wire is

to be mounted to a painted surface, remove the paint under the ring terminal to ensure good contact,

or place a star lock washer between the ring terminal and the painted surface. See the next figure.

Note: The star lock washer method is suitable for a shield ground, but not suitable for a

safety ground.

CPU363, CPU364,

or CPU374

STAB-ON

CONNECTOR

#6 TAPPED HOLE

REMOVE PAINT UNDER

BOTTOM

RING TERMINAL OR

OF CPU MODULE

INSTALL STAR LOCK

USE 1 #6

WASHER BETWEEN

MACHINE SCREW

RING TERMINAL AND

PANEL

MOUNT ON

44A735970-001R01

GROUNDED

ENCLOSURE

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

Additional Modules with Shield Grounding Requirements

Some of the Series 90-30 Option modules, such as the FIP Remote I/O Scanner (IC693BEM330),

and DSM modules (IC693DSM302 and IC693DSM314) also have shield grounding requirements.

These modules come equipped with suitable grounding hardware. Please refer to each module’s

user’s manual for grounding instructions. Appendix G contains a product to publication cross-

reference to help you identify the correct manual.

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

GFK-0356Q

General Wiring Guidelines

Warning

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

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

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

National Electrical Code standard and specify that all wiring conform to its

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

safety to personnel and property you must follow these codes. Failure to do

so can lead to personal injury or death, property damage or destruction, or

both.

Color Coding Wires

These color codes are commonly used in industrial equipment manufactured in the United States.

They are cited here as a reference. Where they are in conflict with codes that apply to your area or

your type of equipment, you should follow your applicable codes instead. Besides satisfying code

requirements, wire color coding makes testing and troubleshooting safer, faster, and easier.

■ Green or green with stripe- Ground

■ Black - Primary AC

■ Red - Secondary AC

■ Blue - DC

■ White - Common or neutral

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

personnel that there may be power present (from an external source) even if the equipment is

disconnected from its main power source.

Wire Routing

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

such as AC power wiring and Discrete Output Module wiring, physically separated from low-level

signal wiring such as DC and Analog Input module wiring or communications cables. This can be

accomplished by grouping separately, where practical, the following categories of wiring:

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

devices in the control cabinet.

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

coupling. See the Series 90-30 I/O Module Specifications Manual, GFK-0898 for details.

■ Discrete Output Module wiring. These often switch inductive loads that produce noise

spikes when switched off.

■ DC Input Module wiring. Although suppressed internally, these low-level inputs should be

further protected against noise coupling by observing these wiring practices.

■ Communications Cables. Wiring such as Genius Bus or serial cables should be kept away

from noise-producing wiring.

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

running them beside each other. Route them so that, if they have to cross, they do so at a right

angle. This will minimize coupling between them.

Grouping Modules to Keep Wires Segregated

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

For example, one rack could contain only AC modules, and a different rack only DC modules, with

further grouping in each rack by input and output types. For smaller systems, as an example, the

left end of a rack could contain Analog modules, the middle could contain DC modules, and the

right end could contain AC modules.

Discrete I/O Module Connection Methods

■

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

which comes with these modules. The removable terminal board makes it easy to prewire

field wiring to the user supplied input and output devices, and to replace modules in the field

without disturbing existing field wiring.

■

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

Connect (TBQC) assembly. This assembly contains a module faceplate, with built-in

connector, that replaces the removable terminal board. The assembly also contains a DIN-rail

mounted terminal block and a cable to connect the module to the terminal block. The

advantage of this method is that it saves about two hours of wiring time per module compared

with hand wiring from a module’s removable terminal board to a user-supplied, panel-mounted

terminal block or strip.

■

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

connected by a cable with a connector on each end to a Weidmuller panel-mounted terminal

block (Weidmuller catalog no. 912263), or is connected by a cable with stripped, tinned leads

to a user-supplied terminal block or strip.

■

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

module may be wired in one of three ways. (1) Use a pair of cables (IC693CBL327/328 - see

data sheet in “Cables” chapter) to connect the module to a user-supplied, panel-mounted

terminal block or strip. These cables have a 24-pin connector on one end, and stripped, tinned

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

the module to a Terminal Block Quick Connect (TBQC) terminal block (IC693ACC377). See

Appendix H for details. (3) Make your own custom cables. Instructions are found in the

IC693CBL327/328 data sheet in Chapter 10.

Connections to I/O Module Terminal Boards

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

two AWG #22 (0.36 mm²) to two AWG #16 (1.3 mm²), or one AWG #14 (2.1 mm²) copper 90°C

(194°F) wire(s). Each terminal can accept solid or stranded wires, but the wires into any given

terminal should be the same type (both solid or both stranded) to ensure a good connection. Wires

are routed to and from the terminals out of the bottom of the terminal board cavity. The suggested

torque for the I/O terminal board connection screws is from 9.6 in-lbs to 11.5 in-lbs (1.1-1.3

Newton-meters).

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

board to supply a limited number of input devices. Also, a 24 volt DC output is available on the

power supply module’s terminal board to supply a limited number of output devices.

Terminal Block Quick Connect Installation for 16-Point Discrete Modules

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

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

■ Remove standard terminal board from module.

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

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

on a standard 35 mm DIN-rail.

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

connector on the TBQC terminal block.

■ Wire I/O devices to the terminal block.

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

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

fulfill standardization requirements. They are mainly used as replacements for existing

installations. For new installations, we recommend the dual 24-pin connector style because they

have additional features not found on the older modules (LED indicators, TBQC), and it is much

easier to fabricate custom-length cables for them. Installation information is provided here for the

convenience of those still using these modules.

Using Weidmuller #912263 Terminal Block

Note: The TBQC is not available for these modules, but you may purchase a Weidmuller #912263

from your electronics distributor for this application.

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

and mounts on a standard 35 mm DIN-rail.

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

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

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

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

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Using a Generic Terminal Block or Strip

■ Mount terminal block/strip to the enclosure panel.

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

connector and wire the stripped ends of the cable to the terminal block/strip. See Chapter 10

for cable data.

■ Wire I/O devices to the terminal block/strip.

Direct Method

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

connector and wire the stripped ends of the cable directly to the field devices. See Chapter 10

for cable data. See the Series 90-30 PLC I/O Module Specifications Manual, GFK-0898, for

pin-out information.

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

Using a TBQC

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

mounts on a standard 35 mm DIN-rail.

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

connector and the connectors on the two TBQC terminal blocks. Note that both a right side

and left side cable is required. See Appendix H for a list of cables.

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

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

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

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

With a Generic Terminal Block/Strip

■ Mount terminal block/strip to the enclosure panel.

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

connectors, and wire the stripped ends of the cables to the terminal block/strip. Note that both

a right side and left side cable is required. See Appendix H for a list of cables. See Chapter 10

for cable data sheets.

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

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

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Direct Method

■ Connect an IC693CBL327/328 cable, or a custom made cable, to the module’s faceplate

connectors, and wire the stripped ends of the cable directly to the field devices. See Chapter

10 for cable data. See the Series 90-30 PLC I/O Module Specifications Manual, GFK-0898,

for pin-out information.

General Wiring Methods for Analog Modules

Twisted, shielded instrumentation cable is strongly recommended for analog module input or

output signal connections. Proper grounding of the shield is also important. For maximum

electrical noise suppression, the cable shield should only be grounded at one end of the cable. For

Input modules, ground the end that is in the noisiest environment (which often is at the field device

end). For Output modules, ground at the module end. See GFK-0898, Series 90-30 PLC I/O

Module Specifications, for more shield grounding information.

Analog Input Module Wiring Methods

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

general, it is generally best to ground the cable shield as close to the source of the noise as possible,

which is usually at the device end. In troubleshooting noise problems, sometimes it is beneficial to

experiment with the shield grounding point location. Remember, the cable shield should be

grounded at one end only. Also, it is best to keep the length of stripped cable leads as short as

possible to minimize the length of unshielded conductors that will be exposed to the noisy

environment. See the Series 90-30 PLC I/O Module Specifications Manual, GFK-0898 for

additional details.

Using a Generic Terminal Block or Strip

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

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

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

shields at the module end (cut shield off at module end of cable and insulate with shrink

tubing).

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

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

Also, keep the length of exposed (outside of shield) leads at the terminal strip and device ends

as short as possible.

Direct Method

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

module.

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

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

noisy environment. Do not connect the shield at the module end (cut shield off at module end

of cable and insulate with shrink tubing).

TBQC not Recommended for Analog Modules

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

modules due to cable shielding requirements.

Analog Output Module Wiring

General

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

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

information.

Using a Generic Terminal Block or Strip

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

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

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

strip end (cut shields off at terminal strip end of cables and insulate with shrink tubing).

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

terminal strip end only (cut shields off at field device end of cables and insulate with shrink

tubing). Also, keep the length of exposed (outside of shield) leads at the terminal strip and

device ends as short as possible.

Direct Method

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

module.

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

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

noisy environment. Do not connect the shield at the device end (cut shield off at device end of

cable and insulate with shrink tubing).

TBQC not Recommended for Analog Modules

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

modules due to cable shielding requirements.

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AC Power Source Connections

AC Input Wiring to AC/DC Power Supplies

Warning

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

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

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

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

Each baseplate must be connected to a common ground.

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

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

VAC is present on the AC Power Supply. The cover protects against

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

operator or maintenance personnel.

Both the Standard (IC693PWR321) and High Capacity (IC693PWR330) AC/DC power supplies

currently have six terminals for user connections. Early versions of some Series 90-30 power

supplies had five terminals (see next figure). The wiring methods for both five-terminal and six-

terminal types is similar, except that step 3 below does not apply to the five-terminal type.

The power supply terminal boards will accept one AWG #14 (2.1 mm²) or two AWG #16 (1.3

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

in any given terminal should be the same type. The suggested torque for the power supply terminal

board is 12 in-lbs (1.36 Newton-meters). Open the door protecting the terminal board and make

the following connections from the AC power source, and ground connections (system grounding

requirements are described in detail later in this chapter).

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

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

maximum range of 85 VAC to 264 VAC. These are auto-ranging supplies that do not require

jumper or switch settings for selection of power source voltage.

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

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

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

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

(see figure below), should be left in place for normal installations. However, this jumper must

be removed and external surge suppressors installed in installations with a “Floating Neutral”

input. Please see the section “Special Instructions for Floating Neutral (IT) Systems” later in

this chapter for details.

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

cover plate should be carefully reinstalled.

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INPUT

100-240 VAC

50/60HZ 90VA

125 VDC, 50W

Input Power

125 VDC, 50W

Input Power

Factory Jumper

24 VDC Output

24 VDC

For I/O Modules

OUTPUT

0.8A MAX.

24 VDC Output

24 VDC

For I/O Modules

OUTPUT

0.8A MAX.

Six-Terminal Board

Five-Terminal Board

Figure 2-15. Power Supply Terminal Boards

Power Supply Overvoltage Protection Devices

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

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

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

supplied upstream, this feature can be disabled by leaving pin 4 unconnected by removing the

jumper strap. Also, this jumper must be removed and external surge suppressors installed in

installations with a “Floating Neutral” input, please see the following section “Special Instructions

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

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

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

the strap.

a47086

Frame Ground

Jumper Strap Connects

Overvoltage Protection

Devices to Frame Ground

Screw Terminals on Terminal Board

Figure 2-16. Overvoltage Protection Devices and Jumper Strap

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Special Installation Instructions for Floating Neutral (IT) Systems

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

not referenced to Protective Earth Ground, these special installation instructions must be followed

to prevent damage to the power supply.

IC693PWR321S (or later version)

IC693PWR330A (or later version)

Definition of Floating Neutral Systems

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

Earth Ground are not tied together by a negligible impedance. In Europe this is referred to as an

IT system (see IEC950). In a Floating Neutral System, voltages measured from input terminals to

protective earth ground may exceed the 264 Volts AC maximum input voltage specified in the

power supply specifications in Chapter 24in this manual.

Example of Floating Neutral System

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

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

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

Neutral Systems.

Examples of Non-Floating Neutral System

N/PE

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

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