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

Cables

Connector Pin

Number (Either End)

Signal Name and Function

VG+, Voltage Generator positive lead

IN+, Current Neutral positive lead

VA+, Voltage phase A positive lead

IA+, Current phase A positive lead

No Connection

VB+, Voltage phase B positive lead

IB+, Current phase B positive lead

VC+, Voltage phase C positive lead

IC+, Current phase C positive lead

Cable shield

No Connection

Frame Ground

No Connection

VG-, Voltage Generator negative lead

IN-, Current Neutral negative lead

VA-, Voltage phase A negative lead

IA-, Current phase A negative lead

No Connection

VB-, Voltage phase B negative lead

IB-, Current phase B negative lead

VC-, Voltage phase C negative lead

IC-, Current phase C negative lead

No Connection

Frame Ground

Documentation

GFK-1734, Series 90-30 PLC Power Transducer Module User’s Manual

GFK-0356Q

Chapter 10 Cables

10-67

Chapter

Programmer Hardware Products

Products Discussed in this Chapter

The following table lists the programmer hardware products discussed in this chapter. Some of the

items are no longer available but are documented here for the convenience of customers still using

them.

Catalog Number

Description

Comment

IC640WMI310

Work Station Interface (WSI) Board

For Workmaster or IBM PC and

compatibles.

IC640WMI320

Work Station Interface (WSI) Board

For Workmaster II or IBM PS/2 and

compatibles.

IC690ACC900

RS-422/485 to RS-232 Converter

No longer available. Use

IC690ACC901 Miniconverter.

IC690ACC901

Miniconverter

Converts RS-422/485 to RS-232.

IC693PRG300

Hand-Held Programmer (HHP)

Used to configure and program Series

90-30 PLCs (except for CPU374).

IC693ACC303

Memory card for HHP

Plugs into HHP. Used for file storage.

IC693PIF301

Personal Computer Interface Card

Installs in PC. Enables PC to control

PLC I/O.

IC693PIF400

Personal Computer Interface Card

More powerful than the IC693PIF301.

IC655CCM590

Isolated Repeater/Converter (also know

No longer available. Use

(IC630CCM390)

as the “Brick”)

IC690ACC903 Port Isolator.

IC690ACC903

Port Isolator

Provides isolation for PLC serial port.

GFK-0356Q

11-1

IC640WMI310/320 Work Station Interface Boards

The Work Station Interface (WSI) board provides an RS-485 serial interface between a Series 90-

30 PLC and a PC-compatible programmer running Logicmaster 90-30/20/Micro software. This

board is available in two versions.

IC640WMI310 (serial operation only) for Workmaster or IBM PC XT or AT or compatible

personal computers.

IC647WMI320 (serial operation only) for Workmaster II or IBM PS/2 or compatible personal

computers.

The WSI board can be ordered as part of a package with Logicmaster 90-30/20/Micro

programming software. When a Workmaster II computer was ordered as the programming device,

the WSI board was installed at the factory. The WSI resides in a full length computer slot. The

computer can be a Workmaster, Workmaster II, Cimstar industrial computer, or a PC-compatible

personal computer.

a44734

SERIAL OPERATION ONLY

IC647WMI320

Figure 11-1. WSI Board for the Workmaster II Computer

WSI

SERIAL

SERIES 90-30

SERIAL

CABLE

PROGRAMMER

Figure 11-2. Location of WSI in a Series II 90-30 PLC System

11-2

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

GFK-0356Q

Programmer Hardware Products

Replacing Workmaster Computers

The Workmaster and Workmaster II computers are no longer available. However, the Work

Station Interface boards are still sold, largely to support customers still using the Workmaster and

related products. GE Fanuc currently sells industrially hardened programming computer/software

packages that are updated replacements for the Workmaster computers. For details, please contact

the GE Fanuc Hotline at 1-800-GE FANUC (1-800-433-2682), or for international customers,

direct dial 804-978-6036.

IC690ACC900 RS-422/RS-485 to RS-232 Converter

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

convenience of those still using this product.

Note

GE Fanuc offers the IC690ACC901 Miniconverter kit, documented in the

next section of this chapter, as a replacement for the IC690ACC900

Converter.

This Converter lets you connect a standard RS-232 serial port, such as found on a PC-compatible

computer, to the RS-422/RS-485 ports in a Series 90-30 PLC.

If using a Workmaster II computer, this converter eliminates the need to have a Work Station

Interface board.

This converter is a small, self-contained device that requires only a cable connection to the Series

90-30 RS-422/RS-485 port on one end and a cable connection to the RS-232 port on the opposite

end.

SERIES 90-30

PROGRAMMER

RS-485

RS-232

CONVERTER

Figure 11-3. Example of IC690ACC900 Converter Connection

The converter operates from a +5 VDC source, which is provided from the PLC backplane +5

VDC bus through the cable connection. The pin assignments for the connections on the cable

required for the RS-232 connection are compatible with available PCM compatible serial cables

(IC690CBL701, PCM to Workmaster; IC690CBL705, PCM to Workmaster II; and IC690CBL702,

PCM to PC-AT). The RS-422/RS-485 connection at the Series 90-30 serial port on the power

supply can be made with an available cable (same cable that is used with the Hand-Held

Programmer), IC693CBL303.

The three PCM compatible cables (IC690CBL701/702/705) are 10 feet (3 meters) in length, and

the HHP compatible cable (IC693CBL303) is 6 feet (2 meters) in length. For those user’s who

may want to build their own cables, pin assignments and recommended cable types for both cables

GFK-0356Q

Chapter 11 Programmer Hardware Products

11-3

required for use with the converter are provided in the “Cables” chapter of this manual. For

detailed information on this converter, refer to Appendix B.

The IC690ACC903 Port Isolator is available for applications requiring ground isolation or for

connection distances up to 4,000 feet. For detailed information, refer to Appendix E.

IC690ACC901 Miniconverter Kit

The Miniconverter Kit consists of an RS-422 (SNP) to RS-232 Miniconverter, a 6 foot (2 meter)

serial extension cable, and a 9-pin to 25-pin adapter. The 15-pin SNP port connector on the

Miniconverter plugs directly into the serial port connector on the Series 90-30 power supply,

Series 90-70 CPU, or Series 90-20 CPU. The 9-pin RS-232 port connector on the Miniconverter

connects to an RS-232 compatible device.

When used with an IBM PC-AT or compatible computer, one end of the extension cable plugs into

the Miniconverter’s 9-pin serial port connector, the other end plugs into the 9-pin serial port of the

computer. The adapter (supplied with kit) is required to adapt the 9-pin serial port connector on

the Miniconverter to the 25-pin serial port connector on the GE Fanuc Workmaster II computer,

or an IBM PC-XT or PS/2 Personal Computer. The GE Fanuc Workmaster computer requires an

additional adapter (not supplied with kit - please contact your local GE Fanuc PLC distributor) for

use with the Miniconverter.

The Miniconverter is shown in the following figure. For more information on the Miniconverter,

refer to Appendix D.

RS-422

RS-232

PORT

Figure 11-4. IC690ACC901 Series 90 SNP Port to RS-232 Adapter

11-4

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

GFK-0356Q

Programmer Hardware Products

IC693PRG300 Hand-Held Programmer (HHP)

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

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

debug, and monitor logic programs, monitor data tables, and configure PLC and I/O parameters.

Note

The user logic program in Series 90-30 CPU numbers 350 and above cannot be

viewed or edited with the Hand-Held Programmer. You must use

Logicmaster 90-30, Control, VersaPro, or Logic Developer-PLC programming

software with those CPUs.

The HHP connects to the CPU serial port through a 15-pin D-type connector on the Series 90-30

PLC power supply in the CPU baseplate. The physical connection is through a 6-foot (2-meters)

long cable (IC693CBL303). This cable also provides power connections to the HHP, and provides

a signal that tells the PLC that an HHP is attached. The HHP can be connected or disconnected

while the PLC is powered-up. The HHP does not require communications parameter configuration

in order to communicate with a PLC. This makes it useful for troubleshooting a communications

problem between a PC and the PLC.

a43052

GE Fanuc

SERIES 90-30

PROGRAMMABLE

CONTROLLER

HAND HELD PROGRAMMER

OUT

SETM

RSTM

TMR

MODE

OUTM

SET

RST

ONDTR

E OR

UPCTR

AND

NOT

BLK

DNCTR

RUN

AQQ

FUNC

DEL

A I

SRCH

SLOT

FOR

WRITE

INS

MEMORY

READ

CARD

VRFY

HEX

ENT

CLR

DEC

SERIAL PORT CONNECTOR

TO CPU SERIAL PORT

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

GFK-0356Q

Chapter 11 Programmer Hardware Products

11-5

HHP Features

The HHP has a sealed-type keypad with tactile feedback and 42 keys, arranged in a matrix of six

keys across by seven keys down. It has a two-line by 16 character LCD display screen.

HHP Memory Card (IC693ACC303)

The HHP has a slot for a removable memory card , which provides a means for non-volatile, off-

line program storage and restoration. The memory card can only be used with CPU numbers 311

through 341. CPU numbers 350 and above do not support either the HHP or the memory card.

The memory card plugs into a connector accessed through a slot on the lower right side of the HHP

(see previous figure).

HHP Modes of Operation

The HHP functionality is basically divided into four modes of operation that are selected through a

key sequence on the keypad.

Program Mode:

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

allows read, write, and verify functions with the memory card, EEPROM, or flash

memory.

Protection Mode

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

program logic, reference data, and configuration information. The use of this function is

optional; however, it is convenient in that it allows you to protect parts of the PLC system

from accidental or deliberate modification. Protection is provided through four levels of

passwords assigned by the user.

Data Mode

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

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

decimal, and timer/counter.

Configuration Mode

Allows you to define the types of I/O modules installed in the PLC system. You can also

assign I/O module addresses to these modules. This feature is convenient in that it allows

you to write and test logic programs using discrete references assigned to I/O modules that

are not yet installed. In this mode, you can also configure CPU data, such as real-time

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

Documentation

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

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

11-6

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

GFK-0356Q

Programmer Hardware Products

IC693PIF301/400 Personal Computer Interface (PCIF) Cards

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

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

ISA-compatible cards can be installed in any IBM-PC/AT ISA bus computer. The cards are

implemented using computer language software (for example, C), or PC control software.

Table 11-1. Personal Computer Interface Card Comparison Table

ITEM

PCIF

PCIF2

Catalog Number

IC693PIF301

IC693PIF400

Amount of I/O controlled

1,280 bytes

25,886 bytes

Number of Series 90-30 racks

Up to four Expansion or Remote

Up to seven Expansion or Remote

controlled

racks

Slot requirement

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

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

Documentation

GFK-0889 (IPI)

GFK-1540 (data sheet)

DOS-BASED

MICROSOFT C/TURBO C

WINDOWS-BASED

SOFTWARE

PROGRAMS

SOFTWARE

C LIBRARY

WINDOWS DLL

DOS TSR ROUTINE

MS-DOS

MS WINDOWS

MS-DOS

I/O EXPANSION CABLE

PCIF or PCIF2

I/O EXPANSION CABLE

SERIES 90-30 I/O

5 OR 10 SLOT

BASEPLATE

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

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

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

Remote racks can be located up to 700 feet ( 213 meters) and Expansion racks up to 50 feet (15

meters) from the personal computer. Several standard prewired I/O expansion cables are available

from GE Fanuc. Alternately, custom length cables can be built. Please refer to the “Cables”

chapter of this manual for information on standard and custom I/O expansion cables.

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

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

software application fails, which makes it useful for interfacing with external safety circuits.

GFK-0356Q

Chapter 11 Programmer Hardware Products

11-7

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

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

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

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

Electric (catalog number HE693SRC844).

Documentation

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

available from Horner Electric, Inc.

IC655CCM590 Isolated Repeater/Converter

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

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

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

Note

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

place of the IC655CCM590 Isolated Repeater/Converter.

IC690ACC903 Port Isolator

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

Repeater/Converter became obsolete. It provides 500 volts of isolation between connected RS-485

ports. It can be used in either single or multi-drop applications, and has a cable length working

distance of 4,000 feet (1,219 meters). It is physically smaller than the IC655CCM590. For details

about this product, please refer to Appendix D.

11-8

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

GFK-0356Q

Chapter

System Design

Introduction

This chapter is not intended to cover every possible aspect of designing a Series 90-30 system, but

it does provide you with basic product selection guidelines and with help in finding the information

you need.

Step 1: Planning Your System

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

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

things to know or have when planning your system:

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

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

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

information, speed, accuracy, repeatability, size, conformance to standards, cost restrictions,

time requirements, etc.

Documentation. If retrofitting existing equipment, you can refer to its documentation (layout

drawings, schematics, etc.). If the documentation is lost, perhaps a copy is available from the

manufacturer. Additional information may be gathered from discussions with the equipment

operators and maintenance technicians. For a new design, there are probably mechanical or

process drawings of the equipment.

Step 2: Determining I/O Requirements

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

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

determines what type and how many baseplates are needed and also is a major factor in CPU

selection. Note that there are some restrictions on the maximum number of certain types of

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

“Maximum Number of Modules Per System” for data.

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

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

new system, use the mechanical drawings or specifications to determine what inputs and

GFK-0356Q

12-1

outputs are needed. Make a list of inputs and outputs needed, separating them into four types:

Discrete Input, Discrete Output, Analog Input, Analog Output. If there are any special

requirements, such as fast response, etc., make a note of them on the page. Also, if parts of

your system are physically separated from other parts, requiring Expansion or Remote Racks,

create a separate list for each location.

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

type you need. Although the “I/O Modules” chapter in this manual contains brief descriptions,

you should refer to GFK-0898, Series 90-30 PLC I/O Module Specifications User’s Manual

for complete details.

Additional I/O Module Selection Factors

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

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

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

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

Manual, for details.

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

meet isolation requirements.

Hard Contact Requirements - Relay output modules can be used.

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

your system. For example, 32-point discrete I/O modules can save rack space compared to

lower density modules.

Standardization - Sometimes a company standardizes on particular types of modules to

simplify training or stocking of spare parts.

Response Time and Noise immunity - In general, higher response speed is attained at the

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

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

I/O modules, regardless of their response time rating, have a reasonable level of noise

immunity. Note that the IC693APU305 I/O Processor Option module, with its 500µs update

time, can handle I/O signals that are too fast for the CPU to handle directly (see GFK-1028,

Series 90-30 I/O Processor Module User’s Manual).

Step 3: Selecting Option Modules

There are several application requirements that determine Option module selection. However, note

that there are some restrictions on the maximum number of certain types of modules (Analog and

Option) that can be supported in one PLC system. See the table “Maximum Number of Modules

Per System” for data.

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

SNP, etc.

Interfacing with GE Fanuc CNC controls - Use the IC693BEM320 and IC693BEM321 I/O

Link modules.

Distance - Genius controller modules can communicate at distances up to 7,500 feet (2,286

meters). Serial communications using the RS-485 standard can cover up to 4,000 feet

12-2

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

GFK-0356Q

System Design and Layout

(1,219 meters). FIP networks are rated for 1,640 feet (500 meters). Modules with serial ports

communicating via modems and telephone lines or satellite links can cover unlimited

distances.

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

count high speed pulse trains. The IC693APU305 I/O Processor module is an intelligent

module that can satisfy high speed input and output requirements independent of the PLC scan.

Motion needs - The IC693APM301/302, IC693DSM302, and IC693DSM314 motion control

modules work with servo motor controllers and other motion devices. The IC693APU300

High Speed Counter module counts high speed pulses from encoders for use in measuring

motion-related data.

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

thermocouple inputs and PWM outputs.

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

application, often an extended feature requirement determines which one to choose. For

example, there are two Ethernet choices, the IC693CMM321 and the IC693CPU364, but only

the IC693CPU364 has Ethernet Global Data (EGD) capability.

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

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

Bus Controller (GBC) module via a twisted-pair cable. The GBC is the only Series 90-30

module that can control Genius Blocks. Other modules (GCM, GCM+) can read input data

broadcast by Genius Blocks, but cannot send commands to them. By selecting the applicable

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

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

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

ladder logic. This makes program creation, documenting, and editing easier for those not

trained in ladder logic programming. Industries that are required by law to thoroughly

document any changes to their system find State Logic to be especially useful.

Cost - In the case where either of two modules are capable of filling a need, an Option module

choice can be made based on the basis of cost.

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

is used. For example, the IC693CMM302 Enhanced Genius Communications Module can

transmit and receive many times more data than the IC693CMM301 Genius Communications

Module, and it transfers data to the PLC CPU at a faster rate. A comparison table for these

two modules is found in Appendix A of GFK-0695.

Standardization - Sometimes a company standardizes on particular types of modules to

simplify training or stocking of spare parts.

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

Human-Machine Interface (HMI) devices. For details, see the GE Fanuc web site,

http://www.gefanuc.com/

Third-party solutions - Many automation solutions are created by combining GE Fanuc

products with third-party products. Examples of third-party Series 90-30 modules are

Profibus, DeviceNet, SDS, LonWorks, Interbus-S, RTU/Modbus, ASCII Basic, RTD, and

Millivolt/Strain Gauge Input. Contact your GE Fanuc distributor for further information, or

check the GE Fanuc Web site for third-party product information.

GFK-0356Q

Chapter 12 System Design

12-3

Step 4: Selecting a CPU

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

can select a CPU. Many of the factors that apply to selecting Option modules, such as

performance, cost, standardization, etc. also apply to selecting a CPU. Details on CPU capabilities

are found in the “CPUs” chapter.

Number of modules required by the system - Embedded CPUs come in 5-slot or 10-slot

sizes and they do not support Extension or Remote baseplates. Therefore, if a system requires

only a few modules, these may be an option. If more than 10 modules are required, you must

select a Modular CPU. The CPU331-341 CPUs support up to 5 total baseplates, and the

CPU350-364 CPUs support up to 8 total baseplates. If you need more than 49 total Option and

I/O modules, you will need to use one of the CPU350-364 group of CPUs.

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

used in one system. This number also varies by CPU. For example, in the case of an

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

4 if using a 311, 313, or 323 CPU

8 if using a 331, 340,or 341 CPU

79 if using a 360-364 CPU

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

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

Modular CPU baseplate. Use of these modules therefore rules out the use of Embedded CPUs

(311, 313, 323). See the section “Location of Modules in the PLC Racks” for more

information.

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

microprocessor than the lower numbered CPUs. For applications where higher performance is

required, one of these would be a good choice. For math-intensive applications, the CPU352,

with its built-in math coprocessor, would give the best performance. For Ethernet applications,

the CPU364 with its built-in Ethernet interface, provides faster performance than separate CPU

and Ethernet modules. This is because the separate modules have to communicate over the

PLC backplane, which is slower than the CPU364’s internal path. For a similar reason, when

using serial communications, the CPUs 351, 352, and 363 (using Ports 1 and 2) perform faster

than a separate serial communications module (IC693CMM311) and CPU combination.

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

eliminate the need for a separate Ethernet module. This would save a PLC slot. The CPU351,

CPU352, and CPU353 each have two additional built-in serial ports which eliminate the need

for a separate serial communications Option module. The CPUs 350-364 have extra features

and capabilities that the other CPUs do not have such as, Floating Point Math, Sequential

Event Recorder, and Memory Protect Key Switch. Also, CPUs 351-364 have larger total

memory size, as well as configurable analog and register memory.

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

memory. This makes them more capable of meeting the needs of Option modules that require

this type of memory and user programs that require larger amounts of register or analog

memory. The CPU360 does not have configurable memory and has a lower base memory size

than the CPU351-364 CPUs. The CPU360-364 CPUs have standard Flash PROM for user

12-4

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

GFK-0356Q

System Design and Layout

data storage. This is not available in some of the other CPUs. See the “CPU Firmware and

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

Expansion and Upgrade - The Embedded CPUs do not support Expansion or Remote racks

and do not allow changing CPU type. Therefore, they have limited options for expansion or

upgrade. Modular CPUs can usually be upgraded to more powerful CPUs. The type of

modular CPU determines whether a system can have a total of 5 or 8 baseplates, which can

have a direct bearing on the future expansion capabilities of a system. For example, if you

only need 49 total Option and I/O Modules, you could use one of the CPU331-341 CPUs.

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

to the system without changing the CPU. If you used, instead, one of the CPU360-364 CPUs,

you could later add up to 30 more modules while keeping the same CPU.

Cost - If some of the other factors such as performance or extended features are not major

issues, one of the lower cost CPUs can be applied. However, sometimes purchasing a more

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

and an additional Option module to cover the feature needed. Besides the direct cost of the

modules, using the single CPU would save a PLC slot, which could help avoid the need for,

and cost of, an extra Baseplate, Power Supply, I/O Bus Expansion Cable, etc. Since prices are

subject to change, it would not be practical to give an example of this. Please check with your

distributor for current pricing information.

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

are often used to communicate with HMI or Operator Interface (OI) devices.

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

CPUs do.

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

system, you can use modules that have dual functions to conserve rack slots. For example, the

CPU364 has CPU and Ethernet communications capability in one module. The CPUs 351,

352, and 363 have CPU and Serial Communications capability in one module. There are

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

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

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

Blocks or Field Control distributed I/O to accommodate the need for additional I/O, since these

do not require a PLC slot; they communicate with the PLC over a communications bus.

Protection against unauthorized changes. CPUs 360—364 have a keylock switch that can

be locked to protect against unauthorized changes to the PLC. CPUs 311—341 do not have a

keylock switch. However, all CPUs have the capability of password protection for the

application program.

Step 5: Selecting Baseplates

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

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

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

you have three choices. The CPU311 and CPU313 are 5-slot sizes, and the CPU323 is a 10-

slot size. The CPU311 has 6K Bytes of memory and the CPU313 has 12K Bytes.

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

baseplate. There can be only one CPU baseplate per system. There are two types, 5-slot and

GFK-0356Q

Chapter 12 System Design

12-5

10-slot. If you only need a 5-slot size, you may want to consider whether the extra slots that a

10-slot size provides would be advantageous for possible future expansion. On the other hand,

the 5-slot size requires less space.

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

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

the better speed performance of the Expansion baseplates. Where a total cable distance of over

50 feet is required, Remote baseplates must be used. In cases where you only need a 5-slot

size, you may want to consider whether it would be advantageous to use a 10-slot size in order

to have open slots for future expansion. That factor should be weighed against the fact that the

5-slot size requires less space and costs less.

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

choice. See the “Baseplates” chapter for baseplate dimensions and clearance requirements.

Number of Modules Required - The number of modules needed at each location will have a

bearing on the sizes of racks required. You may choose to use a smaller rack (5-slot), if

possible, to save cost and space. However, as noted below, a larger rack (10-slot) with unused

slots will leave some room for future expansion, if desired.

Step 6: Selecting Power Supplies

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

chapter for additional details.

Power capacity - All Series 90-30 Power Supplies have three individual outputs: +5VDC,

+24VDC (Relay), and +24VDC (Isolated). Although all of these Power Supplies are rated at

30 Watts maximum total output, the rating of the +5VDC output varies from supply to supply,

as shown in the following table. For applications requiring heavy loading of the +5VDC

supply, choose one of the “High Output” power supplies: IC693PWR330 or IC693PWR331.

Input voltage - As seen in the next table, nominal input voltage choices are 24VDC, 48VDC,

120VAC, 125VDC, and 240VAC.

Table 12-1. Power Supply Feature Comparison Table

Catalog

Load

Nominal

Number

Capacity

Input

Output Capacities (Voltage/Power *)

IC693PWR321

30 Watts

100 to 240 VAC or

+5 VDC

+24 VDC Isolated

+24 VDC Relay

125 VDC

15 watts

20 watts

15 watts

IC693PWR330

30 Watts

100 to 240 VAC or

+5 VDC

+24 VDC Isolated

+24 VDC Relay

125 VDC

30 watts

20 watts

15 watts

IC693PWR322

30 Watts

24 or 48 VDC

+5 VDC

+24 VDC Isolated

+24 VDC Relay

15 watts

20 watts

15 watts

IC693PWR331

30 Watts

24 VDC

+5 VDC

+24 VDC Isolated

+24 VDC Relay

30 watts

20 watts

15 watts

* Total of all outputs combined cannot exceed 30 watts.

12-6

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

GFK-0356Q

System Design and Layout

Reducing PLC Module Count by Using Other GE Fanuc Products

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

Remote racks, a possible solution could be the use of GE Fanuc Genius Blocks, Field Control, or

VersaMax products. These distributed I/O devices can be used instead of Remote racks in remote

locations in some cases, and their use would not add to the Series 90-30 module count.

Genius Blocks

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

communicate with a Genius Bus Controller (GBC) module in the PLC via a shielded, twisted-pair

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

single GBC module in a PLC rack can control up to 31 Genius Blocks. Genius Blocks come in

discrete and analog I/O, high speed counter, RTD, and thermocouple interface types. For more

information on using Genius Blocks, see GEK-90486-1, Genius I/O System and Communications

User’s Manual, and GEK-90486-2, Genius I/O Discrete and Analog Blocks User’s Manual.

Field Control

These are intelligent distributed I/O units that mount at the point-of-use on a 35mm x 7.5mm DIN-

rail. They can communicate over Genius, FIP, or Profibus buses. They are not included in the

PLC module count, but do require I/O memory allocation. A Field Control unit consists of a Bus

Interface Unit (BIU) that interfaces to the applicable bus, from one to eight I/O modules, and

cabling. I/O modules come in various discrete, analog, and RTD types. A local logic processor

module (MFP) is also available. For further information on Field Control, see the following:

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

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

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

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

VersaMax

VersaMax I/O modules can be used as distributed I/O, communicating with a Series 90-30 PLC

over one of three bus types: Genius, Profibus, or Device Net. This arrangement would require an

Option module for the desired bus type in the Series 90-30 PLC as well as the applicable Network

Interface Module in the VersaMax system. For more information on the VersaMax products,

please see GFK-1504, VersaMax Modules, Power Supplies, and Carriers Manual.

GFK-0356Q

Chapter 12 System Design

12-7

Designing For Safety

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

and equipment from harm. Although some basic guidelines are found in the “Installation”

chapter of this manual, it is not possible to cover every aspect of safety because of the diversity of

applications. Additionally, it is not practical for this manual to try to cover all the possible codes

and regulations that may apply to your locality or type of equipment. You have the ultimate

responsibility to consult applicable safety codes for your locality, or that pertain to the

particular type of equipment you are designing, and ensure that your design complies with

these standards. In the United States, the National Electric Code (NEC) has been adopted by

many localities. The United States Occupational Safety and Health Administration (OSHA)

regulations also contain many safety regulations that apply to all industrial equipment in the United

States. In the absence of local regulations, the NEC and OSHA regulations should be followed

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

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

Protection From Electrical Shock

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

Personnel should be prevented from accidentally coming in contact with hazardous voltages. Also,

unauthorized personnel should be prevented from gaining access to high voltage cabinets and

panels. Interlock circuits are often used for this purpose.

Fire Prevention

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

faulty electrical design.

Protection From Mechanical Hazards

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

or index tables or mechanical pinch points. The use of interlocked safety gates, light curtains,

safety mat switches, dual hand buttons, physical barriers (guards), etc. can be used for this purpose.

See the applicable section of the OSHA regulations for details.

Protection From Electrical Failure

In the event of a system component failure, the design should be an acceptable “fail-safe” one in

which the failure does not cause a safety hazard such as a runaway condition or a disabling of

emergency stop circuits. Emergency stop and other safety circuits should consist of hard-wired

components that tend to fail in a harmless manner.

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

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

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

12-8

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

GFK-0356Q

System Design and Layout

circuits, etc. This type of circuit tends to fail “open,” which disables the equipment. For example,

if a wire breaks or a contact wears out, the circuit opens and the MCR drops out. If solid state

devices fail, they tend to fail “shorted,” which in the case of PLC output circuits would cause the

controlled device to turn on or stay on.

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

power to its solenoid coil which magnetically pulls the contacts to their energized states. When de-

energized, the contacts move to their normal, at rest states by the pull of a mechanical spring.

When the Reset pushbutton is pressed, and if all four of the E-Stop and Gate switches are closed,

the MCR relay will energize and “latch” in the energized state through its MCR contact in parallel

with the Reset pushbutton. Its other MCR contact applies power to the motor starter and PLC

output circuits. If any one of the E-Stop or Gate switches opens, or if a wire breaks in this circuit,

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

starters and PLC output circuits.

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

not directly control any outputs. Keeping these circuits energized is desirable because this allows

the PLC to continue gathering data, recording fault information, and controlling communications,

even if its Output module outputs are disabled by the MCR.

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

be wired in parallel, their normally open contacts wired in series, and their normally closed contacts

wired in parallel. This would help guard against the possibility of a “welded contact” on a single

MCR relay.

Master Control

Reset

E-Stop 1

E-Stop 2

Gate 1

Gate 2

Relay (MCR)

MCR

PLC Main Power and

Input Power Circuits

MCR

To Motor Starters, PLC

Output Module Circuits, etc.

Figure 12-1. Hard-Wired MCR Circuit Example

Protection From Design Changes or Overrides

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

of the equipment. Passwords and lockout circuits may be used to accomplish this. Some Series

90-30 CPUs have keylock switches to protect against program changes (see “CPUs” chapter for

keylock switch details).

GFK-0356Q

Chapter 12 System Design

12-9

Safety Documentation

PLC Program Documentation. Thorough documentation will help you and others who work

on the equipment remember and understand how the safety circuits and features work. (In

some industries, applicable regulations may require this type of documentation.) The PLC

programming software gives you extensive documentation abilities.

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

Stop Coil,” and Comments such as “This coil is used to stop the program cycle, but it does not

turn off power to the main hydraulic circuit. However, if the operator opens the safety gate,

the Safety Gate Interlock switch will open and shut off the hydraulic pump.” These

Nicknames, Descriptions, and Comments become part of the PLC program and can be viewed

with the applicable software.

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

it easier to document PLC program design because it uses “Natural Language” expressions

instead of ladder logic symbols.

Electrical and mechanical prints should contain notations pertaining to safety issues.

Written operating and maintenance instructions as well as training should be provided to

operators and maintenance personnel. These should address any applicable safety issues.

Guarding Against Unauthorized Operation

Keylock switches and passwords are frequently used for this purpose.

Labeling, Guarding, and Lighting Issues

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

should be clearly labeled as to their function.

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

activated accidentally. Recessed pushbutton designs or pushbuttons with surrounding guard

rings might help prevent the pushbutton from being depressed if, for example, a tool were

dropped or laid upon it. Mounting pushbutton stations to vertical surfaces also may help avoid

this problem.

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

clearly seen.

Equipment Accessibility Issues

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

safely. Also, sufficient clearance should be provided so that maintenance personnel have safe

access to electrical panels, control boxes, etc. These minimum clearances are specified in the NEC

and OSHA requirements.

12-10

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

GFK-0356Q

System Design and Layout

Number of Modules Per Series 90-30 PLC System

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

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

depends on several factors, including available references for each CPU model, the current rating

for each module to be installed in the system, and other installed modules. Before installing

modules in a baseplate, verify that the total current rating of all of those modules does not exceed

the power rating of the power supply.

Table 12-2. Maximum Number of Modules Per System

CPU

Module Type

Model 311/313/323

Model 331/340/341

Model 350 - 364

Input and Output, Discrete

5 (5-slot baseplate)

49 (331/340/341)

10 (10-slot baseplate)

Input Module, Analog , 4-Channel

5 (5-slot baseplate)

8 (10-slot baseplate)

Input Module, Analog, 16-Channel

8 (Model 331)

12 (Model 340/341)

Output Module (Voltage), Analog, 2-Channel

5 (5-slot baseplate)

16 (Model 331)

6 (10-slot baseplate)

30 (Model 340/341)

Output Module (Current), Analog, 2-Channel

3 (5-slot baseplate)

15 (Model 331)

3 (10-slot baseplate)

15 (Model 340/341)

Output Module, Analog, 8-Channel

8 (Model 331)

32 (Model 340/341)

Combination Input/Output Module, Analog

5 (5-slot baseplate)

21 (Model 331/40/341)

4-Ch In/2-Ch Out

10 (10-slot baseplate)

Programmable Coprocessor Module

n/a

Alphanumeric Display Coprocessor Module

n/a

Communications Control Module

n/a

State Logic Processor Module

n/a

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

Genius Communications Module (1)

Enhanced Genius Communications Module (1)

High Speed Counter

4 (5/10-slot baseplate)

8 (Model 331)

32 (Model 340/341)

I/O Link Interface Module

5 (5/10-slot baseplate)

I/O Processor Module

2 (5-slot baseplate)

8 (Model 331)

4 (10-slot baseplate)

16 (Model 340/341)

Genius Bus Controller (2)

Ethernet Interface Module

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

GFK-1084 for details.

Motion Mate APM300 Module

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

for details.

Motion Mate DSM302 Module

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

Motion Mate DSM314 Module

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

Temperature Control Module

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

Power Transducer Module

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

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

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

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

GFK-0356Q

Chapter 12 System Design

12-11

Calculating Power Supply Loading

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

external loads placed on it by all of the hardware components in the baseplate (backplane, modules,

etc.), as well as external loads connected to the Isolated + 24 VDC supply. Use of the Isolated +24

Volt power supply output is optional; however, this output can be used to drive a limited number

of input devices. The maximum total power output rating of the Power Supplies is 30 watts;

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

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

details.

Load Requirements for Hardware Components

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

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

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

+5 VDC provides primary power to operate most internal circuits

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

+24 VDC Isolated provides power to operate a number of input circuits (input modules only),

and any external circuits connected to the 24 VDC Output terminals on the power supply

terminal strip.

Note that the figures listed in the following table are maximum (worst case) requirements , not

typical requirements.

Table 12-3. Load Requirements (in milliamps)

Catalog

+24 VDC Relay

+24 VDC

Number

Description

+5 VDC

Power

Isolated

AD693SLP300

State Logic Processor Module

425

IC693ACC300

Input Simulator, 8/16 Points

120

IC693ACC307

Expansion Bus Termination Plug

IC690ACC900

RS-422/RS-485 to RS-232 Converter

170

IC690ACC901

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

150

(version B, or later )

100

IC693ADC311

Alphanumeric Display Coprocessor Module

400

IC693ALG220

Analog Input, Voltage, 4 Channel

IC693ALG221

Analog Input, Current, 4 Channel

100

IC693ALG222

Analog Input, Voltage, High Density (16 Channel)

112

IC693ALG223

Analog Input, Current, High Density (16 Channel)

120

IC693ALG390

Analog Output, Voltage, 2 Channel

120

IC693ALG391

Analog Output, Current, 2 Channel

215

IC693ALG392

Analog Current/Voltage Output, 8 Channel

110

IC693ALG442

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

129

IC693APU300

High Speed Counter

250

IC693APU301

Motion Mate APM300, 1-Axis

800

IC693APU302

Motion Mate APM300, 2-Axis

800

IC693APU305

I/O Processor Module

360

12-12

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

GFK-0356Q

System Design and Layout

Catalog

+24 VDC Relay

+24 VDC

Number

Description

+5 VDC

Power

Isolated

IC693BEM320

I/O Link Interface Module (slave)

205

IC693BEM321

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

415

(with Optical Adapter)

615

IC693BEM330

FIP Remote I/O Scanner

609

IC693BEM331

Genius Bus Controller

300

IC693BEM340

FIP Bus Controller

(maximum)

1.2A

(typical)

800

IC693CHS391

10-slot Modular CPU Baseplate

250

IC693CHS392

10-slot Expansion Baseplate

150

IC693CHS393

10-slot Remote Baseplate

460

IC693CHS397

5-slot Modular CPU Baseplate

270

IC693CHS398

5-slot Expansion Baseplate

170

IC693CHS399

5-slot Remote Baseplate

480

IC693CMM301

Genius Communications Module

200

IC693CMM302

Enhanced Genius Communications Module

300

IC693CMM311

Communications Control Module

400

IC693CMM321

Ethernet Interface Module

750

IC693CPU311

Series 90-30 5-Slot Embedded CPU Baseplate

410

IC693CPU313

Series 90-30 5-Slot Embedded CPU Baseplate

430

IC693CPU323

Series 90-30 10-Slot Embedded CPU Baseplate

430

IC693CPU331

CPU (Model 331)

350

IC693CPU340

CPU (Model 340)

490

IC693CPU341

CPU (Model 341)

490

IC693CPU350

CPU (Model 350)

670 **

IC693CPU351

CPU (Model 351)

890 **

IC693CPU352

CPU (Model 352)

910 **

IC693CPU360

CPU (Model 360)

670 **

IC693CPU363

CPU (Model 363)

890 **

IC693CPU364

CPU (Model 364)

1.51A**

IC693CSE313

State Logic CPU, 5-slot baseplate

430

IC693CSE323

State Logic CPU, 10-slot baseplate

430

IC693CSE340

State Logic CPU Module

490

IC693DSM302/314

Motion Mate DSM302 or DSM314 Module

800

1300 with

external

encoder

IC693MAR590

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

IC693MDL230

120 VAC Isolated, 8 Point Input

IC693MDL231

240 VAC Isolated, 8 Point Input

IC693MDL240

120 VAC, 16 Point Input

IC693MDL241

24 VAC/DC Pos/Neg logic, 16 Point

125

IC693MDL310

120 VAC, 0.5A, 12 Point Output

210

IC693MDL330

120/240 VAC, 1A, 8 Point Output

160

IC693MDL340

120 VAC, 0.5A, 16 Point Output

315

IC693MDL390

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

110

IC693MDL630

24 VDC Positive Logic, 8 Point Input

2.5

IC693MDL632

125 VDC Pos/Neg Logic, 8 Point Input

IC693MDL633

24 VDC Negative Logic, 8 Point Input

IC693MDL634

24 VDC Pos/Neg Logic, 8 Point Input

125

IC693MDL640

24 VDC Positive Logic, 16 Point Input

120

IC693MDL641

24 VDC Negative Logic, 16 Point Input

120

GFK-0356Q

Chapter 12 System Design

12-13

Catalog

+24 VDC Relay

+24 VDC

Number

Description

+5 VDC

Power

Isolated

IC693MDL643

24 VDC Positive Logic, FAST, 16 Point Input

120

IC693MDL644

24 VDC Negative Logic, FAST, 16 Point Input

120

IC693MDL645

24 VDC Pos/Neg Logic, 16 Point Input

125

IC693MDL646

24 VDC Pos/Neg Logic, FAST, 16 Point Input

125

IC693MDL652

24 VDC Pos/Neg Logic 32 Point Input

IC693MDL653

24 VDC Pos/Neg Logic, FAST, 32 Point Input

IC693MDL654

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

195/440*

IC693MDL655

24 VDC Pos/Neg, 32 Point Input

195

224

IC693MDL730

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

IC693MDL731

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

IC693MDL732

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

IC693MDL733

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

IC693MDL734

125 VDC Pos/Neg Logic, 6 Point Output

IC693MDL740

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

110

IC693MDL741

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

110

IC693MDL742

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

130

IC693MDL750

12/24 VDC Negative Logic, 32 Point Output

IC693MDL751

12/24 VDC Positive Logic, 32 Point Output

IC693MDL752

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

260

IC693MDL753

12/24 VDC Positive Logic, 0.5A, 32 Point Output

260

IC693MDL930

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

IC693MDL931

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

110

IC693MDL940

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

135

IC693MDR390

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

IC693PCM300

Programmable Coprocessor Module, 65K

425

IC693PCM301

Programmable Coprocessor Module, 85K

425

IC693PCM311

Programmable Coprocessor Module, 380K

400

IC693PRG300

Hand-Held Programmer

170

IC693PTM100

Power Transducer Module

400

IC693TCM302

Temperature Control Module

150

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

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

Power Supply Loading Calculation Examples

Following are examples of calculations for determining the total load placed on a Series 90-30 PLC

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

Note that although each output is rated at 15 or 20 watts (with the exception that the +5 VDC

output for the High Capacity power supply is rated at 30 watts), the total combined output can be

no more than 30 watts. The power required by external circuits connected to the 24 VDC

OUTPUT terminals on the power supply terminal strip should be added to the calculation.

12-14

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

GFK-0356Q

System Design and Layout

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

Component

+5V

+24V Isolated

+24V Relay

IC693CPU323 Embedded CPU

430

Baseplate

IC693PRG300 Hand-Held Programmer

170

IC693ALG390 Analog Output

120

IC693ALG220 Analog Input

IC693APU300 HS Counter

190

24 VDC Input (16 points)

120

IC693MDL340 Input Module

120

IC693MDL740 Output Module

110

IC693MDL240 Input Module

IC693MDL310 Output Module

210

IC693MDL940 Relay Out. Mod.

135

IC693MDL930 Relay Out. Mod.

Totals (milliamps)

1281

458

205

(Watts)

6.41

10.99

4.92

Total Watts = 22.32

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

Component

+5V

+24V Isolated

+24V Relay

IC693CHS391 Modular CPU Baseplate

250

IC693CPU351 CPU Module

890

IC690ACC901 Miniconverter Kit

100

IC693PCM301 PCM Module

425

IC693ALG390 Analog Output

120

IC693ALG220 Analog Input

IC693APU300 HS Counter

190

IC693MDL340 Input Module

120

IC693MDL740 Output Module

110

IC693MDL240 Input Module

IC693MDL310 Output Module

210

IC693MDL940 Relay Out. Mod.

135

Totals (milliamps)

2336

338

135

(Watts)

11.68

8.11

3.24

Total Watts = 23.03

Scan (Sweep) Time Calculation

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

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

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

of the design specification. To help avoid timing issues, the theoretical scan time should be

calculated so that appropriate solutions can be designed into the system up-front.

GFK-0356Q

Chapter 12 System Design

12-15

Major Design Factors Affecting Scan Time

Size of ladder program

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

Types of instructions used in ladder program

Number of modules

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

impact than others such as discrete I/O modules.

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

are installed in.

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

modules or ports.

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

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

should be minimized to ensure proper system timing and margins. Suggested cable types for

I/O Bus Expansion and communication cables are documented in the “Cables” chapter. Any

deviation in cable types from those recommended may result in erratic or improper

system operation.

Where to Find Scan Time Information

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

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

12-16

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

GFK-0356Q

System Design and Layout

Calculating PLC Heat Dissipation

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

determining the enclosure size needed for the system. This is because the enclosure must be able to

adequately dissipate the heat generated by all of the components mounted inside so that no

components overheat. PLC heat dissipation is also a factor in determining the need for enclosure

cooling options such as fans and air conditioning. Enclosure manufacturers generally consider

enclosure heat dissipation as a factor in their enclosure selection guidelines. Instructions for

calculating Series 90-30 PLC heat dissipation can be found in Appendix F, “Series 90-30 Heat

Dissipation.”

System Layout Guidelines

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

possible layout. Instead, this section offers guidelines and an example to help you lay out your

system.

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

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

to install, how well it looks, and how easy and safe it is to maintain:

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

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

make measurements, load software, check indicator lights, remove and replace modules, etc. It

also makes it easier to trace wiring and locate components while troubleshooting.

Reliability -Proper layout promotes good heat dissipation and helps eliminate electrical noise

from the system. Excess heat and noise are two major causes of electronic component failure.

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

unit. This saves time and frustration.

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

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

PLC Rack Location and Clearance Requirement

The following list provides PLC rack mounting location guidelines. For an example layout, see the

figure “Series 90-30 Example Layout” later in this chapter.

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

transformers, power supplies, or power resistors.

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

contacts.

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

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

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

GFK-0356Q

Chapter 12 System Design

12-17

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

maintaining the system.

Route sensitive input wires away from electrically noisy wires such as discrete output and AC

wiring. This can be facilitated by grouping I/O modules to keep Output modules separated

from sensitive Input modules.

The PLC racks each require a 4" clearance space on all four sides (6 inches on the right end if

using I/O Bus Expansion Cables) to ensure adequate ventilation/cooling. See the “Baseplates”

chapter for baseplate size and clearance requirement information.

Location of Modules in the PLC Racks

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

Location restrictions - Although most modules can be located in any type of baseplate, a few

of the Option modules (PCM, ADC, CMM, SLP) will only work in a CPU baseplate. The next

figure identifies where you can locate the modules in your system.

Power Supply capacity - Since some modules draw considerably more power than others, it is

possible to overload the power supply by placing many of the modules requiring higher power

in one rack. Therefore, before finalizing your rack layout you should calculate the power

supply loading to ensure that you will not overload the power supply. See the section

“Calculating Power Supply Loading.”

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

modules. This facilitates keeping noisy wiring separated from sensitive wiring, as

recommended in a previous section.

12-18

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

GFK-0356Q

System Design and Layout

Allowable Module Locations

DISCRETE INPUT/OUTPUT

ANALOG INPUT/OUTPUT

HIGH SPEED COUNTER

MODEL 311/313

I/O PROCESSOR

(5-SLOT)

GENIUS COMMUNICATIONS

ENHANCED GENIUS COMM.

MOTION MATE APM300/DSM302

I/O LINK INTERFACE

GENIUS BUS CONTROLLER

ETHERNET INTERFACE

TEMPERATURE CONTROL

DISCRETE INPUT/OUTPUT

ANALOG INPUT/OUTPUT

HIGH SPEED COUNTER

I/O PROCESSOR

MODEL 313

GENIUS COMMUNICATIONS

(10-SLOT)

ENHANCED GENIUS COMM.

MOTION MATE APM300/DSM302

I/O LINK INTERFACE

GENIUS BUS CONTROLLER

ETHERNET INTERFACE

TEMPERATURE CONTROL

DISCRETE INPUT/OUTPUT

ANALOG INPUT/OUTPUT

HIGH SPEED COUNTER

MODEL 331/340/341

I/O PROCESSOR

and 350/351/352/360/

GENIUS COMMUNICATIONS

ENHANCED GENIUS COMM.

363/364 5-Slot CPU

MOTION MATE APM300/DSM302

I/O LINK INTERFACE

PCM / ADC / CMM / SLP

GENIUS BUS CONTROLLER

ETHERNET INTERFACE

TEMPERATURE CONTROL

DISCRETE INPUT/OUTPUT

ANALOG INPUT/OUTPUT

HIGH SPEED COUNTER

MODEL 331/340/341

I/O PROCESSOR

and 350/351/352/360/

GENIUS COMMUNICATIONS

363/364 10-Slot CPU

ENHANCED GENIUS COMM.

MOTION MATE APM300/DSM302

I/O LINK INTERFACE

GENIUS BUS CONTROLLER

ETHERNET INTERFACE

TEMPERATURE CONTROL

PCM / ADC / CMM / SLP

DISCRETE INPUT/OUTPUT

ANALOG INPUT/OUTPUT

HIGH SPEED COUNTER

I/O PROCESSOR

MODEL 331/340/341

GENIUS COMMUNICATIONS

and 350/351/352/360/

ENHANCED GENIUS COMM.

363/364 5-Slot Expansion

MOTION MATE APM300/DSM302

I/O LINK INTERFACE

GENIUS BUS CONTROLLER

ETHERNET INTERFACE

TEMPERATURE CONTROL

DISCRETE INPUT/OUTPUT

ANALOG INPUT/OUTPUT

HIGH SPEED COUNTER

I/O PROCESSOR

GENIUS COMMUNICATIONS

MODEL 331/340/341

ENHANCED GENIUS COMM.

and 350/351/352/360/

MOTION MATE APM300/DSM302

363/364 10-Slot Expansion

I/O LINK INTERFACE

GENIUS BUS CONTROLLER

ETHERNET INTERFACE

TEMPERATURE CONTROL

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

Figure 12-2. Allowable Location of Modules

GFK-0356Q

Chapter 12 System Design

12-19

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