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

Example of Cable Configurations

Examples of cable configurations required when using the converter can be found in Appendix C.

Specifications for the converter are shown in the following table.

Table B-4. Specifications for IC690ACC900 Converter

Power Requirements:

Voltage

5 volts DC, +5%

Current

170 mA, ±5%

RS-422/RS-485 Interface Cables:

Maximum cable length

1000 feet(300m)

Cable Type: *

6 feet (2m)

Cable type: Belden 9508, AWG #24 (0.22 mm²)

30 feet (10m) **

Cable type: Belden 9309, AWG #22 (0.36 mm²)

≥30 feet, up to 1000 feet (300m) ]

Same cable as for 30 feet.

Connector Type

15-pin D-type Male Subminiature (both ends)

RS-232 Interface Cable:

Maximum cable length

50 feet (15m)

Up to 50 feet (15m)

Connector Type

25-pin D-type Female Subminiature (converter end) 9-pin, 15-pin, or

25-pin (depending on type of connector on your serial device) D-type

Female Subminiature (programming device end)

* Catalog numbers are provided as suggestions only. Any cable having the same electrical

characteristics is acceptable. It is strongly recommended that you use stranded wire. Since it

is sometimes hard to find a cable with the desired number of twisted pairs (the Belden 9309

has an extra pair), you may end up with a cable with extra pairs.

** For distances over 10 feet, the +5 volt DC logic power source must be provided externally by

connecting an external power supply to the +5V and SG (0V) connections at the converter end

of the cable. The +5V pin at the PLC connector end of the cable must not be connected to

the cable. The +5V and SG connections from the external power supply must be isolated from

its own power line ground connection. Ensure that there is no connection between the external

supply and the PLC except the SG cable connection.

GFK-0356Q

Appendix B IC690ACC900 Converter

B-9

Appendix

IC655CCM690 Isolated Repeater/Converter

Note: This product is no longer available. This appendix is for reference by

those already using this product. It has been replaced by catalog number

IC690ACC903 (see Appendix E for details).

This appendix describes how to use the Isolated Repeater/Converter (IC655CCM590) with Series

90 PLCs. The following topics are covered in this appendix.

■ Description of the Isolated Repeater/Converter

■ System Configurations

■ Cable Diagrams

Note: The catalog number for the Isolated Repeater/Converter was previously

IC630CCM390.

Description of the Isolated Repeater/Converter

The Isolated Repeater/Converter (IC655CCM590) can be used for the following purposes.

■ To provide ground isolation where a common ground cannot be established between

components.

■ To boost RS-422 signals for greater distance and more drops.

■ To convert signals from RS-232 to RS-422 or RS-422 to RS-232.

The figure on the next page shows the appearance of the unit and the locations of key features.

GFK-0356Q

C-1

(TOP VIEW)

RS422

POWER

GE Fanuc

FUSE

CORD

115VAC

RS232C

230VAC

ISOLATED

ADAPTOR

POWER

SWITCH

POWER

CORD

FUSE

(BACK

VIEW)

FUSE-1AMP

(SIDE

VIEW)

Figure C-1. Isolated/Repeater Converter

Items of interest to the user on the Isolated Repeater/Converter are described below.

Two 25-pin female D-type connectors (Two 25-pin male, D-type connectors (solder pot), are

included for user cabling.)

115/230 VAC power connection (internal) 4-position terminal block.

Fused 1 Amp power protection.

Power ON (green) indicator LED.

Three-position toggle switch, recessed in the back of the unit, is set according to the system

configurations shown later in this appendix.

C-2

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

GFK-0356Q

IC655CCM590 Converter

Logic Diagram of the Isolated Repeater/Converter

The figure below provides a functional look at the unit. Note the 3-position switch for controlling

the J1 port transmitters. This switch is discussed in System Configurations later in this appendix..

OPTICAL

RS-422/RS-232C

RS-422

ISOLATION

SD (RS-232C)

RD ( B' )

SD (B )

RD ( A' )

SD (A )

RTS (RS-232C)

CTS ( B' )

RTS (B )

RESISTOR

150

RTS (A )

CTS ( A' )

RD ( B' )

SD ( B )

RD ( A' )

SD ( A )

RD (RS-232C)

CTS ( B' )

RTS (B )

RTS (A )

CTS ( A ')

CTS (RS-232C)

( CTS)

(ON)

(SE)

ISOLATED

POWER

SUPPLIES

SE (RS-232C)

115

VAC

Figure C-2. RS-422 Isolated Repeater/RS-232 Converter Logic Diagram

Note: All inputs are biased to the inactive state. Inputs left unconnected will produce a binary 1

(OFF) state on the corresponding output.

GFK-0356Q

Appendix C IC655CCM690 Isolated Repeater/Converter

C-3

Pin Assignments for the Isolated Repeater/Converter

Table C-1. Isolated Repeater/Converter Pin Assignments

J1 RS-422 Port (25-pin female connector)

J2 RS-422/RS-232 Port (25-pin female connector)

Signal

Description

Signal

Description

Send Data (RS-232)

Receive Data (RS-232)

RTS

Request to Send (RS-232)

CTS

Clear to Send (RS-232)

Ground Connection

CTS(B’)

Clear to Send (Optional Termination)

CTS(B’)

Clear to Send Optional Termination)

CTS(A’)

Clear to Send (Optional Termination)

CTS(A’)

Clear to Send (Optional Termination)

CTS(B’)

Clear to Send

RTS(B)

Request to Send

CTS(A’)

Clear to Send

RTS(A)

Request to Send

RTS(B)

Request to Send

CTS(B’)

Clear to Send

RTS(A)

Request to Send

CTS(A’)

Clear to Send

RD(B’)

Receive Data

SD(B)

Send Data

RD(A’)

Receive Data

SD(A)

Send Data

SD(A)

Send Data

RD(A’)

Receive Data

SD(B)

Send Data

RD(B’)

Receive Data

RD(A’)

Receive Data (Optional Termination)

RD(B’)

Receive Data (Optional Termination)

RD(B’)

Receive Data

SD(B)

Send Data (Optional Termination)

RD(A’)

Receive Data

SD(A)

Send Data (Optional Termination)

SD(A)

Send Data

NC=No Connection

SD (Send Data) and RD (Receive Data) are the same as TXD and RXD (used in the Series Six PLC).

(A) and (B) are the same as - and + A and B denote outputs, and A’ and B’ denote inputs.

Caution

The signal ground connections (pin 7 on each connector) must be made

between the Isolated Repeater/Converter and the PLC for J1, and the

Isolated Repeater/Converter and the host computer for J2.

Pin 7 of the J1 port is connected to the metal shell of the J1 connector. Pin 7

of the J2 port is connected to the metal shell of the J2 connector. These two

signal ground connections are isolated from each other and from the power

system ground (green wire on the terminal block). To maintain proper

isolation, these signal grounds cannot be tied together.

C-4

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

GFK-0356Q

IC655CCM590 Converter

RS-232

RS-422 ISOLATED REPEATER

RS-422

a44783

SHIELDED

RS-232 CONVERTER

TWISTED SHIELDED

PAIRS

(IC655CCM590)

PAIRS

150 Ω

RD (B')A' )22

SD ( A )

RD (A')B' )23

SD ( B )

RTS

CTS

SD ( A )15

RD ( A' )

CTS

RTS

SD ( B )14

RD ( B' )

DCD

GND

CTS ( A' )16

SERIES

DTR

CTS ( B' )17

RTS ( A )

90 PLC

HOST

GND

RTS ( A )

RTS ( B )

RS-422

COMPUTER

RTS ( B )10

CTS ( A' )

PORT

CTS ( B' )

SHLD

25-PIN

25- PIN

15- PIN

MALE

FEMALE

MALE

FEMALE

RS-232/

RS-422

PORT

** SWITCH IN CENTER POSITION

PORT

115VAC

TERMINATION RESISTANCE FOR THE RECEIVE DATA (RD) SIGNAL NEEDS TO BE CONNECTED ONLY ON UNITS AT THE END OF THE LINES.

* THIS TERMINATION IS MADE ON THE SERIES 90 PLC PRODUCTS BY CONNECTING A JUMPER BETWEEN PIN 9 AND PIN 10 INSIDE THE

15-PIN D-SHELL WITH THE FOLLOWING EXCEPTION. FOR SERIES 90-70 PLCs, CATALOG NUMBERS IC697CPU731 AND IC697CPU771,

THE TERMINATION FOR RD AT THE PLC IS IMPLEMENTED BY A JUMPER BETWEEN PIN 9 AND PIN 11.

Figure C-3. Example RS-422 Isolated Repeater/RS-232 Converter Connection

System Configurations

The figures below show various ways you can connect the Isolated Repeater/Converter to convert

signals, expand the number of drops, and obtain greater distance. Any system configuration can be

reduced to a minimum number of cables each covering a part of the overall system configuration.

The following examples of system configurations refer to these cables as Cables A through E

which are described in Cable Diagrams later in this section.

Downstream and Upstream Contention. In this section, simple multidrop configurations are

those where a single Isolated Repeater/Converter is used. Complex multidrop configurations

contain one or more multidrop sections where an Isolated Repeater/Converter is included as one

of the drops. In both simple and complex multidrop configurations, the transmitters directed

downstream from the master can be on at all times. There will be no contention for the

communication line because only one device (the master) transmits downstream.

In simple multidrop configurations, there will be no contention when transmitting upstream as long

as devices tri-state their drivers when idle and turn them on only when they have something to

transmit. This is the case for the Series 90-70 and Series 90-30 CMMs.

In complex multidrop configurations, however, special steps must be taken to switch the upstream

transmitters of the Isolated Repeater/Converter.

Switching Upstream Transmitters. For the RS-422 drivers to be active at the J2 port of the

Isolated Repeater/Converter, the RTS input at J1 must be true. The state of the RS-422 drivers at

the J1 port depends on the position of the switch on the unit. When the switch is in the center

position, the J1 transmitters will always be turned on. When the switch is in the CTS position,

(toward the power cable), then either the RS-232 or RS-422 CTS signal must be true to turn on the

J1 drivers.

Note: Note the position of the switch on the Isolated/Repeater Converter in the system

configurations below.

GFK-0356Q

Appendix C IC655CCM690 Isolated Repeater/Converter

C-5

Simple Multidrop Configuration

This configuration shows how to connect a single Isolated Repeater/Converter for signal

conversion or greater distance.

RS-232

RS-422

(CABLE A)

(CABLE B)

(CABLE D)

SERIES 90 PLC

* BRICK

SERIES 90 PLC

HOST

SERIES 90 PLC

* BRICK IS THE NICKNAME FOR THE

ISOLATED REPEATER/CONVERTER

Figure C-4. Simple System Configuration Using the Isolated Repeater/Converter

Complex Multidrop Configuration

This configuration shows how to connect multiple Isolated Repeater/Converters for signal

conversion, greater distance, and more drops.

RS-422

(CABLE

SERIES 90

C OR

HOST

SERIES 90

RS-422

(CABLE

BRICK

SERIES 90

PLC

RS-232

SWON

(CABLE

SERIES 90

)

RS-422

(CABLE

RS-422

(CABLE

SERIES 90

BRICK

SWON

SERIES 90

PLC

RS-232

(CABLE

* BRICK IS THE NICKNAME FOR THE

BRICK

)

SERIES 90

ISOLATED REPEATER/CONVERTER

PLC

CTS

Figure C-5. Complex System Configuration Using the Isolated Repeater/Converter

C-6

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

GFK-0356Q

IC655CCM590 Converter

Rules for Using Repeater/Converters in Complex Networks

When designing a complex multidrop network including PLCs and RS-422 repeater/converters

(bricks), the following rules apply:

Rule 1: When using a brick as a repeater, port J2 should always be directed toward the host

device, and Port J1 should always be directed away from the host device. The switch located on

the side of the brick should always be in the center position (ON). The only case in which Port J1

is directed toward the host is when the brick is used as a converter (RS-232) at the slave. The

switch is in the right position (CTS).

Rule 2: If a Series 90 CMM slave device is located downstream of a brick, set the configuration of

the CMM serial port to NONE flow control with a 10 ms Modem Turnaround Delay (Applies to

CCM, SNP, and SNP-X protocols only).

Rule 3: Do not place more than three bricks in a single communication path between the host and

the slave devices.

GFK-0356Q

Appendix C IC655CCM690 Isolated Repeater/Converter

C-7

Cable Diagrams

The cable diagrams below are referred to as Cables A-E from the system configurations in the

previous figures. These diagrams show the principles for constructing your own cables and can be

modified to fit your specific application.

a44929

SW ON

RTS

CTS

SERIES 90

DCD

GND

DTR

ISOLATED

CMM

REPEATER/

PORT

GND

CONVERTER

1 OR 2

SHLD

(BRICK)

25- PIN

FEMALE

MALE

FEMALE

Figure C-6. Cable A; RS-232 CMM To Converter

a44930

SW ON

SD (A)

RD (A')

SD (B)

RD (B')

RD (A')

SD (A)

RD (B')

SD (B)

RTS (B)

SERIES 90

RTS (A)

CTS (B')

ISOLATED

CMM

TERMA')

TERM)

REPEATER/

PORT

TERMB)

TERM')

CONVERTER

1 OR 2

CTS (B')

GND

(BRICK)

GND

SHLD

25- PIN

FEMALE

MALE

FEMALE

ON THE ISOLATED REPEATER/CONVERTER, INSTALL 150 OHM RESISTOR (SUPPLIED).

* TERMINATE CONNECTION: ON THE CMM, INSTALL JUMPER TO CONNECT INTERNAL 120 OHM RESISTOR.

Figure C-7. Cable B; RS-422 CMM To Converter

C-8

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

GFK-0356Q

IC655CCM590 Converter

SUBSTITUTE APPROPRIATE UP STREAM DEVICE

(WITHIN DOTTED BOX) PER SYSTEM DIAGRAMS.

MAKE CONNECTIONS

SHIELDED

TWISTED

INSIDE D-CONNECTORS

PAIRS

SD (A)

RD (A')

SD (B)

RD (B')

SERIES 90

RD (A')

SD (A)

CMM

RD (B')

SD (B)

SERIES 90

PORT

TERM

CMM

1 OR 2

TERMA)

TERM

PORT

TERMA')

RTS (A)

RTS (B)

CTS (A')

CTS (B')

RTS (B)

GND

CTS (B')

SHLD

25- PIN

FEMALE

MALE

FEMALE

CTS

SD (A)

RD (A')

SD (B)

RD (B')

RD (A')

SD (A)

RD (B')

SD (B)

RTS (B)

TERM

ISOLATED

REPEATER/

CTS (B')

TERM

CONVERTER

RTS (A)

150 OHMS

GND

(BRICK)

CTS (A')

(USED AS A

(BRICK)

TERM

CONVERTER)

GND

150 OHMS

25- PIN

FEMALE

MALE

FEMALE

NOTE

WHEN WIRING RS-422 /485 MULTIDROP

REFLECTIONS ON THE TRANSMISSION LINE

REDUCED BY CONFIGURING THE CABLE IN A

CHAIN FASHION AS SHOWN

RD (A')

MASTER

CMM SLAVE 1

RD (B')

SD (A)

SD (B)

ISOLATED

TERM

REPEATER/

TERM

CONVERTER

150 OHMS

GND

(BRICK)

(USED AS A

CPU BUILT-IN PORT CMM SLAVE 2

REPEATER)

25- PIN

ALSO IT IS RECOMMENDED TO MAKE ANY

MALE

FEMALE

CONNECTIONS INSIDE THE CABLE CONNECTOR

MOUNTED ON THE CMM. IT IS NOT

TO OTHER DEVICES

USE TERMINAL STRIPS OR OTHER TYPES

(MAXIMUM OF 8 DEVICES ON A MULTIDROP)

CONNECTORS ALONG THE LENGTH OF

TERMINATE THE RD (B') SIGNAL ONLY AT END

TRANSMISSION

OF MULTIDROP CABLE

TERMINATE CONNECTION ON FIRST AND LAST DROPS ONLY: ON THE CMM, INSTALL JUMPER TO CONNECT INTERNAL 120 OHM

RESISTOR. ON THE ISOLATED REPEATER/CONVERTER, INSTALL 150 OHM RESISTOR (SUPPLIED)

ON THE CMM311, ONLY PORT 2 CAN SUPPORT RS-422/RS-485.

Figure C-8. Cable C; RS422 Twisted Pair

GFK-0356Q

Appendix C IC655CCM690 Isolated Repeater/Converter

C-9

SHIELDED MAKE CONNECTIONS

a44932

TWISTED INSIDE D-CONNECTORS

PAIRS

SD (A)

RD (A')

SD (B)

RD (B')

RD (A')

SD (A)

RD (B')

SD (B)

SERIES 90

ISOLATED

CTS (A')

RTS (A)

CMM

CTS (B')

RTS (B)

PORT

REPEATER/

TERM

CONVERTER

TERM

GND

(BRICK)

GND

SHLD

25- PIN

FEMALE

MALE

FEMALE

NOTE

WHEN WIRING RS-422 /485 MULTIDROP CABLES,

REFLECTIONS ON THE TRANSMISSION

LINE CAN BE REDUCED BY CONFIGURING THE

CTS

CABLE IN A DAISY CHAIN FASHION AS

SHOWN BELOW.

RD (A')

RD (B')

SD (A)

MASTER

CMM SLAVE 1

SD (B)

ISOLATED

RTS (A)

REPEATER/

RTS (B)

CONVERTER

TERM

(BRICK)

TERM

(USED AS A

GND

CONVERTER)

CPU BUILT-IN PORT CMM SLAVE 2

150 OHMS

25- PIN

MALE

FEMALE

ALSO IT IS RECOMMENDED TO MAKE ANY

NECESSARY CONNECTIONS INSIDE THE

CABLE CONNECTOR TO BE MOUNTED ON

THE CMM. IT IS NOT RECOMMENDED TO

USE TERMINAL STRIPS OR OTHER TYPES

OF CONNECTORS ALONG THE LENGTH OF

SW ON

THE TRANSMISSION LINE.

RD (A')

RD (B')

SD (A)

SD (B)

ISOLATED

RTS (A)

REPEATER/

RTS (B)

CONVERTER

TERM

(BRICK)

TERM

(USED AS A

GND

REPEATER)

^* 150 OHMS

25- PIN

MALE

FEMALE

TO OTHER DEVICES

(MAXIMUM OF 8 DEVICES ON A MULTIDROP)

TERMINATE THE RD (B') SIGNAL ONLY AT END OF MULTIDROP CABLE

TERMINATE CONNECTION ON FIRST AND LAST DROPS ONLY: ON THE CMM, INSTALL JUMPER TO CONNECT INTERNAL

120 OHM RESISTOR. ON THE ISOLATED REPEATER/CONVERTER, INSTALL 150 OHM RESISTOR (SUPPLIED)

ON THE CMM311, ONLY PORT 2 CAN SUPPORT RS-422/RS-485.

Figure C-9. Cable D; RS-422 Twisted Pair

SW CTS

a45239

CTS

GND

RTS

SERIES 90

GND

CMM

ISOLATED

DCD

PORT

REPEATER/

DTR

CONVERTER

SHLD

(BRICK)

25- PIN

FEMALE

MALE

FEMALE

Figure C-10. Cable E; RS-232 Converter to CMM

C-10

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

GFK-0356Q

Appendix

IC690ACC901 Miniconverter Kit

Description of Miniconverter

The Miniconverter Kit (IC690ACC901) 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 Converter Plug assembly. 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.

a44985

RS-422

RS-232

PORT

Figure D-1. Series 90 SNP to RS-232 Miniconverter

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 Converter plug (supplied with kit) is required to convert 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.

GFK-0356Q

D-1

Pin Assignments

The pinouts of the Miniconverter are shown in the following two tables. The first table shows the

pinout for the RS-232 port, the second table shows the RS-422 port.

Pin Assignments, RS-232 Port

Table D-1 is for the RS-232 port. The direction of signal flow is with respect to the Miniconverter.

Table D-1. Miniconverter RS-232 Port

Signal Name

Direction

SD - Send Data

Output

RD - Receive Data

Input

GND - Ground

n/a

CTS - Clear To Send

Input

RTS - Request To Send

Output

The pinouts were chosen to allow direct connection (using a straight through, or 1 to 1 cable (as

provided with kit)) to the IBM PC-AT. Most IBM compatible computers equipped with an RS-232

port will provide a pinout compatible with the one shown above.

Pin Assignments, RS-422 Port

Table D-2 is the pinout for the Miniconverter’s RS-422 serial port. The direction of signal flow is

also with respect to the Miniconverter.

Table D-2. Miniconverter RS-422 Port

Signal Name

Direction

SHLD - Shield

n/a

+5 VDC - Power

Input

CTS(A’) - Clear To Send

Input

GND - Ground

n/a

RTS(B) - Request To Send

Output

RT - Receive Termination

Output

SD(A) - Send Data

Output

SD(B) - Send Data

Output

RD(A’) - Receive Data

Input

RD(B’) - Receive Data

Input

CTS(B’) Clear To Send

Input

RTS(A) - Request To Send

Output

D-2

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

GFK-0356Q

System Configurations

The Miniconverter can be used in a point-to-point configuration as described above, or in a

multidrop configuration with the host device configured as the master and one or more PLCs

configured as slaves.

The multidrop configuration requires a straight through (1 to 1) cable from the Miniconverter’s RS-

422 port to the first slave PLC’s SNP port. Other slaves will require a daisy chain connection

between slaves. A maximum of eight devices can be connected in an RS-422 multidrop

configuration. All of the devices must have a common ground. If ground isolation is required, you

can use the GE Fanuc Isolated Repeater/Converter (IC655CCM590) in place of the Miniconverter.

When using the Miniconverter with a modem connection, it may be necessary to jumper RTS to

CTS (consult the user’s manual for your modem).

Cable Diagrams (Point-To-Point)

When connecting the Miniconverter to IBM PC and compatible computers with hardware

handshaking, the following cable connections should be used.

a44982

TXD

RXD

TXD

CTS

RTS

CTS

GND

DCD

DSR

DTR

MINICONVERTER

IBM PC-AT

RS-232 PORT

9-PIN

CONNECTOR

Figure D-2. Miniconverter to PC-AT

a44983

TXD

RXD

TXD

CTS

RTS

CTS

GND

DCD

DSR

DTR

MINICONVERTER

WORKMASTER II,

RS-232 PORT

IBM PC-XT, PS/2

9-PIN

25-PIN

CONNECTOR

Figure D-3. Miniconverter to Workmaster II, PC-XT, PS/2

GFK-0356Q

Appendix D IC690ACC901 Miniconverter Kit

D-3

a44984

TXD

RXD

TXD

CTS

RTS

CTS

GND

MINICONVERTER

WORKMASTER

RS-232 PORT

9-PIN

CONNECTOR

Note: Additional adapter required

Figure D-4. Miniconverter to 9-Pin Workmaster or PC-XT Computer

Table D-3. Miniconverter Specifications

Mechanical:

RS-422

15-pin D shell male for direct mounting to Series 90 serial port.

RS-232

9-pin D shell male for connection to RS-232 serial port of a Workmaster

II computer or Personal Computer.

Electrical and General:

Voltage Supply

+5 VDC (supplied by PLC power supply)

Typical Current

Version A (IC690ACC901A) - 150 mA

Version B (IC690ACC901B) - 100 mA

Operating Temperature

0 to 70°C (32 to 158°F)

Baud Rate

38.4K Baud maximum

Conformance

EIA-422 (Balanced Line) or EIA-423 (Unbalanced Line)

Ground Isolation

Not provided

D-4

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

GFK-0356Q

Appendix

IC690ACC903 Port Isolator

The IC690ACC903 RS-485 Port Isolator replaces the IC655CMM590 Isolated Repeater/Converter

(also referred to as the “Brick”). The device features 500 volts of isolation in a compact package

servicing all IC693, IC697, and IC200 PLC product lines. The product connects directly to an RS-

485 serial port or though a short extender cable provided with the device. The extension cable is

intended for use in applications where direct connection to the port is obstructed by surrounding

equipment or when it is not acceptable for the device to protrude from a PLC module. The Port

Isolator can operate in either single- or multi-drop mode, which is selected by a slide switch on the

top of the module.

The Port Isolator provides the following features:

• Four opto-isolated signal channels: SD, RD, RTS, and CTS

• Electrical compatibility with RS-485

• Single- or multi-drop operation

• Input termination consistent with standard for serial channels

• A 5V DC/DC converter for power isolation

• Hot insertion is supported

FRONT VIEW

Multidrop

Switch

1.7 in

TOP VIEW

FRONT VIEW

2.6 in

0.7 in

Figure E-1. RS485 Port Isolator

GFK-0356Q

E-1

Connectors

The Isolator provides two connectors, one 15 pin male D-type (PL1) and one

15 pin female D-type (PL2).

RS-485 Connectors

Pin Name

Pin Type

Description

PL1

SHLD

Chassis Ground

+5V power

CTS (A')

Clear to send -

Signal Ground

RTS (B)

Out

Request to send +

SD (A)

Out

Send data -

SD (B)

Out

Send data +

RD (A')

Read data -

RD (B')

Read data +

CTS (B')

Clear to send +

RTS (A)

Out

Request to send -

Pin Name

Pin Type

Description

PL2

+5V power

RTS (A)

Out

Request to send -

Signal Ground

CTS (B')

Clear to send +

Terminating Resistor*

RD (A')

Read data -

RD (B')

Read data +

SD (A)

Out

Send data -

SD (B)

Out

Send data +

RTS (B)

Out

Request to send +

CTS (A')

Clear to send -

* Use the terminating resistor if the Port Isolator is used in port-to-port mode or at the end of a multi-drop

configuration. To terminate the RD balanced line, place a jumper wire from pin 9 to pin 10.

* A denotes - and B denotes +. A and B denote outputs and A' and B' denote inputs.

E-2

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

GFK-0356Q

Installation

The Isolator is packaged in a contoured plastic enclosure designed for either direct attachment to a

serial port or through a 12” extender cable for panel mounted applications. Two M3 thumbscrews

secure the device to its mating connector. The device can be easily inserted into an existing

communication channel with no additional hardware. In Figure E-2, the Isolator is shown

connected directly to a CPU module. Alternatively, the Isolator can be mounted separately from the

PLC system using the extender cable provided. For mounting separately to a panel, you will need

to provide two #6-32 (4 mm)mounting screws (Figure E-3).

When installing the Isolator, tighten the connector screws and panel mounting screws (if used) to

the following torque values:

Screws

Type

Torque

Connector Thumbscrews (supplied with

8 in./lbs. (0.9 Newton-meter)

Isolator)

Panel Mounting Screws (user-supplied)

#6/32 (4 mm)

12 in./lbs. (1.4 Newton-meters)

PLC 1

CPU

RS-485 Port

Isolator

4000 ft

SNP

Cable

PLC 2

CPU

Figure E-3. RS-485 Port Isolator in PLC Network

#6-32 (4 mm) screw

Multidrop Switch

TOP

VIEW

#6-32 (4 mm) screw

Figure E-4. Mounting Port Isolator to Panel

E-4

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

GFK-0356Q

The RS485 Port Isolator supports both port-to-port and multi-drop configurations (Figure E-4). For

installation information, refer to section 3 of the Serial Communications User's Manual

(GFK-0582). One configuration not covered in the User's Manual is the case where the Isolator is

communications if the host system requires a power cycle. It also prevents power loss to equipment

using the port for power. For this, you will need to build a custom cable as shown in Figure E-5.

Terminate at first

and last drop only

Slave Device

Master PLC

15 pin port

Make connectons

Twisted Pairs

inside D connectors

SD(B)

RD(B')

SD(A)

RD(A')

RD(B')

SD(B)

RD(A')

SD(A)

RTS(B)

CTS(B')

RTS(A)

CTS(A')

CTS(B')

RTS(B)

CTS(A')

RTS(A)

SHLD

+5V

GND

Slave Device

15 pin port

RD(B')

RD(A')

SD(B)

SD(A)

CTS(B')

CTS(A')

RTS(B)

RTS(A)

SHLD

+5V

GND

Slave Device

25 pin port

RD(B')

RD(A')

SD(B)

SD(A)

CTS(B')

CTS(A')

RTS(B)

RTS(A)

GND

SHLD

To Other Slave Devices

(Maximum of 8 devices on a multidrop)

Figure E-5. Multidrop Configuration Connecting Devices with 15-Pin Ports and 25-Pin Ports

GFK-0356Q

Appendix E IC690ACC903 Port Isolator

E-5

Specifications

Mechanical

RS-485

15-pin D shell male for direct mounting to serial port on the programmable

controller

15-pin D shell female for communication cable

Installation Hardware

Two M3 thread connector thumbscrews. Recommended torque: 8 in./lbs. (0.9

Newton-meter). These are supplied with Isolator.

Two user supplied #6/32 (4mm) thread panel mounting screws. Recommended

torque: 12 in./lbs. (1.4 Newton-meter)

Electrical

Voltage Supply

+5VDC (supplied by port)

Typical Current

25 mA

100 mA available for external equipment

Ground Isolation

500 Volts

Conformance

EIA-422/485 Balanced Line

Operating

0° - 60°C (32° - 140° F)

Temperature

Baud Rate

Those supported by PLC

Note: This appendix is based on Data Sheet GFK-1663.

GFK-0356Q

Appendix E IC690ACC903 Port Isolator

E-7

Appendix

Calculating Series 90-30 Heat Dissipation

Overview

Series 90-30 PLCs must be mounted in a protective enclosure. The enclosure should be capable of

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

describes how to calculate heat dissipation for a Series 90-30 PLC. The strategy is to calculate a

heat dissipation value, in watts, for each individual module in the PLC. To obtain a total heat

dissipation figure for the PLC, add the individual values together.

The procedure consists of the following steps:

Step 1: Basic Method to Calculate Module Dissipation

F-2

Step 2: Calculation for PLC Power Supplies

F-3

Step 3: Output Calculations for Discrete Output Modules

F-3

Step 4: Input Calculations for Discrete Input Modules

F-4

Step 5: Final Calculation

F-6

Information Required

■ In addition to the information in this manual, you will need GFK-0898, Series 90-30 I/O

Module Specifications Manual.

■ You will need operating current values for the discrete output devices connected to the PLC’s

discrete output modules. These include control relays, motor starters, solenoids, pilot lights,

etc. Each device manufacturer publishes these values. If an exact value is not available for a

device, you can make a close estimate by obtaining the value for a similar device from a

catalog. These values are also needed for selecting Output modules during the design process

in order to ensure that the modules’ maximum ratings are not exceeded.

GFK-0356Q

F-1

Procedure

Step 1: Basic Method to Calculate Module Dissipation

Note that this step does not apply to Power Supply Modules, which are covered in Step 2. The

values needed for this calculation are found in the “Load Requirements” table in Chapter 12.

Use the following electrical power formula in these calculations

Power (in watts) = Voltage (in volts) x Current (in Amps).

Assume that all input power to these modules is eventually dissipated as heat. The procedure is:

■ Look up the module in the “Load Requirements for Hardware Components” table (Chapter 12)

and obtain the current values for each of the three power supply voltages listed. The voltage is

printed at the head of each column. All modules use the 5VDC supply, and a relatively few

modules also use one or both of the two 24VDC supplies.

■ For a given module, calculate the power dissipation for each column in the table that contains a

current value by multiplying the current value (in Amps) times the voltage for that column. For

modules using more than one voltage, add the calculated power values to arrive at the total for

the module.

Example 1:

The “Load Requirements” table shows that the IC693CPU352 module draws:

■

910 mA from the +5VDC supply.

■ No current from either of the two 12VDC supplies

To calculate power dissipation, multiply 0.910 Amps times 5 volts. The answer is:

■

4.55 watts (of heat dissipated by this module)

Example 2:

The “Load Requirements” table shows that the IC693MDL241 module draws:

■

80 mA from the +5VDC supply

■

125 mA from the +24VDC Isolated supply

To calculate power dissipation from the +5VDC supply:

Multiply 0.08 Amps times 5 volts to arrive at a value of 0.40 watts.

To calculate power dissipation from the +24VDC supply:

Multiply 0.125 Amps times 24 volts to arrive at a value of 3.0 watts.

Adding the two together yields a total heat dissipation by this module of 3.4 watts.

F-2

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

GFK-0356Q

Step 2: Calculation for PLC Power Supplies

A basic rule for Series 90 power supplies is that they are 66% efficient. Another way of stating this

is that the power supply dissipates 1 watt of power in the form of heat for every 2 watts of power it

delivers to the PLC. Therefore, you can calculate the total power requirement for all of the

modules in the rack served by a particular power supply using the method in Step 1 above, then

divide that figure by 2 to arrive at the power supply dissipation value. You cannot simply use the

rating of the power supply (such as 30 watts) for this calculation because the application may not

require the full capacity of the power supply. If you are using the +24VDC output on the power

supply’s terminal strip, you should calculate the power drawn, divide the value by 2, and add it to

the total for the power supply. Since each Series 90-30 rack has its own power supply, each rack

should be calculated on an individual basis.

Step 3: Output Calculations for Discrete Output Modules

Discrete solid state Output modules require two calculations, one for the module’s signal-level

circuits, which was already done in Step 1, and one for the output circuits. (This output circuit

calculation is not required for the Relay Output modules.) Since the solid state output switching

devices in these modules will drop a measurable amount of voltage, their power dissipation can be

calculated. Note that the power dissipated by the output circuits comes from a separate power

source, so it is not included in the figure used to calculate PLC power supply dissipation in Step 2.

To calculate output circuit power dissipation:

■ In the Series 90-30 I/O Module Specifications Manual, GFK-0898, find the value for the

Output Voltage Drop for your particular module.

■ Obtain the required current value for each device (such as a relay, pilot light, solenoid,

etc.) connected to an output point on the module and estimate its percent of “on-time.” To

obtain the current values, check the device manufacturer’s documentation or an

electronics catalog. The percent of on-time can be estimated by someone familiar with

how the equipment operates or will operate.

■ Multiply the Output Voltage Drop times the current value times the estimated percent of

on-time to arrive at average power dissipation for that output.

■ Repeat for all outputs on the module. To save time, you could determine if several

outputs were similar in current draw and on-time so that you would only have to make

their calculation once.

■ Repeat these calculations for all Discrete Output modules in the rack.

Discrete Output Module Example:

The Series 90-30 PLC I/O Module Specifications Manual, GFK-0898, lists the following for the

IC693MDL340 16-Point Discrete 120VAC Output Module:

Output Voltage Drop:

1.5 Volts maximum

Use that value for all of the calculations for this module.

In this example, two of the Output module’s output points drive solenoids that control the advance

and retract travel of a hydraulic cylinder. The solenoid manufacturer’s data sheet shows that each

GFK-0356Q

Appendix F Calculating Series 90-30 Heat Dissipation

F-3

solenoid draws 1.0 Amp. The cylinder advances and retracts once every 60 seconds that the

machine is cycling. It takes 6 seconds to advance and 6 seconds to retract.

Since the cylinder takes equal time to advance and retract, both solenoids are on for equal lengths

of time: 6 seconds out of every 60 seconds, which is 10% of the time. Therefore, since both

solenoids have equal current draws and on-times, our single calculation can be applied to both

outputs.

Use the formula Average Power Dissipation = Voltage Drop x Current Draw (in Amps) x Percent

(expressed as a decimal) of on-time:

1.5

x 1.0 x 0.10 = 0.15 watts per solenoid

Then multiply this result by 2 since we have two identical solenoids:

0.15 watts x 2 Solenoids = 0.30 watts total for the two solenoids

Also in this example, the other 14 output points on this 16-point module operate pilot lights on an

operator’s panel. Each pilot light requires .05 Amps of current. Seven of the pilot lights are on

100% of the time and seven are on an estimated 40%.

For the 7 lights that are on 100% of the time:

1.5 x .05 x 1.00 = 0.075 watts per light

Then multiply this value by 7:

0.075 watts x 7 lights = 0.525watts total dissipation for the first 7 lights

For the 7 lights that are on 40% of the time:

1.5 x .05 x 0.40 = .03 watts per light

Then multiply this value by 7:

0.03 watts x 7 lights = 0.21 watts total dissipation for the other 7 lights

Adding up the individual calculations, we get:

0.30 + 0.525 + 0.21 = 1.035 watts for the module’s total output calculation

Step 4: Input Calculations for Discrete Input Modules

A Discrete Input Module requires two calculations, one for the module’s signal-level circuits,

which was already done in Step 1, and one for the input circuits. Note that the power dissipated by

the input circuits comes from a separate power source, so are not included in the figure used to

calculate PLC power supply dissipation in Step 2. We will assume that all input circuit power

delivered to these modules is eventually dissipated as heat. The procedure is:

■ Find the value for the Input Current in the “Specifications” table for your input module in

the Series 90-30 I/O Module Specifications Manual, GFK-0898.

■ Multiply the input voltage times the current value times the estimated percent of on-time

to arrive at average power dissipation for that input.

F-4

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

GFK-0356Q

■ Repeat for all inputs on the module. To save time, you could determine if several inputs

were similar in current draw and on-time so that you would only have to make their

calculation once.

■ Repeat these calculations for all Discrete Input modules in the rack.

Discrete Input Module Example:

The “Specifications” table for the IC693MDL240 16-Point Discrete 120 VAC Input Module in the

Series 90-30 PLC I/O Module Specification Manual, GFK-0898, gives the following information:

Input Current:

12 mA (typical) at rated voltage

Use this value for all of the input calculations for this module.

In this example, eight of the Input Module’s points are used for switches that, for normal operation,

stay on (closed) 100% of the time. These include the Emergency Stop, Over Temperature, Lube

Pressure OK, and similar switches.

Use the formula Average Power Dissipation = Input Voltage x Input Current (in Amps) x Percent

(expressed as a decimal) of on-time:

120 x .012 x 1.0 = 1.44 watts per input

Then multiply this result by 8:

1.44 watts x 8 inputs = 11.52 watts total for the 8 inputs

Also in this example, two input points on this 16-point module are for the Control On and Pump

Start pushbuttons. Under normal conditions, these pushbuttons are only pressed once per day for

about one second - just long enough to start up the control and pump. Therefore, their effect on

our power calculation is negligible and we will assume a power dissipation of zero for them:

0.0 watts total for 2 inputs

For the remaining six inputs of our sixteen point module, it is estimated that they will be on for an

average of 20% of the time. So the following calculation is made for these six inputs:

Using the formula of Average Power Dissipation = Input Voltage x Input Current (in Amps) x

Percent (expressed as a decimal) of on-time:

120 x .012 x 0.20 = 0.288 watts per input

Then multiply this result by 6:

0.288 watts x 6 inputs = 1.728 watts total for the 6 inputs

Finally, adding up the individual calculations, we get:

11.52 + 0.0 + 1.728 = 13.248 watts for the module’s total input calculation

GFK-0356Q

Appendix F Calculating Series 90-30 Heat Dissipation

F-5

Step 5: Final Calculation

Once the individual power dissipations have been calculated, add them all to obtain total PLC heat

dissipation. Note that the PLC baseplate, analog input modules, and analog output modules have

been ignored in this procedure because their power dissipation values are negligible when

compared with the total. Also, since each Series 90-30 rack has its own power supply, each rack

should be calculated on an individual basis. The following table summarizes the final calculation:

Series 90-30 Rack Heat Dissipation Calculation Summary

Step

Description

Value (Watts)

Calculate total of dissipation values for all modules in the rack

Divide value obtained in Step 1 by 2 to obtain Power Supply value

Calculate total of all Output modules’ output dissipation values

Calculate total of all Input modules’ input dissipation values

Add the above four values to obtain the total dissipation of the rack

Other Information Related to Enclosure Sizing

The “Baseplates” chapter of this manual contains rack dimensions and minimum ventilation

clearance distances required around the racks. The “Cables” chapter contains clearance dimensions

for cables that mount on the front of modules.

F-6

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

GFK-0356Q

Appendix

Catalog Number to Publication Cross-Reference

Manuals are not shipped with many of the Series 90-30 products; they must be ordered separately.

This appendix can help you identify the correct documentation to order and use. Products are arranged

in this appendix by categories such as Analog I/O Modules, Baseplates, Communications Modules,

etc. The category headings are listed in alphabetical order. Modules that share common

documentation are grouped under a generic catalog number, such as IC693ALGxxx for the Analog I/O

modules.

Note that you may not need every publication listed for a particular product. Your need for some of

the publications depends on your application. For example, if you intend to use Logicmaster

programming software to configure and program your PLC, you will not need manuals for the other

programming software products or the Hand Held Programmer. Or, if you are going to program your

Programmable Coprocessor module using the C computer language, you will not need the MegaBasic

language manual. A list of publication titles is included at the end of this data sheet.

Abbreviations Used

HHP — Hand-Held Programmer

LM90 — Logicmaster, a DOS-based programming and configuration software

SFC — Sequential Function Chart

GFK-0356Q

G-1

General System Information

90-30 PLC System

Installation: GFK-0356

Installation for Conformance to Standards: GFK-1179

Configuration Options:

Configuration (HHP): GFK-0402

Configuration (LM90): GFK-0466

Configuration (Control): GFK-1295

Configuration (VersaPro): GFK-1670

Configuration (CIMPLICITY Machine Edition Logic Developer-

PLC: GFK-1868

Analog I/O Modules

Catalog Number

Task: Publication Number

All Analog Input, Output, and

Installation, Configuration, Specifications: GFK-0898

Combination. Modules

(IC693ALGxxx)

Baseplates

All Series 90-30 Baseplates

Installation: GFK-0356

(IC693CHSxxx)

Configuration Options:

Configuration (HHP): GFK-0402

Configuration (LM90): GFK-0466

Configuration (Control): GFK-1295

Configuration (VersaPro): GFK-1670

Configuration (CIMPLICITY Machine Edition Logic Developer-PLC:

GFK-1868

G-2

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

GFK-0356Q

FANUC Series 90-30 PLC. Installation and Hardware Manual (GFK-0356Q) - page 13