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Configuring a GE Fanuc 90-30 PLC

Article ID: 91
Last updated: 01 Apr, 2012
With the proper selection of the various hardware components going into the system, it is possible to create a system to fit nearly any application imaginable. Although many hardware choices exist, there are just a few basic categories to consider when configuring the 90-30 PLC.

By EngNet Engineering Network

The GE Fanuc 90-30 PLC is the choice of many engineers for two main reasons:

  • Programmable - it can be designed to fit a multitude of applications.
  • Modular - there is an unlimited number of configurations of the main components of the system providing the utmost versatility.

An entire system consists of the following elements:

The Total GE Fanuc Series 90-30 PLC System: Featuring the sophisticated modular design required by many applications, the GE Fanuc Series 90-30 PLC is available at a low-cost price point, yet is capable of addressing a wide range of PLC configurations. Whether your needs are simple relay placement or advanced discrete automation, the 90-30 is customizable to meet your requirements. Whether the system requires a simple 5 or 10 slot rack with a minimum of modules or a system requiring 100s of modules, the GE Fanuc Series 90-30 PLC can meet the needs of various applications in a cost-effective manner that makes the system worthy of consideration.

GE Fanuc Series 90-30 CPU Racks

CPU Racks

90-30 Rack - This is the mounting plate upon which all the system components are placed. The rack consists of three basic elements: 1. Circuit Board 2. Metal Backplate 3. Plastic Cover. Since many systems require more modules than a primary CPU rack can hold, there are also Remote and Expansion racks that interconnect with each other. Each category of rack is available in 5 or 10 slot models, depending on the system's configuration.

Each Circuit Board is mounted to the Metal Backplate. The Circuit Board's leftmost slot is dedicated for the power supply. The other slots are numbered, (1 to 5) or (1 to 10), depending on the model. In the CPU board slot number 1 is dedicated for the CPU. In the Remote and Expansion boards the # 1 slot is available for any module to use, as it is in the embedded CPU board also.

The embedded CPU board comes in three models: 311, 312, and 323. Models 311 and 323 have 5 slots while Model 312 has 10 slots. All slots are available, since the CPU is embedded. They cannot be used in conjunction with Remote or Expansion Racks, limiting their usage to the slots available. Also, the CPU cannot be changed.

If the application requires more than ten open slots, a modular system must be used, consisting of a primary CPU rack and as many remote or expansion racks as needed. The CPU is always installed in slot 1 of the CPU rack. This rack is automatically labeled 0 in the system. Having a modular CPU gives the system the versatility of being updated at any time.

In a typical system, Expansion racks are used in close proximity to the primary CPU rack, with 50 feet being the maximum. Remote racks are used from 50 to 700 feet away. Each comes in 5 and 10 slot configurations, with all slots available for modules.

PART NUMBER TYPE SIZE (SLOTS)
IC693CPU311 EMBEDDED CPU 5
IC693CPU313 EMBEDDED CPU 5
IC693CPU323 EMBEDDED CPU 10
IC693CHS397 MODULAR CPU 5
IC693CHS391 MODULAR CPU 10
IC693CHS398 EXPANSION 5
IC693CHS392 EXPANSION 10
IC693CHS399 REMOTE 5
IC693CHS393 REMOTE 10

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GE Fanuc Series 90-30 Power Supplies

Power Supplies

Power Supply - Each rack in the system requires its own power supply. There are many power supply options to accommodate any configuration. The power supply mounts in the left, unnumbered slot of each rack. There are 2 main categories of power supplies used in the 90-30 system: the AC/DC Input Power Supplies and the DC Input Only Power Supplies. All of these have 30 watts total output. The AC/DC models come in standard and high capacity models. The DC Only models feature 24/48 VDC input, 48 VDC input, and high capacity 24 VDC input.

PART
NUMBER
LOAD
CAPACITY
NOMINAL
INPUT
OUTPUT CAPACITIES
VOLTAGE/POWER (TOTAL CANNOT EXCEED 30 WATTS)
IC693PWR321 30 WATTS 100 to 240 VAC or
125 VDC
+ 5 VDC
15 WATTS
+ 24 VDC ISOLATED
20 WATTS
+ 24 VDC RELAY
15 WATTS
IC693PWR330 30 WATTS 100 to 240 VAC or
125 VDC
+ 5 VDC
30 WATTS
+ 24 VDC ISOLATED
20 WATTS
+ 24 VDC RELAY
15 WATTS
IC693PWR322 30 WATTS 24 or 48 VDC + 5 VDC
15 WATTS
+ 24 VDC ISOLATED
20 WATTS
+ 24 VDC RELAY
15 WATTS
IC693PWR328 30 WATTS 48 VDC + 5 VDC
15 WATTS
+ 24 VDC ISOLATED
20 WATTS
+ 24 VDC RELAY
15 WATTS
IC693PWR331 30 WATTS 24 VDC + 5 VDC
30 WATTS
+ 24 VDC ISOLATED
20 WATTS
+ 24 VDC RELAY
15 WATTS

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GE Fanuc Series 90-30 CPUs

CPUs

CPU - Three of the 90-30 PLCs have their CPUs embedded directly into the baseplate of the rack, but the majority of them use plug-in modules. The CPU is the brains of the system. Every PLC must have a CPU to function. The CPU controls the system's software, applications, operations, and monitors all aspects of the system's functions, including operations and faults. Some 90-30 PLC systems have their CPU in a personal computer which interfaces with the system.

To properly configure a system to fit your requirements it is necessary to judge a number of aspects about your intended results. The system will only perform as well as the CPU you ultimately select. Comparing the various capabilities of each CPU is necessary to determine what is best for your application. Here are the major considerations to consider:

  • I/O Points - this is the first step because the conclusions you reach here will determine the component choices you will ultimately select. Knowing the number of modules needed and their physical locations determines the ultimate number of remote or extension racks needed in addition to the primary CPU rack. Start by determining the number of input and output points required to create the system. Correlate with the mechanical drawings and specifications. List all inputs and outputs required, noting the various types required. List them according to Discrete Input, Discrete Output, Analog Input, and Analog Output, noting any special requirements, such as physical separation and the need for remote or expansion racks.
  • I/O Modules - Having determined the number of I/O points required, it is time to select the I/O Modules needed. With over 100 different I/O Modules available, you'll want to consider the following selections factors:
    • Voltage/Current Requirements - the Series 90-30 can meet various common voltage and current needs, such as AC/DC and 110/120V or 240V. These consideration will be used to ultimately determine the power supply selected also.
    • Isolation Requirements - do the racks need to be protected from harsh environments, extreme magnetic forces, temperature or humidity extremes, or the like? How far away will the system components need to be? The use of expansion and remote racks will fulfill these needs.
    • Standardization - Does your company use specific modules or components to simplify training and/or stocking of spare parts?
    • Cost - By selecting certain higher volume modules it is possible to reduce overall system design by one or more racks. As an example, 32 point I/O Modules require much less rack space than lower density modules.
  • Communication and Specialty Modules - System needs will need to be assessed with regard to Ethernet or other communication networks, interfacing with equipment such as CNC machinery, high speed inputs such as counters and motion control, temperature controls, and other needs the system might require.

Having determined the number of modules required for the system, it is now possible to make a CPU selection. There are two basic types of CPUs offered in the GE 90-30 Series: 1. CPUs embedded in the system circuit board, and 2. CPU Modules.

The racks with embedded CPUs in the circuit boards all use the 80188 microprocessor. These CPUs do not have a TOD (time of day) clock. The embedded CPU is a low cost alternative for simpler systems requiring fewer input/output points and less memory to perform the needed functions. Embedded CPU systems are limited to the numbers of slots available in the rack chosen. A system with no more than 10 modules is the maximum attainable with the embedded CPU, since they cannot be used in conjunction with remote or expansion racks.

Modular CPUs come in many different configurations to allow greater versatility. The microprocessor in the Series 90-30 handles all operational control and uses RAM working memory. If the modules required for the system is over ten, the modular CPU system is the only option. If the system is no more than 5 racks CPU331 to CPU341 can be used. For systems up to 8 total racks CPU350 to CPU364 can be used. If a total of 49 or more Communication Modules and I/O Modules are to be used, the system requires CPU350 to CPU374.

When comparing the various CPUs available in the chart below you will note some of the differences which need to be considered in addition to the above. Determining the speed of the processor the system requires will aid in the selection. Also, note the memory capabilities of each CPU. Finally, does your application require the use of floating point math? Although all of the Series 90-30 CPUs are capable of working with whole integers, the floating point math feature of CPU350 and above enables the CPU to deal with decimal numbers as well. These CPUs also enable the use of trigonometric, logarithmic, exponential, and radian conversion factors. CPU352 and CPU374 have built in math co-processor chips, affording the fastest speed for math calculations of all the CPUs. The other CPUs in the CPU350 and above group use firmware enabled floating point math. If ultra-fast performance is not a priority, they are a reasonable, cost effective option.

Other considerations include TOD (time of day) clock requirements. None of the embedded CPUs have a TOD clock, while all of the modular CPUs have one. Also, if keylock capability is required, you will need to choose CPU360 to CPU374, which come equipped with keylocks to prevent all unauthorized access. Although all the CPUs have password protection built-in, only these model have physical locks on the system CPU.

The performance values for the various models of the 90-30 PLC are as follows:

PART NUMBER SPEED
(MHz)
PROCESSOR I/O POINTS REGISTER
MEMORY
(BYTES)
USER MEMORY
(MAXIMUM)
(BYTES)
FLOATING
POINT MATH
SYSTEM
IC693CPU311 10 80188 160 1K 6K NO 16 BIT
IC693CPU313 10 80188 160 2K 12K NO 16 BIT
IC693CPU323 10 80188 320 2K 12K NO 16 BIT
IC693CPU331 10 80188 512 4K 16K NO 16 BIT
IC696CPU340 20 80C188XL 512 19.9K 32K NO 16 BIT
IC693CPU341 20 80C188XL 512 19.9K 80K NO 16 BIT
IC693CPU350 25 80386EX 2048 19.9K 32K YES 32 BIT
IC693CPU351 25 80386EX 2048 240K TOTAL 240K TOTAL YES 32 BIT
IC693CPU352 25 80386EX 2048 240K TOTAL 240K TOTAL YES 32 BIT
IC693CPU360 25 80386EX 2048 240K TOTAL 240K TOTAL YES 32 BIT
IC693CPU363 25 80386EX 2048 240K TOTAL 240K TOTAL YES 32 BIT
IC693CPU364 25 80386EX 2048 240K TOTAL 240K TOTAL YES 32 BIT
IC693CPU374 133 586 2048 240K TOTAL 240K TOTAL YES 32 (64) BIT

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GE Fanuc Series 90-30 Digital Input/Output Modules

Digital Input/Output Modules

Digital Input/Output Modules - These modules allow the 90-30 PLC to interface with all varieties of input devices bringing data into the system or output devices transporting data to various actuators. The devices interfaced with include: sensors, solenoids, switches, stepper motors, relays, and virtually all types of electronic functional devices. There are several basic types of Input/Output Modules

  • Discrete Input - converts AC/DC input from user devices to logic levels required by the PLC. Modules are available with options of 8, 16, or 32 points
  • Discrete Output - converts logic levels from the PLC to AC/DC power level required by system devices. Available in 2 models: the Semiconductor Switched Output module has options of 5, 8, 12, 16, or 32 output points; the Relay Output module has options of either 8 or 16 normally open relay points
  • Discrete Input/Output - these combination modules feature AC/DC inputs and relay outputs in one module. They feature 8 inputs and 8 outputs in one module
  • Analog Input, Analog Output, and Analog Combination Modules are also available

Series 90-30 Discrete I/O

PART NUMBER DESCRIPTION
IC693MDL230 120 VAC ISOLATED INPUT - 8 POINTS
IC693MDL231 240 VAC ISOLATED INPUT - 8 POINTS
IC693MDL240 120 VAC INPUT - 16 POINTS
IC693MDL241 24 VAC/VDC INPUT - 16 POINTS
IC693MDL632 125 VDC INPUT - 8 POINTS
IC693MDL634 24 VDC INPUT, NEGATIVE/POSITIVE LOGIC - 8 POINTS
IC693MDL645 24 VDC INPUT, NEGATIVE/POSITIVE LOGIC - 16 POINTS
IC693MDL646 24 VDC INPUT, NEGATIVE/POSITIVE LOGIC, 1 MS - 16 POINTS
IC693MDL654 5/12 VDC (TTL) INPUT, NEGATIVE/POSITIVE LOGIC - 32 POINTS
IC693MDL655 24 VDC INPUT, NEGATIVE/POSITIVE LOGIC, 1 MS - 32
IC693MDL310 120 VAC OUTPUT, 0.5 AMP - 12 POINTS
IC693MDL330 120/240 VAC OUTPUT, 2 AMP - 8 POINTS
IC693MDL340 120 VAC OUTPUT, 0.5 AMP - 16 POINTS
IC693MDL390 120/240 VAC ISOLATED OUTPUT, 2 AMP - 5 POINTS
IC693MDL734 125 VDC OUTPUT - 6 POINTS
IC693MDL730 12/24 VDC OUTPUT, 2 AMP POSITIVE - 8 POINTS
IC693MDL731 12/24 VDC OUTPUT, 2 AMP NEGATIVE - 8 POINTS
IC693MDL732 12/24 VDC OUTPUT, 0.5 AMP POSITIVE - 8 POINTS
IC693MDL733 12/24 VDC OUTPUT, 0.5 AMP NEGATIVE - 8 POINTS
IC693MDL740 12/24 VDC OUTPUT, 0.5 AMP POSITIVE - 16 POINTS
IC693MDL741 12/24 VDC OUTPUT, 0.5 AMP NEGATIVE - 16 POINTS
IC693MDL742 12/24 VDC OUTPUT, 1 AMP POSITIVE - 16 POINTS (FUSED)
IC693MDL752 5/12/24 VDC (TTL) OUTPUT, NEGATIVE - 32 POINTS
IC693MDL753 12/24 VDC OUTPUT, POSITIVE - 32 POINTS
IC693MDL930 RELAY OUTPUT, ISOLATED, 4 AMP - 8 POINTS
IC693MDL931 RELAY OUTPUT, 8 AMP FORM B/C, ISOLATED IN GROUPS OF 4 - 8 POINTS
IC693MDL940 RELAY OUTPUT, 2 AMP - 16 POINTS
IC693MAR590 MIXED I/O, 120 VAC IN - 8 POINTS; RELAY OUT - 8 POINTS
IC693MDR390 MIXED I/O, 24 VDC IN - 8 POINTS; RELAY OUT - 8 POINTS
HE693DQM220 RELAY OUTPUT, BREAKER CONTROL, 30 AMP @ 124 VDC - 4 POINTS

Series 90-30 PLC Analog I/O

PART NUMBER DESCRIPTION
IC693ALG220 ANALOG INPUT, VOLTAGE/CURRENT, 4 CHANNELS
IC693ALG221 ANALOG INPUT, CURRENT, 4 CHANNELS
IC693ALG222 ANALOG INPUT, VOLTAGE, 16 SINGLE/8 DIFFERENTIAL CHANNELS
IC693ALG223 ANALOG INPUT, CURRENT, 16 SINGLE CHANNELS
IC693ALG390 ANALOG INPUT, VOLTAGE, 2 CHANNELS
HE693ADC4XX VARIOUS ISOLATED ANALOG INPUT MODULES (HORNER ELECTRIC)
HE693DAC4XX VARIOUS ISOLATED ANALOG INPUT MODULES (HORNER ELECTRIC)
HE693RTD6XX VARIOUS RTD MODULES (HORNER ELECTRIC)
HE693STG8XX VARIOUS STRAIN GAUGE/MULTIVOLT MODULES (HORNER ELECTRIC)
HE693THMXXX VARIOUS THERMOCOUPLE MODULES (HORNER ELECTRIC)
IC693ALG391 ANALOG OUTPUT, CURRENT, 2 CHANNELS
IC693ALG392 ANALOG OUTPUT, HIGH DENSITY, 8 CHANNELS
IC693ALG442 ANALOG COMBO MODULE, 4 INPUT CHANNELS, 2 OUTPUT CHANNELS

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GE Fanuc Series 90-30 Communications and Specialty Modules

Communications and Specialty Modules

Communication and Specialty Modules - These type modules give versatility to the 90-30 PLC system, allowing it to go beyond generic functionality. Communication Modules allow the system to control advanced functions, such as networking, temperature control, high speed counting, motion control, and even interfacing with machine operators. Other Specialty Modules include Programmable Coprocessor, allowing interfacing with bar code readers, RTUs and other ASCII devices through MegaBasic or C programming; Servo Motion Control Modules come in the DSM Module that is 2 axis high performance digital including servos and amplifiers, and the APM Module available in one or two axis analog. Still others Modules available include Multi-Axis Stepper; Absolute Resolvers/Encoders; Thermocouple; RTD; Millivolt/Strain Gauge; Sequence of Event Recorder; and Modem Modules. The following table represents a sampling of the 100s of Communication and Specialty Modules available.

PART NUMBER DESCRIPTION
IC693CMM301 GENIUS COMMUNICATIONS MODULE, GCM - 256 BITS
IC693CMM302 GENIUS COMMUNICATIONS MODULE, GCM+ - 1 KILOBYTE
IC693CMM311 COMMUNICATIONS MODULE, CCM, RTU, SNP, SNPX
IC693CMM321 ETHERNET INTERFACE MODULE
HE693RTUXXX VARIOUS RTU/MODBUS MODULES (HORNER ELECTRIC)
IC693ACC300 INPUT SIMULATOR MODULE
IC693APU300 HIGH SPEED COUNTER
IC693APU301 AXIS POSITIONING MODULE, 1 AXIS, ANALOG
IC693APU302 AXIS POSITIONING MODULE, 2 AXIS, ANALOG
IC693DSM302 DIGITAL SERVO MODULE, 2 AXIS
HE693STPXXX VARIOUS STEPPED POSITIONING MODULES (HORNER ELECTRIC)
IC693APU305 I/O PROCESSOR MODULE - READS PARALLEL GRAY CODE ENCODER
IC693PCM300 PROGRAMMABLE COPROCESSOR MODULE, 160KB, 35KB BASIC PROGRAM, 2 PORTS
IC693PCM301 PROGRAMMABLE COPROCESSOR MODULE, 192KB, 47KB BASIC PROGRAM, 2 PORTS
IC693PCM311 PROGRAMMABLE COPROCESSOR MODULE, 640KB, 190KB BASIC PROGRAM, 2 PORTS
HE693PCCXXX VARIOUS PC COPROCESSORS (HORNER ELECTRIC)
IC693TCM302 TEMPERATURE CONTROL MODULE, AUTO TUNING, 8 THERMOCOUPLE IN, 8 24 VDC OUT
CS693ATM300 PID AUTO TUNING MODULE (CONTROLS0FT)
DL693MDMXXX VARIOUS MODEM MODULES (DATALINC)
IC693BEM331 GENIUS BUS CONTROLLER MODULE
IC693BEM340 WORLDFIP BUS MODULE, MASTER
IC693BEM330 WORLDFIP BUS MODULE, SLAVE
HE693DNT250 DEVICENET INTERFACE MODULE, MASTER (HORNER ELECTRIC)
HE693IBS100 INTERBUS-S INTERFACE MODULE, SLAVE ONLY (HORNER ELECTRIC)
HE693BEM310 SDS INTERFACE MODULE, MASTER (HORNER ELECTRIC)
HE693PBM100 PROFIBUS-DP INTERFACE MODULE, MASTER (HORNER ELECTRIC)
HE693PBS105 PROFIBUS-DP INTERFACE MODULE, SLAVE (HORNER ELECTRIC)
PE693BEM350 I/OPEN LONWORKS BUS INTERFACE MODULE, MASTER, FTT-10 (PENSAR CORP)
PE693BEM351 I/OPEN LONWORKS BUS INTERFACE MODULE, MASTER, TPXF-78 (PENSAR CORP)
PE693BEM352 I/OPEN BUS INTERFACE MODULE, MASTER, TPXF-1250 (PENSAR CORP)
TM693SWP151 SEQUENCE OF EVENTS SOFTWARE, 256 INPUTS, 1MS RESOLUTION (TRIMATION)
TM693SWP152 SEQUENCE OF EVENTS SOFTWARE, 256 INPUTS, 10MS RESOLUTION (TRIMATION)
TM693SWP202 HOT STANDBY USING GENIUS BUS, 480 INPUTS, 512 OUTPUTS, 7,999 SYNCHRONIZED VARIABLES, REQUIRES CPU 340 (TRIMATION)
TM693SWP203 HOT STANDBY USING GENIUS BUS, 2048 I/O, 8,000 SYNCHRONIZED VARIABLES,
REQUIRES CPU 351 OR CPU 352 (TRIMATION)

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Article ID: 91
Last updated: 01 Apr, 2012
Revision: 1
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