GE 90-30 PLC Assembly Instructions

GE Intelligent Platforms
Programmable Control Products
Series 90*-30 PLC
Installation and Hard are Manual
GFK-0356Q January 2010

GFL-002
Warnings, Cautions, and Notes
as Used in this Publication
Warning
Warning notices are used in this publication to emphasize that hazardous voltages,
currents, temperatures, or other conditions that could cause personal injury exist in this
equipment or may be associated with its use.
In situations where inattention could cause either personal injury or damage to equipment,
a Warning notice is used.
Caution
Caution notices are used where equipment might be damaged if care is not taken.
Note: Notes merely call attention to information that is especially significant to
understanding and operating the equipment.
This document is based on information available at the time of its publication. While efforts
have been made to be accurate, the information contained herein does not purport to cover all
details or variations in hardware or software, nor to provide for every possible contingency in
connection with installation, operation, or maintenance. Features may be described herein
which are not present in all hardware and software systems. GE Intelligent Platforms assumes
no obligation of notice to holders of this document with respect to changes subsequently made.
GE Intelligent Platforms makes no representation or warranty, expressed, implied, or statutory
with respect to, and assumes no responsibility for the accuracy, completeness, sufficiency, or
usefulness of the information contained herein. No warranties of merchantability or fitness for
purpose shall apply.
* indicates a trademark of GE Intelligent Platforms, Inc. and/or its affiliates. All other
trademarks are the property of their respective owners.
©Copyright 2009 GE Intelligent Platforms, Inc.
All Rights Reserved

Support
Technical Support
If you purchased this product through an Authorized Channel Partner, please contact them directly.
General Contact Information
Online Technical Support and GlobalCare: 1Hwww.ge-ip.com/support
Additional information:2H 3Hwww.ge-ip.com
Technical Support
If you have technical problems that cannot be resolved with the information in this guide, please
contact us by telephone or email, or on the web at 4Hwww.ge-ip.com/support
Americas
Online Technical Support: 5H6Hwww.ge-ip.com/support
Phone: [phone]
International Americas Direct Dial: 1-434-978-5100
Technical Support Email: [e-mail]
Customer Care Email: [e-mail]
Primary language of support: English
Europe, the Middle East, and Africa
Online Technical Support: 11H12Hwww.ge-ip.com/support
Phone: [phone]
Technical Support Email: [e-mail]
Customer Care Email: 15H16Hcustomercare.em[email protected]m
Primary languages of support: English, French, German, Italian, Czech, Spanish
Asia Pacific
Online Technical Support: 17H18Hwww.ge-ip.com/support
Phone: [phone]
[phone] (India, Indonesia, and Pakistan)
Technical Support Email: [e-mail] (China)
[e-mail] (Japan)
[e-mail] (remaining Asia customers)
Customer Care Email: 25H26Hcustomercare[email protected]
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RFI Standards
GFK-03 6Q v
The Series 90-30 PLC and its associated modules have been tested and found to meet or exceed the
requirements of FCC Rule, Part 15, Subpart J. The Federal Communications Commission (FCC)
requires the following note to be published according to FCC guidelines.
NOTE
This equipment generates, uses, and can radiate radio frequency energy and if not installed in
accordance with this instruction manual, may cause harmful interference to radio communications.
It has been tested and found to comply with the limits for a Class A digital device pursuant to Part
15 of the FCC Rules, which are designed to provide reasonable protection against harmful
interference when operated in a commercial environment. Operation of this equipment in a
residential area is likely to cause harmful interference, in which case the user will be required to
correct the interference at his own expense.
The following note is required to be published by the Canadian Department of Communications.
NOTE
This digital apparatus does not exceed the Class A limits for radio noise emissions from digital
apparatus set out in the radio interference regulations of the Canadian Department of
Communications.
The following statements are required to appear in the Series 90_-30 Installation Manual and the
Series 90_-30 I/O Specifications Manual for Class I Div 2 Hazardous Locations.
1. EQUIPMENT LABELED ITH REFERENCE TO CLASS I, GROUPS A, B, C, and D,
DIV. 2 HAZARDOUS LOCATIONS IS SUITABLE FOR USE IN CLASS I, DIVISION 2,
GROUPS A, B, C, D OR NON-HAZARDOUS LOCATIONS ONLY.
2. ARNING - EXPLOSION HAZARD - SUBSTITUTION OF COMPONENTS MAY
IMPAIR SUITABILITY FOR CLASS I, DIVISION 2:
3. ARNING - EXPLOSION HAZARD - DO NOT DISCONNECT EQUIPMENT UNLESS
PO ER HAS BEEN S ITCHED OFF OR THE AREA IS KNO N TO BE
NON-HAZARDOUS.
4. ALL UNUSED SLOTS IN ALL BASEPLATES MUST BE POPULATED ITH FILLER
MODULES, IC693ACC310, OR EQUIVALENT.

Preface
GFK-03 6Q vii
This manual describes the GE Series 90-30 Programmable Logic Controller (PLC). It
contains a description of hardware components and provides basic hardware installation
procedures. The Series 90-30 PLC is a member of the Series 90_ family of Programmable Logic
Controllers from GE.
For a list of product standards, refer to data sheet GFK-0867B or later, GE Approvals,
Standards, General Specifications which lists all of the standards for GE products.
Installation instructions in this manual are provided for installations that do not require special
procedures for noisy or hazardous environments. For installations that must conform to more
stringent requirements (such as CE Mark), see GFK-1179, Installation Requirements for
Conformance to Standards.
What’s New in This Manual
Ŷ Added the model 374 CPU, which supports connection to an Ethernet network through two
built-in 10BaseT/100BaseTx auto-negotiating full-duplex Ethernet ports. Models 364 (release
9.10 and later) and 374 are the only Series 90-30 CPUs that support Ethernet Global Data.
Note that the CPU374 is supported only by the indows®-based programmers.
Ŷ Other corrections and clarifications as necessary.
Related Publications
For more information on Series 90-30 products, refer to these publications. (For a publication to
product catalog number cross-reference refer to Appendix G):
GFK-0255 - Series 90 PCM and Support Software User’s Manual
GFK-0256 - MegaBasic Programming Reference Manual
GFK-0293 - Series 90 -30 High Speed Counter User’s Manual
GFK-0401 - orkmaster® II PLC Programming Unit Guide to Operation
GFK-0402 - Series 90 -30 and 90-20 PLC Hand-Held Programmer User’s Manual
GFK-0412 - Genius® Communications Module User’s Manual
GFK-0466 - Logicmaster 90 Series 90 -30/20/Micro Programming Software User’s Manual
GFK-0467 - Series 90 -30/20/Micro Programmable Controllers Reference Manual
GFK-0487 - Series 90 PCM Development Software (PCOP) User’s Manual
GFK-0499 - CIMPLICITY® 90-ADS Alphanumeric Display System User’s Manual

Preface
viii Series 90™-30 PLC Installation and Hardware Manual – August 2002 GFK-03 6Q
GFK-0582 - Series 90 PLC Serial Communications User’s Manual
GFK-0631 - Series 90 -30 I/O LINK Interface User’s Manual
GFK-0641 - CIMPLICITY® 90-ADS Alphanumeric Display System Reference Manual
GFK-0664 - Series 90-30 PLC Axis Positioning Module Programmer’s Manual
GFK-0685 - Series 90 Programmable Controllers Flow Computer User’s Manual
GFK-0695 - Series 90-30 Enhanced Genius) Communications Module User’s Manual
GFK-0726 - Series 90-30 PLC State Logic Processor User’s Guide
GFK-0732 - Series 90-30 PLC ECLiPS User’s Manual
GFK-0747 - Series 90-30 PLC OnTOP User’s Guide
GFK-0750 - OnTop for Series 90-30 (State Logic) Program User’s Manual
GFK-0781 - Motion Mate APM300 for Series 90-30 PLC Follower Mode User’s Manual
GFK-0823 - Series 90 -30 I/O LINK Master Module User’s Manual
GFK-0828 - Series 90 -30 Diagnostic System User’s Manual
GFK-0840 - Motion Mate APM300 for Series 90 -30 PLC Standard Mode User’s Manual
GFK-0867 - GE Product Agency Approvals, Standards, General Specifications
GFK-0898 - Series 90 -30 PLC I/O Module Specifications
GFK-1028 - Series 90 -30 I/O Processor Module User’s Manual
GFK-1034 - Series 90 -30 Genius® Bus Controller User’s Manual
GFK-1037 - Series 90 -30 FIP Remote I/O Scanner User’s Manual
GFK-1056 - Series 90 -30 State Logic Control System User’s Manual
GFK-1186 - TCP/IP Ethernet Communications for the Series 90_-30 PLC Station Manager Manual
GFK-1179 - Series 90 PLC Installation Requirements for Conformance to Standards
GFK-1464 - Motion Mate DSM302 for Series 90-30 PLCs User’s Manual
GFK-1466 - Temperature Control Module for the Series 90-30 PLC User’s Manual
GFK-1541 - TCP/IP Ethernet Communications for the Series 90 PLC User’s Manual

Contents
GFK-03 6Q ix
Chapter 1 Overview of the Series 90-30 PLC .....................................................................1-1
The Basic Parts of a Series 90-30 PLC....................................................................... 1-1
Assembling a Basic Series 90-30 PLC System .......................................................... 1-2
hat else would be needed to make this basic system functional? ........................... 1-6
hat if the application requires more than five modules?......................................... 1-6
hat if the application requires more than ten modules? .......................................... 1-7
hat is the Difference Between Expansion and Remote baseplates?........................ 1-8
hat if I need to cover more than 700 feet (213 meters)?......................................... 1-9
Chapter 2 Installation ...........................................................................................................2-1
Receiving your Products - Visual Inspection ............................................................. 2-1
Pre-installation Check ................................................................................................ 2-1
arranty Claims......................................................................................................... 2-1
orking with Series 90-30 Modules.......................................................................... 2-2
Module Features........................................................................................................ 2-2
Installing a Module.................................................................................................... 2-3
Removing a Module .................................................................................................. 2-4
Installing a Module’s Terminal Board ...................................................................... 2-5
Removing a Module’s Terminal Board..................................................................... 2-6
I/O Module Terminal Board Posts ............................................................................ 2-7
Installing and Removing Terminal Boards with Holding Screws ............................. 2-7
Baseplate Mounting.................................................................................................... 2-8
Mounting a Baseplate to a Panel ................................................................................ 2-8
Mounting a Baseplate to a 19" Rack .......................................................................... 2-8
Grounding Procedures .................................................................................................... 2-11
System Grounding Procedures ................................................................................. 2-11
Ground Conductors ................................................................................................. 2-11
Series 90-30 PLC Equipment Grounding................................................................. 2-12
Baseplate Safety Grounding.................................................................................... 2-12
Grounding 19" Rack-Mounted Baseplates .............................................................. 2-13
Programmer Grounding........................................................................................... 2-13
Module Shield Grounding ........................................................................................ 2-14
Shield Grounding Information for CPUs with External Port Connections.............. 2-14
CPU351 and 352 Shield Grounding........................................................................ 2-14
CPU363, CPU364, and CPU374 Shield Grounding................................................ 2-16
Additional Modules with Shield Grounding Requirements .................................... 2-16
General iring Guidelines ............................................................................................. 2-17
Discrete I/O Module Connection Methods............................................................... 2-18
Connections to I/O Module Terminal Boards .......................................................... 2-18
Terminal Block Quick Connect Installation for 16-Point Discrete Modules ........... 2-19
Installation of 32-Point Discrete, 50-Pin Connector Modules ................................. 2-19
Using eidmuller #912263 Terminal Block .......................................................... 2-19
Using a Generic Terminal Block or Strip................................................................ 2-20
Direct Method ......................................................................................................... 2-20
Installation of Discrete 32-Point, Dual 24-Pin Connector Modules......................... 2-20
Using a TBQC......................................................................................................... 2-20

Contents
xSeries 90™-30 PLC Installation and Hardware Manual – August 2002 GFK-03 6Q
ith a Generic Terminal Block/Strip...................................................................... 2-20
Direct Method ......................................................................................................... 2-21
General iring Methods for Analog Modules......................................................... 2-21
Analog Input Module iring Methods .................................................................... 2-21
Using a Generic Terminal Block or Strip................................................................ 2-21
Direct Method ......................................................................................................... 2-21
TBQC not Recommended for Analog Modules...................................................... 2-22
Analog Output Module iring ................................................................................ 2-22
General .................................................................................................................... 2-22
Using a Generic Terminal Block or Strip................................................................ 2-22
Direct Method ......................................................................................................... 2-22
TBQC not Recommended for Analog Modules...................................................... 2-22
AC Power Source Connections....................................................................................... 2-23
AC Input iring to AC/DC Power Supplies ........................................................... 2-23
Power Supply Overvoltage Protection Devices........................................................ 2-24
Special Installation Instructions for Floating Neutral (IT) Systems ............................... 2-25
Definition of Floating Neutral Systems.................................................................... 2-25
Use These Special Installation Instructions for Floating Neutral Systems............... 2-26
DC Power Source Connections....................................................................................... 2-27
DC Input iring to AC/DC and DC-Only Power Supplies..................................... 2-27
+24 VDC Output (All Supplies)............................................................................... 2-27
Basic Installation Procedure ........................................................................................... 2-28
Chapter 3 Baseplates .............................................................................................................3-1
Baseplate Types ................................................................................................................ 3-1
Common Baseplate Features ...................................................................................... 3-1
Two Baseplate Sizes................................................................................................... 3-2
Baseplate Terms................................................................................................................ 3-3
CPU Baseplates................................................................................................................. 3-4
Embedded CPU Baseplates (Figures 3-2 and 3-3) ..................................................... 3-4
Modular CPU Baseplates (Figures 3-4 and 3-5) ........................................................ 3-6
Expansion Baseplates (Figures 3-6 and 3-7) .............................................................. 3-7
Remote Baseplates (Figures 3-8 and 3-9)................................................................... 3-8
I/O Bus Expansion Cables........................................................................................ 3-10
Differences Between Remote and Expansion Racks................................................ 3-11
Mixing Expansion and Remote Baseplates in a System ................................................. 3-11
Termination Requirement for Expansion or Remote System ......................................... 3-12
Powering Down Individual Expansion or Remote Baseplates ....................................... 3-12
Series 90-30 PLC Backplane .......................................................................................... 3-12
Rack Number DIP Switch on Expansion and Remote Baseplates.................................. 3-13
Expansion and Remote Baseplates Connection Example............................................... 3-15
Baseplate Mounting Dimensions .................................................................................... 3-16
Embedded CPU (311, 313, and 323) Baseplate Dimensions ................................... 3-16
Modular CPU, Expansion, and Remote Baseplate Dimensions............................... 3-18

Contents
GFK-03 6Q Contents xi
Load Ratings, Temperature, and Mounting Position ...................................................... 3-19
Baseplate Adapter Brackets for 19" Rack Mounting...................................................... 3-20
Baseplate Comparison Table.................................................................................... 3-22
Chapter 4 Power Supplies.....................................................................................................4-1
Power Supply Categories.................................................................................................. 4-1
Power Supply Feature Comparison................................................................................... 4-1
AC/DC Input Power Supplies........................................................................................... 4-2
IC693P R321 Standard Power Supply, 120/240 VAC or 125 VDC Input .............. 4-2
IC693P R330 High Capacity Power Supply, 120/240 VAC/125 VDC Input ......... 4-4
Field iring Connections for the AC/DC Input Power Supplies............................... 4-5
Isolated 24 VDC Supply Output Connections............................................................ 4-6
DC Input Only Power Supplies......................................................................................... 4-7
IC693P R322 Standard Power Supply, 24/48 VDC Input....................................... 4-7
Calculating Input Power Requirements for IC693P R322 ............................................. 4-8
IC693P R328 Standard Power Supply, 48 VDC Input.......................................... 4-10
Calculating Input Power Requirements for IC693P R328..................................... 4-11
Input Power/Current Calculation for IC693P R328 Power Supply....................... 4-12
IC693P R331 High Capacity Power Supply, 24 VDC Input................................. 4-13
Current Derating for Higher Temperatures .............................................................. 4-14
Calculating Input Power Requirements for IC693P R331..................................... 4-15
Field iring Connections to the DC Input-Only Power Supplies ........................... 4-15
Common Series 90-30 Power Supply Features............................................................... 4-16
Status Indicator Lights on all Power Supplies.......................................................... 4-16
Input Overvoltage Protection Devices...................................................................... 4-16
Output Voltage Connections to Backplane (All Supplies)....................................... 4-17
Overcurrent Protection (all Supplies)....................................................................... 4-18
Timing Diagram ....................................................................................................... 4-18
CPU Serial Port Connector on Power Supply (All Supplies)................................... 4-19
CPU Serial Port Information .................................................................................... 4-19
Backup Battery for RAM Memory (All Supplies) ................................................... 4-20
Chapter 5 CPUs .....................................................................................................................5-1
CPU Types for Series 90-30 PLCs ................................................................................... 5-1
Embedded CPUs......................................................................................................... 5-1
Modular CPUs............................................................................................................ 5-2
General CPU Features ................................................................................................ 5-3
Microprocessor.......................................................................................................... 5-3
CPU Serial Port (Connector on Power Supply)......................................................... 5-3
Memory Volatility..................................................................................................... 5-4
RAM Memory ........................................................................................................... 5-5
RAM Memory Backup/Backup Battery Information................................................ 5-5
Programmable Read-Only Memory (PROM) Types................................................. 5-5
Uses of PROM devices in the 90-30 CPUs ............................................................... 5-5

Contents
xii Series 90™-30 PLC Installation and Hardware Manual – August 2002 GFK-03 6Q
CPU Firmware........................................................................................................... 5-6
Determining CPU Revision Levels (Versions) ......................................................... 5-7
EPROM and EEPROM User Program Storage Options................................................... 5-8
Comparing EPROM and EEPROM Features............................................................. 5-8
Procedure for Creating an EPROM............................................................................ 5-9
Flash Memory............................................................................................................. 5-9
Series 90-30 CPU Capacities.................................................................................... 5-10
User Memory Addresses (References)..................................................................... 5-10
Difference Between a Memory Address and a Nickname........................................ 5-10
User Memory Reference Types................................................................................ 5-11
Application Program Compatibility ........................................................................ 5-12
CPU Time-of-Day (TOD) Clock Accuracy............................................................. 5-12
Breakfree SNP Protocol .......................................................................................... 5-13
350–374 CPUs.......................................................................................................... 5-13
Compatibility ith Hand-Held Programmer (HHP) and Memory Card................. 5-13
350–374 CPU Advanced Features........................................................................... 5-14
Details of 350 – 374 CPU Advanced Features ........................................................ 5-14
Hardware Features of the 350–364 CPUs....................................................................... 5-18
CPU350 and CPU360 Hardware Features ............................................................... 5-18
CPU Firmware Upgrade.......................................................................................... 5-18
CPU351, CPU352, and CPU363 Hardware Features............................................... 5-19
CPU Firmware Upgrade.......................................................................................... 5-19
Keyswitch................................................................................................................ 5-19
Shield Ground Connection Tab............................................................................... 5-20
Serial Ports .............................................................................................................. 5-20
Serial Port Front Panel Connectors ......................................................................... 5-20
Serial Port Status LEDs........................................................................................... 5-20
Protocols Supported ................................................................................................ 5-21
Pin Assignments for CPU351, CPU352, and CPU363 Serial Ports 1 & 2 .............. 5-22
CPU364 Hardware Features..................................................................................... 5-23
LED Indicators ........................................................................................................ 5-23
Ethernet Restart Pushbutton .................................................................................... 5-23
Keyswitch................................................................................................................ 5-24
Front Panel Connectors ........................................................................................... 5-24
Shield Ground Connection Tab............................................................................... 5-24
Firmware Upgrade................................................................................................... 5-24
CPU374 Hardware Features..................................................................................... 5-25
LED Indicators ........................................................................................................ 5-25
Ethernet Restart Pushbutton .................................................................................... 5-25
Keyswitch................................................................................................................ 5-26
Front Panel Connectors ........................................................................................... 5-26
Shield Ground Connection Tab............................................................................... 5-26
Firmware Upgrade................................................................................................... 5-26
CPU Data Sheets............................................................................................................. 5-27
CPU311 Catalog Number IC693CPU311 ........................................ 5-28
CPU313 Catalog Number IC693CPU313 ........................................ 5-29
CPU323 Catalog Number IC693CPU323 ........................................ 5-30
CPU331 Catalog Number IC693CPU331 ........................................ 5-31

Contents
GFK-03 6Q Contents xiii
CPU340 Catalog Number IC693CPU340 ........................................ 5-32
CPU341 Catalog Number IC693CPU341 ........................................ 5-33
CPU350 Catalog Number IC693CPU350 ........................................ 5-34
CPU351 Catalog Number IC693CPU351 ........................................ 5-35
CPU352 Catalog Number IC693CPU352 ........................................ 5-36
CPU360 Catalog Number IC693CPU360 ........................................ 5-37
CPU363 Catalog Number IC693CPU363 ........................................ 5-38
CPU364 Catalog Number IC693CPU364 ........................................ 5-39
CPU374 Catalog Number IC693CPU374 ........................................ 5-40
Chapter 6 Memory Bac up/Battery Bac up ......................................................................6-1
Backup Battery for RAM Memory (All Supplies)............................................................ 6-1
Battery Replacement Instructions ..................................................................................... 6-2
Battery Replacement/Memory Protection Factors............................................................ 6-3
The Importance of Backing up Your Program.................................................................. 6-3
Factors Affecting Battery Life .......................................................................................... 6-4
Low Battery arning Methods......................................................................................... 6-4
Operating ithout a Memory Backup Battery ................................................................. 6-6
RAM Memory Battery Backup Connection Path ............................................................. 6-8
Super Capacitor Memory Backup..................................................................................... 6-8
Maintaining RAM Memory During Storage or Shipment of a CPU.......................... 6-9
Modular CPUs........................................................................................................... 6-9
Embedded CPUs ....................................................................................................... 6-9
Battery Accessory Kit (IC693ACC315).................................................................... 6-9
Battery Accessory Kit Installation........................................................................... 6-10
External Battery Module (IC693ACC302) ..................................................................... 6-10
Batteries in Power Supplies on Expansion or Remote Racks ......................................... 6-11
Chapter 7 Input/Output Modules ........................................................................................7-1
Basic I/O Module Types ................................................................................................... 7-1
Discrete I/O Modules........................................................................................................ 7-2
Discrete I/O Module Point Density ............................................................................ 7-2
Standard Density Discrete I/O Module Features........................................................ 7-2
iring Standard Density (16-Point or Less) Discrete Modules................................. 7-4
Discrete Relay Output Module Protection ................................................................. 7-4
High Density (32-Point) Discrete Module Features................................................... 7-4
iring Methods for 32-Point Discrete I/O Modules.................................................. 7-6
Modules with Single 50-Pin Connector .................................................................... 7-6
Modules with Dual 24-Pin Connectors ..................................................................... 7-7
Analog Module Features................................................................................................... 7-8
iring Methods for Analog Modules ........................................................................ 7-9
Analog Input Module iring Methods ..................................................................... 7-9
Analog Output Module iring ............................................................................... 7-10
I/O Module Power Supply Current Draw ....................................................................... 7-10

Contents
xivSeries 90™-30 PLC Installation and Hardware Manual – August 2002 GFK-03 6Q
I/O Module ire Routing............................................................................................... 7-11
Grouping Modules to Keep ires Segregated ............................................................... 7-11
IC693DVM300 Digital Valve Driver Module................................................................ 7-12
Indicator LEDs ......................................................................................................... 7-12
DVM Specifications ................................................................................................. 7-13
Fuses......................................................................................................................... 7-13
Chapter 8 Option Modules ...................................................................................................8-1
Third-Party Option Modules and the Accompany Program ............................................. 8-1
Option Modules Discussed in this Chapter....................................................................... 8-1
IC693CMM301 Genius Communications Module (GCM) .............................................. 8-2
Status LEDs................................................................................................................ 8-3
GCM Documentation ................................................................................................. 8-3
IC693CMM302 Enhanced Genius Communications Module (GCM+) ........................... 8-4
Status LEDs................................................................................................................ 8-5
GCM+ Documentation ............................................................................................... 8-5
IC693BEM331 Genius Bus Controller (GBC) ................................................................. 8-6
Number of Genius Bus Controllers ............................................................................ 8-7
Status LEDs................................................................................................................ 8-7
Compatibility.............................................................................................................. 8-7
Series 90-30 PLC ...................................................................................................... 8-7
Series Six PLC .......................................................................................................... 8-7
Genius Hand-Held Monitor....................................................................................... 8-8
Hand-Held Programmer ............................................................................................ 8-8
Genius I/O Blocks ..................................................................................................... 8-8
Genius Bus ................................................................................................................ 8-8
Diagnostics ................................................................................................................. 8-8
Datagrams................................................................................................................... 8-9
Global Data................................................................................................................. 8-9
Sending Global Data ................................................................................................. 8-9
Receiving Global Data .............................................................................................. 8-9
Genius Bus Controller Documentation ..................................................................... 8-9
IC693BEM340 FIP Bus Controller (FBC) Module........................................................ 8-10
Status LEDs.............................................................................................................. 8-11
Serial Port................................................................................................................. 8-11
FIP Bus Connectors.................................................................................................. 8-11
IC693BEM330 FIP Remote I/O Scanner Module .......................................................... 8-12
Features of the Remote I/O Scanner......................................................................... 8-12
FIP Bus Interface...................................................................................................... 8-13
Module Description.................................................................................................. 8-13
Connectors................................................................................................................ 8-14
LEDs......................................................................................................................... 8-14
FIP Remote I/O Scanner Documentation:................................................................ 8-14
IC693APU301/302 Motion Mate Axis Positioning Module (APM) .............................. 8-15

Contents
GFK-03 6Q Contents xv
APM Cables ............................................................................................................. 8-16
Motion Mate APM Module Documentation ............................................................ 8-16
IC693DSM302 Motion Mate Digital Servo Module (DSM302).................................... 8-17
Features. ................................................................................................................... 8-18
IC693DSM302 Documentation................................................................................ 8-18
IC693DSM314 Motion Mate Digital Servo Module (DSM314).................................... 8-20
Features ................................................................................................................... 8-21
IC693DSM314 Documentation............................................................................... 8-22
IC693APU300 High Speed Counter (HSC) Module ...................................................... 8-23
IC693BEM320 I/O LINK Interface (Slave) Module...................................................... 8-24
IC693BEM321 I/O LINK Master Module...................................................................... 8-25
Compatibility........................................................................................................... 8-26
IC693APU305 I/O Processor Module ............................................................................ 8-27
Module Features...................................................................................................... 8-28
IC693CMM321 Ethernet Interface Module.................................................................... 8-29
IC693PCM300/301/311 Programmable Coprocessor Module (PCM) ........................... 8-31
IC693CMM311 Communications Coprocessor Module (CMM)................................... 8-34
IC693ADC311 Alphanumeric Display Coprocessor (ADC).......................................... 8-35
IC693TCM302/303 Temperature Control Modules (TCM).......................................... 8-37
Connections............................................................................................................. 8-37
LED Indicators ........................................................................................................ 8-38
Internal Fuse............................................................................................................ 8-38
Automatic Data Transfers Between TCM and PLC................................................ 8-38
Comparison of TCM302 and TCM303 Modules .................................................... 8-39
IC693PTM100/101 Power Transducer (PTM) ............................................................... 8-40
Difference Between PTM100 and PTM101............................................................. 8-40
Capabilities............................................................................................................... 8-40
Operating Modes ...................................................................................................... 8-40
Automatic Data Transfers Between PTMPM and PLC............................................ 8-41
Compatibility............................................................................................................ 8-41
Dimensions............................................................................................................... 8-42
PTMPM Indicator LEDs .......................................................................................... 8-42
General Mounting Information................................................................................. 8-42
Baseplate Type and Allowable Number of PTMPM Modules................................. 8-43
Power Supply Requirement...................................................................................... 8-43
Memory Requirement............................................................................................... 8-43
Configuration............................................................................................................ 8-43
Ordering Information................................................................................................ 8-43
Documentation ........................................................................................................ 8-43
Chapter 9 State Logic Products............................................................................................9-1
State Logic Overview ....................................................................................................... 9-1
State Logic Products ......................................................................................................... 9-1
Baseplates and Power Supply, I/O, and Option Modules........................................... 9-1

Contents
xviSeries 90™-30 PLC Installation and Hardware Manual – August 2002 GFK-03 6Q
AD693CMM301 State Logic Serial Communications Module (SCM)............................ 9-2
Description ................................................................................................................. 9-2
OK LED .................................................................................................................... 9-2
Reset Button .............................................................................................................. 9-2
Serial Connector........................................................................................................ 9-3
Cable Information....................................................................................................... 9-3
State Logic SCM Documentation............................................................................... 9-3
IC693SLP300 State Logic Processor Module .................................................................. 9-4
Description ................................................................................................................. 9-4
SLP Features............................................................................................................... 9-5
Memory ...................................................................................................................... 9-5
Installation .................................................................................................................. 9-5
Status Light................................................................................................................. 9-6
Pushbutton.................................................................................................................. 9-6
Battery ........................................................................................................................ 9-7
Cable Information....................................................................................................... 9-7
Hardware Specifications............................................................................................. 9-7
State Logic Processor (SLP) Documentation ............................................................. 9-7
State Logic CPUs.............................................................................................................. 9-8
Features of State Logic CPUs..................................................................................... 9-8
Model CSE311, CSE313 and CSE323 Embedded CPU Baseplates .......................... 9-9
Model CSE331 and CSE340 Modular CPUs.................................................................. 9-10
CPU Serial Port Connector on Power Supply .......................................................... 9-11
Configuring the State Logic CPUs ........................................................................... 9-11
State Logic CPU Firmware and PROM Configurations .......................................... 9-13
State Logic CPU Data Sheets ......................................................................................... 9-13
CSE311 Catalog Number IC693CSE311 ........................... 9-14
CSE313 Catalog Number IC693CSE313 ........................... 9-15
CSE323 Catalog Number IC693CSE323 ........................... 9-16
CSE331 Catalog Number IC693CSE331 ........................... 9-17
CSE340 Catalog Number IC693CSE340 ........................... 9-18
Chapter 10 Cables .................................................................................................................10-1
Cable Data Sheets ........................................................................................................... 10-7
IC647CBL704 orkstation Interface to Series 90 CPU (SNP Port) Cable ................... 10-8
Function of cable..................................................................................................... 10-8
IC690CBL701 PCM, ADC, CMM to orkmaster (PC-XT) Cable............................. 10-12
Function of cable................................................................................................... 10-12
Cable Specifications.............................................................................................. 10-12
iring Diagram..................................................................................................... 10-12
PCM to Programmer Cable Installation ................................................................. 10-13
IC690CBL702 PC-AT to PCM, ADC, CMM Cable .................................................... 10-14
Function of cable................................................................................................... 10-14
Cable Specifications.............................................................................................. 10-14

Contents
GFK-03 6Q Contents xvii
iring Diagram..................................................................................................... 10-14
PCM to Programmer Cable Installation ................................................................. 10-15
IC690CBL705 orkmaster II (PS/2) to PCM, ADC, CMM Cable ............................. 10-16
Function of cable................................................................................................... 10-16
Cable Specifications.............................................................................................. 10-16
iring Diagram..................................................................................................... 10-16
PCM to Programmer Cable Installation ................................................................. 10-17
IC690CBL714A Multidrop Cable ................................................................................ 10-18
Purpose.................................................................................................................. 10-18
Specifications ........................................................................................................ 10-18
IC690CBL714A Multi-Drop Cable iring Diagram............................................ 10-19
Connection Diagrams for IC690CBL714A Cable.................................................. 10-20
IC693CBL300/301/302/312/313/314 I/O Bus Expansion Cables ................................ 10-22
Description ............................................................................................................ 10-22
Cable Lengths........................................................................................................ 10-22
Function of Cables ................................................................................................ 10-22
Connecting the Cables........................................................................................... 10-23
Important Notes About I/O Bus Expansion Cables............................................... 10-23
Cable Application Suggestions.............................................................................. 10-23
Using Standard Cables .......................................................................................... 10-23
Using Custom Built cables.................................................................................... 10-24
Building Custom Length I/O Bus Expansion Cables ............................................. 10-24
Two Types of Custom Built Cables ...................................................................... 10-24
Components Needed to Build Custom Length I/O Bus Expansion Cables ........... 10-24
Expansion Port Pin Assignments........................................................................... 10-25
I/O Expansion Bus Termination............................................................................ 10-25
Shield Treatment ................................................................................................... 10-26
Alert for Users of Early Remote Baseplate Versions ............................................ 10-26
Making a 100% Shielded Cable ............................................................................ 10-27
iring Diagrams................................................................................................... 10-28
Application Examples ........................................................................................... 10-31
Expansion System Cable Connections .................................................................. 10-31
Remote and Expansion System Cable Connection Example................................. 10-31
IC693CBL303 Hand-Hand Programmer and Converter (IC690ACC900) Cable ........ 10-33
Function of cable.................................................................................................... 10-33
Cable Specifications............................................................................................... 10-33
iring Diagram...................................................................................................... 10-34
Connecting the Cable ............................................................................................. 10-34
IC693CBL304/305 Port Expansion ( YE) Cables for PCM, ADC, and CMM.......... 10-35
Function of cable.................................................................................................... 10-35
Cable Specifications............................................................................................... 10-35
iring Information................................................................................................. 10-36
IC693CBL306/307 Extension Cables (50-Pin) for 32 Point Modules.......................... 10-38
Function of cable.................................................................................................... 10-38
Cable Specifications............................................................................................... 10-38
IC693CBL308/309 I/O Cables (50-Pin) for 32 Point Modules .................................... 10-40
Specifications ......................................................................................................... 10-40
iring Information................................................................................................. 10-40

Contents
xviii Series 90™-30 PLC Installation and Hardware Manual – August 2002 GFK-03 6Q
IC693CBL310 I/O Interface Cable (24-Pin) for 32 Point Modules.............................. 10-42
Function of cable.................................................................................................... 10-42
Replacement/Obsolescence Information................................................................ 10-43
Connector Depth for Cable IC693CBL310........................................................... 10-43
IC693CBL311/317/319/320 I/O Interface Cables for Power Mate APM Modules...... 10-45
Function of cable.................................................................................................... 10-45
Specifications ......................................................................................................... 10-45
iring Information................................................................................................. 10-46
IC693CBL315 I/O Interface Cable (24-Pin) for 32 Point Modules.............................. 10-49
Function of cable.................................................................................................... 10-49
Building Custom Length Cables for 24-Pin Connectors ........................................ 10-49
Replacement/Obsolescence Information................................................................ 10-51
Connector Depth for IC693CBL315 ..................................................................... 10-51
IC693CBL316 Serial Cable, 9-Pin D-Shell to RJ-11 Connector.................................. 10-53
Description ............................................................................................................. 10-53
Typical Applications .............................................................................................. 10-53
IC693CBL321/322/323 I/O Faceplate Connector to Terminal Block Connector, 24-Pin10-54
Function of cable.................................................................................................... 10-54
Cable Specifications............................................................................................... 10-54
Connector Depth ................................................................................................... 10-55
IC693CBL327/328 I/O Interface Cables with Right Angle 24-Pin Connector ........... 10-57
Description ............................................................................................................. 10-57
Applications............................................................................................................ 10-57
Specifications ......................................................................................................... 10-58
Connector Depth for Cables IC693CBL327/328 .................................................. 10-58
Building Custom Length 24-pin Connector Cables ............................................... 10-59
Connector Depth for Custom Built Cables............................................................ 10-60
Possible Uses for These Cables (Factory or Custom Built) ................................... 10-61
IC693CBL329/330/331/332/333/334 Cables 24-Pin I/O Faceplate Connector to Terminal
Block Connector ........................................................................................................... 10-62
Description ............................................................................................................. 10-62
Connector Depth ................................................................................................... 10-63
Applications............................................................................................................ 10-64
IC693CBL340/341 PTM Interface Cables ................................................................... 10-65
Documentation ....................................................................................................... 10-67
Chapter 11 Programmer Hardware Products ....................................................................11-1
Products Discussed in this Chapter................................................................................. 11-1
IC640 MI310/320 ork Station Interface Boards....................................................... 11-2
Replacing orkmaster Computers........................................................................... 11-3
IC690ACC900 RS-422/RS-485 to RS-232 Converter.................................................... 11-3
IC690ACC901 Miniconverter Kit .................................................................................. 11-4
IC693PRG300 Hand-Held Programmer (HHP).............................................................. 11-5
HHP Features ........................................................................................................... 11-6

Contents
GFK-03 6Q Contents xix
HHP Memory Card (IC693ACC303)...................................................................... 11-6
HHP Modes of Operation........................................................................................ 11-6
Documentation ........................................................................................................ 11-6
IC693PIF301/400 Personal Computer Interface (PCIF) Cards ...................................... 11-7
IC655CCM590 Isolated Repeater/Converter ........................................................... 11-8
IC690ACC903 Port Isolator..................................................................................... 11-8
Chapter 12 System Design ....................................................................................................12-1
Introduction..................................................................................................................... 12-1
Step 1: Planning Your System................................................................................. 12-1
Step 2: Determining I/O Requirements ................................................................... 12-1
Additional I/O Module Selection Factors................................................................ 12-2
Step 3: Selecting Option Modules........................................................................... 12-2
Step 4: Selecting a CPU .......................................................................................... 12-4
Step 5: Selecting Baseplates.................................................................................... 12-5
Step 6: Selecting Power Supplies............................................................................ 12-6
Reducing PLC Module Count by Using Other GE Products .......................................... 12-7
Designing For Safety ...................................................................................................... 12-8
Protection From Electrical Shock............................................................................. 12-8
Fire Prevention ......................................................................................................... 12-8
Protection From Mechanical Hazards ...................................................................... 12-8
Protection From Electrical Failure ........................................................................... 12-8
Protection From Design Changes or Overrides....................................................... 12-9
Safety Documentation ........................................................................................... 12-10
Guarding Against Unauthorized Operation........................................................... 12-10
Labeling, Guarding, and Lighting Issues............................................................... 12-10
Equipment Accessibility Issues............................................................................. 12-10
Number of Modules Per Series 90-30 PLC System...................................................... 12-11
Calculating Power Supply Loading .............................................................................. 12-12
Load Requirements for Hardware Components ..................................................... 12-12
Power Supply Loading Calculation Examples ...................................................... 12-14
Scan (Sweep) Time Calculation.................................................................................... 12-15
Major Design Factors Affecting Scan Time........................................................... 12-16
here to Find Scan Time Information................................................................... 12-16
Calculating PLC Heat Dissipation ................................................................................ 12-17
System Layout Guidelines ............................................................................................ 12-17
Benefits of a Good Layout - Safe, Reliable, and Accessible.................................. 12-17
PLC Rack Location and Clearance Requirement ................................................... 12-17
Location of Modules in the PLC Racks ................................................................. 12-18
Allowable Module Locations ................................................................................. 12-19
Series 90-30 PLC Layout Example............................................................................... 12-20
PLC Mounting Position ................................................................................................ 12-21
Recommended Upright Mounting Orientation....................................................... 12-21
Derated Horizontal Mounting Orientation ............................................................. 12-21

Contents
xxSeries 90™-30 PLC Installation and Hardware Manual – August 2002 GFK-03 6Q
Chapter 13 Maintenance and Troubleshooting ..................................................................13-1
Troubleshooting Features of Series 90-30 Hardware...................................................... 13-1
Indicator Lights (LEDs) and Terminal Board .......................................................... 13-1
Module LED Indicators .................................................................................................. 13-2
Troubleshooting Features of Programming Software..................................................... 13-3
Ladder Screens ......................................................................................................... 13-3
Configuration Screens .............................................................................................. 13-3
Fault Tables .............................................................................................................. 13-3
System Status References......................................................................................... 13-3
Reference Tables ...................................................................................................... 13-4
Override feature........................................................................................................ 13-4
Sequential Event Recorder (SER), DOIO functional instruction ............................. 13-4
Replacing Modules ......................................................................................................... 13-5
Series 90-30 Product Repair..................................................................................... 13-5
Module Fuse List...................................................................................................... 13-6
Spare/Replacement Parts ................................................................................................ 13-7
Preventive Maintenance Suggestions.............................................................................. 13-8
Getting Additional Help and Information....................................................................... 13-9
Appendix A Serial Ports and Cables...................................................................................... A-1
RS-422 Interface .............................................................................................................. A-1
Cable and Connector Specifications.......................................................................... A-2
Series 90 PLC Serial Port.......................................................................................... A-3
orkmaster Serial Port.................................................................................................... A-4
RS-232/RS-485 Converter ............................................................................................... A-7
IC690ACC901 Miniconverter Kit............................................................................. A-7
IC690ACC900 Obsolete Converter........................................................................... A-7
Serial Cable Diagrams ..................................................................................................... A-8
RS-232 Point-to-Point Connections .......................................................................... A-8
RS-422 Point-to-Point Connection.......................................................................... A-10
Multidrop Connections............................................................................................ A-10
Appendix B IC690ACC900 Converter .................................................................................. B-1
Features............................................................................................................................ B-1
Functions.......................................................................................................................... B-1
Location in System .......................................................................................................... B-2
Installation........................................................................................................................ B-2
Cable Description............................................................................................................. B-3
RS-232 Interface Pin Assignments............................................................................ B-4
RS-422/RS-485 Interface Pin Assignments .............................................................. B-5
Logic Diagram ................................................................................................................. B-6
Jumper Configuration ...................................................................................................... B-7