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Series Six Plus User`s Manual

1. BATTERY NOT REQUIRED BOARD OK CPU COMMUNICATIONS NOT RECEIVE 1 USED RECEIVE 2 TRANSMIT 2 TABLE ADDRES DIP SWITCHES CONFIGURATION lt PORT USED COMMUNICATIONS PORT TRANSMIT CN OS D Dn nnne 9 Es a4047 7 Figure 2 17 LINK LOCAL MODULE Physical Equipment Configuration 2 29 GEK 96682 STRUCTURE FOR THE SERIES SIX PLUS PLC The I O structure for the Series Six Plus PLC provides the user with many options of system configurations and a large variety of discrete and special I O modules designed to fit the needs of virtually any application Any of the rack based Series Six I O modules can be used a Series Six Plus PLC system and be placed anywhere within the I O structure except that devices such as the ASCII BASIC module requiring windows from the CPU cannot be used in Remote I O stations The 19 CPU rack has 6 slots in which modules may be placed and the 13 rack has 3 slots for I O modules When an application requires more I O than can be contained in the CPU rack an optional I O rack or racks can be added This allows a system to use the maximum I O points available in a configuration lO RACKS All modules other than those in the CPU rack are housed an I O rack The I O rack uses the same mechanical packaging as the CPU rack and is available in both 13 and 19 racks The I O racks can be mounted in the same manner as the CP
2. oO Ui A Ut 10528 Future Future Input Status Definitions The first input is on if the user has configured the CPU to enable the special diagnostic functions The second input is on if the CPU has detected any fault during its evaluation of each Bus Controller s input data The third input is on if the expanded is enabled i e all 1 serviced from register content The fourth input is on if the fault table is full and an additional fault is received but could not be stored The most recent fault is disregarded These inputs are updated with each scan until reset by user logic unless controlled by a one shot 4 40 Expanded CPU Operation GEK 96692 Output Control Definitions On the output side when the first output is set on all Bus Controllers connected to the CPU will begin to clear faults stored at the I O blocks as well as in the Bus Controller When this master reset is removed new faults can be recorded and reported to the CPU The second output causes a bit to be set which initiates a pulse test of all Genius I O discrete outputs connected to the CPU except those blocks configured to ignore the test If left energized the second output will cause continuous pulse tests to be conducted as soon as the previous test is completed COMPUTER MAIL BOX The Computer Mail Box is an automatic communications window to the Genius I O system The default entry for this option is N To use the Computer Mail Box
3. rack power down Corrective Action Check the position of the jumper pack and DIP shunts on the 1 0 Receiver or Advanced 1 O Receiver modules Refer to I O Receiver and Advanced 1 0 Receiver installation instructions in Chapter 3 for correct positions TROUBLESHOOTING WITH THE ADVANCED RECEIVER MODULE 41083 The rest of the troubleshooting procedures pertain to the Advanced Receiver The numbers 16 25 refer to status indicators on the module as shown in figure 5 12 and also correspond to troubleshooting steps Figure 5 12 ADVANCED I O RECEIVER STATUS INDICATORS Troubleshooting and Repair 5 39 GEK 96602 16 The following troubleshooting procedures assume that the Advanced 1 0 Receiver option switches have been set to send faults back to the CPU If the faults are not sent back to the CPU the CPU will not be affected by these faults CHN XMIT CHN PS OK OK JOK JOK Definition 16 21 22 23 ON ON ON ON Power and cable continuity is and has been OK in This I O rack I O racks downstream from this Advanced I O Receiver Any I O Transmitter or Remote I O Driver link beginning in this rack since the Advanced I O Receiver was last reset OFF OFF A power or continuity problem exists now in the I O Transmitter or Remote I O Driver link The CHAIN OK light on the CPU s I O Control module will be off RUN and ENABLE lights at the CPU will be off and Alarm Relay 1 switches OFF A power or contin
4. Corrective Action e Ensure that good grounding exists between racks in that station no more than 7V between racks especially when intermittent faults occur Ensure that the low level I O cable has not been placed close to any high level power cables power supplies or switching devices especially when intermittent faults occur e Replace the Advanced 1 0 Receiver module e Replace the 1 0 cable between this rack and the next rack upstream back towards the CPU Replace the I O Receiver Advanced 1 0 Receiver 1 0 Transmitter Remote I O Driver 1 0 Control module driving this rack NOTE Reset the status indicators after your corrective action by momentarily pressing the RESET pushbutton on the Advanced I O Receiver module or by momentarily turning Output Byte Bit 2 On then OFF Troubleshooting and Repair 5 43 GEK 96602 21 TRANSMIT OK LIGHT CHN OK XMIT OK 16 2 DEFINITION ON Power and cable continuity is and has been OK in all I O racks connected to an I O Transmitter or Remote I O Driver module in this rack since the last time that the Advanced I O Receiver was reset ON OFF An intermittent power or continuity problem was latched in from the I O Transmitter or Remote I O Driver link and the XMIT OK light has not been reset since then OFF OFF power or continuity problem exists now in the 1 0 Transmitter or Remote I O Driver link The CHAIN OK light on the CPU s I O Control module will
5. GEK 96682 Programming Lanquage for the Series Six Plus PLC The basic programming language used by the Series Six Plus PLC is relay ladder logic This has been expanded to include instructions for applications more complex than those requiring only the basic relay ladder logic functions Three versions of programming instruction sets are available Advanced Expanded and Expanded Il The instruction sets are contained in PROMS on the appropriate Logic Control module The version of the module must be selected depending on the programming instruction set requirements Advanced Functions Expanded Functions or Expanded II Functions The Expanded functions include a group of 7 instructions that provide the capability for floating point math calculations to be performed Several other functions are enhanced to expand their capabilities to allow their use with the full 32K of I O and 16K of user accessible 16 bit data registers and permit the use of the powerful Genius I O diagnostics The Expanded functions include all of the functions available with the Expanded functions Additionally instructions are included for accessing a new I O system to be available in the future and changes in the microcode have been made to allow operation which provides faster execution of ladder logic programs Available programming functions are listed below Table 1 3 PROGRAMMING FUNCTIONAL GROUPS ADVANCED FUNCTIONS RELAY Normally Open and Normally
6. PREINSTALLATION CHECK After unpacking the Series Six Plus CPU and I O racks all modules the Workmaster computer and any peripherals that have been ordered as part of a system it is recommended that serial numbers of the CPU Workmaster computer and any peripherals be recorded The serial numbers are required if Product Service should need to be contacted for any reason during the warranty period of the equipment Verify that all components of the system have been received and that they agree with your order If the system received does not agree with your order call your PtC Distributor or GE Fanuc NA sales representative for further instructions RACK INSTALLATION The Series Six Plus CPU can be rack panel or wall mounted A set of mounting brackets is included with each rack and can be mounted on either the front or rear of each rack The method for mounting the brackets is determined by the system mounting configuration Dimensions and placement of the mounting brackets for racks are shown in figures 3 1 and 3 2 Installation Instructions 3 3 GEK 96602 c41065 FOR RACK MOUNTING REMOVE MOUNTING BRACKETS TURN THEM 90 DEGREES AND RA 208 45 MOUNT ON FRONT OF RACK RECOMMENDED MOUNTING HARDWARE DIMENSIONS IN ARE MILLIMETERS 8 16 x 18 WITH FLAT WASHER Figure 3 2 WALL OR PANEL MOUNTING 19 RACK 3 4 Installation Instructions 96602 EXTRACTION INSERTION TOOL The printed circuit
7. a41087 Figure 1 7 OPERATOR INTERFACE TERMINAL 1 16 Introduction To The Series Six Plus PLC GEK 96602 ProLoop Process Controllers The Protoop Process Controllers are a group of analog control devices that can be integrated into any Series Six Pius PLC system Each ProLoop Controller can operate independent of or under the supervision of a Series Six Plus PLC The ProLoop Controller system is suitable for applications requiring precise control of temperatures fluid levels fluid flows or pressures The ProLoop Controllers are available in a variety of configurations including Single Loop Auto Tune and Multi Loop The Loop Management Module LMM is the interface from the ProLoop Controllers to a PLC Command and setup information is passed from the PLC to the ProLoop Controllers and status information is returned from the ProLoop Controllers to the PLC The ProLoop Controllers can be programmed using a low cost Hand Held Configurator which plugs into the front panel of a ProLoop Controller and allows access to digital information in the ProLoop Controller For more convenient programming of the ProLoop Controllers the Processmaste r software package is available This software package configures a series of screens on the CRT of a Workmaster computer or on the Operator Interface Terminal This allows the ProLoop Controller system to be easily configured by moving the cursor and entering the proper data For compl
8. 024 R1024 R1825 R1825 USER REGISTERS R1152 R1152 R1153 R1153 7K OUTPUTS 0940001 0 1024 3 7K INPUTS 19 0001 1024 R2048 R2048 R2049 R2049 STATUS BITS FOR 32K 1 0 or internal References 00 0001 to 10241 R4096 R4096 R4097 R4097 BUS CONTROLLER STATUS BIT MAP R4112 R4112 R4113 R4113 USER REGISTERS R4116 R4116 R4117 R4117 CLOCK R4119 R4119 R4120 R4120 POINTER FOR FAULT TABLE R4121 R4121 FAULT TABLE ENTRIES RXXXX RXXXX RXXXX RXXXX USER REGISTERS 4 R8222 R16314 R8123 R16315 COMPUTER MAIL BOX R8192 R16384 1 Channel 8 real I O is mapped into Registers 1 through 128 references 00001 01024 and 10001 11024 2 Channel real 1 0 is scanned on Main 1 0 chain references 00001 01024 and 10001 11024 3 Expanded discrete references 00001 through 401024 10001 through 11024 0140001 through 0 1024 11 0001 through 1 1024 are overlaid on the Register table These registers are available for general use if the above references are not used 4 The number of registers available for general use depends on the quantity of Genius I O fault tables selected Figure 4 3 MEMORY MAP FOR 8K AND 16K REGISTERS Expanded CPU Operation 4 7 GEK 96682 31 1K REGISTER REGISTER RANGE CONTENTS R000 1 IK OUTPUTS 00001 A01024 1 IK INPUTS AI0001 AI1024 0128 0129 OUTPUTS 0150001 0141024 1 INPUTS 114 0001 11 10
9. 1 or a 0 to determine if there are any active overrides in the system If the end of the override tables is reached without finding an active override O1016 will be turned OFF If O1015 is turned OFF then O1016 will not be modified Scratch Pad Items The Scratch Pad storage area contains miscellaneous data pertaining to CPU operation The Scratch Pad display as viewed on the Workmaster computer includes these items and the current status of each one Some of the items can be changed by the user others are configured by the CPU and cannot be altered by the user Table 2 7 SCRATCH PAD STORAGE ITEMS DESCRIPTION CPU ID A number assigned to the CPU when there is more thanone CPU in a communications system MEMORY SIZE Number of words oflogicmemory in the CPU CPUMEMORY State of the Memory Protect key switch on the CPU SUBROUTINES USED Number of subroutines in the user s program CPU STATUS Current operating status of the CPU either run enabled run disabled or stop FUNCTIONS Level of the instruction set resident in the CPU either Advanced Expanded or Expanded II WORDS USED Length of current user program in 16 bit words WORDS AVAILABLE Number of unused 16 bit words left in user memory REGISTERS Number of 16 bit Register memory locations in CPU CPU VERSION Revision level of the CPU software CPU ERROR FLAGS A group of 24 bits in Scratch Pad memory used by the CPU to indicate the type and location of faults detected by the C
10. 1 0 racks to I O racks Table 2 12 is a list of the I O interface modules including catalog numbers and basic descriptions A more detailed description of each module is provided in the following pages Table 2 12 1 0 INTERFACE MODULES MODULE CATALOG DESCRIPTION NAME NUMBER I O RECEIVER IC600BF 800 Interfaces the parallel I O bus to the I O modules located in an I O rack Required in each I O rack except the first rack in a Remote I O station ADVANCED I O RECEIVER IC600BF830 Performs same interface functions as the I O Receiver plus adapted for situations requiring additional diagnostics I O TRANSMITTER IC600BF 900 Interfaces a rack in a CPU station or Local 1 0 station to a Local 1 0 station downstream at distances up to 500 feet Contains configurable jumpers to allow selection of either NORMAL or EXPANDED I O modes Each transmitter can drive one I O channel 1K Inputs and 1K Outputs REMOTE 1 0 DRIVER IC600BF901 Interfaces a rack in a CPU or Local 1 0 station to a Remote 1 0 station located at distances up to 10 000 feet by direct cable greater distances by RS 232 modem l nk REMOTE I O RECEIVER IC600BF801 Interfaces a Remote I O station through a serial link from a Remote I O Driver Physical Equipment Configuration 2 43 GEK 96602 1 0
11. 2 56 Physical Equipment Configuration GEK 96602 Remote I O Driver Addressing A block of addresses for the Remote I O station is established by setting the seven segment DIP switch adjacent to the slot selected for the Remote I O Driver For a block of 120 I O switches 5 6 and 7 are set to select the block and for 248 I O switches 6 and 7 are set to select the block of I O addresses All I O modules in the Remote I O station connected to a Remote I O Driver must then have the corresponding DIP switch segments set in the same configuration as the Remote I O Driver In all cases switches 1 to 4 or 1 to 5 in addition to 5 6 7 or 6 7 are configured to set a unique address for each module in the Remote I O station 1 8 249 256 673 680 etc A unique I O reference address must also be set for the Remote I O Driver and can be the first of any group of eight consecutive valid I O references within the selected block The eight input references provide status information which can be monitored on the programmer by observing the byte in the applicable Input Status Table Normal mode or Channel 0 or Register location associated with the I O channel in the EXPANDED mode The eight output references are for future use Table 2 18 REMOTE I O DRIVER STATUS BYTE INPUT REFERENCE INFORMATION PROVIDED 1 10297 1 Input toggles every time new input data is transferred to the CPU 2 10298 Reserved 3 18299 Reserved 4 10300 Re
12. 24 PIN 6 RN WHT SOCKETt6 PIN 25 BLK ORN SOCKET 25 Pik 97 WHT BRN SOCKET dt26 GRN BLK SOCKET 26 PIN 8 BRN WHT SOCKETXB PIN 27 BLK GRN SOCKET 27 Pin 5 WHT BRN sockETs9 Pin 28 BRN BLK SOCKET 28 piwo ORY WHT SOCKET IO Pin 29 BLK BRN SOCKET 29 Pingu wat ery socxetai Pin 30 GRY BLK SOCKET 30 BLU RED f SOCkET 12 pix 311 BLK GRY SOCKET 3 penl ema feaman ORN RED SOCKET 14 PIN 33 YEL BLU SockeT amp 33 rm RED ORN SOCKET 15 NOT USED SEI 8 PIN 5 NOT USED SOCKET 36 ries auam Tener PIN 37 SHIELD soxeres CATALOG CATALOG FEET MET 2 0 6 1C amp 0QNDOC2A 30 0 ICEDOWDIOOA 15 ICE00NDOOSA 60 0 iCE00ND200A 1C600WDOIDA 300 90 0 1C600W03004 25 7 5 IC600WDO2SA 400 120 0 ICED0WD400A 50 15 0 ICE00WDOSDA 500 50 0 ICBOOWDSOOA less than 2 inches Figure 3 19 PARALLEL I O CHAIN CABLE 70126 3 26 Serial Link Cable To Remote I O System Installation Instructions GEK 96692 The following data is provided as an aid to the user for assembling and wiring a twisted pair cable for connecting a Local serial link system to a Remote I O system over PAIR 1 TRANSMIT S 9 RECEIVED a DATA 10 f DATA SATELD RECEIVE f 9 TRANSMIT DATA 1 io f DATA SHIELD REMOTE 1 0 REMOTE 1 0 DRIVER R
13. 9 Time Reference This is a real time clock maintained by the CPU which uses three consecutive registers to keep track of days hours minutes seconds and tenth of seconds It is used by the CPU to keep track of fault occurrences In addition when the Expanded Il functions option is selected a faster scan rate is provided instructions are available for accessing an alternate I O system to be available in the future a dynamic user program memory checksum provides more data integrity by detecting certain types of errors not caught by memory parity checking and a way to detect if there are any overrides active in the system is provided SERIES SIX PLC I O DIAGNOSTICS FOR SERIES SIX PLUS PLCs All of the I O diagnostic features used with earlier models of Series Six PICs are valid for use with Series Six Plus PLCs The address recorded for parity errors includes a channel number for Expanded I O systems The channel number is stored in the Scratch Pad in location SP 10 If a parity error is detected while the Expanded I O mode is not selected or while channel 0 or 8 are being scanned the value in SP 10 will be set to 80H Hexadecimal Transmitter Diagnostic Feature Data received at the CPU from each I O Transmitter is placed in the input status table for input bits 11017 through 11024 for channel 0 Al1017 through A11024 for channel 8 and IX 1017 through IX 1024 for channels 1 7 and 9 The data in this status byte is bits 1 3 c
14. CRT terminals other computers and other ASCII BASIC Modules The ASCII BASIC Module can also be used as a stand alone microcomputer with GE BASIC developed programs entered edited and run independent of the CPU The ASCII BASIC module is available in two versions Catalog Number IC600BF944 which provides I2K bytes of user memory and Catalog Number IC600BF949 which provides 28K bytes of user memory Each module requires a single I O slot and must be installed in a CPU rack or High Capacity I O rack For detailed information on the installation theory and use of the ASCII BASIC Module refer to the ASCII BASIC Module Manual GEK 25398 Axis Positioning Modules The Axis Positioning Modules APMs are intelligent programmable single axis positioning controllers that require only a single slot of a High Capacity I O rack or a CPU rack They provide a real time interface between a Series Six Plus PLC and a servo or stepper controlled axis and thereby fully integrate closed loop position or velocity control with overall machine control The APMs are programmed and monitored using the Workmaster computer Commands and return data are passed to and from an APM through 32 consecutive inputs and outputs The various parameters exchanged between an APM and CPU user logic include discrete commands set up commands move commands and special commands in the output group and in the input group discrete return data and return data The APM is availab
15. Do 1 0 enhanced and Status enhanced COMM REQUESTS SCREQ Same as Advanced DPREQ Enhanced MOVE CONVERT All Advanced Functions MATRIX LIST All Advanced Functions Miscellaneous 11 Advanced Functions EXPANDED II FUNCTIONS All Advanced and Expanded Functions plus Changes in system microcode which provides faster execution of ladder logic Dynamic user program memory checksum calculation Detection of active overrides in system Instructions added to allow accessing a future 1 0 system Support of 64K User Logic memory Auxiliary I 0 overrides introduction To The Series Six Plus PLC 1 11 GEK 966902 PROGRAMMABLE LOGIC CONTROLLER CONCEPTS When using a new product for the first time there are always new concepts and terms to become familiar with Although PLCs are easy to install program and apply there are some simple principles to follow The following paragraphs describe the components of a Programmable Logic Controller Function of the Central Processor Unit The Central Processor Unit CPU is basically a microprocessor containing the circuitry that performs logical decision making functions It reads in the status of the control system makes decisions based upon the logic that has been programmed and then provides decisions to the actuating portion of the control system The CPU also performs self checking of its internal operation to ensure reliable operation This is done by a circuit called t
16. can be represented by entering an 8 16384 can be represented by entering a 16 Default the number of registers indicated by the Scratch Pad The availability of register memory regulates the number of l O points on which Genius I O diagnostics will be performed For a register size of 1K diagnostics are performed up to the first 1024 inputs and 1024 outputs of the Main l O chain Maximum register sizes of 8K or 16K allow the CPU to perform diagnostics on the maximum 16K inputs and 16K outputs The inputs and outputs included are the Main I O chain Main status table I O channels 1 to 7 and the Auxiliary I O chain Auxiliary I O status table O channels 9 to F FAULT TABLE LENGTH The maximum size of the fault tabte which depends on the CPU size and on whether the Computer Mail Box has been enabled Maximum table sizes are listed below Default 8 REGISTER MAXIMUM TABLE LENGTH SIZE COMPUTER MAIL BOX ENABLED NO YES 1K 75 68 8K 406 399 16K 1225 1218 Each table entry is equal to IO registers BUS STATUS CONTROL BYTE LOCATION Some of the bits in the original l O status table can be used to enable and monitor some of the Genius I O functions This is the main l O point address where the diagnostics discrete status input table and control output table bytes are located Allowable entries are 0001 through 1017 Default 0993 Expanded CPU Operation 4 17 GEK 96602 COMPUTER MAIL BOX De
17. catalog numbers 2 16 description of 2 16 illustration of 2 20 location in rack 2 19 memory protection 2 19 precautions when handling 2 19 status indicators 2 18 Communicating to Genius I O system through the DPREQ function 4 44 Communications Control modules 2 22 description of 2 22 type 2 CCM2 2 22 type 2 CCM2 illustration of 2 24 type 3 CCM3 2 25 type 3 CCM3 CCM2 mode 2 25 type CCM3 RTU mode 2 25 lO CCM 2 26 VO Link Local 2 27 Communications networks 1 18 2 33 4 4 Compatibility guide Series Six Plus vs Series Six 1 22 Computer mail box 4 40 Configuration of expanded functions 4 12 Configuration of the Series Six Plus CPU 2 2 Configuration set up menu 4 13 D DIP switch settings for points 2 32 DO I O function addressing 16K I O points 4 26 DPREQ function communicating with Genius I O system 4 44 DPREQ register references 4 45 4 46 Datagram Communications Service 1 20 Definition of terms Discrete references internal 2 34 Dynamic user memory checksum 4 11 E Enabling of expanded functions 4 14 Expanded CPU operation 4 1 Expanded functions 1 10 4 1 Expanded functions menu 4 10 Expanded mode I O addressing 4 3 Expanded mode I O references 2 34 2 35 Expanded mode I O references table of 4 8 Expanded time reference 4 27 Extraction insertion tool 3 4 2 33 F Fault isolation and repair 5 3 Features of Series Six Plus 1 4 Figures list of xvi to xviii Floating p
18. detects that a command is waiting and opens executive window for communications The addressed device can then either read data from the mail box or place data for the CPU in the mail box The window that allows a Bus Controller to access the Computer Mail Box is generated automatically by the CPU at the end of each sweep if commanded to do so by enabling the Computer Mail Box option through the CPU Configuration Set Up menu NOTE The following description of the mechanism for operation of the Computer Mail Box is for use only with Genius I O Bus Controllers Operation of the Computer Mail Box The sequence outlined below describes the operation of the Computer Mail Box and the content of each of the 70 registers is Communications Window Opens The window to the referenced Bus Controller channel 0 to F address 1 to 1000 is opened at the end of each CPU sweep if 1 The Computer Mail Box has been enabled through the CPU Configuration Set Up Menu using Logicmaster 6 software in a Workmaster computer 2 If the content of the window address register in the CPU is in the range of 00001 to 16360 Register R Bus Controller Address The Computer Mail Box address of the Bus Controller to be communicated with is placed in the first of the group of 70 registers The actual address to be entered into this register is calculated by using the following formula Mail Box Window address Channel number 0 to F x 1024 I O addres
19. downstream points Off At least one of these conditions is not met Figure 2 24 I O RECEIVER USER ITEMS 2 44 Physical Equipment Configuration GEK 96602 The I O Receiver module receives signals through the parallel bus link modifies the signals to update the status of inputs and outputs then relays those signals to the next rack in a chain Racks can be connected when they are more than 50 feet 15 meters from a CPU by connecting an I O Receiver in the first rack of the distant grouping to an Transmitter through a 16 pair twisted cable on the parallel bus The length of this cable can not exceed 500 feet 150 meters This distant grouping of racks at the end of a parallel bus cable is referred to as a Local I O station Again up to 10 I O racks can be daisy chained in a Local I O station with no more than 50 feet 15 meters of cable separating the first and the last rack The maximum distance an I O Receiver can be located from the originating I O Control or Auxiliary I O Control module is 2000 cable feet 600 meters In a Remote I O station an I O Receiver is used when connecting racks on the daisy chain in the station if more than one I O rack is required in the station An Receiver is normally installed in the leftmost slot of an I O rack however it could be inserted into any I O slot in an I O rack if required An I O Receiver can be installed in any rack except the first I O rack in a Remote l O station this ra
20. for example programmers printers etc Preset A numerical value specified in a function which establishes a limit for a counter or timer A coil will energize when this value is reached Program A sequence of functions entered into a programmable logic controller to be executed by the processor for the purpose of controlling a machine or process Appendix A Glossary of Terms A 5 GEK 96682 Programmable Logic Controller or Programmable Controller A solid state industrial control device which receives inputs from user supplied control devices such as switches and sensors implements them in a precise pattern determined by ladder diagram based programs stored in the user memory and provides outputs for control of processes or user supplied devices such as relays and motor starters Programmer A device for entry examination and alteration of the PLC s memory including logic and storage areas PROM An acronym for Programmable Read Only Memory A retentive digital device programmed at the factory and not readily alterable by the user RAM An acronym for Random Access Memory solid state memory that allows individual bits to be stored and accessed This type of memory is volatile that is stored data is lost under no power conditions therefore a battery backup is required The Series Six Plus PLC uses a Lithium Manganese Dioxide battery or an optional external back up battery for this purpose RS 232C A standard spec
21. stores the checksum in the Scratch Pad It will then recalculate the checksum and when once again completed the resulting calculation is compared with the previously stored checksum If this calculated number disagrees with the number stored in the Scratch Pad the CPU will STOP if it is running and de energize Alarm 1 It will also set error flags in the Scratch Pad The checksum calculation continues while the CPU is in the STOP mode The calculation adds about 150 us to the CPU s executive routine The total time for the checksum calculation for the maximum 64K words of memory with a 150 ms sweep is 153 seconds Logicmaster 6 Display of Checksum Error The checksum is displayed on the Scratch Pad screen display if Logicmaster 6 is in the on line or monitor mode It is not displayed when Logicmaster 6 is in the off line mode If a checksum error is detected the message LOGIC MEMORY CHECKSUM ERROR is displayed below the CPU ERROR FLAGS line at the bottom of the Scratch Pad display Restarting a CPU Stopped by a Checksum Error The CPU also recalculates the checksum when the CPU is powered up or switched from STOP to RUN if the memory protect switch is set to the WRITE position If the key switch is set to the PROTECT position the checksum error fault indication will remain in the Scratch Pad and the CPU will not be able to be restarted unless either the keyswitch is switched to WRITE or the fault indication in Scratch Pad locations SP 07
22. which must be a valid I O address Three devices can be addressed discrete I O blocks analog I O blocks and the Bus Controller Register R 4 Mailbox Address for Data The fifth register indicates where the received data from the Genius I O system should be stored in the CPU for read operations operations 2 4 and 7 in register R 1 Consecutive registers beginning with the specified register will be used until all received data is stored For write operations operation 3 this register indicates where the data to be sent to the Genius I O system from the CPU is to be stored Each device requires a different number of registers to store the configuration data in a 16 bit format 8 circuit discrete I O block uses 6 CPU registers a 16 circuit discrete I O block uses 10 CPU registers an analog I O block uses 42 registers and the Bus Controller uses 18 registers Register R 5 Data Buffer Length The sixth register specifies the length of the number of bytes to be read or written to by the Bus Controller in a Read Device or Write Device command Data Registers The remaining registers in the group of 70 registers in the Computer Mail Box may contain the data to be read from or written to the specified Bus Controller and are moved in one command Command Verification The Bus Controller then verifies the command block for valid command syntax and the absence of a command of that type already in execution If a syntax error d
23. 0 W x 13 25 H x 9 3 D inches standard 19 Rack 483 x 337 x 236 millimeters Panel Mount Brackets on sides 16 0 W x 13 25 H x 9 3 D inches Panel Mount Brackets on Top 13 25 W x 16 15 H x 9 3 D inches and Bottom Side by Side Mount 337 x 410 x 236 millimeters Typical Battery Life Loaded 1 about 1 year Battery Shelf life No Load 1 8 to 10 years Typical Scan Rate Relay Functions 8 mSec of user memory Maximum Number Normal Mode 2K Inputs of 1 0 Points 2K Outputs Expanded Mode 16K Inputs 16K Outputs Depending Upon Temperature 2 Mode selected by enabling desired Workmaster computer using Logicmaster 6 software to 60 32 to 140 F at outside of rack 20 to 70 4 to 158 F 5 to 95 95 to 260 V ac mode on the CPU Configuration Version 3 01 or greater Set Up Menu on a 1 6 Introduction To The Series Six Plus PLC GEK 96682 GENIUS I O SYSTEM In addition to the standard rack based I O modules the Series Six Plus PLC fully supports the Genius I O system This revolutionary I O system is a major improvement over existing I O systems It can be mixed with the rack based I O or can comprise the total system The Genius I O is available in units called blocks and includes both discrete and analog blocks Genius I O blocks are connected to the Series Six Plus CPU through a Bus Controller by a single twisted pair communications link The total number of Bus C
24. 01017 Redundant Processor Prevents CPU from being a master Unit CPU or switches to backup unit 01022 Redundant Processor Transfers 00001 to 01016 from Unit master to backup CPU 01023 Redundant Processor Transfers R254 from backup to Unit master CPU 01024 Redundant Processor Transfers registers with range Unit specified by R255 START and R256 END from master to backup CPU 10993 1000 Advanced I O Receiver Default status byte AI1001 AI1008 Interrupt Input Status byte A00993 01000 Advanced I O Receiver Default control byte SUMMARY OF REQUIRED REGISTER REFERENCES There are also special register references which must be reserved for several of the optional modules used with a Series Six Plus PLC These register references have special significance for the listed modules and care must be taken when programming so that registers references are not overlapped duplicated or otherwise misused the following table the use of parentheses with a reference is an indication that the register reference be changed Care must also be exercised when referencing Expanded 1 points both real and internal since expanded 1 0 is mapped into registers as described the previous pages R240 R244 R247 R248 R249 R253 R254 R255 R256 R256 R384 R512 R640 R768 R896 R1024 R1280 R1408 R1536 R1664 R1792 R1920 R2048 R400 R485 R509 2259 5259 7009 7759 759 20
25. 10 000 feet 3 Kilometers from a CPU a CPU station or a Local I O station when using a two twisted pair serial cable In addition a Remote I O system can be transmitted over voice grade telephone lines through RS 232 or RS 422 compatible modems to a location a great distance from the originating I O station System Connections A Remote I O system consists of a Remote I O Driver a two twisted pair serial cable or modems and a Remote I O Receiver The Remote I O Driver is installed an I O slot a CPU a CPU station or a Local I O station The Remote I O Driver is then connected by cable or a modem link to a Remote I O Receiver in the first slot of the first I O rack in a Remote I O station If the Remote I O Driver and Remote I O Receiver are to communicate over a modem link the Remote Receiver module must be installed in a High Capacity I O rack and the Remote Driver must be in either a High Capacity I O rack or a CPU I O slot since a 12 V dc source must be available to conform to RS 232 specifications Figure 2 28 illustrates the two methods of system configuration described above b41g6fi 10 000 FEET END JI R z R 0 RR INE an ee MAX 10 000 FEET When connecting to a Remote l O station through modems RS 232 interface the Remote I O Driver and Remote I O Receiver must be installed in High Capacity I O racks Figure 2 28 TYPICAL REMOTE I O SYSTEM CONNECTION
26. 42063 CPU VO 1 ROCEsson LOGIC BTORAGE INPUTS PROGRAMMER MEMORY MEMORY Al a FIELD OUTPUT L E DEVICES E E EL POWER POWER i i SUPPLY SUPPLY L Figure 1 1 PROGRAMMABLE LOGIC CONTROLLER BLOCK DIAGRAM 1 2 Introduction To The Series Six Plus PLC GEK 96602 ADVANTAGES OF PROGRAMMABLE LOGIC CONTROLLERS Programmable Logic Controllers offer many advantages over other control devices such as electrical timers and counters relays and drum type mechanical controllers Some of the many advantages to be considered when planning a system include Improved reliability you do not need to be concerned with frequent breakdown of electro mechanical devices Less space required since a proliferation of relays electrical timers etc are not needed Easier to maintain Built in diagnostics and reliable solid state devices equate to few breakdowns When failures do occur they are quickly detected and repaired In fact the revolutionary Genius I O system with its enhanced diagnostics when used in the I O structure reduces failure detection and repair time to an absolute minimum Easily reprogrammed if control requirements change Flexibility one device is able to perform many functions SERIES SIX PLUS PROGRAMMABLE LOGIC CONTROLLER The Series Six Plus PLC is an extension of the Series Six family of Programmable Logic Controllers previously available models 60 600 and 6000 The Series Six Plus PLC is a
27. 96004 UNS IN AAA THESE SLOTS IA 10 XMT CHO VO TRANSMITTER CH1 VO A Figure 3 24 EXAMPLE 2 CORRECT CONFIGURATION YBQOOA U O TRANSMITTER CH2 Installation Instructions 3 37 GEK 96602 a42210 EXPANDED CHO SERIES SIX PLUS CPU EXPANDED CH1 CHU CH1 THESE RACKS WOULD NEVER SEE CH1 DATA Figure 3 25 EXAMPLE 3 INCORRECT CONFIGURATION 3 38 Installation Instructions GEK 96602 a4221 1 EXPANDED MODE CH1 SERIES SIX PLUS CPU vO IN THESE RACKS RECEIVE DATA FROM ALL ENABLED CHANNELS OUTPUTS APPEAR CHO ERRATIC INPUTS APPEAR IN ALL VO CHANNELS EACH CHANNEL MUST HAVE ITS OWN TRANSMITTER CH1 Figure 3 26 EXAMPLE 4 INCORRECT CONFIGURATION Installation Instructions 3 39 96602 System Design Considerations When programming expanded I O use regular I O references for the primary I O Do not use a channel 0 reference in the program This actually maps into the auxiliary table and should be avoided Channel 8 maps into user registers starting at 1025 This will never be solved to real I O but could be used as internal points The WINDOW command allows you to specify a channel number from 0 The communications window that is opened as a result of executing this command is directed to only one of the Expanded I O channels on one
28. Alarm relay outputs are rated at 115 V ac or 28 V dc 1 amp resistive load Alarm 1 is switched by hard failures the CPU status is set to STOP The RUN and ENABLE lights go off Alarm 2 is switched by a soft failure error indications are recorded in memory the CPU does not go to STOP Alarm conditions are listed in the table shown below Refer to steps 1 through 12 for troubleshooting of alarm conditions Table 5 2 CONDITIONS CAUSING ALARM RELAYS TO SWITCH ALARM 1 ALARM 2 Voltage of memory battery drops too low CPU or 1 0 parity error CPU self test failure CPU or 1 0 power supply is turned off Communications Control or Data Processor error fault jumpers in or out of circuit CPU watchdog timer timed out Memory backup battery dead when power turned on Any CPU or 1 0 power supply voltage out of tolerance CPU or 1 0 power supply turned off Communications Control or Data Processor error fault jumpers in circuit CAUTION User devices connected to each set of alarm terminals should present a resistive load drawing no more than 1 amp of current at 115 V ac or 28 V dc Failure to observe this caution may result in damage to the CPAX circuit board in the power supply 5 20 Troubleshooting and Repair GEK 96602 SECTION 2 1 0 SYSTEM TROUBLESHOOTING TROUBLESHOOTING THE 1 0 RACK POWER SUPPLY Two versions of the I O power supply are available for use the I O
29. DIP switch setting on the backplane a command number and associated operands for the command Typical DPREQ Operation The sequence below describes the operation of a typical DPREQ instruction 1 The window to the addressed Bus Controller is opened at the beginning of the DPREQ instruction 2 pending data transfers from the Genius I O serial bus are copied to or from the CPU registers by the Bus Controller Examples of these transfers are actions such as the Hand Held Monitor reading a CPU register or the Bus Controller completing a previously issued command Any communications or other error resulting from the previous command will be flagged to the user in the status register 3 Bus Controller will then read the CPU Scratch Pad memory address 35 and 36 If bit 7 in location 35 is set to a 1 then the window is interpreted as an executive or Window instruction type The Bus Controller then uses the lower 14 bits of the two Scratch Pad addresses as a pointer to the command block in the registers If bit 7 of location 35 is reset the Bus Controller will use the two bytes as a pointer to the DPREQ instruction located in user memory that contains the 16 bit pointer to the command block in register memory 4 The Bus Controller will then read the registers as described below Expanded CPU Operation 4 45 GEK 96682 In the Series Six Plus ladder logic the DPREQ function references six consecutive registers Data to
30. E CPU OR ADVANCED 1 0 RECEIVER P S 16 PARALLEL CABLE i 1 0 RACK I6 PAIR TO LOCAL 1 0 STATION i 1 0 MODULES E ERN MAXIMUM FROM CPU 0 Wd i DAISY CHAIN alo 7 1 0 RACK 500 MAXIMUM FROM 10 IOT MODULE 1 0 MODULES 1 2 PAIR SERIAL CABLE TO 1 0 STATION ERES ee Scat oe TOTAL OF 0 I6 PAIR 10 000 3KM 1 0 RACKS MAXIMUM CABLE OR IN CPU STATION TO LOCAL RS 232 MODEM LINK 1 0 STATION TO REMOTE 1 0 STATION Figure 2 21 CPU I O STATION 1 19 racks are shown 13 racks can contain a maximum of 8 modules Physical Equipment Configuration 2 39 GEK 96602 Local 1 O Station A Local I O station can have up to 10 I O racks daisy chained on the parallel bus channel No more than 50 feet of cable can separate the first and last rack in a Local 1 0 station A Local I O station is linked to a CPU a CPU I O station or another Local I O station The interface is from an 1 0 Transmitter module to an I O Receiver or Advanced 1 0 Receiver module The I O Receiver module may be located a maximum of 500 feet from the I O Transmitter module The last Local I O station in a chain be a maximum of 2000 feet four I O Transmitter links from the originating VO Control or Auxiliary 1 module in the CPU station A Workmaster or Cimstar I computer or PDT PDT Norm
31. F Byte Address The byte address of the error Range 0 to 125 POINT POINT ADDRESS Not displayed if the error is a Bus ADDR Controller or Serial Bus fault This entry has two fields Input Output The first two characters indicate an input 1 or output 0 Both may appear at the same time Address The address of the error Range 1 to 1000 CIRCUIT NUMBER Displayed only for a circuit fault Range 1 to 16 The number displayed corresponds to a circuit number within a block FAULT CATEGORY This entry shows the category of error that has occurred FAULT BUS ERROR CIRCUIT LOSS OF BLOCK BLOCK ADDITION ADDRESS CONFLICT EEPROM FAILURE 773171227277771 displayed for multiple errors Expanded CPU Operation GEK 96602 FAULT TYPE The error type BLOCK DISCRETE or ANALOG FAULT DESCRIPTION Displayed only if the Fault Category is CIRCUIT FAULT Multiple lines may be displayed Possible descriptions are BLOCK SWITCH FAILED DISCRETE SWITCH FAILED OVER TEMP NO LOAD OPEN WIRE OVERLOAD SHORT CIRCUIT LOSS OF POWER ANALOG INPUT HIGH ALARM INPUT LOW ALARM OUTPUT UNDERRANGE OUTPUT OVERRANGE NPUT OPEN WIRE INPUT UNDE RRANGE INPUT OVER RANGE CHANNEL NUMBER FAULT TIME The day hour minute second and tenth of a second when the error occurred derived from the CPU s real time clock Viewing Additional Fault Listings In order to display or print additional faults in the table foll
32. I O Receiver or Advanced 1 0 Receiver If there is an Transmitter replace it Replace the 1 0 Receiver or Advanced I O Receiver in the next I O rack downstream in the 1 chain 5 32 Troubleshooting and Repair GEK 96602 3 Observe the CHAIN PARITY light on the 1 Receiver or Advanced 1 0 receiver and i O Transmitter modules Definition Status Output parity is good in this rack and all links connected to this rack OFF Indicates that an output parity problem has been identified by an I O Receiver or Advanced I O Receiver module The CHAIN OK light on the CPU I O Control module is off RUN and ENABLE lights at the CPU will also be off and Alarm Relay switches Corrective Action Isolate the problem by following the CHAIN PARITY status indicators until a link is found where CHAIN PARITY is off on an I O Transmitter module but is on in the I O racks in the Local station it is driving Locate the first I O rack in that chain with the LOCAL PARITY light off Ensure that there is good grounding between racks in that station no more than 7V between racks Ensure that the low level I O cable has not been placed close to any high level power cables power supplies or switching devices Replace the I O Receiver or Advanced 1 0 Receiver in that rack e Replace the 1 0 chain interconnecting cable e Replace the I O Transmitter driving the 1 0 station A link is made up of a
33. I O Reference 14 EEPROM Failure 15 Not Used Set to 0 Bit Pattern Low Byte 3 0 0001 Discrete I O Block of Fault 0010 Analog I O Block Register 6 All other patterns Future Use 7 4 Unused Set to 0 If Discrete I O Circuit Fault 8 Loss of Power 9 Short Circuit Upper Byte 10 Overload of Fault 11 No Load Output Open Line Input Register 6 12 Overtemperature 13 Switch Failed 14 Undef i ned 15 Undef i ned NOTE Only one bit from bit numbers 8 15 register 5 will be on and possibly one will be on from bit numbers 0 7 register 6 depending upon fault type Register 7 Only bits 0 and 1 are used in register 7 Bit is on if the fault is with a discrete 1 0 circuit and bit 1 is if the fault is with an analog circuit If register 7 contains a zero the fault is with non circuit hardware Bus Controller or Genius communications The upper byte of register 7 is always set to O 4 36 Expanded CPU Operation GEK 96602 Registers 8 9 10 The final three registers contain the time to the nearest 100 ms at which the fault was received from the Bus Controller When a fault occurs the fault is time stamped or recorded in these three registers The CPU keeps a master clock stored in its registers to record this time In case of power failure the clock stops and retains its previous value Upon restoration of operation it starts from where it left off The user s program is responsible for restoring the cloc
34. I O channels 0 and 8 are to be used In this case an I O Transmitter is not required If more than two channels of Expanded I O are to be used an I O Transmitter module must be used for each channel Any I O Transmitters downstream from the originating one must be configured for the Normal mode The first 3 positions 1 2 3 of the DIP switch on the backplane adjacent to each I O Transmitter must be configured to select the Expanded I O channel that it is driving The switch settings are shown below in table 3 3 Instat lation Instntctions 3 23 GEK 96602 Table 3 3 EXPANDED I O CHANNEL SELECTION CHAN NEL NUMBER DIP SWITCH MAIN AUXILIARY POSITION CHAIN CHAIN 3 2 1 0 8 9 2 A 3 B e 4 C 5 e 6 e 1 F e e Remote I O Driver A Remote I O Driver can be installed in any I O slot except the left slot an I O rack located in a CPU I O station a Local I O station a Series Six Plus CPU I O slot or a model 60 CPU I O slot Before installing this module the seven segment DIP switch on the backplane adjacent to the selected I O slot for the module must be configured to select the group of I O references for the Remote I O station NOTE Both the Remote I O Driver and the Remote I O Receiver must be placed in high capacity I O racks to operate with RS 232 devices Either a standard or high capacity I O rack can be used when the link connections are with twisted pair cable S
35. I O rack as shown in figure 3 16 NOTE CAE CPU OR POWER SUPPLY IS A VERSION THE OUTLET REQUIRES A SEPARATE AC POWER SOURCE GROUNDED PANEL OR CABINET 41053 GROUND CONNECTIONS AT EACH RACK w Figure 3 16 PROGRAMMING DEVtCE GROUND CONNECTION Installation Instructions 3 19 GEK 96602 SYSTEM CONFIGURATION rack s should be rack panel or wall mounted in the same manner as the CPU rack When mounting multiple racks at the same location enough space should be allowed between racks both horizontally and vertically to allow sufficient air flow between racks minimum of 6 inches vertically with the exception that the 13 rack can be mounted side by side Interface modules should be available for installation in racks The types of I O interface modules are determined by the number of I O points required and the location of the racks in a system Refer to Chapter 2 for a discussion of the 3 types of stations in an I O system CPU Local and Remote The type of I O station will determine whether your I O racks will contain I O Receivers Advanced I O Receivers I O Transmitters Remote I O Drivers Remote I O Receivers or combinations of these modules Figure 3 17 is an example of a typical I O rack To prevent accidental mating of an I O module with a faceplate not compatible with that module all of the I O printed circuit boards are keyed to match the corres
36. O Cable for RS 232 Modems Dip Switch Settings for I O Point Selection for 8 Circuit Modules Example 1 Correct Configuration Example 2 Correct Configuration Example 3 Incorrect Configuration Example 4 Incorrect Configuration Transmitter Dip Switch Settings for Expanded I O Channel Selection Expanded I O Reference Format Memory Map for 8K and 16K Registers Memory Map for 1K Registers Floating Point Arithmetic Display Format Bus Controller Input Status Reference Definition Fault Table Registers Bus Controller Output Status Reference Definition Register Format for Computer Mail Box Series Six Plus CPU Indicators and Switches Power Supply Output Voltage Terminals TB1 CPU Power Supply Block Diagram xvii GEK 96602 ONO O1 BO LI L LI 1 LI LI 1 LI 1 YNNN d i ta ONDAN WWWWH 0002 0002 1 FONON xviii Contents EO II REEL I CM CC IM cM EV CC C EL CE I IU RUM M MEE LIE UU C GEK 96602 FIGURES PAGE Figure 5 4 Battery Mounting Clips and Connectors 5 17 5 5 CPU Power Supply Terminal Board 5 18 5 6 Input Voltage Terminal Board 5 21 5 7 Output Voltage Terminal Board for Standard Power Supply 5 21 5 8 Output Voltage Terminal Board for High Capacity Power Supply
37. O Driver Remote system operating normally Fault in Remote I O system Illegal address block loose connection power supply failure etc No parity errors have been detected in this Remote I O system Parity error or errors detected in this Remote I O system Troubleshooting and Repair 5 25 GEK 96602 Table 5 4 1 0 MODULE STATUS INDICATOR DEFINITIONS Continued MODULE INDICATOR STATUS DEFINITION ON Power and cable continuity good to all downstream racks OFF One of the above conditions not met ON Output parity good on rack backplane CHNPAR OFF Output parity error detected from I O Transmitter or Remote I O Driver in rack ON Output parity good in this rack LOCPAR OFF Output parity error detected from an upstream rack ON 1 0 address from CPU is valid ADDPAR OFF Parity error detected in I O address received from CPU Advanced ON I O parity from CPU is valid 1 0 DATPAR OFF Parity error detected in I O data Receiver from CPU ON Power and cable continuity good to all XMITOK downstream racks connected to an I O Transmitter or Remote I O Driver located in this rack OFF Latched off if above conditions not met in one or more connected racks ON Power and cable continuity good to down stream racks connected to this module OFF Latched off if above conditions not met in one or more connected racks Power supply in this rack in tolerance OFF Power supply in this rack is out of tolerance Will be latched of
38. O Transmitter Module Connecting Cable Connections Using the Serial Version of Logicmaster 6 Using the Cimstar Computer With a Series Six Plus PLC Parallel Version of Logicmaster 6 Software Serial Version of Logicmaster 6 Software Programming a Series Six Plus PLC With an IBM PC INSTALLATION INSTRUCTIONS FOR THE SERIES SIX PLUS PROGRAMMABLE LOGIC CONTROLLER Introduction Quality Control Packaging Visual Inspection Preinstallation Check Rack Installation Extraction Insertion Tool Inserting a Printed Circuit Board Removing a Printed Circuit Board Module Installation Combined Memory Module Battery Installation External Auxiliary Battery Select ion Arithmetic Control Module Logic Control Module Advanced Expanded or Expanded Il Control Module Auxiliary Module Communication Control Modules CPU Power Supply Contents GEK 96682 PAGE 2 60 2 62 2 62 2 62 2 62 2 63 2 64 2 64 2 64 2 65 2 65 2 0G 1 1 ODDDOUOFPNNN A aa WWWWWWWWWWWWW L Contents G EK 96602 CHAPTER 3 CHAPTER 4 CONTENTS TITLE INSTALLATION INSTRUCTIONS FOR THE SERIES SIX PLUS PROGRAMMABLE LOGIC CONTROLLER Continued System Grounding Procedures Recommended Grounding Practices Ground Conductors Series Six Plus PLC Equipment Ground ing System Configuration Power Supply AC Power Source Connections DC Power Source Connections lO System Interface Modules Receiver or Advanced I O Receiver
39. O rack or to an I O Transmitter in a CPU Local or Remote I O station The bottom connector connects to the next rack downstream if additional racks in the system I O Receiver and Advanced I O Receiver modules have 2 DIP shunts and a jumper pack that must be configured to specify whether the module is to pass the I O chain signals through to the next rack or if it is the last rack in the chain A 16 pair parallel chain cable of the required length see table 3 4 connects the I O Receiver or Advanced I O Receiver to other modules on the chain Transmitter An I O Transmitter module can be installed in any slot in an I O rack or in an I O slot in a Series Six Plus CPU rack or in a Series Six model 60 CPU rack Connect a parallel I O chain cable from the connector on an I O Transmitter to the first Receiver or Advanced I O Receiver in the next downstream I O station Jumper JP1 must be configured to stop or not stop the system on a system fault Enable system stop for a local fault Jumper over pins 2 3 System does not stop for a local fault Jumper over pins 1 2 A jumper JP2 must be configured to select the I O mode of operation either NORMAL or EXPANDED as shown below NORMAL I O Mode Place jumper over pins 1 2 EXPANDED I O Mode Place jumper over pins 2 3 When in the EXPANDED I O mode one I O Transmitter is required to originate each channel of Expanded I O The exception to this is if only Expanded
40. OK at all downstream stations ISOLATED ON when the output voltage of the 5V dc POWER isolated power supply is within tolerance FAULT ON when the module has been configured to stop ENABLE the system for a local fault condition CHAIN This LED is not visible through the faceplate ACTIVE Used for set up only When ON indicates that the EXPANDED I 0 chain is active Configuration Jumpers Two items are configurable by placing a jumper plug over the desired set of pins By configuring JP1 the user can select to enable the system stop for a local fault or not to stop the system on a local fault The second jumper plug JP2 is used to select the I O mode of operation for this module either NORMAL I O one non selectable I O chain or EXPANDED I O 1 to 8 selectable I O channels Connector One 37 pin D type connector is mounted on the bottom front edge of the circuit board A 16 pair parallel cable plugged into this connector in a Series Six Plus CPU a CPU station or a Local I O station connects to the first Receiver or Advanced I O Receiver in local I O station at a distance not to exceed 500 feet 150 meters 2 52 Physical Equipment Configuration GEK 96682 REMOTE I O SYSTEM A Remote I O system allows a Series Six Plus system to have an I O capability that extends beyond the limit of the 2000 feet 600 meters maximum distance allowed with the parallel I O bus A Remote I O system be located a maximum of
41. ON or OFF that provides information to the plc output A signal typically ON or OFF originating from the PLC with user supplied power to control external devices based upon commands from the CPU field Devices User supplied devices typically providing information to the PLC Inputs pushbutton limit switches relay contacts etc or performing PLC tasks Outputs motor starters solenoids indicator lights etc PLC COMPATIBILITY GUIDE Most of the hardware and software items can be used by both the Series Six Plus and the earlier models of the Series Six CPU s As an aid to the compatibility of these items a basic compatibility guide is provided in table 1 9 For comprehensive information on compatibility of equipment contact your GE Fanuc sales office or PLC Distributor Tablel 9 COMPATIBILITY GUIDE SERIESSIX PLUS PLC VS SERIES SIX PLCs Catalog Number Description Model of PLC 60 600 6000 6 Power Supplies TC600PM500 115 230 V ac Power Supply 600 541 24 V dc Power Supply e IC600PM546 125 V dc power Supply CPU Racks 8 Slot IC600CP619 e 1 CPU Racks 11 Slot 1 600 201 IC600CR301 1 600 401 1 6600 600 Memory IC600CM552 2K Logic 256 Registers 2 2 600 554 4K Logic 1K Registers 2 2 600 544 AK Logic e IC600CM548 8K Logic 1 Required for Expanded II functions 2 Parity checking is not available wit
42. Operator Interface Unit 1 15 Operator Interface Terminal 1 15 Optional devices 1 14 Operator Interface Unit 1 15 Operator Interface Terminal 1 15 ProLoop Process Controllers 1 16 Redundant Processor Unit 1 14 Override Detect ion Active 2 17 P PC compatibility guide 1 22 PC terminology 1 21 Parallel bus cables 2 64 3 24 Physical equipment configuration 2 1 Index GEK 96602 INDEX Planning system 1 20 Power supply 2 4 auxiliary circuit board 2 8 block diagram 2 8 dc voltage outputs 2 8 specifications 2 7 terminal block connections 2 6 user items 2 5 Product structure 2 1 Preface iii ProLoop Process Controllers 1 16 Programmable Controllers Series Six Plus 1 2 advantages of 1 2 block diagram 1 1 concepts 1 11 definition of 1 1 terminology 1 21 Programming functional groups 1 9 1 10 Programming language 1 9 Programming requirements 1 7 Programming the Series Six Plus general information 1 7 with a Cimstar computer 2 64 with an IBM PC 2 65 with a Workmaster computer 2 62 R RPU addressing 2 65 RS 232 to RS 422 Adaptor 1 21 Rack configuration 2 2 Rack mounting brackets 2 3 Real I O mapping 4 5 Real memory allocation 2 34 Real time clock 4 27 Redundant Processor Unit 1 14 Register memory size 4 5 Related publications iv Remote I O Driver 2 55 addressing 2 56 illustration of 2 55 opt ion jumpers 2 57 status byte 2 56 Remote l O Receiver 2 58 illustration of 258 option jumpers 2 60 Remote l O
43. Receiver connected to a Remote Driver through a two twisted pair cable can be installed any I O rack If connection to the Remote I O station is to be through a communications link using RS 232 compatible modems then the Remote I O Receiver must be installed in a high capacity I O rack 41067 0 DRIVER OR RS 232C MODEM TO CIOWNSTREAM lO RECEIVER OR REMOTE 0 RECEIVER Figure 2 30 REMOTE I O RECEIVER MODULE Circuitry on this module converts output data from serial to parallel and converts input data from a parallel to a serial format The Remote I O Receiver also isolates the serial data cable from the backplane bus and provides error checking circuitry If more than one I O rack is required in a Remote I O station the additional racks daisy chained to the Remote I O Receiver through I O Receivers or Advanced I O Receivers Physical Equipment Configuration 2 59 GEK 96602 Connectors A Remote I O Receiver has two edge mounted D type connectors The top connector 25 pin connects to a Remote I O Driver at the opposite end of the serial communications link using a two twisted pair cable or to a modem located no more than 50 feet 15 meters from the Remote I O Receiver The lower connector 37 pin provides a connection through a 16 pair parallel bus cable to an I O Receiver or Advanced I O Receiver module located in the next downstream rack in a Remote l O station If no connection is to be made to
44. Series Six Plus programmable logic controller s CPU Check Position of Key Switches Be sure to note the positions of the key switches on the CPU Workmaster computer or CIMSTAR industrial computer and any pertinent switches on other programming devices which can be the IBM PC PC XT PC AT Personal Computers or the Program Development Terminal Refer to Figure 5 1 which is an illustration of a Series Six Plus programmable logic controllers CPU showing the location of the status indicator lights and the key switches The numbers that point to indicators and switches on the illustration are for reference purposes and refer to the same number in the troubleshooting sequences on the following pages 5 4 Troubleshooting and Repair GEK 96602 Table 5 1 CPU INDICATOR CHART NORMAL MODULE NDI CATOR CONDI TI ON DEFINITI ON POWER POWER ON Power is applied all dc voltages SUPPLY are within tolerance CHAIN OK All 1 0 stations in primary chain have continuity good output parity and power supply is good PARITY Input data parity is good 110 CONTROL ENABLED CPU is in the normal Run Enabled mode outputs enabled DPU DPU connected and operating normally If no DPU in system and DPU present jumper is configured light will be on User program is running with a sweep ti me of less than 300 ms 250 ms ARI THMETI C CONTROL CPU passed self test routine which is executed once per sweep and user program executes in l
45. TYPE TOTAL REGISTER MEMORY IC6001X605 IC600LX612 6001 616 6001 624 IC600LX648 6001 680 Battery Installation Before installing a memory module in a CPU rack the Lithium Manganese Dioxide battery must be connected unless an external auxiliary back up battery is to be used These modules are shipped from the factory with the battery connector disconnected from the battery When connecting a battery the following procedure is recommended Refer to figure 3 7 which shows a mounted connected battery The battery mounting location is located at the bottom front of the memory module on the component side of the module If the battery is not mounted firmly place it in its mounting clip with the cable end facing toward the battery connectors Connect the battery cable to one of the battery connectors The memory module is now ready for installation into the CPU rack Installation Instructions 3 9 GEK 96602 External Auxiliary Battery Selection If an auxiliary back up battery is to be used with your system a jumper on the board must be properly configured This jumper is JP6 and is located next to the Lithium battery Factory default is no auxiliary battery present JP6 over pins 1 and 2 To change the selection to auxiliary battery present place JP6 over pins 2 and 3 order to use this feature the user must supply a battery with the proper voltage 6 to 28 V dc connected to the auxi
46. Underrange Input 4 Open Wire 7 Input 2High Alarm Input 3 Overrange Not Used Expanded CPU Operation 4 39 GEK 96602 BUS STATUS CONTROL BYTE LOCATION Some of the bits the main I O status table can be used to enable and monitor some of the Genius I O functions This is the main I O point address where the diagnostics discrete status input table and control output table bytes are located The range of allowable entries is 0001 through 1017 The user can select an 1 reference that establishes eight input references and eight output references on an even byte boundary The even byte boundary is required so that when divided by eight the remainder is exactly one The one input and one output byte reference provides data relative to the entire CPU system and its operation with Genius I O functions Table 4 9 lists the status information in these references Reference 0521 is used as an example for the start location Table 4 9 BUS CONTROLLER STATUS CONTROL BYTE DEFINITION OUTPUT ON IF REF SIGNIFICANCE INPUT ON IF SIGNIFICANCE RELATIVE REFERENCE NUMBER REF 00521 Master reset 10521 Diagnostics enabled 10522 Fault detected this scan 00522 Conduct pulse Test 00523 Future I0523 Expanded I O enabled I0524 Fault table overflowed 00524 Future I0525 Future 00525 Future 00526 Future I0526 Future 00527 Future I0527 Future
47. VO Transmitter Remote I O Driver Remote I O Receiver Parallel Chain Cables Parallel Cable Configuration Serial Link Cable to Remote I O System Point Selection Power Supply Load Capacity Load Capacity for a Series Six Plus CPU Rack Load Capacity for an I O Rack Initial Start up Instructions for a New Series Six CPU Running Expanded l O on the Series Six Plus PLC As Internal Coils Only To Be Solved to Real World I O Points How It Works System Design Considerations EXPANDED CPU OPERATION Introduction Normal Mode of Operation Expanded Functions Series Six PLC I O Diagnostics for Series Six Plus PLCs Transmitter Diagnostic Feature Interrupt Module Location Normal Mode I O Addressing xi PAGE 3 15 3 15 3 16 3 16 3 19 3 20 3 20 3 21 3 21 3 22 3 22 3 23 3 24 3 24 3 25 3 26 3 27 3 28 3 31 3 39 xii Contents GEK 96602 CHAPTER 4 CONTENTS TITLE EXPANDED CPU OPERATION Continued Expanded Mode I O Addressing lO Channels Channel Reference Numbering Real I O Mapping Internal Mapping of Discrete References Register Memory Size Expanded Mode I O References Summary of Required I O References Summary of Required Register References Dynamic User Memory Checksum Memory Checksum Calculation Logicmaster 6 Display of Checksum Error Restarting a CPU Stopped by a Checksum Error Configuration of Expanded Functions Through Logicmaster 6 Software Expanded Functions Menu CPU Configura
48. any reference A to be compared to any reference B The previous form of this instruction only allowed registers to be compared EXPANDED FUNCTIONS MENU In order to access the configuration menu the Expanded Functions screen must first be selected from the Supervisor menu When the Expanded Functions F7 key is pressed from the Supervisor menu the Expanded Functions screen appears as shown below LOGICMASTER TM 6 EXPANDED FUNCTIONS KEY FUNCTION FI CPU CONFIG Display Modify CPU Configuration F2 1 0 Faults Display Clear Genius 1 0 Faults F3 COMM SET UP Display Modify Communications Setup serial ver MSD FUNC Display Modify Machine Setup Data F8 SUPERV MENU s s s return to Supervisor Menu CPU MSD SUPERV 1CONFIG 2FAULTS 35 UP 4FUNC 5 6 7 8 MENU The applicable function key is then pressed to select the desired Expanded functions CPU CONFIGURATON Select DSPLAY MODIFY CPU CONFIGURATION to display the CPU Configuration menu FAULTS Select DISPLAY CLEAR Genius FAULTS to display the Genius I O Faults screen COMMUNICATIONS SET UP This function key is displayed only for the Serial versions Select COMM SET UP to set up the system parameters for communicating with the CCM card Expanded CPU Operation 4 13 GEK 96602 CPU CONFIGURATION SET UP MENU The CPU Configuration Set Up Menu is used to select Genius 1 0 Bus Controller locations in the Expa
49. be communicated to the Genius I O system must be placed in these registers before the DPREQ function is executed This data in the form of numerical values provide control information which includes Which Bus Controller is to be communicated with What function is performed Which specific I O block if any is involved How much data is to be communicated Where the data is to be sent in the Genius I O system or where data from the Genius I O system is to be stored in the CPU Contents of First Register When programming a DPREQ function the first register referenced indicates which Bus Controller is to be accessed or through which the intended function is to occur The contents of this register must be equal to the Bus Controller s first status reference plus 1000 For example if the first status reference is 425 and the Bus Controller is in the Main I O chain enter the value 1425 Contents of Second Register The second register must contain an operation command number which indicates which of the following operations is to be performed when the DPREQ receives power flow 1 Idle no operation performed 2 Read the configuration of the block or Bus Controller into CPU registers specified in the fourth register 3 Write the configuration of the I O block specified in the fourth register from CPU registers 4 Read diagnostic data of the I O block or Bus Controller into CPU registers bz
50. change this entry to Y If set to Y the CPU will open a communications window to any valid address located in the first of 70 consecutive registers for the Computer Mail Box The window is opened once per sweep when the CPU is in the RUN mode Using the Computer Mail Box to Communicate with Genius I O Bus Controllers The CPU interprets data in the first of 70 consecutive registers as an address to open communications with a Genius Bus Controller The registers in the CPU that are allocated for the Computer Mail Box are used for transfer of data between Genius I O Bus Controllers and a Series Six Plus CPU in the Expanded mode window address of the Bus Controller is placed in the first register and command data is placed in the next five registers The remaining 64 registers provide a buffer area for data to be communicated An illustration of the registers and their content is shown below 41086 BUS CONTROLLER ADDRESS R RXXXX4 FIRST REGISTER IN GROUP 0F70 OPERATION READ WRITE R I REGISTERS COMMUNICATIONS STATUS TIONS STATUS R 2 REGISTERS COMMUNICATIO U TARGET BLOCK START ADDRESS R 3 DATA REGISTERS MAILBOX ADDRESS FOR DATA R4 4 DATA BUFFER LENGTH IN BYTES R 5 FIRST DATAREGISTER R 6 DATA BUFFER ww eee eee eens Figure 4 9 REGISTER FORMAT FOR COMPUTER MAIL BOX Expanded CPU Operation 4 41 6 96602 The CPU at the end of its sweep
51. configuration and operation of a color graphics system as an operator interface for data collection and analysis Series Six PC I O link Local Module User s Manual which describes the link between a Series Six Plus PLC and the I O structure for the Series One family and Series Three PLCs FCC Note GEK 96602 The Series Six Plus Programmable Logic Controller and its associated modules have been tested and found to meet or exceed the requirements of FCC Rule Part 15 Subpart J The FCC requires that the following note be published NOTE This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instruction manual may cause interference to radio communications It has been tested and found to comply with the limits of a Class A computing device pursuant to Subpart J of Part 15 of FCC Rules which are designed to provide reasonable protection against such interference when operated in a commercial environment Operation of this equipment in a residential area is likely to cause interference in which case the user at his or her own expense will be required to take whatever measures may be required to correct the interference Contents vii GEK 96602 CHAPTER f CHAPTER 2 CONTENTS TITLE INTRODUCTION TO THE SERIES SIX PLUS PROGRAMMABLE LOGIC CONTROLLER What are Programmable Logic Controllers Advantages of Programmable Logic Controllers Series Six Plus P
52. device to isolate the user input and output devices from internal circuitry of an module and the CPU Opto Isolator A semiconductor device that isolates input or output circuits from the control circuitry on an I O module These circuits are coupled together by transmission of light energy from a sender LED to a receiver photo isolator Outputs A signal typically ON or OFF originating from the PLC with user supplied power that controls external devices based upon commands from the CPU Output Information transferred from the CPU through a module for level conversion for controlling an external device or process Output Devices Physical devices such as motor starters solenoids etc that receive data from the programmable logic controller Output module An I O module that converts logic levels within the CPU to a usable output signal for controlling a machine or process PLC Commonly used abbreviation for Programmable Logic Controller Parity The anticipated state either odd or even of a set of binary digits Parity Bit A bit added to a memory word to make the sum of the bits in a word always even even parity or always odd odd parity Parity Check A check that determines whether the total number of ones in a word is odd or even Parity Error A condition that occurs when a computed parity check does not agree with the parity bit Peripheral Equipment External units that can communicate with a PLC
53. example a fault other than the normal operating program might detect Cause Input or output parity retried once and reported by CPU Version 105 or higher software or indicated by status indications at an Advanced 1 Receiver module for example loose or incorrect I O cable connections poor or incorrect grounding procedures between racks in an I O system etc Troubleshooting and Repair 5 37 GEK 96602 12 An input is not being recognized by the CPU Corrective Action If an Advanced 1 0 Receiver is used in the I O rack make sure that it is set up to return inputs to the CPU refer to Data sheet GEK 90771 Make sure that the input is not overridden Ensure that the correct voltage level for the type of input is being supplied to the input terminal assembly Verify that two input boards are not addressed the same If the input status indicator LED is not on 1 Reseat the terminal assembly 2 Check wiring connections 3 Replace the input board If the input status indicator LED is on 1 Reseat the input board 2 Check the input number starting point selection on the DIP switch adjacent to the input board DIP switch mounted on motherboard The starting point selected for this input module must agree with the user program 3 Replace the I O Receiver or Advanced 1 0 Receiver as applicable 4 Replace the Input board 5 Replace the I O cable 13 Only 1 output on a board fails to operate Corrective A
54. faults Remote system operating normally Fault exists in Remote I O system Corrective Action Check for loose or improper connection between I O cables connecting racks the Remote O system e Ensure that all boards are seated properly in the Remote I O system racks e f the REMOTE OK and LINK OK lights turn off simultaneously on the Remote 1 0 Driver check for a break in the cable between the Remote 1 0 Driver and Remote 1 Receiver excessive noise on the link or a power down condition in the rack containing the Remote 1 0 Receiver e f the status indicator light on the Remote I O Receiver turns on then off again almost immediately check the DIP switch settings for 1 addresses assigned to 1 0 modules that are outside of the legal blocks of addresses that were assigned at the Remote 1 0 Driver e Replace the Remote 1 0 Receiver module e Replace the Remote 1 0 Driver module 5 36 Troubleshooting and Repair GEK 96602 11 Observe the REMOTE PARITY light on the Remote I O Driver and Remote 1 0 Receiver modules Definition Status No parity errors in Remote I O system Parity error detected in the Remote I O system Corrective Action Clear parity error by switching the CPU from RUN to STOP and back to RUN e Replace Remote I O Receiver if there is only one rack in the Remote system e f more than one rack in the Remote system locate the first rack in the chain with the LOC
55. format 8 discrete O block uses 6 CPU registers 16 circuit discrete I O block uses 10 CPU registers an analog I O block uses 42 registers and the Bus Controller uses 18 registers Contents of Fifth Register The fifth register indicates where the received data from the Genius I O system should be stored in the CPU for read operations operations 2 4 and 7 Consecutive registers beginning with the specified CPU register will be used until all received data is stored For write operations operation 3 this register indicates where the data to be sent to the Genius I O system from the CPU is to be stored 5 The Bus Controller then verifies the command block for valid command syntax and the absence of a command of that type already in execution If a syntax error does exist the Bus Controller writes an error code into the status code of the third register of the command block in the CPU If a command of the same type is already being executed the Bus Controller will not modify the status code in a subsequent DPREQ when the busy condition disappears 6 If the command number specifies a write command the Bus Controller must read the specified amount of data from the CPU register memory and store it in the serial bus output queue 7 The Bus Controller will then close the communications window by issuing a Close Window command which terminates execution of the DPREQ instruction The window address of the Bus Contr
56. high voltage wires or connectors When in doubt unplug the power supply Try to force a failure by gently moving cables and connectors Ensure good connections at all terminal boards and plug on wire connectors Be sure the wires are connected correctly Once the suspected cause has been determined and corrected push the RESET button on the Advanced 1 0 Receiver or momentarily turn Output Byte Bit 2 On then OFF 5 46 Troubleshooting and Repair GEK 96602 24 INPUT PARITY LIGHT gt 0 2 EIE s Ui DEFINITION Input data parity coming from all downstream racks if their switch 6 is closed and this rack s switch 7 15 closed is and has been OK since this Advanced I O Receiver was last reset An intermittent parity error was latched in from a downstream rack if their switch 6 is closed and this rack s switch 7 is closed The parity error was not present long enough to stop the CPU OFF OFF OFF A parity problem exists now downstream from this rack if their switch 6 is closed and this rack s switch 7 is closed At the CPU the RUN light will be off the ENABLED and PARITY lights on the I O Control module will be off and Alarm Relay 1 on the CPU switches Corrective Action If status indicators 24 and 25 are both OFF The first 4 listed actions should have been performed before any system start up Verify that no two input boards have the same address Connect any unused Analog Input Channels to th
57. included listing the compatibility of the Series Six Plus PLC vs the previously available Series Six family of PLCs Chapter 2 Physicaf Equipment Configuration This chapter describes the hardware components included in a Series Six Plus PLC system The CPU rack configuration is such that it contains all of the necessary modules for a complete PLC system including communications options with up to 6 slots for I O modules in the rack All of the system interface modules required when adding I O racks to contain up to the maximum of 32 K of I O 16K Inputs and I6K Outputs are described A description of the various available communications options is included Chapter 3 Installation Instructions This chapter contains installation specifications and instructions required in order to configure and rack panel or wall mount and wire your Series Six Plus Programmable Logic Controller system Chapter 4 Expanded CPU Operation This chapter describes the Expanded functions and Expanded mode of operation for the Series Six Plus Programmable Logic Controller Included is a description of how to configure the Expanded functions on the Workmaster computer using Logicmaster 6 software Also included in this chapter is information on how to use the Genius I O diagnostics with the Expanded functions in a Series Six Plus Programmable Logic Controller Chapter 5 Troubleshooting and Repair This chapter provides the basic information required to maintain yo
58. industrial computer or the CIMSTAR industrial computer Programming the Series Six Plus with Expanded Il functions requires version 4 01 or later of the Logicmaster 6 software Prior versions of Logicmaster 6 may be used to program the Expanded ll instruction set provided that no Auxiliary I O references are used no Auxiliary I O chain and no Expanded features are required PC PC XT or PC AT personal computer can also be used with unbundled software For detailed information on programming the Series Six Plus PLC refer to the Logicmaster 6 Programming and Documentation Software User s Manual GEK 25379 a40532 Figure 1 4 WORKMASTER INDUSTRIAL COMPUTER IBM is a registered trademark of International Business Machines Incorporated 1 8 introduction To The Series Six Plus PLC GEK 96602 Workmaster Industrial Computer The Workmaster industrial computer with Logicmaster 6 software is the main device used for developing and entering new user s programs editing existing programs or real time system monitoring of the PLC The Workmaster computer is built around a portable industrial hardened IBM compatible personal computer It can be configured to have either one or two diskette drives or one or two diskette drives and a 20 megabyte fixed hard disk The diskette drives are 3 5 drives The capacity of each diskette is 720 K bytes double sided double density after formatting The small physical size of t
59. instructions for accessing a new 1 O system to be available in the future support of 64K user program and Auxiliary I O overrides The Logic Control module must be placed in slot 2 immediately to the left of the t O Control module The Logic Control module works in conjunction with the Arithmetic Control module to generate timing and control signals and must be next to it in the rack since they are linked together through a short length of ribbon cable This short ribbon cable is included with the basic CPU rack NOTE Do not attempt to operate the system without the ribbon cable connected between the Logic Control and Arithmetic Control modules If the cable is not connected the CPU will operate unpredictably The Logic Control module has no status indicators or other user accessible items Figure 2 10 is an illustration of a Logic Control module NOTE The Expanded II Functions require the IC600CB524 Arithmetic Control module Logic Memory modules IC600LX 8K minimum registers a 13 rack or a 19 CPU rack with a date code later than 10 87 Physical Equipment Configuration 2 13 GEK 96602 a40759 Expanded Logic Control Module 1 Ribbon Cable Connector Connects Logic Control Module to Arithmetic Control Module Figure 2 10 EXAMPLE OF LOGIC CONTROL MODULE 2 14 Physical Equipment Configuration GEK 96662 ARITHMETIC CONTROL MODULE The Arithmetic Control module catalog number IC600CB500 IC600CB524 re
60. last block with the conflicting address will be ignored Byte 2 Inputs 9 and IO indicates whether this I O block is an input only block Input 9 ON output only I O block Input 10 ON or combination input output I O block Inputs 9 and 10 both ON Bytes 3 and 4 indicate the reference 0001 to 0993 of the lowest reference involved in this conflict Bytes 5 and 6 provide the device numbers 0 to 31 of the two conflicting I O blocks Byte 5 Input 33 LSB Input 37 MSB contains the device number for the I O block that was not accepted This I O block is rejected by the system no inputs accepted no outputs activated and is left in a default state Byte 6 Input 41 LSB Input 45 MSB contains the device number for the existing I O block Bus Controller Status Byte 1 Address 0 Inputs 7 and 8 These two inputs provide data independent of the other inputs They can be turned on as needed for indication of system status regardless of the ON and OFF state of the other inputs Expanded CPU Operation 4 33 96602 Input 7 PULSE TEST ACTIVE This input is turned on for one scan after the Pulse Test is commanded by the CPU and remains on until all discrete I O blocks configured for the Pulse Test have completed the test Faults detected during this test are provided to the CPU through Input 3 Circuit Fault which is described above This allows circuit faults to be identified as normal random actions or as fault
61. modules may require configuration of switches or jumpers Figure 3 6 is provided as a guide to proper module location in the CPU rack Installation GEK 9660 2 Instructions 995 6999569 E r c 230 O vEnevas meur 13 CPU RACK 19 CPU RACK SERIES SIX 69659656 50 Figure 3 6 CPU MODULE LOCATION GUIDE 3 7 42214 42218 3 8 Installation Instructions GEK 96602 Combined Memory Module The Combined Memory module for the Series Six Plus PLC combines the functions of internal memory register memory and logic memory on one module The Combined Memory module should be unpacked and removed from its sleeve Remove the blank faceplate if in place from the slot where the module is to be installed The Combined Memory module should then be inserted into slot 4 which is immediately to the left of the Arithmetic Control module After installing the module install the faceplate which is imprinted with the legend LOGIC MEMORY The Combined Memory module is a required option and is available in 6 different versions as shown below in table 3 1 The Combined Memory modules used in the Series Six model 60 PLC IC600CM552 and IC600CM554 can also be used in a Series Six Plus PLC but do not provide parity checking Table 3 1 COMBINED MEMORY MODULES CATALOG NUMBER MEMORY
62. of the power supply which is 16 5 amps 275 units of load for 5 V dc 1 5 amps 60 units of load for 12 V dc and 1 0 amps for 12 V dc 40 units of load A list of the power requirements expressed in units of load for each I O module is included in Chapter 3 Installation If an Auxiliary I O module is added to a system it can be placed in slot 5 6 or 7 If the GEnet Series Six Network Interface LAN Local Area Network which is a two board module is required for a system those modules must be placed in slots 5 and 6 which would then require the Auxiliary I O module to be placed in slot 7 Slots 1 through 4 for the Control Logic Control Arithmetic Control and Combined Memory in that order If a Communications Control module is selected it is placed in slot 5 13 Inch CPU Rack Configuration The 13 inch 330 millimeters rack is designed to be mounted several different ways including rack mount in a 10 deep rack brackets on front rack mount in a standard 19 rack wide brackets on front panel mount brackets on rear sides and panel mount in a NEMA 12 wide 30 enclosure brackets on rear top and bottom When mounted in a NEMA 12 enclosure two CPUs can be mounted side by side Each 13 rack has 8 slots available to accommodate modules The slots are numbered from 1 through 8 beginning at the right slot next to the power supply All of the modules are located in the same position in the slots as in the 19 rac
63. rack if switch 6 is closed or in downstream racks if their switch 6 is closed and this rack s switch 7 is closed 1 More than one Input board at the same address 2 Floating Analog Input Channels remember there are 8 Channels per board and if any Channels are unused they should be connected to the SHD terminal on the faceplate 3 Poor grounding between local I O racks for example intermittent ground surges causing parity errors 4 Loose or damaged I O cable between 1 0 racks e Verify that no two Input boards have the same address Ensure that good grounding exists between racks in that station no more than 7 V between racks especially with intermittent faults Ensure that the low level I O cable has not been placed close to any high level power cables power supplies or switching devices especially with intermittent faults Replace the parallel chain 1 cable between this rack and the next downstream rack connected to the bottom of this board Replace this Advanced I O Receiver module e Replace the I O Receiver or Advanced 1 0 Receiver module in the next downstream rack e Reset the status indicators after your corrective action by momentarily pressing the RESET pushbutton on the Advanced 1 0 Receiver module 5 48 Troubleshooting and Repair GEK 96602 25 W DOG WATCHDOG LIGHT STATUS DEFINITION ON The CPU has power and has been active without fatal I O parity errors since the W DOG lig
64. racks Standard and High Capacity NOTE Standard and High Capacity power supplies are not interchangeable Standard power supply must go in a Standard 1 0 rack and a High Capacity power supply must go in a High Capacity 1 0 rack Table 5 3 POWER SUPPLIES POMER SUPPLY I O RACK CATALOG TYPE NUMBER DESCRIPTION Power Supply provides 5 V dc at 6 1 amps Standard IC600PM502 allows 100 units of load Operates on input ac voltages from 95 to 260 V ac Power Supply provides 5 V dc at 16 5 High 600 503 amps 12 V dc at 1 5 amps and 12 V dc at 1 0 Capacity amp allows 275 units of load Operates on ac input voltages from 95 to 260 V ac High IC600PM542 Same output voltage ratings as above Capacity 24 V dc Requires a dc input voltage of 20 to 32 V dc dc High IC600PM546 Supplies same output voltages as above Capacity 125 V dc Requires a dc input voltage of 100 to 150 V dc dc There is one status indicator light on the 1 0 power supply INDICATOR STATUS DEFINITION Power is applied output voltage is within tolerances as listed below POWER ON Output Valid Range for Vol age put Voltage 5 V dc 4 75 to 5 25 V dc 12 V dc 11 4 to 12 6 V dc High Capacity only 12 V dc 11 4 to 12 6 V dc High Capacity only No ac or dc input power Output voltage s out of OFF tolerance CHAIN OK lights from the applicable rack back to and including the CPU turn off CPU RUN and ENABLE lights turn off Alarm 1 rela
65. relay systems The user programmed logic is expressed in relay equivalent symbology Latch A PLC function that causes a coil to stay on and remain on even if power or the input is removed Referred to as a retentive function Local I O Station An I O system configuration consisting of a maximum of 10 I O racks interfaced to a Series Six Plus programmable logic controller through an I O Receiver or Advanced I O Receiver module to an I O Transmitter module in a CPU station or another Local I O station The last Local I O station in a chain can be located up to a maximum of 2000 feet from the originating I O Control or Auxiliary module in a CPU station Logic A fixed set of responses outputs to various external conditions inputs All possible situations for both synchronous and non synchronous activity must be specified by the user Also referred to as the program Logic Memory In the Series Six Plus PLC dedicated CMOS RAM memory accessible by the user for storage of user ladder diagram programs Memory A grouping of physical circuit elements that have data entry storage and retrieval capability Memory Protect A hardware capability that prevents user memory from being altered by an external device This capability is controlled by a key switch on the CPU power supply Microprocessor An electronic computer processor section consisting of integrated circuit chips that contain arithmetic logic register control and memor
66. software systems GE Fanuc Automation assumes no obligation of notice to holders of this document with respect to changes subsequently made GE Fanuc Automation 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 The following are trademarks of GE Fanuc Automation North America Inc Alarm Master GEnet Modelmaster Series One CIMPLICITY Genius ProLoop Series Six CIMPLICITY PowerTRAC Genius PowerTRAC PROMACRO Series Three CIMPLICITY 90 ADS Helpmate Series Five VuMaster CIMSTAR Logicmaster Series 90 Workmaster Field Control Copyright 1995 GE Fanuc Automation North America Inc Rights Reserved Preface iii GEK 96602 PREFACE This is the second edition of the Series Six Plus Programmable Logic Controller User s Manual This manual provides the user with the information required to configure install implement and maintain the Series Six Plus Programmable Logic Controller Chapter 1 Introduction to the Series Six Plus PLC This chapter describes the features functions and specifications of the Series Six Plus PLC along with information on programming communications options and optional peripheral equipment that can be included as part of your Series Six Plus PLC system A cross reference guide is
67. source of power either ac or dc depending on whether an ac or dc power supply is selected The 4 remaining terminals on the right side have no internal connections to the power supply 70tmpl1 41063 CT EIE eme d iNO IKO we wary ie 222 cONTACIS 4 IS I HEUS TISDLATEDI san D LINE 2 L2 Weir ISOLATED ONO NEG voc 2NC GROUND 6 2NC E e GROUND 16 AN APPLICABLE Figure 2 6 CPU TERMINAL BLOCK CONNECTIONS The optional external auxiliary battery if included in a system is connected to the 2 top terminals on the left group of terminals The auxiliary battery voltage is routed through a regulator in the power supply which provides a regulated voltage to back up the CMOS RAM memory circuitry in the event of a no power condition to the supply The remaining 5 terminals on the left group of terminals provide external signals when certain internal faults are detected by the CPU The minor alarm terminals 1 0 and 1NC faults are advisory in nature and do not affect the operation or reliability of the PLC The major alarm terminals 2NO and 2NC faults are an indication that the CPU has detected a fault affecting normal operation and has halted its scanning in order to prevent unreliable or unpredictable operation of the PLC If a fault does occur status indicators on various modules will point to the specific cause of the fault NOTE Dur
68. the I O channel bits 12 15 range 0 through F in which the Bus Controller is placed and its starting I O reference bits 0 9 with a range of 0 through 1023 Bits 10 and 11 are unused Register 2 The second register contains the I O channel number in Hexadecimal 0 F and the reference of the faulty circuit or starting reference of the faulty I O block If the fault is with the Bus Controller or the Genius I O communication bus the reference value will be 0 Bits 10 and 11 in register 2 indicate whether the circuit fault is with an input bit 10 on or output bit 11 on circuit or I O blocks containing all inputs or outputs If bits 10 and 11 are on the circuit is an output with feedback or an I O mixed block 4 34 Expanded CPU Operation GEK 96602 Figure 4 7 illustrates a fault table showing the content of each of the 10 registers Register LS BYTE Bus Controller Address I O Address MS BYTE Bus Controller Address Channel Register 2 LS BYTE Block Address I O Address MS BYTE Block Address Channel and I or O Register 3 LS BYTE Circuit Channel Number MS BYTE Bus Controller Status Byte No 3 Register 4 LS BYTE Bus Controller Status Byte No 4 MS BYTE Bus Controller Status Byte No 5 Register 5 LS BYTE Bus Controller Status Byte No 6 MS BYTE Fault Type Register 6 LS BYTE Fault Type MS BYTE Fault Description Register 7 LS BYTE Fault Description MS BYTE Fault Description Register 8 LS BYTE Fault Time Tenths of Se
69. the defective battery and discard it 5 16 Troubleshooting and Repair GEK 96602 WARNING Observe the following precautions when handling a Lithium battery Do not discard the Lithium Manganese Dioxide battery in fire Do not attempt to recharge the battery Do not short the battery The battery may burst or burn or release hazardous materials 5 Care must be taken not to short any runs on the memory board during battery replacement as this will result in the loss of memory data Battery Light Out e f the BATTERY light was out install the new battery as follows 1 Do not disconnect the defective battery from its battery connector but do remove it from its mounting clips As long as system power is not removed the data in the memory is good If power is lost the memory data may become invalid and the CPU will not restart until the new battery is installed Be sure to have a backup of your program 2 Place the new battery in the mounting clip 3 Connect the new battery by using the second unused battery connector 4 Care must be taken not to short any runs on the memory board during battery replacement as this will result in the loss of memory data 5 Disconnect the defective battery from its battery connector and discard it e Replace the faceplate Secure it in place by turning the quarter turn thumbscrews clockwise unti they are tight f power was removed and the BATTERY light had been flashing turn
70. the lower connector the I O chain signals must be terminated This is done by reconfiguring three jumper plugs on the printed circuit board which performs the same function as reconfiguring the jumper pack and DIP shunts on an I O Receiver or Advanced t O Receiver module Status Indicators The Remote I O Receiver has four LED indicators visible through the faceplate lens The legends on the faceplate lens are the same as those on the Remote I O Driver Table 2 21 REMOTE I O RECEIVER STATUS INDICATOR DEFINITIONS INDICATOR DEFINITION LOCAL ON Remote 1 0 Driver module operating normally OK OFF Communications fallure or addressing difference between Local and Remote Stations LINK ON Communications link between this module and Remote I 0 OK Driver established and valid OFF Communications failure between this module and Remote 0 Driver REMOTE ON Remote system Is operating normally OK OFF Fault in Remote I 0 system Illegal address block loose connection power supply failure REMOTE ON Remote system operating normally with no parity errors PARITY OFF Parity error detected 1n Remote I 0 system Option Jumpers There are several circuit board jumpers on this module which are used for option selection and 1 0 chain signal termination Jumpers are factory set prior to shipment and must agree with the Remote I O Driver to which the Remote I O receiver is connected Table 2 22 lists the factory and alternate setti
71. to transmit data twice within 100 ms If Input 2 stays On for several scans or longer it is an indication that the Bus Controller cannot gain access to the bus because of a duplicate block number assignment or that a bus scan is greater than 100 ms Bus Controller Status Byte 1 Address 0 Inputs 3 4 5 6 These inputs are indications of faults detected by the Bus Controller A fault indication is active for one scan These inputs are reset to the OFF state upon power up of the CPU or the Bus Controller Only one of these four inputs will be on during any scan Expanded CPU Operation 4 31 GEK 96602 Bus Controller Status Byte 1 Address 0 Input 3 CIRCUIT FAULT This input when on indicates a fault in one of the circuits on a Genius I O block Bytes 3 and 4 of the 6 input bytes indicate the I O reference 0001 through 1000 that has been assigned to the circuit Byte 2 inputs 9 and IO indicate whether the circuit is an input or output Input 9 ON indicates that the circuit is an input Input 10 ON indicates that the circuit is an output If both are On the circuit is an output with feedback Byte 3 contains the least significant byte of the I O reference Input 17 contains the least significant bit LSB Byte 4 contains the most significant byte of the I O reference Input 26 contains the most significant bit MSB Byte 5 indicates the fault type and the relative circuit reference number of the fault on the I O b
72. used in a system with Expanded I O addressing The older RPU uses 8 outputs O1017 through O1024 to control its operations Setting O1017 in the Master will cause transfer to the Back up CPU if it is available If O1022 is set outputs from the Main I O Status Tables and the Override Table are transferred from the Master to the Back up If O1023 is set register R0254 is transferred from the Back up to the main CPU If 01024 is set a block of registers starting at the address specified by the value in register R0255 and ending at the value in register R0256 will be transferred from the Master to the Back up The 8 inputs 11017 through 11024 and 8 outputs O1017 through O1024 are always mapped into the Main I O Status Table Of the 8 inputs only input 1024 is used It is set to 1 if the associated CPU is the backup Only the upgraded model RPU should be used in an Expanded I O system In Expanded addressing an I O Transmitter Module in either channel 0 or channel 1 will write data into the references formerly assigned only to the RPU For example for channel 0 the status of the I O Transmitter module maps into Main I O at addresses 11017 through 11024 However 11024 is the input normally used by the RPU to specify the end of the register block to be transferred from the Main CPU to the Back up CPU The upgraded model RPU features jumper selectable addressing This allows greater memory access and permits assignment of non conflicting I O
73. will also support the Enhanced Graphics Adaptor EGA card The Logicmaster 6 software for the IBM PC version is available as a set of three 5 25 inch 360K diskettes Performance of the software with other versions of DOS or on other IBM PC compatible computers is not guaranteed The system supports the IBM monochrome adaptor board and the asynchronous communications adaptor board It does not support serial communications adaptors based on the 8250 UART An IBM PC based Logicmaster 6 system communicates with a Series Six Plus PLC through the serial ports to a CCM module in the Series Six Plus CPU rack The IBM PC version of Logicmaster 6 software communicates and functions in the same way as does the serial version for the Workmaster computer REDUNDANT PROCESSOR UNIT The Redundant Processor Unit RPU monitors the CPU and I O When the RPU detects a failure of the CPU or I O it switches to a backup CPU and optionally to a backup I O chain For more information about the module refer to the Redundant Processor Manual GEK 25366 Addressing for the RPU Originally the RPU used pre assigned inputs and outputs in the Main I O Status Tables These inputs and outputs could not be changed The upgraded version of the RPU uses hardware selectable I O addresses IBM is a registered trademark of International Business Machines Incorporated 2 66 Physical Equipment Configuration GEK 96602 The older type of RPU should not be
74. 0 to 10 V dc Analog Output 29 6008 942 10 V dc Analog Output 29 IC600BF943 4 to 20 mA Analog Output 29 IC600BF944 ASCII BASIC Module 12K 20 600 949 ASCII BASIC Module 28K 20 6008 946 Loop Management Module 20 IC600BF947 I 0 Link Local 20 12 IC600BF948 I 0 CCM 20 12 600 950 1 0 4 20 12 1 660 900 Genius Bus Controller 20 2 660 902 Genius Bus Controller w Diag 20 2 660 901 Genius Bus Controller IC660CB903 Genius Bus Controll wo Diaq 7 For 5 V dc 1 unit of load equals 60 mA 300 mw of power For 12 12 V dc 1 unit of load equals 25 mA 300 mw of power XX ke xe doe koe xxx xx xxx IMPORTANT INFORMATION xxx x x x o o ook ox o o oe e e o After you have completed the installation procedures for all of your hardware and have installed the Logicmaster 6 software on your Workmaster industrial computer CIMSTAR industrial computer or IBM PLC PC XT or PC AT Personal Computer you should proceed to the following START UP instructions for a new Series Six CPU INITIAL START UP INSTRUCTIONS FOR A NEW SERIES SIX CPU Any new memory board will usually power up with a parity error The reason this happens is that when the lithium battery is first plugged into the board the RAM memory devices power up in an unknown state These parity errors must be cleared before proper CPU operation can be expected The CPU should be cleared even though it appears to run properly wh
75. 041024 10 0001 10 1024 and 0840001 08 1024 18 0001 18 1024 cannot be used as real 1 0 references but are available for use as discrete programming references Channel 1 through 7 real 1 0 references are for the Expanded Main 1 0 Channels Channel 9 through F real 1 0 references are for the Expanded Auxiliary 1 0 Channels Expanded CPU Operation 4 9 GEK 96602 SUMMARY OF REQUIRED I O REFERENCES There are special I O references which must be reserved for several of the optional modules used with a Series Six Plus PLC These references have special significance for the listed modules and care must be taken when programming so that references are not overlapped duplicated or otherwise misused In the following table the use of parentheses with a reference is an indication that the reference can be changed Table 4 2 RESERVED I O REFERENCES REFERENCES RESERVED FOR FUNCTION 10993 11000 Advanced 1 0 Receiver Default status byte I1001 I1008 Interrupt Input Status byte 11009 I1016 Communication Contro Status byte I1017 11024 I O Transmitter Status byte Main chain channel 0 I1024 Redundant Processor RPU status Set to a I if RPU Unit is operating as backup CPU 00993 01000 Advanced I O Receiver Default control byte 01015 Override Active Detect Override Active in System Main Status Table Enable Bit 01016 Override Active Detect Override Active in System Main Status Table Report Bit
76. 09 3009 3259 3509 3759 5009 5509 5759 7249 7509 ABM Communication Control Data Processor Unit Redundant Processor Unit Redundant Processor Unit Redundant Processor Unit 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 Loop Management Module Loop Management Module RTU Master Transmitter Transmitter Transmitter Transmitter Transmitter Transmitter Transmitter Transmitter Transmitter Transmitter Transmitter Transmitter Transmitter Transmitter 4 10 Expanded CPU Operation GEK 96602 Table 4 3 RESERVED REGISTER REFERENCES REFERENCES RESERVED FOR FUNCTION R128 I O Transmitter Channel 8 Auxiliary I O chain RTU master command registers defaults can be changed Software configuration of CCM optional Default status registers Status register Content of R254 in backup CPU transferred to master or set to O if backup not present or unavailable Control register Content of R255 is first register for data trans fer from master to backup CPU Control register Content of R256 is last register for data trans fer from master to backup CPU Channel 0 Main 1 0 chain Channel 2 Main I O chain Channel 3 Main 1 0 chain Channel 4 Main I O chain Channel 5 Main I O chain Channel 6 Main I O chain Channel 7 Main I O chain Channel 9 Aux I O chain Channel A Aux 1 0 chain Channel B Aux 1 0 chain Channel C Aux I O chain Channel D Aux 1 0 chain
77. 1024 R0321 12 0001 12 1024 N R2369 I2 0001 I2 1024 RO385 03 0001 03 1024 R2433 03 0001 03 1024 R0449 1340001 13 1024 I R2497 13 0001 13 1024 RO513 04 0001 0441024 0 R2561 04 0001 04 1024 R0577 14 0001 14 1024 R2625 14 0001 14 1024 R0641 0540001 0541024 R2689 05 0001 05 1024 R0705 0001 15 1024 H R2753 15 0001 15 1024 RO769 06 0001 06 1024 A R2817 06 0001 06 1024 R0833 16 0001 16 1024 I R2881 16 0001 16 1024 R0897 07 0001 07 1024 R2945 07 0001 07 1024 R0961 17 0001 17 1024 R3009 17 0001 17 1024 R1025 User Registers R3073 08 0001 08 1024 R1089 User registers R3137 18 0001 I8 1024 R1153 09 0001 09 1024 R3201 09 0001 09 1024 R1217 19 0001 19 1024 U R3265 19 0001 19 1024 R1281 0001 OA 1024 X R3329 OA 0001 OA 1024 R1345 IA 0001 IA 1024 R3393 IA 0001 IA 1024 R1409 OB 0001 OB 1024 I R3457 OB 0001 OB 1024 R1473 IB 0001 18 1024 0 R3521 IB 0001 IB 1024 R1537 0 0001 0 1024 R3585 OC 0001 OC 1024 R1601 IC 0001 IC 1024 R3649 IC 0001 IC 1024 R1665 00 0001 OD 1024 R3713 OD 0001 OD 1024 R1729 10 0001 10 1024 R3777 10 0001 10 1024 R1793 OE 0001 0 1024 I R3841 OE 0001 OE 1024 R1857 IE 0001 1 1024 R3905 IE 0001 IE 1024 R1921 OF 0001 OF 1024 R3969 OF 0001 OF 1024 R1985 IF 0001 IF 1024 R4033 IF 0001 IF 1024 1 Channel real I O is scanned on the Main I O chain references 00001 01024 and 10001 11024 Channel 8 re
78. 128 inputs and 128 outputs or 256 inputs and 256 outputs However eight inputs and eight outputs are used by the Remote l O Driver for system status information thus allowing a total of either 120 inputs and outputs or 248 inputs and outputs The block of either 120 I O or 248 I O is selected by positioning of a jumper on the Remote I O Driver module 2 54 Physical Equipment Configuration GEK 96602 The unique I O points addresses for each module in a Remote I O station are selected by setting the seven segment DIP switch on the backplane adjacent to each slot in the rack However all I O points selected must be within the block selected for the Remote station The I O points a remote system must be within one of the blocks as listed in table 2 17 Table 2 17 V O POINT RANGES IN REMOTE I O STATIONS 120 Inputs 128 Outputs 248 Inputs 248 Outputs 128 256 129 256 257 512 257 384 513 768 385 512 769 1000 2 513 640 641 768 769 896 897 1000 1 1 This block selected allows 96 inputs and 96 outputs 2 This block selected allows 224 inputs and 224 outputs The address selected for the Remote I O Driver can fall anywhere within the range of I O points in a block All modules a Remote station including the Remote I O Driver must have switches 5 6 and 7 120 I O or 6 and 7 248 I O set the same By doing this all modules in a Remote station are thus tied to that
79. 19 11 slots Rack Mount 19 0 W x 14 0 H x 10 3 0 inches 483 x 356 x 261 millimeters Panel Mount 20 0 W x 14 0 H x 10 3 D inches 508 x 356 x 261 millimeters Weight Empty 30 Pounds 13 Kg Rack Dimensions 13 8 slots Rack Mount 16 0 W x 13 25 H x 9 3 D inches 406 x 337 x 236 millimeters Rack Mount with Brackets for 19 0 W x 13 25 D x 9 3 D inches standard 19 Rack 483 x 337 x 236 millimeters Panel Mount Brackets on sides 16 0 W x 13 25 H x 9 3 D inches Panel Mount Brackets on Top and 13 25 W x 16 1 H x 9 3 D inches Bottom Side By Side Mount 337 x 418 x 236 millimeters Power Supply Input Requirements AC Standard 1 600 501 Frequency 47 to 63 Hz Voltage 95 132 V ac Jumper 190 269 V ac Selectable Maximum load 80 VA AC High Capacity IC6 YR511 Voltage and Maximum Load 95 260 V ac Wide Range 250 VA DC High Capacity IC6 YR514 Voltage and Maximum Load 20 to 32 V dc 180 VA DC High Capacity 1 600 546 Voltage and Maximum Load 100 to 150 V dc 180 VA Power Supply Voltages to Rack Standard 100 Units of Load 1 5 Vdc 6 1 maximum High Capacity 275 Units of Load 5 V dc 16 5 A maximum 12 V dc 1 5 A maximum 12 V dc 1 0 A maximum Allowable Power Interruptions AC 33 mSec min 115 V ac line DC 10 mSec min 20 V dc line 4 mSec min 100 V dc line Operating Temp Outside of Rack to 60 32F to 140 F Storage Temperature 20 to 806 4 to 176 F Hum
80. 20 10 to 10 V dc 4 Max 4 to 20 mA 4 20 mA Max Thermocouples 12 Bit Types 3 S T B f R Interrupts 8 Introduction To The Series Six Plus PLC 1 13 J GEK 96602 Table 1 5 GENIUS 1 0 BLOCKS BLOCK TYPE CURRENT VOLTAGE NUMBER OF CIRCUITS 115 V ac Grouped 2 A Total 15 A 8 115 V ac dc Isolated 2 Total 16 A 8 24 to 48 V dc Source 2 Total 16 A 16 24 to 48 V dc Sink 2 A Total 16 A 16 Analog 12 bit 115 V ac Power Source 4 In 2 Out Analog 12 bit 24 to 48 V dc Power Source 4 In 2 Out Relay Output NC 115 230 V ac 2A 16 Relay Output NO 115 220 V ac 2A 16 RTD Input 115 V ac 125 V dc 6 Input 24 to 48 V dc 6 In addition to I O modules other available modules include system interface modules communications modules and intelligent modules Table 1 6 OTHER MODULES SYSTEM INTERFACE MODULES Receiver R Remote 1 0 Driver Local hgya ced I 0 Receiver emote Remote I 0 Receiver 1 Transmitter COMMUNICATIONS MODULES CCM2 Communications Control Module Type 2 Multi Mode Protocol Master Slave Peer CCM3 Communications Control Module Type 3 Has Functionality of CCM2 and Also Interfaces To Process Controllers I 0 Link Local Interfaces To Series One and Series Three PLCs Allows 1 0 Communications with Those PLCs I O CCM Functionality of CCM3 in an 1 0 slot Interface Local Area Network Interface Module pro
81. 24 R0256 0257 BUS CONTROLLER STATUS BIT R 258 USER REGISTERS RO266 RO267 CLOCK 0269 0270 POINTER FOR FAULT TABLE 0271 FAULT TABLE ENTRIES RXXXX RXXXX USER REGISTERS 3 R0954 RQ955 COMPUTER MAIL BOX 1024 Expanded discrete references 00001 through 01024 10001 through 11024 and 015 0001 through 0141024 1140001 through 1141004 overlaid on the Register table These registers are available for general use if the above references are not used Channel 1 0 is scanned on the Main 1 0 chain The number of registers available for general use depends on the quantity of Genius 1 0 fault tables selected Figure 4 4 MEMORY MAP FOR 1 REGISTERS 4 8 Expanded CPU Operation GEK 96602 Expanded Mode 1 0 References Table 4 1 is a list of Expanded Mode real and discrete 1 0 point references for each channel and their memory location Q 2 3 4 5 Table 4 1 MEMORY MAP FOR EXPANDED MODE I O REFERENCES REAL 1 0 POINTS INTERNAL DISCRETE REFERENCES REGISTER I O REFERENCE REGISTER I O REFERENCE R0001 00001 A01024 AUX R2049 00 0001 00 1024 R0065 10001 AI1024 AUX R2113 10 0001 10 1024 R0129 01 0001 01 1024 M R2177 01 0001 01 1024 R0193 11 0001 11 1024 A R2241 I1 0001 11 1024 R0257 0240001 02 1024 I R2305 02 0001 02 1024 R0321 12 0001 1241024 R2369 I2 0001 I2 1024 R0385 03 0001 03 1024 R2433 03 0001 03 1024 R0449 13 0001 13 1024 I R2
82. 497 13 0001 13 1024 R0513 04 0001 04 1024 0 R2561 04 0001 04 1024 R0577 14 0001 14 1024 R2625 I4 0001 I4 1024 R0641 05 0001 0541024 R2689 05 0001 05 1024 R0705 15 0001 15 1024 R2753 I5 0001 I5 1024 0769 06 0001 0641024 R2817 06 0001 06 1024 R0833 16 0001 16 1024 I R2881 16 0001 16 1024 R0897 0740001 0741024 R2945 07 0001 07 1024 RO961 17 0001 17 1024 R3009 17 0001 17 1024 A R1025 User Registers U R3073 08 0001 08 1024 R1089 User registers X R3137 I8 0001 I8 1024 R1153 0940001 0941024 I R3201 09 0001 09 1024 R1217 19 0001 19 1024 1 R3265 I9 0001 I9 1024 R1281 0001 OA 1024 1 R3329 OA 0001 OA 1024 R1345 IA 0001 IA 1024 A R3393 IA 0001 IA 1024 R1409 OB 0001 1024 R R3457 OB 0001 1024 R1473 IB 0001 IB 1024 Y R3521 IB 0001 IB 1024 R1537 0 0001 0 1024 R3585 0 0001 OC 1024 R3649 0001 IC 1024 R1601 IC 0001 IC 1024 I R1665 00 0001 00 1024 0 R3713 OD 0001 OD 1024 R1729 10 0001 10 1024 R3777 ID 0001 ID 1024 R1793 OE 0001 0 1024 R3841 OE 0001 OE 1024 R1857 0001 1 1024 R3905 0001 IE 1024 R1921 OF 0001 OF 1024 R3969 OF 0001 OF 1024 R1985 IF 0001 IF 1024 I R4033 IF 0001 IF 1024 N Channel 0 real I O is scanned on the Main 1 0 chain references 00001 01024 and 10001 11024 Channel 8 real I O is mapped into Registers 1 128 references 00001 01024 and 10001 11024 References 0040001 0
83. 5 21 5 9 CPU to I O Rack Configuration 5 28 5 10 Rack to I O Rack Configuration 5 29 5 11 Typical I O Rack Wiring Scheme 5 30 5 12 Advanced I O Receiver Status Indicators 5 38 TABLES Table 1 Series Six Plus PLC Features 4 1 2 General Specifications 5 1 3 Programming Functiona Groups 9 1 4 Standard I O Modules 12 1 5 Genius I O Blocks 13 1 6 Other Modules 13 1 7 Typical PLC Applications 22 1 8 Common PLC Terminology 23 1 9 Compatibility Guide Series Six Plus PLC vs Series Six PLCs 24 2 1 Power Supply User Items 5 2 2 Conditions Causing Alarms 7 2 3 Power Supply Specifications 7 2 4 Control Module Indicators 10 2 5 Arithmetic Control Module Status Indicators 14 1 2 6 Combined Memory Modules 2 7 Scratch Pad Storage Items 2 8 Combined Memory Module Status Indicators 2 9 CCM2 Status Indicator Definitions 2 10 Rack and Power Supply Specifications 2 11 Point References and Register Mapping for Expanded Mode Operation 2 12 Interf ace Modules 2 13 l O Receiver Status Indicators 2 14 Status and Diagnostic Indicator Definitions 2 15 Transmitter Status Indicator Definitions 2 16 Typical System Response Times to Remote I O 2 17 Point Ranges in Remote I O Stations 2 18 Remote I O Driver Status Byte 2 19 Remote I O Driver Status Indicators qn NNNNNNNNN
84. 5 REDUNDANT PROCESSOR UNIT CONFIGURATION Introduction To The Series Six Plus PLC 1 15 GEK 96682 Operator Interface Unit The Operator Interface Unit is an ASCII device that can be driven by the 2 or CCMS module This unit allows an operator to access for the purpose of displaying or altering register data I O states I O override status and timer or counter operation Up to 8 OIUs can be connected to one CPU A detailed description of the OIU can be found in the Series Six Data Sheet Manual GEK 25367 6830103 82121 9000 ALLOWED DISPLAY PENDING WATNG 0 CLEAR By TWO 08 i m ES SEE em Av IMPUT OUTPUT Lie ATIS AC TUR Figure 1 6 OPERATOR INTERFACE UNIT Operator Interface Terminal The Operator Interface Terminal OIT is an industrial hardened CRT terminal designed for use in the factory environment The OIT connects to the CPU through an ASCII BASIC module providing a powerful tool for monitoring and interfacing to a control system The OIT provides CRT background screens for the display of status from the CPU The user can configure the screens to allow the displays to fit a particular application Detailed information on operation and configuration of the OIT can be found in the Operator Interface Terminal Manual GEK 90817
85. 64 to Series Six Plus adapter boards 2 62 to Series Six Plus connections 2 63 system grounding procedures 3 15 to Workmaster connections 2 63 GE FANUC AUTOMATION NORTH AMERICA INC CHARLOTTESVILLE VIRGINIA 966024
86. 75 to 3 0 V dc FLASHING Battery low 2 54 to 2 75 V dc CPU continues running and will restart if stopped Alarm Number 2 switches To ensure continued protection of memory contents replace the battery before it fails OFF Battery failed below 2 54 V dc CPU continues running but will not restart if stopped Alarm Number 2 remains switched Memory contents will be lost when ower is turned off or lost BATTERY REPLACEMENT INFORMATION e The Lithium Manganese Dioxide battery will maintain the user program in memory for a period of 6 months minimum on the shelf at a temperature range of O to 65 t is recommended that the battery be replaced every 4 years a running CPU e lfabattery fails replace it immediately To install a new battery refer to Figure 5 4 on a memory board proceed as described below Replacing a Battery e Power does not need to be turned off to replace a battery The battery can be replaced while the CPU is running e Remove the faceplate from the memory module slot by turning the quarter turn screw counter clockwise and pull the faceplate towards you Battery Light Flashing e f the Battery light was flashing install the new battery Catalog Number 600 507 as follows 1 Do not disconnect the battery but do remove it from its mounting clips 2 Place the new battery in the clip 3 Connect the new battery by using the second unused battery connector 4 Disconnect
87. 8 Typical I O Rack 2 29 2 19 Point Address Switches 2 31 2 20 Dip Switch Settings for 8 Circuit Modules 2 32 2 21 CPU I O Station 2 38 2 22 Local I O Station 2 39 2 23 Remote I O Station Configuration 2 41 2 24 Receiver User Items 2 43 2 25 VO Receiver Dip Shunt Jumper Rack Configuration 2 44 2 26 Location of User Items 2 47 2 27 Transmitter Module 2 50 2 28 Typical Remote I O System Connections 2 52 2 29 Remote I O Driver Module 2 55 2 30 Remote I O Receiver Module 2 58 Contents Figure 2 31 2 32 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 3 9 3 10 3 11 3 12 3 13 3 14 3 15 3 16 3 17 3 18 3 19 3 20 3 21 3 22 3 23 3 24 3 25 3 26 4 1 FIGURES Auxiliary O Module Board Layout Workmaster Computer Connections to the Series Six Plus PLC Rack Mounting 19 Rack Wall or Panel Mounting 19 Rack Extraction Insertion Tool Position of Extraction insertion Tool for Board Insertion Positioning the Extraction Insertion Tool for Board Removal CPU Module Location Guide Memory Board Battery Connect ion Printed Circuit Board Orientation in a Rack Logic Control to Arithmetic Control Ribbon Cable Control Module Jumper Location CPU Power Supply Connections PLC System Grounding Rack Safety Ground Wiring Series Six Plus PLC Rack Signal Ground Connections Station Grounding Programming Device Ground Connection Typical Rack Power Supply Connect ions Parallel I O Chain Cable Remote I O Twisted Pair Cable Remote I
88. A NO Contents xix GEK 96602 TABLES PAGE Table 2 20 Remote I O Driver Option Settings 2 57 2 21 Remote I O Receiver Status indicator Definitions 2 59 2 22 Remote I O Receiver Options 2 60 3 1 Combined Memory Modules 3 8 3 2 Control Option Jumpers 3 12 3 3 Expanded I O Channel Selection 3 22 3 4 Parallel Chain Cable Catalog Numbers 3 24 3 5 CPU Rack Power Supply Capacities 3 28 3 6 Summary of Units of Load for CPU Rack Modules 3 29 3 7 Summary of Units of Load for I O Modules 3 30 4 1 Memory Map for Expanded Mode I O References 4 8 4 2 Reserved I O References 4 9 4 3 Reserved Register References 4 10 4 4 Bus Controller Addresses for Diagnostic Storage 4 29 4 5 Decoding of Byte 6 for Circuit Fault Types 4 31 4 6 Fault Types in Register 6 4 35 4 7 Analog 1 0 Block Reference Example 4 37 4 0 Bit Status Meaning for Analog Blocks 4 38 4 9 Bus Controller Status Control Byte Definition 4 39 5 1 CPU Indicator Chart 5 4 5 2 Conditions Causing Alarm Relays to Switch 5 19 5 3 lO Power Supplies 5 20 5 4 Module Status indicator Definitions 5 22 Introduction To The Series Six Plus PLC 1 1 GEK 96602 CHAPTER 1 INTRODUCTION TO THE SERIES SIX PLUS PROGRAMMABLE LOGIC CONTROLLER The Series Six Plus Programmable Logic Controller is an enhanced version of the Series Six family of programmable logic controllers The Series Six family of programmable logic controllers was first introduced in 1980 and is used extensively in factory autom
89. AL PARITY light off e Replace the 1 0 Receiver or Advanced 1 0 Receiver that rack e Replace the 1 0 chain cable If none of the status indicator lights are observed to be off in the CPU or 1 0 racks must determine what type of fault you are troubleshooting If an input or output point is not working go to the step corresponding to the following Step 12 An input is not being recognized by the CPU Step 13 Only one output on a board fails to operate Step 14 No outputs are operating Step 15 I O status or override changes occur during 1 rack power down If you have Advanced I O Receiver modules in your I O system then proceed to steps 16 through 25 The additional troubleshooting aids provided the Advanced 1 0 Receiver module ease the problems of troubleshooting intermittent fault conditions Without Advanced O Receiver modules it can be very difficult to troubleshoot intermittent faults Examples of Intermittent Fault Conditions and Causes Condition Program has lost all Sealed relays those relays that use their own contact state to retain them in the ON state Cause Power was momentarily lost in a power supply somewhere in the system The cause could be an operator cycling a power switch loose connection on a power supply or cable in the system etc Condition Your program has just sensed a fault of some type and warned an operator that something in the system is not correct for
90. BAT EXETRNAL INO OUTPUTS TO BACKPLANE INC i RELAYS lt COM SYS ROY STOP ROM RAM AUX BAT AC CIRCUIT POS Ll BREAKER poner DC NEG OR L2 M 22 540 p FILTER 12 0 BACKPLANE GND GND o OV Figure 2 7 CPU POWER SUPPLY BLOCK DIAGRAM Physical Equipment Configuration 2 9 GEK 96602 Power Supply Auxiliary Circuit Board An auxiliary circuit board CPAX is mounted inside the power supply This circuit board performs several system functions which are summarized below A block diagram of this board is shown in figure 2 8 Senses the levels of the 5 12 and 12 V dc supplies and provides output signals to the CPU PSI DATA PROTECT and SYS RDY e Provides switch debouncing for the RUN STOP switch located on the front panel e Provides control logic and relay isolation for the 2 user alarm signals Provides voltage regulation for a user supplied 6 to 28 V dc auxiliary back up battery for the CMOS RAM memory devices 7059 BAT O MEMORY VOLTAGE AUXILIARY 12V REFERENCE BAT O BATTERY AUX BAT REGULATOR m C DATA VOLTAGE PROTECT iv O COMPARATORS DELAY DELAY ROTECT CLOCK VS VOLTAGE OPTOISO T BATTERY SENSOR LATOR CONDITION Ys OK STORAGE CPU OK AINC O START RUN STOP AUR C AINO SWITCH STOP C enm S ANC LOWBAT O A2NO Figure 2 8 AUXILIARY CIRCUIT BOARD BLOCK DIAGRAM 2 10 Physical Equipment Co
91. Battery Connectors External Auxiliary Battery Select Figure 2 13 TYPICAL COMBINED LOGIC MEMORY MODULE Physical Equipment Configuration 2 21 GEK 96682 BUS CONTROLLER MODULE The Bus Controller module is the required interface between a Series Six Plus PLC and the Genius I O blocks when they are included in the PLC s I O system The Bus Controller module can be placed in any I O slot in the CPU or in a high capacity I O rack located a CPU station or local I O station up to 2000 feet 600 meters from the CPU Multiple Bus Controllers can be placed in one rack Since each Bus Controller consumes 20 units of load up to 5 modules can be placed in a CPU rack or modules in a high capacity I O rack A Bus Controller can be placed in an I O rack in a Remote I O station if the CPU scan time is greater than 10 ms However because of the reduced capacity of the serial I O communications link window commands would not be supported Each Bus Controller can interface up to 30 Genius I O blocks to the Series Six Plus CPU by twisted pair communications up to 2000 feet 600 meters The only limit to the number of Bus Controllers in any one PLC system is the I O capacity of the Series Six Plus CPU Each Bus Controller similar to any I O module has access to all I O references on its I O chain A 4 segment DIP switch located on the module is used to enable channel selection for Expanded I O addressing If Normal non expanded addressing is u
92. CPU 3 Reset the I O Control board Arithmetic Control board and the Logic Control board Ensure that the Logic Control to Arithmetic Control ribbon cable is securely connected 4 Ensure that there are no I O address DIP switches with all open positions This is an illegal address and conflicts with the Workmaster window 5 f reseating does not solve the problem replace the above boards one at a time in the order given above e Memory Parity error on initial power up On the Workmaster computer select the main Utility menu Then select the CLEAR PARITY soft key F7 Follow the screen prompts to clear the parity error For more detailed information on start up procedures refer to Chapter 3 Installation e DPU light not on I O Control module and DPU is not connected Check 1 Control module board option jumpers Jumper should be connected from A to B ALARM RELAY The CPU can be monitored at a location remote from the CPU by connecting an alarm device buzzer light etc to the alarm relay output terminals on the CPU power supply The alarm contacts on the power supply terminal board are shown below in figure 5 5 70tmp11 ways away 8 lel i o 2 ES GROUND 6i a sRouNo AS APPLICABLE AC SOURCE INPUT DC SOURCE INPUT Figure 5 5 CPU POWER SUPPLY TERMINAL BOARD Troubleshooting and Repair 5 19 GEK 96602
93. Channel E Aux 1 0 chain Channel F Aux I O chain LMM Mailbox Required register for LMM 1 through LMM 16 Expanded CPU Operation 4 11 GEK 96602 DYNAMIC USER MEMORY CHECKSUM The Expanded Il function set is provided through selection of the Logic Control module option IC600CB515 An important feature of this function set is the user program memory checksum The purpose of this checksum is to provide more data integrity within the user program memory This user program checksum will trap certain types of data errors not caught by memory parity checking Specifically the error conditions to be caught through this checksum are an even number of bits changed in memory and stuck address lines Memory Checksum Calculation During normal operation the CPU can detect when the logic memory has been altered by an external device such as Logicmaster 6 etc When it has sensed that the memory has been changed the CPU will begin to calculate a checksum by starting at memory location 00000 and working its way through all logic memory The checksum is the 16 bit sum of all the words of logic memory in the CPU Each time that the internal executive routine is run in the CPU 64 words of memory are summed Since there can be a maximum of 64K words of logic memory it is not possible to complete the entire checksum in one scan Therefore the checksum will take a maximum of 1024 scans to be calculated When the CPU completes the calculation it
94. Closed Contacts Real World Output Coils Internal Coils Latches One shots Timing 0 01 1 and 1 0 Second Increments Counting up and down Auxiliary I 0 References ARITHMETIC Addition Subtraction Unsigned Binary Compare Shift Double Precision Addition Subtraction Signed 2 s Multiply Divide Complement Greater Than CONTROL Master Control Relay and Skip Do Subroutine Do I 0 Suspend 1 0 Return Status MOVE CONVERT Data Moves I 0 Table to Register Register to I O Table Table To Destination Source To Table Move Table Move Table Extended Move Right 8 Bits Move Left 8 Bits Block Move Move A To B Convert Binary to BCD BCD to Binary Introduction To The Series Six Pius PLC GEK 96602 Table 1 3 PROGRAMMING FUNCTIONAL GROUPS Continued ADVANCED FUNCTIONS Cont 1 COMM REQUESTS DPREQ SCREQ MATRIX AND Inclusive amp Exclusive OR Invert Masked Compare Set Sense Clear Sense Bt Shift Right Shift Left LIST Add to Top Remove from Bottom Remove from Top Sort MISCELLANEOUS End of Sweep NO OP EXPANDED FUNCTIONS RELAY All Advanced Functions plus Valid Reference Range Expanded for Full 32K I 0 Points an additional 68K of discrete references and 16K Registers ARITHMETIC All Advanced Functions plus Floating Point Functions Add Subtract Multiply Divide Greater Than Integer to Floating Point Floating Point to Integer CONTROL All Advanced Functions plus
95. D notation Binary A numbering system that uses only the digits 0 and 1 This system is also called base 2 Bit The smallest unit of memory be used to store only one piece of information that has two states for example a One Zero On Off Good Bad Yes No etc Data that requires more than two states for example numerical values 000 999 will require multiple bits Bus An electrical path for transmitting and receiving data Byte A group of binary digits operated on as a single unit In the Series Six Plus PLC a byte is made up of 8 bits CHECK Light An LED indicator on the Arithmetic Control module which when on indicates that the execution sequence is normal and the self test routine has passed at least once every 200 milliseconds 50 milliseconds CMOS An acronym for Complementary Metal Oxide Semiconductor A read write memory that has a low power consumption but requires a battery in order to retain its content upon loss of power CPU Central Processing Unit The central device or controller that interprets user instructions makes decisions and executes the functions based on a stored program This program specifies actions to be taken to all possible inputs A 2 Appendix A Glossary of Terms GEK 96602 CPU Station An I O system consisting of a maximum of 10 I O racks daisy chained on the parallel I O bus through the I O Control module or Auxiliary V O module in Auxiliary chain to a
96. ECEIVER CABLE SPECIFICATIONS Length Maximum 10 000 Feet 3 Kilometers Two Individual Shielded Twisted pairs 22 AWG Minimum 15 pf foot Maximum Cable Type National Electric Cable Co 22P1SLCBT or equivalent Connector Driver and Receiver End D Subminiature Type Cannon DBC25P with 207908 7 Hood or equivalent connector and hood Figure 3 20 REMOTE I O TWISTED PAIR CABLE DATA SET DATA TERMINAL 70111 SHIELD TRANSMIT DATA RECEIVEDATA SIGNAL GROUND CLEARTOSEND CARRIERDETECT MARK SPACE OPTIONAL REMOTE 140 MODEM DRIVER OR RECEIVER CABLE SPECIFICATIONS Length Maximum 50 feet 15 Meters Overall Shield 24 AWG Minimum Connector Driver or Receiver End D Subminiature Type Cannon DBC25P with 207908 7 Hood or equivalent Connector Modem User selected Figure 3 21 REMOTE I O CABLE FOR RS 232 MODEMS Installation Instructions 3 27 GEK 96682 POINT SELECTION After I O racks have been installed cables run and AC or DC power cables connected the racks are ready for installation of I O modules The I O module starting I O point reference numbers should now be programmed by setting the DIP switches on the rack backplane adjacent to the connectors Refer to figure 3 22 as a guide to configuration of the DIP switches for 8 circuit modules The I O point number selected is the first of eight consecutive I O points one I O address starting with that number For m
97. EE format The display for the Floating Point Arithmetic Functions is in decimal scientific notation as shown in figure 4 5 234567412 Two digitsf exponent Sign of exponent Six least significant digits Decimal point Most significant digit 1 Sign of entire number 2 Figure 4 5 FLOATING POINT ARITHMETIC DISPLAY FORMAT 1 Will only be zero 0 when all digits are zero 2 The plus sign is implied and not displayed The minus sign will always be displayed Floating Point numbers are stored in two consecutive registers as shown below R 1 R 15 0 15 0 sign fi f23 8 bit exponent 23 bits of mantissa Valid Number Format The display format requires a total of 12 character spaces and is limited to 7 significant digits With 7 digits any valid number can be stored in the 32 bits 2 registers allocated for floating point numbers A number greater than 7 digits does not conform to the IEEE 4 22 Expanded CPU Operation GEK 96682 32 bit format and is considered to be not a number The references to infinity refer to the limits for numbers that may be operated on These limits are 3 402823 38 An attempt to exceed these limits will be interpreted by Logicmaster 6 software as an overflow Programming Floating Point Arithmetic Functions All of the Floating Point functions are entered on the programmer using Logicmaster 6 version 3 01 or later software When en
98. EIVER TO NEXT 1 0 RACK REMOTE 1 0 115 230 VAC 24 VDC OR 125 VOC DRIVER MODULE TO 1 0 RACK IN REMOTE 1 0 STATION 10 000 MAXIMUM OR RS 232 MODEM TO NOTE GREATER DISTANCES 10 RACKS MAXIMUM ON DAISY CHAIN 1 0 TRANSMITTER AND REMOTE 1 0 DRIVER CAN BE PLACED IN ANY SLOT IN AN 1 0 RACK EXCEPT THE LEFT SLOT WHICH MUST BE AN 1 0 RECEIVER ADVANCED 1 0 RECEIVER OR REMOTE 1 0 RECEIVER AS APPLICABLE SERIAL CHANNEL 2 PAIR TWISTED CABLE Figure 5 10 1 0 RACK I O RACK CONFIGURATION 5 30 Troubleshooting and Repair GEK 96602 7013 FROM CPU OR PREVIOUS 1 0 RACK PARALLEL BUS TWO TWISTED PAIR SERIAL CABLE TO 10 000 3KM IF A l6 PAIR OR REMOTE TWISTED CABLE CABLE FROM MODEM 5 232 LINK STATION 1 0 RECEIVER OR ADVANCED 1 0 RECEIVER 115 230V E 24 VDC TO NEXT R 125 VDC 1 0 RACK IN DAISY CHAIN WIRING TO FROM EXTERNAL DEVICES WIRING TRAY CONTAINS WIRING TERMINAL ASSEMBLY MATCHING COVER ATTACHES BOX LUG TERMINALS 2 0 14 AWG OR 1 0 12 AWG WIRE PER TERMINAL REMOTE 1 0 RECEIVER IF FIRST RACK IN A REMOTE 1 0 STATION Figure 5 11 TYPICAL I O RACK WIRING SCHEME Troubleshooting and Repair 5 31 GEK 96602 SUGGESTED TROUBLESHOOTING SEQUENCES Many problems are first identified by the failure of an input or output to operate properly It is important in the initial stages of troubleshooting to take an overall look at the problem The first step should be to check the condition
99. ENABLED Default Y to enable the minimum Genius I O diagnostics for everything except the diagnostic tables For no Genius I O diagnostics enter DIAGNOSTIC TABLES Default Y to cause a Bus Controller Status Bit Map to contain the locations of Bus Controllers that have reported errors In addition a Point Status Bit Map will specify any real I O points that indicate failures by a block point or Bus Controller fault For no Genius I O diagnostics tables enter B C POINT FAULTS Default N to cause Bus Controller errors to tell the CPU to set all 208 input and 208 output point fault bits associated with that Bus Controller to a 1 The user must exercise caution when referencing any of these points since all will be set to a 1 following a Bus Controller f ailure If all blocks are assigned to addresses within the same 256 register segment as the Bus Controller then a fault of the Bus Controller equals a fault of all I O If all addresses are not assigned as above this feature should not be used Expanded CPU Operation GEK 96602 CPU CONFIGURATION MENU DEFINITIONS Continued GENIUS I O cont DIAGNOSTIC RANGE LIMIT The range by channel pairs of the diagnostics Range 0to 7 Default 7 which is 8 pairs of channels to be checked CPU REGISTER SIZE Enter the exact register size of the CPU 256 Currently not compatible with Genius diagnostics 1024 can be represented by entering a 1 8192
100. Fault Table Pointer Input Data From Bus Controller Selecting Addresses for Diagnostic Data Storage Bus Controller Status Byte 2 Address 0 Input 1 Bus Controller Status Byte 1 Address 0 Input 2 Bus Controller Status Byte 1 Address 0 Inputs 3 4 5 6 Bus Controller Status Byte 1 Address 0 Input 3 Bus Controller Status Byte 1 Address 0 Input 4 Bus Controller Status Byte 1 Address 0 Input 5 Bus Controller Status Byte 1 Address 0 Input 6 Bus Controller Status Byte 1 Address 0 Input 7 amp 8 Fault Table Registers Register 1 Genius I O Bus Controller Address Decoding Register 2 Register 3 Register 4 and 5 Register 5 Upper Byte and Register 6 Register 7 Registers 8 9 10 Bus Controller Output Data Output 1 Bit 0 Definition Disabled Outputs Output 2 Bit 1 Definition Clear Faults Output 3 Bit 2 Definition Clear Circuit Fault Output 4 Bit 3 Definition Pulse Test Output 9 Bit 0 of Byte 2 Definition Circuit Type XIII PAGE Ek I NN RARAHRAHAAA 1 Nm NNOO A N lt CO CO CO CO CO AOO 1 xiv Contents GEK 96682 CONTENTS TITLE CHAPTER 4 EXPANDED CPU OPERATION Continued Point Status Bit Map Bus Status Control Byte Location Input Status Definitions Output Control Definitions Computer
101. IGHT CPU POWER SUPPLY Status Definition ON The voltage levels of all 3 dc outputs V 121 12 are present and within the specified tolerance One or more of the voltage levels is out of tolerance The CPU RUN and ENABLE status indicator lights should also be off Alarm Number 1 switches Troubleshooting and Repair 5 7 GEK 96602 Corrective Action Check the power supply voltages by partially pulling out the power supply module and measuring the voltages The voltages are checked at the terminal board assembly TB1 located at the top of the power supply board The connections are labeled as shown below WIRES FROM THE BACK PLANE WILL BE MARKED a41075 5 9 OR 5V 9 PSTB 7 OR OV B 5 5 OR 12V 5 PSTB 4 OR 12V 4 ToBAcKPLANE AC source input shown If power supply is a dc source input terminals 1 and 2 are labeled POS pin 1 and NEG pin 2 SSSR Figure 5 2 POWER SUPPLY OUTPUT VOLTAGE TERMINALS TB1 Voltage Range 5 V de 4 75 to 45 25 V dc 12 V dc 11 40 to 412 60 V dc 12 V dc 11 40 to 12 60 V dc Check the P1 connections on the CPAX board in the power supply module NOTE A printed circuit board backplane or cable short may be loading down the power supply If a dc voltage is found to be out of tolerance back out all printed circuit boards and then recheck the voltage If it is still bad replace the power supply If the voltage is OK reinsert the pr
102. INPUTS Sink Input mode Input Input data is inverted Input data 15 not inverted High Hold last State Density OFF Disable Outputs when required Output Output Data Inverted OFF Output Data is not inverted mz mz mz mal GEK 96602 Troubleshooting and Repair 5 23 Table 5 4 1 0 MODULE STATUS INDICATOR DEFINITIONS Continued MODULE Analog Input Analog Output Reed Relay Output Interrupt Input Thermo Couple Input 1 0 Receiver 1 0 Transmitter INDICATOR STATUS BOARD OK BOARD OK TEN E OFF through 8 BOARD ON OK OFF CHAIN OK CHAIN PARITY LOCAL PARITY CHAIN OK CHAIN PARITY ISOLATED POWER FAULT ENABLE CHAIN ACTIVE DEFINITION Module operating normally A D converter malfunction 1 0 rack power supply problem CPU in Stop or Run Disabled mode Module operating normally Board malfunction 1 0 rack power supply problem CPU in Stop or Run Disabled mode Relay coil is energized Relay coil is de energized Current flowing through input circuit Module operating normally Board malfunction Power is OK in this and all downstream racks and stations Continuity is OK to all downstream stations Output parity is OK at all downstream stations connected through an I 0 Transmitter in this rack Output parity good at this module Power is OK at all downstream stations Continuity OK to all downstream stations All dow
103. K DESCRIPTION BUS ERROR 2 CIRCUIT FAULT 3 BLOCK SWITCH FAILED LOSS OF BLOCK 4 DISCRETE SWITCH FAILED ADD OF BLOCK 5 OVER TEMP ADDRESS CONFLICT 6 NO LOAD OPEN WIRE PULSE TEST ACTIVE 7 RT C ae FORCED CIRCUIT 8 INPUT 9 LOSS OF POWER 0 INPUT HIGH ALARM CIRCUIT REFERENCE 17 26 INPUT LOW ALARM OUTPUT OVERRANGE OUTPUT UNDERRANGE FAULT TYPE CIRCUIT NO 33 36 37 40 0 BLOCK INPUT OPEN WIRE DISCRETE INPUT OVERRANGE 2 ANALOG INPUT UNDERRANGE CHANNEL NUMBER FAULT DESCRIPTION 41 48 Available when using Bus Controller without diagnostics Figure 4 6 BUS CONTROLLER INPUT STATUS REFERENCE DEFINITION Bus Controller Status Byte 1 Address 0 Input 2 BUS ERROR This input reference is an indication of serious bus errors detected by the Bus Controller The input is normally in the OFF state It is set On by the following two conditions 1 If the Bus Controller receives ten or more messages with incorrect CRC codes within a 10 second period the input will be set ON for one CPU scan If more than ten errors are received in the next 10 second period the input will again turn ON If this input continues turning ON for one scan every 10 seconds it is an indication of excessive CRC errors coming from a device on that bus If the Bus Controller does not get its turn on the bus at least once every 100 ms this input stays ON for at least one scan t turns OFF only after the Bus Controller has been able
104. L 7 POINT 1024 GENIUS 1 0 DIAGNOSTICS ENABLED Y Y N DIAGNOSTICS DIAGNOSTIC TABLES Y Y N B C POINT FAULTS N Y N DIAGNOSTIC RANGE LIMIT 7 0 7 CHANNELS CPU REGISTER SIZE 16 384 REGISTERS FAULT TABLE LENGTH 8 ENTRIES BUS STATUS CONTROL BYTE LOCATION 993 COMPUTER MAIL BOX ENABLED N Y N B C XPNDED 1 MAP 2 3 4 5 6 7 8 FUNCS 4 14 Expanded CPU Operation GEK 96602 Making Entries on the CPU Configuration Set Up Page The CPU Configuration Set Up Menu is used to enable Expanded I O scan Genius I O diagnostics and the Computer Mail Box Entries made on this page change the program file in system memory They do not change the user program in the CPU If the system is in On Line or Monitor mode changes are made to the program logic only If the system is in Off Line mode changes are made to the logic and the table data To edit this display move the cursor to the item you want to change and type in the new value Refer to the definitions that follow for more information Cancelling Entries to the CPU Confiquration Set Up Menu To cancel entries and return to the Expanded Functions menu press the Abort key The screen displays PRESS CONFIRM TO ABORT ANY OTHER KEY TO PROCEED Press the Confirm key to return to the values that were displayed when the page was entered Press any other key to cancel the abort CPU CONFIGURATION MENU DEFINITIONS Refer to the following definitions when changing the CPU Conf
105. LY CONTROL MODULE ARITHMETIC CONTROL MODULE RIBBON CABLE CONNECTS ARITHMETIC CONTROL TO LOGIC CONTROL MOUNTING BRACKETS SEE BELOW AND HARDWARE EXTRACTION INSERTION TOOL TERMINATION PLUG INSTALLATION AND Figure 2 2 BASIC CPU RACK CONFIGURATION FOR THE SERIES SIX PLUS PLC 6830 124 2m RACK MOUNT Figure 2 3 BRACKETS IN POSITION Figure 2 4 BRACKETS IN POSITION FOR RACK MOUNTING FOR WALL OR PANEL MOUNTING 2 4 Physical Equipment Configuration 96602 POWER SUPPLY FOR THE SERIES SIX PLUS PLC The rack power supply is mounted at the extreme right of the rack as shown in the illustration in figure 2 2 The power supply provides regulated 12 12 and 5 V dc to the rack backplane It is used to power the GE Fanuc supplied modules contained in the rack Input and Output field devices must be supplied with their own source of power at the proper voltage levels The power supply is a high capacity supply and is available for the 19 rack in three versions wide range ac 24 V dc or 125 V The 13 rack requires the wide range ac supply The current capacity of each power supply is 275 units of load Each unit of load corresponds to approximately 60 mA of current consumption The ac power supply catalog number IC600PM500 is a wide range switching supply that will accept an ac input ranging from 95 to 260 V ac at 47 to 63 Hz The two dc power supplies that are available can be
106. M Complimentary Metal Oxide Semiconductor Random Access Memory CMOS is a fast low power memory that can be easily examined read and changed written However it is volatile in that it can lose its content if power is removed To avoid reloading memory and losing counts and system status every time power is turned off the CMOS memory is provided with a Lithium Manganese Dioxide battery to maintain its content not system operation when power fails Due to the low power drain of CMOS technology a single new lithium battery can maintain memory without application of power for up to 1 year The battery is not used when power is applied and the system is operating normally Its storage or shelf life is typically 8 to 10 years A dynamic user program memory checksum is available when the Expanded ll Logic Control module option is selected The user program checksum feature provides more data integrity within the user program It traps certain types of errors not caught by memory parity checking 1 12 Introduction To The Series Six Plus PLC GEK 96602 Function of the Input Output Circuitry The final element of a PLC is the Input Output section Electrical noise sudh as spikes on the power lines inductive kickback from loads or interference picked up from field wiring is very prevalent in industrial applications Since the CPU operates at relatively low voltage levels typically 5 volts this noise would have serious impact on it
107. Mail Box Using the Computer Mail Box to Communicate With Genius I O Bus Controllers Operation of the Computer Mail Box Communication Window Opens Register R Bus Controller Address Command Data Registers Register R 1 Operation Read or Write Register R 2 Communications Status Register R 3 Target Block Start Address Register R 4 Mailbox Address for Data Register R 5 Data Buffer Length Data Registers Command Verification Terminating Computer Mail Box Communication Using the DPREQ Function to Communicate With Genius I O Typical DPREQ Operation Contents of First Register Contents of Second Register Contents of Third Register Contents of Fourth Register Contents of Fifth Register CHAPTER 5 TROUBLESHOOTING AND REPAIR Introduction Minimum Downtime Logical Troubleshooting Troubleshooting Replacement Module Concept Isolate the Problem PAGE Contents xv GEK 96602 CONTENTS TITLE PAGE CHAPTER 5 TROUBLESHOOTING AND REPAIR Continued Section 1 Central Processing Unit Troubleshooting Fault Isolation and Repair Check Condition of Status Indicator Lights Check Position of Key Switches Battery Light Out Alarm Relay Section 2 System Troubleshooting Troubleshooting the I O Rack Power Supply Indicator Chart l O Rack Connections Suggested Troubleshooting Sequences Examples of Intermittent Fault Conditions amp Causes Troubleshooting with the Advanced I O Receiver Module Example of Determining the Outp
108. NOTE If at any time when the CPU is switched to the RUN mode it drops out of RUN on a memory parity error most likely the communication ports are locked out To reset the ports turn the RUN STOP keyswitch to STOP power down the CPU and power up again If you are using a Workmaster computer with the parallel version of Logicmaster 6 software proceed with the following steps 1 2 Boot up the Workmaster computer Display the SUPERVISOR MENU Turn the keyswitch to OFFLINE and connect the cable from the Workmaster computer to the CPU Select the US V function with the F6 key and clear the Logicmaster memory while in that function by selecting the F5 CLEAR key Return to the SUPERVISOR MENU and go to the Scratch Pad by selecting the F4 key Set the Scratch Pad values for Logic Memory and Register memory size to match the memory actually installed in the CPU Again go to the L S V function and store the blank program nothing in memory to the CPU by selecting the F2 key and following the instructions on the screen Return to the Supervisor menu and select the UTILITY FUNCTION Menu by selecting the F8 key From this menu select the CLEAR PARITY function with the F7 key and follow the screen instructions Turn the CPU RUN STOP keyswitch to RUN The CPU should be cleared of any memory parity errors at this time If you are using a programming device other than the Workmaster industrial computer start up procedures are simila
109. O modules must not exceed the remaining current capacity CAUTION Do not exceed any of the following limits 1 The total current capacity units of load of each supply 5 1 2 and 12 V dc 2 The sum of units of load for all supplies must not exceed 300 units Installation Instructions 3 29 GEK 96602 The available units of load for each module Table 3 6 Table 3 6 SUMMARY OF UNITS OF LOAD FOR CPU RACK MODULES CATALOG MODULE UNITS OF LOAD 1 NUMBER DESCRIPTION 5 v 12 v 12 v IC600CB524 Arithmetic Control 30 IC600CB525 Logic Control Advanced 12 zs 600 526 Logic Control Expanded 12 IC600CB515 Logic Control Expanded II 12 ES 600 503 I 0 Control 17 2 IC600CB513 Auxiliary I 0 Control IC600LX605 Logic Memory 24 6001 612 Logic Memory 24 1 166001 616 Logic Memory 24 1 6001 624 Logic Memory 24 a 1 166001 648 Logic Memory 24 m 1 6001 680 Logic Memory 24 1 IC600CB516 Communications Control CCM2 17 4 4 IC600CB517 Communications Control CCM3 17 4 4 IC650AELOOO0 LAN Interface Controller Board 20 2 IC650AEMOTO LAN Interface Modem Board 17 16 2 1 For 5 V dc 1 unit of load 60 mA 300 mw of power For 12 V dc 1 unit of load 25 mA 300 mw of power For 12 V dc 1 unit of load 25 mA 300 mw of power to be located in the CPU rack are listed in 3 30 Installation Load Capacity for an I O Rack T
110. O station The Remote Receiver does not require an I O address Before ingalling a Remote Receiver module several jumper plugs on the printed circuit board must be configured to be compatible with the Remote l O Driver to which it is connected The jumper locations are arranged on the board in groups of three pins and are identified by the center pin If direct connection to the Remote I O Driver is to be through a serial two twisted pair cable at a distance up to 10 000 feet 3Km the end of this cable at the Remote I O station should be connected to the top connector If connection is to be through an RS 232 modem link a cable not to exceed 50 feet 15 meters in length should be connected from the top connector to the modem in the Remote I O station If there is to be more than one I O rack in the Remote station the next downstream rack in the daisy chain will connect to the bottom connector using 16 pair parallel chain cable This cable will in turn connect to an I O Receiver in the next rack If the rack containing the Remote Receiver is the only rack in a Remote Station terminate the lO chain signals by configuration of jumpers on the Remote Receiver printed circuit board For detailed information on jumper configuration refer to the Remote I O module data sheet GEK 83537 Parallel l O Chain Cables Cables may be ordered in standard lengths for interconnection between racks on the parallel chain The maximum cable
111. PU during its normal operation or self checking 2 18 Physical Equipment Configuration GEK 96602 Type of Memory Used The Combined Memory modules useCMOS RAM integrated circuit memory as the storage devices CMOS RAM is an integrated circuit memory that uses low power CMOS RAM memory is volatile i e its contents are lost under no power conditions In order to maintain the contents of memory when power fails or is turned off a Lithium Manganese Dioxide battery usually referred to as a Lithium battery is provided as a power back up forthese devices The Lithium battery is located on the module along with circuitry to monitor the batteries voltage level Battery Status Indicator The Lithium battery catalog number IC600MA507 provides about 1 year of data protection under no power conditions One of the 2 LEDs on the board is an indication of the battery condition This LED is labeled BATTERY With power applied to the CPU the LED w ill be ON if the battery condition is normal The normal fully charged voltage of a Lithium battery is 2 95 V dc 1 00 amp hours If the battery voltage is low between 2 55 V and 2 75 V the LED will flash When this happens the battery should be replaced as soon as possible The CPU will continue running if the battery voltage is low If the CPU stops it can be restarted If the battery voltage drops below 2 55 V the LED will turn OFF If the CPU stops it cannot be restarted under t
112. Programmable Control Products Archive Document This electronic manual was created by scanning a printed document then processing the file using character recognition software Please be aware that this process may have introduced minor errors For critical applications use of a printed manual is recommended Series Six Plus Programmable Logic Controller User s Manual GEK 96602A November 1987 GFL 002 Warnings Cautions and Notes as Used in this Publication 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
113. Receiver The function of the I O Receiver figure 2 24 is to connect the 1 0 chain parallel bus to the I O modules an I O rack O racks are connected in a station grouping of I O racks by linking 1 Receivers together through a 16 pair twisted cable No more than 10 racks can be connected in a station A linking of racks in this configuration is referred to as a daisy chain The total cable length in a daisy chain originating from the 1 Control module in a CPU station or the originating I O Receiver in a Local I O station can be no more than 50 feet 15 meters s6840113 uU d EE uri gun Li jp B TIT d T i iil rmi 14 1 P1 D Type 37 Pin Connector to 5 CHAIN PARITY Light Upstream I O Receiver Advanced 1 0 On Output parity is OK at all Receiver I O Transmitter I O downstream stations which are Control or Remote 1 0 Receiver connected through an 1 0 Module Transmitter in this rack 2 J1 D Type 37 Pin Connector to Off There is an output parity error at Downstream Receiver Module one or more of these stations 3 Locations C1 and D1 6 LOCAL PARITY Light Jumper pack or DIP shunts are On Output parity is OK at this module installed in these locations Off This module has detected an 4 CHAIN OK Light output parity error On Power is OK in this and all 7 Locations F3 and F4 downstream racks and stations DIP SHUNT and JUMPER PACK and continuity is OK to all Sockets
114. Reserved for future use 6 Reserved for future use Read analog status all analog inputs from a block Contents of Third Register The third register is loaded with a number by the CPU to indicate the status of the DPREQ The register should initially be cleared to zero and will be loaded by the CPU at the end of each scan when a status is available The content of this register as loaded by the CPU can be 0 Not accepted The CPU or Bus Controller is busy with the previous DPREQ 1 operation is in process but not completed 2 Operation has been completed successfully 12 The operation has been terminated due to a syntax error in the DPREQ registers 20 Other error Any errors that are involved in executing the command such as communications timeout NAK internal Bus Controller error etc 4 46 Expanded CPU Operation GEK 96682 Contents of Fourth Register If the second register contains a 2 it will read the configuration of the I O block or Bus Controller specified in the fourth register The content of the fourth register is an I O reference to indicate the starting location of the desired I O block or Bus Controller The register must contain a value between 1 and 993 which must be a valid I O address Three devices can be addressed discrete I O blocks analog I O blocks and the Bus Controller Each device requires a different number of registers to store the configuration data in a 16 bit
115. S Physical Equipment Configuration 2 53 GEK 96682 Remote System Response Time The response time of a Remote I O system is slightly delayed because of the distance when using up to the 10 000 foot 3Km maximum cable length The response time is delayed further when connection to the Remote I O is made through the communications link using modems Part of the delay is due to the fact that the Remote I O Driver stores output and input data and provides this data when needed to the Remote I O Receiver and the CPU This store and forward technique results in a one sweep delay NOTE A one sweep delay for inputs can be avoided if a DO I O instruction is executed for the Remote I O prior to executing any logic using remote inputs System response times to the Remote I O for each of the valid baud rates are summarized in table 2 16 The times as listed are approximate maximum response times and may vary slightly from system to system These response times are due to hardware considerations related to communications between a Remote I O Driver and a Remote Receiver component tolerance cable length etc Table 2 16 TYPICAL SYSTEM RESPONSE TIMES TO REMOTE Quantity of I O in Block 120 1 0 Output Delay Input Delay 248 I O Output Delay Input Delay 1 1 sweep for all baud rates 2 2 sweeps for all baud rates REMOTE I O ADDRESSING A Remote I O system normally responds to a block of
116. S 2 SLOT OPTION Figure 2 1 PRODUCT STRUCTURE FOR SERIES SIX PLUS PLC Each of the modules shown in figure 2 1 is described on the following pages The descriptions include information relative to module location in the rack and the function of each module in the system For installation instructions refer to Chapter 3 2 2 Physical Equipment Conf igutation GEK 96692 19 Inch CPU Rack Configuration The 19 inch 483 millimeters rack used to contain the Series Six Plus PLC modules is designed for either 19 inch rack or panel mounting Figure 2 2 is an illustration of the rack Each rack is supplied with reversible mounting brackets for mounting as required by the user With the brackets attached to the front of the rack as shown in figure 2 3 the rack can be mounted in a standard 19 inch rack By rotating the brackets 90 degrees and mounting them on the rear of the rack as shown in figure 2 4 the rack can then be either wall or panel mounted Each rack has 11 slots to accommodate modules For reference purposes these slots are numbered from 1 through 11 beginning at the right slot next to the power supply The slot number is printed on the rack backplane adjacent to the bottom board slot Slots 6 through 11 can contain I O modules Any module in the I O system can be placed of these slots as long as their total power requirements in addition to the power requirements of the CPU modules do not exceed the power output
117. U mode Restrictions regarding the use of two ports in different modes are given in the section Simultaneous Port Operations in the CCM3 Supplement GEK 90505 2 26 Physical Equipment Configuration GEK 96602 Communications Control Module 1 0 CCM The CCM catalog number IC600BF948 is a communications module for use as an additional communications interface between the CPU in a Series Six Plus PLC and external devices The I O CCM should be used when the primary communications module CCM2 or CCM3 has both ports committed and additional ports are required for an appl icat ion The I O CCM has two ports labeled PORT 1 and PORT 2 for asynchronous serial communication at data rates from 300 to 19 2K baud using CCM master slave or peer or RTU slave only protocol Unformatted read and write can also be used Both ports support RS 232 and RS 422 In addition Port 1 also supports active or passive 20 mA current loop The two ports can be independently configured by module hardware The I O CCM does not support STR LINK tape recorders the Operator Interface Unit or port configuration from registers However it can interface to most other devices and perform the same tasks as the CCM2 and CCM3 modules The CCM must be inserted in a high capacity I O rack or an I O slot in a Series Six Plus CPU rack Detailed information on the I O CCM can be found in GEK 90824 which is the data sheet for the Input Output Communicat
118. U racks and can be either rack or panel mounted Two 13 racks can be mounted side by side in a NEMA 12 wide rack Each rack is supplied with reversible mounting brackets for mounting as required by the user With the brackets attached to the front of the rack it can be mounted in a standard 19 or 13 rack as applicable By rotating the brackets 90 and mounting them on the rear of the rack the rack can then be wall or panel mounted 9 81pc51 1 0 SERES aQ aN ap ef aQ 5 0 0 o 1 7 Position DIP Switch 10 Per Rack 5 I O Power Supply 2 41 Pin Connector 11 Per Rack 6 Terminal Board 3 Logic Power On Off Circuit Breaker 7 Tray For Containing Field Wiring 4 Power On Indicator 8 Cardguide 11 Per Rack Figure 2 18 TYPICAL RACK 2 30 Physical Equipment Configuration GEK 96602 Each 1 rack provides regulated dc power and backplane signals from the power supply for modules and is available in three versions ac standard and ac or dc high capacity 13 rack requires the high capacity ac supply The difference being the total current supplied from the power supply A standard I O rack provides adequate current for modules for most applications When an application requires I O modules that collectively would draw more than 6 1 amps a high capacity rack must be used Table 2 10 RACK AND POWER SUPPLY SPECIFICATIONS Rack Dimensions
119. ULE The Logic Control module contains the CPU system clock a microprogram sequencer and Programmable Read Only Memory PROM It provides timing and control signals to the CPU backplane for use by other modules and microprogram instructions to the Arithmetic Control module through a ribbon cable The time base for the timer functions in the PLC are derived from a crystal clock on this module PROM memory on the module is programmed with an instruction set which is accessed by the CPU when executing the user programmed instructions The Logic Control module also contains circuitry which allows the CPU to access all 16K of Register memory Three versions of the Logic Control module are available the difference being the level of the instruction set contained in each one The Advanced Logic Control module catalog number IC600CB525 contains instructions that are accessed by the CPU to allow execution of the basic and advanced functions The Expanded Logic Control module catalog number IC600CB526 contains instructions in PROM that are accessed by the CPU in order to execute the basic advanced and expanded functions The Expanded II Logic Control module catalog number IC600CB515 contains all of the instructions that are on the Expanded Logic control module In addition it provides a dynamic user program memory checksum calculation for enhanced memory checking has microcode changes to allow faster execution of ladder logic programs contains new
120. a power supply failure or a break in the I O cable When this module is used with CPU software level 105 or above relay logic can also be used to address the problems of input and output parity errors If any of the advanced diagnostics are to be used an Input and Output address must be selected by setting two sets of DIP switches located on the board The Inputs provide status information to the CPU relative to the Advanced I O Receiver The state of the output data is controlled by CPU relay logic programmed by the user Any valid I O address can be selected The Input and Output addresses do not have to be the same however identical addresses can be selected In many applications it is desirable to allow the user program to decide whether the CPU should stop on an I O system error or continue to run under controlled conditions This module allows that decision to be made decision can also be made to select a particular chain usually the chain that contains the fault to be shut down while allowing the balance of the system to continue to run The Advanced l O Receiver module provides status information accessible to the CPU user program indicating where in the I O system an error occurred and what type of error it was Using this information the CPUlcan be programmed to respond in a controlled manner based upon the type of error detected Errors sensed by this module include input and output parity power supply fail ure and I O cab
121. a total of either 120 inputs and 120 outputs or 248 inputs and 248 outputs jumper selectable be located in a Remote I O station The first and last rack in a Remote I O station daisy chain can be separated by no more than 50 feet 15 meters of cable In addition to the racks on the daisy chain an I O Transmitter located in a rack in the Remote I O station can be the first in a link of I O Transmitters connecting to additional groupings of racks An I O Transmitter can be connected to the first rack in a group of racks by a 16 pair parallel cable with a length up to 500 feet 150 meters Up to four links can be connected in this manner thereby extending the Remote I O station an additional 2000 feet 600 meters NOTE The total number of I O points assigned to a Remote I O station either 120 120 I O or 248 248 I O cannot be exceeded regardless of the rack configuration A Remote I O station connects to an upstream I O rack in either a CPU station Local l O station or to an I O slot in a CPU rack The connection is made through a serial communication channel by a two twisted pair shielded cable or through an RS 232 compatible modem link The system interface module in the CPU rack the CPU I O station or Local I O station is a Remote I O Driver and the system interface module in the Remote I O station is a Remote I O Receiver The serial communications link to the Remote I O station can be up to 10 000 feet 3 Km using a two twist
122. ach successive bit to the left is a location that is 64 greater since each Bus Controller must be on a 64 bit 8 byte boundary The leftmost bit in each channel represents location 961 Each bit with a value of 1 represents a Bus Controller location in the I O system To change the value of a bit 1 Use the cursor keys or the Return key to move the cursor to the bit 2 Press the Insert Delete Bus Controller F2 key to change the bit Cancelling Changes to the Bus Controller Map To exit and restore the values that were displayed when the page was entered press the Abort key The screen prompts PRESS CONFIRM TO ABORT ANY OTHER KEY TO PROCEED Press the Confirm key to exit or press any other key to cancel the abort 4 18 Expanded CPU Operation GEK 96602 DISPLAYING AND CLEARING GENIUS 1 0 FAULTS As faults occur in any of the Genius I O blocks they are written through the Bus Controller to the Genius I O fault table in the CPU Through the previous menu the location of the Bus Controllers was defined and the fault table length was specified The following pages explain how to access and display the fault tables define the items on the fault table and how to clear any of the recorded faults Displaying The GENIUS 1 0 Fault Table The Genius 1 0 Fault Table display shows the Genius 1 0 faults Faults are shown in order of occurrence with the first fault at the top The table can only be displayed if the current program incl
123. ack Grounding There are 2 important requirements for grounding Series Six Plus CPU l O and associated peripheral racks 1 Safetv Ground This connection should be made from the GND terminal or the rack powe supply directly to system earth ground The purpose of this connection is to provide a guaranteed current path to ground in case a malfunction occurs within the rack or the rack is incorrectly wired Figure 3 13 illustrates recommended wiring for the rack safety ground a41 056 CONNECT A SHORT SERIES SIX PLUS AND DIRECT SAFETY CPU RACK GROUND WIRE FROM OR THE G GROUND SERIES SIX TERMINAL TO VO RACK GROUNDED PANEL OR CABINET __ SCREW OR BOLT Figure 3 13 RACK SAFETY GROUND WIRING Installation Instructions 3 17 GEK 96602 2 Signal Ground All racks that are grouped together as a CPU I O station or a Local station MUST have a common ground connection This is especially important for racks in the same I O station which are not mounted in the same control cabinet If this situation exists the control cabinets MUST be tied together using the shortest possible connect ions NOTE If racks in a CPU or Local I O station are distributed among several control cabinets that cannot be directly tied together it is recommended that I O Transmitter modules be used to communicate between these cabinets The GND terminal of the rack power supply should not be used as the Signal Ground connection between racks The best
124. ack in a CPU station or Local I O station racks separated by no more than 500 feet 150 meters be connected from an I O Transmitter through a 16 pair cable to an I O Receiver or Advanced I O Receiver in the first O rack of a chain of no more than ten racks A total of four Local I O stations can be connected in this manner however the last Receiver can be no more than 2000 cable feet 600 meters from the originating CPU Physical Equipment Configuration 2 37 GEK 96602 A Remote I O system allows I O racks to be located up to 10 000 feet 3 km from any rack in a CPU station or a Local I O station by direct cable connection A Remote I O Driver placed in a slot in a CPU station or Local station is connected through a two twisted pair serial cable to a Remote I O Receiver located in the left slot of a remote station Any number of Remote I O Drivers and Remote I O Receivers can be used in a system Up to 243 inputs and 248 outputs can be located a Remote I O station Additionally a CPU station or Local station can be connected to a remote station at distances greater than 10 000 feet 3 Km by using a communications fink consisting of RS 232 modems CPU I O Station The CPU I O station as illustrated in figure 2 21 consists of a Series Six Plus CPU with up to 10 I O racks The racks are daisy chained on the parallel I O bus to the I O Control module with the last I O rack located physically no more than 50 feet
125. activated In the STOP mode scanning is halted and outputs deactivated MEMORY This keyswitch is used to allow user memory to be PROTECT WRITE written to new program entered or existing program KEY SWITCH edited when in the WRITE position When in the MEMORY PROTECT position the user memory can not be accessed This is a safeguard against unauthorized or inadvertent changing of the user program POWER LIGHT This is a visual indicator that the dc voltages provided by the power supply are available and have reached their proper operating levels The LED is viewed through the translucent lens on the faceplate ON The voltage levels of the 3 dc outputs 5 12 and 12 V dc are available and are within the specified tolerance OFF One or more of the 3 dc voltages is out of tolerance TERMINAL BLOCK A terminal block is mounted at the bottom of the power supply faceplate Two groups of 7 screw terminals are located on the block These terminals provide the connections for the source of power either ac or dc 2 sets of alarm relay contacts and an external auxiliary battery The auxiliary battery is optional and is used to provide battery back up of the CMOS RAM memory on the combined memory module 2 6 Physical Equipment Configuration GEK 96602 Terminal Block Connections Figure 2 6 is an illustration of the terminal block The 3 bottom terminals on the right group of terminals are for connecting the input
126. address is recorded in the Scratch Pad CPU Flags Corrective Action e Turn the CPU RUN STOP key switch to STOP and power down the CPU then power up the CPU and observe the CPU SCRATCH PAD data on the Workmaster computer Turn the CPU RUN STOP key switch back to RUN e f the CPU does not go into the RUN mode at this time the parity error is still present and the logic memory will have to be restored using the Workmaster computer e Turn the key switch on the Workmaster computer to OFF LINE e Go to the Supervisor Display activate the LOAD STORE VERIFY function and LOAD a back up copy of your program into the Workmaster computer e f you want to send all of the tables 1 0 Registers Overrides and logic ladder diagram to the CPU leave the Workmaster computer key switch OFF LINE If you want to send only the logic turn the Workmaster computer to ON LINE You must transfer the part of memory that has the fault e STORE the program in the CPU memory e f the parity error still exists replace the Combined Memory module ReSTORE logic memory again as explained above e Also do the CLEAR PARITY ERROR function from the Utilities Menu if SP or TT Scratch Pad or Transition Table parity errors are seen Do this by going from SUPER to UTIL F8 to CLEAR PARITY F7 Troubleshooting and Repair 5 15 GEK 96602 11 BATTERY LIGHT LOGIC COMBINED MEMORY MODULE Definition ON Battery condition is normal 2
127. addresses to the RPU Program References for the I O Transmitter Module If the Expanded mode is enabled the module uses the references listed below If Expanded mode is disabled the module operates without the additional diagnostics and does not use any I O references Channel Return Status Memory Locations MAIN I O CHAIN AUXILIARY I O CHAIN Channel Location Channel Location 0 11017 11024 8 R128 high byte 1 R256 high byte 9 R1280 2 R384 A R1408 3 R512 B R1536 4 R640 C R1664 5 R768 D R1792 6 R896 E R1920 7 R1024 F R2048 Expanded Addressing for a System with an RPU Formerly the Redundant Processor Unit was required to use input 11024 outputs 01017 01022 01023 and 01024 and registers R254 256 Referring to the list above you can see that there is a conflict with the channel status return memory locations for channels 1 and 2 Using channel 0 or 1 results in information from the I O Transmitter module on that channel being written into references assigned to the RPU To avoid this conflict a system with Expanded I O addressing should use the enhanced version of the RPU Installation Instructions 3 1 GEK 96602 CHAPTER 3 INSTALLATION INSTRUCTIONS FOR THE SERIES SIX PLUS PROGRAMMABLE LOGIC CONTROLLER INTRODUCTION This chapter contains information which will aid in installing the Series Six Plus Programmable Logic Controller and preparing the system for use Included are
128. al 1 0 is mapped into Registers 1 128 references AO0001 AO1024 and 10001 11024 References O8 0001 08 1024 1840001 1841024 cannot be used as real I O references but are available for use as discrete programming references Channel 1 7 real 1 0 references are for the Expanded Main 1 0 Channels Channel 9 1 0 references are for the Expanded Auxiliary I O Channels cR ON 2 36 Physical Equipment Configuration GEK 96602 lO SYSTEM CONFIGURATION A Series Six Plus PLC I O system can be configured as 3 types of interconnected I O groupings of racks referred to as stations The 3 systems stations are described in the following pages I O racks are connected by interface modules located in the CPU or I O racks Interfacing is through the parallel bus channel using a 16 pair shielded cable for CPU I O stations and Local stations Interfacing to the Remote station is through a serial communication channel using a 2 pair shielded cable or an RS 232 modem link The number of I O racks and modules a system is determined by the number of I O points required by the application The maximum number of I O points in a system is determined by the mode of operation either NORMAL or EXPANDED and the number of selected channels in the system Each I O rack contains a power supply an interface module and up to 10 additional modules The station configuration will be shown in detail in the illustration in
129. al mode with Advanced functions only can be plugged into any Local I O station This scheme allows the programming device to be located up to 2000 feet from the CPU Each 1 0 rack in the Local I O station can have the same combination of modules as the I O racks in CPU station The illustration shows configurations for 19 racks 13 racks can contain a total of 8 modules 16 PAIR PARALLEL CABLE FROM 1 0 TRANSMITTER AT CPU STATION a41072 LOCAL 1 0 STATION OR SERIES SIX PLUS CPU poz ii a e e e i i 1 0 RACK OR ADVANCED 1 0 RECEIVER 10 1 0 MODULES NOTE UP TO FOUR LOCAL 1 0 STATIONS CAN BE INCLUDED IN A SYSTEM WITH THE LAST ONE BEING NO MORE THAN 2000 6000 METERS FROM THE CPU 1 0 RACK MAXIMUM OF 50 ON 9 DAISY CHAIN 1 0 MODULES IG PAIR PARALLEL CABLE TO LOCAL 1 0 STATION 500 MAXIMUM 8 1 0 MODULES B TA EEE 2 PAIR SERIAL CABLE TO REMOTE 1 0 STATION 10 000 MAXIMUM OR RS 232 MODEM LINK MAXIMUM OF 10 TO REMOTE 1 0 STATION 1 0 RACKS ON DAISY CHAIN 6 PARALLEL CABLE t TO LOCAL 1 0 STATION 500 MAXIMUM i SOEUR 232 TURN RESET RAE Figure 2 22 LOCAL 1 0 STATION 2 40 Physical Equipment Configuration GEK 96682 Remote I O Station A Remote I O station consists of I O racks connected in a daisy chain through the parallel bus A combination of I O modules with
130. and 09 are cleared by an external device A recalculation of the checksum when the CPU is restarted is desired if a Logic Memory board is replaced and the CPU is then restarted Normally the CPU should be left in PROTECT which allows the checksum feature to catch any memory changes that occurred while the CPU was powered down 4 12 Expanded CPU Operation GEK 96602 CONFIGURATION OF EXPANDED FUNCTIONS THROUGH LOGICMASTER 6 SOFTWARE In order to configure the Expanded Functions a Workmaster computer CIMSTAR I computer or an IBM PC PC XT or PC AT Personal Computer with Logicmaster 6 applications software version 3 01 or greater is required for programming This is required to enable configurable features which include expanded Genius diagnostics expanded time reference and the computer mail box Each of these configurable features can be selectively enabled and configured for its range of operation The required configuration is automatically entered into the first 24 words of the CPU user memory as it is selected and entered from a configuration menu The first word of memory location 0000 must be programmed by the user with the SERIES SIX CONFIGURATION DATA instruction Standard features included with the expanded functions that do not require configuration include expanded discrete and register references the Window function and floating point arithmetic An improved basic compare instruction has been added which allows
131. and counter functions are associated only with the O and AOreferences Internal Discrete Reference Memory Allocation The internal discrete references l O states for Channels 0 through 7 which can be used for program references but are not available to real world inputs or outputs are mapped into Registers R2049 through R3072 The internal discrete references for Auxiliary channels 8 through F are mapped into Registers R3073 through R4097 for systems having 8K or 16K of registers Expanded Mode I O References Table 2 11 is a list of Expanded Mode l O point references for each channel and their memory location There is a total of 66K of discrete references supported by the Series Six Plus PC These references include 4K in the Main and Auxiliary I O chain I Al AO 30K of real I O and 32K of internal references when in the Expanded mode Any reference that is not used as a real I O point can be used for internal reference or retentive data storage registers Physical Equipment Configuration 2 35 GEK 96602 Table 2 11 POINT REFERENCES AND REGISTER MAPPING FOR EXPANDED MODE OPERATION REAL I O POINTS INTERNAL DISCRETE REFERENCES REGISTER I O REFERENCE REGISTER I O REFERENCE 0001 00001 A01024 AUX R2049 00 0001 00 1024 R0065 1 AI1024 AUX R2113 10 0001 10 1024 R0129 01 0001 01 1024 M R2177 01 0001 01 1024 R0193 11 0001 11 1024 A R2241 I1 0001 I1 1024 R0257 02 0001 02 1024 I R2305 02 0001 02
132. ards you and LEDs and connectors to the left The jumper configuration and definitions are indicated in the following table To change a configuration move the jumper plug to the correct pins Jumpers should be configured to conform to the requirements for a particular application Table 3 2 V O CONTROL OPTION JUMPERS JUMPER POSITION DEFINITION DPU Present DPU Not Present DPU Fault Trips Alarm No 1 and Alarm No 2 CPU Stops DPU Fault Trips Alarm No 2 Provides an Advisory Indication Communications Control Fault Trips Alarm No 1 and Alarm No 2 CPU Stops Communications Control Fault Trips Alarm No 2 Provides an Advisory Indication The I O Control connects to an I O Receiver or Advanced I O Receiver in the first I O rack in a CPU I O station through a 16 pair parallel cable Location of the 3 jumpers on the lower part of the board is shown below 41076 1814 JUMPERS Figure 3 10 O CONTROL MODULE JUMPER LOCATION Installation Instructions 3 13 GEK 96602 Auxiliary 1 0 Module The Auxiliary O module is available as an option and is required if an Auxiliary I O chain is to be included a Series Six Plus PLC system The Auxiliary I O module can be used in either a Series Six Plus CPU rack or in a Series Six model 6000 CPU rack When used with the Series Six Plus PLC in the Expanded mode of operation up to 8000 Inputs and 8000 Outputs are availa
133. aster slave communications In the multi drop configuration one CCM2 or host device is configured as the master and one or more 25 are configured as slaves only the master slave protocol can be used The GEnet Factory LAN Local Area Network is a Local Area Network through which many devices can be connected A Bus Interface Unit BIU allows Series Six Plus PLCs to access the GEnet Factory LAN and can support a maximum of 4 CCM2s By using multiple BIUs a maximum of 254 Series Six Plus PLCs with CCM2s can be connected to the network User Items The CCM2 requires 1 slot in the Series Six Plus PLC rack and must be installed in slot 5 At the top of the module are 2 switches used during communications with a STR LINK or STR LINK Ill tape recorder The 2 connectors on the board are both capable of RS 232 and RS 422 operation Jis 25 pin D type female connector and J2 is a 9 pin D type female connector If a STR LINK tape recorder is to be used it must be connected to the J1 connector Four LEDs on the board viewable through the faceplate lens are indicators of the operating state of the module Table 2 9 is a description of the indicators Figure 2 14 is an illustration of the CCM2 module Table 2 9 CCM2 STATUS INDICATOR DEFINITIONS INDICATOR STATUS DEFINITION BOARD OK ON Board has passed power upest and is operating properly FLASHING Invalid configuration or CPU number OFF Power up test failed indicating a hardwa
134. ating normally OFF Problem exists in this module if light never comes on LED test or stays off at end of test Corrective Action e Replace the Remote 1 0 Driver module Replace the Remote 1 0 Receiver module 9 Observe the LINK OK light on Remote 1 0 Driver and Remote I O Receiver modules Definition Status ON Option jumpers on both the Remote Receiver and Remote Driver are identical and a communications link is established between the two modules OFF Valid communications between Remote Driver and Remote Receiver not established Baud rates different serial parity sense different or some other option jumper not compatible Corrective Action e Verify that all common circuit board option jumpers are set identical on both boards Check cable connections at each end of link e f REMOTE OK and LINK OK lights turn off simultaneously check for a power down condition the Remote I O station rack containing the Remote I O Receiver Excessive noise on the link could also cause both lights to turn off Replace Remote 1 0 Driver module Replace Remote I O Receiver module Troubleshooting and Repair 5 35 GEK 96602 10 Observe the REMOTE OK light on Remote I O Driver and Remote I O Receiver modules Definition Status Remote I O Driver Valid I O data has been received from the Remote I O Receiver No I O faults in the Remote I O system Remote I O Receiver No I O
135. ation Series Six Plus Programmable Logic Controllers are used worldwide in an ever growing variety of applications Programmable Logic Controllers PLCs are also referred to as Programmable Controllers PCs In this manual in order to avoid any confusion we will refer to these electronic control devices as programmable logic controllers or PLCs since the use of the acronym PC is universally used when referring to Personal Computers WHAT ARE PROGRAMMABLE LOGIC CONTROLLERS Programmable logic controllers are general purpose microprocessor controls that have been designed specifically for operation in the harsh environment usually encountered in the factory A programmable logic controller accepts data from input devices such as limit switches proximity switches and sensors It then performs logical decisions in an orderly and repetitive sequence as determined by a program entered in memory by the user and provides output control for machines or processes Input modules convert electrical signals provided by the input devices to logic levels for processing by the Central Processing Unit CPU and Output modules convert signals from the CPU to the proper electrical signals for control of machines or processes The Input and Output I O modules also provide electrical isolation for signals in the CPU from electrical noise typically found in the factory environment Figure 1 1 is a basic block diagram of a programmable logic controller
136. ations Outputs and System Control Signals Power Supply Auxiliary Circuit Board Control Module User Connections Status Indicators User Configurable Jumpers Logic Control Module Arithmetic Control Module Status Indicators Combined Memory Module Logic Memory Function Register Memory Function Internal Memory Function Detection of Active Override in System Scratch Pad Items Type of Memory Used Battery Status Indicator Location in Rack Precautions When Handling Memory Modules Memory Protection Bus Controller Module Versions of Bus Controller Communications Control Modules Communications Control Module Type 2 CCM2 System Configuration User Items Communications Control Module Type 3 CCM3 CCM2 Mode CCM3 Remote Terminal Unit RTU Mode Dual Mode Usage Communications Control Module CCM Link Local Module Structure for the Series Six Plus PLC l O Racks LI i mi h q LI o M lA lA La S LI I I LI LI NNNNNNNNNNNNN COON OO OI O10 IO IO Contents GEK 96602 CONTENTS TITLE CHAPTER 2 PHYSICAL EQUIPMENT CONFIGURATION Continued l O Addressing Normal Mode I O Addressing Expanded Mode I O Addressing Channel Reference Numb
137. be off RUN and ENABLE lights at the CPU will be off and Alarm Relay 1 switches Corrective Action f status indicator 16 is OFF go to step number 16 If only status indicator 21 is OFF then the problem is intermittent and several causes must be investigated Typical Causes All in the I O Transmitter or Remote 1 0 Driver link 1 Someone momentarily shut off one or more O rack power supply switches then turned them back ON 2 Loss of power to one or more of the 1 0 racks for example utility drop in service or power below specifications 3 Loose power connections to the rack power supply or between the power supply and the I O rack backplane 4 Loose or damaged cable between 1 0 racks 5 Loose or damaged O cable connector on the 1 0 cable or on the connector the module to which it is connected Once the suspected cause has been determined correct it and push the RESET button on the Advanced I O Receiver or momentarily turn Output Byte Bit 2 ON then OFF 5 44 Troubleshooting and Repair GEK 96602 22 CHAIN OK LIGHT CHN OK CHN OK 16 22 DEFINITION ON Power and cable continuity is and has been OK in all 1 0 racks downstream from this Advanced I O Receiver since the last time that the Advanced I O Receiver was reset ON OFF An intermittent power or continuity problem was latched in from one or more of the I O racks connected to the lower connector of the Advanced I O Rec
138. be used to send messages which are destined to a single station or whose delivery must be guaranteed Introduction To The Series Six Plus PtC 1 21 GEK 96602 Global Data Service Global Data service is a proprietary real time protocol which provides a means of sharing data such as blocks of registers or I O points among a group of stations Once a request is initiated using a single SCREQ instruction data continues to be transferred at a rate specified in the request This service is not part of the MAP specification but co exists on the network with MAP messages without interference Global Data services should be used when the application requires that data must be updated on a periodic basis and shared by multiple stations on the network In distributed control applications it allows I O points wired to one PLC to be made available to other PLCs quickly and with minimum intervention by the ladder logic RS 232 to RS 422 Adaptor Unit The RS 232 to RS 422 Adaptor Unit converts RS 232 signal levels to RS 422 signal levels and can be used to isolate and repeat communications signals If a device uses RS 422 signal levels for communications the Adaptor when connected between those devices and devices requiring RS 232 signal levels can be used with no loss in baud rate The Adaptor unit also has a multidrop capability that can expand a normal eight device RS 422 link into a 64 device link by using eight Adaptor units If an RS 422 lin
139. before applying power Connect the alarm relay contacts to external alarm devices as required by system configuration Optional Installation Instructions 3 15 GEK 96682 CAUTION The user devices connected to each set of alarm terminals on the power supply module should present a resistive load drawing no more than one amp of current at 115 V ac or 28 V dc Failure to observe this caution may result in damage to the circuit board Connect the and Auxiliary Battery contacts to an external battery having a voltage from 6 to 28 V dc This is an option that will provide a back up to the memory back up battery mounted on each memory module CAUTION If a memory auxiliary battery is used the circuit connecting it to the power supply module should be isolated from the rest of the system If this caution is not observed the battery could be short circuited After these connections have been completed the protective cover plate should be carefully reinstal led WARNING Ensure that the protective cover is installed over the terminal boards During normal operation either 115 V ac or 230 V ac is present on the ac Power supply or 20 to 32 V dc or 100 to 150 V dc on the dc power supply The cover protects against accidental shorting of terminals which could cause damage to the machine or injury to the operator or maintenance personnel SYSTEM GROUNDING PROCEDURES components of a programmable control system and the
140. ble on the Auxiliary I O chain in addition to the 8000 Inputs and 8000 Outputs on the Main I O chain When used with the Series Six model 6000 CPU the maximum available I O is 2000 Inputs and 2000 Outputs A group of 4 DIP shunts must be inserted in one of two locations determined by which CPU the module is to be used with either Series Six Plus or Series Six model 6000 The Auxiliary module can be installed in slot 5 6 or 7 depending on whether or not the GEnet Factory LAN Series Six Network Interface 2 slot option is selected If the LAN communications option is not selected install the Auxiliary I O module in slot 5 The Auxiliary module connects to the first I O rack in a CPU I O station in the Auxiliary I O chain through a standard 16 pair parallel bus cable Communication Control Modules If a Communications Control Module either CCM2 or has been selected as an option it should be installed in slot 5 immediately to the left of the Combined Memory module There are jumpers or DIP switches on the Communications Control Modules which should be configured to set operating parameters for the module For complete details on configuration of any of the communications modules refer to the applicable manual as listed below CCM2 GEK 25364 Series Six Data Communications Manual CCM3 GEK 90505 Supplement to the Series Six Data Communications Manual 3 14 Installation Instructions GEK 96682 CPU Pow
141. board extraction insertion tool board puller Catalog IC600MA504 included with your Series Six Plus CPU should always be used when installing or removing a module The boards in the CPU require an insertion force of about 50 Ibs 22 68 Kg and the I O boards require about 25 Ibs 11 34 Kg Use of the extraction insertion tool should alleviate any problems of possible board damage which could be caused by hand insertion or removal Refer to figure 3 3 for identifying features of this tool a41115 BOARD PULLER BOARD SEATING RM LOGIC RACK NOTCH FLANGES TOP LOGIC RACK NOTCH BOTTOM iE HANDLE AREA NP sy gt lt BOARD PULLER ies BOARD PULLER LOGIC RACK FLANGE LOGIC RACK FLANGE TOP BOTTOM Figure 3 3 EXTRACTION INSERTION TOOL NOTE It is recommended that power to any rack be turned off before attempting to install or remove any printed circuit board Installation Instructions 3 5 GEK 96682 Inserting a Printed Circuit Board The following instructions should be followed when inserting a printed circuit board into its slot in a rack Grasp the board firmly with your hand and insert it into the cardguide Align the board with the connector s on the rack backplane and slide it towards the connector s until it has started to seat insert the board puller Logic Rack Notch Top into the short siot beside the top of the solder side of the board Insert the Logic Rack Notch Bottom i
142. bwheel Switch A rotating numeric switch which can be used for inputting numeric data to a PLC in the form of BCD digits Unit of Load An expression used to describe the load placed on a power supply by an I O module or a CPU module Also the amount of current or load capacity available from a power supply Unlatch A PLC function that causes an output previously turned on by a latch function to turn off no matter how briefly the function is enabled User Memory Term commonly used when referring to the memory circuits within the PLC used for storage of user ladder diagram programs Volatile Memory A memory that will lose the information stored in it if power is removed from the memory circuit devices Watchdog Timer A hardware timer within the PLC used to ensure that certain hardware conditions are met Used as a system check In the Series Six Plus PLC the duration of the watchdog timer is 300 milliseconds 50 milliseconds Word A measurement of memory length usually 4 8 or 16 bits long 16 bits for the Series Six Plus PLC Write To transfer record or copy data from one storage device to another Index G EK 96602 A ASCII BASIC module 1 17 Adaptor Unit 1 21 Addressing l O 2 31 2 33 Advanced I O Receiver 2 46 chain signal continuation or termination 2 44 illustration of 2 47 status and diagnostic indicators 2 48 troubleshooting with 5 39 to 5 49 Advanced functions 1 10 Alarm conditions 2 7 A
143. c of channels that have been enabled through the Configuration Menu In the Expanded I O mode only the Expanded I O channels that have been enabled will be scanned 2 In addition to the existing of discrete references supported by the Series Six PLC 0 AO an additional 62K of discrete expanded I O references are supported 30K real I O 32K internal I O 3 Configurable features Through Logicmaster 6 software release 3 01 and later the user can enable configurable features including the Expanded I O Genius VO diagnostics expanded time reference and the computer mail box 4 Seven function floating point arithmetic which includes floating point addition floating point subtraction floating point multiplication floating point division floating point compare integer to floating point conversion and floating point to integer conversion 4 2 Expanded CPU Operation 96602 5 Genius I O diagnostics Through user configuration the CPU maintains fault status image of the Genius 1 0 system Faults are reported and logged in the CPU then interpreted by Logicmaster 6 software 6 computer mail box is provided for communications with Genius I O Bus Controllers and intelligent modules 7 Window function An enhanced DPREQ function allows the user specification of channel address and COMM block 8 The DO I O function has been expanded to include the channel number for the start and end addresses
144. cations listed here or any other application you may have contact your local GE Fanuc NA Programmable Logic Controller Distributor GE Fanuc NA sales office or GE Fanuc Automation North America Inc in Charlottesville Virginia Table 1 7 TYPICAL PLC APPLICATIONS Railroad Switching Robots Rolling Routing Security Systems Sewage Treatment Energy Management Engines Engine Test Stands Extrusion Forging Gas Fields Auto Insertion Bagging Baking Bonding Boxing Capping Casting Cement Batching Combustion Control Compresslon Molding Conveyors Cranes Cutting Data Collection Dipping Drawing Drilling Gauging Generators Grinding Heat Treating Injection Molding Joining Milling Mining Operations Navigation Nuclear Plants 011 Fields Pipelines Solar Energy Sorting Spool winding Stackers Tire Body Building Traffic Control Treating Turbines Water Treatment Weaving Welding Well Flooding introduction To The Series Six Plus PLC 1 23 6 96602 TERMINOLOGY In the preceding discussion of Programmable Logic Controller concepts many terms were discussed that you should be familiar with relating to PLCs Table 1 8 provides a list of the most common PLC terms complete list of terms is provided in the glossary in the back of this manual Table1 8 COMMON PLC TERMINOLOGY TERM DEFINITION PLC Programmable Logic Controller or Programmable Controller An
145. cators 2 51 addressing 2 31 expanded mode 2 33 normal mode 2 33 blocks Genius I O 1 13 l O cable catalog numbers 2 64 channels 4 3 circuitry function of 1 12 1 0 interface modules Advanced l O Receiver 2 46 lO Receiver 2 43 Transmitter 2 49 Remote l O Driver 2 55 Remote l O Receiver 2 58 list of 2 42 module load 3 28 modules 1 12 modules table of 1 12 point DIP switch settings 2 32 l O point address switches illustration of 2 31 VO point selection 3 27 power supply 3 20 ac power source connections 3 20 dc power source connections 3 21 specifications 2 30 rack description of 2 29 interconnections 2 36 specifications 2 30 typical 2 22 3 19 references expanded mode table of 2 35 station 2 36 CPU 2 37 Local 2 39 Remote 2 40 definition of 2 36 structure 2 29 l O system cables parallel 3 24 3 25 l O system cables serial link 3 26 lO system configuration 2 36 3 19 INDEX system interface module installation 3 21 VO Receiver 3 22 Transmitter 2 49 3 22 4 2 Remote Driver 3 23 Remote l O Receiver 3 24 lO system troubleshooting 5 20 rack power supply 5 20 5 21 indicator chart 5 22 to 5 27 I O rack connections 5 27 to 5 30 intermittent fault conditions 5 37 suggested sequence of 5 31 CHAIN OK light 5 31 CHAIN PARITY light 5 32 FAULT ENABLE light 5 34 ISOLATED POWER light 5 33 LINK OK light 5 35 LOCAL OK light 5 34 LOCAL PARITY li
146. cause has been determined and corrected push the RESET button on the Advanced I O Receiver or momentarily turn Output Byte Bit 2 On then back OFF ON Troubleshooting and Repair 5 45 GEK 96602 23 POWER SUPPLY OK LIGHT CHN OK PS OK 16 DEFINITION ON Power and continuity is and has been OK in this I O rack since this Advanced I O Receiver was last reset ON OFF An intermittent power or continuity problem was latched in from the power supply or from loose connections in this I O rack OFF OFF A power or continuity problem exists now in this I O rack The CHAIN OK light on the CPU s I O Control module will be off the RUN and ENABLE lights at the CPU will be off and Alarm relay 1 switches Corrective Action Check the POWER light step 5 on the power supply in this rack and if it is OFF go back to step 5 If status indicator 16 is OFF go to step number 16 If only status indicator 23 is OFF then the problem is intermittent and several possible causes must be investigated Typical Causes In this 1 rack only 1 Someone momentarily shut off the I O rack power supply switch then turned it back ON 2 Loss of power to the 1 0 rack for example utility drop in service or power below specification 3 Loose power connections to the I O rack power supply or between the power supply and the I O rack backplane 4 Advanced I O Receiver module not seated correctly CAUTION Be careful not to touch any
147. ck requires a Remote I O Receiver Chain Signal Continuation or Termination Before installation of an I O Receiver in an I O rack it must be determined if the module is to be in the last rack of an I O station daisy chain or in a rack within the chain An I O Receiver as received from the factory is configured to continue the I O chain signals through the module toward the next I O Receiver in the chain If the module is to be the last I O Receiver in the daisy chain a jumper pack must be removed from its socket at location 01 and DIP shunts inserted into the sockets at locations C1 D1 When installed in these locations the DIP shunts will cause the I O chain signals to terminate Figure 2 25 shows the location of these jumpers 6840114 Factory Setting Last Rack in Daisy Chain Cont inues I O Chain Signals Terminates I O Chain Signals Figure 2 25 V O RECEIVER DIP SHUNT JUMPER RACK CONFIGURATION Physical Equipment Configuration 2 45 GEK 96602 If an I O Receiver should be removed from the last rack in a daisy chain and moved to a rack upstream the jumper pack and DIP shunts must be reconfigured to continue the I O chain signals Conversely if an I O Receiver is moved from a rack within the chain to the last rack in the chain the jumper pack and DIP shunts must be reconfigured to terminate the I O chain signals When a jumper pack is not inserted in location or the DIP shunts are not installed
148. cluded in this section for each I O station Rack Interconnections racks are interconnected in a system by using combinations of I O Receivers Advanced I O Receivers I O Transmitters Remote I O Drivers or Remote I O Receivers depending on the number of I O points required the grouping and location of the racks Racks are grouped together in either a CPU station a Local I O station or a Remote I O station depending on their physical location and distance from the CPU and from other racks Each I O rack requires a receiver which isolates the I O data cable from the backplane bus and performs error checking A receiver does not require an address and is normally inserted in the left slot however a receiver can be placed in any I O slot Two connectors are mounted on each receiver the top one is for incoming data andthe bottom one is used to forward datato a receiver in the next rack of an I O chain This method of linking I O racks together in a station is referred to as adaisy chain A group of I O racks in a daisy chain can have no more than 50 feet 15 meters separating the first rack from the last and there can be a maximum of ten I O racks in the chain The last rack in a daisy chain requires termination of the I O signals This is done by configuring the DIP shunts and jumper pack on the last I O Receiver module in the daisy chain Optionally the Workmaster computer can be connected to the bottom connector of the last r
149. computer or microprocessor based devices Color graphics terminals GEnet Factory LAN The CCM2 also provides an interface to the following devices STR LINK or STR LINK Ill tape recorder These recorders are used to facilitate recording or loading of CPU user s programs at the Series Six Plus PLC location The STR LINK tapes are interchangeable with PDT tapes handheld Operator Interface Unit OIU which allows an operator to monitor and modify the register contents of the CPU monitor and modify timers and counters and monitor modify and override Input and Output I O points Adumb terminal or printer The 2 is capable of initiating data transfers to and from any Series Six Plus PLC memory type including register tables input and output tables override tables scratch pad and user logic When a Series Six Plus CPU is connected through a CCM2 to a host computer or other device that is not a Series Six Plus PLC the user must either write or purchase the software necessary to communicate with the CCM2 STR is a trademark of Electronic Processors Inc Physical Equipment Configuration 2 23 GEK 96602 System Configuration Three types of system configurations are supported by the CCM2 point to point multidrop and GEnet A point to point configuration allows only two elements to be connected to the same communications line Using this configuration the CCM2 protocol allows either peer to peer or m
150. conds MS BYTE Fault Time Seconds Register 9 LS BYTE Fault Time Minutes MS BYTE Fault Time Hours Register 10 LS BYTE Fault Time Days MS BYTE Fault Time Hundreds of Days Figure 4 7 FAULT TABLE REGISTERS Register 3 The high byte of register 3 contains Bus Controller status byte 3 This byte contains the relative circuit number of the faulty circuit on the I O block with zero the top circuit lowest reference and 7 or 15 the bottom circuit If the fault is not a circuit fault this value will be zero Registers 4 and 5 Register 4 contains Bus Controller status bytes 4 and 5 The low bye of register 5 contains Bus Controller status byte 6 Registers 4 and 5 copy the Bus Controller status from input bytes 4 5 and 6 refer to figure 4 7 The Bus Controller with diagnostics uses six consecutive input addresses with the starting address selected by the user by configuring the DIP switch at the rear of the I O slot containing the Bus Controller Expanded CPU Operation 4 35 GEK 96602 Register 5 Upper Byte and Register 6 Register 5 Upper byte and register 6 contain a specific indication of the fault type copied from input byte 1 which is defined as shown in table 4 6 Table 4 6 FAULT TYPE DEFINITIONS BIT NUMBER DEFINITION 8 Bus Controller Fault Not OK 9 Error on Genius Communication Bus Upper Byte 10 Individual Circuit Fault of Fault 11 Loss of I O Block Register 5 12 Addition of I O Block 13 Conflict in
151. configuration 4 4 Expanded CPU Operation GEK 96682 CHANNEL NUMBER AUXILIARY CHAIN DIP SWITCH POSITION A dot indicates that a switch is in the OPEN position depressed to the left All other switch segments should be in the CLOSED position depressed to the right Figure 4 1 O TRANSMITTER DIP SWITCH SETTINGS FOR EXPANDED t O CHANNEL SELECTION Channel Reference Numbering The individual channels are numbered from 0 to F the Main I O chain channels are 0 through 7 and the Auxiliary I O chain channels are 8 through F The format for addressing I O in the Expanded mode must include either the prefix or a channel number except for channel 0 and 8 for channel 0 programming references use OXXXX and IXXXX for channel 8 programming references use AOXXXX and AIXXXX a real I O or internal I O reference identifier and the I O reference number This format is shown in figure 4 2 I C 0025 I Input I 0 Reference Number Output 1 0 Reference State Real 1 0 Channel Number 0 F 1 0 Reference Status Internal 1 0 Figure 4 2 EXPANDED I O REFERENCE FORMAT Thus for example the format for real world I O points for channel 3 in the Main I O chain is 1340001 to 134 1024 for Inputs and O3 0001 to O3 1024 for Outputs Each 1K channel requires 64 words of memory 64 words x 16 bits 1024 I O Note that although 1024 bits are available in each channel 0001 to 1000 are
152. ction Make sure that the output is not overridden Check wiring for that output Check for a blown fuse Reseat the output board Replace the output board 14 No outputs are functioning Corrective Action Make sure that the outputs are not overridden If an Advanced 1 0 Receiver is used in the I O rack make sure that it is set up to allow outputs to operate normally refer to Data sheet GEK 90771 If the problem is limited to 1 board Check the 1 point selection DIP switches Reseat the board Check terminal assembly wiring Check terminal assembly voltage Ensure it is proper for the module Replace the output board Replace the 1 cable OA RON o 5 38 Troubleshooting and Repair GEK 96602 e If one 1 0 rack has no functioning outputs 1 If outputs further up the I O chain towards the CPU function replace the 1 Receiver or Advanced 1 0 Receiver in this rack 2 Pull out all boards and reinsert at a time 3 Replace the 1 cable e f there are no functioning outputs in any of the 1 0 racks Check the condition of the CPU status indicator lights If any CPU status light is off troubleshoot that problem if all CPU status lights are on replace the 1 0 Control board in the CPU If problem is in the Auxiliary 1 0 chain and all CPU status lights are on replace the Auxiliary I O board in the CPU 5 Replace the 1 0 cable Bom 15 I O status change or override change during
153. d Retentive Coil A coil that will remain in its last state even though power has been removed Rung A sequence or grouping of PLC functions that control one coil One or more rungs form a ladder diagram Scan The technique of examining or solving all logic steps specified by the program in a sequential order from the first step to the last A 6 Appendix A Glossary of Terms GEK 96682 Serial Communication A method of data transfer within a PLC whereby the bits are handled sequentially rather than simultaneously as in parallel transmission Significant Bit A bit that contributes to the precision of a number The number of significant bits is counted beginning with the bit contributing the most value referred to as the Most Significant Bit MSB and ending with the bit contributing the least value referred to as the Least Significant Bit LSB Sol id State Electronic circuitry using only transistors diodes integrated circuits etc This circuitry has high reliability and low power consumption when compared to electro mechanical devices Storage Used synonymous with memory Terminator A device or load connected to the output end of a transmission line to terminate or end the signals on that line In the Series Six Plus PLC DIP shunts and jumper packs connect on board resistors which terminate the I O chain signals on an I O Receiver or Advanced I O Receiver if it is the last Receiver in any I O chain Thum
154. d Remote Receiver REMOTE ON Remote system is operating normally OK OFF Fault exists in Remote I O system Power supply failure cable loose module not seated properly etc REMOTE ON Remote system has no parity errors operation normal PARITY OFF Parity error detected in Remote I O system CPU will stop unless option jumper on this module is set for CPU to RUN when error detected Option Jumpers Several jumpers located on this module are used for configuration of various options necessary for system and module operation Table 2 20 lists the factory and alternate settings for the Remote I O Driver options Table 2 20 REMOTE I O DRIVER OPTION SETTINGS OPTION FACTORY SETTING OPTIONAL SETTING Block Size 120 Inputs 128 Outputs 248 Inputs 248 Outputs Baud Rate 57 6 Kb UserSelected Serial Yes 0dd Yes Even or No CPU Status on STOP CPU Allow CPU to RUN Communications Failure Remote I 0 STOP CPU Allow CPU to RUN Parity Error Communications Two Twisted Pair To RS 232 Modem Link Link 10 000 feet 3 Km 2 58 Physical Equipment Configuration GEK 96692 Remote I O Receiver The Remote I O Receiver module is the interface to the serial communications link for a Remote I O station It is physically located in the first rack in a Remote I O station normally in the left slot since the Remote I O Receiver does not require an I O address there is no DIP switch on backplane adjacent to the left slot A Remote I O
155. der diagram to find out why it is off or flashing e f light number 19 is ON as well as all the status indicators on the CPU then the fault which brought you to this step is most likely an intermittent fault Examine status indicators 20 through 25 on all Advanced I O Receivers to determine what the fault was 5 42 Troubleshooting and Repair GEK 96602 20 AM three of the status indicators ADDPAR DATPAR and OUTPAR deal with output parity ADDPAR and DATPAR indicate during which part of the output cycle the parity occurred OUTPAR is latched OFF if there is an error ADDPAR and DATPAR are reset if the CPU is running and will be ON DEFINITION Output parity is and has been OK in this rack since the Advanced I O Receiver was last reset gt GERM EN xi e NE cs OFF OFF OFF Output parity has been detected during the address part of the output cycle The CHAIN OK light on the CPU s I O Contro module will be off RUN and ENABLE lights at the CPU will be off and Alarm Relay 1 switches OFF OFF Output parity has been detected during the data part of the output cycle The CHAIN OK light on the CPU s I O Control module will be off RUN and ENABLE lights at the CPU will be off and Alarm Relay 1 switches OFF Intermittent parity was detected and latched but CPU retry corrected the parity error or CPU was restarted after output parity error shutdown and the OUTPAR light has not been reset since then
156. derstanding of the various indicator lights will usually quickly isolate the problem to the CPU rack an I O rack the programming device or any peripheral device in the system By use of the programming device which can be a Workmaster industrial computer CIMSTAR industrial computer IBM PC PC XT PC AT or Program Development Terminal PDT cannot be used with the Expanded functions in conjunction with the CPU troubteshooting of the program is easily accomplished Most inputs or outputs can be looked at and changed or overridden as required The GENIUS I O diagnostics provide a great deal of information about faults that may occur in the Genius I O system For use of the GENIUS I O diagnostics refer to Chapter 4 of this manual For complete information on GENUS I O hardware refer to the GENIUS I O System User s Manual GEK 90486 The total system must be considered when problems occur The CPU Workmaster computer PDT or other programming device Redundant Processor Unit I O modules GENIUS I O blocks and external devices connected to or controlled by the PLC must all be operating and connected properly All screw down or soldered connections should be checked carefully as well as all cable connections Troubleshooting procedures for the RPU and other peripheral devices can be found in the user s manual for the particular device 5 2 Troubleshooting and Repair GEK 96692 TROUBLESt300TING The troubleshooting and repair info
157. determined and corrected push the RESET button on the Advanced I O Receiver or momentarily turn Output Byte Bit 2 and then back OFF A link is made up of an 1 0 Transmitter module a 16 twisted pair shielded parallel bus 1 cable and one or more Receivers or Advanced O Receivers Appendix A Glossary of Terms 1 GEK 96602 APPENDIX A GLOSSARY OF TERMS Address A series of decimal numbers assigned to specific program memory locations and used to access those locations In the Series Six Plus the addresses can range from 0000 to a maximum of 65534 Analog A numerical expression of physical variables such as rotation and distance to represent a quantity AND An operation that places two contacts or groups of contacts in series All contacts in series control the resultant status ASCII An 8 level code 7 bits plus 1 parity bit commonly used for exchange of data which is the American Standard Code for Information Interchange Backplane A group of connectors physically mounted at the back of a rack so that printed circuit boards can be mated to them The connectors are interconnected by wire wrapping Baud A unit of data transmission speed equal to the number of code elements bits per second BCD Binary Coded Decimal A 4 bit system in which individual decimal digits 0 through 9 are represented by 4 bit binary numerals for example the number 43 is represented by 0100 4 001 1 3 in the BC
158. devices it is controlling should be properly grounded This is particularly important for two reasons as stated below 1 SAFETY CONSIDERATIONS A low resistance path from all parts of a system to earth minimizes exposure to shock in the event of short circuits or equipment malfunction PROPER EQUIPMENT OPERATION Some components of the Series Six Plus PLC system require a common ground connection between racks to guarantee correct operation Recommended Grounding Practices The following grounding practices are recommended to ensure proper operator safety and correct equipment operation when installing and using a PLC system 3 16 Installation Instructions GEK 96602 Ground Conductors 1 Ground conductors should be connected in a tree fashion with branches routed to a central earth ground point This ensures that no ground conductor carries current from any other branch This method is shown in figure 3 12 a41055 MOTOR DRIVES AND OTHER ELECTRICAL CONTROL EQUIPMENT SERIES SIX PLUS PC MACHINERY CENTRAL GROUND POINT EARTH GROUND Figure 3 12 PLC SYSTEM GROUNDING 2 Ground conductors should be as short and as large in size as possible Braided straps or welding cables AWG No 8 or larger can be used to minimize resistance Conductors must always be large enough to carry the maximum short circuit current of the path being considered Series Six Plus PLC Equipment Grounding R
159. e Check cable connections to each 1 0 rack Check for power on each I O rack For standard 1 0 power supplies if power indicator is off check the 5 V dc on the terminal board assembly by partially pulling out the Power Supply module Check voltage as in step 3 If the 5 V dc is out of tolerance replace the I O power supply If the power supply is a high capacity supply also check the 12 and 12 V dc terminals e Check CHAIN OK and CHAIN PARITY lights in the CPU station 1 0 racks 1 f any of the above status lights are off proceed to the 1 0 troubleshooting section 2 If all status lights are on replace the I O Control or Auxiliary I O module as applicable 5 10 Troubleshooting and Repair GEK 96602 5 PARITY LIGHT I O CONTROL AND AUXILIARY 1 0 MODULES Definition Status Input data parity is good at the I O Control or Auxiliary I O module OFF Input data parity error exists The CPU RUN and ENABLE lights are off Alarm Number 1 relay switches Corrective Action e Verify that no two input cards have the same address Turn the CPU Key Switch to STOP then power down and back up e f an input parity error is confirmed check Scratch Pad Display on the Workmaster computer which will give the address of the input board where the data originated Refer to GEK 25379 the Logicmaster 6 Programming and Documentation Software User s Manual for more information on the Scratch Pad e R
160. e S Thermocouple Input 29 Type T Thermocouple Input 29 Type B Thermocouple Input 29 Type E Thermocouple Input 29 Type R Thermocouple Input 29 High Speed Counter 19 Advanced I 0 Receiver 12 High Density Input 4 to 10 VdcAnalog Input 29 4 10 V dc Analog Input 29 4 to 20 m Analog Input 29 I O Transmitter 34 Remote I O Driver 38 10 24 V dc Sink Output 7 48 V dc Sink Output 7 115 V ac Output 9 230 V ac Output 9 12 V dc Sink Output 7 12 V dc Source Output 7 For 5 V dc 1 unit of load equals 60 mA 300 mw of power For 12 and 12 V dc 1 unit of load equals 25 mA 300 mw of power 12 V and 12 V current is less than 1 unit of load if RS 232 mode is not used Instructions Installation Instructions 3 31 6 96602 Table 3 7 SUMMARY OF UNITS LOAD FOR I O MODULES Continued CATALOG MODULE UNITS OF LOAD 1 NUMBER DESCRIPTION 5 v 12 v 12 v 600 908 24 V dc Source Output 7 600 909 48 V dc Source Output 7 1 600 910 115 V ac Isolated Output 8 IC600BF912 230 V ac Isolated Output 8 IC600BF914 Reed relay output 13 IC600BF915 Axis Positioning Module Type 23 IC600BF917 Axis Positioning Module Type 21 600 921 5 V TTL Output J IC600BF923 18 to 58 V dc Sink Output J IC600BF924 120 V dc Output 5 IC600BF929 10 to 50 V dc Source output 3 IC600BF930 115 V ac Protected Output 8 6008 941
161. e SHD terminal on their respective faceplates Ensure that good grounding exists between racks in that station no more than 7V between racks especially with intermittent faults Ensure that the low level I O cable has not been placed close to any high level power cables power supplies or switching devices especially with intermittent faults Turn the CPU key switch to STOP then power the CPU down and back up If an Input parity error was detected by the CPU then the second byte the center byte of the CPU flags will contain the address from which the parity error was received CPU flag decoding is done with the Workmaster computer through Logicmaster 6 software Troubleshooting and Repair 5 47 GEK 96602 e Determine the address of the Input board by observing the Scratch Pad CPU Flags and replace the Input board corresponding to the address shown in the Scratch Pad Replace the parallel chain I O cable between this rack and the next downstream rack connected to the bottom of this board e Replace this Advanced 1 0 Receiver module e Replace the I O Receiver or Advanced 1 0 Receiver module in the next downstream rack Reset the status indicators after your corrective action by momentarily pressing the RESET pushbutton on the Advanced Receiver module If only status indicator 24 INPAR is OFF then the problem is intermittent and several possible causes must be investigated Typical Causes In this 1 0
162. ector 9 pin D type position female connector for RS 422 and 10 Jumper JP8 Always set in 1 2 RS 232 position E LED Indicators 1 to 4 11 Jumper 6 1 2 position 1 DIP switch 1 to 8 Configuration disconnects 45 V from pin 20 2 3 selection for port J2 position connects 45 V to pin 20 2 DIP Switches 9 to 16 of port J1 Configuration selection for port J1 Figure 2 14 ILLUSTRATION OF CCM2 MODULE Physical Equipment Configuration 2 25 GEK 96602 Communications Control Module 3 CCM3 catalog number IC600CB517 provides all of the functions of the CCM2plus the protocol required to communicate with selected process control systems Physically the CCM3 is similar to the CCM2 Refer to the illustration figure 2 14 on the preceding page Options for baud rate protocol turn around delay and parity can be selected for the in the same manner as with the CCM2 by hardware using DIP switches and by software using configuration registers The primary difference between the two modules is in the software which for the CCM3 includes 2 modes of operation CCM2 mode and CCM3 Remote Terminal Unit RTU mode Information on the installation operation and protocol of the CCM3 can be found in GEK 90505 which is the Supplement To The Data Communications Manual CCM2 Mode When the is in the CCM2 mode the CCM3 operates the same as the CCM2 module except that the following protoco
163. ed in either the Normal I O mode or the Expanded 1 0 mode Selection of the mode is made through the Configuration Menu screen using Logicmaster 6 software In the Normal I O mode one I O chain per CPU is permitted this is the factory default setting In this mode available I O is 1000 Inputs l000 Outputs in the Main I O chain plus an additional 1000 Inputs l000 Outputs the Auxiliary I O chain if an Auxiliary l O module is included in the system The ON or OFF state of the 1 K Inputs and 1 K Outputs in the main I O chain is maintained in the I O Status Table The ON or OFF states of I O points in the Auxiliary I O chain are maintained in the Auxiliary I O Status Table which is mapped into the first 128 words of Register memory ROOO to R0064 contains the Auxiliary Output Table and R0065 to R0128 contains the Auxiliary Input table Expanded Mode l O Addressing When the Expanded l Omode is selected a total of 8K Inputs and 8K Outputs in the Main chain are available to the user In addition if the Auxiliary I O chain is selected requires an Auxiliary I O module 8K Inputs and 8K Outputs are available in the Auxiliary chain The total real I O available through the use of both chains is 16K Inputs and 16K Outputs 32K total points I O points in the Expanded mode are selected in 1 K tnputs and 1 K outputs increments referred to as channels An I O Transmitter module is required for each channel of I O with the exception t
164. ed pair cable With an RS 232 modem link the distance between local and remote I O is virtually unlimited NOTE A Remote I O Driver module cannot be installed a Remote I O station A Workmaster or Cimstar computer or PDT cannot be connected to a Remote stat ion Figure 2 23 illustrates a typical configuration for a Remote I O station The illustration shows how a Remote I O station can be extended an additional 2000 feet 600 meters by using I O Transmitters to connect additional racks to the parallel bus Physical Equipment Configuration 2 41 GEK 96602 a41073 SERIES SIX PLUS CPU 1 0 RECEIVER OR ADVANCED 1 0 RECEIVER CAN 0 5 CPU 1 0 STATION BE USED TO CONNECT RACKS IN A DAISY CHAIN C LOCAL 1 0 STATION 2000 MAXIMUM LINK MAX 500 MAX 500 MAX 500 MAX 500 1 0 1 0 1 0 1 0 RACK 0 RACK RACK RACK RACK SERIAL LINK 10 000 CABLE MAXIMUM ue 1 0 RS 232 MODEMS TEN 1 0 BUS CABLE RACKS o l 1 0 1 0 1 0 1 0 g RACK R RACK RACK RACK RACK i i i 1 REMOTE 1 1 STATION NOTE TOTAL 1 0 POINTS IN REMOTE STATION NOT TO EXCEED SELECTED BLOCK SIZE 120 120 1 0 OR 248 248 1 0 NOTE Total Points Not To Exceed Selected Block Size 120 120 1 0 or 248 248 1 0 Figure 2 23 REMOTE STATION CONFIGURATION 2 42 Physical Equipment Configuration GEK 96602 INTERFACE MODULES The 1 0 interface modules are used to connect 1 0 racks to the CPU
165. eiver and the CHN OK light has not been reset since then OFF OFF A power or continuity problem exists now in one or more of the I O racks connected to the lower connector of this Advanced I O Receiver CHAIN OK light on CPU s I O Control module will be off RUN and ENABLE lights at the CPU will be off and Alarm 1 relay switches Corrective Action e f status indicator 16 is OFF go to step number 16 e f only status indicator 22 is OFF then the problem is intermittent and several possible causes must be investigated Typical Causes In or more of the 1 0 racks connected to the lower connector of this Advanced 1 0 Receiver 1 Someone momentarily shut off one or more 1 0 rack power supply switches then turned them back ON Loss of power to one or more of the 1 0 racks for example utility drop in service or power below specifications Loose power connections to the 1 0 rack power supply or between the power supply and 1 0 rack backplane Loose or damaged 1 cable between 1 0 racks Loose or damaged I O cable connector on the 1 0 cable or on the connector on the module to which it is connected CAUTION Be careful not to touch any high voltage wires or connectors When in doubt unplug the power supply Try to force a failure by gently moving cables and connectors e Ensure good connections at all terminal boards and plug on wire connectors Be sure the wires are connected correctly Once the suspected
166. el number is set by the first three dip switches on the rack backplane In this way the I O data for each channel stays separated No I O cards Remote I O Drivers or phase A Bus Controller may be installed any I O slot that is not downstream of a decoding transmitter Any such device would receive data from all enabled channels Outputs would respond to all enabled channels and inputs would report back to all channels that scanned that address Phase B Genius Bus Controllers also have the capability of decoding I O channels and could be placed in a non decoded slot Once downstream of a transmitter with a channel selected all normal rules apply for cable length number of racks chain termination etc Any other Y8900C transmitters downstream should be set to normal I O mode Also no other transmitters could decode any other channel For example a transmitter in channel 0 could not be set for channel 1 The data for channel 1 is not present in channel 0 Examples of correct and incorrect configurations for expanded I O are shown in the following examples Installation Instructions 3 35 GEK 96602 a42208 VO XMIT SIX PLUS CPU SET TO SET TO EXPANDED EXPANDED MODE CHO MODE CH1 CHO titi tii tt SET TO NORMAL MODE Y Y CHO CH1 CH1 1 0 vo Figure 3 23 EXAMPLE 1 CORRECT CONFIGURATION Installation instructions 3 36 GEK 96602 SERIES SIX PLUS CPU 0 Em
167. elf test is passed at least once each 300 ms On CPU execution sequence is 50 ms CPU could be in RUN or proceeding the self test is STOP mode passed and the 1 0 scan is completed at least once each Off CPU self test has not been 300 ms 50 ms CPU is in RUN passed within 300 ms 50 ms or mode user program takes longer than 300 ms to execute CPU goes to Off CPU is in STOP mode STOP mode I O chain is reset Figure 2 11 ARITHMETIC CONTROL MODULE 2 16 Physical Equipment Configuration GEK 96602 COMBINED MEMORY MODULE AM of the Series Six Plus PLC memory configuration including Internal Register and Logic user memory is located on the combined memory module This module contains circuitry to perform memory parity checking in order to ensure the integrity of the 16 bit memory words in the Series Six Plus rack This module may be used in a model 60 CPU rack but the parity checking does not function The combined memory module is available in 6 versions which are 5K 12K 16K 24K 48K and 80K modules as shown in table 2 6 In addition the existing combined memory modules for the Series Six PLC model 60 can be used in a Series Six Plus PLC The faceplate for this module is labeled LOGIC MEMORY Table 2 6 COMBINED MEMOR Y MODULES CATALOG LOGIC NUMBER 1 MEMORY IC600LX605 REGISTER 12K IC600LX612 8K 16K IC600LX616 8K 24K IC600LX624 8K IC600LX648 IC600LX680 1 These memory modules are required with
168. elines Be sure that all cables are connected to the proper modules and are secure ALL limitations pertaining to distance between racks and stations must be followed otherwise unpredictable operation of the programmable control system may occur 5 28 Troubleshooting and Repair GEK 96602 a41059 STANDARD 1 0 CABLE 1 0 CONTROL SEU 20 MODULE a NOTE IF AUXILIARY 1 0 CHAIN REQUIRED CONNECTS TO AUXILIARY 1 0 MODULE IN SLOT 6 OR 7 CABLE LENGTH UP TO 50 FEET 1 0 Rn ADVANCED 1 0 RECEIVER 16 TWISTED CABLE DAISY CHAIN TO NEXT 1 0 RACK RECEIVER EXTERNAL ALARMS 1 0 95 260 es 24 VDC 0 RA 125 WoRKMASTER 115 230 VAC 24 VDC CPU OR AN 1 0 RACK OR IN A CPU STATION OR 125 VDC LOCAL 1 0 STATION NOTE 10 1 0 RACKS MAXIMUM ON DAISY CHAIN LAST RACK MAY BE NO MORE THAN 50 FEET FROM THE CPU IN A CPU STATION Figure 5 9 CPU 1 0 RACK CONFIGURATION Troubleshooting and Repair 5 29 GEK 96602 FROM PREVIOUS 155 1 0 RACK OR CPU P 1 0 TRANSMITTER MODULE RECEIVER OR ADVANCED 1 0 RECEIVER SOFT MAXIMUM BETWEEN FIRST AND LAST RACK IN A DAISY CHAIN 95 260 VAC 24 VDC OR 125 VDC PARALLEL BUS 6 TWISTED CABLE TO 1 0 RACK IN t LOCAL 1 0 STATION 1 0 500 MAXIMUM RECEIVER OR ADVANCED 1 0 REC
169. en an RPU is included in a system the I O chain or chains connects to the I O Switch module in the RPU rather then to the I O Control module Status Indicators There are 4 LED indicators on the front of the module viewable through the lens on the faceplate The LED indicators provide system status and are an aid to troubleshooting should a problem occur Table 2 4 l O CONTROL MODULE INDICATORS INDICATOR DEFINITION CHAIN ON when all stations in the main I O chain have OK continuity and have received good output parity PARITY ON when Input data parity is good ENABLED ON when the CPU is in the RUN mode with outputs enabled DPU ON when the optional Data Processor Unit is connected and operating properly NOTE With no I O chain connected to the I O Control module the I O Terminator plug supplied with each CPU must be connected to the bottom connector in order to terminate the I O chain Physical Equipment Configuration 2 11 GEK 96602 User Configurable Jumpers There are three sets of jumpers located on the module which must be configured during installation Two sets of these jumpers allow the option of selecting whether the CPU enters the STOP mode with Alarm 1 and 2 activated or with only Alarm 2 activated if there is a communications window fault during execution of a DPREQ Data Processor Request or a SCREQ Serial Communications Request window sequence The third set of jumpers allows selection of DPU p
170. en it is first powered up The following procedures when followed will clear any parity errors present in the CPU memory when starting up a CPU for the first time 3 32 Installation Instructions GM 96682 WARNING Unpredictable operation of the CPU may occur if the CPU is in the RUN mode with an uninitialized memory board Always place the CPU in the STOP mode when installing a new memory board 1 Install lithium battery on the Logic Memory module Before installing a memory module in a CPU rack the Lithium Manganese Dioxide battery must be connected These modules are shipped from the factory with the battery connector disconnected from the battery When connecting a battery the following procedure is recommended The battery mounting location is at the bottom front of the memory module on the component side of the module If the battery is not mounted firmly place it in the mounting clip with the cable end facing toward the battery connectors Connect the battery cable to one of the battery connectors The memory module is now ready for installation into the CPU rack CAUTION Relatively small amounts of excess charge can cause very intense electrostatic fields in metal oxide semiconductor MOS devices damaging their gate structure Avoid handling the circuit boards under conditions favoring the buildup of static electricity Failure to observe this caution could result in the destruction of the CMOS RAM devic
171. eplace the Input board corresponding to the address shown in the Scratch Pad e Replace I O cables connected to that 1 0 rack e Replace the I O Receiver or Advanced 1 0 Receiver in that 1 0 rack e Replace the I O Transmitter between that rack and the CPU e Replace the I O Control or Auxiliary I O module Troubleshooting and Repair 5 11 GEK 96602 6 ENABLED LIGHT 1 0 CONTROL and AUXILIARY 1 0 MODULES Status Definition CPU is operating in the RUN Outputs are enabled Enabled mode OFF Outputs are disabled CPU is in the Run Disabled or STOP mode If in the STOP mode the RUN light on the Arithmetic Control module is also off NOTE When CPU is in RUN DISABLED mode outputs are disabled but inputs are stil updated in the CPU status table Corrective Action Check the position of the CPU Run Stop key switch See step 1 Check the condition of other status lights PARITY CHAIN OK and POWER e f no other problem is indicated by other status lights try re enabling the CPU from the Workmaster computer or with the RUN STOP key switch 7 DPU LIGHT 1 0 CONTROL Definition Status The Data Processor Unit is connected and operating properly or DPU not connected and option jumper is connected on the board A continuity error or other type problem exists in the DPU OFF Corrective Action Check power to the Data Processor unit Check the power sup
172. er In addition the I O racks in a Remote I O station can be located up to 10 000 feet 3 km from a CPU or Local I O station when connected by a serial link through a 2 pair twisted cable For virtually unlimited distances between I O racks or the CPU and I O racks connection can be made through a serial communications link using RS 232 compatible modems Introduction To The Series Six Plus PLC 1 3 GEK 96602 Figure 1 2 is an illustration of a Series Six Plus Programmable Logic Controller showing the location of modules in the CPU rack I O and CPU racks are available as either 13 or 19 racks a4i 069 Figure 1 2 TYPICAL SERIES SIX PLUS PLC RACK Introduction To The Series Six Plus PLC GEK 96692 General Specifications General specifications for the Series Six Plus PLC are listed below Table 1 2 GENERAL SPECIFICATIONS Operating Temperature Storage Temperature Humidity Non Condensing AC Power Source Frequency 47 to 63 Hz Maximum Load 258 VA DC Power Source 20 to 32 V dc 24 V dc Supply Or 100 to 150 V dc 125 DC Supply Maximum Load 180 VA Rack Weight 19 Filled 37 lbs 17 kg Rack Dimensions 19 11 slots Rack Mount 19 0 W x 14 0 H x 10 3 0 inches 483 x 356 x 261 millimeters Panel Mount 20 0 W x 14 0 H x 10 3 D inches 508 x 356 x 261 millimeters Rack Dimensions 13 8 slots Rack Mount 16 0 W x 13 25 x 9 3 D inches 406 x 337 x 236 millimeters Rack Mount with Brackets for 19
173. er Supply The CPU power supply which is installed at the factory has 2 terminal boards located on the lower part of the faceplate Refer to figure 3 11 which is an illustration of the terminal boards and their connections Remove the protective cover and make the following connect ions 70tmp11 a41063 12 wmd Het 2 wo el wo e nmu uc 2 0 um 10 2 S iem e mu S m NE 100 TO 150 DC auc 0 croun 161 2NC eRoUND 161 AS APPLICABLE AC POWER SUPPLY DC POWER SUPPLY Figure 3 11 CPU POWER SUPPLY CONNECTIONS Provide the required power source for your system either 95V to 260 V ac for the wide range ac power supply 20 to 32 V dc or 100 to 150 V dc for the dc power supply AC power supply COnnections connect a 3 wire AC power cord to the 3 lower terminals of the terminal board on the right The power cord plug should have the proper pin configuration for either 115 V ac or 230 V ac CAUTION If the same ac power source is used to provide ac power to other racks in a Series Six Plus PLC system ensure that all ac input connections are identical at each rack Do not cross line 1 L1 and line 2 L2 A resulting difference in potential can cause damage to equipment DC power supply connections connect 3 wires from the DC power source to the proper terminals on the power supply These terminals are labeled POS NEG and GND Ensure that these wires are of the correct polarity
174. er flows out of the Window function only if the window address specified in the first reference is out of range of the configured expanded address or if the window fails Failure may be caused by Addressed device not responding timeout Addressed device sends bad header checksum Addressed device fails to close window timeout Entering a Window Function The Window function can be placed in columns 1 to 9 of a rung 1 Enter any logic required to control power flow to the function If the function is placed at the left rail it will execute unconditionally upon every sweep Select Advanced Mnemonic Group F7 then Control Functions F6 then Window F7 The DPREQ Window display appears ee e poses WINDOW ADDRESS COMM BLOCK The cursor is at ADDRESS Using the decimal keypad type in number of the reference It may be any reference type After entering the reference press the Enter key The cursor moves to BLOCK Enter the register that will store the communications block or computer mail box address It must be a valid register Press the Enter key Complete the logic for the rung then press the Accept key The Edit key functions reappear at the bottom of the screen 4 26 Expanded CPU Operation GEK 96602 USING THE DO I O FUNCTION TO ADDRESS 16K INPUTS AND OUTPUTS The DO I O function as programmed with the Advanced Functions required entering a start and end address for I O points on the Main o
175. ering Real Memory Allocation Internal Discrete Reference Memory Allocation Expanded Mode I O References lO System Configuration Rack Interconnections CPU Station Local I O Station Remote I O Station Interface Modules Receiver Chain Signal Continuation or Termination Module Connections Status Indicators Advanced l O Receiver Module Connections Signal Continuation or Termination Status and Diagnostic Indicators Transmitter Isolation Circuitry Location in Rack and I O Channel Addressing Status Indicators Configuration Jumpers Connector Remote I O System System Connections Remote System Response Time Remote I O Addressing Printed Circuit Board Jumpers Remote I O Driver Remote I O Driver Addressing Status Indicators Option Jumpers Remote I O Receiver Connectors Status Indicators Option Jumpers PAGE LI BWWOWWWWW Ow WO 1 1 1 P IO LI I ou TR A Ao 2 48 2 49 2 50 2 51 2 51 2 51 2 51 2 52 2 52 2 53 2 53 2 54 2 55 2 56 2 57 2 57 2 58 2 59 2 59 2 59 CHAPTER 2 CHAPTER 3 CONTENTS TITLE PHYSICAL EQUIPMENT CONFIGURATION Continued Auxiliary O System Workmaster Computer to Series Six Plus PLC Connections Workmaster to Series Six Interface Adaptor Boards Connection to I O Control or I O Receiver Modules Connection to an I
176. es Six Data Sheet Manual which contains technical descriptions specifications and wiring information on available modules Series Six Axis Positioning Module Type 1 Manual which describes installation programming and application of the APM Type 1 Series Six ASCII BASIC Module Manual which describes installation programming and troubleshooting procedures for the ABM WORKMASTER Guide to Operation which provides information for configuration and installation of the Workmaster computer Logicmaster 6 User s Manual which provides the information required to program and document a Series Six Plus PLC Genius I O System User s Manual which provides configuration programming operation and troubleshooting information to aid in implementing the Genius I O system into a Series Six Plus PLC system Series Six Axis Positioning Module Type User s Manual which describes installation programming and application of the APM Type 2 ProLoop Process Controllers which contains the information required to use the family of ProLoop Process Controllers Includes data on stand alone operation and the Loop Management Module which interfaces the process controllers to a Series Six Plus PLC system Series Six Operator interface Terminal User s Manual which describes the configuration installation programming and operation of the OIT for use with a Series Six Plus PLC VuMaster Co or Graphics Terminal which describes the installation
177. es available in the Expanded mode provide additional 64K of discrete references in a Series Six Plus PLC Channels I O points in the Expanded mode are selected in 1 increments referred to as channels An I O Transmitter module configured for Expanded Mode is required to originate each channel of I O with the exception that if channels 0 and 8 are the only Expanded mode channels selected an I O Transmitter is not needed for channel origination since the I O is scanned in the same manner as the Main and Auxiliary f O chains when in the Normal mode If more than two channels are to be used I O Transmitters are required The CPU scans only those channels that have been selected Any downstream 1 0 Transmitters in a chain must be configured for the Normal Mode This is true for both the Normal and Expanded Modes of operation A maximum of eight I O Transmitters are required for channel origination in each of the two chains If the maximum of 16 I O Transmitters is used 8 in each chain 16K Inputs and 16K Outputs are available to the user The channel number to be associated with each I O Transmitter is selected by setting the first 3 switches switches 1 2 3 on the DIP switch package on the backplane adjacent to the module as shown in figure 4 1 The total number of I O Transmitters is determined by the number required for channel origination plus any downstream I O Transmitters used in each channel as determined by the system
178. es in this module Be sure that the board covers provided with the Logic Memory module are in place before installing the module CAUTION Do not allow the bottom of a module to come into contact with a conductive metal surface when the board cover is removed Failure to observe this caution could result in the discharge of the non rechargeable lithium battery and the loss of memory contents When installing a Logic Memory module or any module position the component side of the board to your right towards the CPU power supply as shown in figure 3 8 NOTE Proper orientation of printed circuit boards is with component side towards the power supply Instal lation Instructions 3 33 GEK 96602 2 3 4 Install the faceplate by placing the faceplate in the proper position and while pushing in turn the quarter turn thumbscrew clockwise until it feels secure Remove any I O modules from the backplane of the CPU Disconnect any expansion racks from the CPU rack and plug the I O Terminator Plug supplied with the CPU rack into either port of the I O Control module Turn the RUN STOP keyswitch to the STOP position and the MEMORY PROTECT keyswitch to the WRITE position Apply power to the CPU rack and turn on the power switch 5 The CHECK light on the Arithmetic Control module should be on at this time before proceeding to the next step If it is not on power down reseat the CPU boards and power up again
179. ess than 300 ms BATTERY Status of CMOS RAM back up battery LOGIC MEMORY PARITY Parity error in Logic Register or Internal memory CHAIN OK All 1 0 stations in auxiliary chain have 1 0 continuity good output parity and power supply is good AUXILIARY PARITY Input data parity is good ENABLED CPU is in the normal Run Enabled mode outputs enabled Troubleshooting and Repair 5 5 GEK 96602 a42219 Figure 5 1 SERIES SIX PLUS CPU INDICATORS AND SWITCHES Troubleshooting and Repair GEK 96602 1 CPU RUN STOP KEY SWITCH Position Definition STOP CPU is unconditionally in the STOP mode RUN CPU is in the RUN mode unless this condition has been altered by commands from the programmer or other device or by the state of various control signals When this switch is turned from STOP to RUN the system will start with the outputs enabled IF THE CPU WILL NOT RUN CHECK OTHER STATUS LIGHTS 2 MEMORY PROTECT KEY SWITCH Position PROTECT WRITE Definition The contents of Logic Memory and Override Tables are protected from beinq changed The user program stored In the Logic memory may be changed and an overrIde condition may be added to or removed from inputs or outputs through the Override Table If key switches in steps 1 and 2 do not operate and all status indicator lights are OK check the P2 connections on the CPAX board in the power supply module See figure 5 2 3 POWER L
180. ete information on the ProLoop Process Controllers refer to the ProLoop Process Controllers System Manual GEK 90802 a40315 1 PROLOOP Loop CONTROLLER STATUS LEDS _ TRACK LH PROCESS VARIABLE 197599 DIGITAL READOUT PROCESS VARIABLE SETPOINT RATIO 3 TERM OUTPUT MEASURED POWER VERTICAL BARGRAPHS OUTPUT DUTPUT DUT BAR GRAPH DISPLAY Oloj Lalal CONTROL WODE E PUSMBUTTONS P f CONNECTOR T BAR POWER ON INDICATION Figure 1 8 TYPICAL PROLOOP SYSTEM EQUIPMENT Introduction To The Series Six Plus PLC 1 17 GEK 96602 ASCII BASIC Module ASCII BASIC Module is an intelligent module which under control of a built in BASIC programming language GE BASIC can manipulate and transfer data to and from a Series Six Plus CPU This module can be programmed to read the contents of the scratch pad any register or status tables status tables in the Main I O chain or channels 0 and 81 in a CPU In addition this module under program control can write data into the registers and status tables An ASCII BASIC Module has two configurable serial ports which give it the ability to interface to external devices using either RS 232 RS 422 or 20 mA current loop with data rates up to 19 2 K bps Through these ports the module can communicate with devices using an ASCII code These devices typically can be printer terminals bar code readers
181. etected in either the 1 0 address or I 0 data transmitted from the CPU latched OFF if a Parity Error is detected This is a latch for ADDPAR and DATPAR indicators previously discussed For detailed information on operation of the Advanced I 0 Receiver refer to GEK 90771 which can be found in the Series Six Data Sheet Manual GEK 25367 lO Transmitter The VO Transmitter module figure 2 27 provides an interface between the rack backplane signals and the I O bus to a downstream Local I O station In addition the mode of operation either NORMAL or EXPANDED must be specified by jumper configuration In the NORMAL mode there is 1 Main 1 Auxiliary VO chain maximum of 2000 Inputs 2000 Outputs per CPU In the EXPANDED mode there are up to 8 chains 16 with Auxiliary I O per CPU In this configuration up to 16K Inputs and 16K Outputs including Auxiliary I O are allowed per system In the EXPANDED mode if only Channels 0 and 8 are selected an I O Transmitter is not required to drive those channels However if more than 2 channels are selected each channel must be driven by an I O Transmitter Any 1 0 Transmitters located downstream from the first one in a fink must be configured to the NORMAL mode of operation In other words if an lO Transmitter in the CPU rack or the first 1 0 rack has been configured for EXPANDED mode any other I O Transmitters on that link must be configured for NORMAL mode Likewise when the
182. f when power 15 applied to power suppl No input parity error is sensed OFF Latched off if an input parity error is sensed from I O Transmitter or Remote I O Driver in this rack or from any down stream I O rack connected directly to this module Communications to CPU good OFF Latched off if module has not had communications with the CPU within the previous one second No parity error detected in either the OUTPAR I O address or I O data from the CPU OFF Latched off if a parity error has been detected This is a latch for ADDPAR and DATPAR indicators z z z 2 Troubleshooting and Repair GEK 96602 Table 5 4 I O MODULE STATUS INDICATOR DEFINITIONS Continued 5 26 MODULE INDICATOR STATUS FN COUNTER BLINK ON ON AXIS OFF POSITIONING MODULE TYPE 1 ENABLED ON OFF ON OFF ON AXIS OFF POSITIONING MODULE TYPE 2 APM ON ENABLED OFF DRIVE ON ENABLED OFF DEFINITION Output 1 is energized Output 2 is energized Pulses are being received Board has passed self diagnostic test Hardware failure Board has passed self diagnostic test Hardware failure or board is not ina high Capacity I O rack or a Series Six Plus CPU rack Capable of controlling position turned on by discrete command ENABLE APM Any error condition or the REMOTE STOP command Resolver feedback is present Resolver feedback is not present Board has passed self diagnostic test Hardware fai
183. fault N To use the Computer Mail Box change this entry to Y If set to Y the CPU will open a communications window to any valid address located in the first register of the Computer Mail Box The window opens once per sweep when the CPU is in the RUN mode The address is placed in the register using a Window function DISPLAYING AND EDITING THE GENIUS BUS CONTROLLER LOCATIONS PAGE The Genius Bus Controller Locations page is used to specify the locations of the Bus Controllers within the Expanded 1 0 channels of the Series Six Plus PLC To display the Bus Controller page press the Bus Controller Map F1 key from the CPU Configuration Set Up Menu GENIUS BUS CONTROLLER LOCATIONS CURSOR CHANNEL 0 LOCATION 0001 MAIN CHAIN AUX CHAIN CHANNEL LOCATIONS CHANNEL LOCATIONS 0 00000000 01000001 8 10000001 00010001 1 00001000 10000000 9 00011000 01010000 2 00000000 01010101 A 10000001 00010001 3 00001000 10000000 B 00011000 01010000 4 00000000 10101010 C 10000001 00010001 5 00000100 10000010 D 00011000 01010101 6 00000000 01010101 E 10000001 00010001 7 00001000 10000000 F 00011000 01010101 INSERT CPU 1 2 BC 3 4 5 6 7 8CONF IG Editing the Bus Controller Map The display shows the 16 Expanded O channels Beside each there are 16 bits Each binary bit corresponds to a possible Bus Controller location Current cursor position is shown by a reverse video block The rightmost bit in each channel represents 1 location 1 of that channel E
184. first 1 0 Transmitter in a link is configured to the NORMAL mode all other IIO Transmitters downstream must also be configured to the NORMAL mode An I O Transmitter must be used to interface to a Local I O station if I O racks are required beyond the capacity of a CPU station 10 I O racks an existing Local I O station or a Series Six Plus CPU rack Any number of I O Transmitters can be installed in a rack as long as the I O load for the rack and the distance limitations are not exceeded An Transmitter can be installed a Remote I O station and linked to additional I O Transmitters up to 2000 feet 600 meters thereby extending the Remote I O capability by that distance Each I O Transmitter link cannot exceed 500 feet 150 meters No more than four I O Transmitter links can be used with the 2000 foot limitation on the parallel I O chain 2 50 Physical Equipment Configuration GEK 96602 Data received at the CPU from each I O Transmitter is placed in the input status table for input bits IX 1017 through 1 1024 for the addressed channel The data in this status byte is bits 1 3 channel number bit 4 card present bits 5 and 6 set to 0 bit 7 fault trap enable bit 8 fault present If the I O Transmitter does not respond when addressed nothing will be written to the input locations for that channel The channel will be scanned regardless of whether the module responded or not When the I O Transmitter receives its addre
185. for different Bus Controller I O reference assignments 4 32 Expanded CPU Operation GEK 96602 Bus Controller Status Byte 1 Address 0 Input 4 LOSS OF BLOCK This input when ON indicates that the Bus Controller has detected the loss of an I O block that had been operating Bus Controller Status Byte 1 Address 0 Input 5 ADD A BLOCK This input when ON indicates that the Bus Controller has detected that a block has been added to the bus where there had previously not been a block Both input 4 and 5 will be on for at least one CPU scan for each detected loss or addition of a block but they will never be on at the same time Byte 2 Inputs 9 10 indicates whether this I O block is an input only block Input 9 ON output only I O block Input 10 ON or combination input output I O block Inputs 9 and 10 both ON Bytes 3 and 4 indicate the starting reference 0001 to 0993 assigned to this I O block Bytes 5 and 6 contain the number of input and output addresses respectively used by the I O block Bus Controller Status Byte 1 Address 0 Input 6 ADDRESS CONFLICT This input indicates a conflict between two I O blocks on the bus trying to use the same I O reference A block has been added with a reference used by a block already on the bus This conflict may be for two blocks with references overlapping either partially or totally Input 16 will be On for one scan for each conflict to be reported The
186. from the CPU Each I O rack in the chain includes a Power Supply module standard ac or high capacity ac or dc in a 19 rack or high capacity ac in 13 rack an I O Receiver or Advanced Receiver module and up to 10 additional modules a 19 rack or up to 7 additional modules in a 13 rack The modules in the I O rack are determined by the system configuration required The modules can be a combination of the following modules Input modules Output modules I O Transmitter module and Remote I O Driver module Each I O rack must have one and only one I O Receiver or Advanced I O Receiver If more than 10 I O racks are required in a system one or any of the I O racks in the CPU station may contain any combination of I O Transmitter or Remote I O Driver modules for connection to additional I O racks A Workmaster or Cimstar computer or PDT can be plugged into the I O Control module at the CPU an I O Receiver or Advanced I O Receiver in the last I O rack in a CPU I O station or a Local I O station The Workmaster or Cimstar computer can also be plugged into an I O Transmitter in CPU station or Local I O station When connected to an I O Transmitter the Workmaster or Cimstar computer can be connected through the 100 200 or 500 foot lengths of 1 0 cable The PDT can only be used in the Normal mode and only with the Advanced functions 2 38 Physical Equipment Configuration GEK 96602 41071 Pane uU ee
187. ges or gateways are not required The direct connection provides the high performance required for real time applications Carrierband networks are designed to handle small to medium size applications with 6 to 20 stations as a typical number which might be attached although more stations can be connected Carrierband networks can extend over cable distances as far as 2000 feet a4 1993 CARRIERBAND NETWORK LAN INTERFACE LAN INTERFACE NETWORK MODULE MODULE MODULE MANAGEMENT SERIES SIX SERIES SIX CONSOLE PLUS CPU PLUS CPU OPTIONAL SERIES SIX PLUS CPU FIGURE 1 10 LAN Interface Module Connects a Series Six Plus PLC to a Carrierband Network Datagram Communications Service There are two types of communication services which transfer control data on the network They are the Datagram Communication Service and the Global Data Communication Service The Datagram service is a real time service which provides peer to peer message transfers read and write messages from one station on the network to another Each request must be explicitly initiated in the ladder logic program using the Series Six Serial Request SCREQ instruction and the initiating station receives immediate acknowledgement that the data was or was not transferred successfully The Datagram service anticipates MAP EPA specifications and will evolve to comply with them when they are approved as standards Datagram services should
188. ght 5 32 POWER light 5 33 REMOTE OK light 5 36 REMOTE PARITY light 5 37 check at CPU 5 31 input not recognized 5 38 no outputs function 5 38 only 1 output fails 5 38 with the Advanced I O Receiver 5 39 to 5 49 Input Output circuitry function of 1 12 Inserting a printed circuit board 3 5 Instal lation instructions for Series Six Plus 3 1 Installing a battery 3 8 Internal discrete reference memory allocation 2 34 Internal discrete reference mapping 4 5 Internal memory function of 2 17 Interrupt Input module location in system 4 2 Introduction to Series Six Plus 1 1 L LAN interface module 1 20 List of figures xviii to xvix List of tables xx to xxi Local area network GEnet 1 19 Local station 2 39 Local I O station illustration of 2 39 Logic Control module description of 2 12 illustration of 2 13 Logic Control to Arithmetic Control cable 3 11 Logic memory function of 2 16 Logicmaster 6 serial version 2 65 Logicmaster 6 software 1 7 4 12 Loop Management Module 1 16 Maintenance of the Series Six Plus PC 5 1 Manuals related Memory mapping 4 6 4 7 Memory protection key switch 2 19 Memory types of 1 11 2 18 Memory CMOS RAM 1 11 Module installation CPU 3 6 Module replacement concept 5 2 Modules Communications 1 13 Modules I O 1 12 Modules Intelligent 1 13 Modules System Interface 1 1 3 N Network interface 1 20 Normal mode I O addressing 2 33 4 3 Normal mode of operation 4 1 0
189. graphs Workmaster to Series Six Interface Adaptor Boards This is a two board option which provides high speed parallel communications between the Series Six Plus PLC and the Workmaster computer through the Logicmaster 6 software One board is the WorkmasterlSeries Six Interface board IC640BSS303 which contains the circuitry necessary to format and transfer data between a Workmaster computer and a Series Six Plus PLC This board requires a long slot for instaflation The other board in the set is the Workmaster Series Six Terminator board IC640BLD304 which contains the circuitry to terminate and protect data lines between the Series Six Plus PLC and the Workmaster computer This board requires a short slot for installation There are two DIP rocker switches on the board which must be configured as described below These two boards are connected together inside of the Workmaster computer by a 34 wire ribbon cable The boards can be installed in any 2 unused slots in the Workmaster computer with the requirements that the full size board must be installed in a long slot and the half size card be installed close enough for the ribbon cable to reach These boards should be installed as instructed in the Workmaster Guide to Operations Manual GEK 25373 Connection to I O Control or I O Receiver Modules The factory setting for the DIP switches on the Terminator board is ALL of the switches set to the OFF open position This is the correct setti
190. h this combination Introduction To The Series Six Plus PLC 1 25 GEK 96602 Table 1 9 COMPATIBILITY GUIDE SERIES SIX PLUS PLC VS SERIES SIX PLCs Continued Catalog Number Description Model of PLC 60 600 6000 6 Memory Continued IC600CB508 1K Registers IC600CB507 8K Registers e IC600CB511 16K Registers e IC600CB504 Internal Memory IC600LR605 4K Logic 1K Registers 2 IC600LR612 4K Logic 8K Registers 2 IC600LR616 8K Logic 8K Registers 2 IC600LR624 16K Logic 8K Registers 2 IC600LR632 16K Logic 16K Register 2 IC600LR648 32K Logic 16K Registers 2 1 6001 605 4K Logic 1K Registers 2 e 1 IC600LX612 4K Logic 8K Registers 2 e IC600LX616 8K Logic 8K Registers 2 1 IC600LX624 16K Logic 8K Registers 2 1 IC600LX648 32K Logic 16K Register e 2 o IC600LX680 64K Logic 16K Registers 2 e 1 Functions IC600CB525 Advanced Functions e e e IC600CB526 Expanded Functions e e 600 515 Expanded II Functions Arithmetic Control IC600CB500 IC600CB524 e e 1 Input Output System 600 503 I O Contro e IC600CB513 Auxiliary I O Control e e IC600BF 900 I O Transmitter Local e e IC600BF801 Remote I O Receiver a 600 901 Remote I O Driver IC660CBB900 902 Bus Controller e with diagnostics 660 901 903 Bus Controller e e without diagnostics Standard 1 0 modules Genius 1 0 Block
191. hannel number bit 4 card present bits 5 and 6 set to 0 bit 7 fault trap enable bit 8 fault present If the I O Transmitter does not respond when addressed nothing will be written to the input locations for that channel The channel w i ll be scanned regardless of whether the module responded or not Through user logic this byte can be cleared each sweep to determine if the I O Transmitter responded when addressed INTERRUPT MODULE LOCATION A maximum of two Interrupt Input modules can be used 1 in the Main I O chain and 1 in the Auxiliary I O chain in an Expanded I O system The Interrupt Input module for each chain can be placed in any channel in each of the chains The I O Transmitter modules pass the interrupt signal through to the CPU at all times The interrupt input data is placed in the Main Input status table in bits l1001through 11008 for the Main I O chain and 001 through 1 1008 for the Auxiliary chain Expanded CPU Operation 4 3 GEK 96602 NORMAL MODE I O ADDRESSING The Series Six Plus PLC allows I O to be configured in either the Normal mode or the Expanded I O mode Selection of the I O mode is made through the Configuration Menu using Logicmaster 6 software In the Normal mode one I O chain per CPU is permitted this is the factory default setting In this mode available I O is 1000 Inputs 1000 Outputs in the Main chain plus an additional 1000 Inputs 1000 Outputs in the Auxiliary I O chain if an Auxiliar
192. hat if channels 0 and 8 are the only Expanded mode channels selected an I O Transmitter is not needed since the I O is scanned the same as the Main and Auxiliary I O chains in the Normal mode If more than two channels are to be used I O Transmitters are required A jumper on each I O Transmitter module must be configured for either Normal mode or Expanded mode The CPU scans only those channels that have been selected The channel number to be associated with each I O Transmitter is selected by setting the first 3 switches switches 1 2 3 on the DIP switch package on the backplane adjacent to the module Channel Reference Numbering The channels are numbered from 0 to F the Main I O chain channels are referenced 0 through 7 and the Auxiliary I O chain channels are referenced 8 through The format for addressing I O in the Expanded mode must include a channel number either or a real I O state or internal discrete status reference identifier and the I O number The exception to this is for channel 0 and 8 channel 0 programming references are 00001 O1024 and 10001 11024 channel 8 programming references are AO0001 AO1024 and Al0001 11024 References 00 0001 to 00 1024 1040001 to 101024 if Auxiliary Inputs and Outputs are not being used and 8 000 0 08 1024 18 0001 to 1841024 cannot be used as real I O references but are available for use as discrete programming references 2 34 Physical Equipment Configura
193. he diskettes makes them convenient to handle and store Once your program has been developed on the Workmaster computer and stored on a diskette it is retained for future use even through power fail conditions Other Software Packages In addition to program development and entry for the Series Six Plus PLC many other software packages can be run on the Workmaster computer by adding the required software and hardware options Some of these are Processmaster which is used to configure and monitor ProLoop Process Controllers Modelmaster Factory Modeling System which is a graphically enhanced flexible modeling system used to simulate factory manufacturing facilities Vumaster intelligent color graphics operator interface Motionmaster which provides a powerful tool for the development and maintenance of motion control software in conjunction with the Axis Positioning APM1 and APM2 Modules Alarm Master which is used to create fault and alarm monitoring programs and Logicmaster 1 and 3 software which is used for developing and entering programs on the Series One family or Series Three PLCs In addition there are a number of Vendor Logo software packages available for use with a Series Six Plus PLC system For information on other programs that can be run on the Workmaster computer contact your local GE Fanuc NA sales off ice or GE Fanuc Automation North America Inc Charlottesville Va Introduction To The Series Six Plus PLC 1 9
194. he power supply in a standard I O rack can supply 100 units of load while the power supply load capacity in the high capacity I O rack is the same as the load capacity for a Series Six Plus CPU rack 275 units of load for 5 V dc 60 units of load for 12 V dc and 40 units of load for 12 V dc The total load on all outputs for the high capacity supply must not exceed 300 units of load 90 watts of total power The types of I O racks standard or high capacity to be used in a system are determined by the combination of modules to be installed in the racks Table 3 7 is a list of the I O modules and their units of I 2 load Table 3 7 SUMMARY Of UNITS OF LOAD FOR 0 MODULES CATALOG NUMBER 600 800 600 801 600 802 C600BF804 600 8 805 600 806 C600BF808 IC600BF810 600 813 1 6008 814 IC600BF875 C600BF8106 600 817 600 818 C6008F819 IC600BF827 IC600BF830 600 831 600 841 IC600BF842 IC600BF843 600 900 6008 901 6008 902 IC600BF993 600 904 1 600 905 600 906 600 907 12 V 10 2 10 2 MODULE UNITS OF LOAD 1 DESCRIPTION 5 v 12 v I 0 Receiver 9 Remote I 0 Receiver 42 10 24 to 48 V dc Input 2 115 V ac dc Input 2 230 V ac dc Input 2 12 V ac dc Input 2 Interrupt Input 3 115 V ac dc Isolated Input 2 Type J Thermocouple Input 29 Type Thermocouple Input 29 Typ
195. he watchdog timer The watchdog timer is a hardware timer set at 300 ms 50 ms to ensure that memory or internal circuit faults do not cause the CPU to enter an endless loop because of hardware failure If a scan is not completed at least once every 300 ms 50 ms the hardware will shut the CPU down and turn the outputs OFF If an error is detected it will shut itself down The logic entered by the programmer is actually stored in the CPU along with data storage and storage for the operation of timers and counters Memory Types Used in the Series Six Plus PLC All memory for the Series Six Plus PLC is located on one module which is the Combined Memory Module This module contains all internal register and logic user memory The memory provided for these storage functions is normally measured in K words where K is an abbreviation for kilo or 1024 Typically one word is required for storage of each function such as a relay contact timer preset or timer storage These words can be of various lengths such as 16 bits 8 bits or even 4 bits with a bit being the lowest level of measurement and can have only two states on or off The Series Six Plus uses the most common measurement 16 bits per word The number of words required per function will vary however with the more complex functions requiring up to 6 words each The most common type of memory used in PLCs to store both logic and data is CMOS CMOS is an acronym commonly used for CMOS RA
196. his condition Instructions for replacing a defective battery can be found in Chapter 5 System Maintenance Table 2 8 COMBINED MEMORY MODULE STATUS INDICATORS INDICATOR STATUS DEFINITION BATTERY UN Condition of Lithium backup battery is normal FLASHING Battery voltage is low CPU continues running Alarm 2 Advisory is activated To protect the memory contents replace the battery as soon as possible before It fails Battery failed CPU continues running but will not restart if stopped Alarm 2 remams activated Contents of memory wfll be lost if power Is turned off or lost for any reason PARITY Normal operation no parity errors detected by CPU Parity error detected in either Logic Register or Internal memory A bit will be set in the CPU Error Flag and displayed on the Workmaster computer screen in the Scratch Pad display An error message will be displayed which will interpret the content of the error flags An address will be displayed in Hexadecimal format to pinpoint the location of the defective module Physical Equipment Configuration 2 19 GEK 966902 A jumper on the Combined Memory Module allows the user to use an external auxiliary backup battery connected to the terminal block With the external battery configuration the on board battery need not be connected Location in Rack The Combined Memory Module must be placed in slot 4 which is directly to the left of the Arithmetic Contro
197. ht was last reset OFF The Advanced I O Receiver did not communicate with the CPU for a period of 1 second since the last time the light was reset The CPU is not active due to the power supply being turned off or there is or has been a fatal I O parity error or any CPU fault Corrective Action If any of the other status indicators on this Advanced I O Receiver are off proceed to the step number associated with that indicator If any of the status indicators on the CPU are off proceed to the step associated with that indicator If only status indicator 25 is off then the problem is intermittent and several possible causes must be investigated Typical Causes 1 Someone momentarily shut off power to the CPU power supply then turned it back ON Loss of power to one or more of the I O Transmitters driving a link to this rack for example utility drop in service or power below specifications Loose or damaged I O cable between I O racks upstream back toward the CPU Loose or damaged 1 cable connector on the 1 0 cable or on the connector on the module to which it is connected Bo CAUTION Be careful not to touch any high voltage wires or connectors When in doubt unplug the power supply Try to force a failure by gently moving cables and connectors Be sure that power is not turned off at the CPU or any 1 0 rack that has an 1 0 Transmitter driving a link to this I O rack Once the suspected cause has been
198. ications over distances less than 50 feet 15 0 meters is used connection at the Workmaster computer is made to the 9 pin connector on the Combination Adapter card If point to point communications over distances greater than 50 feet or multidrop communications are used the Asynchronous Joystick card must be used in the Workmaster computer When this configuration is used the Combination Adapter card must be configured as COM2 and the Asynchronous Joystick card configured as COM1 For more detailed information on installation and configuration of the above cards refer to the Logicmaster 6 User s Manual GEK 25379 USING THE CIMSTAR COMPUTER WITH A SERIES SIX PLUS PLC The CIMSTAR I computer can also be used as the programming device with a Series Six Plus PLC It can run either the parallel or serial version of the Logicmaster 6 software The serial version does not require any additional equipment added to the CIMSTAR computer The parallel version requires installation of an additional board set Both versions require GE DOS version 1 or later which is equivalent to MS DOS version 3 2 This version of DOS is supplied with the computer Refer to GEK 25379 the Logicmaster 6 Programming and Documentation Software User s manual Chapter 2 and Appendix and GEK 90527 the CIMSTAR I Industrial Computer Reference Manual for further information on the CIMSTAR computer hardware requirements and use Parallel Version of Logicmaster 6 Sof
199. idity Non Condensing 5 to 95 Noise Immunity Meets requirements of NEMA ICS 2 230 and ANSI C37 90A Altitude Up to 10 000 Feet 3000 meters above Sea Level 1 1 unit of load 60 mA Calculations based on worst case all inputs or outputs on Physical Equipment Configuration 2 31 GEK 96602 0 ADDRESSING Every I O module must be assigned a unique address to be used when referencing an input or output in the user program Each 1 slot except the leftmost slot has a seven segment DIP Dual In line Package switch associated with it physically located on the backplane and adjacent to each slot figure 2 18 These switches when set are used to assign a unique address for the Input or Output module placed in that slot Note that each address can be used two times since the same 1 point address can be assigned to 1 Input and 1 output module i e 11 0157 and 01 0157 Either an Input or Output module can be placed in any of the 10 addressable slots The leftmost slot is reserved for an 1 Receiver or Advanced I O Receiver module which is required in each 1 0 rack Figure 2 19 is an illustration of the DIP switches showing their location and individual switch values NOTE When referencing an O point in a program a prefix must be added to properly address the applicable 1 0 chain Normal mode addresses reference the Main and Auxiliary chains for example 10234 AO0456 etc When in the Expanded mode N
200. ified by the Electronics Industries Association EIA for the mechanical and electrical characteristics of the interface for connecting Data Communications Equipment DCE and Data Terminal Equipment DTE RUN Light An LED indicator on the Arithmetic Control module which when on indicates that the execution sequence of the PLC is proceeding normally and the I O scan is completed at least once every 200 milliseconds 50 milliseconds Read To have data entered from a storage device Reference A number used in a program that tells the CPU where data is coming from or where to transfer the data Register Memory In the Series Six Plus PLC dedicated CMOS RAM memory accessible by the user for data storage and manipulation Relay Line A line of logic in a ladder diagram used to simulate the effect of mechanical relays The coil in a relay line is energized when continuity is complete from the left to right vertical rail of a ladder diagram Remote I O Station An I O system configuration allowing access to a maximum of 248 inputs and 248 outputs at a location distant from a CPU station or Local I O station Connection is made through a serial communications interface consisting of a Remote I O Driver a two twisted pair shielded cable and a Remote I O Receiver The serial link can be located up to 10 000 feet from the originating Remote I O Driver When used with an RS 232C modem communications link the distance is virtually unlimite
201. iguration Set Up Menu The entries on this page are stored in the Configuration function in the program EXPANDED I O SCAN ENABLED Y Default Y for Expanded I O scanning by the CPU For normal I O scanning enter N Note that Expanded lO is not required for Genius I O diagnostics on Bus Controllers located in the Main and Auxiliary status tables Expanded I O must be enabled to use the diagnostics on Bus Controllers located on channels 1 7 and 9 F BEGIN RANGE If Expanded I O scanning is enabled this entry specifies the channel and Point number within the channel where the Expanded I O scan should begin The default range is all channels and points Change these entries to select a smaller scan range Expanded CPU Operation GEK 96602 CPU CONFIGURATION MENU DEFINITIONS Continued GENIUS I O The I O structure in an expanded I O system consists of as many as 8 main channels numbered 0 7 and 8 auxiliary channels 8 F Valid entries for Begin Range and End Range Channel are 0 to 7 Each of these specifies a main auxiliary channel I O pair CHAINS MAIN AUXILIARY CHANNELS The value for Point is the I O point from 1 to 1024 in the specified channel The system rounds this value to a byte boundary END RANGE The channel number and Point number within the channel where the Expanded I O scan should end This must be greater than the value for Begin Range DIAGNOSTICS
202. igure 3 22 DIP SWITCH SETTINGS FOR I O POINT SELECTION FOR 8 CIRCUIT MODULES 3 28 Installation instructions GEK 96682 POWER SUPPLY LOAD CAPACITY The load capacity of the power supply in a Series Six Plus CPU rack is the sum of the internal loads placed on it by each of the CPU modules as well as the I O modules and is expressed as units of load with 1 unit of load being equal to 300 milliwatts of power Each unit of load of 300 milliwatts can also be expressed in terms of current as follows 5 Vdc 60 mA of current 12 V dc 25 mA of current 12 V dc 25 mA of current Load Capacity for a Series Six Plus CPU Rack The power supply in a Series Six Plus CPU rack is a high capacity supply with 3 outputs having capacities as follows Table 3 5 CPU RACK POWER SUPPLY CAPACITIES VOLTAGE amp CURRENT UNITS OF LOAD 5 V dc at 16 5 Amps 275 units of load 12 V dc at 13 Amps 60 units of load 12 V dc at 1 0 Amps 40 units of load NOTE In addition to the units of load listed for each voltage type the total load on all outputs of the supply must not exceed 300 units of load 90 watts of total power The number of I O modules that can be used in a rack is determined by adding up the loads of all CPU modules and subtracting that load from the total load capacity The remaining capacity in a Series Six Plus CPU rack usually allows up to 100 units of load for modules to be contained in the rack The total load of those I
203. ime to be lengthened considerably Troubleshooting and Repair 5 13 GEK 96602 9 RUN LIGHT ARITHMETIC CONTROL MODULE Definition Status CPU execution sequence is proceeding such that the self test routine is passed and the I O scan is completed at least once each 300 ms 50 ms CPU is in the RUN mode OFF CPU is in the STOP mode The Enable light is off Corrective Action Check the position of the RUN STOP key switch See step 1 Check the condition of other status lights PARITY BATTERY CHAIN OK CHECK and POWER f no other problem is indicated try restarting the CPU with the Workmaster computer or CPU key switch Ensure that the short length of ribbon cable connecting the Arithmetic Control and Logic Control modules is securely connected e Reset the Arithmetic Control and or the Logic Control modules f reseating does not solve the problem replace the two modules one at a time NOTE Both the RUN and the CHECK indicator may flash momentarily when power is applied to the CPU A valid RUN or CHECK state is indicated by a steady glow of the LED 5 14 Troubleshooting and Repair GEK 96602 10 PARITY LIGHT LOGIC COMBINED MEMORY MODULE Definition Status Logic Memory parity is good OFF Parity error exists in logic register or internal memory The RUN and ENABLE lights are off Alarm Number 1 relay switches The parity error and its
204. in locations Cl and D1 they should be inserted in spare sockets located at the bottom of the printed circuit board These spare sockets are in board locations F2 and F3 Module Connections Two 37 pin D type connectors are mounted on the front edge of the module The bottom connector connects to downstream I O racks The top connector connects to the next upstream I O rack to an I O Transmitter at the opposite end of a parallel bus cable or to an I O Control module in a CPU rack Status Indicators There are three edge mounted LEDs which provide a visual status of certain fault indications on the I O chain The LEDs are viewed through the lens on the faceplate Table 2 13 defines the status provided by each LED Table 2 13 RECEIVER STATUS INDICATORS INDICATOR DEHNITION POWER ON when station power is present continuity is ON present and all stations downstream are OK CHAIN ON when all downstream statlons have received good PARITY parity LOCAL ON when the 1 0 Receiver has received good output PARITY parity 2 46 Physical Equipment Configuration GEK 96602 Advanced I O Receiver The Advanced I O Receiver module allows the I O connected to a Series Six Plus CPU to be more versatile in how I O failures are detected and enables the Series Six Plus CPU to respond to these faults When using this module all levels of Series Six Plus software can be programmed using relay logic to respond to I O faults such as
205. in the CPU rack This is because of the power consumption in units of load of the I O Link Local modules A maximum of 5 I O Link Local module can be installed in a high capacity I O rack In this configuration there 175 units of load remaining for I O modules with 5 V dc power only The actual physical connection between the I O Link Local module and the remote Series One or Three racks is a 2 wire plus ground RS 422 multidrop The maximum distance between the I O Link Local module and the last remote rack in the chain is 3300 ft 1 km The I O Link Local module must be configured for each application by setting DIP switches located on the module The DIP switches determine the starting address of a configuration table in the CPU For detailed information on the use and configuration of an I O system using the I O Link Local module and Series One or Three I O refer to GEK 90825 which is the Series Six PLC I O Link Local Users Manual Figure 2 16 is an illustration of a typical I O communications link between a Series Six Plus PLC and Series One and Three I O a42084 SERIES SIX PLUS CPU OR asta Figure 2 16 LINK LOCAL MODULE SERIES ONE OR SERIES THREE REMOTE I O RACKS 2 28 Physical Equipment Configuration GEK 96602 Figure 2 17 is an illustration of the physical layout of the I O Link Local module LINK ICAL JARD lt JMM REC 1 REC 2 IANS 1 TRANS 2
206. industrial control device using microprocessor technology to perform logic decision making with relay ladder diagram based programming Programmer A device for entry examination and alteration of the PLC s memory including logic and storage areas Logic A fixed set of responses outputs to various external conditions inputs All possible situations for both synchronous and non synchronous activity must specified by the user Also referred to as the program CPU Central Processor Unit the physical unit in which the PLC s intelligence resides Decision making is performed here Memory A physical place to store information such as programs and or data K An abbreviatlon for kilo or exactly 1024 in the world of computers Usually related to 1024 words of memory Word A measurement of memory length usually 4 8 or 16 bits long In the Series Six Plus PLC 16 bits CMOS A read write memory that requires a battery to retain its content upon loss of power PROM A read only memory that requires a special method of loading but is inherently retentive upon power loss I 0 Input Output that portion of the PLC to which field devices are connected Isolates the CPU from electrical noise Noise Undesirable electrical disturbances to normal signals generally of high frequency content 1 24 Introduction To The Series Six Plus PLC GEK 96692 Table 1 8 COMMON PLC TERMINOLOGY Continued Input A signal typically
207. ing normal operation the alarm relays are energized When an alarm condition is detected the contacts 1 0 and 2 0 open and the contacts 1NC and 2NC close The alarm relay logic is located on a terminal board in the power supply The alarm relay provides isolated outputs rated at 115 V ac or 28 V dc 1 amp resistive load The major alarm causes the CPU status to be set to stop The minor alarm causes an error indication to be recorded but the CPU status is not set to stop Table 2 2 lists some of the problems that can cause the alarm relays to switch Physical Equipment Configuration 2 7 IE GEK 96602 Table 2 2 CONDITIONS CAUSING ALARMS MINOR ALARMS Back up battery voltage low MAJOR ALARMS CPU or I O parity error CPU self test failure CPU watchdog timer timed out CPU or I O power supply turned off Back up battery voltage drops below operating leve Communications Control or Data Processor error fault jumpers in or out of circuit Any CPU or I O power supply voltage out of tolerance CPU power supply turned off Communications Control or Data Processor error fault jumpers in circuit Power Supply Specifications Table 2 3 lists specifications for both the ac and dc power supplies Table 2 3 POWER SUPPLY SPECIFICATIONS 95 to 260 V ac 250 Va maximum Frequency 47 to 63 Hz Input ac supply 20 to 32 V dc 180 Va maximum or 100 to 150 v dc 180 Va maximum Input dc supplies 5 V dc 16 5 A ma
208. instructions for unpacking packing inspecting installing in a rack or panel setting internal switches and connecting cables At the end of this chapter is a start up procedure for the Series Six Plus CPU to be followed when bringing up a new CPU for the first time QUALITY CONTROL Each Series Six Plus PLC undergoes a thorough quality control inspection and extensive system testing before being shipped Each part of a system undergoes environmental and operational tests before leaving the factory PACKAGING The method of packing and shipping the components of a Series Six Plus PLC system are outlined in this section CPU racks are shipped to include the following modules and other components Power Supply Control and Arithmetic Control modules I O Terminator plug board extraction insertion tool and rack mounting brackets and screws The power supply Control module and Arithmetic Control modules are seated in their proper slots the rack The ribbon cable for connecting the Arithmetic Control to the Logic Control modules is connected to the Arithmetic Control module Blank faceplates must be ordered separately for the remaining slots and are shipped separately The CPU rack is inserted into 2 halves of foam plastic sections This is then placed in an antistatic plastic bag along with the rack mounting brackets hardware for mounting the brackets a printed circuit board extraction insertion tool an I O Terminator p
209. inted circuit boards one at a time to determine which one is loading down the power supply Keep in mind that the power supply may be bad under normal load conditions If any of the voltages are out of tolerance replace the power supply Figure 5 3 is a block diagram of the CPU power supply for your reference NOTE After a power fault the system will come back on in the mode STOP RUN ENABLED or RUN DISABLED in which it was operating before power was lost 5 8 Troubleshooting and Repair GEK 96602 a41074 INPUTS FROM BACKPLANE EXETRNAL OUTPUTS TO BACKPLANE PSI SYS RDY STOP ROM RAM AUX BAT ALARM RELAYS O 12V DC NEG OR L2 FILTER 1201 BACKPLANE GND 6 O oV Figure 5 3 CPU POWER SUPPLY BLOCK DIAGRAM Troubleshooting and Repair 5 9 GEK 96602 4 CHAIN OK LIGHT 1 0 CONTROL and AUXILIARY 1 0 MODULES Definition Continuity output data parity and power supplies are good at all I O stations in the primary and auxiliary chains OFF A continuity power supply or output data parity error exists at one or more main or auxiliary chain I O station The CPU RUN and ENABLE lights are off Alarm No 1 relay switches When the fault is removed the CPU resumes its previous status Corrective Action Check for proper I O chain signal termination on the last Receiver or Advanced Receiver module in each I O station in a parallel chain
210. ions Control Module Figure 2 15 is an illustration of the CCM a40528 1 LED Status Indicators 6 J2 Connector 25pin D type female 2 Bank A DIP Switches connector Communications Port 2 3 Bank B DIP Switches 7 J2 Communication selection DIP package 4 Bank C DIP Switches RS 232 or RS 422 configuration Read 5 J1 Connector 25pin D type from top of imprinted label female connector Communications 8 Faceplate Port 1 Figure 2 15 ILLUSTRATION OF I O CCM MODULE Physical Equipment Configuration 2 27 GEK 96602 Link Local Module The I O Link Local module catalog number IC600BF947 provides a communication link with diagnostics from a Series Six Plus PLC to a slave Series One PLC and Series Three PLC input and output devices Link Local module can be connected to as many as seven remote Series One or Series Three racks or a combination of both in a single chain It can access a maximum of 96 I O points from a Series One rack and 224 I O points from each Series Three rack The I O Link Local module can be inserted in the I O portion of a Series Six Plus CPU rack or in a Series Six high capacity I O rack The connection to the Series One or Series Three I O is made through the I O Link Remote module in a Series One or Series Three VO rack A maximum of 4 I O Link Local modules can be installed in the I O portion of the CPU rack With this configuration no other I O modules can be resident
211. iples of ten registers For example a length of 27 indicates 271 registers assigned to the fault table Each fault recorded is represented by 10 words registers Input Data From Bus Controller Each Bus Controller with diagnostics uses 6 bytes to provide status information to the CPU The content of each of the bytes is described following figure 4 6 Bus Controllers without diagnostics use only one Byte in the input table to provide status information Expanded CPU Operation 4 29 GEK 96602 Selecting Addresses for Diagnostic Data Storage The starting address for diagnostic input data provided to the CPU from a Bus Controller and command output data received from the CPU is established by setting the DIP switch at the back of the 1 0 slot into which the Bus Controller is inserted The Bus Controller with diagnostics uses six input bytes 48 input status references and four output bytes 32 output status references to store its diagnostic data The Bus Controller without diagnostics uses only one input byte 8 input status references Only diagnostic and status information is provided through these status references 1 states are controlled by their normal 1 0 references To select the starting I O status reference the DIP switch segments must be set before inserting the Bus Controller module in its selected slot If diagnostic data is to be time stamped and stored in a fault table each Bus Controller must be placed on even multiples
212. is I O rack OFF Output parity has been detected by this Advanced I O Receiver module The CHAIN OK light on the CPU s I O Control module will be off RUN and ENABLE lights at the CPU will be off and Alarm Relay 1 switches Corrective Action Check the other status indicators referenced in step 20 ADDPAR DATPAR OUTPAR in combination with the LOCPAR light and go to step number 20 19 You are at this step because there is no apparent fault indicated by the status indicators on the CPU and or light 19 is off or flashing DEFINITION STATUS ON Output Byte Bit 3 is a logic O OFF or FLASHING Output Byte Bit 3 is a logic 1 or is toggling Corrective Action e f light number 19 is OFF or flashing the program in the CPU has told it to do this and you must determine why the program did so The documentation associated with your program should explain what controls this light Status indicators 20 through 25 may also be used to determine what the fault is or was Indicator light 19 is controlled by Bit of the Advanced 1 0 Receiver output byte Determine the address of that byte by checking the DIP switch setting on the module refer to Data Sheet GEK 90771 page 3 call out 7 Example of Determining the Output Byte Address If the DIP Switch for the Output address has all switches closed then the output byte begins at Output 00001 This means bit 3 is Output 00003 and you must search for 00003 in the Lad
213. is normal the self test has passed the I O scan is completed at least once every 300 ms 50 ms and the CPU is in the RUN mode The CHECK LED is ON when the self test has been completed successfully at least once each I O scan the system clock is operating normally or if the scan time is no longer than 300 ms 50 ms Table 2 5 ARITHMETIC CONTROL MODULE STATUS INDICATORS INDICATOR DEFINITION RUN ON Execution sequence proceeding normally self test has passed thel Oscan is completed at least once every 300 ms 4 50 ms and the CPU is in the RUN mode OFF CPU is in the STOP mode CHECK 0N Execution sequence proceeding normally self test has passed at least once each 300 ms 50 ms CPU can be in RUN or STOP mode OFF CPU self test has not passed within 300 ms 4 5 ms or user program takes longer than 300 ms to execute CPU goes to STOP mode and I 0 chain is reset Physical Equipment Configuration 2 15 GEK 96602 NOTE Do not attempt to operate the system without the ribbon cable connected between the Arithmetic Control and Logic Control modules If the cable is not connected the CPU will operate unpredictably Figure 2 11 is an illustration of the Arithmetic Control module with the user items discussed on the preceding page identified e b42223 1 Socket for ribbon cable connection to 3 CHECK Light Logic Control module On CPU execution sequence is 2 RUN Light proceeding the s
214. ity Error XMITOK TRANSMIT OKAY ON if power is okay and cable continuity is okay to all downstream racks connected to a Local Transmitter or Remote I 0 Driver module that is located in this rack latched OFF if the above conditions are not met in one or more of the connected racks CHN OK CHAIN OKAY ON if power and cable continuity is okay to all downstream racks directly connected to this Advanced 1 0 Receiver latched OFF if the above conditions are not met in one or more of the connected racks Physical Equipment Configuration 2 49 GEK 96682 Table 2 14 STATUS AND DIAGNOSTIC INDICATOR DEFINITIONS Continued PS OK POWER SUPPLY OKAY ON If power supply in this rack is within tolerance latched OFF if power supply should fall out of tolerance LED will be latched off when power is applied to power supply IN PAR INPUT PARITY the source of Input Parity Error is determined by the settings of SW6 and SW7 of the diagnostic dip switch the LED is ON if no Input Parity Error is sensed latched OFF if an Input Parity Error is sensed from either a Local 0 Transmitter or Remote 1 0 Driver module mounted In this rack or from any downstream 1 0 rack that may be connected directly to the Advanced I 0 Receiver module in this rack W DOG WATCH DOG TIMER ON when communications to CPU is okay latched OFF if the module has not communicated to the CPU within the last one second OUTPAR OUTPUT PARITY ON if no Parity Error is d
215. k should be required to extend beyond its normal 4000 feet 1 2 Km the Adaptor can be used as a repeater to boost the signal levels and obtain another 4000 feet of driving distance for the signals a42088 ISOLATED 5222 ADAPTOR UNIT figure 1 11 RS 232 to RS 422 ADAPTOR UNIT 1 22 Introduction To The Series Six Plus PLC GEK 96602 SYSTEM PLANNING Decisions such as the number of 115 V ac solenoids 24 V dc solenoids motor starters limit switches operating voltages control panel lamps voltage required pushbuttons and external relays have a major impact on the configuration of any PLC These parameters should be established as early as possible in the overall design of the control system Being a flexibte device the PLC configuration either on paper or in hardware can easily be changed if requirements change Typically the user provides the field devices wires them to the 1 0 section and provides the power source to operate them TYPICAL APPLICATIONS USING PLCs Programmable Logic Controllers are used in a wide variety of machine and process control applications These applications range from replacing a few relays to controlling complete factory automation projects Table 1 7 is a list of typical applications for the Series Six Plus PLC This list is only a very small sampling of possible PLC applications many others are possible and more are being identified all the time For further information on any of the appli
216. k the voltage If still bad replace power supply If voltage is OK reinsert printed circuit boards one at a time to determine which one is loading the supply down Keep in mind that the supply may be bad under normal load conditions 5 22 Troubleshooting and Repair GEK 96602 1 0 INDICATOR CHART Table 5 4 is an chart that gives a quick reference to the meaning of the status lights on the 1 system modules Table 5 4 1 0 MODULE STATUS INDICATOR DEFINITIONS MODULE INDICATOR STATUS DEFINITION POWER ON Power is applied and all dc voltages SUPPLY are present and within tolerance OFF One or more dc voltages is too low AC DC INPUT 1 through 8 AC DC OUTPUT 1 through 8 BF 1 8 12 24 48 1 through 8 V dc Output BF 1 8 Corresponding Input is energized Corresponding output is energized Blown fuse in this Output circuit Corresponding Output is energized Blown fuse in this Output circuit 120 V dc through 8 Corresponding Output is energized Output BF 1 8 Blown fuse in this Output circuit Isolated 115 V ac dc 1 through 8 Corresponding Input circuit is energized Input Isolated 1 through 6 Corresponding Output circuit energized 115 V ac dc Qutput BF 1 6 Blown fuse in this output circuit Board fault detected Protected Board operation normal 115 V ac Output 1 through 4 Corresponding Output circuit energized BF 1 4 Blown fuse in this output circuit High SOURCE Source Input mode Density
217. k to the current time The clock is updated whether or not the scan is operating Run or Stop mode but does not continue upon power failure BUS CONTROLLER OUTPUT DATA A Bus Controller with diagnostics also accepts output data as commands from the CPU There are four addresses of output data The output bytes 1 through 4 start at the same address set by the user as the input bytes Bytes 5 and 6 as shown in the illustration are used by the CPU and should not be referred to by the user The content of each byte is illustrated in figure 4 8 41077 6 i BYTES 21 a F DATA USED BY CPU EXECUTIVE 32 m DISABLED OUTPUTS CLEAR ALL FAULTS 2 CLEAR CIRCUIT FAULT 3 PULSE TEST ACTIVE 4 CIRCUIT TYPE 9 CIRCUIT REFERENCE 17 32 Figure 4 8 BUS CONTROLLER OUTPUT STATUS REFERENCE DEFINITION Output 1 Bit 0 Definition Disabled Outputs This output stops the Bus Controller from sending output data to the Genius 1 0 blocks on that bus When this bit is on no output data is sent however input data is still received from the blocks The I O blocks hold the current state discrete or value analog for up to 500 ms After this output has been on for 500 ms the blocks assume that the communications bus has failed and go to their configured state or value either hold last state or default to a specific state or value When bit O is off the outputs will again receive da
218. k with either 1 or 3 slots available for I O modules The 13 rack requires the wide range ac power supply catalog number IC600PM500 Basic Unit Configuration The Series Six Plus PLC basic CPU unit as received from the factory consists of a rack with cable tray a power supply an I O Control module an Arithmetic Control module and connecting ribbon cable to the Logic Control module a module extraction insertion tool an I O terminator plug rack mounting brackets and hardware and a Series Six Plus Users Manual Any blank faceplates that are required must be ordered separately The Logic Control module must be ordered separately for the required level of functions either Advanced Expanded or Expanded Il of six available Combined Memory modules must also be selected and ordered separately The required power supply for the 19 rack must be specified and can be either the wide range ac version or one of the two dc versions 24 V dc or 125 V dc The only power supply currently available for the 13 rack is the wide range ac supply Expanded Il functions require the IC600CB524 Arithmetic Control module the IC600CB610 8 slot CPU rack or a 19 CPU rack having a date code later than 10 87 and one of the IC600LX logic memory modules 8K minimum registers Physical Equipment Configuration 2 3 GEK 96682 SLOT 11 11 SLOTS FOR MODULES SLOT 1 a41058 BASIC RACK CONFIGURATION PE OO POWER SUPP
219. l Module in the Series Six Plus CPU rack NOTE Existing versions of the Series Six PLC Combined Memory module catalog numbers IC600CM552 and IC600CM554 can be used in a Series Six Plus CPU rack Additionally all Series Six Plus PLC Combined Memory modules can be used with a Series Six PLC model 60 CPU however there is no parity check with this combination Precautions When Handling Memory Modules When installing or removing a Combined Memory module it is recommended that you use the extraction insertion tool IC600MA504 provided with each CPU CAUTION Relatively small amounts of excess charge can cause very intense electrostatic fields in Metal Oxide Semiconductor MOS devices damaging their gate structure Avoid handling the circuit board under conditions favoring build up of static electricity Failure to observe this caution could result in destruction of the CMOS RAM devices in this module A bottom board cover provided with each Combined Memory module acts as an electrical noise shield and helps protect the battery circuits from accidental discharge This cover should not be removed during operation or handling of the board CAUTION Do not allow the bottom of the module to come in contact with a conductive metal surface when the board cover is removed Failure to observe this caution could result in the discharge of the non rechargeable lithium battery and the loss of memory contents Memory Protection A tw
220. l options of the 2 are not available to the CCM3 RS 422 with clock on port J1 Test 1 on port J2 This is because the DIP switch settings and the bit pattern for the software configuration registers which are on the actual CCM2 are used to select the options listed above are reserved on the CCM3 to select mode for ports and J2 If any protocol selection for CCMS3 port is made other than RTU that port will operate as a CCM2 When configuring the CCM3 in CCM2 mode follow the directions found in Chapter 3 Communications Control Module CCM2 in GEK 25364 which is the Series Six Data Communications Manual CCM3 Remote Terminal Unit RTU Mode mode the is a slave device designed to be used on a link with a host computer or other intelligent device capable of emulating RTU master protocol When using this mode the CCM3 is capable of accessing the following Series Six Plus PLC memory types register tables input and output tables override tables scratch pad and user logic In addition several Serial Communications REQuests which do not use RTU protocol the unformatted Write and Read Character String commands can be initiated by application programming when in RTU mode These communications requests are included in CCM3 RTU software for application programming Dual Mode Usage One CCM3 communications port can be configured in CCM2 mode at the same time that the other port is configured in RT
221. le failures Module Connections The Advanced I O Receiver module has two 37 pin connectors available through the faceplate The top connector receives an I O cable that is connected to an upstream I O rack or directly to the CPU If coming from another upstream I O rack it may be connected to a standard or Advanced I O Receiver module or to a Local I O Transmitter module The bottom connector can be left unconnected connected to a standard or Advanced I O Receiver module or be connected to a Workmaster computer or Program Development Terminal Any of the modules mentioned above can be connected and intermixed to meet the requirements of a given application On both the standard and Advanced I O Receivers the top and bottom connectors are connected together internally thus data signals can pass through them even though the VO rack may be non functional In the Advanced module data can also pass through even if the power supply is turned off Physical Equipment Configuration 2 47 96602 lO Signal Continuation or Termination Located on the Advanced I O Receiver module are two identical DIP resistor pacs The location of these DIP pacs determines if the module is used in an intermediate I O rack or used in the last rack of an I O chain The module is configured for use in an intermediate rack when the DIP resistor pacs are located in sockets U7 and US default positions When configured as the last rack in an I O chain the
222. le in two versions Catalog Number IC600BF915 is Type 1 Resolver Feedback and Catalog Number IC600BF917 is APM Type 2 Encoder Feedback For detailed information on Axis Positioning Modules refer to the applicable user s manual These manuals are Axis Positioning Module Type 1 GEK 25368 Axis Positioning Module Type 2 GEK 90800 1 18 Introduction To The Series Six Plus PLC GEK 96602 Communications Control Modules In addition to controlling peripheral devices the Communications Control Modules CCM provide for communications among all of the GE Fanuc NA PLCs which include the Series Six Plus Series Six Series Three Series One Plus Series One and Series One Junior In addition the Workmaster and Cimstar computers Operator Interface Terminals and host computers can be included in a communications system These devices all use the CCM protocol which supports point to point and multidrop configurations with data rates from 300 to 38 4K baud A master CCM device such as the Series Six Plus PLC can poll up to eight slave devices controlled by the Communications Request function SCREQ GENET Factory LAN For applications requiring much broader communications capabilities than the CCM can provide or a Local Area Network LAN for communications with other factory automation equipment the GEnet Factory LAN is available The GEnet Factory LAN is a 10M bps broadband token passing bus which provides high speed co
223. lectronic devices directly through physical wiring Hexadecimal A numbering system having 16 as a base represented by the digits O through 9 then A through F Input A signal typically ON or OFF that provides information to the PLC Inputs are usually generated by devices such as limit switches and pushbuttons Input Module An I O module that converts signals from user devices to logic levels used by the CPU Interface To connect a programmable logic controller with its application devices communications channels and peripherals through various modules and cables lO Input Output That portion of the PLC to which field devices are connected Isolates the CPU from electrical noise lO Electrical isolation A method of separating field wiring from logic level circuitry Typically accomplished through the use of optical isolation devices VO Module printed circuit assembly that interfaces between user devices and the Series Six Plus programmable logic controller Appendix A Glossary of Terms A 3 GEK 96602 VO Scan A method by which the CPU monitors all inputs and controls all outputs within a prescribed time K An abbreviation for kilo or exactly 1024 in the world of computers Usually related to 1024 words of memory LED An acronym for Light Emitting Diode which is a solid state device commonly used as a visual indicator in electronic equipment Ladder Diagram A representation of control logic
224. lengths a system configuration are determined by the type of I O station used For cable limitations refer to Chapter 2 in this manual Table 3 4 lists the standard length I O cables available Table 3 4 PARALLEL i O CHAIN CABLE CATALOG NUMBERS Length Catalog Feet Meters Number IC600WD002A IC600WD005A IC6OOWD010A IC600WD025A IC600WD050A IC600WD100A IC600WD200A IC600WD300A IC600WD400A IC600WD500A Installation Instructions 3 25 GEK 96692 Parallel I O Cable Conf iguration Figure 3 19 is an illustration of the Parallel Chain cable used to connect CPU to I O rack or to connect racks in a daisy chain in a CPU I O station a Local I O station or racks within a Remote l O station Minimum conduit size for running this cable with the hoods in place should be 21N TUBING OVER SHIELD CABLE LENGTH TAL ER CHART BELO WIDE CABLE TIE STAMP CABLE NUMBER IC600WD JR THIS AREA ey turn Jg po MOUNTING HARDWARE 2 PER CONNECTOR MALE FEMALE CONNECTOR Sous CONNECTOR MOUNTING MARDWARE 2 PER CONNECTOR WIRE TABLE FOR ALL CABLE LENGTHS PLUG 4 WIRE TABLE PLUG 2 PLUG 2 2 BLUE WIT SOCKET 2 PIN 2 REO GRY SOCKET 21 PIN 3 WHT BLU SOCKET 3 PIN 22 BLU BLK SOCKET 22 4 ORK WHT SOCKET 4 PIN 23 BLK BLU SOCKET 23 5 WHT ORN SOCKET HS PIN 24 DRN BLK SOCKET
225. liary battery terminals on the power supply terminal block a42221 EXTERNAL AUXILIARY BATTERY SELECT Figure 3 7 MEMORY BOARD BATTERY CAUTION Relatively small amounts of excess charge can cause very intense electrostatic fields in metal oxide semiconductor MOS devices damaging their gate structure Avoid handling the circuit board under conditions favoring the buildup of static electricity Failure to observe this caution could result in the destruction of the CMOS RAM devices in this module Installation Instructions GEK 96602 CAUTION Do not allow the bottom of a module to come into contact with a conductive metal surface when the board cover is removed Failure to observe this caution could result in the discharge of the non rechargeable lithium battery and the loss of memory contents When installing a Combined Memory module or any module position the component side of the board to your right towards the CPU power supply Figure 3 8 shows proper orientation of a printed circuit board a41136 NOTE Proper orientation of printed circuit boards is with component side towards the power supply Figure 3 8 PRINTED CIRCUIT BOARD ORIENTATION IN A RACK Install the faceplate by placing the faceplate in the proper position and while pushing in turn the quarter turn thumbscrew clockwise until it feels secure Installation Instructions 3 11 GEK 9660 2 A
226. location and maximum length of the fault tables can be determined by referencing the memory maps for 1 K 8K and 16K registers figures 4 3 4 4 REGISTER MEMORY SIZE VS GENIUS I O DIAGNOSTICS The register memory size specified by the entry in the Configuration Menu tells the CPU the amount of Genius I O diagnostics to perform Care should be exercised by the user when specifying register sizes in order to ensure upward compatibility For a register size of 1K diagnostics will be performed up to the first 1024 inputs and 1024 outputs Maximum register sizes of 8K or 16K will allow the CPU to perform diagnostics on the maximum of 16K inputs and 16K outputs References other than those specified for diagnostics are available for general use by the user Fault Table Pointer A counter located at the top of the fault table first register in the table is a pointer that indicates how many faults have been stored in the table When the table is full no additional entries are allowed until the counter is cleared or reduced in content by the user s program thus indicating that space is available for new entries The actual content of the table is not cleared to zero The pointer returns to the first register and the next data is loaded into the pointer location Any new data written to a register writes over the old data New data is loaded into the next available location with the oldest data at the top The fault table length is specified in mult
227. lock Inputs 33 36 with 33 the LSB can display the value 0 through 15 however only 0 1 and 2 are used The value 0 indicates a fault with the EEPROM in the block s terminal assembly The value 1 indicates that the circuit fault is on a discrete I O block and the value 2 indicates that the circuit fault is on an analog I O block Inputs 37 through 40 indicate the relative circuit number on this I O block The value 0 represents the top circuit of the block 7 or 15 the bottom circuit for discrete blocks and 5 the bottom circuit on analog blocks On the analog blocks the values 0 to 3 indicate input channels 1 to 4 4 and 5 represent output channels 1 and 2 Byte 6 Inputs 41 through 48 are individual bits that indicate the type of fault Only one of these bits will be on at a time Table 4 5 defines the faults represented by the inputs 41 through 48 Notice that they are decoded differently for discrete and analog blocks as indicated by the fault type in Byte 5 inputs 33 36 Table 4 5 DECODING OF BYTE 6 FOR CIRCUIT FAULT TYPES RELATIVE SIGNIFICANCE F ON INPUT NUMBER DISCRETE 1 0 BLOCK ANALOG I O BLOCK 4 Loss of Circuit Power Low Alarm 42 Output Short Circuit High Alarm 43 Output Overload Input Underrange 44 If Input Open Wire Input Overrange If Output No Load 45 Over Temperature Open Wire 46 Failed Switch Output Underrange 47 not used Output Overrange 48 not used not used Adjust as necessary
228. lug and the Series Six Plus User s Manual This package is then placed in a shipping container Combined Memory Logic Control and any optional modules are shipped separate container Each module is placed in the bottom of a two section foam plastic package Two inserts are provided one for the printed circuit board and one for its faceplate The top section is added and this package is inserted into a sleeve Either 2 5 or 10 module packages are then placed in a shipping container e racks are shipped with only the power supply in place The I O racks and I O modules are packaged the same as the CPU rack and modules 3 2 Installation Instructions GEK 96682 The Workmaster or Cimstar industrial computer is packed in a separate shipping container It is recommended that the shipping containers and all packing material be saved in the event that it becomes necessary to transport or ship any part of the system VISUAL INSPECTION Upon receiving your Series Six Plus PLC system carefully inspect all shipping containers for damage during shipping If any part of the system is damaged notify the carrier immediately The damaged shipping container should be saved as evidence for inspection by the carrier It is the responsibility of the consignee to register a claim with the carrier for damage incurred during shipment However GE Fanuc NA will fully cooperate with the customer should such an action be necessary
229. lure or board is not in a High Capacity I O rack or a Series Six Plus CPU rack Board is good and has received the ENABLED APM command Failed power up self diagnostics any error condition or has received the RESET command Drive Enable relay is closed Drive Enable relay is open Troubleshooting and Repair 5 27 GEK 96602 Table 5 4 1 0 MODULE STATUS INDICATOR DEFINITIONS Continued MODULE INDICATOR STATUS DEFINITION ON Board has passed the self diagnostic test and is operating properly ASCII BASIC OFF Board has failed BATTERY ON On board Lithium battery voltage is OK within tolerance FLASH Battery voltage is low Replace battery OFF Lithium battery voltage is too low and will not maintain the user program stored in CMOS RAM memory Replace battery ON Serial data present at receiver 1 input OFF Receiver input inactive ON Serial data present transmitter 1 output OFF Transmitter 1 output inactive ON Serial data present at receiver 2 input OFF Receiver 2 input inactive TRANS 2 ON Serial data present transmitter 2 output OFF Transmitter 2 output inactive 1 0 RACK CONNECTIONS When troubleshooting the I O system it is important to understand the interconnection of racks and stations Refer to the following illustrations of CPU to I O rack connections 1 rack to I O rack connections and a typical I O rack wiring scheme for proper cable connections and cable length guid
230. mmunications between GE Fanuc NA equipment including Programmable Controllers Numerical Control equipment and higher level factory level management control systems The GEnet Factory LAN is based on accepted industry standards It uses the International Standards Organization s Open System Interconnection OSI model as the basis for its communications architecture GEnet complies with the General Motors Manufacturing Automation Protocol MAP specification and with the ANSI IEEE Standard 802 4 1985 for token bus networks The Programmable Controllers and Numerical Control equipment interface to the broadband token bus through a Bus Interface Unit BIU The BIU is tailored by loading device specific software to provide the required interface to the various automation products As an example any device supporting the CCM protocol can access the GEnet Factory LAN with translation to MAP through the BIU Other basic components of the GEnet Factory LAN are the Network Management Console NMC and the Head End Remodulator The NMC provides overall system configuration management and control It operates on a Workmaster or Cimstar industrial computer equipped with PLC BIU hardware and network management software The head end contains the equipment required to provide for RF operation on the broadband cable For further information on the GEnet Factory LAN refer to the System User s Manual GEK 96608 and the Network Management Console User
231. mote Parity Parity error in Remote 1 0 station Remote parity good 5 19391 Remote OK Fault in Remote System Power supply failure parity error etc Normal operation Remote I O OK 6 10302 Link OK Error detected with communications between Remote 0 Driver and Receiver Communications link good 1 10303 Local OK 0 Fault in Remote I O Driver module Remote 1 0 Driver operation normal 8 100304 Heartbeat This input cycles from to 0 1 0 1 etc changing with each 1 0 scan when Remote I 0 is operating normally If any input status 4 7 is set to zero cycling stops and the status will contain the last valid data received 0 or 1 1 I 0 references shown are typical and are only used as an example Physical Equipment Configuration 2 57 GEK 96682 Status Indicators There are four LED status indicators viewed through the faceplate lens The four LEDs display the same status information as that indicated by the state of Inputs 4 through 7 in table 2 18 These indicators and their meanings are listed below in table 2 19 in the same order as they appear on the module faceplate Table 2 19 REMOTE I O DRIVER STATUS INDICATORS INDICATOR DEFINITION LOCAL ON emote 1 0 Driver module operating normally OK OFF Fault in Remote 1 0 Driver LINK ON Communications link between this module and Remote Receiver good OK 0f Communications error between this module an
232. n I O Receiver or Advanced Receiver located in the rack nearest to the CPU rack The last rack can be no more than 50 feet from the CPU Counter A function within the PLC that records events based upon the On Off transition of a signal coil associated with the counter is energized at a user determined preset value DIP Switch An acronym for Dual n Line Package which is a group of miniature toggle or slide switches arranged side by side in a single package Commonly used as the physical device for setting the configuration of various parameters necessary to the operation of electronic equipment Data Link The equipment including interface modules and cables that allow transmission of information Discrete Consisting of individual distinct things such as bits characters or circuit components Also refers to On Off type of t O modules Field Devices User supplied devices typically providing information to the PLC Inputs pushbutton limit switches relay contacts etc or performing PLC tasks Outputs motor starters solenoids indicator lights etc Firmware A series of instructions contained in ROM Read Only Memory which are used for internal processing functions only These instructions are transparent to the user Hardware All of the mechanical electrical and electronic devices that comprise the Series Six Plus programmable controller and its application s Hardwired Interconnection of electrical and e
233. n I O Transmitter module a 16 pair twisted shielded parallel bus cable and one or more I O Receiver or Advanced I O Receiver modules 4 Observe the LOCAL PARITY light on the I O Receiver or Advanced I O Receiver modules Status Definition Output parity is OK in this I O rack OFF Output parity error has been detected by the I O Receiver module Corrective Action Ensure that there is good grounding between racks in that station Ensure that the low level I O cable has not been placed close to any high level power cables power supplies or switching devices e Replace the 1 0 Receiver or Advanced I O Receiver module e Replace the parallel chain I O cable between this rack and the next rack upstream back toward the CPU e Replace the 1 0 Transmitter or I O Control module driving this station Troubleshooting and Repair 5 33 GEK 96602 5 Observe the POWER light on the 1 power supply Status Definition The voltage level of all dc voltages is within tolerance OFF No ac or dc source voltage The voltage level of any dc voltage is out of tolerance The CHAIN OK light from this rack back to and including the CPU rack will be off The RUN and ENABLE lights on the CPU are off and Alarm Number relay switches Corrective Action e Check the circuit breaker e Standard power supply Ensure that the jumper to select either 115 or 230 V ac is correct and the ac
234. n line or system down for an extended period of time The replacement concept minimizes downtime to minutes as opposed to days The potential savings far outweigh the comparatively small cost of duplicate modules If you did not purchase a duplicate set of modules with your initial system we recommend that you contact your local GE Fanuc NA Programmable Control Distributor or GE Fanuc NA Sales office and do so Then with the help of this manual and adequate spare parts you will be able to troubleshoot and repair just about any problem that may arise Troubleshooting and Repair 5 3 GEK 96602 SECTION 1 CENTRAL PROCESSING UNIT TROUBLESHOOTING FAULT ISOLATION AND REPAIR The malfunction causing the improper operation of a CPU can be isolated by checking the condition of status indicator lights and key switch positions The status indicator lights and key switches indicate the current operating condition of the CPU and I O system Check Condition of Status Indicator Lights The normal condition of the status indicator lights is the ON state If any of the status indicator lights are not on check the troubleshooting sequence in this section for the proper course of action Tables are provided throughout this section which provide definitions of the ON OFF status of each of the indicator lights Table 5 1 is an indicator chart that gives a quick reference to the normal condition and definition of the status indicator lights for the
235. n previously set and enabled Cycling the power of the rack that contains the module will also reset the LED indicators Note that the power supply OK LED indicator will be latched off when this is done The following table describes the function of each diagnostic indicator Table 2 14 STATUS AND DIAGNOSTIC INDICATOR DEFINITIONS CHN OK CHAIN OKAY ON if power is okay in all downstream racks and if cable continuity is okay to all downstream racks OFF if one of the above conditions is not met CHNPAR CHAIN PARITY ON 1f Output Parity is okay on rack backplane OFF if Output Parity Error is sensed from a Local Transmitter or Remote 1 0 Driver in this rack LOCPAR LOCAL PARITY ON if Output Parity 15 okay in this rack OFF if this module has detected an Output Parity Error entering from an upstream rack BLANK The state of this LED is controlled by CPU logic and transmitted to the module via its 1 0 address The default state of this LED is ON ADDPAR ADDRESS PARITY ON if no error 1s detected in the 1 0 address transmitted from the CPU through the 1 0 chain OFF if a Parity Error is detected in the I 0 address transmitted from the CPU Successful retransmission of the address will clear the Parity Error DATPAR DATA PARITY ON if no error is detected in the 1 0 data transmitted from the CPU through the 1 0 chain OFF if a Parity Error is detected in the I 0 data transmitted from the CPU Successful retransmission of data will clear Par
236. nded 1 0 to enable expanded I O scanning to enable Genius 1 0 diagnostics and to enable the Computer Mail Box NOTE Logicmaster 6 software includes HELP screens for information on Expanded mapping These screens display information relative to avoiding multiple use of registers when using modules that reference particular registers ASCII BASIC Loop Management Module etc The following configurable items are described on the following pages How to display the CPU Configuration Set Up menu How to enable and set the range for Expanded 1 0 scanning How to enable and set the range for Genius 1 diagnostics How to display the Bus Controller Map menu How to select the use of the Computer Mail Box The Configuration Set Up Menu can only be displayed in the On Line or Monitor mode if the current program includes the CPU Configuration instruction SERIES SIX CONFIGURATION DATA To display the CPU Configuration Set Up menu when in the On Line or Monitor mode follow the steps below 1 The program must be present in system memory If it is not load it using the Load Store Verify functions Return to the Supervisor menu 2 From the Supervisor menu press the Expanded Functions F7 key 3 From the Expanded Functions menu press the CPU Configuration F1 key The menu will then be displayed as shown below CPU CONFIGURATION SET UP MENU EXPANDED 1 0 ENABLED N Y N SCAN BEGIN RANGE CHANNEL O POINT END RANGE CHANNE
237. nfiguration GEK 9660 2 CONTROL MODULE The purpose of the I O Control module catalog number 6 503 is to provide an interface between the CPU backplane bus and the main I O bus It is also the interface to and controls data transfers between the CPU and certain peripheral devices Logic on this module includes command status port select and data latches a status multiplexer and control and timing circuitry The I O Control module must always be placed in slot 1 which is adjacent to the power supply User Connections There are two 37 pin connectors located on the front of the module The programming device for the Series Six Plus plugs into the top connector which is labeled PP DPU The bottom connector labeled I O provides the connection to the main I O chain The I O Control module is connected through a parallel I O cable to the top connector of an I O Receiver or Advanced I O Receiver located in the first I O rack a CPU station or Local I O station The last rack of a CPU I O station can be located up to 50 feet from the I O Control module If a Redundant Processor Unit RPU is to be included in the control system the bottom connector of the I O Control module is connected to the CPU1 or CPU2 connector on the RPU s CPU Switch module depending on whether the CPU is the main or back up CPU The main CPU connects to the CPU1 connector and the back up CPU connects to the CPU2 connector on the RPU Wh
238. nformation on programming the Expanded functions refer to the Logicmaster 6 Programming and Documentation Software User s Manual GEK 25379 All existing features functions I O modules programming devices and peripheral devices currently available for the Series Six PLCs can be fully used by the Series Six Plus PLC NORMAL MODE OF OPERATION In the Normal mode of operation the Series Six Plus CPU scans the Main I O chain and the Auxiliary I O chain in the same manner as in Series Six PLCs In the Normal mode the maximum number of I O points available is 4000 1000 Inputs and 1000 Outputs in the Main I O chain and 1000 Inputs 1000 Outputs in the optional Auxiliary I O chain Additionally direct addressing of all 16K words of Register memory with all Advanced functions is supported EXPANDED FUNCTIONS With the Expanded functions option the Series Six Plus PLC has access to and can perform many additional functions when compared to the Series Six PLCs These functions are 1 Expanded I O Up to 16 channels 8 on Main I O chain 8 on Auxiliary I O chain of can be configured within a range of stop and start addresses configured by the user with a Workmaster computer using Logicmaster 6 software Each channel has 100 Inputs and 1000 Outputs The I O scanning is done exactly as in the Series Six PLC with the Auxiliary I O chain scanned in parallel with the Main I O chain I O scanning takes 7 ms for each pair 0 and 8 1 and 9 et
239. ng for connecting a Workmaster computer to the I O Control module in the CPU rack or to an I O Receiver or Advanced l O Receiver in a CPU station or Local I O station The maximum distance for this type of connection is 10 feet 3 meters Connection to an I O Transmitter Module When ALL of the switches are set to the ON closed position the parallel I O bus is properly terminated for long distance communications through an I O Transmitter module up to 500 feet 150 meters away With this configuration the I O Transmitter module must be dedicated to communicating with the Workmaster computer WARNING All of the DIP switches on the Terminator Board must be set properly as described above Failure to do so may result in the Series Six Plus CPU stopping in an incorrect state or incorrect operation of the I O bus which may cause the outputs to be directed to an incorrect state Physical Equipment Configuration 2 63 GEK 96692 The valid connections for the Workmaster computer to the parallel 1 0 chain are illustrated in figure 2 32 41085 OTE wx T 77 NE 12755 WoRKMASTER ONLYONEWORKMASTER 1 CAN BE CONNECTED licei AT A TIME SERIES THE CABLE CONNECTING WORKMASTER TO THE SERIES SIX FLUS IS A STANDARD 1 D CABLE 1 0 CONTROL ADVANCED 1 0 RECEIVER 1 0 TRANSMITTER OR 1 0 RECEIVER SERIES SIX CPU STATION 1 0 RACK ADVANCED Q RECEIVER WORKMASTER OR 1 0 RECEIVER L
240. ngs for the Remote I O Receiver options 2 60 Physical Equipment Configuration GEK 96602 Table 2 22 REMOTE I O RECEIVER OPTtONS OPTION FACTORY SETTING CHOICES Baud Rate 57 6 Kb User selected Parity 0 Yes even or Communications Turn all Hold all outputs Failure at outputs Off at last state Remote I O Terminate 1 0 chain Signals at this module I 0 Chain Signals I 0 Chain Signals have continuity through this module Instructions for reconfiguring any of the circuit board jumpers to change options can be found in the applicable data sheet see GEK 25367 Series Six Data Sheet manual for this module Jumper options are required when selecting the RS 232 option and are listed in the chapter on installation in this manual In addition there are jumpers reserved for future expansion or production testing and should not be changed AUXILIARY SYSTEM The Auxiliary I O system allows the total number of I O points in a Series Six Plus PLC system to be doubled If an Auxiliary tO module is inserted into slot 6 or 7 of a CPU rack an I O system functionally identical to the main I O system can be originated at the CPU The Auxiliary I O chain is scanned in parallel with the Main I O chain Auxiliary I O chain does not increase the total CPU scan time The structure of the Auxiliary I O system provides the Series Six Plus CPU with an additional 1000 inputs and 1000 outputs when o
241. nications Control Modules CCM2 CCM3 I O CCM I O Link local provide a serial interface between the Series Six Plus PLC and any intelligent device that can initiate communications based on the CCM protocol and CCM electrical interface requirements A brief description of each of these modules is provided in this manual For detailed descriptions of these modules and pertinent data communications information refer to GEK 25364 which is the Series Six Data Communications Manual GEK 90505 which is the Supplement To The Data Communications Manual and GEK 90824 which is the data sheet for the Input Output Communications Control Module Communications Control Module Type 2 CCM2 The CCM2 catalog number IC600CB516 has 2 serial ports that provide RS 232 and RS 422 electrical interface capability RS 232 is normally used for direct connections at a maximum distance of 50 feet 15 meters The RS 422 interface allows direct connection up to 4000 feet 1200 meters The CCM2 can be connected directly to short haul or telephone line modems through the RS 232 interface if transmission distances greater than the 4000 feet allowed by RS 422 are required The CCM2 can operate at speeds up to 38 4K baud and can originate messages with control by the ladder diagram logic using the Serial Communications Request SCREQ Examples of intelligent devices that can be interfaced to the CCM2 include Communications Control Module Type 3 CCM3 host
242. nstream stations have good output parity Output voltage of the 5 V dc isolated power converter is within tolerance System will stop for a local fault condition System will NOT stop for a local fault condition Expanded I O chain active Expanded I O chain inactive This LED is not visible with faceplate in place for use in system set up onl 5 24 Troubleshooting and Repair GEK 96602 Table 5 4 1 0 MODULE STATUS INDICATOR DEFINITIONS Continued MODULE REMOTE 1 0 DRIVER REMOTE 1 0 RECEIVER INDICATOR REMOTE OK REMOTE PARITY REMOTE OK REMOTE PARITY ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF DEFINITION Module operating normally Fault exists in this module Communications link between this module and Remote I O Receiver is good Communications error between this module and Remote I O Receiver Remote system operating normally Valid I O data received from Remote Receiver Fault in Remote I O system Power supply failure loose cable module not seated properly etc No parity errors in remote I O system Parity error detected in Remote I O system On board jumper selects if CPU will stop or continue running Module operating normally Communications failure due to timeout or successive transmission errors Communications link between this module and Remote I O Driver established and valid Communications error between this module and Remote I
243. nter key 5 Complete the logic for the rung then press the Accept key The Edit key functions reappear at the bottom of the screen When the DO I O function is executed through user logic the I O points specified by START and END will be serviced immediately When active bit 15 or 14 and 15 must have been set to a 1 and the starting channel and address must be equal to or less than the ending channel and address in order for power flow to be passed through the function If either of these conditions are not met the function will not pass power flow Expanded CPU Operation 4 27 GEK 96602 EXPANDED TIME REFERENCE REAL TIME CLOCK This is a three word real time clock maintained by the CPU in three consecutive registers The exact register address is determined by the total register size in the CPU The clock is located in the following registers MAXIMUM REGISTERS CLOCK IN SYSTEM LOCATION 1K R0267 R0268 R0269 8K R4117 R4118 R4119 16K R4117 R4118 R4119 The function of the clock is to record elapsed time and maintain an accurate record of the time that Genius I O faults occur Format of the Real Time Clock The clock keeps track of time in hundreds of days days hours minutes seconds and tenths of seconds Each fault is time stamped with the clock reference and stored in the Genius I O Fault Table if it is enabled The clock stops when power is removed and must be reset by the user when power is
244. nto the short slot beside the bottom of the solder side of the board See figure 3 4 for proper toof positioning for insertion of a board Grasp the handle area of the board puller with either hand and squeeze it until you feel the board seat Visually inspect the board to be sure it has seated properly Remove the tool a42067 Figure 3 4 POSITION OF EXTRACTION INSERTION TOOL FOR BOARD INSERTION 3 6 Installation Instructions GEK 96602 Removing a Printed circuit Board The following instructions should be followed for proper removal of a printed circuit board from its slot Insert the board puller studs into the printed circuit board from the solder side of the board Ensure that the board puller surface is flat against the printed circuit board The board puller is now 180 degrees reversed from the position for inserting a board See figure 3 5 which shows proper positioning of the tool Grasp the handle area with either hand and squeeze it The board should break loose from the connectors and set loose in the cardguides Remove the board puller and slide the board out of its slot Handle the board carefully 41080 EXTRACTION INSERTION TOOL MUST BE FLAT AGAINST BOARD SURFACE Figure 3 5 POSITIONING THE EXTRACTION INSERTION TOOL FOR BOARD REMOVAL MODULE INSTALLATION The modules for your system should now be installed in their proper slots in the CPU and racks Before installation some of the
245. o position key switch located on the power supply is provided for protecting logic and override memory that has been written into The two positions are MEMORY PROTECT and WRITE In the WRITE position the user can write into logic memory to enter or change programs When in the MEMORY PROTECT position logic memory cannot be written into thereby protecting any user program previously entered from being changed or destroyed Once a program has been entered and debugged it is advisable to place the key switch in the MEMORY PROTECT position 2 20 1 BATTERY Light Steady On Battery Normal Flashing Battery Low The CPU continues running 2 advisory alarm is activated To protect the memory contents replace the battery before it fails When the light begins to flash battery failure will occur approximately 30 days Steady Off Battery Failed CPU continues running but will not restart if stopped No 2 alarm remains activated Memory contents will be lost when power is switched off or lost 4 5 Physical Equipment Configuration GEK 96602 a40760 PARITY Light On Table Memory Register Memory and Logic Memory Parity is OK Off Table Memory Register Memory or Logic Memory parity error exists or board is in a model 60 rack error message appears on the Workmaster computer display or in the work area of the Program Development Terminal display Lithium Manganese Dioxide Battery
246. odules requiring different switch settings such as High Density or Analog modules refer to the installation instructions on the applicable data sheet for each module for proper DIP switch configuration After configuring the DIP switches install the I O modules in their respective slots as determined by your program The actual I O reference used for each I O point in your program depends on whether the I O system is in the Normal or Expanded I O mode If the Expanded I O mode is selected the applicable channel number is added before the reference number as described previously NOTE There are limitations on the combination of types of I O modules which be instal led in an I O rack This is determined by the load placed on the power supply by the various modules B _ X ZX x xix TI E25 E32 XT XT XX x j rss x xi x xt THX E Epis XAR L EHIE EE quw 27 388 25 271 1151515 561 568 X FI o eerie X x xL LE TL B p quen DEE xc essi 149 756 X X X X X 595 597 s TR Xf X TX X 9971 54 65 616 196 932 TXT XT EXC terre Tata be pa LXX OX 315 320 IX XXIX et m X Swtich in OPEN Position Depressed to the Left F
247. oes exist the Bus Controller writes an error code into the status code of the third register of the command block in the CPU If a command of the same type is already being executed the Bus Controller will not modify the status code in a subsequent Computer Mail Box window when the busy condition disappears If the command number specifies a write command the Bus Controller must read the specified amount of data from the CPU register memory and store it in the serial bus output queue 4 44 Expanded CPU Operation GEK 96692 Terminating Computer Mail Box Communications The Bus Controller will then close the communications window by issuing a Close Window command which terminates execution of the Computer Mail Box The window address of the Bus Controller in the first register that was communicated with is cleared when the value placed in the status register third register by the CPU is not equal to 1 any valid number except 1 USING THE DPREQ FUNCTION TO COMMUNICATE WITH GENIUS I O The CPU can communicate with the Genius I O system through a window opened during the logic solution of the CPU s sweep When th amp window is opened is determined by programming Data Processor Request DPREQ functions in the user program with a constant parameter which is a pointer to a group of registers that contain the command block The command block contains the Bus Controllers window address which corresponds to its address defined by the
248. of 8 1 0 byte addresses 64 references as shown in table 4 4 These addresses must correspond to the addresses configured on the Bus Controller map The diagnostics will not function if this address guideline is not followed The 2 bytes 16 bits not used by the diagnostics are available for general 1 0 use Table 4 4 BUS CONTROLLER ADDRESSES FOR DIAGNOSTIC STORAGE 1 0 DIP POSITION POSITION WITH DIAGNOSTICS ADDRESS 7 TIED E INPUTS 48 OUTPUTS 32 Positions 1 2 and 3 must always be depressed to the right CLOSED Those positions indicated by must be depressed to the left OPEN Bus Controller Status Byte 1 Address 0 Input 1 BUS CONTROLLER OK This input is set on within one second of power up if the Bus Controller passes a power up self test The input is updated by the Bus Controller every scan to verify proper operation of the Bus Controller The user should turn this input off using a Bit Clear instruction at the end of every CPU scan If power is removed from the I O rack containing the Bus Controller this input may remain in the ON state The user program can set the input off and verify that for every scan the Bus Controller is actively providing an ON state 4 30 Expanded CPU Operation GEK 96602 5 T 4 3 J 2 J 1 J 0 ADDRESS 4 ajo xm fa nfe sfe 1 VOREFEREMCS BYTE 6 BYTE 5 BYTE 3 BYTE 2 BYTE NUMBER INPUTS 40745 20 7 BUS CONTROLLER O
249. of the status indicator lights the 1 0 racks and the originating CPU where an apparent malfunction has occurred The following steps provide a suggested troubleshooting sequence 1 Check at CPU Condition of all status lights If all the CPU status lights on proceed to step 11 e f the CHAIN OK status light on the I O Control module is on but or more of the other CPU status lights are off refer to the CPU troubleshooting section steps 1 through 12 if the CHAIN OK status light on the 1 0 Control module is off a CHAIN OK or CHAIN PARIT Y problem is indicated Proceed to step 11 Check the CPU station I O racks and Local O station and Remote 1 0 station racks for condition of the status lights 2 Observe the CHAIN OK light on the I O Receiver or Advanced I O receiver I O Transmitter modules Status Definition I O power is OK in this and all downstream racks and stations Continuity is OK to all downstream stations OFF A power or continuity problem has occurred The CPU RUN and ENABLE lights also turn off Alarm Number 1 relay switches Corrective Action Locate the last I O rack in the 1 0 chain that has the CHAIN OK light off Check I O Receivers Advanced I O Receivers and I O Transmitters Check cable connections Check circuit breaker on the power supply If Power status light is off check ac or dc input and dc voltages Refer to step 5 Replace the
250. oint Division Program a Floating Point Division function to divide the value in reference A by the value in reference B and place the result in reference C The possible signs Reference A Reference B Quotient 4 T 4 Floating Point Division will not normally output power flow except under the following conditions The result is too big to represent overflow The result is too small to represent underflow Reference B is a zero Both references A and B are infinities One or both of references A or B is not a number invalid format IPONA 4 24 Expanded CPU Operation GEK 96602 Floating Point Greater Than Program a Floating Point Greater Than function to compare the value in reference A to the value in reference B Every scan that power is received the Greater Than function compares the content of reference A to the content of reference B Comparison is based on the signed floating point values of the contents Power flows only if the first value is greater than the second Some example comparisons are shown below Reference A Reference B Power Flow 2 34595 1 2 34595 0 YES 2 34595 2 34595 1 NO 0 00000 0 9 99999 YES 0 00000 0 100000 1 YES 0 00000 0 1 00000 1 NO Convert Integer To Floating Point Every scan that power is received the integer to Floating Point function reads the integer value of reference A and places the floating point equivalent in reference B P
251. oint functions 4 21 addition 4 22 convert floating point to integer 4 24 convert integer to floating point 4 24 display format 4 21 division 4 23 Index GEK 96692 INDEX greater than 4 24 multiplication 4 23 programming of 4 22 subtraction 4 22 Functions advanced 1 10 Functions basic 1 9 Functions expanded 1 10 G Genius I O Bus controller 2 21 Genius l O blocks 1 13 Genius I O diagnostics 4 28 bus controller diagnostic storage 4 29 bus controller input and output addresses 4 29 bus controller input status definitions 4 29 to 4 33 bus controller output data 4 36 bus controller output data definitions 4 36 to 4 37 bus status control byte 4 39 fault table 4 28 fault table pointer 4 28 fault table registers 4 34 point status bit map 4 38 register memory size 4 28 Genius I O system general description 1 6 typical communications ink 1 6 GEnet Factory LAN 1 18 1 19 Global data service 1 21 Glossary of terms Grounding procedures system 3 15 ground conductors 3 16 safety ground 3 16 signal ground 3 17 programming device grounding 3 16 H How to enable expanded functions 4 12 lO 2 26 Control Module description of 2 10 illustration of 2 11 jumpers configurable 2 11 Index GEK 96682 Link Local module 2 27 illustration of 2 28 Receiver module 2 43 chain signal continuation or termination 2 44 illustration of 2 43 lO Transmitter module 2 49 illustration of 2 50 status indi
252. oller in the first register that was communicated with is cleared when the value placed in the status register third register by the CPU is not equal to 1 NOTE for a more detailed description and examples of using the DPREQ function to open communications with the Genius I O system refer to Chapter 6 in the Genius I O System User Manual GEK 90486 Troubleshooting and Repair 5 1 GEK 96602 CHAPTER 5 TROUBLESHOOTING AND REPAIR INTRODUCTION This chapter is a guide to the basic troubleshooting and repair information required if a malfunction of your Series Six Plus PLC system should occur Section 1 contains information on troubleshooting and repair of the Central Processing Unit while Section 2 contains information on troubleshooting and repair of the I O system Parts lists are included as a reference for ordering renewal parts MINIMUM DOWNTIME The technology used in the design of the Series Six Plus programmable logic control system is such that under normat operating conditions few hardware failures are expected If any failures should occur they can quickly be isolated and the defective assembly replaced with minimum downtime If GENIUS i O blocks are included as part of your I O structure downtime is reduced to an absolute minimum for the I O structure LOGICAL TROUBLESHOOTING Troubleshooting is accomplished by thinking logically of the function of each part of the system and how they relate to each other A basic un
253. on the module isolate signals passing through the module and a DC to DC converter provides a 5V dc isolated supply voltage to those circuits connected to the parallel bus This method of isolation ensures that all Local I O stations are electrically isolated from each other and from the CPU station Physical Equipment Configuration 2 51 GEK 96692 Location in Rack and I O Channel Addressing An I O Transmitter be installed any card slot in an I O rack except the leftmost slot which is normally reserved for an I O Receiver The seven segment DIP switch on the backplane adjacent to the selected slot for the module does not need to be set for an l O address since an I O Transmitter does not require an I O address However the first 3 1 2 and 3 switches on the DIP switch package must be set to select an I O channel number when required by system configuration Status Indicators A monitor circuit checks the output level of the isolated 5 dc supply If the output is not within its specified tolerance the monitor circuit causes the I O Transmitter to shut down An LED indicator ISOLATED POWER is on when the voltage is within tolerance The status of other LED indicators are defined in table 2 15 Table 2 15 TRANSMITTER STATUS INDICATOR DEFINITIONS INDICATOR DEFINITION CHAIN ON when station power is OK and continuity is OK present to all downstream stations CHAIN PARITY ON when output parity is
254. on to the Auxiliary I O chain and is made to a connector located at the bottom of the faceplate of the module The cable is connected from the Auxiliary I O module through the I O cable to the top connector on the I O Receiver or Advanced I O Receiver in the first I O rack in the Auxiliary I O chain e b40762 JXXIARY 2 e 1 D Type 37 pin Connector to 3 PARITY LED Auxiliary Chain connects to I O On Input data parity is OK at the Receiver or Advanced I O Receiver Auxiliary I O module in nearest I O rack in auxiliary Off Input data parity error exists chain 4 ENABLED LED 2 CHAIN OK LED On The outputs are enabled CPU is On Continuity power and output operating in the RUN ENABLED data parity are OK at all I O mode stations in the auxiliary chain Off The outputs are disabled CPU in Off A continuity power problem the RUN DISABLED or the STOP or output data parity error mode exists at one or more 5 Shunt location A Factory installed auxiliary chain I O station s locat ion 6 Shunt location B Figure 2 31 AUXILIARY I O MODULE BOARD LAYOUT 2 62 Physical Equipment Configuration GEK 96682 WORKMASTER COMPUTER TO SERIES SIX PLUS PLC CONNECTIONS The Workmaster computer can communicate with a Series Six Plus PLC using either a parallel or serial version of the Logicmaster 6 software The methods of connection from the Workmaster computer to the Series Six Plus PLC are described in the following para
255. ontrollers in a system is limited only by the I O capacity of the Series Six Plus PLC Each Bus Controller can have up to 30 blocks connected to it in a daisy chain thereby providing up to 480 addressable I O points on each bus For detailed information on the Genius I O system refer to GEK 90486 the Genius I O System User s Manual Some of the many benefits of the Genius I O system are as follows e Each block is a stand alone unit no separate rack or power supply required Each discrete block can be configured to be inputs outputs or any combination of inputs and outputs e Extensive diagnostics monitor not only the blocks but also field devices e There are no fuses to be concerned with since the discrete outputs have built in electronic fusing for circuit protection e A convenient easy to use Hand Held monitor is used for system configuration calibration and troubleshooting e Easier installation and troubleshooting and fewer spare parts required in inventory provide a signif icant cost savings over traditional I O systems 341057 TO SERIES SIX PLUS CPU SERIES SIX 1 0 1 HAND HELD MONITOR 43 figure 1 3 GENIUS I O TYPICAL COMMUNICATIONS LINK r3 xowucu 20 422 t B ERE Introduction To The Series Six Plus PLC 1 7 GEK 96682 PROGRAMMING THE SERIES SIX PLUS PLC Programs are entered edited and monitored using the Workmaster
256. operated directly from a dc power source such as batteries or inverters that provide dc power in the range of 20 to 32 V dc catalog number 600 541 or 100 to 150 v dc catalog number IC6OOPM546 Each power supply has several user items mounted on the faceplate Figure 2 5 illustrates the power supplies ac version shown identifying user items Ac and dc version faceplates are both shown for reference 56830116 117 56840224 244 1 Internal Terminal Strip 5 Power Switch Circuit Breaker 2 Chassis Ground Terminal 6 CPU RUN STOP Key Switch 3 18 Pin Connector Connects signal 7 MEMORY PROTECT Key Switch cable from rack backplane 8 POWER Light 4 Front Panel Connector Block Figure 2 5 ILLUSTRATION OF POWER SUPPLIES Physical Equipment Configuration 2 5 GEK 96602 Each of the power supply user items shown in the preceding illustration is described below For detailed information on installation of a power supply refer to the applicable data sheet in the Data Sheet manual wide range ac supply GEK 83505 24 V dc supply GEK 90761 or 125 V dc supply GFK 0065 Table 2 1 POWER SUPPLY USER ITEMS USER ITEM DESCRIPTION LOGIC POWER This switch is used to switch the ac or dc SWITCH power source to the supply ON and OFF CPU RUN STOP This keyswitch is used to put the CPU in either KEYSWITCH the RUN or STOP mode With the CPU in the RUN mode normal scanning operation takes place and outputs are
257. or the other of the I O chains Main or Auxiliary In other words a WINDOW command to channel BH Hexadecimal does not affect any window devices downstream from Expanded Parallel I O Transmitters which are set for channels 0 7 in the Main chain or channels 0 2 and 4 7 in the Auxiliary chain Window devices include the ASCII BASIC Module CCM LMM and Series Six VO link local module The Genius bus controller is also a window device if window commands are issued to it If no window commands are used bus controllers may be used in the same address in main and auxiliary channels without conflict The ASCII BASIC Module and its derivatives LMM I O CCM etc always report their status bytes back to the main input table regardless of what channel they are in An ASCII BASIC Module at address 257 in channel E will report its 8 bits of status to main channel address 1257 Care should be taken not to address any inputs in the main channel to the same address as any of these devices in the system Expanded CPU Operation 4 1 GEK 96692 CHAPTER 4 EXPANDED CPU OPERATION INTRODUCTION The Series Six Plus Programmable Logic Controller operates in one of two user selectable modes either Normal or Expanded Selection of the desired mode is made on the Configuration Menu screen on a Workmaster computer using Logicmaster 6 software This chapter describes the Expanded functions as they are used with the Series Six Plus PLC For detailed i
258. ormal mode references address Expanded 1 channels and 8 for example 10234 00346 Al0222 AO0456 etc Expanded mode references for channels 1 7 and 9 F include the channel number for example 1340101 0340101 1B 0234 OB 0567 etc The individual module DIP switch settings for I O points 1 to 1000 are the same for each chain or channel only the prefix is different a42080 1 Seven Segment DIP Switches One for Each 1 0 Slot Figure 2 19 1 POINT ADDRESS SWITCHES 2 32 Physical Equipment Configuration GEK 96602 Figure 2 20 shows the DIP switch settings for I O point selection for 8 circuit 1 0 modules 7897 X Switch in OPEN Position Depressed to the Left Figure 2 20 DIP SWITCH SETTINGS FOR 8 CIRCUIT MODULES The 1 0 addresses are selected by positioning each of the seven rocker switches on a DIP switch package to either the open or closed position To set a switch to the OPEN position depress the rocker switch to the left Each DIP switch setting allows the selection of a starting I O point reference number and either 8 16 or 32 consecutive I O points The number of consecutive 1 0 points is determined by the type of 1 0 module in the slot Data sheets for modules using more than 8 I O points include a similar table showing the settings required for that module Physical Equipment Configuration 2 33 GEK 96682 Normal Mode I O Addressing The Series Six Plus PLC allows I O to be configur
259. ot could be used for this and change the values in Bytes 3 and 4 to reflect the actual individual circuits to be cleared Output 4 Bit 3 Definition Pulse Test This output activates the pulse test If this output is on for one scan it will cause all discrete I O blocks connected to this bus to conduct a pulse test of their outputs Outputs configured to ignore this signal input only blocks and analog I O blocks will not perform the pulse test The pulse test begins at device number 0 and as fast as it receives a test complete signal from that device proceeds to each block until it reaches device number 31 Faults detected during this test are recorded by the CPU as circuit faults When the test has been completed by all I O blocks on the bus Input 7 Pulse Test Active wi be turned off 4 38 Expanded CPU Operation GEK 96692 If this output is on when one test is completed another will immediately begin It is not recommended that this output be left on for a continuous pulse test It is recommended that the pulse test be activated a minimum of once each 5 minutes Input 7 will then toggle as each pulse test is completed The advantage of turning output 4 on for only one scan is that only one test will be conducted as timed by input 7 Output 9 Bit 0 of Byte 2 Definition Circuit Type The state of this output is determined by the Circuit type either Input or Output If the Circuit Reference indicated by the value
260. ow the steps below To move the display down one line at a time press the Next key or the Down Cursor key To move the display up one line at a time press the Prev key or the Up Cursor key To move the display down one page at a time press SHIFT NEXT or Next Page F1 To move the display up one page at a time press SHIFT PREV or Prev Page F2 To go to the top of the table press the Top F4 function key To go to the end of the table press the Bottom F5 function key Clearing Faults Use the Clear Faults F3 key to clear the Fault Table This sets the fault count to zero and clears the fault data at the Genius I O blocks Subsequent incoming faults fill the Fault Table beginning with the next available location with the oldest data at the top This will cause the Bus Controller to issue a CLEAR ALL FAULT command see the Genius I O System User s Manual for further information Expanded CPU Operation 4 21 GEK 96682 FLOATING POINT FUNCTIONS Seven function floating point arithmetic has been implemented as a feature of the Expanded Functions The available floating point functions are Floating Point Addition Floating Point Compare Floating Point Subtraction Integer to Floating Point Conversion Floating Point Multiplication Floating Point to integer Conversion Floating Point Division Floating Point Display Format Two registers are required to represent each Floating Point reference which is stored in IE
261. ower flows only when an error is encountered Convert Floating Point To Integer Every scan that power is received the Floating Point to Integer function reads the floating point value of reference A and places the integer equivalent in reference 8 Power flows only when an error is encountered WINDOW DPREQ FUNCTION The Window Function is a special Data Processor REQuest that supports the 16 channels of the expanded I O system Each scan that power is received the Window function opens a window to the expanded I O channel that is specified by the hexadecimal value stored in the upper byte of the first reference FIRST REFERENCE i 8 7 aee Address to 7c Channel Address 00 to F or CO Expanded CPU Operation 4 25 GEK 96692 The first reference used by the Window function stores In the high order byte the number in hexadecimal of the I O channel to be opened The number may be either 00 0F valid individual channel numbers as determined by the DIP switch settings on the I O Transmitter modules in the system CO broadcast channel number In the low order byte the window address which is the module s card address as set by the DIP switches on the rack backplane It may be any address from 0 to 7C 7D 7E and 7F are reserved for the Interrupt Input module DPU and PDT windows and can not be used in this function The second reference is the start of the communications block in register memory Pow
262. particular Remote I O Driver More than one Remote I O station can be programmed to the same I O block however each Remote Driver must have its own unique address Each Input module must also have a unique address output module addresses can be duplicated Unused I O points in a Remote I O station be used by another Remote I O station a Local I O station a CPU station or a CPU slot Printed Circuit Board Jumpers There are several printed circuit board jumper plugs which must be properly configured for operation of a Remote I O system Jumper plugs are located on both the Remote I O Driver and the Remote I O Receiver Factory configuration of these jumpers is set for the following options 120 Inputs and 120 Outputs Connection up to 10 000 feet 3Km using two twisted pair serial cable Baud rate 57 6Kb Halt CPU on communications failure or Remote I O parity error Turn all outputs off on communications failure Odd serial parity om If a block of 248 Inputs and 248 Outputs or the Remote system is to be linked with RS 232 compatible modems or any of the other options are to be changed the printed circuit board jumper plugs must be reconfigured Refer to the applicable data sheet in the Series Six Data Sheet manual GEK 25367 for board jumper configuration Physical Equipment Configuration 2 55 GEK 96602 Remote I O Driver The Remote I O Driver module provides control and data signals to a Remo
263. perating in the NORMAL I O mode of operation Thus the total I O capacity of the Series Six Plus PLC when in the NORMAL mode with the Auxiliary system selected is 2000 inputs and 2000 outputs If the Auxiliary module and the EXPANDED I O mode of operation have been selected an additional 8000 Inputs and 8000 Outputs are available to the PLC system This configuration provides a total l O capacity of 16 000 real inputs and 16 000 real outputs The Auxiliary I O module can be used in either a Series Six Plus CPU rack or in a Series Six model 6000 CPU rack When used with the Series Six model 6000 CPU the maximum is 2000 Inputs and 2000 Outputs A group of 4 DIP shunts must be inserted in one of two locations determined by which CPU the module is to be used with either Series Six Plus or Series Six model 6000 All information pertaining to use of Input and Output modules interface modules cable type and distance allowed between racks and stations is applicable when configuring an Auxiliary 1 0 system Inputs and Outputs the Auxiliary I O chain can be overridden as in the Main I O chain with the Expanded II instruction set when in the Normal mode When in Expanded 1 0 mode only Channel 8 AI AO has overrides Physical Equipment Configuration 2 61 GEK 96602 A standard I O cable catalog number IC600WDXXX where XXX is 3 digit number corresponding to the selected cable length provides the connecti
264. ply voltages in the Data Processor Unit rack Refer to the DPU User s Guide for further troubleshooting procedures 5 12 Troubleshooting and Repair GEK 96602 8 CHECK LIGHT ARITHMETIC CONTROL MODULE Definition Status CPU execution sequence is proceeding normally the self test routine is passed at least once each 300 ms 50 ms OFF CPU self test routine has not been passed within 300 ms 50 ms or user program execution time takes longer than 300 ms to execute The RUN and ENABLE lights are off Alarm Number relay switches Reset signal is sent to the 1 0 chain Corrective Action Check the condition of the POWER and memory BATTERY lights If any are off correct them first Turn the CPU key switch to STOP power down and back up e Make sure that the user program has an End of Sweep ENDSW instruction e Disconnect any peripheral device such as the Workmaster computer or Operator Interface Terminal e Ensure that the short length of ribbon cable connecting the Arithmetic Control and Logic Control modules is securely connected e Reseat the Arithmetic Control and Logic Control modules If this does not correct the problem replace the Arithmetic Control and the Logic Control modules one at a time NOTE A program which causes the CPU sweep time to be in the 300 ms 50 ms range can cause the CHECK light to go off Use care when programming subroutines since they can cause the sweep t
265. ponding faceplates a42222 1 O power supply 7 System Interface Module 2 Power source terminal block 8 Connector to I O Control upstream I O 3 DC Power Indicator Receiver Advanced I O Receiver I O 4 Logic Power Switch Circuit Breaker Transmitter or Remote I O Receiver 5 Module Slot 1 9 Connector to a downstream I O Receiver 6 Module Slot 11 10 Tray to contain field wiring Figure 3 17 TYPICAL I O RACK 3 20 Installation Instructions GEK 96602 Power Supply The I O power supply is shipped from the factory installed in the rack 5 V dc at 6 1 A is provided for the standard I O rack or 5 V dc at 16 5A 12 V dc at 1 5A and 12 V dc at 1 0 for the high capacity I O rack 13 rack requires high capacity power supply There is one terminal board located on the lower part of the faceplate Remove the protective cover plate and make the required connections as shown in figure 3 18 SELECT JUMPER 1 FOR 6830122 115 OR 230VAC OPERATION 6830114 a41060 ess 5 230VAC Qt 2 NO CONNECTION Q Q L1 LINE 1 Q L1 LINE 1 Q POS DC INPUT L2 LINE 2 AC INPUT AC INPUT ee 1187230 C 2 UNE 2 oE TO 60 VAL OR GROUND Q GND GROUND Q Standard High Capacity Power Supply Power Supply 115 230 V ac CONNECTIONS 24 or 125 V dc CONNECTIONS Figure 3 18 POWER SUPPLY CONNECTIONS AC Power Source Connections Remove the plastic cover protec
266. power on The CPU should be running in its previous state e f the BATTERY light had been out and power was removed the memory must be reloaded before the CPU can be restarted since the memory may contain invalid data Troubleshooting and Repair 5 17 GEK 96602 a41048 Figure 5 4 BATTERY MOUNTING CLIPS AND CONNECTORS 12 STATUS INDICATOR LIGHTS IN THE CORRECT STATE If the status indicator lights are in the correct state but the CPU is not functioning properly the malfunctions below may describe the problem If so follow the procedures listed under the appropriate malfunction e The CPU is running but is not solving the ladder diagram correctly T Check to see if the problem is resulting from a user program error such as overrides multiple register usage SKIP MCR or Suspend 1 0 instructions Reset the Arithmetic Control and Logic Control boards Ensure that the ribbon connector between the Arithmetic Control and Logic Control modules is secure Replace the Arithmetic Control board Replace the Logic Control board 5 18 Troubleshooting and Repair GEK 96602 e The CPU will not communicate with the Workmaster computer or other programming device which may be a CIMSTAR I industrial computer IBM PC PC XT or PC AT Personal Computer 1 Check the cable connector from the Workmaster computer to the CPU Ensure that it is securely connected 2 Ensure that the Workmaster computer will work with another
267. pplications list of typical 1 20 Arithmetic Control module description of 2 14 illustration of 2 15 Arithmetic Control to Logic Control cable 3 11 Auxiliary O module 2 61 illustration of 2 62 Auxiliary I O system description of 2 61 Axis Positioning modules 1 1 7 Basic functions 1 9 Battery installation 3 8 Battery status indicator 2 18 Blocks Genius I O 1 13 Bus Controller module description of 2 21 C CCM2 2 22 CCM3 2 25 Cimstar computer 2 64 CPU I O station 2 37 illustration of 2 38 CPU alarm conditions 2 7 CPU configuration set up menu 4 13 Genius 4 15 Genius I O fault table 4 16 4 18 Genius I O fault table definitions 4 19 bus controller locations page 4 1 7 computer mailbox 4 17 INDEX definitions 4 14 displaying and clearing Genius I O faults 4 18 expanded I O scan 4 14 CPU module installation 3 7 CPU rack mounting 3 3 CPU troubleshooting 5 3 RUN STOP key switch 5 6 Arithmetic Control module 5 12 5 13 Combined memory module battery light 5 15 Combined memory module parity light 5 14 alarm relay 5 18 battery replacement 5 15 5 16 5 17 fault isolation and repair 5 3 indicators and switches location of 5 5 indicator chart 5 4 Control Auxiliary modules 5 9 5 10 memory protect key switch 5 6 power supply 5 6 to 5 9 start up instructions 3 31 Channel reference numbering Channels of VO 4 3 selection of 4 4 Checksum dynamic user memory 4 11 Combined Memory module 2 16
268. quired with Expanded II functions contains circuitry that performs arithmetic and logical operations on data and address lines There are 4 hardware registers on the board The continuity and buffer registers are each 1 bit wide while the accumulate and preset registers are each 16 bits wide These registers are operated on internally by the CPU and are not user accessible registers The primary hardware for performing the arithmetic and logic functions on this module is a 16 bit Arithmetic Logic Unit The Arithmetic Logic Unit works in conjunction with the Logic Control module to generate timing and control signals and must be next to it in the rack since they are linked together through a ribbon cable connector The AM2903 is a 4 bit expandable bipolar microprocessor slice which is especially useful for arithmetic oriented processors In addition it provides a special set of instructions that ease the implementation of multiplication division and other time consuming operations The Arithmetic Control module must be placed in slot 3 in the CPU rack immediately to the left of the Logic Control module Siatus Indicators There are 2 LED status indicators labeled RUN and CHECK on the front of the board which are viewable through the translucent lens on the faceplate The executive routine in the scan execution sequence contains a self test that is executed once per scan The RUN LED when ON is an indication that the execution sequence
269. r Refer to the Logicmaster 6 Programming and Software User s manual for detailed instructions for start up with those devices 3 34 Installation Instructions GEK 96602 RUNNING EXPANDED I O ON THE SERIES SIX PLUS PLC As Internal Coils Only Simply type 1 or 0 then CNTL channel number followed by the IO point number The I O is mapped into its corresponding register tables No SERIES SIX CONFIGURATION DATA command is needed Channels do not have to be enabled in the CPU Config Menu To Be Solved To Real World I O Points Program the SERIES SIX CONFIGURATION DATA command in rung 1 and then set the number of channels to be scanned in the CPU CONFIG MENU then transfer to the CPU How It Works When running expanded I O channels the CPU generates a code for a particular channel number then does a full I O scan as it normally does The channels are scanned in order from the lowest to the highest enabled channel Each one takes 6 7 ms Auxiliary channels are automatically scanned with their corresponding main channel For example enabling channels 0 3 also enables channel 8 B An I O Transmitter IC600YB900C or later capable of decoding I O channels must be used to separate the real I O channels One and only one transmitter should be set to decode each channel These transmitters have a jumper to allow them to run in expanded or normal mode In expanded mode they turn on only when their channel is called for The chann
270. r Auxiliary chain to be serviced immediately DO I O function for use with the Expanded I O has been expanded to address the full 16K inputs and 16K outputs of the expanded I O references When expanded I O is selected the bits in the Do I O function references have the meanings shown below These can be placed in the start and end references using an A to B Move or similar function 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 I3 TXTXIXI X channe address Bit 15 must be set to 1 by the program If a constant value is used bits 14 and 15 must both be set to 1 Bits 8 9 and 10 are the channel number 0 7 Bits 0 through 6 specify the I O address Entering a Do I O Function The Do I O function can be placed in columns 1 to 7 of a rung 1 Enter any logic required to control power flow to the function If the function is placed at the left rail it will execute unconditionally upon every sweep 2 Select Advanced Mnemonic Group F7 then Control Functions F6 then Do I O F4 The Do I O display appears DO I O START END 3 The cursor is at START Using the decimal keypad type in the reference that contains the beginning I O address It may be a constant from 1 to 1000 any valid register any I O reference in the range 1 1024 After entering the reference press the Enter key 4 The cursor moves to END Using the same parameters enter the reference that contains the final address Press the E
271. re failure MATCH OK ON Good compare between tape and CPU has been made OFF Compare of tape with CPU Memory has failed TAPE OK Indicator also turns off ON Data transmission normal FLASHING Data is being transferred OFF Data incorrect because of parity overrun or framing errors bad data block or the serial link has timed out A CCM2 CPU communications failure will cause this light and the BOARD OK light to turn off TAPE OK ON Tape data transmission normal OFF Data stream interruption caused by parity framing or overrun errors unsuccessful tape comparison or timeout on the tape link 2 24 Physical Equipment Configuration GEK 96602 e be b41084 OM LOAD PROC A Single Pole Double Throw Center 3 DIP Switches 17 to 20 Off switch momentary contact Miscellaneous selection UP position compare tape with CPU 4 Jumper JP3 Always set in 1 2 user program DOWN position position compare tape with user program 5 Jumper JP2 Always set in 1 2 and tables position B Single Pole Double Throw Center 6 Jumper JP1 Always set in 1 2 Off switch momentary contact position UP position initiates loading of tape 7 Jumper JP4 1 2 position OIU into CPU DOWN position initiates DISABLE 2 3 position writing of data from CPU to tape ENABLE C J1 Connector 25 pin D type 8 Jumper JP5 Always set in 1 2 female connector for RS 232 and position RS 422 9 Jumper JP7 Always set in 1 2 D J2 Conn
272. res the status bits of the 1000 inputs and 1000 outputs in the main I O chain from a programming standpoint but in Channel 0 from a real I O point of view The transition table stores the logic state of the inputs to counters and one shots in the main I O chain when in the Normal mode or for Channel 0 when in the Expanded mode The override table stores the staus of overridden input or output bits in both the Main and Auxiliary I O chains in the Normal mode An overridden bit in the status table is not changed when the CPU reads inputs or solves outputs The internal memory is stored as 8 bits of data and 1 bit of parity Detection of Active Overrides in System With the Expanded II functions a means of detecting if there are any active overrides the system is available Two bits in the Main status table are used for this purpose Output O1015 is defined as the Override Active in System Enable bit and O1016 is defined as the Override Active in System Report bit Once each sweep O1015 will be checked by the CPU tf the bit is not set to a 1 the CPU will skip the active Override search If the bit is set the CPU will initiate a search of the Main and Auxiliary Override Tables in search of active override bit bit that has been set to a The search will continue until either an active override is found or the end of the override tables is reached If an active override is found bit O1016 will be turned ON the user can check O1016 for a
273. resent or not present If DPU not present is selected the Data Processor Widow portion of the CPU scan will be bypassed Figure 2 9 is an illustration of the 1 0 Control module with user items described the preceding discussion identified Installation instructions are provided in Chapter 3 56840158 1 D Type 37 Connector 10 Programmer 2 D Type 37 Pin Connector to Primary 1 Chain Connects to I O Receiver or Advanced 1 Receiver module in nearest rack Gago wee primary chain Es 3 User Selection Jumpers a CHAIN OK Light n On Continuity power output data parity are OK s at all 1 0 stations in the primary chain Off A continuity or power E jel f f problem output data ua parity error exists at one or more primary chain 1 s s stations 5 PARITY Light t i PB LUE B On Input data parity is OK at the 1 Control module I vd Off Input data parity error exists i E 1 8 ENABLED Light a amp On The outputs are enabled CPU is operating in the RUN ENABLED mode Off The outputs are disabled CPU is in the RUN DISABLED or the STOP mode DPU Light On Data Processor is OK Off A continuity error or other type of problem exists with the DPU Figure 2 9 1 0 CONTROL MODULE 2 12 Physical Equipment Configuration 96602 LOGIC CONTROL MOD
274. resistor pacs must be located sockets U12 and U50 The resistor pacs are identical and thus can be interchanged Figure 2 26 is an illustration of the Advanced I O Receiver showing the location of user items 40205 10 REYR 1 D type 37 pin connector to 6 Dip switch for selection of Input upstream modules address 2 D type 37 pin connector to 7 Dip switch for selection of Output downstream modules address 3 Resistor pac locations for last I O 8 Location of 12 LED diagnostic rack in chain indicators 4 Resistor pac locations for 9 Location of external Reset intermediate I O rack in chain pushbutton Dip switch for selection of module options Figure 2 26 LOCATION OF USER ITEMS 2 48 Physical Equipment Configuration GEK 96602 Status and Diagnostic Indicators Twelve LED diagnostic indicators visible through the faceplate are mounted on the Advanced I O Receiver module These LED s are used to indicate status and the results of diagnostic routines executed by the module The last six indicators are latched in or turned off when a fault is sensed as some faults may be transitory or intermittent These latched in fault indications can be reset if the fault is cleared by depressing the RESET pushbutton that is accessible through the faceplate or by CPU logic sending a latch reset signal through the I O chain This signal is read by the module via the I O addresses that have bee
275. restored The clock can be synchronized by the user through logic programming The clock is updated once per sweep and has a cumulative accuracy of 8 seconds per day The format for storing the clock data in the three registers is as shown below Data entered in each byte of each register is 2 BCD digits REGISTER MOST SIGNIFICANT BYTE LEAST SIGNIFICANT BYTE RXXXX Seconds 00 59 Tenth of Seconds 00 09 RXXXX 1 Hours 00 23 Minutes 00 59 RXXXX 2 Hundreds of Days 00 99 Days 00 99 4 28 Expanded CPU Operation CEK 96602 GENIUS I O DIAGNOSTICS The Genius I O diagnostics must be enabled from the Configuration Menu in order to be fully utilized by the CPU The diagnostic features which can be enabled are Diagnostic Tables Bus Controller Point Faults Diagnostic range Limit Fault Table Length and Bus Status Control Byte Location Enabling of these features was previously described in the discussion on the Configuration Menu The following discussion describes the diagnostics and the interface between the CPU Bus Controller and the Genius I O Blocks DIAGNOSTIC FAULT TABLE The first function is a diagnostic fault table which automatically stores any fault reported by a Bus Controller along with the time that the CPU received the fault Ten registers are used to store data related to each fault The fault table can be as long as desired limited only by the quantity of registers available in the CPU The
276. rithmetic Control Module Logic Control Module Advanced Expanded or Expanded Il None of these modules have any devices needing user configuration The selected Logic Control module should be installed in slot 2 which is the second slot to the left of the power supply The Arithmetic Control module should be installed in slot 3 immediately to the left of the Logic Control module A short length of ribbon cable is used to interconnect these two modules through sockets on the lower front edge of each printed circuit board Refer to figure 3 9 Ensure that this cable is in place and that the connectors are seated properly NOTE Operation of the system without the ribbon cable connected between the Arithmetic Control and Logic Control modules will result in unpredictable operation by the CPU 41079 RIBBON CABLE figure 3 9 LOGIC CONTROL TO ARITHMETIC CONTROL RIBBON CABLE NOTE To prevent unpredictable operation of your Series Six Plus CPU the CPU should be powered down before installing or removing either module or the connector 3 12 Installation Instructions GEK 96692 Control Module The I O Control module should be inserted in slot 1 immediately to the left of the power supply The I O Control module contains three labeled jumper terminals which are for selection of board options These jumpers are located on the lower right of the component side of the printed circuit board with component side tow
277. rmation contained in this chapter is designed to help you isolate and correct any problems that may arise in your Series Six Plus programmable logic control system It is recommended that all maintenance and programming personnel become familiar with this manual and all applicable related manuals so that if a problem does arise it can be isolated quickly and the defective part replaced thus minimizing downtime of the system However we realize that troubleshooting isn t always that simple Sometimes you need someone to talk to who can answer your questions When you do don t hesitate to call your local authorized GE Fanuc NA Programmable Control Distributor If you are unsure of the location of your nearest authorized Distributor then call your local GE Fanuc NA Sales Office Replacement Module Concept The troubleshooting and maintenance techniques described in this manual promote the concept of complete board replacement The prime objective of this concept is to minimize system downtime Isolate the Problem When a problem arises first isolate it to the major assembly programmer Central Processing Unit I O rack etc then to the defective module within that assembly The defective module is then replaced from a duplicate set of modules maintained on site Your production line or system is back up fast The defective module can be returned through normal channels under warranty or for service without keeping your productio
278. rogrammable Logic Controller features of the Series Six Plus PLC General Specifications Genius I O System Programming the Series Six Plus PLC Workmaster Industrial Computer Other Software Packages Programming Language for the Series Six Plus PLC Programmable Logic Controller Concepts Function of the Central Processor Unit Memory Types Used in the Series Six Plus PLC Function of the Input Output Circuitry Optional Devices Supporting the Series Six Plus PLC Redundant Processor Unit Operator Interface Unit Operator Interface Terminal ProLoop Process Controllers ASCII BASIC Module Axis Positioning Module Communications Control Modules GEnet Factory LAN Series Six PLC Network Interface Datagram Communications Service Global Data Service RS 232 to RS 422 Adaptor Unit System Planning Typical Applications Using PLCs PLC Terminology PLC Compatibility Guide PHYSICAL EQUIPMENT CONFIGURATION Product Structure for the Series Six Plus PLC 19 Inch CPU Rack Configuration 13 Inch CPU Rack Configuration Basic Unit Configuration PAGE LI ee 1 oT nmma NA dou 1 11 1 7 N a e 007 ao ol L o b I I N o Contents GEK 96602 CONTENTS TITLE PAGE CHAPTER 2 PHYSICAL EQUIPMENT CONFIGURATION Continued NOL Power Supply for the Series Six Plus PLC Terminal Block Connections Power Supply Specific
279. s e Other Modules Communications Control Modules e Intelligent Modules e LAN Interface e 1 Required for Expanded II functions 2 Parity checking is not available with this combination 1 26 Introduction To The Series Six Plus PLC GEK 96602 Table 1 9 COMPATIBILITY GUIDE SERIES SIX PLUS PLC VS SERIES SIX PLCs Continued Model of PLC Catalog Number Description 600 6000 6 Peripheral Devices IC600RP551 RPU AC Powered IC600RP554 RPU DC Powered IC600KD500 Operator Interface Unit 9 IC600KD510 Operator Interface Terminal Amber e e IC600KD512 OIT Color e 1 600 ProLoop A11 Programmer Workmaster All Versions e e CIMSTAR I All Versions Serial Version e e Software Packages Logicmaster 6 VuMaster Processmaster e e e Motionmaster Alarm Master 1 For availability of other software packages contact your PLC Distributor GE Fanuc NA sales office or GE Fanuc Automation North America Inc Charlottesville VA Physical Equipment Configuration 2 1 GEK 96602 CHAPTER 2 PHYSICAL EQUIPMENT CONFIGURATION This chapter describes the components of a Series Six Plus Programmable Logic Controller Included are descriptions of the Central Processing Unit power supplies combined memory modules racks optional modules system configuration standard rack based I O system Genius I O
280. s 1 to 993 of the Bus Controller Use the decimal equivalent of the channel number For channels A F use the decimal equivalent A 10 11 etc of the hexadecimal value in your calculation Example Bus controller at I O location 257 in channel 4 4 x 1024 257 4353 Enter 4353 in the first register of the Computer Mail Box 4 42 Expanded CPU Operation GEK 96602 Command Data Registers The next 5 registers contain command data This data which is in the form of numerical values provides control information which includes What function is performed Which specific I O block if any is involved How much data is to be communicated Where the data is to be sent in the Genius I O system or where data from the Genius system is to be stored in the CPU The content of each of the five command registers is described below Register R 1 Operation Read or Write The second register must contain an operation command number which indicates which of the following operations is to be performed when communications is opened DPREQ receives power flow 1 idle no operation performed 2 Read the configuration of the I O block or Bus Controller into CPU registers specified in the fourth register Immediate command X Write the configuration of the I O block specified in the fourth register from CPU registers Not an immediate command 4 Read diagnostic data of the I O block or Bu
281. s or if either reference A or B is not a number Floating Point Subtraction Program a Floating Point Subtraction function to subtract a floating point value in reference B from the floating point value in reference A and place the result in reference C Expanded CPU Operation 4 23 GEK 96602 Every scan that power is received the FSUB function calculates the result using floating point mathematics The result is placed in reference C Only the content of reference C is altered by this function The function will output power flow if overflow occurs if references A and B are infinities having the same sign or if either reference A or B is not a number Floating Point Multiplication Program a Floating Point Multiplication function to multiply the value in reference A by the value in reference B and place the result in reference C Every scan that power flows to the function the system multiplies the value in reference A by the value in reference 8 and places the signed result in reference C The possible sign of the result is shown below Reference A Reference B Reference C T T Floating Point Multiplication will not normally output power flow except under the follow ing conditions The result is too big to store overflow The result is too small to represent underflow Either reference A or B is infinity and the other is zero Either reference A or B is not a number invalid format BOMI Floating P
282. s Controller into CPU registers Immediate command Reserved for future use 6 Reserved for future use 72 Read analog status all analog inputs from a block into the CPU registers Immediate command 8 Reserved 9 Read Status Table Reference Immediate command 102 Reserved Immediate only if the specified Status Table address is that of the Bus Controller Register R 2 Communications Status The third register is loaded with a number by the CPU to indicate the status of the communications DPREQ The register should initially be cleared to zero and will be loaded by the CPU at the end of each scan when a status is available The content of this register as loaded by the CPU can be 0 Not accepted The CPU or addressed Bus Controller is busy with the previous communications request DPREQ 1 operation is in process but not completed 2 Operation has been completed successfully 12 The operation has been terminated due to a syntax error in the DPREQ registers 20 Other error Any errors that are involved in executing the command such as a communications timeout NAK internal Bus Controller error etc Expanded CPU Operation 4 43 GEK 96682 Register R 3 Target Block Start Address The content of the fourth register is an I O reference to indicate the starting location of the desired I O block or Bus Controller The register must contain a value between 1 and 993
283. s Manual GEK 96607 Introduction To The Series Six Plus PLC 1 19 GEK 96602 Figure 1 9 is an illustration of a typical configuration for a GEnet Factory LAN 2000 CNC Series Six Family Series Six Family With MAP Option With CCM With CCM HDLC Interface Software MAIL Head End Remodulator Other MAP Compliant Devices CIMSTARI Network Management Console LI Third Party Graphics Station With CCM support a41051 Series One Family With DCU Series Three Family With nCM RS 422 Multidrop CCM MAP CCM Communications Bus Interface Software 10 5 Broadband Token Bus BIU Ly Any Device DEC HP or f Workmaster figure 1 9 GEnet FACTORY LAN 1 20 Introduction To The Series Six Plus PLC GEK 96602 Series Six PLC Network Interface The Series Six PLC Network or LAN interface modute is a member of the family of GEnet Factory LAN communications products The Series Six LAN Interface module provides a direct connection for a Series Six Plus PLC to a carrierband network The LAN consists of two boards controller board and modem board which plug directly into slots 5 and 6 of the Series Six Plus CPU rack The LAN Interface module connects directly into the carrierband cable plant through the 5 Mbps carrierband modem board Intermediate devices such as brid
284. s identified as part of a pulse test Input 8 FORCED CIRCUIT This input is on any time that at least one discrete I O circuit or Analog circuit is forced by the Genius Hand Held Monitor HHM This input can be used by the CPU to alert operators that a forced condition exists The operator can then determine if the forced condition is proper or should be removed if necessary with the HHM There is no indication as to which I O block or reference contains the forced reference Only forced conditions set by the HHM on blocks controlled by this Bus Controller affect input 8 NOTE When analyzing the data provided by the 48 input references first examine the lower 8 inputs of the reference first byte Input data in higher bytes 2 through 6 is used only if one of the Inputs 3 to 6 is ON Inputs 1 2 7 and 8 are independent and can come ON or go OFF as required regardless of the state of the other inputs If Input 1 is OFF all other inputs have no validity Fault Table Registers The content of each of the registers is further described below The bits are numbered from 0 through 15 Bits 0 through 7 are the Least Significant Byte and bits 8 through 15 are the Most Significant Byte Register 1 Genius I O Bus Controller Address Decoding The first register contains the I O address of the Bus Controller that reported the fault The Bus Controller address is decoded by the state of the bits in this register The register contains
285. s in bytes 3 and 4 is an Input this bit is set to a 1 If the Circuit Reference is an output the bit is set to a 0 POINT STATUS BIT MAP Another Genius I O diagnostic option selected when the Diagnostic Tables are enabled through the Configuration Menu is a point status bit map for each input and each output The status bit initial value will be zero It is set to a one if a fault is received which affects this circuit or its entire I O block that is loss of block Once set status bits remain on until reset by the user s program even if the fault is corrected thus allowing a Matrix Compare function to monitor the status of all I O circuits and identify a faulty circuit quickly and without extensive logic If faults are found with analog blocks they will be indicated in the status by a special pattern since there is no direct relationship between the fault circuit and an individual reference The status for analog inputs is shown below for its three addresses 24 bits Table 4 8 BIT STATUS MEANING FOR ANALOG BLOCKS NUMBER ADDRESS 0 ADDRESS 1 ADDRESS 2 0 Input 1 Low Alarm Input 2 Underrange Input 3 Open Wire Input 1 High Alarm Input 2 Overrange Not Used OFF 2 Input 1 Underrange Input 2 Open Wire Input 4 Low Alarm 3 Input 1 Overrange Not Used OFF Input 4 High Alarm 4 Input 1 Open Wire Input 3 Low Alarm Input 4 Underrange 5 Not Used OFF Input 3 HighAlarm Input 4 Overrange 6 Input 2 Low Alarm Input 3
286. s operation if allowed to reach the internal circuits of the CPU The I O section both inputs and outputs protects the CPU from electrical noise entering through the I O modules or wiring The I O section is where status signals are filtered to remove noise voltage levels are validated and where decisions made by the CPU are put into operation Inputs provide their status to a storage area within the CPU and outputs are driven from similar stored status in the CPU For detailed information on the I O module types and capacities available for use with a Series Six Plus PLC refer to the Series Six Data Sheet Manual GEK 25367 and the Genius I O User s Manual GEK 90486 The exact type of I O module to be specified for example 115 V ac or 24 V dc is usually determined by the field device selected by the user Tables 1 4 and 1 5 list the available I O modules Table 1 4 STANDARD I O MODULES NUMBER OF CIRCUITS AND 1 0 CAPACITY MODULE TYPE INPUT OUTPUT 115 V ac dc 8 8 2 Amp ac 1 5 Amp dc 115 V ac Isolated 6 6 3 Amp 115 V Protected 4 4 Amp 120 V dc 8 2 Amp 220 V ac dc 8 8 2 Amp 220 V ac Isolated 6 ac dc 6 3 Amp 12 V dc 8 ac dc 8 2 Amp Sink Source 24 V dc 8 ac dc 8 2 Amp Sink Source 48 V dc 8 ac dc 8 2 Amp Sink Source 5V TTL 32 32 25 mA 10 to 50 V dc 32 32 250 mA Sink 500 mA Source Reed Relay 6 100 Va Max NO or NC Analog 12 bit 0 to 10 V dc 8 4 5 mA Max 4 to 20 mA l to 5 V dc 4
287. sed or if channel selection is made through I O Transmitter Modules no switch setting is necessary The Genius I O bus must be terminated at the Bus Controller by its characteristic impedance The enhanced version Bus Controller provides three selectable on board impedances 100 150 or 750 Ohms Three jumpers JP1 JP2 and JP3 on the module are used to select one of the listed values or to select no impedance Versions of Bus Controller Two versions of the Bus Controller are available they are 1 Catalog Number IC660CBB901 IC660CBB903 has enhanced features Interfaces with the Genius I O blocks and provides normal Genius I O status information and Hand Held Monitor support It requires one byte of input address 8 references for transfer of its status to the CPU 2 Catalog Number IC660CBB900 IC660CBB902 has enhanced features Provides all functions of the IC660CBB901 Bus Controller plus a wide range of diagnostic data and system functions for the entire Genius I O system This Bus Controller requires 6 addresses for diagnostic input data 48 references provided to the CPU and 4 addresses for command output data 32 references received from the CPU Addresses are selected by the DIP switches at the rear of each I O slot For detailed information on the Bus Controller modules refer to the Genius I O System User s Manual GEK 90466 2 22 Physical Equipment Configuration GEK 96602 COMMUNICATIONS CONTROL MODULES The Commu
288. ss in the output data to address 127 I O points 1017 1024 during the I O scan it connects its channel as selected by DIP switch setting to the CPU s I O chain thereby enabling its I O channel When the data to address 127 is changed to a value other than the DIP switch setting the I O Transmitter disconnects its I O channel from the CPU s I O chain When the value 80H Hexadecimal is written to address 127 by the CPU it is interpreted as a command to all of the I O Transmitters to connect their channels to the CPU s I O chain but will not cause them to send input data to the CPU a40757 1 37 Pin Connector to 1 0 Receiver or Advanced 1 0 Receiver in Downstream Local 1 0 station CHAIN OK Light CHAIN PARITY Light ISOLATED POWER Light FAULT ENABLE Li ght Uu AWUN 6 CHAIN ACTIVE LIGHT Not visible with faceplate in place for use in system set up only ON for EXPANDED I O MODE 7 FAULT ENABLE DISABLE Selector 8 NORMAL EXPANDED 1 0 SELECTOR a Place the jumper JP2 over pins 1 2 for NORMAL 1 0 One nonselectabl e 1 0 chain b Place the jumper JP2 over pins 2 3 for EXPANDED 1 0 Selectable 1 to 8 chains Figure 2 27 I O TRANSMITTER MODULE Isolation Circuitry The I O Transmitter translates the I O rack backplane signals into isolated balanced signals at a level suitable for transmission up to 500 feet 150 meters and with sufficient power to drive up to 10 I O Receivers Optocouplers
289. station 2 40 illustration of 2 41 Index GEK 96682 Remote I O system 2 52 configuration jumpers 2 54 remote I O addressing 2 53 system response time 2 53 typical connections 2 52 Removing a printed circuit board 3 6 Required references summary of 4 9 lO references 4 9 Register references 4 19 S Scan rate 1 5 Scratch pad 2 17 Series Six Plus features of 1 4 VO diagnost ics 4 2 structure 2 29 installation 3 1 Arithmetic Control module 3 11 Auxiliary module 3 13 CPU module installation 3 7 CPU power supply connections 3 14 CPU rack installation 3 2 Combined memory module 3 8 Communications Control modules 3 13 Control module 3 12 Logic Control module 3 11 extract ion insertion tool 3 4 instruct ions 3 1 mounting illustration of 3 3 Software packages 1 8 Specifications General 1 5 Start up CPU 3 31 INDEX System grounding procedures 3 15 ground conductors 3 76 safety ground 3 16 signal ground 3 17 programming device grounding 3 16 System planning 1 20 T Table of contents vii to xvii Tables list of xviii to xix Terminology PC 1 21 Troubleshooting and repair 5 1 Troubleshooting general information 5 2 Troubleshooting sequences 5 31 Troubleshooting with the Advanced lO Receiver 5 39 to 5 49 U W Units of load 3 28 3 29 Window function 4 24 Window function entering a 4 25 Workmaster computer general description of 1 7 1 8 connection to Series Six Plus 2 62 illustration of 2
290. subsystem and peripheral devices For a complete list of available hardware and software refer to GEP 761 Products and Publications Master Price List For further information on any of the individual components described in this chapter that are not part of the CPU refer to the applicable manual PRODUCT STRUCTURE FOR THE SERIES SIX PLUS PLC The product structure for the Series Six Plus PLC is such that many different configurations including combinations of I O modules be contained a single CPU rack The design is flexible to meet the user s requirements Figure 2 1 illustrates this product structure showing the location of modules in the rack SLOT NUMBER a422 13 Hg 7 543 2 1 3 RACK HAS 8 SLOTS WITH UP TO 451075 AVAILABLE FOR 1 0 MODULES uUnzO o0 zczgzzoo lt DOEME omz iuzoco r uucu Umzo ou rTOnD z co0 o mzir 20 ers PROGRAMMING FUNCTION REQUIRED OPTION 1 0 MODULES 4 OR 6 SLOTS ADVANCED EXPANDED OR EXPANDED DISCRETE ANALOG APMI 2 ASCII BASIC 1 0 CCM L AC 95 260 VAC 1 0 TRANSMITTER HIGH SPEED 20 32 voc or 100 150 VDC COUNTER REMOTE 1 0 DRIVER GENIUSBUS CONTROLLER INCLUDED WITH BASIC RACK 1 0 LINK LOCAL LOGIC REGISTER MEMORY 1 0 OR AUXILIARY 1 0 REQUIRED OPTION 1 0 AUXILIARY 1 0 OR AUXILIARY 1 0 COMMUNICATIONS LOCAL AREANETWORK CONTROLOR LOCALAREANETWORK LAN IS A 2 SLOT OPTION LAN I
291. ta and the 1 0 block will drive the new state or value as new communications are received from the CPU Expanded CPU Operation 4 37 GEK 96602 Output 2 Bit 1 Definition Clear All Faults This bit clears all faults that are currently being stored in the I O blocks connected on this controllers bus faults will be cleared once for each transition of the Clear Faults output Output 3 Bit 2 Definition Clear Circuit Fault Output 3 performs a function similar to Output 2 except it is limited to one circuit per scan Only the circuit identified in addresses 2 and 3 bytes 3 and 4 by the I O reference 1 to 1000 input 17 LSB input 32 MSB will be cleared at the I O block No other faults will be affected Since the analog circuits do not have a specific I O reference assigned to them the circuits are identified by the first six references assigned to the block as shown in table 4 7 The example in the table assumes that the Analog I O block starts at I O references 10225 Table 4 7 ANALOG I O BLOCK REFERENCE EXAMPLE I 0 REFERENCE ANALOG CIRCUIT EXAMPLE Starting Reference Input Circuit Starting Reference Input Circuit 2 Starting Reference 2 Input Circuit 3 Starting Reference 3 Input Circuit 4 Starting Reference 4 Output Circuit Starting Reference 5 Output Circuit 2 To clear more than one circuit either discrete or analog Output 3 must go from an off to on transition a one sh
292. te station Circuitry on this module converts output data from parallel to serial and input data from serial to parallel Specifically a Remote I O Driver connects the I O structure in a CPU a CPU station or a Local I O station to a Remote I O station through a serial communications channel by direct connection with a two twisted pair cable or a communications link using RS 232 compatible modems With two twisted pair cable the Remote I O station can be located up to a maximum of 10 000 feet 3 km from the Remote I O Driver A communications link using modems allows connection over a much greater distance An I O Transmitter located in a rack in the Remote I O station can be the first of a link of up to four 500 foot 150 meters links using f O Transmitters thereby extending the remote capability an additional 2000 feet 600 meters a41069 CONNECTOR TO RECEIVER OR RS 232C MODEM Figure 2 29 REMOTE I O DRIVER MODULE The Remote I O Driver can drive up to 248 Inputs and 248 Outputs A Remote I O Driver module can be installed in any unused I O slot in a CPU station a Local I O station or a CPU except the left most slot in an I O rack which is reserved for a Receiver module If connection to the Remote I O station is to be made through a modem link the Remote Driver must be installed a high capacity I O rack This is necessary since the RS 232 specification requires 12 and 12 V dc for operation
293. tering a Floating Point function conditional logic to control power flow to the function should be entered before the function If conditional logic is not entered the function will execute unconditionally with every sweep To access Floating Point Arithmetic with the programmer select Advanced Mnemonic Group F7 then Expanded Arithmetic F2 then Floating Point Arithmetic F6 Next the desired Floating Point Arithmetic function is selected with the applicable soft key KEY MNEMONIC FUNCTION Fl FADD Floating Point Addition F2 FSUB Floating Point Subtract ion F3 FMULT Floating Point Multiplication F4 FDIV Floating Point Division F5 FP GREATER THAN Floating Point Compare F6 INTEGER TO FLOATING POINT Integer to Floating Point Conversion F7 FLOATING POINT TO INTEGER Floating Point to Integer Conversion For detailed information on how to enter the Floating Point functions refer to the Logicmaster 6 User s Manual GEK 25379 Floating Point Addition Program a Floating Point Addition function to add a floating point value in reference A to the floating point value in reference B and place the result in reference C Every scan that power is received the FADD function calculates the result using floating point mathematics The result is placed in reference C Only the content of reference C is altered by this function The function will output power flow if overflow occurs if references A and B are opposite signed infinitie
294. the Expanded II function set Logic Memory Function The Logic Memory portion of the combined memory module stores the user entered program which consists of ladder diagram logic and mnemonic instructions Logic Memory is made up of 16 bit words each with 2 parity bits as illustrated below e a Jis je u o9 8 7 6 5 4 3 211 0 5 7055 BYTE 2 BYTE PARITY BYTE 1 PARITY BYTE 2 Figure 2 12 BASIC WORD STRUCTURE Register Memory Function The Register Memory portion of the Combined Memory is a 16 bit user accessible storage area of memory used for data storage and for data bit manipulation by many mnemonic functions The status of the 1 0 points when the expanded mode is stored in Register Memory This memory is available with 1K 8K or 16K words of CMOS memory storage locations Many registers have special significance to system operation Register memory also has a 2 parity bits Refer to Chapter 4 for a description of Register Memory mapping Internal Memory Function The Internal Memory portion of the Combined Memory module contains data stored in Table and Scratch Pad formats The tables stored in internal memory include status transition and override Physical Equipment Configuration 2 17 GEK 96602 The status table stores bits representing the ON or OFF status of the 1000 inputs and 1000 outputs the main I O chain when in Normal mode In the Expanded mode of operation the status table sto
295. ting the terminal board Select 115 V ac or 230 V ac input by configuring the jumper to the proper terminals as shown for a standard power supply The jumper will be configured for 115 V ac when shipped from the factory The high capacity power supply does not require jumper configuration since it is a wide range supply and will accept an ac input voltage from 95 to 260 V ac Connect a 3 wire AC power cord to the 3 lower terminals CAUTION When connecting multiple I O racks to the same ac power source ensure that all ac input connections are identical at each rack Do not cross line 1 L1 and line 2 L2 A resulting difference in potential can cause damage to equipment Installation Instructions 3 21 GEK 96682 DC Power Source Connections Remove the plastic cover protecting the terminal board Connect a DC power source 20 to 32 V dc or 700 to 150 V dc as required to the proper terminals on the terminal board POS NEG or GND After completing the ac or dc connections as required the protective plastic cover should be reinstalled WARNING Ensure that the protective cover is installed over the terminal board During normal operation either 115 V ac 230 V ac 24 V dc or 125 V dc is present The cover protects against accidental shorting of terminals which could cause damage to the machine or injury to the operator or maintenance personnel lO System Interface Modules The I O system interface mod
296. tion GEK 96602 Thus the format for real I O points for channel 3 in the Main I O chain is for example 13 0001 to 1341024 for Inputs and 03 0001 to 1024 for Outputs Each IK channel requires 64 words of memory 64 words x 16 bits 1024 I O Note that although 1024 bits are available in each channel 0001 to 1000 are used for actual I O points 1001 to 1024 are reserved for special use Real I O Memory Allocation In the Expanded mode the real I O points for Channel 0 are scanned on the Main I O chain references 10001 11024 and O0001 O1024 and their status is maintained in the Main status table Channel 8 which is the first Auxiliary I O channel in Expanded mode is scanned on the Auxiliary I O chain references 10001 11024 and AO0001 01024 and its I O status is maintained in Registers R0001 through R0128 which is the Auxiliary I O status table Channels 1 through 7 of real I O are mapped into Registers R0129 through R0961 and the Auxiliary channel real I O Channels 9 through are mapped into Registers R1153 through R2048 This mapping scheme is valid for systems having either 8K or 16K words of register memory For mapping of 1K or 256 register systems refer to Chapter 4 There you will find illustrations of memory allocation for each register configuration The override tables are associated only with the I Al and AO references The transition tables which are required for operation of one shot
297. tion Set Up Menu Making Entries on the CPU Configuration Set Up Page Cancelling Entries to the CPU Configuration Set Up Menu CPU Configuration Menu Definitions Displaying and Editing the Genius Bus Controller Locations Page Editing the Bus Controller Map Cancelling Changes to the Bus Controller Map Displaying and Clearing Genius I O Faults Displaying the Genius I O Fault Table Genius I O Fault Table Definitions Viewing Additional Fault Listings Clearing Faults Floating Point Functions Floating Point Display Format Valid Number Format Programming Floating Point Arithmetic Functions Floating Point Addition Floating Point Subtraction Floating Point Multiplication Floating Point Division Floating Point Greater Than Convert Integer to Floating Point Convert Floating Point to Integer PAGE L L L L LI an PHEHPHSHHSHHAHLAH a st i i ARR L L i i ONN A 1 A 4 14 4 14 4 17 4 17 4 17 4 18 4 18 4 19 4 20 4 20 4 21 4 21 4 21 4 22 4 22 4 22 4 23 4 23 4 24 4 24 4 24 Contents GEK 96692 CHAPTER 4 CONTENTS TITLE EXPANDED CPU OPERATION Continued Window DPREQ Function Entering a Window Function Using the Do I O Function to Address 16K Inputs and Outputs Entering a Do I O Function Expanded Time Reference Real Time Clock Format of the Real Time Clock Genius l O Diagnostics Diagnostic Fault Table Register Memory Size VS Genius I O Diagnostics
298. tware The parallel version communicates with a Series Six Plus PLC through a standard I O interface cable as with the Workmaster computer The following board set must be installed in the CIMSTAR 1 computer for parallel communications with a Series Six Plus PLC A Workmaster Series Six interface board IC640BSS303 A Workmaster Series Six Terminator board IC640BLD304 This board set was previously described under Workmaster to Series Six Interface Adapter Boards Physical Equipment Configuration 2 65 GEK 96602 Serial Version of Loqicmaster 6 Software The serial version when installed in CIMSTAR I computer communicates with a Series Six Plus PLC over a serial communications channel to a CCM module in the Series Six Plus PLC Communication is possible over a long distance using a wide range of baud rates either with or without modems The system can communicate with a single CCM module and CPU or be used in a multi drop configuration having up to eight CCM modules and CPUs PROGRAMMING A SERIES SIX PLUS PLC WITH AN IBM PC The IBM PC version of the Logicmaster 6 software can be used to program a Series Six Plus PLC when installed in an IBM PC IBM PC XT or IBM PC AT computer that meets the following requirements 640K of RAM memory PC DOS version 2 1 or later for the IBM PC and PC XT PC DOS version 3 1 or later for the IBM PC AT Either a color or monographics monitor adapter card The software
299. ubt unplug the power supply e Replace the power supply in this rack Replace this I O rack Once the problem has been determined and corrected push the RESET button on the Advanced 1 Receiver or momentarily turn Output Byte Bit 2 On then OFF 17 CHAIN PARITY LIGHT DEFINITION STATUS Output Parity is good in this rack and all links connected to this rack OFF Indicates that an output parity problem has been identified by an I O Receiver module The CHAIN OK light on the CPU s I O Control module is off RUN and ENABLE lights at the CPU will be off and Alarm Relay 1 switches Corrective Action isolate the problem by following the PAR status indicators until a link is found where CHAIN PARITY is off on an 1 Transmitter module but is on in the 1 0 racks in the Local station it is driving Locate the first I O rack in that chain with the LOC PAR light off Ensure good grounding between racks in that station no more than 7V between racks Ensure that the low level I O cable has not been placed close to any high level power cables power supplies or switching devices Replace the 1 0 Receiver in that rack Replace the I O chain interconnecting cable e Replace the Transmitter or Remote 1 0 Driver that is driving the I O station Troubleshooting and Repair 5 41 GEK 96602 18 LOCAL PARITY LIGHT STATUS DEFINITION Output parity is OK in th
300. udes the Configuration function In addition Genius 1 diagnostics must be enabled in the CPU Configuration Set Up Menu and the Workmaster must be On Line or Monitor To display the Genius O Fault Table follow the steps below 1 The program must be present in system memory If it is not load it using the Load Store Verify functions Return to the Supervisor menu 2 From the Supervisor menu press the Expanded Functions F7 key 3 From the Expanded Functions menu press the I O Faults F2 key The Genius I O fault Table screen will then be displayed as shown below GENIUS 1 0 FAULT TABLE TOTAL FAULTS 0000 date FAULT DISPLAYED time 0000 00 00 00 0 B C POINT CIRC FAULT FAULT FAULT ADDR ADDR NO CATEGORY TYPE DESCRIPTION DAY HR MN SC T NEXT PREV CLEAR XPNDED 1 PAGE 2 PAGE 3FAULTS 4 TOP 5BOTTOM 6 7 8 FUNC p eed Expanded CPU Operation 4 19 GEK 96602 GENIUS I O Fault Table Definitions If a fault occurs that has more than one cause see the definition of Fault Category below each cause is listed as a separate line in the table The entries in the table show the following information about a fault B C BUS CONTROLLER ADDRESS Displayed for a Bus Controller ADDR error This entry has two fields Channel Number The number of the channel where the error occurred A hex value from 0 to F MAIN AUXILIARY 0 8 9 2 3 B 4 C 5 D 6 E 7
301. uity problem exists now in one or more of the I O racks connected to the lower connector on this module The CHAIN OK light on the CPU s I O Control module will be off RUN and ENABLE lights at the CPU will be off and Alarm Relay 1 switches OFF A power or continuity problem exists now in this I O rack The CHAIN OK light on the CPU s I O Contro module will be off RUN and ENABLE lights at the CPU will be off and Alarm Relay 1 switches Corrective Action 16 and 21 OFF Locate the last I O rack in the I O Transmitter or Remote 1 0 Driver link beginning this rack that has the CHN OK 16 light off Examine the other status indicators 22 and 23 in that rack and go to the corrective action corresponding to those lights 16 and 22 OFF Locate the last I O rack in the chain connected to the lower connector on this Advanced I O Receiver module If the I O rack connected to that connector has all of the status indicator lights ON replace the cable between the two racks Replace the Advanced I O Receiver in this rack Replace the Advanced 1 Receiver in the downstream rack 5 40 Troubleshooting and Repair GEK 96602 16 and 23 OFF Check the POWER light on the power supply in this rack if off go back to step 5 e Reseat the Advanced 1 Receiver module in this rack e Replace the Advanced 1 0 receiver module in this rack CAUTION Be careful not to touch any high voltage wires or connectors When in do
302. ules are the I O Receiver Advanced I O Receiver I O Transmitter Remote l O Driver and Remote l O Receiver Individual functions of these modules are described in Chapter 2 Installation instructions for each of these modules can be found in the individual data sheets for each module Data sheets for all I O system interface modules are included in the Series Six Data Sheet manual GEK 25367 In addition individual data sheets are included with each module shipped from the factory For reference the data sheet numbers for each of the I O system interface module are listed below lO INTERFACE MODULE PUBLICATION NUMBER I O Receiver GEK 83512 Advanced l O Receiver GEK 90771 lO Transmitter GEK 83515 Remote l O Driver GEK 83537 Remote Receiver GEK 83537 A summary of installation requirements for the I O system interface modules is included on the following pages 3 22 Installation Instructions GEK 96682 Receiver or Advanced I O Receiver Either an I O Receiver or an Advanced I O Receiver module must be installed in slot 11 in a 19 rack or in slot 8 in a 13 rack which is the leftmost slot in an I O rack An I O address DIP switch is not required for this module or for any I O communication modules The top connector on the I O Receiver or Advanced I O Receiver in a daisy chain of racks connects to an I O Control module in the main I O chain to an Auxiliary module in an auxiliary I O chain to the next upstream I
303. ur Series Six Plus Programmable Logic Controller system including the CPU and I O system The troubleshooting method described emphasizes a logical approach to analyzing any faults and subsequent replacement of any failed modules Appendix A Glossary of Terms This is a glossary of commonly used programmable logic controller terminology to aid the user in understanding those unique terms A comprehensive index is provided as an aid to quickly finding a particular subject in this manual Shoufd additional information be required contact your GE Fanuc NA Distributor GE Fanuc NA salesperson or GE Fanuc Automation North America Inc P O Box 8106 Charlottesville Virginia 22906 Henry A Konat Senior Technical Writer Preface GEK 96602 RELATED PUBLICATIONS For more information on subjects discussed in this manual refer to these publications GEK 25361 GEK 25365 GEK 25364 GEK 25367 GEK 25368 GEK 25398 GEK 25373 GEK 25379 GEK 90486 GEK 90800 GEK 90802 GEK 90817 GEK 90820 GEK 90825 Series Six Installation and Maintenance Manual which describes the earlier models of Series Six programmable logic Controllers Application Guide for the Series Six Programmable Controller which provides information on how to developement typical applications using a PLC Series Six Data Communications Manual which describes the function and operation of the Communications Control Modules CCM Seri
304. us fault status are mapped into Registers R2049 through R3072 The internal references for Auxiliary channels 8 through F are mapped into Registers R3073 through R4096 The Register Memory located on the Combined Memory module is a 16 bit user accessible storage area of memory used for data storage and for data bit manipulation by many mnemonic functions Many of these registers have special significance to system operation Register Memory Size The maximum register storage available in a system is determined by the Combined Memory module selected The user must also verify the maximum registers in a system by making a selection on the Configuration Menu with Logicmaster 6 software The selections available are 256 1 K 8K and 16K registers Note that if the smaller register sizes are selected the register use should be such that if a larger register size is later used the registers used are compatible Figures 4 3 and 4 4 illustrate register memory use for each of the register sizes NOTE The 256 word register memory option is not currently compatible with Genius l O diagnostics and should not be selected for that use 4 6 Expanded CPU Operation 96602 REGISTER RANGE REGISTER 8K CONTENTS R0001 ROOOl 1K OUTPUTS A00001 A01024 1 3 1K INPUTS AI0001 AI1024 RO128 R0128 60129 0129 7K OUTPUTS 01 0001 to 0741024 3 7K INPUTS 11 0001 to 17 1024
305. used for actual I O points 1001 to 1024 are reserved for special use Expanded CPU Operation 4 5 GEK 96602 NOTE Ensure that when referencing an I O point a program a prefix is added to properly address the applicable I O chain Normal mode references address the Main and Auxiliary I O chains for example 10234 00346 10222 00456 etc Expanded mode references for channels 1 through 7 and 9 through F include the channel number for example 13 0101 O340101 0234 OB 0567 etc The individual module DIP switch settings for I O points 1 to 1000 are the same for each chain or channel only the prefix is different Real I O Mapping In the Expanded mode the real world I O points for Channel 0 are scanned on the Main chain and their status is maintained in the Main I O status table Channel 8 which is the first Auxiliary channel in Expanded mode is scanned on the Auxiliary I O chain with its I O status maintained in Registers R0001 through R0128 which is the same as the Auxiliary I O status table for the Normal mode Auxiliary I O chain Channels 1 through 7 of real I O are mapped into Registers R0129 through R1024 and the Auxiliary channel real I O Channels 9 through F are mapped into Registers R1153 through R2048 Internal Mapping of Discrete References The internal discrete references for Channels 0 through 7 which can be used for program references to control real inputs or outputs or Geni
306. ut WORKMASTER 1 SERIES SIX 1 0 RACK LOCAL 1 0 STATION M Figure 2 32 WORKMASTER COMPUTER CONNECTIONS TO THE SERIES SIX PLUS PLC Connecting Cable The cable to be used for connecting the Workmaster computer to a Series Six Plus PLC is a standard parallel I O bus cable Following is a list of catalog numbers for these cables CATALOG NUMBER CABLE LENGTH IC600WDOG 2 feet 8 6 meters IC600WDOG5 5 feet 1 5 meters 1 6000010 10 feet 3 0 meters IC6900WD025 25 feet 7 5 meters 1 600 0050 50 feet 15 0 ICeg0WDlOD 1 100 feet 30 0 meters 1 600 0700 1 200 feet 60 0 meters IC600CJD50U 1 500 feet 150 0 meters 1 To be used only for direct connection to a dedicated I O Transmitter module in a Series Six Plus PLC system 2 64 Physical Equipment Configuration GEK 96602 Connections Using the Serial Version of Logicmaster 6 The Workmaster computer can also communicate with a Series Six Plus PLC using the serial version of Logicmaster 6 software The Workmaster computer must be connected to the CCM2 in the Series Six Plus CPU rack or to a CCMG operating in the CCM2 mode CCMG catalog number must be IC600CB517C or later The CCM2 must be configured for Workmaster protocol Cable connection to the CCM2 is to the COM1 port on the Workmaster computer The location of the COM1 port is determined by the type of communication to be used When point to point commun
307. ut Byte Address ooooogoogoooogo APPENDIX APPENDIX A GLOSSARY OF TERMS A 1 xvi Contents GEK 96602 FIGURES PAGE Figure 1 1 Programmable Logic Controller Block Diagram 1 1 1 2 Typical Series Six Plus PLC Rack 1 3 1 3 Genius I O Typical Communications Link 1 6 1 4 Workmaster Industrial Computer 1 7 1 5 Redundant Processor Unit Configuration 1 14 1 6 Operator Interface Unit 1 15 1 7 Operator Interface Terminal 1 15 18 Typical Proloop System Equipment 1 16 1 9 GEnet Factory LAN 1 19 1 10 LAN Interface Module Connects a Series Six Plus PLC to a Carrierband Network 1 20 121 RS 232 to RS 422 Adaptor Unit 1 21 2 1 Product Structure for Series Six Plus PLC 2 1 2 2 Basic CPU Rack Configuration for the Series Six Plus 2 3 2 3 Brackets in Position for Rack Mounting 2 3 2 4 Brackets in Posit ion for Wall or Panel Mounting 2 3 2 5 Illustration of Power Supplies 2 4 2 6 CPU Terminal Block Connections 2 6 2 7 CPU Power Supply Block Diagram 2 8 2 8 Power Supply Auxiliary Circuit Board 2 9 2 9 Control Module 2 11 2 10 Example of Logic Control Module 2 13 2 11 Arithmetic Control Module 2 15 2 12 Basic Word Structure 2 16 2 13 Typical Combined Logic Memory Module 2 20 2 14 Illustration of CCM2 Module 2 24 2 15 Illustration of O CCM Module 2 26 2 16 Link Local Module to Series One or Series Three Remote I O Racks 2 27 2 17 Link Local Module 2 28 2 1
308. vailable as a single 19 or 13 rack referred to as the CPU rack that can be configured to meet the application requirements Memory is available on a combined memory board that contains the internal memory up to 64K of logic memory and up to 16K of register memory Up to 16K of I O points 16K Inputs I6K Outputs are available to the user in system All of the existing Series Six I O modules are compatible with and can be used a Series Six Plus PLC system The 6 left slots in the 19 CPU rack are available for modules 3 slots available for I O in a 13 rack If the PLC system is to include an Auxiliary I O module which must be placed in slot 6 or 7 numbered from the right 5 slots are available for I O modules in the 19 CPU rack or 2 slots in the 13 CPU rack When more than the 3 13 rack or 6 19 rack I O modules that can be contained in the CPU rack are required standard Series Six I O racks are available to add to the I O system I O racks connected directly to the CPU through the I O Control module can be located up to 50 feet 15 meters from the CPU in a daisy chain in a CPU station I O racks in a Local I O station can be located up to 500 feet 150 meters from the CPU connected by I O Transmitters to I O Receivers or Advanced I O Receivers through cables on the parallel I O bus Up to 4 I O Transmitters can be used in series to allow up to 2400 feet 600 meters from the CPU station to the most distant I O Receiv
309. vides a direct LAN attachment to IEEE 802 4 carrierband network has two communication services for control data transfer and provides extensive station configuration management and diagnostic tools INTELLIGENT MODULES Axis Positioning Type 1 Resolver Axis Positioning Type 2 Encoder High Speed Counter ASCII BASIC Loop Management 1 14 Introduction To The Series Six Plus PLC GEK 96602 OPTIONAL DEVICES SUPPORTING THE SERIES SIX PLUS PLC Several devices are available as options for the Series Six Plus PLC system These devices enhance a PLC system by providing capabilities not provided by the PLC itself Redundant Processor Unit The Redundant Processor Unit RPU allows two CPUs to operate in parallel connected to one I O structure within one system A fault in either system can be detected and alarmed and the alternate CPU will continue system operation The RPU also allows a second l O structure to be added to the system which allows switching between CPUs or l O systems For a detailed description and operation of the RPU refer to the Series Six Redundant Processor Unit Manual GEK 25366 CPUH2 94tmp8 TO AUXILIARY 1 0 N CPUI AND CPU2 RUN HOLD KEY SWITCH ON OFF POWER SWITCH CPUL AUTO CPU2 KEY SWITCH POWER ON LIGHT POWER H 227 TERMINALS TERMINAL ALARM TO AUXILIARY 1 0 STRIP TERMINALS CHAIN NO I AND H0 2 1 0 CHAIN NO I 1 0 CHAIN NO 2 Figure 1
310. voltage is present e For high capacity ac power supplies check the ac power source Voltage should be 95 to 260 V ac e For dc power supplies check the dc power source Voltage should be 20 to 32 V dc for the 24 V dc power supply or 100 to 150 V dc for the 125 V dc power supply e Partially remove the power supply module from its slot and measure the 5 V dc output in a standard supply In a high capacity supply also measure the 12 and 12 V dc output 6 Observe the ISOLATED POWER light on the I O Transmitter module Definition Isolated 5 V dc bus is out of tolerance CHAIN OK lights from this rack back to and including the CPU will turn off RUN and ENABLE lights will turn off Alarm Number 1 relay switches Corrective Action e Replace the 1 0 Transmitter if the POWER status light is off e If the POWER Status light is off go back to step 5 and troubleshoot that problem first 5 34 Troubleshooting and Repair GEK 96602 7 Observe the FAULT ENABLE light on the I O Transmitter module older versions do not have this light Definition Status ON Board jumper set 2 3 CPU will stop if there is a fault on this link OFF Board jumper set 1 2 CPU will not stop if there is a fault on this link No Corrective Action Set the board jumper to the desired function 8 Observe the LOCAL OK light on Remote O Driver and Remote I O Receiver Definition Status ON This module is oper
311. way to provide Signal Ground connections is to ensure that the Series Six Plus PLC rack metal frames are directly connected to the control panels or racks in which the racks are mounted This can be accomplished by connecting a ground strap from one of the ground lugs on the rack plate on either side of the rack to the control panel or cabinet These Signal Ground methods are illustrated in figures 3 14 and 3 15 a4 1054 GROUNDED PANEL OR CABINET 1 STAR WASHERS UNDER RAIL MOUNTING BOLTS SERIES SIX PLUS OR 2 GROUND STRAP FROM GREEN GROUNDING SCREW IN CENTER OF RACK SIDE PLATE TO PANEL SAFETY GROUND WIRE EARTH GROUND Figure 3 14 SERIES SIX PLUS PLC RACK SIGNAL GROUND CONNECTIONS 3 18 Installation Instructions GEK 96692 FROM TRANSMITTER CONTROL CABINET 41052 GROUND CONNECTIONS AT EACH RACK Li CONTROL CABINETS MUST TIED TOGETHER AND HAVE A COMMON EARTH GROUND GROUND Figure 3 15 Q STATION GROUNDING 3 Programming Device Grounding For proper operation the programming device Workmaster computer CMSTAR 1 computer or a Program Development Terminal must have a ground connection in common with the CPU or VO rack to which the PDT or Workmaster computer interface cable is connected Normally this common ground connection is provided by ensuring that the programmer s power cord is connected to the same power source with the same ground reference point as the CPU or
312. witches 5 6 and 7 are used to establish the I O references for groups of 120 Inputs and 120 outputs If the option is selected for 248 Inputs and 248 Outputs then switches 6 and 7 will establish the I O references The remaining switches either 1 2 3 and 4 or 1 2 and 3 respectively are used to select a unique address for the Remote I O Driver The unique address will assign 8 consecutive I O points to the Driver which will be used to provide status data to the CPU for the Remote I O station A group of jumper plugs must also be configured for proper system operation These items configured by the jumpers include the following Quantity of I O 120 120 or 2481248 Remote I O Parity Error Effect on the CPU STOP or Continue to RUN Communications Failure Effect on the CPU STOP or Continue to RUN Even or Odd Parity Specify Parity Check Yes or No Baud Rate Selectable from 110 baud to 57 6K baud Carrier Detect No or Yes Clear To Send No or Yes Output Mode Twisted Pair or RS 232 Input Mode Twisted Pair or RS 232 Sensitivity Medium or Minimum e e oe 6 9 9 SE 6 For detailed instructions on jumper configuration for a Remote I O Driver module refer to the Remote I O module data sheet GEK 83537 3 24 Installation Instructions 6 96602 Remote Receiver A Remote I O Receiver must be installed in the left slot slot 11 in a 19 rack or slot 8 in 13 rack of the first I O rack in a Remote I
313. ximum Total power from al 12 V dc 1 5 A maximum outputs must be less 12 V dc 1 0 A maximum than 90 watts Output Voltage Current ac 33 mSec minimum 115 V ac line dc 10 mSec minimum 20 V dc line 4 mSec minimum 100 V dc line Allowable power interruptions Meets requirement of NEMA ICS 2 230 and ANSI C37 90A Noise Immunity 0 to 60 C 32 to 140 F outside of rack 20 to 70 4 to 158 F 5 to 95 non condensing Operating Temperature Storage Temperature Humidity 8 to 28 V dc 12 46 x 9 0 x 2 75 inches 317 x 229 x 70 mm Auxiliary Battery Input Dimensions Power Supply 2 8 Physical Equipment Configuration GEK 96602 Outputs and System Control Signals The CPU power supply provides 3 dc outputs 45 V dc 12 V dc and 12 V dc It also generates system control signals for use throughout the CPU The dc voltages are connected directly to the rack backplane Logic signals are distributed through connectors connected to the backplane Figure 2 7 is a block diagram of the CPU power supply showing connections to the terminal blocks dc voltages available and system control signals to and from the power supply a41074 MEMORY PROTECT SWITCH INPUTS FROM BACKPLANE lav BAT OK CPU OK ALARM 1 ALARM 2 LOW
314. y module is included in the system It should be noted that each chain actually has 1024 inputs and Outputs however only the first 1000 are available for I O References 1001 through 1024 are reserved for special use The ON or OFF state of the 1K Inputs and 1K Outputs in the main I O chain are maintained in the I O Status Table The ON or OFF states of I O points in the Auxiliary VO chain are maintained in the Auxiliary I O Status Table which is mapped into the first 128 words of Register memory R0001 to R0064 contains the Auxiliary Output Table and 0065 to R0128 contains the Auxiliary Input table EXPANDED MODE I O ADDRESSING When the Expanded I O mode is selected through the Configuration Menu a jumper must also be configured on each I O Transmitter that is to drive a chain a total of 8K Inputs and 8K Outputs in the Main I O chain are available to the user In addition if the Auxiliary O chain is selected requires an Auxiliary I O module 8K Inputs and 8K Outputs are available in the Auxiliary chain total real I O available through the use of both chains is therefore 16K Inputs and 16K outputs 32K total points The I O references 00001 01024 10001 11024 are used as real I O references for channel 0 and 0001 AO1024 and 10001 11024 are used as real I O references for channel 8 These references in addition to channel 1 through 7 and 9 through F references for real world and 32K of internal referenc
315. y switches Troubleshooting and Repair 5 21 GEK 96602 If any voltage is missing or out of tolerance use the following procedure Check ac input power to power supply terminal board for power supply requiring an ac voltage source Check dc input power to power supply termina board for power supply requiring a dc voltage source SELECT JUMPER 1 FOR 115 OR 230VAC OPERATION s6830122 s6830144 Q a41060 115 S 777 ul 5 las PEE d No connection Q lenis Q Q none GROUND 5 DC INPUT 20 TO 32 VDC NEG OR 100 TO 150 VDC GND L2 LINE 2 GND GROUND AC INPUT 95 TO 260 VAC OSOA 2 STANDARD AC IN HIGH CAPACITY AC IN HIGH CAPACITY DC IN Figure 5 6 INPUT VOLTAGE TERMINAL BOARD e Check the 5 V dc also 12 V dc and 12 V dc on High Capacity power supplies output by pulling the power supply module partially out of its slot and measuring the voltage at the screw connection on the board The terminal board connections are as shown below If any voltage is out of tolerance replace the applicable power supply 5 4 3 2 1 a42217 FOR DC INPUT a41062 TERMINAL 1 IS POS SOURCE TERMINAL 2 IS NEG SOURCE FOR HIGH CAPACITY POWER SUPPLY NOTE A Printed circuit board backplane or cable short may be loading down the power supply If any dc voltage is out of tolerance back out all printed circuit boards and rechec
316. y functions Microsecond us One millionth of a second 1 x 10 6 or 0 000001 second Millisecond ms One thousandth of a second 1 x 1073 or 0 001 second Mnemonic An abbreviation given to an instruction usually an acronym formed by combining initial letters or parts of words Modules A replaceable electronic subassembly usually plugged in and secured in place but easily removable in case of fault or system redesign In the Series Six Plus PLC a combination of a printed circuit board and its associated faceplate which when combined form a complete assembly Nanosecond ns One billionth of a second 1 x 109 0 000000001 second Noise Undesirable electrical disturbances to normal signals generally of high frequency content A 4 Appendix A Glossary of Terms GEK 96602 Non Retentive Coil A coil that will go off when power is removed Non Volatile Memory A memory capable of retaining its stored information under no power conditions power removed or turned off OFF Line Equipment or devices that are not connected to a communications line for example the Workmaster computer when off line operates independent of the Series Six Plus CPU ON Line Descriptive of equipment or devices that are connected to the communications line OR An operation that places two contacts or groups of contacts in parallel Any of the contacts can control the resultant status Optical Isolation Use of a solid state

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