Series One” Programmable Controllers Series One/One Plus User’s Manual GE Fanuc Automation hgust 1988 GEK-90842C WARNINGS, CAUTIONS, AND NOTES AS USED IN THIS PUBLICATION Warning notices are used in this publication to emphasize that hazardous voltages, -ts, mmtures, or other conditions that could cause personal injuryexist in this equipment or may be asso&ted with its use. In situations where inattention could cause eitkr personal injury or damage to equipment, a Waning noticeis used. El 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 he1611does not purport to cover all details or variations in hardware ad software, nor to provide for every possible contingency in connection with installation, operation, and maintenance. Features may be described herein which are not present in all hardware and 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 accuraq, completeness, suBiciency, or usefulness of the information contained herein. No wananties of merchantability of fitness for purpose shall apply. Wopyright 1987GE Fanuc Auto&n North Amerka, Inc. l Preface e* Rll GE&90842 The purpose of this manual is to provide information for the user to install, program and implement the family of Series One TMfamily of Programmable Controllers (PCs) into a control system. The Series One family of PCs includes the Series One, Series One Model E, Series One Plus and Series One Plus 3.7K PCs, which are described in this manual. The Series One Junior PC is described in a separate User’s Manual, GEK-90503. The Series One PC provides the user with the capability of developing and programming a control system using the familiar ladder diagram logic approach. The Series One Plus includes the same ladder diagram function plus a group of data operation functions, which includes data moves, math functions, conversion, and fault diagnosis. Chapter 1, Introduction, is an introduction to the Series One and Series One Plus PCs, with emphasis on features and capabilities. A summary of terms common to PCs is provided at the end of this chapter as an aid to first-time PC users. Chapter 2, Physical Equipment Configuration, provides a detailed description of the hardware components of the PC. This chapter provides an understanding of the components of a Series One or Series One Plus PC system and how they are related to the overall system Chapter 3, Installation, provides the specifications Programmable and instructions required for installation of your Control system. Chapter 4, J?C Operation, describes the operation of the Series One and Series One Plus PCs, including features and functions of the programmer used for entering new programs, editing existing programs, monitoring the status of inputs or outputs, displaying timer or counter accumulated values, and displaying register contents. The last part of this chapter describes operation of peripheral devices Peripherals include an audio cassette tape which may be used with both Programmable Controllers. recorder for recording your program after it has been entered in order to have a permanent record of that program, a PROM Writer Unit, which allows a non-volatile means of program storage within the PC, and a Printer Interface Unit to allow documenting of your programs. Chapter 5, Programming, provides the basic information required in order to develop, enter, and implement your programs. A description of each function is provided, including examples of using each Progr amming, Basic Instructions, function. Three sections are included: and Data Operation Instructions. Chapter 6, I/O Specifications and Wiring, is a guide to the specifications modules and their physical connections of the input and output (I/O) to field devices. Chapter 7, Maintenance, is a guide to basic maintenance of your system, should it be needed. Reliability of the Series One family of PCs is excellent and other than changing the Lithium back-up battery, when required, there should be little maintenance required of your PC. This chapter includes troubleshooting procedures and information on replacing components. Chapter 8, Applications, provides several typical Applications and Series One Plus PCs. mable controller. This chapter should be especially using the capabilities of the Series One helpful to first-time users of a program- Appendices A through D contain a summary of Related Documentation, a Glossary of Programmable Controller Terms, a guide to the compatibility of the Series One family of Programmable Controllers, and a Description of other GE Fanuc Automation North America, Inc. Programmable Controllers. A comprehensive index is included as an aid to the location in the manual of particular items of interest. iv Preface GEK-90842 All references to Series One in this manual for hardware and programming apply to both the Series One and Series One Model E PCs, except where specifically noted in the text. Similarly, all references to Series One Plus apply to both the Series One Plus and Series One Plus 3.7K PCS. Should further infomation be required, contact your salesperson America, Inc., P. 0. Box 8106, Charlottesville, Virginia 22906. or GE Fanuc Automation First Edition - May 1986 Second Edition - March 1987 Third Edition -September 1987 Henry A. Konat Senior Technical Writer North Preface V GEK-90842 NOTE The Series One/Series One Plus and associated modules have been tested and found to meet or exceed the requirements of FCC Rule, Part 15, Subpart J. The following note is required to be published by the FCC. This equipment generates, uses, and can radiate radio frequency energy and if not installed and used in accordance with the instruction manual, may cause interfe=nce 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 own expense will be required to take whatever measures may be required to correct the interference. Content vii GE&90842 CHAPTER CHAPTER CHAPTER CHAPTER 1. 2. 3. 4. SERIES ONE/SERIES ONE PLUS PC INTRODUCTION History of Programmable Controllers Advantages Over Other Control Devices Series One Programmable Controllers Series One Model E Programmable Controller Series One Plus 3.7K Programmable Controller Concepts Programming the Series One and Series One Plus PCS Function of the Central Processing Unit Memory Word Length Types of Memory for Program Storage Function of the Input/Output Circuitry Communicating With Other Devices Remote I/O for Series One and Series One Plus PC Terminology PHYSICAL EQUIPMENT CONFIGURATION Rack Description Module Location in Rack Heat Dissipation Adding Racks Programmer Tape Port Programmer Mount Assembly Hardware Requirements System Estimating Peripheral Devices Supporting Series One Family of PCS Data Communications Unit Printer Interface Unit PROM Writer Unit l-1 1-1 1-1 l-3 1-3 l-5 1-5 1-6 1-6 1-7 1-7 l-8 l-8 l-8 2-1 2-1 2-2 2-2 2-4 2-4 2-7 2-7 29 2-10 2-11 2112 INSTALLATION Specifications for Installation Installation Power Supply Limitations for Racks units of Load Safety Considerations Recommended Field Wiring Procedures 3-l 32 3-13 3-13 3-15 3:15 PC OPERATION Introduction to PC Operation Programmer Programmer Features Mode Switch Atikhwss Data Display Status Display Logic Display Logic Keys Editing Keys 4-l 4-l 4-2 4-2 4-2 4-2 4-2 4-3 4-4 Content GEK-90842 Shifted Functions Data Operation Keys Peripheral Jack Program Checking and Error Codes Operation Sequences Monitor CPU Logic Search CPU Logic Alter One Logic Element Delete One Logic Element Clear All Memory Insert One Logic Element Monitor I/O Status Monitor Timer or Counter Status Display a Specific Address Monitor Data Register Contents Change Contents of a Data Register Enter or Change a Password Access to Programmer Functions with Password in Effect Forcing References Operation With Peripheral Devices Tape Recorder Operation Recording A Program . Verifying A Program Loading A Program Printer Interface Unit Hardware Description Hardware Features 80/l 32 Column Selection Switch External Power Supply Connector Power Supply Select Switch Sequence of Operation Power-up Sequence User Program Transfer From PC To Printer Interface unit Selection of Printout Format and Type of PC Start Printer Operation Printing Of Error Messages During Ladder Diagram Listing Printing Of Error Messages During Boolean Listing Cross Reference Printout Expanded Print Format Printout Annotation Explanation Sample Printout PROM Writer Unit Front Panel Features Sequence of Operation External Power Supply Connector Power Supply Select Switch 4-5 4-6 4-7 4-7 48 4-10 4-11 4-11 4-12 4-12 4-12 4-12 4-13 4-13 4-14 4-14 4114 4-14 4-15 4-15 4-15 4-16 4-16 4-18 4-18 4-19 4-20 4-21 4-21 4-21 4-22 4-22 4-22 4-22 4-22 4-23 4-23 4-23 4-24 4-24 4-25 4-29 4-30 4-3 1 4-31 4-31 ix Content GEK-90842 Timer/Counter Setpoint Unit Timer/Counter Setpoint Unit Specifications Remote Mounting of Timer/Counter Setpoint Unit References for the Timer/Counter Setpoint Unit Example of Using Thumbwheel Inputs CHAPTER 5. Section 1. Section 2. PROGRAMMING Introduction to Programming General Information Planning a PC System How to Use This Chapter Programming Fundamentals Significance of References Significance of Input/Output References Internal Coils Use of the Special Function Coils Shift Register References Timer and Counter References Data Registers Flexibility in Using References Operating Principles scanning Programmer Functions Basic Ladder Diagram Format Concept of Power Flow Unlimited References Basic Instructions Basic Instructions How to Begin Programming Entering a Rung With Series Contacts Entering the Clear all Memory Sequence Entering a Rung with Parallel Contacts Entering a Simple Timer Rung Basic Relay Logic (Motor Starter) Motor Starter Logic Description Normally Closed Input Push-Down Stack Detailed Example of AND SIR, OR STR Description of Operation Use of Retentive Coils as Latches Programming a Latched Relay Master Control Relay Functional Description Programming a Master Control Relay Function Multiple Master Control Relay Functions Disabling of Outputs Timer and Counter Functional Description Special Timer/Counter References Programming Timers Specifying Timer Preset Values Programming Counters 4-32 4-33 4-33 4-33 4-34 5-1 5-l 5-l 5-1 5-7 5-7 58 5-13 5-13 5113 5-13 5-13 5-14 5-14 5-14 5-15 5-17 5-17 5-18 5-19 5-19 5-19 5-19 5-19 5-20 S-20 5-20 S-21 5-22 5-23 5-24 5-24 5-26 5-26 5-27 5-28 5-28 5-29 S-30 5-30 5-30 5-31 5-32 Content X GEK-90842 Section 3. Extending the Timer and Counter Range Sequencer Operation Referencing Sequencer Contacts with a Series One Plus PC Shift Register Functional Description Shift Register References Shift Register Operation Forcing I/O References Data Operation Instructions for the Series One Plus Programmable Controller Data Operations Using References for Data Operations Entering a Constant Value Entering a Group Reference Data Register References Timer/Counter References Example of Specifying a Group Reference Programming the Data Operation Instructions Special Function Coils for Data Operations D*STR (FSO) D.STRl (F51) D.STR-2 (F52) D*STR3 (F53) D*STRS (FSS) DeOUT (F60) D.OUTl (F61) D*OUT2 (F62) D*OUT3 (F63) D*OUTS (F65) CMPR (F70) Addition (+), BCD 4 Digit (F71) Subtraction (-), BCD 4 Digit (F72) Multiplication (X), BCD 4 Digit (F73) Division (:), BCD 4 Digit (F74) DoAND (DATA AND) (F75) D.OR (DATA OR) (F76) Shift Right (FSO) shift Left (F81) Decode (F82) Encode (F83) INV (F84) BIN (BCD to Binary) (F85) BCD (Binary to BCD) (F86) External Fault Diagnosis (F20) CHAPTER 6. I/O SPECIFICATIONS AND WIRING I/O system IntKKhlctio~ Field Wiring to I/O Modules 16 Circuit J/O Modules with Connectors I/O References for 16 Circuit Modules 5-34 5-36 5-37 5-38 5-39 5-40 5-42 5-43 5-43 5-44 5-44 5-44 5-44 5-45 5-45 5-45 5-46 5-47 5-48 5-48 5-49 5-49 5-50 5-50 5-51 5-51 5-52 5-52 5-53 5-56 5-58 5-59 5-61 5-63 5-65 S-65 5-67 5-68 5-68 5-69 5-70 5-71 6-1 6-2 6-4 6-4 xi Content GEK-90842 I/O Interface Cable Cross Reference List I/O Module Catalog Numbers I/O Module Specifications and Wiring 115 V ac Input IC61OMDL125 230 V ac Input IC61OMDL127 115 V ac Isolated Input IC61OMDL126 24 V dc Sink Input (8 Circuits) IC61OMDLlOl 24 V dc Sink Input (16 Circuits) IC61OMDL106 24 V dc Sink Load Input (16 Circuits) with Removable Terminal Board IC61OMDL107 24 V ac/dc Source Input IC61OMDLlll 24 V ac/dc Source Input (16 Circuits) with Removable Terminal Board IC61OMDL112 115/230 V ac Output IC61OMDL175 115/230 V ac Isolated Output IC61OMDL176 24 V dc Sink Output (8 Circuits) IC61OMDL151 24 V dc Sink Output (16 Circuits) IC6lOMDL156 24 V dc Sink Output (16 Circuits) with Removable Terminal Board IC6lOMDL157 24 V dc 2 Amp Sink Output IC61OMDL153 24 V dc 2 Amp Sir&/Source Output IC61OMDL154 24 V dc Source Output IC61OMDL155 24 V dc Source Output (16 Circuits) with Removable Terminal Board IC61OMDL158 _ Relay Output (8 Circuits) IC61 OMDL180 Relay Output (16 Circuits) with Removable Terminal Board IC61OMDL182 24 V dc Input/Output (4 In/4 Out) IC61OMDL103 24 V dc Input/Relay Output (4 In/4 Out) IC61OMDL104 Thumbwheel InterfaceIC61OMDL105 High Speed CounterIC6lOMDLllO Module Location Interface to Field Devices Up/Down Counter Inputs Encoder Interface 1 Binary Coded Decimal (BCD) Output Counter Output Interface to User Logic Interface Function Definition Ouptut Logic Manual Mode Counter Mode Fitter Selection Fast Response I/OIC61OMDLll!5 Mode Selection Output Logic - Manual Mode Output Logic - Fast Response Mode I/O SimulatorIC61OMDL124 Analog InputIC61OMDL116 6-5 6-6 6-7 6-7 6-8 69 6-10 6111 6-12 6-13 6-14 6-16 6-17 6-18 6-19 6-20 6-22 6-23 6-24 6-26 6-27 6-29 6-31 6-33 6-36 6-39 6-41 6-42 6-43 6-44 6-46 6-48 6-49 6-50 6-53 6-53 6-53 6-55 6-56 6-58 6-58 6-58 6-61 6-62 Content xii GEK-90842 Introduction Hardware Features Power Requirements General and Electrical Specifications I/O Reference Definitions Sample Ladder Logic Analog Input Module Features Selection Of Operating Mode Analog OutputIC61OMDL166 Introduction Hardware Features Power Requirements General and Electrical Specifications I/O Reference Definitions Sample Ladder Logic Analog Output Module Features UL Listed Products 5-Slot Rack, UL ListedIC61OCHS 111 115 V ac Input Module, UL ListedIC61OMDL135 Relay Output Module, UL ListedIC61OMDL181 115 V ac Output Module, UL ListedIC61OMDL185 115 V ac Input Module (16 Circuits) with Removable Terminal Board IC61OMDL129 ,~ 115/230 V ac Output Module (8 Circuits) with Removable Terminal Board IC61OMDL179 CHAPTER 7. 8. 6-76 6-77 MAINTENANCE Introduction to Maintenance Procedures Troubleshooting Aids Basic Troubleshooting Procedure General Troubleshooting Procedure Replacement of Components Replacing a Rack Replacing a CPU Module Replacing I/O Modules Replacing the Battery Adding Memory Spare Parts and Components Fuse List CHAPTER 6-62 6-62 6-62 6-62 6-63 6-64 6-66 6-66 6-67 6-67 6-67 6-67 6-67 6-68 6-69 6-70 6-71 6-72 6-73 6-74 6-75 7-1 7-1 7-1 7-2 7-3 7-3 7-3 7-4 7-4 7-5 7-6 7-7 APPLICATIONS Application 1 - One-Shots Application 2 - Flip Flop Application 3 - Event/I%ne Drum Application 4 - Cascaded Counters Application 5 - Coil 374, Power-Up One-Shot Description of Operation Application 6 - Coil 375, lOHz Clock Example 1: - Cumulative Timer Example 2: - Time of Day Clock Application 7 - Start/Stop Circuit 8-1 8-2 8-3 8-5 8-7 8-7 8-8 8-8 88 8111 e Content GEK-90842 Application 8 - High Speed Counter Applications Programmable Cam Switch Cut to Length Measuring a Random Length Sample Calculation Application 9 - Typical Shift Registers Shift Register References APPENDIX A. Related Documentation Introduction GEK-90477 Series One/Three Data Communications Manual GEK-90507 Remote I/O User’s Manual GEK-90825 Series Six PC I/O Link Local Module User’s Manual GEK90846Portable Programmer User’s Manual GEK-96662 Logicmaster 1 Programmer Documentor Manual GFK-0075 Logicmaster 1 Family Programming and Documentation Software User’s Manual APPENDIX B. APPENDIX C. APPENDIX D. Glossary of Terms Series One Family of Programmable Controllers Compatibility Guide 0 t her Programmable Controllers Series OneTMJunior Programmable Controller Series ThreeTMProgrammable Controller Available I/O Types Series SixTMProgrammable Controller Programming Optional Items Series SixTMPlus Programmable Controller 8-12 8-13 8-16 8-18 8-18 8-21 8-21 A-l A-l A-l A-l A-2 A-2 A-3 A-4 B-l Cl D-l D-l D-2 D-2 D-3 D-3 D-4 D-4 Figures xiv GEK-90842 Figure 1-l l-2 2-l 2-2 2-3 2-4 2-5 2-6 2-7 2-8 29 2110 3-l 3-2 3-3 3-4 3-5 3-6 3-7 3-8 39 3-10 3-11 3-12 3-13 3114 4-l 4-2 4-3 4-4 4-5 4-6 4-7 4-8 49 4-10 4111 5-1 5-2 5-3 5-4 5-5 5-6 5-7 5-8 59 5110 Series One/Series One Plus Programmable Controllers Basic PC Block Diagram Typical Rack Typical Hardware Typical (5 Slot) Rack Typical (10 Slot) Rack Expander Cable Installation Programmer Mount Assembly Example of Relay Control Data Communications Unit Printer Interface Unit Prom Writer Unit Rack Mounting Dimensions for Proper Heat Dissipation Recommended Rack Grounding 10 Slot Rack, 19 Inch Mounting Dimensions I/O Expansion Cable Connection I/O Addressing Switches in Series One Plus 10 Slot Racks Examples of Rack Configuration Switch Setting Series One Plus Typical Installation Dimensions CPU Module Proper Module Insertion _ Proper Module Removal Typical Routing of I/O Wiring Pull Tab on Programmer Cable Installation of Programmer Cable Programmer Mount Assembly Programmer Features Series Logic (AND) Parallel Logic (OR) Volume Control Range Setting Printer Interface Unit Sample Ladder Diagram Printout Sample Boolean Printout Sample Outputs Used Table Printout Sample Outputs Used Table Printout (continued) PROM Writer Unit Features Timer/Counter Setpoint Unit I/O References Per Physical Placement for 5 and lo-Slot Racks CPU Scanning Sequence Programmer for Series One and Series One Plus Typical Ladder Diagram Sample Relay Logic (Motor Starter) Example of Normally Closed Inputs AND STR and OR STR COMCCtiOIlS Push-Down Stack Storage Locations Push-Down Stack Logical Opcmtions AND SIR/OR STR Example Number 1 l-2 l-5 2-l 2-2 2-3 2-3 2-4 2-5 29 2-10 2-11 2112 3-2 3-3 3-4 3-4 3-5 3-6 3-7 3-8 3-9 39 3-11 3-12 3-12 3113 4-l 4-3 43 4-17 4-20 4125 4-26 4-27 4-28 4-29 4-32 59 5-15 5-16 5-17 5-21 5-22 5-23 5-24 5-24 5125 Figures XV GEK-90842 5-11 5-12 5-13 5-14 5-15 5-16 5-17 5-18 5-19 5-20 5-21 5-22 5-23 5-24 5-25 5-26 5-27 6-l 6-2 6-3 6-4 6-5 6-6 6-7 6-8 69 6-10 6-11 6-12 6-13 6-14 6-15 6.16 6-17 6.18 6-19 6-20 6-21 6.22 6-23 6-24 6-25 6-26 6-27 6-28 6-29 Q30 6-31 6-32 AND SIR/OR STR Example Number 2 Example of Latching Logic Example of Master Control Relay Logic Multiple Master Control Relay Logic Sample Coil Disabler Logic Sample of Timer Logic Example of Timer Logic Example of Counter Logic Example of Counters Example of Extended Counters Illustration of Sequencer Operation Example of Sequencer Typical Sequencer Logic Typical Shift Register Example of Shift Register Example of Shift Register Logic Data Operation Block Diagram A. Typical I/O Module B. High Density Module With Removable Connector Typical I/O Terminal Configuration I/O Interface Cable Wiring List Example of 16 Circuit I/O References Wiring for 115 V ac Inputs Wiring for 230 V ac Inputs Wiring for 115 V ac Isolated Inputs Wiring for 24 V ac Sink Inputs I/O Points VS Temperature Wiring for 16 CIRCUIT, 25 V dc Sink Input Module J/O Points VS Temperature Wiring for 16 Circuit, 24 V dc Sink Load Inputs Wiring for 24 V ac/dc Inputs If0 Points vs Temperature Chart Wiring for 16 Circuit 24 V ac/dc Source Load Inputs I/O Points vs Temperature Wiring for 115/230 V ac Outputs I/O Points vs Temperature Chart Wiring for 15 V ac Isolated Outputs YO Points vs Temperature Chart Wiring for 24 V dc Sink Outputs x/O Points vs Temperature Wiring for 16 Circuit 24 V dc Sink Outputs YO Points vs Temperature Chart Wiring for 16 Circuit 24 V dc Sink Outputs I/O Points vs Temperature Chart Wiring for 24 V dc 2 Amp Sink Outputs UO Points vs Temperature Wiring of 24 V dc 2 Amp Sink/Source Output I/O Points vs Temperature Chart Wiring for 24 V dc Source Outputs I/O Points vs Temwrature 5-26 5-27 5-28 5-29 5-30 5-31 5-32 5-33 5-34 5-35 5-36 5-37 5-38 5-39 5-40 5-41 5-43 6-3 6-3 6-4 6-5 6-7 6-8 69 6-10 6-11 6-11 6-12 6-12 6-13 6-14 6-15 6.16 6.16 6-17 6-17 6.18 818 6-19 6-19 6-20 6-21 6-22 6-22 6-23 6-23 6-24 6-25 6126 Figures xvi GEIWO842 6-33 6-34 6-35 6-36 6-3’7 6-38 6-39 6-40 641 6-42 6-43 6-44 645 6-46 6-47 6-48 6-49 6-50 6-51 6-52 6-53 6-54 6-55 6-56 6-57 6-58 6-59 6-60 6-61 6-62 6-63 6-64 6-65 6-67 7-l 7-2 7-3 7-4 8-l 8-2 8-3 8-4 8-5 Wiring for 24 V dc Source Outputs Wiring for 8 Circuit Relay Outputs Wiring for 16 Circuit Relay Outputs Wiring for 24 V dc Inputs/Outputs Typical Wiring Diagram Sample 24 V dc INPUT/RELAY OUTPUT Circuits Wiring for Thumbwheel Interface Thumbwheel Interface Cable Wire List High Speed Counter Overview HSC Location in 5-Slot Rack HSC Connector Pin Definition Signal Direction UP/DOWN/RESET Input Circuit Encoder with RESET/MARKER Option Resetting Counter Once per Revolution of Encoder Shaft Encoder with RESET Option in Series with Home Limit Switch Such That Counter is Reset When Both Home Limit Switch and RESET/MARKER Pulse are Enabled Encoder With Limit Switch Resetting Counter and Photoelectric Cell Inhibiting the Counter Operation Sample BCD Output Circuit BCD Output Wiring Diagram User Load Wiring Diagram I/O and Counter Function Reference Chart Filter Selection with Dip Switch Module Reference NUMBER/LOGIC Symbol Definition Fast Response Module Logic Diagram Wiring for Fast Response I/O Module I/O Simulator Module Faceplate Analog Input Module Faceplate Analog Output Module Faceplate UL Listed 5-Slot Rack Wiring for UL Listed 115 V ac Input Module Wiring for UL Listed Relay Output Module Wiring for UL Listed 115V ac Output Module YO Points vs Temperature Chart Wiring for 115 V ac Inputs with Removable Terminal Board J/O Points vs Temperature Chart Wiring for 115/230 V ac Output with Removable Terminal Board Troubleshooting Indicators Battery Location and Connection Location of Extra Memory Socket Acccssury Kit for Series One/One Plus Typical One-Shot Timing Typical One-Shot Logic Typical Flip-Flop Timing Diagram Typical Flip-Flop Logic . Evenflime Drum Logic 6-26 6-28 6-30 6-32 6-34 6-35 6-37 6-38 6-40 6-41 642 6-43 6-43 6-44 6-44 6-45 646 6-47 6-48 6-49 6-55 6-57 6-59 6-60 6-61 6-66 6-70 6-72 6-73 6-74 6-75 6-76 6-76 6-77 6-77 7-2 7-4 7-5 7-7 8-l 8-l 8-2 8-2 8-3 xvii Figures GE&90842 8-6 8-7 8-8 89 8-10 8-11 8-12 8-13 8-14 8-15 8.16 8-17 8-18 8-19 8-20 8121 Sample Cascaded Counter Logic Typical Machine or Process Power-Up Inhibit Logic Cumulative Timer Sample 24 Hour Time Clock Logic Time Clock Resetting Fast Response Start/Stop Logic Worst Case Timing Diagram Application System Programmable CAM Switch Logic Timing Diagram Programmable CAM Switch Output No. 1 Logic Diagram Wiring Diagram Cut to Length Program Measuring a Random Length Shift Register Example Typical Shift Register Logic 8-6 8-7 8-8 89 8-10 8111 8-11 8-12 8-13 8-14 8-16 8-16 8-17 8-18 8-21 8-22 Tables moo XVIII GEK-90842 Table l-l l-2 2-l 3-1 3-2 3-3 3-4 3-5 4-l 4-2 4-3 4-4 4-5 4-6 4-7 4-8 5-l 5-2 5-3 5-Q 5-5 5-6 5-7 5-8 6-1 6-2 6-3 6-4 6-5 6-6 6-7 6-8 6-9 6-10 6-11 6-12 6-13 6-14 6-15 6-16 6-17 7-1 c-1 Series One Family General Specifications Common PC Terminology Series One/Series One Plus Catalog Numbers Series One Installation Specifications CPU Option Settings Memory Size Units of Load Supplied by Rack Units of Load Used by Modules Error Code Definitions PC Operation Sequences Printer Interface Unit Specifications Printer Requirements Format and PC Selection Ladder Diagram Listing Error Messages and Definitions Boolean Listing Error Messages and Definitions Timer/Counter Setpoint Specifications Series One Model E/One Plus Basic Ladder Diagram Instructions Series One Execution Times Series One Plus Data Operation Instructions Series One/One Plus Instruction Groups Summary of References -Summary of I/O References for 8 Circuit Modules ^ Effect of Coil 376 (Output Disabler) Data Operation Function Numbers I/O Module Catalog Numbers Maximum Current vs Load Type for Relay Outputs Maximum Current vs Load Type for Relay Outputs Maximum Current vs Load Type for Relay Outputs Number of HSCs vs Discrete I/O Capacity Manual Mode Output Logic Truth Table Real Time Comparison Table for Preset Initially > Current count Real Time Comparison Table for Preset Initially < Current count Output State vs Real Time Comparison Status in Counter Mode Output Logic in Counter Mode Maximum Current vs. Load Type for Relay Outputs Operating Mode Selection Truth Table for Output in Fast Response Mode (S5 or S7 Have Been Enabled) Analog Input Module Specifications &!o Poh Iwinition Analog Output Module Specifications I/O Point Definition I/O Module Fuse List I/O Module Capability/Compatibility Guide l-4 l-8 2-5 3-1 3-8 38 3-14 3114 4-7 49 4-19 4-19 4-22 4-23 4123 4-33 5-2 5-3 5-4 5-7 58 5-10 5-29 5-46 66 6-27 6-29 6-34 6-42 6-53 6-53 6-54 6-54 6-55 6-57 6-58 6-58 6-63 6-63 6-68 6-68 7-7 c-3 xix Tables c-2 c3 cb D-l D-2 D-3 D-4 Summary of Progr amming References for Series One Family of Programmable Controllers Pv!r amming Function Compatibility Guide Examples of Valid System Configurations for I/O Points Series One Junior Capabilities Series Three PC Specifications Series Six CPU Capacities Series Six Plus Combined Memory Configurations C-4 c5 C-6 D-l D-2 D-3 D-4 Chapter m 11 1 Series One/Series One Plus PC Introduction ? GEL90842 History of Programmable Controllers The factory with a future is here today, with machine and process controls provided by modem electronic devices. Today’s automated factory can provide improved system reliability, product quality, information flow, reduced costs, efficiency, and flexibility. One of the basic building blocks of such a factory is an electronic device called a Programmable Controller. This device was first introduced in 1970 and has been refined every 4-7 years as newer electronic components, such as microprocessors, are made available. Today’s Programmable Controllers are designed using the latest in microprocessor designs and electronic circuitry which provide reliable operation in industrial applications where many hazards such as electrical noise, high temperature, unreliable AC power, and mechanical shock exist. Here is where the Programmable Controller is in its element; it was designed for the industrial environment from its conception. Advantages Over Other Control Devices Programmable Controllers, or PCs or PLCs as they are frequently referred to, offer many advantages over other control devices such as relays, electrical timers and counters, and drum type mechanical controllers. These advantages should be considered beyond just price when selecting any control device: l Improved reliability Smaller space required Easiertomaintain 0 Reusable 0 Reprogrammable if requhments change 0 More flexible-performs more fhctions Series One Programmable Controllers A complete Series One PC contained in one S-slot rack can have over 1700 words of user logic, up to 64 timer/counters, and up to 64 I/O points in a panel surface area of only 54 square inches. That is less space than four 4pole relays might occupy. An available lo-slot rack can contain up to 120 I/O points. By adding additional racks (up to a total of three), the I/O can be expanded up to a total of 112 I/O points in a Series One PC or 168 points in a Series One Plus PC. Modules can be replaced individually without disturbing adjacent modules or their field wiring. The VO can be intermixed in many configurations, limited only by the module types available (either 4,8, or 16 circuits per module - see Chapter 6). Users need only purchase those modules required for their application; there is no fixed mix such as 12 in/8 out or 20 in/l2 out, The hand-held programmer can be fixed onto the CPU for quick reference, removed and carried in a pocket for future use, connected to the CPU via a 5 foot (1.5m) cable for flexible temporary use or mounted on the outside of a panel or console. It is a simple pushbutton and display unit designed for easy transportation and rugged use. Progr amming can also be done with the Portable Programmer or with a Workmaster Industrial computer using Logicmaster 1 application software for Series One or Logicmaster 1F application software for Series One Model E, Series One Plus and Series One Plus 3.7K. The Series One and Series One Plus PCs are designed control replacements. One Plus PCs. to be very cost effective relay or other sequential Despite the low cost, there is a lot of capability within the Series One and Series 12I) Series One/Series One Plus PC Introduction GEK-90842 The advantages l l l l l l l l l a 0 a l l 0 l 0 l l 0 0 l and features offered by the Series One and Series One Plus PCs include: Small size - (64 I/O points in a 5-slot rack) Large Memory Capacity Timers/Counters Programming LanguageMaximum I/O Latching relays &bit Data Registers Flexible I/O Replaceable I/O Modules Portable ProgrammerPersonal Password Security 54 in2 panel space, 5 l/2 in. maximum depth, 250 i.19total volume Up to 1724 wonk of CMOS or PROM Up to 64 (4 digit, 9999 maximum preset) Boolean Based Relay Ladder Data Operations (Series One Plus Only) 112 (Series One) - 168 (Series One Plus) 28 total 64 (Series One Plus), 124 with TC refennces Anymixingroupsof4,8or16 Weight only 7 02s. Series One Plus and Series One Model E (Permits only Authorized Access To User’s Programs) Internal and external indication of low battery Reliable operation without fan finm 0’ to 60’ C (convection cooling) Retentive counters Shift Registers (128) Built-in Sequencers Standard - Up to 64, each with up to 1000 steps Meets or exceeds NEMA ICS3-304 for noise rejection Self Diagnostics htemal Power for 24 V dc Inputs Inexpensive High Speed Counter Remote I/O - Saves instalktion and wiring cost a40793 Figure l-l. Series One/Series One Plus Programmable Controllers Series One/Series One Plus PC Introduction m 13 GEK-90842 Series One Model E Programmable Controller The Series One Model E PC is an enhanced version of the Series One PC that offers more capability while retaining all of the features and functions of the Series One PC. The Model E requires an Ic610CPUI04 CPU module. The additional features of the Series One Model E are: Faster Scan Rate.Typical scan times are: 8 mSec for a OSK word program 12 mSec for a l.OK program 15 mSec for a 1.7K word program Password ProtectionAs with the Series One Plus PC, this is a valuable feature in that it permits only authorized access to user programs stored in the PC memory. A unique 4digit password is entered by the user and thereafter access to all functions (except monitor functions) is gained through a LOG ON sequence entered by the operator. After completion of required operations, a LOG OUT sequence returns the PC to password protection. Faster Data Communications.The Series One Model E PC requires the IC61OCCM.105 Data Communications Unit to communicate with external devices. Communications speed is noticeably faster when communicating with external devices, such as a host computer, than with a Series One PC using either the older version IC61OCCMlOO or the IC61OCCM105 Data Communications Unit. Program upload or download time, and access time to I/O, and timer/counter data is reduced during I communications sessions. Series One Plus 3.7K The Series One Plus 3.7K PC is an enhancement of the Series One Plus PC which offers greater memory capability, while retaining all other features and functions of the Series One Plus PC. The Series One Plus 3.7K PC uses an IC61OCPU106 CPU module that provides 3700 words of CMOS RAM: or optional PROM memory (compared to 1700 words of memory available with a Series One Plus with an IC61OCPU105 CPU module). A typical scan time for a 3.7K word program is 36 milliseconds. This additional memory capability allows the Series One Plus 3.7K PC to moTe fully take advantage of programming with the data operations since those ladder logic programs that require numerous data operations also require more memory than do programs using the basic functions. The additional memory in a Series One Plus 3.7K PC provides the user with a great deal of capability in a small package. An additional feature of the Series One Plus 3.7K PC is that timers can be programmed to be .Ol second timers instead of .l second. This is done by setting output 770 (SET 770) to the ON condition. The timer preset range with a .Ol second duration selected is 0.01 to 99.99 seconds. When selecting timers to be .Ol in this manner, care must be exercised to prevent your program from resetting coil 770, since this would cause all timers programmed to then be .l second timers. Timer durations cannot be mixed, they can all only be .l second or .Ol second in the same program. Any Timer/Counter accumulate registers not being used for a Timer/Counter can be accessed and used as data registers as with the Series One Plus PC. Table l-1 provides a summary of general specifications for both PCs. (I) 14 Series One/Series One Plus PC Introduction I GEK-90842 Table M. Series One Family General Specifications Operating Temperature Storage Temperature Humidity (non-condensing) AC Power Required: 1C610CHS101/110/130 Rack vohage FFequency Maximum Load output CwTeen~ Maximum Individual DC Power Required IC61OCHS114/l34 Rack Voltage Ripple output current Maximum Individual Maximum, Total (All Voltages) Typical Battery life * (loaded) shelf We * (no load) 0’ to 60°C (32” to 14OOF) -loo to 7ooc (14O to +lSs”F) 5 to 95% llSV/230 v ac 15% 47-63 Hz 30 VA (CHSlOl/llO) 36.7 VA (CHS130) 1.4 A at 5 V dc, (0.4 A, CHSlOl) 0.8 A at 9 V dc, CHSllO (1.7 A, CHS130), (0.6 A, CHSlOl) 0.5 A at 24 V dc, (0.2 A, CHSlOl) 20.5 - 30 V dc (100% of capacity used) 18 - 30 V dc (90% of capacity used) 10% of Input Voltage 1.4 A at 5 V dc 0.8 A at 9 V dc, CHS114 (1.7 & cHS134) 0.4 A at 24 V dc, -114 (0.5 A, CHS134) 22 A, CHS114 (2.3 A, CHS134) 2-5 years 8-10 years *Depends upon operating temperature Memory Size and Type (16-bit words) 700 words (CMOS) or 1724 words (CMOS or EPROM) 3700 words (Series One Plus 3.7K (CMOS or EPROM) Typical Scan Time per K of Memory) (Only memory programmed is scanned) 20 m&c (O.SK) Series One Overhead time must be added to the 40 m&c (l.OK) 65 msec (1X) logic solution for total real scIu1, time overhead is typically 4 to 5 m&c. series one Plus aadModelE one Plus 3.7K Maximum I/O Intemal coils special Fbuaction coils Retintive Coils (Latches) Timer/Counters Shift Register Stages seqrrepcers Data Rm (Series One Pius and Series one Pius 3.7K) 8 mSec (0.5K) 12 mSec (l.OK) 15 mSec (1.7K) 36 m&c (3.7K) 112 (s&es one) 168 (Series One Plus) 144 4 28 64 (Wigit) 128 64atlooOstepseach ’ 64 (&bit), up to 124 with mused T/C references l-5 Series One/Series One Plus PC Introduction GEK-90842 Programmable Controller Concepts When using a new product for the first time, there are always new concepts and terms to become familiar with. Although PC’s are relatively easy to install, program, and apply, there are some simple principles to follow. Figure 1-2 illustrates a general block diagram of a Programmable Controller. Specific hardware components to illustrate this diagram will be described in Chapter 2. 1 c INPUT/ OUTPUT I 0 II I 1 I I I CENTRAL PROCESSOR UNIT PROGRAMMER 1 I I 1 USER SUPPLIED FIELD DEVICES L ---B-B--- I I 1 I J Figure l-2. Basic PC Block Diagram Programming the Series One and Series One Plus PCs The programmin g devices are used to enter the specific logic the user desires the PC to follow. This logic, to be described in detail in Chapter 5 is what makes the user’s PC a unique unit, different from all others unless the identical logic is entered into another unit. Recording and reloading logic from one PC to another or to itself is also a standard feature with the programmers. Hand-Held Programmer The programmer can display any previously entered logic, allow the user to edit it (make changes, add or delete portions of the logic), or display the current value of any internal timer or counter. It is a very valuable and powerful piece of peripheral equipment, for entry of logic, control system checkout, and troubleshooting. It can be permanently comected to the CPU or removed without disturbing the operation of the CPU. If removed, one programmer can service several CPUs. The exact quantity of CPUs is dependent upon the expected rate of usage but typically is between 5 and 20 CPUs. Portable Programmer The portable programmer uses a liquid crystal display (LCD) screen to allow ladder for both the Series One and Series One Plus PCs. New programs can be created, ladder logic displayed and existing logic edited. An on-line monitor function is Portable Programmer is used with the Series One Plus. Programs can be transferred logic programming previously entered available when the to the PCs or stored 16m Series One/Series One Plus PC Introduction GEK-90842 on cassette tape. The program can be printed using a standard parallel or Centronics compatible printer through the printer port located on the rear of the Portable Programmer. For detailed information refer to GEK-90846, which is the Portable Programmer User’s Manual. Logicmaster 1 Family Application Software Another option available for programmin g the Series One Family of PCs is the Workmaster industrial computer with Logicmaster 1 Family application software. This software allows you to write, edit, display, and print programs in ladder diagram format. You can view up to 7 lines of your ladder diagram program on one screen. Programs can be annotated by assigning names and nicknames to program elements, assigning labels to coils and adding explanations of program rungs or segments. Many programs can be stored on a single 3 inch diskette and each program can be assigned a unique name. For detailed information on using the Workmaster industrial computer with Logicmaster 1 application software refer to GFK-0075, which is the Logicmaster 1 Family Programming and Documentation Software User’s Manual. Series One Plus Program Protection The Series One Plus and Series One Model E PCs allow the user to enter a unique password with the hand-held programmer or the LCD Portable Programmer, which prevents unauthorized users or inadvertent program access. When a password is entered, all programmer functions are disabled except the I/O, T/C accumulated value and register monitor functions. In order to have access to all programmer functions when a password has been entered, a log on sequence must be entered. i Function of the Central Processing Unit The next element of the PC is the Central Processor Unit (CPU). The CPU is the “brain” behind all logical decision making. It reads in the status of the control system, makes decisions based upon the logic it has been provided, 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. If an error is detected, it will shut itself down. The logic entered by the programmer is actually stored in the CPU along with storage for the operation of timers and counters. Memory Word Length The memory provided for this storage diction is normally measured in K words, where K is an abbreviation for kilo or 1024. Typically, one word is required storage for 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, wherein a bit is the most elementary measurement and can have only two states (on or off). The word length is much like a ruler used to measure wire, sheet steel, or fabric. It can be a yard long (16 bits) or a foot (8 bits) or an inch (4 bits). Numerical values are for illustrative purposes only and do not represent exact ratios. Thus when quoting memory in K words (lK, UC, 4K, etc.) always check to verify the word length. The Series One and Series One Plus PCs use the most common measurement, 16 bits per word. Series One/Series One Plus PC Introduction 17- GEK-90842 Types of Memory for Program Storage There are several types of memory used in PCs to store both logic and data. ‘Ike two used in the Series One and Series One Plus PCs are CMOS and PROM. CMOS or CMOS RAM, which is an acronym for Complimentary Metal-oxide Semiconductor, Random Access Memory, provides a fast, low cost, low power memory that can be both examined (read) and also changed (written) easily. However, it is volatile, which means 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 usually provided (as it is in Series One and Series One Plus) with a back-up 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 2 to 5 years. The battery is not used when the power is applied and the system is operating normally. Its storage or shelf life is many years, typically 8 to 20 years. The second memory is PROM(Programmable Read only Memory) that again is fast, relatively low cost, and retentive upon loss of power. However, this memory cannot be easily changed. It can be examined (read) at anytime, but to change (write) it requires some special action on the part of the user. In this system, the PROM must be cleared of all previous contents (new PROM, or erased with an intense ultraviolet light) and then placed into a special loader. A previous logic program developed in CMOS is then written into the PROM. Finally, the PROM is removed from the loader and placed into the CPU. Function of the Input/Output Circuitry The final element of the PC is the Input/output section. Electrical noise such as spikes on the power lines, inductive “kick-back” 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 its 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 via 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. In general, the I/O section is modular in design and can accommodate a variety of signals. A complete discussion of the types and capacities available for both the Series One and Series One Plus PCs is provided in Chapter 6. The specific type of module (e.g. 115 V ac or 24 V dc) is usually determined by the field device the user selects. Decisions such as number of 115 V ac solenoids, 24 V dc solenoids, motor starters, limit switches (their voltages), control panel lamps (what voltage), pushbuttons, and external relays have a major impact on the configuration of any PC. These parameters should be established as early as possible in the overall design of the control system. Of course, being a flexible device, the PC configuration either on paper or in hardware, can be changed if rtQuireirements change. Typically, the user provides the field devices, wires them to the I/O section, and provides the power source to operate them. UL Listed Products Several Series One family products are available that have been tested and approved by the Underwriters Laboratory (UL). These UL listed products should be used in installations where UL listed products are required. The UL listed products include the Series One CPU (IC61OCPU101, revision C), 5-slot 18- Series One/Series One Plus PC Iutroduction GE&90842 rack (IC610CHSlll), 115 V ac Input module (IC61OMDL135), Relay Output module (IC61OMDLl81), and a 115 V ac Output module (IC61OMDLl85). Specifications and wiring information for the UL listed modules can be found in chapter 6 of this manual. When installing a system requiring UL approval, do not mix non UL listed products with the UL listed products. Communicating With Other Devices An available Data Communications Unit (DCU) allows the Series One and Series One Plus to communicate with external devices. The Series One PC uses the IC61OCCMlOO DCU, while the Series One Model E, Series One Plus and Series One Plus 3.7K PCs use the IC61OCCM.105 DCU. These devices can be other programmable controllers, computers, or other smart devices. User programs and I/O information in a Series One or Series One Plus PC can be uploaded and downloaded to or from any master device that supports the Series Six CCM2 protocol as defined in the Series Six Data Communications Manual, GEK-25364. For detailed information on how to use a DCU in a Series One or Series One Plus PC system, refer to the Series One Data Communications Manual, GEK-90477. Remote I/O for Series One and Series One Plus Another option available for a Series One or Series One Plus PC system is Remote I/O. By using Remote I/O, I/O modules can be located in a rack convenient to the input sensors or the&output devices being controlled by the PC at a distance of up to .6 miles (1 km) from the PC. This is accomplished by installing a Link Local module in the CPU rack, a Link Remote module in the distant I/O rack and connecting them through a single twisted-pair cable. For detailed information on using Remote I/O in a Series One or Series One Plus PC system, refer to the Series One Remote I/O Manual, GEK-90507. PC Terminology To summarize the preceding discussion of Programmable Controller concepts, table 1-2 provides a definition of terms discussed above that you should be familiar with, relating to PCs. A more complete list of terms is provided in a glossary at the end of this manual. Table l-2. Common PC Terminology TERM PC Programmer Logic CPU Memory DEFINTTION Programma&kController or Rogrammable Logic Controller. An indudal control device using microprocessor technology to perform logic decision maEng with r&y ladder diagram based programming* *A device for entry, examdtion and alteration of the PC’s memory including logic and storage ~RXS. A fixed set of respond (outputs) to various external conditions (inputs). All possible situations for both syncbr~nous and non-synchronous activity must be sped% by the user. Also r&d to as the pTo8T8m* Central Processor Unit - the physical unit in which the PC’s intelligence ~lesides. Decision making is performMi heI& A physical place to stow information such as programs and/or data. Series One/Series One Plus PC Introduction \ 19m GEE90842 Table l-2. Common PC Terminology - Continued TERM K word CMOS PROM I/O Noise [email protected] outputs Modules Field Devices DEFINITION An abbreviation for kilo or exactly 1024 in the world of computers. Usually r&ted to 1024 words of memory. A measurement of memory usually 16, 8, or 4 bits long. A read/write memory that requires a battery to retain content upon loss of power. A read only memory that requires a special method of loading, but is inherently retentive upon power loss. Input/Output - that portion of the PC to which field devices are connected. Isolates the CPU from electrical noise. Undesirable electrical disturbances to normal signals genefly of high frequency content. A signal, typically ON or OFF, that provides information to the PC. A signal typically ON or OFF, that originates h-am the PC with user supplied power that controls earnal devices based upon commands from the CPU. A replaceable electronic subassembly usually plugged in and secured in place but easily removable in case of fault or system redesign User supplied &vices typically providing information to the PC (Inputs: pushbutton, limit switches, day contacts etc.) or performing PC tasks (Outputs: motor starters, solenoids, indicator lights, etc.). Chapter 2 Physical Equipment Configuration 21 m . .c GEK-90842 Rack Description The Series One and Series One Plus PCs are provided as a family of racks into which modules can be inserted. Each rack contains a power supply to the right and space for up to either 5 or 10 modules (see figure 2-1). Racks are available in 6 versions, 5 or lo-slot that accept 115/230 V ac input power, 5 or lO-slot that accept 24 V dc, a UL listed 5-slot rack, IC61OCHSlll which accepts only a 115 V ac power source, and a low-cost 5-slot rack (IC6lOCHSlOl) that does not include an expansion part, 24 V dc tetials for external use, or a RUN relay. Each supplies internal power to the modules inserted into the rack. Mounting is provided by the brackets each with two keyholes at the rear of the rack. All racks are similar. The differences being the function of the rack as determined by the placement of modules by the user, the number of modules which may be inserted into a rack, and the input power required. Figure 2-2 illustrates typical modules for the Series One Family of PCs, illustrating in hardware, the block diagram concept of figure l-l. a40535 Figure 24. Typical Rack Module Location in Rack The CPU module is always placed adjacent to the power supply in the first ra& it contains the microprocessor and required memory storage. There is a connector on the CPU to which the programmer is attached when mounted on the rack. As an option, between the CPU and programmer a 5 foot (1.5m) cable can be installed for more flexible operation. The remaining slots can contain I/O modules in any mix of inputs versus outputs or voltage levels desired by the user for his particular application. Ail modules as well as the programmer are secured to the rack by two snap-locks which can be released by squeezing the module top and bottom toward the center (see Chapter 3 fo+ additional installation details). 22m Physical Equipment Configuration GE&90842 a40019 Figure 2-2. Typical Hardware Heat Dissipation The rack is designed to dissipate internal heat through convection cooling only and does not require a fan for forced air cooling. However, to ensure efficient operation, free air flow should not be inhibited at the top and bottom of the unit. A minimum of 3 inches (75mm) is recommended at the top and 4 inches (1OOmm) at the bottom with 6 inches (15Omm) between racks. Both sides should be free of obstacles to allow easy removal of the unit, approximately 3 inches (75 mm) from each side excluding the mounting brackets is recommended. Furthermore, the unit should be mounted horizontally as shown in figure 2-3 and not inverted nor rotated 90’. If not oriented as shown, derating of the maximum ambient temprature specification would need to be considered. Placements of other sources of large volumes of heat near the units should also be avoided, especially directly below the rack. For reliable operation, the air entering the bottom of the rack should not be at a higher temperature than 60°C (140”. Wiring to the I/O modules and the power supplies should be placed so as to avoid blocking the air flow, yet provide a suitable service loop to allow easy removal of modules with wiring attached. Wires should be tied to maintain their order in the event they must be disconnected during module replacement. Adding Racks If more ?/O points a~ required than one rack can contain, additional racks can be installed similar to the first unit previously discussed (IC61OCHS101 cannot be used as an expansion rack). At the left of each rack are two connectors used to connect to additional I/O. An 18 inch (46Omm) cable is available to connect the rack containing the CPU module to the first I/O expansion rack. The ends of this cable are marked “CPU” and “EXP” (Expander). The CPU end is plugged into the bottom connector at the first rack and the EXP end similarly connected to the second rack using the top connector (see figure 2-S). If a third rack is used, another cable links the second rack to the third rack, the CPU end is inserted into the bottom conneztor on the second rack and the EXP end into the top connector on the last rack. Within these added racks, I/0 modules can be inserted in any order desired, up to five modules in a S-slot rack and up to 10 modules in a lo-slot rack. No additional CPU modules can be installed, nor are reckred. .\ 23- Physical Equipment Configuration GE&90842 a4001 8 Figure 2-3. Typical (5 Slot) Rack lo-Slot Rack The 100slot rack provides in a single housing, as shown in figure 2-4, the same number of I/O module slots as two 5-slot racks. An added advantage of the lO-slot rack is easier and less expensive installation since fewer racks have to be mounted and wired. A system can be configured in many ways to contain Refer to Appendix B, which contains examples of valid I/O rack various quantities of I/O. configurations. Rack Mount Brackets Rack mount brackets (IC610CHS191) are available to adapt the lo-slot racks for mounting in 19 inch racks. With the brackets assembled on either version of a lo-slot rack, the rack can be mounted on standard mounting rails in 19 inch cabinets and consoles. a40792 Figure 24. Typical (10 Slot) Rack 24m Physical Equipment Configuration GEK90842 83-pc-3Sm m-4-1 -3 1a Figure 24. Expander Cable Installation Programmer Tape Port The hand-held programmer, when installed on the CPU module, provides an auxiliary tape port for memory transfers to peripheral devices. Tape recordings of user programs can be made on virtually any audio cassette recorder and once made can be used to initialize any CPU to that program. Thus programs can be made once and transported to other CPUs without manually being reentered. Of course, once entered they can be edited if additional tailoring is required. In the unlikely event that a CPU fails, a replacement can be installed and quickly reloaded to perform specifically the task its predecessor was accomplishing, if a tape record was made. The tame recorder functions are discussed in detail in Chapter 4, PC Operation. A Programmer Mount Assembly A Programmer Mount Assembly (IC610PRG190) is available that can be used to mount and protect the hand-held programmer on the outside of a panel or console. A hand-held programmer, when mounted externally, can be used as an operator interface unit to change timer or counter presets, monitor timer or counter current values, monitor 16 consecutive I/O points, monitor the entire contents of the user program, and, with a Series One Plus PC, monitor register contents. The programmer mount assembly includes a mounting bezel, a clear plastic cover, and a cable fastener. In addition to the mounting assembly, a shielded, round CPU/Programmer cable (Catalog No. IC61OCBLl02), designed specifically for mounting the hand-held programmer away from the CPU rack must be ordezed separately for use when installing the hand-held programmer in this manner. The Programmer Mount Assembly bezel installs on the outside of a panel or console with only four screws. The hand-held programmer snaps into the bezel using its two snap-locks. A clear plastic cover then fits over the bezel and programmer, thereby protecting it &om its industrial environment. The Programmer Mount Assembly can also be used as a table top stand for the hand-held programmer by 250 Physical Equipment Configuration GEK90842 mounting four rubber feet, which are included with the assembly, on the reverse side of the bezel using the panel mounting holes. a401 48 l WHENUSEDASABENW-TYPE l WHENMOWTEDONARSEL Figure 2-6. Programmer Mount Assembly Table 2-1 lists the Series One/Series One Plus PC catalog numbers and nomenclature for the various For detailed information on I/O module specifications modules, cables, peripherals, and accessories. and wiring diagrams, see Chapter 6. Table 2-l. Series One/Series I One Plus Catalog Numbers DESCRIPTION CPU, Series One (700 wonls of CMOS Memory, standad) Version C is UL listed CPU, Series One Model E (Enhanced Version of CPUlOl) CPU, Series One Plus (700 words of CMOS Memory, std) CPU, Series One Plus 3.7K (3700 wads of CMOS Memory) I/O Expander Cable Programmer with Keylock Programmer w/Keybck (Required for Series One Plus) CPU to Programmer Cable, 5’ (1Sm) CATALOG NUMBER 1C61OCPu101 IC61OCPU104 IC61OCPU105 IC61OCPU106 IC61OCBLlOl IC61OPRG100 IC61OPRGlOS IC61OCBLlOO 26(I Physical Equipment Configuration GE&90842 Table 2-l. Series One/Series One Plus Catalog Numbers - Continued CATALOG DESCRIPTION Rack, 115/230 V ac Power Source, 5-&t Rack, 115/230 V ac Power Source, S-slot (no expansion, 24 V dc Tee, NUMBER IC61OCHSllO or Run Relay) Rack 115 V ac Power Source, 5-slot, UL listed IC61OCHSlOl IC61OCHSlll Rack w/24 V dc Power Source, S-slot IC61OCHS114 Rack, 115/230 V ac Power Source, lO_slot IC61OCHS130 Rack, w24 V dc Power Source, l&slot IC61OCHS134 Kller Module 24 V dc Sink Input, 8 circuits IC61OMDLlOO IC61OMDLlOl 14 V dc Input/Output, 4 Inputs/4Outputs IC61OMDL103 IC61OMDL104 Z4 V dc Sink Input/Relay Output, 4 Inputs/4 Outputs humbwheel Interface Z4 V dc Sink Input, 16 Circuits w/LEDs L/OInterface Cable 10’ (3m) 24VdcSinkLoadI~put,16Circuits 14 V ac/dc SoInput, 8 Circuits 14 V ac/dc Source Input, 16 circuits 115 V ac Input, 8 Circuits 115 V ac Isolated Input, 4 Chuits 230 V ac Input, 8 circuits 115 V ac Input, 6 Circuits (UL listed) IC61OMDL105 IC61OMDL106 IC61OCBL105 IC61OMDL107 IC61OMDLlll IC61OMDL112 IC61OMDL125 IC61OMDL126 IC61OMDL127 14VdcSinkOutput,8Circuits 24 V dc 2 Amp Sink Output, 4 Circuits 24 V dc 2 Amp Si&hurce Output, 4 Circuits IC61OMDL135 IC6lOMDL151 IC61OMDL153 IC61OMDL154 24VdcSourceOutput,8C!ircuits 24VdcSinkOutput,16CircuitswjLEDs 24 V dc Sink Output, 16 Cixuits 24 V dc Source Output, 16 Cinxxits 115/230 V ac Output, 8 Circuits 115/230 V ac Isolated Output, 4 Circuits IC61OMDL155 IC61OMDL156 IC61OMDL157 IC61OMDL158 IC61OMDL175 IC61OMDL176 Relay Output, 8 Chuits Relay Output, 5 Circuits (‘UL listed) Relay Output, 16 Circuits 115 V ac Output, 6 Circuits (UL listed) [email protected] Speed Counter I/O Interthe Cable (High Speed Counter) IC61OMDL180 IC6lOMDLl85 IC61OMDL182 IC61OMDL181 IC61OMDLllO IC61OCBL107 Fast Response &/O I/O Simulator, 8 Inputs printer Interface Unit PROM Writer Unit IC61OMDLl15 IC61OMDL124 IC61OPER151 IC6lOPER154 IC61OACC120 IC61OACCl50 Accessory Kit Lithium Battery PROM Memory (4 Chips), Series CMOS Memory (4 Chips), Series PROM Memory (4 Chips), Sties CMOS Memory (4 Chips), Series Rack Mount Brackets Programmer Mount Assembly One, Series One Junior One One Plus One Plus IC61OACC151 IC61OACC152 IC61OACC155 IC61OACC156 IC61OCHS191 IC61OPRG190 27I Physical Equipment Configuration GEK-90842 Table 2-l. Series One/Series One Plus Catalog Numbers - Continued I DESCRIPTION CATALOG Remote CPU/Programmer Cable Data Communications Unit I/o Link Local I/O Link Remote NUiiiiii~ IC61OCBL102 1C61OCCM105 IC61OCCMllO IC61OCCMlll Hardware Requirements The Series One and Series One Plus PCs are an excellent relay and timer/counter replacer or substitute for other sequential type control devices, such as drum or stepping switch based systems. However, one question always arises - how much hardware do I need to buy ? The answer varies extensively based upon different applications and their attendant complexities. Areas of concern include amount of memory, mix of inputs versus outputs, voltages of I/O, and physical size of the Series One or Series One Plus PC system. The following steps are guides to estimate the requirements of the Series One or Series One Plus PC system. With a little experience, estimating required components will become second nature. If you require assistance, please contact your local GE Fanuc Automation distributor who handles the Series One Family of PCs. NOTE CPU Module IC61OCPUlOlA is different from 1OlB and 1OlC in that 1OlA has a 3 digit preset for Timers and Counters, while the updated modules, 1OlB and 1OlC have a 4 digit preset. The 1OlA method of monitoring the accumulated value of Timers and Counters is also different. With the 1OlA module, each individual Timer or Counter must be accessed by using the sequence SHF, 6X, MON for each Timer/Counter to be monitored. With the 1OlB or the 1OlC CPU module, the keys NXT or PRV will move the monitor display to the next or previous Timer or Counter. System Estimating The Series One and Series One Plus PCs are provided with 700 words of CMOS memory as a standard feature. Expansion to 1724 words is possible by adding a CMOS memory chip. If the unit is to be PROM based, the program can be up to 1724 words. The Series One Plus 3.7K PC provides the user with 3700 words of CMOS memory as a standard feature. For average complexity relay replacement, 700 words should be adequate for up to 64 I/O, and the 1724 should be adequate for up to 168 I/O. If the logic is conside& more complex than that used as examples in this manual, a representative sample (10 to 15%) of the logic should be programmed. From the amount of memory (on paper) the sample requires, the total memory requirements can be estimated. If in doubt, obtain the optional memory with your unit to ensure simple system design. The key to many of the answers (cost, physical size, memory requirements, etc.) is the I/O structure. If a design exists such as shown in figure 2-7, assume that all the relays and timers are enclosed within a box; these are the elements to be replaced. This figure is for illustrative purposes only; no indication is given that it performs any real functions. Passing through this box are wires tirn switches, auxiliary contacts, overload relays, etc.; these are inputs to the control system. There are wires connecting to loads or actuating devices such as solenoid valves, motor starters, indicator lights, etc.; these are outputs 280 Physical Equipment Configuration GEK-90842 from the control system. The power lines (e.g., 115 V ac and 24 V dc) are not considered important to estimating the number of I/O modules required. Use the following steps to estimate rack and module quirements; I/O, but are figure 2-7 is used as an example: 1 . Add total number of inputs and outputs separating them by type and voltage. (5) 24 V dc inputs plus (3) 115 V ac and (1) 24 V dc output). (e.g. (4) 115 V ac and 2 . Divide each separate category by 8 (assume 8 circuit modules), (e.g. (1) 115 V ac and (1) 24 V dc input modules and (1) 115 V ac and (1) 24 V dc output modules). See Chapter 6 for I/O that uses 4 or 16 circuits per module. 3 . Add total I/O modules (e.g. 4 I/O modules). One 5-slot rack is required for l-4 I/O modules, two 5-slot racks for 5-9, and three 5-slot racks for 10-14. 4 . If lo-slot racks are used one lo-slot rack is required for 1-9 I/O modules, lo-slot and a 5-slot rack will contain 1-14 I/O modules. 5. wo lo-slot racks or a Each additional rack also requires an I/O expander cable. Empty slots should be covered by blank filler plates. 6 . Estimate memory requirements Total I/O Points l-64 65-168 as follows: Estimated Memory Basic Unit with 700 words Add 1K Memory Chip 7 . The following optional hardware is available and should be considered Had-Held Programmer Portable Programmer Extender Cable Programmer Mount Assembly when configuring a system: PROM Writer Unit Printer Interface Unit Thumbwheel Illunit Timer/Counter Setpoint Unit (Series One Plus) If the system has not yet been designed, the same basic technique can be used. Inputs are signals the PC will require to perform its assigned functions. Any device or person regardless of intelligence can not respond to events it does not know occurred. Plan to provide the PC all the information you would require to perform the same function. Make a list of those inputs, including source and voltage level (if currently defined). Outputs, on the other hand, are devices the PC will use to perform its fimctions. Again, even if the PC knows it must do something, if it is not given control over these actuating devices, it can not maintain proper control. Make a list of these devices including their voltage levels and current/power requirements. Use the above steps with the list of l/O devices. In any case, when 290 Physical Equipment Configuration GEL90842 estimating system requirements, review the following define their impact on your control needs: standard features as discussed in later chapters to Up to 64 Timers and Counters (4 digits each) 128 Stage Shift Register Up to 64 Sequencers Each With Up to 1000 Steps 28 Latched Relays Data Operations (Series One Plus and Series One 3.7K) 64 Sixteen Bit Data Registers (Series One Plus and Series One 3.7K) - Up to 124 Data Registers are possible when unused T/C references are used as Data Registers. a421 53 Figure 2-7. Example of Relay Control Peripheral Devices Supporting Series One Family of PCs Several peripheral units are available to support a Series One or Series One Plus Programmable Controller. A basic description of these units is provided in the following paragraphs. For a more detailed description of the use and operation of these units, refer to Chapter 4, Operation, in this manual. 2-10 Physical Equipment Configuration GEK-90842 Data Communications Unit The Data Communications Unit (DCU), 1C610CCM100/105, provides the ability for external devices to communicate with the Series One, Series One Model E, Series One Plus or Series One Plus 3.7K PC. Series One Model E, Series One Plus and Series One Plus 3.7K PCs require the CCM105 DCU. These devices function as a host to the Series One or One Plus PC and can be other programmable controllers, computers, or other smart devices. User programs and I/O information in the Series One or One Plus PC can be uploaded and downloaded to or from any master device that supports the Series Six CCM2 (Communications Control Module, Version 2) master/slave protocol as defined in GEK-25364, which is the Series Six Data Communications Manual. The Series One or Series One Plus can only function as a slave device during a communications session. a40537 Figure 2-8. Data Communications Unit 241 Physical Equipment Configuration GE&90842 Printer Interface Unit The Printer Interface Unit, IC61OPER151, is a compact, easy to use device that attaches to the Series One, One E, One Plus or One Plus 3.7K PC in the same manner as the programmer. This peripheral interfaces to many readily available personal computer printers and provides a means of obtaining a hard-copy printout of the user program in either boolean or ladder diagram format. Version B works with Series One, One E and One Plus PCs. A higher revision will be available that will also work with the Plus 3.7K PC. a40538 Figure 2-9. Printer Interface Unit 2-12 Physical Equipment Configuration GEK-90842 PROM Writer Unit Also available is a PROM Writer unit, IC61OPER154, which allows the user program in CMOS memory to be transferred to PROM memory, thereby providing a convenient method of non-volatile (permanent) storage for those programs. The PROM Writer unit is a compact, easy to use unit which attaches directly to the PC in the same manner as the programmer. In addition to providing a means of non-volatile storage, an added advantage of PROM memory is that several PROMS can be programmed, each containing a different program, for use as required. Version B of this unit replaces version A and can be used with a Series One Plus PC as well as Series One and Series One Junior PCs. Version B will not work with the Series One Plus 3.7K PC. A revisedversion will be available that can be used for all Series One Family PCs. a40539 Figure 2-10. Prom Writer Unit PROGRAMMABLE CONTROLLER series One/OneE series OIX!Plus/3.7K PROM 2732A-2 27256-25 Chapter I 31 3 Installation GEK-90842 Specifications for Installation The Series One and Series One Plus PC can be easily installed in any NEMA panel or similar metal surface. Figure 3-1 provides details on the mounting of up to three racks except for input voltage requirements to form a single PC system. Since a completed &lot rack weighs less than five pounds (lo-slot rack, less than 7 pounds), it can be easily installed by one technician. Table 3-1 provides specifications to be met during installation. Table 3-l. Series One Installation Specifications Rack size 11.4“ x 4.7” x 5.5“ (290 x 120 x 14Omm) 18.3” x 4.7“ x 5.5” (465 x 120 x 14Omm) S-slot lo-slot Completed Rack Weight (less [email protected] 0’ to 60°C (32” to 14OOF’) Ambient Temperature Storage Temperature -10’ to 7oOC (14’ to 158°F) 5-95s (Non-CorKieIlsing) HUmidiQ AC Power Required: 1C61OCHS101/110/l30 Vohage FrequeW Maximum Load output current Maximum Individual DC Power Required IC16OCHSll4/l34 Voltage Ripple output current Maximum Individual Maximum, Total (All vohRges) Run relay 4.5 lbs (2.0 Kg), 5-Slot 6.5 lbs (2.9 Kg), lo-slot Rack 115v/230 v ac 15% 47-63 Hz 30 VA, CHSlOl/llO (70 VA, CHS130) 1.4 A at 5 V dc (0.4 A CHSlOl) 0.8 A at 9 V dc, CHSllO (0.6 A, CHSlOl; 1.7 A, CHS130) 0.5 A at 24 V dc, (0.2 A, CHSlOl) 20.5 - 30 V dc (100% of capacity used) 18 - 30 V dc (90% of capacity used) 10% of Input Voltage 1.4 A at 5 V dc 0.8 A at 9 V dc, CHS114 (1.7 A, CHS134) 0-4 A at 24 V &, CHSll4 (0.5 A, CHS134) 2.2 A, CHS114 (2.9 A, CHS134) 250 V, 4 amp, Resistive Load (Not Present on CHSlOl) Vibration MestsJISC0911IIBClass3 Shock Tested to ML STD 810C Method 514.2 Meets JIS C 0912 Meets NE&IA ICS3-304 Noise Immunity Installation GEK-90842 W7.52 t *#18.3 (445) ** C465, FOR lO-SLOT CHASSIS 11.41,, -AL 12 PLACES MAX: MIN: 7.2 (183) 4" 4 ,3:40, MIN MMENsK)(ys IN PARENTHESES ARE MI MUMETERS, OTHERS IN INCHES. Figure 3-l. Rack Mounting Dimensions for Proper Heat Dissipation Installation Unpack each unit candidly and retain any instructions shipped with the units. Two spare fuses are attached to the top of each rack; they should be removed and retained for future use. The racks can be installed either with no modules or with modules installed. The following steps will assist in organizing and simplifying the installation of a Series One or Series One Plus PC System. 1 Using the rack as a template, l 2 . Drill the four mounting tapped holes). ma& where mounting holes are to be drilled. holes (l/4“ (6mm) if using pass through bolts, or 3/16” 3 . Insert top 2 bolts (3/16“ X l-1/2” washers, lock washers and nuts. or 5mm X 4Omm),put unit ,. CR in place, (5mm) if using and loosely secure with Installation GEK-90842 4. Tap holes and insert top two bolts. Place unit onto mounting bolts and loosely secure. NOTE men inserting the 2 top bolts, attach the green jumper as shown in figure 3-2. This jumper wire is packed with each rack and provides a method of groundingthe rack when an earth ground (such as the shield or hard wire in the power cord) is also connected to a mounting bolt. 5. The power supply ground connection is made to one of the mounting bolts (step 3 or 4 above). A jumper wire is included with each rack to interconnect the mounting brackets. The “C” terminals on the power supplies are interconnected when more than one rack is used. Otherwise, the “C” terminal is not connected to anything in a single rack system. a40147 jumper wtre tncluded wtth Ix> base star washer W to 8n earth ground Figure 312. Recommended Rack Grounding 6. Complete the installation of the bottom two bolts and tighten supplies are shipped installed in each base. 7. If additional racks are to be used, repeat steps l-4 above. 15 . all mounting hardware. Power If only one base unit is used, go to step NOTE When drilling or tapping holes ensure that work area before installing base units chips do not enterunit afready installed. clear 8. Obtain flat ribbon cable used to interconnect racks. Locate end marked “To CPU”, remove dust cover from bottom connector of first (CPU) rack, and insert cable co~ector (see figure 3-d) fully into receptacle until locking tabs capture connector. 9. Fold cable as shown on figure 3-7. Remove dust cover from top connector of second rack and insert opposite end of cable marked “To Expander.” 10. Secure cable in place with wire wraps or cable ties. 34m Installation GEL90842 11 . a third rack is used, repeat steps 8-10 with CPU end of cable *in bottom connector on second rack and Expander end in top connector of third and last rack. If 12 . If a lo-slot rack (IC61OCHS130 or IC61OCHS134)) is to be included in a system, it can be mounted on standard mounting rails in 19 inch cabinets and consoles by attaching the rack mount brackets. Two adapter brackets and hardware required for assembly are included in the bracket package, IC6lOCHS191. a4021 4 I ohmmoNs IN INCHES, WLLIMnERS ARE W PARENTHESIS I Figure 3-3. 10 Slot Rack, 19 Inch Mounting Dimensions ’ a40280 Figure 3-4. I/O Expansion Cable Connection 13. Unused rack connectors such as at the top of the CPU unit and the bottom of the last rack should retain their dust covers. 35m Installation GE&90842 14 . Inside each 5-slot rack at the rear of the leftmost module slot is a two position switch. On the CPU unit, this switch must be positioned towards the left. On the first expander it must be towards the right. If a third rack is used, the switch must be towards the left again. An exception to the described switch settings is when a 5-slot rack is used as an expansion rack in a Series One Plus system, where the CPU rack is a 10.slot rack. In this case, the switch must be positioned to the left This switch is not included in the IC6lOCHSlOl rack, since it cannot be used as an expansion rack. All switches must be set properly. The Series One or Series One Plus PC may not function correctly if any switch is not in the correct position. 15 . The lo-slot racks, IC61OCHS130/134 have two bridge connectors on the back plane which must be configured. Bridge connector SWl, located between slots 3 and 4, has 2 positions EXP and CPU. The jumper must be positioned on the corresponding pins to specify whether the rack is a CPU rack or an Expansion rack. Bridge connector SW2, located between slots 9 and 10, selects the address to be assigned to slot 10 and the expansion rack slots. The selections are either 100 EXP or 700. Figure 3-5 shows the location of SW1 and SW2. a40794 SW2 700 loo EXP BRIDGE-CONNECTOR I, : s ml3 : -Bf?IDGE-CONNECTOR 2 A Fiire 3-5. I/O Addressing SW1 EXP CPU -- A IC6lOCHSl30 OR IC6~OCHSi34 Switches in Series One Plus 10 Slot Racks 360 Installation GEK-90842 16. Example of SW1 and SW2 settings are shown below in figure 3-6. a40795 SW2 Ii00 EXP) SW2 1700 EXPI SET TO LEFT POSITION SW2 t100 ExPr SWI IEXPI Figure 3-6. Examples of Rack Configuration Switch Setting Series One Plus 37I Installation GEK-90842 ET- Its v&c Itsv - MEUT 1 23ovAC 23OvWEUT + 24 VDC -2uDC PC 1 COMMON CONNECTION ' Figure 3-7. Typical Installation Dimensions NOTE Ground Connection should be made to mounting bracket, not to the terminal strip. CPU 17. Locate the CPU module (see figure 3-8) and set switches and shorting bridge connectors per table 3-2. If additional CMOS or PROM memory is to be installed, now is the time to do it. For detailed instructions, see Chapter 7. 18. The CPU module must be installed adjacent to the power supply in the first or topmost rack. 38m Installation GEK-90842 a40281 s2 Figure 3-8. CPU Module Table 3-2. CPU Option Settings SWITCH 1 - POWER OFF ON SWITCH UP FUNCTIONS 2 - MEMORY PROM CMOS OFF ON Clear coils Retain Coils TYPE NOTE ON is Towards the Faceplate. Factory setting is: Clear Coils and Select CMOS memory. Retain Coils affects 340-373 only. Copters and Shift Registers are always retentive. Table 3-3. Memory Size MEMORY CONNECT SIZE JUMPERS BETWEEN PINS ABandDE B Cad-i? ABandDE 700 words CMOS 1724 words CMOS 1724 Words PROM I CAUTION I Remove jumper EF before installing PROM. Battery will discharge in a very short time if is not disconnected. E NOTE Pin A is towards the faceplate. Factory setting is: 700 words CMOS, 1724 words PROM (same Setting) Installation GEK-90842 a40282 Figure 3-9. Proper Module Insertion 19. Tilt the module approximately 10’ as shown in figure 3-9. Insert bottom of the large printed circuit board into the bottom card slot. 20. When the bottom slot is engaged, rotate the module to engage top slot. Slide module into base unit until it is firmly seated and snap locks engage. II0 21. Other modules are installed into racks at slot locations as determined by installation plans. Follow steps 19 and 20 above for each I/O module. 22. To remove a module, squeeze the snap locks top and bottom (see figure 3-10) towards the center and pull the module straight out. Squeeze force should be approxbately 10 pounds (5 Kg) and pull force 8-12 pounds (4-5 Kg). a40283 Figure 3-10. Proper Module Removal 3-10 Installation GEK-90842 Power Co~ections 23 . AC or DC power connections are made to the terminal strip on the far right of each unit. See table 3-l for power requirements. The minim um recommended wire size for power connections is AWG No. 18 (lmm). 24 . Strip 0.4 2 0.1 inches (10 & 2mm) of insulation from each wire (hot, neutral, and ground or + and -) or place a No. 6 insulated lug (ringed or forked) onto each wire. 25 . Remove plastic cover over terminal strip and retain. Connect the hot wire to the top terminal. The neutral is connected to either the next (second) terminal for 115 V ac operation or the third terminal for 230 V ac operation as marked on the base unit. For 24 V dc racks, connect the + and - terminals to the DC power source. Do not use the top screw for power connections; it secures the terminal block connections before applying power. Verify 26 . Connect an earth ground wire to the rack mounting bracket as shown in figure 3-2. (Typically this ground wire is the green wire from the ac power source.) Ensure that aI1 exposed wiring is either under the screw-down plate of the terminals or insulated by shrink tubing or sleeves. 27 . The terminals labeled +24 V dc and -24 V dc provide 24 V dc @ 100 mA for connection external sensor (not on IC61OCHSlOl). to an 28 . The two remaining terminals are used with the RUN indicator. Use of this standard feature on all racks is optional. It can be used to drive an external indication of the functional state of this rack. The Run relay is closed when the CPU is scanning (not on IC61OCHSlOl). 29 . If the Run indication is desired, it can be wired separately to an external indicator (light, bell, whistle, etc.) or in series with other racks. Follow steps 24-25 above for guidance on connecting these wires. Then replace the plastic cover. If0 Field Wiring 30 . Recommended wire size for connection to the I/O modules is stranded AWG No. 12 (0.65~2mm) wire. Two wires per terminal are possible with AWG No. 14 (0.65.1.6mm) wire. 31 . Strip 0.3 i 0.05 inches (8 * 1.5mm) from each wire to be connected to the I/O modules or install a No. 6 insulated lug (ringed or forked). Bare wire co~ections are recommended for multiple wire co~ections to one terminal. 32 . Carefully remove plastic covers over I/0 terminal sliding it to right or left. co~ections by lifting top or bottom leg and 33 . starting with the lower terminals, connect the field wires to all UO terminals. Power connections such as those to commons (C) should be made last. No co~ections are required to unused circuits; however, screws on unused terminals should be tightened. Instdlation 3-11 GEK-90842 34. For 16 point I/O modules that connect to I/O through a connector on the faceplate, connector on the I/O Interface cable to the connector on the module. secure the Ensure that wires to the top set of terminals do not extend beyond the screw-down plate. Any wire exposed before the terminal plate must be covered by shrink tubing or sleeves. 35. Wires should be laced together to leave a service loop adequate for removal of I/O modules without discoMecting wires. See figure 3-11. After testing of I/O wiring, replace plastic covers. a4001 7 Figure 3-11. Typical Routing of I/O Wiring Programmer 36 . The hand-held programmer (catalog no. IC61OPRGlOO or IC61OPRG105) can be placed over the CPU and power supply for permanent or temporary mounting. Its connector fits into the receptacle on the CPU and it snap locks onto the power supply. 37 . If an extender cable is used with the programmer, it should be installed next or when required. One end of the cable has a push tab (see figure 3-12). This end is connected to the programmer (see figure 3-13). The other end is connected to the 26.pin coMector on the CPU. Both ends m keyed for proper instaIlation. The red edge of the ribbon cable is installed up at both ends. Installation 342 GEK-90842 a40163 Figure 342. Pull Tab on Programmer Cable NOTE For proper noise immunity, it is recommended that the extender cable be used on a temporary basis and not permanently installed with the programmer. 38. TO installthe programmer of the power supply and directly onto the CPU, align the programmer gently push down to engage snap locks. on the outside dimensions To ensure proper. CPU operation, it is recommended that the programmer not be connected nor disconnected with ac power applied. 83-pc-35m m-4-3-3 1a Figure 3-13. Installation of Programmer Cable Installation 3-13 39. The Programmer Mount Assembly (catalog no. IC610PRG190) can be used when installing the hand-held programmer on the outside of a panel or console, or can be used as a table top stand for the programmer. Figure 3-14 shows how to install the mounting assembly. The CPU/Programmer cable must be ordered separately. a40148 *cABLEwsTBE OmEREDsEPARAELY Figure 3114. Programmer Mount Assembly Power Supply Limitations for Racks If the power supply in either a CPU or expansion rack should become overloaded, unpredictable system operation may occur. To ensure that this does not happen, the total current capabilities of the modules placed in the rack must not exceed the current carrying capabilities of the rack power supply. Units of Load The power used by each module is expressed in (units of load), where 1 unit equals 10 mA. Calculations are based on the worst case condition with all inputs and outputs on. Table 3-4 list the units of load supplied by each rack, and table 3-5 is a list of units of load used by each module. When configuring a rack, note the units of load supplied, then add the total units of load used by the modules you have selected. The total units of load for the modules must not exceed the total units of load supplied by the rack. If they do, the system should be redesigned. 3-14 Installation GEK-90842 Table 3-4. Units of Load Supplied by Rack CATALOG NUMBER POWER SUPPLIED IN UNITS OF LOAD RACK DESCRIPTION +s v +9 v +24v +24VExtemaI *If an external sensor is connected to the 24 V + and - terminals on the power supply, the current used by the sensor (up to the maximum of 100 mA), should be deducted from the available listed units of load. Table 3-S. Units of Load Used by Modules CATALOG NUMBER IC6lOCPUlOl IC61OCPU104 IC61OCPU105 IC61OCPU106 IC610PRGlOO IC61OPRG105 IC61OMDLlOl IC61OMDL103 IC61OMDL104 IC61OMDL105 IC61OMDL106 IC61OMDL107 IC61OMDLllO IC61OMDLlll IC61OMDLll2 IC6lOMDLll5 IC61OMDL124 IC61OMDL125 IC6lOMDL126 IC61OMDL127 IC61OMDL135 IC6lOMDL151 IC61OMDL153 IC61OMDLl54 IC61OMDL155 IC61OMDLI ,-“: IC61OMDL157 L MODULE DESCRIPTION CPU CPU25 CPU CPU Programmer Programmer 24 V dc Sir& Input (8) 24 V dc In/Out (4/4) 24 v dc In/Relay out (4/4) Thumbwheel Interhce 24 V dc Sink In wm (16) 24 V dc Sink Load In (16) High Speed Counter 24 V dc ac/dc Input (8) 24 V ac/dc Source In (16) Fmt Resgonse UO (4/2) m Simllatm (8) Inputs 115 V ac Input (8) 115vacIsolatedIIpt(4) 230 V ac Input (8) UL, 115 V ac Input (6) 24 V dc Sink Output (8) 24V&2ASinkOut(4) 24 v dc sink/Soum! out (4) 34 V dc Source Output (8) ’ G. -J dc Sink Out W/WEDS(16) I 24VdcShkOutw/LEDs(16) POWER USED IN UNITS OF LOAD +s v 25 m 25 25 6 6 +9v _ +24V I) 5 5 1 2 20 1 3 3 7 1 13 8 1 1 1 1 1 2 10 7 6 9 24 23 m 6 11 1 0 10 Installation 345 GEL90842 Table 36. Units of Load Used by Modules - Continued CATALOG NUMBER IC61OMDL158 IC61OMDLl75 IC61OMDL176 Ic61oMDL18o IC61OMDL181 IC61OMDL1.82 IC61OMDL185 IC61OCCM105 IC61OCCMllO IC61OCCMlll IC6lOPERlSl IC61OPER154 IC609CTUlOO MODULE DESCRIPTION POWER USEDINUNITSOF LOAD +s v +P v +24 V 24 V dc Source Out w/LEDs (16) 115/230 V ac Output (8) 115/230 v ac Isolated OUT (4) Relay Output (8) UL, Relay Output (5) Relay Output (16) UL, 115 V ac Output (6) Data Communications Unit I/Ok&Local I/O Ihk Remote Printer Interface Unit PROM Writer Unit Timer/Counter Setpoint Unit 1 unit of load = 10 m4. Calculations are based on the worst case, that is, all inputs and outputs on. Safety Considerations When planning the layout of a system, safety should be a prime consideration. System planning should include procedures and methods to ensure the physical safety of personnel, the Series One or One Plus Those personnel who are involved in the system and the equipment or process being controlled. planning and installation of a system should be familiar with all local and national electrical codes as well as installation instructions in this manual. All practices should be followed that are specified by the IEEE (Institute of Electrical Engineers) Standard 510 which includes tray and conduit spacing and wiring procedures. standard can be obtained by writing: and Electronic A copy of this Institute of Electrical and Electronic Engineers 345 East 47th Street New York, NY 10017 Recommended Field Wiring Procedures The following Drocedures are recommended _ _ when runnine. field wiring: Low-level $nal wires should be separated fkom other yfield wiring.” AC power wiring should be separated from DC field wiring. . Wiring should not be routed near devices causing electrical interference. If severe noise problems are present, additional power supply filtering or an isolation transformer may be required. Contact your GE Fanuc Automation sales representative if assistance is required. Proper grounding should be provided to minim& hazards to personnel. Label all I/O wires. Circuit numbers or other identification can also be marked on the cover over the wire terminals on each ?!O module. I/O wires should be no larger than No. 12 AWG.
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