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Series Six Installation and Maintenance Manual, GEK

1. 1 43 iore 1 44 Auxiliary Circuit Board 1 45 Alarm Relay eei eee ERR 1 46 Section 4 Input Output System VO ET ETE 1 47 Point Addressing 1 49 VO Rack Interconnection 1 5 1 VO Power Supply 1 52 ANPU tete rete ope coder 1 52 Auxiliary Circuit Board 1 53 6 1 53 Module Hardware Features 1 53 Module Electrical Features 1 54 Connections to I O Modules 1 55 AC DC 8 Circuit Input Modules 1 55 High Density Input Modules 1 57 Analog Input Modules 1 60 Interrupt Input Module 1 67 Thermocouple Input 1 69 AC Output 1 74 Isolated AC Output Module 1 77 DC Output 1 78 High Density Output Modules 1 82 Analog Output Modules 1 84 Reed Relay Output Module 1 89 lO System Config
2. 1 49 Switch Settings for O Point Selection for Eight Circuit Modules 1 50 l O Power Supply Block Diagram 1 52 Input 1 56 High Density Input 1 59 DIP Switch Settings for High Density Modules 1 60 Analog Input 1 1 62 DIP Switch Settings for Analog Input Modules 1 63 Interrupt Input Module 1 68 Thermocouple Input Module 1 70 DIP Switch Settings for Thermocouple Input Modules 4 1 1 72 AC Output Module 1 75 Isolated AC Output Module 1 77 DC Output Module Typical 1 79 High Density Outputs 1 82 DIP Switch Settings 1 83 42 Table of Contents GEK 25361A FIGURES Chapter 1 43 Analog Output Module 1 85 44 DIP Switch Settings for Analog Output eet ete ut 1 86 45 Reed Relay Output Module 1 90 46 M Receiver 1 92 47 1 0 Receiver DIP Shunt Jumper Pack Configuration ERO Qd 1 93 48 VO eas 1 95 49 Connect
3. 2 20 Option Jumper Settings ICGOOCB5 14B 2 21 DIP Switch Settings for Remote 1 0 2 31 Remote I O Driver Jumpers 2 33 Selectable Baud Rate Jumpers RS 232 oie ee E 2 34 Remote I O Receiver Jumpers 2 36 Selectable Baud Rate Jumpers RS 232 Boios 2 37 Board Jumpers Reference Only 2 37 Cables for Local I O Equipment 2 38 Summary of I O Loads 2 43 Data Format Options 2 58 Sample Rate Options 2 58 Operating Mode Options 2 58 User Selectable Options 2 59 Channel Configuration 2 78 TABLES Chapter 3 PDT Troubleshooting 3 11 Renewal Parts List for Program Development Terminal 25 dicione ce 3 13 CPU Indicator Chart 3 15 CPU Module Renewal Parts List 3 33 Indicator Chart 3 37 Renewal Parts 3 52 Module Calibration 9 56 Channel Adjustment 3 59 Module Calibration 3 59 General Description of the Seri
4. INN aa gt lt gt lt gt lt gt lt B z H NIN gt OX c gt z tz X x Switch in OPEN Position Depressed to the Left Switches 1 and 2 Should be in CLOSED Position Figure 33 THERMOCOUPLE INPUT MODULE I O POINT SELECTION Ref 70 151 2 57 Installation EEK 25361A I O Module Wiring In addition to setting the DIP switches for 1 0 point selection several circuit board jumper plugs and a configuration DIP switch must be set to conform with the user application The following tables provide a guide to configuration of the various board options Table 14 is for selection of the format for data transferred to the CPU The data format can be either signed magnitude or 2 s complement Data Format Jumper Setting Signed Magnitude 56 58 2 s Complement 56 57 Table 14 DATA FORMAT OPTIONS Table 15 lists the optional conversion rates for the sampled temperature readings Line Sample Frequency Rate Jumper Settings 45 46 50 51 69 70 46 47 49 51 68 69 45 46 48 50 51 52 69 70 46 47 48 49 51 52 68 69 Table 15 SAMPLE RATE OPTIONS Table 16 lists the jumpers used to select either the RUN mode or the calibrate mode MODE JUMPER SETTING RUN Calibrate Table 16 OPERATING MODE OPTIONS Installation GEK 25361A I O Module Wiring Table 17 lists the DIP switch settings for module type configuration h Po On Typ
5. 545 576 x 897 928 225 256 577 608 ix 929 960 X 257 288 x 609 640 x x x 961 992 x x x X 993 1024 fX X 289 320 X X 641 672 X XXXX 321 352 X X 673 704 X X NOT USED Switch in OPEN Position Depressed to the Left Switches 1 and 2 Should be in CLOSED Position Figure 37 DIP SWITCH SETTINGS FOR THERMOCOUPLE INPUT MODULES Four consecutive 1 addresses are required to transfer all 32 bits of information to the CPU for each channel read Data from a single Thermocouple channel will normally be transferred with each 1 sweep Usually all eight channels are read and transferred in sequence during consecutive 1 0 sweeps The module will automatically index to the next channel as each channel is read This action is indepen dent of the input sampling rate The CPU can strobe this module every 80 usec for up to eight Sweeps it then must allow the module to return to its data sampling routine for 20 msec before reading the input points again The 32 bits corresponding to the group of 32 inputs specified for each module are transferred into the appropriate Input Status Table in the sequence shown below INPUT STATUS TABLE DISPLAY 24 17 16 9 8 1 I O Address 1 0 Address I O Address Address Bit 32 25 VO Scan 1 72 Ref 70 150 General Description of the Series Six GEK 25361A
6. eere 1 1 1 Program Development Terminal l 11 Section 2 Hardware Description of the Central Processing Unit Model 6000 CPU 1 15 Options for Model 6000 CPU 1 16 CPU Power 1 16 Logic 1 1 18 Arithmetic Control 1 1 20 WO Control 2 1 22 Memory dece 1 24 CMOS III 1 24 Internal 1 24 Memory Addressing and Memory Map Allocation 27 Register 1 28 Logic 41 29 Memory Protection 1 31 Visual Status of Backup Battery 1 32 Auxiliary 1 0 2 1 32 Communications Control 1 34 Model 600 CPU 1 35 Model 60 1 37 Table of Contents GEK 25361A Section 3 Power Supply MOUMOU 1 41 Logic Power Switch 1 41 AG Input tet Na ts 1 42 Key SWItCH 42 Terminal 111 1 42 Terminal Block Cover
7. 2 71 43 High Density Output Module I O Point Selection 2 creer ee Ent 2 72 xiv Table of Contents 44 45 46 47 48 49 GEK 25361A FIGURES Chapter 2 High Density Output Modules 2 73 High Density Output Typical User Connections 11 2 74 Analog Output Module 1 0 Point Selection 2 75 Analog Output Module 2 76 Analog Output Typical User Connections 2 77 Reed Relay Output Module 2 80 Typical Reed Relay Output Circuit 2 8 1 50 51 52 Reed Relay Output Typical User Connections 2 82 Program Development Terminal Storage Compartment 2 83 FIGURES Chapter 3 1 2 11 13 Program Development Terminal Connectors Control and Fuse 35 Program Development Terminal Component LOCAHON i ocio eoe DE COO MEE Ue Se Le ta e ds 3 6 CRT Adjustment Controls Video Monitor ChEIPREREICEIII 3 9 CPU Indicator Keyswitch 3 16 CPU Power Supply Block Diagram ee 79 20 Battery Mounting Clips and Connectors 3 29 CPU Power Supply Terminal Board 3 3 1 lO Power Supply Block Diagram Standard 3 35 CPU to I O Rack 3 41 l O Ra
8. or 230V AC Check the P1 connections on the CPAXI 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 printed 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 3 18 Ref 70 108 Troubleshooting and GEK 25361A Central Processing Unit Troubleshooting 5V DC 4 75 to 5 25V DC 412VDC 11 40t0412 60VDC 12VDC 1140 to 12 60V DC If any of the voltages are out of tolerance replace the power supply Figure 5 is a block diagram of the CPU power supply for 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 3 19 Troubleshooting and Repair GEK 25361A Central Processing Unit Troubleshooting mene Wid CPAXI Switch Board Inputs from Backplane bi OK CPU OK Alarm Bat O Low Bat External V Cm INO INC Outputs m Backplane COM N Plt Data Protect MEM SYS RDY 10 STOP m 7 ROM RAM C AUX BAT Circuit 23 Line
9. H P d H H E H M 1 Connector to I O Control I O Transmitter 4 Connector to I O Receiver in Next Down or Another I O Receiver Upstream stream I O Rack 2 Board Location Cl 5 Board Location F2 3 Board Location DI 6 Board Location F3 Figure 17 RECEIVER CONFIGURATION LOCATIONS Ref 82 PC 12 2 29 Installation GEK 25361A The I O Rack The top connector on an l O Receiver can be connected to several points as determined by system configuration Possible connections are Control module in a CPU rack Next upstream I O rack in a daisy chain of racks An I O Transmitter in a model 60 CPU I O slot CPU I O station a Local I O station or a Remote station The lower connector connects to the next rack downstream if additional racks are to be included in a daisy chain of I O racks lO TRANSMITTER The I O Transmitter requires no field configuration An I O Transmitter module can be installed in any slot in an I O rack or in an I O slot in a model 60 CPU Connect an I O cable refer to Table 12 from the connector on an Transmitter to the first I O Receiver in the next downstream 1 station The maximum distance separating an I O Trasmitter from the I O Receiver to which it is connected is 500 feet 150 meters Also no Local station should interface through more than four I O Transmitter links Install the I O Transmitter in the selected I O slot using the extraction insertion
10. 1 1 Series Six Family 1 3 Universal Rack For Series Six CPU and DPU 1 7 Series Six Faceplates 1 8 Input Output Rack with Wiring 1 10 Program Development Terminal 1 12 Scan I 14 Model 6000 CPU 1 15 Series Six CPU Power 1 17 Logic Control Module 19 Arithmetic Control Module 1 2 1 O Control Module 1 23 Internal Memory Module 4 26 Register Memory Module 1 28 Basic Word Structure 1 29 Model 6000 Logic Memory Slot Reference 1 29 Logic Memory 8 1 31 Auxiliary 1 0 1 33 Model 600 CPU 1 36 Model 60 CPU eene 1 37 Combined Memory Module for Model 60 CPU 1 38 Series Six Power Supplies 1 41 CPU Power Supply Front Panel 1 42 CPU Power Supply Block Diagram 1 44 Auxiliary Circuit Block Diagram 1 45 VO Rack obe ME 1 48 I O Address Switches
11. 2 25 5715 RECOMMENDED MOUNTING HARDWARE 5 16 X 19 WITH FLAT WASHER WEIGHT 45 LBS WITH ALL SLOTS FILLED AND POWER SUPPLY INSTALLED WEIGHT 30 LBS WITH ALL SLOTS EMPTY AND POWER SUPPLY INSTALLED Figure 2 RACK MOUNTING 1 75 298 45 2 3 Installation GEK 25361A Rack and CPU Module InstallationA EXTRACTION INSERTION TOOL The printed circuit board extraction insertion tool board puller Catalog No IC6QOMA504A included with your Series Six CPU should always be used when installing or removing a module The boards in the CPU require an insertion force of about 50 lbs 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 for identifying features of this tool BOARD PULLER BOARD SEATING FLANGES BOARD PULLER LOGI Wace NOTCH eee Go LOGIC RACK NOTCH mos HANDLE AREA y A y HANDLE AREA n gt 7 BOARD PULLER PULLER BOARD PULLER STUDS vce RAGE FLANGE LOGIC RACK FLANGE BOTTOM TOP Figure 3 EXTRACTION INSERTION TOOL 24 Ref 50541 Installation GEK 25361A Rack and CPU Module Installation NOTE Power to a rack should be turned off before installing or removing any printed circuit board REMOVING A PRINTED CIRCUIT BOARD Insert the board puller studs int
12. 4 Devices User provided devices such as switches pushbuttons relays motor starters solenoids etc By virtue of the family concept a number of common modules may be interchanged among the models The models differ with respect to memory size register capacity I O capacity and options available An important advantage of the family concept is that the spare parts inventory training requirements and documentation needs for large multiple model installations are held to a minimum Figure 2 is the Series Six Model 60 Model 600 Model 6000 and the Program Development Terminal General Description of the Series Six GEK 25361A Introduction Figure 2 SERIES SIX FAMILY MEMORY SIZE User program Logic memory can store up to 32 768 sixteen bit words Logic Memory consists of CMOS RAM Random Access Memory backed up by a Lithium Manganese Dioxide battery In addition to the Logic Memory modules the Model 600 and 6000 have a Register Memory module which con tains 1024 sixteen bit registers and an Internal Memory module The Model 60 has a combined memory module which includes logic memory either 2K or 4K sixteen bit words register memory con sisting of either 256 or 1024 sixteen bit registers and internal memory circuits Ref 8 PC O 1 3 General Description of the Series Six GEK 25361A Introduction MODELS Model 6000 is the top of the line and has the greatest capacity for control process
13. System Troubleshooting lO SYSTEM RENEWAL PARTS LIST A list of the replaceable parts in the I O system is provided in Table 6 Catalog Module Name Name Function IC600YB800A Interfaces between the parallel I O Chain bus and the I O Receiver modules within an I O rack Checks output parity and generates input parity IC600YB900A Translates the I O backplane signals into isolated and balanced Transmitter signals for transmission up to 500 feet to one or more 1 0 Receivers IC600PM502A Power Supply Provides a 5V DC 6 1 amp regulated voltage for the stan Standard dard I O rack Allows 100 units of load Strap selectable for 115VACand either 1 15V AC or 230V AC operation 230V AC 600 505 Power Supply Provides 5V DC 16 5 amps 12V DC 1 5 amps and High Capacity 12V DC 1 0 amps regulated voltages for the high capacity 115VAC I O rack Allows 275 units of load IC600PM504A Power Supply High Capacity 230V AC IC600YB801 A Remote I O Circuitry provides for a serial full duplex I O data communica Receiver tions link via a two twisted pair cable Allows communication up to 10 000 feet from a CPU station or a Local I O station greater distances using RS 232C modems Allows up to 248 IC600YB901A Remote I O Driver inputs 248 outputs in a Remote I O station IC600YB804A Board Contains 8 isolated input circuits with LED indicators and noise 115V AC DC filtering
14. 689 696 X 1 aa L 869 316 105 7112 41 48 X 377 384 1713 70 X 49 56 X X 135 532 721 728 dee P339 65 12 x 401 408 13 80 X X 409 416 81 88 X X X 417 424 89 96 X X X 425 432 97 104 I IX X 4383 440 O AX X 441 448 113 120 LI 449 4567 121 128 X X X X 457 464 X 46 42 L IX X 1773 480 Pd Ea PSI DS gt sS LIX 714 175 2 X 1793 7600 X 161 168 XIXIXIX X L 17 69 T6 XIX X 77784 XIX X ree 792 X EX OOA p x4 al S a E EEEEEEEEEE E E E eS 13 160 X X X 409 400 Bd Bree Txt et sro X X X X X X X X IEEE te Sa 513 520 xt 1849 296 XIX 185 192 X X 8 193 200 523 386 xT X _ 865 872 201 28 537 544 9813 880 945 592 Ht 881 888 889 896 897 904 905 912 929 9
15. Installation GEK 25361A Module Wiring Connect one side of the load to be controlled to one of the output terminals 1 through 8 Connect the other side of each load connected to terminals 1 through 4 to a common line connect ed to the Neutral 1 N 1 terminal Connect the other side of each load connected to terminals 5 through 8 to a common line connect ed to the Neutral 2 N2 terminal Connect a user power source between the High 1 H1 and Neutral 1 1 terminals and between the High 2 H2 and Neutral 2 2 terminals After completing field wiring to the module install the terminal cover by guiding both of its edges onto the top of the terminal block and sliding it down over the terminals Voltages from user field devices may be present on the faceplate terminals even if the power supply in the I O rack is off Care should be taken when handling the faceplate or any wires connected to it ISOLATED AC OUTPUT MODULE The Isolated AC Output module providing six isolated outputs is available in two versions as listed below Module Catalog Number 115VAC 600 91 230 600 9 12A Isolated AC Output module can be installed any slot in model 60 CPU or in any slot in rack except the left most slot Before installing one of these modules select the I O starting point number for the module by configuring the seven segment DIP s
16. 1 1 connection illustrates the shield grounded to the faceplate Channel 2 2 2 shows the shield connected to the thermocouple device ground Either ground connection can be used on any of the eight channels Terminals CuJl through CJ4 are for the optional cold junction compensation element It is recommended that calibration of the Thermocouple Input module be performed at least every 180 days at normal operating temperature Calibration procedures can be found in Chapter 3 Ref 70 123 2 61 Installation GEK 25361A I O Module Wiring AC OUTPUT MODULE The discrete 8 point AC Output module is available in two versions as listed below Catalog Number 115VAC 1 600 904 230V AC IC600BF905A These modules be installed any I O slot in a model 60 CPU or in any I O slot in I O rack except the left most slot Before installing an AC Output module select the I O starting point number for the module by configuring the seven segment DIP switch on the backplane adjacent to the selected 1 0 slot The 1 0 point selected is the first of eight consecutive I O points for that module For specific switch settings refer to Figure 23 Terminals for field connections are arranged on the faceplate connector in two groups with four outputs in each group Each group has its own H High and N Neutral connection Figure 36 is an AC Output module showing the terminal arrangement along with other module featu
17. 1 Input ON Lights 4 Terminal Cover 2 Circuit Board Terminal Block 5 Markable Lens Surface 3 Box Lug Terminals For Field Wiring Figure 30 INPUT MODULE 1 56 Ref 81 PC 13 General Description of the Series Six GEK 25361A Input Output System The starting I O point for each module is selected by setting the seven segment DIP switch on the back plane adjacent to the I O slot in which the module is inserted The starting I O point establishes starting reference for eight consecutive I O points reserved for that module by setting the DIP switch Refer to Figure 28 or the Installation section of this manual for instructions on setting the DIP switches Input connections for field wiring are arranged in two groups of four inputs each with two neutral con nections in each group Detailed installation instructions can be found in Chapter 2 High Density Input Modules The High Density Input module provides 32 input circuits on one module and allows the user a choice of two modes of operation either 5V TTL IO 50V DC This module provides an optically isolated inter face between the backplane I O bus and user digital circuitry TTL mode or input devices 10 50 DC mode Table 9 is a list of specifications for this module TTL MODE 10 50V DC MODE Power Requirements 5V DC 200 mA maximum Supplied by I O rack power supply User Supplied Voltage 5 0 25V DC 10 50 DC Ripple 100 mV lt 1 0 Current 200 mA plus 7 mA
18. 833 864 X 161 192 xX x 513 544 x 865 896 xix 193 241 xaf 263 376 x 5 897 928 HEU 577 608 x x I 929 960 x 257 288 XL BUB 993 1024 TX X X X X 289 320 641 672 321 352 673 704 X Switch in OPEN Position Depressed to the Left Switches 1 and 2 Should be in CLOSED Position NOT USED Figure 32 DIP SWITCH SETTINGS FOR HIGH DENSITY MODULES Analog Input Modules The Analog Input module is availabe in three versions unipolar bipolar and current Ranges available for each version are shown below The 4 20 mA range can also be configured to read voltages in the range of 1 5V by a change of front panel connections Each of the three versions has been as signed a separate part number and should be ordered as such ENT Bipolar 10 10V 4 20 mA 1 5V Table 10 ANALOG INPUT MODULE RANGES 1 60 Ref 70 150 General Description of the Series Six GEK 25361A Input Output System Each of the above modules functions as an analog to digital A D converter for signals applied to each of its eight input channels The sampled value of the input level is converted to I2 bit binary number which provides a resolution of 1 part in 4096 This number along with binary information which gives various operating conditions and the number of the channel being read is sent to the Input Status Table in the CPU Spe
19. GE Fanuc Automation 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 Seres Six Installation andMaintenance User s Manual GEK 25361A July 1982 Warning Caution and Notes As Used In This Publication WARNING Warning notices are used in this publication to emphasize that hazardous voltages currents and temperatures that could cause personal injury exist in this equipment Caution notices are used where equipment might be damaged if care is not taken In situations where inattention could cause either personal injury or damage to equipment a Warning notice is used NOTE Notes merely call attention to information that is especially significant in 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 and software nor to provide for every possible contingency in connec tion with installation operation and maintenance Features may be described herein which are not present in all hardware and software systems GE Fanuc Automation assumes
20. IC600CM552A IC600CM554A IC600PM506A IC600PM501 A 3 34 MODULE NAME Auxiliary Control Communications Contra Communications Contro Logic Memory 2K CMOS Logic Memory 4K CMOS Logic Memory 8K CMOS Combined Memory Combined Memory Power Supply 115VAC Power Supply 230VAC GEK 25361A FUNCTION Interfaces the CPU to an Aux iliary bus with 1000 inputs and 1000 outputs Contains circuitry for serially interfacing the CPU to a Mini cartridge Tape Unit or a high speed Data Highway Same as above Has additional baud rates and current loop capabilities Contains CMOS circuitry for storing the user s ladder dia gram program Has a Lithium Manganese Dioxide backup battery for memory retention during no power situations Battery will retain memory for about 6 months Combines Register memory Internal memory and Logic Memory 2K CMOS Combines Register memory Internal memory and Logic Memory 4K CMOS Provides 5V DC 12V DC and 12V DC regulated voltages Also used in DPU CPU MODULE RENEWAL PARTS LIST Continued Troubleshooting and Repair GEK 25361A I O System Troubleshooting SECTION 4 I O SYSTEM TROUBLESHOOTING Part 1 POWER SUPPLY Two versions of the I O power supply are available for use in the I O racks standard and high capacity NOTE The Standard and High Capacity power supplies are not interchangeable A Standard power supply must go
21. gt IISV AC 230V AC lt No Connection LI Line L2 Line 2 AC Input 15 2304 AC GND Ground Check the 5V DC output by pulling the power supply module partially out of its slot and measuring the voltage at the screw conection on the board There are 4 screw con nections labeled as show below Se 0 468 6 AC AC Ifthe 5V is out of tolerance replace the power supply NOTE A Printed circuit board backplane or cable short may be loading down the power supply If 5V DC is out of tolerance back out all printed circuit boards and recheck the voltage If still bad replace the power supply If voltage is OK reinsert the 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 Ref 70 6 3 36 70 106 Troubleshooting and Repair GEK 25361A System Troubleshooting INDICATOR CHART Table 5 is an indicator chart that gives a quick reference to the status indicator lights on the I O system modules Brains pue gt Power POWER Power is applied and DC voltage s within Supply tolerance AC DC 1 through 8 Input is energized Input 1 through 8 Output is energized BF I 8 Blown fuse in output circuit No problem High Module is in the Inverting mode Density Input Module is in the Non Inverting mode High Module is in the Inverting mode Density outp
22. 130v 0 30v 10 20 ms 20 5 5 115V 230V Input AC DC 180 260V 0 50 10 20 ms 39 0 5 8 mA 230V Power Requirements 5V DC 104 mA maximum Supplied by 1 0 power supply Power for Input devices must be supplied by the user Operating Temperature to 60 320 to 140 F at outside of rack Storage Temperature 200 to 800 40 to 1 76 Humidity 5 95 non condensing These specifications are common to all I O modules Table 8 SPECIFICATIONS DISCRETE INPUT MODULES 1 55 General Description of the Series Six GEK 25361 A Input Output System Each module contains 8 isolated input circuits AC or DC voltages in the ranges shown in the table can be input to the modules Each input circuit has a high impedance Schmitt trigger which improves the life of the circuitry Maximum turn on voltage is 78 of the nominal input voltage and turn off is 20 of the nominal voltage Each input circuit also contains an opto isolator a rectifier to detect an AC input or a DC input of either polarity and a filter to provide immunity against various noise signals An LED is provided for each circuit which indicates an input ON condition Figure 30 is a 115V Input module that indicates features common to each of the 8 circuit discrete modules An Input module can be inserted in any slot of an I O rack except the left most slot or in an I O slot in a Model 60 CPU ZEN a 008525
23. 3 PIN 44 ORN RED PIN 15 RED ORN NOT USED PIN 94 ORN WHT SOCKET 4 SOCKET 23 PIN 5 WHT ORN SOCKET 5 SOCKET 24 PIN 6 GRN WHT SOCKET 6 SOCKET 25 SOCKET 7 SOCKET e26 BRN WHT SOCKET 27 SOCKET 28 PIN 0 GRY WHT SOCKET e29 PIN e WHT GRY SOCKET ll SOCKET 30 PIN 2 BLU RED SOCKET 2 SOCKET 31 PIN 13 RED BLU SOCKET 13 SOCKET 32 PLUG 2 SOCKET 20 SOCKET 21 SOCKET 22 SOCKET 33 SOCKET 34 PIN 16 GRN RED SOCKET 6 NOT USED SOCKET 35 PIN 7 RED GRN SOCKET 7 NOT USED SOCKET 36 PIN 18 BRN RED SOCKET 48 PIN 37 SHIELD SOCKET 37 ie PIN 49 RED BRN SOCKET 9 LENGTH CATALOG LENGTH CATALOG METERS FEET METERS NUNBER 0 6 16600 0002 100 30 0 iC600WDIOOA 5 LS 16600 0005 200 60 0 16600 0200 0 3 0 1C600WDOIOA 300 90 0 16600 0300 25 15 iC600WD025A 400 120 0 10600904004 50 15 0 10600400504 500 150 0 iC600WD500A NOTE Minimum conduit size for running this cable with the hoods in place should be 2 inches Figure 20 1 0 PARALLEL CHAIN CABLE Ref 70 126 2 39 Installation GEK 25361A The I O Rack The following data is provided as an aid when building cables for connecting a local I O system to
24. Connect the grounding wire from the faceplate to the rack With the board in place in the rack slip the edge connector on the faceplate over the circuit board so that proper contact is made between the two parts An Analog Output module has four channels Refer to Figure 48 for typical user output connections to the Analog Output modules O 10V or MODULE 4 20 mA MODULE 1G 4 10V Individual External Source 18 42 DC Q 20mA 1 LOAD 4 24 20 mA MODULE 4 320 mA MODULE Internal Loop Supply Common Extemal Source LOAD LOAD 18 42V DC 100 mA NOTE Maximum loading of an output channel on the 0 10 V or the 10 10 V module is 5 mA The loading of the 4 20 mA module should be in accordance with ISA transmitter class 2L when using the internal loop supply or class 4U when using an external power source Ref ISA S50 1 Figure 48 ANALOG OUTPUT TYPICAL USER CONNECTIONS Ref 70 131 2 TI Installation GEK 25361A I O Module Wiring For the 0 10V and 10 10 V modules any output channel can be connected as shown For the 4 20 mA module the channels can be connected for internal or external common source operation depending on the setting of the circuit board jumper previously discussed Alternately any individual channel can be connected with its own external source All of the common COMM terminals are con nected together inside the module To minimize capacitive l
25. 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 of the status indicator lights in the I O racks and the originating CPU where ap parent malfunction has occurred Check at CPU Condition of all status lights fall the CPU status lights are on proceed I O troubleshooting f the CHAIN OK status light on the I O Control module is on but one or more of the other CPU status lights are off refer to the CPU troubleshooting section 1 through f the CHAIN OK status light on the Control module is off a CHAIN OK or CHAIN PARITY problem is indicated Proceed I O troubleshooting Check the CPU station I O racks for the condition of the status lights CHAIN OK 1 0 Receiver Light Transmitter Se a era a a a AE GU CCS GO NNNM ON GR power is OK in this and all downstream racks and stations Conti nuity is OK to all downstream stations OFF A power or continuity problem has occurred The CPU RUN and ENABLE lights also turn off Alarm No 1 relay switches sud Corrective Action Locate the last l O rack in the I O chain that has the CHAIN OK light off Check 1 0 Re ceivers and I O Transmitters Check cable connections Check circuit breaker on the power supply If Power statu
26. Remote I O system Received Dota Transmit J Data Shield Received f L Transmit Data z Dota Shield Remote I O Remote 1 0 Driver Receiver 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 22P 1 SLCBT or equivalent Connector Driver and Receiver End D Subminiature Type Cannon DBC25P with 207908 7 Hood or equivalent connector and hood Figure 21 REMOTE TWISTED PAIR CABLE Data Data Terminal Set Shield Transmit Data Receive Dato 11 2 1 Clear To Send Carrier Detect Optional Remote I O Driver or Receiver CABLE SPECIFICATIONS Length Maximum 50 feet 15 Meters Overall Shield Modem 24 AWG Minimum Connector Driver or Receiver End D Subminiature Type Cannon DBC25P with 207908 7 Hood or equivalent Connector Modem User selected Figure 22 REMOTE I O CABLE FOR RS 232 MODEMS Ref 70 110 2 40 70 111 Installation GEK 25361A The I O Rack 1 0 POINT SELECTION After 1 0 racks have been installed cables run and AC power cables connected the racks are ready for installation of I O modules The 1 module starting point numbers should now be programmed by set ting the DIP switches mounted on the rack backplane adjacent to the connectors Refer to Figure 23 which is a guide to con
27. Therefore the I O system can have up to 1000 inputs and 1000 outputs Since only one Logic Memory module can be used and the Auxiliary 0 module is not available as an option for the Model 600 4 slots are available for the optional Data Processor The Model 600 CPU is the only model of the Series Six family that allows the Data Processor option to be installed in the CPU rack The Data Processor option for the Models 6000 and 60 is mounted in its own universal rack with power supply The Data Processor option is more fully described in Section 7 If data storage require ments exceed the capacity of the Data Storage module the Model 600 CPU should be interfaced to a Data Processor in its own rack The Communications Control module is available as an option which allows the CPU to connect to an external Minicartridge Tape Unit and the Data Highway 1 35 General Description of the Series Six Central Processing Unit Figure 19 is the Model 600 CPU which shows the modules available and their locations 1 Data Processor Option Slots 3 Communications Control Option 2 Logic Memory 8K Maximum Figure 19 MODEL 600 CPU 1 36 GEK 25361A Ref 81 PC 37 General Description of the Series Six GEK 25361A Central Processing Unit MODEL 60 CPU For applications not requiring a large quantity of I O the Model 60 Figure 20 is a self contained PC system which combines the CPU and up to 6 I O modules in the same standard 11 slot Series Si
28. Troubleshooting 2 3 3 Replacement Module Concept 3 3 Section 2 Program Development Terminal Troubleshooting Troubleshooting Sequences 1 through 5 3 4 Preventive Maintenance ree me 3 13 Program Development Terminal Renewal Parts List 3 13 Section 3 Central Processing Unit Troubleshooting Fault Isolation And 3 14 Troubleshooting Sequences through 13 3 17 Al rmi Relay z ire her a 3 31 CPU Renewal Parts 3 33 Section 4 System Troubleshooting Part 1 Power a 3 35 Indicator Chart 3 37 Troubleshooting Sequences 1 through 3 44 System Troubles Troubleshooting Sequences 1 4 3 50 System Renewal Parts 3 52 Paint Touch 2 2 6 3 54 Section 5 Module Calibration Analog Input Module REN EE shee 3 55 Analog Output Module 3 58 APPENDIX A Glossary Of Terms 1 Table of Contents xii 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 GEK25361A FIGURES Chapter 1 Basic Block Diagram of Series Six System
29. more than 2000 600 meters from the CPU 50 on 0 1 0 Modules Daisy Chain T l amp Pair Parallel Cable to Local 1 0 Station 500 maximum 1 0 Rack 0 T 1 0 Modules 2 Pair Serial Cable to Remote 1 0 Station 10 000 3km maximum or RS 232 Modem Link to Remote 1 0 Statien isy Chai 6 Parallel Cable to Local 1 0 Station 500 maximum ENDE e EUR REIR PRENSA ERE EE 41 Figure 55 LOCAL I O STATION Ref 70 8 1 113 General Description of the Series Six GEK 25361A Input Output System REMOTE STATION A Remote 1 0 station see figure 56 consists of racks connected in a daisy chain through the parallel bus A combination of 0 modules with a total of either 120 inputs and 120 outputs or 248 inputs and 248 outputs jumper selectable be used in a Remote 1 0 station The first and last rack in a Remote l O station daisy chain be separated by no more than 50 feet 15 meters of cable In addition to the racks on the daisy chain 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 l O Transmit ter 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
30. should be connected to the Local 1 O station CPU station or a model 60 CPU through a serial communication link using RS 232 compatible modems In the Remote I O station racks can be daisy chained from the Remote I O Receiver through I O Receivers in racks other than the first one 1 128 General Description of the Series Six GEK 25361A System Configuration from previous Rack or CPU 10 0 Transmitter Module Rack 15 230 AC 50f t maximum 30 60 Hz between first and last rack in a Parallel Bus Daisy Chain 16 air Twisted Cable To 1 0 Rack in 10 Remote 1 0 Station Rack 1 0 BT e e Receiver 9 Module 15 230V AC To next 1 0 Rack Remot UM 50 60 Hz 2 To 1 0 Rack in Serial Channel 2 Pair Twisted Cable Remote 1 0 Station 5 10 000 maximum or RS 232 Modem to NOTE greater distances 10 racks maximum on Daisy Chain D Transmitter and Remote 1 0 Driver may be placed in any slot in an I O Rack except the leftmost slot which must be an I O Receiver or Remote 1 0 Receiver Figure 63 10 RACK TO I O RACK CONFIGURATION Ref 70 12 1 129 General Description of the Series Six GEK 25361A System Configuration 1 0 RACK WIRING I O rack wiring consists of cabling between racks 115 230V AC power and wiring to and from exter nal devices Interconnections between racks should be made as described in the two previous descriptions
31. 1000 outputs Logic on the module which performs the interfacing includes command status port select and data latches a status multiplexer and control and timing circuits This module also provides interrupt circuitry and control for the Auxiliary I O module and the Communi cations Control module Two 37 pin connectors are accessible on the faceplate of the I O Control module The top connector is for connection to either the Program Development Terminal or the optional Data Processor Unit The bottom connector interfaces the CPU to the primary I O chain Four LED indicators are provided on the front panel of the I O Control module From top to bottom they are DEFINITION On when all I O stations in the primary chain have normal continuity and have received good output parity PARITY On when input data parity is okay ENABLED On when the CPU is in the normal Run mode with outputs enabled DPU On when the optional Data Processor Unit is connected and is operating Figure 12 is the I O Control module and its faceplate showing connectors and LED indicators NOTE If an I O chain is not connected to the I O Control module a jumper plug supplied with each CPU should be connected to the lower connector to terminate the I O chain signals Three jumpers are provided on the board to allow selection of board options The 3 options are Data Processor Present Data Processor Interrupt Enable and Communications Control Interrupt
32. 103 1 104 106 106 1 108 1 109 1 109 I 10 1 1 11 l l 1 2 l 1 14 Table of Contents GEK 25361A CHAPTER 2 Installation Section 1 Rack and CPU Module Installation Quality Control 1 2 1 Packaging cerei 2 2 Visual Inspection eere 2 2 Pre installation Check 2 2 Rack Installation 2 2 Extraction Insertion TOO 2 4 Removing a printed circuit 2 5 Inserting a printed circuit board 2 6 Faceplate Grounding Wire 2 6 Module Installation 2 7 Logic Memory Modules 2 10 Battery Installation eee 2 10 Internal Memory Module 2 14 Register Memory Module 2 16 Arithmetic Control Logic Control Module 2 16 1 0 Control Module 2 18 Auxiliary 1 0 Module 2 18 Communications Control Module 2 19 CPU Power Supply eene 2 22 System Ground 122 2 23 Section 2 The I O Rack System Configuration 2 24 l O Power Supply eere 2 26 System Communi
33. 2 Wall or Panel 0 2 3 2 Hack MOoUhtiligisces d spe rto RP Beret ened els HOS 2 9 3 Extraction nsertion 00 2 4 4 Positioning the Extraction Insertion Tool for Board LE 2 5 5 Positioning the Extraction Insertion Tool for Board 4444 8 n nn 2 6 6 Faceplate Grounding 2 7 7 CPU Module Location yyy ee 28 xiii Table of Contents GEK2SB IA FIGURES Chapter 2 8 Logic Memory Slots 2 10 9 Memory Board Battery Connection 211 10 Board Orientation in Rack eS 2 13 11 Logic Memory Location Switches 2 14 12 Logic Control to Arithmetic Control Ribbon Connector 2 17 13 CPU Power Supply Connections 2 22 14 Typical 2 25 15 I O Power Supply Connections 2 26 16 I O Receiver DIP Shunt Jumper Pack Configuration 2 2 2 2 2 28 17 VO Receiver Configuration Locations 2 29 18 Remote I O Driver Jumper Locations 2 32 19 Remote I O Receiver Jumper Locations 2 35 20 I O Parallel Chain Cable 2 39 21 Remote I O Twisted
34. 27 SYSTEM RESPONSE TIMES TO REMOTE I O Remote I O Addressing A Remote I O system normally responds to a block of 128 inputs 128 outputs or 256 inputs and 256 outputs However eight inputs and eight outputs are used by the Remote 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 1 0 is selected by positioning of a jumper the Remote I O Driver module The unique 1 points addresses for each module in a Remote station are selected by setting the seven segment DIP switch on the backplane adjacent to each slot in the 1 0 rack However all 1 0 points selected must be within the block selected for the Remote I O station The 1 0 points a remote system must be within one of the blocks as listed in Table 28 1 98 General Description of the Series Six GEK 25361A Input Output System 120 Inputs and 248 Inputs and 120 outputs 248 Outputs 1 128 1 256 129 256 257 512 257 384 513 768 385 512 769 1000 2 513 640 641 768 769 896 897 1000 D 9 This block selected allows 96 inputs 96 outputs Q This block selected allows 224 inputs and 224 outputs Table 28 POINT RANGES AVAILABLE IN REMOTE I O STATIONS The address selected for the Remote I O Driver fall anywhere within the range of I O points in a block All I O modules in a Remote I O station including the Remote I O Driver mus
35. 3 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 keyswitch positions The status indicator lights and keyswitches indicate the current operating condition of the CPU and system 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 Be sure to note the positions of the keyswitches on both the CPU and the Program Development Terminal Table 3 is an indicator chart that gives a quick reference for the normal condition and definition of the status indicator lights Refer to Figure 4 which is an illustration of a Series Six CPU showing the location of the Status indicator lights and the keyswitches The numerals and references on the illustration refer to a step in the trou bleshooting sequence Troubleshooting Repair GEK 25361A Central Processing Unit Troubleshooting NORMAL MODULE INDICATOR CONDITION DEFINITION Power POWER ON Power is applied DC voltages are within tolerance Supply CHAIN ON All I O stations in primary chain have continuity Control good output parity and power supply is O K PARITY Input data parity is O K ENABLED CPU is in the normal Run Enabled mode outputs enabled DPU connected and operating
36. After every 100 hours of operation demagnetize the recorder heads If mechanical parts begin to squeak they may be oiled sparingly with TSI 301 oil or equivalent taking care to avoid dripping oil onto other parts or leaving an oil film that may attract dirt deposits Proper care of the tape cartridges can contribute to the long term operation of the unit Tape cartridges should be protected from dirt and dust preferably being stored in closed containers The surface of the tape must not be touched with fingers or other foreign objects Cartridges in storage should be protect ed from heat and electromagnetic fields PROGRAM DEVELOPMENT TERMINAL RENEWAL PARTS LIST A list of the replaceable parts in the PDT is provided in Table 2 Catalog Number Name Function IC600PB553A Processor Board Generates addresses and data via an 8086 microprocessor Contains circuitry for a Direct memory Access DMA between the CPU and the PDT Contains interrupt controller circuitry ICe00DM736A RAM Board 128K bytes of dynamic RAM memory Random Access Memory IC600PB552A PROM Board Contains Executive instructions in PROM memory for proper PDT operation IC600PB55 1 A Video Control Board Video control circuitry keyboard interface serial and parallel data port interfaces IC600WE5OOA PDT to CPU Cable Connects PDT to the CPU Table 2 RENEWAL PARTS LIST FOR PROGRAM DEVELOPMENT TERMINAL 3 13 Cli Processing Gan SECTION
37. Before installing an I O Receiver determine whether the I O Receiver is to be in the last rack of an I O station daisy chain or in a rack within the chain If it is to be in the last rack the I O chain signals must be terminated If the receiver is to be in a rack within the daisy chain it must be configured to continue the VO chain signals through the module passing these signals on to the next I O rack 2 27 Installation GEK 25361A The I O Rack All 1 O Receivers are shipped from the factory configured to continue the I O chain signals through the module Refer to Figure 16 DIP DIP SHUNT SHUNT F2 F3 Factory Setting Last 1 0 Rack in Daisy Chain Continues 1 0 Chain Signals Terminates 1 0 Chain Signals Figure 16 1 O RECEIVER DIP SHUNT JUMPER PACK CONFIGURATION Procedure for configuring I O Receiver if in last rack of a daisy chain Remove jumper from location D1 Remove DIP shunts from locations F2 and F3 These two locations are for storing the DIP shunts or the jumper pack when they are not being used Insert the DIP shunts in locations C1 and D1 Insert the jumper pack in location F2 for storage 2 28 Ref 70 110 Installation GEK 25361A The I O Rack If an Receiver should be removed from the last rack and moved to an upstream rack in a daisy chain the module must be reconfigured to continue the I O chain signals Figure 17 shows the physical loca tions described above H H ae
38. Byte I Parity Byte 2 Figure 15 BASIC WORD STRUCTURE CMOS RAM memory modules require a Lithium Manganese back up battery installed on each module for retention of memory under power down conditions since this type of memory is volatile The Model 6000 CPU must have at least one memory module and can have a maximum of four modules This allows a memory capacity of 2K to 32K words in 2K increments It should be noted that it is physically impossible to have 30K of memory The 4 slots to the left of the Register Memory module are reserved for installation of Logic Memory modules These 4 slots are referenced A B C and D for ease of explanation See Figure 16 It is recommended that the 4 slots are filled from right to left begin ning with slot A LOGIC MEMORY BOARD SLOTS eere C 774571 pi Figure 16 MODEL 6000 LOGIC MEMORY SLOT REFERENCE When installing or removing a memory module it is recommended that you use the extraction insertion tool to install or remove the module This tool is furnished with each Series Six CPU Ref 70 55 70 1 1 29 1 30 General Description of the Series Six GEK 25361A Central Processing Unit Relatively small amounts of excess charge can cause very intense elec trostatic fields in metal oxide semiconductor MOS devices damaging their gate structure When the board covers are removed avoid handling the circuit board under conditions favoring the build up of s
39. CPU rack For applications requiring no more than 192 points the Model 60 is a complete system within one rack The I O Control module connects the Model 60 CPU to an I O system having a maximum of 256 inputs and 256 outputs 2K Model or 1000 inputs and 1000 outputs 4K Model The 6 I O modules which can be located in the CPU rack will allow 192 inputs or 192 outputs or a combination of inputs and out puts up to total of 192 The I O modules selected must not exceed 100 units of load See Chapter 2 for details If more than 6 I O modules or 192 I O points are required for a particular application addi tional I O racks must be used The optional Communications Control module is offered with the Model 60 This allows the Model 60 to be interfaced to the Minicartridge Tape Unit and the Data Highway If the Data Processor option is used with the Model 60 it is located in a separate rack with its own power supply The Data Processor Option will connect by cable to a port connector on the I O Control module NOTE In order for the Model 60 to function properly using only the I O modules contained within its rack a terminator plug supplied with each CPU must be connected to the I O connector lower connector on the I O Control module 1 39 General Description of the Series Six GEK 25361A Power Supply SECTION 3 POWER SUPPLY The power supply used in the Series Six family of programmable controllers is a multiple output
40. Electric Cable Co 22P1 SLCBT or equivalent Connector Driver and Receiver End D Subminiature Type Cannon DBC25P with 207908 7 Hood or Equivalent connector and hood Figure 50 REMOTE I O CONNECTION USING TWISTED PAIR CABLE 1 100 Ref 70 110 General Description of the Series Six GEK 25361A Input Output System Data Data Terminal Set Shield 2 Data 2 Receive Data 3 VER da it D 3 7 Sianal Ground 1 Clear To Send v 8 Carrier Detect Mark Optional 23 Remote 1 0 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 5 1 REMOTE 1 0 CONNECTION USING RS 232 MODEMS If connection is to be by the RS 232 method control signals are available if required by the RS 232 device Jumpers would need to be changed to configure both the Remote Driver and Receiver to recog nize these signals If RS 232 outputs such as Request to Send are expected RS 232 MARK and SPACE signals are available for use as required Ref 70 111 1 101 General Description of the Series Six GEK 25361A Input Output System 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
41. INPUT MODULE The interrupt modules can be used in a Model 60 CPU a CPU station or a Local I O station They can not be used in a Remote l O station located at the distant end of a serial link The Extended Function Set must be selected in order to use an Interrupt Input module The eight interrupt input connections on a module are arranged in four groups of two isolated inputs each The eight inputs on the main 1 0 chain Interrupt module correspond to subroutines through 8 and the eight inputs on the auxiliary I O chain Interrupt module correspond to subroutines 9 through 16 When the CPU is initially powered up or set to the RUN mode the CPU clears the Interrupt Input modules Thereafter any interrupts which occur will be latched on the appropriate interrupt module A signal will also be sent to the CPU alerting it that an interrupt has occurred The CPU will read the inter rupt module and place the state of each interrupt in the input status table The CPU will then execute the subroutine associated with the highest priority interrupt 1 2 3 etc in order interrupt one time then the next one in sequential order When all of the interrupts that were read have been serviced the CPU resumes operation at the point where it was interrupted 1 68 Ref 82 PC 3 General Description of the Series Six GEK 25361A Input Output System AC Output Module AC Output modules are available in either a 115V AC or 230V AC version The outputs are capab
42. Message received correctly OK Off Data incorrect because of parity overrun or framing errors bad data block or the Serial Link has timed out TAPE On Tape Mode Data stream normal OK Off Data stream interruption caused by parity framing or overrun errors unsuccessful tape comparison or timeout on tape link Table 4 COMMUNICATIONS CONTROL STATUS INDICATORS There are 2 switches located at the top of the module These are used to initiate operation during the reading from or writing to external tape units A tape and CPU data compare mode is also initiated by a switch action 1 34 General Description of the Series Six GEK 25361A Central Processing Unit MODEL 600 CPU The Model 600 CPU is functionally identical to the Model 6000 however the Logic Memory and 1 0 capacity is not as great An important feature is that a Data Processor Unit can be contained in the same rack Logic Memory is allocated one slot to contain one Logic Memory module thereby allowing the CPU user program capacity in 16 bit words to be 2K 4K or 8K of CMOS RAM The Logic Memory programming switches on the Internal Memory module must be programmed for slot A Parity error detection is standard as on the Model 6000 The register memory is standard which allows 1024 sixteen bit registers The optional Auxiliary I O module cannot be used on the Model 600 CPU The 1 0 Control module is identical to the I O Control module used in the Model 6000 CPU
43. O modules can easily be interchanged between lO Racks Available modules are listed in Table 3 Ref SI PC 45 General Description of the Series Six GEK 25361A Introduction INPUT MODULES OUTPUT MODULES 8 Circuit Modules 8 Circuit Modules 2 amps 12V AC DC 12V DC Sink or Source 24 48V AC DC 24V DC Sink or Source 115V AC DC 48V DC Sink or Source 230V AC DC 115VAC 230V AC 32 Circuit Modules 32 Circuit Modules 1 4 amp 5V TTL 5V TTL 10 50V DC 10 50 V DC 8 Circuit Analog Modules 4 Circuit Analog Modules 12 bit A D conversion 12 bit D A conversion 0 10VDC 0 10V DC 4 to 20 mAA to 5V DC 4 20 mA lOto lIOVDC 10 to DC 8 Interrupt Circuits 6 Circuit Module 2 amps Reed Relay 8 Circuit Thermocouple 6 Circuit Module 3 amps Type J Isolated 115V AC Type K Isolated 230V AC 5 SYSTEM INTERFACE MODULES Local Interface Remote Interface Receiver Remote I O Receiver lO Transmitter Remote l O Driver Table 3 MODULES General Description of the Series Six GEK 25361A Introduction An I O rack can be located up to 2000 feet with no more than 500 feet between links from the CPU when using I O communications originating at a parallel I O transmitter IOT Using a serial communica tion channel an I O rack can be located up to 10 000 feet from a Remote I O Driver Greater distances when using an RS 232 modem link A more detailed explanation of the I O structure is provided in Section 5
44. Option Jumpers There are several circuit board jumpers on this module which are used for option selection and chain signal termination Jumpers are factory set prior to shipment and must agree with the Remote Driver to which it is to be connected Table 33 lists the factory settings and alternate settings for the Remote Receiver options Factory Setting Optional Setting Baud Rate 57 6 Kb User Selected Parity Yes Odd Yes Even or No Communiations Failure Remote Turn All Outputs Off Hold All Outputs at Last State JO Chain Signals Chain Signals have conti Terminate I O Chain Signals nuity through this module at This Module Table 33 REMOTE I O RECEIVER OPTIONS Instructions for reconfiguring any of the circuit board jumpers to change options can be found in the In stallation chapter of this manual Other jumper options are required when selecting the RS 232 option and are listed in the Installation chapter In addition other jumpers are for future expansion or production testing and should not be altered CPU STATION The CPU I O station Figure 54 consists of a Series Six 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 from the CPU Each I O rack in the chain includes a Power Supply module standard or high capacity an I O Receiver module and up to 10 additional mo
45. Pair Cable 2 40 22 Remote I O Cable for RS 232 Modems 2 40 23 Switch Settings for I O Point Selection for 8 Circuit Modules 2 4 1 24 Typical Input 2 45 25 Typical Input Module Wiring Connections 2 47 26 High Density Input Module I O Point Selection xou ettet thee 2 48 27 High Density Input Module 2 49 28A Typical User Input Connections TTL Mode 2 50 28B Typical User Input Connections 50 Mode 2 51 29 Analog Input Module I O Point Selection 2 52 30 Typical User Input Connections for Analog 2 53 31 Interrupt input Module 2 54 32 Typical User Connections 2 56 33 Thermocouple Input Module I O Point Selection EE 2 57 34 Jumper 2 60 35 Typical User Connections 2 61 36 Output 2 63 37 Output Module Typical User Connections 2 64 38 Isolated AC Output Module 2 66 39 Isolated AC Output Typical User Connections 2 67 40 DC Output 2 69 41 DC Sink and Source Output Module Wiring 2 70 42 DC Output Typical User Connections
46. RO OYA GO NS Ow uh PG M 00 Qe in Ww Hoe FE IB ES PEEP IEE SELES bi 4 1E 564 TIL EJ 1 DATA INVert Light 3 User Connector 8lock On The module is in the Inverting mode NOTE Off module is in the Non Inverting mode In early versions of this module the sense of the DATA INVert light is the reverse of the le 2 NON NV INV Jumper scription above i e the light is On in the Nc In A B Connected Sets module to the Inverting mode Non Inverting mode B C ConnectedSets module to the Invert ing mode Figure 31 HIGH DENSITY INPUT MODULE Ref 82 PC 5 1 59 General Description of the Series Six GEK 25361A Input Output System The starting I O point number for a High Density Input module is selected by setting the seven segment DIP switch on the backplane adjacent to the I O slot containing the module When a DIP switch is confi gured according to the chart in Figure 32 a group of 32 consecutive 1 0 points is reserved for that module beginning with the selected 1 point INPUT DIP SWITCH INPUT DIP SWITCH INPUT DIP SWITCH NUMBER POSITION NUMBER POSITION NUMBER POSITION e EUN 353 384 705 736 z Hg 385 416 z fa xf ia 65 96 x 417 448 x x 769 800 97 1281 xx 449 480 x xix 801 832 x 129 160 x 481 5312 x x xix
47. Rack and CPU Module Installation INTERNAL MEMORY MODULE The Logic Memory location switches which tell the CPU how much memory has been installed in a Model 600 or 6000 should be programmed before the Internal Memory module is installed in the CPU Position the module in front of you so that the Logic Memory location switches are to your upper right See Figure 11 for an illustration of the switches 2K 4K 6K eK 10K 12K 14K 16K 18K 20K 22K 24K 26K 28K 30K 32K toggle is on depressed to the closed position which will activate a 2K increment of memory NOTE The DIP switch settings in the example are programmed for 28k of memory Figure 1 1 LOGIC MEMORY LOCATION SWITCHES 2 14 Ref 70 102 Installation GEK 25361A Rack and CPU Module Installation Note that there are 4 rows of switches which have 2 DIP switches per row Each DIP switch has 8 tog gles or positions per switch for a total of 16 toggles per row The right row of switches control logic Memory slot A the next row of switches control Logic Memory slot B the next row controls slot C and the left row controls slot D Each toggle in each row of switches turns on a 2K increment of memory in the appropriate slot An increment of memory is activated turned on when the proper toggle is depressed to the closed position The toggles of the switches are connected so that the toggle at the top DIP switch position I turns on the first 2
48. See Figure 64 Wiring between external devices to and from the I O racks should be run in conduit The cables will be run into the rack through a wiring tray located at the bottom of each I O rack Each group of wires or cable will run up to the applicable I O module and fan out to box lug terminals The box lug terminals will accept two No 14 AWG or one No 12 AWG wire per terminal After all wiring has been completed and checked a cover snaps over the wiring tray for operator safety and to give a neat appearance For detailed instructions on wiring of individual types of modules refer to the following chapter Installation in this manual From CPU or previous O Rack Two Twisted Pair Serial Cable to 10 000 3km If a or Cable from Modem RS 232 Link Remote Station Parallel Bus 16 Pair Twisted Cable 1 0 Receiver Module I5 230V AC 90 60 Hz uuuuuyuuuuuuu 1 0 Rack in Daisy Chain Wiring to from External Devices Wiring tray contains wiring Terminal Assembly Matching cover attaches Box Lug Terminals 2 No 14 or 1 12 Awg wire per terminal T Remote 1 0 Receiver if first rack in a Remote 1 0 Station Figure 64 1 0 RACK WIRING SCHEME 1 130 Ref 70 13 General Description of the Series Six GEK 25361A Data Processor SECTION 7 DATA PROCESSOR This section describes the hardware and functions of the Data Processor Unit DPU for
49. Ta 5 15 18 MTG 10 25 63 ue RESON ARE 260 35 46 1 68 FRONT o o o o D 2 Q 2 9 Q 2 Q 9 13 98 355 09 e MOUNTING 12 84 BRACKET 326 13 E 1 62 1295 14 i 5 15 62 345 94 SEE BELOW 1 18 72 REF 1475 481 S P nnn 2 D 9810 P un i 3 Lfd i 41 09 Tre A 2 28 10 161 3 75 195 25 NIRE DUCT ONLY SUPPLIED OK VO RACK 98 9 S m f Brno FOR RACK MOUNTING REMOVE MOUNTING E j n BRACKETS TURN THEM 90 DEGREES AND 475 i 1099 MOUNT ON FRONT OF RACK 298 45 DIMENSIONS IN 1 ARE MILLIMETERS RECOMMENDED MOUNTING HARDWARE 5 16 18 WITH FLAT WASHER 2 20 571 WEIGHT 45 185 WITH ALL KEYHOLE DETAIL SCOTS FILLED ANO POWER SUPPLY INSTALLED WEIGHT 30 LBS WITH ALL SLOTS EMPTY AND POWER SUPPLY INSTALLED RACK MOUNTING DIMENSIONS 10 25 1 poem MR 18 98 260 35 482 091 48 2 9 09 2 28 FRONT T IDEE 307 12 49 ded BRACKET 4 98 555 09 8 49 215 64 FRONT 18 02 457 70 FOR WALL AND PANEL MOUNTING REMOVE MOUNTING BRACKET TURN THEM AROUND 30 DEGREES AND MOUNT REAR OF RACK DIMENSIONS 1 ARE MILLIMETERS Ref 44C716406 sheet 1 44C716406 sheet 2 3 75 MIRE DUCT ONLY SUPPLED OK YD i95 25 1RE DUCT
50. Type Range Unipolar Bipolar Current Table 21 ANALOG OUTPUT MODULE RANGES Each module has 4 output channels and provides conversion from 12 data bits An Analog Output module receives from the CPU twelve bits of binary output data and a binary number indicating which channel is to be accessed The module functions as a digital to analog D A converter and delivers the correct output voltage or current to the designated channel Conversion from 12 data bits provides a resolution of 1 part in 4096 Specifications for the Analog Output module are as shown in Table 22 Power Requirements 5V DC 1 5A Supplied by I O Rack Power Supply User Supplied 4 20 mA 18 42 DC Regulated 9 100 mA Can be common for Module only Optional all Channels or for individual channels Output Current 5mA On voltage ranges Output Load Capacitance 750 pF maximum Cross Talk Offset of channel change from full scale to Full Scale is 0 005 Accuracy Resolution 12 Binary Bits 1 part in 4096 Linearity 0 012 of Full Scale Noise Current Loop lt 1 uA rms DC to 10 KHz Total Output Drift 10 ppm of Full Scale per C Typical 0 Volts out 30 ppm of Full Scale per C Maximum Total Output Drift 20 ppm of Full Scale per C Typical Full Scale Table 22 ANALOG OUTPUT SPECIFICATIONS Each module contains an address decoder to determine when the module is being addressed opto
51. User Terminal Block 3 K1 to K6 Mercury Wetted Contact Reed 8 Circuit Board Terminal Block Relays 9 LED1 to LED6 On When Relay Coil 4 Fuse Clip European Style Fuses 6 Energized 5 Fuse 3A Normal Blow 6 10 Markable Lens Surface Figure 49 REED RELAY OUTPUT MODULE 1 80 Ref 82 PC 19 Installation GEK 25361A Module Wiring One of the circuit board jumpers is set to select the de energized state of each relay to have either normally open N O or normally closed N C contacts In addition a second jumper in each circuit is in series with the RC protection circuit for each output When this jumper is removed the RC circuit is re moved which allows operation with low level analog and instrumentation signals where arc suppression is not a factor during normal operation Install the printed circuit board by using the extraction insertion tool Connect the grounding wire from the faceplate to the rack With the board in place in the rack slip the edge connector on the faceplate over the circuit board so that proper contact is made between the two parts Secure the faceplate to the rack using the quarter turn thumbscrews NOTE A Reed Relay Output module must be installed in a vertically oriented position Otherwise the module will not function properly Figure 50 is a schematic representation of a Reed Relay output circuit circuit No 1 is illustrated each of the six circuits are identical SOURCE V
52. 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 I O racks Each of the i O communica tion modules and stations are described in detail later in this section Each 1 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 and the bottom one is used to forward data to 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 a daisy 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 The bottom connector on the last i O Receiver is not used for I O signal connection thereby allowing a PDT to be connected to the last rack in a CPU station or a Local i O station I O racks separated by no more than 500 feet 150 meters can be connected by use of an I O Transmitter through a 16 pair cable to an I O Receiver in the first I 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 howev
53. by the program Figure 7 illustrates the sequence of the scanning technique used by the Series Six detailing the l O scan Each Model of the Series Six CPU is mounted in a universal rack which is a standard 19 inch rack or panel mount that is described on page 6 1 13 General Description of the Series Six GEK 25361A Central Processing Unit HOUSEKEEPING PDT WINDOW DATA PROCESSOR WINDOW COMMUNICATION 5 CONTROL WINDOW EXECUTIVE ROUTINE LOGIC MEMORY SOLUTION MODULE ADDRESS FROM CPU OUTPUT DATA FROM CPU CPU SCANNING SEQUENCE CYCLE I O cycle occurs 125 times during each I O scan once for each of the 125 possible I O addresses Each address references 8 inputs and 8 outputs Figure 7 SCAN SEQUENCE 1 14 Ref 78 98 General Description of the Series Six GEK 25361A Central Processing Unit MODEL 6000 CPU The Model 6000 is the most powerful CPU in the Series Six family A user program containing as many as 32 768 32K sixteen bit words can be stored in the logic memory of the Model 6000 A photograph of the Model 6000 CPU is shown in Figure 8 Module locations are indicated along with as sociated hardware ut Eom p too 50 MEMORY E Y QA 1 Auxiliary Option If Selected 6 Terminal Strips 2 Program Development Terminal or Data Auxiliary External Battery Conn
54. center line of the display Linearity of the vertical scanning can be checked by observing crowding or spreading from top to bottom in the raster and displayed information Horizontal Centering Video Center The horizontal centering control L101 allows centering of the picture from left to right Rotate L101 slowly until the raster and displayed information are centered in the display area Display Width The display width control L102 allows adjustment of the width of the display area Rotate L102 until the display area is sufficiently filled Horizontal Linearity This control L103 allows adjustment to provide equal spacing on either side of the center line Horizontal linearity can be checked by observing crowding or spreading from left to right in the raster and displayed information Troubleshooting and Repair Program Development Terminal 25361 Troubleshooting If the problem still persists after making the above checks and adjustments proceed according to the type of malfunction encountered Refer to the following table PROBLEM NO DISPLAY OR DISTORTED DISPLAY NO COMMUNICATIONS NO RESPONSE TO KEYBOARD ENTRY DISPLAY OK NO RESPONSE FROM SOME KEYBOARD PUSHBUTTONS INTERNAL MAGNETIC TAPE UNIT FAILURE PROCEDURE N Replace Replace Replace Replace Replace Replace Replace Replace Check CRT to PDT cable connection at both ends Adjust CR
55. connected in this manner thereby extending the Remote station an additional 2000 feet 600 meters NOTE The total number or 1 0 points assigned to a Remote 1 0 station either 120 120 I O or 248 248 1 0 cannot be exceeded regardless of the rack configuration The Remote I O station connects to an upstream 1 0 rack in either a CPU station or Local I O station or to an 1 0 slot in a model 60 CPU 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 communications module in the model 60 the CPU station or Local 1 0 station is a Remote I O Driver while the communi cations module in the Remote I O station is a Remote I O Receiver The serial communications link to the Remote 1 0 station can be up to 10 000 feet 3 Km using a two twisted pair cable Using an RS 232 modem link the distance between local and remote 1 0 is virtually unlimited NOTE A Remote 1 0 Driver module cannot be installed a Remote I O station A Program Development Terminal cannot be connected to a Remote station Figure 56 illustrates a possible configuration for a Remote l O station The illustration shows how a Remote 1 0 station can be extended an additional 2000 feet 600 meters by using I O Transmitters to connect additional racks to the parallel bus 1 114 General Description of the Series Six GEK 25361A Input Output System Model 60 CPU C
56. detected with communications between Remote l O Driver Receiver 1 Communication link good Local OK 0 Fault in Remote I O Driver module Remote I O Driver operation normal Heartbeat This input cycles from 0 to 1 0 1 0 1 with each I O scan when Remote I O is operating normally If any input status 4 7 is set to zero cycling stops and the status will contain the last valid data re ceived 0 or 1 Table 29 REMOTE I O DRIVER INPUT STATUS INFORMATION 1 105 General Description of the Series Six GEK 25361A Input Output System 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 fnputs 4 7 listed in Table 29 These indicators and their meanings are listed below in table 30 in the same order as they appear on the module faceplate Indicator gDeflnmon LOCAL ON Remote I O Driver module operating normally OK OFF Fault in Remote I O Driver LINK ON Communications link between this module and Remote Receiver good OK OFF Communications error between this module and 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 PARITY ON Remote system has no parity errors operation normal OFF Parity error detected in Remote I O system CPU will stop unless
57. each System as an aid for insertion and extraction of modules MODULES Each module consists of 2 parts the faceplate and the logic board All printed circuit boards are mount ed vertically in the rack with 11 card or module slots available plus a slot for the power supply After each module is inserted into its slot the faceplate is secured to the enclosure by 2 quarter turn thumb screws one at the top and one at the bottom of the faceplate The faceplate for each of the I O CPU or Communications Interface modules is 12 46 inches high x 1 175 inches wide 316 5 x 29 85 millimeters The faceplate on the power supply module is 12 46 inches high x 2 67 inches wide 316 5 x 67 8 millimeters See Figure 4 The cover is engraved with the module name as an identifier Most of the CPU modules have a plastic cover centered on the module with legends for indicator LED s Light Emitting Diodes The LED s indicate the state of various status or error conditions in the system Ref XI W 1 5 General Description of the Series Six GEK 25361A Introduction 1 175 in 29 85 mm 12 46 in 316 5 365 Ai ENABLED Power Supply Others Figure 4 SERIES SIX FACEPLATES BACKPLANE The CPU and DPU rack backplane consists of two 41 pin connectors for each slot that are connected by wire wrapping Common signals connected between each connector of the backplane form a bus STRUCTURE The 1 0 structure allows flexibility to the user in that I
58. end of the serial communications link using a two twisted pair cable or to a modem located no more than 50 feet 5 meters from the Remote I O Receiver The lower connector 37 pin provides a connection through 16 pair parallel bus cable to an I O Re ceiver module located in the next downstream rack in a Remote I O station If no connection is to be made to 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 module Status Indicators The Remote 1 0 Receiver has four LED indicators visable through the faceplate lens The legends on the faceplate lens are the same as those on the Remote I O Driver Table 32 defines the status provided by these indicators INDICATOR DEFINITION LOCAL ON Remote 1 0 Driver module operating normally OK OFF Communications failure or Addressing Difference between Local and Remote ON Communications link between this module and Remote I O Driver esta blished valid OFF Communications failure between this module and Remote f O Driver ON Remote system is operating normally OFF Fault in Remote I O system lllegal address block loose connection power supply failure Table 32 REMOTE I O RECEIVER INDICATOR STATUS 1 109 General Description of the Series Six GEK 25361A Input Output System
59. instructions Reset the Arithmetic Control and Logic Control boards Replace the Arithmetic Control board Replace the Logic Control board Ref 81 K 25 3 29 Troubleshooting and Repair GEK 25361A Central Processing Unit Troubleshooting The CPU will not communicate with the PDT Check the cable connector from the PDT to the CPU be sure that it is mated securely Insure that the PDT will work with another CPU Reset the I O Control board Arithmetic Control board and the Logic Control board If reseating does not solve the problem replace the above boards one at a time in the order given above Parity error on initial power up Call up the Supervisor display on the PDT and perform the CLEAR SCRATCH PAD AND TRANSITION TABLE PARITY ERROR and CLEAR LOGIC MEMORY PARITY ERROR functions DPU light not on lO Control module and DPU is not connected Check I O Control module board option jumpers Jumper should be connected from to 3 30 Troubleshooting and Repair GEK 25361A Central Processing Unit Troubleshooting 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 7 Auxiliary Battery eo e 6 28V DC _ o Connection O eiu AC Input Alarm 2 O 18 030 AC e Relay contac
60. last I O Receiver in the daisy chain a jumper pack must be removed from its socket at location Di and DIP shunts inserted into the sockets at locations Cl and DI When installed in these locations the DIP shunts will cause the I O chain signals to terminate J UMPER DI pack DIP DIP JUMPER SHUNT SHUNT PACK F2 F3 F2 F3 Factory Setting Last I O Rack in Daisy Chain Continues I O Chain Signals Terminates 1 0 Chain Signals Figure 47 T 10 RECEIVER DIP SHUNT JUMPER PACK CONFIGURATION 1 93 General Description of the Series Six GEK 25361A Input Output System If an I O Receiver should be removed from the last rack 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 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 D1 or the DIP shunts are not installed 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 Connectors 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 paral
61. maximum CPU DPU High Capacity I O Rack Power Supply Output 5V DC 16 5 A maximum CPU DPU and 12V DC 1 5 A maximum High Capacity 12V DC 10 A maximum 1 0 Rack 5V DC 6 1 A maximum Standard 1 0 Rack Table 34 POWER REQUIREMENTS FOR CPU DPU AND I O RACKS 1 124 General Description of the Series Six GEK 25361A System Configuration INITIAL SYSTEM CHECKOUT It is recommended that an initial basic system checkout be performed before the system is configured mounted cables run and wiring of external devices to the 1 0 modules is made The following list of items to be checked is intended as a guide to the user Visual Verify that all racks modules and cables conform to the system configuration as ordered Record model and serial number If you have to communicate with the General Electric Co regarding any problems this information must be given to them Check for physical damage during shipment If any damage is noted notify the carrier immediately You should also call the Programmable Control Product Service Specialist in Charlottesville Virginia at 804 978 5624 A Customer Service representative will give you further instructions at this time Each Input or Output module has a seven position DIP switch mounted on the I O rack back plane adjacent to its respective slot in a rack Select and configure the proper VO module start ing point at this time When modules are mounted in the CPU and or I
62. microprocessor slice The Am2903 is especially useful in arithmetic oriented processors and in addition provides a special set of instructions which eases the implementation of multiplication division and other time consuming operations The faceplate has 2 LED indicators Run and Check The executive routine in the sweep execution se quence contains a self test routine which is executed once per sweep If several conditions are met normal the CHECK LED remains on If the CPU fails the test if the clock stops or if anything interrupts the sweep for more than 200 milliseconds the LED goes out The 200 milliseconds is generated by a re triggerable one shot and is the watchdog timer for the Series Six The RUN light when on indicates that the CPU execution sequence is proceeding normally the self test has passed and the I O scan is completed at least once every 200 milliseconds NOTE The watchdog timer interval is 200 msec 50 msec 1 20 General Description of the Series Six Central Processing Unit 1 Connector for interfacing 2 CHECK Light 3 RUN Light Ref 81 PC 18 to Logic Control Figure 11 ARITHMETIC CONTROL MODULE GEK 25361A General Description of the Series Six GEK 25361A Central Processing Unit CONTROL The I O Control module interfaces the CPU s bus to the main I O bus which allows up to 1000 inputs and
63. module to the Invert GEK 25361A 4 8574535 1 2 a 4 5 a i 2 3 4 E D i 2 3 14 5 1 2 3 4 5 7 a 5V TTL 3 Fuse TTL Module 3A normal blow IO 50V Module 1 A normal blow 4 User Connector Block NOTE In early versions of this module the sense of the DATA INVert light is the reverse of the des ription above i e the light is On in the Non Inverting mode Figure 41 HIGH DENSITY OUTPUT MODULE 1 82 Ref 82 PC 6 82 PC 4 General Description of the Series Six GEK 25361A Input Output System NOTE When using a High Density Output module to drive a High Density Input module both modules should be configured in the same mode either In verting or Non Inverting Following this procedure will ensure that the bit values sent from the Output Status Table to the Input Status Table are not inverted The On state of an output point results when a 1 is in the Output Status Table with the module in the Non Inverting mode Conversely an Off state exists with a O in the Output Status Table On the 10 50V module an output terminal in the On state is virtually at the same voltage as the module common COM terminals An output terminal in the Off state floats A TTL module operates with negative logic i e a 1 in the Output Status Table causes the correspond ing output voltage to go low To use positive logic the module s
64. 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 useful ness of the information contained herein No warranties of merchantability of fitness for purpose shall apply Copyright 1987 GE Fanuc Automation North America Inc GEK 25361A Preface This manual provides the reader with the information required to in stall and maintain the Series Six family of Programmable Controllers The Series Six family includes Central Processing Unit models 6000 600 and 60 along with a flexible Input Output lO system and a Program Development Terminal for entering user created ladder diagram programs Chapter provides a general description of the hardware used in a Series Six system Sufficient information is provided to enable the user to plan select and assemble a system suited to virtually any application Chapter is a guide to the installation of a Series Six system Includ ed is a recommended sequence of installation setting of switches requiring configuration in the field connection of cables and wiring of the I O modules Chapter Ill provides the basic information needed to maintain Series Six system Included are guides to the troubleshooting and repair of the Program Development Terminal Central
65. of the load is con nected through the power source to terminals SI through S6 Each terminal will accommodate up to one No 12 AWG or two No 14 AWG wires Further instructions for installation of this module can be found in Chapter 2 of this manual VO SYSTEM CONFIGURATION A Series Six I O system can be configured by using 3 types of interconnected I O groupings of racks An I O system is compatible with all 3 models of Series Six CPU s The systems stations are de scribed in this section I O racks are connected by interface modules in the CPU or I O racks Interfacing is through the parallel bus channel using a 16 pair shielded cable for the CPU I O station and the Local station Interfacing to the Remote I O station is through a serial communication channel using a 2 pair shielded cable or RS 232 modem link The number of I O racks and modules a system is determined by the number of I O points supported by the model of Series Six CPU used in a system Each I O rack contains a power supply an interface module and up to 10 additional modules The station configuration will be explained in more detail in the illustrations of each I O station in this section VO SYSTEM COMMUNICATION MODULES The I O system communication modules connecting I O racks to the CPU and I O racks to I O racks are described in this section VO RECEIVER The function of the I O Receiver Figure 46 is to interface the I O chain parallel bus to the I
66. on the power supply Voltages must be within the specified range Voltage 4 75 to 5 25V DC 11 40to 1260V DC 11 40to 12 60VDC These voltages may be checked on the terminal board located at the side of the power supply The following illustration shows the location of each terminal for checking the voltages TERMINAL 9 Used by Video Control Processor Control PROM RAM and Tape Interface Boards 8 GND 7 GND 6 2V Used by CRT 5 12V Used by Video Control and RAM Boards 4 2V Used by Video Control RAM and Tape Interface Boards 3 GND 2 NEU ll5or 230V AC HOT NOTE A printed circuit board mother board or cable short may be loading down the power supply Remove circuit boards that use the voltage in question and check again If any voltage is out of range replace the power supply Check all of the internal cable connections to insure proper seating Figure 2 previous page shows the location of the various cables Reseat the circuit boards in the PDT Board positions are shown in Figure 2 Ref 70 112 3 7 Troubleshooting and Repair GEK 25361A Program Development Terminal Troubleshooting To change the PDT power supply use the following procedure Remove AC power to the PDT by unplugging the line cord Set the PDT on a table with the display screen facing up Open the cable storage compartment door and remove 2 screws holding the bottom of the power supply bracket Remove 2 screws holding the to
67. ore Line 2 L2 230V AC Ground GND Terminal Board on Front Panel Figure 29 10 POWER SUPPLY BLOCK DIAGRAM outputs Two versions of the I O power supply are available dependent on the I O load to be used in a rack Chapter 2 INSTALLATION describes how to determine the I O load in a rack Voltage provided to the rack is 5V DC at 6 1 amps standard rack or 5V DC at 16 5 amps 12V DC at 1 5 amps and 12V DC at 1 O amp high capacity rack 1 32 Rc f 7n 116 General Description of the Series Six GEK 25361A Input Output System Auxiliary Circuit Board An auxiliary circuit board is mounted in the I O power supply module The auxiliary circuit board IOAXI senses the 5V DC output to determine if it is within its normal operating range A protection signal PSOK is generated if the 5V is within its specified limits The PSOK signal is normally at OV when the power supply is on and 5V is within its normal limits When the power supply is turned off or the 5V drops below 4 75V PSOK switches high which provides a power fail signal to the CPU When connecting an AC power source to an 1 0 rack ensure that all AC input connections are identical on each of the terminal blocks on each rack Do no cross Line 1 LI and Line 2 L2 A difference in potential may result which can cause damage to equipment MODULES Each I O module uses one physical I O slot an I O rack and can be placed anywhere in the I O structure A m
68. outweigh the compara tively small cost of duplicate modules If you did not purchase a duplicate set of modules with your initial system we recommend that you con tact your General Electric Sales Engineer and do so Then with the help of this manual and the staff at the Programmable Control Service Center you will be able to troubleshoot and repair just about any problem that may arise NOTE The following symbols are used to identify steps in the troubleshooting sequences HEX symbol PDT sequence Square symbol I O system sequence Q CPU sequence Corrective action to be taken for repair 3 3 Troubleshooting and Repair Program Development Terminal Troubleshooting GEK 25361A SECTION 2 PROGRAM DEVELOPMENT TERMINAL TROUBLESHOOTING Q Initial troubleshooting steps for any suspected Program Development Terminal PDT malfunction should include the following 34 Check the keyswitch position on both the PDT and CPU Insure that the proper sequence of pushbuttons was entered Check all external cable connections If there is a communications problem with a CPU check for proper PDT operation by connecting the PDT to another CPU if one is available Check for blown fuse Ensure that the fan filter is clean and passes air easily Failure to do so on a regular basis can result in overheating of the PDT and possible erratic operation Troubleshooting and Repair GEK 25361A Program Development Term
69. print ed circuit board using the extraction insertion tool Connect the faceplate grounding wire and install the faceplate by placing it in position and securing it by turning the quarter turn thumbscrews clockwise Connection from the Remote I O Driver to a Remote I O station is by a two shielded twisted pair cable for direct cable connection up to 10 000 feet 3 Km or a cable with a length up to 50 feet 15 meters to a modem for RS 232 connection Refer to Figures 50 and 51 in Chapter 1 for connector cable and wiring specifications These cables are to be user supplied REMOTE I O RECEIVER A Remote I O Receiver should be installed in the left slot of the first I O rack in a Remote I O station The Remote Receiver does not require an I O address Before installing a Remote Receiver module several jumper plugs on the printed circuit board must be configured to be compatible with the Remote I 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 Figure 19 shows the board location for each of the jumpers 2 34 GEK 25361A Installation The I O Rack amp 90 lt lt Figure 19 REMOTE RECEIVER JUMPER LOCATIONS 2 35 Ref 82 PC 2 Installation GEK 25361A The I O Rack Table 9 lists the options and jumper settings necessary for configuration of this module for proper system operation Factory configuration is for operation
70. tool provided with each CPU REMOTE DRIVER A Remote I O Driver can be installed in any I O slot except the left slot in I O rack located in CPU station a Local I O station or a model 60 CPU I O slot Before installing this module the seven seg ment 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 station Switches 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 wilt 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 Table 6 is a guide to the switch settings for selecting the I O references a Remote l O station 2 30 Installation GEK 25361A The I O Rack STATION I O USER I O DIP SWITCH POSITION REFERENCES QUANTITY 0001 0128 120 120 0129 0256 120 120 0257 0384 120 120 0385 0512 120 120 Selects Group s of 8 Consecutive 0513 0640 120 120 Points For Individual Modules 0641 0768 120 120 0769 0896 120 120 0897 1000 96 96 0001 0256 248 248 0257 0512 248 248 0513 0768 248 248 0769 1000 224 224 Switch
71. transfer logic is also generated on this board The Register Memory module has 2 LED indicators which are viewed through the lens on the faceplate One of the LED s is the status indicator BATTERY for the Lithium back up battery The other LED PARITY indicates a table or register memory parity error If a table memory parity error is detected a bit is set in an error register and the LED goes out Figure 14 is a photograph of the Register Memory module showing its circuitry and the faceplate REGISTER MEMORY I Lithium Manganese Dioxide Battery Battery Status Light Parity Light Mother Board Daughter Board oa C0 nm Figure 14 REGISTER MEMORY MODULE 1 28 Ref 81 PC22 General Description of the Series Six GEK 25361A Central Processing Unit LOGIC MEMORY The Logic Memory module Figure 17 contains the CMOS RAM semiconductor devices used to store the user ladder diagram program This memory is available in modules containing either 2K 4K or 8K words The basic word is 2 bytes 16 bits plus 2 parity bits 1 parity bit for each byte The basic word is illustrated below in Figure 15 Parity error detection is standard in the Series Six Parity is used to check the validity of the data contained in each word Parity check is performed automatically by the CPU Note that parity error detection is not standard in the Model 60 B is fia is i2 u jio o s j 7 6 5 4 3 2 110 Bits Byte 2 Byte Parity
72. use with the Series Six family of CPU s The Data Processor provides the ability to perform complex functions and to access large quantities of data without interrupting or slowing down logic processing in the PC For detailed operation of the DPU refer to the Data Processor Users Guide GEK 25363 PHYSICAL DESCRIPTION The Data Processor interfaces to the Series Six CPU by physically connecting to the I O Control module Two methods of housing the Data Processor modules are used by the Series Six family Model 600 CPU Four module slots are provided in the Model 600 CPU rack for the Data Processor modules They are the 4 left slots as viewed from the front of the rack This is the only CPU that can have the Data Proces sor self contained One each of the Data Control Data Prom Data Storage and Dual Serial Port modules are required for a DPU system in a model 600 CPU Data Processor Rack The modules for the Data Processor in its own rack are contained in a Series Six universal rack with its own power supply Eleven slots are available for modules This separate rack can be used with any model CPU See Figure 65 DPU modules are described below Figure 65 DATA PROCESSOR UNIT Raf RIPO 1 131 General Description of the Series Six GEK 25361A Data Processor Data Control The Data Control Module contains an 8086 microprocessor and its associated support devices lts pri mary function is to perform data processing functions with
73. x 289 304 641 656 X Xx 993 1008 X X X X X 305 320 657 672 x i XXXXX 321 336 673 688 X x iX Not Used 337 352 689 704 x xk x Switch in OPEN Position Depressed to the Left Switch 1 Should be in CLOSED Position Figure 46 ANALOG OUTPUT MODULE I O POINT SELECTION Ref 70 151 2 75 Installation GEK 25361A Module Wiring A jumper on the printed circuit board must be configured properly when using the 4 20 mA module If the internal loop supply is used to power the outputs the jumper should connect pins 1 and 2 Refer to Figure 47 item 2 If a common external source that provides a regulated 18V to 42V DC 100 mA is used the jumper should be connected between pins 2 and 3 During operation there is a signifi cant voltage drop across the output device i e between the low side of the load and the low side of the source MO o do KO do KO 1 Board OK light 5 R43 Gain Pot Channel 1 9 R13 Gain Pot Channel 3 2 Jumper to select Internal 6 R35 Offset Pot Channel 10 R6 Offset Pot Channel 3 Loop Supply or Common 7 R27 Gain Pot Channel 2 11 User Connector Block External Source 3 R59 Gain Pot Channel 1 8 R20 Offset Pot Channel 2 4 R5 1 Offset Pot Channel 0 Figure 47 ANALOG OUTPUT MODULE 2 76 Ref 8 74 Installation GEK 25361A Module Wiring Install the printed circuit board by using the extraction insertion tool
74. 0 x X 873 880 X X X 209 216 X X X 1545 X 881 X X X X X 217 XIX X X 553 560 X EE SPX tara xax 225 232 B X 897 9 X X X 2 40 X X X X 1565 5516 X m 8 XX x 41 24 X X X X 841 X 913 9 X X X X 85 59 X X 921 928 X X X Hx X 93 X X 9 X X X X 601 608 X 3 X X x X X x x 609 6 x IX X 545 X X X 811 6 XIX 955 960 X X X X X 625 6 X 961 968 X Xi X X x X 633 64 X X X 968 976 X X X X x X X X 641 648 X 977 9584 X X X X X 3 570 x X X X 1649 6561 X X X 985 59 X X X X X X 21 X Xx 1697 004 X TX X 993 1000 X X X X X X x 865 6722 X XTX Li X Switch in OPEN Position Depressed to the Left DIP SWITCH SETTINGS FOR 1 POINT SELECTION Figure 23 DIP SWITCH SETTINGS FOR I O POINT SELECTION FOR 8 CIRCUIT MODULES Daf 70 07 2 41 Installation GEK 25361A The I O Rack lO MODULE LOAD Two I O racks are available the difference being the load capacity of the power supply The load capaci ty of the power supply is the internal load placed on it by the I O modules and is expressed as units of load The power supply in a standard 1 0 rack can supply 100 units of load while the power supply in the high capacity 1 0 rack can supply 275 units of load The 1 0 racks to be used in a system are deter mined by installation of modules in the racks in a combination that does not exceed the loa
75. 0BF941A 10 10VDC IC600BF942A 4 20 mA IC600BF943A An Analog Output module can be installed in any 1 slot a model 60 CPU or in any slot in I O rack except the left most slot Before installing the module select the starting I O point number by configur ing the seven segment DIP switch on the backplane adjacent to the selected slot This will assign a group of 16 consecutive output points to the module Refer to Figure 46 for specific DIP switch settings DIP SWITCH NUMBER POSITION DIP SWITCH NUMBER POSITION DIP SWITCH POSITION TET PO B E ES UN 17 32 LLL Ix 369 384 Ix 721 736 Hua 33 48 X 385 400 X due 737 752 49 64 401 416 x 753 768 65 80 X 417 432 x x 769 784 X 81 96 x x 433 448 xix xix 785 800 x 97 112 Ix x 449 464 xIx x 801 816 x x 113 128 X X X 465 480 x X x x 817 832 A 129 144 X 481 496 Ix X XIx 833 848 x X 145 160 Tx X 497 512 x x x x x 849 864 161 176 X 513 528 X 865 880 x x 177 192 X 529 544 X 881 896 x 193 208 X 545 560 897 912 X X X 209 224 X 561 570 L 913 928 x xx 225 240 X 577 592 X 929 944 Ix Ix x 241 256 593 608 E 945 960 Ix Ix x 257 272 609 624 X 961 976 x x x x 273 288 625 640 x aH 977 992 k Ix
76. 13 544 x 865 896 XIX 193 224 xix 545 576 xf x 897 928 ER EE IEBEMETE EE 257 288 er SETTE RE 289 320 641 672 993 1024 X X X X X 321 352 673 704 NOT USED ov Switch in OPEN Position Depressed to the Left Switches 1 and 2 Should be in CLOSED Position Figure 29 ANALOG INPUT MODULE 1 POINT SELECTION 2 52 Ref 70 150 Installation GEK 25361A I O Module Wiring Install the printed circuit board by using the extraction insertion tool provided with each CPU Connect the grounding wire from the faceplate to the rack With the board in place in the rack place the terminal assembly over the circuit board so that proper contact is made An Analog Input module has eight channels Each channel has four terminals that can be used for input device wiring The combination of terminals used depends on the voltage or current input from user devices Figure 30 shows typical user input connections to each of the Analog Input modules 0 10V MODULE O 10V VOLTAGE O SOURCE 10 10V VOLTAGE o SOURCE ue 4 20 mA 1 5V MODULE VOLTAGE SOURCE _ 1 5V CURRENT SOURCE BE 10 50mA L Precision Resistor Figure 30 TYPICAL USER INPUT CONNECTIONS FOR ANALOG INPUTS To operate as 10 50 mA module 100 preci
77. 19 Specifications DC Output Modules 1 78 20 Specifications High Density Output 1 80 21 Analog Output Module Ranges f 84 22 Analog Output Specifications 4 84 23 Digital Data Format 1 87 24 Specifications Reed Relay Module 1 89 25 10 Receiver Status Indicators 1 94 26 10 Transmitter Status Indicators 1 96 27 System Response Times to Remote 1 98 28 O Point Ranges Available in Remote 1 0 Stations 1 99 29 Remote I O Driver Input Status Information 1 105 30 Remote W O Driver Indicator Status 1 106 31 Remote 1 0 Driver Options 1 106 32 Remote W O Receiver Indicator Status 1 1 09 33 Remote I O Receiver Options 1 1 10 34 Power Requirements 124 TABLES Chapter 2 1 Faceplate Printed Circuit Board Name Cross Reference o 2 9 2 WO Control Option 2 18 3 Option Jumper Settings 6 5 14 2 19 Table of Contents 4 11 12 13 14 15 16 17 18 25361 TABLES Chapter 2 Selectable Baud Rate Jumper Configuration IC600CB514B
78. 200 mA plus 7 0 m per input point used per input point used Input Requirements On State Vin lt 0 8V Vin 4096 of supply voltage Off State Vin gt 2 0V Vin gt 50 of supply voltage NOTE For proper operation in the On state each user input device must be able to sink 7 mA of current in the TTL mode or 10 mA in the 50 mode In the Off state negligible current is drawn through each input terminal Response Time Table 9 SPECIFICATIONS HIGH DENSITY INPUT 1 57 General Description of the Series Six GEK 25361A Input Output System The 32 inputs available on this module are arranged in four groups with eight inputs in each group A single group is read by the CPU during an I O cycle All 32 inputs four groups are read in four consecu tive I O cycles A user supplied power source is connected to either the 5V TTL mode or 50V 10 50 DC mode and COM terminals as required Further details for installation of this module can be found in Chapter 2 of this manual By connecting a jumper plug on the circuit board to the proper terminals the user can select whether the data sent to the CPU is inverted complemented or non inverted An LED viewed on the faceplate provides a visual indication of the selected mode Figure 31 shows the High Density Input module including features described above 1 58 General Description of the Series Six GEK 25361A Input Output System E gt LO
79. 36 937 944 961 968 X 825 832 X x 833 840 H 595 x m a X dd e 553 560 X 261 566 Al 233 20 1X Duos rr xxx forsee x 245 256 X X X X X 585 592 xt L 98 6005 265 2 2 X X 1601 6081 271 280 x X 199 667 281 288 X X X 817 624 X 289 298 1X X 165 621 X xj 3 X X 633 640 X 305 312 x X X 841 648 X X 971 084 13 00 x pe e x 546 2 321 328 x x 167 64 X X X 1993 1000 528 338 Switch in OPEN Position Depressed to the Left E mm bii E vi vim jji d xx s T SGC COREE RAGE His ted xd gt AMI tal beri Bar oe te lod DIP SWITCH SETTINGS FOR I O POINT SELECTION Figure 28 DIP SWITCH SETTINGS FOR 1 0 POINT SELECTION FOR EIGHT CIRCUIT MODULES 1 50 Ref 78 97 General Description ofthe Series Six GEK 25361A Input Output System RACK INTERCONNECTION racks are interconnected in a system by using combinations of I O Receivers I O Transmitters Remote I O Drivers or Remote I O Receivers depending on the grouping and location of the racks Racks are grouped together in either
80. A and 4 20 mA 1 5 volts YB8434A 12 bit resolution Contains 4 output circuits with ranges of 0 to 10V YB941 A 10 to 10V YB942A and 4 20 mA YB943A 12 bit resolution Contains eight input channels for temperature measurement Four types J YB813A K YB814A S YB815A and T YB816A 12 bit resolution Contains six isolated output circuits 3 amp outputs Two versions 1 15V AC YB910A and 230V 912 Contains six form C mercury wetted relays Each circuit has a coil energized LED indicator Table 6 Troubleshooting and Repair GEK 25361A System Troubleshooting SECTION 5 I O MODULE CALIBRATION This section provides the information required for performing the periodic calibration of I O modules requiring calibration The recommended frequency of calibration for each of the modules assumes that the module is operating at its normal operating temperature which is 0 to 60 C 32 to 140 F at the outside of the rack containing the module The frequency of calibration should be adjusted as required for specific applications Analog Input Module CALIBRATION PROCEDURE Calibration of the Analog Input module should be performed every 90 days at normal operating temperature 1 SET UP Disconnect the field wiring going to the channel 1 connections the faceplate Connect analog source with an accurate voltmeter between the first IN1 and third VR1 terminals along the fro
81. CMOS IC6OOCM544A 8K CMOS IC600CM548A Combined Model 60 552 with 2K CMOS Combined Model 60 IC600CM554A with 4K CMOS Auxiliary I O IC600CB513A Table 1 FACEPLATE PRINTED CIRCUIT BOARD NAME CROSS REFERENCE LIST 2 9 Installation GEK 25361A Rack and CPU Module Installation LOGIC MEMORY MODULE S The Logic Memory module s either 2 4 or 8K should be unpacked and removed from their sleeves Remove any blank faceplates from the slot s where the modules are to be installed The memory module s should then be inserted into the slot or slots beginning with the slot immediately to the left of the Register Memory module A Model 600 requires 1 Logic Memory module while a Model 6000 con tains a minimum of 1 and a maximum of 4 Logic Memory modules See Figure 8 which shows the Logic Memory slot s available Logic Memory Slots Optional Model 6000 only Register REDE PTT Model 600 1 slot Model 6000 4 slots available Figure 8 LOGIC MEMORY SLOTS The Model 60 CPU Logic Memory module combines the functions of internal memory register memory and logic memory on one module This module in a Model 60 CPU only should be installed in the slot immediately to the left of the Arithmetic Control module BATTERY INSTALLATION Before installing any memory module in a CPU rack the Lithium Manganese Dioxide battery should be connected These modules are shipped from the factory with the bat
82. Decodes input addressing and puts input data on the bus On range is 90 130V AC DC IC600YB806A Input Board Accepts 20 AC DC input voltage Input voltage isolated 12V AC DC from 5V logic by an opto isolator Contains filtering and threshold detection circuitry IC600YB802A Input Board Accepts 20 60V AC DC input voltage Input voltage isolated 24 48V AC DC from 5V logic by an opto isolator Has filtering and threshold detection circuitry IC600YB805A Input Board Contains 8 isolated input circuits with LED indicators and noise 230V AC DC filtering Decodes input addressing and puts input data on the bus On range is 180 to 260V AC DC Table 6 RENEWAL PARTS LIST Troubleshooting Repair System Troubleshooting GEK 2536 1A Catalog Module Name Name IC600YE3811A Input Board High Density IC600YB808A Input Board Interrupt IC600YB906A Output Board 12V DC 9 20V Sink IC600YB902A Output Board 24V DC 19 40V Sink IC600YB903A Output Board 48V DC 38 55V Sink IC600YB907A Output Board 12V DC 9 20V Source IC600YB908A Output Board 24V DC 19 40V Source IC600YB909A Output Board 48V DC 38 55V Source IC600YB904A Output Board 115VAC IC600YB905A Output Board 230V AC IC600YB911 A Output Board 5V TTL High Density IC600YB913A Output Board lo 50V DC High Density Contains 32 circuits Accepts inputs of 5V TTL or 50 DC user selectable Contains 8 ci
83. Depressed To Left OPEN Table 6 DIP Switch Settings For Remote i O All 1 O modules used a Remote 1 station must use references within the group established by the Remote l O Driver backplane DIP switch setting For example if the group selected is 0129 0256 1 0 module in a remote station cannot use 10625 as a reference All 1 0 modules in the remote station must have switches 5 6 and 7 120 120 1 0 or switches 6 and 7 248 248 1 0 set the same as the Remote I O Driver In addition to setting the DIP switches for a Remote Driver several jumper plugs on the printed circuit board must be configured for proper system operation These jumpers are used to select various options Figure 18 shows the location of each of the jumpers on the printed circuit board Each option selection location has three pins with the center pin being common to the two outer pins jumper plug connects the center pin to one of the outer pins The jumpers are identified by the center pin i e pins 1 2 and 3 are identified as Jumper 2 2 31 GEK 25361A Installation The I O Rack EM Dres EE gone Mowry big i LIII 499v e n Pdvenvanel nis od dain a EN ies Figure 18 REMOTE I O DRIVER JUMPER LOCATIONS Ref 82 1 1 3 Installation GEK 25361A The I O Rack Table 7 lists the options and jumper settings necessary for configuration of this module for proper system operation The ta
84. Enable 1 22 GEK 25361 A General Description of the Series Six Central Processing Unit ight DPUL 5 6 1 Connector to PDT or DPU 2 CHAIN OK Light 3 PARITY Light In I O cha In Connector to ma IONS Jumpers for selectable board opt Y 4 ENABLED Light 12 igure F CONTROL MODULE 1 23 Ref 81 PC 17 General Description of the Series Six GEK 25361A Central Processing Unit MEMORY The type of memory as well as the internal memory register memory and logic memory modules are de scribed below Also described are memory protection visual status of backup battery memory address ing and memory allocations CMOS CMOS RAM is an integrated circuit memory that is desirable in that it uses very low power CMOS RAM memory is available in either 2K 4K or 8K words of memory Since CMOS RAM memory is volatile loses contents of memory with no power a Lithium Manganese Dioxide battery located on the memory module protects the memory contents when power fails or is turned off This battery provides approximately six months of data protection When power is applied to the CPU an LED indicator lights if the battery condition is normal The normal fully charged voltage of a Lithium battery is 2 95V 1 75 amp hours Lithium batteries are not rechargeable The battery indicator LED provides 3 states If the battery voltage is normal the LED is on If the battery voltage is low between 2 55
85. GES FOR THERMOCOUPLE INPUT MODULES Each of the four types of modules functions as an analog to digital A D converter for signals on each of its eight input channels The sampled value of the input level is converted to a 12 bit binary number which is linearized over its usable range and then converted to either OC or OF This temperature value is sent along with binary information that gives various operating conditions and the number of the chan nel being read to the Input Status Table in the CPU 1 69 General Description of the Series Six Input Output System Terminal Cover 2 User Terminal Block 3 Circuit Board Terminal Block Mates With User Terminal Block GEK 25361A 4 Output ON Lights l 8 5 BF Blown Fuse Lights l 8 6 Fuses 3A One Per Circuit 7 Markable Lens Surface Figure 38 OUTPUT MODULE An AC Output module can be installed in any slot in an I O rack except the left slot or in an I O slot in Model 60 CPU Before installing the module the I O starting point number for the group of eight outputs should be established by setting the seven segment DIP switch on the backplane adjacent to the select ed I O slot Refer to Figure 28 or the Installation chapter in this manual for instructions on setting the DIP switches Instructions for connecting field wiring to the terminals on this module can also be found in Chapter 2 Installation Ref 81 PC 10 1 75 General Description o
86. ION Board OK HIGH if both 5V and 15V power supply levels are OK LOW otherwise Underrange HIGH if input level is at or below the low end of the module range LOW otherwise Data will saturate at minimum reading Overrange HIGH if input level is at or above the high end of the module range LOW otherwise Data will saturate at maximum reading Bit 16 Heartbeat Changes state when the reading of a channel is complete Bits 17 24 Data Eight least significant of the twelve bits of data Bit No 17 is the least sig nificant bit LSB Bits 25 32 Data Four most significant of the twelve bits of data bits 25 281 plus four bits of sign extension bits 29 32 Bit No 28 is the most significant bit MSB The sign extension bits all have the same value as the Sign bit bit No 12 and bit 28 Table 12 Continued DIGITAL DATA FORMAT The 12 bits of data and the sign extension make up a 16 bit binary number which is in straight binary form for positive data or 2 s complement form for negative data For the bipolar 10 10V module bit No 28 functions as a sign bit The 2 s complement form of a binary number is found by inverting complementing all bits and then adding one For example the decimal number 770 can be expressed as the I6 bit binary number 0000001 0000001 0 To find the 2 s complement form first invert giving 11 1 1 110011 11 1 101 then add one to this giving 11 1 1 11001 11 111 10 This woul
87. Input Output System I O Rack The I O rack is the same as the CPU rack in physical size and structure See page 1 6 for details One 41 pin connector is provided for each slot Wiring from input or output devices is made by connection to box lug terminals located on the Faceplate of each I O module At the bottom of each I O rack is a wire trough or tray for running field wiring to and from the I O connectors Indicators are provided on each I O module for status indication Figure 5 illus trates a typical I O rack showing location of indicators and the wiring tray Ir SERES f HALE p WEE m ud a E M Er i M 1 1 0 Module Slots 11 Per Rack 2 Power Supply Standard Model 3 Wiring Tray Figure 5 INPUT OUTPUT RACK WITH WIRING TRAY Ref 81 PC 55 General Description of the Series Six GEK 25361A Introduction PROGRAMMING The Series Six uses the familiar ladder diagram approach The instruction set contains the commonly used functions such as open and closed contacts relay coils timers counters latches and one shots Additional instruction capability is provided in mnemonic form The users ladder diagram program is stored in the logic memory of the CPU Instructions in the program may reference the status table or register memory The status table is composed of the input and output tables In mnemonic instructions that reference the statu
88. Input Output System Power Requirements DC 1 7A maximum Supplied Rack Power Supply Input Voltage Levels Type J 8 096 to 42 922 millivolts Type K 6 061 to 49 988 millivolts Type S 0 000 to 18 698 millivolts Type T 6 250 to 20 869 millivolts Sample Rate 66 4 msec input Provides a conversion rate of 15 per second Conversion rate can be changed jumper selectable 12 Binary Bits 1 part in 4096 Accuracy Temperature Drift Max Time Drift Max Type J 19 0 10 C month Type K 30 0 15 C month TypeS 39C 0C 15 C month 10 C month Type T 19 0 Table 15 THERMOCOUPLE INPUT SPECIFICATIONS Each module contains two four channel isolated thermocouple conditioners a microprocessor with EPROM memory for linearization address decoding logic and data bus drivers Circuitry is also provided for open thermocouple detection and for protection of overrange and underrange conditions One LED indicator viewed through the faceplate lens provides a visual indication of module status The format for data to be transferred to the CPU is jumper selectable and can be either signed magni tude or 2 s complement Temperature readings are sampled for a period of 66 4 msec input The aver age value of a 12 bit sample is then linearized and converted to a temperature reading At 66 4 msec input the module will sample the same point every 532 msec This equates to a conversion rate of 15 per sec
89. It should be noted that no more than four I O Transmitter links can be used with the 2000 foot limitation on the parallel I O chain 2 Oe 1 Connector to I O Receiver Module in 3 CHAIN PARITY Light Downstream I O Station 4 ISOLATED POWER Light 2 CHAIN OK Light Figure 48 VO TRANSMITTER 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 1 0 Receivers Optocouplers on the module isolate signals passing through the module and a DC to DC con verter provides a 5V DC isolated supply voltage to those circuits connected to the parallel I O bus This method of isolation ensures that all Local I O stations are electrically isolated from each other and from the CPU station An I O Transmitter can be installed any card slot in an I O rack except the left most slot which is nor mally 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 since it does not affect the operation of the module An I O Transmitter does not require an I O address Ref 5 30 1 95 General Description of the Series Six 25361 Input Output System Status Indicators A monitor circuit checks the output level of the isolated 5V DC supply If the output is not within its specified t
90. K of memory the second toggle turns on the second 2K of memory and so on until the last toggle on the bottom turns on the last 2K of memory which gives a total of 32K of Logic Memory The starting address of the first 2K of memory is 0 the next 2K starts at 2K the third 2K starts at 4K the fourth 2K starts at 6K and so on until the last 2K increment which starts at 30K Some basic rules must be observed when programming the Logic Memory location switches Do not close more than one switch per 2K of memory in its appropriate slot The memory should be kept in sequence do not split up a memory Do not double program memory locations If a memory in slot A is an 8K memory and toggles are on at locations 2K 4K 6K and 8K do not start a second 8K memory in slot B at locations 2K 4K 6K or 8K it must start at location 1 OK Do not program more switches then there is memory present Do not leave holes in a memory If you have an 8K memory in slot A it cannot be programmed at 2K 4K 6K and 1 OK If you start at 2K the switches must be in sequence 2K 4K 6K and 8K In the illustration Figure 11 as an example the switches are programmed for an 8K memory in slots A B and C and a 4K memory in slot D A shaded toggle position means that the toggle is turned on When the Logic Memory location switches have been properly set the Internal Memory module is ready to be installed wa RNING If the Logic Memory location switches
91. N fC LOCAL OK Module operating normally Fault exists in this module 0 0 0 Remote yo LINK Communications link between this module and Driver OK Remote I O Receiver good 0 Communications error between this module and Remote I O Receiver REMOTE O OK 0 REMOTE No parity errors in Remote system PARITY Parity error detected in Remote I O system On board jumper selects if CPU will stop or con tinue running Table 5 INDICATOR CHART Continued Remote system operating normally Valid I O data received from the Remote Receiver Fault in Remote I O system Power supply failure loose cable module not seated properly etc N FF N FF N FF ON OFF 3 39 Troubleshooting Repair GEK 25361A System Troubleshooting MODULE INDICATOR STATUS DEFINITION D LOCAL OK Module operating normally Communications failure due to timeout or suc cessive transmission errors Remote Receiver LINK ON Communications link between this module and OK Remote I O Driver established and valid OFF Communications failure between this module and Remote Driver ON OFF ON OFF REMOTE Remote system operating normally OK Fault in Remote I O system Illegal address block loose connection power supply failure etc REMOTE No parity errors in this Remote I O system PARITY P
92. NALOG INPUT BOARD OK Light The LED is Off if there is an A D converter malfunction an I O rack power supply problem or the CPU is in the Stop or the Run Disabled mode It is also Off if the module has not been read since one of these conditions existed or since power has been applied wda amp 0 002 G Wdhi AiddhS jg 9 RORUL INN 2 RI 2 Offset Pot All Channels 3 RI 1 Gain Pot All Channels 4 User Connector Block Figure 12 POTENTIOMETER LOCATIONS Ref XI PC 77 25361 Troubleshooting and Repair GEK 25361A System Troubleshooting Analog Output Module CALIBRATION PROCEDURE Calibration of the Analog Output module should be performed every 90 days at normal operating temperature 1 3 58 SETUP After loosening the thumbscrews remove the faceplate taking care that the field wiring is disturbed For the 0 10 V or the 10 10 V module connect a digital voltmeter DVM between the terminals along the front edge of the card which are listed in the V column for the first channel in Table 8 For the 4 20 mA module connect a 250 ohm precision resistor in parallel with the DVM using the terminal numbers in the I column in Table 8 Note that the terminals are numbered from the top downward and that the double common printed circuit pads count as two terminals Be sure that the circuit
93. 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 If a block of 248 Inputs and 248 Outputs or the Remote I O system is to be linked with RS 232 com patible modems or any of the other options are to be changed the printed circuit board jumper plugs must be reconfigured A table listing all jumpers which can be configured by the user can be found in Chapter 2 1 102 General Description of the Series Six 25361 Input Output System REMOTE DRIVER The Remote I O Driver module Figure 52 provides control and data signals to a Remote I O station Cir cuitry 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 model 60 CPU a CPU station or a Local 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 Using the two twisted pair cable the Remote I O station can be located up to a maximum of 10 000 feet 3 kilometers from the Remote I Q Driver A communications link using mode
94. O modules in an I O rack I O racks are connected a station grouping of I O racks by linking I O Receivers together through 16 pair twisted cable No more than 10 racks can be connected a station A linking of racks in this configuration is referred to as a daisy chain The total cable length in a daisy chain from the I O Control module in a CPU station or the originating I O Receiver a Local I O station can be no more than 50 feet 15 meters 1 91 General Description of the Series Six GEK 25361A Input Output System Connector to Upstream I O Receiver I O 6 Socket Location DI Contains Jumper Transmitter I O Control or Remote I O Re Pack for Continuation of I O Chain Signals ceiver Module DIP Shunt for VO Chain Signal 2 Socket Location Cl Contains a DIP Termination Shunt when used for I O Chain Signal 7 Connector to Downstream I O Receiver s Storage of DIP Shunts or 3 CHAIN OK Light 8 Socket Location F2 Jumper Pack uem het 4 CHAIN PARITY Light 9 Socket Location use 5 LOCAL PARITY Light Figure 46 RECEIVER 1 92 Ref 82 PC 12 General Description of the Series Six GEK 25361A Input Output System 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 con nected when they are more than 50 feet 15 meters fro
95. O racks be sure theyare seated properly and that the quarter turn thumb screws securing the faceplates to the rack are tight If modules have been shipped separate from the racks install them in the proper slots and attach their respective faceplates Electrical Ensure that the AC power source is within the stated specifications Provide isolated circuits to minimize any problems with line interference Isolated AC circuits are recommended when using microprocessor controlled equipment because of the negative effects that noise or line spikes may have on operation of the equipment Connect 115 or 230V AC to the proper screw connections on the CPU power supply Depress the Logic Power On Off switch to the ON position Ensure that the Power ON LED comes on If it is okay turn the power off WARNING Voltage is present 115 or 230V AC on the power supply terminal board which could be hazardous and may cause personal injury if care is no i taken 1 125 General Description of the Series Six GEK 25361A System Configuration Connect the Program Development Terminal to the CPU with the cable provided Connect the AC power plug to either 1 AC or 230V AC as required Refer to the Series Six Programming Manual GEK 25362 page 2 5 for start up instructions If all of the above checks are completed satisfactorily the system is ready to be configured and l O modules wired to their respective input and output devices If any
96. OLTAGE LED 1 Figure 50 TYPICAL REED RELAY OUTPUT CIRCUIT JI is the protection circuit jumper 2PL is the jumper plug 3PL is the N C jumper plug LED1 is the energized coil indicator and FUT is the fuse for this circuit Each output has two connections One of the connections is the output terminal 1 through 6 the other terminal SI through S6 connects to the user power source Each of the box lug terminals accom modate one No 12 AWG or two No 14 AWG wires Figure 51 shows typical user connections to the module Wiring instructions follow the figure Ref 70 132 2 81 Installation GEK 25361A IO Module Wiring OUTPUT MODULE R Relay Contacts L User Load E User Power Source Figure 5 1 REED RELAY OUTPUT TYPICAL USER CONNECTIONS Connect one side of the load to be controlled to one of the output terminals 1 through 6 Connect the other side of the load to the user power source Connect the other side of the user power source to the applicable terminal S1 through 56 After completing field wiring install the terminal block protective cover by guiding both its edges onto the top of the terminal block and sliding it down over the terminals The markable area on the lens beside each circuit indicator can be used for noting the function or destination of each output Voltages from user field devices may be present on the faceplate terminals even if the power supply in the I O rack is of
97. OR Ref 81 PC 39 2 17 Installation GEK 25361A Rack and CPU Module Installation CONTROL MODULE 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 towards 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 JUMPER CONFIGURATION DEFINITION A B DPU Present B C DPU Not Present D E DPU Fault Trips Alarm No 1 and Alarm No 2 CPU Stops E F DPU Fault Trips Alarm No 2 Provides an Advisory Indication G H Communications Control Fault Trips Alarm No 1 and Alarm No 2 CPU stops H I Communications Control Fault Trips Alarm No 2 Provides an Advisory Indication Table 2 CONTROL OPTION JUMPERS The I O Control connects to an I O Receiver in the first I O rack in CPU I O station through a 16 pair parallel cable AUXILIARY MODULE The Auxiliary I O module is available as an option for the Model 6000 CPU only This module contains no programmable devices The Auxiliary I O module should be installed in the leftmost slot of the Model 6000 CPU rack This module connects to the first I O rack a CPU I O station i
98. Output terminal is pulled down toward the negative side of the user power source when the corresponding output is ON A circuit is provided that disables all of the outputs in the event of an I O power supply I O chain or CPU failure This prevents improper operation which could damage equipment or cause injury to an operator A DC Output module can be installed in an I O rack or in an I O slot in a Model 60 CPU rack Before in stalling the module the seven segment DIP switch the backplane adjacent to the selected I O slot should be configured to establish the I O starting point number for the group of 8 outputs on the module Refer to Figure 28 or Chapter 2 of this manual for instructions on setting the DIP switches In structions for connecting field wiring to a DC Output module can also be found in Chapter 2 High Density Output Modules The High Density Output modules provide 32 output circuits on each module and are available as either a 5V TTL or a 10 50V DC module Both modules provide an optically isolated interface between the backplane I O bus and user digital circuitry BV TTL module or discrete loads 10 50V DC module Table 20 lists the specifications for both modules 5V TTL Module 10 50V DC Module Power Requirements 5V DC 200 mA maximum Supplied by I O rack power supply User Supplied Voltage 5 0 25V DC 10 50 DC Ripple lt 100 mV Current 400 mA plus 5 mA 350 mA plus 10 mA per output point used pe
99. P switch settings DIP SWITCH DIP SWITCH INPUT DIP SWITCH POSITION POSITION NUMBER POSITION Switch in OPEN Position Depressed to the Left Switches 1 and 2 Should be in CLOSED Position Figure 26 HIGH DENSITY INPUT MODULE I O POINT SELECTION In addition to setting the DIP switches a circuit board jumper for configuration of the module to operate in the Inverting or Non Inverting state should be set Refer to Figure 27 for the location of this jumper 2 48 Ref 70 151 Installation GEK 25361A I O Module Wiring l Jumper For Selection of Inverting or Non Inverting Mode Figure 27 HIGH DENSITY INPUT MODULE Install the printed circuit board by using the extraction insertion tool provided with each CPU Connect the grounding wire from the faceplate to the rack With the board in place in the rack slip the terminal assembly over the circuit board so that proper contact is made Secure the faceplate to the rack using the quarter turn thumbscrews Refer to Figure 28 for typical user input connections Both the TTL mode and the 10 50V mode are shown Ref 81 PC 13 2 49 Installation GEK 25361A I O Module Wiring When using the TTL mode the module operates with negative logic i e a high input is read to the Input Status table as a O To use positive logic the module should be configured to operate in the Inverting mode When using the TTL mode the TIL module operates with negative Compatible lo
100. PU 1 0 Station Local 1 0 Station Serial Link amp 10 000 Cable 2000 Maximum Link or Li 1 LI RS 232 Modems Max 500 Max 500 Max 500 Max 500 1 0 0 VO 0 1 0 jo VO o 1 0 Rack 1 Rack 7 Rock F Rock F Rack 16 ME Parallel 1 0 Ten 1 0 Bus Cable Racks 1 0 1 0 1 0 1 0 1 0 Rack Rack Rack Rack Rack 1 eB NOTE 5 Total 1 0 Points not to exceed selected block size on 120 120 1 0 or 248 248 1 0 roo Figure 56 REMOTE STATION CONFIGURATION Raf 7n 1 n 1 114 General Description ofthe Series Six GEK 25361A Input Output System AUXILIARY I O SYSTEM The Auxiliary I O system is available only with the Model 6000 CPU If a Model 6000 CPU has an Auxili ary I O module an O system identical to the main I O system can be originated at the CPU The struc ture of the Auxiliary I O system allows the Model 6000 CPU to accept an additional 1000 inputs and 1000 outputs The total I O capacity of the Model 6000 CPU with the Auxiliary I O system is 2000 inputs and 2000 outputs All information pertaining to use of Input and Output modules Interfacing modules cable type and dis tance allowed between racks and stations is applicable when configuring the Auxiliary I O system with the exception that inputs and outputs cannot be overridden 1 116 General Description of the Series Six GEK 25361A Program Development Terminal SECTION 5 PROGRAM DEVELOPMENT TERMINAL This
101. PU Module Installation Installation AlddNS H3MOd Ndd TOULNOD O 1 TOHLNOD SNOILYIINNWINO 2 TOWLNOD 91907 TOHINOO OI13AHLIBV TVNH3INI H31SID3H AHOWS 21501 JOHINOO V LVG WOMd VLVG ADVYOLS V1VG 1HOd Aiddns u3MOd Ndo 10 1 0 TOHINOO SNOLLV2INQINWOO TOHINOO 21901 TOHINOO OILSWHLIEV TWNUALNI ABOWSW H31SID3H AHONN 91907 je 21901 AHONIN 21901 AHOIBW 91901 MODEL 600 MODEL 6000 AlddNS H3MOd po TOULNOD SNOILVIINNWWOD IOYLNOD 21901 1OHLNOO OLL3INH LIHV Ref 70 121 MODEL 60 Figure 7 CPU MODULE LOCATION GUIDE Optional Modules 2 8 Installation GEK 25361A Rack and CPU Module Installation NOTE Some of the printed circuit board names printed on the board may differ from the module designation imprinted on the faceplate To avoid the possibility of placing a printed circuit board in the wrong slot refer to the following cross reference list FACEPLATE AND BOARD CATALOG NUMBER PRINTED CIRCUIT BOARD LABEL NAME IMPRINTED NAME Control IC6OOCB509A Communications Control IC600CB514A Logic Control Basic IC600CB50 A Logic Control Extended IC600CB502A Arithmetic Control IC600CB500A Internal Memory IC600CB504A Register Memory IC600CB508A Logic Memory 2K CMOS IC600CM542A 4K
102. Processing Unit and the Input Output system Replacement parts lists are provided for each part of the Series Six system The contents of this publication will be updated and added to as ap plicable in order to maintain a quality product consistent with the policies and practices of General Electric Company For informatiuon on programming a Series Six system refer to GEK 25362 PROGRAMMING MANUAL FOR SERIES SIX PRO GRAMMABLE CONTROLLERS Warranty and Service Information General Electric backs up its Series Six programmable control equipment with an exclusive one year up to 18 months if the customer resells or leases the equipment to a third party warranty Specific terms of the war ranty can be obtained from your General Electric Sales Office Table of Contents CHAPTER 1 General Description Section 1 Introduction General Overview eere 1 1 Basic System Description 1 2 Memory Size eere 1 3 Models 3 1 4 Optional Devices 1 4 Portable Tape Unit eee 1 4 Comparison 1 4 HP E 1 6 Mod lesS cee 4 7 Backplane iiie 1 8 WO Structure e nere 1 8 l O Rack een l 10 Programming
103. RAM with Battery with Battery with Battery NNNM Mosi NN NT Program Memory Size 16 Bit Words Register Storage 16 Bit Words 1024 1024 256 2K Model 1024 4K Model Data Processor Integrated 16 Bit Microcomputer Internally inter faced to programmable controller CPU Networking Multiple CPU Com munication High Speed Serial Maximum 1 Address Capacity 5 12 2K Model 2000 4K Model Remote I O Parallel 2000 feet Yes Serial 10 000 feet greater with modems Functions Relay Contact Logic Timing 01 l 1 O second increment Counting up and down Latch 16 Bit Logic Operations Bit Manipulation Multi bit shifting 4 Function Arithmetic Indexing Circular List Handling MCR SKIP function 3 Mode PID Control Message Generation Reports Data Base Handling Analog I O High Speed Positioning Control Peripheral Devices Program Development Terminal Tape Unit Optional Table 1 SERIES SIX FEATURES AND FUNCTIONS General Description of the Seres Six 2 GEK 25361A Introduction PHYSICAL DESCRIPTION Table 2 lists the general physical and electrical characteristics of the Series Six Physical and Electrical Characteristics Operating Temperature 0 60 C 32 40 deg F at outside of rack Humidity 5 95 Non condensing Required Power 115VACOor230VAC 15 47 63Hz Maximum 250 Volt amps Dimensions Outside Measurement Rack Mount 19 0 x 14 x 10 3 i
104. RUN and ENABLE lights are off Alarm No 1 relay switches The parity error and its address is recorded in the Scratch Pad CPU Flags Corrective Action Turn the MEMORY PROTECT keyswitch to WRITE e If the CPU will not go into the RUN Mode at this time because the parity error has reoccurred go to the Supervisor Display on the PDT Move the cursor down to CLEAR LOGIC MEMORY PARITY ERROR and depress the ENTER key then SHIFT and ENTER simultaneously This will clear soft parity errors Reload the user program The program can be transferred from the CPU to the PDT then from the PDT back to the CPU Try to restart the CPU by turning the CPU Key switch to STOP then back to RUN Try to restart the CPU e f the parity error still exists replace the Logic Memory module Model 600 In a Model 6000 with multiple Logic Memory modules the Scratch Pad error message display on the PDT must be decoded to determine which Logic Memory module is defective Replace that module 3 26 Troubleshooting and Repair GEK 25361A Central Processing Unit Troubleshooting PARITY Light Register Memory Module Table Memory parity is good OFF Table Memory parity error exists The RUN and ENABLE lights will be off Alarm No 1 relay switches The parity error and its address is recorded in the Scratch Pad memory CPU flags a Corrective Action Reload the user program program be transferred from the CPU to the PDT then
105. Status of Backup Battery There is one LED indicator viewed through the faceplate window on each memory module This indica tor BATTERY is a visual status of the Lithium backup battery located on each module Battery status is described below STATUS DESCRIPTION ON Lithium battery is normal Memory contents are saved on power loss FLASHING Battery low CPU continues running and will restart if stopped The battery should be replaced before it fails Battery Failed Voltage too low or no voltage CPU continues running will not restart if stopped Memory contents will be lost if power is turned off or lost Battery should be replaced AUXILIARY I O The Auxiliary 1 0 Figure 18 module contains circuitry for interfacing an Auxiliary I O chain to the CPU bus in a Model 6000 CPU This module allows a second I O system with the same structural features as the primary I O system to be connected to the CPU The Auxiliary I O system is functionally identical to the primary I O system except that the Auxiliary inputs and outputs cannot be overridden The Auxiliary system allows an additional 1000 inputs and 1000 outputs thereby allowing the Model 6000 a total of 4000 I O points The auxiliary I O status tables are physically stored in registers 1 to 128 Regis ters 1 to 64 are the auxiliary output tables and registers 65 to 128 are the auxiliary input tables The Extended CPU instruction set must be present in order to access the Auxilia
106. Switching 12 Gnd s ele sIs ers 0v 5 230 ac Figure 5 CPU POWER SUPPLY BLOCK DIAGRAM 3 20 Ref 70 58 Troubleshooting and Repair GEK 25361A Central Processing Unit Troubleshooting CHAIN OK 1 0 Control Module Light Auxiliary 1 0 Module Continuity output data parity and power supplies are good at all f O stations in the primary and auxiliary chains more primary or auxiliary chain I O station s The CPU RUN and ENABLE lights are off Alarm No 1 relay switches When the fault is removed CPU resumes its previous status 7 A continuity power supply or output data parity error exists at one or Corrective Action Check for proper i O chain signal termination on the fast I O Receiver module of each lO station in a parallel chain Check cable connections to each I O rack Check for power on each I O rack If power indicator is off check the 5V DC on the terminal board assembly by partially pulling out the Power Supply module Check vol tage as in If the 5V DC is out of tolerance replace the I O power supply Check CHAIN OK and CHAIN PARITY lights in the CPU station I O racks 1 If any of the above status lights are off proceed to the 1 0 troubleshooting section 2 If all status lights are on replace the 0 Control or Auxiliary I O module as applicable 321 Troubleshooting Repair GEK 25361A Central Processing Unit Troubleshooting PARITY 1 0 Contro
107. T controls as required See above procedure Turn PDT keyswitch to off line then power down Wait a few seconds and power up Video Control board Processor Control board PROM board RAM board Processor Control board RAM board Video Control board PROM board Replace cable Replace Replace Replace Replace Perform Replace Replace Replace Check keyboard connector at keyboard and Video Control board Replace Replace Replace Replace Replace Processor Control board Video Control board RAM board PROM board keyboard Replace keyboard Video Control board Processor Control board RAM board PROM board preventive maintenance see below Video Control board Processor Control board magnetic tape transport and tape interface board Call Service Programmable Control Replace RAM board Replace PROM board Table 1 PDT TROUBLESHOOTING 3 11 GEK 25361A Troubleshooting and Repair Program Development Terminal PROBLEM EXTERNAL TAPE LOADER DOES NOT OPERATE WRITE PROTECT message is dis played in work area of PDT when attempting to write to tape BAD RAM LOC message on power up Troubleshooting PROCEDURE 1 Check front panel switch settings STR LINK Baud rate 300 600 or 1200 same as PDT Recommended by General Electric Stop bit 1 Select RS232 Mode Select Half duplex STR LINK III Track
108. Table 6 lists some of the problems that can cause the alarm relay outputs to switch ALARM NO 1 MAJOR ALARM NO 2 ADVISORY CPU or I O parity error Voltage of any memory battery drops too low CPU self test failure CPU watchdog timer timed out CPU OR I O power supply turned Off Any memory backup battery dead when power turned on Any CPU or I O power supply voltage out of tolerance Communications Control or Data Processor error CPU power supply turned off fault jumpers in or out of circuit Communications Control or Data Processor error fault jumpers in circuit Table 6 ALARM CONDITIONS User devices connected to each set of alarm terminals should present a resistive load drawing no more than 1 amp of current at 1 15V AC or 28V DC Failure to observe this CAUTION may result in damage to the CPAXI circuit board in the power supply 1 46 General Description of the Series Six GEK 25361A Input Output System SECTION 4 INPUT OUTPUT SYSTEM This section describes the Input Output l O system used by the Series Six family of programmable controllers The I O system is common to all models of the Series Six family racks and modules can be interchanged between systems using the Model 60 Model 600 or the Model 6000 As indicated in Table 1 Section 1 the maximum number of I O points available with the Models 6000 600 and 60 re spectively are 4000 2000 and 2000 The Model 60 is the onl
109. V and 2 75V the LED flashes The CPU will run if the battery voltage gets low If the CPU stops it can be restarted If the battery voltage drops below 2 55V the LED turns off If the CPU is stopped it cannot be restarted INTERNAL MEMORY The Internal Memory Module Logic is made up of various tables stored in CMOS RAM with Lithium bat tery back up The RAM s are 256 x 8 bit words each The following tables are stored in the Internal Memory module Status Stores bits which represent the status ON or OFF of all of the 1000 inputs and 1000 outputs available on the 1 0 main chain Override The status of overridden input or output bits is stored here An overridden bit in the status table will not be changed when the CPU reads inputs or solves outputs Transition The logic state of the inputs to counters and one shots is stored in this table 1 24 General Description of the Series Six GEK 25361A Central Processing Unit In addition the Scratch Pad memory is stored in the Internal Memory module The Scratch Pad contains miscellaneous data pertaining to CPU operation SCRATCH PAD DEFINITION ITEM CPU ID Number assigned to the CPU if there is more than one CPU in a system MEMORY SIZE Number of words of logic memory in the CPU CPU STATUS Current operating status of the CPU either run enabled run disabled or stop INSTRUCTION Selected instruction set basic or extended Also shows version of software SET in the PDT an
110. WER slots d POWER SUPPLY INSTALLED Figure 61 UNIVERSAL RACK MOUNTING Ref 44 716406 Sh 2 1 123 General Description of the Series Six GEK 25361A System Configuration HARDWARE REQUIREMENTS A system consists of a CPU rack and I O racks each containing their own power supply For a system requiring a Model 600 CPU or a Model 6000 CPU the I O modules will be contained in a separate rack or racks The Model 60 if no more than 192 1 0 points are required can be completely contained in one rack The proper length cables for interconnection of CPU rack to I O rack or I O rack to I O rack must be determined and be available for initial system check out and installation Standard I O cables available for interconnection on the parallel I O bus in standard lengths ranging from 2 to 500 feet 6 to 150 meters Remote I O requires a cable with two twisted shielded pairs for direct connection to 10 000 feet 3Km and is normally user supplied If connection to the Remote I O is to be by RS 232 compatible modems a cable of no more than 50 feet 15 meters is required to connect the modems on each end of the serial link Cabling must be provided by the user from external devices to be controlled to the 1 0 modules POWER REQUIREMENTS Power Supply Input 115VAC 15 47 63 Hz 700 mA maximum Standard I O Rack 20A maximum CPU DPU High Capacity 1 0 Rack 230V AC 15 47 63 Hz 350 mA maximum Standard I O Rack 1 0 A
111. a 32K program to be read or written on a single cartridge in less than three minutes See Figure 60 TAPE SPECIFICATIONS The DC1 OOA Data Cartridge is a highly reliable bi directional tape medium of shirt pocket size The DC1 contains 140 feet 42 7m of 0 150 inch 3 81 mm tape in a package measuring 2 4 x 3 2 x 0 5 inches 6 1 x 8 1 x 1 2 cm Complete specifications are shown below ae Speed 0 to 90 inches per second 0 to 2 29m per second Tap Employs computer grade magnetic tape 140 feet 42 7 m of usable storage Sensing File Protect Manually operated sliding tab provides file protect capability Temperature 32 F to 122 F 0 C to 50 C Humidity 20 to 80 non condensing Construction High impact plastic cover over heavy gauge metal base plate No deck compo nents penetrate the cartridge shell 2 415 x 3 188 x 0 470 inches 6 12 x 8 10 x 1 119 cm Weight 2 ounces 56 7 gm 1 120 General Description of the Series Six GEK 25361A Program Development Terminal LINE 222 PROGRAMMABLE wr DE GENERAL ELECTRIC OFF LINE 1 CRT 2 Built In Tape Unit Optional Figure 60 OPTIONAL BUILT IN TAPE UNIT AND SWITCHES POWER SWITCH Power input to the Program Development Terminal is controlled by an illuminated rocker switch When the top of the switch is depressed AC power is applied to the unit and the light in the switch turns on to indicate th
112. ace it immediately install a new battery on a memory board proceed as follows Refer to Figure 6 3 27 Troubleshooting and Repair GEK 25361A Central Processing Unit Troubleshooting ie Corrective Action 3 28 Turn off power to the CPU Remove the faceplate from the appropriate memory slot Remove the memory board using the extraction insertion tool Remove the top board cover component side by pinching in the fangs of the clips that hold the cover on while pulling up on the cover If the light was flashing install the new battery Catalog Number IC600MA5074 as follows 1 Do not disconnect the battery but do remove it from its mounting clips 2 Place the new battery in the clips 3 Connect the battery by using the second unused battery connector 4 Disconnect the defective battery and discard it WARNING Do not discard the Lithium Manganese Dioxide battery in fire Do not at tempt 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 If the BATTERY light was out install the new battery as follows Disconnect the defective battery from its battery connector Memory data will be lost Be sure to have a backup program on tape or in PDT Remove the battery from its mounting clips Discard the def
113. al backup for CMOS RAM memory Two key switches are on the front panel a CPU Run Stop switch and a Memory Protect switch The terminal strips have a cover supplied as a safety precaution Figure 9 is the Series Six CPU power supply with a view of the front panel and the electronics 1 16 General Description of the Series Six GEK 25361A Central Processing Unit 1 Logic Power Switch Circuit Breaker 6 Standoffs 4 for Terminal Block Covers 2 Terminal Block Connections to Rack 7 DC Power OK Indicator Backplane 8 Memory Protect Write Keyswitch 3 Power Supply Board 9 CPU RUN STOP Switch 4 Auxiliary Circuit Board 5 Terminal Block AC Input Alarm Contacts Auxiliary Battery Figure 9 SERIES SIX CPU POWER SUPPLY Ref 81 PC 35 1 17 General Description of the Series Six GEK 25361A Central Processing Unit LOGIC CONTROL The Logic Control module contains circuitry for generation of signals which provide control to all of the other CPU modules The circuitry includes an Am2910 microprogram controller and 512 or 2048 words by eighty eight bit PROMs for microprogram storage Figure 10 is a view of the Logic Control module showing the faceplate and the Logic Control circuitry Two versions of the Logic Control module are available the difference being the program entered into them One Part Number IC600CB501A is programmed for the Basic Functions the other Part Number IC600CB5024 is pro grammed for the Extended Functi
114. any reason verify the position of these jumpers prior to returning the module See Table 11 Factory Factory Jumper Setting Jumper Setting 78 79 81 82 84 85 96 97 99 100 Table 1 1 BOARD JUMPERS REFERENCE ONLY 2 37 Installation GEK 25361A The I O Rack When the option jumpers have been properly configured for operation using either a two twisted pair cable or an RS 232 modem link the Remote I O Receiver can then be installed its I O slot Install the printed circuit board using the extraction insertion tool Connect the grounding wire from the faceplate to the rack then install the faceplate by placing it in position and securing it by turning the quarter turn thumbscrews clockwise 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 Wiring connections and part numbers for the connectors and cable required are listed in Figures 50 and 51 in Chapter 1 The cables are to be user supplied If there is to be more than one 1 0 rack in the Remote l O station the next downstream rack will connect to the bottom connector using 16 pair parallel I O chain cable This ca
115. are clearly marked on the board Figure 3 VR103 VR105 VR104 FOCUS SUB BRIGHTNESS VERTICAL LINEARITY VR102 VERTICAL HEIGHT 7 VR101 VERTICAL HOLD HORIZ RTAL DISPIIANOWIDTH LINEARITY HORIZONTAL CENTERING Figure 3 CRT ADJUSTMENT CONTROLS VIDEO MONITOR BOARD n r 70 nN 3 9 Troubleshooting and Repair GEK 25361A Program Development Terminal Troubleshooting 3 10 Sub Brightness The brightness can be controlled by adjusting VR104 Set the external brightness control on panel inside of the cable storage compartment to its center position then adjust VR104 so that the back ground raster is barely visable Back off VR1 04 until the raster just disappears The focus is affected to some extent as the brightness control is adjusted to provide the user with optimum viewing conditions Focus The focus control VR105 allows adjustment for the sharpest display on the CRT screen The focus control should be adjusted to provide the desirable amount of line detail in the display Vertical Hold Vertical Frequency The vertical hold control VRI 01 allows adjustment to eliminate vertical rolling of the display Rotate this control slowly until the display locks in vertically Vertical Height The vertical height control VRI 02 adjusts the vertical height of the display area Vertical Linearity The vertical linearity control VR103 allows an adjustment to provide equal spacing on either side of the
116. 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 l O station i e 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 pro vide status information which can be monitored on the Program Development Terminal by observation of the Input Status Table The eight output references are for future use Table 29 lists the information provided by these inputs In the table I O references 0297 0304 are used as an example As viewed in the Status Table a 1 indicates that the input is on and a 0 indicates that the input is off 1 104 General Description of the Series Six GEK 25361A Input Output System Reference Information Provided Input toggles every time new input data is transferred to the CPU Reserved Reserved Remote Parity 0 Parity error in Remote I O station Remote parity good Remote OK 0 Fault in Remote System Power supply failure parity error etc 1 Normal operation Remote I O OK Link OK 0 Error
117. arity error detected in this Remote I O system Table 5 INDICATOR CHART Continued When troubleshooting the I O system it is important to understand the interconnection of I O racks and stations Refer to the following illustrations of CPU to I O rack connections I O rack to I O rack connec tions and an I O rack wiring scheme sure that all cables are connected to the proper modules and are secure The limitations as to distance between racks and stations should be followed otherwise unpredictable problems may occur 3 40 Troubleshooting and Repair I O System Troubleshooting NOTE If Auxiliary 1 0 Module CPU required Auxiliary 1 0 System will connect to slot no only in a Model 6000 600 60 Model 6000 CPU Cable length up to 50 feet a 25361 1 0 Control Module External Alarms 115 230 AC 1 0 50 60 Hz Rack 15 230 50 60 Hz 4 16 Twisted Cable Daisy Chain to next 1 0 Rack IOR Module NOTE 10 Racks maximum on Daisy Chain Last rack may be no more than 50ft from the CPU in a CPU Station Figure 9 CPU TO I O RACK CONFIGURATION Ref 7n 11 Program Development Terminal Can connect to CPU or an 1 0 Rack in a CPU Station or Local 1 0 Station 3 41 Troubleshooting and Repair GEK 25361A I O System Troubleshooting From previous 1 0 Rack or CPU 1 0 1 0 Transmitter Mo
118. ble lists the jumper number its function factory setting and the alternate setting Factory configuration is for operation with a two twisted pair cable communications up to 10 000 feet 3 Km FACTORY ALTERNATE JUMPER FUNCTION SETTING SETTING Quantity of 1 0 1 2 120 120 I O 248 248 I O Remote I O Parity STOP CPU CPU Continues Error Effect On CPU to RUN Communications Failure STOP CPU CPU Continues Effect on CPU to RUN Even or Odd Parity Odd Even Specify Parity Check Yes No Baud Rate 57 6 Kb Carrier Detect No Yes Clear To Send No Yes Output Mode Twisted Pair RS 232 Input Mode Twisted Pair RS 232 Sensitivity Medium Minimum Alternate setting for the baud rate is a selectable baud rate for RS 232 operation The selectable baud rates and their appropriate jumper settings are listed in Table 8 Note that three jumpers must be set when changing the baud rate configuration Table 7 REMOTE O DRIVER JUMPERS 2 33 Installation GEK 25361A The I O Rack Table 8 SELECTABLE BAUD RATE JUMPERS RS 232 OPTION NOTE If the RS 232 option is selected the Remote I O Driver module must be installed in a High Capacity I O rack Catalog Number IC600YR510A 115V AC or IC600YR5 12A 230V AC or a Model 60 CPU rack When all of the option jumpers are properly configured for either operation with two twisted pair cable RS 232 modem as required the Remote I O Driver can then be installed in its I O slot Install the
119. ble will in turn connect to an 1 0 Receiver in the next rack If the rack containing the Remote Receiver is the only rack in a Remote Station terminate the I O chain signals by configuration of jumpers 89 91 and 94 on the Remote Receiver printed circuit board see Table 9 CABLE CONNECTIONS Cables are available for interconnection between racks on the parallel I O chain in standard lengths The maximum cable lengths a system configuration are determined by the type of I O station used For cable limitations refer to Figures 54 55 and 56 in section 4 of Chapter 1 in this manual Table 12 lists the standard length I O cables available IC600WD002A IC600WDOO5A IC600WDO1 IC600WD025A IC600WDO050A IC600WD 100A IC600WD200A IC600WD300A IC600WD400A IC600WD500A Table 12 lO CABLES FOR LOCAL I O EQUIPMENT 2 38 Installation The I O Rack GEK 25361A CABLES The following drawing is the I O Cable used to connect a CPU to 1 0 rack of between I O racks when utilizing local I O equipment 2 IN TUBING OVER SHIELD IN CABLE LENGTH ER CHART BELOW CABLE TIE STAMP CABLE NUMBER 1C600WD 5A IN THIS AREA gt HOOD MOUNTING HARDWARE 2 PER CONNECTOR PIN el THIS END MALE CONNECTOR MOUNTING HARDWARE 2 PER CONNECTOR WIRE TABLE FOR ALL CABLE LENGTHS 3 IN NSIDE PLUG WIRE TABLE PLUG e2 NO CONNECTION SOCKET BLUE WHT SOCKET 2 WHT BLU SOCKET
120. board jumper is set for the internal loop supply Display the Ouput Status Table on the screen of the Program Development Terminal with the cursor on the lowest output number assigned to this module by the DIP switches Shift the dis play to hex format obtaining a display of four hexadecimal digits corresponding to the 16 Output Status bits used by this module LOW END Using the PDT keyboard enter the four hex digits shown in the LOW END column of the Cali bration Table into the Output Status Table Note that the first digit assigns the channel number 0 3 Adjust the Offset Pot Refer to Figure 13 for this channel until the DVM reads the voltage shown in Table 9 HIGH END Using the PDT keyboard enter the four hex digits shown in the HIGH END column of Table 9 into the Output Status Table Adjust the Gain Pot Refer to Figure 13 for this channel until the DVM reads the voltage shown in Table 9 Repeat steps No 2 and No 3 until no further change in either pot setting is required Troubleshooting and Repair GEK 25361A I O System Troubleshooting 5 Change the connections according to Table 8 and repeat steps No 2 No 3 and No 4 for the second channel the third channel thefourth channel Terminals Channel Offset Gain V Number X Pot Pot First Channel 5 4 1 2 0 51 R59 Second Channel 10 9 6 7 1 R35 R43 Third Channel 15 14 11 12 2 R20 R27 Fourth Channe
121. can communicate with the CPU through the Communications Control module This interface allows an external intelligent device such as a computer to communicate with a Series Six Programmable Controller Two connectors are provided for connection to the module The connectors are mounted at the bottom of the module The upper connector is a 25 pin D type and is configured to accept a device using either an RS 232 RS 422 or 20mA current loop interface The baud rate of the low speed port is jumper selectable See Chapter 2 Installation The lower connector is a 9 pin D type and can accept a device using either an RS 232 or an RS 422 interface The baud rate of the high speed port is the same speed as the low speed port There are 4 LED indicator lights which are viewed through the faceplate lens The LED s and their func tions are as listed in the following table INDICATOR DESCRIPTION BOARD On Board diagnostic has passed the self check test and is operating properly OK Flashing Configuration jumper s in wrong position Off Indicates a hardware failure MATCH On Tape Mode Instruction set for tape data and CPU is compatible A OK good compare has been made Off An attempt has been made to write to an illegal address in the CPU or tape does not compare to CPU contents The data on tape has ex ceeded the capacity of the CPU memory or CPU and tape incompa tibility because of instruction set differences DATA On Serial Link
122. cation Modules 2 27 VO iudice 2 27 VO Transmitter 2 30 Remote 1 0 Driver 2 30 Remote 1 0 2 2 4 2 34 Cable Connections 2 38 0 0 eR 2 39 l O Point Selection 1 2 41 l O Module 1 2 42 Section 3 1 0 Module Wiring AC DC Input Module 2 45 High Density Input Module 2 48 Analog Input Module esee 2 52 Interrupt Input Module 2 54 Thermocouple Input Module 2 57 AC Output Module 2 62 Isolated AC Output Module 2 65 Table of Contents GEK 25361A Section 3 Module Wiring Continued DC Output Modules 2 68 High Density Output Module 2 72 Analog Output Module 2 75 Reed Relay Output Module 2 79 Section 4 Program Development Terminal Installation Instructions 2 83 CHAPTER 3 Troubleshooting and Repair Section 1 Introduction Programmable Control Service Center 3 2
123. ce the Remote I O Receiver does not require an I O address no DIP switch on backplane adjacent to the leftmost slot A Remote I O Receiver connected to a Remote I O Driver located in a model 60 CPU CPU station or a Local I O station through a two twisted pair cable can be installed in any I O rack If connection to the Remote l 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 REMOTE RECEIVER 1 Connector From Remote l O Driver 6 Connector to Downstream Receiver Module in Upstream Local I O System Module 2 LOCAL OK Light 3 LINK OK Light NOTE 4 REMOTE OK Light For Location of Option Jumpers 5 REMOTE PARITY Light Refer to Chapter 2 Figure 19 Figure 53 REMOTE I O RECEIVER MODULE 1 108 Ref 82 PC2 General Description of the Series Six GEK 25361A Input Output System Circuitry on this module converts output data from serial to parallel and converts input data from a paral lel 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 are daisy chained to the Remote I O Receiver through I O Receivers Connectors A Remote I O Receiver has two edge mounted D type connectors The top connector 25 pin connects to a Remote Driver at the opposite
124. ceiver 9 l O Transmitter 34 115V AC DC Input 6 115V AC Output 54 103 Total Example 2 is not allowable The total units of load exceed the 100 units available This combination of modules requires the high capacity I O rack with 275 units of load available 2 44 Installation GK 25361 A I O Module Wiring SECTION 3 I O MODULE WIRING AC DC INPUT MODULE An Input module can be installed in any I O slot in an I O rack except the one at the extreme left This slot does not have DIP switch for setting an l O point starting number and is reserved for a communi cation module In a Model 60 CPU the 6 slots to the left are for I O modules More than 192 I O points in a Model 60 system require an I O rack s to be connected to the CPU Before installing a discrete 8 circuit AC DC module select the starting I O point reference number by configuring the seven segment DIP switch on the backplane adjacent to the selected I O slot Refer to Figure 23 for DIP switch settings The module has 2 parts the terminal assembly and the logic board see Figure 24 Typical Input Module Install the printed circuit board using the extraction insertion tool furnished with the CPU With the circuit board in place in its I O slot slip the terminal assembly over the circuit board so that the terminals near the bottom of each part are mated properly Next secure the terminal assembly to the rack using the quarter turn thumbscrews 1 Input O
125. ciated with the input 2 56 Ref 70 125 Installation GEK 25361A Module Wiring NOTE We recommend that you power down your Series Six Programmable Controller before installing or removing the Interrupt Input module A parity error could result at any address in the I O structure if you do not power down as recommended THERMOCOUPLE INPUT MODULE The installation and wiring instructions which follow are for the Thermocouple Input module available in the four versions listed below Temperature Range Catalog Number 210 to 760 C ICGOOBF813A 346 to 1400 F 212 to 1232 C IC600BF814A 350 to 2250 F O to 1768 C 81 32 to 3200 F 270 to 400 C ICGOOBF816A 454 to 752 F A Thermocouple Input module can be installed in 1 slot in a model 60 CPU or in an I O slot in an 1 0 rack except the left most slot Before installing the module select the starting l O point number by configuring the seven segment DIP switch on the backplane adjacent to the selected 1 0 slot This will assign a group of 32 consecutive input points required for operation of this module Refer to Figure 33 for specific DIP switch settings Module DIP SWITCH POSITION INPUT DIP SWITCH NUMBER POSITION EE 705 73 737 76 769 80 801 83 833 86 865 89 897 92 929 96 961 99 993 10 ECCERI 4 UNA PT a AN P
126. cifications for the Analog Input module are as listed in Table 11 5V DC 1 5A Supplied by Rack Power Supply Power Requirements User must supply analog input voltage or current levels Input Overvoltage Protection provided for input voltages up to 30V Input 8ias Currents 200 pA at 25 C maximum 8 nA at 70 C maximum Input Impedance 100 M 0 Typical Input Capacitance lt 1 OpF for OFF channel lt 1 OOpF for ON channel Common Mode Rejection 7 60 dB DC to 1 kHz Noise Immunity Cross Talk gt 74dBat 1 kHz 12 Binary Bits 1 part in 4096 gt 0 025 of Full Scale at 250C Temperature Coefficient Linearity 6ppm of Full Scale per OC Gain 18ppm of Full Scale per 9C Offset lt 10 of Full Scale per OC Table 11 ANALOG INPUT SPECIFICATIONS Each module contains an eight to one analog multiplexer A D circuitry opto isolation circuitry an ad dress decoder and data bus drivers Circuitry is also provided for detection of open wire overrange and underrange conditions One LED indicator viewed on the faceplate displays module status Figure 33 is an Analog Input module showing various features of the module 1 61 General Description of the Series Six Input Output System GEK 25361A Four connections are provided for each channel on the user connector block mounted on the faceplate The input wiring is configured according to the type of module An illustration is provided in Chapter 2 showing ty
127. circuit boards are keyed to match the corresponding faceplates 224 Installation The Rack 3 eeu Rees ea GEK 25361AA Umen 1 0 Sasa dpt 1 Power Supply Available in Stan 7 System Communications Module dard or High Capacity Model Receiver Shown 2 Power supply Terminal Block AC Input a Connector to I O Control Another 1 Connections Receiver an I O Transmitter or a 3 DC Power OK Light Remote Receiver 4 Logic Power Switch Circuit Breaker 9 Connector to a Downstream I O 5 Slot Number 11 For Reference Only Receiver 6 Slot Number 1 For Reference Only lO Tray for Field Wiring Figure 14 TYPICAL I O RACK Ref 81 PC 56 1 15 Installation GEK 25361A The I O Rack POWER SUPPLY The I O power supply is shipped from the factory installed in the rack 5V DC at 6 1 A is provided for the standard I O rack or 5V DC at 16 5A 12V DC at 1 5A and 12V DC at 1 0A for the high capacity lO rack There is one terminal board located on the lower part of the faceplate Remove the protective cover plate and make the following connections Refer to Figure 15 which is an illustration of the terminal board and its connections E ae for 15 or 230V AC Operation gt 30V AC No Connection LI Line i AC input L2 Line 2 AC GND Ground Figure 15 POWER SUPPLY CONNECTIONS Select 115V AC or 230V AC in
128. ck to I O Rack Configuration DET 3 42 VO Rack Wiring 5 3 43 Potentiometer Locations Analog Input Module 3 57 Potentiometer Locations Analog Output Modules ios d entere no cect eneddenetsctereceeeszeces 9700 Table of Contents GEK 25361A TABLES Chapter 1 1 Series Six Features and Functions 1 5 2 Physical Electrical Characteristics 1 6 3 WO Modules essere 1 9 4 Communications Control Status Indicators 1 34 5 Power Supply Electrical and Environmental Characteristics 1 40 6 Alarm Conditions 1 46 WO Module Color Code 1 54 8 Specifications Discrete Input Modules 1 55 9 Specifications High Density Input 1 57 10 Analog Input Module Ranges 1 60 11 Analog Input Specifications 1 61 12 Digital Data Format 1 64 13 Specifications Interrupt 1 67 14 Temperature Ranges for Thermocouple Input Modules esse 1 69 15 Thermocouple Input Specifications 7 1 16 Digtal Data Format 1 73 17 Specifications AC Output Modules 1 74 18 Specifications Isolated AC Output Modules 1 76
129. ct the Pro duct Service Specialist at 804 978 5624 for assistance REED RELAY OUTPUT MODULE The Reed Relay Output module Catalog Number IC600BF914A provides six form C mercury wetted contact outputs A Reed Relay Output module can be installed in any 1 0 slot a model 60 CPU or in any slot in an 1 0 rack except the left most slot Before installing the module select the I O starting point number by con figuring the seven segment DIP switch on the backplane adjacent to the selected 1 0 slot The I O point selected will be the first of six consecutive outputs assigned to the Reed Relay module Figure 23 can be used as a guide for setting the DIP switches however remember that only the first six I O points will be used by this module There are two jumper selectable options on the circuit board It should be determined if the factory con figuration is suitable for the application Factory configuration is for normally open contacts and RC pro tection circuits for each of the six output circuits 2 79 Installation GEK 25361A I O Module Wiring DRRAI 9110 2100 700 20 Malice bd 4M3 1Cl21i09 6 3 4 1 Jumpers 2 4 6 8 10 12 PL Select 6 Jumpers JI J6 from Selection of Contact Normally Open Contacts Protection RC Network to be In or 2 Jumpers 3 5 7 9 11 13 PL Select Out of Circuit Normally Closed Contacts 7
130. d CPU REGISTER Number of words of register memory in the CPU either 256 or 1024 MEMORY WORDS USED Number of words of memory in user program NUMBER OF Number of subroutines used in the user program SUBROUTINES CPU FLAGS Type of CPU error and location The Internal Memory module has 2 LED indicators viewed through the faceplate One of the LED s BATTERY displays the status of the Lithium back up battery for the CMOS RAM memory The other LED PARITY shows that Logic Memory parity errors exist Figure 13 is a photograph of the Internal Memory module 1 25 General Description of the Series Six Central Processing Unit GEK 25361A INTERNAL MEMORY 1 Programming Switches For Memory 3 Parity Light Size Slot Location 4 Battery Connectors 2 Battery Status Light 5 Lithium Manganese Dioxide Battery Figure 13 INTERNAL MEMORY MODULE 1 26 Ref 81 PC 19 General Description of the Series Six GEK 25361A Central Processing Unit Memory Addressing and Memory Map Allocation The CPU must be told how much logic memory is to be used for proper addressing and memory map allocation This function is performed by a group of 8 DIP Dual In line Package switches located on the Internal Memory module There are 4 slots available for Logic Memory modules in a Model 6000 Each slot has 2 DIP switches which correspond to these slots located on this module In the CPU the slot to the left of the Register Memory
131. d be a representation of the decimal number 770 1 65 General Description of the Series Six GEK 25361A Input Output System It is recommended that calibration of the Analog Input module be performed every 90 days at normal Operating temperature Calibration procedures are detailed in Chapter 3 of this manual NOTE The Analog Input module will function properly only when used with CPUs with the following serial numbers Model 60 CPU Cl 88 8135 0130 and higher Model 600 CPU CI 88 8138 0100 and higher Model 6000 CPU CI 88 8138 6000 and higher If your CPU has a serial number lower than that listed contact the PC Product Service Specialist at 804 978 5624 for assistance 1 66 General Description of the Series Six GEK 25361A Input Output System Interrupt Input Module The Interrupt Input module provides a method of initiating a subroutine in the user program that is stored in the CPU memory A signal to an Interrupt Input module is generated by a user device The re quired voltage level of the interrupt signal from a user device is 10 to 30V DC An interrupt input to the CPU can occur on either a positive or on a negative transition of the interrupt signal The transition either an ON OFF or OFF ON edge trigger is jumper selectable by positioning a jumper plug on the proper terminals on the circuit board Figure 35 is an interrupt module Specifications for the Interrupt Input module are as listed in Table 13 Pow
132. d by com mands from the Program Development Terminal DPU 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 MEMORY PROTECT KEY SWITCH Position DEFINITION PROTECT The contents of the Logic Memory and the Override Table are protect ed from being changed WRITE The User program in the Logic Memory may be changed and an over ride condition may be added to or removed from inputs or outputs through the Override Table If keyswitches in and Q do not operate and all status indicator lights are OK check the P2 connections on the CPAXI board in the power supply module See Figure 5 3 17 Troubleshooting and Repair GEK 25361A Central Processing Unit Troubleshooting CPU Power Supply DEFINITION The voltage levels of all 3 DC outputs 5V 1 2V 12V are within the specified tolerance At least one of the voltage levels is out of tolerance The CPU RUN and ENABLE status lights should also be off Alarm No 1 relay switches aa 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 The connections are labeled as shown below 6 6 2 6 2 0 6 6 9 6 G 6 N H 5 N N 2 212 N E 0 V D D V V V D U
133. d by other status lights try re enabling the CPU from the PDT or with the RUN STOP keyswitch DPU lO Control Module Light Status Definition The Data Processor 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 De Corrective Action Check power to the Data Processor unit f the Data Processor is in its own rack check the power supply voltages Refer to the DPU Users Guide for further troubleshooting procedures 3 23 Troubleshooting and Repair GEK 25361A Central Processing Unit Troubleshooting Arithmetic Control Module Status Definition CPU execution sequence is proceeding normally self test routine is passed at least once each 200 milliseconds 50 milliseconds CPU self test routine has not been passed within 200 milliseconds 50 milliseconds The RUN and ENABLE lights are off Alarm No 1relay switches Reset signal is sent to the l O chain ee Corrective Action Check the condition of the POWER and memory BATTERY lights If any are off correct them first Turn the CPU Keyswitch to STOP power down and back up Make sure that the user program has an End of Sweep Disconnect any peripheral device such as the Program Development Terminal or Mini cartridge Tape Unit Reseat the Arithmetic Control and Logic Control modules if this does not correct the problem replace th
134. d capacity of the power supply in a rack Table 13 lists the I O load for each module The power supply Model 60 CPU rack allows up to 100 units of load for the I O modules contained in that rack 2 42 Installation GEK 25361A The I O Rack MODULE NO OF CIRCUITS UNITS OF LOAD 12V AC DC Input 24 48V AC DC Input 115V AC DC Input 230V AC DC Input 12V DC Sink Output 24V DC Sink Output 48V DC Sink Output 1 15V AC Output 230V AC Output 12V DC Source Output 24V DC Source Output 48V DC Source Output 0 1 OV DC Analog Input 10 to 1 OV DC Analog Input 4 20 mA 1 5V DC Analog Input 0 to 10V DC Analog Output 10 to 10V DC Analog Output 4 20 mA Analog Output Isolated AC Output Reed Relay Output 5V TTL 10 50V DC Input 5V TTL Output 10 50V DC Output Interrupt Input Thermocouple Input lO Receiver Remote 1 0 Receiver l O Transmitter Remote 1 0 Driver Table 13 SUMMARY OF I O LOADS 2 43 Installation GEK 25361A The I O Rack The following 2 examples show combinations of modules in standard I O racks with 11 avaiiable I O slots Example 1 Standard I O Rack 100 Units of Load Unit of Load Total Quantity Per Module Units 1 0 Receiver 9 115V AC DC Input 10 115V AC Output 45 64 Total Example 1 is an allowable combination since the total of the units of load do not exceed the 100 units available Example 2 Standard I O Rack 100 Units of Load Quantity 1 0 Re
135. dule Rack 1 0 Receiver Module 15 230 AC 50ft maximum 30 60 Hz between first and last rack in a Parallel Bus Daisy Chain l6 Poir Twisted Cable To 1 0 Rack in t Local 1 0 Station 500 maximum 1 0 Module 15 230 AC Remote 1 0 50 60 Hz To next 1 0 Rack 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 may be placed in any slot in an 1 0 Rack except the leftmost slot which must be an 1 0 Receiver or Remote 1 0 Receiver Serial Channel 2 Pair Twisted Cable Figure 10 1 0 RACK TO I O RACK CONFIGURATION 3 42 Ref 70 12 GEK 25361A Troubleshooting Repair System Troubleshooting From CPU ot previous 1 0 Rack Two Twisted Pair Serial Cable to 10 000 3km If a Remote or a Cable from Modem RS 232 Link Station Parallel Bus l6 Pair Twisted Cable 0 Receiver Module 15 230 AC 90 60 Hz To next 1 0 Rack y Dais ain Wiring to from External Devices Terminal ASSET Box Lug Terminals 2 Wo 4 Awg i I No 12 Awg wire per terminal Wiring tray contains wiring Matching cover attaches Remote 1 0 Receiver if first rack in a Remote 1 0 Station Figure 1 1 I O RACK WIRING SCHEME Ref 70 13 3 43 Troubleshooting and Repair GEK 25361A I O System Troubleshooting
136. dule can be used to switch loads with voltages up to 250V AC DC at 2 amps Each of the outputs is individually fused and has an LED indicator that turns on when the corresponding reed relay coil is energized Table 24 is a list of specifications for this module Contact Type Form C Normally Open 0 or Normally Closed N C Jumper Selectable Power Requirements 5V DC 1 0A maximum Supplied by I O rack power supply User Supplied Voltage 250V AC DC maximum Current 2A continuous 2A inrush Voltage Drop AV Q 2A Power 100 VA maximum ON Delay OFF Delay Contact Resistance 50 millohms maximum Contact Life 100 000 000 108 operations with contact protection Contact Protection RC network 68 Q 012 Jumper selectable for in or out of circuit Table 24 SPECIFICATIONS REED RELAY MODULE Each circuit has a jumper plug to allow selection of the de energized state of the relay in that circuit to have either normally open N O or normally closed N C contacts A second jumper in each circuit allows removal of the RC protection circuit across each output Removal of this jumper plug which is in series with the RC circuit allows for the operation of low level analog and instrumentation signals where arc suppression is not a factor during normal operation Fuse clips are provided for both American 1 4 x 1 1 4 and European 5mm x 20mm style fuses Figure 45 is a Reed Relay Output module with the described features ind
137. dules The modules in the I O rack are determined by the system con figuration 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 Receiver If more than IO 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 racks A Program Development Terminal can be plugged into the CPU or the last I O rack in a CPU I O station or a Local I O station 1 110 General Description of the Series Six GEK 25361A Input Output System he SSS SSS SSS Eee 7 CPU l 0 C 16 Parallel Cable 1 0 Rack 16 Cable 1 to Local 10 1 0 Station 1 0 Modules ee ee le EE 1 0 Rack of 50 E from CPU on 1 Daisy Chain olo 7 TIT 1 0 Modules 1 0 Rack 500 maximum from 10 IOT Module 1 0 Modules l 2 Pair Serial Cable to Remote 1 0 Station DRIN 225364225223 OQ Total of 10 16 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 54 CPU I O STATION General Description of t
138. e 44 DIP SWITCH SETTINGS FOR ANALOG OUTPUT MODULES 1 86 F 37732 x IX X X IX 753 768 x IxIxIXIX 65 80 l 17 32 Ixxi ixl 762 784 751 96 x 433 228 ix 785 800 xix Ix 37332 xx 249 464 IX x X 801 816 X X 1X 113 128 x X X 465 480 x X X X 817 832 IX X 129184 XL i aare l 833 848 XIX xt H S IS RELL 39758 OR EX IET 823 864 DOT TX LC X 161 176 x x 513 3238 x 865 880 x x X X 177 192 x xix 529 544 xT ix 881 896 x x xxix 193 208 x x 1545 5560 x ix 897 912 209 224 IX X x 1561 56 x xix 913 928 xixix ix 225 240 xixix 577 592 x x 929 944 x x x x 241 256 I x x x 593 608 x Ix x 945 960 x xx x X 257 272 x 609 624 x xix 961 976 x x XIx EU NM MEME ores iddi d 289 304 x Ix 641 656 x x 993 1008 x x X X X 305 320 X xk 657 672 x k k 1009 1024 x x x X X X 321 336 Ix x xi kiki s Used pras k KT DAAE Ref 70 151 General Description of the Series Six GEK 25361A Input Output System Two consecutive I O addresses 16 I O points are required to write all 16 bits of information associated with each channel A single channel is normally accessed dur
139. e 58 MN Depth 16 1 2 in n 419 1 mm SHY FE Heigl 124 210 317 5r 3 nm Handle Figure 58 PROGRAM DEVELOPMENT TERMINAL ENCLOSURE KEYBOARD The Program Development Terminal incorporates a keyboard assembly which folds out from the enclosure With the unit resting on its back the keyboard will open to a position which allows operation from an upright position The keyboard extends 8 1 4 inch 209 55mm When the terminal is setting on its base the keyboard folds down to an angle that is comfortable for data entry The keyboard folds up into the terminal for storage and transportation thus protecting the unit in a secure rugged enclosure A molded ridge around the edge of the keyboard protects against damage to the keys if the handle should be in the way when the keyboard is closed The pushbuttons are reliable solid state modules with good tactile feel and travel which helps greatly in speed and ease of data entry and reduction of operator fatigue Keys are grouped and color coded by function The color coded keys provide a quick reference for the operator when entering programs The key tops are two shot injection molded By use of this method of molding the legend color goes all the way through the key and will not rub off Figure 59 is an illustration of the keyboa
140. e Arithmetic Control and the Logic Control modules one at a time NOTE A program which causes the CPU sweep time to be in the 200 milliseconds 50 milliseconds range can cause the CHECK light to go off Use care when programming subroutines 324 Troubleshooting Repair GEK 25361A Central Processing Unit Troubleshooting t RUN Light Arithmetic Control Module CPU execution sequence is proceeding such that the self test routine is passed and the I O scan is completed at least once every 200 milliseconds 50 milliseconds CPU is in the Run mode CPU is in the Stop mode The Enable light is also off gt Corrective Action Check the position of the RUN STOP keyswitch See Check the condition of other status lights PARITY BATTERY CHAIN OK CHECK and POWER If no other problem is indicated try restarting the CPU with the Program Development Terminal or CPU keyswitch Reset the Arithmetic Control and or the Logic Control modules If 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 turned on in the CPU A valid RUN or CHECK state however is indicated by a steady glow of the LED 3 25 Troubleshooting and Repair GEK 25361A Central Processing Unit Troubleshooting PARITY Light Internal Memory Module Logic Memory parity is good OFF Logic Memory parity error exists The
141. e Central Processing Unit This section contains a hardware description of the Central Processing Unit for the Series Six pro grammable controllers Since the CPU for the Model 6000 and 600 are functionally identical the description of the CPU given for the 6000 applies with some exceptions to the 600 These exceptions are described under Model 600 CPU page I 35 The differences in the Model 60 are described on page 1 37 The primary purpose of the CPU is to perform all logic solving and decision making operations as defined by the user s program that has been entered into the programmable controller In addition the CPU contains various memory circuitry for storing the user s program for storing various tables neces sary for bit status and data manipulation and for storing the firmware program instructions that tells the programmable controller how to perform its operations The Series Six Programmable Controller performs its function by continually scanning the various logic circuits in the CPU Scanning is a technique whereby various logic bits are checked for their current state and certain decisions are made based on those states Lines of logic are examined and solved one at a time in numerical sequence from the first to the last The scan time is variable dependent on the program The scan determines what the states of the I O s should be by examining the user s program The CPU then drives the appropriate outputs as determined
142. e J T C ON ON ON ON ON ON Type K T C OFF ON ON OFF ON ON Type S T C ON OFF ON ON OFF ON Type T T C OFF OFF ON OFF OFF ON 4 Channels 4 8 Channels 1 8 Degrees C Degrees F Table 17 USER SELECTABLE OPTIONS DIP switch positions 1 through 6 select the thermocouple type either J K S or T for the module DIP switch position 7 selects either one 4 channel input group allows four input channels or two 4 channel input groups allows eight input channels DIP switch position 8 selects the temperature scale 2 59 Installation GEK 25361A I O Module Wiring Figure 34 identifies the location of the jumpers and DIP switch referenced in Tables 14 15 16 and 17 Figure not available Figure 34 JUMPER LOCATIONS Install the printed circuit board by using the extraction insertion tool Connect the grounding wire from the faceplate to the rack With the board in place in the rack place the terminal assembly over the circuit board so that proper contact is made between the two parts Secure the faceplate to the rack by push ing in on the quarter turn thumbscrews and turning them clockwise 2 60 Installation GEK 25361A I O Module Wiring Refer to Figure 35 for typical user input connections to a Thermocouple input module A K A O K 2 Fo 2 2 2 A o E 2 e E73 Kaa AON Figure 35 TYPICAL USER CONNECTIONS Each of the eight channels has two connections and Channel 1
143. e presence of power Ref RI PC 65 1 121 General Description of the Series Six GEK 25361A Program Development Terminal KEYSWITCH A three position key operated switch key removable in the Monitor position allows for 3 operating modes Monitor On Line and Off Line In the Monitor mode the Program Development Terminal can read data from the CPU but cannot write data to it All tables input output and override registers and Scratch Pad memory are updated automatically to reflect the status of the CPU The On Line mode allows the user to read data from the CPU and to write data to the CPU Status tables register memory and Scratch Pad memory are updated automatically to reflect the status of the CPU In the On Line mode certain single word changes can be made to the CPU while it is running A main difference between the Off Line and On Line modes is that in the Off Line mode tables and registers are updated by a command not automatically and single word changes while the CPU is run ning are not permitted With the Program Development Terminal in the Off Line mode programs can be created which can be dumped to tape without the necessity of having a CPU present CONNECTION TO I O CHAIN The Series Six Program Development Terminal can be plugged into the last I O Receiver in CPU Station or a Local I O Station This allows the user to connect the Program Development Terminal to an 1 0 rack distant from the CPU the featur
144. each High Density module Analog Input modules have 8 circuits per module and Analog Output modules have 4 circuits per module Isolated AC Output modules provide 6 output circuits and the Reed Relay Output modules also provide 6 output circuits Specifications and features of the various types of modules are more fully described in the discussion of each individual module 1 54 General Description of the Series Six GEK 25361A Input Output System Connections To I O Modules Connections are made to the I O modules by inserting wiring from field devices into box lug terminals These lugs will accept one No 12 AWG wire or two No 14 AWG wires on discrete modules one No 14 AWG wire on Analog and High Density modules Wiring connections conform to UL standard 230 C When the Logic Power switch is turned off on an 1 0 or CPU rack poten tially dangerous voltages may remain at the box lug terminal connections on I O modules These voltages are user supplied and are controlled ex ternally from the CPU or I O racks Operators and maintenance personnel should exercise extreme care when working with the I O modules to pre vent personal injury AC DC 8 Circuit Input Modules Eight circuit discrete AC DC modules are available in the ranges shown in Table 8 ON ON OFF MODULE RANGE DELAY DELAY INPUT LOADING 12V Input AC DC 1 0 20 ms 1 KQ 7 0 mA 12V 24 48V Input AC DC 10 20 ms 3K 0 6 3 mA 24V 115V input AC DC 90
145. ear parity error by switching the CPU from RUN to STOP and back to RUN Replace Remote Receiver if only one rack in the Remote system If more than one rack in the Remote system locate the first rack in the chain with the LOCAL PARITY light off Replace the 1 0 Receiver in that rack Replace the I O chain cable 3 49 Troubleshooting and Repair GEK 25361A System Troubleshooting l O System Troubleshooting Part 2 If none of the status indicator lights are found to be off in the CPU or I O racks but the malfunction ap pears to be an input or output problem then proceed with the troubleshooting in part 2 an An input is not being recognized by the CPU gt Corrective Action Ensure that the correct voltage level for your type of input is being supplied to the input terminal assembly f 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 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 Replace the input board 5 Replace the I O cable gt 3 50 Troubleshooting and Repair System Troubleshooting 12 Only 1 output on a board fa
146. ection Processor Connector Alarm No 1 3 CPU Run Stop Keyswitch Alarm No 2 4 Logic Power Switch Circuit Breaker AC Power Connection 5 Memory Protect Write Switch 7 Connector to Main I O Chain 8 LED Status Indicators Figure 8 MODEL 6000 CPU Ref 81 PC 42 1 15 General Description of the Series Six GEK 25361A Central Processing Unit Options for Model 6000 CPU The optional Auxiliary I O module which interfaces the CPU to the Series Six Auxiliary I O System allows an additional 1000 inputs and 1000 outputs Another option offered with the Model 6000 is the Data Processor The Data Processor is a microprocessor based unit capable of performing functions which are too time consuming or require too much memory for the CPU to perform efficiently CPU POWER SUPPLY The Series Six CPU power supply is self contained on one assembly AC power input is made through connection to a terminal board located on the front panel 115 or 230V AC input voltage may be used as required Three voltages are provided 5V DC 12V DC and 12V DC In addition system control signals are generated by the power supply Input power is turned on or off with a circuit breaker located on the front panel An LED provides visual indication that the power supply is turned on and all operating DC voltages are within tolerance Terminal strips on the front panel also provide 2 sets of alarm contacts and connection for an external battery for use as an extern
147. ective battery Place the new battery in the mounting clips Connect the new battery to either of the battery connectors Replace the top cover of the memory board by pushing it down on the 7 plastic clips Install the memory board in the CPU using the extraction insertion tool The compo nent side of the board should be to your right toward the power supply Replace the faceplate Secure it in place by turning the quarter turn thumbscrews clockwise until they are tight If the BATTERY light had been flashing turn power on and the CPU should commence running in its previous state If the BATTERY light had been out the memory must be reloaded before the CPU can be restarted since the memory may contain invalid data ap oP Troubleshooting and Repair GEK 25361A Central Processing Unit Troubleshooting 4 L3 6 MOUNTING CLIPS BATTERY CABLE PLUG i BATTERY CONNECTORS Figure 6 BATTERY MOUNTING CLIPS AND CONNECTORS 9 If the status indicator lights in the correct state but the CPU is not functioning properly the malfunc tions below may describe the problem If so follow the procedures listed under the appropriate malfunction The CPU is running but is not solving the ladder diagram correctly Check to see if the problem is resulting from a user program error such as overrides multiple register usage SKIP MCR or suspend
148. ed on the back plane adjacent to each slot See Figure 27 These switches are used to assign a unique address for each Input or Output module placed in that slot An Input or Output module can be placed in any of the ten addressable slots Programming of these switches is accomplished by setting each position of a DIP switch either to the open or closed position To set a switch to the OPEN position depress the switch to the left Each DIP switch setting allows the selection of a starting I O point number and either 8 16 or 32 consecutive 1 0 points The number of 1 0 points is determined by the type of I O module Figure 28 is a chart indicating the DIP switch settings for 8 circuit modules Modules requiring selection of more than eight I O points have a similar chart showing the switch settings included in the module descrip tions later in this section It should be noted that each address can be used two times once for an input module and once for an Output module erececcecrre 2 1 Seven Segment DIP Switches IO In Each I O Rack Figure 27 lO ADDRESS SWITCHES Ref 50 1 49 General Description of the Series Six GEK 25361A Input Output System pon oT 15 213 ZI 1 0 POINT 6 5 4 3 2 1 PomT 1716 514 3 211 POINT r7 6 5 4 3 2 L LLILLLI 1337344 xX 613 60 x X X 9 16 X 345 3527 x X 1681 688 X X 1 34 xy 1353 50
149. egative values The 2 s complement form of a binary number is found by inverting complementing all bits and then adding one For example the decimal number 770 can be expressed as the 16 bit binary number 0000001 100000010 To find the 2 s complement form first invert giving 1 1 1 1 1 1001 1 11 1 101 then add one to this giving 1 1111 1001 1 11 1 1 10 This would be a representation of the decimal number 770 Each channel on the module can be set independently for an output range of either 0 1 OV 1 0 10V or 4 20 mA by configuring jumpers on the printed circuit board Refer to the Installation section Chapter 2 of this manual for instructions on configuration of the jumpers It is recommended that calibration of the Analog Input Module be performed every 90 days at normal operating temperature Calibration procedures are detailed in Chapter 2 of this manual NOTE The Analog Output module will function properly only when used with CPUs with the following serial numbers Model 60 CPU 88 8135 0130 and higher Model 600 CPU CI 88 8138 0100 and higher Model 6000 CPU CI 88 8138 6000 and higher If your CPU has a serial number lower than that listed contact the PC Pro duct Service Specialist at 804 978 5624 for assistance 1 88 General Description of the Series Six GEK 25361A Input Output System Reed Relay Output Module The Reed Relay Output Module provides six form C mercury wetted outputs This mo
150. el 60 or a model 600 CPU A model 6000 CPU can support two Inter Input modules one in the main 1 0 chain and one in the auxiliary chain An Interrupt Input module has eight input circuits The input terminals are arranged in four groups of two with each group having an isolated neutral Figure 31 is an Interrupt Input module 1 Jumpers for Selection of Either Rising Edge or Falling Edge Transitions for each Input Figure 31 INTERRUPT INPUT MODULE 2 34 Rd 87 PC Installation GEK 25361A I O Module Wiring The DIP switch on the backplane is ignored by the Interrupt Input module since the module address is hardwired on the circuit board In the main chain the module input numbers 1 8 lO points 11001 11008 correspond to subroutines 1 8 in the user program In the auxiliary 1 0 chain the module input numbers 1 8 points Al 1001 Al 1008 correspond to subroutines 9 16 in the user program Before installing the module the eight blue jumper plugs on the circuit board refer to Figure 3 should be configured to respond to either rising edge transitions or falling edge transitions Each of the eight jumper locations has three pins For rising edge transitions the jumper plug should connect the middle pin to the N pin For falling edge transitions connect the jumper plug from the middle to the I pin Input response to rising or falling edge transitions can be configured as required for each individual in
151. elected is the first of eight consecutive 1 0 points for the module Use Figure 23 as a guide for setting the DIP switches Terminals for connection to loads to be controlled by one of the DC Output modules are arranged in two groups with four outputs in each group 1 4 and 5 8 Each group has a neutral and a high H connection Each terminal can accommodate one No 12 AWG wire or two No 14 AWG wires Figure 40 is a typical DC Output module showing the terminal arrangement and other module features 2 68 Installation GEK 25361A I O Module Wiring 2 2 a 212507 1 Terminal Cover 4 Output ON Light 1 8 2 User Terminal Block 5 BF Blown Fuse Light 1 8 3 Circuit Board Terminal Block 6 Output Circuit Fuses 3A Normal Blow AGC3 Figure 40 DC OUTPUT MODULE Raf RIPOTA Installation GEK 25361A Module Wiring Install the circuit board using the extraction insertion tool With the circuit board in place in the rack slip the faceplate over the board ensuring that the terminals near the bottom of each part are properly mated Secure the faceplate to the rack by pushing in on the quarter turn thumbscrews while turning them clockwise When wiring the 12V 24V and 48V DC sink and source modules the location of the module in relation to the high side of the user DC power source and the load must be considered Refer to Figure 41 When using a sink module current must flow through the
152. er 5V DC 225 mA maximum Requirements Supplied by I O Rack power supply User Power Source 10 30V DC Interrupt OFF Condition 3V DC Interrupt ON Condition 10VDC Card Filtering OFF ON Delay 300us maximum ON OFF Delay 8ms minimum 10ms typical 12ms maximum Table 13 SPECIFICATIONS INTERRUPT INPUT Eight interrupts are available on each module A maximum of two interrupt modules be used in a system one in the main I O chain and one in the auxiliary chain thereby allowing a total of sixteen in terrupt inputs a system An I O starting point number does not need to be set on the DIP switch on the backplane adjacent to the I O slot containing an Interrupt Input module since the number is fixed hard wired on the circuit board at 11001 to 11008 on the main I O chain and 11001 to 11008 on the auxili ary l O chain 1 67 General Description of the Series Six GEK 25361A Input Output System 1 LED 1 to LED 8 LED numbers correspond to interrupt input numbers Active LED ON indicates current flow through the input circuit 2 Jumper 1 to Jumper 8 Jumper numbers correspond to interrupt input numbers Jumper at N terminal causes corre sponding interrupt input to respond to rising edge Jumper at I terminal causes corresponding interrupt input to respond to falling edge 3 User Connector Block 4 Markable Lens Surface 350884 Figure 35 INTERRUPT
153. er the last I O Re ceiver can be no more than 2000 cable feet 600 meters from the originating CPU 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 sta tion or a Local I O station by direct cable connection A Remote l O Driver placed in a slot in a CPU sta tion or Local station is connected through a two twisted pair serial cable to a Remote i O Receiver placed the left slot of a remote station Any number of Remote I O Drivers and Remote i O Receivers can be used a system Up to 248 inputs and 248 outputs can be used in a Remote 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 link consisting of RS 232 modems 1 51 General Description of the Series Six GEK 25361A Input Output System lO POWER SUPPLY The I O power supply module will accept either 1 15V AC or 230V AC jumper selectable The AC input voltage is routed through a terminal block on the front panel to a circuit breaker LOGIC POWER ON OFF switch then through a line filter to the switching power supply Figure 29 is a block diagram of the I O power supply The standard rack power supply AC input is jumper selectable the high capacity is available in either a 1 15V or 230V AC version Input 15 VAC qu E ge Selectable 230 por D45Y No uj Connection Circuit AC Input Line LI Breaker
154. er completing field wiring to the module install the terminal cover by guiding both of its edges onto the top of the terminal block and sliding it down over the terminals Ref 70 124 2 71 Installation GEK 25361A Module Wiring HIGH DENSITY OUTPUT MODULE The High Density Output module providing 32 output points per module is available in two versions as listed below 5V TTL 6 11 10 50V DC IC600BF913A A High Density Output module can be installed I O slot in a model 60 CPU or in any 1 0 slot in an I O rack except the left most slot Before installing the module select the I O starting point number by configuring the seven segment DIP switch on the backplane adjacent to the selected 1 0 slot This will assign a group of 32 consecutive output points to this module Refer to Figure 43 for specific DIP Switch settings DIP SWITCH DIP SWITCH DIP SWITCH NUMBER POSITION NUMBER POSITION NUMBER POSITION Uh ix xix 205 36 x 385 416 xix 737 768 x x 417 448 xjx x 769 800 449 480 801 832 481 512 2 53 545 576 225 256 257 288 289 320 X 321 352 X Switch in OPEN Position Depressed to the Left Switches 1 and 2 Should be in CLOSED Position 1 32 a 24 p eie gt Figure 43 HIGH DENSITY OUTPUT MODULE I O POINT SELECTION 2 72 Re
155. es Six GEK 25361A Introduction SECTION 1 INTRODUCTION This manual contains a general description of the Series Six programmable controller installation structions and data for troubleshooting if system malfunctions should occur For a detailed explanation of programming the Series Six refer to the PROGRAMMING MANUAL FOR SERIES SIX PROGRAM MABLE CONTROLLERS GEK 25362 GENERAL OVERVIEW The Series Six is a family of programmable controllers Programmable controllers are general purpose microprocessor controls specifically designed for operation in harsh industrial environments A grammable controller accepts data from input devices switches sensors etc performs logical deci sions determined by a program stored in memory and provides output control for machines processes Figure 1 is a basic block diagram of the Series Six programmable controller Input Modules GEN IJO Developmen Terminal Output Devices Modules Power Power SUPPIY SUPPIY Figure 1 BASIC BLOCK DIAGRAM OF SERIES SIX SYSTEM Ref 70 14 1 1 General Description of the Series Six GEK 25361A Introduction Programs are entered edited and monitored with the Program Development Terminal PDT Input data is evaluated logic decisions are made based on the stored program and appropriate outputs are driven by the Central Processing Unit CPU The Input Output I O modules convert electrical signals to logic levels for
156. es of the Program Development Terminal can be used to debug pro grams or diagnose faults for troubleshooting while being close to the device being controlled The only noticeable effect in having the Program Development Terminal distant from the CPU is that communication between devices becomes slightly slower with increasing distance due to propagation delays 1 122 General Description of the Series Six GEK 25361A System Configuration SECTION 6 SYSTEM CONFIGURATION Configuration of a system using the Series Six family of CPU s and I O system has been simplified by the universal rack Mounting hole dimensions and layout allow for ease of mounting in a standard 19 inch rack or in a panel The mounting scheme should be determined by taking into consideration the sur rounding environment allowable space etc See Figure 61 for layout and dimensions of mounting holes For detailed installation instructions refer to Chapter 2 RACK MOUNTING DIMENSIONS 10 25 260 35 18 98 1482 09 48 2 9 09 2 26 MOUNTING BRACKET 3 98 555 09 18 02 457 70 425 18 351 T Tois 3 75 WIRE DUCT ONLY SUPPLEO QN V0 95 25 MIRE OUCT 2 25 57 15 u 75 298 45 FOR WALL ANQ PANEL DAR REMOVE wou UNTI BRACKET TURN mey 50 AND 0 du ON REAROF RACK RE COMHENQED MUN AS WEIGHT 45 Em TH ALL DIMENSIONS IN 1 1 ARE MILLIMETERS SLOTS sd PO
157. etected by the I O Receiver module udi Corrective Action Replace the I O Receiver module Replace the parallel chain I O cable between this rack and the next rack upstream Back toward the CPU Replace the I O Transmitter or Control module driving this station 3 45 Troubleshooting and Repair GEK 25361A System Troubleshooting POWER Light Power Supply fs Ean ne ns ee ee oe ey The voltage level of the 5V DC supply is within tolerance 4 75 to 5 25V DC The voltage level of the 5V DC supply 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 No 1 relay switches gt Corrective Action Check the circuit breaker Check the AC power line Input voltage should be either 115V AC or 230V AC 15 Partially remove the power supply module from its slot and measure the 5V DC output The voltage level should be 4 75 to 5 25V DC Refer to 1 power supply troubleshooting page 3 36 for further troubleshooting ISOLATED POWER l O Transmitter Status Definition 0N Isolated 5V DC bus is within tolerance Isolated 5V DC bus is out of tolerance CHAIN OK lights from this rack back to and including the CPU will turn off RUN and ENABLE Corrective Action Replace the l O Transmitter if the POWER status light is on l
158. f 70 150 Installation GEK 25361A Module Wiring In addition to setting the DIP switches a circuit board jumper for configuration of the module to operate in either the Inverting or Non Inverting state should be set Refer to Figure 44 for the board location of this jumper 10 56 VOC OUTPUT 0 PET 1 7 ETT R o 2 v PEO ED 1 a 4 5 5 H H 3 4 EI 2 7 L 1 2 E 4 5 6 7 1 2 a 4 5 7 a 10 50V DC 5V TTL 1 Jumper for Selection of Either inverting or Non Inverting state Figure 44 HIGH DENSITY OUTPUT MODULES Ref 82 PC 6 82 PC 4 2 73 Installation GEK 25361A I O Module Wiring NOTE When using a High Density Output module to drive a High Density Input module both modules should be configured in the same mode Inverting or Non Inverting Following this procedure ensures that the bit values sent from the Output Status Table to the Input Status Table are not inverted Install the printed circuit board using the extraction insertion tool Connect the grounding wire from the faceplate to the rack With the board in place slip the terminal assembly over the circuit board so that proper contact is made between the two parts Secure the faceplate to the rack by pushing in on the quarter turn thumbscrews while turning them clockwise Refer to Figure 45 for typical user input connectio
159. f Care should be taken when handling the faceplate or any wires connected to it 2 82 Ref 70 113 Program Terminal SECTION 4 PROGRAM DEVELOPMENT TERMINAL The Program Development Terminal requires minimal installation procedures It is recommended that the following sequence be followed For detailed installation procedures refer to GEK 25362 Program ming Manual For Series Six Lower the hinged panel in the back of the Program Development Terminal allowing access to the cable storage compartment as shown below in Figure 52 Figure 52 PROGRAM DEVELOPMENT TERMINAL STORAGE COMPARTMENT Ref 8 1 PC 62 2 83 Installation GEK 25361A Program Development Terminal 2 84 Unwrap the Program Development Terminal to CPU cable and the AC line cord from the cable wrap area Plug the 3 prong grounding line cord into a 115VAC outlet The Program Development Terminal and CPU should be connected to an AC source providing a common ground between the two units if the PDT is connected directly to the CPU Connect the 12 foot interface cable to the top connector of the I O Control module in the CPU rack Tighten the mounting screws on the connector to ensure a secure connection If any peripheral equipment is to be used connect the appropriate cable Connectors are provided for a printer or a minicartridge tape unit A connector is also provided for a composite video monitor Close the hinged cover the cables will feed out of the ope
160. f the Series Six GEK 25361A Input Output System Isolated AC Output Module The Isolated AC Output module is available in either a 115V AC or 230V AC version Each module pro vides six isolated outputs i e each output circuit can use a separate power source The modules are capable of driving 10 mA to 3 amps The module contains comparator circuitry for decoding the ad dresses presented to the module from the I O bus thereby determining when the module is being addressed Output data is stored in a register on the module before being presented to the output drivers Each output has overvoltage protection and is also protected from inadvertent turn on Each of the six output drivers uses a triac as a switching device which connects the corresponding output terminal to the high side of the user power source when that output is turned ON An LED indicator is present in each circuit to indicate when the circuit is in the ON state Each output circuit is fused and has a neon lamp blown fuse indicator as a visual indication of a blown fuse condition Both the LED output On and the neon lamp blown fuse indicators are visible through the translucent lens on the faceplate Specifi cations for the Isolated AC Output modules are listed in Table 18 User Supplied OFF Output Current ON Leakage Voltage Delay Delay Minimum Maximum OFF 115V AC 90 130V AC lt 1 2 lt 1 2 cycle 10mA 4 400 4 0 mA cycle maximum 230V 180 260VAC 1 2
161. figuration of the DIP switches for 8 circuit modules The I O point number select ed is the first of eight consecutive 1 points one I O address starting with that number Several modules require different switch settings Refer to the installation instructions for each module for the proper configuration of the DIP switches After configuring the DIP switches install the I O modules in their respective slots as determined by your program NOTE There are limitations on the combination of types of I O modules which may be installed in an I O rack The combination of I O modules allowed is determined by the load placed on the power supply by the various modules VO DIP swt POSITIO soo Pee Eero ore 716 514 31211 LT 6 S 4 3T2 1 7161514131211 8 4 X X 673 680 X 68 8 X X X 607 104 X X X 705 112 X LIXX X X 29 76 X Tx X x XIX LL xx 745 751 x xT xt xy X x x 16 XIX xt X XH 769 776 XIX XIX X 185 79 XIR a 53 800 XIX XE 501 508 160 XI X X X 1825 83 Z X X X XIX X m X i XE 841 848 xT xL X 1 X X X 513 x 549 X X 192 921 520 X 564 XIX X XX 2001 6 X 865 872 201 2
162. gic i e a high input is read to Outputs the Input Status table as a O To use positive logic the module should be configured to operate in the Inverting mode TTL Mode Figure 28A TYPICAL USER INPUT CONNECTIONS TTL Mode Connections For operation in the TTL mode the 5V and 5OV terminals should be jumpered together The positive side of the user 5V DC power supply is connected to one of these terminals Connect the negative side of the power supply to either of the COM terminals Connectthe high side of each user input to the appropriate numbered terminal Connect the low side of each input to either of the COM terminals The two COM terminals are tied together inside the module 2 50 Ref 70 127 Installation GEK 25361A I O Module Wiring When using the 10 50V mode a closed switch turns its corresponding input On an open switch turns the input Off When using the 10 50 mode a closed switch turns its corresponding input ON on open switch turns input OFF 10 50 Mode Figure 28B TYPICAL USER INPUT CONNECTIONS 10 50V Mode Connections Connect the positive side of a power supply providing 1 O 50V DC to the 50V terminal Connect the negative side of the power supply to either of the COM terminals Connect the high side of each user input to the appropriate numbered terminal Connect the low side of each user input to either of the COM terminals Both COM terminals are tied toget
163. gram Development Terminal Program Development Terminal Function Enclosure Cable Display Tape tiit ir erben Tape Specifications Power Switch 1212 KeySWIICh uiscera PUR EE Connection to I O Chain Section 6 System Configuration Hardware Requirements Power Requirements Initial System CPU To VO Rack Configuration Rack Configuration VO Rack Wiring Section 7 Data Processor Physical Description Model 600 Data Processor Rack Modules c en ei Data Control Data Prom iuis bela Pii Data Dual Serial Port Programms ceo gb Leine E ERR Message Generator File Storage and Retrieval GEK 25361A 1
164. h the board covers in place it is unlikely that normal handling of the memory modules will cause any damage Be sure that the board covers provided with each of the Logic Memory modules are in place before in stalling the modules Do not allow the bottom of a module to come into contact with a conduc tive metal surface when the board covers are removed Failure to ob serve this CAUTION could result in the discharge of the non rechargeable Lithium battery and the loss of memory contents 2 12 GEK 25361A Installation Rack and CPU Module Installation When installing a Logic Memory module position the side of the board with the LED on it to your right towards the CPU power supply Figure 10 shows proper orientation of a printed circuit board GeNeRaL 7022 45 SERES ee STER ML MC ED NOTE Proper orientation of printed circuit boards is with component side to wards the power supply Figure 10 PRINTED CIRCUIT BOARD ORIENTATION IN A RACK Connect the grounding wire from the faceplate to the rack Install the faceplate s by placing the facep late in the proper position and while pushing in turn the quarter turn thumbscrew clockwise until it feels Secure You are now ready to program the Memory Slot Location switches which activate the memory or memories These switches are located on the Internal Memory module Ref 81 PC 38 2 13 Installation GEK 25361A
165. he Series Six GEK 25361A Input Output System LOCAL I O STATION A Local I O station can have up to 10 I O racks daisy chained through the parallel bus channel No more than 50 feet of cable can separate the first and last rack in a Local I O station A Local I O station is linked to a Model 60 CPU a CPU I O station or another Local I O station through the parallel bus The in terface is from an I O Transmitter module to an I O Receiver module An I O Receiver module may be located a maximum of 500 feet from the I O Transmitter module The last Local l O station in a chain can be a maximum of 2000 feet four I O Transmitter links from the originating I O Control or Auxiliary module in the CPU station A Program Development Terminal can be plugged into any Local I O station This scheme allows the Program Development Terminal to be located up to 2000 feet from the CPU Figure 55 illustrates the allowable configurations for a Local I O station Each rack in the Local I O station can have the same configuration of modules as the I O racks a CPU station 1 112 General Description of the Series Six GEK 25361A Input Output System 16 Parallel Cable from 0 Transmitter at CPU Station Local 1 0 Station or Model 60 CPU SSeS Se rc eS SS SS Se SS ee 1 0 Rack 1 0 Modules Up ee 1 0 Stations can be included a system 1 0 Rack with the last one being no
166. he additional storage provided by these files can be used to expand the CPU s register capability to store recipes for batch processes to retain production data for inventory control and to perform many other processing functions The file structure is illustrated below The maximum file size is 4000 registers Any allowable combina tion of files records and registers can be used up to the maximum number of registers pu x gt an C LL 7 286 M in Registers N 256 maximum Maximum File Size is 4000 Registers Figure 7 1 DATA PROCESSOR FILE STRUCTURE Ref 70 119 1 135 Installation GEK 25361A Rack and CPU Module Installation SECTION 1 RACK AND CPU MODULE INSTALLATION This chapter contains information which will aid in installing the Series Six family of Programmable Con trollers and preparing the system for use Included are instructions for unpacking packing inspecting in stalling in a rack or panel setting internal switches connecting cables input output wiring and initial checkout QUALITY CONTROL Each Series Six system undergoes a thorough quality control inspection and extensive system testing before being shipped Each part of a system has had environmental and operational tests before leaving the factory If any problems should arise with a Series Six system Programmable Control Customer Ser vice should be contacted for instructions Pr
167. her inside the module Note that the 32 inputs are divided into four groups with each group containing eight inputs During the four consecutive I O cycles required to read all 32 inputs GROUP 1 is read during the first I O cycle GROUP 2 during the second l O cycle etc Ref 70 128 2 51 Installation GEK 25361A I O Module Wiring ANALOG INPUT MODULE The installation and wiring instructions following are for the Analog Input module available in the three versions listed below The 4 20 mA module can also be connected to operate as a 1 gt 5 10 50 mA module 0 10V DC 6 10 gt 10 VDC IC600BF842A 4 20mA IC600BF843A An Analog Input module be installed in any 1 slot except the left most slot in an I O rack or in an slot in a model 60 CPU Before installing the module select the starting I O point number by con figuring the seven segment DIP switch on the backplane adjacent to the selected 1 slot This will assign a group of 32 consecutive input points to the module Refer to Figure 29 for specific DIP switch settings INPUT DIP SWITCH ET DIP za SWITCH NUMBER POSITION ET POSITION POSITION a ete e reseo 34 L 97 128 X X 449 480 X XiX 801 832 x 129 160 x 481 512 x xix x 833 864 X 161 192 x x 5
168. hould be configured to operate in the In verting mode A High Density Output module can be installed an I O rack or in an 1 0 slot in Model 60 CPU Before installing the module the starting I O point for that module should be selected by setting the seven seg ment DIP switch on the backplane adjacent to the I O slot which will contain the module Setting the DIP switches according to the chart in Figure 42 will reserve a group of 32 consecutive I O points for that module beginning with the selected 1 point DIP SWITCH INPUT DIP SWITCH DIP SWITCII POSITION NUMBER POSITION POSITION 353 384 385 416 417 448 97 128 449 480 129 160 481 512 3 57 193 224 545 576 225 256 577 608 257 288 609 640 289 320 641 672 321 352 673 704 ESSE EIE LT EH eb EE z 5 gt j Bi Switch in OPEN Position Depressed to the Left Switches 1 and 2 Should be in CLOSED Position Figure 42 DIP SWITCH SETTINGS Installation procedures for High Density modules including field wiring to the box lug terminals on the user connector block can be found in Chapter 2 of this manual Ref 70 150 1 83 General Description of the Series Six GEK 25361A Input Output System Analog Output Modules The Analog Output module is available in three versions unipolar bipolar and current Ranges for each version are shown in Table 2 1 Module
169. icance of each of the bits is defined in the following table Bit 1 corresponds to the lowest input number in the group of 32 inputs while Bit 32 corresponds to the highest number in the group For example if DIP switch No 6 is set OPEN and all the others are in the closed position refer to Figure 37 then Inputs 257 to 288 in the CPU input Status Table as well as in the user program would corre spond to Bits 1 to 32 in the data format definition DEFINITION Channel number 3 bit binary number giving number of channel 0 7 being read Not Used Valid Data HIGH if the data is valid LOW if the data is invalid Not Used Open Thermocouple HIGH if the input circuit is open 0 4V on the channel being read LOW otherwise Sign Bit is 1 if temperature is negative 0 if positive Board OK HIGH if DC power supply levels are OK LOW otherwise Underrange HIGH if input level is at or below the low end of the module range LOW otherwise Overrange HIGH if input level is at or above the high end of the module range LOW otherwise Heartbeat Changes state when reading of a channel is complete Data 12 bits of temperature data Sign Extension Four bits of sign extension for 2 s complement format they are zeros in sign plus magnitude format Table 16 DIGITAL DATA FORMAT The twelve bits of data and the sign extension make up a 16 bit binary number which can be a signed magnitude or a 2 s complement number fo
170. icated 1 89 General Description of the Series Six Input Output System REED RELAY 1 Jumpers 2 4 6 8 10 12 PL Select Nor mally Open Contacts 2 Jumpers 3 5 7 9 11 13 PL Select Nor mally Closed Contacts 3 to K6 Mercury Wetted Contact Reed Relays 4 Fuse Clip European Style Fuses 6 5 Fuse 3A Normal Blow 6 IO Figure 45 GEK 2536IA Jumpers Jl J6 for Selection of Contact Protection RC Network to be In or Out of Circuit User Terminal Block Circuit Board Terminal Block LED 1 to LED 6 On when Relay Coil Energized Markable Lens Surface REED RELAY OUTPUT MODULE A Reed Relay Output module can be installed any slot an I O rack except the left slot or in an I O slot in a Model 60 CPU Before installing the module the I O starting point number for that module should be selected by setting the seven segment DIP switch on the backplane adjacent to the selected I O slot A Reed Relay Output module since it has six outputs will respond to the first six output points in the selected group Refer to Figure 28 or Chapter 2 of this manual for instructions on setting the DIP switches 1 90 Ref 82 PC 19 General Description of the Series Six GEK 25361A Input Output System Each circuit has two output connections for user field wiring One side of each load to be controlled by this module connects to the appropriate output terminal 1 through 6 The other side
171. ides a safety precaution against accidental shorting of terminals and is a safeguard against shock to the user or maintenance personnel The terminal block cover attaches to four stand offs mounted on the front panel WARNING Extreme care must be taken when making connections to the terminal boards 115V AC or 230V AC may be present 1 43 General Description of the Series Six GEK 25361A Power Supply OUTPUTS The Series Six CPU power supply provides DC outputs of 5V DC 12V DC and 12V DC In addition system control signals are generated for use throughout the CPU DC voltages are hard wired to the backplane Logic signals are distributed through a connector Figure 24 is a block diagram of the CPU power supply The block diagram shows connections to the terminal blocks DC voltages available and system control signals to and from the power supply Memory Protect Switch Inputs from Backplane t 12 CPU Run Stop Bat OK Switch External PSI Mum ata Protect Relays No Connection Line LI S eu DC 2 Line 2 L2 O 12 Backplane Ground Gnd O Ov AC Input 115 230 V AC Figure 24 CPU POWER SUPPLY BLOCK DIAGRAM 1 44 Ref 70 58 General Description of the Series Six GEK 25361A Power Supply AUXILIARY CIRCUIT BOARD An auxiliary circuit board CPAX1 is mounted in the CPU power supply module Figure 23 shows the in ternal connections to this b
172. ights will turn off Alarm No 1 relay switches if the POWER Status light is off go back to and troubleshoot that problem first 3 46 Troubleshooting and Repair GEK 25361A I O System Troubleshooting LOCAL OK Light Status Remote 1 0 Driver Remote I O Receiver I a Ne CRE I PEN NE UI EOP CNN NCC RNC NUUS Fe LANE C sara aO Definition This module is operating normally OFF Problem exists in this module if light never comes on during power up LED test or stays off at end of test Corrective Action Replace the Remote 1 0 Driver module Replace the Remote I O Receiver module Remote I O Driver Remote I O Receiver Option jumpers on both the Remote Receiver and Remote Driver are identical Communications link established between the two modules Corrective Action Verify that all common circuit board option jumpers are set identical on both boards Refer to Tables 7 8 9 and 10 Chapter 2 Check cable connections at each end of link f REMOTE OK and LINK OK lights turn off simultaneously check for a power down condition in the Remote station rack containing the Remote Receiver Excessive noise on the link could also cause both lights to turn off Replace Remote 1 Driver module Replace Remote I O Receiver module Valid communications between Remote Driver and Remote Receiver not established Baud rates different seria
173. ils to operate Corrective Action Check wiring for that output Check for a blown fuse Reseat the output board Replace the output board No outputs function gt Corrective Action If the problem is limited to 1 board GEK 25361A 1 Check the l O point selection DIP switches Check terminal assembly wiring Check terminal assembly voltage 2 3 4 Replace the output board 5 Replace the I O cable Ensure it is proper for your module If one I O rack has no functioning outputs 1 If outputs further up the I O chain towards the CPU function replace the Receiver in this rack 2 out all I O boards and reinsert at a time Replace the I O cable A O Ncl f there are no functioning outputs any of the I O 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 I O Control board in the CPU Model 6000 system only If problem is in the Auxiliary I O chain and all CPU racks status lights are on replace the Auxiliary I O Control board in the CPU 5 Replace the l O cable status change or override change during W O rack power down Corrective Action gt Check the position of the jumper pack and DIP shunts on the I O Receiver modules Refer to l O Receiver installation in Chapter 2 for correct positions Troubleshooting and Repair GEK 25361A
174. in a Standard I O rack and a High Capacity power supply must go in a High Capacity I O rack CATALOG 1 0 RACK NUMBER DESCRIPTION Standard IC6OOPM502A Power Supply provides 5V DC at 6 1 amps allows 100 units of load Strap selectable for 115V AC or 230V AC High IC600PM505A Power Supply provides 5V DC at 16 5 amps 12V Capacity 115V AC DC at 1 5 amps and 12V DC at 1 0 amps allows 275 IC600PM504A units of load 230V AC A block diagram of the I O power supply is shown below for reference IIS VAC Select TA Jumper 1 Standard Rack 5V Only z DC To 0V Backplane Switchi xi ag PSOK To Backplane Gnd A Circuit u OH Se Line 5 CIR um Figure 8 1 0 POWER SUPPLY BLOCK DIAGRAM STANDARD Ref 70 60 3 35 Troubleshooting and Repair GEK 25361A I O System Troubleshooting There is 1 status indicator light on the I O power supply INDICATOR STATUS DEFINITION Power is applied 5V DC output voltage is within tolerance 4 75 to 5 25V DC No AC power 5V DC out of tolerance CHAIN OK lights from the applicable rack back to and including the CPU turn off CPU RUN and ENABLE lights turn off Alarm No 1 relay switches Corrective Action Check AC input power to power supply terminal board Ensure that the jumper is in the correct position for either 115V AC or 230V AC Standard rack only Select Jumper 1 For ll5 or 230V AC Operation
175. in the Data Processor See Figure 66 The Data Processor physically connects to the CPU through a cable which connects from the top connector of the I O Control module in the CPU to either of the connectors on the Data Control module The cable distance should not exceed 25 feet 7 5 meters 1 Connector To CPU 2 Connector to PDT Figure 66 DATA CONTROL MODULE 1 132 Ref 82 PC 15 General Description of the Series Six GEK 25361A Data Processor Data Prom The Data Prom module contains firmware used for control functions within the Data Processor Firm ware instructions are a set of software program instructions entered in PROM which are not alterable See Figure 67 Figure 67 DATA PROM MODULE Data Storage Contains either 8K or 16K of sixteen bit words of CMOS RAM memory with Lithium battery back up or 64K of sixteen bit words of dynamic RAM memory See Figure 68 Figure 68 DATA STORAGE MODULE Ref 82 PC 11 82 PC 1A 1 133 General Description of the Series Six GEK 25361A Data Processor Data Serial Port The Dual Serial Port module provides two serial communication ports for interfacing peripheral devices to a Data Processor This module supports RS 232C and 20mA current interfaces for message genera tion and operator interface A selectable baud rate of 110 300 600 1200 2400 4800 or 9600 baud is configured by a jumper strap A system must use at least one Dual Port module and can support up to eight
176. inal Troubleshooting To check the fuse and connections to the PDT open the cable storage compartment of the PDT See Figure 1 for location of these items 1 AC Power Cable 5 Fuse 1 54 Slo Blo 2 Printer Connection 6 Brightness Control 3 External Tape Unit 7 Program Development Terminal To CPU 4 Composite Video Connector Cable Figure 1 PROGRAM DEVELOPMENT TERMINAL CONNECTORS CONTROL AND FUSE LOCATION Ref 8 1 PC 64 3 5 Troubleshooting and Repair GEK 25361A Program Development Terminal Troubleshooting If the malfunction is isolated to the PDT proceed as follows Remove the top cover from the PDT to gain access to internal circuitry Locatic of the internal components is shown below 9 1 12 inch 304 8mm CRT 8 Spare Connector 2 Power Supply 9 RAM Board 3 Video Monitor board 10 PROM Board 4 Connection to tape unit 11 Connection to Keyboard 5 Video Control Board 12 Connection to CRT Keyswitch and EIA 6 Processor Control Board Connectors in storage compartment 7 Connection to CPU 13 Tape Interface board Figure 2 PROGRAM DEVELOPMENT TERMINAL COMPONENT LOCATION WARNING i Cathode Ray Tube CRT has 12 000 Volt potential A high voltage potential may remain for a period of time after removal of power 3 6 Ref SI PC 59 Troubleshooting and Repair GEK 25361A Program Development Terminal Troubleshooting Check power supply voltages at the terminal board
177. ing each sweep The channel number is determined by the CPU under control of the user program The information in the Output Status Table is accessed during the 0 scan as shown below OUTPUT STATUS TABLE DISPLAY Bit 16 9 8 1 l O Address I O Address Bit 1 corresponds to the lowest output number in the group of 16 outputs reserved for the module while Bit 16 corresponds to the highest output number in the group For example if DIP switches 2 and 6 are set OPEN and all others are in the closed position see Figure 44 then Outputs 273 to 288 in the CPU Output Status Table and in the user program would correspond to Bits 1 to 16 in the Digital Data Format description The significance of each of the bits is defined in Table 23 w wmm me Bits 1 8 Data Eight least significant Channel Number 2 bit binary of the twelve bits of data number which determines the Bit 1 is the least significant number of the channel 0 3 bit LSB being written Bit 14 is the MSB Data Four most significant Not used May be in either a of the twelve bits of data HIGH or LOW state Bit 12 is the most signifi cant bit For the bipolar 10 4 10V module Bit 12 functions as a sign bit Table 23 DIGITAL DATA FORMAT 1 87 General Description of the Series Six GEK 25361A Input Output System The twelve bits of data should be in straight binary form for positive output values or in 2 s complement form for n
178. ing functions and op tions available This is followed in order of capacity by the Models 600 and 60 The Models 60 and 600 are upward compatible which means that any Model 60 program can run on the Model 600 or 6000 and any Model 600 program can run on the Model 6000 OPTIONAL DEVICES Optional devices are available for use with all 3 Models of the Series Six These optional devices are the Data Processor Unit and a Portable tape loader The Series Six Data Processor is a microprocessor based unit designed to perform functions which are too time consuming or require too much memory for the CPU to perform efficiently For a detailed de scription of the Data Processor see Section 3 PORTABLE TAPE UNIT A Portable Tape Unit is available which is interfaced to the CPU through the Communication Control module This is a portable unit which allows fast loading of programs into the CPU The tape unit oper ates at a selectable baud rate and allows a 32K x 16 bit program to be loaded in less than three minutes The Portable Unit is highly reliable and is compatible with the tape unit in the Program Devel opment Terminal COMPARISON A comparison of the functions and features available for the Series Six is shown in Table l The f unc tions and features will be explained in detail in later paragraphs or sections of this manual General Description of the Series Six GEK 25361A Introduction Program Memory Type CMOS RAM CMOS RAM CMOS
179. ion a great distance from the originating l O station System Connection 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 a model 60 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 of a Remote I O station If the Remote I O Driver and Remote I O Receiv er are to communicate by connection to modems 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 model 60 CPU since a 2 DC source must be available to conform to RS 232 specifications Figure 49 illus trates the two methods of system configuration described above General Description of the Series Six GEK 25361A Input Output System 10 000 feet 3km maximum Two Shielded Twisted Pair Model 60 CPU Serial cable Remote CPU Station 1 0 Station Local 1 0 Station OR 50 feet 50 feet I5 meters 15 meters maximum maximum ir S M RS 232 Communications Link Piin Local 1 0 Station When connecting to a Remote 1 0 Station through modems RS 232 Interface the Remote 1 0 Driver and Remote 1 0 Receiver must be installed in High Capacity 1 0 Racks Figure 49 CONNECTION A REMOTE 1 0 SYSTEM The response time of a Remote 1 0 system is slightly de
180. ion to a Remote 1 97 50 Remote Q Connection Using Twisted Pair dca hue denies 1 100 51 Remote I O Connection Using RS 232 Modems 1 101 52 Remote I O Driver Module 1 103 53 Remote I O Receiver Module l 108 54 CPU I O Station eem l 11 1 55 Local l O Station 113 56 Remote I O Station Configuration H15 57 Program Development Terminal 1 117 58 Program Development Terminal Enclosure 18 59 Keyboard Layout 1 119 60 Optional Built In Tape Unit and Switches I 12 1 61 Universal Rack Mounting 123 62 Rack Configuration 1 127 63 I O RackTo O Rack Configuration 1 129 64 I O Rack Wiring Scheme l I 30 65 Data Processor Unit 1 131 66 Data Control 1 132 67 Data PROM Module l 1 33 68 Data Storage Module 1 133 69 Dual Serial Port Module 134 70 Maximum Memory 16 Bit Words 1 134 71 Data Processor File Structure 1 35 FIGURES Chapter
181. is slot A the next one is slot B etc for the purpose of memory size addressing A switch is closed for each 2K of memory in each board slot Each CPU must have the DIP switches set for the proper memory configuration If memory is added to a system the switches will have to be reconfigured to the proper settings Chapter 2 Section 1 of the Installation and Maintenance Manual GEK 25361A will further detail the switch settings d zm 1 3 C C ba a a C C px 2 3 4 9 6 7 8 Oop C4 9 LOGIC MEMORY SIZE LOCATION DIP SWITCHES Do not change the settings of the programming switches on the Internal Memory module with a program already loaded into the logic memory System Failure to observe this WARNING will cause the user program to run out of sequence and could result in damage to plant equipment and or injury to personnel Ref 70 107 1 27 General Description of the Series Six GEK 25361A Central Processing Unit REGISTER MEMORY The Register Memory module is comprised of a Mother board which contains memory parity genera tion and checking functions and a Daughter board that contains 1024 sixteen bit registers storage locations in CMOS RAM with Lithium battery back up The registers are used for bit manipulation by certain mnemonic functions The lower 128 words of the Register Memory are used as a storage loca tion for the Auxiliary I O status table Data bus
182. isolation circuitry D A and output amplifier circuitry On the unipolar and bipolar voltage output modules an internal power converter DC DC converter delivers output levels that are isolated from the bus On the current output module output power be derived from this converter or an external power source can be provided by the user thereby reducing the load on the I O rack power supply One LED indicator displays the status of the module 1 84 General Description of the Series Six GEK 25361A Input Output System A jumper must be set on the current output module If the internal loop supply is used to power the out puts the circuit board jumper refer to Figure 43 should connect pins and 2 If a common external source that provides a regulated 18V to 42V DC 100 mA is used the jumper should connect pins 2 and 3 During operation there is a significant voltage drop across the output devices i e between the low side of the load and the low side of the source Five connections are provided on the user connector block for each of the four output channels Field wiring is configured at these terminals according to the type of module Detailed installation and wiring instructions are provided in Chapter 2 1 BOARD OK Light 12 Jumper to Select Internal Loop 2 R69 Factory Set Pot Supply Common External Source 3 R61 Factory Set Pot 13 User Connector Block 4 R59 Gain Pot Channel No 0 5 R51 Offse
183. l 20 19 16 17 3 R6 R13 TABLE 8 CHANNEL ADJUSTMENT LOW END HIGH END Digital Output Digital Output MODULE Input Voltage Input Voltage O 10V X000 0 0000 V XFFF 9 9976 V 10 410V X800 10 0000V X7FF 9 9951 V 4 20 000 1 0000 XFFF 4 9990 V n Hexadecimal Format Table 9 MODULE CALIBRATION 3 59 Troubleshooting and Repair GEK 25361A System Troubleshooting 718 5994 50 051 51 Hdt A CS uS R59 Gain Pot Channel 0 1 5 R27 Gain Pot Channel No 2 2 R5l Offset Pot Channel No 0 6 R20 Offset Pot Channel No 2 3 R43 Gain Pot Channel No 1 7 RI 3 Gain Pot Channel No 3 4 R35 Offset Pot Channel No 8 R6 Offset Pot Channel No 3 Figure 13 POTENTIOMETER LOCATIONS 3 60 Ref 8 1 PC 74
184. l Module Light Auxiliary 1 0 Module Status Definition Input data parity is good at the I O Control module Input data parity error exists The CPU RUN and ENABLE lights are off Alarm No 1 relay switches dili Corrective Action Verify that no two input cards have the same address Turn the CPU Keyswitch to STOP then power down and back up If an input parity error is confirmed check Scratch Pad CPU Flags see GEK 25362 page 4 21 which will give the address of the input board where the data originated Replace the Input board corresponding to the address shown in the Scratch Pad Replace the 1 Receiver in that I O rack Replace the 1 0 Transmitter between that rack and the CPU Replace the 1 0 Control board 322 Troubleshooting and Repair GEK 25361A Central Processing Unit Troubleshooting 0 ENABLED lO Control Module Light Auxiliary 0 Module Outputs are enabled CPU is operating in the Run Enabled mode Outputs disabled CPU is the Run Disabled 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 still updated in the CPU status table Corrective Action Check the position of the CPU Run Stop key switch See m Check the condition of other status lights PARITY CHAIN OK and POWER If no other problem is indicate
185. l parity sense different or some other option jumper not compatible 3 47 Troubleshooting and Repair GEK 25361A System Troubleshooting REMOTE Remote I O Driver Remote l O Receiver Status Definition ON Remote Driver Valid I O data has been received from the Remote Receiver No I O faults in the Remote system Remote Receiver No I O faults Remote system operating normally OFF Fault exists in Remote system gt Corrective Action Check for loose or improper connection between I O cables connecting racks in the Remote system Ensure that all boards are seated properly in the Remote system racks If the REMOTE OK and LINK OK lights turn off simultaneously on the Remote Driver check for a break in the cable between the Driver and Receiver excessive noise on the link or a power down condition in the rack containing the Remote Receiver if the light on the Remote Receiver turns on then off again almost immediately check the DIP switches for I O addresses assigned to I O modules that are outside of the legal blocks of addresses assigned at the Remote Driver Replace Remote I O Receiver module Replace Remote I O Driver module Troubleshooting and Repair GEK 25361A System Troubleshooting REMOTE Remote l O Driver PARITY Remote I O Receiver Light Status Definition No parity errors in Remote system Parity error detected in the Remote system Corrective Action Cl
186. laceable parts in the Central Processing Unit is provided in Table 4 CATALOG MODULE NUMBER NAME FUNCTION 600 500 Arithmetic Control Contains circuitry that per forms arithmetic and logical operations on data and ad dress lines IC600CB5O1A Basic Logic Control Contains the Basic instructon set Has a microprogram con troller and PROM memory for generation of Control signals for all CPU boards Generates timing signals IC600CB502A Extended Logic Contains the Extended in struction set Generates con trol and timing signals for the CPU Controls the Auxiliary l O s IC600CB504A Internal Memory Contains a status table for all inputs and outputs Has an override table for inputs and outputs Contains Logic Memory size location pro gramming switches and has battery back up IC600CB509A l OControl Interfaces the CPU bus to the primary I O bus 1000 inputs 1000 outputs Pro vides control circuitry for the Auxiliary 0 module and the Communications Control module IC600C8508A Register Memory Contains 1024 Register memory locations Contains parity memories for the 4 in ternal memory tables Has memory parity checking circuitry Has battery back up Table 4 CPU MODULE RENEWAL PARTS LIST 3 33 Troubleshooting and Repair Central Processing Unit Troubleshooting CPU RENEWAL PARTS LIST CATALOG NUMBER IC600CB5 13A IC600CB514A IC600CB514B 542 IC600CM544A IC600CM548A
187. lay Table 5 OPTION JUMPER SETTINGS IC600CB5 14B Other jumpers have been factory set and should not be changed Connect the grounding wire from the faceplate to the screw adjacent to the cardguide for the board Insert the printed circuit board using the extraction insertion tool Install the faceplate and tighten the quarter turn thumbscrews NOTE When all of the jumpers and switches have been configured as described in the previous paragraphs the CPU module configuration is complete Installation GEK 25361A Rack and CPU Module Installation CPU POWER SUPPLY The CPU power supply has 2 terminal boards located on the lower part of the faceplate Remove the protective cover and make the following connections Refer to Figure 13 which is an illustration of the terminal boards and their connections Auxiliary Battery e Connection Alarm S eiu L2 AC input Alarm 2 15 230V GND Figure 13 CPU POWER SUPPLY CONNECTIONS Provide an AC power source of the proper voltage for your system either 115V AC or 230V AC Connect a 3 wire AC power cord to the 3 lower terminals of the terminal board on the right The power cord plug should be of the proper pin configuration for either 115V AC or 230V AC If the same AC power source is used to provide AC power to other racks in a Series Six system ensure that all AC input connections are identical at each rack Do not cross Line 1 LI and Line 2 L2 A resu
188. layed 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 in response time is due to the fact that the Remote 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 one sweep delay for inputs can be avoided if a DO I O instruction is ex ecuted for the Remote 1 0 prior to executing any logic using remote inputs Ref 70 122 1 97 General Description of the Series Six GEK 25361A Input Output System System Response System response times to the Remote l O for each of the valid baud rates are summarized in Table 27 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 1 0 Receiver component tolerance cable length etc Quantity of BAuDRATE 1201 0 70 ms 40 ms 20 ms 1 sec 60 ms 25 ms 6 sec 2 sec 10 sec 4 sec Output Delay Input Delay 248 1 0 Output Delay 11 sec 4sec 1 sec 30 ms Input Delay 18sec 6 5 1 6 sec 46 ms 1 sweep for all baud rates 2 sweeps for all baud rates Table
189. le of driving 5 mA to 2 amps The module contains comparator circuitry to determine when the module is being addressed and a register to store the output data before presenting it to the output drivers Each output has overvoltage protection and is protected from inadvertent turn on The eight output drivers each use a triac as a switching device to connect the corresponding output terminal to the high side of the user power source when that output is in the ON state Each output circuit is fused and has a neon lamp blown fuse indicator which is viewed through the translucent lens on the faceplate There is also a neon lamp to indicate an output ON condition Specifications for the AC Output module are shown in Table 17 User Supplied ON OFF Output CurrentlON Leakage Module Voltage Delay Delay OFF 115VAC 90 130VAC 1 2 cycle 1 7MA 115V 230V AC 180 260VAC lt I 2 cycle 1 0 mA 230V Power Requirement 5V DC 535 mA maximum Supplied by I O power supply ON State Voltage Drop 1 5 typical 2 5V maximum Inrush Current I2A for 33ms maximum Fuse Rating 3A Table 17 SPECIFICATIONS AC OUTPUT MODULES A protection circuit automatically disables the entire group of eight output drivers in the event of an I O chain or CPU failure The outputs are arranged in two groups of four with each group sharing a common power source Refer to Figure 38 1 74 General Description of the Series Six GEK 25361A Input Output System The signif
190. lel bus cable or to an I O Control module in a CPU rack Indicators There are three edge mounted LEDs which provide a visual status of various fault indications on the I O chain The LEDs are viewed through the lens on the faceplate Table 25 defines the status indicated by each LED INDICATOR DEFINITION ON when station power is present continuity is present and all stations OK downstream are OK CHAIN PARITY ON when all downstream stations have received good parity LOCAL PARITY ON when the I O Receiver has received good output parity Table 25 RECEIVER STATUS INDICATORS 1 94 General Description of the Series Six GEK 25361A Input Output System lO TRANSMITTER The I O Transmitter module Figure 48 is used to provide an interface between the rack backplane sig nals and the i O bus to a downstream Local I O station An Transmitter should 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 ex isting Local I O station or a model 60 CPU 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 I O Transmitter can be installed in 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
191. load into the output terminal of the module When using a source module current is provided by the module and current flows out of the module to wards the load output Current flow ere output Module Sink Output Source Output Figure 41 DC SINK AND SOURCE OUTPUT MODULE WIRING Refer to Figure 42 for typical user connections to a DC Output module Wiring instructions follow the figure 2 70 Ref 70 103 Installation GEK 25361A I O Module Wiring DC Source Module User Wiring DC Sink Module User Wiring Output Switching Device L User Load REE O2 E User Power Source Figure 42 DC OUTPUT TYPICAL USER CONNECTIONS 9 Connect one side of each load to be controlled by the module to an appropriate output terminal 1 8 Connect the other side of each load connected to terminals 1 through 4 to a common line connect ed to the Neutral No 1 NI terminal for a SOURCE module or to the High No 1 H 1 terminal for a SINK module Connect the other side of each load connected to terminals 5 through 8 to a common line connect ed to the Neutral No 2 N2 terminal for a SOURCE module or to the High No 2 H2 terminal for a SINK module Connect the positive side of a user DC power source to the HI terminal Connect the negative side of a user DC power source to the NI terminal A user DC power source must also be connected between the H2 and the N2 terminals Aft
192. logically of the function of each part of the system and how they relate to each other A basic understanding of the various indicator lights will usually quickly isolate the problem to the CPU rack DPU rack an I O rack or the Program Development Terminal By use of the Program Development Terminal in conjunction with the CPU troubleshooting of the pro gram is accomplished Any input or output can be looked at and changed or overridden as required The total system has to be considered when problems occur The CPU Program Development Terminal DPU l O s and external devices connected to or controlled by the programmable controller 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 DPU can be found in the Data Processor Unit Users Guide 3 1 Troubleshooting and Repair GEK 25361A Introduction PROGRAMMABLE CONTROL SERVICE CENTER The Programmable Control Service Center is staffed by experienced Programmable Control Service Personnel The Service Center is available to aid the customer in diagnosing and solving equipment problems 24 HOUR NUMS8ER FOR PROGRAMMABLE CONTROL EMERGENCY SERVICE 1 800 GEFANUC This number is for Programmable Control Service only Contact your normal service number for service on other General Electric products 32 Troubleshooting and Repair GEK 25361A Int
193. lt 1 2 cycle 10 4A9409C 4 0 mA cycle maximum 30mA 2 D With resistive load 2 With inductive load Power Requirement 5V DC 460 mA maximum Supplied by O power supply On state Voltage Drop 1 2V typical 2 2V maximum Inrush Current 20A for 33ms maximum Fuse Rating 5A Table 18 SPECIFICATIONS ISOLATED AC OUTPUT MODULES A protection circuit automatically disables all six output drivers in the event of a CPU or I O chain failure Each output has two connections H1 H6 is the high side of the user power source and 01 06 is the output connection to the corresponding load for each circuit Each terminal can accommodate up to one No 12 AWG or two No 14 AWG wires Figure 39 is an Isolated AC Output module indicating the de scribed features As an added convenience fuse clips are provided on the module for both American 1 4 x 1 1 4 and European bmm x 20mm style fuses General Description of the Series Six GEK 25361A Input Output System ISOLATED 3 1 Output ON Lights 1 6 5 Circuit Board Terminal Block 2 BF Blown Fuse Lights l 6 6 User Terminal Block 3 European Fuse Clip 6 7 Markable Lens Surface 4 Fuse 5A 6 Figure 39 ISOLATED AC OUTPUT MODULE An Isolated AC Output module can be installed any slot an I O rack except the left slot or in an I O slot a Model 60 CPU Before installing the module the I O starting point number for that module should be selec
194. lting dif ference in potential can cause damage to equipment 2 22 Ref 70 5A Installation GEK 25361A Rack and CPU Module Installation Connect the alarm relay contacts to external alarm devices as required by your system configuration Optional Connect the Auxiliary Battery contacts to an external battery with a voltage of 6 28V DC This is an option that will provide a back up to the memory back up battery mounted on each memory module 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 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 115V AC or 28V DC Failure to observe this CAUTION may result in damage to the circuit board After these connections have been completed the protective cover plate should be reinstalled Ensure that the protective cover is installed over the terminal boards During normal operation either 115V AC or 230V AC 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 SYSTEM GROUND A common system ground connection is provided by the GND connection from the 115V AC or 230V AC power source to the terminal board on
195. ly cooperate with the customer should such an action be necessary PREINSTALLATION CHECK After unpacking the Series Six CPU and I O racks modules Program Development Terminal and Data Processor rack and modules if included as an option it is recommended that serial numbers of the CPU and DPU racks and the Program Development Terminal be recorded The serial numbers are required if Programmable Control Customer Service should need to be contacted for any reason during the warran ty 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 Programmable Control Product Service at 1 800 GEFANUC A Customer Service representative will give you further in structions at this time RACK INSTALLATION The Series Six CPU DPU or I O racks 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 are shown in figures 1 and 2 2 2 Installation Rack and CPU Module Installation WALL OR PANEL MOUNTING DIMENSIONS GEK 25361A 19 98 1507 49 d
196. m a CPU by connecting an I O Receiver in the first rack of the distant grouping to an I O 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 Local I O station Again up to 10 1 0 racks can be daisy chained in Local I O station with no more than 50 feet 1 5 meters of cable separating the first and the last rack The maximum distance an I O Receiver can be located from the originating l O Control or Aux iliary 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 I O Receiver be installed in 1 0 rack except the first I O rack in a Remote I O station This module is normally installed the left most slot of an I O rack however it could be inserted into l O slot in an 1 O rack if required Chain Signal Continuation Or Termination Before installation of an l O Receiver in an l O rack it should 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 See Figure 47 If the module is to be the
197. modules are a bright color Colors used range progres sively from blue for low voltage modules to white for the highest voltage modules 1 53 General Description of the Series Sip ERDA Input Output System The terminal assembly has a dual keying system to prevent the accidental connection of the terminal as sembly to a circuit card that is not compatible with the field wiring on the terminals This feature is help ful in troubleshooting in that if a circuit card fails it can only be replaced with the same type of card since the keying system will only allow that type of card to be connected to the terminal assembly VOLTAGE AC DC COLOR 230V Input White 230V Output Red 115V Input Orange 1 15v output Yellow Low V Input Green Low v output Blue Table 7 MODULE COLOR CODE Module Electrical Features Discrete I O modules have 8 input or output circuits per board All input or output circuits are isolated from the control logic circuitry by optically coupled isolation devices OCI OCI couples the 2 cir cuits together by transmission of light energy from a sender LED to a receiver photo transistor Each lO module is isolated in 2 groups of 4 circuits each High Density modules have either 32 input or 32 output circuits per module Optical isolation is provided between logic circuitry and user input or output connections Connections are provided for user power supply wiring on the bottom terminals of
198. ms allows connection over a much greater distance An I O Transmitter located 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 I O Transmitters thereby extending the remote capability an additional 2000 feet 600 meters 1 LOCAL OK Light 5 Connector to Remote I O Receiver in a 2 LINK OK Light Remote System 3 REMOTE OK Light 4 REMOTE PARITY Light NOTE For Location of Option Jumpers Refer to Chapter 2 Figure 18 Figure 52 REMOTE I O DRIVER MODULE Ref 82 PC 1 1 103 General Description of the Series Six GEK 25361A Input Output System The Remote I O Driver has circuitry sufficient to drive up to 248 Inputs and 248 Outputs A Remote Driver module can be installed in any unused slot in a CPU station a Local I O station or a model 60 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 I O Driver must be installed in a High Capacity I O rack This is necessary since the RS 232 specification requires 12 and 12V DC for operation Addressing As described previously 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 switches 5 6 and 7 are set to select the block and for 248 I O switches 6 and 7
199. n Indicators 2 Markable lens surface 3 Box Lug Terminals 4 Cover Figure 24 TYPICAL INPUT MODULE Ref 81 PC 13 2 45 Installation GEK 25361A I O Module Wiring Wiring to field devices should be routed through the tray attached to the bottom front of the rack Run the wiring to the appropriate module and fan the individual wires to their respective terminals Then insert the wires into the box lugs on the terminal assembly and tighten the screws to ensure a good connection The lugs will accept one No 12 AWG wire or two No 14 AWG wires Wiring connections conform to UL standard 230 C The following wiring instructions can be used for these modules Module Catalog Number 12V AC DC Input IC600BF806A 24 48V AC DC Input IC600BF802A 1 15V AC DC Input IC600BF804A 230V AC DC Input IC600BF805A Note that the input connections are divided into 2 groups of 4 each having 2 neutral connections See Figure 25 Remove the cover from the terminal assembly before proceeding with wiring Connect the high side of each input to the appropriate input terminal 1 through 8 Connect the low side of the inputs going to terminals 1 through 4 to either of the NI terminals Neutral No 1 Connect the low side of the inputs going to terminals 5 through 8 to either of the N2 terminals Neutral No 2 All wires connected to either NI terminal are at the same potential as are all wires connected to either N2 terminal After co
200. n the auxiliary I O chain through a 16 pair parallel cable 2 18 Installation GEK 25361A Rack and CPU Module Installation COMMUNICATIONS CONTROL MODULE The Communications Control module is to be installed in the slot immediately to the left of the I O Con trol module There are jumpers on the board which should be configured to set operating parameters for the module The jumpers and their functions are listed in the following table STR LINK IIA 1200 Baud Operation STR LINK Ill 17 18 9600 Baud Operation RS 232C 63 Operation 66 55 59 RS 422 63 Operation 66 17 55 59 Turnaround Delay 1 O 20ms No Turnaround Delay Test Mode Timeouts Enabled Disabled Table 3 OPTION JUMPER SETTINGS IC600CB5 14 NOTE The jumper settings in Table 3 are for the Communications Control module Catalog No IC600CB514A Catalog No IC600CB514B has several options not available on 514A The following tables list all of the jumpers required for operation by the 514B module 2 19 Installation GEK 25361A Rack and CPU Module Installation 2 20 Baud hate ee 9600 Table 4 SELECTABLE BAUD RATE JUMPER CONFIGURATION IC600CB514B Installation GEK 25361A Rack and CPU Module Installation Odd Parity No Parity 55 59 RS 232C 63 Operation 66 55 RS 422 59 and 63 Current Loop Operation Test Mode Timeouts Enabled Disabled 66 Turnaround Delay 31 10 20 ms No De
201. nches 483 x 356 x 261 millimeters Panel Mount 20 0 x 14 x 10 3 inches 508 x 356 x 261 millimeters Weights CPU rack 45 Ibs 21 kg with all slots filled rack 45 lbs 21 kg with all slots filled Program Development Terminal 57 Ibs 25 kg Table 2 PHYSICAL AND ELECTRICAL CHARACTERISTICS Enclosure All Models of the Series Six family are mounted in the same size enclosure rack See Figure 3 This uni versal rack provides a professional appearance and eases some of the problems associated with installation specifically the need for multiple mounting schemes because of various sizes of enclosure The rack is a standard 19 inch 483 millimeters rack or panel mount enclosure General Description of the Series Six GEK 25361A Introduction ar a T w 8 g 1 41 Pin Backplane Connectors Two 5 DC Power OK Indicator Slot 6 Terminal Block AC Input Connections 2 CPU RUN STOP Keyswitch Alarm Connections and External Memory 3 Logic Power Switch Circuit Breaker Back up Battery 4 Memory Protect Keyswitch 7 Cardguide One per Slot Figure 3 UNIVERSAL RACK FOR SERIES SIX CPU AND DPU The area available in the rack allows for vertical mounting of 11 modules and a power supply The modules slide into the enclosure on cardguides and require an insertion force of 25 Ibs 1 1 3 kg for I O modules and 50 lbs 22 7 kg for CPU modules A card extraction insertion tool is included with
202. ng to the group of 32 inputs reserved for each module are read into the Input Status Table in the sequence as shown below INPUT STATUS TABLE DISPLAY 24 17 16 9 8 1 I O Address l O Address l O Address Address Bit 32 25 I 1 0 Seat S The significance of each of the bits is defined in the table below Bit 1 corresponds to the lowest input number in the group of 32 inputs reserved for the module while Bit 32 corresponds to the highest number in the group For example if DIP switch No 5 is set OPEN and all the others are in the closed po sition refer to Figure 34 then Inputs 129 to 160 in the CPU Input Status Table as well as in the user program would correspond to Bits 1 to 32 in the digital data format definition DEFINITION Channel Number 8 bit binary number giving the number of the channel 0 7 being read It consists of three significant bits bits 1 3 and five leading zeroes bits 4 8 Status Byte Valid Data HIGH if the Board OK Light is On LOW if the light is Off Not Used Open Wire HIGH if input circuit is open 0 4V on channel being read with the 4 20 1 5V module LOW otherwise Should be ignored with the 0 10V and 10 10V modules Sign HIGH with negative input to the 10 10V module LOW with positive input Other modules same as bit 28 Table 12 DIGITAL DATA FORMAT 1 64 General Description of the Series Six GEK 25361A Input Output System DEFINIT
203. ning towards the top of the unit If the front hinged cover has not been lowered do so at this time This will allow access to the keyboard CRT and switches Turn power on by depressing the illuminated rocker switch towards the top Call up the Supervisor Display select each item from the menu and observe that they are operating properly Select the item DISPLAY PROGRAM from the menu and enter a sample ladder diagram program If all keys and functions appear to be working properly you are ready to begin entry of your ladder diagram program If any problems are encountered proceed to Chapter 3 Troubleshooting and Repair in this manual Troubleshooting and Repair GEEK 25361 A Introduction SECTION 1 INTRODUCTION This chapter provides the data required for basic troubleshooting and repair should a malfunction of your system occur Included are sections on troubleshooting and repair of the Central Processing Unit the I O system and the Program Development Terminal Parts lists are included as a guide for ordering parts Calibration procedures are included for those modules requiring periodic calibration for required accuracy The technology used in the design of the Series Six system is such that under normal operating condi tions few hardware failures are expected If any failures should occur they can quickly be isolated and the defective assembly replaced with minimum downtime Troubleshooting is accomplished by thinking
204. nnections have been made to the box lug terminals the terminal cover should be installed by guiding both of its edges onto the top of the terminal board and sliding it downward over the terminals The markable area provided on the left side of the plastic lens beside each LED should be used for noting the function or source of each input WARNING When the Logic Power switch is turned off on an I O or CPU rack poten tially dangerous voltages may remain at the box lug terminal connections on I O modules These voltages are user supplied and are controlled ex ternally from the CPU or I O racks Operators and maintenance personnel should exercise extreme care when working with the I O modules to pre vent personal injury 2 46 Installation I O Module Wiring Ref 70 105 Input Module X X X OOOC X AC or DC Source Figure 25 TYPICAL INPUT MODULE WIRING CONNECTIONS GEK 25361A 2 47 Installation GEK 25361A T O Module Wiring HIGH DENSITY INPUT MODULE A High Density Input module 5V TTL 10 50V DC catalog number IC600BF811A can be installed in any I O slot in an I O rack except the left most slot or an I O slot in a model 60 CPU Before installing the module select the I O starting point number by configuring the seven segment DIP switch on the backplane adjacent to the selected slot This will assign a group of 32 consecutive inputs to the module Refer to Figure 26 for DI
205. normally If DPU in system and DPU present jumper is in light will be on Arithmetic ON Run signal from I O Control toggles within every Control 200 milliseconds 50 milliseconds ON CPU passed self test routine which is executed once per sweep Internal BATTERY ON Status of CMOS RAM back up battery Memory PARITY ON Logic Memory parity error Register BATTERY ON Status of CMOS RAM back up battery Memory PARITY ON Table memory parity error on Internal or Register memory board Logic BATTERY ON Status of CMOS RAM back up battery Memory Auxiliary CHAIN ON All I O stations in auxiliary chain have y o continuity good output parity and power supply Control is O K PARITY ON Input data parity is O K ENABLED ON CPU is in the normal Run Enabled mode outputs enabled Table 3 CPU INDICATOR CHART 3 15 Troubleshooting and Repair GEK 25361A Central Processing Unit Troubleshooting AUXILIARY LOSIC LOGIC Vb MEMORY 4 CHAIN OK 5 PARITY 5 gt 6 2 2 6 Figure 4 CPU INDICATOR KEYSWITCH REFERENCE Ref 70 106 Troubleshooting Repair GEK 25361A Central Processing Unit Troubleshooting CPU RUN STOP KEY SWITCH Position DEFINITION STOP CPU is unconditionally in the STOP mode CPU is in the RUN mode unless this condition has been altere
206. not set properly the CPU will not operate properly An accident to an operator or to your machine could result due to the program running out of sequence Position the module so that the side with the LED on it is to your right facing the CPU power supply Using the extraction insertion tool insert the Internal Memory module into its proper slot which is im mediately to the left of the Arithmetic Control module 2 15 Installation GEK 25361A Rack and CPU Module Installation Connect the grounding wire attached to the faceplate to the rack Install the proper faceplate securing it to the rack with the quarter turn thumbscrews by pushing them in and turning clockwise NOTE Ensure that the proper faceplate is installed over the corresponding module Incorrect placement may cause confusion to future operators REGISTER MEMORY MODULE The Register Memory module has no internal devices which need programming Your CPU will be re ceived with this module installed if you have a Model 600 or 6000 Model 60 does not have a separate Register Memory module since all memories are combined onto one module If you should remove this module when replacing it be sure to install it in the proper slot which is the slot immediately to the left of the Internal Memory module When installing a new Register Memory it is recommended that the following procedure be used Power down the PDT switch to the OFF LINE mode then power back up From the Scra
207. ns Note that the 32 output terminals on the connector block are divided into four groups each group containing eight inputs A single group is updated by the CPU during an 1 0 cycle Four consecutive I O cycles are required to update all 32 outputs DIGITAL CIRCUITRY TTL Compatible INPUTS 5 SOURCE ov 10 50V DC Jumper for Active Pullup Outputs Only TTL MODULE 10 50V MODULE NOTE The two separate power supplies shown for the 10 50 V module can be replaced by a single supply provided the 50 V and CLP terminals are connected together The voltage of this supply should be the voltage to be switched to each of the loads i e that voltage formerly applied between the CLP and COM terminals Although up to 50 volts may be applied between the 50 V and COM terminals only 10 volts is required and any excess represents wasted power which must be dissipated by the module Figure 45 HIGH DENSITY OUTPUT TYPICAL USER CONNECTIONS 2 74 Ref 70 130 Installation GEK 25361A Module Wiring Both common COM terminals are tied together inside the module If active pullup outputs are required with the TTL module a jumper should be connected between the 5V and PUL terminals For open collec tor operation the jumper is not required ANALOG OUTPUT MODULE The following installation and wiring instructions are for the Analog Output module which is available in the three versions listed below 0 10V DC IC60
208. ns as a CPU RUN STOP switch the other is a MEMORY PROTECT WRITE switch The keys for these switches are interchangeable TERMINAL BLOCK The CPU power supply has two terminal blocks each having seven screw down terminals Figure 23 shows the power supply front panel with connections to each of the terminals indicated The I O power supply connections are described in Section 4 INPUT OUTPUT SYSTEM 1 Jumper For Selection of Either 115 4 Connections To External Alarms or 230V AC On Dual Voltage Models Alarm 1 Advisory 2 AC Input 115 230V AC Alarm 2 CPU Stops Scanning 3 Auxiliary Back Up Battery 6 28V DC Figure 23 CPU POWER SUPPLY FRONT PANEL In addition to the AC input connections on the terminal blocks several other connections are provided Connections are provided for 2 sets of isolated alarm contacts for external visual or audible alarms which indicate status or error conditions in the CPU or its associated I O chain The alarm relay contacts are internal to the power supply 1 42 Ref 8 1 PC 45 General Description of the Series Six GEK 25361A Power Supply Contacts are also provided for connecting an auxiliary battery of 6 to 28V DC for use as an external memory back up 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 TERMINAL BLOCK COVER A cover is provided for attachment to the terminal blocks The cover prov
209. nt edge of the card counting from the top downward Program the CPU to move the converted digital data from this channel to a convenient register location where its value can be observed using the Program Development Terminal This can be done by using the following program ee O where IWWWW Lowest of the 32 consecutive input numbers used by this Analog Input module IXXXX Next input number XXXX WWWW 1 IYYYY Next input number YYYY WWWW 2 12222 Input number corresponding to the LSB of digital input data 2222 WWWW 16 RAAAA Register to display digital input data 3 55 Troubleshooting and Repair GEK 25361A System Troubleshooting 2 LOW END Set the voltage source as close as possible to the value shown in Table 7 Adjust R12 Refer to Figure 12 until the digital output agrees with the value in Table 7 3 HIGH END Set the voltage source as close as possible to the value in Table 7 Adjust RI 1 Refer to Figure 12 until the digital output matches the value in Table 7 4 Repeat steps No 2 and No 3 until the module is in calibration at both ends of its range simultaneously LOW END Source Digital Source Digital MODULE Voltage output Voltage Output 0 410V 0 0024V 0001 49 9951v T1 45V 1 0010V 4 9980V 4 20mA Hexadecimal Format Table 7 MODULE CALIBRATION 3 56 Troubleshooting and Repair I O System Troubleshooting 1 A
210. o the printed circuit board from the solder side of the board Ensure that the board puller surface is flat against the printed circuit board See Figure 4 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 SERES S Vui Te IE Se A prd QE S kum Wk amp MEMORY mone dh went must IE PANT ANS BOND SURFACE Figure 4 POSITIONING THE EXTRACTION INSERTION TOOL FOR BOARD REMOVAL Ref 81 PC 57 2 5 Installation GEK 25361A Rack and CPU Module Installation INSERTING A PRINTED CIRCUIT BOARD 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 slot beside the top of the solder side of the board Insert the Logic Rack Notch Bottom into the short slot beside the bottom of the solder side of the board The board puller is now 1809 reversed from the position for removing a board See Figure 5 for proper tool positioning for insertion of a board e Grasp the handle area of the board puller with either hand and s
211. oading of the outputs twisted pair cables should be used for wiring to the output connections whenever possible NOTE Pots R69 and R61 the two top pots on the board are factory set and should not be adjusted tings are accidentally changed contact the assistance Each channel on the module be set independently for an output range of 0 10 V 10 10 V or 4 20 mA by configuring the jumpers so that the numbered pins on the circuit board are connected as shown in Table 18 Note that whenever the range of a channel is changed the channel should be recalibrated See Chapter 3 for calibration procedures OUTPUT First Second Third Fourth RANGE Channel Channel Channel Channel o 10V 30 31 23 24 16 1 7 9 10 27 28 20 21 13 14 6 7 41 42 38 39 35 36 32 33 10 10V 29 30 22 23 15 16 8 9 25 27 18 20 11 13 4 6 42 43 39 40 36 37 33 34 4 20 30 31 23 24 16 17 26 27 19 20 12 13 41 42 38 39 35 36 4 20 mA output range only For Common External Source connect 2 3 For Internal Loop Supply connect 1 2 Table 18 CHANNEL CONFIGURATION 2 78 Installation GEK 25361A Module Wiring NOTE The Analog Output module will function properly only when used with CPU s with the following serial numbers Model 60 CPU Cl 88 8135 0130 and higher Model 600 CPU 88 8138 0100 and higher Model 6000 CPU 88 8138 6000 and higher If your CPU has a serial number lower than that listed conta
212. oard Figure 25 is a block diagram of the auxiliary circuit board BAT O Memory Voltage l2v Reference _ ae O AUX BAT PSI Regulator Q Power 79 DATA Voltage PROTECT lv Comparators Delay 5 O O SYS RDY Clock VSt Voltage Optoiso BAT Battery Sensor lator OK O Condition vs Storage CPU OK C AINC START Run Stop Alarm Switch STOP Mam Relays C START Debounce arm Q A2NC LOW BAT A2NO Figure 25 AUXILIARY CIRCUIT BLOCK DIAGRAM The auxiliary circuit board performs several functions which are summarized below Senses the levels of the 5V 12V and 12V supplies in the CPU rack and provides 3 outputs PSI SYS RDY and Data Protect Provides switch debouncing for the front panel CPU Run Stop switch Provides control logic and relay isolation for the 2 user alarm signals Provides voltage regulation for a user supplied memory auxiliary back up battery 6 28V DC Ref 70 59 1 45 General Description of the Series Six GEK 25361A Power Supply ALARM RELAY The alarm relay logic is located on the CPAXI board Various system problems cause the alarm relay outputs to switch The alarm relay outputs are rated at 115V AC or 28V DC 1 amp resistive load Alarm no 1 causes the CPU status to be set to stop Alarm no 2 causes an error indication to be recorded but the CPU status in most cases does not stop
213. ocedures for contacting Programmable Control Customer Service are given later in this section PACKAGING The method of packing and shipping the components of a Series Six system are outlined in this section CPU racks are shipped with the following modules in their respective slots Power Supply I O Control Logic Control and Arithmetic Control In addition the Internal Memory module and the Register Memory module are installed in a Model 600 or 6000 In a Model 60 the combined memory module is shipped installed in its respective slot Blank faceplates are shipped separately for the remaining slots 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 plug and the Series Six Installation and Maintenance Manual This package is then placed in a shipping container The Logic Memory and any optional modules are shipped in a 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 IO 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 a
214. odule can be placed anywhere in an I O rack except the left most slot which is reserved for communication modules Modules have either 4 6 8 or 32 input or output circuits according to type Module Hardware Features Each module consists of two parts a printed circuit board and a terminal assembly The printed circuit board contains the electronic circuitry which interfaces a CPU to Input Output devices and provides iso lation from electrical noise The printed circuit board plugs into a slot in an W O rack and the terminal as sembly attaches to the front edge of the printed circuit board The terminal assembly is mounted on a faceplate Each faceplate contains various legends depending on the type of module The discrete 8 circuit modules have a markable lens surface for custom visual indication of input or output wiring The lens is on the upper half of the faceplate and is numbered 1 through 8 top to bottom The numbers correspond to input or output circuitry on the printed circuit board The terminal strips mounted on the faceplates have box lug terminals for ease of connection to field wiring Each box lug terminal is electrically rated at 10 amps Each I O rack has a tray mounted on the bottom front for the purpose of running field wiring from external devices to and from the box lug terminals Modules are color coded for convenience and as a visual safety feature The color scheme is shown below in Table 7 Note that the higher voltage
215. of these modules thereby allowing a system a total of sixteen serial ports DUAL SER PORT PORTA TRANS A TRANS BG RECY Figure 69 DUAL SERIAL PORT MODULE Figure 70 indicates maximum memory available in the Data Processor when used with the indicated CPU DPU memory capacity when the separate DPU rack is used with a model 600 CPU is the same as in a DPU rack used with a model 60 or 6000 CPU MODEL DPU modules in same rack as CPU Figure 70 MAXIMUM DPU MEMORY IN 16 BIT WORDS Ref 82 PC21 General Description of the Series Six GEK 25361A Data Processor PROGRAMS Programs supplied with the Data Processor are briefly explained below Additional programs will be available in the future Message Generator This program allows the Data Processor to store up to 256 different messages with various formats Each message can be up to 8000 characters long and can include variables supplied to the Data Proces sor by the CPU The CPU also initiates the printing of messages specifies the command number and identifies the port if more than one port is used in a system File Storage and Retrieval This is a program that allows the Data Processor to store a large quantity of data in a structured file System that is directly accessible by the CPU Each structure consists of files each file contains records each record contains registers The CPU can read or write into any segment of the file structure T
216. olerance the monitor circuit causes the I O Transmitter to shut down An LED indicator is on when the voltage is within tolerance In addition there are LED indicators for CHAIN OK and CHAIN PARITY status Table 26 defines the status information provided by the indicators INDICATOR DEFINITION CHAIN ON when station power is OK and continuity is present to all downstream OK stations CHAIN PARITY ON when output parity is OK at all downstream stations ISOLATED ON when the output voltage of the 5V DC isolated power supply is within POWER tolerance Table 26 TRANSMITTER STATUS INDICATORS Connector One 37 pin D type connector is mounted on the bottom front edge of the circuit board 16 paral lel cable plugged into this connector in a model 60 CPU a CPU station or a Local I O station connects to the first I O Receiver Local I O station at a distance not to exceed 500 feet 150 meters REMOTE SYSTEM The Remote I O system allows a Series Six system to have an I O capability that extends beyond the limit of the 2000 feet 600 meters maximum distance allowed with the parallel bus A Remote I O system can be located a maximum of 10 000 feet 3 Kilometers from a model 60 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 loca t
217. ond Alternate conversion rates for both 50 and 60Hz systems can be selected by reposi tioning of jumper plugs on the printed circuit board Instructions on reconfiguring of any jumpers on this module can be found in Chapter 2 of this manual 1 71 General Description of the Series Six GEK 25361A Input Output System Illustration not available Figure 36 THERMOCOUPLE INPUT MODULE Accuracy of temperature measurement is assured through a Cold Junction Sensing module connected directly to the terminals on the Thermocouple module faceplate This module connects to internal logic and provides an automatic offset to the effect of ambient air temperature at the point where the ther mocouple wires are connected to the Thermocouple module faceplate terminals Specifications for the Thermocouple Input modules are listed in Table 15 1 70 General Description of the Series Six GEK 25361A Input Output System Thermocouple Input Module The Thermocouple Input see Figure 36 module is available in four versions types J K S and T each having a different range of temperature measurement Temperature ranges for each of these modules is listed below in Table 14 TYPE DEGREES CENTIGRADE C DEGREES FAHRENHEIT F J 210to 760 C 1 39 346 to 14000F 2 430 K 212 to 12320 1 40 350 to 22500F 2 520 O to 17689C 3 50 32 to 3200 F 6 30 270 to 400 C 1 39 454to 7520F 2 430 Table 14 TEMPERATURE RAN
218. ons A connector on the bottom front edge of the module allows inter facing to the Arithmetic Control Module The ribbon cable connecting the two modules must be in place for proper system operation NOTE Attempting to operate the system without the ribbon cable connected be tween an Arithmetic Control module and a Logic Control module will cause the CPU to operate unpredictably 1 18 GEK 25361A General Description of the Series Six Central Processing Unit e o o EXTENDED BASIC Module Control interface To Arithmetic Connector For if Figure 10 LOGIC CONTROL MODULE Ref 81 PC 16 1 19 82 PC 7 General Description of the Series Six GEK 25361A Central Processing Unit ARITHMETIC CONTROL The Arithmetic Control See Figure 11 module contains circuitry which performs arithmetic and logical operations on data and address lines The time base for the timer functions in the CPU are derived from a 3 2 MHz clock on this module The Series Six CPU has 4 hardware registers located on the Arithmetic Control board The continuity and buffer registers are each one bit wide The accumulate and preset registers are sixteen bits wide The registers are operated on internally by the CPU and are not accessible by the user The logic for performing these operations is a sixteen bit Arithmetic Logic Unit The ALU is made up of 4 Am2903 bit slice microprocessors The Am2903 is a 4 bit expandable bipolar
219. option jumper on this module set for CPU to RUN when error detected Table 30 REMOTE I O DRIVER INDICATOR STATUS Option Jumpers Several jumpers located on this module are used for configuration of various options necessary for proper system and module operation Table 31 lists the factory and alternate settings for the Remote Driver options 120 outputs 248 Outputs Communications STOP CPU Allow CPU to RUN Failure CPU Status Remote 1 STOP CPU Allow CPU to RUN Parity Error Communications Two Twisted Pair To RS 232 Modem Link Link 10 000 feet 3 Km Table 31 REMOTE I O DRIVER OPTIONS 1 106 General Description of the Series Six GEK 25361A Input Output System Instructions for reconfiguring circuit board jumpers to change any of the options can be found in the In stallation chapter of this manual The options listed in the table are those most necessary for proper system operation Other jumpers on the board are available for RS 232 operation if required In addition several jumpers are factory set and are for future expansion or production testing These jump ers should not be altered 1 107 General Description of the Series Six GEK 25361A Input Output System REMOTE RECEIVER The Remote I O Receiver module Figure 53 is the interface to the serial communications link for a Remote l O station It is physically located in the first rack in a Remote I O station normally in the left most slot sin
220. p of the power supply bracket The power supply can now be re moved from the PDT and set on the table with wiring intact Remove the power supply shield by removing 3 screws from the top of the power supply and 1 screw from each corner of the lower part of the power supply bracket Remove the power supply bracket by removing 4 screws from the rear of the bracket Set the new power supply next to the one being replaced Remove the wires from the terminal board of the old power supply and connect them to the terminal board on the new power supply Remove the wires one at a time Ensure that the wires are connected to the correct terminals Attach the power supply bracket to the new power supply Attach the power supply shield to the new power supply and to the bracket Install the new power supply and tighten the screws holding the shield and bracket Be careful not to pinch the cable going to the CRT Check all power supply voltages 4 CRT ADJUSTMENT PROCEDURES 3 8 High voltage exists in the Program Development Terminal CRT assembly Use extreme caution when making adjustments or personal injury may result No adjustments should be performed on the CRT assembly by anyone not familiar with servicing procedures and precautions Troubleshooting Repair GEK 25361A Program Development Terminal Troubleshooting The following adjustments are made on the video monitor board See Figure 2 for location of board All adjustment controls
221. pical user input connections BOARD OK Light The LED is Off if there is an A D converter malfunction an I O rack power supply problem or the CPU is in the Stop or the Run Disabled mode It is also Off if the module has not been read since one of these conditions existed or since power has been applied Figure 33 sas UNWIN 4 7 9894 za 051 51 4 0 002 S Wdh HIMOS U3LUJANDI 1090 i NAN USANI 61 R12 Offset Pot All Channels RI 1 Gain Pot All Channels User Connector Block ANALOG INPUT MODULE Ref 81 PC 77 General Description of the Series Six GEK 25361A Input Output System An Analog Input module can be installed in any slot in an 1 0 rack except the left most slot or in one of the six I O slots a model 60 CPU rack Before the module is installed the seven segment DIP switch on the backplane adjacent to the selected 1 0 slot should be configured to select the starting I O point number for the module A group of 32 consecutive I O points are selected by setting the DIP switch Figure 34 shows the DIP switch settings for an Analog Input module Further installation procedures for this module can be found in Chapter 2 INPUT DIP SWITCH Em DIP SWITCH INPUT DIP SWITCH NUMBER POSITION Em POSITION NUMBER POSITION ej ons EE 353 384 x ixix x 385 416 xix BNNZZI REIHE Xp LL L 97 128 x x 449 480 x xi
222. problems are encountered during any of the above steps and they are not readily solved contact the Programmable Control Service Center at 804 978 5747 in Charlottesville Virginia A Customer Service representative will take the proper course of action to solve your problem RACK CONFIGURATION The CPU and I O racks should be mounted in a rack or panel as required Connect 115 or 230V AC to the proper terminals on the respective power supplies If audible or visual alarms are required for various system malfunctions connect them to the proper terminals located on the terminal board on front of the CPU power supply Run cables between the CPU and I O rack or racks as required Run interconnect ing wiring between external devices and I O modules and make the proper connections Then connect the Program Development Terminal Now you can apply power enter a program and system check the input and output modules See Figure 62 1 126 General Description of the Series Six System Configuration GEK 25361A NOTE If Auxiliary 1 0 Module CPU 1 0 Control required Auxiliary 1 0 Model Module System will connect to 6000 600 60 slot no only in a External Alarms 12 Model 6000 CPU T s Cable length up to 50 feet 115 230V 1 0 50 60 Hz Rack sH e NM CPU or an 1 0 Rac in a CPU Station o Local 1 0 Station 15 250 AC 50 60 Hz 16 Twisted Cable Daisy Chain to ne
223. processing by the CPU and convert CPU signals to the proper electrical levels for control of user devices The I O modules also provide isolation for signals in the CPU from electrical noise in the typical factory environment The basic programming language used by the Series Six is relay ladder logic This has been expanded to include as an option a powerful Extended Instruction Set which adds the capability of programming ap plications more complex than those requiring only relay timing and counting functions Detailed infor mation on programming the Series Six can be found in GEK 25362 PROGRAMMING MANUAL FOR SERIES SIX PROGRAMMABLE CONTROLLERS BASIC SYSTEM DESCRIPTION The Series Six consists of 3 models which are the Model 60 Model 600 and Model 6000 The same Input Output I O system and Program Development Terminal are used by all of the Series Six models The basic components of the Series Six are as follows 1 Program Development Terminal PDT Allows user programs to be entered into the system May be used on line or off line 2 Central Processing Unit CPU Stores user programs and interfaces to input output modules for solving logic and performing desired functions Contains various control modules 3 Input Output modules I O Converts user signals to low level voltages for processing by CPU and converts CPU signals to proper level for control of user devices Also provides optical isolation from electrical noise
224. put The module is shipped from the factory with all eight inputs configured to respond to rising edge transitions After configuring the eight jumpers install the module using the extraction insertion tool Connect the grounding wire between the faceplate and the rack When the board is in place in the rack the edge connector on the faceplate should be slipped over the circuit board so that proper contact is made Secure the faceplate to the rack by pushing in on the quarter turn thumbscrews while turning them clockwise 2 55 Installation GEK 25361A I O Module Wiring For typical user connections to an Interrupt Input module refer to Figure 32 No Isolation All inputs on one Maximum Isolation Two 10 30V DC supply inputs on each 0 amp 30V DC supply Figure 32 TYPICAL USER CONNECTIONS As shown above all neutral connections N 1 N2 N3 and N4 can be tied together when all inputs are connected to the same 10 to 30V DC power supply For electrical isolation each of the four groups of two inputs and the corresponding neutral connection can be connected to separate power supplys Provide either a single or for electrical isolation up to four 10 to 30V DC power supplies Connect one side of the switching device to the corresponding input terminal 1 8 Connect the other side of the switching device to the positive side of the power supply Connect the negative side of the power supply to the neutral terminal asso
225. put by configuring the jumper to the proper terminals as shown jumper will be configured for 115V AC when shipped from the factory If a dual voltage model Connect a 3 wire AC power cord to the 3 lower terminals 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 2 26 Ref 70 6 Installation GEK 25361A The O Rack After completing the above connections the protective coverplate should be reinstalled WARNING Ensure that the protective cover is installed over the terminal board During normal operation either 115V AC or 230V AC 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 VO SYSTEM COMMUNICATION MODULES The I O system communication modules are the 1 0 Receiver I O Transmitter Remote I O Driver and Remote I O Receiver Individual functions of these modules are described in Chapter 1 Installation in structions for each of these modules is included in this section RECEIVER The I O Reciever module is normally installed in the left most slot of an 1 0 rack since this module does not require an I O address The left most slot does not have a seven segment DIP switch adjacent to the slot on the backplane
226. queeze it until you feel the board seat Visually inspect the board to be sure it has seated properly Remove the tool Figure 5 POSITION OF EXTRACTION INSERTION TOOL FOR BOARD INSERTION FACEPLATE GROUNDING WIRE Each faceplate has a short green wire connected to the inside bottom of the faceplate The purpose of this wire is to ground the faceplate to the rack Before mounting a faceplate the opposite end of the green wire must be connected to the rack Figure 6 shows this connection 2 6 Ref 8 1 40 Installation GEK 25361A Rack and CPU Module Installation A hex head screw is mounted adjacent to each bottom cardguide about 1 inch 25 mm in from the front of the rack Remove this screw put it through the eyelet of the terminal lug and reinsert the screw into its mounting hole Loop the wire so that it will not interfere with the insertion of a printed circuit board into its cardguide Tighten the screw securely to insure a good ground connection between the faceplate and the rack l Faceplate Grounding Wire Attaches from Faceplate to Rack Figure 6 FACEPLATE GROUNDING WIRE MODULE INSTALLATION The modules for your system should now be installed in their proper slots in the CPU DPU or I O racks Before installation some of the modules may require configuration of switches or jumpers Figure 7 is provided as a guide to proper module location in the CPU racks Ref 8 1 PC 39 GEK 25361A Rack and C
227. r negative data The 2 s complement form of a binary number is found by inverting complementing all bits and then adding one It is recommended that calibration of the Thermocouple Input module be performed every 180 days at normal operating temperatures Calibration procedures are detailed in Chapter 3 of this manual A cali bration connector is available for ease of connecting a voltage meter and a voltage source 1 73 General Description of the Series Six GEK 25361A Input Output System A Thermocouple Input module can be installed in any I O slot in a model 60 CPU rack or in any slot in an 1 0 rack except the left most slot Before the module is installed the seven segment DIP switch on the backplane adjacent to the selected 1 0 slot should be configured to select the starting I O point number for that module This will cause a group of 32 consecutive bits in the appropriate Input Status Table to be specified for the module Figure 37 shows the DIP switch settings that can be selected for a Ther mocouple Input module INPUT DIP SWITCH INPUT DIP SWITCH INPUT DIP SWITCH NUMBER POSITION NUMBER POSITION NUMBER POSITION PEE 705 736 Lxx EN zx 1 EC n BE 7 33 4 x 385 416 x x 769 800 XIX 65 96 x 417 448 801 832 x x x 129 160 x 481 512 x x x x 833 864 X 161 192 xl x 513 544 1 865 896 x x x 193 224
228. r output point used Output Capabilities ON State Output Low Module acts as Current Sink OFF State Output Floats Output High Module acts as Current Source Response Time 30 us maximum 30 us maximum Fuse Normal Blow 1 A Normal Blow Table 20 SPECIFICATIONS HIGH DENSITY OUTPUT 1 80 General Description of the Series Six GEK 25361A Input Output System The 32 outputs on this module are arranged in four groups with eight outputs in each group A single group is read by the CPU during an cycle All 32 outputs four groups are read in four consecutive I O cycles A user supplied power source is connected to either the 5V TTL module or 50V 50 DC module and COM terminals as required By connecting a jumper plug on the circuit board to the proper terminals the user can select whether the data sent to the CPU is inverted complemented or non inverted An LED viewed on the faceplate provides a visual indication of the selected mode See Figure 41 1 81 General Description of the Series Six Input Output System TUPCOxo t BU 10 50V DC DATA INVert Light On The module is in the Inverting mode Off The module is in the Non Inverting mode 2 NONHNV NV Jumper A B Connected ing mode B C Connected Sets module to the Non Inverting mode
229. rcuits for user interrupts lo 30V DC required 2 amp sink versions of the DC output modules which are isolated in 2 groups of 4 outputs Each output has an Output On indicator and a Blown Fuse indicator Each output stage has overload protection 2 amp source versions of the DC output modules which are isolated in 2 groups of 4 outputs Each output has an Output On in dicator and a Blown Fuse indicator Each output stage has overload protection Contains 8 isolated Triac outputs capable of switching 2 amperes each Each circuit has an Output On indicator and a Blown Fuse indicator Decodes address and accepts output data from the 1 0 bus 32 outputs capable of driving 11 TTL loads each Maximum of 50 mA per output Requires user supplied 5V DC supply 32 unfused outputs Maximum of 250 mA per output Requires user supplied power supply Table 6 l O RENEWAL PARTS LIST Continued Troubleshooting and Repair System Troubleshooting GEK 25361A Catalog Module Name Name IC600YB841A Input Board IC600YB842A High Level IC600YB843A Analog IC600YB941A Output Board ICBOOYB942A High Level IC600YB943A Analog IC600YB813A Input Board IC600YB814A Thermocouple 815 IC600YB816A iC600YB910A Qutput Board IC600YB912A Isolated AC IC600YB9I4A Output Board Reed Relay RENEWAL PARTS LIST Continued Contains 8 input circuits with ranges of 0 to 10V YB841 9 to 10V YB842
230. rd layout 1 118 Ref 81 PC 61 General Description of the Series Six GEK 25361A Program Development Terminal Extended Mnemonic Group Relay Group Numeric Group Dark Brown Dark Brown White Basic Mnemonic Group Operand Group Mode Control Group Dark Brown White Light Brown figure 59 KEYBOARD LAYOUT Ref 70 1n I 119 General Description of the Series Six GEK 25361A Program Development Terminal CABLE STORAGE A storage compartment is provided to secure all cables necessary for operation of the PDT Molded in cable wraps are provided to allow the AC power and PDT to CPU cables to be neatly stored A hinged panel folds up to enclose the cables for transporting and storage Additionally the compartment contains a panel with connectors for external devices e g printer Minicartridge Tape Unit composite video monitor a fuse and a CRT brightness control CRT DISPLAY The CRT has a 12 inch 304 8mm diagonal measure screen with an anti glare faceplate for good visibil ity under adverse lighting conditions The characters are displayed on the screen in a 5 x 7 dot matrix A brightness control allows adjustment to various ambient lighting conditions TAPE UNIT An optional built in tape unit allows the user to read in programs or to write a program to tape The tape unit uses the 3M DC100A minicartridge Data is transferred between the PDT and the tape unit in a parallel mode of operation This mode of operation allows
231. re pack aged the same as the CPU rack and modules 2 1 Installation GER 25361A Rack and CPU Module Installation Data Processor racks are shipped with only the power supply mounted in the rack The rack is pack aged the same as a CPU rack Each of the DPU modules is packed in an individual two section package All of the individual packages are then placed in a shipping container The Program Development Terminal is enclosed by a Urethane foam molded two piece package The back of the Program Development Terminal is placed in the bottom cap the carrying handle is folded to its bottom position and the top cap is placed over the Program Development Terminal The foam package is then inserted in a shipping container One GEK 25362 Programming Manual for Series Six Programmable Controllers is included with each Program Development Terminal It is recommended that the shipping containers and all packing material be saved in the event that it be comes necessary to transport or ship any part of the system VISUAL INSPECTION Upon receiving your Series Six 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 reponsibility of the consignee to register a claim with the carrier for damage incurred during shipment However General Electric Company will ful
232. res Installation GEK 25361 A I O Module Wiring 115 VAC OUTPUT ebeneesa aGeergeaae 2 a TP m 1 Terminal Cover 4 Output ON Lights 1 8 2 User Terminal Block 5 BF Blown Fuse Lights 1 8 3 Circuit Board Terminal Block 6 Fuses 3A One Per Circuit Mates With User Terminal Block 7 Markable Lens Surface Figure 36 AC OUTPUT MODULE DoF 01 DA in 2 63 Installation GEK 25361A I O Module Wiring Install the circuit board using the extraction insertion tool With the circuit board in place in the rack slip the faceplate over the circuit board so that the terminals near the bottom of each part are properly mated Secure the faceplate to the rack by pushing in on the quarter turn thumbscrews while turning them clockwise Wiring to devices to be controlled should be routed from the devices through conduit or cabling to the rack into the wiring tray and to the output module The wires should then fan out to the proper box lug terminals insert the wires into their respective box lug terminal and tighten each screw to ensure a good contact Each box lug will accept one No 12 AWG or two No 14 AWG wires Refer to Figure 37 for typical user output connections Wiring instructions for an AC output module follow the figure OUTPUT MODULE 5 Output Switching Device L User Load E User Power Source Figure 37 AC OUTPUT MODULE TYPICAL USER CONNECTIONS 2 64 Ref 702
233. ription of the Series Six GEK 25361A Power Supply ELECTRICAL SHOCK HAZARD CO I P EIN Pa TO Potter pond SERVICE TG C CPU Power Supply Standard High Capacity Power Supply Power Supply Figure 22 SERIES SIX POWER SUPPLIES MOUNTING The power supply slides into the rack on cardguides as do all modules mounted in the Series Six racks The power supply module is held secure in the rack by 2 quarter turn thumb screws one at the top of the panel and one at the bottom Mounting of the power supply is at the far right side of the rack as viewed from the front LOGIC POWER SWITCH A circuit breaker is mounted on the front panel for switching the AC input power on or off With the cir cuit breaker in the ON position a POWER OK LED indicator turns on when all DC voltages have reached their specified operating range The LED is viewed through the translucent lens on the front panel Ref 81 PC 35 81 PC 48 82 PC 9 1 41 General Description of the Series Six GEK 25361A Power Supply AC INPUT Two sources of AC input voltage may be used either 115V AC or 230V AC AC input to the power supply circuitry is provided by connection to screw down terminals on a terminal block mounted on the front panel Only dual voltage models are jumper selectable KEY SWITCH The CPU power supply has two key switches mounted on the front panel Both are two position One of the switches functio
234. roduction TROUBLESHOOTING The maintenance and troubleshooting section of this manual is designed to help you isolate and correct any problems that may arise in your Series Six system It is recommended that all maintenance and pro gramming personnel read this manual thoroughly so that if a problem does arise it can be isolated quick ly 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 please don t hesitate to call Programmable Control Service at 1 800 GEFANUC REPLACEMENT MODULE CONCEPT The troubleshooting and maintenance techniques described in this manual promote the concept of com plete board replacement The prime objective of this concept is to minimize system downtime When a problem arises first isolate it to the major assembly Program Development Terminal Central Processing Unit 1 0 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 production 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
235. ry chain I O modules The Auxiliary 1 0 module interfaces internally to the 1 0 Control module for control signals There is one 37 pin connector located on the bottom front edge of the Auxiliary I O module This connector provides a physical connection to the Auxiliary I O chain 1 32 General Description of the Series Six GEK 25361A Central Processing Unit There are 3 LED indicators which are viewed through the window on the face plate The LED s and their functions are as shown below INDICATOR DEFINITION On when all I O stations in the Auxiliary O chain have continuity and power and have received good output data parity PARITY On when good input data parity has been received from the Auxiliary I O chain during the I O scan ENABLED On when outputs are enabled The CPU is operating in the RUN ENABLED mode 1 D Type 37 Pin Connector to Auxiliary I O Chain Connects to I O Receiver module in nearest I O rack in auxiliary chain 2 CHAIN OK Light 3 PARITY Light 4 ENABLED Light Figure 18 AUXILIARY I O MODULE Ref PC 6CPU 24 1 33 General Description of the Series Six GEK 25361A Central Processing Unit COMMUNICATIONS CONTROL The Communications Control module which is an option with any model of the Series Six provides a serial interface to the CPU A Portable Tape Unit and a high speed data highway
236. s light is off check AC input and 5V DC voltages Refer to 5 Replace the 1 0 Receiver If there is an O Transmitter replace it Replace the I O Receiver in the next 1 rack downstream in the I O chain 3 44 Troubleshooting and Repair GEK 25361A I O System Troubleshooting CHAIN PARITY 1 O Receiver Light O Transmitter e E m RE A PE e E Ee Ee i Output parity is good in this rack and all links connected to this rack Indicates that an output parity problem has been identified by an 1 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 1 switches gt 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 rack s of the Local station it is driving Locate the first 1 0 rack in that chain with the LOCAL PARITY light off Replace the Receiver in that rack Replace the I O chain interconnecting cable Replace the I O Transmitter that is driving the I O station link is made up of an I O Transmitter module a 16 pair twisted shielded parallel bus I O cable and one or more I O Receiver boards LOCAL PARITY Light Receiver a NEM a Output parity is OK in this I O rack Output parity has been d
237. s table such as Ri O Move Register to I O table the desired table input or output must be specified A basic or extended instruction set is offered for programming the Series Six CPU s For detailed pro gramming information refer to the Series Six Programming Manual GEK 25362 PROGRAM DEVELOPMENT TERMINAL The Program Development Terminal PDT used with the Series Six family of programmable controllers is a transportable microprocessor based CRT terminal The terminal gives the user the ability to create edit and store ladder diagrams See Figure 6 Programs can be created and entered directly into the CPU or they can be created and stored on tape without the necessity of having the PDT connected to the CPU With the PDT connected to the CPU the user can load programs monitor program operation start and stop the CPU and control operation of the system A convenient feature of the Series Six Program Development Terminal is that it may be plugged into an I O rack that is distant from the CPU thereby allowing the user to be near the device being controlled General Description of the Series Six Introduction 1 Tape Unit Optional 2 Power Switch 1 12 3 Keyswitch 4 Keyboard 5 Handle Figure 6 PROGRAM DEVELOPMENT TERMINAL 6 Foam Enclosure 7 CRT Display GEK 25361A Ref 81 PC 72 General Description of the Series Six GEK 25361A Central Processing Unit SECTION 2 Hardware Description of th
238. section provides an introduction to the Program Development Terminal PDT See figure 57 For a detailed description of the operation of the Program Development Terminal refer to GEK 25362 Pro gramming Manual For Series Six Programmable Controllers This section will give the user a familiarity with the hardware features and uses of the terminal PROGRAM DEVELOPMENT TERMINAL FUNCTIONS The Program Develoment Terminal allows the user to create modify and monitor programs for the Series Six family of programmable controllers Programs are written in free format ladder diagram form The Program Development Terminal also provides a means of monitoring and overriding inputs and outputs An interface to a printer is provided to allow the printing of ladder diagrams and cross reference tables Programs can also be loaded or stored by means of an optional built in Minicartridge Tape Unit or by interfacing through the external tape port to an external portable tape loader Figure 57 PROGRAM DEVELOPMENT TERMINAL Ref 81 72 1 117 General Description ofthe Program Development Terminal ENCLOSURE The enclosure for the Program Development Terminal is made of structural foam for strength and durability Dimensions of the unit with the keyboard closed are 12 5 x 21 5 x 16 5 inches 317 5 x 546 1 x 419 1 mm The unit weighs 57 pounds 26kg A carrying handle is provided for convenience as an aid to transporting the unit See Figur
239. select 1 Baud select 1200 Baud recommended Must be same as PDT The sliding tab on the tape cartridge should be in the RECORD position Power down then back up to reinitiate the PROM INTEGRITY CHECK If it fails a second time check seating of all four printed cir cuit boards check the RAM board first If problem still exists re place the RAM board BAD PROM LOC Same as above except check seating of PROM board message on message on power up power up first If problem still exists replace the PROM board 3 12 Table 1 Cont PDT TROUBLESHOOTING Troubleshooting and Repair GEK 25361A Program Development Terminal Troubleshooting PREVENTIVE MAINTENANCE The preventive care and maintenance of the STR LINK mini cartridge recorders involves only simple easily accomplished procedures that enhance the performance of the unit and assure long term trouble free operation After every 8 hours of operation clean the read write heads with a magnetic head cleaner solvent Use cotton swabs to clean and dry the heads taking care not to touch the heads with fingers or other foreign objects After every 8 hours of operation clean the capstan drive roller with a rubber drive cleaner solvent and wipe the roller dry After every 100 hours of operation clean the entire unit thoroughly removing any dust metal oxide particles and lint that may have accumulated Use an air hose or a soft brush to accomplish this cleaning
240. ser Load E User Power Source Figure 39 ISOLATED AC OUTPUT TYPICAL USER CONNECTIONS Ref 70 114 2 67 Installation GEK 25361A I O Module Wiring Connect the high side of the user power source to one of the High terminals H6 Connect one side of the load to be controlled to the corresponding Output terminal 01 06 Connect the other side of the load to the low side of the user power source After completing field wiring to the module install the terminal cover by guiding both of its edges onto the top of the terminal block and sliding it down over the terminals WARNING Voltages from user field devices may be present on the faceplate terminals even if the power supply in the I O rack is off Care should be taken when handling the faceplate or any wires connected to it DC OUTPUT MODULES The discrete 8 point DC Output modules are available as 12V 24V and 48V DC sink or source modules as listed below Catalog Number 12V DC SINK IC600BF906A 24V DC SINK IC600BF902A 48V DC SINK IC600BF903A 12V DC SOURCE iC600BF907A 24V DC SOURCE ICGOO0BF908A 48V DC SOURCE IC600BF909A A DC Output module can be installed any I O slot in a model 60 CPU or in any slot in an I O rack except the left most slot Before installing one of these modules select the I O starting point number for the module by configuring the seven segment DIP switch the backplane adjacent to the selected I O slot The I O point s
241. sion resistor is connected between the and VR terminals as shown For the O 10V and 10 10V modules any input channel should be connected as shown for the 4 20 1 module any input channel can be connected in any of the three ways shown If driving an input from an unbalanced source one side grounded you should connect the cable shield to the ground side at the source In any event neither the input terminal IN nor the return terminal VR should be more than 11 V from the shield terminal SHD at the module Both the input terminal and the return terminal of any unused input channel s should be connected to the shield terminal Note that all shield terminals are connected inside the module Ref 70 129 2 53 Installation GEK 25361A I O Module Wiring NOTE The Analog Input module will function properly only when used with CPUs with the following serial numbers Model 60 CPU CI 88 8135 0130 and higher Model 600 CPU C188 81 38 0100 and higher Model 6000 CPU 88 8138 6000 and higher If your CPU has a serial number lower than that listed contact a PC Pro duct Service specialist at 1 800 GEFANUC for assistance INTERRUPT INPUT MODULE An Interrupt Input module Catalog Number 6 can be installed in an 1 slot in a model 60 CPU or 1 0 slot an I O rack in a CPU station or a Local I O station One Interrupt Input module can be used by a system with a mod
242. switching regulated supply with its electronic circuitry completely self contained on one assembly The power supply assembly is attached to a faceplate which has various hardware mounted on it Two variations of the power supply are used by the Series Six one is mounted in the CPU rack DPU rack and the PDT the second is mounted in the I O rack The I O version is available in either a stan dard or a high capacity model dependent on the load placed on the supply by the I O modules The power supplies are described in Section 4 of this chapter Table 5 lists the electrical and environ mental characteristics of the power supplies Figure 22 shows the three variations of the power supply ELECTRICAL CHARACTERISTICS Input Voltage 95 130VAC 190 260V AC Input Frequency 47 63 Hz Output Voltages 5 DC 4296 16 5A CPU DPU PDT 12V DC 5 1 5 CPU DPU PDT 12V DC 5 OA CPU DPU PDT Standard 1 0 Rack 5V DC 42 6 1A High Capacity 1 0 Rack 5V DC 42 16 5A 12V DC 4 296 1 5A 12VDC 44296 1 0A Noise amp Ripple 2 pp maximum Overvoltage Protection 6 2V 0 5V 5V DC Output Overcurrent Protection All outputs GENERAL CHARACTERISTICS Temperature Range O9C to 60 C Operating Outside of Rack 20 C to 85 C Storage Relative Humidity 5 to 95 Non Condensing Altitude maximum Operating 50 000 ft Storage Table 5 1 40 POWER SUPPLY ELECTRICAL AND ENVIRONMENTAL CHARACTERISTICS General Desc
243. t Pot Channel No 0 NOTE 6 R43 Gain Pot Channel No 1 Pots R69 and R61 are set at the 7 R35 Offset Pot Channel No 1 factory and should not be 8 R27 Gain Pot Channel No 2 adjusted If the settings are acci 9 R20 Offset Pot Channel No 2 dentally changed contact the 10 RI 3 Gain Pot Channel No 3 GE PC Service Center at 804 11 6 Offset Pot Channel No 978 5747 for assistance Figure 43 ANALOG OUTPUT MODULE Ref 8 1 PC 74 1 85 General Description of the Series Six Input Output System GEK 25361A An Analog Output module can be installed an I O rack or in one of the six 1 0 slots in a Model 60 CPU Before the module is installed the seven segment DIP switch on the backplane adjacent to the selected slot should be configured to select the starting I O point number for the module A group of 16 con secutive I O points are reserved for the module by setting the DIP switch Figure 44 shows the DIP switch settings for an Analog Output module INPUT NUMBER DIP SWITCH POSITION INPUT NUMBER INPUT NUMBER DIP SWITCH POSITION DIP SWITCH POSITION TTT TT LE Lasse fef d 5 4 3 17 32 x 369 384 09140 Li 2 XIX 33 48 x 385 400 Ix x 49 64 xix 17501 16 IX X x Switch in OPEN Position Depressed to the Left Switch 1 Should be in CLOSED Position Figur
244. t 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 particular Remote I O Driver More than one Remote I O station can be programmed to the same l 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 can be used by another Remote I O station a Local I O station a CPU station or a model 60 I O slot For additional information on selection of I O points in a Remote I O station refer to Chapter 2 Installation of this manual 1 99 General Description of the Series Six GEK 24361A Input Output System Cable Wiring Wiring connections required for use with the remote 1 0 modules are shown in Figures 50 and 5 1 Two methods of connection are shown Figure 50 shows two twisted pairs Figure 51 shows wiring for con nection using RS 232 modems Note that both the Remote I O Driver and Remote I O Receiver are con figured as Data Terminal devices when connection is by RS 232 modems Pair J T 5 Received Data Data Shield Receive f T Transmit Data M Data Shield Remote 1 0 Remote 1 0 Driver Receiver CABLE SPECIFICATIONS Length Maximum 10 000 feet 3 kilometers Two Individual Shielded Twisted Pairs 22 AWG Minimum 15 pf foot Maximum Cable Type National
245. tatic electricity Failure to observe this CAUTION could result in the destruc tion of the CMOS RAM devices in this module With the board covers in place it is unlikely that normal handling of this module will cause any damage The board covers provided with each Logic Memory module are a non conductive material These boards are provided for protection of the CMOS RAM devices Do not allow the bottom of the module to come into contact with a con ductive metal surface when the board covers are removed Failure to ob serve this CAUTION could result in the discharge of the non rechargeable Lithium battery and the loss of memory contents General Description of the Series Six GEK 25361A Central Processing Unit ak Lithium Manganese Dioxide Battery 2 Battery Status Light Figure 17 LOGIC MEMORY 8K Memory Protection A two 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 memory and programs can be entered or changed In the MEMORY PROTECT position memory cannot be written into thereby protecting any user program that has been previously entered Once a program has been entered it is advisable to switch the key to the MEMORY PROTECT position Ref 81 PC 23 1 31 General Description of the Series Six GEK 25361A Central Processing Unit Visual
246. tch Pad Display set the Register Memory size then from the Supervisor Display perform the Clear Scratch Pad and Transition Parity Error function ARITHMETIC CONTROL MODULE LOGIC CONTROL MODULE BASIC OR EXTENDED Neither of these modules have any devices needing on site programming The Logic Control module should be installed in the third slot to the left of the CPU power supply NOTE Control adjustment and jumper placement on the Logic Control circuit board have been done at the factory and should not be changed by the user The Arithmetic Control module should be installed in the slot 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 See Figure 12 Ensure that this cable is in place and that the connectors are well seated Attempting to operate the system without the ribbon cable connected be tween these two modules will cause the CPU to operate unpredictably 2 16 Installation GEK 25361A Rack and CPU Module Installation Logic REGISTER MEMORY MEMORY pies MEMORY PROTECT lc _ BATERY PP DPU BATTERY A z CHAIN PARI Y p Parity ENABLED 1 Ribbon Cable Connector Between Logic 2 Logic Control Module Control and Arithmetic Control Modules 3 Arithmetic Control Module Figure 12 LOGIC CONTROL TO ARITHMETIC CONTROL CONNECT
247. ted by setting the seven segment DIP switch on the backplane adjacent to the selected slot An Isolated AC Output module will respond to the first six output points the selected group Refer to Figure 28 or the Installation chapter in this manual for instructions on setting the DIP switches Instructions for connecting field wiring to the terminals on this module are also found in Chapter 2 Installation Ref 82 PC 18 1 77 General Description of the Series Six GEK 25361A Input Output System DC Output Modules The discrete 8 point DC Output module is available in three voltage ranges The module for each voltage range is available in either a sink or a source version Each module has eight outputs arranged in two groups of four outputs Each group shares a common power source and has a high positive and a neu tral negative terminal Table 19 lists the specifications for the DC Output modules User Supplied Response ON State output Leakage Inrush Voltage Time Voltage Current OFF Current Drop ON 12VDC 9 20V DC 1 ms 1 75v 5mA 7A Sink maximum maximum 60 C maximum Source maximum 24V DC 19 40V DC 1 ms 1 75v 5mA 7A Sink maximum maximum 60 C maximum Source maximum 48V DC 38 55V DC 1 ms 1 75v 5mA 7A Sink maximum maximum 600C maximum Source maximum Power Requirements 5V DC 400 mA maximum Supplied by I O power supply Fuse Rating 3A Table 19 SPECIFICATIONS DC OUTPUT MODULES Each of the eight outpu
248. tery connector disconnected from the battery When connecting a battery the following procedure is recommended Refer to Figure 9 which is a memory board showing a mounted connected battery and a board cover 2 10 Ref 70 101 Installation GEK 25361A Rack and CPU Module Installation 1 Lithium Battery 4 Board Cover Mounting Clips 2 Battery Connectors 5 Board Cover Mounting Clips 3 Top Board Cover Figure 9 MEMORY BOARD BATTERY CONNECTION Remove the top board cover from the component side of the module by pinching in the fangs of the clips holding the cover on while pulling up on the cover f battery is not mounted firmly place it in its mounting clips with the cable end facing toward the battery connectors Connect the battery cable to one of the battery connectors Replace the protective board cover by pressing it down firmly onto the seven plastic clips The memory module is now ready for installation into the CPU rack Ref 81 PC 20 Installation GEK 25361A Rack and CPU Module Installation Relatively small amounts of excess charge can cause very intense elec trostatic fields metal oxide semiconductor MOS devices damaging their gate structure When the board covers are removed 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 devices in this module Wit
249. the power supply The programmable control is connected in ternally to this point All racks located within a CPU station a Local I O station or a Remote station must have a common ground between racks Stations do not need to have a common ground run between them since they are isolated from one another by circuitry on the transmitter and receiver modules 2 23 Installation GEK 25361A The I O Rack SECTION2 THE 1 0 RACK SYSTEM CONFIGURATION VO 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 lO Communication modules should be available for installation in racks The types of I O Communica tion modules are determined by the number of 1 0 points required and the location of the racks in system Refer to Section 4 of Chapter 1 for a discussion of the 3 types of stations possible in 1 0 system CPU Local and Remote The type of 1 0 station will determine whether your I O racks will con tain 0 Receivers I O Transmitters Remote 1 0 Drivers Remote l0 Receivers or combinations of these modules Figure 14 is an example of a typical I O rack To prevent accidental mating of an 1 O module with a faceplate containing voltages not compatible with that module all of the I O printed
250. transferred back to the CPU Do the PDT to CPU transfer in the off line mode the CPU will not go into the Run mode because the parity error is still present call up the Supervisor display on the PDT for access to its menu Move the cursor down to CLEAR SCRATCH PAD AND TRANSITION PARITY ERROR depress the ENTER key then SHIFT and ENTER simultaneously Try to restart the CPU If the parity error still exists use the Scratch Pad CPU Flags to determine if the error was Register or Table parity If a Register parity error replace the Register Memory module If a Table parity error replace the Internal Memory module if that error still exists replace the Register Memory module BATTERY Light All Memory Modules Battery condition is normal 2 75 to 3 0V DC FLASHING Battery low 2 54 to 2 75V DC CPU continues running will restart if stopped Alarm No 2 switches To ensure protection of memory contents replace the battery before it fails Battery failed below 2 54V DC CPU continues running but will not restart if stopped Alarm No 2 remains switched Memory contents will be lost when power is turned off or lost Replacement Information 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 650C It is recommended that the battery be replaced every 4 years a running CPU battery fails repl
251. ts are internal to the power supply Figure 7 CPU POWER SUPPLY TERMINAL BOARD Ref 70 5 3 31 Troubleshooting and Repair GEK 25361A Central Processing Unit Troubleshooting Alarm relay outputs are rated at 115V AC or 28V DC 1 amp resistive load Alarm No 1 is switched by hard failures the CPU status is set to STOP The RUN and ENABLE lights go off Alarm No 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 See through 2 for troubleshooting alarm conditions Alarm No 1 Alarm No 2 CPU or I O parity error Voltage of any memory battery drops too low CPU self test failure CPU watchdog timer timed out CPU or I O power supply turned Off Any memory backup battery dead when power turned on Any CPU or I O power supply voltage out of tolerance Communications Control or Data Processor error fault jumpers in or out of circuit CPU or I O power supply turned off Communications Control or Data Processor error fault jumpers in circuit User devices connected to each set of alarm terminals should present a resistive load drawing no more than 1 amp of current at 115V AC or 28V DC Failure to observe this CAUTION may result in damage to the CPAX1 circuit board in the power supply Troubleshooting and Repair GEK 25361A Central Processing Unit Troubleshooting CPU RENEWAL PARTS LIST A list of the rep
252. ts on a module are capable of either sinking or sourcing up to two amperes All output stages have overvoltage protection and are fused Two LED indicators associated with each output are provided The top LED is an indication of the state ON OFF of the output and the second LED functions as a blown fuse indicator Each output I 8 has both LEDs which are viewed through the module faceplate lens Figure 40 is a DC Output module showing features common to each of the modules 1 78 General Description of the Series Six GEK 25361A Input Output System te 017807 1 Terminal Cover 5 BF Blown Fuse Lights 1 8 2 User Terminal Block 6 Output Circuit Fuses 3A Normal Blow 3 Circuit Board Terminal Block AGC 3 4 Output ON Lights l 8 Figure 40 DC OUTPUT MODULE TYPICAL The module contains comparator circuitry to determine when the module is being addressed and an on board register for storing data before presenting that data to the output stages Each of the eight output drivers uses a Darlington transistor as a switching device Ref 81 PC 70 1 79 General Description of the Series Six GEK 25361A Input Output System Two types of output amplifiers are used on the DC Output modules a sink version and a source version With the source module when an output is in the ON state the Output terminal is pulled up towards the voltage of the positive side of the user power source With the sink module an
253. uration 1 91 System Communication Modules 1 91 Receiver iai 1 91 Chain Signal Continuation or Termination 1 93 CONNECTIONS Rr 1 94 Indicators 1 94 VO Transmitter iiti tbi ete 1 95 Status 1 96 CONNECTION 1 96 Remote I O System 1 96 System Connection 1 96 System 1 98 Remote I O Addressing 1 98 Cable Wiring 100 Printed Circuit Board Jumpers l 102 wil Table of Contents Section 4 Input Output System Continued Remote I O Driver eese Addressing iic eec Status Indicators Option Jumpers Remote GOnFectOIS o tat D ERR AER Status Indicators Option Jumpers CPU I O Station Local I O Station Remote l O Station Section 5 Pro
254. using a two twisted pair cable for communica tions up to 10 000 feet 3Km FACTORY ALTERNATE FUNCTION SETTING SETTING Communications Failure 4 5 Turn all 5 6 Hold All JUMPER Effect on Remote I O Outputs OFF Outputs at Last State Even or Odd Parity 7 8 Odd 8 9 Even Specify Parity Check Yes No Baud Rate 57 6Kb Sensitivity Medium 52 54 Minimum Carrier Detect 57 0 56 57 Yes Clear To Send 60 0V No 59 60 Yes Output Mode Twisted Pair 62 63 RS 232 66 67 Input Mode Twisted Pair 50 61 RS 232 103 104 Terminate I O 88 89 Additional 87 89 Last Chain Signals If Last 91 92 Racks in 90 91 Rack Rack in Remote Station 94 95 Remote Sta 93 94 tion Alternate setting for the baud rate is selectable baud rate for RS 232 operation Table 10 lists the selectable baud rates and their jumper settings Table 9 REMOTE I O RECEIVER JUMPERS 2 36 Installation GEK 25361A The I O Rack Table 10 SELECTABLE BAUD RATE JUMPERS RS 232 OPTION NOTE If the RS 232 option is selected the Remote I O Receiver module must be installed in a High Capacity I O rack In addition to the above jumpers there are a number of other jumpers on the board which are for future expansion or production testing These jumpers are not to be changed They are listed for reference only If this module should need to be returned to the factory for
255. ut Module is in the Non Inverting mode Module operating normally A D converter malfunction I O rack power supply problem CPU in Stop or Run Disabled Module operating normally Board malfunction I O rack power supply problem CPU in Stop or Run Disabled mode Isolated 1 through 6 Output is energized 115VAC output BF 1 6 Blown fuse in output circuit Fuse good Table 5 INDICATOR CHART 3 37 Troubleshooting and Repair GEK 25361A System Troubleshooting MODULE INDICATOR STATUS DEFINITION LEE eu ca UMS Reed Relay 1 through 6 ON Relay coil is energized output OFF Relay coil is de energized Interrupt 1 through 8 ON Current flowing through input circuit Input Thermocouple BOARD ON Module operating normally Input OK OFF Board malfunction ON Power is OK in this and all downstream racks and stations Continuity is OK to all downstream stations Vo Output parity is OK at all downstream stations Receiver connected through an I O Transmitter in this rack Output parity good at this module Power is OK at all downstream stations Conti nuity OK to all downstream stations All downstream stations have good output Transmitter PARITY parity ISOLATED Output voltage of the 5V DC isolated power POWER converter is within tolerance Table 5 INDICATOR CHART Continued 3 38 Troubleshooting and Repair GEK 25361A System Troubleshooting MODULE INDICATOR STATUS DEFINITIO
256. witch on the backplane adjacent to the selected slot The I O point selected is the first of six consecutive I O points for that module Figure 23 can be used as a guide for setting the DIP switches however for each DIP switch setting this module will respond to only the first six I O points Installation GEK 25361A I O Module Wiring Terminals for connecting loads to be controlled by this module are arranged in six groups Each group has an output number 01 through 06 and a corresponding High terminal HI through H6 Figure 38 is an Isolated AC Output module showing the terminal arrangement and other module features 1 Output ON Lights LED1 LED6 4 Fuse 5A 6 2 Blown Fuse Lights BF6 5 Circuit Board Terminal Block 3 European Style Fuse Clip 6 Figure 38 ISOLATED AC OUTPUT MODULE 2 66 Ref 82 PC 18 Installation GEK 25361A Module Wiring Install the circuit board using the extraction insertion tool With the circuit board in place in the rack slip the faceplate over the board ensuring that the terminals near the bottom of each part are properly mated Secure the faceplate to the rack by pushing in on the quarter turn thumbscrews while turning them clockwise Refer to Figure 39 for typical user connections to this module Wiring instructions follow the figure Each box lug terminal can accommodate one No 12 AWG wire or two No 14 AWG wires OUTPUT MODULE S Output Switching Device L U
257. x 801 832 XIX x 129 160 x 481 312 Ix xixix 833 864 xt 161 192 xf x 513 544 x 865 896 E REI I aah e hh X 225 256 RE 577 608 E EE 929 960 257 288 609 640 ETAREN ix 961 992 x x x x 289 320 641 672 321 352 673 704 Switch in OPEN Position Depressed to the Left Switches 1 and 2 Should be in CLOSED Position Figure 34 DIP SWITCH SETTINGS FOR ANALOG INPUT MODULES Four consecutive I O addresses are required to read all 32 bits of information associated with each channel a single channel is normally read during each sweep Usually all eight channels are read in se quence during consecutive sweeps the first channel read terminals INT CR1 VR1 has channel number the eighth channel read terminals INB CR8 VR8 has channel number 7 The sequence then begins again The channel number is incremented by the module each time a channel is read The data read corresponds to the input voltage or current detected on the present channel immediately after the previous channel was read The A D conversion time is approximately 25 microseconds Using the CPU Extended Functions the user can choose to read repeatedly the same channel at a much faster rate than the normal I O scan rate Ref 70 150 1 63 General Description of the Series Six GEK 25361A Input Output System The 32 bits correspondi
258. x rack Power Supply Logic Control Arithmetic Control and the optional Communications Control modules are identical to those used in the Models 6000 and 600 x poured seta eae ln imei ye g AKIR Ld ig omeo Loo COMMAS ee 2 1 Me 1 W O Modules 192 I O Points Maximum 6 Modules 3 Tray for Field Wiring 2 Combined Memories Internal Register Logic Figure 20 MODEL 60 CPU Ref 81 44 General Description of the Series Six GEK 25361A Central Processing Unit The Memory module Figure 21 combines the functions of the Logic Memory Register Memory and In ternal Memory modules used in Models 6000 and 600 The user memory available in the Model 60 is either 2K or 4K of 16 bit words Maximum register Memory capacity is either 256 or 1024 sixteen bit words The Register Memory is standard in the Model 60 NOTE The Memory module used in the Model 60 is not compatible with the Logic Memory modules used in the Models 6000 and 600 ER oo Daughter Board 3 Lithium Manganese Dioxide battery 2 Mother Board 4 Battery Status Light Figure 21 COMBINED MEMORY MODULE FOR MODEL 60 CPU 1 38 Ref 8 1 PC 8 General Description of the Series Six GEK 25361A Central Processing Unit By combining the 3 memories into one module and with no Auxiliary I O module offered the Model 60 has 6 slots available for I O modules within the
259. xt 1 0 Rack IOR Module NOTE 10 Racks maximum on Daisy Chain Last rack may be no more than 5Oft from the CPU in a CPU Station Figure 62 CPU TO I O RACK CONFIGURATION Ref 70 11 1 127 General Description of the Series Six GEK 25361A System Configuration lO RACK TO O RACK CONFIGURATION If I O racks are to be daisy chained on the parallel communications channel a maximum of 10 racks can be on a daisy chain Interconnect each rack from the I O Receiver one rack to the I O Receiver in the next rack downstream A maximum total cable length of 50 feet 15 meters can interconnect I O racks on the daisy chain See Figure 63 The last I O Receiver module in a daisy chain must have the I O chain signals terminated at that module Refer to the Installation Chapter in this manual for instruction on terminating the I O chain signals The I O chain of 10 racks can be part of a CPU station or a Local station If another Local station is required an I O Transmitter module must be located in any I O slot any of the I O racks This allows connection to an I O Receiver module in an I O rack no more than 500 feet 150 meters away If a Remote station is required a Remote I O Driver module must be installed and connection made by a cable of no more than 10 000 feet 3 Km two pair twisted shielded to an I O rack containing a Remote I O Receiver module Remote I O stations at distances greater than 10 000 feet 3 Km
260. y model in the Series Six family that ac commodates both the CPU and I O modules the same rack A maximum of 6 I O modules 192 I O points maximum can be self contained in the Model 60 Modules according to type are available that will allow 4 6 8 or 32 Inputs or Outputs The I O rack is the same universal rack as the one used with the Series Six CPU s and is described in Section 1 of this chapter VO RACK All I O modules are housed an I O rack See Figure 26 An I O rack uses the same mechanical packag ing as a CPU or DPU and can be mounted in a standard 19 inch 483 mm rack or panel Each rack con tains a power supply either standard or high capacity depending on the I O load to be contained in the rack In addition to the power supply each rack has slots for eleven I O modules 1 47 General Description of the Series Six Input Output System G 1 7 Position DIP Switch 10 Per Rack 2 41 Pin Connector 1 1 Per Rack 3 Logic Power On Off Circuit Breaker 4 Power On Indicator 5 Power Supply 1 48 Figure 26 RACK GEK 25361A ef 4 1 6 Terminal Board 1 15V 23OV AC Input Selected By Jumper Tray For Containing Field Wiring Cardguide 1 1 Per Rack Ref 81 PC 51 General Description of the Series Six GEK 25361A Input Output System POINT ADDRESSING Each 1 0 slot except the left most slot has a seven segment DIP switch physically locat

Series Six Installation and Maintenance Manual, GEK

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