ge fanuc · pdf filethe series 90–70 plc is a member of the series 90 tm family of...

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GE Fanuc Automation

P.O. Box 8106Charlottesville, VA 22906

GFZ–0086

Î

GE Fanuc Automation

Programmable Control Products

Series 90TM–70Programmable Controller

Troubleshooting Guide

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Î

GE Fanuc Automation

Programmable Control Products

Series 90TM–70Programmable ControllerTroubleshooting Guide

GFZ–0086 November1993

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This document is based on information available at the time of its publication. While effortshave been made to be accurate, the information contained in this document does not purportto cover all details or variations in hardware and software, nor to provide for every contingen-cy in connection with installation, operation and maintenance. This document may describefeatures not present in all hardware and software systems. GE Fanuc Automation assumes noobligation of notice to holders of this document with respect to changes subsequently made.

GE Fanuc Automation makes no representation or warranty, expressed, implied, or statutorywith respect to, and assumes no responsibility for the accuracy, completeness or usefulness ofthe information contained in this document. No warranties of merchantability of fitness forpurpose shall apply.

The following are trademarks of GE Fanuc Automation North America, Inc.

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Alarm Master ÁÁÁÁÁÁÁÁ

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CIMSTAR ÁÁÁÁÁ

ÁÁÁÁÁHelpmate

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Series Six ÁÁÁÁÁ

ÁÁÁÁÁCIMPLICITY

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Series 90 ÁÁÁÁÁÁÁÁ

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CIMPLICITY 90–ADS ÁÁÁÁÁ

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Genius

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Modelmaster ÁÁÁÁÁÁÁÁ

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Series Three ÁÁÁÁÁ

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VuMaster

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Workmaster ÁÁÁÁÁÁÁÁ

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Copyright 1993 GE Fanuc Automation North America, Inc.

All Rights Reserved.

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Stand clear of controlled equipment when power is applied. If the problem is intermittent,sudden unexpected machine motion could occur, causing injury. Also reference NFPA 70EPart II for additional guidelines for safety practices.

Never reach into a machine to operate a switch since unexpected motion could occur, causinginjury.

Remove all electrical power at the Main Power Disconnect to ensure total power removal.

Always remove power before inserting or removing modules, or before connecting I/O cab-ling.

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This guide describes a logical sequence for troubleshooting your Series 90–70 program-mable controller. The Series 90–70 PLC is a member of the Series 90TM family of program-mable logic controllers from GE Fanuc Automation.

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This is the first release of this Troubleshooting Guide. Included are models CPU models 731,732, 771, 772, 781, 782, and CPM914. CPU models 788 and 789 are also included; however,troubleshooting these models may require techniques beyond the scope of this Troubleshoot-ing Guide.

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Series 90TM–70 Programmable Controller Installation Manual (GFK–0262).

LogicmasterTM 90–70 Programming Software User’s Manual (GFK–0263)

Series 90TM–70 Programmable Controllers ReferenceManual (GFK–0265)

Series 90TM–70 Programmable Controller Data Sheets (GFK–0600)

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At GE Fanuc Automation, we strive to produce quality technical documentation. After youhave used this troubleshooting guide, please take a few moments to write us with your com-ments and suggestions. Our address is: Manager Technical Publications, GE Fanuc Automa-tion. PO Box 8106, Charlottesville, VA 22906

Drake C. Fink

Sr. Staff Systems Engineer

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Although your PLC CPU may be running in RUN/IO ENABLED mode, and you may havecommunications between the PLC and Logicmaster 90, the system may not be operating cor-rectly. The following pages suggest some areas to investigate:

Grounding:� Verify all power supply mounting screws are tightened.� Verify the green grounding wire provided with the power supply is securely

attached to the rack grounding stud.� Verify all racks are grounded to a common ground. Reference the System

Grounding Procedures in the Series 90–70 Programmable ControllerInstallation Manual (GFK–0262) for additional information.

Loss of Rack Fault:� Verify all inter–rack cables are securely connected on both ends. Verify cables

connect to all racks.� Verify the bottom connector on the last Bus Receiver Module has a terminator

plug. (No terminator is needed on a Bus Transmitter Module when there are noexpansion racks.)

� Verify all power supplies are powered on (Green LEDs on). Follow the sametroubleshooting procedures for expansion racks power supplies as you use for themain rack.

� Verify each expansion rack has a unique address. ONLY the rack containing theCPU is address zero. All other racks are in the range 1 to 7. NO rack is in therange 8 to 15.

� If all the above are true and you still have LOSS OF RACK, then:� Power off all racks. Remove expansion rack cable from bottom connector on the

Bus Transmitter Module (BTM) in the main rack. Power on the main rack. Youshould see LOSS OF RACK faults for all expansion racks in the PLC Fault Table.Place the PLC in RUN mode. (If you have configured the LOSS OF RACK faultto be FATAL, you will have to clear the PLC Fault Table before you can placethe PLC in RUN mode.)

� Power off all racks. Connect expansion cable to next rack, so previous rack isstill in the chain. Connect terminator plug to bottom connector on BRM. Poweron all expansion racks. Power on main rack. LOSS OF RACK faults for allnon–connected expansion racks should appear in the PLC CPU Fault Table.Place PLC in RUN mode. Replace BRM and cable if LOSS OF RACK faultpersists.

� Continue debugging the expansion rack chain one rack at a time until all rackshave been added to the chain and no LOSS OF RACK faults occur.

Other Faults:� Position the cursor on the fault. Using Release 4 Logicmaster, press the ZOOM

(F10) key. Read the fault explanation and follow the suggestions for eliminatingthe fault.

No Input:� Verify no LOSS OF MODULE fault for the module containing the input in the

I/O Fault Table. Replace the module if the LOSS OF MODULE fault is present.

� Verify no ADDITION OF MODULE fault occurs in the I/O Fault Table whenyou power cycle the PLC or store the configuration to the PLC. If so, the modulephysically resides in the slot, but is not present in the PLC configuration. Addthe module to the configuration and restore the configuration.

� Verify the %I address assigned for the input in the configuration is the same %Iaddress as used in the program.

� Verify pins in the VME bus connector are not bent or corroded.� Verify the input device functions correctly.� Verify wiring from input device through terminal strip to input module is intact.� Verify presence of power at the input device.

– 2 –

� Verify no fuses are blown.� Replace the module if other input channels on this module function.

No Output:� Verify no LOSS OF MODULE fault for the module containing the output in the

I/O Fault Table. Replace the module if the LOSS OF MODULE fault is present.� Verify no ADDITION OF MODULE fault occurs in the I/O Fault Table when

you power cycle the PLC or store the configuration to the PLC. If so, the modulephysically resides in the slot, but is not present in the PLC configuration. Addthe module to the configuration and restore the configuration.

� Verify the %Q address assigned for the output in the configuration is the same%Q address as used in the program.

� Verify pins in the VME bus connector are not bent or corroded.� Verify fuse on output module (if present) is not blown.

� Verify the output device functions correctly.� Verify wiring from output module through the terminal strip to the field device

is intact.� Verify presence of power at the output module.� Verify no fuses are blown in the path from the output module to the field device

.� Replace the module if other output channels on this module function.

Genius Devices Do Not Function:� Verify the Genius Bus Controller appears in the configuration and the

configuration in the PLC and LM90 are equal.� Verify the %I/%Q addresses assigned to the Genius device in the configuration

match those used in the ladder logic.� Follow the general debug guidelines above for No Input and No Output.� Refer to the Series 90–70 Programmable Controller Genius Bus Controller &

Genius I/O System Troubleshooting Guide for more detailed GeniusTroubleshooting.

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1. WARNING: Do not discard the lithium–manganese dioxide battery in fire. Do not at-tempt to discharge the battery. The battery may burst or burn or release hazardous mate-rials. Dispose of the battery as you would any hazardous material.

2. CAUTION: After a power fault, the system will come back on in the mode (STOP/ IOE-NABLED, STOP/IODISABLED, RUN/IOENABLED, RUN/IODISABLED) in which itwas operating before power loss, unless a fatal fault occurs during the power up process.

3. Supply (input) voltage tolerances for Series 90–70 power supplies:

IC697PWR710 & 711: 93 to 132 VAC, fornominal 115 VAC input;180 to 264 VAC, fornominal 230 VAC input;47 to 63 HZ

IC697PWR722 21.6 to 26.4 VDC for24VDC nominal input

IC697PWR732 122.5 to 137.5 VDC for125VDC nominal input

4. Total cable length must not exceed 50 feet between the CPU rack (rack 0) and the lastexpansion rack. No termination plug is needed on a Bus Transmitter Module in a one–rack system.

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START

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ARE ALL 3CPU LEDS

ON?

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ONLY TOPCPU LED ON?ÁÁÁÁÁÁÁÁÁÁ

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TOGGLE CPU SWITCH TO RUN(UP) POSN. IF SWITCH IS UP,TOGGLE IT OFF, THEN ON AGAIN

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ARE ALL 3CPU LEDS

ON?

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1(PAGE 2)

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ÁÁÁÁÁÁIS POWER

SUPPLY LEDON?

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PAGE 1

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DIAG70AGFZ-0086

NO

YESYES

NO NO

YES

YES

NO

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YES

NO

YES

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IS TOP CPULED STEADY

ON?

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IS TOP CPULED ALWAYSBLINKING?

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1

PAGE 2 DIAG70B

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POSITION OFPWR SUP ON/OFF SWITCH?

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MOVE POWERSUPPLY SWITCH

TO ON (UP)POSITION

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IS POWERSUPPLY LED

ON?

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START(PAGE 1)

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CHANGE POWERSUPPLY JUMPERTO AGREE WITH

SUPPLY VOLTAGE.

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REPLACELINEFUSE

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APPLYPROPERVOLTAGE

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START(PAGE 1)

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IS VOLTAGEAPPLIED TOPWR SUP?

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IS SUPPLY ADUAL–VOLTAGE

SUPPLY?ÁÁ

NO

YES

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SUPPLYVOLTAGE =SETTING?

YES

NO

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NO

YES

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CORRECT FAULTYSUPPLY VOLTAGE

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1(THIS PAGE)

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IS LINE FUSEBLOWN?

NO

YES

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IS SUPPLYVOLTAGE INTOLERANCE?

NO

YES

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· REMOVE POWER· REMOVE ALL CARDS· APPLY POWER

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2

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IS POWERSUPPLY LED

ON?

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· REMOVE POWER· REPLACE POWER SUPPLY· APPLY POWER

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IS POWERSUPPLY LED

ON?

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ARE ALLMODULES

INSTALLED?

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START(PAGE 1)

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IS POWERSUPPLY LED

ON?ÁÁÁÁÁ

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PAGE 3DIAG70C

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ÁÁÁÁÁÁÁ· REMOVE POWER· INSTALL NEXT CARD· APPLY POWER

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· REMOVE POWER· REPLACE FAULTY MODULE· APPLY POWER

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YESNO

YES

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IS POWERSUPPLY LED

ON?

YES

NO

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· REMOVE POWER· REPLACE POWER SUPPLY

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3

YES

NO

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START(PAGE 1)

PAGE 4 DIAG70D

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· REMOVE POWER· REMOVE ALL MODULES· VERIFY PINS ON MODULES ARE NOT CORRODED OR BENT· REPLACE MODULES AS NECESSARY· REPLACE RACK· VERIFY RACK AND POWER SUPPLY GROUNDING· REINSTALL POWER SUPPLY

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POWER SUPPLYREPLACED

ONCE?

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· REINSTALL MODULES· APPLY POWER

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IS CPU INSTOP/FAULT

MODE?

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IS FAULTSYSTEMCONFIG

MISMATCH?

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IS CPU INSTOP/HALT

MODE?

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5(PAGE 6)

PAGE 5

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ÁÁÁÁÁÁÁDETERMINE &CORRECT CAUSEOF FATAL FAULT

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USE LM90 TOCLEAR PLC & I/OFAULT TABLES

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PLACE PLC IN RUNMODE

Á

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ARE ALL 3CPU LEDS

ON?

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START(PAGE 1)

NO

YES

NO

YES

NO

YES

YES

NO

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CAN CPUCOMMUNICATE

WITH LM90?

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4

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10(PAGE 11)

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YES

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DIAG70E

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13(PAGE 13)

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5

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START(PAGE 1)

PAGE 6 DIAG70F

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THE RACK AND SLOT OF THEMISMATCHED MODULE AREGIVEN IN THE PLC FAULT TABLEAS A DECIMAL NUMBER (E.G., 0.1,1.3, ETC.) AT THE FAR LEFT SIDEOF THE TABLE.

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· SELECT LM90 CONFIG· SELECT I/O CONFIG

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CHANGE LM90 CONFIG ORHARDWARE SO BOTH ARETHE SAME.






· EXIT I/O CONFIG· SELECT & CLEAR PLC FAULT TABLE· SELECT & CLEAR I/O FAULT TABLE· SELECT UTILITIES· STORE CONFIGURATION TO PLC

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STILLCONFIG

MISMATCH?

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PLACE PLC IN RUN MODE

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13(PAGE 13)

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ARE ALL 3CPU LEDS

ON?

YES

NO

NO

YES

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IS CONFIG’DTYPE SAME AS

THE HARDWARE?

NO

YES

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DIAG70G

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6

PAGE 7

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ÁÁÁÁÁÁÁONLY TOP,

CENTER CPULEDS ON?

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ONLY TOP,BOTTOM, CPU

LEDS ON?

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DEFECTIVE CPU.CALL YOURDISTRIBUTOR FORREPLACEMENT CPU.

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RUN I/O DISABLED.TOGGLE CPU SWITCHOFF, THEN ON.(UP POSITION)

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STOP I/O ENABLED.TOGGLE CPU SWITCHOFF, THEN ON.(UP POSITION)

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13(PAGE 13)

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· REMOVE POWER· REPLACE CPU· APPLY POWER

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START(PAGE 1)

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ARE ALL 3CPU LEDS

ON?

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YES

NO

YES

NO

YES

NO

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START(PAGE 1)

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DIAG70HPAGE 8

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4(PAGE 5)

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7

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ÁÁÁÁÁÁÁÁTOP CPU LED

FAST OR SLOWBLINK?

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NO

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POWER CYCLEPLC

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TOP CPU LEDSTILL

BIINKING?

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ÁÁÁÁÁÁÁÁ

ANY BLANKSLOTS

BETWEEN CPU& SMART

CARDS?

NO

YES

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· REMOVE POWER· VERIFY MODULE PINS NOT BENT OR BROKEN· RESET ALL MODULES IN BACK PLANE· APPLY POWER

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· REMOVE POWER· ELIMINATE EMPTY SLOT· APPLY POWER

YES YES

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TOP CPU LEDBLINKING?

NO

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Á ÁÁ

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Á

FAST

SLOW

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· REMOVE POWER· REMOVE MODULES ONE BY ONE ANDINSPECT MODULE FOR BENT PINS & CORROSION

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START(PAGE 1)

DIAG70JPAGE 9

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8

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ÁÁÁÁÁÁÁPOWER CYCLE

PLC

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9(PAGE 10)

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START(PAGE 1)

NO

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TOP CPU LEDSTEADY ON?

YES

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REPLACE MODULEYES

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PROBLEMSFOUND WITH

MODULE?

NO

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· SEAT ALL MODULES FIRMLY IN RACK· APPLY POWER

YES

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NO

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START(PAGE 1)

DIAG70KPAGE 10

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9

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· REMOVE POWER· TRY ORIGINAL CPU IN ANOTHER SYSTEM

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START(PAGE 1)

NO

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YES

YES

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CPUFUNCTION IN

OTHERSYSTEM?

NO ÁÁÁÁÁÁÁÁ

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· REMOVE POWER· REPLACE POWER SUPPLY AND BACKPLANE· APPLY POWER

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ÁÁÁÁ

ÁÁÁÁSTART

(PAGE 1)

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4(PAGE 5)

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10

NO

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ÁÁÁÁÁÁÁÁ

RACK GROUNDEQUAL

PROGRAMMERGROUND?

YES

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ENSURE RACK &PROGRAMMER

GROUND ARE THESAME.

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POWR CYCLE PLC& PC*Á

DIAG70LPAGE 11

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CAN CPUCOMMUNICATE

WITH LM90?

YES

NO

ÁÁ

ÁÁ








· VERIFY PLC COMMUNICATIONS OPTION SELECTED IN LM90 SETUP (F9) MATCHES PACKAGE TYPE (WSI, STANDARD SERIAL, ETHERNET)· VERIFY PC COMMUNICATES WITH ANOTHER CPU

*PC REFERS TO THEPERSONAL COMPUTERWHICH RUNS THE LM90SOFTWARE.

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11(PAGE 12)

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DIAG70MPAGE 12

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12(PAGE 13)

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11

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WHICHCOMM TYPE?


















· CHECK SERIAL PORT SETTINGS IN CPU AND LM90.

· VERIFY LM90 GENERATES NO ERRORS WHEN STARTING THE LM90 PROGRAMMER PACKAGE.

· CHECK CABLE CONNECTIONS FROM COMMUNICATIONS PORT ON PC TO CONVERTER TO PLC.

· VERIFY CONVERTER AND CABLES WORK WITH ANOTHER PLC.

· IF MULTIDROP, VERIFY CPU ID IS SELECTED. (F7, F4).

· REMOVE ANY MOUSE DRIVER OR CONFLICTING TERMINATE– AND–STAY RESIDENT ROUTINE FROM YOUR PC.















· VERIFY SNP/PARALLEL CHOICE IN PROG MODE & SETUP MENU (F7 ON PROGRAMMER MENU).

· CHECK SERIAL PORT SETTINGS IN CPU AND LM90 IF USING SERIAL.

· CHECK CABLE CONNECTION AT WSI AND AT BTM (PARALLEL) OR CPU (DIRECT/MULTIDROP).

· IF MULTIDROP, VERIFY CPU IS SELECTED (F7, F4).

· VERIFY NO OTHER DEVICE IN THE PC USES THE SAME ADDRESS AS THE WSI (CE00– CFFF) OR SAME INTERRUPT. (IRQ3 ON WMII). ÁÁÁÁÁ

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13(PAGE 13)

SERIAL COMM

WSI

ETHERNET

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DIAG70NPAGE 13














· CHECK CABLE CONNECTION BETWEEN ETHERNET PORT ON PC AND ETHERNET ADAPTER.

· VERIFY ETHERNET CABLE IS SOLIDLY CONNECTED TO ETHERNET ADAPTER.

· VERIFY PLC IS IN PLC LIST. USE NETWORK UTILITY IN LM90 UTILITIES (F7, F1 IN MAIN MENU) TO BROWSE NETWORK FOR PLCS.

· VERIFY PROPER PLC CPU IS SELECTED IN PLC CONNECTION MENU (F7, F3).

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12

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REFER TO THE FOLLOWING PAGES”ADDITIONAL TROUBLESHOOTINGTIPS FOR THE 90–70 PLC” FOR MOREINFORMATION.

IF YOU ARE STILL UNABLE TO SOLVEYOUR PLC PROBLEM, THEN CALLYOUR GE FANUC DISTRIBUTOR ORTHE GE FANUC HOTLINE FORASSISTANCE.

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IS SYSTEMOPERATING

OK?

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PROBLEMSOLVED!

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YES

NO

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Á

ge fanuc · pdf filethe series 90–70 plc is a member of the series 90 tm family of...

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