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GE Fan

Programmable Contro


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Warning, CautioAs Used In This


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Preface

This manual provides

stall and maintain th


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Warranty anInforma

General Electric backs up its Series S


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Table o

CHAPTER 1 - Gener

Section 1 IntroGeneral Over


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Table of Contents

Section 3 Pow

Mounting .....

Logic Power

AC Input ......

Key Switch .

Terminal Blo

Terminal Bloc

Outputs .......

Auxiliary Circ

Alarm Relay .


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Table of Contents

Section 4 Inp

Remote I/OAddressing

Status Ind

Option Ju

Remote l/O

Connectors

Status Ind

Option Ju

CPU I/O StaL l I/O St


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Table of Contents

CHAPTER 2 - Insta

Section 1 Rack

Quality Contro

Packaging.. ...

Visual Inspect

Pre-installation

Rack Installati

Extraction/Inse

Removing a pInserting a pri


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Table of Contents

Section 3 I/O

DC Output High Densit

Analog Out

Reed Relay

Section 4 Pr

Installation

CHAPTER 3 - Tr


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.

Table of Contents

FIGURES - Chapter1

2

3

4

5

6

7

8

910

Basic Block DSeries Six Fa

Universal Rac

Series Six F

Input/Output

Program Dev

Scan Sequen

Model 6000

Series Six CPL i C t


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Table of Contents

FIGURES - Chap43

44

45

46

47

48

49

Analog Ou

DIP Switch

Modules

Reed Rela

I/O ReceivI/O ReceivConfigurat

I/O TransConnection


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Table of Contents

FIGURES - Chapte89

10

11

12

13

14

15

Logic MemoMemory Boa

Printed-Circu

Logic Memo

Logic Contro

Ribbon Co

CPU Power

Typical I/O R

l/O Power SI/O R i


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Table of Contents

FIGURES - Chap

4 4

45

46

47

48

49

50

51

High Dens

High Dens

Connectio

Analog Out

Analog Ou

Analog Ou

Reed Relay

Typical Re

Reed Relay


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Table of Contents

TABLES - Chapter

6

7

8

Series Six F

Physical Ele

I/O Modules

Communicat

Power Suppl

Characteris

Alarm Cond

I/O Module C

Specification


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Table of Contents

TABLES - Chapte

4

5

6

7

8

9

IO

Selectable B

(lC600CB5Option Jump

DIP Switch

Remote I/O

Selectable B

Option ....

Remote I/O

Selectable B


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General Description of the Series SixIntroduction

IN

This manual contains a general description of the S


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Programs are entered, edited, and monitored with the

is evaluated, logic decisions are made based on the s

by the Central Processing Unit (CPU). The Input/Outp

levels for processing by the CPU and convert CPU si

user devices. The I/O modules also provide isolation f

typical factory environment.

The basic programming language used by the Series Si

include (as an option) a powerful Extended Instruction

plications more complex than those requiring only re


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MODELS

Model 6000 is the top of the line and has the greatest c

tions available. This is followed in order of capacity by

are upward compatible which means that any Model

and any Model 600 program can run on the Model 600

OPTIONAL DEVICES

Optional devices are available for use with all 3 ModelsD P U i d P bl l d


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Features

Program Memory Type

Maximum Program Memory Size

(16 Bit W d )

Model 60

C MO S -R A

wi t h B a t t

Backup

32K


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PHYSICAL DESCRIPTION

Table 2 lists the general physical and electrical characteris

Physical and Electrical Cha

Operating Temperature:0-60C (32-l40


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I-- 2 . 6 7 i n .67.8 mm


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INPUT MODULES

8-Circuit Modules

12V AC/DC

24-48V AC/DC

115V AC/DC

230V AC/DC


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An I/O rack can be located up to 2000 feet (with no mwhen using I/O communications originating at a parallel

tion channel an l/O rack can be located up to 10,000 feet

when using an RS-232 modem link).

A more detailed explanation of the I/O structure is prov

I/O Rack

Th I/O k i h h CPU k i h i l i


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The Series Six uses the familiar ladder diagram appr

used functions such as open and closed contacts, rela

Additional instruction capability is provided in mnemon

The users ladder diagram program is stored in the logi

may reference the status table, or register memory.

Th bl i d f h i d


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General Description of the Series Six

Introduction


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General Description of the Series SixCentral Processing Unit

Hardwathe Central

Thi ti t i h d d i ti f th C


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RUN

STOPI

HOUSEKEEP ING

P D T

WINDOW


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MODEL 6000 CPU

The Model 6000 is the most powerful CPU in the S

many as 32,768 (32K) sixteen-bit words can be stor

photograph of the Model 6000 CPU is shown in Figure

sociated hardware.


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Options for Model 6000 CPU

The optional Auxiliary I/O module which interfaces th

allows an additional 1000 inputs and 1000 outputs. Ano

Data Processor. The Data Processor is a microprocess

which are too time consuming or require too much memo

CPU POWER SUPPLY

Th S i Si CPU l i lf t i d


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Central Processing Unit


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LOGIC CONTROL

The Logic Control module contains circuitry for generat

other CPU modules. The circuitry includes an Am29

words by eighty-eight bit PROMS for microprogram sto

module showing the faceplate and the Logic Contro

module are available, the difference being the pro

IC600CB501A) is programmed for the Basic Functions

grammed for the Extended Functions. A connector on t

f i h A i h i C l M d l Th ibb b


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General Description of the SeriesCentral Processing Unit

Six

ARITHMETIC CONTROL

The Arithmetic Control (See Figure 11) module contains

operations on data and address lines. The time base for

a 3.2 MHz clock on this module.

The Series Six CPU has 4 hardware registers located

and buffer registers are each one bit wide. The accum

The registers are operated on internally by the CPU and a


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l/O CONTROL

The I/O Control module interfaces the CPUs bus to th

and 1000 outputs.

Logic on the module which performs the interfacing i

latches, a status multiplexer, and control and timing circ

This module also provides interrupt circuitry and contro


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MEMORY

The type of memory as well as the internal memory, reg

scribed below. Also described are memory protection, v

ing and memory allocations.

CMOS

CMOS-RAM is an integrated circuit memory that is des


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In addition the Scratch Pad memory is stored in the Inte

miscellaneous data pertaining to CPU operation.

SCRATCH PAD

ITEM

CPU ID Number assigned to the CPU if t


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REGISTER MEMORY

The Register Memory module is comprised of a Mothe

tion and checking functions and a Daughter board t

locations) in CMOS-RAM with Lithium battery back-up.

certain mnemonic functions. The lower 128 words of t

tion for the Auxiliary I/O status table. Data bus transfer lo

The Register Memory module has 2 LED indicators whic


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Relatively small amounts of excess ch

trostatic fields in metal-oxide-semicon

their gate structure. When the board c

the circuit board under conditions

electricity. Failure to observe this CAU

tion of the CMOS-RAM devices in this

With the board covers in place, it is u


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Visual Status of Backup Battery

There is one LED indicator viewed through the facepl

tor BATTERY is a visual status of the Lithium backup

described below.

STATUS


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There are 3 LED indicators which are viewed through the

functions are as shown below.

INDlCATOR

CHAIN

OK

On when all I/O stations in the

and have received good outp


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COMMUNICATIONS CONTROL

The Communications Control module, which is an op

serial interface to the CPU. A Portable Tape Unit and a

the CPU through the Communications Control modu

device such as a computer to communicate with a Serie

Two connectors are provided for connection to the mo

of the module. The upper connector is a 25-pin D-type

an RS-232 RS-422 or 20mA current loop interface T


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MODEL 600 CPU

The Model 600 CPU is functionally identical to the Mod

capacity is not as great. An important feature is that a Da

rack.

Logic Memory is allocated one slot to contain one Logic M

program capacity in 16-bit words to be 2K, 4K, or 8K of

switches on the Internal Memory module must be program


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Figure 19 is the Model 600 CPU which shows the mod


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MODEL 60 CPU

For applications not requiring a large quantity of I/O

system which combines the CPU and up to 6 l/O mod

Power Supply, Logic Control, Arithmetic Control and

identical to those used in the Models 6000 and 600.


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The Memory module (Figure 21) combines the functions of

ternal Memory modules used in Models 6000 and 600. Teither 2K or 4K of 16-bit words. Maximum register Mem

words. The Register Memory is standard in the Model 60.

NOTE

The Memory module used in the Model

Logic Memory modules used in the Model


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By combining the 3 memories into one module, and wi

has 6 slots available for I/O modules within the CPU r

I/O points the Model 60 is a complete system within on

The I/O Control module connects the Model 60 CPU to

and 256 outputs (2K Model) or 1000 inputs and 1000

can be located in the CPU rack will allow 192 inputs o

puts up to a total of 192. The I/O modules selected m

for details). If more than 6 I/O modules or 192 l/O po

tional I/O racks must be used.

The optional Communications Control module is offere



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General Description of the Series SixPower Supply

PO

The power supply used in the Series Six family of prog

switching, regulated supply with its electronic circuitry

The power supply assembly is attached to a faceplate


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Power Supply


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AC INPUT

Two sources of AC input voltage may be used, either

supply circuitry is provided by connection to screw dow

front panel. Only dual voltage models are jumper selecta

KEY SWITCH

The CPU power supply has two key switches mounted o


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Contacts are also provided for connecting an auxiliary

memory back-up.

If a memory auxiliary battery is used

Power Supply module should be isolated


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Power Supply

ALARM RELAY

The alarm relay logic is located on the CPAXl boar

outputs to switch. The alarm relay outputs are rated

Alarm no. 1 causes the CPU status to be set to st

recorded, but the CPU status in most cases does not

cause the alarm relay outputs to switch.

1 ALARM NO. 1 (MAJOR)


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Input/Output System

IN


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Input/Output System


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Input/Output System

I/O POINT ADDRESSING

Each I/O slot (except the left-most slot) has a seven seg

plane adjacent to each slot (See Figure 27). These sw

each Input or Output module placed in that slot. An Inp

ten addressable slots. Programming of these switches

switch either to the open or closed position. To set a sw

the left. Each DIP switch setting allows the selection of

32 consecutive I/O points. The number of I/O points is

is a chart indicating the DIP switch settings for 8 circu


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General Description ofInput/Output System

the Series Six

I/O RACK INTERCONNECTION

i/O racks are interconnected in a system by using co

Remote I/O Drivers or Remote I/O Receivers depending on

are grouped together in either a CPU station, a Local l/O

their physical location and distance from the CPU and from

tion modules and stations are described in detail later in th

Each l/O rack requires a receiver which isolates the I/O d


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General Description of the Series SixInput/Output System

Auxiliary Circuit Board

An auxiliary circuit board is mounted in the I/O pow

(IOAXI) senses the +5V DC output to determine if it is

signal PSOK is generated if the +5V is within its spe

when the power supply is on and +5V is within its no

the +5V drops below 4.75V, PSOK switches high, whi


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The terminal assembly has a dual keying system to preven

sembly to a circuit card that is not compatible with the fieful in troubleshooting in that if a circuit card fails it can

since the keying system will only allow that type of card t

VOLTAGE AC/DC


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Input/Output System

Connections To I/O Modules

Connections are made to the I/O modules by inserting w

These lugs will accept one No. 12 AWG wire or two No.

14 AWG wire on Analog and High-Density modules. Wir

Wh h L i P i h i d


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Each module contains 8 isolated input circuits. AC or D

be input to the modules. Each input circuit has a high of the circuitry. Maximum turn-on voltage is 78% of the

nominal voltage. Each input circuit also contains an o

DC input of either polarity, and a filter to provide immu

An LED is provided for each circuit which indicates an

module that indicates features common to each of the

be inserted in any slot of an I/O rack (except the left mos


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The starting I/O point for each module is selected by set

plane adjacent to the I/O slot in which the module is insreference for eight consecutive I/O points reserved for

Figure 28 or the Installation section of this manual for in

Input connections for field wiring are arranged in two gr

nections in each group. Detailed installation instructions c

High-Density Input Modules


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Input/Output System

The 32 inputs available on this module are arranged in

single group is read by the CPU during an I/O cycle. All 3

tive I/O cycles. A user supplied power source is connect

DC mode) and COM terminals as required. Further detai

Chapter 2 of this manual.

By connecting a jumper plug on the circuit board to th

the data sent to the CPU is inverted (complemented) o

provides a visual indication of the selected mode. Fig

including features described above.


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-.General Description of the Series Six

Input/Output System


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Each of the above modules functions as an analog-to-dig

of its eight input channels. The sampled value of the inp

which provides a resolution of 1 part in 4096. This num

various operating conditions and the number of the chann

in the CPU.

Specifications for the Analog Input module are as listed in

5V DC, 1.5A - Supplied b


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Input/Output System

Four connections are provided for each channel on the

The input wiring is configured according to the type of

showing typical user input connections.


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The 32 bits corresponding to the group of 32 inputs r

Status Table in the sequence as shown below.

Bit#

INPUT STATUS TA

l/O Address I/O Address


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BI T

Bit 13

DEFINITION

Board OK: HIGH if both +5V and

otherwise.

Bit 14 Underrange: HIGH if input level is a

LOW otherwise. (Data will saturate


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Interrupt Input Module

The Interrupt Input module provides a method of initi

stored in the CPU memory. A signal to an Interrupt Inpu

quired voltage level of the interrupt signal from a user d

CPU can occur on either a positive or on a negative tr

either an ON/OFF or OFF/ON edge trigger is jumper s

proper terminals on the circuit board. Figure 35 is an in

Input module are as listed in Table 13.


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04


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AC Output Module

AC Output modules are available in either a 115V AC or

driving 5 mA to 2 amps. The module contains compara

being addressed and a register to store the output data

output has overvoltage protection and is protected fromeach use a triac as a switching device to connect the co

the user power source when that output is in the ON sta

lamp blown fuse indicator which is viewed through the tra


89/300


Input/Output System

The significance of each of the bits is defined in the f

input number in the group of 32 inputs, while Bit 32 c

For example, if DIP switch No, 6 is set OPEN and all the

37), then Inputs 257 to 288 in the CPU input Status Tab

spond to Bits 1 to 32 in the data format definition.

BI T DEFINITION


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Input/Output System

07


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Input/Output System

DC Output Modules

The discrete 8-point DC Output module is available inrange is available in either a sink or a source version

groups of four outputs. Each group shares a common p

tral (negative) terminal. Table 19 lists the specification

User Supplied

Module Voltage

Response

T i m e

ON-Stat

Voltage

Drop


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Two types of output amplifiers are used on the DC Outpu

With the source module, when an output is in the ON sta

voltage of the positive side of the user power source. Wdown toward the negative side of the user power source

A circuit is provided that disables all of the outputs in

CPU failure. This prevents improper operation which

operator.

A DC Output module can be installed in an I/O rack or i


100/300


The 32 outputs on this module are arranged in four gr

group is read by the CPU during an I/O cycle. All 32 ou

I/O cycles. A user supplied power source is connectedDC module) and COM terminals as required.

By connecting a jumper plug on the circuit board to th

the data sent to the CPU is inverted (complemented) o

provides a visual indication of the selected mode. See


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Input/Output System


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Input/Output System

Analog Output Modules

The Analog Output module is available in three versioversion are shown in Table 2 1.

( Module Type 1 RanUnipolar

Bipolar

Current

o --1


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A jumper must be set on the current output module. I

puts the circuit board jumper (refer to Figure 43) sh

source that provides a regulated +18V to +42V DC @

2 and 3. During operation, there is a significant voltage

low side of the load and the low side of the source.

Five connections are provided on the user connector

wiring is configured at these terminals according to th

instructions are provided in Chapter 2.


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Two consecutive I/O addresses (16 l/O points) are requ

with each channel. A single channel is normally acces

determined by the CPU under control of the user prograaccessed during the f/O scan as shown below.

OUTPUT STATUS TA

Bit 16


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Input/Output System

The twelve bits of data should be in straight binary form

form for negative values.

The 2s-complement form of a binary number is found

adding one. For example, the decimal number 770 c

OOOOOOI 100000010. To find the 2s-complement fthen add one to this, giving 1 1 1 1 1 1001 1 11 1 1 10.number -770.


108/300


Reed Relay Output Module

The Reed Relay Output Module provides six form C, meto switch loads with voltages up to 250V AC/DC at 2 a

and has an LED indicator that turns on when the corresp

list of specifications for this module.

Contact Type Form C, Normally Ope

Selectable


109/300


Input/Output System

C10


110/300


Each circuit has two output connections for user field w

this module connects to the appropriate output terminal,

nected through the power source to terminals Sl throone No. 12 AWG or two No. 14 AWG wires. Further

found in Chapter 2 of this manual.

I/O SYSTEM CONFIGURATION

A Series Six I/O system can be configured by using

A I/O t i tibl ith ll 3 d l f S


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The I/O Receiver module receives signals through the pa

the status of inputs and outputs, then relays those signals

nected when they are more than 50 feet (15 meters) fromfirst rack of the distant grouping to an I/O Transmitter t

bus. The length of this cable can not exceed 500 feet (1

the end of a parallel bus cable is referred to as a Local I/O

chained in a Local I/O station with no more than 50 feet

last rack. The maximum distance an I/O Receiver can be l

iliary l/O Control module is 2000 cable feet (600 meters

used when connecting racks on the daisy chain in the stat



113/300


Input/Output System

If an I/O Receiver should be removed from the last ra

the jumper pack and DIP shunts must be reconfigured

I/O Receiver is moved from a rack within the chain to t

shunts must be reconfigured to terminate the I/O chai

When a jumper pack is not inserted in location D1 or t

D1 they should be inserted in spare sockets located

spare sockets are in board locations F2 and F3.

Connectors


114/300

I/O TRANSMITTER

The I/O Transmitter module (Figure 48) is used to provnals and the i/O bus to a downstream Local I/O station

to a Local I/O station if I/O racks are required beyond the

isting Local I/O station or a model 60 CPU. Any number

long as the I/O load for the rack and the distance limita

be installed in a Remote I/O station and linked to ad

meters), thereby extending the Remote I/O capability b


115/300


Input/Output System

Status Indicators

A monitor circuit checks the output level of the isolatedspecified tolerance, the monitor circuit causes the I/O Tr

when the voltage is within tolerance. In addition, there

PARITY status. Table 26 defines the status information

I INDICATOR I DEFINITION


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G l D i i f h S i Si


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Input/Output System

120 Inputs and 248 In

120 outputs 248 O

l -128

129-256

257-384

385512513-640

641-768

l -2

257-5

513-7

769 -



119/300


Cable Wiring

Wiring connections required for use with the remote I / Omethods of connection are shown. Figure 50 shows tw

nection using RS-232 modems. Note that both the Rem

figured as Data Terminal devices when connection is b

9

G l i i f h S i Si


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Input/Output System

DataTerminal

Transmit Data

h&Receive Data


121/300


Printed Circuit Board Jumpers

There are several printed circuit board jumper plugs wha Remote I/O system. Jumper plugs are located on b

Receiver. Factory configuration of these jumpers is set f

- 120 Inputs and 120 Outputs

- Connection up to 10,000 feet (3Km) using two twi

- Baud rate -57.6Kb

GEK 25361A


122/300

General Description of the Series Six GEK-25361A

Input/Output System

REMOTE I/O DRIVER

The Remote I/O Driver module (Figure 52) provides contrcuitry on this module converts output data from parallel

Specifically, a Remote I/O Driver connects the I/O structu

I/O station to a Remote I/O station through a serial com

two twisted pair cable or a communications link usin

twisted pair cable, the Remote l/O station can be

kilometers) from the Remote l/Q Driver. A communicatio

G l D i ti f th S i Si


123/300


The Remote I/O Driver has circuitry sufficient to drive u

Driver module can be installed in any unused l/O slot in

CPU (except the left most slot in an I/O rack which is the Remote I/O station is to be made through a modem

High-Capacity I/O rack. This is necessary since the RS-

operation.

Addressing



124/300


Input/Output System

input # I/O Reference Information

1 10297

2 10298

3 10299

Input togg

to the CPU

Reserved

Reserved

4 10300 Remote P



125/300


Input/Output System

Status Indicators

There are four LED status indicators viewed through the status information as that indicated by the state of fnpu

their meanings are listed below in table 30 in the same or

IndicatorI--

Deflnmon

LOCAL ON - Remote l/O Driver module ope



126/300


Instructions for reconfiguring circuit board jumpers to

stallation chapter of this manual. The options listed i

system operation. Other jumpers on the board are addition, several jumpers are factory set and are for fut

ers should not be altered.



127/300

p

Input/Output System

REMOTE I/O RECEIVER

The Remote I/O Receiver module (Figure 53) is the in

Remote l/O station. It is physically located in the first racmost slot since the Remote I/O Receiver does not requi

adjacent to the leftmost slot).

A Remote l/O Receiver connected to a Remote I/O Drive

Local I/O station) through a two twisted pair cable can b

Remote I/O station is to be through a communications

General Description of the Series SixI t/O t t S t


128/300

Input/Output System

Circuitry on this module converts output data from serial

lel to a serial format. The Remote I/O Receiver also isolat

and provides error checking circuitry. If more than one

additional racks are daisy chained to the Remote I/O Re

Connectors

A Remote I/O Receiver has two edge mounted D-type co

to a Remote I/O Driver at the opposite end of the seria

cable or to a modem located no more than 50 feet (I 5


Input/Output System


129/300

Input/Output System

Option Jumpers

There are several circuit board jumpers on this module

signal termination. Jumpers are factory set prior to shipto which it is to be connected. Table 33 lists the facto

I/O Receiver options.

Options Factory Setting

Baud Rate I 57 6 Kb


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131/300

Input/Output System

LOCAL I/O STATION

A Local I/O station can have up to 10 l/O racks daisy

than 50 feet of cable can separate the first and last ra

linked to a Model 60 CPU, a CPU I/O station or anothe

terface is from an I/O Transmitter module to an I/O R

located a maximum of 500 feet from the I/O Transmit

can be a maximum of 2000 feet (four I/O Transmitter

I/O module in the CPU station.


132/300

General Description of theInput/Output System

Series Six


133/300

Input/Output System

REMOTE I/O STATION

A Remote I/O station (see figure 56) consists of I/O rack

I/O bus. A combination of I/O modules with a total of

and 248 outputs (jumper selectable) can be used in a

Remote I/O station daisy chain can be separated by no

In addition to the racks on the daisy chain an I/O Tran

can be the first in a link of l/O Transmitters connecting

ter can be connected to the first rack in a group of rac


134/300

General Description of the Series SixI t/O t t S t


135/300

Input/Output System

AUXILIARY I/O SYSTEM

The Auxiliary I/O system is available only with the Mode

ary I/O module, an l/O system identical to the main l/O

ture of the Auxiliary I/O system allows the Model 600

1000 outputs. The total I/O capacity of the Model 60

inputs and 2000 outputs.

All information pertaining to use of Input and Output m

tance allowed between racks and stations is applicable


P D l T i l


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Program Development Terminal

D


137/300

ENCLOSURE

The enclosure for the Program Development Terminal

durability. Dimensions of the unit with the keyboard clo

546.1 x 419.1 mm). The unit weighs 57 pounds (26kg)

as an aid to transporting the unit. See Figure 58.

General Description of the Series SixP D l t T i l


138/300


Extended

Mnemonic Group

(Dark Brown)

Relay Group

(Dark Brown)

General Description of the Series SixProgram Development Terminal


139/300


CABLE STORAGE

A storage compartment is provided to secure all cables

cable wraps are provided to allow the AC power and PD

panel folds up to enclose the cables for transporting an

a panel with connectors for external devices (e.g. pri

monitor), a fuse and a CRT brightness control.

CRT DISPLAY

General Description of the Series SixProgram De elopment Terminal


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141/300


KEYSWITCH

A three position, key-operated switch (key removable

modes: Monitor, On-Line, and Off-Line. In the Monitor

read data from the CPU but cannot write data to it. All ta

Scratch Pad memory are updated automatically to reflect

The On-Line mode allows the user to read data from

tables, register memory, and Scratch Pad memory are u

CPU In the On Line mode certain single word changes ca

General Description of the Series SixSystem Configuration


142/300

System Configuration

CO




143/300

y g

HARDWARE REQUIREMENTS

A system consists of a CPU rack and I/O racks each c

requiring a Model 600 CPU or a Model 6000 CPU, the I/or racks, The Model 60, if no more than 192 I/O points a

rack. The proper length cables for interconnection of C

be determined and be available for initial system chec

available for interconnection o n the parallel I/O bus in s

150 meters). Remote I/O requires a cable with two t

10 000 feet (3Km) and is normally user supplied If co




144/300

INITIAL SYSTEM CHECKOUT

It is recommended that an initial basic system checkou

mounted, cables run and wiring of external devices toitems to be checked is intended as a guide to the user.

Visual

Verify that all racks, modules and cables conform



145/300

Connect the Program Development Terminal to AC power plug to either 1 l5V AC or 230V AC a

Refer to the Series Six Programming Manual, GEK

If all of the above checks are completed satisfactorily

modules wired to their respective input and output devic

If any problems are encountered during any of the abo

the Programmable Control Service Center at (804) 9

Service representative will take the proper course of act


146/300



147/300

y g

I/O RACK-TO-l/O RACK CONFIGURATION

If I/O racks are to be daisy chained on the parallel com

be on a daisy chain. Interconnect each rack from the

next rack downstream. A maximum total cable length

on the daisy chain. See Figure 63.

The last I/O Receiver module in a daisy chain must hav

Refer to the Installation Chapter in this manual for ins




148/300

from previousI/O Rack or CPU

I / ORack

I I/OReceiverModule

* I/

l-6QO-


149/300

General Description of the Series SixData Processor


150/300

DAT


Data Processor


151/300

Data Control

The Data Control Module contains an 8086 microproce

mary function is to perform data processing functions Data Processor physically connects to the CPU through

of the l/O Control module in the CPU to either of the co

distance should not exceed 25 feet (7.5 meters).



152/300

Data Prom

The Data Prom module contains firmware used for coware instructions are a set of software (program) instruc

See Figure 67.



153/300

Data Serial Port

The Dual Serial Port module provides two serial com

to a Data Processor. This module supports RS-232C a

tion and operator interface. A selectable baud rate of

is configured by a jumper strap. A system must use at l

eight of these modules, thereby allowing a system a tot



154/300

PROGRAMS

Programs supplied with the Data Processor are brie

available in the future.

Message Generator

This program allows the Data Processor to store up

Each message can be up to 8000 characters long and


155/300

Installation

Rack and CPU Module Installation


156/300

R

IN

InstallationRack and CPU Module Installation


157/300

Data Processor racks are shipped with only the powe

aged the same as a CPU rack. Each of the DPU

package. All of the individual packages are then pla

The Program Development Terminal is enclosed b

The back of the Program Development Terminal is

folded to its bottom position, and the top cap is

The foam package is then inserted in a shipping

for Series Six Programmable Controllers is include


158/300

Installation

Rack and CPU Module InstallationA


159/300

EXTRACTION/INSERTION TOOL

The printed circuit board extraction/insertion tool (board

with your Series Six CPU should always be used whethe CPU require an insertion force of about 50 Ibs. (22.6

(11.34 Kg). Use of the extraction/insertion tool should a

which could be caused by hand insertion or removal.

tool.



160/300

NOTE

Power to a rack should be turned off b

printed circuit board.

REMOVING A PRINTED-CIRCUIT BOARD

Insert the board puller studs into the printed-circuit bthat the board puller surface is flat against the pr


161/300



162/300

A hex head screw is mounted adjacent to each bottom

front of the rack. Remove this screw, put it through the e

into its mounting hole. Loop the wire so that it will no

board into its cardguide. Tighten the screw securely to

faceplate and the rack.


163/300



164/300

NOTE

Some of the printed-circuit board names

from the module designation imprinted possibility of placing a printed-circuit boa

following cross reference list.

FACEPLATE AND BOARD CATALOG NU


165/300


166/300



167/300

Relatively small amounts of excess cha

trostatic fields in metal-oxide-semicon

their gate structure. When the board c

the circuit boards under conditions

electricity. Failure to observe this CAUT

of the CMOS RAM devices in this modu

Installation



168/300

When installing a Logic Memory module, position the si(towards the CPU power supply). Figure 10 shows pro



169/300

INTERNAL MEMORY MODULE

The Logic Memory location switches which tell the CPU

or 6000) should be programmed before the Internal Mem

Position the module in front of you so that the Logic M

See Figure 11 for an illustration of the switches.



170/300

Note that there are 4 rows of switches, which have 2 DIP

gles or positions per switch for a total of 16 toggles per r

The right row of switches control logic Memory slot A, slot B, the next row controls slot C, and the left row cont

Each toggle in each row of switches turns on a 2K inc

increment of memory is activated (turned on) when

position.

Installation

Rack and CPU Mo du le Installation


171/300

Connect the grounding wire attached to the faceplate to

to the rack with the quarter-turn thumbscrews by pushing

NOTE

Ensure that the proper faceplate is i

module, , Incorrect placement may cause

REGISTER MEMORY MODULE



172/300

o-



173/300

I/O CONTROL MODULE

The I/O Control module contains three labeled jump

options. These jumpers are located on the lower right o

(with component side towards you and LEDs and conne

The jumper configuration and definitions are indicated i

move the jumper plug to the correct pins. Jumpers sho

for a particular application.

InstaHationRack and CPU Module Installation


174/300

COMMUNICATIONS CONTROL MODULE

The Communications Control module is to be installed

trol module.

There are jumpers on the board which should be config

The jumpers and their functions are listed in the followin

Jumper Option



175/300

Jumper

28-29

out

134.5 I I n

150I

I n

300 I out



176/300

J u m p e r

49

55

59

63

66

Option

Odd Parity

No Parity

RS-232C

Operation



177/300

CPU POWER SUPPLY

The CPU power supply has 2 terminal boards located

protective cover and make the following connections.

terminal boards and their connections.

A i l i B t t

Installation



178/300

Connect the alarm relay contacts to external aconfiguration. (Optional)

0 Connect the + and - Auxiliary Battery contacts to aThis is an option that will provide a back-up to t

memory module.

If a memory auxiliary battery is used

InstallationThe I/O Rack


179/300

I/O SYSTEM CONFIGURATION



180/300

o-7

o-8

Installation

The I/O Rack


181/300

I/O POWER SUPPLY

The l/O power supply is shipped from the factory installe

the standard I/O rack or 5V DC at 16.5A, + 12V DC at 1.5

I/O rack.

There is one terminal board located on the lower part

plate and make the following connections. Refer to Fig

board and its connections.

InstallationThe I/U Rack


182/300

After completing the above connections the protective co

Ensure that the protective cover is ins

During normal operation either 115V A

cover protects against accidental shor

cause damage to the machine or injury

personnel


183/300



184/300

If an I/O Receiver should be removed from the last rack

the module must be reconfigured to continue the I/O c

tions described above.


Th t t I/O R i b


185/300

The top connector on an I/O Receiver can be connec

configuration. Possible connections are:

I/O Control module in a CPU rack. Next upstream I/O rack in a daisy chain of racks. An l/O Transmitter in a model 60 CPU I/O slot, a

l/O station.

The lower connector connects to the next rack downst

daisy chain of I/O racks


186/300



187/300


188/300



189/300

Baud

Rate

57.6K19.2K

9600

2400

1200

300

21

21-2221-22

21-22

21-22

20-21

20-21



190/300


191/300



192/300

Baud

Rate 23 I

57.6K 22~2319.2K 23 -24

9600 22-23

2400 23 -24

1200 22-23

300 23-24


Wh th ti j h b l fi


193/300

When the option jumpers have been properly configu

cable or an RS-232 modem link, the Remote I/O Recei

printed circuit board using the extraction/insertion too

to the rack, then install the faceplate by placing it in p

thumbscrews clockwise.

If direct connection to the Remote I/O Driver is to be t

up to 10,000 feet (3Km), the end of this cable at the Re

connector. If connection is to be through an RS-232

t ) i l th h ld b t d f th t


194/300


The following data is provided as an aid when buildin


195/300

e o o g da a s p o ded as a a d e bu d

Remote I/O system.

Remote I/O


196/300


I/O MODULE LOAD


197/300

I/O MODULE LOAD

Two I/O racks are available, the difference being the lo

ty of the power supply is the internal load placed on it

load. The power supply in a standard I/O rack can suthe high capacity I/O rack can supply 275 units of load

mined by installation of modules in the racks in a com

the power supply in a rack. Table 13 lists the I/O load

The power supply in a Model 60 CPU rack allows up to

The I/O Rack


198/300

MODULE

12V AC/DC Input

24-48V AC/DC Input115V AC/DC Input

230V AC/DC Input

12V DC Sink Output

24V DC Sink Output

NO. OF C

8

88

8

8

8

Installation

The I/O Rack

The following 2 examples show combinations of modu


199/300

The following 2 examples show combinations of modu

slots.

Example 1

Standard l/O Rack (100 Units of Load)

Q tit M d l

Unit of Lo

P M d

Installation

I/O Module Wiring


200/300

InstallationI/O Module Wiring

Wiring to field devices should be routed through the tra


201/300

Wiring to field devices should be routed through the tra

the wiring to the appropriate module, and fan the ind

insert the wires into the box lugs on the terminal asse

connection. The lugs will accept one No. 12 AWG wir

conform to UL standard 230 C.

The following wiring instructions can be used for these

M d l Catalo

Installation

I/O Module Wiring


202/300

c


203/300

Installation

I/O Module Wiring


204/300


205/300


When using the lo-50V mode, a closed switch turns it


206/300

g ,

the input Off.


207/300


208/300

Installation

I/O Module Wiring

NOT


209/300

The Analog Input module will function

with CPUs with the following serial nu

Model 60 CPU: Cl 88-8135-0130,

Model 600 CPU: (X88-81 38-010


The DiP switch on the backplane is ignored by the Interrhardwired on the circuit board In the main I/O chai


210/300

hardwired on the circuit board. In the main I/O chai

II OOI-11008), correspond to subroutines l-8 in the user input numbers l-8 (l/O points Al 1001 -Al 1008) correspo

Before installing the module, the eight blue jumper plugs o

be configured to respond to either rising edge transition

jumper locations has three pins. For rising edge transitio

pin to the N pin. For falling edge transitions, connect th

Input response to rising or falling edge transitions can


For typical user connections to an Interrupt lnput modul


211/300

I


212/300


In addition to setting the DIP switches for I/O point sele

fi ti DIP it h t b t t f ith t


213/300

configuration DIP switch must be set to conform with t

a guide to configuration of the various board options.

Table 14 is for selection of the format for data transfesigned magnitude or 2s complement.

Data Format

Signed Magnitude

Installation

I/O Module Wiring

Table 17 lists the DIP switch settings for module type c


214/300

DIPsb?&Jl PnsOPTION

12 3 4

Type J T/C ON ON ON ON

Type K T/C OFF ON ON OFF

Type S T/C ON OFF ON ON

Type T T/C OFF OFF ON OFF


Figure 34 identifies the location of the jumpers and DIP


215/300


216/300


AC OUTPUT MODULE


217/300

The discrete 8-point AC Output module is available in tw

I Module II 115VAC I230V AC



218/300

0I---


Install the circuit board using the extraction/insertion tool.

th f l t th i it b d th t th t i


219/300

the faceplate over the circuit board so that the termina

mated. Secure the faceplate to the rack by pushing in

them clockwise.

Wiring to devices to be controlled should be routed from

rack, into the wiring tray and to the output module. The

terminals. insert the wires into their respective box lug te

contact. Each box lug will accept one No. 12 AWG or two


l Connect one side of the load to be controlled to one


220/300

l Connect the other side of each load connected to te

ed to the Neutral # 1 [N I) terminal.l Connect the other side of each load connected to te

ed to the Neutral #2 (N2) terminal.

l Connect a user power source between the High #I (

Installation

I/O Module Wiring

Terminals for connecting loads to be controlled by this

has an output number (01 through 06) and a correspon


221/300

has an output number (01 through 06) and a correspon

an Isolated AC Output module showing the terminal arr


Install the circuit board using the extraction/insertion tool. W

the faceplate over the board, ensuring that the termin


222/300

the faceplate over the board, ensuring that the termin

mated. Secure the faceplate to the rack by pushing in

them clockwise.

Refer to Figure 39 for typical user connections to this

Each box lug terminal can accommodate one No. 12 AWG


l Connect the high side of the user power source to


223/300

l Connect one side of the load to be controlled to th

l

Connect the other side of the load to the low side

After completing field wiring to the module, install the

the top of the terminal block and sliding it down over



224/300

Installation

I/O Module Wiring

Install the circuit board using the extraction/insertion too

the faceplate over the board ensuring that the term


225/300

the faceplate over the board, ensuring that the term

mated. Secure the faceplate to the rack by pushing

them clockwise.

When wiring the 12V, 24V, and 48V DC sink and sour

to the high side of the user DC power source and the

When using a sink module, current must flow through t



226/300

HI

2

1L t

I [L

L


227/300


In addition to setting the DIP switches, a circuit board ju

in either the Inverting or Non-Inverting state should be se


228/300

this jumpe!r.


229/300


230/300


A jumper on the printed circuit board must be configure


231/300

A jumper on the printed circuit board must be configure

lf the internal loop supply is used to power the outputs,

to Figure 47, item 2). If a common external source that

mA is used, the jumper should be connected between pcant voltage drop across the output device; i.e. betwee

source.


Install the printed circuit board by using the extraction/

the faceplate to the rack. With the board in place in the


232/300

over the circuit board so that proper contact is made be

An Analog Output module has four channels. Refer to

the Analog Output modules.


233/300


NOTE


234/300

The Analog Output module will functio

CPUs with the following serial numbers

Model 60 CPU: Cl 88-8135-0130, a

Model 600 CPU: Cl 88-8138-0100,



235/300


One of the circuit board jumpers is set to select the

normally-open (N.O.) or normally-closed (N.C.) contacts.


236/300

series with the RC protection circuit for each output. W

moved which allows operation with low level analog a

is not a factor during normal operation.

Install the printed circuit board by using the extraction

the faceplate to the rack. With the board in place in th

over the circuit board so that proper contact is made be

lnstallation

I/O Module Wiring


237/300

s2R 2s3

Installation

Program Terminal


238/300

DE

InstallationProgram Development Terminal

Unwrap the Program Development Terminal to CPU

area.


239/300

Plug the 3-prong (grounding) line cord into a 115V

and CPU should be connected to an AC source p

if the PDT is connected directly to the CPU.

Connect the 12 foot interface cable to the top con

Tighten the mounting screws on the connector to e

Troubleshooting and RepairIntroduction

IN


240/300

IN

This chapter provides the data required for basic trou


PROGRAMMABLE CONTROL SERVICE CENTER

The Programmable Control Service Center is staffed


241/300

The Programmable Control Service Center is staffed

Service Personnel. The Service Center is available to

solving equipment problems.


TROUBLESHOOTING

The maintenance and troubleshooting section of this man


242/300

The maintenance and troubleshooting section of this man

any problems that may arise in your Series Six system. It

gramming personnel read this manual thoroughly so that

ly and the defective part replaced, thus minimizing downt

However, we realize that troubleshooting isnt always tha

to who can answer your questions. When you do, please

S i t 1 800 GEFANUC

Troubleshooting and RepairProgram Development Terminal Troubleshooting


243/300

D

TROUB


02To check the fuse and connections to the PDT open


244/300

To check the fuse and connections to the PDT open

Figure 1 for location of these items.


03If the malfunction is isolated to the PDT proceed as foll


245/300

p

? Remove tk le top cover from the PDT to gain acccomponen ts is shown below.


l Check power supply voltages at the terminal boar

the specified range.


246/300

Voltage

+5V DC +4

+12VDC +


TO change the PDT power supply, use the following pro

Remove AC power to the PDT by unplugging the line


247/300

y gg g

Set the PDT on a table with the display screen facin

and remove 2 screws holding the bottom of the pow

Remove 2 screws holding the top of the power su

moved from the PDT and set on the table with wirin

Troubleshooting and Repair

Program Development Terminal Troubleshooting

The following adjustments are made on the video mon

adjustment controls are clearly marked on the board (Fig


248/300

VI 3105 VI 3104F O C U S S U B - B R I G H

\ I


0 Sub-BrightnessThe brightness can be controlled by adjusting VR10

inside of the cable storage compartment) to its cent


249/300

g p )

ground raster is barely visable. Back off VRI 04 untito some extent as the brightness control is adjus

conditions.

Focus

The focus control (VR105) allows adjustment for

f l h ld b dj d id h d i


05If the problem still persists after making the above che


250/300

If the problem still persists after making the above che

type of malfunction encountered. Refer to the following t

PROBLEM

NO DISPLAY OR

DISTORTED DtSPLAY

PROCEDURE

1. Adjust CRT controls

2. Turn PDT keyswitch

seconds and power


PROBLEM

EXTERNAL TAPE

PROCEDURE

1 Ch k f t l


251/300

EXTERNAL TAPE

LOADER DOES NOT

OPERATE

1. Check front panel s

STR LlNK IIA

l Baud rate: 300,60

*Reco

lStop bit: 1

l l/O Select: RS232

l Mode Select: Half


PREVENTIVE MAINTENANCE

The preventive care and maintenance of the STR LlN


252/300

p

easily accomplished procedures that enhance the pe

trouble-free operation.

l After every 8 hours of operation, clean the read/writ

Use cotton swabs to clean and dry the heads, takother foreign objects.


253/300

Troubleshooting and RepairCentral Processing Unit Troubleshooting

MODULE

NORMAL

INDICATOR CONDITION DEFIN


254/300

MODULE

Power

SUPPlYI/O

Control

INDICATOR CONDITION

POWER ON

CHAIN O.K. ON

DEFIN

Power

All I/O

good



255/300


01


256/300

CPU RUN/STOP KEY

Position I DEFINITION

STOP I CPU is unconditionally in th

RUN CPU is in the RUN mode u

mands from the Program

03Troubleshooting and RepairCentral Processing Unit Troubleshooting

P o e r


257/300

P o w e r

Light

Status

ON

CPU Power Supply

DEFINITION

The voltage levels of a

the specified tolerance

Troubieshooting and RepairCentral Processing Unit Troubleshooting

Voltage Rang

+5V DC +4 7


258/300

+5V DC +4.7

I +12VDC I +11

I -12VDC I - 11.

If any of the voltages are out of tolerance re


t 1 1 -emo;;q&otect. CPAXBoard


259/300

u-lCPURylc$stOp Board?? P2


04


260/300

CHAIN OK

Light

Status

ON

I/O Control Module

Auxiliary I /O Module

Definition

Continuity, output data

stations in the primary a


Central Processing Unit Troubleshooting

05

PARITY I/O Control Module


261/300

PARITY

II/O Control Module

Light Auxiliary I/O Module

I Status I DefinitionON I Input data parity is good

OFF Input data parity error ex



06

ENABLED l/O Control Module


262/300

ENABLED

Light

Status

ON

OF F

l/O Control Module

Auxiliary I/O Module

Definition

Outputs are enabled. CPU

Outputs are disabled. C


263/300

-~~ ~ ~~Troubleshooting and RepairCentral Processing Unit Troubleshooting

09


264/300

RUN

Light

Status

ON

Arithmetic Control Mod

Definition

CPU execution sequen


010

PARITY


265/300

PARITY

Light

Status

ON

OFF

Internal Memory Module

Definition

Logic Memory parity is go

Logic Memory parity error


011PARITY

Light Register Memory Module


266/300

Light Register Memory Module

Status Definition

ON Table Memory parity is go

OFF Table Memory parity erro

off. Alarm No. 1 relay s


Corrective Action

l Turn off power to the CPU.

l Remove the faceplate from the approp


267/300

l Remove the faceplate from the approp

l Remove the memory board using the

l

Remove the top board cover (compothat hold the cover on, while pulling up

l If the light was flashing, install the n

follows.

1 Do not disconnect the battery bu



268/300

BATTERYMOUNT I NG

CLIPS


1 The CPU will not communicate with the PDT.I Check the cable connector from the PDT to


269/300

Insure that the PDT will work with another

Reset the l/O Control board, Arithmetic Co

If reseating does not solve the problem, r

order given above.


ALARM RELAY

The CPU can be monitored at a location remote from th

light etc ) to the alarm relay output terminals on the C


270/300

light, etc.) to the alarm relay output terminals on the C

power supply terminal board are shown below in Figure 7


Alarm relay outputs are rated at 115V AC or 28V DC,

Alarm No. 1 is switched by hard failures, the CPU statu

off.


271/300

Alarm No. 2 is switched by a soft failure, error indicati

to STOP.

Alarm conditions are listed in the table shown

alarm conditions


CPU RENEWAL PARTS LIST

A list of the replaceable parts in the Central Processing Un


272/300

CATALOG MODULE 6

NUMBER NAME 0

IC6OOCB500A Arithmetic Control x x



CPU RENEWAL PARTS LIST


273/300

CATALOG MODULE 6

NUMBER NAME 0

IC6OOCB5 13A Auxiliary I /O Control


274/300


275/300

Troubleshooting and RepairI/O System Troubleshooting

I/O INDICATOR CHART

Table 5 is an indicator chart that gives a quick referenc

modules.


276/300

MODULE INDICATOR STATUS D

P o w e r POWER ON P


I/O System Troubleshooting

MODULE INDICATOR STATUS

Reed Relay 1 through 6 ON

output

D

R


277/300

output

OFF

Interrupt 1 through 8 ON

Input

Thermocouple BOARD ON

R

C

M



MODULE INDICATOR

LOCAL

OK

STATUS

ON

D

M


278/300

Remote

I/O

Driver

OK

LINK

OK

OFF

ON

F

C

R



MODULE INDICATOR

LOCAL

OK

STATUS

ON

DE

Mo


279/300

Remote

I/O

Receiver

OK

OFF Co

ce


280/300


281/300

Troubleshooting and RepairI/O System Troubleshooting

From CPU

i R k


282/300

previous ;/O Rackh)Parallel Bus Two Twisted Pair SerE-Pair_I_C

Twisted Cable Cable from Mo


283/300


284/300


285/300


286/300


cl9REMOTE

OK

Remote I/O Driver

Remote I/O Receiver


287/300

OK

Light

Remote I/O Receiver

Status

ON

Definition

Remote Driver: Valid I/
