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GE Fanuc Automation

Programmable Control Products

GE Fanuc Automation
P.O. Box 8106
Charlottesville, VA 22906
GFZ–0086

Î Series 90 TM–70
Programmable Controller

Troubleshooting Guide

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|__ __|__ __|

GE Fanuc Automation

Programmable Control Products

Series 90 TM–70
Programmable Controller
Troubleshooting Guide

GFZ–0086 November1993

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 |__ __|__ __|


   
This document is based on information available at the time of its publication. While efforts
have been made to be accurate, the information contained in this document does not purport

  
to 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 describe
features not present in all hardware and software systems. GE Fanuc Automation assumes no
obligation of notice to holders of this document with respect to changes subsequently made.
GE Fanuc Automation makes no representation or warranty, expressed, implied, or statutory
with respect to, and assumes no responsibility for the accuracy, completeness or usefulness of
the information contained in this document. No warranties of merchantability of fitness for
purpose shall apply.
 
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 70E
Part II for additional guidelines for safety practices.

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

ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
Alarm Master
ÁÁÁÁÁ CIMSTAR Helpmate Never reach into a machine to operate a switch since unexpected motion could occur, causing

ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ
PROMACRO Series Six CIMPLICITY injury.

ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ
GEnet Logicmaster Series One
Series 90 CIMPLICITY 90–ADS Genius

ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ
Modelmaster Series Three VuMaster
Remove all electrical power at the Main Power Disconnect to ensure total power removal.

ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ
ProLoop CIMPLICITY PowerTRAC Series Five
Workmaster Genius Power TRAC

 Copyright 1993 GE Fanuc Automation North America, Inc.

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

      At GE Fanuc Automation, we strive to produce quality technical documentation. After you
have 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-
This is the first release of this Troubleshooting Guide. Included are models CPU models 731,
tion. PO Box 8106, Charlottesville, VA 22906
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. Drake C. Fink


 
 Sr. Staff Systems Engineer

Series 90 TM–70 Programmable Controller Installation

Manual (GFK–0262).
Logicmaster TM 90–70 Programming Software User’s Manual (GFK–0263)
Series 90 TM–70 Programmable Controllers Reference
Manual (GFK–0265)
Series 90 TM–70 Programmable Controller Data Sheets (GFK–0600)

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Although your PLC CPU may be running in RUN/IO ENABLED mode, and you may have
communications between the PLC and Logicmaster 90, the system may not be operating cor-
rectly. The following pages suggest some areas to investigate:
Grounding:
D Verify all power supply mounting screws are tightened.
D Verify the green grounding wire provided with the power supply is securely
attached to the rack grounding stud.
D Verify all racks are grounded to a common ground. Reference the System
Grounding Procedures in the Series 90–70 Programmable Controller
Installation Manual (GFK–0262) for additional information.
Loss of Rack Fault:
D Verify all inter–rack cables are securely connected on both ends. Verify cables
connect to all racks.
D 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 no
expansion racks.)
D Verify all power supplies are powered on (Green LEDs on). Follow the same
troubleshooting procedures for expansion racks power supplies as you use for the
main rack.
D Verify each expansion rack has a unique address. ONLY the rack containing the
CPU is address zero. All other racks are in the range 1 to 7. NO rack is in the
range 8 to 15.
–1–
D If all the above are true and you still have LOSS OF RACK, then:
D 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. You
should 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 fault
to be FATAL, you will have to clear the PLC Fault Table before you can place
the PLC in RUN mode.)
D Power off all racks. Connect expansion cable to next rack, so previous rack is
still in the chain. Connect terminator plug to bottom connector on BRM. Power
on all expansion racks. Power on main rack. LOSS OF RACK faults for all
non–connected expansion racks should appear in the PLC CPU Fault Table.
Place PLC in RUN mode. Replace BRM and cable if LOSS OF RACK fault
persists.
D Continue debugging the expansion rack chain one rack at a time until all racks
have been added to the chain and no LOSS OF RACK faults occur.
Other Faults:
D Position the cursor on the fault. Using Release 4 Logicmaster, press the ZOOM
(F10) key. Read the fault explanation and follow the suggestions for eliminating
the fault.
No Input:
D 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.
D 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 module
physically resides in the slot, but is not present in the PLC configuration. Add
the module to the configuration and restore the configuration.
D Verify the %I address assigned for the input in the configuration is the same %I
address as used in the program.
D Verify pins in the VME bus connector are not bent or corroded.
D Verify the input device functions correctly.
D Verify wiring from input device through terminal strip to input module is intact.
D Verify presence of power at the input device.
D Verify no fuses are blown.
D Replace the module if other input channels on this module function.
No Output:
D 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.
D 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 module
physically resides in the slot, but is not present in the PLC configuration. Add
the module to the configuration and restore the configuration.
D Verify the %Q address assigned for the output in the configuration is the same
%Q address as used in the program.
D Verify pins in the VME bus connector are not bent or corroded.
D Verify fuse on output module (if present) is not blown.
–2–
D Verify the output device functions correctly.
D Verify wiring from output module through the terminal strip to the field device
is intact.
D Verify presence of power at the output module.
D Verify no fuses are blown in the path from the output module to the field device
.
D Replace the module if other output channels on this module function.
Genius Devices Do Not Function:
D Verify the Genius Bus Controller appears in the configuration and the
configuration in the PLC and LM90 are equal.
D Verify the %I/%Q addresses assigned to the Genius device in the configuration
match those used in the ladder logic.
D Follow the general debug guidelines above for No Input and No Output.
D Refer to the Series 90–70 Programmable Controller Genius Bus Controller &
Genius I/O System Troubleshooting Guide for more detailed Genius
Troubleshooting.
 

   


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 it
was 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, for
nominal 115 VAC input;
180 to 264 VAC, for
nominal 230 VAC input;
47 to 63 HZ
IC697PWR722 21.6 to 26.4 VDC for
24VDC nominal input
IC697PWR732 122.5 to 137.5 VDC for
125VDC nominal input
4. Total cable length must not exceed 50 feet between the CPU rack (rack 0) and the last
expansion rack. No termination plug is needed on a Bus Transmitter Module in a one–
rack system.

–3–
 ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
START

ÁÁÁÁÁÁ
Á ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁ ÁÁÁÁÁÁÁ
Á ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁ ÁÁÁÁÁÁÁ
IS POWER YES YES ARE ALL 3 YES
IS TOP CPU
SUPPLY LED

ÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ

LED STEADY CPU LEDS
ON? ON?
ON?

ÁÁÁÁÁÁ
Á
ÁÁÁÁÁ
NO
ÁÁÁÁÁÁÁ NO ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
Á
NO

Á
ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ
1 TOGGLE CPU SWITCH TO RUN
(PAGE 2) (UP) POSN. IF SWITCH IS UP,

ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ
TOGGLE IT OFF, THEN ON AGAIN

ÁÁÁÁÁÁÁ
Á ÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁ
ÁÁÁÁÁÁÁ ÁÁÁÁÁ
ARE ALL 3 YES

ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁ

CPU LEDS
YES IS TOP CPU ON?

ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ
LED ALWAYS
13

ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ
Á ÁÁÁÁÁ
BLINKING? NO
(PAGE 13)

NO
ÁÁÁÁÁÁÁ
ÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁ YES

ÁÁÁÁÁÁÁ ÁÁÁÁÁ
ONLY TOP
CPU LED ON?

ÁÁÁÁ
ÁÁ Á Á
ÁÁÁÁÁÁÁ ÁÁÁÁÁ
ÁÁÁÁ ÁÁÁÁÁ
7 8 NO

ÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ

Á ÁÁÁÁÁ
(PAGE 8) (PAGE 9) 4
(PAGE 5)

ÁÁÁÁÁ ÁÁÁÁÁ
6

ÁÁÁÁÁ
     
     (PAGE 7)
 
   


ÁÁÁÁÁ
DIAG70A
PAGE 1         GFZ-0086
 ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
1

ÁÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ
Á ÁÁÁÁÁÁÁ
Á ÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁÁ
POSITION OF ON IS VOLTAGE NO NO APPLY
IS LINE FUSE

ÁÁÁÁÁÁÁ
PROPER

ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁÁ

PWR SUP ON/ APPLIED TO
OFF SWITCH? PWR SUP? BLOWN? VOLTAGE

ÁÁÁÁÁÁÁÁ
Á ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁ Á
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
Á
YES YES
OFF

ÁÁÁÁÁÁÁ
Á ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ
REPLACE
Á
ÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ
LINE
MOVE POWER FUSE

ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁ

SUPPLY SWITCH IS SUPPLY A NO
DUAL–VOLTAGE START

ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁ

TO ON (UP)
POSITION SUPPLY? (PAGE 1)

ÁÁÁÁÁÁÁ
Á ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁ YES
ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ ÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁ
Á ÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ ÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁ
DOES
YES IS SUPPLY NO

ÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ

IS POWER NO SUPPLY CORRECT FAULTY
SUPPLY LED VOLTAGE = VOLTAGE IN
SUPPLY VOLTAGE

ÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ

ON? SETTING? TOLERANCE?

YES

ÁÁÁÁÁÁ
ÁÁ
NO
ÁÁÁÁÁÁÁ YES

ÁÁÁÁÁ
Á ÁÁÁÁÁÁ Á
ÁÁÁÁÁ Á
ÁÁÁÁÁ
ÁÁÁÁÁ ÁÁÁÁÁÁ Á Á
CHANGE POWER
START SUPPLY JUMPER

ÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ

(PAGE 1) TO AGREE WITH 2 1
(PAGE 3)

ÁÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ

SUPPLY VOLTAGE. (THIS PAGE)

PAGE 2 DIAG70B
ÁÁÁÁÁ ÁÁÁÁÁÁÁ
ÁÁÁÁÁ ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ
· REMOVE POWER
2 · REMOVE ALL CARDS

ÁÁÁÁÁ ÁÁÁÁÁÁÁ
· APPLY POWER

ÁÁÁÁÁÁÁ
Á ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ
NO · REMOVE POWER NO
IS POWER IS POWER
· REPLACE POWER SUPPLY

ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ

SUPPLY LED · APPLY POWER SUPPLY LED
ON? ON?

ÁÁÁ
ÁÁÁÁÁÁÁ YES
ÁÁÁÁÁÁÁÁÁ ÁÁ
ÁÁÁÁÁÁÁ YES

ÁÁ
Á
ÁÁÁÁÁÁÁ
Á ÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
· REMOVE POWER
· INSTALL NEXT CARD
Á
ÁÁÁÁÁ
ÁÁÁÁÁÁÁ Á
ÁÁÁÁÁ
· APPLY POWER

ÁÁÁÁÁÁÁ
Á ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁ
3
(PAGE 4)

ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁ
ÁÁÁÁÁÁÁ
IS POWER · REMOVE POWER

ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
NO
SUPPLY LED · REPLACE FAULTY MODULE
· APPLY POWER

ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ
ON?

ÁÁÁÁÁÁÁ
Á ÁÁÁÁÁÁÁ
Á
YES

ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ
ARE ALL
NO MODULES IS POWER YES

ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ
INSTALLED? SUPPLY LED

ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ
ON?

ÁÁÁÁÁ
Á Á
YES
NO

ÁÁÁÁÁSTART
ÁÁÁÁÁ
Á
ÁÁÁÁÁ ÁÁÁÁÁ
(PAGE 1) 3
PAGE 3 (PAGE 4)

ÁÁÁÁÁ
DIAG70C
 ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁ ÁÁÁÁÁÁÁÁ POWER SUPPLY NO
Á
ÁÁÁÁÁÁÁÁÁ
· REMOVE POWER

ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ ÁÁÁÁÁÁÁÁ
3
REPLACED · REPLACE POWER SUPPLY

ÁÁÁÁÁÁÁÁ
ONCE?

YES

ÁÁÁÁÁÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁ
· REMOVE POWER
· REMOVE ALL MODULES

ÁÁÁÁÁÁÁÁÁÁÁÁ
· VERIFY PINS ON MODULES ARE

ÁÁÁÁÁÁÁÁÁÁÁÁ
NOT CORRODED OR BENT
· REPLACE MODULES AS NECESSARY

ÁÁÁÁÁÁÁÁÁÁÁÁ
· REPLACE RACK

ÁÁÁÁÁÁÁÁÁÁÁÁ
· VERIFY RACK AND POWER SUPPLY
GROUNDING

ÁÁÁÁÁÁÁÁÁÁÁÁ
· REINSTALL POWER SUPPLY

Á
Á
ÁÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
· REINSTALL MODULES
· APPLY POWER

ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ
Á
ÁÁÁÁÁ
ÁÁÁÁÁ
START

ÁÁÁÁÁ
(PAGE 1)

PAGE 4 DIAG70D
 ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
4

ÁÁ
ÁÁÁÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ ÁÁÁÁÁ
ÁÁ
ÁÁÁÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁÁ
IS CPU IN
STOP/HALT
YES ÁÁÁÁÁ
ÁÁÁÁÁÁ
7
(PAGE 8)

ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁ

CAN CPU NO 10
MODE?
COMMUNICATE (PAGE 11)

ÁÁÁÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁ

WITH LM90?

ÁÁÁÁÁÁÁÁ Á
NO

ÁÁÁÁÁÁÁ
ÁÁ ÁÁ
YES

ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
IS CPU IN NO PLACE PLC IN RUN
STOP/FAULT MODE

ÁÁÁÁÁÁÁ
MODE?

YES

ÁÁ
ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ
Á
ÁÁ
ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁÁ Á
ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁ NO START

ÁÁÁÁÁÁÁ ÁÁÁÁÁ
IS FAULT ARE ALL 3
DETERMINE & CPU LEDS (PAGE 1)
SYSTEM NO

ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ

CORRECT CAUSE ON?
CONFIG
OF FATAL FAULT

ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ
MISMATCH?
YES

ÁÁÁÁÁÁÁÁ YES

ÁÁÁÁ
ÁÁ ÁÁÁÁÁÁÁ
Á ÁÁÁÁÁ
Á
ÁÁÁÁ 5
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ ÁÁÁÁÁ 13

ÁÁÁÁ ÁÁÁÁÁ
(PAGE 6) USE LM90 TO (PAGE 13)
CLEAR PLC & I/O

ÁÁÁÁ ÁÁÁÁÁÁÁ
FAULT TABLES

ÁÁÁÁÁÁÁ
PAGE 5 DIAG70E
 ÁÁÁÁÁ
Á
ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ 5

ÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ
Á ÁÁ ÁÁ
ÁÁÁÁÁÁÁÁÁÁÁ
· EXIT I/O CONFIG
· SELECT & CLEAR PLC FAULT TABLE

ÁÁÁÁÁÁÁÁÁÁÁ
Á ÁÁ ÁÁÁÁÁÁÁÁÁÁÁ
· SELECT & CLEAR I/O FAULT TABLE

ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ
· SELECT UTILITIES
THE RACK AND SLOT OF THE · STORE CONFIGURATION TO PLC

ÁÁÁÁÁÁÁÁÁÁÁ
MISMATCHED MODULE ARE
GIVEN IN THE PLC FAULT TABLE

ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ
Á
AS A DECIMAL NUMBER (E.G., 0.1,
1.3, ETC.) AT THE FAR LEFT SIDE

ÁÁÁÁÁÁÁÁÁÁÁ
OF THE TABLE.
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
STILL YES
CONFIG

ÁÁÁÁÁÁÁÁ
Á ÁÁÁÁÁÁÁ
MISMATCH?

ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
· SELECT LM90 CONFIG
· SELECT I/O CONFIG
ÁÁÁÁÁÁÁÁÁ
Á
NO

ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
PLACE PLC IN RUN MODE

ÁÁÁÁÁÁÁÁ
Á ÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁÁ ÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ IS CONFIG’D YES

Á
ÁÁÁÁÁÁÁ ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
TYPE SAME AS
THE HARDWARE? ARE ALL 3 NO START

ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁ

CPU LEDS (PAGE 1)

ÁÁÁÁÁÁÁ
ON?
NO

ÁÁÁÁÁÁÁÁÁ
Á
YES

ÁÁÁÁÁÁÁÁÁ
CHANGE LM90 CONFIG OR

ÁÁÁÁÁÁÁÁÁ Á
ÁÁÁÁÁ
Á
HARDWARE SO BOTH ARE
THE SAME.

ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁ
13

ÁÁÁÁÁ
(PAGE 13)

PAGE 6 DIAG70F
 ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ 6

ÁÁÁÁÁ
ÁÁÁÁÁÁÁ
Á ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
YES RUN I/O DISABLED.
ONLY TOP, TOGGLE CPU SWITCH ARE ALL 3 YES

ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ

CENTER CPU OFF, THEN ON. CPU LEDS

ÁÁÁÁÁÁÁÁ
LEDS ON?

ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ
(UP POSITION) ON?

NO NO

Á
ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ
Á ÁÁÁÁÁ
Á
Á
ÁÁÁÁÁÁÁ YES
ÁÁÁÁÁÁÁÁ
STOP I/O ENABLED
.
ÁÁÁÁÁÁÁ ÁÁÁÁÁ
13

ÁÁÁÁÁÁÁ Á
ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁ
ONLY TOP, · REMOVE POWER (PAGE 13)
TOGGLE CPU SWITCH
BOTTOM, CPU · REPLACE CPU

ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ

OFF, THEN ON.
LEDS ON? · APPLY POWER
(UP POSITION)

ÁÁÁÁÁÁÁ NO ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁ
Á ÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁ ÁÁÁÁÁ
ÁÁÁÁÁ
START
(PAGE 1)

ÁÁÁÁÁÁÁ
DEFECTIVE CPU.

ÁÁÁÁÁÁÁ
CALL YOUR
DISTRIBUTOR FOR ÁÁÁÁÁ
ÁÁÁÁÁÁÁ
REPLACEMENT CPU.

PAGE 7 DIAG70G
 ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ 7

ÁÁÁÁÁ ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
Á ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
ANY BLANK · REMOVE POWER
TOP CPU LED FAST NO · VERIFY MODULE PINS NOT BENT OR BROKEN

ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

SLOTS
FAST OR SLOW BETWEEN CPU · RESET ALL MODULES IN BACK PLANE

ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

BLINK? & SMART · APPLY POWER
CARDS?

Á
SLOW
ÁÁÁÁÁÁÁÁ
ÁÁ
YES

ÁÁÁÁÁÁÁ
Á ÁÁÁÁÁÁÁÁ
ÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
POWER CYCLE ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
· REMOVE POWER
· ELIMINATE EMPTY SLOT
ÁÁ
ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ
PLC
· APPLY POWER

Á
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁ ÁÁÁÁÁÁ
ÁÁ
Á
ÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
TOP CPU LED YES
Á
ÁÁÁÁÁÁ Á
· REMOVE POWER

ÁÁÁÁÁÁ ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁ
YES TOP CPU LED
STILL · REPLACE CPU
BLINKING?

ÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ

BIINKING? · APPLY POWER

Á
ÁÁÁÁÁ
NO

ÁÁ
NO

Á
ÁÁÁÁÁ
4
(PAGE 5)
ÁÁ
ÁÁÁÁÁ ÁÁÁÁ
ÁÁ
ÁÁÁÁ
START
(PAGE 1)

PAGE 8 ÁÁÁÁ DIAG70H

 ÁÁÁÁÁ ÁÁÁÁÁÁÁ
ÁÁÁÁÁ ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ Á
ÁÁÁÁÁÁÁ
ÁÁÁÁÁ 8

ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁ
PROBLEMS YES
FOUND WITH REPLACE MODULE

ÁÁÁÁÁÁÁ
Á ÁÁÁÁÁÁÁ
MODULE?
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ
Á
NO

ÁÁÁÁÁÁÁ Á
POWER CYCLE

ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ
Á
PLC

Á ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
· SEAT ALL MODULES
FIRMLY IN RACK

ÁÁÁÁÁÁÁ
Á ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ
· APPLY POWER

ÁÁÁÁÁÁÁ Á
ÁÁÁÁÁÁÁÁÁ Á
ÁÁÁÁÁÁÁ
· REMOVE POWER

ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ
Á Á
ÁÁÁÁÁÁÁ ÁÁÁÁ
NO · REMOVE MODULES ONE
TOP CPU LED BY ONE ANDINSPECT

ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁ

ÁÁÁÁ
STEADY ON? MODULE FOR BENT PINS &

ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁ

ÁÁÁÁ
CORROSION YES
TOP CPU LED START

Á
ÁÁÁÁÁ
YES

ÁÁÁÁÁÁÁ ÁÁÁÁ
STEADY ON? (PAGE 1)

Á
ÁÁÁÁÁ ÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁ
NO

ÁÁÁÁÁ
START

Á
ÁÁÁÁÁÁÁ
ÁÁÁÁÁ
(PAGE 1)

ÁÁÁÁÁÁÁ
· REMOVE POWER

ÁÁÁÁÁÁÁ
· REPLACE CPU

ÁÁÁÁÁÁÁ
· APPLY POWER

ÁÁÁÁÁ
Á
ÁÁÁÁÁ
ÁÁÁÁÁ
9
(PAGE 10)

PAGE 9 ÁÁÁÁÁ DIAG70J

 ÁÁÁÁÁÁÁ
ÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ ÁÁÁÁÁÁÁÁ
TOP CPU LED NO ÁÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁÁ
· REMOVE POWER
· TRY ORIGINAL CPU

ÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ

9
STEADY ON? IN ANOTHER SYSTEM

ÁÁÁÁÁÁÁ YES

ÁÁÁÁÁ
Á ÁÁÁÁÁÁ
ÁÁ
ÁÁÁÁÁ ÁÁÁÁÁÁ
ÁÁ
ÁÁÁÁÁ ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
START CPU
YES
(PAGE 1) FUNCTION IN

ÁÁÁÁÁ ÁÁ
ÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ
OTHER

ÁÁ
ÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ
SYSTEM?

NO
· REMOVE POWER

ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
· REPLACE POWER
SUPPLY AND BACKPLANE
· APPLY POWER

ÁÁ ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁ ÁÁÁÁ
ÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁ ÁÁÁÁ
· REMOVE POWER

ÁÁÁÁÁÁ ÁÁÁÁ
START
· REPLACE CPU
(PAGE 1)

ÁÁÁÁÁÁ ÁÁÁÁ
· APPLY POWER

ÁÁÁÁ
ÁÁ
ÁÁÁÁ
ÁÁÁÁ
START
(PAGE 1)

PAGE 10
ÁÁÁÁ DIAG70K
ÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ
ÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁ
ÁÁÁÁÁ ÁÁÁÁÁÁÁÁ Á Á
ÁÁÁÁÁÁÁ
RACK GROUND
YES POWR CYCLE PLC
10 EQUAL

ÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ

PROGRAMMER & PC*

ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ
GROUND?
*PC REFERS TO THE

ÁÁÁÁÁÁÁÁ
PERSONAL COMPUTER
NO WHICH RUNS THE LM90
SOFTWARE.

Á
ÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ENSURE RACK &
ÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁ
PROGRAMMER
GROUND ARE THE

ÁÁÁÁÁÁÁ
SAME.
ÁÁÁÁÁÁÁ ÁÁÁÁÁÁ
CAN CPU 4

ÁÁÁÁÁÁÁ ÁÁÁÁÁÁ
YES
COMMUNICATE (PAGE 5)

ÁÁÁÁÁÁÁ ÁÁÁÁÁ
WITH LM90?

NO

ÁÁÁÁÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁ
· VERIFY PLC COMMUNICATIONS

ÁÁÁÁÁÁÁÁÁÁÁ
OPTION SELECTED IN LM90
SETUP (F9) MATCHES PACKAGE

ÁÁÁÁÁÁÁÁÁÁÁ
TYPE (WSI, STANDARD SERIAL,
ETHERNET)

ÁÁÁÁÁÁÁÁÁÁÁ
· VERIFY PC COMMUNICATES

ÁÁÁÁÁÁÁÁÁÁÁ
WITH ANOTHER CPU

ÁÁÁÁÁ
Á
ÁÁÁÁÁ
ÁÁÁÁÁ
11
(PAGE 12)

PAGE 11 ÁÁÁÁÁ DIAG70L

 ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ 11

ÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
Á ÁÁÁÁÁÁÁÁÁÁ
· CHECK SERIAL PORT SETTINGS
IN CPU AND LM90.

ÁÁÁÁÁ ÁÁÁÁÁÁÁ
Á ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ
12 · VERIFY LM90 GENERATES NO
ETHERNET WHICH SERIAL COMM ERRORS WHEN STARTING THE
(PAGE 13)

ÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ

COMM TYPE? LM90 PROGRAMMER PACKAGE.

ÁÁÁÁÁÁÁ WSI
ÁÁÁÁÁÁÁÁÁÁ
· CHECK CABLE CONNECTIONS

ÁÁÁÁÁÁÁÁÁÁ
FROM COMMUNICATIONS PORT
ON PC TO CONVERTER TO PLC.

ÁÁÁÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁÁÁÁ· VERIFY SNP/PARALLEL CHOICE
ÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
· VERIFY CONVERTER AND
CABLES WORK WITH ANOTHER

ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ
PLC.
IN PROG MODE & SETUP MENU

ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ
(F7 ON PROGRAMMER MENU).
· IF MULTIDROP, VERIFY CPU ID

ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ
IS SELECTED. (F7, F4).
· CHECK SERIAL PORT SETTINGS

ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ
IN CPU AND LM90 IF USING
· REMOVE ANY MOUSE DRIVER
SERIAL.
OR CONFLICTING TERMINATE–

ÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
· CHECK CABLE CONNECTION AT
WSI AND AT BTM (PARALLEL) ÁÁÁÁÁÁÁÁÁÁ
AND–STAY RESIDENT ROUTINE

ÁÁÁÁÁÁÁÁÁÁ
FROM YOUR PC.

ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ
OR CPU (DIRECT/MULTIDROP).

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

ÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
· VERIFY NO OTHER DEVICE IN
THE PC USES THE SAME ÁÁ
ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁ
Á
ADDRESS AS THE WSI (CE00–

ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁ
CFFF) OR SAME INTERRUPT.
(IRQ3 ON WMII). 13

ÁÁÁÁ
(PAGE 13)

PAGE 12 DIAG70M
 ÁÁÁÁÁ ÁÁÁÁÁ
ÁÁÁÁÁ ÁÁÁÁÁ
ÁÁÁÁÁ 12
ÁÁÁÁÁ 13

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

ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ
Á ÁÁÁÁ
· VERIFY ETHERNET CABLE IS

ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁ
ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁÁÁ ÁÁ
SOLIDLY CONNECTED TO IS SYSTEM YES PROBLEM

ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁ

ETHERNET ADAPTER. OPERATING SOLVED!
OK?

ÁÁÁÁÁÁÁÁÁÁ
· VERIFY PLC IS IN PLC LIST.
USE NETWORK UTILITY IN LM90 NO

ÁÁÁÁÁÁÁÁÁÁ
UTILITIES (F7, F1 IN MAIN MENU)

ÁÁÁÁÁÁÁÁÁÁ
TO BROWSE NETWORK FOR
PLCS.

ÁÁÁÁÁÁÁÁÁÁ
· VERIFY PROPER PLC CPU IS

ÁÁÁÁÁÁÁÁÁÁ
SELECTED IN PLC CONNECTION
ÁÁÁÁÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ
MENU (F7, F3).

ÁÁÁÁÁÁÁÁÁÁÁ
REFER TO THE FOLLOWING PAGES
”ADDITIONAL TROUBLESHOOTING

ÁÁÁÁÁÁÁÁÁÁÁ
TIPS FOR THE 90–70 PLC” FOR MORE
INFORMATION.

ÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁ
IF YOU ARE STILL UNABLE TO SOLVE
YOUR PLC PROBLEM, THEN CALL

ÁÁÁÁÁÁÁÁÁÁÁ
YOUR GE FANUC DISTRIBUTOR OR
THE GE FANUC HOTLINE FOR

ÁÁÁÁÁÁÁÁÁÁÁ
ASSISTANCE.

PAGE 13 DIAG70N