Future Programmable Logic Controllers to Feature New Layers of Security

Cyber security has been a hot topic since the Stuxnet worm incident occurred in 2010, sparking debate among those involved in automation architecture and the future of its overall security landscape.

Not only did engineers begin to recognize flaws within their cyber security arrangements, they acknowledged the myriad of reasons hackers may want to take down an entire plant.

Vulnerable control systems could potentially lead to power plants being shut down, or road, rail and air traffic management compromised, not to mention drinking water becoming contaminated.

At the moment, larger control systems have many points with potential for unauthorized access, requiring layers of protection to be built into the system at the network, hardware and software levels.

As a result, future programmable logic controllers (PLCs) will include multiple embedded features such as hardware security keys and multi-layer password structures to prevent programs from being opened or edited on unapproved personal computers that have not been ‘bound’ to the security key.

PLC’s that do not have a registered security key will not be capable of executed certain programs thanks to embedded technologies and intellectual property being protected from compromise.

Unauthorized access, hacking or implantation of malware, will be much more difficult with future programmable logic controllers as a result of an IP filter that can be used to register the IP addresses of devices approved to access each PLC.

Of course, the new layers of security will need to be continuously worked in order to find the best solution for end users.

While maximum security is important, so is ease of operation, meaning control engineers will employ a holistic view of security that needs to be taken, considering all aspects of the operation.

How To Troubleshoot GE Fanuc 9070 Processor, Part IC697CPX782

Introduction: GE Fanuc IC697CPX782 Troubleshooting Guide

This troubleshooting guide is a simple test of the 9070 processor, part number IC697CPX782.

Step 1: Power Up, Connect Cable & Verify Port Light Blinking

Go ahead and power it up: The processor is in an IC697CHS750 rack, it is a five slot rack, it is empty, and it is being powered by a IC697PWR711 power supply.

Connect using a AS693232SNP cable (see image below) which has LEDs that will blink showing the communication. If you’ve plugged into Port 3, for example, you’ll be looking at the Port 3 LED blinking to make sure that it is working.

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If you are unable to connect then there is a problem with your processor (CPX782) and this is something that is commonly repaired at PDF Supply or provided via the exchange program that ships used parts, new parts, and re-manufactured parts quickly to you.

Step 2: Clear Controller & I/O Faults, Download & Run Processor

Next clear any controller faults or I/O faults. You do NOT want to clear any other information from your processor, you do NOT want to clear all memory or any hardware configuration, logic, or anything like that. Just controller logic and I/O fault. Once you’ve done check to make sure that the slots are empty.

Next, go ahead and download and run. Only download your hardware configuration and logic, nothing else, nothing to the permanent flash memory. Use your Proficy* Machine Edition GE Software in the background here and once this build is completed, it will allow you to get the processor into run mode.

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Step 3: Check LED Lights

Note the LED lights in the image below. The first one (on top) is processor, second one is RUN or RUN mode and the third is I/O enabled or Inputs Outputs enabled.

There’s also a toggle switch that you can use right below the LED’s to turn on and off so you want to make sure that that’s working. Second, test the memory protect switch to make sure it works. Now that you’ve turned that to the ON position see that you have a solid memory protect switch. (second image below).

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Step 4: Check To See if Communication Ports are Communicating

Next is to check the 2 ports to see that they are communicating. If you used Port 3 try plugging into Port 2, that’ll be the middle LED on the right side. You’ll see that it’s blinking and communicating so you’ll now Port 2 is good too.

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Step 5: Check To See If Cable IC693CBL316 is Communicating in Port 1

Lastly, check cable IC693CBL316. It looks like a phone jack on one side and on the other side is a serial connection that’s going to go to your computer. So, go ahead and plug that in on the back of the computer; you should have communication out of Port #1 blinking LED.

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Step 6: Now that the Test is Complete, is your Processor Still Falling Out of Run Mode?

That’s a complete test! If you still feel like the processor may not working correctly you might want to leave it running overnight or over a weekend. What you’re trying to do is make sure the processor stays in run mode over a few days on its own.

If it doesn’t, then go back into your Proficy Machine Edition, go to the top menu bar target, hit the drop down and then there’s Diagnostic. Open the diagnostics table and it should tell you what happened and why it fell out of run mode.

If you still can’t figure it out, this is something that we commonly look at.

Easy Troubleshooting Guide for GE Fanuc IC697CGR772

Introduction: GE Fanuc 90-70 Central Processor IC697CGR772

This troubleshooting guide is a test of the 90-70 central processor, part number IC697CGR772. No need to consider the revision letters, this test will be the same for all of them. The door is removed so you can better see everything and we’re using a IC697CHS750 rack.

Step 1: Power up using a IC697PWR711 Power Supply

When you power up the LED should be blinking at first and then turn solid. If it’s only blinking and you do not get a solid light, then there’s obviously an immediate problem with your processor.

GE Fanuc Troubleshooting Guide

Step 2: Connect the AS693SNP232 Cable to Port 3

Now that it’s powered up, connect up to Port 3 using the AS693SNP232 cable. Plug that in and confirm that the bottom right hand LED, Port #3, is blinking; this is a test of Port 3 as well. If it’s blinking we know it’s working, and also we know it’s communicating and talking.

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Step 3: Clear Controller Fault & IO Fault Table & Get Processor Into Run Mode

Now that that’s connected you’re going to go to target >> online commands and clear controller fault and I/O fault table, the bottom two selections in the clear memory category. You’re then going to hit OK. You DO NOT want to hit ALL MEMORY or any of your saved information, just those two faults. Note: In this illustration we’re using Proficy* Machine Edition GE software to control this processor.

Now that you’re done that, you’re going to hit the Download and Run icon which is the download information and run button in one icon. You’re going to download the hardware Configuration and Logic. You are not going to write anything to the flash memory or initial force values. This is just a simple test. Your goal here is to get the processor here into run mode.

Step 4: Complete Building & Confirm LEDs On

After a successful build, if you look up to right hand corner of the processor the first light again is the OK light for the Processor. Second light, middle light left side, is the Run Enabled. And the third LED in the bottom left, is the I/O enabled. Input Output Enabled.

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Step 5: Use 3-Part Switch to Test 3 LED lights

The first setting is all the way up and all 3 LED lights are on with Processor, Run and I/O enabled. The second setting, in the middle, is I/O disabled. Then down one more, the third setting, is run disabled. If the LEDs behave in this manner, the switch is working.

Step 6: Test Memory Protect Switch

The next switch you want to test is your Memory Protect switch which is located on the TOP of your processor, above the LED lights. When you turn this on you are looking for this LED to turn on and this tells you that the memory protect feature is working.

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Step 7: Check to see that Port 2 is working

The last thing you want to do is test the three ports. You know Port 3 is working so you’re going to go ahead and unplug this and go to Port 2. If you have communication in Port 2 you can be confident it is working.

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Step 8: Check to see that Port 1 is working

The last step involves a special cable to plug into Port #1. This cable is the IC693CBL316 and appears to be like a phone jack on one side and the other side you can’t see has a serial port connection to go into your computer.

Plug that in, and then plug into the computer side and check to see if the top right LED is blinking and Port 1 is communicating.

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Step 9: Additional Steps To Take if Problems Persists

Now you know that your GE Fanuc IC697CGR772 central processor is working properly and some of the features and functions about this processor and it’s in run mode.

However, if you feel that this processor has a problem its a good idea to leave it running over night or over a weekend or for a few days. You hope to find that the processor stays in run mode, that usually indicates that its o.k.

If it falls out of run mode, using your Proficy* Machine Edition software, go to the top menu bar: Target >> Diagnostics towards the bottom of that selection. Then, your diagnostics table will open up and you can see why your processor fell out of run mode.

If that still doesn’t work, we offer repair services and you can reach us at www.pdfsupply.com with all the information.

IC697ALG320: Manual Troubleshooting Tutorial GE Fanuc PLC Training Series 90-70 ALG

This video is a tutorial for training and troubleshooting purposes using the 9070 IC697ALG320 and GE Proficy* Machine Edition Software.

Link to IC697ALG320 Manual PDF: http://www.pdfsupply.com/pdfs/ic697alg320.pdf

Click here for more information on the IC697ALG320: http://www.pdfsupply.com/automation/ge-fanuc/series-90-70/IC697ALG320

IC697ALG230: How-to Troubleshoot GE Fanuc PLC Programming 90-70 Analog Module

This video is a tutorial for training and troubleshooting purposes using the 9070 ALG and GE Proficy* Machine Edition Software.

Click here for more information on the IC697ALG230: http://www.pdfsupply.com/automation/ge-fanuc/series-90-70/IC697ALG230

IC693CPU331: How To Troubleshoot GE Fanuc PLC Training Series 90-30 CPU

This video is a tutorial for training and troubleshooting purposes using the IC693CPU331 and GE Proficy* Machine Edition Software.

Click here for more information on the IC693CPU331: http://www.pdfsupply.com/automation/ge-fanuc/series-90-30/IC693CPU331

IC693CPU363: How To Troubleshoot & Test GE Fanuc PLC Training Series 90-30 CPU

This video is a tutorial for training and troubleshooting purposes using the CPU363 and GE Proficy* Machine Edition Software.

Click here for more information on the IC693CPU363: http://www.pdfsupply.com/automation/ge-fanuc/series-90-30/IC693CPU363

IC693CPU374: GE Fanuc PLC Programming Proficy Machine Edition Series 90-30 CPU

This video is a tutorial for training and troubleshooting purposes using the CPU374 and Machine Proficy Software.


Click here for more information on the IC693CPU374: http://www.pdfsupply.com/automation/ge-fanuc/series-90-30/IC693CPU374

IC693CPU374 is a GE Fanuc Series 90-30 single slot CPU that has a processor speed of 133MHz. The GE Fanuc 90-30 IC693CPU374/IC693CPU374 Plus is a single slot CPU that has a processor speed of 133 MHz and has user memory of 240KB.