How-To Troubleshoot GE Fanuc PLC IC660BBS103 Genius Block Training Proficy Software Tutorial

Introduction: GE Fanuc IC690BBS103 Genius Block Troubleshooting Guide

This troubleshooting guide is a test of a GE Fanuc IC660BBS103 Genius Block.

Step 1: The Setup

You are going to be testing a IC660BBS103 and what you are going to do with this test is make sure the handheld monitor is able to program the block through this port, which is an IC660HHM501 Hand-held monitor. (see below)

IC660HHM501-handheld-monitor

The next thing is the Serial Port information 1 and 2. This is connected to a Genius bus controller
IC693BEM331 attached to a IC693CHS397 5-Slot Rack. (see below) And this is being powered by an IC693PWR330. The controller illustrated here is an IC693CPU374.

Below you will be testing the inputs and the outputs, and making sure they are working and learning how to configure them.

serial-port-genius-bus

Step 2: Setting Up in Proficy Machine Edition

So, to begin with, in Proficy Machine Edition, the same information that is stored in the block is how your IC693BEM331 should be configured. (see below)

proficy-machine-edition-setup

So that is the first thing you will need to do, and that is the reason you have an I/O Enabled light LED on. (see image)

IO-enabled-LED-ON

So the information stored on here, the physical setup, matches Proficy Machine Edition. And to illustrate that this port is working, you are going to shut off the CPU so that you can see the I/O Enabled light go off and then flick it back on.

What that tells you is that the Genius bus controller and the Genius block are talking through the serial port so you can be satisfied with that.

There is also information that is going to be transferred from and to this Genius block through the Proficy Machine Edition in your input and output tables of which more on this topic below.

The handheld monitor, IC660HHM501, (see image in Step 1 above) you are going to turn that on, select OK. For the purpose of this test, the Genius blocks are being kept at their factory settings and configurations. However, for your purposes, you would likely keep your configurations the same. You do not need to change your configurations to what is illustrated here.

So, using the handheld monitor, select F3 for Configuration and F1 for Block ID. In this illustration the handheld monitor is being set up as block number 1, which matches Proficy Machine Edition and 8 inputs for the first part of the test. And that’s the reason the light is on.

So make sure you have things matching to get that light on.

Step 3: Testing Inputs & Outputs

So the next thing you are going to test is the inputs and outputs. You are going to go to Home, F2 to Analyze, F1 to Monitor Block.

Note that in this illustration the hot and neutral leads are connected as suggested on the Genius block door. H for hot and N for neutral. (see below)

testing-inputs-outputs

So you should have this wiring set up and you should also have a probe connected to your hot lead, which means this is live. It has 120 AC and it will shock you. Do not touch it and definitely do not touch your hot lead to any of your Neutrals. You will create a short and likely destroy the Genius block and any other circuitry in the path previous to this wiring.

Now note that there are three ways to see the inputs being activated. The first way you can see it is if you touch lead 1 and the LED comes on. Now this doesn’t exactly mean that the input is working. The other two ways you can see if the input is working are: 1) you can open up Proficy Machine Edition and look at your discreet inputs and make sure that the channels changing from 0 to a 1. 2) Or you can hold the hand-held monitor as illustrated here and this is the preferred method. (see below)

Step 4: Operating the Handheld Monitor for this Test

testing-wtih-handheld-monitor

Analyzing Inputs

Again, select F2 to Analyze, and F1 to Monitor Block. This is going to show you inputs 1 through 8, and the 0’s are the current status of that bit. Zero means they are off, 1 means they are on. So you will go ahead and touch your hot lead to 1, and it turns to a 1. Two, 0 turns to a one and inputs 1-8 turn from a 0 to a 1. You should be very careful with where you are putting this probe.

OK, all of my inputs should be working and you can see that in Proficy Machine Edition.

Now you are going to go back Home, Configuration F3, F1 Program Block ID. And you are going to reset this as an output. You are going to do that by hitting F1 for Reference, Enter, and you are going to put a 1 in and Enter. Next you are going to toggle using F2. it will be a Q represents output and you are going to hit F3 which is Enter. Now it will configuring the block and when that is done you will be able to set up to do output.

Analyzing Outputs

You are going to go to Home, F2 for Analyze, F2 to control the different outputs. Then you are going to use the F1 and F2 key. F2 turns the output on. There is an underline under the zero, that means that it is on. Then you are going to hit F1 to go to the next output, F2 turn it on. F1 for the next output, F2 to turn it on, and so on. You will want to do that with all the channels through 8 and you’ll see LEDs 1 through 8 are on telling you that the outputs are on. , it doesn’t necessarily mean they are working but this is part of the test.

Now note that there is a utility light (see below), a drop light underneath this test that you will see turn on and off as you touch each hot lead to each corresponding terminal.

utility-light-test

The neutral lead from that light is connected to the very last terminal, terminal 22 which is a neutral lead. So you will pick up your neutral and get the hot. So as you touch this from 1 through 8, you should get the light coming on. And that is half the test.

Step 5: Confirming Outputs are Really Off

Now the other half of the test is to make sure that nothing is wrong when you shut off the outputs and to make sure they are really off. So you are going to use F4 to Release F1 to go to the next output, F4 Release, next output, F4 Release, and so on. You keep touching these two until all of your outputs are off. So they are all in the off state or so you hope.

Now before you touch your lead, the hot lead from your drop light to the outputs, you want to test again to make sure that your light is still working. You never know. So you touch your hot and the light comes on and so you know you have a good working light and you know you won’t get any false readings. So you now touch the probe to 1 though 8 to confirm that they are all truly off and if they are you can be satisfied that this is a good working block.

Step 6: Additional Steps if Necessary

As far as troubleshooting, the common problem that you normally would see with this would be:

  • an output that doesn’t truly stay off, which would be a circuitry problem, or
  • the hand-held monitor is unable to store information to the Genius block to configure and program it, or
  • if the serial port is not working. Perhaps you go to touch an input and it is not working or the light stays on but it is not giving any indication that there in an input working and may give you an error in the hand-held monitor called “failed switch”.

If you find these or any other problems with your IC660BBS103 Genius Block see links to help, parts and service below.