How-to Troubleshoot & Test IC660BBA020 Genius Block GE Fanuc PLC Training Tutorial & Troubleshooting

Introduction: GE Fanuc Genius Block IC660BBA020 Troubleshooting Guide

This troubleshooting guide is a test of the GE Fanuc Genius Block IC660BBA020, connected to an IC693BEM331, that is a bus controller (see image):

Bus-Controller

and there is an IC693CPU374 CPU, and a IC693PWR330 Power Supply. These are connected in a IC693CHS397 5-Slot Rack.

Step 1: The Purpose of this Test

So these devices mentioned above are all the peripheral devices that you are going to be using currently. Also illustrated and in use here is Proficy Machine Edition Software.

And what you are going to do is configure the software with the CPU374 and BEM331 to work with a 4-input, 2-output Genius Block (Analog Genius Block). During this test you are going to learn how to check for the I/O Enabled light coming from the CPU and BEM. How to use the hand-held monitor and configure the device. How this should be powered up and the physical inputs and outputs of this device and how to test them.

Step 2: The Setup

Currently, this is hooked to a 24-volt power supply, as you can see coming in below. That is DC Plus. DC Minus, and then Serial 1, Serial 2, Shield In and Shield Out. This is all going to and from the BEM331. Also illustrated is a monitor plugged in here so that you can communicate with the device. (see below)

the-setup

First thing you have to make sure the device is configured. First you need to know that
typically from the factory that the baud rate that it communicates at is 153.6k Standard
(That’s ST).

Genius

So you are going to click OK. It’s working. Next thing you want to do is go into your configuration. F3 and program your block ID. Then F1. As illustrated here, in this case, the block number matches what is displayed in Proficy Machine Edition.

Step 3: Configuration for the Tests

And just for a simple test, you are going to call it Block #1. You are going to hit Next, and you are going to check your baud rate, which is at standard. Tha’ts very important. You are going to go back to Configuration, F2, configure block this time. This is set to the factory settings, so you are going to go through these quickly: Report Fault- Input Input Input Input Output Output and Yes. You want to be able to report faults if there is an issue.

Here is something important: You want to set the range in which its reading or giving power. So, in this illustration it is set currently for 0-10 Volts. So you are going to do a voltage test first, and then a mili amp test next.

So you hit next, your scaling is preset. If you are checking to see if your block is working its recommended that you leave your scaling the way it is, the way it has been working in your factory or plant, or whatever application you are using it for.

In this illustration it is automatically set to the factory standards. Next, hit filter, 128 mili-seconds. Alarm Input: the high and low alarm factory standard is -32,767 to a high of 32,767. That is the alarm range and again, that is factory standard. If you have something different, that is fine.

Out 1 to fault 0. BSM Present, again factory standard, no. CPU redundancy, no central redundancy. Configuration protect, in this illustration it is off for the sake that changes can be made, although you may need to keep it in protected mode; but illustrated here  is currently disabled, so do not go by that.

Step 4: Analyzing the Block

Next thing is you want to analyze is the block. So you are going to go to F2. Again, note that illustrated here is a set up for 0-10 Volts, so what you want to do is press F1- monitor the block. And this gives you your two inputs. Input #1 and Input #2. Then if you toggle this arrow with F1, it shows you your other 2 inputs: input #3 and input #4.

So you are going to start with 1 and 2. Now you will set up a 3 volt battery in order to get a reading. What is illustrated here is just one of the memory batteries.

memory battery

You should have the red and black for positive and negative (see above). And you are going to take this away for just a second so you can see. What I want to do is press these leads against In and Return.(see below)

leads-against-in-and-return

And you are looking for a reading, it is going to be a different reading depending on what your value of setting for scaling is, but you do want to see a reading and if all the values of all your settings are the same, then all your readings should be the same.

Another tip is, make sure that all your screws are screwed down. They have to be screwed down tightly because there will be times where if a screw is loose, and it is not making contact, you go to press and get a read of value, you are not going to get anything because there is a loose connection.

So, now you are going to go ahead and press on this and what you want to do is take a look at the reading in you monitor. So, again, In and Return, and you are looking at Input #1. If you look at the monitor, it is 6,179. Now all your scanning is the same for every channel. So you are looking for a similar figure for Input #2. 6,179 is what about what you should get for Input #2. So you have two channels that are reading the same. That is a good sign. Continuing on: channel 3 is 6,172, still very good. Channel 4 is 6,172. Excellent! So that is good.

Step 5: Analyzing the Output

Next thing you want to check, since you are on voltage and you are on the monitor, is the Output. So you are going to go back one, click Menu, and F2 Monitor, this is Input 1, Input 2, 3, 4. Output 1. Now you can force value in there. If you remember, your high range value was 32k. So what you are going to do is Force F2, 32K for a round figure and you are going to click Enter. Now that is forced into the system. Next you are going to Output 2, same thing: F2 Forced 32K, F3 Enter, and now that value is in there. You are going to go back to one, and here is what you are going to do. You have a multimeter that you use in a test lab (see below).

And I currently got it set for voltage DC.

multimeter-set-for-voltage-DC

And as you recall the block has been set for 0-10 volts, DC every channel. What you want to do is connect these two leads to where it says on the block “Common Voltage output 1” and then the next one you want to check is common, your black lead or negative lead and your red positive lead goes to voltage output 2.

Again, black is on common, red or positive is on voltage out and the results will be visible. So, Common
voltage out, and I am looking for a value of about 10 volts.(see below)

voltage-out

The next thing you want to do is on the hand-held monitor, you are going to click Release, which is F4. What you are doing there is you are trying to make sure that you are able to release that value. And you should get a reading of 0, and if you do, that’s great.

Then the next input, 10 volts DC, you are going to hit Release. You released the value and now you are back down to zero. So that is important to make sure that the output can be on or off whatever value that you have put in.

Step 6: Doing the Milliamps Test

Next thing you want to quickly test here is you want to do all of the same thing with milliamps. Before you go any further take note that the I/O Enable light is on. And thats because youI have the IC693BEM331 set to this being a 4 Input 2 Output Analog Block, and it is configured as block number 1.(see below)

And once you’ve got the CPU into Run Mode and you can see it’s enabled which you can tell by the LED. What this also means is that this port is communicating, it is working properly and if you want to you can force the inputs and outputs off or on using Proficy Machine Edition.

light is set

Back to the hand-held monitor, this is an IC660HHM501 hand-held monitor (see below).

monitor

Go to Configuration, F2 Configure block. Here’s your range: You are going to toggle 1,2, 4 to 20 mili amp. You have to do that with all of the inputs and outputs, and toggle using F1 throughout all the channels. These should have all been entered, so you are going to go back to home, F2, F1 monitor block.

Now you have a 4 to 20 milliamp generator. So this generates the very small milliamp value. You have 2 probes that you are going to use to connect to your inputs. You are going to be using the same inputs and outputs as was used for voltage. They connect through the same area. So, for the inputs, input and return 1, 2, 3 and 4 and when you get to the outputs, it is a little bit different. You are going to be touching I-plus an I-minus, and I-plus and I-minus to the corresponding outputs.

So, right now you can try touching the leads to the input and return of input #1. And it should be giving you a value of about 24,522. Input and Return #2, 24,522, and that is excellent. You are going to toggle using F1 to your Inputs 3 and 4. 24,536, still definitely in the range. And input #4, 24,536, that is good; these are very consistent numbers. That is what we want to see. Again, illustrated here is factory scaling, please keep that in mind.

Next thing is you want to check your outputs. So, go back to the hand-held monitor. Go to Home, Analyze, Monitor, F2, and using the F1 key you go over to 1, 2, 3, 4, Output #1, same thing you are going to put in that 32k value by hitting force F2, 32,000, ENTER. Force 32,000, ENTER.

Now you have values in there and go back to #1 first. You are going to take your multi-meter again, switch it to milliamps reading. DC. Ok, as a reminder, Output for milliamp  is I-plus and I-negative. You want to touch the probes to those terminals. First you are going to test Output 1. You are looking for a value of about 20 milliamps.

The next thing you are going to do is hit Release to make sure you can shut that off and .005 or .001 is a common number when it is in the off position. You are going to go to output #2, and it is 21 mili-amp. You are going to release that and make sure you can get back to it. Zero figure or as close as we can get to it, and if it is, that’s excellent.

Step 7: Additional Steps if Necessary

So that concludes and entire test of a BBA020. If for any reason you go to power it up and do not have any lights on at all, obviously there is something wrong with the Genius Block. If that’s the case for you please see links to help, parts and service below.