IC660BBA021 How-to Test & Troubleshoot GE Fanuc PLC Training with Genius Block & Hand-Held Monitor

Introduction: GE Fanuc IC660BBA021 Genius Block Troubleshooting Guide

This troubleshooting guide is a test of a GE Fanuc IC660BBA021 Genius Block which is a resistance temperature detector, input only and it has 6 inputs, as you can see in the wiring diagram.

Step 1: The Setup

As illustrated below it is connected to a 24 volt power supply, see positive and negative wires And a serial cable, serial 1, serial 2, shield in and shield out going to and from a ICC660 IC693BEM331 Bus Controller.

24-volt-power-supply2

It is also in a rack with an IC693CPU374 and an IC693PWR330. And those are all in a IC693CHS397 5-Slot Rack. So those are all the devices you will be using to run this test.

Step 2: Setup of Proficy Machine Edition

Also illustrated is Proficy Machine Edition Software to run the BEM. In the Proficy Machine Edition, you should have the BEM331 using block #1 or SBA #1. and you should have it set for 6 Analog input or 6Ai. Do not go looking for RTD, you wont find it. It’s just 6 Analog Input as the reading. Its currently in Run Mode and you can tell because the I/O is enabled.

So first thing, if the serial port here is working properly and you have your CPU in Run Mode and all the things configured into your block match what is in Proficy Machine Edition, you should be able to have an I/O enabled LED on. This is very important. Without that, that would mean the serial port is not working.

So, if you do have a problem, you will not be able to follow us on this test. There is something that is wrong with the device and if this is the case for you please see links to help, parts and service at the bottom of this page.

Step 2: Review of Physical Configuration

Ok, so in the test, you are going to go over the physical configuration using the hand-held monitor. Illustrated here is an IC660HHM501. (see below)

IC660HHM501

And what you are going to do is go through the basic configurations. Now if you already have this block set up working in your plant, there is no need to change your configurations, you can still follow the test. It’s recommended that you do not re-configure. So just for simplicity purposes, in this illustration there is a specific setup as follows: Go to Configuration F3, Program Block Identification F1. It is just set as block #1. Again, Proficy Machine Edition has it as block #1 also, it is easy to follow. And then you click next just to see the speed at which is it communicating at, 153.6K Standard. And that is the program and the active rate that it is communicating at.

communicating

That is important. If those do not match, you can have a big problem communicating and you will get lost.

Step 3: Hand Held Monitor Factory Settings

So, go back to Home, F3 configuration. F2 Configure Block. You want to go over settings and you want to report a fault if there is a fault, so you will toggle all items to yes. All the channels are active, input 1 through 6 are all yes. This is being measured in ohms. Platinum. Again this is the factory settings. In this illustration it is set at 100 ohms and i have a test resistor here. (see below)

test-resistor

This test resistor is 100 ohms and technically if you ohm it out with a multi-meter it is only 105 or 106, but it is basically 100 Ohms. You will see your high and low alarms and in this illustration they are set to the factory standards. Filter is 400 milliseconds. Configuration protect is disabled to make changes if needed.  If yours needs to be protected, please leave it enabled.

So go back to Home, Analyze, Monitor Block F1. And there will be values that have been established in there and those will change when you touch the resistor to the corresponding terminals. So what you are going to do is touch the terminals in the same order as illustrated here and the information in the monitor will change accordingly.

Again, illustrated here is a 100 Ohm Resistor, but it is really more like 105 Ohms, to be specific. So you are going to touch it to terminals 9 and 10. You should have a reading of about 106.2 and that is very very good, it is pretty much exactly what this resistor is. Again that is input #1.

Step 4: Checking Terminal Screws

Another tip is to make sure the screws that you are touching are screwed all the way down. If they are loose it is very likely, almost certain, you are going to get an incorrect reading. Make sure the terminals are screwed down.

Next is channel #2, touching numbers 13 and 14, and you should be getting a very consistent number if you hold these leads down. You should get something like 106.1 that is excellent. Then you are going to toggle over using the F1 button so you can see channels or inputs 3 and 4.

Input 3 you are going to be touching 17 and 18, and you should get something like 105.8 or 105.7, that is excellent. Channel 4, you are going to be touching numbers 21 and 22, and it should be excellent, ie: about 105.8. 5 and 6 and you are touching terminals 25 and 26 for input 5. And for input 6, touching terminals 29 and 30.

So if you are getting these readings. Then this is a good test and this shows you that all of your scaling is set to be the same for every channel. And all the readings that you get should be  almost completely identical down to a decimal point. And that tells you that the reading ability of this analog block is nearly perfect.

Step 5: Additional Steps if Necessary

So, this block, in addition to the fact that the serial port is communicating is working perfectly.

However, if you get inconsistent readings or if you do not get any readings at all, or zero communications or no lights that come on, or you cannot follow using the IC660HHM501 Hand-held monitor . . . anyone of those things is definitely a major problem with your block and it will not work properly in a functioning situation. If this is the case for you, please see links to help, parts and service below.