IC660BBA104 How-to Troubleshoot Test with Programmer Genius Block I/O – GE Fanuc PLC Training

Introduction: GE Fanuc IC660BBA104 Genius Block Troubleshooting Guide

This troubleshooting guide is a test of a GE Fanuc IC660BBA104 Genius Block and what you are going to do is test all the functions and features of this block.

Step 1: The Setup

First is the hand-held monitor, which is the IC660HHM501 (see below).



The port should be working and able to configure the device. The Serial Port is connected to the Genius Bus Controller. That part number for that is IC693BEM331 and that, in this illustration, is attached to an IC693CHS397 5 Slot Rack which is being powered by an IC693PWR330 Power Supply and being controlled by an IC693CPU374 processor.

Step 2: Setting Up Proficy Machine Edition

So those are the parts in this setup and that you should have working in this test. Also, you should have the block powered up right now.


First, what you are going to do is go to Proficy Machine Edition (see above) and make sure you have the same configuration in the Genius Block as you do coming from the Genius Bus Controller. The reason you are going to do that is because you want to make sure that the port works and that it is communicating.

As you will see at this point, the I/O Enabled LED is/should be off. So your test here is to try to get that on by making sure your configuration is the same as the Genius Block when the CPU is in Run Mode. And when the CPU is in Run Mode it should turn on the Genius Block I/O Enabled light.

IO Enabled Light ON

OK, so now the I/O Enabled light is on (see above) and you are going to see how that is done using the hand-held Genius programmer.

In this illustration the factory setting standards 153.6K standard baud rate are being used/illustrated, that should be OK and pass a self diagnostic. Note that you do not need to change any of your settings if you are testing a block that is already set to work in the field. This is just an illustration of how to do a test to make sure these things are working. Now go to F3 Configuration, F1 Program Block ID. And as you can see here Block #1.  A block is F2, and you are going to use block number 1 and hit Enter F3, and that is configured and the light is on. And so this is how you get to having the I/O Enabled light on.

Next go back to Home, Configuration F3, F2 Configure Block, Report Faults Yes. You want all channels active because you are going to test all channels. Your scaling is all set to factory standard. The reason you do that is that you want to make sure that your readings are all the same. If channels 1 through 4 are all set exactly the same, then my readings should be the same.

The rest, ie: your high and low alarm is all factory settings. BSM Present, No. No central redundancy. And your Configuration Protection is disabled. If yours is set then just leave the protection enabled to protect it.

Step 3: Analyzing Input Channels

So the next thing you want to do is analyze your input channels.  Always do input channels first. Now hit F2 for Analyze, F1 for Monitor Block. And now you have your two digits that you are going to see change in just a minute.(see below)


You should also have a 4 to 20 mili-amp generator and you are going to be using two probe leads (see below) that are going to touch the inputs to get these readings.


Now you’ll use/see 4 to 20 milliamp because this Genius Block is a current source reading analog block For input 1, which is input and common. Now you should be in 18 and 19 which is terminal 1. You are in input 1 touching terminals 18 and 19. Input 2 touching terminals input and common which is 22 and 23.

Now you are going to use the F1 button to toggle over to inputs 3 and 4 so you can test those. Input number 3 is terminals 26 and 27 and input number 4 is terminals 30 and 31. All of the readings in this illustration were just about 20 thousand or just 20. And they are/should be almost exactly the same. and that is what you are looking for. You want all of the readings to be the same because they are all configured the same.

So, those channels are good.

Step 4: Getting the Outputs “On”, Checking Power Outputs

Now go back to Home, F2 for Analyze, F2 for Monitor and Control, and you are going to toggle using F1 to go past input 1 through 4, and now you are in the output. Now you are going to put in a figure of force F2. 20,000, F3 Enter, and then F1 to toggle over to output number 2. Force F2, 20,000, F3 Enter. And then you are going to use F1 to toggle over again to Output #1.

Now that those outputs are on, you need to check to see if they are giving the right amount of power. In order to do that i will be using a multimeter (see below), another test fixture, and you are going to set it for reading milliamp DC. Illustrated here is a Fluke multimeter.



So you are going to turn this to milliamp and toggle this to DC (see above)

Next you will probe terminals, as detailed below, to get information. On the top of the Genius Block it is going to read out and return. But on the terminal side, the actual terminalsyou want to be touching terminals 11 and 12 for output number 1.

What you are going to do is shut off or release the 20,000 figure by pressing F4 Release on your Genius handheld monitor. And what you are trying to do here is make sure that you are able to shut it off because yes, it was on, but you want to be sure that when you are asking it not to be on, that it is able to shut off.

Back to terminals 11 and 12, you have or should have a reading of 0.001. And that’s good. Output number 2, out and return. Terminals are 14 and 15, you should have an accurate reading of 21. Then you are going to press release, F1 to toggle over to output number 2, F4 to Release.

Your hand-held monitor, the IC660HHM501 gives you or should give you a reading of 0. So you should have a reading of 0 when you probe 4 and 5, indicating you are able to shut those off.

Step 5: Additional Steps if Necessary

Now for your Genius Block, for your test purposes, if you powered up your IC660BBA104 and you were unable to get any lights on and is unable to power itself up, or the hand-held monitor communicating with the devices is unable to store information, or if inputs or outputs are not working properly, then there is a problem with the Block. If this is the case with you, see links to help, past and service below.