GE Fanuc Genius I/O Troubleshooting

Troubleshooting Guide for the GE Genius I/O PLC System.

Genius I/O blocks are intelligent, self-contained, configurable I/O modules. A Genius I/O block is made of cast aluminum, and weighs about 4 pounds (1.8 Kg). Block size is approximately 9" (22 cm) x 4" (10 cm) x 3" (9 cm).

For further reading and reference:

• Environmental specifications and related details are attached in Appendix 1.
• Types of Genius Blocks along with their ordering part numbers have been stored at Appendix 2.

Abbreviations

GE Fanuc Genius I/O Troubleshooting

STEP 1 - Basic Diagnostics via LED Indications

GE Fanuc Genius I/O Troubleshooting

A Genius Block has two LEDs that indicate vital diagnostic information regarding the Block and the field circuits that are connected to it.

• 'Unit OK' LED
• 'I/O Enabled' LED
• At startup, both LEDs shall be powered ON (Steady RED Light).

Details concerning these LEDs are indicated in the subsequent sub-sections.

STEP 2 - Healthy Genius Block

GE Fanuc Genius I/O Troubleshooting

A Healthy Genius Block shall have both the 'Unit OK' & 'I/O Enabled LEDs in the Steady ON state (RED Light).

STEP 3 - Genius Block with Bus Fault

GE Fanuc Genius I/O Troubleshooting

A Genius Block that does not communicate with the Genius Bus Controller (in other words with the PLC) shall exhibit the following characteristics:

• 'Unit OK' LED - Steady ON State
• 'I/O Enabled' LED - OFF State

Corrective Action

• Cycle Power to the GBC.
• Verify CPU is RUN/ENABLED.
• Verify Genius Bus Connection is intact and terminated properly.
• Verify Baud rate of the GBC and all Genius Blocks (usually indicated on the blocks as a sticker) are the same.

STEP 4 - Genius Block with Forced Channel(s)

GE Fanuc Genius I/O Troubleshooting

A Genius Block that has its channel(s) forced from either the program or the HHM shall exhibit the following characteristics:

• 'Unit OK' LED - Steady ON State
• 'I/O Enabled' LED - Blinking ON State

STEP 5 - Corrective Action for Genius Block with Forced Channel(s)

GE Fanuc Genius I/O Troubleshooting

STEP 6 - Genius Block with Channel Fault

GE Fanuc Genius I/O Troubleshooting

A Genius Block that has channel(s) fault shall exhibit the following characteristics:

• 'Unit OK' LED - Blinking ON State
• 'I/O Enabled' LED - Steady ON State

STEP 7 - Corrective Action for Genius Block with Channel Fault

GE Fanuc Genius I/O Troubleshooting

STEP 8 - Genius Blocks LED Status Table

GE Fanuc Genius I/O Troubleshooting

The table below is a comprehensive list of all diagnostics that can be derived by simply observing the LED status of Genius Blocks.

STEP 9 - Additional Genius Blocks Information

GE Fanuc Genius I/O Troubleshooting

Environmental Specifications

Genius I/O blocks meet the following specifications for vibration, noise, and ambient temperature.

Vibration

Genius I/O blocks are compact and sturdy; they perform well in conditions where vibration is a factor. All Genius I/O block designs are vibration-tested (according to Mil-Std 810C and IEC 68-2-6) to meet the following specifications:

• 5 to 10 Hz .200 in displacement (peak to peak)
• 10 to 200 Hz at 1 g
• Shock: 15G

Noise

Genius I/O blocks are resistant to noise levels found in most industrial applications when installed according to accepted industry practices. This includes proper separation of wiring by voltage and power levels.

Blocks are tested to the following noise specifications:

• Radiated: FCC part 15, section J, class A, Computing Devices
• Received: NEMA ICS 2-230

ANSI/IEEE C37.90 (Relay and relay systems associated with Electrical Power Apparatus)

Temperature

I/O blocks operate reliably in temperatures up to 60C (140F). Temperatures are measured adjacent to the block at the bottom of the Electronics Assembly. Between 35C and 65C (95-149F) each 10C reduction in the ambient temperature increases the electronics Mean Time Between Failures by a factor of two.

STEP 10 - Additional Support Options

GE Fanuc Genius I/O Troubleshooting

We hope our troubleshooting guide has helped you track down the problem in your PLC system.

Should you to need to repair or replace any parts for your GE Fanuc Genius I/O, please contact us at 1-800-360-6802 or visit our website at www.pdfsupply.com

We offer:

• Repair
• Repair with Exchange Credit
• Remanufactured - 3 year PDF Supply warranty