IC693MDL940 & IC693MDL645 GE Fanuc 90-30 How-to Troubleshoot User Manual Proficy Programming

Introduction: GE Fanuc IC693MDL940 Relay Output Troubleshooting Guide

This troubleshooting guide is a test of a GE Fanuc IC693MDL940 discrete output, 16 channel, and an IC693MDL645 discrete input, 16 channel. Both of these modules are 24 volt. The MDL645 where if you happen to have an MDL646 is positive, negative logic so it doesn’t matter whether you’re using positive or negative polarities. What you’re going to do is learn how to test these MDL modules and what to look for in a trouble shooting situations and how to work with it in Proficy Machine Edition.

Step 1: The Setup

Note the setup illustrated here. Everything is attached to an IC693CHS397 5 slot rack. It’s being powered by an IC693 PWR330 power supply. The processor is an IC693CPU374 plus. Of course there is MDL940 in slot number 2 and an MDL645 in slot number 3.

Step 2: Setting Up Proficy Machine Edition

In Proficy Machine Edition you want to emulate exactly what you see illustrated physically. To do that you are going to go in and select a new open file. Underneath main rack you are going to select a CHS397 5 slot rack, a PWR330 power supply, CPU374, and an MDL940 in slot number 2, and an MDL645 or MDL646 in slot number 3.

Step 3 – Configuration of Output & Input Wires

In this test procedure outputs from the IC693MDL940  are going to go to corresponding inputs in the MDL645 or 646. Your goal is that when you turn on a relay from the MDL940 that power is being transferred from, let’s say, channel A1 to A1 in the MDL645.

You want to see a light come on, on your MDL940 and then let the same light come on on your MDL645. If for some reason you don’t have an MDL645, you can always use a 24 volt light bulb or a 24 volt solenoid. Any of these things would work. You don’t have to have an MDL645, but typically if you’re using it in the field with an MDL940 you would normally have an MDL645 or MDL646 handy.
That’s just the test procedure illustrated here. You’re welcome to have a different way to do it. Same thing goes for the MDL645 and MDL646. You can always hold a lead, a positive or a negative, to terminal number 1.
As you can see illustrated there is a positive lead. You can touch the opposite polarity, whichever it may be, positive or negative, to all the corresponding channels to test your inputs and read it in the input table. What you are going to do now, in Proficy Machine Edition, is select these modules and assemble the rack, the same way that you see it physically in front of you.

You are going to go to the lightning bolt icon and click it. This is going to get you connected to, this is the online, offline button, it will get you connected to the processor. When you can see the LED blinking you know you are connected.
Then the next thing is you are going to hit the hand print which puts you in program mode. (see below) Once it’s in program mode, you are going to go to target, down to online commands, you are going to select clear.

What you want to clear here in the clear memory screen is just the bottom 2 selections which is controller fault table and IO fault table. Don’t clear any other memory information that you may have. Then you are going to select okay.

Step 4: Hit Download and Run Button

Once that’s clear, you are going to hit the download and run button. This is going to download the information to the processor and the information, of course, that you’re going to download once you click this here. It’s going to ask you what you want to download to the controller. In this particular situation it’s just hardware configuration and logic. You don’t want to create any forced values. You’re going to toggle on and off the bits on your own and that will be reviewed in a moment. You don’t want to write anything to permanent flash memory. This is just a test of an output and in your case, an output and an input module.
Once that’s done, it’s going to ask you if you want to put the controller into run mode. You are going to select yes. Okay, now you’re in run mode. The outputs are enabled. The next thing you want to do is quickly look, if you double click on slot number 2, double click on slot number 3, or you can right click and hit configuration (see below), these slots are of course the MDL940 and the MDL645.
The reason you want to open those and check your configuration is you want to look at your reference addresses. You want to see where the outputs and inputs are so when you go to the output or input discreet tables you know where to put in the bits to turn on each relay.

Illustrated here is a new fresh file. It should be the same for you. Your output is starting on %Q, which means output, 00001 and that’s where you are going to want to place a 1 to turn the bit on. Now that you know where your reference addresses are, you are going to go to default tables which is underneath reference view tables, go down to output, double click on that and your output table opens up.
All right, starting in the top right hand corner with output number 1, you can see what’s happening as described before (see image of LED lights on below) when your A’s 1 through 8 are on, as they’re being turned on, they are being turned on, on the input module.

Now that you see all these outputs are on you know this is a good working module.

Step 5: Additional Steps if Necessary

A couple trouble shooting ideas if you are still having issues. There are a few very obvious ways to know that the modules not working.
If you turn the bits on, if you’re turning each output on and you’re not hearing the click of the relay and you’re not getting a light on, then there’s obviously something wrong with it. Sometimes you’ll connect the device and power it up and you’ll see 1 of the bits are already on before you’ve had a chance to turn it on. Sometimes the relays fail and they’re stuck together. Sometimes you might have an output that’s not on, there’s no light on it, and you haven’t toggled it on. Yet, if you look over to your input or if you touch it with a solenoid or a light bulb you can see that that output is on and it’s stuck in the on position. Any of those things is a potential problem that you can have with a relay module. There’s 16 channels so there could be something wrong with any of them; you want to test each channel thoroughly.

Tags: GE Fanuc, IC693MDL645, IC693MDL940, Troubleshooting Guide

This entry was posted on May 26th, 2015 and is filed under GE Fanuc, Troubleshooting Guide. Both comments and pings are currently closed.