IC697ALG320 Manual Troubleshooting Tutorial GE Fanuc PLC Training Series 90-70 Analog Output

Introduction: GE Fanuc IC697ALG320 Troubleshooting Guide

This troubleshooting guide is a test of a GE Fanuc IC697ALG320 analog output module in an IC697CHS750 5 slot rack. Illustrated from left to right is an IC697PWR711 power supply, an IC697CPX772 CPU and the IC697ALG320. And for a later test only there is an ALG230.

Step 1: Configuring Prophecy Machine Edition

In Proficy Machine Edition you should configure what you see here illustrated in the software so that the ALG320 here is in slot number 2 and you should configure it to give a voltage reading which. Note that what is illustrated is actually set up for a voltage test or a milliamp (mA) test so this is 0 to 10 volts, 4 to 20 mA. There are jumpers on 1 and 3, 9 and 11, 17 and 19, 25 and 27 and then for your mA test coming up you’ll see there is a 34 and 36, that’s screws 34 and 36.

So what you will typically do to test this device is go into your analog output table which you’ll find in your navigator bar under reference view tables and then subcategory default tables. So Analog Output you’re going to be testing channels 1, 2, 3, 4. So what you usually will do is you’ll put in the maximum value 32K, 32,000 in each channel, see if you get a full reading for a full 10 volts and it’s typically like 9.99 volts to a meter it’s nothing to be concerned about but it’s usually what you want to see.

 Step 2: Taking Readings Using a Voltage Meter

You will use a meter (see above) to take voltage readings. You’re going to be getting the readings on terminals 3 and 5 and you should get close to a solid ten volts. Now, you are going to hold the probes on there and you’re going to remove the 32,000 from address 1001 analog address so you are going to put a 0 in there and hit enter and it should drop down to a nominal value and in this case 0.  
The reason you want to do that is because if the unit has failed, if the channel has failed, it would still read 32,000 they usually fail at full value or at partial value. Now you are going to work your way to number 2, and do the same thing, you are going to 0 it out 3.
Now here you are going to do something a little different that you could do. As you know you have a value in here of 32,000 so go ahead and cut that value in half to 16,000 so you should get half the reading 5 volts. Then cut that in half to 8,000 and you will get half that reading which should be 2.5 volts and then go ahead and zero that out. That’s something that you could do to all the channels

Step 3: Doing the Milliamp Test

So now you’re going to test milliamp (mA).
You are going to stop your processor, go into the configuration of the ALG320, 4 channels and you are going to switch it to 4 to 20 mA and it will change your output and the output location and once you’ve configured that you need to go back in and clear controller and I/O fault table because you’ve made a change and the CPU is used to something else and you’re going to trigger a fault if you don’t clear those two.
You have to go into Target Clear Online Commands, Clear Controller Fault Table, asI/O Fault Table and then you are going to go ahead and download and run that. You just want make sure you clear those because you are going to create a hindrance for yourself if you don’t. Note we’re just downloading Hardware Configuration and Logic when it asks you nothing else. You don’t want to write any of this to permanent flash memory, it is just a simple test and once you’re back in Run Mode you’re going to do the same procedure.
Now, you should be in Run Mode so you can go back to Analog Output put in your values of 32,000 all four channels. Now go ahead and switch your meter to read mA in DC.

If you have a meter like this (image above), it selects AC or DC and you want DC and it’s set up for mA and you have it over to the far left hand side so you have more detailed reading, more decimals, so you are going to go to terminal points 2 and 4 and the reading you are looking for is 20 mA. So something on the order of .021 is fine.
Next you will cut it in half to a reading of 12 or 13 is normal so that’s a value of 16,000. Now go to a value of eight thousand and a reading value of 8 or 9 is normal. So that’s what you do there and you are going to zero it out.
It is recommended that you do that on every channel but for this test we’re going to go back to terminals 10 and 12 and you should get on the order of 21 mA. Then you are going to go ahead and zero that out til it drops. Note that you should zero it out so that if it does fail it’s going to fail at full value the full 20 mA typically.
For output number 3 you are looking for terminals 18 and 20. And the last one is number 4, 26 and 28 showing 21 mA and you are going to drop it to zero. So you know everything’s fine and this is what you should expect to see.

Step 4: Additional Steps if Necessary

You might have a situation where the OK light isn’t on but it comes on once it’s configured so it’s not something that you always go by with the OK light although you should typically have it on.
Next, considering the channels that you just went over: voltage 0 to 10 volts mA, you should get readings like the ones you saw, ie: .999 to 10 volts. As you did, you should keep cutting those worlds and a half to make sure that it’s able to read that different voltage.

Tags: GE Fanuc, IC697ALG320, Troubleshooting Guide

This entry was posted on May 5th, 2015 and is filed under GE Fanuc, Troubleshooting Guide. Both comments and pings are currently closed.