Product Core Brief

• Model:
• Brand: GE Fanuc / GE
• Series: Series 90-30 PLC
• Core Function: Independent high-speed counter (HSC) module. Processes fast pulse/encoder signals in hardware without relying on CPU scan cycle; triggers preset outputs based on count values.
• Product Type: High Speed Counter Module (HSC)
• Key Specs: Max 200kHz input frequency | Supports quadrature A/B encoders | 12 inputs + 4 sourcing DC outputs Note: Discontinued legacy hardware; factory new stock exhausted, surplus and refurbished units widely traded. Important distinction: NOT a servo positioning module (APU301/302). Hot swapping is not supported on Series 90-30 backplanes.

Key Technical Specifications

• Input Configuration: 12 positive logic inputs (5VDC differential / 10–30VDC single-ended)
• Output Configuration: 4 sourcing DC outputs
• Output Ratings: 10–30VDC @500mA; 4.75–6VDC @20mA
• Maximum Count Frequency: 200kHz
• Supported Count Modes: Up, Down, Bidirectional, Quadrature (X1/X2/X4 decoding)
• Hardware Presets: Onboard threshold comparison to directly toggle outputs independent of CPU
• Input Filter Options: 2.5μs high-speed filter / 12.5ms low-speed noise filter
• Backplane Power Draw: 250 mA @5 VDC
• Internal Protection: Shared 3A field-replaceable fuse for outputs
• Isolation Rating: 250 VAC field-to-logic isolation
• Status LEDs: BOARD OK, CONFIG OK
• Operating Temperature: 0°C to 60°C horizontal cabinet mounting
• Storage Temperature: -40°C to 85°C
• Form Factor: Single-width Series 90-30 rack slot
• Compatible Chassis: IC693CHS391, IC693CHS392, IC693CHS397, IC693CHS398
• Supported Software: Logicmaster 90, Proficy Machine Edition
• Typical Applications: Encoder position tracking, flowmeter pulse counting, speed measurement, high-speed product sorting

Product Introduction

This unit handles high-frequency pulse signals that standard discrete input modules cannot reliably capture due to PLC scan latency. Counting and preset output triggering run locally on the module hardware, reducing backplane communication load.

It works with incremental encoders, turbine flow meters and pulse generators. Engineers configure counter modes, preset values and filter parameters in programming software. Widely used on machine retrofits requiring precise position or speed monitoring without dedicated servo motion control.

QA & Testing SOP (Transparency Building)

1. Incoming Inspection: Verify part marking. Inspect backplane edge pins for bending or corrosion; check terminal block housing for cracks.
2. Live Testing: Mount into validated Series 90-30 rack, apply nominal rack power. Inject simulated pulse/quadrature signals, verify counting accuracy and preset output triggering over a continuous 24-hour test cycle.
3. Electrical Testing: Use Fluke 115 to monitor backplane 5VDC rail stability. Insulation resistance testing must exceed 10MΩ between field terminals and chassis protective ground.
4. Firmware/Config Backup: Record module firmware revision. Photograph terminal wiring layout before disassembly.
5. Final QC & Packaging: Place unit inside anti-static shielding. Attach dated QC test tag confirming counter function and output triggering validation prior to shipment.

Installation Pitfalls & Guide (Engineer to Engineer)

❗ No Hot Swap Support: Series 90-30 backplanes lack hot-swap bus logic. Live removal disrupts rack operation and risks permanent backplane trace damage. Full rack power shutdown mandatory. ❗ Critical Model Mix-Up Risk: = High Speed Counter; IC693APU301/302 = Servo Axis Positioning Modules. They cannot substitute for each other. ❗ Quadrature Wiring Polarity: Reversed A/B encoder channels causes reverse counting direction. Verify wiring before commissioning. ❗ Filter Parameter Selection: High-frequency signals require the 2.5μs filter; noisy low-speed signals should use the 12.5ms filter to eliminate false triggers. ❗ ESD Dangers: Un-grounded handling damages input receiver circuits. Static faults manifest as miscounting or intermittent signal loss. ❗ Fuse Rating Rule: If internal fuse blows, only fit factory matching rating; uprating the fuse removes short-circuit protection.

Replacement Guide:

1. Pre-install: Activate lockout-tagout on rack power; back up hardware configuration and photograph all field wiring.
2. Removal: Unplug terminal block, unlatch module and slide straight out without twisting backplane connectors.
3. Install: Seat new unit fully into vacant slot, lock latches, reattach terminal block and replicate wiring connections.
4. Power-on Test: Restore rack power, confirm BOARD OK LED illuminates, download saved configuration, verify pulse counting and preset output operation.

FAQ (Frequently Asked Questions)

Q: Does this module support hot swapping? A: No. Series 90-30 architecture does not implement hot-swap functionality. Complete rack power shutdown is required before removing or installing the unit.

Q: What is the core difference between and IC693APU301 / 302? A: = High-speed counter for encoder/pulse measurement, no servo drive command outputs. IC693APU301/302 = Motion Mate APM servo positioning modules with pulse/direction drive signals. They are not interchangeable.

Q: Can this module be installed inside PACSystem RX3i racks? A: No. Form factor and backplane signaling are exclusive to Series 90-30 chassis. It cannot operate within RX3i systems.

Q: Does this module output motion commands to servo drives? A: No. It only counts incoming pulses; it cannot generate positioning profiles or servo command pulses.

Q: What happens if the internal output fuse blows? A: All four sourcing outputs become inoperable. Inspect field wiring for shorts before replacing the fuse with matching rated part.

Q: Will saved configuration load directly onto a replacement unit? A: Counter configuration imports without modification. After replacement, verify encoder direction, filter settings and preset trigger thresholds.

Q: Can multiple modules be installed in one rack? A: Yes, subject to overall CPU backplane bandwidth limits and per-baseplate module quantity constraints.