FAQ's

The most likely cause is that the rack that the CPU is located in is not configured with the proper rack number. The rack that contains the CPU should always be set to Rack 0. Any other setting will result in the CPU’s OK LED being off. To check the settings, disconnect power from the power supply and remove it from the rack. In the upper left-hand of the rack, there are several jumpers that are used to assign a rack number to the rack. (Refer to the manual GFK-0262 for a diagram of the jumpers.) Set the rack number to 0.

There are 3 software packages available for this purpose.

Logicmaster 90-70 – This is the original software for the Series 90-70. It is DOS-based and can run in Windows 95, 98 and 2000 environments. It is not supported by GE Fanuc in Windows XP and Vista environments. This is a mature product, meaning no further enhancements are planned.

VersaPro Professional Edition – This is a Windows-based package and can run in Windows 95, 98, 2000 and XP environments. It is not supported by GE Fanuc in the Windows Vista environment. In addition to the Series 90-70, VersaPro Professional can also program Series 90 Micros, 90-30s, and certain VersaMax Micro and modular PLCs. This is also a mature product.

Proficy Machine Edition Logic Developer PLC Professional Edition – This is a Windows-based package and can run in Windows 2000, XP and Vista environments. This is the current software package for Series 90-70 PLCs. It supports all of the same PLCs as VersaPro Professional plus the RX3i and RX7i PACs. Enhancements to this software are on-going. This is the only software that will support new PAC, Series 90-30 and VersaMax CPUs and modules as they come out.

Yes. However, you need to be aware that using this output reduces the amount of current available on the 24VDC output that goes to the Series 90-30 modules via the baseplate. There is only 0.625A total available current on the 24VDC output of the power supply.

No. This port is for the Ethernet Station Manager only.

There are several possibilities:

Bad port on the PC – Try using the PC’s serial port to communicate to another device in order to confirm proper operation

Bad cable – Try connecting to another Series 90 PLC in order to confirm the condition of the cable.

Incorrect communication settings in the software – The default settings for the Series 90 CPU programming port is 19200 BAUD, 8 data bits, 1 stop bit and odd parity. In cases where you suspect that the setting has changed and you have a copy of the PLC configuration, compare the CPU’s port configuration to your software’s port settings.

Bad programming port – Check the +5 volt pin (pin 5) on the programming port versus pin 7 (0 volts). If the +5 volts is not present, the fuse for that port is blown and this fuse is not field-replaceable.

If none of these suggestions solves the problem, please contact our technical support specialists at 1-800-784-9385.

This error occurs when the user tries to download a configuration where the CPU is configured for “Passwords Enabled” and the CPU being downloaded to is set for “Passwords Disabled.” Once passwords are disabled in a Series 90 CPU, the only way to download a configuration where the CPU is configured for “Passwords Enabled” is to completely erase the memory in the target CPU. This can be done by powering down the CPU, disconnecting the battery, and powering up the CPU with the battery still disconnected. This should clear the memory. In certain cases with the Series 90-30 CPUs, you may have to clear the memory by shorting out a super-capacitor on the CPU module by removing the CPU from the baseplate and shorting across two solder pads labeled “MEM CLR” for about 10 seconds. Once the memory is erased, a configuration with passwords enabled can be downloaded to the CPU.

An alternative solution would be to change the configuration being downloaded to a “Passwords Disabled” setting and then download the configuration to the CPU. Only do this when passwords are not a concern.

There are 3 software packages available for this purpose.

Logicmaster 90-30 – This is the original software for the Series 90-30. It is DOS-based and can run in Windows 95, 98 and 2000 environments. It is not supported by GE Fanuc in Windows XP and Vista environments. This is a mature product, meaning no further enhancements are planned.

VersaPro Standard Edition – This is a Windows-based package and can run in Windows 95, 98, 2000 and XP environments. It is not supported by GE Fanuc in the Windows Vista environment. In addition to the Series 90-30, VersaPro Standard can also program Series 90 Micros and certain VersaMax Micro and modular PLCs. This is also a mature product.

Proficy Machine Edition Logic Developer PLC Standard Edition – This is a Windows-based package and can run in Windows 2000, XP and Vista environments. This is the current software package for Series 90-30 PLCs. It supports all of the same PLCs that VersaPro Standard can plus a number of newer Series 90-30 and VersaMax PLC that VersaPro Standard does not. Enhancements to this software are on-going. This is the only software that will support new Series 90-30 and VersaMax CPUs and modules as they come out.

Take note of the LEDs on the power supply and the CPU. Key LEDs are the POWER LED (power supply health) and the OK LED (CPU health).If these are OK, use one of the available programming packages (Logicmaster 90, VersaPro or Proficy Machine Edition Logic Developer PLC), connect to the Series 90’s programming port and display the PLC and I/O fault tables. These should lead you to the root cause of the stoppage. Please note that if the CPU’s OK LED is out, the software will not communicate.

This LED turns off when the Genius block has not communicated with Genius Bus Controller (GBC) for 3 bus scans. This condition can be caused by several things.

The PLC CPU is stopped. Check this first.

There is a problem with the Genius bus cable. Review the following items:

Verify that the Genius bus cable is of the same type and manufacturer throughout that particular Genius bus. Mixing cable type and manufacturers on the same Genius bus can cause erratic communication between the Genius block and the GBC. Also, make sure that the cable in use is one of the cables listed in Chapter 2 of GEK-90486-F1 (Visit our Genius Manuals page or an equivalent cable to one of those listed.

Verify that the terminating resistors are properly matched to the cable in use and are located at both ends of the Genius bus. Also, make sure that the termination resistors are not wire-wound resistors. Improper termination can cause erratic communication between the Genius block and the GBC. Information on terminating resistors can be found in Chapter 2 of GEK-90486-F1 or an equivalent cable to one of those listed.

Verify that the cable is properly installed. This includes:

The same wire within the twisted pair goes to the same terminal on each Genius device, including the GBC. For example, if one wire in the pair has black insulation and the other wire has yellow insulation and the black-insulated wire is connected to “Serial 1” on the GBC, it should go to the “Serial 1” connection on every Genius device on that bus. The other wire in that pair (yellow) should be connected to “Serial 2” on every Genius device on that bus. Keep in mind that different cables use different color combinations and this is an example only.

Verify that the shields are properly connected. Typically, “Shield Out” on a Genius device located at one end of the Genius bus is connected to “Shield In” of the next downstream device and this pattern is repeated as you go from device to device until you reach the other end. (It is legal to start with “Shield In” and connecting it to “Shield Out” of the next device and repeating this pattern also.) If the shields are not properly connected, ground loops and/or ineffective shielding can result.

Verify that all connections are solid and keep splices to a minimum, preferably none.

Verify that the Genius bus cable is routed properly. While Genius busses are robust and are resistant to electrical noise, it, like most field busses, is not totally immune to electrical noise, especially strong noise sources like arc welders.

Verify that the Genius block is properly grounded.

The data rate on the Genius block is set to the wrong data rate (does not match the bus). Remove the block from the bus, place a terminating resistor between “Serial 1” and “Serial 2” and use the HHM to correct the data rate.

The Genius block is defective.

A blinking UNIT OK LED usually indicates that there are one or more faults present on the block. In order to identify the fault(s), connect a Genius Hand-held Monitor (IC660HHM501) to the block, and power up the HHM, making sure that the data rate of the HHM matches the Genius block it is plugged into. Once the main menu is displayed, select ANALYZE. Under ANALYZE, there are several choices for analyzing the block at the circuit and block level. Use one or more of these selections to identify the fault. Once identified, try clearing the fault. If the fault clears, the fault condition may have been a temporary condition. If the fault does not clear or returns after clearing, take corrective action.

Yes, we are interested in all GE PLC products. You can send an email to info@qualitrol.com and attach a list of the parts you would like to sell. We will look over the list and send you an offer. Naturally, some components are more valuable than others based on condition, availability and current need.

Logicmaster Six software is your answer. The Parallel version of Logicmaster Six requires a special interface card, IC641WMI610, that plugs into an ISA slot in a computer with a bus speed of less than 100mhz. The parallel card will use a parallel cable (IC600WD005) to communicate to the Series Six CPU via the I/O Control Module. However, these cards are hard to come by – please contact us for current availability of this card.

We recommend the serial option, which communicates via a standard serial port in your computer. Your Series 6 PLC will need a communications card, IC600CB536 to connect the PC serial port to.

One note: LogicMaster software for Series Six is a DOS software package - Windows does not support the program. The original software has no communication drivers or memory handler routines for Windows. This means that you will need a PC with DOS or an equivalent. An equivalent that has been successful is a “virtual PC with a DOS type operating system.” I use this method on my XP laptop and have no problems. You can contact us about getting the software with virtual PC option. Our computer savvy technicians have put together a virtual PC that will work on XP computers.

One note: LogicMaster software for Series Six is a DOS software package - Windows does not support the program. The original software has no communication drivers or memory handler routines for Windows. This means that you will need a PC with DOS or an equivalent. An equivalent that has been successful is a “virtual PC with a DOS type operating system.” I use this method on my XP laptop and have no problems. You can contact us about getting the software with virtual PC option. Our computer savvy technicians have put together a virtual PC that will work on XP computers.

Hopefully the circuit boards are just loose inside. Simply remove the top and with the power off, re-seat the cards in their sockets. Replace the top and power on. If this worked, you are indeed lucky, as there are no parts left for the PDT. While your unit is working, we recommend that you upgrade to Logicmaster software which can run on a PC (see How do I communicate to my Series Six PLC on our Series Six programming page). Then when the PDT finally powers down for the last time, you will be prepared for the transition.

The letter at the end of the part number is referred to as the Revision code. Typically, the revisions were changed to keep up with events with the card’s circuitry. If a change in components on a module required a circuit change, the redesign would result in incrementing the revision code.

GE had many customers ask about this revision letter so they tested all cards and brought all cards to Revision “K.” This revision says all cards have been tested and work with other cards. All cards with the same part number will work the same way. The exception to this rule is Rev “A” cards. Therefore, if you are using a rev “A” card you will want to ask for that revision to ensure your system works. This is documented in the Series Six Data Sheet manual.

Qualitrol has made the upgrade process straightforward. Several options determine which conversion is best for your process. If cost is an issue, the choice to replace only the PLC CPU section will provide a fast and cost-effective solution. If downtime is an issue, a combination of CPU swap out and Genius distributed I/O can be used to speed the conversion. All options offer diagnostic capability. The modern PLC now has fault-recording features that you can use to troubleshoot failures resulting in a huge reduction in downtime. Visit our Series Six Conversions page to learn more about our conversion options.

First, you will need a replacement battery, IC600MA507, for the card. Replace the battery, verify that all of the lights come back on the front of the CPU cards, and reload your program. Qualitrol provides several Series Six programming tools that assist you in re-loading your program.

If you do not have a copy of your program on a diskette, you have several options:

Re-key the program into the PLC from a printout.

Contact the OEM who made your machine.

Copy the program from another machine and, with minor changes, adapt it to your process.

Contact Qualitrol to request an engineer who can come on site and re-write the program. Our technical support staff is ready to assist you by phone at 1-800-784-9385 or through email to support@qualitrol.com

The Series Six PLC should have all lights on the CPU cards (I/O Control, Arithmetic Control, Logic Control, and Logic Memory) for normal operation. Often one or more of the lights will be off when a PLC shuts down. You will want to make a note of the status of the CPU lights.

When it is safe, turn the key switch on the front of the Power Supply from Run to Stop. Turn the power switch to the off position, wait for 1 – 2 minutes and turn the power back on. After you turn the power on, turn the key switch to Run. If all the lights are on and the process starts, then you had a soft fault. You should be fine and continue running.

However, if the lights go back out after cycling power, then you have a hard fault. This is caused by a hardware failure or loss of the program. To know what boards to change first, you will want to refer to the manual GEK-25361, Installation and Maintenance manuals, and look at the chapter Troubleshooting and Repair. This section will have a flowchart to follow showing what cards are suspect based on which lights are off. You may also contact us directly at 1-800-784-9385 or through email to support@qualitrol.com.

Error code E21 signifies a memory parity failure and is one of more frequently seen error codes on the Series Three PLC. This error is displayed when the program data stored in RAM has become corrupt and is no longer valid. It is common for this condition to occur following a temporary power outage in cases where the battery is too weak to retain the program stored in memory. The only way to resolve an E21 error is to reload or reenter the program. In rare circumstances, E21 can also indicate a hardware fault within the CPU itself. Our technical support staff can help you determine whether or not hardware replacement is warranted. We can be reached by phone at or through email to . For information on other error codes, please refer to "Series Three Error Code Definitions" available on the Series Three documentation page.

A table containing descriptions of all possible errors and the actions necessary to correct them is "Series Three Error Code Definitions" available on the Series Three documentation page.

Error code E41 is displayed when the Series Three CPU detects a change in I/O module configuration or if an error occurs when transferring data between I/O modules and the CPU. It is normal for this error code to appear whenever I/O modules are added or removed from the system, or when I/O modules are relocated from one slot to another in the base unit. In most circumstances, an E41 error can be cleared by placing the key switch on the front of the Series Three CPU in the RUN 1 position and pressing the SET key. If this procedure fails to clear the error, a fault may be present in the hardware of the CPU, one or more I/O modules, or the base unit. Our technical support staff will be glad to assist you in pinpointing the source of this and other Series Three PLC errors. We can be reached by phone at or through email to. For information on other error codes, please refer to "Series Three Error Code Definitions" available on the Series Three documentation page.

For the Series Three PLC, error code E22 indicates that the backup battery in the CPU has reached the end of its useful life. The battery should be replaced as soon as possible to ensure that the ladder-logic program contained in the unit’s RAM will not be lost in the event of a power outage. The replacement part number is IC610ACC150.

The Series Three PLC was designed to allow permanent program backups to be stored on consumer-grade audio cassette tapes. The backup is created by transferring data to a cassette recorder through an audio cable connected to the Series Three CPU’s built-in tape port.

Almost any cassette recorder with a tone control and an external microphone input can be used, but we have put together a kit (QIC610RECORDER) consisting of a compatible cassette recorder, batteries, and two cassette tapes. More information on the QIC610RECORDER is available on our Series Three documentation page, including instructions for program transfer using the tape port.

No such software is currently available. Although the Series Three Programmable Controller User’s Manual refers to a program known as LogicMaster 3, this software was never released to market.

No such software is currently available. Although the Series Three Programmable Controller User’s Manual refers to a program known as LogicMaster 3, this software was never released to market.

Reviewing and editing the program stored in a Series Three CPU using the built-in display and keypad can often be frustrating because the LED display can only show one program instruction at a time. Thankfully GE produced a Portable Programmer unit that makes it easier for the user to visualize a PLC program by displaying several rungs of ladder-logic at once.

The Portable Programmer is an optional accessory to the Series Three, Series One, and Series One Junior PLCs that allows ladder-logic programs to be viewed, edited, and printed. With its 5-line, dot-matrix LCD display and rugged, industrialized enclosure, the Portable Programmer is a specialized ladder-logic programming device ideal for use in the field.

Program transfer and on-line monitoring are available through the Portable Programmer’s serial interface. Programs can also be transferred to and from the PLC using the unit’s built-in tape port. A printer port allows hard copies of programs to be printed to any parallel printer using the included cable. The part number for the Portable Programmer is IC610PRG110.

We also offer a kit, called the QS3INTEGRATOR, which includes the Portable Programmer, a Series Three Program Pack (IC610PRG117), and a CD containing a complete set of manuals for the Series Three and Series One product families. More information on the QS3INTEGRATOR is available by visiting our Series Three programming page or calling our sales representatives at 1-800-784-9385.

We offer copies of the manufacturer’s troubleshooting guides for the Series Three PLC available in the Series Three documentation section. If you need additional help, our technical support staff is ready to assist you by phone at 1-800-784-9385 or through email to support@qualitrol.com.

By the late 1980s, the Series One was the top selling small-form-factor PLC in the world. Its exceptional reliability and performance made it ideal for a myriad of applications, and, because of its versatility and robust design, there typically has not been any reason to replace it. In today’s manufacturing world, however, where Ethernet communications, high-speed processors, and Windows-based programming software are all commonplace, the Series One just seems out of place.

While your maintenance team might say "if it isn’t broken, don’t fix it," management is concerned about downtime should the Series One finally expire, and you do not have the time to engineer a seamless conversion that minimizes lost production time. If this sounds familiar, then you are the customer we had in mind when we developed our Series One conversion process. Qualitrol International provides a conversion program to replace your Series One PLC system that is fast, cost-effective and let’s you take advantage of modern GE Fanuc PLC technology, specifically the 90-30 PLC system. Visit our Series One conversion page to learn more about the benefits of upgrading your Series One PLC.

One of the most common components to fail in any PLC system is the power supply. The internal components used in all power supplies tend to degrade with use and this normal component aging is accelerated by extreme temperatures and harsh environments. We have prepared a guide, entitled "How to Check Series One Backplane Voltages" on our Series One documentation page, that describes how to check the backplane voltages on most Series One PLC racks to determine if the power supply is operating within the manufacturer’s original specifications.

A table containing descriptions of all possible errors and the actions necessary to correct them, entitled "Series One Error Code Definitions" is available for download on our Series One documentation page.

Error code E21 signifies a memory parity failure and is one of more frequently seen error codes on Series One and Series One Junior PLCs. This error is displayed when the program data stored in RAM has become corrupt and is no longer valid. It is common for this condition to occur following a temporary power outage in cases where the battery is too weak to retain the program stored in memory. The only way to resolve an E21 error is to reload or reenter the program. In rare circumstances, E21 can also indicate a hardware fault within the CPU itself. Our technical support staff can help you determine whether or not hardware replacement is warranted. We can be reached by phone at 1-800-784-9385 or through email to support@qualitrol.com. For information on other error codes, please refer to the "Series One Error Code Definitions" available for download on our Series One documentation page.

For Series One and Series One Junior PLCs, the battery light on the CPU is turned off during normal operation. If this light is illuminated, the CPU battery should be replaced as soon as possible to ensure that the ladder-logic program contained in the unit’s RAM will not be lost in the event of a power outage. The replacement part number is IC610ACC150.

The Series One and Series One Junior PLCs were designed to allow permanent program backups to be stored on consumer-grade audio cassette tapes. The backup is created by using a Hand-held Programmer unit to transfer data through an audio cable to a cassette recorder. Two versions of the Hand-held programmer were produced: IC610PRG100 and IC610PRG105. We recommend the IC610PRG105 in most cases since this unit supports the advanced functionality of the Series One Plus CPU while still maintaining compatibility with older models.

Almost any cassette recorder with a tone control and an external microphone input can be used, but we have put together a kit (QIC610RECORDER) consisting of a compatible cassette recorder, batteries, and two cassette tapes. More information on the QIC610RECORDER is available by calling our sales representatives at 1-800-784-9385.

There are a variety of methods for communicating with the Series One PLC and the best option will vary depending on what you need to accomplish. We have put together the following guides to make it easy for you to determine which method is best suited to your needs:

View the Series One documentation page for more information.

In addition, you can learn more about our pre-configured Series One Integrator Kits which allow you to view, print, or change the ladder-logic program.

We offer copies of the manufacturer’s troubleshooting guides for both Series One and Series One Junior PLCs available in the Series One documentation section. If you need additional help, our technical support staff is ready to assist you by phone at 1-800-784-9385 or through email to support@qualitrol.com.