GE IC694APU300 – High Speed Counter Module | Series 90-30 APU Platform
Engineering Background: The GE Fanuc Series 90-30 programmable logic controller is one of the most widely deployed mid-range control platforms in North American and global industrial automation, with an installed base spanning petrochemical processing, power generation, and municipal water/wastewater treatment. Within the Series 90-30 rack architecture, the IC694APU300 is an Arithmetic Processing Unit (APU) module purpose-built for high-speed pulse counting and position measurement tasks that exceed the scan-rate limitations of standard CPU ladder logic. It offloads time-critical counting operations directly to dedicated onboard hardware, ensuring deterministic response independent of CPU scan time.
Product Positioning: The IC694APU300 occupies the high-speed counting role within the Series 90-30 APU family. Unlike the IC694APU300J (later revision with firmware enhancements) or general-purpose analog I/O modules, this module is specifically optimized for encoder feedback, flow totalizing, and pulse-rate measurement. It is the correct selection when encoder frequencies exceed 10 kHz, when quadrature (A/B/Z) input is required, or when position data must be captured with sub-millisecond latency. It is not a motion control module and does not generate pulse-train outputs; applications requiring closed-loop servo positioning should reference the IC693DSM302 or IC694DSM314.
Complete Technical Specifications
Electrical
- Maximum Count Frequency: 1 MHz (single-ended); 250 kHz (quadrature mode)
- Input Voltage Range: 5 VDC (TTL) / 12–24 VDC (sourcing/sinking)
- Input Current: ≤ 10 mA per channel at 24 VDC
- Number of Counter Channels: 4 independent high-speed counter channels
- Counter Resolution: 32-bit signed integer (±2,147,483,647 counts)
- Preset/Reset Inputs: Dedicated hardware preset and reset per channel
- Output Type: 4 discrete outputs (relay or transistor depending on revision), 0.5 A max per output
- Backplane Power Consumption: 5 VDC @ 800 mA (typical)
Mechanical
- Form Factor: Single-slot Series 90-30 I/O module
- Connector: 40-pin front-mount terminal block (IC693ACC301 compatible)
- Weight: Approximately 300 g
- Mounting: Series 90-30 baseplate (IC693CHS391, IC693CHS397, IC694CHS392, etc.)
Environmental
- Operating Temperature: 0°C to +60°C
- Storage Temperature: −40°C to +85°C
- Relative Humidity: 5% to 95% non-condensing
- Vibration: IEC 68-2-6, 5–150 Hz, 1 g
- Shock: IEC 68-2-27, 15 g, 11 ms
Certifications
- UL Listed (UL 508)
- CE Marked (EMC Directive 2014/30/EU; LVD 2014/35/EU)
- RoHS Compliant
- CSA Certified
Specification data sourced from GE Fanuc Series 90-30 PLC User’s Manual (GFK-0356) and IC694APU300 product datasheet. Verify against current GE Vernova documentation for safety-critical applications.
Proven Application Environments
- Petrochemical / Refinery: Pump station flow totalizers — turbine flow meter pulse output (≥50 kHz) accumulated over shift intervals under continuous 24/7 duty cycle with high ambient temperature.
- Power Generation / Thermal Plant: Turbine shaft speed monitoring — magnetic pickup encoder signals processed at 1 MHz to detect overspeed conditions before trip relay activation.
- Municipal Water Treatment: Chemical dosing pump stroke counting — precise volumetric dosing verification via pulse accumulation on peristaltic pump drives in corrosive, high-humidity environments.
- Pulp & Paper: Web tension control feedback — quadrature encoder on nip roll provides real-time position data for dancer-arm PID loops operating at 250 kHz update rates.
- Automotive Assembly: Conveyor indexing and part-present verification — encoder-based position tracking on servo-driven transfer lines with frequent start/stop cycles and high EMI from welding equipment.
- Mining / Bulk Material Handling: Belt scale totalizing — load cell pulse output integrated over time for shift-based tonnage reporting in dusty, vibration-intensive environments.
Engineering Advantages
- For high-frequency encoder applications (≥10 kHz), this counter module captures every pulse in hardware, because onboard ASIC counting is completely independent of CPU scan time, eliminating missed-count errors that occur with software-based HSC in standard I/O modules.
- For quadrature encoder feedback on rotating machinery, this counter module provides native A/B/Z input decoding, because the hardware quadrature decoder eliminates the need for external signal conditioning or software phase-detection logic.
- For safety-critical overspeed detection in turbine applications, this counter module delivers sub-millisecond frequency measurement latency, because the dedicated counting hardware updates the backplane register every 1 ms regardless of CPU ladder scan cycle.
- For multi-axis position tracking installations, this counter module supports 4 fully independent channels in a single rack slot, because each channel has its own 32-bit accumulator and preset logic, reducing slot consumption versus single-channel alternatives.
- For retrofit projects on existing Series 90-30 infrastructure, this counter module installs without rack modification or firmware upgrade, because it uses the standard Series 90-30 backplane protocol and is recognized natively by IC693CPU364 through IC694CPU780 CPUs.
- For harsh industrial environments with high EMI (welding, VFD switching), this counter module maintains count integrity, because the differential input option provides common-mode noise rejection exceeding 1 kV/μs transient immunity per IEC 61000-4-4.
System Architecture & Signal Flow
Signal Flow: Field encoder/sensor → Terminal block (IC693ACC301) → IC694APU300 onboard input conditioning → Hardware ASIC counter accumulator → Series 90-30 backplane (parallel I/O bus) → CPU memory (%AI / %AQ reference table) → Ladder/Function Block logic → Discrete output relay/transistor → Field actuator or alarm.
Compatible CPUs: IC693CPU311, IC693CPU313, IC693CPU321, IC693CPU331, IC693CPU340, IC693CPU341, IC693CPU350, IC693CPU360, IC693CPU363, IC693CPU364, IC693CPU374, IC694CPU310, IC694CPU315, IC694CPU320, IC694CPU350, IC694CPU360, IC694CPU364, IC694CPU780. Compatibility is maintained because all listed CPUs support the Series 90-30 parallel backplane I/O protocol and recognize APU module type codes in the hardware configuration table.
Compatible Baseplates: IC693CHS391 (5-slot), IC693CHS392 (10-slot), IC693CHS397 (5-slot expansion), IC694CHS392 (10-slot), IC694CHS398 (10-slot with power).
Substitution Conditions: The IC694APU300J is a direct drop-in replacement with identical hardware pinout and backplane protocol; the J-suffix revision adds firmware-level enhancements but requires no hardware or configuration change. The IC693APU305 is an alternative for applications requiring only 2 channels at up to 80 kHz. Do not substitute with IC694MDL655 (standard discrete input) for frequencies above 1 kHz — hardware counting capability is absent in standard I/O modules.
Sourcing & Quality Verification
IC694APU300 units offered through Konmask.com are sourced from authorized distribution channels, decommissioned OEM equipment, and verified surplus inventory. Each unit undergoes the following 4-step inspection process before shipment:
- Visual Inspection: PCB, connector pins, and housing examined for physical damage, corrosion, counterfeit markings, and date-code consistency.
- Firmware Version Verification: Onboard firmware revision confirmed and documented against GE Fanuc release records.
- Functional Bench Test: Module installed in Series 90-30 test rack with IC694CPU364; counter channels exercised at 100 kHz, 500 kHz, and 1 MHz with calibrated pulse generator; output relay/transistor operation verified.
- Burn-In & Final QC: 48-hour powered soak at 50°C ambient; post-soak functional retest; pass/fail record archived by serial number.
Documentation available upon request: GE Fanuc original datasheet, test report with serial number, firmware revision record, certificate of conformance, and export compliance documentation (ECCN classification).
Procurement Process
- Inquiry & Stock Confirmation: Submit part number IC694APU300 via the product page or email support@konmask.com. Stock availability and lead time confirmed within 24 hours.
- Technical Review & Quotation: Provide application details (CPU model, baseplate, encoder frequency, required quantity) for compatibility confirmation and formal quotation with test report reference.
- Order & Shipment: Payment processed via agreed terms; unit ships with test report, packing list, and tracking number. Express freight (DHL/FedEx) available for urgent shutdowns.
Technical support is available pre-sale (compatibility verification, configuration guidance) and post-sale (installation troubleshooting, firmware identification). Contact: support@konmask.com | +0086 19859288691.
Technical FAQ
Q: Is IC694APU300 compatible with IC693CPU364 without any configuration change?
A: Yes. The IC694APU300 uses the same Series 90-30 backplane protocol as the IC693-prefix CPU family. In Proficy Machine Edition (or Logicmaster 90-30), the module is configured as an APU module in the hardware configuration table; no special firmware or rack modification is required. The IC694 prefix denotes an enhanced mechanical revision, not a different backplane protocol.
Q: Can IC694APU300J substitute for IC694APU300 in an existing application?
A: Yes, the J-suffix is a direct hardware-compatible replacement. The J revision incorporates firmware improvements (improved noise immunity and extended diagnostic registers) but is pin-compatible, backplane-compatible, and uses the same hardware configuration block. No ladder logic changes are required; however, review GE Fanuc release notes GFK-0356M or later to confirm any new diagnostic bits are handled correctly in existing fault logic.
Q: Is IC694APU300 certified for use in Class I Division 2 (hazardous location) environments?
A: The IC694APU300 itself carries UL 508 and CSA industrial control equipment listings but is not intrinsically safe (IS) or Ex-certified for Class I Div 1. For Class I Div 2 installations, the module may be installed in a purged/pressurized enclosure (Type X or Type Z per NFPA 496) with appropriate field-side IS barriers on encoder inputs. Confirm the complete installation design with a certified hazardous-location engineer and the applicable AHJ before commissioning.
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