GE IC693APU302 Two‑axis motion control / axis positioning module for Series 90‑30

Description

GE IC693APU302 is used in machines that need precise, multi‑axis motion control tightly coordinated with PLC logic, rather than handled by a separate stand‑alone motion controller. Typical applications include packaging machines, pick‑and‑place systems, assembly cells, and material handling equipment where two axes—such as X/Y gantries, infeed/finishing axes, or synchronized rollers—must move in a controlled profile while the Series 90‑30 PLC manages the rest of the machine. In these environments, engineers want deterministic motion that stays synchronized to sensors, product detection, and line speed, so embedding motion directly in the PLC rack is attractive. The GE IC693APU302 lets designers run index moves, cams, and coordinated positioning sequences while still using familiar 90‑30 programming tools and I/O structures, which is critical when machines must be supported for years by plant technicians.​

This module is particularly applicable in control systems where high‑speed feedback from encoders or pulse trains is needed. It supports pulse/direction, up/down, and quadrature A/B feedback, making it suitable for servo drives, stepper drives, and encoder‑based position feedback in a wide range of mechanical designs. OEMs use GE IC693APU302 to handle motion for tasks like cutting to length, registration control on packaging film, and coordinated feeder/control axes, leaving the main CPU to focus on interlocks, recipe management, and network communication. Because it fits directly into the Series 90‑30 rack, wiring stays concentrated in one panel, and motion diagnostics are available alongside standard PLC status—an advantage for troubleshooting and lifecycle support in industrial automation.​

Product introduction and positioning

The GE IC693APU302 is an intelligent, 2‑axis motion control module (often referred to as a Motion Mate or Axis Positioning Module) designed for the GE Fanuc / Emerson Series 90‑30 PLC family. It functions as a dedicated motion controller on a plug‑in card, handling real‑time trajectory generation, position loops, and high‑speed I/O associated with motion while communicating with the main 90‑30 CPU over the backplane. Rather than forcing the PLC CPU to calculate motion profiles and service encoder inputs directly, the GE IC693APU302 offloads these demanding tasks to its own processor, enabling more precise and responsive axis control. This architecture lets engineers blend PLC and motion functionality in a single system without adding an external motion controller.​

Within a control system, GE IC693APU302 sits in the I/O and specialty‑module layer, interfacing between the CPU and the drives or stepper amplifiers. The CPU sends commands such as move profiles, speeds, and mode selections; the motion module executes the moves, monitors feedback, and reports status and faults back to the PLC. It supports Standard mode (stand‑alone axis control based on PLC commands) and Follower mode (axes following a master encoder or virtual axis), giving flexibility for applications like line‑shaft replacement and synchronized conveyors. For integrators, this positioning is valuable: the module is tightly integrated into the 90‑30 ecosystem but still offers motion‑centric features, allowing them to standardize on a single PLC platform for both logic and motion​

Key technical features and functional benefits

A key feature of GE IC693APU302 is its capability to independently control two axes, either operating separately or synchronized depending on the application. It offers fast servo loop update rates (on the order of a few milliseconds) and short block processing times so that profile segments and motion blocks can be executed smoothly. This responsiveness allows accurate positioning and velocity control even at high machine speeds, which is crucial for operations like cut‑to‑length, registration, and coordinated infeed/outfeed. Engineers can implement complex positioning sequences—such as multi‑segment moves, jogs, homing routines, and cams—without burdening the main PLC CPU.​

The module provides four high‑speed input channels that support pulse/direction, up/down, and quadrature A/B encoder signals, typically rated up to around 1 MHz per channel. This capability enables precise feedback from incremental encoders or pulse sources, giving reliable position and speed measurement even on fast‑moving axes. Configurable presets and limits, together with onboard position compare and capture, allow direct implementation of features like registration marks, hardware limits, and immediate stop or slowdown behaviors. For machine builders, this means critical motion reactions can occur inside the motion module itself, reducing latency versus routing everything through general‑purpose PLC inputs​

From a hardware and integration standpoint, GE IC693APU302 is designed as an easy‑to‑use, fully programmable motion module for the Series 90‑30 rack. It communicates with the CPU through standard backplane registers, so configuration, status, and diagnostics are available via the normal PLC programming environment. This simplifies engineering and troubleshooting because motion parameters and alarms can be viewed alongside discrete and analog I/O in the same tools. The module also supports different control modes and can be used with a wide range of servo and stepper drives that accept pulse and direction or similar command formats, giving flexibility in component choice. Over the life of a machine, these features help reduce downtime and make GE IC693APU302 a practical, long‑term solution for embedded motion control in 90‑30‑based systems.

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Detailed technical specifications

Related modules or compatible units

IC693CPU363 – Series 90‑30 CPU commonly used to host applications that command motion sequences executed by GE IC693APU302.

IC693ALG221 – Analog input module often paired with GE IC693APU302 when motion axes must respond to process values like tension, pressure, or position feedback from analog sensors.

IC693MDL645 – Discrete output module used alongside GE IC693APU302 to control brakes, clamps, and other on/off actuators associated with moving axes.

IC693CMM321 – Communication module that lets a 90‑30 system using GE IC693APU302 exchange status and setpoints with higher‑level SCADA or motion supervisors.

IC693APU301 – Related high‑speed counter or motion module in the same family, used where single‑axis or simpler motion/positioning tasks complement the functions of GE IC693APU302.

IC200 family VersaMax I/O – Remote I/O platform often combined with a 90‑30 CPU and GE IC693APU302 to place I/O near drives and motors in distributed motion systems.

Installation notes and maintenance best practices

When installing GE IC693APU302, engineers should allocate an appropriate slot in the Series 90‑30 rack and confirm that the power supply and baseplate can support the additional load. High‑speed encoder and pulse wiring should be routed separately from high‑voltage or high‑current power cables to minimize electrical noise, using shielded twisted‑pair cable where possible. Shields should be terminated according to plant grounding practices to avoid ground loops while still providing noise immunity. Before commissioning, axis definitions, scaling factors (counts per unit), limits, and home positions should be carefully configured and documented to ensure motion behavior matches the mechanical design.

For maintenance, the GE IC693APU302 should be part of routine control‑panel inspections. Technicians should periodically verify tightness and condition of terminal connections, inspect encoder and drive cables for wear or damage, and monitor motion‑related diagnostics from the PLC to catch issues such as following errors or missed pulses early. It is good practice to back up the module’s configuration and motion parameters within the PLC project so that, if the card needs replacement, it can be returned to service quickly without re‑tuning from scratch. When mechanical changes are made—such as replacing a gearbox or changing a pulley—maintenance staff should revisit scaling and limit settings in the motion configuration so GE IC693APU302 continues to position accurately and safely.