IC693ACC350 Flash Image Burn and Restore via PME: A Practical Guide for Industrial Automation Engineers
Many field engineers mislabel the IC693ACC350 as a flash memory card. In reality, this module is a Redundant Power Supply Adapter (RPSA) for the GE Fanuc Series 90-30 platform. It fits into the power supply slot of a standard IC693 baseplate. Moreover, it carries the PLC's RAM backup battery and a 15-pin serial connector. These features are absent on individual power supplies inside a redundant baseplate. Therefore, professionals must understand that this unit manages power redundancy and memory retention—not standalone flash storage. This distinction matters before any Proficy Machine Edition (PME) operation begins.
Backup Battery: The Silent Guardian of Program Integrity
Program retention on the Series 90-30 depends heavily on the backup battery. Specifically, the IC693ACC350 houses a lithium battery that sustains the CPU's SRAM memory. This battery keeps the program alive through power cycles. Field data shows that battery failure is a leading cause of program loss. In similar GE systems, roughly 68% of card-related failures stem from power-loss events during write cycles. Consequently, a healthy battery in the RPSA is essential. Engineers should check battery voltage regularly. A reading above 3.0V DC generally ensures reliable retention.
Preparing PME for Flash Operations on Compatible CPUs
Before any burn or restore action, verify that the target CPU supports flash memory. Notably, not all Series 90-30 CPUs include internal flash ROM. For example, the IC693CPU351 offers 256KB of memory and supports flash storage. However, you must configure the CPU correctly in PME. Set the "Startup Source" parameter to "Flash Memory." If it stays at "RAM Only," the program will not load from flash after a power cycle. Additionally, place the controller in Program mode before writing to flash. This step prevents the CPU from scanning I/O during the critical write process.
Burning a Program Image to Flash via PME
The burn procedure requires a live connection between PME and the controller. After establishing communication, navigate to the Online menu. Then select the "Download to CPU" function. Critically, choose "Download to Flash Memory" instead of the standard RAM download. The CPU's indicator LEDs will flash during the write cycle. Typically, this process completes within 45 to 90 seconds, depending on project size and memory capacity. Avoid disconnecting power during this window. A power interruption at this stage can corrupt the flash image permanently.
Restoring a Program from Flash to the CPU
Restoration happens automatically under the correct configuration. When the CPU powers up with "Startup Source" set to Flash, it copies the stored image into RAM. This process enables rapid recovery after battery replacement or CPU swap. Field service data suggests that about 85% of unformatted or corrupted memory errors are resolved through proper formatting and restoration procedures. If automatic loading fails, trigger a manual restore. Connect PME to the CPU and verify the flash contents through the hardware configuration view. A successful transfer is confirmed when the OK LED remains steady green.
Verification and Post-Restore Checks
Verification ensures the restored image is valid and complete. First, cycle power to the PLC. The CPU should transition to RUN mode within 120 seconds if the program is intact. Second, examine the fault table in PME for new entries. Any flash-related faults indicate an incomplete write or a failing memory component. Third, compare the program logic against the source project. Discrepancies may arise if the original burn was interrupted. Finally, document the flash image version and the date of restoration in maintenance records. This practice supports future troubleshooting and audit requirements.
Key Numerical Specifications for Field Reference
Several numerical values guide reliable operation. The IC693ACC350 supports an operating temperature range of 0°C to 60°C. Its storage temperature tolerance extends from -40°C to 85°C. The module provides a 24 VDC isolated output rated at 20 watts for I/O modules. Redundant 24 VDC user power is available at up to 0.83 Amps. The backup battery typically provides 1200mAh of capacity. These figures help engineers assess whether the module operates within specification. Any deviation should prompt an investigation before flash operations proceed.
Author Insight: Why This Distinction Matters in Factory Automation
In industrial automation, mixing up an RPSA with a flash card can lead to costly downtime. The IC693ACC350 plays a dual role—power redundancy and memory retention—that directly affects PLC reliability. From my experience, teams that treat this module as a simple storage device often skip battery checks. As a result, they face unexpected program losses during power events. Moreover, the flash burn and restore workflow through PME demands careful attention to the "Startup Source" setting. I recommend adding battery voltage verification to routine maintenance schedules. This small step can prevent major disruptions in control systems.
Application Case: Flash Restoration After Battery Replacement
A food processing plant recently replaced a failing battery on its Series 90-30 PLC. The maintenance team followed the restore procedure outlined here. They set "Startup Source" to Flash and cycled power. The CPU loaded the program into RAM within 90 seconds. The OK LED stayed green, and the fault table showed no new entries. This case highlights how proper flash management reduces recovery time in factory automation. It also shows that the IC693ACC350—when understood correctly—supports both power redundancy and fast program restoration.
Frequently Asked Questions (FAQ)
Q1: Is the IC693ACC350 a flash memory card?
No. It is a Redundant Power Supply Adapter (RPSA) for the GE Fanuc Series 90-30. It hosts the RAM backup battery and a serial port, but it does not store flash images itself.
Q2: How often should I check the backup battery in the IC693ACC350?
Check battery voltage every three to six months. A reading above 3.0V DC is generally acceptable. Replace the battery if voltage drops below this threshold to prevent program loss.
Q3: What happens if I set "Startup Source" to "RAM Only" instead of "Flash Memory"?
The CPU will not load the program from flash after a power cycle. You must set "Startup Source" to "Flash Memory" to enable automatic restoration from the flash image.
Q4: Can I disconnect power during the flash burn process?
No. Disconnecting power during the write cycle can permanently corrupt the flash image. The process typically takes 45 to 90 seconds, so avoid any power interruption during this window.
Q5: How do I verify a successful flash restore?
Cycle power to the PLC and confirm the CPU enters RUN mode within 120 seconds. Check the fault table in PME for flash-related entries. Also, compare the program logic against your source project.
