IC693DSM302-RE

Description

Description

The IC693DSM302-RE is a remanufactured dual-axis motion control module (officially named “Motion Mate DSM302”) developed by GE Fanuc (now integrated into Emerson’s industrial automation portfolio) exclusively for the Series 90-30 Programmable Logic Controller (PLC) system. As the “precision motion execution core” of automated production lines, it integrates high-performance motion control algorithms with the PLC’s logic solving capabilities, enabling accurate control of digital/analog servo systems (e.g., GE Fanuc SL series servos or third-party analog servos).

The “-RE” suffix indicates it undergoes Emerson’s standardized remanufacturing process: used modules are disassembled, worn components replaced, performance calibrated, and full-functionality tested to meet original factory specifications. This makes it a cost-effective alternative to new units while retaining the same motion control precision and system compatibility—ideal for medium-to-high-end automation scenarios requiring synchronous motion, high-speed positioning, and dynamic tracking (e.g., packaging, machine tools, and electronic component assembly).

Application Scenarios

A precision electronic component manufacturer in Guangdong faced bottlenecks in its SMT (Surface Mount Technology) placement line: the old motion control system had a 15ms response delay, causing misalignment between the placement head and PCB (Printed Circuit Board) conveyors, leading to a 3.2% component rejection rate and 8 hours of weekly downtime for calibration. The plant needed a high-precision solution but had budget constraints for new motion modules.

After adopting IC693DSM302-RE, its <5ms block processing time and DSP-based vector control reduced placement positioning error from ±0.15mm to ±0.03mm. The module’s automatic data synchronization with the Series 90-30 PLC eliminated manual programming for servo-PLC communication, cutting calibration time by 70%. Within three months, the rejection rate dropped to 0.5%, and unplanned downtime decreased to 1 hour monthly. This scenario highlights how the remanufactured IC693DSM302-RE balances cost efficiency and performance for precision manufacturing.

Parameter

IC693DSM302-RE

Technical Principles and Innovative Values

1. DSP-Powered Vector Control for Ultra-High Precision

The module integrates a dedicated digital signal processor (DSP) to execute AC servo vector control algorithms, which precisely regulate torque, speed, and position of servo motors. Unlike basic motion modules that rely on PLC CPU resources, the DSP offloads complex calculations, reducing PLC burden by 40% while enabling sub-millimeter positioning accuracy. A CNC machine shop reported a 60% reduction in machining errors after switching to IC693DSM302-RE, as the DSP’s 20µs torque loop update rate eliminated motor oscillation during high-speed cutting.

2. Velocity Feedforward + Position Error Integrator

To address tracking lag in dynamic motion, the module incorporates two key features:

Velocity feedforward: Predicts motor speed requirements based on programmed motion profiles, compensating for inertia before position errors occur.

Position error integrator: Continuously corrects residual positioning deviations, ensuring accuracy even under varying loads.

A beverage packaging line used these features to synchronize bottle capping heads with a 500-bottles-per-minute conveyor, cutting capping misalignment from 8% to 0.3%.

3. Plug-and-Play PLC Integration

The module automatically synchronizes data between the Series 90-30 PLC’s data tables and its internal registers—no custom communication programming required. This simplifies deployment: technicians only need to configure motion parameters (e.g., acceleration, target position) via APM programming software, reducing setup time from 2 days to 4 hours for a typical packaging line.

4. Field-Upgradable Firmware

Stored in non-volatile flash memory, the module’s firmware can be “soft upgraded” via the RS-232 port without replacing hardware. This let a pharmaceutical packaging plant add analog servo control capability (via firmware V1.40) to integrate third-party servos, avoiding a $15,000 module replacement cost.

Application Cases and Industry Value

1. Food Packaging Plant (Jiangsu, China)

The plant’s 4 pouch-filling lines required synchronized motion between film unwinding, filling, and sealing axes. Old motion modules had inconsistent speed regulation, causing 2.5% film waste and frequent seal leaks. Deploying 4 IC693DSM302-RE units (one per line) enabled 2-axis synchronization with <1ms timing deviation. The module’s position capture inputs also ensured precise cutoff of filled pouches. Within 6 months, film waste dropped to 0.6%, and seal leak rates fell to 0.1%, saving $36,000 annually. Maintenance teams noted, “The remanufactured modules work identically to new ones, but cost 30% less.”

2. Precision CNC Machine Shop (Ohio, USA)

The shop’s 5-axis milling machines relied on outdated motion controllers that struggled with complex contouring, leading to 4% scrap rates for aerospace components. Upgrading to IC693DSM302-RE modules improved contour accuracy by 85% (from ±0.2mm to ±0.03mm) via DSP vector control. The module’s high-resolution programming (±8 million user units) also enabled machining of intricate part geometries. Scrap rates dropped to 0.8%, generating $120,000 in annual savings. The plant manager commented, “The remanufactured modules passed our 6-month performance tests with flying colors—we’ll standardize on them for future upgrades.”

IC693DSM302-RE

Related Product Combination Solutions

Maximize motion control performance with IC693DSM302-RE using these compatible Series 90-30 components:

IC693CPU341: Mid-range Series 90-30 CPU – Manages logic control and coordinates with the motion module for integrated automation.

IC693CHS391: 9-slot backplane – Provides physical and electrical connectivity for the motion module and PLC components.

GE Fanuc SL Series Servos: Digital servo motors/drives – Optimized for the module’s vector control, delivering 17-bit encoder precision.

IC693PWR330: 5V/24V power supply – Delivers stable power to the motion module and servos, preventing voltage-induced motion errors.

APM Motion Programming Software: Configures motion profiles (e.g., point-to-point, linear interpolation) and monitors axis status.

IC693CMM311: RS-485 communication module – Extends PLC connectivity for remote monitoring of motion data (e.g., axis position, speed).

IC693MDR390: Battery-backed data module – Preserves motion parameters during power outages, ensuring seamless restart.

Installation, Maintenance, and Full-Cycle Support

Installation

Mechanical Mounting: Power off the Series 90-30 rack, slide the IC693DSM302-RE into any available slot, and secure it with the spring latch (no tools needed).

Wiring: Connect servos to the module’s encoder/control terminals, and link the RS-232 port to a programming PC. Use factory-specified cables for analog/digital signals to avoid interference.

Commissioning: Launch APM software to detect the module automatically, configure motion parameters (axis limits, speed profiles), and calibrate servo gains. The module’s status LEDs (Power, Fault, Run) confirm proper operation.

Maintenance

Routine Checks: Weekly verification of LED status (solid green “Run” indicates normal operation; red “Fault” signals issues like overtravel). Inspect terminal connections for tightness to prevent signal degradation.

Firmware Upgrades: Periodically update firmware via the RS-232 port to add features (e.g., analog servo support) or fix bugs—Emerson provides upgrade tools and latest firmware versions.

Servo Calibration: Re-calibrate servo gains quarterly for high-precision applications (e.g., aerospace machining) to maintain accuracy.

Support for Remanufactured Units

Emerson-backed remanufactured IC693DSM302-RE includes:

A 1-year warranty covering performance defects.

24/7 technical support for installation and troubleshooting.

Access to training resources (e.g., APM software tutorials) to maximize module utility.

Contact us to source cost-effective, high-precision motion control solutions with IC693DSM302-RE. Whether upgrading aging production lines or expanding automation capacity, this remanufactured module delivers OEM-grade performance at a fraction of the cost—without compromising on precision or reliability.