# 1) Quick overview—what is GL20?
The GL20 is INOVANCE’s slim, modular distributed I/O family (remote I/O modules and couplers) designed to expand PLCs (e.g., INOVANCE Easy / AC / AM families) over industrial Ethernet (EtherCAT / PROFINET / Ethernet-IP, etc.). It emphasises compactness, fast response, broad I/O types (digital, analogue, and temperature), tool-free wiring, and modular expansion. ([inovance.eu][1])
# 2) Key electrical & communication specs (high-value facts):
Minimum EtherCAT cycle time: down to 125 µs
Digital I/O hardware response time: typically ≤100 µs
Analog I/O capture cycle: up to 62.5 µs for AI/AO sampling reported in datasheets.
Local bus/D-BUS connector between modules (gold-plated terminals on bus).
Couplers/master interfaces: GL20 includes EtherCAT/PROFINET/Ethernet-IP coupler modules (GL20-RTU-ECT, etc.) that act as bus slaves to the network and provide local expansion.
# 3) Typical module types (what’s available):
Digital input modules—single/16-ch variations (sourcing/sinking).
Digital output modules—transistor outputs, relay outputs (8-ch variations).
Analog input/analogue output modules—multiple ranges, resolutions up to 24-bit ADC for some modules.
Temperature / RTD / thermocouple modules (e.g., GL20-4PT).
Communication interface/coupler modules (e.g., GL20-RTU-ECT for EtherCAT).
(Exact part numbers and pinouts vary by module—see the module’s user manual for terminal assignment and wiring examples.)
# 4) Mechanical / installation features:
Slim/compact profile (modules designed for compact cabinets; some GL20 marketing shows thickness of approximately 12 mm per module design family for space saving).
DIN-rail mount with easy lever/removal system (tool-free module removal).
Push-in/spring clamp terminals with larger apertures for easy wiring (often removable terminal blocks to reduce wiring errors).
Bus termination: when modules are at network ends, a matching resistor/termination may be required per the manual.
# 5) Environmental & compliance (typical ranges—confirm per module manual):
Operating temp/humidity/shock & vibration: each module’s user manual lists exact ranges and standards (GL20 manuals include standard compliance tables). Always check the module’s user manual for exact numbers and certifications before installation. ([simecs.ru][11])
# 6) Useful installation checklist (step-by-step):
1. Read the specific module manual (model code on module)—wiring terminals, LED meanings, and power ratings differ by module.
2. Power sizing: confirm module power consumption (mA) and ensure 24 VDC supply has margin; check separate supply requirements for sensors/actuators.
3. Bus wiring & termination: follow network topology guidelines (line/line-terminations for EtherCAT) and fit end-terminator resistor if required.
4. Grounding/shielding: ground shields at one end and follow the installation notes in the manual to avoid noise. (Manuals include recommended wiring diagrams.)
5. LED check: after powering, verify RUN/ERR and I/O LEDs show expected status (modules have independent diagnosis LEDs).
6. Firmware & config: load any vendor-recommended firmware/firmware levels for couplers; configure in the PLC/engineering tool and map I/O.
# 7) Maintenance checklist—daily/weekly/monthly/annually:
Practical periodic tasks (adapt frequency to your plant and environment):
Daily / Before shift
Visual check of module LEDs (RUN/ERR/UP) and network status on PLC HMI.
Weekly:
Check enclosure temperature and ventilation; remove dust if necessary.
Quick inspection of loose wiring/terminal blocks.
Monthly:
Inspect and lightly tighten removable terminal blocks (if the design uses the screw type), or verify push-in connections remain secure for vibration-prone locations.
Check bus connectors (D-BUS) seating between modules.
Quarterly:
Review bus diagnostic logs on PLC (error frames, timeouts), and check for intermittent errors.
Annually:
Clean the cabinet interior (air-blow, vacuum) and inspect for corrosion on terminals.
Verify the firmware of the coupler/modules and update if INOVANCE recommends it (follow release notes & test in staging).
# 8) Troubleshooting common faults & quick remedies:
Module not responding / ERR LED on: check network cable, terminator, and module power, and verify coupler status in the master PLC tool. If ERR persists, swap with the spare module of the same type to isolate.
Intermittent I/O/noise: inspect grounding and shield termination, shorten sensor wires, or use twisted/shielded cable. Check for high-current conductors and signaling cables.
Bus error frames/high cycle jitter: check network topology and termination, and confirm cycle time settings (e.g., 125 µs minimum for EtherCAT performance).
Fail analogue log readings: verify excitation/reference wiring and sensor wiring, and apply module calibration or replacement if drift persists.
# 9) Recommended spare parts to keep on hand:
1 × coupler module (GL20-RTU-ECT or equivalent)
1 × digital input module and 1 × digital output module of common channel counts used in the machine
Extra removable terminal block(s), a spare DIN rail clip, and spare bus terminator resistors
(Keep firmware images & latest user manuals saved locally.)
# 10) Safety & warranty notes:
Only open modules when powered down unless the manual states safe hot-swap procedures. Many manuals show removable terminals and tool-free removal, but do not assume hot-swap capability without checking that specific module’s manual. ([inovance.eu][9])
Follow the safety/EMC/insulation class and the wiring diagrams in the official user manual to avoid warranty voids.
# 11) Where to get official manuals & datasheets:
INOVANCE product brochures and module user manuals (PDFs) are the authoritative source—examples I used: GL20 brochures and multiple GL20 module user manuals (GL20-RTU-ECT, GL20-1600END, GL20-0008ER, GL20-4PT). If you want, I can fetch the exact user manual or datasheet for a specific GL20 part number you have (example: GL20-0008ER, GL20-1600END, GL20-RTU-ECT, GL20-4PT).
If you want, tell me one of the exact part numbers you’re using (from the module label), and I’ll pull the module’s full user manual/datasheet and extract the terminal/wiring diagram, exact power consumption, operating temp range, pinouts, LED table, and exact troubleshooting steps—I can also produce a short printable maintenance checklist for technicians.