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Genius Modular Redundancy TMR System Technical Product

1. Bus Interface P E Unit Module Terminal Block with Communications and Power Terminals for gt Bus Interface Unit o kb ae ole 1 0 Modules ESI L E Se NCBBI LJ Bej E I Bie Bel m iere 2 ENO als D e LL I O Terminal Block SS H esL sen H EJ E eo e DIN Rail 46403 TO Terminal Blocks provide universal field wiring terminals for two I O modules allowing I O module types to be mixed on the same I O Terminal Block The I O Terminal block is mounted on a DIN rail The DIN rail which is an integral part of the grounding system must be mounted to a panel As many as eight Field Control I O modules four I O terminal blocks can be connected to one Bus Interface Unit One optional 21 inch 0 53 meter cable IC670CBL002 can be used per Field Control station The remaining connections must be made using the shorter connectors supplied with the bases Bus Interface Units The Bus Interface Unit provides the I O scanning diagnostics and communications capabilities needed to link the I O modules to the control system In addition the Bus Interface Unit may provide many characteristics for I O GFT 177A Section 4 Product Specifications m
2. 2A PL Max 15A Max Total 244485 Each Genius I O block is a standalone unit with built in power supply microprocessor and Genius network communications circuitry Each block is made of cast aluminum and weighs about 4 pounds 1 8Kg The size of most block types is approximately 9 22cm high x 3 5 9cm wide x 4 10cm deep Each block consists of a matching terminal assembly and electronics assembly The terminal assembly forms the base of the block and is electrically and mechanically keyed to accept only an electronics assembly of the same type All field connections are made to the terminal GFT 177A Section 4 Product Specifications assembly All active components are located in the electronics assembly portion of the block which can be removed without disturbing the field wiring Electronics Assembly Retaining Screws Terminal Assembly w Genius blocks have no switches or jumpers and are software configured via a Hand Held Monitor HHM This soft configuration is stored in the terminal assembly so there is no need to reconfigure if an electronics assembly is changed Genius blocks are unique in that many types allow each circuit to be configured as either an input or an output providing excellent flexibility and the ability to easily customize the I O system to the application In the tables that follow you will
3. After system initialization the HHM is a versatile start up and maintenance tool At any time the HHM itself can be configured and locked so that functionality may be restricted to preset parameters The HHM may be battery operated for up to 6 hours or run off the AC charger adapter unit In battery operation an auto off circuit can be enabled to prolong battery life The HHM can also be continuously powered via an AC charger adapter from a 115 or 230 Vac power source Voltage 230V Selection we Switch J 46620 The NiCad battery pack can be easily replaced with freshly charged pack for continued operation An optional auto shutoff feature prevents unintentional battery drain if a key is not pressed within 10 minutes MODEL IC660 Display Keyboard Keyswitch Battery Battery Charger Communications Cable Weight Size HxWxD Display Languages Communication Data Rates 4 26 Genius amp Modular Redundancy Flexible Triple Modular Redundant TMR System Technical Product Overview February 1998 HHM501 4 line 16 character each line 0 2 5mm high LCD 20 key sealed membrane with tactile feedback 2 position Monitor Configure with 2 keys NiCad pack providing 6 hours of operation with a full charge 115 230Vac 15 47 63 Hz 5 feet 1 5 meter coiled 1 3 Ibs 0 6 Kg without case 1 8 Ibs 0 8 Kg with case 8 x3 75 x1 25 without case 10 85 x4 3 x2 25 with case
4. English German French or Italian 153 6 Kbaud Standard 153 6 Kbaud Ext 76 8 Kbaud or 38 4 Kbaud GFT 177A Genius Block GM R Termination Boards and Interface M odules Termination boards and interface modules which can be used to simplify the integration of Genius blocks into redundant groups have been developed by Silvertech Limited Termination boards and interface modules are available for 2 or 4 block discrete output groups and for 2 or 3 block discrete and analog input groups The use of termination boards and interface modules is optional The interface modules perform basic grouping and conditioning of I O device signals The termination boards interface these signals to the Genius blocks performing any additional signal conditioning if necessary Interface modules are DIN rail mountable with connectors for the I O devices and termination board wiring 34 wire ribbon cables the mating connector and cable are not supplied are used to connect interface modules with termination boards The interface module segregates I O wiring from internal panel wiring Termination boards attach to the side of each Genius block in a group The board is held in position by its connection pins which are inserted into the screw terminals of the Genius block Spacers on the termination board provide the necessary clearance between the board and the Genius block The termination board also has a connector for power and ground wiring wh
5. REN p 4 27 16 Point Discrete Input Termination Boards and Interface Modules Operating voltage Temperature range Humidity Connectors Interface Module Size Termination Boards Size Interface Modules External Inputs Open Switch Voltage Closed Switch Current Silvertech part numbers GBCI SC DI16 GBC1 SK DI16 IMC3 SC DO16 IMC3 SK DO16 CBL1 CK RRnn CBL1 CK EEnn CBL1 CK EBnn 20V to 32V DC 0 degrees C to 60 degrees C 5 to 95 non condensing One ELCO male 8016 series 38 pin exposed contacts Three 34 pin IDC connectors for ribbon cable 219mm length X 95mm width X 30mm depth 145mm length X 109 mm width X 101mm depth including mating connector including mounting bracket GMR Mode 15 16 normally closed switches with zener diodes in series for tristate inputs 15 with autotest Non GMR Mode 15 16 normally open switches with zener diodes in parallel for tristate inputs 15 with autotest Bistate or tristate GMR Mode supply voltage Tristate non GMR Mode zener voltage Bistate 11mA at 24V supply Tristate GMR Mode 7mS at 24V supply Tristate non GMR Mode 11mA at 24V supply Termination Board for 16 circuit Source block Termination Board for 16 circuit Sink block Interface Module for 16 circuit Source block group Interface Module for 16 circuit Sink block group 34 way ribbon cable termination board to interface module Field device connection cab
6. SERIES 90 70 PROGRAMMABLE CONTROLLER Power 2 3 4 Supply Series 90 70 PLC 19 inch Main Rack with Typical Modules GENIUS GENIUS PROGRAMMABLE LomMUNICATIONS BUS CONTROLLER BUS CONTROLLER COPROCESSOR _ Modules can be selected to suit the application Larger applications can include up to seven Expansion Racks daisy chained from the Main Rack of each GMR PLC In a system with Expansion Racks there must be a Bus Transmitter Module in the Main Rack and a Bus Receiver Module BRM in each Expansion Rack The last Expansion Rack can be up to 50 feet 15 meters from the Main Rack Each Expansion Rack supports up to nine modules with one slot used fora BRM A GMR system with three PLCs can include up to 24 racks with to 93 Genius Bus Controllers 31 triplicated sets Some intelligent modules must be located in the Main Rack GMR Bus Controllers can be located in the Main Rack or in any Expansion Rack No spare slots are required in any rack for spares or hot replacements Mechanical keying prevents modules from being inserted into the wrong location The architecture of a GMR system makes it possible to replace any module while the system continues operating ETHERNET CONTROLLER 5 6 7 8 9 a46600 GFT 177A 3 1 PLC Redundancy Options Redundancy options for the PLC portion of a GMR system include a Simplex one PLC Duplex two PLCs a Triplex three PL
7. Master Control Relay Starts a master control relay range All logic rungs between the MCR and its subsequent ENDMCR will be executed with no power flow End Master Control Ends a Master Control Relay range Relay Label Jumps to a specified location indicated by LABEL in the logic The target location of a JUMP instruction A rung explanation Service Request A special PLC service function ISA Algorithm Selects the standard ISA PID algorithm Selects the non interacting independent PID algorithm Independent Algorithm Start End Exit Used to repeat rung logic a specified number of times while varying the value of the FOR INDEX VAR in the loop FOR loop SFC Reset Resets the SFC topology and if the OVR input is active clears all overrides TUV Approved yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes except functions 1 3 4 6 8 14 19 Can be used only for operations that are not required by the GMR system and which are not safety related These portions of the system may receive I O status from TUV or non TUV approved I O including certain other Genius blocks non approved rack based modules or any other allowable Genius and Series 90 Family components not specifically approved for use in a safety application GFT 177A Section 5 Configuring amp Programming a GMR System 5 13 System Data Types Supported and Typical
8. GFT 177A System Technical Product Overview February 1998 GFT 177A Online Programming and Storing of the GMR Application Program Online application program storing may be done from a PC through a standard serial port without any reconnection of cables and to all CPUs connected on the multidrop cable provided in the GMR programmer s kit The download utility file included with the GMR software allows multiple CPUs to have programs stored conveniently The utility is prompt driven Single keystroke entries move the utility through the downloading steps Because online changes are considered potentially dangerous the GE Fanuc TMR system provides an alternative method of downloading Using this alternate method a single CPU may receive the new program alone If there are any discrepancies they are reported via the CPU fault tables If any undesired response is observed the program may be modified without any averse effect on the control system operation NOTICE Once a critical system has been implemented T V requires that online programming be disabled during the final commissioning TW1 This is done using the GMR configuration software utility After storing the configuration and program logic to the CPU the system hardware is checked upon initialization The configuration data is checked with the actual hardware system to insure it matches GMR configuration mismatches are reported through the Logicmaster 90 fault
9. Global Data may be received by any intelligent connected device GMR An acronym for Genius Modular Redundancy GMR is a triple modular redundant TMR and flexible high integrity system It has scaleable configuration for m single dual or triple input support m single dual or triple CPU support m fail safe fault tolerant and fault tolerant fail safe output support H H Pattern Output A fault tolerant output whose state is controlled by two parallel sink Genius blocks and two parallel source Genius blocks Hot Backup A redundant component ready to and capable of coming online without causing a bump in the process Typically this requires synchronization and online supervisory diagnostics P Hot Standby A redundant device ready to be manually or automatically placed online Hot Standby devices help shorten the MTTR cycle I Fault Tolerant for Control Operational A Fault Tolerant circuit when used in safety circuits that are normally de energized to safe See Fault Tolerant 1 0 Fault Table A diagnostic table in the Series 90 70 PLC that lists I O faults Each fault is described and identified by time date and location 1 0 Module A rack mounted or remotely installed assembly that interfaces field input and output devices such as actuators and sensors to a controller such as a Series 90 70 PLC Initialization Data At system startup a GMR CPU synchronizes
10. Number GBCI SC DII6 GBCI SK DI16 IMC3 SC DI16 IMCI SK DI16 GBCI SC DI32 GBCI SK DI32 IMC3 SC DI32 IMCI SK DI32 GBCI CK AI6 IMC3 CK AI6 IMC4 CK DO16 GBC1 SC DO32 GBCI SK DO32 IMC4 CK DO32 CBLI CK RRnn CBLI CK EEnn CBLI CK EBnn GBC1 CK DO16 TUV Approved Termination Boards amp Interface Modules T V Approved Yes Refer To n a n a n a n a Refer To Page 4 27 Page 4 27 Page 4 27 Page 4 27 Page 4 27 Page 4 27 Page 4 27 Page 4 27 Page 4 27 Page 4 27 Page 4 27 Page 4 27 Page 4 27 Page 4 27 Page 4 27 Page 4 27 Page 4 27 Page 4 27 All Series 90 70 PLC and Genius I O products can be used in a GMR system however not all of the available components are TUV approved for use in the safety relevant portion of a system GFT 177A Section 4 Product Specifications 4 3 GMR I O Components List Genius Discrete Inputs Description 24 48V dc Source 15 16 Circuit 24 48V dc Sink 15 16 Circuit 12 24V dc Source 31 32 Circuit 5 12 2A4V dc Sink 31 32 Circuit 115Vac 8 Circuit 115Vac 125Vdc 8 Circuit Isolated 115Vac 125Vdc 8 Circuit Isolated 115Vac 16 Circuit Isolated Genius Discrete Outputs 4 4 Description 24 48V dc Source 15 16 Circuit 24 48V dc Sink 15 16 Circuit 24 48V dc Source 31 32 Circuit 5 24 48N dc Sink 31 32 Circuit 115Vac 8 Circuit 115Vac 125Vdc 8 Circuit Isolated 115Vac 125Vdc 8 Circuit Isolated Relay N C 16 Circuit Relay N O 16 Ci
11. OFF BM Switch POWER SUPPLY MODULE INPUT 120 240VAC 14A 0 7A 50 60HZ 125 VDC 14A OUTPUT 45V AT 20A 412 AT 2A 12 AT 1A 100 WATTS WARNING DO NOT DISCONNECT WHILE CIRCUIT IS ALIVE UNLESS AREA IS KNOWN TO BE NONHAZARDOUS Replace with same type and rating 2A 250V INPUT u 7 eG ru pauls 120 240VAC 125 VDC ud rd 7l Torque 12 in Ib 1 3 N m 75_C Copper Conductors Protected Input Power Source Screws O O Power Supply Module with Door Open and with Door Closed The input power source connects to the power supply through a group of protected screw connections on the front of the power supply module The module LED is visible through the transparent upper portion of the door The LED indicates the status of the power supply If the LED is off it indicates an overload condition or output voltage levels that are out of tolerance Each supply provides automatic overvoltage and overcurrent protection for its DC outputs Some supply types include a replaceable input power fuse Most supply types have an on off toggle switch located inside the hinged door LOGIC POWER POWER SUPPLY PROGRAMMABLE CONTROLLER GFT 177A Section 4 Product Specifications 4 9 Dual Rack Configuration The use of the power supply expansion cable IC697CBL700 provides the capability to power a second rack with 5 volts only from the sa
12. Simplex Duplex amp TMR Depends on amount of TMR I O Max Total voted analog inputs Max Total simplex inputs outputs Maximum Application Program Size Approximate Cooling Fans CPU788 CPU789 CPM790 112 2048 2048 80 2048 2048 112 4096 4096 352 12288 12288 1024 1024 1024 8192 8192 8192 200K bytes 200K bytes 512K bytes Not required Not required Not required for ambient 40 C Fan kit is required for ambient 240 C All Remaining CPU Module Specifications are common to the CPU788 CPU789 and CPM790 Max Register Table Size Max Analog Inputs Max TMR Analog Inputs Max Analog Outputs Autotest Time Interval Ladder Logic Execution Rate Lithium Battery for Memory Backup Clock Ladder Instruction Set WatchDog Timer Digital Vote Type Analog Vote Type Degradation Options On Line Programming Write Protection for Application Program Variables Processor Synchronization Effect of CPU Failure 4 12 Technical Product Overview February 1998 Genius amp Modular Redundancy Flexible Triple Modular Redundant TMR System 16 Kwords 8192 Depends on amount of TMR Analog Inputs 1024 8192 0 to 65535 Minutes Boolean 0 4ms per 1024 elements 3 Volt 1000mA hours 6 months minimum retention Battery Backed Calendar Clock Contacts Coils Links Timers Counters Bit Operation Conversion Relational Control Math Data Table and Data Move Configurable from 10 to 2250 milliseconds 2 out
13. Supervised Inputs A method of monitoring inputs for short circuits during GMR system operation System Architecture The overall configuration of a system including the types of components it contains and the ways they interact GMR provides very flexible configurations for implementing a wide variety of control solutions Appendix D GMR System Glossary L2 T T Fail Safe for Safety De energized T creates an electrical Fail Safe circuit when used in safety circuits that are normally energized to safe See Fail Safe Test Interval The time between autotest executions This time interval can be modified Threshold Discrepancy The amount by which an individual analog input may deviate from the voted input value Triple Modular Redundancy TMR A system architecture that is both fault tolerant and failsafe GMR is a TMR system Triplex Systems or subsystems that utilize three sets of components to perform the same operation Tri state Inputs A physical input that is configured and installed to report three independent discrete states to the CPU Tristate inputs provide a level of supervision and or diagnostics unavailable in simple On Off state monitoring Also see Supervised Inputs TUV Rheinland TUV is the acronym for Technisher berwachungs Verin T V is an independent German technical inspection agency and test laboratory It is widely recognized and respected for its te
14. TMR inputs continue to operate with the remaining blocks or legs of the input group Failed TMR input blocks may replaced hot power on without disturbing the functioning portion of the input group or any other part of the system blocks also provide supervised input diagnostics input shorted to 24Vdc MODEL 1C660 Number of Points With Autotest Number of Points W O Autotest Nominal Voltage Source or Sink Operation DC Voltage Range Required DC Power Max Block Isolation Point Status LEDs Diagnostic LEDs Supervised Input Diagnostic P S Dropout Time Operating Modes Input Autotest Stuck On Off Input Autotest Channel to Channel Short Loss of Block Diagnostic Selectable Filter Time Input Impedance Typical On Threshold 12Vdc Power On Threshold 24Vdc Power On Threshold 48Vdc Power Off Threshold 12Vdc Power Off Threshold 24Vdc Power Off Threshold 48Vdc Power Weight BBD020 BBD021 BBD024 BBD025 Bom OR p 24 A8V dc 24 48V dc 12 24V dc 5 12 24Vdc 18 56 18 56 10 30 10 30 amp 4 9 5 3 1500V 1500V 850V 850V Unit OK Block or Point Fault Indication O Enabled On Line and Forced Point Indication Ye ves ve ma 10 ms 10 ms 4ms 12V 4ms 12V 20ms 24V 20ms 24V TMR HSB TMR HSB TMR HSB TMR HSB oy lt a SIMPLEX T hau Deme dts s 4 bs 1 8 kg These blocks can operate as inputs or outputs in any combination when in
15. Unused rack slots should be covered with blank slot covers to slot minimize connector exposure to foreign material Dimensions of a Standard Series 90 70 PLC Rack WITH OPTIONAL VME J2 BACKPLANE KIT la 9 00 12 60 gt je 1 00 WE atid acm 25 4 9 14 lt gt 232 gt 460 297 lt 7 25 gt j 184 REMOVABLE o9 f yo TERMINAL E BLOCK CONNECTOR FOR POWER SUPPLY SPACER QTY 4 Besse HINGED SIDEMEW DOOR de ce FRONT VIEW 25 DIA TYPICAL VO TERMINAL E RANGE 8 64 RESTRAINING STRAP FROM BOTTOM DIMENSIONS FOR DIMENSIONS IN INCHES MILLIMETERS ARE IN PARENTHESIS 5SLOTRACK 242984 4 8 Genius amp Modular Redundancy Flexible Triple Modular Redundant TMR System GFT 177A Technical Product Overview February 1998 Power Supply M odules CPU and expansion rack power supplies are inherently redundant in the GMR system because an individual power supply is normally used in each rack In some configurations a single power supply may be used to power both a CPU rack and an expansion rack by using a power supply expansion cable Power supplies are available that handle input power sources of 24 Vdc 48Vdc 125 Vdc 120 Vac and 240 Vac Power supplies are also available with different output wattage capabilities up to 100 watts at 60 degrees C Selection of a power supply can be tailored to the needs of your system Q LED ON On
16. clB Time to Store 16 Kbyte 20 to 30 seconds ID M 3 Program Maximum Cable Length 50 Feet 15 Meters Total Effective I O Data Rate 500 Kbytes Second Main Rack Programmer C Electrical Isolation Non isolated Differential n Communications R b M o aT Bus Transmitter or Bus Receiver Module VI NOTE with Door Open TOTAL LENGTH OF ALL B INTERCONNECTING CABLES R FROM BTM TO LAST BRM IS 50 e M o FEET 15 METERS MAXIMUM Q ALL RACKS MUST BE AT SAME GROUND POTENTIAL 8 L9 RACKS MAXIMUM LEDs 3 P R o S fm o i a46617 Expansion gt The Bus Transmitter Module is used in the main CPU Port rack to begin the daisy chain of rack s using parallel I O cables ICG600WDFXXX where XXX length in feet The upper connector on the BTM can be used as a high performance interface to the running LM90 0 programming and configuration software The bottom connector of the BTM is for daisy chain cable connections between the Main CPU rack and all expansion racks LEDs at the top of the BTM module Expansion gt provide Module OK Programmer Port Enabled and Port Expansion Port Enabled status information The Bus Receiver Module is used in each of the expansion racks and is always installed in slot one Both connectors in the BRM are for connections between O racks LEDs on the BRM module provide Rack Configured Termination Installed and Expansion Port Enabled status i
17. faulty module can be replaced online Process protection continues without interruption 1 3 Section Operation 2 The purpose of this section is to explain how a GMR system operates how field inputs are gathered stored and processed how field outputs are generated how voting occurs and how the extensive diagnostics capabilities of a GMR system assure maximum I O data integrity Genius Modular Redundancy is an extremely flexible system that is able to provide variable redundancy from the input modules through one to three PLC CPU processors to the output modules Input data is gathered from field input devices wired to groups of one to three Genius discrete or analog blocks or Field Control analog input modules Each input may be simplex single duplex double or triplex triple depending on the needs of the application Each Genius or Field Control device transmits input data once each scan on a Genius bus Because these devices broadcast their input data the same inputs are available to all PLCs on the bus Depending on the redundancy needs of the application there may be one two or three PLCs in the GMR system Each PLC CPU votes on the input data it has received before each execution of the application program CPUs run asynchronously from each other and do not share their I O data which eliminates the possibility of one CPU corrupting input data memory in another CPU This feature reduces overall system c
18. selected areas of R and M memory with the corresponding memory in the other GMR CPU s M memory is usually used for latches while R memory is used for timers and counters Input Discrepancy See Discrepancy ISO 9001 Certification that certain required procedures for quality and customer satisfaction are in place and are being continually followed GE Fanuc has received ISO 9001 certification L Ladder Diagram See Relay Ladder Logic Latent Fault See Covert Fault Limit Discrepancy The percent by which an analog input may deviate from the full scale deflection values set up for that channel Minimum and maximum full scale deflection values for each input are configured for the application Logic The user application program Logicmaster 90 The programming and configuration software used with Series 90 PLCs M Mean time between failures MTBF The mean number of hours a device or system may be expected to operate before a failure The number is based upon a large group of physical field samples Mean time to repair MTTR An average time required to repair equipment after a failure It is based upon user experience the type of equipment installed the locations of the devices or components and the availability of replacements Mid value Select When three values of a triplex analog input are measured the GMR voting mechanism discards the high and low values and uses the middle
19. 1 Sinplex da Ze cere tice 790 corso EMEN OBNJIUIEEES 0 Enable aS m I O limits for the system W Initialization data for the system Genius Modular Redundancy Flexible Triple Modular Redundant TMR System Technical Product Overview February 1998 W Fault actions for the system W All GBC bus controller groups with all Genius I O blocks that will use GMR features G C Group Voted nput Group igital Genius W I O addresses and other features of GMR block groups 1 Triplex In 16 ID Start zI SBA est VoteAdapt W For each circuit synchronous or asynchronous Autotest at intervals ranging from minute to more than 45 days fiutoTest Test pe Tb xa m How long inputs may be discrepant before the CPU places a message in the I O Fault Table and sets a fault contact The range is 1 second to 18 hours W Starting addresses and lengths for any memory areas to which data can be written to through a CMM PCM or Ethernet Communications Module GFT 177A GFT 177A PLC System Configuration The overall PLC system configuration is completed using the Logicmaster 90 70 software which also runs on a personal computer Modules are quickly selected from lists by function key It is possible to completely configure the system offline with no PLC hardware present Typical Module Type Selection Menu ACK tps 4 6 8 9 0 CATALOG DESCRIPTION TYPE
20. 17 These communications interface modules may be used in a TUV approved system when the appropriate variable write access protection is configured in the CPU Expansion Interfaces Description Bus Transmitter Module Bus Receiver Module Field Control Genius Bus Interface Unit Field Control I O Terminal Block with Barrier Terminals Field Control I O Terminal Block with Box Terminals Field Control I O Terminal Block with Wire to Board Connectors Catalog Number 1C697BEM713F IC697BEM711J IC670GBI002 102 IC670CHS001 101 IC670CHS002 102 IC670CHS003 103 TUV Approved Yes Yes Refer To Page 4 16 Page 4 16 Page 4 31 Page 4 32 Page 4 32 Page 4 32 Cables Etc Description Multi Drop SNP Cable RS232 RS485 Converter Parallel I O Expansion Cables Parallel Bus Terminator Plug Description TB 16 Disc Src Inputs TB 16 Disc Sink Inputs IM 16 Disc Src Inputs IM 16 Disc Sink Inputs TB 32 Disc Src Inputs TB 32 Disc Sink Inputs IM 32 Disc Src Inputs IM 32 Disc Sink Inputs TB 6 Analog Inputs IM 6 Analog Inputs TB 16 Discrete Outputs IM 16 Discrete Outputs TB 32 Disc Src Outputs TB 32 Disc Sink Outputs IM 32 Discrete Outputs TB to IM Cable Cable w 2 ELCO 8016 connectors Cable w 1 ELCO 8016 connector stripped tinned connectors at other end Catalog Number IC690CBL714 IC690ACC901 IC600WDXXX IC697ACC702 Catalog
21. 177A Section 3 GMR System Architectures Input Redundancy Options Redundancy options for input devices in a GMR system The flexibility of the GMR system makes it possible to are shown in the following illustrations apply the exact mix of input redundancy options needed for the application The use of duplex or triplex sensors The types of redundant input options shown in these that provide signals to either two or three Genius blocks illustrations are available for both discrete inputs and or Field Control analog input modules from the same analog inputs Note that analog inputs can use either portion of the monitored process provides maximum Genius or Field Control devices including inputs from input redundancy thermocouples and RTDs m Three Input Devices Connected to Three Blocks or One Input Device Connected to Three Blocks Field Device P T mmrromdzoowcn H B BIB u uu s ss c cc o olo N N N T T T R R R o ojo L LL L tye E Ele R R R m omdzooncm 2m rom4dzooncm e Field Device Triplex sensors Discrete analog thermocouple RTD Separate Genius bus for each block Single sensor All PL
22. 2 79 Bytes When L used is in the range 1 to 64 the L allocated 96 Otherwise compute the number of L allocated of L used 64 32 rounded up to whole integer 32 96 AI Memory If point fault DISABLED AI used x 2 Bytes or If point fault ENABLED AI used x 3 Bytes AQ Memory If point fault DISABLED AQ used x 2 Bytes or If point fault ENABLED AQ used x 3 Bytes If point fault ENABLED add 3072 Bytes GRAND Total Bytes aismesamamuua RR DNRRNRAURRURKUR MUR MNA CPU Memory Total Bytes For CPU790 524 288 19 840 G M R09 block 504 448 or For CPU788 or 789 524 288 323 936 GMR System S W 200 352 Subtract Grand Total From Above enne Application Program Memory Available in Bytes Note P or L allocation for a program block cannot be changed while Logicmaster 90 70 software is online unless no P or L is currently used in that block To change the current P or L allocation Logicmaster 90 70 software must be offline The resulting program must then be stored to the PLC in STOP mode A 2 Genius Modular Redundancy Flexible Triple Modular Redundant TMR GFT 177A System Technical Product Overview February 1998 Appendix Estimating Scan Time b CPU Scan Time The application program in GMR CPUs normally executes in a repetitive fashion until it is stopped by a command from the programme
23. 60 160 Watts 160 Watts 100 Watts 90 Watts 5 12 12Vdc 5 12 12Vdc 5 12 12Vdc 5 12 12Vdc 100 Watts 90 Watts 60 watts 90 Watts 5 7 6 7 Volts 5 7 6 7 Volts 5 7 6 7 Volts 5 7 6 7 Volts 2 amp 5V 26 amp 5V 32 amp 5V 26 amp 5V 3 5 amp 12V 4 amp 12V 10 amp 12V 4 amp 12V 1 6 amp 12V 2 amp 12V 10 amp 12V 2 amp 12V 2 ms min 10 ms min 10 ms min 10 ms min GFT 177A CPU M odules Three Series 90 70 CPUs are available for TMR applications The high performance CPM790 CPU which supports 2048 TMR I O points is based on a 64 MHz 80486DX2 microprocessor and includes a 1 megabyte memory daughterboard The model 788 CPU supports approximately 100 TMR I O points and the model 789 CPU supports approximately 2048 TMR I O points Both the 788 and 789 have a 16 Mhz 80386DX microprocessor and occupy one slot in the CPU rack with memory daughterboard attached Software configuration of the CPUs is done using the LM90 70 programming and configuration software no switches or jumpers are used These CPUs execute both the GMR system software and the application program logic Application program logic is typically written in ladder logic form but Sequential Function Chart SFC programming and C programming capabilities also exist These CPUs along with the GMR system software perform the following functions User application program execution Inter CPU communications Majority voting of all i
24. 70 Genius Bus Controller User s Manual GFK 0398 PLC C CVO Multidrop Cable RS 232 422 Converter Multidrop cable is catalog number IC690CBL714 1 cable Two cables are needed for 3 CPUs 46623 Section 5 Configuring amp Programming a GMR System 5 9 Program Functions All Series 90 70 instructions can be used in the non safety portion of the GMR application program The comprehensive set of T V supported ladder program functions indicated in the righthand table column can be used to create complete Emergency Shutdown ESD Safety Interlock System SIS or Critical Safe Control CSC safety system programs The GMR system can take advantage of the extensive set of coils contacts and program functions that are available for the Series 90 70 PLC These include standard coils and contacts fault and alarm contacts logical and relational functions math functions bit operations timers and counters and many other advanced functions as listed in the following table Contacts TUV Approved 1I yes 1 yes 11 yes LU yes fault yes noflt Passes power if the associated discrete point or rack slot module does not have a yes fault hialr High Alarm Passes power if the associated analog point has a high alarm fault yes loalr Passes power if the associated analog point
25. CONFIGURATION GMR Configuration Pee Printout GMR Diskette 790 788 789 CONFIG EXE G M R10 GMRxxyy Program KEYO DEF Block LM90 LM90 PROGRAMMING Librarian gt The Application Program future program x updates LM90 LM90 LM90 Store Store Store i I I I I I O Block Configuration with Hand held Monitor GFT 177A 5 1 GM R Configuration The GMR characteristics of a system are set up using special GMR software on a personal computer The GMR configuration is the same for the redundant PLCs there is only one GMR configuration for the system The GMR configuration presents the configuration items as choices on menu screens like the examples on this page Typical GMR Configuration Screen OC Group ll TEES m Voted tlut 15 is ripi h hh TER ES The GMR Configuration Software automatically supplies default values Only items that are different from the defaults need to be changed Configurable items include W The number of CPUs CPU type ability to enable disable online programming ability to shut down if only one PLC remains operating timeout period from 1 second to 18 hours System CPU EG
26. Cycle 1 Cycle 10ms DC 10ms DC Diagnostic LEDs Unit OK Block or Point Fault Indication J O Enabled On Line and Forced Point Indication Diagnostics Available Loss of Block Loss of I O Power Short Circuit Overload No Load Failed Switch Overtemp Max Inrush Current for 2 cycles AC or 25amps peak 25 amps 25 amps 2 amps 10 ms DC Output Off Leakage Current 7 ma 7 ma AC 7 ma AC 0 1 ma 2ma DC 2 ma DC Weight 4 lbs 1 8 kg These blocks can operate as inputs or outputs in any combination GFT 177A Section 4 Product Specifications 4 23 Genius Analog Input Blocks All of the listed block types may be used as TMR Analog input blocks These blocks include those that can handle Voltage Current R T D and Thermocouple input signals TMR Analog input blocks function in a group of up to three blocks of the same type The duplicate and triplicate input data is received at all GMR CPUS and then voted just prior to executing the application program to ensure the highest integrity of the input data used Voting on triplicated data is mid value select with the vote adapting to average select high or select low in the event of a failure A second failure results in further vote adaptation to either use the last operational input or go to a preconfigured minimum maximum or hold last state value AC MODEL IC660 DC MODEL IC660 Number of Points Operating Modes Input Range s 4 2
27. For Hot Standby redundancy a load must be connected to one sink type or source type discrete Genius block Blocks in Hot Standby mode receive outputs from all GMR CPUs and use the output data from the CPU with the Bus Controllers at the highest serial bus address 31 30 29 that are currently online Output loads that must be both failsafe and fault tolerant are connected to a standard H pattern group of two parallel source type blocks and two parallel sink type blocks A T pattern output group can provide fault tolerant operation with two parallel sink type or source type blocks This type of group might be used in high availability or fire and gas applications where it is necessary to be able to turn ON a critical load An I pattern output group can provide failsafe operation with one sink type and one source type block wired in series with a load This type of group might be used in failsafe applications where it is necessary to be able to turn OFF a critical load Non critical outputs can be wired to individual discrete or analog blocks Such blocks can be configured for no redundancy or for one of the three CPU redundancy modes Hot Standby Duplex or GMR 2 out of 3 For clarity the illustrations show only one output load connected to a single block or to a group of blocks However each block or group of blocks can control outputs to 16 or 32 loads depending on the block type Single Hot Standby Output zm
28. GMR system can be sent to a printer so a hard copy of the current configuration documentation is easily prepared The information may also be exported to documentation software under the DOS or Windows operating systems I O Configuration Genius I O blocks and Field Control Bus Interface Units in the system are configured separately to assign parameters such as address type diagnostics operation communication and mode settings Programming The Logicmaster 90 70 software is also used to create the Relay Ladder Logic GMR application program An example screen of logic during edit is shown below The top of the Logicmaster screen always shows the current assignments of the function keys which are used to select program functions For example on the program editing screen illustrated below the second row shows Contacts Each Contact can be selected with one key press The status information at the bottom of the screen can be turned off for even more program display area Example Relay Logic with Contacts 700002 7100001 I 4 xM00121 100002 D NLMSONLESSUN zal n MAIN SIZE 234 nUNG 0007 REPLACE JA The Series 90 70 PLC provides a large and extremely versatile set of coils contacts relational functions logical functions and many advanced functions for use in the application program They are described in the table that begins on page 5 10 The same application program is used for each GM
29. HSB or Simplex Mode 4 20 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFT 177A Technical Product Overview February 1998 Discrete Input Block Specifications Continued The following blocks can be used as simplex input blocks in a GMR system MODEL IC660 Number of Points Nominal Voltage Operating Modes AC Voltage Range 47 63Hz DC Voltage Range P S Dropout Time Block Isolation Point Status LEDs Diagnostic LEDs Open Input Diagnostic Shorted Input Diagnostic Loss of I O Power Diagnostic Selectable Filter Time Input Impedance Typical AC On Threshold Normal Mode AC Off Threshold Normal Mode DC On Threshold Normal Mode DC Off Threshold Normal Mode Weight Simplex input blocks also provide a variety of diagnostic capabilities depending on the block type Please refer to the Genius I O User s Manuals for more details BBD101 BBD102 BBD103 BBD110 8 Grouped 8 Isolated 8 Isolated 16 Grouped 4 Groups 4 Groups 115Vac 115Vac 115Vac 115Vac 125Vdc 125Vdc SPLX HSB SPLX HSB SPLX HSB SIMPLEX 93 132 93 132 93 13 93 132 1 Cycle 1 Cycle 1 Cycle 1 Cycle 10ms DC 10ms DC 1500V 1500V 1500V 1500V Unit OK Block or Point Fault Indication J O Enabled On Line and Forced Point Indication a a 4 Ibs 1 8 kg These blocks can operate as inputs or outputs in any combination GFT 177A Section 4 Product Specifications 4 21 Geni
30. ability to electronically transfer system data between the CPU and other intelligent master and slave devices Data Memory Areas of memory that are used by the application program to store data Datagram A message sent from one Genius device to another The message length can be up to 128 8 bit bytes De energize to Trip Most elements in a GMR system are engineered to be energized operational For such elements the safe state is to be de energized upon a signal or voted signal Degradation Path The method used to keep an area of a fault tolerant system operational when some part of it is lost Detected Failure An apparent not covert failure The failure is detectable because it causes a change of operation request For a control or ESD system this is the safe state Diagnostic Coverage The extent to which a system is able to diagnose improper operation and failed system components Diagnostics Active mechanisms that can detect both covert and apparent faults GFT 177A Appendix D GMR System Glossary L2 Discrepancy Disagreement among corresponding votes in a votoing system Discrepancy Filter A selectable time delay that may be applied to corresponding elements in a voted group in real time transitional systems The delay allows system asynchronicity at the field device I O scan and logic execution level If a discrepancy occurs it is not reported until the selected amount of time
31. accomplished by using the LM90 70 programming and Configuration software The CMM module utilizes a 12 Mhz 80C186 microprocessor CMM Module with Door Open LEDs Restart Pushbutton RS 232 RS 485 Serial Port RS 232 RS 485 Serial Port 846613 MODEL IC697 CMM711 Protocols CCM RTU SNP SNP X Port 1 Interface type RS 232 or RS 422 RS 485 Port 2 Interface type RS 232 or RS 422 RS 485 Port 1 Max Data Rate 19 2 Kbps full duplex Port 2 Max Data Rate 19 2 Kbps full duplex Dual Port Max Data 19 2 Kbps full duplex on both port Rate simultaneously Battery None Required Microprocessor 12 Mhz 80C186 Configuration Via LM90 70 Software No Switches or Jumpers 4 13 Communications M odules continued Programmable Coprocessor Module PCM The Programmable Coprocessor Module PCM functions as a coprocessor to the CPU It can be programmed to perform operator interface real time computations data storage and custom protocols for data acquisition or data communications functions CCN2 functions provided by the PCM module are read write of register input and output tables bit set clear of inputs and outputs read scratch pad Q sequence commands for fast reads and modify diagnostic status word In the master and peer CCM configurations the PCM module initiates communications with other devices through application program req
32. can be set to synchronize with Distributed Control Systems the programmer PC CPU and other devices It is battery backed 5 5 Program Annotation Each contact or data variable in the GMR application program is given a 1 to 7 character nickname e g tag number etc Each reference can have a four line by 7 character label The nickname and label can be entered in the program imported from a cut paste utility such as found in Windows or through the Logicmaster Variable Declaration table illustrated below Logic Display with More Annotation PROGRE O EGRE Intake Valve Control Switch START OF PROGRAM LOGIC fir Intake Valve Switch 1140_01 FOLDER UTILTY PRINT Hinsert edit Rnd iruik isearch ED Byoptionfiiyoto inore izom Example Variable Declaration Table Registr Input Data REG 111 TB EM PROGRE O RES FOLDER UTILTY PRINT 700002 E Winsertlgedit MedcleteiscarchE ED d soto Brey ionfidswitch s VARIABLE DECLARATION TABLE REFERENCE NICKNAME REFERENCE DESCRIPTION 7100001 weld duell timer 100033 7100037 7100101 7 100102 7100105 7400002 DWELL_T LIMIT_T FREE 1140_00 1140_01 1141 0 spare input not uired Program Searches fiir Intake Valve Suitch Intake Valve Control Suitch The Search function will quickly find an identifier name and or a reference address and or a nickname and or an instruction anywhere in the program START B152_00 machi
33. has passed Discrete One bit application data that is capable of indicating two states The term discrete includes both real and internal I O Distributed Control System DCS A proprietary control system designed for the process industry The DCS system usually has embedded algorithms for continuous and batch control Distributed Inputs Outputs Digital signals representing both discrete and analog inputs and outputs that are exchanged between the CPU and external devices The external devices may be widely distributed at remote locations Data transfer occurs over twisted pair twinax wire or fiber optic cables with modems Duplex Two parallel elements in a voting system Duplex mode default A voting mode in which outputs may be voted 1002 or 2002 Duplex mode provides fault degradation to simplex operation if one system CPU fails If both CPUs fail a pre selected default FTS fail to safe state is used by each output P E Edison Testing Labs ETL An OSHA approved testing laboratory In conjunction with Wilson Fire the GMR system has NFPA approval as certified by ETL Energize to Trip Typically non ESD applications such as Fire and Gas protection systems use this convention In normal operation most elements are engineered to be de energized operational The safe state is then considered to be energized upon a signal or voted Fail to danger The inability of a system to
34. main rack to the last expansion rack is 50 feet 15 meters Fault Tolerance F If a single element fails the ability of a system to remain functional as if no fault had occurred The diagnostics will report the fault to the proper fault table Factory Mutual FM An OSHA approved testing and certification lab GMR PLCs and I O products are certified by FM for use in Class I Division II incendiary environments without additional enclosures Fail safe The ability of an element to go to a safe state when a system failure has occurred Final Control Element The actuator indicator or other electrical field device controlled by an output point Firmware A series of instructions contained in ROM Read Only Memory of a CPU which are used for internal processing functions These instructions provide the structure for application program operations D 4 Genius Modular Redundancy Flexible Triple Modular Redundant TMR GFT 177A System Technical Product Overview February 1998 L2 Forcing l 0 Deliberately changing an I O point value regardless of the actual input value or commanded output value The Genius Hand held Monitor HHM can be configured to perform I O forcing The PLC s I O Fault Table indicates both forces and released forces G Genius Bus The LAN local area network used for Genius communications Genius bus protocol is an enhanced type of IEEE 802 4 token passing scheme Each transm
35. of 3 also configurable for 2002 1002 or 1001 Mid value select also for duplex average high or low select 3 2 1 0 or 3 2 0 available for inputs outputs and CPUs Configurable as Enabled or Disabled Configurable limits for R I WQ WAI WAQ 96 T M and G None Asynchronous None Remaining CPU s will report loss of CPU only and continue to operate GFT 177A Communications M odules Communications Coprocessor Module CMM The Communications Coprocessor Module CMM provides Communications Control CCM Remote Terminal RTU and Series Ninety SNP communications CCM RTU slave and SNP are available on the serial ports in nine selectable combinations CCM CCM CCM RTU RTU CCM RTU RTU SNP SNP SNP CCM CCM SNP SNP RTU and RTU SNP CCM Functions in CCM mode are read write of register input and output tables bit set clear of inputs and outputs read scratch pad Q sequence commands for fast reads and modify diagnostic status word In the master and peer CCM configurations the CMM module initiates communications with other devices through the application program RTU In the RTU Slave protocol the following functions are provided read input and output tables read analog input read register table read scratch pad read exception status force a single or multiple outputs preset a single or multiple registers report device type and perform loopback maintenance RTU master protocol is availabl
36. sections of the program while preventing entry into areas of the logic that must not be changed System Scan Time Estimated scan time depends on the PLC system I O system program complexity and several other factors Appendix B gives information about estimating scan times Embedded Protocol Communications A variety of communication protocols media and connectivity types are available for interfacing to a wide range of intelligent devices 5 7 Automatic Program Documentation me Se D Logicmaster 90 includes the ability to produce many types of documentation about the GMR application program The Logicmaster Print Menu is used to specify the content and format of the printout Logicmaster Print Menu fees I HUS TP REA PR PRINT aue PRINT PROGRAM LOGIC MIEEBMINMLLLLLL SB ML LBS IA LL Ax TJ pabet TS oF HEADER PAGE Y N LOGIC MyXODA UMTSEP UMLHUEER IS aP VARIABLE TABLE N REFERENCE LIST Lit 6 11 ALL BLOCKS N NICKNAME REFERENCE BLOCK STRUCTURE N REFERENCE DESCRIPTION sidis if SFC TOPOLOGY Y RUNG COMMENTS 1 DATA INIT VALUES FROM RUNG 0 TO RUNG 9999 STARTING PAGE NUMBER lt lt Press ENTER Key to Start Printout gt gt LAFEE II u CMRGST CVERSEMCY CEN 5 15 21 LPT1 LPT1 COM1 LPT2 COMZ FILE D D NLMSONLESSON za BLK MAIN REPLACE ELE Sones Selecting items from this menu customizes the printout to include configuration data program logic cro
37. system Availability The probability that a component or system will operate from a time t 0 until a given time at time ty 2 B Backplane A printed circuit board at the back of a rack The board has connectors into which modules are inserted Battery Backup Th use of a battery to protect information stored in volatile memory against power loss Data protected by battery backup includes data values logic states the application program and clock settings Block See Genius I O Block and Genius I O Bus See Genius Bus Bus Controller See Genius Bus Controller Bus Group A group of two or three Genius Bus Controllers and their busses which have GMR configured blocks attached C C Block An application Program Block written in the C programming language Channel When applied to analog signals a channel consists of the single input signal or output signal electrical conversion either analog to digital or digital to analog Checksum A mathematical computation done on a range of bits from a set parallel pattern performed to see D 2 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System Technical Product Overview February 1998 whether the data has changed This is done in the GMR CPU to verify that the program logic has not been altered It is dynamically checked CIMPLICITY A family of operator MMI Man Machine Interface products rangin
38. unwanted activation of other levels of mitigation such as mechanical pressure relief devices Boiler Burner Management Systems If a process boiler stops operating reliably other parts of the system are soon affected leading to loss of both quality and profits With the fail safe and fault tolerant GMR system operations such as purge sequencing fuel control burner ignition and flame safety can also be cost effectively integrated into a single system meeting even the most stringent NFPA requirements Fire and Gas Detection Systems Fire and Gas Detection systems require many of the same high integrity considerations as Emergency Shutdown ESD applications However special design strategies must be integrated in a Fire and Gas Detection system for monitoring the field wiring of de energized control devices and other functions specific to energize to trip systems GE Fanuc Genius I O blocks are easily configured to meet these special application requirements They can be certified by leading specification underwriters In addition reduction in spare parts costs can be achieved through commonality of component requirements for ESD and Fire amp Gas systems and through the availability of more than 250 stocking distributors around the globe On line Replacement of Modules The reliability of GE Fanuc Series 90 70 products has been field proven by millions of hours of operation If a GMR system component should ever need repair the
39. 0ma or Linearization RTD or T C Types T C 0 10Vdc 10 10Vdc BBA100 BBA104 BBA020 BBA024 BBA026 BBA021 BBA023 4In 20ut 4In 20ut 6 In R T D 6In T C T 4 20ma 4 20ma Platinum Nickel R SN Copper 0 5Vdc Linear A failure of a block or circuit results in both the appropriate block diagnostic LED indication and the fault being logged into fault tables of each PLC TMR analog inputs continue to operate with the remaining blocks or legs of the input group Failed TMR analog input blocks may replaced hot power on without disturbing the functioning portion of the input group or any other part of the system All analog input blocks provide a variety of diagnostic capabilities In addition the blocks perform automatic self calibration of internal circuitry Please refer to the Genius I O user s manuals for more details BBA106 BBAI101 BBA103 Type J K T E B Nominal P S Voltage AC 115 115 115 Nominal P S Voltage DC AC Voltage Range 47 63Hz DC Voltage Range P S Dropout Time Block Isolation Common Mode Rejection Common Mode Voltage Input Resolution Accuracy 25 C Input Filter Ranges ms Diagnostic LEDs Diagnostics Available Loss of Block Under Overrange High Low Alarm Open Wire Input Shorted Wiring Error Internal Fault Weight 4 24 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System 98 132 93 132 93 132 93 132 93 132 18 56
40. 1 IC697CBL700 POWER SUPPLY CABLE FILLER PSFILL IC697PUR710 POWER SUPPLY 120 240 VAC 55W SSW 3 IC697PWR 711 POWER SUPPLY 120 240 VAC 100W 1004 4 IC697PWR720 POWER SUPPLY ADAPTER PSA ADAPTER 5 IC697PUR 721 POWER SUPPLY 24 VDC 90W amp PSA 90U 6 IC697PWR731 POWER SUPPLY 125 UDC 60U amp PSA 60U lt lt CURSOR TO THE DESIRED CATALOG NUMBER AND PRESS THE ENTER KEY gt gt lt lt PRESS PGDN KEY FOR NEXT PAGE PGUP KEY FOR PREVIOUS PAGE gt gt FFL INE RG LESSON D LMSO LESSON REPLACE ONFIG VALID After selecting a module it appears on a screen that represents that rack being configured Example Rack Definition Screen REF UU DELETE UNDEL m0 iogayeniuspeben ps Barckselfijconm yune Bother E zon Sey ROG EIN CONFIGURATION D NLMSONLESSON Section 5 Configuring amp Programming a GMR System Zooming into a slot shows a detailed description of the module configuration Detail Screen for a Module SERIES 90 70 MODULE IN RACK J SLOT 5 SOFTWARE CONFIGURATION TS fem 1 CO97BEN 31 90 70 GENIUS BUS CONTROLLER Bus 1 Addr 31 Baud Rate 153K STD Error Rate 10 Ref Adr Chk DISABLED Redund Mode NONE Paired GBC NVA Suitch Time N A Dual GBC Addr Rack N A SEND GLOBAL DATA Slot N A nf ig Mode NONE Bus N A D NLM9ONLESSON REPLACE Automatic Configuration Documentation The configuration information for the
41. 100 See GFK 0366 Red Safety Labels Qty 20 n a for IC660BBA020 n a IC660SLA020 n a for IC660BBA021 n a IC660SLA021 n a for IC660BBA023 n a IC660SLA023 n a for IC660BBA024 n a IC660SLA024 n a for IC660BBA026 n a IC660SLA026 a n a for IC660BBA100 n a IC660SLA100 n a for IC660BBA101 n a IC660SLA101 n a for IC660BBA 103 n a IC660SLA 103 n a for IC660BBA 104 n a IC660SLA104 n a for IC660BBA 106 n a IC660SLA 106 n a for IC660BBD020 n a IC660SLD020 n a for IC660BBD021 n a IC660SLD021 n a for IC660BBD024 n a IC660SLD024 d n a for IC660BBD025 n a IC660SLD025 n a Genius Hand Held Monitor n a IC660HHM501 7 Page 4 27 Prefab Cable 15 Inch qty 3 n a IC660BLC001 n a Prefab Cable 3 Foot qty 1 n a IC660BLCO003 i n a A All Series 90 70 PLC Field Control I O and Genius I O products can be used in a GMR system however not all of the available components are T V approved for use in the safety relevant portion of a system NOTE Not listed here are more than 30 other Field Control I O rack based I O and special purpose intelligent modules which can be used in a simplex manner with GMR systems Please contact your GE Fanuc Sales office for more details 4 6 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFT 177A Technical Product Overview February 1998 General Environmental Specifications 90 70 Components Operating Temperature 0 to 60 C 32 to 140 F 0 to
42. 105 145 105 145 105 145 105 145 18 56 18 56 18 56 18 56 1 Cycle 1 Cycle 1 Cycle 1 Cycle 1 Cycle 10ms DC 10ms DC 10ms DC 10ms DC 10ms DC 1500V 1500V 1500V 1500V 1500V 60dB 45dB 45dB 0 1Khz 50 60Hz 50 60Hz s 170V po pee XE 12 bits sign ET 1 0 2 Typ 0 5 C Typ lt 10uv 0 1024 16 6 400 16 6 400 400 1600 2000 Unit OK Block or Point Fault Indication O Enabled On Line and Forced Point Indication TMR HSB TMR HSB MR TMR TMR SIMPLEX SIMPLEX SIMPLEX SIMPLEX SIMPLEX 25 4 48 125 1 125 125 24 48 24 48 24 48 24 48 4 Ibs 1 8 kg GFT 177A Technical Product Overview February 1998 GFT 177A Genius Analog Output Block Specifications All of the listed block types may be used as Hot Standby HSB or simplex analog output blocks These blocks include those that can handle Voltage 10v 0 10v t 5v and 0 5v and Current 4 20ma type loads Hot Stand By is a mode in which a block uses output data from only one CPU unless that CPU fails in which case the block uses output data from an alternate CPU AC MODEL IC660 DC MODEL 1C660 cd Number of Points Operating Modes Output Range s Nominal P S Voltage AC Nominal P S Voltage DC AC Voltage Range 47 63Hz DC Voltage Range P S Dropout Time Block Isolation Common Mode Rejection Common Mode Voltage Accuracy 25 C Output Resolution Output Update Frequency Output Load Volta
43. 40 C 32 to 104 F for CPU model CPM790 without forced air See I O racks for catalog number of fan assembly Storage Temperature 40 to 85 C 40 to 185 F Humidity 5 to 95 non condensing Vibration 5 9 Hz 3 5mm displacement 9 150 Hz at 1 0 G Shock 15 Gs for 11 msec Genius I O Components Operating Temperature Storage Temperature Humidity Vibration 0 to 60 C 32 to 140 F 40 to 100 C 40 to 212 F 5 to 9596 non condensing 5 10 Hz 5 08mm displacement 10 200 Hz at 1 0 G Field Control Components Operating Temperature 0 to 55 C 32 to 131 F Storage Temperature Humidity Vibration Shock A gency A pprovals Compliances Standards TUV TUV Rheinland The Genius Modular Redundancy system has been certified by TUV Rheinland for the following system configurations and classes Wm Triple Modular Redundant TMR 2v3 Fault Tolerant and Fail Safe up to Class 6 m Duplex 2v2 Fail Safe up to Class 5 W Duplex 1v2 Fault Tolerant and Fail Safe up to Class 4 For details and restrictions refer to T V report 945 EL 340 96 or contact GE Fanuc for more information ISO GE Fanuc Automation is ISO 9000 certified and ISO 9001 registered GE Fanuc is also registered with Underwriters Laboratories USA the British Standards Institute UK and the Quality Management Institute of the Canadian Standards Association Standards Most GMR components 90 70 Field Control and Genius
44. 46418 The I O Terminal Block has two separate sets of module terminals Each set corresponds to a slot in a conventional rack type PLC The cable connectors provide easy attachment of the cable that carries communications signals The DIN rail latches clip the I O Terminal Block to a DIN rail The keying slots permit protective module keying Terminal Styles I O Terminal Blocks are available with the I O terminal styles shown below Different I O Terminal Block types can be intermixed within a station ze ww wm amp o amp one e Bis tue it ae m Hi tt Q mt rel bien id e e Sg o so Eo S ojlo D amp Shey um i i eB San it Q Li amp Erg n e a Li 9 tt amp p INI e Sig Barrier Box Wire to Board Terminals Terminals Connectors 46418 The I O Terminal Block with Barrier Terminals catalog number IC670CHS101 has 37 terminals Each terminal can accommodate one or two wires up to 2 AWG 14 avg 2 1mm cross section The Terminal Block with Box Terminals catalog number IC670CHS102 has 51 terminals each of which accommo
45. 516m 909m 1364m M M4230 A 9110 274in 00 ohms 4 two pair 22 150v 200 C 1200ft 1700ft 3000ft 4500ft B 89696 6 96mm 364m 516m 909m 1364m B 89855 A 9814C 243in 75 ohms 2 320 150v 60 C 800ft 1500ft 2500ft 3500ft B 9463 6 17mm 242m 455m 758m 1061m M M4154 A 5902C 244in 75 ohms 4 two pair 22 300v 80 C 200ft 500ft 1200ft 2500ft B 9302 6 20mm 60m 152m 333m 758m M M17002 Notes A Alpha B Belden C Consolidated E Essex M Manhattan O Olflex Limited to 16 taps at 38 4 Kbaud Suitable for applications requiring high flexibility continuous flex or vibration 4 18 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFT 177A Technical Product Overview February 1998 Genius I O Blocks Genius I O blocks provide a full range of I O types and densities All block types may be used in a GMR system as non critical or simplex I O A subset of the available blocks may be used as GMR I O Genius I O blocks make it possible to distribute I O in quantities as low as 6 points Distributed and remote placement of the I O at the point of control reduces problems associated with large amounts and lengths of control wiring Genius I O blocks can also be grouped at a central location e g in a main control panel Genius I O Block E GENIUS 24 48 VDC Source In Out GE Fanuc
46. 8 30VDC GBI002 90 135VAC 105 150VDC GBI102 120dB 50 60Hz 120dB 50 60Hz x 250V RMS 250V RMS he 381 nanoamps 15 bits sign 15 bits sign en E bits with the vote adapting to average select high or select low in the event of a failure A second failure results in further vote adaptation to either use the last operational input or go to a preconfigured minimum maximum or hold last state value A failure of a BIU module or circuit results in both the appropriate diagnostic LED indication and the fault being logged into fault tables of each PLC TMR analog inputs continue to operate with the remaining legs of the input group I O Terminal Blocks IC670CHS 101 102 and 103 TMR SIMPLEX 4 33 Section Configuring amp Programming 5 a GMR System The purpose of this section is to explain the basics of GMR system software setup and programming The illustration below is an overview of configuration and programming for three GMR 788 798 or 790 PLCs Both the special GMR Software and the Logicmaster 90 70 Software contribute to the system configuration and to the completed application program Genius I O blocks and Field Control BIUs in the system are independently configured Basic GMR System Configuration and Programming Steps GMR CONFIGURATION LM90
47. CBLI CK RRnn CBLI CK EEnn CBL1 CK EBnn Genius Modular Redundancy Flexible Triple Modular Redundant TMR System 10V to 30V DC 0 degrees C to 60 degrees C 5 to 95 non condensing Two ELCO male 8016 series 38 pin exposed contacts Four 34 pin IDC connectors for ribbon cable 219mm length X 110mm width X 30mm depth 145mm length X 109 mm width X 101mm depth 32 loads at 5 Amps per channel max Supply Voltage 1V typical 0 5A indicating fuses Bussman type GMT Termination Board for 32 circuit Source block Termination Board for 32 circuit Sink block Interface Module for 32 circuit output block group 34 way ribbon cable termination board to interface module Field device connection cable with 2 ELCO 8016 connectors Field device connection cable with 1 ELCO 8016 connector and stripped and tinned connectors at the other end GFT 177A Technical Product Overview February 1998 Field Control Bus Interface U nits and I O M odules Field Control modules which are mounted on separate terminal assemblies are interfaced to a Genius bus by a Genius Bus Interface Unit Together the Bus Interface Unit and its modules are referred to as an I O Station A Field Control I O Station can be used in a GMR system as GMR inputs or as non GMR I O It can not be used for GMR outputs or non voted GMR inputs and it cannot be autotested Fidd Control I O Station
48. CPU789 CPUs utilize a memory daughterboard which provides a total of 512K 524 288 bytes of battery backed RAM memory Of this 512K of memory 336 788 bytes is used by the GMR System Software leaving 187 500 bytes for the application program and data Memory Available for the Application Program When the worksheet on the next page is completed the resulting value will be the number of bytes remaining and available for use by the application program If the required application program functionality is well known to the point of knowing roughly the type and quantity of instructions to be used the size of the application program in bytes can be estimated GFT 177A A 1 Use this worksheet to determine the total number memory left for the application program subtract of bytes of memory used by R AI 96AQ P the grand total from the number of bytes for the L and associated point faults if used Then add memory size being used all the totals together To determine the amount of GMR Memory Allocation Worksheet Totals R Memory Multiply amount of R used x 2 Bytes Amount of R used is in 1K increments based on configuration P Memory P Block Memory Used P allocated 2 79 Bytes When P used is in the range 1 to 128 the P allocated 160 Otherwise compute the number of P allocated of P used 128 32 rounded up to whole integer 32 160 L Memory L Block Memory Used L allocated
49. Cs Each PLC CPU resides in an independent rack eliminating mechanical and electrical common mode failure Individual PLC CPU racks may be located up to 7500 apart the maximum distance between PLCs depends on the baud rate selected for the Genius bus that connects them A minimum of two bus controllers per PLC are required for fault tolerant inter processor communications This allows the GMR PLCs to exchange initialization data at startup and exchange up to 64 words of global data during operation For maximum system integrity two or three PLCs protect against failure of the PLC CPU or power source or even loss of an entire PLC system The ability to have processing performed by two or three independent PLCs is an additional important advantage of GMR Even when only one PLC is used triplicated Genius Bus Controllers and bus cables along with the ability to have triplicated inputs and fault tolerant failsafe voted outputs provides significant levels of redundancy The GMR redundancy options for both inputs and outputs can be used with one two or three GMR PLCs as shown by the following illustrations For clarity the illustrations show PLCs without expansion racks and only a few Genius blocks per bus In an actual system there can be up to eight racks per PLC and 32 devices Genius blocks Bus Controllers etc per Genius bus _ GMR System with One PLC Independent Field Input Device s Single Nonvoted or
50. Cs receive all inputs Discrete analog thermocouple RTD Separate Genius bus for each block All PLCs receive all inputs a46604 3 4 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFT 177A Technical Product Overview February 1998 Two Input Devices Connected to Two Genius Blocks or One Input Device Connected to Two Blocks pmrrom4zoowcm Field Device Field Device ia Duplex sensors Single sensor Discrete analog thermocouple RTD Discrete analog thermocouple RTD Separate Genius bus for each block Separate Genius bus for each block All PLCs receive all inputs All PLCs receive all inputs a46605 m One Input Device Connected to Simplex or Non voted Block Field Device ll Simplex or non voted Discrete analog thermocouple RTD All PLCs receive all inputs 246606 GFT 177A Section 3 GMR System Architectures 3 5 Output Redundancy Options Output redundancy options can be mixed as appropriate within the system Options for output devices in a GMR system include a Single hot standby outputs a Single voted outputs a H pattern group for fault tolerant failsafe outputs m T pattern group for fault tolerant outputs wm I pattern group failsafe for shutdown outputs A single block in GMR mode receives outputs from all CPUs and performs voting 2 out of 3 2 out of 2 or 1 out of 2
51. FANUC GE Fanuc Automation Programmable Control Products Genius Modular Redundancy Flexible Triple Modular Redundant TMR System Technical Product Overview GFT 177A February 1998 GFL 002 Warnings Cautions and Notes as Used in this Publication Warning notices are used in this publication to emphasize that hazardous voltages currents temperatures or other conditions that could cause personal injury exist in this equipment or may be associated with its use In situations where inattention could cause either personal injury or damage to equipment a Warning notice is used Caution notices are used where equipment might be damaged if care is not taken Note Notes merely call attention to information that is especially significant to understanding and operating the equipment This document is based on information available at the time of its publication While efforts have been made to be accurate the information contained herein does not purport to cover all details or variations in hardware or software nor to provide or every possible contingency in connection with installation operation or maintenance Features may be described herein which are not present in all hardware and software systems GE Fanuc Automation assumes no obligation of notice to holders of this document with respect to changes subsequently made GE Fanuc Automation makes no representation or warranty expressed implied or statutory with respec
52. GFT 177A Program Diagnostics The GMR system provides extensive diagnostic capabilities by combining standard Genius I O diagnostics with the special autotesting and discrepancy reporting features of the GMR software Fault Tables Each PLC provides a full range of fault table and program access to fault and status information in two detailed Fault Tables Both tables are available through Logicmaster 90 software CIMPLICITY Intouch operator interface software and the Access Display System with no additional programming Upon the detection of a fault or system status change a location description and time appear in the appropriate fault table Pressing a function key displays additional descriptive information about a fault Options allow for a print log for permanent recording Typical PLC Fault Table Display PLC FAULT TABLE OP FAULT DISPLAYED 00003 TOTAL FAULTS 00003 TABLE LAST CLEARED 04 24 ENTRIES OVERFLOWED 00000 PLC DATE TIME 04 24 FAULT FAULT DATE LOCATION DESCRIPTION M D Low battery signal 04 24 System configuration mismatch 04 24 Application stack overf low 04 24 aad 4 ACC WRITE LOGIC ONFIG EQUAL i Fault and No Fault Contacts To integrate specific diagnostics actions into the application program discrete or analog fault and non GMR configured analog alarm bits can be associated with voted or physical inputs and simplex and fault tolerant outputs The following example shows Fault Cont
53. I O comply with the following standards However not every component complies with every standard listed For specific information please refer to the appropriate technical manual or contact your GE Fanuc Sales office GFT 177A Section 4 Product Specifications IEC No 142 C22 2 JIS A 1978 DIN 871 877 ULA Hazardous Location Class I Div II NEMA ICS 40 to 485 C 40 to 185 F 5 to 95 non condensing 10 to 57 Hz 0 012 in displacement p p 57 to 500 Hz at 2 g or as specified 15G 11 ms half sine wave 435 380 CSA C 0912 JISC ANSI IEEE 0911 435 380 VDE 508 1012 FCC 2 230 40 VME C22 C 37 90 805 806 15J Part CI Those components identified earlier in the components list of this document which were marked as being T V approved YES also have passed the following tests per the identified standards which are required for T V approval Cold test IEC 682 1 Dry Heat test IEC 682 2 Shock test IEC 68 227 Change of Temp test IEC 682 14 Damp Heat Cyclic test IEC 682 30 Vibration test IEC 68 2 6 Electrostatic Discharge IEC 801 2 RF amp Electromag Immunity IEC 801 3 Burst test IEC 801 4 Surge test ANSI IEEE 37 90 1 Overvoltage test P S Interrupt test P S Variation test DIN VDE 0160 7 3 DIN VDE 0116 DIN VDE 0116 4 7 Racks Standard racks are available in five slot panel mount nine slot panel mount and 19 inch rack mount styles Also available is a rack with 17 standa
54. LEDs Unit OK Block or Point Fault Indication O Enabled On Line and Forced Point Indication Diagnostics Available Loss of Block Short Circuit Overload No Load Failed Switch Overtemp Output to Output Short Short to 24 Vdc Short to 0 Vdc Steady State Output Current 0 5 amps Max Inrush Current for 10 ms 4 amps Total Current per Block 35 C 16 amps Output Off Leakage Current 10 pa Output Voltage Drop 2 0 V max Minimum Load with No Load Enabled TMR wa These blocks can operate as inputs or outputs in any combination when in HSB or Simplex Mode 4 22 Genius amp Modular Redundancy Flexible Triple Modular Redundant TMR System GFT 177A Technical Product Overview February 1998 Discrete Output Block Specifications Continued The blocks listed below used individually can operate in output data from only one CPU unless that CPU fails in either a simplex mode duplex mode or Hot Stand By which case the block uses output data from an alternate HSB mode HSB is a mode in which a block uses CPU MODEL IC660 BBD101 BBD102 BBD103 BBR100 BBR101 Number of Points 8 Grouped 8 Isolated 8 Isolated 16 Isolated 4 Groups 4 Groups 4 Groups Nominal Voltage 115Vac 115Vac 115Vac 115 230Vac 125Vdc 125Vdc Operating Modes SPLX HSB SPLX HSB SPLX HSB SPLX HSB AC Voltage Range 47 63Hz 93 132 93 132 93 132 5 250 DC Voltage Range n a 105 132 105 132 5 220 P S Dropout Time 1 Cycle 1 Cycle 1
55. M H Programmable Coprocessor Module PCM O Factory LAN Ethernet Controller Module Bus Transmitter amp Bus Receiver Modules Genius Bus Controller Module O Genius I O Network Genius I O Blocks Genius Hand Held Monitor O Genius Block GMR Termination Boards and Interface Modules Field Control Bus Interface Units and I O Modules H Field Control Analog Input Modules o TO Terminal Blocks If you need more information about any of these products please refer to other GMR Series 90 70 and Genius manuals for further details GFT 177A 4 1 GM R Components List Software Power Supply Modules Description Catalog Number T V Refer Description Catalog T V Refer To Approved To Number Approved GMR System Software for IC641SWP715 Yes n a 120 240Vac IC697PWR710 Page 4 9 CPU 788 789 and 790 125Vdc 50 Watt Logicmaster 90 70 IC640HWC706 Yes n a 120 240Vac IC697PWR712 Page 4 9 Programming Software 125Vdc 50 Watt i B 115 240Vac IC697PWR711 Yes Page 4 9 E 125Vde 100 watt Logicmaster 90 70 IC640HWP706 Yes n a 1 15 240Vac IC697PWR7 1 3 Page 4 9 Programming Software 125Vdc 100 watt w Paper Documentation 24Vdc 90 watt IC697PWR724 Page 4 9 Tet Ee LOIS WMS na 48Vdc 90 Watt IC697PWR748 Page 4 9 Logicmaster 90 70 Programming Software Power Supply IC697CBL700 Page 4 9 w CD ROM Expansion Cable Documentation For 2 rack P S functi TCP IP Ethernet 1C641SWM713 n a unction Logicmaster 90 70 Programming Software w Paper D
56. R PLC eliminating the need for individual logic programs and simplifying user programming Application programming assistance is available from your GE Fanuc sales office or GE Fanuc s 24 hour support hotline 804 978 5747 Through Logicmaster 90 the GMR CPU supports structured programming techniques Program logic can be separated by functionality equipment areas or other logical sections The GMR programmer may write an efficient program with reduced effort using structured programming tools which include W Function Blocks for complex functions W Custom Parameterized Subroutine Blocks W Program Blocks Genius amp Modular Redundancy Flexible Triple Modular Redundant TMR System Technical Product Overview February 1998 Function Blocks for Complex Functions Function blocks simplify programming complex functions in the GMR application program using Relay Ladder Logic Multiple parameters are easily included in a function block in a clearly understood fashion The illustration screen below shows two Addition function blocks Example Function Block 4100002 3 EENM 22727777711 Q 0 catty BLK MAIN SIZE Z260MRUNG 0007 D LMSO LESSON REPLACE For more complex function blocks a ZOOM feature opens a window on the instruction GFT 177A GFT 177A Program Blocks Program blocks can be used to organize program sections Up to 255 program blocks can be d
57. R busses using Global Data GFT 177A Section 2 Operation PLC Diagnostics Each PLC executes continuous diagnostics to detect internal overt and covert failures Memory errors are detected via parity or checksum Each CPU receives the other CPUs status as part of the Global Data exchange This status information is available for the diagnostic fault table system default operation and application program Each PLC can monitor the actions of the two other PLCs to detect voting discrepancies Each PLC also compares its application program checksum with those of the other PLCs and can be shut down if it is in discrepancy with the other two A PLC that goes off line is reported by the other two The application program can make use of additional diagnostics mechanisms provided by the Series 90 70 PLC and special diagnostics features of the GMR system software m System Status References m Fault and Alarm contacts GMR Status and Control references System Status References are pre defined references that can be included in the application program to check for specific fault related conditions Additional system status references indicate when the fault table has a new entry has any entry or is full Fault and Alarm Contacts The GMR system software can optionally utilize the Fault and Alarm contacts capability of the Series 90 70 PLC to make fault and alarm information available to the application program Fault and No Fault co
58. Simplex Duplex or Triplex Voted Fault Tolerant Fail Safe Voted Outputs 846601 3 2 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System Technical Product Overview February 1998 GFT 177A Independent Field Input Device s Single Nonvoted or Simplex Duplex or Triplex Voted m GMR System with Two PLCs TTE Fault Tolerant Fail Safe Voted Outputs i Single Hot Standby or Voted Outputs a46602 Independent Field Input Device s Single Nonvoted m GMR System with Three PLCs Fault Tolerant Fail Safe Voted Outputs or Simplex Duplex or Triplex Voted 8 is lt Single Hot Standby or Voted Outputs a46603 GFT
59. System Program Initialization If one or more CPUs are taken offline while the system continues to operate a warm start is automatically initiated when the offline CPU s are re introduced This optionally allows data to synchronize with the other CPU s verifies that system operation is correct and determines the application logic is equal in the PLCs Optional data synchronization eliminates potential discrepant control commands being issued between individual processors that are joining the online operational system Inputs and Outputs Genius and Field Control devices broadcast the status of all inputs simultaneously to all online CPUs Each CPU independently solves the application logic and transmits the resulting commanded output states independently to the output modules Global Data During GMR system operation the PLCs use Global Data to automatically exchange eight registers of system status and diagnostic data This data is directly available for the application program in each PLC Global Data transfer occurs on two of the fault tolerant GMR busses so each PLC actually receives two sets of Global Data from each of the other PLCs The use of two busses provides redundant operation in case a bus or bus controller is not available In some applications it may also be desirable to regularly exchange additional application data between the PLCs Up to 56 registers of application data can be exchanged on the redundant GM
60. Two Sink blocks Blocks must be on two different busses Each block receives command from all PLCs Either block can control the load SRC a46634 2 Block I Pattern Group for Redundant Shutdown i I pattern REN One Source and One Sink block connected to different busses LOAD Each block receives command from all PLCs Both blocks must be active to control the load If either fails On turning the other Off turns the load Off a46633 3 6 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFT 177A Technical Product Overview February 1998 Section 4 Product Specifications The purpose of this section is to describe in detail the Series 90 70 PLC Genius I O and Field Control I O products that might be included in a GMR system The section begins with a group of lists of components Each list includes product catalog numbers and the individual T V approval status of each component Following the component listings you will find information on agency approvals and standards Detailed product information begins on page 4 8 immediately after the listings The product descriptions are included under the following headings Racks Power Supply Modules CPU Modules Communications Modules O Communications Coprocessor Module CM
61. Use in a GMR System In order to process information execute logic The ability to exchange data between DCS systems field comparisons and move information within the CPU bus systems computer and other intelligent host devices several data types are available for use in the GMR as well as slave devices is important for any technically application program The table below indicates the current system By default all memory areas are write various types and notation used for the referenced bit and protected The GMR configuration utility restricts access word oriented operations It also indicates which memory to safety critical areas of the memory Areas that can be types can potentially be written to by a communications written to are segregated by type address starting module location and size in length This greatly reduces the possibility that a WRITE command from an external device will be placed in a critical area of memory Type Description Can Write Access be Enabled R System registers 16 bit word references that store program data such as the results of calculations yes AI Analog input registers A 16 bit analog input register holds the value of one analog input or other yes value AQ Analog output registers A 16 bit analog output register holds the value of one analog output or yes other value P Program registers 16 bit word references which store program data from the MAIN block This no data can be accessed
62. a 4 block or 2 block output arrangement Specifications for 16 Point Discrete Output Termination Boards and Interface Modules Operating voltage Temperature range Humidity Connectors Interface Module Size Termination Boards Size Interface Modules Outputs Load Voltage at 1A Minimum Load Silvertech part numbers GBC1 CK DO16 IMC4 CK DO16 CBLI CK RRnn CBLI CK EEnn CBLI CK EBnn 20V to 36V DC 0 degrees C to 60 degrees C 596 to 9596 non condensing One ELCO male 8016 series 38 pin exposed contacts Four 34 pin IDC connectors for ribbon cable 219mm length X 95mm width X 30mm depth 145mm length X 109 mm width X 101mm depth 16 loads at 2 Amps per channel max 15 Amps total at 35 C Supply Voltage 2V typical 100mA with No Load Reporting enabled Termination Board for Source or Sink block Interface Module for 16 circuit output block group 34 way ribbon cable termination board to interface module Field device connection cable with 2 ELCO 8016 connectors Field device connection cable with 1 ELCO 8016 connector and stripped and tinned connectors at the other end Specifications for 32 Point Discrete Output Termination Boards and Interface Modules Operating voltage Temperature range Humidity Connectors Interface Module Size Termination Boards Size Interface Modules Outputs Load Voltage at 5A Fusing Silvertech part numbers 4 30 GBCI SC DO32 GBCI SK DO32 IMC4 CK DO32
63. acts associated with a specific rack and circuit and a No Fault Contact associated with a specific slot Example Fault Contacts RACK 01 SLOT 15 11033 FAULT NOFLT FAULT Q00002 Fault bits are reset when a fault is cleared from the fault table Section 5 Configuring amp Programming a GMR System GMR Program Protection To assure integrity the GMR system provides selectable levels of hardware and software protection for the application program The entire program and GMR software can be hardware locked using the keyswitch at the top of each CPU module An LED on the CPU provides visual confirmation that the keyswitch is locked For additional protection a range of four privilege levels can be used to restrict access to specific software functions Each level may have a unique password assigned The example shown below applies to a T V TMR system Access Level Software Security Access Description 4 Change Password Write or Modify Program Logic and or Configuration 3 Write or Modify Program Logic and or Configuration 2 Write to data memory i e change timer and counter values presets 1 Read PLC data only except passwords No PLC memory changes Protection even extends to individual Program Blocks within the application program which can be locked and passworded This flexible program protection scheme makes it possible to allow authorized users to access non critical
64. any type GMR capable blocks can be configured to perform GMR voting as described above Any single block can be configured for Hot Standby or Duplex redundancy or for no CPU redundancy at all GFT 177A Section 2 Operation Analog Outputs Analog blocks can be used as single blocks in a GMR output subsystem They can be configured for either No CPU Redundancy or Hot Standby Redundancy In Hot Standby mode a block prefers outputs from one of the PLCs but it will accept outputs from a second PLC if the first becomes unavailable Current and voltage type outputs are available 2 9 Output Diagnostics In a GMR system the output subsystem provides extensive diagnostic capabilities through a Genius Output Diagnostics which include Short Circuit detection Overtemperature detection and Failed Switch detection which compares the actual output state with the commanded state The 16 circuit DC Sink Source blocks also perform No Load reporting which monitors individual outputs for the presence of a minimum load m Output Autotest which determines whether each output can attain the opposite of its normal state a Output Discrepancy Reporting which informs each PLC of any output which is not the same among all PLCs Discrepancy reporting also reports on each PLC s online offline status Genius Output Diagnostics Each I O point on a 16 point discrete DC Sink Source block incorporates a current sensor and a voltage sensor in the
65. ations with other devices through the application program RTU As the industry standard communications for operator interface and DCS the RTU Modbus link provides access to all I O and register data within the GMR PLCs In the RTU Slave protocol the following functions are provided read input and output tables read analog input read register table read scratch pad read exception status force a single or multiple outputs preset a single or multiple registers report device type and perform loopback maintenance SNP Each serial port on the CMM can be configured to provide SNP master or slave capability The SNP protocol on the CMM module provides read and write access to registers inputs outputs analog inputs analog outputs T 76M P L and G variable types Full Series Ninety datagram capability and many status and control functions are also supported An autodial feature is provided to control a Modem SNP X extensions to the SNP protocol provide high performance read and write access to the same variable types listed above SNP X is especially useful for high speed data acquisition and control in multidrop configurations In the master SNP configurations the CMM module initiates communications with other devices through application program communications requests The CMM provides both the RS 232 and RS 485 Interfaces and communicates with the CPU over the backplane It is typical in a GMR system to use one CMM in each of
66. be able to respond safely due to a failure within the control hardware Fault Contacts See Alarm and Fault Contacts Fault Degradation The ability of a group of components in a GMR system to adjust to the loss or failure of corresponding components The two permissible degradation paths are 3 2 1 0 or 3 2 0 The method of fault degradation is selected during signal Ethernet Protocol LAN Ethernet is a published communication format that uses a high speed LAN and a CSMA CD Collision Sense Multiple Access Collision Detection non deterministic protocol GMR CPUs can exchange data with other system devices via TCP IP Ethernet modules GMR configuration of each group When the fault degradation path reaches 0 outputs default to individually selected safe states Note T V limits use of lool mode to a predefined time period Non T V systems may be set 1001 for indefinite periods of time Fault Tables The Series 90 70 PLC has two Fault Tables the PLC Fault Table and the I O Fault Table Both are valuable aids in maintaining and repairing the system The Fault Tables show the exact location of each fault its type an explanation and the date and time the fault occurred The tables are retentive until reset or cleared Expansion Cable A cable that transmits the parallel I O bus signals between a Series 90 70 PLC main rack and its expansion racks The maximum total length of the expansion cables from the
67. ble Triple Modular Redundant TMR System Technical Product Overview February 1998 compatible computer Configuration and programming can be done with the programming computer either online or offline from the PLC The software architecture provides a structured platform upon which to build application programs An application program may be built of many smaller program blocks each related to a specific machine or process function This approach makes it easier to isolate and associate control logic with machine and process functions GMR is shipped as a complete package providing all safety system functions such as voting diagnostics and startup control A programmer macro allows all three PLCs to appear as one for the purpose of downloading and verification of the application program saving time and increasing accuracy Communications A variety of communications options make it possible to interface the GMR system to Distributed Control Systems DCS operator interfaces or workstations host computers and other devices which communicate using serial communications either RTU MODBUS or GE Fanuc protocols Ethernet TCP IP or GE Fanuc s Genius LAN Quality is Built In GE Fanuc has been awarded ISO 9001 certification assuring built in product quality GMR products are built in our award winning Charlottesville Virginia manufacturing facility GMR is based on two thoroughly field tested product families the Serie
68. cronym for Random Access Memory RAM is a solid state memory that allows individual bits to be stored and accessed at random In the Series 90 70 PLC RAM stores the application program files and related data RAM memory must receive constant power to retain its contents Therefore a backup battery is provided to prevent data loss The backup battery used in the Series 90 70 PLC is a long life lithium battery The backup battery is mounted in the CPU module D 8 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System Technical Product Overview February 1998 References The logical annotation used in an application program for representing data types and locations Relay Ladder Logic RLL A programming language that uses a boolean representation in electrical schematic format to represent application program logic Reference Type Memory type definitions for the Series 90 70 PLC For example I represents discrete inputs and Q represents discrete outputs The symbol identifies the characters that follow it as a reference Register A group of 16 consecutive bits located in register R memory Register memory is used for temporary storage of numerical values and for bit manipulation Reliability The probability that the system will not fail and will perform as originally installed at time t 0 during the required operational period Remote 1 0 I O which may be located at a considerab
69. cuting the application program to ensure the highest integrity of the input data used Voting on triplicated data is mid value select Catalog Number Number of Points Operating Modes Input Range s or Linearization RTD Nominal P S Voltage Voltage Range Isolation Common Mode Rejection Common Mode Voltage Input Resolution Accuracy 25 C Input Filter Ranges ms Diagnostic LED Diagnostics Available Loss of Block Under Overrange High Low Alarm Open Wire Input Shorted GFT 177A Field Control Analog Input Modules IC670ALG230 IC670ALG240 IC670ALG620 IC670ALG630 1C670GBI002 IC670GBI102 TMR TMR SIMPLEX SIMPLEX Platinum Copper Nickel Nickel Iron Resistance Powered from BIU 24VDC 24VDC 18 30VDC 20 28VDC 1500VAC for 1 1500VAC 1500VAC for 1 min 250 VAC continuous min 250 VAC continuous 0 05 0 05 Typ Joose 0 15 0 15 Typ Module status 10ms 20ms digital Section 4 Product Specifications Inputs from J K T E S R B N G C D Platinel II Thermocouples Spans from 19 5mV to 625mV Powered from BIU 1500VAC for 1 min 250 VAC continuous 0 15 40 15 TY Yes Yes Yes Open T couple Thermistor error Bus Interface Units 4 In RTD 8 Thermocouple or Millivolt Inputs TMR TMR TMR SIMPLEX SIMPLEX SIMPLEX 24VDC GB1002 115VAC 125VDC GBI102 1
70. d The maximum length of a network depends on the 7 speed selected it can be up to 7 500 feet Maximum bus cable lengths depend on which of four baud rates is selected and the cable type as shown in the chart below Cable Outer Terminating Number of Dielectric Ambient Maximum Length Cable Run amp Make Diameter Resistor Conductors Voltage Temp feet meters at baud rate 10 to 20 AWG Rating Rating 153 65 153 6e 76 8 38 4 e eas Se A 9823 350in 50 ohms 2 22 30v 60 C 2000ft 3500ft 4500ft 7500ft B 9182 8 89mm 606m 1061m 364m 2283m C 4596 MMW o o o B 89182 322in 50 ohms 2 922 150v 200 C 2000ft 3500ft 4500ft 7500ft 8 18mm 606m 1061m 364m 2283m B 9841 270in 120 ohms 2 124 30v 80 C 1000ft 1500ft 2500ft 3500ft M M3993 686mm O 303m 455m 758m 1061m A 9818C 330in 00 ohms 2 320 300v 80 C 1500ft 2500ft 3500ft 6000ft B 9207 8 38mm 455m 758m 061m 1818m M M4270 A 9109 282in 00 ohms 2 20 150v 200 C 1500ft 2500ft 3500ft 6000ft B 89207 7 16mm 455m 758m 061m 1818m C 4798 M M44270 A 9818D 330in 00 ohms 2 920 1500ft 2500ft 3500ft 6000ft B 9815 8 38mm 455m 758m 061m 1818m O 911264 260in 00 ohms 2 22 flexing 250v 80 C 1500ft 2000ft 3000ft 4500ft 6 60mm 455m 606m 909m 1364m E 532185 approx 50in 00 ohms 4 pairs 24 solid gt 150v 80 C 1500ft 2000ft 3000ft 4500ft BBDN 12 7m 455m 606m 909m 1364m A 9818 315in 00 ohms 4 two pair 22 150v 60 C 1200ft 1700ft 3000ft 4500ft B 9855 8 00mm 364m
71. dates one AWG 14 avg 21mm cross 2 section to AWG 22 wire avg 0 36mm cross section or two wires up to AWG 18 avg 0 86mm cross section An insulated external 5mm 0 2in jumper such as Altech 8879 can be used to connect adjacent points When an external jumper is used the 2 wire capacity is reduced from AWG 14 2 10mm to 2 AWG 16 1 32mm The I O Terminal Block with Connectors catalog number IC670CHS 103 has two 20 pin male connectors for I O wiring The mating connector is Amp part number 178289 8 The connectors are keyed to prevent wrong insertion Any tin plated contact in the AMP D 3000 series can be used with the connector Amp part number 1 175217 5 for high contact force receptacle for 20 24 gauge 0 20 0 56mm wires 1 175218 5 for high contact force receptacle for 16 20 gauge 0 56 1 42mm A kit containing two mating connector housings and contacts is available as GE Fanuc part number C670ACC003 4 32 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFT 177A Technical Product Overview February 1998 Field Control Module Specifications The Bus Interface Units Field Control analog input modules and Terminal Blocks listed below may be in GMR input groups TMR Analog inputs are provided by a group of up to three Field Control I O stations with modules of the same type The duplicate and triplicate input data is received at all GMR CPUs and then voted just prior to exe
72. dules The Ethernet Controller module IC697CMM741 provides direct connection to IEEE 803 2 CSMA CD LANs The module has an 802 3 standard D connector for attachment of a user supplied AUI Attachment Unit Interface or transceiver cable The AUI cable connects directly to a user supplied transceiver that is directly connected to the 10Mbps Ethernet network The transceiver must be 802 3 compatible and must have the SQE option The Ethernet Interface Type 2 Module I1C697CMM742 provides high performance TCP IP communications The module s 10BaseT and 10Base2 ports permit direct connection to a network without an external transceiver The AUI port permits attachment to a user supplied AUI cable and user supplied transceiver Ethernet Interfae Module FTHFRNFT INTERFACE O wobuLE ok lO an ont ine SERIAL STATUS J RESTART LEDs Restart Pushbutton STATION Station Manager MGR Serial Port 222 SFRvicF Service Option OPTION Connector Software Load RS 485 Serial Port zO dOT ZZO O n 10BaseT Network AUI Network Port zo donzzoo dmz mr4m 10Base2 Network Port GFT 177A Section 4 Product Specifications These Ethernet modules plug into a single slot of a PLC rack Module LEDs indicate status The module s Restart pushbutton is used to restart the module and to reload the software A local serial por
73. dvanced functionality of Genius I O The result an excellent PLC based fault tolerant Triple Modular Redundancy TMR choice for Critical Control Applications GMR is GE Fanuc s sole offering for safety critical applications Genius Modular Redundancy is an extremely flexible system that is able to provide variable redundancy from the input modules through one two or three PLC CPU processors to the output modules This flexibility means less critical inputs and outputs may be configured for simplex or duplex operation while maintaining triplicated elements for critical control Depending upon the level of redundancy required sensor signals are brought into isolated Genius input blocks Isolated CPUs located in separate racks receive the input signals from each Genius I O bus The CPUs independently vote on the inputs then execute the application program utilizing the voted results Programs may be initially stored to one CPU for monitoring before storing to the other CPU s Typical Operator Display Showing Basic System mper GFT 177A Sov 9m mh In a GMR system the CPUs provide optional data synchronization only at startup not during normal operation The need for repeated synchronization is avoided because GMR inputs are broadcast to all PLCs simultaneously Other systems that require ongoing CPU synchronization risk a common point of system failure In its triplicated TMR configuration GMR incl
74. e Less Than or Equal Tests for one number less than or equal to another yes To cmp Compare Compares two numbers and determines if one is less than equal to or greater yes than the other M ath Functions add Addition yes sub yes mul yes div yes mod yes sqrt Finds the square root of an integer value yes abs Absolute Value Finds the absolute value of an integer double precision integer or real value yes D ata Conversion Functions to bed 4 Convert to BCD 4 Converts a value to 4 digit BCD format yes to bcd 8 Convert to BCD 8 Converts a value to 8 digit BCD format yes to uint yes to int yes to dint yes to real yes trun to int yes trun to dint Truncate to Double Truncates to a 32 bit signed number yes Precision Integer GFT 177A Section 5 Configuring amp Programming a GMR System 5 11 Bit Operations TUV Approved and yes or yes xor yes not yes shi yes shr yes rol yes ror yes bittst yes bitset yes bitelr yes bitpos yes mkcomp yes D ata Table Functions in the table the table liford yes lifowr yes fiford FIFO Read Removes the first entry from the table yes fifowr yes sort yes we arrmov Array Move Copies a specified number of data elements from a source array to a es destination array srh eq Search Equal Searches an array for values equal to a specified value f yes srh ne yes srh gt yes or Equal srh It yes Equal arrrng Tests an input value against two arrays of delimiters
75. e causes the final element to be de energized OFF 2v2 or 2002 Voting Two out of Two Voting For applications where the safe state is OFF when the voting is 2002 both votes must be in an OFF state to cause the final element to be de energized OFF 2v3 or 2003 Voting Two out of Three Voting When the voting is 2003 when two of the three votes are in an OFF state the final element is de energized OFF A Address A reference type and numerical offset which together refer to a specific memory location that is accessible to the application program For example for the address 96Innnnn l is the reference type and nnnnn is the offset GFT 177A Alarm and Fault Contacts Programmable contacts available to the application program which are associated with I O references Fault and Alarm contacts can change operations based upon point or device failures or exceeded alarm values Analog An electrical signal with more than two states representing force pressure temperature flow etc Application Program A program written by the user for control of a machine or process known as the application Autotest Automatic test routines in a GMR system They check the complete system from input modules to output modules and even detect failures in the I O wiring Autotesting does not affect the normal state of the field devices Use of autotesting is optional it can be implemented as needed in a GMR
76. e in the PCM module with application code SNP Each serial port on the CMM can be configured to provide SNP master or slave capability The SNP protocol on the CMM module provides read and write access to registers inputs outputs analog inputs analog outputs T M P L and G variable types Full Series Ninety datagram capability and many status and control functions are also supported An autodial feature is provided to control a Modem SNP X extensions to the SNP protocol provide high performance read and write access to the same variable types listed above SNP X is especially useful for high speed data acquisition and control in multidrop configurations In the master SNP configurations the CMM module initiates communications with other devices through application program communications requests The CMM provides both the RS 232 and RS 485 Interfaces and communicates with the CPU over the backplane It is typical in a GMR system to use one CMM in each of up to three CPUs however GFT 177A Section 4 Product Specifications each CPU can support multiple CMMs mounted in either the CPU rack or an expansion rack Three status LEDs at the top of the module indicate module OK and Port 1 and Port 2 transmit receive activity A single pushbutton in located beneath the LEDs and can be pushed to reinitialize communications at both serial ports No other switches or jumpers exist on the board configuration is
77. eclared in the main program block Program blocks may be individually Locked That aids software security while allowing access to required functions such as specific timers counters and other data Program Block Declarations PROGRE BY oe Ry Hinsert edit MedcleteiscorchESlock E FOLDER UTILTY PRINT yo Rvoto hoon L START OF PROGRAM BLOCK DECLARATIONS 1 LANG LD Ice Control block LANG LD NOT EXECUTABLE LANG EXT PARAM 2 END OF PROGRAM BLOCK DECLARATIONS 1 G Pump Controller 1 block Block from external source Re LAC eR Each program block may be executed from the main GMR application program block based upon time scan or logical pre conditions Additional subprogram blocks can be called from within program blocks Nesting of program blocks is generally limited to two layers for safety related application logic In non critical portions of the program there can be up to eight nested layers IBLK MAIN ENTRY 0003 PACK_EM Block from external source Parameterized Subroutine Blocks A parameterized subroutine block is a user definable function block with up to seven input output parameter pairs A parameterized subroutine block allows the re use of logic within the same GMR program which simplifies programming and reduces the overall amount of logic A parameterized subroutine block can have up to 16K bytes of logic with up to 1000 local nicknames and description
78. ed other GBC s in the redundant group continue to operate 4 17 Genius I O Network The Genius I O network interfaces Genius I O blocks to the Each Genius serial bus conveys data by passing a token GMR PLC system It serves as a communications interface to among the devices When the token is received by a pass startup diagnostic and application data between the CPUs device it is that device s turn to communicate A bus of the GMR PLC system The Genius network also provides scan occurs when all devices on the bus have received an open architecture interface to a variety of third party the token one time During one bus scan the GBC devices including personal computers receives all inputs from all blocks receives any fault information from all blocks updates all outputs on the I O blocks sends any commands received from the CPU The Genius bus scan is independent and asynchronous from the GMR CPU sweep Bus Scan Cycle 243528 Typical bus cable is shielded twisted pair or twinaxial cable No special connectors are required saddle clamp screw connectors are provided on all devices Each physical end of a bus is terminated with appropriate termination resistors which are provided Fiber optics cable with modems can be used for long distance GONEBOLTER ici ea eocsa OKEN PATH roe aueecenct requirements or if additional isolation is required DEVICE 31 m The Genius network operates at 4 speeds up to 153 6K 5 E bau
79. ere appropriate Input Interface Module Z 1 0 Wiring Connector Ribbon Cable GFT 177A Section 4 Product Specifications Power and Ground Terminals Pas Termination Board The illustration below represents an input interface module with three ribbon connectors the output interface module has four Discrete Input Termination Boards and Interface Modules Discrete input termination boards are available for 16 point and 32 point sink and source Genius blocks Complementary discrete input interface modules are available with polarized locking two part connectors for I O wiring Discrete input termination boards and interface modules incorporate all the diodes needed for the input autotest feature no other diodes are required In addition the termination board includes circuitry to support the asynchronous input autotest feature The tristate or supervised input feature of 16 point blocks can be used with these termination boards The discrete input interface module provides the grouping and distribution of the power and input signals Each input is protected from a short circuit in the power wiring by a self resetting thermistor No fuse replacement is needed Input autotest may be disabled by jumpering two terminals on the termination boards All 16 or 32 points are then available as inputs x per OOO HVHHHHOHHOGHHHHHO9 WIAA SHLD IN SHLD OUT
80. es retained through power failure and STOP TO RUN transitions A discrete reference is set ON if the coil receives power The state is retained yes through power failure and STOP TO RUN transitions If power to the coil is ON the continuation coil sets the next continuation contact yes ON If power is OFF the continuation coil sets the next continuation contact OFF M Retentive lt gt Continuation 5 10 Genius Modular Redundancy Flexible Triple Modular Redundant TMR GFT 177A System Technical Product Overview February 1998 Timers and Counters On Delay Stopwatch Accumulates time while receiving power The current value is reset to zero Timer when the Reset input receives power Off Delay Timer Accumulates time while NOT receiving power On Delay Timer Accumulates time while receiving power The current value is set to zero when there is no power flow Up Counter Increments by 1 each time the function receives transitional power Down Counter Counts down from a preset value every time the function receives transitional power yes tmr yes dnctr yes Relational O perations eq Tests for equality between two numbers yes ne Not Equal Tests for non equality between two numbers yes gt Greater Than Tests for one number greater than another yes ge Greater Than or Tests for one number greater than or equal to another yes Equal To It Tests for one number less than another yes l
81. f four 16 circuit blocks Up to 32 field devices can be connected to a group of four 32 circuit blocks 4 Block Discrete Output Group 24 Volts idis Source Source TRIPLICATED BUS E lt e FIELD LOAD e e eo Sink Sink ae 0 Volts 2 8 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System Technical Product Overview February 1998 For each output device each PLC sends a commanded state output to each of the four blocks Under ordinary circumstances the outputs received from all the PLCs match For each output the block group performs voting on the data received from the PLCs to determine the output state If the blocks receive outputs from three PLCs they perform 2 out of 3 voting If only two outputs are received the blocks do either 1 out of 2 or 2 out of 2 voting The method of voting is easily configured for each output group If only a single output is received the outputs follow the commanded state The system can be configured to default the outputs if only a single output is received In a four block output group the combination of the voted output states of all four blocks controls the load due to the electrical characteristics of the four b
82. from all program blocks PL Local registers 16 bit word references which store program data unique to a block no GAI Input references Bit references located in the input status table which stores the state of all inputs yes received from input modules during the last input scan A reference address is assigned to discrete input modules using the configuration software Q Physical output references Bit references located in the output status table which stores the state of yes the output references as last set by the application program This output status table s values are sent to output modules at the end of the program scan A reference address is assigned to discrete output modules using the configuration software The coil check function of Logicmaster 90 70 software checks for multiple uses of Q references with relay coils or outputs on functions 94M Internal references A bit reference that may be either retentive or non retentive The coil check yes function of Logicmaster 90 70 software checks for multiple uses of 96M references with relay coils or outputs on functions T Temporary references These bit references are never checked for multiple coil use so they can be yes used many times in the same program even when coil use checking is enabled T may be used to prevent coil use conflicts while using the cut paste and file write include functions Because this memory is intended for temporary use it is never retained through po
83. g from small single stations to large multi station systems CMF Common Mode Failure See Common Cause Cold Start When one or more CPUs are initiated if they are the only CPUs in a system that is no other CPUs are currently present the startup sequence for diagnostic and error detection goes from offline to operational for all activated components Configuration The process of defining the hardware architecture and system component settings such as communication parameters diagnostic limits and variable scaling Configuration Software The portion of the Logicmaster 90 programming software used to configure the I O and many system parameters Common Cause failures faults An unreliable or error based signal from one part of the system that causes the whole system to become inoperable or unstable No Common Mode of Failure CMF is considered acceptable Covert Fault A hidden latent or undetected fault that may affect overall system availability and reliability Diagnostic detection of covert faults increases reliability and availability and reduces MTTR CPU Sweep The process by which the CPU repeatedly executes the application program updates the I O status handles communications and other tasks and performs internal diagnostics GFT 177A CPU Central Processing Unit The master module in the main PLC system rack which executes the application program D Data Communications The
84. ge Mode Output Load Current Mode Diagnostic LEDs Diagnostics Available Loss of Block Under Overrange Feedback Error Weight BBA100 BBA020 4In 20ut HSB SPLX 4 to 20ma 0 to 10Vdc BBA104 BBA024 4In 20ut HSB SPLX 4 20ma 10 to 10Vdc 0 to 5Vdc 5 to 5Vde 5 24 48 2 125 24 48 93 132 105 145 18 56 1 Cycle 10ms DC 98 132 18 56 1 Cycle 10ms DC 1500V 60dB 0 1Khz 170V 0 2 Typ 1500V 45dB 50 60Hz 0 1596 12 bits sign 6ua 6 8ms 22000ohms n a 0 300ohms 0 850ohms IN All analog output blocks provide a variety of diagnostic capabilities depending on the block type In addition the blocks perform automatic self calibration of internal circuitry Please refer to the Genius I O user s manuals for more details A failure of a block or circuit results in both the appropriate block diagnostic LED indication and the fault being logged into fault tables of each PLC BBA105 BBA025 6 Out HSB SPLX 4 20ma 115 125 24 48 93 132 105 145 18 56 1 Cycle 10ms DC 1500V 0 15 6ua 25ms n a 0 8500hms Unit OK Block or Point Fault Indication I O Enabled On Line and Forced Point Indication 4 Ibs 1 8 kg Section 4 Product Specifications Yes Yes Yes 4 25 Genius H and H eld M onitor The Hand Held Monitor HHM is a convenient maintenance configuration and operator interface
85. gnostics The GMR input subsystem provides extensive diagnostic capabilities through a Genius diagnostics a Input Discrepancy Reporting flags any input which is not in agreement with the majority vote a Input Autotest determines the ability of each input to attain the safe state opposite of its normal state and checks for channel to channel shorts Genius Diagnostics Genius devices provide extensive diagnostics protection 16 circuit DC Sink Source blocks detect line faults on tristate inputs supervised inputs For blocks that are configured to be in GMR mode this diagnostic detects short circuit faults on the field wiring Some analog Input devices allow embedded detection of open wire and other faults Genius blocks identify fault type and exact location to the point level and automatically provide that information to the PLC fault tables The information is also available to the application program This level of precision in the diagnostics makes it possible to perform specific repairs without disrupting other elements of the system unnecessarily Input Autotest The GMR Input Autotest feature accommodates normally closed and normally open devices with the devices in either state Input Autotest detects any failure associated with an input that would result in a failure to respond It does not cause spurious inputs Input Autotesting is configurable on a circuit by circuit basis for discrete GMR input circuit
86. has a low alarm fault yes lt gt Passes power to the right if the preceding continuation coil is set ON yes Coils Normally Open The associated reference is set ON if the coil receives power yes Negated The associated discrete reference is set ON if the coil does not receive power yes 1 Positive Transition If the associated discrete reference is OFF when the coil receives power the yes reference will be set ON for one logic scan This coil can be used as a one shot Negative Transition If the associated discrete reference is ON and the coil is not receiving power the yes reference will be set ON for one logic scan S SET The associated discrete reference is set ON if the coil receives power It remains set yes until reset by an R coil R RESET The associated discrete reference is set OFF if the coil receives power It remains yes reset until set by an S coil SM Retentive SET The associated reference is set ON if the coil receives power The reference yes remains set until reset by an RM coil Its state is retained through power failure and STOP TO RUN transitions A discrete reference is reset OFF if the coil receives power It stays reset until set yes RM Retentive RESET by an SM coil Its state is retained through power failure and STOP TO RUN transitions M Negated Retentive A discrete reference is set ON if the function does not receive power The state is y
87. he CPU Inputs from Bus Controllers to a CPU 46631 Each CPU places the input data it receives from the Bus Controllers in separate input tables shown as A B and C in the next illustration The parallel update of these input tables eliminates the need for additional I O data communication networks between processors along with the possibility of one CPU corrupting input data memory in another CPU This reduces overall system components and prevents a common mode single point failure Before each execution of the application program each CPU votes on the input data in input tables A B and C and places the results into its Voted Inputs table The 2 6 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System Technical Product Overview February 1998 Voted Inputs data is used in the application program The original unvoted input data is also available if needed Input Table Mapping in Each CPU GMR Inputs VOTED INPUTS A e INPUT BR UE B VOTING LOGIC w C L 9 245492 Input Discrepancy Reporting Each PLC performs Input Discrepancy Reporting on all discrete and analog blocks for which the feature is enabled For discrete inputs a discrepancy exists if one input remains at variance with the other two For analog inputs a discrepancy exists if one analog channel deviates by more than a configurable pe
88. high x 2 inches 5 25 cm wide They are 2 90 inches 7 3 cm deep I O Module LEDs are easily visible through the transparent central portion of the label Analog input modules have one module status LED Discrete modules also have individual circuit LEDs that show the on off status of each input or output circuit 4 31 1 0 Terminal Blocks I O Terminal Blocks are generic wiring bases for Field Control I O modules They provide I O module mounting backplane communications and terminals for user connections Modules screw onto the terminal block for vibration resistance I O modules can be removed from the I O Terminal Block without disturbing field wiring Field Control I O Terminal Block Terminals or Module 1 16 89 15 O C7 Panel Mounting Foot 14 88 S 13 Be 12 Q eu m Cable Connector 10 1 9 d 8 LST 7 DIN rail latch 6 8 amp s 4 18 3 2 169 eii a o B Ler A oO Keying Slots KO 3 O 16 8 15 le _ Keying Slots 14 LS Tes 13 12 87S 11 B 10 Dlo rea 7 J lt DIN rail latch 6 LST 5 4 HEE 3 2 S amp ll1 Bd Cable Connector p Bila OIL lt Panel Mounting Foot Terminals or Module 2
89. hown by the next diagram Any compatible MI can be used to obtain the data from that PLC Section 6 Communications Simple Human Machine Interface to a GMR System 46625 Monitoring One PLC with Switching This type of HMI requires the ability to switch communications from one PLC to another either automatically or as the result of operator action In this type of system if the PLC that usually communicates with the HMI becomes unavailable the HMI can switch to the backup PLC and continue to provide data In addition to basic I O data the HMI can monitor the status data that is exchanged by the GMR PLCs on the Genius bus This type of HMI is also easy to implement by adding communications modules in two of the PLCs Two communications modules can be used in each PLC as shown in the illustration below for redundancy m Simple Human Machine Interface with Switching 46626 6 3 s Monitoring and Data from Three GMR PLCs Most HMI systems can provide this functionality which uses a communications module in each PLC or two communications per PLC as shown here This type of interface can potentially provide large amounts of raw data from all three PLCs to the operator In addition to basic I O data the HMI can monitor the status data that is exchanged by the GMR PLCS on the Ge
90. ication memory plus an additional 49K of W MS DOS Version 5 0 or later High Memory Area HMA Upper Memory Block UMB or Expanded Memory EMS m The Expanded COM Port version of Logicmaster Both monochrome and color monitors are supported Printer Requirements 90 70 software requires O Either a minimum of 590 K 604 160 Bytes Use of an optional printer is recommended for program MS DOS application memory or 545 K and configuration documentation purposes 558 080 bytes of MS DOS application memory plus an additional 49 Kbytes of High Memory Area HMA Upper Memory Blocks UMB or Expanded Memory EMS for the communications driver O Atleast 1024 Kbytes of Lotus Intel Microsoft Expanded Memory LIM EMS 3 2 or higher W For the Standard Serial COM Port version of the Logicmaster software a computer with a serial COM port serviced by the National Semiconductor 16550 UART chip is recommended For more information please refer to chapter 7 section 4 Standard Serial COM Port in the Logicmaster 90 70 Programming Software User s Manual GFK 0263 GFT 177A C 1 Appendix GMR System Glossary D 1v1 or 1001 Voting One out of One Voting A single path signal or command that is used exclusively to set a bit or data The output follows the commanded state 1v2 or 1002 Voting One out of Two Voting For applications where the safe state is OFF when the voting is 1002 either vote in an OFF stat
91. ime and date stamps these from a possible 128 user assigned events This table is reset from the user request or may be automated for operation with a DCS HMI or other device Additionally a historical log will maintain the last First Out events for the past 10 occurrences In order to establish a Sequential Order of Events when a trip request or shutdown occurs an application program is available from GE Fanuc to store the information in the PLC CPUs Contact GE Fanuc for details The date and time stamps may be read into a DCS HMI or other system asynchronously without concern for losing the sequence information GFT 177A Appendix Memory Allocation A PLC memory in the GMR system is used to store the following e GMR System Software e Application Program Data e g R P PL WAI WAQ e Point Fault Diagnostic Data e Application Program This appendix includes a worksheet for calculating the amount of memory that will be available for the application program Total Memory in the GMR CPU GMR CPM790 CPUs include a memory daughterboard that provides a total of 1 megabyte of battery backed RAM memory 512 Kbytes of this memory can be used only for standalone C programs and a portion of it is occupied by the GMR System Software Of the remaining 512 Kbytes 19 840 bytes are used for the G M R09 User Interface Program Block leaving 504 448 bytes for the application program and data GMR CPU788 and
92. isolated from the alarm and fault information so that corrective Distributed Control System to ensure that its safety maintenance can be applied expediently functions are protected from failures of the process controller GMR has a built in Limited Memory Write feature which ensures that only those areas of memory specifically made accessible to external interfaces can have data written to it All safety related data and logic The following diagram represents a typical GMR installation with an RTU Modbus link between the PLCs and the Distributed Control System DCS Communications to a GMR System using RTU Modbus Protocol DCS or Process Controller DCS LANS GMR Controllers Genius I O Busses 46624 GFT 177A 6 1 s Communications M odules for a GM R System A variety of communications options for the Series 90 70 PLC can be used to link GMR PLCs to other devices such as host computers personal computers or other devices Communications Coprocessor Module CMM The Communications Coprocessor Module provides Communications Control CCM RTU Modbus RTU and Series Ninety SNP communications protocols CCM Functions in CCM mode are read write of register input and output tables bit set clear of inputs and outputs read scratch pad Q sequence commands for fast reads and modify diagnostic status word In the master and peer CCM configurations the CMM module initiates communic
93. ission is voted 2003 by the receiving device to assure data integrity The bus operates at up to 153 6Kb without special connectors or amplifiers A single Genius LAN supports up to 32 devices and up to 31 LANs may be included in one Series 90 70 PLC The bus uses twisted pair cable It may be multidrop wired up to 7500 Longer busses are possible using fiber optic cable and modems Genius Bus Controller The PLC module that interfaces the GMR Series 90 70 PLC with a Genius bus acting as the master communications module I O blocks in a system communicate with the Bus Controller over the Genius bus Genius 1 0 An family of intelligent distributed I O products including many types of Genius I O blocks Genius Bus Controllers and other devices GFT 177A Appendix D GMR System Glossary Genius I O Block An electrical signal interface module capable of reporting inputs and controlling outputs for both digital and analog devices A Genius block converts signals from user devices to from the logic levels used by the CPU Each block is self contained with a built in communications processor block power supply and I O control Genius blocks may be mounted locally or remotely and are rated for use in hazardous locations Extensive block diagnostics report failures even in the I O device system back to the Bus Controller Genius LAN See Genius Bus Global Data Data that is broadcast on the Genius LAN each bus scan
94. ius Bus Controllers for communications in each PLC GFT 177A GFT 177A Human M achine Interfaces for a GM R System GMR systems often include some type of Human Machine Interface HMI for data gathering and display Example O perator Display The complexity of the HMI depends on the needs of the application A simple HMI might collect data from one GMR PLC only A very complex HMI might collect and process data from three GMR PLCs emulating the GMR voting process itself Operation of the Human Machine Interface is independent of the GMR system Regardless of the level of complexity of the HMI the integrity of GMR system operation is not compromised The GMR configuration software provides a selectable level of write access to data memory in a GMR PLC By default write access is not permitted Depending on the needs of the application limited write access can be allowed to certain areas of data memory Monitoring Data from One GMR PLC The most basic type of a Human Machine Interface for a GMR system communicates with one of the GMR PLCs monitoring data from that PLC only In addition to basic T O data the HMI can monitor the status data that is exchanged by the GMR PLCS on the Genius bus This type of a Human Machine Interface is very easy to incorporate into a GMR system by adding a communications module to one of the GMR PLCs A second communications module can also be installed in the same PLC for redundancy as s
95. lable for Non voted Simplex Outputs Outputs GMR EM Logic Reserved memory Lo __ Fault tolerant Fault tolerant Output Outputs Devices 46632 GFT 177A Section 2 Operation The Genius blocks in GMR output groups perform output voting as described on the following pages I O Shutdown When the GMR system diagnoses a discrete I O fault it logs the appropriate faults in its fault tables and sets appropriate fault contacts For certain types of discrete I O faults the system optionally allows a predefined amount of time for the problem that caused the fault to be repaired If the problem is not rectified within this period of time an I O Shutdown of the I O corresponding to the affected block s occurs I O Shutdown is defined as setting the affected I O to its safe state For outputs this is the Off state For discrete inputs the shutdown state is the default state for an input group in the GMR configuration This is selectable for each input group The application program can monitor status bits to be made aware of a pending I O Shutdown or to completely prevent an I O Shutdown from occurring The period of time before an I O Shutdown occurs depends on the autotest interval which is set for the system The initial autotest interval is set by the autotest interval value selected in the GMR configuration The configured autotest interval can be adjusted in each CPU through the application program by varying the value in the a
96. lar Redundancy Flexible Triple Modular Redundant TMR System GFT 177A Technical Product Overview February 1998 Analog Input Termination Boards and Interface Modules An analog input termination boards is available for the distribution to the termination boards The resistor is 6 point current input Genius block A complementary fully protected from short circuits in the power wiring analog input interface module is available with a The termination board incorporates a high input polarized locking two part connector for I O wiring impedance voltage to current converter for each point The analog input interface module converts the input which is powered by the point power supply current into a voltage signal via a precision resistor for Specifications for Analog Input Termination Boards and Interface Modules Operating voltage Temperature range Humidity Connectors Interface Module Size Termination Boards Size Interface Modules External Inputs Input Impedance Input Protection Signal Accuracy Silvertech part numbers GBCI CK 0I6 IMC3 CK AI6 CBLI CK RRnn CBL1 CK EEnn CBLI CK EBnn 18V to 56V DC 0 to 60 degrees C 5 to 95 non condensing One ELCO male 8016 series 38 pin exposed contacts Three 34 pin IDC connectors for ribbon cable 219mm length X 95mm width X 30mm depth 145mm length X 109 mm width X 101mm depth including mating connector including mounting bracket 6 point isolated 4 20mA current in
97. le distance from the PLC Removable Terminal Connector A removable assembly that attaches to the front of a printed wire board or module It contains the screw terminals to which field wiring is connected Restart Pushbutton A pushbutton on the front of a PCM ADC or GDC module that can be used to reinitialize or reset it RTU Protocol An acronym for Remote Terminal Unit protocol which is a serial communications standard for industrial controls GFT 177A GFT 177A RUN Mode The mode a PLC is in when it executes an application program S Smart Switch A component of the principal types of Genius blocks used in GMR input and output subsystems The Smart Switch provides configurable features and comprehensive diagnostics SNP An acronym for GE Fanuc Series Ninety Protocol serial communications Soft Configuration The ability to configure the GMR hardware system off line using a personal computer STOP Mode The mode in which the PLC no longer executes the application program In the Series 90 70 PLC there are two types of Stop mode STOP NO IOSCAN and STOP IOSCAN In STOP NO IOSCAN mode the CPU communicates only with the programmer and certain special modules recovers faulted boards reconfigures boards and executes background tasks In STOP IOSCAN mode the CPU can also monitor I O The STOP IOSCAN mode makes it possible to monitor and debug I O without executing the application program
98. le with 2 ELCO 8016 connectors Field device connection cable with 1 ELCO 8016 connector and stripped and tinned connectors at the other end Specifications for 32 Point Discrete Input Termination Boards and Interface Modules Operating voltage Temperature range Humidity Connectors Interface Module Size Termination Boards Size Interface Modules External Inputs Open Switch voltage Closed Switch current Silvertech part numbers GBCI SC DI32 GBCI SK DI32 IMC3 SC DI32 IMC3 SK DI32 CBL1 CK RRnn CBL1 CK EEnn CBL1 CK EBnn 16V to 30V DC 0 to 60 degrees C 5 to 95 non condensing Two 32 point ELCO male 8016 series 38 pin exposed contacts Three 34 pin IDC connectors for ribbon cable 219mm length X 110 mm width X 30mm depth 145mm length X 109 mm width X 101mm depth including mating connector including mounting bracket 32 switched inputs with Short Circuit protection31 with autotest Supply voltage 1V 7mA per point per Genius Block 21mA max with 3 blocks at 24V Termination Board for 32 circuit Source block Termination Board for 32 circuit Sink block Interface Module for 32 circuit Source block group Interface Module for 32 circuit Sink block group 34 way ribbon cable termination board to interface module Field device connection cable with 2 ELCO 8016 connectors Field device connection cable with 1 ELCO 8016 connector and stripped and tinned connectors at the other end 4 28 Genius amp Modu
99. locks T Output Groups consist of of two source type shown here or sink type Genius blocks connected in parallel on one side of the load The other side of the load is tied to ground when two source blocks have been configured In the T configuration where two sink blocks have been used the other side of the load is tied to 24V A 2 Block T Output group is fault tolerant This type of group might be used in high availability or fire and gas applications where it is necessary to be able to turn ON a critical load m 2 Block T Discrete Output Group Separate Busses Hs Source Source LOAD 0 Volts GFT 177A T Output Groups consist of a source type Genius block connected to one side of the load and a sink type Genius block connected to the other side of the load This type of group is most suitable for redundant shutdown applications This type of group might be used in fail safe applications where it is necessary to be able to turn OFF a critical load If either block faults The other can still turn the load OFF m 2 Block I Discrete Output Block Group L Separate Busses Source p I LOAD O Sink gt iu ST Non critical discrete outputs may be wired to Genius blocks of
100. lternatively two Genius Bus Controllers can be used for a duplex GMR bus or a single Genius Bus Controller for a simplex GMR bus or a non GMR bus Triplex GMR System with Two Triplicated Busses PLCA PLC B PLC C Qele e GGG o Giag CRER GGG I zB BIB 4 PEGE BBB PEGG BBB ele CCC ule e e C co ukele cicc S A BIC BOGGA BC CB ig BC Bus A Bus B Bus C Bus A Bus B Bus C 46618 Additional Genius Bus Controllers can be outside the scope of the GMR configuration but still part of a GMR system Through the exchange of directed communications datagrams and global data they can serve as communications nodes linking other devices and provide peer to peer information transfer Such a network can provide communications between multiple PLCs and host computers MODEL IC697 Devices Supported per Bus Communications Rates Maximum Cable Lengths Configuration Effect of Failure of One GBC in a group BEM731 28 Blocks Typical 31 Maximum including up to 3 GBCs and 1 HHM 153 6 Kbaud Standard 153 6 Kbaud Extended 76 8 Kbaud 38 4 Kbaud 2000 feet 153 6 Kbaud Standard 3500 feet 153 6 Kbaud Extended 4500 feet 76 8 Kbaud 7500 feet 9 38 4 Kbaud Via LM90 70 Programming and Configuration Software No Hardware Switches or Jumpers None Loss of IOC report
101. me power supply if the power supply s maximum current rating is not exceeded POWER SUPPLY TWO RACK POWER CABLE MODEL 1C697 Nominal Voltage Input Voltage 47 63Hz AC Input Vdc Input Power Output Voltage Output Power Overvoltage Limit Overcurrent Limit Holdup Time 4 10 PWR710 PWR712 120 240Vac 90 132 180 264 N A 90 Watts 5Vdce 55 8 Watts 5 7 6 7 Volts 12 14 5 amps 2 ms min Input Power Source Connections The illustration below shows input power source connections to the power supply through the protected screw connections on the front of the module The AC input supplies have a jumper that must be attached to the bottom terminals for 120Vac operation This jumper must be removed for 240Vac operation r Example Power Connections Technical Product Overview February 1998 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System to the Power Supply FIRST RACK a47077 1697 o RACK STUD 8 32 WARMING DO NOT DISCONNECT 12 3 3 mm2 WHILE CIRCUIT IS EARTH Q Pe and rang GROUND 1A 250V SECOND RACK INPUT E NE POWER roll aee 125 125 po SOURCE 2 e m J 75_C Copper Conductors a46611 o PWR711 713 PWR724 PWR731 PWR748 Version H or later PWR732 120 240Vac or 125 VDC 24Vdc 125Vdc 48Vdc 90 264 N A N A N A 100 150VAC 18 32 100 150 35
102. mitting device sends each bit three times Each receiving device performs a 2 out of 3 vote on each bit received anda CRC checksum on each packet This process automatically corrects any bits received in error and eliminates the need for retransmission anccomszoo wee Input Device 2 4 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System Technical Product Overview February 1998 prooeer wee ancceaneen Gee aperondoa scs zmrromazoo oco ff 46629 GFT 177A Synchronization Unlike other triplicated systems GMR does not require ongoing processor synchronization greatly reducing the probability of software and hardware common mode failures In a GMR system each PLC typically runs the same application program Application program data is optionally synchronized among the PLCs during system startup It is also optionally synchronized whenever one or more PLCs is taken offline and then restarted Initial System Program Synchronization Upon initialization of the application program each PLC runs a startup diagnostic checks the status of all system components and provides an orderly controlled startup If any errors occur they are logged into a fault table in the PLC and made available to the application program through diagnostic status bits Initialization errors may or may not stop the PLC this is determined by the GMR configuration set up for the application Partial Restart
103. n In a GMR system Genius I O electronic modules may be replaced without disconnecting the power supply In addition Series 90 racks are completely isolated from each other Therefore spare slots and spare devices are not required in the installation Appendix D GMR System Glossary L2 On Line Testing An integrated ability to do complete electrical testing without bypassing the system Open Architecture The rack based non proprietary design of the GMR system Open architecture makes it possible to include many kinds of application specific modules including custom modules in the overall GMR system Output Autotest See Autotest Output Block A Genius I O module that converts logic level signals received from the CPU to signals for controlling output devices Output Devices Physical devices such as motor starters solenoids etc that are controlled by the PLC Overload and Short circuit detection The Genius I O blocks used for GMR can provide stepped overload and instantaneous short circuit electronic protection per point If an overload or short circuit occurs an output circuit diagnoses the condition turns itself off for protection then reports the fault to the I O Fault Tables in the CPUs In fault tolerant configurations each leg is individually protected This prevents the type of common mode failure that can occur in systems with single slow operating fuses P Parallel Commu
104. n environmental release protection and safety critical protection systems For details of the following typical applications of the GE Fanuc Series 90 70 GMR system technology please contact your local GE Fanuc distributor or sales representative Emergency Shutdown The GMR system was specifically designed tested and certified to provide redundancy in both CPU and I O subsystems together with the latent fault diagnostic coverage required for Emergency Shutdown applications in refining chemical manufacturing and other continuous batch operation environments Functions that cannot be implemented in traditional relay DCS or PLC based systems are standard features of GMR Typical factors that contribute to its reputation for operation on demand are High Availability 99 999 fault coverage that extends to the field device elimination of nuisance trips and fail safe fault tolerant design Environmental Protection Systems Environmental Protection systems are becoming extremely important in many processing facilities Uncontrolled events in chemical production centers can lead to release of toxic substances into the environment exposing plant personnel and adjacent communities to materials now controlled by OSHA By monitoring critical variables on reactors vapor recovery and other potentially volatile process units GMR can react to bring the unit back to a controlled GFT 177A Section 1 Introduction state eliminating the
105. ne start coil Bulb B152 Circ 00 Switch Sump Pump 1 Density Meter ConveyrCheck Seconds to Chk Completion Registr Input Data Pointer to Read Data D BLK _MAIN REG 111 REG 112 D NLMSONLESSUN ENTRY 0006 REPLACE Example Search Screen B P OLDER ptionigoto gnore ROGRM insertipedit zoom od if ymesearch Rung comments expanded text documentation may be added to describe the logic contained within individual rungs Program annotation display can be selectively turned off or on as shown in the next two example screens E SEARCH Search for c Replace With Scope LOCAL LOCAL GLOBAL Usage EXPLICIT EXPLICIT IMPLICIT 000 Prompt NO YES NO FORWARD BACKWARD Direction FORWARD 00 Start From CURRENT CURRENT TOP BOTTOM 0000 Q0000 Q0000 lt lt Press Enter key to begin search function gt gt Q0000 lt lt Press Esc key to exit search screen gt gt Logic Display with Partial Annotation 00016 HUT E ae EUH PROGRE O RE FFL INE D NLMSONLESSUN RG LESSON MBLK MAIN IZE 294 RUNG 0004 REPLACE PROGRAM BLOCK DECLARATIONS INTERRUPTS E START OF PROGRAM LOGIC 100101 7100105 7100102 Al WORD 00002 PTR Q P00004 D LM9O LESSON RUNG 0005 REPLACE M0099 Sump Pump 1 Density Meter 5 6 Genius Modular Redundancy Flexible Triple Modular Redundant TMR GFT 177A System Technical Product Overview February 1998
106. nformation 242986 4 16 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFT 177A Technical Product Overview February 1998 Genius Bus Controller M odule The Genius Bus Controller GBC is a single channel controller that occupies a single rack slot in either the CPU rack or any expansion rack Its primary purpose is to interface the I O subsystem to the GMR CPUs Multiple GBCs may be installed in each rack to suit the I O capacity needs for an application The front of the module provides a port for direct connection of a Genius Hand held Monitor and screw terminals for the Genius bus Two LEDs show Module OK and Channel One OK status information The Bus Controller scans I O blocks asynchronously and transfers I O data to the GMR CPU once per CPU scan over the backplane of the rack The Bus Controller also passes fault information from the I O devices to the GMR CPU which time stamps faults and queues them in a table Genius Bus Controller Module with Door Open J LEDs 7T for Genius Hand held Monitor o 88 Connector 2 o o Terminals for Connecting Genius Bus Cable O a42985 GFT 177A Section 4 Product Specifications Typically three Genius Bus Controllers are used per GMR PLC for a triplex GMR bus Two triplicated GMR Buses are shown in the following drawing of a triplex GMR system A
107. nications A method of communications in which data is transferred on several wires simultaneously Peripheral Equipment Devices external to the PLC for example personal computers and printers with which the PLC can communicate 2 PLC Programmable Logic Controller A solid state control device designed to operate in an industrial environment The PLC receives signals from user supplied control devices such as switches and sensors It implements them in a precise pattern determined by application programs stored in user memory The PLC then provides output signals for control of processes or user supplied devices such as relays or motor starters PLCs are usually programmed in relay ladder logic PLC Fault Table A fault table listing PLC faults Each fault is described and identified by time date and location Program Block Structured programming techniques can be used to separate areas of a GMR application program into functional blocks Program blocks can be called from the main program or from other program blocks Program blocks may contain logic in one of several available programming languages Programmer The computer used to run the Logicmaster 90 programming and configuration software R Rack The chassis of the Series 90 70 PLC consisting of a baseplate and structural frame Modules install in mating connectors on the baseplate and are supported by the rack frame RAM An a
108. nius bus Human Machine Interface for Gathering GMR PLC Data Genius bus DOU 46627 Monitoring All PLCs and Emulating the Voting Process The most powerful type of HMI system processes the raw data obtained from the GMR PLCs mimicking the actual voting carried out by the PLCs This type of system uses a sophisticated HMI or an general purpose HMI plus a data concentrator and an additional PLC with special application logic to process the collected data The additional PLC might be a cost effective Series 90 30 PLC This type of system gives a detailed picture of what is happening to data in the GMR PLCs and at the level of the Genius blocks themselves Genius Modular Redundancy Flexible Triple Modular Redundant TMR System Technical Product Overview February 1998 The illustration shows two communications modules used in each PLC and two host systems for redundancy of the HMI system r Complex Human Machine Interface with Voting O DOU 46628 Sequence of Events SOE Recording SOE Sequence Of Events Logging can be accomplished using standard documented library functions in the GMR software diskette The SOE establishes the correct sequence of ten current events per user category t
109. nputs Input and output autotesting Input and output discrepancy checking General system diagnostics Fault reporting The CPM790 CPU module includes 1 megabyte of memory Approximately 512K bytes of this memory is available for the application program The CPU 788 and 789 modules require a 512K byte memory daughterboard Approximately 200K bytes of this memory is available for the application program This CMOS RAM is battery backed by a lithium battery on each CPU module The battery can retain memory contents for up to six months The battery has a life of at least ten years The module has two battery connectors so a replacement battery can be added before a low battery is disconnected A low battery dead battery and missing battery are all diagnosed and alarmed by the CPU Each of up to three CPUs in a system operates entirely independent from each other CPU The CPUs exchange general status information autotesting and fault information program checksum and configuration data checksum information and optionally user application data via a built in global data facility This information and data is exchanged between the physically isolated CPUs over the same Genius I O buses that are already present to interface to I O modules Extensive CPU module and memory diagnostics are performed both at powerup and continuously by each CPU Faults are logged in a PLC fault table which can be viewed with the Logicmaster programming and config
110. ntacts can be used to detect fault or lack of fault conditions on a discrete or analog point Fault and No Fault contacts can also be programmed with the Series 90 70 s built in fault locating references Fault locating references identify faults associated with the system hardware to the point level Alarm contacts can be used to indicate when an analog value has reached an assigned alarm limit GMR Status and Control References The GMR system includes many status and control bits that can be used in an application program Status bits provide information about GMR operations such as system fault at startup output discrepancy autotest in progress I O reset in progress PLC is online I O shutdown is activated PLC is OK These references can be read as needed by the application program Control bits can be used to command system operations such as clearing fault tables initiating or inhibiting autotesting and canceling I O shutdown 2 5 Input Processing Each block in an Input Group is attached to a separate Genius bus When the Genius blocks in the Input Group broadcast their inputs each PLC CPU receives a copy of the corresponding inputs from each block in the group Input Group Broadcasting Inputs Input Device Bus A Bus B Bus C His 46630 In each PLC the Bus Controller on each bus receives the input data and provides it to t
111. ocumentation CPU Modules Description Catalog T V Refer To Number Approved Racks pp 790 GMR CPU IC697CPM790 Yes Page 4 11 Catalog T V Refer To 2048 TMR I O Description Number Approved Includes 1 meg of memory 9 slot rear mount IC697CHS790D Yes Page 4 8 panel mount EO IC697CPU788 Yes Page 4 11 9 slot front mount 19 IC697CHS791 Page 4 8 inch rack mount 789 GMR CPU IC697CPU789 Yes Page 4 11 5 slot rear mount IC697CHS750 Page 4 8 CO8STMR VO panel mount 512K byte Memory IC697MEM735 Yes 17 VME slot rear IC697CHS782 Page4 8 Daughterboard mount panel mount One required for 17 VME slot front IC697CHS783 Page4 8 each CPU 788 or mount 19 inch rack CPU 789 mount Rack Fan Assembly IC697ACC721 724 X A All Series 90 70 PLC and Genius I O products can be used in a GMR system however not all of the available components are T V approved for use in the safety relevant portion of a system 4 2 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFT 177A Technical Product Overview February 1998 GM R Components List Communications Interface Modules Description Ethernet Communication Module Comm Coprocessor Module CMM Programmable Coprocessor Module PCM Genius Bus Controller GBC Module Catalog Number 1C697CMM741 1C697CMM711 1C697PCM711 1C697BEM731 TUV Approved xk xk xk Yes Refer To Page 4 15 Page 4 13 Page 4 14 Page 4
112. odule Genius Analog Outputs Description 115Vac Volt Current 4In 2Out 24 48Vdc Volt Current 4In 2Out 115Vac 125Vdc Current Src 4In 2Out 24 48Vdc Current Src 4In 2Out 115Vac 125Vdc Current Src 6 Out 24 A48V dc Current Src 6 Out Type MR Simplex HSB MR Simplex HSB MR Simplex HSB MR Simplex HSB MR Simplex MR Simplex MR Simplex MR Simplex MR Simplex T T T T T T T T T T Type TMR Simplex TMR Simplex TMR Simplex TMR Simplex Type Simplex HSB Simplex HSB Simplex HSB Simplex HSB Simplex HSB Simplex HSB Section 4 Product Specifications Catalog Number IC660BBA100 IC660BBA020 IC660BBA104 IC660BBA024 IC660BBA106 IC660BBA026 IC660BBA101 IC660BBA021 IC660BBA 103 IC660BBA023 Catalog Number IC670ALG230 IC670ALG240 IC670ALG620 IC670ALG630 Catalog Number IC660BBA100 IC660BBA020 IC660BBA104 IC660BBA024 IC660BBA105 IC660BBA025 TUV Approved T V Approved T V Approved Refer To Page 4 245 Page 4 24 Page 4 24 Page 4 24 Page 4 24 Page 4 24 Page 4 24 Page 4 24 Page 4 24 Page 4 24 Refer To Page 4 33 Page 4 33 Page 4 33 Page 4 33 Refer To Page 4 25 Page 4 25 Page 4 25 Page 4 25 Page 4 25 Page 4 25 4 5 GMR I O Components List Additional Genius Components Description Type Catalog TUV Refer To Number Approved High Speed Counter HSC Block Simplex HSB IC660BBD120 See GFK 0367 PowerTRAC Block Simplex HSB IC660BPM
113. odules such as fault reporting output defaults analog range selection and analog scaling The BIU has four status LEDs and a connector for a Hand held Monitor The BIU provides logic power for the modules in the station External power must be supplied for field wiring of I O devices The BIU mounts on a separate terminal block to which all of the bus wiring is connected The configuration of the I O station is stored in the BIU terminal block BIUs IC670GBIOO2F or GBI102A or later support Hot Insertion Removal of I O modules Modules can be removed and replaced while station power is applied without affecting the BIU and other modules in the I O Station Separate power must be off to the module being inserted or removed Hot Insertion Removal requires I O modules having catalog number suffix J and above and I O Terminal Blocks IC670CHS101 102 or 1034 Bus Interface Unit IC670GBIO002 operates on 24VDC IC670GBI102 operates on 11SVAC 125VDC Field Control I O Modules Field Control I O modules are available in a wide range of TO types and densities All module types may be used in a GMR system as non critical or simplex I O Field Control analog input modules may be used as TMR I O Fidd Control A nalog Input M odule X Se uL Status EL LED 46406 Field Control I O modules are small rugged components with sturdy aluminum housings Modules are approximately 3 25 inches 8 2 cm
114. omponents and prevents a common mode single point failure Any input voting discrepancies are reported to the built in PLC Fault Table in each PLC Each CPU executes the same application program processing the input data and creating new output data Each bus scan each PLC sends output data to groups of Genius I O blocks that control field output devices The intelligent Genius output block groups perform output voting The manner of voting is configurable for the application Because output voting is performed by the block groups at the point of control output data discrepancies are caught by the voting process Overview of GMR System Operation Voted Inputs Field Input IX EIU nput e Field Input 3 p EE o Single Dual or Triple Single Dual or Triple 2003 Voted Outputs C l P Field Logic 6 Input 2 Output a rp Ei ER i PUs Simplex or Fault Tolerant Output 4 Output Logic Logic Output 245497 GFT 177A 2 1 Input Subsystem A GMR Input sub system is a A group of 2 or 3 discrete GENIUS blocks 16 or 32 points each with 1 circuit reserved for autotest connected to redundant GENIUS lans Either common or redundant sensors may be used as represented in the next two illustrations A group of 2 or 3 analog GENIUS blocks 2 or 6 channels o
115. onds or higher depending GFT 177A on configuration size of the application program and instructions used in the application program To estimate the total scan time and or scan time contributions for the other operations that take place during a scan please refer to the Series 90 70 Programmable Controller Reference Manual GFK 0265 Appendix A CPU Performance Data That appendix includes worksheets to assist you in estimating scan time for your own system If you are estimating total scan time using these worksheets you must add the scan time associated with executing the GMR system software as noted above separately Genius Bus Scan Time The GMR system utilizes Genius I O as its input and output subsystem Genius I O blocks operate on a serial communications network that interfaces to the GMR CPU subsystem through Genius bus controllers This serial token passing type of network has its own scan time which is separate and asynchronous from the CPU scan time discussed above This Genius bus scan time is the time required for all devices on a Genius network to communicate on the network one time The Genius bus scan time can be estimated if all of the devices and their configurations to be put on a bus are known Typical Genius bus scan time range from 5 milliseconds to 60 milliseconds or higher depending on the configuration Please refer to GEK 90486 1 the Genius I O System and Communications User s Manual Chap
116. pancy fault or Genius fault occurs the GMR software rejects the faulty data Depending on the configuration of the input group input voting may go from three inputs to two inputs to one input or from three inputs to two inputs to the configured default value GFT 177A Output Processing Each CPU executes the same application program processing the input data and creating new output data The PLC uses separate areas of the Output Table for non voted discrete outputs fault tolerant outputs and copies of the fault tolerant outputs m Data for blocks that are included in the GMR configuration is placed at the start of the Output Table In the illustration below the application program outputs for redundant blocks are labeled logic outputs This data is followed by outputs for non voted blocks m The CPU copies these logic outputs into the bottom portion of the Output Table This data shown as Fault tolerant Outputs in the illustration is used for physical outputs for the blocks This separation of physical outputs from logical outputs prevents disruption of outputs such as latches and seal circuits during autotesting m Each bus scan the Bus Controllers automatically send the non voted outputs plus the copied fault tolerant outputs to the Genius blocks m Discrete Output Processing in Each CPU Application Discrete Output Table Program L Y Avai
117. pplication program T V specifies restrictions on the areas and size of data to which write access may be permitted Z Zener Diode A special semiconductor that provides high conduction when current is applied in one direction and a specific voltage drop when current is passed in the reverse direction D 10 Genius amp Modular Redundancy Flexible Triple Modular Redundant TMR GFT 177A System Technical Product Overview February 1998
118. put for sink or source operation 230 Ohms 5 Thermistor limited to less than 100mA typical 0 2 over temperature Termination Board for 6 circuit blocks Interface module for 6 circuit input block group 34 way ribbon cable termination board to interface module Field device connection cable with 2 ELCO 8016 connectors Field device connection cable with 1 ELCO 8016 connector and stripped and tinned connectors at the other end GFT 177A Section 4 Product Specifications 4 29 Discrete Output Termination Boards and Interface Modules Discrete output termination boards are available for 16 point and 32 point sink and source Genius blocks Complementary discrete output interface modules are available with polarized locking two part connectors for I O wiring Both the 16 and 32 point discrete interface modules group the output signals and incorporate a diode for each point to prevent reverse load leakage current It is highly recommended that an external kickback suppression diode be fitted to the field loads The 16 point discrete output uses a single termination board type which operates with either sink or source blocks The 32 point source block termination board incorporates a self indicating fuse in accordance with T V recommendations which is visible from the installed position A blown fuse will be revealed during the output autotest The termination boards and interface module can easily be configured for either
119. r Field Control modules 4 8 or 16 channels connected to redundant GENIUS lans Voltage inputs may use a common sensor current inputs requires separate sensors a A single GENIUS or Field Control device not safety related Two block Groups Single Sensor Discrete Inputs Each Genius block is attached to a separate Genius bus Each block independently broadcasts its inputs to all PLCs so each PLC CPU receives an independent copy of all inputs Each input can be configured for Input Autotesting default state and Voting Adaptation mode The Voting Adaptation method determines how the PLC will perform voting when fewer than three input signals are present in a group All voting for discrete and analog inputs is performed independently at each PLC For a two or three block input group the CPU performs a 2 out of 3 vote on corresponding inputs Depending on the configuration of the input group input voting may adapt from three inputs to two inputs to one input or from three inputs to two inputs to the configured Default State When three inputs are present the vote is a simple majority vote If only two inputs are present the PLC uses the point s configured duplex state as the third input and performs a majority vote If only one input is present and the circuit is configured for 3 2 1 0 voting adaptation the single input is used as the voted input value However if the circuit is configu
120. r or a command from another device The sequence of operations necessary to execute a program one time is called a sweep or a scan In addition to executing the application program the scan includes the operations of executing the GMR system software obtaining data from input devices sending data to output devices performing internal housekeeping servicing the programmer and servicing other communications devices The time required for the portion of the scan related to the execution of the GMR system software depends on GMR configuration parameters such as Input and Output table sizes Typical times required for the execution of the GMR system software for either the CPU788 or CPU789 are shown below In this example there are six bus controllers in each PLC With Table sizes of Voted I 64 With Table sizes of Voted I 256 Voted AI 64 Voted AI 256 Logical Q 64 Logical Q 256 Scan Time Contribution 2 Scan Time Contribution CPU788 789 79 ms CPM790 22 ms CPU788 789 88 ms CPM790 24 ms The scan time contribution for the execution of the GMR system software for your system could be more or less depending on the table sizes you configure Also this time varies by 10ms for the CPU788 and 789 2ms for the CPM790 during single scans when the GMR system software performs diagnostics on the CPU subsystem and I O subsystems Typical GMR CPU total scan times range from 22 milliseconds to 300 millisec
121. rcentage from the selected mid value If a discrepancy is detected the PLC places a message in the I O fault table indicating which input does not agree The fault message can be seen by an operator and by the application program Discrete Input Voting Adaptation For a two or three block input group the CPU performs a 2 out of 3 vote on corresponding bits in each section A B C and places the result in the Voted input section of the input table For single Genius input block the actual input value is used by the application program If a discrepancy fault Input Autotest fault or Genius fault occurs on any point the CPU rejects that input Depending on the configuration of the input group input voting may adapt from three inputs to two inputs to one input a 3 2 1 0 degradation path or from three inputs to two inputs to the configured Default State a 3 2 0 degradation path Analog Input Voting Adaptation For a three block analog input group or Field Control analog input group the Input Voting Logic in each PLC selects the mid value from three corresponding inputs and places the result in the Voted Input section of the Analog Input Table for use by the application program For a group with two analog inputs the CPU uses the high low or average value of the two inputs depending on how that input group has been configured If there is only one input value that is used for the application program value If a failure discre
122. rcuit Type TMR Simplex TMR Simplex TMR Simplex TMR Simplex Simplex Simplex Simplex Simplex Type TMR Simplex HSB TMR Simplex HSB TMR Simplex HSB TMR Simplex HSB Simplex HSB Simplex HSB Simplex HSB Simplex HSB Simplex HSB Catalog Number IC660BBD020M IC660BBD021M IC660BBD024N IC660BBD025N IC660BBD101 IC660BBS 102 IC660BBS103 IC660BBD110 Catalog Number IC660BBD020M IC660BBD021M IC660BBD024N IC660BBD025N IC660BBD101 IC660BBS 102 IC660BBS103 IC660BBR100 IC660BBR101 TUV Approved Yes Yes Yes Yes T V Approved Genius Modular Redundancy Flexible Triple Modular Redundant TMR System Technical Product Overview February 1998 Refer To Page 4 20 Page 4 20 Page 4 20 Page 4 20 Page 4 21 Page 4 21 Page 4 21 Page 4 21 Refer To Page 4 22 Page 4 22 Page 4 22 Page 4 22 Page 4 23 Page 4 23 Page 4 23 Page 4 23 Page 4 23 GFT 177A GFT 177A Genius Analog Inputs Description 115Vac Volt Current 4In 2Out 24 48V dc Volt Current 4In 2Out 115Vac 125Vdc Current Src 4In 2Out 24 48V dc Current Src 4In 2Out 115Vac 125Vdc Current Src 6 Input 24 48V dc Current Src 6 Input 115Vac 125Vdc R T D 6 Input 24 48Vdc R T D 6 Input 115Vac 125Vdc Thermocouple 6 Input 24 48V dc Thermocouple 6 Input Field Control Analog Inputs Description 0 20 or 4 20mA 8 Input Module 0 20 4 20 or 4 24mA 16 Input Module RTD Input Module Thermocouple Input M
123. rd VME slots which can be used to facilitate integration of 3 party modules It is also available in panel mount or rack mount styles Each of the racks can function either as the main CPU rack or as an expansion rack Rack fan assemblies are available for use in installations where heat buildup is a problem The fans have a low noise level and use ball bearings for extended life Module Retention All Series 90 70 modules have molded latches that automatically snap onto the upper and lower rails of the rack when the module is fully inserted Optionally M2 5X8 screws may be used to secure the modules to the rack for high vibration applications Slot Covers Rack and Mounting Specifications Dimensions Height Width Depth Nine Slot Rack 266mm 483mm 190mm 10 47 19 00 7 5 Five Slot Rack 266mm 320mm 190mm 10 47 12 6 7 5 Note All modules extend 43mm 1 7 beyond the front of the rack Number of Slots 5 or 9 plus power supply slot Maximum 5 Volt 18 amps with 100 watt power supply Current 11 amps with 55 watt power supply Current Required 0 5 amps from I O bus Ground Connection Ground terminals are provided on each side of the rack Ring terminal star washer and AWG 12 wire is recommended I O Reference User configurable via software no switches Assignment Rack Identification Rack select jumpers at back of power supply
124. red for 3 2 0 voting adaptation the circuit s configured default value is used instead The result of voting is provided to the application program Single Genius input blocks of any type can be connected to any Genius bus The actual input value is used by the application program Analog Inputs Genius analog blocks and Field Control analog input modules can be used in GMR input groups in the input subsystem Analog input blocks can support 0 to 10V 10V 5V 0 to 5V and 4ma to 20ma RTD and thermocouple modules are also available Analog inputs are handled very much like discrete inputs Groups of one to three analog input blocks are connected to separate Genius busses They broadcast their inputs to all PLCs The PLCs select the mid value from among the three corresponding inputs Depending on the configuration of the input group input voting may adapt from three inputs to two inputs to one input or from three inputs to two inputs to the configured Default Value The result of the voting is provided for use by the application program The ability of Genius Analog blocks and Field Control Analog Input modules to convert raw data to engineering units and directly drive discrete preset alarm limit points reduces the complexity of software at the CPU and increases system reliability 2 2 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFT 177A Technical Product Overview February 1998 Input Dia
125. rrozdzooocm smrrosazoovcs P xmrromazoooce pe mmrroz4zooucm B u s c o N T R o L L E R zmrroz4zoovcm mrro azoovc _ m ozazoooco Single Genius block Block receives command from all PLCs For Hot Standby redundancy a load must be connected to one sink type or source type discrete Genius block Blocks in Hot Standby mode receive outputs from all GMR CPUs and use the output data from the CPU with the Bus Controllers at the highest serial bus address that are currently online 9 846607 3 6 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System Technical Product Overview February 1998 GFT 177A Single Voted Output zm rozx4zooncm Single Genius block Block receives command from all PLCs 2 out of 3 voting done by output block Duplex default selection determines 1 out of 2 or 2 out of 2 voting LOAD a46608 Fail Safe and Fault Tolerant Output Standard H pattern Sink and source blocks LOAD Each block receives command from all PLCs 2 out of 3 voting done by output block group Duplex default selection determines 1 out of 2 or 2 out of 2 voting 246609 GFT 177A Section 3 GMR System Architectures 3 7 _ 2 Block T Pattern Group for High Availability T pattern Two Source or
126. s r Parameterized Subroutine Block CALL LOAD_41 SUBROUTINE B050 w075 QUT 7 B099 CLS NONE 3 W016 Section 5 Configuring amp Programming a GMR System Programming Languages The main part of the GMR application program is created in familiar Relay Ladder Logic Additional program blocks can be in Relay Ladder Logic or in C Program Blocks in C are created externally and imported into the main Relay Ladder Logic program Coprocessing modules may be added and programmed in C MegaBASIC Toolkit provided by GE Fanuc Programming languages other than Relay Ladder Logic are restricted to non critical portions of the program Logic for non safety functions must be in separate program block s Timed Interrupts The timed interrupt feature enables the interrupt declaration editor to specify timed execution of program blocks including external blocks A time base of 1 0 0 10 0 01 or 0 001 seconds may be selected for each of the 16 timed interrupts The following example screen shows various types of interrupts in the program logic Timed Interrupts Calling Program Blocks pnocng pne ERES FOLDER UTILTY PRINT HinsertBedit modifulisearch i Bioption iiyoto enore izon cma CALL CL 001 41000991 CONST 00200 CONST 00005 41000981 oCALL EXE PO EXTERNAL C NLMSONLESSUN ENTRY 0001 Time of Day Date Clock A time of day clock
127. s GFT 177A Section 2 Operation On blocks set up for autotesting power to the input device is provided by Power Feed Outputs from the blocks in the Input Group as illustrated below This output occupies one of the block s I O circuits leaving either 15 or 31 circuits available for use with input devices depending on the block type On a configurable time interval Input Autotest pulses the Power Feed Output to Off this does not change the input reported to the application If an input does not turn Off during the Autotest period the CPU places a message in the I O Fault Table Off inputs are also tested to ensure that the blocks input circuits can detect the On state Input to input shorts are also detected Input Autotest TRIPLICATED BUS LL L1 Em o LT POWER FEED 3 OUTPUT CHANNELS 245496 2 3 Processors In a GMR system processing is performed by one to three Programmable Logic Controllers PLCs Each PLC is modular in design consisting of a rack with a power supply module a CPU module and other modules that perform specific operations needed for the application Unlike other triplicated systems GMR does not require ongoing processor synchronization greatly reducing the probability of software and hardware commonmode failures The illustration below represents the basic par
128. s 90 70 PLC and the Genius I O system Both have demonstrated mean time between failure MTBF statistics that allow system designers to easily achieve the safety integrity level SIL required in critical applications In addition they are both approved for hazardous location Class I Division II installation TUV has certified GMR for classification to these requirements triplex Class 5 duplex Class 4 and 5 according to the DIN V19250 DIN V VDE 081 standards Field data has been accumulated and submitted for Class 6 type approval anticipated by the end of 1997 For information about using the GMR system in a TUV approved safety critical installation refer to information in the GMR User s Manual GFK 1277 na ISO 9001 Z UF REGISTERED S amp Reg A2003 T A Division of CSA Miro e GFT 177A GMR Applications The GMR input subsystem PLC subsystem and output subsystem combine to provide a high availability high reliability system PLC Subsystem PLCA PLCB ABC ABC keen tel we i i or Hot Standby MER EE or Duplex z 2 Block T ORE SIOUp Fault Tolerant 2 Block 1 eBoek H Output Group utpu HighAvailability OWtput Group Group Typical uses of Genius Modular Redundancy technology are applications that require operation on demand high system availability These applications include equipment protectio
129. s a CCM communication interface PCM Module with Door Open LEDs gt MODEL 1C697 Dual Tasking Protocols Port 1 Interface type Port 2 Interface type Port 1 Max Data Rate Port 42 Max Data Rate Dual Port Max Data Rate Microprocessor Memory Expansion Memory Lithium Battery for PCM711 CCM Megabasic CCM2 or Custom via Megabasic application program RS 232 or RS 422 RS 485 RS 232 or RS 422 RS 485 19 2 Kbps full duplex 19 2 Kbps full duplex 19 2 Kbps full duplex on both port simultaneously 12 Mhz 80C186 Up to 96 Kbytes of battery backed CMOS RAM on board 64 128 256 or 512 Kbytes battery backed CMOS RAM 3 Volt 1000mA hours 6 months Restart Pushbutton Dual x Battery Connectors O RS 232 RS 485 Serial Port 000000000000 0000000000000 O Expansion Memory Board O RS 232 000000000000 0000000000000 Memory Backup minimum retention RS 485 Clock Real time calendar clock synchronized Serial to GMR CPU Port Q Configuration Via LM90 70 Programming and Configuration Software or PCM Development Software No Switches or JUMPED a46614 Controls Indicators Reset Pushbutton Three Status LEDs 4 14 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFT 177A Technical Product Overview February 1998 Communications M odules continued Ethernet Mo
130. see these block types listed in both the input section and the output section In addition to individual circuit indicators on most blocks every block provides two diagnostic LEDs which show the health of the block and its individual circuits and show whether a block is online or has a forced circuit The I O data for each block is communicated over the Genius bus with the Genius Bus Controllers in GMR PLCs Blocks can be located up to 7500 feet or more by using fiber optics Modems and form a truly distributed I O system All blocks can be used in a GMR system as simplex I O Those identified in the tables that follow can also be used as triplex duplex or in the case of some outputs in a Hot Stand By HSB mode Optional field termination boards are available to facilitate the wiring of TMR blocks Genius Discrete Input Block Specifications The blocks listed on this page may be used as TMR input blocks or as simplex input blocks in a GMR system For these blocks the duplicate and triplicate input data is received at all GMR CPUs and then voted just prior to executing the application program to ensure the highest integrity of the input data used Selected discrete input blocks can diagnose stuck on and stuck off input circuit electronics and diagnose circuit to circuit shorts Some A failure of a block or circuit results in both the appropriate block diagnostic LED indication and the fault being logged into fault tables of each PLC
131. smart switch design This provides data about output circuitry and load state On 16 point blocks discrete output circuits are protected by a short circuit sensor at the switching device If the instantaneous current on an output exceeds 20 Amps the output turns off within several microseconds The Genius block automatically tries to restart the load If repeated tries fail the block turns the output Off and sends a Short Circuit diagnostic message which is received by each PLC CPU In the event of a transient short normal operation can be restored by clearing the fault in any of the PLCs Output Autotest Each output can be configured for Output Autotesting The GMR Output Autotest checks the ability of each discrete output block to respond to the commanded output state Discrete Output Autotest works on outputs that are either On or Off with or without load monitoring Output Autotest does not cause spurious faults to be logged and does not affect field output devices the Genius blocks still control the physical outputs Output Autotest can be inhibited for repair The test uses the blocks built in Pulse Test capability Single blocks configured for Duplex or No CPU Redundancy cannot be autotested but can be pulse tested Output Discrepancy Reporting If the blocks receive different outputs for the same load from the PLCs they report the discrepancy back to each PLC where a discrepancy message is placed in the Fault Tables A
132. ss line testing Genius I O with its distributed design and technology allows the I O to monitor the actions of other intelligent devices in the system and provide automatic diagnostics without long wiring runs Genius I O accommodates both local and remote installation requirements and can reduce installation costs up to 50 percent Special Features of a GMR System In addition to the normal features of typical TMR systems such as fault tolerance comprehensive diagnostics remote I O online module repair and high reliability and availability GMR provides these benefits m Application flexibility Configurable per point redundancy makes it possible to customize system hardware to specific application requirements thereby saving money m Genius I O speeds startup and eliminates long wire runs saving time and money m Elimination of fuses Temporary shorts are electronically cleared reducing Mean Time To Repair MTTR m Fault identification to point level further reducing MTTR Ability to stage and debug input and output circuitry before CPU installation using a Hand held Monitor m Readily available modules through worldwide distribution channels m Software driven and self documenting configuration System Programming and Configuration System configuration and programming are done using software that installs on an IBM PC or BSI Certificate FM13400 ot Qa aw 1 2 Genius Modular Redundancy Flexi
133. ss references Partial Program Logic Printout variables and program annotation for the entire GMR program TETE Erose reference far A00 Vi 5 7 or a selected section of the program The example below Bie eee eae shows portions of a rack configuration printout and an d 773749272 be d individual module configuration printout from the Logicmaster Lm un vel j software The configuration made using the GMR software is also printed out not shown here Var ie Partial Configuration Printout pibe MINUM CLAMPED NADER eren 19 4 GE Fast ENE CIMENTA lin tee j 1 1 c RUM T zc Cross referesos for WEDOM e T ow b 4 5 6 8 SONI sssssasassssssosossass FREMMPEO OMFIGINATIEN esenasnsasssaasnsas caos POR 710 C02 TSS TEN 253 8D 72 0013 w DM Sron wens oes SEH iE l x013 suon 3 DEFERENCE WICKS REFERENCE RESTETPTTOM wos amii SERIES 50 70 KORUL Mwy OLT TET RAD Meo gt wqorors 2101 atalog Tis9 3 etn t00 nto i CPETRS A 2 IQQ a ATO PUGH BUTTON WSean Seop nO Baud Rate 185200 Faecwor ds CKEOLEN Parity bin WEPSEMCY FETTEN Stop Bits 1 Ton twEPoEW Y STEP PR ib Mir scar LOCI 15 UP Lass Bits 5 TODA US25IF UNLOABER 15 IF aden 1T i 1f100 bacon Count nade T Si aie Pragas fIRS1 D SM CME COSE IRN IRS T Flock METH Meade see s Wartchdg Tar 100 nsec 5 6 Genius amp Modular Redundancy Flexible Triple Modular Redundant TMR
134. sting and approval of electronic components and systems for use in safety critical applications P U Underrange Fault The fault caused by an analog signal that is lower than the lowest value typically read for that signal User Memory The portion of system memory in which the application program and data are stored In the Series 90 70 PLC user memory is battery backed CMOS RAM V VME An acronym for Versa Module European Vote Adaptation A configurable and automatic change in a voting algorithm based on failure s of components in a system See Fault Degradation Voted Input The voted result of a single dual or triple input received in the Input Status Table All raw and voted points are available to the application program W Warm Start The initializing of a CPU when one or more CPUs are already on line Watchdog Timer A timer in the CPU used to ensure that certain hardware and software conditions are met within a predetermined time The watchdog timer value is configurable based on application program needs Word A measurement of memory length usually 16 bits long Write Access Certain areas of data memory in the PLC may be written to by intelligent external devices such as computers DCS devices and MMI devices In a GMR system the use and extent of write access can be tailored for the application To safeguard the data in the safety related portion of the a
135. t is provided to connect to the Factory LAN System Manager GSM terminal The communications software may be loaded through this port Note Fault tolerant redundant serial communications can be provided by using communications modules in rack 1 and rack 2 Model 1C697 Protocols Supported Interface Media Software System Management Tools Configuration Controls Indicators CMM742 CMM741 TCP IP MMS OSI TCP IP SRTP SRTP IEEE 802 3 CSMA CD Medium Access Control 10 Mbps 10Base5 10Base2 10BaseT 10BaseF 10Broad36 Stored in RAM Memory easily updated GSM System Manager provides Network Performance Measurement Fault Diagnosis Configuration Management and Software Downloading Via LM90 70 Programming and Configuration Software Soft Switches Restart Pushbutton Three Restart Pushbutton Status LEDs Four Status LEDs 4 15 Bus Transmitter amp Bus Receiver M odules Bus Transmitter and Receiver Modules permit expansion Model 4 IC697 BEM713 BTM and from the main GMR CPU rack to a maximum of 7 BEM711 BRM additional racks using up to 50 feet 15 meters of interconnecting cable Expansion Racks Supported 7 Maximum PARALLEL Parallel Programmed Interface High Performance 500 included on BTM Kbytes Second p
136. t the same time a status bit is set By checking this bit the application program can automatically be alerted to output discrepancies at the blocks Output Discrepancy reporting also supplies the online offline status of each PLC to the other PLCs Genius Output Diagnostics Genius 3 C COMM MICRO VLSI Bus IC PROCESSOR SMART SWITCH V Switch O Drive ee Load Voltage Feedback SWITCH DRIVE and DIAGNOSTICS LOGIC a45495 2 10 Technical Product Overview February 1998 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFT 177A Section 3 GMR System Architectures The purpose of this section is to give an overview of the elements that make up a GMR system and to describe different types of GMR systems that can be designed PLC System Architecture The GMR CPU resides in the Main Rack of a Series 90 70 PLC immediately to the right of the power supply The rest of the slots in the Main Rack can be used for communication modules coprocessors Genius Bus Controllers and rack based I O modules Special purpose modules and custom modules as illustrated below in slot 9 can also be included A Main Rack with six Bus Controllers can handle hundreds of single dual and triple discrete and analog I O points using Genius I O blocks and Field Control modules CENTRAL GENIUS BUS POWER SUPPLY PROCESSOR BUS CONTROLLER UNIT GE Fanuc
137. t to and assumes no responsibility for the accuracy completeness sufficiency or usefulness of the information contained herein No warranties of merchantability or fitness for purpose shall apply The following are trademarks of GE Fanuc Automation North America Inc Alarm Master Field Control Modelmaster Series One CIMPLICITY GEnet PowerMotion Series Six CIMPLICITY Control Genius ProLoop Series Three CIMPLICITY PowerTRAC Genius PowerTRAC PROMACRO VuMaster CIMPLICITY 90 ADS Helpmate Series Five Workmaster CIMSTAR Logicmaster Series 90 Copyright 1995 1998 GE Fanuc Automation North America Inc All Rights Reserved Contents Section 1 Introductions enne 1 1 Section 2 Operation ioi ene ay Manatee ER EE 2 1 Section 3 GMR System Architectures 0 0 0 eeesscccesesneeeeeesseeeeeesseeereesaes 3 1 Section 4 Product Specifications seen 41 Section 5 Configuring amp Programming a GMR System 5 1 Section 6 COMMUNICATIONS eee e ieser enne enne nennen 6 1 Appendix A Memory Allocation eeessseeeeeeeeeeeeneeene ener A 1 Appendix B Estimating Scan Time eene B 1 Appendix C Computer Requirements for Configuration amp Programming C1 Appendix D GMR System Glossary eene een D 1 iii Section Introduction l The GE Fanuc Genius Modular Redundancy GMR system combines the flexibility and power of the Series 90 70 PLC with the a
138. tables with a location and description of the fault The GMR configuration utility allows the source code to be saved in a separate file for future review update and PLCA Multidrop Programmer Connection Between Programmer and GMR PLCs PLCB revision to the system A hard copy printout of the GMR configuration is a valuable reference to configuration I O addressing assignment and overall system memory map Offline Program Downloading Once commissioned a T V approved system normally receives new program changes offline All CPUs are downloaded without cable reconnection through the single connection from the programmer while in STOP mode When the CPUs are placed in RUN mode the checksums are compared to assure that the same program exists in all CPUs The programmer may be located local to the CPU racks For some applications remote programming and or monitoring may be accomplished via a network phone modem or other means Additional Reference Material The following reference manuals are available in printed form and on CD ROM W Genius Modular Redundancy GMR User s Manual GFK 1277 The current revision of this document supersedes information in other manuals W Genius I O System and Communications Manual GEK 90486 1 W Genius Discrete and Analog Blocks User s Manual GEK 90486 2 W Series 90 70 PLC Installation and Operation Manual GFK 0262 W Logicmaster 90 70 User s Manual GFK 0263 W Series 90
139. ter 9 Timing Considerations for further details on estimating Genius Bus scan times I O Response Time If input output or total input to output response time estimates are desired both the CPU and Genius Bus scan times must be taken into account Please refer to GEK 90486 1 the Genius I O System and Communications User s Manual Chapter 9 Timing Considerations for details on estimating I O response times B 1 Appendix Computer Requirements for Configuration amp C Programming This appendix describes equipment needed to configure C omputer Memory Requirements for the and program a GMR system Logicmaster 90 70 Software General C omputer Requirements Specific memory requirements for running the Logicmaster 90 70 software depend on its version The configuration and programming software used for GMR require an IBM or IBM compatible personal W The Release 6 5 version of Logicmaster 90 70 software for GMR requires computer O Aminimum of 545 K 558 080 bytes of Minimum requirements for running the Logicmaster available conventional RAM memory to run soltwareare O At least 1024 Memory LIM EMS 3 2 or W An Intel 80386 or higher microprocessor higher W A hard disk with at least 4 Megabytes of space m Running Logicmaster 90 70 v 6 5 under a DOS available shell in windows 95 or NT requires W Atleast 2 megabytes of RAM memory see O A minimum of 590K bytes of available DOS additional information at right appl
140. tool for use with Genius I O blocks Field Control I O Stations and networks Its main functions in a GMR system are to initially configure each Genius block and Field Control I O Station to assist in verifying I O wiring and the operation of each I O point and to monitor the performance of an I O network Longer term it can be used as a maintenance and troubleshooting tool to track down faults and read detailed fault information from any I O block or Field Control I O module It is typically used temporarily and not permanently connected to a system The HHM connects to any Genius I O network at any I O block Field Control I O Station or Genius Bus Controller GBC The ability to connect the HHM at any point on a network provides remote monitoring of any device A Monitor Configure keyswitch allows the configuration of the Hand Held Monitor to either restrict or allow the HHM to access certain functions such as clearing faults making I O block or module configuration changes and forcing of I O circuits The HHM display is menu driven and utilizes four function keys to select menu items The HHM can be easily upgraded by replacing a socketed PROM which defines its functions Genius H and held M onitor Mode Select X Keyswitch GENIUS a Hand Held Monitor GE Fanuc L mee Function Keys 5 e nou Decimal Keys mug BOGE ate S S Connection for Charger Adapter rs
141. ts of a sample GMR system three PLCs three Genius busses three Genius Bus Controllers in each PLC one input group of Genius blocks and one output group of Genius blocks In an actual system there can be many input groups output groups and triplex busses Although the illustration shows each block connected to just one field device there can be up to 32 field devices connected to each block or block group 31 if autotesting is used Genius Bus Controllers and Busses One to three Genius busses transmit I O and communications data for the GMR system Redundant PLCs Bus Controllers and Busses Bus Controllers and bus cables prevents a single point of failure in the communications subsystem A Bus Controller manages data transfer between its bus and the CPU by maintaining two separate onboard RAM memories One interfaces with the bus and the other interfaces with the CPU The Bus Controller automatically transfers data between these two memories making data available to the bus or to the CPU when it is needed In addition to being used for I O data the Genius busses provide communications between the PLCs which regularly exchange status data A limited amount of application data can also be exchanged Separate busses can be used for additional data exchanges between the PLCs and with host devices that communicate using Genius protocol The Genius Bus Protocol provides inherent protection against transmission errors Each trans
142. udes three isolated PLCs and extensive diagnostics which are integrated into a single system Utilizing two out of three voting the GMR system provides high reliability and error free operation There are no hardware common failure modes due to GMR s physically uncoupled design and separate leg circuit protection In the TMR configuration each of the three CPUs sends output state results of the logic to the output subsystem via triplicated Genius I O busses Genius output blocks perform output voting on the triplicated output data Discrete output circuits incorporate current and voltage sensors that provide output and load state diagnostics 1 1 GMR identifies system faults compensates for them automatically and allows repair or replacement without interrupting system operations Faults are handled by a software alarm processor function that time stamps and logs I O and system faults in two diagnostic tables that can be displayed by the programmer or uploaded to a host computer or other coprocessor Each PLC executes continuous diagnostics to detect overt and covert failures reducing mean time to repair MTTR and generating automatic fault reports for maintenance or operations personnel This fault information is readily available to the application program making it possible to take appropriate control action and alerting maintenance personnel Memory errors are detected via parity or checksum along with data and addre
143. uests The PCM communicates with the CPU over the backplane It can access user and system data using extensions to the powerful Megabasic language No application program support is required in the PLC CPU Multiple PCMs can be supported by each CPU The PCM board has up to 95 Kbytes of user memory In addition a PCM can accommodate an optional expansion memory daughterboard up to 512 Kbytes in size Both types of memory are backed by a replaceable lithium battery The PCM has three Status LEDs One indicates the condition of the module Module OK The others may be assigned a function The module pushbutton is used to restart a PCM application or to set the PCM to its factory default configuration but retain any application program Both serial ports are RS 232 and RS 422 485 compatible Both ports operating simultaneously can support up to 19 2 Kbaud full duplex communications The PCM is a dual tasking processor a custom Megabasic program can run while the PCM is being used as a communications interface Software is used to configure the port parameters to define the interface to the CPU to select task functions and to program Megabasic applications Configurations include m CCM only CCV2 master slave or peer on both ports W BASIC Megabasic only where the Megabasic application has access to both serial ports W BAS CCM Megabasic and CCM2 together The Magabasic application has access to port 1 and port 2 is used a
144. unication protocols TCP IP ETHERNET Allows communications with hosts and or LM90 70 programming and configuration software using GE Fanuc s SRTP over a 4 layer TCP IP Internet protocol stack For the highest system throughput GE Fanuc also offers the Ethernet Interface for the GMR system The highly popular TCP IP protocol is available to facilitate the integration of the GE Fanuc TCP IP driver within a third party DCS In addition to data monitoring the Ethernet Interface also provides remote programming services using the Logicmaster 90 software Redundant communications can be implemented by utilizing two Ethernet cards in each PLC MMS ETHERNET Allows communications with hosts and or LM90 70 programming and configuration software using MMS Manufacturing Message Specification ISO 9506 on a 7 layer OSI protocol stack SRTP Allows communications only with LM90 70 programming and configuration software using SRTP over a 4 layer OSI protocol stack Genius Bus Controller GBC The highly robust Genius communications system is supported by most operator interface manufacturers such as Intellution Factorylink and others The Genius LAN provides a medium speed option to access the database of the GMR PLCS over a single twisted pair media In particular the Global Data service is highly efficient for applications requiring performance approaching that of Ethernet Redundant communications can be implemented by providing two Gen
145. up to three CPUs however each CPU can support multiple CMMs mounted in either the CPU rack or an expansion rack Programmable Coprocessor Module PCM This module functions as a coprocessor to the CPU It can be programmed to perform operator interface real time computations data storage and custom protocols for data acquisition or data communications functions CCM2 functions provided by the PCM module are read write of register input and output tables bit set clear of inputs and Genius amp Modular Redundancy Flexible Triple Modular Redundant TMR System Technical Product Overview February 1998 outputs read scratch pad Q sequence commands for fast reads and modify diagnostic status word In the master and peer CCM configurations the PCM module initiates communications with other devices through application program requests This module has two serial ports which are both RS 232 and RS 422 485 compatible Both ports operating simultaneously can each support up to 19 2 Kbaud full duplex communications The PCM has up to 95 Kbytes of user memory In addition a PCM can accommodate an optional expansion memory daughterboard up to 512 Kbytes in size Both types of memory are backed by a replaceable lithium battery Factory LAN Ethernet Controller Module The Ethernet Controller module provides direct connection between the Series 90 70 PLC and IEEE 803 2 CSMA CD LANs The Ethernet Controller supports three alternative comm
146. uration software The GFT 177A Section 4 Product Specifications other CPUs are made aware of any individual CPU faults by reading status information Each CPU has a built in RS 422 RS 485 serial port which is typically used for a multi drop connection to the programming and configuration system It can also be used for connection to a host system or operator interface A three position toggle switch can be used select Run Mode or Stop mode A Memory Protect prevents accidental program changes passwords can also be used Four status LEDs all normally on show the CPU s status W OK LED CPU diagnostic tests executed successfully no faults W RUN LED CPU is in Run mode and executing application program W ENABLED LED CPU has enabled outputs to turn on off as set in the application program W MEM PROTECT LED Memory Protect keyswitch is on CPU Module with Door Open and with Door Closed O l 3 OK LEDs 9 ENABLED Oo R MEM PROTECT Mode gt 9 i Selection z 8 CENTRAL i PROCESSOR Switch P NY qa Dual Battery Connectors o RS 485 gt Serial H Port o 846612 4 11 CPU Module Specifications MODEL IC697 Max fully triplicated TMR Digital Inputs Max fully triplicated TMR Digital Outputs Max fully triplicated TMR Digital I O Combined I amp O Max Total Digital I O
147. us Discrete Output Block Specifications The Genius blocks listed below may be used as GMR to be logged in the fault table of each GMR CPU Please Output blocks or as Hot Standby or simplex blocks in a refer to the Genius I O user s manuals for more details A GMR system Output data is received individually from failure of a block or circuit results in both the appropriate each GMR CPU by each output block in a group and then block diagnostic LED indication and fault logged into to ensure the highest integrity of the data used the output fault tables of each PLC TMR outputs continue to block group votes the data before driving critical loads on operate with the remaining blocks or legs of the output or off group Failed TMR output blocks may replaced hot power on without disturbing the functioning portion of Most output blocks employ electronic overload and short the output group or any other part of the system circuit protection which allow an output circuit to be reset without the need to replace a fuse and cause a fault MODEL IC660 BBDO25 Weight 4 lbs 1 8 kg Nominal Voltage 5 12 24Vdc Source or Sink Operation Sink Operating Modes TMR HSB TMR HSB TMR HSB TMR HSB SIMPLEX SIMPLEX SIMPLEX SIMPLEX Number of Points 16 16 32 32 20ms 24V 20ms 24V DC Voltage Range 10 30 amp 4 9 5 3 Required DC Power Max 300ma P S Dropout Time 4ms 12V Block Isolation 1500V 1500V 850V Point Status LEDs 1 per point Diagnostic
148. utotest interval register For example the system allows a total maximum time of 24 hours between a fault occurring and the resultant I O shut down when the autotest interval is set to 8 hours 2 7 Output Subsystem The output subsystem portion of a GMR system can include m Output Groups of two or four Sink and Source DC discrete Genius blocks wired to up to 32 actuators and other field output devices a Individual Sink and Source DC discrete Genius blocks wired to up to 32 field output devices for processor redundancy and pulse testing m Other types of discrete and analog blocks which can provide Hot Standby or Duplex PLC Redundancy The intelligent Genius Sink and Source DC blocks store multiple sets of outputs in internal output tables These block groups perform the voting The manner of voting is configurable for the application Because output voting is performed by the blocks at the point of control bus errors are compensated for by the voting process Discrete Outputs A standard H pattern output Genius block group provides fault tolerant control for discrete outputs An output group consists of two parallel Source type blocks connected to one side of the actuator or other device and two parallel Sink type blocks connected to other side The diagram below represents connections between a triplicated bus a group of 16 circuit Genius blocks and one load device Up to 16 field devices can be connected to a group o
149. value as the voted input This mid value voting method avoids the inaccuracy that results from averaging methods when a failure in one reading has occurred D 6 Genius amp Modular Redundancy Flexible Triple Modular Redundant TMR GFT 177A System Technical Product Overview February 1998 GFT 177A Module A replaceable electronic subassembly usually plugged into connectors on a backplane and secured in place but easily removed In the Series 90 70 PLC a module consists of a printed circuit board with appropriate connectors and terminals and a protective faceplate N No Load Diagnostic A diagnostic that detects of a no load condition when one occurs The information is automatically supplied to the CPU The No Load diagnostic is provided by a current discriminator built into the Smart Switch output circuit in the Genius block O Off Line Mode A selectable mode of the Logicmaster programming and configuration software Off line mode is used for program development In Off line mode the programmer does not communicate with the PLC although the two may be physically connected In Off line mode program power flow display and reference values are not updated On Line Mode A selectable mode of the Logicmaster programming and configuration software On Line mode provides full CPU communications allowing data to be both read and written On Line Repair A repair made without interrupting system operatio
150. wer loss or RUN TO STOP TO RUN transitions and is not used with retentive coils S SC System status references The 96S WSA SB and SC bit references are used to access special no PLC data such as timers scan information and fault information For example the SC0012 bit can be used to check the status of the PLC fault table G GE Global data references These bit references are used to access data shared among several PLCs yes They can be used on contacts and retentive coils because the memory is always retentive G GE cannot be used on non retentive coils G Global Data memory GD Global Data memory GE Global Data memo GA Global Data memory no GB Global Data memory GC Global Data memory 5 14 Genius amp Modular Redundancy Flexible Triple Modular Redundant TMR GFT 177A System Technical Product Overview February 1998 Section Communications 6 The purpose of this section is to provide an overview of application communications capabilities that can be incorporated into a Genius Modular Redundancy system Individual communications modules are summarized here and described in more detail in Section 4 GM R with Distributed Control Systems and HM Systems Safety systems such as GMR generally interface to a are thereby protected Despite the independence of the process controller or Distributed Control System The safety system the DCS operator must still be aware of GMR system is usually independent and
151. yes 5 12 Genius Modular Redundancy Flexible Triple Modular Redundant TMR GFT 177A System Technical Product Overview February 1998 D ata M oveFunctions move blkmov blkclr shfreg bitseq swap comreq vme rd vme wr vme rmw vme ts vme cfgrd vme cfgwr Swap Communication Request VME Read VME Read Modify Write VME Test and Set VME Configuration Read VME Configuration Write Program Control Functions call do io sus io mcr endmcr jump label commnt svcreq pidisa pidind for endfor exit sfcres Call Do I O Sequences a 1 through a group of bits in PLC memory Swaps two types of data in a word or two words in a double word Sends a communications request to a smart module in the PLC Reads data from a third party VME board at a specified VME address Writes data to a third party VME board at a specified VME address Updates a data element on a third party VME board using the read modify write cycle on the VME bus Handles semaphores located on third party VME boards Reads the configuration for a VME module Writes the configuration to a VME module Causes a program execution to go to a specified program block or external block Services a specified range of inputs or outputs immediately Optionally a copy of the scanned I O can be placed in internal memory Suspend I O Suspends all normal I O updates except those specified by the Do I O instructions

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