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Series 90-70 System Manual for Control Software Users, GFK

1. Index Genius Global Data Genius I O 2 78 2 79 analog grouped block 2 79 Index T O fault table full 3 29 V O fault type B 24 interpreting fault tables IOC hardware failure 3 50 IOC software fault loss of block loss of I O module loss of IOC 3 45 loss of or missing option module 3 19 loss of or missing rack 3 18 low battery signal low level analog fault microcycle time exceeded 3 29 module fault 3 49 module hardware failure 3 26 no user program on power up 3 32 non configurable faults 3 31 null system configuration for RUN mode 3 34 option module software failure 3 27 password access failure PLC CPU hardware failure PLC CPU system software failure 3 35 PLC fault action B 6 PLC fault group B 4 PLC fault table explanations 3 17 PLC system fault table full program block checksum failure 3 28 reset of addition of or extra option module run mode store failure system bus error system bus failure 3 32 system configuration mismatch 3 22 system reaction to faults 3 11 too many bus controllers 3 36 window completion failure 3 34 3 21 FIP 1 0 2 80 default conditions 2 81 FIP I O bus configuration FIP I O data mapping 2 81 FIP I O sweep impact times worksheet Floating point numbers D 1 entering and displaying floating point numbers D 4 errors in floating point numbers and oper
2. Index Constant Sweep 2 10 Constant Window mode 2 10 Convenience references See System status references Corrupted memory 3 17 CPU performance chart A 38 CPU default memory sizes 2 13 CPU performance data base sweep time A 11 calculating predicted sweep times A 30 FIP I O sweep impact times worksheet A 22 Genius I O sweep impact times A 17 A 19 worksheet T O interrupt performance and sweep impact T O module sweep impact times e 15 T O scan and I O fault sweep impact A 14 instruction timing A 1 programmer sweep impact time sweep impact of Ethernet global data sweep impact of FIP I O and FBCs sweep impact of Genius I O and GBCs A 17 sweep impact of intelligent option modules sweep impact of Series 90 70 I O modules Ala Configuration oa CPU redundancy 3 35 CTRL F B 2 D Data coherency in communications windows 2 8 data flow limit 2 29 Data mapping default conditions FIP I O data mapping 2 81 Genius I O data mapping 2 78 Data nan Data scope Data types 2 17 Diagnostic data analog I O Diagnostic faults 3 4 addition of block addition of I O module addition of roc 3 45 addition of or extra ae 21 application fault 3 30 block switch 3 50 circuit fault 3 41 constant sweep time exceeded 3 29 Index 1 Index Index 2 extra block 3 47 extra I O module T O bus fault I O f
3. Block configured for outputs only Block has both inputs and outputs Discrete Analog Indication Discrete block Analog block LOSS_OF_IOC Error Code IOC failed to respond to a CPU request CPU and IOC lost synchronization CPU IOC communications failed VME bus error VME bus error CPU IOC communications failed CPU IOC communications failed IOC failed to respond to a CPU request 1 2 3 4 5 6 7 8 9 CPU IOC communications failed VME bus error BME bus error CPU IOC communications failed CPU IOC communications failed CPU IOC communications filed TOC failed to respond to a CPU request E a a a Rn nA A WN KF D STM UNO WPF CDC HMAADU BR WHND CPU IOC communications failed CPU IOC communications failed IOC failed to respond to a CPU request CPU IOC communications failed CPU IOC communications failed re O won U N N N SD Gopi AR Internal I O scanner fault detected N N en oN IOC failed to respond to a CPU request N UW a Dn TOC failed to respond to a CPU request N R m o0 IOC failed to respond to a CPU request N nn O TOC failed to respond to a CPU request Y ON gt IOC failed to respond to a CPU request CPU IOC communications failed Y N on QW VME bus error occurred while reading input data Table B 20 I O Fault Specific Data cont d B 28 Series 90 70 System Manual for Control Software Users Novembe
4. Number Description Fault Descriptions for Discrete Circuit Faults 01 Loss of user side power 02 Short in user wiring for Genius current level greater than 20 Amps 04 Sustained overcurrent for Genius current level greater than 2 Amps 08 Very low or no current flow 10 Switch temperature too high 20 Genius smart switch failure 83 Series 90 70 I O individual point fault also indicated for I O Module Fault category 84 Series 90 70 output fuse blown also indicated for I O Module Fault category Fault Descriptions for Analog Circuit Faults 01 Input channel low alarm 02 Input channel high alarm 04 Input channel under range 08 Input channel over range 10 Open wire detected on input channel 20 Output channel under range 40 Output channel over range 80 Expansion channel not responding 80 Feedback error for Genius Current Source Analog Block Appendix B Interpreting Faults B 25 B 26 Table B 19 I O Fault Descriptions cont d Number Description Fault Descriptions for Low level Analog Circuit Faults 20 Improper RTD connection or thermocouple reverse junction fault 40 Cold junction sensor fault on thermocouple block or internal error in RTD block 80 Input channel shorted Genius RTD and Strain Gauge Blocks only Fault Descriptions for Module Faults 08 Genius EEPROM or NVRAM failure 20 Genius calibration memory failure 40 Genius shared RAM fault 80 Genius internal circuit faul
5. Memory Allocation provides a worksheet for determining the total number of bytes of user data used and how much is still available for the user program data 9 data oP a _MAIN BLOCK BLOCK 2 _ data L BLOCK 3 data AL BLOCK 4 All blocks within the LD program can use data associated with the _MAIN block P Blocks can use their own L references as well as the P references that are available to all blocks The _MAIN block cannot use L Note External blocks and Parameterized Subroutine Blocks do not have their own L data instead they inherit the L data of the calling block GFK 1192B Chapter 2 System Operation Parameterized Subroutine Blocks A Parameterized Subroutine Block PSB is an optional user defined function block configured with between zero and seven input output parameter pairs As with other blocks Parameterized Subroutine Blocks can be called by the _MAIN block other blocks or itself The calling block may pass parameters to the Parameterized Subroutine Block When a Parameterized Subroutine Block is declared it must be assigned a unique block name along with the number type and length of the parameters Each parameter other than the Enable and Enable Out parameters is designated as a BOOL WORD or NWORD type along with a specified length BOOL lengths range from to 256 WORD and NWORD lengths
6. The last time a Q or M reference is programmed on a coil instruction determines whether the Q or M reference is retentive or non retentive based on the coil type For example if Q00001 was last programmed as the reference of a retentive coil the QO0001 data will be retentive However if QO0001 was last programmed on a non retentive coil then the Q00001 data will be non retentive Note When only standalone C programs are used the retentive nature of data is based solely on the memory type since there are no coil instructions In this case Q and M memory types are retentive GFK 1192B Chapter 2 System Operation 2 15 Data Scope 2 16 Each of the user references has scope that is it may be available throughout the system available to all programs restricted to a single program or restricted to local use within a block Table 2 7 Data Scope of User Reference Data User Reference Range Scope 1 WQ WM T PS WSA PSB System From any program block or host computer SC G PWR WAI WAQ convenience references fault locating references P Program From any block but not from other programs L Local From within a block only In an LD block e P should be used for program references that are shared with other blocks e L are local references which can be used to restrict the use of register data to that block These local references are not available to other parts of the pro
7. 1 Bus address 2 Installed module s model number 3 Configured model number Fault Extra Data Byte Number T O Type Mismatch 0 FF 1 Bus address 2 Installed module s I O type 3 Configured module s I O type Fault Extra Data Byte Number BCD Length Mismatch 0 FF 1 Bus address 2 Module s broadcast data length 3 Configured module s broadcast data length Fault Extra Data Byte Number DCD Length Mismatch 0 FF 1 Bus address 2 Module s directed data length 3 Configured module s directed data length GFK 1192B Appendix B Interpreting Faults B 11 The following table shows the Genius numbers used when a model number mismatch occurs Table B 6 Genius Block Model Numbers Number Decimal Hexadecimal Description 4 4 Genius Network Interface GENI 5 5 Phase B Hand Held Monitor 6 6 Phase B Series Six Genius Bus Controller with Diagnostics 7 7 Phase B Series Six Genius Bus Controller without Diagnostics 8 8 PLCM Series Six 9 9 PLCM Series 90 40 10 A Series 90 70 Single Channel Bus Controller 11 B Series 90 70 Dual Channel Bus Controller 12 C Series 90 10 Genius Communications Module 13 D Series 90 30 Genius Communications Module 32 20 High Speed Counter 69 45 Phase B 115Vac 8 point 2 amp Grouped Block 70 46 Phase B 115Vac 125Vdc 8 point Isolated Block 70 46 Phase B 115Vac 125Vdc 8 point Isolated Block without Failed Switch 71 47 Phase B 220Vac 8 point Grouped Block 72 48 Phase B
8. GE Fanuc Automation Programmable Control Products Series 90 70 System Manual for Control Software Users GFk 1192B November 1999 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 respect to and assumes no responsibility for the accuracy
9. If no Ethernet Global Data EGD exchanges are configured then the consumption and production scans are skipped For the base sweep the lack of configuration means that the input and output scan phases of the sweep are NULL i e check for configuration and then end The presence of a configuration with no I O modules or intelligent I O modules GBC PSM etc would have the same effect Appendix A CPU Performance Data A 11 The logic execution time is not zero in the base sweep The time to execute the empty MAIN program is included so that you only need to add the estimated execution times of the functions actually programmed The base sweep also assumes no missing I O modules The lack of programmer attachment means that the Programmer Communications Window is never opened The lack of intelligent option modules means that the System Communications Window is never opened The following table gives the base sweep times in milliseconds for each CPU model Table A 3 Base Sweep Times CPX CPX 924 914 CPX 781 782 CPX 731 732 CPU Model 935 928 925 915 782 788 789 772 771 772 Programmer Sweep Impact Times A 12 The following table shows the programmer sweep impact times in milliseconds The times are broken up into parallel and serial since these interfaces are significantly different Each item in the table is described in more detail at the end of the table Table A 4 Programmer Sweep Impact Tim
10. Operation of the PLC system 2 1 Option module dual port interface tests 2 69 Option module self test completion 2 69 Ordered programs 2 51 Ordered scheduling mode Output references Q 2 12 Output scan 2 5 Overhead sweep impact time base sweep time A 11 calculating predicted sweep times A 30 FIP I O sweep impact times voke re Genius I O sweep impact times A 17 HATET T O interrupt performance and sweep impact A 26 I O module sweep impact times waiksh etl A 15 T O scan and I O fault sweep impact programmer sweep impact time sweep impact of FIP I O and FBCs sweep impact of Genius I O and GBCs A 17 sweep impact of intelligent option modules sweep impact of Series 90 70 I O modules A Overrides 2 15 P parameterized subroutine block Parameterized subroutine block how parameterized subroutine blocks are called 2 33 referencing formal parameters 2 34 restrictions on formal parameters Passwords 2 74 Performance CPU chart Index Index Periodic scheduling mode 2 51 PLC fault table B 3 error code explanations 3 17 fault action fault extra data fault group B 4 fault time stamp B 15 interpreting fault tables long short indicator PLC memor validation 2 68 PLC ea S application program task execution programmer communications window STOP mode 2 9 system communications window 2 7 PLC sweep modes 2 10 Constant Sweep
11. fatal mode The PLC does not check the configuration parameters set up for individual modules such as Genius I O blocks The IOC software fault will have the same action as what you set for LOS_IOC Note If the fault action for a fault logged to the fault table is informational the configured action is not used For example if the logged fault action for an SBUS_ERR is informational but you configure it as fatal the action is still informational Chapter 3 Fault Explanation and Correction 3 5 3 6 NonConfigurable Faults For nonconfigurable faults the fault action cannot be changed These faults must always be either fatal or informational faults The following table lists noneonfigurable faults If the fault also causes additional faults only the initiating fault is logged Table 3 3 NonConfigurable Faults SBUS_FL fatal NO_PROG information BAD_RAM fatal WIND_ER information BAD_PWD information NUL_CFG fatal SFT_CPU fatal MAX_IOC fatal STOR_ER fatal Series 90 70 System Manual for Control Software Users November 1999 System bus failure The PLC CPU was not able to access the VME bus BUSGRT NM error No application program is present at powerup Should only occur the first time the PLC is powered up or if the batterybacked RAM containing the program fails Corrupted program memory at powerup Program could not be read and or did not pass checksum test
12. 1234 000 Seven digits six or seven significant Outside the range listed above only six significant digits are displayed and the display has the form 1 23456E 12 Exponent signed power of 10 Exponent indicator and sign of exponent Five less significant digits Decimal point Most significant digit Sign of the entire number Internal Format of Floating Point Numbers Floating point numbers are stored in single precision IEEE standard format This format requires 32 bits which translates to two adjacent 16 bit PLC registers The encoding of the bits is diagrammed below kooo Bits 17 32 pl Bits 1 16 H b2 FER PR TEATE E i gt 23 bit mantissa 8 bit exponent 1 bit sign Bit 32 Register use by a single floating point number is diagrammed below In this diagram if the floating point number occupies registers R5 and R6 for example then RS is the least significant register and R6 is the most significant register Least Significant Register Bits 1 16 gt fie 2 Least Significant Bit Bit 1 Most Significant Bit Bit 16 D 2 Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Most Significant Register gt Bit
13. 915 788 789 771 772 925 915 788 789 771 772 925 915 788 789 771 772 Size tact Data Move MOVE WORD MOVE DWORD BLKMOV WORD BLKMOV DWORD SWAP WORD SWAP DWORD BLKCLR BITSEQ SHFR WORD SHFR DWORD SORT Data Table TBLRD INT TBLRD DINT TBLWR INT TBLWR DINT FIFORD INT FIFORD DINT FIFOWRT INT FIFOWRT DINT LIFORD INT LIFORD DINT LIFOWRT INT LIFOWRT DINT wiin BID in ofjoinpr iina A ARRAY_MOVE BIT ARRAY_MOVE BYTE ARRAY_MOVE WORD ARRAY_MOVE DWORD SRCH BYTE SRCH WORD SRCH DWORD ARRAY_RANGE WORD ARRAY_RANGE DWORD Conversion to INT UINT to INT DINT to INT BCD 4 to DINT INT to DINT UINT to DINT BCD 8 to UINT INT to UINT DINT to UINT BCD 4 to BCD 4 INT to BCD 4 UINT to BCD 8 DINT Note 1 Time in microseconds is based on Release 5 0 of Logicmaster 90 70 software For information not availal the IPI for each CPU 2 For table functions increment is in units of length specified For bit operation functions microseconds bit 3 Enabled time is for single length units of type R 4 COMMREQ time has been measured between CPU and EX7 with NOWAIT option 5 DOIO is the time to output values to discrete output module GFK 1192B Appendix A CPU Performance Data le when this manual was being printed represented by a dash refer to For data move functions microseconds the number of bits or words A
14. Function 924 914 781 782 731 732 924 914 781 782 731 732 924 914 781 782 731 732 Group Function 925 915 788 789 771 772 925 915 788 789 771 772 925 915 788 789 771 772 Size Floating Point Math ADD_REAL SUB_REAL MUL_REAL DIV_REAL ABS_REAL SQRT_REAL Trigonometric SIN Cos TAN ASIN ACOS ATAN Logarithmic LOG LN EXPT EXP Comparison EQ_REAL NE_REAL k GT_REAL k GE_REAL 3 LT_REAL 3 3 LE_REAL E CMP_REAL 4 Conversion REAL_TO_INT REAL_TO_UINT REAL_TO_DINT INT_TO_REAL UINT_TO_REAL DINT_TO_REAL REAL_TRUN_INT REAL_TRUN_DINT DEG_TO_RAD RAD_TO_DEG BCD4_TO_REAL BCD8_TO_REAL D wn RRBRUBRUUNUKR RUE HR wn DNMOMDAUNAUBDAADA wa Note 1 Time in microseconds is based on Release 5 0 of Logicmaster 90 70 software For information not available when this manual was being printed represented by a dash refer to the IPI for each CPU For table functions increment is in units of length specified For bit operation functions microseconds bit For data move functions microseconds the number of bits or words Enabled time is for single length units of type R COMMREQ time has been measured between CPU and EX7 with NOWAIT option DOIO is the time to output values to discrete output module wn we GFK 1192B Appendix A CPU Performance Data A 5 A 6 Function Group Table A 1 Instruction Timing sali Timers Co Rel O
15. P WL ZAI WAQ WUR const none INTVL DELAY e Valid data type or place where power may flow through the function Note Parameterized Subroutine Blocks PSBs with zero parameters and External blocks C blocks and C FBKs with zero parameters may also be triggered by a timed interrupt Zero parameter subroutine blocks are called SUBRs in Control For these types of blocks the local data L is inherited from the _MAIN local data P for example LO005 PO000S Interrupt Handling and Scheduling with User Programs l 0 Triggered Programs GFK 1192B Beginning with Release 6 of the PLC CPU one of the scheduling modes available for user programs is the activation of programs from an I O interrupt The I O Triggered scheduling mode allows a user program to be invoked along with its corresponding input and output specification copy when a configured I O interrupt occurs I O Triggered programs execute during any phase of the PLC sweep or only during the Logic Window based on sweep mode Refer to User Program Execution earlier in this section for more information on the scheduling and execution of I O Triggered programs To program an I O Triggered program the program must first be declared in the programming software The scheduling mode must then be set to I O Interrupt Triggered Chapter 2 System Operation 2 63 Timed Programs Beginning with Release 6 of the PLC CPU one of the scheduling modes avai
16. PCM BTM or BRM fails to respond The failure may occur at powerup if the module is missing or during operation if the module fails to respond The default fault action for this group is Diagnostic Error Code Name Description Correction Error Code Name Description Correction Error Code Name Description Correction Error Code Name Description Correction Error Code Name Description Correction 3 Bus Transmitter Module Found in Expansion Rack The PLC generates this error when a Bus Transmitter Module is found in an expansion rack Power off the system and remove the BTM from the expansion rack 16 Analog Expander Located to the Left of the Base Converter module An Analog Expander module has been placed in a rack to the left of its Base Converter module Power off the system Move the Analog Expander module to the right of the Base Converter module 19 Lost Analog Expander module Base Converter module has lost communications with the Analog Expander module Verify wiring linking Base Converter module with the Analog Expander module Replace the Analog Expander module If communication with all Analog Expanders is lost replace the Base Converter module 2C 2D Option Module Soft Reset Failed PLC CPU unable to reestablish communications with option module after soft reset Try soft reset a second time Replace the option module Power off the system
17. Verify that both the BTM and the BRM are seated properly in their respective racks and that all cables are properly connected and seated Replace the cables Replace the BRM Bus Receiver Module Replace the BTM Bus Transmitter Module Report failure to GE Fanuc PLC Field Service Loss of or Missing Communications Driver The PLC generates this error when VME communications fail between the PLC CPU and a third party VME module using the FULL MAIL configuration mode 1 Update the configuration file with the correct communications parameters 2 Replace the communications driver on the module 3 Remove the module from the configuration file 4 Replace the module GFK 1192B Chapter 3 Fault Explanation and Correction 3 19 3 20 Error Code Name Description Correction Error Code Name Description Correction Error Code Name Description Correction Error Code Name Description Correction 3C Module in Firmware Update Mode The PLC generates this error when it finds a module in Firmware Update mode Modules in this mode will not communicate with the PLC CPU 1 Run the firmware update utility for the module 2 Reset the module with the push button 3 Powereycle the entire system 4 Powereycle the rack containing the module 41 Unable to Establish VME Communications The PLC generates this error when it finds a module in Standalone mode A module in Standalon
18. function on the previous sweep Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Application Program Task Execution Logic Window The Logic Window is the phase of the sweep where user programs execute Immediately following the completion of the input scan the PLC Executive determines which user program s are to be run Programs are then resumed and or invoked as necessary Solving the logic provides a new set of outputs Interrupt programs and blocks can execute during any phase of the sweep Refer to section 4 for further details There are many ways in which program execution can be controlled to meet the system s timing requirements The following is a partial list of the commonly used methods e Mask Compare and JUMP functions can be used to skip portions of the logic e The Suspend I O function can be used to stop both the input scan and output scan for one sweep I O can be updated as necessary during the logic execution through the use of DO I O instructions e The Service Request function can be used to suspend or change the time allotted to the window portions of the sweep e Program logic can be structured so that blocks and programs are called more or less frequently depending on their importance and on timing constraints e Microcycle sweep mode can be used to phase programs which need to run less often while limiting the logic window execution time A list of execution times fo
19. main rack Number of analog input exander modules same segment main rack Sweep impact per analog input expander module same segment main rack Number of analog input exander modules new segment main rack Sweep impact per analog input expander module new segment main rack Number of analog input base and output modules expansion rack Sweep impact per analog input base and output module expansion rack Number of analog input base and output modules same segment exp rack Sweep impact per analog input base and output module same seg exp rack Number of analog input base and output modules new segment exp rack Sweep impact per analog input base and output module new seg exp rack Predicted Series 90 70 I O Module Sweep Impact Table A 22 Sample Worksheet B Programmer sweep impact IOM first module open comm window IOM per module polling LAN module I O scan Total IOM Sweep Impact PLC memory access from IOMs T O interrupt sweep impact T O interrupt response time Predicted Sweep Time Other A 36 Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Relative CPU Performance Comparison This section contains a relative CPU performance comparison based on lab test results on the Series 90 70 CPUs Test Program The test program used for the performance tests consisted of a 190 Kilobyte folder run on a CPX935 CPU Sweep
20. when the I O fault table is cleared SA0014 LOS_IOM Set when an I O module stops communicating with the PLC CPU Cleared by replacing the module and cycling power on the rack containing the module or when the I O fault table is cleared SA0015 LOS_SIO Set when an option module stops communicating with the PLC CPU Cleared by replacing the module and cycling power on the rack containing the module or when the PLC fault table is cleared SA0017 ADD_RCK Set when an expansion rack is added to the system Cleared by cycling power on the rack containing the module and the configuration matches the hardware after a store or when the PLC fault table is cleared SA0018 ADD_IOC Set when a Bus Controller is added to a rack Cleared by cycling power on the rack containing the module and when the configuration matches the hardware after a store or when the I O fault table is cleared or when the T O fault table is cleared SA0019 SA0020 SA0022 SA0023 ADD_IOM IOC_FLT IOM_FLT Set when an I O module is added to a rack Cleared by cycling power on the rack containing the module and when the configuration matches the hardware after a store Set when an option module is added to a rack Cleared by cycling power on the rack containing the module and when the configuration matches the hardware after a store or when the PLC fault table is cleared Set when a Bus Controller rep
21. 0584 0900 per byte discrete I O data in the main rack J 0017 0475 0031 0475 0032 per byte discrete I O data in expansion racks l 0025 0442 0045 0442 0045 per word analog I O data in the main rack i i 0011 0604 0042 0604 0029 per word analog I O data in expansion racks 0654 f 0057 0623 0131 0623 0077 Asynchronous Events Fault Message 2 00 Times are in milliseconds except for those identified as microseconds The extra time for the first GBC is the same time as shown in the next table for the first intelligent option module This time should be counted only once Note Functions in bold type in Table A 8 above impact the sweep continuously All other functions impact the sweep only when invoked Note Not all of the timing information needed for the above table was available at print time for this manual the blank spaces Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Use the following form for predicting the sweep impact due to Genius I O The sweep impact times can be found in table A 8 Table A 9 Worksheet B Genius I O Sweep Time Open system communications window GBC I O scan GBC poll for background messages Number of GBCs Input block scan segments number of Input block scan segments sweep impact Output block scan segments number of Output block scan segments sweep impact Bytes of discrete I O data on GBCs ma
22. 12 volts is required to operate the LAN Interface module Correction 1 Install replace a GE Fanuc 100 watt power supply 2 Connect an external VME power supply that supplies 12 volts Error Code 1C2 1C6 Name LAN Interface Hardware Failure Description Refer to the LAN Interface manual GFK0868 or GFK 9869 previously GFK9533 for a description of these errors Error Code All Others Name Module Hardware Failure Description A module hardware failure has been detected Correction Replace the affected module 3 26 Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Option Module Software Failure The fault group Option Module Software Failure occurs when a nonrecoverable software failure occurs on a PCM It is also generated when the identification data read from a module indicates that the module is a GE Fanuc module but the module type is not a supported GE Fanuc type The default fault action for this group is Fatal Error Code Name Description Correction Error Code Name Description Correction Error Code Name Description Correction Error Code Name Description Error Code Name Description Correction 1 Unsupported Board Type The PLC generates this fault when the identification data read from a board indicates that the board is a GE Fanuc board but the type of board is not one of the GE Fanuc board t
23. 2 4 Application Program Task Execution Logic Window esseeessseeeeeesseeeeeesnaeees 2 5 Output Scan x ay vs se te Ry AR Re ot A oo et 2 5 Programmer Communications Window cceesssececeesseeecesseeecesseeecessaeeeeesaeees 2 6 System Communications Window ceesseeeceesseceeeessseeecesssaeeceessaeeecessaeeseesaeees 2 7 Background Window ostenten enana E aea OE EAEE EEO EE EE DE EREE EE enin 2 7 WIIN MOLES SSG eR 2 7 Data Coherency in Communications WindowWs seseeessssssseseeesssssssseresssssssseereeesss 2 8 CPU Sweep in SFOR Moden inicis nsi a A o eh betes es ited 2 9 PECS Weep MOJE SES anera NE E EEA EAA A E AGA 2 10 Section 2 User Reference Data oesessoocsessocsessoocesssocesessocsssssoesessooesesssosse 2 11 WSer RelerenCes is E E E E A E E E A A ET 2 11 User Reference Siz and Defa ltsmirsspsnipos esner neces sesiertaveseoen sane SEDES 2 13 G User References and CPU Memory Locations ceessceceessseeeceesneeeeeenneees 2 14 Bulk Memory Access BMA cccccceeeeeeeeeneaneeeeeeeeeeeeesnaaeeeeeeeeeeeeenaaeeeeeeeneeees 2 14 Gents Global Data saree E Meee eter eR URE UNL et tts ties 2 14 Tramsitions and Overrides i ceeeeeeecccccccccecceceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeess 2 15 Retentiveness of Logic and Data eee eeeesscceessneeecessneeeeeessaeeeeesnaeecsessaeeseesaes 2 15 Data S COpC i settee ee as a a de Tra te Tae Ae Te Ae eT late 2 16 Data Types c
24. 3 Typical Sweeps in Normal Sweep Mode SWEEP n 2 PAK SYS System Communications Window BG Background Window HK PRG SYS BG Constant Sweep Mode 2 46 In Constant Sweep mode each PLC sweep begins at a specified Constant Sweep time after the previous PLC sweep began The Logic Window is executed in its entirety each sweep If there is sufficient time at the end of the sweep the PLC will alternate among the Programmer Communications System Communications and Background Windows allowing them to execute in Run to Completion mode until it is time for the next sweep to begin Some or all of the Communications and Background Windows may not be executed The Communications and Background Windows will terminate when the overall PLC sweep time has reached the value specified as the Constant Sweep time One reason for using Constant Sweep mode is to ensure that I O are updated at constant intervals The value of the Constant Sweep timer can be configured to be any value from 3 to 255 milliseconds The Constant Sweep timer value may also be set and Constant Sweep mode may be enabled or disabled by your programming software or by the user program using Service Request function 1 The Constant Sweep timer has no default value a timer value must be set prior to or at the same time Constant Sweep mode is enabled If the PLC sweep exceeds the Constant Sweep time in a given sweep the PLC places an oversweep alarm in the PLC fault table
25. Available in bytes Note Although 915 and 925 CPUs have a total of one megabyte 1024K both CPUs have the same 512K limit for a single user program as other CPUs The additional 512K can be used for standalone C programs Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Appendix Using Floating Point Numbers D Floating Point Numbers GFK 1192B Your programming software provides the ability to edit display store and retrieve numbers with real values Some functions operate on floating point numbers However in order to use floating point numbers you must have a 732 772 782 914 or higher CPU Floating point numbers are represented in decimal scientific notation with a display of six significant digits Note Use of floating point numbers within a parameterized subroutine block PSB usually necessitates the use of NWORD parameters rather than WORD parameters Note In this manual the terms floating point and REAL are used interchangeably to describe the floating point number display entry feature of the software In the software the following format is used For numbers in the range 9999999999 to 0001 the display has no exponent and up to six or seven significant digits For example Entered Displayed Description 000123456789 0001234567 Ten digits six or seven significant 12 345e 2 1234500 Seven digits six or seven significant 1234
26. Consumption and Production Scans consist of two parts exchange overhead and byte transfer time Exchange Overhead Byte Transfer Time Exchange Overhead Exchange overhead includes the setup time for each exchange that will be transferred during the sweep When computing the sweep impact include overhead time for each exchange Exchange Overhead CPU Model Exchange Type 924 925 914 915 Consumed Produced Times are in microseconds Byte Transfer Time This is the time required to transfer the data between the PLC CPU module and the Ethernet module The times shown in the following table represent the time to transfer one data byte Byte Transfer Time CPU Models Exchange Type 924 925 914 915 Consumed 2 4 2 4 Produced 1 8 1 8 Times are in microseconds GFK 1192B Appendix A CPU Performance Data A 23 Table A 12 Worksheet Ethernet Global Data Sweep Time Number of consumed exchanges Sweep impact per exchange Number of data bytes in all of the consumed exchanges Sweep impact per consumed data byte Number of produced exchanges Sweep impact per exchange Number of data bytes in all of the produced exchanges Sweep impact per produced data byte Predicted Ethernet Global Data Sweep Impact Note If the PLC is configured for Microcycle Sweep Mode the EGD sweep impact time is allocated to the Logic Window Therefore the time available to exe
27. EE E eevee At eek hore bd ee 2 44 Section 4 PLC Sweep Modes and Program Scheduling Mode 2 45 Normal S weep Mod6 i 4 s 3 4 0S8 sts belie ORE Eee tes 2 45 Constant Sweep Mode a a a a a A p E EEE EE ETN iin aden adnate 2 46 Constant Window Mode ssssseeeeeesssssssesresssssssserrerssssssssereesssssssrressssssssseeeesssst 2 47 Microcycle Sweep Mode eesceessscccesssseeecessseeeeesssaeecesssaeeesessaeesessnaeessessaeeeeees 2 48 Program Scheduling Modes cc ceeesessccesesseceesesseeecesseeecesssaeeeesssaeeesesseeeseesaes 2 51 Choosing PLC Sweep and Program Scheduling Modes eesseeeesseeeeeesneeeeeeees 2 52 User Program Executioner crion n ae an orereta are E epbiout ns Seren TST A 2 52 User Program Priorities sisun a a a A G 2 52 User Program Execution in Normal Sweep Constant Sweep and Constant Window MOE S a a E EA cua tesa naa netevaetare divas 2 53 User Program Execution in Microcycle Sweep Mode ccsscccesssseeeeeesneeeeeeaes 2 56 Global Data in Microcycle Sweep Mode eeseeeeeeeeeeeeeeeeereseresrresrrrsrersresres 2 59 Interrupt m Fetale Irin eE ESEESE TE TAE E GG UGE RG BORO E BUG Gl 2 60 Interrupt Handling and Scheduling with Blocks 0 0 0 0 eeeseeeeeseneeeeeesteeeeeeeaeees 2 60 TO nterrupt BlOcks sei reei a hack vetouber eae abe av vanvabani abet 2 61 Timed Interrupt Blocks 20 eee eeececeeccceeeeeeesnnaceeeeeeeeeeeenaaaeaaaeeeeeeeeeeeeeaaeeeeeeeeeeees 2 62 Paraim
28. EIEN MEE RENIE EN KEENE RERNE eaeh 2 81 Discrete I O Diagnostic Information sssssseessesseeseeessssssssereesssssssrrresssssssssereessss 2 82 Analog I O Diagnostic Data eeeeeecseccccceeeeeeeenaeeeeeceeeeeeenaaeeeeeeeeseesnaaaeeeeeeeeeeees 2 82 Fault Explanation and Correction essssssssscocccseesssssoccccesessssoooccccsessssosoocceseee 3 1 Section 1 System Faults ssssosceescccssoossccccecccsoossccesseccsoossscoeseccsosssseceseesssss 3 2 System Fault References 20 0 0 eeeeceeesssececessseeeceessececcesseeecessaeecsessaeeesessaeeseenaeees 3 3 Configurable Pault ACN OS r a Te a aa a a aaa rra r ae n an a a ai ara aa arni einat 3 4 NonContigurable Faults incr anemic tn eet etn r eVa an ad 3 6 FaultiGontacts 2c ccnancadnadnndnnnannnannnwn inane 3 7 Fault Locating References Rack Slot Bus Module c ccccccccsceeeeeeeeeeeeeeeeeees 3 7 Bormat of Fault Reterences a sete ide a aaa e nena aa ana E r eaa in aeni kni 3 7 Behavior of Fault References cccccccssescccccccceceseseeeccccceecaaaneseecceseeeuaaneeeeeeeeeeaaa 3 8 AlarnivC ontactss 32st n e a Ae eee a Ae athe 3 8 Pom PaSa Me en a A 3 9 Section 2 Fault Handling ooooeeeessssscoocesesssssscocccccessssooccccsessssssoocccessesssso 3 10 Alarm Ea RO 0E 0 nA EEIE EEE OI EE A LE 3 10 Glasses Of Fasen ass saasaa aaa tek tet tet O O O O O OE O O OT 3 11 System Reaction to Paulsson o enee eID aO IETU oT TTi 3 11 JEENE LES Deia AE EEE
29. Ee ae produces a double integer result The DIV function takes a double 32 16 16 integer dividend and an integer divisor to product an integer Co Pd Cd result ASCII ASCII Eight bit encoded characters A single reference is required to make up 2 packed ASCII characters The first character of the pair corresponds to the low byte of the reference word The remaining 7 bits in each section are converted Command codes and non displayable characters appear on the screen as non alphanumeric characters for example S Sign bit 0 positive 1 negative GFK 1192B Chapter 2 System Operation 2 17 Note Using function blocks that are not explicitly bit typed will affect transitions for all bits in the written byte word dword Also for information about using floating point numbers refer to Appendix D Using Floating Point Numbers System Status References System status references formerly called Convenience references in the Series 90 70 PLC are assigned to S SA SB and SC memory They each have a system supplied nickname that enables you to enter the nickname rather than the exact S reference Examples of time tick references include T_1OMS T_100MS T_SEC and T_MIN Examples of other system status references include FST_SCN ALW_ON and ALW_OFF Note S bits are read only bits do not write to these bits You may however write to SA SB and SC bits Listed below are available system status references th
30. Genius blocks on the same bus with consecutive reference addresses and consecutive bus addresses The time to process a single scan segment is higher for an input scan segment than it is for an output scan segment The scan segment processing is the same for analog discrete and global data scan segments Discrete data is transferred a byte at a time and takes longer to complete the transfer than analog data which is transferred a word at a time Global data should be counted as either discrete or analog based on the memory references used in the source or destination Note Not all of the sweep time information was available at the time this manual was printed the blank spaces in the table below Refer to the IPI for the specific CPU for this information GFK 1192B Appendix A CPU Performance Data A 17 A 18 Table A 8 Sweep Impact Time of Genius I O and GBCs CPX CPX 924 914 CPX 781 782 CPX 731 732 935 928 925 915 782 788 789 772 771 772 Genius Bus Controller open system communications 0432 0616 1625 1890 1625 window per Genius Bus Controller polling 0081 0086 0160 0200 0160 for background messages per Genius Bus Controller I O 4237 6476 5215 8110 5215 Scan First Genius Bus Controller Subsequent Genius Bus Controllers Genius I O Blocks per I O block scan segment i 0300 0314 0444 0314 0300 per I O block scan segment w point faults enabled i 0600 0584 0725
31. I O data in expansion racks per word analog I O data in the main rack per word analog I O data in expansion racks Asynchronous Events Fault Message Times are in milliseconds except for those identified as microseconds These are typical scan impacts It is possible to incur up to an additional 2 1 milliseconds per scan segment but this is not typical This additional scan impact can usually be avoided when using synchronous scan sets that include only 1 FBC he The extra time for the first FBC is the same time as shown in the next table for the first intelligent option module This time should be counted only once Note Functions in bold type in Table A 8 above impact the sweep continuously All other functions impact the sweep only when invoked Also please note that the blank lines represent information not available at this time GFK 1192B Appendix A CPU Performance Data A 21 A 22 Use the following form for predicting the sweep impact due to FIP I O The sweep impact times can be found in table A 10 Table A 11 Worksheet B FIP I O Sweep Time Open system communications window FBC I O scan FBC poll for background messages Number of FBCs Input block scan segments number of Input block scan segments sweep impact Output block scan segments number of Output block scan segments sweep impact Bytes of discrete I O data on FBCs main rack Sweep impact bytes of discrete I O data main rack Bytes of dis
32. I O specification data within a standalone C program Data Coherency of I O Specifications Since standalone C programs can be interrupted by other programs and Interrupt blocks data incoherency within an I O specification can occur Each individual I O specification is limited to 2048 bytes for a maximum of 16KB of input data and 16KB of output data The 90 70 PLC will ensure the following e Each byte within an individual I O specification is coherent with respect to that individual specification e Ifthe total length of all input specifications is no more than 2048 bytes the entire input specification will be coherent e Ifthe total length of all output specifications is no more than 2048 bytes the entire output specification will be coherent If the total length of an input or output specification exceeds 2048 bytes groups of individual specifications whose combined lengths do not exceed 2048 bytes will be coherent The following table indicates coherency in this case Table 2 14 Coherency of I O Specification T O specification Length bytes 1 2000 2 48 Interrupts may occur 3 1024 Interrupts may occur 4 1026 Interrupts may occur 5 10 6 20 7 20 8 20 Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Using LD vs Standalone C Programs Several options need to be considered when determining which type of program is to be used The
33. IO Scan Stop No IO Scan In this mode the PLC runs user programs and continually scans inputs and updates physical outputs including Genius and Field Control outputs The Programmer and System Communications Windows are run in either Limited Run to Completion or Constant mode In this mode the PLC runs user programs and continually scans inputs but updates to physical outputs including Genius and Field Control are not performed Physical outputs are held in their configured default state in this mode The Programmer and System Communications Windows are run in either Limited Run to Completion or Constant mode In this mode the PLC does not run user programs but the inputs and outputs are scanned The Programmer and System Communications Windows are run in Run to Completion mode The Background Window is limited to 10 ms In this mode the PLC does not run user programs and the inputs and outputs are not scanned The Programmer and System Communications Windows are run in a Run to Completion mode The Background Window is limited to 10 ms Note You cannot store changes to P and L references in Run Mode unless the P and L references are the first of their type in the block being stored or the block being stored is a totally new block Stop IO Scan mode is not supported in Microcycle Sweep mode 2 66 Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Mode Transitions Stop to Run Tran
34. It also contains timing information for other tasks that can be used in conjunction with instruction timings to predict CPU sweep times Interpreting Faults describes how to interpret the message structure format when reading the fault tables Memory Allocation provides a worksheet for determining total number of bytes of user data used and how much is still available for the user program Using Floating Point Numbers describes considerations for using floating point math operations Series 90 70 Programmable Controller Installation Manual C Programmer s Toolkit for Series 90 PLCs User s Manual Control User s Manual At GE Fanuc Automation we strive to produce quality technical documentation After you have used this manual please take a few moments to complete and return the Reader s Comment Card located on the next page Henry Konat Technical Writer iii Chapter 1 Chapter 2 GFK 1192B Contents FRC OG UC CON sosekiscgnwestenitincuvasyeesieusspedicasnnecucd tovanwecpedsteussseaiecsresehoedteavencosicbestvees 1 1 System OQ PEratiOn oi siccvisesseacecdssessscusceasinidcssaneeiecnctedswcavendensasgodsosssaevenasgemeesacess 2 1 Section 1 Basic PLC Sweep Summary ccccccssssssssssssscccccssssssssssssceecees 2 2 Basic PLCS Weep se ccececec erences aaan ETRE E R TE E R ai 2 3 Housekeeping setini roces aeree CnES Ee DE EE eI ODSTO SATE ESHEETS IDEEKS oT ES TENNE eee 2 4 INpUtSCans 120s ee RTI PM IG Seta N AA
35. Otherwise compute the number of P allocated Totals P allocated of P used 128 32 rounded up to whole integer 32 160 P Block Memory Used P allocated 2 79 bytes When L used is in the range 1 to 64 the L allocated 96 Otherwise compute the number of L allocated L allocated of L used 64 32 rounded up to whole integer 32 96 L Block Memory Used L allocated 2 79 bytes Note P or L allocation for a program block cannot be changed when the programming software is online unless no P or L is currently used in that block To change the current P or L allocation the programming software must be offline The resulting program must then be stored to the PLC in Stop mode GFK 1192B C 1 C 2 Table C 1 Series 90 70 PLC Memory Allocation Worksheet cont d AI allocated if point fault Disabled AI used x 2 bytes OR AI allocated if point fault Enabled AI used x 3 bytes AQ allocated if point fault Disabled AI used x 2 bytes OR AQ allocated if point fault Enabled AI used x 3 bytes If point fault is Enabled add 128 bytes for 731 732 CPU OR add 512 bytes for 771 772 CPU OR add 3072 bytes for 781 782 CPU OR add 3072 bytes for 914 925 CPUs GRAND Total bytes CPU Memory Total Bytes 32768 OR 65536 OR 131072 OR 262144 OR 524288 Subtract Grand Total from above User Program Memory
36. PLC does an Inclusive OR on all the bits in the diagnostic byte except the process bits The alarm contact is closed if any diagnostic bit is ON and OFF only if all bits are OFF Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Chapter 3 GFK 1192B Fault Explanation and Correction This chapter is an aid to troubleshooting a Series 9070 PLC system It explains the fault descriptions which appear in the PLC fault table and the fault categories which appear in the TO fault table Each fault explanation in this chapter lists the fault description for the PLC fault table or the fault category for the I O fault table Find the fault description or fault category corresponding to the entry on the applicable fault table displayed on your programmer screen Beneath it is a description of the cause of the fault along with instructions to correct the fault Chapter 3 contains the following sections System Faults Describes the PLC system faults SY_FLT and the I O faults IO_FLT Describes configurable faults changing the fault action noneonfigurable faults and locating fault references rack slot bus and FIP locating references Fault Handling Describes the type of faults that may occur in the Series 9070 PLC and how they are displayed in the fault tables Descriptions of the PLC and I O fault table displays are also included PLC Fault Table Provides a description of each PLC fault and instru
37. Table Explanations ccccsscsssssssccccssssssssssscceseees 3 38 CCU FRIS AARE AAEE ee ee eee 3 41 DYISCTCLE SNEIN AEAEE BEA E RERE IEI I I EES 3 42 Analog Pault meeer e eeit esetei eriari erster eedt e ieot E Seea T tees 3 43 LowLevel Analog Fault 20 0 0 ceeececeeessccceeesseeesessaeeecesseeecesssaeeeesssaeeesesseeessesaes 3 44 GENA Falt oe neire teteiis Bo hs eS I 3 45 Loss of TOC C O Controller ccccccccccccccccccccecccceceeeeeeeeeeeeeeeeeeeseeeeeeeeeeeeeeeeeeeeseeeees 3 45 Addition of IOC 1 0 Controller ann enna nannnadnnanRnadnnadnananands 3 45 E0ss 0f V O MOdule ccccceneaiiiveterekieuscssecosscabacesseobosnbveabasesbsabesbbseabersdsaavensyes 3 46 Addition of I O Modulle c cc ccceeccesssnnecccceeeeeeennaceeeeeeeeseeeenaaeeeeeeeeeeeenaaaeeeeeeeeeeees 3 46 Extra L Ov MOUS 35 sects sous senses tas vous iene evan ve soe one eta see sone abe cata sees poe ua nate teaa SIONS 3 46 POSS OL BLOCK siecle Sees Cee Se ee CSA Ea Lo alla Coed lta dates tdusetesee tas 3 47 Addition of Blocker ccccesesreecesesctecvecsezesteevezdeceewtoedecwtoredecctoredecotesedecovesedes e 3 47 Xt BIGCK EEE E busneedecacaaeds busensdecucasaessuenentaniaes soeaeeetes 3 47 VO Bus Halts aA a Aaa A A AA AA 3 48 A Ere Ii GA Re Ti IAA ARAARA AARAA A AARAA AAAA ARAARA ARAA ARAARA 3 49 IOC d O Controller Software Fault c ccesssssessseccsecessssnenstecesesesessnenssecesssesess 3 49 IOC I O Controller Hardware Failure ccccccc
38. Window highest priority is given to board configuration Boards are configured as needed up to the total time allocated to the Programmer Window The Programmer Window is used for communication between the CPU and the two dedicated programmer ports the built in SNP connection and the parallel programmer connection The CPU will complete any previously unfinished requests and then begin to process any pending requests in the queue When the time allocated for the window expires processing stops The Programmer Window time defaults to 10 milliseconds This value can be configured and stored to the PLC or it can be changed online using your programming software Time and execution of the Programmer Window can also be dynamically controlled from the user program using Service Request function 3 The Programmer Communications Window time can be set to a value from 0 to 255 milliseconds Note Even if the Programmer Window is skipped the PLC can still respond to commands to change mode or state or to redefine the Programmer Window if the programmer is attached through the parallel port on the Bus Transmitter Module BTM or by manually putting the PLC into stop mode Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B System Communications Window The System Communications Window is the part of the sweep used for communication between the CPU and intelligent modules such as the PCM Genius Bus Controller FIP
39. Window in Microcycle Sweep mode Cleared when the PLC detects that the previous sweep did have enough time to perform the window SB0009 NO_PROG Set when the PLC CPU powers up with memory preserved but no user program is present Cleared when the PLC powers up with a program present or when the PLC fault table is cleared Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Reference Name Definition SBO0010 BAD_RAM _ Set when the CPU detects corrupted RAM memory at power up Cleared when the CPU detects that RAM memory is valid at power up or when the PLC fault table is cleared SBOO11 BAD_PWD Set when a password access violation occurs Cleared when the PLC fault table is cleared SBO0012 NUL_CFG Set when an attempt is made to put the PLC in Run mode when there is no configuration data present Cleared when configuration data is present and the PLC is in Run mode or when the PLC fault table is cleared SBO0013 SFT_CPU Set when the CPU detects an error in the CPU operating system software Cleared by cycling power to the CPU or when the PLC fault table is cleared SBO0014 STOR_ER Set when an error occurs during a programmer store operation Cleared when a store operation is completed successfully SBO0016 MAX_IOC Set when more than 32 IOCs are configured for the system Cleared by modifying the configuration and storing it to the PLC CPU or when the PLC fault table is
40. a a 2 76 Section 9 Series 9070 PLC I O System ccccssssssssssccsssssssssssscccecsssees 2 77 VO Data Mapping eenn i he ele E AE AT ata 2 78 Default Condi OS errari teana ar tanata aretan are an taa aaa aaa ea ar neat ane een nE Ea 2 78 EA O AA E AAA E E E E A E E 2 78 Genius I O Bus C ntis rati M e teree a aaae T KaT aai arai iia 2 78 Genius I O Data Mapping esseseseeseseeessssrerssrrerssrrrrsssrresssrresssrierssreeesssreerssreeeseet 2 78 Analog Grouped DO o a a a a a ee anit laa 2 79 EowLevel Analog Blocks oee cess cocccvss cece ceesebstcesicbstcnvicbstcevbetotcepbetenctvecvecevecestce 2 79 Default Conditions tainen innesti ee a i ee e aa ai eest 2 79 Genius Global Data Communications 0 0 ceceececeecceeeeeeeenneeeeeeeeeeeeeenaaeeeeeeeeeeees 2 80 FIRT aaae AEAEE A A A E EEA 2 80 Contents vii Contents Chapter 3 viii FIP I O Bus Configuration eseeeeeseeeeeeesreerserrerserrersesrerrserressereeessrreesssrrerserereesees 2 80 9030 FIP Remote I O Scanner secesii nne a O E 2 80 FIP Bus Interface Unit Field Control 0 0 0 0 cccecsssccccceesssceeeeeeessensseeeeeens 2 80 Generic FIP V O 2 5 scscsiesteccdieseseesen dak ieee eco cedan bak edob a a a 2 81 HIPIO Fault DAA ected calle cette aaa eed E eea 2 81 PIP VO Data Mappings t riisct eho a aaae a e aa aaae a Aa aa aE ea Ea e e e hi behe hale 2 81 Default CONGINONS ea FAFE PAA FOr TUA ERIEN 2 81 Diagnostic Data CoEctoh Aerenea aertruo Er EUNA ae
41. a reference address is assigned no data will be received from the module I memory is always retentive PQ The Q prefix represents physical output references The coil check function checks for multiple uses of Q references with relay coils or outputs on functions Beginning with Release 4 of the software you can select the level of coil checking desired Single Warn Multiple or Multiple Refer to Rung Acceptance in the online help for additional information The Q prefix is followed by the reference s address in the output table for example Q00016 Q references are located in the output status table which stores the state of 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 your programming software Until a reference address is assigned no data is sent to the module A particular Q reference may be either retentive or non retentive M The M prefix represents internal references The coil check function of your programming software checks for multiple uses of M references with relay coils or outputs on functions A particular M reference may be either retentive or non retentive T The T prefix represents temporary references These references are never checked for multiple coil use and can therefore be used many times in the
42. and sets the OV_SWP SA0002 status reference at the beginning of the next sweep The OV_SWP status reference is reset when the time of the last sweep does not exceed the Constant Sweep timer or the PLC is not in Constant Sweep mode Additional sweep time due to an oversweep condition in a given sweep does not affect the time given to the next sweep Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B The following figure illustrates four successive PLC sweeps in Constant Sweep mode with a Constant Sweep time of 100 milliseconds Note that the total sweep time is constant but an oversweep may occur due to the Logic Window taking longer than normal a45530 SWEEP n SWEEP n 1 SWEEP n 2 SWEEP n 3 t 0 ms t 100 ms t 220 ms t 320 ms Constant Sweep Time OUTPUT Abbreviations HK Housekeeping PRG Programmer Window SYS System Communications Window BG Background Window Figure 2 4 Typical Sweeps in Constant Sweep Mode Constant Window Mode GFK 1192B In Constant Window mode each PLC sweep can consume a variable amount of time The Logic Window is executed in its entirety each sweep In this mode the PLC will alternate among the three windows allowing them to run in a Run to Completion mode for a time equal to the value set for the Constant Window timer The overall PLC sweep time is equal to the time required to execute the Housekeeping Input Scan Logic Window and Output Scan phases of
43. current date and time This is also maintained by the PLC Note The size of the PLC fault table is configurable with a default of 16 and a maximum of 40 configurable in Control Additional faults over the configured limit cause the table to overflow and faults are lost The system reference SY_FULL S0009 is set to indicate that the fault table is full GFK 1192B Chapter 3 Fault Explanation and Correction 3 13 3 14 I O Fault Table The I O fault table displays I O faults such as circuit faults address conflicts forced circuits and T O bus faults The programmer may be in any operating mode However if the programmer is in Offline mode no faults are displayed In Online or Monitor mode PLC fault data is displayed In Online mode faults can be cleared this feature may be password protected Top Top Fault Displayed The index of the VO fault currently at the top of the fault displayis Displayed The index of the I O fault currently at the top of the fault display is nia on the first line of this screen Total Faults Faults The total number of faults since the table was last cleared o total number of faults since the table was last cleared Fault Description A more specific indication of the type of fault that is currently highlighted in the TVO fault table Table Last Cleared The date and time faults were last cleared from the fault table This information is maintained by the PLC En
44. does not match configuration stored from software Correction Change MAC address on softswitch utility or in software Error Code 11 Name LAN Softswitch Modem mismatch Description Configuration of LAN module does not match modem type or configuration programmed by softswitch utility Correction 1 Correct configuration of modem type 2 Consult LAN Interface manual for configuration setup Error Code 17 Name Invalid Memory Reference Description Memory references in the logic program exceed what is available Correction Update the configuration file and store it to the PLC Error Code 1E Name Reference Length Mismatch Description The PLC generates this error when the I O reference lengths specified in the configuration for this module do not match the actual data sizes reported by the board Correction Update the configuration file with the correct reference lengths GFK 1192B Chapter 3 Fault Explanation and Correction 3 23 Error Code 1F Name Invalid Configuration Parameters Description The PLC generates this error when it determines that critical values in the module s configuration are unacceptable Correction Update the configuration file with the correct values Error Code 20 Name New Configuration Requires Reset Description The PLC generates this error when it determines that a store of configuration attempted to change critical configuration values for the specified
45. enen Ea EE raei aei Taraa 2 68 System Configuration oc esececcsssseeecessseeeceesseeeceessaeeceesseeecessneeesessnaeeeeesaeees 2 69 Option Module SelfTest Completion 0 0 0 eeeseeceessececeesseeecessneeeceesnaeeeeesaeees 2 69 Option Module Dual Port Interface Tests 0 0 0 eeeceesenceeceeeeeeeeeennneeeeeeeeeeeeesaaees 2 69 T O System Initialization sso ottaen a a a a a T S 2 70 Power Down Sequence or E EE Eaa TaT TRT 2 70 Retention of Data Memory Across Power Failure cceccccccceeeeeeeennneeeeeeeeeeeees 2 71 Section 7 Clocks and TiMerS seesseeessossseoessoesssosssosessosssosessosssoesssossssosssose 2 72 Elapsed Time Clot Ricieroieessse retiris rssoirioteriroesrerdior iro iseia eE T T tend 2 72 Aiino DEDA Coe G E EEEE 2 72 Watehdo g TINET aan e E eek Oh Rh IE E E EO AE 2 73 Software Watchdog Tamer c t cctisasesecaccdasasagacasacacecacasibagascacadacasababasecaceassacacesnseate 2 73 Hardware Watchdog Timerticisccv ctrcr rivers cir iter ries eit eee ener eee 2 73 Section 8 System Security css lt scvsscssdencesecsseevesvsonecssesceveesennvecersesesvsvvssrevencnseers 2 74 Passwords and Privilege Levels ssccceessssccceesessneeecessneeeceessaeeecessaeeesessaeeeseesaes 2 74 Protection Level Request from Programmer sseeeeesereeeerereserrerssrreerssrrerserrerseres 2 75 IDRE ETA ERO a CAA AAAA AAAA 2 76 OEM Protect Oee erosi th Anan net hao eee leo eT O ITE Oe ee 2 76 Write Protect KeyS witch a aaa AA AA A A
46. error when the Genuis Analog module detects an improper RTD connections or thermocouple reverse junction fault Correct the problem causing the condition Internal Fault The Genius Bus Controller generates this error when the Genuis Analog module reports a cold junction sensor fault on a thermocouple block or an internal error in an RTD block Correct the problem causing the condition Input Channel Shorted The Genius Bus Controller generates this error when it detects an input channel shorted on a Genius RTD or Strain Gauge Block Correct the problem causing the condition Invalid Data The Genius Bus Controller generates this error when it detects invalid data from a Genuis Analog input block Correct the problem causing the condition Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B GENA Fault The GENA Fault has no fault descriptions associated with it GENA Fault Byte 2 is the first byte of the fault specific data Description The Genius I O operating software generates this error when it detects a failure in a GENA block attached to the Genius I O bus Correction Replace the GENA block Loss of IOC I O Controller The fault category Loss of IOC has no fault types or fault descriptions associated with it The default fault action is Fatal Name Loss of or Missing IOC Description The PLC generates this error when it cannot communicate with an I O Controller and an entry fo
47. failure in the PLC CPU one of the faults reported as a PLC CPU hardware failure the address of the failure is stored in the first four bytes of the field Application Fault Indirect Reference Overflow The offset address of where the call was made is located in the first two bytes The offending reference segment selector and offset is located in the next four bytes The name of the program block in which the function call resides is contained in the next eight bytes Bad COMREQ Status Pointer The first byte contains a hex FF The next four bytes contain the segment selector and offset of the status pointer into which the PLC CPU could not write Bad Genius Bus Request Four bytes are used unless the request is a read or write device In these two datagrams eight bytes are used Table B 10 Fault Specific Data Bad Genius Bus Request Fault Specific Data Bad Genius Bus Request 0 FF 1 Bus address of requestor 2 Function code 3 Subfunction code 4 Segment selector if Read Write device 5 LSB of offset if Read Write device 6 MSB of offset if Read Write device 7 Length if Read Write device Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B PLC Fault Time Stamp The six byte time stamp is the value of the system clock when the PLC CPU recorded the fault Values are coded in BCD format Table B 11 PLC Fault Time Stamp Byte Number Description 1 Seconds
48. faults the fault action cannot be changed Other faults called configurable faults can have their fault type changed to another fault action if such a change is suitable for the application The following table lists configurable faults If the fault also causes additional faults only the initiating fault is logged Table 3 2 Configurable Fault References Fault Default Action Description May Also Be Set SBUS_ER System bus error HRD_FLT diagnostic The BSERR signal was generated on the VME SY_PRES SY_FLT system bus Other references may also be set depending on the type of access when the BSERR occurred HRD_CPU PLC CPU hardware fault such as failed memory device SY_FLT SY_PRES fatal or failed serial port HRD_FLT HRD_SIO Nonfatal hardware fault on any module in the system SY_FLT SY_PRES diagnostic such as failure of a serial port on a PCM HRD_FLT SFT_IOC Nonrecoverable software error in a Genius Bus IO_FLT IO_PRES diagnostic Controller SFT_FLT SFT_SIO Nonsecoverable software error in a PCM or LAN SY_FLT SY_PRES diagnostic interface module SFT_FLT PB_SUM Program or block checksum failure during powerup or SY_FLT SY_PRES fatal in Run mode LOW_BAT Low battery signal from CPU or another module in SY_FLT SY_PRES diagnostic system OV_SWP Constant sweep time exceeded SY_FLT SY_PRES diagnostic SY_FULL PLC fault table full 16 entries SY_FLT SY_PRES IO_FULL VO fault table full 32 entri
49. format of a rack fault name is RACK_Or where r is the rack number 0 to 7 For example RACK_01 shown in the example below represents rack 1 The format of a slot fault name is SLOT_rs where r is the rack number 0 to 7 and s is the slot number 0 to 9 For example SLOT_15 shown in the example below represents rack 1 slot 5 RACK_01 SLOT_15 Q00002 1 FAULT NOF LT A Chapter 3 Fault Explanation and Correction 3 7 The format of a bus fault name is a BUS_rsb where r is the rack number 0 to 7 s is the slot number 0 to 9 and b is the bus number or 2 For example BUS_241 represents rack 2 slot 4 bus 1 The format of a module fault name is M_rsbmm where r is the rack number 0 to 7 s is the slot number 0 to 9 b is the bus number or 2 and mm is the module number 00 to 31 For example M_26128 represents rack 2 slot 6 bus 1 module 28 The format of a FIP module fault is F_rsmmm where r is the rack number 0 to 7 s is the slot number 0 to 9 and mmm is the FIP station address Behavior of Fault References At powerup all fault locating references are cleared in the PLC When a fault is logged the PLC transitions the state of the affected reference s The state of the fault reference remains in the fault state until one of the following actions occurs e Both the PLC and the I O fault tables are cleared through your programming software either by clearing each table individually or clearing the entire PLC me
50. g Window i C Input Spec Copy Suspended Background Window SWEEP n 1 A Execution x x A Execution s C Input Spec Copy Suspended Programmer Communications window suspended due to window time expiring C Execution System Communications Window suspended due to window time expiring X I O interrupt occurs invoking Event Triggered program Figure 2 10 Periodic and l 0 Triggered Execution Sequence 2 58 Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Global Data in Microcycle Sweep Mode Incoherent data can result if a program uses global data R I Q etc that is suspended across multiple sweeps The data referenced will be from two successive sweeps Although data cannot be incoherent within a byte or word global data should only be accessed using its basic type byte word etc otherwise incoherency can apply to individual elements as well If possible the input and output specifications should be used to access and update global data areas GFK 1192B Chapter 2 System Operation 2 59 Interrupt Handling There are two types of interrupts available for user program handling in the 90 70 PLC VO Interrupts These interrupts are generated by 90 70 I O modules to indicate discrete input state changes rising falling edge analog range limits low high alarms and high speed signal counting events Timed These interrupts are generated by the 90 70 PLC CPU based
51. information needed for the above table was available at print time for this manual the blank spaces Table A 15 1 0 Triggered Interrupt Performance and Sweep am Times a CPX a ne 781 782 Bedale eal Item 928 T O interrupt response time Input card filter time typical interrupt latency interrupt to logic time Minimum response time 3046 3259 4796 Typical response time 3072 3273 4797 Maximum response time 4618 4822 9921 T O interrupt rate limit T O interrupt rate limit w no IOMs Times are in milliseconds Not all of the timing information needed for the above table was available at print time for this manual the blank spaces The following form is a worksheet for the sweep impact times of programmer sweep impact intelligent option modules and I O Interrupts Refer to tables A 4 A 10 and A 11 Note GFK 1192B Appendix A CPU Performance Data A 27 Not all of the timing information needed for the above table was available at printing time for this manual the blank spaces Refer to the IPI for each CPU for this information Table A 16 Worksheet C Programmer IOM I O Interrupt Sweep Time Programmer sweep impact IOM first module open comm window IOM per module polling LAN module I O scan Total IOM Sweep Impact PLC memory access from IOMs T O interrupt sweep impact T O interrupt response time Predicted Sweep Time Other A 28 Series 90 70 System Manual for Control Soft
52. length use the form ab ccc a X denotes an input formal parameter a Y denotes an output formal parameter b is a parameter number between 1 and 7 c is a valid BOOL WORD or NWORD index The labels X1 through X7 and Y1 through Y7 may be assigned a nickname of up to three characters Assigned parameters are PLC references or data flow that pass their address or data into or out of a Parameterized Subroutine Block An assigned parameter may pass either the value of the data in the assigned parameter BOOL type parameters or the address of the assigned parameter WORD or NWORD type parameters Assigned parameters are defined in a parameter assignment table Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Restrictions on Formal Parameters within a Parameterized Subroutine Block In general formal BOOL parameters are allowed on all contacts coils and function block parameters that allow discrete references I Q M T S G and U Formal WORD and NWORD parameters are allowed on all function block parameters that allow register references R WAI WAQ P L and WUR NWORDS should not be used in Control The type exists only to maintain compatibility with folders created through Logicmaster and imported into a Control folder In Logicmaster NWORD parameters are allowed only on multiword type parameters that is DINT DWORD or REAL An NWORD is a number of words passed into a Parameter
53. lists a maximum of eight input and eight output ranges The input ranges will be copied to the program at the start of program execution The output ranges are copied from the standalone C program to the global reference on the completion of program execution Note that this differs from external block parameters that are passed by reference not by value This operation is especially important for programs that may be time sliced over multiple sweeps which can occur when using Microcycle Sweep mode Caution When the PLC runs in Microcycle Sweep mode programs can be suspended in the middle of execution possibly in the middle of a line of C code or in the middle of a rung of logic or function block If the program uses global references such as Q R etc a possibly inconsistent set of reference values may be present at the time an Interrupt program or output scan occurs This inconsistency could even be within a given reference value if the value is not accessed according to its type Incoherent data can result if a program uses global data and is suspended across multiple sweeps The data referenced will be from two successive sweeps Although data cannot be incoherent within a byte or word global data should only be accessed using its basic type byte word etc otherwise incoherency can apply to individual elements as well Chapter 2 System Operation 2 39 2 40 To illustrate the possibility of inconsistent output data consi
54. locating reference Caution Do not override transitional coils If a transitional coil is overridden and the override is then removed the coil will come on for one sweep This can cause unexpected consequences in the PLC ladder logic and in field devices attached to the PLC When override bits are set the associated references cannot be changed from the program or the input device they can only be changed on command from the programmer Retentiveness of Logic and Data Data is defined as retentive if it is saved by the PLC when the PLC is stopped The Series 90 70 PLC preserves program logic fault tables and diagnostics checksums for program logic overrides and output forces word data R L P AI AQ bit data I S G fault locating references and reserved bits Q and M data unless used with non retentive coils T data is not saved Q and M references are non retentive that is cleared when the PLC transitions from Stop to Run including power up in Run mode whenever they are used with non retentive coils Non retentive coils include coils negated coils SET coils S and RESET coils R When Q or M references are used with retentive coils or are used as function block outputs the contents are retained through power loss and Run to Stop to Run transitions Retentive coils include retentive coils M negated retentive coils M retentive SET coils SM and retentive RESET coils RM
55. mode each PLC sweep takes a fixed amount of time The user specifies the total sweep time base cycle time and the total time for the Communications and Background Windows The Logic Window can be preempted in order to maintain the total sweep time and the Communications Windows and Background Window times To satisfy the specified window times the PLC alternates among the Programmer Communications Window the System Communications Window and the Background Window allowing them to execute until it is time for the next sweep to begin Note The information presented above summarizes the different sweep modes For detailed information on PLC Sweep Modes refer to PLC Sweep Modes and Program Scheduling Modes in section 4 of this chapter 2 10 Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Section 2 User Reference Data User References GFK 1192B The PLC data used in an application program is stored as either discrete or register references Table 2 2 Register References Type R Description Use the prefix R to assign system register references which will store program data such as the results of calculations AI The prefix AI represents an analog input register This prefix is followed by the register address of the reference for example AI0015 An analog input register holds the value of one analog input or another value AQ The prefix AQ represents an a
56. not meaningful on this fault The fault specific data contains a byte from the GBC echoing the fault 02 FF0100 O004011EFF7F 0302 02 00 00 8403101000 Series 90 70 System Manual for Control Software Users November 1999 Fault Specific Data Fault Description Fault Type Fault Category Fault Action Fault Group Point Block I O Bus Slot Rack Reference Address Long Short GFK 1192B Addition of I O Block Example The Addition of I O Block fault is described below All data is in hexadecimal Field Value Description Long Short 02 This fault contains up to 5 bytes of fault specific data Reference 1F0100 1F 31 decimal indicates that the block has a discrete grouped reference Address address The software shows this by displaying a QI in the reference address column 0100 indicates this is address 0001 hexadecimal data is displayed low byte first then high byte in the discrete grouped address space Rack 00 Main rack rack 0 Slot 04 Slot 4 In this configuration slot 4 contains a Genius Bus Controller Bus 01 Bus 1 on the bus controller When this byte is significant the single channel bus controller always shows this field as a 1 Block 1E 1E is 30 decimal This fault was logged for the Genius device at serial bus address 30 Point FF7F FF in the first low byte indicates that the point is not meaningful for this fault entry Fault Group
57. of output data located at reference addresses T00001 T00016 and at register memory addresses RO00200 RO0201 The logic within the subroutine can also control the OK output of the Parameterized Subroutine Block This example shows the subroutine CALL instruction as it will appear in the calling block ere I00001 Q00001 I CALL LOAD 41 ss SUBROUTINE B012 B016 I00100 ABC Y1 T00001 B016 wo02 I00001 X2 2 R00200 GFK 1192B Chapter 2 System Operation 2 33 2 34 Referencing Formal Parameters Within a Parameterized Subroutine Block Formal parameters are those parameters used within Parameterized Subroutine Block that are passed from and to the calling block They are either BOOL WORD or NWORD types NWORD type parameters may be used on any multiword type operands but not on discrete types An NWORD is a number of words passed into a Parameterized Subroutine Block The formal parameters are identified as X input parameters or Y output parameters followed by the number of the input or output parameter respectively For example X2 indicates the parameter used at location X2 in the parameterized subroutine declaration The X2 label could be followed by a value of 1 to 16 to the length provided in the subroutine declaration B016 Up to seven formal parameter pairs may be declared in a Parameterized Subroutine Block The formal parameter type number and
58. on a user Interrupts specified time interval with an initial delay if specified applied on Stop to Run transition of the PLC Both of these types of interrupts may invoke a user program or block Interrupt blocks and programs can interrupt the execution of non interrupt logic as well as other Timed and I O Triggered programs Therefore unexpected results may occur if the interrupting logic and interrupted logic access the same data If necessary Service Request 17 or Service Request 32 can be used to temporarily mask I O and Timed Interrupt blocks and programs from executing when shared data is being accessed Interrupt Handling and Scheduling with Blocks An Interrupt block has the highest priority of any user logic in the system and may be programmed to execute upon the receipt of a Timed or I O Interrupt block The execution of a block triggered from a timed or I O interrupt preempts the execution of the normal PLC sweep activities Execution of the normal PLC sweep activities is resumed after the Interrupt block completes There can be a maximum of 64 I O Interrupt blocks and 16 Timed Interrupts blocks Note Timer function blocks do not accumulate time if used in a block that is executed as a result of a Timed or I O Interrupt block Beginning with Release 6 of the PLC CPU LD Interrupt blocks may make calls to other blocks The application stack used during the execution of Interrupt blocks is different from the stack used by t
59. or block in which the error occurred The default fault action for this group is Fatal Error Code Name Description Correction Low Battery Signal All Program or Block Checksum Failure The PLC generates this error when a program or block is corrupted 1 Clear PLC memory and retry the store 2 Examine C application for errors 3 Display the PLC fault table on the programmer Contact GE Fanuc PLC Field Service giving them all the information contained in the fault entry The fault group Low Battery Signal occurs when the PLC CPU detects a low battery on the PLC CPU board the PLC CPU memory daughter board or a module such as the PCM reports a low battery condition The default fault action for this group is Diagnostic Error Code Name Description Correction Error Code Name Description Correction 0 Failed Battery Signal The CPU module or other module having a battery battery is dead Replace the battery Do not remove power from the rack until replacement is complete 1 Low Battery Signal A battery on the CPU or other module has a low signal Replace the battery Do not remove power from the rack until replacement is complete 3 28 Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Constant Sweep or Microcycle Time Exceeded The fault group Constant Sweep or Microcycle Time Exceeded occurs when the PLC CPU operates in Constant Sweep or Microcycl
60. power up will only perform the CPU processor and BCP Boolean Coprocessor tests along with a minimal RAM test The goal of a quick power up is to get the CPU up and running as quickly as possible The remaining tests ROM CRC exhaustive memory tests and peripheral tests are only performed on a full power up If a low battery indication is present then a low battery fault is logged into the PLC fault table PLC Memory Validation The next phase of system power up is the validation of the PLC memory within the CPU First the system verifies that the battery is not low and that battery backed RAM areas are still valid A known area of battery backed application RAM is checked to determine if data was preserved Next if a ladder diagram program exists then a checksum is calculated across the _MAIN ladder block If no ladder diagram program exists then a checksum is calculated across the smallest standalone C program Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B When the system is sure that the application RAM is preserved then a known area of the BCP Boolean Coprocessor bit cache area is checked to determine if the BCP bit cache data was preserved If this test passes then the Bit Cache memory is left containing its power up values Non retentive outputs are cleared on a transition from Stop to Run mode If this checksum does not compare or the retentive test on the application RAM fails the Bit Cach
61. range from 1 to 512 Default is one bit for BOOL lengths or one word for WORD and NWORD lengths In addition you may also declare an optional three character formal parameter reference name Parameterized Subroutine Blocks and Local Data 2 32 Parameterized Subroutine Blocks support the use of P global data Parameterized Subroutine Blocks do not have their own L data but instead inherit the L data of the calling block Parameterized Subroutine Blocks also inherit S contacts such as FST_EXE from the calling block If L references are used within a Parameterized Subroutine Block and the block is called by _MAIN L references will be inherited from the P references wherever encountered in the Parameterized Subroutine Block for example LO005 PO0005 data P Inherits as L _MAIN PSB 1 BLOCK gt data AL Inherits as L BLock pees 1 Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B How Parameterized Subroutine Blocks Are Called A Parameterized Subroutine Block executes when called from the program logic in the _MAIN block another block or itself In the following example if 100001 is set the parameterized subroutine named LOAD_41 is executed The LOAD_41 subroutine block operates on the input data located at reference addresses 1I00100 100111 and I00001 1I00016 and produces values in the block
62. restrict access to selected PLC functions After passwords have been set up access to the PLC via any communications path is restricted unless the proper password has been entered Once a password has successfully been accepted access to the privilege level requested and below will be granted for example provide password for level 3 will allow access to functions at levels 0 1 2 and 3 If the PLC communications are suspended protection level will automatically return to the lowest privilege level of the highest unprotected level or privilege level 2 Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Table 2 18 Privilege Levels Priv Level Password Access Description 4 Yes Write to all configuration or logic Configuration may only be written in Stop mode logic may be written in Stop or Run mode Set or delete passwords for any level 3 Yes Write to all configuration or logic when the CPU is in Stop mode including word for word changes the addition deletion of program logic and the overriding of discrete I O 2 Yes Write to any data memory This includes the toggle force of reference values but does not include overriding discrete I O The PLC can be started or stopped PLC and I O fault tables can be cleared NOTE This is the default if no passwords are defined 1 Yes Read any PLC data except for passwords This includes reading fault tables performing datagrams verifying logi
63. should be counted only once between the Series 90 70 I O scan and the Genius I O scan There is also a per Genius Bus Controller sweep impact a per scan segment sweep impact and a transfer time per word sweep impact for all I O data The sweep impact per Genius Bus Controller has three parts 1 Sweep impact to open the System Communications Window This is added only once when the first intelligent option module of which the Genius Bus Controller is one is placed in the system 2 Sweep impact to poll each Genius Bus Controller for background messages datagrams This part is an impact for every Genius Bus Controller in the system Note Both the first and second parts of the Genius Bus Controller s sweep impact may be eliminated by closing the System Communications Window setting its time to 0 This should only be done to reduce scan time during critical phases of a process to ensure minimal scan time Incoming messages will timeout and COMMREQs will stop working while the window is closed Communications with PCM and LAN modules will also stop 3 Sweep impact to scan the Genius Bus Controller This impact results from the PLC CPU notifying the Genius Bus Controller that its new output data has been transferred and commanding the Genius Bus Controller to ready its input data as well as informing the Genius Bus Controller that the PLC has finished another sweep and is still in RUN mode A scan segment for Genius I O consists of
64. table Description of System Faults updated chapter 3 pg 3 2 Appendix A CPU Performance Data tables revised all information not available will be added to a future version Paragraph added beginning with Each Ethernet Global page A 23 Section titled Relative CPU Test Performance added at end of Appendix A Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Chapter 2 GFK 1192B System Operation This chapter describes certain system operations of the Series 90 70 PLC system The table displayed below summarizes the content of each section in this chapter Section Title Description Page 1 Basic PLC Sweep Describes the major steps in a typical PLC sweep including 2 2 Summary application program task execution Programmer Communications Window System Communications Window and Background Window 2 User Reference Data Describes user reference data system status fault references 2 11 and data types 3 Program Organization Describes the structure and use of LD blocks PSB blocks 2 24 external blocks and standalone C programs 4 PLC Sweep Modes and Explains Normal Sweep Constant Sweep Constant Window 2 45 Program Scheduling Microcycle Sweep and Stop modes Also describes Triggered Modes Interrupt blocks programs and timed interrupts 5 Run Stop Operations Describes the four modes of operation supported by the 90 70 2
65. the end of the Logic Window the I O Triggered program will be scheduled to execute in the Logic Window of the current PLC sweep Otherwise it will be scheduled to execute in the Logic Window of the next PLC sweep I O Triggered programs will preempt the execution or resumption of Periodic programs and lower priority I O Triggered programs These programs are subject to the same time sliced execution over multiple sweeps as Periodic programs based on the time available to the Logic Window The input specification for an I O Triggered program is copied at the time the 2 56 Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B program is scheduled to execute that is when the I O interrupt occurs not at the beginning of the Logic Window as with Periodic programs The output specification is copied upon completion of the program Timed and I O Interrupt blocks execute during any phase of the PLC sweep when the PLC is in Microcycle Sweep mode These blocks will preempt the execution of all programs and have the highest priority of any user logic in the PLC Timed and I O Interrupt blocks do not have an input or output specification copy The following figure depicts two Periodic programs A and B and one I O Triggered program C executing in two successive Microcycle Sweeps Periodic programs A and B both have a period of 1 GFK 1192B Chapter 2 System Operation 2 57 Housekeeping A Input Spec Copy System Comm
66. the sweep plus the value of the Constant Window timer This time may vary due to sweep to sweep variances in the execution time of the Logic Window An application that requires a certain amount of time between the Output Scan and the Input Scan permitting inputs to settle after receiving output data from the program would be ideal for Constant Window mode The value of the Constant Window timer can be configured to be any value from 5 to 255 milliseconds The Constant Window timer value may also be set by your programming software or by the user program using Service Request functions 3 4 and 5 The following figure illustrates three successive PLC sweeps in Constant Window mode Note that the total sweep times may vary due to sweep to sweep variations in the Logic Window but the Chapter 2 System Operation 2 47 2 48 time given to the Communications and Background Windows is constant Some of the Communications or Background Windows may be skipped suspended or run multiple times based on the Constant Window time Abbreviations eel HK Housekeeping PRG Programmer Window SYS System Communications Window BG Background Window SWEEP n SWEEP SWEEP a45531 LOGIC LOGIC ial PRG Fre a aio SYS OUTPUT PRG i C aiei 4 Time SYS Figure 2 5 Typical Sweeps in Constant Window Mode Microcycle Sweep Mode In Microcycle Sweep mode each PLC sweep begins at an absolute time which is a multiple of the bas
67. time base INTVL time base after the PLC is placed in Run mode The figure below shows two timed interrupt declarations The LD block BLK1 will be executed at times of 3 seconds 5 seconds 7 seconds etc after the PLC is placed in Run mode The LD block BLK2 will be executed at two second intervals beginning two seconds after the PLC is placed in Run mode The absence of a DELAY value for BLK2 indicates that there will not be an initial delay in the first execution of the block l p TIMER gt CALL BLK1 LANG LD CONST 1 00s 00002 INTVL CONST 00001 DELAY a TIMER gt CALL BLK2 LANG LD CONST 1 00s 00002 INTVL __ DELAY Figure 2 12 Timed Interrupt Block Declarations Parameters Parameter Description INTVL INTVL is a constant value that will be multiplied by the time base of the interrupt to establish the frequency of execution of the associated block DELAY DELAY is an optional field for the timed interrupt It is a constant value that will be multiplied by the interrupt time base to establish an additional delay for the first execution of the associated block 2 62 Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Valid Memory Types Parameter flow I WQ WM T PS G WU MR
68. time to output values to discrete output module Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B GFK 1192B Table A 1 Instruction Timing Continued Function 928 CPX772 935 928 CPX772 935 928 CPX772 Group Function CPX782 CPX782 CPX782 Size Floating Point Math Note 1 Nv me ADD_REAL SUB_REAL MUL_REAL DIV_REAL ABS_REAL SQRT_REAL Trigonometric SIN Cos TAN ASIN ACOS ATAN Logarithmic LOG LN EXPT EXP Comparison EQ_REAL NE_REAL i GT_REAL GE_REAL k a LT_REAL LE_REAL CMP_REAL 3 3 6 6 3 3 E 3 3 X 5 5 3 5 3 5 i 5 5 3 3 z Conversion REAL_TO_INT REAL_TO_UINT REAL_TO_DINT INT_TO_REAL UINT_TO_REAL DINT_TO_REAL REAL_TRUN_INT REAL_TRUN_DINT DEG_TO_RAD RAD_TO_DEG BCD4_TO_REAL BCD8_TO_REAL Time in microseconds is based on Release 5 0 of Logicmaster 90 70 software For information not available when this manual was being printed represented by a dash refer to the IPI for each CPU For table functions increment is in units of length specified For bit operation functions microseconds bit For data move functions microseconds the number of bits or words Enabled time is for single length units of type R COMMREQ time has been measured between CPU and EX7 with NOWAIT option DOIO is the time to output values to discrete output module Appendix A CPU Performance Data A
69. time was approximately 115 ms In this test program the Main block calls the same subroutine S1 4 times The S1 subroutine in turn calls 60 other subroutines S2 S61 which each contain the same logic The logic consists of e 140 contacts e 50 70 coils e 5 ADDs e 2DNCTRs e 5 UPCTRs e 10EQ_ INT e 3 FIFO RDs e 12 MOVEs e 1MUL_INT e 1NE_INT e 8 ONDTRS e 1 CALL e 2 Bit Shifts e 4SUB_INTs e 4TMRs e 1 DIVIDE e 1PLISA Interpreting the Chart The CPX935 performance time for running the test program was assigned a value of 100 and the other CPUs were compared to that standard The chart shows that the CPX935 had the fastest time The CPU782 took the longest 446 longer than the CPX935 Note The figures in the following chart were measured for the test program described above They will not be exactly the same for different programs but should provide a basic guide to relative CPU performance GFK 1192B Appendix A CPU Performance Data A 37 Relative Time Required to Run the Test Program 500 450 R 400 c 350 5 300 250 o3 200 150 100 50 0 CPX935 CPM925 CPM915 CPX782 with CPU782 cache disabled Series 90 70 CPUs Figure A 1 Chart of Relative CPU Performance A 38 Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Appendix B GFK 1192B Interpreting Faults The Series 90 70 PL
70. 0 70 I O modules is impacted as much by location and reference address of a module as it is by the number of modules The I O scan has several basic parts T O Scan Overhead Includes the setup for input and output scan and the selection of the main rack Rack Setup Time Each expansion rack is selected separately because of the addressing of expansion racks on the VME bus This results in a fixed overhead per expansion rack regardless of the number of modules in that rack Per Module Setup Each Series 90 70 I O module has a fixed setup scan time Time Byte Transfer Time The actual transfer of bytes is much faster for modules located in the main rack than for those in expansion racks The byte transfer time differences will be accounted for by using different times for I O modules in the main rack versus expansion racks In addition analog input expander modules the same as Genius blocks have the ability to be grouped into a single transfer as long as consecutive reference addresses are used for modules that have consecutive slot addresses Each sequence of consecutively addressed modules is called a scan segment There is a time penalty for each additional scan segment The following form can be used for computing I O module sweep impact The calculation contains times for analog input expanders that are either grouped into the same scan segment as the preceding module or are grouped in a separate new scan segment The sweep impact t
71. 07 Addition of or extra I O module fault Fault Action 02 Diagnostic fault Fault Category 03 Fault category 03 is an addition of block Fault Type 00 No fault type data occurs for an Addition of Block fault The 00 is meaningless Fault 00 No fault description information is given Description Fault Specific 80 GBC reported an added device Only 1 byte of fault specific data is Data significant The bus controller in slot 4 in the main rack received data from the device at serial bus address 30 indicating that the device was again on the bus From the configuration table stored from your programming software to the PLC CPU the CPU determined that the first point on the device was QI0001 The fault type and fault description are not meaningful on this fault The fault specific data contains a byte from the GBC echoing the fault Appendix B Interpreting Faults B 31 02 1F0100 0004011EFF7F 0702 03 00 00 a Fault Specific Data Fault Description Fault Type Fault Category Fault Action Fault Group Point Block I O Bus Slot Rack Reference Address Long Short B 32 Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B GFK 1192B Loss of IOC I O Controller The Loss of IOC fault is explained below All values are in hexadecimal Field Value Description Long Short 02 This fault contains up to 5 bytes of fault specific
72. 2 10 Constant Window 2 10 Microcycle 2 10 Normal Sweep PLC system operation Point faults 3 9 Power down sequence 2 67 2 68 2 70 microcycle 2 67 Power up self test 2 68 Power up sequence 2 68 I O system initialization 2 70 option module dual port interface tests option module self test completion PLC memory validation power up self test 2 68 system configuration 2 69 Privilege levels 2 75 Program block examples of using program blocks 2 27 how blocks are called 2 30 main program block 2 26 nesting 2 29 parameterized subroutine block program blocks and local data 2 31 2 32 user defined function block Program blocks size restrictions 2 27 Program organiation and user data user references 2 11 Program organization and user data floating point numbers D 1 Program register references P 2 11 Program scheduling 2 52 Index 5 Index Index 6 Program structure how blocks are called 2 30 how parameterized subroutine blocks are called 2 33 1 O triggered interrupt programs 2 63 2 64 main program block 2 26 parameterized subroutine block program blocks and local a 2 32 timed interrupts 2 62 triggered interrupt blocks user defined function block 2 32 Programmer communications window Programmer sweep impact time A 12 Programming scheduling modes 2 51 2 52 1 O triggered 2 51 Ordered periodic Timed 2 51 Protection level request 2
73. 2 Minutes 3 Hours 4 Day of the month 5 Month 6 Year GFK 1192B Appendix B Interpreting Faults B 15 B 16 Genius Block I O Type Mismatch Example The Genius Block I O Type Mismatch fault entry is explained below All data is in hexadecimal Field Value Description Long Short 00 This fault contains 8 bytes of fault extra data Rack 00 Main rack rack 0 Slot 03 Slot 3 In this configuration slot 3 contains a Genius Bus Controller Task 01 Single channel bus controller has only one task Fault Group OB System Configuration Mismatch fault Fault Action 02 Diagnostic fault Error Code 04 Error code 04 in the System Configuration Mismatch group is a Genius Block I O Type Mismatch Fault Extra Data IO Type Mismatch error has four bytes of fault extra data 0 FF Flag byte 1 16 Serial bus address 16 hex is 22 decimal 2 01 Installed module type 01 is an inputs only module 3 04 Configured module I O type 04 is a combination module The configuration file stored from the programming software shows that the device at serial bus address 22 is a combination mixed module However the Read ID Reply message the Genius Bus Controller received from the device at serial bus address 22 shows that the device is configured for inputs only The Genius Bus Controller logged this fault when it detected the mismatch 00 000080 00030100 0B02 0400 FF16010400000000 ce Fault Extra Data E
74. 24 48Vdc 16 point Proximity Sink Block 72 48 Phase B 24Vdc 16 point Proximity Sink Block 73 49 Phase B 24 48Vdc 16 point Source Block 73 49 Phase B 24Vdc 16 point Proximity Source Block 74 4A Phase B 12 24Vdc 32 point Sink Block 75 4B Phase B 12 24Vdc 32 point Source Block 76 4C Phase B 12 24Vdc 32 point 5V Logic Block TI 4D Phase B 115Vac 16 point Quad State Input Block 78 4E Phase B 12 24Vdc 16 point Quad State Input Block 79 4F Phase B 115 230Vac 16 point Normally Open Relay Block 80 50 Phase B 115 230Vac 16 point Normally Closed Relay Block 81 51 Phase B 115Vac 16 point AC Input Block 82 52 Phase B 115Vac 8 point Low Leakage Grouped Block 127 7F Genius Network Adapter GENA 131 83 Phase B 115Vac 4 input 2 output Analog Block 132 84 Phase B 24Vdc 4 input 2 output Analog Block 133 85 Phase B 220Vac 4 input 2 output Analog Block 134 86 Phase B 115Vac Thermocouple Input Block 135 87 Phase B 24Vdc Thermocouple Input Block 136 88 Phase B 115Vac RTD Input Block 137 89 Phase B 24 48Vdc RTD Input Block 138 8A Phase B 115Vac Strain Gauge mV Analog Input Block 139 8B Phase B 24Vdc Strain Gauge mV Analog Input Block 140 8C Phase B 115Vac 4 input 2 output Current Source Analog Block 141 8D Phase B 24Vdc 4 input 2 output Current Source Analog Block B 12 Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B If the model number is 7FH Genius Network Adapter the block may be one of the following The GENA A
75. 3 Table A 1 Instruction Timing Continued Enabled Disabled Increment Function 924 914 781 782 731 732 924 914 781 782 731 732 924 914 781 782 731 732 Group Function 925 915 788 789 771 772 925 915 788 789 771 772 925 915 788 789 771 772 Size 25 2 5 6 5 13 2 2 25 5 D Control JUMP FOR NEXT MCR ENDMCR Combined DOIO DOIO with ALT SUSIO COMMREQ CALL RETURN LD CALL RETURN SFC CALL RETURN PSB CALL RETURN External Block PIDISA PIDIND VMERD BYTE VMERD WORD VMEWRT BYTE VMEWRT WORD VMERMW VMETST VME_CFG_RD VME_CFG_WRT SVCREQ 1 2 3 4 oee CERT ETT eee Note 1 Time in microseconds is based on Release 5 0 of Logicmaster 90 70 software For information not available when this manual was being printed represented by a dash refer to the IPI for each CPU For table functions increment is in units of length specified For bit operation functions microseconds bit For data move functions microseconds the number of bits or words Enabled time is for single length units of type R COMMREQ time has been measured between CPU and EX7 with NOWAIT option DOIO is the time to output values to discrete output module Yn wp A 4 Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Table A 1 Instruction Timing Continued Enabled Disabled ss Increment Increment
76. 66 PLC Run Outputs Enabled Run Outputs Disabled Stop IO Scan and Stop No IO Scan 6 Power Up and Describes the three parts of system power up including 2 68 Power Down Sequences power up self test PLC operation initialization and system configuration the power down sequence and the retention of data memory d Clocks and Timers Describes the elapsed time clock time of day clock and 2 72 watchdog timers 8 System Security Describes protection level request from the programmer 2 74 including password assignment and block lock OEM protection and password and the write protect keyswitch 9 Series 90 70 PLC I O Describes I O data mapping and diagnostic data 2 77 System 2 1 2 2 Section 1 Basic PLC Sweep Summary The user program s in the Series 90 70 PLC execute in a repetitive fashion until stopped by a command from the programmer or a command from another device In addition to executing the user program s the PLC obtains data from input devices sends data to output devices performs internal housekeeping services the programmer services other communications and performs self tests The sequence of operations necessary to execute these components one time is called a sweep This section summarizes the sweep phases for more detailed information refer to section 4 of this chapter Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Basic PLC Sweep GFK 1192B There are seven major phase
77. 7 to AQ1 Further output scans will output a 7 to AQ Note Remember that standalone C programs are truly separate programs They do not have access to memory types local to an LD program L and P The internal or local data used in a standalone C program should not be confused with L and P data Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Standalone C Programs and Local Data Standalone C programs do not have a local data copy provided by the PLC Similarly they are not able to access P memory of an LD program nor can they access any L memory associated with a block within an LD program Standalone C programs do have local data that is declared within the C source file s used to create the standalone C program Refer to the C Programmer s Toolkit User s Manual GFK 0646 for further information Local Data Initialization When a standalone C program is stored to the PLC a copy of its internal data is saved This data is used to reinitialize the program s data area whenever the PLC transitions from Stop to Run GFK 1192B Chapter 2 System Operation 2 41 2 42 Referencing I O Specification Data Within a Standalone C Program Several new C macros used to define and access input and output specification data are defined for standalone C programs Refer to the C Programmer s Toolkit User s Manual GFK 0646 revision C or later for information regarding referencing
78. 75 PSB 2 27 R References user 2 11 G references and CPU memory 2 14 analog input register references AT 2 11 analog output register references AQ 2 11 associated transitions and overrides data scope data types 2 17 discrete references 2 12 global data references G 2 12 input references I 2 12 internal references M 2 12 local register references L output references Q 2 12 program register references P 2 11 register references size and default 2 13 system fault references 3 3 system register references R 2 11 system status references 2 18 system status references S J 2 12 system status fault references temporary references T 2 12 Register references 2 11 analog input register references AT 2 11 analog output register references AQ 2 11 global data references G input references 1 2 12 internal references M 2 12 local register references L output references Q 2 12 program register references P 2 11 size and default 2 13 system register references R system status references cokel temporary references T 2 12 Retention of data memory across power failure 2 71 Retentiveness of logic and data 2 15 Revisions to this manual RLD v standalone C programs 2 43 Run stop operations 2 66 run outputs disabled run outputs enabled 2 66 stop IO scan 2 66 stop No I
79. 9 Overhead Sweep Impact Time This part of the appendix contains overhead timing information for the Series 90 70 PLC CPU This information can be used in conjunction with the estimated logic execution time to predict sweep times for each of the Series 90 70 CPUs The information in this section is made up of a base sweep time plus sweep impact times for each of the CPU models 731 732 771 772 781 782 914 915 924 925 928 and 935 The predicted sweep time is computed by adding the sweep impact time s the base sweep and the estimated logic execution time Two examples of predicting sweep times are provided at the end of this appendix Sweep impact times are composed of four basic sections 1 Programmer communications sweep impact 2 TO Scan and fault sweep impact 3 Ethernet Global Data sweep impact 4 Intelligent Option Module PCMs and LAN modules sweep impact 5 I O interrupt performance and sweep impact Each of these sections describes the functions and provides tables with the corresponding times for each CPU model The information in these tables may be used to predict sweep time based on a given configuration What the Tables Contain A 10 The following tables contain sweep impact times for overhead functions for the Series 90 70 PLC Base sweep time is the time for an empty _MAIN program block to execute with no configuration stored and none of the windows active The rest of the timing values are given as sweep i
80. 90 PLC Any I O fault Indicates a new entry in the PLC fault table Indicates a new entry in the I O fault table Any hardware fault Any software fault Chapter 2 System Operation 2 21 2 22 Table 2 11 Configurable Fault References Configurable Fault References Default Action SBUS_ER diagnostic Description System bus error The BSERR signal was generated on the VME system bus HRD_CPU fatal PLC CPU hardware fault such as failed memory device or failed serial port HRD_SIO diagnostic Non fatal hardware fault on any module in the system such as the failure of a serial port on a PCM SFT_IOC diagnostic Non recoverable software error in a Genius Bus Controller SFT_SIO diagnostic Non recoverable software error in a PCM or LAN interface module PB_SUM fatal Program or block checksum failure during power up or in Run mode LOW_BAT diagnostic Low battery signal from CPU or another module in the system OV_SWP diagnostic Constant sweep time exceeded SY_FULL IO_FULL diagnostic PLC fault table full configurable with a default of 16 entries T O fault table full configurable with a default of 32 entries APL_FLT diagnostic Application fault LOS_RCK diagnostic Loss of rack BRM failure loss of power or missing a configured rack LOS_IOC diagnostic Loss of Bus Controller channel or missing a configured B
81. Bus Controller and TCP IP Ethernet modules At the start of the System Communications Window the CPU will complete any previously unfinished request before executing any pending requests in the queue When the time allocated for the window expires processing stops The System Communications Window defaults to Run to Completion mode This means that all currently pending requests on all intelligent option modules are processed every sweep A different mode can be configured and stored to the PLC or it can be changed online using your programming software Time and execution of the System Communications Window can also be dynamically controlled from the user program using Service Request function 4 This allows communications functions to be skipped during certain time critical sweeps The System Communications Window time can be set to a value from 0 to 255 milliseconds Background Window A CPU self test is performed in this window Included in this self test is a verification of the checksum for the 90 70 CPU operating system software The Background Window time defaults to 0 milliseconds A different value can be configured and stored to the PLC or it can be changed online using your programming software Time and execution of the Background Window can also be dynamically controlled from the user program using Service Request function 5 This allows background functions to be skipped during certain time critical sweeps Windo
82. C maintains two fault tables the I O fault table for faults generated by I O devices including I O controllers and the PLC fault table for internal PLC faults The information in this appendix will enable you to interpret the message structure format when reading these fault tables This is a sample I O Fault Table CURRENT TABLE I0 COMMUNICATIONS STATUS Connected TOP FAULT DISPLAYED 0 TABLE LAST CLEARED 09 17 96 12 37 48 TOTAL FAULTS 1 ENTRIES OVERFLOWED 0 FAULT DESCRIPTION PLC DATE TIME 10 09 96 06 53 59 CIRC REFERENCE FAULT LOCATION NO ADDR CATEGORY I 00081 Loss of IJO Module 10 09 96 06 53 22 40 This is a sample PLC Fault Table CURRENT TABLE PLC COMMUNICATIONS STATUS Connected TOP FAULT DISPLAYED 0 TABLE LAST CLEARED 10 02 96 16 06 03 TOTAL FAULTS 6 ENTRIES OVERFLOWED 0 PLC DATE TIME 10 09 96 10 42 52 FAULT DESCRIPTION Null system configuration 10 03 96 Null system configuration 10 03 96 LAN data memory exhausted z 10 03 96 User application fault 10 02 96 Null system configuration 10 02 96 Null system configuration 10 02 96 B 1 Both tables contain similar information e The PLC fault table contains oO Oo Oo Fault location Fault description Date and time of fault e The I O fault table contains oO m m O Oo oO Fault location Circuit number Reference address Fault category Fault type Date and time of fault The Series 90 70 PLC maintains additiona
83. Correction Error Code Name Description Correction Error Code Name Description Correction Error Code Name Description 1 Indirect Address Out of Range The PLC generates this error when one of the parameters to a function block is an indirect reference that is the parameter is an address within that memory type which contains the parameter value and the contents of the indirect reference are out of range for the memory type For example consider a system with 500 R registers defined This fault would be generated if the parameter address were R00100 and the contents of R00100 were greater than 500 or zero The Fault Extra Data field contains in the first two bytes the offset address of where the call was made the segment selector and offset reference in the next four bytes and the name of the program or block in which the function call resides in the next eight bytes 1 Correct the indirect reference 2 Increase the number of registers available if possible 2 Software Watchdog Timer Expired The PLC generates this error when the watchdog timer expires The PLC CPU stops executing the user program and enters Stop mode The only recovery is to cycle power to the PLC CPU Examples causing timer expiration Looping via jump very long program etc 1 Determine what caused the expiration logic execution external event etc and correct 2 Use the system service function block t
84. E N E EEE EE OE EEA EEE N EE eas 3 11 Balt Actin ARAARA AARAA AARAA AAA AAAA AAAA AAAA AAAA 3 12 Fa lt Response eorr oopen eee entree reine VE o PEE E Ur O Per ONPE OPU EE etter te te 3 12 PELC Faut Taba ea 3 13 TO Fault Tablesnennnnnnninnnnn ninni a irarri aan 3 14 Wser Defined EET A EE E A E ETE 3 15 Accessing Additional Fault Information c ccccccccseeseneecnneceeeeeeeeeeenneeeeeeeeeeees 3 16 Section 3 PLC Fault Table Explanations ccssssssssssscccssssssssssseceeeees 3 17 Configurable Faults aea kana enn aial 3 18 Loss of or Missing Rack arisane o in a e eN EE E E ES 3 18 Loss of or Missing Option Module ssseeeeeeeeeeeeeseeesesrerssrresssrrerssrrersssreerserreeseres 3 19 Addition oror Eia Rat kisss noada d Sonn na ERUR UR OEEO O ROE O Bette 3 21 Reset of Addition of or Extra Option Module 200 000 ecceceeeceeccceeeeeeeeeneeeeeeeeeeeees 3 21 System Configuration Mismatch eeeesseeeeeesseesssreesssrresssrrerssrrerssreessrreerssrresssree 3 22 System Bus SEKO s ss3s5s2 6s0cdecededssasadadncacedhasdsbadasecadsl A A 3 25 Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B GFK 1192B Contents PLC CPU Hardware Falluinn roon e e Es E E E ES E EE E er 3 26 Module Hardware FE E a E E E E RES 3 26 Option Module Software Failure seeeeeeeeseeeeeeeesesreererssrrerssrrerssrreesssreerssrresssrees 3 27 Program or Block Checksum Failure ecsecceeessceceecessseee
85. E aeeieielaaeiess 2 36 v Contents vi How External Blocks Are Called ccccccccececseesnneeceeeeeeeeeeneeeeeeeeeseesennaeeeeeeeeeeees 2 36 External Blocks and Local Data ii eienaar 2 37 Local Data Initial Zationissecccs eeccectyecoys tyeetytecpecezecctecesccgoceecctyeetsecdyecteccdgt teed tctetes 2 37 Standalone Propsrams ics eis coszis ss voectnessaestoessaesinescusvtuescyostnensessinstceesiucnseesiues nesinercens 2 38 Data Encapsulation csss ccccc icicle n ch cieececnedie iicnesvecicesouscncesousciseveuscuresrobsete 2 38 Input Output Specifications eeeesessseecsneecsseecsseeceseeeseeceseeeesaeecsaeesseeeneers 2 39 Standalone C Programs and Local Data cc eeeeeeeeessceecesssceeceesneeeceesnaeeseesaeees 2 41 Local Data Initialization sinear A E E A EE 2 41 Referencing I O Specification Data Within a Standalone C Program 2 42 Data Coherency of I O Specifications eseeeseeeeeseeesreesrrertserererreresrrrerererrssrreeee 2 42 Using LD vs Standalone C Programs ssessesssesssessesrssressersresseresseessersseeeseres 2 43 Differences in Operation LD and Standalone C Programs eeeeeeeeerreeeereeeeree 2 43 R tentiveness of Datace n week eh a ee a e eds Aa E E 2 43 Global Data cr er Pe i re ee S 2 44 Interrupt EXe Cution sees kerpeten an eonidas oere eiee enetan p eenei T Snae Ee e 2 44 Queuing of Interrupts earn eE E E A EE E EE E 2 44 System Status ReferenCes isc c sc0 vk escst eves testevegheed
86. Error Code Name Description Correction Error Code Name Description Correction 1 Rack Lost The PLC generates this error when the main rack can no longer communicate with an expansion rack The error is generated for each expansion rack that exists in the system 1 Power off the system Verify that both the BTM and the BRM are seated properly in their respective racks and that all cables are properly connected and seated 2 Replace the cables 3 Replace the BRM 4 Replace the BTM 2 Rack Not Responding The PLC generates this error when the configuration file stored from the programmer indicates that a particular expansion rack should be in the system but none responds for that rack number 1 Check rack number jumper behind power supply first on missing rack and then on all other racks for duplicated rack numbers 2 Update the configuration file if a rack should not be present 3 Add the rack to the hardware configuration if a rack should be present and one is not 4 Power off the system Verify that both the BTM and the BRM are seated properly in their respective racks and that all cables are properly connected and seated 5 Replace the cables 6 Replace the BRM 7 Replace the BTM 3 18 Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Loss of or Missing Option Module The fault group Loss of or Missing Option Module occurs when a GEnet
87. Error Code Name Description Correction Error Code Name Description Correction Error Code Name Description Correction Error Code Name Description Correction Error Code Name Description Correction 2 Genius I O Block Number Mismatch The PLC generates this fault when the configured and physical Genius I O blocks have different model numbers 1 Replace the Genius I O block with one corresponding to the configured module 2 Update the configuration file 4 T O Type Mismatch The PLC generates this fault when the physical and configured I O types of Genius grouped blocks are different Remove the indicated Genius module and install the module indicated in the configuration file Update the Genius module descriptions in the configuration file to agree with what physically installed Daughter Board Mismatch The PLC generates this error when the configuration file indicates one size memory daughter expansion board should be on the PLC CPU and a different size is actually present Replace the module Replace the daughter board with the size indicated in the configuration file Update the configuration file to agree with the size of the daughter board actually installed on the PLC CPU Analog Expander Mismatch The PLC generates this error when the configured and physical Analog Expander modules have different model numbers 1 Replace the Analog Expande
88. FLT 5 contacts can be used to detect the presence of various faults in the system These contacts can not be overridden The following table shows the state of fault and nofault contacts aun NORA Fault Present ON OFF Fault Absent OFF ON Fault Locating References Rack Slot Bus Module GFK 1192B The Series 9070 PLC supports reserved fault names for each rack slot bus and module if the hardware is configured By programming these names on the FAULT and NOFLT contact instructions logic can be executed to locate faults associated with configured racks and modules Format of Fault References Table 3 4 Fault Reference Names Type Name Bus BUS_rsb Where r is rack number 0 to 7 s is slot number 0 to 9 and Genius only b is the Genius bus number or 2 M_rsbmm Where r is rack number 0 to 7 s is slot number 0 to 9 b is Genius only the Genius bus number 1 or 2 and mm is the Serial Bus Address SBA number 00 to 31 FIP Module F_rsmmm Where r is rack number 0 to 7 s is slot number 0 to 9 and FIP only mmm is the FIP station address 000 to 255 These fault names can only be programmed on the FAULT and NOFLT contacts The reserved fault names are always available It is not necessary to enable a special option such as point faults These fault names do not correspond to SA SB SC or to any other reference type Only the name is displayed A reference table screen is not provided for the fault references The
89. GENA fault the second byte contains the data that was reported from the GENA module in fault byte 2 of its Report Fault message If the fault type is not a GENA fault the second byte contains the circuit configuration and is encoded as shown in table B 20 Loss Addition of Block In the case of a Loss of Block or Addition of Block fault four bytes of fault specific data are used The first byte is encoded as shown in table B 20 The second byte contains the block configuration and is encoded as shown in table B 20 The third byte specifies the number of input circuits possibly used and the fourth byte specifies the number of output circuits possibly used Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B GFK 1192B Global Memory Fault The Global Memory fault uses 10 data bytes The first byte contains the subnet group number The other nine bytes contain the global variable name formatted as a null terminated string Forced Unforced Circuit Three bytes of fault specific data are present when a circuit force is added or removed Forced circuit or Unforced circuit The first byte contains a code from table B 20 The second byte contains the block configuration and byte 3 contains the discrete analog indication Loss of or Missing IOC When the PLC CPU registers a Loss of or Missing IOC fault it includes in the I O fault specific data one of the codes in table B 20 Other I O Faults In add
90. I O connections to each I O bus on the I O controller and obtaining all I O configuration data from that I O controller This configuration data is compared with the user specified I O configuration and any differences reported in the I O fault table The I O Scanner then sends each I O controller a list of the I O modules to be configured on the I O bus After the I O controllers have been initialized the I O Scanner replaces the factory default settings in all I O modules with any application specified settings For Model 70 input modules the board may be set to interrupt when the signal s change state and whether the interrupt will occur when the signal s transitions from high to low or low to high For Model 70 output modules their default state may be changed from Off to Hold Last State Power Down Sequence System power down occurs when the power supply detects that incoming AC power has dropped for more than one power cycle A signal line on the backplane is driven low to indicate the condition which causes an interrupt to the CPU From the time this signal occurs a minimum of 5 milliseconds remain to complete power down processing Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Retention of Data Memory Across Power Failure Because application RAM and BCP memory are battery backed the following types of data are preserved across a power cycle e Application program e Fault tables and other di
91. IN STOP IOSCAN ONLY EXECUTES ee IN STOP IOSCAN ONLY PROGRAMMER RUNS COMMUNICATIONS lt i TO WINDOW COMPLETION SYSTEM RUNS COMMUNICATIONS OJ To WINDOW COMPLETION BACKGROUND lt i LIMITED WINDOW 10 MS Figure 2 2 CPU Sweep in Stop NolO and Stop IOScan Mode Note Stop IOScan is not supported in Microcycle Sweep mode Chapter 2 System Operation 2 9 PLC Sweep Modes The 90 70 PLC supports four PLC sweep modes Normal Sweep Constant Sweep Constant Window Microcycle Sweep In Normal Sweep mode each PLC sweep can consume a variable amount of time The Logic Window is executed in its entirety each sweep The Communications and Background Windows can be set to execute in a Limited or Run to Completion mode In Constant Sweep mode each PLC sweep begins at a user specified Constant Sweep time after the previous PLC sweep began The Logic Window is executed in its entirety each sweep If there is sufficient time at the end of the sweep the PLC will alternate among the Communications and Background Windows allowing them to execute until it is time for the next sweep to begin In Constant Window mode each PLC sweep can consume a variable amount of time The Logic Window is executed in its entirety each sweep The PLC will alternate among the Communications and Background Windows allowing them to execute for a time equal to the user specified Constant Window timer In Microcycle Sweep mode like Constant Sweep
92. K words reference Maximum R 1K 16K words 16K words 16K words 16K words 16K words 16K words word increments Maximum L per 8K words 8K words 8K words 8K words 8K words 8K words block Maximum P 8K words 8K words 8K words 8K words 8K words 8K words Total number of physical input and output points together cannot exceed 352 points This corresponds to approximately 100 redundant points Refer to Chapter 1 of GFK 1277 for more information gt Prior to Release 6 of Logicmaster the programming software restricted the total I and Q to the limit shown individually for each For example when using previous programming packages with a 782 CPU there was a maximum of 12288 points of 1 and Q combined This restriction no longer exists with the newer versions of Logicmaster Table 2 5 Default Memory Sizes CPU Model Memory 935 928 780 78 1 782 Type 925 915 790 924 914 788 789 781 782 771 772 731 732 AI 64 words 64 words 64 words 64 words 64 words 64 words PAQ 64 words 64 words 64 words 64 words 64 words 64 words R 1024 words 1024 words 1024 words 1024 words 1024 words 1024 words P 0 words 0 words 0 words 0 words 0 words 0 words L 0 words 0 words 0 words 0 words 0 words 0 words Chapter 2 System Operation 2 13 G User References and CPU Memory Locations The Series 90 70 CPU contains only one data space for all of the global data references G GA GB GC GD and GE The inter
93. LC fault table it places a 7F in the task byte of the fault Fault Group 16 User Application fault Fault Action 01 Informational fault Error Code 04 Error code 04 in the Application Fault group is a Bad Genius Bus Request This fault occurs when the Genius Bus Controller receives a Read or Write Device datagram from another device on the Genius Bus that cannot be successfully completed Fault Extra Data Bad Genius Bus Request error has eight bytes of fault extra data 0 FF Flag byte O 1D Serial bus address 1D hex is 29 decimal 2 20 Function code in the datagram a GE Fanuc datagram 3 1E Subfunction code in the datagram a Read Device 4 08 Segment selector 08 is R memory 5 FF Least significant byte of offset 6 FF Most significant byte of offset 7 03 Length of data to read 3 words The Genius Bus Controller received a Read Device datagram from serial bus address 29 which requested three words of R memory be read starting at R65536 Since this is beyond the range of the largest value R can have the bus controller registered an informational user application fault in the PLC fault table 00 F28407 00037F00 1601 0400 FF1D201E08FFFF03 Fault Extra Data Error Code Fault Action Fault Group Task Slot Rack Spare Long Short Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B 1 0 Fault Table GFK 1192B The following diagram identifies the hexadecimal informatio
94. O scan 2 66 S Scheduling modes 2 51 2 52 O triggered ordered periodic timed scheduling programs 2 52 Security system 2 74 privilege levels Self test V O system initialization 2 70 option module dual port interface tests option module self test completion power up self test 2 68 Series 90 70 PLC I O system 2 77 analog I O diagnostic data 2 82 discrete I O diagnostic information 2 82 FIP 1 0 Genius I O data mapping 2 78 Standalone C programs data encapsulation 2 38 internal data Standalone C v RLD programs 2 43 STOP mode 2 9 Sweep impact Ethernet global data A 23 Sweep PLC 2 2 application program task execution programmer communications window STOP mode 2 9 system communications window 2 7 SYS_FULL 2 19 System communications window 2 7 System configuration 2 69 System fault references hardware faults other faults software faults System operation Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B clocks and timers 2 72 passwords 2 74 power down sequence 2 68 2 70 power down sequence with microcycle mode Per power up sequence 2 68 PSection 1 Basic PLC Sweep SummaryLC sweep summary ai of data memory across power failure 2 71 Series 90 70 PLC I O system 2 77 system security 2 74 System register references R 2 11 System status se Orr differences w
95. Relational EQ INT EQ DINT NE INT NE DINT GT INT GT DINT GE INT GE DINT LT INT LT DINT LE INT LE DINT CMP INT CMP DINT RANGE INT RANGE DINT Bit AND WORD Operation AND DWORD OR WORD OR DWORD XOR WORD XOR DWORD NOT WORD NOT DWORD MCMP WORD MCMP DWORD SHL WORD SHL DWORD SHR WORD SHR DWORD ROL WORD ROL DWORD ROR WORD ROR DWORD BTST WORD BTST DWORD BSET WORD BSET DWORD BCLR WORD BCLR DWORD MOVE BIT BPOS WORD BPOS DWORD SHER BIT Time in microseconds is based on Release 5 0 of Logicmaster 90 70 software For information not available at print time for this manual represented by a dash refer to the IPI for that CPU For table functions increment is in units of length specified For bit operation functions microseconds bit For data move functions microseconds the number of bits or words Enabled time is for single length units of type R COMMREQ time has been measured between CPU and EX7 with NOWAIT option DOIO is the time to output values to discrete output module a w RRUBRKRHKRKRHRUNWTUAUNUAY A Note pprt E a A 2 Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Table A 1 Instruction Timing Continued Enabled Disabled Increment Function 924 914 781 782 731 732 924 914 781 782 731 732 924 914 781 782 ae Group Function 925
96. S S Complement INT data type is 32768 to 32767 16 1 value DINT Double Double precision integers are stored in 32 bit data memory Register 2 Register 1 Precision locations two consecutive 16 bit memory locations and are SE ee Integer always signed values bit 32 is the sign bit The valid range of a 32 Binary vane f DINT data type is 2147483648 to 2147483867 REAL Floating Real numbers use 32 consecutive bits two consecutive 16 bit Register 2 Register 1 Point memory locations The range of numbers that can be stored in this format is from 1 401298E 45 to 3 402823E 38 Refer to 32 IEEE fo tenet 1 Appendix D Using Floating Point Math for IEEE format BCD 4 Four Digit Four digit BCD numbers use 16 bit data memory locations Each Register 1 Binary Coded BCD digit uses four bits and can represent numbers between 0 4 BCD digits Decimal and 9 This BCD coding of the 16 bits has a legal value range of 13 9 5 1 0 to 9999 BCD 8 Eight Eight digit BCD data types use two consecutive 16 bit data Reaister 2 Reaister 1 Digit Binary memory locations 32 consecutive bits Each BCD digit uses 4 8s 7 6e 5 lalala 1 Coded bits per digit to represent numbers from 0 to 9 The complete 32 29 25 21 17 16139 5 1 Decimal valid range of the 8 digit BCD data type is 0 to 99999999 8 BCD digits MIXED Mixed A Mixed data type is available only with the MUL and DIV 16 16 32 functions The MUL function takes two integer inputs and a
97. Software Users November 1999 GFK 1192B Module Fault The fault category Module Fault has one fault type one headend fault and eight fault descriptions No fault specific data is present The default fault action for this category is Diagnostic Name Description Correction Name Description Correction Name Description Correction Name Description Correction Name Description Correction Name Description Correction Configuration Memory Failure The Genius Bus Controller generates this error when it detects a failure in a Genius block s EEPROM or NVRAM Replace the Genius block s electronics module Calibration Memory Failure The Genius Bus Controller generates this error when it detects a failure in a Genius block s calibration memory Replace the Genius block s electronics module Shared RAM Fault The Genius Bus Controller generates this error when it detects an error in a Genius block s shared RAM Replace the Genius block s electronics module Watchdog Timeout The PLC generates this error when it detects that a Model 70 input module watchdog timer has expired Replace the Model 70 input module Output Fuse Blown The PLC generates this error when it detects a blown fuse on a Model 70 output module 1 Determine and repair the cause of the fuse blowing and replace the fuse 2 Replace the module Module Fault An internal failure has been dete
98. act is linear as the program block gets larger High Priority There are several programmer high priority requests change PLC mode includes Request ALT R read constant sweep state time read window times change constant sweep Parallel only state time and change window times Unlike the other programmer service requests which are serviced inside the programmer communications window high priority requests interrupt the sweep and are serviced asynchronously at the time they are issued by the programmer The worst case high priority request is monitoring changing the window times This time is shown below GFK 1192B Appendix A CPU Performance Data A 13 I O Scan and I O Fault Sweep Impact The I O scan sweep impact has two parts Series 90 70 I O and Genius I O The equation for computing I O scan sweep impact is VO Scan Sweep Impact LI O Scan Overhead Series 90 70 O Scan Genius I O Scan The following table shows the I O scan overhead in milliseconds for each CPU Table A 5 1 0 Scan Overhead CPX CPX 924 914 CPX 781 782 oe 731 732 CPU Model 935 928 925 915 782 788 789 771 772 Times are in milliseconds For information not available when this manual was being printed represented by a dash refer to the IPI for each CPU Note T O scan overhead impacts the sweep continuously Sweep Impact of Series 90 70 I O Modules The I O scan of the Series 9
99. agnostic data e Checksums on programs and blocks e Override data e Data in register R local register L and program register P memory e Data in analog memory AI and AQ e State of discrete inputs I e State of retentive discrete outputs Q e State of retentive discrete internals M e State of discrete system internals system bits fault bits reserved bits The following types of data are not preserved across a power cycle e State of discrete temporary memory T e M and Q memories used on non retentive coils GFK 1192B Chapter 2 System Operation 2 71 Section 7 Clocks and Timers Clocks and timers provided by the Series 90 70 PLC include an elapsed time clock a time of day clock and software and hardware watchdog timers Three types of timer function blocks include an on delay timer an off delay timer and a start reset timer Timed contacts cycle on and off in square wave form every 0 01 second 0 1 second 1 0 second and 1 minute Elapsed Time Clock The elapsed time clock uses 100 microsecond ticks to track the time elapsed since the CPU powered on The clock is not retentive across a power failure it restarts on each power up Once per second the hardware interrupts the CPU to enable a seconds count to be updated This seconds count rolls over seconds count returns to zero approximately 100 years after the clock begins timing Because the elapsed time clock provides the base for s
100. aken by CPU Code Informational Log fault in fault table Diagnostic Log fault in fault table 2 Set fault references Fatal Log fault in fault table 3 Set fault references Go to Stop mode Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Error Code The error code further describes the fault Each fault group has its own set of error codes The first table below shows error codes for the PLC Software Error Group Group 87H Table B 3 Alarm Error Codes for PLC CPU Software Faults Hexa Name Decimal decimal 20 14 Corrupted PLC Program Memory 39 27 Corrupted PLC Program Memory 82 52 Backplane Communications Failed 90 5A User Shut Down Requested 123 7B Remote I O Scanner Communications Failure 149 95 Store from Flash on Power Up Failed Note The first byte of the Fault Specific Data describes why the store from flash failed Fault Specific Error Data Value Description DEVICE_NOT_ AVAILABLE CF Specific device is not available in the system BAD_DEVICE_ CC Data stored on device has been corrupted DATA and is no longer reliable Or Flash Memory has not been initialized DEVICE_RW_ CB Error occurred during a read write of the ERROR Flash Memory device FLASH_ 8E Data in Flash Memory is incompatible with INCOMPAT_ the PLC CPU firmware release due to the ERROR CPU firmware revision numbers the instruction groups supported or the CPU mode
101. an execute during any phase of the PLC sweep regardless of the current PLC sweep mode Pending Timed Interrupt blocks will execute before pending I O Interrupt blocks but once an Interrupt block Timed or I O begins executing it will run until it completes If an interrupt occurs which attempts to execute a Timed or I O Interrupt block which has not fully completed execution due to a previous interrupt the interrupt will be queued and the block will be executed again after the Interrupt block completes execution If an Interrupt block has already been queued in this manner once any additional interrupts that occur for this block will be ignored Upon receipt of the Interrupt Timed or I O Triggered programs are immediately scheduled to begin execution including the copying of the input specification However the actual execution of the program occurs on a priority basis Unlike Interrupt blocks the execution of Timed or I O Triggered programs can be delayed or preempted by other Timed or I O Triggered programs of a higher priority as well as other Interrupt blocks Additionally if an interrupt occurs which attempts to schedule a Timed or I O Triggered program which has not fully completed execution due to a previous interrupt a Program not Readied application fault will be logged in the PLC fault table and the interrupt will be ignored When the PLC is in Normal Sweep Constant Sweep or Constant Window mode Interrupt programs can exec
102. an interrupt declaration The figure below shows two I O interrupt declarations The trigger ST_BUT calls LD block INT1 if the input from a stop button wired to input transitions in the configured direction The module can be configured to generate the interrupt on a rising edge or a falling edge of the input The LD block INT2 is triggered by AIO0009 ST_BUT gt INTI LANG LD Al00009 gt INT2 LANG LD Figure 2 11 I O Interrupt Block Declarations GFK 1192B Chapter 2 System Operation 2 61 Note Parameterized subroutine blocks PSBs with zero parameters and External blocks C blocks and C FBKs with zero parameters may also be triggered by an interrupt input Zero parameter subroutine blocks are called SUBRs in Control For these types of blocks the local data L is inherited from the _MAIN local data P for example LO005 P0005 Timed Interrupt Blocks A block may be executed on a user specified time interval with an initial delay if specified applied on a Stop to Run transition of the PLC In Control the time base is 0 001 second abbreviated msec within the Task Definitions dialog box To program a Timed Interrupt block the block must first be declared It must then be associated with a timed interrupt and given an interval and initial delay through the use of an interrupt declaration The first execution of a Timed Interrupt block will occur at DELAY
103. applications for errors Replace the battery on the PLC CPU Replace the expansion memory board on the PLC CPU Replace the PLC CPU Illegal Boolean OpCode Detected The PLC generates this error when it detects a bad instruction in the user program 1 2 3 4 6 Restore the user program and references if any Examine any C applications for errors Replace the expansion memory board on the PLC CPU Replace the PLC CPU Corrupted Remote I O Scanner EEPROM The configuration in the Remote I O Scanner EEPROM was found to be corrupted at powerup Restore the Remote I O Scanner configuration GFK 1192B Chapter 3 Fault Explanation and Correction 3 33 3 34 Window Completion Failure The fault group Window Completion Failure is generated by the prelogic and endofsweep processing software in the PLC The fault extra data contains the name of the task that was executing when the error occurred The default fault action for this group is Informational Error Code 0 Name Window Completion Failure Description The PLC generates this error when the PLC is operating in Constant Sweep mode and the constant sweep time was exceeded before the programmer window had a chance to begin executing Correction Increase the constant sweep timer value Error Code 1 Name Logic Window Skipped Description The logic window was skipped due to lack of time to execute Correction 1 Increase base cycle time 2 Reduce Com
104. ared or when the PLC is power cycled SY_PRES SCO0012 Indicates the presence of at least one entry in the PLC fault table Cleared when the PLC fault table is cleared IO_PRES SC0013 Indicates the presence of at least one entry in the I O fault table Cleared when the I O fault table is cleared HRD_FLT SC0014 Set when a hardware fault occurs Cleared when both fault tables are cleared or when PLC is power cycled SFT_FLT SC0015 Set when a software fault occurs Cleared when both fault tables are cleared or when PLC is power cycled These bits are set or reset during the input scan of the sweep following the one in which the change occurs Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B System Fault References When a system fault reference is set additional fault references are also set The following table lists these other types of faults References marked with asterisks below are configurable system fault references Table 3 1 System Fault References Fault Type PLC System Fault SY_FLT T O Fault IO_FLT Hardware SBUS_ER System bus error HRD_CPU PLC CPU hardware fault HRD_SIO Module hardware fault SBUS_FL System bus failure Fault HRD_FLT Software Fault spr sio Option module software fault SFT_IOC Bus Controller software fault SFT_FLT SFT_CPU PLC software fault MAX_IOC Too many Bus Controllers STOR_ER Programmer download failed Other Faults PB_SUM block che
105. at may be used in an application program When entering logic either the reference or the nickname can be used Refer to Chapter 3 Fault Explanation and Correction for more detailed fault descriptions and information on correcting faults While it is possible to use these special names in another context their use is restricted for example you cannot use them as a block name or folder name Note Most references not listed in the following table for example S0002 are not used for the Series 90 70 PLC Products that have Genius Modular Redundancy CPU788 CPU789 and CPU790 have additional references as do the CPU780 CGR772 and CGR935 with CPU redundancy Refer to GFK 1277 for status references for Genius Modular Redundancy GMR GFK 0827 for Hot Standby CPU Redundancy and GFK 1427 for Enhanced Hot Standby CPU Redundancy Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B GFK 1192B Table 2 9 System Status References S0121 SA0001 Reference Name Definition S0001 FST_SCN Current sweep is the first sweep in which the LD or standalone C program executed Set the first time the user program is executed after a Stop Run transition and cleared upon completion of its execution S0003 T_10MS 0 01 second timer contact S0004 T_100MS 0 1 second timer contact S0005 T_SEC 1 0 second timer contact S0006 T_MIN 1 0 minute timer contac
106. ational faults forced and unforced circuit no user program on power up 3 32 null system configuration for RUN mode 3 34 password access failure window completion failure 3 34 Input references Jl 2 12 Input scan 2 4 Instruction timing CPU A 1 Intelligent option modules A 25 sweep impact times A 25 Internal references M interrupt handling timed interrupts Interrupt handling standalone programs I O triggered interrupts 2 63 2 64 ESN erupt blocks 2 61 1O_FULL 2 19 L Local register references L 2 11 M Maintenance 3 1 Mapping I O data 2 78 default conditions FIP I O data mapping Genius I O data mapping Memory retention of data memory across power failure ei Memory allocation worksheet C 1 Memory corrupted 3 17 Microcycle program microcycle time exceeded fault 3 29 wind down period 2 67 Microcycle Sweep mode 2 10 Microcycle wind down period Modes of operation run outputs disabled 2 66 run outputs enabled 2 66 stop IO scan 2 66 stop No IO scan 2 66 Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B GFK 1192B N esting 2 29 Non configurable faults 3 6 3 31 Normal Sweep 2 10 Normal sweep mode application program task execution 2 4 programmer communications window system communications window NWORDs in parameterized subroutine block restrictions on formal parameters 2 35 0
107. ations D 5 internal format of floating point numbers D 2 values of floating point numbers D 3 FST_SCN 2 19 G Index 3 Index Index 4 default conditions 2 79 diagnostic data collection Genius I O bus configuration 2 78 Genius I O data mapping 2 78 low level analog blocks 2 79 Genius I O sweep impact times worksheet A 19 Global Data Genius2 14 Global data communications Global data in microcycle mode Global data references G H Housekeeping 2 4 T O data mapping default conditions 2 78 FIP I O data mapping Genius I O data mapping T O fault sweep impact A 14 V O fault table 3 14 B 19 explanations fault action fault address fault category fault description B 25 fault group fault specific data fault time stamp B 29 fault type B 24 T O bus interpreting fault tables long short indicator B 19 point rack B 20 reference address B 19 slot B 20 symbolic fault specific data B 27 I O interrupt performance and sweep impact worksheet A 27 T O module sweep impact times worksheet T O scan sweep impact T O sweep impact times T O system initialization TO system Series 90 70 PLC analog I O diagnostic data 2 82 discrete T O diagnostic information 2 82 FIP 1 0 Genius I O T O data mapping 2 78 1 O triggered interrupt programs 2 63 2 64 1 O Triggered programs Inform
108. ault is logged and the PLC transitions to Stop Fault mode The call depth is guaranteed to be at least four on the 731 and 732 CPUs and eight on all other models The actual call depth allowed depends on the amount of data non boolean flow used in the blocks If less than the 171 word data flow limit is used then more nested calls may be made The call level nesting counts the _MAIN block as level 1 The illustration above shows three levels of calls Note Before a block can be used you need to define it in the block declarations For information on block declarations refer to the documentation of your programming software GFK 1192B Chapter 2 System Operation 2 29 2 30 How Blocks Are Called A block executes when called from the program logic in the _MAIN block or another block l J CALL PBK1 I00500 Q00076 I I I CALL PBK2 In the example above PBK1 will always be called Conditional logic can be used to control calling the block In order for PBK2 to be called both input 100500 and output Q00076 must be ON Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Blocks and Local Data Each block in the LD program can have an associated data block The _MAIN data block is referenced by P all other data blocks are referenced by L The size of the data block is dependent on the highest reference in its block for L and in all blocks for P Appendix C
109. ault table full 3 29 IOC hardware failure loss of block 3 47 loss of I O module 3 46 loss of or missing option module 3 19 low battery signal 3 28 module fault 3 49 module hardware failure PLC system fault table full 3 29 program microcycle time exceeded 3 29 reset of addition of or extra option module 3 21 system bus error 3 25 Diagnostic information discrete 1 0 2 82 Discrete I O diagnostic information Discrete references 2 12 size and default 2 13 Elapsed time clock 2 72 Error code B 7 Ethernet global data sweep impact time Fatal faults communications failure during store 3 36 corrupted user program on power up 3 33 IOC software fault 3 49 loss of 10c 3 45 loss of or missing rack 3 18 option module software failure 3 27 PLC CPU hardware failure PLC CPU system software failure 3 35 program block checksum failure 3 28 run mode store failure system bus failure 3 32 system configuration mismatch 3 22 too many bus controllers 3 36 Fault action diagnostic fault response I O fault action B 22 informational PLC fault action B 6 Fault category B 23 Fault contacts 3 7 Fault description Fault explanation and correction 3 1 accessing additional fault information 3 16 addition of block addition of I O module 3 46 addition of IOC 3 45 addition of or extra rack 3 21 analog fault application fault 3 30 b
110. ble click the fault as it appears in the programming software to access the Details window The last entry Correction for each fault explanation in this chapter lists the action s to be taken to correct the fault Note that the corrective action for some of the faults includes the statement Display the PLC fault table on the programmer Contact GE Fanuc PLC Field Service giving them all the information contained in the fault entry This second statement means that you must tell Field Service both the information readable directly from the fault table and the hexadecimal information Field Service personnel will then give you further instructions for the appropriate action to be taken Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Section 3 PLC Fault Table Explanations Each fault explanation contains a fault description and instructions to correct the fault Many fault descriptions have multiple causes In these cases the error code and additional fault information are used to distinguish among different fault conditions sharing the same fault description The error code is the first two hexadecimal digits in the fifth group of numbers as shown in the following example 01 000000 01030100 0902 0200 si e Error Code first two hex digits in fifth group Some faults can occur because random access memory on either the PLC CPU board or the expansion memory board has failed These same
111. buted with Control for CPU and programming features not described in this version of the manual Reference information is available in this manual as described below Appendix A CPU Performance Data lists the memory size in bytes and the execution time in microseconds for each of the programming instructions Appendix A also contains timing information for other PC tasks which when used in conjunction with the instruction timings can be used to predict CPU sweep times Appendix B Interpreting Faults describes how to interpret the message structure format when reading the PLC and I O fault tables Use the worksheet in Appendix C Memory Allocation to determine the total number of bytes of user data used and how much is still available for the user program Refer to Appendix D Using Floating Point Numbers for IEEE formats when dealing with floating point math operations Revisions to This Manual 1 2 Appropriate changes have been made to this manual to reflect feature changes corrections and updates to existing information The changes are Name of manual changed to reflect that this reference manual is for Control software users References made to CPX and CGR model CPUs where appropriate throughout the manual Bulk Memory Access information added chapter 2 Value for Constant Sweep timer corrected chapter 2 pg 2 46 Note added after Table 2 18 regarding CPU Mode switch and description of privilege level 1 updated in
112. c config and load program and configuration etc from the PLC None of this data may be changed 0 No Read the current status of the PLC including features supported by the PLC read the name of the Resource CP name prior to release 6 0 change privilege level and log in as programmer Note The CPU mode switch on the CPU overrides the password protection Even though the programmer may not be able to switch between RUN and STOP mode the physical switch can Protection Level Request from Programmer Upon connection to the CPU the Programmer requests the protection status of each privilege level from the CPU The Programmer then requests the CPU to move to the highest non protected level thereby giving the programmer access to the highest non protected level without having to specifically request any particular level A programmer requests a privilege level change by supplying the new privilege level and the password for that level If the password sent by the programmer does not agree with the password stored in the PLCs password access table for the requested level the privilege level change is denied and a fault is logged in the PLC fault table The current privilege level is maintained and no change will occur A request to change to a privilege level that is not password protected is made by supplying the new level and a null Hex 0 password A privilege change may be to a lower level as well as to a higher leve
113. can be up to 512 KB in size Standalone C programs cannot call other standalone programs nor can they call blocks within an LD program Similarly blocks within an LD program cannot call a standalone program Instead standalone C programs are scheduled for execution using one of several possible program scheduling modes described in section 4 of this chapter A maximum of 16 standalone programs can be used at one time If an LD program is used only 15 standalone programs are allowed for a total of 16 programs Note Since standalone C programs are truly separate programs they do not have access to memory types local to an LD program L and P The internal or local data used in a standalone C program should not be confused with L and P data Data Encapsulation 2 38 Each standalone C program is provided with a means of obtaining its own local copy of user data references Instead of operating on the global set of user references each standalone program can operate on its own local set of data This feature is supported through the use of an input output specification The following steps occur when using an I O specification with a standalone C program 1 When the program is scheduled for execution any corresponding input specification is copied from the global user reference data area s to an area local to the program 2 As the program executes it can operate on its local set of input and output data Any interruptions du
114. cccccccccccceeceeeeeeeeeeeeeeeeeeeeeeeseeeees 3 50 Forced and Unforced Circuit cecccccccccceeeeeeesneceeceeeeeeeennneeeeceeeeceeeeeeeenaeeeeeeeesenes 3 50 BOC KS Witch eee nee oan ne en eae an eee eh ore eta et et ete atest Talay 3 50 Contents ix Contents Appendix A Appendix B Appendix C Appendix D CPU Performance Data ccccsccsccssssccccsssscccccssscscccssscscccssssccsccsssccsccssccccsess Ethernet Global Data Sweep Impact eeessseeesssesreesssresssrrerssrreessrrresserrerssrresseres A 23 Relative CPU Performance Comparison sseesesssessesrerssrrersssrressrrreresrrerserresseres A 37 Test Prost ans cos sacs cces sect cdesacab AET E EEA A beutesvadeab guvecta coereutheaevacbenyas A 37 Interpreting the Chart scsissssndskcestisiasevedaucesiaseundateiem aE Tia aens A 37 Interpreting F ults inesset a aa DL Memory AMO Cation isis si cisciesacceecesicincievisccacevastessesicoavacaeasedesicceebecacesesesaventeonasvener Using Floating Point Numbers ssscccccccsssssssssssscsccccsssssssssssssscsscssssssssssee D 1 Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Chapter Introduction 1 The Series 90 70 PLC is a member of the GE Fanuc Series 90 PLC family of programmable logic controllers PLCs It is easy to install and configure offers advanced programming features and is designed for compatibility with other PLCs offered in the Series 90 fa
115. ch Failure Point Fault Output Fuse Blown Input Channel Low Alarm Input Channel High Alarm Input Channel Under Range Input Channel Over Range Input Channel Open Wire Output Channel Under Range Output Channel Over Range Invalid Data Expansion Channel Not Responding Input Channel Low Alarm Input Channel High Alarm Input Channel Under Range Input Channel Over Range Input Channel Open Wire Wiring Error Internal Fault Input Channel Shorted Invalid Data GENA Circuit Fault Remote I O Scanner Circuit Fault Communications Lost Chapter 3 Fault Explanation and Correction Circuit Configuration Circuit Configuration Circuit Configuration Circuit Configuration Circuit Configuration Circuit Configuration Circuit Configuration Circuit Configuration Circuit Configuration Circuit Configuration Circuit Configuration Circuit Configuration Circuit Configuration Circuit Configuration Circuit Configuration Circuit Configuration Circuit Configuration Circuit Configuration Circuit Configuration Circuit Configuration Circuit Configuration Circuit Configuration Circuit Configuration Circuit Configuration Circuit Configuration Circuit Configuration GENA Fault Byte 2 Byte 1 Circuit Type Byte 2 I O Type Timeout Unexpected State Unexpected Mail Status VME Bus Error Subnet Group Number Global Variable Name 3 39 Table 3 8 Continued Fault Category Descriptions Fa
116. ck is installed and the remaining programs and blocks were cleaned up None required This fault is informational 3 Power was lost in the middle of a Run Mode Store Delete and restore the program This error is fatal GFK 1192B Chapter 3 Fault Explanation and Correction 3 37 3 38 Section 4 I O Fault Table Explanations The I O fault table reports data about faults in three classifications e Fault category e Fault type e Fault description All faults have a fault category but a fault type and fault group may not be listed for every fault For additional information pertaining to each fault double click the fault to access its Details window Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B The following table describes the information provided with each fault category Table 3 8 Fault Category Descriptions Fault Category Fault Type Fault Description Fault Specific Data Circuit Fault Discrete Fault Analog Fault LowLevel Analog Fault GENA Fault Remote I O Scanner Fault Fault Not Specified Loss of IOC Addition of IOC Loss of I O Module Addition of I O Module Loss of Block Addition of Block Extra Block T O Bus Fault Bus Fault Bus Outputs Disabled Global Memory Refer to table on next page GFK 1192B Loss of User Side Power Short Circuit in User Wiring Sustained Overcurrent Low or No Current Flow Switch Temperature Too High Swit
117. cksum fault LOS_IOC Loss of Bus Controller LOW_BAT Low battery signal LOS_IOM Loss of I O module OV_SWP Over constant sweep time ADD_IOC Addition of bus controller SY_FULL PLC fault table full ADD_IOM Addition of I O module IO_FULL I O fault table full JOC_FLT Bus or Bus Controller fault APL_FLT Application program fault IOM_FLT I O module fault NO_PROG No application program at powerup BAD_RAM Corrupted program memory WIND_ER Incomplete window service BAD_PWD Password access failure NUL_CFG No configuration present LOS_SIO Loss of option module ADD_RCK Addition of expansion rack ADD_SIO Addition of option module CFG_MM Configuration mismatch LOS_RCK Loss of rack Configurable system fault references GFK 1192B Chapter 3 Fault Explanation and Correction 3 3 Configurable Fault Actions 3 4 For some faults the PLC must stop execution For other faults the appropriate response to a fault may depend on the nature of the application All faults are initially assigned to one of these three actions These faults halt the system set diagnostic variables and are logged in a fault table Diagnostic These faults do not halt the system They do however set diagnostic variables and are i a in a fault table Informational _ These faults are These faults are logged in a fault table but cause no other action in a fault table but cause no other action For some faults called noneconfigurable
118. cleared SBO017 SBUS_FL Set when the PLC fails to gain access to the bus Cleared by cycling power on the main rack or when the PLC fault table is cleared SCO009 ANY_FLT Set when any fault occurs Cleared when both fault tables are cleared SCO0010 SY_FLT Set when any fault occurs that causes an entry to be placed in the PLC fault table Cleared when the PLC fault table is cleared SCO011 IO_FLT Set when any fault occurs that causes an entry to be placed in the I O fault table Cleared when the I O fault table is cleared SCO0012 SY_PRES Set as long as there is at least one entry in the PLC fault table Cleared when the PLC fault table is cleared Once the bit is set on by an error it will not be reset until after the sweep SCO0013 IO_PRES Set as long as there is at least one entry in the I O fault table Cleared when the I O fault table is cleared SCO0014 HRD_FLT Set when a hardware fault occurs Cleared when both fault tables are cleared SCO0015 SFT_FLT Set when a software fault occurs Cleared when both fault tables are cleared Fault References GFK 1192B Table 2 9 System Status References Continued For a detailed discussion of fault references please refer to Chapter 3 Table 2 10 System Fault References System Fault Reference ANY_FLT SY_PRES IO_PRES SY_FLT IO_FLT HRD_FLT SFT_FLT Description Any fault in the system Any system fault in the Series
119. 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 GEnet ProLoop Series Three CIMPLICITY Genius PROMACRO VersaMax PowerTRAC Genius PowerTRAC Series Five VersaPro CIMPLICITY 90 ADS Helpmate Series 90 VuMaster CIMSTAR Logicmaster Series One Workmaster Field Control Modelmaster Series Six All Rights Reserved 1996 1999 GE Fanuc Automation North America Inc Charlottesville U S A and ALSTOM Levallois Perret France Preface Content of This Manual Related Publications GFK 1192B Chapter 1 Chapter 2 Chapter 3 Appendix A Appendix B Appendix C Appendix D GFK 0262 GFK 0646 GFK 1292 Introduction provides an overview of the Series 90 70 PLC and of the layout of this manual System Operation provides general information about the 90 70 PLC sweep cycle and handling of programs blocks and interrupts This includes a discussion of PLC system sweep sequences the system power up and power down sequences clocks and timers and security Fault Explanation and Correction Provides trouble shooting information for the Series 90 70 PLC It explains fault descriptions in the PLC fault table and I O faults CPU Performance Data lists memory size in bytes and execution time in microseconds for each programming instruction
120. crete I O data on FBCs expansion racks Seep impact bytes of discrete I O data expansion racks Words of analog I O data on FBCs main rack Sweep impact word analog I O data main rack Words of analog I O data on FBCs expansion racks Sweep impact word analog I O data expansion racks Predicted FIP I O Scan Impact Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Ethernet Global Data Sweep Impact Depending on the relationship between the CPU sweep time and an Ethernet Global Data EGD exchange s period the exchange data may be transferred every sweep or periodically after some number of sweeps Therefore the sweep impact will vary based on the number of exchanges that are scheduled to be transferred during the sweep However at some point during the operation of the PLC all of the exchanges will be scheduled to transfer data during the same sweep Therefore all of the exchanges must be taken into account when computing the worst case sweep impact Each Ethernet Global Data exchange configured for either consumption or production can add up to ms to the sweep time This sweep impact should be taken into consideration when configuring the PLC constant sweep mode and setting the watchdog timeout The Ethernet Global Data EGD sweep impact has two parts Consumption Scan and Production Scan EGD Sweep Impact Consumption Scan Production Scan Where the
121. cted in a module Replace the affected module IOC I O Controller Software Fault The fault category IOC Software Fault applies to any type of I O Controller There are no fault types or fault descriptions associated with it The default fault action is Fatal Name Description Correction Name Description Correction Datagram Queue Full Read Write Queue Full Too many datagrams or read write requests have been sent to the Genius Bus Controller Adjust the system to reduce the request rate to the Genius Bus Controller Response Lost The Genius Bus Controller is unable to respond to a received datagram or read write request Adjust the system to reduce the request rate to the Genius Bus Controller GFK 1192B Chapter 3 Fault Explanation and Correction 3 49 IOC I O Controller Hardware Failure The fault category IOC Hardware Fault has no fault types or fault descriptions The default fault action is Diagnostic Description The Genius operating software generates this error when it detects a hardware failure in the Bus Communication hardware or a baud rate mismatch Correction 1 Verify that the baud rate set in the configuration file for the Genius Bus Controller agrees with the baud rate programmed in every block on the bus Change the configuration file and restore it if necessary Replace the Genius Bus Controller Selectively remove each block from the bus until the offending block is isolate
122. ctions Explanations to correct the fault VO Fault Table Provides a description of each I O fault and instructions to Explanations correct the fault 3 1 3 2 Section 1 System Faults Certain discrete system references are assigned to correspond to specific fault types These system references will go to a Logic 1 state when their corresponding fault occurs They will remain at a Logic 0 level when no corresponding fault is detected These fault references are summarized in the table below Although some of these seem to be duplicates such as SY_FLT and SY_PRES for example there is a difference in how these bits can be cleared In this example SY_FLT can be cleared either by cycling PLC power or by clearing the PLC fault table SY_PRES however can only be cleared by clearing the PLC fault table The PLC and I O fault tables are maintained in battery backed RAM memory As long as the battery is maintaining memory contents cycling power will not clear these two fault tables ANY_FLT SCO0009 Set when any fault occurs that causes an entry in the PLC or I O fault tables Cleared when both fault tables are cleared or when the PLC is power cycled SY_FLT SCO0010 Set when any fault occurs that causes an entry in the PLC fault table Cleared when the PLC fault table is cleared or when the PLC is power cycled IO_FLT SCO0011 Set when any fault occurs that causes an entry in the I O fault table Cleared when the I O fault table is cle
123. cution of the user program is reduced by the time required by Ethernet Global Data exchanges Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Sweep Impact of Intelligent Option Modules GFK 1192B Intelligent option modules include Programmable Coprocessor Modules PCM Alphanumeric Display Coprocessor ADC Modules Graphics Display Coprocessor GDC Modules MAP LAN Modules Ethernet LAN Modules and Genius Bus Controllers being used for Genius LAN capabilities The sweep impact for these intelligent option modules is highly variable The opening of the System Communications Window and the polling of each module have relatively small impacts compared to the sweep impact of CPU memory read or write requests The following equations show how to calculate the fixed sweep of each module PCM ing Sweep Impact Clock Refresh Impact once every 1 2 sec ADC olling Sweep Impact Clock Refresh Impact once every 1 2 sec GDC Polling Sweep Impact Clock Refresh Impact once every 1 2 sec MAP LAN Polling Sweep Impact LAN I O Scan Impact Ethernet LAN Polling Sweep Impact LAN I O Scan Impact GBC Polling Sweep Impact GBC I O Scan Impact FBC Polling Sweep Impact FBC I O Scan Impact The table below shows the fixed sweep impact times in milliseconds for intelligent option modules It also contains sweep impact times for reading and writing the PLC s system memories includes all memories exce
124. d e T O Triggered e Periodic Ordered Timed 1 O Triggered Periodic Ordered programs are executed in the Logic Window with all other Ordered programs Ordered programs are executed once per sweep in the sequence in which they are declared in the programming software Ordered programs are not supported in Microcycle Sweep Mode Timed programs are scheduled to execute on a specified time interval with an initial delay if specified applied on Stop to Run transition of the PLC Timed programs are scheduled to execute on a priority basis during any phase of the PLC sweep Timed programs are not supported in Microcycle Sweep mode 1 O Triggered programs are scheduled to execute on the receipt of a configured T O Interrupt I O Triggered programs are scheduled to execute on a priority basis during any phase of the PLC sweep when the PLC is in Normal Sweep Constant Sweep or Constant Window Sweep mode In Microcycle Sweep mode I O Triggered programs are scheduled to execute on a priority basis in the Logic Window In this case the execution of I O Triggered programs may be time sliced over multiple sweeps Periodic programs are scheduled for execution based on the user configured period for the program and are scheduled to execute in the Logic Window with all other Periodic programs Periodic programs execute on a priority basis relative to all other programs and may be time sliced over multiple sweeps Periodic programs are only s
125. d then replace it Forced and Unforced Circuit The fault categories Forced Circuit and Unforced Circuit report point conditions and therefore are not technically faults They have no fault types or fault descriptions These reports occur when a Genius I O point was forced or unforced with the HandHeld Monitor The default fault action is Informational Fault Specific Data contains data as shown below 1 Block Configuration 2 Analog Discrete Information Block Switch The Fault Category Block Switch has no fault types or fault descriptions The default fault action is Diagnostic Name Block Switch Description The PLC generates this error when a Genius block on redundant Genius buses switches from one bus to another Correction 1 No action is required to keep the block operating 2 The bus that the block switched from needs to be repaired a Verify the bus wiring b Replace the I O controller c Replace the Bus Switching Module BSM 3 50 Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Appendix A Instruction Timing GFK 1192B CPU Performance Data This appendix contains instruction and overhead timing for each Series 90 70 CPU module This timing information can be used to predict CPU sweep times The Series 90 70 PLC supports many different functions and function blocks Table A 1 beginning on the next page lists the execution time in microseconds and the
126. dard form for display once the user has entered the data and pressed the Enter key Examples of valid floating point number entries and their normalized display are shown below Entered Displayed 250 250 0000 4 4 000000 2383019 2383019 34 34 00000 0036209 003620900 12 E 9 1 20000E 10 0004E 11 4 00000E 15 731 0388 731 0388 99 20003e 29 9 92000E 28 Examples of invalid floating point number entries are shown below Invalid Entry Explanation 433E23 Missing decimal point 10e 19 Missing decimal point 1 0 e19 The mantissa cannot contain spaces between digits or characters This is accepted as 10 e0 and an error message is displayed 4 1e1 9 The exponent cannot contain spaces between digits or characters This is accepted as 4 1e0 and an error message is displayed Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B 2 Errors in Floating Point Numbers and Operations Overflow occurs when a number greater than 3 402823E 38 or less than 3 402823E 38 is generated by a REAL function When this occurs the Enable Out output of the function is set Off and the result is set to positive infinity for a number greater than 3 402823E 38 or negative infinity for a number less than 3 402823E 38 You can determine where this occurs by testing the sense of the Enable Out output POS_INF NEG_INF 7F800000h IEEE positiv
127. data Reference 000000 All zeros in this field indicates that the reference address is not meaningful Address for this fault Rack 00 Main rack rack 0 Slot 03 Slot 3 In this configuration slot 3 contains a Genius Bus Controller Bus 7F Since this is a single channel GBC the bus number is not needed 7F indicates that the bus number is not significant Block 7F A block number of 7F hex indicates that the block is not meaningful for this fault Point FF7F FF in the first low byte indicates that the point is not meaningful for this fault entry Fault Group 02 Loss of or missing IOC fault Fault Action 03 Fatal fault Fault Category OA Fault Category 0A 10 decimal is a Loss of or Missing IOC fault Fault Type 00 No fault type data occurs for a Loss of or Missing IOC fault Fault Description 00 No fault description information is given Fault Specific 00 There is no entry for a zero in fault specific data so there is no additional Data information available on this instance of LOSS of IOC The PLC CPU detected a loss of or missing IOC and logged this fault The fatal action indicates that the PLC CPU will not transition to RUN mode until the fault is cleared Fault type and fault description are not meaningful for this fault fault specific data may be meaningful 02 000000 00037F7FFF7F 0203 OA 00 00 0002400000 Fault Specific Data Fault Description Fault Type Fault Category Fault Action Fault Gro
128. der the following example program which updates a given output value in several locations For this example assume that the user has configured AQI as an output specification from the second program and that user reference AQ 1 contains the value 0 when the two programs begin execution Differences Between Accessing Global and Local Internal Data Program Accessing Global Data Program Using I O lt program begins gt Specification lt program begins gt AQ1L 0 An output scan occurring after this line of code would output a 0 to AQI LOC 1 An output scan occurring after this line of code would output a 0 to AQI AQI AQI 2 An output scan occurring after this line of code would output a2 to AQI LOC 1 LOC 1 2 An output scan occurring after this line of code would output a 0 to AQI AQI AQI 12 An output scan occurring after this line of code would output a 14 to AQI LOC 1 LOC 1 12 An output scan occurring after this line of code would output a 0 to AQI AQL AQI 2 An output scan occurring after this line of code would output a7to AQI LOC 1 LOC 1 2 An output scan occurring after this line of code would output a 0 to AQI lt program completes gt lt program completes gt The PLC copies the output specification from a local area back to the global areas when the program completes Further output scans will output a
129. discrete point has a fault reference available that may be interrogated using two special contacts a fault contact FAULT and a no fault contact NOFLT The PLC only collects this fault data if enabled to do so through your programming software The following table shows the state of the fault and no fault contacts Condition FAULT NOFLT Fault Present ON OFF Fault Absent OFF ON Analog l O Diagnostic Data Diagnostic information is made available by the PLC CPU for each analog channel associated with Series 90 70 analog input modules Series 90 70 analog output modules Genius analog blocks etc Two memory blocks are allocated for analog diagnostic data One is associated with AI analog input memory and the other with AQ analog output memory One byte of diagnostic memory is allocated for each analog I O channel Since each analog I O channel uses two bytes of AI and AQ memory the diagnostic memory is half the size of the data memory The analog diagnostic data contains both diagnostics and process data with the process data being the High Alarm and Low Alarm bits The diagnostic data is referenced with the FAULT and NOFLT contacts The process bits are referenced with the HIALR and LOALR contacts The memory allocation for analog diagnostic data is one byte per word of analog input and analog output allocated by the user When an analog fault contact is referenced in the application program the
130. done to reduce scan time during critical phases of a process to ensure minimal scan time Incoming messages will timeout and COMMREQs will stop working while the window is closed Communications with PCM and LAN modules will also stop 3 Sweep impact to scan the FIP Bus Controller This impact results from the PLC CPU notifying the FIP Bus Controller that its new output data has been transferred and commanding the FIP Bus Controller to ready its input data as well as informing the FIP Bus Controller that the PLC has finished another sweep and is still in RUN mode A scan segment for FIP I O consists of FIP Transfer Variables TVAs on the same bus with consecutive reference addresses containing up to 256 bytes The scan segment processing is the same for analog and discrete scan segments A 20 Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Note Some of the sweep time information was not available at the time this manual was printed the blank spaces in the table below Table A 10 Sweep Impact Time of FIP 1 0 and FBCs FIP Bus Controller open system communications window 0616 per FIP Bus Controller polling for background messages 0086 per FIP Bus Controller I O Scan First FIP Bus Controller Subsequent FIP Bus Controllers FIP I O Blocks per I O block scan segment per I O block scan segment w point faults enabled per byte discrete I O data in the main rack per byte discrete
131. e Fault Description Fault Specific Data Category Circuit Fault Discrete Fault Analog Fault LowLevel Analog Fault Loss of User Side Power Short Circuit in User Wiring Sustained Overcurrent Low or No Current Flow Switch Temperature Too High Switch Failure Point Fault Output Fuse Blown Input Channel Low Alarm Input Channel High Alarm Input Channel Under Range Input Channel Over Range Input Channel Open Wire Output Channel Under Range Output Channel Over Range Invalid Data Expansion Channel Not Responding Input Channel Low Alarm Input Channel High Alarm Input Channel Under Range Input Channel Over Range Input Channel Open Wire Wiring Error Internal Fault Input Channel Shorted Invalid Data Circuit Configuration Circuit Configuration Circuit Configuration Circuit Configuration Circuit Configuration Circuit Configuration Circuit Configuration Circuit Configuration Circuit Configuration Circuit Configuration Circuit Configuration Circuit Configuration Circuit Configuration Circuit Configuration Circuit Configuration Circuit Configuration Circuit Configuration Circuit Configuration Circuit Configuration Circuit Configuration Circuit Configuration Circuit Configuration Circuit Configuration Circuit Configuration Circuit Configuration Circuit Configuration Chapter 3 Fault Explanation and Correction 3 41 3 42 Discrete Fault Discrete Fault has eight fault descriptions More than one conditio
132. e a fault will be logged in the PLC fault table System Status References The following differences exist when using System Status References called Convenience References in previous editions of 90 70 Reference manual e The reference FST_EXE is not available to standalone C programs e The reference FST_SCN does not refer to S0001 within standalone C programs Instead a macro is provided by the C Toolkit to provide identical functionality For information on System Status References refer to Table 2 9 as well as section 2 of this chapter 2 44 Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Section 4 PLC Sweep Modes and Program Scheduling Modes Normal Sweep Mode In Normal Sweep mode each PLC sweep can consume a variable amount of time The Logic Window is executed in its entirety each sweep The Communications and Background Windows can be set to execute in a Limited or Run to Completion mode Normal Sweep is the most common sweep mode used for PLC applications The following figure illustrates three successive PLC sweeps in Normal Sweep mode Note that the total sweep times may vary due to sweep to sweep variations in the Logic Window Communications Windows and Background Window a45529 SWEEP n aK PRG HK PRG YS G Abbreviations SWEEP n 1 PAK HK PRG SYS BG HK Housekeeping PRG Programmer Window Chapter 2 System Operation Figure 2
133. e cycle time telative to the Stop to Run transition of the PLC The base cycle time specifies how long each sweep should take similar to the Constant Sweep time in Constant Sweep mode The user programs are scheduled for execution each sweep based on their period and may execute in a time sliced fashion over multiple PLC sweeps The PLC will alternate between the Communications and Background Windows allowing them to run in a Run to Completion mode until it is time for the next sweep to begin Microcycle Sweep mode can be used to allow some programs to execute more often than others This allows more processing time to be applied to the more important or more time critical tasks Microcycle Sweep mode also allows programs to execute more in line with the time when their inputs are available Although Microcycle Sweep mode has a fixed sweep time it is significantly different from Constant Sweep mode First user programs do not necessarily execute in their entirety each sweep In order to maintain the base cycle time and the Communications and Background Window times user programs may be suspended during execution and resumed the following PLC sweep Also additional sweep time due to an oversweep condition in a given sweep causes Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B the next sweep to be shortened by the oversweep time In this way each PLC sweep with the exception of sweeps which follow an overswee
134. e functions microseconds the number of bits or words Enabled time is for single length units of type R COMMREQ time has been measured between CPU and EX7 with NOWAIT option DOIO is the time to output values to discrete output module Appendix A CPU Performance Data A 7 A 8 Function Group Function Control Note 1 Nv eS Table A 1 Instruction Timing Continued Enabled FOR NEXT MCR ENDMCR Combined DOIO DOIO with ALT SUSIO COMMREQ CALL RETURN LD CALL RETURN SFC CALL RETURN PSB CALL RETURN External Block PIDISA PIDIND VMERD BYTE VMERD WORD VMEWRT BYTE VMEWRT WORD VMERMW VMETST VME_CFG_RD VME_CFG_WRT SVCREQ 1 2 3 4 t HHH HH H YAWARWNHS 546 772 3025 782 112 99 381 47 935 928 CPX772 935 928 CPX772 935 928 CPX782 CPX782 k 5 3 6 6 4 4 4 4 4 6 5 5 UnanepepR RR RAD CPX772 CPX782 _ Time in microseconds is based on Release 5 0 of Logicmaster 90 70 software For information not available when this manual was being printed represented by a dash refer to the IPI for each CPU For table functions increment is in units of length specified For bit operation functions microseconds bit For data move functions microseconds the number of bits or words Enabled time is for single length units of type R COMMREQ time has been measured between CPU and EX7 with NOWAIT option DOIO is the
135. e infinity representation in hex FF800000h IEEE negative infinity representation in hex Il If the infinities produced by overflow are used as operands to other REAL functions they may cause an undefined result This undefined result is referred to as an NaN Not a Number For example the result of adding positive infinity to negative infinity is undefined When the ADD_REAL function is invoked with positive infinity and negative infinity as its operands it produces an NaN for its result Each REAL function capable of producing an NaN produces a specialized NaN that identifies the function NaN_ADD 7F81FFFFh Real addition error value in hex NaN_SUB 7F81FFFFh Real subtraction error value in hex NaN_MUL 7F82FFFFh Real multiplication error value in hex NaN_DIV 7F83FFFFh Real division error value in hex NaN_SQRT 7F84FFFFh Real square root error value in hex NaN_LOG 7F85FFFFh Real logarithm error value in hex NaN_POWO 7F86FFFFh Real exponent error value in hex NaN_SIN 7F87FFFFh Real sine error value in hex NaN_COS 7F88FFFFh Real cosine error value in hex NaN_TAN 7F89FFFFh Real tangent error value in hex NaN_ASIN 7F8AFFFFh Real inverse sine error value in hex NaN_ACOS 7F8BFFFFh Real inverse cosine error value in hex NaN_BCD 7F8CFFFFh BCD 4 to real error REAL_INDEF FFC00000 Real indefinite divide 0 by 0 error When an NaN result is fed into another func
136. e memory is assumed to be in error and all areas are cleared The PLC is now in a cleared state the same as if a new CPU module were installed All logic and configuration files must be stored from the programmer to the PLC System Configuration After completing its own self test the CPU performs the system configuration It first clears all of the system diagnostic bits in the BCP Boolean Coprocessor Bit Cache memory This prevents faults that were present before power down but are no longer present from accidentally remaining as faulted Then it polls each module in the system checking for completion of the module s self test The CPU reads information from each module comparing it with user provided rack slot configuration information Any differences between actual configuration and user specified configuration are logged in the fault tables Option Module Self Test Completion Option modules may take a longer time to complete their self tests than the CPU due to the time required to test communications media or other interface devices As an option module completes its initial self tests it tells the CPU the time required to complete the remainder of these self tests During this time the CPU provides whatever additional information the module needs to complete its self configuration and the module continues self tests and configuration If the module does not report back in the time it specified the CPU marks the module as fault
137. e mode and detects that the sweep has exceeded the constant sweep timer The fault extra data contains the name of the folder in eight bytes The default fault action for this group is Diagnostic Error Code 0 Constant Sweep 1 Microcycle Correction If Constant Sweep 1 Increase constant sweep time 2 Remove logic from application program If Microcycle 1 Increase the time 2 Modify execution intervals to give programs more time to execute PLC System Fault Table Full The fault group PLC System Fault Table Full occurs when the PLC Fault Table reaches its maximum configured limit see page 3 13 The default fault action for this group is Diagnostic Error Code 0 Correction Clear the PLC fault table 1 0 Fault Table Full The fault group I O Fault Table Full occurs when the I O Fault Table reaches its maximum configured limit see page 3 14 To avoid loss of additional faults clear the earliest entry from the table The default fault action for this group is Diagnostic Error Code 0 Correction Clear the I O fault table GFK 1192B Chapter 3 Fault Explanation and Correction 3 29 3 30 Application Fault The fault group Application Fault occurs when the PLC CPU detects a fault in the user program The default fault action for this group is Diagnostic Error Code Name Description Correction Error Code Name Description Correction Error Code Name Description
138. e mode will appear to be operating correctly but it will not communicate with the PLC CPU 1 Reset the module with the push button 2 Powereycle the entire system 3 Powereycle the rack containing the module FF Option Module Communications Failed PLC CPU generates this error when communication to the option module has failed 1 Check the bus for abnormal activity 2 Replace the intelligent option module to which the request was directed 3 Check the parallel programmer cable for proper attachment All Others Module Failure During Configuration The PLC generates this error when a module fails during powerup or configuration store Power off the system Replace the module located in that rack and slot If the board is located in an expansion rack verify BTM BRM cable connections are tight and the modules are seated properly verify the addressing of the expansion rack Replace the BTM Replace the BRM Replace the rack Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Addition of or Extra Rack The fault group Addition of Extra Rack occurs when a configured expansion rack with which the PLC CPU could not communicate comes online or is powered on or an unconfigured rack is found The default fault action for this group is Diagnostic Error Code Name Correction 1 Extra Rack 1 Check rack jumper behind power supply for correct setting 2 Update the configura
139. ecutive logic scans The sweep impact of these functions can be spread out over multiple sweeps limited by adjusting the window times to a value lower than the documented sweep impact time For the programmer the default time is 10 milliseconds therefore some of the functions listed in that section will naturally timeslice over successive sweeps The base sweep time for each CPU model is shown below This time is for an empty _MAIN program block with no programmer attached no configuration downloaded and no other module present in the system other than the CPU The following diagram shows the full sweep phases and the base sweep phases contrasted so that the optional parts of the sweep are illustrated Table A 2 Base Sweep vs Full Sweep Phases BASE SWEEP FULL SWEEP lt START OF SWEEP gt lt START OF SWEEP gt Sweep Housekeeping Sweep Housekeeping Vv NULL Input Scan Vv Input Scan i al Vv Program Logic Execution EGD Consumption Scan Vv NULL Output Scan Vv Program Logic Execution Bil Vv Output Scan Vv Vv EGD Production Scans he Vv Poll for Missing I O Modules Vv Programmer Communications Window Vv Vv lt END OF SWEEP gt System Communications Window lt END OF SWEEP gt If I O is suspended then the input and output scans are skipped Polling for missing I O modules only occurs if a Loss of fault has been logged for a Series 90 70 I O module
140. ed and makes an entry in one of the fault tables When all self tests are complete the CPU obtains reports generated during the module s power up self test and places fault information if any in the fault tables Option Module Dual Port Interface Tests After completion of the option module self test and results reporting integrity tests are jointly performed on the dual port interface used by the CPU and option module for communications These tests validate that the two modules are able to pass information back and forth as well as verify the interrupt and semaphore capabilities needed by the communications protocol After dual port interface tests are complete the communications messaging system is initialized GFK 1192B Chapter 2 System Operation 2 69 I O System Initialization If the module is a Model 70 input module no further configuration is required If the module is a Model 70 output module the module is commanded to go to its default state A Model 70 output module defaults to all inputs off at power up and in failure mode unless told otherwise When the module is a Bus Transmitter Module BTM it is interrogated about what remote racks are present in the system Based upon the BTM s response the CPU adds those racks and their associated slots into the list of slots to be configured Finally the I O Scanner performs its initialization The I O Scanner initializes all the I O controllers in the system by establishing the
141. ed in the appropriate table any diagnostic variables to be set and the system to be stopped Diagnostic faults are recorded in the appropriate table and any diagnostic variables are set Informational faults are only recorded in the appropriate table Table 3 7 Fault Actions Fault Action Response by CPU Fatal Log fault in fault table Set fault references Go to Stop mode Diagnostic Log fault in fault table Set fault references Log fault in fault table Your programming software provides the capability to change the fault action of certain faults There are two possible classifications in the utility fatal and nonfatal These correspond to fatal and diagnostic fault action in the PLC Only fatal faults cause the system to halt Additionally the informational fault action only logs faults in the fault table When a fault is detected by the CPU it uses a default fault action for that fault For those faults which may have their action changed by the programming software the CPU uses the fault action specified by the software this may be the default action or the action chosen by the user Fault Response Fault response refers to the ability of a fault to have its fault action changed Those faults that can have their fault action changed are called configurable faults Those which cannot are called nonconfigurable faults Nonconfigurable faults are either fatal or informational Also nonconfigurable faults do not cause ap
142. ed programs 1 Increase the base cycle time or decrease the interrupt rate 2 Increase the execution interval time to allow the program to finish execution OE External Block RunTime Error A runtime error occurred during execution of an external block Based on the fault information correct the specific problem in the external block OF SORT Interrupt Error A SORT function executed in a timed or I O interrupt at the same time a SORT function was executing in another block Do not use the SORT function in both Interrupt and Non4Interrupt blocks 11 Standalone RunTime Error A runtime error occurred during execution of a Standalone program Based on the fault information correct the specific problem in the external block NonConfigurable Faults The fault action of Non Configurable Faults cannot be changed Fatal faults cause the PLC to enter a form of Stop mode at the end of the sweep in which the error occurred Diagnostic faults are logged and corresponding fault contacts are set Informational faults are simply logged in the PLC fault table GFK 1192B Chapter 3 Fault Explanation and Correction 3 31 System Bus Failure The fault group System Bus Failure occurs when the PLC CPU software receives the nonconfigurable interrupt bus failure from the bus system The default fault action for this group is Fatal Error Code 1 Name Bus Grant Failure Description The PLC operating software generates this error when
143. educes the overall amount of logic needed for the program Examples of Using Blocks As an example the logic for an LD program could be divided into three blocks each of which could be called as needed from the _MAIN block A block cannot call the _MAIN block In this example the _MAIN block might contain little logic serving primarily to sequence the other blocks read inputs _MAIN BLOCK BLOCK 2 write outputs BLOCK 3 BLOCK GFK 1192B Chapter 2 System Operation 2 27 2 28 A block can be used many times as the program executes Logic that needs to be repeated several times in a program could be entered in a block Calls would then be made to that block to access the logic read inputs BLOCK write outputs _MAIN BLOCK Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B In addition to being called from the _MAIN block blocks can also be called by other blocks A block may even call itself read inputs MAIN gt BLOCK BLOCK 2 write outputs gt gt BLOCK BLOCK eS 3 ed 5 i BLOCK 4 There may be no limit to the number of levels of calls to blocks that your programming software will allow However the PLC will only allow a certain number of nested calls before an Application Stack Overflow f
144. eeesnececeessaeeesessaeeeseesaes 3 28 Low Battery Signalene enee e e a AEE AEE EEE o aSa 3 28 Constant Sweep or Microcycle Time Exceeded s ec eeescceeessseeeceessneeeeeesneeeeeenaes 3 29 PLC System Fault Table Full innen ne opererte nepen en r aan aan tnt nes 3 29 VO Fault Table Full Ah ohanaa nariai nae enna 3 29 Application Fault asss EEEE ENVEE EE ner Tar rr E 3 30 NonConfigurable Faults 0 0 0 eesceeessssceceessseeeceesnececeesnaeeesessaeecessaeeesessaeeeeees 3 31 Systemi Bus Parltiresty oye tele E EET 3 32 No User Program on PowerUp ceessccceessseeeceesseeeceessaeeceeeessaeeeceesaeeeeessaeeeeees 3 32 Corrupted User Program on PowerUp 00 eeeceeesseeecessnceeeeesseeeceessaeeeeesseeesessaaeas 3 33 Window Completion Failure eeesecccessssceccessseeecessneeecessnaeecsessaeeeeessaeeeeesaes 3 34 Password Access Failure cssssssscccsccccccoessssnnnacccceceessnsnensccescesesssnenscecseseesees 3 34 Null System Configuration for Run Mode 0 cc eesececesssseeeeeesneeeceesaeeeeessaeeesees 3 34 PLC CPU System Software Failure ee esceeesssceccessneeeceessaceceessaeeesesseeeseesaes 3 35 Too Many Bus Controllers eeeseccceesseceeeesseeececesseeecesssaeecessaeeesessaeeeeesaes 3 36 Communications Failure During Store eeesecceessneeeeeesnececeesnaeeecessaeeeseesaes 3 36 Run Mode S torte Failure oi sccccesecoettetetiectecetetecccctndcresctsdccuccdsdctycctecetecstsdedesstetctye tees 3 37 Section 4 I O Fault
145. es CPX CPX 914 924 CPX 781 782 CPX 731 731 Sweep Impact Item 935 928 925 925 782 788 789 772 771 772 Parallel Programmer Programmer window 0 75 Reference table monitor 4 90 Editor monitor 4 90 Word for word change 28 10 ALT S store 14 80 High priority request 9 90 Serial programmer 0 50 Programmer Window 5 60 Reference table monitor 6 40 Editor monitor Not all of the timing information needed for the above table was available at print time for this manual the blank spaces Note Functions in bold type in Table A 4 above impact the sweep continuously All other functions impact the sweep only when invoked Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Each of the items included in the table is described below Sweep Impact Description Item Programmer Parallel The time to open the Programmer Window but not process any requests The Window programmer is attached with a parallel connection no reference values are being monitored Serial Same as above except attached serially Unlike the parallel programmer the sweep impact cannot be limited to a single sweep Serial communications in addition to the service processing time that is performed inside the Programmer Communications Window has processing time associated with the receiving of data over the RS422 485 serial link This serial communications processing time is asynchronous to the sweep in orde
146. es IO_FLT IO_ PRES diagnostic Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B GFK 1192B Table 3 2 Continued Configurable Fault References Fault Default Action Description May Also Be Set APL_FLT Application fault SY_FLT SY_PRES diagnostic LOS_RCK Loss of rack BRM failure loss of power or missing a SY_FLT SY_PRES diagnostic configured rack IO_FLT IO_PRES LOS_IOC Loss of Bus Controller channel or missing a configured IO_FLT IO_PRES diagnostic Bus Controller LOS_IOM Loss of I O module does not respond or missing a IO_FLT IO_PRES diagnostic configured I O module LOS_SIO Loss of option module does not respond or missing a SY_FLT SY_PRES diagnostic configured module ADD_RCK New rack added or previously faulted rack has SY_FLT SY_PRES diagnostic returned ADD_IOC Previously faulted Bus Controller is no longer faulted JO_FLT IO_PRES diagnostic ADD_IOM Previously faulted I O module is no longer faulted JO_FLT IO_PRES diagnostic IOC_FLT Nonfatal bus or Bus Controller error more than 10 bus IO_FLT IO_PRES diagnostic errors in 10 seconds error rate is configurable ADD_SIO New option module is added or previously faulted SY_FLT SY_PRES diagnostic module no longer faulted IOM_FLT Point or channel on an I O module a partial failure of IO_FLT IO_PRES diagnostic the module CFG_MM Wrong module type detected during powerup or Run SY_FLT SY_PRES
147. es Go to Stop mode Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B I O Fault Category The I O fault category specifies a general classification of the fault It is similar to the I O fault group discussed earlier I O fault categories are listed in the following table Table B 17 I O Fault Categories Decimal Number Hex Code Description 1 1 Circuit fault Short circuit open wire etc 2 2 Loss of block Block no longer responding 3 3 Addition of block New block appeared 4 4 Unused category 5 5 Unused category 6 6 Genius bus fault 7 vi Global memory fault 8 8 EEPROM fault watchdog timeout 9 9 Addition of IOC 10 A Loss of or missing IOC 11 B IOC software fault 12 C Forced circuit A Genius I O point was forced with the HHM 13 D Unforced circuit HHM force was removed 14 E Loss of Series 90 integral card 15 F Addition of Series 90 integral card 16 10 Found extra Series 90 integral card 17 11 Found extra Genius block 18 12 An IOC detected a hardware failure or a baud rate mismatch 19 13 Genius bus controller has stopped reporting faults because too many faults have occurred 20 14 Configuration mismatch fault for I O modules 21 15 GBC software exception 22 16 Redundant Genius block switched bus 23 17 Block not active on redundant bus GFK 1192B Appendix B Interpreting Faults B 23 I O Fault Type The I O fault type component creates subcategories under the circ
148. eters ss ie 2i c eect heiseth nibh tet eesti bbe yea eae eae a vedi 2 62 Valid Memory TYPES dh oepeti seenen Tarere cepted aiatevodeeie dy ete 2 63 Interrupt Handling and Scheduling with User Programs eeeeseeeeeerrereereereeree 2 63 VO Triggered Programs areon aaaea AN dee eee E ELELEE RE 2 63 Timed Programs veo e EEEE Vare DE ENEE KIE EEI NIEPE alia NETON K SENEE SEES 2 64 Interrupt Blocks vs Interrupt Programs eeeeseeeeeeeeeeeessrrerssrrerssrreesssreerssrresssrress 2 65 Interrupt Blockish tenga hee ged ease gee 2 65 Interrupt Prora h necede seise Ereren E EE roe SERET iea ipa E 2 65 Section 5 Run Stop Operations seoccssessssssooocccesssssooocccseessssoococcsesesssssooee 2 66 Modes Of Operations essaie aa ae a a aA Aa Aaa 2 66 Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B GFK 1192B Contents Mode Transitions 3 3 255 3 3 sashes e ees E E EE bodes EE E EE EE T TEE 2 67 StoptoRun Transition esierieereririroriroeira eieh etnie eeinetan r REAA AA ei aS 2 67 R ntoStop Transition c2secc2vesoee tea sees nan aan E E E Bet tes Rt Sees 2 67 WindDown Period for Microcycle Sweep Mode c esceeseessseeceseeeeseeeeseeenaes 2 67 Section 6 PowerUp and PowerDown Sequences ssssscsssesssssocooccceeesssooooee 2 68 Power Up EAA AAAA 2 68 PowerUp SelfTest c enticprn nnn denice iol er il ae nee SLEI EENE IPEE SE 2 68 PLLC Memory Validationti s sant cain denn cana kann a
149. expansion racks connected to the PLC through a Bus Transmitter Module in the main rack and Bus Receiver Modules in the expansion racks Slot The slot number ranges from 0 to 9 The PLC CPU always occupies slot 1 in the main rack rack 0 Appendix B Interpreting Faults B 3 B 4 Task The task number ranges from 0 to 65 535 Sometimes the task number provides additional information to PLC engineers typically however the task number can be ignored PLC Fault Group Fault group is the highest classification of a fault It identifies the general category of the fault The fault description text displayed by your programming software is based on the fault group and the error codes Table B 1 lists the possible fault groups in the PLC fault table Group numbers less than 80 Hex are maskable faults while group numbers greater than or equal to 80 Hex are non maskable faults The last non maskable fault group Additional PLC Fault Codes is declared for the handling of new fault conditions in the system without the PLC having to specifically know the alarm codes All unrecognized PLC type alarm codes belong to this group Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Table B 1 PLC Fault Groups Group Number Decimal Hexa Group Name Fault Action decimal 1 1 Loss of or missing rack Fatal 4 4 Loss of or missing option module Diagnostic 5 5 Addition of or extra rack Diagnos
150. fault is a point type fault I O Fault Group Fault group is the highest classification of a fault It identifies the general category of the fault The fault description text displayed by the software is based on the fault group and the error codes Table B 15 lists the possible fault groups in the I O fault table Group numbers less than 80 Hex are maskable faults The last non maskable fault group Additional I O Fault Codes is declared for the handling of new fault conditions in the system without the PLC having to specifically know the alarm codes All unrecognized I O type alarm codes belong to this group Table B 15 1 0 Fault Groups Group Group Name Fault Action Number 2 Loss of or missing IOC Fatal 3 Loss of or missing I O module Diagnostic 6 Addition of or extra IOC Diagnostic 7 Addition of or extra I O module Diagnostic 9 IOC or I O bus fault Diagnostic A T O module fault Diagnostic F IOC software failure Fatal Additional I O fault codes As specified Appendix B Interpreting Faults B 21 B 22 1 0 Fault Action The fault action specifies what action the PLC CPU should take when a fault occurs The following table lists possible fault actions Table B 16 PLC Fault Actions Fault Action Action Taken by CPU Code Informational Log fault in fault table Diagnostic Log fault in fault table 2 Set fault references Fatal Log fault in fault table 3 Set fault referenc
151. faults may also occur because the system has been powered off and the battery voltage is or was too low to maintain memory To avoid excessive duplication of instructions when corrupted memory may be a cause of the error the correction simply states Perform the corrections for Corrupted Memory This means 1 Ifthe system has been powered off replace the battery Battery voltage may be insufficient to maintain memory contents 2 Replace the expansion memory board Integrated circuits on the memory board may be failing 3 Replace the PLC CPU board The integrated circuits on the PLC CPU board may be failing Note For information about values for fault groups refer to Appendix B GFK 1192B Chapter 3 Fault Explanation and Correction 3 17 Configurable Faults Configurable faults can have their fault action fatal or diagnostic changed The CPU uses the fault action specified by the software this may be the default action or a fault action chosen by the user In this section the default fault action is listed for configurable faults Loss of or Missing Rack The fault group Loss of or Missing Rack occurs when the system cannot communicate with an expansion rack because the BTM in the main rack failed the BRM in the expansion rack failed power failed in the expansion rack or the expansion rack was configured in the configuration file but did not respond during powerup The default fault action for this group is Diagnostic
152. figuration file indicates an I O module is to occupy a slot and no module exists in the slot Correction 1 Replace the module 2 Correct the configuration file 3 Display the PLC fault table on the programmer Contact GE Fanuc PLC Field Service giving them all the information contained in the fault entry Addition of I O Module The fault category Addition of I O Module applies to Model 70 discrete and analog I O modules There are no fault types or fault descriptions associated with this category The default fault action is Diagnostic Name Addition of I O Module Description The PLC generates this error when an I O module which had been faulted returns to operation Correction 1 No action necessary if module was removed or replaced or if the remote rack was power cycled 2 Update the configuration file or remove the module Extra I O Module The fault category Extra I O Module applies only to Model 70 I O modules There are no fault types or fault descriptions associated with this category The default fault action is Diagnostic Name Extra I O Module Description The PLC generates this error when it detects a Model 70 I O module in a slot which the configuration file indicates should be empty Correction 1 Remove the module It may be in the wrong slot 2 Update and restore the configuration file to include the extra module 3 46 Series 90 70 System Manual for Control Software Users No
153. following list summarizes many of the features supported in each of the types of programs e Interrupt Blocks are preferred over standalone programs when interrupt latency is a concern The overhead to process an Interrupt Standalone program is much larger than that of an Interrupt block e LD programs may operate only on global user reference data This can introduce data coherency problems when the LD program is run in Microcycle Sweep mode and the program is suspended over multiple sweeps e Standalone C programs incur an 8K overhead per program e AnLD program is preferred over a standalone C program when you are using large amounts of boolean instructions LD programs are better suited for relay type logic than are standalone C programs Table 2 15 LD vs Standalone C Program Tradeoffs Programming Program Size Data Types Local Data Scheduling Data Block Types Language Limit Accessible Size Modes Encapsulation Supported LD Ladder smaller of All 8k P 8K L All No LD Logic 512K or per block SFC available PSB memory size External organized intol6K blocks Standalone C using the C smaller of All except unlimited All Yes n a Programmer s 512K or P WL counts as part Toolkit available of program memory size size Using Microcycle Sweep mode with an LD program is not recommended LD programs always operate on global data directly which can lead to inconsistent output values if t
154. for Control Software Users November 1999 GFK 1192B run mode store failure system bus error 3 25 system bus failure 3 32 system configuration mismatch 3 22 too many bus controllers window completion failure 3 34 Fault group Fault handling alarm processor 3 10 Fault locating references 3 7 Fault references alarm contacts 3 8 configurable fault actions 3 4 fault contacts 3 7 fault locating references non configurable faults point faults 3 9 Fault response 3 12 Fault tables interpreting fault tables B 1 Fault type Faults accessing additional fault information addition of block addition of I O module 3 46 addition of IOC 3 45 addition of or extra rack 3 21 analog fault application fault 3 30 block switch 3 50 circuit fault 3 41 classes of faults 3 11 communications failure during store 3 36 configurable faults 3 18 constant sweep time exceeded 3 29 corrupted user program on power up 3 33 CTRL F key sequence B 2 discrete fault 3 43 displaying user defined faults 3 15 error code B 7 explanation and correction 3 1 extra block 3 47 extra I O module fault action fault attributes 3 11 fault description B 25 fault handling fault response forced and unforced circuit 3 50 GENA fault T O bus fault 3 48 V O fault action B 22 T O fault categor T O fault group T O fault table 3 14 T O fault table explanations 3 38
155. gram 1 Q WM T S WSA SB WSC G WR WAI and WAQ references are available throughout the system Appendix C contains a Memory Allocation worksheet for determining the total number of bytes of user data used and how much is still available for the user program Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Data Types Table 2 8 Data Types Type Name Description Data Format BOOL Boolean A Boolean data type is the smallest unit of memory It has two states 1 or 0 A BOOL string may have length N BYTE Byte A Byte data type has an 8 bit value It has 256 values 0 255 A BYTE string may have length N WORD Word A Word data type uses 16 consecutive bits of data memory The Register 1 valid range of word values is 0000 hex to FFFF hex L___ SC dsz sC 16 bot states 16 1 DWORD Double Word A Double Word data type has the same characteristics as a single Register 2 Register 1 word data type except that it uses 32 consecutive bits in data memory instead of only 16 bits 32 17 16 1 32 bit states UINT Unsigned Unsigned integers use 16 bit memory data locations They havea Register 1 Integer valid range of 0 to 65535 FFFF hex L Binary value 16 1 INT Signed Signed integers use 16 bit memory data locations and are Register 1 Two s Integer represented in 2 s complement notation The valid range of an
156. gramming software version 2 2 or later On line help for the BMA feature are available in Control software version 2 3 The BMA is a contiguous block of memory up to 4 Mbytes that can be used by logic programs and external devices BMA is available in the CPX CPUs CPX772 782 928 935 with CPU release 7 80 or later A service request SVCREQ 36 is used to read from the BMA to a local buffer area in the PLC write from the local buffer to the PLC and retrieve the address of the BMA in the PLC Genius Global Data The Series 90 70 PLC supports the sharing of data among multiple PLC systems that share a common Genius I O bus This mechanism provides a means for the automatic and repeated transfer of G I WQ WAI AQ and R data No special application programming is required to use global data since it is integrated into the I O scan All GE Fanuc PLCs that have Genius I O capability can send and receive global data from a Series 90 70 PLC Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Transitions and Overrides The I Q M and G user references have associated transition and override bits T S SA SB and SC references have transition bits but not override bits The CPU uses transition bits for counters transitional contacts and transitional coils Note that counters do not use the same kind of transition bits as contacts and coils Transition bits for counters are stored within the
157. he LD program Therefore the nested call limit is different from the limit described for calls from the _MAIN block The PLC will log an Application Stack Overflow fault and the PLC will transition to Stop Fault mode if a call results in insufficient stack space to complete the call Note Blocks which may execute as a result of a timed or I O interrupt should not be called from the _MAIN block or other Non Interrupt blocks because portions of the code executed by blocks are not re entrant In the example below INT1 2 60 Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B INT2 BLOCKS and PSB should not be called from _MAIN BLOCK2 BLOCK3 or BLOCK4 INT1 _MAIN Block INT2 BLOCK 2 BLOCK 5 BLOCK 3 gt PSB 1 BLOCK bo yj 4 I O Interrupt Blocks A block may be triggered by an interrupt input from certain hardware modules For example on the 32 Circuit 24 VDC Input Module IC697MDL650 the first input can be configured to generate an interrupt on either the rising or falling edge of the input signal If the module is configured in this manner that input can serve as a trigger to cause the execution of an LD or External block To program an I O Interrupt block the block must first be declared in the programming software It must then be associated with the interrupt through the use of
158. he LD program is suspended mid execution Refer to section 4 of this chapter for more information on Microcycle Sweep mode Differences in Operation LD and Standalone C Programs GFK 1192B Retentiveness of Data When only standalone C programs are used the retentive nature of data is based solely on memory type since there are no coil instructions In this case Q and M are retentive If both LD and standalone C programs are used the retentive property of memory types is driven by their use in the LD program For more information about retention of logic and data refer to the Retentiveness of Logic and Data discussion in section 2 of this chapter For more information on retentive properties of specific memory types refer to the Table 2 3 Chapter 2 System Operation 2 43 Global Data LD programs only have access to global data areas since they do not have the ability to use input output specifications This can lead to inconsistent output values if an LD program is used in Microcycle Sweep mode Interrupt Execution Interrupt blocks within the LD program have the highest priority in the system In addition they cannot be preempted while standalone C programs can be Queuing of Interrupts The 90 70 PLC can queue the invoking of Interrupt blocks within the LD program A standalone C program triggered by an interrupt will not be queued should another interrupt occur during the processing of the first interrupt In this cas
159. hen used with standalone C programs 2 44 System status references S 2 12 2 18 System status fault references 2 18 Sytem status references 2 19 T_MIN T_SEC 2 19 Temporary references T 2 12 Timed interrupts 2 62 Timed scheduling mode 2 51 Time of day clock 2 72 using SVCREQ function 16 to read the clock Rn using SVCREQ function 7 to read and set the clock 2 72 Timers 2 72 watchdog timer 2 73 using SVCREQ function 8 to restart the timer 2 73 Timing instruction A 1 Transitions 2 15 Triggered interrupt blocks Troubleshooting 3 1 accessing additional fault information 3 16 configurable faults 3 18 CTRL F key sequence B 2 fault handling 3 10 T O fault table 3 14 T O fault table explanations interpreting fault tables non configurable faults PLC fault table explanations 3 17 TroubleshootingFault category Index Index U User references 2 11 analog input register references AI analog output register references AQ 2 11 associated transitions and overrides 2 15 data scope data types 2 17 discrete references 2 12 global data references G 2 12 input references lI 2 12 internal references M 2 12 local register references L 2 11 output references Q 2 12 program register references P 2 11 register references size and default 2 13 system fault references 3 3 system register references R syste
160. iggered programs and Interrupt Blocks Timed and I O Triggered programs have higher priority than Ordered and Periodic programs The priority of a Timed or I O Triggered program specifies its priority relative to other Timed and 1 O Triggered programs The priority range 10 99 10 being the highest priority is reserved for Timed and I O Triggered programs which can run during any phase of the PLC sweep that is not restricted to running in the Logic Window Timed and I O Triggered programs operate this way when the PLC is running in Normal Sweep Constant Sweep or Constant Window mode In Microcycle Sweep mode I O Triggered programs are executed in the Logic Window and priorities of 100 109 100 being the highest priority are reserved for this mode Timed and I O Interrupt blocks have the highest priority of any user logic 2 52 Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B GFK 1192B Table 2 17 Priority Values for Timed and I 0 Triggered Programs Sweep Mode f Normal Sweep Scheduling Constant Sweep Mode Constant Window Microcycle Sweep Ordered Executed in order Not supported declared in the programming software Periodic Not supported Smallest period has highest priority 1 O Triggered 10 99 100 109 Timed 10 99 Not supported Ordered and Periodic scheduling modes have lower priority than Timed and 1 O Triggered scheduling modes User Program Execut
161. igured into the system The background checksum calculation also occurs during the output phase of the sweep During each output scan phase of the sweep the configured amount of words of user program is included in the checksum calculation This checksum helps to ensure the integrity of the user logic while the CPU is executing If the CPU is configured to perform a background checksum calculation 16 is the default then this part of the output phase is performed otherwise it is skipped There are other tests performed during the Output Scan Processor test checks basic operation of the microprocessor and BCP Opcode test checks basic operation of all BCP instructions Note Beginning with the Release 7 CPUs for Microcycle Sweep only the background checksum calculation will occur during the input phase of the sweep Programmer Communications Window 2 6 This part of the sweep is dedicated to communicating with the programmer and performing faulted board reconfiguration This is also when communication with the C debugger occurs If there is a programmer attached a debugging session is active or if there is a board in the system that requires reconfiguration as detected during the faulted board polling portion of the sweep the CPU executes the Programmer Window The Programmer Window will not execute if there is no programmer attached no active debug session occurring and no board to be configured in the system During the Programmer
162. imes can be found in table A 7 A 14 Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B GFK 1192B Table A 6 Worksheet A I O Module Sweep Time Number of expansion racks Sweep impact per expansion rack Number of discrete I O modules main rack Sweep impact per discrete I O module main rack Number of discrete I O modules expansion rack Seep impact per discrete I O module expansion rack Number of analog input base and output modules main rack Sweep impact per analog input base and output module main rack Number of analog input exander modules same segment main rack Sweep impact per analog input expander module same segment main rack Number of analog input exander modules new segment main rack Sweep impact per analog input expander module new segment main rack Number of analog input base and output modules expansion rack Sweep impact per analog input base and output module expansion rack Number of analog input base and output modules same segment exp rack Sweep impact per analog input base and output module same seg exp rack Number of analog input base and output modules new segment exp rack Sweep impact per analog input base and output module new seg exp rack Predicted Series 90 70 I O Module Sweep Impact Note If point faults are enabled substitute the corresponding times for point faults enabled as shown
163. in rack Sweep impact bytes of discrete I O data main rack Bytes of discrete I O data on GBCs expansion racks Seep impact bytes of discrete I O data expansion racks Words of analog I O data on GBCs main rack Sweep impact word analog I O data main rack Words of analog I O data on GBCs expansion racks Sweep impact word analog I O data expansion racks Predicted Genius I O Scan Impact GFK 1192B Appendix A CPU Performance Data A 19 Sweep Impact of FIP 1 0 and FBCs The sweep impact of FIP I O and FIP Bus Controllers FBC is similar to that of Series 90 70 I O There is an overhead for the I O scan that should be counted only once between the Series 90 70 T O scan and the FBC I O scan There is also a per FIP Bus Controller sweep impact a per scan segment sweep impact and a transfer time per word sweep impact for all I O data The sweep impact per FIP Bus Controller has three parts 1 Sweep impact to open the System Communications Window This is added only once when the first intelligent option module of which the FIP Bus Controller is one is placed in the system 2 Sweep impact to poll each FIP Bus Controller for background messages datagrams This part is an impact for every FIP Bus Controller in the system Note Both the first and second parts of the FIP Bus Controller s sweep impact may be eliminated by closing the System Communications Window setting its time to 0 This should only be
164. in rack per input expander module w point faults enabled in same segment in main rack per input expander module in new segment in main rack per input expander module w point faults enabled in new segment in main rack per input expander module in same segment in expansion rack per input expander module w point faults enabled in same segment in expansion rack per input expander module in new segment in expansion rack per input expander module w point faults enabled in new segment in expansion rack per fault message Rough Average per Channel no point faults Rough Average per Channel w point faults Times are in milliseconds except for those identified as microseconds Faults for discrete Series 90 70 I O modules are always polled for by the PLC CPU When one occurs it is always logged during one of the I O scan phase of the sweep These faults are only polled when point faults are enabled A 16 Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Note Functions in bold type in Table A 7 above impact the sweep continuously All other functions impact the sweep only when invoked Also not all of the timing information needed for the above table was available at print time for this manual the blank spaces Sweep Impact of Genius I O and GBCs The sweep impact of Genius I O and Genius Bus Controllers GBC is similar to that of Series 90 70 I O There is an overhead for the I O scan that
165. in the following table Appendix A CPU Performance Data An approximate per point or per channel average is shown in the following tables These averages are based on 1024 points 512 in and 512 out for discrete and 128 channels 96 in and 32 out for analog The 96 analog input channels consist of two base modules and five expanders Actual values will vary from the approximate average depending on the system I O configuration Note Not all of the sweep time information was available at the time this manual was printed the blank spaces in the table below Refer to the IPI for the specific CPU for this information Table A 7 Sweep Impact Time for Model 70 I O Modules and Racks CPX CPX 924 914 CPX 781 782 CPX 731 732 935 928 925 915 782 788 789 772 771 772 Rack Setup per expansion rack 0010 0010 0010 0010 0010 0010 0010 0500 Discrete I O Modules per I O module in main rack per I O module in main rack w point faults enabled per I O module in expansion rack per I O module in expansion rack w point faults enabled per fault message Rough Average per Point no point faults Rough Average per Point w point faults Analog I O Modules per input output module in main rack per input output module w point faults enabled in main rack per input or output module in expansion rack per input output module w point faults enabled in exp rack per input expander module in same segment in ma
166. increase the configured size of the reference data Error Code 26 Name Bad Program Specification Description The I O specification of a program is corrupted Correction Contact GE Fanuc Field Service Error Code All Others Name Module and Configuration Do not Match Description The PLC generates this fault when the module occupying a slot is not of the same type that the configuration file indicates Correction 1 Replace the module in the slot with the type indicated in the configuration file 2 Update the configuration file 3 24 Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B System Bus Error The fault group System Bus Error occurs when the PLC CPU receives a nonconfigurable interrupt bus error from the bus system The default fault action is Diagnostic Error Code 4 Name Unrecognized VME Interrupt Source Description The PLC generates this error when a module generates an interrupt not expected by the CPU unconfigured or unrecognized Correction 1 Ensure that all modules configured for interrupts have corresponding interrupt declarations in the program logic 2 Ensure that no thirdparty VME module is generating interrupts on the IRQ6 and IRQ7 lines Error Code All Others Name System Bus Error Description The PLC generates this fault when it has detected an error signal on the VME backplane such as a parity error Correction 1 Ens
167. ion in Normal Sweep Constant Sweep and Constant Window Modes In Normal Sweep Constant Sweep and Constant Window modes the 90 70 PLC can execute Ordered Timed and I O Triggered programs as well as Timed and I O Interrupt blocks Ordered programs execute in their entirety once per sweep in the Logic Window The programs execute in the order in which they are declared in the programming software The input specification is copied prior to execution of the program and the output specification is copied upon completion of the program In this way the output of one program can be used as input for the next if desired Chapter 2 System Operation 2 54 The following figure depicts two Ordered programs A and B executing in a typical PLC sweep in Normal Sweep mode Housekeeping Input Scan A Input Spec Copy A Execution A Output Spec Copy B Input Spec Copy B Execution B Output Spec Copy Output Scan Programmer Comm System Comm Background Window Figure 2 7 Ordered Program Execution Sequence In Normal Sweep Constant Sweep and Constant Window mode Timed and I O Triggered programs execute during any phase of the PLC sweep These programs will preempt the execution of Ordered programs and lower priority Timed and I O Triggered programs The input specification is copied at the time the program is scheduled to execute that is when the time interval expires or the I O Interrupt occurs The output specificati
168. it Refer to the C Programmer s Toolkit for Series 90 PLCs GFK 0646 for detailed information regarding external blocks How External Blocks Are Called External blocks are added to a user program by using the Librarian function in your programming software An external block executes when called from the program logic in the _MAIN block or from another block To facilitate the passing and returning of data an external block may have 0 to 7 parameter pairs In the following example if I00001 is set the external block named EXT_11 is executed The block operates on the input data located at reference addresses 100100 I00111 and 100001 100016 and produces values in the block of output data located at reference addresses T00001 T00016 and at register memory addresses RO00200 RO00201 The logic within the block can also control the Enable Out output of the external block l I00001 I I CALL EXT_11 l EXTERNAL Q00001 Q l l I00001 X2 R00200 I00100 X1 X1 T00001 Note Unlike other block types external blocks cannot call any other blocks Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B External Blocks and Local Data External blocks support the use of P global data External blocks do not have their own L data but instead inherit the L data of the calling block External blocks also inherit S c
169. ition to those faults listed above when the Genius Bus Controller reports one of the following faults it includes one of the bytes in table B 20 in the I O fault specific data e I O Bus fault e Module fault e IOC software fault e Extra Genius block e IOC hardware fault e Fxcessive faults e GBC software exception Block Switch When the fault category is Block Switch five bytes of fault specific data are used The first byte is encoded as shown in table B 20 The second byte contains the block configuration and is encoded as shown in table B 20 The third byte specifies the number of input circuits possibly used and the fourth byte specifies the number of output circuits possibly used The last byte byte 5 of fault specific data contains the rack slot address of the Genius bus controller which controlled the bus that the block switched off It is encoded with the slot number in the low four bits and the rack number in the high four bits Symbolic Fault Specific Data The following table lists data that is required for four kinds of fault specific data e Block circuit configuration e Block usage indication e Discrete analog indication e Loss of IOC error code Appendix B Interpreting Faults B 27 Table B 20 I O Fault Specific Data Decimal Number Description Circuit Configuration Circuit is an input Circuit is an output Circuit is an output with feedback Block Configuration Block configured for inputs only
170. ized Subroutine Block The following list contains several exceptions and restrictions that have been identified when using formal parameters within a Parameterized Subroutine Block 1 Transitional contacts transitional coils and retentive coils are not allowed with formal parameters The editor that is the editor tool within the programming package will substitute the non retentive equivalent of these functions M SM and M and display an appropriate warning message Formal BOOL input parameters cannot be used as output parameters on a function block The DO I O function is not allowed with formal parameters Multiword type function block parameters that is DINT DWORD or REAL are only allowed with formal NWORD parameters Formal parameters are not allowed on the following function block parameters Function Parameter Service Request Service Request PARMS input parameter Communications Request COMMREQ _ IN input parameter DATA_INIT Q output parameter DATA_INIT_COMM DATA_INIT_PID DATA_INIT_ASCII A Parameterized Subroutine Block s BOOL type formal parameters may not be passed to another Parameterized Subroutine Block WORD formal parameters cannot be passed into another Parameterized Subroutine Block s NWORD input parameter GFK 1192B Chapter 2 System Operation 2 35 2 36 External Blocks External blocks are created using the C Programmer s Toolk
171. l GFK 1192B Chapter 2 System Operation 2 75 Disabling Passwords The use of password protection is optional If the user desires to prevent the use of password protection passwords can be disabled using the programming software Note To re enable passwords after passwords have been disabled the PLC must be power cycled with the battery removed Password protection also prevents firmware upgrades to the FLASH memories used on the CPM 914 915 924 925 and the CPX772 782 928 and 935 Prior to attempting a firmware upgrade in any of these modules disable password protection then re enable it after the upgrade OEM Protection OEM protection is similar to the passwords and privilege levels however OEM protection provides a higher level of security The OEM protection feature is enabled disabled using a to 7 character password When OEM protection is enabled all read and write access to the PLC program and configuration is prohibited Protection for OEMs investment in software is provided in the form of a special password known as the OEM key When the OEM key has been given a non NULL value the CPU may be placed in a mode in which reads and writes of the logic as well as writes to the configuration are prohibited This allows a Third party OEM to create Control Programs for the PLC CPU and then set the OEM locked mode that prevents the end user from reading or modifying the program Note OEM protection also prevents fi
172. l information on each fault that is helpful when troubleshooting your system This information is called CTRL F data or Fault Detail You can access this information by highlighting the fault and pressing the CTRL and F keys together You can also double click the fault to see the Fault Detail dialog box DEFAULT PLC Detail LAN data memory exhausted check parms resu Fault Attributes Attribute Value Fault Extra Data Oc 01 03 00 00 00 00 00 00 00 00 00 00 00 00 00 0 Byte Help Fault Selector Raw Data Format B 2 Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B PLC Fault Table GFK 1192B The following diagram identifies each field in the fault entry 00 000080 00030100 OBO2 0400 FF16010400000000 Fault Extra Data Error Code Fault Action Fault Group Task Slot Rack Spare Long Short The following paragraphs describe each field in the fault entry Included are tables describing the range of values each field may have Long Short Indicator This byte indicates whether the fault contains 8 bytes or 24 bytes of fault extra data Type Code Fault Extra Data Short 00 8 bytes Long 01 24 bytes Spare These 3 bytes are pad bytes used to make the PLC fault table entry exactly the same length as the VO fault table entry Rack The rack number ranges from 0 to 7 Zero is the main rack containing the PLC Racks 1 through 7 are
173. l number ITEM_NOT_ 8D One or more specified items were not found FOUND_ERROR in Flash Memory All All PLC CPU Internal System Error GFK 1192B Appendix B Interpreting Faults B 7 The next table shows the error codes for all the other fault groups Table B 4 Alarm Error Codes for PLC CPU Faults Decimal Hexa Name decimal PLC Error Codes for Loss of Option Module Group 3 3 Bus Transmitter Module Found in Expansion Rack 22 16 Analog Expander Located to Left of Base Converter Module 25 19 Lost Analog Expander Module 44 2C Option Module Soft Reset Failed 45 2D Option Module Soft Reset Failed 59 3B Loss of or missing communications driver 60 3C Module in firmware update mode 65 41 Module is in Standalone mode mail system not initialized 255 FF Option Module Communication Failed Error Codes for Addition of or Extra Rack Group 1 1 Addition of or Extra Rack Error Codes for Reset of Addition of or Extra Option Module Group 2 2 Module Restart Complete 3 3 LAN Interface Restart Complete Running a Utility All others Reset of Addition of or Extra Option Module Error Codes for Module Hardware Error Group 1 1 Non fatal LAN Hardware error 416 1A0 Required 12V PS failed or missing 450 1C2 LAN Controller Underrun Overrun Resuming 451 1C3 LAN Interface Failure Switched Off Network 452 1C4 LAN Network Problem Performance Degraded 453 1C5 LAN Severe Network Problem Attempting Recovery 454 1C6 LAN Tra
174. lable for user programs is the activation of a program from a timed interrupt The Timed scheduling mode allows a user program to be executed along with its corresponding input and output specification copy on a user specified time interval with an initial delay if specified applied on a Stop to Run transition of the PLC Timed programs execute during any phase of the PLC sweep Refer to the User Program Execution earlier in this section for more information on the execution of Timed programs To program a Timed program the program must first be declared The scheduling mode must then be set to Timed Interrupt The time base options for Timed programs are specified in milliseconds The first execution of a Timed program will occur at Initial Delay Time Interval time base milliseconds after the PLC is placed in Run mode Note Standalone programs execute on a priority basis The user controls the setting of the priorities in I O Triggered and Timed scheduling modes via the chapter programming software 2 64 Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Interrupt Blocks vs Interrupt Programs GFK 1192B There are important differences to be aware of when choosing a program instead of a block to handle an interrupt When a block is selected to handle a Timed or I O Interrupt the block will execute immediately upon receipt of the interrupt and run until it completes Interrupt blocks c
175. les 2 4 and 2 5 for a listing of program sizes and reference limits for each CPU model The following figure depicts 3 user programs two of which are standalone C programs The LD program consists of four blocks MAIN LD_1 PSB_X and EXT4 The figure further illustrates the scoping of various memory types all references except P and L are visible to the standalone programs P memory is visible to all of the program blocks and the LD_1 block has its own local data L Details of standalone programs and blocks are described later in this section Program A Standalone Program B RLD Program C Standalone _MAIN P Memor LD_1 L User Data References l Q R Al AQ etc Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Ladder Logic Programming GFK 1192B An LD program for the Series 90 70 PLC consists of one or more units called blocks Four types of blocks are supported by the Series 90 70 PLC Table 2 13 Block Types Number of Block Programming Parameter Type Language Size Limit Pairs Notes LD Ladder Logic 32 KB in n a Control SFC Ladder 32 KB in n a SFC blocks cannot be used as Logic SFC Control Interrupt blocks PSB Ladder Logic 32 KB in 0 7 Control External C 64 000 bytes 0 7 External blocks cannot call any other blocks External blocks are created using the C Programmer s Toolkit When running in Logicma
176. lock switch circuit fault communications failure during store 3 36 configurable faults 3 18 constant sweep time exceeded 3 29 corrupted user program on power up 3 33 CTRL F key seq uence B 2 discrete fault 3 42 error code extra block 3 47 extra I O module fault category 3 38 fault description 3 38 Fault description 3 38 fault handling fault type 3 38 Fault type 3 38 forced and unforced circuit 3 50 GENA fault I O bus fault 3 48 T O fault group VO fault table V O fault table explanations 3 38 T O fault table full 3 29 interpreting fault tables IOC hardware failure 3 50 IOC software fault loss of block loss of I O module 3 46 loss of IOC 3 45 loss of or missing option module 3 19 loss of or missing rack 3 18 low battery signal low level analog fault microcycle time exceeded 3 29 module fault 3 49 module hardware failure 3 26 no user program on power up 3 32 non configurable faults 3 31 null system configuration for RUN mode 3 34 option module software failure 3 27 password access failure PLC CPU hardware failure PLC CPU system software failure 3 35 PLC fault group B 4 PLC fault table explanations 3 17 PLC system fault table full program block checksum failure 3 28 program microcycle time exceeded 3 29 reset of addition of or extra option module B21 Series 90 70 System Manual
177. lt conditions that may be set using the Genius I O Hand Held Monitor These defaults include the following e Report faults e Range select e Analog input and output scaling e Input filter time e Alarm input mode e Output hold last state e Output default These defaults are stored in EEPROM in the block itself The Series 90 70 PLC configuration utility supports the changing of only a small subset of these defaults For more information refer to the Genius I O System User s Manuals GEK 90486 1 and 2 Through the COMMREQ function block the application program can request the Bus Controller to change any default condition on a specific block However this change will only be accepted by the block if it is not in Config Protect mode If Config Protect mode is set only the Hand Held Monitor can be used to change the defaults The format of the COMMREQ function block for Genius I O is described in the Genius Bus Controller User s Manual GFK 0398 GFK 1192B Chapter 2 System Operation 2 79 Genius Global Data Communications 2 80 FIP 1 0 The Series 90 70 PLC supports the sharing of data among multiple PLC systems that share a common Genius I O bus This mechanism provides a means for the automatic and repeated transfer of G I WQ WAI AQ and R data No special application programming is required to use global data since it is integrated into the I O scan All GE Fanuc PLCs that have Genius I O capability can send global da
178. lue is 200 milliseconds The software watchdog timer always starts from zero at the beginning of each sweep The software watchdog timer is useful in detecting abnormal operation of the application program which prevents the PLC sweep from completing within the user specified time Examples of such abnormal application program conditions are as follows e Excessive recursive calling of a block e Excessive looping large loop count or large amounts of execution time for each iteration e Infinite execution loop When selecting a software watchdog value always set the value higher than the longest expected sweep time to prevent accidental expiration For Constant Sweep and Microcycle Sweep modes allowance for oversweep conditions should be considered when selecting the software watchdog timer value If the software watchdog timeout value is exceeded the OK LED blinks and the CPU goes to Stop Halt mode Certain functions however are still possible A fault is placed in the PLC fault table and outputs go to their default state If you are using serial communications not Ethernet the CPU will only communicate with the programmer no other communications or operations are possible To recover power must be cycled on the rack containing the CPU To extend the current sweep beyond the software watchdog timer value the application program may restart the software watchdog timer using Service Request function 8 However the software watchdog ti
179. lues to discrete output module Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Table A 1 Instruction Timing Continued Enabled Disabled Function 935 928 CPX772 935 928 CPX772 935 928 CPX772 Group Function CPX782 CPX782 CPX782 e 15 Data Move MOVE WORD Data Table TBLRD INT MOVE DWORD BLKMOV WORD BLKMOV DWORD SWAP WORD SWAP DWORD BLKCLR BITSEQ SHFR WORD SHFR DWORD SORT v N TBLRD DINT TBLWR INT TBLWR DINT FIFORD INT FIFORD DINT FIFOWRT INT FIFOWRT DINT LIFORD INT LIFORD DINT LIFOWRT INT LIFOWRT DINT ARRAY_MOVE BIT ARRAY_MOVE BYTE ARRAY_MOVE WORD ARRAY_MOVE DWORD SRCH BYTE SRCH WORD SRCH DWORD ARRAY_RANGE WORD ARRAY_RANGE DWORD ARUBUKR UUW AJXOwM XO A BN AN WN AN WwW BN ANWN AH wn a 2 5 5 5 uv ufi n Conversion to INT UINT Note 1 N Gro Be GFK 1192B to INT DINT to INT BCD 4 to DINT INT to DINT UINT to DINT BCD 8 to UINT INT to UINT DINT to UINT BCD 4 to BCD 4 INT to BCD 4 UINT to BCD 8 DINT Time in microseconds is based on Release 5 0 of Logicmaster 90 70 software For information not available when this manual was being printed represented by a dash refer to the IPI for each CPU For table functions increment is in units of length specified For bit operation functions microseconds bit For data mov
180. m status references S J 2 12 system status fault references 2 18 temporary references T 2 12 User defined fault 3 15 User defined function block 2 32 how parameterized subroutine blocks are called 2 33 referencing formal parameters restrictions on formal parameters 2 35 W Watchdog timer 2 73 using SVCREQ function 8 to restart the timer b 73 Wind down period Window modes Constant Window mode 2 7 Limited mode 2 7 Run to Completion 2 7 Index 7
181. match Category roo kW DN Model number mismatch detected by I O scanner Nonexistent I O module detected by I O scanner T O type mismatch detected by I O scanner Integral analog module detected expansion analog module mismatch Broadcast Data Length mismatch A configured feature is not supported B 24 Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B GFK 1192B Table B 18 I O Fault Types cont d I O Fault Types for GBC Software Exception Category Incoming datagram queue is full The queue for Read Write requests in the GBC is full The requests may be from the Genius Bus or from COMMREQs The low priority mail queue from the GBC to the PLC is full The response to the PLC was lost Genius background message requiring PLC action was received before PLC completed initialization Message was ignored Genius Report Fault message was not processed because GBC software revision is too old Excessive usage of internal GBC memory User should verify COMMREQ usage I O Fault Description The I O fault description component provides a specific fault code when the I O fault category is a circuit fault discrete circuit fault analog circuit fault low level analog fault or module fault It is undefined for other faults but is always set to zero The next two tables list the possible fault descriptions Table B 19 1 0 Fault Descriptions
182. mber 1999 GFK 1192B GFK 1192B Predicted Sweep Calculations Predicted Sweep Base Sweep IOM Impact Base Sweep Time T O Scan overhead 90 70 I O scan impact see table Worksheet A Genius I O scan impact see table ____ Worksheet B T O scan overhead PCM impact Number of PCMs LAN impact IOM impact Predicted Sweep Time Note Times are in milliseconds Appendix A CPU Performance Data A 33 A 34 Table A 19 Worksheet A Number of expansion racks Sweep impact per expansion rack Number of discrete I O modules main rack Sweep impact per discrete I O module main rack Number of discrete I O modules expansion rack Seep impact per discrete I O module expansion rack Number of analog input base and output modules main rack Sweep impact per analog input base and output module main rack Number of analog input exander modules same segment main rack Sweep impact per analog input expander module same segment main rack Number of analog input exander modules new segment main rack Sweep impact per analog input expander module new segment main rack Number of analog input base and output modules expansion rack Sweep impact per analog input base and output module expansion rack Number of analog input base and output modules same segment exp rack Sweep impact per analog input base and output module same seg exp rack Number of analog input base and output modules new
183. memory size in bytes for each function supported by these CPUs 1 GOP ST DN IE og SON Model CPM 924 925 Model CPM 914 915 Model CPU 781 782 Model CPU 788 89 Models CPU 731R and later CPU 732 CPU 771P and later and CPU 772 Models CPX 935 and CGR 935 Model CPX 928 Models CPX 772 and CGR 772 and CPX 782 Note All timing information for all CPUs was not available at the time this manual was printed Additional information will be added to a future edition Two execution times are shown for each function Execution Time Description Enabled Time required to execute the function or function block when power flows into and out of the function Typically best case times are when the data used by the block is contained in user RAM word oriented memory Disabled Time required to execute the function when it is not enabled Note Timers are updated each time they are encountered in the logic by the amount of time consumed by the last sweep A 1 Table A 1 Instruction Timing Enabled Disabled Increment Function 924 914 781 782 731 732 924 914 781 782 731 732 924 914 781 782 731 732 Group Function 925 915 788 789 771 772 925 915 788 789 771 772 925 915 788 789 771 772 Timers 6 5 10 5 78 5 5 8 22 5 53 Counters DINT SUB INT SUB DINT MUL INT MUL DINT DIV INT DIV DINT MOD INT MOD DINT ABS INT ABS DINT SQRT INT SQRT DINT
184. mer value may only be changed from the configuration software Hardware Watchdog Timer A backup circuit provides additional protection for the PLC If this backup circuit activates the PLC is immediately placed in Reset mode Outputs go to their default state no communications of any form are possible and the CPU will halt To recover power must be cycled GFK 1192B Chapter 2 System Operation 2 73 Section amp System Security The Series 90 70 PLC supports the following three types of system security 1 Passwords privilege levels 2 OEM protection 3 Write protect keyswitch Passwords and Privilege Levels Passwords are a configurable feature of the Series 90 70 PLC Their use is optional and may be set up using your programming software The purpose of passwords is to provide different levels of access privilege for the PLC when the programmer is in Online or Monitor mode Passwords are not used if the programmer is in Offline mode The use of passwords may restrict the following e Changing I O and PLC configuration data e Changing programs e Reading PLC data e Reading programs e Locking blocks The default state is no password protection There is one password for each privilege level in the PLC Each password may be unique however the same password can be used for more than one level Passwords are one to seven ASCII characters in length Only the programmer may change passwords PLC password protection can be used to
185. mily of PLCs Through the use of the latest design and manufacturing technology open architecture VME bus and the ability to connect to Genius and FIP I O and several CPU models the Series 90 70 PLC provides a powerful cost effective platform for small applications through the very largest Software Architecture The programming software architecture provides a platform upon which to build structured control programs Programs may be built from many program blocks each of which is related to a control function Structured programs permit parallel development of a complete program as a collection of program blocks developed independently by many different individuals or OEMs Structured programs are also easier to understand and debug A control program may be built of many smaller program blocks each of which can relate to a specific machine function This approach makes it easier to isolate and associate control logic with machine functions The programming language and representation are based on IEC working draft 65A standard Eventual adoption of this standard will make it easier to create programs that can be understood globally It establishes the Series 90 70 PLC in the vanguard of the movement toward recognized international standards Beginning with Release 6 PLC CPUs it has been possible to incorporate multiple programs into a folder All of these programs can be written in C or one program can be an RLD or SFC program with the remai
186. mmended This fault is logged each time the redundancy state changes and the two 780 CPUs contain incompatible firmware Ensure that both 780 CPUs have compatible firmware All Others PLC CPU Internal System Error An internal system error has occurred that should not occur in a production system Display the PLC fault table on the programmer Contact GE Fanuc PLC Field Service giving them all the information contained in the fault entry GFK 1192B Chapter 3 Fault Explanation and Correction 3 35 Too Many Bus Controllers The fault group Too Many Bus Controllers occurs when the I O Scanner portion of the PLC operating software detects that more than the maximum number 32 of bus controllers has been defined The PLC CPU itself is a bus controller for the Model 70 I O present in the system The default fault action for this group is Fatal Note Genius bus controllers which are configured for redundant and nonredundant blocks count as two bus controllers Correction Determine which modules are bus controllers and remove the extra ones Delete a bus controller from the configuration file and store the file to the PLC CPU If bus controllers have been moved from one slot in the rack to a different slot and this error did not occur before the move cycle power on the rack No module should be inserted with power applied to rack Display the PLC fault table on the programmer Contact GE Fanuc PLC Field Service giving them all the i
187. mmunications Windows When running in Constant or Limited Window mode the Programmer and System Communications Windows may be terminated early in all PLC sweep modes If an external device such as a GBC Genius Bus Controller is transferring a block of data the coherency of the data block may be disrupted if the communications window is terminated prior to completing the request The request will complete during the next sweep however part of the data will have resulted from one sweep and the remainder will be from the following sweep When the PLC is in Normal Sweep mode and the Communications Window is in Run to Completion mode the data coherency problem described above does not exist Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B CPU Sweep in STOP Mode GFK 1192B The 90 70 PLC has two modes of operation while it is in Stop mode Stop NoIO and Stop IOScan When the PLC is in Stop NoIO mode the Input Scan Logic Window and Output Scan phases of the PLC sweep are skipped When the PLC is in Stop IOScan mode the Logic Window phase of the PLC is skipped but the Input Scan and Output Scan phases are performed each sweep In both Stop NoIO and Stop IOScan modes the two Communications Windows run in Run to Completion mode and the Background Window runs in Limited mode with a 10 millisecond limit START OF SWEEP HOUSEKEEPING EXECUTES MPMT Hal
188. module The new configuration will not take effect until the module is reset Correction 1 Powereycle the entire system 2 Powereycle the rack containing the module Error Code 27 Name Unresolved or Disabled Interrupt Reference Description The PLC generates this error when an interrupt trigger reference is either out of range or disabled in the I O module s configuration Correction 1 Remove or correct the interrupt trigger reference 2 Update the configuration file to enable this particular interrupt Error Code 1D Name Incompatible Scheduling Mode Description A program with a scheduling mode that is incompatible with the sweep mode has been stored Logged on a StoptoRun transition Correction 1 Change the sweep mode and try again 2 Change the scheduling mode or delete the offending program s from the program declaration screen Error Code 24 Name TO Specification Mismatch Description The I O specification of a program does not match the specification given in the program Correction Correct the mismatch between the I O specification by changing the I O specification declaration or the corresponding macro declaration in the C program source file Error Code 25 Name Controller Reference Out of Range Description A reference on either the trigger disable or I O specification is out of the configured limits Correction Modify the incorrect reference to be within range or
189. mory e The associated device rack I O module or Genius device is added back into the system Whenever an Addition of fault is logged the PLC initializes all fault references associated with the device to the NoFlt state These references remain in the NoFIt state until another fault associated with the device is reported This could take several seconds for distributed I O faults especially if the bus controller has been reset e For FIP faults refer to the Series 90 70 FIP Bus Controller User s Manual GFK 1038 Note These fault references are set for informational purposes only They should not be used to qualify I O data The I O point fault references described on page 3 9 may be used to qualify I O data The PLC does not halt execution as a result of setting a fault locating reference to the Fault state The fault references have a cascading effect If there is a problem in the module located at rack 5 slot 6 bus 1 module 29 the following faults references are set RACK_05 SLOT_56 BUS_S61 and M_56129 There will only be one entry in the fault table to describe the problem with the module The fault table does not show entries pertaining to the rack slot and bus in this case A fault in FIP device at rack 5 slot 6 module 29 results in the following fault references being set RACK_05 SLOT_S6 F_56029 A module fault for a FIP Remote I O Scanner device results in only one module fault type fault reference bei
190. mote I O node on a FIP T O network The FIP Remote I O Scanner module provides the communications interface to the FIP I O network communications with the 90 70 FIP Bus Controller and also provides the I O scanning function for the local 90 30 I O modules For more information on the 90 30 FIP Remote I O Scanner please refer to the 90 30 FIP Remote I O Scanner User Manual GFK 1037 FIP Bus Interface Unit Field Control The FIP Bus Interface Unit provides the ability to use Field Control I O as a remote I O node on a FIP I O network The FIP Bus Interface Unit module provides the communication interface to the FIP I O network communications with the 90 70 FIP Bus Controller and also provides the I O Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B scanning function for the local Field Control modules For more information on FIP Field Control please refer to the FIP Bus Interface Unit User s Manual GFK 1175 Generic FIP 1 0 Generic FIP I O allows for configuring FIP I O other than the FIP Remote I O Scanner and FIP Bus Interface Unit This permits the 90 70 CPU and the 90 70 FIP Bus Controller to assign I O reference addresses to the generic FIP I O device The configuration selection also permits the 90 70 FIP Bus Controller to recognize the generic FIP I O module on the FIP I O network FIP I O Fault Data In the I O fault table the rack slot FIP drop ID remote rack and remote slot number a
191. mpact times that is the time added to the sweep by the function in question Sweep impact times are nominal Note There are two categories of sweep impact numbers listed in the tables those that impact the sweep every sweep and those that impact the sweep only when invoked The functions that impact the sweep every sweep are listed in bold type in each table In some of the tables functions are shown as asynchronously impacting the sweep This means that there is not a set phase of the sweep in which the function takes place For instance the scanning of all I O modules takes place during either the input or output scan phase of the PLC CPU s sweep However I O interrupts are totally asynchronous to the sweep and will interrupt any function currently in progress Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Base Sweep Times GFK 1192B The communication functions with the exception of the high priority programmer requests are all processed within one of the two windows in the sweep the Programmer Communications Window and the System Communications Window Sweep impact times for the various service requests are all minimum sweep impact times for the defined functions where the window times have been adjusted so that no timeslicing limiting of the window occurs in a given PLC sweep This means that as much as possible each function is completed in one occurrence of the window between cons
192. munications Window time Password Access Failure The fault group Password Actual Failure occurs when the PLC CPU receives a request to change to a new privilege level and the password included with the request is not valid for that level The default fault action for this group is Informational Error Code 0 Correction Retry the request with the correct password Null System Configuration for Run Mode The fault group Null System Configuration for Run Mode occurs when the PLC transitions from Stop to one of the Run modes and a configuration file is not present The transition to Run is permitted but no I O scans occur The effect of this fault is to perform the function of a Suspend T O The default fault action for this group is Informational Error Code 0 Correction Download a configuration file Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B PLC CPU System Software Failure Faults in the fault group PLC CPU System Software Failure are generated by the operating software of the Series 9070 PLC CPU They occur at many different points of system operation When a fatal fault occurs the PLC CPU immediately transitions into a special Error Sweep mode The only activity permitted when the PLC is in this mode is communications with the programmer The only method of clearing this condition is to cycle power on the PLC The default fault action for this group is Fatal Error Code Name De
193. n Extra Block The PLC operating software generates this error when it detects a Genius I O block on the bus at a serial bus address which the configuration file should not have a block 1 Remove or reconfigure the block It may be at the wrong serial bus address 2 Update and restore the configuration file to include the extra block GFK 1192B Chapter 3 Fault Explanation and Correction 3 47 3 48 I O Bus Fault The fault category I O Bus Faults has two fault types associated with it The default fault action is Diagnostic Name Description Correction Name Description Correction Name Description Correction Bus Fault The Genius Bus Controller operating software generates this error when it detects a failure with a Genius I O bus 1 Determine the reason for the bus failure and correct it 2 Replace the Genius Bus Controller Bus Outputs Disabled The Genius Bus Controller operating software generates this error when it times out waiting for the PLC CPU to perform an I O scan 1 Replace the PLC CPU 2 Display the PLC fault table on the programmer Contact GE Fanuc PLC Field Service giving them all the information contained in the fault entry SBA Conflict The Genius Bus Controller detected a conflict between its serial bus address and that of another device on the bus Adjust one of the conflicting serial bus addresses Series 90 70 System Manual for Control
194. n below does not include the two unbound events Table A 17 Timed Interrupt Performance and Sweep Impact Times CPX CPX 924 914 CPX 781 782 CPX 731 732 Sweep Impact Item 935 928 925 915 782 788 789 772 771 772 Timed interrupt sweep impact Fs Timed interrupt response time Typical interrupt latency interrupt to logic time Minimum response time Typical response time Maximum response time Times are in milliseconds Not all of the timing information needed for the above table was available at print time for this manual the blank spaces GFK 1192B Appendix A CPU Performance Data A 29 Table A 18 1 0 Triggered Interrupt Performance and Sweep Impact Times CPX CPX os 914 CPX 781 782 CPX i Impact Item Timed Timed interrupt sweep impact sweep impact Timed interrupt response time Typical interrupt latency interrupt to logic time Minimum response time Typical response time Maximum response time Times are in milliseconds Not all of the timing information needed for the above table was available at print time for this manual the blank spaces Examples of Calculating Predicted Sweep Times The following two examples are provided to show how to calculate predicted sweep times The first example is a small system and the second is a large system Neither of these sweep time estimates include a time for logic execution In both of these systems the calculated
195. n displayed in each field in the fault entry 02 1F0100 00030101FF7F 0302 02 00 00 84000000000003 Fault Specific Data Fault Description Fault Type Fault Category Fault Action Fault Group Point Block I O Bus Slot Rack Reference Address Long Short The following paragraphs describe each field in the I O fault table Included are tables describing the range of values each field may have Long Short Indicator This byte indicates whether the fault contains 5 bytes or 21 bytes of fault specific data Table B 12 1 0 Fault Table Format Indicator Byte Type Code Fault Specific Data Short 02 5 bytes Long 03 21 bytes Reference Address Reference address is a three byte address containing the I O memory type and location or offset in that memory which corresponds to the point experiencing the fault Or when a Genius block fault or integral analog module fault occurs the reference address refers to the first point on the block where the fault occurred Appendix B Interpreting Faults B 19 B 20 Table B 13 1 0 Reference Address Byte Description Range 0 Memory Type 0 FF 1 2 Offset 0 12K decimal The memory type byte is one of the following values Table B 14 I O Reference Address Memory Type Name Value Hexadecimal Analog input OA Analog output oC Analog grouped OD Discrete input 10 or 46 Discrete output 12 or 48 Discre
196. n may be present in a particular reporting of the fault Name Description Correction Name Description Correction Name Description Correction Name Description Correction Name Description Correction Name Description Correction Name Description Correction Name Description Correction Loss of User Side Power The Genius Bus Controller generates this error when there is a power loss on the field wiring side of a Genius I O block Correct the power failure Short Circuit in User Wiring The Genius Bus Controller generates this error when it detects a short circuit in the user wiring of a Genius block A short circuit is defined as a current level greater than 20 amps Fix the cause of the short circuit Sustained Overcurrent The Genius Bus Controller generates this error when it detects a sustained current level greater than 2 amps in the user wiring Fix the cause of the over current Low or No Current Flow The Genius Bus Controller generates this error when there is very low or no current flow in the user circuit Fix the cause of the condition Switch Temperature Too High The Genius Bus Controller generates this error when the Genius block reports a high temperature in the Genius Smart Switch 1 Ensure that the block is installed to provide adequate circulation 2 Decrease the ambient temperature surrounding the block Switch Failure The Ge
197. nal CPU memory for this data is 7680 bits long Your programming software provides the user with a subdivided representation by using G GA GB GC GD and GE prefixes allowing each of these prefixes to be used with bit offsets in the range 1 1280 Your programming software interprets the requested global reference type G GA GB GC GD or GE and converts it to the G memory type and correct bit offset for use by the CPU The actual mapping is shown in the table displayed below Table 2 6 G References and Memory Locations Global Data Type G GA GB GC GD GE References G1 1280 GA1 1280 GB1 1280 GC1 1280 GD1 1280 GE1 1280 Used by the Programming Software Memory G1 1280 G1281 G2561 G3841 G5121 G6401 Locations Used 2560 3840 5120 6400 7680 by the CPU This information is useful when programming 90 70 CPU applications in C language using the C Programmer s Toolkit For more information about using the C Programmer s Toolkit refer to the C Programmer s Toolkit for Series 90 PLCs User s Manual GFK 0646 Note A model 731 CPU supports only G since it has only 1280 points of global data Bulk Memory Access BMA Bulk Memory Access provides a large block of memory that can be accessed from your application program Possible uses include recipe files bulk storage memory allocation temporary memory blocks and so forth Use of this feature requires Control pro
198. nalog output register This prefix is followed by the register address of the reference for example AQO0056 An analog output register holds the value of one analog output or another value P Use the prefix P to assign program register references that will store program data from the _MAIN block This data can be accessed from all program blocks The size of the P data block is based on the highest P reference in all blocks For more information refer to the Appendix C Memory Allocation L Use the prefix L to assign local register references that will store program data unique to a block The size of the L data block is based on the highest L reference in the associated block For more information refer to Appendix C Memory Allocation These reference types are scoped at a program level and are therefore only visible to LD programs Note All register references are retained across a power cycle to the CPU Chapter 2 System Operation 2 11 2 12 Table 2 3 Discrete References Type I Description The I prefix represents input references This prefix is followed by the reference s address in the input table for example 100121 I references are located in the input status table which stores the state of all inputs received from input modules during the last input scan A reference address is assigned to discrete input modules using your programming software Until
199. ne condition may be present in a particular reporting of the fault Name Description Correction Name Description Correction Name Description Correction Name Description Correction Name Description Correction Name Description Correction Name Description Correction Name Description Correction Name Description Correction Input Channel Low Alarm The Genius Bus Controller generates this error when the Genuis Analog module reports a low alarm on an input channel Correct the condition causing the low alarm Input Channel High Alarm The Genius Bus Controller generates this error when the Genuis Analog module reports a high alarm on an input channel Correct the condition causing the high alarm Input Channel Under Range The Genius Bus Controller generates this error when the Genuis Analog module reports an underrange condition on an input channel Correct the problem causing the condition Input Channel Over Range The Genius Bus Controller generates this error when the Genuis Analog module reports an overrange condition on an input channel Correct the problem causing the condition Input Channel Open Wire The Genius Bus Controller generates this error when the Genuis Analog module detects an open wire condition on an input channel Correct the problem causing the condition Wiring Error The Genius Bus Controller generates this
200. nformation contained in the fault entry Communications Failure During Store 3 36 The fault group Communications Failure During Store occurs during the store of programs or blocks and other data to the PLC The stream of commands and data for storing programs or blocks and data starts with a special startofsequence command and terminates with an endofsequence command If communications with the programming device performing the store is interrupted or any other failure occurs which terminates the store this fault is logged As long as this fault is present in the system the controller will not transition to Run mode This fault is not automatically cleared on powerup the user must specifically clear the condition The default fault action for this group is Fatal Error Code 0 Correction Clear the fault and retry the download of the program or configuration file Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Run Mode Store Failure Error Code Description Correction Error Code Description Correction Error Code Description Correction 1 Communications was lost or power was lost during a Run Mode Store The new program or block was not activated and was deleted Perform the Run Mode Store again This fault is diagnostic 2 Communications was lost or power was lost during the cleanup of old programs or blocks during a Run Mode Store The new program or blo
201. ng set For example if FIP module with station ID 43 in 9070 rack 3 slot 9 is an FIP Remote I O Scanner and within the FIP Remote I O Scanner there is a faulted module in the FIP Remote I O Scanner s rack 1 slot 5 then only fault reference F_39043 will be set Alarm Contacts 3 8 High HIALR and low LOALR alarm contacts are used to represent the state of the analog input module comparator function However the use of point faults must first be enabled in Hardware Configuration For details about enabling Point Fault References refer to the Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Logicmaster User s Manual GFK 0263 or the online help in Hardware Configuration within Control The following example logic uses both high and low alarm contacts l I AI0001 Q00003 HIALR SAIO002 LOALR l Note HIALR and LOALR contacts will not create an entry in a fault table Point Faults Point faults pertain to external I O faults although they will also be set due to the failure of associated higherlevel internal hardware for example IOC failure or loss of a rack In order to use point faults they must be enabled in Hardware Configuration For details about enabling Point Fault References refer to the Logicmaster User s Manual GFK 0263 or the online help in Hardware Configuration within Control When enabled a boolean reference for each discrete I O
202. ning programs written in C In addition Release 6 and later CPUs have built in debugging capabilities for C programs and external blocks For more information on this feature refer to the C Programmer s Toolkit manual GFK 0646C or later Terminology Used in This Manual The following terms are used with their defined meanings throughout this manual User program any user generated code that is an RLD program an SFC program or a standalone C program Block any RLD block Parameterized Subroutine Block or external block an external block being either a C block or an C function block CFBK GFK 1192B 1 1 Fault Handling Faults are handled by a software alarm processor function which time stamps and logs I O and system faults in two tables the PLC fault table and the I O fault table These tables can be displayed on the programming software screen or uploaded to a host computer or other coprocessor Application programs can also gain access to the fault information Hardware Configuration Using This Manual Configuration is the process of assigning physical locations logical addresses and parameter values to the hardware modules in the system It may be done either before or after programming however it is recommended that configuration be done first This manual is distributed with Control programming software and describes the PLC hardware and programming features available in the CPU Refer to the current IPI distri
203. nius Bus Controller generates this error when the Genius block reports a failure in the Genius Smart Switch Replace the Genius I O block Point Fault The PLC generates this error when it detects a failure of a single I O point on a Genius I O module Replace the Genius I O block Output Fuse Blown The PLC generates this error when it detects a blown fuse on a Genius I O output block 1 Determine and repair the cause of the fuse blowing and replace the fuse 2 Replace the block Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Analog Fault Analog Fault has nine fault descriptions More than one condition may be present in a particular reporting of the fault Name Input Channel Low Alarm Description The Genius Bus Controller generates this error when the Genius Analog module reports a low alarm on an input channel Correction Correct the condition causing the low alarm Name Input Channel High Alarm Description The Genius Bus Controller generates this error when the Genius Analog module reports a high alarm on an input channel Correction Correct the condition causing the high alarm Name Input Channel Under Range Description The Genius Bus Controller generates this error when the Genuis Analog module reports an underrange condition on an input channel Correction Correct the problem causing the condition Name Input Channel Over Range Description The Genius Bus Contr
204. nsceiver Fault Off Network Until Fixed Error Codes for Option Module Software Failure Group 1 1 Unsupported Board Type 2 2 COMREQ _ mailbox full on outgoing message that starts the COMREQ 3 3 COMREQ _ mailbox full on response 4 4 More Than One BTM in Rack 5 5 Backplane Communications with PLC Lost Request 10 A Error with LAN interaction 11 B Resource alloc tbl ovrflw etc error 12 C VME backplane error 13 D User program error 401 191 Module Software Corrupted Requesting Reload 402 192 LAN System Software Fault Resuming 403 193 LAN System Software Fault Aborted Assoc and Resuming 404 194 LAN System Software Fault Restarted LAN I F 405 195 LAN System Software Fault Reinitializing LLC B 8 Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Table B 4 Alarm Error Codes for PLC CPU Faults continued Name Error Codes for System Configuration Mismatch Group Genius Block Model Number Mismatch Genius Block I O Type Mismatch Daughter Board Mismatch Analog Expansion Mismatch Genius Block Broadcast Control Data BCD Length Mismatch Unsupported Feature Revision A BTM not in Right Slot LAN Duplicate MAC Address LAN Duplicate MAC Address Resolved LAN MAC Address Mismatch LAN Soft Switch Modem Mismatch Genius Block Direct Control Data DCD Length Mismatch Program exceeds memory limits Incompatible scheduling mode Reference length mismatch Invalid configuration parameter
205. ntroller or a FIP Bus Controller Heavily loaded I O controllers should be placed in the main rack whenever possible Any one of these events extends the interrupt latency the time from when the interrupt card signals the interrupt to the CPU to when the CPU services the interrupt beyond the typical value However the latency of an interrupt occurring during the processing of a preceding I O interrupt is unbounded I O interrupts are processed sequentially so that the interrupt latency of a single I O interrupt is affected by the duration of the execution time of all preceding interrupt blocks Worst case is that every I O interrupt in the system occurs at the same time so that one of them has to wait for all others to complete before it starts A 26 Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B The maximum response time shown below does not include the two unbound events Table A 14 1 0 Interrupt Block Performance and Sweep Impact Times CPX CPX 924 914 CPX 781 782 CPX 731 732 Sweep Impact Item 935 928 925 915 782 788 789 772 771 772 THO imerptsveepinpae oss T O interrupt response time Input card filter time typical interrupt latency interrupt to logic time Minimum response time Typical response time Maximum response time T O interrupt rate limit 450 ints sec T O interrupt rate limit w no 750 ints sec IOMs Times are in milliseconds Not all of the timing
206. o restart the watchdog timer 5 COMMREQ WAIT Mode Not Supported The module receiving the COMMREQ does not support WAIT mode COMMREQs Use NOWAIT mode COMMREQs 6 COMMREQ Bad Task ID The task selected by the COMMREQ does not exist on the option module Correct the task ID 7 Application Stack Overflow Block call depth has exceeded the PLC capability Increase the program s stack size or adjust application program to reduce nesting 8 through D LAN Interface Application Faults Refer to the LAN Interface manual GFK9868 or GFK 9869 previously GFK 9533 for a description of these errors Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Error Code Name Description Correction Error Code Name Description Correction Error Code Name Description Correction Error Code Name Description Correction Error Code Name Description Correction 1C Program Exceeded Wind Down A program failed to complete execution within the winddown period currently 2 5 seconds after the PLC was commanded to stop A program has gone into an infinite loop or is taking too long to execute Correct the coding error or modify the program 1D Program Not Readied A program scheduled to be readied has not completed its previous execution The base cycle time is too small Periodic programs or the interrupt rate is too high I OTriggered or Tim
207. oe eame ninina bdo ole Ga seta c eda i en eii e e e ooeacetees 2 17 System Status References nnnc arenans esteris teei eiie iiaa 2 18 Fault References rninn lhon edie ett hs he akar N he ets 2 21 Section 3 Program Organization cccssssssscssccsssssssssssssccccsssssssssssccsesees 2 24 Ladder Logic Programming seeeseceeeeseeeeeesseeecesseeeesesaeeceesesnaeeeeessaeeeseesaes 2 25 Main BlOCKiticciddnaada tite dete tei teltsicteictsicteictsicteicbsictei tes tei cts tei bei teke 2 26 BIOCKS 0055 amp sieves sian ees vastness ninae otic omen eu D mata cae E N Mca NNSA SNAS eS ENS 2 27 Examples of Using BIOcKS 0 ccesscceesseceeseceeeeeeeeeeeesaeeecnneeesseaeeeeeesnseeeeenneeseas 2 27 How Blocks Are Called ss ars cs5c deus iets een a ict agen a e ea e E A 2 30 Blocks and Local Data cccccccssssccccccesssssseeeeeeececcesssssseeeeeeceesssssneeeeeeeeeess 2 31 Parameterized Subroutine BIOCKS ccccccceeeseccccceecceseseeeececeeeeeeeeecesseesaaaaeeeeeess 2 32 Parameterized Subroutine Blocks and Local Data ccccccccccccccccccceeeeeeeeeeeeeeeeees 2 32 How Parameterized Subroutine Blocks Are Called ccccccccccecscccecceecesseeeeeeeees 2 33 Referencing Formal Parameters Within a Parameterized Subroutine Block 2 34 Restrictions on Formal Parameters within a Parameterized Subroutine Block 2 35 External BIOCKS ccecccescccsccccccdscccsccctccescccug edsvee cveusseuds sues E
208. ogram or block exiting the program or block and restarting the interrupted task The maximum I O interrupt rate reflects the limit of T O interrupts invoking a minimal program or block at a sustained rate over time The time to execute the logic contained in the interrupt program or block will affect the limit by causing the PLC to spend more time servicing I O interrupts and thus reduce the maximum I O interrupt rate The minimum typical and maximum interrupt response times reflect the time from when a single I O module sees the input pulse until the first line of ladder logic or C code is executed in the I O interrupt program or block Minimum response time reflects a 300 microsecond input card filter time time from interrupt occurrence to first line of ladder logic in I O interrupt program or block The minimum response time can only be achieved when no intelligent option modules are present in the system and the programmer is not attached Typical response time is the minimum response time plus a maximum interrupt latency of 2 0 milliseconds for the model 731 CPU This interrupt latency time is valid except when one of the following operations occurs e The programmer is attached e A store of logic RUN mode store or word for word change occurs e A fault condition logging of a fault occurs e Another I O interrupt occurs e The CPU is transferring a large amount of input or output data from an I O controller such as a Genius Bus Co
209. oller generates this error when the Genuis Analog module reports an overrange condition on an input channel Correction Correct the problem causing the condition Name Input Channel Open Wire Description The Genius Bus Controller generates this error when the Genuis Analog module detects an open wire condition on an input channel Correction Correct the problem causing the condition Name Output Channel Under Range Description The Genius Bus Controller generates this error when the Genuis Analog module reports an underrange condition on an output channel Correction Correct the problem causing the condition Name Output Channel Over Range Description The Genius Bus Controller generates this error when the Genuis Analog module reports an overrange condition on an output channel Correction Correct the problem causing the condition Name Invalid Data Description The Genius Bus Controller generates this error when it detects invalid data from a Genuis Analog input block Correction Correct the problem causing the condition Name Expansion Channel Not Responding Description The PLC generates this error when data from an expansion channel on a multiplexed analog input board is not responding Correction 1 Check wiring to the module 2 Replace the module GFK 1192B Chapter 3 Fault Explanation and Correction 3 43 3 44 LowLevel Analog Fault Low Level Analog Fault has nine fault descriptions More than o
210. ollowing figure illustrates three successive PLC sweeps in Microcycle Sweep mode with a base cycle time of 100 milliseconds Note that the sweep time is constant and the Communications and Background Windows are guaranteed to run for the configured window timer In sweep n and sweep n 1 the Logic finishes early an I O Triggered program can execute during that time In sweep n 2 the Logic Window is not complete and is suspended so that the Communications and Background Windows can run for the specified window time In each case the logic window stays open for the entire time allowed for logic GFK 1192B Chapter 2 System Operation 2 49 2 50 SWEEP n t Oms Time Allowed for Base Logic Cycle Time SWEEP n 1 t 100 ms OUTPUT BG Abbreviations HK Housekeeping PRG Programmer Window SYS System Communications Window BG Background Window Figure 2 6 Typical Sweeps in Microcycle Sweep Mode Note a45532 SWEEP n 2 t 200 ms Run Mode Store of logic is not supported in Microcycle Sweep mode Also the Single Sweep Debug feature is not supported in Microcycle Sweep mode Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Program Scheduling Modes Each user program in the 90 70 PLC can execute subject to sweep mode restrictions in one of four program scheduling modes This section will briefly describe the following four available program scheduling modes e Ordered e Time
211. om Stop to Run mode Only valid if the PLC is in Constant Sweep or Microcycle Sweep mode Also cleared when the PLC fault table is cleared S A0003 APL_FLT Set when an application fault occurs Cleared when the PLC fault table is cleared S A0009 CFG_MM Set when a configuration mismatch is detected during system power up or during a store of the configuration Cleared by powering up the PLC when no mismatches are present or during a store of configuration that matches hardware Also cleared when the PLC fault table is cleared SAO0010 HRD_CPU Set when the diagnostics detects a problem with the CPU hardware Cleared by replacing the CPU module Also cleared when the PLC fault table is cleared SA0011 LOW_BAT Set when a low battery fault occurs Cleared by replacing the battery and ensuring that the PLC powers up without the low battery condition Also cleared when the PLC fault table is cleared SA0012 LOS_RCK Set when an expansion rack stops communicating with the PLC CPU Cleared by fixing the problem and power cycling the rack Also cleared when the PLC fault table is cleared Chapter 2 System Operation 2 19 2 20 Table 2 9 System Status References Continued Reference SA0013 Name LOS_IOC Definition Set when a Bus Controller stops communicating with the PLC Cleared by replacing the module and cycling power on the rack containing the module or
212. on is copied upon completion of the program Timed and I O Interrupt blocks execute during any phase of the PLC sweep These blocks will preempt the execution of all programs and have the highest priority of any user logic in the PLC Timed and I O Interrupt blocks do not have an input or output specification copy The following figure depicts 2 Ordered programs A and B an I O Triggered program C with priority 10 a Timed program D with priority 20 and an I O Interrupt block all executing in a typical PLC sweep in Normal Sweep mode Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B SWEEP n Housekeeping Input h San Suspended F Input Scan D Input Spec Copy F C Input Spec Copy i 2 B Execution i D Execution H Suspended Suspended C Execution Suspended Interrupt Block E E i I lt Od l B Execution B Output Spec Copy System Comm System Comm Window Interrupt Block E Suspended Background Window X I O interrupt occurs invoking Event Triqgered Program Y Timed interrupt occurs invoking Timed Program Z I O interrupt occurs invoking 1 O interrupt block E Figure 2 8 Ordered Timed 0 Triggered and Interrupt Block Execution Sequence GFK 1192B Chapter 2 System Operation 2 55 User Program Execution in Microcycle Sweep Mode In Microcycle Sweep mode the 90 70 PLC can execute Periodic and I O Triggered programs as well a
213. ontacts such as FST_EXE from the calling block If L references are used within an external block and the block is called by _MAIN L references will be inherited from the P references wherever encountered in the external block for example LO005 P0005 data P Inherits as L _MAIN EXT 1 BLOCK gt data AL Inherits as L BLOCK EXT 2 1 Local Data Initialization When an external block is stored to the PLC a copy of most of its internal data is saved Global and static initialized data are saved but if static variables are declared without an initial value the initial value is undefined and must be initialized by the C application Refer to the Global Variable Initialization and Static Variable parts in Section 6 of Chapter 2 of the C Programmer s Toolkit for Series 90 PLCs GFK 0646 This data is used to reinitialize the block s data area whenever the PLC transitions from Stop to Run External standalone programs do not use L data but the internal data they use is somewhat similar to local data as discussed above Internal data used in a standalone program should not be confused with L data GFK 1192B Chapter 2 System Operation 2 37 Standalone C Programs Like external blocks standalone programs are developed using the C Programmer s Toolkit Unlike external blocks however standalone C Programs
214. orts a bus fault a global memory fault or an IOC hardware fault Cleared by cycling power on the rack containing the module and when the configuration matches the hardware after a store or when the I O fault table is cleared Set when an I O module reports a circuit or module fault Cleared by cycling power on the rack containing the module and when the configuration matches the hardware after a store or when the I O fault table is cleared SA0027 HRD_SIO Set when a hardware failure is detected in an option module Cleared by replacing the module and cycling power on the rack containing the module or when the PLC fault table is cleared SA0029 SFT_IOC Set when there is a software failure in the I O Controller or when the I O fault table is cleared S A003 1 SFT_SIO Set when an option module detects an internal software error Cleared by cycling power on the main rack and when the configuration matches the hardware or when the PLC fault table is cleared S A0032 SBUS_ER Set when a bus error occurs on the VME bus backplane Cleared by cycling power on the main rack SA0081 SAOI12 Set when a user defined fault is logged in the PLC fault table These bits are cleared when the PLC fault table is cleared SB0001 WIND_ER Set when there is not enough time to start the Programmer Window in Constant Sweep or Microcycle Sweep mode or when there is not enough time to start the Logic
215. p condition begins at an absolute time relative to the Stop to Run transition of the PLC Finally the Communications and Background Windows are guaranteed to run for at least the specified Window time each sweep The Logic Window will be suspended if necessary to guarantee that the Communications and Background Windows get to run for the specified Window time The base cycle time and the window timer value can be configured with a base cycle time of between 5 and 2550 milliseconds The Constant Window timer can be any value from 5 to 255 milliseconds The base cycle time and Constant Window timer may also be set while the PLC is in Stop mode The base cycle time and window timer cannot be changed while the PLC is in Run mode In Microcycle Sweep mode Periodic programs execute on a priority basis Periodic programs have priority inverse to their period smallest period has highest priority Refer to the User Program Execution discussion later in this section for more information on Periodic programs and their execution If the PLC sweep exceeds the base cycle time in a given sweep the PLC places an oversweep alarm in the PLC fault table and sets the OV_SWP SA0002 status reference at the beginning of the next sweep The OV_SWP status reference is reset when the last sweep time does not exceed the base cycle time Sweep time due to an oversweep condition in a given sweep causes the next sweep to be shortened by the oversweep time The f
216. peration A unters ADD INT ADD DINT SUB INT SUB DINT MUL INT MUL DINT DIV INT DIV DINT MOD INT MOD DINT ABS INT ABS DINT SQRT INT SQRT DINT ational EQ INT EQ DINT NE INT NE DINT GT INT GT DINT GE INT GE DINT LT NT LT DINT LE INT LE DINT CMP INT CMP DINT RANGE INT RANGE DINT Bit AND WORD AND DWORD OR WORD OR DWORD XOR WORD XOR DWORD NOT WORD NOT DWORD MCMP WORD MCMP DWORD SHL WORD SHL DWORD SHR WORD SHR DWORD ROL WORD ROL DWORD ROR WORD ROR DWORD BTST WORD BTST DWORD BSET WORD BSET DWORD BCLR WORD BCLR DWORD MOVE BIT BPOS WORD BPOS DWORD SHER BIT 935 Function 5 5 25 6 5 5 Enabled 928 eee CPX772 6 935 GEX782 935 928 CPX782 CPX772 CPX772 Size 16 5 20 5 Increment Time in microseconds is based on Release 5 0 of Logicmaster 90 70 software For information not available at print time for this manual represented by a dash refer to the IPI for that CPU For table functions increment is in units of length specified For bit operation functions microseconds bit For data move functions microsec onds the number of ts or rds Enabled time is for single length units of type R COMMREQ time has been measured between CPU and EX7 with NOWAIT option DOIO is the time to output va
217. plication available references to be set and cannot have alarm blocks associated with the detection of the fault Some non configurable faults also have other effects associated with them Generally these effects control the changing of the CPU s execution mode Stop Run Disabled Run Enabled An example of such an effect is the disabling of I O when a null system configuration is detected in the system Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B PLC Fault Table The PLC fault table displays PLC faults such as password violations PLC configuration mismatches parity errors and communications errors The programmer may be in any operating mode However if the programmer is in Offline mode no faults are displayed In Online or Monitor mode PLC fault data is displayed In Online mode faults can be cleared this may be password protected Top Fault Displayed The index of the PLC fault currently at the top of the fault display is shown on the first line of this screen Total Faults The total number of faults since the table was last cleared Table Last Cleared The date and time faults were last cleared from the fault table This information is maintained by the PLC Entries Overflowed The number of entries lost because the fault table has overflowed since it was cleared The PLC fault table can contain up to 40 faults 16 prior to Release 6 configurable in Control PLC Time Date The
218. point fault and a byte reference for each analog I O channel level fault are allocated in PLC memory The PLC memory used for point faults is included in the total reference table memory size The FAULT and NOFLT contacts described above provide access to the point fault GFK 1192B Chapter 3 Fault Explanation and Correction 3 9 Section 2 Fault Handling Note This information on fault handling applies to systems programmed using Control Faults occur in the Series 9070 PLC system when certain failures or conditions happen which affect the operation and performance of the system These conditions such as the loss of an I O module or rack may affect the ability of the PLC to control a machine or process These conditions may also have beneficial effects such as when a new module comes online and is now available for use Or these conditions may only act as an alert such as a low battery signal which indicates that the battery protecting the memory needs to be changed For information on system status fault references refer to Chapter 2 section 3 Program Organization Alarm Processor 3 10 The condition or failure itself is called a fault When a fault is received and processed by the CPU it is called an alarm The software in the CPU which handles these conditions is the Alarm Processor The interface to the user for the Alarm Processor is through the programming software Any detected fault is recorded in a fault table and di
219. pplication ID is shown for reference Table B 7 GENA Application ID Numbers Number Decimal Hexadecimal Description 131 83 115Vac 230Vac 125Vdc Power Monitor Module 132 84 24 48Vdc Power Monitor Module 160 AO Genius Remote 90 70 Rack Controller When the system configuration mismatch is an I O type mismatch the installed module I O type is one of the following Table B 8 Genius Installed Module I O Types Value Description 01 Input only 02 Output only 03 Combination When the system configuration mismatch is an I O type mismatch the configured module I O type is one of the following All values are in hexadecimal Table B 9 Genius Configured Module I O Types Value Decimal Hexadecimal Description 0 0 Discrete input Discrete output 2 2 Analog input 3 3 Analog output 4 4 Discrete grouped 5 5 Analog grouped 20 14 Analog in discrete in 21 15 Analog in discrete out 24 18 Analog in discrete grouped 30 1E Analog out discrete in 31 1F Analog out discrete out 34 22 Analog out discrete grouped 50 32 Analog grouped discrete in 51 33 Analog grouped discrete out 54 36 Analog grouped discrete grouped GFK 1192B Appendix B Interpreting Faults B 13 B 14 Program Block Checksum Failure The name of the offending program block is contained in the first eight bytes of the Fault Specific Data field PLC CPU Hardware Failure RAM Failure For a RAM
220. process or whenever else the module may go through configuration Model 70 discrete output modules default to all outputs off The configuration utility provides the ability to specify whether the CPU transitions from Run Enabled to Run Disabled or Stop mode It also applies this default information when the system halts Information relative to using Genius I O in a Series 90 70 PLC system is presented in the following paragraphs For specific information on Genius I O block types configuration and setup refer to the Genius I O System User s Manuals GEK 90486 1 and 2 Genius I O Bus Configuration The Bus Controller used in the Series 90 70 PLC controls a single Genius I O bus Any type of Genius I O block may be attached to the bus In the I O fault table the rack slot bus module and I O point number are given for a fault Bus number one refers to the bus on the single channel Genius Bus Controller Genius I O Data Mapping Genius I O discrete inputs and outputs are stored as bits in the CPU Bit Cache memory Genius T O analog data is stored in the application RAM allocated for that purpose AI and AQ Analog data is always stored one channel per one word 16 bit An analog grouped module consumes in the input and output data memories only the amount of data space required for the actual inputs and outputs For example the Genius I O 115 VAC Grouped Analog Block IC660CBA100 has four inputs and two outputs it consumes fou
221. pt P and L which are slightly slower The read and write service requests have two boundary conditions that change the times and are therefore broken up into three sets of times to reflect these boundary conditions Table A 13 Fixed Sweep Impact Times for Intelligent Option Modules CPX CPX 924 914 CPX 781 782 CPX 731 732 Sweep Impact Item 935 928 925 915 782 788 789 772 771 772 Intelligent Option Modules First module open comm window Per module polling LAN module I O Scan PCM ADC GDC clock refresh PLC Memory Access from IOMs Read write 1 to 3 words Read write 4 to 128 words Read write each additional 128 words Times are in milliseconds Not all of the timing information needed for the above table was available at print time for this manual the blank spaces Refer to the IPI for each CPU for this information Ik Reads can only fit 3 words into the basic message Writes can fit 4 words before a 256 byte text buffer is needed Appendix A CPU Performance Data A 25 Note Functions in bold type in the previous table impact the sweep continuously All other functions impact the sweep only when invoked I O Interrupt Performance and Sweep Impact There are several important performance numbers for I O interrupt blocks or I O Triggered programs The sweep impact of an I O interrupt invoking an empty program or block measures the overall time of fielding the interrupt starting up the pr
222. r 1999 GFK 1192B GFK 1192B Decimal Number Description 29 1D VME bus error occurred while reading input diagnostics 30 1E CPU IOC communications failed 31 1F VME bus error occurred while writing output data to IOC 32 20 CPU IOC communications failed 33 21 CPU IOC communications failed 34 22 CPU IOC communications failed 35 23 VME bus error 36 24 VME bus error 37 25 Unable to read data from IOC for redundant I O blocks 38 26 Unable to write data to IOC for redundant I O blocks 39 27 IOC does not support configured I O redundancy 40 28 IOC failed to respond to a CPU request 41 29 I O scanner detected too many IOCs in the system 42 2A I O scanner detected too many IOCs in the system 43 2B VME bus error 44 2C VME bus error Fault Actions for Specific Faults Forced unforced circuit faults are reported as informational faults All others are diagnostic or fatal The model number mismatch I O type mismatch and nonexistent I O module faults are reported in the PLC fault table under the System Configuration Mismatch group They are not reported in the T O fault table I O Fault Time Stamp The six byte time stamp is the value of the system clock when the PLC CPU recorded the fault Values are coded in BCD format Table B 21 1 0 Fault Time Stamp Byte Number Description 1 Seconds 2 Minutes 3 Hours 4 Day of the month 5 Month 6 Year Appendix B Interpreting Faults B 29 B 30 Loss of I O Block E
223. r instructions can be found in Appendix A Note In Microcycle Sweep mode the Logic Window can be skipped or preempted as necessary by the PLC Executive Output Scan Outputs are scanned immediately following logic solution During the output scan the CPU sends output data to the Genius Bus Controllers FIP Bus Controllers and Series 90 70 output modules Beginning with Release 7 0 Ethernet global data is also produced in this phase Series 90 70 output modules are scanned from lowest to highest I O reference address Bus Controllers are scanned from rack 0 to rack 7 and lowest to highest slot number within each rack Note The output scan will not be performed if a program has an active Suspend I O function on the current sweep When referring to FIP in this scan only periodic VCOM MPS services are affected Messages are received in the System Communication Window GFK 1192B Chapter 2 System Operation 2 5 Polling for faulted boards also occurs during the output scan phase of the sweep Faulted board polling recognizes replacement boards for faulted ones and reconfigures them into the system If a board that was previously in the system or configured by the user to be in the system is listed as faulted it must be polled periodically to determine if a new board has replaced it Once a previously faulted board is detected as no longer faulted reconfiguration is run in the Programmer Communications Window until the board s are reconf
224. r module with one corresponding to configured module 2 Update the configuration file 9 Genius I O Block Size Mismatch The PLC generates this error when block configuration size does not match the configured size Reconfigure the block Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Error Code A Name Unsupported Feature Description Configured feature not supported by this revision of the module Correction 1 Update the module to a revision that supports the feature 2 Change the module configuration Error Code B Name Revision A of BTM not in Right most Slot Description The BTM Revision A version is not the rightmost module in the rack Correction 1 Move the BTM to the right of all other modules in the rack 2 Upgrade the BTM to a newer version Revision B or higher Error Code E Name LAN Duplicate MAC Address Description This LAN Interface module has the same MAC address as another device on the LAN The module is off the network Correction 1 Change the module s MAC address 2 Change the other device s MAC address Error Code F Name LAN Duplicate MAC Address Resolved Description Previous duplicate MAC address has been resolved The module is back on the network This is an informational message Correction None required Error Code 10 Name LAN MAC Address Mismatch Description MAC address programmed by softswitch utility
225. r the IOC exists in the configuration file Correction 1 Verify that the module in the slot bus address is the correct module 2 Review the configuration file and verify that it is correct 3 Replace the module 4 Display the PLC fault table on the programmer Contact GE Fanuc PLC Field Service giving them all the information contained in the fault entry Addition of IOC I O Controller The fault category Addition of I O Module has no fault types or fault descriptions associated with it The default fault action for this category is Diagnostic Name Addition of IOC Description The PLC generates this error when an IOC which has been faulted returns to operation or when an IOC is found in the system and the configuration file indicates that no IOC is to be in that slot Correction 1 No action is necessary if the faulted module is in a remote rack and is returning due to a remote rack power cycle 2 Update the configuration file or remove the module GFK 1192B Chapter 3 Fault Explanation and Correction 3 45 Loss of I O Module The fault category Loss of I O Module applies to Model 70 I O discrete and analog modules There are no fault types or fault descriptions associated with this category The default fault action is Diagnostic Name Loss of I O Module Description The PLC generates this error when it detects that a Model 70 I O module is no longer responding to commands from the PLC CPU or when the con
226. r to meet the timing requirements of the serial protocol Reference Table The sweep impact to refresh the reference table screen The R table was used as the Monitor example Mixed table display impacts are slightly larger The sweep impact may not be continuous depending on the sweep time of the PLC and the speed of the host of the programming software Editor Monitor The sweep impact to refresh the editor screen when monitoring ladder logic The times given in the table are for a logic screen containing one contact two coils and eleven registers As with the reference table sweep impact the impact may not be continuous Word for Word The sweep impact to change a constant input on a MOVE_UINT function from 1 to 2 Change This is the smallest change that can be made A change to a coil requires updates to the coil use and retentive maps contained in the PLC If the Q or M reference address is changed on a function block then the size of the change to the coil use and retentive maps can be quite large A large word for word change will have very little sweep impact if done with the parallel programmer worst case of 35 ms on a 731 CPU A large word for word change will have a big sweep impact if done with the serial programmer The time is linear for the number of bytes in the request with the worst case being slightly larger than the worst case for parallel ALT S Store The sweep impact to store a 933 byte program block The sweep imp
227. r words of Analog Input memory AJ and two words of Analog Output memory A discrete grouped module each point of which is configurable with the Hand Held Monitor HHM to be input output or output with feedback consumes an amount in both discrete input memory I and discrete output memory Q equal to its physical size Therefore the 8 I O 115 VAC Discrete Grouped Block IC660CBD100 requires 8 bits in the I memory and 8 bits in the Q memory regardless of how the block is configured Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B The following four Genius I O blocks are assigned to the analog memories e 6 Channel Analog Grouped Block e 6 Channel Thermocouple Block e 6 Channel RTD Block e 4 Channel Strain Gauge mV Analog Input Block The Thermocouple and RTD blocks are also referred to as Low Level Analog Input blocks Analog Grouped Block The Analog Grouped block contains four analog input channels and two analog output channels When a block gets its turn on the Genius I O Bus it broadcasts the data for all four input channels in one broadcast control message Then when the Bus Controller gets its turn it sends the data for both output channels to the block in a directed control message Low Level Analog Blocks Unlike the Analog Grouped block the low level analog blocks are input only blocks All have six channels Default Conditions Genius I O blocks have a number of defau
228. re 1001000 00000000 00000000 The value of the mantissa then is 5625 that is Fig 2 Since e gt 0 and e lt 255 we use the third formula in the table above number 15 287127 1 f 10 2130 127 1 5625 1 23 1 5625 8 1 5625 12 5 GFK 1192B Appendix D Using Floating Point Numbers D 3 2 Thus you can see that the above binary representation is correct The range of numbers that can be stored in this format is from 1 401298E 45 to 3 402823E 38 and the number zero Entering and Displaying Floating Point Numbers In the mantissa up to six or seven significant digits of precision may be entered and stored however the software will display only the first six of these digits A positive or negative sign may precede the mantissa If no sign is entered the floating point number is assumed to be positive If an exponent is entered it must be preceded by the letter E or e and the mantissa must contain a decimal point to avoid mistaking it for a hexadecimal number The exponent may be preceded by a sign but if none is provided it is assumed to be positive If no exponent is entered it is assumed to be zero No spaces are allowed in a floating point number To provide ease of use several formats are accepted in both command line and field data entry These formats include an integer a decimal number or a decimal number followed by an exponent These numbers are converted to a stan
229. re given for faults occurring in an FIP Remote I O Scanner or FIP Bus Interface Unit controlled remote I O node No fault information can be obtained from generic FIP I O FIP I O Data Mapping FIP I O discrete inputs and outputs are stored as bits in the CPU Bit Cache memory FIP I O analog data is stored in the application RAM allocated for that purpose AI and AQ Analog data is always stored one channel per one word 16 bit An analog grouped module consumes in the input and output data memories only the amount of data space required for the actual inputs and outputs For example an analog module with four inputs and two outputs consumes four words of Analog Input memory AJ and two words of Analog Output memory Default Conditions FIP I O devices have a number of default conditions that may be set using your programming software The default conditions include the following e Range select e Analog input scaling e Analog output scaling e Discrete output default Off fixed e Analog output default Hold Last State fixed Diagnostic Data Collection GFK 1192B Diagnostic data in a Series 90 70 PLC I O system is obtained in one of the following two ways 1 If an I O module has an associated Bus Controller Genius Bus Controller or FIP Bus Controller then the Bus Controller provides the module s diagnostic data for the CPU 2 Ifan I O module is a Model 70 I O module then the CPU s I O Scanner subsystem genera
230. ring the execution phase will not affect this program s local copies of input or output data 3 When the program completes its local output specification is copied back to the specified set of user data reference areas Two particular concerns are addressed by using an input output specification First if a program is suspended in mid execution and an output scan is performed before execution is resumed output values will remain consistent since the output scan values are obtained from the user data reference locations Second if a program is interrupted mid execution by another program the first program is unaffected by changes to global data caused by the second program since it has its own local copy of data Another benefit to using an input specification is to provide a more accurate sampling of input values If a program s execution is postponed due to higher priority programs the input specification may provide the program with a set of data that more accurately represents the state of that data when the program was scheduled since global user reference data may have been modified by higher priority programs or by the scanning of input values Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B GFK 1192B Input Output Specifications Unlike external blocks standalone C and LD programs cannot have any input or output parameters Standalone C programs may utilize an input output specification that
231. rmware upgrades to the FLASH memories used on the CPM 914 915 924 925 and CPX772 782 928 and 935 Prior to attempting a firmware upgrade in any of these modules disable OEM protection then enable it again after the upgrade Write Protect Keyswitch The 90 70 CPU models CPU 780 781 782 788 789 914 924 915 925 CGR 772 and 935 and CPX 772 782 928 and 935 all contain a memory write protect keyswitch This keyswitch is located on the top of the faceplate above the upper faceplate to rack clip When in the protected position the PLC program and configuration cannot be modified or deleted Note The write protect keyswitch when in the write protected position also prevents firmware upgrades to the Flash memories used on the CPM 914 915 924 925 and CPX 772 782 928 and 935 Prior to attempting a firmware upgrade in any of these modules place the write protect keyswitch into the write enabled position 2 76 Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Section 9 Series 90 70 PLC I O System The Series 90 70 PLC I O system provides the interface between the Series 90 70 PLC and user supplied devices and equipment The I O system supports the rack type Model 70 I O the Genius I O system and the FIP I O system A Genius I O Bus Controller GBC module provides the interface between the Series 90 70 PLC CPU and a Genius I O bus A FIP I O Bus Controller FBC module provides
232. rror Code Fault Action Fault Group Task Slot Rack Spare Series 90 70 System Manual for Control Software Users November 1999 Long Short GFK 1192B Low Battery Signal Example The Low Battery fault is described below All data is in hexadecimal Field Value Description Long Short 00 This fault contains 8 bytes of fault extra data Rack 00 Main rack rack 0 Slot 01 Slot 1 In all configurations slot 1 in rack 0 contains the PLC CPU Task 00 PLC CPU Fault Group 12 Low battery signal Fault Action 02 Diagnostic fault Error Code 01 Error code 01 in the Low Battery group is one of four low battery conditions detected by the PLC CPU Fault Extra Data No fault extra data for a low battery signal This fault occurred because the PLC CPU detected a low battery signal 00 1F4100 00010000 1202 0100 01010B300BE069602 Fault Extra Data Error Code Fault Action Fault Group Task Slot Rack Spare Long Short GFK 1192B Appendix B Interpreting Faults B 17 B 18 User Application Fault Example The User Application Fault is described below All data is in hexadecimal Field Value Description Long Short 00 This fault contains 8 bytes of fault extra data Rack 00 Main rack rack 0 Slot 03 Slot 3 In this configuration slot 3 contains a Genius Bus Controller Task 7F When the GBC registers a User Application fault in the P
233. s BAD_RAM fatal Corrupted program memory at power up Program could not be read and or did not pass checksum tests WIND_ER information Window completion error Servicing of Programmer or Logic Window was skipped Occurs in Constant Sweep or Microcycle Sweep mode BAD_PWD information Change of privilege level request to a protection level was denied bad password NUL_CFG fatal No configuration present upon transition to Run mode Running without a configuration is equivalent to suspending the I O scans SFT_CPU fatal CPU software fault A non recoverable error has been detected in the CPU May be caused by Watchdog Timer expiring MAX_IOC fatal The maximum number of bus controllers has been exceeded The Series 90 PLC supports 32 bus controllers STOR_ER fatal Download of data to PLC from the programmer failed some data in PLC may be corrupted Note Fault and FIP locating references are discussed in Chapter 3 section 1 of this manual Refer to the Series 90 Sequential Function Chart Programming Language User s Manual GFK 0854 for SFC references Chapter 2 System Operation 2 23 Section 3 Program Organization The user program s contains the logic that is used to process input data and control output data Program logic is executed repeatedly by the PLC The Series 90 70 PLC allows up to 16 user programs with a maximum of 1 LD program Refer to Tab
234. s Window completion error Servicing of Programmer or Logic Window was skipped Occurs in Constant Sweep or Microcycle Sweep Mode Change of privilege level request to a protection level was denied bad password No configuration present upon transition to Run mode Running without a configuration is equivalent to suspending the I O scans CPU software fault A nonrecoverable error has been detected in the CPU May be caused by Watchdog Timer expiring The maximum number of bus controllers has been exceeded The Series 90 PLC supports 32 bus controllers Download of data to PLC from the programmer failed some data in PLC may be corrupted Sets SY_FLT HRD_FLT and SY_PRES Does not set any references PLC will not go to Run mode it continues executing Stop mode sweep until a valid program is loaded This can be a null program that does nothing Sets SY_FLT and SY_PRES Sets SY_FLT and SY_PRES Sets SY_FLT and SY_PRES Sets SY_FLT and SY_PRES Sets SY_FLT and SY_PRES PLC immediately transitions to Error Sweep mode The only activity permitted is communication with the programmer To be cleared PLC power must be cycled Sets SY_FLT SY_PRES and SFT_FLT Sets SY_FLT SY_PRES and SFT_FLT PLC will not transition to Run mode This fault is not cleared at powerup intervention is required to correct it Sets SY_FLT and SY_PRES GFK 1192B Fault Contacts Fault FAULT and nofault NO
235. s 17 32 32 Erast Significant Bit Bit 17 La Most Significant Bit Bit 32 Values of Floating Point Numbers Use the following table to calculate the value of a floating point number from the binary number stored in two registers Exponent e Mantissa f Value of Floating Point Number 255 Non zero Not a valid number NaN 255 0 15 oo 0 lt e lt 255 Any value 15 je 127 1f 0 Non zero 15 7 126 x 0 f 0 0 0 f the mantissa The mantissa is a binary fraction o Il the exponent The exponent is an integer E such that E 127 is the power of 2 by which the mantissa must be multiplied to yield the floating point value the sign bit the multiplication operator Ilol For example consider the floating point number 12 5 The IEEE floating point binary representation of the number is 01000001 01001000 00000000 00000000 or 41480000 hex in hexadecimal form The most significant bit the sign bit is zero s 0 The next eight most significant bits are 10000010 or 130 decimal e 130 The mantissa is stored as a decimal binary number with the decimal point preceding the most significant of the 23 bits Thus the most significant bit in the mantissa is a multiple of 2 the next most significant bit is a multiple of 2 and so on to the least significant bit which is a multiple of 2 The final 23 bits the mantissa a
236. s New configuration requires reset T O specification mismatch Controller reference out of range Bad interrupt trigger Error Codes for System Bus Error Group Unrecognized VME Interrupt Error System Bus Error Error Codes for Program Block Checksum Group Corruption of program block header in the Series 90 70 PLC Corruption of stored OMF records stored in Series 90 70 PLC Corruption of stored OMF records stored in Series 90 70 PLC Program or program block checksum failure Error Codes for Low Battery Signal Decimal Hexa decimal 2 2 4 4 ob 7 8 8 9 9 10 A 11 B 14 E 15 F 16 10 17 11 19 13 23 17 29 1D 30 1E 31 1F 32 20 36 24 37 25 39 27 4 4 All others 0 0 1 1 2 2 3 3 0 0 1 1 2 2 3 3 Failed battery on PLC CPU or other module Low battery on PLC CPU or other module Failed battery from VME backplane Low battery from VME backplane GFK 1192B Appendix B Interpreting Faults B 9 Table B 4 Alarm Error Codes for PLC CPU Faults continued Decimal Hexa Name decimal Error Codes for User Application Fault Group 1 1 Indirect Reference Address Out of Range 2 2 PLC Watchdog Timer Timed Out 3 3 GBC COMREQ 4 4 GBC Bkgnd msg Bad Genius Bus Request 5 5 COMREQ WAIT mode not available for this command 6 6 COMREQ Bad Task ID 7 7 Application Stack Overflow 8 8 LAN Data Memory Exhausted Check Parms Resuming 9 9 Bad Remo
237. s Timed and I O Interrupt blocks Periodic programs execute in the Logic Window These programs are scheduled to execute based on the program s period For example a program with a period of will be scheduled to execute every PLC sweep and a program with a period of 2 will be scheduled to execute every other PLC sweep Periodic programs have priority inverse to their period smallest period has highest priority These programs are subject to time sliced execution over multiple sweeps based on the time available to the Logic Window Unlike Ordered programs the input specification is copied at the beginning of the Logic Window for all Periodic programs that are scheduled to begin execution in a given sweep In other words all input specification copies will occur for Periodic programs before any of the Periodic programs begin or continue executing The output specification is copied upon completion of the program The following figure depicts two Periodic programs A and B executing in a typical PLC sweep in Microcycle Sweep mode Housekeeping Input Scan A Input Spec Copy B Input Spec Copy A Execution A Output Spec Copy B Execution B Output Spec Copy Output Scan Programmer Comm System Comm Background Window Figure 2 9 Periodic Program Execution Sequence Unlike other sweep modes I O Triggered programs execute in the Logic Window only when the PLC is in Microcycle Sweep mode If the I O Interrupt occurs during or prior to
238. s in a typical PLC sweep as shown in the following figure t Figure 2 1 Phases of a Typical PLC Sweep Chapter 2 System Operation HOUSEKEEPING START OF SWEEP INPUT SCAN APPLICATION PROGRAM TASK EXECUTION LOGICWINDOW OUTPUT SCAN PROG WINDOW SCHEDULED 2 4 YES PROGRAMMER COMMUNICATIONS WINDOW COMM WINDOW SCHEDULED 4 YES SYSTEM COMMUNICATIONS WINDOW BACKGROUND TASK SCHEDULED 4 BACKGROUND WINDOW START NEXT SWEEP 2 3 Housekeeping Input Scan 2 4 Table 2 1 Major Phases in a Typical PLC Sweep Step Description Housekeeping Updating S bits determining timer update values and determining the sweep mode occur in this phase Input Scan The CPU reads input data from Bus controllers and input modules during this phase Application Program Task Execution Logic Window The CPU solves the logic program s using data obtained from the input devices and sets bits to affect the state of output devices Output Scan The CPU writes output data to Bus controllers and output modules during this phase The user program checksum is computed during this phase of the sweep Polling for faulted boards also occurs during this phase Programmer Communications Window Communication with the programmer when using serial occurs here with data and or s
239. 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 power loss or Run to Stop to Run transitions and cannot be used with retentive coils PS PSA SB PSC The S SA SB and SC prefixes represent system status references These references are used to access special 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 Once the bit is set on by an error it will not be reset until after the sweep S SA SB and SC can be used on any contacts e 6 SA SB and SC can be used on retentive coils M e S can be used as word or bit string input arguments to functions or function blocks 6 SA SB and SC can be used as word or bit string input or output arguments to functions and function blocks S SA SB and SC references are non retentive G PGA GB GC GD GE The G GA GB GC GD and GE prefixes represent global data references These references are used to access data shared among several PLCs G GA GB GC GD and GE references can be used on contacts and retentive coils because the memory is always retentive G GA GB GC GD and GE cannot be used on non retentive coils Retenti
240. scription Correction Error Code Name Description Correction Error Code Name Description Correction Error Code Name Description Correction Error Code Name Description Correction Error Code Name Description Correction 14 27 Corrupted PLC Program Memory The PLC generates these errors when certain PLC operating software problems occur These should not occur in a production system 1 Display the PLC fault table on the programmer Contact GE Fanuc PLC Field Service giving them all the information contained in the fault entry 2 Perform the corrections for corrupted memory 52 Backplane Communications Failed The PLC generates this error when it attempts to comply with a request that requires backplane communications and receives a rejected mail response 1 Check the bus for abnormal activity 2 Replace the intelligent option module to which the request was directed Check parallel programmer cable for proper attachment 5A User Shut Down Requested The PLC generates this informational alarm when SVCREQ 13 User Shut Down executes in the application program None required Informationonly alarm 7B Remote I O Scanner Communications Heartbeat Failure Refer to the Series 9070 Remote I O Scanner User s Manual GFK9579 for a description of this error None required Informationenly alarm 94 Units Contain Mismatched Firmware Update Reco
241. segment exp rack Sweep impact per analog input base and output module new seg exp rack Predicted Series 90 70 I O Module Sweep Impact Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B GFK 1192B Table A 20 Worksheet B Open system communications window GBC I O scan GBC poll for background messages Number of GBCs Input block scan segments number of Input block scan segments sweep impact Output block scan segments number of Output block scan segments sweep impact Bytes of discrete I O data on GBCs main rack Sweep impact bytes of discrete I O data main rack Bytes of discrete I O data on GBCs expansion racks Seep impact bytes of discrete I O data expansion racks Words of analog I O data on GBCs main rack Sweep impact word analog I O data main rack Words of analog I O data on GBCs expansion racks Sweep impact word analog I O data expansion racks Predicted Genius I O Scan Impact Appendix A CPU Performance Data A 35 Table A 21 Sample Worksheet A Number of expansion racks Sweep impact per expansion rack Number of discrete I O modules main rack Sweep impact per discrete I O module main rack Number of discrete I O modules expansion rack Seep impact per discrete I O module expansion rack Number of analog input base and output modules main rack Sweep impact per analog input base and output module
242. sition Several operations are performed by the CPU on Stop to Run transition These operations include the following e Validation of sweep mode and program scheduling mode selections e Validation of references used by programs with the actual configured sizes e Reinitialization of data areas for external blocks and standalone C programs e Clearing of non retentive memory Run to Stop Transition Wind Down Period for Microcycle Sweep Mode When the PLC is running in Microcycle Sweep mode refer to section 4 for information about Microcycle Sweep mode a wind down or logic solution period may occur after the PLC is commanded to Stop mode This wind down period is equal to the amount of time that the currently executing program s take to complete their execution unless that amount of time exceeds 2 5 seconds If the currently executing programs exceed 2 5 seconds in their attempt to complete their executions a fault will be logged in the PLC fault table and the CPU will complete its transition to Stop mode During the wind down period no additional programs including Interrupt programs and blocks will be scheduled for execution Input Scans Output Scans Communications Windows Programmer and System and the Background Window continue during the wind down period Note By definition exceeding the CPU wind down period means that not all programs completed execution prior to the PLC going to Stop mode Furthermore when the PLC is nex
243. splayed on either the PLC fault table screen or the I O fault table screen as applicable Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Classes of Faults The Series 9070 PLC detects several classes of faults These include internal failures external failures and operational failures Table 3 5 Classes of Faults Internal Failures Nonresponding modules Low battery condition Memory checksum errors External I O Failures Loss of rack or module Addition of rack or module Loss of Genius I O block Operational Failures Communication failures Configuration failures Password access failures System Reaction to Faults Typically hardware failures require that either the system be shut down or the failure be tolerated T O failures may be tolerated by the PLC system but they may be intolerable by the application or the process being controlled Operational failures are normally tolerated Series 9070 PLC faults have three attributes Table 3 6 Fault Attributes Fault Table Affected I O fault table PLC fault table Fault Action Fatal Diagnostic Informational Fault Response Configurable Noneonfigurable Fault Tables The two fault tables the PLC fault table and the I O fault table are provided in this chapter to make faults easier to find GFK 1192B Chapter 3 Fault Explanation and Correction 3 11 3 12 Fault Action Fatal faults cause the fault to be record
244. ster compatibility mode the limit is 16 KB e SFC programming is described in detail in the Series 90 Sequential Function Chart Programming Language User s Manual GFK 0854 Sequential Function Chart SFC is an IEC compliant graphical state language specifically designed for controlling sequential processes e LD also known as Relay Logic Diagram language is the language used in the LD Editor window within Control and in Logicmaster e PSB Parameterized Subroutine Blocks are LD blocks that have input and output parameters Note Up to 255 blocks can be used The maximum number of block calls that can be programmed within a given block is 64 The maximum number of programmed calls to a particular block is 255 A block can be executed any number of times but there cannot be more than 255 explicit calls to any given block Chapter 2 System Operation Main Block When using an LD program there is always a_MAIN block LD program execution begins with the _MAIN block read inputs _MAIN BLOCK write outputs 2 26 Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Blocks Structuring a program as blocks enables you to reuse logic Logic that needs to be repeated can be entered in a block Calls would then be made to that block to execute the logic In this way total program size is reduced Dividing a program into smaller blocks also simplifies programming and r
245. sweep is for normal sweep time with point faults disabled the PCM idle and the programmer not attached The times used in the calculation are extracted from tables A 3 A 5 A 7 A 8 and A 10 Sample forms for calculating predicted sweep times are provided after the examples Small System 32PT 32PT 32PT 32PT Input Input Output Output 4 5 6 MAIN RACK A 30 Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Sweep Calculations Predicted Sweep Base Sweep 4 170 Scan PCM Impact Base Sweep Time T O Scan Impact I O Scan Overhead Series 90 70 I O Scan Impact Number of discrete I O modules main rack Sweep impact time per discrete I O module Number of analog base and output modules main rack Sweep impact time per analog base and output module TO Scan Impact 0 32 16 T O scan overhead PCM Impact First module open comm window Per module polling Predicted Sweep Time Note Times are in milliseconds GFK 1192B Appendix A CPU Performance Data A 31 Large System GBC GBC GBC GBC 20Blks 20Blks 16Blks 16Blks MAIN RACK 32PT 32PT 16CHN Output Output Analog Expander 32PT 32PT 16CHN Output Output Analog Expander Note The Genius block configuration used for this example is ala 16 point grouped QD blocks with all bus addresses having contiguous reference addresses A 32 Series 90 70 System Manual for Control Software Users Nove
246. t 81 Watchdog timeout discrete I O modules only 82 Aux fault on discrete I O modules 83 Series 90 70 I O individual point fault also indicated for CIRCUIT_FAULT category 84 Series 90 70 output fuse blown also indicated for CIRCUIT_FAULT category Fault Descriptions for GENA Faults 80 Fault on a GENA analog or discrete point 87 Fault on Remote I O Scanner The following analog faults also apply when the low level analog fault type is indicated AI_LOW_ALARM AI_HI_ ALARM AI_UNDER_RANGE AI_OVER_RANGE and OPEN_WIRE EE These faults are reported under the HEADEND_FAULT fault type I O Fault Specific Data An I O fault table entry may contain up to 21 bytes of I O fault specific data In general this area contains additional information related to the fault Not all entries contain I O fault specific data This section describes those that do All but one of these faults uses five bytes of I O fault specific data the global memory fault uses the 21 byte entry If a fault is not listed it does not have I O fault specific data Faults originated by the Genius Bus Controller always have at least one byte of I O fault specific data This byte is in addition to whatever other data might be present Circuit Fault Circuit fault entries use one or two bytes of the fault specific data area When the Genius Bus Controller reports the fault the Genius Bus Controller generates the first byte If the fault type is a
247. t S0007 ALW_ON Always ON S0008 ALW_OFF Always OFF S0009 SY_FULL Set when the PLC fault table fills up size configurable with a default of 16 entries Cleared when the PLC fault table is cleared S0010 IO_FULL Set when the I O fault table fills up size configurable with a default of 32 entries Cleared when the I O fault table is cleared S0011 OVR_PRE Set when an override exists in I Q M or G memory S0012 FRC_PRE Set when force exists on a Genius point S0013 PRG_CHK Set when background program check is active S0014 PLC_BAT Set to indicate a bad battery in a Release 4 or later CPU The contact is updated when a change in the battery status occurs FST_EXE PB_SUM Current sweep is the first time this block has been called Set when transitioning from Stop to Run FST_EXE is not available to standalone C programs Set when a checksum calculated on the application program does not match the reference checksum If the fault was due to a temporary failure the discrete bit can be cleared by again storing the program to the CPU If the fault was due to a hard RAM failure then the CPU must be replaced Cleared when the PLC fault table is cleared S A0002 OV_SWP Set when the PLC detects that the previous sweep took longer than the time specified by the user Cleared when the PLC detects that the previous sweep did not take longer than the specified time It is also cleared during the transition fr
248. t commanded to Run mode all programs will begin execution at their normal beginning point Program s are not resumed at their wind down exceeded execution point GFK 1192B Chapter 2 System Operation 2 67 2 68 Section 6 Power Up and Power Down Sequences Power Up System power up consists of the following parts e Power up self test e PLC memory validation e System configuration e Option module self test completion e Option module dual port interface tests e T O system initialization Power Up Self Test On system power up many modules in the system perform a power up diagnostic self test Series 90 70 PLC modules execute hardware checks and software validity checks Intelligent option modules perform setup and verification of onboard microprocessors software checksum verification local hardware verification and notification to the CPU of self check completion Any failed tests are queued for reporting to the CPU during the system configuration portion of the cycle In the CPU power up will be either a quick power up a warm start or a full power up a cold start depending on whether the CPU is able to go to Run mode after powering up If all the conditions are met for the CPU to go to Run mode a valid program or configuration is present the switch is in Run mode and no fatal fault exists then the CPU will perform a quick power up If any of the conditions are not met a full power up is performed A quick
249. ta to a Series 90 70 PLC and can receive data from a Series 90 70 PLC Your programming software is used to configure the receiving and transmitting of global data on a Genius I O bus Note Genius global data communications do not continue to operate when the 90 70 PLC is in STOP NOIO mode However if the 90 70 PLC is in STOP IOSCAN mode then Genius global data communications will continue to operate Information relative to using FIP I O in a Series 90 70 PLC system is presented in the following paragraphs For specific information on FIP I O types configuration and setup refer to the Series 90 70 FIP Bus Controller User s Manual GFK 1038 FIP I O Bus Configuration The FIP Bus Controller used in the Series 90 70 PLC controls a single FIP I O bus Currently supported are the 90 30 FIP Remote I O Scanner FIP Bus Interface Unit for Field Control and generic FIP I O module configurations All of the FIP I O interface modules for example the FIP Remote I O Scanner must provide input data to the 90 70 FIP Bus Controller so that the FIP Bus Controller has this same input data to provide to the 90 70 CPU during the next normal input scan Similarly when the 90 70 CPU performs the next output scan the FIP Bus Controller accepts this output data and passes it on to the appropriate FIP I O interface module to then update the local I O 90 30 FIP Remote I O Scanner The FIP Remote I O Scanner provides the ability to use 90 30 I O as a re
250. tatus transfer in both directions In addition reconfiguration of a module or rack also occurs during this portion of the sweep System Communications Communications with all intelligent devices except the programmer when Window using a serial occur during this window For example supplying data to a PCM that is driving a process display would occur during this window Background Task Window CPU self tests occur in this window For information about the PCM refer to the Series 90 Programmable Coprocessor Module and Software Support GFK 0255 The housekeeping portion of the sweep performs all of the tasks necessary to prepare for the start of the sweep This includes updating S bits determining timer update values and determining the mode of the sweep Stop or Run The scanning of the inputs occurs just prior to the logic solution During the input scan the CPU reads input data from the Genius Bus Controllers FIP Bus Controllers and Series 90 70 input modules Note Beginning with Release 7 0 Ethernet global data is also read during this scan When referring to FIP in this scan only periodic VCOM MPS services are affected Messages are received in the System Communication Window Series 90 70 I O modules are scanned from lowest to highest I O reference address There is no guaranteed scanning order for Bus Controllers Note The input scan will not be performed if a program has an active Suspend I O
251. te Application Request Discarded Request 10 A Bad Local Application Request Discarded Request 11 B LAN I F Capacity Exceeded Discarded Request 12 C LAN PROM Software Mismatch Running Soft Sw Util 13 D LAN I F Can t Init Check Parms Running Soft Sw Util 14 E Run time error detected in an external block 15 F SORT function in an interrupt did not execute 17 11 Standalone Run Time Error 28 1C Program Exceeded Wind Down 29 1D Program Not Readied 1 1 Operating system Error Codes for Corrupted User RAM on Powerup Group 1 1 Corrupted User RAM on Power up 2 2 Illegal Boolean Opcode Detected 5 5 Partial Store failure on second pass of parsing OMF 6 6 Corrupted Remote I O Scanner EEPROM Config Lost Error Codes for PLC CPU Hardware Faults 2169 879 Remote I O Scanner Comm Failure Verify Bus 2172 87C Remote I O Scanner Serial Bus Address Conflict 2048 800 Remote I O Scanner Hardware Fault to to 4095 FFF All other codes PLC CPU Hardware Failure B 10 Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B PLC Fault Extra Data The Fault Extra Data field in the PLC fault table contains details of the fault entry Some examples of what data may be present are System Configuration Mismatch Four error codes in the System Configuration Mismatch group supply fault extra data Table B 5 PLC Fault Extra Data System Configuration Mismatch Fault Extra Data Byte Number Model Number Mismatch 0 FF
252. te grouped 1F I O Fault Address The I O fault address is a six byte address containing rack slot bus block and point address of the I O point which generated the fault The point address is a word all other addresses are one byte each All five values may not be present in a fault When an I O fault address does not contain all five addresses a 7F hex appears in the address to indicate where the significance stops For example if 7F appears in the bus byte then the fault is a module fault Only rack and slot values are significant Rack The rack number ranges from 0 to 7 Zero is the main rack that is the one containing the PLC Racks 1 through 7 are expansion racks connected to the PLC through a Bus Transmitter Module in the main rack and Bus Receiver Modules in the expansion racks Slot The slot number ranges from 0 to 9 The PLC CPU always occupies slot 1 in the main rack rack 0 1 0 Bus The I O bus number ranges from 0 to 15 When the module in the slot is a single channel Genius Bus Controller this number is always one When the module is an integral analog module this designates which expansion channel generated the fault Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Block Block refers to the serial bus address of the Genius block that reported or has the fault Point Point ranges from 1 to 1024 decimal It tells which point on the block has the fault when the
253. tes the diagnostic bits based on the data provided by the I O module Chapter 2 System Operation 2 81 2 82 Discrete I O The diagnostic bits are derived from the diagnostic data sent from the I O modules to their I O controllers Genius Bus Controller FIP Bus Controller or 90 70 CPU Diagnostic bits always indicate the current fault status of the associated module Bits are set when faults occur and are cleared when faults are cleared In general diagnostic data is not maintained by the Series 90 70 PLC for foreign I O not GE Fanuc modules Any diagnostic information provided by those boards must be specifically accessed by the application program using the VME Read and VME Write function blocks Beginning with 90 70 CPU release 5 50 the 90 70 system has supported foreign I O modules when developed under license agreement with GE Fanuc These boards are then configured as Foreign VME and the interface mode is I O Scan Boards developed to conform to the I O Scan interface can provide discrete and analog diagnostic information to the 90 70 CPU Diagnostic Information Diagnostic information is maintained by the Series 90 70 PLC for each discrete I O point Two memory blocks are allocated in application RAM for discrete diagnostic data One is associated with I memory and the other with Q memory One bit of diagnostic memory is associated with each I O point This bit indicates the validity of the associated I O data Each
254. the PLC CPU is unable to obtain control of the VME bus when required Correction 1 Ensure that any nonGE Fanuc boards which can become bus masters are relinquishing control of the VME bus when requested to do so by the PLC CPU 2 Replace the PLC CPU module No User Program on PowerUp The fault group No User Program on Power Up occurs when the PLC CPU powers up with its memory preserved but no user program exists in the PLC The PLC CPU detects the absence of a user program on powerup the controller stays in Stop mode performing the Stop mode sweep until a valid program is downloaded The default fault action for this group is Informational Download an application program before attempting to go to Run mode 3 32 Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Corrupted User Program on PowerUp The fault group Corrupted User Program on Power Up occurs when the PLC CPU detects corrupted user RAM The PLC CPU will remain in Stop mode until a valid user program and configuration file are downloaded The default fault action for this group is Fatal Error Code Name Description Correction Error Code Name Description Correction Error Code Name Description Correction 1 Corrupted User RAM on PowerUp The PLC generates this error when it detects corrupted user RAM on powerup 0 2 3 4 5 2 Cycle power without battery Examine any C
255. the interface between the Series 90 70 PLC CPU and a FIP I O bus In addition to supporting these three I O subsystems the I O system will also support Ethernet Interfaces and PCMs The I O structure for the Series 90 70 PLC is shown in the following figure APPLICATION RAM vO CONFIGURATION A t ers 1 F a42946 BCP k Bit p gt 90 70 90 70 90 70 DISCRETE DISCRETE ANALOG INPUT OUTPUT INPUT MODULE S GENIUS MODULE S EXPANDER S GENIUS DEVICES SUCH AS FIELD CONTROL ETC Figure 2 13 Series 90 70 PLC I O Structure GFK 1192B Chapter 2 System Operation CONTROLLER S FIP BUS CONTROLLER S FIP DEVICES SUCH AS FIELD CONTROL STATIONS FIP REMOTE I O SCANNERS ETC 2 77 I O Data Mapping Discrete inputs and outputs are stored as bits in the CPU BCP Bit Cache memory Analog I O is stored in the application RAM allocated for that purpose Analog data is always stored in the demultiplexed state with each channel requiring one word 16 bits Default Conditions Genius 1 0 The programming software provides the ability to specify that the first input may be an interrupt input and for the filter speed to be fast or slow but upon power up Model 70 discrete input modules always default to the first input on the module not interrupting and the input filter being slow speed If changed by the user new defaults are applied when the board is configured by the CPU during the power up
256. tic 8 8 Addition of or extra option module Diagnostic 11 B System configuration mismatch Fatal 12 C System bus error Diagnostic 13 D PLC CPU hardware failure Fatal 14 E Non fatal module hardware failure Diagnostic 16 10 Option module software failure Diagnostic 17 11 Program block checksum failure Fatal 18 12 Low battery signal Diagnostic 19 13 Constant sweep time exceeded Diagnostic 20 14 PLC system fault table full Diagnostic 21 15 T O fault table full Diagnostic 22 16 User Application fault Diagnostic Additional PLC fault codes As specified 128 80 System bus failure Fatal 129 81 No user s program on power up Informational 130 82 Corrupted user RAM detected Fatal 131 83 Window completion failure in Constant Sweep mode Informational that is all windows failed to receive their allotted time 132 84 Password access failure Informational 134 86 Null system configuration for RUN mode Informational 135 87 PLC CPU software failure Fatal 136 88 More than the allowable number of I O bus controllers Fatal were found in the system 137 89 PLC sequence store failure Fatal The PLC OK LED will flash on and off to indicate that the failure was not serious enough to prevent programmer communications from retrieving the fault table information GFK 1192B Appendix B Interpreting Faults B 5 PLC Fault Action Each fault may have one of three actions associated with it Table B 2 PLC Fault Actions Fault Action Action T
257. tion it passes through to the result For example if an NaN_ADD is the first operand to the SUB_REAL function the result of the SUB_REAL is NaN_ADD If both operands to a function are NaNs the first operand will pass through Because of this feature of propagating NaNs through functions you can identify the function where the NaN originated Note For NaN the Enable Out output is Off not energized GFK 1192B Appendix D Using Floating Point Numbers D 5 GFK 1192B G References G references and CPU memory2 14 A Alarm contacts Alarm error codes B 7 Alarm processor 3 10 Analog T O diagnostic data 2 82 Analog input register dar 2 82 CADIZ Analog output register references al on a Application program task execution bal housekeepin input scan output scan Background window Base sweep time Bulk Memory Access BMA 2 14 Bus configuration FIP I O 2 80 Bus configuration Genius I O 2 78 C C debugger in the programmer communications window 2 6 C program structure size restrictions C programs 2 38 data encapsulation C v RLD programs Calculating predicted sweep times A 30 Classes of faults 3 11 Clocks 2 72 elapsed time clock time of day clock using SVCREQ function 16 to read the clock 2 72 using SVCREQ function 7 to read and set the clock Configurable fault actions 3 4 diagnostic 3 4 fatal 3 4 informational Configurable faults 3 18
258. tion file to include the expansion rack 3 Remove the expansion rack from the hardware configuration Note No correction necessary if rack was just powered on Reset of Addition of or Extra Option Module The fault group Reset of Addition of or Extra Option Module occurs when an option module PCM BTM etc comes online is reset or a module is found in the rack but none is specified in the configuration The default fault action for this group is Diagnostic Error Code Name Correction Error Code Name Description Correction Error Code Name Description Correction 1 Extra Option Module 1 Update the configuration file to include the module 2 Remove the module from the system 2 Module Restart Complete Restart of module is complete None 3 LAN Interface Restart Complete Running Utility The LAN Interface module has restarted and is running a utility program Refer to the LAN Interface manual GFK9868 or GFK 9869 previously GFK0533 GFK 1192B Chapter 3 Fault Explanation and Correction 3 21 3 22 System Configuration Mismatch The fault group Configuration Mismatch occurs when the module occupying a slot is different from that specified in the configuration file The default fault action is Fatal When the I O Scanner generates the mismatch because of a Genius block the second byte in the Fault Extra Data field contains the bus address of the mismatched block
259. tries Overflowed The number of entries lost because the fault table has overflowed since it was cleared The I O fault table can contain up to 32 faults PLC PLCTime Date The current date and time This is also maintained by the PLC Note The size of the I O fault table is configurable with a default of 32 and a maximum of 40 configurable in Control Additional faults over the configured limit cause the table to overflow and faults are lost The system reference IO_FULL S0010 is set to indicate that the fault table is full Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B UserDefined Faults Userdefined faults can be logged in the PLC or I O fault table When a userdefined fault occurs it is logged in the appropriate fault table as Application Msg error_code and may be followed by a descriptive message up to 24 characters All characters in the descriptive message can be defined by the user Although the message must end with the null character e g zero 0 the null character does not count as one of the 24 characters If the message contains more than 24 characters only the first 24 characters are displayed GFK 1192B Chapter 3 Fault Explanation and Correction 3 15 Accessing Additional Fault Information 3 16 The fault tables displayed by the programming software contain basic information regarding the fault For additional information a pertaining to each fault dou
260. uit fault module fault I O bus fault loss of block excessive faults I O configuration mismatch and GBC software exception categories It is undefined for other fault categories but is always set to zero when the fault category is something other than these seven categories Table B 18 lists the I O fault types Table B 18 1 0 Fault Types Number Description I O Fault Types for the Circuit Fault Category nA BW NY Circuit fault on a discrete I O point Circuit fault on an analog I O channel Fault on a GENA Fault on a low level analog input channel Fault on Remote I O Scanner I O Fault Types for the Module Fault Category Block Fault EEPROM watchdog Analog to digital communications fault or calibration error User scaling error caused out of range values I O Fault Types for I O Bus Fault Category Genius IOC disabled all outputs on the bus because communications timed out between the PLC CPU and the Genius IOC Genius Bus fault No interrupt to the GBC for its turn on the bus within the time out period Genius IOC detected a conflict between its SBA and another device on the bus I O Fault Types for the Loss of Block Category No reason specified Loss of A D communications I O Fault Types for Excessive Faults Category Genius IOC detected a high error count on the Genius I O Bus and dropped off the bus for at least 1 5 seconds I O Fault Types for Configuration Mis
261. ult Category Fault Type Fault Description Fault Specific Data Module Fault Headend Fault EPROM or NVRAM Failure Calibration Memory Failure Shared Ram Failure Configuration MisMatch Watchdog Timeout Output Fuse Blown IOC Software Fault eS o IOC Hardware Failure Forced Circuit Block Configuration Discrete Analog Indication Unforced Circuit Block Configuration Discrete Analog Indication Refer to table below Three types of fault specific data occur in more than one fault category they are block configuration circuit configuration and analog discrete indication The codings are shown in the following table Circuit Configuration Circuit is an input Circuit is an output Circuit is an output with feedback Block Configuration Block is configured for inputs only Block is configured for outputs only Block is configured for inputs and outputs grouped block Discrete Analog Indication Block is a discrete block Block is an analog block 3 40 Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Circuit Fault GFK 1192B Circuit Fault has four fault types Three of the four fault types have fault descriptions Fault specific data is available for all faults Circuit faults apply specifically to Genius I O modules The default fault action is Diagnostic The following table describes the circuit fault category Table 3 9 Circuit Fault Category Description Fault Fault Typ
262. up Point Block I O Bus Slot Rack Reference Address Long Short Appendix B Interpreting Faults B 33 B 34 Circuit Fault The Circuit Fault is explained below All values are in hexadecimal Field Value Description Long Short 02 This fault contains up to 5 bytes of fault specific data Reference 0D0200 OD 13 decimal indicates that the block has an analog grouped reference Address address Your programming software shows this by displaying a AQI in the reference address column 0200 indicates this is address 0002 hexadecimal data is displayed low byte first then high byte in the analog grouped address space Rack 00 Main rack rack 0 Slot 03 Slot 3 In this configuration slot 3 contains a Genius Bus Controller Bus 01 Bus 1 on the bus controller When this byte is significant the single channel bus controller always shows this field as a 1 Block 02 This fault was logged for the Genius device at serial bus address 02 Point 0200 This fault was logged for point 2 on the device at serial bus address 02 Fault Group OA OA hexadecimal is 10 decimal I O Module fault Fault Action 02 Diagnostic fault Fault Category 01 Fault Category 01 is a circuit fault Fault Type 02 Fault Type 02 under the Circuit Fault category is a circuit fault on an analog T O channel Fault 10 A fault description of 10 hex under the analog circuit fault description is Description open
263. upported in Microcycle Sweep mode GFK 1192B Chapter 2 System Operation 2 51 Choosing PLC Sweep and Program Scheduling Modes The table shown below indicates the availability of each program scheduling mode in each of the available PLC sweep modes Table 2 16 Available Program Scheduling Modes in Each PLC Sweep Mode Program Scheduling Mode ro Interrupt Ordered Timed Triggered Periodic Blocks Normal Constant Yes Yes Yes No Yes Constant Yes Yes Yes No Yes Window Microcycle No No Yes Yes Yes Executes in Logic Window only User Program Execution User Program Priorities The priority of a user program specifies its priority relative to other programs Higher priority programs execute before lower priority programs If two or more programs with the same priority are scheduled at the same time the order of execution is undefined Programs can be suspended in the middle of execution by higher priority programs and Interrupt blocks Ordered programs all have the same priority and are executed in the order that you specify in the programming software Ordered programs have lower priority than Timed programs I O Triggered programs and Interrupt blocks Periodic programs have priority inverse to their period smallest period has highest priority The order of execution of Periodic programs with the same period is undefined Periodic programs have lower priority than Timed programs I O Tr
264. ure that all expansion rack cables are properly connected and seated 2 Take action to minimize system noise GFK 1192B Chapter 3 Fault Explanation and Correction 3 25 PLC CPU Hardware Failure The fault group PLC CPU Hardware occurs when the PLC CPU detects a hardware failure such as a RAM failure or a communications port failure When the failure is a RAM failure the address of the failure is stored in the first four bytes of the Fault Extra Data field When a PLC CPU Hardware failure occurs the PLC OK LED will flash on and off to indicate that the failure was not serious enough to prevent programmer communications to retrieve the fault information The default fault action for this group is Fatal Error Code 6Eh Name TimeofDay Clock not BatteryBacked Description The batterybacked value of the timeofday clock has been lost Correction 1 Replace the battery Do not remove power from the main rack until replacement is complete Reset the timeofday clock using your programming software 2 Replace the module Error Code All Others Correction Replace the module Module Hardware Failure The fault group Module Hardware Failure occurs when the PLC CPU detects a nonfatal hardware failure on any module in the system for example a serial port failure on a PCM The default fault action for this group is Diagnostic Error Code 1A0 Name Missing 12 Volt Power Supply Description A power supply that supplies
265. us Controller LOS_IOM diagnostic Loss of I O module does not respond or missing a configured I O module LOS_SIO diagnostic Loss of option module does not respond or missing a configured module ADD_RCK diagnostic New rack added or previously faulted rack has returned ADD_IOC diagnostic Previously faulted Bus Controller is no longer faulted ADD_IOM diagnostic Previously faulted I O module is no longer faulted ADD_SIO diagnostic New option module is added or previously faulted module no longer faulted IOC_FLT diagnostic Non fatal bus or Bus Controller error more than 10 bus errors in 10 seconds error rate is configurable IOM_FLT diagnostic Point or channel on an I O module a partial failure of the module CFG_MM fatal Wrong module type detected during power up or Run mode The PLC does not check the configuration parameters set up for individual modules such as Genius I O blocks Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Table 2 12 Non Configurable Faults Non Configurable Faults SBUS_FL fatal Description System bus failure The PLC CPU was not able to access the VME bus BUSGRT NMI error NO_PROG information No application program is present at power up Should only occur the first time the PLC is powered up or if the battery backed RAM containing the program fail
266. ute during any phase of the PLC sweep When the PLC is in Microcycle Sweep mode Interrupt programs are scheduled to execute in the Logic Window In summary the primary differences between Interrupt blocks and Interrupt programs are as follows Interrupt Block e Executed immediately upon receipt of interrupt e Cannot be preempted by other logic once Interrupt block begins execution e One additional interrupt is queued if the block is still executing due to a previous interrupt e Executes during any phase of the PLC sweep Interrupt Program e Scheduled to execute on a priority basis e Can be preempted by higher priority Interrupt program or Interrupt block e Additional interrupts are ignored and a fault is logged if the program is still executing due to a previous interrupt e Executes during any phase of the PLC sweep when PLC is in Normal Sweep Constant Sweep or Constant Window mode e Executes in Logic Window when PLC is in Microcycle Sweep mode Chapter 2 System Operation 2 65 Section 5 Run Stop Operations Modes of Operation Four run stop modes of operation are supported by the 90 70 PLC You can change these modes in the following ways the toggle switch programming software LD function blocks and system calls from C applications Switching to and from various modes can be restricted based on privilege levels position of the PLC toggle switch passwords etc Run Outputs Enabled Run Outputs Disabled Stop
267. vember 1999 GFK 1192B Loss of Block The fault category Loss of Block applies to Genius blocks There are no fault types or fault descriptions associated with this category The default fault action is Diagnostic Name Description Correction Name Description Correction Addition of Block Loss of Block The PLC generates this error when it receives a Loss of Block fault from a Genius Bus Controller but the reason for the loss is unspecified 1 Verify power and wiring to the block 2 Replace the block Loss of Block A D Communications Fault The Genius I O operating software generates this error when it detects a loss of communications with a Genius I O block 1 Verify power and serial bus wiring to the block 2 Replace the block The fault category Addition of Block applies only to Genius blocks There are no fault types or fault descriptions associated with this category The default fault action is Diagnostic Name Description Correction Extra Block Addition of Block The Genius operating software generates this error when it detects that a Genius block which stopped communicating with the controller starts communicating again Informational only None required The fault category Extra Block applies only to Genius I O blocks There are no fault types or fault descriptions associated with this category The default fault action is Diagnostic Name Description Correctio
268. veness is based on the type of coil For more information refer to Retentiveness of Logic and Data later in this section Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B User Reference Size and Default Maximum user references and default reference sizes for each CPU are listed in the tables below GFK 1192B Table 2 4 User Reference Sizes CPU Model Item 935 928 780 781 925 915 79 924 914 788 782 789 771 772 731 732 0 Maximum I 12288 points 12288 points 352 points 12288 points 2048 points 512 points reference Maximum Q 12288 points 12288 points 352 points 12288 points 2048 points 512 points reference Maximum M 12288 points 12288 points 12288 points 12288 points 4096 points 2048 points reference Maximum T 256 points 256 points 256 points 256 points 256 points 256 points reference S total 512 points 512 points 512 points 512 points 512 points 512 points S SA SB SC G GA GB GC 7680 points 7680 points 7680 points 7680 points 7680 points 1280 points GD GE User RAM 1024K bytes 512K bytes 512K bytes 512K bytes CPU771 2 32K bytes 6MB for 928 CPX 782 has_ 64 128 256 512 1024 KB KB depending on expansion memory board purchased CPX772 512 KB Maximum AI 8K words 8K words 8K words 8K words 8K words 8K words reference Maximum WAQ 8K words 8K words 8K words 8K words 8K words 8
269. w Modes The previous sections have described the phases of a typical PLC sweep The Programmer Window System Communications Window and Background Window phases of the PLC sweep can be run in various modes based on the PLC Sweep mode PLC sweep modes are described in detail in section 4 The following three window modes are available Run to In Run to Completion mode all requests made when the window has started Completion are serviced When all pending requests in the given window have completed the PLC will transition to the next phase of the sweep Constant In Constant Window mode the total amount of time that the Programmer Communications Window and Background Window run is fixed If the time expires while in the middle of servicing a request these windows are closed and communications will be resumed the next sweep If no requests are pending in this window the PLC will cycle through these windows the specified amount of time polling for further requests If any window is put in constant window mode all will be in constant window mode GFK 1192B Chapter 2 System Operation 2 7 2 8 Limited In Limited mode the maximum time that the window runs is fixed If time expires while in the middle of servicing a request the window is closed and communications will be resumed the next time that the given window is run If no requests are pending in this window the PLC will proceed to the next phase of the sweep Data Coherency in Co
270. ware Users November 1999 GFK 1192B Timed Interrupt Performance The sweep impact of a timed interrupt invoking an empty program block or timed program measures the overall time of fielding the interrupt starting up the program or block exiting the program or block and restarting the interrupted task The minimum typical and maximum interrupt response times reflect the time from when a single timed interrupt occurs until the first line of ladder logic or C code is executed in the timed interrupt program or block The minimum response time can only be achieved when no intelligent option modules are present in the system and the programmer is not attached Typical response time is the minimum response time plus the CPU s maximum latency time This interrupt latency time is valid except when one of the following operations occurs e The programmer is attached e A store of logic ALT S store RUN mode store or word for word change occurs e A fault condition logging of a fault occurs e Another timed interrupt or I O interrupt occurs Any one of these events extends the interrupt period beyond the typical value However the latency of an interrupt occurring during the processing of a preceding timed or I O interrupt is unbounded For interrupts the worst case is that every timed and I O interrupt in the system occurs at the same time so that one of them has to wait for all others to complete before it starts The maximum response time show
271. wire Fault Specific 9B03 The GBC reported a circuit fault Only the 9B byte is significant Data The Genius Bus Controller in slot 3 in the main rack received a circuit fault Report Fault message from the analog block located at serial bus address 2 The block reported an Open Wire fault on point 2 From the configuration tables stored from your programming software the PLC CPU determined that the analog block at serial bus address 02 was mapped to both the AI and AQ user references and that point 2 corresponded to location 0002 02 0D0200 000301020200 OA02 01 02 10 9803000000 _ Fault Specific Data Fault Description Fault Type Fault Category Fault Action Fault Group Point Block O Bus Slot Rack Reference Address Long Short Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Appendix Memory Allocation C Use this worksheet to determine the total number of bytes of memory used by R AI WAQ P L and associated point faults if used Then add all the totals together To determine the amount of memory left for the user program subtract the grand total from the number of bytes for the memory size being used Table C 1 Series 90 70 PLC Memory Allocation Worksheet PR allocated of R used x 2 bytes of R used is in 1K increments based on configuration When P used is in the range to 128 the P allocated 160
272. xample The loss of I O Block fault is described below All data is in hexadecimal Field Value Description Long Short 02 This fault contains up to 5 bytes of fault specific data Reference FF0100 FF indicates that the reference address is not given The fault applies to the entire Address block Rack 00 Main rack rack 0 Slot 04 Slot 4 In this configuration slot 4 contains a Genius Bus Controller Bus 01 Bus 1 on the bus controller When this byte is significant the single channel bus controller always shows this field as a 1 Block 1E 1E is 30 decimal This fault was logged for the Genius device at serial bus address 30 Point FF7F FF in the first low byte indicates that the point is not meaningful for this fault entry Fault Group 03 Loss of or missing I O module fault Fault Action 02 Diagnostic fault Fault 02 Loss of block Category Fault Type 00 00 fault type in the Loss of Block category indicates no specific fault was given Fault 00 No fault description information is given Description Fault Specific 84 GBC reported a lost device Only 1 byte of fault specific data is significant Data The Genius Bus Controller in slot 4 determined that the device at serial bus address 30 on bus 1 failed to send data in three consecutive bus scans The bus controller then marked the device as lost and logged a fault in the I O fault table The fault type and fault description are
273. ypes Upload the configuration file and verify that the software recognizes the board type in the file If there is an error correct it download the corrected configuration file and retry Display the PLC fault table on the programmer Contact GE Fanuc PLC Field Service giving them all the information contained in the fault entry 2 3 COMMREQ Frequency Too High COMMREQs are being sent to a module faster than it can process them Change the PLC program to send COMMREQs to the affected module at a slower rate or monitor the completion status of each COMMREQ before sending the next 4 More Than One BTM in a Rack There is more than one BTM present in the rack Remove one of the BTMs from the rack there can only be one in a CPU rack 191 195 LAN Interface Software Failure Refer to the LAN Interface manual GFK 9868 or GFK 9869 previously GFK 0533 for a description of these errors All Others Option Module Software Failure Software failure detected on an option module 1 Reload software into the indicated module 2 Replace the module GFK 1192B Chapter 3 Fault Explanation and Correction 3 27 Program or Block Checksum Failure The fault group Program or Block Checksum Failure occurs when the PLC CPU detects error conditions in program or blocks received by the PLC It also occurs during Run mode background checking In all cases the Fault Extra Data field of the PLC fault table record contains the name of the program
274. ystem software operations and timer function blocks it may not be reset from the user program or the programmer However the application program can read the current value of the elapsed time clock by using Service Request function 16 Time of Day Clock The time of day in the Series 90 70 PLC is maintained by a hardware time of day clock The time of day clock maintains the following seven time functions e Year two digits e Month e Day of month e Hour e Minute e Second e Day of week The time of day clock is battery backed and maintains its present state across a power failure However unless the user initializes the clock the values it contains are meaningless The application program can read and set the time of day clock using Service Request function 7 The time of day clock can also be read and set from your programming software The time of day clock is designed to handle month to month and year to year transitions It automatically compensates for leap years into the second half of the twenty first century Series 90 70 System Manual for Control Software Users November 1999 GFK 1192B Watchdog Timer Software Watchdog Timer A software watchdog timer in the Series 90 70 PLC is designed to detect failure to complete sweep conditions The timer value for the software watchdog timer is set by using your programming software The allowable range for this timer is 10 to 2550 milliseconds the default va

Series 90-70 System Manual for Control Software Users, GFK

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