GE GFK-0787B Manual - Free PDF Download

Page 3 - Preface; Content of this Manual

iii GFK–0787B Preface This manual is a reference to planning, configuring and programming a Series 90 t -70 PLC system that utilizes Genius Modular Redundancy (GMR). The information in this manual is intended to supplement the basic system installation,programming, and configuration instructions loc...

Page 4 - Related Publications; We Welcome Your Comments and Suggestions

Preface iv Genius t Modular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 GFK–0787B H The GMR configuration software now allows selection of memory addresses forexternal write access. Serial and network communication ports are restricted; theGenius bus is not....

Page 5 - Contents

Contents v GFK-0787B Genius t Modular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 Chapter 1 Introduction 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Components of a GMR System 1-2 . . . . . . . . . . . . ...

Page 6 - Chapter 6

Contents vi GFK-0787B Genius t Modular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 Diagnostics in a GMR System 5-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting Up Blocks to Report Genius Faults 5-3 . . . . . . . . . . . . ....

Page 7 - Genius Bus Connections

Contents vii GFK-0787B Genius t Modular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 Chapter 8 Installation Information 8-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Genius Bus Connections 8-2 . . . . . . . . . . . . . . . . . . ...

Page 8 - Genius Modular Redundancy

1 section level 1 1figure bi level 1 table_big level 1 restart lowapp ARestart oddapp: ARestarts for autonumbers that do not restart ineach chapter. figure bi level 1, reset table_big level 1, reset chap_big level 1, reset1Lowapp Alwbox restart evenap:A1app_big level 1, resetA figure_ap level 1, res...

Page 9 - Components of a GMR System; GMR Software; Additional Items

1 1-2 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 GFK-0787B Components of a GMR System GMR Software GMR software version 2.06 (catalog number IC641SWP714B) provided on disketteconsists of: H Easy-to -use GMR configuration software. H GMR syst...

Page 10 - Inter -processor Communications

1 1-3 GFK-0787B Chapter 1 Introduction Series 90-70 PLCs A GMR system normally consists of one to three identical CPUs running identicalapplication software. Each CPU is connected to the same input and output subsystems. Each CPU receives all inputs and performs voting for discrete inputs and mid-va...

Page 11 - Busses and Bus Controllers; Additional Bus Controllers for Communications

1 1-4 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 GFK-0787B Busses and Bus Controllers In a GMR system, there can be one to three bus controllers per bus, per PLC. Larger systemsmay require more than one I/O subsystem. For example, the GMR sy...

Page 12 - Operation Overview

1 1-5 GFK-0787B Chapter 1 Introduction Operation Overview Genius Modular Redundancy has been developed for use in systems that have static or nearlystatic I/O under normal operating conditions. The system may have: H Normally- on inputs with normally-energized outputs, as in emergency shutdown syste...

Page 14 - PLC Subsystem: Providing Output Data; Output Subsystem; Automatic System Test

1 1-7 GFK-0787B Chapter 1 Introduction PLC Subsystem: Providing Output Data Running the same application program, each PLC (referred to here by Genius BusController (GBC) serial bus addresses: 31, 30, and 29) processes the voted input data andproduces appropriate outputs. Because each of the three P...

Page 15 - Discrete Blocks

1 1-8 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 GFK-0787B Genius I/O Blocks Inputs and outputs in a GMR system are provided by Genius I/O blocks. Some types ofGenius blocks are now enhanced for GMR operation. In addition, these and other ty...

Page 16 - Number of I/O Points in a GMR System; Number of Non-GMR I/O Available for the 788 CPU

1 1-9 GFK-0787B Chapter 1 Introduction Number of I/O Points in a GMR System The I/O capacity of the system depends on whether the CPU is a model 788 or model 789. Formost applications, these limits will not be reached. If you need help estimating I/O sizes for alarge application, contact GE Fanuc at...

Page 17 - Configuration and Programming; The GMR Software

1 1-10 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 GFK-0787B Configuration and Programming The GMR Software The GMR software consists of: H The GMR configuration software file, CONFIG.EXE. This file, which runs under DOS, isused to enter the ...

Page 18 - The Basic Steps of Configuration and Programming

1 1-11 GFK-0787B Chapter 1 Introduction The Basic Steps of Configuration and Programming 1. Use the GMR configuration software to complete the GMR configuration. There isonly one GMR configuration needed for the system. GMR configuration sets up the parameters that will be used by the system, includ...

Page 20 - Overview

2 2-2 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 GFK-0787B Overview The input subsystem is the part of a GMR system that gathers input data. It may consist of: H GMR Input groups of 1 to 3 discrete or analog blocks H Individual non-voted dis...

Page 21 - GMR Input Groups; one sensor to three Genius inputs, three busses, three PLCs

2 2-3 GFK-0787B Chapter 2 Input Subsystem GMR Input Groups The configuration can include as many as 128 16-circuit voted discrete and 256 four-input analoginput groups. (The actual I/O capacity of the system depends on the CPU type. See page 1-9). In an system that has normally-energized discrete in...

Page 22 - Example; Block A

2 2-4 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 GFK-0787B Non-Voted I/O in the Input Subsystem The input subsystem can also include three types of non-voted inputs: H Inputs from single-block (simplex) GMR input groups Individual blocks can...

Page 23 - Discrete Inputs; Types of Blocks in the Input Subsystem; Discrepancy Reporting for GMR Inputs

2 2-5 GFK-0787B Chapter 2 Input Subsystem Discrete Inputs Types of Blocks in the Input Subsystem The following discrete block versions can be configured for GMR version 2.06 operationand used as GMR input blocks: 24/48 VDC 16-Circuit Source block: IC660BBD020M or later 24/48 VDC 16-Circuit Sink bloc...

Page 24 - Input Autotest for GMR Inputs; Calculating Voltage Drops on Tristate Inputs

2 2-6 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 GFK-0787B Input Autotest for GMR Inputs During GMR configuration, input autotesting can be individually turned on or off for eachinput in an input group. The GMR software will automatically te...

Page 25 - Line Monitoring for Discrete Inputs; Normally-closed Inputs; Normally-open Inputs; Input Filter Time

2 2-7 GFK-0787B Chapter 2 Input Subsystem Line Monitoring for Discrete Inputs Normally-closed inputs on GMR-configured blocks can be monitored for short circuitfaults. Normally- open inputs on blocks which are not configured in GMR mode can bemonitored for open circuit faults. Normally-closed Inputs...

Page 26 - Manual Input Controls

2 2-8 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 GFK-0787B Manual Input Controls Safety systems often use controls for manual trip and manual inhibit. The GMR autotest andfault processing operations are unaffected by such controls. H A manua...

Page 27 - Analog Inputs; Voted Analog Inputs; Number of Input Sensors per Voted Channel

2 2-9 GFK-0787B Chapter 2 Input Subsystem Analog Inputs Like discrete blocks, analog blocks can be used in the input subsystem as members ofGMR input groups of 1 to 3 blocks, or as non-voted blocks. Also like discrete blocks,individual circuits of analog blocks in multiple-block GMR input groups can...

Page 28 - Analog Discrepancy Reporting

2 2-10 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 GFK-0787B Analog Discrepancy Reporting When the GMR software compares analog input data, it checks each channel againstdiscrepancy limits provided as a part of the configuration for that inpu...

Page 30 - Types of Blocks in the Output Subsystem

3 3-2 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 GFK-0787B Overview The output subsystem is the part of a GMR system that provides output data. It may consist of: H GMR Output groups of 4 discrete blocks H Individual non-GMR discrete and ana...

Page 31 - GMR Output Handling; Output Voting; Duplex Default for Outputs

3 3-3 GFK-0787B Chapter 3 Output Subsystem GMR Output Handling Unlike GMR input voting, which is done by the GMR software in the PLCs, output voting isperformed at the output block groups. To perform output voting, the blocks must be one of thelisted types, and they must be configured (with a Hand-h...

Page 32 - Results of Block Group Voting with Three PLCs Online

3 3-4 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 GFK-0787B The following three tables compare voting results for a block group receiving outputsfrom all three PLCs with results when one of the three PLCs is offline. Results of Block Group Vo...

Page 33 - Results of Block Group Voting with One PLC Online; PLC Logon Control; Output Fault Reporting

3 3-5 GFK-0787B Chapter 3 Output Subsystem Results of Block Group Voting with One PLC Online If two PLCs are offline, the “voted” outputs are the same as the outputs from the PLCwhich is still online (x = don’t care). PLC A Output State PLC B Output State PLC C Output State Duplex Default Setting in...

Page 34 - -Block Output Groups; Output Load Sharing

3 3-6 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 GFK-0787B 4-Block Output Groups All four blocks in a group must be either 16-circuit or 32-circuit blocks. In a group, twosource-type Genius blocks are connected in parallel on one side of eac...

Page 35 - Operation of a 4-Block Output Group; Electrical Characteristics of Sink and Source Blocks; Bus Redundancy in a 4-Block Output Group; Fault

3 3-7 GFK-0787B Chapter 3 Output Subsystem Operation of a 4-Block Output Group Each GMR output state is sent to four blocks set up in an H-pattern as shown on theopposite page. This type of grouping creates a fault-tolerant system where any singlepoint of failure does not cause the system to lose co...

Page 36 - Manual Output Controls and Diagnostics

3 3-8 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 GFK-0787B Manual Output Controls and Diagnostics Safety systems are often provided with controls for manual trip and manual override. H A manual trip causes the output to assume the alarm cond...

Page 37 - Redundancy Modes for Output Blocks; GMR Mode

3 3-9 GFK-0787B Chapter 3 Output Subsystem Redundancy Modes for Output Blocks There are three separate configuration processes for a GMR system: H GMR configuration, which supplies parameters used by the GMR system software. H PLC configuration, which is performed as usual for a Series 90-70 PLC sys...

Page 38 - Hot Standby Mode; Basic Hot Standby Mode Operation; Bus Controller; Hot Standby Mode in a GMR System; outputs

3 3-10 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 GFK-0787B Hot Standby Mode Individual blocks can be included in the output subsystem as GMR blocks, Hot Standbyblocks, or non-GMR blocks. There are significant differences in block operation ...

Page 40 - System Startup; PLC C

4 4-2 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 GFK-0787B System Startup The following actions occur during orderly startup of the GMR system: 1. Each PLC disables its outputs to Genius blocks. If the Outputs Disable function doesnot comple...

Page 41 - Online Changes

4 4-3 GFK-0787B Chapter 4 PLC Subsystem output states of the blocks, the block does not use those outputs in its output voting.The block(s) continue to ignore outputs from the PLC until they match those of theblock’s voted outputs or until commanded to do so by setting the FORCLOGcommand bit (%M1226...

Page 42 - Data Initialization

4 4-4 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 GFK-0787B Data Initialization During startup, a PLC either sets a flag to notify the application program to initialize %Rand %M memory, or synchronizes the data with corresponding data in the ...

Page 43 - CPU Sweep in a GMR System; PLC Operation

4 4-5 GFK-0787B Chapter 4 PLC Subsystem CPU Sweep in a GMR System The special functions required for Genius Modular Redundancy include autotest, inputvoting, and alarming. These GMR functions are provided by a set of Program Blocks thatare placed into the Program Folder using the LM90 librarian feat...

Page 44 - Estimating CPU Sweep Time; with table sizes of; Sweep Time Contribution of Genius I/O and GBCs; Impor tant Note

4 4-6 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 GFK-0787B Estimating CPU Sweep Time The GMR system software runs on Series 90-70 CPU788 or CPU789 PLCs. It produces a“base” CPU sweep time that becomes a part of the overall sweep time of the ...

Page 45 - Input Processing; Discrepancies

4 4-7 GFK-0787B Chapter 4 PLC Subsystem Input Processing During the Input Scan portion of the CPU sweep, the PLC receives inputs from thediscrete and analog input blocks. It stores the input data in different areas of memory asdescribed below. After the Input Scan, the GMR logic performs voting on t...

Page 46 - Discrete Input Voting; Duplex State

4 4-8 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 GFK-0787B Discrete Input Voting Immediately after the input scan, before the application program execution begins, theGMR software performs input voting. It automatically reads and votes on th...

Page 47 - Voting with Three Discrete Inputs

4 4-9 GFK-0787B Chapter 4 PLC Subsystem Voting with Three Discrete Inputs For a triplex input group with three inputs present, the GMR software performs 2 out of3 voting. Field Input Data Input A Input B Input C 0 1 1 GMR Software Performs 2 out of 3 Voting 1 Single Input Provided to Application Log...

Page 48 - Voting with Two Discrete Inputs

4 4-10 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 GFK-0787B Voting with Two Discrete Inputs Two inputs may be present in either a Duplex input group, or in a Triplex input groupwhere one of the three inputs has failed. For its 2 out of 3 vot...

Page 49 - Voting for One Discrete Input

4 4-11 GFK-0787B Chapter 4 PLC Subsystem Voting for One Discrete Input One input may be present in a non-voted input group, in a Simplex input group, in aDuplex input group where one input has failed, or in a Triplex input group where twoinputs have failed. In a non-voted input group, the actual inp...

Page 51 - Analog Input Voting

4 4-13 GFK-0787B Chapter 4 PLC Subsystem Analog Input Voting Immediately after the input scan, before the application program execution begins, theGMR software performs input voting. It automatically reads and votes on the three setsof data in areas A, B, and C of the analog Input Table. How it does...

Page 52 - Voting for Three Analog Inputs; average

4 4-14 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 GFK-0787B Voting for Three Analog Inputs For a triplex input group with three inputs present, the GMR software compares threecorresponding analog input values. It selects the intermediate val...

Page 53 - Voting for Two Analog Inputs

4 4-15 GFK-0787B Chapter 4 PLC Subsystem Voting for Two Analog Inputs Two inputs may be present in either a Duplex input group, or in a Triplex input groupwhere one of the three inputs has failed. Three vote options in duplex mode are determined by the duplex state: highest, lowest,or average. h If ...

Page 54 - Voting for One Analog Input

4 4-16 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 GFK-0787B Voting for One Analog Input One input may be present in a non-voted input group, in a Simplex input group, in aDuplex input group where one input has failed, or in a Triplex input g...

Page 55 - Output Processing; Discrete Outputs

4 4-17 GFK-0787B Chapter 4 PLC Subsystem Output Processing For outputs, the PLC does not perform “redundancy ” voting. Instead, voting is done bythe specified types of discrete output block groups. Analog blocks do not provideredundancy voting or autotest features. Both discrete and analog Genius bl...

Page 56 - Synchronous or Asynchronous Input Autotest and I/O Shutdown

4 4-18 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 GFK-0787B I/O Shutdown When the GMR system diagnoses a discrete I/O fault, it logs the appropriate faults in itsfault tables and set the appropriate fault contacts. For certain types of discr...

Page 57 - Output Faults that Cause I/O Shutdown; Programming for I/O Shutdown; Examples; Hours

4 4-19 GFK-0787B Chapter 4 PLC Subsystem Output Faults that Cause I/O Shutdown For discrete output groups there are also two types of faults which may prevent theoutput autotest from continuing to execute for that output group and thus cause an I/Oshut down for the outputs in the group. 1.) Loss of ...

Page 59 - I/O Shut Down Prevention

4 4-21 GFK-0787B Chapter 4 PLC Subsystem I/O Shut Down Prevention If an I/O fault causes an I/O shutdown to initiate, there is up to 16 hours of time to repairthe fault and put the block(s) back into operation before the shutdown occurs. Whenthe next autotest occurs on the PLC(s) that started its sh...

Page 60 - Communications Between PLCs; Sending PLC; Receiving PLCs; Global Data Redundancy

4 4-22 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 GFK-0787B Communications Between PLCs Data is transferred between the PLCs in the system using Genius global data. Two bussesare used to transfer duplicate data. While the system is operating...

Page 61 - Programming for Diagnostics

5 section level 1 1figure bi level 1 table_big level 1 5-1 GFK-0787B Chapter 5 Diagnostics This chapter describes: H Diagnostics in a GMR System H GMR Autotesting H GMR Discrepancy Reporting H Input Line Fault Detection in a GMR Application H The PLC and I/O Fault Tables in a GMR System H Monitoring...

Page 62 - Diagnostics in a GMR System; Input Diagnostics; Output Diagnostics

5 5-2 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual –March 1995 GFK-0787B Diagnostics in a GMR System In a GMR system, extensive diagnostic capabilities are provided by standard Genius I/Odiagnostics and by the special autotesting and discrepancy reporting ...

Page 63 - Setting Up Blocks to Report Genius Faults; Setting Up Other Blocks to Send Multiple Fault Reports; Summar y Table

5 5-3 GFK-0787B Chapter 5 Diagnostics Setting Up Blocks to Report Genius Faults By default, most Genius blocks, including the types of blocks normally used in GMRsystems, send only one copy of a Fault Report. For a GMR system, blocks can be set up tosend additional Fault Reports. The setup needed fo...

Page 64 - GMR Autotesting; Autotest Sequence

5 5-4 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual –March 1995 GFK-0787B GMR Autotesting The GMR software automatically performs autotesting on discrete inputs and outputs thathave been configured to be autotested. Analog inputs and outputs are not autotes...

Page 65 - Discrete Input Autotest; Configuration Required for Discrete Input Autotest

5 5-5 GFK-0787B Chapter 5 Diagnostics Discrete Input Autotest Discrete Input Autotest exercises the system inputs to assure their ability to detect and respondto actual inputs. It can be used on both 16-point and 32-point blocks. Input autotest will: H accommodate normally-closed and normally- open ...

Page 66 - Operation of the Input Autotest; Test Verification

5 5-6 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual –March 1995 GFK-0787B Single Input Sensor to Triplex Block Group FieldSwitch ZenerDiode Power feed outputs require isolation diode when single input device iswired to more than one block. Operation of the ...

Page 67 - Discrete Output Autotest

5 5-7 GFK-0787B Chapter 5 Diagnostics Discrete Output Autotest Discrete output autotest checks the ability of outputs to respond to the commanded outputstate. Load Bus A Bus B Bus C A B C D ÉÉ ÉÉ ÉÉ ÉÉ ÉÉ ÉÉ ÉÉ ÉÉ The discrete output autotest will: H work on outputs that are either on or off, with o...

Page 68 - Operation of the Discrete Output Autotest

5 5-8 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual –March 1995 GFK-0787B Operation of the Discrete Output Autotest The PLC that is presently the autotest master informs the other PLCs (if any) which autotestgroup it is about to test. All PLCs read the diag...

Page 70 - Pulse Test Operation; Note

5 5-10 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual –March 1995 GFK-0787B Pulse Test Operation The Output Autotest uses the standard Genius block Pulse Test feature. During this test, thesystem is on-line and available. For the test to be performed: H All ...

Page 71 - GMR Discrepancy Reporting; Discrete Input Discrepancy Reporting; Input Data

5 5-11 GFK-0787B Chapter 5 Diagnostics GMR Discrepancy Reporting The GMR software performs discrepancy reporting for: H Voted discrete inputs H Discrete outputs H Analog inputs There is no discrepancy reporting for analog outputs. Discrete Input Discrepancy Reporting As explained in the chapter on P...

Page 72 - Discrete Output Discrepancy Reporting; How Output Discrepancy Checking is Per formed

5 5-12 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual –March 1995 GFK-0787B Discrete Output Discrepancy Reporting Output discrepancy monitoring is the process of monitoring the block output voting functionto detect both processor discrepancies and lost commu...

Page 73 - Analog Input Discrepancy Reporting

5 5-13 GFK-0787B Chapter 5 Diagnostics Analog Input Discrepancy Reporting If there is a discrepancy in the data from a set of inputs, so that a channel deviates by morethan a configurable percentage from the voted value, the PLC automatically places a messagein the I/O Fault Table where it is availa...

Page 74 - Input Line Fault Detection in a GMR Application

5 5-14 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual –March 1995 GFK-0787B Input Line Fault Detection in a GMR Application The 16-circuit Genius blocks are capable of continually monitoring field circuits for inputshort circuit or open circuit faults. The b...

Page 75 - The PLC and I/O Fault Tables in a GMR System; Clearing the Fault Tables in a GMR System

5 5-15 GFK-0787B Chapter 5 Diagnostics The PLC and I/O Fault Tables in a GMR System Faults and alarms from I/O devices, Bus Controller faults, and bus faults are automati-cally logged into the Series 90–70 PLC ’s I/O Fault Table. Faults can be displayed withthe programmer in either On–Line or Monito...

Page 76 - I/O Fault Table Messages for GMR; Reporting of No-Load Faults on 4-Block Output Groups

5 5-16 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual –March 1995 GFK-0787B I/O Fault Table Messages for GMR I/O Fault Table format is detailed in the Series 90-70 PLC Reference Manual (GFK-0265). Fault Specific Data Fault CategoryFault ActionFault GroupPoin...

Page 77 - Meaning

5 5-17 GFK-0787B Chapter 5 Diagnostics Displaying Additional Fault Information About I/O Faults (with CTRL/F) Pressing the programmer CTRL/F keys provides more information about a fault. Entriesthat apply to the GMR system are described below. Fault Description: Code (Hex) Meaning 00 Loss of Device ...

Page 78 - PLC Fault Table Messages for GMR; Code

5 5-18 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual –March 1995 GFK-0787B PLC Fault Table Messages for GMR The following tables lists PLC Fault Table messages for GMR.. If you need additionalhelp, call GE Fanuc Technical Service at 1–800–828–5747. Code Mes...

Page 84 - Monitoring Manual Output Controls

5 5-24 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual –March 1995 GFK-0787B Monitoring Manual Output Controls The operation of manual trip and output override devices can be monitored and reported byconnecting them as inputs to Genius blocks. These inputs sh...

Page 85 - Discrete Input Fault Contacts for GMR; Conditions that Cause Discrete Input Fault Contacts to be Set; For the voted input

5 5-25 GFK-0787B Chapter 5 Diagnostics Fault, No Fault, and Alarm Contacts Fault and No Fault contacts can optionally be used to detect fault or lack of faultconditions on a discrete (%I or %Q) or analog (%AI or %AQ) reference. They can also beprogrammed with the Series 90-70’s built-in fault-locati...

Page 86 - Discrete Output Fault Contacts for GMR; Conditions that Cause Discrete Output Fault Contacts to be Set; For redundant outputs

5 5-26 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual –March 1995 GFK-0787B Discrete Output Fault Contacts for GMR For discrete outputs, the fault contact is associated with the logical outputs (outputs from theapplication program). Logical reference Physica...

Page 87 - For non-redundant outputs

5 5-27 GFK-0787B Chapter 5 Diagnostics Short circuit fault Overtemperature fault Overload fault h DiscrepancyThe blocks each report the discrepancy status for the data from each PLC, togetherwith the PLC online/offline status. All PLCs periodically monitor all blocks’ discrepancy status. Three discr...

Page 88 - Analog Fault and Alarm Contacts for GMR; Fault Contacts for Analog Inputs; Fault Contacts for Analog Outputs; Alarm Contacts

5 5-28 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual –March 1995 GFK-0787B Analog Fault and Alarm Contacts for GMR The fault, high alarm and low alarm contacts of non-voted analog inputs and outputs are notaffected by GMR analog I/O processing. Fault Contac...

Page 90 - Configuration Overview; The Basic Steps of Configuration

6 6-2 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 GFK-0787B Configuration Overview In a GMR system, there are three basic configuration steps: H Completing the GMR configuration using the GMR configuration software. H Configuring the Series 9...

Page 91 - Folder; (a) For Source Folder, enter the name of the folder containing the

6 6-3 GFK-0787B Chapter 6 Configuration (2) In the Program Folder functions menu, select F1 ... Select/Create a Program Folder . On the Select/Create screen, select the folder for the second PLC (for example CONFIGB) as the current folder. (3) In the Program Folder functions menu, select F10, Copy C...

Page 92 - Using the GMR Configuration Software; GMR Configuration Software Revision and Checksum

6 6-4 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 GFK-0787B Using the GMR Configuration Software The GMR Configuration Software is used to enter data needed by the GMR programsoftware. H Autotest interval H CPU type for the system H I/O limit...

Page 93 - Getting Started; Installing the Configuration Software; config

6 6-5 GFK-0787B Chapter 6 Configuration Getting Started To complete the configuration, you will need to provide the following information: H the CPU type (788 or 789) H the register memory table size. H the Analog Input table size. H the CPU Watchdog timer value. H I/O block serial bus addresses. H ...

Page 94 - Mouse and Keyboard Guide for the Configuration Software; Using a Mouse

6 6-6 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 GFK-0787B Mouse and Keyboard Guide for the Configuration Software Either a mouse or keyboard can be used with the GMR Configuration Software. It iseasiest to use a mouse. Using a Mouse When us...

Page 96 - GMR Configuration Summary

6 6-8 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 GFK-0787B GMR Configuration Summary GMR configuration is described in detail on the following pages. The basic steps are: 1. Select File to create a New System configuration 2. In the System m...

Page 97 - GMR configuration output file.

6 6-9 GFK-0787B Chapter 6 Configuration 9. [Insert] the first GBC (bus controller) group A. Select each bus controller in the group (GBC_A, GBC_B, GBC_C). (1) Specify a rack and slot location (2) Select [OK] or [C]ancel to quit the Rack/Slot window B. Configure all the input and output block groups ...

Page 98 - Creating/Selecting a File; Opening a Previously-Saved Configuration File; Select Open to open the file.

6 6-10 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 GFK-0787B Creating/Selecting a File To create a new configuration, or begin editing an existing file, select File. (If you areusing a mouse, click on “File” in the upper left corner of the sc...

Page 99 - Saving a Configuration File

6 6-11 GFK-0787B Chapter 6 Configuration Saving a Configuration File Select Save (F2) to save the configuration file presently in RAM memory (the onedisplayed on your computer screen). This function saves the file with the selected name,overwriting the previous version. If you want to specify anothe...

Page 100 - Changing to Another Directory

6 6-12 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 GFK-0787B Changing to Another Directory Use the Change Directory function if you want to access another directory. (Additionaldirectories must be created in DOS.) Select Chdir to change thedi...

Page 101 - Star ting a New Configuration; Entering a System Description

6 6-13 GFK-0787B Chapter 6 Configuration Star ting a New Configuration When you select New System from the File menu using the mouse, or using the Enter(Retur n) key, the System screen appears: From this screen, you can: H return to the file-handling functions (click on File or press ALT/F) H change...

Page 102 - GMR Configuration Selections

6 6-14 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 GFK-0787B GMR Configuration Selections When you select System, the following menu appears CPU configurationSelect autotesting intervalInput Discrepancy FilterSet configuration limitsSelect In...

Page 103 - CPU Configuration; Exiting the Window; CPU Type

6 6-15 GFK-0787B Chapter 6 Configuration CPU Configuration Complete the entries on the CPU Configuration menu. The defaults are indicated withdots in the parentheses, as shown below. If a default selection is correct for your system,you don’t need to edit that item. ' Specify whether the CPU is mode...

Page 104 - Test Interval; Period

6 6-16 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 GFK-0787B Test Interval First, configure the interval for autotesting, and a register where this interval should bestored. ' On this screen, enter: Specify an autotest interval of 1 to 65535 ...

Page 105 - Input Discrepancy Filter

6 6-17 GFK-0787B Chapter 6 Configuration Input Discrepancy Filter ' On this screen, enter the input discrepancy filter time in seconds. This is the amount oftime, in seconds, that a particular input may be discrepant before the CPU places amessage in the I/O Fault Table, and sets the appropriate fau...

Page 106 - Item; Tables

6 6-18 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 GFK-0787B I/O Limits Select System again. From the configuration menu, select Config Limits (click the mouseon that line or cursor down and press Enter). ' Entries made on this screen determi...

Page 108 - Initialize Data

6 6-20 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 GFK-0787B Initialize Data Next, select System to configure the Initialization Data. ' Initialization data, as explained in the PLC Subsystem chapter of this book, is exchangedbetween PLCs dur...

Page 110 - Fault Actions; data fault

6 6-22 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 GFK-0787B Fault Actions Next, select System to configure Initialization Fault Actions: ' These entries determine how the GMR software will respond to either of the followingfaults during CPU ...

Page 111 - Write Access

6 6-23 GFK-0787B Chapter 6 Configuration Write Access Next, select System to configure Write Access: ' On this screen, you can configure starting addresses and lengths for any memory areasto which data can be written to through a CMM, PCM, or Ethernet CommunicationsModule. These configuration parame...

Page 112 - Adding Bus Controllers and I/O Modules

6 6-24 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 GFK-0787B Adding Bus Controllers and I/O Modules When you select Insert from the System screen, the following menu appears Configure Bus Controller groups Configure Input GroupConfigure Outpu...

Page 113 - Genius Bus Controller Group Configuration

6 6-25 GFK-0787B Chapter 6 Configuration Genius Bus Controller Group Configuration Note: It is possible that an application may include bus controllers in the PLC racks that are not part of the GMR system. Do not include non-GMR bus controllers in the GMRconfiguration. The only exception to this is ...

Page 115 - Configuring the Input Subsystem for a Bus Controller Group; Exiting a Block Group Window

6 6-27 GFK-0787B Chapter 6 Configuration Configuring the Input Subsystem for a Bus Controller Group With the rack and slot locations for a bus controller group configured, the next step is toconfigure the input subsystem for that bus controller group. Click on Insert or press ALT–I to display the In...

Page 116 - Configuring a Triplex, Duplex, or Simplex Discrete Input Group; SBA

6 6-28 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 GFK-0787B Configuring a Triplex, Duplex, or Simplex Discrete Input Group To configure a discrete group, click on that line, or move the cursor there and press theReturn key, or press the high...

Page 117 - Asynchronous Autotesting:; Synchronous Autotesting:; Auto Test

6 6-29 GFK-0787B Chapter 6 Configuration Highlight this item then press the space bar key to display a screen forsetting up Input Autotest and Test Type for individual circuits (screen for16-circuit blocks shown here). If input circuits on the blocks in the group should be autotested, circuit16 (the...

Page 119 - Vote Adapt Mode

6 6-31 GFK-0787B Chapter 6 Configuration Similarly, select which Voting Adaptation method will be used for eachcircuit. Vote Adapt Mode : Specify the manner in which the PLCs should perform voting adaptation. During operation, if a failure (discrepancy fault, Autotestfault, or Genius fault) occurs, ...

Page 120 - Bus Connects

6 6-32 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 GFK-0787B Default State: Choose a default state: OFF (0), ON (1), or hold last state. For a triplex group, this state will be provided to the application programif communications from all thr...

Page 121 - Analog I/O Group Configuration

6 6-33 GFK-0787B Chapter 6 Configuration Analog I/O Group Configuration Select Analog to configure any analog group. Select a triplex, duplex, or simplex analoginput group, then select the block type (6 inputs or 4 inputs/2 outputs). For example: ' Note: A “simplex” input group has just one I/O bloc...

Page 123 - Default State

6 6-35 GFK-0787B Chapter 6 Configuration Default State : For a triplex group, if all three blocks in the group are lost or if only twoblocks are lost and Voting Adaptation is selected as 3–2–0, the GMRsystem software will use a selected minimum or maximum value (seebelow) in voting, or hold the last...

Page 124 - Threshold Discrepancy; Limit Discrepancy; Analog Discrepancy Thresholds and Limits

6 6-36 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 GFK-0787B Threshold Discrepancy : Specify by what percent an individual input for the channel may deviate from the voted input value. Duringoperation, if any of the corresponding physical inp...

Page 125 - Configuring the Output Subsystem for a Bus Controller Group

6 6-37 GFK-0787B Chapter 6 Configuration Configuring the Output Subsystem for a Bus Controller Group Next, configure the output subsystem for that bus controller group. Select Output Group from the menu. Repeat the following procedure for each group in the output subsystem: Note: It is possible for ...

Page 127 - Options

6 6-39 GFK-0787B Chapter 6 Configuration Finally, for each 4-block group, specify the bus and location (serial busaddress) of the fourth block (the “D” block) in the group. While the A, B,and C blocks are installed on busses A, B, and C, respectively, the Dblock must be installed on either bus A or ...

Page 128 - Configuring the Non-Voted Discrete I/O for a Bus Controller Group; Start Ref

6 6-40 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 GFK-0787B Configuring the Non-Voted Discrete I/O for a Bus Controller Group If the bus controller group includes any non-voted discrete I/O, select nonVoted D I/O.(Inputs and outputs may be m...

Page 130 - Configuring the Non-Voted Analog I/O for a Bus Controller Group

6 6-42 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 GFK-0787B Configuring the Non-Voted Analog I/O for a Bus Controller Group If the bus controller group includes any non-voted analog I/O, select nonVoted A I/O. Note: Non-voted analog I/O bloc...

Page 131 - CONFIG4

6 6-43 GFK-0787B Chapter 6 Configuration Creating the G_M_R10 Output File The output of the GMR configuration process is a program block named G_M_R10,which can be imported to the application program folder in Logicmaster 90. The Write Output function of the GMR configuration software automatically ...

Page 132 - Next, you select Open a Configuration File. A list of files appears:; Printing the GMR Configuration

6 6-44 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 GFK-0787B In this example, you decide that you don’t want to keep CONFIG4, soyou go to the file functions and select Close. That ends the configurationsession without creating a .SAV file. Ne...

Page 133 - Completing the Logicmaster 90 Configuration; Configuring Bus Controllers

6 6-45 GFK-0787B Chapter 6 Configuration Completing the Logicmaster 90 Configuration Logicmaster 90 configuration steps for a PLC In a GMR system are the same as for anon- GMR system. A typical configuration is summarized on the following pages. Youshould refer to the Logicmaster 90 Software User’s ...

Page 134 - Creating and Copying the PLC Configuration

6 6-46 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 GFK-0787B Creating and Copying the PLC Configuration The recommended method of completing the PLC configuration is described below. A. Create a Folder for PLC A, PLC B, and PLC C. In this dis...

Page 135 - Logicmaster Configuration Summary

6 6-47 GFK-0787B Chapter 6 Configuration Logicmaster Configuration Summary 1. Change the CPU to the correct type (inthis example, it is a CPU 789) and addappropriate memory. 2. Move the cursor to the rack and slotlocation for the first Bus Controller. Be sure the location matches the entrymade with ...

Page 137 - Configuring GMR Bus Controllers and I/O Blocks

6 6-49 GFK-0787B Chapter 6 Configuration Configuring GMR Bus Controllers and I/O Blocks Each bus controller that serves the same input and/or output groups is configured similarly;so it is usually easiest to copy the first completed bus/bus controller in a group to configurethe other bus controller(...

Page 138 - Configuring Genius I/O Blocks; Editing the Reference Addresses; Setting Up Non-GMR Blocks to Send Multiple Fault Reports

6 6-50 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 GFK-0787B Configuring Genius I/O Blocks Genius I/O block configuration for a GMR system is similar to configuration for anon- GMR system. You should refer to the Genius Discrete and Analog Bl...

Page 139 - Configuring 16-Circuit and 32-Circuit Discrete DC Blocks

6 6-51 GFK-0787B Chapter 6 Configuration Configuring 16-Circuit and 32-Circuit Discrete DC Blocks The table below lists configuration parameters for 16-circuit and 32-circuit discreteblocks. Configuration options with special requirements in GMR systems are describedafter the table. Configuration op...

Page 140 - Baud Rate

6 6-52 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 GFK-0787B Any discrete block that is part of a redundant input group (triplex,duplex, or simplex) must be configured as a “combination” (I/O) typeblock. Any block that is part of an output gr...

Page 141 - Hot standby

6 6-53 GFK-0787B Chapter 6 Configuration If the block will use Input Autotest, circuit 16 must be configured as anoutput, as explained above. For circuit 16, Hold Last State must beconfigured to NO. If the block will use Input Autotest, circuit 16 must be configured withOutput Default set to ON. Por...

Page 142 - Results of Block Voting with Three PLCs Online

6 6-54 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 GFK-0787B For output blocks set up for GMR redundancy, the duplex default stateis used when a block determines that only two PLCs are online. TheDuplex Default state of On or Off is used by t...

Page 143 - Results of Block Voting with Only Two PLCs Online

6 6-55 GFK-0787B Chapter 6 Configuration Results of Block Voting with Only Two PLCs Online In the two tables below, PLC C is shown as offline, but it could be eitherof the other two instead. Using 0 as the Duplex Default state means that when only two PLCs areonline, the voted output state will be 0...

Page 145 - Programming Overview; Create a new Program Folder.; Add the GMR system software to the new program folder.

7 7-2 Genius t Modular Redundancy Flexible Triple Modular Redundant (TMR) System User’s Manual – March 1995 GFK-0787B Programming Overview The following figure represents the basic GMR programming steps. As explained previously,the GMR configuration, which assigns I/O reference addresses and produce...

Page 146 - Program Instruction Set for GMR; Programming Restrictions for TÜV Applications; Estimating Memory Usage

7 7-3 GFK-0787B Chapter 7 Programming Information Program Instruction Set for GMR The CPUs used for GMR support the all of the following Series 90-70 ladder logic instructions: ContactsAny Contact–| |––|/|––| ↑ |– –| ↓ |– –[F AULT]––|NOFL T]––[HIALR]––[LO ALR]–<+>––– CoilsAny Coil–( )––(/)––( ...

Page 147 - Reserved References; References; Memor y Write Access

7 7-4 Genius t Modular Redundancy Flexible Triple Modular Redundant (TMR) System User’s Manual – March 1995 GFK-0787B Reserved References In a GMR system, the following references are reserved or assigned special functions: References Reserved For: %I0001 to %I1024 (788 CPU)%I00001 to %I12288 (789 C...

Page 148 - Input and Output Addressing for GMR; Discrete I/O Addressing

7 7-5 GFK-0787B Chapter 7 Programming Information Input and Output Addressing for GMR I/O addressing for GMR is unlike a that of conventional Series 90-70 application. In aconventional application, input and output addresses are assigned sequentially, starting at thebeginning of the Input Table and ...

Page 150 - Analog I/O Addressing

7 7-7 GFK-0787B Chapter 7 Programming Information Analog I/O Addressing The size of the Analog Input Table is defined during configuration. The maximum size is8192 analog channels (words). Like the discrete Input and Output Tables, the AnalogInput Table is divided into sections. Analog Input Table É...

Page 151 - Analog Output Addressing

7 7-8 Genius t Modular Redundancy Flexible Triple Modular Redundant (TMR) System User’s Manual – March 1995 GFK-0787B Example: An application has sixteen analog input groups (each of which is a 6–input group),including spares. The total number of analog inputs from these blocks would be: 16 x 6 = 96...

Page 152 - %R Memory Required for Startup Initialization Data

7 7-9 GFK-0787B Chapter 7 Programming Information Register (%R) Memory Assignment for GMR The GMR software uses several areas of %R memory for specific functions, asdiagrammed below. Only the area labelled “Application Registers” should be used by theapplication program. Within that area, a portion ...

Page 153 - Monitoring Forces and Overrides; Monitoring the Fault Tables

7 7-10 Genius t Modular Redundancy Flexible Triple Modular Redundant (TMR) System User’s Manual – March 1995 GFK-0787B System Status (%S) References System status references are pre-defined locations and nicknames. They can be includedin the application program to check for fault-related conditions....

Page 154 - %M Status References

7 7-11 GFK-0787B Chapter 7 Programming Information GMR Status and Control (%M) References The GMR system software uses several %M references as status or control bits. Statusbits are used by the GMR software to provide information about GMR operations. Thesereferences can be read as needed by the ap...

Page 155 - PLC OK Flags

7 7-12 Genius t Modular Redundancy Flexible Triple Modular Redundant (TMR) System User’s Manual – March 1995 GFK-0787B PLC OK Flags The meanings associated with the three PLCOK flags are listed below: At PLC A PLCAOK PLC A outputs enabled At PLC A PLCBOK PLC B communications with PLC A healthyand PL...

Page 156 - %M Control References

7 7-13 GFK-0787B Chapter 7 Programming Information %M Control References The application program can use the following %M references to provide information tothe GMR software. The references are located at %M12257 – %M12288. Reference Nickname Description Meaning %M12257 CONTINU Continue with initia...

Page 157 - The GMR Software Version currently running in the PLC. Example:; Clearing the PLC Fault Tables; Caution; Do not use the Logicmaster F9 key to clear the Fault Tables.

7 7-14 Genius t Modular Redundancy Flexible Triple Modular Redundant (TMR) System User’s Manual – March 1995 GFK-0787B %M12262 (Report) When this control bit is turned on, it causes the GMR software to report and record thefollowing into the PLC Fault Table of the PLC(s) that turned it on: H The GMR...

Page 158 - Programming for Startup

7 7-15 GFK-0787B Chapter 7 Programming Information Programming for Startup The PLC Subsystem chapter of this book describes the sequence of actions that occurwhen the PLCs in a GMR system are started up. H The GMR software in the PLCs only allows one PLC to come online at a time. First, aPLC determi...

Page 159 - Monitoring Startup Status; COLDST; Enabling Outputs At Startup

7 7-16 Genius t Modular Redundancy Flexible Triple Modular Redundant (TMR) System User’s Manual – March 1995 GFK-0787B h If both of the other PLCs are already online, the initializing PLC reads the %R (only)initialization data from the other PLC with the higher serial bus address. It then setsits ow...

Page 160 - Powerup Note

7 7-17 GFK-0787B Chapter 7 Programming Information Prior to sending the outputs, the application program may check the status flags. If anyare found to be 1, the application program may decide to process the initialized databefore continuing. When the application program has computed valid outputs t...

Page 161 - Example Ladder Logic:

7 7-18 Genius t Modular Redundancy Flexible Triple Modular Redundant (TMR) System User’s Manual – March 1995 GFK-0787B an I/O Fault Reset be performed when any of the GMR CPUs are initialized, which willcause any current I/O fault information to be re–reported. If manual output controls are used in ...

Page 163 - Enabling I/O Point Faults; Programming for I/O Shutdown

7 7-20 Genius t Modular Redundancy Flexible Triple Modular Redundant (TMR) System User’s Manual – March 1995 GFK-0787B I/O Point Faults The GMR system can optionally use the standard Series 90-70 I/O Point Fault references. The I/O Point Faults feature allocates a bit reference for each potential di...

Page 164 - Programming for Fault and Alarm Contacts; Fault and No Fault Contacts; Clearing Faults Associated with Fault/No Fault Contacts

7 7-21 GFK-0787B Chapter 7 Programming Information Programming for Fault and Alarm Contacts The GMR system software can optionally utilize the Fault and Alarm contacts capability of theSeries 90-70 PLC to make fault and alarm information available to the application program logic.Conditions that cau...

Page 166 - Analog Fault Contacts for GMR; Analog Alarm Contacts for GMR

7 7-23 GFK-0787B Chapter 7 Programming Information Analog Fault Contacts for GMR As for discrete inputs, voted analog inputs have fault contacts associated with both theraw data inputs and the corresponding voted inputs. Non-voted analog inputs also haveassociated fault contacts. Analog Input Table ...

Page 167 - Reading GMR Diagnostics; Parameters for the Call Function

7 7-24 Genius t Modular Redundancy Flexible Triple Modular Redundant (TMR) System User’s Manual – March 1995 GFK-0787B Reading GMR Diagnostics The application program can obtain the following diagnostic information from the GMRsystem software: H Autotest faults H Discrepancy faults H Genius faults H...

Page 168 - Data Table Numbers; Table

7 7-25 GFK-0787B Chapter 7 Programming Information Data Table Numbers Table Contains Range for Start Value Range for End Value 11 Digital Input Discrepancy faults Greater than or equal to thefirst digital input address for A,B, or C. Less than the start plus themaximum digital input ad-dress for A, ...

Page 169 - Error Codes for GMR Diagnostics

7 7-26 Genius t Modular Redundancy Flexible Triple Modular Redundant (TMR) System User’s Manual – March 1995 GFK-0787B Error Codes for GMR Diagnostics The following error codes may be generated by the GMR diagnostics routine (seepage 7-24): Code Meaning 10908 An attempt was made to read an I/O shutd...

Page 170 - Programming for Global Data; Global Data for the Application Program

7 7-27 GFK-0787B Chapter 7 Programming Information Programming for Global Data In a Series 90-70 PLC/Genius system, Global Data is data that is automatically broadcastby a PLC bus controller, each bus scan. The GMR software uses this Global Data capability as the vehicle for exchanging systeminforma...

Page 171 - Enter a name for the new folder.

7 7-28 Genius t Modular Redundancy Flexible Triple Modular Redundant (TMR) System User’s Manual – March 1995 GFK-0787B Adding the GMR System Software toa New Application Program Folder The GMR system software provided on the diskette must be added to the foldercontaining the application program. Fol...

Page 172 - Adding the GMR Configuration to the Application Program Folder; Adding GMR_10 to the Logicmaster Librarian; Select “External Block” as the Element Type.

7 7-29 GFK-0787B Chapter 7 Programming Information Adding the GMR Configuration to the Application Program Folder The GMR configuration software outputs a program block file named G_M_R10.EXE,which must be added to the folder containing the application program. By default, thisfile is located in the...

Page 173 - Press ESC to return to the Librarian menu.; Impor ting G_M_R10 from the Librarian to the Application Program; Press the Enter key to begin the operation.; Impor tant

7 7-30 Genius t Modular Redundancy Flexible Triple Modular Redundant (TMR) System User’s Manual – March 1995 GFK-0787B 5. Add G_M_R10 to the library by pressing the Enter key. 6. When prompted for the number of paired input and output parameters, enter 2. 7. Press ESC to return to the Librarian menu...

Page 174 - Storing a Program to the PLC

7 7-31 GFK-0787B Chapter 7 Programming Information Storing a Program to the PLC All redundant PLCs in the GMR system must use the same application program, butdifferent configurations: PLC A PLC B PLC C Program: GMRPROG Configuration: CONFIGA Program: GMRPROG Configuration: CONFIGB Program: GMRPROG ...

Page 175 - Things to Consider when Storing to the PLC from the Programmer; In STOP MODE STORE, the following can be performed:

7 7-32 Genius t Modular Redundancy Flexible Triple Modular Redundant (TMR) System User’s Manual – March 1995 GFK-0787B Things to Consider when Storing to the PLC from the Programmer Use the Store function to copy program logic, configuration data, and /or referencetables from the programmer to the P...

Page 176 - Using the Store Function; Field

7 7-33 GFK-0787B Chapter 7 Programming Information Using the Store Function To use the Store function, press Store (F4) from the Program Utility Functions menu. TheStore Program screen appears. The screen shows the currently-selected program folder,which cannot be changed. Three types of data can be...

Page 177 - Storing an Identical Program Following CPU Replacement

7 7-34 Genius t Modular Redundancy Flexible Triple Modular Redundant (TMR) System User’s Manual – March 1995 GFK-0787B Storing a Program to the PLC:the System is NOT Configured for Online Changes If the GMR system is configured not to allow online changes, the PLC must be placed inStop mode to store...

Page 178 - Using the Program Download Utility; Using the Download Utility with the Default PLC IDs; Press the Space Bar to Continue

7 7-35 GFK-0787B Chapter 7 Programming Information Using the Program Download Utility If the redundant PLCs are linked by an SNP network, you can use the Download utilityprovided on the GMR software diskette when making future application programupdates. The Download utility: 1. works with the Logic...

Page 179 - Customizing the Download Utility for Other PLC IDs; UPLC

7 7-36 Genius t Modular Redundancy Flexible Triple Modular Redundant (TMR) System User’s Manual – March 1995 GFK-0787B Customizing the Download Utility for Other PLC IDs For PLCs with other PLC IDs, you need to edit the file KEY0.DEF before adding it to theProgram Folder in Logicmaster. 1. Install t...

Page 180 - Notes

7 7-37 GFK-0787B Chapter 7 Programming Information Storing a Program to the PLC:the System IS Configured for Online Changes For a system configured to allow online changes, the following sequence illustrates howan online ladder logic program change could be done in a triplex CPU System. Systemconfig...

Page 183 - Termination Boards

8 8-2 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 GFK-0787B Genius Bus Connections When planning and installing a Genius bus, it is extremely important to follow theguidelines given in the Genius I/O System and Communications User’s Manual. T...

Page 184 - Input Wiring

8 8-3 GFK-0787B Chapter 8 Installation Information Input Wiring Calculating Voltage Drops on Tristate Inputs It is important to consider the field wiring runs required for devices configured astristate inputs. Devices that are powered by 24V DC will have a voltage-reducingcomponent inserted at the f...

Page 185 - Single Sensor to Three Blocks (Triple Bus)

8 8-4 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 GFK-0787B Single Sensor to Three Blocks (Triple Bus) DC+ I1 I15/32 O16 DC+ I1 I15/32 O16 DC+ I1 I15/32 O16 Input 1 Input 15 or 32 C P U G B C C G B C A G B C B C P U G B C A G B C B G B C C C ...

Page 186 - Three Sensors to Three Blocks (Triple Bus)

8 8-5 GFK-0787B Chapter 8 Installation Information Input Wiring (continued) Three Sensors to Three Blocks (Triple Bus) DC+ I1 I15/32 O16 I1 I15/32 O16 I1 I15/32 O16 Input 1 Input 15 or 32 Input 1 Input 15 or 32 Input 1 Input 15 or 32 DC+ DC+ PLC A PLC B PLC C 6.2V Zener Diodes for Line Monitoring (o...

Page 187 - Block Wiring for 16-Circuit Source Block in an Input Group

8 8-6 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 GFK-0787B Input Wiring (continued) Block Wiring for 16-Circuit Source Block in an Input Group S1 S2 SHLD IN SHLD OUT DC+ 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 DC– Genius BusConnections 22V to...

Page 188 - Block Wiring for 16-Circuit Sink Block in an Input Group

8 8-7 GFK-0787B Chapter 8 Installation Information Input Wiring (continued) Block Wiring for 16-Circuit Sink Block in an Input Group S1 S2 SHLD IN SHLD OUT DC+ 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 DC– Genius BusConnections 22V to 56V DC Typical for each of up to 15 inputs DC Sink Block IC660BBD021...

Page 189 - Block Wiring for 32-Circuit Source Block in an Input Group

8 8-8 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 GFK-0787B Input Wiring (continued) Block Wiring for 32-Circuit Source Block in an Input Group S1 S2 SHLD IN SHLD OUT DC+DC+DC+DC+DC+10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 DC–DC–44 ...

Page 190 - Block Wiring for 32-Circuit Sink Block in an Input Group

8 8-9 GFK-0787B Chapter 8 Installation Information Input Wiring (continued) Block Wiring for 32-Circuit Sink Block in an Input Group S1 S2 SHLD IN SHLD OUT +5VDC+DC+DC+DC+10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 DC–DC–44 DC–DC–46 DC– Genius BusConnections 22V to 30V DC DC Sink Block IC660B...

Page 192 - Block Wiring for a 16-Circuit 4-Block Output Group

8 8-11 GFK-0787B Chapter 8 Installation Information Output Wiring for a 16-Circuit, 4-Block Group (continued) Block Wiring for a 16-Circuit 4-Block Output Group More detailed installation information is provided in the block datasheets. The labels BlockA , Block B, Block C, and Block D refer to the ...

Page 193 - Maximum inrush current:; Maximum total load for block group:; Output Autotest and Pulse Testing

8 8-12 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 GFK-0787B Output Wiring for a 16-Circuit, 4-Block Group (continued) Output Load Considerations for 16-Circuit 4-Block “H” PatternRedundant Output Groups Minimum load: 100 milliamps Maximum lo...

Page 194 - GE Catalog Number CR7RBXXEL Spectra 700 IEC Control Relay

8 8-13 GFK-0787B Chapter 8 Installation Information commanded state. If it does not, the point is pulsed Off again for about 7.5mS. Amaximum of two pulses of approximately 5mS and 7.5mS duration can occur. The 7.5mSpulse occurs only if the volts feedback for the first pulse is incorrect. Each output...

Page 196 - Block Wiring for a 32-Circuit 4-Block Output Group

8 8-15 GFK-0787B Chapter 8 Installation Information Output Wiring for a 32-Circuit, 4-Block Group (continued) Block Wiring for a 32-Circuit 4-Block Output Group More detailed installation information is provided in the block datasheets. The labels BlockA , Block B, Block C, and Block D refer to the ...

Page 197 - Warning

8 8-16 Genius tModular Redundancy Flexible Triple Modular Redundant (TMR) System User ’s Manual – March 1995 GFK-0787B Warning In certain cases, removing the DC power source from an output blockor blocks which are part of a 32-circuit 4-block output group, causesleakage currents through the output d...

Page 200 - TÜV Restrictions; Catalog Number

A GFT-166 Revision 1.3 April 4, 1995 A-2 Genius t Modular Redundancy Flexible Triple Modular Redundant (TMR) System User’s Manual – March 1995 GFK-0787B TÜV Restrictions For all safety relevant applications the safe state must be the de-energized (0) state. A Functional test must be performed to che...

Page 201 - For EMC purposes, the enclosure must provide protection equal; For High Limit processing

A GFT-166 Revision 1.3 April 4, 1995 GFK-0787B A-3 Appendix A TÜV Certification The installation procedures in the Series 90-70 Programmable Controller Installation Manual(GFK-0262D) and this GMR User’s Manual (GFK-0787A) are to be closely observed and compliedwith, especially the grounding procedur...

Page 203 - Maintenance Override Procedures

B section level 1 1figure_ap level 1 table_ap level 1 B-1 GFK-0787B Appendix B Maintenance Override The information in this appendix is reprinted by permission of TUV. Abstract Suggestions are made about the use of maintenance override of safety relevant sensorsand actuators. Ways are shown to overc...

Page 204 - Requirements for maintenance override handling

B B-2 Genius t Modular Redundancy Flexible Triple Modular Redundant (TMR) System User’s Manual – March 1995 GFK-0787B The following table shows common requirements. The differences between solution Aand B are shown by typeface italic. Requirements for maintenance override handling Responsibility Alr...

Page 205 - Recommendations; Version History

B GFK-0787B B-3 Appendix B Maintenance Override Recommendations The following recommendations are given to improve the primary safety as describedby the list: ' A program in the DCS that checks regularly that no discrepancies exist between theoverride command signals from the DCS and the override ac...

Page 206 - Index

Index Index-1 GFK-0787B A Alarm and Fault contacts, 5-25 , 5-28 , 7-21 Analog blocks, 1-8 Analog I/O, addressing, 7-7 Analog inputs, 4-12 configuring memory for, 6-18 configuring references for, 6-33 discrepancy, 5-13 , 6-36 maximum, minimum, 6-35 Application program inhibiting, 4-4 , 7-11 storing t...