GE GFK-0787B user manual

GE Fanuc Automation

Programmable Control Products

Genius Modular Redundancy

Flexible Triple Modular

Redundant (TMR) System

User’s Manual

GFK-0787B March 1995

Contents

Main Warnings, Cautions, and Notes as Used in this Publication Warning Preface Content of this Manual Changes for this Version of the Manual Preface Related Publications We Welcome Your Comments and Suggestions Jeanne L. Grimsby Page 1 Chapter 1Introduction Components of a GMR System GMR Software Series 90-70 PLCs Genius I/O Blocks Additional Items Series 90-70 PLCs Inter-processor Communications Busses and Bus Controllers Additional Bus Controllers for Communications Operation Overview Input Subsystem PLC Subsystem: Voting on Input Data PLC Subsystem: Providing Output Data Output Subsystem Automatic System Test Genius I/O Blocks Discrete Blocks Analog, RTD, and Thermocouple Blocks I/O Block Summary Number of I/O Points in a GMR System Number of Non-GMR I/O Available for the 788 CPU Number of Non-GMR I/O Available for the 789 CPU Configuration and Programming The GMR Software The Basic Steps of Configuration and Programming 2 Chapter 2Input Subsystem Overview GMR Input Groups Non-Voted I/O in the Input Subsystem Example Discrete Inputs Types of Blocks in the Input Subsystem Discrete Input Processing 1 Discrepancy Reporting for GMR Inputs Input Autotest for GMR Inputs Calculating Voltage Drops on Tristate Inputs Line Monitoring for Discrete Inputs Normally-closed Inputs Normally-open Inputs Input Filter Time Manual Input Controls Analog Inputs Voted Analog Inputs Number of Input Sensors per Voted Channel Analog Voting Adaptation Analog Discrepancy Reporting Non-Voted Analog Inputs in GMR Input Groups Non-GMR Analog Blocks 3 Chapter 3Output Subsystem Overview Types of Blocks in the Output Subsystem GMR Output Handling Output Voting Duplex Default for Outputs Page PLC Logon Control Output Fault Reporting 4-Block Output Groups Output Load Sharing Operation of a 4-Block Output Group Electrical Characteristics of Sink and Source Blocks Bus Redundancy in a 4-Block Output Group Manual Output Controls and Diagnostics Redundancy Modes for Output Blocks GMR Mode Hot Standby Mode Basic Hot Standby Mode Operation outputs Hot Standby Mode in a GMR System 4 Chapter 4PLC Subsystem System Startup Online Changes Data Initialization CPU Sweep in a GMR System PLC Operation Estimating CPU Sweep Time Sweep Time Contribution of Genius I/O and GBCs Important Note Input Processing Discrepancies Discrete Inputs Discrete Input Voting Voting with Three Discrete Inputs Voting with Two Discrete Inputs Voting for One Discrete Input Analog Inputs Analog Input Voting Voting for Three Analog Inputs 4-15 Voting for Two Analog Inputs Voting for One Analog Input Output Processing Discrete Outputs I/O Shutdown Synchronous or Asynchronous Input Autotest and I/O Shutdown Output Faults that Cause I/O Shutdown Programming for I/O Shutdown Interval Until Shutdown in Each PLC Examples Hours Hours 16 124 9 I/O Shut Down Prevention I/O Shut Down Recovery Communications Between PLCs Global Data Redundancy Entering, Clearing, or Setting Global Data 5 Chapter 5Diagnostics Programming for Diagnostics Diagnostics in a GMR System Input Diagnostics Output Diagnostics Setting Up Blocks to Report Genius Faults Setting Up 16- and 32-Circuit DC Blocks to Send Multiple Fault Reports Setting Up Other Blocks to Send Multiple Fault Reports Summary Table GMR Autotesting Autotest Sequence Discrete Input Autotest Configuration Required for Discrete Input Autotest Setup for Input Autotest Operation of the Input Autotest Test Verification * Discrete Output Autotest Operation of the Discrete Output Autotest Page Pulse Test Operation GMR Discrepancy Reporting Discrete Input Discrepancy Reporting Discrete Output Discrepancy Reporting How Output Discrepancy Checking is Performed Discrete Output Discrepancy Reporting with Dynamic Outputs Analog Input Discrepancy Reporting Input Line Fault Detection in a GMR Application The PLC and I/O Fault Tables in a GMR System Clearing the Fault Tables in a GMR System I/O Fault Table Messages for GMR Reporting of No-Load Faults on 4-Block Output Groups Displaying Additional Fault Information About I/O Faults (with CTRL/F) PLC Fault Table Messages for GMR 5-19 Page 5-21 Page Manual Output Controls and Diagnostics Monitoring Manual Output Controls Fault, No Fault, and Alarm Contacts Discrete Input Fault Contacts for GMR Conditions that Cause Discrete Input Fault Contacts to be Set Discrete Output Fault Contacts for GMR Conditions that Cause Discrete Output Fault Contacts to be Set Page Analog Fault and Alarm Contacts for GMR Fault Contacts for Analog Inputs Fault Contacts for Analog Outputs Alarm Contacts 6 Chapter 6Configuration Configuration Overview The Basic Steps of Configuration Page Using the GMR Configuration Software GMR Configuration Software Revision and Checksum Getting Started Installing the Configuration Software Mouse and Keyboard Guide for the Configuration Software Using a Mouse Using a Keyboard Page GMR Configuration Summary Page Creating/Selecting a File Opening a Previously-Saved Configuration File Saving a Configuration File Changing to Another Directory Closing a Configuration File without Saving It Starting a New Configuration Entering a System Description Closing and Deleting the System Configuration File GMR Configuration Selections CPU Configuration Test Interval Page I/O Limits Example * Initialize Data Page Fault Actions Write Access Adding Bus Controllers and I/O Modules Genius Bus Controller Group Configuration Page Configuring the Input Subsystem for a Bus Controller Group Exiting a Block Group Window Configuring a Triplex, Duplex, or Simplex Discrete Input Group Page Page Page Page Analog I/O Group Configuration Page Page Analog Discrepancy Thresholds and Limits Configuring the Output Subsystem for a Bus Controller Group Page Page Configuring the Non-Voted Discrete I/O for a Bus Controller Group Page Configuring the Non-Voted Analog I/O for a Bus Controller Group Creating the G_M_R10 Output File Example: Printing the GMR Configuration Completing the Logicmaster 90 Configuration Configuring Bus Controllers Creating and Copying the PLC Configuration Logicmaster Configuration Summary Page Configuring GMR Bus Controllers and I/O Blocks Configuring Genius I/O Blocks Editing the Reference Addresses Editing the Block I/O Type Copying Configurations Setting Up Blocks for Fault Reporting Configuring 16-Circuit and 32-Circuit Discrete DC Blocks * Page Page Page Page 7 Chapter 7Programming Information Programming Overview 7-3 Program Instruction Set for GMR If you want to estimate the bus scan time, see page 4-6 for instructions. The CPUs used for GMR support the all of the following Series 90-70 ladder logic instructions: Use of Do I/O and Suspend I/O Programming Restrictions for TV Applications Reserved References Memory Write Access Input and Output Addressing for GMR Discrete I/O Addressing Discrete I/O Tables: Example Analog I/O Addressing Example: Analog Output Addressing Register (%R) Memory Assignment for GMR %R Memory Required for Startup Initialization Data System Status (%S) References Monitoring Forces and Overrides Monitoring the Fault Tables 7-11 GMR Status and Control (%M) References %M Status References The following table lists the GMR system status flags. * PLC OK Flags Resetting Status Flags 7-13 %M Control References %M12257 (Continue) %M12262 (Report) Clearing the PLC Fault Tables Do not use the Logicmaster F9 key to clear the Fault Tables. Programming for Startup Monitoring Startup Status Enabling Outputs At Startup PLC Logon Control Powerup Note Performing I/O Fault Reset Example Ladder Logic: Page I/O Point Faults Enabling I/O Point Faults Programming for I/O Shutdown Programming for Fault and Alarm Contacts Fault and No Fault Contacts Clearing Faults Associated with Fault/No Fault Contacts Fault-Locating References Discrete Input Fault Contacts for GMR Discrete Output Fault Contacts for GMR Analog Fault Contacts for GMR Analog Alarm Contacts for GMR Reading GMR Diagnostics Parameters for the Call Function 7-25 Data Table Numbers Table Contains Range for Start Value Range for End Value Error Codes for GMR Diagnostics Programming for Global Data Global Data for the Application Program Adding the GMR System Software to a New Application Program Folder Adding the GMR Configuration to the Application Program Folder Adding GMR_10 to the Logicmaster Librarian Importing G_M_R10 from the Librarian to the Application Program Important Storing a Program to the PLC Things to Consider when Storing to the PLC from the Programmer Using the Store Function Storing a Program to the PLC: the System is NOT Configured for Online Changes Storing an Identical Program Following CPU Replacement Storing a Revised Program Using the Program Download Utility Using the Download Utility with the Default PLC IDs Customizing the Download Utility for Other PLC IDs Storing a Program to the PLC: the System IS Configured for Online Changes Notes Page 8 Chapter 8Installation Information Genius Bus Connections Termination Boar ds Input Wiring Calculating Voltage Drops on Tristate Inputs Single Sensor to Three Blocks (Triple Bus) 8-5 Three Sensors to Three Blocks (Triple Bus) PLC A PLC B PLC C 6.2V Zener Diodes for Line Monitoring (optional) 8-6 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System Block Wiring for 16-Circuit Source Block in an Input Group DC Source Block IC660BBD020 O * * Block Wiring for 16-Circuit Sink Block in an Input Group DC Sink Block IC660BBD021 * * If an input is wired for tristate operation, the circuit LED glows dimly when the input off. Block Wiring for 32-Circuit Source Block in an Input Group DC Source Block IC660BBD024 8-9 Block Wiring for 32-Circuit Sink Block in an Input Group DC Sink Block IC660BBD025 8-10 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System Output Wiring for a 16-Circuit, 4-Block Group 16-Circuit, 4-Block Output Group 8-11 Output Wiring for a 16-Circuit, 4-Block Group Block Wiring for a 16-Circuit 4-Block Output Group Block C Block D Block A Output Wiring for a 16-Circuit, 4-Block Group (continued) Output Load Considerations for 16-Circuit 4-Block H Pattern Redundant Output Groups Output Autotest and Pulse Testing OFFONOFF Test ONOFFON Test GE Catalog Number CR120BDXXX48 Series A 600Volt Industrial Relay GE Catalog Number CR7RBXXEL Spectra 700 IEC Control Relay 8-14 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System Output Wiring for a 32-Circuit, 4-Block Group 32-Circuit, 4-Block Output Group 8-15 Output Wiring for a 32-Circuit, 4-Block Group Block Wiring for a 32-Circuit 4-Block Output Group Block C Block D Block A Warning Output Wiring for a 32-Circuit, 4-Block Group (continued) Output Load Considerations for 32-Circuit 4-Block H Pattern Redun- dant Output Groups Output Autotest and Pulse Testing A Appendix ATV Certification A TV Restrictions A A B Appendix BMaintenance Override Abstract Maintenance Override B B-2 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System A. B Recommendations Version History A B C D F G H I L M N O P S T U W Z