Operation Overview | GE GFK-0787B specification

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Operation Overview

Genius Modular Redundancy has been developed for use in systems that have static or nearly static I/O under normal operating conditions. The system may have:

HNormally-on inputs with normally-energized outputs, as in emergency shutdown systems.

HNormally-off inputs with normally-deenergized outputs, as in fire and gas detection systems.

Genius Modular Redundancy provides:

Hhigh degree of self-test and monitoring with diagnostics

Hfault tolerance.

Hsupport for centralized or fully distributed systems.

HScalable voting: 2-out-of-3, 2-out-of-2, 1-out-of-2, or simplex.

The example that follows illustrates how the GMR input subsystem, PLC subsystem, and output subsystem combine to provide a high-availability, high-reliability system.

PLC Subsystem

PLC A

PLC B

PLC C

Load

Input Subsystem

Output Subsystem

GFK-0787B

Chapter 1 Introduction

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GE GFK-0787B user manual Operation Overview

Contents

GE Fanuc Automation GFL±002 Preface Preface Related Publications Contents Chapter Configuration Appendix a TÜV Certification Appendix B Maintenance Override Chapter Introduction Components of a GMR System 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 SubsystemAutomatic System Test Genius I/O Blocks Discrete BlocksAnalog, RTD, and Thermocouple Blocks Block Summary Number of I/O Points in a GMR System Number of Non-GMR I/O Available for the 788 CPUNumber of Non-GMR I/O Available for the 789 CPU 798 Configuration and Programming GMR Basic Steps of Configuration and Programming Chapter Input Subsystem Overview GMR Input Groups One sensor to one Genius input Non-Voted I/O in the Input Subsystem Inputs from single-block simplex GMR input groupsInputs from non-GMR I/O blocks Discrete Inputs Types of Blocks in the Input SubsystemDiscrete Input Processing Discrepancy Reporting for GMR Inputs Input Autotest for GMR Inputs Calculating Voltage Drops on Tristate Inputs Line Monitoring for Discrete Inputs Normally-closed InputsNormally-open Inputs Input Filter Time Manual Input Controls Analog Inputs Voted Analog InputsNumber of Input Sensors per Voted Channel Analog Voting Adaptation Analog Discrepancy Reporting Non-Voted Analog Inputs in GMR Input GroupsNon-GMR Analog Blocks Chapter Output Subsystem Types of Blocks in the Output Subsystem Duplex Default for Outputs GMR Output HandlingOutput Voting Results of Block Group Voting with Three PLCs Online Output Fault Reporting PLC Logon Control Block Output Groups Output Load Sharing Electrical Characteristics of Sink and Source Blocks Operation of a 4-Block Output GroupBus Redundancy in a 4-Block Output Group Manual Output Controls and Diagnostics GMR Mode Redundancy Modes for Output Blocks Hot Standby Mode Basic Hot Standby Mode OperationHot Standby Mode in a GMR System Chapter PLC Subsystem System Startup All GMR bus controllers at serial bus address Online Changes Data Initialization CPU Sweep in a GMR System PLC Operation Estimating CPU Sweep Time Sweep Time Contribution of Genius I/O and GBCsImportant Note Input Processing DiscrepanciesDiscrete 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 Voting for Two Analog Inputs Voting for One Analog Input Output Processing Discrete Outputs Shutdown Synchronous or Asynchronous Input Autotest and I/O Shutdown Output Faults that Cause I/O Shutdown M12244 ± Iosd Any I/O Shutdown Timer ActivatedM12265 ± Sdcan Cancel I/O Shutdown Programming for I/O Shutdown Hours Shut Down Recovery Shut Down Prevention Entering, Clearing, or Setting Global Data Communications Between PLCsGlobal Data Redundancy Chapter Diagnostics Programming for Diagnostics Diagnostics in a GMR System Input DiagnosticsOutput Diagnostics Setting Up Blocks to Report Genius Faults Setting Up Other Blocks to Send Multiple Fault ReportsCPU Redundancy Mode Configuration Block Type Summary Table GMR Autotesting Autotest Sequence Configuration Required for Discrete Input Autotest Setup for Input AutotestDiscrete Input Autotest Operation of the Input Autotest Circuit Fail Mask Discrete Output Autotest Operation of the Discrete Output Autotest Block a Pulse-tested Pulse Test Operation GMR Discrepancy Reporting Discrete Input Discrepancy ReportingInput Data Voted Discrepancy Inputs Discrete Output Discrepancy Reporting How Output Discrepancy Checking is PerformedDiscrete Output Discrepancy Reporting with Dynamic Outputs Analog Input Discrepancy Reporting Input Line Fault Detection in a GMR Application PLC and I/O Fault Tables in a GMR System Clearing the Fault Tables in a GMR System Fault Table Messages for GMR Reporting of No-Load Faults on 4-Block Output Groups Fault Description Code Hex Meaning Fault Specific DataFault Type for Output Autotest PLC Fault Table Messages for GMR CodeMessage Code Code 10903 Code Manual Output Controls and Diagnostics Monitoring Manual Output Controls Fault, No Fault, and Alarm Contacts Discrete Input Fault Contacts for GMR Discrete Output Fault Contacts for GMR Contact References Associated with an Output ShortCircuitfault Overtemperaturefault Overloadfault Analog Fault and Alarm Contacts for GMR Alarm ContactsFault Contacts for Analog Inputs Fault Contacts for Analog Outputs Chapter Configuration Configuration Overview Basic Steps of Configuration For Information to be copied set only Configuration to yes Using the GMR Configuration Software GMR Configuration Software Revision and Checksum Installing the Configuration Software Getting Started Mouse and Keyboard Guide for the Configuration Software Using a Mouse Configuration GMR Configuration Summary Insert the first GBC bus controller group Opening a Previously-Saved Configuration File Creating/Selecting a File Saving a Configuration File Closing a Configuration File without Saving It Changing to Another Directory Starting a New Configuration Closing and Deleting the System Configuration FileEntering a System Description GMR Configuration Selections When you select System, the following menu appears CPU Configuration SimplexShutdown Test Interval Period Input Discrepancy Filter Limits Initialization Data + %R data needed for the application SpareGlobal Data Initialize Data GBC1 GBC2 Parame Comment Ters Fault Actions M12232M12234 Write Access Adding Bus Controllers and I/O Modules Genius Bus Controller Group Configuration Exiting the Window Configuring the Input Subsystem for a Bus Controller Group Select To ConfigureExiting a Block Group Window Start %I SBA Auto Test GFK-0787B Duplex State GFK-0787B Analog I/O Group Configuration Vote Adapt Mode Vote Adaptation Default State Analog Discrepancy Thresholds and Limits Configuring the Output Subsystem for a Bus Controller Group Start %Q GFK-0787B Options Start Ref Bus C inputs Reserved inputs Configuration References are 0001 to CONFIG4 Creating the GMR10 Output File Printing the GMR Configuration Completing the Logicmaster 90 Configuration Configuring Bus Controllers Creating and Copying the PLC Configuration Logicmaster Configuration Summary GFK-0787B Configuring GMR Bus Controllers and I/O Blocks Configuring Genius I/O Blocks Copying ConfigurationsSetting Up Blocks for Fault Reporting Editing the Reference Addresses Configuring 16-Circuit and 32-Circuit Discrete DC Blocks Feature Circuit or Factory Selections Block SettingDevice Serial bus Circuit I/O Type Report Faults Block I/O Type Baud Rate Pulse Test Input Filter Time Configuration Duplex Default Duplex Output Default State Setting Block Duplex Voted Output Default State Setting Block Results of Block Voting with Only Two PLCs Online Chapter Programming Overview Program Instruction Set for GMR Estimating Memory UsageEstimating Bus Scan Time Use of Do I/O and Suspend I/O Memor y Write Access Reserved ReferencesReferences Reserved For Input and Output Addressing for GMR Discrete I/O Addressing Q1009 to %Q1024 I1009 to %I10241024 ± 16 ± 3 x 32 +1 = 913 = %I0913 Analog I/O Addressing AnalogOutput Addressing Example16 x 6 = 96 words required Register %R Memory Assignment for GMR Memory Required for Startup Initialization Data Monitoring the Fault Tables System Status %S ReferencesMonitoring Forces and Overrides GMR Status and Control %M References Status References Resetting Status Flags PLC OK Flags Control References M12257 ContinueReference Nickname Description Meaning Clearing the PLC Fault Tables 40-characterConfiguration File DescriptionM12262 Report Programming for Startup Monitoring Startup Status Enabling Outputs At Startup Powerup Note Performing I/O Fault Reset Fault. If both are not 1, initialization continues Example Ladder LogicThese Program Blocks represent logic Routines that are appropriate for Application When a third PLC comes on line Triplex bit is optional the need for this bit depends on Point Faults Enabling I/O Point FaultsProgramming for I/O Shutdown Programming for Fault and Alarm Contacts Fault and No Fault ContactsClearing 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 FunctionY3 dummy not used Data Table Numbers ContainsRange for Start Value Range for End Value Error Codes for GMR Diagnostics Code Meaning Programming for Global Data Global Data for the Application Program GFK-0787B Adding GMR10 to the Logicmaster Librarian Select F6 Add Element to Library Do not Rename GMR10 Storing a Program to the PLC GFK-0787B Using the Store Function Field Description Storing an Identical Program Following CPU Replacement Storing a Revised Program Using the Program Download Utility Using the Download Utility with the Default PLC IDsPress the Space Bar to Continue Customizing the Download Utility for Other PLC IDs Processing Complete Programming Information GFK-0787B Chapter Installation Information Genius Bus Connections Termination Boards Input Wiring Single Sensor to Three Blocks Triple Bus Three Sensors to Three Blocks Triple Bus Block Wiring for 16-Circuit Source Block in an Input Group DC Source Block IC660BBD020 Block Wiring for 16-Circuit Sink Block in an Input Group DC Sink Block IC660BBD021 Block Wiring for 32-Circuit Source Block in an Input Group DC Source Block IC660BBD024 Block Wiring for 32-Circuit Sink Block in an Input Group DC Sink Block IC660BBD025 Output Wiring for a 16-Circuit, 4-Block Group Circuit, 4-Block Output Group Block Wiring for a 16-Circuit 4-Block Output Group Block a Output Autotest and Pulse Testing OFF±ON±OFF TestON±OFF±ON Test GE Catalog Number CR7RBXXEL Spectra 700 IEC Control Relay Output Wiring for a 32-Circuit, 4-Block Group Block Wiring for a 32-Circuit 4-Block Output Group Block a GFK-0787B Milliamp Appendix TÜV Restrictions Catalog Number Firmware Description Revision Level Appendix a TÜV Certification COMMREQ, DATAINITCOMM, Call SUB, Callexternal Appendix Maintenance Override Project engineer Projectengineer, Typeapproval Recommendations Index Index-2 Index-3 Index-4