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
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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
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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
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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
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5-21
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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
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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
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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
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GMR Configuration Summary
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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
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I/O Limits
Example
*
Initialize Data
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Fault Actions
Write Access
Adding Bus Controllers and I/O Modules
Genius Bus Controller Group Configuration
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Configuring the Input Subsystem for a Bus Controller Group
Exiting a Block Group Window
Configuring a Triplex, Duplex, or Simplex Discrete Input Group
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Analog I/O Group Configuration
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Analog Discrepancy Thresholds and Limits
Configuring the Output Subsystem for a Bus Controller Group
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Configuring the Non-Voted Discrete I/O for a Bus Controller Group
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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
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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
*
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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:
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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
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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
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B
Appendix BMaintenance Override
Abstract
Maintenance Override
B
B-2 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System
A.
B
Recommendations
Version History
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