Preface | GE GFK-0787B specs

Preface

This manual is a reference to planning, configuring and programming a Series 90t-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 located in the manuals listed on the next page.

Content of this Manual

Chapter 1. Introduction: describes the concept of GMR, and gives an overview of system components, configuration, and programming.

Chapter 2. Input Subsystem: provides information about the inputs to a GMR system.

Chapter 3. Output Subsystem: describes GMR output groups, output handling, manual output controls, and load sharing.

Chapter 4. PLC Operation: describes system startup, the CPU sweep in a GMR system,

PLC operation, I/O processing, and communications between redundant PLCs

Chapter 5. Diagnostics: chapter 5 describes the various types of diagnostics available in a GMR system.

Chapter 6. Configuration: describes configuration for a Series 90-70/Genius GMR system.

Chapter 7. Programming Information: describes the application program interface to the GMR software.

Chapter 8. Installation Information: provides supplementary installation information for GMR.

Appendix A. TÜV Certification: describes restrictions placed on the design, configuration, installation and use of a GMR system that will be applied in an Emergency Shut Down (ESD) application, for which for a TÜV site application approval will be sought.

Appendix B. Maintenance Override: The information in this appendix is reprinted by permission of TÜV. Suggestions are made about the use of maintenance override of safety relevant sensors and actuators. Ways are shown to overcome the safety problems and the inconvenience of hardwired solutions. A checklist is given.

Changes for this Version of the Manual

This manual describes a group of features and product enhancements that are collectively referred to as ªGMR Phase IIº:

HProgramming can now be done online. This capability is intended for use during debug and commissioning.

H32-circuit DC Genius I/O blocks can now be used in ºH-patternº output subsystems.

GFK±0787B

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GE GFK-0787B user manual Preface

Contents

GE Fanuc Automation GFL±002 Preface Related Publications Preface Contents Chapter Configuration Appendix a TÜV Certification Appendix B Maintenance Override Chapter Introduction Components of a GMR System Inter-processor Communications Series 90-70 PLCs Additional Bus Controllers for Communications Busses and Bus Controllers Operation Overview PLC Subsystem Voting on Input Data Input Subsystem PLC Subsystem Providing Output Data Output SubsystemAutomatic System Test Block Summary Genius I/O BlocksDiscrete Blocks Analog, RTD, and Thermocouple Blocks 798 Number of I/O Points in a GMR SystemNumber of Non-GMR I/O Available for the 788 CPU Number of Non-GMR I/O Available for the 789 CPU GMR Configuration and Programming Basic Steps of Configuration and Programming Chapter Input Subsystem Overview One sensor to one Genius input GMR Input Groups Non-Voted I/O in the Input Subsystem Inputs from single-block simplex GMR input groupsInputs from non-GMR I/O blocks Discrepancy Reporting for GMR Inputs Discrete InputsTypes of Blocks in the Input Subsystem Discrete Input Processing Calculating Voltage Drops on Tristate Inputs Input Autotest for GMR Inputs Input Filter Time Line Monitoring for Discrete InputsNormally-closed Inputs Normally-open Inputs Manual Input Controls Analog Voting Adaptation Analog InputsVoted Analog Inputs Number of Input Sensors per Voted Channel 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 PLC Logon Control Output Fault Reporting Output Load Sharing Block Output Groups 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 Redundancy Modes for Output Blocks GMR Mode Hot Standby Mode Basic Hot Standby Mode OperationHot Standby Mode in a GMR System Chapter PLC Subsystem All GMR bus controllers at serial bus address System Startup Online Changes Data Initialization PLC Operation CPU Sweep in a GMR System 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 Discrete Outputs Output Processing Synchronous or Asynchronous Input Autotest and I/O Shutdown Shutdown Programming for I/O Shutdown Output Faults that Cause I/O ShutdownM12244 ± Iosd Any I/O Shutdown Timer Activated M12265 ± Sdcan Cancel I/O Shutdown Hours Shut Down Prevention Shut Down Recovery Entering, Clearing, or Setting Global Data Communications Between PLCsGlobal Data Redundancy Programming for Diagnostics Chapter Diagnostics Diagnostics in a GMR System Input DiagnosticsOutput Diagnostics Summary Table Setting Up Blocks to Report Genius FaultsSetting Up Other Blocks to Send Multiple Fault Reports CPU Redundancy Mode Configuration Block Type Autotest Sequence GMR Autotesting Configuration Required for Discrete Input Autotest Setup for Input AutotestDiscrete Input Autotest Circuit Fail Mask Operation of the Input Autotest Discrete Output Autotest Operation of the Discrete Output Autotest Block a Pulse-tested Pulse Test Operation Voted Discrepancy Inputs GMR Discrepancy ReportingDiscrete Input Discrepancy Reporting Input Data 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 Clearing the Fault Tables in a GMR System PLC and I/O Fault Tables in a GMR System Reporting of No-Load Faults on 4-Block Output Groups Fault Table Messages for GMR 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 Discrete Input Fault Contacts for GMR Fault, No Fault, and Alarm Contacts Contact References Associated with an Output Discrete Output Fault Contacts for GMR ShortCircuitfault Overtemperaturefault Overloadfault Fault Contacts for Analog Outputs Analog Fault and Alarm Contacts for GMRAlarm Contacts Fault Contacts for Analog Inputs Chapter Configuration Basic Steps of Configuration Configuration Overview For Information to be copied set only Configuration to yes GMR Configuration Software Revision and Checksum Using the GMR Configuration Software Getting Started Installing the Configuration Software Using a Mouse Mouse and Keyboard Guide for the Configuration Software Configuration GMR Configuration Summary Insert the first GBC bus controller group 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 Closing and Deleting the System Configuration FileEntering a System Description When you select System, the following menu appears GMR Configuration Selections CPU Configuration SimplexShutdown Period Test Interval Input Discrepancy Filter Limits Initialization Data + %R data needed for the application SpareGlobal Data GBC1 GBC2 Initialize Data 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 SBA Start %I Auto Test GFK-0787B Duplex State GFK-0787B Analog I/O Group Configuration Vote Adaptation Vote Adapt Mode Default State Analog Discrepancy Thresholds and Limits Start %Q Configuring the Output Subsystem for a Bus Controller Group GFK-0787B Options Bus C inputs Reserved inputs Start Ref Configuration References are 0001 to Creating the GMR10 Output File CONFIG4 Printing the GMR Configuration Configuring Bus Controllers Completing the Logicmaster 90 Configuration Creating and Copying the PLC Configuration Logicmaster Configuration Summary GFK-0787B Configuring GMR Bus Controllers and I/O Blocks Editing the Reference Addresses Configuring Genius I/O BlocksCopying Configurations Setting Up Blocks for Fault Reporting Serial bus Configuring 16-Circuit and 32-Circuit Discrete DC BlocksFeature Circuit or Factory Selections Block Setting Device Block I/O Type Baud Rate Pulse Test Input Filter Time Circuit I/O Type Report Faults Configuration Duplex Output Default State Setting Block Duplex Default Results of Block Voting with Only Two PLCs Online Duplex Voted Output Default State Setting Block Chapter Programming Overview Use of Do I/O and Suspend I/O Program Instruction Set for GMREstimating Memory Usage Estimating Bus Scan Time Memor y Write Access Reserved ReferencesReferences Reserved For Discrete I/O Addressing Input and Output Addressing for GMR 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 Memory Required for Startup Initialization Data Register %R Memory Assignment for GMR Monitoring the Fault Tables System Status %S ReferencesMonitoring Forces and Overrides Status References GMR Status and Control %M References PLC OK Flags Resetting Status Flags Control References M12257 ContinueReference Nickname Description Meaning Clearing the PLC Fault Tables 40-characterConfiguration File DescriptionM12262 Report Programming for Startup Enabling Outputs At Startup Monitoring Startup Status Performing I/O Fault Reset Powerup Note Routines that are appropriate for Application Fault. If both are not 1, initialization continuesExample Ladder Logic These Program Blocks represent logic Triplex bit is optional the need for this bit depends on When a third PLC comes on line Point Faults Enabling I/O Point FaultsProgramming for I/O Shutdown Fault-Locating References Programming for Fault and Alarm ContactsFault and No Fault Contacts Clearing Faults Associated with Fault/No Fault Contacts Discrete Output Fault Contacts for GMR Discrete Input Fault Contacts for GMR Analog Alarm Contacts for GMR Analog Fault Contacts for GMR Reading GMR Diagnostics Parameters for the Call FunctionY3 dummy not used Range for End Value Data Table NumbersContains Range for Start Value Code Meaning Error Codes for GMR Diagnostics Global Data for the Application Program Programming for Global Data GFK-0787B Select F6 Add Element to Library Adding GMR10 to the Logicmaster Librarian Do not Rename GMR10 Storing a Program to the PLC GFK-0787B Field Description Using the Store Function Storing a Revised Program Storing an Identical Program Following CPU Replacement Using the Program Download Utility Using the Download Utility with the Default PLC IDsPress the Space Bar to Continue Processing Complete Customizing the Download Utility for Other PLC IDs Programming Information GFK-0787B Chapter Installation Information Termination Boards Genius Bus Connections Input Wiring Single Sensor to Three Blocks Triple Bus Three Sensors to Three Blocks Triple Bus DC Source Block IC660BBD020 Block Wiring for 16-Circuit Source Block in an Input Group DC Sink Block IC660BBD021 Block Wiring for 16-Circuit Sink Block in an Input Group DC Source Block IC660BBD024 Block Wiring for 32-Circuit Source Block in an Input Group DC Sink Block IC660BBD025 Block Wiring for 32-Circuit Sink Block in an Input Group Circuit, 4-Block Output Group Output Wiring for a 16-Circuit, 4-Block Group Block a Block Wiring for a 16-Circuit 4-Block Output Group 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 a Block Wiring for a 32-Circuit 4-Block Output Group GFK-0787B Milliamp Appendix Catalog Number Firmware Description Revision Level TÜV Restrictions Appendix a TÜV Certification COMMREQ, DATAINITCOMM, Call SUB, Callexternal Appendix Maintenance Override Project engineer Projectengineer, Typeapproval Recommendations Index Index-2 Index-3 Index-4