Chapter Introduction | GE GFK-0787B specs

Chapter

1

Introduction

Genius Modular Redundancy (GMRt) has been developed by GE Fanuc Automation and Silvertech Limited of the United Kingdom. Silvertech has many years experience applying GE Fanuc products to high-integrity safety system applications such as Emergency Shutdown and Fire & Gas Detection in the petrochemical/oil and gas industries. They have captured this expertise in the GMR system software.

GMR is a high-reliability, high-availability redundancy system that provides a scalable solution for many types of redundancy applications, including critical TMR (Triple Modular Redundancy) applications.

TÜV has certified GMR for classification to these requirements: triplex Class 5, duplex Class 4 and 5, and simplex Class 4 according to the DIN V19250/DIN V VDE 081 standards. For use of the GMR system in a TÜV approved safety critical installation, refer to information in Appendix A.

The GMR system is based on standard, off-the-shelf hardware. It utilizes field-proven Series 90-70 PLC and Genius I/O products. Enhancements have been incorporated into the standard PLC CPU, bus controller, and several Genius I/O blocks specifically for use in GMR systems. These enhanced products, together with GMR system software, provide input voting by the PLCs, output voting, support for both discrete and analog I/O, automatic testing of discrete inputs and outputs, and extensive fault-monitoring capabilities for the application program.

A basic GMR system consists of groups of Genius blocks gathering data from multiple or single sensors, multiple PLCs running the same application program, and groups of Genius blocks controlling shared output loads. Communications between the blocks and PLCs and among the PLCs is provided by the Genius bus.

Triple PLCs

Triple Genius Busses

Load

Triple Input Sensors

GMR provides great configuration flexibility. A system can include 1, 2, or 3 PLCs. There can be just one I/O subsystem, as represented above, or more than one. Each I/O subsystem can include 1, 2, or 3 busses. A bus can serve up to a total of 32 devices (I/O blocks, PLCs, and a Hand-held Monitor). The system can include both non-redundant I/O blocks and individual non-redundant points on redundant blocks.

GFK-0787B

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GE GFK-0787B user manual Chapter Introduction

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 Automatic System Test PLC Subsystem Providing Output DataOutput Subsystem 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 Inputs from non-GMR I/O blocks Non-Voted I/O in the Input SubsystemInputs from single-block simplex GMR input groups 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 Non-GMR Analog Blocks Analog Discrepancy ReportingNon-Voted Analog Inputs in GMR Input Groups Chapter Output Subsystem Types of Blocks in the Output Subsystem Output Voting Duplex Default for OutputsGMR Output Handling Results of Block Group Voting with Three PLCs Online Output Fault Reporting PLC Logon Control Block Output Groups Output Load Sharing Bus Redundancy in a 4-Block Output Group Electrical Characteristics of Sink and Source BlocksOperation of a 4-Block Output Group Manual Output Controls and Diagnostics GMR Mode Redundancy Modes for Output Blocks Hot Standby Mode in a GMR System Hot Standby ModeBasic Hot Standby Mode Operation 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 Important Note Estimating CPU Sweep TimeSweep Time Contribution of Genius I/O and GBCs Discrete Inputs Input ProcessingDiscrepancies 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 Global Data Redundancy Entering, Clearing, or Setting Global DataCommunications Between PLCs Chapter Diagnostics Programming for Diagnostics Output Diagnostics Diagnostics in a GMR SystemInput 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 Discrete Input Autotest Configuration Required for Discrete Input AutotestSetup for 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 with Dynamic Outputs Discrete Output Discrepancy ReportingHow Output Discrepancy Checking is Performed 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 Type for Output Autotest Fault Description Code Hex MeaningFault Specific Data Message PLC Fault Table Messages for GMRCode 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 Entering a System Description Starting a New ConfigurationClosing and Deleting the System Configuration File GMR Configuration Selections When you select System, the following menu appears Shutdown CPU ConfigurationSimplex Test Interval Period Input Discrepancy Filter Limits Global Data Initialization Data+ %R data needed for the application Spare Initialize Data GBC1 GBC2 Parame Comment Ters M12234 Fault ActionsM12232 Write Access Adding Bus Controllers and I/O Modules Genius Bus Controller Group Configuration Exiting the Window Exiting a Block Group Window Configuring the Input Subsystem for a Bus Controller GroupSelect To Configure 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 References Reserved For Memor y Write AccessReserved References Input and Output Addressing for GMR Discrete I/O Addressing 1024 ± 16 ± 3 x 32 +1 = 913 = %I0913 Q1009 to %Q1024I1009 to %I1024 Analog I/O Addressing 16 x 6 = 96 words required AnalogOutput AddressingExample Register %R Memory Assignment for GMR Memory Required for Startup Initialization Data Monitoring Forces and Overrides Monitoring the Fault TablesSystem Status %S References GMR Status and Control %M References Status References Resetting Status Flags PLC OK Flags Reference Nickname Description Meaning Control ReferencesM12257 Continue M12262 Report Clearing the PLC Fault Tables40-characterConfiguration File Description 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 Programming for I/O Shutdown Point FaultsEnabling I/O Point Faults 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 Y3 dummy not used Reading GMR DiagnosticsParameters for the Call Function 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 Press the Space Bar to Continue Using the Program Download UtilityUsing the Download Utility with the Default PLC IDs 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 ON±OFF±ON Test Output Autotest and Pulse TestingOFF±ON±OFF 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