GE GFK-0825F System Wiring Guidelines

GFK-0825F Chapter 3 Installation 3-3

3

System Wiring Guidelines

Four types of wiring may be encountered in a typical factory installation:

1. Power wiring - the plant power distribution, and high power loads such as high

horsepower motors. These circuits may be rated from tens to thousand s of KVA at 220

VAC or higher.

2. Control wiring - usually either low voltage DC or 120 VAC of limited energy rating.

Examples are wiring to start/stop switches, contactor coils, and machine limit switches.

This is generally the interface level of the Genius discrete I/O.

3. Analog wiring - transducer outputs and analog control voltages. This is the interface level

to Genius I/O analog blocks.

4. Communications and signal wiring - the communications network that ties everything

together, including computer LANs, MAP, and Genius I/O and communi cations bus.

These four types of wiring should be separated as much as possible to reduce the hazards from

insulation failure, miswiring, and interaction (noise) between signals. A typical PLC system with

Genius I/O may require some mixing of the latter three types of wiring, particularly in cramped

areas inside motor con tr ol centers and on control pan el s. In general, it is acceptabl e t o mix the

communications bus cable with the I/O wiring from the blocks, as well as associated control level

wiring. All noise pickup is cumulative, depending on both the spacing between wires, and the

distance span they run tog et her. I/O wires and communi cations bus cable can be placed ran domly

in a wiring trough for lengths of up to 50 feet. If wiring is cord-tied (harnessed), do not include the

bus cable in the harness, sin ce binding wires tightl y together increases the coupl ing and mechanical

stress that can damage the relatively soft insulation of some serial cable types.

Wiring which is external to equipment, and in cable trays, should be separated following NEC

practices.

Installing Additional Suppression

It is possible some insta llations might exceed the s ur ge immunity capabilities specified in chapter

1. This is most likely in outd oor installa t i ons or where th e power source i s from another bu ilding or

ground system . It is pruden t to provide local transient pr otection.

Appendix B describes installation of additional suppression at the power and communications

lines.

Contents

Main Warnings, Cautions, and Notes as Used in this Publication Warning Caution Note Preface Content of this Manual Preface Related Publications Jeanne Grimsby Contents Page Page Page Page Introduction Overview Field Control Features Field Control Modules Genius Bus Interface Unit Bus Interface Unit Terminal Block I/O Modules Micro Field Processor I/O Terminal Blocks and Auxiliary I/O Terminal Blocks For more information, please refer to: Environmental Specifications For information about installing Field Control modules, please see: Configuration for Field Control For more information about configuration, please refer to: Field Control in a Genius System The Host CPU A More Complex Field Control and Genius System For more information about Genius systems and communications, please refer to: Required Genius and Host System Equipment Using Field Control in a CPU Redundancy System CPU/Bus Controller Redundancy: Overview Hot Standby CPU Redundancy Duplex CPU Redundancy Using Field Control in a Genius Bus Redundancy System Redundant Bus Configurations Page Description Genius Bus Interface Un it LEDs Bus Interface Unit Power Supply Timing Backplane Current Calculating Input Power Requirements for a Bus Interface Unit Page Load Requirements for Hardware Components Hand-held Monitor and Hand-held Programmer Hot Insertion/Removal of Modules Faults Reported During Hot Insertion/Removal I/O Module Data During H ot Insertion/Removal Hot Insertion/Removal for a Micro Field Processor Hot Insertion/Removal Not Permitted in Hazardous Locations Bus Interface Unit Terminal Block Functional Specificati o ns Bus Interface Unit: Bus Interface Unit Terminal Block: Installation For more information, please refer to: Page System Wiring Guidelines Installing Additional Suppression System Grounding All components of a control system and the devi ces it co ntrols must be properly grounded. Locations for Field Control Installing the DIN Rail Page Installing the Bus Interface Unit Terminal Block on the DIN Rail Removing the Bus Interface Unit Terminal Block from the DIN Rail Installing the Cables Between Terminal Blocks Power Wiring to the Bu s Interface Unit + - Connecting the Communications Bus Bus Cables Making Bus Connections Terminating a Bus Using Prefabricated Terminating Resistors 3-12 Field Control Genius Bus Interface Unit Users Manual October 1999 GFK-0825F Installing Pre-Molded Bus Cables Premolded Cable Positions for Bus Interface Unit Mounted with Terminals on Left Premolded Cable Positions for Bus Interface Unit Mounted with Terminals on Right Bus Connection for Critical Processes Installing the B us Interface Unit o n the Terminal Bl ock Warnings Removing the Bus Interface Unit from the Terminal Block Removing/Replacing the Bus Interface Unit Fuse Upgrading the BIU Firmware Page Operation BIU Data Handling at the I/O Station I/O Data for Conventional Modules I/O Data, Status Data, and Control Data for Intelligent Modu les Group Data for Intelligent Modules Selective Sweep Examples The BIU Sweep 1 BIU Reads Inputs from Conventional Modules 2 BIU Reads All Input Reference Parameters 3 BIU Reads Group Data Whose Destination is BIU 4 BIU Sends Group Data to Synchronization Module Page BIU Backplane Scan Time Example 1: Example 2: Five modules, one Group Data Move. Genius bus speed is 26mS. Data Transfer Between the BIU and the Host Data in the BIU's Network (Bus) Map Communications on the Genius Bus Input Data Sent by the Bus Interface Unit Input Defaults I/O Data Handling by Hos t Outputs from the Host to the BIU Output Data Format Output Defaults Genius Bus Scan Time Procedure for Estimating Bus Scan Time for a Field Control Station Throughput Operation of the BIU with a Micro Field Processor MFP and BIU Synchronization MFP I/O References MFP Operating Modes Synchronous Operation of a BIU and a Micro Field Processor Overview of Synchronous Operation The following diagram and table show how data is handled during synchronous operation. Backing Up Micro Field Processor Outputs How the Network Backs Up MFP Outputs Backing Up BIU Outputs with a Micro Field Processor Example Ladder Logic Station Configuration For Additional Information, Also See: Configuring the Serial Bus Address and Baud Rate Special Instructions for Series 90-70 PLC Systems Set Up the Hand-held Monitor 2. Begin with the HHM turned off. Attach it to the connector on the Bus Interface Unit. 3. Tur n the Hand-held Monitor on. Adjust its baud rate if necessary. F1:HHM UTILITIES F2:ANALYZE F3:CONFIGURATION F4:DEVICE MEMORY Create a New Configuration Assigning a Serial Bus Address to a New BIU Configure the Bus Interface Unit 5-6 Field Control Genius Bus Interface Unit Users Manual October 1999 GFK-0825F Field Control HHM Menu Overview F2 Individual Module Configuration Screens Field Control Configuration Screens Field Control Monitor I/O Screens Specific Hand-held Monitor versions may have different menus from those shown here. Change the Serial Bus Address of the Bus Interface Unit Device SBA 14 Prv > entr Select the Baud Rate Select a Series Six or Series Fi ve PLC Reference Address Stat Tbl Addr < > IO6 entr Configure Fault Reporting Configure Genius Bus Redundancy Configure CPU Redundancy CPU Redundancy No Cntl Redund < > tgl entr Hot Standby CPU Redundancy Duplex CPU Redundancy Page Page Configure Field Control Modules Enable/Disable the I/O Sca Disable Network I/O Update Configure the Network Map for the Bus Interface Unit Blk Map Start I ? Configuring Extra References in the BIU I/O Map Example Module References and Reference Parameters Worksheet Page 5-20 Field Control Genius Bus Interface Unit Users Manual October 1999 GFK-0825F Add Modules and Assign References S:1 Empty < > tgl read If the slot has previously been configured, the HHM shows the existing configuration. For exam ple: S:1 Q:16 Q01785-Q01800 < > del zoom Configuration with No Module Present Read a Module Identification with the Module Present Delete an Existing Module Configuration Configure a Discrete Input Module S:1 I:16 I tgl entr S:1 I:16 I00001- I00016 Default Inputs or Hold Last State Configure a Discrete Output Module S:1 Q:16 Q tgl entr Default Outputs or Hold Last State Configure a Discrete Input/Output Module S:1 I:16 I tgl entr Assign I/O References Default Inputs or Hold Last State Default Outputs or Hold Last State Configure a Conventional Analog Input Module S:1 AI:08 AI tgl entr Channel Fault Reporting S1 Faults Ch 01 YYYYYYYY S1 Active Ch 01 YYYYYYYY Input Current Ranges S1 Range Ch 01 0ma - 20mA Input Scaling S1 Scale 1 Ch 01 00000 Eng lo S1 Alarm Ch 01 00000 low S1 Alarm Ch 01 00000 high Example 1: Example 2: Default Inputs or Hold Last Values Configure a Conventional Analog Output Module S:1 AQ:04 AQ_ tgl entr Default Outputs or Hold Last Values Output Default Values Channel Fault Reporting S1 Faults Ch 01 NNYY S1 Active Ch 01 NYYN Output Current Ranges S1 Range Ch 01 0ma - 20mA Output Scaling S1 Scale 1 Ch 01 5-40 Field Control Genius Bus Interface Unit Users Manual October 1999 GFK-0825F Configure a 16-Point Grouped Analog Input Module Default data length When you select Read fr om the empty slot HHM screen, thi s module screen appears: S:4 ALG240 1.0 When you "zoom" into the mod u l e's slot, a screen like this ap p ear s: Page Page Page Page Page S:4 CH1 EU L 00000 Page Configure an 8-Point Grouped Analog Voltage Input Module Page Page Page Page Channel Active Input Range Page Alarm Limits Configure a 16-Point Grouped Analog Voltage Input Module S:2 AI AI tgl entr S:2 AI AI:016 clr entr Page Page Page Page Page S:2 CH1 ENG LO -10000 Page 5-64 Field Control Genius Bus Interface Unit Users Manual October 1999 GFK-0825F Configure an RTD Input Module When you select Read from the empty slot HHM screen, this module screen appears: S:4 ALG620 *.* Module version Press F4 to zoom into the slot. A screen like this appears: Page Line Frequency Page Page RTD Type S:1 CH1 RTD TYPE 100 PT 385 Wire Type S:1 CH1 WIRE TYP 3 WIRE Low Alarm Limit High Alarm Limit Resistance S:1 RESIST.1 00000 5-72 Field Control Genius Bus Interface Unit Users Manual October 1999 GFK-0825F Configuring a Thermocouple Input Module When you select Read from the empty slot HHM screen, this module screen appears: S:4 ALG630 *.* Press F4 to zoom into the slot. A screen like this appears: Number of references for this module type Page Page Page Page Thermocouple Type S:1 CH1 TC TYPE NONE Range Type S:1 CH1 RANGE TP 625 Page Page Page Configure an 8-Point Analog Voltage Output Module S:1 ALG310 1.0 S:1 I * I:024 I00257-I00280 Page Page Page Configure Local Default Outputs S:1 CH 1 ACTIVE Scaling Range S:1 CH1 RANGE -10V TO +10V Page Page Configure an 8-Point Analog Current Output Module S:1 ALG330 1.0 Assign I/Assign I/O References for the Module Page Page Page Configure Local Default Outputs S:1 CH 1 ACTIVE Scaling Range S:1 CH1 DEF RNG 1 Output Scaling Custom Scaling S:1 CH1 ENG L 04000 S:1 CH1 ENG H 20000 Page Configure a Micro Field Processor Configure the Reference Parameters for the Micro Field Processor F1 Monitor F2 Configuration S:1 EMPTY tgl read S7: MFP1.0 Select Data Types for Micro Field Processor Data Page Configure Group Data Moves Group Data Moves Worksheet Set Up a Group Data Move Group Move 1:0 Dest Slot: 7 Page Configure the Defaults for Each Move in a Group Move Deflt 1:1 YYYY Specify the BIU Scanning Frequency for the Data Group Sweep Enab 02:03 YYYYYYYYYYYYYYYY Return to the Group Screen Deleting a Group Data Move Diagnostics and Fault Clearing Diagnostics and Fault Clearing for Intelligent Modules Diagnostics and Fault Clearing for the BIU and Conventional Modules Maximum Number of Uncleared Faults Display and Clear Faults from a Genius Hand-held Monitor F1 First 16 Flts F3 Previous Menu F2 Last 16 Flts Slot #1 Fault#01 < > exit EXTRA I/O MODULE Clearing Faults Display and Clear Faults from a PLC Series 90 PLC: I/O Fault Table Series 90 PLC: PLC Fault Tab l e Series Five or Series Six PLC Monitoring and Controlling Field Control Data Overview Forcing Circuits Notes Overriding I/O Circuits Genius Hand-held Monitor I00001 *0 B < > frc hex Forcing/Unforcing the Displayed Reference Series 90 PLC Series Six PLC or Series Five PLC Field Control Data in I/O T able Memory Field Control Data in Register Memory Computer Datagrams For Additional Information, Also See: Datagram Types Read Map Read Map Reply Write Map How a Write Map Datagram Affects I/O Modules in the Station Report Fault Datagram Format Fault Byte 1 Fault Byte 2 Fault Byte 3 Fault Bytes 4 and 5 Fault Bytes 6 and 7 Configuration Data Read Configuration Data Read Configuration Data Format for Field Control Conventional Modules Read Configuration Datagram Format for Field Control Intelligent Modules Read Configuration Reply Data Write Configuration Data Write Configuration Data Format for Field Control Conventional Modules Example: Write Configuration Datagram Format for Field Control Intelligent Modules When using the Write Con fi g ur a tion datagram to configur e Group Moves, the datagram form at is: 8-10 Field Control Genius Bus Interface Unit Users Manual October 1999 GFK-0825F Bus Interface Unit Configuration Data Format For the Bus Interface Unit, the slot number is 0. The length varies. Discrete Input Modules Configuration Data Format Specify the actual slot number and a length of 13. module's data. Specify only one address, typically in the discrete input (I) table. Set the other Discrete Output Modules Configuration Data Format Specify the actual slot number and a length of 30. module's data. Specify only one address, typically in the discrete output (Q) table. Set the other (Byte #) Byte Descripti on (Byte #) Byte Description Discrete Combination Input/Output Modules Configuration Data Format Specify the actual slot number and a length of 20. Entering the Reference Addresses 8-14 Field Control Genius Bus Interface Unit Users Manual October 1999 GFK-0825F Conventional Analog Input Modules Configuration Data Format Specify the actual slot number and a length of 126. module's data. Specify only one address, typically in the analog input (AI) table. Set the other Bytes 14 - 125: Channel Configuration 8-16 Field Control Genius Bus Interface Unit Users Manual October 1999 GFK-0825F Conventional Analog Output Modules Configuration Data Format Specify the actual slot number and a length of 62. module's data. Specify only one address, typically in the analog output (AQ) table. Set the other Bytes 14 - 61: Channel Configuration 8-18 Field Control Genius Bus Interface Unit Users Manual October 1999 GFK-0825F Intelligent Modules Con figuration Data Format Configuration Data for Intelligent Modules, B ytes 0 to 13 Additional Configuration Data for a 16 Point Grouped Analog Input Module (ALG240) Additional Configuration Data for an 8 Point Grouped Analog Voltage Input Module (ALG281) Additional Configuration Data for a 16 Point Grouped Analog Voltage Input Module (ALG282) Additional Configuration Data for an RTD Input Module Additional Configuration Data for a Thermocouple Input Module Additional Configuration Data for a Current Source Analog Output Module Additional Configuration Data for an Analog Voltage Output Module Additional Configuration Data for a Micro Field Processor Module Group Data Move Configuration Data Format 8-28 Field Control Genius Bus Interface Unit Users Manual October 1999 GFK-0825F Group Move 1 Set Bus Interface Unit Operating Mode Bytes 0 and 1 (Must Match) Set Micro Field Processor Operating Mode Intelligent Analog Module Recalibration Datagram Message Content for Calibrating Low End of Channel Message Content for Calibrating High End of Channel Field Recalibration Message Content for Storing New Calibration to Field Area Message Content for Reverting to Factory Calibration Message Content for Putting Module in Warmup Mode Read I/O Forces Read I/O Forces Reply Read Slot Diagnostics Read Slot Diagnostics Reply Board Status (Byte 1) Board ID (Byte 2) Bytes 3 - 18 (Slot Diagnostics Data) A How Scaling Works Scaling Values for 1mV or 1A Engineering Units: BIU Version 1.3 Analog Current Input Module Analog Current Output Module Analog Current Source Output Module (IC670ALG320) in Voltage Mode Horner Analog Voltage Input Module (HE670ADC810) Scaling Values for 1mV or 1A Engineering Units: BIU Version 2.0 or Later Analog Current Input Module Analog Current Output Module Analog Current Source Output Module (IC670ALG320) in Voltage Mode Measuring Scaling Values Finding the Digital Value with the Module Online to the Process Finding the Digital Value without the Module Online Example of Scaling an Analog Input Installing Additional Suppression B Suppression at the Power Lines B Suppression for Devices in an Enclosure Suppression at the Communications Line The Genius Serial Bus C Wiring Guidelines Electrical Interface Genius Transceiver Electrical Specification C-4 Field Control Genius Bus Interface Unit Users Manual October 1999 GFK-0825F Selecting a Cable Type Cable # & Make NEC (USA) Type Outer Diameter Terminating Serial Bus Waveforms Using Other Cable Types Prefabricated Cables Effect of Long Cables, Repeaters, or Unspecified Cable Types On Maximum Length Bus Attenuation Distortion Propagation Delay Serial Data Format Bus Access Bus Length Bus Length and Baud Rate for Busses with Phase A Devices Baud Rate Selection Bus Ambient Electrical Information Lightning Transient Suppression Configuration Examples D Example 1: Discrete Data, Network Processing Example 2: Discrete and Analog Data, Network Processing Example 3: Discrete and Analog Data, Network and Local Processing Example 4: Discrete and Analog Data, Network and Local Processing and Group Data Moves Page Example 5: Group Move Index A B C D E F G H I L M N O P R S T U V W