Genius Bus Installation
Contents
1. AE T g E d p male female male female terminating re connector connector connector connector sistor male Mating Mating connectors connectors 2 6 Genius I O System and Communications U ser s Manual November 1994 G EK 90486F 1 Terminating the Bus at an 1 0 Block Connect the bus cable to each device on the bus For the first device on the bus Shield In can be left unconnected For the last device on the bus Shield Out can be left unconnected For devices on either end of the bus install the appropriate terminating resistor across the Serial 1 and Serial 2 terminals N S a Or o oo F lli s Ql s2 C SHLD IN C SHLD OUT Q wes AIRI N Terminating a Dual Bus at a Bus Switching Module Each cable of a redundant bus pair must be terminated independently If either cable of a redundant bus ends at a Bus Switching Module ignoring any bus stubs install its terminating resistor across the Serial 1 and Serial 2 terminals where the cable attaches to the BSM No terminating resistor is used at the end of the bus stub Terminating the Bus at a Bus Controller or PCIM For some bus controllers at the end of a bus the correct terminating impedance must be set using on board jumpers before installing the module The Series 90 70 G enius Bus Control2. Genius I O System and Communications U ser s Manual November 1994 G EK 90486F 1 Specifications Fiber optic cable type Multimode Mating connector SMA stype 906 ST option available Transmit launch power 15dbm Receive sensitivity 32dbm Environmental Operating temperature OC to 60C Storage temperature 40C to 80C Relative humidity 0 to 95 non condensing Modem dimensions Series 90 70 plug in Standard Series 90 70 module Stand alone modem 3 5 8 89cm H x 17 0 43 18cm W x 7 0 17 78cm D G EK 90486F 1 Chapter 2 The Communications Bus 2 11
3. Phase A Devices If a bus has any Phase A Genius products catalog numbers IC 660C BD nnn IC 660C BSnnn IC 660C BA nnn IC 660H H M 500 or IC 660C BB900 901 the bus must use 153 6 Kbaud standard and the maximum bus length is 2000 feet Therefore only the cable lengths listed under 153 6s are permitted 153 6e refers to 153 6 K baud extended which is not compatible with 153 6 K baud standard B aud Rate Selection 2 4 A Genius I O or communications bus can operate at one of four baud rates 153 6 Kbaud standard 153 6 K baud extended 76 8 Kbaud or 38 4 K baud Follow these guidelines when selecting the baud rate for a bus 1 All devices on a bus must operate at the same baud rate other busses in the system may operate at different baud rates 2 Ifthere are any older Genius products on the bus catalog numbers IC 660C BD nnn IC 660C BSnnn IC 660C BA nnn IC 660H H M500 or IC 660C BB900 901 the bus must be set up to use 153 6 Kbaud standard 3 Ifthe cable length is between 4500 and 7500 feet you must select 38 4 Kbaud This data rate only supports a maximum of 16 device on the bus 4 Ifthe cable length is between 3500 and 4500 feet select 76 8 K baud 5 Ifcable length is between 2000 and 3500 feet select 153 6 K baud extended 6 Ifthe cable length is less than 2000 feet either 153 6 Kbaud standard or 153 6 Kbaud extended can be used The products are set to operate at 153 6 Kbaud standard whe
4. atbaud rate 10 to 20 AWG Rating Rating 12Vatt 1536 1536 768 3840 A 9823 350in 1500hms 2 22 30v 60C 2000ft 3500ft 4500ft 7500ft B 9182 8 89mm 606m 1061m 1364m 2283m C 4596 M M 39240 B 89182 322in 1500hms 2 22 150v 200C 2000ft 3500ft 4500ft 7500ft 8 18mm 606m 1061m 1364m 2283m B 9841 270in 120 ohms 2 24 30v 80C 1000ft 1500ft 2500ft 3500ft M M 3993 6 86mm 303m 455m 758m 1061m A 9818C 330in 100ohms 2 20 300v 80C 1500ft 2500ft 3500ft 6000ft B 9207 8 38mm 455m 758m 1061m 1818m M M 4270 A 9109 282in 1000hms 2 20 150v 200C 1500ft 2500ft 3500ft 6000ft B 89207 7 16mm 455m 758m 1061m 1818m C 4798 M M 44270 A 9818D 330in 100ohms 2 20 1500ft 2500ft 3500ft 6000ft B 9815 8 38mm 455m 758m 1061m 1818m A 9818 315in 100ohms 4 two pair 150v 60C 1200ft 1700ft 3000ft 4500ft B 9855 8 00mm 22 364m 516m 909m 1364m M M 4230 A 9110 274in 100ohms 4 two pair 150v 200C 1200ft 1700ft 3000ft 4500ft B 89696 6 96mm 22 364m 516m 909m 1364m B 89855 M M 64230 A 9814C 243in 750hms 2 20 150v 60C 800ft 1500ft 2500ft 3500ft B 9463 6 17mm 242m 455m 758m 1061m M M4154 A 5902C 244in 75ohms 4 two pair 300v 80C 200ft 500ft 1200ft 2500ft B 9302 6 20mm 22 60m 152m 333m 758m M M17002 Notes A Alpha B Belden C Consolidated M Manhattan e Limited to 16 taps at 38 4 K baud 2 2 Genius I O System and Communications U ser s Manual November 1994 G EK 90486F 1 Using O
5. each block must be connected to Shield Out of the preceding device For the first device on the bus Shield In can be left unconnected For the last device on the bus Shield Out can be left unconnected When making bus connections the maximum exposed length of bare wires should be two inches For added protection each shield drain wire should be insulated with spaghetti tubing to prevent the Shield In and Shield Out wires from touching each other Start End of Bus of Bus gt gt gt gt gt ar Terminating Terminating Resistor Resistor AA AL NVS Serial 1 j Serial 1 Serial 2 i Serial 2 Shield In i i Shield In Shield Out es ie ir bry ie Shield Out N N N N N aE Because of reflections caused by the high speed of the bus taps from a single bus should not be made N either T nor star configurations as shown below are supported T Configuration STAR Configuration Exceptions to the T restriction are dual bus redundant systems w here short stubs are permitted with Bus Switching Modules C hapter 8 and fiber optic links where fiber forms the trunk line and fiber optic modems link the fiber trunk li
6. C hapter TheC ommunications Bus 2 This chapter describes the selection and installation of the bus cable that links G enius devices It also explains how fiber optics cable and modems can be utilized in applications requiring immunity to higher levels of interference or lightning strikes freedom from ground loops or greater distance between devices A communications bus consists of two or more G enius devices and usually the serial bus cable that connects them A single block or bus controller with a Hand held Monitor directly attached properly terminated with a 75Q resistor are considered the smallest possible Genius communications bus 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 horse power motors These circuits may be rated from tens to thousands 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 LAN s MAP and Genius I O and communications bu
7. ansients beyond the 1 500 volt transient rating of the system Installing cable underground reduces the probability of a direct lightning strike However buried cables can pick up hundreds of amperes of current when lightning contacts the ground nearby Therefore it is important to protect the installation by including surge protectors on underground data lines The cable shields should be grounded directly Surge suppressors and spark gaps should be used to limit the voltage that might appear on the signal lines It is recommended to install two only silicon surge suppressors or spark gaps to control transients of 1 to 25 Kilovolts from 100 to 1000 amps or more These devices should be installed close to the entrance of the bus to the outdoors Silicon Surge Suppressors are available many sources including Clare G eneral Instruments Motorola and Ledex lucas Ledex type DFPO 27 is one such device For information about this product in the US contact Lucas Industries Incorporated 5500 New King Street Troy Michigan 48098 tel 313 879 1920 fax 313 552 1020 Spark gaps are available from Clare Refer to the vendor s literature for installation details In extreme situations such as totally isolated power systems additional protection against lightning damage should be provided by adding surge suppressors for groups of I O blocks Such suppressors should be installed from incoming power leads to ground enclosure baseplate block case wher
8. cottsdale AZ 85260 phone 602 483 7393 or FAX 602 483 7391 provides a full line of fiber optic communication products and services They can provide modems that install directly in a Series 90 70 PLC as well as stand alone modems in rackmount panelmount industrial enclosures with integral power supplies Fiber optic cables are available for industrial aerial direct burial riser and plenum installations Pheonix Digital also supplies modems for SN P applications for controller programmercommunications Product features include Online error checking Fault prediction fault location fault tolerance Redundant fiber media Distances from 6 feet 1 8 Meters to 6 miles 9 6 Km m Selectable wavelengths 850 nanometers 1300 nanometers The following example shows three Series 90 70 PLCs connected to both Genius and SNP fiber optic busses using rack mounted and stand alone modems G enius Bus Controllers and I O blocks can be cabled directly to modems using standard twisted pair wire PLCs and programmer computers can be cabled directly to modems using Pheonix Digital s interconnection cables wepow weapon SNP Bus Genius Bus Modem Fiber Optic SNP Bus Fiber Optic Genius Bus Bus Controller a
9. e leads enter the enclosure A ltematively fiber optics cable and modems described on the next page can be used to provide immunity against lightning induced transients Using a Dual Bus For applications where communications between the controller and I O blocks must be maintained even if a cable break should occur a dual bus can be used Genius I O blocks are interfaced to such a dual bus via one or more Bus Switching Modules Each bus cable of the pair requires its own bus controller A dual bus can provide the same types of functions as a single bus If cable breaks are not a problem or if it is not necessary to maintain communications if a break should occur dual cables are not needed Chapter 8 describes the use of dual busses and bus controllers for different types of CPU Belden 9855 and 9302 are 4 conductor cables and can be used for dual busses Identify the separate twisted pairs on these types and do not use extra pairs for any other purpose G EK 90486F 1 Chapter 2 The Communications Bus 2 9 Using F iber Optics If the installation requires immunity to higher levels of interference or lightning strikes freedom from ground loops or greater distance between devices fiber optics cable can be used GE Fanuc does not supply fiber optics products directly The products described on the following pages have been used successfully with GE Fanuc systems Pheonix Digital Pheonix Digital 7650 East Evans Rd Bldg A S
10. flon polyethelene or polypropylene are usually more durable 7 Electrical characteristics cable manufacturers information about pulse rise time and N RZ data rate is useful for comparing cable types The Genius bit consists of three AC pulses the equivalent N RZ bit rate is about three times as great For assistance in selecting a specific cable type please consult your local G E Fanuc application engineer Prefabricated Cables For applications using 150 ohm cables such as Belden 9182 prefabricated cables are available in 15 IC 660BLC 001 and 36 IC 660BLC 003 lengths These cables terminate in mating connectors that simplify wiring between I O blocks The 36 cable is recommended for Field C ontrol installations a LNO AHS NI GHS zy3S buas Sg gt SHD SHD SER SER OUT IN 2 1 G EK 90486F 1 Chapter 2 The Communications Bus 2 3 Bus Length The maximum bus length for shielded twisted pair cable is 7500 feet Some cable types are restricted to shorter bus lengths For example for buses with a total cable length of 100 feet to 2000 feet Belden 9182 or Alpha 9823 or Belden 89182 can be used In turn the bus length determines which baud rate may be selected If the application requires greater bus length fiber optics cable and modems can be used as explained later in this chapter Bus Length and Baud Rate for Busses with
11. k and termi nated at both ends Proper cable selection is critical to successful operation of the system Each bus in the system can be any cable type listed in the table below The 89182 89207 4794 89696 and 89855 types are high temperature cables for use in severe environments and are qualified for use in air plenums The 9815 type is water resistant and can be used where direct burial is required Similar cables of equivalent terminating resistance such as 9207 89207 and 9815 can be mixed Do not mix cables of different impedance regardless of cable run length The maximum run for mixed cable type equals the shortest length recommended for any of the types used Other small size twisted pair shielded wire of unspecified impedance can be used for short runs of 50 feet or less using 75 ohm terminations The excellent noise reduction of these cable types and of the Genius communications system allow the communications bus to be mixed with other signalling systems and 120 volt AC con trol circuits without needing added shielding or conduits Conservative wiring practices and national and local codes require physical separation between control circuits and power dis tribution or motor power Refer to sections 430 and 725 of the N ational Electric Code Cable Outer Terminating Numberof Dielectric Ambient Maximum Length CableRun amp Make Diameter Resistor Conductors Voltage Temp feet meters
12. ler if terminated must use an external resistor If a bus controller is at the end of a redundant bus do not set the on board terminating resistors Instead install a resistor of the appropriate value across the Serial 1 and Serial 2 connectors on the Bus Controller This technique enables boards to be replaced if needed without disrupting the entire bus since the busses always remain terminated G EK 90486F 1 Chapter 2 The Communications Bus 2 7 Bus Connection for Critical Processes The recommended method of connecting the bus to an I O block is to wire it directly to the block s Terminal Assembly Such bus connections are normally considered permanent They should never be removed while the bus is in operation the resulting unreliable data on the bus could cause hazardous control conditions If the possible removal or replacement of a block s Terminal Assembly would result in breaking the continuity of the bus the bus should first be turned off If the bus controls critical processes that cannot be shut down blocks can be wired to the bus via an intermediate connector as shown below fw 2 i lf s1 SHLD IN gt l f s2 SHLD OUT i o sho iN I SHLD OUT Q aes YO SISP OES The connector shown is A 107204N L from Control Design 458 Crompton Street Charlotte NC 28134 Altematively the wire ends can be soldered together before inserting the
13. m into the terminals When removing the Terminal A ssembly cover the ends of the wires with tape to prevent shorting the signal wires to one another or to ground Both of these methods allow the block s Terminal Assembly to be removed while maintaining data integrity on the bus If blocks are connected to the bus in this way field wiring to the blocks should also provide a means of disconnecting power to individual blocks 2 8 Genius I O System and Communications U ser s Manual November 1994 G EK 90486F 1 Bus Ambient Electrical Information Mostcapacitively and magnetically coupled noise shows up as common mode voltage on the bus The bus provides a 60 dB common mode rejection ratio A noise spike above 1000 volts would be required to corrupt the data The bus receivers filter out corrupted data and perform a 6 bit cyclic redundancy check to reject bad data Corrupted signals due to noise show up as missed data rather than incorrect data The bus continues operating to the maximum extent possible when bus errors are detected random bus errors do not shut down communications Bad data is rejected by the receiving device and excessive errors are reported to the controller Bus errors are indicated by flickering of I O block and bus controller LEDs If excessive bus errors occur the problem should be found and corrected Lightning Transient Suppression Running the bus cable outdoors or between buildings may subject it to lightning tr
14. n shipped from the factory The use of 153 6 Kbaud extended is recommended especially if the system will include a dual bus with Bus Switching Modules In noisy environments 153 6 Kbaud extended provides improved noise immunity with little effect on bus scan time If a system is experiencing excessive blinking of the bus controller s COMM OK light or if the I O blocks I O Enabled LEDs go off frequently 153 6 Kbaud extended should be used The baud rate selected should be indicated on all blocks especially if different busses in the facility use different baud rates Before connecting a Hand held Monitor to a functioning bus check that it has been configured to the correct baud rate If not change the HHM baud rate selection turn off the HHM connect it to the bus then turn the HHM on Genius I O System and Communications U ser s Manual November 1994 G EK 90486F 1 Connecting Devices to the Bus Devices can be placed in any physical sequence on the bus however communications will be most efficient if devices are placed in the same sequence as their D evice N umbers Block Numbers Each device has four terminals for the serial bus cable Serial 1 Serial 2 Shield In and Shield Out Connect the Serial 1 terminal of each block to the Serial 1 terminals of the previous device and the next device C onnect the Serial 2 terminal of each block to the Serial 2 terminals of the previous device and the next device Shield In of
15. ne to G enius wire bus branches G EK 90486F 1 Chapter 2 The Communications Bus 2 5 Bus Termination A bus must be terminated at each end by impedance that is correct for that cable type Impedance will be 75 100 120 or 150 ohms The method used to terminate a bus depends on the type of device at the end of the bus as explained on the next page Using Prefabricated Terminating Resistors Prefabricated molded connectors with terminating resistors are available for 75 ohms catalog number IC 660BLM 508 and 150 ohms IC 660BLM 506 They can be used with conventional bus cable and with the cables with pre molded connectors With pre molded cables attach the prefabricated resistor to the female cable end as shown below 46493 rst elt fee nal eel ee Underside of prefabricated resistor showing projection Slide prefabricated resistor onto female cable end Alola Where two prefabricated cable ends meet join the male and female ends see below If a prefabricated cable will be at the end of the bus and you want to use a prefabricated terminating resistor make the cable installation so that a female connector will be located at the device where the cable will be terminated 464 Connect to Last Device
16. s 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 control centers and on control panels In general it is acceptable to 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 together I O wires and communications bus cable can be placed randomly 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 since binding wires tightly together increases the coupling and mechanical stress that can damage the relatively soft insulation of some serial cable types like 9182 Wiring which is external to equipment and in cable trays should be separated following NEC practices The pickup over long distance runs with adequate spacing consists of common mode and ground voltage differences These are rejected due to the differential transmission mode of the communications bus and the bus isolation transformers built into each G enius I Oblock G EK 90486F 1 2 1 Selecting a Cable Type The Genius bus is a shielded twisted pair wire daisy chained from block to bloc
17. ther C able Types The cable types listed in the preceding table are recommended for use If the cable types listed above are not available the cable selected must meet the following guidelines 1 High quality construction Most important is uniformity of cross section along the length of the cable Poor quality cable may cause signal distortion and increase the possibility of damage during installation 2 Precision twisted shielded wire of EIA RS422 standard type having a uniform number of twists per unit of length In a catalog this type of cable may also be listed as twinaxial cable data cable or computer cable 3 Relatively high characteristic impedance 100 to 150 ohms is best 75 ohms is the minimum recommended 4 Low capacitance between wires typically less than 20pF foot 60pF meter This may be accomplished by inner dielectrics of foamed type usually polypropylene or polyethylene having a low dielectric constant Alternatively the conductors may be spaced relatively far apart Lower impedance types have smaller cross sections and provide easier wiring for shorter total transmission distances 5 Shield coverage of 95 or more Solid foil with an overlapped folded seam and drain wire is best Braided copper is less desirable spiral wound foil is least desirable 6 An outer jacket that provides appropriate protection such as water oil or chemical resistance While PVC materials can be used in many installations Te
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