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GE GFK-0787B User's Manual

1. PLC GMR redundant outputs in a group have the same reference addresses on each bus in the group PLCA PLCB PLCB gegee gasss BBSS Bus A Bus B Bus C aij aij Ic a iF l11265 111521 111777 Q12033 Q12033 Input blocks in a group are at Output blocks in a group are different raw data addresses at the same physical address Te Q12033 Q12033 GFK 0787B Chapter 6 Configuration 6 49 s Configuring Genius I O Blocks 6 50 Genius I O block configuration for a GMR system is similar to configuration for a non GMR system You should refer to the Genius Discrete and Analog Blocks User s Manual for specific configuration instructions A copy of the configuration prepared with the GMR Configuration Software should be used for reference during block configuration to assure consistency Editing the Reference Addresses For Genius blocks in a GMR system blocks within a group use the same reference addresses in each of the redundant PLCs so these are not changed Editing the Block I O Type Any discrete block that is part of a redundant input group triplex duplex or simplex must be configured as a combination I O block CopyingConfigurations Because the blocks in a redundant input or output group usually have the same configuration it would be most convenient to copy configuration from one block to another However the Copy C
2. Bus Controller Bus Controller 31 30 m kl outputs b gt Selection of Hot Standby mode is made during block configuration Hot Standby Mode in a GMR System If a block is set up for Hot Standby mode in the GMR configuration its Hot Standby operation is automatically expanded to include three PLCs 31 30 and 29 PLC 31 PLC 30 PLC 29 FEFFE outputs o gt The manner of operation is the same The block uses outputs from PLC 31 if they are available If not it uses outputs from PLC 30 If outputs from both PLC 31 and PLC 30 are not available the block uses outputs from PLC 29 If output data is not available from any of the three PLCs outputs go to their configured default or hold their last state The PLC at bus address 31 always has priority so that when 31 is on line it always has control of the outputs As mentioned this assignment of an additional Hot Standby PLC happens automatically for a Hot Standby block that is included in the GMR configuration Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 Chapter GFK 0787B 4 This chapter describes operation of the PLC subsystem in a GMR system PLC Subsystem System Startup CPU Sweep in a GMR System PLC Operation
3. Number of Non GMR I O Available for the 789 CPU These numbers are determined by the limits of physical I O based on the Logicmaster configuration and table size limitations based on the manner in which GMR maps I O into multiple locations in the I O tables this is explained in chapter 4 Number Number of Redundant GMR Outputs of Voted GMR 0 256 512 768 1024 1280 1536 1792 2048 Inputs 0 12288 11264 10240 9216 8192 7168 6144 5120 4096 256 11264 10496 9472 8448 7424 6400 5376 4352 3328 512 10240 9728 8704 7680 6656 5632 4608 3584 2560 768 9216 8960 7936 6912 5888 4864 3840 2816 1792 1024 8192 7936 7168 6144 5120 4096 3072 2048 1024 1280 7168 6912 6400 5376 4352 3328 2304 1280 256 1536 6144 5888 5632 4608 3584 2560 1536 512 1792 5120 4864 4608 3840 2816 1792 768 2048 4096 3840 3584 3072 2048 1024 GFK 0787B Chapter 1 Introduction 1 9 Configuration and Programming The GMR Software The GMR software consists of The GMR configuration software file CONFIG EXE This file which runs under DOS is used to enter the system parameters that will be used by the GMR system software When the GMR configuration is completed it produces a Program Block named G_M_R10 Adirectory named GMRxxyy containing the GMR system software files to which the application program will be added In the directory name GMRxxyy xx is two digits representing
4. N JAA N Closed 1 Open 0 e a Each PLC in the example system votes on the input data received from these three sensors as summarized below For a more detailed description of input processing see chapter 2 PLC Subsystem Voting on Input Data The example system uses three PLCs Each PLC receives corresponding inputs from all three blocks in the input group The GMR software in each PLC automatically votes on the input data and provides the voted input to the application program the program can also access the unvoted input data Each of these example voted inputs represents the same input sensors voted voted voted inputA 1 XS input inputA 1 NS input inputA 1 a input inputB 1 Fi 1 inputB 1 A 1 inputB 1 F 1 inputC 0 0 0 input C input C PLCA PLC B PLCC If an input is faulty the PLC s follow a configurable predetermined voting scheme based on the remaining input data 1 6 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 GFK 0787B PLC Subsystem Providing Output Data Running the same application program each PLC
5. Discrepancy The blocks each report the discrepancy status for the data from each PLC together with the PLC online offline status All PLCs periodically monitor all blocks discrepancy status Three discrepancy bits are maintained for each output one for each of the PLCs One of the bits is set if a block reports a discrepancy for any of its outputs m For non redundant outputs the single fault contact is associated with the physical output The fault contact is set under the following conditions Discrepancyfault Geniusfaults including Loss of Block and the following additional faults Failedswitch Occurs if the actual output state differs from the commanded state No Load fault For 16 circuit blocks only individual outputs can be configured to enable or disable reporting No load faults The minimum load current required to assure proper no load reporting is 50mA not 100mA as it would be for a block ina GMR group For a single block no load fault reports for block outputs that are ON may be generated at any time except during a Pulse Test For block outputs that are OF no load fault reports are generated during a Pulse Test Short Circuit fault Overtemperaturgault Overloadfault GFK 0787B Chapter 5 Diagnostics 5 27 5 28 Analog Fault and Alarm Contacts for GMR The fault high alarm and low alarm contacts of non voted analog inputs and outputs are not affected by GMR analog I O proce
6. Note For input blocks in GMR groups the I O addresses configured on these screens are for the raw input data received directly from the blocks for the A B and C areas of the Table as described in the Programming chapter For output blocks in GMR groups the output addresses configured on these screens are for the physical redundant output data not the logical addresses used in the application program These addresses are produced by the GMR Configuration Software and are listed in the configuration printout 6 48 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 6 Configuring GMR Bus Controllers and I O Blocks Each bus controller that serves the same input and or output groups is configured similarly so it is usually easiest to copy the first completed bus bus controller in a group to configure the other bus controller s in the same group Any additional changes can be made to the individual bus controller bus configurations as needed for example to accommodate non voted I O ona bus or the D block of a 4 block output group GMR redundant input blocks in a group each have a unique raw data address on each bus in the same PLC However the blocks have the same reference addresses in another GMR
7. Item Parame Comment ters Starting reference for M init data 1to 12224 Mustbe on 8 bit boundaries Length of M initialization data 0 to 764 Length in words start ref 16 X length lt 12288 0 if no M init data Starting reference for M temporary ini 0to 16384 Oiflength of M init data above is 0 tialization data to be stored in R Starting reference for R init data 1 to 16384 Length of R initialization data 0 to 4096 Oif no R init data Exiting the Window When you have completed this screen select OK to return to the System screen When you select OK your entries are saved and the window disappears If you want to exit the window and reset all fields to their previous content select Close or Cancel instead Chapter 6 Configuration 6 21 Fault Actions Next select System to configure Initialization Fault Actions PU est Interval In Disc Filter Initialization Fault Actions Config Limits Init Data Data Fault System Fault ault Actions Diag Diag rite Access Fatal Fatal TE B These entries determine how the GMR software will respond to either of the following faults during CPU initialization m an initialization data error data fault m a hardware fault system fault For each type select whether the GMR software will Halt the PLC fatal a the PLC to continue operating diagnostic and set the appropriate M status ag M
8. R Temp Ref If when the PLC is starting up the other two PLCs are already online if following the previous example R Start Ref R Length M data from the second online PLC the one with the lower serial bus address is also received by the initializing PLC In the R Temp Ref field enter a starting reference in R memory to receive M data from the second online PLC In this field the M refers to the type of data being received In the two fields on the previous page it refers both to the type of data being received and the memory location where it will be placed Notice that this field shows a initial starting reference of 257 By default the M data from the second online PLC is stored directly after the R data from the first R0001 R Initialization from Fi line PL R0256 irst Online PLC RAOZIN M Initialization from Second Online PLC R0272 If the PLCs will exchange R data during startup enter a starting reference and length in words If the PLCs will not exchange R data at startup enter 0 in the R length field Enter an starting reference for the R data to be received from the other PLC s online during CPU initialization By default this starting reference is R0001 Enter a length in words for the R data The amount needed depends on R memory usage in the application program The default length is 256 The table below lists total limits for these items
9. ol Dc 46 Dc i pe FS Ovpc Connection if no points on the block are to be autotested pepe Qroung must disconnect output 16 GFK 0787B m In three block input group each block is connected to one bus of three m If redundant power supplies are to be used they should be diode ORed power supplies providing common power to all blocks in a group Different groups may use different power sources Chapter 8 Installation Information 8 9 Output Wiring for a 16 Circuit 4 Block Group 16 Circuit 4 Block Output Group w OWQD O OND O OND cud F Q1 Q1 Block A Block B Source Source Q16 i Hi jee o Output 16 Low DC Bus C AA T Q1 Block D Sink Q16 o Q16 m Allblocks in an output group must have the same number of circuits 16 or 32 m Block D must be connected to the system through bus A or bus B not bus C The bus selected must be the one specified in the GMR configuration m Unused voted outputs cannot be used as non voted I O points 8 10 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 Output Wiring for a 16 Circuit
10. Enter Y for Yes 7 30 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 Storing a Program to the PLC All redundant PLCs in the GMR system must use the same application program but different configurations PLCA PLC B PLCC d o J o o o gt gt gt Program GURPROG Program GURPROG Program GURPROG Configuration CONFIGA Configuration CONFIGB Configuration CONFIGC Supplying the configuration and program as separate files as shown above makes it easier to perform program updates in the future Note The method used for storing a program depends on whether the system has been configured to permit online changes m f online changes are NOT permitted the process shuts down all PLCs m If online changes ARE permitted a program can be stored without shutting down the PLCs This method requires extreme caution It is important to match the configuration to the method described on the following pages you will be using Regardless of which method you use the system will be shut down unless the GMR configuration has online changes enabled Configuration for online changes is described on page 6 15 GFK 0787B Chapter 7 Programming Information 7 31 Things to Consider when Stor
11. Hardware control usually consists of switch contacts applied to the input circuit as shown below for a normally energized input Repeat contacts of the control switches are often input into the system for reporting purposes Field Circuit f System Input Manual Inhibit gt Manual Trip Genius Modular Redundancy Flexible Triple Modular Redundant TMR System User s Manual March 1995 System Input O point 1 Source Genius Block point 16 point 1 Source Genius Block point 16 point 1 Source Genius Block point 16 GFK 0787B Analog Inputs Like discrete blocks analog blocks can be used in the input subsystem as members of GMR input groups of 1 to 3 blocks or as non voted blocks Also like discrete blocks individual circuits of analog blocks in multiple block GMR input groups can be used as non voted analog inputs Analog blocks in GMR input groups are not autotested by the GMR software All of the available types of analog blocks can be used including the Thermocouple and RTD blocks See the Genius I O Discrete and Analog Blocks User s Manual for information about the various analog Genius blocks The application program can reference all analog inputs directly whether they are located in the non voted analog inputs area or not Voted Analog Inputs Fo
12. QI 00017 FORCED CIRCUIT 03 08 11 23 16 Q 00017 CIRCUIT FAULT DISCRETE FAULT 03 08 11 23 16 CIRCUIT FAULT DISCRETE FAULT 03 08 11 23 16 ACC WRITE LOGIC LOGIC EQUAL D P060 GMRSYS The same fault table features are available in a GMR system with the following additional types of messages Autotest fault messages I O Fault Table m Discrepancy fault messages I O Fault Table m PLC Fault Table messages for GMR More fault information can be displayed by pressing CTRL F as described on the next page Clearing the Fault Tables in a GMR System Although the Fault Tables seem to operate as they would in a non GMR system they are actually controlled by the GMR software not the PLC firmware Therefore ina GMR application the fault tables must be monitored and cleared from the application program logic Caution Use these M references to clear the PLC Fault Tables Do not use the Logicmaster F9 key to clear the Fault Tables m To clear the PLC Fault Table in a single PLC set reference M12259 to 1 for at least one PLC sweep in that PLC m To clear the PLC Fault Table in all PLCs set reference M12264 to 1 for at least one PLC sweep in any PLC m Toclear the I O Fault Table and corresponding fault contacts in all PLCs set reference M12258 to 1 for at least one PLC sweep in any PLC GFK 0787B Chapter 5 Diagnostics 5 15 I O Fault Table Messages for GMR I OFault Table format is detailed in the Series 90 70 PLC
13. 1 Select File to create a New System configuration 2 Inthe System menu create the CPU configuration CPU Type 788 789 Number of CPUs 1 3 Watchdog timer must match PLC configuration Enable or disable online programming Simplexshutdown enable disable Timeout 0 65535 seconds Select O K or C ancel to quit the CPU Configuration window 3 Inthe System menu select Autotest Interval and Register 4 Inthe System menu select Input Discrepancy Filter Time 5 Inthe System menu specify the I O Configuration Limits Number of Voted Discrete Input Groups for that GBC group Number of Voted Discrete Output Groups for that GBC group Number of Analog Input Groups for that GBC group Number of words of AI memory must match PLC configuration Number of registers of R memory must match PLC configuration Select O K or C ancel to quit the I O Config window 6 Inthe System menu specify the Initialization Data m Rack and slot locations of the two bus controllers that will be exchanging global data m R and M references and lengths for startup initialization data Select O K or C ancel to quit the Initialize Data window 7 Inthe System menu specify the initialization Fault Actions m Data fault diagnostic or fatal m System fault diagnostic or fatal Select O K or C ancel to quit the Fault Actions window 8 Inthe System menu specify Write Access Genius Modular Redundancy Flexible Triple Modular Redu
14. Input Processing Discrepancies Discrete Inputs Analog Inputs Output Processing Discrete Outputs I OShutdown Communications Between PLCs Global Data Redundancy Entering Clearing or Setting Global Data System Startup The following actions occur during orderly startup of the GMR system 1 Each PLC disables its outputs to Genius blocks If the Outputs Disable function does not complete successfully the GMR software sets the flag GMR System Initialization Fault and the GMR software puts the PLC in Halt mode 2 Each PLC determines its PLC identity PLC A PLC B or PLCC For a PLC all bus controllers that have been included in the GMR software configuration must have been assigned the same serial bus address 29 30 or 31 Each PLC checks its GMR configuration to be sure this has been done If it has the PLC determines its identity as follows PLCA all GMR bus controllers at serial bus address 31 PLCB all GMR bus controllers at serial bus address 30 PLCC all GMR bus controllers at serial bus address 29 If a PLC determines that its GMR bus controllers have been configured with differing serial bus addresses or with addresses outside the range 29 31 it logs an Invalid Bus Address fault into its PLC Fault Table and stops the PLC 3 Each PLC checks the online status of the other PLCs Online means the other PLC is running its application program and
15. Loss of Block fault 4 18 6 30 M command flags 7 13 M initialization data 7 9 7 16 M status definitions Manual inhibit Manual override 3 8 Manual trip 2 8 8 8 5 23 N No Load fault 6 9 5 2 5 16 5 26 Non voted analog inputs 2 10 Non voted discrete I O l 9 O Open Wire fault 5 28 Output blocks configuring serial bus address Output controls 5 23 Output groups 3 2 Output subsystems 3 1 Outputs autotesting 6 7 Index configuring autotest disabled at startup 4 2 discrepancy reporting discrepancy status discrete in PLC discrete voting enabled enabling at orup Zi fault reporting GMR configuration load sharing 8 6 5 16 logical references manual trip and reece Output Table addressing physical references reference addresses voting by blocks 8 1 Outputs and inputs number available Overhead sweep impact time sweep im pact of Genius I O and GBCs Overload fault 5 2 5 26 Overrange fault 5 28 Overtemperature fault P PLC Online status PLC operation 1 3 1 7 4 4 5 Power supplies for blocks 8 3 8 4 b 7 Ba Power feed output 4 18 6 30 Program Download utility 7 35 Programming overview 1 10 Pulse test operation 5 10 Pulse testing configuring for I O blocks 6 52 R R memory 7 9 Redundancy mode 3 9 6 53 Reference address configuring for
16. Programming When a discrepancy occurs the PLC sets the fault contact for that voted input and adapts according to its configuration See page 5 25 for information about these fault contacts Discrepancy signals are filtered for the configured input discepancy filter time to eliminate transient discrepancies caused by timing differences Chapter 5 Diagnostics 5 13 Input Line Fault Detection ina GMR Application The 16 circuit Genius blocks are capable of continually monitoring field circuits for input short circuit or open circuit faults The blocks detect On Off Short Circuit or Open Wire conditions on circuits set up as tristate inputs If a block is in a non GMR mode a resistor must be installed in the circuit to provide Open Wire fault detection However if the block is in GMR mode a zener diode is used instead to detect short circuits The diode is installed in series between the field switch and the tristate input blocks but physically at the field switch device The Zener diode rating is 6 2V Block Setup for Tristate Inputs V Field Switch gt H gt F Zener ZN _ LL Diode When a block is in GMR mode the status and on off state of a tristate input have different specifications than they do in non GMR mode DC Source Range Non GMR GMR ea Status Input Status Input Input lt 30 VDC open circuit fault 0 off 0 Thresho
17. Typeapproval A Theoverride is activated via DCS A Operator Maintenanceengineer B Themaintenanceengineer activates the override via the B Tiypeapproval Maintenance engineer Direct overrides on inputs and outputs are not allowed Overrides have to be checked and to be implemented in allowed as long as only one override is used ina given safety related group The alarm shall not be overridden relation to the application Multiple overrides in a PLC are A Project engineer B Projectengineer Typeapproval The PLC alerts the operator e g via the DCS indicating the override condition The operator will be warned until the override is removed Project engineer Commissioner A Theoverride is removed via DCS B The maintenance engineer removes the override via the programmingenvironment A Operator Maintenanceengineer Maintenancengineer A There should be a second way to removethemaintenance overrodecondition B If urgent the maintenance engineer can remove the override by the hard wiredswitch A Project engineer B Maintenancengineer Type approval During the time of override proper operational measures have to be implemented The time span for overriding shall be limited to one shift typically not longer than 8 hours or hard wired common maintenance override switch MOS lamps shall be provided on the operator console one per PLC or per process unit Project engineer Com
18. amp 4 22 Chapter 5 Diagnostics 4 5 setae se cdteeis esd hess exter es Peedi aes es 5 1 Programming for Diagnostics eusceda ease idee cea dea Pi adele 5 1 GFK 0787B Genius Modular Redundancy Flexible Triple Modular Redundant TMR System v User s Manual March 1995 Contents Diagnostics in a GMR System sits ositce tee oles hte OSC ke 5 ls eg 5 2 Setting Up Blocks to Report Genius Faults 0000 5 3 NER AUIOLESHING oat ea eeu eat ee a E EEE AE Rad ae Wed 5 4 GMR Discrepancy Reporting o s puna od Ue ow aed ete y ek Ueow ete Sees 5 11 Input Line Fault Detection ina GMR Application 5 14 The PLC and I O Fault Tables ina GMR System 005 5 15 Manual Output Controls and Diagnostics eee eee 5 23 Fault No Fault and Alarm Contacts 0 0000 c cece cece eens 5 25 Chapter 6 Configuration ecese ecs cedcrrcrecre nia wad ieee aa eee ee4 6 1 Configuration OVERVIEW sese seie seit Poa See Rend Guat eek 6 2 Using the GMR Configuration Software cece eee eee 6 4 Completing the Logicmaster 90 Configuration 040 6 45 Configuring Genius I O Blocks 2 i020 perccyannnoh feted Bias guar hip d 6 50 Chapter 7 Programming Information eeeeeeeeeeeeeeeeees 7 1 Programming Overview 55556 A sbi coon EGA S 258 emanate HORE OR 7 2 Program Instruction Set for GMR 4 4 wei seach soe Pee UN ee gee he 7 3 Estimating Memory sae esc sis t
19. by GMR_09 11001 Null GMR Configuration Configuration Module has detected a Null GMR configuration 11101 Unauthorized GMR Access GMR Configuration Module was invoked with incorrectpassword 11102 GMRS WExcept L L parameter out of range 11201 Unauthorized GMR Access GMR Configuration Module was invoked with the incorrectpassword 11202 GMRS WExcept L L parameter out of range 11401 Unauthorized GMR Access GMR14 was invoked with the incorrectpassword 11402 Incorrect GMR Version GMR14 version does not match the GMR system version number 11403 GMR Software Exception Invalid call number was detected 11404 Invalid GMR Pointer The error code pointer was out of bounds 11410 GMRI IS x at y GMR1 state machine went to step x illegal Step no at offset y in GMR1 diagnostics 11411 GMRI1 ST x at y GMR1 state mach exceeded allowed time in step x Step no at offset y in GMR1 diag nostics 11412 GMRI1 IW x GMR1 has output an illegal waycode of x 11413 GMR1 tmplt too small GMR14 has detected an internal error condition 11415 GMR2 IS x at y GMR2 state machine went to step x illegal Step no at offset y in GMR2 diagnostics 11416 GMR2 ST x at y GMR2 state mach exceeded allowed time in step x Step no at offset y in GMR2 diag nostics 11417 GMR2 IW x GMR2 has output an illegal waycode of x 11418 GMR2 tmplt too small GMR14 has detected an internal error condition 11420 GMR3 IS x at y GMR3 state machine went to step x illegal Step no at
20. duplex CPU redundancy which is described in the Genius I O System User s Manual does not provide autotesting or the other special features of GMR described in this book Hot standby CPU redundancy can be selected for blocks ina GMR system Instead of voting on CPU output data blocks that are set up for hot standby mode give preference to outputs received from bus controller 31 Should outputs from 31 fail a block in hot standby mode starts using outputs received from bus controller 30 Finally should outputs from 30 fail the block will use outputs from bus controller 29 Only the specific types of enhanced 16 circuit and 32 circuit DC discrete blocks listed in this book are capable of receiving outputs from bus controller 29 Other types of blocks can only receive outputs from bus controllers 30 and 31 GFK 0787B Chapter 6 Configuration 6 53 6 54 Duplex Default For output blocks set up for GMR redundancy the duplex default state is used when a block determines that only two PLCs are online The Duplex Default state of On or Off is used by the 2 out of 3 voting algorithm in the block instead of the state that would have been supplied by the third PLC The Duplex Default state determines whether voting will be 1 out of 2 or 2 out of 2 in the On or Off state when only two PLCs are providing outputs This is explained below The following three tables compare voting results for a block receiving outputs from all three PLCs wit
21. orChange Detected Changed StartedPLC Other PLC s Changed StartedPLC OtherPLC s Program Checksum ProgramMismatch ProgramMismatch Program Mismatch mes No Action mismatch at startup message logged message logged sage logged PLC stopped Following PLC Fault ProgramMismatch ProgramMismatch N A PLC is stopped No Action Reset message re logged message re logged Program Checksum Program Change mes Program Changed mes Program Changed mes No Action change while running sage logged sage logged sage logged PLC stopped Following PLC Fault ProgramMismatch ProgramMismatch N A PLC is stopped No Action Reset message logged message logged GMR Configuration GMR Configuration No Action GMR Configuration No Action Checksum mismatch Mismatch and Pro Mismatch and Program at startup gram Mismatch mes Mismatch messages sages logged PLC logged PLC stopped stopped Following PLC Fault N A PLC is stopped No Action N A PLC is stopped No Action Reset ConfigurationCheck GMRConfiguration GMR Configuration GMR Configuration No Action sum mismatch while Changed and Program Changed and Program Change and Program running Changed messages Changed messages Changed messages logged logged logged PLC stopped Following PLC Fault GMR Configuration GMR Configuration N A PLC is stopped No Action Reset Mismatch mes
22. s Manual March 1995 Results of Block Group Voting with One PLC Online If two PLCs are offline the voted outputs are the same as the outputs from the PLC which is still online x don t care PLCA Output PLCB Output PLCCOutput DuplexDefault OutputState State State State Setting in Block 0 x 0 0 x 0 0 x 0 0 x 0 1 x 1 1 x 1 1 x 1 1 x 1 PLC Logon Control To prevent untripping of tripped block outputs blocks do not use output data from a PLC that has previously been offline until one of the following occurs A all of the output data received from the newly online PLC agrees with the voted output data of the block B the user forces the PLC to log onto the output block s by turning on the GMR control bit FORCLOG Force Logon For more information about PLC Logon control please see page 7 17 Output Fault Reporting On detection of any block or circuit fault a directed fault message is transferred to the three PLCs on an event driven basis The PLC currently operating as the Autotest Master also monitors output blocks for discrepancies between the output values commanded by the PLCs If a PLC is offline its data is not considered discrepant But if a PLC is online and its data is discrepant the GMR software logs a fault into the I O Fault Table of the PLC that detects the discrepancy which is copied to the other PLCs The appropriate fault refere
23. 0 Byte 4 Fault type see below Byte 5 Always 0 OutputDiscrepancy Byte 1 Master PLC AA BB or CC Hex Bytes 2 and 3 Always 0 Byte 4 discrepant PLC AA BB or CC Hex Byte 5 Always 0 AnalogInputDiscrepancy Byte 1 5 Always 0 GMRI OFault Byte 1 Master PLC AA BB or CC Hex Bytes 2 and 3 Always 0 Byte 4 1 Logon fault Byte5 discrepant PLC AA BB or CC Hex Fault Type for Output Autotest For Output Autotest the Fault Type byte may have the following content hex values 11 Block A amp B short circuit to 0V 12 Block C amp D short circuit to 24V 22 Block B switch failed off 23 Block C switch failed off 24 Block D switch failed off 25 Block A not connected to Block B 26 Block C not connected to Block D 27 Block A cannot turn off 28 Block B cannot turn off 13 Block A cannot turn on 14 Block B cannot turn on 15 Block C cannot turn on 16 Block D cannot turn on 17 Load disconnection 18 No Load connection on Block A 19 No Load connection on Block B 1A No Load connection on Block C 1B No Load connection on Block D 1C Inconsistent No Load reporting 21 Block A switch failed off Chapter 5 Diagnostics 29 Block A amp B cannot turn off 2A Block C cannot turn off 2B Block D cannot turn off 2C Block C amp D cannot turn off 30 Force override spurious trip 5 17 PLC Fault Table Messages for GMR The following tables lists PLC Fault Table messages for GMR If you need additional
24. 1 O block Index 3 Index Index 4 References for inputs References reserved 7 4 Register memory assignments for GMR configuring m reserved RTD blocks 1 8 S S status references Seriali bus ae configuring 6 28 Short Circuit fault 5 2 5 26 SNP communications 1 3 Startup Startup status 7 16 Startup programming for 7 15 State fault 5 26 Status bits Shutdown Timer Activated 4 19 Status flags resetting Status information Status references system 7 10 a Neen asc data 4 2 4 2 1 4 6 19 j F 9 z 11 7 15 Synchronous Autotest k 18 6 29 T Test interval Thermocouple blocks 1 8 Threshold discrepancy 5 12 6 36 Thresholds Ai 2 4 3 9 Tristate in ras 2 6 p 7 5 14 6 52 2 8 3 Bg 7 U Underrange fault W Wiring Error fault 5 28 b 28 U eo ag Bat Z Zener Izz Yr 6 8 7 2 3 2 7 5 14 6 52 6 3 GFK 0787B
25. 20 11 21 50 12 23 24 13 inputs gt gt 25 26 14 27 958 29 30 output lt i 31 32 16 circuit block 32 circuit block Installing isolation diodes permits the Input Autotest to also detect circuit to circuit shorts When a single input sensor is wired to more than one input block isolation diodes are also required on the power feed outputs The following illustration shows connections from a single input sensor to a group of three blocks The Zener diode shown at the field switch is for line monitoring as explained on page 5 14 Chapter 5 Diagnostics 5 5 5 6 Single Input Sensor to Triplex Block Group Field Switch Zener VAN Diode Power feed outputs require isolation diode when single input device is wired to more than one block Operation of the Input Autotest The following actions are performed during the Input Autotest m the power feed outputs are pulsed Off Selected input channels are pulsed On m all associated inputs are checked for their ability to detect the On or Off state as appropriate and a fault is reported if the correct state is not detected While it is being tested a block continues to supply its last valid set of inputs instead of the physical inputs to the PLCs Test Verification By allowing some inputs to be turned On the Input Autotest checks its own operation The following table shows cycles in which blocks are aut
26. 4 Block Group continued Block Wiring for a 16 Circuit 4 Block Output Group More detailed installation information is provided in the block datasheets The labels Block A Block B Block C and Block D refer to the previous system diagram GFK 0787B BusA f Ve BusB od Wo Genius Bus 10 Genius Bus Block A 7 Block B Connections IC660BBD020 Connections IC660BBD020 a Source f Fa Source s2 ll s2 DC Power 4 ll sup in DC Power iT al suo In L T SHLD out L T SHLD out Ol DC l DC oll 1 Ol 1 all 2 el 2 ol 3 jal 3 4 ell 4 lll 5 2l 5 ll 6 6 ll 7 alll 7 ol 8 2l 8 oll 9 al 9 rol 10 Qi 10 oll 11 Ciel 11 Ol 12 O 12 o 13 13 O 14 l 14 oll 15 15 oll 16 lel 16 lel DC B DC TAS ar Te 77 Ground Ground Load Load 100mA minimum O lt Typical 16 places Load Bus C Uo BusAorB 4 Woe Genius Bus Genius Bus f Block C Block D Con
27. 8 Configuration and Programming sp scois sito ehos area oy ioe tials 1 10 Chapter 2 InputSubsystemt ccs cvcsws ceaiiws neswuneeeees ead ceadiewees 2 1 Overview A Al Ban dats OAC OS a tds a ee tk ee tla ot 2 2 GMR Input Groups ayes eed oe ele Ge ee ee eel ee ae UY eile Gah 2 3 Non Voted I O in the Input Subsystem 02 cece eee eee 2 4 Discrete NUS wae os Ne oe e es Bi ee ee eel EEA Bee A i 2 5 PUNO Pa Oise 3 Sit Yt bits ott Ot ee A toe tile ne Ome eeo a e bs 2 9 Chapter 3 OutpulSubsystem sissies nw ew eee waeee ee os 3 1 OVERVIEW fbi araea ow eae ee bee oe es eat bod eee iey ad 3 2 GMR Output Handling vhs cyse heen eyae ee heenee aw eere a eee earas 3 3 Output Fault Reporting tase eactauats pode ada heehee as ee 3 5 A Block Output Groupe isse cr eoeds de tier is Geeta tesa ead 3 6 Manual Output Controls and Diagnostics 00 eee eeee 3 8 Redundancy Modes for Output Blocks 0 eee 3 9 Chapter 4 PLO Subsystem nesne tes pa anes aria waesw aan e sa wes 4 1 System Startpris eiue ee eg eS eee tees oe ewes es wen ee ae 4 2 CPU Sweep in a GMR System jas 24s44 oics eee Sev inss eat ina eees 4 5 Estimating CPU Sweep Time aisecsdd sie ead eu tented et eee ee ia 4 6 laput Processio opto dua es ema riea ipg Ea Ae na Ren AREE 4 4 7 Output Processing oleae eee See ee hE ae AEE E E EE EAR 4 17 MO SILO WIR erorten te ad e eai a Boag le ay ey aay AaS 4 18 Communications between PLCS ous viny es be enly eeekee ced Bee eiss
28. AI0001 The size of the voted analog input area is determined by the number of voted analog inputs including spares Physical input data from analog block groups is located at the end of the Analog Input Table in the areas labelled A B and C in the preceding illustration Each of these areas is equal in length to the number of voted inputs at the beginning of the table Unused portions of the Analog Input Table may be used for simplex inputs Example The following illustration shows an example Analog Input memory configuration for a system with multiple GMR busses There are a total of 30 input groups having 6 inputs each and 19 input groups having 4 inputs each So the total number of voted inputs is 6inputs X 30 groups 4 inputs X 19 groups 256 voted inputs The simplex inputs could then begin at AI0257 A10001 Al0256 gt Voted Inputs A10257 l Simplex Inputs AI7424 AI7525 A 7680 A inputs AI7681 17936 B inputs AI7937 AI8192 C inputs Data from an analog block occupies either 4 or 6 input words depending upon the number of analog input channels on the block R Size In addition to any other specific R memory required for the application program there must be R memory available to the GMR software for bus controller data and communications data To configure the correct amount of R memory for the application use this worksheet R Initialization Data M Initialization Data num
29. C Change the CPU Memory Protect keyswitch to the unprotected position Make the same program change at PLC C Program Changed C is logged into the PLC Fault Table of PLC C If the change affects the state of any outputs these outputs would now agree for PLC A PLC B and PLC C and the output state s should no longer be discrepant The Program Changed C messages can now be cleared along with any output discrepancy errors that were logged due to the program change Change the CPU Memory Protect keyswitch back to the protected position the Mem Protect LED is on Notes After many online changes are made fragmentation of memory may occur That will prevent subsequent online changes from being made To make changes place the Chapter 7 Programming Information 7 37 CPU being stored to in Stop mode and store a complete program from the programmer to the PLC This cleans up any fragmentation that exists and enables future online changes m If an online program change is made to a single PLC and subsequently deleted before the same change is made to the other PLCs in the system it is possible that the program checksum will not match even though the programs in the CPUs appear to be the same Logicmaster 90 70 may also indicate Logic Not Equal when connected to a PLC in which the change deletion was not made To recover from this condition a run mode store may be required at the PLCs in which the deletion was not mad
30. FOLDER N Y N PROGRAM LOGIC N Y N CONF IGURAT ION Y CYAN REFERENCE TABLES N Y N TO CURRENT FOLDER The ENTIRE FOLDER selection will copy everything from the source folder logic config reference data teach files and any other files to the current folder D If there are three PLCs repeat this for the other PLC E Return to Logicmaster configuration then edit the configurations for PLC B and PLC C as necessary For example change the bus controller serial bus addresses and Global Data send and receive addresses 3 Also complete the Genius block configuration Genius block configuration sets up the operating characteristics of each block in the GMR system Basic configuration steps for Genius blocks are the same as for a non redundant system Instructions for completing configuration are detailed in the Genius I O Blocks User s Manual This chapter gives additional details needed to configure blocks for use ina GMR system GFK 0787B Chapter 6 Configuration 6 3 s Using the GMR Configuration Software The GMR Configuration Software is used to enter data needed by the GMR program software Autotest interval CPU type for the system I O limits for the system initialization data for the system fault actions for the system all GBC bus controller groups with all Genius I O blocks that will use GMR features The GMR Configuration Software is not part of the Logicmaster 90 software pack
31. Fault contacts can be programmed with fault locating references to identify faults associated with the system hardware These fault references are for informational purposes only The PLC does not halt execution if one of these reference faults occurs For a Genius device the format of the fault locating reference is M_rsbmm Where r is the rack number 0 to 7 s is the slot number of the bus controller b is the bus number and mm is the serial bus address of the affected Genius device For example M_46128 represents rack 4 slot 6 bus 1 module 28 For more information about fault locating references please refer to the Logicmaster 90 70 Software User s Manual Chapter 7 Programming Information 7 21 Discrete Input Fault Contacts for GMR In the discrete Input Table there are fault contacts associated with each item of voted input data non voted input data and raw data input from bus A B and C Discrete Input Table Input is Voting D Logic Bus A inputs Bus B inputs Bus C inputs Fault contacts are set for m Input Genius faults m Input discrepancy faults for A B and C inputs Input autotest faults m Line faults Voted Inputs Non voted Inputs Reserved inputs See page 5 25 for detailed information on conditions that cause fault contacts to be set Discrete Output Fault Contacts for GMR For discrete outputs fault contacts are associated with logical ou
32. File If you want to quit from this window without creating a file or saving any entries you can click on the close button in the upper left corner of the screen Chapter 6 Configuration 6 13 GMR Configuration Selections When you select System the following menu appears PU CPU configuration est Interval Select autotesting interval In Disc Filter Input Discrepancy Filter Config Limits Set configuration limits Init Data Select Initialize data areas ault Actions Select fault actions rite Access Configure memory write access Create the configuration by selecting items from the menu then completing entries on the screens that appear Instructions for completing these screens begin on the next page To display the configuration screen for the currently highlighted menu selection click on it with the mouse or press the Enter key 6 14 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 GFK 0787B 6 CPU Configuration Complete the entries on the CPU Configuration menu The defaults are indicated with dots in the parentheses as shown below If a default selection is correct for your system you don t need to edit that item PU CPU Type CPUs Watch dog 78 Simplex est Interval 78 Duplex msecs In Disc Filter Triplex Config Limits y Init Data On line Prog o ault Actions fan ee rite Access Simplex Shutdown Tim
33. On and Off pulse times of approximately 1 millisecond GFK 0787B Chapter 8 Installation Information 8 17 Appendix GFK 0787B GFT 166 Revision 1 3 April 4 1995 TUV Certification T V is an acronym for Technischer Uberwachungs V erein which has a rough translation to English of Technical Supervisory Group TUV is an independent German technical inspection agency and test laboratory widely recognized and respected for their testing and approval of electronic components and systems for use in safety critical applications GE Fanuc has received TUV type approval for the GMR system for use in safety relevant applications such as Emergency Shut Down ESD according to class 1 through 5 of DIN VDE 0801 standards and requirements The type approval certificate is 945 EL 273 95 TUV type approval for the GMR system for use in Fire and Gas applications is pending The GMR system may be used in the following configuration for class 4 or 5 applications respectively Class 5 Triplex 2v3 Fail Safe and Fault Tolerant Class 5 Duplex 2v2 Fail Safe Class 4 Duplex 1v2 Fail Safe and Fault Tolerant The Genius Modular Redundancy system is a high reliability high availability system It is based on the field proven Series 90 70 PLC and Genius I O products These standard off the shelf general purpose PLC products are capable of a very wide range of applications and uses All of this general purpose capabilit
34. Output Discrepancy faults PLC C start gt 1 end lt 12228 end lt start 24 Digital Output Autotestfaults start gt 1 end lt 12228 end lt start 25 Digital Output Genius faults start gt 1 end lt 12228 end lt start 26 Digital Output Point faults start gt 1 end lt 12228 end lt start 27 Digital Logon faults PLC A First group number required Last group number required 28 Digital Logon faults PLC B First group number required Last group number required 29 Digital Logon faults PLC C First group number required Last group number required 31 Analog Input Discrepancy faults Greater than or equal to the Less than the start plus the first digital input address for A maximum digital input ad B or C dress for A B or C 35 Analog Input Genius faults start gt 1 end lt 8192 end lt start 36 Analog Input Point faults start gt 1 end lt 8192 end gt start 37 AnalogInput Low Alarms start gt 1 end lt 8192 end gt start 38 Analog Input High Alarms start gt 1 end lt 8192 end gt start 45 Analog Output Genius faults start gt 1 end lt 8192 end gt start 46 Analog Output Point faults start gt 1 end lt 8192 end gt start 47 Input shutdown timers per block High byte contains rack num High byte contains the number Returns a single word indicating the shutdown ber 0 7 and low byte con 1 Low byte contains the Serial timer value as seconds of elapsed time A value tains slot number 1 9 Bus Address SBA of the de of 1 means a fa
35. PLC controls the system e M12242 DUPLEX Duplex mode Two PLCs control the system M12243 TRIPLEX Triplex mode Three PLCs control the system e M12244 IO_SD AnyI OShutdown At least one of the PLCs has begun timing an I O Timeractivated Shutdown M12245 through M12256 M12233 Reserved for future GMR use Will only be set at startup if condition occurs Only one of these three will be set at a time Chapter 7 Programming Information 7 11 7 12 PLC OK Flags The meanings associated with the three PLCOK flags are listed below PLCAOK PLC A outputs enabled AtPLC A PLCBOK PLC B communications with PLC A healthy and PLC B outputs enabled PLCCOK PLC C communications with PLC A healthy and PLC C outputs enabled PLCAOK PLC A communications with PLC B healthy At PLCB and PLC A outputs enabled PLCBOK PLC B outputs enabled PLCCOK PLC C communications with PLC B healthy and PLC C outputs enabled PLCAOK PLC A communications with PLC C healthy AtPLCC and PLC A outputs enabled PLCBOK PLC B communications with PLC C healthy and PLC B outputs enabled PLCCOK PLC C outputs enabled Resetting Status Flags Startup status flags with asterisks in the table on the previous page remain set until the sys tem is restarted They can also be reset by the application program To reset a status flag enter 0 in its M reference Genius Modular Redundancy Flexible Triple Modular
36. R memory before sending it m Additional R data used by the GMR software Each scan of the Genius bus a PLC takes the application program global data it has copied into R memory plus its own additional R data and broadcasts it on the bus During the same Genius bus scan when the other PLCs have their turn on the bus they send global data in the same way When a PLC receives Global Data it copies that portion of the data that is intended for application program use into GA GB or GC memory see the Programming chapter for details The following diagram summarizes the transfer of GMR global data Sending PLC Receiving PLCs G R R GA GB or GC Memory Memory Memory Memory GMR Genius Bus GMR Global Data Global Data Application Application gt Global Global Data Data PONY Application Application ra Global Global Data Data Global Data Redundancy During normal GMR operation each PLC receives two sets of global data from each of the other PLCs one set over each of the two busses mentioned above The system defaults to use the data from the first bus bus a unless that bus has failed in which case the data from the second bus bus b will be used If a PLC loses communications with another PLC on both busses the global data from that device is held at its last state The GMR software places a fault in the PLC fault table when communications are lost See the chap
37. Reference Manual GFK 0265 02 1F0100 00030101FF7F 0302 02 00 00 84000000000003 Fault Description Fault Type Fault Category Fault Action Fault Group Point Block O Bus Slot Rack Reference Address Long Short Fault Specific Data In the I O Fault Table the following additional types of messages are available for GMR Autotest fault messages m Discrepancy fault messages These faults have the following fields on the Logicmaster Fault Table display Fault Location Rack Slot Bus always 1 Block serial bus address Circuit Number Block circuit number Reference Address Physicall Oreference Fault Category Circuit Fault Fault Type Discrete Fault For autotest faults only the fault location given is for block A of the group if the fault affects all blocks in the group otherwise the location is that of the affected block Reporting of No Load Faults on 4 Block Output Groups The pairs of source and sink blocks in a four block output group share loads If outputs are off a No load will be reported in the normal manner if any block in the group has a no load condition However if outputs are on and a No load fault occurs on just one block of the pair it does not appear in the fault table because the other block of the pair is still supporting the load Therefore an output No load fault is reported only if both sink blocks in the group or both source
38. Voting Duplex Default for Outputs Output Forces and Overrides Output Fault Reporting m 4 Block Output Groups Output Load Sharing Manual Output Controls and Diagnostics m Redundancy Modes for Output Blocks GMR Mode Hot Standby Mode Overview The output subsystem is the part of a GMR system that provides output data It may consist of GMR Output groups of 4 discrete blocks m Individual non GMR discrete and analog blocks The following illustration represents basic elements of an output subsystem ABC ABC ABC a No redundancy or Hot Standby or Duplex 4 Block Output Group In a 4 block output group each field output is supported by two Genius source outputs connected in parallel on one side of the actuator and two Genius sink outputs connected in parallel on the other Each block in the group receives outputs from each of the three separate processors Three Genius busses are used Individual Genius blocks can also be connected to the system These blocks may be configured for either hot standby or duplex CPU redundancy if desired Types of Blocks in the Output Subsystem The following discrete block versions can be configured for GMR operation They will perform output voting and autotesting when used in GMR mode 24 48 VDC 16 Circuit Sour
39. a 3 digit number identifying the type and number of contacts This relay has a NEMA A600 rating Maximum AC Voltage 600 Maximum continuous current 10A The 24 VDC coil typically draws 117 milliamps at 24 VDC when the relay is picked up This meets the GMR requirement of a minimum of 100 milliamps to be able to use the No Load diagnostic without using additional external components to increase the load However the 24 VDC coil is a dual winding type which draws a higher current during the first part of the armature stroke Its inrush current is approximately 9 8 Amps at 24 VDC which causes an Overload diagnostic overload more than 2 8 Amps to be generated by the Genius output circuits To overcome the high inrush current the Overload diagnostic must be set to NO for those outputs that would be wired to this type or relay This relay with no external components does not exhibit any chatter during the output autotesting although a flyback diode is still recommended to reduce noise on the 24VDC power lines GE Catalog Number CR7RBXXEL Spectra 700 IEC Control Relay XX represents a 2 digit number identifying the type and number of contacts This relay has a NEMA A600 rating Maximum AC Voltage 600 Maximum continuous current 10 A The 24 VDC coil typically draws 230 milliamps at 24 VDC when the relay is picked up This also meets the GMR requirement of a minimum of 100 milliamps to be able to use the No Load diagnostic without us
40. addresses are not allowed within a GBC group You will not be permitted to continue until you have entered a unique address SBA Enter a serial bus address also referred to as the device number from 0 to 28 6 40 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 Options Select this item to display additional configuration choices AutoTest Out Disc XI 1 No X1 2 Yes X13 X 4 Bus Connects X 5 GOA X 6 COB X Gore X 8 xX 9 Hot Standby X 10 No X 11 C Yes X 12 X 13 Block Type X 14 nput 0X 15 D utput X 16 ixed Input Autotest This feature applies to 16 and 32 circuit DC Sink Source I O Blocks IC660BBD020 021 024 and 025 only The block can be either in GMR mode or not in GMR mode If any input circuits on the blocks in the group should be autotested select them here Circuit 16 must have autotest enabled If no circuits are to be autotested circuit 16 can have autotest disabled and input devices can be wired directly to the power source instead of being wired to circuit 16 By default each circuit is set up for autotesting as shown by the X next to the circuit number To turn off autotesting for any circuit select that circuit click on the circuit or select it using the cursor keys Press the space bar key to remove the X Note For all unused circuits on the block autotest should
41. analog AI or AQ reference They can also be programmed with the Series 90 70 s built in fault locating references In a GMR system there are fault contacts associated with voted inputs with the original block inputs and with logical outputs Alarm contacts can also be used to detect high or low alarm conditions on an analog AI or AQ reference See the Programming chapter for information about using these contacts Discrete Input Fault Contacts for GMR In the discrete Input Table there are fault contacts associated with each item of voted input data non voted input data and raw data input from bus A B and C Conditions that Cause these Discr In Tabl serete Input table Fault Contacts to be Set Input FFF FF FF AR 2 y fault 3 Voting Voted Inputs see text below Logic e Genius fault Non voted Inputs Autotest fault Genius fault Autotest fault Discrepancy fault Genius f ult totest fault Discrepancy fault Genius fault Autotest fault Discrepancy fault Genius fault Bus A inputs Bus B inputs Bus C inputs Reserved inputs Conditions that Cause Discrete Input Fault Contacts to be Set For more information about fault contacts see page 7 21 For the voted input a fault contact is set if any of the physical inputs has an associated fault contact set For example if a there is an autotest fault on input A a
42. and configuration m A program block named G_M_R10 This is later added to imported into the application program 2 Create a Logicmaster configuration for each PLC The easiest way to do that is to A Create a Folder for PLC A PLC B and PLC C B Select to the folder for PLC A With the GMR configuration printout as a reference complete its Logicmaster configuration C Use the Copy Folder feature of the Logicmaster 90 programming software to copy the configuration of PLC A to the folders for PLC B and PLC C To do this 1 From the Logicmaster configuration software return to the Logicmaster programming software Select the Program Folder functions 6 2 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 6 2 In the Program Folder functions menu select F1 Select Create a Program Folder On the Select Create screen select the folder for the second PLC for example CONFIGB as the current folder 3 In the Program Folder functions menu select F10 Copy Contents of Program Folder to Current Program Folder On the Copy Folder screen a For Source Folder enter the name of the folder containing the configuration of PLC A for example CONFIGA b For Information to be copied set only Configuration to yes COPY PROGRAM FOLDER Source Folder Suha kei Current Folder CONFIGB Current drawer is D NLM90 Information to be copied ENTIRE
43. and simplex Class 4 according to the DIN V19250 DIN V VDE 081 standards For use of the GMR system in a TUV 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 O CuO Triple PLCs Triple Genius Busses Triple Input Sensors GMR provides great configuration flexibility A system can include 1 2 or 3 PLCs There can be just one ILO subsystem as represe
44. as part of the GMR input group can be used as non redundant inputs or outputs m All blocks in the input group must be assigned the same serial bus address m Ifthe block group is configured for input autotesting it must be wired appropriately Each input that is configured by the GMR Configuration Software to be autotested must have its input device wired to receive power from output Q16 of the block group as shown above m Isolation diodes must also be wired as shown above for any input to be autotested The suggested diode is 1N5400 or equivalent Chapter 8 Installation Information 8 5 Input Wiring continued Block Wiring for 16 Circuit Source Block in an Input Group DC Source Block IC660BBD020 l z If single sensor it must also be wired to corresponding point on Connection if no points on the two other input blocks block are to be autotested o oo must disconnect output 16 a S1 S2 SHLD IN SHLD OUT DC 22V to 56V DC Genius Bus Connections a gt a K X Tristate input requires A series zener diode voltage i 2V r rating6 Required at each input for Input Zener should be wired at Autotesting 1N5400 or the input device equivalent Use of such super vised inputs is optional If group inputs are configured for autotesting ci
45. at startup The GMR Configuration Software default for the beginning of the initialization data is R0001 In addition by default the configuration software assigns R0257 as the beginning location for M initialization data which is directly after the R initialization data Chapter 7 Programming Information 7 9 System Status S References System status references are pre defined locations and nicknames They can be included in the application program to check for fault related conditions For example status references can be used to m Detect forces and overrides Monitor the fault tables For a complete listing of S references see the Series 90 70 PLC Reference Manual Monitoring Forces and Overrides The GMR software cannot detect point forces and overrides and their use is not recommended and may affect the results of autotesting Forcesand oroverrides can also affect GMR voting of inputs and outputs Therefore if the system will include the use of forcesand oroverrides it is important to include application program logic to detect them These system status references detect forces and overrides in an individual PLC S0011 OVR_PRE when set indicates an override in I Q M or G memory S0012 FRC _PRE when set indicates a force on a Genius point Monitoring the Fault Tables These system status references are associated with the fault tables in an individual PLC S0009 SY_FULL when set indicates tha
46. automatically send three copies of all fault reports one each to the bus controllers at serial bus addresses 29 30 and 31 6 52 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 6 Hold Last If the block will use Input Autotest circuit 16 must be configured as an State output as explained above For circuit 16 Hold Last State must be configured to NO Output If the block will use Input Autotest circuit 16 must be configured with Default Output Default set to ON Redundancy Portions of the overall system can be configured for no CPU redundancy Mode duplex redundancy hot standby redundancy or GMR mode See page 5 3 for information about how the configured Redundancy Mode affects Fault Reporting by blocks in the GMR system For 16 circuit and 32 circuit DC blocks select GMR mode for blocks that will be part of input or output groups as described in this book Individual circuits on the blocks can be configured using the GMR Configuration Software to utilize the special GMR features GMR mode can be selected even if there is just one block in an input group and it should use the extra diagnostics capabilities provided by GMR Select no redundancy for non critical individual blocks that do not require any type of redundancy The duplex CPU redundancy selection is for blocks on a bus with two PLCs This is not the same as duplex GMR redundancy Conventional
47. be set to off Also it is possible for an input block to include I O circuits that are not part of the GMR system and which are not to be autotested Be sure to turn autotest off for non GMR circuits Output Discrepancy Specify whether the block should report output discrepancies This applies to 16 and 32 circuit DC Sink Source I O Blocks IC660BBD020 021 024 and 025 only The block must be in GMR mode Bus Connect Select the bus to which the block is connected Hot Standby Specify whether the block should use Hot Standby output redundancy This feature applies to 16 and 32 circuit DC Sink Source I O Blocks IC660BBD020 021 024 and 025 only Operation of Hot Standby mode is described in chapter 3 If the block is not in GMR mode selecting Hot Standby here tells the system to configure the block to send fault reports to three PLCs Block Type Specify input output or mixedI O If the block will use the Input Autotest feature it must be set up as a mixedI Oblock GFK 0787B Chapter 6 Configuration 6 41 Configuring the Non Voted Analog I O for a Bus Controller Group If the bus controller group includes any non voted analog I O select nonVoted A I O Note Non voted analog I O blocks that are configured here are considered part of the GMR system It is possible for a bus to include I O blocks that are not part of the GMR system Do not include non GMR blocks in the GMR configuration Non GMR blocks are included in the Logicm
48. blocks in the group report a No load fault The fault location listed in the I O Fault Table is that of the second block reporting the fault For example 0 3 1 1 1 Q 00019 CIRCUIT FAULT DISCRETE FAULT 03 08 11 23 16 In this example the location of the output block reporting the fault is rack 0 slot 3 bus 1 serial bus address 1 However both of the source or sink blocks in that pair actually have No load faults for output Q00019 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 Displaying Additional Fault Information About I O Faults with CTRL F Pressing the programmer CTRL F keys provides more information about a fault Entries that apply to the GMR system are described below Fault Description GFK 0787B Code Hex Meaning 00 Loss of Device FO Digital Input Autotest Fault F1 Digital Input Discrepancy Fault F2 Digital Output Autotest Fault F3 Digital Output Discrepancy Fault F4 Analog Input Discrepancy Fault FF GMRI OFault Fault Specific Data Lossof Device Byte 1 84 Hex Bytes 2 5 Always 0 DigitalInputDiscrepancy Byte 1 5 Always 0 Input Autotest Byte 1 Master PLC AA BB or CC Hex Bytes 2 and 3 Always 0 Byte 4 Fail State 01 input stuck at 0 02 input stuck at 1 Byte 5 Always 0 AnalogInputDiscrepancy Byte 1 5 Always 0 Output Autotest Byte 1 Master PLC AA BB or CC Hex Bytes 2 and 3 Always
49. bus A B and C use the same serial bus address The fourth block which must be located on either bus A or bus B must be assigned a different serial bus address Reference All blocks in the same output group must use the same reference Address address However blocks in an input group each have a unique address as explained on page 6 37 Refer to the reference address assignments made using the GMR Configuration Software when assigning addresses to blocks Reference addresses must be assigned on 8 bit boundaries The system may include individual blocks that are not set up for redundancy Chapter 6 Configuration 6 51 Block I O Type Baud Rate Pulse Test Input Filter Time Circuit I O Type Report Faults Any discrete block that is part of a redundant input group triplex duplex or simplex must be configured as a combination I O type block Any block that is part of an output group must be set up as an outputs only block Baud rate should be selected on the basis of the calculations in the Genius I O System and Communications User s Manual GFK 90486 Note that for correct autotesting in a GMR system the Genius bus scan time should not be be more than 60mS Pulse testing should be enabled for all GMR output blocks It should be disabled for all GMR input blocks except for GMR input blocks that have output circuits that you wish to output pulse test Input Filter Time should be set up according to t
50. can still control the load The following chart shows how the GMR system uses the 4 block H pattern output group to maintain control of critical loads following certain types of failures All operating blocks receive the same I O data because within a fault tolerant 4 block H pattern group all four blocks are configured at the same output address The chart indicates which blocks actually affect the state of the load under different fault scenarios All operating blocks act on the I O data received Other Blocks Used Other Blocks Used Fault To Turn the Load Off To Turn the Load On output at block A fails On turn outputs at block C and D Off turn output at block C or D On output at block A fails Off turn output at block B off turn output at block B and either C or D On output at block B fails On turn outputs at block C and D Off turn output at block C or D On output at block B fails Off turn output at block A off turn output at block B and either C or D On output at block C fails On turn outputs at block A and B Off turn output at block A or B On output at block C fails Off turn output at block D off turn output at block D and either A or B On output at block D fails On turn outputs at block A and B Off turn output at block A or B On output at block D fails Off turn output at block C off turn output at block C and either A or B On Bus Redundancy in a 4 Block Output Group If one of the three busses in an ou
51. combination For any bus controller not present select none as the slot On the middle window shown above you can use the Tab key to select bus controller A B or C Use the space bar key to display the Rack Slot configuration data for the selected bus controller To configure a bus controller rack slot location select GBC_A GBC_B or GBC_C and press the space bar key The rack slot configuration window shown on the right above for that bus controller appears By default bus controller A is specified in rack 0 slot 2 as shown Toeditrack slotlocation choices use the tab keys to move from field to field Use the cursor keys to move within a field When both the rack and slot locations are correct for the bus controller select O K Complete the same steps for other bus controllers in the same group GFK 0787B Chapter 6 Configuration 6 25 6 26 Exiting the Window Normally the GBC Genius Bus Controller group window remains on the screen so you can insert the I O groups for that bus controller group It must be the active window identified by the double line border to insert an I O group into it However if you want to exit the window and delete the window from your configuration click on the Close button in the upper left corner of the window Be aware that in this window and in the windows for I O blocks and in the System screen window clicking on the Close button deletes the window and its content Thi
52. configuration as simplex groups and can utilize the GMR features such as autotesting Inputs from simplex blocks are placed into the area of the Input Table used for GMR inputs Inputs from non GMR I O blocks Non voted blocks are individual blocks that are present on a GMR bus and are included in the GMR configuration However their inputs are not voted on by the PLC s and are located in a different area of the Input Table Non voted points on individual blocks in a multiple block GMR input group Non voted I O points may be placed within a voted input group to take advantage of unused circuits These extra circuits can be used as either inputs or outputs If the group utilizes GMR autotesting of inputs circuit 16 on each block which is required for autotest cannot be used for non GMRI O Example a discrete input group consisting of three 16 circuit blocks has only four voted inputs That leaves circuits 5 through 15 on each block for use as non GMR inputs or outputs Circuit 16 is used for the autotest feature Block A 1st GMR input Can be used as non GMR inputs and outputs Blocks B and C are the same Individual input points used in this way can be autotested if autotesting is set up as part of their GMR configuration 2 4 Genius Modular Redundancy Flexible Triple Modular Redundant TMR
53. deflection for the input They are used by the software to monitor the point for limit discrepancy This is explained in more detail on the next page Enter a maximum and minimum value for each GMR analog input channel by first selecting the channel using the mouse or Tab and Return keys i Min Value Max Value ot ee oe Discrepancy 7 Threshold Limit The range for either maximum or minimum is 32767 to 32767 GFK 0787B Chapter 6 Configuration 6 35 Bus Connects 4 A C B G Threshold Discrepancy Specify by what percent an individual input for the channel may deviate from the voted input value During operation if any of the corresponding physical inputs deviates from the voted input value by more than this amount in either direction it will generate a fault that must be cleared by the application program For example if the physical inputs for a channel were 91 100 and 111 degrees the voted input value would be 100 degrees If the Discrepancy Threshold for the channel had been configured as 10 the input reporting 111 degrees would be outside the acceptable range Limit Discrepancy Similarly specify by what percent an individual input for the channel may deviate from the full scale deflection of the channel represented by the entries maximum and minimum value During operation if any of the corresponding physical inputs deviates by more than this amount in either direction from the voted
54. discrepancies caused by timing differences The following table shows possible discrepancies between the input data and voted input data Input Data Discrepancy Voted 0 0 0 0 0 0 0 0 0 1 0 0 0 1 0 1 0 0 0 1 0 0 1 1 1 1 0 0 1 0 0 0 1 0 0 1 0 1 1 0 1 0 1 1 0 1 0 0 1 1 1 1 1 0 0 0 GFK 0787B Chapter 5 Diagnostics 5 11 Discrete Output Discrepancy Reporting Output discrepancy monitoring is the process of monitoring the block output voting function to detect both processor discrepancies and lost communication between the block and the other processors All PLCs periodically monitor all blocks discrepancy status On interrogation by any PLC the block responds with a discrepancy message indicating the discrepant output and disagreeing PLC The system uses output discrepancy checking to determine if the output data sent from each of the PLCs agrees with the voted output state If a discrepancy check reveals that a PLC is sending incorrect output data to a block the GMR system logs an output discrepancy fault in the I O fault table and sets the appropriate fault contacts The GMR system performs output discrepancy checking whenever it is not performing input or output autotesting i e between autotests during the autotest interval It checks all output blocks in redundant output groups and any non redundant output blocks marked for discrepancy checking in the GMR configuration How Output Discrepan
55. e IC660BBD024 Ea s Source s2 DC Power 1 Coll sup in L SHLD OUT Blo 2 lo O 10 lo iG 12 o2 14 te 16 3 z Power discon 2 3 22 nects for ae z Source blocks 2 6 28 should be lo 30 wired here lal ss l2 36 2 40 e a DC if CEEE ASAS Ground OV DC Load _ Load Load Typical 32 places BusAorB Wo Genius Bus f Connections Block D oe IC660BBD025 Ke s Sink f S2 DC Power lt M SHLD IN i Hg SHLD OUT 5V Loo 8 Dc ae O 10 o 12 o 14 o 16 18 7 Power discon Slol 2 nects for Sink olll x blocks should Bll 2 be wired here B Q 30 o 32 Q 34 Q 36 22 40 Qo all oc A ____ In 8 J J GFK 0787B Chapter 8 Installation Information Ov DC 8 15 In certain cases removing the DC power source from an output block or blocks which are part of a 32 circuit 4 block output group causes leakage currents through the output driver circuits of the powered down block s To ensure that these potential leakage currents do not adversly affect the output devices being controlled the following installation instructions must be followed All 4 blocks in an output group must be powered from the same common power source If redundant power supplies are to be used they should be diode ored power supplies that provide a common power source for the 4 blocks in a group Different output groups may use different power sources Power disconnects for the bl
56. fault contact is set both for input A and for the voted input For non voted inputs the single fault contact is associated with the physical input It is set under the following conditions Autotestfault Set on digital inputs configured for autotesting if autotesting detects a fault Geniusfaults including Loss of Block Linefault These are a feature of the 16 circuit DC blocks To report line faults an input must be configured for tristate operation For blocks in GMR mode a line fault represents a short circuit fault on the field wiring For non GMR blocks a line fault represents an open circuit fault in the field wiring m For bus A bus B and bus C inputs fault contacts are set under the following conditions Autotest fault see above Linefault see above Geniusfaults including Loss of Block Discrepancy between the raw input data and the corresponding voted input Chapter 5 Diagnostics 5 25 Discrete Output Fault Contacts for GMR For discrete outputs the fault contact is associated with the logical outputs outputs from the application program m Contact References Associated with an Output Logical reference Fault contact Physical reference These logical references are copied to the physical output references If a fault is detected on a physical output the fault contact associated with that o
57. from the master PLC 11511 DQ x y 1 z gt d f s The PLC expected to dequeue an input autotest results datagram from the device at rack x slot y SBA serial bus address z Instead an invalid datagram was dequeued with function code f and subfunction code s from SBA bus address d 11511 CQ x y 1 z gt d f s The PLC expected no datagram to be in the queue for the device at rack x slot y seri al bus address z Instead an invalid datagram was found with function code f and subfunction code s from serial bus address d 11513 Xtalk results read flt Non master could not read input autotest results from master PLC 11521 CR fail x y Lzf s COMREQ with function code f and subfunction code s failed when sent to the device at rack x slot y SBA z 11522 Trans x y l zecccecce Output discrepancy processing could not be completed for the channels marked in c on the device at rack x slot y SBA z due to transitioning outputs 11523 Null timeout from PLC A Timeout occurred while waiting for PLC A to transmit a null test number 11524 Null timeout from PLC B Timeout occurred while waiting for PLC B to transmit a null test number 11525 Null timeout from PLC C Timeout occurred while waiting for PLC C to transmit a null test number 11530 1 OS Drs b d I OShutdown on the specified block 11530 I OS Deancelr s b d I O Shutdown cancelled on the specified block 11530 I OS D8hrsr s b d I O Shutdown in 8 hours on the specified block 11530 I OS Dthrrs b d I O Shutdown
58. future GMR to use M12288 M12257 Continue When the application program has computed valid outputs that can be sent to output blocks the application program must set control bit M12257 CONTINUE to 1 When this is done outputs to the blocks are enabled Chapter 7 Programming Information 7 13 M12262 Report When this control bit is turned on it causes the GMR software to report and record the following into the PLC Fault Table of the PLC s that turned it on The GMR Software Version currently running in the PLC Example Application message 10840 GMR Ver 02 06 m The GMR Configuration Utility Version used to create the G_M_R10 Program Block Example Application message 10841 Config Util Ver 04 01 m The GMR Configuration File G_M_R10 Program Block Checksum Example Application message 10842 GMR config CRC 2F4E This checksum value can be used to verify what configuration file is running ina GMR PLC It should be recorded for each different configuration that is created so it can be used to determine exactly what configuration file is ina GMR PLC The GMR configuration checksum is also recorded in the GMR configuration utility printout of a configuration m The 40 character Configuration File Description This GMR control bit is infrequently used It is typical to turn it on manually using the Logicmaster 90 70 software although it can also be turned on by the application program if desired
59. help call GE Fanuc Technical Service at 1 800 828 5747 Code Message Meaning 100 No CPU Clock There is no PLC clock present 100 No PLC Clock There is no PLC clock present 101 Illegal state step Internal GMR error invalid step 101 Illegal trans code Internal GMR error invalid transition code 101 Bad trans x from wwww Internal GMR error attempted transition to invalid step 100 CFPT 0 attempts wwww Number of attempts exhausted while trying to send a COMREQ GBC ID 10009 GMRx ornge GBC g req Out of range Bus Controller g was requested by GMRx module 10009 GMRx bad GBC g req Unconfigured Bus Controller g was requested by GMRx module 10010 GMRx ornge GBC g rel Out of range Bus Controller g was released by the GMRx module 10010 GMRx bad GBC g rel Unconfigured Bus Controller g was released by the GMRx module 10011 GMRx ornge GBC g flt Out of Range Bus Controller g was faulted by the GMRx module 10011 GMRx bad GBC g flt Unconfigured Bus Controller s was faulted by the GMRx module 1 Unauthorized GMR Access Initialization module was invoked with incorrectpassword 10102 Incorrect GMR Version Initialization module was called with incorrect version number 10103 GMR Software Exception An invalid call number was detected 10104 Invalid GMR Pointer Initialization module was invoked with invalid pointer for diagnostics area 10109 Prog Checksum Timeout PLC didn t calculate the program checksum within 10 seconds 10110 In
60. in 1 hour on the specified block irsdd I PA Trestimeout A Tresults for SBA ddon GBC at rack r slot s 5 22 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System User s Manual March 1995 GFK 0787B Manual Output Controls and Diagnostics GFK 0787B Safety systems are often provided with controls for manual trip and manual override A manual trip causes the output to assume the alarm condition For example a normally energized output would be de energized A manual override causes the output to remain in the normal condition For example a normally energized output is held energized These manual controls can be implemented either in hardware as represented below or in software If the software method is used the GMR autotest and fault processing operations are unaffected Hardware control usually consists of switch contacts applied to the output circuit as shown below for a normally energized output 24V Manual Source Override ee Genius Bone Block Block Manual Trip RN Input X LOAD he Sink Genius Genius PIPES Block Manual eN Input Override 0 VDC In this circuit operation of either the trip or override switch can cause no load faults state faults and autotest faults to be generated If these manual inputs are wired in the GMR system fault reporting is modified to suppress no load faults and Failed Switch faults Use of
61. manual controls does not affect fault reporting for Short Circuit Overtemperature Overload or Discrepancy faults Chapter 5 Diagnostics 5 23 5 24 Monitoring Manual Output Controls The operation of manual trip and output override devices can be monitored and reported by connecting them as inputs to Genius blocks These inputs should be configured to use references at the end of the Discrete Input Table shown as reserved inputs below Discrete Input Table Discrete Output Table 10001 Yy Voted Inputs Y Ae Logical Outputs Q0001 f 4 aaa Available for Available for Non voted Inputs Non voted Outputs Bus A inputs Reserved memory Bus B inputs Bus C inputs Reserved inputs Physical Outputs 11024 Q1024 or or 112288 Q12288 There is a one to one correspondence between Reserved Inputs and physical outputs The GMR software in each PLC automatically monitors the Reserved Inputs On detection of either manual control it disables the appropriate Genius diagnostics and the output autotest for the corresponding output circuit s The application program must not command pulse testing on GMR outputs Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 Fault No Fault and Alarm Contacts GFK 0787B Fault and No Fault contacts can optionally be used to detect fault or lack of fault conditions on a discrete I or Q or
62. minimize the total time required Therefore the overall time depends on the data lengths and the number of busses available 5 Ifthe initializing PLC is unable to successfully read all the data from the other PLC s it sets a flag Synchronization hardware failure for the application program The entire synchronization sequence then begins again excluding the Genius bus with which communications failed During GMR configuration the PLC can be configured to either stop or continue in the event of synchronization failure After successful synchronization the PLC clears a flag Inhibit User Application This must be used in the application program to prevent execution of the program until it has been cleared Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 CPU Sweep ina GMR System The special functions required for Genius Modular Redundancy include autotest input voting and alarming These GMR functions are provided by a set of Program Blocks that are placed into the Program Folder using the LM90 librarian feature After this is done the GMR logic is executed automatically by the CPU as shown below Start of Sweep Housekeeping y Input Scan y GMR functions y Application Program GMR functions Yy Output Scan y Additional CPU Tasks PLC Operation Each PLC in the
63. of Global Data capacity are available for use by the application program Since each PLC can broadcast just one Global Data message per bus scan the system Global Data and the application Global Data are a sent in the same message Global Data for the Application Program The application program can send Global Data by placing it into G memory as detailed below Each PLC uses G0001 through G0896 to send application Global Data It is not necessary to use all of the references The application program can read Global Data received from the other PLCs from GA GB and GC memory In addition each PLC can also read a copy of its own Global Data As explained in the PLC chapter of this book each PLC actually receives two sets of Global Data from each of the other PLCs It gives preference to Global Data from the bus designated bus a If that data isn t available a PLC uses Global Data received from the bus designated bus b Under ordinary circumstances these two sets of data would match The use of two busses provides redundant operation in case a bus or bus controller is not available The incoming Global Data is data that can be read in GA GB or GC memory therefore is the Global Data received on bus a if that data is available Otherwise it is the Global Data received on bus b All PLCs G0001 G0896 Global data to be transmitted PLCA GA0N001 G A0896 Copy of transmitted global data GB0001 GB0896 Data receive
64. on the following pages Fault and No Fault Contacts Fault and No Fault contacts can be used to detect fault or lack of fault conditions on a discrete I or Q or analog AI or AQ reference They can also be programmed with the Series 90 70 s built in fault locating references see below Unless they are used ONLY with fault locating references fault memory for their use must be set up using the CPU Configuration function of the Logicmaster 90 software A Fault contact is programmed as shown below using the reference address to be monitored here 10014 10014 Q0056 FAULT C A Fault contact passes power flow if the associated reference has a fault Fault contacts are also set if a block logs off the bus A similar contact called the No Fault contact passes power flow while the associated reference has no fault 10167 Q0168 NOFLT Clearing Faults Associated with Fault No Fault Contacts When used with a I Q AI or AQ reference a fault associated with the FAULT contact must be cleared to remove it from the fault table and stop the contact from passing power flow Fault contacts are cleared by being reset from the application program by sending a command to the GMR software using the M bit for I O Reset M12258 Clearing such a fault with a Hand held Monitor does not remove it from the fault table or stop the contact passing power flow Fault Locating References Both Fault and No
65. or disk error occurs during the Store process indicated by a message on the screen the selected items are cleared from the attached PLC Correct the error and repeat the Store function To stop a program Store in progress press ALT A if the PLC is in STOP mode If the PLC is in RUN mode when the Store begins you cannot stop the Store process To return to the Program Utility Functions menu press the Escape key Chapter 7 Programming Information 7 33 Storing a Program to the PLC the System is NOT Configured for Online Changes If the GMR system is configured not to allow online changes the PLC must be placed in Stop mode to store a program or make a change to the GMR system Storing an Identical Program Following CPU Replacement If a PLC is to be stored with an identical program following replacement of a faulty CPU then only the PLC to be stored to needs to be placed in Stop mode The other PLCs in the system can remain online providing output control When the new PLC is switched to Run Enable mode the GMR software compares its program checksum with that of the other online PLCs while it is initializing Storing a Revised Program If a PLC is to be stored with a program that is not exactly the same as the program running in the other PLCs then all PLCs must be stopped and the same program must be stored into each The GMR software diskette includes a special utility that can be used to facilitate storing an updated app
66. program turns on the Continue bit M12257 Without PLC Logon Control outputs have the potential to change state if a PLC just coming online has output states that differ from those of other PLCs that are already online due to the output voting done by each Genius output block group PLC Logon Control causes the output states from a PLC that has just come online to be compared with the voted output states at each output block group If the states do not agree for any output block the block ignores the new output data and effectively keeps the new PLC offline with respect to that output block This condition continues until either the voted output states match for the complete output block or until the Force PLC Logon control bit M12263 FORCLOG is turned on A GMR status bit M12240 LOGONFT is available That bit indicates if this condition exists with one ore more output blocks It is the responsibility of the application program to monitor the LOGONFT status bit and to turn on the FORCLOG control bit if desired to cause output block groups to vote on and respond to output data from all online PLCs Note that if set the LOGONFT status bit remains set until the I O fault table is cleared by using the IORES control but M12258 Typically the FORCLOG and IORES control bits are set through the application program via an operator interface or simple pushbutton wired to an input circuit Powerup Note PLC Logon Control is also in effec
67. referred to here by Genius Bus Controller GBC serial bus addresses 31 30 and 29 processes the voted input data and produces appropriate outputs Because each of the three PLCs is running the same program they produce three copies of the same output data Each PLC then sends this triplicated output data on the bus PLCA PLC B PLCC Q O y v v output 1 output 1 output 1 Output Subsystem The basic element of an output subsystem is the output group Each block in the group has the same reference address in the application program so each block receives the same output data The output group votes on the three outputs and uses the result as the physical output In this example communications are lost on bus C Upon losing communications the block on bus C follows its configuration instructions which are to default its outputs to 0 However the remaining blocks in the group continue to receive valid output data from all three PLCs over busses A and B and the actual state of the output load is controlled properly The loss of block or loss of bus diagnostic would be recorded providing an aid to troubleshooting and annunciating the problem voted CA B voted output 31 1 coe amet y 1 output 31 1 output 30 1 out
68. state of any circuit should be Off select that circuit click on the circuit or select it using the cursor keys Press the space bar key to remove or replace the X Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 6 Options Finally for each 4 block group specify the bus and location serial bus address of the fourth block the D block in the group While the A B and C blocks are installed on busses A B and C respectively the D block must be installed on either bus A or bus B as in the illustration shown below Bus A Bus C Bus B Source een AVES Blocks A B Load i Sink Blocks While busses A B and C can use the same serial bus address on their respective busses block D which is on the same bus as either block A or block B must have a different serial bus because each device on a Genius bus must have a unique serial bus address D Block Connection SBA Bus A Bus B K ll e ee il GFK 0787B Chapter 6 Configuration 6 39 Configuring the Non Voted Discrete I O for a Bus Controller Group If the bus controller group includes any non voted discrete I O select nonVoted D I O Inputs and outputs may be mixed ona block Non voted I O are inputs and outputs on individual blocks blocks that are not part of an input or output group that are present on the GMR busses A sub menu appears where
69. the 2 out of 3 voting mechanism although output discrepancy errors may be generated G The message Shut down in 1 hour is logged at PLCB H The shutdown timer expires in PLCB The message I O Shut Down is logged in fault table of PLCB PLCB shuts down the I O of the affected I O group Real I O IS NOW affected because of the 2 out of 3 voting mechanism This example shows the IO Shutdown sequence when the autotest interval is 8 hours Hours O 1 9 15 16 23 24 A A fault occurs just after the autotest interval at PLCA begins B PLCA executes the autotest and detects the fault then starts the 8 hour shutdown timer The message Shut down in 8 hours is logged in the fault table The I O Shut Down in Progress status bit M12244 is set in each PLC The autotest master function passes to PLCB Q The message Shut down in 1 hour is logged at PLCA The shutdown timer expires in PLCA PLCA shuts down the I O of the affected I O group The message I O Shut Down is logged in fault table of PLCA RealI Ois not yet affected because of the 2 out of 3 voting mechanism although output discrepancy errors may be generated PLCB executes the autotest and detects the fault then starts its 8 hour shutdown timer The message Shut down in 8 hours is logged in the fault table The autotest master function passes to PLCC J E The message Shut down in 1 hour is logged at PLCB E The shut do
70. the address range to which write access will be permitted It may be from 1 to the maximum table size The Length parameter is the length of the address range to which write access will be permitted A value of 0 the default means the entire contents of that memory type is write protected For R AI and WAQ memory length is in units of registers words For discrete bit memories I Q T M G GD and GE the starting reference must be on a byte boundary 1 9 17 etc For these memory types the length is in units of points bits It must be specified in multiples of 8 bits 8 16 24 etc Global Data GA GB and GC memories are not available Those memory areas are used by the GMR system to exchange data as explained on page 7 27 and cannot be accessed directly Exiting the Window When you have completed this screen select OK to return to the System screen When you select OK your entries are saved and the window disappears If you want to exit the window and reset all fields to their previous content select Close or Cancel instead Chapter 6 Configuration 6 23 6 24 Adding Bus Controllers and I O Modules When you select Insert from the System screen the following menu appears Configure Bus Controller groups Input Group gt Configure Input Group Cutput Group gt Configure Output Group nonVoted DIO gt Configure non voted discrete I O nonVoted AIO gt Configure non voted analog I O Create
71. the configuration by selecting items from the menu then completing entries on the screens that appear Instructions for completing these screens begin on the next page To display the configuration screen for the currently highlighted menu selection click on it with the mouse or press the Enter key The Bus Controller and I O group configuration windows have some additional mouse or keyboard features not used in other configuration windows On the example screen below three Bus Controller groups have been configured Group 1 has five input and output block groups Group 2 has two I O block groups No I O has yet been configured for Bus Controller Group 3 a SO IIIa System Description Aa S GBC Group 1 E I GEC Group 2 1 E 1 GBC Group 3 iis a al e Triplex In 16 H Voted Out 16 ID ID Triplex In 16 Triplex In 16 ID ID Voted Dut 16 Start 711 SBA 1 ID Voted Dut 16 _estg ll ID Duplex In 32 ID Start 711 On this screen you can move between Bus Controller groups by clicking the mouse on the group you want or by pressing the Alt key then entering the number of the Bus Controller group If you want to display all of the I O group windows as they are shown above select Windows then Cascade from the functions at the top of the screen File System Insert I imdoW Output Cal Su esz Description ascade i e O T l Next G Genius Modular Re
72. the field for Config Mode to Ee i Im pu pain en om unc kuma Seed MANUAL Enter a beginning R reference and length 64 for global data See the Programming chapter of this book for more information about Global Data addressing RACK J 4 5 6 CONFIGURATION 9 Press the ESC key to return to the rack configuration screen 10 The rack configuration screen now includes the Bus Controller D 11 Press F10 zoom to go to the bus Pen systa configuration screen GFK 0787B Chapter 6 Configuration 6 47 s f Gorm cory REF VU DELETE UNDEL CFGSEL 12 On the bus configuration screen the Bus in Beton Rte Bbc Bac ont Raed Rather e icon z Controller appears at its configured Bus Rack J Slot Bus Address 31 in this example BUS ADR BUS ADR BUS ADR BUS ADR BUS ADR BUS ADR BUS ADR uN 24 Zo 26 2 26 29 30 13 From here you can configure the devices on the bus including the other bus controllers in the group Each bus controller must be configured both individually and as a device on the bus of the other bus controller s on the same bus In addition the bus controllers on a Global Data bus must be configured with an appropriate Global Data address and length 0 D SLHSONSYS TENS PRET SYSTEN ONF IG VALID REPLACE When configuring I O blocks be sure to match I O address assignments and serial bus addresses of GMR blocks to those made using the GMR Configuration Software
73. the major revision level of the GMR software The last two digits yy represent the minor software revision level A teach file named KEYO DEF for use in future application program updates Subsequent chapters of this book explain configuration steps and programming guidelines fora GMR system The basic steps are illustrated below GMR CONFIGURATION LM90 CONFIGURATION GMR Configuration Printout GMR j Diskette J j H G_M_R10 Program CONFIG EXE Block P GMRxxyy LM90 KEY0 DEF T LM90 PROGRAMMING Soranian i T T T Y The PETER E Application ae CONFIGB CONFIGC Program i l future program updates LMg90 LMg90 LM90 Store Store Store y PLC A E er Li i 5 W O Block Configuration with Hand held Monitor 1 10 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 The Basic Steps of Configuration and Programming 1 Use the GMR configuratio
74. the same as the actual input This is also true if there is just one actual input present on a Duplex or Triplex group configured for 3 2 1 0 Voting Adaptation Field Input Data Single Input Provided 2 ae 152 oe to Application Logic lt input2 a 2 152 Field Input Data GMR Software Performs Inout 3 1 out of 1 Voting if Voting Adapta tion is 3 2 1 0 Duplex State lowest minimum value low high or average value 100 Default State hold last max 175 maximum value minimum or maximum Discrete Input Voting with One Input Present and Voting Adaptation Set to 3 2 0 Configuring a Duplex or Triplex input group for 3 2 0 Voting Adaptation prevents the data from just one input being used as the only input data for that group If a Duplex or Triplex group configured for 3 2 0 Voting Adaptation has just one input present the configured input Default State is used instead of the remaining actual input Field Input Data Single Input Provided Input 1 152 to Application Logic Field Input nput2 D 17S Data GMR Software Performs Input 3 a 1 out of 1 Voting if Voting Adapta tion is 3 2 1 0 Duplex State lowest ini low high or average value 100 minimumyalie Default State hold last max a 175 maximum value minimum or maximum Genius Modular Redundancy Flexible Triple Modular Redundant TMR Sy
75. two busses two PLCs SS QU Triple PLCs Triple Genius Busses f Shaded items omitted leas j for duplex operation Optional Zener 5 7 y diode for line monitoring 1 One Input Sensor m three sensors to three Genius inputs three busses three PLCs m two sensors to two Genius inputs two busses two PLCs y y e Triple PLCs Triple Genius Busses lp Shaded items omitted eal inal for duplex operation M M Optional Zener l J diodes for line 4 monitoring L Triple Input Sensors m one sensor to one Genius input Single blocks can be configured as non voted GMR blocks allowing them to take advantage of the GMR autotest feature Both discrete and analog blocks can be used however analog blocks cannot be autotested Chapter 2 Input Subsystem 2 3 Non Voted I O in the Input Subsystem The input subsystem can also include three types of non voted inputs 2nd GMR input 3rd GMR input 4th GMR input GMR Autotest Inputs from single block simplex GMR input groups Individual blocks can be included in the GMR
76. which allows the individual blocks in a group to stay isolated from each other LE the power feed outputs point 16 of each block ARE NOT wired together asynchronous input autotesting can be selected Asynchronous input autotesting can also be selected if non redundant simplex discrete input devices are used with isolation between blocks Using this option allows the input autotest to continue executing on other blocks in a group which are not affected by the fault Because input autotesting continues in this case an I O shutdown is not necessary and WILL NOT occur See Chapter 8 installation information ele 6s Sh Ss T wo ty Blocks Wired Together Blocks Not Wired Together If non redundant simplex discrete input devices are used without isolation between blocks LE the power feed outputs point 16 of each block ARE wired together then synchronous input autotesting must be selected in the GMR configuration for the input group See Chapter 8 installation information For this configuration there are two types of faults which may prevent the autotest from continuing to execute for that input block group and thus cause a I O shut down for the inputs in the group 1 Loss of a block within the group IE any failure which causes the block to no longer comm
77. you specify whether the blocks in that particular group are 16 point or 32 point blocks For example BC Group nput Group gt utput Group gt nonVoted I0 gt 6 Point Block 2 Point Block ee Press Return to configure the block The configuration screen shown at the right appears ID Enter a name or a description of up to 12 characters such as nonvoted 1 This entry is for your information only It is not used by the GMR software Start Ref Enter the starting I O Table reference for the block This is the I and Q addresses used for the block s I O data Voted I O data and non voted I O data use different areas of the I O tables This is shown below and explained in more detail on page 7 5 Discrete I O tables are shown the analog I O tables are similar Discrete Input Table 10001 Discrete Output Table Q0001 z pe Voted Inputs 4 gt Inputs to Logical Redundant Outputs eedt is PLC Outputs lt from PLG Available for x non voted Available for gt non voted non voted Inputs J 1 0 non voted Outputs fe ooa l Bus A inputs Reserved memory Bus A B C Reserved us A B Output Bus B inputs Inputs Memmory Bus C inputs J EEPE R d Reserved inputs gt Reserved Physical Redundant y Ouiputs Outputs to Blocks 11024 or 112288 Q1024 or Q12288 The starting address for non voted data depends on the amount of redundant data as explained in chapter 7 Duplicate
78. 024 Bus C inputs 96 As with discrete inputs all of the analog inputs are available to the PLC application program Analog Output Addressing Analog blocks with outputs can be used in a GMR system but they do not operate in GMR mode They can be configured for Hot Standby CPU redundancy operation In Hot Standby mode an analog block accepts outputs from a bus controller at serial bus addresses 31 If that bus controller stops sending output data the block accepts outputs from bus controller 30 Remember that each PLC in the GMR system normally executes the same application program 7 8 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System User s Manual March 1995 GFK 0787B Register R Memory Assignment for GMR GFK 0787B The GMR software uses several areas of R memory for specific functions as diagrammed below Only the area labelled Application Registers should be used by the application program Within that area a portion is reserved for initialization data as explained below R Memory Allocation for GMR R and M Ry Initialization Data Application Registers Defaults Rmax 320 66xN 66 words Bus Controller 1 Interface Rmax 452 Rmax 451 Bus Controller N 1 Interface max 66 words Rmax 386 R Bus Controller N Interface eR max 385 66 words Hinapi Rmax 319 Global Data to be Sent max 6
79. 1 GMR12 ST x at y GMR12 state mach exceeded allowed time in step x Step no at offset y in GMR12 diag nostics 11452 GMR12 IW x GMR12 has output an illegal waycode of x GFK 0787B Chapter 5 Diagnostics 5 21 Code Message Meaning 11453 GMR12 tmplt too small GMR14 has detected an internal error condition 11455 GMRI15 IS x at y GMR15 state machine went to step x illegal Step no at offset y in GMR15 diagnos tics 11456 GMRI15 ST x at y GMRI15 state mach exceeded allowed time in step x Step no at offset y in GMR15 diag nostics 11457 GMR15 IW x GMR15 has output an illegal waycode of x 11458 GMR15 tmplt too small GMR14 has detected an internal error condition 11501 Unauthorized GMR Access GMR15 was invoked with incorrectpassword 11502 Incorrect GMR Version GMR15 version number does not match the GMR system version number 11503 GMR Software Exception An invalid call number was detected 11504 Invalid GMR Pointer The error code pointer was out of bounds 11505 More than 1 Master GMR15 detected that more than 1 PLC was operating as master 11506 Invalid Switch Case GMR detected an illegal internal condition 11507 Discrep NAKPLCA PLC A failed to acknowledge discrepancy results 11508 Discrep NAK PLCB PLCB failed to acknowledge discrepancy results 11509 Discrep NAK PLCC PLC C failed to acknowledge discrepancy results 11510 Disc results read fault The PLC was unable to read output discrepancy results data
80. 10837 GMR cfg err no of GBCs GMR Configuration Module detected invalid number of GBCs 10840 GMR version MM mmE GMR software version number 10841 Cfg util ver MM mmE GMR config utility version number 10842 GMR config crc OxXXXX Config utility CRC value 10843 XXXXXXXXXXXXXXXXXXXX First 20 characters of config description 10844 XXXXXXXXXXXXXXXXXXXX Remaining characters of description 10850 Invalid DigI Pdata Invalid data detected in voted digital input record 10851 Invalid NV DigI P data Invalid data detected in nonvoted digital input record 10852 Invalid AnalI Pdata Invalid data detected in voted analog input record 10853 Invalid NV AnaI P data Invalid data detected in nonvoted analog input record 10860 GMR cfg err R Write R register external device write access range is invalid 10861 GMR cfg err AI Write Al register external device write access range is invalid 10862 GMR cfg err AQ Write AQ register external device write access range is invalid 10863 GMR cfg err I Write l register external device write access range is invalid 10864 GMR cfg err Q Write Q register external device write access range is invalid 10865 GMR cfg err T Write T register external device write access range is invalid 10866 GMR cfg err M Write M register external device write access range is invalid 10867 GMR cfg err G Write G register external device write access range is invalid 10870 Shutdown in hh mm ss System simplex shutdown in hh hours mm minu
81. 11009 to 11024 One input group of three discrete 32 circuit blocks The application program will use voted inputs at addresses I0001 to I0032 O The beginning Input Table reference for the data is equal to T O Table length reserved inputs 3 X input data length for one group 1 For the example this is 1024 16 3 x 32 1 913 10913 O In the output table the corresponding area Q0913 to Q1008 is reserved One non voted discrete 16 circuit block If configured as a combination block it occupies references 10033 to 10048 in the Input Table and Q0033 to Q0048 in the Output Table Notice as shown in the illustration that these references begin after the last voted input reference and that output references Q0017 to Q0032 are not used The illustration shows where these inputs and outputs would be located in the I O tables Shaded portions represent unused I O table memory Discrete Input Table Discrete Output Table 10001 9 Voted inputs 32 l001 l0032 Been 290001 Q0001 Q0016 oe 1033 10048 10033 Q0033 Q0033 Q0048 bus A inputs 32 10913 l0944 10913 Q0913 Q0913 Q1008 bus B inputs 32 10945 10976 bus C inputs 32 10977 11008 11008 Q1008 fo 9 Reserved inputs 16 11009 11024 Lagan zaio Q1009 Q1024 7 6 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B U
82. 12232 Init Miscompare at startup M12234 System fault at startup Exiting the Window When you have completed this screen select OK to return to the System screen When you select OK your entries are saved and the window disappears If you want to exit the window and reset all fields to their previous content select Close or Cancel instead 6 22 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 GFK 0787B Write Access Next select System to configure Write Access PU est Interval MR In Disc Filter l Config Limits a Init Data ZAQ ault Actions rite Access Start Length z e i On this screen you can configure starting addresses and lengths for any memory areas to which data can be written to through a CMM PCM or Ethernet Communications Module These configuration parameters do not prevent write access through Genius Bus Controllers the CPU s built in port or with serial or parallel Logicmaster 90 70 The following memory areas can potentially be written to R Registers AI Analog Input Table AQ Analog Output Table Yl Discrete Input Table Q Discrete Output Table T Temporary internal reference bits that are not saved through power loss M Internal reference bits that are saved through power loss G Global Data memory GD Global Data memory GE Global Data memory The Start parameter for each memory area is the start of
83. 4 words Saas es Global Data Received from PLC on Rmax 255 Bus a with highest serial bus address 64 words Rmax 192 Global Data Received from PLC on Rmax 191 64 words Bus a with lower serial bus address Rmax 128 Global Data Received from PLC on Rmax 127 Bus b with highest serial bus address 64 words Rmax 64 Global Data Received from PLC on Rmax 63 64 words Bus b with lower serial bus address Rmax Each PLC receives two sets of incoming Global Data from the other PLC s Both of these are placed into R memory as can be seen in the diagram Only one set is copied to G memory for access by the application program however Directly ahead of the incoming Global Data in R memory is a copy of the outgoing Global Data This data should be programmed using G memory not R memory The GMR software automatically moves the data to the appropriate R location prior to the Global Data being sent Ahead of the Global Data areas of R memory are additional areas used by the GMR software for communications with I O blocks for functions such as autotesting and diagnostics and with other bus controllers on the bus The overall length of this area depends on the number of other bus controllers in the system R Memory Required for Startup Initialization Data R and M initialization data that may be received during startup are stored in R memory the second set of incoming M initialization data is stored there temporarily
84. 787B User s Manual March 1995 Output Wiring for a 32 Circuit 4 Block Group continued Block Wiring for a 32 Circuit 4 Block Output Group More detailed installation information is provided in the block datasheets The labels Block A Block B Block C and Block D refer to the previous system diagram Bus A ql Ue Genius Bus Connections ed Block A 1C660BBD024 7 DC Power 1 Source BI s1 s2 Sl SHLD IN Sl SHLD OUT DC DC 10 Power discon nects for Source blocks should be wired here 12 14 16 18 20 22 24 26 28 30 32 34 36 40 VQOOS PV OOO OO OV OV OOOO VOD COV SGV VPP PPV VV VVVVOEed DC L As 4 7 Ground Rectifier Clamping Diode should be wired here for each load 1 Amp 75 to 100 Volt PIV Bus C dl Vo Genius Bus Connections Block C IC660BBD025 r sll st Sink Ol S2 IO SHLD IN DC Power SI SHLD our 5V lorog DC 2 10 12 14 16 18 Power discon Sjell 2 nects for Sink oll 5 blocks should Zla 2 be wired here a Q 30 32 34 36 a2 40 2 21 pc 4 eS TS 77 Ground Bus B g Ve Genius Bus a Connections Block B
85. 9 M12228 PLCAOK PLC A is online Meaning depends on the PLC where the flag is set See the table on the next page M12229 PLCBOK PLC Bis online r M12230 PLCCOK PLC Cis online 4 M12231 INHIBIT Inhibituserapplication Set by the GMR software at startup to prevent execution of the application program until data initializationiscomplete M12232 MISCMP Init miscompare at Initializing PLC detects miscompare between startup M bit init data from two online PLCs M12234 SYSFLT System fault at startup At startup communications failure witha GMR buscontroller M12235 SYSFLT System fault Communications failure with a GMR bus con troller This reference is cleared when PLC Fault Resetisissued M12236 OPDISC O Wiscrepancy Outputdiscrepancy This reference is cleared when PLC Fault Reset is issued M12237 COLDST Cold start performed At startup the initializing PLC detects no other PLCs online When the application program detects this flag has been set it can initialize any M and R initialization data M12238 IORESIP I Oresetinprogress An I O fault reset is in progress Bit is On for one scan when the internal GMR fault tables are cleared M12239 ATINPRG Autotestin progress An input or output autotest is in progress not necessarily initiated by this PLC the state of this bit will be the same in all running PLCs M12240 LOGONFT Blocklogon fault See page 7 17 M12241 SIMPLEX Simplex mode One
86. Clearing the PLC Fault Tables Use these M references to clear the PLC Fault Tables m Toclear the PLC Fault Table in a single PLC set reference M12259 to 1 for at least one PLC sweep m Toclear the PLC Fault Table in all PLCs set reference M12264 to 1 for at least one PLC sweep m Toclear the I O Fault Table and corresponding fault contacts in all PLCs set reference M12258 to 1 for at least one PLC sweep m Monitor M12238 IORESIP to determine when an I O Fault Table reset is complete Do not use the Logicmaster F9 key to clear the Fault Tables Fault Table Clearing from the Logicmaster software can be prevented by keeping it in Monitor mode Although the Fault Tables seem to operate as they would in a non GMR system they are actually controlled by the GMR software not the Logicmaster software Instead in a GMR application the fault tables must be monitored and cleared from the application program logic Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 Programming for Startup The PLC Subsystem chapter of this book describes the sequence of actions that occur when the PLCs in a GMR system are started up m The GMR software in the PLCs only allows one PLC to come online at a time First a PLC determines its ID by reading the serial bus addresses of the GMR Bus Controllers PLC A 31 PLC B 30 PLC C 29 It then sets the corresponding PLC Iden
87. Counterblock no no no no yes Power Tracblock no no no no yes 1 8 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System User s Manual March 1995 GFK 0787B Number of I O Points in a GMR System The I O capacity of the system depends on whether the CPU is a model 788 or model 789 For most applications these limits will not be reached If you need help estimating I O sizes for a large application contact GE Fanuc at 1 800 828 5747 CPU Model Total Discrete Maximum Maximum Maximum Total Physical I O Number of Number of Voted I O Voted Inputs Voted Outputs 788 352 112 80 100 798 12288 2048 2048 4096 Non GMR I O Non GMR I O is I O that is not included in the GMR configuration The amount of non GMR I O that can be used depends on the amount of GMR I O present and the CPU memory capacity The tables below show how much memory is available for non GMR I O main part of tables for given numbers of GMR inputs and GMR outputs In the equations the GMR Inputs and GMR Outputs are the actual number of I O configured with the programming software Number of Non GMR I O Available for the 788 CPU Number of Number of Redundant GMR Outputs Voted GMR Inputs 0 16 32 48 64 80 96 0 352 288 224 160 96 32 16 304 240 176 112 48 32 256 192 128 64 0 48 208 144 80 16 64 160 96 32 80 112 48 96 64 0 112 16
88. Diagnostics Discrete Inputs During the Input Scan data from discrete input blocks is placed in the Input Table as shown below Inputs from blocks that have been included in the GMR configuration is placed in the areas labelled A B and C Data from any additional discrete input blocks non voted GMR blocks or blocks on other busses is placed in a separate area as shown Discrete Input Table Input f gt Voting oy Voted Inputs Logic Non voted Inputs Bus A inputs Bus B inputs Bus C inputs 4 B Q Reserved inputs The GMR software creates and maintains the separate areas of the discrete Input Table In addition to the four areas used for the inputs received from Genius blocks there are two additional areas The first at the beginning of the Input Table is for voted inputs The other at the end of the table is for reserved inputs which are used to inhibit diagnostics for outputs that are being controlled manually The chapter on Programming explains in detail how the Discrete Input table memory is allocated Chapter 4 PLC Subsystem 4 7 Discrete Input Voting Immediately after the input scan before the application program execution begins the GMR software performs input voting It automatically reads and votes on the three or two sets of data in areas A B and C of the discrete Input Table If a failure discrepancy fault Autotest fault or Genius fa
89. 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 TUV Certification describes restrictions placed on the design configuration installation and use of aGMR system that will be applied in an Emergency Shut Down ESD application for which for a TUV site application approval will be sought Appendix B Maintenance Override The information in this appendix is reprinted by permission of TUV 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 GMR Phase II m Programming can now be done online This capability is intended for use during debug and commissioning m 32 circuit DC Genius I O blocks can now be used in H pattern output subsystems GFK 0787B iii Preface m The GMR configuration software now allows selection of memory addresses for external write access Serial and network c
90. E E Beardie aang Steph 4 8 3 Output Wiring for a 16 Circuit 4 Block Group 000000 8 10 Output Wiring for a 32 Circuit 4 Block Group 000005 8 14 AppendixA T V Certification c cece cence cece cee ence eneeees A 1 AppendixB Maintenance Override ccc cece cece ee cee eee e eee B 1 Abstracte ered oe fae eek Rae ade OR He PAG ea ee bh ew al B 1 Maintenance Override Procedures 0 cee cee eee eee eee B 1 Recommendations 0 00 cee cece cent eee ene eens B 3 Version HIStory denira i nate E a E E as ove higtine E E nate A B 3 GFK 0787B Genius Modular Redundancy Flexible Triple Modular Redundant TMR System vit User s Manual March 1995 Chapter Introduction GFK 0787B 1 Genius Modular Redundancy GMR 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 amp 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 T V has certified GMR for classification to these requirements triplex Class 5 duplex Class 4 and 5
91. Each block the group uses same serial bus address on its respective bus The exception to this is the 4th block block D in the output group which will have its SBA identified in the Options window Auto Test Highlight this item then press the space bar key to display a screen for setting up Output Autotest for the output circuits Follow the instructions on the next page to complete the entries on that screen GFK 0787B Chapter 6 Configuration 6 37 6 38 Autotest By default each circuit is set up for autotesting as shown by the X next to the circuit number To turn off autotesting for any circuit select that circuit click on the circuit or select it using the cursor keys Press the space bar key to remove or replace the X fAutoTest X Yes X X X X X X X X X X X X X X X X DONDA A U N e 10 11 12 13 14 15 16 X X X X X X X X X X X X X X X X Normal State X On DONDAN A UN e 10 11 12 13 14 15 16 Note It is possible for an output block to include circuits that are not part of the GMR system and which are not to be autotested Be sure to turn autotest off for any unused and non GMR circuits Normal State By default each circuit is set up to have On as its Normal non alarm State for purposes of autotesting The selection is shown by the X next to the circuit number If the autotest alarm
92. FANUC GE Fanuc Automation Programmable Control Products Genius Modular Redundancy Flexible Triple Modular Redundant TMR System User s Manual GFK0787B March 1995 GFL 002 Warnings Cautions and Notes as Used in this Publication Warning notices are used in this publication to emphasize that hazardous voltages cur rents temperatures or other conditions that could cause personal injury exist in this equipment or may be associated with its use In situations where inattention could cause either personal injury or damage to equip ment a Warning notice is used Caution notices are used where equipment might be damaged if care is not taken Note Notes merely call attention to information that is especially significant to understanding and operating the equipment This document is based on information available at the time of its publication While ef forts have been made to be accurate the information contained herein does not purport to cover all details or variations in hardware or software nor to provide for every pos sible contingency in connection with installation operation or maintenance Features may be described herein which are not present in all hardware and software systems GE Fanuc Automation assumes no obligation of notice to holders of this document with respect to changes subsequently made GE Fanuc Automation makes no representation or warranty expressed implied or stat utory with respect t
93. GMR system receives the input state from each connected block on each PLC sweep The GMR software performs any input voting required for both discrete and analog inputs and provides voted input data to the PLC It notes any data discrepancies and provides fault bits and fault messages that can be accessed by application program As always the application program determines the required state of the outputs as a function of the inputs received The application program sets a single output bit for each device to be controlled The appropriate number of redundant Genius blocks are configured to identical output references The CPUs monitor the voted output state computed by each Genius output block group and provide diagnostic information on the detection of any output discrepancy and identifies the discrepant PLC The executive path in each processor field input to field output is independent of any inter processor data exchange with the exception of initialization data at powerup GFK 0787B Chapter 4 PLC Subsystem 4 5 Estimating CPU Sweep Time The GMR system software runs on Series 90 70 CPU788 or CPU789 PLCs It produces a base CPU sweep time that becomes a part of the overall sweep time of the CPU with a ladder logic application program in it This base sweep time should be taken into consideration during the application program design and development Base sweep time depends on GMR configuration parameters such as Input and Outp
94. Line Monitoring optional alBlc alele alele t 3 gt oe Input 1 Hee o a0 Input 15 or 32 p m 6 2 volt Zener diodes are used for optional line monitoring on circuits configured as tristate inputs This option is only available with 16 circuit DC blocks m All blocks in an input group must have the same number of circuits either 16 or 32 m On either 16 circuit or 32 circuit blocks circuit 16 is used as an output if the block group is configured for input autotesting m On any block circuits that are not configured as part of the GMR input group can be used as non redundant inputs or outputs m If redundant power supplies are used on the blocks they should be diode ORed power supplies providing a common power source for all blocks in the group Different groups may use different power sources m All blocks in the input group must be assigned the same serial bus address m Ifthe block group is configured for input autotesting it must be wired appropriately Each input that is configured by the GMR Configuration Software to be autotested must have its input device wired to receive power from output Q16 of the block group as shown above The Q16 outputs from each block are diode ORed together to function as the power feed f
95. MRS WExcept L GMR Configuration Module detected invalid diagnostic or errorreferences 10806 GMR Invalid switch GMR Configuration Module detected invalid switch case 10810 GMR config util invalid GMR Config Module detected incompatibility with configuration utility 10811 GMR cfg err GBCxx GMR Configuration Module detected invalid GBC record xx in the config data 10812 GMR cfg err GBCxxI Oyy GMR Configuration Module detected invalid GBC record yy in GBC record xx of the config data 10813 GMR cfg err CPU type GMR Configuration Module detected incompatible CPU type in the config data GFK 0787B Chapter 5 Diagnostics 5 19 Code Message Meaning 10814 GMR cfg err no of PLCs GMR Configuration Module detected more than 3 PLCs in the config data 10815 GMR cfg errW dogtimer GMR Configuration Module detected invalid watchdog time in the config data 10817 GMR Cfg Err R usage GMR Configuration Module detected insufficient R registers 10818 GMR cfg err AI Usage GMR Configuration Module detected insufficient PLC Analog Inputs 10819 GMR cfg err comreq R GMR Configuration Module detected invalid positioning of the comreq status R area 10820 GMR cfg err Tx global GMR Configuration Module detected invalid positioning of the Tx global comms R area 10821 GMR cfg err Rx global GMR Configuration Module detected invalid positioning of the Rx global comms R area 10822 GMR cfg err I O gt max GMR Configuration Module detect
96. PLC The table on page 4 3 shows in detail what happens if a configuration mismatch is detected 6 4 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 GFK 0787B 6 Getting Started To complete the configuration you will need to provide the following information the CPU type 788 or 789 the register memory table size the Analog Input table size the CPU Watchdog timer value I Oblock serial bus addresses IQ block logical Q and voted I and AI addresses to be used in the application program m Bus controller rack and slot locations The GMR Configuration Software will supply default values for these selections However the defaults may not be appropriate for your application Before beginning decide on entries for the items listed above During configuration change any defaults that are not suitable Installing the Configuration Software The GMR Configuration Software can be run directly from diskette or copied to a hard drive Operation from a hard drive is more efficient To copy the GMR Configuration Software to a backup disk or to the hard drive of a personal computer on which it will be run copy all of the files listed below from the CONFIG subdirectory of your Master GMR software disk CONFIG EXE G_M_R10 16K G_M_R10 32K G_M_R10 48K G_M_R10 64K If you are using a mouse with the configuration utility you also need to ins
97. RB aaa In rung 12 the transition of IORESIP I O Reset in Progress to the Off state indicates that the requested I O fault reset has been completed This rung resets command bit IORES I O Reset to the Off state lt lt RUNG 13 gt gt LOGONFT FORCLOG _ 4 S S a In rung 13 the transition of LOGONFT Logon Fault to the Off state indicates that the requested I O fault reset has been completed This rung resets command bit FORCLOG Force Logon to the Off state lt lt RUNG 14 gt gt DUPLEX LOGONFT FORCLOG I I I S TRIPLEX IORES I I lS l In rung 14 if the GMR system is in DUPLEX mode two CPUs are on line and a logon fault occurs at an output block LOGONFT turns on This turns on the Force Login FRCLOG control bit which forces the output block to accept outputs from the newly online CPU even if the output states do not agree with the present voted outputs at the output block This logic also turns on the control bit IORES I O Reset IORES is required to clear the Logon Fault status bit LOGONFT This last action also clears the fault tables in all running PLCs The TRIPLEX bit is optional the need for this bit depends on the application If used it provides the same type of PLC logon control when a third PLC comes on line Depending on the application you may prefer to use only the DUPLEX logic shown above to turn on the FORCLOG Force Logon
98. ROGRAMMING LM90 LM90 Librarian lj me CONFIGA CONFIGB CONFIGC gt Application Program LM90 LM90 Store Store Y PLC A PLC B PLC C Create a new Program Folder In the Logicmaster programmer create a folder with a new name such as GMRPROG Add the GMR system software to the new program folder Using the Copy Folder feature of Logicmaster copy the GMR system software folder GMRxxyy from the diskette to your new program folder The application program can now be added to this folder It can be newly created and edited into the folder or imported via the library Using the Logicmaster librarian feature add the external program block containing the GMR configuration parameters G_M_R10 to the LM90 library Then use the Librarian to import G_M_R10 from the Library to the application program folder After completing the application program and the configuration s store them to the PLCs Supplying the configuration and program as separate files as shown above makes it easier to perform program updates in the future Genius Modular Redundancy Flexible Triple Modular Redunda
99. Redundant TMR System User s Manual March 1995 GFK 0787B GFK 0787B M Control References The application program can use the following M references to provide information to the GMR software The references are located at M12257 M12288 Reference Nickname Description Meaning M12257 CONTINU Continuewith initialization amp enable outputs M12258 IORES PerformI OFault Tableclear See next page M12259 PLCRES Perform PLC Fault Table Atan individual PLC clear M12260 ATMANIN Autotest Manual Initiate Initiates a single autotest both input and outout any time it is turned on even if the Autotest Inhibit bit is on M12261 ATINHIB Autotestinhibit Prevents the automatic autotest both input and output from oc curring at the Autotest Interval specified in the GMR Configura tion for as long as this bit is On Note it does not prevent an Au totest Manual Initate M12262 REPORT ReportGMRversion status See description of M12262 Re port on page 7 14 M12263 FORCLOG Force block s to log on See the description of PLC Logon Control on page 7 17 M12264 PLCRESG Clear PLC Fault Tablesinall See next page PLCs M12265 SDCAN Cancell OShutdown IfanI OShutdown was initiated by any PLC turning this bit On cancels it and prevents the shut down from occurring If this bit is setcontinuously no I O Shut down willbe initiated M12266 Reserved for
100. System GFK 0787B User s Manual March 1995 Discrete Inputs GFK 0787B Types of Blocks in the Input Subsystem The following discrete block versions can be configured for GMR version 2 06 operation and used as GMR input blocks 24 48 VDC 16 Circuit Source block IC660BBD020M or later 24 48 VDC 16 Circuit Sink block IC660BBD021M or later 12 24 VDC32 Circuit Source block IC660BBD024N or later 5 12 24VDC32 Circuit Sink block IC660BBD025N or later All types of Genius blocks can be used as non GMR blocks ina GMR system Note that the GMR Input Autotest feature requires point 16 so if the system uses Input Autotest point 16 is not available as an I O point for the application leaving either 15 or 31 points available on the blocks listed above Discrete Input Processing Discrete input processing is handled in each PLC by the GMR system software The manner in which inputs are handled depends upon whether a block is included in the GMR configuration and if it is upon whether it is part of a 3 block 2 block or 1 block group Input processing by the PLC is explained in detail in the PLC chapter In general the GMR system software compares input data from all corresponding inputs 3 2 or 1 for each point and provides a voted input result for use by the application program If all the input data is not available the GMR system software follows a configured voting adaptation scheme The application program can also access t
101. U sweep Current loop inputs 2 9 D D Block 6 39 Data initialization 4 4 Datagram communications Default state 6 35 Diagnostics autotest Autotest fault 5 25 Channel Shorted fault 5 28 Discrepancy fault 5 25 5 28 discrepancy reporting Failed Switch fault Internal Channel fault Line fault 5 2 5 25 No Load fault Open Wire fault Overload fault 5 2 Overrange fault Overtemperature fault 5 2 Short Circuit fault 5 2 State fault types of input diagnostics types of output diagnostics Underrange fault 28 Directory configuration change 6 12 Discrepancy fault 5 28 5 11 5 25 Discrepancy reporting analog inputs discrete inputs discrete outputs DoI Oand Suspend I O Duplex default 3 3 Index 1 Index Index 2 Duplex state 6 34 F Failed Switch detection 3 9 Failed Switch fault Fault actions configuring 6 22 6 23 Fault and Alarm contacts 6 25 5 28 Fault Reporting Fault reporting 2 2 configuring REI blocks in GMR mode 3 9 Fault Reportting Fault Tables 5 15 clearing 7 14 messages for GMR monitoring Fault locating references 7 21 Forces and Overrides 7 10 G G memory mapping G_M_R10 Program Block Genius blocks configuration enhanced for GMR 1 2 number per input group bal using in GMR application Genius bus PLC connections 6 4 Global Data amount of Eu in G me
102. User s Manual GFK 0787A are to be closely observed and complied with especially the grounding procedures in chapter 3 of the Series 90 70 Programmable Controller Installation Manual GFK 0262D All GMR components must be installed in a panel or cabinet which offers protection equal to or greater than specification IP54 For EMC purposes the enclosure must provide protection equal to or greater than an enclosure having the following characteristics Steel sides with a thickness of 0 040 inches no RFI gasketing and all enclosure sides grounded to a common point with grounding straps equal to or larger than 14 AWG The panels or cabinets must be closed during operation of the system They may be opened only during maintenance or for short term supervised operation The on line programming option must be set to DISABLED in the configuration The simplex shutdown option must be set to be enabled at 60 seconds For applications needing to meet DIN VDE 0116 specifications the maximum Input to Output response time allowed is 1 0 second To ensure this response time is met under all circumstances the maximum watchdog timer setting must be one of the following whichever is smaller 2 the typical scan time of the application program 10 milliseconds OR 310 milliseconds if Genius bus baud rate 153 6K 250 milliseconds if Genius bus baud rate 76 8K 130 milliseconds if Genius bus baud rate 38 4K The Data and System Fault actions
103. a GBC group However each block in the group uses the same serial bus address on its respective bus Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 6 Auto Test Highlight this item then press the space bar key to display a screen for setting up Input Autotest and Test Type for individual circuits screen for 16 circuit blocks shown here AutoTest X X X X X X X X X X X X 12 X X X X Test Type Sync Async WOnNTORWNe ee he eee oh Ww i od an If input circuits on the blocks in the group should be autotested circuit 16 the powerfeed output must have autotest enabled If no circuits are to be autotested circuit 16 can have autotest disabled and input devices can be wired directly to the power source instead of being wired to circuit 16 the powerfeed output By default each circuit is set up for autotesting as shown by the X next to the circuit number To turn off autotesting select that circuit click on the circuit or select it using the cursor keys Press the space bar to remove the X Note For all unused circuits on the blocks autotest should be set to off Also it is possible for an input block to include I O circuits that are not part of the GMR system and which are not to be autotested Be sure to turn autotest off for non GMR circuits Test Type Select whether the t
104. ae oa ine See ee Se ie Ne 7 3 Estimating Bus Scan Time 25 2nase 0h hee es ag OR AS RL eR Oe 7 3 Reserved References iss suet cek n hod hese steven Geol Beek eae s 7 4 Input and Output Addressing for GMR 0c cece eee 7 5 Register R Memory Assignment for GMR 0 eee 7 9 System Status S References 035i cho hye es 55S ewe eas ares ches 7 10 GMR Status and Control M References 0 00 e eee 7 11 Programming for Startup is ico tcaiaieb ola aa Cee eee ays eke 7 15 OVO Fault 230423 wel ee ene wate aaa wiv oa ree es 7 20 Programming for I O Shutdown 33 lt i eens Pea bo cade Bed Feats kA 7 20 Programming for Fault and Alarm Contacts 00000005 7 21 Reading GMR Diagnostics 0x4 ees slewid lea oe eke ue ie od Se a ee 7 24 Programming tor Global Data cas c lt die iss eh teehee Peete ee PER 7 27 Adding the GMR System Software to a New Application Program Folder 7 28 Adding the GMR Configuration to the Application Program Folder 7 29 Storing a Program to the PLC ede fate Pi ae salt ca tdy od heen ed ele 7 31 GFK 0787B Genius Modular Redundancy Flexible Triple Modular Redundant TMR System vi User s Manual March 1995 Contents Chapter 8 Installation Information i334 s334 960i wee ba ase basa wee ao 8 1 Genius Bus Connections 00 cece cece tenet e eens 8 2 Termination Boards 0 ccc eect tte e neces 8 2 laput Wing seta tandem leant eek op e a cary
105. age It is a separate utility that operates on an IBM PC or compatible computer It runs under DOS Either a keyboard or mouse can be used for making entries After all the necessary configuration entries have been made the data is added to the GMR system software The GMR system software is provided as a Logicmaster 90 Program Folder to which the application program is then added To assure matching the entries made with the GMR Configuration Software to corresponding entries made during Logicmaster 90 configuration and Genius block configuration the GMR configuration data should be printed out and used as a reference The GMR software requires that m all PLCs have the same number of bus controllers in the same positions not including non GMR bus controllers m all PLCs are connected to the same GMR Genius busses Genius busses used for either I O or communications that are not common to all PLCs in the system or that do not use bus addresses as described above must not be included in the GMR configuration GMR Configuration Software Revision and Checksum The system monitors the checksums of both the configuration data and the application program including the GMR software modules As part of the GMR configuration you can select whether to permit online changes If online changes are permitted a configuration mismatch will not stop the PLC If online changes are not permitted a configuration mismatch will stop the
106. alization data M and R It then sets its own M and R initialization data areas to match This is shown by the following simplified example A counter in PLC A starts a d 1 2 3 4 5 6 7 8 9 10 11 PLC A starts up Time The counter in PLC B starts G 4 6 7 8 9 10 11 PLC B starts up and initializes its counter with PLC A GFK 0787B Chapter 7 Programming Information 7 15 If both of the other PLCs are already online the initializing PLC reads the R only initialization data from the other PLC with the higher serial bus address It then sets its own data to match as shown above Word type data that will be included in the initialization data exchanged among the PLCs at startup such as timer and counter accumulators should be located at the top of the configured R memory space This is because the last portion top of the configured R initialization data is copied last Locating changeable data at the top of the R data assures that the most recent values will be included when the data is copied The third initializing PLC also reads any M bit initialization data from both of the online PLCs and compares the two sets of data If they don t match the initializing PLC sets the Miscompare status reference M12232 to 1 m When the PLC completes its data initialization the GMR sof
107. ar Redundant TMR System GFK 0787B User s Manual March 1995 GFK 0787B 6 Starting a New Configuration When you select New System from the File menu using the mouse or using the Enter Return key the System screen appears F File System Insert Window Output L 1 System Description _ F2 Save F3 Open Alt F3 Close FS Zoom Ctrl F5 Move F6 Next Alt X Exit SA From this screen you can m return to the file handling functions click on File or press ALT F m change a system parameter click on System or press ALT S m add a configuration item to the current file click on Insert or press ALT I When the Configuration menu appears click on the item to insert or press the highlighted letter key m print out a copy of the configuration click on Output or press ALT O When the Output menu appears click on Print Out or press P m create the configuration output file click on Output or press ALT O When the Output menu appears click on Write Config or press W Additional key functions are displayed on the bottom of the screen Entering a System Description At the top of the screen enter a description of up to 40 characters This information will appear when you print out the configuration It is also saved in the G_M_R10 file and can be used to determine what configuration is used in the system with the Report function M12262 Closing and Deleting the System Configuration
108. ary f TE cory REF VU DELETE as CFGSEL IEN ERE E ips Birckselficonn Bijune peer Sm oem 1 Change the CPU to the correct type in this example it is a CPU 789 and add i RACK appropriate memory Raok oa i PRREER MMED CONFIGURATION 2 Move the cursor to the rack and slot location for the first Bus Controller PWR 10 CPU 789 55W Be sure the location matches the entry made with the GMR Configuration Software 3 Press F2 genius 4 From the Catalog screen press F1 Fre Sti gbc 5 From the Description screen press Enter fF ACK a 7 7 p 6 Complete the entries on the left side gt of the screen Remember that all of SERIES 90 70 MODULE IN RACK J SLOT SOFTWARE CONFIGURATION the bus controllers in the PLC must Catalog 99 79 GENIUS BUS CONTROLLER have the same serial bus address 31 in the illustration at right Leave the Morass SL Acadia Wie MONE Ref Adr Chk selection disabled the Hau Mte seas Pared eee Error Rate 10 Switch Time N A default Ref Adr Chk DISABLED Dual GBC Addr Rack NA o i SEND GLOBAL DATA Slot NA 7 On the right side of the screen leave Conf ig Mode NONE Bus H NA Redund mode set to NONE The entries below it cannot then be edited 0 D SLHSONSYS TENS PROT SYSTEN ONFIG VALID REPLACE 8 If this Bus Controller was configured in the INIT DATA window of the Configuration utility for Global Data set
109. aster configuration and in the Genius block configuration however A sub menu appears where you specify whether the blocks in that particular group are 6 input or 4input 2 output blocks For example BC Group nput Group utput Group nonVoted DIO nonVoted I0 mT YY Circuit Block In 20ut Block een ID Enter a name or a description of up to 12 characters such as nonvoted 2 This entry is for your information only It is not used by the GMR software Start Ref Enter the starting Analog I O Table reference for the block This is the AI and or AQ addresses used for the block s I O data The allowable references are 0001 to 8192 Duplicate addresses are not allowed within a GBC group You will not be permitted to continue until you have entered a unique address SBA Enter a serial bus address from 0 to 28 Options Select this item to display additional configuration choices Bus Connects COA B RAS Hot Standby No CY Yes Block Type nput utput ixed Ca W Hot Standby Hot standby mode is supported for analog blocks This mode allows analog outputs to respond to CPU A or B Selecting Hot Standby here tells the system to configure the block to send fault reports to three PLCs Bus Connect Select the bus to which the block is connected Block Type Specify input output or mixedI O 6 42 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B Us
110. ate areas of the analog Input Table In addition to the four areas used for the inputs received from Genius blocks there is an additional area at the beginning of the analog Input Table for voted inputs The chapter on Programming explains in detail how Analog Input table memory is allocated Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 Analog Input Voting Immediately after the input scan before the application program execution begins the GMR software performs input voting It automatically reads and votes on the three sets of data in areas A B and C of the analog Input Table How it does the voting is described below It places the resulting voted input value into the voted inputs area of the Input Table If a failure discrepancy fault or Genius fault occurs the GMR software rejects the faulty data Depending on the configuration of the input group input voting may go from three inputs to two inputs to one input or from three inputs to two inputs to the configured default value Field Input Data Single Input Provided to Application Logic Input 4 152 a lt Input 2 150 150 Field Input Data Input 3 110 is Duplex State low high or average Default State hold last minimum or maximum In addition to field input data the GMR software may also make use of the input group s co
111. ated correctly calculations should include the field signal voltage the wire resistance times the length and the voltage drop in any barriers or isolation devices to determine the actual voltage present at the input terminal Additional information about input blocks is located in the Genius I O Discrete and Analog Blocks User s Manual GEK 90486 2 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 GFK 0787B Line Monitoring for Discrete Inputs Normally closed inputs on GMR configured blocks can be monitored for short circuit faults Normally open inputs on blocks which are not configured in GMR mode can be monitored for open circuit faults Normally closed Inputs For applications such as Emergency Shutdown ESD normally closed inputs are generally monitored for short circuits across the lines since that represents a fail to danger condition that is trip is not detected In general these inputs are powered from 24V and a field short to ground is interpreted as a trip condition m Typical Normally closed Input yp y P 24V Source Genius Block Normally open Inputs For applications such as Fire and Gas Detection normally open inputs are generally monitored for open circuits on the lines since that represents a fail to danger condition that is trip is not detected In general these inputs are powered from 24V and a fi
112. ately for GMR use Feature Circuit or Factory Selections Block Setting Device Number Block null 0 to 31 anumber must be selected Reference Address Block none Depends on host CPU type BlockI OType Block input input output combination Baud Rate Block 153 6std 153 6 std 153 6 ext 76 8 38 4 Kbd Pulse Test for Outputs Block enabled enabled disabled Input Filter Time Block 20mSec 16 ckt 5 100mSec 32 ckt 1 100mSec Circuitl OType Circuit input input output tristate input Report Faults Circuit yes yes no Hold Last State Circuit no yes no Output Default State Circuit off on off Detect No Load Circuit yes yes no Overload Shutdown Circuit yes yes no BSM Present Block no yes no BSM Controller Block no yes no Output Default Time Block 3busscans for bus redundancy 2 5 or 10 sec Redundancy Mode Block none none hot standby duplex GMR Duplex Default Block off on off Available only with 16 circuit blocks Device In a triple redundancy GMR system serial bus addresses 29 31 are Number reserved for the bus controllers By convention serial bus address 0 is ee s often used for the Genius Hand held Monitor The serial bus addresses address assigned to the blocks must match those entered using the GMR Configuration Software Therefore 1 28 are available for blocks All the blocks in an input group must be configured to use the same serial bus address In a 4 block output group three of the blocks one each on
113. ber of 16 bit words R data needed for the application R spare 320 words Global Data Number of GMR Bus Controllers in CPU x 66 registers Total Words of Register Data Configure the next higher 1K increment For more information please see chapter 7 Exiting the Window When you have completed this screen select OK to return to the System screen When you select OK your entries are saved and the window disappears If you want to exit the window and reset all fields to their previous content select Close or Cancel instead Chapter 6 Configuration 6 19 Initialize Data Next select System to configure the Initialization Data PU GBC_1 GBC_2 Rack Slot Rack Slot est Interval 0 none 0 none In isc Filter C1 4 2 Coy N GHee Conf i imit C2 3 C2 ea oni ig Limits 3 4 Coa 4 I it Data 4 95 oA 5 A C95 96 5 96 ault Actions Cole POOR 6 rite Access Gon fools Gacy POOLA 29 9 ZR Start Ref zM Start Ref ieee al E ZR Length zM Length words 256 16 M Temp Be T panes Initialization data as explained in the PLC Subsystem chapter of this book is exchanged between PLCs during startup It consists of data such as timers and counters and latched logic states It is important to be sure that the memory assignments you make here do not directly conflict with R and M memory used in the application program or required elsewhere by the GMR software Fo
114. cation etc for programs cannot be modified In STOP MODE STORE the following can be performed 1 You can store program logic configuration data and or reference tables from the programmer to the PLC 2 If you choose to store logic only and the PLC program name is different than the program name in the folder the current logic in the PLC will be cleared and replaced by the new logic in the current folder The current configuration data and reference tables in the PLC are left intact 3 If you choose to store logic and configuration data and or reference tables the logic configuration data and reference tables in the PLC are cleared and the new data is stored from the programmer to the PLC Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 GFK 0787B Using the Store Function To use the Store function press Store F4 from the Program Utility Functions menu The Store Program screen appears The screen shows the currently selected program folder which cannot be changed Three types of data can be stored from the programmer to the PLC program logic configuration data and reference tables When this screen first appears only the program logic is set to Y yes which is the default selection To store all of the data change the selection for reference tables and configuration to Y yes To store only part of the data select N no for any of the thr
115. caused the I O shutdown to initiate This may require simply replacing a blown fuse which had supplied power to a block or replacing a damaged or failed block or repairing field wiring 2 Initiate an IO autotest in each of the three PLCs so that the PLC s can determine that the block s is repaired and again functioning properly The autotest has to be executed at the PLCs which had actually started and expired their shutdown timers The autotests can be those that occur automatically as specified by the configured autotest interval or initiated manually via the GMR control bit Autotest Manual Initiate M12260 ATMANIN 3 Inthe case of a block being powered off or replaced a shut down of outputs the output block s may require a force logon to get them to accept output data from the CPUs This can be done by using the GMR control bit M12263 FORCLOG 4 To clear any standing faults at the block s and in the I O fault table of the PLCs an I O Fault Reset should be executed by turning on GMR Control bit M12258 IORES GFK 0787B Chapter 4 PLC Subsystem 4 21 Communications Between PLCs Data is transferred between the PLCs in the system using Genius global data Two busses are used to transfer duplicate data While the system is operating they transfer global data automatically This global data includes two types of information m Application program global data from G memory The GMR software automatically copies this data into
116. ce block IC660BBD020M 24 48 VDC 16 Circuit Sink block IC660BBD021M 12 24 VDC32 Circuit Source block IC660BBD024N 5 12 24VDC32 Circuit Sink block IC660BBD025N 3 2 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 GMR Output Handling GFK 0787B Unlike GMR input voting which is done by the GMR software in the PLCs output voting is performed at the output block groups To perform output voting the blocks must be one of the listed types and they must be configured with a Hand held Monitor to be in GMR mode Output Voting A GMR output block group compares corresponding output data for each point as received from each of the three PLCs If all three PLCs are online the data from at least two must match The block group sets each output load to match the state commanded by at least two of the PLCs Outputs from 3 PLCs Single Output a ra Soc PLC B 0 gt 0 picc E a GMR Block Performs 2 out of 3 Voting If only two of the three PLCs are communicating on the bus and they send matching output data for a point the block group sets the output to that state If only two PLCs are communicating the block group performs 2 out of 3 voting using the data from the two online PLCs and the block s configured duplex default state in place of the offline PLC data If only one of the three bus con
117. chC A amp B PLC C program mismatch with A and B 10136 ProgrammismatchA B C All three PLCs mismatch 10137 Program changed A PLC A program changed 10138 Program changed B PLC B program changed 10139 Program changed C PLC C program changed 10140 ConfigmismatchA B PLCs A amp B config mismatch C not online 10141 ConfigmismatchB C PLCs B and C config mismatch A is not online 10142 ConfigmismatchA C PLCs A and C config mismatch B is not online 10143 ConfigmismatchA B amp C PLC A config mismatch with B and C 10144 ConfigmismatchB A amp C PLC B config mismatch with A and C 10145 ConfigmismatchC A amp B PLC C config mismatch with A and B 5 18 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System User s Manual March 1995 GFK 0787B Code Message Meaning 10146 ConfigmismatchA B C Allthree PLCs mismatch 10147 Config changed A PLC A config changed 10148 Config changed B PLC B config changed 2 Config changed C PLC C config changed 10201 Unauthorized GMR Access Inter PLC Comms module was invoked with incorrectpassword 10202 Incorrect GMR Version Inter PLC Comms module has incorrect GMR version number 10203 GMR Software Exception Inter PLC Comms module was called with invalid call number 10204 Invalid GMR Pointer Inter PLC Comms module was called with invalid data pointer 10211 Comms Fail PLC A bus a Communications with PLC A has failed on bus a 10212 Comms Fail PLC B bus a Commun
118. ck IC660BBD021 M 12 24VDC32 Circuit Source block IC660BBD024 N 5 12 24VD 2 Circuit Sink block IC660BBD025 N Analog RTD and Thermocoupleblocks nospecificsuffix required m Other types of Genius blocks can be used as non redundant blocks in the same system Additional Items m SPECIALSAFETY SYSTEM red I O block labels package of 20 of the same type are available IC660SLA020 A021 A023 A024 A026 A100 A101 A103 A104 A106 D020 D021 D024 D025 These numbers correspond to the numbers of the blocks For example order label IC660SLA021 for block IC660BBA021 Logicmaster 90 70 Software release 4 02 or later Hand held Monitor optional IC660HHM501H version 4 5 or later SNP Programming Cable and RS 232 RS 485 adapter IC690ACC901 Multidrop Cable IC690CBL714 Two required for connecting 3 CPUs Incompatible Products m Graphics Display System GDS GMR is incompatible with Cimplicity 70 GDS Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 Series 90 70 PLCs GFK 0787B A GMR system normally consists of one to three identical CPUs running identical application software Each CPU is connected to the same input and output subsystems Each CPU receives all inputs and performs voting for discrete inputs and mid value selection for analog inputs Each CPU computes the required outputs as a function of the inputs and the application prog
119. command bit The purpose of PLC logon control is to prevent a CPU that is coming online from changing the state of a critical voted output Automatic PLC logon is sensible with the DUPLEX status bit because it ensures that at least two PLCs are driving output information before outputs that disagree with the voted outputs are used when a system is initially powered up The third PLC coming online has the ability to change an output state if the first two PLCs are already online and already disagree Because of this it may not be suitable to automatically log on the third PLC Chapter 7 Programming Information 7 19 I O Point Faults The GMR system can optionally use the standard Series 90 70 I O Point Fault references TheI O Point Faults feature allocates a bit reference for each potential discrete point fault and a byte reference for each potential analog point fault Note that space for these references is taken from the space available for the application logic WithI O Point Faults enabled when a fault occurs the fault reference IO_FLT is set The FAULT and NOFLR contacts can be used to access the point fault Point fault data is written to the references at the start of each CPU sweep so they always contain the most recent data Enabling I O Point Faults The use of I O point faults requires the following setup during Logicmaster 90 configuration A During CPU configuration select Memory Allocation and Po
120. correct address of digital I O was specified 10308 Invalid Analog Address Incorrect address of analog I O was specified 10310 Invalid block type Block type currently unsupported 10311 GMR3 Rr Ss comreq Fail A COMREQ sent by GMR to a bus controller in rack r slot s has failed 10312 GMRS WExcept L oL range error 10313 Value out of range Calculated value is out of range 10322 IO Reset Seq Timeout I Oreset timed out in step 2 10323 IO Reset Seq Timeout I Oreset timed out in step 4 10324 IO Reset Seq Timeout I Oreset timed out in step 6 10328 IO Reset Seq Timeout I Oreset timed out in step 8 10330 IO Reset Seq Timeout I Oreset timed out in step 10 10601 Unauthorized GMR Access I O Module wasinvoked with the incorrectpassword 10602 Invalid GMR Version I OModuleS W version does not match expected version 10603 GMRS WExcept Call I OModule wasinvoked with incorrect call number 10604 GMRS WExcept L I OModule wasinvoked with out of range input parameters 10607 Invalid Switch Case No cases satisfied by switch condition 10801 Unauthorized GMR Access GMR Configuration Module was invoked with incorrectpassword 10802 GMRS WExcept Null FH GMR Configuration Module failed to load fault handler 10802 GMRS WExceptI OFH GMR Configuration Module encountered an error loading the fault handler 10803 GMRS WExcept call no GMR Configuration Module detected call number exception 10804 ADL rack r slot s flt GMR Configuration Module failed to build active device list 10805 G
121. cy Checking is Performed If the GMR system determines that an output changed state during a discrepancy check it attempts up to three times to properly complete the discrepancy check on an output block This prevents logging false discrepancy faults that might be caused by the application program changing the state of an output while a discrepancy check is being performed Discrete Output Discrepancy Reporting with Dynamic Outputs Output Discrepancy Checking gives valid results as long an output changes state less frequently than approximately once per 10 PLC scans If an output changes state more rapidly than approximately once per 10 PLC scans the results of Output Discrepancy Checking may be ignored Nuisance discrepancy faults caused by transitioning outputs should NOT ever be logged However a message is logged in the PLC fault table The message indicates that output discrepancy processing could not be completed for a device at rack X slot Y SBA x due to transitioning outputs In an ESD system outputs are normally static Outputs that are not static that is outputs that normally change state may not be autotested as frequently as expected Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 GFK 0787B Analog Input Discrepancy Reporting If there is a discrepancy in the data from a set of inputs so that a channel deviates by more than a configurable percentage
122. d Duplex State Set to 0 If the Duplex Default state is set to 0 and two inputs are available both of the actual inputs must be 1 for the voted input to be 1 The voted input is 0 if either of the remaining inputs is 0 InputA State Input B State InputC Voted Input State Duplex State 0 0 0 0 0 0 0 0 0 1 0 0 0 1 0 0 1 0 0 0 1 0 0 0 1 1 0 1 1 1 0 1 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 Voting for One Discrete Input One input may be present in a non voted input group in a Simplex input group in a Duplex input group where one input has failed or in a Triplex input group where two inputs have failed In a non voted input group the actual input is always provided to the application logic In a voted input group if only one input is available the result of the voting depends on the Voting Adaptation mode that has been configured for the input group Discrete Input Voting with One Input Present and Voting Adaptation Set to 3 2 1 0 For a Simplex Input group one input the voted input is the same as the actual input This is also true if there is just one actual input present on a Duplex or Triplex group configured for 3 2 1 0 Voting Adaptation Field Input Data Input Provided to Application Input A o E F Logic Field Input ao 0 Data Input B P a Input C GMR S
123. d from PLC B GC0001 GC0896 Data received from PLC C PLCB GA0001 G A0896 Data received from PLC A GB0001 GB0896 Copy of transmitted global data GC0001 GC0896 Data received from PLC C PLCC GA0N001 G A0896 Data received from PLC A GB0001 GB0896 Data received from PLC B GC0001 GC0896 Copy of transmitted global data GFK 0787B Chapter 7 Programming Information 7 27 Adding the GMR System Software to a New Application Program Folder The GMR system software provided on the diskette must be added to the folder containing the application program Follow the steps below to add the GMR system software to a new application program folder 1 Place the GMR software diskette in a drive where it can be accessed by the Logicmaster programming software Enter the Logicmaster programming software and go to the folder functions F8 Create a new Program Folder F1 Enter a name for the new folder Press the Enter key When prompted that the new name is not that of the current folder respond yes a un PF Y NN In the Program Folder functions menu select F10 Copy Contents of Program Folder to Current Program Folder 7 Copy the GMR directory containing the GMR system software to the new folder A For Source Folder enter the actual name of your GMRxxyy file for example GMR0206 B Current Folder should already be selected For Information to be copied set Program Logic and Reference Tables only to ye
124. d redundant outputs 1 2048 789 CPU Number of voted analog inputs 1 1024 In increments of 4 or 6 AI Analog Input Table size 1 8192 R register table size 1to16 Specified in increments of 1K Voted Enter the number of 16 circuit and 32 circuit discrete input and output Discrete groups in the system plus any spare groups you may add in the future Each input group may consist of 1 2 or 3 blocks The GMR software will assign these voted I O addresses at the beginning of the I O tables and raw data addresses at the end of the I O tables similar to the illustration of analog inputs below and discussed in detail in chapter 7 Analog Enter the number of groups made up of 6 input analog blocks and the In Groups number of groups made up of 4 input 2 output blocks Include any spare groups you may add in the future Tables Enter the amounts of word memory to be allocated to analog input data AI and register data YR These values must match the corresponding values configured using Logicmaster 90 AI Size Allow enough AI memory to accommodate all analog input data as explained below The maximum size is 8192 analog channels words AI memory is divided into sections AI0001 yJ mpa g Voted Inputs Logic non voted Inputs A inputs B inputs C inputs Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 GFK 0787B 6 The voted analog references start at
125. daptation adaptation For a simplex group this option does not apply If a failure discrepancy fault or Genius fault occurs the GMR software rejects the faulty data Depending on the configuration entered here input voting may go from three inputs to two inputs to one input or from three inputs to two inputs to the configured default value Vote Adapt Mode Duplex State E 1 3 2 1 0 Low X 3 2 0 High X 1 Average X 2 X 3 Default State X 4 Hold X 5 Min X 6 Max CH_1 CH_2 m paa CH_3 CH_4 mol oneal CH_S CH_6 ee ell K ll i For a4 input 2 output block group the window shows only four inputs Vote Adapt Mode For a Triplex group if voting should go from three inputs to two to one select 3 2 1 0 If voting should go from three inputs to two to the default value select 3 2 0 For a duplex group if voting should go from two inputs to one select 3 2 1 0 If voting should go from two inputs to the default value select 3 2 0 Duplex State For a triplex group the Duplex State determines the vote type when there are two analog inputs present It may be configured as the higher actual input value the lower value or an average of the two For more information see page 4 13 For a duplex group the voted input data can be m an average of the two channels that are present m mid value selection based upon the two input channels that are present with
126. dundancy Hot Standby Hot Standby is selected on Non Voted IO screen of the GMR configuration software Setting Up Other Blocks to Send Multiple Fault Reports Other blocks may also send extra copies of Fault Reports m Inputs only blocks automatically send two Fault Reports to serial busses 30 and 31 with no additional configuration Output and mixedI O blocks configured for CPU Redundancy Hot Standby will send two Fault Reports to serial bus addresses 30 and 31 m If the block is configured in the GMR configuration the GMR software issues an Assign Monitor datagram to cause a block to send the third fault report Summary Table The following table summarizes how many Fault Report messages are sent by blocks configured for different types of CPU Redundancy with or without the Assign Monitor datagram X means the feature is not configurable for that block Page 6 50 describes configuring Genius blocks for Fault Reporting CPU Redundancy Mode Configuration none Hot Standby Block Type GMR noAssign yesAssign noAssign yesAssign Monitor Monitor Monitor Monitor datagram datagram datagram datagram 16 or 32 Ckt DC Sink Sre 3 1 2 2 3 8 Ckt ACGroupedI O X 1 2 2 3 Relay OutputsNO NC X 1 2 2 3 16 Ckt AC Inputs X 2 3 X X 4In 2 Out Analog X 1 2 2 3 Crnt source Analog In X 2 3 X X Crnt source Analog Out X 1 2 2 3 Thermocouple or RTD X 2 3 X X High speedCount
127. dundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 6 Genius Bus Controller Group Configuration Note It is possible that an application may include bus controllers in the PLC racks that are not part of the GMR system Do not include non GMR bus controllers in the GMR configuration The only exception to this is a bus controller pair that is used for global data communications between PLCs Other non GMR bus controllers are included in the Logicmaster configuration only In each PLC GMR Bus Controllers must be installed in the same rack and slot locations The first default rack and slot locations are bus controller A rack 0 slot 2 bus controller B rack 0 slot 3 bus controller C rack 0 slot 4 If those are the actual bus controller rack and slot locations that will be used for this GBC group you can use the defaults and skip directly to the next step Click the mouse on the GBC Group button or cursor to it and press the Return key I GBC Group 2 1 I I GBC Group 2 1 BC Group a nput Group a oe utput Group nonVoted DIO nonVoted IO x RAR ARAAAZ weeweweee wo NDOOARWNES ewe eee eee SENNO ESE This display represents the three bus controllers that would be present in the PLC system for a triple bus They are shown as GBC A GBC B and GBC C If there are fewer bus controllers they can be identified in any
128. e Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 Chapter Installation Information 8 m Genius Bus Connections m Termination Boards m Input Wiring Single Sensor to Three Blocks Triple Bus Three Sensors to Three Blocks Triple Bus Block Wiring for a 16 Circuit Block in an Input Group Block Wiring for a 32 Circuit Block in an Input Group m Output Wiring Block Wiring for a 16 Circuit Four block Output Group Block Wiring for a 32 Circuit Four block Output Group The information in this chapter is intended only to supplement the installation instructions in the Series 90 70 PLC and Genius I O Manuals and datasheets Those documents should be the primary references for installation of any GMR system GFK 0787B 8 1 Genius Bus Connections When planning and installing a Genius bus it is extremely important to follow the guidelines given in the Genius I O System and Communications User s Manual That manual describes correct cable types wiring guidelines bus length bus termination baud rate and bus ambient electrical information In GMR system GMR busses can operate at any baud rate with the following restrictions D All busses ina group must use the same baud rate E Each individual GMR bus must have a scan time of 60 milliseconds or less Bus cable connections to a Genius block ina GMR sy
129. e PLCs Online For comparison this table shows how a block group votes on outputs received from three PLCs when all three are online The block group doesn t use the Duplex Default so it is shown as an X don t care PLCA Output PLCB Output PLCCOutput DuplexDefault OutputState State State State Setting in Block 0 0 0 x 0 0 0 1 X 0 0 1 0 X 0 0 1 1 X 1 1 0 0 X 0 1 0 1 X 1 1 1 0 X 1 1 1 1 X 1 Results of Block Group Voting with Two PLCs Online and Duplex Default Set to 1 If one PLC is offline the outputs from both online PLCs must be 0 for the voted output state to be 0 The voted output is 1 if either of the online PLCs outputs a 1 PLC A Output PLC B Output PLCCOutput DuplexDefault OutputState State State State Setting in Block 0 0 1 0 0 0 1 0 0 1 1 1 0 1 1 1 1 0 1 1 1 0 1 1 1 1 1 1 1 1 1 1 Results of Block Group Voting with Two PLCs Online and Duplex Default Set to 0 If one PLC is offline the inputs from both online PLCS must be 1 for the voted output to be 1 The voted output is 0 if either of the online PLCs outputs a 0 PLCA Output PLCB Output PLCCOutput DuplexDefault OutputState State State State Setting in Block 0 0 0 0 0 0 0 0 0 1 0 0 0 1 0 0 1 0 0 0 1 0 0 0 1 1 0 1 1 1 0 1 3 4 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System User
130. e out isable seconds nable LEa E Saced CPU Type Specify whether the CPU is model IC697CPU788 or 798 On Line Prog Specify whether Online programming will be permitted If this item is set to Yes online run mode stores single word online changes or block edits can be made without shutting down the PLCs See page 7 37 for information about online changes Note online changes are intended for system debug and commissioning only CPUs Specify 1 2 or 3 CPUs in the GMR system Simplex If Simplex Shutdown is enabled a PLC will shut down if it determines Shutdown that it is the only PLC still operating The timeout period before it shuts down is configured as the next item When the PLC shuts down the system it sets its outputs to their default state or last state as configured for each block Timeout If Simplex Shutdown is enabled this selects the timeout period The timeout period may be 0 to 65535 seconds 18 2 hours Watchdog This must be the same value as the watchdog timer in the Logicmaster 90 70 CPU Configuration The default is 200mS Exiting the Window When you complete this screen select OK to return to the System screen When you select OK your entries are saved in RAM and the window disappears If you want to exit the window and reset all fields to their previous content select Close or Cancel instead Chapter 6 Configuration 6 15 Test Interval First configure the interval for autote
131. ed they should be diode ORed power supplies providing common power to all blocks in a group Different groups may use different power sources 8 8 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 Input Wiring continued Block Wiring for 32 Circuit Sink Block in an Input Group DC Sink Block IC660BBD025 eN i eo ae agi re Ee If single sensor it must also be wired to corresponding point on two other input blocks Rar R 2 ma 1 22V to 30V DC l s Genius Bus RA S2 Connections HA SHLD IN Q SHLD out 5V DC ano a22 amp A DC Device 1 A 10 12 Required at each input for Input j 14 Autotesting 1N5400 or equivalent o 6 Q 18 20 22 Output 16 i 24 hg 26 If group inputs are configured for autotesting circuit 16 must be used as an output I If no autotesting is to be done on this group of inputs the input devices must not be wired to Q 30 circuit 16 They must be wired to the power source instead oj 32 If group uses single sensors point 16 must also be wired to corresponding point on two ol 34 other input blocks Q Zener diode required at each powerfeed output for Input Autotesting 1N5400 or equivalent Q OC 3 Q 38 ny Caen Bl 4 2 5 go Device 32
132. ed that after the inhibit input is turned off anI O fault reset be performed which will cause any current I O fault information to be re reported Example Ladder Logic The following example shows some typical program startup logic This is only an example You will probably need to modify the logic shown for your application lt lt RUNG 5 gt gt START OF LD PROGRAM EXAMPLE IL VARIABLE DECLARATIONS PROGRAM BLOCK DECLARATIONS IL START OF PROGRAM LOGIC _ _ _ _ gt END CALL IN_CO CALL FILTER l These Program Blocks represent logic CALL HR_344 routines that are appropriate for the lt lt RUNG 9 gt gt application lt lt RUNG 10 gt gt CALL DIAGNO e lt lt RUNG 11 gt gt MISCOMP SYSFLT CONTINU ERAT el MAN_COM I _ In rung 11 the logic tests for Miscompare and System Fault If both are not 1 initialization continues An optional parallel input MAN_COM in this example can be used to allow a manual continue input to be supplied by an operator Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 GFK 0787B lt lt RUNG 12 gt gt IORESIP IORES _ 4
133. ed that the maximum I O points has been exceed ed 10823 GMR cfg err voted DIN GMR Configuration Module detected that the maximum number of voted digital inputs has been exceeded 10824 GMR cfg err voted AIN GMR Configuration Module detected that the maximum number of voted analog inputs is exceeded 10825 GMR cfg errredundO P GMR Configuration Module detected that the maximum number of redundant out puts is exceeded 10826 GMR cfg err alpha rack GMR Configuration Module detected that alpha inter PLC GBC is in an invalid rack 10827 GMR cfg err alpha slot GMR Configuration Module detected that alpha inter PLC is in an invalid slot 10828 GMR cfg err beta rack GMR Configuration Module detected that beta inter PLC is in an invalid rack 10829 GMR cfg err beta slot GMR Configuration Module detected that beta inter PLC is in an invalid slot 10830 GMR cfg err M sync GMR Configuration Module detected invalid positioning of the M sync area 10831 GMR cfg err R sync GMR Configuration Module detected invalid positioning of the R sync area 10832 GMR cfg err R temp GMR Configuration Module detected invalid positioning of the R temp M sync area 10833 GMR cfg err RA Tint GMR Configuration Module detected invalid positioning of the R autotest interval pointer 10834 GMR cfg err ssu flt act GMR Configuration Module detected invalid system startup fault action 10835 GMR cfg err syc flt act GMR Configuration Module detected invalid startup sync fault action
134. ee types of data you do not want to store When a program is being stored to a new CPU for the first time it is most common to store all data and select Y yes for all three types Field Description ProgramLogic The ladder logic program and L and P data Reference Tables The reference tables for the program except L and P data Configuration The currentconfiguration Note Annotation files nicknames reference descriptions and comment text remain in the folder and are not stored to the PLC Logicmaster 90 70 software identifies external blocks with a unique block type when storing logic to the PLC If the PLC rejects the external block because it is not the proper MS DOS executable file format the software will display an appropriate error message based on an error code which is unique to external blocks Use the cursor keys to select items and type in new selections as appropriate To restore the original selections while editing this screen press ALT A The information to be transferred must fit within the configured boundaries of the PLC for example its register memory size To begin storing press the Enter key The program must be complete and must not contain errors in syntax or any instructions which are not supported by the attached PLC If there are errors the Store operation will be aborted After a successful Store the software displays the message Store Complete If a communication
135. eld short to 24V is interpreted as a trip condition m Typical Normally open Input 24V z A3 es Source Genius Block When a block is configured with a Hand held Monitor as a GMR block its input thresholds change to those listed below Input Voltage InputStatus InputState Source Blocks tristateinputs lt 30 Vac off 0 gt 50 Vde on 1 lt Vae 7V lt VaV shortcircuitfault 1 bi stateinputs lt 30 Vdc off 0 gt 50 Vac on 1 SinkBlocks tristateinputs lt 4V shortcircuitfault 1 gt 7V on 1 lt 50 Vac gt 70 Vac off 0 bi stateinputs lt 50 Vac on 1 gt 70 Vac off 0 Input Filter Time For any circuit configured as a tristate input the Input Filter Time configured for the block using a Hand held Monitor must be at least 30mS Chapter 2 Input Subsystem 2 7 2 8 Manual Input Controls Safety systems often use controls for manual trip and manual inhibit The GMR autotest and fault processing operations are unaffected by such controls A manual trip causes the input to assume the alarm condition For example for a normally energized input the input is open circuit A manual inhibit causes the input to remain in the normal condition For example for a normally energized input the input is held high even if the device is in the Off state These manual controls can be implemented either in hardware or in software
136. enius blocks broadcast their inputs So each block s input data is received by all PLCs on the bus The GMR system software in each PLC then performs input voting and provides the results to its application program If all input data is not available the software follows a configured voting adaptation scheme Details of both discrete and analog input voting are in the PLC chapter In addition to the diagnostics capabilities of the Series 90 70 PLC and Genius I O blocks the GMR system provides autotesting and discrepancy reporting for GMR inputs Genius blocks configured for GMR operation automatically generate three copies of their standard Genius fault report messages They send one copy to the PLC Bus Controller configured with serial bus address 31 one to 30 and one to 29 So all of the GMR PLCs are able to monitor the blocks for Genius diagnostics 2 2 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 GMR Input Groups GFK 0787B The configuration can include as many as 128 16 circuit voted discrete and 256 four input analog input groups The actual I O capacity of the system depends on the CPU type See page 1 9 In an system that has normally energized discrete inputs the following combinations of sensors and Genius inputs can be used with Genius Modular Redundancy m one sensor to three Genius inputs three busses three PLCs m one sensor to two Genius inputs
137. ent GFK 0787B starting at page 7 31 should be observed Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 Appendix Maintenance Override B The information in this appendix is reprinted by permission of TUV Abstract 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 Maintenance Override There are basically two methods used now to check safety relevant peripherals connected to PLCs Special switches connected to inputs of the PLC These inputs are used to deactivate actuators and sensors under maintenance The maintenance condition is handled as part of the application program of the PLC During maintenance sensors and actuators are electrically switched off of the PLC and checked manually by special measures In some cases e g where space is limited there is the wish to integrate the maintenance console to the operator display or to have the maintenance covered by other strategies This introduces the third alternative for maintenance override Maintenance overrides caused by serial communication to the PLC This possibility has to be handled with care and is introduced in this paper Maintenance Override Procedures Connecting to PLC via serial lines is
138. er s Manual March 1995 6 Creating the G_M_R10 Output File The output of the GMR configuration process is a program block named G_M_R10 which can be imported to the application program folder in Logicmaster 90 The Write Output function of the GMR configuration software automatically creates a file named G_M_R10 EXE This is the file required by Logicmaster 90 If the configuration you want to use is not the one currently displayed first use the file utilities of the GMR configuration software to load it into RAM memory Example Previously you created and saved three different configuration files named CONFIG1 CONFIG2 and CONFIG3 as represented below All three files are currently stored on your hard disk A different configuration CONFIG4 is currently in RAM memory Saved i i Configuration Configuration in RAM Files CONFIG1 SAV CONFIG4 CONFIG2 SAV CONFIG3 SAV j N L J At this point you decide you want to use CONFIG3 as the GMR configuration for the application First you need to load CONFIG3 into RAM memory If you wanted to keep the file already in RAM memory CONFIG4 you would need to use the file functions of the GMR software to save it GFK 0787B Chapter 6 Configuration 6 43 6 44 In this example you decide that you don t want
139. er X 1 2 2 3 PowerTRAC X 1 2 2 3 Chapter 5 Diagnostics GMR Autotesting The GMR software automatically performs autotesting on discrete inputs and outputs that have been configured to be autotested Analog inputs and outputs are not autotested by the GMR software GMR autotesting can be used in a system with one two or three PLCs Autotest Sequence GMR autotesting goes on at the configured interval 0 to 65535 minutes during system operation Each PLC in turn controls the sequence PLC A PLC B PLC C 1 Autotest GMR inputs 1 Autotest GMR inputs 1 Autotest GMR inputs 2 Complete GMR 2 Complete GMR 2 Complete GMR output autotest output autotest output autotest 3 Pass autotest control 3 Pass autotest control 3 Pass autotest control to next PLC here B to next PLC here to next PLC here A If one or two of the PLCs are not available autotesting continues with the remaining PLC s During its turn as the autotest master a PLC tests all input and output groups that are set up for autotesting These may include the following types of groups Input groups non voted 1 block simplex 1 block duplex 2 blocks triplex 3 blocks Output group 4 block redundant 5 4 Genius Modular Redundancy Flexible Triple Modular Redu
140. er of bus controllers supporting GMR functions in a GMR system must be the same in each PLC Other non GMR bus controllers can be added to an individual PLC configuration All Genius bus controllers that are included in the GMR system must be assigned serial bus addresses device numbers as follows PLCA bus address 31 PLCB bus address 30 PLCC bus address 29 For example if the system consists of three PLCs with two triple bus GMR I O subsystems each PLC would require six bus controllers All six in PLC A would have to be configured at bus address 31 all six in PLC B at bus address 30 and all six in PLC C at bus address 29 PLCA PLC B PLCC ssa saseee Bases GFK 0787B Chapter 6 Configuration 6 45 Creating and Copying the PLC Configuration The recommended method of completing the PLC configuration is described below A Create a Folder for PLC A PLC B and PLC C In this discussion PLC A is considered to be the PLC using serial bus address 31 PLC B is the one that uses serial bus address 30 and PLC C is the one that uses 29 B Select the folder for PLC A With the GMR configuration printout as a reference complete its Logicmaster configuration Summary steps are described on the following pages C Use the Copy Folder feature of the Logic
141. erride Handling hard wired Application Program _ Waning to switch the Operator serial line e g Modbus serial line Distributed Engineering Control System Workstation DCS Version History This version 2 2 supersedes the version 2 1 from 24 Jun 1994 GFK 0787B Appendix B Maintenance Override B 3 GFK 0787B A Alarm and Fault contacts 6 25 5 28 7 21 Analog blocks Analog O addressing Analog inputs configuring memory for 6 18 configuring references for 6 33 discrepancy 5 13 maximum minimum Application program inhibiting 4 4 storing to PLC updating on SNP network 1 3 Asynchronous autotest 4 18 6 29 Autotest 1 7 4 18 6 29 configuring for inputs configuring for outputs discrete inputs fault i sequence 5 4 B Block I O type configuring Bus connections 8 2 Bus Controllers configuration for 6 25 ns extra for communicatio model numbers number fi 4 C Cancel I O Shutdown control bit Channel Shorted fault 5 28 Circuit O type configuring forI Oblock 6 52 Command flags 7 13 Communications between PLCs Configuration 6 1 Index CPU 6 15 Genius blocks GMR software GMR create or select 6 10 Logicmaster 90 6 45 overview storing to PLC Control bits Cancel I O Shutdown CPU model numbers 1 2 CPU performance data sweep impact of Genius I O and GBCs 4 6 CP
142. ess 30 or C from the PLC using serial bus address 29 GFK 0787B User s Manual March 1995 Configuring the Output Subsystem for a Bus Controller Group Next configure the output subsystem for that bus controller group Select Output Group from the menu BC Group nput Group gt utput Group gt 6 Point Blocks 2 Point Blocks Repeat the following procedure for each group in the output subsystem Note It is possible for a bus to include output blocks that are not part of the GMR system Do not include non GMR blocks in the GMR configuration Non GMkR blocks are included in the Logicmaster configuration and in the Genius block configuration however Select either 16 circuit Blocks or 32 Circuit Blocks from the menu An additional configuration screen appears to configure the GMR features for that group Auto ests 5 On this screen use the tab key to move from item to item ID Enter a name or a description of up to 12 characters such as out group 1 Start Q Enter the starting Q Input Table reference for the group all blocks in the group will have the same Output Table reference addresses The allowable reference ranges are 0001 to 0080 788 CPU 0001 to 2048 789 CPU Duplicate addresses are not allowed within a GBC group You will not be permitted to continue until you have entered a unique address SBA Enter a serial bus address also referred to as the device number from 0 to 28
143. esting should be Synchronous the default or asynchronous Asynchronous Autotesting allows the input autotest to continue executing on other blocks in a group which are not affected by the fault It can be selected if A redundant discrete input devices are used the power feed outputs of each block ARE NOT wired together B non redundant simplex discrete input devices are used with isolation between blocks Synchronous Autotesting synchronous input autotesting must be selected if non redundant simplex discrete input devices are used without isolation between blocks I E the power feed outputs of each block ARE wired together With Synchronous Autotest Loss of Block faults or certain autotest faults may prevent the autotest from continuing to execute for that input block group and thus cause a I O shutdown for the inputs in the group See page 4 18 for more information GFK 0787B Chapter 6 Configuration 6 29 1 Loss of a block within the group IE any failure which causes the block to no longer communicate on the Genius Bus such as loss of power 2 Autotest failure of the power feed output point Q16 of any of the blocks in a group For discrete output groups there are also two types of faults which may prevent the output autotest from continuing to execute for that output group and thus cause an I O shut down for the outputs in the group 1 Loss of a block within the group LE any failure which causes the bloc
144. faults of any of the types listed this is the actual address of the start point to be accessed For example to see if there was an output point fault for Q00015 you would enter the value 15 for START the end offset within the area of information specified in the table the location where the requested information will be placed after it has been obtained the location where the error code will be placed The error code is generated if the CALL function fails to execute successfully The table on page 7 26 lists error codes may be be read in this location Y3 dummy not used 7 24 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 Data Table Numbers Table Contains Range for Start Value Range for End Value 11 Digital Input Discrepancy faults Greater than or equal to the Less than the start plus the first digital input address for A maximum digital input ad B or C dress for A B or C 14 Digital Input Autotestfaults start gt 1 end lt 12228 end lt start 15 Digital Input Genius faults start gt 1 end lt 12228 end lt start 16 Digital Input Point faults start gt 1 end lt 12228 end lt start 21 Digital Output Discrepancy faults PLC A start gt 1 end lt 12228 end lt start 22 Digital Output Discrepancy faults PLC B start gt 1 end lt 12228 end lt start 23 Digital
145. from the voted value the PLC automatically places a message in the I O Fault Table where it is available to the Logicmaster 90 software and the application program logic Discrepancy is calculated for engineering units values inputs Two distinct discrepancy bands are provided threshold and limit m The threshold discrepancy occurs where an A B or C engineering units input value exceeds a specified percentage of the voted value For example if channels A B and C report 91 100 and 111 respectively the GMR software selects 100 as the intermediate value If the threshold discrepancy for the input is set to 10 this yields 90 and 110 as the upper and lower threshold discrepancy values In this example channel A is within the threshold band but channel C is outside and is discrepant m The limit discrepancy occurs where an engineering units input exceeds a given percentage of the full scale deflection of the input For example if channels A B and C report 9 10 and 15 respectively then the GMR software selects 10 as the intermediate value If the limit discrepancy is set to 10 of a 200 full scale deflection 20 in this case then no limit discrepancy is reported An analog discrepancy is reported where the limit discrepancy and the threshold are both exceeded Up to two of the three analog inputs may be discrepant at any given time Discrepancy faults are latched but can be cleared by performing an I O Fault Reset see chapter 7
146. g Discrepancy Reporting When the GMR software compares analog input data it checks each channel against discrepancy limits provided as a part of the configuration for that input group Any channel that varies by more than a configurable percentage from the intermediate value is reported Discrepancy signals are filtered for a configurable time period to eliminate transient discrepancies caused by timing differences Non Voted Analog Inputs in GMR Input Groups If a system includes analog inputs that do not require redundancy they are usually located on individual analog blocks However they can also be located on channels of blocks in a GMR analog input group that do not require redundancy For example a group of three 6 channel analog input blocks might use only four voted inputs on each block That would leave inputs 5 and 6 available for connection to other sensors not requiring voting Non GMR Analog Blocks Individual analog blocks can be used as input blocks or combination input output blocks All of the operating features of these blocks are available Individual non voted analog blocks can be included in the GMR configuration Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 Chapter Output Subsystem GFK 0787B 3 This chapter describes GMR output subsystem m Overview m Types of Blocks in the Output Subsystem GMR Output Handling Output
147. g checks the ability of the input electronics to recognize both the On and the Off state During each Input Autotest some inputs are forced to the Off state by de energizing the power feed output and some are forced to the On state via the Genius block electronics See page 5 6 for more detailed information Input autotesting also detects circuit to circuit shorts m Note blocking diodes are required to use the Input Autotest feature These diodes are in addition to a Zener diode that may be added for line monitoring 24V Optional Zener diode for line monitoring a Source Genius D Block See page 5 6 for more detailed information about input autotesting Also see pages 8 3 through 8 9 for Autotest wiring information Calculating Voltage Drops on Tristate Inputs It is important to consider the field wiring runs required for devices configured as tristate inputs Devices that are powered by 24V DC will have a voltage reducing component inserted at the field device to provide an input threshold range for three states The table on the next page shows appropriate ranges Wiring runs can reduce the voltage at the input block terminal further to an inoperable level depending on the length conductor and gauge Isolation diodes placed before the terminal on the input will also drop the voltage Most applications do not have limitations created by these factors However to ensure that all input state operations are indic
148. gram Folder that contains the application program at any time 1 From the Librarian menu select Import F3 LIBRARIAN FUNCTIONS FZ List Contents of Library F3 Import Library Element To Folder F4 Import Library Block To Folder and Redefine Variables F5 Export Folder Element To Library Fo Add Element To Library F CreatevEdit Reference Offset Templates 2 Inthe upper window on the Import screen select G_M_R10 from the files available in the Librarian IMPORT LIBRARY ELEMENT TO FOLDER RENAME TO CURRENT LIBRARY D LM9O P70_LIB ANNUN DIAGNO FIX G10516 G_M_R10 H2 FLOW N SIG J1024 MR513 CURRENT FOLDER D LM9ONGMRPROG AI FLT_CON MOV SID TABLST USER_IF G_M_R01 GM R02 GM R03 GM R06 GM ROS G M_ R09 GMRIO GMRII GMRI2 GMRI4 GMRIS GMR_ lt lt Use cursor keys to select a library element Press Enter to start Import gt gt lt lt Use PgUp PgDn to scroll library Use Ctrl PgUp Ctrl PgDn to scroll folder gt gt The lower window lists the blocks currently in the selected folder Be sure you want to import the element before you continue If you abort an import operation it is not always possible to completely restore the folder to its original contents 3 DO NOT RENAME G_M_R10 4 Press the Enter key to begin the operation 5 The original GMRxxyy folder contains a null G_M_R10 Program Block This causes the prompt Import G_M_R10 Replacing Element in Folder
149. h results and with one of the three PLCs is offline Results of Block Voting with Three PLCs Online For comparison this table shows how a block votes on outputs received from three PLCs In this case the block doesn t use the Duplex Default so it is shown as an X don t care PLCA PLCB PLCC Duplex Output Output Output Output Default State State State State Setting in Block 0 0 0 X 0 0 0 1 X 0 0 1 0 X 0 0 1 1 X 1 1 0 0 X 0 1 0 1 X 1 1 1 0 X 1 1 1 1 X 1 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System User s Manual March 1995 GFK 0787B Results of Block Voting with Only Two PLCs Online 6 In the two tables below PLC C is shown as offline but it could be either of the other two instead Using 0 as the Duplex Default state means that when only two PLCs are online the voted output state will be 0 if either PLC sets it to 0 It will not be 1 unless both online PLCs set it to 1 PLCA PLCB PLCC Duplex Voted Output Output Output Default Output State State State Setting in State Block 0 0 0 0 0 1 0 0 1 0 0 0 1 1 0 1 Similarly using 1 as the Duplex Default state means that when only two PLCs are online the voted output state will be 1 if either PLC sets it to 1 It will not be 0 unless both of the PLCs set it to 0 PLCA PLCB PLCC Duplex Voted Out
150. haracteristics of the blocks themselves It is during Genius block configuration that the redundancy mode of blocks is selected This is particularly relevant to the operation of output blocks The four possible choices for redundancy mode are A GMR B Hot Standby PLC Redundancy C Duplex PLC Redundancy D No PLC Redundancy Blocks in an output group must be set up for GMR mode This changes the operating characteristics of the block as described Individual output blocks or combination I O blocks can be set to any of the latter three modes above Block operation in these modes is described in the Genius I O System User s Manual and in the Genius Discrete and Analog Blocks User s Manual If an individual block is configured for Hot Standby redundancy mode it can be included in the GMR configuration as a Non voted Discrete Group Blocks that are set up for Duplex PLC redundancy or no redundancy are not autotested They operate in the same manner as Duplex blocks in a non GMR system GMR Mode Configuring a block for GMR mode changes its operating characteristics as described below m GMR mode supports non redundant outputs with or without pulse test and redundant outputs with or without output autotest m To prevent false Failed Switch diagnostics during switching transitions detection of Failed Switches is delayed for one second m For the 16 circuit DC block detection of No load faults is delayed for one second Th
151. he needs of the application If an input block will also have outputs and those outputs will be pulse tested the Input Filter Time must be set at a minimum of 20mS This is necessary because the power feed output the output supplying power for autotesting input circuits will also be pulse tested and could cause false inputs at filter times under than 20mS On 16 circuit blocks any circuits configured as tristate inputs must have an Input Filter Time of at least 30mS On non voted blocks in the system circuits can be any mix of inputs and outputs On blocks in output groups all circuits should be configured as outputs GMR output blocks must not be configured as outputs with feedback blocks GMR fault monitoring provides this feature On blocks in input groups GMR input circuits on 16 circuit blocks only can be configured as regular inputs or tristate inputs They should be configured as tristate inputs to permit short circuit detection In a system with normally energized inputs short circuit represents Fail to Danger mode Short circuit detection requires the installation of a zener diode in series with the field switch See page 2 7 for details If the block will be set up for Input Autotest circuit 16 must be configured as an output regardless of whether it is a 16 or 32 circuit block Fault reporting must be enabled on all GMR block circuits The 16 circuit and 32 circuit DC Genius blocks will
152. he original unvoted input data along with any non GMR inputs that have been included in the input subsystem Field Input Data Single Input Pro vided to Applica Input A opu 0 M tion Logic 0 0 Input B 1 GMR Software Performs Input C 2 out of 3 Voting Discrepancy Reporting for GMR Inputs For GMR inputs if there is a discrepancy between the original input data for an input and the voted input state the GMR software automatically places a message in the I O Fault Table where it is available to the Logicmaster 90 software and the application program logic This is also described in more detail in the PLC chapter Fault bits are also set for input discrepancies These fault bits are available for use in the application program for further annunciation or corrective action Discrepant signals are filtered for a configurable time period to eliminate transient discrepancies caused by timing differences Chapter 2 Input Subsystem 2 5 2 6 Input Autotest for GMR Inputs During GMR configuration input autotesting can be individually turned on or off for each input in an input group The GMR software will automatically test the selected inputs for the ability to reach the alarm state The ability to diagnose short circuits on inputs depends on whether the circuit is set up as a bistate or tristate input and on whether the block itself is configured for GMR mode using the Hand held Monitor m Autotestin
153. his is done by turning on the GMR control bit M12258 IORES Perform I OFault Table Clear Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 Output Wiring for a 32 Circuit 4 Block Group continued Output Load Considerations for 32 Circuit 4 Block H Pattern Redun dant Output Groups Minimum load 1 0 milliamp Maximum load 0 5 Amp Maximum inrush current 4 Amps for up to 10 milliseconds Maximum total load for block group 16 Amps at 35 degrees C Output Off Leakage Current 20 microamps For Outputs to be Autotested Minimum pickup time Greater than 1 millisecond Minimum dropout time Greater than 1 millisecond Check the characteristics of each output device against the list above to verify that it can be autotested and or used in the 4 block output group Otherwise critical output loads could be adversely affected Output Autotest and Pulse Testing If output circuits are to be autotested the loads will be subject to pulse testing which is an integral part of the output autotest sequence Pulse testing verifies the ability of a block s outputs to change state with a short pulse that is not intended to affect the actual load Pulse testing occurs whether the output is in the On state or in the Off state by executing one of two tests These are the pulse ON OFF ON test and the pulse OFF ON OFF test Outputs that are to be autotested must be able to withstand
154. iagnostics 5 7 Operation of the Discrete Output Autotest The PLC that is presently the autotest master informs the other PLCs if any which autotest group it is about to test All PLCs read the diagnostic status of all blocks in the group to be tested and will ignore any subsequent faults that may occur in that group The autotest master PLC reads the current output state and force state for each circuit in the output group Then the autotest master pulse tests the blocks in the output group details of pulse test operation are explained on page 5 10 The test sequence is described below 1 For the 4 block output group the autotest master overrides the normally deenergized outputs on block C to ON Te Block C normally deenergized c outputs overridden ON TaT is 2 The autotest master pulse tests block B Any faults on block B are noted l gt B Block B Pulse tested i cs I Block C outputs still c overridden ON T Load 3 If any outputs on block B configured as normally energized logged a Failed Switch when pulsed the master overrides them to OFF Normally energized B outputs with Failed Switch A are overridden OFF g as Block C outputs still C D overridden ON 5 8 Genius Modular Redundancy Flexible Triple Modular Redundant TMR Sy
155. iated shutdown timer All input blocksreturn the value 0 1000h Configuration textdescription unused unused GFK 0787B Chapter 7 Programming Information 7 25 Error Codes for GMR Diagnostics The following error codes may be generated by the GMR diagnostics routine see page 7 24 Code Meaning 10908 Anattempt was made to read anI O shutdown timer for an invalid block 10909 Anattempt was made to read all I O shutdown timers for an invalid GBC 0900hex User I F No Error 0902hex User I F Incorrect GMR software version 0903hex User I F Invalid table number 0904hex User I F Unsupported table number 0905hex User I F Invalid table offset 0906hex User I F Invalid destination address 0907hex User I F No FaultContacts 0908hex User I F Bad Block Location 0909hex User I F Bad GBC Location 09FFhex User I F Disabled 7 26 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System User s Manual March 1995 Programming for Global Data Ina Series 90 70 PLC Genius system Global Data is data that is automatically broadcast by a PLC bus controller each bus scan The GMR software uses this Global Data capability as the vehicle for exchanging system information between the PLCs Each PLC provides 8 words of system data to the other PLCs as Global Data Because Global Data messages can be up to 64 words in length up to 56 additional words
156. ications with PLC B has failed on bus a 10213 Comms Fail PLC C bus a Communications with PLC C has failed on bus a 10221 Comms Fail PLC A bus b Communications with PLC A has failed on bus b 10222 Comms Fail PLC B bus b Communications with PLC B has failed on bus b 10223 Comms Fail PLC C bus b Communications with PLC C has failed on bus b 10241 Big err rate PLC Aona PLC detected a high data CRC failure rate communicating with PLC A on bus a 10242 Big err rate PLC A on b PLC detected a high data CRC failure rate communicating with PLC A on bus b 10243 Big err rate PLC Bona PLC detected a high data CRC failure rate communicating with PLC B on bus a 10244 Big err rate PLC B onb PLC detected a high data CRC failure rate communicating with PLC B on bus b 10245 Big err rate PLC C ona PLC detected a high data CRC failure rate communicating with PLC C on bus a 10246 Big err rate PLC Conb PLC detected a high data CRC failure rate communicating with PLC C on bus b 10251 Invalid Switch Case GMR2 software detected an illegal internal condition 10301 Unauthorized GMR access Fault Processor Module was invoked with incorrectpassword 10302 Incorrect version number Fault Processor Module was invoked with incorrect version number 10303 Invalid call number Call number was invalid 10305 Invalid GMR Pointer The supplied diagnostics pointer is out of range for the required memory type 10306 Invalid Block Size Incorrect block size was specified 10307 Invalid Digital Address In
157. iew Genius Modular Redundancy has been developed for use in systems that have static or nearly static I O under normal operating conditions The system may have Normally on inputs with normally energized outputs as in emergency shutdown systems Normally off inputs with normally deenergized outputs as in fire and gas detection systems Genius Modular Redundancy provides high degree of self test and monitoring with diagnostics fault tolerance support for centralized or fully distributed systems Scalable voting 2 out of 3 2 out of 2 1 out of 2 or simplex The example that follows illustrates how the GMR input subsystem PLC subsystem and output subsystem combine to provide a high availability high reliability system PLC Subsystem PLCA PLC B PLC C y duo Input Subsystem Output Subsystem GFK 0787B Chapter 1 Introduction 1 5 Input Subsystem In a GMR system the basic elements of an input subsystem are single or triple sensors connected to triple Genius blocks Each block is on a different communications bus shown below as A B and C For this example there are triple input sensors which are normally on However one of these input sensors is off Cc
158. ime you select Save the software automatically displays the Save As screen so you can select a name for the file GMR configuration files are stored in the currently selected directory By default this is the directory in which the GMR configuration utility software was installed but you can change it before saving the file as explained on the next page GFK 0787B Chapter 6 Configuration 6 11 6 12 Changing to Another Directory Use the Change Directory function if you want to access another directory Additional directories must be created in DOS eu Systen pen F3 1 at As FZ Directory ree Drives Change ir ELA l lose hdir i evert J Select Chdir to change the directory Select Revert to return to the previous directory If you are using a mouse you can click on the elevator bar at the right of the Directory Tree to scroll through the directory structure By default the GMR configuration software uses the directory in which the GMR configuration utility was installed to save your configuration file s However can use other directories if you prefer If you have made changes in this window but want to exit without saving your changes you can click on the close button in the upper left corner of the window Closing a Configuration File without Saving It If you want to exit a configuration without saving it select Close from the File menu Genius Modular Redundancy Flexible Triple Modul
159. in the application program the High Alarm and Low Alarm contacts These contacts indicate when an analog reference has reached one of its alarm limits Alarm contacts are not considered to be fault contacts Alarm contacts for a GMR system are the same as for a conventional system GFK 0787B Chapter 7 Programming Information 7 23 Reading GMR Diagnostics The application program can obtain the following diagnostic information from the GMR system software Autotest faults m Discrepancy faults m Genius faults m Point faults m Analogalarms This information is described in detail in the Diagnostics chapter To obtain this information the application program should CALL an external Program Block named G_M_R09 Information is read only it cannot be written to Call G_M_R09 Table X1 Y1 Dest Start X2 Y2 Error End X3 Y3 Dummy Each call to G_LM_RO9 can access one type of data as listed in the table on the next page Data is returned in bit format The data length is selected by the Start and End entries Parameters for the Call Function You must specify the following information X1 Table X2 Start X3 End Y1 Destination Y2 Error a number representing the type of data to be read For example to read Digital Input Discrepancy faults you would specify item 11 the start offset within the area of information specified in the table For discrete point faults input or output
160. ing additional external components to increase the load The inrush current for this relay is low enough that the Overload can be left enabled However this relay with no external components does exhibit very minor chatter during the output autotesting although its contacts do not begin to open A flyback diode wired across the coil eliminates all the chatter and is also recommended to reduce noise on the 24VDC power lines GFK 0787B Chapter 8 Installation Information 8 13 Output Wiring for a 32 Circuit 4 Block Group 32 Circuit 4 Block Output Group P cja aja e c a a a P c a ala o S P B B B o o S P B B B o o S P B B B o ujc c c ulc c c c c c A B C A BIC A B C kd Block A Block B Source Source i a32 e a32 Bus A Output 1 Low Output32 7 Low Bus C Block C Block D Sink Sink a32 Q32 m Allblocks in an output group must have 32 circuits m Block D must be connected to the system through bus A or bus B not bus C The bus selected must be the one specified in the GMR configuration m Unused voted outputs cannot be used as non voted I O points 8 14 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0
161. ing operations are unaffected Hardware control usually consists of switch contacts applied to the output circuit as shown below for a normally energized output 24V Manual Source Override aaa Genius Bone a Block Manual Trip D Input X LOAD Sink Genius Block Manual Doe Input Override 0 VDC In this circuit operation of either the trip or override switch can cause no load faults state faults and autotest faults to be generated In the GMR system fault reporting can be modified to suppress no load faults and state faults by wiring additional inputs that reflect the states of the manual override and manual trip input switch to the GMR system The GMR system then takes these into account before reporting faults Use of manual controls does not affect fault reporting for Short Circuit Overtemperature Overload or Discrepancy faults see chapter 5 Monitoring Manual Output Controls Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 Redundancy Modes for Output Blocks GFK 0787B There are three separate configuration processes for a GMR system GMR configuration which supplies parameters used by the GMR system software m PLC configuration which is performed as usual for a Series 90 70 PLC system using the Logicmaster 90 software m Genius block configuration which sets up the operating c
162. ing to the PLC from the Programmer Use the Store function to copy program logic configuration data and or reference tables from the programmer to the PLC The Store function copies the program which remains unchanged in the programmer If the PLC program name is not the same as the folder name the Store function clears the program from the PLC The selected data is then stored from the new program folder If the function is password protected in the PLC you must know the password in order to use this function Note In the configuration software only the configuration may be stored No operations on program logic or tables may be performed In RUN MODE STORE you can only store program logic under these conditions 1 Only blocks that have been changed are stored 2 The old program executes until the blocks are completely stored then the new program begins executing in a bumpless manner 3 The data sizes for L and P are based on the highest references used in each block regardless of whether the block is called L and P data is increased as these references are programmed If a reference to L or P is deleted the new smaller size is calculated when the folder is selected Interrupt declaration changes cannot be made There must be enough PLC memory to store both old and new program blocks Timed or event triggered programs cannot be added or deleted wo GO OTe Control information scheduling mode I O specifi
163. input value it will generate a fault that must be cleared by the application program For example if the physical inputs for a channel were 9 10 and 15 and the full scale deflection were configured at 200 with a limit discrepancy of 10 the voted input would be 10 and all three inputs would be within the discrepancy limit of 20 and no fault would be reported Analog Discrepancy Thresholds and Limits Threshold Discrepancy Discrepancy Threshold Discrepancy Genius Modular Redundancy Flexible Triple Modular Redundant TMR System of Reading Value of Reading a Negative Positive z 3 gt lll re ees AI mE Voted Limit Discrepancy gt of FSD NOTE Both a Threshold Discrepancy and a Limit Discrepancy must exist for a input channel before an Analog Input Discrepancy is logged in the fault table Bus Connects a triplex group connects to all three busses so no entry is needed for Bus Connects For a duplex or simplex group specify the bus connections as explained below For a duplex group configure the two busses the group is connected to A from the PLC using serial bus address 31 and B from the PLC using serial bus address 30 or B and C the PLC using serial bus address 29 or A and C For a simplex group configure the bus the group is connected to A from the PLC using serial bus address 31 B from the PLC using serial bus addr
164. int Fault Enable F4 from the CPU Configuration menu B Change the Point Fault Reference setting from DISABLED to ENABLED Programming for I O Shutdown When the GMR system diagnoses a discrete I O fault it logs the appropriate faults in its fault tables and set the appropriate fault contacts For certain types of discrete I O faults the system allows a predefined amount of time for the problem which has caused the fault to be repaired If it is not rectified within this period of time an I O shutdown of the I O which corresponds to the block s occurs unless I O shutdown is disabled by the cancel I O Shutdown control bit M12265 I O shutdown is defined as setting the affected I O to its safe state For more information about I O Shutdown please refer to page 4 18 To be aware of a pending I O Shutdown monitor Status Bit M12244 IO_SD To completely prevent an I O Shut Down from occurring set Control Bit M12265 SD_CAN Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 Programming for Fault and Alarm Contacts GFK 0787B The GMR system software can optionally utilize the Fault and Alarm contacts capability of the Series 90 70 PLC to make fault and alarm information available to the application program logic Conditions that cause Fault and Alarm contacts to be set are described in the Diagnostics chapter Programming for Fault and Alarm contacts is explained
165. ired to corresponding point on two other input blocks as 1 ev to 56V DC 2 s Genius Bus l s2 Connections HA SHLD IN sHLo out DC a A l 2 Q 3 i Required at each input for Input Tristate input requires par Autotesting 1N5400 or equivalent allel zener diode voltage 5 rating 6 2V Ol amp Zener should be wired at If group inputs are configured for S 7 the input device autotesting circuit 16 must be used as an output 12 h Use of such super If no autotesting is to be done on this group of 9 vised inputs is optional inputs the input devices must not be wired to cir me 9 cuit 16 They must be wired to the power source lt x instead 1 e If group uses single sensors point 16 must also be Q Ji wired to corresponding point on two other input O 12 e block L lt i A Diode required at each power feed output for input autotesting 1N5400 or equivalent Q 14 Typical for each of up to 15 inputs 15 lt o gt QO 16 DC 4 ge eS S a Connection if no points on the Ovpc Z block are to be autotested pig fe Ground must disconnect output 16 m In three block input group each block is connected to one bus of three m Ifan input is wired for tristate operation the circuit LED glows dimly when the input off m If redundant power supplies are to be used they should be diode ORed power supplies providing common power to all block
166. is prevents No load faults being falsely reported during switching transitions m Operation of Block OK LED is modified For the 16 circuit DC block the Unit OK LED does not indicate No load faults when the block is in GMR mode This is necessary since blocks may share output loads m Modified fault reporting In GMR mode blocks automatically report faults to bus controllers at serial bus addresses 29 30 and 31 Chapter 3 Output Subsystem 3 9 Hot Standby Mode Individual blocks can be included in the output subsystem as GMR blocks Hot Standby blocks or non GMR blocks There are significant differences in block operation between these three operating modes Operation of GMR output blocks and non GMR blocks is explained elsewhere in this chapter Hot Standby mode is a type of Genius redundancy that can be used with or without GMR Basic Hot Standby Mode Operation In basic Hot Standby mode without GMR blocks receive outputs from two PLCs but they are normally controlled directly by the PLC at serial bus address 31 If no output data is available from bus address 31 for a period of three bus scans the outputs are immediately controlled by the PLC at bus address 30 If output data is not available from either 30 or 31 outputs go to their configured default or hold their last state The PLC at bus address 31 always has priority so that when 31 is online it always has control of the outputs
167. its outputs are enabled 4 Each PLC compares its initial program checksum with those of the other PLCs If they do not match the PLC may as configured either stop or keep running The next table compares the effects of checksum mismatches with the PLC configured to allow or reject online program changes 5 Each PLC compares its initial GMR configuration checksum with those of the other PLCs If they do not match the PLC stops After successful initialization when the application program is running the PLC will continuously compare its program checksum against the initial program checksum and if they do not match the PLC will as configured either stop or keep running Note that if a synchronizing PLC detects that an online PLC has gone offline during synchronization it attempts to restart data synchronization with the other PLC If the other PLC is not online the synchronizing PLC will flag that synchronization is not possible and halt 6 PLCC which uses serial bus address 29 sends an AssignController datagram to all blocks and also sends an Assign Monitor datagram to the blocks configured for Hot Standby mode to ensure correct operation with three PLCs If this function does not complete successfully the GMR software places a GMR System Initialization fault into the PLC Fault Table This fault can be configured to stop initialization and halt the PLC or allow it to continue 7 PLCB or PLC C initializes da
168. ject to pulse testing which is an integral part of the output autotest sequence Pulse testing verifies the ability of a block s outputs to change state with a short pulse that is not intended to affect the actual load Pulse testing occurs whether the output is in the On state or in the Off state by executing one of two tests These are the pulse ON OFF ON test and the pulse OFF ON OFF test The actual pulse width and the number of times a point is tested depend greatly on its configuration state ON or OFF and the type of load or absence of load on the point So output circuits that are to be autotested must be able to withstand On and Off pulse times that are discussed below Each output device s characteristics should be checked against the list above to verify that it can be autotested and or used in the 4 block output group The following Pulse Test descriptions refer to Pulse Test operation of a block configured in the GMR mode only OFF ON OFF Test The first ON pulse is for about 1 7mS During this time if the No Load diagnostic is enabled the current data is checked and recorded After this time the test turns the point Off and the diagnostic volts and current data if No Load is enabled are checked If the correct voltage and or current data is NOT reported the time constant is increased and the process repeats If the correct voltage and or current data is reported after any of the pulses the test is passed and no further pul
169. k to no longer communicate on the Genius Bus such as loss of power 2 Output autotest failure detected of a type which could potentially prevent a normally energized output from being tripped off An example is the short of a source block output to 24 Vdc After completing the selections for Autotest select OK Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 6 Vote Similarly select which Voting Adaptation method will be used for each Adaptation circuit Vote Adapt Mode E 3 2 1 0 X 3 2 0 Duplex State X 1 0 X 2 pee X 3 X 4 Default State X15 Hold X 6 40 0 X 7 CA X 8 X 9 HotStandby X 10 No X 11 Yes X 12 X 13 X 14 X 15 K X 16 l Vote Adapt Mode Specify the manner in which the PLCs should perform voting adaptation During operation if a failure discrepancy fault Autotest fault or Genius fault occurs the GMR software will reject the faulty data and perform voting adaptation as configured here For a triplex group if input voting should go from three inputs to two inputs to one input select 3 2 1 0 If voting should go from three inputs to two inputs to the default state select 3 2 0 For a duplex group if input voting should go from two inputs to one input select 3 2 1 0 If voting should go from two inputs to the default state select 3 2 0 For a simple
170. l and recommissioning Regulations or procedures for the use of servicing and repair of the system with regard to the application must be available as a part of the operational documents All GE Fanuc manufactured components may be used in the non safety relevant portion of the system if appropriately de coupled from the safety relevant portion of the system Specifically approved hardware components for the safety relevant portion are Catalog Number Firmware Description Revision Level 1C697BEM711J n a Bus Receiver 1C697BEM713F n a Bus Transmitter IC697BEM731N 4 8 Genius Bus Controller IC697CHS790D n a 9 Slot Rack IC697CPU788DA 5 50 GMR CPU 100 Triplex voted I O IC697CPU789DA 5 50 GMR CPU 2K Triplex voted I O IC697MEM735D n a Expansion memory module 512KB IC697PWR711CX n a PowerSupply 120 240Vac 100 Watts IC660BBA023K 1 4 Genius Thermocouple Input Block 24 48Vdc Power 6 in IC660BBA021K 1 1 Genius RTD Input Block 24 48Vdc Power 6 in IC660BBA106K 1 0 Genius Current Source Analog Input Block 115Vac 125Vdc 6in IC660BBA026K 1 0 Genius Current Source Analog Input Block 24Vdc 6in IC660BBA024K 1 8 Genius Current Source Analog I O Block 24 48Vdc 4in 2out IC660BBD020M 3 6 Genius Source I O Block 16 circuit 24 48Vdc IC660BBD021M 3 6 Genius SinkI O Block 16 circuit 24 48Vdc IC660BBD024N 3 7 Genius Source I O Block 32 circuit 12 24Vdc IC660BBD025N 3 7 GeniusSinkI OBlock 32circuit 5 12 24Vdc Analog input blocks that are used in
171. l autotesting and discrepancy reporting features of the GMR software Standard Genius diagnostics which are covered in other books are not described in detail here Each PLC provides a full range of fault table and program access to fault information Input Diagnostics m GeniusDiagnostics Line fault a feature of the 16 circuit DC blocks To report line faults an input must be configured for tristate operation and installed as explained on page 5 14 For blocks in GMR mode a line fault represents a short circuit fault on the field wiring For blocks in any other mode a line fault represents an open circuit fault in the field wiring AutotestDiagnostics for discrete inputs configured for autotesting autotesting determines whether inputs can attain their opposite state alarm state and checks for channel to channel shorts m DiscrepancyReporting between the raw input data from each bus and the corresponding voted inputs Output Diagnostics m GeniusDiagnostics No loadfault For 16 circuit blocks only individual outputs can be configured to enable or disable reporting No load faults The minimum load current required to assure proper no load reporting is 100mA not 50mA as it would be for a block not used in a GMR group For an individual block If outputs are On with no output load no load fault reports may be generated at any time except during a Pulse Test If outputs are Off with
172. l can be adjusted in each CPU through the application program by varying the value in the autotest interval register The system allows for a total maximum time of 24 hours between a fault occurring and the resultant I O shut down when the autotest interval is set to 8 hours Examples The first example shows the I O Shutdown sequence when the autotest interval is 3 hours Hours 0 1 3 6 9 1011 13 14 24 A A fault occurs just after the autotest interval at PLCA begins B PLCA executes the autotest and detects the fault then starts the 8 hour shutdown timer The message Shut down in 8 hours is logged in the fault table The I O Shut Down in Progress status bit M12244 is set in each PLC The autotest master function passes to PLCB C PLCB executes the autotest and detects the fault then starts its 8 hour shutdown timer The message Shut down in 8 hours is logged in the fault table The autotest master function passes to PLCC Chapter 4 PLC Subsystem 4 19 D PLCC executes the autotest and detects the fault then starts its 8 hour shutdown timer The message Shut down in 8 hours is logged in the fault table The autotest master function passes to PLCA E The message Shut down in 1 hour is logged at PLCA E The shutdown timer expires in PLCA The message I O Shut Down is logged in fault table of PLCA PLCA shuts down the I O of the affected I O group Real I O is not yet affected because of
173. lds gt 50 lt VDC Off 0 On 1 7V gt VDC 4V On 1 shortcircuitfault 1 DC Sink Range Non GMR GMR Seea Status Input Status Input Input lt 4V On 1 shortcircuitfault 1 Thresholds gt 7V lt 50 VDC Off 0 On 1 gt 70 VDC open circuit fault 0 Off 0 When used with a GMR block a Genius Hand held Monitor will correctly report a short circuit fault instead of Open Circuit 5 14 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 The PLC and I O Fault Tables in a GMR System Faults and alarms from I O devices Bus Controller faults and bus faults are automati cally logged into the Series 90 70 PLC sI OFault Table Faults can be displayed with the programmer in either On Line or Monitor mode PROGRM TABLES scares LIB SETUP FOLDER UTILTY PRINT lplcrunPpasswd eplcflt Plio flt yblcmem mikmem Mefsiz p e b 02 481200 00301010200 0A02 01 01 02 9B03010000000000000000000000000000000000000 I o FAULT TABLE TOP FAULT DISPLAYED 0007 TABLE LAST CLEARED 09 21 11 22 17 TOTAL FAULTS 0007 ENTRIES OVERFLOWED 00000 FAULT DESCRIPTION SHORT IN USER WIRING PLC DATE TIME 10 14 10 05 13 FAULT CIRC REFERENCE FAULT FAULT DATE TIME LOCATION NO ADDR CATEGORY TYPE M D H M S QI 00017 FORCED CIRCUIT 03 08 11 23 16 QI 00017 UNFORCED CIRCUIT 03 08 11 23 16 QI 00017 FORCED CIRCUIT 03 08 11 23 16 9 00019 CIRCUIT FAULT DISCRETE FAULT 03 08 11 23 16
174. le Input Provided to Application Logic eae 152 Pte 150 152 Field Input Input 2 Data inputs M _ Duplex State highest 100 minimum value low high or average value Default State hold last max 175 maximum value minimum or maximum If average has been configured the GMR software averages the two remaining input values and supplies the result to the PLC Input Table Field Input Data Single Input Provided to Application Logic Ma 152 150 151 Field Input Input 2 Data nous a _ Duplex State average 125 minimum value low high or average value Default State hold last max 175 maximum value minimum or maximum GFK 0787B Chapter 4 PLC Subsystem 4 15 4 16 Voting for One Analog Input One input may be present in a non voted input group in a Simplex input group in a Duplex input group where one input has failed or in a Triplex input group where two inputs have failed In a non voted input group the actual input is always provided to the application logic In a voted input group if only one input is available the result of the voting depends on the Voting Adaptation mode that has been configured for the input group Discrete Input Voting with One Input Present and Voting Adaptation Set to 3 2 1 0 For a Simplex Input group one input the voted input is
175. lication program in a system that includes SNP serial network protocol communications between PLCs This utility is described on the following pages If the system does not include SNP communications then the update must be done manually 7 34 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 Using the Program Download Utility If the redundant PLCs are linked by an SNP network you can use the Download utility provided on the GMR software diskette when making future application program updates The Download utility 1 works with the Logicmaster 90 programming software 2 stops each of the PLC CPUs with outputs disabled 3 stores the updated application program to each of the CPUs The Download utility assures more efficient accurate downloading However its use is optional The Download utility includes three files m the download utility file itself named KEY0 DEF m two files named UPLC and LM_KEYS LST that can be used to edit the PLC IDs used by the download utility By default the download utility requires the IDs PLCA PLCB and PLCC If your PLCs use those PLC IDs you can use the utility with modifying it If your PLCs use other PLC IDs you can customize the utility as described on the next page Using the Download Utility with the Default PLC IDs For PLCs with the IDs PLCA PLCB and PLCC the download utility can be used as is 1 Using DOS co
176. log block select Simplex Analog from the menu of analog group types as described above ID Enter a name or a description of up to 12 characters such as in group 6 This entry is for your information only It is not used by the GMR software Start AI The voted analog references start at AI0001 The size of the voted analog input area is determined by the number of voted analog inputs including spares Within this area enter the starting AI Input Table reference for the block This will be the AI address of the voted input data The actual AI references used for the raw input data from the block shown as A inputs B inputs C inputs in the diagram below are configured using the Logicmaster 90 software The GMR configuration software will provide a printout of the addressing required for Logicmaster 90 The allowable reference range is 1 to 1024 AI0001 gt ee Voted Inputs Logic non voted Inputs A inputs B inputs C inputs Duplicate addresses are not allowed within a GBC group You will not be permitted to continue until you have entered a unique address SBA Enter a serial bus address from 0 to 28 Duplicate bus addresses are also not permitted within a GBC group However each block in the group uses the same serial bus address on its respective bus GFK 0787B Chapter 6 Configuration 6 33 Vote Specify how each circuit in a triplex or duplex group should utilize vote A
177. lt State hold last minimum or max 175 maximum value maximum The Duplex State and Default State are not used when three field inputs are available In the illustration above inputs A B and C might represent the first input channel on each block in a three block group The PLC would place the selected input value into the first voted input word for that group 4 14 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 Voting for Two Analog Inputs Two inputs may be present in either a Duplex input group or ina Triplex input group where one of the three inputs has failed Three vote options in duplex mode are determined by the duplex state highest lowest or average If lowest has been configured the GMR software selects the intermediate value with the unused third channel being assigned its minimum configured value Field Input Data Single Input Provided to Application Logic Input 1 152 a 150 150 Field Input Input 2 Data inputs M _Duplex State lowest 100 minimumvalue low high or average value Default State hold last max 175 maximum value minimum or maximum If highest has been configured the GMR software selects the intermediate value with the unused third channel being assigned its maximum configured value Field Input Data Sing
178. master 90 programming software to copy the configuration of PLC A to the folders for PLC B and PLC C 1 From the Logicmaster configuration software return to the Logicmaster programming software Select the Program Folder functions 2 In the Program Folder functions menu select F1 Select Create a Program Folder On the Select Create screen select the folder for the second PLC for example CONFIGB as the current folder 3 wm In the Program Folder functions menu select F10 Copy Contents of Prog ram Folder to Current Program Folder On the Copy Folder screen a For Source Folder enter the name of the folder containing the configuration of PLC A for example CONFIGA b For Information to be copied set only Configuration to yes COPY PROGRAM FOLDER TO CURRENT FOLDER Source Folder Auha kei Current Folder CONFIGB Current drawer is D LM9O Information to be copied The ENTIRE FOLDER selection ENTIRE FOLDER N Y N will copy everything from the PROGRAM LOGIC N Y N source folder logic config CONF IGURAT ION Y Y N reference data teach files REFERENCE TABLES N Y N and any other files to the current folder D If there are three PLCs repeat this for the other PLC E Edit the configurations for PLC B and PLC C as necessary 6 46 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 Logicmaster Configuration Summ
179. missioner DCS program PLCprogram Genius Modular Redundancy Flexible Triple Modular Redundant TMR System User s Manual March 1995 GFK 0787B Recommendations The following recommendations are given to improve the primary safety as described by the list gt A program in the DCS that checks regularly that no discrepancies exist between the override command signals from the DCS and the override activated signals received by the DCS from the PLC The use of the maintenance override function should be documented on the DCS and on the programming environment if connected The printout should include time stamp of begin and end ID of the person who is activating the maintenance override maintenance engineer or operator if the information cannot be printed it should be entered in the work permit tag name of the signal being overridden The communication packages different from a type approved MODBUS should include CRC address check and check of the communication time frame Lost communications should lead to a warning to the operator and maintenance engineer After loss of communication a time delayed removal of the override should occur after a warning to the operator PLC Sensors Actuators a Safeguarding ooo Application Program 2 L f Maintenance Ov
180. mory 7 27 length 7 27 programming redundancy stored in R memory 7 9 GMR configuration adding to application program 7 2 zo creating the G_M_R10 a file information needed for menus open saved file 6 10 printing saving software text description GMR mode 2 4 3 9 GMR software adding to application program 7 28 files on diskette operation of 4 overview revision level H Hand held Monitor 6 50 version required Hot Standby mode F 13 10 16 53 y mode p d I OPoint faults I O Shutdown 4 18 7 20 Initialization data 4 4 Input block groups 2 2 Input subsystems 2 1 4 Inputs analog b 9 4 12 analog input voting analog configuring autotest 2 6 broadcast configuring autotest discrete discrete input voting fault table messages GMR configuration for Input Table addressin line monitoring 2 7 manual controls 2 non voted number of groups 2 3 number of sensors processing by PLC AEZ reserved sensors thresholds a i voting adaptation 6 31 6 wiring 8 3 6 5 9 8 7 64 53 era reporting GFK 0787B GFK 0787B Inputs and outputs number available 1 9 Installation information Internal Channel fault L LED Block OK Limit discrepancy 5 12 6 36 Line fault 5 2 5 25 Line monitoring 2 7 Load sharing by output blocks 3 6 Logicmaster software version required i2 Logon control
181. mpleted a block group screen you can continue to configure another block group GFK 0787B Chapter 6 Configuration 6 27 6 28 Configuring a Triplex Duplex or Simplex Discrete Input Group To configure a discrete group click on that line or move the cursor there and press the Return key or press the highlighted letter key Then select whether the blocks in the group are 16 point or 32 point blocks For example riplex Discrete uplex Discrete implex Discrete na log aE ll A configuration screen like the one shown above right appears To item on this screen use the Tab key or mouse ID Enter a name or a description of up to 12 characters such as in group 3 This entry is for your information only It is not used by the GMR software Start I Enter the starting I Input Table reference for the group This is the I address of the voted input data The actual I references used for the input data from each block are configured using the Logicmaster 90 software This configuration utility will provide a printout of the addressing required for Logicmaster 90 The allowable reference ranges are 0001 to 0112 788 CPU 0001 to 2048 789 CPU Duplicate addresses are not allowed within a GBC group You will not be permitted to continue until you have entered a unique address SBA Enter a serial bus address also referred to as the device number from 0 to 28 Duplicate bus addresses are also not permitted within
182. must be set as follows Data Fault DIAGNOSTIC System Fault FATAL All redundant I O groups must be configured to be autotested and the autotest interval must not exceed a maximum of 480 minutes 8 hours The write access length parameters for I AI Q and AQ must be set to 0 If the configuration is set to allow write access the T UV Maintenance Override document must be complied with This document is reprinted in Appendix B of this manual Autotesting must be set to ENABLED for all used circuits of each discrete input group Vote Adaptation must be set to 3 2 0 for all used circuits of each discrete input group The Duplex State must be set to 0 for all used circuits of each discrete input group The Default State must be set to 0 for all used circuits of each discrete input group Autotesting must be set to ENABLED for all used circuits of each discrete output group Normal State must be set to ON for all used circuits of each discrete output group Vote Adaptation must be set to 3 2 0 for each analog input group The Duplex State and Default State settings for each analog input group are dependent on the application and must be set as follows For High Limit processing The Duplex State must be set to High The Default State must be set to Max For Low Limit processing The Duplex State must be set to Low The Default State must be set to Min For each analog input channel the Threshold Discrepancy Percentage must be se
183. n depend on the presence of other scheduled tasks and the configuration of the points Note Use of the Genius output Pulse Test feature from the application program or Hand held Monitor is NOT recommended for GMR applications since it will produce erroneous results Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 GMR Discrepancy Reporting The GMR software performs discrepancy reporting for m Voted discrete inputs m Discrete outputs m Analog inputs There is no discrepancy reporting for analog outputs Discrete Input Discrepancy Reporting As explained in the chapter on PLC operation the PLC compares corresponding inputs from bus A bus B and bus C and performs voting Field Input Data PLC Performs Single Input Provided 2 out of 3 Voting to Application Logic Input A 0 4 Input B 0 0 Input C 1 If there is a discrepancy between any original input data value for an input and its voted input state the PLC automatically places a message in the I O Fault Table where it is available to the Logicmaster 90 software and the application program logic Discrepancy faults are latched When a discrepancy occurs the PLC sets the fault contact for that voted input See page 5 25 for information about these fault contacts Discrepancy signals are filtered for the configured input discepancy filter time to eliminate transient
184. n software to complete the GMR configuration There is only one GMR configuration needed for the system GMR configuration sets up the parameters that will be used by the system including reference addresses The GMR configuration software produces m A printout of the GMR Configuration m A program block named G_M_R10 This is later added to the application program 2 Using the LM90 configuration software create a Logicmaster configuration for each PLC The easiest way to do that is to A Create a Program Folder for PLC A With the GMR configuration printout as a reference complete its Logicmaster configuration B Use the Copy Folder feature of the Logicmaster 90 programming software to copy the configuration of PLC A to additional folders for PLC B and PLC C C Edit the configurations for PLC B and PLC C as necessary 3 Using a Hand held Monitor complete the Genius block configuration Genius block configuration sets up the operating characteristics of each block in the GMR system 4 Using the Logicmaster 90 programming software create the application program While there can be up to three PLCs in a GMR system each of which has a slightly different configuration there is normally only one application program A Using Logicmaster 90 copy the folder named GMRxxyy for example GMRO0101 from the GMR software diskette to a program folder with your application program name such as GMRPROG B Using Logicmaster 90 add
185. nces are also set in each PLC GFK 0787B Chapter 3 Output Subsystem 3 5 4 Block Output Groups Allfour blocks in a group must be either 16 circuit or 32 circuit blocks In a group two source type Genius blocks are connected in parallel on one side of each load and two sink type Genius blocks are connected in parallel on the other side Bus A Bus C Bus B Source Blocks IC660BBD020 or IC660BBD024 Sink Blocks IC660BBD022 or IC660BBD025 There are three busses One source block and one sink block are connected to either bus A or bus B see blocks B and D on bus B in the illustration above The other two blocks are connected to the remaining two busses A and C above The illustration shows just one load for a group of four blocks However up to 16 loads could be controlled by the same group of four blocks using 16 circuit blocks When the blocks are configured each is assigned the same output reference addresses using Logicmaster 90 Then the blocks are configured for GMR mode using the Genius Hand held Monitor Output circuits that are to be autotested must be able to withstand the On and Off pulse times used by the test Check each output device s characteristics against the specifications listed on page 8 12 for 16 point blocks and page 8 17 for 32 point blocks to verify that it can be autotested and or used in a 4 block output group Output Load Sharing In a 4 block output g
186. nd Redefine Variables F5 Export Folder Element To Library Fo Add Element To Library F CreaterEdit Reference Offset Templates 2 Select F6 Add Element to Library ADD ELEMENT TO LIBRARY NEW ELEMENT D GMRNG_M_R10 EXE ELEMENT TYPE EXTERNAL BLOCK PROGRAM BLOCK EXTERNAL BLOCK PROGRAM SEGMENT RENAME TO CURRENT LIBRARY D LNSONP70_LIB ANNUN DIAGNO FIX G10516 G_M_R10 H2 FLOW N_SIG J1024 MR513 lt lt Type full path for new element Press Enter to add element to library gt gt lt lt Use PgUp PgDn to scroll list of existing eclemnts gt gt 3 Type the full path and name of the G_M_R10 EXE file that was created with the GMR configuration software You must enter a valid path and filename before you can exit this field For example D GMR G_M_R10 EXE 4 Select External Block as the Element Type Press the Tab key to display External Block in the Element Type field as illustrated above Donot rename the file Be sure the selection for Current Library is the correct destination for the file GFK 0787B Chapter 7 Programming Information 7 29 5 Add G_M_R10 to the library by pressing the Enter key Important gt 6 When prompted for the number of paired input and output parameters enter 2 7 Press ESC to return to the Librarian menu Importing G_M_R10 from the Librarian to the Application Program After G_M_R10 has been added to the Librarian it can be imported to the Pro
187. ndant TMR System User s Manual March 1995 GFK 0787B GFK 0787B 9 10 11 12 13 14 Insert the first GBC bus controller group A Select each bus controller in the group GBC_A GBC_B GBC_C 1 Specify a rack and slot location 2 Select OK or Cancel to quit the Rack Slot window B Configure all the input and output block groups for the GBC group 1 Insert each Input block group For each Input block group a Select the group type triplex duplex simplex discrete analog b Configure the Input block group m Enter an ID starting reference address serial bus address m Select Autotest and specify each input to be autotested and Test Type for the block group Sync or Async Select O K or C ancel to quit the Autotest window m Select VoteAdapt and specify each input for vote adaptation Select the Duplex state 0 or 1 Default state 0 1 hold last and Hot Standby mode for any outputs on the block group Select O K or C ancel to quit the VoteAdapt window 2 Insert each Output block group For each Output block group a Select the group type 16 point or 32 point b Configure the Output block group m Enter an ID starting reference address serial bus address m Select Autotest and specify each output to be autotested and its normal state Select O K or C ancel to quit the Autotest window m Select Options and specify the bus and bus address for the 4th block Selec
188. ndant TMR System GFK 0787B User s Manual March 1995 GFK 0787B Discrete Input Autotest Discrete Input Autotest exercises the system inputs to assure their ability to detect and respond to actual inputs It can be used on both 16 point and 32 point blocks Input autotest will m accommodate normally closed and normally open devices with the device in either state m detect any input failure associated with an input that would result in a failure to respond m not cause spurious outputs Input autotest is internal to each Genius block With the exception of an initiation command it requires no interaction with the PLCs during the autotest sequence Configuration Required for Discrete Input Autotest Blocks that will be autotested must be configured as combination input and output blocks However the blocks must be used as all input blocks with point 16 only on each block set up as an output Point 16 must be configured to be Default On Whether or not inputs on an input block group will be autotested is configurable on a circuit by circuitbasis Setup for Input Autotest Inputs to be autotested must have their power controlled by circuit 16 which functions as the power feed output Each power feed output is capable of providing power to up to 32 input devices m Block Setup for Input Autotest 1 1 2 2 3 4 3 5 6 4 inputs gt gt 7 g 5 ed mi 10 6 12 7 13 44 18 10 19
189. nections IC660BBD021 Connections ice60BBD021 Sink s Sink S2 S2 DC Power g SHLD IN DC Power g SHLD IN SHLD OUT Io SHLD OUT S des Ol bce ol Ql ol 2 al 2 Gil 3 Bll 3 4 o 4 ol 3 g 5 ol Sil 6 al 7 Gil 7 BZ 8 ol 8 ll 9 S 2 10 10 AE SH 44 SI 42 LISI 12 A 13 He 13 el 14 Hel 14 Bi 15 o 18 5 16 o 16 g Pc o 2c f AS li Ro 77 Ground Ground Ov DC m If redundant power supplies are to be used they should be diode ORed power supplies providing common power to all blocks in a group Different groups may use different power sources Chapter 8 Installation Information 8 11 Output Wiring for a 16 Circuit 4 Block Group continued Output Load Considerations for 16 Circuit 4 Block H Pattern Redundant Output Groups Minimum load 100 milliamps Maximum load 2 0 Amps Maximum inrush current 10 Amps for up to 10 milliseconds Maximum total load for block group 15 Amps at 35 degrees C Output Off Leakage Current 2 0 milliamps For Outputs to be Autotested Minimum pickup time Greater than 20 milliseconds Minimum dropout time Greater than 7 5 milliseconds Check the characteristics of each output device against the list above to verify that it can be autotested and or used in the 4 block output group Otherwise critical output loads could be adversely affected Output Autotest and Pulse Testing If output circuits are to be autotested the loads will be sub
190. nfigured Duplex State and Default State in determining the final input value to provide to the PLC Duplex State The Duplex State is a tiebreaker value that is used when there are two field inputs present The Duplex State may be configured as the higher actual input value the lower value or an average of the two Default State The Default State is the value that will be provided directly to the PLC instead of a voted input value if the following inputs fail m The single input in a Simplex group m The remaining input in a Duplex or Triplex group configured for 3 2 1 0 Voting Adaptation m Either of the two inputs to a Duplex group configured for 3 2 0 Voting Adaptation m Either of the two remaining inputs to a Triplex group configured for 3 2 0 Voting Adaptation The Default State can be configured as the last input state or a specified maximum or minimum value GFK 0787B Chapter 4 PLC Subsystem 4 13 Voting for Three Analog Inputs For a triplex input group with three inputs present the GMR software compares three corresponding analog input values It selects the intermediate value and places it into the voted inputs portion of the Analog Input Table Field Input Data Single Input Provided to Application Logic Input 1 152 150 150 Field Input Input 2 Data Input 3 110 Duplex State average low high or average value 100 minimum value Defau
191. no output load no load fault reports are generated during a Pulse Test Short circuit fault Overtemperaturgault Overloadfault Failedswitch Occurs if the actual output state differs from the commanded state m AutotestDiagnostics for discrete outputs configured for autotesting Autotesting determines whether outputs can attain the opposite of their normal state Output Discrepancy Reporting Blocks configured for GMR mode operation report to each PLC the discrepancy status for the data from each PLC together with each PLC sonline offlinestatus Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 Setting Up Blocks to Report Genius Faults By default most Genius blocks including the types of blocks normally used in GMR systems send only one copy of a Fault Report For a GMR system blocks can be set up to send additional Fault Reports The setup needed for a block depends on two things what type of block it is and how many PLCs should receive its Fault Reports Setting Up 16 and 32 Circuit DC Blocks to Send Multiple Fault Reports A 16 or 32 Circuit DC Sink Source block only will send three Fault Reports one each to serial bus addresses 29 30 and 31 if set up in either of the following ways m For blocks in a GMR group block configuration is CPU Redundancy GMR m For non GMR group blocks block configuration is CPU Re
192. nt TMR System GFK 0787B User s Manual March 1995 Program Instruction Set for GMR The CPUs used for GMR support the all of the following Series 90 70 ladder logic instructions Contacts Coils BitOperation Conversion Control AnyContact AnyCoil AND to BCD 4 CALL l OR to BCD 8 DOIO I XOR toUINT SUSIO I I T NOT toINT MCR sidis 4 SHL to DINT ENDMCR F AULT S SHR BCD 4 to JUMP INOFLT r ROL UINT LABEL HIALR SM ROR BCD 4 to INT COMMENT LO ALR RM BTST BCD 8 to SVCREQ lt gt M BSET DINT PIDISA M BLCR PIDIND lt gt BPOS FOR MCMP END_FOR EXIT Timers Counters Links Relational Math ONDTR UPCTR Horizontal EQ ADD OFDT DNCTR Vertical NE SUB TMR GT MUL GE DIV LT MOD LE SQRT CMP ABS Data Table TBLRD TBLWR LIFORD LIFOWRT FIFORD FIFOWRT SORT ARRAY_MOVE SRCH_EQ SRCH_NE SRCH_GT SRCH_GE SRCH_LT SRCH_LE DataMove MOVE BLKMOV BLKCLR SHFR BITSEQ SWAP COMMREQ VMERD VMEWRT VMERMW VMETST VME_CFG_RD VME_CFG_WRT DATA_INIT DATA_INIT_COMM DATA_INIT_ASCII Use of Do I O and Suspend I O The Do I O and Suspend I O program functions can interfere with the output autotest They should not be used in any GMR application program Programming Restrictions for TUV Applications Some of the program instructions listed above can not be used for a GMR system that will be applied in an Emergency Shut D
193. nted 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 IO 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 1 1 Components of a GMR System GMR Software GMR software version 2 06 catalog number IC641SWP714B provided on diskette consists of m Easy to use GMR configuration software m GMR system software which automatically processes monitors and tests redundant I O A download utility for updating programs in systems with SNP multidrop communications Series 90 70 PLCs Two models of the Series 90 70 PLC CPU support GMR CPU 788 and CPU 789 If the GMR system includes either two or three PLC CPUs they must be the same model Each PLC requires one to three Bus Controllers per bus Minimum suffixes for GMR version 2 06 are CPUs and Bus Controllers Catalog Number Minimum Suffix Series 90 70 PLC CPU IC697CPU788 DA IC697CPU789 DA Series 90 70 PLC CPU Memory IC697BEM735 D Series 90 70 Bus Controller IC697BEM731 N Genius I O Blocks m The following standard Genius blocks are supported by the GMR system These blocks contain GMR modifications for version 2 06 beginning with the minimum suffix listed Block Type Catalog Number Minimum Suffix 24 48VDC 16 CircuitSource block IC660BBD020 M 24 48VDC16 Circuit Sink blo
194. nual Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 6 Completing the Logicmaster 90 Configuration Logicmaster 90 configuration steps for a PLC In a GMR system are the same as for a non GMR system A typical configuration is summarized on the following pages You should refer to the Logicmaster 90 Software User s Manual for detailed configuration instructions Since the configuration and program for the redundant PLCs ina GMR system are nearly identical it is easiest to complete the configuration and program for one PLC then copy and edit them for the other PLCs m One necessary change in the configuration is to edit the serial bus addresses also referred to in other Genius documentation as device numbers of the Bus Controllers See below m Genius I O blocks use the same reference addresses in each of the redundant PLCs so reference addresses are not changed from PLC to PLC It is very important to be sure that entries made during Logicmaster configuration match similar entries made during GMR configuration Complete the GMR configuration first print it out and use the printout for reference during the Logicmaster configuration Configuring Bus Controllers A Series 90 70 PLC can have up to 31 Genius bus controllers Ina GMR system bus controllers perform the dual function of supporting Genius I O and providing inter PLC communications The numb
195. o and assumes no responsibility for the accuracy completeness suf ficiency or usefulness of the information contained herein No warranties of merchant ability or fitness for purpose shall apply The following are trademarks of GE Fanuc Automation North America Inc Alarm Master Genius Modelmaster Series Five CIMPLICITY Genius PowerTRAC ProLoop Series Six CIMPLICITY 90 ADS GMR PROMACRO Series 90 CIMPLICITY PowerTRAC Field Control Series One VuMaster CIMSTAR Helpmate Series Three Workmaster GEnet Logicmaster Copyright 1995 GE Fanuc Automation North America Inc All Rights Reserved Preface This manual is a reference to planning configuring and programming a Series 90 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
196. o include GMR functions These blocks can be used in either GMR or non GMR systems When configured for GMR operation only they perform output voting support GMR autotesting and provide diagnostic reports to up to three PLCs In addition certain of their operating parameters are changed when they are in GMR mode Analog RTD and Thermocouple Blocks Analog blocks can be included in the GMR configuration and used in GMR input groups as either voted or non voted inputs However analog blocks in GMR input groups are not autotested by the GMR software Analog blocks do not provide output voting so they cannot be used in GMR output block groups However they can be used as non voted blocks in a GMR system and support standard Hot Standby Redundancy Analog RTD and Thermocouple blocks operate the same way in either GMR or non GMR systems No specific versions of these blocks are required for GMR use I O Block Summary The following table summarizes how different types of blocks can be used in a GMR system Basic Block Types CanbeGMR CanbeGMR Canbe Canbe Canbe InputBlock Output Block non voted Autotested non GMR GMRblock block 24 48VDC16 CircuitSource block yes yes yes yes yes 24 48VDC16 Circuit Sink block 12 24VDC32 Circuit Source block 5 12 24VD 2 Circuit Sink block Any other discrete block no no yes no yes Analog RTD and Thermocouple yes no yes no yes blocks High speed
197. ocks in a group should be wired such that either a single disconnect powers down all 4 blocks simultaneously or each individual block is powered down by its own disconnect An individual disconnect and or fuse for each individual block provides the greatest flexibility in replacing a failed block without disturbing the controlled output devices Ideally the disconnect for a source block IC660BBD024 should be wired in the DC supply line and for a sink block IC660BBD025 in the DC supply line A rectifier diode must be wired in parallel with each output load as shown in the diagram This diode should have a minimum 1 Amp forward current rating and 75 volt to 100 volt PIV rating This diode does not affect the ability of the system to do output autotesting of each output if configured to do so When a 32 circuit 4 block output group is wired according to the instructions above and a single block is powered down for maintenance purposes the following normal procedures should be followed A PLC Force Logon may be required as always when an output block has power restored to it to cause the output block to start accepting data from the PLC s It is not required if the current output data the PLC s is sending matches the output default states at the block To execute a PLC Force Logon turn on the GMR control bit M12263 FORCLOG Force Block s to Log on An I O fault reset should executed after restoring power to a block in an ouput group T
198. offset y in GMR3 diagnostics 11421 GMR3 ST x at y GMR3 state mach exceeded allowed time in step x Step no at offset y in GMR3 diag nostics 11422 GMR3 IW x GMR3 has output an illegal waycode of x 11423 GMR3 tmplt too small GMR14 has detected an internal error condition 11430 GMRS6 IS x at y GMR6 state machine went to step x illegal Step no at offset y in GMR6 diagnostics 11431 GMR 6 ST x at y GMR6 state mach exceeded allowed time in step x Step no at offset y in GMR6 diag nostics 11432 GMR6 IW x GMR6 has output an illegal waycode of x 11433 GMR6 tmplt too small GMR14 has detected an internal error condition 11440 GMR8 IS x at y GMRS8 state machine went to step x illegal Step no at offset y in GMR8 diagnostics 11441 GMR8 ST x at y GMRS8 state mach exceeded allowed time in step x Step no at offset y in GMR8 diag nostics 11442 GMR8 IW x GMRS8 has output an illegal waycode of x 11443 GMR8 tmplt too small GMR14 has detected an internal error condition 11445 GMR11 IS x at y GMR11 state machine went to step x illegal Step no at offset y in GMR11 diagnos tics 11446 GMRI11 ST x at y GMR11 state mach exceeded allowed time in step x Step no at offset y in GMR11 diag nostics 11447 GMR11 IW x GMR11 has output an illegal waycode of x 11448 GMR11 tmplt too small GMR14 has detected an internal error condition 11450 GMR12 IS x at y GMR12 state machine went to step x illegal Step no at offset y in GMR12 diagnos tics 1145
199. oftware Performs 1 out of 1 Voting if Voting 0 Adaptation is 3 2 1 0 Duplex State Default State 1 Discrete Input Voting with One Input Present and Voting Adaptation Set to 3 2 0 Configuring a Duplex or Triplex input group for 3 2 0 Voting Adaptation prevents the data from just one input being used as the only input data for that group If a Duplex or Triplex group configured for 3 2 0 Voting Adaptation has just one input present the configured input Default State is used instead of the remaining actual input Field Input Data Input Provided Input A 0 to paleo Field Input Input C OO GMR Software uses Default State if Voting Adaptation is 3 2 0 Duplex State 0 Default State 1 GFK 0787B Chapter 4 PLC Subsystem 4 1 4 12 Analog Inputs The method of analog input processing is similar to the method used for discrete inputs During the Input Scan data from analog input blocks is placed in the Analog Input Table as shown below Inputs from blocks that have been included in the GMR configuration are placed in the areas labelled A B and C Data from any additional analog input blocks non voted blocks or blocks on other busses is placed in a separate area as shown Analog Input Table WY veo Logic Non voted Inputs ky A inputs B inputs B C inputs The GMR software creates and maintains the separ
200. ommunication ports are restricted the Genius bus is not A GMR Genius bus must not be used for communications Input autotest is enhanced External isolation diodes are required The method used for input voting adaptation can now be configured to suit the application m New diagnostics including parity checks and checksums are provided m Fault text displayed by the Logicmaster software is improved Related Publications For more information refer to these publications Genius I O System User s Manual GEK 90486 1 Reference manual for system designers programmers and others involved in integrating Genius I O products ina PLC or host computer environment This book provides a system overview and describes the types of systems that can be created using Genius products Datagrams Global Data and data formats are defined Genius Discrete and Analog Blocks User s Manual GEK 90486 2 Reference manual for system designers operators maintenance personnel and others using Genius discrete and analog I O blocks This book contains a detailed description specifications installation instructions and configuration instructions for all currently available discrete and analog blocks Series 90 70 PLC Installation and Operation Manual GFK 0262 This book describes the modules of a Series 90 70 PLC system and explains system setup and operation Logicmaster90 70 User s Manual GFK 0263 Reference manual for sys
201. on of a program must be de coupled or segregated from the safety relevant portion by using separate program blocks or subroutines In addition there must be no overlap of I O reference addresses in the two separate portions of the program Control algorithms must NOT be in any way integrated with the safety relevant portion of the program No forces or overrides can be present in the system This is checked by verifying system variables S0012 FRC_PRE and S0011 OVR_PRE are equal to 0 The application program must include code that issues a warning to the operator via a redundant PLC output if S0012 or S0011 are in the on state in any of the three PLCs The application program must include code that issues a warning to the operator to indicate that a fault any fault exists in the system via a redundant PLC output if system variable SC0009 ANY_FLT is in the on state in any of the three PLCs The GMR control bits M12258 IORES M12259 PLCRES and M12264 PLCRESG must not be driven by the application automatically They must be driven only under control of an operator Operator interface or hard wired push button inputs A status report must be produced by setting the GMR REPORT bit M12262 The resultant information must be checked verified against the configuration printout Two backup copies of the system configuration and application program must be made for documentation and backup purposes These backups must be
202. onfiguration feature of the Genius Hand held Monitor only works when blocks are online on the same bus and GMR blocks in a group are on separate busses Of course it is possible to use the Copy Configuration feature between similar blocks on a bus that are not in the same group Setting Up Blocks for Fault Reporting Configuring a block for CPU Redundancy GMR automatically sets up the block to send three fault reports when a fault occurs one fault report each to serial bus addresses 29 30 and 31 The blocks require no further setup to send multiple fault reports Setting Up Non GMR Blocks to Send Multiple Fault Reports Inputs only blocks automatically send up to two Fault Reports to serial busses 30 and 31 However non GMR output and mixed I O blocks must be configured for Hot Standby redundancy to send two Fault Reports to serial bus addresses 30 and 31 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 GFK 0787B 6 Configuring 16 Circuit and 32 Circuit Discrete DC Blocks The table below lists configuration parameters for 16 circuit and 32 circuit discrete blocks Configuration options with special requirements in GMR systems are described after the table Configuration options that are not changed for GMR systems are not described here Note that blocks do not prevent selecting incorrect parameters for a GMR system It is important to configure blocks appropri
203. or F2 Save and Rename Save As A Change directory Change Dir D Close without saving Close C Exit Quit configuration X In a menu to select an item with a mouse move the cursor to it and click To select a menu item from the keyboard use the cursor keys to move the cursor and press Enter Return or press the highlighted letter key without the ALT key Opening a Previously Saved Configuration File The GMR configuration software stores files with the filename you choose and the extension SAV For example CONFIG1 SAV If you want to view edit write or print a previously saved configuration file select Open F3 from the File menu ew System pen F3 4 ave F2 ries Save As E Change Dir lose Select Open to open the file This loads the selected file into the computer s RAM memory Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 6 Saving a Configuration File Select Save F2 to save the configuration file presently in RAM memory the one displayed on your computer screen This function saves the file with the selected name overwriting the previous version If you want to specify another filename for example to create a new version of a configuration file without writing over the old one select Save As instead The software gives each saved file the filename extension SAV During a file editing session the first t
204. or autotested input devices Input devices for input circuits that are not configured for autotesting should not be wired to the power feed output m Isolation diodes must also be wired as shown above for any input to be autotested The suggested diode is 1N5400 or equivalent Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 Input Wiring continued Three Sensors to Three Blocks Triple Bus GFK 0787B PLC A PLC B PLC C nv cud gt ODD w OWD O ODD 6 2V Zener Diodes for o Line Monitoring optional o nv ge gt OWO w OwO O ODD cud gt ODD w OWD O on 11 Hp Input 1 a 4o Input 15 or 32 nput 1 A nput 15 or 32 Cr A Input 1 A Input 15 or 32 115 32 H bf 0 016 p m 6 2 volt Zener diodes are used for optional line monitoring on circuits configured as tristate inputs This option is only available with 16 circuit DC blocks m All blocks in an input group must have the same number of circuits either 16 or 32 m On either 16 circuit or 32 circuit blocks circuit 16 is used as an output if the block group is configured for input autotesting m On any block circuits that are not configured
205. ory Protect keyswitch to the unprotected position the Mem Protect LED will be off Make the run mode store single word online change or block edit at PLC A A Program Changed A message is logged into the PLC Fault Table at PLC A Program Changed A is logged into the PLC Fault Table of PLC B and PLC C If the change affects the state of any outputs the discrepant outputs are voted out at the output blocks by the 2 out of 3 voting algorithm The appropriate output discrepancy error s if any are logged at all three PLCs Change the CPU Memory Protect keyswitch to the protected position the Mem Protect LED is on Using the Logicmaster 90 70 Programing Software make a direct or multidrop connection to PLC B Change the CPU Memory Protect keyswitch to the unprotected position Make the same program change at PLC B Program Changed B is logged into the PLC Fault Table of PLC B If the change affects the state of any outputs these outputs would now agree for PLC A and PLC B and the output state s from PLC C are voted out at the output blocks by the voting algorithm The appropriate output s from PLC C will now be discrepant and the appropriate discrepancy and the appropriate redundancy error s are logged at all three PLCs Change the CPU Memory Protect keyswitch to the protected position the Mem Protect LED is on Using the Logicmaster 90 70 Programing Software make a direct or multidrop connection to PLC
206. otested and circuits that are turned On in the same cycle Block 1st A T 2nd A T 3rd A T 4th A T Circuits Turned Circuit Fail Type Cycle Cycle Cycle Cycle On at the Same Mask Time 16 Cir BlockA Block C Block B BlockA 1 3 5 7 10 12 14 2A55 cuit DC Block B BlockA Block C Block B 2 4 6 8 00AA Block C Block B Block A Block C 9 11 13 15 5500 32 Cir Block A Block C Block B 1 5 9 13 17 21 25 29 11111111 cuit DC Block B Block A Block C 2 6 10 14 18 22 26 30 22222222 Block C Block B Block A 3 7 11 15 19 23 27 31 44444444 Block C Block B Block A 4 8 12 20 24 28 32 88880888 Notes Bit 16 corresponds to the power feed output It is always 0 For 16 Circuit blocks each circuit is turned On each cycle when looked at across all 3 blocks but the same circuit is never turned On at more than one block at a time For 32 Circuit blocks almost all circuits are turned On each cycle when looked at across all 3 blocks but the same circuit is never turned On at more than one block at a time alsosee chapter 8 for installation and wiring information Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 GFK 0787B Discrete Output Autotest Discrete output autotest checks the ability of outputs to respond to the commanded output state Bus A Bus C Bus B Hal Load The discrete output autotest will m work on outputs that are ei
207. oup m In addition for each block output that is associated with a given system output within the group there may be no I O force applied there may be no hardware fault such as a failed switch all block outputs associated with the system output must presently be in the same logical state Monitoring of system status references to detect forces and overrides is discussed later in this chapter Outputs that are OFF are pulsed OFF ON OFF and checked for correct voltage for the presence of diagnostic data and for correct current if the No Load diagnostic is enabled If a point reports correct voltage and or current data the point passes and is not re pulsed However if a point does not report correct voltage and or current data it is retested up to a maximum of seven times in successively longer pulses The ON pulse times begin at approximately 1 7mS and can increase up to approximately 20mS There is a delay of approximately 5mS to 15mS between successive pulses of the same point Outputs that are ON are pulsed ON OFF ON This checks whether a point s feedback voltage matches its commanded state Points are pulsed OFF for approximately 5ms If the voltage matches a point passes If not the point is pulsed OFF again for approximately 7 5m5S Note that the times given here are typical for 16 circuit blocks pulse times and quantities are different for 32 circuit blocks Actual times in any applicatio
208. own ESD application for which for a TUV site application approval will be sought See Appendix A for details Estimating Memory Usage Estimating Bus Scan Time GFK 0787B The GMR system software version 2 06 uses approximately 318 688 bytes of the CPU s memory To determine how much of the 512 Kbyte memory IC697MEM735 used on the CPU788 and CPU789 remains for the ladder logic application program use this equation Max User Ladder Logic Application Program Size 524 288 bytes 318 688 bytes User Reference Tables The size of the User Reference Tables depends on your configuration and actual application program See the LM90 70 Programming Software User s Manual GFK 0263 for more information If you want to estimate the bus scan time see page 4 6 for instructions Chapter 7 Programming Information Reserved References 7 4 In a GMR system the following references are reserved or assigned special functions References Reserved For 10001 to 11024 788 CPU 100001 to 112288 789 CPU Input Table Some references are automatically assigned by the GMR Configuration Software Others are available for use as explained in this chapter Q0001 to Q1024 788 CPU Q00001 to Q12288 789 CPU Output Table Some references are automatically assigned by the GMR Configuration Software Others are available for applicationuse AI0001 to AT max The length of AI data shown at left a
209. possible mainly in two ways A The serial link is done via the MODBUS RTU protocol or other approved serial protocols The maintenance override may not be performed by the engineering workstation or programming environment B The engineering workstation or programming environment is allowed to be connected to the PLC to perform maintenance override That requires additional safety measures inside the associated PLC to prevent a program change during maintenance intervals These measures shall be approved e g by TUV GFK 0787B B 1 B 2 The following table shows common requirements The differences between solution A and B are shown by typeface italic Requirements for maintenance override handling Responsibility Alreadyduring the software configuration of the PLC system it is determined ina table or in the application program whether the signal is allowed to be overridden Project engineer and commissioner responsible for correctconfiguration The configuration may also specify by a table whether simultaneousoverriding in independent parts of the ap A Project engineer programmingenvironment As an organizational measure the operator should con firm the overridecondition plicationisacceptable B Projectengineer Typeapproval Maintenance overrides are enabled for the whole PLC or A OperatororMaintenanceengineer a subsystem process unit by the DCS or a hard wired switch e g key switch B
210. program block G_M_R10 created with the configuration utility to the application program folder C Create or add the application program logic in this folder 5 After completing the application program and the configuration s store them to the PLCs As explained above all redundant PLCs in the GMR system normally use the same application program but different configurations PLCA PLC B PLCC d o J o o o gt gt gt Program GMRPROG Program GURPROG Program GURPROG Configuration CONFIGA Configuration CONFIGB Configuration CONFIGC Supplying the configuration and program as separate files as shown makes it easier to perform program updates in the future The GMR Configuration Software allows the system to be set up for online program changes Online changes are intended for system debug and commissioning GFK 0787B Chapter 1 Introduction 1 11 Chapter GFK 0787B 2 This chapter provides information about the inputs to a GMR system Input Subsystem Overview GMR Input Groups Non Voted I O in the Input Subsystem Discrete Inputs Types of Blocks in the Input Subsystem Discrete Input Processing Discrepancy Reporting for GMR Inputs Input Autotest for GMR Inputs Line Monitoring for Discrete In
211. put 30 Vo a output 29 1 1 output 29 A B default Load voted 1 output 31 output output via 0 1 1 output 30 C D 1 output 29 co co In a 4 block output group each field output is supported by two Genius source outputs connected in parallel on one side of the actuator and two Genius sink outputs connected in parallel on the other Each block in the group receives outputs from each of the three separate processors Automatic System Test Optional autotest routines test the complete system from input modules through to output modules including failures in the I O wiring Autotesting does not affect the normal state of field devices Chapter 1 Introduction 1 7 Genius I O Blocks Inputs and outputs ina GMR system are provided by Genius I O blocks Some types of Genius blocks are now enhanced for GMR operation In addition these and other types of blocks can be included in a GMR system as non voted blocks Non voted blocks are individual blocks that are present on GMR busses in the system they are not part of any GMR input group or output group They are included in the GMR configuration and they may be autotested Discrete Blocks Alltypes of discrete blocks can be used as non voted blocks in a GMR system The discrete blocks listed on page 1 2 are standard Genius blocks that are now enhanced t
212. put Output Output Default Output State State State Setting in State Block 0 0 1 0 0 1 1 1 1 0 1 1 1 1 1 1 Chapter 6 Configuration 6 55 Chapter Programming Information This chapter describes the following aspects of the application program interface to the GMR software GFK 0787B Programming Overview Program Instruction Set for GMR Estimating Memory Usage Reserved References Input and Output Addressing for GMR Register R Memory Assignment for GMR System Status S References GMR Status and Control M References Programming for Startup I OPoint Faults Programming for Fault and Alarm Contacts Programming for I O Shutdown Reading GMR Diagnostics Programming for Global Data Adding the GMR System Software to a New Application Program Folder Adding the GMR Configuration to the Application Program Folder Storing a Program to the PLC Storing a Program to the PLC if the System is NOT Configured for Online Changes Storing a Program to the PLC if the System IS Configured for Online Changes Programming Overview 7 2 The following figure represents the basic GMR programming steps As explained previously the GMR configuration which assigns I O reference addresses and produces the G_M_R10 Program Block should be done first GMR Diskette CONFIG EXE GMRxxyy Download utilities G_M_R10 gl Program Block i Pein Copy Folder LM90 P
213. puts Manual Input Controls Analog Inputs Voted Analog Inputs Analog Discrepancy Reporting Non Voted Analog Inputs in GMR Input Groups Non GMR Analog Blocks Overview The input subsystem is the part of a GMR system that gathers input data It may consist of GMR Input groups of 1 to 3 discrete or analog blocks m Individual non voted discrete and analog blocks The following illustration represents basic elements of an input subsystem Triple Genius Busses Input Block Group l non redundant Input Block B C Y Non voted Pla o L Triple Input Sensors GMR blocks are arranged in groups of 1 2 or 3 blocks Within a group all the blocks must be the same type The input group shown above consists of three Genius blocks Each has its own input sensors monitoring the same parts of the application process Each block sends the input data from its sensors to three Series 90 70 PLCs For simplification the illustration only shows one input circuit on each block However each group can serve multiple GMR inputs In addition circuits that are not needed for GMR inputs can be used for non voted inputs or outputs G
214. py the download utility file KEY0 DEF from the GMR software diskette to the folder that contains the application program This can be done at any time 2 When you are ready to store an updated application program to the redundant PLCs go to the Logicmaster 90 main programming menu 3 To begin the store operation from the main menu screen press the ALT and 0 keys at the same time For each redundant PLC in sequence the software will prompt Press the Space Bar to Continue 4 When you press the Space Bar the PLC is put into Stop mode with its outputs disabled 5 With all PLCs stopped the software again prompts Press the Space Bar to Continue 6 For each PLC when you press the Space Bar the utility stores the updated application program and places the PLC in Run mode with its outputs enabled 7 After all PLCs have been restarted the Logicmaster 90 main menu returns GFK 0787B Chapter 7 Programming Information 7 35 Customizing the Download Utility for Other PLC IDs For PLCs with other PLC IDs you need to edit the file KEY0 DEF before adding it to the Program Folder in Logicmaster 1 2 3 Install the GMR software diskette in your computer s diskette drive At the DOS prompt log onto that drive Copy the Download utility files from the diskette to your fixed disk drive UPLC EXE Update PLC Names utility LM_KEYS LST List of keynames required by the Download utility KEY0 DEF Download utility file Log onto
215. r 1 Introduction 1 3 Busses and Bus Controllers In a GMR system there can be one to three bus controllers per bus per PLC Larger systems may require more than one I O subsystem For example the GMR system represented below has two I O subsystems for a total of six independent Genius busses and 18 bus controllers 1 0 Sub system 7 VO Sub system Each Genius bus uses a single twinax cable over distances of up to 7500 feet and data rates of up to 153 6K baud Each PLC may have up to 31 Genius bus controllers in multiple racks Additional Bus Controllers for Communications The Genius busses that support GMR input output groups are also used for internal communications between PLCs as explained on the previous page They should not be used for datagram communications Separate busses for communications can be used for datagrams or additional global data in the application program The Bus baud rate should be selected on the basis of the calculations in the Genius I O System and Communications User s Manual GFK 90486 For correct autotesting ina GMR system the Genius bus scan time should not be be more than 60mS Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 Operation Overv
216. r more information about memory requirements for GMR refer to the Programming chapter GBC_1 Enter the rack and slot location for the two bus controllers in the GMR GBC_2 group that will be exchanging global data These can be any two bus controllers in the system but they must be at the same rack and slot location in each PLC M Start Ref If the PLCs will exchange M data during startup enter a starting reference and length in words If the PLCs will not exchange M data at startup enter 0 in the M length field If another PLC is already online during initialization the initializing PLC will place M data received from that PLC into its own M memory in this location If both other PLCs are already online the initializing PLC will place data from the PLC with the highest serial bus address into this M location This M location can be the same as the M memory used in the application program It is a temporary storage area that is only used at startup to store a copy of another PLC s M data It must begin on a byte boundary multiple of 8 1 By default this starting reference is M0001 The default length next field is 16 M Length Enter the length in words for the M temporary storage area It should equal the quantity in words of M memory used in the application program 6 20 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 GFK 0787B 6
217. r voted analog inputs analog blocks must be set up as 2 block or 3 block input groups The input values are in engineering units For a 3 block group the GMR software compares the three corresponding inputs for each channel and selects the intermediate value This value is made available to the application program The application program can also access the original input values Field Input Data PLC Selects the Single Input Provided Intermediate Value to Application Logic Input A 152 T Input B 150 150 Input C 110 For example in the illustration above inputs A B and C might represent the first channel on each block in a three block group The PLC would place the selected input value into the first voted input word for that group Number of Input Sensors per Voted Channel For each voted input channel in a 3 block group either single or triple input sensors that are compatible with the input drive requirements of the Genius blocks can be used Current loop 4 20mA devices must be converted to voltage when a single sensor is used Analog Voting Adaptation If a failure discrepancy fault or Genius fault occurs the GMR software rejects the faulty data Depending on the configuration of the input group input voting may go from three inputs to two inputs to one input or from three inputs to two inputs to the configured default value GFK 0787B Chapter 2 Input Subsystem 2 9 Analo
218. ram logic Inter processor Communications The PLCs exchange initialization data at startup then operate asynchronously They communicate regularly using Global Data Each Genius bus scan each PLC broadcasts up to 64 words of Global Data This includes 8 words of system information An additional 56 words of Global Data are available for use by the application program Redundancy is also built into Global Data communications Each message is sent twice using different busses The PLCs may also be joined in a multidrop Series Ninety Protocol SNP network A host computer on the network can be used for gathering data from the system In addition the SNP network permits convenient program updates using the Logicmaster 90 programming software and the Program Download utility included on the GMR software diskette PLCA PLC B PLC C v v CuO Multidrop Cable RS 232 422 Converter Multidrop cable is catalog number IC690CBL714 1 cable Two cables are needed for 3 CPUs All other normal Series 90 70 communications interfaces are also available If required for the application the host software should collect data from each CPU and perform the necessary voting Chapte
219. rcuit 16 must be used as an e output SaM 10 e If no autotesting is to be done on this group e of inputs the input devices must not be 11 wired to circuit 16 They must be wired to 12 Typical for each of up to 15 inputs the power source instead Diode required at each powerfeed output for Input Autotesting 1N5400 or equivalent lt o e Point 16 must also be wired to i corresponding point on two other input blocks if simplex Ovpc sensors are used SSSSSSSSSS08 VIVIL V V VIG V P O V VIG V G O VIVIG O VIO S A Ground m In three block input group each block is connected to one bus of three m Ifan input is wired for tristate operation the circuit LED glows dimly when the input off m If redundant power supplies are to be used they should be diode ORed power supplies providing common power to all blocks in a group Different groups may use different power sources 8 6 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 Input Wiring continued Block Wiring for 16 Circuit Sink Block in an Input Group DC Sink Block IC660BBD021 gt were gt gt 0 If single sensor it must also be w
220. rite Access a a On this screen enter the input discrepancy filter time in seconds This is the amount of time in seconds that a particular input may be discrepant before the CPU places a message in the I O Fault Table and sets the appropriate fault contact for that voted input This input discrepancy filter time applies to both discrete and analog inputs This time defaults to one second The range is 1 to 65535 seconds Exiting the Window When you select OK your entries are saved and the window disappears If you want to exit the window and reset all fields to their previous content select Close or Cancel instead GFK 0787B Chapter 6 Configuration 6 17 VO Limits Select System again From the configuration menu select Config Limits click the mouse on that line or cursor down and press Enter PU est Interval Input Output Ana log Tables isc Filter Conf ig Init Data ault Actions rite Access In Voted Discrete Groups Groups In Groups imits 16 Pt 6In val Size E 1 E J 4In 20ut ZR Size k Sal ae Qo 32 Pt Entries made on this screen determine how the GMR software allocates memory The maximum number of groups that can be configured is 128 Additional parameter limits for this screen are summarized below Item Parameters Comment Totalnumber of voted digital inputs 1 112 788 CPU In increments of 16 or 32 an
221. roup current to output loads is shared Therefore it is not possible to be sure exactly how much power is being provided by each block If 16 circuit blocks in a GMR output group are configured for No Load fault reporting the minimum connected load that can be used is 100mA If blocks in a 4 block output group are configured for No Load reporting a system output No Load fault will only be reported if both of the source blocks or both of the sink blocks report No Load faults 3 6 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 Operation of a 4 Block Output Group Each GMR output state is sent to four blocks set up in an H pattern as shown on the opposite page This type of grouping creates a fault tolerant system where any single point of failure does not cause the system to lose control of a critical load This is achieved by m output voting which is explained on page 3 3 and m the electrical characteristics of sink and source blocks and m redundant busses Electrical Characteristics of Sink and Source Blocks If a load is wired between a sink and source block both the sink output and the source output must be active to control the load If either the sink output or the source output fails On turning the other Off turns the load Off Doubling the number of blocks to four and putting them in an H pattern means that if any single point of failure occurs the system
222. s COPY PROGRAM FOLDER TO CURRENT FOLDER Source Folder TRAxe ito Current Folder GMRPROG Current drawer is D LN9O Information to be copied The ENTIRE FOLDER selection ENTIRE FOLDER N CYN will copy everything from the PROGRAM LOGIC Y CYAN source folder Clogic config CONF IGURAT ION N CYN reference data teach files REFERENCE TABLES Y CYAN and any other files to the current folder 7 28 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 Adding the GMR Configuration to the Application Program Folder The GMR configuration software outputs a program block file named G_M_R10 EXE which must be added to the folder containing the application program By default this file is located in the GMR Configuration Utility subdirectory To add the G_LM_R10 program block to the application program folder use the Librarian function of the Logicmaster software There are two basic procedures to complete m Add G_M_R10 to the Logicmaster librarian Import G_M_R10 from the Librarian to the application Program Folder Adding GMR_10 to the Logicmaster Librarian 1 Inthe Logicmaster 90 programming software select Program Block Librarian Press F6 from the Programming Software menu The Librarian menu appears LIBRARIAN FUNCTIONS FZ List Contents of Library F3 Import Library Element To Folder F4 Import Library Block To Folder a
223. s plus the copied fault tolerant outputs to the Genius blocks Discrete Output Table Application Program O Logic Output iy A oie Oups CI Available for a gt Non voted Simplex Outputs Outputs GMR o Logi k Reserved memory 2 ooe Fault tolerant _ Fault tolerant Outputs ___ gt Output Devices Chapter 4 PLC Subsystem 4 17 I O Shutdown When the GMR system diagnoses a discrete I O fault it logs the appropriate faults in its fault tables and set the appropriate fault contacts For certain types of discrete I O faults the system optionally allows a predefined amount of time for the problem that caused the fault to be repaired If the problem is not rectified within this period of time an I O Shutdown of the I O corresponding to the affected block s occurs I O shut down can be completely disabled and prevented by turning on the Cancel I O Shutdown control bit M12265 I O Shutdown is defined as setting the affected I O to its safe state For outputs this is the Off state For discrete inputs the shutdown state is the default state for an input group in the GMR configuration This can be selected on an input group basis Synchronousor Asynchronous Input Autotest and I O Shutdown In the GMR configuration discrete input groups can be configured for either Synchronous or Asynchronous input autotesting If redundant discrete input devices are used
224. s 90 70 PLC Reference Manual GFK 0265 Important Note In the section on Sweep Time Impact the Series 90 70 PLC Reference Manual describes the technique of eliminating the first and second parts of the Bus Controller s sweep time contribution by closing the system communications window setting its time to 0 This technique should NOT be used in a GMR system 4 6 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 Input Processing GFK 0787B During the Input Scan portion of the CPU sweep the PLC receives inputs from the discrete and analog input blocks It stores the input data in different areas of memory as described below After the Input Scan the GMR logic performs voting on the inputs configured for GMR redundancy and places the results into the discrete and analog input tables where they are available to the application program Discrepancies If there is a discrepancy between the original input data for an input and the voted input state the GMR software automatically places a message in the I O Fault Table where it is available to the Logicmaster 90 software and the application program logic Also fault bits that report the discrepancy fault for each voted input are available to the application program so it can take appropriate action if a discrepancy fault occurs Discrepancy faults are latched Discrepancy reporting is discussed in the chapter on
225. s in a group Different groups may use different power sources GFK 0787B Chapter 8 Installation Information 8 7 Input Wiring continued Block Wiring for 32 Circuit Source Block in an Input Group DC Source Block IC660BBD024 Uo If single sensor it must also be wired to corresponding point on Connection if no points on the two other input blocks Rae block are to be autotested gt gt 3 must disconnect output 16 ma i 22V to 30V DC s Genius Bus RA S2 Connections Q SHLD IN J Q SHLD out Bo A gt DCs DC 10 Device 1 A Required at each input for Input Autotesting 1N5400 or equivalent Required at each powerfeed output for Input Autotesting 1N5400 or equivalent Ee Ng 16 lt If group inputs are configured for autotesting circuit 16 must be used as an output If no autotesting is to be done on this group of inputs the input devices must not be wired to circuit 16 They must be wired to the power source instead If group uses single sensors point 16 must also be wired to corresponding point on two other input blocks ac re Device 32 QOVN OV OV OO VY CV CVO V OCYV OY VOVVOOCVOVOV VO VVYVVVOOYN J Ovpc PoP Ground m In three block input group each block is connected to one bus of three m If redundant power supplies are to be us
226. s is different from operation of the Close button in windows that are part of the standard GMR default configuration for example the CPU Configuration window where default entries may be used Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 6 Configuring the Input Subsystem for a Bus Controller Group With the rack and slot locations for a bus controller group configured the next step is to configure the input subsystem for that bus controller group Click on Insert or press ALT I to display the Insert menu Select Input Group from the menu by clicking on that item or by pressing I Click on the type of group to insert or press its highlighted letter key or use the cursor keys to select an item then press the Return key to display a sub menu of input block types BC Group nput Group gt riplex Discrete uplex Discrete implex Discrete na log From this menu select and configure the types of input groups in the input subsystem Select To Configure triplex discrete each group of three input blocks duplex discrete each group of two input blocks simplex discrete each group of one input block analog each group of analog blocks After you select the group type additional configuration screens appear for configuring the GMR features for that group See the instructions on the following pages Exiting a Block Group Window When you have co
227. s max is configur able Some references are automatically assigned by the GMR software Others are available for application use Rmax 320 66xN to Rmx The length of R data is configurable At left the letter N rep resents the number of bus controllers on the bus The GMR software requires the use of several areas of R memory as detailed in this chapter defaults starting reference and lengthare configurable G0001 to G0896 The GMR software provides these memory areas for applica GA0001 to GA0896 tion global data transfer The correct method of program GBO0001 to GB0896 ming global data ina GMR system is described in this chap GCO0001 to GC0896 ter M12225 to M12256 System status bits M12257 to M12288 System control flags ROO01 to RO256 K startup initialization data from another online PLC References shown at left are the defaults refer to your GMR configuration printout for the actual references used RO257 to RO272 defaults starting reference is con figurable M startup initialization data from another PLC Refer ences shown at left are the defaults refer to your GMR con figuration printout for the actual references used M defaults to 16 words long Memor y Write Access With the exceptions noted above the following memory areas can be written to if Write Access is enabled during GMR configuration R Registers AI Analog Input Table AQ Analog O
228. sage Mismatch message logged logged In all cases a fault message is logged into the PLC Fault Table If the fault condition remains after the PLC Fault is reset the message is relogged The message indicates which PLC has changed or which mismatches A change to the GMR Configuration information takes effect only when the PLC is transitioned from Stop to Run mode Therefore the PLC should be placed in Stop mode before downloading a new GMR Configuration Autotesting is suspended if a PLC is started up with a new configuration After all PLCs have been given the same configuration autotesting will resume Chapter 4 PLC Subsystem Data Initialization During startup a PLC either sets a flag to notify the application program to initialize R and M memory or synchronizes the data with corresponding data in the other PLC s The M data is typically latch logic states while the R data is typically timer counter data The beginning addresses and lengths of both areas are set up during configuration m If both the other PLCs are offline application programs not running and not sending output data the initializing PLC sets a cold start flag to the application program which can initialize the selected memory areas YR and M as appropriate m If either or both of the other PLCs is already online running the application program and transmitting output data the initializing PLC synchronizes
229. ser s Manual March 1995 Analog I O Addressing The size of the Analog Input Table is defined during configuration The maximum size is 8192 analog channels words Like the discrete Input and Output Tables the Analog Input Table is divided into sections Analog Input Table Logic non voted Inputs a ONS A inputs B inputs B C inputs amp The voted analog references are assigned starting at A10001 The size of the voted analog input area is determined by the number of voted analog inputs including spares Physical input data from analog block groups is located at the end of the Analog Input Table in the areas labelled A B and C above Each of these areas is equal in length to the number of voted inputs at the beginning of the table GFK 0787B Chapter 7 Programming Information 7 7 Example An application has sixteen analog input groups each of which is a 6 input group including spares The total number of analog inputs from these blocks would be 16 x 6 96 words required If the Analog Input Table had a configured length of 1024 these inputs would be located in the table as shown below A10001 A10096 Analog Input Table Voted Analog Inputs 96 A10097 A10736 Available for single Genius analog inputs or other use A10737 A10832 Bus A inputs 96 A10833 A10928 Bus B inputs 96 A10929 A11
230. sing of the point occurs The maximum number of pulses that can occur is 7 with a minimum duration of 1 7mS and a maximum duration of 20mS Also these is a delay of approximately 5 to 15 mS until the same point is pulsed again These times depend greatly on the configurations of the other points ON OFF ON Test Similar activity occurs for this test The initial time a point is Off is about 5mS The only fault checked for in this case however is that the volts feedback agrees with the Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 commanded state If it does not the point is pulsed Off again for about 7 5mS A maximum of two pulses of approximately 5mS and 7 5mS duration can occur The 7 5mS pulse occurs only if the volts feedback for the first pulse is incorrect Each output device s characteristics should be checked against the list above to verify that it can be autotested and or used in the 4 block output group Often in cases where a desired output device does not by itself meet a requirement external components can be added to change its characteristics and allow it to operate in a 4 block output group and be autotested Or a diagnostic feature such as autotest No Load or Overload can be disabled to allow it to operate in a 4 block output group The following are two examples GE Catalog Number CR120BDXXX48 Series A 600 Volt Industrial Relay XXX represents
231. ssing Fault Contacts for Analog Inputs As with discrete inputs voted analog inputs have fault contacts associated with both the raw data inputs and the corresponding voted inputs Non voted analog inputs also have associated fault contacts For more information about fault contacts see page 7 21 Conditions that Cause these Analog In Tabl alog Input Table Fault Contacts to be Set ge Any fault bel Voting i Voted Inputs ny fault below Logic Pe e Genius fault Non voted Inputs Genius fault Discrepancy fault Bus A inputs Genius fault Discrepancy fault Bus B inputs Genius fault Bus C inputs Discrepancy fault m Genius faults include Loss of Block plus the following Underrange the input exceeds 32 767 engineering units or 4095 counts The block transmits an underrange message and sets the value to its minimum Overrange the input exceeds 32 767 engineering units or 4095 counts The block transmits an overrange message and sets the value to its maximum Open wire Used only for 4 20mA inputs The fault contact is set if the input current falls below 2mA Note that a 4 to 20 mA signal to two or more blocks must be converted to a voltage in which case Open Wire faults are not detected Wiring error Internal channel fault an internal channel fault such as the failure of the A D converter Block outp
232. stem GFK 0787B User s Manual March 1995 Output Processing GFK 0787B For outputs the PLC does not perform redundancy voting Instead voting is done by the specified types of discrete output block groups Analog blocks do not provide redundancy voting or autotest features Both discrete and analog Genius blocks can be used in the output subsystem as non GMR blocks however Discrete Outputs As it does for inputs the GMR software uses separate areas of the Output Table for non voted outputs fault tolerant outputs and copies of the fault tolerant outputs After the application program executes the GMR software processes discrete output data as described below The application program places outputs into the discrete Output Table Data for blocks that are included in the GMR configuration is placed at the start of the output table In the illustration below the application program outputs for redundant blocks are labelled logic outputs This data is followed by outputs for non voted blocks m The GMR software copies these logic output into the bottom portion of the Output Table This data shown as Fault tolerant Outputs in the illustration below is used for physical outputs for the blocks This separation of physical outputs from logical outputs prevents disruption of outputs such as latches and seal circuits during autotesting m During the output scan portion of the CPU sweep the CPU sends the non voted output
233. stem GFK 0787B User s Manual March 1995 4 The autotest master pulse tests Block A Any faults on block A are noted Block A Pulse tested A il B Failed Switch outputs still overridden OFF Load Block C outputs still c D overridden ON c 5 The master resets all four blocks in the output group 6 Overrides on block C are cancelled l n gt g Failed Switch outputs still overridden OFF ig E Load L Block C output overrides C cancelled 7 The master cancels overrides on block B except for any outputs that have tripped erroneously d e C D g Overrides conditionally cancelled Load 8 The autotest master repeats the above process for blocks D A B then A D C then B C D 9 The autotest master reports faults to the other PLCs if any All the PLCs log any faults that occur into their Fault Tables 10 The autotest master continues testing with the next group GFK 0787B Chapter 5 Diagnostics 5 9 5 10 Pulse Test Operation The Output Autotest uses the standard Genius block Pulse Test feature During this test the system is on line and available For the test to be performed m All blocks in the group must be on line m There may be no I O override applied to any block in the gr
234. stem should be made in such a way that a block s terminal assembly can be removed from the bus during system operation without breaking the bus and disrupting communications To do that the bus can be installed at each block using an intermediate connector as shown below ae an l 2 oy N uU T pes lt S1 s2 v i l s sow WL gt l 2 ee UL Oll SHLD IN SHLD OUT ea sho our AEAN Drm An alternative method but somewhat less desirable is to solder together the corresponding wire ends before inserting then into the block s terminals If such soldered wires are removed while the system is operating it is important to cover the ends of the wires with tape to prevent shorting the signal wires to one another or to ground Both of these installations allow a block s terminal assembly to be removed while maintaining data integrity on the bus When blocks are connected to the bus in this manner field wiring to the blocks should also provide a means of disconnecting power to individual blocks Termination Boards 8 2 Termination boards that will make it easier to integrate Genius blocks into redundant groups 4 block output groups or 3 or 2 block input groups are currently being developed by a third party supplier Please contact your GE Fanuc Sales representative for more information abou
235. sting and a register where this interval should be stored PU est Interval In Disc Filter Period Register Config Limits minutes ZR Init Data Test end to test start ault Actions rite Access 0 Continuous a ee On this screen enter Period Specify an autotest interval of 1 to 65535 minutes This becomes the time interval the system will wait between autotests of the I O subsystem Register Specify a R register When the system is started and goes through initialization this register is initialized to the period configured above The GMR system reads this register to determine the autotest interval The contents of this register can be modified by the application program or changed using the Logicmaster programming software to alter the autotest interval if desired without reconfiguring the system See the Programming chapter for information about R memory usage in a GMR system When you have completed this screen select OK to return to the System screen Exiting the Window When you select OK your entries are saved and the window disappears If you want to exit the window and reset all fields to their previous content select Close or Cancel instead 6 16 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 Input Discrepancy Filter PU est Interval In isc Filter Filter seconds Config Limits Init Data ault Actions K
236. system for a Bus Controller Group Configuring the Output Subsystem for a Bus Controller Group Completing the Logicmaster 90 Configuration Configuring Bus Controllers Creating and Copying the PLC Configuration Logicmaster Configuration Summary Configuring Genius I O Blocks Editing the Reference Addresses Copying Configurations s Configuration Overview In a GMR system there are three basic configuration steps m Completing the GMR configuration using the GMR configuration software m Configuring the Series 90 70 PLCs m Configuring the Genius blocks in the system not shown below GMR CONFIGURATION LM90 CONFIGURATION GMR Configuration Printout EE GMR G_M_R10 Diskette Program Block CONFIG EXE oe LM90 Copy Folder LM90 Copy Folder y 1 CONFIGA CONFIGB CONFIGC GMRxxyy Download utilities The basic configuration steps are described below The Basic Steps of Configuration 1 Complete the GMR configuration This information is the same for the redundant PLCs there is only one GMR configuration needed for the system GMR configuration sets up the parameters that will be used by the system including reference addresses The GMR configuration produces m A printout of the GMR Configuration Use it as a reference during subsequent programming
237. t L aut from SSIIE ET z Outputs ed Available for S non voted Available for S non voted non voted Inputs 1 0 non voted Outputs 1 0 J EA eee E E S N a Bus A inputs Reserved memory Bus A B C paren 7B utpu Bus B inputs gt Inputs gt Mernory Bus C inputs 2 a eae Reserved Reserved inputs gt Reserved Physical Redundant NS Outputs to Outputs Blocks 110240r l12288 Q1024 or Q12288 m Voted inputs and logical redundant outputs occupy the beginning of the discrete 1 O tables Normally the application program utilizes these inputs and outputs although it can also access the rest of the I O table data if necessary Non voted inputs and outputs occupy the next portions of the Input and Output Tables These are the inputs and outputs of blocks that are present in the system either as non voted blocks on GMR busses or on other busses The starting address for non voted data depends on the amount of redundant data as explained above In the same example if there were 64 voted inputs and 48 logic outputs non voted I O data would begin at addresses 10065 and Q049 m The area of Output Table memory that corresponds to the bus A B and C input data in the Input Table is reserved The reason this area is reserved is that input blocks used in redundancy are configured as combination input output blocks So the corresponding output references should not be used for other purposes m The last part of the O
238. t O K or C ancel to quit the Options window Insert any additional GMR bus controller groups in the same PLC s Configure each additional bus controller group as described in step 6 Save the configuration This creates a file with the filename extension SAV in the selected directory by default this is the same directory where the GMR CONFIG EXE software is located With the configuration file still present in the computer s RAM memory create the GMR configuration output file Select Output then select Write Configuration from the Output menu This creates an output file with the filename G_M_R10 EXE This file is stored in the currently selected directory Print out the configuration Select Output then select Print Out from the Output menu Import the configuration into your application folder as described on page 6 46 Chapter 6 Configuration 6 9 Creating Selecting a File To create a new configuration or begin editing an existing file select File If you are using a mouse click on File in the upper left corner of the screen If you are making keyboard entries type Alt F You can now start a new configuration or open an existing configuration From the same screen you can also save a file with the same name or with a new name close a file or exit the GMR Configuration Software Start new configuration New System N or Enter Open previously saved configuration Open O or F3 Save a configuration Save S
239. t for the first PLC in the GMR system to come online The first PLC to come online has its output states compared with the voted outputs currently present at the output block groups Remember that the output states of each output block with no PLCs online are determined by the output default configuration 0 1 or hold last state for each individual output circuit at each output block For example if output defaults are set to Off 0 and a PLC is put online with the same outputs already driven to On 1 states the output block keeps the PLC offline until the driven output states agree or until the FORCLOG control bit is set to force the PLC online with respect to the output block Performing I O Fault Reset It is very unlikely but possible that I O faults would occur during the initialization powerup or stop start cycle of one of the GMR CPUs Faults occurring during the initialization of aGMR CPU are reported to that CPU Therefore it is recommended that GFK 0787B Chapter 7 Programming Information 7 17 anI O Fault Reset be performed when any of the GMR CPUs are initialized which will cause any currentI O faultinformation to be re reported If manual output controls are used in a GMR system and the appropriate GMR Autotest inhibit inputs are used to block faults created by the manual controls any standard Genius type fault open overload short etc is also blocked during the time the inhibit input is on It is therefore recommend
240. t the PLC Fault Table is full S0010 IO_FULL when set indicates that the I O Fault Table is full SC0010 SY_FLT when set indicates that an entry has been placed in the PLC Fault Table SC0011 IO_FLT when set indicates that an entry has been placed in the I O Fault Table SC0012 SY_PRES when set indicates that there is presently at least one entry in the PLC Fault Table SC0013 IO_PRES when set indicates that there is presently at least one entry in the I O Fault Table Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 GMR Status and Control M References The GMR system software uses several M references as status or control bits Status bits are used by the GMR software to provide information about GMR operations These references can be read as needed by the application program The control bits can be used by the application program to provide information to the GMR software M Status References The following table lists the GMR system status flags Reference Nickname Name Meaning M12225 PLCA PLC Ident is A This is PLC A all GMR bus controllers 31 For references M12225 26 and 27 only one will be set in each PLC M12226 PLCB PLC Ident is B This is PLC A all GMR bus controllers 30 M12227 PLCC PLC Ident is C This is PLC A all GMR bus controllers 2
241. t these GMR Termination Boards Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 Input Wiring Calculating Voltage Drops on Tristate Inputs It is important to consider the field wiring runs required for devices configured as tristate inputs Devices that are powered by 24V DC will have a voltage reducing component inserted at the field device to provide an input threshold range for three states The table on page 2 7 shows appropriate ranges Wiring runs can reduce the voltage at the input block terminal further to an inoperable level depending on the length conductor and gauge Isolation diodes placed before the terminal on the input will also drop the voltage Most applications do not have limitations created by these factors However to ensure that all input state operations are indicated correctly calculations should include the field signal voltage the wire resistance times the length and the voltage drop in any barriers or isolation devices to determine the actual voltage present at the input terminal Additional information about input blocks is located in the Genius I O Discrete and Analog Blocks User s Manual GEK 90486 2 GFK 0787B Chapter 8 Installation Information 8 3 Single Sensor to Three Blocks Triple Bus 8 4 PLCA PLC B PLC C aaa FIGS JSG Rice 6 2V Zener Diodes for i celcle ar 7 clele I Tulelele i
242. t to 0 or to a percentage value that causes a discrepancy if inputs at the low portion of a range vary by an amount more than that already allowed by the Limit percentage setting The GMR configuration utility must be used to print the GMR specific configuration data The TUV site engineer will use this printout to verify the configuration data with the requirements of the overall application Appendix A T V Certification A 3 GFT 166 Revision 1 3 April 4 1995 Configuration worksheets are available for all I O block types in the Genius I O Discrete and Analog Blocks User s Manual GEK 90486 2 Each I O block used in the safety relevant portion of the system must have a worksheet prepared Configuration Protect must be Enabled in each block The HHM must be configured to use serial bus address 0 the default The following configuration options must be disabled and the HHM keyswitch must be set to MON and the key removed Change Block ID Change Block Baud Rate Change Block Configuration Circuit Forcing Clear Block Faults All Series 90 70 instructions can be used in the non safety portion of the user program but the following instructions must not be used in the safety relevant portion of the user program VME_CFG_RD VME_CFG_WRT PIDISA PIDIND DO_IO SUSIO ALL SFC functions COMMREQ DATA_INIT_COMM CALL SUB CALLEXTERNAL SVCREOQ functions 1 3 4 6 8 14 and 19 may not be used The NON safety relevant porti
243. ta values This is described in more detail on page 4 4 8 The Inhibit bit is released allowing the PLCs to start executing the application program 9 When the Continue control flag is set by the user s application program the PLC begins sending outputs computed by the application program to Genius blocks 10 If these outputs match the current output states of the blocks they are accepted by the blocks If a block detects that outputs from a PLC do not match the current 4 2 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 GFK 0787B Startup requires multiple PLC sweeps to complete Execution of the application program output states of the blocks the block does not use those outputs in its output voting The block s continue to ignore outputs from the PLC until they match those of the block s voted outputs or until commanded to do so by setting the FORCLOG command bit M12263 This is covered on more detail on page 7 17 should not be started until initialization and synchronization have been completed successfully Online Changes The GMR configuration can be set up to either permit or reject online program changes These changes result in checksum mismatches Such mismatches are handled as described below by the PLCs in the system Typeof Mismatch Configured to Allow Changes Configured to RejectChanges
244. tall any necessary mouse driver on your computer When you are ready to begin using the software at the DOS prompt type config lt retur n gt The following screen appears a File System Insert Window Output GENIUS MODULAR REDUNDANCY Configuration Utility Revision xx yy c GE Fanuc Automation press any key to continue C F2 Save F3 Open Alt F3 Close F5 Zoom Ctrl F5 Move F6 Next Alt X Exit A Chapter 6 Configuration 6 5 Mouse and Keyboard Guide for the Configuration Software Either a mouse or keyboard can be used with the GMR Configuration Software It is easiest to use a mouse Using a Mouse When using a mouse simply move to the item you want to select and click on it Some windows can be closed zoomed or resized using a mouse Look for the symbols illustrated below 01 GBC Group Click hereto N close window x Click here to zoom window Click and drag here to 74 resize window Using a Keyboard When making selections and entries from a keyboard refer to the special key assignments shown at the bottom of the configuration screen F2 Save F3 Open Alt F3 Close F5 Zoom Ctrl F5 Move F6 Next Alt X Exit Additional keyboard functions are described below Alt letter Press the Alt key then the highlighted letter key to select one of the functions displayed at the top of the configuration screen File System Insert Window Output Save F2 Use the F2 ke
245. tem operators and others using the Logicmaster 90 70 software to program configure monitor or control a Series 90 70 PLC and or a remote drop Logicmaster 90 Software Reference Manual GFK 0265 Reference manual which describes program structure and defines program instructions for the Series 90 70 PLC Series 90 70 Bus ControllerUser s Manual GFK 0398 Reference manual for the Bus Controller which interfaces a Genius bus to a Series 90 70 PLC This book describes the installation and operation of the Bus Controller It also contains the programming information needed to interface Genius I O devices to a Series 90 70 PLC We Welcome Your Comments and Suggestions At GE Fanuc automation we strive to produce quality technical documentation After you have used this manual please take a few moments to complete and return the Reader s Comment Card located on the next page Jeanne L Grimsby Senior Technical Writer Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 Contents Chapter 1 INGOUUCHON fata ciaee E E bea Saeed em ware 1 1 Components of a GMR Systetigs aeiyad peNelee ewes eek 1 2 Series 90 70 PECS iesin eae pte etes Mnhebe tree oie Waal arent 1 3 Busses and Bus Controllers so 2405 Aee oS ses eee ewe ees ee ees 1 4 Operation Overview pcwiastited oo al hee Pea dey Pat rnrn rennen 1 5 Gemius IZO BlotKS s tans ie caine eieiei le eas ee baled oy ott ees 1
246. ter on Diagnostics for more information In addition the GMR software maintains status flags that can be monitored by the application program to check the state of communications between PLCs These are described in the chapter on Programming Entering Clearing or Setting Global Data The application program can read or transmit Global Data as required Refer to the Programming chapter for details In addition the application program can use the PLC OK flag to clear or preset the data as required This is also described in the Programming chapter Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 Chapter Diagnostics This chapter describes m Diagnostics ina GMR System GMR Autotesting m GMR Discrepancy Reporting Input Line Fault Detection ina GMR Application m The PLCandI O Fault Tables in a GMR System m Monitoring Manual Output Controls m Faultand Alarm Contacts Programming for Diagnostics The Programming chapter of this book explains some programming considerations for a GMR application It includes information about GFK 0787B Programming for Fault and Alarm contacts I OPoint Faults Monitoring the System Status references Monitoring system forces and overrides Monitoring the I O and PLC Fault Tables Diagnostics in a GMR System In a GMR system extensive diagnostic capabilities are provided by standard Genius I O diagnostics and by the specia
247. tes and ss seconds 10871 Shutdown Cancelled System simplex shutdown cancelled 10872 System Shutdown System has shut down 10894 Config changed rs b d The block level configuration was changed by the specified device 10898 GMR Fault Handler Error Fault handler received a fault for an invalid discrete block 10899 GMR Fault Handler Error Fault handler received a fault for an invalid analod block 10902 User_IF GMR version Module version number does not match the GMR system version number 5 20 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System User s Manual March 1995 GFK 0787B Code Message Meaning 10903 User_IF Invalid Table Module was called with extended mode table number when the module was in nor mal mode 10903 Bad Table c h Module was called with an invalid table number c requested table in decimal h requested table in hexadecimal 10905 User_IF Invalid Range Start or end address parameter is out of range for the specified table type 10906 User_IF T able Space Destination parameter is out of range for the destination type of memory 10907 No fault contacts An attempt was made to read fault contact data but no fault contacts were configured 10908 Bad blk loc rs b d An attempt was made to read an I O shutdown timer for an invalid block Generated by GMR_09 10909 Bad GBC Loc rs An attempt was made to read all I O shutdown timers for an invalid GBC Generated
248. that fixed disk drive At the DOS prompt enter UPLC At the prompt enter the PLC ID you want to use instead of PLCA The name can be from 1 to 7 characters long It can include any alphanumeric characters and the following special characters 7 lt gt amp Continue and enter new names for PLCB and PLCC The software creates a new Download utility file named NEW DEE When it is completed it displays Processing Complete Copy the new file to the Logicmaster Program Folder containing the application program Rename the file to KEYO DEF during the copy For example C COPY NEW DEE FOLDERS PROGRAM KEY0 DEF The edited file can now be used as described on the previous page Genius Modular Redundancy Flexible Triple Modular Redundant TMR System User s Manual March 1995 GFK 0787B Storing a Program to the PLC the System IS Configured for Online Changes GFK 0787B For a system configured to allow online changes the following sequence illustrates how an online ladder logic program change could be done in a triplex CPU System System configuration changes are not intended to be done online Online ladder logic changes are intended for system debug and commissioning 1 Using the Logicmaster 90 70 Programming Software in the Monitor mode make a direct or multidrop connection to PLC A Change the Logicmaster 90 70 programmer mode to the Online mode and change the CPU Mem
249. that when the PLC started up the other two PLCs were already online and running their application programs When the PLC compared the M initialization data from the other PLCs it found a discrepancy M12234 SYSFLT If set to 1 this flag indicates that when the PLC started up it experienced a problem trying to communicate with one of the bus controllers or a Genius I O block Enabling Outputs At Startup Following initialization the application program begins to execute As a result of one or more sweeps through the logic output data is generated However outputs remain disabled and the output data is not sent on the bus Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 Prior to sending the outputs the application program may check the status flags If any are found to be 1 the application program may decide to process the initialized data before continuing When the application program has computed valid outputs that can be sent to output blocks the application program must set control bit M12257 CONTINUE to 1 When this is done outputs to the blocks are enabled If outputs fail to be enabled successfully the GMR Software sets the System Fault status flag M12235 to 1 PLC Logon Control PLC Logon Control prevents output states from inadvertently changing state when a newly initialized PLC is put online by the application program The application
250. the M and R data with that of the other PLC s 1 The initializing PLC first reads R then M data from the online PLC with the higher bus controller serial bus address 31 takes precedence over 30 30 over 29 Data is read in ascending order The PLC reads data only once If data in the online PLC changes after the initializing PLC reads it the change is not noticed To minimize data differences on continually changing data such as timer and counter accumulators they should be located at the end top of the R area because it is read last 2 After reading all of the selected R and M data from the first online PLC the initializing PLC then reads M data from the other online PLC It places this data into a configurable area of R memory 3 After reading the M data from both online PLCs the initializing PLC compares the data If the data does not match it tries again After a total of three retries if the data still does not match the PLC may either Halt the PLC if this fault is configured as fatal Allow the PLC to continue operating if it is configured as diagnostic and set the appropriate M status flag M12232 Init Miscompare at startup M12234 System fault at startup The action taken is determined by the GMR configuration see page 6 22 4 It may take several CPU sweeps to read all the data from both PLCs Data is read in quantities of up to 64 words at a time The data transfer is divided across the busses to
251. the safety relevant portion of the system must be periodically e g once per year checked and verified manually by the application and verification of input signals of at least 10 equally spaced points starting at the low end of the range of the input and ending at the high end At least two physical points of every triplex analog input must be tested in this manner Simplex analog sensors can be connected to redundant analog inputs only if those analog inputs are de coupled by suitable devices When blocks IC660BBD024 and IC660BBD025 are used as part of a redundant H pattern output group an appropriately sized fuse must be included on each side of the load If Power Supply IC697PWR711CX is used with a 230 Volt AC power source a surge protector filter device is required Any incoming overvoltage transients of up to 4 Kvolts 1 2076 must be limited by this device to 2 5 Kvolts 1 2 40n6 according to VDE 0160 overvoltage category II This device must be installed between the power source and the power supply 115 Volt AC power source applications do not require a surge protector filter device Each CPU module must be memory protected and the key removed Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 GFK 0787B GFT 166 Revision 1 3 April 4 1995 The installation procedures in the Series 90 70 Programmable Controller Installation Manual GFK 0262D and this GMR
252. the third unused channel assigned to its configured low value m mid value selection based upon the two input channels that are present with the third channel assigned to its configured high value For a simplex group this information is not used Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 6 Default State For a triplex group if all three blocks in the group are lost or if only two blocks are lost and Voting Adaptation is selected as 3 2 0 the GMR system software will use a selected minimum or maximum value see below in voting or hold the last value updated For a duplex group select what should happen if both inputs for a channel are lost or if one block is lost and Voting Adaptation is selected as 3 2 0 The input can be m set to its configured maximum value m set to its configured minimum value m Hold its last value For a simplex group select which of the above should be done if the input data for the channel is lost Maximum Minimum The maximum and minimum values shown in the next illustration entered for an input represent the block s configured engineering units The maximum and minimum values are used in two ways First either the specified maximum or minimum value can be used as the Default State if actual input data for that channel is not available Second the maximum and minimum values entered here represent the full scale
253. ther on or off with or without load monitoring for normally deenergized outputs that are off when tested the test detects Open Circuit load if No load Diagnostic is enabled Block A B short to 0V Block C D short to 24V Any single block open circuit if No load Diagnostic is enabled Any single block Switch Failed off for normally deenergized outputs that are on when tested the test detects Open Circuit load if No load Diagnostic is enabled Any single block open circuit more precise if No load Diagnostic is enabled Any single block Switch Failed off for normally energized outputs that are off when tested the test detects Block A B short to 0V Block C D short to 24V Any single block Switch Failed off for normally energized outputs that are on when tested the test detects Open Circuit load if No load Diagnostic monitoring is enabled Any single block open circuit more precise if No load Diagnostic is enabled Block A B short to 24 Block C D short to 0V Any single block Switch Failed off Any single block Switch Failed on m detect any output failure that would result in a failure to respond m although no test results are generated if outputs change state during the test it does not cause spurious faults to be logged During output autotest the Genius block group still controls the physical outputs so output devices are not affected by the test Chapter 5 D
254. tification status bit see page 7 11 M12225 for PLC A or M12226 for PLC B or M12227 for PLC C m While a PLC is initializing the GMR software sets the Inhibit status flag M12231 This Inhibit flag should be used to prevent the application program from executing until initialization is complete Example ladder logic that provides this functionality is shown on page 7 18 In addition the PLC s outputs are disabled If outputs do not disablesuccessfully the GMR software halts the PLC m If the initializing PLC is PLC C the GMR software automatically commands any discrete Genius blocks configured for Hot Standby operation to accept outputs from the PLC at serial bus address 29 If this function fails to complete successfully the GMR software sets the System status flag M12234 to 1 m During initialization a PLC also communicates with the GMR I O blocks and with Bus Controllers in other PLCs If any of these communications fails status bit M12234 which indicates System Failure at Powerup is turned on The application program can use this bit as a permissive for continuing and annunciation m As each PLC starts up it checks to see whether another PLC is already online and sending outputs if not the PLC sets the Cold Start flag M12237 The application program can use this flag to initialize the application program data If one other PLC is already online the initializing PLC reads that PLC s initi
255. to be used as outputs will operate in Hot Standby mode see chapter 3 for a description of Hot Standby operation Bus Connects a triplex group connects to all three busses so no entry is needed for Bus Connects For a duplex or simplex group specify the bus connections as explained below Bus Connects tay AVASH Fora duplex group configure the two busses the group is connected to A C B amp C from the PLC using serial bus address 31 and B from the PLC using CAREC serial bus address 30 or B and C the PLC using serial bus address 29 or A and C Bus Comnects For a simplex group configure the bus the group is connected to A from os the PLC using serial bus address 31 B from the PLC using serial bus C C address 30 or C from the PLC using serial bus address 29 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 6 Analog I O Group Configuration Select Analog to configure any analog group Select a triplex duplex or simplex analog input group then select the block type 6 inputs or 4 inputs 2 outputs For example BC Group nput Group gt riplex Discrete uplex Discrete implex Discrete nalog riplex Analog Note A simplex input group has just one I O block installed on one bus but configured as a GMR block It is not the same a non voted block To configure a GMR group with just one ana
256. to keep CONFIG4 so Peu SUSTER you go to the file functions and select Close That ends the configuration Open Save session without creating a SAV file Save As Change Dir Exit Alt X Next you select Open a Configuration File A list of files appears New System Save F2 Save As Change Dir EEU Close lies Exit Alt X CONF IGZ SAV ell QONF IG3 SAV TaN we ss gt D GMR x SAU CONFIG1 SAY 869 Jun 07 1993 01 23p Click on the name of the SAV file you want or type in its filename When the filename appears in the name box click on Open The configuration file is loaded into RAM With the correct configuration file displayed select Output Write Config to create a G_M_R10 output file File Insert utput rite Config Print Out After creating the file you can add it to the application program as instructed on page 7 29 System Descr Printing the GMR Configuration When the GMR configuration is finished select Output to print it out The GMR software establishes many parameters of the system configuration that you will need to be familiar with during Logicmaster configuration and Genius block configuration File Insert System Descr Write Config orint Ot Printing defaults to the parallel port of the computer running the GMR Configuration Software If you want to redirect printing to a serial port exit to DOS and use the DOS mode command as instructed in your DOS ma
257. tput group is damaged or cut there is still I O data communicated to at least one sink output and one source output to control the load When a block loses communication with all the PLCs its outputs go to a default state If the default state is Off the system is fault tolerant as shown in the following chart Fault To Turn the Load Off or On bus A fails busses B and C still provide I O communications to blocks B C and D turning outputs at those blocks On or Off turns the load On or Off bus B fails busses A and C still provide I O communications to blocks A and C if the block B and D outputs are configured to default Off turning output at blocks A and C On or Off turns the load On or Off bus C fails busses A and B still provide I O communications to blocks A B and D turning outputs at those blocks On or Off turns the load On or Off GFK 0787B Chapter 3 Output Subsystem 3 7 Manual Output Controls and Diagnostics 3 8 Safety systems are often provided with controls for manual trip and manual override m A manual trip causes the output to assume the alarm condition For example a normally energized output would be de energized A manual override causes the output to remain in the normal condition For example a normally energized output is held energized These manual controls can be implemented either in hardware as represented below or in software If the software method is used GMR autotest and fault process
258. tputs outputs from the application program These logical references are copied to the physical output references If a fault is detected on a physical output the fault contact associated with that output s logical reference is set m Contact References Associated with an Output Logical reference Physical reference Fault contact Fault contacts are set for Genius faults m Discrepancy faults Autotest faults See page 5 26 for detailed information on conditions that cause fault contacts to be set Genius Modular Redundancy Flexible Triple Modular Redundant TMR System User s Manual March 1995 GFK 0787B Analog Fault Contacts for GMR As for discrete inputs voted analog inputs have fault contacts associated with both the raw data inputs and the corresponding voted inputs Non voted analog inputs also have associated fault contacts Analog Input Table a YY Logic Non voted Inputs A inputs B inputs B C inputs Q For analog inputs fault contacts are set for m Genius faults m Discrepancy faults For analog outputs a fault contact is set for any Genius fault including Loss of Block See page 5 28 for detailed information on conditions that cause analog fault contacts to be set Analog Alarm Contacts for GMR For analog data there are two additional types of diagnostic contacts that can be used
259. trollers is present on the bus the block group sets output states to match the output data sent by that PLC If the Simplex Shutdown feature is enabled a PLC will shut down if it determines that it is the only PLC still operating The timeout period before it shuts down is configured as the next item When the PLC shuts down and a block group is no longer receiving output data outputs will go to their default state or last state as configured at each block group If all PLCs are offline the block group forces its outputs to the block s configured default state The voted state of the output is available to the GMR system for monitoring purposes to determine output discrepancies However the voted output state is not available to the application program Duplex Default for Outputs As mentioned the duplex default state is used when a block determines that only two PLCs are online The Duplex Default state of On or Off is used by the 2 out of 3 voting algorithm in the block group instead of the state that would have been supplied by the third PLC The Duplex Default state determines whether voting will be 1 out of 2 or 2 out of 2 when only two PLCs are providing outputs This is explained on the next page Chapter 3 Output Subsystem 3 3 The following three tables compare voting results for a block group receiving outputs from all three PLCs with results when one of the three PLCs is offline Results of Block Group Voting with Thre
260. tware clears the Inhibit status flag M12231 At that point the application program can monitor the startup status flags as suggested on the next page before continuing startup m When the application program has computed a set of outputs it must enable sending outputs to Genius blocks m The application program enables outputs to the I O blocks by turning on control bit M12257 the Continue bit As the example shows it is important to have this occur at the end of the program so the outputs have been solved at least once before being enabled Monitoring Startup Status The application program should include logic to cause it to begin executing when the Inhibit flag is cleared to 0 Depending on the needs of the application the application program can begin by checking the startup status flags to determine whether or how to proceed with the rest of the logic See page 7 11 for a complete list of status flags The GMR software provides several initialization flags It can also monitor the application program M data for miscompares and make program execution conditional upon voting of the data See below The following flags are of particular interest immediately following startup M12237 COLDST If this reference has been set to 1 it means the PLC detected no other PLC s online when it started up The application program must initialize its own M and R initialization data M12232 MISCMP If set to 1 this flag indicates
261. tware performs 2 out of 3 voting Single Input Provided to Application Logic Input A 0 Field Input N 1 1 Data Input B GMR Software Performs Input C 1 eee 2 out of 3 Voting Duplex State 1 Default State 0 The Duplex State and Default State are not used when three field inputs are available GFK 0787B Chapter 4 PLC Subsystem 4 9 4 10 Voting with Two Discrete Inputs Two inputs may be present in either a Duplex input group or in a Triplex input group where one of the three inputs has failed For its 2 out of 3 voting the GMR software uses the group s configured Duplex State in place of a third actual input Field Input Data Single Input Provided to Application Logic a Input A 0 Field Input as ield Inpu 1 1 Data Input B Input C GMR Software Performs 2 out of 3 Voting Duplex State 1 Default State 0 Discrete Input Voting with Two Inputs Present and Duplex State Set to 1 If the Duplex State is set to 1 and two inputs are available both of the actual inputs must be 0 for the voted input state to be 0 The voted input is 1 if either of the actual inputs is 1 Input A State Input B State InputC Voted Input State Duplex State 0 0 1 0 0 0 1 0 0 1 1 1 0 1 1 1 1 0 1 1 1 0 1 1 1 1 1 1 1 1 1 1 Discrete Input Voting with Two Inputs Present an
262. ult occurs the GMR software adapts to reject the faulty data Depending on the configuration of the input group input voting may adapt from three inputs to two inputs to one input or from three inputs to two inputs to the configured default state Single Input Provided Input A 0 to Application Logic seins Input B 1 a AG 1 Input C Ae Duplex State 1 Default State 0 In addition to field input data the GMR software may also make use of the input group s configured Duplex State and Default State in determining the final input value to provide to the PLC Duplex State The Duplex State is a tiebreaker value used when there are two field inputs operating Its operation is described on page 4 10 Default State The Default State is the value that will be provided directly to the PLC instead of a voted input value if the following inputs fail m The single input in a Simplex group m The remaining input in a Duplex or Triplex group configured for 3 2 1 0 Voting Adaptation m Either of the two inputs to a Duplex group configured for 3 2 0 Voting Adaptation m Either of the two remaining inputs to a Triplex group configured for 3 2 0 Voting Adaptation 4 8 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 Voting with Three Discrete Inputs For a triplex input group with three inputs present the GMR sof
263. ult exists but the timer has not sired block you want shut started the Shutdown Cancel bit is On down information from 0 28 48 Output shutdown timers per block High byte contains rack num High byte contains the number Returns a single word indicating the shutdown ber 0 7 and low byte con 1 Low byte contains the Serial timer value as seconds of elapsed time Avalue tains slot number 1 9 Bus Address SBA of the de of 1 means a fault exists but the timer has not sired block you want shut started the Shutdown Cancel bit is On down information from 0 28 49 Input shutdown timers per GBC High byte contains rack num unused For each SBA returns a word indicating the ber 0 7 and low byte con shutdown timer value as seconds of elapsed tains slot number 1 9 where time A value of 1 means a fault exists butthe the desired Bus Controller is timer has not started the Shutdown Cancel bit located is On A value of 0 means a block does not exist or has no associated shutdown timer All output blocksreturn the value 0 50 Output shutdown timers per GBC High byte contains rack num unused For each SBA returns a word indicating the ber 0 7 and low byte con shutdown timer value as seconds of elapsed tains slot number 1 9 where time A value of 1 means a fault exists butthe the desired Bus Controller is timer has not started the Shutdown Cancel bit located is On A value of 0 means a block does not exist or has no assoc
264. unicate on the Genius Bus such as loss of power 2 Autotest failure of the power feed output point Q16 of any of the blocks in a group Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 Output Faults that Cause I O Shutdown For discrete output groups there are also two types of faults which may prevent the output autotest from continuing to execute for that output group and thus cause an I O shut down for the outputs in the group 1 Loss of a block within the group LE any failure which causes the block to no longer communicate on the Genius bus such as loss of power 2 Output autotest failure detected of a type which could potentially prevent a normally energized output from being tripped off An example is the short of a source block output to 24 Vdc Programming for I O Shutdown GFK 0787B To be made aware of a pending I O Shutdown the program can monitor this GMR Status Bit M12244 IO_SD Any I O Shutdown Timer Activated To completely prevent an I O Shutdown from occurring the program can set this GMR Control Bit M12265 SD_CAN Cancel I O Shutdown Interval Until Shutdown in Each PLC The period of time before an I O Shutdown occurs depends on the autotest interval which is set for the system The initial autotest interval is set by the autotest interval value selected in the GMR configuration The configured autotest interva
265. ut table sizes Typical base sweep times for 788 and 789 CPUs are shown below In this example there are six Bus Controllers in each PLC with table sizes of with table sizes of Voted I 64 Voted I 256 Voted AI 64 Voted AI 256 Logical Q 64 Logical Q 256 Base Sweeptime 79Milliseconds Base Sweeptime 88 Milliseconds The base sweep time for your system could be less or more depending on the table sizes you configure Also base sweep time varies by 10mS during single sweeps when the GMR system software performs diagnostics on the CPU subsystem and I O subsystems Sweep Time Contribution of Genius I O and GBCs The contribution of Genius I O and Genius Bus Controllers to the sweep time of the PLC CPU is similar to that of Series 90 70 I O There is an overhead for the I O scan a per Bus Controller sweep time impact a per scan segment sweep time impact and a transfer time per word sweep time impact for all I O data The potential Bus Controller sweep time impact on the CPU has three parts 1 Time to open the system communications window added only once when the first intelligent option module such as a Bus Controller is placed in the system 2 Time needed to poll each Bus Controller for background messages datagrams This must be added for every Bus Controller in the system 3 Time needed for the CPU to scan the Bus Controller For detailed information about estimating CPU sweep time refer to the Serie
266. ut is indeterminate Channelshorted For RTD blocks only Block output is indeterminate Discrepancyfault the A B or C input is subject to voting and is outside the discrepancy range Fault Contacts for Analog Outputs For analog outputs a fault contact is set for any Genius fault including Loss of Block Alarm Contacts For analog data there are two additional types of diagnostic contacts that can be used in the application program the High Alarm and Low Alarm contacts These contacts indicate when an analog reference has reached one of its alarm limits Alarm contacts are not considered to be fault contacts Alarm contacts can be used on a separate bus in a GMR system but they can not be used on any parts of the system that are included in the GMR configuration Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 Chapter 6 Configuration This chapter describes configuration for a GMR system GFK 0787B Configuration Overview The Basic Steps of Configuration Using the GMR Configuration Software Getting Started Creating Selecting a File System Configuration Screen Autotest Interval CPU Configuration I O Limits Initialization Data Fault Actions Genius Bus Controller Group Configuration Configuring the Input Sub
267. utput s logical reference is set Conditions that Cause Discrete Output Fault Contacts to be Set The following illustration summarizes the conditions that cause discrete output fault contacts to be set for logical physical and non redundant outputs Conditions that Cause these Discrete Output Table Fault Contacts to be Set Logical Outputs Any fault fii eee ee ee see the text below Available for Diocropancy fai Non redundant Outputs Genius fault Discrepancy fault Reserved memory Genius fault Autotest fault Discrepancy fault Physical Outputs For redundant outputs the fault contact is set and fault messages logged for Autotestfault Geniusfaults including Loss of Block and the following additional faults Failedswitch Occurs if the actual output state differs from the commanded state No loadfault For 16 circuit blocks only individual outputs can be configured to enable or disable reporting No load faults The minimum load current required to assure proper no load reporting is 100mA not 50mA as it would be for a block not used in a GMR group For a 4 block group a system output no load fault is produced if outputs are ON blocks A and B or blocks C and D report no load faults 5 26 Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 Short circuit fault Overtemperaturgault Overloadfault
268. utput Table Yl Discrete Input Table Q Discrete Output Table T Temporary internal reference bits that are not saved through power loss M Internal reference bits that are saved through power loss G Global Data memory GD Global Data memory GE Global Data memory For discrete bit memories I Q T and M the starting reference must be on a byte boundary 1 9 17 etc Global Data GA GB and GC memories are not available Those memory areas are used by the GMR system to exchange data see above and cannot be accessed directly Page 6 23 describes configuration for setting up Write Access Genius Modular Redundancy Flexible Triple Modular Redundant TMR System User s Manual March 1995 GFK 0787B Input and Output Addressing for GMR GFK 0787B I O addressing for GMR is unlike a that of conventional Series 90 70 application In a conventional application input and output addresses are assigned sequentially starting at the beginning of the Input Table and Output Table In a GMR application the GMR software automatically divides the Discrete Input and Output Tables and the Analog Input Table into special purpose areas Discrete I O Addressing The discrete Input Table and Output Table are divided up into separate areas for redundant and non voted data as shown below Discrete Input Table 10001 Discrete Output Table Q0001 ra r i Voted Inputs gt Inputs to PLC Logical Redundan
269. utput Table is used for the copied physical redundant output data This is the data that is actually sent to the Genius blocks that are included in the GMR configuration The same amount of memory is reserved in the corresponding area of the Input Table It is used to allow GMR fault processing to be inhibited on a circuit by circuit basis for the corresponding physical redundant outputs The total amount of I O data available depends on the CPU type For the model 788 CPU there can be a total of 352 physical inputs and outputs or approximately 100 redundant I Opoints For the model 789 there can be a total of 12288 physical inputs and outputs or a maximum of 4096 redundant I O points Chapter 7 Programming Information 7 5 Discrete I O Tables Example In this very simple example there are a model 788 CPU with 352 physical I O One output group of four discrete 16 circuit blocks The application program will use logical outputs at addresses Q0001 to Q0016 o This requires just 16 output references because the references used by all four blocks in the group are the same The references that these blocks will be configured to respond to are assigned to the 16 bits at the end of the output table Since the example CPU is a model 788 the 16 references at the end are Q1009 to Q1024 O The corresponding 16 bits in the Input Table are also reserved for GMR fault detection disabling The reserved input references are
270. valid Bus Address Initialization detected bus addresses not equal to 29 30 or 31 10111 Sync Not Possible Synchronization cannot be performed 10112 Outputdiscrepancy Output discrepancy detected 10113 Miscomp no more retries Sync detected miscompare 10114 GMRColdstart GMR is performing coldstart 10115 GMR Warmstart GMR is performing a warmstart 10116 Cannot get all GBCs Cannot acquire all GBCs during initialization 10117 Cannot do VME Write The VME Write to 7F3h was unsuccessful 10119 Invalid Switch Case An invalid case condition was detected during a switch 10120 Failed Disable Ops The Disable Outputs command COMREQ failed to complete successfully 10121 Failed Enable Ops The Enable Outputs command COMREQ failed to complete successfully 10122 Failed Set GMR Mode The Set GMR Mode command COMREQ failed to complete successfully 10123 Failed DG Dgrams The Clear Datagrams Dequeue command COMREQ failed to complete successfully 10124 Failed Read Address The Read Bus Address command COMREQ failed to complete successfully 10129 Num dequeues n N dequeue entries were dequeued at startup 10130 ProgrammismatchA B PLCs A and B program mismatch C is not online 10131 ProgrammismatchB C PLCs B and C program mismatch A is not online 10132 ProgrammismatchA C PLCs A and C program mismatch B is not online 10133 ProgrammismatchA B amp C PLC A program mismatch with B and C 10134 ProgrammismatchB A amp C PLC B program mismatch with A and C 10135 Programmismat
271. verified to be identical to what resides in the PLCs by use of the Logicmaster 90 70 software Inputs from other systems to any part of the safety relevant portion of the application program must be made via the safety relevant inputs of the GMR system If a software interface it must be made through that group of input addresses reserved for the safety relevant portion of the application In addition it must be verified that any non safety inputs cannot override a demand made to an output by the safety relevant portion of the program or prevent any field input to the safety relevant portion of the program Manual trips and overrides must be executed exclusively during maintenance of the system The specific requirements are described in the document Maintenance Override Version 2 2 Sept 8 1994 which is reprinted in GFK 0787B The Force Logon control bit must be set via a hard wired input device as described in chapter 7 of GFK 0787B PLC force logon is to be considered a maintenance override and shall be subject to requirements described in the document Maintenance Override Version 2 2 Sept 8 1994 which is reprinted in GFK 0787B The Cancel I O Shut Down control bit M12265 SD_CAN must left in the off 0 state and must not used in any portion of the application program When the final commissioned application program is stored to the PLCs all program data including reference tables must be stored The procedures in docum
272. wn timer expires in PLCB I O Shut Down message is logged in fault table of PLCB PLCB shuts down the I O of the affected I O group Real 1 0 IS NOW affected because of the 2 out of 3 voting mechanism Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 1 0 Shut Down Prevention If an I O fault causes an I O shutdown to initiate there is up to 16 hours of time to repair the fault and put the block s back into operation before the shutdown occurs When the next autotest occurs on the PLC s that started its shutdown timer that PLC automatically cancels its I O shutdown If the autotest is executed without faults on the affected block s before the actual shut down occurs This autotest can be one that occurs automatically as specified by the configured autotest interval or one that is initiated manually via the GMR control bit Autotest Manual Initiate M12260 ATMANIN To clear any standing faults at the block s and in the I O fault table of the PLCs an I O fault reset should be executed by turning on GMR Control bit M12258 IORES Also note that at any time the Cancel I O Shutdown M12265 SD_CAN bit can be used to prevent the shutdown from occurring I O Shut Down Recovery If an I O shutdown is allowed to complete the affected I O is set to its safe state Recovery from an I O shutdown is accomplished with the following steps 1 Repair the fault that
273. x group select 3 2 1 0 Duplex State For a triplex group the Duplex State determines the vote type when there are just two inputs present Its operation is described on page 4 8 m Using 0 as the Duplex State means that when two I O blocks duplex are online the voted input state will be 0 if either input sets it to 0 It will not be 1 unless both inputs set it to 1 m Similarly using 1 as the Duplex State means that when two blocks are online the voted input state will be 1 if either input sets it to 1 It will not be 0 unless both of the inputs set it to 0 For a duplex group this state is used as the third input in the 2 out of 3 vote For a simplex group this field does not apply GFK 0787B Chapter 6 Configuration 6 31 Default State Choose a default state OFF 0 ON 1 or hold last state For a triplex group this state will be provided to the application program if communications from all three blocks in the group are lost if Voting Adaptation is 3 2 1 0 Alternatively if Voting Adaptation is set to 3 2 0 this state is provided to the application program if communications from two blocks in the group are lost For a duplex group this state will be provided to the application program if communications from both blocks in the group are lost For a simplex group this state will be provided to the application program if communications from the single block are lost Hot Standby Select whether unused circuits
274. y carries over to the GMR system All Series 90 70 PLC and Genius I O products can be used with a GMR system However not all of the available components are TUV approved for use in the safety relevant portion of a system All components can be used but with restrictions as described in this appendix The subset of components that are approved are also listed in this appendix In addition this appendix 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 TUV site application approval will be sought A T V site application approval consists of a review and check of the system as installed and commissioned at the final site by a TUV site engineer The process includes a review and check of all installed hardware software configuration procedures and the specific application program to ensure conformance with the User s Manuals the specified environmental conditions and the following restrictions GFT 166 Revision 1 3 April 4 1995 TUV Restrictions For all safety relevant applications the safe state must be the de energized 0 state A Functional test must be performed to check for the correct design and operation of the system as a whole This is to include the user s application program No change of the system software operating system I O drivers diagnostics etc is allowed without TUV type approva
275. y to save a configuration Open F3 Use the F3 key to open a previously saved configuration Close Alt F3 Use the Alt F3 pair only if you want to close an open configuration without saving it NOTE No prompt will appear Zoom F5 Use the F5 key to enlarge a configuration window or to return a window to its original size Move Ctl F5 Use the Ctl F5 pair to move a configuration window on the screen The window color changes to show that is in a movable state Use the cursor Home End PgUp or PgDn keys to move the window When it is positioned where you want it press the Return enter key Next F6 Use the F6 key to move from one window to the next Exit Alt X Use the Alt X pair to exit the GMR Configuration Software NOTE if the configuration is not saved it will be lost Genius Modular Redundancy Flexible Triple Modular Redundant TMR System GFK 0787B User s Manual March 1995 6 There are two basic ways to select a menu item from the keyboard A pressing the letter key that corresponds to the highlighted letter on the display for example the letter c in CPU below PU est Interval In Disc Filter Config Limits Init Data ault Actions rite Access B moving the cursor to that item using the cursor keys and pressing Return enter GFK 0787B Chapter 6 Configuration 6 7 GMR Configuration Summary GMR configuration is described in detail on the following pages The basic steps are

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