GE GFK-0787B manual

GE F anuc Automation Programmable Control Pr oducts Genius Modular Redundancy Flexible T riple Modular Redundant (TMR) System User’s Manual GFK -0787B March 1995[...]

GFL–002 W arnings, Cautions, and Notes as Used in this P ublication W ar ning W arning 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 eith[...]

iii GFK–0787B Pr eface This manual is a reference to planning, configuring and programming a Series 90 -70 PLC system that utilizes Genius Modular Redundancy (GMR). The infor mation in this manual is intended to supplement the basic system installation, programming, and configuration instr uctions located in the manuals listed on the next page. C[...]

Pr eface iv Genius Modular Redundancy Flexible T riple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK–0787B The GMR configuration software now allows selection of memor y addresses for exter nal write access. Serial and network communication ports are restricted; the Genius bus is not. A GMR Genius bus must not be used for c[...]

Contents v GFK-0787B Genius Modular Redundancy Flexible T riple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 Chapter 1 Intr oduction 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Components of a GMR System 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

Contents vi GFK-0787B Genius Modular Redundancy Flexible T riple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 Diagnostics in a GMR System 5-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting Up Blocks to Report Genius F aults 5-3 . . . . . . . . . . . . . . . . . . . . . . . . . GMR A utotesting 5-[...]

Contents vii GFK-0787B Genius Modular Redundancy Flexible T riple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 Chapter 8 Installation Infor mation 8-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Genius Bus Connections 8-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

1 section level 1 1 figure bi level 1 table_big level 1 restart lowapp ARestart oddapp: ARestarts for autonumbers that do not restart in each chapter . figure bi level 1, reset table_big level 1, reset chap_big level 1, reset1 Lowapp Alwbox restart evenap:A1app_big level 1, resetA figure_ap level 1, reset table_ap level 1, reset figure level 1, res[...]

1 1-2 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B Components of a GMR System GMR Software GMR software version 2.06 (catalog number IC641SWP714B) provided on diskette consists of: Easy -to -use GMR configuration software. GMR system software, which automatically processes, mon[...]

1 1-3 GFK-0787B Chapter 1 Introduction Series 90-70 PLCs A GMR system nor mally consists of one to three identical CPUs r unning identical application software. Each CPU is connected to the same input and output subsystems. Each CPU receives all inputs and perfor ms voting for discrete inputs and mid-value selection for analog inputs. Each CPU comp[...]

1 1-4 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B 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. F or example, the GMR system represented below has two I/O subsyste[...]

1 1-5 GFK-0787B Chapter 1 Introduction Operation Overview 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: Nor mally - on inputs with normally -energized outputs, as in emergency shutdown systems. Nor mally - off inputs with nor mally -deene[...]

1 1-6 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B 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). F or this e[...]

1 1-7 GFK-0787B Chapter 1 Introduction PLC Subsystem: Providing Output Data Running the same application program, each PLC (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 th[...]

1 1-8 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B Genius I/O Blocks Inputs and outputs in a 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 syste[...]

1 1-9 GFK-0787B Chapter 1 Introduction 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. F or most applications, these limits will not be reached. If you need help estimating I/O sizes for a large application, contact GE F anuc at 1-800-828-5747. CPU Model T otal Discr ete Ph[...]

1 1-10 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B 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[...]

1 1-1 1 GFK-0787B Chapter 1 Introduction The Basic Steps of Configuration and Programming 1. Use the GMR configuration software to complete the GMR configuration. Ther e is only one GMR configuration needed for the system. GMR configuration sets up the parameters that will be used by the system, including r efer ence addresses . The GMR configurati[...]

2 section level 1 1 figure bi level 1 table_big level 1 2-1 GFK-0787B Chapter 2 Input Subsystem This chapter provides infor mation about the inputs to a GMR system. Over view GMR Input Groups Non-V oted I/O in the Input Subsystem Discrete Inputs T ypes of Blocks in the Input Subsystem Discrete Input Processing Discrepancy Reporting for GMR Inputs I[...]

2 2-2 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B 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 Individual non-voted discrete and analog blocks The following illustratio[...]

2 2-3 GFK-0787B Chapter 2 Input Subsystem GMR Input Groups 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 nor mally -energized discrete inputs, the following combinations of sensors an[...]

2 2-4 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B Non- V oted I/O in the Input Subsystem The input subsystem can also include three types of non-voted inputs: Inputs from single-block (simple x) GMR input groups Individual blocks can be included in the GMR configuration as “[...]

2 2-5 GFK-0787B Chapter 2 Input Subsystem Discr ete Inputs T ypes 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 VDC 32-Circuit S[...]

2 2-6 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B Input Autotest for GMR Inputs Duri n g GMR con figur ati on, input aut ote sting can be indiv i dual l y tur ne d on or off for each i nput in an input group. The GMR so ftware wil l automatical l y te st the se lected inputs f[...]

2 2-7 GFK-0787B Chapter 2 Input Subsystem Line Monitoring for Discrete Inputs Nor mally -closed inputs on GMR-configured blocks can be monitored for short circuit faults. Nor mally - open inputs on blocks which are not configured in GMR mode can be monitored for open circuit faults. Normally-closed Inputs F or applications such as Emergency Shutdow[...]

2 2-8 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B 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 co[...]

2 2-9 GFK-0787B Chapter 2 Input Subsystem Analog Inputs Lik e 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 blo[...]

2 2-10 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B Analog Discrepancy Repor ting 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 th[...]

3 section level 1 1 figure bi level 1 table_big level 1 3-1 GFK-0787B Chapter 3 Output Subsystem This chapter describes GMR output subsystem. Over view T ypes of Blocks in the Output Subsystem GMR Output Handling Output V oting Duple x Default for Outputs Output F orces and Over rides Output F ault Reporting 4-Block Output Groups Output Load Sharin[...]

3 3-2 Genius Modular Redundancy Flexible T riple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B 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 Individual non- GMR discrete and analog blocks The following illustration represent[...]

3 3-3 GFK-0787B Chapter 3 Output Subsystem GMR Output Handling Unlik e GMR input voting, which is done by the GMR software in the PLCs, output voting is per for med at the output block groups . T o per for m 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 V [...]

3 3-4 Genius Modular Redundancy Flexible T riple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B 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 V oting with Three PLCs Online F or compariso[...]

3 3-5 GFK-0787B Chapter 3 Output Subsystem Results of Block Group V oting 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). PLC A Output State PLC B Output State PLC C Output State Duple x Default Setting in Block Output State 0 x 0 0 x 0 0 x 0 0 [...]

3 3-6 Genius Modular Redundancy Flexible T riple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B 4-Block Output Groups All four 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[...]

3 3-7 GFK-0787B Chapter 3 Output Subsystem 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: o[...]

3 3-8 Genius Modular Redundancy Flexible T riple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B Manual Output Controls and Diagnostics Safety systems are often provided with controls for manual trip and manual over ride. A manual trip causes the output to assume the alarm condition. F or example, a nor mally -energized o[...]

3 3-9 GFK-0787B Chapter 3 Output Subsystem Redundancy Modes for Output Blocks There are three separate configuration processes for a GMR system: GMR configuration, which supplies parameters used by the GMR system software. PLC configuration, which is perfor med as usual for a Series 90-70 PLC system using the Logicmaster 90 software. Genius block c[...]

3 3-10 Genius Modular Redundancy Flexible T riple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B 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. Opera[...]

4 section level 1 1 figure bi level 1 table_big level 1 4-1 GFK-0787B Chapter 4 PLC Subsystem This chapter describes operation of the PLC subsystem in a GMR system. System Startup CPU Sweep in a GMR System PLC Operation Input Processing Discrepancies Discrete Inputs Analog Inputs Output Processing Discrete Outputs I/O Shutdown Communications Betwee[...]

4 4-2 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B 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 [...]

4 4-3 GFK-0787B Chapter 4 PLC Subsystem 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-[...]

4 4-4 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B Data Initialization During startup, a PLC either sets a flag to notify the application program to initialize %R and %M memor y , or synchronizes the data with corresponding data in the other PLC(s). The %M data is typically lat[...]

4 4-5 GFK-0787B Chapter 4 PLC Subsystem CP U Sweep in a GMR System The special functions required for Genius Modular Redundancy include autotest, input voting, and alar ming. These GMR functions are provided by a set of Program Blocks that are placed into the Program F older using the LM90 librarian feature. A fter this is done, the GMR logic is ex[...]

4 4-6 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B Estimating CP U Sweep T ime The GMR system software r uns 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 p[...]

4 4-7 GFK-0787B Chapter 4 PLC Subsystem Input Processing 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 . A fter the Input Scan, the GMR logic perfor ms voting on the inputs configured for GMR redundancy , and[...]

4 4-8 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B Discrete Input V oting Immediately after the input scan, before the application program ex ecution begins, the GMR software perfor ms input voting. It automatically reads and votes on the three (or two) sets of data in areas A,[...]

4 4-9 GFK-0787B Chapter 4 PLC Subsystem V oting with Three Discrete Inputs F or a triplex input group with three inputs present, the GMR software perfor ms 2 out of 3 voting. Field Input Data Input A Input B Input C 0 1 1 GMR Software Performs 2 out of 3 V oting 1 Single Input Provided to Application Logic Duplex State 1 Default State 0 The Duplex [...]

4 4-10 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B V oting with T wo Discrete Inputs T wo inputs may be present in either a Duplex input group, or in a T riple x input group where one of the three inputs has failed. F or its 2 out of 3 voting, the GMR software uses the group?[...]

4 4-1 1 GFK-0787B Chapter 4 PLC Subsystem V oting for One Discrete Input One input may be present in a non-voted input group, in a Simplex input group, in a Duple x input group where one input has failed, or in a T riple x input group where two inputs have failed. In a non-voted input group, the actual input is always provided to the application lo[...]

4 4-12 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B 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 T able as shown below . Inputs from bloc[...]

4 4-13 GFK-0787B Chapter 4 PLC Subsystem Analog Input V oting Immediately after the input scan, before the application program ex ecution begins, the GMR software perfor ms input voting. It automatically reads and votes on the three sets of data in areas A, B, and C of the analog Input T able. How it does the voting is described below . It places t[...]

4 4-14 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B V oting for Three Analog Inputs F or a triple x input group with three inputs present, the GMR software compares three corresponding analog input values. It selects the inter mediate value and places it into the voted inputs p[...]

4 4-15 GFK-0787B Chapter 4 PLC Subsystem V oting for T wo Analog Inputs T wo inputs may be present in either a Duplex input group, or in a T riple x input group where one of the three inputs has failed. Three vote options in duplex mode are deter mined by the duplex state: highest, lowest, or average. If lowest has been configured, the GMR software[...]

4 4-16 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B V oting for One Analog Input One input may be present in a non-voted input group, in a Simplex input group, in a Duple x input group where one input has failed, or in a T riple x input group where two inputs have failed. In a [...]

4 4-17 GFK-0787B Chapter 4 PLC Subsystem Output Processing F or outputs, the PLC does not per form “ 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 [...]

4 4-18 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B 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. F or certain types of discrete I/O faults, the system optionally allow[...]

4 4-19 GFK-0787B Chapter 4 PLC Subsystem Output F aults that Cause I/O Shutdown F or discrete output groups there are also two types of faults which may prevent the output autotest from continuing to ex ecute 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. (I.E. any failure w[...]

4 4-20 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B D). PLCC ex ecutes 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 ?[...]

4 4-21 GFK-0787B Chapter 4 PLC Subsystem I/O 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 it[...]

4 4-22 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B Communications Between PLCs Data is transferred between the PLCs in the system using Genius global data. T wo busses are used to transfer duplicate data. While the system is operating, they transfer global data automatically .[...]

5 section level 1 1 figure bi level 1 table_big level 1 5-1 GFK-0787B Chapter 5 Diagnostics This chapter describes: Diagnostics in a GMR System GMR A utotesting GMR Discrepancy Reporting Input Line F ault Detection in a GMR Application The PLC and I/O F ault T ables in a GMR System Monitoring Manual Output Controls F ault and Alar m Contacts Progra[...]

5 5-2 Genius Modular Redundancy Flexible T riple Modular Redundant (TMR) System User ’ s Manual –Mar ch 1995 GFK-0787B Diagnostics in a GMR System In a GMR system, extensive diagnostic capabilities are provided by standard Genius I/O diagnostics and by the special autotesting and discrepancy reporting features of the GMR software. Standard Geni[...]

5 5-3 GFK-0787B Chapter 5 Diagnostics Setting Up Blocks to Report Genius F aults By de fault, most Ge n ius blocks , includ i ng the type s of bloc ks nor mall y use d in GMR sys te ms, se nd on ly one copy of a Faul t Re port. F or a GMR syste m, blocks can be se t up to s end a dd i ti ona l F au l t Rep or ts . The setup needed for a block depen[...]

5 5-4 Genius Modular Redundancy Flexible T riple Modular Redundant (TMR) System User ’ s Manual –Mar ch 1995 GFK-0787B GMR A utotesting The GMR software automatically per for ms 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[...]

5 5-5 GFK-0787B Chapter 5 Diagnostics Discrete Input Autotest Discrete Input A utotest ex ercises 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: accommodate nor mally -closed and nor mally - open devices with the device in either state. dete[...]

5 5-6 Genius Modular Redundancy Flexible T riple Modular Redundant (TMR) System User ’ s Manual –Mar ch 1995 GFK-0787B Single Input Sensor to T riplex Block Group Field Switch Zener 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[...]

5 5-7 GFK-0787B Chapter 5 Diagnostics Discrete Output Autotest Discrete output autotest checks the ability of outputs to respond to the commanded output state. Load Bus A Bus B Bus C A B CD The discrete output autotest will: work on outputs that are either on or off , with or without load monitoring. for normally deenergized outputs that are off wh[...]

5 5-8 Genius Modular Redundancy Flexible T riple Modular Redundant (TMR) System User ’ s Manual –Mar ch 1995 GFK-0787B Operation of the Discrete Output Autotest The PLC that is presently the autotest master infor ms 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 t[...]

5 5-9 GFK-0787B Chapter 5 Diagnostics 4. The autotest master pulse tests Block A. Any faults on block A are noted. Load AB C D Block C outputs still overridden ON Failed Switch outputs still overridden OFF . Block A Pulse-tested. 5. The master resets all four blocks in the output group. 6. Over rides on block C are cancelled. Load AB C D Block C ou[...]

5 5-10 Genius Modular Redundancy Flexible T riple Modular Redundant (TMR) System User ’ s Manual –Mar ch 1995 GFK-0787B Pulse T est Operation The Output A utotest uses the standard Genius block Pulse T est feature. During this test, the system is on-line and available. F or the test to be per for med: All blocks in the group must be on-line. Th[...]

5 5-1 1 GFK-0787B Chapter 5 Diagnostics GMR Discrepancy Reporting The GMR software per for ms discrepancy reporting for: V oted discrete inputs Discrete outputs Analog inputs There is no discrepancy reporting for analog outputs. Discrete Input Discrepancy R epor ting As explained in the chapter on PLC operation, the PLC compares corresponding input[...]

5 5-12 Genius Modular Redundancy Flexible T riple Modular Redundant (TMR) System User ’ s Manual –Mar ch 1995 GFK-0787B Discrete Output Discrepancy R epor ting 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 [...]

5 5-13 GFK-0787B Chapter 5 Diagnostics Analog Input Discrepancy Repor ting If there is a discrepancy in the data from a set of inputs, so that a channel deviates by more than a configurable percentage from the voted value, the PLC automatically places a message in the I/O F ault T able where it is available to the Logicmaster 90 software and the ap[...]

5 5-14 Genius Modular Redundancy Flexible T riple Modular Redundant (TMR) System User ’ s Manual –Mar ch 1995 GFK-0787B Input Line F ault Detection in a 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 O[...]

5 5-15 GFK-0787B Chapter 5 Diagnostics The PLC and I/O F ault T ables in a GMR System F aults and alar ms from I/O devices, Bus Controller faults, and bus faults are automati- cally logged into the Series 90–70 PLC ’s I/O F ault T able. F aults can be displayed with the programmer in either On–Line or Monitor mode. |PROGRM |TABLES | STATUS | [...]

5 5-16 Genius Modular Redundancy Flexible T riple Modular Redundant (TMR) System User ’ s Manual –Mar ch 1995 GFK-0787B I/O Fault T able Messages for GMR I/O F ault T able for mat is detailed in the Series 90-70 PLC R efer ence Manual ( GFK -0265). Fault Specific Data Fault Category Fault Action Fault Group Point Block I/O Bus Slot Rack Referen[...]

5 5-17 GFK-0787B Chapter 5 Diagnostics Displaying Additional Fault Information About I/O F aults (with CTRL/F) P ressing the programmer CTRL/F k eys provides more infor mation about a fault. Entries that apply to the GMR system are described below . F ault Description: Code (Hex) Meaning 00 Loss of Device F0 Digital Input A utotest F ault F1 Digita[...]

5 5-18 Genius Modular Redundancy Flexible T riple Modular Redundant (TMR) System User ’ s Manual –Mar ch 1995 GFK-0787B PLC Fault T able Messages for GMR The following tables lists PLC F ault T able messages for GMR .. If you need additional help, call GE F anuc T echnical Ser vice at 1–800–828–5747. Code Message Meaning 100 No CPU Clock [...]

5 5-19 GFK-0787B Chapter 5 Diagnostics Code Meaning Message 10146 Config mismatch A/B/C All three 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 incor rect password 10202 Incorrect GMR[...]

5 5-20 Genius Modular Redundancy Flexible T riple Modular Redundant (TMR) System User ’ s Manual –Mar ch 1995 GFK-0787B Code Meaning Message 10814 GMR cfg er r no of PLCs GMR Configuration Module detected more than 3 PLCs in the config data 10815 GMR cfg err W/dog timer GMR Configuration Module detected invalid watchdog time in the config data [...]

5 5-21 GFK-0787B Chapter 5 Diagnostics Code Meaning Message 10903 User_IF–Invalid T able Module was called with e xtended mode table number when the module was in nor- mal mode 10903 Bad T able 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 [...]

5 5-22 Genius Modular Redundancy Flexible T riple Modular Redundant (TMR) System User ’ s Manual –Mar ch 1995 GFK-0787B Code Meaning Message 11453 GMR12–tmplt too small GMR14 has detected an inter nal er ror condition 11455 GMR15–IS x at y GMR15 state machine went to step x (illegal). Step no. at offset y in GMR15 diagnos- tics 11456 GMR15?[...]

5 5-23 GFK-0787B Chapter 5 Diagnostics Manual Output Controls and Diagnostics Safety systems are often provided with controls for manual trip and manual over ride. A manual trip causes the output to assume the alarm condition. F or example, a nor mally -energized output would be de-energized. A manual over ride causes the output to remain in the no[...]

5 5-24 Genius Modular Redundancy Flexible T riple Modular Redundant (TMR) System User ’ s Manual –Mar ch 1995 GFK-0787B Monitoring Manual Output Controls The operation of manual trip and output over ride devices can be monitored and reported by connecting them as inputs to Genius blocks. These inputs should be configured to use references at th[...]

5 5-25 GFK-0787B Chapter 5 Diagnostics F ault, No F ault, and Alar m Contacts F ault and No F ault contacts can optionally be used to detect fault or lack of fault conditions on a discrete (%I or %Q) or analog (%AI or %A Q) reference. They can also be programmed with the Series 90-70’s built-in fault-locating references. In a GMR system, there ar[...]

5 5-26 Genius Modular Redundancy Flexible T riple Modular Redundant (TMR) System User ’ s Manual –Mar ch 1995 GFK-0787B Discrete Output Fault Contacts for GMR F or discrete outputs, the fault contact is associated with the logical outputs (outputs from the application program). Logical reference Physical reference Fault contact Contact Refer en[...]

5 5-27 GFK-0787B Chapter 5 Diagnostics Short circuit fault Overtemperature fault Overload fault 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 [...]

5 5-28 Genius Modular Redundancy Flexible T riple Modular Redundant (TMR) System User ’ s Manual –Mar ch 1995 GFK-0787B Analog F ault 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 processing. F ault Contacts for Analog Inputs As with discrete inp[...]

6 section level 1 1 figure bi level 1 table_big level 1 6-1 GFK-0787B Chapter 6 Configuration This chapter describes configuration for a GMR system: Configuration Overview The Basic Steps of Configuration Using the GMR Configuration Software Getting Started Creating/Selecting a File System Configuration Screen A utotest Inter val CPU Configuration [...]

6 6-2 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B Configuration Over view In a GMR system, there are three basic configuration steps: Completing the GMR configuration using the GMR configuration software. Configuring the Series 90-70 PLCs. Configuring the Genius blocks in the [...]

6 6-3 GFK-0787B Chapter 6 Configuration (2) In the Program F older functions menu, select F1 ... Select/Cr eate a Program F older . On the Select/Create screen, select the folder for the second PLC (for example CONFIGB) as the current folder . (3) In the Program F older functions menu, select F10, Copy Contents of P rogram F older to Curr ent Progr[...]

6 6-4 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B Using the GMR Configuration Sof twar e The GMR Configuration Software is used to enter data needed by the GMR program software. A utotest inter val CPU type for the system I/O limits for the system initialization data for the s[...]

6 6-5 GFK-0787B Chapter 6 Configuration Getting Star ted T o 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 W atchdog timer value. I/O block serial bus addresses. I/ O block “log ical” (% Q ) an d “ vo te d” ( % I [...]

6 6-6 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B Mouse and K eyboard 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 wa[...]

6 6-7 GFK-0787B Chapter 6 Configuration There are two basic ways to select a menu item from the keyboard: A. pressing the letter key that cor responds to the highlighted letter on the display (for example, the letter “c” in CPU, below . B. moving the cursor to that item (using the cursor keys) and pressing Return (enter).[...]

6 6-8 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B GMR Configuration Summary GMR configuration is described in detail on the following pages. The basic steps are: 1. Select File to cr eate a New System configuration 2. In the System menu, create the CPU configuration CPU T ype [...]

6 6-9 GFK-0787B Chapter 6 Configuration 9. [Insert] the first GBC (bus controller) gr oup A. Select each bus controller in the group (GBC_A, GBC_B, GB C_C). (1) Specify a rack and slot location (2) Select [OK] or [C]ancel to quit the Rack/Slot window B. Configure all the input and output block groups for the GBC group. (1) [Insert] each Input block[...]

6 6-10 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B Creating/Selecting a File T o create a new configuration, or begin editing an existing file, select File. (If you are using a mouse, click on “F ile” in the upper left corner of the screen. If you are making k eyboard entr[...]

6 6-1 1 GFK-0787B Chapter 6 Configuration 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, over writing the previous version. If you want to specify another filename (for example, to create a new versi[...]

6 6-12 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B Changing to Another Directory Use the Change Director y function if you want to access another directory . (Additional directories must be created in DOS.) Select Chdir to change the directory . Select Revert to return to the [...]

6 6-13 GFK-0787B Chapter 6 Configuration Star ting a New Configuration When you select New System from the File menu using the mouse, or using the Enter (Retur n) key , the System screen appears: F rom this screen, you can: retur n to the file-handling functions (click on File or press AL T/F) change a system parameter (click on System or press AL [...]

6 6-14 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B GMR Configuration Selections When you select System, the following menu appears CPU configuration Select autotesting interval Input Discrepancy Filter Set configuration limits Select Initialize data areas Select fault actions [...]

6 6-15 GFK-0787B Chapter 6 Configuration 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. Specify whether the CPU is model IC697CPU788 or 798. Specify whether Online pr[...]

6 6-16 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B T est Interval F irst, configure the inter val for autotesting, and a register where this inter val should be stored. On this screen, enter: Specify an autotest inter val of 1 to 65535 minutes. This becomes the time inter val [...]

6 6-17 GFK-0787B Chapter 6 Configuration Input Discrepancy Filter 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 F ault T able, and sets the appropriate fault contact for that voted input. This input disc[...]

6 6-18 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B I/O Limits Select System again. F rom the configuration menu, select Config Limits (click the mouse on that line or cursor down and press Enter). Entries made on this screen determine how the GMR software allocates memor y . T[...]

6 6-19 GFK-0787B Chapter 6 Configuration 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 . Physical input data from analog block groups is located at the end of the Analog Input T able, in the areas labelled A, B, and C in the preceding illustr[...]

6 6-20 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B Initialize Data Next, select S ystem to configure the Initialization Data. Initialization data, as explained in the PLC Subsystem chapter of this book, is ex changed between PLCs during startup. It consists of data such as tim[...]

6 6-21 GFK-0787B Chapter 6 Configuration If , when the PLC is starting up, the other two PLCs are already online, %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 T emp Ref field, enter a starting reference in %R memor y to receive %M data from the second online PLC. [...]

6 6-22 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B F ault Actions Next, select S ystem to configure Initialization F ault Actions: These entries deter mine how the GMR software will respond to either of the following faults during CPU initialization: an initialization data err[...]

6 6-23 GFK-0787B Chapter 6 Configuration Write Access Next, select S ystem to configure W rite Access: 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 [...]

6 6-24 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B Adding Bus Controllers and I/O Modules When you select Insert from the System screen, the following menu appears Configure Bus Controller groups Configure Input Group Configure Output Group Configure non-voted discrete I/O Con[...]

6 6-25 GFK-0787B Chapter 6 Configuration 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 ex ception to this is a bus controller pair that is used for global da[...]

6 6-26 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B Exiting the Window Nor mally , the GB C (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 [...]

6 6-27 GFK-0787B Chapter 6 Configuration Configuring the Input Subsystem for a Bus Controller Group W ith 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 AL T–I to display the Insert menu. Select Input Group from the menu b[...]

6 6-28 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B Configuring a T riplex, Duplex, or Simplex Discrete Input Group T o configure a discrete group, click on that line, or move the cursor there and press the Retur n key , or press the highlighted letter k ey . Then select whethe[...]

6 6-29 GFK-0787B Chapter 6 Configuration Highlight this item then press the space bar key to display a screen for setting up Input A utotest and T est T ype for individual circuits (screen for 16-circuit blocks shown here). If input circuits on the blocks in the group should be autotested, circuit 16 (the power feed output) must have autotest enabl[...]

6 6-30 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B 1.) Loss of a block within the group. (I.E. any failure which causes the block to no longer communicate on the Genius Bus such as loss of power .) 2.) A utotest failure of the power feed output (point Q16) of any of the blocks[...]

6 6-31 GFK-0787B Chapter 6 Configuration Similarly , select which V oting Adaptation method will be used for each circuit. V ote A dapt Mode : Specify the manner in which the PLCs should perform voting adaptation. During operation, if a failure (discrepancy fault, A utotest fault, or Genius fault) occurs, the GMR software will reject the faulty dat[...]

6 6-32 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B Default State: Choose a default state: OFF (0), ON (1), or hold last state. F or a triplex group, this state will be provided to the application program if communications from all three blocks in the group are lost (if V oting[...]

6 6-33 GFK-0787B Chapter 6 Configuration Analog I/O Group Configuration Select Analog to configure any analog group. Select a triplex, duple x, or simplex analog input group, then select the block type (6 inputs or 4 inputs/2 outputs). F or example: Note: A “simplex” input group has just one I/O block, installed on one bus, but configured as a [...]

6 6-34 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B Specify how each circuit in a triple x or duple x group should utilize vote adaptation F or a simple x group, this option does not apply . If a failure (discrepancy fault, or Genius fault) occurs, the GMR software rejects the [...]

6 6-35 GFK-0787B Chapter 6 Configuration Default State : F or a triplex group , if all three blocks in the group are lost or if only two blocks are lost and V oting 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. F or a duplex group , se[...]

6 6-36 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B 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 cor responding physical inputs deviates from the voted input value by [...]

6 6-37 GFK-0787B Chapter 6 Configuration 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. R epeat the following procedure for each gr oup in the output subsystem: Note: It is possible for a bus to include output blocks that are not part[...]

6 6-38 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B A utotest: By default, each circuit is set up for autotesting, as shown by the X next to the circuit number . T o tur n off autotesting for any circuit, select that circuit (click on the circuit or select it using the cursor k[...]

6 6-39 GFK-0787B Chapter 6 Configuration F inally , 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 belo[...]

6 6-40 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B Configuring the Non- V oted Discrete I/O for a Bus Controller Group If the bus controller group includes any non-voted discrete I/O , select nonV oted D I/O . (Inputs and outputs may be mixed on a block.) Non-voted I/O are inp[...]

6 6-41 GFK-0787B Chapter 6 Configuration Select this item to display additional configuration choices. Input A utotest: 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 in put ci rcui t s on th e blocks in th e group sh o uld be [...]

6 6-42 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B Configuring the Non- V oted Analog I/O for a Bus Controller Group If the bus controller group includes any non-voted analog I/O , select nonV oted A I/O . Note: Non-voted analog I/O blocks that are configured here are consider[...]

6 6-43 GFK-0787B Chapter 6 Configuration 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 W rite Output function of the GMR configuration software automatically creates a file named G_M_R10.EXE. This is the fi[...]

6 6-44 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B In this example, you decide that you don’t want to k eep CONFIG4, so you go to the file functions and select Close. That ends the configuration session without creating a .SA V file. Next, you select Open a Configuration Fil[...]

6 6-45 GFK-0787B Chapter 6 Configuration 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. Y ou should refer to the Logicmaster 90 Software User ’s Manual for detailed configuration instructio[...]

6 6-46 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B Creating and Copying the PLC Configuration The recommended method of completing the PLC configuration is described below . A. Create a F older for PLC A, PLC B, and PLC C. In this discussion, PLC A is considered to be the PLC [...]

6 6-47 GFK-0787B Chapter 6 Configuration L ogicmaster Configuration Summar y 1. Change the CPU to the cor rect type (in this example, it is a CPU 789) and add appropriate memory . 2. Move the cursor to the rack and slot location for the first Bus Controller . Be sure the location matches the entry made with the GMR Configuration Software. 3. P ress[...]

6 6-48 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B 12. On the bus configuration screen, the Bus Controller appears at its configured Bus A ddress, 31 in this e xample. 13. F rom here, you can configure the devices on the bus, including the other bus controllers in the group. E[...]

6 6-49 GFK-0787B Chapter 6 Configuration Configuring GMR Bus Controllers and I/O Blocks Each bus controller that ser ves 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 ca[...]

6 6-50 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B Configuring Genius I/O Blocks Genius I/O block configuration for a GMR system is similar to configuration for a non- GMR system. Y ou should refer to the Genius Discr ete and Analog Blocks User ’s Manual for specific configu[...]

6 6-51 GFK-0787B Chapter 6 Configuration 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[...]

6 6-52 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B Any discrete block that is part of a redundant input group (triple x, duple x, 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- onl[...]

6 6-53 GFK-0787B Chapter 6 Configuration If the block will use Input A utotest, circuit 16 must be configured as an output, as explained above. F or circuit 16, Hold Last State must be configur ed to NO . If the block will use Input A utotest, circuit 16 must be configur ed with Output Default set to ON. P ortions of the overall system can be confi[...]

6 6-54 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B F or output blocks set up for GMR redundancy , the duplex default state is used when a block determines that only two PLCs are online. The Duple x Default state of On or Off is used by the 2 out of 3 voting algorithm in the bl[...]

6 6-55 GFK-0787B Chapter 6 Configuration Results of Block V oting with Only T wo PLCs Online 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 Duple x 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 [...]

7 section level 1 1 figure bi level 1 table_big level 1 7-1 GFK -0787B Chapter 7 Programming Infor mation This chapter describes the following aspects of the application program inter face to the GMR software: P rogramming Overview P rogram Instruction Set for GMR Estimating Memory Usage Reser ved References Input and Output Addressing for GMR Regi[...]

7 7-2 Genius Modular R edundancy Flexible T riple Modular R edundant (TMR) System User’s Manual – March 1995 GFK -0787B Programming Overview 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 P rogram Block should be don[...]

7 7-3 GFK -0787B Chapter 7 Programming Infor mation Program Instr uction Set for GMR The CPUs used for GMR support the all of the following Series 90-70 ladder logic instr uctions: Contacts Any Contact –| |– –|/|– –| ↑ |– –| ↓ |– –[F A UL T]– –|NOFL T]– –[HIALR]– –[LO ALR]– <+>––– Coils Any Coil –( [...]

7 7-4 Genius Modular R edundancy Flexible T riple Modular R edundant (TMR) System User’s Manual – March 1995 GFK -0787B Reserved Refer ences In a GMR system, the following references are reser ved or assigned special functions: R eferences Reserved F or: %I0001 to %I1024 (788 CPU) %I00001 to %I12288 (789 CPU ) Input T able. Some references are [...]

7 7-5 GFK -0787B Chapter 7 Programming Infor mation Input and Output Addressing for GMR I/O addressing for GMR is unlik e 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 T able and Output T able. In a GMR application, the GM[...]

7 7-6 Genius Modular R edundancy Flexible T riple Modular R edundant (TMR) System User’s Manual – March 1995 GFK -0787B Discrete I/O T ables: Example In this ver y 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[...]

7 7-7 GFK -0787B Chapter 7 Programming Infor mation Analog I/O Addressing The size of the Analog Input T able is defined during configuration. The maximum size is 8192 analog channels (words). Like the discrete Input and Output T ables, the Analog Input T able is divided into sections. Analog Input T able V oted Inputs non-voted Inputs Input V otin[...]

7 7-8 Genius Modular R edundancy Flexible T riple Modular R edundant (TMR) System User’s Manual – March 1995 GFK -0787B 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 T ab[...]

7 7-9 GFK -0787B Chapter 7 Programming Infor mation Register (%R) Memor y Assignment for GMR The GMR software uses several areas of %R memor y for specific functions, as diagrammed below . Only the area labelled “ Application Registers” should be used by the application program. W ithin that area, a portion is reserved for initialization data, [...]

7 7-10 Genius Modular R edundancy Flexible T riple Modular R edundant (TMR) System User’s Manual – March 1995 GFK -0787B System Status (%S) R efer ences System status references are pre-defined locations and nicknames. They can be included in the application program to check for fault-related conditions. F or example, status references can be u[...]

7 7-11 GFK -0787B Chapter 7 Programming Infor mation GMR Status and Control (%M) Refer ences 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 us[...]

7 7-12 Genius Modular R edundancy Flexible T riple Modular R edundant (TMR) System User’s Manual – March 1995 GFK -0787B PLC OK Flags The meanings associated with the three PLCOK flags are listed below: A t PLC A PLC A OK PLC A outputs enabled A t PLC A PLCBOK PLC B communications with PLC A healthy and PLC B outputs enabled PLCCOK PLC C commun[...]

7 7-13 GFK -0787B Chapter 7 Programming Infor mation %M Control R eferences The application program can use the following %M references to provide infor mation to the GMR software. The references are located at %M12257 – %M12288. R eference Nickname Description Meaning %M12257 CONTINU Continue with initialization & enable outputs %M12258 IORE[...]

7 7-14 Genius Modular R edundancy Flexible T riple Modular R edundant (TMR) System User’s Manual – March 1995 GFK -0787B %M12262 (R epor t) When this control bit is tur ned on, it causes the GMR software to report and record the following into the PLC F ault T able of the PLC(s) that tur ned it on: The GMR Softwar e V ersion currently running i[...]

7 7-15 GFK -0787B Chapter 7 Programming Infor mation 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. The GMR software in the PLCs only allows one PLC to come online at a time. First, a PLC deter mines its ID by reading the serial bus addresses [...]

7 7-16 Genius Modular R edundancy Flexible T riple Modular R edundant (TMR) System User’s Manual – March 1995 GFK -0787B 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. W ord type d[...]

7 7-17 GFK -0787B Chapter 7 Programming Infor mation P rior 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 applica[...]

7 7-18 Genius Modular R edundancy Flexible T riple Modular R edundant (TMR) System User’s Manual – March 1995 GFK -0787B an I/O Fault Reset be perfor med when any of the GMR CPUs are initialized, which will cause any cur rent I/O fault infor mation to be re–reported. If manual output controls are used in a GMR system and the appropriate GMR A[...]

7 7-19 GFK -0787B Chapter 7 Programming Infor mation | | << RUNG 12 >> | |IORESIP IORES |——| # |—————————————————————————————————————————————————————————————————(R)——— | | | | | | | | | | << R[...]

7 7-20 Genius Modular R edundancy Flexible T riple Modular R edundant (TMR) System User’s Manual – March 1995 GFK -0787B I/O P oint F aults The GMR system can optionally use the standard Series 90-70 I/O P oint F ault references. The I/O P oint F aults feature allocates a bit reference for each potential discrete point fault and a byte referenc[...]

7 7-21 GFK -0787B Chapter 7 Programming Infor mation Programming for F ault and Alar m Contacts Th e G M R sy st e m so f t w a r e c a n o p t io n a lly ut iliz e t h e Fa ult a n d Ala r m co n t a ct s ca p a b ilit y o f t h e Series 90-70 PL C to make fault and al ar m in for mation avail able to th e appli cation program logi c. Condi ti ons[...]

7 7-22 Genius Modular R edundancy Flexible T riple Modular R edundant (TMR) System User’s Manual – March 1995 GFK -0787B Discrete Input F ault Contacts for GMR In the discrete Input T able 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[...]

7 7-23 GFK -0787B Chapter 7 Programming Infor mation Analog F ault 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 T able V oted Inputs Non-voted Inputs Input V oting[...]

7 7-24 Genius Modular R edundancy Flexible T riple Modular R edundant (TMR) System User’s Manual – March 1995 GFK -0787B Reading GMR Diagnostics The application program can obtain the following diagnostic infor mation from the GMR system software: A utotest faults Discrepancy faults Genius faults P oint faults Analog alarms This information is [...]

7 7-25 GFK -0787B Chapter 7 Programming Infor mation Data T able Numbers T able Contains R an g e f o r S t a r t V al u e Range for End V alue 11 Digital Input Discrepancy faults Greater than or equal to the first digital input address for A, B, or C. Less than the start plus the maximum digital input ad- dress for A, B, or C. 14 Digital Input A u[...]

7 7-26 Genius Modular R edundancy Flexible T riple Modular R edundant (TMR) System User’s Manual – March 1995 GFK -0787B Error Codes for GMR Diagnostics The following error codes may be generated by the GMR diagnostics routine (see page 7-24): Code Meaning 10908 An attempt was made to read an I/O shutdown timer for an invalid block 10909 An att[...]

7 7-27 GFK -0787B Chapter 7 Programming Infor mation Programming for Global Data In a 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 ex changing system information between the PLCs. Each PLC provides 8 w[...]

7 7-28 Genius Modular R edundancy Flexible T riple Modular R edundant (TMR) System User’s Manual – March 1995 GFK -0787B Adding the GMR System Sof twar e to a New Application Program F older The GMR system software provided on the diskette must be added to the folder containing the application program. F ollow the steps below to add the GMR sys[...]

7 7-29 GFK -0787B Chapter 7 Programming Infor mation Adding the GMR Configuration to the Application Program F older 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 . T o[...]

7 7-30 Genius Modular R edundancy Flexible T riple Modular R edundant (TMR) System User’s Manual – March 1995 GFK -0787B 5. A dd G_M_R10 to the library by pressing the Enter key . 6. When pr ompted for the number of pair ed input and output parameters, enter 2. 7. P ress ESC to r eturn to the Librarian menu. Impor ting G_M_R10 from the Libraria[...]

7 7-31 GFK -0787B Chapter 7 Programming Infor mation Storing a Program to the PLC All redundant PLCs in the GMR system must use the same application program, but different configurations: PLC A PLC B PLC C Program: GMRPROG Configuration: CONFIGA Program: GMRPROG Configuration: CONFIGB Program: GMRPROG Configuration: CONFIGC Supplying the configurat[...]

7 7-32 Genius Modular R edundancy Flexible T riple Modular R edundant (TMR) System User’s Manual – March 1995 GFK -0787B Things to Consider when Storing 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, [...]

7 7-33 GFK -0787B Chapter 7 Programming Infor mation Using the Store Function T o use the Store function, press Stor e (F4) from the Program Utility F unctions 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: pr[...]

7 7-34 Genius Modular R edundancy Flexible T riple Modular R edundant (TMR) System User’s Manual – March 1995 GFK -0787B 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 sys[...]

7 7-35 GFK -0787B Chapter 7 Programming Infor mation 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 [...]

7 7-36 Genius Modular R edundancy Flexible T riple Modular R edundant (TMR) System User’s Manual – March 1995 GFK -0787B Customizing the Download Utility for Other PLC IDs F or PLCs with other PLC IDs, you need to edit the file KEY0.DEF before adding it to the Program F older in Logicmaster . 1. Install the GMR software diskette in your compute[...]

7 7-37 GFK -0787B Chapter 7 Programming Infor mation Storing a Program to the PLC: the System IS Configured for Online Changes F or 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 [...]

7 7-38 Genius Modular R edundancy Flexible T riple Modular R edundant (TMR) System User’s Manual – March 1995 GFK -0787B 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. If an online program change is made to a single PLC[...]

8 section level 1 1 figure bi level 1 table_big level 1 8-1 GFK-0787B Chapter 8 Installation Infor mation Genius Bus Connections T er mination Boards Input W iring Single Sensor to Three Blocks (T riple Bus) Three Sensors to Three Blocks (T riple Bus) Block W iring for a 16-Circuit Block in an Input Group Block W iring for a 32-Circuit Block in an [...]

8 8-2 Genius Modular Redundancy Flexible T riple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B 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 cor rect cable typ[...]

8 8-3 GFK-0787B Chapter 8 Installation Information Input W iring Calculating V oltage Drops on T ristate Inputs It is important to consider the field wiring r uns 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 ra[...]

8 8-4 Genius Modular Redundancy Flexible T riple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B Single Sensor to Three Blocks (T riple Bus) DC+ I1 I15/32 O16 DC+ I1 I15/32 O16 DC+ I1 I15/32 O16 Input 1 Input 15 or 32 C P U G B C C G B C A G B C B C P U G B C A G B C B G B C C C P U G B C A G B C B G B C C P S P S P S PLC[...]

8 8-5 GFK-0787B Chapter 8 Installation Information Input W iring (continued) Three Sensors to Three Blocks (T riple Bus) DC+ I1 I15/32 O16 I1 I15/32 O16 I1 I15/32 O16 Input 1 Input 15 or 32 Input 1 Input 15 or 32 Input 1 Input 15 or 32 DC+ DC+ PLC A PLC B PLC C 6.2V Zener Diodes for Line Monitoring (optional) C P U G B C C G B C A G B C B C P U G B[...]

8 8-6 Genius Modular Redundancy Flexible T riple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B Input W iring (continued) Block Wiring for 16- Circuit Source Block in an Input Group S1 S2 SHLD IN SHLD OUT DC+ 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 DC– Genius Bus Connections 22V to 56V DC If single sensor , it must also[...]

8 8-7 GFK-0787B Chapter 8 Installation Information Input W iring (continued) Block Wiring for 16- Circuit Sink Block in an Input Group S1 S2 SHLD IN SHLD OUT DC+ 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 DC– Genius Bus Connections 22V to 56V DC T ypical for each of up to 15 inputs DC Sink Block IC660BBD021 O VDC Ground If group inputs are configured[...]

8 8-8 Genius Modular Redundancy Flexible T riple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B Input W iring (continued) Block Wiring for 32- Circuit Source Block in an Input Group S1 S2 SHLD IN SHLD OUT DC+ DC+ DC+ DC+ DC+ 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 DC– DC– 44 DC– DC– 46 DC– Genius Bus[...]

8 8-9 GFK-0787B Chapter 8 Installation Information Input W iring (continued) Block Wiring for 32- Circuit Sink Block in an Input Group S1 S2 SHLD IN SHLD OUT +5V DC+ DC+ DC+ DC+ 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 DC– DC– 44 DC– DC– 46 DC– Genius Bus Connections 22V to 30V DC DC Sink Block IC660BBD025 O VDC Ground If group [...]

8 8-10 Genius Modular Redundancy Flexible T riple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B Output W iring for a 16-Circuit, 4-Block Group 16- Circuit, 4-Block Output Group Q1 Block C (Sink) DC+ Q1 Block A (Source) Q1 Block D (Sink) Q16 Q1 Block B (Source) Hi Low Hi Low Output 1 Output 16 DC+ DC+ DC+ Q16 Q16 Q16 Bus[...]

8 8-1 1 GFK-0787B Chapter 8 Installation Information Output W iring for a 16-Circuit, 4-Block Group (continued) Block Wiring for a 16- Circuit 4-Block Output Group More detailed installation infor mation is provided in the block datasheets. The labels Block A , Block B , Block C , and Block D refer to the previous system diagram. S1 S2 SHLD IN SHLD[...]

8 8-12 Genius Modular Redundancy Flexible T riple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B Output W iring for a 16-Circuit, 4-Block Group (continued) Output Load Considerations for 16-Circuit 4-Block “H” P attern Redundant Output Groups Minimum load: 100 milliamps Maximum load: 2.0 Amps Maximum inrush cur r ent[...]

8 8-13 GFK-0787B Chapter 8 Installation Information 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 a[...]

8 8-14 Genius Modular Redundancy Flexible T riple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B Output W iring for a 32-Circuit, 4-Block Group 32- Circuit, 4-Block Output Group Q1 Block C (Sink) DC+ Q1 Block A (Source) Q1 Block D (Sink) Q32 Q1 Block B (Source) Hi Low Hi Low Output 1 Output 32 DC+ DC+ DC+ Q32 Q32 Q32 Bus[...]

8 8-15 GFK-0787B Chapter 8 Installation Information Output W iring for a 32-Circuit, 4-Block Group (continued) Block Wiring for a 32- Circuit 4-Block Output Group More detailed installation infor mation is provided in the block datasheets. The labels Block A , Block B , Block C , and Block D refer to the previous system diagram. S1 S2 SHLD IN SHLD [...]

8 8-16 Genius Modular Redundancy Flexible T riple Modular Redundant (TMR) System User ’ s Manual – Mar ch 1995 GFK-0787B Warning In certain cases, r emoving the DC power sour ce fr om an output block or blocks which are part of a 32-cir cuit 4-block output group, causes leakage cur rents thr ough the output driver cir cuits of the power ed down[...]

8 8-17 GFK-0787B Chapter 8 Installation Information Output W iring for a 32-Circuit, 4-Block Group (continued) Output Load Considerations for 32-Circuit 4-Block “H” P attern R edun - dant Output Groups Minimum load: 1.0 milliamp Maximum load: 0.5 Amp Maximum inrush cur r ent: 4 Amps for up to 10 milliseconds Maximum total load for block group: [...]

A section level 1 1 figure_ap level 1 table_ap level 1 GFT -166 Revision 1.3 April 4, 1995 A-1 GFK -0787B Appendix A TÜV Certification TÜV is an acronym for “T echnischer Über wachungs–V erein”, which has a rough translation to English of “T echnical Supervisory Group”. TÜV is an independent Ger man technical inspection agency and tes[...]

A GFT -166 Revision 1.3 April 4, 1995 A-2 Genius Modular R edundancy Flexible T riple Modular R edundant (TMR) System User’s Manual – March 1995 GFK-0787B TÜV Restrictions F or all safety relevant applications the safe state must be the de-energized (0) state. A F unctional test must be per for med to check for the cor rect design and operatio[...]

A GFT -166 Revision 1.3 April 4, 1995 GFK -0787B A-3 Appendix A TÜV Certification The installation procedures in the Series 90-70 Programmable Controller Installation Manual (GFK -0262D) and this GMR User ’s Manua l (GFK -0787A) are to be closely observed and complied with, especially the grounding procedures in chapter 3 of the Series 90–70 P[...]

A GFT -166 Revision 1.3 April 4, 1995 A-4 Genius Modular R edundancy Flexible T riple Modular R edundant (TMR) System User’s Manual – March 1995 GFK-0787B 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[...]

B section level 1 1 figure_ap level 1 table_ap level 1 B- 1 GFK -0787B Appendix B Maintenance Over ride The information in this appendix is reprinted by per mission of TUV . Abstract Suggestions are made about the use of maintenance override of safety relevant sensors and actuators. W ays are shown to overcome the safety problems and the inconvenie[...]

B B -2 Genius Modular R edundancy Flexible T riple Modular R edundant (TMR) System User’s Manual – March 1995 GFK-0787B The following table shows common requirements. The differences between solution A and B are shown by typeface italic. R equirements for maintenance override handling R esponsibility Already during the software configuration of[...]

B GFK -0787B B-3 Appendix B Maintenance Override Recommendations The following recommendations are given to improve the primary safety as described by the list: A program in the DCS that checks regularly that no discrepancies exist between the over ride command signals from the DC S and the over ride activated signals received by the DC S from the [...]

Index Index-1 GFK-0787B A Alar m and F ault contacts, 5-25 , 5-28 , 7-21 Analog blocks, 1-8 Analog I/O , addressing, 7-7 Analog inputs, 4-12 configuring memory for , 6-18 configuring references for , 6-33 discrepancy , 5-13 , 6-36 maximum, minimum, 6-35 Application program inhibiting, 4-4 , 7-11 storing to PLC, 7-31 updating on SNP network, 1-3 Asy[...]

Index Index-2 GFK-0787B Duple x state, 6-34 F F ailed Switch detection, 3-9 , 5-2 F ailed Switch fault, 5-26 F ault actions, configuring, 6-22 , 6-23 F ault and Alarm contacts, 5-25 , 5-28 , 7-21 F ault Reporting, 5-3 F ault reporting, 2-2 configuring for I/O blocks, 6-52 in GMR mode, 3-9 F ault Reportting, 6-50 F ault T ables, 5-15 clearing, 5-15 [...]

Index Index-3 GFK-0787B Inputs and outputs, number available, 1-9 Installation information, 8-1 Inter nal Channel fault, 5-28 L LED, Block OK, 3-9 Limit discrepancy , 5-12 , 6-36 Line fault, 5-2 , 5-25 Line monitoring, 2-7 Load sharing by output blocks, 3-6 , 5-16 Logicmaster software, version required, 1-2 Logon control, 7-17 Loss of Block fault, [...]

Index Index-4 GFK-0787B References for inputs, 6-28 References, reserved, 7-4 Register memory assignments for GMR, 7-9 configuring amount, 6-18 reser ved, 7-4 R TD blocks, 1-8 S %S status references, 7-10 Serial bus address, configuring, 6-28 , 6-33 , 6-37 , 6-45 , 6-51 Short Circuit fault, 5-2 , 5-26 SNP communications, 1-3 Startup, 4-2 Startup st[...]