GEP-9145

g

GE Ind Industri strial al Systems

Innovation Series Controller Product Catalog ™

Pre-empt Pre mptii ve M u l ti ti--tas taski kin ng Control

Contents Commitment Commitment to Quality .......................... ........................................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ ......................... ........... 1 Six Sigma Sigma Dependabil Dependability.......... ity........................ ............................ ............................ ............................ ............................ ............................ ........................ ...................... .......................... ............................ ................ .. 1 ISO 9001 Certifi Certificatio cation n ........................... ......................................... ............................ ............................ ............................ ............................ .............................. ............................. ........................... ....................... ......... 1 Technical Technical Support Support ............................ .......................................... ............................ ............................ ............................ ........................... ............................. ............................. ........................... ............................ ................ .. 1 Training............... Training............................. ............................ ............................ ............................ ............................ ............................ ............................ ........................... ........................... ............................ ............................ .................. .... 1 Overview............. Overview ........................... ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ .................... ...... 2 Primary Primary Controller Controller ........................... ......................................... ............................ ........................... ........................... ............................ ........................... ........................... ............................ ............................ .................. .... 2 Series 90 �-70 PLC Interface Interface Module................... Module................................. ............................ ............................ ............................ ............................ ............................. ............................ ...................... ......... 3 Mill Stand Control Control Applicati Application................... on................................. ............................ ............................ ........................... ........................... ....................... ....................... ............................ ......................... ........... 4 Innovation Series Controllers ........................... ........................................ ........................... ............................ ............................ ............................ .............................. .............................. ........................... ............. 5 Common Common Features Features – VME Controller Controllers..................... s................................... ............................ ............................ ............................ ............................ ......................... ......................... ....................... ......... 5 Differentiating Differentiating Features – VME Controllers. ........... .......... ........... .......... ........... .......... ........... ............... ........... .......... ..... 7 Common Common Features Features – ACL Controller Controllers...................... s.................................... ............................ ............................ ............................ ............................ ......................... ......................... ....................... ......... 9 Differentiating Differentiating Features – ACL Controllers.. ........... .......... ........... .......... ........... ........... .......... ............... ........... .......... ... 10 Execution of Control Logic ........................... ......................................... ............................ ............................ ............................ ............................ .......................... .......................... ............................ .................. .... 11 I/O Drivers.................................... Drivers.................................................. ............................ ............................ ............................ ............................ ............................ ........................... ........................... ............................ ..................... ....... 14 Control System Toolbox ........................... ......................................... ............................ ........................... ........................... ............................ ........................... ........................... ............................ ....................... ......... 25 Configuration of I/O Drivers and Hardware.............. ........... .......... ........... .......... ........... .......... ............ ........... .......... ..... 26 Organizati Organization on of Control Control Logic Logic ........................... ......................................... ........................... ........................... ............................ ............................ ............................ ............................ ......................... ........... 27 Instruct Instruction ion Blocks Blocks .......................... ........................................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ ................ .. 29 Permissive Permissive Diagnostic Function .......................... ........................................ ............................ ............................ ............................ ............................ ........................ ........................ ............................ .............. 32 Fault Detection................. Detection............................... ............................ ............................ ............................ ............................ ............................ ......................... ........................ .......................... ........................... ..................... ....... 33 Presentin Presenting g the Diagnosis Diagnosis ........................... ......................................... ............................ ............................ ............................ ............................ ........................ ........................ ............................ ....................... ......... 35 Ordering Information Information.............. ............................ ............................ ............................ ............................ ............................ ............................ ........................... ........................... ............................ ......................... ........... 36 Innovatio Innovation n Series Series Controller Controllers...................... s.................................... ............................ ........................... ........................... ............................ .......................... ......................... ........................... ..................... ....... 36 Innovatio Innovation n Series Series Controller Controller I/O .......................... ........................................ ............................ ............................ ............................ ........................... ........................... ............................ ....................... ......... 36 Genius Genius I/O System System Blocks Blocks and Options Options ............................ .......................................... ............................ ............................ ............................ .......................... .......................... ......................... ........... 37 Field Control I/O System Components and Options .......... ........... .......... ........... .......... ........... .......... .............. .......... ..... 38 Control System Solutions (Windows NT Applications Applications & Service)........ .......... ........... ........... .......... ........... .............. ..... 39 Catalog Catalog Number Number Structure...... Structure.................... ............................ ............................ ............................ ............................ ............................ ........................... ........................... ............................ ......................... ........... 40

CIMPLICITY, Genius, and Series 90 are registered trademarks of GE Fanuc Automation North America, Inc. Ethernet is a trademark of Xerox Corporation. Field Control is a trademark of GE Fanuc Automation North America, Inc. IBM and PC are registered trademarks of Internation Business Machines Corporation. Innovation Series and ISBus are trademarks of General Electric Company, USA. Windows is a registered trademark of Microsoft Corporation.

Commitment to Quality GE Industrial Control Systems is committed to improve customer productivity with the best industrial automation automation technology, reliability, and service worldwide.

Six Sigma Dependability GE businesses are committed to attaining a Six Sigma level of quality. This program has been initiated to identify quality issues and to address these in such a way that all our business and manufacturing processes are performed correctly 99.99966% of the time. There are only a few firms in the world, including hospitals and airlines that have attained Six Sigma quality, and GE has made a commitment, backed by training and resources to join this select group.

ISO 9001 Certification GE Industrial Control Systems’ quality processes and software development have earned the ISO 9001 certification in accordance with TickIT from Lloyds’s Register of London. This certification is the most comprehensive of all standards developed by the International Organization for Standardization. It promotes consistent quality of design and manufacturing processes world-wide.

Technical Support GE provides responsive service and support at any time. GE’s OnSite Support SM remote monitoring and diagnostics system puts you online with a team of experienced engineers to answer questions and diagnose problems. They are available 24 hours a day to support your team. Over 3,000 sales people are now available to serve you through our new DS-750 D istribution Network "2000" program linking GE Industrial Control System Solutions authorized authorized GE distributors d istributors to better serve our end customers.

Training Extensive training training tailored to your needs is available for both operating and maintenance maintenance personnel. Training can be taught at your site or at the GE T raining Center in Salem, Virginia. All training facilities feature professionally developed courses taught by experienced, knowledgeable instructors in well-equipped classrooms and laboratories.

GEP-9145 Innovation Series Controller Product Catalog

1

Overview The pre-emptive multi-tasking feature allows the scheduled execution of a high priority control task to interrupt the execution of a low or medium priority control task.

Innovation Series™ controllers are specifically designed for application in large integrated drive systems and high performance hydraulic regulators. Each controller has a pre-emptive multi-tasking operating system with revolutionary networking and diagnostic features. The Windows -based Control System toolbox provides unique configuration and monitoring tools with an integrated Graphics Window, Data Historian, and Trend Recorder. T wo controller form factors allow installation in a Versa Module Eurocard (VME) rack (two forms available) or in an Innovation Series drive rack (known as the Application Control Layer (ACL) as follows: �

VME Form Factor • Primary controller in the system • Interface between sequencing logic in programmable logic controller (PLC) and drives in the system •

ACL Form Factor • High speed coordination of drives • Tension regulation in a coordinated line Coil diameter calculation in paper and metal applications

•

Mill stand control in the metals manufacturing industry

Primary Controller As the primary controller in a system, the Innovation Series controller uses the Genius® I/O and/or Field Control™ I/O for interface with field devices. I/O drivers for the Drive LAN+ (DLAN+), Ethernet™ Global Data (EGD), and ISBus™ provide connectivity to the AC/DC2000 and Innovation Series drives. Additional I/O drivers are available for interfaces with other components in the system. Control logic is edited and monitored in a graphic block diagram format using the toolbox. The CIMPLICITY® Human Machine Interface (HMI) and the controller communicate over Ethernet using Serial Request Transfer Protocol (SRTP) or EGD. CIMPLICITY HMI Viewer

CIMPLICITY HMI Server

Control System Toolbox


Ethernet

Innovation Series Controllers

Genius

Field Control DLAN+ ISBus ISBus +

-

AC/DC2000

AC/DC2000

AC/DC2000

AC

+

-

AC

+

-

AC

Innovation

Innovation

Innovation

Series

Series

Series

Motor Control Layer Application Control Layer

Innovation Series controllers system configuration in a general purpose sequencing application

2 in


Series 90�-70 PLC Interface Module The Innovation Series controller can be used to interface the Series 90-70 PLC to the AC/DC2000 and Innovation Series drives. The AC/DC2000 and Innovation Series drives have different LAN options for coordination between drive control and the sequencing software as follows:

Product

LAN Connectivity

AC/DC2000

DLAN+ Genius Bus

Innovation Series Drives

Ethernet Serial Request Transfer Protocol (SRTP) Ethernet Global Data (EGD) ISBus Genius Bus

In this type of system, the sequencing logic is implemented in the Series 90-70 PLC and the Innovation Series controller provides the interface with the drives. VME read/write commands initiated from the Series 90-70 central proccessing unit (CPU) provide the mechanism for data exchange between the CPU and the Innovation Series controller. CIMPLICITY HMI Viewer

CIMPLICITY Control or LM90



Ethernet Series 90-70

U P C

t e n r e h t E

s u B s u i n e G

U P C

t e n r e h t E

s u B s u i n e G


Series 90-70

DLAN+ ISBus ISBus +

-

AC/DC2000

AC/DC2000

AC

+

-

AC

+

-

AC

AC/DC2000

Motor Control Layer

Innovation

Innovation

Innovation

Series

Series

Series

Application Control Layer

Innovation Series controllers system configuration in a VME PLC-based drive system application


3

Mill Stand Control Application In metal rolling mills, there are several high performance control functions associated with the mill stand. The Innovation Series controller has several features specifically tied to this class of applications as follows: •

Control block programming language well suited for configuration of regulators

•

Pre-emptive multi-tasking operating system with task scheduling (1ms, 2ms, 4ms, 8ms, 16ms, etc)

•

Special purpose I/O modules tailored for hydraulic cylinder driven regulators

•

Coherent sampling of process feedback data for inter-related mill stand regulators

•

Integrated trending package in toolbox for commissioning and maintenance

Control functions implemented in steel and aluminum mills include the following: Metal Rolling Mill Rod & Bar Mill Hydraulic Cylinder Control Waterbox Control Work Roll Bending Laying Head Control Work Roll Shifting Laying Head Pinch Roll Control Hydraulic Loopers (hot strip mill) Roll Change Sequencing Eccentricity Control Automatic Gauge Control Backup Roll Balance Wedge Pass Line Adjust Elongation Control Automatic Width Control (hot strip mill) Roll Change Sequencing CIMPLICITY HMI Viewer



Ethernet


CTR 1

CTR 1

CTR 1

CTR 2

CTR 2

CTR 2

CTR 3

CTR 3

Field Control

CTR 3

A/I 1

A/O 1

A/I 1

A/O 1

A/I 1

A/O 1

A/I 8

A/O 4

A/I 8

A/O 4

A/I 8

A/O 4 Load Cell

DLAN+ ISBus ISBus +

-

AC

+

-

AC

+

-

AC

Innovation

Innovation

Innovation

Series

Series

Series

A C/ DC 20 00

A C/ DC 20 00

A C/ DC 20 00

Motor Control Layer Application Control Layer

Innovation Series controllers system configuration in a mill stand control application

4 in


Innovation Series Controllers The VME rack-based controllers share a common processor platform with different drive LAN connectivity options to address a particular application. The ACL controllers are designed to mount in the Innovation Series drive control rack. The following section describes common and differentiating features of these controllers.

Common Features – VME Controllers Processor

Pentium 133 MHz

Memory

16 MB DRAM, 256KB of level 2 cache

Operating System

Pre-emptive multi-tasking operating system built on QNX platform (refer to the section, Execution of Control Logic).

LEDs

LEDs on the faceplate of the CPU provide status information as follows:

Ethernet Interface

COM Ports

LED

Description

Active

Microprocessor is active

Slot 1

Controller configured as the slot 1 controller in VME bus system

BMAS

Indicates VME master access is occurring

ENET

Ethernet packets are being transmitted

BSLV

Indicates VME slave access is occurring

STATUS

Display rotating LED pattern when OK -displays flashing error code when faulted

FLSH

Flash memory is being written

GEN_

Genius I/O is active

•

Thinwire 10base2, BNC connector

•

TCP/IP protocol used for communication between controller and toolbox

•

Serial Request Transfer Protocol (SRTP) interface between controller and HMI

•

Ethernet Global Data (EGD) protocol used for communication with Innovation Series drives, Series 90-70 PLCs, or CIMPLICITY HMI

•

Ethernet Modbus™ protocol supported for communication between controller and Distributed Control System (DCS)

•

9-pin D connector

•

COM 1– reserved for diagnostics only

•

COM 2 – can be used for serial protocols, such as Modbus communication between controller (slave only) and DCS as follows:

Parameter Baud Rate

Description 19200

Mode

Binary (Remote Terminal Unit), ASCII

Data Bits

7, 8

Parity

None, Odd, Even

Stop Bits

1, 2

GEP-9145 Innovation Series Controller

5

Genius Bus Interface

DLAN+ Interface

Programming Language

One or two Genius bus controllers are integrated with the CPU. For additional Genius buses, up to five third party VME modules can be installed in the rack. Each module supports two Genius buses. Full support of communication services on the Genius bus includes: •

Run time communication with Genius I/O blocks and Field Control I/O System for status of inputs and controlling of outputs.

•

Datagram communication services with Genius I/O blocks and Field Control I/O System for upload and download of configuration data. Local forcing of I/O points is also supported using datagrams from the controller. This allows the user to remotely force I/O points from the toolbox.

•

Global Genius services allow communication (32 or 128 bytes broadcast from each node) between GE Fanuc PLCs and Innovation Series controllers.

•

Datagram communication services provide read/write access of process variables for GE Fanuc Data Panels and Computer Technology Corporation (CTC) Power Stations.

Full support of DLAN+ communication services includes: •

Direct access to all 255 Status_S pages. Each page is 256 words in length. Each device on the DLAN+ has a Status_S page partitioned into commands and feedback data. The Status_S pages are periodically (default of 320 ms) broadcast to all other devices on the network.

•

Directed and group command messages can be sent to any device’s Status_S page with an instruction from user logic.

•

Each Innovation Series controller can have up to five pages.

Control block language with Boolean logic represented in relay ladder diagram format. Supported data types include: •

Environmental

Boolean

•

16-bit signed integer

•

32-bit long signed integer

•

32-bit floating point

•

64-bit long floating point

Temperature

0 to 45 Celsius inlet air operating -40 to 85 Celsius , storage

6 in

Cooling

Forced Air, 100 linear feet per minute minimum

Humidity

10 to 95% relative humidity, non-condensing

Shock

6G Max. operating, 10G Max. non-operating


Differentiating Features – VME Controllers VME Catalog Number

DS215UCVBG1

DLAN+ 10 8

E t h e r n e t

1 H L

DLAN+A 10 8

E t h e r n e t

DLAN+B 10 8

1 H L

1 H L

S T A RSET T U S

S T RSET A T U S

C O M 1

DS215UCVBG3

C O M 1

2

S T A T U S

2

D L A N +

D L A N +

GENIUS SER 1 SER 2

D L A N +

GENIUS A

GENIUS B

SER 1 SER 2

SER 1 SER 2

DLAN+ Interfaces

1

2

Genius Interfaces

1

2

ISBus Interfaces

none

none

Required VME Slots

2

4

Power Requirements

+5 V dc 5.64 A

+5 V dc 6.08 A

+12 V dc 900 mA

+12 V dc 900 mA

-12 V dc 200 mA

-12 V dc 200 mA


7

VME Catalog Number

IS215UCVCH1

E t h e r n e t

E t h e r n e t

S T A RSET T U S

S T RSET A T U S

C O M 1

8 in

IS215UCVCH3

2

C O M 1

I S B u s A

IS215UCVCH5

10

E t h e r n e t

S T A T U S

1

S T A RSET T U S

C O M 1

2 I S B u s A

8

I S B u s A

S T A T U S

2 I S B u s A

I S B u s B

I S B u s B

I S B u s B

I S B u s B

GENIUS

GENIUS

GENIUS

GENIUS

D L A N +

GENIUS

DLAN+ Interfaces

none

none

1

Genius Interfaces

1

2

2

ISBus Interfaces

2

4

2

Required VME Slots

2

4

4

Power Requirements

+5 V dc 5.64 A

+5 V dc 6.08 A

+5 V dc 6.08 A

+12 V dc 900 mA

+12 V dc 900 mA

+12 V dc 900 mA

-12 V dc 200 mA

-12 V dc 200 mA

-12 V dc 200 mA


Common Features - ACL Controllers Processor

486 100MHz

Memory

8 MB DRAM 128KB of level 2 cache

Operating System

Pre-emptive multi-tasking operating system built on QNX platform (refer to the section, Execution of Control Logic).

LEDs

LEDs on the faceplate of the CPU provide status information as follows:

Ethernet Interface

COM Ports

Environmental

LED

Description

ACTIVE

Microprocessor is active

ENET

Ethernet packets are being transmitted

OK

Runtime code is executing

ACTIVE

CPU is accessing DRAM

FLSH

Flash memory is being written

STATUS

Display rotating LED pattern when OK -displays flashing error code when faulted

•

10BaseT or AUI connector

•

TCP/IP protocol used for communication between controller and toolbox

•

Serial Request Transfer Protocol (SRTP) interface between controller and HMI

•

Ethernet Global Data (EGD) protocol used for communication with Innovation Series drives, Series 90-70 PLCs, or CIMPLICITY HMI

•

Ethernet Modbus™ protocol supported for communication between controller and Distributed Control System (DCS)

•

Micro-miniature 9-pin socket D connector

•

COM 1– reserved for diagnostics only

•

COM2 – Modbus communication between controller (slave only) and DCS

Parameter

Description

Baud Rate

9600, 19200

Mode

Binary (Remote Terminal Unit), ASCII

Data Bits

7, 8

Parity

None, Odd, Even

Stop Bits

1, 2

Temperature

0 to 45 Celsius inlet air, operating -40 to 85 Celsius, storage

Cooling

Forced Air, 100 linear feet per minute minimum

Humidity

10 to 95% relative humidity, non-condensing

Shock

6G Max. operating, 10G Max. non-operating


9

Differentiating Features – ACL Controllers ACL Catalog Number

IS215ACLAH1

1

IS215ACLIH1

RST

RST

OK ACTIVE ENET FLASH S T A T U S



2

C O M

1

2

C O M

E t h e r n e t

1

IS215ACLIH2

RST

RST

E t h e r n e t

Ethernet Interface

IS215ACLAH2

2


ISBus A

C O M

ISBus B

E t h e r n e t

1

2

ISBus A

C O M

ISBus B

E t h e r n e t

10BaseT

AUI

10BaseT

AUI

None

None

2

2

ISBus Interface

10 in


Execution of Control Logic Large industrial drive systems and mill stand controls require a wide range of performance in execution of control functions. The following table displays typical sweep rate requirements for common control functions. Function Required Sweep Rate Sequencing of hydraulic pumps

128 ms

Sequencing of material handling equipment

32 ms

Hydraulic position regulator for a coil car in a metals process line

16 msec

Work roll bending regulator in a mill stand

8 ms

Eccentricity control in a mill stand

1 msec

To meet this wide range of sweep rate requirements, the Innovation Series controllers provide a pre-emptive multi-tasking environment for the execution of control logic. Control functions are organized into tasks, which are scheduled and prioritized per the requirements of the mechanical equipment. The following table displays available priorities and rates for a given control task. Priority of Control Task Available Sweep Rates (ms)

High

Medium

Low

1, 2

Yes

-

-

4

Yes

Yes

-

8, 16

-

Yes

-

32

-

Yes

Yes

64, 128, 256

-

-

Yes

The pre-emptive multi-tasking feature allows the scheduled execution of a high priority control task to interrupt the execution of a low o r medium priority control task. Also, a medium priority control task can interrupt a low priority control task. Control task execution is as follows (refer to figure on following page):

Configured I/O drivers read and write the I/O Table values to hardware asynchronously with the execution of control logic tasks.

1.

Copy all of the external inputs referenced in the task from the I/O Table to the Software Signal Table.

2.

Execute the control logic in the task per the numbered sequence of blocks.

3.

When execution is complete, all external outputs referenced in the task are copied from the Software Signal Table to the I/O Table except:

•

Mill Stand VME I/O outputs that are written directly to the I/O board at the completion of high priority tasks.

•

DLAN+ command messages sent on the network according to the priority of the task. All high and medium priority tasks run to completion before the message is sent. In low priority tasks, the message is sent when the block is executed.

Tasks can be dynamically enabled and disabled from the control logic by connecting the task enable to a signal and modifying the online value. When a task is disabled, neither the I/O or user logic is executed.


11

I/O Drivers Limit_Switch CPU Based Genius

Start_PB Stop_PB

I/O Table

Inputs at start of task Outputs at end of task

Software Signal Table

Sequencing Tasks (Low Priority)

Limit_Switch

Read Task Inputs into Software Signal Table

Start_PB Stop_PB Solenoid

Solenoid GE Fanuc PLC

Start_ PB

VME Board Based Genius

Stop_ PB

Limit_ Switch

Solenoid

Solenoid

DLAN+

Write Task Outputs into I/O Table

E-Net SRTP & Genius Datagram

Low Performance Regulators Tasks (Medium Priority)

E-Net Global Data

Read Task Inputs into Software Signal Table

ISBus

Modbus RTU

Write Task Outputs into I/O Table

Modbus E-Net

High Performance Regulators Tasks (High Priority)

Allen Bradley DH+

Read Task Inputs into Software Signal Table VME Bus Read/Write Cylinder_ Reference VME Interface SysTran Scram Net

Cylinder_Position

CTR 1 Cylinder_ Position Cylinder_ Reference

CTR 2 CTR 3 A/I 1

A/O 1

A/I 8

A/O 4

Mill Stand VME I/O

Cylinder_ Position

Write Task Outputs Directly to Stand Controller I/O Board

Signal Flow / Control Logic Task Execution

12 in


In the following example, consider a skin pass mill in steel galvanizing process line with the control functions listed: Control Functions

Required Control Sweep Rate (ms)

Task Priority

Task Sweep Rate

Hydraulic gap control (HGC)

2

High

2

Work roll bending regulators

4

Medium

4

Mill sequencer

64

Low

64

Elongation control

64

Low

64

The following figure shows the execution of control tasks. High priority tasks, such as HGC are run before medium and low priority tasks. The HGC task is run in each two-millisecond time slice. The remaining time in that time slice executes lower priority tasks.

HGC Task

Remainder of Portion of Mill Mill Sequencer Sequencer Task Task HGC Task Work Roll Bending Task

0

Elongation Control Task HGC Task Idle Time

2 msec

4 msec

HGC Task Work Roll Bending Task

Idle Time

6 msec

Idle Time

8 msec

Time line for control logic execution


13

I/O Drivers I/O drivers interface the Innovation Series controllers with sensors, actuators, and other components in the system. They generally operate asynchronously with control tasks, periodically writing inputs to the I/O table and reading outputs.

I/O Drivers

Software Signal Table

I/O Table

Inputs at start of task, scaled each time

I/O Driver

Outputs at end of task, scaled each time

Limit_Switch Start_PB Stop_PB Solenoid

Operation of I/O drivers

All input points referenced in a control logic task are read from the I/O Table, scaled, and written to the Software Signal Table at the beginning of that task. All output points referenced in a control logic task are read from the Software Signal Table, scaled, and written to the I/O Table at the completion of the task.

Genius I/O Driver

Genius I/O

Genius Bus This bus can have up to 32 devices such as, Genius I/O blocks, Field Control I/O Bus Interface Units (BIU), controllers, and a hand held monitor.

Both the Genius I/O system and Field Control I/O system use the Genius bus for communication. The Genius bus has features well suited for industrial I/O applications including: •

High noise immunity (1500 volt isolation to ground)

•

Wide range of baud rates for different lengths and cable plants

•

Protocol specifically designed for I/O, configuration, and diagnostic data

Genius I/O Blocks The Genius I/O blocks are a well-proven I/O system with unmatched diagnostic features as follows: Discrete I/O Blocks Analog I/O Blocks Open-wire detection (inputs) Open-wire detection (inputs) Sense shorted wire (inputs) High alarm (inputs) Failed switch (inputs/outputs) Low alarm (inputs) Over temperature (inputs/outputs) Internal fault (inputs) Loss I/O power (inputs/outputs) Wiring error (inputs) Short-circuit (outputs) Input short (inputs) Load state feedback (outputs) Under-range (input/outputs) Pulse Test (outputs) Over-range (inputs/ouputs) No-load (outputs) Feedback error (output) Overload (outputs)

14 in


The diagnostic information related to a Genius I/O point can be referenced in control logic with two additional signals. These signals are automatically defined for each point as follows: Genius I/O Point Signals Data Type Description Signal_Name Point Health #Signal_Name Point Health Detail ##Signal_Name

Boolean or Integer Boolean

Value of I/O point

4 Bytes

Byte 1 – I/O point fault code Byte 2 – Block fault code Byte 3 – Block present Byte 4 – Controller OK

Indicates point health

These diagnostic signals can be used in control logic to intelligently react to electrical/mechanical faults in a split second and annunciate the fault in the HMI. Blocks can be monitored or configured from the Genius bus hand held monitor or the toolbox. Function

Hand Held Monitor

Toolbox

Configure block

Yes

Yes

Monitor block

Yes

Yes

Force I/O at the block level

Yes

Yes

Force list of I/O points

No

Yes

Reset faults

Yes

Yes

Set node number

Yes

No

Field Control I/O System Field Control I/O provides a cost effective I/O system on the Genius bus with limited diagnostics relative to the Genius blocks. Each I/O station contains a BIU, field terminal bases, and field I/O modules. Several terminal block options are designed to eliminate auxiliary terminal blocks. DIN-rail is an international standard for I/O connectors.

The BIU interfaces the I/O station to the Genius bus. The universal field terminal bases are DIN-rail (Deutsche Industrie Norm) mounted in the I/O enclosure and can accept two I/O modules. Up to eight field terminal bases can be mounted in a given I/O station. Field Control Data Type Description I/O Point Signals Signal_Name Boolean or Value of I/O point Integer Point Health Boolean Indicates point health #Signal_Name Point Health Detail ##Signal_Name


4 Bytes

Byte 1 – I/O point fault code Byte 2 – Block fault code Byte 3 – Block present Byte 4 – Controller OK, bit 0 Module fault code, bits 4-7

15

VME Bus Farrand Inductosyn

VME High Speed Regulator I/O Driver

Resolver I/O Module

Incremental Encoders

High Speed Regulator I/O

CTR 1 CTR 2 CTR 3 A/I 1

A/O 1

A/I 8

A/O 4

A VME rack-based I/O module is available to provide the I/O requirements of high performance regulators. The inputs tied to each VME high-speed regulator I/O module are read into the I/O table once per millisecond, allowing synchronization of inputs across several inter-related regulators. The outputs are written directly to the module at the completion of the control logic task. Features of the VME I/O driver are as follows: Physical Mounting DIN-rail is an international standard for I/O connectors

The universal I/O board, SIOB, occupies one VME slot using the P1 connector. Module faceplate connectors, J1 and J2, attach through cabling to a terminal base. Field wiring connections on the terminal base are DIN-rail (Deutsche Industrie Norm) mounted. Three High-Speed Counters Each counter has a marker pulse input that can also be configured for low speed or high speed operation. The marker can be optionally enabled/disabled from a software jumper. Each 16-bit counter operates in one of the following modes based on jumper settings: Low Speed (100 KHz) Isolated Differential - Optically isolated differential input at +/- 5V or +/-15V differential. Maximum of 100 KHz in the A quad B or up/down mode.

When using high speed, use Beldon 813X cable (X is number of cable pairs), for no longer than 37m (120 ft).

High Speed (4/2.5 MHz) Differential – Differential input at +/-5 V or +/-15 V. Maximum frequency of 2.5 MHz in the A quad B mode or 4 MHz in the up/down mode.

3-pulse Tachometer Alarm Inputs Each of the 3-pulse counter input circuits has a corresponding discrete alarm input circuit. This input is commonly used with the Sony Magnescale MSD-560N product, to alert the control system that there is a problem with the sensor. Eight Analog Inputs Each analog input can be configured to one of the following ranges:

16 in

•

0 to 20mA

•

-10 to +10mA

•

0 to 10V

•

-10 to +10V

•

-5 to +5V


A voltage-controlled oscillator (VCO) technology is used for these circuits that yield a variable resolution based on: •

Sweep rate of the control logic task using the referenced point

•

Range selected for the point

For ranges 0 to 10V and -5 to +5V: Resolution = 10 / [(2*10 6)*(Scan Rate of Control Task)] ( V/Cnt)

For –10 to +10V: Resolution = 20 / [(2*10 6)*(Scan Rate of Control Task)] ( V/Cnt)

For ranges 0 to 20mA and -10 to +10mA: Resolution = 10 / [(10 9)*(Scan Rate of Control Task)] (A/Cnt)

3-Pulse Tach Alarm Outputs Each of the 3-pulse counter input circuits has a corresponding discrete alarm reset output circuit. This output is commonly used with the Sony Magnescale MSD-560N product, to reset an alarm tied to a fault condition. Three Analog Outputs (buffered) Each of the buffered analog outputs can operate in one of the following modes: •

10 to +10V

•

20 to +20mA

•

60 to +60mA

Each of the outputs is capable of driving up to 60mA at +/-10V. This allows the output to directly (without amplifier) control two stage servo valves. 16-bit analog to digital converter with 13-bits of monotonicity and 12-bits of accuracy Dither on each output is software configurable to allow 20/15.4/12.5/10.5% peak to peak of full scale at 400 Hz. (This is used with servo valves to prevent sticking.) One Analog Output Operates at –10 to +10 V at 5 ma. 16-bit analog to digital converter with 13-bits of monotonicity and 12-bits of accuracy. Power Requirements Nominal P5 = 2 A With 3 Analog Outputs at 60 mA, power required = 2.6 A VME I/O Point Signals

Data Type

Description

Signal_Name

Boolean or Integer

Value of I/O point

Point Health #Signal_Name

Boolean


Point Health Detail ##Signal_Name

4 Bytes

Byte 1 – board health and present Byte 2 – stall status; set true if not stalled


17

DLAN+

DLAN+ I/O Driver

AC/DC2000 Innovation Series Controller

The Attached Resource computer NETwork is a LAN communications protocol that serves as the basis for DLAN+.

The Drive Local Area Network (DLAN+) is a control network for the Innovation Series controllers (VME) and AC/DC2000 drives. The DLAN+ supports up to 255 devices, using a token-pass, peer-to-peer communication protocol. When a device has the token, it can send a directed, group, or broadcast message. Each device on the network has a page of memory that contains feedback and command data. The addresses of the points on the pages are made known to other devices through the System Database (SDB). Each page in the system is broadcast every 320 milliseconds to all devices. This is the default time and can be modified. To save bandwidth, only the variables of a page that have changed are broadcast. To ensure that devices coming online are properly initialized, the entire feedback page is broadcast every five seconds. The Innovation Series controller maintains a copy of all pages in memory. Thus, it can reference any feedback or command signal from any page. The diagnostic information related to a page is carried into the control logic in two additional signals that are automatically defined for each point: DLAN+ I/O Point Signals

Data Type

Description

Signal_Name

Boolean, Integer, or Real

Value of signal


Boolean



4 long (only 2 bytes used)

Byte 1 – page health Byte 2 – point health

These diagnostic signals can be used in control logic to intelligently react to electrical/mechanical faults in a split second and annunciate the fault in the Human Machine Interface (HMI) system. Blocks and alarms/diagnostics are available in control logic to send command messages to one or a group of devices. These messages are sent out on the DLAN+ immediately after execution of the instruction, provided the instruction is not in a low priority task.

18 in


DCS / HMI System

TM

Serial Modbus I/O Driver

Com 1/2

Modbus Protocol

This protocol is a master/slave scheme, where the master device (typically DCS or HMI system) initiates all transactions (read or write). The Innovation Series controller is always the follower, responding to requests from the master. Error checking is done at both the byte (optional) and message level. Parity check is done on each byte and either a Cyclical Redundancy Check (CRC) or Longitudinal Redundancy Check (LRC) check sum is appended to each transmission based on the mode. There are two transmission modes: ASCII Mode - Each 8-bit byte in the message is sent as two ASCII characters. This allows time intervals of up to one second to occur between characters without causing an error. Each transmission has an LRC check sum appended to the message. Remote Terminal Unit (RTU) Mode - Each 8-bit byte in the message is sent as two 4-bit hexadecimal characters. This mode packs the data more efficiently than the ASCII mode, providing better throughput at the same baud rate. Each message must be sent as a continuous stream in this mode. Each transmission has a CRC check sum appended to the message. Serial Modbus I/O Point Signals Signal_Name Point Health #Signal_Name Point Health Detail ##Signal_Name


Data Type

Description

Boolean, Integer, or Real N/A (set to always health)

Value of signal

N/A

19

Ethernet Modbus I/O Driver

DCS / HMI System

Ethernet

Modbus Application Protocol

The Ethernet Modbus is a multi-layer protocol, providing peer-to-peer communication between controllers and other intelligent components in the system. The Innovation Series controllers support the Data Access (register read/write) class of services. A transaction consists of a request-response message pair. The request has a function code that defines its mission. The response contains the data in a read or an acknowledge in a write operation. The layers of Modbus application protocol used are: •

Application layer is the Modbus Application Protocol (MBAP).

•

Transport layer (TCP) provides a reliable flow of data between two applications TCP/UDP system.

•

Network layer handles routing of packets around the network.

•

Link layer handles communication to a specific network.

•

Physical layer is 10base T.

Ethernet Modbus I/O Point Signals

20 in

Data Type

Description

Signal_Name

Boolean, Integer, or Real

Value of signal

Poin Health #Signal_Name

N/A


N/A


Ethernet Serial Request Transfer Protocol (SRTP) & Genius Datagram I/O Driver

Genius Bus

E-Net SRTP & Genius Datagram

Ethernet

%Rxx %Mxx

CIMPLICITY HMI

The Ethernet SRTP and Genius Datagram I/O drivers share a common I/O page of memory designed to mimic the Series 90 PLC register (%Rxx) and internal Boolean (%Mxx) areas of memory. This is used to tie variables to some external host. T wo examples are: •

CIMPLICITY HMI system using the Ethernet SRTP protocol

•

GE Fanuc Data Panel 1060 using Genius datagrams

The Innovation Series controller’s implementation of the SRTP protocol supports reading and writing of Boolean, 16-bit integers, and 32-bit real variables. The support of Genius datagram services is similar, with support of reading and writing of Boolean, 16-bit integers, and 32-bit real variables SRTP I/O Point Signals Signal_Name Point Health #Signal_Name Point Health Detail ##Signal_Name


Data Type

Description

Boolean, Integer, or Real N/A

Value of signal

N/A

21

Ethernet Global Data (EGD) I/O Driver

Ethernet +

-

U P C 0 7 0 9

CIMPLICITY HMI

Innovation Series Controller

+

-

t e N E

+

AC

Ethernet Gobal Data (EGD)

AC

AC

-

Innovation Series

Most industrial control systems need to repeatedly send out a set of process variables to other components in the system. This sharply contrasts with the connectionoriented model that is associated with most Ethernet TCP/IP protocols. Using the EGD protocol, a data producer sends the data once and all data consumers receive it simultaneously. This greatly reduces the network and device processing overhead tied to the exchange of control data. EGD uses a low level protocol (UDP/IP), which requires less overhead than fully acknowledged stream oriented protocols. This type of protocol is very useful in the following classes of applications: •

Exchange of interlocks between PLCs and Innovation Series controllers in a large system.

•

HMI systems that need periodic updates of selected variables to animate process mimic screens.

•

Data collection processes that require periodic updates of certain process variables.

EGD protocol is currently supported in the following control system products: •

Series 90-70 PLCs

•

Innovation Series controllers

•

Innovation Series drives

•

CIMPLICITY HMI System

•

Mark VI Turbine Control System

A Windows NT Host Communication Toolkit is available from GE Fanuc for the integrator that would like to establish EGD connectivity.

EGD I/O Point Signals

22 in

Data Type

Description

Signal_Name

Boolean or Integer

Value of I/O point


Boolean



4 Bytes



SCRAMNet I/O Driver SCRAMNet

U P C 0 7 0 9

n a r T s y S

SCRAMNet

n a r T s y S

Innovation Series Controller �

The SCRAMNet Network (Shared Common RAM Network) was developed by SYSTRAN to satisfy the demanding real-time requirements of aircraft simulators. The LAN utilizes a 150 Mb fiber optic ring topology communication scheme to achieve speed and noise immunity. The network memory appears in the address space of each node in the system. GE has taken this raw memory transfer scheme and added a layer that provides global memory allocation rules for each node, and node and variable health status rules. This layer is fully documented in the system manual for third-party interface. SCRAMNet I/O Point Signals Signal_Name Point Health #Signal_Name Point Health Detail ##Signal_Name

Allen-Bradley Data HighwayTM Plus (DH+) I/O Driver

Data Type

Description

Boolean, Integer or Real Boolean

Value of I/O point

4 Bytes


Data Highway Plus

Data Link DL 200


Com 1/2

Allen Bradley DH+

C L P B A

The Allen-Bradley DH+ is used for remote programming of A-B PLCs and sharing data between different devices in the control system. It is a token passing protocol that operates at 57.6 KB. Using the Datalink DL2000, the Innovation Series controller can share data with other devices on the network. DH+ I/O Point Signals Signal_Name Point Health #Signal_Name Point Health Detail ##Signal_Name


Data Type

Description

Boolean, Integer, or Real N/A

Value of signal

N/A

23

Series 90-70 PLC VME Interface I/O Driver

90-70 PLC VME

VME Bus U P C

Series 90-70

The Series 90-70 PLC VME I/O driver exchanges control data between the Innovation Series controller and 90-70 CPU using the VME bus on the backplane. Boolean, 16-bit integers, and 32-bit real variables are supported data types. Full data coherency is guaranteed. Series 90-70 PLC VME I/O Point Signals

Data Type

Description

Signal_Name

Boolean or Integer

Value of I/O point


Boolean



4 Bytes

Byte 1 – page version mismatch Byte 2 – page heartbeat timeout Byte 3 – read/write semaphore timeout

ISBus I/O Driver ISBus

ISBus +

-

+ +

-

-

AC

AC

AC

Innovation Series

Innovation Series Controller

ISBus is a fast synchronous serial bus, which provides a high performance replacement for a parallel I/O bus. Its primary purpose is to maintain tight synchronous coupling (1, 4, 8 msec) between different devices in a control system. Two services are provided, the majority of the bandwidth is allocated for sharing register data between a master device and a set of slave devices. Any remaining bandwidth is used to implement an asynchronous channel for configuration data. For example, the following table shows permissible maximum frame rates for different numbers of slave drives. Number of Maximum drives frame rate (ms) 4 1 16 4 30 8

24 in

ISBus I/O Point Signals Signal_Name

Data Type Boolean, Integer, or Real

Description Value of signal


N/A

N/A


N/A

N/A


Control System Toolbox The Control System Toolbox is used to configure and maintain the Innovation Series controllers. It is a Windows-based application, which runs on an IBM PC compatible personal computer (PC). Primary functions of the toolbox include: �

•

Configuration of controller and I/O hardware

•

Configuration, monitoring, and documentation of control logic

•

Configuration and monitoring of trend graphs

�

The toolbox work area has three views that can be dynamically sized: Outline View (left hand side) contains device configuration items. Summary View (right hand side) contains detailed view of item selected. Error Log View (bottom) displays function errors when they occur in the toolbox. The status bar displays toolbox commands and device settings. Ethernet is used as the communications network between the Innovation Series controllers and toolbox. Choose Detached Summary to display a separate window

Summary View

Outline View

Error Log View Status Bar


25

Configuration of I/O Drivers and Hardware Hardware modules and I/O devices define the I/O used by the controller and connect I/O with signals referenced in control logic. Each of the I/O drivers and hardware devices are configured as follows:

26

1.

Insert an I/O driver or I/O device under the item, Hardware and I/O Definitions item in the Outline View.

2.

Modify the hardware parameters using the associated dialog box.

3.

Define the I/O points associated with the I/O device or driver and connect them to internal signals.


Organization of Control Logic Control logic is organized at several levels to address functional partitioning, code reuse, and performance requirements. The following table describes these levels on the heirarchy, from the bottom up. Control Logic Item

Examples

Instruction Block

Description A library of instructions provide fundamental building blocks for the control logic. The order of execution for the instructions is determined by the order of entry within the task. There are two views of the library: A list view of the instruction blocks in order of sequence that does not illustrate signal connection between blocks. A connected view that displays signal connection (lines) between blocks and order of execution with block numbers. This connected view is auto generated. Logic is documented by inserting comment blocks.

User Defined Macro

Instance of Toggle macro

User-defined instruction used for common control functions. Attributes of a Macro include: Name – 12 characters Revision – V##.##n Enable Pin – Enables execution Pins – Parameters for the macro

Logic within Toggle macro Macros can be nested up to three levels. Each time a macro is inserted in logic, a unique copy is generated. This allows the user to monitor the logic within the macro.

Task

Outline View of task

A task has 1 to n instruction blocks and macros that are executed at a given rate (1 – 256 msec) and priority (high/medium/low). At the beginning of the task, all external inputs are copied from the I/O Table to the Software Signal Table for reference during execution of control logic. After completion of the control logic, external outputs are copied to the I/O Table.


27

Control Logic Item

Examples

Description

Module

Outline View of modules

A module provides another method for dividing up the control logic and is also a tool for control logic reuse at a higher level than a macro. Normally, a macro is used at the device (motor or solenoid valve) level and a module is used at the manufacturing function (furnace section, coil car, mill stand) level. A module is made up of 1 to n tasks that can operate at different rates and the same priorities. A Graphic Window file can be associated with each module.

Function

Outline View of functions

A function acts as a grouping mechanism for related modules. All external I/O signals to be used in the function are defined in the item, Signal Definitions in the Outline View. All macros specific to the function are defined in the item, Macro Definition in the Outline View.

Graphics Window that can be associated with a module

28


Instruction Blocks Instruction Block Communications ALARM_XMIT

Description Sends a Status-S alarm message (TXTS message with text substitution or TXTV message with variable substitution) whenever the alarm state changes on either DLAN+ or Ethernet.

DYNAMIC_GRP

Transmits a message that adds or removes a device from various dynamic groups and is similar to the message maker block

LD_AUTO

Evaluates the INPUT variable using the limit information available from the signal definition and communicates the results through five Boolean variables.

LD_MAN

Evaluates the INPUT variable per a list of limit specifications and communicates the results through five Boolean variables.

SS_ONE_DEST

Transmits Status-S Command (protocol 2) messages over a DLAN+ network attached to the controller.

SS_PERIOD

Changes the transmission period of an owned Status_S feedback page.

Math AVRG

Computes a rolling average of the last N inputs presented to the block.

MENG_n

Solves a mathematical equation of up to 8 inputs and places the result in the output signal, whose data-type is implied by the block suffix.

MIN_MAX

Passes the minimum or maximum value from the input list to the output.

CLAMP_n

Restricts the output to values of the input between and/or equal to the maximum and minimum limits.

COMHYS

Compares two real values implementing hysteresis and sensitivity, and sets an output Boolean reflecting the result.

COMPARE_D/F

Compares two real values and sets an output Boolean reflecting the result.

COMPARE_I/L

Compares two integer values and sets an output Boolean reflecting the result.

Logic BIT_CNTR

Counts the number of input bits that are currently set to TRUE.

BENG

Solves a Boolean equation of up to 16 Boolean inputs, placing the result in the output variable.

BENG_D

Solves a Boolean equation of up to 16 Boolean inputs, placing the result in the output variable.

Filters BFILT FIR

Passes a rising TRUE value on the input pin to the out pin if it remains TRUE for PU_DEL time . Implements a finite impulse response filter.


29

Instruction Block Table – continued `

Instruction Block

Description

Sequencing BRANCH

Used to create up to eight branches from a single Sequential Function Block (_SFB) step.

CHG_DET_n

Sets the OUT to TRUE whenever it detects a difference between IN and STATE greater than the absolute value of DBAND.

MERGE

Used to merge up to eight branches into a single Sequential Function Block (_SFB) step.

PE_DA

Used to start and stop some function with evaluation of permissives and diagnosis of such permissives when required.

PENG

Sets its ON output TRUE when the ONREQ input goes TRUE, provided the start and run permissive inputs are TRUE.

PE_SA

Used to initiate some maintained function with evaluation of permissives and diagnosis of such permissives when required.

PE_TOGGLE

Used to initiate and end (in a toggle fashion) some maintained function with evaluation of permissives and diagnosis of such permissives when required.

PULSE

Generates a Boolean one-shot of the specified width at the output pin on the rising edge of the trigger.

SEQMGR

Collects global status information from all of the Sequential Function blocks (_SFBs) in a sequence and distributes global inputs to each of these blocks.

SFB

Creates a step in an automatic sequence.

Data Collection CAPTURE FUNGEN

Collects samples of up to 32 signals in a buffer that may be uploaded by the toolbox for display and analysis. Creates common signal functions for test and verification.

Memory Move

30

CNT_TO_BOOL

Uses an integer input to linearly select one of up to 32 Boolean outputs, where N can range from 1 to 32.

COMPRESS

Packs up to 16 Booleans into a single integer variable.

EXPAND

Transforms the input into its binary equivalent form and stores the expanded information into 16 simple, Boolean outputs.

GET_n

Moves a value from an array into a signal of the same data-type.

LATCH

Sets or resets OUT based on the current values of SET and RESET, and the previous value of OUT

MOVE_n

Transfers the value of any signal into another signal whose datatype matches that denoted by the block suffix.

PUT_n

Moves a value from a signal into an array element of the same datatype.

SELECT_n

Moves one of the eight inputs, or the cascade pin into the output, based on the prioritized evaluation of the eight selection pins.

SET_ARRAY_n

Initializes an entire array with a single value when enabled.

STEER_n

Move the input to one of the eight outputs, or to the cascade pin, based on the prioritized evaluation of the eight selection pins.


Instruction Block Table – continued

Instruction Blocks

Description

Pseudo-Control COMMENT

Used to force a break in the hard copy block diagram.

Timers / Counters COUNTER

Accumulates rising edges of the INC pin into CUR_CNT while the RUN is TRUE and CUR_CNT is less than MAX_CNT.

TIMER

Accumulates incremental time into CURTIME while RUN is TRUE.

Test CTIME

Calculates the time in µs between successive executions of the block.

NOP

Performs no execution at all.

Diagnostics DEV_FLTS

Displays the state of selected CPU device faults.

Program Control EX_MAC

Immediately exits the execution of a block macro if its ENABLE pin is TRUE.

EX_TSK

Immediately exits the execution of a task if its ENABLE pin is TRUE.

I/O GENI_HSCB

Sets the Preload Value and On/Off Preset registers of type B High-speed Counter blocks with specified values.

IN_CVRT

Converts coded decimal Booleans into a long integer.

OUT_CVRT

Converts a long integer into coded decimal Booleans.

OUT_XFER

Conditionally transfers a value to an input point owned by this Innovation Series controller.

PRESET_CNTR

Provides a mechanism to preset a given VME High Speed Regulator I/O module counter input to a specified value.

Regulators INTW LEAD

Computes the integral of IN with a lead term.

PID

Performs proportional, integral and derivative control on the setpoint, measured value feedback, and a derivative source.

RAMPH

Takes a current_ramp and increments and decrements the value until the final value is reached.

SRAMP

Modifies the SPEED Output to the FINAL value following a S-Curve.

TRNFUN_n

Provides a digital implementation of a transfer function. This equation can approximate a phase lead, phase lag, simple lag, phase lead/lag, or a bridged-T (Notch) compensator depending upon the choice of the appropriate coefficients. The block can also be used to create Butterworth, Chebyshev, etc., second order filters and can be cascaded to form higher order filters.


31

Permissive Diagnostic Function The Innovation Series controllers provide a unique diagnostic function for permissive faults in control logic. The following sections describe how controllers diagnose and present faults. A common problem in control system maintenance today is the length of time required to diagnose a permissive related machine fault. The following are examples of permissive related faults: Permissive Fault

Root Cause

Pump motor does not start

Intake valve is closed

Conveyor motor does not start

Broken limit switch

Material handling system does not go to automatic mode

Safety gate is open

Electrical drive trips out

Intermittent current overload fault

The typical scenario for troubleshooting a permissive fault is as follows:

Step

Time (Minutes)

Description

5 – 10

Operator alerts maintenance of the problem.

10 – 15

Technician locates programming software for the controller and connects to the suspect controller.

10 – 20

Technician traces back from device that will not start (or is tripped out) through the control logic, looking for the root permissive (or group of permissives) causing the problem.

Total = 25 – 45 minutes

32


Currently HMI permissive screens help operators and technicians troubleshoot permissive faults. These screens contain animated lists of permissives for key functions. However, there are two significant problems with this approach: 1.

Extensive engineering is required to design and test an animated permissive screen for every control function.

2.

Synchronization of the permissive screens in the HMI system and control logic is a manual operation.

The Innovation Series controllers resolve this problem with a unique set of control instruction blocks and associated operator interface tools (Diagnose). By categorizing the permissives and identifying the start and stop triggers, the controller firmware can detect and diagnose permissive faults. The operator is alerted to p ermissive faults and presented with a relay ladder logic (RLD) representation of the permissives causing the fault.

This dramatically changes the common troubleshooting as follows:

Time (Minutes)

Step

Description

-

Operator detects problem with pushbutton

5

Permissive diagnostic function graphically tells the operator the cause of the problem.

Total = 5 minutes

Fault Detection The instructions blocks in the following figure contain the permissive logic for a Spot Jog Forward and Spot Jog Reverse function. The permissives are categorized into start (SPRM) and run permissives (RPRM), and on requests (ONREQ), off requests (OFFREQ). This allows the Permissive Engine (PENG) block to detect permissive faults.


33

A start permissive fault occurs when the ONREQ input transitions to True and either the SPRM or RPRM inputs are False. A run permissive fault occurs when the ON output transitions to False due to the loss of SPRM or RPRM. Upon detection of a permissive fault, the state of all Boolean variables involved (including variables referenced in instructions feeding into the permissive engine instruction) in the control logic are captured and archived with Message View. A chronological log of permissive faults is available in a tabular Windows application for the operator and maintenance personnel. A fault code is also put into STATUS output allowing the graphical HMI system to indicate a permissive fault.

HMI Operator Screen

Message View

Spot Jog Spot Jog Foward Foward

Spot Forward Jog Start Permissive Fault

01:23:34.34 04/03/98

Spot Rerverse Jog Start Permissive Fault

01:15:03.54 04/03/98

Spot Jog Spot Jog Reverse Reverse

Hydraulic Pump 1 Run Permissive Fault

01:09:34.34 04/03/98

Entry Auto Mode Start Permissive Fault

01:04:35.36 04/03/98

Animation Variable

Permissive Fault

Innovation Series Controller Permissive Logic

Detection of permissive faults with the Innovation Series Controllers

34


Presenting the Diagnosis The permissive diagnostic application (Diagnose) can be started from the graphical HMI system or the chronological permissive fault log (Message View). When started from the HMI system, Diagnose is given the name of the controller and name of signal being controlled. It then passes that information to the controller, where the diagnostic function is performed. The diagnostic information is then passed back to Diagnose, which presents the missing permissives in a relay ladder diagram (RLD) format (see figure below). When started from Message View, Diagnose is given the name of the controller, name of signal being controlled, and the status of all B oolean variables involved in the control logic for that signal at the time of the fault. This allows the permissive diagnostic function to detect the loss of a permissive in the controller. After completing the diagnosis, the results are sent to Diagnose, which presents the missing permissives in RLD format (see figure below).

HMI Operator Screen

Message View

Spot Jog Spot Jog Foward Foward

Spot Forward Jog Start Permissive Fault

01:23:34.34 04/03/98

Spot Rerverse Jog Start Permissive Fault

01:15:03.54 04/03/98

Spot Jog Spot Jog Reverse Reverse

Hydraulic Pump 1 Run Permissive Fault

01:09:34.34 04/03/98

Entry Auto Mode Start Permissive Fault

01:04:35.36 04/03/98

Animation Variable

Permissive Fault

Innovation Series Controller Permissive Logic

Presentation of missing permissives to operator


35

Ordering Information Innovation Series Controllers VME controllers are to be installed in the Series 90-70 integrators rack only. Each controller is shipped with a System Manual.

CL controllers are available only as an option in the drive control rack (not sold separate).

Catalog Number

Description

DS215UCVBG1

VME, 1 DLAN+ / 1 Genius bus

DS215UCVBG3

VME, 2 DLAN+ / 2 Genius buses

IS215UCVCH1

VME, 1 ISBus bus / 1 Genius bus

IS215UCVCH3

VME, 2 ISBus buses / 2 Genius buses

IS215UCVCH5

VME, 1 ISBus bus / 1 DLAN+ / 2 Genius buses

IC697CHS782

Series 90-70 VME integrators rack, 17 slots, rear mount

IC697CHS783

Series 90-70 VME integrators rack, 17 slots, front mount

Innovation Series Controller I/O There is a limit of five VME highspeed regulator I/O modules or ive VME dual Genius bus controllers in an Innovation Series VME rack.

Catalog Number

Description

DS200SIOBH1A

VME High-speed regulator I/O module, 1 VME slot

259B2405P1

Terminal block for DS200SIOBBH1A (one per module)

259B2409AA:

Interface cable for J1: G01

250 cm (98”)

G02

226 cm (89”)

G03

201 cm (79”)

G04

264 cm (104”)

G05

236 cm (93”)

259B2409AB:

36

Interface cable for J2: G01

244 cm (92”)

G02

211 cm (83”)

G03

185 cm (73”)

G04

250 cm (98”)

G05

221 cm (87”)

DS2020LRPAG2

Inductosyn I/O module (panel mounted) 2 Farrand Inductosyn inputs 2 A Quad B outputs DLAN+ (57 KB serial) 120/230 V ac input

DS2020LRPBG1

Resolver I/O Module (panel mounted) 2 dual resolver (fine/coarse) inputs 2 A Quad B outputs DLAN+ (57 KB serial) 120/230 V ac input

DS2020LRPBG2

Resolver I/O module with Genius (panel mounted) 2 dual-resolver (fine/coarse) inputs 2 A Quad B outputs DLAN+ (57 KB serial) 120/230 V ac input power Genius bus interface for configuration and exchange of runtime data


Genius I/O System Blocks and Options Catalog Number

Description

IC660BBD101

115 V ac 8-Circuit I/O block, low leakage *

IC660BBS102

115 V ac/125 V dc Isolated 8-Circuit I/O block, with failed switch diagnostics *

IC660BBS103

115 V ac/125 V dc Isolated 8-Circuit I/O block, without failed switch diagnostics *

IC660BBD110

115 V ac 16-Circuit block

IC660BBD020

24 48 V dc Source I/O block, 16-Circuit, 3-wire sensor compatible*

IC660BBD021

24 48 V dc Sink I/O block, 16-Circuit, 3 wire sensor compatible *

IC660BBD022

24 V dc Source I/O block, 16-Circuit, 2 or 3 wire sensor compatible *

IC660BBD023

24 V dc Sink I/O block, 16-Circuit, 2 or 3 wire sensor compatible *

IC660BBD024

12/24 V dc Source I/O block, 32-Circuit *

IC660BBD025

5/12/24 V dc Sink I/O block, 32-Circuit *

IC660BBR100

Relay output block, normally closed, 16-Circuits

IC660BBR101

Relay output block, normally open, 16-Circuits

IC660BBA100

Analog I/O block, 115 V ac Power, 4 inputs / 2 outputs

IC660BBA104

Analog I/O block, current source, 115 V ac/125 V dc power, 4 inputs / 2 outputs

IC660BBA105

Analog output block, current source, 115 v ac/125 v dc power, 6 outputs

IC660BBA106

Analog input block, current source, 115 v ac/125 v dc power, 6 inputs

IC660BBA020

Analog I/O block, 24/48 v dc power, 4 inputs / 2 outputs

IC660BBA024

Analog I/O block, current source, 24/48 V dc power, 4 inputs / 2 outputs

IC660BBA025

Analog output block, current source, 24/48 V dc power, 6 outputs

IC660BBA026

Analog input block, current source, 24/48 v dc power, 6 inputs

IC660BBA103

Thermocouple input block, 115 V ac/125 V dc power, 6 channels

IC660BBA023

Thermocouple input block, 24/48 V dc power, 6 channels

IC660BBA021

RTD input block, 24/48 V dc power, 6 channels

IC660BBA101

RTD input block, 115 V ac/125 V dc power, 6 channels

IC660BBD120

High-speed counter, up to 200 KHz, 4 inputs, 4 outputs, 115 V ac power

IC660BPM100

Power TRAC block, 3-phase power monitoring, 115/230 V ac, monitors frequency and total harmonic power content of each phase

IC660HHM501

Hand held monitor

* Points can be individually configured as inputs or outputs


37

Field Control I/O System Components and Options Catalog Number

Description

IC670GBI002

Bus Interface Units (BIUs) Genius BIU, 24V dc power Genius BIU, 115 V ac power

IC670CHS001

Field Terminal Bases I/O base, barrier style, accepts 2 modules

IC670CHS002

I/O base, box style, accepts 2 modules

IC670CHS003

High-density connector base, accepts 2 modules

IC670CHS004

Thermocouple cold junction compensation base

IC670TBM001

Auxiliary Terminal block, quantity 2 barrier style

IC670TBM002

Auxiliary Terminal block, quantity. 2 box style

IC670CBL002

53 cm (21”) I/O base expansion cable (limit 1 per station)

IC670CBL003

2 m cable for connector style base, connector on one end

IC670CBL004

1 m cable for connector style base, connector on one end Field I/O Modules

IC670MDL640

24 V dc positive/negative input 16-point grouped

IC670MDL740

12/24 V dc 0.5A positive output 16-point grouped

IC670ALG230

Analog input current 8-point, grouped

IC670ALG320

Analog output current/voltage 4-point, grouped

IC670MDL641

48 V dc positive/negative input 16 point, grouped

IC670MDL240

120 V ac input 16-point, grouped

IC670MDL241

240 V ac input 16-point, 2 groups

IC670MDL331

120 V ac 2A output 8-point, isolated

IC670MDL330

12-120 V ac output 16-point, grouped

IC670MDL930

Relay 2A 8-point 6-form a/2-form C isolated

IC670MDL642

125 V dc input 16-point, grouped

IC670ALG240

Analog input current 16-point, grouped

IC670ALG330

Analog output current 8-point, grouped

IC670ALG630

Thermocouple 8-point, isolated

IC670ALG620

RTD 4-channel isolated – 3-wire

IC670MDL643

5/12 V dc input 16-point, 2 groups

IC670MDL742

5/12 V dc output negative, 16-point, grouped

IC670MDL644

12/24 V dc positive/negative 16-point, grouped fast input

IC670MDL730

24 V dc electronic short circuit protection 8-point, output

IC670MDL233

120 V ac 8 point, isolated input Accessories

38

IC660HHM501

Hand held monitor

IC670ACC001

8 cm (3 inch) base-to-base replacement connector cable (quantity 16)

IC670ACC002

I/O module keying kit, quantity for 16 modules

IC670ACC003

Connector kit for connector style base


Control System Solutions (Windows NT Applications & Service) To determine catalog numbers, refer to the section, Catalog Number Structure on the next page and enter the proper numbers (where x = a number or a letter).

Catalog Number

Product

DS208xxxxxx

Innovation Series Controller Configuration (toolbox application) •

Innovation Series controller configuration Genius & Field Control I/O configuration

•

Operator Console 2000 (OC2000) configuration

•

Dual Resolver I/O module configuration

•

System Database Server

•

Graphics Window Check In/Out Utility

•

•

Innovation Series Drive Configuration (toolbox application) •

Innovation Series drive configuration

AC/DC/EX2000 Drive Configuration (toolbox application) •

AC/DC/EX2000 drive configuration

AV-300/DV-300 Drive Configuration (toolbox application) •

AV-300/DV-300 drive configuration

Trend Recorder (toolbox application) •

Trend window configuration and monitoring

Data Historian (toolbox application) •

Data Historian service and configuration (requires SDB)

System Integration Applications •

System Database Utilities

•

CIMPLICITY HMI Alarm Manager Service (GECAMS)

•

CIMPLICITY HMI DLAN+ Devcom

•

CIMPLICITY HMI Integrated Control Network (ICN) Devcom

• •

System Database Server SDB Interface From CimEdit

•

System Database Exchange

•

SDB Interface for CIMPLICITY Control, GE Fanuc Data Panels (WinConfig), and for Third Party Devices

•

Series 90-70 Interface Module Configuration (BEM763)

Maintenance & Diagnostic Applications •

Diagnose

•

Mode Logger

•

Message Archiver (DLAN+ & Ethernet)

•

DLAN+ Status

•

Message View

Demonstration CD - Contains all functionality for 30 days


39

Catalog Number Structure Catalog Number DS208

X

X

Quantity Option A = Quantity 1 PC B = Quantity 5 PC’s C = Quantity 10 PC’s D = Quantity 15 PC’s

X

X

X

X

X

X = Selected Option

Demonstration CD 0 = Not Demonstration CD D = Demonstration CD (30 days)

Trend Recorder / Data Historian Option 0 = No Trend Recorder or Data Historian

Controller Option 0 = No Controller Configuration

2 = Trend Recorder and Data Historian

1 = Innovation Series Controller Configuation

System Integration Applications

Drive Option

0 = No System Integration Tools

0 = No Drive Configuration 1 = Innovation Series Drive Configuation 2 = AC/DC/EX2000 Drive Configuration 3 = AV-300/DV-300 Drive Configuration 4 = Innovation Series, AC/DC/EX2000, and AV-300/DV-300 Drive Configuration

40

1 = Trend Recorder, no Data Historian

1 = System Integration Tools

Advanced Maintenance & Diagnostic Applications 0 = No Advanced Maintenance & Diagnostic Tools 1 = Advanced Maintenance & Diagnostic Tools


GEP-9145

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