GE GFK-0825F User Manual
GE Fanuc Automation
Field Control™
User’s Manual
Programmable Cont rol Products
Genius® Bus Interface Unit
GFK-0825F October 1999
Warnings, Cautions, and Notes
as Used in this Publication
Warning
Warning notices are used in this publication to emphasize that hazardous voltages,
currents, temperatures, or other conditions that could cause personal injury exist in this
equipment or may be associate d with its use.
In situations where inattention could cause either personal injury or damage to
equipment, a Warning notice is used.
Caution
Caution notices are used where equipment might be damaged if care is not taken.
Note
Notes merely call attention to information that is especially significant to understanding and
operating the equipment.
GFL-002
This document is based on information available at the time of its publication. While efforts
have been made to be accurate, the information contained herein does not purport to cover all
details or variations in hardware or software, nor to provide for every possible contingency in
connection with installation, operation, or maintenance. Features may be described herein
which are not present in all hardware and software systems. GE Fanuc Automation assumes no
obligation of notice to holders of this document with respect to changes subsequently made.
GE Fanuc Automation makes no representation or warranty, expressed, implied, or statutory
with respect to, and assumes no responsibility for the accuracy, completeness, sufficiency, or
usefulness of the information contained herein. No warranties of merchantability or fitness for
purpose shall apply.
The following are trademarks of GE Fanuc Automation North America, Inc.
Alar m M aster Genius ProL oop Series Three
CIMPLICITY Helpmate PROMACRO VersaMax
CIM P LIC IT Y 90 – ADS Logicm aster Series Five VersaPro
CIMSTAR Modelmaster Series 90 VuMaster
Field Control Motion Mate Series One Workmaster
GEnet PowerTRAC Series Six
©Copyright 1996-1999 GE Fanuc Automation North America, Inc.
All Rights Reserved .
Content of thi s M a nual
This manual describes the Field Control® Genius™ Bus Interface Unit (IC670GBI002). It explains
operation of the Bus Interface Unit as a Genius bus device. It also contains complete configuration
instructions for the Bus Interface Unit and all Field Control I/O modules.
Chapter 1. Introduction: Chapter 1 introduces Field Control systems, the Genius Bus Interface
Unit, and other equipment that may be used with the Bus Interface Unit. It will help you locate
more information about the components and operation of Field Control products.
Chapt er 2. Descrip tion : Chapter 2 describes the Genius Bus Interface Unit module, the Bus
Interface Unit Power Supply, and the Bus Interface Unit Terminal Block, and lists their
specifications.
Chapter 3. Installation: Chapter 3 describes Bus Interface Unit installation and gives system
installation guidelines.
Chapter 4. Operation: Chapter 4 explains how a Bus Interface Unit interacts with the modules in
its station, how it stores data, and how it exchanges data with a PLC or other type of system host.
Preface
Chapter 5. Station Configuration: Chapter 5 explains how to configure a Bus Interface Unit and
the modules in a station using a Hand-held Monitor.
Chapter 6. Diagnosti c s and Fault Cleari ng: Chapter 6 describes the diagnostics capabilities of
the Bus Interface Unit an d exp lains how faul ts are cleared.
Chapter 7. Monitoring and Controlling Field Control Data: Chapter 7 explains how to monitor
or control Field Control I/O data using Genius Hand-held Monitor or a programmer.
Chapter 8. Datagrams: Chapter 8 lists datagrams that can be sent to a Bus Interface Unit, and
shows the datagram format s for Fi el d Control modul es.
Appendix A. Scali ng Analog Channel s: Appendi x A ex pl ains how to select scal ing values when
configuring an analog input or output. (Configuration instructions are in chapter 5).
Appendix B. Install i ng Addit i onal Suppressi on: Appendix B describes some precautions that
can be taken in an installation to help assure proper operation.
Appendix C. The Genius Serial Bus: This appendix describes the selection and operating
chara cteristics of the bus cable that links Genius devices.
Appendix D. Configurati on Examples: Th is append ix includ es ex amples of di fferen t Field Control I/O
Station configurations.
GFK-0825F iii
Preface
Relat e d Publi ca t ions
For more information, refer to these publications:
Field Control I/O Modules User's Manual (GFK-0826). This book desc ri bes Field C ontrol I/O
Modules and I/O Terminal Blocks and explains how to install them.
The Se rie s 90® Micro Fiel d Proce sso r User' s Manual (GFK-1171). This book describes the
Micro Field Processor (IC670MFP100) and provides installation procedures, operation
info rmation, and d iagnostic s infor mation.
Genius I/O System User' s Manual (GEK-90486-1). Reference manual for system designers,
programmers, and others involved in integrating Genius I/O products in a PLC or host co mputer
environmen t . T his book provides a syst e m overview, and des c ribes th e t ypes of systems that ca n be
created using Genius products. Datagrams, Global Data, and data formats are defined.
Series 90® −30 Bus Controller User's Manual (GFK-1034). Reference manual for the Bus
Controller, which interfaces a Genius bus to a Series 90-30 PLC. This book des c ribe s th e
inst allation and operation of the Bus C ontroll er .
Series Six® Bus Controlle r Use r's Manual (GFK-0171). Reference manual for the Bus Controller,
whi c h int e rfac e s a G e nius bus to a S eries Six PLC. This book d e scribes t he installation and
operation of the Bus Controller. It also contains the programming information needed to interface
Genius I/O devices to a Series Six PLC.
Series Five® Bus Controller User's Manual (GFK-0248). Reference manual for the Bus
Controller, which interfaces a Genius bus to a Series Five PLC. This book describes the installation
and operation of the Bus Controller. It also contains the programming information needed to
inter face Geni u s I/ O devi ces to a Series Five PLC.
Genius I/O PCIM User's Manual (GFK-0074). Reference manual for the PCIM, which interfaces
a Genius bu s to a suitable h ost com put e r. This book d escribes the installation and operation of t he
PCIM. It also contains the programming information needed to interface Genius I/O devices to a
host computer.
Installa ti on Re quire me nts for Conformance to Standards (GFK-1179)
Jeanne Grimsby
Lead Technical Writer for I/O Products
iv Field Control™ Genius® Bus Interface Unit User’s Manual– October 1999 GFK-0825F
Contents
Chapter 1 Introduction..................................................................................................... 1-1
Overview......................................................................................................................1-1
Field Control Modules..................................................................................................1-2
Environmental Specifications........................................................................................1-5
Configuration for Field Control.....................................................................................1-6
Field Control in a Genius System..................................................................................1-7
Required Genius and Host System Equipment...............................................................1-9
Using Field Control in a CPU Redundancy System.....................................................1-10
Using Field Control in a Genius Bus Redundancy System...........................................1-11
Chapter 2 Description....................................................................................................... 2-1
Genius Bus Interface Unit.............................................................................................2-1
Bus Interface Unit Power Supply..................................................................................2-3
Backplane Current........................................................................................................2-4
Bus Interface Unit Power Dissipation............................................................................2-5
Load Requirements for Hardware Components.............................................................2-6
Bus Interface Unit Terminal Block................................................................................2-8
Functional Specifications..............................................................................................2-9
Chapter 3 Installation....................................................................................................... 3-1
Preinstallation Check....................................................................................................3-2
Static Protection............................................................................................................3-2
Hand-held Monitor Connector......................................................................................3-2
System Wiring Guidelines............................................................................................3-3
Installing Additional Suppression.................................................................................. 3-3
System Grounding ........................................................................................................3-4
Locations for Field Control ...........................................................................................3-5
Installing the DIN Rail..................................................................................................3-5
Installing the Bus Interface Unit Terminal Block on the DIN Rail.................................3-7
Installing the Cables Between Terminal Blocks.............................................................3-8
Power Wiring to the Bus Interface Unit.........................................................................3-9
Connecting the Communications Bus..........................................................................3-10
Bus Cables..................................................................................................................3-10
Making Bus Connections............................................................................................3-11
Installing the Bus Interface Unit on the Terminal Block..............................................3-14
Removing the Bus Interface Unit from the Terminal Block.........................................3-14
Removing/Replacing the Bus Interface Unit Fuse .......................................................3-15
Upgrading the BIU Firmware......................................................................................3-16
GFK-0825F v
Contents
Chapter 4 Operation......................................................................................................... 4-1
BIU Data Handling at the I/O Station............................................................................4-2
I/O Data for Conventional Modules..............................................................................4-3
I/O Data, Status Data, and Control Data for Intelligent Modules....................................4-3
Group Data for Intelligent Modules...............................................................................4-4
The BIU Sweep............................................................................................................4-5
BIU Backplane Scan Time............................................................................................4-7
Data Transfer Between the BIU and the Host................................................................4-9
Data in the BIU's Network (Bus) Map...........................................................................4-9
Communications on the Genius Bus..............................................................................4-9
Input Data Sent by the Bus Interface Unit...................................................................4-10
Outputs from the Host to the BIU................................................................................4-11
Genius Bus Scan Time................................................................................................4-12
Operation of the BIU with a Micro Field Processor.....................................................4-14
MFP and BIU Synchronization................................................................................... 4-14
MFP I/O References ...................................................................................................4-14
MFP Operating Modes................................................................................................4-14
Overview of Synchronous Operation...........................................................................4-16
Backing Up Micro Field Processor Outputs................................................................4-17
How the Network Backs Up MFP Outputs..................................................................4-18
Backing Up BIU Outputs with a Micro Field Processor...............................................4-19
Example Ladder Logic................................................................................................4-20
Chapter 5 Station Configuration...................................................................................... 5-1
For Additional Information, Also See:..........................................................................5-1
Configuring the Serial Bus Address and Baud Rate.......................................................5-2
Special Instructions for Series 90-70 PLC Systems .......................................................5-2
Set Up the Hand-held Monitor......................................................................................5-3
Create a New Configuration..........................................................................................5-4
Assigning a Serial Bus Address to a New BIU..............................................................5-4
Configure the Bus Interface Unit................................................................................... 5-5
Field Control HHM Menu Overview.............................................................................5-6
Change the Serial Bus Address of the Bus Interface Unit ..............................................5-7
Select the Baud Rate.....................................................................................................5-8
Select a Series Six or Series Five PLC Reference Address............................................. 5-9
Configure Fault Reporting.......................................................................................... 5-10
Configure Genius Bus Redundancy.............................................................................5-11
Configure CPU Redundancy.......................................................................................5-12
Configure Field Control Modules................................................................................5-15
Enable/Disable the I/O Scan ....................................................................................... 5-15
vi Field Control™ Genius® Bus Interface Unit User’s Manual– October 1999 GFK-0825F
Contents
Disable Network I/O Updates.....................................................................................5-15
Configure the Network Map for the Bus Interface Unit...............................................5-16
Configuring Extra References in the BIU I/O Map......................................................5-17
Add Modules and Assign References..........................................................................5-20
Configure a Discrete Input Module.............................................................................5-22
Configure a Discrete Output Module...........................................................................5-24
Configure a Discrete Input/Output Module..................................................................5-26
Configure a Conventional Analog Input Module.........................................................5-29
Configure a Conventional Analog Output Module.......................................................5-35
Configure a 16-Point Grouped Analog Input Module..................................................5-40
Configure an 8-Point Grouped Analog Voltage Input Module..................................... 5-48
Configure a 16-Point Grouped Analog Voltage Input Module..................................... 5-56
Circuit Configuration..................................................................................................5-60
Configure an RTD Input Module................................................................................5-64
Circuit Configuration..................................................................................................5-67
Configuring a Thermocouple Input Module.................................................................5-72
Configure an 8-Point Analog Voltage Output Module.................................................5-81
Configure an 8-Point Analog Current Output Module.................................................5-90
Configure a Micro Field Processor..............................................................................5-99
Chapter 6 Diagnostics and Fault Clearing....................................................................... 6-1
Diagnostics and Fault Clearing for Intelligent Modules.................................................6-1
Diagnostics and Fault Clearing for the BIU and Conventional Modules.........................6-2
Display and Clear Faults from a Genius Hand-held Monitor..........................................6-3
Display and Clear Faults from a PLC............................................................................6-5
Series 90 PLC: I/O Fault Table....................................................................................6-5
Series 90 PLC: PLC Fault Table...................................................................................6-5
Series Five or Series Six PLC.......................................................................................6-5
GFK-0825F Contents vii
Contents
Chapter 7 Monitoring and Controlling Field Control Data............................................ 7-1
Overview......................................................................................................................7-2
Forcing Circuits ............................................................................................................7-2
Overriding I/O Circuits.................................................................................................7-2
Monitor/Control I/O Data: Genius Hand-held Monitor..................................................7-3
Forcing/Unforcing the Displayed Reference..................................................................7-5
Monitor/Control I/O Da ta: Series 90 PLC....................................................................7-6
Monitor/Control I/O Data: Series Six PLC or Series Five PLC.....................................7-6
Monitor/Control I/O Data: Computer............................................................................7-7
Chapter 8 Datagrams....................................................................................................... 8-1
Datagram Types............................................................................................................8-2
Read Map.....................................................................................................................8-3
Read Map Reply...........................................................................................................8-3
Write Map....................................................................................................................8-4
Report Fault Datagram Format......................................................................................8-5
Configuration Data.......................................................................................................8-7
Read Configuration Data ..............................................................................................8-7
Set Bus Interface Unit Operating Mode.......................................................................8-29
Set Micro Field Processor Operating Mode.................................................................8-29
Intelligent Analog Module Recalibration Datagram.....................................................8-30
Read I/O Forces.......................................................................................................... 8-32
Read I/O Forces Reply................................................................................................8-32
Read Slot Diagnostics ................................................................................................. 8-33
Read Slot Diagnostics Reply.......................................................................................8-33
viii Field Control™ Genius® Bus Interface Unit User’s Manual– October 1999 GFK-0825F
Contents
Appendix A Scaling Analog Channels.................................................................................A-1
How Scaling Works..................................................................................................... A-1
Scaling Valu es for 1mV or 1µA Engineering Units: BIU Version 1.3........................... A-2
Scaling Valu es for 1mV or 1µA Engineering Units: BIU.............................................. A-3
Measuring Scaling Values............................................................................................A-4
Example of Scaling an Analog Input............................................................................ A-5
Appendix B Installing Additional Suppression .................................................................. B -1
Suppression at the Power Lines.................................................................................... B-1
Suppression for Devices in an Enclosure...................................................................... B-2
Suppression at the Communications Line..................................................................... B-2
Appendix C The Genius Serial Bus.....................................................................................C-1
Wiring Guidelines........................................................................................................C-1
Electrical Interface.......................................................................................................C-2
Genius Transceiver Electrical Specification................................................................. C-3
Selecting a Cable Type................................................................................................ C-4
Serial Bus Waveforms................................................................................................. C-5
Using Other Cable Types............................................................................................. C-6
Serial Data Format....................................................................................................... C-8
Bus Access.................................................................................................................. C-9
Bus Length................................................................................................................ C-10
Baud Rate Selection................................................................................................... C-10
Bus Ambient Electrical Information........................................................................... C-11
Lightning Transient Suppression................................................................................ C-11
Appendix D Configuration Examples.................................................................................D-1
Example 1: Discrete Data, Network Processing............................................................ D-1
Example 2: Discrete and Analog Data, Network Processing......................................... D-2
Example 3: Discrete and Analog Data, Network and Local Processing ......................... D-3
Example 4 : Discrete and A nalo g D ata, Netw ork a nd Local Proces sing and Gr oup Data
Moves...................................................................................................................... D-4
Example 5: Group Move.............................................................................................D-6
GFK-0825F Contents ix
Chapter
1
Overview
Bus
Interface
Unit
I/O
I/O
I/O
Introduction
This chapter introduces Field Control modules, the Genius Bus In terface Un it, and oth e r
equipment that may be used with the Bus Interface Unit. It will help you locate more information
in other Field Control and Genius documents.
Field Control is a family of highly modular distributed I/O and control products. They are suitable
for us e in a wid e range of host architectures.
The hear t of the Field Control system is th e Bu s Interface Unit. Th e Bus Interface Unit provid es
intelligent processing, I/O scanning, and feature configuration for a group of up to eight I/O
modules. Together, the Bus Interface Unit and its modules make up a Field Control station (see the
illustration, left).
The Bus Interface Unit and I/ O modu les are en closed in st urdy, compa ct aluminum housin g s. Bus
Interface Unit and I/O modules bolt securely to separate Terminal Blocks, which provide all field
wiring terminals. The I/O Terminal blocks are generic and allow different I/O module types to be
mounted on the same base. I/O Terminal Blocks are available with box-type terminals, barrier-type
terminals, or wire-to-board connectors. All Terminal Blocks must be mounted on a DIN rail. The
DIN rail, which serves as an integral part of the grounding system, can also be mounted on a panel.
Field Control Features
I/O
I/O
I/O
I/O
I/O
GFK-0825F 1-1
Features and benefits of Field Control include:
wiring savings
better up time
easy installation and maintenance
spare parts savings
low cost
feature flexibility
open architect ure / adaptable to a var iety of networks
distributed I/O
small, compact I/O modules with generic terminal wiring bases.
DIN rail mounted
1
Field Control Modules
Ther e are three basic types of Fi eld Control modul es:
Bus Interface Unit. The illustration below shows a Genius Bus Interface Unit.
I/O modules
Micro Field Pr ocessor
Terminal Blocks:
Bus Interface Unit Terminal Block.
I/O Terminal Blocks, each of which accommodates two I/O modules.
Auxiliary Term in al Blocks. These opti onal terminal strips can be connected t o the side of
an I/O Ter minal Block if extra common terminals ar e n eed ed .
Auxiliary
Terminal Blocks
Bus Interface Unit
Terminal Block
I/O Terminal
Block
Genius
Bus Interface Unit
Micro
Field Processor
I/O Modules
1-2 Field Control™ Genius® Bus Interface Unit User’s Manual – October 1999 GFK-0825F
Genius Bus Interface Unit
The Genius Bus Interface Unit (IC670GBI002 or IC697GBI102) interfaces Field Control I/O
modules to a host PLC or computer via a Genius bus. It can exchange up to 128 bytes of input data
and 128 bytes of output data with the host, each Genius bus scan. It can also handle Genius
datagram communicati ons.
The intelligent processing capabilities of the Genius Bus Interface Unit allow the configuration of
features such as fault reporting, selectable input and output defaults, analog scaling and analog
range selection for the modules in the station. In addition, the Genius Bus Interface Unit performs
diagnostic checks on itself and its I/O modules, and relays diagnostic information to the host (if
configured for fault reporting) and to a Hand-held Monitor.
The Genius Bus Int erface Unit can be used on a bus controlled by redundant CPUs or Bus
Contr ol lers. It can also be used on a dual bus.
The Bus In terface Un it mounts on a Bus In terface Un it Termin a l Block. It c a n be re moved and
replaced if necessary without removing the wiring or reconfiguring the I/O station.
Bus Interface Unit Terminal Block
The Bus Interface Unit Terminal Block, which included with the BIU, has connections for power
wiring and single or dual communications cables. It has built-in bus switching circuitry, allowing
the Bus Interface Unit to be used on a dual (redundant) Genius bus (no external Bus Switching
Module is needed). The Bus Interface Unit Terminal Block stores the configuration parameters
selected f or the station.
1
I/O Modules
Field Control I/O Modules are available in many types to suit a wide range of application needs.
Modules can be installed and removed without disturbing field wiring. One or two I/O modules
may be mounted on an I/O Terminal Block.
Micro Field Processor
The Series 90 Micro Field Pr ocessor ( MFP) is a Micro PLC that provides local logic within a Field
Control stati on . The Micr o Fi eld Processor is the same size as a Fi eld Control I/ O module and
occupies one of the eight available I/O slots in a Field Control station.
MFP features in clude:
Compatible with Logicmaster 90-30/20/Micro programming software, revision 6.01 or later.
Alarm processor
Password protecti on
Built-in communications port that supports Series 90 protocols (SNP and SNPX)
The Micr o F ield P roces sor requires a G e nius Bus In ter face Un it revision 2. 0 or later.
GFK-0825F Chapter 1 Introduction 1-3
1
I/O Terminal Blocks and Auxiliary I/O Terminal Blocks
An I/O Terminal Block provides mounting, electrical, and field wiring connections. Each half of
the I/ O T erm in al Block can be mechanically keyed to accept only an I/O module of a sp ecific type.
Auxiliary I/O Terminal Blocks can be easily attached to an I/O Terminal Block. They can be used
to provide additional common terminals if needed.
For more information, please refer to:
Chapter 3: Installation
inst all the Bus Interface Unit modul e on the Field T er minal Block.
Chapter 2: Description
Block in detail.
Chapter 4, Operation
Chapter 5: Hand-Held Monitor Configuration
The
Series 90 Micro Field Processor User's Manual
Field Processor (IC670MFP100) and provides installation procedures, operation information, and
diagnos tics inf ormation .
The
Field Control I/O Modules User' s Manual
Terminal Blocks. This manual also explains module installation and field wiring.
, which explains wiring to the Bus Interface Unit, and explains how to
, which describes the Bus Interface Unit and Bus Interface Unit Terminal
, which explains how the Genius Bus Interface Unit services I/O.
, which explains how to configure I/O modules.
(GFK-1171), which describes the Micro
(GFK-0826) which describes I/O modules and I/O
1-4 Field Control™ Genius® Bus Interface Unit User’s Manual – October 1999 GFK-0825F
Environmental Specifications
Vibration Modules per form well wh ere vibrat ion is a factor. Designs are shock and
vibration tested to meet the following specifications when installed on a
panel-mounted DIN rail using the clamp supplied, and with the panelmount ing feet secured:
IEC68-2-6: 10 to 57 Hz 0.012 in displacement (peak to peak)
IEC68-2-27: Shock: 15G, 11 milliseconds, half sine wave
Noise Modules are resistant to noise levels found in most industrial applications
when in s talled according to accepted p r actices, inclu ding proper s ep aration
of wiring by voltage and power levels, on a conductive (unpainted) DIN rail.
The DIN ra i l is an in tegr al part of the grounding system.
Modules are tested to the specifications listed in the Conformance to
Standards document (GFK-1079).
1
57 to 500 Hz at 2 g (unless otherwise specified)
Temperature Modules operate reliably in ambient air temperatures from 0 deg. C (32 deg.
F) up to 55 deg. C (131 deg. F).
Storage temperatures are -40 deg. C (-40 deg. F) to +85 deg. C (185 deg. F).
Humidity 5% to 95%, non-condensing.
For information about installing Field Control modules, please see:
Chapter 2 of this manual. It describes installation and wiring for the Bus Interface Unit module and
terminal block.
Chapter 2 of the
for modules and terminal blocks.
The individual module datasheets included in the
which provide specific module wiring information.
Chapter 2 of the
instructions for selecting and installin g a Genius bus.
Field Control I/O Modules User's Manual
Field Control I/O Modules User's Manual
Genius I/O System and Communications User's Manual
. It summarizes installation instructions
, which includes detailed
,
GFK-0825F Chapter 1 Introduction 1-5
1
Configuration for Field Control
Configuration is an important part of the process of setting up a Field Control station. It establishes
the following features:
For the Bus Interface Unit:
Genius serial bus address
Baud rate for Genius bus communications
Faul t r eportin g to the host
Use of the Bus Interface Unit as a bus switching device in a dual (redundant) bus system
Redundancy mode for CPU redundancy
Configuration protection
For I/O Modules:
I/O addressing
Wheth er faults wi ll be reported to the host
Hold Last State for inputs or outputs
Output defaults
Range selection for analog modules
Scaling for analog modules
Alarm limits for analog modules
For a Micro Field Processor:
Reference a ddress e s
Data Lengths
A Bus Interface Unit and I/O modules can be fully configured using a Hand-held Monitor.
Optionally, a previously-configured Bus Interface Unit can be reconfigured using datagrams.
For more information about configuration, please refer to:
Chapter 5 of this manual (
HHM Configuration
(IC660HHM501J ) or later, can be used to configure a Bus Interface Unit. HHM configuration
instructions are given in chapter 5.
In addition, chapter 8 of this manual (
Datagrams)
Interface Unit can be completed or changed by sending it Write Configuration datagrams.
The
Series 90 Micro Field Processor User's Manual
Field Processor (IC670MFP100), and provides installation procedures, operation information, and
diagnos tics inf ormation .
If the system host is a Seri es 90™70 PLC, the Geni u s Bus Inter face Uni t m u st be incl ud ed in th e
system configuration as a d evi ce on the bus . P lease see the programming soft wa re documentati on
for instructions.
). A Genius Hand-held Monitor, version 4.6
explains how the configuration of a Bus
(GFK-1171), which describes the Micro
1-6 Field Control™ Genius® Bus Interface Unit User’s Manual – October 1999 GFK-0825F
Field Control in a Genius System
Using Field Control modules on a Genius bus combines the low cost, small size, and flexibility of
Field Control with the versatility, power, and communications features of the Genius system.
The Genius bus is an industrially-hardened Local Area Network (LAN). It passes I/O (control)
data and background information (datagrams) between the Bus Interface Unit and a Genius bus
controller. A Genius bus can support up to 32 devices. Each Bus Interface Unit station counts as
one device on the bus, regard less of th e nu m ber or type of modul es present in the sta tion.
Oth e r devi c es on the sa me bus c a n be Field C ontr ol sta t ions , remote dr ops, I/O bloc ks, Bus
Controllers and Hand-held Monitors. Typical busses reserve one location for a Bus Controller and
one for a Hand-held Monitor, leaving 30 for additional devices. The illustration below shows a
Series 90-70 PLC connected to a Genius bus with I/O blocks and two Field Control stations.
Series 90-70 PLC
1
The Host CPU
The Genius Bus Inter face Unit is ideally suited for use with a Series 90-70 or Series 90-30 PLC.
However, any type of PLC or computer capabl e of c ontrolling a Genius bus can be us ed as the host .
Possible hosts in cl ud e Seri es Six PLCs, Seri es Fi ve PLCs, an d comput ers equip p ed with a PCIM
(Personal Computer Interface Module), QBIM (Q-Bus Interface Module), or a third-party GENIbased interfa ce modul e, in cluding several in DCS systems.
Hand-held
Monitor
Genius Bus
GFK-0825F Chapter 1 Introduction 1-7
1
PCIM
A More Complex Field Control and Genius System
A more complex communications and control system is illustrated below. In this system, the Field
Control stations and Genius blocks on the lower left are controlled by a Series 90-70 PLC. The
Field Control stations and Gen i us blocks on the lower right are controlled by a host computer
equipped with a PCIM (Personal Computer Interface Module).
The PLC communicat es with a computer runn ing programming softwar e via an SNP (Serial
Network Protocol) link. And the PLC, host computer, and programmer computer exchange system
data vi a an Ethernet com munications link.
Series 90-70 PLC
SNP
Ethernet
Genius Bus
Genius Bus
For more information about Genius systems and communications, please refer to:
The
Genius I/O System and Communications User's Manual
operation, and communications formats.
, which describes Genius system
The
Bus Controller User's Manual
for the system host, wh ich inclu d es s p ecific system interfa ce
instructions.
1-8 Field Control™ Genius® Bus Interface Unit User’s Manual – October 1999 GFK-0825F
Required Genius and Host System Equipment
The following system equipment is required:
Genius Hand-held Monit or version 4.6 (IC660HHM501J) or later.
For a Series 90-70 PLC
Series 90-70 CPU firmware, release 3.0 or later.
A Series 90-70 Genius Bus Contr oller, release 3.0 or later. The Bus Controller must be 4.0
or later for full diagnostics display from Logicmaster 90-70, or for redundancy
applications.
If Logicmaster 90-70 programming and configuration software is used, it must be
release 3.0 or later:
.
A
B
For a Series 90 30 PLC
Series 90 30 CPU firmware: any version.
Logicmaster 90-30 programming and configuration software: any version.
Series 90-30 Genius Bus Controller: any ver sion.
IC641SWP701F (3.5", 2DD, 5.25" 2S/HD)
.
IC641SWP704C (5.25" 2S/2D)
1
For a Series Six™ PLC
CPU: rev. 105 or later.
Logicmaster 6 Programming Software: release 4.02 or later.
Bus Controllers: IC660CBB902 or 903, version 1.7 or later.
For a Series Five™ PLC
CPU: rev. 3.2 (catalog number with E suffix) or later.
Logicmaster 5 Programming Software: release 2.01 or later.
Bus Controller: any version
For a Host Computer
PCIM: any version
QBIM: any version
GFK-0825F Chapter 1 I ntroduction 1- 9
1
Using Field Control in a CPU Redund ancy System
Most systems use only one Bus Controller and CPU to control the I/O on the Genius bus. CPU
redundancy, which can be used for backup CPU/Bus Controller protection in critical applications,
is described in detail in the Genius documentation. The section that follows here summarizes how
Field Control product s can fit into a Genius CPU Redun dancy system.
CPU/Bus Controller Redundancy: Overview
In CPU redundancy, two Bus Controllers on the same bus can send control outputs at the same
time. Both Bus Controllers automatically receive i nputs an d fa u lt repor t s from all devi ces on the
bus that have been configured as being in “CPU Redundancy” mode. The Bus Controllers must
use serial bus addresses (devic e numbers) 30 and 31.
Field Control stations can be used on a bus controlled by redundant CPUs/Bus Controllers.
Bus
Controller
(Device 30)
How the two sets of outputs from the dual CPUs are handled by a Bus Interface Unit depen ds on
whether the Bus Interface Unit is set up for Hot Standby or Dupl ex redundancy.
contains any analog modules, the only form of CPU redundancy permitted is Hot Standby.
Bus
Controller
(Device 31)
If the station
46471
Hot Standby CPU Redundancy
A Bus Interface Unit con figured for Hot Stan dby mode is normally controlled by the Bus
Controller assigned to serial bus address 31. If no outputs are available from 31 for three bus
scan s, the Bus Inter face Unit accep ts outpu ts from the Bus Contr oller assigned to serial bus address
30. If outputs are not available fr om either Bus Controller, outputs go to th eir configur ed defaults
or hold their last state. In Hot Standby redundancy, Bus Controller -31 always has priority; when it
is on-line, it has control of the outputs.
Duplex CPU Redundancy
A Bus Int er face Unit configur ed for D u p lex mode compares outp uts it recei ve s from the two Bu s
Controllers, to determin e if they match. If corresponding outputs are th e same, th e Bus Interface
Unit set s the output to that state. If corres p onding outputs are not the same, the Bus Int erface Unit
sets the output to its config ur ed ON or OFF Duplex Default Stat e. If either Bus Controller stops
sending outputs to a Bus Interface Unit, its outputs are directly controlled by the r emaining Bus
Controller.
mode if the station contains any analog I/O modules.
1-10 Field Control™ Genius® Bus Interface Unit User’s Manual – October 1999 GFK-0825F
Only discret e I/O modules can operate in Duple x redundancy mode; do not use Duplex
Using Field Control in a Genius Bus Redundancy System
In Geni u s bu s r edundancy, there ar e two bus cables ea ch connected to a Bus C ontroller. I/O
devices may be connected to either one bus of the pair, or to both. However, a device that is
connected to both busses actually communicates on only one bus at a time. Before the alternate
bus can be used for communication s, a bus switchover must occur and th e device must “log in”
with the Bus Controller (s) on the alternate bus.
The Bus Interface Unit Terminal Block contains a built-in bus switching r elay that is used to switch
busses in a dual bus system. Other types of devices with this capability ar e dedicated Bus
Switching Modules and Series 90-70 Remote I/O Scanner modul es. These are the only types of
devices that can be directl y connect ed to both redundant bus ca bl es .
A Bus Int er face Unit can not be used a s the BSM Contr ol ler for a bus stub. Other devices cannot be
located on a stub downstream of a BIU.
Also, the Bus Interface Unit should n ot be con nected to an externa l Bu s S wi t ching Mod u le.
Redundant Bus Configurations
Many different redundant bus configurations are possible. T hree basic ways of using a Bus
Interface Unit wi th a r edundant bu s are descr i bed below.
1
A Bus Interface Unit can be installe d directly on both cables of the dual bus pair. The
Bus Interface Unit is configured to operate as a bus switching device in addition to perfor ming
its nor mal functions. Here, two Field Control stations ar e installed on a dual bus. Each Bus
Interface Unit would be set up as a bus switching devi ce.
Bus A
Bus B
A Bus Interface Unit can be located on just one bus of a redundant bus pair, i f bus
46472
redundancy is n ot needed for the modules in th at station . In this exam ple, the Bus Interface
Unit on th e left is connected to both Bus A and Bus B an d is configur ed as a bus swi tching
device. The Bus Interface Unit on the right, which serves non-critical I/O modules, is
conn ected to Bus A only, and is n ot configur ed as a bus switching device.
Bus A
Bus B
46473
GFK-0825F Chapter 1 I ntroduction 1-11
1
A Bus Interface Unit can be located on a bus stub.
A Bus Interface Unit can also be located
on a bus stub, which is a short length of unterminated cable downstream of either a Genius I/O
block/Bus Switching Module combination, or a Remote I/O Scanner connected to a dual bus.
Because the bus stub cable itself is not r edundant, this type of installation does not provide as
much protection as conn ecting directly to a dual bus. The bus switching device to which the
bus stub i s connected can be another Geni u s block wi th a Bus Swi tching Module atta ched, as
shown below, or a Series 90-70 Remote I/O Scanner.
In thi s ex ample, th er e are two Field Contr ol stations install ed on a bus stu b. Each is
configu red as “BSM Presen t” but not con fi g ured as a “BSM Controll er ”.
Bus A
Bus B
Bus
Switching
Module
Genius Block
Acting as a
BSM Controller
Up to 7 Additional Devices on the Bus Stub
46474
Up to seven device s (not counting th e BS M /block or Re mote I /O Sca nner to which the dua l bus is
connected) can be installed on a bus stub. Each device on a bus stub counts towar d the total of 32
devices on the Geniu s bus.
Restric tions on the number and length of bus st ubs that may be used on a dual bu s a re exp lained in
the
Genius I/O System and Communications User's Manual.
1-12 Field Control™ Genius® Bus Interface Unit User’s Manual – October 1999 GFK-0825F
Chapter
2
Description
This chapter descr ibes:
Genius Bus Interface Unit
Bus Interface Unit Power Su pply
Bus Interface Unit Terminal Block
Specification s
Genius Bus Inter face Unit
The Genius Bus Interface Unit is a small, rugged, intelligent module with a sturdy aluminum
housing. The module has four status LEDs, described below, and a connector for attaching a
Genius Hand-held Monitor.
3.25" (8.2mm)
HHM
Connector
5.0" (12.7mm)
LEDs
The Bus Interface Unit contains th e logic power s u p pl y n eed ed to opera te the I/O modules
connected to it. It mounts on a separate terminal block, to wh ich it and all bus wiring are attached.
The configuration is stored in non-volatile memory located in the terminal block. Both the power
supply and terminal block a re described in this chapter.
The Bus Interface Unit has a replaceable 1A, 5x20mm 250VAC slow-blow fuse on the input power
lines. The fuse can be changed without disturbing the wiring of any other modules (instructions are
in chapter 3).
GFK-0825F 2-1
2
LEDs
The LEDs on the Bus Interface Unit show its operating status.
BUS B PWR
RUN OK
ACTIVE
PWR
OK
lights to indicate that +5V power is available for logic oper ation.
lights to indicate that the module has passed its powerup diagnostic tests.
See the table below for more information.
RUN
lights only if output modules ar e in the BIU configuration and are written
to by the controlling bus controller . See the table below.
BUS B
if the Bus Interface Unit is installed on a dual (redundant) bus, this LED
lights if Bus B is the currently-active bus.
OK RUN Meaning
ON ON Module functioning, CPU communicating
ON OFF Modul e functioning, no CPU communications f or 3 bus scans
ON Blinking Module functioning, circuit forced
Blinking ON Circuit fault, CPU com m unic ati ng
Blinking OFF Circuit fault, no CPU communications for 3 bus scans
Alternate Bli nki ng Circuit fault, Circ ui t forced
Synchronous Blinki ng No CPU communications - block number conflic t
OFF Blinking Electronics/Terminal Assembly mismatch
OFF OFF No block power, or Block faulty
2-2 Field Control™ Genius® Bus Interface Unit User’s Manual – October 1999 GFK-0825F
Bus Interface Unit Power Supply
The power supply in the Bus Interface Unit provides power for the Bus Interface Unit itself an d
logic power for all I/O modules that may potentially be installed at that station. External power
must be supplied for field wiring of input and output devices.
The power supply is not da maged by either of t he following:
Reversing input voltage on terminals 1 and 2.
Timing
Temporary
The Bus Interface Unit provides power to all I/O modules that are installed at the station. I/O
module operation is governed by a System Reset sign al to ensur e controlled operation during the
power up and sh ut down processes. As sh own in the timing diagram below, momentary power
losses of less than 10 mS (for 24VDC BIU) or 20mS (for 115VAC/125VDC BIU) do not affect I/O
module operation. Longer power losses generate a Reset for all system I/O modules.
overcurrent conditions on the 6.5 VDC output.
2
24VDC
Nominal
or 115 VAC
Nominal
6.5V Output
Input Power
On
RST*
Voltage
Overshoot
5% (max)
200mS
(min)
95% (min)
Minimum:
10mS for 24VDC BIU
20mS for 115VAC/12 5V DC BIU
Momentar y
Power
Loss
Hold
Up
Time
3mS
(min)
Voltage
Overshoot
5% (max)
200mS
(min)
Input Power
Off
Hold
Up
Time
10mS
(min)
3mS
(min)
GFK-0825F Chapter 2 Description 2-3
2
Backplane Current
With a DC input voltage, the amount of current available to the backplane may be limited by lower
input voltage as indicated below.
Backplane
Current
Available
(Amps)
Calculating Input Power Requirements for a Bus Interface Unit
The charts below show typical input power requirements for a Bus Inter face Unit.
For 24VDC Bus Interface Unit
15.9
14.1
Typical
12.3
Input
10.0
Power
(Watts)
7.7
5.5
3.4
0.25 0.50 0.75 1.0 0 1.20 1.400
Total Backplane Cu r rent (Amps)
For 24VDC Supply
1.4
1.2
1.0
18
19
Voltage In
21
Typical
Input
Power
(Watts)
for DC
Inputs
For 125VDC Supply
Backplane
Current
Available
(Amps)
2.0
1.8
For 115VAC/125VDC Bus Interface Unit
24.0
18.75
13.5
8.25
3.0
0
0.50 1.501.00 2.0
Total Backplane Cu r rent (Volts)
105
110
Voltage In
48.0
37.75
27.5
17.25
7.0
Typical
Input
Power
(Volt/Amps)
for AC
Inputs
Note
For a 24VDC Bus Interface Unit, start-up surge at full load is 15-50 Amps for 3
milliseconds (maximum). For a 115VAC/125VDC Bus Interface Unit, startup
surge at full load is 20 Amps peak for 3mS.
To deter m ine speci fi c system requirem en ts:
Determine total output load from typical specifications listed for individual modules.
Use the appropriate graph of input power a bove to determine avera ge input power.
Divide the input power by the operating source voltage to determine the input curr ent
requirements.
Use the lowest input voltage to determine the maximum input current.
Allow for s t artup sur g e cur rent requirem en ts. Startu p surge curr ent levels are a function of
source impedance an d, therefore, are installation-dependent. Startup surge currents can vary
for approximately 3mS. For th e 24VDC Bus Interface Unit, variance is between 25A and 50A.
For the 115VAC/125VDC Bus Interface Un i t, startup surge current is 20A maximum peak.
Allow margins (10% to 20%) for variations.
2-4 Field Control™ Genius® Bus Interface Unit User’s Manual – October 1999 GFK-0825F
Bus Interface Unit Power Dissipation
The Bus Interface Unit power dissip ation can be determined once th e ba ck p lane curr en t supplied to
the I/O modules is known.
The following equation can be used to calculate BIU power dissipation:
BIU Power Dissipat ion = Input P ower - (t otal back plane c ur r ent x 6.5 volts)
For exa mp le:
A. Total backplane cur rent = 0.5 Am ps
B. Typical Input power = 7.7 Watts
Therefore:
BIU Power Dissipat ion = 7.7 W - ( 0.5 x 6.5 ) = 4.45 Watts
2
GFK-0825F Chapter 2 Description 2-5
2
Load Requirements for Hardware Components
The tabl e bel ow shows the DC load r eq u ired by each module an d har dware component. All r atings
are in milliamps. Input and Output module current ratings are with all inputs or outputs on. These
are maximum requirements, not typical.
Catalog Number Description Current (mAmps)
IC670MDD441 Mixed I/ O Module, 24 VDC 10 Inputs, 6 Outputs 110
IC670MDL233 Input Module, 120 VAC 8 Isolated Points 40
IC670MDL240 Input Module, 120 VAC 16 Grouped Points 77
IC670MDL241 Input Module, 16 Points, 2 groups 240 VAC 77
IC670MDL640 Input Module, 24 VDC 16 Grouped Pos/Neg Points 83
IC670MDL641 Input Module, 48 VDC 16 Grouped Pos/Neg Points 83
IC670MDL642 Input Module, 125 VDC 16 Grouped Pos/Neg Points 77
IC670MDL643 Input Module, 5/ 12 VDC 16 Point 80
IC670MDL644 Input Module, 12/24 VDC 16 Grouped Pos/Neg Fast Inputs 80
IC670MDL730 Output Module, 8 Pt 24 VDC Elect ronic Short Circuit Protection 125
IC670MDL740 Output Module, 12/24 VDC 0.5 Amp, 16 Grouped Pos. 111
IC670MDL742 Output Module, 5/12/24 VDC Negative Outputs 111
IC670MDL330 Output Module, 16 Point 12-120 VAC 16 Pt 1.0 Amp 285
IC670MDL331 Output Module, 120 VAC 2 Amp, 8 Isolated Points 154
IC670MDL930 Relay Output Module, 2 Amp, 6 Form A Points and 2 Isolated
Form C Points
IC670ALG230 Analog Current Input Module, 8 Grouped Points 51
IC670ALG240 Analog Input Module, 16 point Grouped 251
IC670ALG281 Analog Voltage Input Module, 8 Grouped Points 150
IC670ALG282 Analog Voltage Input Module, 16Grouped Points 150
HE670ACC100 Input Simulator Module, Horner 100
HE670ADC810 Analog Input Module, Horner, +/-10VDC, 0-10 VDC 131
IC670ALG620 RTD Input Module 190
IC670ALG630 Therm ocouple Input Module 195
IC670ALG320 Analog Current/Voltage Output M odul e, 4 Grp Points 51
IC670ALG330 Analog Current source Output Module, 8 Points 85
IC670MFP100 Micro Field Processor 111
IC693PRG300 Hand-held P rogram m er 170
313
IC660HHM501 Genius Hand-held Monitor 0
Hand-held Monitor and Hand-held Programmer
The Genius Hand-held Monitor (IC660HHM501), used for configuring and monitoring the BIU,
has it s own ba ttery and does not add to the load on the BI U.
However, if a Han d-held Programmer (IC693PRG300) will be attached to a Micro Field Processor
or other module in the I/O Station, it must be con sidered as a load component as listed above.
2-6 Field Control™ Genius® Bus Interface Unit User’s Manual – October 1999 GFK-0825F
Hot Insertion/Removal of Modules
Bus Interface Un i ts IC670GBI002(F) and IC670GBI102A or later support Hot Insertion/Removal
of modules in the I/O Station.
Hot Insertion/Removal means that modules can be removed and replaced while I/O Station power
is applied without affecting the BIU or other modules in the I/O Station. Separate I/O module
power must be switched off to the module being inserted or removed.
Hot Insertion/Removal requires the use of specific modules and I/O terminal blocks:
• I/O modules having catalog num ber suffix J or above. These modules have a projecting
alignment tab that fits into a corresponding alignment tab on I/O Terminal Blocks listed below.
Note that modules with this tab can also be installed on older I/O Terminal Blocks that do not
have mating alignment tabs. However, Hot Insertion/Removal are not suppor t ed in such an
installation.
• I/O Term inal Blocks IC670CHS101, 102, or 103. These I/O Terminal Blocks have pr ojecting
alignment tabs designed to facilitate Hot Insertion/Removal of modules. Modules that are
earlier than r evi sion J cannot be mount ed on these ter minal blocks .
I/O Terminal Blocks IC670CHS001, 002, and 003, which lack alignment tabs, do not support
Hot Insertion/Removal of modules. With th ese terminal blocks, I/O Station power should be
off when installing or r emoving modules.
2
Mixing IC670CHS10x terminal blocks with IC670CHS00x terminal blocks in the same I/O
statio n is no t recommended.
Faults Reported During Hot Insertion/Removal
When using the recommended equipment listed above, Hot Insertion/Removal will cause the
expected fault reports r elated to the loss of or addition of the module and its I/O circuits. These
faults should be cleared in the normal manner. However, Hot Insertion/Removal of a r ev. J or later
module will NOT cause Configuration Mismatch errors that in some types of systems can sh ut
down the controller.
I/O Module Data During Hot Insertion/Removal
As men tioned, separate I/O module power must be turned off for Hot Insertion/Removal. When th e
module is installed and power is r eapplied, module data will quickly return to normal. For
intelligent I/O modules, there m a y be a delay of a few seconds while the m odule goes through its
powerup sequence.
Hot Insertion/Removal for a Micro Field Processor
A Micr o Field Processor that is r evision J or later may be removed/inserted as described above.
Note, however, that although the Micro Field Processor will start functioning upon reinstallation,
the MFP's applica ti on pr ogram must be rel oa ded . I/O data controlled by the Micr o Fiel d Processor
will be incorrect until that has been don e. (The BIU configuration of the Micro Field Processor is
not affected by Hot Insertion/Removal).
Hot Insertion/Removal Not Permitted in Hazardous Locations
In hazardous locations, I/O Station power must be turned off before inserting/removing module.
Failure to observe this precaution may result in personal injury, system malfunction and/or damage
to the eq u ipment.
GFK-0825F Chapter 2 Description 2-7
2
Bus Interface Unit Terminal Block
The Bus Interface Unit provides terminals for power and ground conn ections. Maximum wir e size
is AWG #14. (avg 2.0690mm2 cross-section).
The Bus Inter face Unit Terminal Block also has eight input terminals for connection to a single or
dual Genius bus. Th ese terminals accom modate up to two AWG #14 wires. The Bus Interface Unit
Terminal Block contains bus-switching circuitry per mitting it to be used
dual bus redundancy system.
A connect ing cable is provided wi th each I/ O Ter minal Block. It is used to connect th e Bus
Interface Unit Terminal Block t o the first I/O Terminal Block. The same type of cable
inter con nects su bseq uent I/O Terminal Blocks. The cable has molded connector s th at are keyed t o
assure prope r o rientation.
The Bus Interface Unit Terminal Block is designed to be extremely r eliable; it should not be
necessary to replace or rewire it after installation.
The Bus Interface Unit Terminal Block stores the configuration parameters for the station. The Bus
Interface Unit can be removed without removing the wiring or recon figuring the station.
as a BSM Controller
in a
Terminals for
power and
communications
wiring
I/O Terminal Block
Connectors
to next terminal block
46457
Connecting
Cable
2-8 Field Control™ Genius® Bus Interface Unit User’s Manual – October 1999 GFK-0825F
Functi on a l Sp eci fi cations
Bus Interface Unit:
Reliability More than 183,000 hours operation MTBF, calculated
24VDC Power Supply Input
Nominal Rated Volt age 24 VDC
Voltage Range 18 VDC to 30 VDC
Power 16.8 Watts maximum at full load (nominal volt age)
Inrush Current 15-50 Amps peak, 3 mS maximum. Inrush current is installation
Power Supply Output
to I/O modules:
Holdup Time 10mS maximum from nominal input voltage.
115VAC/125VDC Power Supply Input
Nominal Rated Voltage 115 VAC, 125 VDC
Voltage Range 90 to 135 VAC, 105 to 150 VDC
Frequency (AC) 47 to 63 Hz
Power 115 VAC: 48VA maximum at full load (nominal volt age)
Inrush Current 20 Amps peak, 3 mS maximum.
Power Supply Output
to I/O modules:
Holdup Time 20mS maximum from nominal input voltage.
2
dependent. See page 2-4.
6.5 VDC ±5%
1.4 Amp maximum. See page 2-4.
125 VAC: 24W maximum at full load (nominal voltage)
6.5 VDC ±5%
2 Amp maximum. See page 2-4.
Bus Interface Unit Terminal Block:
Power Requirements 16mA maximum
Reliability More than 600,000 hours operation MTBF, calculated
For power requir ements of specific I/O modules, please see the
Manual
GFK-0825F Chapter 2 Description 2-9
, (GFK-0826).
Field Control I/ O Modules User's
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