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GE Industrial Systems

Innovation Series Controller


Product Catalog

Pre-emptive
Multi-tasking
Control

Contents
Commitment to Quality ..................................................................................................................................................... 1
Six Sigma Dependability.................................................................................................................................................. 1
ISO 9001 Certification ..................................................................................................................................................... 1
Technical Support ............................................................................................................................................................ 1
Training............................................................................................................................................................................ 1
Overview ............................................................................................................................................................................. 2
Primary Controller ........................................................................................................................................................... 2
Series 90-70 PLC Interface Module.............................................................................................................................. 3
Mill Stand Control Application........................................................................................................................................ 4
Innovation Series Controllers ........................................................................................................................................... 5
Common Features VME Controllers............................................................................................................................. 5
Differentiating Features VME Controllers .................................................................................................................... 7
Common Features ACL Controllers.............................................................................................................................. 9
Differentiating Features ACL Controllers ................................................................................................................... 10
Execution of Control Logic ............................................................................................................................................. 11
I/O Drivers........................................................................................................................................................................ 14
Control System Toolbox .................................................................................................................................................. 25
Configuration of I/O Drivers and Hardware................................................................................................................... 26
Organization of Control Logic ....................................................................................................................................... 27
Instruction Blocks .......................................................................................................................................................... 29
Permissive Diagnostic Function ...................................................................................................................................... 32
Fault Detection............................................................................................................................................................... 33
Presenting the Diagnosis ................................................................................................................................................ 35
Ordering Information...................................................................................................................................................... 36
Innovation Series Controllers......................................................................................................................................... 36
Innovation Series Controller I/O .................................................................................................................................... 36
Genius I/O System Blocks and Options ......................................................................................................................... 37
Field Control I/O System Components and Options ...................................................................................................... 38
Control System Solutions (Windows NT Applications & Service)................................................................................ 39
Catalog Number 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 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 Lloydss 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. GEs OnSite SupportSM
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 Distribution Network "2000" program linking GE Industrial
Control System Solutions authorized GE distributors to better serve our end
customers.

Training
Extensive training tailored to your needs is available for both operating and
maintenance personnel. Training can be taught at your site or at the GE Training
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

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. Two 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

Mill stand control in the metals


manufacturing industry

ACL Form Factor

High speed coordination of drives

Tension regulation in a coordinated


line

Coil diameter calculation in paper


and metal applications

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

Control System
Toolbox

Ethernet

Genius

Innovation Series
Controllers

Field Control
DLAN+
ISBus
ISBus
+

AC/DC2000

AC/DC2000

AC/DC2000

Motor Control Layer


Application Control Layer

AC

Innovation
Series

AC

Innovation
Series

AC

Innovation
Series

Innovation Series controllers system configuration in a general purpose sequencing application

2
in

GEP-9145 Innovation Series Controller Product Catalog

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

CIMPLICITY HMI
Server

Control System
Toolbox

Ethernet

Genius Bus

CPU

Ethernet

Genius Bus

CPU

Ethernet

Series 90-70

Innovation Series
Controllers

Series 90-70

DLAN+
ISBus
ISBus
+

AC/DC2000

AC/DC2000

AC

AC

AC

AC/DC2000

Motor Control Layer

Innovation
Series

Innovation
Series

Innovation
Series

Application Control Layer

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

GEP-9145 Innovation Series Controller Product Catalog

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:
Rod & Bar Mill
Metal Rolling Mill
Waterbox Control
Hydraulic Cylinder Control
Laying Head Control
Work Roll Bending
Laying Head Pinch Roll Control
Work Roll Shifting
Roll Change Sequencing
Hydraulic Loopers (hot strip mill)
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

Control System
Toolbox

CIMPLICITY HMI
Server

Ethernet

Innovation Series
Controllers

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

Innovation
Series

AC

Innovation
Series

AC

Innovation
Series

AC/DC2000

AC/DC2000

AC/DC2000

Motor Control Layer


Application Control Layer

Innovation Series controllers system configuration in a mill stand control application

4
in

GEP-9145 Innovation Series Controller Product Catalog

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
Memory

Pentium 133 MHz


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
Description
Baud Rate
19200
Mode
Binary (Remote Terminal Unit), ASCII
Data Bits
7, 8
Parity
None, Odd, Even
Stop Bits
1, 2

GEP-9145 Innovation Series Controller

Genius Bus Interface

DLAN+ Interface

Programming Language

Environmental

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 devices


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:

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

GEP-9145 Innovation Series Controller Product Catalog

Differentiating Features VME Controllers


VME
Catalog Number

DS215UCVBG1

DLAN+A
10
8

Ethernet

Ethernet

DLAN+
10
8

DS215UCVBG3

1
H L

DLAN+B
10
8

1
H L

1
H L

S
T
RSET A
T
U
S

S
T
RSET A
T
U
S

S
T
A
T
U
S

COM

COM

DLAN+

DLAN+

DLAN+
GENIUS
SER 1
SER 2

GENIUS A

GENIUS B

SER 1
SER 2

SER 1
SER 2

DLAN+ Interfaces

Genius Interfaces

ISBus Interfaces

none

none

Required VME Slots

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

GEP-9145 Innovation Series Controller

VME
Catalog Number

IS215UCVCH1

IS215UCVCH3

IS215UCVCH5

10
Ethernet

Ethernet

Ethernet

1
S
T
RSET A
T
U
S

S
T
RSET A
T
U
S

S
T
A
RSET T
U
S

S
T
A
T
U
S

COM

COM

COM

DLAN+

GENIUS

ISBus A ISBus B

ISBus A ISBus B

ISBus B

ISBus A ISBus B

ISBus A

GENIUS

GENIUS

8
in

S
T
A
T
U
S

GENIUS

GENIUS

DLAN+ Interfaces

none

none

Genius Interfaces

ISBus Interfaces

Required VME Slots

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

GEP-9145 Innovation Series Controller Product Catalog

Common Features - ACL Controllers


Processor
Memory

486 100MHz
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

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

Environmental

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

GEP-9145 Innovation Series Controller

Differentiating Features ACL Controllers


ACL
Catalog Number

IS215ACLAH1

IS215ACLAH2

IS215ACLIH1

RST

RST

RST

RST

OK
ACTIVE
ENET
FLASH
S
T
A
T
U
S

OK
ACTIVE
ENET
FLASH
S
T
A
T
U
S

OK
ACTIVE
ENET
FLASH
S
T
A
T
U
S

OK
ACTIVE
ENET
FLASH
S
T
A
T
U
S

ISBus A

ISBus B

ISBus A

ISBus B

COM

COM

COM

COM

Ethernet

Ethernet

Ethernet

Ethernet

Ethernet Interface

IS215ACLIH2

10BaseT

AUI

10BaseT

AUI

None

None

ISBus Interface

10
in

GEP-9145 Innovation Series Controller Product Catalog

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


Sequencing of material handling equipment

128 ms
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
4

Yes
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 or 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):
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:

Configured I/O drivers read and

write the I/O Table values to


hardware asynchronously with the
execution of control logic tasks.

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.

GEP-9145 Innovation Series Controller

11

I/O
Drivers
Limit_Switch
CPU
Based
Genius

Start_PB
Stop_PB
Solenoid
GE Fanuc PLC

I/O
Table

Inputs at
start of task
Outputs at
end of task

Software
Signal
Table

Sequencing Tasks
(Low Priority)

Limit_Switch
Start_PB

Read Task Inputs into Software


Signal Table

Stop_PB
Solenoid

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

GEP-9145 Innovation Series Controller Product Catalog

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)


Work roll bending regulators

2
4

High
Medium

2
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

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

GEP-9145 Innovation Series Controller

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
Open-wire detection (inputs)
Sense shorted wire (inputs)
Failed switch (inputs/outputs)
Over temperature (inputs/outputs)
Loss I/O power (inputs/outputs)
Short-circuit (outputs)
Load state feedback (outputs)
Pulse Test (outputs)
No-load (outputs)
Overload (outputs)

14
in

Analog I/O Blocks


Open-wire detection (inputs)
High alarm (inputs)
Low alarm (inputs)
Internal fault (inputs)
Wiring error (inputs)
Input short (inputs)
Under-range (input/outputs)
Over-range (inputs/ouputs)
Feedback error (output)

GEP-9145 Innovation Series Controller Product Catalog

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

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

Point Health
#Signal_Name
Point Health Detail
##Signal_Name

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
Monitor block

Yes
Yes

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
I/O Point Signals

Data Type

Description

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

Point Health
#Signal_Name
Point Health Detail
##Signal_Name

Indicates point health

Byte 4 Controller OK, bit 0


Module fault code, bits 4-7

GEP-9145 Innovation Series Controller

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

GEP-9145 Innovation Series Controller Product Catalog

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*106)*(Scan Rate of Control Task)] (V/Cnt)

For 10 to +10V:
Resolution = 20 / [(2*106)*(Scan Rate of Control Task)] (V/Cnt)

For ranges 0 to 20mA and -10 to +10mA:


Resolution = 10 / [(109)*(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
Signal_Name
Point Health
#Signal_Name
Point Health Detail
##Signal_Name

GEP-9145 Innovation Series Controller

Data Type

Description

Boolean or
Integer
Boolean

Value of I/O point

4 Bytes

Byte 1 board health and present


Byte 2 stall status; set true if not stalled

Indicates point health

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
Signal_Name
Point Health
#Signal_Name
Point Health Detail
##Signal_Name

Data Type

Description

Boolean,
Integer, or Real
Boolean

Value of signal

4 long (only 2 bytes


used)

Byte 1 page health


Byte 2 point health

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 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

GEP-9145 Innovation Series Controller Product Catalog

Serial Modbus

TM

DCS / HMI
System

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

GEP-9145 Innovation Series Controller

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
Signal_Name
Poin Health
#Signal_Name
Point Health Detail
##Signal_Name

20
in

Data Type

Description

Boolean,
Integer, or Real
N/A

Value of signal

N/A

GEP-9145 Innovation Series Controller Product Catalog

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. Two
examples are:

CIMPLICITY HMI system using the Ethernet SRTP protocol

GE Fanuc Data Panel 1060 using Genius datagrams

The Innovation Series controllers 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

GEP-9145 Innovation Series Controller

Data Type

Description

Boolean,
Integer, or Real
N/A

Value of signal

N/A

21

Ethernet Global Data


(EGD) I/O Driver

Ethernet
+

CIMPLICITY HMI
Innovation Series
Controller

E-Net

90-70 CPU

+
+

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
Signal_Name
Point Health
#Signal_Name
Point Health Detail
##Signal_Name

22
in

Data Type

Description

Boolean or
Integer
Boolean

Value of I/O point

4 Bytes

Byte 1 page health


Byte 2 point health

Indicates point health

GEP-9145 Innovation Series Controller Product Catalog

SCRAMNet I/O Driver


SCRAMNet

SysTran

SysTran

90-70 CPU

SCRAMNet

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

Byte 1 page health


Byte 2 point health

Data Link
DL 200

Com 1/2

Allen
Bradley
DH+

AB PLC

Data Highway Plus

Indicates point health

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

GEP-9145 Innovation Series Controller

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

CPU

VME Bus

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

Point Health
#Signal_Name

Boolean

Indicates point health

Point Health Detail


##Signal_Name

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
drives
4
16
30

Maximum
frame rate (ms)
1
4
8

ISBus I/O Point Signals


Signal_Name
Point Health
#Signal_Name
Point Health Detail
##Signal_Name

24
in

Data Type
Boolean,
Integer, or Real
N/A

Description
Value of signal

N/A

N/A

N/A

GEP-9145 Innovation Series Controller Product Catalog

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

GEP-9145 Innovation Series Controller

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.

GEP-9145 Innovation Series Controller

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.

GEP-9145 Innovation Series Controller

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

GEP-9145 Innovation Series Controller

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.

GEP-9145 Innovation Series Controller

29

Instruction Block Table continued


Instruction Block
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
Memory Move
CNT_TO_BOOL

30

`
Description

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.
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.

GEP-9145 Innovation Series Controller

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 s 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
INTWLEAD

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.

GEP-9145 Innovation Series Controller

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

GEP-9145 Innovation Series Controller

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 permissive 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

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.

GEP-9145 Innovation Series Controller

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 Jog
Spot Jog
Reverse
Reverse

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

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

GEP-9145 Innovation Series Controller

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 Boolean 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

GEP-9145 Innovation Series Controller

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.

ACL 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
five 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

GEP-9145 Innovation Series Controller

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

GEP-9145 Innovation Series Controller

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

38

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

IC670MDL640

Field I/O Modules


24 V dc positive/negative input 16-point grouped

IC670MDL740

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

IC670ALG230
IC670ALG320

Analog input current 8-point, grouped


Analog output current/voltage 4-point, grouped

IC670MDL641
IC670MDL240

48 V dc positive/negative input 16 point, grouped


120 V ac input 16-point, grouped

IC670MDL241

240 V ac input 16-point, 2 groups

IC670MDL331
IC670MDL330

120 V ac 2A output 8-point, isolated


12-120 V ac output 16-point, grouped

IC670MDL930

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

IC670MDL642
IC670ALG240

125 V dc input 16-point, grouped


Analog input current 16-point, grouped

IC670ALG330

Analog output current 8-point, grouped

IC670ALG630
IC670ALG620

Thermocouple 8-point, isolated


RTD 4-channel isolated 3-wire

IC670MDL643
IC670MDL742

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


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

IC660HHM501

Accessories
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

GEP-9145 Innovation Series Controller

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

GEP-9145 Innovation Series Controller

39

Catalog Number Structure


Catalog Number
DS208

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

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 Innovation Series Controller

GEP-9145
CADMUS
SEPTEMBER 1998

GE Industrial Systems

General Electric Company


1501 Roanoke Blvd.
Salem, VA 24153, USA
Av. L. N. Alem 619
Piso 9, Buenos Aires,
Argentina 1001
146 Arthur Street, Suite 501
North Sydney, NSW 2060,
Australia
Av. Nove de Julho; 5229
01407-907 Sao Paulo
Sao Paulo, Brazil

General Electric Company


All Rights Reserved

2300 Meadowvale Blvd.


Mississauga, Ontario,
Canada L5N 5P9
Al Cantara 200, 11th Fl.
Las Condes, Santiago, Chile
Beijing East Ocean Ctr. Rm.109
24 Jian Guo Men Wai Dajie
Beijing, China 100022
1085 Corniche EL-Nil
Garden City, Cairo, Egypt
Pasilantie 8 B1
Anjalankoski, Finland 46900

18, rue Horace Vernet,


92136 Issy-les-Moulineaux
Cedex
Paris, France
Marzahner Strasse 34
D-13053 Berlin
Germany
Praunheimer Landstrasse 50
D-60488 Frankfurt/Main
Germany
Unit 1725 17/F Pacific Trade Ctr.
2 Kai Hing Road
Kowloon Bay, Hong Kong
Via S. Girolamo
31/C Parco Massimo
Bari, Italy 70100

No. 35 Kowa Bldg.; 5th Floor


1-14-14; Akasaka 1-chome
Minato-ku; Tokyo 107, Japan
17F, Kunja Buiding
942-1 Daechi-dong, Kangnam-ku
Seoul,135-280 Korea
Zaragoza 1300 Sur; Edificio Kalos
Piso A-3; Despacho 339
6400 Monterrey, N.L., Mexico
9 Boh.Getta Warszawskiego St.
Gliwice, Poland 44-100
Kosmodamianskaya Nab 52
Bldg. 1, 6th Floor
Moscow, Russia 113054

GE Towers; 10th Floor


240 Tanjong Pagar Road
Singapore 088540
8F-2; No. 6; Ming-Chung; 2nd Rd
Kaohsiung, Taiwan
Unit 1103; 11/F Diethelm Twr. B
93/1 Wireless Road
Patumwan, Bangkok, Thailand
Apt. No. 2319
Mim Kemal Oke Cad. Lal
80200 Nisantasi, Ist, Turkey