Series 90 -70 GE Fanuc Automation

Genius
Modular

Redundancy

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 Series 90 -70 GE Fanuc Automation

GMR

• GENIUS Modular Redundancy

• Scaleable, Exclusive Elements:
• CPU
• LAN
• Input Subsystem
• Output Subsystem

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 Series 90 -70 GE Fanuc Automation

GMR

• GENIUS Modular Redundancy

• GMR is GE Fanuc’s Scaleable, Modular Application of
Standard Products in Simplex, Duplex and Triplicated
(TMR) Configurations
• Safety Critical Applications
• System De-energised - F&G
• System Energised - ESD

• TUV Approved

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 Series 90 -70 GE Fanuc Automation

GMR System
PLC A PLC B PLC C

Field
Device
Genius

Genius Genius

LOAD C
Genius

Genius Genius

D
Genius

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 Series 90 -70 GE Fanuc Automation

GMR

• GENIUS I/O Diagnostics

• Market Requirements call for a Packaged,
PLC-Based ESD System that is Easy to
Apply
• Customers Demand Scaleable Costs for
Small or non-Critical Applications
• TUV Approved - Class 6

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 Series 90 -70 GE Fanuc Automation

Certified

• Triplicated (2oo3) Fault Tolerant and Fail

Safe Controller System Certified
• TUV Approved - Class 6
• DIN V 19250 / DIN V VDE 0801 Standards
• Issued March 1995

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 Series 90 -70 GE Fanuc Automation
Genius Field Bus I/O

P C G P C G
S P B S P B
U U C U U C

Genius

Inputs are Broadcast to all Devices

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 Series 90 -70 GE Fanuc Automation
Genius Field Bus I/O

P C G
S P B
U U C

Genius
Genius

Outputs are Targeted to a Device

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 Series 90 -70 GE Fanuc Automation
Genius Field Bus I/O

P C G P C G P C G
S P B S P B S P B
U U C U U C U U C

31 30 29

Genius

GMR Mode
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 Series 90 -70 GE Fanuc Automation
Genius Field Bus I/O

P C G P C G P C G
S P B S P B S P B
U U C U U C U U C

31 30 29

Genius

GMR Mode
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 Series 90 -70 GE Fanuc Automation
Genius Field Bus I/O

P C G P C G P C G
S P B S P B S P B
U U C U U C U U C

31 30 29

Genius

GMR Mode
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 Series 90 -70 GE Fanuc Automation
Voting with 3 PLC’s Online

PLC A PLC B PLC C Duplex Output

Output Output Output Default State
0 0 0 X 0
0 0 1 X 0
0 1 0 X 0
0 1 1 X 1
1 0 0 X 0
1 0 1 X 1
1 1 0 X 1
1 1 1 X 1

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 Series 90 -70 GE Fanuc Automation
Voting with 2 PLC’s Online

PLC A PLC B PLC C Duplex Output

Output Output Output Default State
0 0 1 0
0 0 1 0
0 1 1 1
0 1 1 1
1 0 1 1
1 0 1 1
1 1 1 1
1 1 1 1

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 Series 90 -70 GE Fanuc Automation
Voting with 2 PLC’s Online

PLC A PLC B PLC C Duplex Output

Output Output Output Default State
0 0 0 0
0 0 0 0
0 1 0 0
0 1 0 0
1 0 0 0
1 0 0 0
1 1 0 1
1 1 0 1

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 Series 90 -70 GE Fanuc Automation
Voting with 1 PLC Online

PLC A PLC B PLC C Duplex Output

Output Output Output Default State
0 X 0
0 X 0
0 X 0
0 X 0
1 X 1
1 X 1
1 X 1
1 X 1

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 Series 90 -70 GE Fanuc Automation

Duplex System - 1oo2 to trip 1oo1d

PLC A PLC B

Field
Device
Genius Genius Genius

A LOAD B
Genius

SIL 2
TUV 6
Fail Safe

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 Series 90 -70 GE Fanuc Automation

Duplex System - 2oo2 to trip

PLC A PLC B

Field
Device
Genius Genius

-ve Common

A LOAD
Pending
B
Genius

SIL 2
TUV 4
Genius

16 Point Fault Tolerant

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 Series 90 -70 GE Fanuc Automation

Duplex System - 1oo2 / 2oo2 to trip 1oo2d

Quad Block Output
PLC A PLC B

Field
Device
Genius Genius Genius

SIL 3
TUV 6
LOAD C Fail Safe
Genius
Genius Genius

SIL 2
TUV 4
B D Fault Tolerant

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 Series 90 -70 GE Fanuc Automation
GMR Dual Operation

• No Single Point of Failure

• Input Voting Options in each PLC
• Logic is performed Independently by each PLC
• Outputs Voted at O/P Blocks
• GENIUS I/O Embedded Diagnostics
• Scaleable System
• Fail Safe OR Fault Tolerant

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 Series 90 -70 GE Fanuc Automation
Triplicated System 2oo3 to trip 1oo2d
PLC A PLC B PLC C

Field
Device
Genius

Genius Genius

LOAD C
Genius

Genius Genius

SIL 3
TUV 6
D
Genius

Fail Safe & Fault Tolerant

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 Series 90 -70 GE Fanuc Automation

GMR - 2oo3 Load Operation

• Attributes of GMR 1oo2 / 2oo2

• Increased Integrity & Availability
• Capability for Entire System to be
Triplicated
• Fail Safe AND Fault Tolerant

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 Series 90 -70 GE Fanuc Automation

GMR - Features

• Scaleable Redundancy Architecture

• Mechanical Isolation of System Components
• Input, Processor, Output
• Field Proven Series 90-70 PLC, Genius I/O
• Centralised
• Distributed
• High Levels of Integrity and Availability
• High Degree of Self Test and Monitoring
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 Series 90 -70 GE Fanuc Automation
GMR Input Sub-system
PLC A PLC B PLC C

Field
Devices • Three Separate Input Blocks
Genius
• Separate Genius LAN for Each Block
Genius Genius

• All PLC’s Receive All Three Inputs

Genius
• Input Autotest
LOAD Function
• Initiated By Any PLC
Genius Genius

• Performed By Each Input Block

Genius

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 Series 90 -70 GE Fanuc Automation

GMR Discrete Input Diagnostics

• Input Autotest
- Input to Input Short
Field
Devices - Stuck On Input
Genius
• Supervised Inputs
- Input Shorted High - Tri-State
• Input Discrepancy Checking
Genius

• Input Vote Adaptation

• Loss of Block
Genius

• Fault Table Entries

• App. Program Fault Contacts
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 Series 90 -70 GE Fanuc Automation
GMR Analogue Input Diagnostics
• High and Low Alarm
• Underrange and Overrange
Field
Devices • Input Open Wire
-
V
+ Genius
• Input Shorted (RTD)
• Wiring Error (RTD)
• Internal Fault
- +
Genius

V
• Input Discrepancy Checking
• Input Vote Adaptation
Genius
• Loss of Block
-
V
+
• Fault Table Entries
• App. Program Fault Contacts
Page 25
 Series 90 -70 GE Fanuc Automation

GMR System Overview

PLC A PLC B PLC C

• Three Separate PLC CPU’s

• Separate Genius
LOAD Bus LAN’s
Genius

• All PLC’s Receive And Transmit

Genius Genius

on all Three LAN’s

• Application Data Initialisation
Genius

(Auto Start-Up)
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 Series 90 -70 GE Fanuc Automation
GMR PLC Sub-system Diagnostics
PLC A PLC B PLC C

• Embedded Power Up and Runtime Module Tests

• Extensive Comprehensive Memory testing
• Automatic Data Fault and System Fault Detection
• Shared / Distributed Autotest Responsibilities
• Automatic PLC and I/O Fault Tables
• Utilises Inter - PLC Communication Busses
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 Series 90 -70 GE Fanuc Automation

GMR Logical Voting

OUTPUT ADDRESS
INPUT ADDRESS %Q
%I
SIMPLEX
VOTED INPUTS USER PHYSICAL
Single APPLICATION OUTPUTS
Inputs PLC TEST SIMPLEX
SINGLE INPUTS LOGIC TEST LOGIC 2oo3 VOTED
LOGIC
OUTPUT
SIMPLEX, DUAL
A or TRIPLE INPUTS “H” PATTERN
LOGICAL
SIMPLEX, DUAL OUTPUTS
B or TRIPLE INPUTS
“H” PATTERN
SIMPLEX, DUAL
Simplex, C or TRIPLE INPUTS
PHYSICAL
Dual or OUTPUTS
Triplicated
Inputs FAULT-
TOLERANT
INPUT VOTING 2oo3 VOTED
LOGIC OUTPUTS

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 Series 90 -70 GE Fanuc Automation
GMR Output Sub-system
PLC A PLC B PLC C

• Standard ‘H’ Pattern

Genius

• Sink and Source Blocks Geniu

s
Geniu
s

• Each Block Receives Command from

LOAD
All Three PLC’s Genius

Geniu Geniu
s s

• 2oo3 Vote in the Output

Subsystem
• Discrepancies are Reported to Each
CPU
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 Series 90 -70 GE Fanuc Automation
GMR Output Diagnostics
• Output Autotest
- Open Circuit Load - Load Shorted Low
- Open Circuit Output - Load Shorted High
- Stuck On Output - Output to Output Short
- Stuck Off Output

• Output Overload Genius Genius

• Output Overtemp C
A LOAD

• Output Discrepancy Checking Genius Genius

• Loss of Block
B D
• Fault Table Entries
• App. Program Fault Contacts
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 Series 90 -70 GE Fanuc Automation

GMR - Input / Output Testing

• Automatic, Periodic
• Complete Continuity Checks - Sensor to Load
• Complete Output Fault Coverage and Isolation
• Bad Block
• Shorted or Open Load
• Wiring Faults
• Diagnostics Reported to Operator Interface
• Genius Hand Held Monitor
• Programming Terminal
• CIMPLICITY HMI
• DCS
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 Series 90 -70 GE Fanuc Automation

GMR - The Solution

• Each Point Configurable - 1oo1, 1oo2, 2oo2, 2oo3

• All Voting and Diagnostics Transparent to User
• Inputs Broadcast and Voted at PLC, Outputs
Voted at Load
• Program Design as per Single PLC System
• Series 90-70 GMR CPU’s Provide Continuous
Internal Error Checking and External Discrepancy
Checking
• PLC Program Equivalence Checks

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 Series 90 -70 GE Fanuc Automation

GMR - The Solution

• On-line Diagnostics Expose System Failures in I/O

and each PLC
• Diagnostics Automatically Reported Through
Built-in “Fault Table”
• On-Line Repair, Modular Replacement Philosophy
• Configurable Fault Degradation Path:
• 3 to 2 to SHUTDOWN (TUV)
• 3 to 2 to 1 to SHUTDOWN

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 Series 90 -70 GE Fanuc Automation

GMR - Competitive Strengths

• Flexible
• Independent Manufacturer
• Scalability - Configurable Redundancy
• Fully Isolated CPU’s
• Distributed Intelligent I/O
• No Fuses
• Hand Held Monitor Reduces Installation and
Maintenance Periods

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