GE PACSystems* RX3i User guide

GE
Automation & Controls
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Programmable Control Products
PACSystems* RX3i Genius Dual Bus Application Guide
Application Guide GFK-2928
PACSystems* RX3i
Genius Dual Bus
Application Guide
GFK-2928
December 2017

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GFK-2928 December 2017 i
Table of Contents
PACSystems* RX3i Genius Dual Bus Application Guide Application Guide GFK-2928
Table of Contents............................................................................................................................................................... i
Table of Figures................................................................................................................................................................ iii
Chapter 1 Introduction ................................................................................................................................................ 1
1.1 Revisions in this Manual ........................................................................................................................... 2
1.2 PACSystems Documentation ................................................................................................................... 3
1.3 Abbreviations.............................................................................................................................................. 4
Chapter 2 Overview ...................................................................................................................................................... 5
Chapter 3 Application System Architecture ............................................................................................................ 7
3.1 PROFINET Network Arrangement ........................................................................................................... 8
3.2 System and Dual Bus References............................................................................................................ 8
3.3 Dual Bus Mapping Description ................................................................................................................ 8
3.4 Development Environment ...................................................................................................................... 9
3.5 Simplified Description of Project Upgrade Steps ................................................................................. 9
Chapter 4 Toolchest Components ........................................................................................................................... 11
4.1 Add Toolchest items to your project .................................................................................................... 12
Place into User Defined Types ........................................................................................................................... 12
Place into Program Blocks................................................................................................................................... 12
4.2 Adding Dual Bus Logic............................................................................................................................. 14
Dual Bus Parameters.............................................................................................................................................. 15
Dual Bus Mapper ...................................................................................................................................................... 16
Adding a Dual Bus Configuration Block........................................................................................................ 17
Chapter 5 PLC Hardware Configuration (Primary PLC)........................................................................................ 23
5.1 LC Reference Memory Settings.............................................................................................................. 23
5.2 Transfer List Entries................................................................................................................................. 23
Input Transfer Points .............................................................................................................................................. 23
Output Transfer Points........................................................................................................................................... 23

Contents
ii PACSystems* RX3i Genius Dual Bus Application Guide GFK-2928
5.3 Configure the Built-in Ethernet Port of the CPU ................................................................................ 24
5.4 Configure the PROFINET Controller Module ....................................................................................... 25
5.5 Configure the Genius Communication Gateway Modules ............................................................... 26
Settings Tab .................................................................................................................................................................26
GENIUS Gateway Parameter Tab.....................................................................................................................26
Genius Devices...........................................................................................................................................................26
5.6 Dual Bus Function Block ......................................................................................................................... 27
Input.................................................................................................................................................................................27
Output.............................................................................................................................................................................27
Other DBUS Functionality.....................................................................................................................................28

Contents
GFK-2928 December 2017 iii
Table of Figures
Figure 1: Genius Dual Bus Combined with RX3i Hot Standby Redundancy..................................................................................5
Figure 2: RX3i Genius Dual Bus Interfaced to RX3i via Genius Gateway Modules (GCG001)................................................7
Figure 3: System and Dual Bus References....................................................................................................................................................8
Figure 4: Fault Table Display .................................................................................................................................................................................9
Figure 5: PME Toolchest Checkbox..................................................................................................................................................................11
Figure 6: Import Toolchest Drawer Menu Item .........................................................................................................................................11
Figure 7: Select Toolchest Drawer File to Import......................................................................................................................................11
Figure 8; Folders in DualBus Drawer..............................................................................................................................................................12
Figure 9: PME Form: Enter Variable Name ..................................................................................................................................................12
Figure 10: Edit Genius Bus Definition Block(s)............................................................................................................................................15
Figure 11: Edit Block for Mapping Each Dual Bus....................................................................................................................................16
Figure 12: Copy INIT_GBnn Block ....................................................................................................................................................................17
Figure 13: Paste INIT_GBnn Block ...................................................................................................................................................................17
Figure 14: Rename and Edit INIT_GBnn Block...........................................................................................................................................17
Figure 15: Genus Bus Number Assignment ................................................................................................................................................18
Figure 16: PNC Assignments ..............................................................................................................................................................................18
Figure 17: GCG Assignments –Bus A............................................................................................................................................................. 19
Figure 18: GCG Assignments –Bus B............................................................................................................................................................. 19
Figure 19: Dual Bus Parameters.......................................................................................................................................................................20
Figure 20: References by SBA of Genius Devices on Bus .....................................................................................................................20
Figure 21: Include ACTV_CSB in Input Transfer List................................................................................................................................24
Figure 22: Assign Ethernet Status Address .................................................................................................................................................24
Figure 23: Assign PROFINET Status Address ..............................................................................................................................................25
Figure 24: Disable Port Criticality (for Debug only) ..................................................................................................................................25
Figure 25: GCG Genius Status Data Reference Assignments.............................................................................................................26
Figure 26: GCG Gateway Status Data Reference Assignments ........................................................................................................26
Figure 27: GCG Baud Rate & Output at Startup Settings .....................................................................................................................26
Figure 28: Dual Bus Function Block ................................................................................................................................................................27
Figure 29: Monitor SBA Connection Status .................................................................................................................................................28
Figure 30: Switch BSM Logic ..............................................................................................................................................................................28
Figure 31: Automatic Role Switch (AUT_SW) Function Block .............................................................................................................30

GFK-2928 December 2017 1
Chapter 1 Introduction
This document provides application-level information on the functionality, configuration and application of the
logic components that support the operation of Dual Genius I/O Busses. The application solution:
•Operates upon Dual-Redundant Hot-Standby RX3i PLC platforms
•Interfaces to existing Genius I/O devices by way of PROFINET Controllers and Genius
Communications Gateway modules.
•Is scalable and configurable allowing it to service up to 16 Genius I/O bus pairs
•Allows a mixture of Genius I/O Redundancy and PROFINET System Redundancy
•Furnished as Proficy Machine Edition Toolchest items that can be added to an existing PLC
project.

Chapter 1. Introduction
2 PACSystems* RX3i Genius Dual Bus Application Guide GFK-2928
1.1 Revisions in this Manual
Rev
Date
Description
Dec-
2017
•Initial publication.

Chapter 1. Introduction
GFK-2928 December 2017 3
1.2 PACSystems Documentation
PACSystems Manuals
PACSystems RX7i, RX3i and RSTi-EP CPU Reference Manual
GFK-2222
PACSystems RX7i, RX3i and RSTi-EP CPU Programmer’s Reference Manual
GFK-2950
PACSystems RX7i, RX3i and RSTi-EP TCP/IP Ethernet Communications User Manual
GFK-2224
PACSystems TCP/IP Ethernet Communications Station Manager User Manual
GFK-2225
C Programmer’s Toolkit for PACSystems
GFK-2259
PACSystems Memory Xchange Modules User’s Manual
GFK-2300
PACSystems Hot Standby CPU Redundancy User Manual
GFK-2308
PACSystems Battery and Energy Pack Manual
GFK-2741
Proficy Machine Edition Logic Developer Getting Started
GFK-1918
Proficy Process Systems Getting Started Guide
GFK-2487
PACSystems RXi, RX3i, RX7i and RSTi-EP Controller Secure Deployment Guide
GFK-2830
PACSystems RX3i & RSTi-EP PROFINET I/O Controller Manual
GFK-2571
RX3i Manuals
PACSystems RX3i System Manual
GFK-2314
PACSystems RX3i PROFIBUS Modules User’s Manual
GFK-2301
PACSystems RX3i Max-On Hot Standby Redundancy User’s Manual
GFK-2409
PACSystems RX3i Ethernet Network Interface Unit User’s Manual
GFK-2439
PACSystems RX3i PROFINET Scanner Manual
GFK-2737
PACSystems RX3i CEP PROFINET Scanner User Manual
GFK-2883
PACSystems RX3i Serial Communications Modules User’s Manual
GFK-2460
PACSystems RX3i Genius Communications Gateway User Manual
GFK-2892
RX7i Manuals
PACSystems RX7i Installation Manual
GFK-2223
PACSystems RX7i User's Guide to Integration of VME Modules
GFK-2235
Series 90-70 Genius Bus Controller User’s Manual
GFK-2017
Series 90 Manuals
Series 90-30 Genius Bus Controller User’s Manual
GFK-1034
Distributed I/O Systems Manuals
Genius I/O System User’s Manual
GEK-90486-1
Genius I/O Analog and Discrete Blocks User’s Manual
GEK-90486-2
Genius Hand-Held Monitor User’s Guide
GFK-0121
In addition to these manuals, datasheets and product update documents describe individual modules and
product revisions. The most recent PACSystems documentation is available on the GE Automation & Controls
support website www.geautomation.com.

Chapter 1. Introduction
4 PACSystems* RX3i Genius Dual Bus Application Guide GFK-2928
1.3 Abbreviations
Abbreviation
Meaning
BSM
Genius Bus Switching Module
CPE
RX3i CPU with embedded Ethernet
GCG
Genius Communication Gateway (GCG001)
HHM
Genius Hand-Held Monitor
MRP
Ethernet Media Redundancy Protocol
PME
Proficy Machine Edition (programming & configuration software tool)
PNC
PROFINET Controller
PNSR
PROFINET System Redundancy
SBA
Genius Serial Bus Address

GFK-2928 December 2017 5
Chapter 2 Overview
Genius Dual Busses are typically deployed in applications such as that diagrammed in Figure 1, where high
availability, in particular ability to withstand faults in the I/O network and in the PLC CPU system, is required.
In the RX3i environment, Genius devices must be interfaced via the Genius Communications Module (GCG001),
which then communicates over PROFINET with the host PLC.
GCG001 supports a number of different Genius head-ends, allowing other types of I/O rack to be attached to
the Genius bus.
Figure 1: Genius Dual Bus Combined with RX3i Hot Standby Redundancy
For details, refer to the PACSystems RX3i Genius Communications Gateway User Manual, GFK-2892C or later.

GFK-2928 December 2017 7
Chapter 3 Application System Architecture
Figure 2: RX3i Genius Dual Bus Interfaced to RX3i via Genius Gateway Modules (GCG001)
A typical system consists of at least two RX3i racks, with the following components in each rack:
•One or more power supplies
•One PLC CPU module (IC695CPE330 or equivalent)
•Two RMX reflective memory exchange modules (for CPU synchronization)
1
•Fiber optic cables for the RMX modules
•One or more PROFINET Controller modules
Additionally, the system will require the following items to interface with each dual Genius I/O network:
•Four Genius Communications Gateway modules (two associated with the Primary PLC interface and
two with the Secondary PLC interface).
•Cat5 or 6 Ethernet Cables to interconnect the Gateways with the PROFINET Controllers
•Optional - interposing Ethernet switches that may be installed to provide additional MRP ring
functionality
•Optional –Connectors that provide Hand Held Monitor attachment points for each of the Genius
busses. (GE catalog number 44A736310-001-R001. Refer to Genius Hand-Held Monitor User’s Guide,
GFK-0121, page 2-9 for further information).
1
If a CPE400 is used, the RMX links are replaced with LAN3 links.

Chapter 3. Application System Architecture
8 PACSystems* RX3i Genius Dual Bus Application Guide GFK-2928
3.1 PROFINET Network Arrangement
A ring topology using MRP is the preferred arrangement. With this topology, a system may use a combination
of PROFINET System Redundancy (PNSR) devices and non-PNSR devices (specifically Genius Communication
Gateway modules).
Also, systems may incorporate managed network switches that support MRP. The approach is particularly
useful for large systems that are upgraded incrementally. In this case, Genius dual busses (each consisting of
four GCG modules –Primary A & B, Secondary A & B) may be grouped into one of multiple subrings.
3.2 System and Dual Bus References
Appl. Refs
%I Addresses
Bus A
(1..8192)
App. Refs.
%AI Addresses
Bus A
(1..8192)
Hardware Status
Addresses
(16385..32767)
Input addresses for the Backup Bus B. The addresses are
offset by the constant DI_OFST (for Discrete Inputs) or
AI_OFST (for Analog Inputs)
These addresses are used by certain types of modules to
display status, diagnostics, etc. Typical modules are CPU,
Ethernet, Serial Communications, Genius bus controllers,
Genius Communications Gateway, Profinet controller, etc.
Input addresses for Bus A. These are the principal references
used in the application’s program logic.
%I Addresses
Bus B
(8193..16384)
%AI Addresses
Bus B
(8193..16384)
DI_OFST AI_OFST
Figure 3: System and Dual Bus References
Each Genius device that has been configured to have discrete inputs must have one block of references
assigned to Bus A and a separate unique block of references assigned to Bus B. The application logic is
always solved using the references that are assigned to Bus A. There is fixed offset that specifies the location
of Bus B references relative to Bus A.
The references for analog inputs are configured in a similar fashion.
The offset for discrete inputs (DI_OFST) and the offset for analog inputs (AI_OFST), as shown above, are
recommended values. However, they may be configured independently for each dual bus pair.
3.3 Dual Bus Mapping Description
The dual-bus application evaluates the attachment state for each Genius device on both of the busses.
•If the device is attached to Bus A, then the corresponding inputs appearing in the Areferences are
valid and no further action is needed.
•If the Genius device is attached to Bus B, then the inputs appearing in the Breference area are
remapped (i.e., MOVed) into the Areference area.
•If the Genius device is not attached to either Bus A or Bus B, then the inputs will “Hold Last State”.
There are two choices for the time period that the inputs are frozen.
oNormally, the inputs are frozen for a specified time. When the period expires, the values in
the block of references are reset to OFF or 0. The preset time may be configured
independently for each pair of dual busses.
oOr, the alternate choice is to hold last state continuously until the device re-attaches to one
of the busses.
•A fault message will be posted in the PLC Fault Table if a device changes its online/offline state for the
dual bus.

Chapter 3. Application System Architecture
GFK-2928 December 2017 9
Figure 4: Fault Table Display
The message provides the slot number (S08 in the example) in which the PROFINET Controller is installed, the
device number (D004) for the Bus A GCG, the serial bus address (SBA02) for the Genius device, and either Loss
of Device (LOD) or Addition of device (AOD).
3.4 Development Environment
The software components require Proficy Machine Edition, version 9.5 or later.
3.5 Simplified Description of Project Upgrade Steps
•Convert the existing Series 90 project into an RX3i project.
•Import Software Components for Dual Bus into the Proficy Machine Edition Toolchest.
•Edit the Primary/Secondary Hardware Configurations.
•Drag the Dual Bus application components from the Toolchest into the project’s PLC Program Blocks.
•Add/Edit the Dual Bus Application Blocks:
oAdd an instance of the ladder block BUSSES in _Main.
oEnter GBusses for the name.
oEdit INIT_GB00 in BUSSES to match the configuration of the Genius devices on the first dual
bus pair.
oIf there are more dual busses then:
▪Copy, then paste the block named INIT_GBnn in BUSSES.
▪Rename INIT_GBnn by changing nn to the next bus number.
▪Edit the block contents to accommodate the configuration settings for the PNC,
GCG, and Genius device reference addresses.
▪Add a new instance of the function block DBUS.
▪Name the instance using DBnn by changing nn to the next bus number.
▪Repeat for the remaining busses, if any.

GFK-2928 December 2017 11
Chapter 4 Toolchest Components
In order to use the dual bus application components, they must first be added to the Proficy Machine Edition
Toolchest.
Click on the View Tab in PME. Then make certain that the Toolchest item is checked.
Figure 5: PME Toolchest Checkbox
The Toolchest will be displayed (normally docked on the right side of PME). Right click on the Toolchest to
display a popup menu that will allow you to import a Toolchest Drawer. Double click on the menu item Import
Drawer.
Figure 6: Import Toolchest Drawer Menu Item
A dialog box, similar to the one below, will be displayed. Navigate to the location containing the application
Toolchest components and then Import the Toolchest drawer for dual bus support by selecting DualBus.ZDRW
(or a designated upgrade filename). Click on the Open button.
Figure 7: Select Toolchest Drawer File to Import

Chapter 4. Toolchest Components
12 PACSystems* RX3i Genius Dual Bus Application Guide GFK-2928
The Toolchest now contains the DualBus drawer. Using the dropdown text box, click on DualBus. Expand the
drawer so that the individual folder items are visible as shown below:
Figure 8; Folders in DualBus Drawer
4.1 Add Toolchest items to your project
While depressing the Ctrl key, drag the following items from the Toolchest’s DualBus folders into the PLC
target. Please make certain that the items are added in the proper order:
Place into User Defined Types
Group01 –UDTs
•GCG
•G_Device
Group02 –UDTs
•G_Bus
Place into Program Blocks
When function blocks are dragged from the Toolchest into the Program Blocks collection, Proficy Machine
Edition may prompt for an entry into which a variable name must be provided.
Figure 9: PME Form: Enter Variable Name

Chapter 4. Toolchest Components
GFK-2928 December 2017 13
The blocks and corresponding entries are as follows:
Group03 –LDs
Block
Variable Name Entry
INIT_GBnn
<no name required>
INIT_GB00
IGB00
ALM_DEV
DEV
EXE_CR
CR01
Group04 –LDs
Block
Variable Name Entry
DB_SVCS
DBS
SW_BSM
SW01
AUTO_SW
Aut_Sw
Group05 –LDs
Block
Variable Name Entry
DBUS
DB00
Group06 –LDs
Block
Variable Name Entry
BUSSES
GBusses