GE PACSystems* RX3i Application Manual

For Public Disclosure 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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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

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

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

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.

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

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.

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

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.

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.

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 A references are valid and no further action is needed. • If the Genius device is attached to Bus B, then the inputs appearing in the B reference area are remapped (i.e., MOVed) into the A reference 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. o Normally, 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. o Or, 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.

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: o Add an instance of the ladder block BUSSES in _Main. o Enter GBusses for the name. o Edit INIT_GB00 in BUSSES to match the configuration of the Genius devices on the first dual bus pair. o If 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.

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

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

GFK-2928 December 2017 13 The blocks and corresponding entries are as follows: Group03 – LDs Block Variable Name Entry INIT_GBnn 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

14 PACSystems* RX3i Genius Dual Bus Application Guide GFK-2928 4.2 Adding Dual Bus Logic In the ladder block named _Main, insert a new row at the beginning of the program. While holding down the Ctrl-key, drag the program block named BUSSES and place it into the first rung. This will create a new instance of the block. It will require a name: enter GBusses for the name. Zoom into the ladder block named BUSSES. Note that the program block already contains multiple rungs of logic. Program blocks in these rungs perform the following: INIT_GB00 This structured text block defines the parameters for a dual bus (the instance is named IGB00 for “Initialize Genius Bus 00”). The block must be edited to match the specific design characteristics of the system. DBUS This ladder block maps the discrete and analog inputs for the dual bus (the instance is named DB00). It does not require additional editing. AUTO_SW This ladder block provides a simple automatic role switching method (the instance is named Aut_Sw). It does not require additional editing, but you may wish to modify or enhance the PLC failover operation. The logic at this point is sufficient to service one pair of dual busses. If there are more dual busses, then additional rungs will be required.

GFK-2928 December 2017 15 Dual Bus Parameters Select the function block in the rung that immediately follows the comment rung containing the text “Initialize the Genius Bus definition blocks”. Double-click on the function block to zoom into, and explore the logic that is contained in the block. This block will require editing in order to enter parameters that define the operation and devices on the corresponding dual bus. Figure 10: Edit Genius Bus Definition Block(s) Note the variable on the left side of the function block. This a “user-defined type” that contains the detailed information specific to the dual bus. When the function block executes, the user-supplied entries present in the structured text are assigned to the members of the bus variable. NOTE: A new variable must be declared for each additional dual bus.

16 PACSystems* RX3i Genius Dual Bus Application Guide GFK-2928 Dual Bus Mapper Each dual bus will require a separate instance of the DBUS function block. In this case the block refers to the first dual bus. The name DB00 relates to the first bus. Figure 11: Edit Block for Mapping Each Dual Bus Note the bus variable on the left side of the function block. This passes the configuration parameters (that were set by INIT_GB00, or INIT_GBnn) into the dual bus mapping logic.

GFK-2928 December 2017 17 Adding a Dual Bus Configuration Block Each dual bus requires the addition of a unique configuration block. To add a block, follow the steps below: 1. In the Navigator pane, right-click on INIT_GBnn. (This block is the general template, since all of its entries have been initialized to zeroes). 2. A pop-up menu will be displayed. Click on Copy. Figure 12: Copy INIT_GBnn Block 3. Right-click on Program Blocks in the Navigator pane. The following pop-up menu will be displayed: Figure 13: Paste INIT_GBnn Block 4. Click on Paste Block. 5. Because the block already exists, Proficy Machined Edition will prompt for further action. Click on the Duplicate button. 6. A new copy of the function block will be added to the Program blocks in the Navigator pane. Rename the block by editing the Name in the Inspector pane. The name should reflect the bus number that will be edited in the configuration entries. Figure 14: Rename and Edit INIT_GBnn Block 14. Editing the Configuration Block

18 PACSystems* RX3i Genius Dual Bus Application Guide GFK-2928 Click and zoom into INIT_GBnn, so that the “soft” configuration parameters associated with the dual bus may be updated. (Note: in this case nn represents any of the dual busses that have been included in the project). The various parameters are described in the following paragraphs. Dual Bus Number Figure 15: Genus Bus Number Assignment BUS.NUM The bus number provides a bus identity to various software components. Each dual bus must have a unique value that is in the range of 0 to 15. PNC Configuration Figure 16: PNC Assignments BUS.PNC_SLOT2 The PNC slot number is used to identify the slot location in which the PROFINET controller is installed. (Up to four PROFINET controllers may be installed in each CPU rack). BUS.PNC_ADD The PNC address is the input reference that the PROFINET controller utilizes to return its status and diagnostic information. It is recommended that the reference should be placed in the upper segment of the discrete input references (%I16465 and above). 2 If using an embedded PROFINET Controller in a CPE400, use slot 0 here. If using an embedded PROFINET Controller in a CPE330, use the slot number location of the CPU itself.

GFK-2928 December 2017 19 Genius Communication Gateway Modules Figure 17: GCG Assignments – Bus A BUS.GCG_A.PRI_NUM The PROFINET Device Number for the Primary PLC Gateway module attached to Bus A. BUS.GCG_A.SEC_NUM The PROFINET Device Number for the Secondary PLC Gateway module attached to Bus A. BUS.GCG_A.PSDA The PROFINET Status/Diagnostic bits for the Primary PLC Gateway module attached to Bus A. BUS.GCG_A.GSDA The Genius Device Status bits for the Primary PLC Gateway module attached to Bus A. Figure 18: GCG Assignments – Bus B BUS.GCG_B.PRI_NUM The PROFINET Device Number for the Primary PLC Gateway module attached to Bus B. BUS.GCG_B.SEC_NUM The PROFINET Device Number for the Secondary PLC Gateway module attached to Bus B. BUS.GCG_B.PSDA The PROFINET Status/Diagnostic bits for the Primary PLC Gateway module attached to Bus B. BUS.GCG_B.GSDA The Genius Device Status bits for the Primary PLC Gateway module attached to Bus B.

20 PACSystems* RX3i Genius Dual Bus Application Guide GFK-2928 Dual Bus Parameters Figure 19: Dual Bus Parameters BUS.DEF_TO The Default Timer Preset establishes the time interval (in milliseconds) during which inputs are frozen while a device is missing from Bus A AND from Bus B. BUS.DEF_HLS This parameter (a Boolean) determines the behavior of a missing device: • If the parameter is set to 0, the inputs for that device will default to OFF or 0 after the Default Timer expires. • If the parameter is set to 1, the inputs for that device will be frozen in their last state until the device is reattached to either Bus A or Bus B. BUS.DI_OFST This applies to discrete inputs. It is the reference offset between a discrete input configured on Bus A and the alternate address on Bus B. For instance, a device configured at %I0001 on Bus A must be configured at %I (1+DI_OFST) on Bus B. The offset must be in multiples of 8 (i.e., on a byte boundary). BUS.AI_OFST This applies to analog inputs. It is the reference offset between an analog input configured on Bus A and the alternate address on Bus B. For instance, a device configured at %AI0001 on Bus A must be configured at %AI (1+AI_OFST) on Bus B. Figure 20: References by SBA of Genius Devices on Bus BUS.Devices[nn].DI_Add This parameter applies to devices that contain discrete inputs. It is the starting reference assignment for the device installed at Serial Bus Address nn. BUS.Devices[nn].DI_Len This parameter applies to devices that contain discrete inputs. It is the number of inputs (i.e., length) associated with the device installed at Serial Bus Address nn. BUS.Devices[nn].DQ_Add This parameter applies to devices that contain discrete outputs. It is the starting reference assignment for the device installed at Serial Bus Address nn. BUS.Devices[nn].DQ_Len This parameter applies to devices that contain discrete outputs. It is the number of outputs (i.e., length) associated with the device installed at Serial Bus Address nn. BUS.Devices[nn].AI_Add This parameter applies to devices that contain analog inputs. It is the starting reference assignment for the device installed at Serial Bus Address nn. BUS.Devices[nn].AI_Len This parameter applies to devices that contain analog inputs. It is the number of inputs (i.e., length) associated with the device installed at Serial Bus Address nn. BUS.Devices[nn].AQ_Add This parameter applies to devices that contain analog outputs. It is the starting reference assignment for the device installed at Serial Bus Address nn. BUS.Devices[nn].AQ_Len This parameter applies to devices that contain analog outputs. It is the number of outputs (i.e., length) associated with the device installed at Serial Bus Address nn.

GFK-2928 December 2017 21 NOTE: Devices that contain outputs must be configured so that the dual mapping routine can post loss-of-device or addition-of-device messages. Also, the device status (i.e., the presence on either Bus A or Bus B) is shared between the Primary and Secondary PLCs for the purpose of Automatic Role Switching (if enabled).

5.1 LC Reference Memory Settings In the Hardware Configuration (Primary) double-click on the RX3i CPU module to display the configuration settings. Click on the Memory tab and adjust the upper memory limits. The minimum settings are shown below: %AI Analog Input 16384 %AQ Analog Output 8192 %R Register Memory 32640 %W Bulk Memory 65536 Symbolic Discrete 65536 Symbolic Non-Discrete 65536 I/O Discrete 65536 I/O Non-Discrete 65536 5.2 Transfer List Entries Input Transfer Points %I configured for length=0 %Q (as needed) %M (as needed) %G (as needed) %AI configured for length=0 %AQ (as needed) %R (as needed) %W (as needed) Output Transfer Points %I configured for length=0 %Q typically configured to the highest reference used for physical outputs, as a minimum %M (as needed) %G (as needed) %AI configured for length=0 %AQ typically configured to the highest reference used for physical outputs, as a minimum %R (as needed) %W (as needed)

24 PACSystems* RX3i Genius Dual Bus Application Guide GFK-2928 Optionally, there is one symbolic variable that may be included in the synchronized data transfer list. It is located in the program logic block named AUTO_SW. The variable ACTV_CSB must be included in the Input Transfer List if you wish to perform automatic role switches based upon the loss of devices on a GCG. Figure 21: Include ACTV_CSB in Input Transfer List 5.3 Configure the Built-in Ethernet Port of the CPU The RX3i CPU includes two built-in Ethernet ports that share an 80-bit diagnostic/status reference. The recommended starting reference is %I16385. Figure 22: Assign Ethernet Status Address Note that there are additional port settings for LAN1 and LAN2. These will require configuration entries as well.

GFK-2928 December 2017 25 5.4 Configure the PROFINET Controller Module The PROFINET Controller Module has a 32-bit diagnostic/status reference. The recommended starting reference is %I16465 (the next available reference following the Ethernet port status reference). Figure 23: Assign PROFINET Status Address NOTE 1: For each slot in which a PROFINET Controller is installed, the Primary module and the Secondary module will always have identical Status Addresses. (However, the PROFINET Controllers from one slot to another will have separate, unique addresses). NOTE 2: For the purposes of early project development/debug, it may be simpler to disable the port criticality parameters. However, these should be enabled before the project is installed in an operating environment. Figure 24: Disable Port Criticality (for Debug only)

26 PACSystems* RX3i Genius Dual Bus Application Guide GFK-2928 5.5 Configure the Genius Communication Gateway Modules Settings Tab Genius Status Data The GCG provides 32 bits that indicate status information on devices associated with the GCG’s Genius Bus. The bits indicate the attachment state for a device. Bit 0 corresponds to a device at Serial Bus Address 0. Bit 31 corresponds to a device at Serial Bus Address 31. ON=Attached; OFF=Missing. Refer to the PACSystems RX3i Genius Communications Gateway User Manual, GFK-2892, Section 5.1.2. Figure 25: GCG Genius Status Data Reference Assignments Gateway Status Data The GCG provides 32 bits of status information for the network (MRP, Port Availability), Genius Device Fault state, and GCG Module OK. Refer to the PACSystems RX3i Genius Communications Gateway User Manual, GFK-2892, Section 5.1.1. Figure 26: GCG Gateway Status Data Reference Assignments NOTE: The reference addresses in the Primary group and the Secondary group must be configured identically. For example, in Figure 25, the Genius Status Data reference for Primary PLC, Dual Bus 0, Genius Bus A is %I16529. The Secondary PLC, Dual Bus 0, Genius Bus A is also configured for %I16529. Similarly for the Gateway Status Data (Figure 26). GENIUS Gateway Parameter Tab Baudrate This setting must be configured to match the current Genius bus baud rate characteristic. Output at Startup This parameter must be set to enabled. Figure 27: GCG Baud Rate & Output at Startup Settings Genius Devices Refer to the PACSystems RX3i Genius Communications Gateway User Manual, GFK-2892C or later, for instructions on configuring I/O devices that are attached to the GCG.

GFK-2928 December 2017 27 5.6 Dual Bus Function Block The main function of the Dual Bus (DBUS) function block is to remap the discrete and analog inputs from the backup bus to the main bus by monitoring the status bits of the Genius devices that are installed on the dual bus pair. Figure 28: Dual Bus Function Block These are the external connections: Input DB This receives the Genius bus parameters (via a variable of “user defined type” G_Bus). Note that the parameters are configured using the function blocks derived from either INIT_GB00 or INIT_GBnn. Output PNCST Provides a copy of the status information for the associated PROFINET Controller module. A_PSD Provides a copy of the Genius Communication Gateway status information from Bus A. B_PSD Provides a copy of the Genius Communication Gateway status information from Bus B. DSB_A Provides a copy of the device connection status for all Configured Genius devices on Bus A. DSB_B Provides a copy of the device connection status for all Configured Genius devices on Bus B. CSB: Provides device connection status for all configured Genius devices on the dual bus pair.

28 PACSystems* RX3i Genius Dual Bus Application Guide GFK-2928 Other DBUS Functionality Alarms Posted in PLC Fault Table LOD An internal function that posts Loss-of-Device if the device is not attached to either Bus A or Bus B, and the default timer has expired. The time-stamped message appears in the PLC Fault Table. AOD If the device has been offline, this internal function posts Addition-of-Device if the Genius device successfully logs onto either Bus A or Bus B. The time-stamped message appears in the PLC Fault Table. Real-time View of Genius Devices on Dual Busses Device Status Bits Zoom into the block to observe the current connection status for all configured Genius devices on the dual bus pair. Four rungs display the device status on Bus A and Bus B. The index inside the brackets correspond to the Genius Serial Bus Address. Figure 29 demonstrates the logic for monitoring SBA 0 through 7, so it needs to be expanded to cover the entire bus. Figure 29: Monitor SBA Connection Status Switch Devices on Busses SW_BSM Zoom into the block to display the Switch BSM (SW_BSM) function block. This function block allows the user to switch a specified Genius device to either Bus A or to Bus B. Figure 30: Switch BSM Logic NOTE: The highlighted elements may be used to control and execute the Switch BSM function.

GFK-2928 December 2017 29 User Accessible Inputs EXE Initiates the execution of a bus switch operation. This may be done by selecting the contact at the top right of the function block and then turning the reference ON using a right-click. Note: do not force this reference. It will automatically reset. SBA This variable contains the value (i.e., the Serial Bus Address) for the Genius device that is to be switched. You may change this value by selecting the variable and then depress the Control key and Enter key simultaneously. TO_A Issues a datagram to switch the specified device to Bus A (if it is on Bus B currently). A fault will be reported if the device is already connected onto Bus A. This reference may be turned on by selecting the contact and then right click. The reference maintains its state. NOTE: The function will turn ON its fault output if TO_A and TO_B are both ON or both OFF. TO_B This is similar to TO_A, except that it applies to switching a device to Bus B. Outputs OK The function executed successfully. BSY The function is busy executing a communication request that has been issued to the associated PROFINET Controller module. Typically, this will be related to the current Bus Switch event. FLT The bus switching request was not completed due to an error in the COMMREQ structure, a fault related to the GCG/PNC/Genius device, or a timeout because a component is not available. ST_LO The value of the low-order word of the COMMREQ. Refer to the GCG User Manual to interpret the result. ST_HI The value of the high-order word of the COMMREQ. Refer to the GCG User Manual to interpret the result.

30 PACSystems* RX3i Genius Dual Bus Application Guide GFK-2928 Automatic Role Switch Zoom into the DBUS block to display the Automatic Role Switch (AUT_SW) function block. This function block allows the user to transfer control from the current Active PLC to the current Backup PLC in the event that a GCG associated with the Active PLC fails. While the function block is enabled, it will evaluate the Genius combined status bits that are received from the Active PLC and compare them with the Genius combined status bits in the Backup PLC. The comparison is performed within the Serial Bus Address range of 01..29. If any bit in the Backup PLC is ON while it’s comparable bit in the Active PLC is OFF, a corresponding timer will be enabled. If the timer expires, a service request will be issued to effect a role switch. Figure 31: Automatic Role Switch (AUT_SW) Function Block EN_AUTO This Boolean reference determines if automatic switching is active in the Backup PLC. SP The timer preset that is applied to the bit comparisons. CSB This should not be changed. (It is the reference to the Combined Status Bits). NUM This should not be changed. (It is the reference to the Bus Number [0..15]).

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