Genius II Wp Gft844.PDF

GEIntelligent Platforms

Genius™ IIModernizing Genius installations with PROFINET

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Genius in the 21st century

GE introduced the Genius™ fieldbus network in 1985, and it continues to be sold today. With an installed base of tens of thousands of units, its impact on industrial automa-tion and control is widespread and the application of Genius I/O diverse. This paper is intended to help guide the reader with various modernization strategies, ranging from straight-forward controller modernization to full-fledged updates of an entire system.

A significant portion of this paper will focus on migrating Genius based systems to Genius II, GE Intelligent Platforms’ next generation of PROFINET-based Genius offerings. Whether you are interested in performance upgrades, enhancing your existing system with new features, or understanding what our new Genius II products can do for you, this guide will point you in the right direction. You are in complete control of how and when to augment or update your system using one or more of the strategies described in the following sections.

Devices and Components of a Typical Genius I/O System•Geniusblocks•90-70remoteI/Oscanner•FieldcontrolI/Ostation•Communicationbusandtermination•Buscontrollers•Handheldmonitor•Personalcomputerinterfacemodule(PCIM)•Third-partyGeniusdevices

Modernizing Genius – an OverviewIn2011,GEintroducedPROFINETsupportforthePACcontrollerfamily.Ourcompanyremains committed to the PROFINET standard, selecting it as our flagship Ethernet-based network. Selecting PROFINET as the communications medium for the next generation of Genius was an obvious choice. We have married the flexibility of an open standard(PROFINET)togetherwiththehighperformanceofmodernnetworks,andtherich feature set and robustness of Genius I/O to create Genius II.

GE has a reputation for enabling customers to keep their installations up to date via world-class support and modernization strategies. To that end, Genius II has been designed from the ground up to be both a logical modernization path and next-generation I/O product, without compromise. For customers wanting to migrate some or all of their Genius instal-lation**, we offer Genius II I/O in a form factor that allows them to leave field-side wiring in place. For new installations, we offer a form factor that utilizes proven RX3i I/O on a single-slotbase–thesameI/OusedinRX3iCPUandPNSrack-basedsystems!

Genius II: Modernizing Genius installations with PROFINET

** GE Intelligent Platforms manufactured and branded product only

Genius II with RX3i IO

GeniusIIwithCompatibleField-sidewiring

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Acronyms Used in this DocumentGBC . . . . . . . . . . . . . . . . . . . . . . . . . GeniusBusControllerGMR . . . . . . . . . . . . . . . . . . . . Genius Modular RedundancyMRP . . . . . . . . . . . . . . . . . . . . . Media Redundancy ProtocolPGG . . . . . . . . . . . . . . . . . GeniusCommunicationsGateway

PNC . . . . . . . . . . . . . . . . . . . . . . . . . . PROFINETControllerPNS . . . . . . . . . . . . . . . . . . . . . . . . . . . PROFINET ScannerSBA . . . . . . . . . . . . . . . . . . . . . . . . . . . SerialBusAddressSIL3 . . . . . . . . . . . . . . . . . . . . . . . . Safety Integrity Level 3

Genius Genius ii notes

Genius Analog & Discrete I/O Blocks • • Each Genius I/O Electrical Assembly has an equivalent Genius II catalog number

Genius I/O Diagnostics • • Genius II I/O supports all diagnostics available on Genius I/O

Field Wiring • • Genius II I/O is compatible with Genius I/O field wiring

Communication Bus Genius PROFINET PROFINETprovides100Mbpsbandwidthwithupto10kmreach(/wfiber)

I/O Performance • • Genius II I/O performance meets or beats Genius I/O

Programming • • Genius II I/O configured with GSDML file

Genius and Genius II, a Comparison

Genius PRoFinet notes

I/O update cycleToken Ring (upto32devices)

Configured

Data Integrity 6bitCRCStandard TCP/IP

Checksums

Global Data Support Via Genius Global Data

Bus Redundancy DualBus Ring Ring topology provides same level of protection as dual bus.

Network Performance 153.6kBaud(maximum)

100Mbit,1Gig

TheRX3iPNCandRX3iPNSsupport1Gig,theVersamaxPNS,PGGandGeniusIIblocksare100Mbitdevices.

Devices per Controller (GBC/PNC) Upto32 Upto64

MediaVarious, typi-cally shielded twisted pair

StandardCat5 or Fiber

Genius and PROFINET Compared


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Modernization OptionsModernization options and strategies employed will depend on thedevicesbeingused,goalsoftheupgrade(increasedperfor-mance,lifecycleconcerns,etc.).Mixandmatchtheoptionsbelowthat best meet the needs of your system.

Migrating Your Control System Containing Genius I/OGenius I/O is supported on several GE products:

•PACSystemsPLCs(Rx7i,RX3i,andRXi)

•90-70PLCs•90-30PLCs•Series6andSeries6PlusPLCs•Series5PLC•PersonalcomputersviaaPCIMmodule

ThispaperaddressesmodernizationofPACSystems,90-70,and90-30systemsthathaveGeniusI/Oconnecteddirectlytothecontroller. For other configurations, please contact GE for recom-mendations. Email [email protected]

item uPGRade Path notes

90-70 System RetrofitwithRx7iorRX3i ThebestchoicebetweenRx7iorRX3idependsonwhatGeniusfunctionsareutilized.GE can assist with a recommendation.

90-30 System Retrofit with RX3i

Field Control I/O Station Review I/O mix of the field control station.

90-70 Remote I/O Scanner (GR7) 90-70conversionrackwithRX3i PNS

The90-70conversionsystemwouldreplacethe90-70rackwithanRX3iPNShead-endandRX3iIO.The90-70fieldwiringwouldberetained.

GMR GMR modernization is out of scope for this document. A separate SIL3 program is in progress.

Dual Bus (using Bus Switching Module (BSM))

The ring topology of PROFINET can provide equiv-alent or better redundancy

Refer to the Network Redundancy with PROFINET and MRP white paper for addi-tional details.

Handheld Monitor Functionality will be provided by alternative device.

Hot Standby CPU Redundancy CPURedundancywithPROFINET BumplesssynchronizationbetweenCPUsystems,switchingcontrolofI/O

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Augment your System with PROFINETFor customers looking to expand their system, PROFINET can be usedinadditiontoyourexistingGeniusnetwork(s).OneormoreRX3iPNCmodulescanbeaddedtoyourRX3isystem,enablingawidevarietyofI/O(aswellasothermoduletypes)tobeusedin your system. Genius and PROFINET can coexist, and you can progressively migrate your Genius I/O to PROFINET.

Using Genius I/O in a PROFINET NetworkGE is committed to supporting our customers through both evolutionary and revolutionary developments of control systems. PROFINET is the network of choice for moving forward, and we willthereforebeintroducingaGeniusCommunicationsGateway(PGG)devicethatallowsGeniusdevicestobeconnectedtoandcontrolled by a PROFINET network. When the PGG is coupled with anRX3icontrollerwithfourPNCs,acustomercanconvertupto32Geniusbusesandupto1,024Geniusdevicestooperateonthe PROFINET network.

PROFINET over Genius CablingMany of our customers have installed long runs of Genius wire between their control system and their I/O, and replacing this wiring may be very difficult or extremely expensive to replace. Although Ethernet wiring is increasingly common, we under-stand that for many customers long Genius wire runs remain a viable network. For this purpose, we are validating the possibility of utilizing technology similar to that found on DSL modems to transport the PROFINET protocol with MRP over Genius wiring. We expect to update the current section of this document in the secondhalfof2012withtheresultsofthisresearch.

Replacing Genius Electronics with Genius IIUpgradingfieldwiringisanonerouspartofmanyupgradeprocesses. To alleviate this challenge, we are providing customers with the option of updating to a PROFINET network while leaving existing field wiring in place. Genius II has been designed to allow simple retrofits to existing Genius blocks using a three-step process:

1. Replace Genius Electrical Assembly with Genius II Electrical Assembly(thefieldwiringisuntouched)

2. Discard Genius bus connection3.ConnectEthernetcopperorfiberopticscablestotheGeniusII

electrical assembly and configure the device as a PROFINET sub-slot device.

Genius II stores the block configuration information along with the user application. This information will be stored to the block as will all other PROFINET devices.


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Genius RedundancyGenius I/O can be used in several different redundant configura-tions including:

• Geniusbusredundancy(usingaBSM)• HotstandbyCPUredundancy• Duplexredundancy• GMR

Genius Bus RedundancyGenius bus redundancy provides two network paths to Genius devicesviaaBusSwitchingModule(BSM).WithGeniusII,PROFINETwithMediaRedundancyProtocol(MRP)providesbetterperfor-mancewithlessnetworkinfrastructure.UsingMRP,thenetworkis configured as a ring topology, and network link failures can be detected in as little as 3 µs. Refer to the white paper, Network Redundancy with PROFINET and MRP, for additional details.

Genius Devices Configured for Hot Standby ModeInthismode,Geniusdevices“prefer”datafromSBA31overdatafromSBA30.Ifonesystemfailstoprovidedatainaspecificamountoftime,thedevicewillswitchtousethedatafromSBA30.ThebehaviorofPROFINETdevicesinaCPUredundancywithPROFINETsystem will be similar to devices configured for hot standby mode inaCPUredundancysystemusingGenius.RefertothesectionentitledCPURedundancywithPROFINETforadditionaldetails.

Genius Devices Configured For Duplex ModeUnlikehotstandbymode,SBA30and31aretreatedequallywhenconfiguredinduplexmode.IfbothSBA30and31areprovidingdata(i.e.,nofailures)andtheoutputvaluesfromthecontrollersare different, the outputs will be set to a preconfigured state. In a failure scenario where one or the other controller fails, the block continues to output the values from the active controller.

PROFINET does not provide native support for duplex mode. It does, however, have provisions for application specific behavior “above” the PROFINET layer. Some third parties already use this strategy, and we are investigating a similar scheme to mimic duplex mode for our controllers and I/O.

Input VotingThe PROFINET specification does not provide a native concept of inputvoting.UnlikeGenius,inputvaluesareNOTbroadcast;every-thing is communicated in a point-to-point manner. For a redundant controllertoseetheinputsfromtheotherunitsPNC,thedatawould need to be transferred in the Redundant Transfer List.

We plan to provide input voting and configuration of inputs as a pair by extending PROFINET via provisions provided by the PROFINET specification. Input voting could be done by the appli-cation program, and we are also investigating voting within the PNCmodule.

Other Genius ConfigurationsGenius supports additional configurations beyond those described in prior pages of this document. These include:

•SharedstandbyCPU(analternativeCPUisconfiguredusingbuscontrollerswithSBA30)

•Distributedcontrol(twoormorebuscontrollerssendcontroloutputstodifferentI/Odevicesonthesamebus;thesebuscontrollersmaybeinthesameordifferentPLCSystem)

If your Genius installation uses either of these configurations, please contact GE Intelligent Platforms to discuss your options in more detail.

CPU Redundancy with PROFINETGE has an active development that updates our hot standby CPUredundancyproducttoutilizePROFINETforitsI/O.LikethehotstandbyCPUredundancyofthe90-70andPACSystemsplatforms, the two systems remain synchronized via reflec-tive memory links. One system controls the I/O. Failure of a one system results in control being switched to the second unit.

GeniusBusRDNvs.ProfinetRing

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Output Behavior using PROFINETThe PROFINET specification defines how outputs behave when a controller is lost. The devicescanbeconfiguredto“HoldLastState,”“SettoZero,”or“SettoConfiguredValue.”Whenusedinredundancy,alossofthecontrollerwillfirsttransitionthedevicesto“HoldLast State.” Assuming the other controller is running, the devices will then be controlled by the backup controller. If the second controller does not take over in a specified amount of time, the devices will then transition to their configured state.

Conclusion

The Genius network is a key component of many control systems, even after more than 25 years of use, and it will continue to be an integral of many control systems for years to come. At the same time, needs change, and GE Intelligent Platforms is committed to supporting our customers whether they choose to update their systems now, or in the future. Numerous modernization strategies and options can be employed to enhance andextendthefunctionalityoftheseinstallations.Usetheoptionsthatworkbestforyour installation at a pace that is best for you.


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GE Intelligent Platforms Contact Information

Americas: 1 800 433 2682 or 1 434 978 5100Global regional phone numbers are listed by location on our web site at www.ge-ip.com/contact

www.ge-ip.com

©2012GEIntelligentPlatforms,Inc.Allrightsreserved.*TrademarkGEIntelligentPlatforms,Inc.All other brands or names are property of their respective holders.


Frequently Asked Questions

1. Will GENIUS II have both copper and fiber option with SFC?

Yes. Genius II will support both copper and fiber on the same block.

2. Do we have more information on the SHDSL modem?

OurtestshowsthatSHDSLmodemsolutionwouldwork.We will update the Genius customer white paper with more information later.

3. How do we assemble the RJ45 connector on the Genius cable?

NeedtocutandrewiretheGeniuscabletoRJ45connector.

4. Can we still have the ring network with the Genius cabling?

Yes.

5. What about the speed between Genius cabling and Profinet (Ethernet cable)?

The expected speed is around 1.5Mbps if Genius cable is used insteadofCAT5Ethernetcable,whichisenoughforthe32nodes.

6. How many blocks can we have on a single Profinet scanner?

Upto64onasingleRX3iPROFINETController(PNC).AnRX3irackcanhaveupto4PNCs.

7. What is the maximum blocks can we have on a single RX3i or RX7i CPUs? Now and in the future….

Upto256.Wecando128atthemoment,butwillextendto256 in the following release this year.

8. Are we going to have a new base as well?

No, Genius II blocks can be used with the existing base, which will continue to be sold.

9. Will Genius II be compatible with Phase A terminal bases?

No,weplantosupportPhaseBterminalblocksonly.

10. How will GMR modernization be managed?

As a part of the Genius II development program, new SIL 3 functional safety modules are being developed. They will have the same form factor as our Genius II modules, and modernization will be carried out as with conventional Genius II modernization. As such, the field wiring will be left in place, connected to the existing base. The GMR module will be replaced by a new SIL 3-compliant module, which will be connectedtoanewPROFINETbus.Controllersthatcomplywith SIL 3 functional safety requirements are also being developedthatwillreplacethe90-70controllersusedinGMRinstallations. GE intends to provide tools that will simplify the transitionfrom90-70applicationcodetocodethatcomplieswith SIL 3 functional safety standards.

Genius II Wp Gft844.PDF

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