g 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 Lloyds’s 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. GE’s 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 1

Overview
Innovation Series™ controllers are specifically designed for application in large
The pre-emptive multi-tasking
integrated drive systems and high performance hydraulic regulators. Each controller
feature allows the scheduled
has a pre-emptive multi-tasking operating system with revolutionary networking and
execution of a high priority 
diagnostic features. The Windows -based Control System toolbox provides unique
control task to interrupt the
execution of a low or medium configuration and monitoring tools with an integrated Graphics Window, Data
priority control task. 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 ACL Form Factor
• Primary controller in the system • High speed coordination of drives
• Interface between sequencing logic • Tension regulation in a coordinated
in programmable logic controller line
(PLC) and drives in the system • Coil diameter calculation in paper
• Mill stand control in the metals and metal applications
manufacturing industry

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 CIMPLICITY HMI Control System Control System

Viewer Server Toolbox Toolbox

Ethernet

Innovation Series
Controllers
Genius

Field Control
DLAN+
ISBus

ISBus
+ + +
- AC - AC - AC

AC/DC2000 AC/DC2000 AC/DC2000 Innovation Innovation Innovation

Series Series Series
Motor Control Layer
Application Control Layer

Innovation Series controllers system configuration in a general purpose sequencing application

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 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 CIMPLICITY HMI CIMPLICITY Control System

Viewer Server Control or LM90 Toolbox

Ethernet
Series 90-70
Genius Bus

Genius Bus
Ethernet

Ethernet
CPU

CPU

Innovation Series
Series 90-70
Controllers

DLAN+
ISBus

ISBus
+ + +
- AC - AC - AC

AC/DC2000 AC/DC2000 AC/DC2000

Innovation Innovation Innovation
Motor Control Layer Series Series Series
Application Control Layer

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

GEP-9145 Innovation Series Controller Product Catalog 3

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

Viewer Server Toolbox

Ethernet

Innovation Series
Controllers

CTR 1 CTR 1 CTR 1 Field

CTR 2 CTR 2 CTR 2 Control

CTR 3 CTR 3 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 - AC - AC

Innovation Innovation Innovation AC/DC2000 AC/DC2000 AC/DC2000

Series Series Series
Motor Control Layer
Application Control Layer

Innovation Series controllers system configuration in a mill stand control application

4 GEP-9145 Innovation Series Controller Product Catalog

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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 Pentium 133 MHz

Memory 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:
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
Ethernet Interface • 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)
COM Ports • 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 5

 Genius Bus Interface 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.
DLAN+ Interface 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 device’s
Status_S page with an instruction from user logic.
• Each Innovation Series controller can have up to five pages.
Programming Language 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
Environmental 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

6 GEP-9145 Innovation Series Controller Product Catalog

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 Differentiating Features – VME Controllers

VME
Catalog Number DS215UCVBG1 DS215UCVBG3

  DLAN+A DLAN+B
DLAN+
10 10 10
8 8 8

Ethernet

Ethernet
1 1 1
H L H L H L
S S S
T T T
RSET A
RSET A A
T T T
U U U
S S S
COM

COM
1

2
DLAN+

DLAN+
DLAN+

GENIUS GENIUS A GENIUS B

SER 1 SER 1 SER 1
SER 2 SER 2 SER 2

DLAN+ Interfaces 1 2
Genius Interfaces 1 2
ISBus Interfaces none none
Required VME Slots 2 4
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 7

 VME
Catalog Number IS215UCVCH1 IS215UCVCH3 IS215UCVCH5

  
10
8

Ethernet
Ethernet

Ethernet
1

S S S S S
T T T T T
RSET A RSET A A A A
T T T RSET T T
U U U U U
S S S S S

COM
COM
COM

2
1

2
1

ISBus A

ISBus A ISBus B

ISBus A ISBus B

ISBus A ISBus B

DLAN+
ISBus B

GENIUS GENIUS GENIUS GENIUS GENIUS

DLAN+ Interfaces none none 1

Genius Interfaces 1 2 2
ISBus Interfaces 2 4 2
Required VME Slots 2 4 4
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

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 Common Features - ACL Controllers
Processor 486 100MHz
Memory 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:
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
Ethernet Interface • 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)
COM Ports • Micro-miniature 9-pin socket D connector
• COM 1– reserved for diagnostics only
• COM2 – Modbus communication between controller (slave only) and DCS
Parameter Description
Baud Rate 9600, 19200
Mode Binary (Remote Terminal Unit), ASCII
Data Bits 7, 8
Parity None, Odd, Even
Stop Bits 1, 2
Environmental 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 9

 Differentiating Features – ACL Controllers
ACL
Catalog Number IS215ACLAH1 IS215ACLAH2 IS215ACLIH1 IS215ACLIH2

   

RST RST RST RST

OK OK OK OK
ACTIVE ACTIVE ACTIVE ACTIVE
ISBus A ISBus A
ENET ENET ENET ENET
FLASH FLASH FLASH FLASH
S S S S
T T T T
A A A A
T T T T
U U U U
S S S S
ISBus B ISBus B

COM
COM
COM

COM

2
1
1

2
2

Ethernet
Ethernet
Ethernet

Ethernet

Ethernet Interface 10BaseT AUI 10BaseT AUI

ISBus Interface
None None 2 2

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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 128 ms
Sequencing of material handling equipment 32 ms
Hydraulic position regulator for a coil car in 16 msec
a metals process line
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 Yes - -
4 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
• Mill Stand VME I/O outputs that are written directly to the I/O board at the
write the I/O Table values to
completion of high priority tasks.
hardware asynchronously with the
execution of control logic 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 I/O Software
Sequencing Tasks
Drivers Signal
Table Table (Low Priority)
Inputs at
start of task
Limit_Switch
CPU
Limit_Switch Read Task Inputs into Software
Start_PB Outputs at Start_PB
Based end of task Stop_PB
Signal Table
Stop_PB Genius
Solenoid
Solenoid
Start_ Stop_ Limit_
GE Fanuc PLC PB PB Switch Solenoid
VME
Board
Based
Genius Solenoid

DLAN+
Write Task Outputs into I/O
Table
E-Net
SRTP &
Genius
Datagram

Low Performance
E-Net
Global Regulators Tasks
Data
(Medium Priority)
Read Task Inputs into Software
ISBus Signal Table

Modbus
RTU

Write Task Outputs into I/O

Modbus
Table
E-Net
High Performance
Allen
Regulators Tasks
Bradley
DH+
(High Priority)
Read Task Inputs into Software
Signal Table
VME Bus
Read/Write
Cylinder_
Reference

VME
Interface Cylinder_Position
SysTran
Scram Net
CTR 1

Cylinder_ CTR 2
Position Cylinder_ Write Task Outputs Directly to
CTR 3
Mill Stand Position Stand Controller I/O Board
A/I 1 A/O 1 VME I/O
Cylinder_
Reference
A/I 8 A/O 4

Signal Flow / Control Logic Task Execution

12 GEP-9145 Innovation Series Controller Product Catalog

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 In the following example, consider a skin pass mill in steel galvanizing process line
with the control functions listed:

Control Functions Required Control Task Task Sweep

Sweep Rate (ms) Priority Rate
Hydraulic gap control (HGC) 2 High 2
Work roll bending regulators 4 Medium 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.

Elongation
Remainder of
Portion of Mill Control
Mill
Sequencer Task
Sequencer
Task Task
HGC HGC HGC HGC
Task Task Task Task
Work Roll Idle Work Roll Idle Idle
Bending Time Bending Time Time
Task Task

0 2 msec 4 msec 6 msec 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.

Software
I/O I/O
Signal
Drivers Table Table

Inputs at start of task, scaled

each time Limit_Switch
I/O Outputs at end of task, scaled Start_PB
Driver each time 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 Both the Genius I/O system and Field Control I/O system use the Genius bus for
devices such as, Genius I/O communication. The Genius bus has features well suited for industrial I/O
blocks, Field Control I/O Bus applications including:
Interface Units (BIU), • High noise immunity (1500 volt isolation to ground)
controllers, and a hand held
monitor. • 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 Analog I/O Blocks
Open-wire detection (inputs) Open-wire detection (inputs)
Sense shorted wire (inputs) High alarm (inputs)
Failed switch (inputs/outputs) Low alarm (inputs)
Over temperature (inputs/outputs) Internal fault (inputs)
Loss I/O power (inputs/outputs) Wiring error (inputs)
Short-circuit (outputs) Input short (inputs)
Load state feedback (outputs) Under-range (input/outputs)
Pulse Test (outputs) Over-range (inputs/ouputs)
No-load (outputs) Feedback error (output)
Overload (outputs)

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 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 Value of I/O point
Integer
Point Health Boolean Indicates point health
#Signal_Name
Point Health Detail 4 Bytes Byte 1 – I/O point fault code
##Signal_Name Byte 2 – Block fault code
Byte 3 – Block present
Byte 4 – Controller OK

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 Toolbox

Monitor
Configure block Yes Yes
Monitor block 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 The BIU interfaces the I/O station to the Genius bus. The universal field terminal
standard for I/O connectors. 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 Data Type Description
I/O Point Signals
Signal_Name Boolean or Value of I/O point
Integer
Point Health Boolean Indicates point health
#Signal_Name
Point Health Detail 4 Bytes Byte 1 – I/O point fault code
##Signal_Name Byte 2 – Block fault code
Byte 3 – Block present
Byte 4 – Controller OK, bit 0
Module fault code, bits 4-7

GEP-9145 Innovation Series Controller 15

 High
VME Bus Speed
Farrand
VME High Speed Regulator Inductosyn
Regulator
I/O Driver Resolver I/O
I/O CTR 1
Module
CTR 2
Incremental
Encoders 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 The universal I/O board, SIOB, occupies one VME slot using the P1 connector.
standard for I/O connectors 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 High Speed (4/2.5 MHz) Differential – Differential input at +/-5 V or +/-15 V.
Beldon 813X cable (X is Maximum frequency of 2.5 MHz in the A quad B mode or 4 MHz in the up/down
number of cable pairs), for no mode.
longer than 37m (120 ft).
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:
• 0 to 20mA
• -10 to +10mA
• 0 to 10V
• -10 to +10V
• -5 to +5V

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 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 Data Type Description
Signal_Name Boolean or Value of I/O point
Integer
Point Health Boolean Indicates point health
#Signal_Name
Point Health Detail 4 Bytes Byte 1 – board health and present
##Signal_Name Byte 2 – stall status; set true if not stalled

GEP-9145 Innovation Series Controller 17

 DLAN+
DLAN+ I/O Driver

AC/DC2000
Innovation Series
Controller

The Attached Resource The Drive Local Area Network (DLAN+) is a control network for the Innovation
computer NETwork is a LAN Series controllers (VME) and AC/DC2000 drives. The DLAN+ supports up to 255
communications protocol that devices, using a token-pass, peer-to-peer communication protocol. When a device
serves as the basis for has the token, it can send a directed, group, or broadcast message.
DLAN+.
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 Data Type Description
Signal_Name Boolean, Value of signal
Integer, or Real
Point Health Boolean Indicates point health
#Signal_Name
Point Health Detail 4 long (only 2 bytes Byte 1 – page health
##Signal_Name used) Byte 2 – 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 GEP-9145 Innovation Series Controller Product Catalog

in
 DCS / HMI Modbus
TM System Protocol
Serial Modbus I/O Driver Com 1/2

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 Data Type Description
Signal_Name Boolean, Value of signal
Integer, or Real
Point Health N/A (set to always health)
#Signal_Name
Point Health Detail N/A
##Signal_Name

GEP-9145 Innovation Series Controller 19

Ethernet Modbus I/O Driver DCS / HMI Modbus
System Application
Ethernet 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 Data Type Description
Signal_Name Boolean, Value of signal
Integer, or Real
Poin Health N/A
#Signal_Name
Point Health Detail N/A
##Signal_Name

20 GEP-9145 Innovation Series Controller Product Catalog

in
Ethernet Serial Request Genius Bus

Transfer Protocol (SRTP)

& Genius Datagram I/O E-Net SRTP %Rxx
& Genius
Driver Datagram %Mxx
Ethernet

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 controller’s 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 Data Type Description
Signal_Name Boolean, Value of signal
Integer, or Real
Point Health N/A
#Signal_Name
Point Health Detail N/A
##Signal_Name

GEP-9145 Innovation Series Controller 21

Ethernet Global Data Ethernet
(EGD) I/O Driver Ethernet Gobal
Data
+
AC
(EGD)
-
+
AC

90-70 CPU
-
+

E-Net
- AC

CIMPLICITY HMI Innovation

Innovation Series Series
Controller

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 connection-
oriented 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 Data Type Description
Signal_Name Boolean or Value of I/O point
Integer
Point Health Boolean Indicates point health
#Signal_Name
Point Health Detail 4 Bytes Byte 1 – page health
##Signal_Name Byte 2 – point health

22 GEP-9145 Innovation Series Controller Product Catalog

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SCRAMNet I/O Driver
SCRAMNet
SCRAMNet

90-70 CPU
SysTran

SysTran
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 Data Type Description
Signal_Name Boolean, Value of I/O point
Integer or Real
Point Health Boolean Indicates point health
#Signal_Name
Point Health Detail 4 Bytes Byte 1 – page health
##Signal_Name Byte 2 – point health

Allen-Bradley Data
HighwayTM Plus (DH+) I/O Allen
Data Highway Plus Data Link Com 1/2
Bradley
Driver DL 200
DH+
AB PLC

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 Data Type Description
Signal_Name Boolean, Value of signal
Integer, or Real
Point Health N/A
#Signal_Name
Point Health Detail N/A
##Signal_Name

GEP-9145 Innovation Series Controller 23

Series 90-70 PLC VME 90-70
VME Bus
Interface I/O Driver PLC
VME

CPU
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 Data Type Description

I/O Point Signals
Signal_Name Boolean or Value of I/O point
Integer
Point Health Boolean Indicates point health
#Signal_Name
Point Health Detail 4 Bytes Byte 1 – page version mismatch
##Signal_Name 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 Maximum
drives frame rate (ms)
4 1
16 4
30 8

ISBus I/O Point Signals Data Type Description

Signal_Name Boolean, Value of signal
Integer, or Real
Point Health N/A N/A
#Signal_Name
Point Health Detail N/A N/A
##Signal_Name

24 GEP-9145 Innovation Series Controller Product Catalog

in
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:
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.

26 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 Description

Instruction Block 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 Description

Communications
ALARM_XMIT 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 Passes a rising TRUE value on the input pin to the out pin if it remains TRUE for
PU_DEL time .
FIR Implements a finite impulse response filter.

GEP-9145 Innovation Series Controller 29

 Instruction Block Table – continued
`
Instruction Block Description
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 Collects samples of up to 32 signals in a buffer that may be uploaded by the
toolbox for display and analysis.
FUNGEN Creates common signal functions for test and verification.
Memory Move
CNT_TO_BOOL 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.

30 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 µs 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 Safety gate is open

not go to automatic mode

Electrical drive trips out Intermittent current overload fault

The typical scenario for troubleshooting a permissive fault is as follows:

Time
Step (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.

Technician traces back from device that will

not start (or is tripped out) through the
10 – 20 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
Step (Minutes) Description

- Operator detects problem with pushbutton

5 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
Message View
Screen

Spot Jog Spot Forward Jog Start Permissive Fault [Link].34 04/03/98
Spot Jog
Foward
Foward Spot Rerverse Jog Start Permissive Fault [Link].54 04/03/98

Spot Jog Hydraulic Pump 1 Run Permissive Fault [Link].34 04/03/98

Spot Jog
Reverse
Reverse Entry Auto Mode Start Permissive Fault [Link].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 Forward Jog Start Permissive Fault [Link].34 04/03/98
Spot Jog
Foward
Foward Spot Rerverse Jog Start Permissive Fault [Link].54 04/03/98

Spot Jog Hydraulic Pump 1 Run Permissive Fault [Link].34 04/03/98

Spot Jog
Reverse
Reverse Entry Auto Mode Start Permissive Fault [Link].36 04/03/98

Animation Permissive
Variable 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 Catalog Number Description
installed in the Series 90-70
integrators rack only. DS215UCVBG1 VME, 1 DLAN+ / 1 Genius bus
DS215UCVBG3 VME, 2 DLAN+ / 2 Genius buses
Each controller is shipped with a IS215UCVCH1 VME, 1 ISBus bus / 1 Genius bus
System Manual.
IS215UCVCH3 VME, 2 ISBus buses / 2 Genius buses
IS215UCVCH5 VME, 1 ISBus bus / 1 DLAN+ / 2 Genius buses
ACL controllers are available
IC697CHS782 Series 90-70 VME integrators rack, 17 slots, rear mount
only as an option in the drive
control rack (not sold separate). IC697CHS783 Series 90-70 VME integrators rack, 17 slots, front mount

Innovation Series Controller I/O

There is a limit of five VME high- Catalog Number Description
speed regulator I/O modules or DS200SIOBH1A VME High-speed regulator I/O module, 1 VME slot
five VME dual Genius bus
259B2405P1 Terminal block for DS200SIOBBH1A (one per module)
controllers in an Innovation
Series VME rack. 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: 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

36 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
Bus Interface Units (BIUs)
IC670GBI002 Genius BIU, 24V dc power
Genius BIU, 115 V ac power
Field Terminal Bases
IC670CHS001 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
Field I/O Modules
IC670MDL640 24 V dc positive/negative input 16-point grouped
IC670MDL740 12/24 V dc 0.5A positive output 16-point grouped
IC670ALG230 Analog input current 8-point, grouped
IC670ALG320 Analog output current/voltage 4-point, grouped
IC670MDL641 48 V dc positive/negative input 16 point, grouped
IC670MDL240 120 V ac input 16-point, grouped
IC670MDL241 240 V ac input 16-point, 2 groups
IC670MDL331 120 V ac 2A output 8-point, isolated
IC670MDL330 12-120 V ac output 16-point, grouped
IC670MDL930 Relay 2A 8-point 6-form a/2-form C isolated
IC670MDL642 125 V dc input 16-point, grouped
IC670ALG240 Analog input current 16-point, grouped
IC670ALG330 Analog output current 8-point, grouped
IC670ALG630 Thermocouple 8-point, isolated
IC670ALG620 RTD 4-channel isolated – 3-wire
IC670MDL643 5/12 V dc input 16-point, 2 groups
IC670MDL742 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
Accessories
IC660HHM501 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

38 GEP-9145 Innovation Series Controller

Control System Solutions (Windows NT Applications & Service)
Catalog Number Product

To determine catalog DS208xxxxxx Innovation Series Controller Configuration (toolbox application)

numbers, refer to the • Innovation Series controller configuration
section, Catalog • Genius & Field Control I/O configuration
Number Structure on • Operator Console 2000 (OC2000) configuration
the next page and • Dual Resolver I/O module configuration
enter the proper • System Database Server
numbers (where x =
• Graphics Window
a number or a letter).
• 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 X X X X X X X X = Selected Option

Quantity Option Demonstration CD

0 = Not Demonstration CD
A = Quantity 1 PC
D = Demonstration CD (30 days)
B = Quantity 5 PC’s

C = Quantity 10 PC’s Trend Recorder /

D = Quantity 15 PC’s Data Historian Option
0 = No Trend Recorder or Data Historian

1 = Trend Recorder, no Data Historian

Controller Option
2 = Trend Recorder and Data Historian
0 = No Controller Configuration

1 = Innovation Series Controller Configuation

System Integration
Applications
0 = No System Integration Tools
Drive Option
1 = System Integration Tools
0 = No Drive Configuration

1 = Innovation Series Drive Configuation Advanced Maintenance &

2 = AC/DC/EX2000 Drive Configuration Diagnostic Applications
0 = No Advanced Maintenance & Diagnostic Tools
3 = AV-300/DV-300 Drive Configuration

4 = Innovation Series, AC/DC/EX2000, and 1 = Advanced Maintenance & Diagnostic Tools

AV-300/DV-300 Drive Configuration

40 GEP-9145 Innovation Series Controller

 GEP-9145
CADMUS
SEPTEMBER 1998

g GE Industrial Systems
General Electric Company
1501 Roanoke Blvd. 2300 Meadowvale Blvd. 18, rue Horace Vernet, No. 35 Kowa Bldg.; 5th Floor GE Towers; 10th Floor
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Argentina 1001 Las Condes, Santiago, Chile Marzahner Strasse 34 942-1 Daechi-dong, Kangnam-ku Kaohsiung, Taiwan
D-13053 Berlin Seoul,135-280 Korea
146 Arthur Street, Suite 501 Beijing East Ocean Ctr. Rm.109 Unit 1103; 11/F Diethelm Twr. B
Germany
North Sydney, NSW 2060, 24 Jian Guo Men Wai Dajie Zaragoza 1300 Sur; Edificio Kalos 93/1 Wireless Road
Australia Beijing, China 100022 Praunheimer Landstrasse 50 Piso A-3; Despacho 339 Patumwan, Bangkok, Thailand
D-60488 Frankfurt/Main 6400 Monterrey, N.L., Mexico
Av. Nove de Julho; 5229 1085 Corniche EL-Nil Apt. No. 2319
Germany 9 [Link] Warszawskiego St.
01407-907 Sao Paulo Garden City, Cairo, Egypt Mim Kemal Oke Cad. Lal
Sao Paulo, Brazil Unit 1725 17/F Pacific Trade Ctr. Gliwice, Poland 44-100 80200 Nisantasi, Ist, Turkey
Pasilantie 8 B1 2 Kai Hing Road
Anjalankoski, Finland 46900 Kosmodamianskaya Nab 52
Kowloon Bay, Hong Kong Bldg. 1, 6th Floor
Via S. Girolamo Moscow, Russia 113054
31/C Parco Massimo
Bari, Italy 70100
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