GE Intelligent Platforms

Genius II

Modernizing Genius installations with PROFINET

Genius II: Modernizing Genius installations with PROFINET

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 automation 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

Genius blocks 90-70 remote I/O scanner Field control I/O station Communication bus and termination Bus controllers Handheld monitor Personal computer interface module (PCIM) Third-party Genius devices

Modernizing Genius an Overview

In 2011, GE introduced PROFINET support for the PAC controller family. Our company remains committed to the PROFINET standard, selecting it as our flagship Ethernetbased 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) together with the high performance of modern networks, and the rich 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 worldclass 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 installation**, 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 singleslot basethe same I/O used in RX3i CPU and PNS rack-based systems!

Genius II with Compatible Field-side wiring

Genius II with RX3i IO

** GE Intelligent Platforms manufactured and branded product only

Genius II: Modernizing Genius installations with PROFINET

Acronyms Used in this Document

GBC . . . . . . . . . . . . . . . . . . . . . . . . . Genius Bus Controller GMR . . . . . . . . . . . . . . . . . . . . Genius Modular Redundancy MRP . . . . . . . . . . . . . . . . . . . . . Media Redundancy Protocol PGG . . . . . . . . . . . . . . . . . Genius Communications Gateway PNC . . . . . . . . . . . . . . . . . . . . . . . . . . PROFINET Controller PNS . . . . . . . . . . . . . . . . . . . . . . . . . . . PROFINET Scanner SBA . . . . . . . . . . . . . . . . . . . . . . . . . . . Serial Bus Address SIL3 . . . . . . . . . . . . . . . . . . . . . . . . .Safety Integrity Level 3

Genius and Genius II, a Comparison

Genius Genius Analog & Discrete I/O Blocks Genius I/O Diagnostics Field Wiring Communication Bus I/O Performance Programming Genius Genius II PROFINET Notes Each Genius I/O Electrical Assembly has an equivalent Genius II catalog number Genius II I/O supports all diagnostics available on Genius I/O Genius II I/O is compatible with Genius I/O field wiring PROFINET provides 100Mbps bandwidth with up to 10km reach (/w fiber) Genius II I/O performance meets or beats Genius I/O Genius II I/O configured with GSDML file

Genius and PROFINET Compared

Genius Token Ring (up to 32 devices) 6 bit CRC PROFINET Notes

I/O update cycle

Configured Standard TCP/IP Checksums

Data Integrity

Global Data Support

Via Genius Global Data

Bus Redundancy

Dual Bus

Ring

Ring topology provides same level of protection as dual bus.

Network Performance

153.6 kBaud (maximum)

100Mbit, 1Gig

The RX3i PNC and RX3i PNS support 1Gig, the Versamax PNS, PGG and Genius II blocks are 100Mbit devices.

Devices per Controller (GBC/PNC)

Up to 32 Various, typically shielded twisted pair

Up to 64

Media

Standard Cat 5 or Fiber

Genius II: Modernizing Genius installations with PROFINET

Modernization Options
Modernization options and strategies employed will depend on the devices being used, goals of the upgrade (increased performance, lifecycle concerns, etc.). Mix and match the options below that best meet the needs of your system.

90-70 PLCs 90-30 PLCs Series 6 and Series 6 Plus PLCs Series 5 PLC Personal computers via a PCIM module This paper addresses modernization of PACSystems, 90-70, and 90-30 systems that have Genius I/O connected directly to the controller. For other configurations, please contact GE for recommendations. Email ccs.modernization@ge.com

Migrating Your Control System Containing Genius I/O

Genius I/O is supported on several GE products: PACSystems PLCs (Rx7i, RX3i, and RXi)

Item

Upgrade Path

Notes The best choice between Rx7i or RX3i depends on what Genius functions are utilized. GE can assist with a recommendation.

90-70 System

Retrofit with Rx7i or RX3i

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)

90-70 conversion rack with RX3i PNS

The 90-70 conversion system would replace the 90-70 rack with an RX3i PNS headend and RX3i IO. The 90-70 field wiring would be retained. GMR modernization is out of scope for this document. A separate SIL3 program is in progress.

GMR The ring topology of PROFINET can provide equivalent or better redundancy

Dual Bus (using Bus Switching Module (BSM))

Refer to the Network Redundancy with PROFINET and MRP white paper for additional details.

Handheld Monitor

Functionality will be provided by alternative device.

Hot Standby CPU Redundancy

CPU Redundancy with PROFINET

Bumpless synchronization between CPU systems, switching control of I/O

Genius II: Modernizing Genius installations with PROFINET

Augment your System with PROFINET

For customers looking to expand their system, PROFINET can be used in addition to your existing Genius network(s). One or more RX3i PNC modules can be added to your RX3i system, enabling a wide variety of I/O (as well as other module types) to be used in your system. Genius and PROFINET can coexist, and you can progressively migrate your Genius I/O to PROFINET.

PROFINET over Genius Cabling

Many 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 understand 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 second half of 2012 with the results of this research.

Replacing Genius Electronics with Genius II

Upgrading field wiring is an onerous part of many upgrade processes. 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 (the field wiring is untouched) 2. Discard Genius bus connection 3. Connect Ethernet copper or fiber optics cables to the Genius II electrical assembly and configure the device as a PROFINET sub-slot device.

Using Genius I/O in a PROFINET Network

GE 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 will therefore be introducing a Genius Communications Gateway (PGG) device that allows Genius devices to be connected to and controlled by a PROFINET network. When the PGG is coupled with an RX3i controller with four PNCs, a customer can convert up to 32 Genius buses and up to 1,024 Genius devices to operate on the PROFINET network.

3 2

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.

Genius II: Modernizing Genius installations with PROFINET

Genius Redundancy
Genius I/O can be used in several different redundant configurations including: Genius bus redundancy (using a BSM) Hot standby CPU redundancy Duplex redundancy GMR

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 Voting
The PROFINET specification does not provide a native concept of input voting. Unlike Genius, input values are NOT broadcast; everything is communicated in a point-to-point manner. For a redundant controller to see the inputs from the other units PNC, the data would 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 application program, and we are also investigating voting within the PNC module.

Genius Bus Redundancy

Genius bus redundancy provides two network paths to Genius devices via a Bus Switching Module (BSM). With Genius II, PROFINET with Media Redundancy Protocol (MRP) provides better performance with less network infrastructure. Using MRP, the network is configured as a ring topology, and network link failures can be detected in as little as 3 s. Refer to the white paper, Network Redundancy with PROFINET and MRP, for additional details.

Other Genius Configurations

Genius supports additional configurations beyond those described in prior pages of this document. These include: Shared standby CPU (an alternative CPU is configured using bus controllers with SBA 30) Distributed control (two or more bus controllers send control outputs to different I/O devices on the same bus; these bus controllers may be in the same or different PLC System) If your Genius installation uses either of these configurations, please contact GE Intelligent Platforms to discuss your options in more detail.

Genius Bus RDN vs. Profinet Ring

Genius Devices Configured for Hot Standby Mode

In this mode, Genius devices prefer data from SBA 31 over data from SBA 30. If one system fails to provide data in a specific amount of time, the device will switch to use the data from SBA 30. The behavior of PROFINET devices in a CPU redundancy with PROFINET system will be similar to devices configured for hot standby mode in a CPU redundancy system using Genius. Refer to the section entitled CPU Redundancy with PROFINET for additional details.

CPU Redundancy with PROFINET

GE has an active development that updates our hot standby CPU redundancy product to utilize PROFINET for its I/O. Like the hot standby CPU redundancy of the 90-70 and PACSystems platforms, the two systems remain synchronized via reflective memory links. One system controls the I/O. Failure of a one system results in control being switched to the second unit.

Genius Devices Configured For Duplex Mode

Unlike hot standby mode, SBA 30 and 31 are treated equally when configured in duplex mode. If both SBA 30 and 31 are providing data (i.e., no failures) and the output values from the controllers are 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.

Genius II: Modernizing Genius installations with PROFINET

Output Behavior using PROFINET

The PROFINET specification defines how outputs behave when a controller is lost. The devices can be configured to Hold Last State, Set to Zero, or Set to Configured Value. When used in redundancy, a loss of the controller will first transition the devices to Hold Last 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 and extend the functionality of these installations. Use the options that work best for your installation at a pace that is best for you.

Genius II: Modernizing Genius installations with PROFINET

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? Our test shows that SHDSL modem solution would work. We will update the Genius customer white paper with more information later. 3. How do we assemble the RJ45 connector on the Genius cable? Need to cut and rewire the Genius cable to RJ45 connector. 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 instead of CAT5 Ethernet cable, which is enough for the 32 nodes. 6. How many blocks can we have on a single Profinet scanner? Up to 64 on a single RX3i PROFINET Controller (PNC). An RX3i rack can have up to 4 PNCs. 7. What is the maximum blocks can we have on a single RX3i or RX7i CPUs? Now and in the future. Up to 256. We can do 128 at the moment, but will extend to 256 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, we plan to support Phase B terminal blocks only. 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 connected to a new PROFINET bus. Controllers that comply with SIL 3 functional safety requirements are also being developed that will replace the 90-70 controllers used in GMR installations. GE intends to provide tools that will simplify the transition from 90-70 application code to code that complies with SIL 3 functional safety standards.

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