PACSystems RX3i CPUs, IC695CRU320-DF, v. 6.71, GFK

PACSystems RX3i CPUs, IC695CRU320-DF, v. 6.71, GFK
PACSystems* RX3i
IC695CRU320
Redundancy CPU
GFK-2514J
May 2011
The PACSystems* RX3i Redundancy CPU can be
used to perform real time processing and discrete
automation for various applications. The CPU
communicates with the programmer and HMI devices
via serial SNP Slave protocol. It communicates with
I/O and smart option modules over a dual backplane
bus that provides:
■
High-speed PCI backplane for fast throughput of
advanced I/O.
■
Serial backplane for easy migration of existing
Series 90-30 I/O.
■
Time synchronization to SNTP Time Server on
Ethernet network when used with Ethernet
module version 5.0 or later.
Features
■
Hot standby (HSB) redundancy. Two redundant
units make up a redundancy system. Each unit
requires one Redundancy CPU (IC695CRU320)
and a redundancy Memory Xchange module
(IC695RMX128) configured as a redundancy link.
■
Contains 64 Mbytes of battery-backed and 64
Mbytes of non-volatile flash user memory.
■
Configurable data and program memory.
■
Programming in Ladder Diagram, Structured
Text, Function Block Diagram, and C.
■
Supports auto-located Symbolic Variables that
can use any amount of user memory.
■
Reference table sizes include 32Kbits for discrete
%I and %Q and up to 32Kwords each for analog
%AI and %AQ.
■
Supports most Series 90-30 modules and
expansion racks. For a list of supported modules,
see the PACSystems RX3i System Manual,
GFK-2314.
■
Ordering Information
Description
Catalog Number
Supports up to 512 program blocks. Maximum
size for a block is 128KB.
RX3i CPU, 1GHz Intel 32 bit processor
IC695CRU320
Lithium Smart Battery
IC695ACC302
In-system upgradeable firmware.
Auxiliary Battery Module
IC693ACC302
■
Two serial ports: an RS-485 serial port and an
RS-232 serial port.
Standard Power Supplies
120/240VAC, 125VDC, 40W
24VDC, 40W
IC695PSA040
IC695PSD040
■
Ethernet communications via the rack-based
Ethernet Interface module (IC695ETM001). For
details, refer to TCP/IP Ethernet Communications
for PACSystems User’s Manual, GFK-2224.
Multifunctional Power Supplies
120/240 VAC, 125 VDC, 40W
24 VDC, 40 Watt
■
indicates a trademark of GE Intelligent Platforms,
Inc. and/or its affiliates. All other trademarks are
the property of their respective owners.
*
IC695PSA140
IC695PSD140
[Optional] RS-232 Cable
IC200CBL001
Rx3i Standard 12 Slot Rack
IC695CHS012
Rx3i Standard 16 Slot Rack
IC695CHS016
Note:
For Conformal Coat option, please consult the factory
for price and availability.
2
GFK-2514J
RX3i CRU320
Hot Standby CPU Redundancy Features
For details on the configuration and operation of a Hot Standby CPU redundancy system, refer to the PACSystems Hot
Standby CPU Redundancy User’s Manual, GFK-2308.
■
Survives any one single point of failure
■
Bumpless switching

Synchronized CPUs

One scan switching

Transfer data size up to 2Mbytes; selected in CPU hardware configuration and in variable properties
■
Supports two redundancy communications links
■
Online repair of failed component
■
Online programming
■
Redundancy Memory Xchange Module

Manual toggle switch for role switching, which transitions control from the active unit to the backup unit

Redundancy status LEDs
■
Application-initiated role switching to switch the active unit to backup status
■
Redundancy status bits and message logging
■
Supports single and redundant Ethernet remote I/O LANs through Ethernet Network Interface Unit (ENIU) modules.
■
Memory error checking and correction (ECC) single bit correcting and multiple bit checking
■
Background diagnostics
HSB Control Strategy
The HSB control strategy has the following characteristics:
■
Active unit does not automatically switch to primary on resynchronization
■
Critical control data plus all redundant outputs must be included in the output data transfer
■
Bumpless switchover from active unit to backup unit
Product Documentation
PACSystems CPU Reference Manual, GFK-2222M or later
TCP/IP Ethernet Communications for PACSystems User’s Manual, GFK-2224
TCP/IP Ethernet Communications for PACSystems Station Manager Manual, GFK-2225
PACSystems Hot Standby CPU Redundancy User’s Manual, GFK-2308D or later
PACSystems Memory Xchange Modules, GFK-2300D or later
PACSystems RX3i System Manual, GFK-2314D or later
PACSystems RX3i Ethernet NIU User’s Manual, GFK-2439
Proficy* Machine Edition Getting Started, GFK-1868
Proficy Logic Developer, GFK-1918
RX3i CPU Lithium Smart Battery, IC695ACC302, GFK-2592
Series 90-30 Lithium Battery Pack, IC693ACC302, GFK-2124
RX3i CPU
3
GFK-2514J
CRU320 Specifications
Note:
For environmental specifications and compliance to standards (for example, FCC or European Union Directives),
refer to the PACSystems RX3i System Manual, GFK-2314.
Battery: Memory retention
Lithium Smart Battery, IC695ACC302 (recommended), or
Series 90-30 Lithium Battery Pack, IC693ACC302
Note: The IC698ACC701 Lithium Battery Pack is not compatible with
the CRU320 and must not be used.
Program storage
Up to 64 Mbytes of battery-backed RAM
64 Mbytes of non-volatile flash user memory
Power requirements
+3.3 VDC: 1.0 Amps nominal
+5 VDC: 1.2 Amps nominal
Operating Temperature
0 to 60°C (32°F to 140°F)
Floating point
Yes
Boolean execution speed, typical
0.047 ms per 1000 Boolean instructions
Time of Day Clock accuracy
Maximum drift of 2 seconds per day
Elapsed Time Clock (internal timing)
accuracy
0.01% maximum
Embedded communications
RS-232, RS-485
Serial Protocols supported
Modbus RTU Slave, SNP Slave, Serial I/O
Backplane
Dual backplane bus support: RX3i PCI and high speed serial bus
PCI compatibility
System designed to be electrically compliant with PCI 2.2 standard
Program blocks
Up to 512 program blocks. Maximum size for a block is 128KB.
Memory
%I and %Q: 32Kbits for discrete
%AI and %AQ: configurable up to 32Kwords
%W: configurable up to the maximum available user RAM
Symbolic: configurable up to 64 Mbytes
Flash memory endurance rating
100,000 write/erase cycles minimum
Memory error checking and
correction (ECC)
Single bit correcting and multiple bit checking.
Switchover Time*
Maximum 1 logic scan, minimum 3.133 msec.
Typical Base Sweep Time (Reference
Data Transfer List Impact)**
3.66 msec: 1K Discrete I/O, 125 Analog I/O and 1K Registers
3.87 msec: 2K Discrete I/O, 250 Analog I/O and 2K Registers
4.30 msec: 4K Discrete I/O, 500 Analog I/O and 4K Registers
5.16 msec: 8K Discrete I/O, 1K Analog I/O and 8K Registers
Maximum amount of data in transfer list
Up to 2 Mbytes
Number of redundancy links supported
Up to two IC695RMX128 synchronization links are supported.
*
Switchover time is defined as the time from failure detection until backup CPU is active.
**
Symbolic variable and Reference data can be exchanged between controllers. Up to 2 Mbyte of data is available for
transfer.
Important installation instructions for battery
Do not connect the battery until the CPU is installed in the rack and the rack is powered on. The battery may then be
attached to either of the two terminals in the battery compartment. Once that is done, the CPU may be powered down and
normal battery back up operation will begin. To save battery life, do not connect the battery for the first time until the CPU
is powered up.
RX3i CRU320
4
GFK-2514J
Estimated Battery Life
IC695ACC302 RX3i CPU Lithium Smart Battery:
Battery Life in Good State Battery Life in Low State Total Battery life
8 days
15 days
23 days
Notes: The Battery Low indication can be detected only on the power up condition of the CPU either by the
LED indication or the fault table.
The nominal backup values are estimated at 20ºC. Backup time increases approximately 17% at 60ºC and
decreases approximately 32% at 0ºC.
IC693ACC302 Auxiliary Battery Module:
30 days at 20ºC
Release History
Catalog Number
Firmware
Version
Comments
IC695CRU320-DF
6.71
Corrects the behavior of the Logic Driven Read/Write to Flash service
requests, SVC_REQ56 and SVC_REQ 57.
IC695CRU320-DE
6.70
Implements a hardware design update that improves the noise
immunity of the CPU module during power up from flash operations.
IC695CRU320-CE
6.70
Introduces support for new modules, enhancements to the Modbus
RTU protocol, improved Run signal handling in the expansion rack and
other improvements. Resolves several problems.
IC695CRU320-CD
6.02
Provides capability for low battery detection. The new hardware is
EU-ROHS compliant. For details, see GFK-2514F.
IC695CRU320-BC
6.01
Provides for OEM protection in flash-based systems that do not use a
battery. For additional problems resolved, see GFK-2514E.
IC695CRU320-BB
6.00
Adds User Defined Types, Variable Indexed Arrays, Logic Driven Write
to Flash, and Backplane Operations Controller Enhancement features.
See GFK-2514D for details and problems resolved.
IC695CRU320-BA
5.70
Hardware-only upgrade to enhance manufacturability. Does not affect
product features or functional compatibility.
IC695CRU320-AA
5.70
Initial release.
Important Product Information for this Release
Release 6.71 corrects the behavior of the Logic Driven Read/Write to Flash service requests, SVC_REQ56 and
SVC_REQ 57. For details, see “Problems Resolved in Release 6.71” on page 6.
Updates
IC695CRU320 can be field upgraded to firmware version 6.71 using the Winloader firmware upgrade utility kit, 82A1559MS10-000-A5, which can be downloaded from http://www.ge-ip.com/support.
RX3i CPU
5
GFK-2514J
CPU Functional Compatibility
Subject
Description
Redundancy operation with dissimilar CPU
models is not allowed
The CRU320 does not support synchronization with RX7i redundancy
units.
Programmer Version Requirements
Proficy Machine Edition Logic Developer PLC, version 6.0 or later is
required to use the features added in firmware release 6.00.
Proficy Machine Edition Logic Developer PLC, version 5.9 SP1 SIM5 or
later is required to configure a Genius Bus Controller
(IC693BEM331/IC694BEM331) with a CRU320. Only single bus
Genius networks are allowed.
Proficy Machine Edition Logic Developer 5.90 SIM1 or later version is
required to configure and program the CRU320.
C Toolkit Compatibility
The C Toolkit for PACSystems is distributed with Proficy Machine
Edition Logic Developer. Updates can be downloaded from
http://www.ge-ip.com/support.
The C Toolkit Release 5.50, distributed with Machine Edition Logic
Developer 5.9 or later, is required for use with the CRU320.
Note: C blocks that were built using C Toolkit versions earlier than
5.00 Build 16C1 must be recompiled using a newer toolkit
version for use with CPU firmware release 5.00 or higher.
Note: The Series 90 Toolkit (IC641SWP709/719) is not
compatible with PACSystems.
Low Battery Detection
To use the low battery detection feature provided in 6.02 and later
firmware releases, you will need CRU320 hardware version -Cx or
later. Hardware cannot be field upgraded. For the low battery detection
circuit to function properly, an RX3i CPU Lithium Smart Battery
(IC695ACC302) must be used.
Rx3i Backplane Hardware Revision
For the CRU320 CPU, one of the following backplane hardware
revisions MUST be used:
IC695CHS012-BAMP
IC695CHS016-BAMP
IC695CHS012CA-BAMP
IC695CHS016CA-BAMP
or
IC695CHS012-CA (or later)
IC695CHS016-CA (or later)
IC695CHS012CA-CA (or later)
IC695CHS016CA-CA (or later)
Power supplies and system modules
As listed in the PACSystems RX3i System Manual, GFK-2314D or later,
with the following exceptions:
Note: The CRU320 does not support the PMM335 PACMotion MultiAxis Motion Controller.
Series 90-30 Expansion Rack Compatibility
The PACSystems RX3i supports Series 90-30 expansion racks, both
local and remote.
PACSystems RX3i CPUs do not operate in a Series 90-30 Rack.
Series 90-30 Main Rack Compatibility
Series 90-30 Main Racks cannot be used in a PACSystems RX3i
system.
Series 90-30 CPUs do not operate in PACSystemsRX3i Racks.
Isolated 24V power
In applications that use the IC69xALG220/221/222, consult
PACSystems RX3i Hardware and Installation Manual, GFK-2314 for
details of wiring the 24V power.
RX3i CRU320
6
GFK-2514J
Subject
Description
COMMREQ to PBM300
In Release 3.0, the behavior of the COMMREQ fault output on a
COMMREQ sent to the PROFIBUS master module IC695PBM300 was
changed to be compatible with the Series 90-30 CPU366 PROFIBUS
Master. Previously, the fault output is enabled when the module
receives a COMMREQ and it is busy. Now, the busy condition does not
result in the fault output enabled.
Recommended IC200ALG240 revision
When a VersaMax* system Genius* Network Interface Unit
(IC200GBI001) operates with a Genius Bus Controller located in a
PACSystems controller, and the VersaMax system contains an
IC200ALG240 Analog Input Module, it is recommended to update the
IC200ALG240 firmware to Revision 1.10 or later. Use firmware update
kit 44A752313-G01, available in Knowledge Base Article i023269 at
http://www.ge-ip.com/support.
Problems Resolved by Release 6.71
Subject
Problems with Logic Driven Read/Write of
Flash
Description
The SVC_REQ functions 56 and 57 had several problems that were
caused by incorrect address and offset calculations. These problems
caused a variety of symptoms, including:

When SVC_REQ 57 was used to update a block of Word-type
memory where at least 1 word value changed and at least 1 word
value did not change, the data written to flash was incorrect.

Problems occurred with SVC_REQ 56 when the source memory type
was byte-oriented and the destination was bit-oriented (or vice versa).

Reading flash using SVC_REQ 56 and writing to flash using
SVC_REQ 57 with large offsets (e.g. %W32769) did not work with
firmware versions prior to 6.71.
Reference out of range errors caused by
bit-oriented functions inside a function block
The use of certain bit-oriented functions (MOVE_BOOL, SHFR_BIT,
ARRAY_MOVE_BOOL) inside a function block was causing Reference
out of range errors at runtime. The problem was caused by incorrect
bounds testing for the parameters of the function.
Clearing of fault tables could cause CPU to
miss a module interrupt
When the programmer was clearing the I/O fault table, interrupts from a
PMM module could be missed by the CPU. Interrupts are disabled during
the clearing operation. Release 6.71 resolves this problem by minimizing
the interval during which interrupts are disabled.
Restrictions and Open Issues in this Release
Subject
The Ethernet module fails to exchange EGD
properly during power cycling
Description
Very rarely, after experiencing multiple rapid power cycles, the
CPU may fail to establish communication with one or more
modules in the backplane at power up. When this occurs, several
pairs of "Loss of, or missing option module" and "Reset of option
module" faults will be logged in the controller fault table.
If the module is an ETM, an event 30H is recorded in its station
manager event log.
To recover from this issue, cycle power again.
RX3i CPU
7
GFK-2514J
Subject
Description
Loss of power supplies after firmware
update.
A Loss of Power Supplies after firmware update may occur. This
does not happen with all firmware updates and will NOT occur if
the system is power cycled after the firmware upgrade has
completed. The faults displayed when this issue occurs are as
follows:
Loss of, or missing option module
Error Code: 36
Group: 4
Action: 3:Fatal
Task Num: 9
Fault Extra Data: 01 58 02 4f 80 08 0a 07 00 00
00 00 00 00 00 00 00 00 00 00 00 00 00 00
Battery installation.
When installing a new battery, if there currently is no battery
installed, the battery must be installed while the CPU has power.
Failing to follow this procedure could result in the CPU not
powering up.
If a battery is installed while power is off (and there was no battery
previously installed), and the CPU fails to power up, remove the
battery, power cycle the CPU and then install the battery.
Hot swapping some analog modules slowly
may result in modules not being recognized.
Occasionally during a hot insertion (hot swap) of RX3i
Non-Isolated Analog Input Modules, input channels may take up to
2 seconds to reflect actual input values after the module OK bit is
enabled in the module status word. This has only been seen when
the hot insertion has been done slowly (i.e. approximately 1.5
seconds to insert the module).
Ethernet disconnect during Word-for Word
change.
If the Ethernet connection is broken during a word-for-word
change, the programmer may not allow a subsequent
word-for-word change after reconnecting due to the fact that it
thinks another programmer is currently attached. If this occurs, you
should go offline and then back online again.
Simultaneous Clears, Loads and Stores not
supported.
PACSystems CPUs do not support multiple programmers
changing CPU contents at the same time. The programming
software may generate an error during the operation.
Simultaneous loads from a single CPU are allowed.
Hardware configuration Not Equal after
changing target name.
If you store a hardware configuration to flash that sets
Logic/Config Power up Source to Always Flash or Conditional
Flash and then change the name of the target in the programming
software, the hardware configuration will go Not Equal and will not
verify as equal.
Controller and IO Fault Tables may need to
be cleared twice to clear faulted state.
Both Controller and IO fault tables may need to be cleared to take
the CPU out of Stop/Fault mode. If one of the tables contains a
recurring fault, the order in which the tables are cleared may be
significant. If the CPU is still in Stop/Fault mode after both tables
are cleared, try clearing the fault tables again.
Setting Force On/Off by storing initial value.
Once a force on or force off has been stored to the controller, you
cannot switch from force on to force off or vice-versa by
downloading initial values. To turn the force on or off, download
the project.
Number of active programs returned as zero.
The SNP request Return Controller Type and ID currently returns
the number of active programs as zero.
Serial I/O fails at 115K during heavy interrupt
load.
Rare data corruption errors have been seen on serial
communications when running at 115K under heavy interrupt load
on the controller. Under heavy load applications, users should
restrict serial communications to 57K or lower.
SNP ID not always provided.
Unlike the Series 90-30, the RX3i CPU’s SNP ID does not appear
in the Machine Edition programmer Show Status display. Service
Request 11 will always return zeros.
RX3i CRU320
8
GFK-2514J
Subject
Description
Second programmer can change logic while
in Test & Edit mode.
While currently active in a Test and Edit session using Machine
Edition on one PC, Machine Edition running on another PC is not
prevented from storing new logic to the controller.
Must have logic if powering up from flash.
If the application will configure the CPU to retrieve the contents of
flash memory at power-up, be sure to include logic along with
hardware configuration when saving to flash memory.
CPU may not detect low-battery condition.
An IC693ACC302 battery with very low capacity may still have a
terminal voltage high enough to report that it is a good battery. In
this case, when the battery starts supplying the memory power
(battery backup), the battery voltage quickly drops to unacceptable
levels, with little warning to the user before failure.
To insure against data loss, users should replace batteries in
accordance with the guidelines provided in the PACSystems CPU
Reference Manual, GFK-2222. Additionally, users could save logic
and hardware configuration to flash.
Power up of Series 90-30 HSC module may
take as long as 20 seconds.
As power is applied to a 90-30 High-Speed Counter, the Module
Ready bit in the status bits returned each sweep from the module
may not be set for as long as 20 seconds after the first controller
sweep, even though there is no Loss of Module indication. I/O
data exchanged with the module is not meaningful until this bit is
set by the module. See pages 4-3 to 4-5 of the Series 90-30 High
Speed Counter User’s Manual, GFK-0293C.
Two Loss of Module faults for Universal
Analog module.
Occasionally, the hot removal of the Universal Analog Input
Module (IC695ALG600) results in two Loss of I/O Module faults
instead of one.
Informational fault at power up.
Intermittently during power-up, an Informational non-critical CPU
software fault may be generated with fault extra data of
01 91 01 D6. This fault will have no effect on the normal operation
of the controller. But, if the hardware watchdog timer expires after
this fault and before power has been cycled again, then the
outputs of I/O modules may hold their last state, rather than
defaulting to zero.
Extended memory types for IO triggers.
%R, %W and %M cannot be used as IO triggers.
Possible Machine Edition inability to
connect.
Infrequently, an attempt to connect a programmer to a controller
via Ethernet will be unsuccessful. The normal connection retry
dialog will not be displayed. Rebooting the computer that is
running the programmer will resolve the behavior.
SNP Update Datagram message.
If an Update Datagram message requests 6 or less bits or bytes of
data, the controller will return a Completion Ack message without
Text Buffer. The protocol specifies that the returned data will be in
the Completion Ack message, but it may not be.
GBC30 may not resume operation after
power cycle.
In rare instances, a GBC30 in an expansion rack may not resume
normal operation after a power cycle of either the expansion rack
or the main rack.
To restore GBC operation, power cycle the rack again.
Configuration of third-party modules.
Do not specify a length of 0 in the configuration of a third-party
module. The module will not work properly in the system.
Power supply status after CPU firmware
update.
The controller will report a Loss of or Missing Option Module fault
for the IC695PSD140 RX3i power supply following an update of
CPU firmware. Also, the slot will appear empty in the
programmer’s online status detail view. The power supply
continues to operate normally. Power cycle to restore normal
status reporting.
Power supply status after power cycling.
Rarely, turning a power supply on or off may not result in an Add
or Loss fault. Also, the slot will appear empty in the programmer’s
online status detail view. The power supply continues to operate
normally. Power cycle to restore normal status reporting.
RX3i CPU
9
GFK-2514J
Subject
Description
Don’t use multiple targets.
In a system in which the hardware configuration is stored from one
target and logic is stored from a different target, powering-up from
flash will not work. The observed behavior is that, following a
power up from flash, Machine Edition reports hardware
configuration and logic Not Equal.
Missing Loss of Terminal Block fault.
The IC695ALG600/608/616 analog input modules do not produce
a Loss of Terminal Block fault when hardware configuration is
stored or the module is hot-inserted, and the terminal block is not
locked into place.
Sequence Store failure.
When downloading projects with very large hardware
configurations or which use large amounts of user memory, it is
possible to encounter a controller Sequence Store Failure error
when writing the configuration to flash. To work around this error,
either, either or both of the following actions may be helpful:
1. Perform an explicit clear of flash prior to performing the write.
2. Increase the operation timeout used by Machine Edition prior
to performing the write. This is done by expanding the
Additional Configuration in the Inspector window for the target
controller, and adjusting the Request Timeout. The timeout
may need to be increased to as much as 60,000 msec,
depending on the amount of memory used and the condition
of the flash memory.
IC694MDL754: Must configure module status
bits.
Always configure 16 bits of module status when using this module.
Configuring 0 bits of module status will result in invalid data in the
module’s ESCP status bits.
IC695ALG600 Lead Resistance
Compensation setting.
A configuration store operation will fail if a channel is configured
for 3-wire RTD and Lead Resistance Compensation is set to
Disabled. A Loss of Module fault will be logged in the I/O Fault
table at the end of the store operation.
To recover the lost module, the configuration must be changed to
enable Lead Resistance Compensation and module must be
power cycled.
C Toolkit PlcMemCopy documentation
incorrect.
This routine does allow the destination and source pointers to be
outside of reference memory. If the destination points to discrete
reference memory, overrides and transitions will be honored. Note
that the header for PlcMemCopy has been updated in Release
3.50 of the C toolkit.
WinLoader may stop operating.
On computers running Windows 2000 and using some versions of
Symantec Antivirus protection, WinLoader will lock up if used in
advanced mode. Recovery requires cycling the computer's power.
Logic and HWC not equal after power cycle.
If the Hardware Configuration from Target 1, with
Logic/Configuration Power-up Source and Data Source both set to
Always from Flash, is stored in Flash, then Logic and Hardware
Config from Target 2, with Logic/Configuration Power-up Source
both set to Always from RAM, are stored to RAM and there is a
good battery, then when power is cycled the programmer may
show that Logic and Hardware Config are not equal.
The remedy is to clear Flash and re-store the Logic and Hardware
Config from Target 2.
WinLoader does not detect PC COM port in
use when upgrading PACSystems CPU.
WinLoader does not detect if a PC's COM port is in use when
attempting to connect to a PACSystems CPU to perform a
firmware upgrade. If the port is already in use it displays the status
"trying to connect" followed by "waiting for target." To proceed with
the upgrade, press the "abort" button and disconnect the other
application that is using the COM port.
RX3i CRU320
10
GFK-2514J
Subject
Description
CPU320, CRU320 user application and values
cleared after power cycle
Under rare circumstances during multiple rapid power cycles the
CPU320/CRU320 will power up with the user application and data
in RAM cleared. There will be a “Corrupted user memory” fault in
the controller fault table (Group 130, Error code 1). This will not
occur if the user application and data are loaded from flash on
power-up (“Always Flash” or “Conditional Flash”).
WinLoader does not display error when it
can't connect serially with PACS CPU.
WinLoader does not display an error message if it cannot connect
to the PACS CPU when attempting to connect to a PACSystems
CPU to perform a firmware upgrade. This occurs if the cable is
physically not connected to the CPU or if the CPU's serial port is
not configured for the same baud as WinLoader. In this case
Winloader displays the status "trying to connect" followed by
"waiting for target." To proceed with the upgrade, press the "abort"
button and correct the cable or baud rate setting.
Operational Notes
Subject
Multiple calls to SVC_REQ 57 in a single
sweep may cause CPU watchdog timeouts
Error response 1 is no longer returned for
Modbus RTU requests with invalid or
undefined function codes.
Description
Multiple calls to SVC_REQ 57 (Logic Driven Write to Nonvolatile
Storage) could result in the CPU tripping the watchdog timer and
going to STOP-HALT mode. The number of calls to SVC_REQ
57 that can be made requires consideration of many variables,
what the software watchdog timeout value is, how much data is
being written, how long the sweep is, age of nonvolatile storage
(flash), etc. If the application attempts to write to flash too
frequently, the CPU could experience a watchdog timeout while
waiting for a preceding write operation to complete.
The Logic Driven Read/Write to Flash service requests are not
intended for high frequency use. GE Intelligent Platforms
recommends limiting the number of calls to SVC_REQ 57 to one
call per sweep to avoid the potential of for causing a watchdog
timeout and the resulting transition to Stop-Halt.
Prior to release 6.70 for the RX3i, the Modbus RTU slave
protocol would return an Invalid Function Code error response
(1) upon receipt of a request with an invalid or undefined
function code. Starting with release 6.70, the Modbus RTU
slave ignores requests with an invalid or undefined function
code, and no response is sent.
RUN LED not illuminated on the Series 90-30
power supply for an RX3i remote/expansion
rack with input modules only (releases earlier
than 6.70).
For firmware version 6.70 and later, the RUN LED for
remote/expansion racks reflects the current IO enable/disable
state (even when there are no output modules in the expansion
rack).
The RUN LED for remote/expansion rack with input modules
only works as follows for all versions prior to version 6.70:
When a remote or expansion baseplate is used with the
RX3i, the RUN LED on the Series 90-30 power supply for
that baseplate is illuminated when the system is in Run
mode only if the rack contains at least one output module. If
the rack contains input modules only, the RUN LED is not
illuminated. This is due to the way input modules are
managed in the PACSystems design and does not indicate
an error.
Monitoring RMX links.
Applications should monitor the fault locating references
corresponding to the RMX modules at power up and during run
time to validate the RMX links are operating. The fault locating
reference name format is #SLOT_00XX where XX is the slot
number of the RMX module.
RX3i CPU
11
GFK-2514J
Subject
Description
Undefined symbols in C Blocks.
In Release 5.00 or later, if an attempt is made to download a C
block containing undefined symbols, the download will fail.
Machine Edition will display the following message in the
Feedback Zone: Error 8097: Controller Error – Controller
aborted the request [0x05][0xFF]
Prior to Release 5.00, C blocks containing undefined symbols
could be successfully downloaded, but if they were executed the
CPU would transition to Stop/Halt mode.
For details, see “C Toolkit Compatibility” on page 5.
Length of serial I/O buffer
(Release 5.0 or later) The "Set Up Input Buffer Function" always
allocates a buffer containing 2049 bytes. This is one byte more
than previous PACSystems releases.
Changing IP address of Ethernet interface
while connected.
Downloading a hardware configuration with a new IP address to
the RX3i while connected via Ethernet will succeed, then
immediately disconnect because the RX3i is now using a
different IP address than the Programmer. You must enter a new
IP address in the Target Properties in the Machine Edition
Inspector window before reconnecting.
Duplicate station address for Modbus will
conflict with other nodes.
The default serial protocol for the RX3i is Modbus RTU. The
default Station Address is 1. If the RX3i is added to a multi-drop
network, care must be taken that the RX3i is configured with a
unique Station Address. Nodes with duplicate Station Addresses
on the same network will not work correctly.
Timer operation.
Care should be taken when timers (ONDTR, TMR, and OFDTR)
are used in program blocks that are NOT called every sweep.
The timers accumulate time across calls to the sub-block unless
they are reset. This means that they function like timers
operating in a program with a much slower sweep than the
timers in the main program block. For program blocks that are
inactive for large periods of time, the timers should be
programmed in such a manner as to account for this catch up
feature.
Related to this are timers that are skipped because of the use of
the JUMP instruction. Timers that are skipped will NOT catch up
and will therefore not accumulate time in the same manner as if
they were executed every sweep.
Constant Sweep
Constant Sweep time, when used, should be set at least 10
milliseconds greater than the normal sweep time to avoid any
over-sweep conditions when monitoring or performing on-line
changes with the programmer. Window completion faults will
occur if the constant sweep setting is not high enough.
Large number of COMMREQs sent to module
in one sweep causes faults.
A large number of COMMREQs (typically greater than 8) sent to
a given board in the same sweep may cause Module Software
faults to be logged in the RX3i fault table. The fault group is
MOD_OTHR_SOFTWR (16t, 10h) and the error code is
COMMREQ_MB_FULL_START (2). When this occurs, the “FT”
output of the function block will also be set. To prevent this
situation, COMMREQs issued to a given board should be spread
across multiple sweeps so that only a limited number (typically 8
or less) of COMMREQs are sent to a given board in each
sweep. In addition, the FT output parameter should be checked
for errors. If the FT output is set (meaning an error has been
detected), the COMM_REQ could be re-issued by the
application logic.
C Block standard math functions do not set
errno.
In C Blocks, standard math functions (e.g. sqrt, pow, asin, acos)
do not set errno to the correct value and do not return the correct
value if an invalid input is provided.
RX3i CRU320
12
GFK-2514J
Subject
Description
Upgrading firmware.
The process of upgrading the CPU firmware with the WinLoader
utility may fail when multiple IO modules are in the main rack,
due to the time it takes to power cycle the rack system. If the
upgrade process fails, move the CPU to a rack without IO
modules and restart the upgrade process.
Winloader initial connect baud rate is fixed at 19200 baud. Note
that the firmware download will occur at 115.2K baud by default.
Note that if you have hyperterm open on a port, and then try to
use Winloader on the same port, Winloader will often say
“Waiting for Target” until the hyperterm session is closed.
Hot swap.
Hot Swap of power supplies or CPUs is not supported.
Serial port configuration COMMREQs.
With the following combination of circumstances, it is possible to
render serial communications with the CPU impossible:
User configuration disables the Run/Stop switch
User configures the power up mode to Run or Last
Logic is downloaded to FLASH and user configures
CPU to load from FLASH on power up
User application issues COMMREQs that set the
protocol on both of the serial ports to something that
does not permit communications to the Machine Edition
programmer.
Incorrect COMMREQ status for invalid
program name.
The program name for PACSystems is always "LDPROG1".
When another program name is used in a COMM_REQ
accessing %L memory, an Invalid Block Name (05D5) error is
generated.
FANUC I/O Master and Slave operation.
Scan sets on the master do not work properly for the first
operation of the scan set after entering RUN mode. They do
work properly for subsequent scans.
After downloading a new hardware configuration and logic, a
power cycle may be required to resume FANUC I/O operation.
Use controllers of similar performance in FANUC I/O networks.
If a master or slave is located in an RX3i system, the other
controllers should be RX3i or Series 90-30 CPU374.
Repeated power up/down cycles of an expansion rack
containing FANUC I/O slaves may result in failure of the slaves’
operation, with the RDY LED off.
Lost count at power up for Serial IO
Processor.
The serial IO Processor (IC693APU305) will lose the first count
after every power up or every time the module receives a
configuration.
COMMREQ status words declared in bit
memory types must be byte-aligned.
In previous releases, the CPU allowed configuration of
COMMREQ Status Words in bit memory types on a non-bytealigned boundary. Even though the given reference was not
byte-aligned, the firmware would adjust it the next-lowest byte
boundary before updating status bits, overwriting the bits
between the alignment boundary and specified location. To
ensure that the application operates as expected, release 3.50
requires configuration of COMMREQ Status Words in bit
memory types to be byte-aligned. For example if the user
specified status bit location of %I3, the CPU aligns the status bit
location at %I1. Release 3.50 firmware requires the user to
specify the appropriate aligned address (%I1) to ensure that the
utilized location is appropriate for their application. Note that the
actual reference location utilized is not changed, but now is
explicitly stated for the user.
RX3i CPU
13
GFK-2514J
Subject
Description
STOP and RUN mode transition priority
The PACSystems CPU receives requests to change between
stop and run mode from many different sources. These include
(but are not limited to) Proficy Machine Edition, HMIs, the user
application, and the RUN/STOP switch. Since there are many
potential sources for a mode change request, it is possible to
receive a new mode change request while another is already in
progress. When this occurs, the CPU evaluates the priority of
the new mode change request with the mode change that is in
progress. If the new mode change request has an equal or
higher priority than the one already in progress, the CPU
transitions to the new mode instead of the one in progress. If,
however, the new mode change request has a lower priority than
the one in progress, the new mode request is discarded and the
CPU completes the mode change that is in progress. The sweep
mode priorities are (listed from highest to lowest priority): STOP
HALT, STOP FAULT, STOP, and RUN. (Note: The IO
ENABLED/DISABLED state is not part of the mode priority
evaluation.) For example, a CPU is in RUN IO ENABLED mode
and a Service Request 13 function block is executed to place the
CPU into STOP IO DISABLED mode. Before the transition to
STOP IO DISABLED is completed, the RUN/STOP switch is
changed from RUN IO ENABLED to RUN IO DISABLED. In this
case, the CPU ignores the new request from the RUN/STOP
switch to go to RUN IO DISABLED mode because it is already
processing a request to go to STOP IO DISABLED mode and
STOP mode has a higher priority than RUN mode.
Suspend IO Function Block does not
Suspend EGD
In a Series 90-70 the SUSPEND_IO function block suspends
EGD in addition to IO Scan. In PACSystems controllers the
SUSPEND IO only suspends IO Scan.
Installation in Hazardous Locations
The following information is for products bearing the UL marking for Hazardous Locations:

WARNING - EXPLOSION HAZARD - SUBSTITUTION OF COMPONENTS MAY IMPAIR SUITABILITY FOR CLASS
I, DIVISION 2;

WARNING - EXPLOSION HAZARD - WHEN IN HAZARDOUS LOCATIONS, TURN OFF POWER BEFORE
REPLACING OR WIRING MODULES; AND

WARNING - EXPLOSION HAZARD - DO NOT CONNECT OR DISCONNECT EQUIPMENT UNLESS POWER HAS
BEEN SWITCHED OFF OR THE AREA IS KNOWN TO BE NONHAZARDOUS.

EQUIPMENT LABELED WITH REFERENCE TO CLASS I, GROUPS A, B, C & D, DIV. 2 HAZARDOUS
LOCATIONS IS SUITABLE FOR USE IN CLASS I, DIVISION 2, GROUPS A, B, C, D OR NON-HAZARDOUS
LOCATIONS ONLY

The tightening torque range for the control terminals is 9.6–11.5 in. lb. Use only wire rated for 90°C. Be sure to
observe any additional ratings that are provided with the modules.
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