This technical note describes the porcedure for using the PLC IO Interface to auto-configure a GE Genius or TRIO IO network installation.

Cable pinout for connecting GE PIO unit to GE Block for Auto-Configure

See section 2.3 of the manual for some diagrams, which will help with the wiring.

The Genius Bus uses a 3-conductor cable (such as the BELDEN 3108A). The cable is wired to a 6-pin Weidmuller plug connector (supplied). The cable connects to the plug as follows. Note that the screws are facing you in the diagram below.

For plant testing the PIO can be connected to the Genius bus using the communicator port on any of the I/O blocks or the controller. A special cable is made using the 6-pin Weidmuller plug connector and a GE Block 9-pin connector. The PIO is added to the existing Genius bus by simply plugging the cable into the Hand Held Communicator port on any of the I/O blocks or the controller. The pin out is as follows:

Do not connect a resistor, as the live bus should have terminating resistors already attached. For more details regarding GE Genius block wiring, please refer to GE Genius I/O Systems & Communications Manual.

Procedure

Before beginning the Auto-Configure, the following information will need to be gathered about the GE Genius Bus:

1. DeltaV Controller name(s)
2. Serial Card number(s)
3. Layout of GE Genius Blocks - Address (so an unused address may be selected).

The following steps for modifying the PIO must be done by carefully setting the dipswitches on the internal boards of the PIO unit:

4. The unit is removed from the base. In a static free environment open the box (remove the screw and pop the lid free. Pull the circuit boards out as little as possible to view the two dipswitch blocks (top right of the right most circuit board.(LED's are attached to the left board).

DIP Switch Locations

SW 1 (Circuit board and dipswitch block viewed from side)

Sets the initial default IO cards bus address and connection baud rate (default settings are shaded). Setting any other switches on dipswitch block 1 (switch 8) or 2 (switches 1-8) will have unpredictable results.

Note switches in each switch block are numbered from top to bottom, and off is to the unit front. In addition, to come up with Address 30 we evaluate SW5-SW1 as 11110 in binary which is 30 decimal.

5. Set PIO Address to a unique, unused Address on the Bus. The Default Address is 31. If this PIO is connected to a live system with a bus controller at address 31, it will not be able to communicate with the blocks and may even prevent the bus controller from communicating. This address must be changed. Any unused address, but 0 is usually available (this is used by the HHM (Hand Held Monitor). If set to 0, do not attach a HHM unless the PLC IO module is disconnected or offline.

6. Baud Rate of Blocks on Bus and PIO must match. While a PIO module set to 153.6 Std may be able to communicate with 153.6 Ext blocks, there may be sporadic data loss. This may be acceptable for communicating data, but will fail configuration upload.

7. Reseat the circuit boards and refit the unit top.

Upload Procedure

1. Connect PLC IO unit to Laptop and GE Genius Bus
2. Open PLC Explorer application.
3. Add a new controller of type DeltaV Controller name must match DeltaV Controller name.
4. Add a new card of type GE RIO – Card number must match DeltaV card number.
5. Assign IP Address information of PLC IO unit. (see manual)
6. Select Advanced and Disable Watchdog. (see manual), set from “Offline” to “Standby”, then select “Active”.
7. Open GEDiagnostics application.
8. Check for Bus Errors - Any Bus Errors must be fixed by troubleshooting before upload can proceed.
9. Close GEDiagnostics, return to PLC Explorer.
10. Right-Click Card and select Auto-Configure.
11. Scan will begin. During Scan, if prompted, select appropriate Block type (refer to Layout information previously gathered).
12. Once Scan is complete. Save File.

Data Verification

1. Confirm data acquired in PLC Explorer matches the layout of the GE Genius Bus.
2. Export PLC Explorer data to FHX:
   1. If PLC Explorer is on a DeltaV ProPlus, export to FHX
   2. If PLC Explorer is NOT on a DeltaV ProPlus, export to FHX, copy to ProPlus & run Migration Tool from DeltaV Database Administrator

   When finished with the capture, the PIO unit should have its address reset to 31 (or whatever bus address is being used for control communications) before it is used as a bus controller.