GE Fanuc Genius Block Selection Guide
The GE Fanuc Genius block is a distributed I/O platform produced by Emerson Automation, previously known as GE Fanuc Automation. Genius blocks are intelligent, rugged, and self-contained Input/Output modules. They are enhanced with advanced diagnostics capabilities and a variety of software-configurable features.
The Genius I/O systems are popular for providing considerably shorter wiring runs, fewer terminations to document, as well as simpler and more effective diagnostics and troubleshooting. They automatically provide diagnostic information on the state of the communication network, the I/O modules circuits, and the field wiring, as well as the power and loads conditions. The Genius blocks' diagnostics drastically reduce the time required for initial systems control and debugging.
GE Fanuc Genius blocks are highly preferred since they also provide predictable I/O system operation in the event of CPU, network cable, or bus interface failure. For instance, if a GE Fanuc Genius block is connected in a redundant configuration with two or more PLC/Computer CPUs operating simultaneously, it will automatically shift to a backup CPU whenever the main controller malfunctions or fails to communicate.
Selection Criteria
Several key features should be considered whenever you’re selecting a GE Fanuc Genius Block for a given application. These features include the parts of a Genius I/O Block, the available Genius I/O Blocks, controller compatibility, communication features, power monitoring blocks, and environmental specifications.
Parts of a Genius I/O Block
A GE Fanuc Genius Block consists of a matching electronics assembly and a terminal assembly. The electronics assembly consists of all active components, Input/Output, and communications circuits. The terminal assembly forms the base of the Genius block. It is electrically and mechanically designed to accept only a similar electronics assembly. Ensure that you select an electronics assembly that is compatible with the terminal assembly of the Genius block you’re considering. Check the compatibility in terms of the same voltage rating, an equal number of I/O circuits, and the same type of wiring configuration.
The mounting of the electronics assembly should allow you to easily disconnect and remove it, without interfering with the field wiring. Also, the configuration of the GE Fanuc Genius block should be stored in the terminal assembly, such that you will not need to reconfigure the block in case you switch out the electronics assembly.
Available Genius I/O Blocks
GE Fanuc Genius blocks provide an interface to a wide range of analog, discrete, and special-purpose Input/Output field devices. Depending on your application, select the Genius I/O blocks that are compatible with the field devices you intend to interface with. The available discrete, analog, and special-purpose Genius blocks include:
- 115 VAC 8-Circuit Grouped I/O Genius Block: This block supports up to 8 discrete I/O configurable circuits with a nominal voltage rating of 115 volts AC. Each of the 8 circuits can be an input, a tristate input, or a discrete output. The available I/O modules within this category include a 115-volt AC Grouped I/O block, as well as a low-leakage 115-volt AC Grouped I/O block. This block does not require a separate power supply as the control power is tapped off the input/output device voltages wired to the terminal assembly.
- 115 VAC/125 VDC Isolated I/O Genius Block: Each of these blocks has an operating voltage of 115 volts AC or 125 volts DC. GE Fanuc Automation provides four isolated modules of two I/O discrete circuits, which include the 115 VAC/125 VDC Isolated I/O module with output failed switch diagnostic, as well as the low-leakage 115 VAC/125 VDC Isolated I/O module with output failed switch diagnostic. These Genius Blocks report a failed switch diagnostic when the actual state of the Genius block’s internal switch does not match the command-based output. There is also the 115 VAC/125 VDC Isolated I/O module, as well as the low-leakage 115VAC/125VDC Isolated I/O module. These GE Fanuc Genius Blocks ignore the differences between the actual state of the block’s internal switch and the command-based outputs state. They are well suited for applications where field wiring, such as a manual switch, is to be wired in parallel with the Genius block outputs. If you were to select these blocks, ensure that their isolation rating can withstand 250 VAC/VDC continuous voltage between any of the four groups and ground, or between any two isolated groups. Check that the transient rating for these groups is a 2000V peak for 10 seconds.
- 115 VAC 16-Circuit Input Genius Block: This block has sixteen (16) discrete input circuits contained in two groups, with each having eight (8) circuits. It can be used with both 3-wire and 2-wire proximity switch inputs. Typical inputs for this block are limit switches, contact closures from switches, or pushbuttons.
- Relay Output Blocks: GE Fanuc offers Genius Relay Output Blocks that provide 16 output circuits within four independent groups, with each group having four-relay type outputs. There are two types of Relay Output Genius Blocks. These include the 115VAC/230VAC Relay Output Block (IC660BBR100) with normally closed (NC) contacts and the 115VAC/230VAC Relay Output Block (IC660BBR101) with normally open (NO) contacts.
- 16-Circuit DC Input/Output Genius Blocks: This category is comprised of four different types of 16 discrete I/O configurable circuits from Ge Fanuc Automation. Two of these blocks are source blocks that provide current to compatible field output devices, while the other two are sink blocks, which are powered by field output devices. The source blocks include the 24 VDC source block (IC660BBD022), which is to be used with 3-wire and 2-wire electromechanical and solid-state sensors, and the 24/48 VDC (IC660BBD020) source block, which can be used with 3-wire electromechanical and solid-state sensors. The two sink Genius Blocks are the IC660BBD021, which can only be used with 3-wire electromechanical sensors and solid-state sensors, as well as the IC660BBD023, which can be used with both 3-wire and 2-wire electromechanical sensors and solid-state sensors.
- 32-Circuit DC Input/Output Genius Blocks There are two types of 32-discrete I/O configurable circuits from GE Fanuc. There is the 32-circuit 12/24 VDC source block (IC660BBD024), which provides current to field I/O modules, and the 32-circuit 5/12/24 VDC sink block (IC660BBD025) powered by field output I/O devices. The two blocks operate with a nominal input voltage of 12 volts DC to 24 volts DC. However, the sink Genius block is also +5 volts TTL (Transistor-Transistor Logic)-compatible, meaning that it can sink higher current levels than it can source. The 32-circuit sink version is best suited for applications where the loads exceed the available source current.
- Analog I/O Genius Blocks: In this category, GE Fanuc Automation provides 4 analog inputs with four independent input circuits, and 2 analog outputs with four independent output circuits. The available Genius Blocks are the IC660BBA020 with a voltage rating of 24/48 volts DC, and the IC660BBA100 with a voltage rating of 115 VAC/125 VDC.
- Analog Current-source 6-Input Blocks: These Genius Blocks have 6 input circuits and are used to interface a controller to field devices that provide an analog signal of 4 milliamperes to 20 milliamperes. The available GE Fanuc Genius blocks in this category have two different power supplies. They include the IC660BBA026 24/48 VDC current-source analog input block and the IC660BBA106 115 VAC/125 VDC current-source analog input block. Other than the power supplies, the two blocks are similar in all other aspects.
- Analog Current-source 6-Output Blocks: These blocks have 6 output circuits that accept analog signals between 4 milliamperes and 20 milliamperes. Note that you can use output 5 and 6 circuits for voltage applications. There are two Genius Blocks available in this category. These Genius Blocks include the IC660BBA025 24/48 VDC current–source analog 6-output block and the IC660BBA105 115 VAC/125 VDC current–source analog 6-output block.
- RTD 6-Input Blocks: These blocks monitor temperature inputs from RTDs (Resistive Temperature Detectors). The GE Fanuc Genius blocks in this category can accommodate either 3-wire or 2-wire RTD sensors. The 6 RTD Inputs are isolated from the logic. There are two available 6-RTD input blocks. These include the IC660BBA021 24/48 VDC RTD Block and the IC660BBA101 115 VAC/125 VDC RTD Block.
- Thermocouple 6-Input Blocks: Thermocouple 6-Input Genius Blocks from GE Fanuc are used to monitor temperature from standard thermocouple input devices. You can use these input blocks to measure low-level input signals. The available blocks within this category include the IC660BBA103 115 VAC/125 VDC Thermocouple Block and the IC660BBA023 24/48 VDC Thermocouple Block.
Controller Compatibility
You can use GE Fanuc Genius Blocks with any Genius Bus Controller and other controllers. The compatible controllers of the Genius Blocks are computer bus controllers, PLC bus controllers, and a handheld monitor.
Computer Bus Controllers
GE Fanuc Automation offers three different types of computer-host bus controllers which can be used in IBM PC/XT/AT or other equivalent PCs (Personal Computers). Please note that you can only use the three Genius bus controllers within EISA-compatible and ISA-compatible computers. However, these bus controllers are not compliant with EISA backplane extensions.
You can interface the IC660ELB922 PCIM (Personal Computer Interface Module) to two independent Genius buses, while the IC660ELB921 single-slot PCIM only interfaces to one Genius bus. If your computer has an XT-type slot, you can install the IC660ELB906 PCIM, which interfaces to one Genius bus only.
While selecting the Computer Bus Controllers to interface with the selected Genius blocks, you also need to check the PCIM software requirements. For a computer controller, ensure that the diagnostics messages and routine handling of I/O devices are included in the application program. This is because a personal computer does not have built-in logic like a PLC, hence, it cannot handle those functions automatically. In that case, the PCIM should be provided with a software interface consisting of easy-to-use macro-oriented function calls that can be included in C or BASIC (Beginners' All-purpose Symbolic Instruction Code) language application routines.
PLC Bus Controllers
In a PLC, the Genius bus controller automatically transmits Input/Output data between the bus and the CPU. Various types of CPUs can interface to a PLC Genius bus, including the Series Five PLC, the Series 90-70 PLC, the Series Six Plus and Series Six PLCs, and the Series 90-30 PLC.
PLC Genius controllers do not require special programming for routine I/O service, like PCIM modules. The aforementioned PLC CPUs automatically handle the diagnostics available from the Genius bus controller.
Note that in Personal Computer Interface Modules (PCIMs) or PLC controllers, the Genius bus controllers are used to manage data exchange between the Genius bus and the CPU. Then, the Application program on the host computer or PLC receives the data, and on sorting it out, it provides the essential data to be sent back via the bus. In that regard, check that the Application programming features and techniques suit your requirements.
A Genius bus I/O controller may be enhanced with communications commands based on the Application program. In some cases, the bus can be dedicated to I/O control with numerous I/O devices, and without additional communication features. In other cases, the bus may be used entirely for CPU communications, between multiple CPUs, and without any I/O devices. Therefore, you can use the Genius bus controllers to develop more complex systems with dual CPUs, dual buses, and additional CPUs for data monitoring.
Handheld Monitor
This is a convenient operator interface device used to configure GE Fanuc Genius blocks. It is also used to set up and monitor Genius I/O blocks and communication systems. Ensure that the Hand-held Monitor (HHM) you purchase is capable of communicating with the I/O Genius blocks and can force discrete and analog I/O modules on and off, whether or not a PCIM or PLC is connected to the Genius bus. This simplifies system checkout before full-scale operation.
Communication Features
Contrary to the traditional rack-mounted I/O modules, GE Fanuc Genius Blocks communicate with the system CPUs over a Genius LAN. The Genius LAN performs equally well with either low- or high-density I/O Genius blocks. It can be used to integrate a variety of GE Fanuc I/O blocks, Field Control, and VersaMax systems. This flexibility will enable you to deploy the most efficient combination of low-density and high-density Genius blocks for your application. The Genius LAN also greatly simplifies the installation of the Genius block system and network tools.
You can use EtherNet/IP to GE Genius Gateway (AN-X2-GENI) if you want to upgrade or replace the GE Genius-based 90-70 and 90-30 bus controllers. This gateway supports a phased migration approach. It enables Allen-Bradley PAC (Programmable Automation Controllers) systems to control GE Fanuc Genius I/O blocks. Also, if you intend to minimize the risk of excessive downtime when upgrading Genius bus controllers for your GE Genius blocks, then the EtherNet/IP to GE Genius Gateway is your ideal choice.
Power Monitoring Blocks
Confirm that the GE Fanuc Genius Block is fitted with power monitoring blocks. For power monitoring, GE Fanuc Automation provides the Genius PowerTRAC block, which monitors voltage and current inputs, and stores digitized waveform values for each current and voltage input. Using the stored values, the block calculates RMS current, voltage, KWH, power factor, active power, and reactive power. After which it automatically sends the calculated data values to a host PCIM or PLC approximately two times per second. The same calculated data values can also be displayed on a Genius HHM (Hand-Held Monitor), either remotely or from any connection point to the Genius bus.
You can use a PowerTRAC Genius block with a delta- or wye-configured single-phase or three-phase power system. This block can accept current inputs from, at most, three-line current transformers and an additional neutral current transformer. It also accepts voltage inputs from either one or three potential transformers. This makes it well-suited for many types of industrial power monitoring applications.
Environmental Specifications
The GE Fanuc Genius block you select should meet the following environmental specifications for proper operation:
- Temperature: The Genius I/O blocks are designed to operate reliably in temperatures of up to 60 degrees Celsius (140 degrees Fahrenheit). Ensure that the temperatures have been measured adjacent to the Genius block at the bottom of the Electronics Assembly. The optimum operating temperatures range between 35 degrees Celsius to 65 degrees Celsius (95 degrees Fahrenheit to 149 degrees Fahrenheit), where each 10 degree Celsius reduction in the ambient temperature leads to an increase in the electronics Mean Time Between Failures (MTBF) with a factor of two.
- Noise: When installed according to standard industry practices, the GE Fanuc Genius I/O blocks are resistant to industrial noise. Therefore, ensure that installation of the Genius blocks includes proper separation of the wiring by power and voltage levels. The Genius blocks you are to select should also be compliant with the following noise specifications: (i) Radiated: FCC part 15, class A, and section J (Computing Devices). (ii) Received: NEMA ICS 2–230 ANSI/IEEE C37.90 (Relay systems and relays associated with Electrical Power Apparatus).
- Vibration: The Genius I/O blocks are built as compact and sturdy modules, which can withstand an optimum amount of vibration. Check that the Genius I/O block design you select is vibration-tested according to IEC 68–2–6 and Mil-Std 810C standards. The vibration tests should meet the following specifications: (i) 5 to 10 Hz 0.200-inch displacement (peak to peak), (ii) Shock: 15G, and (iii) 10 to 200 Hz at 1 g.
Conclusion
By providing distributed I/O control on the factory floor, the GE Fanuc Genius Blocks offer considerably shorter wiring runs, fewer terminations to document, as well as simpler and more effective diagnostics and troubleshooting. In a variety of industries, from food processing to automotive to steel plants, more than half a million Genius blocks from GE Fanuc Automation are assisting companies to address the challenges of an increasingly competitive industrial automation marketplace.
This article guides you on how to select discrete, analog, and special-purpose Genius I/O blocks based on your application needs. It also provides a brief description of the controllers that are compatible with the GE Fanuc Genius blocks, as well as the available communication features for the blocks. Moreover, the recommended environmental specifications which you should check to make sure that your Genius block system is operating within safe ranges, have been outlined.