GE VersaMax User Manual

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IC200CMM020

GE Fanuc

Versamax

New In Stock!

Modbus Master module for Versamax Genius NIU. Module

supports one RS-485 serial port. IC200C IC200CM IC200CMM

http://www.pdfsupply.com/automation/ge-fanuc/versamax/IC200CMM020

www.pdfsupply.com

1-919-535-3180

Email: sales@pdfsupply.com

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Warnings, Cautions, and Notes

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as Used in this Publication

Warning

Warning notices are used in this publication to emphasize that hazardous voltages, currents, temperatures, or other conditions that could cause personal injury exist in this equipment or may be associated with its use.

In situations where inattention could cause either personal injury or damage to equipment, a Warning notice is used.

Caution

Caution notices are used where equipment might be damaged if care is not taken.

Note

Notes merely call attention to information that is especially significant to understanding and operating the equipment.

GFL-002

This document is based on information available at the time of its publication. While efforts have been made to be accurate, the information contained herein does not purport to cover all details or variations in hardware or software, nor to provide for every possible contingency in connection with installation, operation, or maintenance. Features may be described herein which are not present in all hardware and software systems. GE Fanuc Automation assumes no obligation of notice to holders of this document with respect to changes subsequently made.

GE Fanuc Automation makes no representation or warranty, expressed, implied, or statutory with respect to, and assumes no responsibility for the accuracy, completeness, sufficiency, or usefulness of the information contained herein. No warranties of merchantability or fitness for purpose shall apply.

The following are trademarks of GE Fanuc Automation North America, Inc.

Alarm Master Genius PowerTRAC Series Six CIMPLICITY Helpmate ProLoop Series Three CIMPLICITY 90–ADS Logicmaster PROMACRO VersaMax CIMSTAR Modelmaster Series Five VersaPoint Field Control Motion Mate Series 90 VersaPro GEnet PowerMotion Series One VuMaster

Workmaster

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Contents

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Chapter 1

Chapter 2

Introduction................................................................................................ 1-1

Getting Started .........................................................................................................1-1

The VersaMax

CPU Modules for VersaMax PLCs.......................................................................... 1-4

Network Interface Units........................................................................................... 1-6

Power Supplies......................................................................................................... 1-8

I/O Modules .............................................................................................................1-9

Carriers................................................................................................................... 1-13

Expansion Modules................................................................................................ 1-15

Communications Modules......................................................................................1-17

VersaMax General Product Specifications.............................................................1-19

Installation Instructions.............................................................................2-1

Preinstallation Check ...............................................................................................2-1

Conformance to Standards ....................................................................................... 2-2

Thermal Considerations ........................................................................................... 2-2

DIN Rail and Panel Mounting.................................................................................. 2-3

Installing an Expansion Transmitter Module ........................................................... 2-5

Installing a Power Supply ........................................................................................ 2-9

System Wiring Guidelines .....................................................................................2-11

System Grounding.................................................................................................. 2-15

Installing Wiring for I/O Devices...........................................................................2-16

Installing Modules.................................................................................................. 2-36



Family of Products ........................................................................1-3

Chapter 3

Chapter 4

GFK-1504K iii

Power Supplies ...........................................................................................3-1

IC200PWR001 24VDC Power Supply ...................................................................................3-2

IC200PWR002 24VDC Expanded 3.3 V Power Supply.........................................................3-4

IC200PWR101 120/240VAC Power Supply..........................................................................3-6

IC200PWR102 120/240VAC Expanded 3.3V Power Supply.................................................3-8

IC200PWR201 12VDC Power Supply ................................................................................. 3-10

IC200PWR202 12VDC Expanded 3.3 V Power Supply.......................................................3-12

Carriers ....................................................................................................... 4-1

IC200CHS001 Barrier-Style I/O Carrier.................................................................................4-2

IC200CHS002 Box-Style I/O Carrier .....................................................................................4-5

IC200CHS003 Connector-Style I/O Carrier ...........................................................................4-8

IC200CHS005 Spring-Style I/O Carrier ...............................................................................4-11

IC200CHS022 Compact Box-Style I/O Carrier....................................................................4-14

IC200CHS025 Compact Spring-Style I/O Carrier................................................................4-17

IC200CHS006 Communications Carrier ..............................................................................4-20

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Contents

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IC200PWB001 Power Supply Booster Carrier..................................................................... 4-21

Chapter 5

Chapter 6

Chapter 7

Interposing Terminals and Auxiliary I/O Terminal Strips....................5-1

IC200CHS011 Barrier-Style Interposing I/O Terminals........................................................5-2

IC200CHS012 Box-Style Interposing I/O Terminals .............................................................5-4

IC200CHS014 Thermocouple Compensation Box-Style Interposing I/O Terminals..............5-6

IC200CHS015 Spring-Style Interposing I/O Terminals .........................................................5-8

IC200CHS101, Main Base IC200CHS102, Expansion Base Disconnect-Style Interposing

I/O Terminals........................................................................................................................5-10

IC200CHS111, Main Base IC200CHS112, Expansion Base Relay-Style Interposing I/O

Terminals..............................................................................................................................5-14

IC200TBM001 Barrier-Style Auxiliary I/O Terminal Strip..................................................5-19

IC200TBM002 Box-Style Auxiliary I/O Terminal Strip ......................................................5-20

IC200TBM005 Spring-Style Auxiliary I/O Terminal Strip ..................................................5-21

Expansion Modules.................................................................................... 6-1

IC200ETM001 Expansion Transmitter Module......................................................................6-2

IC200ERM001 Expansion Receiver Module, Isolated ...........................................................6-7

IC200ERM002 Expansion Receiver Module, Non-isolated .................................................6-11

Discrete Input Modules..............................................................................7-1

IC200MDL140 Input Module, 120VAC 8 Points...................................................................7-2

IC200MDL141 Input Module, 240VAC 8 Points...................................................................7-5

IC200MDL143 Input Module, 120VAC Isolated 8 Points .....................................................7-8

IC200MDL144 Input Module, 240VAC Isolated 4 Points ...................................................7-11

IC200MDL240 Input Module, 120VAC 16 Points............................................................... 7-14

IC200MDL241 Input Module, 240VAC16 Points................................................................ 7-18

IC200MDL243 Input Module, 120VAC Isolated 16 Points .................................................7-21

IC200MDL244 Input Module, 240VAC Isolated 8 Points ...................................................7-25

IC200MDL631 Input Module, 125VDC Pos/Neg Logic Isolated 8 Points...........................7-28

IC200MDL632 Input Module, 125VDC Pos/Neg Logic Isolated 16 Points.........................7-31

IC200MDL635 Input Module, 48VDC Pos/Neg Logic Grouped 16 Points .........................7-35

IC200MDL636 Input Module, 48VDC Pos/Neg Logic Grouped 32 Points .........................7-38

IC200MDL640 Input Module, 24VDC Pos/Neg Logic 16 Points........................................7-42

IC200MDL643 Input Module, 5/12VDC Pos/Neg Logic Grouped 16 Points ......................7-45

IC200MDL644 Input Module, 5/12VDC Pos/Neg Logic Grouped 32 Point........................ 7-49

IC200MDL650 Input Module, 24VDC Pos/Neg Logic 32 Points........................................7-53

Chapter 8

iv VersaMax® Modules, Power Supplies, and Carriers User's Manual– March 2003 GFK-1504K

Discrete Output Modules........................................................................... 8-1

IC200MDL329 Output Module, 120VAC 0.5 Amp, Isolated 8 Points...................................8-2

IC200MDL330 Output Module, 120VAC 0.5 Amp, Isolated 16 Points.................................8-6

IC200MDL331 Output Module, 120VAC 2.0 Amp, Isolated 8 Points.................................8-10

IC200MDL730 Output Module, 24VDC Positive Logic 2.0 Amps, w/ESCP 8 Points ........8-14

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Contents

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IC200MDL740 Output Module, 12/24VDC Positive Logic 0.5 Amp, 16 Points .................8-17

IC200MDL741 Output Module, 24VDC Positive Logic 0.5 Amp, w/ESCP 16 Points....... 8-21

IC200MDL742 Output Module, 24VDC Positive Logic 0.5 Amp, w/ESCP 32 Points....... 8-25

IC200MDL743 Output Module, 5/12/24V DC Negative Logic 0.5 Amp, 16 Points............ 8-29

IC200MDL744 Output Module, 5/12/24VDC Negative Logic 0.5 Amp, 32 Points.............8-32

IC200MDL750 Output Module, 12/24VDC Positive Logic 0.5 Amp, 32 Points .................8-36

IC200MDL930 Output Module, Relay 2.0 Amp Isolated Form A 8 Points..........................8-40

IC200MDL940 Output Module, Relay 2.0 Amp, Isolated Form A 16 Points......................8-44

Chapter 9

Discrete Mixed Modules ............................................................................ 9-1

IC200MDD840 Mixed Module, 24VDC Positive Logic Input 20 Points / Output Relay 2.0

Amp 12 Points ........................................................................................................................ 9-2

IC200MDD842 Mixed Module, Output 24VDC Pos. Logic 0.5A Grouped w/ESCP 16 Points

/ Input 24VDC Pos/Neg Logic Grouped 16 Points................................................................. 9-6

IC200MDD843 Mixed Module, 24VDC Positive Logic Input Grouped 10 Points / Output

Relay 2.0A per Point Grouped 6 Points................................................................................ 9-12

IC200MDD844 Mixed Module, Output 12/24VDC Pos. Logic 0.5A 16 Points / Input 24 VDC

Pos/Neg Logic Grouped 16 Points........................................................................................9-16

IC200MDD845 Mixed Module, Output Relay 2.0A Isolated 8 Points / Input 24VDC Pos/Neg

Logic Grouped 16 Points......................................................................................................9-21

IC200MDD846 Mixed Module, Output Relay 2.0A per Pt Isolated 8 Points / Input 120VAC

Grouped 8 Points .................................................................................................................. 9-27

IC200MDD847 Mixed Module, Output Relay 2.0A per Pt Isolated 8 Points / Input 240VAC

Grouped 8 Points .................................................................................................................. 9-31

IC200MDD848 Mixed Module, Output 120VAC 0.5A per Pt Isolated 8 Points / Input

120VAC Grouped 8 Points...................................................................................................9-35

IC200MDD849 Mixed Module Output Relay 2.0A per Pt Isolated 8 Points / Input 120VAC

Isolated 8 Points....................................................................................................................9-40

IC200MDD850 Mixed Module, Output Relay 2.0A per Pt Isolated 8 Points / Input 240VAC

Isolated 4 Points....................................................................................................................9-44

IC200MDD851 Mixed Module, Output 12/24VDC Positive Logic Grouped 16 Points / Input

5/12VDC Pos/Neg Logic Grouped 16 Points ......................................................................9-48

Chapter 10 Analog Input Modules ............................................................................. 10-1

IC200ALG230 Analog Input Module, 12 Bit Voltage/Current 4 Channels.......................... 10-2

IC200ALG240 Analog Input Module, 16 Bit Voltage/Current, 1500VAC Isolation, 8

Channels ...............................................................................................................................10-9

IC200ALG260 Analog Input Module, 12 Bit Voltage/Current 8 Channels........................ 10-17

IC200ALG261 Analog Input Module, 15 Bit Differential Voltage 8 Channels..................10-24

IC200ALG262 Analog Input Module, 15 Bit Differential Current 8 Channels..................10-29

IC200ALG263 Analog Input Module, 15 Bit Voltage 15 Channels ...................................10-36

IC200ALG264 Analog Input Module, 15 Bit Current 15 Channels ...................................10-42

Chapter 11 Analog Output Modules ..........................................................................11-1

IC200ALG320 Analog Output Module, 12 Bit Current, 4 Channels.................................... 11-2

GFK-1504K Contents v

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Contents

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IC200ALG321 Analog Output Module, 12 Bit Voltage 0 to 10VDC 4 Channels................11-9

IC200ALG322 Analog Output Module, 12 Bit Voltage -10 to +10VDC 4 Channels.........11-15

IC200ALG325 Analog Output Module, 13 Bit Voltage 8 Channels ..................................11-21

IC200ALG326 Analog Output Module, 13 Bit Current, 8 Channels.................................. 11-28

IC200ALG327 Analog Output Module, 13 Bit Voltage 12 Channels ................................11-34

IC200ALG328 Analog Output Module, 13 Bit Current, 12 Channels................................ 11-41

IC200ALG331 Analog Output Module, 16 Bit Voltage/Current, 1500VAC Isolation, 4

Channels .............................................................................................................................11-48

Chapter 12 Analog Mixed I/O Modules ..................................................................... 12-1

IC200ALG430 Analog Mixed Module, 12 Bit Input Current 4 Channels and Output Current 2

Channels ...............................................................................................................................12-2

IC200ALG431 Analog Mixed Module, 12 Bit 0 to 10VDC Input 4 Channels and Output 2

Channels ...............................................................................................................................12-9

IC200ALG432 Analog Mixed Module, 12 Bit +/-10VDC Input 4 Channels and Output 2

Channels .............................................................................................................................12-16

Chapter 13 Mixed Discrete/High-speed Counter Module ........................................ 13-1

IC200MDD841 Mixed Module, 24VDC Positive Logic Input 20 Points / Output 12 Point / (4)

High Speed Counter, PWM, or Pulse Train Configurable Points .........................................13-2

Chapter 14 Temperature-Sensing Modules...............................................................14-1

IC200ALG620 Analog Input, 16 Bit RTD, 4 Channels........................................................ 14-2

IC200ALG630 Analog Input, 16 Bit Thermocouple, 7 Channels....................................... 14-10

Chapter 15 Accessories ................................................................................................ 15-1

IC200ACC301 I/O Filler Module.........................................................................................15-2

IC200ACC302 Input Simulator ............................................................................................ 15-3

IC200ACC303 I/O Shorting Bar...........................................................................................15-4

Appendix A Panel Mounting Dimensions..................................................................... A-1

Thermal Considerations .......................................................................................... A-2

Module Space Requirements................................................................................... A-3

Module Sizes........................................................................................................... A-4

Panel-Mounting Details .......................................................................................... A-5

Example Mounting Dimensions............................................................................ A-11

Appendix B Relay Contact Ratings .............................................................................. B-1

Appendix C Power Supply Load Requirements.......................................................... C-1

Appendix D I/O Module Keying Summary.................................................................. D-1

vi VersaMax® Modules, Power Supplies, and Carriers User's Manual– March 2003 GFK-1504K

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Chapter

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Getting Started

Guide to the VersaMax Document Set

Introduction

Read this chapter first to learn about the basics of VersaMax I/O®. To locate detailed information, check the Guide to the VersaMax Document Set below.

This manual contains descriptions of the many VersaMax I/O and option modules, power supplies, and carriers.

Installation procedures are described in Chapter 2.

The rest of the chapters in this manual describe the wide variety of VersaMax I/O modules, carriers, and accessories that are available.



Power Supplies: chapter 3



Carriers: chapter 4



Interposing Terminals and Terminal Strips: chapter 5



Expansion Modules: chapter 6



Discrete Input Modules: chapter 7



Discrete Output Modules: chapter 8



Discrete Mixed Modules: chapter 9



Analog Input Modules: chapter 10



Analog Output Modules: chapter 11



Analog Mixed Modules: chapter 12



Discrete Mixed/High Speed Counter Module: chapter 13



Temperature-sensing Modules: chapter 14



Accessories: chapter 15

The appendixes to this manual contain detailed reference information.

GFK-1504K 1-1

Page 9

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Other VersaMax Manuals

For more information about VersaMax products, consult the manuals described below.

VersaMax PLC System Manual (catalog number GFK-

1503)

VersaMax Ethernet Network Interface Unit User’s Manual

(catalog number GFK-1860)

VersaMax DeviceNet Modules User’s Manual (catalog

number GFK-1533)

VersaMax Profibus Network Modules User’s Manual

(catalog number GFK-1534)

Describes the installation and operation of the PLC System. This manual also contains general information about CPU operation and program features.

Describes the installation and operation of the Ethernet NIU. The Ethernet NIU interfaces an I/O station of VersaMax modules to an Ethernet Network.

Describes the installation and operation of the DeviceNet NIU and DeviceNet Network Communications Module.

The DeviceNet NIU interfaces an I/O station of VersaMax modules to a DeviceNet Network. It operates as a slave on the network.

The DeviceNet Network Communications Module can operate as a master or slave on the DeviceNet network.

Describes the installation and operation of the Profibus Network Interface Unit and Profibus Network Slave Module.

The Profibus NIU interfaces an I/O station of VersaMax modules to a Profibus Network. It operates as a slave on the network.

The Profibus Network Slave Module operates as a slave on the Profibus network.

Describes the installation and operation of the Genius NIU. The

VersaMax Genius Network Interface Unit User’s Manual

(catalog number GFK-1535)

VersaMax AS-i Network Master Module User’s Manual

(catalog number GFK-1697)

1-2 VersaMax® Modules, Power Supplies, and Carriers User's Manual – March 2003 GFK-1504K

Genius NIU interfaces an I/O station of VersaMax modules to a Genius Network.

Describes the installation and operation of the VersaMax AS-Interface Network Master module (IC200BEM104), which can be used to interface a VersaMax PLC or I/O station NIU to an AS-i network.

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The VersaMax Family of Products

The VersaMax family of products provides universally-distributed I/O that spans PLC and PC-based architectures. Designed for industrial and commercial automation, VersaMax I/O provides a common, flexible I/O structure for local and remote control applications. The Versamax PLC provides big-PLC power with a full range of I/O and option modules. VersaMax I/O Stations with Network Interface Modules make it possible to add the flexibility of VersaMax I/O to other types of networks. VersaMax meets UL, CUL, CE, Class1 Zone 2 and Class I Division 2 requirements.

As a scaleable automation solution, VersaMax I/O combines compactness and modularity for greater ease of use. The 70-mm depth and small footprint of VersaMax I/O enables easy, convenient mounting as well as space-saving benefits. Modules can accommodate up to 32 points of I/O each.

The compact, modular VersaMax products feature DIN-rail mounting with up to eight I/O and option modules per “rack” and up to 8 racks per VersaMax PLC or VersaMax I/O Station system. Expansion racks can be located up to 750 meters from the main VersaMax PLC or VersaMax I/O Station rack. Expansion racks can include any VersaMax I/O, option, or communications module.

VersaMax provides automatic addressing that can eliminate traditional configuration and the need for hand-held devices. Multiple field wiring termination options provide support for two, three, and four-wire devices.

For faster equipment repair and shorter Mean-Time-To-Repair, the hot insertion feature enables addition and replacement of I/O modules while a machine or process is running and without affecting field wiring.

GFK-1504K Chapter 1 Introduction 1-3

Page 11

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CPU Modules for VersaMax PLCs

A VersaMax PLC consists of a group of VersaMax modules with a VersaMax CPU and attached power supply in the first position.

VersaMax PLC CPU

power supply

All VersaMax CPUs provide powerful PLC functionality. They are designed to serve as the system controller for up to 64 modules with up to 2048 I/O points. Two serial ports provide RS-232 and RS-485 interfaces for SNP slave and RTU slave communications.

VersaMax Modules

VersaMax CPUs are described in the 1503 also provides programming information for the VersaMax PLC.

VersaMax PLC User’s Manual

(GFK-1503). GFK-

Basic CPU Features



Programming in Ladder Diagram, Sequential Function Chart, and Instruction List



Floating point (real) data functions



Non-volatile flash memory for program storage



Battery backup features for program, data, and time of day clock



Super capacitor provides power to memory for 1 hour



Over 1 hour, backup battery protects memory contents up to 6 months.



Backup battery has shelf life of 5 years when not in use.



Run/Stop switch



Embedded RS-232 and RS-485 communications

1-4 VersaMax® Modules, Power Supplies, and Carriers User's Manual – March 2003 GFK-1504K

Page 12

Available VersaMax CPUs

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CPU with Two Serial Ports, 34kB of Configurable Memory IC200CPU001

CPU with Two Serial Ports, 42kB of Configurable Memory IC200CPU002

CPU with Two Serial Ports, 64kB of Configurable Memory IC200CPU005

CPU with Two Serial Ports and Embedded Ethernet Interface, 64kB of Configurable Memory

IC200CPUE05

Status LEDs

Serial Ports

CPU001

PWR

RUN

FAULT

FORCE

PORT 1

PORT 2

PORT 1

RS232

PORT 2

RS485

CPU001 CPU002

CPU005

PORT 2

FORCE

PORT 1

PWR

RUN

FAULT

PORT 1

RS232

PORT 2

RS485

CPU005

CPUE05

PWR

RUN

FAULT

FORCE

PORT 1

PORT 2

PORT 1

GFK-1504K Chapter 1 Introduction 1-5

RS232

PORT 2

RS485

Ethernet Interface

ETHERNET

10 BASE T / 100 BASE TX

ETHERNET

RESTART

PORT 1

LAN

STAT

Page 13

NAN

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Network Interface Units

A VersaMax I/O Station consists of a group of VersaMax modules with a VersaMax Network Interface Unit module and attached power supply in the first position.

VersaMax NIU

power supply

The Network Interface Unit provides I/O scanning and a communications interface, allowing a group of VersaMax modules to function as an I/O station on a communications bus. The power supply on the NIU provides power for the modules in the I/O Station. Additional “booster” power supplies can be included in the system if needed for modules with high current requirements.

A Network Interface Unit module has connectors appropriate for its communications network type and status LEDs. NIUs also have rotary dials that can be used to set communications ID information and other parameters. A Genius NIU is shown below.

VersaMax Modules

1-6 VersaMax® Modules, Power Supplies, and Carriers User's Manual – March 2003 GFK-1504K

GBI001

PWR

FAULT

I/O ENBL

FORCE

SBA ERR

BUS B

91 8 7

IC200GBI001

Genius®

NIU

SBA

X10

SBA

X1 5 0

BAUD

RATE

SERIAL A1

SERIAL A2

SHIELD IN

SHIELD OUT

SERIAL B1

SERIAL B2

SHIELD IN

SHIELD OUT

Page 14

Available VersaMax NIUs

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Ethernet Network Interface Unit IC200EBI001

Profibus Network Interface Unit IC200PBI001

Genius Network Interface Unit IC200GBI001

DeviceNet Network Interface Unit IC200DBI001

Ethernet NIU

The Ethernet Network Interface Unit (IC200EBI001) serves as the connection point between VersaMax I/O modules and a single 10/100Base-T Ethernet network. The NIU supports Modbus/TCP protocol.

For information about the Ethernet Network Interface Unit, refer to the

Ethernet Network Communications User’s Manual

(GFK-1860).

VersaMax System

DeviceNet NIU

The DeviceNet Network Interface Unit (IC200DBI001) is a DeviceNet slave module. DeviceNet supports a variety of communication structures including peer to peer, multimaster and master/slave with broadcasting capabilities. Up to 64 nodes can be connected to a DeviceNet network without bridging or routing.

For information about the DeviceNet Network Interface Unit, refer to the

System DeviceNet Network Communications User’s Manual

(GFK-1533).

VersaMax

Profibus NIU

The Profibus Network Interface Unit (IC200PBI001) operates as a slave on a Profibus-DP Network, automatically exchanging I/O, status, control, and diagnostic data with a master device. The NIU is capable of handling up to 375 bytes of I/O data, consisting of up to 244 bytes of discrete and analog input data and up to 244 bytes of discrete and analog output data. The system host can be any device capable of operating as a bus master.

For information about the Profibus-DP Network Interface Unit, refer to the

System Profibus Network Modules User’s Manual

(GFK-1534, revision A or later).

VersaMax

Genius NIU

The Genius Network Interface Unit (IC200GBI001) operates as a device on a Genius bus. The NIU is capable of handling up to 128 bytes of discrete and analog input data and 128 bytes of discrete and analog output data. The system host can be any PLC or computer capable of controlling the Genius bus.

For information about the Genius Network Interface Unit, refer to the

Genius Network Interface Unit User’s Manual

GFK-1504K Chapter 1 Introduction 1-7

(GFK-1535).

VersaMax System

Page 15

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Power Supplies

An AC or DC Power Supply module installs directly on the CPU or NIU. The Power Supply provides +5V and +3.3V power to the modules in the station. Additional power supplies can be installed on special booster carriers if needed for systems where the number of modules creates the need for a booster. The AC or DC Power Supply on the CPU or NIU and the Power Supply that resides on the Booster Carrier must share the same external power source.

24 VDC, 11 W POWER SUPPLY

WARNING: EXPLOSION HAZA RD WHEN IN HAZARDOUS LOCATIONS TURN OFF POWER BEFORE REPLACING OR WIR ING MODULES.

IND CONT EQ FOR HAZ LOC CLASS I DIV 2 GROUPS ABCD Temp Code T4A Ambient 60C

MADE IN USA

IC200PWR001

INPUT

VDC

NOT USED

Available Power Supplies and Carrier

The following VersaMax power supplies and carrier are available:

24VDC Power Supply IC200PWR001

24VDC Expanded 3.3V Power Supply IC200PWR002

120/240VAC Power Supply IC200PWR101

120/240VAC Expanded 3.3V Power Supply IC200PWR102

12VDC Power Supply IC200PWR201

12VDC Expanded 3.3V Power Supply IC200PWR202

Power Supply Booster Carrier IC200PWB001

Power supplies are described in chapter 3 of this manual.

1-8 VersaMax® Modules, Power Supplies, and Carriers User's Manual – March 2003 GFK-1504K

Page 16

I/O Modules

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VersaMax IO and option modules are approximately 110mm (4.3in) by 66.8mm (2.63in) in size. Modules can be mounted either horizontally or vertically on several types of available I/O Carriers. Modules are 50mm (1.956 in) in depth, not including the height of the carrier or the mating connectors.

110mm (4.33in)

Color code:

Red: AC Blue: DC Gold: Mixed Gray: Analog/other

Module Description

OK LED indicates presence of power f rom VersaMax power supply

66.8mm (2.63in)

Individual Point LEDS

on Discrete M odules

1 2 3 4 5 6 7 8 9 10 111213 141516

IND CONT EQ FOR HAZ LOC CLASS I DI V 2 GROUPS ABCD Temp Code T4A Ambient 60C CLASS I ZONE 2 GROUP IIC Ex nA IIC T4 OC≤To≤60C Ex nV T4 Demko No. 98Y. 125014

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

Latch

OUTPUT 12/24VDC POS GRP .5A 32PT

FLD

IC200MDL750

1234567 831

FLD

Field Power LED indicates pres ence of power from extern al

VersaMax I/O modules are described in this manual. They are grouped into chapters by module type. For more information about a specific module, please refer to the Table of Contents or Index to locate the module description.

GFK-1504K Chapter 1 Introduction 1-9

Page 17

(-)

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Discrete Module Point LEDs

Individual point LEDs on discrete modules provide status information at a glance. Laser markings on the module identify the LEDs. The positions of the point LEDs always correspond to the module’s wiring diagram, whether the module is simple:

LEDs for Discrete Mixed Module IC200MDD845

Q (output points)

Point numbers

123 45678

123456789101112 13 14 15 16

I (input points)

Wiring Diagram for Module IC200MDD845

or more complex:

LEDs for Discrete Mixed High-speed Counter Module IC200MDD841

Q (Output points 1 - 12)

I (input points 17 - 20)

I (input points 1 - 16)

Wiring Diagram for Mixed High-speed Counter Module IC200MDD841

Q1 Q2 Q3 Q4 Q5 Q6 Q7 Q8

1 2 3 4 5 6 7 8 9 11 12 13 14 15 16 17 18

123456789 111213141516171810

I1 I2 I3 I4 I5 I6 I7 I8 I9 I10

followed by

Point numbers

vvvv v

I11 I12 I13 I14 I15 I16

(+)

Q/I

1 2 3 4 5 6 7 8 910 111217181920

1 2 3 4 5 6 7 8 9 10 111213 141516

(+)

FLD

(+)-(+)

1-10 VersaMax® Modules, Power Supplies, and Carriers User's Manual – March 2003 GFK-1504K

Q2 Q3

2 3

Q5 Q6 Q7 Q8 Q9 Q10 Q11 Q12

5 6 7 8 9

11 12 13 14 15 16 17 18

12 13 14 15 16 17 18

1 2 3

I1 I2 I3 I4 I5 I6 I7 I8 9 I1 0 I11 I1 2 I13 I14 I15 I16

I17 I18 I19 I20

Page 18

vailable I/O Modules

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The following types of VersaMax I/O Modules are available:

Discrete Input Modules

Input Module, 120VAC 8 Points IC200MDL140

Input Module, 240VAC 8 Points IC200MDL141

Input Module, 120VAC Isolated 8 Points IC200MDL143

Input Module, 240VAC Isolated 4 Points IC200MDL144

Input Module, 120VAC 16 Points IC200MDL240

Input Module, 240VAC16 Points IC200MDL241

Input Module, 120VAC Isolated 16 Points IC200MDL243

Input Module, 240VAC Isolated 8 Points IC200MDL244

Input Module, 125VDC Positive/Negative Logic Isolated 8 Points IC200MDL631

Input Module, 125VDC Positive/Negative Logic Isolated 16 Points IC200MDL632

Input Module, 48VDC Positive/Negative Logic Grouped 16 Points IC200MDL635

Input Module, 48VDC Positive/Negative Logic Grouped 32 Points IC200MDL636

Input Module, 24VDC Positive/Negative Logic 16 Points IC200MDL640

Input Module, 5/12VDC Positive/Negative Logic Grouped 16 Points IC200MDL643

Input Module, 5/12VDC Positive/Negative Logic Grouped 32 Point IC200MDL644

Input Module, 24VDC Positive/Negative Logic (32 Points IC200MDL650

Discrete Output Modules

Output Module, 120VAC 0.5 Amp, Isolated 8 Points IC200MDL329

Output Module, 120VAC 0.5 Amp, Isolated 16 Points IC200MDL330

Output Module, 120VAC 2.0 Amp, Isolated 8 Points IC200MDL331

Output Module, 24VDC Positive Logic 2.0 Amps, w/ESCP 8 Points IC200MDL730

Output Module, 12/24VDC Positive Logic 0.5 Amp, 16 Points IC200MDL740

Output Module, 24VDC Positive Logic 0.5 Amp, w/ESCP 16 Points IC200MDL741

Output Module, 24VDC Positive Logic 0.5 Amp, w/ESCP 32 Points IC200MDL742

Output Module, 5/12/24V DC Negative Logic 0.5 Amp, 16 Points IC200MDL743

Output Module, 5/12/24VDC Negative Logic 0.5 Amp, 32 Points IC200MDL744

Output Module, 12/24VDC Positive Logic 0.5 Amp, 32 Points IC200MDL750

Output Module, Relay 2.0 Ampt Isolated Form A 8 Points IC200MDL930

Output Module, Relay 2.0 Amp, Isolated Form A 16 Points IC200MDL940

GFK-1504K Chapter 1 Introduction 1-11

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Discrete Mixed I/O Modules

Mixed Module, 24VDC Positive Logic Input 20 Points / Output Relay 2.0 Amp 12 Points IC200MDD840 Mixed Module, 24VDC Positive Logic Input 20 Points / Output 12 Point / (4) High Speed

Counter, PWM, or Pulse Train Configurable Points Mixed Module, Output 24VDC Pos. Logic 0.5A Grouped w/ESCP 16 Points / Input 24VDC

Pos/Neg Logic Grouped 16 Points Mixed Module, 24VDC Positive Logic Input Grouped 10 Points / Output Relay 2.0A per Point

Grouped 6 Points Mixed Module, Output 12/24VDC Pos. Logic 0.5A 16 Points / Input 24 VDC Pos/Neg Logic

Grouped 16 Points Mixed Module, Output Relay 2.0A Isolated 8 Points / Input 24VDC Pos/Neg Logic Grouped

16 Points Mixed Module, Output Relay 2.0A per Pt Isolated 8 Points / Input 120VAC Grouped 8 Points IC200MDD846 Mixed Module, Output Relay 2.0A per Pt Isolated 8 Points / Input 240VAC Grouped 8 Points IC200MDD847 Mixed Module, Output 120VAC 0.5A per Pt Isolated 8 Points / Input 120VAC Grouped 8

Points Mixed Module Output Relay 2.0A per Pt Isolated 8 Points / Input 120VAC Isolated 8 Points IC200MDD849 Mixed Module, Output Relay 2.0A per Pt Isolated 8 Points / Input 240VAC Isolated 4 Points IC200MDD850 Mixed Module, Output 12/24VDC Pos. Grouped 16 Pts / Input 5/12VDC Pos/Neg Grp16 Pts IC200MDD851

Analog Input Modules

Analog Input Module,12 Bit Voltage/Current 4 Channels IC200ALG230 Analog Input Module, 16 Bit Voltage/Current, 1500VAC Isolation, 8 Channels IC200ALG240 Analog Input Module, 12 Bit Voltage/Current 8 Channels IC200ALG260 Analog Input Module, 15 Bit Voltage Differential 8 Channels IC200ALG261 Analog Input Module, 15 Bit Current Differential 8 Channels IC200ALG262 Analog Input Module, 15 Bit Voltage 15 Channels IC200ALG263 Analog Input Module, 15 Bit Current 15 Channels IC200ALG264 Analog Input Module, 16 Bit RTD, 4 Channels IC200ALG620 Analog Input Module, 16 Bit Thermocouple, 7 Channels IC200ALG630

Analog Output Modules

Analog Output Module, 12 Bit Current, 4 Channels IC200ALG320 Analog Output Module, 12 Bit Voltage 0 to 10VDC 4 Channels IC200ALG321 Analog Output Module, 12 Bit Voltage -10 to +10VDC 4 Channels IC200ALG322 Analog Output Module, 13 Bit Voltage 8 Channels IC200ALG325 Analog Output Module, 13 Bit Current 8 Channels IC200ALG326 Analog Output Module, 13 Bit Voltage 12 Channels IC200ALG327 Analog Output Module, 13 Bit Current 12 Channels IC200ALG328 Analog Output Module, 16 Bit Voltage/Current, 1500VAC Isolation, 4 Channels IC200ALG331

Analog Mixed I/O Modules

Analog Mixed Module, 12 Bit Input Current 4 Channels and Output Current 2 Channels IC200ALG430 Analog Mixed Module, 12 Bit 0 to 10VDC Input 4 Channels and Output 2 Channels IC200ALG431 Analog Mixed Module, 12 Bit +/-10VDC Input 4 Channels and Output 2 Channels IC200ALG432

IC200MDD841

IC200MDD842

IC200MDD843

IC200MDD844

IC200MDD845

IC200MDD848

1-12 VersaMax® Modules, Power Supplies, and Carriers User's Manual – March 2003 GFK-1504K

Page 20

Carriers

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Carriers provide mounting, backplane communications, and field wiring connections for all types of VersaMax modules. I/O modules can be installed on carriers or removed without disturbing field wiring.

There are three basic I/O Carrier types:



Terminal-style I/O carriers. Modules mount parallel to the DIN rail.



Compact Terminal-style I/O Carriers. Modules mount perpendicular to the DIN rail.



Connector-style I/O Carriers. Modules mount perpendicular to the DIN rail. These carriers are normally used with Interposing I/O Terminals. One type of Interposing I/O Terminals is illustrated below; other types are also available.

See chapter 4 for information about VersaMax I/O Carriers.

Terminal-style I/O carriers have 36 individual terminals for direct connection of field wiring. Auxiliary I/O Terminal Strips are available for applications requiring additional wiring terminals. Chapter 5 of this manual describes the VersaMax Interposing Terminals and Auxiliary I/O Terminal Strips.

Terminal-style I/O

Carrier

Auxiliary I/O

Terminal Strip

Compact Terminal-

style I/O Carrier

Connector-style I/O

Carrier and

Interposing Terminals

MADE IN USA

GFK-1504K Chapter 1 Introduction 1-13

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Available I/O Carriers and Terminal Strips

The following types of I/O Carriers, terminals, and cables are available:

Terminal-Style I/O Carriers

Barrier-Style Terminal I/O Carrier IC200CHS001

Box-Style Terminal I/O Carrier IC200CHS002

Spring-Style Terminal I/O Carrier IC200CHS005

Compact Terminal-Style I/O Carriers

Compact Box-Style I/O Carrier IC200CHS022

Compact Spring-Style I/O Carrier IC200CHS025

Connector-Style I/O Carrier

Connector-Style I/O Carrier IC200CHS003

Interposing Terminals for use with Connector-Style Carrier

Barrier-Style Interposing I/O Terminals IC200CHS011

Box-Style Interposing I/O Terminals IC200CHS012

Thermocouple-Style Interposing I/O Terminals IC200CHS014

Spring-Style Interposing I/O Terminals IC200CHS015

Disconnect-Style Interposing I/O Terminals, Main Base Disconnect-Style Interposing I/O Terminals, Expansion Base

Relay-Style Interposing I/O Terminals, Main Base Relay-Style Interposing I/O Terminals, Expansion Base

Cables for use with Connector-Style I/O Carriers

2 connectors, 0.5m, no shield IC200CBL105

2 connectors, 1.0m, no shield IC200CBL110

2 connectors, 2.0m, no shield IC200CBL120

1 connector, 3.0m, no shield IC200CBL230

Auxiliary I/O Terminal Strips for use with Terminal-style I/O Carriers and Interposing Terminals

Barrier-Style Auxiliary I/O Terminal Strip IC200TBM001

Box-Style Auxiliary I/O Terminal Strip IC200TBM002

Spring-Style Auxiliary I/O Terminal Strip IC200TBM005

Other Carriers

Communications Carrier IC200CHS006

Power Supply Booster Carrier IC200PWB001

IC200CHS101 IC200CHS102

IC200CHS111 IC200CHS112

1-14 VersaMax® Modules, Power Supplies, and Carriers User's Manual – March 2003 GFK-1504K

Page 22

Expansion Modules

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There are two basic types of VersaMax I/O expansion systems, Multi-Rack and Two-Rack Local:



Multi-Rack: A VersaMax PLC or NIU I/O Station with an Expansion Transmitter Module (IC200ETM001) and one to seven expansion “racks”, each with an Expansion Receiver Module (IC200ERM001 or IC200ERM002). If all the Expansion Receivers are the Isolated type (IC200ERM001), the maximum overall cable length is 750 meters. If the expansion bus includes any non-isolated Expansion Receivers (IC200ERM002), the maximum overall cable length is 15 meters.

VersaMax PLC or I/O Station Main Rack (0)

ETM

CPU/NIU

VersaMax ExpansionRack 1

15M with any

IC200ERM002 ERMs

750M with all

IC200ERM001 ERMs

ERM

IC200CBL601,

602, 615

Terminator

Plug



Two-Rack Local: A PLC or NIU I/O Station connected directly to one expansion

VersaMax ExpansionRack 7

ERM

rack with non-isolated Expansion Receiver Module (IC200ERM002). Maximum cable length is 1 meter.

VersaMax PLC or NIU I/O Station Main Rack

1 M

IC200CBL600

GFK-1504K Chapter 1 Introduction 1-15

CPU/NIU

VersaMax Expansion Rack

ERM

Page 23

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VersaMax Modules for Expansion Racks

All types of VersaMax I/O and communications modules can be used in expansion racks. Some VersaMax analog modules require specific module revisions as listed below:

Module Module Revision

IC200ALG320 B or later

IC200ALG321 B or later

IC200ALG322 B or later

IC200ALG430 C or later

IC200ALG431 C or later

IC200ALG432 B or later

Available Expansion Modules

The following Expansion Modules and related products are available:

Expansion Modules

Expansion Transmitter Module IC200ETM001

Expansion Receiver Module, Isolated IC200ERM001

Expansion Receiver Module, Non-isolated IC200ERM002

Cables

Expansion Cable, 1 meter IC200CBL601

Expansion Cable, 2 meters IC200CBL602

Expansion Cable, 15 meters IC200CBL615

Firmware Update Cable IC200CBL002

Terminator Plug (included with ETM) IC200ACC201

Connector Kit IC200ACC302

See chapter 6 for information about VersaMax Expansion modules.

1-16 VersaMax® Modules, Power Supplies, and Carriers User's Manual – March 2003 GFK-1504K

Page 24

Communications Modules

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Communications modules provide additional flexibility for VersaMax systems.

These communications modules install on a VersaMax Communications Carrier. Power for the communications module comes from the main system power supply or from a booster supply as shown below.

VersaMax PLC CPU

power sup ply

Available VersaMax PLC Communications Modules

The following VersaMax PLC communications modules are available:

Optional booster

power sup ply

Profibus Network Slave Module

Communications Modules

Profibus-DP Network Slave Module IC200BEM002

DeviceNet Network Control Module IC200BEM103

Asi Network Master Module IC200BEM104

Communications Carrier IC200CHS006

For information about the Communications Carrier, please see chapter 4.

GFK-1504K Chapter 1 Introduction 1-17

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Profibus-DP Network Slave Module

The Profibus-DP Network Slave Module (IC200BEM002) is a communications module that exchanges PLC reference table data on the Profibus network. The VersaMax PLC CPU can read and write this data as though it were conventional bit- and word-type I/O data.

Multiple Profibus-DP Network Slave Modules may be used in the same VersaMax PLC. Each one can read up to 244 bytes of data from the network, and send up to 244 bytes of output data. The total amount of combined inputs and outputs is 384 bytes.

For information about the Profibus-DP Network Slave Module, refer to the

System Profibus Network Modules User’s Manual

DeviceNet Network Control Module

The DeviceNet Network Control Module (IC200BEM103) is a communications module that can be configured to operate as a master, as a slave, or as both simultaneously. It can exchange up to 512 bytes of input data and 512 bytes of output data with other devices on the DeviceNet network. The VersaMax PLC CPU can read and write this data as though it were conventional bit- and word-type I/O data.

The Network Control Module operates as a Group 2 Only Client (master) and can communicate only with Group 2 Slave devices. It can also operate as a Group 2 Only or a UCMM-capable Server (slave), or as a master and slave simultaneously.

For information about the DeviceNet Network Control Module, refer to the

System DeviceNet Network Communications User’s Manual

VersaMax

(GFK-1534, revision A or later).

VersaMax

(GFK-1533).

Asi Network Master Module

The VersaMax AS-Interface Network Master (IC200BEM104) conforms to the ASInterface Specification for the master AS-Interface protocol. It can be used to connect a VersaMax PLC or I/O station NIU to an Actuator-Sensor network.

The AS-Interface module supports communications with up to 31 slave devices, exchanging to exchange up to 4 bits of input data and 4 bits of output data per slave address on the Actuator-Sensor network.

For information about the AS-Interface Network Master Module, refer to the

System ASI Network Communications User’s Manual

1-18 VersaMax® Modules, Power Supplies, and Carriers User's Manual – March 2003 GFK-1504K

(GFK-1697).

VersaMax

Page 26

VersaMax General Product Specifications

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VersaMax products should be installed and used in conformance with product-specific guidelines as well as the following specifications:

Environmental

Vibration IEC68-2-6 1G @57-150Hz, 0.012in p--p @10-57Hz

Shock IEC68-2-27 15G, 11ms

0 deg C to +60 deg C ambientOperating Temp.

-40 deg C to +60 deg C ambient for I/O carriers, interposing I/O terminals, and auxiliary I/O terminals

Storage Temp. -40 deg C to +85 deg C

Humidity 5% to 95%, noncondensing

Enclosure Protection IEC529 Steel cabinet per IP54:

protection from dust & splashing water

EMC Emission

Radiated, Conducted CISPR 11/EN 55011 Industrial Scientific & Medical Equipment

(Group 1, Class A)

CISPR 22/EN 55022 Information Technology Equipment (Class A)

FCC 47 CFR 15 referred to as FCC part 15,

Radio Devices (Class A)

EMC Immunity

Electrostatic Discharge EN 61000-4-2 8KV Air, 4KV Contact

RF Susceptibility EN 61000-4-3 10V

ENV 50140/ENV 50204 10V

Fast Transient Burst EN 61000-4-4 2KV: power supplies, 1KV: I/O, communication

Surge Withstand ANSI/IEEE C37.90a Damped Oscillatory Wave: 2.5KV:

IEC255-4 Damped Oscillatory Wave: Class II,

EN 61000-4-5 2 kV cm(P/S); 1 kV cm (I/O and communication

Conducted RF EN 61000-4-6 10V

Isolation

Dielectric Withstand UL508, UL840, IEC664 1.5KV for modules rated from 51V to 250V

Power Supply

Input Dips, Variations EN 61000-4-11 During Operation: Dips to 30% and 100%,

/m, 80Mhz to 1000Mhz, 80% AM

rms

/m, 900MHz +/-5MHZ

rms

100%AM with 200Hz square wave

power supplies, I/O [12V-240V]

modules)

, 0.15 to 80Mhz, 80%AM

rms

Variation for AC +/-10%, Variation for DC +/-20%

GFK-1504K Chapter 1 Introduction 1-19

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1-20 VersaMax® Modules, Power Supplies, and Carriers User's Manual – March 2003 GFK-1504K

Page 28

Chapter

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Installation Instructions

This section gives basic installation instructions.



Preinstallation Check



Conformance to Standards



Thermal Clearance



DIN Rail and Panel Mounting



Installing Carriers



Expansion System Installation



Installing a Power Supply



System Wiring Guidelines



System Grounding



Installing Wiring for I/O Devices



Installing Modules

Preinstallation Check

Carefully inspect all shipping containers for damage during shipping. If any part of the system is damaged, notify the delivery service immediately. The damaged shipping container should be saved as evidence for inspection by the delivery service. As the consignee, it is your responsibility to register a claim with the delivery service for damage incurred during shipment. However, GE Fanuc will fully cooperate with you, should such action be necessary. After unpacking the VersaMax modules and other equipment, record all serial numbers. Serial numbers are required if you should need to contact Product Service during the warranty period of the equipment. All shipping containers and all packing material should be saved should it be necessary to transport or ship any part of the system.

GFK-1504K 2-1

Page 29

(

)

(

)

(

)

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Conformance to Standards

Before installing VersaMax products in situations where compliance to standards or directives from the Federal Communications Commission, the Canadian Department of Communications, or the European Union is required please refer to GE Fanuc’s Installation Requirements for Conformance to Standards, GFK-1179.

Thermal Considerations

The thermal performance specified for modules in this manual requires a clearance of 2 inches (5.1cm) above and below the modules and 1 inch (2.54cm) on each side of the modules as shown below, regardless of the orientation of the DIN rail.

When using a vertical DIN rail, the CPU or NIU module must be installed at the bottom.

Individual modules have may additional clearance requirements as shown in appendix A.

5.1cm

2.0in

2.54cm (1.0in)

5.1cm (2.0in)

CPU or NIU

at Bottom

2.54cm

1.0in

2.54cm

1.0in

2.54cm (1.0in)

5.1cm (2.0in)

2-2 VersaMax® Modules, Power Supplies, and Carriers User's Manual – March 2003 GFK-1504K

Page 30

DIN Rail and Panel Mounting

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Each rack in a VersaMax PLC or VersaMax I/O Station must be installed on a single section of 7.5mm X 35mm DIN rail, 1mm thick. Steel DIN rail is recommended. “Rack” is the term used for a CPU, NIU, or Expansion Receiver, plus up to 8 physically-connected I/O carriers. The first rack in a system is called Rack 0. If there are multiple expansion racks, Rack 0 also includes an Expansion Transmitter module installed in the leftmost position, before the CPU or NIU.

The DIN rail used in a VersaMax installation must be electrically grounded to provide EMC protection. The rail must have a conductive (unpainted) corrosion-resistant finish. DIN rails compliant with DIN EN50022 are preferred.

For vibration resistance, the DIN rail should be installed on a panel using screws spaced approximately 5.24cm (6 inches) apart. DIN-rail clamps (available as part number IC200ACC313) can also be installed at both ends of the station to lock the modules in position.

For applications requiring maximum resistance to mechanical vibration and shock, the DIN-rail-mounted carriers should also be mounted on the panel. Panel mount holes can be located on the panel by using the carrier as a template, or by following the dimensions shown in appendix A. Pre-drill the mounting holes and install the CPU, NIU, ERM , and carriers using M3.5 (#6) screws.

Hole for Optional

Panel-Mountin

GFK-1504K Chapter 2 Installation Instructions 2-3

Page 31

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DIN Rail Installation Steps

VersaMax CPUs, Network Interface Unit (NIU) modules, Expansion Receiver (ERM) modules, and module carriers snap easily onto the DIN rail. No tools are required for mounting or grounding to the DIN rail.

Before joining module carriers to a CPU, NIU, or ERM, remove the connector cover on the righthand side of the CPU, NIU, or ERM. Do not discard this cover; you will need to install it on the last carrier.

Connector Cover

Slide carriers along the DIN rail to engage the connectors in the sides of adjacent carriers. To avoid damaging connector pins, do not force or slam carriers together.

Install the connector cover that was removed over the connector on the last carrier to protect the connector pins and to provide compliance with standards.

Connector Cover

2-4 VersaMax® Modules, Power Supplies, and Carriers User's Manual – March 2003 GFK-1504K

Page 32

Installing an Expansion Transmitter Module

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An Expansion Transmitter Module must be installed to the left of a CPU or NIU.

1. Make sure rack power is off.

2. Attach the Expansion Transmitter to DIN rail to the left of the CPU or NIU.

3. Slide the module toward the CPU or NIU and press together until the connectors are mated.

4. After completing any additional system installation steps, apply power and observe the module LEDs.

On indicates presence of 5VDC power.

Off indicates no 5VDC

PWR

EXP TX

Blinking or On indicates active communications on expansion bus.

Off indicates no communications.

ower.

Removing an Expansion Transmitter Module

1. Make sure rack power is off.

2. Slide module on DIN rail away from the CPU or NIU in the main rack.

3. Using a small screwdriver, pull down on the tab on the bottom of the module and lift the module off the DIN rail.

GFK-1504K Chapter 2 Installation Instructions 2-5

Page 33

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Installing an Expansion Receiver Module

An Expansion Receiver Module (IC200ERM001 or 002) must be installed in the leftmost slot of each VersaMax expansion “rack”.

1. Insert the label inside the small access door at the upper left corner of the module.

2. Attach the module to the DIN rail at the left end of the expansion rack.

3. Select the expansion rack ID (1 to 7) using the rotary switch under the access door at upper left corner of the module. Each rack must be set to a different rack ID. With a single-ended cable (one expansion rack only), set the Rack ID to 1.

4. Install a VersaMax Power Supply module on top of the Expansion Receiver. See “Installing a Power Supply” in this chapter for details.

5. Attach the cables. If the system includes an Expansion Transmitter Module, attach the terminator plug to the EXP2 port on the last Expansion Receiver Module.

6. After completing any additional system installation steps, apply power and observe the module LEDs.

On indicates presence of 5VDC power.

PWR

SCAN

EXP RX

Green indicates CPU/NIU is scanning I/O in expansion racks.

Amber indicates not scannin

Blinking or On indicates module is communicating on expansion bus

Off indicates module not communicatin

Removing an Expansion Receiver Module

1. Make sure rack power is off.

2. Un-install the Power Supply module from the Expansion Receiver Module.

3. Slide the Expansion Receiver Module on DIN rail away from the other modules.

4. Using a small screwdriver, pull down on the tab on the bottom of the module and lift the module off the DIN rail.

2-6 VersaMax® Modules, Power Supplies, and Carriers User's Manual – March 2003 GFK-1504K

Page 34

Connecting the Expansion Cable: RS-485 Differential

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For a multiple-rack expansion system, connect the cable from the expansion port on the Expansion Transmitter to the Expansion Receivers as shown below. If all the Expansion Receivers are the Isolated type (IC200ERM001), the maximum overall cable length is 750 meters. If the expansion bus includes any non-isolated Expansion Receivers (IC200ERM002), the maximum overall cable length is 15 meters.

VersaMax PLC or I/O Station Main Rack (0)

ETM

15M with any

IC200ERM002 ERMs

750M with all

IC200ERM001 ERMs

CPU/NIU

VersaMax ExpansionRack 1

ERM

IC200CBL601,

602, 615

Terminator

Plug

VersaMax ExpansionRack 7

ERM

Install the Terminator Plug (supplied with the Expansion Transmitter module) into the lower port on the last Expansion Receiver. Spare Terminator Plugs can be purchased separately as part number IC200ACC201 (Qty 2).

RS-485 Differential Inter-Rack Connection (IC200CBL601, 602, 615)

Expansion

Transmitter or

Expansion

Receiver

Module

Transmitting

Port

26-PIN

FEMALE

FRAME+

FRAME-

RIRQ/+

RIRQ/-

RUN+

RUN-

RERR+

RERR-

IODT+

IODT-

RSEL+

RSEL-

IOCLK+

IOCLK-

SHIELD

26-PIN MALE

VARIABLE (SEE

TEXT)

FRAME+

FRAME-

RIRQ/+

RIRQ/-

RUN+

RUN-

RERR+

RERR-

IODT+

IODT-

RSEL+

RSEL-

IOCLK+

IOCLK-

SHIELD

26-PIN

MALE

Expansion

Receiver

Module

Receiving

Port

26-PIN

FEMALE

Building a Custom Expansion Cable

Custom expansion cables can be built using Connector Kit IC200ACC202, Crimper AMP 90800-1, and Belden 8138, Manhattan/CDT M2483, Alpha 3498C, or equivalent AWG #28 (0.089mm

) cable.

GFK-1504K Chapter 2 Installation Instructions 2-7

Page 35

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Connecting the Expansion Cable: Single-ended

For a two-rack local system with one non-isolated expansion rack (IC200ERM002) and NO Expansion Transmitter, connect the expansion cable from the serial port on the VersaMax CPU or NIU to the Expansion Receiver as shown below. The maximum cable length is one meter. Cables cannot be fabricated for this type of installation; cable IC200CBL600 must be ordered separately.

VersaMax PLC or NIU I/O Station Main Rack

1 M

IC200CBL600

CPU/NIU

VersaMax Expansion Rack

ERM

No Terminator Plug is needed in a single-ended installation; however, it will not impede system operation if installed.

Single-Ended Inter-Rack Connection Cable (IC200CBL600)

4 7 22 14 18 15 11 10 19 23

SINGLE_ 0V T_IOCLK T_RUN T_IODT_ T_RERR T_RIRQ_ T_FRAME T_RSEL 0V

SHIELD

26-PIN

MALE

Expansion

Receiver

IC200ERM002

Receiving

Port

26-PIN

FEMALE

VersaMax

CPU or NIU

Serial Port

16-PIN MALE

1516

T_IOCLK

T_RUN

T_IODT_

T_RERR

T_RIRQ_

T_FRAME

T_RSEL

1 M

16-PIN

FEMALE

2-8 VersaMax® Modules, Power Supplies, and Carriers User's Manual – March 2003 GFK-1504K

Page 36

Installing a Power Supply

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I/O and option modules receive power for their operation from the CPU, NIU, or Expansion Receiver Module via the mating connector on the carrier. The number of modules that can be supported depends on the power requirements of the modules (which are listed in the individual module specifications).

Power Supply Booster Carriers can be used as needed to meet the power needs of all modules. The AC or DC Power Supply on the CPU or NIU and the Power Supply that resides on the Booster Carrier must share the same external power source.

In some cases, the field devices served by an I/O module require additional AC or DC power, which must be provided using an “external” power supply. Specifications and connection details for such external power supplies are given in the module specifications in this manual.

Installing a Power Supply Module

The power supply module installs directly on top of a CPU, NIU, ERM, or booster carrier. The latch on the power supply must be in the unlocked position.

Align the connectors, tab, and latch post on the power supply to be parallel with the CPU, NIU, ERM, or carrier. Press the power supply module down firmly, until the two tabs on the bottom of the power supply click into place. Be sure the tabs are fully inserted in the holes in bottom edge of the CPU, NIU, ERM, or booster carrier.

Turn the latch to the locked position to secure the power supply in place.

Note: The VersaMax power supply is not hot-swappable. Hot inserting or extracting the power supply is an improper method to power-down or power-up. Hot inserting the power supply can cause a “Corrupted User Memory Fault” condition. Power-cycling should only be accomplished by switching the main power going into the power-supply.

GFK-1504K Chapter 2 Installation Instructions 2-9

Page 37

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Removing a Power Supply

1.Switch off the external power source to the power supply module.

Turn the latch to the unlocked position.

3.Press in the tabs on the lower edge of the power supply

Pull the power supply straight off.

2-10 VersaMax® Modules, Power Supplies, and Carriers User's Manual – March 2003 GFK-1504K

Page 38

System Wiring Guidelines

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Four types of wiring may be encountered in a typical factory installation:



Power wiring – the plant power distribution, and high power loads such as high horsepower motors. These circuits may be rated from tens to thousands of KVA at 220 VAC or higher.



Control wiring – usually either low voltage DC or 120 VAC of limited energy rating. Examples are wiring to start/stop switches, contactor coils, and machine limit switches. This is generally the interface level of discrete I/O.



Analog wiring – transducer outputs and analog control voltages. This is the interface level to I/O analog blocks.



Communications and signal wiring – the communications network that ties everything together, including computer LANs, MAP, and field busses.

These four types of wiring should be separated as much as possible to reduce the hazards from insulation failure, miswiring, and interaction (noise) between signals. A typical control system may require some mixing of the latter three types of wiring, particularly in cramped areas inside motor control centers and on control panels.

In general, it is acceptable to mix the communications bus cable with the I/O wiring from the blocks, as well as associated control level wiring. All noise pickup is cumulative, depending on both the spacing between wires, and the distance span they run together. I/O wires and communications bus cable can be placed randomly in a wiring trough for lengths of up to 50 feet. If wiring is cord–tied (harnessed), do not include the bus cable in the harness, since binding wires tightly together increases the coupling and mechanical stress that can damage the relatively soft insulation of some serial cable types. Consider using shielded cable in electrically noisy environments.

Wiring which is external to equipment, and in cable trays, should be separated following National Electrical Code practices.

GFK-1504K Chapter 2 Installation Instructions 2-11

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Installing Power and Ground Wiring

Power Supply terminals accommodate one AWG #14 (avg. 2.1mm2 cross section) to AWG #22 (avg. 0.36mm cross section). Use copper wire rated for 90 degrees C. When inserting two wires in the same position, the wires must be the same size and the same type (solid or stranded).

Connect the ground terminal to the conductive mounting panel with a 4-inch maximum length of AWG #14 (avg. 2.1mm ground integrity.

Grounding DC Power Supplies

DC power supplies are non-isolated. DC- must be grounded to frame / earth ground. DCis grounded to frame internally in the Power Supply. As a result, floating power supplies cannot be used.

cross section) wire, or two wires up to AWG #18 (avg. 0.86mm

) wire. Use hardware such as star washers to ensure

DC+ DC-

Grounding AC Power Supplies

AC power supplies are isolated. Therefore, the AC source does not have to be grounded. However, it is recommended to only use ground-referenced sources such as a neutral line or grounded center-tap transformer.

2-12 VersaMax® Modules, Power Supplies, and Carriers User's Manual – March 2003 GFK-1504K

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Jumper Installation on an AC Power Supply Module

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AC power supply modules (IC200PRW101 and IC200PWR102) can be used with either 120VAC or 240VAC nominal input power. For 120VAC nominal operation, install a jumper as marked on the power supply. Use insulated AWG #14 (avg. 2.1mm section) to AWG #22 (avg. 0.36mm

The power supply operates without a jumper installed; however, the hold-up specification is not met. If a jumper is not installed for 120VAC operation, the power supply will not cause hazardous conditions.

DO NOT USE A JUMPER FOR 240VAC OPERATION. If a jumper is used on the input connector for 240VAC nominal operation, the power supply will be damaged and may cause hazardous conditions.

Do not touch the exposed portions of the jumper wire with power applied to the system. Hazardous voltages are present that could cause personal injury.

cross section) wire.

JUMPER

FOR 120V

Warnings

cross

GFK-1504K Chapter 2 Installation Instructions 2-13

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Installing Additional Suppression

For agency compliance, external MOV suppression is required from both the positive and negative input to frame ground or at the power line input of a system enclosure (see below). The axial-leaded ZA series of MOVs from Harris is often used. The 20mm size, model V36ZA80 rated at 160 joules is sufficient for both supply types. The MOV should be able to handle most line transients. Measurement of actual transients may be required in extreme cases to decide what MOV is best.

Installing Suppression at the Power Supply

Typical power and ground connections are shown below.

DC: +

AC: H

DC: -

AC: N

Installing Suppression for Devices in an Enclosure

For a group of devices installed in an enclosure, MOVs can be installed at the point where the power lines enter the enclosure. Ideally, MOVs should be used at each cabinet in the system for maximum protection. The following illustration shows suppression on both power lines and a communications bus entering an enclosure.

Enclosure

Power

Modules

Short Length of

Communications

Bus Cable

Periodic Inspection and Replacement of MOVs

MOVs do a good job of absorbing transients on communications, control, and power lines, provided the total energy of those transients does not exceed the rating of the device. However, if the energy of the transient exceeds the rating of the device, the MOV may be either damaged or destroyed. should be regularly inspected for signs of damage to assure continued protection against transients. For some applications, periodic replacement of critical MOVs is recommended, even if they do not show signs of damage.

This failure may not be visibly or electrically evident.

MOVs

2-14 VersaMax® Modules, Power Supplies, and Carriers User's Manual – March 2003 GFK-1504K

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System Grounding

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All components of a control system and the devices it controls must be properly grounded. Ground conductors should be connected in a star fashion, with all branches routed to a central earth ground point as shown below. This ensures that no ground conductor carries current from any other branch.

Motor Drives and

Programming

Device

Each Terminal

Block

Other Electrical

Control

Equipment

Machinery

Earth Ground

The control panel and enclosure should also be bonded to the plant system ground per code. Inadequate grounding may compromise system integrity in the presence of power switching transients and surges.

Central Ground Point

Signal and power

connections not shown

GFK-1504K Chapter 2 Installation Instructions 2-15

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Installing Wiring for I/O Devices

Wiring to Inductive Loads

When wiring outputs to inductive loads, use of external suppression circuits is recommended. If possible, the external suppression circuits should be connected across the actual load. If that is not possible, external suppression circuits should be connected to each point that will drive an inductive load as shown below.

AC Inductive Loads

For AC inductive loads, the snubber network should consist of a 250VAC, 0.1µF capacitor connected in series with a 100 Ohm ½ Watt or higher resistor. A capacitor with a different working voltage may be chosen, as appropriate for the application.

Recommended snubber packages include 104M06QC100 or 104M06RL100 from Paktron.

Isolated Outputs, AC

Isolated Output

Point

100 Ohm

Return for Isolated

Output Point

Grouped Outputs, AC

Output Point

A18 and/or

B18

½ Watt

0.1µF 250VAC

100 Ohm ½ Watt

0.1µF 250VAC

Inductive Load

DC Inductive Loads

For DC inductive loads, a diode should be placed across the load as shown below. Recommended diodes include:

1N4934 100 volt, 1A; 1N4936 400 volt, 1A; 1N4937 600 volt, 1A.

These diodes are available from most manufacturers.

Isolated Outputs, DC

Isolated Output

Point

Inductive Load

Return for Isolated

Output Point

Grouped Outputs, DC

Output Point

A18 and/or

B18

Diode

2-16 VersaMax® Modules, Power Supplies, and Carriers User's Manual – March 2003 GFK-1504K

Page 44

Wiring for a Compact I/O Carrier (IC200CHS022, IC200CHS025)

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Field Wiring

rminal

Each terminal on a Compact-style I/O Carrier accommodates one solid or stranded AWG #14 (avg. 2.1mm wires up to AWG #18 (avg. 0.86mm

cross section) to AWG #22 (avg. 0.36mm2 cross section) wire, or two

cross section). Use copper wire rated for 90 degrees C. When inserting two wires in the same position, the wires must be the same size and type (solid or stranded).

The I/O carrier can accommodate current levels up to 2 Amps per point or 8 Amps per each power and ground, and a voltage range of up to 264 VAC. Voltage transients up to 300 VAC will not damage the carrier.

For a Box-Style I/O Carrier, recommended terminal torque is .37 to .45 ft-lbs.

The label provided with the module can be folded and inserted in the label holder.

Terminal Numbering for a Box- or Spring-Style Compact I/O Carrier

B11

B17 B18A17 A1 8

B12B9 B10B7 B8A11 A12

A13

A7 A8

A1 A2 A3

A14

A15

A16 B15 B1 6B13 B14

A10

A5 B5 B6B3 B4B1 B2A6

GFK-1504K Chapter 2 Installation Instructions 2-17

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Wiring for a Box-Style I/O Carrier or Spring-Style I/O Carrier (IC200CHS002, IC200CHS005)

Field Wiring

Terminals

Each terminal on a Box-Style or Spring-Style I/O Carrier accommodates one solid or stranded AWG #14 (avg. 2.1mm wire, or two wires up to AWG #18 (avg. 0.86mm for 90 degrees C. When inserting two wires in the same position, the wires must be the same size and type (solid or stranded).

For a Box-Style I/O Carrier, recommended terminal torque is .37 to .45 ft-lbs.

The label provided with the module can be folded and inserted in the module’s transparent door.

cross section) to AWG #22 (avg. 0.36mm2 cross section)

cross section). Use copper wire rated

Terminal Numbering for a Box-Style or Spring-Style I/O Carrier

A1 A2 A3

B2 B3

A5 A6 A7 A8 A9

B5 B6 B7 B8 B9

A13

A10

B10B1

A12

A11

B12 B13 B14 B15 B16 B17 B18

B11

A15 A16 A17 A18

A14

2-18 VersaMax® Modules, Power Supplies, and Carriers User's Manual – March 2003 GFK-1504K

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Wiring for a Barrier-Style I/O Carrier (IC200CHS001)

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Field Wiring

rminal

Each terminal on a Barrier-Style I/O Carrier accommodates one or two solid or stranded wires from AWG #22 (avg. 0.36mm

cross section) to AWG #14 (avg. 2.1mm2 cross section). Use copper wire rated for 90 degrees C. When inserting two wires in the same position, the wires must be the same size and type (solid or stranded).

For a Barrier-Style I/O Carrier, recommended terminal torque is .37 to .50 ft-lbs.

The label provided with the module can be folded and inserted in the module’s transparent door.

Terminal Numbering for a Barrier-Style I/O Carrier

GFK-1504K Chapter 2 Installation Instructions 2-19

A13

A7 A8 A9 A11 A12

A1 A2 A3

A15 A16 A17 A18

A14

A10

A5 A6

B13

B7 B8 B9 B11 B12

B1 B2 B3

B15 B16 B17 B18

B14

B10

B5 B6

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Wiring for a Connector-Style I/O Carrier (IC200CHS003)

For a Connector-Style I/O Carrier field connections are usually made to an Interposing I/O Terminal unit and one or more Auxiliary I/O Terminals. However, it is also possible to make field wiring connections directly to the Connector-Style I/O Carrier itself using contacts crimped to the ends of the field wires.

Field Wiring Connector

Prewired Cables for a Connector-Style I/O Carrier

Connection between a Connector-Style I/O Carrier and Interposing I/O Terminals is made by cable. The following cables are available:

IC200CBL105 2 connectors, 0.5m, no shield IC200CBL110 2 connectors, 1.0m, no shield IC200CBL120 2 connectors, 2.0m, no shield IC200CBL230 1 connector, 3.0m, no shield

2-20 VersaMax® Modules, Power Supplies, and Carriers User's Manual – March 2003 GFK-1504K

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Installing and Removing a Prewired Cable

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To install a prewired connecting cable, place the cable connector over the connector on the carrier and press downward until the latch engages the tab on the connector. (If you have an IC200CBLxxx cable with a non-molded style connector, please turn to appendix E for installation and removal instructions).

Cable

Latch

To remove the cable, hold the cable connector and press up on the latch to release the connector. When removing the cable, remember that operating equipment may be very hot, especially at higher ambient temperatures. If the equipment is hot, do not touch it directly.

DO NOT TOUCH exposed connector pins if the system is operating.

Connector Kit

A connector kit (part number IC200ACC304) is available for building custom cables or for connecting wires directly from field devices. The kit includes a connector and cover, two screws, 36 small contacts, and 6 large contacts. The following equipment is also required but not included in the kit:

Crimping Tools small contact Molex 11-01-0008

large contact Molex 11-01-0084

Extraction Tools small contact Molex 11-03-0002

large contact Molex 11-03-0006

Terminal Numbering

The illustration below shows the terminal assignments of the connector pins as viewed from above.

A terminals

A1 A2 A3A4A5

A17

A6 A7 A8A9A10 B12 B9 B10 B7 B8

A18

A11 A12 A13

GFK-1504K Chapter 2 Installation Instructions 2-21

A15 A16 B15 B16 B13 B14 B11

A14

Cable

B terminals

B5 B6 B3 B4 B1 B2

B17

B18

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Terminal Assignments for Cable IC200CBL230

The tables that follow show terminal assignments for cable IC200CBL230. Cable IC200CBL230 is available in two cable types. They are functionally equivalent. The cable type is marked on the cable.

“Belden” Cable Terminal Assignments

Terminal Block Position Base color 1st spot 2nd spot terminal # wire #

A1 Black 36 32 A2 Black Red 35 34 A3 Black White Green 34 23 A4 Orange Red 33 11 A5 Red Green 32 36 A6 Blue Red 25 16 A7 Black White Orange 24 22 A8 Green White 23 38

A9 Red Black Green 22 10 A10 Blue W hite 21 13 A11 Blue W hite Orange 15 37 A12 Orange Black Green 14 21 A13 Green Black Orange 13 9 A14 Blue Black 12 12 A15 Black Red Green 11 30 A16 Blue Black White 10 24 A17 White Red 4 7 A17 White Black Red 4 8 A18 White 3 5 A18 White Red Green 3 6

B1 Red Black 27 35

B2 Red 26 33

B3 Red White Green 29 17

B4 Black White Red 28 18

B5 Orange White Blue 31 19

B6 Orange Green 30 15

B7 Green 17 14

B8 Orange Black 16 27

B9 Green Black 19 29 B10 Orange 18 40 B11 Red Black White 5 31 B12 Red White 20 39 B13 Orange Black White 7 26 B14 Green Black White 6 25 B15 Blue 9 28 B16 Black White 8 20 B17 White Black Green 2 3 B17 White Black 2 4 B18 White Red Blue 1 1 B18 White Red Orange 1 2

2-22 VersaMax® Modules, Power Supplies, and Carriers User's Manual – March 2003 GFK-1504K

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“Alpha” Cable Terminal Assignments

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Terminal Block Position Base color 1st stripe 2nd stripe terminal # wire #

A1 White Brown Blue 36 32 A2 White Brown Gray 35 34 A3 White Black Yellow 34 23 A4 White Black 33 11 A5 White Red Yellow 32 36 A6 White Green 25 16 A7 White Black Orange 24 22 A8 White Red Blue 23 38

A9 White 22 10 A10 White Red 21 13 A11 White Red Green 15 37 A12 White Black Red 14 21 A13 Gray 13 9 A14 White Brown 12 12 A15 White Brown Yellow 11 30 A16 White Black Green 10 24 A17 Blue 4 7 A17 Violet 4 8 A18 Yellow 3 5 A18 Green 3 6

B1 White Red Orange 27 35

B2 White Brown Violet 26 33

B3 White Blue 29 17

B4 White Violet 28 18

B5 White Gray 31 19

B6 White Yellow 30 15

B7 White Orange 17 14

B8 White Black Gray 16 27

B9 White Brown Orange 19 29 B10 White Red Gray 18 40 B11 White Brown Green 5 31 B12 White Red Violet 20 39 B13 White Black Violet 7 26 B14 White Black Blue 6 25 B15 White Brown Red 9 28 B16 White Black Brown 8 20 B17 Red 2 3 B17 Orange 2 4 B18 Black 1 1 B18 Brown 1 2

GFK-1504K Chapter 2 Installation Instructions 2-23

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Caution

Do not insert a test probe into the contacts. Permanent damage to the contacts will result.

2-24 VersaMax® Modules, Power Supplies, and Carriers User's Manual – March 2003 GFK-1504K

Page 52

Installing Interposing I/O Terminals IC200TBM011, IC200TBM012,

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IC200TBM014, IC200TBM015

Interposing I/O Terminals are used to provide field-wiring connections to a Connectorstyle I/O Carrier (IC200CHS003). Installation and wiring for several styles of Interposing I/O Terminals is described in this section.

The Interposing I/O Terminals illustrated below are available with box-style terminals (IC200TBM002), spring-clamp style terminals (IC200TBM005), or barrier-style terminals (IC200TBM001). A version with box-style terminals and a built-in thermistor (IC200TBM014) is also available for use with Thermocouple modules, as described in chapter 14. A clear protective hinged door covers the wiring terminals. The printed wiring card provided with each I/O module can be folded and inserted in this door.

Cable Connector

Field Wiring Terminals

Clear Protective Cover

These Interposing I/O Terminals unit can be mounted on the same DIN rail as the Connector-Style I/O Carrier, or on a separate DIN rail. For applications requiring maximum resistance to mechanical vibration and shock, the Interposing I/O Terminals must also be panel-mounted.

Use copper wire rated for 90 degrees C. When inserting two wires in the same position, the wires must be the same size and type (solid or stranded). Wire specifications depend on the terminal type.

Interposing I/O Terminals

Wiring Specifications for IC200TBM012, IC200TBM014, and IC200TBM015

For box-type or spring type terminals, each terminal accommodates one solid or stranded AWG #14 (avg. 2.1mm two wires up to AWG #18 (avg. 0.86mm

cross section) to AWG #22 (avg. 0.36mm2 cross section) wire, or

cross section).

Wiring Specifications for IC200TBM011

For barrier-type terminals, each terminal accommodates one or two solid or stranded wires from AWG #22 (avg. 0.36mm

cross section) to AWG #14 (avg. 2.1mm2 cross section).

GFK-1504K Chapter 2 Installation Instructions 2-25

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Installing Disconnect-Style Interposing I/O Terminals IC200CHS101, IC200CHS102

The Disconnect-Style Interposing I/O Terminals (IC200CHS101 and IC200CHS102) interface a VersaMax Connector-Style I/O Carrier to field wiring and provide an integrated disconnect option for field devices connected to VersaMax I/O modules. The Main Base, IC200CHS101, provides terminals that correspond to the "A" terminals on a VersaMax I/O module. If the I/O module also has "B" terminals, an Expansion Base, IC200CHS102) is also needed.

Field wiring to the interposing disconnect bases follows the standard wiring diagram for each module. Terminals A1-A18 and B1-B18 on the interposing disconnect terminal bases are connected in the same fashion as all other bases. The built-in auxiliary terminals (W1-W8, X1-X8, Y1-Y8, Z1-Z8) are positioned directly below the A or B terminals to provide for simple two-wire connection of field devices.

A18 A17 X W

Each group of auxiliary terminals has a dedicated terminal to jumper the group to the appropriate VersaMax terminal (The “W” terminal is the connection point for W1-W8, etc.). The installation of these jumpers depends on the grouping present on the I/O module, as shown on the following pages.

2-26 VersaMax® Modules, Power Supplies, and Carriers User's Manual – March 2003 GFK-1504K

A16 A15 A14 A13 A12 A11 A10 A9 A8 A7 A6 A5 A4 A3 A2 A1

X8 X7 X6 X5 X4 X3 X2 X1 W8 W7 W6 W5 W4 W3 W2 W1

Page 54

Disconnect-Style Interposing I/O Bases, Terminal Wiring

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Each terminal accommodates:



one solid (0.2 to 4.0mm2 cross section) or stranded (0.2 to 2.5mm2 cross section), AWG #12 to AWG #24.

When inserting two wires in the same position, the wires must be the same size and type (solid or stranded):



Rigid or flexible wires: 0.2 to 1.5mm2 cross section.



Stranded wires with ferrules, no plastic sleeve: 0.25 to 0.75mm2 cross section



Stranded wires with twin ferrule, with plastic sleeve: upper level (A/B terminals): 0.5 to 1.5mm lower level (W/X/Y/Z terminals): 0.5 mm



Recommended torque for the terminal screws is 0.5 to 0.6 Nm.

cross section

cross section.

GFK-1504K Chapter 2 Installation Instructions 2-27

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Disconnect-Style Interposing I/O Terminals, Wiring for Modules with One Group per Row

This wiring format generally applies when the associated VersaMax module provides for connection of I/O in 16-point groups. An example of such a module is the VersaMax 24VDC 16pt Output Module, IC200MDL740:

Q2 Q3

123456789 111213141516171810

Q5 Q6 Q7 Q8

Q9 Q10 Q11 Q12 Q13 Q14 Q15 Q16

When connecting an Interposing Disconnect base in this format, follow these guidelines:



Connect the field devices to A1-A16 (or B1-B16 where appropriate)



Connect the return wires of field devices to the corresponding common connections – A1 to W1, A2 to W2, A9 to X1, A10 to X2, etc.



Connect jumpers between the A17, W, and X terminals (or B17, Y, and Z)



Connect the power supply between A17 and A18 (or B17 and B18)

Example: Wiring for Output Module IC200MDL740

Example field wiring for IC200CHS101 when used with VersaMax modules with 1 group per terminal row

A18 A17 X W

2-28 VersaMax® Modules, Power Supplies, and Carriers User's Manual – March 2003 GFK-1504K

A16A15A14A13A12A11A10A9A8A7A6A5A4A3A2A1

X8 X7 X6 X5 X4 X3 X2 X1 W8 W7 W6 W5 W4 W3 W2 W1

Page 56

Disconnect-Style Interposing I/O Terminals,

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Wiring for Modules with Two Groups per Row

This wiring format generally applies when the associated VersaMax module provides for connection of I/O in 8-point groups. An example of such a module is the VersaMax 24VDC 16pt Input Module, IC200MDL640:

(-)

(+)

(+)(-)

I1 I2 I3 I4 I5 I6 I7 I8 I9 I10 11 I12 I13 I14 I15 I16

1 2 3 4 5 6 7 8 9 11 12 13 14 15 16 17 1810

When connecting the Interposing Disconnect bases in this format, follow these guidelines:



Connect field devices to A1-A16 (or B1-B16 where appropriate)



Connect return wires of field devices to the corresponding common connections – A1

to W1, A2 to W2, A9 to X1, A10 to X2, etc.



Connect jumpers between the A17, W, and X terminals (or B17, Y, and Z).



Connect power supply between A17 and W (or B17 and Y).



Connect power supply between A18 and X (or B18 and Z).

(+)-(+)

Example Wiring Diagram for Module IC200MDL640

Example field wiring for IC200CHS101 when used with VersaMax modules with 2 groups per terminal row

A16A15A14A13A12A11A10A9A8A7A6A5A4A3A2A1

X8 X7 X6 X5 X4 X3 X2 X1 W8 W7 W6 W5 W4 W3 W2 W1

A18 A17 X W

GFK-1504K Chapter 2 Installation Instructions 2-29

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Disconnect-Style Interposing I/O Terminals, Wiring for Modules with Connections that are Not Grouped

This wiring format generally applies when the associated VersaMax module provides for connection of isolated I/O devices, but may also be used when a non-isolated module provides dedicated terminals for each common connection. An example of an isolated module is the VersaMax 120VAC 8pt Isolated Input Module, IC200MDL143:

I1 I2 I3 I4 I5 I6 I7 I8

NN N NNN N N

12345678

When connecting the Interposing Disconnect bases in this format, additional jumpers are usually not needed. Field wiring is connected to terminals A1-A16 (or B1-B16 where appropriate). The auxiliary terminals are not generally connected.

Example Wiring Diagram for Module IC200MDL143

Example field wiring for IC200CHS101 when used with VersaMax modules without grouped points.

11 12 13 14 15 16 17 1810

A16 A15 A14 A1 3 A12 A11 A10 A9 A8 A7 A6 A5 A4 A3 A2 A1

X8 X7 X6 X5 X4 X3 X2 X1 W8 W7 W6 W 5 W4 W3 W 2 W1

A18 A1 7 X W

2-30 VersaMax® Modules, Power Supplies, and Carriers User's Manual – March 2003 GFK-1504K

Page 58

Installating Relay-Style Interposing I/O Terminals IC200CHS111 and IC200CHS112

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The Relay-Style Interposing I/O Terminals (IC200CHS111 and IC200CHS112) each provide dry contacts capable of switching high current outputs (up to 8A) . For the Relay Style Interposing I/O Terminals, power for operation of the relay coils must be provided by an external 24VDC power supply. This power must be provided to both the main base (IC200CHS111) and the expansion base (IC200CHS112). Connection of this external power supply is made at the terminals A17 & A18 (B17 & B18 for the expansion base). This power connection is for the relay coils only. User loads must be powered by an

external source.

Components labeled A1-A16 correspond to points Q1-Q16. Components labeled B1-B16 correspond to points Q17-Q32. Each point is associated with 3 terminal connections, labeled NO (Normally Open), C (Common), and NC (Normally Closed). Loads may be connected between C and NO, C and NC, or both.

24VDC

A17A18

A16 A15 A14 A13 A8 A7 A6 A5 A4 A3 A2 A1A12 A11 A10 A9

NO C NC

Relay-Style Interposing I/O Terminals, Terminal Wiring

Each terminal accommodates:



One solid (0.2 to 4.0mm2 cross section) or stranded (0.2 to 2.5mm2 cross section),

AWG #12 to AWG #24. When inserting two wires in the same position, the wires must be the same size and type (solid or stranded), as specified below:



Rigid or flexible wires: 0.2 to 1.5mm2 cross section.



Stranded wires with ferrules, no plastic sleeve: 0.25 to 0.75mm2 cross section



Stranded wires with twin ferrule, with plastic sleeve Recommended torque for the terminal screws is 0.5 to 0.6 Nm.

GFK-1504K Chapter 2 Installation Instructions 2-31

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Wiring for Auxiliary I/O Terminals

Auxiliary I/O Terminals can be used to provide extra field wiring connections if needed. They can be attached to either a terminal-style I/O carrier or to Interposing I/O Terminals.

Auxiliary I/O Terminals units are available with 18 box-style terminals (as shown below) or with 18 spring style terminals or 12 barrier-style terminals.

CLASS I ZONE 2 Ex nA IIC T4 OC Ta Ex nV II T4 Dem ko

Terminal-Style

Auxiliary I/O Terminals

Auxiliary I/O

Interposing

The terminals are electrically tied together. There is no electrical connection from the I/O Carrier or Interposing Terminals to the Auxiliary I/O Terminals; any necessary electrical reference must be provided. Multiple Auxiliary I/O Terminals can be connected together to provide the additional wiring terminals that may be needed for high-density modules, or for 2-, 3-, and 4-wire field devices.

16 Point Module 32 Point ModuleField

Barrier-Style

Carrier

no Auxiliary Terminals

Box-, Spring-, or

Connector Carrier

Barrier-Style

Carrier

Device

1-wire

Diagram

Box-, Spring-, or

Connector Carrier

Point

2-wire

3-wire

4-wire

* for 16-point modules that only use one row of terminals for point wiring, a shorting bar may be used to provide extra terminals. See the heading

2-32 VersaMax® Modules, Power Supplies, and Carriers User's Manual – March 2003 GFK-1504K

Point

Common

Point

Common

Point

Common

-V

1 Auxiliary

Terminals *

2 Auxiliary

Terminals *

3 Auxiliary

Terminals *

3 Auxiliary

Terminals

6 Auxiliary

Terminals

9 Auxiliary

Terminals

Using A Shorting Bar

2 Auxiliary

Terminals *

4 Auxiliary

Terminals *

6 Auxiliary

Terminals *

in this chapter.

3 Auxiliary Terminals

6 Auxiliary Terminals

9 Auxiliary Terminals

Page 60

For example, a 16-point module might use 3 Auxiliary I/O Terminals for 4-wire devices:

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Point Connections

Common Connec tions

+V Connections

-V Connections

Auxiliary I/O Terminals accommodate current levels up to 8 Amps and voltage up to 264 VAC. Voltage transients up to 300 VAC will not cause damage.

Installing Auxiliary I/O Terminals

Auxiliary I/O Terminals are installed by inserting the tabs into the slots on the I/O Carrier or Interposing Terminals and pressing downward. Screws can be inserted through the panel-mount holes for added stability if needed.

Auxiliary Carriers must be installed on the I/O Carrier or Interposing Terminals before connecting field wiring.

Wire Specifications for Auxiliary I/O Terminals

Wire specifications depend on the terminal type. For box-type or spring type terminals, each terminal accommodates one solid or stranded AWG #14 (avg. 2.1mm AWG #22 (avg. 0.36mm cross section).

For barrier-type terminals, each terminal accommodates one or two solid or stranded wires from AWG #22 (avg. 0.36mm

Use copper wire rated for 90 degrees C. When inserting two wires in the same position, the wires must be the same size and type (solid or stranded).

GFK-1504K Chapter 2 Installation Instructions 2-33

cross section) wire, or two wires up to AWG #18 (avg. 0.86mm

cross section) to AWG #14 (avg. 2.1mm2 cross section).

cross section) to

Page 61

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Using Shorting Bars

Shorting Bars (part number IC200ACC303, quantity 2) can be a cost-effective solution for providing additional bussed terminals for modules that include only one I/O board. The shorting bar has a maximum current-carrying capacity of 2 Amps per point. See the individual module descriptions to determine whether a shorting bar can be used for a particular module.

The figures below show how a Shorting Bar can be used on a 2-row or 3-row carrier to provide extra field wiring connections for an I/O module.

Example Connection for Carriers with Two

Rows of Terminals

Example Connection

for Carriers with

Three Rows of

Terminals

Q2 Q3Q4Q5 Q6 Q7 Q8

123456789

Q13

Q14 Q15

14 15 16 17 18

Q7 Q8 Q9 Q10 Q11 Q12

789 111210

Q9 Q10 Q11 Q12 Q13 Q14 Q15 Q16

12 13 14 15 16 17 18

Q16

14 15 161718

789 111210

Q2 Q3

Q5 Q6

123456

before installing the I/O module.

A B

A Shorting Bar must be installed

123456

directly on the carrier

2-34 VersaMax® Modules, Power Supplies, and Carriers User's Manual – March 2003 GFK-1504K

Page 62

With a Shorting Bar in place, the unused terminals on the I/O Carrier or Interposing I/O

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Terminals unit can be used in the same way as the Auxiliary I/O Terminals described earlier.

Device

1-wire

2-wire

3-wire

4-wire

Diagram

Point

Common

Point

Common

Point

Common

16 Point Module 32 Point ModuleField

Box-, Spring-, or Connector

Carrier

1 Auxiliary

Terminals

2 Auxiliary

Terminals

3 Auxiliary

Terminals

-V

Barrier-

Style

Carrier

3 Auxiliary

Terminals

6 Auxiliary

Terminals

9 Auxiliary

Terminals

Box-, Spring-,

or Connector

Carrier with a

Shorting Bar

no Auxiliary Terminals

no Auxiliary

Terminals

1 Auxiliary Terminals

2 Auxiliary Terminals

Barrier-Style

Carrier with

a Shorting

Bar

Right side of

barrier

terminals on

I/O Carrier

3 Auxiliary

Terminals

6 Auxiliary

Terminals

Box-, Spring-,

or Connector

Carrier

2 Auxiliary

Terminals

4 Auxiliary

Terminals

6 Auxiliary

Terminals

Barrier-Style

Carrier

3 Auxiliary

Terminals

6 Auxiliary

Terminals

9 Auxiliary

Terminals

GFK-1504K Chapter 2 Installation Instructions 2-35

Page 63

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Installing Modules

Module to Carrier Connectors

Keying Dials

Field Wiring

Setting the Carrier Keying

Keying dials on the carrier must be used to assure that the correct module type will be installed on that carrier. One dial selects alphabetic characters and the other selects numbers. These dials must be set to match the factory keying on the underside of the module. Module keying assignments are listed in appendix D.

Keying Dials

2-36 VersaMax® Modules, Power Supplies, and Carriers User's Manual – March 2003 GFK-1504K

Latch hole

Module to Carrier Connectors

Page 64

Installing a Module on a Carrier

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Note: Before installing a module in an operating system, refer to the information below about Module Hot Insertion and Removal.

The latch on the module must be in the unlocked position as illustrated to install a module on its carrier.

Align the three T-shaped projections on the module side with the slots on the carrier and align the latch post on the module with the hole on the carrier.

Alignment

projections

Latch Hole

Press the module straight down onto the carrier, seating it fully.

Turn the latch to the locked position to secure the module to the top of the carrier.

GFK-1504K Chapter 2 Installation Instructions 2-37

Page 65

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Hot Insertion and Removal of I/O Modules

If external power to an I/O module’s field devices is removed, the module itself can be removed/inserted in an operating system (backplane power and CPU or NIU active) without affecting the rest of the system. Communications modules are not hot-insertable or removable.

For hot insertion, the I/O module must be properly seated on the carrier with all pins connected within 2 seconds. For removal, the module must be completely disengaged from the carrier within 2 seconds. If hot insertion or removal takes longer than 2 seconds, a System Misconfiguration fault may be generated, which may shut down the I/O Station.

CAUTION

Operating equipment may be very hot, especially at higher ambient temperatures. If the equipment is hot, do not touch it directly.

Such “hot insertion” and removal should not be attempted in hazardous locations. Personal injury, system malfunction and/or damage to the equipment may occur.

VersaMax equipment is suitable for use in non-hazardous locations or in Class 1, Div. 2, Groups A, B, C, and D, and Class 1 Zone 2 locations.

Explosion hazard: Substitution of components may impair suitability for Class 1, Division 2 and Class 1 Zone 2.

NOTE

The VersaMax power supply is not hot-swappable. Hot inserting or extracting the power supply is an improper method to power-down or power-up. Hot inserting the power supply can cause a “Corrupted User Memory Fault” condition. Power-cycling should only be accomplished by switching the main power going into the power-supply.

2-38 VersaMax® Modules, Power Supplies, and Carriers User's Manual – March 2003 GFK-1504K

Page 66

Chapter

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Power Supplies

This chapter describes the VersaMax power supply modules. See chapter 4 for information about the Power Supply Booster Carrier, which can be used to install an additional “booster” power supply in the system.



IC200PWR001 24VDC Power Supply



IC200PWR002 24VDC Expanded 3.3V Power Supply



IC200PWR101 120/240VAC Power Supply



IC200PWR102 120/240VAC Expanded 3.3V Power Supply



IC200PWR201 12VDC Power Supply



IC200PWR202 12VDC Expanded 3.3V Power Supply

GFK-1504K 3-1

Page 67

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IC200PWR001 24VDC Power Supply

24VDC Power Supply IC200PWR001 provides backplane power for CPU, NIU, and I/O modules. It supplies up to 1.5 Amps output current via 3.3 volt and 5 volt outputs, with up to 0.25 Amp on the 3.3 Volt output. This is ample power for most installations. Module backplane current consumption is summarized in appendix C.

24 VDC, 11 W POWER SUPPLY

WARNING: EXPLOSION HAZARD WHEN IN HAZARDOUS LOCATIONS TURN OFF POWER BEFORE REPLACING OR WIRING MODULES.

IND CONT EQ FOR HAZ LOC CLASS I DIV 2 GROUPS ABCD Temp Code T4A Ambient 60C

When mounted on the CPU or NIU module, it serves as the main power supply for the station. It can also be used as a supplemental power supply when mounted on a Power Supply Booster Carrier. Refer to the Power Supply Booster Carrier section of chapter 4 for more information.

3-2 VersaMax® Modules, Power Supplies, and Carriers User's Manual – March 2003 GFK-1504K

MADE IN USA

IC200PWR001

INPUT

VDC

NOT USED

Page 68

Specifications

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IC200PWR001

24VDC Power Supply

Input Voltage 18 to 30VDC, 24VDC nominal

Input Power 11W

Holdup Time 10ms

Inrush Current 20A at 24VDC

25A at 30 VDC

Output Voltage 5VDC, 3.3VDC

Protection Short circuit, overload, reverse polarity

Output Current

) maximum

3.3V

Total

3.3VDC Output 5VDC Output

• The total output current should not exceed 1.5A. For example, if 3.3V @

0.25A is required, 1.25A is available on the 5V output.

1.5A maximum

0.25A maximum (1.5A - I

Wiring

DC- must be grounded to frame / earth ground. DC- is grounded to frame internally in the Power Supply. As a result, floating power supplies cannot be used.

DC+ DC-

GFK-1504K Chapter 3 Power Supplies 3-3

Page 69

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IC200PWR002 24VDC Expanded 3.3 V Power Supply

24VDC Expanded 3.3V Power Supply IC200PWR002 provides backplane power for CPU, NIU, and I/O modules. It supplies up to 1.5 Amps output current via 3.3 volt and 5 volt outputs, with up to 1.0 Amp on the 3.3 Volt output. Module backplane current consumption is summarized in appendix C.

24 VDC, 11 W POWER SUPPLY EXPANDED 3.3VDC

WARNING: EXPLOSION HAZARD WHEN IN HAZARDOUS LOCATIONS TURN OFF POWER BEFORE REPLACING OR WIRING MODULES.

IND CONT EQ FOR HAZ LOC CLASS I DIV 2 GROUPS ABCD Temp Code T4A Ambient 60C

3-4 VersaMax® Modules, Power Supplies, and Carriers User's Manual – March 2003 GFK-1504K

MADE IN USA

IC200PWR002

INPUT

VDC

NOT USED

Page 70

Specifications

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IC200PWR002

24VDC Expanded 3.3 V Power Supply

Input Voltage

Input Power

Holdup Time

Inrush Current

Output Voltage

Protection

Output Current Total

3.3VDC Output 5VDC Output

• The total output current should not exceed 1.5A. For example, if 3.3V @ 1.0A

is required, 0.5A is available on the 5V output.

18 to 30 VDC, 24VDC nominal

11W

10ms

20A at 24VDC 25A at 30 VDC

5VDC, 3.3VDC

Short circuit, overload, reverse polarity

) maximum

3.3V

1.5A maximum

1.0A maximum (1.5A - I

Wiring

DC- must be grounded to frame / earth ground. DC- is grounded to frame internally in the Power Supply. As a result, floating power supplies cannot be used.

GFK-1504K Chapter 3 Power Supplies 3-5

DC+ DC-

Page 71

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IC200PWR101 120/240VAC Power Supply

120/240VAC Power Supply IC200PWR101 provides backplane power for CPU, NIU, and I/O modules. It supplies up to 1.5 Amps output current via 3.3 Volt and 5 Volt outputs, with up to 0.25 Amp on the 3.3 volt output. This is ample power for most installations. Module backplane current consumption is summarized in appendix C.

120/240 VAC, 27VA POWER SUPPLY

WARNING: EXPLOSION HAZARD WHEN IN HAZARDOUS LOCATIONS TURN OFF POWER BEFORE REPLACING OR WIRING MODULES.

IND CONT EQ FOR HAZ LOC CLASS I DIV 2 GROUPS ABCD Temp Code T4A Ambient 60C

When mounted on the CPU or NIU module, this power supply serves as the main power supply for the station. It can also be used as a supplemental power supply when mounted on a Power Supply Booster Carrier. Refer to the Power Supply Booster Carrier section of chapter 4 for more information.

3-6 VersaMax® Modules, Power Supplies, and Carriers User's Manual – March 2003 GFK-1504K

MADE IN USA

IC200PWR101

INPUT

VAC

ADD JUMPER

FOR 120V

Page 72

Specifications

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IC200PWR101

120/240VAC Power Supply

Input Voltage

Input Power

Frequency

Holdup Time

Output Voltage

Protection

Output Current Total

3.3VDC Output 5VDC Output

• The total output current should not exceed 1.5A. For example, if 3.3V @ 0.25A

is required, 1.25A is available on the 5V output.

Jumper Selection of 120VAC or 240VAC

This power supply can be used with either 120VAC or 240VAC nominal input power. For 120VAC nominal operation, a jumper should be installed as marked on the power supply.

85 to 132 VAC with jumper installed, 120VAC nominal 176 to 264 VAC w/o jumper installed, 240VAC nominal

27VA

47 to 63Hz

20ms

5VDC, 3.3 VDC

Short circuit, overload

) maximum

3.3V

JUMPER

FOR 120V

1.5A maximum

0.25A maximum (1.5A - I

DO NOT USE A JUMPER FOR 240VAC OPERATION. If a jumper is used on the input connector for 240VAC nominal operation, the power supply will be damaged and may cause hazardous conditions.

GFK-1504K Chapter 3 Power Supplies 3-7

WARNING:

Page 73

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IC200PWR102 120/240VAC Expanded 3.3V Power Supply

120/240VAC Expanded 3.3 Power Supply IC200PWR102 provides backplane power for CPU, NIU, and I/O modules. It supplies up to 1.5 Amps output current via 3.3 Volt and 5 Volt outputs, with up to 1.0 Amp on the 3.3V output. Module backplane current consumption is summarized in appendix C.

120/240 VAC, 27VA POWER SUPPLY EXPANDED 3.3VDC

WARNING: EXPLOSION HAZARD WHEN IN HAZARDOUS LOCATIONS TURN OFF POWER BEFORE REPLACING OR WIRING MODULES.

IND CONT EQ FOR HAZ LOC CLASS I DIV 2 GROUPS ABCD Temp Code T4A Ambient 60C

3-8 VersaMax® Modules, Power Supplies, and Carriers User's Manual – March 2003 GFK-1504K

MADE IN USA

IC200PWR102

INPUT

VAC

ADD JUMPER

FOR 120V

Page 74

Specifications

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IC200PWR102

120/240VAC Expanded 3.3V Power Supply

Input Voltage

Input Power

Frequency

Holdup Time

Output Voltage

Protection

Output Current Total

3.3VDC Output 5VDC Output

• The total output current should not exceed 1.5 A. For example, if 3.3V @ 1.0 A

is required, 0.5 A is available on the 5V output.

85 to 132 VAC with jumper installed, 120VAC nominal 176 to 264 VAC w/o jumper installed, 240VAC nominal

27VA

47 to 63Hz

20ms

5VDC, 3.3 VDC

Short circuit, overload

) maximum

3.3V

1.5A maximum

1.0A maximum (1.5A - I

Jumper Selection of 120VAC or 240VAC

This power supply can be used with either 120VAC or 240VAC nominal input power. For 120VAC nominal operation, a jumper should be installed as marked on the power supply.

JUMPER

FOR 120V

DO NOT USE A JUMPER FOR 240VAC OPERATION. If a jumper is used on the input connector for 240VAC nominal operation, the power supply will be damaged and may cause hazardous conditions.

GFK-1504K Chapter 3 Power Supplies 3-9

WARNING:

Page 75

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IC200PWR201 12VDC Power Supply

12VDC Power Supply IC200PWR201 provides backplane power for CPU, NIU, and I/O modules. It supplies up to 1.5 Amps output current via 3.3 volt and 5 volt outputs, with up to 0.25 Amp on the 3.3 Volt output. This is ample power for most installations. Module backplane current consumption is summarized in appendix C.

12 VDC, 11 W POWER SUPPLY

WARNING: EXPLOSION HAZARD WHEN IN HAZARDOUS LOCATIONS TURN OFF POWER BEFORE REPLACING OR WIRING MODULES.

IND CONT EQ FOR HAZ LOC CLASS I DIV 2 GROUPS ABCD Temp Code T4A Ambient 60C

3-10 VersaMax® Modules, Power Supplies, and Carriers User's Manual – March 2003 GFK-1504K

MADE IN USA

IC200PWR201

INPUT

VDC

NOT USED

Page 76

Specifications

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IC200PWR201

12VDC Power Supply

Input Voltage 9.6 to 15VDC, 12VDC nominal

Input Power 11W

Holdup Time 10ms

Inrush Current 25A at 12VDC

30A at 15VDC

Output Voltage 5VDC, 3.3VDC

Protection Short circuit, overload, reverse polarity

Output Current

) maximum

3.3V

Total

3.3VDC Output 5VDC Output

• The total output current should not exceed 1.5A. For example, if 3.3V @

0.25A is required, 1.25A is available on the 5V output.

1.5A maximum

0.25A maximum (1.5A - I

Wiring

DC- must be grounded to frame / earth ground. DC- is grounded to frame internally in the Power Supply. As a result, floating power supplies cannot be used.

DC+ DC-

GFK-1504K Chapter 3 Power Supplies 3-11

Page 77

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IC200PWR202 12VDC Expanded 3.3 V Power Supply

12VDC Expanded 3.3V Power Supply IC200PWR202 provides backplane power for CPU, NIU, and I/O modules. It supplies up to 1.5 Amps output current via 3.3 volt and 5 volt outputs, with up to 1.0 Amp on the 3.3 Volt output. Module backplane current consumption is summarized in appendix C.

12 VDC, 11 W POWER SUPPLY EXPANDED 3.3VDC

WARNING: EXPLOSION HAZARD WHEN IN HAZARDOUS LOCATIONS TURN OFF POWER BEFORE REPLACING OR WIRING MODULES.

IND CONT EQ FOR HAZ LOC CLASS I DIV 2 GROUPS ABCD Temp Code T4A Ambient 60C

CLASS I ZONE 2 GROUP IIC T4A CLASS I ZONE 2 Ex nA IIC T4

0C Ta 60C Ex nV II T4 Demko No

3-12 VersaMax® Modules, Power Supplies, and Carriers User's Manual – March 2003 GFK-1504K

MADE IN USA

IC200PWR202

INPUT

VDC

NOT USED

Page 78

Specifications

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IC200PWR202

12VDC Expanded 3.3 V Power Supply

Input Voltage

Input Power

Holdup Time

Inrush Current

Output Voltage

Protection

Output Current Total

3.3VDC Output 5VDC Output

The total output current should not exceed 1.5A. For example, if 3.3V @ 1.0A is required,

0.5A is available on the 5V output.

9.6 to 15VDC, 12VDC nominal

11W

10ms

25A at 12VDC 30A at 15VDC

5VDC, 3.3VDC

Short circuit, overload, reverse polarity

) maximum

3.3V

1.5A maximum

1.0A maximum (1.5A - I

Wiring

DC- must be grounded to frame / earth ground. DC- is grounded to frame internally in the Power Supply. As a result, floating power supplies cannot be used.

GFK-1504K Chapter 3 Power Supplies 3-13

DC+ DC-

Page 79

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3-14 VersaMax® Modules, Power Supplies, and Carriers User's Manual – March 2003 GFK-1504K

Page 80

Chapter

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Carriers

This chapter describes the Carriers that provide mounting and backplane communications for VersaMax modules.



IC200CHS001 Barrier-Style I/O Carrier



IC200CHS002 Box-Style I/O Carrier



IC200CHS003 Connector-Style I/O Carrier



IC200CHS005 Spring-Style I/O Carrier



IC200CHS022 Compact Box-Style I/O Carrier



IC200CHS025 Compact Spring-Style I/O Carrier



IC200CHS006 Communications Carrier



IC200PWB001 Power Supply Booster Carrier

GFK-1504K 4-1

Page 81

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IC200CHS001 Barrier-Style I/O Carrier

The Barrier-Style I/O Carrier (IC200CHS001) has 36 barrier-style terminals. It provides mounting, backplane communications, and field wiring for one I/O module.

110.5mm (4.35in)

IC200CHS001

I/O CARRIER BARRIER STYLE

IND CONT EQ FOR HAZ LOC CLASS I DIV 2 GROUPS ABCD Ambient 60C CLASS 1 ZONE 2 GROUP IIC Ex nA IIC 0C <To<60C Ex nV II Dem ko No. 98Y.125014

139.7mm (5.5in)

The I/O module mounts lengthwise (parallel to the DIN rail) on this carrier.

4-2 VersaMax® Modules, Power Supplies, and Carriers User's Manual – March 2003 GFK-1504K

Page 82

Barrier-Style I/O Carrier

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Din Rail Mounting

The I/O carrier snaps easily onto a 7.5mm X 35mm DIN rail. The DIN rail must be electrically grounded to provide EMC protection. The rail must have a conductive (unpainted) corrosion-resistant finish.

For applications requiring maximum resistance to mechanical vibration and shock, the carrier must also be panel-mounted. See chapter 2 for installation instructions.

Features



The Barrier-Style I/O carrier supports wiring for up to 32 I/O points and 4 common/power connections.



Easily-set keying dials to assure installation of the correct type of module on the carrier. Keys are set to match the keying on the bottom of the module. A complete list of module keying assignments is included in appendix D.



Carrier-to-carrier mating connectors for quick installation of the backplane connection with no additional cables or tools needed.

IC200CHS001



Module latch hole for securely fastening the module to the carrier.



A clear protective hinged door covering the wiring terminals. The printed wiring card provided with each I/O module can be folded and inserted in this door.



Notches on the lower edge for attaching an Auxiliary I/O Terminal Strip if extra bussed connection points are needed.

Carrier to Carrier Connector

Module to Carrier Connectors

Keying Dials

Field W iring Terminals

GFK-1504K Chapter 4 Carriers 4-3

Module latch hole

Transparent

rotective door

Page 83

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IC200CHS001 Barrier-Style I/O Carrier

Field Wiring Terminals

Each terminal accommodates one or two solid or stranded wires from AWG #22 (avg.

0.36mm

The carrier accommodates current levels up to 2 Amps per point or 8 Amps per each power and ground, and a voltage range of up to 264 VAC. Voltage transients up to 300 VAC will not damage the carrier.

One or more Auxiliary I/O Terminal Strips can be added to provide extra field wiring connections if needed. Auxiliary I/O Terminal Strips insert directly into the lower edge of the I/O Carrier.

cross section) to AWG #14 (avg. 2.1mm2 cross section).

A13

A7 A8 A9 A11 A12

A1 A2 A3

A15 A16 A17 A18

A14

A10

B13

B7 B8 B9 B11 B12

A5 A6

B1 B2 B3

B15 B16 B17 B18

B14

B10

B5 B6

4-4 VersaMax® Modules, Power Supplies, and Carriers User's Manual – March 2003 GFK-1504K

Page 84

IC200CHS002

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Box-Style I/O Carrier

The Box-Style I/O Carrier (IC200CHS002) has 36 IEC box-style terminals. It provides mounting, backplane communications, and field wiring for one I/O module.

110.5mm (4.35in)

IC200CHS002

I/O CARRIER BOX STYLE

IND CONT EQ FOR HAZ LOC CLASS I DIV 2 GROUPS ABCD Ambient 60C CLASS 1 ZONE 2 GROUP IIC Ex nA IIC 0C <To<60C Ex nV II Demk o No. 98Y.125014

139.7mm (5.5in)

The I/O module mounts lengthwise (parallel to the DIN rail) on this carrier.

GFK-1504K Chapter 4 Carriers 4-5

Page 85

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IC200CHS002 Box-Style I/O Carrier

Din Rail Mounting

For applications requiring maximum resistance to mechanical vibration and shock, the carrier must also be panel-mounted. See chapter 2 for installation instructions.

Features



The Box-Style I/O carrier supports wiring for up to 32 I/O points and 4 common/power connections.



Carrier-to-carrier mating connectors for quick installation of the backplane connection with no additional cables or tools needed.



Module latch hole for securely fastening the module to the carrier.



A clear protective hinged door covering the wiring terminals. The printed wiring card provided with each I/O module can be folded and inserted in this door.



Notches on the lower edge for attaching an Auxiliary I/O Terminal Strip if extra bussed connection points are needed.

Carrier to Carrier Connector

Module to Carrier Connectors

Keying Dials

Field W iring Terminals

4-6 VersaMax® Modules, Power Supplies, and Carriers User's Manual – March 2003 GFK-1504K

Module latch hole

Transparent

rotective door

Page 86

Field Wiring Terminals

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IC200CHS002

Box-Style I/O Carrier

Each terminal accommodates one solid or stranded AWG #14 (avg. 2.1mm2 cross section) to AWG #22 (avg. 0.36mm

0.86mm

The carrier accommodates current levels up to 2 Amps per point or 8 Amps per each power and ground, and a voltage range of up to 264 VAC. Voltage transients up to 300 VAC will not damage the carrier.

One or more Auxiliary I/O Terminal Strips can be added to provide extra field wiring connections if needed. Auxiliary I/O Terminal Strips insert directly into the lower edge of the I/O Carrier.

cross section).

A1 A2 A3

B2 B3

cross section) wire, or two wires up to AWG #18 (avg.

A5 A6 A7 A8 A9 A11 A12 A13

B5 B6 B7 B8 B9 B11 B12 B13 B14 B15 B16 B17 B18

A10

B10

A15 A16 A17 A18

A14

GFK-1504K Chapter 4 Carriers 4-7

Page 87

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IC200CHS003 Connector-Style I/O Carrier

The Connector-Style I/O Carrier (IC200CHS003) has a 36-pin connector for attaching an I/O cable. It provides mounting, backplane communications, and field wiring for one I/O module.

66.8mm (2.63in)

I/O CARRIER

IC200CHS003

CONNECTOR STYLE

IND CONT E Q FOR HAZ L OC

CLASS I DIV 2 GROUPS ABCD

Ambient 60C

CLASS 1 ZONE 2 GROUP IIC

Ex nA IIC 0C <To<60C

Ex nV II Demko No. 98Y.125014

133.4mm (5.25in)

The I/O module mounts vertically (perpendicular to the DIN rail) on this carrier.

4-8 VersaMax® Modules, Power Supplies, and Carriers User's Manual – March 2003 GFK-1504K

Page 88

IC200CHS003

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Connector-Style I/O Carrier

Din Rail Mounting

The carrier snaps easily onto a 7.5mm X 35mm DIN rail. The DIN rail must be electrically grounded to provide EMC protection. The rail must have a conductive (unpainted) corrosion-resistant finish.

For applications requiring maximum resistance to mechanical vibration and shock, the carrier must also be panel-mounted. See chapter 2 for installation instructions.

Features



Carrier-to-carrier mating connectors for quick installation of the backplane connection with no additional cables or tools needed.



Module latch hole for securely fastening the module to the carrier.



Connector provides quick attachment of wiring for up to 32 I/O points and 4 common/power connections.

Carrier to Carrier Connector

Module to Carrier Connectors

Keying Dials

Field Wiring

Module latch hole

GFK-1504K Chapter 4 Carriers 4-9

Page 89

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IC200CHS003 Connector-Style I/O Carrier

Field Wiring Connection

I/O devices can be wired directly to Interposing I/O Terminals, described separately in this chapter, or other types of terminal strips.

Connection to the Connector Style I/O Carrier is made by cable. The following cables are available:

IC200CBL105 2 connectors, 0.5m, no shield IC200CBL110 2 connectors, 1.0m, no shield IC200CBL120 2 connectors, 2.0m, no shield IC200CBL230 1 connector, 3.0m, no shield

The notch on the connector indicates the orientation of the pins.

A1 A2 A3

A17

A6 A7 A8

A18

A11 A12 A13

A connector kit is available for building custom cables. The kit is part number IC200ACC304.

The carrier accommodates current levels up to 2 Amps per point or 8 Amps per each power and ground, and a voltage range of up to 264 VAC. Voltage transients up to 300 VAC will not damage the carrier.

A5 B5 B6 B3 B4 B1 B2

A10 B12 B9 B10 B7 B8

A15 A16 B15 B16 B13 B14 B11

A14

B17

B18

Compatiblity

This carrier can be used with all VersaMax I/O modules EXCEPT the following, due to their high isolation requirements:

IC200MDL144 Input 240VAC 4 Point Isolated Module

IC200MDL244 Input 240VAC 8 Point Isolated Module

IC200MDD850 Mixed 240VAC Isolated 4 Point / Output Relay 2.0A Isolated 8 Point Module

4-10 VersaMax® Modules, Power Supplies, and Carriers User's Manual – March 2003 GFK-1504K

Page 90

IC200CHS005

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Spring-Style I/O Carrier

The Spring-Style I/O Carrier (IC200CHS005) has 36 spring-clamp style terminals for field wiring. It provides mounting, backplane communications, and field wiring for one I/O module.

110.5mm (4.35in)

IC200CHS005

I/O CARRIER SPRING STYLE

CD7

IND CONT EQ FOR HAZ LOC CLASS I DIV 2 GROUPS ABCD Ambient 60C CLASS 1 ZONE 2 GROUP IIC Ex nA IIC 0C <To<6 0C Ex nV II Demko No. 98Y.125014

139.7mm (5.5in)

The I/O module mounts lengthwise (parallel to the DIN rail) on this carrier.

GFK-1504K Chapter 4 Carriers 4-11

Page 91

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IC200CHS005 Spring-Style I/O Carrier

Din Rail Mounting

The carrier snaps easily onto a 7.5mm X 35mm DIN rail. The DIN rail must be electrically grounded to provide EMC protection. The rail must have a conductive (unpainted) corrosion-resistant finish.

For applications requiring maximum resistance to mechanical vibration and shock, the carrier must also be panel-mounted. See chapter 2 for installation instructions.

Features



The Spring-Style I/O Carrier supports up to 32 I/O points and 4 common/power connections.



Easily-set keying dials to assure installation of the correct type of module on the carrier. Keys can be set to match the keying on the bottom of the module. A complete list of module keying is included in appendix D.



Carrier-to-carrier mating connectors for quick installation of the backplane connection with no additional cables or tools needed.



Module latch hole for securely fastening the module to the carrier.



A clear protective hinged door covering the wiring terminals. The printed wiring card provided with each I/O module can be folded and inserted in this door.



Notches on the lower edge for attaching an Auxiliary I/O Terminal Strip if extra bussed connection points are needed.

Carrier to Carrier Connector

Module to Carrier Connectors

Keying Dials

Field Wiring Terminals

4-12 VersaMax® Modules, Power Supplies, and Carriers User's Manual – March 2003 GFK-1504K

Module latch hole

Transparent rotective door

Page 92

Field Wiring Terminals

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IC200CHS005

Spring-Style I/O Carrier

Each terminal accommodates one solid or stranded AWG #14 (avg. 2.1mm2 cross section) to AWG #22 (avg. 0.36mm

0.86mm

The carrier accommodates current levels up to 2 Amps per point or 8 Amps per each power and ground, and a voltage range of up to 264 VAC. Voltage transients up to 300 VAC will not damage the carrier.

One or more Auxiliary I/O Terminal Strips can be added to provide extra field wiring connections if needed. Auxiliary I/O Terminal Strips insert directly into the lower edge of the I/O Carrier.

cross section).

A1 A2 A3

B2 B3

cross section) wire, or two wires up to AWG #18 (avg.

A5 A6 A7 A8 A9 A11 A12 A13

B5 B6 B7 B8 B9 B11 B12 B13 B14 B15 B16 B17 B18

A10

B10

A15 A16 A17 A18

A14

GFK-1504K Chapter 4 Carriers 4-13

Page 93

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IC200CHS022 Compact Box-Style I/O Carrier

The Compact Box-Style I/O Carrier (IC200CHS022) has 36 IEC box-style terminals. It provides mounting, backplane communications, and field wiring for one I/O module.

66.8mm (2.63in)

BOX STYLE

IC200CHS022

COMPACT I/O CARRIER

IND CONT EQ FOR HAZ LOC

CLASS I DIV 2 GROUPS A BCD

Temp Code T4 Ambient 60C

CLASS 1 ZONE 2 GROUP IIC

Ex nA IIC 0C <To<60C

Ex nV II Demko No. 98Y.125014

163.5mm (6.45in)

The I/O module mounts vertically (perpendicular to the DIN rail) on this carrier.

4-14 VersaMax® Modules, Power Supplies, and Carriers User's Manual – March 2003 GFK-1504K

Page 94

Compact Box-Style I/O Carrier

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Din Rail Mounting

For applications requiring maximum resistance to mechanical vibration and shock, the carrier must also be panel-mounted. See chapter 2 for installation instructions.

Features



The Compact Box-Style I/O carrier supports wiring for up to 32 I/O points and 4 common/power connections.



Carrier-to-carrier mating connectors for quick installation of the backplane connection with no additional cables or tools needed.

IC200CHS022



Module latch hole for securely fastening the module to the carrier.



A printed wiring card provided with each I/O module can be folded and inserted in the built-in card holder.

Carrier to Carrier Connector

Module

Module to Carrier Connectors

Keying Dials

Field Wiring

GFK-1504K Chapter 4 Carriers 4-15

latch hole

Holder for

Page 95

PDFsupply.com

IC200CHS022 Compact Box-Style I/O Carrier

Field Wiring Terminals

Each terminal accommodates one solid or stranded AWG #14 (avg. 2.1mm2 cross section) to AWG #22 (avg. 0.36mm

0.86mm

The carrier accommodates current levels up to 2 Amps per point or 8 Amps per each power and ground, and a voltage range of up to 264 VAC. Voltage transients up to 300 VAC will not damage the carrier.

cross section).

A13

A7 A8

A1 A2 A3

cross section) wire, or two wires up to AWG #18 (avg.

A14

A15

A16 B15 B1 6B13 B1 4

A10 B12B9 B10B7 B8A11 A12

A5 B5 B6B3 B4B1 B2A6

B17 B18A17 A1 8

B11

Wiring Card Holder

The Compact I/O Carrier has a built-in card holder that hinges down over the terminal wiring. The wiring card provided with the I/O module can be inserted in the holder. During system operation, the card holder should be in the retracted position.

Wiring Card in

Holder, Hinged

Over Terminals

Card Holder

Retracted

4-16 VersaMax® Modules, Power Supplies, and Carriers User's Manual – March 2003 GFK-1504K

Page 96

IC200CHS025

(

)

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Compact Spring-Style I/O Carrier

The Compact Spring-Style I/O Carrier (IC200CHS025) has 36 IEC box-style terminals. It provides mounting, backplane communications, and field wiring for one I/O module.

66.8mm

2.63in

SPRING STYLE

IC200CHS025

COMPACT I/O CARRI ER

IND CONT EQ FOR HAZ LOC

CLASS I DIV 2 GROUPS ABCD

Temp Cpde T4 Ambient 60C

CLASS 1 ZONE 2 GROUP IIC

Ex nA IIC 0C <To<60C

Ex nV II Demko No. 98Y.125014

163.5mm (6.45in)

The I/O module mounts vertically (perpendicular to the DIN rail) on this carrier.

GFK-1504K Chapter 4 Carriers 4-17

Page 97

atc

g card

PDFsupply.com

IC200CHS025 Compact Spring-Style I/O Carrier

Din Rail Mounting

For applications requiring maximum resistance to mechanical vibration and shock, the carrier must also be panel-mounted. See chapter 2 for installation instructions.

Features



The Compact Spring-Style I/O carrier supports wiring for up to 32 I/O points and 4 common/power connections.



Carrier-to-carrier mating connectors for quick installation of the backplane connection with no additional cables or tools needed.



Module latch hole for securely fastening the module to the carrier.



A printed wiring card provided with each I/O module can be folded and inserted in the built-in card holder.

Carrier to Carrier Connector

Module l

Module to Carrier Connectors

Keying Dials

Field Wiring

4-18 VersaMax® Modules, Power Supplies, and Carriers User's Manual – March 2003 GFK-1504K

h hol

Holder for

wirin

Page 98

Field Wiring Terminals

PDFsupply.com

IC200CHS025

Compact Spring-Style I/O Carrier

Each terminal accommodates one solid or stranded AWG #14 (avg. 2.1mm2 cross section) to AWG #22 (avg. 0.36mm

0.86mm

The carrier accommodates current levels up to 2 Amps per point or 8 Amps per each power and ground, and a voltage range of up to 264 VAC. Voltage transients up to 300 VAC will not damage the carrier.

cross section).

cross section) wire, or two wires up to AWG #18 (avg.

A13

A14

A7 A8

A1 A2 A3

A15

A16 B15 B16B13 B1 4

A10

A5 B5 B6B3 B4B1 B2A6

B17 B18A17 A18

B11

B12B9 B10B7 B8A11 A12

Wiring Card Holder

Wiring Card in Holder, Hinged Over Terminals

Card Holder

Retracted

GFK-1504K Chapter 4 Carriers 4-19

Page 99

PDFsupply.com

IC200CHS006 Communications Carrier

The Communications Carrier (IC200CHS006) provides mounting and backplane communications and field wiring for a fieldbus communications module.

66.8mm (2.63in)

IC200CHS006

COMMUNICATIONS

CARRIER

IND CONT EQ FOR HAZ LOC CLASS I DIV 2 GROUPS ABCD Ambient 60C CLASS 1 ZONE 2 GROUP IIC Ex nA IIC 0C <To<60C Ex nV II Demko No. 98Y.125014 MADE IN USA

133.4mm (5.25in)

Din Rail Mounting

The carrier snaps easily onto a 7.5mm X 35mm DIN rail. The DIN rail must be electrically grounded to provide EMC protection. The rail must have a conductive (unpainted) corrosion-resistant finish.

For applications requiring maximum resistance to mechanical vibration and shock, the carrier must also be panel-mounted. See chapter 2 for installation instructions.

Features



Compatible with all VersaMax fieldbus communications modules.



Fast DIN-rail mounting.



Can be located in any “slot”.



Module latch hole for securely fastening the module to the carrier.

4-20 VersaMax® Modules, Power Supplies, and Carriers User's Manual – March 2003 GFK-1504K

Page 100

IC200PWB001

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Power Supply Booster Carrier

Power Supply Booster Carrier IC200PWB001 can be used to mount an additional power supply in sequence with other module carriers. A power supply mounted on a booster carrier provides power to all I/O modules to its right, or until the next booster power supply. The AC or DC Power Supply on the CPU or NIU and the Power Supply that resides on the Booster Carrier must share the same external power source.

66.8mm (2.63in)

IC200PWB001

POWER SUPPLY

BOOSTER CARRIER

IND CONT EQ FOR HAZ LOC CLASS I DIV 2 G ROUPS ABCD Temp Cpde T4A Ambient 60C CLASS 1 ZONE 2 GROUP IIC Ex nA IIC 0C <To<60C Ex nV II

PWR

Demko No. 98Y. 125014

MADE IN USA

GFK-1504K Chapter 4 Carriers 4-21

133.4mm (5.25in)

GE VersaMax User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual