GE VersaMax User Manual
IC200CMM020
GE Fanuc
Versamax
New In Stock!
Modbus Master module for Versamax Genius NIU. Module
supports one RS-485 serial port. IC200C IC200CM IC200CMM
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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
©Copyright 2001-2003 GE Fanuc Automation North America, Inc.
All Rights Reserved
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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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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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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
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
Chapter
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1
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
1
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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.
1
GFK-1504K Chapter 1 Introduction 1-3
1
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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
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
1
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
OK
RUN
FAULT
PORT 1
RS232
PORT 2
RS485
OK
CPU005
CPUE05
CPUE05
PWR
OK
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
1
U
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
64
OK
IC200GBI001
Genius®
NIU
0
1
2
SBA
3
X10
0
2
SBA
3
X1
5
0
1
2
BAUD
3
RATE
SERIAL A1
SERIAL A2
SHIELD IN
SHIELD OUT
SERIAL B1
SERIAL B2
SHIELD IN
SHIELD OUT
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
1
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
1
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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
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)
1
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
Q
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
Q
Latch
OUTPUT 12/24VDC
POS GRP .5A 32PT
FLD
OK
IC200MDL750
1234567 831
FLD
OK
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
1
(-)
(-)
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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
Q
123 45678
123456789101112 13 14 15 16
OK
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
I
vv
Q1 Q2 Q3 Q4 Q5 Q6 Q7 Q8
A
1 2 3 4 5 6 7 8 9 11 12 13 14 15 16 17 18
B
123456789 111213141516171810
I1 I2 I3 I4 I5 I6 I7 I8 I9 I10
followed by
Point numbers
v
vvvv v
10
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
I
+
-
(+)
FLD
OK
OK
-
(+)-(+)
1-10 VersaMax® Modules, Power Supplies, and Carriers User's Manual – March 2003 GFK-1504K
Q2 Q3
2 3
Q4
Q5 Q6 Q7 Q8 Q9 Q10 Q11 Q12
5 6 7 8 9
4
5 6 7 8 9
4
11 12 13 14 15 16 17 18
10
12 13 14 15 16 17 18
11
10
Q1
1
A
1 2 3
B
I1 I2 I3 I4 I5 I6 I7 I8 9 I1 0 I11 I1 2 I13 I14 I15 I16
I17 I18 I19 I20
vailable I/O Modules
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A
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
1
GFK-1504K Chapter 1 Introduction 1-11
1
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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
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.
1
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
1
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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
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)
PS
ETM
CPU/NIU
VersaMax ExpansionRack 1
15M with any
IC200ERM002 ERMs
750M with all
IC200ERM001 ERMs
PS
ERM
1
IC200CBL601,
602, 615
Terminator
Plug
Two-Rack Local: A PLC or NIU I/O Station connected directly to one expansion
VersaMax ExpansionRack 7
PS
ERM
rack with non-isolated Expansion Receiver Module (IC200ERM002). Maximum cable
length is 1 meter.
VersaMax PLC or NIU I/O Station Main Rack
PS
1 M
IC200CBL600
GFK-1504K Chapter 1 Introduction 1-15
CPU/NIU
VersaMax Expansion Rack
PS
ERM
1
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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
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
1
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
1
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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
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]
power supplies, I/O [12V-240V]
modules)
, 0.15 to 80Mhz, 80%AM
rms
Variation for AC +/-10%,
Variation for DC +/-20%
1
GFK-1504K Chapter 1 Introduction 1-19
1
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1-20 VersaMax® Modules, Power Supplies, and Carriers User's Manual – March 2003 GFK-1504K
Chapter
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2
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
2
(
)
(
)
(
)
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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)
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
DIN Rail and Panel Mounting
g
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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.
2
Hole for Optional
Panel-Mountin
GFK-1504K Chapter 2 Installation Instructions 2-3
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