GE Digital VersaMax Operating Manual

GE
Intelligent Platforms

Programmable Control Products

VersaMax*

Modules, Power Supplies and
Carriers

User Manual

August

2014

, GFK-1504N

These instructions do not purport to cover all details or variations in equipment, nor to provide for every

possible contingency

to be met
during installation, operation, and maintenance. The information is supplied for informational purposes only, and GE makes no warranty
as to the accuracy of the information included herein. Changes, modifications, and/ or improvements to equipment and specifications are
made periodically and these changes may or may not be reflected herein. It is understood that GE may make changes, modifications, or
improvements to the equipment referenced herein or to the document itself at any time. This document is intended for trained personnel
familiar with the GE products referenced herein.

This document is approved for public disclosure.
GE may have patents or pending patent applications covering subject matter in this document. The furnishing of this document

does not provide any license whatsoever to any of these patents.
GE provides the following document and the information included therein as is and without warranty of any kind, expressed or implied,

including but not limited to any implied statutory warranty of merchantability or fitness for particular purpose.
For further assistance or technical information, contact the nearest GE Sales or Service Office, or an authorized GE Sales

Representative.

Revised: Aug 2014
Issued: Sept 2006

Copyright © 2006 - 2014 General Electric Company, All rights reserved.

* Indicates a trademark of General Electric Company and/or its subsidiaries. All other
trademarks are the property of their respective owners.

Refer to the section, Contact Information for support on this

product

.

Online Technical Support

www.ge-ip.com/support

Phone

[phone]

or dialing from a mobile telephone)

Technical Support Email

[e-mail]

Custome r Care Email

[e-mail]

Primary languages of support

English, French, German, Italian, Czech, Spanish

Phone
[phone]

[phone] (India, Indonesia, and Pakistan)

[e-mail] (remaining Asia customers)

[e-mail] (China)

Contact Information

If you purchased this product through an Authorized Channel Partner, contact the seller
directly.

General Contact Information

Online technical support and GlobalCar e http://www.ge-ip.com/support
Additional information http://www.ge-ip.com/
Solution Provider [e-mail]

Technical Support

If you have technical problems that cannot be resolved with the information in this guide,
contact us by telephone or email, or on the web at www.ge-ip.com/support

Americas

Online Technical Support www.ge-ip.com/support
Phone [phone]
International Americas Direct Dial 1-780-420-2010 (if toll free 800 option is unavailable)
Technical Support Email [e-mail]
Customer Care Email [e-mail]
Primary language of support English

.

Europe, the Middle East, and Africa

EMEA Direct Dial [phone] (if toll free 800 option is unavailable

Asia Pacific

Online Technical Support www.ge-ip.com/support

Technical Support Email [e-mail] (China)

[e-mail] (Japan)

Custome r Care Email [e-mail]

Contents

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

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

The VersaMax Family of Products ............................................................... 1-3

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

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

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

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

Discrete Module Point LEDs ........................................................................ 1-9

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

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

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

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

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

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

Thermal Considerations ............................................................................... 2-4

DIN Rail and Panel Mounting ....................................................................... 2-5

Installing an Expansion Transmitter Module ................................................ 2-7

Installing a Power Supply ........................................................................... 2-12

System Wiring Guidelines .......................................................................... 2-14

System Grounding ..................................................................................... 2-19

Installing Wiring for I/O Devices ................................................................. 2-20

Installing Modules ...................................................................................... 2-39

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

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

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

IC200PWR011 and IC200PWR012 24VDC Isolated Power Supplies ........ 3-6

IC200PWR101 120/240VAC Power Supply ................................................ 3-9

IC200PWR102 120/240VAC Expanded 3.3V Power Supply .................... 3-11

IC200PWR201 12VDC Power Supply ....................................................... 3-13

IC200PWR202 12VDC Expanded 3.3 V Power Supply ............................ 3-15

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

GFK-1504N iii

Contents

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

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

IC200PNS001 and IC200PNS001 PROFINET Scanner Carriers ............. 4-21

IC200PWB001 Power Supply Booster Carrier .......................................... 4-23

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 Thermoc ouple 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

IC200CHS121, Main Base IC200CHS122, Expansion Base

Fuse-Style Interposing I/O T erminals ........................................................ 5-20

IC200TBM001: Barrier-Style Auxiliary I/O Terminal Strip .......................... 5-24

IC200TBM002 Box-Style Auxiliary I/O Terminal Strip ............................... 5-25

IC200TBM005 Spring-Style Auxiliary I/O Terminal Strip ........................... 5-26

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

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

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

IC200ERM002 Expansion Receiver Module, Non-isolated ....................... 6-14

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 ......................... 7-22

IC200MDL244 Input Module, 240VAC Isolated 8 Points ........................... 7-26

IC200MDL631 Input Module, 125VDC Pos/Neg Logic Isolated 8 Points .. 7-29
IC200MDL632 Input Module, 125VDC Pos/Neg Logic Isolated 16 Points 7-32
IC200MDL635 Input Module, 48VDC Pos/Neg Logic Grouped 16 Points. 7-36
IC200MDL636 Input Module, 48VDC Pos/Neg Logic Grouped 32 Points. 7-39

IC200MDL640 Input Module, 24VDC Pos/Neg Logic 16 Points ................ 7-43

iv VersaMax Modules, Power Supplies and Carriers GFK-1504N

Contents

IC200MDL643 Input Module, 5/12VDC Pos/Neg Logic Grouped

16 Points .................................................................................................... 7-46

IC200MDL644 Input Module, 5/12VDC Pos/Neg Logic Grouped

32 Point ...................................................................................................... 7-50

IC200MDL650 Input Module, 24VDC Pos/Neg Logic 32 Points ................ 7-54

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 Posi ti ve Log ic 2.0 Amps,

w/ESCP 8 Points ........................................................................................ 8-14

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

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 ...................... 9-13

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

16 Points / Input 24 VDC Pos/Neg Logic Grouped 16 Points ................... 9-17

IC200MDD845 Mixed Module, Output Relay 2.0A Isolated

8 Points / Input 24VDC Pos/Neg Logic Grouped 16 Points ...................... 9-23

IC200MDD846 Mixed Module, Output Relay 2.0A per Pt Isolated

8 Points / Input 120VAC Grouped 8 Points .............................................. 9-30

GFK-1504N Contents v

Contents

IC200MDD847 Mixed Module, Output Relay 2.0A per Pt Isolated

8 Points / Input 240VAC Grouped 8 Points ............................................... 9-34

IC200MDD848 Mixed Module, Output 120VAC 0.5A per Pt Isolated

8 Points / Input 120VAC Grouped 8 Points .............................................. 9-38

IC200MDD849 Mixed Module Output Relay 2.0A per Pt Isolated

8 Points / Input 120VAC Isolated 8 Points ................................................ 9-43

IC200MDD850 Mixed Module, Output Relay 2.0A per Pt Isolated

8 Points / Input 240VAC Isolated 4 Points ................................................ 9-47

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

16 Points / Input 5/12VDC Pos/Neg Logic Grouped 16 Points ................. 9-51

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, IC200ALG265 Analog Input Module, 15 Bit Voltage

15 Channels ............................................................................................. 10-34

IC200ALG264, IC200ALG266 Analog Input Module, 15 Bit Current

15 Channels ............................................................................................. 10-39

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

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

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

vi VersaMax Modules, Power Supplies and Carriers GFK-1504N

Contents

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 ............................................................................ 12-17

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

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

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

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

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

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

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

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

Panel-Mounting Details ................................................................................ A-3

Module Space Requirements ....................................................................... A-4

Module Sizes ................................................................................................ A-5

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

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

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

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

Compatibility Matrix .............................................................................. E-1

GFK-1504N Contents vii

Chapter

1

Introduction

Getting Started

Read this chapter first to learn about the basics of VersaMax I/O. To locate
detailed information, refer to the following section, Guide to the VersaMax
Document Set.

Guide to the VersaMax Document Set

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 appendices to this manual contain detailed reference information.

GFK-1504N 1-1

Describes the installation and operation of the VersaMax PROFINET

1

Related VersaMax Manuals

For more information about VersaMax products, consult the following manuals.

GFK-1503, VersaMax PLC
System Manual

GFK-1860, VersaMax Ethernet
Network Interface Unit User’s
Manual

GFK-1533, VersaMax
DeviceNet Modules User’s
Manual

GFK-1534, VersaMax Profibus
Network Modules User’s
Manual

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.

GFK-1535, VersaMax Genius
Network Interface Unit User’s
Manual

GFK-1697, VersaMax AS-i
Network Master Module User’s
Manual

GFK-2571, VersaMax
PROFINET Scanner Manual

1-2 VersaMax Modules, Power Supplies and CarriersUser Manual GFK-1504N

Describes the installation and operation of the Genius NIU. The
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.

Scanner, which interfaces a remote node of VersaMax modules to a
PROFINET IO network.

1

VersaMax Product Line

The VersaMax product line 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-1504N Chapter 1 Introduction 1-3

VersaMax PLC CPU

power supply

VersaMax Modules

1

CPU Modules for VersaM ax P LCs

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

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 CPUs are described in GFK-1503, VersaMax PLC User’s Manual.
This document also provides programming information for the VersaMax PLC.

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 CarriersUser Manual GFK-1504N

1

RS485

PORT 2

RS232

PORT 1

CPU001

PORT 2

FORCE

PORT 1

FAULT

RUN

PWR

OK

RS485

PORT 2

RS232

PORT 1

CPU005

FAULT

RUN

PWR

OK

PORT 2

FORCE

PORT 1

CPU001
CPU002

CPU005

Status LEDs

Serial Ports

RS485

PORT 2

RS232

PORT 1

CPUE05

FAULT

RUN

PWR

OK

PORT 2

FORCE

PORT 1

PORT 1

LAN

STAT

ETHERNET

10 BASE T /
100 BASE TX

ETHERNET

RESTART

CPUE05

Ethernet Interface

Available VersaMax CPUs

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, 128kB of Configurable Memory IC200CPU005

CPU with Two Serial Ports and Embedded Ethernet Interface,
128kB of Configurable Memory

IC200CPUE05

GFK-1504N Chapter 1 Introduction 1-5

VersaMax NIU

power supply

VersaMax Modules

SHIELD OUT

SERIAL B2

SHIELD IN

SERIAL A2

SHIELD OUT

SERIAL B1

SHIELD IN

SERIAL A1

0

1

0 0 7

6

4

5

8

9

1

1

BAUD

RATE

SBA

X10

3

2

3

2

3

2

GBI001

BUS B

SBA ERR

I/O ENBL

FORCE

PWR

FAULT

OK

SBA

X1

U

N

A

N

Genius® NIU

IC200GBI001

1

Network Interface Uni t s

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

The NIU 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 NIU 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.

Genius NIU

1-6 VersaMax Modules, Power Supplies and CarriersUser Manual GFK-1504N

1

Available VersaMax NIUs

Ethernet NIU

The Ethernet NIU (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 NIU, refer to
GFK-1860, VersaMax System Ethernet Network Communications User’s
Manual.

DeviceNet NIU

The DeviceNet NIU (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 NIU, refer to GFK-1533, VersaMax System DeviceNet
Network Communications User’s Manual.

Ethernet NIU IC200EBI001

Profibus NIU IC200PBI001

Genius NIU IC200GBI001

DeviceNet NIU IC200DBI001

Profibus NIU

The Profibus NIU (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
NIU, refer to GFK-1534, VersaMax System Profibus Network Modules User’s
Manual (revision A or later).

Genius NIU

The Genius NIU (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 NIU, refer to GFK-1535, VersaMax System Genius Network Interface

Unit User’s Manual.

GFK-1504N Chapter 1 Introduction 1-7

IC200PWR001

VDC

+

INPUT

-

24 VDC, 11 W
POWER SUPPLY

NOT

USED

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

1

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.

Available Power Supplies and Carrier

1-8 VersaMax Modules, Power Supplies and CarriersUser Manual GFK-1504N

The following table lists the available VersaMax power supplies and carrier.

Power supplies are described in chapter 3 of this manual.

1

66.8mm
(2.63in)

110mm
(4.33in)

Latch

Individual Point LEDS

on Discrete Modules

Field Power LED
indicates presence of
power from external
supply

OK LED indicates
presence of power from
VersaMax power supply

Color code:
Red: AC

Blue: DC
Gold: Mixed

Gray: Analog/other

Module
Description

1234567 831

FLD
PWR

OK

IC200MDL750

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

OK

FLD
PWR

1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16

Q

Q

17 18 19

20

21 22

23

24 25 26 27 28 29 30 31

32

I/O Modules

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

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

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:

GFK-1504N Chapter 1 Introduction 1-9

Q (output points)

Point numbers

I (input points)

1234567

8

123456789

10111213141516

OK

Q

I

OK

I1 I2 I3 I4 I5 I6 I7 I8 I9 I10 I11 I12 I13 I14 I15 I16

Q1

Q2

Q3

Q4

Q5

Q6

Q7

Q8

v v v v v v v v

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

1 2 3 4

5 6 7 8 9 11 12 13 14 15 16 17 18 10

10

B

A

+

-

(+)

(-)

+

-

(+)

(-)

-

(+) - (+)

OK

123456789101112171819

20

123456789101112131415

16

FLD

Q/I

I

Q (Output points 1 - 12)

followed by

I (input points 17 - 20)

Point numbers

I (input points 1 - 16)

1

A B

2

3

4

5

6 7

8

9

1

2

3

4

5

6 7 8

9

11

12

13

14

15

16

17

18

11

12 13

14

15

16

17

18

10

10

I1

I2

I3

I4

I5

I6

I7

I8 9 I10

I11

I12

I13

I14

I15

I16

I17

I18

I19

I20

Q1

Q2

Q3

Q4

Q5

Q6

Q7

Q8

Q9

Q10

Q11

Q12

1

LEDs for Discrete Mixed
Module IC200MDD845

Wiring Diagram for Module
IC200MDD845

or more complex:

LEDs for Discrete Mixed
High-speed Counter Module
IC200MDD841

Wiring Diagram for Mixed
High-speed Counter Module
IC200MDD841

1-10 VersaMax Modules, Power Supplies and CarriersUser Manual GFK-1504N

1

Available I/O Modules

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-1504N Chapter 1 Introduction 1-11

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

IC200MDD841

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

IC200MDD842

Mixed Module, 24VDC Positive Logic Input Grouped 10 Points / Output Relay 2.0A per Point
Grouped 6 Points

IC200MDD843

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

IC200MDD844

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

IC200MDD845
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

IC200MDD848
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, 15 Bit Voltage 15 Channels, SIL2 Rated, Enhanced Diagnostics

IC200ALG265

Analog Input Module, 15 Bit Current 15 Channels, SIL2 Rated, Enhanced Diagnostics

IC200ALG266

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

1

Counter, PWM, or Pulse Train Configurable Points

1-12 VersaMax Modules, Power Supplies and CarriersUser Manual GFK-1504N

1

Terminal-style I/O

Carrier

Compact Terminal-

style I/O Carrier

Connector-style I/O

Carrier and

Interposing Terminals

Auxiliary I/O

Terminal Strip

Carriers

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.

Refer to 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 describes the VersaMax Interposing
Terminals and Auxiliary I/O Terminal Strips.

GFK-1504N Chapter 1 Introduction 1-13

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 wit h 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

IC200CHS101
IC200CHS102

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

IC200CHS111
IC200CHS112

Fuse-Style Interposing I/O Terminals, Expansion Base

IC200CHS122

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

1

Available I/O Carriers and Terminal Strips

Fuse-Style Interposing I/O Terminals, Main Base

IC200CHS121

1-14 VersaMax Modules, Power Supplies and CarriersUser Manual GFK-1504N

1

PS

CPU/NIU

PS

ERM

PS

ERM

ETM

VersaMax ExpansionRack 1

Terminator

Plug

15M with any

IC200ERM002 ERMs

750M with all

IC200ERM001 ERMs

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

VersaMax ExpansionRack 7

IC200CBL601,

602, 615

PS

ERM

VersaMax Expansion Rack

1 M

VersaMax PLC or NIU I/O Station Main Rack

PS

CPU/NIU

IC200CBL601

Expansion Modules

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.

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

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

GFK-1504N Chapter 1 Introduction 1-15

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

1

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 in the following table.

Available Expansion Module s

Expansion Modules

Expansion Transmitter Module IC200ETM001

Expansion Receiver Module, Isolated IC200ERM001

Expansion Receiver Module, Non-isolated IC200ERM002

Cables

Expansion Cable, Shielded, 1 meter IC200CBL601

Expansion Cable, Shielded, 2 meters IC200CBL602

Expansion Cable, Shielded, 15 meters IC200CBL615

Firmware Update Cable IC200CBL002

Terminator Plug (included with ETM) IC200ACC201

Connector Kit IC200ACC302

Refer to chapter 6 for information about VersaMax Expansion modules.

1-16 VersaMax Modules, Power Supplies and CarriersUser Manual GFK-1504N

1

VersaMax PLC CPU

power supply

Optional booster

power supply

Profibus Network
Slave Module

Communications Modules

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 displayed in the following figure.

Available VersaMax PLC Communications Modules

Communications Modules

Profibus-DP Network Slave Module IC200BEM002

DeviceNet Network Control Module IC200BEM103

Asi Network Master Module IC200BEM104

Communications Carrier IC200CHS006

Serial Communications Module IC200CMM020

For information about the Communications Carrier, refer to chapter 4.

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.

GFK-1504N Chapter 1 Introduction 1-17

1

For information about the Profibus-DP Network Slave Module, refer to GFK­1534, VersaMax System Profibus Network Modules User’s Manual (revision A
or later).

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 word­type 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 GFK­1533, VersaMax System DeviceNet Network Communications User’s Manual.

Asi Network Master Module

The VersaMax AS-Interface Network Master (IC200BEM104) conforms to the
AS-Interface 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 GFK­1697, VersaMax System ASI Network Communications User’s Manual.

Serial Communications Module

The VersaMax Serial Communications Module, IC200CMM020, operates as a
Modbus RTU Master in a VersaMax I/O Station. The Serial Communications
module receives commands from a remote host such as an RX7i PLC.

1-18 VersaMax Modules, Power Supplies and CarriersUser Manual GFK-1504N

1

Environmental

Vibration

IEC68-2-6

1G at 57-150Hz, 0.012in p--p at 10-57Hz

Shock

IEC68-2-27

15G, 11ms

0 to +60 deg C ambient

auxiliary I/O terminals

Storage Temperature

-40 to +85 deg C

Humidity

5% to 95%, noncondensing

protection from dust & splashing water

EMC Emission

(Group 1, Class A)

CISPR 22/EN 55022

Information Technology Equipment (Class A)

Radio Devices (Class A)

EMC Immunity

Electrostatic Discharge

EN 61000-4-2

8KV Air, 4KV Contact

rms

100%AM with 200Hz square wave

Fast Transient Burst

EN 61000-4-4

2KV: power supplies, 1KV: I/O, communication

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

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

modules)

rms

Isolation

Dielectric Withstand

UL508, UL840, IEC664

1.5KV for modules rated from 51V to 250V

Power Supply

Variation for DC ±20%

VersaMax General Product S pecifications

VersaMax products should be installed and used in conformance with product­specific guidelines, as well as the specifications listed in the following table.

Operating Temperature

Enclosure Protection IEC529 Steel cabinet per IP54:

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

FCC 47 CFR 15 Referred to as FCC part 15,

RF Susceptibility EN 61000-4-3 10V

ENV 50140/ENV 50204 10V

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

IEC255-4 Damped Oscillatory Wave: Class II,

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

/m, 80 to 1000Mhz, 80% AM

/m, 900MHz ±5MHZ

rms

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

Conducted RF EN 61000-4-6 10V

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

GFK-1504N Chapter 1 Introduction 1-19

, 0.15 to 80Mhz, 80%AM

Variation for AC ±10%,

Chapter

2

Installation

This section provides the following installation instructions:

 Pre-installation 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

GFK-1504N 2-1

2

Pre-installation 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. It is the user’s responsibility to register a claim with the delivery
service for damage incurred during shipment.

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.

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 GFK-1179, Installation Requirements for Conformance to
Standards.

▪ Power Supply Modules: Be sure to read the installation instructions

provided with each Power Supply module. These instructions specify the
use of copper conductors for the power supply, wire gauge and type.

▪ Control circuit modules: Be sure to read the installation instructions provided

with the module. These instructions specify the use of copper conductors
and wire gauge and type requirements.

▪ Equipment labeled with reference to Class I, Div. 2, Groups A, B, C and D,

Hazardous Locations is suitable for use in Class I, Div. 2, Groups A, B, C, D
or non-hazardous locations only.

▪ Equipment labeled with reference to Class I, Zone 2, Groups A, B, C and D,

hazardous locations is suitable for use in Class I, Zone 2, Groups A, B, C, D
or non-hazardous locations only.

▪ Battery in CPU Category No. IC200CPU001 and IC200CPU002 is to be

replaced only with Matsushita No. BR2032. The correct battery type is
available as Accessory Kit IC200ACC001.

2-2 VersaMax Modules, Pow er S uppl i es and CarriersUser Manual GFK-1504N

2

Installation in Hazardous Locations

▪ WARNING - EXPLOSION HAZARD - SUBSTITUTION OF COMPONENTS

MAY IMPAIR SUITABILITY FOR CLASS I, DIVISION 2;

▪ WARNING - EXPLOSION HAZARD - WHEN IN HAZARDOUS

LOCATIONS, TURN OFF POWER BEFORE REPLACING OR WIRING
MODULES; AND

▪ WARNING - EXPLOSION HAZARD - DO NOT CONNECT OR

DISCONNECT EQUIPMENT UNLESS POWER HAS BEEN SWITCHED
OFF OR THE AREA IS KNOWN TO BE NONHAZARDOUS.

GFK-1504N Chapter 2 Installation 2-3