GE Digital VersaMax Micro 20 Operating Manual

USER MANUAL

GFK-1645M

Dec 2019

PACSystems

TM

VersaMax

MICRO PLC & NANO PLC
USER MANUAL

User Manual Contents

GFK-1645M Dec 2019

Contents i

Contents

Chapter 1: Introduction .......................................................... 1

1.1 VersaMax Micro, Micro PLUS and Nano PLC Models .............................................. 2

1.1.1 VersaMax Nano PLCs ................................................................................. 2

1.1.2 VersaMax Micro and Micro PLUS PLCs ........................................................ 3

1.1.3 VersaMax Micro PLC Expansion Units ......................................................... 4

1.1.4 Option Modules ........................................................................................ 5

1.2 Comparison of Program and Data Memory Available ........................................... 6

1.3 Comparison of PLC Features ................................................................................ 7

1.4 Comparison of I/O and Power Features for PLCs ................................................... 9

1.5 Comparison of I/O and Power Features for Expansion Units ................................ 10

1.6 VersaMax Serial to Ethernet Adapter .................................................................. 12

1.6.1 Firmware Options .................................................................................... 12

1.6.2 Serial Interface ........................................................................................ 12

1.6.3 Network Interface ................................................................................... 12

1.6.4 Power Requirements ............................................................................... 12

1.7 Logic-Driven Read/Write Flash Memory Feature ................................................ 13

1.8 Online Program Changes ................................................................................... 13

1.8.1 Word for Word Changes .......................................................................... 13

1.8.2 Run Mode Store ...................................................................................... 13

1.9 Documentation ................................................................................................. 14

1.10 Revisions in this Manual ..................................................................................... 14

Chapter 2: VersaMax Nano PLCs ............................................ 15

2.1 VersaMax Nano PLC Features ............................................................................. 15

2.1.1 Nano PLC General Specifications ............................................................. 16

2.1.2 RS-232 Serial Port .................................................................................... 16

2.1.3 Status LEDs ............................................................................................. 16

2.1.4 High-Speed Counters .............................................................................. 17

2.2 IC200NAL110 Nano PLCs with 10 Discrete Points and 1 Analog Input: (6) 12Vdc In, (4)

Relay Out, 1 Analog Input, 12Vdc Power Supply ................................................ 17

2.2.1 DC Inputs ................................................................................................ 17

2.2.2 Analog Input ........................................................................................... 17

2.2.3 Relay Outputs ......................................................................................... 18

2.2.4 Nano PLC IC200NAL110 Specifications .................................................... 18

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2.2.5 Wiring Diagram, IC200NAL110 ............................................................... 19

2.3 IC200NAL211 Nano PLC with 10 Discrete Points and 1 Analog Input: (6) 12Vdc In, (4) Relay

Out, 1 Analog Input, 24Vdc Power Supply .......................................................... 20

2.3.1 DC Inputs ................................................................................................ 20

2.3.2 Analog Input ........................................................................................... 20

2.3.3 Relay Outputs ......................................................................................... 20

2.3.4 Nano PLC IC200NAL211 Specifications .................................................... 21

2.3.5 Wiring Diagram, IC200NAL211 ............................................................... 22

2.4 IC200NDD010 10 Point Nano PLC: (6) 12Vdc In, (4) 12Vdc Out, 12Vdc Power Supply 23

2.4.1 DC Inputs ................................................................................................ 23

2.4.2 Transistor Outputs .................................................................................. 23

2.4.3 Nano PLC IC200NDD010 Specifications ................................................... 23

2.4.4 Wiring Diagram, IC200NDD010 .............................................................. 25

2.5 IC200NDD101 10 Point Nano PLC: (6) 24Vdc In, (4) 12Vdc Out, 24Vdc Power Supply 25

2.5.1 DC Inputs ................................................................................................ 25

2.5.2 Transistor Outputs .................................................................................. 25

2.5.3 Nano PLC IC200NDD101 Specifications ................................................... 26

2.5.4 Wiring Diagram, IC200NDD101 .............................................................. 27

2.6 IC200NDR001 ................................................................................................... 28

2.6.1 DC Inputs ................................................................................................ 28

2.6.2 Relay Outputs ......................................................................................... 28

2.6.3 Nano PLC IC200NDR001 Specifications ................................................... 28

2.6.4 Wiring Diagram, IC200NDR001 ............................................................... 30

2.7 IC200NDR010 10 Point Nano PLC: (6) 24Vdc In, (4) Relay Out, 12Vdc Power Supply 30

2.7.1 Inputs ..................................................................................................... 30

2.7.2 Relay Outputs ......................................................................................... 30

2.7.3 Nano PLC IC200NDR010 Specifications ................................................... 31

2.7.4 Wiring Diagram, IC200NR010 ................................................................. 32

Chapter 3: VersaMax 14-Point Micro PLCs ............................. 33

3.1 VersaMax 14-Point Micro PLC Features .............................................................. 33

3.2 14-Point Micro PLC General Specifications ......................................................... 34

3.3 High-Speed Counters ........................................................................................ 34

3.4 IC200UAA003 14-Point Micro PLC, (8) 120Vac In, (6) 120Vac Out, 120/240Vac Power

Supply ............................................................................................................... 35

3.4.1 AC Inputs ................................................................................................ 35

3.4.2 AC Outputs ............................................................................................. 35

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3.4.3 Micro PLC IC200UAA003 Specifications ................................................... 35

3.4.4 Wiring Diagram, IC200UAA003 ............................................................... 36

3.5 IC200UAR014 14-Point Micro PLC, (8) 120Vac In, (6) Relay Out, 120/240Vac Power Supply

.......................................................................................................................... 37

3.5.1 Inputs ..................................................................................................... 37

3.5.2 Relay Outputs ......................................................................................... 37

3.5.3 Micro PLC IC200UAR014 Specifications ................................................... 37

3.5.4 Wiring Diagram, IC200UAR014 ............................................................... 39

3.6 IC200UDD104 14-Point Micro PLC, (8) 24Vdc In, (6) 24Vdc Source Out, 24Vdc Power

Supply ............................................................................................................... 39

3.6.1 DC Power ................................................................................................ 39

3.6.2 DC Inputs ................................................................................................ 40

3.6.3 Outputs .................................................................................................. 40

3.6.4 Micro PLC IC200UDD104 Specifications .................................................. 40

3.6.5 Wiring Diagram, IC200UDD104 .............................................................. 42

3.7 IC200UDD112 14 Point Micro PLC, (8) 12Vdc In, (6) 12Vdc Out, 12Vdc Power Supply 43

3.7.1 DC Power ................................................................................................ 43

3.7.2 DC Inputs ................................................................................................ 43

3.7.3 Transistor Outputs .................................................................................. 43

3.7.4 Micro PLC IC200UDD112 Specifications .................................................. 44

3.7.5 Wiring Diagram, IC200UDD112 .............................................................. 45

3.8 IC200UDR001 14-Point Micro PLC, (8) 24Vdc In, (6) Relay Out, 120/240Vac Power Supply

.......................................................................................................................... 46

3.8.1 DC Inputs ................................................................................................ 46

3.8.2 Relay Outputs ......................................................................................... 46

3.8.3 Micro PLC IC200UDR001 Specifications ................................................... 46

3.8.4 Wiring Diagram, IC200UDR001 ............................................................... 48

3.9 IC200UDR002 14-Point Micro PLC, (8) 24Vdc In, (6) Relay Out, 24Vdc Power Supply 49

3.9.1 DC Power ................................................................................................ 49

3.9.2 DC Inputs ................................................................................................ 49

3.9.3 Relay Outputs ......................................................................................... 49

3.9.4 Micro PLC IC200UDR002 Specifications ................................................... 50

3.9.5 Wiring Diagram, IC200UDR002 ............................................................... 51

3.10 IC200UDR003 14-Point Micro PLC, (8) 12Vdc In, (6) Relay Out, 12Vdc Power Supply 52

3.10.1 DC Power ................................................................................................ 52

3.10.2 DC Inputs ................................................................................................ 52

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3.10.3 Relay Outputs ......................................................................................... 52

3.10.4 Micro PLC IC200UDR003 Specifications ................................................... 53

3.10.5 Wiring Diagram, IC200UDR003 ............................................................... 54

Chapter 4: VersaMax 20-Point Micro/Micro PLUS PLCs .......... 55

4.1 Features of VersaMax 20-Point Micro PLCs ......................................................... 55

4.1.1 Run/Stop Switch...................................................................................... 56

4.1.2 Ports ....................................................................................................... 56

4.1.3 Analog Inputs .......................................................................................... 57

4.1.4 Removable Terminal Strips ...................................................................... 57

4.1.5 Status LEDs ............................................................................................. 57

4.1.6 Backup Battery ........................................................................................ 57

4.2 General Specifications of 20-Point VersaMax Micro PLCs .................................... 58

4.3 High-Speed Counters ........................................................................................ 58

4.4 IC200UDD020 20-Point Micro PLC, (12) 24Vdc In, (4) 24Vdc Out with ESCP, (4) LCDC Out,

24Vdc Power Supply .......................................................................................... 59

4.4.1 DC Power ................................................................................................ 59

4.4.2 DC Inputs ................................................................................................ 59

4.4.3 DC Outputs ............................................................................................. 59

4.4.4 Micro PLC IC200UDD020 Specifications .................................................. 60

4.4.5 Wiring Diagram, IC200UDD020 .............................................................. 61

4.5 IC200UDD220 20-Point Micro PLC, (12) 24Vdc In, (8) 24Vdc Out (Sink), 24Vdc Power

Supply ............................................................................................................... 62

4.5.1 DC Power ................................................................................................ 62

4.5.2 DC Inputs ................................................................................................ 62

4.5.3 DC Outputs ............................................................................................. 62

4.5.4 Micro PLC IC200UDD220 Specifications .................................................. 63

4.5.5 Wiring Diagram, IC200UDD220 .............................................................. 64

4.6 IC200UDR020 20-Point Micro PLC, (12) 24Vdc In, (8) Relay Out, 24Vdc Power Supply 65

4.6.1 DC Inputs ................................................................................................ 65

4.6.2 Relay Outputs ......................................................................................... 65

4.6.3 Micro PLC IC200UDR020 Specifications ................................................... 65

4.6.4 Wiring Diagram, PLC IC200UDR020 ........................................................ 67

4.7 IC200UDR120 20-Point Micro PLC, (12) 24Vdc In, (8) Relay Out, 120/240Vac Power Supply

.......................................................................................................................... 67

4.7.1 DC Inputs ................................................................................................ 67

4.7.2 Relay Outputs ......................................................................................... 68

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4.7.3 Micro PLC IC200UDR120, Specifications .................................................. 68

4.7.4 Wiring Diagram, PLC IC200UDR120 ........................................................ 69

Chapter 5: Micro PLCs with 23 Discrete Points and 3 Analog Channels
70

5.1 VersaMax 23 Discrete / 3 Analog Micro PLC Features ......................................... 70

5.2 General Specifications for 23-Point VersaMax Micro PLCs .................................. 71

5.2.1 Run/Stop Switch...................................................................................... 72

5.2.2 Serial Ports .............................................................................................. 72

5.2.3 Analog Potentiometers ........................................................................... 72

5.2.4 Removable Terminal Strips ...................................................................... 73

5.2.5 Status LEDs ............................................................................................. 73

5.2.6 Backup Battery ........................................................................................ 73

5.3 High-Speed Counters ........................................................................................ 73

5.3.1 Analog I/O ............................................................................................... 73

5.4 IC200UAL004 Micro PLC, 23 Discrete Points and 3 Analog Channels: (13) 12Vdc In, (10)

Relay Out, (2) Analog In, (1) Analog Out, 12Vdc Power Supply ........................... 74

5.4.1 DC Inputs ................................................................................................ 74

5.4.2 Normally-Open Relay Outputs ................................................................. 75

5.4.3 DC Power Supply ..................................................................................... 75

5.4.4 Micro PLC IC200UAL004 Specifications.................................................... 75

5.4.5 Wiring Diagram, IC200UAL004................................................................ 76

5.5 IC200UAL005 Micro PLC, 23 Discrete Points and 3 Analog Channels: (13) 24Vdc In, (1)
24Vdc Out, (9) Relay Out, (2) Analog In, (1) Analog Out, 24Vdc Power Supply ... 77

5.5.1 DC Inputs ................................................................................................ 77

5.5.2 DC Output (Q1) ....................................................................................... 77

5.5.3 Normally-Open Relay Outputs ................................................................. 77

5.5.4 DC Power Supply ..................................................................................... 77

5.5.5 Micro PLC IC200UAL005 Specifications.................................................... 78

5.5.6 Wiring Diagram, IC200UAL005................................................................ 80

5.6 IC200UAL006 Micro PLC, 23 Discrete Points and 3 Analog Channels: (13) 24Vdc In, (1)
24Vdc Out, (9) Relay Out, (2) Analog In, (1) Analog Out, 120/240Vac Power Supply 80

5.6.1 DC Inputs ................................................................................................ 81

5.6.2 DC Output (Q1) ....................................................................................... 81

5.6.3 Normally-Open Relay Outputs ................................................................. 81

5.6.4 Micro PLC IC200UAL006 Specifications.................................................... 81

5.6.5 Wiring Diagram, IC200UAL006................................................................ 83

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5.7 Analog Operation .............................................................................................. 84

5.7.1 Analog I/O Parameters ............................................................................ 84

5.7.2 Input/Output Values Compared to Process Data ..................................... 84

5.7.3 Analog Input Processing .......................................................................... 85

5.7.4 Analog Output Processing ....................................................................... 86

5.7.5 Adjusting the Calibration of Analog Channels .......................................... 87

Chapter 6: VersaMax 28-Point Micro PLCs ............................. 88

6.1 Features of VersaMax 28-Point Micro PLCs ......................................................... 88

6.1.1 Run/Stop Switch...................................................................................... 89

6.1.2 Serial Ports .............................................................................................. 90

6.1.3 Analog Potentiometers ........................................................................... 90

6.1.4 Removable Terminal Strips ...................................................................... 90

6.1.5 Status LEDs ............................................................................................. 90

6.1.6 Backup Battery ........................................................................................ 90

6.2 General Specifications for 28-Point VersaMax Micro PLCs .................................. 91

6.3 High-Speed Counters ........................................................................................ 91

6.4 IC200UAA007 28-Point Micro PLC, (16) 120Vac In, (12) 120Vac Out, 120/240Vac Power

Supply ............................................................................................................... 92

6.4.1 Inputs ..................................................................................................... 92

6.4.2 AC Outputs ............................................................................................. 92

6.4.3 Micro PLC IC200UAA007 Specifications ................................................... 93

6.4.4 Wiring Diagram IC200UAA007 ................................................................ 94

6.5 IC200UAR028 28-Point Micro PLC, (16) 120Vac In, (2/10) Relay Out, 120/240Vac Power

Supply ............................................................................................................... 94

6.5.1 Inputs ..................................................................................................... 94

6.5.2 Relay Outputs ......................................................................................... 94

6.5.3 Micro PLC IC200UAR028 Specifications ................................................... 95

6.5.4 Wiring Diagram IC200UAR028 ................................................................ 96

6.6 IC200UDD110 28-Point Micro PLC, (16) 24Vdc In, (12) 24Vdc Out, 24Vdc Power Supply

.......................................................................................................................... 96

6.6.1 DC Power ................................................................................................ 96

6.6.2 DC Inputs ................................................................................................ 97

6.6.3 Transistor Outputs .................................................................................. 97

6.6.4 Micro PLC IC200UDD110 Specifications .................................................. 97

6.6.5 Wiring Diagram IC200UDD110 ............................................................... 99

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6.7 IC200UDD120 28-Point Micro PLC, (16) 24Vdc In, (12) 24Vdc Out with ESCP, 24Vdc Power

Supply ............................................................................................................. 100

6.7.1 DC Power .............................................................................................. 100

6.7.2 DC Inputs .............................................................................................. 100

6.7.3 Transistor Outputs ................................................................................ 100

6.7.4 Micro PLC IC200UDD120 Specifications ................................................ 101

6.7.5 Wiring Diagram IC200UDD120 ............................................................. 102

6.8 IC200UDD212 28-Point Micro PLC, (16) 12Vdc In, (12) 12Vdc Out, 12Vdc Power Supply

........................................................................................................................ 103

6.8.1 DC Power .............................................................................................. 103

6.8.2 DC Inputs .............................................................................................. 103

6.8.3 Transistor Outputs ................................................................................ 103

6.8.4 Micro PLC IC200UDD212 Specifications ................................................ 104

6.8.5 Wiring Diagram IC200UDD212 ............................................................. 105

6.9 IC200UDR005 28-Point Micro PLC, (16) 24Vdc In, (1) 24Vdc Out, (11) Relay Out,

120/240Vac Power Supply ............................................................................... 106

6.9.1 DC Inputs .............................................................................................. 106

6.9.2 DC Output (Q1) ..................................................................................... 106

6.9.3 Relay Outputs (Q2 – Q12) ..................................................................... 106

6.9.4 Micro PLC IC200UDR005 Specifications ................................................. 106

6.9.5 Wiring Diagram IC200UDR005 .............................................................. 108

6.10 IC200UDR006 28-Point Micro PLC, (16) 12Vdc In, (12) Relay Out, 12Vdc Power Supply 109

6.10.1 DC Power .............................................................................................. 109

6.10.2 Inputs ................................................................................................... 109

6.10.3 Relay Outputs (Q1 – Q12) ..................................................................... 109

6.10.4 Micro PLC IC200UDR006 Specifications ................................................. 110

6.10.5 Wiring Diagram IC200UDR006 .............................................................. 111

6.11 IC200UDR010 28-Point Micro PLC, (16) 24Vdc In, (1) 24Vdc Out, (11) Relay Out, 24Vdc PS
IC200UDR228 28-Point Micro PLC, (16) 24 VC In, (1) 24Vdc Out, (11) Relay Out, 12/24Vdc

PS .................................................................................................................... 112

6.11.1 DC Power .............................................................................................. 112

6.11.2 DC Inputs .............................................................................................. 112

6.11.3 DC Output (Q1) ..................................................................................... 112

6.11.4 Relay Outputs (Q2 – Q12) ..................................................................... 113

6.11.5 Micro PLC IC200UDR010, IC200UDR228 Specifications ......................... 113

6.11.6 Wiring Diagram IC200UDR010, IC200UDR228 ...................................... 115

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Chapter 7: VersaMax 40-Point Micro/Micro PLUS PLCs ........ 116

7.1 Features of VersaMax 40-Point Micro PLCs ....................................................... 116

7.1.1 Run/Stop Switch.................................................................................... 117

7.1.2 Ports ..................................................................................................... 117

7.1.3 Analog Inputs ........................................................................................ 118

7.1.4 Removable Terminal Strips .................................................................... 118

7.1.5 Status LEDs ........................................................................................... 118

7.1.6 Backup Battery ...................................................................................... 118

7.2 General Specifications of 40-Point VersaMax Micro PLCs .................................. 119

7.3 High-Speed Counters ...................................................................................... 119

7.4 IC200UDD040 40-Point Micro PLC, (24) 24Vdc In, (12) 24Vdc Out with ESCP,(4) LCDC Out,

24Vdc Power Supply ........................................................................................ 120

7.4.1 DC Power .............................................................................................. 120

7.4.2 DC Inputs .............................................................................................. 120

7.4.3 DC Outputs ........................................................................................... 120

7.4.4 Micro PLC IC200UDD040 Specifications ................................................ 121

7.4.5 Wiring Diagram, IC200UDD040 ............................................................ 122

7.5 IC200UDD240 40 Point Micro PLC, (24) 24Vdc In, (16) 24Vdc Out (Sink), 24Vdc Power

Supply ............................................................................................................. 123

7.5.1 DC Power .............................................................................................. 123

7.5.2 DC Inputs .............................................................................................. 123

7.5.3 DC Outputs ........................................................................................... 123

7.5.4 Micro PLC IC200UDD240 Specifications ................................................ 124

7.6 IC200UDR040 40 Point Micro PLC, (24) 24Vdc In, (16) Relay Out, 24Vdc Power Supply
IC200UDR140 40 Point Micro PLC, (24) 24Vdc In, (16) Relay Out, 120/240Vac Power
Supply IC200UDR440 40 Point Micro PLC, (24) 24Vdc In, (16) Relay Out, 12/24Vdc Power

Supply ............................................................................................................. 126

7.6.1 DC Inputs .............................................................................................. 126

7.6.2 Relay Outputs ....................................................................................... 126

7.6.3 Micro PLC IC200UDR040, IC200UDR140, IC200UDR440 Specifications . 127

7.6.4 Wiring Diagram, IC200UDR040, IC200UDR140, IC200UDR440 ............. 129

Chapter 8: VersaMax 64-Point Micro/Micro PLUS PLCs ........ 130

8.1 Features of VersaMax 64-Point Micro PLCs ....................................................... 130

8.2 General Specifications of 64-Point VersaMax Micro PLCs .................................. 131

8.3 High-Speed Counters ...................................................................................... 131

8.3.1 Run/Stop Switch.................................................................................... 132

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8.3.2 Ports ..................................................................................................... 132

8.3.3 Analog Inputs ........................................................................................ 133

8.3.4 Removable Terminal Strips .................................................................... 133

8.3.5 Status LEDs ........................................................................................... 133

8.3.6 Backup Battery ...................................................................................... 133

8.4 IC200UDD064 64 Point Micro PLC, (40) 24Vdc In, (24) 24Vdc Out (Source), 24Vdc Power

Supply ............................................................................................................. 133

8.4.1 DC Power .............................................................................................. 133

8.4.2 DC Inputs .............................................................................................. 134

8.4.3 Transistor Outputs ................................................................................ 134

8.4.4 Micro PLC IC200UDD064 Specifications ................................................ 134

8.4.5 Wiring Diagram, IC200UDD064 ............................................................ 136

8.5 IC200UDD164 64 Point Micro PLC, (40) 24Vdc In, (24) 24Vdc Out (Sink), 24Vdc Power

Supply ............................................................................................................. 136

8.5.1 DC Power .............................................................................................. 136

8.5.2 DC Inputs .............................................................................................. 136

8.5.3 DC Outputs ........................................................................................... 137

8.5.4 Micro PLC IC200UDD164 Specifications ................................................ 137

8.5.5 Wiring Diagram, IC200UDD164 ............................................................ 138

8.6 IC200UDR064 64 Point Micro PLC, (40) 24Vdc In, (24) Relay Out, 24Vdc Power Supply 139

8.6.1 DC Inputs .............................................................................................. 139

8.6.2 Relay Outputs ....................................................................................... 139

8.6.3 Micro PLC IC200UDR064 Specifications ................................................. 139

8.6.4 Wiring Diagram, PLC IC200UDR064 ...................................................... 141

8.7 IC200UDR164 64 Point Micro PLC, (40) 24Vdc In, (24) Relay Out, 120/240Vac Power

Supply ............................................................................................................. 141

8.7.1 DC Inputs .............................................................................................. 141

8.7.2 Relay Outputs ....................................................................................... 141

8.7.3 Micro PLC IC200 UDR164, Specifications ............................................... 142

8.7.4 Wiring Diagram, IC200UDR164 ............................................................. 143

Chapter 9: VersaMax Micro PLC 8-, 14-, and 16-Point Expansion Units
144

9.1 Features of VersaMax 8-, 14-, and 16-Point Expansion Units ............................. 145

9.1.1 Removable Terminal Strips .................................................................... 145

9.1.2 Expansion Connector ............................................................................ 145

9.1.3 Status LEDs ........................................................................................... 145

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9.1.4 Cables ................................................................................................... 145

9.2 IC200UEC008 8 Point Expansion Unit, (4) 24Vdc Inputs, (4) 24Vdc Outputs with ESCP,

24Vdc Power Supply ........................................................................................ 146

9.2.1 DC Inputs .............................................................................................. 146

9.2.2 Transistor Outputs ................................................................................ 146

9.2.3 Expansion Unit IC200UEC008 Specifications .......................................... 147

9.2.4 Wiring Diagram, IC200UEC008 ............................................................. 148

9.3 IC200UEC108 8 Point Expansion Unit, (4) 24Vdc Inputs, (4) 24VC Transistor Outputs,

24Vdc Power Supply ........................................................................................ 148

9.3.1 DC Inputs .............................................................................................. 148

9.3.2 Transistor Outputs ................................................................................ 149

9.3.3 Expansion Unit IC200UEC108 Specifications .......................................... 149

9.4 IC200UEC208 8 Point Expansion Unit , (4) 24Vdc Inputs, (4) Relay Outputs, 24Vdc Power

Supply ............................................................................................................. 150

9.4.1 DC Inputs .............................................................................................. 150

9.4.2 Relay Outputs ....................................................................................... 151

9.4.3 Expansion Unit IC200UEC208 Specifications .......................................... 151

9.4.4 Wiring Diagram, IC200UEC208 ............................................................. 152

9.5 IC200UEI008 8 Point Expansion Unit, (8) 24Vdc Inputs, 24Vdc Power Supply IC200UEI016

16 Point Expansion Unit, (16) 24Vdc Inputs, 24Vdc Power Supply .................... 153

9.5.1 DC Inputs .............................................................................................. 153

9.5.2 Expansion Units IC200UEI008 and IC200UEI016 Specifications .............. 153

9.5.3 Wiring Diagram, IC200UEI008 ............................................................... 154

9.5.4 Wiring Diagram, IC200UEI016 ............................................................... 154

9.6 IC200UEO008 8 Point Expansion Unit, (8) 24Vdc Outputs with ESCP, 24Vdc Power Supply
IC200UEO016 16 Point Expansion Unit, (16) 24Vdc Outputs with ESCP, 24Vdc Power

Supply ............................................................................................................. 155

9.6.1 Transistor Outputs ................................................................................ 155

9.6.2 Expansion Units IC200UEO008 and IC200UEO016 Specifications .......... 156

9.6.3 Wiring Diagram, IC200UEO008 ............................................................. 157

9.6.4 Wiring Diagram, IC200UEO016 ............................................................. 157

9.7 IC200UEO108 8 Point Expansion Unit, (8) 24Vdc Transistor Outputs, 24Vdc Power Supply
IC200UEO116 16 Point Expansion Unit, (16) Transistor Outputs, 24Vdc Power Supply 158

9.7.1 Transistor Outputs ................................................................................ 158

9.7.2 Expansion Units IC200UEO108 and IC200UEO116 Specifications .......... 158

9.7.3 Wiring Diagram, IC200UEO108 ............................................................. 159

9.7.4 Wiring Diagram, IC200UEO116 ............................................................. 160

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9.8 IC200UER008 8 Point Expansion Unit, (8) Relay Outputs, 24Vdc Power Supply
IC200UER016 16 Point Expansion Unit, (16) Relay Outputs, 24Vdc Power Supply161

9.8.1 Relay Outputs ....................................................................................... 161

9.8.2 Expansion Units IC200UER008 and IC200UER016 Specifications ........... 161

9.8.3 Wiring Diagram, IC200UER008 ............................................................. 162

9.8.4 Wiring Diagram, IC200UER016 ............................................................. 162

9.9 IC200UEX009 14 Point Expansion Unit, (8) 120Vac In, (2) Relay Out at 10 Amps, (4) Relay

Out at 2 Amps, 120/240Vac Power Supply ....................................................... 163

9.9.1 AC Inputs .............................................................................................. 163

9.9.2 Relay Outputs ....................................................................................... 163

9.9.3 Expansion Unit IC200UEX009 Specifications .......................................... 163

9.9.4 Wiring Diagram, IC200UEX009 ............................................................. 164

9.10 IC200UEX010 14 Point Expansion Unit, (8) 120Vac In, (6) 120Vac Out, 120/240Vac Power

Supply ............................................................................................................. 165

9.10.1 AC Inputs .............................................................................................. 165

9.10.2 AC Outputs ........................................................................................... 165

9.10.3 Expansion Unit IC200UEX010 Specifications .......................................... 165

9.10.4 Wiring Diagram, IC200UEX010 ............................................................. 166

9.11 IC200UEX011 14-Point Expansion Unit with AC Power, (8) 24Vdc Inputs, (6) Relay Outputs

........................................................................................................................ 167

9.11.1 DC Inputs .............................................................................................. 167

9.11.2 Relay Outputs ....................................................................................... 167

9.11.3 Expansion Unit IC200UEX011 Specifications .......................................... 167

9.11.4 Wiring Diagram, IC200UEX011 ............................................................. 168

9.12 IC200UEX012 14-Point Expansion Unit with 24DC Power, (8) 24Vdc Inputs, (6) Relay

Outputs ........................................................................................................... 169

9.12.1 DC Inputs .............................................................................................. 169

9.12.2 Relay Outputs ....................................................................................... 169

9.12.3 Expansion Unit IC200UEX012 Specifications .......................................... 169

9.12.4 Wiring Diagram, IC200UEX012 ............................................................. 170

9.13 IC200UEX013 14-Point Expansion Unit with 12Vdc Power, (8) 12Vdc Inputs, (6) Relay

Outputs ........................................................................................................... 171

9.13.1 DC Inputs .............................................................................................. 171

9.13.2 Relay Outputs ....................................................................................... 171

9.13.3 Expansion Unit IC200UEX013 Specifications .......................................... 171

9.13.4 Wiring Diagram, IC200UEX013 ............................................................. 172

9.14 IC200UEX014 14-Point Expansion Unit with 24DC Power, (8) 24DC Inputs, (2) High-

Current and (4) Low-Current Transistor Outputs .............................................. 173

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9.14.1 DC Inputs .............................................................................................. 173

9.14.2 Transistor Outputs ................................................................................ 173

9.14.3 Expansion Unit IC200UEX014 Specifications .......................................... 174

9.14.4 Wiring Diagram, IC200UEX014 ............................................................. 175

9.15 IC200UEX015 14-Point Expansion Unit with 12DC Power, (8) 12DC Inputs, (6) 12Vdc

Outputs ........................................................................................................... 176

9.15.1 DC Inputs .............................................................................................. 176

9.15.2 Transistor Outputs ................................................................................ 176

9.15.3 Expansion Unit IC200UEX015 Specifications .......................................... 177

9.15.4 Wiring Diagram, IC200UEX015 ............................................................. 178

9.16 IC200UEX122 14-Point Expansion Unit with 24DC Power, (8) 24DC Inputs, (2) High-

Current and (4) Low-Current Transistor Outputs with ESCP .............................. 179

9.16.1 DC Inputs .............................................................................................. 179

9.16.2 Outputs ................................................................................................ 179

9.16.3 Expansion Unit IC200UEX122 Specifications .......................................... 180

9.16.4 Wiring Diagram, IC200UEX122 ............................................................. 181

Chapter 10: VersaMax Micro PLC 28-Point Expansion Units ... 182

10.1 Features of VersaMax 28-Point Micro PLC Expansion Units ............................... 182

10.1.1 Removable Terminal Strips .................................................................... 183

10.1.2 Expansion Connector ............................................................................ 183

10.1.3 Status LEDs ........................................................................................... 183

10.1.4 Cables ................................................................................................... 183

10.2 IC200UEX209 28 Point Micro PLC Expansion Unit, (16) 120Vac In, (2/10) Relay Out,

120/240Vac Power Supply ............................................................................... 183

10.2.1 AC Inputs .............................................................................................. 183

10.2.2 Relay Outputs ....................................................................................... 183

10.2.3 Expansion Unit IC200UEX209 Specifications .......................................... 184

10.2.4 Wiring Diagram, IC200UEX209 ............................................................. 185

10.3 IC200UEX210 28 Point Micro PLC Expansion Unit, (16) 120Vac In, (12) 120Vac Out,

120/240Vac Power Supply ............................................................................... 186

10.3.1 AC Inputs .............................................................................................. 186

10.3.2 AC Outputs ........................................................................................... 186

10.3.3 Expansion Unit IC200UEX210 Specifications .......................................... 187

10.3.4 Wiring Diagram, IC200UEX210 ............................................................. 188

10.4 IC200UEX211 28 Point Micro PLC Expansion Unit, (16) 24Vdc In, (12) Relay Out,

120/240Vac Power Supply ............................................................................... 188

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10.4.1 DC Inputs .............................................................................................. 188

10.4.2 Relay Outputs (Q1 – Q12) ..................................................................... 188

10.4.3 Expansion Unit IC200UEX211 Specifications .......................................... 189

10.4.4 Wiring Diagram, IC200UEX211 ............................................................. 190

10.5 IC200UEX212 28 Point Micro PLC Expansion Unit, (16) 24Vdc In, (12) Relay Out, 24Vdc

Power Supply................................................................................................... 191

10.5.1 DC Power .............................................................................................. 191

10.5.2 DC Inputs .............................................................................................. 191

10.5.3 Relay Outputs (Q1 – Q12) ..................................................................... 191

10.5.4 Expansion Unit IC200UEX212 Specifications .......................................... 191

10.5.5 Wiring Diagram, IC200UEX212 ............................................................. 192

10.6 IC200UEX213 28 Point Micro PLC Expansion Unit, (16) 12Vdc In, (12) Relay Out, 12Vdc

Power Supply................................................................................................... 193

10.6.1 DC Power .............................................................................................. 193

10.6.2 DC Inputs .............................................................................................. 193

10.6.3 Relay Outputs (Q1 – Q12) ..................................................................... 193

10.6.4 Expansion Unit IC200UEX213 Specifications .......................................... 193

10.6.5 Wiring Diagram, IC200UEX213 ............................................................. 195

10.7 IC200UEX214 28 Point Micro PLC Expansion Unit, (16) 24Vdc In, (12) 24Vdc Out, 24Vdc

Power Supply................................................................................................... 196

10.7.1 DC Power .............................................................................................. 196

10.7.2 DC Inputs .............................................................................................. 196

10.7.3 Transistor Outputs ................................................................................ 196

10.7.4 Expansion Unit IC200UEX214 Specifications .......................................... 197

10.7.5 Wiring Diagram, IC200UEX214 ............................................................. 198

10.8 IC200UEX215 28 Point Micro PLC Expansion Unit, (16) 12Vdc In, (12) 12Vdc Out, 12Vdc

Power Supply................................................................................................... 199

10.8.1 DC Power .............................................................................................. 199

10.8.2 DC Inputs .............................................................................................. 199

10.8.3 Transistor Outputs ................................................................................ 199

10.8.4 Expansion Unit IC200UEX215 Specifications .......................................... 200

10.8.5 Wiring Diagram, IC200UEX215 ............................................................. 201

10.9 IC200UEX222 28 Point Micro PLC Expansion Unit, (16) 24Vdc In, (12) 24Vdc Out with

ESCP, 24Vdc Power Supply .............................................................................. 202

10.9.1 DC Power .............................................................................................. 202

10.9.2 DC Inputs .............................................................................................. 202

10.9.3 Transistor Outputs ................................................................................ 202

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10.9.4 Expansion Unit IC200UEX222 Specifications .......................................... 203

10.9.5 Wiring Diagram, IC200UEX222 ............................................................. 204

Chapter 11: VersaMax Micro PLC 64-Point Expansion Units ... 205

11.1 Features of VersaMax 64-Point Micro PLC Expansion Units ............................... 205

11.1.1 Removable Terminal Strips .................................................................... 205

11.1.2 Expansion Connector ............................................................................ 206

11.1.3 Status LEDs ........................................................................................... 206

11.1.4 Cables ................................................................................................... 206

11.2 IC200UEX064 64 Point Micro PLC Expansion Unit,(40) 24Vdc In, (24) Relay Out, 24Vdc

Power Supply................................................................................................... 206

11.2.1 DC Inputs .............................................................................................. 206

11.2.2 Relay Outputs ....................................................................................... 206

11.2.3 Expansion Unit IC200UEX064 Specifications .......................................... 207

11.2.4 Wiring Diagram, IC200UEX064 ............................................................. 208

11.3 IC200UEX164 64 Point Micro PLC Expansion Unit, (40) 24Vdc In, (24) Relay Out,

120/240Vac Power Supply ............................................................................... 208

11.3.1 DC Inputs .............................................................................................. 208

11.3.2 Relay Outputs ....................................................................................... 209

11.3.3 Expansion Unit IC200UEX164 Specifications .......................................... 209

11.3.4 Wiring Diagram, IC200UEX164 ............................................................. 210

11.4 IC200UEX264 64 Point Micro PLC Expansion Unit, (24) 24Vdc In, (4) LCDC, (16) LCDC with

ESCP, (4) HCDC with ESCP Out, 24Vdc Power Supply ....................................... 210

11.4.1 DC Inputs .............................................................................................. 210

11.4.2 DC Outputs ........................................................................................... 211

11.4.3 Expansion Unit IC200UEX264 Specifications .......................................... 211

11.4.4 Wiring Diagram, IC200UEX264 ............................................................. 212

11.5 IC200UEX364 64 Point Micro PLC Expansion Unit, (40) 24Vdc In, (24) LCDC Out, 24Vdc

Power Supply................................................................................................... 213

11.5.1 DC Power .............................................................................................. 213

11.5.2 DC Inputs .............................................................................................. 213

11.5.3 DC Outputs ........................................................................................... 213

11.5.4 Expansion Unit IC200UEX364 Specifications .......................................... 214

11.5.5 Wiring Diagram, IC200UEX364 ............................................................. 215

Chapter 12: Analog Expansion Units ..................................... 216

12.1 Features of Analog Expansion Units ................................................................. 216

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12.1.1 Removable Terminal Strips .................................................................... 216

12.1.2 Expansion Connector ............................................................................ 216

12.1.3 Status LEDs ........................................................................................... 217

12.1.4 Cables ................................................................................................... 217

12.2 Analog Expansion Unit Specifications............................................................... 217

12.2.1 Power Specifications for Analog Expansion Units ................................... 217

12.2.2 Input and Output Specifications ............................................................ 217

12.3 Analog Operation ............................................................................................ 218

12.3.1 Analog I/O Parameters .......................................................................... 218

12.3.2 Input/Output Values Compared to Process Data ................................... 219

12.3.3 Count Resolution for Analog Expansion Units ........................................ 219

12.3.4 LED Indications ...................................................................................... 219

12.3.5 Analog Input Processing ........................................................................ 220

12.3.6 Analog Output Processing ..................................................................... 221

12.3.7 Wiring Diagram ..................................................................................... 222

Chapter 13: RTD and Thermocouple Expansion Units ............ 223

13.1 Description of RTD and Thermocouple Modules .............................................. 223

13.1.1 Removable Terminal Strips .................................................................... 224

13.1.2 Expansion Connector ............................................................................ 224

13.1.3 Status LEDs ........................................................................................... 224

13.1.4 Cables ................................................................................................... 224

13.2 RTD Expansion Modules................................................................................... 224

13.2.1 Compatibility ........................................................................................ 225

13.2.2 RTD Module General Specifications ....................................................... 225

13.2.3 RTD Module Input Specifications ........................................................... 226

13.2.4 RTD Module Output Specifications ........................................................ 226

13.2.5 Scaling .................................................................................................. 227

13.2.6 Wiring for RTD Expansion Modules ........................................................ 228

13.3 Module Installation .......................................................................................... 229

13.3.1 DIP Switches ......................................................................................... 229

13.3.2 LED Indications ...................................................................................... 230

13.3.3 Data Conversion for RTD Expansion Units (in Compatible mode) ........... 230

13.4 Thermocouple Expansion Modules .................................................................. 233

13.4.1 Compatibility ........................................................................................ 233

13.4.2 Thermocouple Module General Specifications ....................................... 234

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13.4.3 Analog Output Specifications (Model IC200UEX826) ............................. 234

13.4.4 Thermocouple Module Input Specifications ........................................... 235

13.4.5 Scaling for Thermocouple Module Data ................................................. 236

13.4.6 Scaling for Analog Outputs (Model IC200UEX826) ................................ 236

13.4.7 Thermocouple Module Configuration .................................................... 237

13.4.8 Wiring for Thermocouple Expansion Modules ........................................ 238

13.5 Module Installation .......................................................................................... 239

13.5.1 DIP Switch Settings ............................................................................... 239

13.5.2 LED Indications ...................................................................................... 240

13.5.3 Basic Temperature Conversion Logic ..................................................... 241

13.5.4 High-Resolution Temperature Conversion Logic for Thermocouple Units242

Chapter 14: CPU Option Modules .......................................... 244

14.1 Using Option Modules ..................................................................................... 244

14.2 IC200UMB001 Memory Pack Module ............................................................... 244

14.2.1 Features ................................................................................................ 245

14.3 IC200USB001 RS232 Extra Port Option Module with 2 Analog Inputs ............... 246

14.3.1 Analog Inputs ........................................................................................ 247

14.4 IC200USB002 RS-422/485 Extra Port Option Module with 2 Analog Inputs ...... 248

14.4.1 Analog Inputs ........................................................................................ 249

14.5 IC200UUB001 USB / RS232 Conversion Option Module ................................... 249

14.6 IC200UEM001 RJ-45, 10/100 Mbit Ethernet Communications Module ............. 250

14.6.1 Module Specifications ........................................................................... 250

14.6.2 Status LEDs ........................................................................................... 251

14.6.3 Configuration Options ........................................................................... 251

14.6.4 Enhanced Data Throughput .................................................................. 252

14.6.5 Setting the IP Address ........................................................................... 252

14.6.6 Downloading Ethernet Drivers............................................................... 252

14.6.7 Modbus/TCP Client Support .................................................................. 252

14.6.8 Security Settings for the Ethernet Option Module .................................. 266

14.7 Installing Option Modules ................................................................................ 267

Chapter 15: Installation Instructions ..................................... 269

15.1 Preinstallation Check ....................................................................................... 269

15.2 Agency Approvals, Standards, and General Specifications ................................ 270

15.2.1 Immunity and Emission Specifications, Relevant Standards, and Level Passed 271

15.3 Installation Guidelines ..................................................................................... 271

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15.3.1 CE Mark Installation Requirement .......................................................... 272

15.3.2 UL Requirements for Class I Div 2 Installations ....................................... 272

15.3.3 Additional Environmental Guidelines ..................................................... 272

15.4 Mounting Dimensions ..................................................................................... 273

15.4.1 Dimensions of Nano PLCs ...................................................................... 273

15.4.2 Dimensions of 14-, 20-, 23-, 28-, 40-, and 64-Point Micro PLCs and Expansion Units

274

15.5 Grounding the Equipment ............................................................................... 274

15.5.1 Grounding the Programmer .................................................................. 275

15.6 Installing a PLC or Expansion Unit on a DIN Rail ................................................ 275

15.6.1 Mounting the PLC on a DIN Rail ............................................................. 276

15.6.2 Removing the PLC from a DIN Rail ......................................................... 276

15.6.3 Panel-Mounting .................................................................................... 276

15.6.4 Grounding the Metal Panel or DIN Rail ................................................... 277

15.7 Connecting an Expansion Unit to a Micro PLC................................................... 277

15.7.1 The Expansion Cable ............................................................................. 277

15.8 System Wiring Guidelines ................................................................................ 278

15.8.1 Safety Measures .................................................................................... 278

15.8.2 Installing Additional Suppression ........................................................... 278

15.9 I/O Installation and Wiring ............................................................................... 279

15.9.1 Wiring for Power Supply and I/O Connections........................................ 280

15.9.2 Removable Wiring Terminals ................................................................. 280

15.9.3 General Wiring Procedures .................................................................... 281

15.9.4 Providing Fusing for Outputs ................................................................. 282

15.9.5 Providing Suppression Circuits for Inductive Loads ................................ 283

15.9.6 Typical DC Input Circuits ....................................................................... 283

15.9.7 Typical DC Output Circuits .................................................................... 284

15.9.8 Typical High-Speed Counter Connections .............................................. 286

15.9.9 Added Resistance for 20-, 40-, and 64-Point Micro PLCS at Higher Count Rates 287

15.9.10 Typical AC Input and Output Circuits ............................................... 288

15.9.11 Typical Analog Input and Output Circuits ......................................... 289

15.10 Starting Up the PLC.......................................................................................... 290

15.10.1 Turning off Power to the PLC ........................................................... 290

15.10.2 Normal Power-up Sequence ............................................................ 291

15.11 Adjusting the Analog Potentiometers .............................................................. 292

15.12 DIP Switches .................................................................................................... 293

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15.12.1 4-Position DIP Switches on Micro PLC CPUs ...................................... 293

15.12.2 DIP Switches on an Analog Expansion Module Select Count Resolution293

15.12.3 DIP Switches on an RTD Expansion Module Select Update Rate ........ 293

15.12.4 DIP Switches on a Thermocouple Expansion Module Select Input Sensors/Mode

294

15.13 Installing/Replacing a Backup Battery .............................................................. 294

15.13.1 CPU Battery Consumption Data ....................................................... 294

15.14 Serial Port Connections.................................................................................... 295

15.14.1 Providing Power to an External Device from Port 1 or 2 .................... 295

15.14.2 Short Circuit Protection on 5Vdc for Units Later than June 2005 ....... 295

15.14.3 Cable Lengths and Baud Rates ......................................................... 296

15.14.4 Port 1: RS-232 ................................................................................. 296

15.14.5 Port 2 on 23-Point and 28-Point Micro PLCs: RS-485 ........................ 298

15.14.6 Port 2 RS-485 Option Module on 20-/ 40-/ 64-Point Micro PLCs ....... 300

15.14.7 RS-485 Multidrop Serial Connections ............................................... 301

15.14.8 RS-485 Port Isolator ......................................................................... 302

15.14.9 RS-232 to RS-485 Adapter ............................................................... 307

15.15 Replacing AC Output Module Fuses ................................................................. 310

15.15.1 AC Output Fuse Specifications ......................................................... 311

Chapter 16: Configuration .................................................... 312

16.1 Configuration Overview ................................................................................... 312

16.1.1 Autoconfiguration ................................................................................. 312

16.1.2 Software Configuration ......................................................................... 312

16.2 Storing a Configuration from a Programmer .................................................... 313

16.3 CPU Configuration ........................................................................................... 314

16.4 Port 1 Configuration ........................................................................................ 316

16.4.1 Timing Note for RTU Communications .................................................. 316

16.5 Port 2 Configuration ........................................................................................ 317

16.6 Configuring Analog I/O Parameters ................................................................. 318

16.7 Configuring High-Speed Counter, PWM or Pulse Train ..................................... 318

16.7.1 HSC, PWM, and PTO Settings ................................................................ 318

16.7.2 Channel #1, 2, 3, 4 Parameters .............................................................. 320

Chapter 17: PLC Operation .................................................... 323

17.1 Operating Modes............................................................................................. 323

17.2 Parts of the CPU Sweep .................................................................................... 324

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17.3 Standard CPU Sweep Operation ....................................................................... 326

17.3.1 The Sweep Windows ............................................................................. 326

17.3.2 The Watchdog Timer ............................................................................. 327

17.4 Constant Sweep Time Operation ..................................................................... 327

17.4.1 Changing the Configured Default for Constant Sweep Mode ................. 327

17.4.2 The Constant Sweep Timer .................................................................... 327

17.4.3 Enabling/Disabling Constant Sweep Time, Reading or Setting the Length of the

Timer .................................................................................................... 327

17.5 CPU Stop Modes .............................................................................................. 328

17.6 Controlling the Execution of a Program ........................................................... 328

17.6.1 Calling a Subroutine Block ..................................................................... 328

17.6.2 Creating a Temporary End of Logic ........................................................ 328

17.6.3 Executing Rungs of Logic without Logical Power Flow ............................ 328

17.6.4 Jumping to Another Part of the Program................................................ 329

17.7 Privilege Levels and Passwords ......................................................................... 329

17.7.1 Protection Level Request from Programmer .......................................... 330

17.7.2 The OEM Protection Feature .................................................................. 330

17.7.3 Clearing All Memory .............................................................................. 331

17.8 Run/Stop Mode Switch Operation.................................................................... 331

17.8.1 Run/Stop Mode Operation .................................................................... 331

17.8.2 Configurable Memory Protection .......................................................... 332

17.8.3 Configuration Parameters and Switch Position for Run/Stop Modes ...... 332

17.8.4 Configuration Parameters and Switch Position for Memory Protection .. 332

17.8.5 Configuration Parameters and Switch Position for Simultaneous Run/Stop

Operation and Memory Protection ........................................................ 333

17.8.6 Configuration Parameters and Switch Position for Fault Operations....... 333

17.9 Power-Up and Power-Down Sequence ............................................................. 333

17.9.1 Power-Up Sequence .............................................................................. 333

17.9.2 Flash Memory ........................................................................................ 334

17.9.3 Default Conditions for Micro PLC Output Points..................................... 334

17.9.4 Power-Down Conditions........................................................................ 335

17.9.5 Power Cycle .......................................................................................... 335

17.10 Input Filters ..................................................................................................... 336

17.10.1 Discrete Input Filtering .................................................................... 336

17.11 Hardware R/C Filters ........................................................................................ 337

17.12 Analog Potentiometer Input Filtering .............................................................. 339

17.12.1 Input Settings .................................................................................. 339

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17.12.2 Default Filter Time ........................................................................... 339

17.12.3 Limitations of Analog Potentiometer Input Filtering ........................ 339

Chapter 18: High-Speed Counter, PWM, and Pulse Train Operation
340

18.1 Overview ......................................................................................................... 340

18.1.1 Operation at Power-up and Mode Change ............................................. 341

18.1.2 Basic Setup ............................................................................................ 341

18.2 HSC/PWM/PTO Channels ................................................................................. 342

18.2.1 HSC/PWM/PTO Channels for Micro PLCs (14 Point/ 28 Point) ................. 342

18.2.2 HSC/PWM/PTO Channels for Micro-20, -40, or -64 PLC .......................... 343

18.2.3 HSC/PWM/PTO Channels for Nano PLCs ................................................ 343

18.3 Type A Counter ................................................................................................ 344

18.3.1 Type A Counter Program References ..................................................... 344

18.3.2 Type A Counter Operation ..................................................................... 345

18.3.3 Type A High-Speed Counter Operation Details ...................................... 345

18.4 Type B Counter ................................................................................................ 347

18.4.1 Type B Counter Program References ..................................................... 348

18.4.2 Type B Counter Operation ..................................................................... 348

18.5 High-Speed Counter Outputs .......................................................................... 350

18.5.1 Pulldown Resistor .................................................................................. 350

18.5.2 Duty Cycle Limits: with 1.5k pulldown resistor - UDR005/006/010 &

UAL004/005/006 .................................................................................. 350

18.5.3 Duty Cycle Limits: with 1.5k pulldown resistor - UDD104/110 & NDD101351

18.5.4 Counter Output Presets ......................................................................... 351

18.6 PWM Outputs .................................................................................................. 352

18.6.1 Enabling and Disabling a PWM Output .................................................. 352

18.6.2 PWM Frequency .................................................................................... 353

18.6.3 PWM Duty Cycle .................................................................................... 353

18.6.4 Load Correction for PWM Outputs ......................................................... 353

18.7 Pulse Train Outputs ......................................................................................... 354

18.7.1 Configuring a Pulse Train Output ........................................................... 354

18.7.2 Program References for Pulse Train Outputs .......................................... 354

18.7.3 Enabling and Disabling Pulse Train Operation ........................................ 355

18.7.4 Setting Up the Pulse Frequency ............................................................. 355

18.7.5 Setting Up the Number of Pulses ........................................................... 356

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18.7.6 Load Correction Time ............................................................................ 356

18.8 Pulse Train with Ramp ..................................................................................... 357

18.8.1 Configuring Pulse Train with Ramp ........................................................ 357

18.8.2 Program References for Pulse Train with Ramp Outputs ........................ 357

18.8.3 Setting Up the Pulse Frequency for Pulse Train with Ramp ..................... 358

18.8.4 Setting Up the Number of Pulses ........................................................... 358

18.8.5 Changing the Acceleration and Deceleration ......................................... 358

18.8.6 Controlling Operation of a Pulse Train with Ramp Output ...................... 358

18.9 COMMREQs for the HSC/PWM/PTO Functions ................................................. 360

18.9.1 The COMMREQ Command Block ........................................................... 361

18.9.2 COMMREQ Example .............................................................................. 364

18.10 HSC Application Examples ............................................................................... 366

18.10.1 RPM Indicator .................................................................................. 366

Chapter 19: Motion Control Functions .................................. 367

19.1 Overview ......................................................................................................... 368

19.1.1 Program References for Motion Features ............................................... 368

19.1.2 Position Registers .................................................................................. 368

19.1.3 Function Block Instance Registers .......................................................... 369

19.1.4 Error Codes and Warnings for Motion Features (Hexadecimal) ............... 371

19.1.5 Avoiding Abrupt Start/Stop of Motion ................................................... 374

19.2 Finding a Home Position .................................................................................. 374

19.2.1 Find Home Function Block ..................................................................... 376

19.2.2 Example Program Logic for Find Home .................................................. 379

19.3 Moving to the Home Position .......................................................................... 379

19.3.1 Go Home Function Block ....................................................................... 380

19.3.2 Example Program Logic for Go Home .................................................... 383

19.4 Jogging ............................................................................................................ 383

19.4.1 Jogging Function Block .......................................................................... 384

19.4.2 Example Program Logic for Jogging ....................................................... 386

19.5 Blending .......................................................................................................... 387

19.5.1 Examples of Blended Moves .................................................................. 387

19.5.2 Blending Function Block ........................................................................ 390

19.5.3 Example Program Logic for Blending ..................................................... 393

19.6 Stopping Motion on an Axis ............................................................................. 394

19.6.1 Stop Motion Function Block ................................................................... 394

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19.6.2 Example Program Logic for Stop Motion ................................................ 396

Chapter 20: Fault Handling ................................................... 397

20.1 Faults and Fault Handling................................................................................. 397

20.1.1 Fault Handling ....................................................................................... 397

20.1.2 Classes of Faults .................................................................................... 397

20.2 System Responses to Faults ............................................................................. 397

20.2.1 Fault Actions ......................................................................................... 398

20.3 Fault References .............................................................................................. 399

20.3.1 Example Program Logic for Fault References ......................................... 399

Chapter 21: Elements of an Application Program .................. 400

21.1 Structure of an Application Program ................................................................ 400

21.2 Subroutines ..................................................................................................... 401

21.2.1 Declaring a Subroutine .......................................................................... 402

21.2.2 Calling a Subroutine .............................................................................. 402

21.2.3 Locking/Unlocking Subroutines ............................................................. 402

21.3 Program Languages ......................................................................................... 403

21.3.1 Ladder Diagram .................................................................................... 403

21.4 The Instruction Set .......................................................................................... 403

21.4.1 Contacts ............................................................................................... 404

21.4.2 Coils ...................................................................................................... 404

21.4.3 Timers and Counters ............................................................................. 405

21.4.4 Math Functions ..................................................................................... 405

21.4.5 Relational Functions .............................................................................. 406

21.4.6 Bit Operation Functions ......................................................................... 406

21.4.7 Data Move Functions ............................................................................. 406

21.4.8 Table Functions ..................................................................................... 407

21.4.9 Conversion Functions ............................................................................ 407

21.4.10 Control Functions ............................................................................ 407

21.4.11 Communication Function ................................................................ 408

21.4.12 Motion Functions ............................................................................ 408

Chapter 22: Program Data and References ............................ 409

22.1 Data Memory References ................................................................................ 409

22.1.1 Memory Allocation ................................................................................ 409

22.1.2 Word Memory References ..................................................................... 410

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22.1.3 Bit Memory References ......................................................................... 411

22.2 Fixed I/O Map Locations ................................................................................... 412

22.2.1 Reserved Bit Memory Locations: %I ........................................................ 412

22.2.2 Reserved Bit Memory Locations: %Q ...................................................... 413

22.2.3 Reserved Word Memory Locations: %AI ................................................. 414

22.2.4 Reserved Word Memory Locations: %AQ ............................................... 415

22.3 Retentiveness of Data ...................................................................................... 416

22.4 System Status References ................................................................................ 417

22.4.1 Using the System Status References ...................................................... 417

22.4.2 Time-Tick References ............................................................................ 417

22.4.3 %S References ....................................................................................... 418

22.4.4 %SA, %SB, and %SC References .............................................................. 419

22.5 How Program Functions Handle Numerical Data ............................................. 421

22.5.1 Real Numbers (Floating Point) ............................................................... 422

22.5.2 Errors in Real Numbers and Operations.................................................. 422

Chapter 23: Instruction Set Reference ................................... 423

23.1 Bit Operation Functions ................................................................................... 424

23.1.1 Data Lengths for the Bit Operation functions ......................................... 424

23.1.2 Bit Operation Functions Logical AND, Logical OR ................................... 425

23.1.3 Bit Operation Functions Exclusive OR..................................................... 426

23.1.4 Bit Operation Functions Logical Invert (NOT) ......................................... 427

23.1.5 Bit Operation Functions Shift Bits Right, Shift Bits Left ........................... 428

23.1.6 Bit Operation Functions Rotate Bits Right, Rotate Bits Left ..................... 431

23.1.7 Bit Operation Functions Bit Test ............................................................ 432

23.1.8 Bit Operation Functions Bit Set and Bit Clear .......................................... 433

23.1.9 Bit Operation Functions Masked Compare ............................................. 434

23.1.10 Bit Operation Functions Bit Position ................................................. 436

23.1.11 Bit Operation Functions Bit Sequencer ............................................. 438

23.2 Control Functions ............................................................................................ 440

23.2.1 Control Functions Do I/O ....................................................................... 440

23.2.2 Control Functions Call ........................................................................... 443

23.2.3 Control Functions End of Logic .............................................................. 443

23.2.4 Control Functions Master Control Relay (MCR) / End MCR ...................... 444

23.2.5 Control Functions Jump, Label ............................................................... 445

23.2.6 Control Functions Comment ................................................................. 446

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23.2.7 Control Functions Drum Sequencer ....................................................... 447

23.3 Data Move Functions ....................................................................................... 449

23.3.1 Data Move Functions Move Data ........................................................... 450

23.3.2 Data Move Functions Block Move .......................................................... 451

23.3.3 Data Move Functions Block Clear ........................................................... 453

23.3.4 Data Move Functions Shift Register ....................................................... 454

23.3.5 Data Move Functions Communication Request ..................................... 456

23.4 Data Type Conversion Functions ...................................................................... 458

23.4.1 Data Type Conversion Functions Convert Signed Integer Data to BCD-4 458

23.4.2 Data Type Conversion Functions Convert to Signed Integer ................... 459

23.4.3 Data Type Conversion Functions Convert to Double Precision Signed Integer 460

23.4.4 Data Type Conversion Functions Convert to Real Data ........................... 461

23.4.5 Data Type Conversion Functions Convert Real Data to Word Data ......... 462

23.4.6 Data Type Conversion Functions Truncate Real Number ........................ 463

23.5 Math and Numerical Functions ........................................................................ 464

23.5.1 Converting Data for the Math and Numerical Functions ......................... 464

23.5.2 Math and Numerical Functions Add, Subtract, Multiply, Divide .............. 464

23.5.3 Math and Numerical Functions Add, Subtract, Multiply, Divide .............. 465

23.5.4 Math and Numerical Functions Modulo Division .................................... 466

23.5.5 Math and Numerical Functions Scaling .................................................. 467

23.5.6 Math and Numerical Functions Square Root .......................................... 469

23.5.7 Math and Numerical Functions Trigonometric Functions ....................... 470

23.5.8 Math and Numerical Functions Logarithmic / Exponential Functions ...... 472

23.5.9 Math and Numerical Functions Radian Conversion Functions ................ 473

23.6 Relational Functions ........................................................................................ 474

23.6.1 Data Types for Relational Functions ....................................................... 474

23.6.2 Relational Functions Equal, Not Equal, Less Than, Less/Equal, Greater Than,

Greater/Equal ........................................................................................ 475

23.6.3 Relational Functions Range ................................................................... 476

23.7 Relay Functions ............................................................................................... 477

23.7.1 Relay Functions Normally-open, Normally-closed, Continuation Contacts478

23.7.2 Relay Functions Coils ............................................................................. 479

23.8 Table Functions ............................................................................................... 483

23.8.1 Table Functions Array Move................................................................... 483

23.8.2 Table Functions Search for Array Values ................................................ 486

23.9 Timer and Counter Functions ........................................................................... 488

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23.9.1 Time-Tick Contacts ............................................................................... 488

23.9.2 Function Block Data Required for Timers and Counters .......................... 489

23.9.3 Timer and Counter Functions On Delay Stopwatch Timer ...................... 490

23.9.4 Timer and Counter Functions On Delay Timer ........................................ 492

23.9.5 Timer and Counter Functions Off Delay Timer ....................................... 494

23.9.6 Timer and Counter Functions Up Counter .............................................. 496

23.9.7 Timer and Counter Functions Down Counter ......................................... 498

Chapter 24: Service Request Function ................................... 500

24.1 SVCREQ Functions ........................................................................................... 501

24.2 Format of the SVCREQ Function....................................................................... 502

24.2.1 Parameters of the SVCREQ Function ...................................................... 502

24.3 SVCREQ 1: Change/Read Constant Sweep Timer ............................................. 503

24.3.1 Input Parameter Block for SCVREQ 1 ..................................................... 503

24.3.2 Disable Constant Sweep Mode .............................................................. 503

24.3.3 Enable Constant Sweep Mode ............................................................... 503

24.3.4 Change the Constant Sweep Time ......................................................... 503

24.3.5 Read the Constant Sweep State and Time.............................................. 503

24.4 SVCREQ 2: Read Window Times ....................................................................... 505

24.4.1 Output Parameter Block for SVCREQ 2 .................................................. 505

24.5 SVCREQ 3: Change Programmer Communications Window Mode ................... 506

24.5.1 Changing the Programmer Communications Window Mode ................. 506

24.6 SVCREQ 4: Change System Communications Window Mode ........................... 506

24.6.1 Changing the System Communications Window Mode ......................... 507

24.7 SVCREQ 6: Change/Read Number of Words to Checksum ................................ 507

24.7.1 Parameter Block Formats for SVCREQ 6 ................................................. 507

24.8 SVCREQ 7: Read or Change the Time-of-Day Clock .......................................... 508

24.8.1 Parameter Block Format for SVCREQ 7 .................................................. 508

24.9 SVCREQ 7 Parameter Block Content: BCD Format ............................................ 509

24.9.1 2-Digit Year ........................................................................................... 509

24.9.2 4-Digit Year ........................................................................................... 509

24.10 SVCREQ 7 Parameter Block Content: Packed ASCII Format ............................... 510

24.10.1 2-Digit Year ..................................................................................... 510

24.10.2 4-Digit Year ..................................................................................... 511

24.11 SVCREQ 8: Reset Watchdog Timer ................................................................... 512

24.11.1 Parameter Block Format for SVCREQ 8 ............................................. 512

24.12 SVCREQ 9: Read Sweep Time from Beginning of Sweep ................................... 513

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24.12.1 Output Parameter Block Format for SVCREQ 9................................. 513

24.13 SVCREQ 10: Read Folder Name ........................................................................ 514

24.13.1 Output Parameter Block Format for SVCREQ 10............................... 514

24.14 SVCREQ 11: Read PLC ID .................................................................................. 515

24.14.1 Output Parameter Block Format for SVCREQ 11............................... 515

24.15 SVCREQ 13: Shut Down (Stop) PLC .................................................................. 516

24.15.1 Parameter Block for SVCREQ 13 ....................................................... 516

24.16 SVCREQ 14: Clear Fault .................................................................................... 517

24.16.1 Input Parameter Block for SVCREQ 14 .............................................. 517

24.17 SVCREQ 15: Read Last-Logged Fault Table Entry .............................................. 518

24.17.1 Input Parameter Block for SVCREQ 15 .............................................. 518

24.18 SVCREQ 16: Read Elapsed Time Clock .............................................................. 520

24.18.1 Output Parameter Block for SVCREQ 16........................................... 520

24.19 SVCREQ 18: Read I/O Override Status .............................................................. 521

24.19.1 Output Parameter Block for SVCREQ 18........................................... 521

24.20 SVCREQ 23: Read Master Checksum ................................................................ 521

24.20.1 Output Parameter Block for SVCREQ 23........................................... 521

24.21 SVCREQ 26/ SVCREQ 30: Interrogate I/O ......................................................... 522

24.22 SVCREQ 29: Read Elapsed Power Down Time ................................................... 523

24.22.1 Output Parameter Block for SVCREQ 29........................................... 523

24.23 SVCREQ 34: Enter Analog Calibration Mode ..................................................... 523

24.24 SVCREQ 35: Store Analog Calibration .............................................................. 524

24.24.1 Input Parameter Block for SVCREQ 35 .............................................. 525

24.24.2 Output Parameter Block for SVCREQ 35........................................... 526

24.25 SVCREQ 52: Read from Flash ............................................................................ 527

24.25.1 Input Parameter Block for SVCREQ 52 .............................................. 528

24.25.2 Status Data for SVCREQ 52 .............................................................. 528

24.26 SVCREQ 53: Write to Flash ............................................................................... 529

24.26.1 Input Parameter Block for SVCREQ 53 .............................................. 530

24.26.2 Status Data for SVCREQ 53 .............................................................. 530

Chapter 25: Serial I/O, SNP & RTU Protocols .......................... 531

25.1 Format of the Communication Request Function ............................................. 532

25.1.1 Parameters of the COMMREQ Function ................................................. 532

25.1.2 Command Block for the COMMREQ Function ........................................ 533

25.2 Configuring Serial Ports Using the COMMREQ Function ................................... 534

25.2.1 Timing .................................................................................................. 534

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25.2.2 Sending Another COMMREQ to the Same Port ...................................... 534

25.2.3 Invalid Port Configurations .................................................................... 534

25.2.4 RTU Slave/SNP Slave Operation with Programmer Attached .................. 535

25.2.5 COMMREQ Command Block for Configuring SNP Protocol .................... 536

25.2.6 COMMREQ Command Block for Configuring RTU Protocol .................... 537

25.2.7 COMMREQ Command Block for Configuring Serial I/O Protocol............. 539

25.3 Calling Serial I/O COMMREQs from the PLC Sweep ........................................... 540

25.3.1 Compatibility ........................................................................................ 540

25.3.2 Status Word for Serial I/O COMMREQs ................................................... 541

25.4 Serial I/O COMMREQ Commands ..................................................................... 542

25.4.1 Overlapping COMMREQs ....................................................................... 542

25.4.2 Initialize Port Function (4300) ............................................................... 543

25.4.3 Set Up Input Buffer Function (4301) ...................................................... 544

25.4.4 Flush Input buffer Function (4302) ........................................................ 545

25.4.5 Read port status Function (4303) .......................................................... 545

25.4.6 Write port control Function (4304) ........................................................ 547

25.4.7 Cancel COMMREQ Function (4399) ....................................................... 548

25.4.8 Autodial Function (4400)....................................................................... 549

25.4.9 Write bytes Function (4401) .................................................................. 550

25.4.10 Read bytes Function (4402) ............................................................. 551

25.4.11 Read String Function (4403) ............................................................ 553

Chapter 26: PID Function ...................................................... 557

26.1 Format of the PID Function .............................................................................. 557

26.1.1 Parameters of the PID Function ............................................................. 558

26.2 Operation of the PID Function ......................................................................... 559

26.2.1 Automatic Operation ............................................................................ 559

26.2.2 Manual Operation ................................................................................. 559

26.2.3 Time Interval for the PID Function ......................................................... 560

26.2.4 Scaling Input and Outputs ..................................................................... 560

26.3 Parameter Block for the PID Function ............................................................... 561

26.3.1 Internal Parameters in RefArray ............................................................. 561

26.4 PID Algorithm Selection (PIDISA or PIDIND) and Gains ..................................... 567

26.4.1 Error Term ............................................................................................. 567

26.4.2 Derivative Term..................................................................................... 567

26.4.3 Delta Time ............................................................................................ 568

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26.4.4 Independent Term Algorithm (PIDIND) ................................................. 569

26.4.5 Sample Period and PID Block Scheduling ............................................... 570

26.5 Determining the Process Characteristics .......................................................... 571

26.6 Setting Parameters Including Tuning Loop Gains ............................................. 572

26.6.1 Setting Loop Gains Using the Ziegler and Nichols Tuning Approach ...... 573

26.6.2 The Ideal Tuning Method ....................................................................... 573

26.7 Sample PID Call ............................................................................................... 574

Chapter 27: Reading and Writing Data in Flash Memory ....... 575

27.1 Logic-Driven Write to Flash .............................................................................. 575

27.1.1 Data Quantities ..................................................................................... 575

27.1.2 If Flash Memory Becomes Full ................................................................ 576

27.1.3 Important Note ..................................................................................... 576

Appendix A: Instruction Timing .............................................. 587

A-1 Notes on the Timing Information ..................................................................... 587

A-1.1 Execution Times with Function Block Enabled or Disabled ..................... 587

A-1.2 Additional Notes ................................................................................... 587

A-2 Typical Execution Times for Boolean Contacts ................................................. 588

A-2.1 Sweep Times for Micro-64 CPUs ............................................................ 588

A-3 Typical Execution Times for Release 4.0 CPUs .................................................. 589

A-4 Typical Execution Times for Release 3.8 CPUs .................................................. 593

A-5 Typical Execution Times for Release 3.0 CPUs .................................................. 598

A-6 Typical Execution Times for Release 2.0 CPUs .................................................. 603

A-7 Typical Execution Times for Release 1.1 CPUs .................................................. 608

A-8 Typical Execution Times for Release 1.0 CPUs .................................................. 613

Appendix B: Feature Comparison ............................................ 617

B-1 Operating Differences ..................................................................................... 617

B-2 VersaMax Nano/Micro PWM/Pulse Outputs ..................................................... 619

B-2.1 %AQ References for PWM ...................................................................... 619

B-2.2 %AQ References for Pulse Train ............................................................. 620

B-2.3 Enabling Outputs .................................................................................. 620

B-2.4 Load Correction..................................................................................... 620

B-2.5 Formulas for Converting Series 90 Micro Frequencies and Duty Cycles... 620

B-3 Functions Supported ....................................................................................... 621

B-4 Program References ........................................................................................ 625

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Appendix C: Battery Backup Options ...................................... 626

C-1 CPU Battery Consumption ............................................................................... 626

C-2 Backup Batteries for VersaMax Micro PLCs ....................................................... 626

C-3 Calculating the Life of a Battery ....................................................................... 627

C-3.1 For Standard Backup Battery IC200ACC403 ........................................... 627

C-3.2 For High Capacity Battery IC200ACC414 ............................................... 627

Appendix D: Input Simulators ................................................. 628

D-1 IC200ACC450 Input Simulator for DC-powered VersaMax Nano PLCs .............. 628

D-1.1 Compatibility ........................................................................................ 628

D-1.2 Installation Instructions ......................................................................... 629

D-2 IC200ACC451 Input Simulator for DC-powered VersaMax Micro PLCs and Expansion Units

........................................................................................................................ 629

D-2.1 Compatibility ........................................................................................ 629

D-2.2 Installation Instructions ......................................................................... 630

Appendix E: Relay Contact Ratings .......................................... 631

E-1 125Vac ............................................................................................................ 631

E-2 250Vac ............................................................................................................ 632

E-3 30Vdc.............................................................................................................. 632