GE Digital VersaMax PLC Operating Manual

GE Intelligent Platforms

VersaMax* PLC

User Manual

September 2015

GFK-1503E

For public disclosure

These instructions do not purport to cover all details or variations in equipment, nor to provide for every possible contingency to be met during installation, operation, and maintenance. The information is supplied for informational purposes only, and GE makes no warranty as to the accuracy of the information included herein. Changes, modifications, and/or improvements to equipment and specifications are made periodically and these changes may or may not be reflected herein. It is understood that GE may make changes, modifications, or improvements to the equipment referenced herein or to the document itself at any time. This document is intended for trained personnel familiar with the GE products referenced herein.

This document is approved for public disclosure.

GE may have patents or pending patent applications covering subject matter in this document. The furnishing of this document does not provide any license whatsoever to any of these patents.

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For further assistance or technical information, contact the nearest GE Sales or Service Office, or an authorized GE Sales Representative.

Revised: September 2015 Issued: March 2001

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

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Please send documentation comments or suggestions to controls.doc@ge.com

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Document Updates

Location Description

Throughout the document Edits to support release of IC200CPUE05-JL.

Acronyms and Abbreviations

ASI Actuator Sensor Interface

AUP Advanced User Parameter

CPU Central Processing Unit

EGD Ethernet Global Data

ERM Expansion Receiver Module

ESD Electrostatic Discharge

LAN Local Area Network

LED Light-emitting Diode

MCR Master Control Relay

NIU Network Interface Unit

NTP Network Time Protocol

OEM Original Equipment Manufacturer

PLC Programmable Logic Controller

RAM Random Access Memory

SLIP Serial Line Protocol

SRTP Service Request Transport Protocol

UDP User Datagram Protocol

4 GFK-1503E VersaMax PLC User Manual

For public disclosure

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Warning

Indicates a procedure, condition, or statement that, if not strictly observed, could result in damage to or destruction of equipment.

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6 GFK-1503E VersaMax PLC User Manual

For public disclosure

1 Introduction ..................................................................................................................................... 17

1.1 The VersaMax Family of Products .... ..................... .. .............................................. ................................... 17

1.2 CPU Modules for VersaMax PLCs ........ .............................................. ..................... .. ............................... 18

1.2.1 Basic CPU Features ............................. .............................................. ..................... ......................... 18

1.2.2 Available VersaMax CPUs ........ .............................................. .. .............................................. .......... 18

1.2.3 EZ Program Store ....................... .............................................. ....................... ....................... ........ 20

1.3 Power Supplies .. ....................... ....................... .............................................. ....................................... 20

1.3.1 Available Power Supplies and Carrier .............. ....................... .............................................. .............. 21

1.4 I/O Modules .............................................................. .............................................. ....................... ...... 21

1.4.1 Available I/O Modules ..................... .............................................. ..................... ............................. 22

1.5 Carriers.. .............................................. .............................................. ..................... ............................. 25

1.5.1 Available Carriers and Terminal Strips .... .............................................. .............................................. 26

1.6 Expansion Modules........... .............................................. ..................... .............................................. .... 27

1.6.1 VersaMax Modules for Expansion Racks ....... .............................................. .. ...................................... 27

1.6.2 Available Expansion Modules..................................... .............................................. ......................... 28

1.7 Communications Modules .................. .. ..................... .............................................. ................................ 29

1.7.1 Available VersaMax PLC Communications Modules .................... .............................................. ........... 29

1.7.2 Profibus-DP Network Slave Module ................. .............................................. ....................... ............. 29

1.7.3 DeviceNet Network Control Module................ ....................... .............................................. .............. 30

1.7.4 Asi Network Master Module ......................................... .............................................. .. .................... 30

1.7.5 Serial Communications Module ......... .............................................. ..................... ............................. 30

2 CPU Module Datasheets: CPU001, CPU002, CPU005 ...........................................................31

2.1 Features .............. ....................... ....................... ....................... .............................................. .............. 32

2.2 Module Specifications ..................... .............................................. ..................... .................................... 32

2.3 VersaMax General Product Specifications ...... .............................................. .............................................. 33

2.4 Serial Ports ......................... .............................................. ..................... .. ............................................ . 34

2.4.1 Serial Port Baud Rates ............................... ....................... ....................... ....................... ................. 35

2.5 Mode Switch ............................................ ..................... .............................................. ......................... 35

2.6 CPU LEDs .......................................... .. ............................................ .. ..................... ............................ 36

2.7 Configurable Memory ............................................. ....................... ....................... ....................... .......... 37

3 CPU Module Datasheet: CPUE05 ............................................................................................... 39

3.1 Features .............. ....................... ....................... ....................... .............................................. .............. 40

3.2 Module Specifications ..................... .............................................. ..................... .................................... 41

3.3 VersaMax General Product Specifications ...... .............................................. .............................................. 42

3.4 Serial Ports ......................... .............................................. ..................... .. ............................................ . 43

3.4.1 Cable Lengths ...... .. ............................................ .. .............................................. ..................... ....... 44

3.4.2 Serial Port Baud Rates ............................... ....................... ....................... ....................... ................. 44

3.5 Ethernet LAN Port .................. ..................... .. .............................................. .......................................... 45

3.6 Mode Switch ............................................ ..................... .............................................. ......................... 45

3.7 CPU LEDs .......................................... .. ............................................ .. ..................... ............................ 46

3.8 Ethernet Restart Pushbutton .................... ..................... .. .............................................. ............................ 47

3.9 Ethernet LEDs ............................................. .............................................. ....................... .................... 47

3.10 Configurable Memory .. .. ............................................ .. .............................................. ..................... ....... 48

3.11 Ethernet Interface Overview ........ ....................... .............................................. ....................................... 49

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3.11.1 SRTP Server ............... .. ..................... .............................................. .............................................. 49

3.11.2 Ethernet Global Data ........................................ .............................................. .. ..................... .......... 49

3.11.3 Station Manager Functionality................. ....................... .............................................. ..................... 49

4 Installation........................................................................................................................................51

4.1 Mounting Instructions.............. ..................... .. .............................................. .......................................... 52

4.1.1 Removing the CPU from the DIN Rail ............................ .............................................. .. .................... 52

4.1.2 Panel-mounting .... .. ..................... ....................... ....................... .............................................. ....... 52

4.2 Installing an Expansion Transmitter Module .. ..................... .. ............................................ .. ........................ 54

4.2.1 Removing an Expansion Transmitter Module ............................. .. ..................... ................................... 54

4.3 Installing an Expansion Receiver Module ................ .. ..................... .............................................. .............. 55

4.3.1 Removing an Expansion Receiver Module ............................................. .............................................. 55

4.3.2 Expansion Rack Power Sources ........ .. ............................................ .. .............................................. ... 55

4.3.3 Connecting the Expansion Cable: RS-485 Differential......................................... ..................... .............. 56

4.3.4 RS-485 Differential Inter-Rack Connection (IC200CBL601, 602, 615)........... ........................................... 56

4.3.5 Building a Custom Expansion Cable ....................................... .............................................. .............. 56

4.3.6 Connecting the Expansion Cable: Single-ended ...... .............................................. ................................ 57

4.3.7 Single-ended Inter-Rack Connection (IC200CBL600) ........................................... .. ............................... 57

4.3.8 Power Sources for Single-ended Expansion Rack Systems ............................................. ......................... 57

4.4 Installing Power Supply Modules........................... .. ..................... .............................................. .............. 58

4.4.1 Removing the Power Supply ......................................... ....................... ....................... ..................... . 58

4.5 Installing Additional Modules ................. .. ............................................ .. ..................... ............................ 59

4.6 Activating or Replacing the Backup Battery................. .............................................. .. ............................... 60

4.6.1 Lithium Battery Replacement ..... .............................................. ..................... .................................... 60

4.7 Serial Port Connections......... .............................................. ..................... .. ............................................ . 61

4.7.1 Providing Power to an External Device from Port 2 ..................... .. .............................................. .......... 61

4.7.2 Cable Lengths and Baud Rates............................... .. ..................... .............................................. ....... 61

4.7.3 Port 1: RS-232................................ ..................... .............................................. ............................. 62

4.7.4 Port 2: RS-485................................ ..................... .............................................. ............................. 64

4.7.5 RS-485 Point-to-Point Connection with Handshaking ................ .............................................. .............. 65

4.7.6 RS-485 Multidrop Serial Connections ............ .............................................. ....................................... 65

4.8 Ethernet Connection for CPUE05 ............ .. ............................................ .. .............................................. ... 67

4.8.1 Network Connection................. ..................... .............................................. .................................... 67

4.9 CE Mark Installation Requirements........... .............................................. .............................................. .... 68

5 Configuration...................................................................................................................................69

5.1 Using Autoconfiguration or Programmer Configuration .. .............................................. ................................ 70

5.1.1 Autoconfiguration ..................................... ....................... ....................... ....................... ................. 70

5.1.2 Software Configuration ... ..................... .............................................. .............................................. 70

5.2 Configuring Racks and Slots .................... .............................................. ..................... ............................. 71

5.3 Software Configuration.................................. .............................................. ..................... .. .................... 72

5.3.1 Configuring CPU and Expansion Parameters .. ....................... ....................... ....................... ................. 72

5.3.2 Configurable Memory for CPU Module IC200CPU001, CPU002, CPU005............ ....................... ............. 74

5.3.3 Configurable Memory for CPU Module IC200CPUE05 ..................................... ....................... ............. 75

5.3.4 Configuring Serial Port Parameters .... ....................... .............................................. ............................ 76

5.3.5 RTU and Serial I/O Delays..................................... .............................................. ..................... .. ...... 77

5.3.6 Configuration Required to use Winloader ...... .............................................. .. ...................................... 78

5.3.7 Note for RTU Communications ........................... .............................................. ..................... ........... 78

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5.3.8 Storing a Configuration from a Programmer .............. .............................................. ....................... ...... 78

5.4 Autoconfiguration................ .............................................. ....................... ....................... ..................... . 79

5.4.1 Autoconfiguration Assigns Reference Addresses ................................. .............................................. .... 79

5.4.2 Autoconfiguration Diagnostics ..................... .............................................. ....................................... 79

5.4.3 Diagnostic Message Summary ........................................... .............................................. .................. 80

6 Ethernet Configuration ................................................................................................................. 81

6.1 Ethernet Configuration Overview ................ ....................... ............................................ .. ........................ 82

6.1.1 Autoconfiguration ..................................... ....................... ....................... ....................... ................. 82

6.2 Configuring the Ethernet Interface ....................... .............................................. ..................... .................. 83

6.3 Configuring Ethernet Global Data................. .............................................. .............................................. 85

6.3.1 Before You Configure EGD Exchanges ............. .............................................. ....................... ............. 85

6.4 Configuring a Global Data Exchange for a Producer..................... ..................... ........................................... 86

6.5 Configuring a Global Data Exchange for a Consumer ................................ .. ..................... ............................ 87

6.5.1 Selective Consumption......................................... .. ..................... .............................................. ....... 88

6.6 Configuring Advanced User Parameters ...................... ..................... .. .............................................. .......... 89

6.6.1 Format of the Advanced User Parameters File ........ .............................................. ................................ 89

6.6.2 Example Advanced User Parameter File ......................................... .............................................. ....... 89

6.6.3 Advanced User Parameter Definitions.................................... ....................... ....................... ............... 89

7 CPU Operation ................................................................................................................................93

7.1 Parts of the CPU Sweep ..... .............................................. .............................................. ..................... .... 94

7.2 Standard CPU Sweep Operation ........................................ .............................................. ..................... .... 97

7.2.1 The Sweep Windows ................... .............................................. ....................... ....................... ........ 97

7.2.2 The Watchdog Timer .................. ....................... .............................................. ................................ 97

7.2.3 Constant Sweep Time Operation ........................................ .............................................. .................. 97

7.3 CPU Stop Modes .................... .............................................. .. .............................................. ................. 98

7.4 Flash Memory...................................... .. ..................... ....................... ....................... ............................ 99

7.5 Controlling the Execution of a Program ........ .............................................. .. ............................................ . 99

7.5.1 Calling a Subroutine Block . ..................... .............................................. ........................................... 99

7.5.2 Creating a Temporary End of Logic ... .. ............................................ .. .............................................. ... 99

7.5.3 Executing Rungs of Logic without Logical Power Flow ...... .............................................. ..................... 99

7.5.4 Jumping to Another Part of the Program ............................. .. .............................................. ................. 99

7.6 Run/Stop Mode Switch Operation ............................................. .............................................. .................100

7.6.1 Configurable Run/Stop Mode Operation........................................ ..................... .. ..............................100

7.6.2 Configurable Memory Protection ...... ....................... .............................................. ...........................100

7.6.3 Summary of CPU Switch Run/Stop Operation ......................................................... ............................100

7.7 Privilege Levels and Passwords ..................................... ..................... .............................................. .. .....101

7.7.1 Protection Level Request from Programmer ........... .............................................. ...............................102

7.7.2 The OEM Protection Feature . ....................... .............................................. ......................................102

8 Elements of an Application Program ......................................................................................103

8.1 Structure of an Application Program......................................... .. ..................... .........................................103

8.2 Subroutines .......... ..................... .............................................. .............................................. .. ............104

8.2.1 Declaring a Subroutine.......................................... .............................................. ....................... .....104

8.2.2 Calling a Subroutine ......... ..................... .. .............................................. .........................................105

8.3 Program Languages.......... ....................... ....................... ..................... .. .............................................. ..105

8.3.1 Sequential Function Chart......... ..................... .. .............................................. ..................................105

8.3.2 Ladder Diagram.............................. .............................................. ..................... ............................106

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8.4 The Instruction Set .............................................. ....................... .............................................. .............107

8.4.1 Contacts ................................. ..................... .............................................. ...................................107

8.4.2 Coils...... .............................................. .............................................. ..................... .. ...................107

8.4.3 Timers and Counters............. .............................................. .............................................. .. ............108

8.4.4 Math Functions ........................................... .. .............................................. ..................... .............108

8.4.5 Relational Functions ................ .............................................. .. ..................... ..................................109

8.4.6 Bit Operation Functions .... .............................................. .. ..............................................................109

8.4.7 Data Move Functions .. ..................... .............................................. .............................................. ...109

8.4.8 Table Functions ............................................... ..................... .. .............................................. .........110

8.4.9 Conversion Functions ........ ................................................................... ..........................................110

8.4.10 Control Functions ...... .............................................. ..................... .............................................. ...111

9 Program Data................................................................................................................................. 113

9.1 Data Memory References ......... .............................................. .. .............................................. ................114

9.1.1 Word Memory References . ..................... .. .............................................. .........................................114

9.1.2 Bit Memory References..... ....................... .............................................. .........................................115

9.1.3 Transition Bits and Override Bits .......................................... ....................... ....................... ..............115

9.2 Retentiveness of Data ................................ ....................... ....................... ....................... .......................116

9.3 System Status References ..................................... .. .............................................. ..................... .............117

9.3.1 Using the System Status References ...... .............................................. .. ..................... .......................117

9.3.2 %S References ......................................... ....................... ....................... ....................... ................117

9.3.3 %SA, %SB, and %SC References ............................... ..................... .............................................. ...118

9.4 How Program Functions Handle Numerical Data ................................ .............................................. ..........120

9.4.1 Real Numbers .. .. ..................... .............................................. .............................................. ..........121

9.4.2 Errors in Real Numbers and Operations ...... .............................................. ..................... .. ...................121

9.5 Time-tick Contacts. .............................................. .............................................. ..................... .. ............122

10 Instruction Set Reference ........................................................................................................123

10.1 Bit Operation Functions ....................................... .. .............................................. ..................... .............124

10.1.1 Data Lengths for the Bit Operation Functions ...................... .. .............................................. ................124

10.1.2 Bit Operation Functions Logical AND, Logical OR . ................................................................... ..........124

10.1.3 Bit Operation Functions Exclusive OR ....................................... .............................................. ..........126

10.1.4 Bit Operation Functions Exclusive OR ....................................... .............................................. ..........127

10.1.5 Bit Operation Functions Logical Invert (NOT)..................... .. .............................................. ................127

10.1.6 Bit Operation Functions Shift Bits Right, Shift Bits Left .................... .............................................. ......128

10.1.7 Bit Operation Functions Rotate Bits Right, Rotate Bits Left .................. ..................... ............................129

10.1.8 Bit Operation Functions Bit Test .................. .............................................. .. ..................... ................130

10.1.9 Bit Operation Functions Bit Set and Bit Clear ........................... ..................... ......................................131

10.1.10Bit Operation Functions Masked Compare............... .. .............................................. ...........................132

10.1.11Bit Operation Functions Bit Position...................................... ....................... ....................... ..............134

10.1.12Bit Operation Functions Bit Sequencer.............. .............................................. ...................................135

10.2 Control Functions ............................................ ..................... .. .............................................. ................138

10.2.1 Control Functions Do I/O .. ..................... .. .............................................. .........................................138

10.2.2 Control Functions Call ................ .. .............................................. .............................................. ......140

10.2.3 Control Functions End of Logic .......................... ....................... ....................... ....................... .........141

10.2.4 Control Functions Master Control Relay (MCR) / End MCR .......................................... ........................142

10.2.5 Control Functions Jump, Label ....... ....................... ....................... .............................................. ......143

10.2.6 Control Functions Comment ......................................... ..................... .. ............................................144

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10.2.7 Control Functions Drum Sequencer ............................ .. ..................... ....................... ....................... ..144

10.3 Data Move Functions ....................................... ..................... .. .............................................. ................147

10.3.1 Data Move Functions Move Data ...................... ....................... ....................... ..................................147

10.3.2 Data Move Functions Block Move .................. .. .............................................. ..................................149

10.3.3 Data Move Functions Block Clear ..................................... .. .............................................. ................150

10.3.4 Data Move Functions Shift Register .......... .............................................. ..................... .. ...................151

10.3.5 Data Move Functions Communication Request .......... .............................................. ..................... .. .....153

10.4 Data Type Conversion Functions ........................................... ..................................................................156

10.4.1 Data Type Conversion Functions Convert Signed Integer Data to BCD-4........... ....................... ................156

10.4.2 Data Type Conversion Functions Convert to Signed Integer ........................................... ........................157

10.4.3 Data Type Conversion Functions Convert to Double Precision Signed Integer ................... ........................158

10.4.4 Data Type Conversion Functions Convert to Real Data..... ....................... ..................... .. .......................159

10.4.5 Data Type Conversion Functions Convert Real Data to Word Data ........ ....................... ...........................160

10.4.6 Data Type Conversion Functions Truncate Real Number ........ .............................................. .................160

10.5 Math and Numerical Functions............. ................................................................... .. ..............................162

10.5.1 Math and Numerical Functions Add, Subtract, Multiply, Divide..... ....................... ..................................162

10.5.2 Math and Numerical Functions Modulo Division .... ..................... .............................................. ..........164

10.5.3 Math and Numerical Functions Scaling ...... ..................... .............................................. .. ...................165

10.5.4 Math and Numerical Functions Square Root................. ..................... .. .............................................. ..166

10.5.5 Math and Numerical Functions Trigonometric Functions ....... ....................... .........................................167

10.5.6 Math and Numerical Functions Logarithmic / Exponential Functions .............................. .. ..................... ..169

10.5.7 Math and Numerical Functions Radian Conversion Functions............ .............................................. .. .....170

10.6 Relational Functions..... .. ............................................ .. .............................................. ..................... ......171

10.6.1 Relational Functions Equal, Not Equal, Less Than, Less/Equal, Greater Than, Greater/Equal .. .. ...................171

10.6.2 Relational Functions Range.............................................. .. ..................... .........................................172

10.7 Relay Functions.................. .. .............................................. .............................................. ....................174

10.7.1 Relay Functions Normally-open, Normally-closed, Continuation Contacts .................................. .. ............174

10.7.2 Relay Functions Coils ........ .............................................. .............................................. .................175

10.8 Table Functions............................................ .............................................. ....................... ...................179

10.8.1 Table Functions Array Move .................... .............................................. ..........................................179

10.8.2 Table Functions Search for Array Values ..... ....................... ....................... .........................................181

10.9 Timer and Counter Functions ........................................ .............................................. ....................... .....184

10.9.1 Timer and Counter Functions On Delay Stopwatch Timer............. .. .............................................. .........185

10.9.2 Timer and Counter Functions On Delay Timer..................... ....................... .........................................187

10.9.3 Timer and Counter Functions Off-Delay Timer .......... .............................................. ....................... .....189

10.9.4 Timer and Counter Functions Up Counter .............. .............................................. ...............................191

10.9.5 Timer and Counter Functions Down Counter ........................... .............................................. .. ............192

11 The Service Request Function................................................................................................195

11.1 SVCREQ Function Numbers .............. .. .............................................. ..................... ...............................196

11.2 Format of the SVCREQ Function ................ ....................... ....................... ..................... .. .......................197

11.2.1 Parameters of the SVCREQ Function.......................... .. ..................... ....................... ....................... ..197

11.2.2 Example of the SVCREQ Function........................................... .. .............................................. .........197

11.3 SVCREQ 1: Change/Read Constant Sweep Timer.. ....................... ....................... ....................... ................198

11.3.1 Input Parameter Block for SCVREQ 1 .................. .............................................. ...............................198

11.4 SVCREQ 2: Read Window Times........................ .............................................. ..................... .................200

11.4.1 Output Parameter Block for SVCREQ 2 ........... .. ..................... .............................................. .............200

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11.5 SVCREQ 3: Change Programmer Communications Window Mode.............................. ..................................201

11.5.1 Changing the Programmer Communications Window Mode .... ..................... ..........................................201

11.6 SVCREQ 4: Change System Communications Window Mode................................. ..................... .................202

11.6.1 Changing the System Communications Window Mode............................ .. ............................................202

11.7 Change/Read Number of Words to Checksum ..... .............................................. .........................................203

11.7.1 Parameter Block Formats for SVCREQ 6 .. .. .............................................. ..................... ....................203

11.8 SVCREQ 7: Read or Change the Time-of-Day Clock ...................... ..................... .. .....................................205

11.8.1 Parameter Block Format for SVCREQ 7........................................ ..................... .. ..............................205

11.8.2 SVCREQ 7 Parameter Block Content: BCD Format ....................................... ..................... .................206

11.8.3 SVCREQ 7 Parameter Block Content: Packed ASCII Format .............................. ...................................207

11.9 SVCREQ 8: Reset Watchdog Timer ........................ .............................................. ..................... .. ............210

11.9.1 Parameter Block Format for SVCREQ 8........................................ ..................... .. ..............................210

11.9.2 Example of SVCREQ 8........................ .............................................. ..................... ........................210

11.10SVCREQ 9: Read Sweep Time from Beginning of Sweep ................ .............................................. .............211

11.10.1Output Parameter Block Format for SVCREQ 9...... .............................................. ...............................211

11.11SVCREQ 10: Read Folder Name ............................................ .. .............................................. ................212

11.11.1Output Parameter Block Format for SVCREQ 10 .... .............................................. ...............................212

11.11.2Example of SVCREQ 10 ........................................... .............................................. ..................... ...212

11.12SVCREQ 11: Read PLC ID ........................... .............................................. ..................... .. ...................213

11.12.1Output Parameter Block Format for SVCREQ 11 .... .............................................. ...............................213

11.12.2Example of SVCREQ 11 ........................................... .............................................. ..................... ...213

11.13SVCREQ 13: Shut Down (Stop) PLC ...... ....................... ....................... ....................... ...........................214

11.13.1Parameter Block for SVCREQ 13 ........................... ..................... .............................................. .. .....214

11.13.2Example of SVCREQ 13 ........................................... .............................................. ..................... ...214

11.14SVCREQ 14: Clear Fault . .............................................. .. ............................................ .. ..................... ..215

11.14.1Input Parameter Block for SVCREQ 14..... .. ..................... .............................................. ....................215

11.14.2Example of SVCREQ 14 ........................................... .............................................. ..................... ...215

11.15SVCREQ 15: Read Last-Logged Fault Table Entry ........................... .. .............................................. .........216

11.15.1Input Parameter Block for SVCREQ 15..... .. ..................... .............................................. ....................216

11.15.2Long/Short Value ................................... ..................... .............................................. .. ...................217

11.15.3Example of SVCREQ 15 ........................................... .............................................. ..................... ...217

11.16SVCREQ 16: Read Elapsed Time Clock.............. ....................... .............................................. ................218

11.16.1Output Parameter Block for SVCREQ 16 .. ....................... .............................................. ....................218

11.16.2Example of SVCREQ 16 ........................................... .............................................. ..................... ...218

11.17SVCREQ 18: Read I/O Override Status....................... ..................... .............................................. ..........219

11.17.1Output Parameter Block for SVCREQ 18 .. ....................... .............................................. ....................219

11.17.2Example of SVCREQ 18 ........................................... .............................................. ..................... ...219

11.18SVCREQ 23: Read Master Checksum ............ .. .............................................. .........................................220

11.18.1Output Parameter Block for SVCREQ 23 .. ....................... .............................................. ....................220

11.18.2Example of SVCREQ 23 ........................................... .............................................. ..................... ...220

11.19SVCREQ 24: Reset Ethernet Daughter Board........... .............................................. ....................... ............221

11.20SVCREQ 26/30: Interrogate I/O ............... ....................... ..................... .. .............................................. ..222

11.20.1Example of SVCREQ 26 ........................................... .............................................. ..................... ...222

11.21SVCREQ 29: Read Elapsed Power Down Time ................................. .............................................. ..........223

11.21.1Output Parameter Block for SVCREQ 29 .. ....................... .............................................. ....................223

11.21.2Example of SVCREQ 29 ........................................... .............................................. ..................... ...223

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12 Serial I/O / SNP / RTU Protocols .............................................................................................225

12.1 Format of the Communication Request Function............................. ....................... ....................... ..............226

12.1.1 Parameters of the COMMREQ Function......................................... ..................... ...............................226

12.1.2 Command Block for the COMMREQ Function....... ..................... .............................................. ..........227

12.1.3 Example of the COMMREQ Function............ .............................................. ......................................227

12.2 Configuring Serial Ports Using the COMMREQ Function ............................... ..................... ........................228

12.2.1 Timing................. .............................................. .............................................. ..................... .. .....228

12.2.2 Sending Another COMMREQ to the Same Port .......... ....................... ....................... ...........................228

12.2.3 Invalid Port Configuration Combinations..... ....................... ....................... .........................................229

12.2.4 RTU Slave/SNP Slave Operation With Programmer Attached.................... .............................................229

12.2.5 Example COMMREQ Command Block for Configuring SNP Protocol .............. ..................... .................230

12.2.6 Example COMMREQ Data Block for Configuring RTU Protocol ........................................... ................231

12.2.7 Example COMMREQ Data Block for Configuring Serial I/O Protocol ............................................... ......232

12.3 Calling Serial I/O COMMREQs from the PLC Sweep .............................................. ...................................233

12.3.1 Compatibility ......................... ..................... .. .............................................. ..................................233

12.3.2 Status Word for Serial I/O COMMREQs ....................... ....................... ..................... .. .......................233

12.4 Serial I/O COMMREQ Commands ................. ....................... .............................................. ....................236

12.4.1 Overlapping COMMREQs............... .. ............................................ .. ..................... ...........................236

12.4.2 ......... ..................... .............................................. .. ............................................ ....................... ..236

12.4.3 COMMREQs that Can be Pending While Others Execute ................................ ..................... .................237

12.4.4 Initialize Port Function (4300) ....................................... .............................................. .. ...................237

12.4.5 Set Up Input Buffer Function (4301)................. ................................................................... .. ............238

12.4.6 Flush Input Buffer Function (4302) .............................................. ..................... .. ..............................238

12.4.7 Read Port Status Function (4303) .................... .. .............................................. ..................... .............239

12.4.8 Write Port Control Function (4304) ............................. .............................................. ........................242

12.4.9 Cancel Commreq Function (4399)...................................... .............................................. .................243

12.4.10Autodial Function (4400) ..................... .............................................. ..................... ........................243

12.4.11Write Bytes Function (4401) .................... .............................................. ....................... ...................245

12.4.12Read Bytes Function (4402) .......... .............................................. ....................... ....................... .......246

12.4.13Read String Function (4403) ............................................ .............................................. .................247

13 Ethernet Communications.......................................................................................................249

13.1 Overview of the Ethernet Interface ..................................... .............................................. ........................250

13.1.1 Ethernet Global Data ........................................ .............................................. .. ..................... .........250

13.1.2 SRTP Server ............... .. ..................... .............................................. .............................................251

13.1.3 SRTP Channels............................................ .. ................................................................... .............251

13.1.4 Attachment to the Ethernet LAN ........................................... ....................... ....................... ..............251

13.1.5 The Station Manager Software.............. .............................................. .. ..................... .......................251

13.2 IP Addressing.................................... .............................................. ....................... ....................... .......252

13.3 Routers ..................................... .............................................. ....................... ....................... ..............253

13.4 Ethernet Global Data ............ ................................................................... .. ............................................254

13.4.1 The Frequency of Sending/Receiving an Exchange ........ .. ............................................ .. .......................254

13.4.2 The Consumer Update Timeout Period .............................................. .............................................. ...254

13.4.3 Ethernet Global Data Groups.................... ................................................................... .. ...................255

13.4.4 Timestamping of Ethernet Global Data Exchanges ....................... .............................................. ..........255

13.4.5 Configuring NTP for the CPUE05 Ethernet Interface ........................ .............................................. ......257

13.4.6 The Content of an Ethernet Global Data Exchange .................... .............................................. .............258

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13.4.7 Data Types for Ethernet Global Data ....................... .. .............................................. ..................... ......258

13.4.8 Effect of PLC Modes and Actions on Ethernet Global Data .. .............................................. ....................259

13.4.9 EGD Synchronization .......... .. .............................................. ..................... ......................................259

13.5 Diagnostic Tools............................. ..................... .............................................. ...................................261

13.5.1 What to do if you Cannot Solve the Problem ................................... .............................................. ......261

13.5.2 Checking the Ethernet LEDs ................. ..................... .............................................. ........................261

13.5.3 Using the PLC Fault Table........... .. .............................................. .............................................. ......264

13.5.4 Checking the Status of the Ethernet Interface......................................... .. ............................................265

13.5.5 Checking the Status of an Ethernet Global Data Exchange ......................................... ....................... .....266

13.5.6 Using the Ethernet Station Manager Function .............................. .............................................. ..........268

13.6 Troubleshooting Common Ethernet Difficulties .............................. .............................................. .. ............269

13.6.1 PLC Timeout Errors ..................................... .. .............................................. ..................... .............269

13.6.2 Unexpected Ethernet Restart or Runtime Errors ..................................... .. ..................... .......................270

13.6.3 EGD Configuration Mismatch Errors ............................... .............................................. ....................271

13.6.4 Receive Resource Exhaustion Errors.................... ..................... .. .............................................. .........271

13.6.5 Station Manager Lockout under Heavy Load .................... .............................................. .. ...................272

13.6.6 PING Restrictions ................................. .. ..................... .............................................. ....................272

13.6.7 SRTP Connection Timeout................... .............................................. .. ............................................272

14 PID Built-in Function Block .....................................................................................................273

14.1 Operands of the PID Function ..................... ..................... .. ............................................ .. .......................274

14.1.1 Parameters of the PID Function Block........... .............................................. .. ..................... ................274

14.2 Reference Array for the PID Function.................. ....................... ....................... ....................... ................275

14.2.1 Scaling Input and Outputs..... ....................... .............................................. ......................................275

14.2.2 Reference Array Parameters............. .. ............................................ .. .............................................. ..275

14.3 Operation of the PID Function. ....................... ....................... .............................................. ....................282

14.3.1 Automatic Operation ................... .............................................. ....................... ....................... .......282

14.3.2 Manual Operation ..... ....................... ....................... ..................... .. .............................................. ..282

14.3.3 Time Interval for the PID Function . .............................................. ....................... ....................... .......283

14.4 PID Algorithm Selection (PIDISA or PIDIND) and Gain Calculations .............. .. ..................... .......................284

14.4.1 Error Term................ ..................... .............................................. .............................................. ...284

14.4.2 Derivative Term................................. ....................... ....................... ..................... .. .......................285

14.4.3 CV Bias Term .......... .............................................. ....................... ....................... ....................... ..285

14.4.4 CVAmplitude and Rate Limits ................ ....................... .............................................. ....................286

14.4.5 Sample Period and PID Function Block Scheduling ................................. .............................................287

14.5 Determining the Process Characteristics ................................. ....................... ....................... .....................288

14.6 Setting Tuning Loop Gains .................................... ..................... .............................................. .. ............289

14.6.1 Basic Iterative Tuning Approach..................... ....................... .............................................. .............289

14.6.2 Setting Loop Gains Using the Ziegler and Nichols Tuning Approach ....................... .. ..................... .........289

14.6.3 Ideal Tuning Method ................... ................................................................... .. ..............................290

14.6.4 Example.... .............................................. .............................................. .. ..................... ................290

15 The EZ Program Store Device.................................................................................................293

15.1 Read/Write/Verify Data with a Programmer Present .................. .............................................. ....................295

15.1.1 Including All the Necessary Information.................. ....................... .............................................. ......295

15.1.2 Matching OEM Protection .................... ..................... .............................................. ........................295

15.1.3 Adjusting the Configuration Timeouts..................................... .............................................. .............295

15.1.4 Writing Data to RAM or Flash.................................... .............................................. ..................... ...296

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15.1.5 Using the EZ Program Store Device with the Programmer ......................................... ..................... .. .....296

15.2 Update a PLC CPU without a Programmer Present......... .............................................. ...............................298

15.2.1 Error During Update............. .............................................. ..................... .. .....................................300

Appendix A Performance Data........................................................................................................301

................... .............................................. ..................... .............................................. .. ...................301

Base Sweep Time............................................. ....................... ....................... ....................... .........301

Boolean Instruction Time ....................... .. ..................... .............................................. ....................301

Function Block Timing ..... ....................... ....................... ..................... .. .............................................. ..302

Sweep Impact Times............ .. ................................................................... ......................................302

Sizes of Timers, Counters, Math Functions, Trig Functions, Log Functions ..... ..................... .. ...................302

Sizes of Exponential Functions, Radian Conversion, Relational Functions ................................................304

Sizes of Bit Operations, Data Move Functions . .............................................. ......................................305

Sizes of Table Functions........... .............................................. .. ..................... ..................................306

Sizes of Conversion and Control Functions ....................... .............................................. ....................308

I/O Module Scan Times ....... .. .............................................. .............................................. ....................309

Reference to Discrete Module Types in the Scan Time Tables............. ..................... ...............................309

Modules Located in Main PLC Rack ..................................... ....................... ....................... ..............310

Modules Located in Single-ended Expansion Rack ...................... ....................... ..................................311

Modules Located in Multiple Remote Expansion Rack..................... ..................... .. ..............................312

Modules Located in Single-ended Isolated Expansion Rack.... .. .............................................. ................313

Ethernet Global Data Sweep Impact ................. .............................................. ....................... ...................314

Exchange Overhead....... .............................................. ....................... ....................... .....................314

Byte Transfer Time........................................ ..................... .............................................. .. ............314

Support for Large Ethernet Global Data Configurations .................... .............................................. .............315

For public disclosure

GFK-1503E User Manual 15

Notes

16 GFK-1503E VersaMax PLC User Manual

For public disclosure

1 Introduction

Guide to the VersaMax®Document Set

This manual contains general information about CPU operation and program content. It also provides detailed descriptions of specific programming requirements.

Chapter 1 is a general introduction to the VersaMax family of products.

CPU Modules are described in detail in chapter 2 and chapter 3.

Installation procedures are described in Chapter 4.

PLC Configuration is described in chapter 5. Configuration determines certain

characteristics of module operation and also establishes the program references used by each module in the system.

Ethernet Configuration for CPU model IC200CPUE05 is described in chapter 6.

CPU Operation is described in chapter 7.

Serial Communications are described in chapter 12.

Ethernet Communications for CPU model IC200CPUE05 is described in chapter 13.

The rest of the manual describes many programming features.

• Elements of an Application Program: chapter 8

• Program Data: chapter 9

• Instruction Set Reference: chapter 10

• The Service Request Function: chapter 11

• The PID Function: chapter 14

• Instruction Timing: Appendix A

1.1 The VersaMax Family of Products

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

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

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

Introduction GFK-1503E User Manual 17

For public disclosure

VersaMax provides automatic addressing that can eliminate traditional configuration and

VersaMax PLC CPU

power supply

VersaMax Modules

the need for hand-held devices. Multiple field wiring termination options provide support for two, three, and four-wire devices.

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

VersaMax I/O may be remotely located. Remote I/O interfaces for Genius, DeviceNet, Profibus, and Ethernet are available.

1.2 CPU Modules for VersaMax PLCs

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

All VersaMax CPUs provide powerful PLC functionality. They are designed to serve as the system controller for up to 64 modules with up to 2048 I/O points. Two serial ports provide RS-232 and RS-485 interfaces for SNP slave and RTU slave communications. CPU model IC200CPUE05 provides a built-in Ethernet port.

1.2.1 Basic CPU Features

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

• Floating point (real) data functions

• Non-volatile flash memory for program storage

• Run/Stop switch

• Embedded RS-232 and RS-485 communications

• Compatible with EZ Program Store device

1.2.2 Available VersaMax CPUs

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

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

CPU with Two Serial Ports, 128kB of Configurable Memory IC200CPU005

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

IC200CPUE05

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RS485

PORT 2

RS232

PORT 1

CPU001

PORT 2

FORCE

PORT 1

FAULT

RUN

PWR

RS485

PORT 2

RS232

PORT 1

CPU005

FAULT

RUN

PWR

PORT 2

FORCE

PORT 1

CPU001 CPU002

CPU005

Status LEDs

Serial Ports

RS485

PORT 2

RS232

PORT 1

CPUE05

FAULT

RUN

PWR

PORT 2

FORCE

PORT 1

LAN

STAT

ETHERNET

10 BASE T /

100 BASE TX

ETHERNET

RESTART

CPUE05

Ethernet Interface

Introduction GFK-1503E User Manual 19

For public disclosure

1.2.3 EZ Program Store

PLC

IC200PWR001

VDC

INPUT

24 VDC

POWER SUPPLY

NOT

USED

The EZ Program Store device (IC200ACC003) can be used to store and update the configuration, application program, and reference table data of a VersaMax PLC. A programmer and PLC CPU are used to initially write data to the device.

1.3 Power Supplies

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

CPU models IC200CPU005 and IC200CPUE05 require the use of an expanded 3.3V power supply. Refer to the following table.

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1.4 I/O Modules

66.8mm (2.63in)

110mm (4.33in)

Latch

Individual Point LEDS on Discrete Modules

Fie

ld Power LED indicates presence of power from external supply

OK LED indicates presence of power from VersaMax power supply

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

Module Description

1234567 831

FLD

PWR

IC200MDL750

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

FLD

PWR

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

17 18 19

21 22 23 24 25 26 27 28 29 30 31 32

1.3.1 Available Power Supplies and Carrier

The following VersaMax power supplies and carrier are available:

24VDC Power Supply IC200PWR001

24VDC Expanded 3.3V Power Supply IC200PWR002

120/240VAC Power Supply IC200PWR101

120/240VAC Expanded 3.3V Power Supply IC200PWR102

12VDC Power Supply IC200PWR201

12VDC Expanded 3.3V Power Supply IC200PWR202

Power Supply Booster Carrier IC200PWB001

Power supplies are described in the VersaMax Modules, Power Supplies, and Carriers User Manual (GFK-1504).

VersaMax I/O and option modules are approximately 110mm (4.33in) by 66.8mm (2.63in) in size. Modules can be mounted either horizontally or vertically on several types of available I/O Carriers. Modules are 50mm (1.956 in) in depth, not including the height of the carrier or the mating connectors.

Introduction GFK-1503E User Manual 21

For public disclosure

VersaMax I/O modules are described in the VersaMax Modules, Power Supplies, and Carriers User’s Manual (GFK-1504).

Discrete Input Modules

1.4.1 Available I/O Modules

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

Input 120VAC 8 Point Grouped Module

Input 240VAC 8 Point Grouped Module

Input 120VAC 8 Point Isolated Module

Input 240VAC 4 Point Isolated Module

Input 120VAC (2 Groups of 8) 16 Point Module

Input 240VAC (2 Groups of 8) 16 Point Module

Input 120VAC 16 Point Isolated Module

Input 240VAC 8 Point Isolated Module

Input 125VDC Positive/Negative Logic Grouped 8 Point Module

Input 125VDC Positive/Negative Logic Grouped 16 Point Module

Input 48VDC Positive/Negative Logic Grouped 16 Point Module

Input 48VDC Positive/Negative Logic Grouped 32 Point Module

Input 24VDC Positive/Negative Logic (2 Groups of 8) 16 Point Module

Input 5/12VDC (TTL) Positive/Negative Logic 16 Point Module

Input 5/12VDC (TTL) Positive/Negative Logic Grouped 32 Point Module

Input 24VDC Positive/Negative Logic (4 Groups of 8) 32 Point Module

IC200MDL140

IC200MDL141

IC200MDL143

IC200MDL144

IC200MDL240

IC200MDL241

IC200MDL243

IC200MDL244

IC200MDL631

IC200MDL632

IC200MDL635

IC200MDL636

IC200MDL640

IC200MDL643

IC200MDL644

IC200MDL650

Discrete Output Modules

Output 120VAC 0.5A per Point Isolated 8 Point Module

Output 120VAC 0.5A per Point Isolated 16 Point Module

Output 120VAC 2.0A per Point Isolated 8 Point Module

Output 24VDC Positive Logic 2.0A per Point (1 Group of 8) w/ESCP 8 Point Module,

Output 12/24VDC Positive Logic 0.5A per Point (1 Group of 16) 16 Point Module

Output 24VDC Positive Logic 0.5A per Point (1 Group of 16) w/ESCP 16 Point Module

Output 24VDC Positive Logic 0.5A per Point (2 Groups of 16) w/ESCP 32 Point Module

Output 5/12/24VDC Negative Logic 0.5A per Point (1 Group of 16) 16 Point Module

Output 5/12/24VDC Negative Logic 0.5A per Point (2 Groups of 16) 32 Point Module

Output 12/24VDC Positive Logic 0.5A per Point (2 Groups of 16) 32 Point Module

Output Relay 2.0A per Point Isolated Form A 8 Point Module

IC200MDL329

IC200MDL330

IC200MDL331

IC200MDL730

IC200MDL740

IC200MDL741

IC200MDL742

IC200MDL743

IC200MDL744

IC200MDL750

IC200MDL930

Output Relay 2.0A per Point Isolated Form A 16 Point Module

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IC200MDL940

Discrete Mixed I/O Modules

Mixed 24VDC Positive Logic Input Grouped 20 Point / Output Relay 2.0A per Point Grouped 12 Point Module

IC200MDD840

Mixed 24VDC Positive Logic Input 20 Point / Output 12 Point / (4) High Speed Counter, PWM, or Pulse Train Configurable Points

Mixed 16 Point Grouped Input 24VDC Pos/Neg Logic / 16 Pt Grouped Output 24VDC Pos. Logic 0.5A w/ESCP

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

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

Mixed 16 Point Grouped Input 24VDC Pos/Neg Logic / 8 Pt Relay Output

2.0A per Pt Isolated Form A

Mixed 120VAC Input 8 Point / Output Relay 2.0A per Point 8 Point Module

Mixed 240VAC Input 8 Point / Output Relay 2.0A per Point 8 Point Module

Mixed 120VAC Input 8 Point / Output 120VAC 0.5A per Point Isolated 8 Point Module

Mixed 120VAC In Isolated 8 Point / Output Relay 2.0A Isolated 8 Point Module

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

Analog Input Modules

IC200MDD841

IC200MDD842

IC200MDD843

IC200MDD844

IC200MDD845

IC200MDD846

IC200MDD847

IC200MDD848

IC200MDD849

IC200MDD850

Analog Input Module, 12 Bit Voltage/Current 4 Channels

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

Analog Input Module, 12 Bit Voltage/Current 8 Channels

Analog Input Module, 15 Bit Differential Voltage 8 Channels

Analog Input Module, 16 Bit Differential Current 8 Channels

Analog Input Module, 15 Bit Voltage 15 Channels

Analog Input Module, 15 Bit Current 15 Channels

Analog Input Module, 16 Bit RTD, 4 Channels

Analog Input Module, 16 Bit Thermocouple, 7 Channels

Analog Output Modules

Analog Output Module, 12 Bit Current, 4 Channels

Analog Output Module, 12 Bit Voltage 4 Channels. 0 to +10VDC Range

Analog Output Module, 12 Bit Voltage 4 Channels. -10 to +10VDC Range

Analog Output Module, 13 Bit Voltage 8 Channels

Analog Output Module, 12 Bit Current 8 Channels

Analog Output Module, 13 Bit Voltage 12 Channels

IC200ALG230

IC200ALG240

IC200ALG260

IC200ALG261

IC200ALG262

IC200ALG263

IC200ALG264

IC200ALG620

IC200ALG630

IC200ALG320

IC200ALG321

IC200ALG322

IC200ALG325

IC200ALG326

IC200ALG327

Analog Output Module, 12 Bit Current 12 Channels

IC200ALG328

Introduction GFK-1503E User Manual 23

For public disclosure

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

Analog Mixed I/O Modules

IC200ALG331

Analog Mixed Module, Input Current 4 Channels, Output Current 2 Channels

Analog Mixed Module, 0 to +10VDC Input 4 Channels, Output 0 to +10VDC 2 Channels

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

IC200ALG430

IC200ALG431

IC200ALG432

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1.5 Carriers

MADE IN USA

Terminal-style I/O Carrier Compact Terminal-style

I/O Carrier

Connector-style I/O

Carrier and

Interposing Terminals

Auxiliary I/O Terminal Strip

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

There are three basic I/O Carrier types:

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

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

• Connector-style I/O Carriers. Modules mount perpendicular to the DIN rail. These carriers are normally used with Interposing I/O Terminals as illustrated below.

Refer to the VersaMax Modules, Power Supplies, and Carriers User Manual (GFK-1504) for information about VersaMax I/O Carriers.

Terminal-style I/O carriers have 36 individual terminals for direct connection of field wiring. Auxiliary I/O Terminal Strips are available for applications requiring additional wiring terminals.

Introduction GFK-1503E User Manual 25

For public disclosure

Terminal-Style I/O Carriers

1.5.1 Available Carriers and Terminal Strips

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

Barrier-Style Terminal I/O Carrier

Box-Style Terminal I/O Carrier

Spring-Style Terminal I/O Carrier

Compact Terminal-Style I/O Carriers

Compact Box-Style I/O Carrier

Compact Spring-Style I/O Carrier

Connector-Style I/O Carrier

Interposing Terminals for use with Connector-Style Carrier

Barrier-Style Interposing I/O Terminals

Box-Style Interposing I/O Terminals

Thermocouple-Style Interposing I/O Terminals

Spring-Style Interposing I/O Terminals

Disconnect-Style Interposing I/O Terminals, Main Base

Disconnect-Style Interposing I/O Terminals, Expansion Base

Relay-Style Interposing I/O Terminals, Main Base

IC200CHS001

IC200CHS002

IC200CHS005

IC200CHS022

IC200CHS025

IC200CHS003

IC200CHS011

IC200CHS012

IC200CHS014

IC200CHS015

IC200CHS101

IC200CHS102

IC200CHS111

Relay-Style Interposing I/O Terminals, Expansion Base

Fuse-Style Interposing I/O Terminals, Main Base

Fuse-Style Interposing I/O Terminals, Expansion Base

Cables for use with Connector-Style I/O Carriers

2 connectors, 0.5m, no shield

2 connectors, 1.0m, no shield

2 connectors, 2.0m, no shield

1 connector, 3.0m, no shield

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

Barrier-Style Auxiliary I/O Terminal Strip

Box-Style Auxiliary I/O Terminal Strip

Spring-Style Auxiliary I/O Terminal Strip

Other Carriers

Communications Carrier IC200CHS006

Power Supply Booster Carrier

IC200CHS112

IC200CHS121

IC200CHS122

IC200CBL105

IC200CBL110

IC200CBL120

IC200CBL230

IC200TBM001

IC200TBM002

IC200TBM005

IC200PWB001

26 GFK-1503E VersaMax PLC User Manual

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1.6 Expansion Modules

CPU/NIU

ERM

ETM

VersaMax ExpansionRack 1

Terminator

Plug

15M with any

IC200ERM002 ERMs

750M with all

IC200ERM001 ERMs

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

VersaMax ExpansionRack 7

IC200CBL601,

602, 615

ERM

VersaMax Expansion Rack

1 M

VersaMax PLC or NIU I/O Station Main Rack

CPU/NIU

IC200CBL600

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

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

• Single-ended: A CPU or NIU I/O Station connected directly to one expansion rack with non-isolated Expansion Receiver Module (IC200ERM002). Maximum cable length is 1 meter.

1.6.1 VersaMax Modules for Expansion Racks

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

Module Module Revision

IC200ALG320 B or later

IC200ALG321 B or later

IC200ALG322 B or later

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IC200ALG430 C or later

IC200ALG431 C or later

IC200ALG432 B or later

1.6.2 Available Expansion Modules

The following Expansion Modules and related products are available:

Expansion Modules

Expansion Transmitter Module

Expansion Receiver Module, Isolated

Expansion Receiver Module, Non-isolated

Cables

Expansion Cable, Shielded, 1 meter

Expansion Cable, Shielded, 2 meters

Expansion Cable, Shielded, 15 meters

Firmware Update Cable

Terminator Plug (included with ETM)

Connector Kit IC200ACC302

IC200ETM001

IC200ERM001

IC200ERM002

IC200CBL601

IC200CBL602

IC200CBL615

IC200CBL002

IC200ACC201

Refer to the VersaMax Modules, Power Supplies, and Carriers User Manual (GFK-1504) for information about VersaMax Expansion modules.

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1.7 Communications Modules

VersaMax PLC CPU

power supply

Optional booster

power supply

Profibus Network

Slave Modu

Communications modules provide additional flexibility for VersaMax systems.

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

1.7.1 Available VersaMax PLC Communications

Modules

The following VersaMax PLC communications modules are available:

Communications Modules

Profibus-DP Network Slave Module IC200BEM002

DeviceNet Network Control Module IC200BEM103

Asi Network Master Module IC200BEM104

Serial Communications Module IC200CMM020

Communications Carrier IC200CHS006

For information about the Communications Carrier, refer to the VersaMax Modules, Power Supplies, and Carriers User Manual (GFK- 1504).

1.7.2 Profibus-DP Network Slave Module

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

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

For information about the Profibus-DP Network Slave Module, refer to the VersaMax System Profibus Network Modules User Manual (GFK-1534, revision A or later).

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1.7.3 DeviceNet Network Control Module

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

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

For information about the DeviceNet Network Control Module, refer to the VersaMax System DeviceNet Network Communications User Manual (GFK-1533).

1.7.4 Asi Network Master Module

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

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

For information about the AS-Interface Network Master Module, refer to the VersaMax System ASI Network Communications User Manual (GFK-1697).

1.7.5 Serial Communications Module

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

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+ 288 hidden pages

GE Digital VersaMax PLC Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Document Updates

Acronyms and Abbreviations

Contact Information

Contents

1 Introduction

1.1 The VersaMax Family of Products

1.2 CPU Modules for VersaMax PLCs

1.2.1 Basic CPU Features

1.2.2 Available VersaMax CPUs

1.2.3 EZ Program Store

1.3 Power Supplies

1.4 I/O Modules

1.3.1 Available Power Supplies and Carrier

1.4.1 Available I/O Modules

1.5 Carriers

1.5.1 Available Carriers and Terminal Strips

1.6 Expansion Modules

1.6.1 VersaMax Modules for Expansion Racks

1.6.2 Available Expansion Modules

Communications Modules

Profibus-DP Network Slave Module IC200BEM002

1.7.3 DeviceNet Network Control Module

1.7.4 Asi Network Master Module

1.7.5 Serial Communications Module