GE Fanuc Versamax PLC
A VersaMax PLC is a DIN rail mounted modular chassis-based platform, consisting of a CPU, power supply, assorted I/O, communication, and/or accessory modules, and carrier units (backplanes that modules mount to). Common features across the entire VersaMax Family include:
- High-powered PLC capabilities in a compact 70mm modular chassis format
- Stand-alone or fully networked communication options
- Highly scalable – up to eight I/O or accessory modules per rack, and up to eight racks per VersaMax PLC or I/O Station system
- Up to 64 modules and 2048 I/O points total per CPU
- I/O modules up to 32 points each
- Automatic I/O addressing feature
- I/O serving two, three, and four-wire devices
- Programmable in Ladder Diagram, Sequential Function Chart, and Instruction List
- Floating point (real) data functions
- Hot-insertion feature for accessory modules, with no impact on running processes
- Communication protocols including Genius, DeviceNet, Modbus/TCP, PROFINET, PROFIBUS DP, ASi, and Ethernet Global Data (EGD)
- Two onboard serial ports for RS-232 and RS-485 connectivity
- Fully compliant design meeting UL, CUL, CE, UL HazLoc Class 1 Zone 2 and Class 1 Division 2, and ATEX Zone 2 requirements
- Battery backup for program, data, and time of day clock
- Non-volatile flash memory for program storage
- Run/Stop switch
- Compatible with EZ Program Store device
Configuring a VersaMax PLC requires selecting part numbers for all of the individual modules needed to make up a chassis build-out.
VersaMax PLC Model Selection
Emerson’s VersaMax PLC components span approximately one hundred different part numbers, so it takes a bit of research and preparation to put together a full PLC kit.
CPU Models
Selecting a CPU is perhaps the natural starting point for selecting a build, as you’ll want to size your build based on the application size and functionality desired. GE Fanuc’s original documentation lists the following four (4) CPU models for their VersaMax PLCs. The '002’ and ‘005’ models can still be found in the used parts market. The CPU models are as follows:
- IC200CPU001: This is a CPU with two (2) serial ports and a 34-kilobyte configurable memory.
- IC200CPU002: This is a CPU with two (2) serial ports and a 42-kilobyte configurable memory.
- IC200CPU005: This is a CPU with two (2) serial ports and a 64-kilobyte configurable memory.
- IC200CPUE05: This is a CPU with two (2) serial ports and an embedded Ethernet interface, as well as a 64-kilobyte configurable memory.
Power Supply Models
Next, we’ll select a Power Supply unit, specified to match the I/O and device interface requirements that we’ll need for our system. Available models (and their carrier backplane) are listed below.
- IC200PWR001: This is a 24 volts DC Power Supply.
- IC200PWR002: This is a 24 volts DC Expanded 3.3-Volt Power Supply.
- IC200PWR101: This is a 120/240 volts AC Power Supply.
- IC200PWR102: This is a 12/240 volts AC Expanded 3.3-Volt Power Supply.
- IC200PWR201: This is a 12 volts DC Power Supply.
- IC200PWR202: This is a 12 volts DC Expanded 3.3-Volt Power Supply.
- IC200PWB001: This is a Power Supply Booster Carrier.
Carriers and I/O Modules
As mentioned previously, a carrier is GE Fanuc’s term for the backplane that mounts to the DIN rail in your panel, which serves as the mounting surface for all modules. Carriers provide the physical mounting, inter-module communication, and field wiring connections that together build out your chassis. Carriers come in three variants, which include:
- Terminal-style I/O Carriers are modules that are mounted parallel to the DIN rail.
- Compact Terminal-style I/O Carriers, which are modules mounted perpendicular to the DIN rail.
- Connector-style I/O Carriers, which are modules mounted perpendicular to the DIN rail. These carriers are normally used with Interposing I/O Terminals.
Carriers are matched to the Modules intended to snap in place, as well as the wiring methods intended to be employed. There are over twenty carrier model numbers to choose from as you select your IO and accessory modules. Additionally, several I/O categories are available for VersaMax PLC systems. These include discrete input modules, discrete output modules, relay output modules, mixed discrete I/O modules, analog input modules, analog output modules, mixed analog I/O modules, and remote I/O interfaces, as well as many more I/O modules.
Network Communication Modules
The last module type to note is the Network Communication Module. As with the carrier group, you’ll want to check manuals and datasheets for specific part numbers, due to the quantity and selection details available. Please note that PROFIBUS, Ethernet, Genius, and ASI interfaces have specific versions and variants to choose from, as well as specific carriers.
Other Accessories
Emerson’s VersaMax PLCs have a few additional accessories worth mentioning. I/O Interposing Bases offer integrated disconnect means for field devices wired to them and allow other connector-style carriers to interface with field wiring. There are six models to choose from.
Emerson also offers an EZ Program Store Flash Device, catalog number IC200ACC003, which can be used to store and update the configuration, application program, and reference table data saved on the device out to a PLC.
Lastly, a series of expansion and Remote I/O options round out the accessories available for the VersaMax.
VersaMax PLC Scalability
As a scalable system, we must not forget that VersaMax PLCs can be expanded to multiple racks, which requires the use of Remote I/O units and Expansion Receiver Modules. VersaMax PLCs can be expanded in either Multi-Rack or Single-Ended schemes.
- Multi-Rack: This is an expansion scheme using a Transmitter Module in the master CPU rack, and using Expansion Receiver Modules downstream in the slave racks. There are multiple options for each module depending on your distance and networking requirements.
- Single-Ended: This is an expansion scheme with a direct connection from a master CPU rack to a single slave rack. In this case, a single non-isolated Expansion Transmitter Module (IC200ERM002) can be used, having a maximum cable length of 1 meter.
Emerson Automation supplies a range of expansion cables, terminator plugs, and connector kits for use with expansion racks.
CPU Technical Specifications
CPU Specifications - 001, 002, 005 Models
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Size:
- IC200CPU001/002: 2.63 inches x 5.04 inches (66.8 mm x 128 mm)
- IC200CPU005: 4.20 inches x 5.04 icnhes (106.7 mm x 128 mm)
- Program Storage: System flash, battery-backed RAM
-
Backplane Current Consumption:
- IC200CPU001/002
- No serial port converter or EZ Programs Store device: 40 milliamperes for a 5-volt output and 100 milliamperes for a 3.3-volt output.
- With a serial port converter or EZ Program Store device: 140 milliamperes for a 5-volt output and 100 milliamperes for a 3.3-volt output.
- IC200CPU005
- No serial port converter or EZ Program Store device: 80 milliamperes for a 5-volt output and 290 milliamperes for a 3.3-volt output.
- With a serial port converter or EX Program Store device: 180 milliamperes for a 5-volt output and 290 milliamperes for a 3.3-volt output.
- IC200CPU001/002
- Embedded Communications: These CPUs have RS-232 and RS-485.
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Boolean Execuation Speed:
- IC200CPU001/002: 1.8 ms/K (typical)
- IC200CPU005: 0.5 ms/K (typical)
- Realtime Clock Accuracy (for timer functions): 100ppm (0.01%) or +/- 9 seconds per day
- Time of Day Clock Accuracy: 23ppm (0.0023%) or +/- 2 seconds per day at 30 degrees Celsius, as well as 100ppm (0.01%) or +/- 9 seconds per day at a full temperature range.
CPU Configurable Memory - 001, 002, 005 Models
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Configurable Memory:
- IC200CPU001: 34k bytes maximum
- IC200CPU002: 42k bytes maximum
- IC200CPU005: 64k bytes maximum
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Application Program Size (Not Configurable): 128 bytes minimum
- IC200CPU001, for rel. 1.50 compatibility: 12K bytes
- IC200CPU002, for rel. 1.50 compatibility: 20K bytes
- Hardware Configuration Size (Not Configurable): 400 bytes minimum
-
Registers (%R): 256 bytes minimum
- IC200CPU001/002, for rel. 1.50 compatibility: 4,096 bytes
- Analog Inputs (%AI): 256 bytes minimum
- Analog Outputs (%AQ): 265 bytes minimum
CPU Specifications - E05 Model
- Size: 4.95 inches x 5.04 inches (126 mm x 128 mm)
- Program Storage: System flash, battery-backed RAM
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Backplane Current Consumption:
- IC200CPUE05
- No serial port converter or EZ Program Store device: 160 milliamperes for a 5-volt output and 650 milliamperes for a 3.3-volt output.
- With a serial port converter or EZ Program Store device: 260 milliamperes for a 5-volt output and 650 milliamperes for a 3.3-volt output.
- IC200CPUE05
- Boolean Execution Speed: 0.5 ms/K (Typical)
- Relatime Clock Accuracy (for timer functions): 100ppm (0.01%) or +/- 9 seconds per day
- Time of Day Clock Accuracy: 23ppm (0.0023%) or +/- 2 seconds per day at 30 degrees Celsius, as well as 100 ppm (0.01%) or +/- 9 seconds per day at the full temperature range.
- Embedded Communications: This CPU has RS-232, RS-485, and an Ethernet Interface.
- Configurable Memory: 64K bytes maximum
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Ethernet Interface Specifications:
- Number of SRTP Server Connections: 8
- Ethernet Data Rate: 10 Mbps
- Physical Interface: 10BaseT RJ45
CPU Configurable Memory - E05 Model
- Configurable Memory: 64K bytes maximum
- Application Program Size (Not Configurable): 128 bytes minimum
- Hardware Configuration Size (Not Configurable): 528 bytes minimum
- Registers (%R): 256 bytes minimum
- Analog Inputs (%AI): 256 bytes minimum
- Analog Outputs (%AQ): 256 bytes minimum