Emerson PaCSystems VersaMax Series User manual

User Manual
GFK-1503F
Jan 2020
PACSystemsTM VersaMax
PLC USER MANUAL

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Contents
Chapter 1: Introduction ..........................................................1
1.1 The VersaMaxTM Family of Products...................................................................... 2
1.2 CPU Modules for VersaMax PLCs .......................................................................... 3
1.2.1 Basic CPU Features .................................................................................... 3
1.2.2 Available VersaMax CPUs........................................................................... 3
1.2.3 EZ Program Store ...................................................................................... 4
1.3 Power Supplies .................................................................................................... 5
1.3.1 Available Power Supplies and Carrier ......................................................... 5
1.4 I/O Modules......................................................................................................... 6
1.4.1 Available I/O Modules................................................................................ 6
1.5 Carriers................................................................................................................ 8
1.5.1 Available Carriers and Terminal Strips ........................................................ 9
1.6 Expansion Modules............................................................................................ 10
1.6.1 VersaMax Modules for Expansion Racks ................................................... 11
1.6.2 Available Expansion Modules................................................................... 11
1.7 Communications Modules................................................................................. 12
1.7.1 Available VersaMax PLC Communications Modules ................................. 12
1.7.2 Profibus-DP Network Slave Module ......................................................... 12
1.7.3 DeviceNet Network Control Module ........................................................ 13
1.7.4 Asi Network Master Module..................................................................... 13
1.7.5 Serial Communications Module............................................................... 13
Chapter 2: CPU Module Datasheets: CPU001, CPU002, CPU00514
2.1 Features ............................................................................................................ 15
2.2 Module Specifications........................................................................................ 15
2.3 VersaMax General Product Specifications .......................................................... 16
2.4 Serial Ports ........................................................................................................ 17
2.4.1 Serial Port Baud Rates.............................................................................. 18
2.5 Mode Switch ..................................................................................................... 18
2.6 CPU LEDs........................................................................................................... 19
2.7 Configurable Memory........................................................................................ 20
Chapter 3: CPU Module Datasheet: CPUE05 ..........................21
3.1 Features ............................................................................................................ 21

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3.2 Module Specifications ....................................................................................... 22
3.3 VersaMax General Product Specifications .......................................................... 23
3.4 Serial Ports ........................................................................................................ 24
3.4.1 Cable Lengths ......................................................................................... 25
3.4.2 Serial Port Baud Rates.............................................................................. 25
3.5 Ethernet LAN Port.............................................................................................. 26
3.6 Mode Switch ..................................................................................................... 26
3.7 CPU LEDs........................................................................................................... 27
3.8 Ethernet Restart Pushbutton ............................................................................. 28
3.9Ethernet LEDs .................................................................................................... 28
3.10 Configurable Memory........................................................................................ 29
3.11 Ethernet Interface Overview .............................................................................. 30
3.11.1SRTP Server ............................................................................................. 30
3.11.2Ethernet Global Data............................................................................... 30
3.11.3Station Manager Functionality................................................................. 30
Chapter 4: Installation ..........................................................31
4.1 Mounting Instructions ....................................................................................... 31
4.1.1 Removing the CPU from the DIN Rail ....................................................... 31
4.1.2 Panel-Mounting ...................................................................................... 32
4.2 Installing an Expansion Transmitter Module....................................................... 33
4.2.1 Removing an Expansion Transmitter Module ........................................... 33
4.3 Installing an Expansion Receiver Module............................................................ 34
4.3.1 Removing an Expansion Receiver Module ................................................ 34
4.3.2 Expansion Rack Power Sources ................................................................ 35
4.3.3 Connecting the Expansion Cable: RS-485 Differential .............................. 35
4.3.4 RS-485 Differential Inter-Rack Connection (IC200CBL601, 602, 615)....... 36
4.3.5 Building a Custom Expansion Cable ......................................................... 36
4.3.6 Connecting the Expansion Cable: Single-ended ....................................... 36
4.3.7 Single-Ended Inter-Rack Connection (IC200CBL600) ............................... 37
4.3.8 Power Sources for Single-Ended Expansion Rack Systems ........................ 37
4.4 Installing Power Supply Modules........................................................................ 37
4.4.1 Removing the Power Supply.................................................................... 38
4.5Installing Additional Modules............................................................................. 39
4.6 Activating or Replacing the Backup Battery........................................................ 40
4.6.1 Lithium Battery Replacement .................................................................. 40
4.7 Serial Port Connections...................................................................................... 41

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4.7.1 Providing Power to an External Device from Port 2................................... 41
4.7.2 Cable Lengths and Baud Rates ................................................................. 41
4.7.3 Port 1: RS-232 ......................................................................................... 41
4.7.4 Port 2: RS-485 ......................................................................................... 43
4.7.5 RS-485 Point to Point Connection with Handshaking ............................... 44
4.7.6 RS-485 Multidrop Serial Connections ...................................................... 45
4.8 Ethernet Connection for CPUE05 ....................................................................... 46
4.8.1 Network Connection ............................................................................... 46
4.9 CE Mark Installation Requirements .................................................................... 47
Chapter 5: Configuration ......................................................48
5.1 Using Autoconfiguration or Programmer Configuration .................................... 48
5.1.1 Autoconfiguration................................................................................... 48
5.1.2 Software Configuration ........................................................................... 48
5.2 Configuring “Racks” and “Slots” ........................................................................ 49
5.3 Software Configuration ..................................................................................... 51
5.3.1 Configuring CPU and Expansion Parameters ............................................ 51
5.3.2 Configurable Memory for CPU Module IC200CPU001, CPU002, CPU005 . 53
5.3.3 Configurable Memory for CPU Module IC200CPUE05 .............................. 53
5.3.4 Configuring Serial Port Parameters .......................................................... 54
5.3.5 RTU and Serial IO Delays.......................................................................... 55
5.3.6 Configuration Required to use Winloader ................................................ 56
5.3.7 Note for RTU Communications................................................................ 56
5.3.8 Storing a Configuration from a Programmer............................................ 56
5.4 Autoconfiguration ............................................................................................. 57
5.4.1 Autoconfiguration Assigns Reference Addresses ..................................... 58
5.4.2 Autoconfiguration Diagnostics................................................................ 58
5.4.3 Diagnostic Message Summary................................................................. 59
Chapter 6: Ethernet Configuration ........................................60
6.1 Ethernet Configuration Overview ...................................................................... 60
6.1.1 Autoconfiguration................................................................................... 61
6.2 Configuring the Ethernet Interface .................................................................... 61
6.3 Configuring Ethernet Global Data ...................................................................... 62
6.3.1 Before You Configure EGD Exchanges ..................................................... 62
6.4 Configuring a Global Data Exchange for a Producer ........................................... 63
6.5 Configuring a Global Data Exchange for a Consumer ......................................... 64

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6.5.1 Selective Consumption ........................................................................... 67
6.6 Configuring Advanced User Parameters............................................................. 67
6.6.1 Format of the Advanced User Parameters File.......................................... 67
6.6.2 Example Advanced User Parameter File ................................................... 68
6.6.3 Advanced User Parameter Definitions ..................................................... 68
Chapter 7: CPU Operation .....................................................70
7.1 Parts of the CPU Sweep...................................................................................... 71
7.2 Standard CPU Sweep Operation......................................................................... 73
7.2.1 The Sweep Windows ............................................................................... 74
7.2.2 The Watchdog Timer............................................................................... 74
7.2.3 Constant Sweep Time Operation............................................................. 74
7.3 CPU Stop Modes................................................................................................ 75
7.4 Flash Memory.................................................................................................... 75
7.5 Controlling the Execution of a Program ............................................................. 76
7.5.1 Calling a Subroutine Block ....................................................................... 76
7.5.2 Creating a Temporary End of Logic .......................................................... 76
7.5.3 Executing Rungs of Logic without Logical Power Flow.............................. 76
7.5.4 Jumping to Another Part of the Program.................................................. 76
7.6 Run/Stop Mode Switch Operation...................................................................... 77
7.6.1 Configurable Run/Stop Mode Operation.................................................. 77
7.6.2 Configurable Memory Protection ............................................................ 77
7.6.3 Summary of CPU Switch Run/Stop Operation .......................................... 77
7.7 Privilege Levels and Passwords........................................................................... 78
7.7.1 Protection Level Request from Programmer ............................................ 79
7.7.2 The OEM Protection Feature.................................................................... 79
Chapter 8: Elements of an Application Program ....................81
8.1 Structure of an Application Program.................................................................. 81
8.2 Subroutines....................................................................................................... 82
8.2.1 Declaring a Subroutine ............................................................................ 83
8.2.2 Calling a Subroutine ................................................................................ 83
8.3 Program Languages........................................................................................... 83
8.3.1 Sequential Function Chart ....................................................................... 83
8.3.2 Ladder Diagram ...................................................................................... 84
8.4 The Instruction Set ............................................................................................ 85
8.4.1 Contacts ................................................................................................. 85

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8.4.2 Coils........................................................................................................ 85
8.4.3 Timers and Counters ............................................................................... 86
8.4.4 Math Functions ....................................................................................... 86
8.4.5 Relational Functions ................................................................................ 87
8.4.6 Bit Operation Functions........................................................................... 87
8.4.7 Data Move Functions............................................................................... 88
8.4.8 Table Functions ....................................................................................... 88
8.4.9 Conversion Functions .............................................................................. 88
8.4.10Control Functions.................................................................................... 89
Chapter 9: Program Data ......................................................90
9.1 Data Memory References .................................................................................. 90
9.1.1 Word Memory References ....................................................................... 90
9.1.2 Bit Memory References ........................................................................... 91
9.1.3 Transition Bits and Override Bits .............................................................. 92
9.2 Retentiveness of Data........................................................................................ 92
9.3 System Status References.................................................................................. 93
9.3.1 Using the System Status References ........................................................ 93
9.3.2 %S References ......................................................................................... 94
9.3.3 %SA, %SB, and %SC References ................................................................ 95
9.4 How Program Functions Handle Numerical Data ............................................... 96
9.4.1 Real Numbers.......................................................................................... 98
9.4.2 Errors in Real Numbers and Operations.................................................... 98
9.5 Time-tick Contacts ............................................................................................ 98
Chapter 10: Instruction Set Reference...................................100
10.1 Bit Operation Functions ................................................................................... 101
10.1.1Data Lengths for the Bit Operation Functions ........................................ 101
10.1.2Bit Operation Functions Logical AND, Logical OR ................................... 101
10.1.3Bit Operation Functions Exclusive OR..................................................... 103
10.1.4Bit Operation Functions Exclusive OR..................................................... 104
10.1.5Bit Operation Functions Logical Invert (NOT) ......................................... 104
10.1.6Bit Operation Functions Shift Bits Right, Shift Bits Left ........................... 105
10.1.7Bit Operation Functions Rotate Bits Right,Rotate Bits Left...................... 107
10.1.8Bit Operation Functions Bit Test ............................................................ 108
10.1.9Bit Operation Functions Bit Set and Bit Clear.......................................... 109

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10.1.10 Bit Operation Functions Masked Compare ....................................... 110
10.1.11 Bit Operation Functions Bit Position................................................. 112
10.1.12 Bit Operation Functions Bit Sequencer............................................. 113
10.2 Control Functions ............................................................................................ 116
10.2.1Control Functions Do I/O ....................................................................... 116
10.2.2Control Functions Call ........................................................................... 118
10.2.3Control Functions End of Logic .............................................................. 119
10.2.4Control Functions Master Control Relay (MCR) / End MCR...................... 120
10.2.5Control Functions Jump, Label ............................................................... 121
10.2.6Control Functions Comment ................................................................. 122
10.2.7Control Functions Drum Sequencer....................................................... 122
10.3 Data Move Functions ....................................................................................... 125
10.3.1Data Move Functions Move Data ........................................................... 125
10.3.2Data Move Functions Block Move .......................................................... 128
10.3.3Data Move Functions Block Clear........................................................... 129
10.3.4Data Move Functions Shift Register ....................................................... 130
10.3.5Data Move Functions Communication Request ..................................... 132
10.4 Data Type Conversion Functions...................................................................... 134
10.4.1Data Type Conversion Functions Convert Signed Integer Data to BCD-4 134
10.4.2Data Type Conversion Functions Convert to Signed Integer................... 135
10.4.3Data Type Conversion Functions Convert to Double Precision Signed Integer 136
10.4.4Data Type Conversion Functions Convert to Real Data........................... 137
10.4.5Data Type Conversion Functions Convert Real Data to Word Data ......... 138
10.4.6Data Type Conversion Functions Truncate Real Number........................ 139
10.5 Math and Numerical Functions ........................................................................ 140
10.5.1Math and Numerical Functions Add, Subtract,Multiply, Divide............... 141
10.5.2Math and Numerical Functions Modulo Division .................................... 143
10.5.3Math and Numerical Functions Scaling .................................................. 145
10.5.4Math and Numerical Functions Square Root .......................................... 146
10.5.5Math and Numerical Functions Trigonometric Functions ....................... 147
10.5.6Math and Numerical Functions Logarithmic / Exponential Functions...... 149
10.5.7Math and Numerical Functions Radian Conversion Functions ................ 150
10.6 Relational Functions ........................................................................................ 151
10.6.1Relational Functions Equal, Not Equal, Less Than, Less/Equal, Greater Than,
Greater/Equal........................................................................................ 152
10.6.2Relational Functions Range ................................................................... 152

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10.7 Relay Functions ............................................................................................... 154
10.7.1Relay Functions Normally-open, Normally-closed, Continuation Contacts154
10.7.2Relay Functions Coils............................................................................. 155
10.8 Table Functions ............................................................................................... 159
10.8.1Table Functions Array Move................................................................... 159
10.8.2Table Functions Search for Array Values ................................................ 162
10.9 Timer and Counter Functions........................................................................... 164
10.9.1Timer and Counter Functions On Delay Stopwatch Timer ...................... 165
10.9.2Timer and Counter Functions On Delay Timer........................................ 168
10.9.3Timer and Counter Functions Off Delay Timer ....................................... 170
10.9.4Timer and Counter Functions Up Counter.............................................. 172
10.9.5Timer and Counter Functions Down Counter ......................................... 173
Chapter 11: The Service Request Function.............................176
11.1 SVCREQ Function Numbers ............................................................................. 176
11.2 Format of the SVCREQ Function....................................................................... 177
11.2.1Parameters of the SVCREQ Function...................................................... 178
11.2.2Example of the SVCREQ Function .......................................................... 178
11.3 SVCREQ 1: Change/Read Constant Sweep Timer ............................................. 178
11.3.1Input Parameter Block for SCVREQ 1 ..................................................... 178
11.4 SVCREQ 2: Read Window Times....................................................................... 180
11.4.1Output Parameter Block for SVCREQ 2 .................................................. 181
11.5 SVCREQ 3: Change Programmer Communications Window Mode ................... 181
11.5.1Changing the Programmer Communications Window Mode ................. 181
11.6 SVCREQ 4: Change System Communications Window Mode ........................... 182
11.6.1Changing the System Communications Window Mode ......................... 182
11.7 Change/Read Number of Words to Checksum ................................................. 183
11.7.1Parameter Block Formats for SVCREQ 6 ................................................. 183
11.8 SVCREQ 7: Read or Change the Time-of-Day Clock .......................................... 184
11.8.1Parameter Block Format for SVCREQ 7 .................................................. 184
11.8.2SVCREQ 7 Parameter Block Content: BCD Format.................................. 185
11.8.3SVCREQ 7 Parameter Block Content: Packed ASCII Format .................... 186
11.9 SVCREQ 8: Reset Watchdog Timer................................................................... 188
11.9.1Parameter Block Format for SVCREQ 8 .................................................. 188
11.9.2Example of SVCREQ 8 ............................................................................ 188
11.10 SVCREQ 9: Read Sweep Time from Beginning of Sweep .................................. 188
11.10.1 Output Parameter Block Format for SVCREQ 9................................. 188

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11.11 SVCREQ 10: Read Folder Name ........................................................................ 189
11.11.1 Output Parameter Block Format for SVCREQ 10............................... 189
11.11.2 Example of SVCREQ 10 .................................................................... 189
11.12 SVCREQ 11: Read PLC ID .................................................................................. 190
11.12.1 Output Parameter Block Format for SVCREQ 11............................... 190
11.12.2 Example of SVCREQ 11 .................................................................... 190
11.13 SVCREQ 13: Shut Down (Stop) PLC .................................................................. 191
11.13.1 Parameter Block for SVCREQ 13....................................................... 191
11.13.2 Example of SVCREQ 13 .................................................................... 191
11.14 SVCREQ 14: Clear Fault.................................................................................... 192
11.14.1 Input Parameter Block for SVCREQ 14.............................................. 192
11.14.2 Example of SVCREQ 14 .................................................................... 192
11.15 SVCREQ 15: Read Last-Logged Fault Table Entry .............................................. 193
11.15.1 Input Parameter Block for SVCREQ 15.............................................. 193
11.15.2 Long/Short Value ............................................................................ 194
11.15.3 Example of SVCREQ 15 .................................................................... 194
11.16 SVCREQ 16: Read Elapsed Time Clock .............................................................. 195
11.16.1 Output Parameter Block for SVCREQ 16........................................... 195
11.16.2 Example of SVCREQ 16 .................................................................... 195
11.17 SVCREQ 18: Read I/O Override Status .............................................................. 196
11.17.1 Output Parameter Block for SVCREQ 18........................................... 196
11.17.2 Example of SVCREQ 18 .................................................................... 196
11.18 SVCREQ 23: Read Master Checksum ................................................................ 197
11.18.1 Output Parameter Block for SVCREQ 23........................................... 197
11.18.2 Example of SVCREQ 23 .................................................................... 197
11.19 SVCREQ 24: Reset Ethernet Daughter Board .................................................... 198
11.20 SVCREQ 26/30: Interrogate I/O........................................................................ 199
11.20.1 Example of SVCREQ 26 .................................................................... 199
11.21 SVCREQ 29: Read Elapsed Power Down Time................................................... 199
11.21.1 Output Parameter Block for SVCREQ 29........................................... 199
11.21.2 Example of SVCREQ 29 .................................................................... 200
Chapter 12: Serial I/O / SNP / RTU Protocols........................... 201
12.1 Format of the Communication Request Function............................................. 201
12.1.1Parameters of the COMMREQ Function ................................................. 202
12.1.2Command Block for the COMMREQ Function ........................................ 203
12.1.3Example of the COMMREQ Function...................................................... 203

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12.2 Configuring Serial Ports Using the COMMREQ Function ................................... 204
12.2.1Timing .................................................................................................. 204
12.2.2Sending Another COMMREQ to the Same Port ...................................... 204
12.2.3Invalid Port Configuration Combinations ............................................... 205
12.2.412.2.4 RTU Slave/SNP Slave Operation With Programmer Attached ...... 205
12.2.5Example COMMREQ Command Block for Configuring SNP Protocol ...... 206
12.2.6Example COMMREQ Data Block for Configuring RTU Protocol ............... 207
12.2.7Example COMMREQ Data Block for Configuring Serial I/O Protocol........ 209
12.3 Calling Serial I/O COMMREQs from the PLC Sweep........................................... 210
12.3.1Compatibility ........................................................................................ 210
12.3.2Status Word for Serial I/O COMMREQs................................................... 210
12.4 Serial I/O COMMREQ Commands..................................................................... 212
12.4.1Overlapping COMMREQs....................................................................... 213
12.4.2COMMREQS that Must Complete Execution .......................................... 213
12.4.3COMMREQs that Can be Pending While Others Execute ........................ 213
12.4.4Initialize Port Function (4300) ............................................................... 213
12.4.5Set Up Input Buffer Function (4301) ...................................................... 214
12.4.6Flush Input Buffer Function (4302) ........................................................ 215
12.4.7Read Port Status Function (4303) .......................................................... 216
12.4.8Write Port Control Function (4304) ....................................................... 217
12.4.9Cancel Commreq Function (4399)......................................................... 218
12.4.10 Autodial Function (4400)................................................................. 219
12.4.11 Write Bytes Function (4401) ............................................................ 220
12.4.12 Read Bytes Function (4402)............................................................. 221
12.4.13 Read String Function (4403) ............................................................ 223
Chapter 13: Ethernet Communications .................................225
13.1 Overview of the Ethernet Interface .................................................................. 225
13.1.1Ethernet Global Data............................................................................. 226
13.1.2SRTP Server ........................................................................................... 226
13.1.3SRTP Channels ...................................................................................... 226
13.1.4Attachment to the Ethernet LAN ........................................................... 226
13.1.5The Station Manager Software .............................................................. 227
13.2 IP Addressing................................................................................................... 227
13.3 Routers ........................................................................................................... 228
13.4 Ethernet Global Data ....................................................................................... 229

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13.4.1The Frequency of Sending/Receiving an Exchange................................. 229
13.4.2The Consumer Update Timeout Period.................................................. 229
13.4.3Ethernet Global Data Groups ................................................................. 230
13.4.4Timestamping of Ethernet Global Data Exchanges................................. 231
13.4.5Configuring NTP for the CPUE05 Ethernet Interface............................... 232
13.4.6The Content of an Ethernet Global Data Exchange................................. 233
13.4.7Data Types for Ethernet Global Data...................................................... 233
13.4.8Effect of PLC Modes and Actions on Ethernet Global Data ...................... 234
13.4.9EGD Synchronization............................................................................. 234
13.5 Diagnostic Tools.............................................................................................. 236
13.5.1What to do if you Cannot Solve the Problem.......................................... 236
13.5.2Checking the Ethernet LEDs................................................................... 236
13.5.3Using the PLC Fault Table ...................................................................... 240
13.5.4Checking the Status of the Ethernet Interface........................................ 242
13.5.5Checking the Status of an Ethernet Global Data Exchange ..................... 243
13.5.6Using the Ethernet Station Manager Function........................................ 244
13.6 Troubleshooting Common Ethernet Difficulties............................................... 244
13.6.1PLC Timeout Errors................................................................................ 245
13.6.2Unexpected Ethernet Restart or Runtime Errors..................................... 245
13.6.3EGD Configuration Mismatch Errors ...................................................... 246
13.6.4Receive Resource Exhaustion Errors....................................................... 247
13.6.5Station Manager Lockout under Heavy Load .......................................... 247
13.6.6PING Restrictions .................................................................................. 247
13.6.7SRTP Connection Timeout..................................................................... 248
Chapter 14: PID Built-in Function Block................................. 249
14.1 Operands of the PID Function .......................................................................... 249
14.1.1Parameters of the PID Function Block .................................................... 250
14.2 Reference Array for the PID Function ............................................................... 250
14.2.1Scaling Input and Outputs ..................................................................... 251
14.2.2Reference Array Parameters .................................................................. 251
14.3 Operation of the PID Function ......................................................................... 260
14.3.1Automatic Operation ............................................................................ 260
14.3.2Manual Operation ................................................................................. 260
14.3.3Time Interval for the PID Function ......................................................... 261
14.4 PID Algorithm Selection (PIDISA or PIDIND) and Gain Calculations ................... 261

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14.4.1Error Term............................................................................................. 262
14.4.2Derivative Term..................................................................................... 263
14.4.3CV Bias Term ......................................................................................... 263
14.4.4CV Amplitude and Rate Limits ............................................................... 264
14.4.5Sample Period and PID Function Block Scheduling................................. 265
14.5 Determining the Process Characteristics.......................................................... 266
14.6 Setting Tuning Loop Gains............................................................................... 267
14.6.1Basic Iterative Tuning Approach ............................................................ 267
14.6.2Setting Loop Gains Using the Ziegler and Nichols Tuning Approach ....... 267
14.6.3Ideal Tuning Method ............................................................................. 268
14.6.4Example ................................................................................................ 268
Chapter 15: The EZ Program Store Device ............................. 271
15.1 Read/Write/Verify Data with a Programmer Present ........................................ 272
15.1.1Including All the Necessary Information ................................................ 273
15.1.2Matching OEM Protection ..................................................................... 273
15.1.3Adjusting the Configuration Timeouts................................................... 273
15.1.4Writing Data to RAM or Flash................................................................. 273
15.1.5Using the EZ Program Store Device with the Programmer ..................... 274
15.2 Update a PLC CPU without a Programmer Present ........................................... 275
15.2.1Error During Update .............................................................................. 278
Appendix A: Performance Data...............................................279
A-1 Base Sweep Time............................................................................................. 279
A-2 Boolean Instruction Time................................................................................. 279
A-3 Function Block Timing ..................................................................................... 279
A-3.1 Sweep Impact Times ............................................................................. 279
A-3.2 Sizes of Timers, Counters, Math Functions, Trig Functions, Log Functions280
A-3.3 Sizes of Exponential Functions, Radian Conversion, Relational Functions281
A-3.4 Sizes of Bit Operations, Data Move Functions ........................................ 282
A-3.5 Sizes of Table Functions......................................................................... 284
A-3.6 Sizes of Conversion and Control Functions............................................. 285
A-4 I/O Module Scan Times .................................................................................... 287
A-4.1 Reference to Discrete Module Types in the Scan Time Tables................. 287
A-4.2 Modules Located in Main PLC Rack ........................................................ 288
A-4.3 Modules Located in Single-ended Expansion Rack ................................. 289
A-4.4 Modules Located in Multiple Remote Expansion Rack ............................ 290

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A-4.5 Modules Located in Single-ended Isolated Expansion Rack .................... 291
A-5 Ethernet Global Data Sweep Impact ................................................................ 292
A-5.1 Exchange Overhead .............................................................................. 292
A-5.2 Byte Transfer Time ................................................................................ 292
A-6 Support for Large Ethernet Global Data Configurations.................................... 293

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Warnings, Caution Notes as Used in this Publication
Warning
Warning notices are used in this publication to emphasize that hazardous voltages,
currents, temperatures, or other conditions that could cause personal injury exist in
this equipment or may be associated with its use.
In situations where inattention could cause either personal injury or damage to
equipment, a Warning notice is used.
Caution
Caution notices are used where equipment might be damaged if care is not taken.
Notes: Notes merely call attention to information that is especially significant to understanding and operating the
equipment.
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 Emerson 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 Emerson 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 Emerson products referenced herein.
Emerson 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.
Emerson provides the following document and the information included therein as-is and without warranty of
any kind, expressed or implied, including but not limited to any implied statutory warranty of merchantability
or fitness for particular purpose.

User Manual Chapter 1
GFK-1503F Jan 2020
Introduction 1
Chapter 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: Chapter14:
•Instruction Timing: AppendixA:
Other VersaMax Manuals
VersaMax Modules, Power Supplies,
and Carriers User’s Manual (catalog
number GFK-1504)
Describes the many VersaMax I/O and option
modules, power supplies, and carriers. This
manual also provides detailed system installation
instructions.
VersaMax PLC Ethernet Station
Manager’s Manual (catalog number
GFK-1876)
Describes the diagnostic interface to the
Ethernet functions of CPU module
IC200CPUE05.
VersaMax Ethernet Network Interface
Unit User’s Manual (catalog number
GFK-1860)
Describes the installation and operation of the
Ethernet Network Interface Unit module.
VersaMax Genius NIU User’s Manual
(catalog number GFK-1535)
Describes the installation and operation of the
Genius NIU.

User Manual Chapter 1
GFK-1503F Jan 2020
Introduction 2
VersaMax DeviceNet Communications
Modules User’s Manual (catalog
number GFK-1533)
Describes the installation and operation of the
DeviceNet Network Interface Unit module and
the DeviceNet Network Slave Module.
VersaMax Profibus Communications
Modules User’s Manual (catalog
number GFK-1534)
Describes the installation and operation of the
Profibus Network Interface Unit module and the
Profibus Network Communications Module.
1.1 The VersaMaxTM Family of Products
The VersaMax family of products provides universally-distributed I/O that spans PLC and PC-
based architectures. Designed for industrial and commercial automation, VersaMax I/O
provides a common, flexible I/O structure for local and remote-control applications. The
VersaMax PLC provides big-PLC power with a full range of I/O and option modules. VersaMax
I/O Stations with Network Interface Modules make it possible to add the flexibility of
VersaMax I/O to other types of networks. VersaMax meets UL, CUL, CE, Class1 Zone 2 and
Class I Division 2 requirements.
As a scaleable automation solution, VersaMax I/O combines compactness and modularity
for greater ease of use. The 70-mm depth and small footprint of VersaMax I/O enables easy,
convenient mounting as well as space- saving benefits. Modules can accommodate up to 32
points of I/O each.
The compact, modular VersaMax products feature DIN-rail mounting with up to eight I/O
and option modules per “rack” and up to 8 racks per VersaMax PLC or VersaMax I/O Station
system. Expansion racks can be located up to
750 meters from the main VersaMax PLC or VersaMax I/O Station rack. Expansion racks can
include any VersaMax I/O, option, or communications module.
VersaMax provides automatic addressing that can eliminate traditional configuration and
the need for hand-held devices. Multiple field wiring termination options provide support
for two, three, and four-wire devices.
For faster equipment repair and shorter Mean-Time-To-Repair, the hot insertion feature
enables addition and replacement of I/O modules while a machine or process is running and
without affecting field wiring.
VersaMax I/O may be remotely located. Remote I/O interfaces for Genius, DeviceNet,
Profibus, and Ethernet are available.

User Manual Chapter 1
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Introduction 3
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.
Figure 1
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
IC200CPU00
1
CPU with Two Serial Ports, 42kB of Configurable Memory
IC200CPU00
2
CPU with Two Serial Ports, 128kB of Configurable Memory
IC200CPU00
5
CPU with Two Serial Ports and Embedded Ethernet
Interface, 128kB of Configurable Memory
IC200CPUE05

User Manual Chapter 1
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Introduction 4
Figure 2
1.2.3 EZ Program Store
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.
Figure 3

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Introduction 5
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. See the table below.
Figure 4
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’s
Manual (GFK-1504).

User Manual Chapter 1
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Introduction 6
1.4 I/O Modules
VersaMax IO 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.
Figure 5
VersaMax I/O modules are described in the VersaMax Modules, Power Supplies, and
Carriers User’s Manual (GFK-1504).
1.4.1 Available I/O Modules
The following types of VersaMax I/O Modules are available:
Discrete Input Modules
Input 120VAC 8 Point Grouped Module
IC200MDL140
Input 240VAC 8 Point Grouped Module
IC200MDL141
Input 120VAC 8 Point Isolated Module
IC200MDL143
Input 240VAC 4 Point Isolated Module
IC200MDL144
Input 120VAC (2 Groups of 8) 16 Point Module
IC200MDL240
Input 240VAC (2 Groups of 8) 16 Point Module
IC200MDL241
Input 120VAC 16 Point Isolated Module
IC200MDL243
Input 240VAC 8 Point Isolated Module
IC200MDL244
Input 125VDC Positive/Negative Logic Grouped 8 Point Module
IC200MDL631
Input 125VDC Positive/Negative Logic Grouped 16 Point Module
IC200MDL632
Input 48VDC Positive/Negative Logic Grouped 16 Point Module
IC200MDL635
Input 48VDC Positive/Negative Logic Grouped 32 Point Module
IC200MDL636
Input 24VDC Positive/Negative Logic (2 Groups of 8) 16 Point Module
IC200MDL640
Input 5/12VDC (TTL) Positive/Negative Logic 16 Point Module
IC200MDL643
Input 5/12VDC (TTL) Positive/Negative Logic Grouped 32 Point Module
IC200MDL644