GE VersaMax PLC User manual

GE
Intelligent Platforms
GFK-1503E
VersaMax* PLC
User Manual
September 2015
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
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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
Copyright © 2001 - 2015 General Electric Company, All rights reserved.
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All other trademarks are the property of their respective owners.
Refer to the section, Contact Information for support on this product.
Please send documentation comments or suggestions to [e-mail]
For public disclosure

Document Updates
Location Description
Throughout the document Edits to support release of IC200CPUE05-JL.
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GFK-1503E User Manual 3
For public disclosure

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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damage to or destruction of equipment.
Attention
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these applications.
For public disclosure

Contact Information
If you purchased this product through an Authorized Channel Partner, then contact the seller directly.
General Contact Information
Online technical support and GlobalCare http://support.ge-ip.com
Additional information http://www.ge-ip.com/
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Technical Support
If you have technical problems that cannot be resolved with the information in this manual, please contact us by
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[email protected] (remaining Asia customers)
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[email protected] (China)
6 GFK-1503E VersaMax PLC User Manual
For public disclosure

Contents
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
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Notes
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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
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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.
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.
VersaMax PLC CPU
power supply VersaMax Modules
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
RS2
32
PORT 1
CPU001
PORT 2
FORCE
PORT 1
FAULT
RUN
PWR
OK
RS485
PORT 2
RS232
PORT 1
CPU005
FAULT
RUN
PWR
OK
PORT 2
FORCE
PORT 1
CPU001
CPU002 CPU005
Status LEDs
Serial Ports
RS485
PORT 2
RS232
PORT 1
CPUE05
FAULT
RUN
PWR
OK
PORT 2
FORCE
PORT 1
PORT 1
LAN
STAT
ETHERNET
10 BASE T /
100 BASE TX
ETHERNET
RESTART
CPUE05
Ethernet Interface
Introduction GFK-1503E User Manual 19
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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.
PLC
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.
IC200PWR001
VDC
+
INPUT
-
24 VDC
POWER SUPPLY
NOT
USED
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