GE VersaPoint IC220PBI002 User manual

Programmable Control Products
VersaPoint* I/O System
Profibus-DP NIU
User’s Manual, GFK-1911B
March 2010
GE
Intelligent Platforms

GFL-002
Warnings, Cautions, and 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.
Note: Notes merely call attention to information that is especially significant to
understanding and operating the equipment.
This document is based on information available at the time of its publication. While efforts
have been made to be accurate, the information contained herein does not purport to cover all
details or variations in hardware or software, nor to provide for every possible contingency in
connection with installation, operation, or maintenance. Features may be described herein
which are not present in all hardware and software systems. GE Intelligent Platforms assumes
no obligation of notice to holders of this document with respect to changes subsequently made.
GE Intelligent Platforms makes no representation or warranty, expressed, implied, or statutory
with respect to, and assumes no responsibility for the accuracy, completeness, sufficiency, or
usefulness of the information contained herein. No warranties of merchantability or fitness for
purpose shall apply.
* indicates a trademark of GE Intelligent Platforms, Inc. and/or its affiliates. All other
trademarks are the property of their respective owners.
©Copyright 2010 GE Intelligent Platforms, Inc.
All Rights Reserved

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Contents
GFK-1911B v
Chapter 1 Introduction ........................................................................................... 1-1
Features ............................................................................................................................ 1-2
Advantages ....................................................................................................................... 1-2
I/O Station Capacity.................................................................................................. 1-2
What’s In This Manual....................................................................................................... 1-3
Other Documents You’ll Need........................................................................................... 1-4
Example Plant ...................................................................................................................1-5
Chapter 2 The Profibus NIU.................................................................................... 2-1
The Profibus System......................................................................................................... 2-2
Typical Profibus-DP VersaPoint I/O Station............................................................. 2-2
Structure of a VersaPoint I/O Station ....................................................................... 2-3
The Profibus-DP Network Interface Unit........................................................................... 2-4
Features ................................................................................................................... 2-4
Comparison of Features ........................................................................................... 2-5
Items Used with the NIU........................................................................................... 2-6
Ordering Information................................................................................................. 2-6
Connectors on the NIU...................................................................................................... 2-7
Profibus Connector................................................................................................... 2-7
Power Connector...................................................................................................... 2-8
NIU Power ................................................................................................................ 2-8
DIP Switches on the NIU................................................................................................... 2-9
LEDS on the NIU............................................................................................................. 2-10
DPV1 Communications for Profibus NIU
IC220PBI002................................................................................................................... 2-11
NIU Specifications ........................................................................................................... 2-12
Chapter 3 VersaPoint Modules............................................................................... 3-1
Modules in a VersaPoint Station....................................................................................... 3-2
Input/Output Modules ............................................................................................... 3-3
Terminal Points......................................................................................................... 3-3
Power Losses for I/O Modules ................................................................................. 3-4
Analog Modules........................................................................................................ 3-5
Power Terminal Modules.......................................................................................... 3-6
Segment Terminal Modules ..................................................................................... 3-7
Parts of a VersaPoint Module ........................................................................................... 3-8
The Electronics Base ........................................................................................................ 3-9
Diagnostic and Status Indicators............................................................................ 3-10
Module Color Coding.............................................................................................. 3-10
Status LEDs and I/O Points.................................................................................... 3-11

Contents
viVersaPoint™ I/O System Profibus-DP NIU User’s Manual– August 2005 GFK-1911B
Connectors ............................................................................................................. 3-12
Module Dimensions......................................................................................................... 3-14
Chapter 4 Installation.............................................................................................. 4-1
Parts of a VersaPoint I/O Station ...................................................................................... 4-2
End Plate .................................................................................................................. 4-2
End Clamps .............................................................................................................. 4-2
Planning Module Sequence in the I/O
Station ............................................................................................................................... 4-3
Locations for Analog Modules .................................................................................. 4-3
Power for the Station......................................................................................................... 4-4
Electrical isolation..................................................................................................... 4-5
Dangerous voltage! .................................................................................................. 4-5
Setting the NIU Switches .................................................................................................. 4-6
Keying Connectors and Modules ...................................................................................... 4-7
Installing Modules on the DIN Rail.................................................................................... 4-8
Removing Modules................................................................................................... 4-9
Replacing a Module.................................................................................................. 4-9
Connecting Unshielded Cables....................................................................................... 4-10
Connecting Shielded Cables........................................................................................... 4-11
Connecting Shielded Cables to the Shielded Terminal Strip ................................. 4-11
Repositioning the Shield Clamp ............................................................................. 4-12
Grounding........................................................................................................................ 4-13
Grounding the NIU and Power Modules................................................................. 4-13
Required Additional Grounding .............................................................................. 4-13
Installing the Profibus Cable ........................................................................................... 4-14
Profibus Cable Specifications................................................................................. 4-14
The Profibus Cable Connector ............................................................................... 4-15
Shielding the Profibus Cable .................................................................................. 4-15
Bus Termination ..................................................................................................... 4-16
Connecting Power at the NIU.......................................................................................... 4-17
Providing the 24V Segment Supply (US ) at the NIU ............................................. 4-17
Fusing for Short Circuit Protection ......................................................................... 4-17
Replacing Power and Segment Terminal
Fuses............................................................................................................................... 4-18
Connecting Sensors and Actuators................................................................................. 4-19
Connecting Discrete Devices ................................................................................. 4-19
Connections for Discrete Input Modules ................................................................ 4-19
Connections for Discrete Output Modules.............................................................. 4-19
Connecting 2-Wire Discrete Sensors and Actuators.............................................. 4-20
Connecting 3-Wire Discrete Sensors and Actuators.............................................. 4-20
Connecting 4-Wire Discrete Sensors and Actuators.............................................. 4-21

Contents
GFK-1911B Contents vii
Connecting Analog Devices ................................................................................... 4-22
Connecting Field Devices to an Analog Input Module ........................................... 4-22
Connecting a Thermocouple Analog Input Module ................................................ 4-22
Connecting Field Devices to an Analog Output Module......................................... 4-23
Danger of creating ground loops! ........................................................................... 4-23
Connection of actuators for Signal Cables Longer than 10 Meters (32.8
Ft) ........................................................................................................................... 4-23
Module Labeling.............................................................................................................. 4-24
Chapter 5 Power for the Station............................................................................. 5-1
Supply of the Profibus-DP Network
Interface Unit..................................................................................................................... 5-2
The Logic Circuit: UL................................................................................................. 5-3
The Analog Circuit: UANA........................................................................................... 5-3
The Main Circuit: UM................................................................................................. 5-4
Segment Circuit: US.................................................................................................. 5-5
Electrical Isolation ............................................................................................................. 5-8
Electrical Isolation: Profibus ..................................................................................... 5-8
Electrical Isolation: I/O.............................................................................................. 5-8
Electrical Isolation: Discrete Modules....................................................................... 5-9
Electrical isolation: Analog module......................................................................... 5-10
Electrical isolation: Other........................................................................................ 5-11
VersaPoint Power Consumption Example ...................................................................... 5-12
Chapter 6 Diagnostics ............................................................................................ 6-1
Local Diagnostics .............................................................................................................. 6-2
LEDS on the Network Interface Unit ........................................................................ 6-2
Possible LED combinations...................................................................................... 6-3
Determining the Error Cause and Remedy from the NIU LEDs............................... 6-4
Power and Segment Module LEDs ........................................................................ 6-10
I/O Module LEDs .................................................................................................... 6-11
Local Diagnostics Example .................................................................................... 6-12
Example Station for Error Identification.................................................................. 6-12
Diagnostics on the Profibus Master ................................................................................ 6-14
Profibus Standard Diagnostics ............................................................................... 6-14
Profibus – Device-Specific Diagnostics (For NIU Model IC670PBI002) ................ 6-17
Profibus – Device-Specific Diagnostics (For NIU Model IC670PBI001) ................ 6-18
Module Diagnostics, NIU Model IC670PBI002 ...................................................... 6-19
Chapter 7 Configuration ......................................................................................... 7-1
Powerup Autoconfiguration of the NIU.............................................................................. 7-2
Configuration of the Profibus Master ................................................................................ 7-3
The GSD File............................................................................................................ 7-3

Contents
viii VersaPoint™ I/O System Profibus-DP NIU User’s Manual– August 2005 GFK-1911B
Configuring the Profibus Master............................................................................... 7-3
Configuring Profibus Parameters for the Profibus Master CPU ............................... 7-5
Network Settings for the Profibus Master................................................................. 7-6
Adding the Profibus NIU to the
IC693CPU366 Master Configuration ................................................................................ 7-8
Configuring the Modules in the I/O Station ....................................................................... 7-9
Configuring Module Data Areas ............................................................................. 7-10
Byte Rotation for 16-Point Discrete Modules ......................................................... 7-12
Byte Rotation for 32-Point Discrete Modules ......................................................... 7-12
Configuring DP-V1 Settings for the Profibus NIU................................................... 7-13
Dynamic Configuration.................................................................................................... 7-16
Indexes ................................................................................................................... 7-16
Index 6: Activation/deactivation of terminals and slots Access: Read and write ................ 7-16
Index 7: Read back active/inactive terminals and slots .................................................. 7-17
Index 8: Read/write ID Access: Read and write ............................................................ 7-17
Accessing the Indexes via Process Data ............................................................... 7-17
Specify an ID .......................................................................................................... 7-20
Chapter 8 Communications.................................................................................... 8-1
Types of Acyclic Communication ...................................................................................... 8-2
Acyclic Communication Via the Class 1 Master ....................................................... 8-2
Acyclic Communication Via the Class 2 Master ....................................................... 8-2
PCP Communication Basics ............................................................................................. 8-3
Device Parameter Data ............................................................................................ 8-3
Acyclic Communication in DP/V1 Mode............................................................................ 8-4
Accessing NIU Data ................................................................................................. 8-5
Accessing Module Data............................................................................................ 8-5
DP/V1 Examples ...................................................................................................... 8-9
PCP Communication Via Process Data
(Class1 Master in DP/V0 Mode)...................................................................................... 8-17
Mechanism for Transmission in the Process Data................................................. 8-17
Process Data Width of the Virtual C1 “Module” ..................................................... 8-17
Responses.............................................................................................................. 8-21
Examples of Communications using a Virtual C1 Module ..................................... 8-22
Format of the Parameter Telegram................................................................................. 8-29
NIU Parameters...................................................................................................... 8-29
Module Parameters ................................................................................................ 8-30
Object Dictionary for the Profibus-DP/V1 NIU........................................................ 8-31
Error Codes for DP/V1 and VC1
Communication ............................................................................................................... 8-35
Error Codes for PCP Communication .................................................................... 8-36
Other Error Messages ............................................................................................ 8-36

Contents
GFK-1911B Contents ix
Appendix A Reference Data.......................................................................................A-1
I/O Station Information ......................................................................................................A-2
Ambient Conditions ...........................................................................................................A-3
Mechanical Demands........................................................................................................A-4
Noise Immunity Test .........................................................................................................A-4
Electrical Specifications ....................................................................................................A-5
Cables ...............................................................................................................................A-7
I/O Modules .......................................................................................................................A-7
Air and Creepage Distances .............................................................................................A-8
Test Voltages ....................................................................................................................A-9
Appendix B Glossary .................................................................................................B-1
Appendix C Output Module Derating ........................................................................C-1
Power Loss of the Housing Within the
Operating Temperature Range Depending
on the Ambient Temperature ............................................................................................C-2
Power Loss of the Housing ...............................................................................................C-3
Permissible Operating Temperature Range .....................................................................C-4
Appendix D The NIU GSD File ...................................................................................D-1
GSD File for NIU Version IC220PBI002 ...........................................................................D-2
GSD File for NIU Version IC220PBI001 .........................................................................D-21

Contents
xVersaPoint™ I/O System Profibus-DP NIU User’s Manual– August 2005 GFK-1911B

GFK-1911B 1-1
Introduction
The VersaPoint product family is a modular automation system. With
VersaPoint modules you can easily add one module to the next and build
functional units that meet your automation requirements exactly.
A set of interconnected VersaPoint I/O modules can be selected to suit the
application, and connected as a slave on a Profibus-DP network. The
interface between the network and the modules is a VersaPoint Profibus-DP
Network Interface Unit (NIU).
The NIU is located to the left of the other modules. Together, the NIU and
the modules selected for the application function as an I/O Station. The I/O
Station can include up to 63 I/O modules.
Within the VersaPoint station the bus connection, power supply, and power
distribution for the devices connected to the bus terminal are realized by
connecting modules together on the DIN rail.
Sensors and actuators are easily wired to the VersaPoint I/O modules via
spring-clamp terminals on the modules' removable connectors. These
connectors can be keyed so that they cannot be mixed up. If a module must
be exchanged the wiring does not need to be removed. Just remove the
connector from the terminal.
Chapter
1

1-2 VersaPoint™ I/O System Profibus-DP NIU User’s Manual – August 2005 GFK-1911B
1
Features
Characteristic VersaPoint features are:
– Modules can be easily installed/interconnected without tools.
– Automatic creation of isolated groups, current, data, and safety circuits
– Open, flexible, and modular structure
– Modules of varying point counts can be combined to create a
VersaPoint station that optimizes unit space while minimizing unit cost.
Advantages
VersaPoint design offers the following advantages:
– Reduced control cabinet space.
– The amount of costly parallel wiring is reduced. Within a station, voltage
and data routing can be carried out without additional wiring.
– The modular structure makes it possible to assemble standard function
blocks in advance. Different parts of the system can be operated
independently of one another. This means that pretests can be carried
out when the system is set up and that the whole system can be
adapted and expanded.
I/O Station Capacity
– Up to 63 devices can be connected to an NIU (Depending on power
consumption. See chapter 5).
– The sum of all input and output data can be up to 184 bytes per station.

GFK-1911B Chapter 1 Introduction 1-3
1
What’s In This Manual
This manual contains the instructions and reference information needed to
plan and install a VersaPoint I/O Station on a Profibus-DP network.
Chapter 1 is a quick introduction to VersaPoint.
Chapter 2. The Profibus NIU, describes the Profibus Network Interface
Unit module, which connects the VersaPoint I/O Station to the Profibus
network.
Chapter 3. VersaPoint Modules, describes the parts and dimensions of
VersaPoint I/O and power modules.
Chapter 4. Installation, describes basic VersaPoint module installation
and cable connections.
Chapter 5 Power for the Station, explains how power is utilized by the
station and routed among the modules.
Chapter 6. Diagnostics, describes in detail the indications of the NIU and
module LEDs, as well as additional diagnostics features of the VersaPoint
station.
Chapter 7. Configuration, describes the configuration options of the
VersaPoint Profibus NIU.
Chapter 8. Communications, describes the data structures used for
communications with the Profibus NIU.
Appendix A. Reference Data, summarizes the standard data for a
VersaPoint Profibus I/O system..
Appendix B. Glossary explains many of the terms used in this manual.
Appendix C. Output Module Derating, describes how to calculate power
loss and operating temperature limits for I/O modules.

1-4 VersaPoint™ I/O System Profibus-DP NIU User’s Manual – August 2005 GFK-1911B
1
Other Documents You’ll Need
These documents are available online at http://www.ge-ip.com/, and on the
Infolink for PLC document library on CDs (catalog number IC690CDR002).
Check the GE website for the most up-to-date document versions
and other important product information.
Module Number Module Description Document Number
Discrete Input Modules
IC220MDL641 Input 24VDC Positive Logic 2 Points GFK-1901
IC220MDL642 Input 24VDC Positive Logic 4 Points GFK-1902
IC220MDL643 Input 24VDC Positive Logic 8 Points GFK-2000
IC220MDL644 Input 24VDC Positive Logic 16 Points GFK-2001
IC220MDL661 Input 24VDC Negative Logic 2 Points GFK-2002
Discrete Output Modules
IC220MDL721 Output 24VDC Positive Logic 2.0A 2 Points GFK-1903
IC220MDL751 Output 24VDC Positive Logic 0.5A 2 Ppoints GFK-2003
IC220MDL752 Output 24VDC Positive Logic 0.5A 4 Points GFK-1904
IC220MDL753 Output 24VDC Positive Logic 0.5A 8 Points GFK-2004
IC220MDL754 Output 24VDC Positive Logic 0.5A 16 Points GFK-1913
IC220MDL761 Output 24VDC Positive Logic 0.5A 2 Points GFK-2005
Special Function Modules
IC220BEM232 RS-232 Communications Module GFK-2394
IC220BEM485 RS-485/422 Communications Module GFK-2395
IC220MDD840 High-speed Counter 1 In/1 Out 24VDC GFK-2052
IC220MDD841 Absolute Encoder Module
IC220MDD842 Incremental Encoder Module GFK-2125
IC220STR001 Motor Starter Direct, 1.5KW/400VAC
IC220STR002 Motor Starter Direct, 3.7KW/400VAC
IC220STR003 Motor Starter Reversing
GFK-2134
Analog Input Modules
IC220ALG220 Analog In 15 Bit Voltage/Current 2 Channels GFK-1906
IC220ALG620 Analog In 16 Bit RTD 2 Channels GFK-2013
IC220ALG630 Analog In 16 Bit Thermocouple 2 Channels GFK-2012
Analog Output Modules
IC220ALG320 Analog Out 16 Bit Voltage/Current 1 Channel GFK-1907
IC220ALG321 Analog Out 13 Bit Voltage 1 Channel GFK-1908
IC220ALG322 Analog Out 13 Bit Voltage 2 Channels GFK-2011
Power and Segment Terminals
IC220PWR001 Power Terminal 24VDC GFK-1909
IC220PWR002 Power Terminal Fused 24VDC GFK-2006
IC220PWR003 Power Terminal Fused with Diag. 24VDC GFK-2007
IC220PWR011 Segment Terminal 24VDC GFK-1910
IC220PWR012 Segment Terminal Fused 24VDC GFK-2008
IC220PWR013 Segment Terminal Fused W/Diag 24vdc GFK-2009
IC220PWR014 Segment Terminal Elec Fused 24vdc GFK-2010

GFK-1911B Chapter 1 Introduction 1-5
1
Example Plant
The following example provides an illustration of how the VersaPoint I/O
System may be applied. This example highlights the distributed nature of
the VersaPoint product line as well as its ability to fit a variety of difficult
applications within a single system.

1-6 VersaPoint™ I/O System Profibus-DP NIU User’s Manual – August 2005 GFK-1911B
1
Key:
A Plant control
B Material removal area 1
C Press
D Punching device
E Material removal area 2
F Welding robot
G Material area 3
1, 3, 5, 6, 9, 10, 12 VersaPoint™ stations
2, 4, 7, 8,13 Motor starter
11 Robot controller
Emergency stop switch
This example is a schematic diagram of a plant which is controlled by a host
computer.
VersaPoint station 1 modules control the removal of material from area 1.
The motor starter (2) is directly connected to the remote bus. This controls a
conveyor belt motor.
VersaPoint station 3 controls the press. As this machine must be
particularly well protected, an emergency stop switch has been integrated.
VersaPoint station 5 controls the punching device. Station 6 is connected to
station 5, and its modules monitor the status of the press. An emergency
stop switch has also been provided here.
Two motor starters are connected at points (7) and (8). They control
conveyor belt motors.
VersaPoint station 9 controls the removal of material from area 2.
A robot control system (11) is connected to the communications bus using
VersaPoint station 10. An emergency stop switch has also been connected
here.
VersaPoint station 12 controls the storage of material in area 3.
Motor starter 13 is directly connected to the remote bus and controls the
conveyor belt motor.

GFK-1911B 2-1
The Profibus NIU
This section describes the Profibus Network Interface Unit module IC220PBI002.
▪The Profibus System
▪Typical Profibus-DP VersaPoint I/O Station
▪Structure of a VersaPoint I/O Station
▪The Profibus-DP Network Interface Unit
▪Features
▪Items Used with the NIU
▪Ordering Information
▪Connectors on the NIU
▪Profibus Connector
▪Power Connector
▪DIP Switches on the NIU
▪LEDs on the NIU
▪Diagnostics
▪NIU Specifications
Chapter
2

2-2 VersaPoint™ I/O System Profibus-DP NIU User’s Manual – August 2005 GFK-1911B
2
The Profibus System
Profibus is a serial bus system for data transmission between control systems and
distributed input and output modules, to which sensors and actuators are
connected.
Profibus has a star tree structure. In the Profibus topology the single bus devices
can be differentiated by means of their addressing. The communication profiles
determine how the devices transmit their data via the bus.
Profibus DP is normally a single master system. It is designed for easy
transmission of input and output data and specifically designed for communication
between automation systems and the distributed I/O devices.
Typical Profibus-DP VersaPoint I/O Station
A set of interconnected VersaPoint I/O modules can be selected to suit the
application, and connected as a slave on a Profibus-DP network. The interface
between the network and the modules is a VersaPoint Profibus-DP Network
Interface Unit (NIU) module.
The intelligent wiring method used in the VersaPoint modules allows I/O stations
to be constructed easily and quickly. Normally, it is only necessary for the power
supply units integrated in the Profibus NIU to be supplied with 24VDC on the input
side. They generate the operating voltage required for the NIU itself and for the
connected VersaPoint I/O modules.

GFK-1911B Chapter 2 The Profibus NIU 2-3
2
Structure of a VersaPoint I/O Station
A VersaPoint station with a Profibus NIU consists of:
– (1) End clamps (part number IC220ACC313, supplied with the NIU)
– (2) Profibus-DP Network Interface Unit
– (3) Modules appropriate to the application
– (4) End plate (supplied with the NIU)

2-4 VersaPoint™ I/O System Profibus-DP NIU User’s Manual – August 2005 GFK-1911B
2
The Profibus-DP Network Interface Unit
The VersaPoint ™ Profibus-DP Network Interface Unit (NIU), IC220PBI002, is the
link between Profibus-DP and the VersaPoint station. This module is an enhanced
version of the earlier Profibus-DP Network Interface Unit module IC220PBI001,
which it replaces. Differences between the two versions are explained below.
Features
The Profibus-DP Network Interface Unit has the following properties:
– A maximum of 63 VersaPoint I/O modules can be connected to Profibus DP
by simply plugging them in side by side next to the NIU. The NIU and the
VersaPoint modules create a station. Check chapter 5 to verify power
consumption.
– The sum of all input and output data can be up to 176 bytes per station for
module IC220PBI002 with its DIP switch 8 in the ON position. The maximum
is 184 bytes per station with DIP switch 8 in the OFF position. The maximum
for module IC220PBI001is 184 bytes.
– The NIU can be used at a baud rate of 9.6 kbps for Profibus DP with a
maximum total expansion of 1200m (3937ft) or at baud rate of 12mbps with a
maximum of 100m (328 ft). The NIU automatically adjusts to the speed
specified by the Profibus master.
– Model IC220PBI002 also provides:
– DP/V1for Class 1and Class 2 masters.
– Acyclic communications with modules such as RS-232 modules in the
process data channel.
– Fail-safe values
– Acknowledgement of I/O errors from the user program.
– Adaptation of the high byte/low byte format in 16-channel input and output
modules.