VersaMax Genius NIU IC200GBI001-GL, GFK-1551Q
Contents
1. IC697BEM713 standard width Version BZ or higher is required Mgr firmware release 6 0 Comm firmware release 4 8 GMR Software IC641SWP745 version C or higher is required GMR System Software version 4 05 GMR Configurator version 8 06 The safety certified versions of the VersaMax power supply and I O carriers must be used See the TUV website for specifics http Awww tuv fs com To assure that the host PLC will display the correct reference addresses for Loss and Addition of I O Faults reported by the Genius NIU the host controller must be one of the following IC697CPM790 firmware version 6 04 or higher Other Series 90 70 controllers Future PACSystems RX7i controllers Firmware version 5 50 or higher To use Enhanced Diagnostics mode in any GMR System version 4 05 of the GMR System Software is required Do not enable Enhanced Diagnostics Mode on a Genius NIU that is part of a GMR system that is using GMR System Software version 4 04 or earlier To use the GMR CPU Redundancy mode in any GMR system version 4 05 of the GMR System Software is required Do not set the CPU Redundancy parameter to GMR on a Genius NIU that is part of a system that is using GMR System Software version 4 04 or earlier VersaMax analog input modules IC200ALG240 IC200ALG620 and IC200ALG630 installed in Genius I O stations must be upgraded to firmware version 1 20 or later Previous versions of analog input module firmware may pr2. Connector Cover Connector Cover With power off install additional modules by mounting modules on their carriers and sliding them along the DIN rail to fully engage the connectors in the sides of the carriers Power up the NIU The modules in the I O station will GFK 1551Q General Module Installation Instructions A Modules may be mounted on a al horizontal or vertical DIN rail When mounted on a vertical DIN rail the NIU must be located at the bottom 1 Allow sufficient finger clearance for opening NIU door Allow adequate clearance for serial port cables 3 Allow adequate space for power 2 wiring The NIU with power supply attached fits into a 70mm deep enclosure Rated thermal specifications are based on a clearance of 5 1cm 2in above and below the equipment and 2 54cm 1in to the left of the NIU module 133 35mm 2 5 25in 85 85mm 3 38in ENAT Installation in Hazardous Locations e This equipment is suitable for use in CLASS DIVISION 2 GROUPS A B C D or non hazardous locations only WARNING EXPLOSION HAZARD substitution of components may impair suitability for CLASS DIVISION 2 WARNING EXPLOSION HAZARD when in hazardous locations turn off power before replacing or wiring modules and WARNING EXPLOSION HAZARD Do not connect or disconnect equipm
3. GBI001 DF January 2004 Component change IC200GBI001 EF April 2004 Changed to VO plastic for module housing IC200GBI001 CF January 2004 ATEX approval for Group 2 Category 3 applications IC200GBI001 BF June 2002 Firmware version 2 20 Added support for High Density Analog Modules IC200GBI001 BD May 2001 Hardware change IC200GBI001 AD September 2000 Firmware version 2 00 Added support for Remote I O Configuration IC200GBI001 AC May 2000 Firmware version 1 50 Added support for expansion racks IC200GBI001 AB March 1999 Firmware version 1 10 Added support for intelligent modules December 1998 Initial product release IC200GBI001 BE June 2001 Firmware version 2 10 IC200GBI001 AA GFK 1551Q Problems Resolved for Release 3 20 IC200GBI001 modules with firmware version 3 10 or earlier versions may report unexpected and highly intermittent Loss of I O Module faults for the VersaMax analog input modules IC200ALG240 IC200ALG620 and IC200ALG630 the analog output module I C200ALG331 the Mixed Discrete High Speed Counter Module IC200MDD841 and the Serial Communications module IC200CMM020 These faults never occur for most users This issue has been corrected in C200GBI001 firmware version 3 20 VersaMax analog input modules IC200ALG240 IC200ALG620 and IC200ALG630 installed in a Genius I O station with NIU firmware version 3 20 must be upgraded to firmware version 1 20 or later Previous versions of analog input mod
4. Max Genius Network Interface Unit May 8 2009 Operating Notes Restrictions Enhanced Diagnostics Mode When used in the safety relevant portion of a GMR system the GNIU s Enhanced Diagnostics Mode must be enabled Select whether to enable or disable Enhanced Diagnostics Mode via a hardware configuration option for the GNIU The default is disabled When Enhanced Diagnostics Mode is enabled the following requirements must be met Note More information about Enhanced Diagnostics Mode is available in the Genius NIU User s Manual System Requirements The only modules allowed in the rack are the Power Supply the GNIU and up to four total ALG265 ALG266 modules any combination of ALG265 and ALG266 modules is allowed All of the analog modules must be located in the main rack Expansion racks are not allowed Empty IO carriers are not allowed Configuration Requirements 1 The GNIU s Report Faults parameter must be set to Enabled In addition the Report Faults parameter on every analog module must be set to Enabled The GNIU s CPU Redundancy parameter must be set to GMR The GNIU s BSM Present and BSM Controller parameters must be set to No 4 For each module except the last one analog input channel becomes unusable These unused channels still count towards the number of AI channels that the GNIU will send to the Genius Bus Controller Operating Requirements 1 Avoid situations where all of th
5. VersaMax Genius Network Interface Unit May 8 2009 The Genius Network Interface Unit acts as controller for a set of I O modules Power for module operation is provided by a power supply that installs directly on the NIU NIU power supply Specifications 8 per rack up to eight racks Network inputs per bus scan 128 bytes Network outputs per bus scan 128 bytes Discrete Input Memory 1024 points Discrete Output Memory 1024 points Analog Input Memory 128 bytes Analog Output Memory 128 bytes Power Consumption 5V 250mA 3 3V 10mA Serial Bus Address 0 to 31 153 6 Kbaud extended 153 6 Kbaud standard 76 8 Kbaud or 38 4 Kbaud Number of modules Network data rate Product Description Revision Letters Revision tets pe SSCS 44A748000 G10 Firmware upgrades Compatibility Any type of PLC or computer capable of controlling the bus can be used as the host This Network Interface Unit is compatible with 1 When a Genius NIU all versions is on a Genius bus controlled by a Series 90 70 or PACSystems RX7i the Series 90 70 Genius Bus Controller must have firmware version 5 4 or greater Upgrading the 90 70 Genius Bus Controller firmware to version 6 0 or higher is strongly recommended When a Genius NIU all versions that has one or more expansion racks is on a Genius bus cont
6. are configuration is NOT available Connect the Windows PC running the programming software to the Genius NIU using a VersaMax NIU serial cable IC200CBL002 Create a new project for a GE Fanuc PLC Within the new project create a new Genius NIU target Upload the hardware configuration from the Genius NIU to the target Under the NIU target right click on Hardware Configuration and select Hardware Reference View For each I O data tab l etc use the largest address in the End column as the data size for that I O data type If there are no entries for a data type the data length for that type is zero If the GNIU attempts to come online with a configuration that has I O types and lengths that do not match those expected by the controller a System Configuration Mismatch fault for the GNIU will appear in the controller s PLC fault table This fault is generated by the controller itself Additional faults present in the GNIU do not appear until the mismatch in I O types and lengths is corrected When the host controller is in STOP mode and the GNIU is configured for dual bus operation a power cycle to the GNIU switches the bus from BUS A to BUS B immediately The GNIU does not switch back from BUS B to BUS A even if the host controller goes to RUN mode Documentation Update In the VersaMax I O Modules and Carriers Manual GFK 1504K The note on page 2 38 should have the addition Carriers cannot be plugged tog
7. ates diagnostics executed successfully Is ON if there are one or more faults This bicolor LED is green if the I O scan is enabled and data is being received from the bus Otherwise this LED is amber Is ON if one of more I O points is forced Is ON if a duplicate device SBA or invalid SBA exists Is ON if bus B is active Removing the NIU from the DIN Rail 1 Turn off power to the power supply 2 Ifthe NIU is attached to the panel with a screw remove the power supply module Remove the panel mount screw 3 Slide the NIU away from the other modules until the connector on the right side disengages from the next carrier 4 With a small flathead screwdriver pull the DIN rail latch out while tilting the other end of the NIU down to disengage it from the DIN rail VersaMax Genius Network Interface Unit May 8 2009 Bus Installation Guidelines The maximum exposed length of unshielded wires should be 5cm 2in For added protection each shield drain wire should be insulated with spaghetti tubing to prevent the Shield In and Shield Out wires from touching each other or the signal wires Connect Serial 1 to the Serial 1 terminals of the previous device and the next device Connect Serial 2 to the Serial 2 terminals of the previous device and the next device Connect Shield In to Shield Out of the preceding device Connect Shield Out to Shield In of the next device If the NIU is the first de
8. ciated with that GNIU If the GNIU is able to revive itself it tries to resume normal operation several seconds later If this is successful the host PLC s will log an GFK 1551Q Addition of Device fault For the case of a GMR PLC an operator must issue a GMR I O Reset command M12258 to recover the use of those input channels Hot Removal and Hot Insertion of the VersaMax GNIU is not permitted Attempting to hot insert or hot remove the GNIU may interfere with backplane transfers between the GNIU and other modules in the station and can cause the GNIU s diagnostic tests to declare an error That can cause other modules in the station to be marked as faulted and may also cause the entire input station to go offline For cases where a VersaMax GNIU needs to be replaced the system s operating procedures must require the operator to remove power from the GNIU before attempting the repair Powering down the entire VersaMax station will cause the system to temporarily lose all analog channels up to 60 in that station not just the channels associated with the module that is being replaced If a redundant VersaMax Input Station is available the procedures may optionally allow the overall system to continue to operate with a degraded level of input channel redundancy for a short time while the faulted input station is being repaired a See When performing a firmware upgrade on an intelligent I O module in the Genius NIU station th
9. e following are true at the same time the GNIU s Enhanced Diagnostics Mode is set to Enabled the GNIU is online with a Genius Bus Controller serial communications programmer operations download remote I O configuration verify equality clear configuration or Winloader are taking place Disconnect the GNIU from the Genius bus before attempting any serial communications if a hardware configuration with Enhanced Diagnostics Mode set to Enabled either is currently installed or will be installed in the GNIU After completing serial communications disconnect the serial cable from the GNIU s expansion port The GNIU can then be reattached to the Genius bus An alternative to disconnecting the GNIU from the Genius bus is to power off or disconnect all of the Genius Bus Controllers on the bus Forcing an I O point on the GNIU is not permitted In Enhanced Diagnostics mode the GNIU continually runs extensive diagnostic tests in the background during normal operation These diagnostics cause the GNIU to be more sensitive to disturbances on the Genius bus When a Genius bus disturbance or spontaneous hardware failure causes a diagnostic test to declare an error the GNIU stops communicating on the Genius bus and attempts to reset itself The loss of communications causes the host PLC s to log a Loss of Device fault and default the affected inputs according to the host s configuration GMR PLCs will disregard the channels asso
10. e host controller must be put into Stop mode or the Genius network cable must be removed from the NIU Most Genius NIU faults will appear in the I O fault table of the I O controller However some Genius NIU faults such as Loss of rack and System configuration mismatch appear in the controller s PLC fault table The Genius NIU re reports unresolved faults when the controller s I O fault table is cleared It does not re report unresolved PLC faults when the PLC fault table is cleared When clearing faults clear both the PLC and I O fault tables in that order Then view both the I O and PLC fault tables to ascertain the Genius NIU station s status The power supply mounted on a Genius NIU and any booster power supplies that are used in the same rack should be powered on and off together There is no response from the Genius NIU to a Write Configuration Datagram COMMREQ The application program must issue a Read Configuration Datagram to determine the effectiveness of a previous Write Configuration Datagram If the Genius NIU is configured using datagrams for example by issuing a COMMREQ to a Genius Bus Controller the value of the Force BSM bit is accessible but must not be changed If the Genius NIU s CPU Redundancy parameter is set to Duplex analog output and intelligent modules must not be used in the I O Station Intelligent I O modules IC200ALG240 ALG331 ALG620 ALG630 and MDD841 should not be used in an extended d
11. ed in the installation instructions provided with the Power Supply Adjust the rotary switches on the front of the NIU using a 2 44mm 3 32in flat screwdriver Select the serial bus address with the two upper rotary switches SBA X10 for the tens digit and SBA X1 for the ones digit Each device on a bus must have a unique serial bus address in the range 0 31 Select the baud rate to match that used by the other devices on the bus by setting the bottom rotary switch 3 153 6 Kbaud extended 2 153 6 Kbaud standard 1 76 8 Kbaud or 0 38 4 Kbaud Cycle power to the NIU after changing the switch settings May 8 2009 VersaMax Genius Network Interface Unit Connect the communications bus to the NIU Refer to the heading Bus Installation Guidelines if the NIU is at the end of the bus or for detailed bus installation instructions Main Bus Connections Redundant a Connections gt SERIAL A1 SERIAL A2 SHIELD IN SHIELD OUT SERIAL B1 SERIAL B2 SHIELD IN SHIELD OUT The NIU has two sets of bus terminals The upper terminals are for the main bus cable The lower bus terminals are for an optional redundant dual bus cable Remove the connector cover on the right hand side of the NIU Do not discard this cover you will need to install it on the last carrier It protects the connector pins from damage and ESD during handling and use Do not remove the connector cover on the left hand side
12. ent unless power has been switched off or the area is known to be non hazardous Panel Mounting For best stability the DIN rail should be installed on a panel using screws spaced approximately 5 24cm 6in apart If excessive vibration is a factor the NIU should also be screwed down to the mounting panel Note Tolerances are 0 13mm 0 005in non cumulative Note 1 1 1 4Nm 10 12 in Ibs of torque should be applied to M3 5 6 32 steel screw threaded into material containing internal threads and automatically be configured starting at slot 1 in each rack including expansion racks If an empty slot or faulted module is encountered autoconfiguration for that rack stops Autoconfiguration then skips to the next rack and continues until all racks are configured Note If the I O station includes any additional power supplies those power supplies should be turned on at the same time Observe the NIU LEDs which indicate the presence of power and show the operating mode and status of the NIU having a minimum thickness of 2 4mm 0 093in 4 3mm gt 0 170in ES A Yj i 4 3mm 0 170in _ 7 FLAT WASHER SEE NOTE 2 M35 6 SCREW SPLIT LOCK WASHER 15 9mm 0 62in REF q PWR Indicates that the NIU is receiving power 0 200in l TAPPED HOLE_ IN PANEL NIU OK FAULT VO ENBL FORCE SBA ERR BUS B Indic
13. ether or unplugged with power applied The descriptions of the operation of jumpers should have the addition Jumper positions cannot be modified with power applied GFK 1551Q Quick Start Guide Preinstallation Check Carefully inspect all shipping containers for damage If any equipment is damaged notify the delivery service immediately Save the damaged shipping container for inspection by the delivery service After unpacking the equipment record all serial numbers Save the shipping containers and packing material in case it is necessary to transport or ship any part of the system Install the NIU on the DIN Rail by simply clicking it into place Note The NIU and connecting carriers must be installed on the same section of 35mm x 7 5mm DIN rail The DIN rail must have a conductive unpainted finish for proper grounding Refer to the heading Module Installation for information about space requirements or module orientation or if you are installing the NIU in an area of excessive vibration Install the Power Supply on the NIU N The latch on the power supply must be in the unlocked position gt Align the connectors and the latch post and press the power supply module down until the two tabs on the bottom of the power supply click into place Turn the latch to the locked position to secure the power supply to the top of the NIU Complete the power supply wiring as describ
14. hort runs of 50 feet or less using 75 ohm terminations Selection of wire type may be limited by local and national codes and industry standards Consult the cable manufacturer to determine the cable s suitability for a particular type of installation Installing Suppression at the Communications Line o For an individual NIU suppression can SHLD OUT be supplied by connecting two small Q SHLD IN MOVs from Serial 1 and Serial 2 to the Shield Out terminal Suitable MOVs Q s2 include Harris part number V220MA2A O s1 Panasonic ERZ CO5FK221U and Siemens 505K140 Higher energy MOVs bus cable rated devices can also be used Follow not shown the wiring instructions above for installing MOVs Be sure the MOV leads do not cause shorts between the serial data and shield connectors GFK 1551Q
15. istance expansion system If a rack with an intelligent I O module in an extended distance expansion system is power cycled or if a single slot Genius configuration datagram is sent to an intelligent module in an extended distance expansion rack the other expansion racks and the other devices on the Genius network may default their outputs briefly VersaMax Genius Network Interface Unit May 8 2009 When configuring a Genius NIU in the bus configuration for a Genius Bus Controller the data lengths specified for l Q Al and AQ data must match the hardware configuration of the NIU If the I O data lengths of the Bus Controller and NIU do not match the NIU will not join the bus and will not report the System configuration mismatch fault caused by the mismatch The correct I O data lengths can be determined by examining the hardware configuration for the Genius NIU The procedure described here is for Machine Edition Logic Developer PLC programming software a Ifthe Genius NIU hardware configuration is available Open the project that includes the Genius NIU target and select the NIU target Under the NIU target right click on Hardware Configuration and select Hardware Reference View For each I O data tab l etc use the largest address in the End column as the data size for that I O data type If there are no entries for a data type the data length for that type is zero If the Genius NIU hardw
16. oduce unexpected Loss of I O Module faults when used with any Genius NIU firmware version See Problems Resolved for Release 3 20 for more information VersaMax Genius Network Interface Unit May 8 2009 Upgrading The IC200GBI001 HL replaces IC200GBI001 GK and previous versions of the hardware and firmware Hardware version IC200GBI001 Gx and later hardware versions can be upgraded in the field to firmware revision 3 20 and used in safety certified applications Version 3 20 firmware may be downloaded to any hardware revision of the Genius NIU However Fx and earlier hardware versions do not include the external windowed watchdog timer circuit Thus versions Fx and earlier are not certified for use in the safety relevant portion of a GMR system For users who want newer GNIU firmware a firmware upgrade kit is available for download at http gefanuc com support Firmware upgrades require a PC to NIU serial cable IC200CBL002 Product Revision History Rev Date Description IC200GBI001 GL May 2009 Firmware release 3 20 IC200GBI001 GK November 2008 Firmware version 3 10 J 8 IC200GBI001 GJ July 2007 Hardware and firmware update Firmware version 3 00 GJ is the minimum required version for safety relevant portion of a GMR system 6 IC200GBI001 FH March 2007 Firmware version 2 40 IC200GBI001 FG anuary 200 Firmware version 2 30 IC200GBI001 FF March 2005 Improved Winloader compatibility IC200
17. rolled by an Rx3i PLC the PLC must use CPU firmware version 2 90 or higher When a Genius NIU all versions that has one or more expansion racks is on a Genius bus controlled by a Series 90 30 PLC the PLC must use one of the following CPU models CPU366 367 or 374 any version or CPU350 352 360 363 or 364 with firmware release 10 0 or higher GFK 1551Q If any of the following are used either a Loss of rack or Addition of rack fault will cause the CPU to go to Stop Fault mode CPU350 352 360 363 or 364 with firmware version 9 11 or lower or CPU311 313 321 323 331 340 341 or 351 all versions VersaMax analog I O modules IC200ALG320 321 322 and 432 that are used on Genius NIU expansion racks must be revision B or greater VersaMax analog I O modules IC200ALG430 and 431 that are used in Genius NIU expansion racks must be revision C or greater When a Genius NIU version GJ or later is used in a control loop that is seeking SIL2 or SIL3 status Proficy Machine Edition version 5 60 plus SIM 8 or later is required to configure Enhanced Diagnostics mode z The Series 90 70 PLCs must be the IC697CPM790 Hardware version Cx or higher of the CPM790 is required Firmware version 6 04 xD or higher of the CPM790 is required The Series 90 70 Genius Bus Controller can be either IC687BEM731 single width Version AB or higher is required Mgr firmware release 6 0 Comm firmware release 4 8
18. ule firmware may produce unexpected Loss of I O Module faults when used with any version of Genius NIU firmware including version 3 20 An entirely different issue in the analog module firmware causes these faults However I O Fault table entries for the faults caused by both issues contain identical Fault Location and Extra Data information Restrictions and Open Issues When a store of a new configuration is interrupted for example by removal of the serial cable the Genius NIU generally reverts operation to match the previous configuration However if the interruption occurs during a certain 2 second window the Genius NIU does not restore Enhanced Diagnostics operation The EDM LED will be OFF Re try the store of the new configuration or power cycle the GNIU to revert to the previous configuration If an intelligent I O module ALG240 ALG320 ALG620 ALG630 MDL841 or a Network Communications Module is present in the Genius NIU station and the GNIU is commanded to clear its configuration the before mentioned module is not included in the subsequent auto configuration nor are any modules that are located to the right of that module This is not an issue when storing hardware configuration It is only an issue for the clear configuration operation If you have one of these modules present and need to generate an auto configuration using this method cycle power of the GNIU after the clear configuration command completes Versa
19. vice on a bus Shield In can be left unconnected If it is the last device on a bus Shield Out can be left unconnected When inserting two wires into the same terminal block position the wire size must be 0 86mm 18AWG or smaller Both wires should be of the same size and style Do not mix stranded with solid wire in the same position Terminating the Bus Terminating Start Terminating Resistor of Bus Resistor sey WN Serial 1 Serial 1 Serial 2 7 Serial 2 Shieidn 2 Shield In Shield Out IZ IG Shield Out If either bus will terminate at the NIU connect a 75 100 120 or 150 ohm terminating resistor across the Serial 1 and Serial 2 terminals The use of a ferrule is recommended to crimp each resistor lead to the corresponding serial line If ferrules are not used twist each resistor lead with the corresponding serial line and solder them together before inserting the wires into the terminal block System Bus Installation Guidelines The serial bus can be treated as a Class 2 circuit when appropriate wiring practices are followed Maximum bus lengths may be affected when installation requires the high voltage rated CM rating CM types can replace CL2 but not vice versa Do not mix cables of different impedance regardless of cable run length Do not mix cable types in long and or noisy installations Other small size twisted pair shielded wire of unspecified impedance can be used for s
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