EMERSON PACSystems VersaMax MICRO PLC & NANO PLC. USER MANUAL (2019)

User Manual

Chapter 15

GFK-1645M

Dec 2019

Installation Instructions

290

15.10

Starting Up the PLC

Before applying power to the PLC:

•

Be sure all mounting screws, terminal screws, cables and other items are properly
tightened and secured.

WARNING

•

On a Micro PLC CPU or Expansion Unit, be sure the protective covers are installed over
terminals when power is applied to the unit. The covers protect against accidental
shock hazard that could cause severe or fatal injury.

•

Double-check all wiring. Faulty wiring may damage the PLC.

•

Do not turn on the power supply to a broken PLC.

•

Be sure that Expansion Units connected to the Micro PLC are wired to the same power
source and that the PLC and Expansion Units will power up together. If an attached
Expansion Unit is left unpowered, the Micro PLC may not power up properly.

WARNING

Always turn off the power supply to the PLC before attempting any of the following.
Performing any of these acts may result in electrical shock, damage to the PLC or faulty
operation.

Assembling the PLC.

Connecting or disconnecting cables or wiring.

Connecting a Frame Ground (earth) terminal to the metal plate or metal case.

15.10.1

Turning off Power to the PLC

CAUTION

During a gradual power down, when the input power supply voltage is below the minimum
operating voltage, the PLC may power off and then power on again until the input voltage
drops low enough to prevent power on again. You should take precautions if this type of
behavior cannot be tolerated in your application.

User Manual

Chapter 15

GFK-1645M

Dec 2019

Installation Instructions

291

15.10.2

Normal Power-up Sequence

Apply the required power to the power inputs and observe the LEDs. A 14-point Micro PLC
is shown below. Other PLC models and expansion units have different LEDs.

Figure 156

•

The PWR LED should light.

•

The  OK  LED  blinks  during  power-up  diagnostics.  (Micro  PLCs  that  do  not  have
expansion  units  can  be  configured  to  skip  power-up  diagnostics,  as  explained  in
Chapter 16:.) When diagnostics have successfully completed, the OK LED changes
to a steady on state. The RUN LED goes ON if the unit is configured to run on power-
up.  If  the  Run  LED  does  not  light  when  you  go  to  Run mode,  the  cause  could  be
invalid configuration or a fatal error in the CPU fault table.

•

If any input points have been wired to field devices that energize those circuits, the
corresponding input LEDs should also be ON. (On Analog, RTD and Thermocouple
Expansion Units, the input 1-4 LEDs should be OFF during normal operation). Refer
to Chapter 12: for details of LED operation for analog expansion units. Refer to
Chapter 13: for details of LED operation for RTD and Thermocouple units.

•

If the RUN LED on the Micro PLC CPU is not ON, all output LEDs should be OFF (in
STOP with I/O Disabled mode).

•

After power-up and program download, check the program for proper execution.

User Manual

Chapter 15

GFK-1645M

Dec 2019

Installation Instructions

292

Micro PLC LEDs

Symptom

Action

PWR LED does not light.

1. Check that the proper power source is provided and is on.
2. With power supply off, check wiring to the module unit to be sure it
is connected correctly.

PWR LED is ON
OK LED is OFF

(This indicates that the power source is good and that the CPU has
detected an internal fault. Be sure all the DIP switches are in

the “OFF”

position (down).

PWR LED is ON.
OK and RUN blink
together.

The PLC is in system bootloader mode and is awaiting a system
firmware download from the WinLoader tool.

PWR LED is ON.
OK is blinking.

The PLC features built-in blink codes to assist in troubleshooting.

15.11

Adjusting the Analog Potentiometers

Two potentiometers located behind the left door of a 14-, 23-, or 28-point Micro PLC can be
adjusted to lower or raise the values in analog registers %AI16 and %AI17. The left
potentiometer, labeled VR1, adjusts the value in register %AI16. The right potentiometer,
VR2, adjusts the value in %AI17.

To adjust the potentiometers, use a small screwdriver. Turning a potentiometer clockwise
increases the value.

Figure 157

User Manual

Chapter 15

GFK-1645M

Dec 2019

Installation Instructions

293

15.12

DIP Switches

15.12.1

4-Position DIP Switches on Micro PLC CPUs

The DIP switches located behind the removable door on the front of a 14-, 20-, 23-, 28-,
40-, or 64-point Micro PLC are factory-set to OFF (down position) as shown below, and
should not be changed.

Figure 158

15.12.2

DIP Switches on an Analog Expansion Module Select
Count Resolution

For analog expansion units, count resolution is controlled by DIP switch 6, which should be
set to ON by default. If unexpected results are observed, check the position of switch 6. If
switch 6 is not ON, power down the system and set switch 6 to ON. Do NOT change any of
the other switches.

For details, refer to “Count Resolution for Analog Expansion Units” in

Chapter 12:.

15.12.3

DIP Switches on an RTD Expansion Module Select Update
Rate

For RTD expansion units, DIP switch 2 can be changed to select channel update rate. For
firmware versions 4.0 and higher, DIP switch 3 can be used to select between Compatible
and High Accuracy modes.

For IC200UEX726 and UEX736 modules with firmware version 4.0 and higher, DIP switch 6
can be used to select output range.

For details, refer to “DIP Switches” in

Chapter 13:.

User Manual

Chapter 15

GFK-1645M

Dec 2019

Installation Instructions

294

15.12.4

DIP Switches on a Thermocouple Expansion Module
Select Input Sensors/Mode

On Thermocouple modules, DIP switches 1

–

3 can be used to select input sensors for

channels 1

–

On Thermocouple modules with firmware versions 4.0 and higher, DIP switch 6 can be used
to select between Compatible and High Accuracy modes.

If these settings are configured using Machine Edition software version 6.0 or later, the
software configuration will override the DIP switch setting.

For details, refer to “DIP Switches” in

Chapter 13:.

15.13

Installing/Replacing a Backup Battery

For 20-, 23-, 28-, 40-, and 64-point Micro PLCs, a backup battery can be installed to protect
the RAM memory contents of the PLC when the PLC power supply is removed or turned off.

It also backs up the CPU’s real

-time clock. Note: Use of another battery type may present a

risk of fire or explosion.

Important: The Micro PLC power must be OFF when installing/replacing the battery.

IC200ACC414

Nominal Voltage 3.6Vdc @ 790 mAh

Battery shelf life, not
installed

Up to 5 years typical at 30 °C
Up to 3 years typical at 55 °C

Backup time with
battery installed, Micro
PLC continuously
powered down

For units with serial number
before 07000069274
13 months minimum at 70°C
30 months minimum at 20°C

For units with serial number after
07000069274
19 months minimum at 70°C
121 months minimum at 20°C

This battery replaces an earlier coin-type battery, IC200ACC403.

15.13.1

CPU Battery Consumption Data

Power

Battery Consumption per Hour

Micro PLC with a serial
number before
07000069274

Micro PLC with a serial
number after
07000069274

20-, 40-, and 64-Point
Micro PLCs

30 µA

3 µA

0 µA

OFF

83 µA @ 70°C
36 µA @ 20°C

56 µA @ 70°C
9 µA @ 20°C

31 µA @ 55°C
3 µA @ 25°C

To replace a previously-installed battery, open the battery compartment door and remove
the old battery assembly.

Insert the battery plug into the connector at the bottom of the battery compartment. Press
it in until it clicks. Do not force the connection

–

the plug is keyed to prevent accidentally

installing the battery in a reverse polarity.

User Manual

Chapter 15

GFK-1645M

Dec 2019

Installation Instructions

295

Figure 159

For a cylinder-type battery, tuck in the wires and snap the battery holder (see the illustration
above) onto the VersaMax Micro PLC. The original battery compartment door is no longer
needed.

For a coin-type battery, place the battery into the holder on the left side of the battery
compartment and tuck in the wires. Close the battery compartment door securely.

CAUTION

Battery may explode if mistreated.

Do not recharge, disassemble, heat above 100°C (212°F), or incinerate.

15.14

Serial Port Connections

15.14.1

Providing Power to an External Device from Port 1 or 2

If either port is set up for communications with a serial device that requires 100mA or less
at 5Vdc, the device can obtain power from either Port 1 or Port 2. The total current drawn
from both ports added together cannot exceed 100mA.

15.14.2

Short Circuit Protection on 5Vdc for Units Later than June
2005

In the event that a short occurs across 5Vdc on any serial port on a VersaMax Micro or Nano
PLC manufactured after June 2005, date code 523 (the date code is a three-digit code
located on side of unit) the unit will power down until the short is removed. By removing
the short, the unit will recover fully.

Micro and Nano PLCs prior to date code 523 have a non-replaceable internal fuse for 5Vdc.
On those units, if the fuse blows, the RS-232 continues to function but the port no longer
provides 5Vdc to external devices. The 5Vdc is also lost on the RS-485 port.

User Manual

Chapter 15

GFK-1645M

Dec 2019

Installation Instructions

296

15.14.3

Cable Lengths and Baud Rates

Maximum cable lengths (the total number of feet from the CPU to the last device attached
to the cable) are:

Port

(RS-232)

meters

(50

ft.)

Port 2 (RS-485) = 1200 meters (4000 ft.)

Both ports support configurable baud rates from 300 to 19.2k bps (4800 bps to 38.4k bps
for Micro 20/40/64 PLCs).

15.14.4

Port 1: RS-232

Port 1 is an RS-232 port with an 8-pin RJ-45 vertical jack. In addition to be a general serial
communications port, this port is also used as the boot loader port for upgrading the PLC
firmware.

Figure 160

Note:

There is no shield or frame-ground or shield pin on this connector.

Pin

Signal

Direction

Function

RTS

Output

Request to Send output

CTS

Input

Clear to Send input

RXD

Input

Receive Data input

TXD

Output

Transmit Data output

DCD

Input

Data Carrier Detect input

DTR

Output

Data Terminal Ready output

+5V

Output

+5Vdc output to power external protocol converters

GND

0V/Gnd signal reference

User Manual

Chapter 15

GFK-1645M

Dec 2019

Installation Instructions

297

Port 1 Cable Wiring to a 9-pin D-sub PC-style RS-232 Port

An RJ-45 to DB9F adapter can be used to connect Port 1 to the standard 9-pin D-Sub port
found on most PCs. Programmer wiring to an RJ-45 to DB9F adapter is shown below. For a
PC that is not used as a programmer, only the Transmit, Receive, and Ground wires are
needed on Port 1 and Port 2.

Figure 161

RJ-45 to DB9F Adapter Wiring

The color codes shown below are standard for most RJ-45 to DB9F adapter kits but be sure

to review your kit’s particular documentation. Wire the adapter kit following the pin

numbers as shown.

Adapter Wire
Color

DB9F pin RJ45 pin Micro PLC signal DB9F (PC Serial Port) signal

n/c

DCD (in)

Green

TxD (out)

RxD (in)

Yellow

RxD (in)

TxD (out)

Red

DCD (in)

DTR (out)

Blue

Ground

Black

DTR (out)

DSR (in)

Brown

CTS (in)

RTS (out)

White

RTS (out)

CTS (in)

Orange

+5V (out)

RI (in)

User Manual

Chapter 15

GFK-1645M

Dec 2019

Installation Instructions

298

15.14.5

Port 2 on 23-Point and 28-Point Micro PLCs: RS-485

Pin Assignments for Port 2

Port 2 on 23-point and 28-point VersaMax Micro PLCs is an RS-485 port with a 15-pin female
D-sub connector.

Figure 162

This can be attached directly to an RS-485 to RS-232 adapter (IC693ACC901 or similar).

Pin

Signal

Direction

Function

SHLD

Cable Shield Drain wire connection

2, 3, 4

n/c

P5V

Output

+5Vdc to power external devices (100mA max.)

RTSA

Output

Request to Send (A) output

GND

0V/GND reference signal

CTSB’

Input

Clear to Send (B) input

Resistor Termination (120Ω) for RDA’

RDA’

Input

Receive Data (A) input

RDB’

Input

Receive Data (B) input

SDA

Output

Transmit Data (A) output

SDB

Output

Transmit Data (B) output

RTSB

Output

Request to Send (B) output

CTSA’

Input

Clear to Send (A) input

Shell

SHLD

Cable Shield wire connection / 100% (Continuous ) shielding
cable shield connection

User Manual

Chapter 15

GFK-1645M

Dec 2019

Installation Instructions

299

Connector and Cable Specifications for Port 2 on 23-Point
and 28-Point Micro PLCs

Vendor Part numbers below are provided for reference only. Any part that meets the same
specification can be used.

Cable:
Belden 8105

Low Capacitance Computer cable, overall braid over foil shield
5 Twisted-pairs

Shield Drain Wire

30 Volt / 80



C (176



24 AWG tinned copper, 7x32 stranding
Velocity of Propagation = 78%
Nominal Impedance = 100



15 Pin Male
Connector:

Type:
Crimp

Vendor:
ITT/Cannon
AMP

Plug:
DAA15PK87F0
205206-1

Pin:
030-2487-017
66506-9

Solder

ITT/Cannon
AMP

ZDA15P
747908-2

--
--

Connector Shell: Kit

–

ITT Cannon DA121073-50 [15-pin size backshell kit]:

Metal-Plated Plastic (Plastic with Nickel over Copper)

Cable Grounding Clamp (included)



cable exit design to maintain low-profile installation

Plus

–

ITT Cannon 250-8501-009 [Extended Jackscrew]:

Threaded with (metric) M3x0.5 for secure attachment

Order Qty 2 for each cable shell ordered

RS-485 Point to Point Connection with Handshaking

In point-to-point configuration, two devices are connected to the same communication
line. For RS-485, the maximum cable length is 1200 meters (4000 feet). Modems can be
used for longer distances.

Figure 163

Critical Information

–

any other part selected should meet or exceed this criteria.

Use of this kit maintains the 70mm (2.76in) installed depth.

User Manual

Chapter 15

GFK-1645M

Dec 2019

Installation Instructions

300

15.14.6

Port 2 RS-485 Option Module on 20-/ 40-/ 64-Point
Micro PLCs

See Chapter 13: for more information about communications option modules.

Figure 164

Connections: Peripheral Device to RS-485 Option Module

Figure 165

Note:

•

The connection to peripheral device is through 232/485 converter. Diagram gives the RS 485
communication part of the PLC with the converter.

•

On the RS-232 side of the converter peripheral device needs to be connected.

User Manual

Chapter 15

GFK-1645M

Dec 2019

Installation Instructions

301

Connections: Micro 28- PLC to Micro20-, 40- or -64- PLC
Master/Slave

Figure 166

15.14.7

RS-485 Multidrop Serial Connections

The Micro PLC supports a maximum of eight devices on a single serial link per network. This
number can be increased with the use of a repeater. For additional information on serial

communications, refer to the Series 90 PLC Serial Communications User’s Manual, GFK

0582.

In the multi-drop configuration, the host device is configured as the master and one or more
PLCs are configured as slaves. The maximum distance between the master and any slave
may not exceed 4000 feet (1200 meters). Any installation with PLCs over 50 feet (15.2
meters) apart must include optical isolation.

Figure 167

The RS-485 line must include handshaking and use wire type specified earlier. Reflections
on the transmission line can be reduced by daisy-chaining the cable as shown. Make
connections inside the connector to be attached to the PLC. Avoid using terminal strips to
other types of connectors along the length of the transmission line.

Termination resistance for the Receive Data (RD) signal must be connected only on units at
the ends of lines. This termination is made at the CPU by connecting a jumper between pin
9 and pin 10 inside the D-shell connector.

Ground Potential: Multiple units not connected to the same power source must have
common ground potential or ground isolation for proper operation of the system.

User Manual

Chapter 15

GFK-1645M

Dec 2019

Installation Instructions

302

15.14.8

RS-485 Port Isolator

The IC690ACC903 RS-485 Port Isolator can be connected directly to the Micro PLC RS-485
serial port, or panel-mounted and connected to the Micro PLC using a short extender cable.
The extender cable is intended for use in applications where direct connection to the port is
obstructed by surrounding equipment or where it is not acceptable for the device to
protrude from the Micro PLC. The Port Isolator can operate in either single- or multi-drop
mode, which is selected by a slide switch on the top of the module. The Port Isolator
provides the following features:

•

Four opto-isolated signal channels: SD, RD, RTS, and CTS

•

Electrical compatibility with RS-485

•

Single- or multi-drop operation

•

Input termination consistent with standard for serial channels

•

A 5V DC/DC converter for power isolation

•

Hot insertion is supported

Figure 168

Port Isolator Specifications

Mechanical

RS-485

15-pin D shell male for direct mounting to serial port on the CPU
15-pin D shell female for communication cable

Installation Hardware

Two M3 thread connector thumbscrews. Recommended torque:
8 in./lbs. (supplied with Isolator). Two #6/32 thread panel mounting
screws. Recommended torque: 12 in./lbs. (user supplied)

Electrical

Voltage Supply
Typical Current

+5Vdc (supplied by port)
25 mA; 100 mA available for external equipment

Ground Isolation
Conformance

500 Volts
EIA-422/485 Balanced Line

Operating Temperature



C - 70



C (32



F - 158



Baud Rate

Those supported by PLC

User Manual

Chapter 15

GFK-1645M

Dec 2019

Installation Instructions

303

Port Isolator Connectors

The Isolator has two connectors, one 15-pin male D-type (PL1) and one 15-pin female D-
type (PL2). The pin assignments are identical, except that pin 4 on PL2 is connected to the
module ID resistor.

RS-485 Connector Pin Assignments

Pin

Pin Name

Pin Type

Description

PL1

SHLD

Chassis Ground

+5V power

RTS (A)

Request to send -

Signal Ground

CTS (B')

Out

Clear to send +

RD (A')

Out

Read data -

RD (B')

Out

Read data +

SD (A)

Send data -

SD (B)

Send data +

RTS (B)

Request to send +

CTS (A')

Out

Clear to send -

PL2

TESTID

ID resistor

+5V power

RTS (A)

Out

Request to send -

Signal Ground

CTS (B')

Clear to send +

Terminating Resistor*

RD (A')

Read data -

RD (B')

Read data +

SD (A)

Out

Send data -

SD (B)

Out

Send data +

RTS (B)

Out

Request to send +

CTS (A')

Clear to send -

User Manual

Chapter 15

GFK-1645M

Dec 2019

Installation Instructions

304

•

Use the terminating resistor if the Port Isolator is used in port-to-port mode or at the
end of a multi-drop configuration. To terminate the RD balanced line, place a jumper
wire from pin 9 to pin 10.

•

A denotes

–

and B denotes +. A and B denote outputs and A' and B' denote inputs.

Installing the Port Isolator

The Isolator is packaged in a contoured plastic enclosure designed for either direct

attachment to a serial port or through a 12” extender cable for panel

-mounted equipment.

Two M3 thumbscrews secure the device to its mating connector. It can be easily inserted
into an existing communication channel with no additional hardware.

Figure 169

When installing the Port Isolator on a panel, you will need to provide two #6-32 mounting
screws.

Figure 170

When installing the Isolator, tighten the connector screws and panel mounting screws (if
used) to the following torque values:

Screws

Type

Torque

Connector Thumbscrews (supplied with Isolator)

8 in/lbs

Panel Mounting Screws (user-supplied)

#6/32

12 in/lbs

The RS-485 Port Isolator supports both port-to-port and multi-drop configurations.

EMERSON PACSystems VersaMax MICRO PLC & NANO PLC. USER MANUAL (2019) - page 21