Troubleshooting Guide For VersaMax PLC and I/O Modules

1.   ABBREVIATIONS

2.   INTRODUCTION

The VersaMax family of products provides universally-distributed I/O that spans PLC and PC-based architectures. Designed for industrial and commercial automation, VersaMax I/O provides a common, flexible I/O structure for local and remote control applications. The VersaMax PLC provides big-PLC power with a full range of I/O and option modules. VersaMax I/O Stations with Network Interface Modules make it possible to add the flexibility of VersaMax I/O to other types of networks. VersaMax meets UL, CUL, CE, Class1 Zone 2 and Class I Division 2 requirements.

As a scaleable automation solution, VersaMax I/O combines compactness and modularity for greater ease of use. The 70-mm depth and small footprint of VersaMax I/O enables easy, convenient mounting as well as space- saving benefits. Modules can accommodate up to 32 points of I/O each. (VersaMax® PLC User’s Manual, 2006)

3.   DIAGNOSTICS

3.1. Power Supply Module (PSU)

VersaMax Power Supply modules power the CPU, I/O modules on a VersaMax carriers/rack.

3.1.1.    Removing a Power Supply Module

1. Switch off the external power source to the power supply module.
2. Turn the latch to the unlocked position.
3. Press in the tabs on the lower edge of the power supply.
4. Pull the power supply straight off (VersaMax® Modules, Power Supplies, and Carriers, 2003).

(VersaMax® Modules, Power Supplies, and Carriers, 2003) FIGURE 3 2: VERSAMAX POWER SUPPLY UNLOCK POSITION

(VersaMax® Modules, Power Supplies, and Carriers, 2003)
FIGURE 3 3: VERSAMAX POWER SUPPLY REMOVAL

3.1.2.    Installing a Power Supply Module

The power supply module installs directly on top of a CPU, NIU, ERM, or booster carrier.

1. The latch on the power supply must be in the unlocked position.
2. Align the connectors, tab, and latch post on the power supply to be parallel with the CPU, NIU, ERM, or carrier.
3. Press the power supply module down firmly, until the two tabs on the bottom of the power supply click into place. Be sure the tabs are fully inserted in the holes in bottom edge of the CPU, NIU, ERM, or booster carrier (VersaMax® Modules, Power Supplies, and Carriers, 2003).
4. Turn the latch to the locked position to secure the power supply in place (VersaMax® Modules, Power Supplies, and Carriers, 2003).

(VersaMax® Modules, Power Supplies, and Carriers, 2003)
FIGURE 3 4: VERSAMAX POWER SUPPLY UNLOCK POSITION

(VersaMax® Modules, Power Supplies, and Carriers, 2003)
FIGURE 3 5: VERSAMAX POWER SUPPLY INSERTION

(VersaMax® Modules, Power Supplies, and Carriers, 2003)
FIGURE 3 6: VERSAMAX POWER SUPPLY LOCK POSITION

3.2. Central Processing Unit (CPU)

VersaMax® PLC CPUs IC200CPU001, CPU002, and CPU005 provide powerful PLC functionality in a small, versatile system. 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 (VersaMax® PLC User’s Manual, 2006).

3.2.1.    Run/Stop Switch

The CPU module has a convenient switch that can be used to place the PLC in Stop or Run mode. The same switch can also be used to block accidental writing to CPU memory and forcing or overriding discrete data. Use of this feature is configurable.

The default configuration enables Run/Stop mode selection and disables memory protection (VersaMax® PLC User’s Manual, 2006).

(VersaMax® PLC User’s Manual, 2006)
FIGURE 3 4: RUN/STOP SWITCH (CPU)

3.2.2.    LED Diagnostics

(VersaMax® PLC User’s Manual, 2006)
FIGURE 3 9: CPU LED DIAGNOSTICS

3.2.3.    Ethernet enabled CPUE05

The CPUE05 has an Ethernet Interface port at the bottom right hand side for interfacing it with the plant Ethernet Network.

(VersaMax® PLC User’s Manual, 2006)

3.3. I/O Modules

Typical VersaMax I/O module is indicated below with explanation of colors/codes used.

3.3.1.    Digital Input Module (DI)

The Digital Input module interfaces the field digital inputs such as limit switches, pushbuttons, feedback signals etc. with the VersaMax PLC system.

3.3.2.    LED Diagnostics

Individual Green LEDs indicate the on/off state of each input point. The Green OK LED is ON when backplane power is present to the module (VersaMax® Modules, Power Supplies, and Carriers, 2003).

3.4. Digital Output Module (DO)

The Digital Output module interfaces the field digital outputs such as valves, beacons, sounders etc. with the VersaMax PLC system.

3.4.1.    LED Diagnostics

Individual Green LEDs indicate the on/off state of the output points. Operation of these LEDs is dependent on field power but independent of load conditions.

The green FLD PWR LED is ON when field power is applied to the module. The Green OK LED is on when backplane power is present to the module (VersaMax® Modules, Power Supplies, and Carriers, 2003).

3.5. Analog Input Module (AI)

The Analog Input module interfaces the field analog instruments such as transmitters, detectors etc. with the VersaMax PLC system.

3.5.1.    LED Diagnostics

The Green OK LED is ON when backplane power is present, internally generated field power is functioning properly, the module has been configured, and the module has been recognized on the backplane (VersaMax® Modules, Power Supplies, and Carriers, 2003).

The module reports a Loss of Internal Power fault for field-side circuits. The module reports an Open Wire fault for each channel, when in 4-20mA mode (VersaMax® Modules, Power Supplies, and Carriers, 2003). These are however viewed in the I/O Fault table using the programming software (Machine Edition).

3.6. Analog Output Module (AO)

The Analog Output Module interfaces field analog output devices such as Control Valves, Display Meters etc. with the VersaMax PLC system.

3.6.1.    LED Diagnostics

The Green FLD PWR LED indicates the presence of user-side power for the analog field side circuits.

The Green OK LED is ON when backplane power is present to the module.

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This entry was posted on April 25th, 2014 and is filed under GE Fanuc, Troubleshooting. Both comments and pings are currently closed.