VersaMax Genius NIU IC200GBI001-HK, GFK

VersaMax Genius NIU IC200GBI001-HK, GFK
VersaMax® Genius® Network Interface Unit
November 18, 2008
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
or greater. VersaMax analog I/O modules IC200ALG430 and 431
that are used in Genius NIU expansion racks must be revision C or
power supply
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.
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
Number of modules
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
[email protected], [email protected]
Serial Bus Address
0 to 31
Network data rate
153.6 Kbaud extended, 153.6
Kbaud standard, 76.8 Kbaud, or
38.4 Kbaud.
IC697BEM713 (standard-width): Version -BZ (or higher) is
required (Mgr firmware release 6.0; Comm firmware release
Product Description
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 (
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:
Revision Letters:
Firmware version:
Firmware upgrades:
Any type of PLC or computer capable of controlling the bus can be used
as the host. This Network Interface Unit is compatible with:
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 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
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).
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.
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.
If any of the following were used, then either a Loss of rack or
Addition of rack fault would cause the CPU to go to Stop/Fault
IC697CPM790: firmware version 6.04 or higher
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.
VersaMax analog I/O modules IC200ALG320, 321, 322, and 432
that are used on Genius NIU expansion racks must be revision B
The IC200GBI001-GK replaces IC200GBI001-GJ and previous
versions of the hardware and firmware.
Hardware version IC200GBI001-Gx can be upgraded in the field to
firmware revision 3.10 and used in safety-certified applications.
Version 3.10 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 Firmware
upgrades require a PC to NIU serial cable, IC200CBL002.
VersaMax® Genius® Network Interface Unit
November 18, 2008
Restrictions and Open Issues
▪ [Applies to a system with a Series 90-70 PLC system, with any CPU
Product Revision History
July 2007
Hardware and firmware update. Firmware
version 3.00. GJ is the minimum required
version for safety-relevant portion of a
GMR system.
Firmware version 2.40
March 2007
January 2006
March 2005
Improved Winloader compatibility.
April 2004
Changed to V0 plastic for module
January 2004
Component change
January 2004
ATEX approval for Group 2 Category 3
June 2002
Firmware version 2.20. Added support for
High-Density Analog Modules.
June 2001
Firmware version 2.10
May 2001
Hardware change
Firmware version 2.30
September 2000 Firmware version 2.00. Added support for
Remote I/O Configuration.
May 2000
Firmware version 1.50. Added support for
expansion racks.
March 1999
Firmware version 1.10. Added support for
intelligent modules.
other than IC697CPM790, having a firmware version lower than
6.04]. When a Genius NIU module generates a Loss of I/O module
or Addition of I/O module fault, the Ref. Address in the I/O fault
displayed by programming software should be the starting I/O
address configured for the lost/added I/O module. However, an
incorrect data type or offset may be displayed.
November 2008 Updated Power Supply OK signal circuitry.
November 2008 Firmware version 3.10
December 1998 Initial product release.
Problems Resolved for Release 3.10
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
Operating Notes/Restrictions: Enhanced
Diagnostics Mode
With Firmware version 3.00, every time the NIU logged onto the
bus or switched busses, it produced a Loss of I/O Module fault for
every module in the I/O station that was not specified in the
rack/slot configuration. This operation could cause significant bus
switch delays when commissioning or testing a large Genius bus,
before storing the rack/slot configurations to all the VersaMax I/O
stations. Firmware version 3.10 corrects this problem.
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.)
In firmware version 3.00, if bus B was active when a hardware
configuration was stored that disabled dual bus operation, bus B
remained active but the module’s BUS B/EDM LED indicated that
bus A was the active bus. Firmware version 3.10 corrects this
problem by automatically switching to bus A when a new hardware
configuration is downloaded for disabling the dual bus.
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.
New Features for this Release
Expansion racks are not allowed.
No new features for this release.
Empty IO carriers are not allowed.
Configuration Requirements
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
VersaMax® Genius® Network Interface Unit
November 18, 2008
Operating Requirements
Operating Notes: General
1. Avoid situations where all of the following are true at the same time:
1. When performing a firmware upgrade on an intelligent I/O module in
the Genius NIU station, the host controller must be put into Stop
mode, or the Genius network cable must be removed from the NIU.
- 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.
2. 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.
After completing serial communications disconnect the serial cable
from the GNIU’s expansion port. The GNIU can then be reattached
to the Genius bus.
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.
An alternative to disconnecting the GNIU from the Genius bus is to
power off or disconnect all of the Genius Bus Controllers on the
3. 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.
2. Forcing an I/O point on the GNIU is not permitted.
4. 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.
3. 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 associated
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 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.
5. 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.
6. 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
7. Intelligent I/O modules (IC200ALG240, ALG331, ALG620, ALG630,
and MDD841) should not be used in an extended distance
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.
4. Hot Removal and Hot Insertion of VersaMax modules is not
permitted. Attempting to hot insert or hot remove a module 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 module 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 of the 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
8. When configuring a Genius NIU in the bus configuration for a
Genius Bus Controller, the data lengths specified for %I, %Q, %AI
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.
If the 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 (%I, 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 hardware configuration is NOT available:
Connect the Windows PC running the programming
software to the Genius NIU using a VersaMax NIU serial
cable, IC200CBL002.
VersaMax® Genius® Network Interface Unit
November 18, 2008
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 (%I, 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.
Quick Start Guide
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
9. 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.
(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.
The latch on the power supply must be
in the unlocked position.
10. 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.
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.
11. When the GNIU is configured for dual bus operation, the Change
Network Baud Rate datagram must not be fired after Switch BSM
datagram. In such cases the baud rate may not be updated and as
a side effect the bus switching may occur.
Turn the latch to the locked position to
secure the power supply to the top of
the NIU.
Documentation Update
Complete the power supply wiring as described in the installation
instructions provided with the Power Supply.
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 together or unplugged with power applied”.
The descriptions of the operation of jumpers should have the
addition “Jumper positions cannot be modified with power applied”.
Adjust the rotary switches on the front of the NIU using a
2.44mm (3/32in) flat screwdriver.
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.
U 0 1
9 0 1
6 5 4
0 1
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.
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
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
VersaMax® Genius® Network Interface Unit
November 18, 2008
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.
General Module Installation Instructions
Modules may be mounted on a
horizontal or vertical DIN rail. When
mounted on a vertical DIN rail, the NIU
must be located at the bottom.
Allow sufficient finger clearance
for opening NIU door.
2. Allow adequate clearance for
serial port cables.
3. Allow adequate space for power
The NIU with power supply attached fits
into a 70mm deep enclosure.
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.
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.
Installation in Hazardous Locations
Power up the NIU. The modules in the I/O station will
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.
For best stability, the DIN rail should be installed on a panel using
screws spaced approximately 5.24cm (6in) apart.
Note: If the I/O station includes any additional power supplies,
those power supplies should be turned on at the same time.
If excessive vibration is a factor the NIU should also be screwed down to
the mounting panel.
Observe the NIU LEDs, which indicate the presence of power and
show the operating mode and status of the NIU.
Indicates that the NIU is receiving
Indicates diagnostics executed
Is ON if there are one of 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
Is ON if a duplicate device SBA or
invalid SBA exists.
Is ON if bus B is active.
This equipment is suitable for use in CLASS I, DIVISION 2,
GROUPS A, B, C, D or non-hazardous locations only.
WARNING - EXPLOSION HAZARD - substitution of
components may impair suitability for CLASS I, DIVISION
WARNING - EXPLOSION HAZARD - when in hazardous
locations, turn off power before replacing or wiring
modules; and
WARNING - EXPLOSION HAZARD - Do not connect or
disconnect equipment unless power has been switched off
or the area is known to be non-hazardous.
Note: Tolerances are +/- 0.13mm (0.005in) non-cumulative.
Note: 1.1-1.4Nm (10-12 in/lbs) of torque should be applied to M3.5 (#632) steel screw threaded into material containing internal threads and
having a minimum thickness of 2.4mm (0.093in).
M3.5 (#6) SCREW
0.62in REF
Removing the NIU from the DIN Rail
1. Turn off power to the power supply.
2. (If the 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
VersaMax® Genius® Network Interface Unit
November 18, 2008
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
device 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 0.86mm2 (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
of Bus
of Bus
Serial 1
Serial 2
Shield In
Shield Out
Serial 1
Serial 2
Shield In
Shield Out
If either bus will terminate at the NIU, connect a 75, 100, 120, or 150ohm 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 short 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
(bus cable
not shown)
For an individual NIU, suppression can
be supplied by connecting two small
MOVs from Serial 1 and Serial 2 to the
Shield Out terminal. Suitable MOVs
include Harris part number
V220MA2A, Panasonic ERZCO5FK221U, and Siemens 505K140.
Higher energy-rated devices can also
be used. Follow the wiring instructions
above for installing MOVs. Be sure the
MOV leads do not cause shorts
between the serial data and shield
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