VersaMax® Genius® Network Interface Unit

May 8, 2009 GFK-1551Q

The Genius Network Interface Unit acts as controller for a set of I/O If any of the following are used, either a Loss of rack or Addition of
modules. Power for module operation is provided by a power supply that rack fault will cause the CPU to go to Stop/Fault mode:
installs directly on the NIU
- CPU350, 352, 360, 363, or 364 with firmware version 9.11 or
NIU power supply lower; or
- CPU311, 313, 321, 323, 331, 340, 341, or 351 (all versions).
4. 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.
5. 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
Specifications version -Cx or higher of the CPM790 is required. Firmware
version 6.04 (-xD) or higher of the CPM790 is required.
Number of modules 8 per rack, up to eight racks.
Network inputs per bus scan 128 bytes ▪ The Series 90-70 Genius Bus Controller can be either:
Network outputs per bus scan 128 bytes
IC687BEM731 (single-width): Version –AB (or higher) is
Discrete Input Memory 1024 points required (Mgr firmware release 6.0; Comm firmware release
Discrete Output Memory 1024 points 4.8).
Analog Input Memory 128 bytes IC697BEM713 (standard-width): Version -BZ (or higher) is
Analog Output Memory 128 bytes required (Mgr firmware release 6.0; Comm firmware release
Power Consumption +5V@250mA, +3.3V@10mA 4.8).
Serial Bus Address 0 to 31
▪ GMR Software IC641SWP745 version C (or higher) is required
Network data rate 153.6 Kbaud extended, 153.6 (GMR System Software version 4.05; GMR Configurator
Kbaud standard, 76.8 Kbaud, or version 8.06)
38.4 Kbaud.
▪ The safety-certified versions of the VersaMax power supply
and I/O carriers must be used. See the TUV website for
Product Description specifics (http://www.tuv-fs.com/).

6. To assure that the host PLC will display the correct reference
Revision Letters: GL
addresses for Loss and Addition of I/O Faults reported by the
Firmware version: 3.20 Genius NIU, the host controller must be one of the following:
Firmware upgrades: 44A748000-G10 - IC697CPM790: firmware version 6.04 or higher
- Other Series 90-70 controllers: Future.
- PACSystems RX7i controllers: Firmware version 5.50 or higher.
Compatibility
7. To use Enhanced Diagnostics mode in any GMR System, version
Any type of PLC or computer capable of controlling the bus can be used 4.05 of the GMR System Software is required.
as the host. This Network Interface Unit is compatible with:
Do not enable Enhanced Diagnostics Mode on a Genius NIU that is
1. When a Genius NIU (all versions) is on a Genius bus controlled by part of a GMR system that is using GMR System Software version
a Series 90-70 or PACSystems RX7i, the Series 90-70 Genius Bus 4.04 or earlier.
Controller must have firmware version 5.4 or greater. Upgrading 8. To use the GMR CPU Redundancy mode in any GMR system,
the 90-70 Genius Bus Controller firmware to version 6.0 (or higher) version 4.05 of the GMR System Software is required. Do not set
is strongly recommended. the CPU Redundancy parameter to GMR on a Genius NIU that is
2. When a Genius NIU (all versions) that has one or more expansion part of a system that is using GMR System Software version 4.04
racks is on a Genius bus controlled by an Rx3i PLC, the PLC must or earlier.
use CPU firmware version 2.90 or higher. 9. VersaMax analog input modules IC200ALG240, IC200ALG620 and
3. When a Genius NIU (all versions) that has one or more expansion IC200ALG630 installed in Genius I/O stations must be upgraded to
racks is on a Genius bus controlled by a Series 90-30 PLC, the firmware version 1.20 or later. Previous versions of analog input
PLC must use one of the following CPU models: module firmware may produce unexpected Loss of I/O Module
- CPU366, 367, or 374 (any version) or faults when used with any Genius NIU firmware version. See
“Problems Resolved for Release 3.20” for more information.
- CPU350, 352, 360, 363, or 364 with firmware release 10.0 or
higher.

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 VersaMax® Genius® Network Interface Unit
May 8, 2009 GFK-1551Q

Upgrading Problems Resolved for Release 3.20

▪ The IC200GBI001-HL replaces IC200GBI001-GK and previous
versions of the hardware and firmware. ▪ IC200GBI001 modules with firmware version 3.10 or earlier
▪ Hardware version IC200GBI001-Gx and later hardware versions
versions may report unexpected and highly intermittent Loss of I/O
Module faults for the VersaMax analog input modules
can be upgraded in the field to firmware revision 3.20 and used in
safety-certified applications. IC200ALG240, IC200ALG620 and IC200ALG630; the analog
output module, IC200ALG331; the Mixed Discrete / High-Speed
▪ Version 3.20 firmware may be downloaded to any hardware Counter Module, IC200MDD841; and the Serial Communications
revision of the Genius NIU. However, -Fx and earlier hardware module, IC200CMM020. These faults never occur for most users.
versions do not include the external windowed watchdog timer
circuit. Thus, versions Fx and earlier are not certified for use in the This issue has been corrected in IC200GBI001 firmware
safety-relevant portion of a GMR system. version 3.20.
▪ For users who want newer GNIU firmware, a firmware upgrade kit
VersaMax analog input modules IC200ALG240, IC200ALG620 and
is available for download at http://gefanuc.com/support. Firmware
upgrades require a PC to NIU serial cable, IC200CBL002. 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 module firmware may produce
Product Revision History unexpected Loss of I/O Module faults when used with any version
Rev Date Description of Genius NIU firmware, including version 3.20. An entirely
IC200GBI001-GL May 2009 Firmware release 3.20. different issue in the analog module firmware causes these faults.
IC200GBI001-GK November 2008 Firmware version 3.10 However, I/O Fault table entries for the faults caused by both issues
IC200GBI001-GJ July 2007 Hardware and firmware update. Firmware contain identical Fault Location and Extra Data information.
version 3.00. GJ is the minimum required
version for safety-relevant portion of a
GMR system.
IC200GBI001-FH March 2007 Firmware version 2.40
Restrictions and Open Issues
IC200GBI001-FG January 2006 Firmware version 2.30
IC200GBI001-FF March 2005 Improved Winloader compatibility. ▪ When a store of a new configuration is interrupted (for example, by
IC200GBI001-EF April 2004 Changed to V0 plastic for module removal of the serial cable), the Genius NIU generally reverts
housing. operation to match the previous configuration. However, if the
IC200GBI001-DF January 2004 Component change interruption occurs during a certain 2-second window, the Genius
IC200GBI001-CF January 2004 ATEX approval for Group 2 Category 3 NIU does not restore Enhanced Diagnostics operation. The EDM
applications. LED will be OFF. Re-try the store of the new configuration, or
IC200GBI001-BF June 2002 Firmware version 2.20. Added support for power-cycle the GNIU to revert to the previous configuration.
High-Density Analog Modules.
IC200GBI001-BE June 2001 Firmware version 2.10 ▪ If an intelligent I/O module (ALG240, ALG320, ALG620, ALG630,
IC200GBI001-BD May 2001 Hardware change
MDL841) or a Network Communications Module is present in the
Genius NIU station, and the GNIU is commanded to clear its
IC200GBI001-AD September 2000 Firmware version 2.00. Added support for
Remote I/O Configuration. configuration, the before-mentioned module is not included in the
IC200GBI001-AC May 2000 Firmware version 1.50. Added support for subsequent auto-configuration, nor are any modules that are
expansion racks. located to the right of that module. This is not an issue when storing
IC200GBI001-AB March 1999 Firmware version 1.10. Added support for hardware configuration; It is only an issue for the clear configuration
intelligent modules. operation. If you have one of these modules present, and need to
IC200GBI001-AA December 1998 Initial product release. generate an auto-configuration using this method, cycle power of
the GNIU after the clear configuration command completes.

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 VersaMax® Genius® Network Interface Unit
May 8, 2009 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
Operating Notes/Restrictions: Enhanced use of those input channels.
Diagnostics Mode 4. Hot Removal and Hot Insertion of the VersaMax GNIU is not
When used in the safety-relevant portion of a GMR system, the GNIU’s permitted. Attempting to hot insert or hot remove the GNIU may
Enhanced Diagnostics Mode must be enabled. Select whether to interfere with backplane transfers between the GNIU and other
enable or disable Enhanced Diagnostics Mode via a hardware modules in the station, and can cause the GNIU’s diagnostic tests
configuration option for the GNIU. The default is disabled. When to declare an error. That can cause other modules in the station to
Enhanced Diagnostics Mode is enabled, the following requirements be marked as faulted, and may also cause the entire input station to
must be met. (Note: More information about Enhanced Diagnostics go offline. For cases where a VersaMax GNIU needs to be
Mode is available in the Genius NIU User’s Manual.) replaced, the system’s operating procedures must require the
operator to remove power from the GNIU before attempting the
System Requirements repair.
1. The only modules allowed in the rack are the Power Supply, the 5. Powering down the entire VersaMax station will cause the system
GNIU, and up to four total ALG265 / ALG266 modules (any to temporarily lose all analog channels (up to 60) in that station, not
combination of ALG265 and ALG266 modules is allowed). just the channels associated with the module that is being replaced.
2. All of the analog modules must be located in the main rack. If a redundant VersaMax Input Station is available, the procedures
3. Expansion racks are not allowed. may optionally allow the overall system to continue to operate with
a degraded level of input channel redundancy for a short time while
4. Empty IO carriers are not allowed.
the faulted input station is being repaired.
Configuration Requirements
1. The GNIU's Report Faults parameter must be set to Enabled. In Operating Notes: General
addition, the Report Faults parameter on every analog module 1. When performing a firmware upgrade on an intelligent I/O module
must be set to Enabled. in the Genius NIU station, the host controller must be put into Stop
2. The GNIU’s CPU Redundancy parameter must be set to GMR. mode, or the Genius network cable must be removed from the NIU.
3. The GNIU’s “BSM Present” and “BSM Controller” parameters must 2. Most Genius NIU faults will appear in the I/O fault table of the I/O
be set to No. controller. However, some Genius NIU faults (such as Loss of rack
and System configuration mismatch) appear in the controller’s PLC
4. For each module except the last, one analog input channel becomes
fault table. The Genius NIU re-reports unresolved faults when the
unusable. These unused channels still count towards the number
controller’s I/O fault table is cleared. It does not re-report
of %AI channels that the GNIU will send to the Genius Bus
unresolved PLC faults when the PLC fault table is cleared.
Controller.
When clearing faults, clear both the PLC and I/O fault tables in that
Operating Requirements order. Then view both the I/O and PLC fault tables to ascertain the
1. Avoid situations where all of the following are true at the same time: Genius NIU station’s status.

- the GNIU's Enhanced Diagnostics Mode is set to Enabled 3. The power supply mounted on a Genius NIU and any booster
power supplies that are used in the same rack should be powered
- the GNIU is online with a Genius Bus Controller.
on and off together.
- serial communications (programmer operations: download remote
I/O configuration, verify equality, clear configuration; or Winloader) 4. There is no response from the Genius NIU to a Write Configuration
are taking place. Datagram COMMREQ. The application program must issue a
Read Configuration Datagram to determine the effectiveness of a
Disconnect the GNIU from the Genius bus before attempting any
previous Write Configuration Datagram.
serial communications if a hardware configuration with Enhanced
Diagnostics Mode set to Enabled either is currently installed or will 5. If the Genius NIU is configured using datagrams (for example, by
be installed in the GNIU. issuing a COMMREQ to a Genius Bus Controller), the value of the
After completing serial communications disconnect the serial cable Force BSM bit is accessible but must not be changed.
from the GNIU’s expansion port. The GNIU can then be reattached 6. If the Genius NIU's CPU Redundancy parameter is set to "Duplex",
to the Genius bus. analog output and intelligent modules must not be used in the I/O
An alternative to disconnecting the GNIU from the Genius bus is to Station.
power off or disconnect all of the Genius Bus Controllers on the bus.
7. Intelligent I/O modules (IC200ALG240, ALG331, ALG620, ALG630,
2. Forcing an I/O point on the GNIU is not permitted. and MDD841) should not be used in an extended distance
3. In Enhanced Diagnostics mode, the GNIU continually runs extensive expansion system. If a rack with an intelligent I/O module in an
diagnostic tests in the background during normal operation. These extended distance expansion system is power cycled, or if a single
diagnostics cause the GNIU to be more sensitive to disturbances slot Genius configuration datagram is sent to an intelligent module
on the Genius bus. When a Genius bus disturbance or in an extended distance expansion rack, the other expansion racks
spontaneous hardware failure causes a diagnostic test to declare and the other devices on the Genius network may default their
an error, the GNIU stops communicating on the Genius bus and outputs briefly.
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
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 VersaMax® Genius® Network Interface Unit
May 8, 2009 GFK-1551Q

8. When configuring a Genius NIU in the bus configuration for a

Genius Bus Controller, the data lengths specified for %I, %Q, %AI Quick Start Guide
and %AQ data must match the hardware configuration of the NIU.
Preinstallation Check
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 Carefully inspect all shipping containers for damage. If any equipment is
configuration mismatch fault caused by the mismatch.) damaged, notify the delivery service immediately. Save the damaged
shipping container for inspection by the delivery service. After unpacking
The correct I/O data lengths can be determined by examining the
the equipment, record all serial numbers. Save the shipping containers
hardware configuration for the Genius NIU. The procedure
and packing material in case it is necessary to transport or ship any part
described here is for Machine Edition Logic Developer – PLC
of the system.
programming software.
a. If the Genius NIU hardware configuration is available:
1. Install the NIU on the DIN Rail by simply clicking it into place.
1) Open the project that includes the Genius NIU target and
select the NIU target. Note: The NIU and connecting carriers
must be installed on the same section
2) Under the NIU target, right-click on Hardware of 35mm x 7.5mm DIN rail.
Configuration and select “Hardware Reference View”.
The DIN rail must have a conductive
3) For each I/O data tab (%I, etc.), use the largest address (unpainted) finish for proper
in the “End” column as the data size for that I/O data grounding.
type. If there are no entries for a data type, the data
length for that type is zero.
b. If the Genius NIU hardware configuration is NOT available: (Refer to the heading Module Installation for information about
1) Connect the Windows PC running the programming space requirements or module orientation, or if you are installing
software to the Genius NIU using a VersaMax NIU serial the NIU in an area of excessive vibration).
cable, IC200CBL002. 2. Install the Power Supply on the NIU.
2) Create a new project for a GE Fanuc PLC. Within the The latch on the power supply must be
new project, create a new Genius NIU target. in the unlocked position.

3) Upload the hardware configuration from the Genius NIU to

the target. Align the connectors and the latch post
and press the power supply module
4) Under the NIU target, right-click on Hardware down until the two tabs on the bottom of
Configuration and select “Hardware Reference View”. the power supply click into place.
5) For each I/O data tab (%I, etc.), use the largest address in Turn the latch to the locked position to
the “End” column as the data size for that I/O data type. If secure the power supply to the top of
there are no entries for a data type, the data length for the NIU.
that type is zero.
9. If the GNIU attempts to come online with a configuration that has Complete the power supply wiring as described in the installation
I/O types and lengths that do not match those expected by the instructions provided with the Power Supply.
controller, a System Configuration Mismatch fault for the GNIU will 3. Adjust the rotary switches on the front of the NIU using a 2.44mm
appear in the controller's PLC fault table: This fault is generated by (3/32in) flat screwdriver.
the controller itself. Additional faults present in the GNIU do not
appear until the mismatch in I/O types and lengths is corrected.
U 0 1
A 2 SBA
10. When the host controller is in STOP mode and the GNIU is N 3 X10

configured for dual bus operation, a power cycle to the GNIU 9 0 1

2
switches the bus from BUS A to BUS B immediately. The GNIU 8
7 3
SBA
X1
6 5 4
does not switch back from BUS B to BUS A even if the host 0 1
controller goes to RUN mode. N
2
3
BAUD
RATE

Documentation Update a. Select the serial bus address with the two upper rotary
In the VersaMax I/O Modules and Carriers Manual, GFK-1504K: switches, SBA X10 (for the tens digit) and SBA X1 (for the
ones digit). Each device on a bus must have a unique serial
▪ The note on page 2-38 should have the addition “Carriers cannot be bus address in the range 0 - 31.
plugged together or unplugged with power applied”. b. Select the baud rate to match that used by the other devices
on the bus by setting the bottom rotary switch: (3) 153.6
▪ The descriptions of the operation of jumpers should have the Kbaud extended, (2) 153.6 Kbaud standard, (1) 76.8 Kbaud,
addition “Jumper positions cannot be modified with power applied”. or (0) 38.4 Kbaud.
c. Cycle power to the NIU after changing the switch settings.

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 VersaMax® Genius® Network Interface Unit
May 8, 2009 GFK-1551Q

4. Connect the communications bus to the NIU. (Refer to the General Module Installation Instructions
heading Bus Installation Guidelines if the NIU is at the end of
Modules may be mounted on a
the bus, or for detailed bus installation instructions.)
horizontal or vertical DIN rail. When
1
SERIAL A1
The NIU has two sets of bus mounted on a vertical DIN rail, the NIU
Main Bus SERIAL A2 terminals. The upper terminals must be located at the bottom.
SHIELD IN
Connections SHIELD OUT are for the main bus cable. The 1. Allow sufficient finger clearance for
lower bus terminals are for an opening NIU door.
Redundant SERIAL B1 optional redundant (dual) bus 133.35mm 2. Allow adequate clearance for
Connections
SERIAL B2
SHIELD IN
cable. (5.25in) serial port cables.
SHIELD OUT
3. Allow adequate space for power
2 wiring.
5. Remove the connector cover on the right-hand side of the The NIU with power supply attached fits
NIU. Do not discard this cover; you will need to install it on the 85.85mm
(3.38in)
into a 70mm deep enclosure.
last carrier. It protects the connector pins from damage and ESD
Rated thermal specifications are based
during handling and use. Do not remove the connector cover on
on a clearance of 5.1cm (2in) above
the left-hand side. 3 and below the equipment and 2.54cm
(1in) to the left of the NIU module.
Connector Cover
Installation in Hazardous Locations
Connector Cover • 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
2;
• WARNING - EXPLOSION HAZARD - when in hazardous
locations, turn off power before replacing or wiring modules;
6. With power off, install additional modules by mounting
modules on their carriers and sliding them along the DIN rail to and
fully engage the connectors in the sides of the carriers. • WARNING - EXPLOSION HAZARD - Do not connect or
disconnect equipment 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/lbs) of torque should be applied to M3.5 (#6-
7. Power up the NIU. The modules in the I/O station will 32) steel screw threaded into material containing internal threads and
automatically be configured, starting at slot 1 in each rack including having a minimum thickness of 2.4mm (0.093in).
expansion racks. If an empty slot or faulted module is encountered, SEE NOTE 2.
autoconfiguration for that rack stops. Autoconfiguration then skips 4.3mm M3.5 (#6) SCREW
to the next rack and continues until all racks are configured. 0.170in
SPLIT LOCK
WASHER
Note: If the I/O station includes any additional power supplies,
those power supplies should be turned on at the same time. FLAT WASHER

8. Observe the NIU LEDs, which indicate the presence of power and 4.3mm
show the operating mode and status of the NIU. 0.170in 15.9mm
0.62in REF

PWR Indicates that the NIU is receiving 5.1mm

PWR 0.200in
power. TAPPED HOLE
OK NIU
IN PANEL
OK Indicates diagnostics executed
FAULT successfully.
I/O ENBL FAULT Is ON if there are one or more faults. Removing the NIU from the DIN Rail
FORCE
I/O ENBL This bicolor LED is green if the I/O 1. Turn off power to the power supply.
SBA ERR scan is enabled and data is being
received from the bus. Otherwise, 2. (If the NIU is attached to the panel with a screw) remove the power
BUS B
this LED is amber. supply module. Remove the panel-mount screw.
FORCE Is ON if one of more I/O points is 3. Slide the NIU away from the other modules until the connector on
forced. the right side disengages from the next carrier.
SBA ERR Is ON if a duplicate device SBA or 4. With a small flathead screwdriver, pull the DIN rail latch out while
invalid SBA exists. tilting the other end of the NIU down to disengage it from the DIN
BUS B Is ON if bus B is active. rail.

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 VersaMax® Genius® Network Interface Unit
May 8, 2009 GFK-1551Q

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.
1. Connect Serial 1 to the Serial 1 terminals of the previous device
and the next device.
2. Connect Serial 2 to the Serial 2 terminals of the previous device
and the next device.
3. 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.
4. 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

Terminating Start End Terminating
Resistor of Bus of Bus Resistor

Serial 1 Serial 1
Serial 2 Serial 2
Shield In Shield In
Shield Out 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
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

For an individual NIU, suppression can
SHLD OUT be supplied by connecting two small
SHLD IN MOVs from Serial 1 and Serial 2 to the
Shield Out terminal. Suitable MOVs
S2
include Harris part number V220MA2A,
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.