GE VersaMax Nano/Micro Replacement Guide

GE VersaMax Nano/Micro Replacement Guide

Introduction: When VersaMax PLC faces discontinuation and upgrade

In the fields of food processing, packaging machinery, water treatment, chemical and engineering machinery, GE Fanuc's (now Emerson) VersaMax Nano and Micro series PLCs have been widely used in small and medium-sized automation systems due to their compact structure, high cost-effectiveness, and flexible scalability. However, over time, some early models (especially the Nano 10 point series) have entered the "Mature" lifecycle state, and users are facing practical problems such as difficulty in finding spare parts, program migration, and incompatible communication interfaces.

This article is based on the latest VersaMax Nano/Micro product selection guide (2023-2024), and from the perspective of engineers, provides a detailed analysis of the technical specifications, expansion unit configuration methods, second port communication options, and the use of portable program download devices (PPDDs) for Micro 14/20/23/28/40/64 models that are still in the "Active" state. At the same time, provide alternative suggestions for discontinued Nano models and common troubleshooting processes to help maintenance teams quickly complete system upgrades or fault recovery.

VersaMax Nano Series: Selection and Replacement of Compact Integrated PLCs

2.1 Nano 10 o'clock model list

The VersaMax Nano is characterized by its "integrated and ultra compact" design, with a width of only 75mm, and can be directly mounted on a DIN rail. Its 10 point I/O configuration (6 in/4 out) is non scalable and suitable for standalone devices or distributed slaves. The following are the main models of the Nano series (with a lifecycle status of "Mature", which means it is not recommended to use them in new designs):

Model Input Specification Output Specification Power Supply Built in Analog Quantity

IC200NAL110 6 × 12 VDC 4 × Relay 12 VDC 1-channel voltage input

IC200NAL211 6 × 24 VDC 4 × Relay 24 VDC 1-channel voltage input

IC200NDD010 6 × 12 VDC 4 × 12 VDC 12 VDC None

IC200NDD101 6 × 24 VDC 4 × 24 VDC 24 VDC None

IC200NDR001 6 × 24 VDC 4 × Relay 24 VDC None

IC200NDR010 6 × 12 VDC 4 × Relay 12 VDC None

Common features:

Program memory: 2K words (logic)

Register: 256 words

Two analog potentiometers (for online adjustment)

High speed counter: 2 Type A+1 Type B, 10 kHz, 16 bits

Serial port: RJ-45 (RS-232), supports SNP/SNPX, Modbus RTU slave station

Working temperature: 0~55 ℃

Shutdown replacement suggestion: When the Nano 10 point controller fails and cannot be repaired, priority should be given to upgrading to the Micro 14 or Micro 20 series. Although the volume increases, it can obtain larger program capacity (9-24 K words), more I/O points, and support for expansion units. For example, using IC200UDR001 (14 points) instead of IC200NDR001 requires redesigning the installation base plate and wiring terminals.

2.2 Precautions for migrating from Nano to Micro

Power supply voltage consistency: Nano has two types of power supply: 12 VDC and 24 VDC. Micro 14/20/28 also provides 12 V, 24 V, and 120/240 VAC versions. Please choose according to the original system voltage.

Output type: Relay output can be directly replaced, but if the original Nano is a transistor output (12/24 VDC), the corresponding DC output model of Micro (such as IC200UDD104) needs to be selected.

Program conversion: Use Machine Edition Logic Developer (VersaPro 2.0 or above) to open the original Nano project, modify the hardware configuration to the new Micro model, recompile and download. Note that I/O address mapping may change.

Terminal block: The terminal blocks of Nano and Micro are not compatible and need to be re crimped or replaced with terminal blocks.

VersaMax Micro Series: The Core of Modular Flexibility

The Micro series offers integrated CPUs from 14 to 64 points and supports up to 4 expansion units, with a maximum scalability of 176 I/O. The following is divided by points.

3.1 Micro 14 points (still active)

Micro 14 integrates 8 inputs/6 outputs, supports 4 expansion units, and has a maximum of 126 points. Common models:

Model Input/Output Power Supply High Speed Counter User Power Output

IC200UA003 8 × 120 VAC 6 × 120 VAC 120/240 VAC None None

IC200UA014 8 × 120 VAC 6 × Relay 120/240 VAC None None

IC200UDD104 8×24 VDC 6×24 VDC (2×1.0A,4×0.5A) 24 VDC 4A+1B @10kHz 200 mA

IC200UDR001 8 × 24 VDC 6 × Relay 120/240 VAC 4A+1B 200 mA

IC200UDR002 8 × 24 VDC 6 × Relay 24 VDC 4A+1B 200 mA

IC200UDR003 8 × 12 VDC 6 × Relay 12 VDC 4A+1B 200 mA

All Micro 14 devices share 9K word program memory, 256 word registers, two analog potentiometers, and an RJ-45 RS-232 serial port.

Selection points: If a large number of relay outputs are required on site and there is already 220 VAC power supply, choose IC200UA014 or UDR001; If it is a 24 VDC transistor output and requires ESCP short-circuit protection, choose IC200UDD104.

3.2 Micro 20/40/64 (High Performance Series)

These three series share 24K word program memory, 32K word registers, support 4 expansion units, and offer a second port option (RS-232/RS-485/USB/Ethernet). In addition, they also support portable memory modules (IC200UMB001) for downloading programs without a PC.

Micro 20 (12 in/8 out, maximum 132 points)

Model Output Type Power Supply High speed Counter Built in User Power Supply

IC200UDD020 24 VDC source type, with ESCP 24 VDC 4A+1B @ 100kHz 32-bit 435 mA

IC200UDD220 24 VDC leakage type 24 VDC as above 435 mA

IC200UDR120 Relay 120/240 VAC Same as 435 mA

IC200UDR020 relay 24 VDC as above 435 mA

Micro 40 (24 in/16 out, maximum 152 points)

Model: IC200UDD040 (Source ESCP), IC200UDD240 (Leakage), IC200UDR140 (Relay AC), IC200UDR040 (Relay DC), IC200UDR440 (Relay 12/24 VDC). The parameters are similar to Micro 20, only doubling the number of I/O points.

Micro 64 (40 inputs/24 outputs, maximum 176 points)

Model: IC200UDD064 (Source ESCP), IC200UDD164 (Leakage), IC200UDR164 (Relay AC), IC200UDR064 (Relay DC). Width 190 mm.

Highlight: The high-speed counter performance of Micro 20/40/64 has been greatly improved: 4 A-type+1 B-type, 100 kHz, 32-bit. PWM/pulse output up to 4 channels, 65 kHz, 32-bit. Suitable for servo pulse control and high-speed counting applications.

3.3 Micro 23 and Micro 28 (built-in analog, still active)

Micro 23 (13 in/10 out, maximum 135 points)

Built in 2 analog inputs (0~10V/0~20mA/4~20mA, 12 bits) and 1 analog output (same range).

The program memory is 9 K words and the registers are 2 K words.

Model: IC200UAL004 (12 VDC power supply) IC200UAL005（24 VDC）、IC200UAL006（120/240 VAC）。

Micro 28 (16 in/12 out, maximum 140 points)

No built-in analog, but expandable.

Provide a variety of output types: 120 VAC thyristors, relays, 24 VDC transistors.

The models include: IC200UAA007 (AC input/AC output), IC200UAR028 (AC input/relay), IC200UDD110/120 (24 VDC input/output), IC200UDD212 (12 VDC input/output), IC200UDR005/006/228/010, etc.

Both Micro 23/28 provide two serial ports: Port 1 is RJ-45 RS-232, and Port 2 is DB-15 RS-485 (supporting Modbus RTU master/slave and SNP master/slave). In addition, they support portable program download devices (PPDDs), which are very convenient for on-site maintenance.

Expansion Unit Configuration Guide

VersaMax Micro supports up to 4 expansion units and can mix discrete I/O and analog I/O modules. The width of all expansion units is 95 mm (Micro 20/40/64 expansion units come in two types: 150 mm and 190 mm).

4.1 Discrete Extended Unit Selection Table (Some Typical)

Model I/O configuration power supply characteristics

IC200UE108 8 × 24 VDC input 24 VDC -

IC200UE016 16 × 24 VDC input 24 VDC -

IC200UE0008 8 × 24 VDC output (ESCP) 24 VDC self recovery electronic protection

IC200UE0016 16 × 24 VDC output (ESCP) 24 VDC -

IC200UER008 8 × 2A relay output 24 VDC universal

IC200UER016 16 16 × 2A relay output 24 VDC -

IC200UEC108 4-in/4-out (24 VDC source type) 24 VDC balanced type

IC200UEC208 4 in/4 out (relay) 24 VDC -

IC200UEX015 8 × 12 VDC input/6 × 12 VDC output 12 VDC 14 point combination module

IC200UEX011 8 × 120 VAC input/6 × relay output 120/240 VAC AC input combination

IC200UEX009 8 × 120 VAC input/6 × relay (2 × 10A+4 × 2A) 120/240 VAC large capacity output

IC200UEX215 16 × 12 VDC input/12 × 12 VDC output 12 VDC 28 point combination

IC200UEX222 16 × 24 VDC input/12 × 24 VDC output (ESCP) 24 VDC transistor protection

IC200UEX064 40 × 24 VDC input/24 × relay output 24 VDC 64 point combination (only supported by Micro 20/40/64)

Selection skills:

For situations that require a large number of relays, UER016 or UEX064 are preferred.

For output that requires short-circuit protection and frequent switching, a transistor output module with the "ESCP" symbol (such as UE0008) must be selected to avoid external fuses.

The combination module (UEX series) can save rack space, but it should be noted that its power supply voltage must match the CPU.

4.2 Simulation Expansion Unit

The Micro series supports up to 4 analog extensions, with a maximum of 16 inputs/8 outputs. Typical model:

Model Type Input/Output Range Resolution Power Supply

IC200UEX624 4-channel analog input 0~10V/4~20mA 12 bit 24 VDC

IC200UEX616 4 In/2 Out Same as 12 Bit 12 VDC

IC200UEX626 4 In/2 Out Same as 12 Bit 24 VDC

IC200UEX724 4-channel RTD (PT100) 2/3 line 16 bit 24 VDC

IC200UEX726 4 RTD input/2 analog output PT100+current/voltage 16/12 bit 24 VDC

IC200UEX824 4-channel thermocouple/mV K, J, E, S, T, B, N; ± 50/± 100mV 12 bit (16 bit optional) 24 VDC

Note: 16 bit resolution is only available when supported by Micro 20/40/64 (requires Machine Edition 5.0 SP3 Hotfix).

Communication and Network Options

The communication capability of VersaMax Nano/Micro is a key consideration in its replacement and upgrade.

5.1 Built in serial port

Nano: Single RJ-45 RS-232, supports SNP, SNPX, Modbus RTU slave.

Micro 14: Same as above.

Micro 23/28: Port 1 RS-232 (RJ-45), Port 2 RS-485 (DB-15), Port 2 supports Modbus RTU master/slave, SNP master/slave, and serial port read/write commands.

Micro 20/40/64: Port 1 RS-232, Port 2 is a modular slot that can be plugged into the following option boards:

Options board model, interface, additional functions, memory module support

IC200UEM001 Ethernet (10/100) SRTP, Modbus TCP server is

IC200USB001 RS-232 (RJ-45) 2-channel 0~10V analog input (10 bits) is

IC200USB002 RS-485 (RJ-45) 2-channel analog input is

IC200UUB001 USB 2.0 slave only has SNP/Modbus slave and no analog

Ethernet configuration: Using IC200UEM001 allows Micro 20/40/64 to directly connect to the factory Ethernet, supporting SRTP (GE specific protocol) and Modbus TCP servers for easy communication with the upper computer or SCADA.

5.2 External Ethernet Serial Port Server

For CPUs such as Nano or Micro 14 that do not have a second port, the VersaMax SE (IC200SET001) module can be used. It is independently powered (12/24 VDC), providing an Ethernet port and an RS-232/RS-485 serial port to achieve protocol conversion from Ethernet to SNP or Modbus TCP to Modbus RTU. Supports up to 16 serial devices.

5.3 Portable Program Download Device (PPDD)

IC690ACC990 is a field program downloader designed specifically for Micro 23/28. Its characteristics:

No need for a PC, programs and configurations can be uploaded/downloaded through a USB memory stick.

Connect to the CPU via DB-15 RS-485 port (the CPU needs to have port 2).

Support remote transmission of ZIP files: Engineering designers compress binary files and email them to the site, and on-site personnel extract them to a USB drive, insert PPDD, and download them with one click.

Three LED indicator lights (Error red/Status green) provide status feedback: flash indicates CPU type mismatch or file missing, slow flash indicates download in progress, constant light indicates completion or idle.

Usage steps (from original text):

Turn the PPDD selection switch to the USB memory stick, press the button, and store the programs in the CPU to the USB flash drive.

Insert the USB flash drive into the computer, copy the files, and send an email to the remote site.

Remote on-site storage of received files on a USB drive, inserting the USB drive into the PPDD, and turning the switch to the controller.

Press the download button, and PPDD will automatically stop the CPU, download and verify. After completion, the CPU can be run by turning on the key switch or re powering on.

This device greatly simplifies on-site services, especially suitable for equipment upgrades in remote areas.

Common troubleshooting and maintenance

6.1 Fault Symptoms and Countermeasures Table

Possible causes and solutions for the phenomenon

CPU not running (Run LED off) not set to Run mode; Program error; Watch dog timeout check key switch position; Use software to clear faults; Increase scanning time setting

Unable to communicate with programming software due to cable error; Serial port settings do not match; SNP address conflict using IC200CBL500 programming cable; Confirm baud rate (default 19.2k); Check CPU station address

The output point does not operate, and the output fuse is blown; Load short circuit; Check if the electronic protection of the ESCP module is activated when the output point is burnt out (it can be restored when power is turned off and back on); Replace output point

The expansion unit is not working and the expansion cable is loose; Insufficient power supply; Configuration does not enable re plugging of IC200CBL50x cable; Measure the power supply of the expansion unit; Add modules to hardware configuration

Poor shielding of analog reading jump signal line; Common mode voltage is too high; Short sampling time using shielded twisted pair cables and single ended grounding; Increase filtering time constant

Program loss and battery depletion (Micro 23/28), replace IC200ACC403 (standard) or IC200ACC414 (long life); Download the program again

PPDD Error LED is constantly on. No USB flash drive inserted. Insert formatted FAT32 USB flash drive

6.2 Battery replacement and data retention

Micro 23/28/64 uses battery backup for real-time clock and partial RAM. The standard battery IC200ACC403 can maintain data for 5.2 months at 70 ℃ and 32.4 months at 20 ℃. The long-life battery IC200ACC414 maintains a temperature of 70 ℃ for 19 months and 20 ℃ for 121 months. When the battery voltage is low, the "BATT" LED of the CPU will light up. The replacement must be carried out while the CPU is powered on to avoid data loss.

6.3 Complete process for replacing discontinued models

Assuming the original system is damaged using IC200NDR001 (Nano 10 points), the plan is to upgrade to IC200UDR001 (Micro 14 points):

Hardware preparation: Measure the installation space. The size of Micro 14 is 95 × 90 × 76 mm, which is larger than Nano (75 × 80 × 47), and requires rearranging the DIN rail or base plate.

Wiring conversion: Nano's 6-in/4-out terminal block is not compatible with Micro 14's 8-in/6-out terminal block. I/O addresses need to be reassigned according to the original circuit diagram and new terminal blocks need to be crimped.

Program migration: create a new project in Machine Edition, select IC200UDR001, import the logic of the original Nano (export as text or upload through SNP), and then adjust the I/O mapping. Note that the analog input of the original Nano (if any) requires an additional analog expansion module on the Micro 14.

Download test: Connect the IC200CBL500 cable to the CPU, download the program, set to RUN, and test the input and output one by one.

Expansion plan: If the original device requires more I/O, the expansion capability of Micro 14 can be utilized to add UE series modules.

Programming software and toolchain

VersaPro: Version 1.1 or higher supports Micro 14/23/28, version 2.0 supports Nano. But VersaPro is no longer updated, it is recommended to use Machine Edition Logic Developer.

Machine Edition: Requires 5.0 Service Pack 3+Hotfix to support Micro 20/40/64 and 16 bit analog signals. Provide an integrated programming environment (logic, visualization, motion control).

DataDesigner (IC752DDZ000): Used for programming Data Panel operator panels (DP45, etc.), supports 2x16, 4x16, 4x20 LCD with backlight, NEMA 4 protection.

IC646MPM101: Specialty Logic Developer Nano/Micro Programming Cable Kit.

Important note: All Nano/Micro series do not support portable memory modules (except for Micro 20/40/64 using IC200UMB001). Although Micro 23/28 does not support memory modules, it supports PPDD.

Accessories and power supply selection

8.1 Cable

IC200CBL500: Programming cable, RJ-45 to DB-9 (female), 3 meters, RS-232。

IC200CBL501: Expansion cable, 0.1 meters (pack of 5), used to connect CPU and expansion unit.

IC200CBL505: 0.5m extension cable.

IC200CBL510: 1 meter extension cable.

8.2 External 24 VDC power supply

IC690PWR024:24 VDC/5A, 120/230 VAC input.

IC690PWR124：24 VDC/10A。

8.3 Other accessories

IC200ACC402: Spare pluggable terminal block (10 per pack), suitable for Micro 14/23/28 and expansion units.

IC200ACC404: Spare parts set (2 terminal blocks+4 plastic door covers).

IC200ACC451: Input simulator (8 switches), used to test the input points of Micro 14/23/28.