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Industrial Automation & Network Hardware
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VersaMax PLC Component Selection Guide

May 30, 2025

The VersaMax Programmable Logic Controller (PLC) platform is a well-established industrial automation solution known for its reliability, compact form factor, and broad adaptability across various industrial applications. Originally launched in 1998 by GE Fanuc, the VersaMax platform is now under Emerson Automation. While the manufacturer has changed, the platform remains active with continued enhancements in controller capabilities and support for modern industrial demands.

Given that the processor is the most expensive and critical part of any PLC system, this guide provides the essential knowledge for selecting the right VersaMax processor for a control system.

II. The VersaMax PLC Family VersaMax PLCs are available in four major types:

  • Nano

  • Micro

  • Micro Plus

  • Modular

A. Compact Controllers (Nano, Micro, Micro Plus) Compact controllers are ideal for small to mid-size applications such as packaging, material handling, conveyor systems, and process industries like water treatment or chemical processing. These models feature integrated power supply, CPU, I/O channels, and communication ports.

  • VersaMax Nano: Up to 11 I/O points.

  • VersaMax Micro: 14 to 40 I/O points.

  • VersaMax Micro Plus: Supports I/O expansion up to 64 points.

B. Modular Controllers Designed for mid- to large-scale applications, modular VersaMax controllers offer separate CPU, I/O, power supply, and communication modules. This enables highly customizable, scalable control architectures.

III. VersaMax Processor Selection Criteria

A. Application Size Select based on I/O count:

  • ≤ 256 I/O: Compact VersaMax

  • 256 to 1024 I/O: Modular VersaMax

  •  

    1024 I/O: Modular VersaMax with advanced expansion

B. Application Criticality High-criticality systems often demand:

  • Redundant power supplies

  • Redundant communication networks

  • Hot-swappable modules

  • I/O redundancy

Only Modular VersaMax controllers support these redundancy features.

C. Analog Loop Control Analog control is essential for applications requiring continuous control:

  • Nano: Limited to one analog input, no output

  • Micro, Micro Plus, Modular: Full analog support (voltage, current, RTD, thermocouples)

D. Controller Memory & Processing Speed Modular CPUs support up to 4096 I/O points. Memory consumption depends on I/O type:

  • All discrete: ~512 bytes

  • All analog (16-bit): ~8.2 KB

Example: IC200CPU001 offers 34 KB configurable memory ample for discrete or mixed I/O control applications.

E. I/O Scalability I/O scalability factors:

  • Micro & Micro Plus: Up to 140 and 320 local I/Os respectively

  • Modular: Up to 4096 I/Os via:

    • Local Expansion

    • Remote I/O via Genius, PROFIBUS-DP, DeviceNet, and PROFINET

F. Communication Capabilities All VersaMax PLCs include at least one RS232 port. Additional communication options include:

  • Ethernet (only built-in on IC200CPUE05)

  • Optional communication modules for Ethernet and PROFINET

  • Supported protocols: SNP, RTU (serial), Modbus, and more

IV. Summary Choosing the correct VersaMax processor depends on your application’s size, criticality, analog needs, scalability, and communication requirements. While compact controllers are ideal for small-scale and cost-conscious solutions, modular controllers offer the customization and redundancy necessary for complex, high-reliability systems.

For personalized guidance on selecting your VersaMax processor, contact:

PLG Automation
Email: sales@plgautomation.com
Phone: 800-906-9271