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Siemens SIMATIC 545/555/575 Manual

1. Upgrade Path Series 505 I O 4 8 or 16 slots 545 555 or VMEbus 575 Local I O 545 1104 or 1106 CPU 555 1103 1104 1105 or 1106 CPU or 575 2104 2105 or 2106 CPU with 575 2126 annex card Series 505 remote O link Figure C 2 Upgrading an RS 485 Based 560 560T 565 565P System SIMATIC 545 555 575 System Manual Upgrading Existing Series 500 Installations C 7 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com C 4 Upgrading an RF Based 560 560T 565 565P System Upgrading an RF based System to 545 555 Installing an RS 485 RF I O channel converter allows you to update an existing 560 560T 565 or 565P system that uses coaxial RF cables with 545 555 or 575 CPUS providing the advantages of greater speed and greater remote distance and the option of dual media To upgrade to a 545 555 system you need to replacethe existing programmable controll
2. Upgrade Path 8 Copper Ground Strap VME pus VME Base Bases must be within three feet of each other and connected by a 8 copper ground strap Local I O Series 505 Base ODOM aon xm oo Remote Series 500 505 Bases with RF RBCs Notes n order to use its Series 505 remote I O port thereby connecting to the RS 485 RF I O channel converter the 575 CPU must have an installed 575 2126 annex card No remote bases can be connected on the RS 485 link between the 575 CPU and the PPX 505 6860 Figure C 4 Upgrading an RF Based 560 560T 565 565P System to 575 SIMATIC 545 555 575 System Manual Upgrading Existing Series 500 Installations C 11 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com C 5 Installing a PPX 500 5114 A RBC Installin
3. Figure 4 9 Selecting Input Voltage on the PPX 575 6663 Power Supply CAUTION The PPX 575 6663 power supply has selectable voltage Ensure that the voltage selector is set to match the input power See Figure 4 9 for an example of how to set the voltage selector Attempting to operate the power supply at 220 VAC with 110 VAC selected or 110 VAC with 220 VAC selected results in damage to the power supply Double check your power supply voltage before you connect input power 4 16 Installing 575 System Hardware SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Installing the 575 The 16 slot VM E bus base accepts either one of the 575 power supply Power Supply modules PPX 575 6660 and PPX 575 6663 To install a power supply module align the metal backplate of the module in the metal guiderails on the left side of the chassis as shown in Figure 4 10 Push firmly until the module is properly seated in the backplane connector and tighten the four securing screws at the corners of the faceplate Align metal backplate of power supply module within guiderails Figure 4 10 Installing the 575 Power Supply Module Wiring Guidelines When you connect your 575 VME power supply module to the external power
4. H OFF Switch position ON termination and bias enabled B Attaching connector to midpoint of cable Switch position OFF termination and bias disabled Figure 6 20 Attaching Connector and Selecting Termination SIMATIC 545 555 575 System Manual Cabling and Wiring the System 629 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Installing PROABUS DP I O Cables continued 8 Putthe cover back on the connector housing Besurethat the bare cable shielding makes contact with the metal cable guide on the connector to ensure proper grounding for the connection 9 Tighten the connector housing screws to a maximum torque of 8 in Ib 0 9 N m in order to ensure a good connection 630 Cabling and Wiring the System SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com PRORBUS DP Port Figure 6 21 shows the pinout for the PROFIBUS DP port for the products Pinout e g CPUs RBCs that are described in this manual NOTE Pins 2 and 7 are No Connect for the p
5. Special Maximum DC Power Model Number Description Function mediate Consumption Watts PPX 1 0 Module 505 4508 1 24 VDC Output 8 point a 2 5 505 4516 24 VDC Output 16 point y 2 5 505 4532 1 24 VDC Output 32 point y 2 5 505 4608 1 110 VAC Output 8 point d 2 5 505 4616 1 110 VAC Output 16 point a 2 5 505 4632 1 110 VAC Output 32 point al 2 5 505 4708 1 24 VDC Output 8 point al 5 0 505 4716 24 VDC Output 16 point d 5 0 505 4732 1 24 VDC Output 32 point d 5 0 505 4808 1 220 VAC Output 8 point al 5 0 505 4816 1 220 VAC Output 16 point D 5 0 505 4832 1 220 VAC Output 32 point al 5 0 505 4908 1 Relay Output Form C 8 point D 2 5 505 4916 Relay Output Form A 16 point a 2 5 505 4932 A Relay Output F orm A 32 point al 2 5 505 5100 TurboPlastic in 7 0 0 505 5103 TurboParison al 7 0 0 505 5184 MODNIM Modbus NIM Kn 8 0 505 5190 6MTCC 505 to 6MT Interface al 4 0 505 5417 1 Relay Output 115 VDC 16 point d 3 0 ex 505 5518 Relay Output Form C uw 2 0 505 5918 48 VDC Output al 2 5 505 6010 Input Simulator v 2 0 505 6011 1 Output Simulator a 2 5 E 505 6108 Analog Input Dd 4 0 505 6108 A Analog Input al 4 0 505 6202 Analog Output 2 point al 2 5 505 6204 Analog Output 4 point In 5 0 505 6208 Analog O
6. DR OututseonDrdum D4 form o P4 Ds fowm P6 pg fowm o P8 pc Output section D user ponar oo E 6 575 O Module Specification amp Pinouts SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com E 3 Discrete AC Output Module The discrete AC output module PP X 575 4616 allows the controller to drive 110 VAC loads Table E 6 shows module specifications and Figure E 2 illustrates the effect that temperature has on current output capabilities Table E 7 shows connector pinouts Table E 6 Discrete AC Output Module Specifications ames E One 5A 125 V normal bl ow 5x20 mm Fuses fuse per common Replace only with UL CSA listed fuse Output type Non latching unprotected Surge suppression Veatt 5 V STDBY current consumption On state indicators one per channel One blown fuse indicator which lights when any fuse blows user power and Indicators base power must be on Indicators A5 A8 B5 B8 C5 C8 and D5 D8 are unused SIMATIC 545 555 575 System Manual 575 O Module Specification amp Pinouts E 7 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Discrete AC Output Module continued Figure E 2 illustrates the effect that temperature has on current outp
7. sssssssssssssee eee 4 10 Mounting a Base in a 19 inch Rack 6 cece 4 11 NEMA Cabinet Mounting Measurements sssssssssssssess esee 4 12 Panel Mounting the Base 0c cece tee 4 12 Grounding the ControllerChassis 0 cece eens 4 13 Installing the 575 Power Supply 00ccceceeeeeeee seen eee eee e eee eee eee 4 14 OVEWIEW P p ELTE 4 14 Selecting Input Voltage PPX 575 6663 Only sssssssseeeee ee eee eees 4 16 Installing the 575 Power Supply sseeseeee RI 4 17 Winng Guidelines 22 net Due E reet DIT deere dare doirada bv s ee E Durus 4 17 Wiring Procedure isis i kel p ede Rx cd ewe ca cbecdeeeea dees Eaa a 4 18 Installing the Battery 00cccecc cece cece cere eee 4 20 Battery Backup forthe 575 cc cece ccc 4 20 Mounting the Battery 0 cece cect tte 4 20 Disabling the Battery 0 ccc cece cc tte 4 22 Qihnuir UEM 4 22 Installing the Hoating Point Coprocessor Optional 0eeeeeee eee ee eeeeeeee 4 23 Configuring the CPU ccc eee cece eee eens 4 24 Configuring the 575 2105 2106 CPU 0 eee nes 4 24 Configuring the 575 2104 CPU 0 ene eee eens 4 24 Using the AUTO CONFIGURED Mode ssssssssse eene anna 4 26 Using the USER C O NFIG URED Mode ssssssesese eene 4 26 Configuring the 575 Primary and Secondaries selle esee 4 26 Enabling the Auto Recompile Function 000 cee 4
8. 0 00 cece B 7 Determining the Compatibility of a Module 00 eee B 7 Series 505 High Speed Counterfor545 555 10 ccc cece eee nn B 8 Determining the Manufacturing Date 0 cece B 9 SIMATIC 545 555 575 System Manual Power and Compatibility B 1 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com B 1 Power Consumption Influence of Annex Table B 1 shows the power consumption of 545 and 555 CPUs with and Cards on CPU without PROFIBUS DP annex cards Table B 2 shows the power Power consumption of 575 CPUs with or without an annex card The Series 505 Consumption remote I O and PROFIBUS DP I O annex cards have the same effect on power consumption Table B 1 545 555 CPU Power Consumption Without PROFIBUS DP Annex Card With PROFIBUS DP Annex Card CPU Model 545 1103 1105 4 W 0 8 A 0 20 W 04 A 8 5 W 1 7 A 0 20 W 04 A 0 20 W 04 A 555 1103 1104 Not applicable Not applicable 8 5 W 1 7 A 0 20 W 04 A 555 1105 1106 Not applicable Not applicable 8 5 W 1 7 A 0 20 W 04 A Note Power consumption given in watts amps in parentheses PROFIBUS DP communication port built into 555 1105 and 1106 CPU board 545 1104 1106 Not applicable Not applicable 85W 17A Table B 2 575 2104 CPU Power Consumption Voltage Power Consumption without Power Consumption with Either 9 Either Annex Card Annex Card 45
9. 1 Mbaud Series 505 Base with RBC PPX 505 6851 A B RBC PROFIBUS DP I O Channel 12 Mbaud Series 505 Base with 505 PROFIBUS DP RBC PPX 505 6870 RBC ET200U Series 500 Base with RBC PPX 500 5114 A RBC 95U PROFIBUS DP Series 500 Base with 500 PROFIBUS DP RBC PPX 500 6870 RBC ET200B Block I O ET200C AS Interface Master AS Interface Bus Allen Bradley m F Limit SW P B Solenoid PE Cell Metlore Toledo Data Logic Third Party ABB Products Siemens AC DC APG Modicon Motors and Drives Turk etc Notes The Series 505 remote I O channel supports up to 15 Series 505 Series 500 remote bases The PROFIBUS DP I O channel supports up to 112 SIMATIC and third party DP I O slaves A 575 2104 CPU can support either the 505 I O channel or the PROFIBUS DP channel but not both simultaneously The 545 1103 1105 CPUs support only the PROFIBUS DP channel up to 32 SI
10. Variable V 1905 K bytes 1905 K bytes 52 Kbytes Constant K 1904 K bytes 1904 K bytes OKbytes Special S 1904 K bytes 1904 K bytes 32 Kbytes User U 1904 K bytes 1904 K bytes OKbytes Timer 20480 100 Kbytes 1024 Drum 2304 108 Kbytes 64 Shift Register 16384 16 Kbytes 1024 Table Move 14336 28 Kbytes 1024 One Shot Number per block 32768 32Kbytes 1024 Table 8 5 555 1105 CPU Memory Configuration Memory Total Memory Required Required for Default Allocation per Block Maximum Size Total memory 384 K bytes Ladder L 123 K bytes 369 K bytes 32 Kbytes Variable V 369 Kbytes 369 K bytes 52 Kbytes Constant K 368 Kbytes 368 Kbytes 0 Kbytes Special S 368 Kbytes 368 Kbytes 32 Kbytes Compiled Special CS 368 Kbytes 368 Kbytes 0 Kbytes User U 368 Kbytes 368 Kbytes 0 Kbytes Timer 20480 100 K bytes 1024 Drum 2304 108 K bytes 64 Shift Register 16384 16 K bytes 1024 Table Move 14336 28 K bytes 1024 One Shot N umber per block 8 6 Starting Up the System 32768 32Kbytes 1024 SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Table 8 6 555 1106 CPU Memory Configur
11. sssssesesesseeeeerrees E 16 Contents xvii Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Preface AboutThis Manual This SIMATIC 545 555 575 System Manual indudes requirements and specifications for preparing your control site and installing a SIMATIC 545 555 or 575 programmable logic controller system This manual describes the following equipment e 545 1103 1104 1105 and 1106 CPUs e 555 1103 1104 1105 and 1106 CPUs e 575 2104 2105 and 2106 CPUs e 575 2126 Remote I O Annex Card e 505 CP5434 DP Remotel O Annex Card e 505 6851 A B Remote Base Controllers e 505 6850 A B Remote Base Controllers e 505 6870 PROFIBUS DP Remote Base Controller Thefollowing major topics are covered e Site preparation including power and grounding requirements and other safety considerations e Hardware installation including Series 505 and VMEbus bases power supplies 545 555 575 CPUs remote base controllers RBCs I O modules and annex cards e System cable and wiring procedures e System startup including modem operation e System troubleshooting including use of AU X functions status words and other diagnostic aids e General maintenance procedures such as changing power supply fuses e Using EEPROMs and EPROMs e Upgrade of Series 500 bases for connection to the 545 555 The material about 575 interboard communication which wa
12. 3 Either perform a power cycle or else issue SY SRESET from a source other than the 575 CPUs to put the 575 in PROGRAM mode NOTE A 575 CPU can issue SYSRESET only if it occupies slot 1 Table 4 4 summarizes the conditions under which the 575 CPU issues SY SRESET or else waits for SYSRESET during FAULT recovery Table 4 4 575 CPU SW5 On During Fault Recovery Off On xi X Off On X X X Off On X X lin this configuration the 575 CPUs do not recover from FAULT unless SYSRESET is issued SIMATIC 545 555 575 System Manual Installing 575 System Hardware 4 27 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 4 11 Installing a Remote I O Annex Card Optional Configuring Annex Card Dipswitch Annex Card Power Consumption There are two ways to connect your 575 CPU to remote I O e Usea PPX 575 2126 remote I O annex card to connect the 575 CPU to Series 505 remote I O by means of the Series 505 remote I O channel e Alternatively you can use a PPX 505 CP5434 DP PROFIBUS DP annex card to connect the 575 CPU to DP and Series 505 I O by means of the PROFIBUS DP 1 O channel You can only use one remote I O annex card per 575 CPU The Series 505 remote I O and PROFIBUS DP annex cards use a dipswitch for configuration when used with the 575 2104 CPU only When used with the 575 2105 2106 CPUs configuration is done with the dipswitch located on the CPU R
13. 505 7340 Dual Media NIM al 8 0 505 7354 Peerlink a 8 0 e E e 7 me we 505 CP1434TF H1 Communication Processor w 22 02 0 100 ee h d FMS Communication ps u 5 0 0 200 Fa T Programmable Logic Controller 4 0 8 53 0 200 PP SIDE Programmable Logic Controller 8 5 0 200 555 1103 rg SIDE Programmable Logic Controller 8 5 0 200 555 1106 1 Modules that are affected by date code restrictions See Section B 2 for information Maximum power consumption 22 0 W with jumper E1 installed Without jumper E 1 maximum power consumption is 10 0 W 3 Without PROFIBUS DP annex card with PROFIBUS DP annex card Note For any module not listed here consult the manual for that module SIMATIC 545 555 575 System Manual Powerand Compatibility B 5 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Power Consumption continued Power Table B 4 shows the DC current requirements for 575 VME devices Requirements for pis DEVICES Table B 4 DC Curent Requirements for 575 Devices FE odel Number Description PPX g 1 120 mA 1 mA 575 2104 VME CPU 2 2A 50 mA 50 mA ifi Ma 1 120 mA 1 mA 575 2105 VME CPU 2 2A 50 mA 50 mA in backup 1 120 mA 1 mA 575 2106 VME CPU 2 2A 50 mA 50 mA in backup 575 2124 9 slot 1 inch VMEbus base 10A 575 2126 Series 505 remote I O annex card 10A
14. Guaranteed 888 88 SOURCE www artisantg com Spares for 575 System Thefollowing is the recommended list of spare parts for a 575 system PPX 575 2130 16 slot VME base with 0 8 inch spacing PPX 575 2131 115 230 VAC fan kit for 751 2130 base PPX 575 6660 185 watt power supply module PPX 575 6663 300 watt power supply module PPX 2587679 8016 4 0 A fuse kit for battery on all VME bases PPX 2589739 8008 8 0 A 250 V slow blow fuse 3 AG for PPX 575 6660 qty 5 PPX 2589739 8013 10 0 A 250 V slow blow fuse 3 AG for PPX 575 6663 qty 5 PPX 2587679 8019 5 0 A 125 V normal blow fuse 5 x 20 mm for PPX 575 4616 PPX 575 4366 and PPX 575 4532 PPX 2587679 0310 3 0 A normal blow fuse 5 x 20 mm for PPX 575 4916 qty 5 PPX 2587679 8020 8 0 A normal blow fuse 5 x 20 mm for PPX 575 4732 qty 5 PPX 2587679 8002 3 0 A fuse kit for 575 2131 fan pack PPX 2589739 8006 battery pack 4 V 5 Ah gel cell PPX 2589739 8016 Z rails DIN connector rail kit with hardware qty 2 PPX 2589739 8012 575 J 2 power connector kit PPX 2589739 8014 0 8 inch blank filler bezel qty 1 PPX 2589739 8015 0 6 inch blank filler bezel qty 1 SIMATIC 545 555 575 System Manual Series 505 and VME Components D 7 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Appendix E 575 I O Module Specifications amp Pinouts E1 Disc rete AC Input Module cccccceceee
15. ssessesennn nnn nnn nnn 7 12 SIMATIC 545 555 575 System Manual Using EEPROMsfor Program Storage 7 1 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 7 1 Program Storage Options Overview On Board Hash EEPROM Program Storage Optional Portable E EPROM Program Storage You can download your program into a non volatile read only memory chip for additional program security Program storage options indude portable Electrically Erasable Programmable Read Only Memory EEPROM or Erasable Programmable Read Only Memory U V erasable EPROM chips and permanent on board EEPROMs The CPUs listed in Table 7 1 provide on board permanent non volatile flash EEPROM memory for program storage The program memory storage capacities for each CPU are also listed The 575 2105 and 575 2106 CPUs provide only on board program storage Table 7 1 Program Storage Capacities CPU Model User Memory in RAM On Board User Memory Capacity 545 1105 96 K bytes 96 K bytes 545 1106 192 K bytes 192 Kbytes 555 1105 384 K bytes 384 K bytes 555 1106 1856 Kbytes 1790 Kbytes 575 2105 832 K bytes 832 Kbytes 575 2106 1856 Kbytes 1790 Kbytes All 545 and 555 CPUs offer the option of storing your application program in non volatile form by means of portable dual in line pin DIP EEPROM or EPROM chips The 575 CPUs do not support this option Table 7 2 lists the E EPROMS available for use wit
16. 0 0c cece cette ett 6 35 575 Ready Busy Printer Handshaking 0c cece eect tte 6 35 E EPROM Socket and J umper Pins for 1103 1104 CPUs ccc cece eee 7 7 E EPROM Socket and J umper Pins for 1105 1106 CPUs 0c cece eens 7 7 Jumper Pin Settings for On Board Memory Program Storage ssssssssss 7 9 Typical AUX 29 Screen ssssssssseese ehh 9 5 Example Replacing Power Supply Fuse sssssseees ees 9 20 SerialNumber Definition lsselseeeesseeessee n nnn B 9 Upgrading a 520 520C 530 530C 530TSystem 0 eee C 5 Upgrading an RS 485 Based 560 5601 565 565P System 0 00 0 C 7 Upgrading an RF Ba sed 560 560T 565 565P System to 545 555 ss C 9 Upgrading an RF Ba sed 560 560T 565 565P System to 575 2 eee eee eee C 11 Installed Series500 RBC ssssssssseeseeeeeeee II rran C 13 Series 500 RBC Switch Selection ssssssssssseee III C 14 Series 500 Remote Base Controller and Baud Rate Settings 205 C 16 RS 485 RF Connector Ports 2 cece en C 23 Low Current DC Output Current Point vs Ambient Temp suueeeeee E 4 16 point AC Output Curent Point vs Ambient Temp 00 cece eee eee eee E 8 Field Wiring for Relay Output Module 0 cece E 11 Relay Output Module Curent Point vs Ambient Temp 0 cece cece eens E 11 PPX 575 4532 Cument Point vs Ambient Tem
17. 3 2 Installing 505 System Hardware SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 3 2 Enclosure and Temperature Considerations Enclosure Selection Temperature Considerations An enclosure should provide the following features e Easy access to components e A common ground potential on the cabinet e A secure vertical panel or rails e Conformance to electrical standards e An electromagnetic shield if needed to meet FCC or CE emission standards e Access restricted to authorized personnel only e Adequate cooling and heat dissipation e Protection from dust and dirt as required by the environment Mount the components in a dustproof and drip tight endosure such as a NEMA enclosure The enclosure must provide a minimum depth of 10 inches 254 mm from the panel to the inside surface of the enclosure door The enclosure should be located so that the doors can be opened fully permitting easy access to the controller wiring and components If environmental conditions permit a 19 inch rack may be used instead of a NEMA enclosure Use either the 11 slot PPX 505 6511 or the 16 slot PPX 505 6516 base for 19 inch rack installations The SIMATIC 505 575 PLC Systems comply with the requirements of the EMC Directive 89 336 EEC when installed in accordance with the specifications in this manual and when installed in a grounded metal c
18. 575 CP5434 DP PROFIBUS DP I O annex card LOA 575 2128 14 slot 1 inch VMEbus base 10A 575 2130 16 slot 0 8 inch VME bus base 10A 575 4232 110 VAC Input 32 point 0 9A 575 4332 LVDC Input 32 point 0 4A 575 4366 24 VDC Input Output 16 16 0 9A 575 4532 LVDC Output 32 point 1 2 Amp 10A 575 4616 110 VAC Output 16 point 1 2 Amp 0 9A 575 4732 LVDC Output 32 point 2 Amp 1 00A 575 4916 Relay Output 16 point 0 9A 2589739 80122 J2BackplaneKit 0 16A 1 Installation of 68882 coprocessor PPX 2589739 8010 increases this by 0 1 A 2 Power connector B 6 Powerand Compatibility SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com B 2 Module Compatibility with C PUs I O Modules Not Compatible with CPUs Determining the Compatibility of a Module Unmodified Series 505 discrete I O modules manufactured prior to J anuary 1988 are unable to report module status and therefore cannot be recognized by the 545 555 or 575 CPU that is inputs are not read and outputs are not written Series 505 discrete I O modules manufactured in J anuary 1988 or later and those manufactured prior to this date that have been modified do contain the status reporting mechanism and are compatible with 545 555 or 575 CPUs TheSeries 50
19. 888 88 SOURCE www artisantg com Installing a PPX 500 5114 A RBC continued Output State When I O channel communication to a base is lost the state of the outputs Selection is determined by the selection made on the RBC Off F reeze switch See Figure C 6 Figure C 6 Series 500 RBC Switch Selection For discrete output modules the state of the outputs is determined solely by the position of the RBC Off F reeze switch For analog word output modules the state of the outputs is influenced not only by the position of the RBC Off F reeze switch but by the output module s Zero H old Last Value selection if the module has that option See Table C 1 C 14 Upgrading Existing Series 500 Installations SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Table C 1 Analog Word Output States Analog Word Module Analog Word RBC Off F reeze Selection Zero Hold Selection Output State Zero Zero Zeo Noticethat the F reeze option on the RBC overrides the Zero selection on the analog word output module likewise when Hold Last Value is selected on the analog word output module that selection overrides the Off option on the RBC jumper NOTE If the RBC watchdog timer is activated an RBC failure the state of the outputs is determined by the output module with no reference to the RBC s Off F reeze switch Discrete outputs go off
20. Baud rates O channel PROFIBUS DP 1 4 Series 505 3 23 4 25 RBC PROFIBUS DP 5 17 Series 500 C 16 Series 505 5 8 Bias and termination overview 6 24 Boards VME bus installing 4 32 Index 1 Guaranteed 888 88 SOURCE www artisantg com C Cable connecting modems overview 6 32 PROFIBUS DP installations attaching connector 6 28 cable requirements 6 22 equipment needed 6 21 guidelines 6 23 maximum line length 6 22 media options 6 20 sample system 6 20 termination and bias 6 24 termination guidelines 6 24 termination schematics 6 26 termination selection switch 6 25 troubleshooting 9 23 twisted pair 6 20 resistance of line to line 9 21 RS 485 measuring resistance 9 21 Series 505 installations cable requirements 6 7 connecting drop lineto CPU 6 14 connecting drop lineto RBC 6 14 connecting trunk line to terminal block 6 17 drop line 6 5 equipment needed 6 4 extending trunk line 6 18 guidelines 6 8 media options 6 4 preparing drop line 6 12 preparing trunk line 6 16 proper termination 6 15 6 18 selecting cable 6 6 terminal blocks 6 4 trunk line 6 5 twisted pair 6 4 Cable routing back of 575 unit 2 20 guidelines 6 2 in ceiling 6 3 mounting tap 6 4 Communication establishing 4 45 Communication ports CPU 545 555 3 24 575 4 47 RBC PROFIBUS DP 5 5 Series 505 5 5 Configuration CPU 575 primary and secondaries 4 26 RBC PROFIBUS DP 5 24 softw
21. CS C1 Output 9 C1 C2 Output 10 C2 C3 Output 11 C3 Output 12 C C DR Output section D return D1 Output 13 D Output section C user power D1 1 Output 14 D2 pa Output P4 DC__ Outpatsecion Duserpowe cr 24 VDC user ail power positive ineton su cs 2A VOC user col power return eturn Tine to supp E 10 575 VO Module Specification amp Pinouts SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Figure E 3 shows a sample of field wiring for the discrete relay output module Terminal Block AC Module Figure E 3 Field Wiring for Relay Output Module Figure E 4 illustrates the effect that temperature has on current output capabilities With fan cooling ds Without fan cooling 10 20 30 40 50 60 70 10 20 30 40 50 60 70 Temperature C Temperature C Figure E 4 Relay Output Module Current Point vs Ambient emp SIMATIC 545 555 575 System Manual 575 I O Module Specification amp Pinouts E 11 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com E 5 Discrete DC Output Module The discrete DC output module
22. Figure 2 14 Grounding Connection and Altemate Location Use the ground connection Figure 2 14 to attach one end of a ground wire attach the other end to a nearby grounding rod that meets all electrical specifications required for an earth ground Use the shortest possible length of 8 gauge copper wire or equivalent braided cable to make the connection Grounding the If the system is mounted in a cabinet or rack use the same grounding Cabinetor Rack procedure Ensure that a good cabinet or rack ground connection is achieved by removing existing paint and attaching a 8 gauge copper wire or equivalent using a bolt washers and nut as necessary 2 20 Pre installation Guidelines SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Chapter 3 Installing 505 System Hardware 3 1 Overview of Installation Procedures ccee eee eee eee mm mmm 32 3 2 Enclosure and Temperature Considerations eere 3 3 Enclosure Selection 2 ee ke rer ke RR neu Er Eee E DET E uan 3 3 Temperature ConsiderationsS assuran nrnna 3 3 3 3 Senes 505 Bases 5 2 en nes nde nni n nma s Sie calefe mie eae mee ee RUE ese NU 8 Sie bie 3 4 pejus 3 4 Grounding the ControllerChassis 0 cece eee II 3 4 3 4 Rack Mounting Series 505 Bases ccccecceeeeeee cece eee eee eee eee 35 3 5 Panel Mounting Series 505 Bases 00cccec
23. Guaranteed 888 88 SOURCE www artisantg com 4 19 4 8 Installing the Battery Battery Backup for the 575 Mounting the Battery For the 575 controller a 4 V 5 amp hour Ah maintenance free gel cell battery and cable are included with the base The battery is continuously recharged by the power supply and maintains user memory and programming during a power loss The 5 Ah battery will maintain the memory until the battery is depleted The length of battery maintained memory time may be calculated by totaling the battery backup current for the entire chassis and dividing the 5 Ah by this current For example Total battery backup current for two 575 CPUs 2 x 1mA 22 mA 5 Ah 2 mA 5 Ah 0 002 A 2500 hours 104 days of battery life a WARNING If the battery is discharged completely below 3 6 V it may be damaged so that it does not recharge This can cause unpredictable operation that could result in death or serious injury to personnel and or damage to equipment Disconnect the battery if the system is to be left unpowered for an extended period The formula listed above shows you how to calculate battery life Mount the battery in an accessible location as shown by Figure 4 12 Be sure that the battery is disabled for the initial powerup of your system A WARNING Do not install the battery in a gas tight enclosure The battery can vent explosive gases that must be allowed to dissipate through adequate ve
24. Guaranteed 888 88 SOURCE www artisantg com Setting the VMEbus bases provide a daisy chain interrupt feature which passes Daisy C hain through every module installed in the base When a base slot is ski pped Switc hes i e left empty this daisy chain is broken unless provision is made to pass the signals across the empty slot For this reason the PPX 575 2130 16 slot VMEbus base provides a set of daisy chain dipswitches to the immediate left of connectors J 1 through J 15 on the backplane Slide all switches to the right On Daisy Chain if the corresponding connector is skipped Signal Lines Switch Signal Name Ji J2 1 pen 2 B 2 2 3 BG2 For example if slots u u 4 BG3 J1 J2 J4 and J5 have Term ER modules installed set llle hull switches in S3 to the a right On to pass the ita signals across the empty d J3 slot to the connector Tm at J4 ui Leave switches set to p the left Off position for all slots which will have modules installed Empty slot Figure 4 20 Setting Daisy Chain Signal Dipswitc hes on VMEbus Backplane NOTE Whenever a 575 module with a 1 inch or 1 6 inch front bezel is installed a slot is skipped Set the daisy chain switches corresponding to the empty slot to pass the signals on tothe next slot and use blank filler bezels if there is empty space Sl
25. serere 9 23 PROHBUS DP Communications Watchdog Timer sssssssssnsnnennnnnnnnnnn 9 24 Troubleshooting 575 Improperlogin sseee een nnnm nnn 9 25 Contents Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Appendix A System Specifications A 1 A2 A 3 A4 Physical and Environmental Specifications 0ccceeeeeee eee eee eee A 2 General Series 505 Specifications seeeeeeeere een nnn nnne A 3 575 Power Supply Specifications Leeeeeeeeeeeee nnn nnn nnn nnn A 4 Series 505 Power Supply Specifications eseeeeeeeee eren n nnn A 5 Appendix B Power and Compatibility B l B 2 PowerConsumption eseesn nnn nn nnn eee B 2 Influence of Annex Cardson CPU Power Consumption sueueeeese B 2 PowerSupply Loading sssssseeee e mma B 2 Power Requirements for Series 505 Modules sssseee ee B 3 Power Requirements for 575 Devices 0 cece B 6 Module Compatibility with CPUs 0cccccce eee e eee eee eee B 7 VO Modules Not Compatible with CPUS 0 0 eee B 7 Determining the Compatibility of a Module 00 eee B 7 Series 505 High Speed Counterfor545 555 10 cece ccc cence eee ene eeees B 8 Determining the Manufacturing Date sssssssssssssssess eese B 9 Appendix C Upgrading Series 500 Installations C 1 C
26. 2 Disconnect power from the chassis At room temperature you have approximately twenty minutes to replace the battery after power is removed from the CPU If the CPU detects a bad battery before power is either removed or lost e 9 power failure you must replace the battery before restoring power or lose memory contents 3 20 Installing 505 System Hardware SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 3 Removethe CPU from the chassis and place the CPU component side Up on a static dissipative surface The components in the CPU card can be degraded or destroyed by electrostatic discharge ESD Follow proper handling precautions in order to prevent ESD damage 4 Removethe battery from the socket observing the following precautions A WARNNG The terminals of the lithium coin cell are extremely close together In the course of removing the battery it is possible for you to short the battery Shorting the battery presents the danger of explosion and or high temperatures and could cause death or serious injury to personnel and or damage to equipment Follow the instructions given below in order to avoid shorting the battery e Usea non conductive implement when removing the battery from the socket Do not allow a conductive device for example a metal screwdriver blade to contact both sides of the battery simultaneous
27. 6 Checkthe BATT GOOD indicator on the CPU to make surethat it lights back up to confirm that the repl acement battery is good Front Bezel Battery Cover Battery Connectors Figure 3 10 Replacing the Battery in 1105 and 1106 CPU Modules SIMATIC 545 555 575 System Manual Installing 505 System Hardware 3 17 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Replacing and Handling the Battery continued Lithium Battery in The 545 1103 1104 and 555 1103 1104 CPUs use a lithium coin battery for the 545 and 555 maintaining CPU memory contents while power is not present The battery 1103 1104 CPUs is a Panasonic BR2325 PPX 2587678 8010 or equivalent 23 mm diameter with a nominal capacity of 165 mAh The lithium battery is a primary cell it is not rechargeable Figure 3 11 shows the location of the battery on the CPU card Battery Clip Vues f Battery Socket C Replaceable Lithium Battery Figure 3 11 Battery Location on 545 555 CPU Modules Indicators A fresh battery can typically maintain your system with power off for three months at room temperature or a substantially shorter time at elevated temperatures The battery indicator is illuminated as long as power is present and the battery voltage is adequate for maintaining the memory however the indicator does not show the amount of battery life remaining When the batt
28. 888 88 SOURCE www artisantg com Features 545 555 onl y 1 9 575 only 1 10 shared system 1 8 Floating point coprocessor installing 4 23 Fuse replacing 575 battery fuse 4 22 replacing on fan assembly 4 9 replacing on power supply 9 20 Fuses guidelines for 2 11 G Global reset PROFIBUS DP RBC 5 20 Grounding 545 555 chassis 2 19 575 chassis 2 20 cabinet or rack 545 555 2 19 575 2 20 chassis connections 545 555 2 19 575 2 20 earth 2 17 planning for 2 17 H H1 support 1 4 Hardware overview 1 12 Hot backup C 8 C 10 Hotline for technical assistance xxi 1 0 expansion See Expansion I O local See Local 1 O remote See Remote I O Series 505 system architecture 1 4 VMEbus installing 4 40 1 O modules compatibility with CPU B 7 manufacturing date B 9 Index 4 Artisan Technology Group Quality Instrumentation I O modules continued mismatches troubleshooting 9 4 serial number B 9 Series 505 installing 3 26 mixing 3 26 power requirements B 3 VMEbus 24 VDC SeeDiscrete DC 161 O AC input E 2 AC output E 7 DC input E 15 DC output E 12 discrete DC 161 O E 4 installing 4 42 power requirements B 6 relay output E 9 O port description 3 25 Inch switch location 2 5 Installation annex card PROFIBUS DP into 545 1103 CPU 3 12 into 575 CPU 4 30 Series 505 into 575 CPU 4 29 base Series 505 3 5 VMEbus 4 10 battery backup
29. A rtisan Artisan Technology Group is your source for quality TecmoogyGroup new and certified used pre owned equipment FAST SHIPPING AND SERVICE CENTER REPAIRS WE BUY USED EQUIPMENT DELIVERY Experienced engineers and technicians on staff Sell your excess underutilized and idle used equipment TENS OF THOUSANDS OF at our full service in house repair center We also offer credit for buy backs and trade ins IN STOCK ITEMS www artisantg com WeBuyEquipment EQUIPMENT DEMOS HUNDREDS OF InstraV ea REMOTE INSPECTION LOOKING FOR MORE INFORMATION MANUFACTURERS Remotely inspect equipment before purchasing with Visit us on the web at www artisantg com 7 for more our interactive website at www instraview com 7 information on price quotations drivers technical LEASING MONTHLY specifications manuals and documentation RENTALS ITAR CERTIFIED yop aed Contact us 888 88 SOURCE sales artisantg com www artisantg com SIEMENS SIMATIC 545 555 575 oystem Manual Order Number PPX 505 8201 3 Manual Assembly Number 2804693 0003 Third Edition Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ADANGER DANGER indicates an imminently hazardous situation that if not avoided will result in death or serious injury DANGER is limited to the most extreme situations A WARNNG WARNING indicates a potentially hazardous situation that if not avoided co
30. O configuration e Password if installed e Scan configuration NOTE Thecurrent values for timer counter and drum presets TCP DSP and DCP are not copied tothe EEPROM You must ensure that your RLL program has the preset values that you desire for TCP DSP and DCP before you save your program to the EEPROM When your program is restored from the EEPROM preset values for TCP DSP and DCP are restored from the program s RLL instructions Values stored in V memory are not copied to EEPROM Any operational constants that are to be retained following restoration from EEPROM must be kept in K memory or as part of the RLL program V memory is initialized to zero when the program is restored from EEPROM After storage in the EEPROM this data is saved even if power is cycled without a back up battery H owever other data in memory e g V memory will be lost if you do not have a back up battery NOTE To help ensure that the data listed above is saved the total user memory space to be stored in the EEPROM must not exceed the EEPROM capacity depending on EEPROM model see Table 7 2 If the total user memory not system memory space occupied by these areas is greater than the EEPROM capacity no data is saved The error message OPERATION FAILED is displayed on the screen if the user memory exceeds the applicable size when attempting to save the data 7 4 Using EEPROMs for Program Storage SIMATIC 545 555 575 System Manual Artisan T
31. PPX 505 4318 16 input 48 VDC isolated interrupt PPX 505 4319 16 input 125 VDC isolated interrupt PPX 505 4332 32 input 14 30 VDC 8 inputs common PPX 505 4408 8 input 164 265 VAC 2 inputs common PPX 505 4408 A 8 input 164 265 VAC 2 inputs common PPX 505 4416 A 16 input 164 265 VAC 4 inputs common PPX 505 4432 A 32 input 164 265 VAC 8 inputs common PPX 505 4508 8 output 4 5 34 VDC 0 5 A 2 outputs common D 2 Series 505 and VME Components SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Discrete O Modules Analog amp Word 1 0 Modules SIMATIC 545 555 575 System Manual Table D 1 Series 505 System Components continued PPX 505 4516 16 output 4 5 34 VDC 0 5 A 4 outputs common PPX 505 4532 32 output 4 5 34 VDC 0 5 A 8 outputs common PPX 505 4608 8 output 20 132 VAC 0 5 A 2 outputs common PPX 505 4616 16 output 20 132 VAC 0 5 A 4 outputs common PPX 505 4632 32 output 20 132 VAC 0 5 A 8 outputs common PPX 505 4708 8 output 4 5 34 VDC 2 A 2 outputs common PPX 505 4716 16 output 4 5 34 VDC 2 A 4 outputs common PPX 505 4732 32 output 4 5 34 VDC 2A 8 outputs common PPX 505 4808 8 output 85 265 VAC 2 A 2 outputs common PPX 505 4816 16 output 85 265 VAC 2 A 4 outputs co
32. Termination and bias required Figure 6 12 Terminate CPU at Endpoint If the CPU with PROFIBUS DP interface is not at an extreme end of the cable do not terminate and bias it Only terminate and bias the devices at each cable end See Figure 6 13 N PROFIBUS DP Node CPU with PROFIBUS DP aE ONE MUSEO VO interface terminated and biased Cable end must be terminated and biased inc Do not terminate and bias Figure 6 13 Do Not Terminate at Midpoint 624 Cabling and Wiring the System SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Using a Termination Siemens PROFIBUS DP connectors have selectable termination and bias Selection Switch built in The connectors designed to handle baud rates from 9600 baud to 12 Mbaud see Table 6 4 have an external switch see Figure 6 14 The low baud rate connectors 9600 baud to 1 5 M baud Table 6 5 have an internal switch see Figure 6 15 In both cases you set the selection switch to the On position to enable termination and bias or Off to disable termination and bias 9 pin D connector SIEMENS External Termination Switch Figure 6 14 Prefened Connector Exte
33. e Useseparate wires for long return lines to the power supply do not usethe same wire for input and output modules Using separate return wiring for these modules minimizes the voltage drop on the return lines of the input connections Pre installation Guidelines SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 2 8 Grounding the Power System a WARNNG O A good grounding system is essential for proper operation of the system It is one of the most important considerations in planning your installation Failure to provide a good grounding system could lead to erratic operation of the equipment which could result in death or serious injury to personnel and or damage to equipment Ensure that you have a good grounding system when you install your equipment Earth Ground In some installations a metal conduit that connects to the neutral phase at the circuit breaker box supplies the earth ground of the power receptacle Depending on site conditions this metal conduit could conduct current from other sources that can interfere with the operation of the equipment To reduce this possibility isolate earth ground and neutral from the conduit except at the service entrance housing see Figure 2 11 Ensurethat system power is wired in accordance with NEMA specifications Also comply with the following e Ensure that the protective ground
34. www artisantg com 9 11 Troubleshooting 575 Improper Login If the 575 CPU does not log in to the local I O properly or if other vendors modules are not communicating properly first check to make certain that the daisy chain backplane dipswitches are set correctly Switches immediately to the left of installed modules should all be set tothe left Off position All unused slots should have their associated switches set to the right On position SIMATIC 545 555 575 System Manual Troubleshooting 9 25 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Appendix A System Specifications A 1 Physical and Environmental Specifications 0cceeeeee eee eee A 2 A2 General Series 505 Specifications lseueeeeeee mmm A 3 A 3 575 Power Supply Specifications eueeeeeeeeeee nnn nnn nnn A 4 A 4 Series 505 Power Supply Specifications 00cccceee cece nennen nnn nnn nnn A 5 SIMATIC 545 555 575 System Manual System Specifications A 1 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com A 1 Physical and Environmental Specifications Table A 1 Physical and Environmental Spec ific ations PPX 545 1103 CPU PPX 545 1105 CPU PPX 555 1103 CPU PPX 555 1105 CPU PPX 545 1104 CPU PPX 545 1106 CPU PPX 555 1104 CPU PPX 555 1106 CPU PPX 575 2104 CPU PPX 575 2105 CPU PPX 575 2106 CPU PPX 505 685
35. 1024 Table move 2 Kbytes 14336 28 Kbytes 1024 One shot Number per block 1 Kbyte SIMATIC 545 555 575 System Manual 32768 32 Kbytes 1024 Starting Up the System 8 7 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com CPU Memory Configuration continued Table 8 8 575 2105 CPU Memory Configuration Total Memory Required for Default Maximum Size Allocation Total memory 832 Kbytes Ladder L 1 Kbyte 3 Kbytes 1 Kbyte 273 Kbytes 819 K bytes 64 K bytes Variable V 1 Kbyte 1 Kbyte 1 Kbyte 817 Kbytes 817 Kbytes 52 K bytes Constant K 1 Kbyte 1 Kbyte 0 Kbytes 816 Kbytes 816 K bytes OKbytes Special S 1 Kbyte 1 Kbyte 0 Kbytes 816 Kbytes 816 Kbytes 32 K bytes SES 1Kbyte 1Kbyte OKbytes 816Kbytes 816 Kbytes 0 Kbytes User U lKbyte lKbyte 0 Kbytes 816 Kbytes 816 Kbytes 0 Kbytes Timer 1024 5 Kbytes 1024 20480 100 K bytes 1024 Drum 64 3Kbytes 64 2304 108 K bytes 64 Shift Register 1024 lKbyte 1024 16384 16 Kbytes 1024 Table Move 1024 2 Kbytes 1024 14336 28 Kbytes 1024 One Shot 1024 1 Kbyte 1024 32768 32 K bytes 1024 N umber per block Total Memory Required for Maximum Size Default Allocation Total memory 1856 K bytes Ladder L 614 K bytes 1842 Kbytes 64 K bytes Variable V 1 Kbyte 1841 Kbytes 1841 Kbytes 52 K bytes Constant
36. 19200 9600 2400 1200 300 INVALID INVALID oO P ol HP ol Hi HIo DHoooonunu Switches 4 through 10 on the dipswitch are used to assign a station address to the RBC for identification in the PROFIBUS DP I O channel Each station in the PROFIBUS DP I O channel must be uniquely numbered The station address is assigned as a binary number with SW10 as the L east Significant Bit LSB Table 5 7 shows how to set the dipswitch to a station address between 0 and 125 the valid range of station addresses The station address switch settings are read only on powerup or after pressing the reset button AWARNNG O Pressing the RESET button when the system is operating causes the RBC to be logged off the system and may change the output states of the output modules in the base Logging the RBC off the system or changing output states inadvertently can cause unpredictable process operation Unpredictable process operation can result in death or serious injury to personnel and or damage to equipment Do not push the reset button unless you intend to log the RBC off the system SIMATIC 545 555 575 System Manual Installing Remote Base Controllers RBCS 517 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com PPX 505 6870 RBC continued Station Address Sta 0 Sta 1 Sta 2 Sta 3 Sta 4 Sta 5 Sta 6 Sta 7 oO oO o oO
37. 9 pin D connector SIEMENS External Termination Switch 2 Housing screws Cable guide Figure 6 18 Typical PROHBUS DP Connector 2 Removethe cover of the housing 3 Remove 1 25 inches 31 mm of the cable sheath to expose the shielding below See Figure 6 19 Approx 1 4 in 6 mm L Approx 1 2 in 13 mm 1 Approx 3 4 in 19 mm Approx 1 2 in 12 mm Cable shielding Figure 6 19 Stripping the Wires 6 28 Cabling and Wiring the System SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 4 Remove a 0 75 inch 19 mm portion of the cable shielding to expose the two signal wires To ensure that the connection is properly grounded you must leave enough exposed cable shielding 0 5 inches 13 mm to make a proper contact with the metal cable guide on the connector See Figure 6 19 5 Remove 0 25 inches 6 mm of insulation at the wire ends 6 Insertthesignal wires intothe cable terminals Be sure to connect the same wire color to the TX RX4 pin for every device throughout your system Crossing the wires at any point creates communications problems 7 Setthetermination switch tothe correct position See Figure 6 20 A Attaching connector at cable end
38. Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 7 2 Configuring the CPU for Non Volatile EEPROM Program Storage Configuring the Follow the instructions in this section to configure and install an EEPROM CPU for Portable in your 545 or 555 CPU The 575 CPUs do not support this option EEPROM Usage NOTE If you are installing an EEPROM and intend to download a program from RAM memory ensure that the back up battery is enabled and good BATT GOOD LED is on Power to the base must be turned off and without a functioning back up battery your program may be lost when power is restored You may want to useTISOFT AUX 60 SAVE PLC gt ALL or the corresponding function in SoftShop to save your program to disk before proceedi ng 1 Placethe CPU in PROGRAM Mode 2 Ensurethat switch 9 on the CPU dipswitch is turned On tothe left This enables the back up battery 3 Turn off all user supplied power to the 545 555 base The CPU is sensitive to and can be damaged by electrostatic discharge Personnel must make contact with a static dissipative pad and or wear a grounded wrist strap when handling the CPU 4 Removethe CPU from the base assembly and place the CPU component side up on a stati c dissipative surface 5 Insert the E EPROM into the socket on the CPU aligning the notches on the E EPROM and the socket see Figure 7 1 or Figure 7 2 depending on your CPU model 6
39. Example Replacing Power Supply Fuse SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 9 8 Checking RS 485 Twisted Pair Cable Installation Using Digital or Analog Meter Resistance below Tolocate problems with RS 485 communication links use a digital or analog meter capable of measuring resistance between 0 and 150 ohms Measure the line to line and line to shield resistance as follows 1 Remove power from the local base and all remote bases 2 Disconnec the CPU and all RBCs from the cable by removing the 9 pin D connector 3 Measuretheresistance from either isolated wiretothe other isolated wire line to line and record this value 4 Measuretheresistance from one line to the shield wire and record this value 5 Measuretheresistance from the other linetothe shield wire and record this value 6 Comparethe values you recorded with those in Table 9 6 Table 9 6 RS 485 Cable Resistance runk Cable Type mi Mac Mm Ma This table assumes two terminating resistors Line to lineresistance that is below the minimum specified in Table 9 6 Minimum may be caused by the following e Incorrect termination resistors are installed e Morethan two termination resistors are installed e A short exists in the cable Line to shield resistance that is below the minimum specified in Table 9 6 may be caused by the followin
40. Guaranteed 888 88 SOURCE www artisantg com RS 485 RF I O Channel Converter continued Cabling Use the following instructions to install cables for the PP X 505 6860 NOTE Since 545 1104 1106 555 1103 1104 1105 1106 and 575 2104 2105 2106 CPUs use RS 485 cabling the RS 485 RF 1 0 channel converter is only needed if you are connecting the CPU to an RF remote base The CPU can be connected directly to an RS 485 remote base 1 Usean RS 485 cable to connect the CPU s RS 485 I O port to the converter s RS 485 I O port The cable should be as short as possible You cannot connect any other devices on this RS 485 cable it is not possible to operate an RS 485 I O link with an RF converter and RF link Notice that the connection requires two twisted shielded pairs with 9 pin subminiature male D connectors at each end rather than the single pair cable that is used for an RS 485 Series 505 remote I O channel Suggested cable types include the following Alpha 5472 2TP w shield 24 AWG Belden 9502 2TP w shield 24 AWG Table C 4 shows the pinout specifications for the cable that connects from the CPU tothe RS 485 RF I O channel converter Pair like named signals 3 and 8 and 4 and 9 Table C 4 Pinout Specifications CPU Module Tw Ground Shields D485 RTS485 D485 RTS485 C 22 Upgrading Existing Series 500 Installations SIMATIC 545 555 575 System Manual Artisan Technology Group Qua
41. Load your program s 575 VME CPU 1 a BAT No battery backup RuN 4 4 Run WDG Watchdog woB 4 Master on bus System failure eo cM PLC good SERIAL PORT 1 Figure 4 19 Location of the CPU LEDs SIMATIC 545 555 575 System Manual Installing 575 System Hardware 4 35 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Installing VMEbus Boards continued Guidelines for Installing orAdding a 575 Secondary to the System A 575 secondary is any 575 CPU other than the primary 575 CPU If you want to add a 575 secondary to your system follow the steps below NOTE Read and abide by the warnings and cautions at the beginning of this section Ensure that all power is disconnected from the VM E bus base It is not necessary to disconnect the battery to add a 575 secondary Your 575 CPU secondary must conform to the dipswitch configuration established by your 575 primary If the primary 575 CPU is set tothe USER C ONHGURED mode then all 575 secondaries must also be set to the USER CONRGURED mode 575 2104 CPUs require an I O annex card in order to select user configured mode NOTE You must know the di pswitch settings of your primary 575 before you can correctly configure your 575 secondary All primary and secondary 575 CPUs must havethe same dipswitch settings for switches SW3 through SW6 Refer to Secti
42. PPX 505 6660 B power supply n A Figure 3 4 Input Voltage Selectors 3 Position the power supply sothat the bezel is facing you 4 Grasp the top and bottom of the power supply 5 Carefully push the power supply into the slot until it mates with the backplane connectors 6 Tighten top and bottom bezel screw to between 2 6 in Ib 0 3 N m and 5 2 in Ib 0 6 N m torque To remove the Series 505 power supply simply reverse the procedures used during installation SIMATIC 545 555 575 System Manual Installing 505 System Hardware 3 9 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Installing Series 505 Power Supply continued Wiring the Power After installing the power supply you are ready to connect your power Supply supply to an external power source Observe these guidelines as you carry out the procedure below e Usel14 to 22 AWG solid or stranded wire If you use stranded wire the wire should be twisted and trimmed e Stripinsulation back 0 4 inches 10 mm e Insert the wires fully into the terminal block so that the insulation butts against the block NOTE The connector is rated for 50 wire insertions at no more than 5 in Ib 0 56 N m torque AWARNNG Electrical shock hazard is possible if you do not turn off all power before attempting the wiring procedure Failure to turn off power could cause death or serious inju
43. RBCs 5 1 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 5 1 Overview Through the Series 505 remote I O channel your CPU can communicate to Series 505 Series 500 remote I O modules by means of an RBC The PROFIBUS DP I O channel allows you to communicate not only to SIMATIC and third party DP I O but to Series 505 remote I O modules in a Series 505 base by means of a DP RBC the PPX 505 6870 Figure 5 1 shows the RBC models available for each I O channel and base type Series 505 Remote PROFIBUS DP I O Channel I O Channel A 3 a Series 505 Base with Series 505 Base 505 PROFIBUS DP RBC with RBC PPX 505 6870 RBC PPX 505 6851 A B Note 505 Special Function modules cannot be used in a DP base Series 500 Base with RBC Series 500 Base with PPX 500 5114 A 500 PROFIBUS DP RBC PPX 500 6870 RBC SIMATIC DP Remote I O Third Party Products Earlier non A B versions of these RBCs can be used Figure 5 1 RBC Models Bases and I O Channels 5 2 Installing Remote Base Controllers RBCs SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE
44. Serial Port 4 Port 3 is an RS 422 port This is the alternate programming port You can connect it to a programming device that has an RS 422 interface or you can use an RS 422 to R S 232 converter and connect it to an RS 232 programming device This port allows the programming device to be separated from the 575 by 100 meters For proper operation over long distances the CPU transmitter should be terminated with 120 O 1 8 W 596 tolerance low inductance resistors at both the receiving end and the transmitting end The CPU receiver is terminated with an internal 120 Q resistor The programming device s transmitter should be terminated at the programming device Connect the programming device s transmitter to pins 9 and 10 Connect the programming device s receiver to pins 12 and 13 Refer to Figure 4 30 for a connection example You can change the baud rate of this port by using your SoftShop or TISOFT programming software o Programming Device with RS 422 Interface o N OO GO OOO O O D oO OCU oO OOOO OO N 25 Pin Male D Connector ee Port 3 RS 422 Optional see text Figure 4 30 Cable to Connect Port 3 to an RS 422 Programming Device Port 4 is reserved for factory use SIMATIC 545 555 575 System Manual Installing 575 System Hardware 4 49 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 4 15 Using Boards i
45. Series 505 products have been developed with consideration of the draft standard for programmable controllers as described in the proposed standard of the International Electrotechnical Commission Committee IEC 65A WG6 Part 2 released as IEC 1131 2 Programmable Controllers Part 2 Equipment Requirements and Tests First Edition 1992 09 Information concerning product reliability and compliance to the IEC or other standards can be provided upon request Contact your Siemens Energy amp Automation Inc distributor If you need assistance in contacting your distributor call 800 964 4114 or write to the Customer Services Center at the following address Siemens Energy amp Automation Inc 3000 Bill Garland Road P O Box 1255 J ohnson City TN 37605 1255 Attention Customer Service Center SIMATIC 545 555 575 System Manual System Specifications A 5 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Appendix B Powerand Compatibility B l PowerConsumption eeseenn eee eee eee B 2 Influence of Annex Cardson CPU Power Consumption suueeeese B 2 Power Supply Loading ssssssseee Im B 2 Power Requirements for Series 505 Modules sse B 3 Power Requirements for 575 Devices lsssssssssssssesseee eae B 6 B2 Module Compatibility with CPUs 0ccccccee eee eee eee B 7 V O Modules Not Compatible with CPUs
46. Shared Features 2c cece bedew tees XR ERG BERI he eee ew enh ER Cn EX I PEXG eru 1 8 545 555 Only Features slccscteces ee ve tad poor eden db oes dw dee dele eden gee eee 1 9 575 Only FeatureS 2 cencc ceeds kl kA beeen gece sheen eee en eee en ORR AY REE HES 1 10 L3 Programming Tools 2000ceceee cece cece cere eee eee eee 1 11 oppor ieee a te aie een weed eee eee oe er Red eee nee Dee eae 1 11 TISOFT ceca Rue REC add bhade deities suede ace ad Vee ered Weed eee 1 11 COM PROFIBUS 22 s Dae db pias donre puc Re prever na ed ee ae dee eens 1 11 Communicating with the CPU 2 eee n 1 11 L4 Hardware Overview eeueeeeeeeen eee uuu nhu unn unn 1 12 Seres505Bases ecuseccee inea subdi bae OR Re ER RI a E abet ENa 1 12 VME Base cns xkx4e9 kx exe REESE EXER RES CREERRREPGOOREXT C REX CR REXXTRE Y Cd 1 12 Expansion hO saresti nn kk Yer ities etre aae dr er Rabe Free OR I ees 1 13 VO Channel Suppor ssscessca sacco e x RE eREESIMESTIRREXTAEREYREETATZREYA RE 1 13 Chapter2 Pre installation Guidelines 2 1 22 2 3 Planning Your Installation seeesseeeeee eee 2 2 Defining Control Requirements sssssssseeeee eae 2 2 Calculating PowerNeeds uususeesssessssess sse n 2 2 Safety Considerations uuuueereeeeereeeern nnn nnn nnns 2 3 Operator Safety Switches ssusesesssselsssees sse eens 2 4 Emergency Stop Switch sssssssssssseeeee ehh 2 4 J
47. continued Table E 12 shows connector pinouts for both discrete DC output modules Table E 12 Discrete DC Output Module Connector Pinouts Ra osa e o e SSS AC OutputsetinAusepower BR Output section Breau B1 Output 9 B1 B2 Output Ba pa ouptig2 E B6 Output 14 B6 B7 Output 15 B7 Sc OwpusesinBusrpowr CR owpusesikncrdunt cc Output section Cuserpower t DR JOwtputsecionDreumt id 4 Ouputz8 P4 foe Ouput30 P5 o8 omes y e pc owpusesnDusrpoeri l E 14 575 V O Module Specification amp Pinouts SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com E 6 Discrete DC Input Module The discrete low voltage DC input module PPX 575 4332 allows the controller to monitor user inputs of various DC voltages An LED indicator on the module faceplate signals a blown fuse in the module Table E 13 shows the module specifications Table E 13 Discrete DC Input Module Specifications Fetue Desripion Optical isolation 1500 Vrms Isolation between commons 1000 Vrms Chassis to user circuits 1000 Vrms omm
48. for 545 555 CPU 3 20 3 21 for 575 CPU 4 20 for new 545 555 CPUs 3 17 CPU 545 555 3 14 fan assembly 575 CPU 4 6 flowchart 575 system 4 2 Series 505 3 2 O modules Series 505 3 26 VMEbus 4 42 power supply 575 4 14 4 17 Series 505 3 8 RBC PROFIBUS DP 5 4 Series 500 C 12 Series 505 5 4 RS 485 RF converter C 20 site planning 2 2 system controller into 575 CPU 4 34 VME bus boards 4 32 Guaranteed 888 88 SOURCE www artisantg com J J 1 Backplane connectors pin assignments 4 54 J 2 Backplane connectors installing on 575 VME bus base 4 56 4 59 J og switch location 2 5 J umper Off F reeze PROFIBUS DP RBC 5 14 Series 500 RBC C 14 Series 505 RBC 5 6 L LED indicators Series 500 RBC C 16 troubleshooting 545 555 CPUs 9 6 575 CPUs 9 7 575 power supply 9 7 Local area networks supported 1 4 Local base Series 505 1 12 numbering 5 9 Local I O supported by CPU model 1 13 M Math coprocessor installing 4 23 Memory system requirements overview 1 6 1 7 types 545 1103 CPU 8 4 545 1104 CPU 8 5 555 1103 CPU 8 5 555 1104 CPU 8 6 555 1105 CPU 8 6 555 1106 CPU 8 7 575 2104 CPU 8 7 575 2105 CPU 8 8 575 2106 CPU 8 8 Modbus support 1 4 Modem connecting overview 6 32 dedicated line operation 6 32 6 33 dial up phone line 6 33 Artisan Technology Group Quality Instrumentation Noise avoiding electrical 2 12 contact snubbing 2 14 isolat
49. n order to attach the annex card to your CPU board it may be necessary to remove some of the standoffs from the annex card If there is no corresponding hole on the CPU for a standoff remove the standoff before attempting to install the annex card 4 Insert metal screws supplied into the screw holes of the PROFIBUS DP communication port and tighten to a maximum of 5 in Ib 0 6 N m torque 5 Insert plastic screws supplied through the CPU into the annex card standoffs and tighten 4 30 Installing 575 System Hardware SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com SERIAL PORT 1 000000000000 Ol SERIAL PORTS 2 3 4 Dipswitch PROFIBUS DP 0000000000c 0000000000000 9 575 2104 NN Figure 4 17 Installing the PROHBUS DP Annex Card SIMATIC 545 555 575 System Manual Installing 575 System Hardware 4 31 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 4 12 Installing VMEbus Boards Introduction The guidelines in this section apply when you install boards into the local VME bus base AUTON Never attempt to install Series 505 I O in a VMEbus base Doing so results in damage to equipment Series 505 I O is only available as an option for the remote bases in your
50. sinking in 2 5 505 3532 24 VDC Output 32 point sinking in 2 5 505 3708 24 VDC Output 8 point sinking in 5 0 505 3716 24 VDC Output 16 point sinking al 5 0 505 3732 24 VDC Output 32 point sinking al 5 0 505 4008 1 24 VAC Input 8 point D 2 0 505 4016 24 VAC Input 16 point rv 2 0 505 4032 1 24 VAC Input 32 point y 2 0 505 4108 1 LVDC TTL 8 point D 2 0 505 4116 1 LVDC TTL 16 point al 2 0 505 4132 1 LVDC TTL 32 point al 2 0 505 4208 1 110 VAC Input 8 point v 2 0 505 4216 1 110 VAC Input 16 point y 2 0 505 4232 1 110 VAC Input 32 point v 2 0 505 4308 1 24 VDC Input 8 point y 2 0 505 4316 1 24 VDC Input 16 point v 2 0 505 4317 24 VDC Interrupt Input 16 32 w 2 0 505 4318 48 VDC Interrupt Input 16 32 al 2 0 505 4319 125 VDC Interrupt Input 16 32 a 2 0 505 4332 1 24 VDC Input 32 point Dd 2 0 505 4408 1 220 VAC Input 8 point al 2 0 505 4416 220 VAC Input ais i Modules that are affected by date code restrictions See Section B 2 for information SIMATIC 545 555 575 System Manual Powerand Compatibility B 3 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Power Consumption continued Table B 3 Series 505 Module Power Requirements continued
51. www artisantg com 1 3 Programming Tools SoftShop TISOFT COM PROHRBUS Communicating with the CPU SIMATIC 505 SoftShop for Windows is a Windows based programming software that supports all SIMATIC 505 series as well as previous generation Series 500 programmable controllers SoftShop also reads in and automatically converts all your Series 505 500 TISOFT program files SoftShop provides familiar Windows features such as menu driven commands tool bars and point and click functions to help simplify creating and editing your application program Refer to your SoftShop manual for detailed instructions about how to enter a program SoftShop for Windows Release 2 2 or greater is required to support all the new features in the 555 1105 and 555 1106 CPUs You can also use the TISOFT2 MS DOS based programming software to create and edit your application program TISOFT allows you to work directly in the ladder logic environment as you design the RLL program F or loops analog alarms and SF programs TISOFT presents menu driven programming tools To program the features that are described in this manual you need TISOFT2 Release 6 3 or greater which runs on an IBM compatible personal computer NOTE TISOFT 6 3 does not support the following features in the 555 1105 and 555 1106 CPUs SmarTune PID loops above 64 the RLL PID box instruction or analog alarms above 128 Refer to your TISOFT manual for detailed instructions ab
52. www artisantg com 5 2 Installation Models Used in Series 505 Base RBC Placement in Base Thefollowing RBCs can be installed in a Series 505 base PPX 505 6870 communicates over PROFIBUS DP I O channel using 12 M baud RS 485 cable Note Series 505 Special Function modules cannot be used in a DP base PPX 505 6851 A B communicates over Series 505 remote I O channel using 1 Mbaud RS 485 cable This RBC can be used in a redundant configuration i e you can use two RBCs and or two power supplies in the PPX 505 6511 base The RBC does not support dual media cabling 505 6850 A B communicates over Series 505 remote I O channel using a PPX 505 6860 adapter to connect between coaxial cable and 1 Mbaud RS 485 cable This RBC can be used in a redundant configuration i e you can use two RBCs and or two power supplies in the PPX 505 6511 base The RBC also supports dual media cabling RBCs used in a Series 505 base must always be installed in the second slot from the left adjacent to the power supply module See Figure 5 2 Figure 5 2 Location of REC in a Series 505 Base SIMATIC 545 555 575 System Manual Installing Remote Base Controllers RBCs 5 3 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Installation continued Installing and Usethe following steps to install an RBC i
53. 110 220 VAC PPX 505 6660 A for user supplied 110 220 VAC PPX 505 6663 for user supplied 24 VDC PPX 575 6660 for user supplied 110 VAC PPX 575 6663 for user supplied 110 220 VAC 545 555 1103 1104 Battery Backup 3 0 V Non rechargeable lithium battery 3 years typical storage battery off 0 to 60 C 3 months typical continuous life 25 C 545 555 1105 1106 Battery Backup front bezel accessible 3 0 V Non rechargeable lithium battery 5 years typical storage battery off 0 to 60 C 3 years typical continuous life 25 C 6 months typical continuous life 60 C 575 Battery Backup 4 V 5 Ah sealed rechargeable lead acid battery 6 months typical continuous life 25 C 1 0 Port Remote RS 485 and PROFIBUS DP Local back plane connectors User Memory Capacity RAM for 545 1103 96 K bytes user configurable RAM for 545 1104 192 K bytes user configurable RAM for 545 1105 96 K bytes user configurable RAM for 545 1106 192 K bytes user configurable RAM for 555 1103 384 K bytes user confi gurable RAM for 555 1104 1920 K bytes user configurable RAM for 555 1105 384 K bytes user configurable RAM for 555 1106 1856 K bytes user configurable RAM for 575 2104 832 K bytes user configurable RAM for 575 2105 832 K bytes user configurable RAM for 575 2106 1856 K bytes user configurable Agency Approvals All controller models and power supply modules UL Listed industr
54. 2 C 3 C 4 C 5 Series 500 System Installations eeeeeeeeeeeen nnn nnn nnn C 2 Upgrading a 520 520C 530 530C 530T System cece cece cece e eee eeeeeee c 3 Check Base to Be Upgraded uuuueuueesseellselllse enne C 4 Upgrading 14 Slot 12 Slot 6 Slot Bases 6 cece C 4 Upgrading 16 Slot and 8 Slot Bases ssssssssseeseseee eh C 4 Finish Upgrade with These Steps sssssssseseeeen e I C 4 Upgrading an RS 485 Based 560 560T 565 565P System esee C 6 Upgrading an RF Based 560 560T 565 565P System eeseeeeeeee C 8 Upgrading an RF based System to 545 555 ssssssssessssesee eee C 8 Upgrading an RF based System to 575 2 cece cece eee nee nn C 10 Installing a PPX 500 5114 A RBC sseeeseee nnn nnn hh hh hhhh nnn C 12 Installing a Seres 500 RBC sssssssssseeeseee RI C 12 Output State Selection uusuuuusseesssselllselss nnn C 14 Status Display ns ite teats ere three el ered orrc be deh bine LIAE EAE akin ERE E C 16 Setting Baud Rates esses se i aikaa i aia aria eee Ra T Raw Un RU Eua Ran Fa gusce C 16 Using the Base Thumbwheel ssssssssssseeeee eee C 17 Resetting the RBC 0 cece ccc ehh hh C 17 Assigning Base NUMbEDS 00 cece tee C 18 Contents xi Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com C 6 R
55. 4 Input type IEC type 1 14 0 VDC UH minimum 0 0 VDC UL minimum Off voltage 5 0 VDC UL maximum i 2 0 mA IH minimum On input current limits 15 0 mA IH maximum 1ms minimum Vbatt Current consumption 45 V STDBY None SIMATIC 545 555 575 System Manual 575 O Module Specification amp Pinouts E15 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Disc rete DC Input Module continued Table E 14 shows connector pinouts for the discrete DC input module Table E 14 Discrete DC Input Module Connector Pinouts LLNEML MEER n AR inputsedionAreturn BR ipusetinBrdun 1 Input 10 B2 B4 mue a B6 nptia E Input 19 DR Input section Dreturn i ba inputg8 E ps input38 p5 E58 input os E 16 575 O Module Specification amp Pinouts SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Appendix F Enhancements in Late Model CPUs F1 Enhancements to Enor Handling 00ccccceee eee eee eee eee F2 CPUs with Enhanced Firmware 0 cece een nn F 2 Fatal Emor Conditions aissi ia ieii aeaaea im a ER Ge ind RAS e RU M le ACE wd F 2
56. 4 Emergency Stop Switch ssssssssssssee eee ehh 2 4 JOG Or INCH Switch 0 cece hs 2 5 Software State Diagram 6 nent tte ttt 2 7 Safety Chain Controlling Outputs Example sees 2 9 Safety Chain Controlling Control System Power Example sssssssss 2 10 Fuse Circuit BreakerPlacement ssssssssseeees ee 2 11 Load Noise Snubbing sssssssssseee ehh 2 13 Contact Noise Snubbing ssusssssssssssss essen 2 14 Grounding Shielded Twisted PairCables ccc ccc cece arrra anra 2 15 Isolating Ground and Neutral From Conduit 000s 2 17 Example of Ground Connections 00 ccc 2 18 Grounding the 545 555 Controller Chassis ccc ccc cece eee e 2 19 Grounding Connection and Altemate Location ccc ccc cee eens 2 20 Mounting Base to Standard 19 inch Rack ccc eee 3 5 Mounting Base in NEMA Enclosure 0 00 e 3 6 Placement of Power Supply in Series 505 Base 0 0 0 eee 3 8 Input Voltage Selectors ssssssseeee tte 3 9 Series505 PowerConnector 1 eect nnn 3 11 Installing the PROFIBUS DP Annex Card in 545 1103 1105 CPU 3 13 Location of CPU RBC in a Seres 505 Base 0 cee 3 14 Installing CPU Module in a Series 505 Base sees 3 15 Battery Location in 1105 and 1106 CPU Modules ccc cece eese 3 16 Replacing the Battery in 1105 an
57. 4 5 Installing the Fan Assembly Operating With You can operate the PP X 575 2130 base with the fan assembly at standard Fan Assembly rated power of each I O module and the power supply at any ambient temperature up to 60 C Refer to Appendix E for O module derating charts with and without forced air flow Operating Without Table 4 1 lists the requirements that apply when you set up your system Fan Assembly without the fan assembly Table 4 1 Derating Requirements for Operation without Fan Assembly edule J BerstingG40C wie Fans PPX 575 6660 185 watt power supply 60 watts maximum power load PPX 575 6663 300 watt power supply 100 watts maximum power load 575 I O modules Refer to Appendix E for 1 O module derating charts without forced air flow Other vendor s VME modules Refer to vendor s specifications for operating requirements without forced air flow 1F or use without fans power supply PPX 575 6660 must have manufacturer date after 2 94 You can verify this by ensuring that the Prodok revision label is marked with numeral 3 or higher as shown here 12 as 6 7 8 9 1 Installation To install the fan assembly you must perform three tasks select the correct Sequence voltage connect power to the AC terminals and mount the assembly Because the voltage selector switch and AC terminals are located at the rear of the unit see F igure 4 1 you should set the voltage selection and
58. 5 14 placement in base 5 3 reset button 5 20 setting baud rate 5 17 station address dipswitch 5 17 status display 5 22 setting RBC parameters 5 24 Guaranteed 888 88 SOURCE www artisantg com Program connecting to 575 CPU 4 28 copying into EEPROM 7 10 supported by CPU model 1 13 editing in EEPROM 7 12 software Reset button PROFIBUS DP RBC 5 20 SoftShop 1 11 TISOFT 1 11 Program storage configuring CPU 7 6 7 9 EPROM EEPROM 7 2 7 5 R RBC 505 PROFIBUS DP assigning station address 5 17 hardware watchdog ti mer 5 15 installing in base 5 4 overview 5 14 placement in base 5 3 reset button 5 20 setti ng baud rate 5 17 station address dipswitch 5 17 status display 5 22 PROFIBUS DP configuring 5 24 Series 500 assigning base numbers C 18 base thumbwheel C 18 hardware watchdog timer C 15 installing in base C 12 setting baud rate C 16 status display C 16 Series 505 assigning base numbers 5 9 base number switch 5 9 hardware watchdog ti mer 5 6 installing in base 5 4 overview 5 6 placement in base 5 3 setting baud rate 5 8 status display 5 12 Redundant configuration 3 4 5 3 C 19 Remote I O connecting to 545 1103 CPU 3 12 Restart auxiliary function 9 2 list of auxiliary functions 9 3 9 25 Rotary switch assigning base numbers Series 505 RBC 5 9 RS 485 RF converter compatibility with CPU C 19 connecting cables C 22 installing C 20 overview C 19 upg
59. 5 NO HOLD MODE SELECTION 6 INVALID RS 232 BAUD RATE 7 NO I O CONFIGURATION 8 WATCHDOG TIMER EXPIRED C SEE MANUAL Dipswitch cover Set RBC Station Address See Table 5 7 RESET pushbutton recessed pe ee ll AE BSARS ASSES Mt at ee et eel Set Status Display Mode cLiLOL6 8 29 GVE Spare RS 232 423 Dipswitch block serial port located behind door male PROFIBUS DP 0000 00000 x l O channel port female 505 6870 e Figure 5 10 505 PROHBUS DP Remote Base Controller 5 16 Installing Remote Base Controllers RBC s SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Baud Rate for the RS 232 Port Assigning the RBC Station Address Switches 1 through 3 on the dipswitch control the baud rate of the RS 232 423 port Table 5 6 lists the baud rates available Invalid selections causethe RBC to report an error on the Status Display and cause the RS 232 423 port to default to 9600 baud The RS 232 423 baud rate switch settings are read only on power up or after pressing the reset button NOTE TheRS 232 port is disabled by default To enable the port change the default parameter of the module in COM PROFIBUS See Table 5 9 Table 5 6 RS 232 Port Baud Rate Settings Bau Rate Sui Switch switcha 38400
60. 575 2130 VMEbus Base Overview The 575 2104 2105 and 2106 CPUs are compatible with the PPX 575 2130 base which accommodates any of the 575 power supply modules and up to sixteen 0 8 inch wide VM E bus modules including the system controller The VM E bus 16 slot base also supports all of the 575 CPU and I O modules The PPX 575 2130 base conforms to the DIN 41494 IEC 297 and ANSI IEEE 1014 standards that define the requirements for a VMEbus chassis The base includes the following features e 166U that is double height slots with standard VMEbus 0 8 inch spacing e Mount to wall cabinet or 19 inch rack e Front or rear mountable in 19 inch rack e Option toinstall J 2 backplane or individual J 2 DIN connectors e 4VDC battery pack e Fan assembly kit option e Daisy chain option switches front accessible For information about how to install the PPX 575 2130 base see Section 4 6 SIMATIC 545 555 575 System Manual Installing 575 System Hardware 4 3 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 4 3 Features Required of a Third Party VMEbus Base VMEbus Base Requirements Determining the Condition of the 575 CPU Battery In order to use a 575 CPU ina third party VM E bus base the base must conform to the following requirements e Each 575 CPU must be supplied with 5 V STDBY power in order to avoid unpredictable operation Table 4 5 in Section 4 15
61. 68020 processor PPX 555 1105 384 K bytes 25 MHz math coprocessor PowerM ath SmarTune PPX 555 1106 1856 K bytes 25 MHz math coprocessor PowerMath SmarTune PPX 505 2580 16 input 120 VAC isolated PPX 505 2590 16 output 24 120 VAC isolated PPX 505 3508 8 output 4 5 34 VDC 0 5 A 2 outputs common sinking PPX 505 3516 16 output 4 5 34 VDC 0 5 A 4 outputs common sinking PPX 505 3532 32 output 4 5 34 VDC 0 5 A 8 outputs common sinking PPX 505 3708 8 output 4 5 34 VDC 2 A 2 outputs common sinking PPX 505 3716 16 output 4 5 34 VDC 2 A 4 outputs common sinking PPX 505 3732 32 output 4 5 34 VDC 2 A 8 outputs common sinking PPX 505 4008 A 8 input 20 56 VAC 2 inputs common PPX 505 4016 A 16 input 20 56 VAC 4 inputs common PPX 505 4032 A 32 input 20 56 VAC 8 inputs common PPX 505 4108 8 input 4 15 VDC 2 inputs common PPX 505 4116 16 input 4 15 VDC 4 inputs common Discrete PPX 505 4132 32 input 4 15 VDC 8 inputs common 1 O Modules PPX 505 4208 A 8 input 79 132 VAC 2 inputs common PPX 505 4216 A 16 input 79 132 VAC 4 inputs common PPX 505 4232 A 32 input 79 132 VAC 8 inputs common PPX 505 4308 8 input 14 30 VDC 2 inputs common PPX 505 4316 A 16 input 14 30 VDC and 42 56 VDC PPX 505 4317 16 input 10 33 VDC isolated interrupt
62. 7 6 8 6 9 6 10 6 11 6 12 6 13 6 14 6 15 6 16 6 17 6 18 6 19 6 20 6 21 6 22 6 23 6 24 6 25 6 26 7 1 7 3 9 1 9 2 B 1 CA Ca C 3 C4 C 6 C 7 C 8 E1 E2 E 3 EA E 5 E 6 Connecting to a Series505 Terminal Block cc ccc cee eee eee ee 6 14 Adding a Terminating Resistor sssssssssseese eee 6 15 Connecting Trunk Line to Terminal Block 0 eens 6 17 Extending and Terminating Trunk Line sssssssese eee m nm 6 19 Sample System Layout for PROFIBUS DP 0c cece III III 6 20 Terminate CPU at Endpoint 0 cece eae 6 24 Do Not Terminate at Midpoint 0 0 e 6 24 Preferred Connector External Termination Switch 000 e eee 6 25 Low Baud Rate Connector Internal Termination Switch suuuuuuueee 6 25 9600 baud to 12 Mbaud ConnectorSchematic cece ees 6 26 9600 baud to 1 5 Mbaud Connector Schematic 0 c cece ees 6 27 Typical PROFIBUS DP Connector 0 0 ceca 6 28 Stripping the Wires 0 0 ne RR nnn 6 28 Attaching Connectorand Selecting Termination 00 0c e eee e eee 6 29 PROFIBUS DP I O Port Pinouts sssssssseeee eI a 6 31 Modem Configuration cece ccc 6 32 545 555 XON XOFF Printer Handshaking 0 cece teens 6 34 545 555 READY BUSY PrinterHandshaking 0cccc cece teens 6 34 575 XON XOFF Printer Handshaking
63. 9860 is a large conductor cable that provides a low attenuation and distortion for long trunk lines e Belden cable 9271 is a smaller and more flexible cable suitable for short trunk lines and all drop line cables e Belden cable 9182 provides an intermediate level of size flexibility and useful length The 9182 cableis also available in a version 89182 rated for a higher level of fire resistance and low smoke producing properties Thefollowing restrictions apply to Belden cable e Belden cable types 9860 and 9271 can be mixed on the trunk line but cable type 9182 must be used alone e If the trunk lineis Belden cable type 9860 or 9271 the drop line can be Belden cable type 9271 or 9182 If the trunk line is Belden cable type 9182 the drop line must be Belden cable type 9182 6 6 Cabling and Wiring the System SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Table 6 1 lists the characteristics of the Belden cables recommended for Series 505 installations Table 6 1 Series 505 Cable Characteristics Belden Center Outside P 16 AWG solid 13 8 ohm km 124 ohms 35 8 pf m 25 AWG 7x33 104 3 ohm km 22 AWG 19x34 46 ohm km 124 ohms 40 pf m 150 ohms 28 9 pf m The cable you use should have a specified characteristic impedance between 100 and 150 ohms 124 ohms being optimum Also look for the following features in the ca
64. A B and PPX 505 6850 A B RBCs continued 2 2 REMOTE BASE REMOTE BASE CONTROLLER CONTROLLER 7 mu ud Status display EN I L1 STATUS STATUS RBC GOOD 0 RBC GOOD SELF DIAG FAILURE 1 SELF DIAG FAILURE MODULE MISMATCH 2 MODULE MISMATCH O COMM TIME OUT 3 O COMM TIME OUT RAM PARITY ERROR 4 RAM PARITY ERROR STANDBY NO CONF 5 STANDBY NO CONF ADDR MISMATCH 6 ADDR MISMATCH COMM OK NO CONF 7 COMM OK NO CONF WATCHDOG TIME OUT 8 WATCHDOG TIME OUT STANDBY CONF C STANDBY CONF Q0 001 amp 0oNn o Base number BASE thumbwheel BASE Switch Base number 60 rotary switch ee Use a flat head or Phillips screwdriver to change base number on the 505 6851B RBC Note On the rotary switch the hexadecimal characters A through F represent the following decimal base numbers RS 232 serial port male namo 0000 00000 Ped Modem F connector for RBC model 505 6850 A B e000 00000 I O channel port female 505 6851A 505 6851B 2 2 Figure 5 7 RBC Status Display and Base Number Switch 5 10 Insta lling Remote Base Controllers RBC s SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Resetting the RBC The following actions take place when an RBC is reset The CPU logs the RBC off the system and zeroe
65. Assembly 2103 CPU 2104 CPU Power supply i A Figure 4 18 575 Controller SIMATIC 545 555 575 System Manual Installing 575 System Hardware 4 33 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Installing VMEbus Boards continued General Guidelines Thefollowing guidelines apply when installing the 575 CPU intothe VME bus base If you are using a 575 2105 2106 ensure that you have correctly configured the dipswitch on the CPU board before installing the board into the VM E bus base Refer to Section 4 10 for the configuration settings If you are using a 575 2104 CPU ensure that you have correctly configured the dipswitches on any Series 505 remote I O or PROFIBUS DP I O annex cards if installed Refer to Section 4 10 for information on how to configure the annex card dipswitch The board that you install in slot 1 leftmost VM E bus slot must perform as the VM E bus system controller If this board is a 575 with the USER C ONAG URED option set you must also set the PRIMARY 575 dipswitch SW7 A third party master can be system controller When the 575 configures applications at powerup the primary 575 is assigned as application A Secondary 575s are assigned to application B C etc starting with the leftmost secondary 575 and proceeding to the right most secondary 575 To avoid confusion when viewing the system configuration with TI SOFT install th
66. Cabling and Wiring the Sytem 6 11 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Installing Series 505 Remote I O Cables continued Preparing Drop Use the following procedures to attach a D connector and terminal lugs to Line Cables your drop line cable 1 Strip back 1 50 inches 38 mm of the sleeving on one end of the cable There arethree wires when the sleeving is stripped back two wires have color coded insulation jackets and one the shield is bare 2 RemoveO0 13 in 3 3 mm of each color coded insulation jacket to expose the bare wires 3 Install the cable wires to a 9 pin D connector according to directions provided by the connector vendor NOTE Install the wire without insulation to pin 5 of the 9 pin D connector Install the wires with the color coded insulation to pins 3 and 78 It does not matter which wire is installed to pin 8 or 8 but all connectors must be installed identically See Figure 6 6 for pinout information 612 3 Cabling and Wiring the System SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 4 Strip back 1 50 in 38 mm of the sleeving on the other end of the cable 5 Remove 0 13 in 3 3 mm of each color coded insulation to expose the bare wires 6 Install each wire end onto a terminal lug according to directions provided by the vendor Th
67. Do not add the A24 A16 base address to these addresses This address range is used if any 575 VME bus I O module is installed 4 52 Installing 575 System Hardware SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Daisy Chain Signals Assigning Addresses to Third Party Slaves All VMEbus masters including the 575 CPUs require access to the VMEbus daisy chain control signals including the bus grant and interrupt acknowledge signals e ACKIN e BGIIN e BG2OUT e ACKOUT e BGIOUT e BG3IN e BGOIN e BG2IN e BG3OUT e BGOOUT Refer to Table 4 7 for pinouts Place any board that does not provide the BGxOUT signals to the right of any board that requires these signals All of the 575 boards CPUs and I O modules pass through the daisy chain signals Third party slaves may occupy any unused address There are two ways to assign addresses to third party slaves e Calculate used address spaces and hard assign an address e Design the software on a third party master CPU to log in slave boards and to assign their addresses refer tothe SIMATIC 575 Interboard Communication S pecification PPX 575 8103 A WARNING Memory overlaps in board addresses can cause erratic system operation Erratic system operation can cause death or serious injury to personnel and or damage to equipment To minimize the risk of erratic system operatio
68. E3 and EA nn e nnn 5 15 Dipswitch Optons exe guria eee er Leda oa dee Doede PROCEDE CER CE OP ds ae 5 16 Baud Rate forthe RS 232 Port 6 cece ea 5 17 Assigning the RBC Station Address 6 0c cca 5 17 Reset Pushbutton 0 cece tees 5 20 Resetting the RBC vc cnniedsiavdiue recieve ds bre di fee os See deine Eu tEEPETE Ribes 5 20 Status Display Mode 2 ees nn 5 22 Setting User Pa ra meters forthe 505 PROFIBUS DP RBC 00 cece eee eee eees 5 24 Discrete I O Interval iere siene Ko tee 5 24 Word I O Update Factor ccc cece cece cece eee eens eens eens nns 5 24 50X Ignore Mismatch Mode sssssssssss e nnn 5 24 50X RS 232 Comm Port sidii gosn goie aoii ean 5 24 Chapter6 Cabling and Wiring the System 6 1 6 2 6 3 viii Cable Routing cece eee eee eee eee eee eee eee eee a E 6 2 Guldelln amp s 4 aane a a a etd cadedan cde eb c Hb cp AD Bid pate 6 2 Cable Routing Methods 2 ccc eee nnn 6 2 Under FloorRouting 0 ccc ccc eee 6 3 In Ceiling RoUtingi 4 eine chee clay ree Boles dedre hd fee ed ee deine E v LE CPI Cadets 6 3 Surface Duct Routing 0 ee nett eens 6 3 Installing Series 505 Remote I O Cables 0cccceeeeeee eee eee n n n n nn nnn nn nnn 6 4 Media Options serez preck dhe PHP EE REX FERE UENEN DENR E 6 4 Equipment Needed ssssssssssesseeeese ehh 6 4 Mounting TapsorTerminalBlocks ssssssseee
69. In order to ensure a proper level of safety compliance check with local authorities for specific system installation requirements Another option for supplying the second power connector is to install a single connector in the form of a mini J 2 backplane with a single DIN connector and power leads available from Siemens as PP X 2589739 8012 Refer to theJ 2 connector installation instructions included in the kit for additional details Refer to Figure 4 31 for rear panel disassembly Battery retaining screws A Rear panel retaining screws Rear panel Battery connector Break away tab Figure 4 31 RearPanel Disassembly for 2 Backplane Installation 4 56 Installing 575 System Hardware SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Installing Optional J2 Backplane SIMATIC 545 555 575 System Manual Toinstall aJ 2 backplane follow these steps 1 Unplug the battery connector unscrew the two battery retaining screws and remove the battery from the rear of the unit Remove the 6 screws 3 per side that hold the rear panel and remove the rear panel from the unit see Figure 4 31 Remove the M2 5 x 10mm screws that hold the backplane spacers Mount the backplane with the spacers between the chassis rails and the backplane using the M2 5 x 10mm screws as shown in Figure 4 32 NOTE To help align the back
70. K 1 Kbyte 1840 Kbytes 1840 K bytes 0 Kbytes Special S 1 Kbyte 1840 K bytes 1840 K bytes 32 K bytes Compiled Special CS 1 Kbyte 1840 Kbytes 1840 K bytes 0 Kbytes User U 1 Kbyte 1840 K bytes 1840 Kbytes 0 Kbytes Timer 5 Kbytes 20480 100 K bytes 1024 Drum 3 Kbytes 2304 108 K bytes 64 Shift Register 1 Kbyte 16384 16 Kbytes 1024 Table Move 2 Kbytes 14336 28 Kbytes 1024 One Shot 1 Kbyte 32768 32 Kbytes 1024 Number per block 8 8 Starting Up the System SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Chapter 9 9 1 Troubleshooting by Using Auxiliary Functions 0ccceeee eee eee eee nnn nn nnn nn nnn 9 2 OVEINIEW MP 9 2 Power up Restart Partial Restart and Complete Restart 0000000004 9 2 575FaultRestarts ossis aiiai cece cece cee ehh 9 2 Compare PLC to Disk reserve fter ee idee ed sea D ERES UE a deeded 9 4 Run 545 555 PLC Diagnostics ssssssssesss eee 9 4 Display Falled l O iausen iaaii needed p e eti delen cest d Dod niet ie ean 9 4 PLC Operational Status sssssssssse ehh 9 4 9 2 Troubleshooting by Reading LEDs cccceeeccee cece eee 9 6 543 539 LEDS eama a EET 9 6 575 LEDS ise iaia aE e CARA Ia e ATEA KE a eim ue e rea E AE DEE Rb Ab P 9 7 9 3 Tro
71. K 0 45 ms K 0 45 ms K Digital I O Points 8192 8192 8192 8192 Analog I O Points 8192 8192 8192 8192 Control Relays 32768 32768 23552 23552 Timers Counters 20480 20480 20480 20480 Integer F loating Point Yes Yes Yes Yes PowerM ath Yes Yes Yes Yes PID Loops 128 128 64 64 SmarTune PID loops Yes Yes No No Fast Loops 128 128 No No Analog Alarms 512 512 128 128 SFPGMs SFSUBs 1023 1023 1023 1023 1023 1023 1023 1023 Local I O Series 505 Series 505 VME VME Series 505 Remote I O 15 Bases 15 Bases 15 Bases 1 15 Bases 1 PROFIBUS DP 1 02 112 Devices 112 Devices 112 Devices 112 Devices Ethernet H 1 Ethernet H 1 Ethernet H1 Ethernet H1 Communications TI od P TI cic P TI Mom P TI ge ee P PROFIBUS FMS PROFIBUS FMS PROFIBUS FMS PROFIBUS FMS Local Comm Forts 19232422 485 1 RS232 422 485 1 RS 422 185422 Baud Rates up to 115 200 up to 115 200 up to 115 200 up to 115 200 Portable EEPROM 128K 256K 128K 256K On board EEPROM 384 K bytes 1856 K bytes 832 K bytes 1856 K bytes Multiple CPUs No No Yes Yes Fault Relay No No Yes Yes Real Time Clock 10 ms 10 ms 10 ms 10 ms Resolution Accuracy 2 2 min mo 2 2 min mo 2 2 min mo 2 2 min mo Replaceable Battery Yes front bezel Yes front bezel Yes on chassis Yes on chassis Flash O S EEPROM Yes Yes Yes Requires optional PPX 575 2126 Series 505 remote I O annex card The number for devices supported includes both masters and slaves The actual number that y
72. Kbytes then S memory cannot be configured to 32 Kbytes because the 96 K bytes of system memory would be exceeded Refer to your SIMATIC 505 TISOFT2 User Manual and SIMATIC 545 555 575 Programming Reference User Manual for additional information on memory configuration and configuring I O Table 8 amp 1 545 1103 1105 CPU Memory Configuration Block Total Memory Default Memory Type Allocation sal Required for t x Allocation Size per Block Maximum Size Total memory 96 Kbytes Ladder L 30 Kbytes 90 K bytes 30 K bytes Variable V 32 Kbytes 32 Kbytes 1 Kbyte Constant K 32 Kbytes 32 Kbytes 0 Kbytes Special S 32 Kbytes 32 Kbytes 0 Kbytes User U 32 Kbytes 32 Kbytes 0 Kbytes Timer 1024 5120 bytes 10 Drum 20 960 bytes 2 Shift Register 1024 1024 bytes 10 Table Move 512 1024 bytes 10 One Shot 512 512 bytes 10 Number per block 8 4 Starting Up the System SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Table 8 2 545 1104 1106 CPU Memory Configuration Block Memory Memory Type Allocation Required Size per Block Total memory 192 K bytes Total Memory Required for Maximum Size Default Allocation Ladder L 59 Kbytes 177 Kbytes 32 Kbytes Variable V 177 Kbytes 177 Kbytes 52 Kbytes Constant K 176 Kbytes 176 Kbytes OKbytes Special S 176 K
73. N a DIR IL ILC CEE O 00 0000 Serial Printer Ds Lu D ao 25 Pin Male D Connector Port 2 RS 232 m oa Figure 6 26 575 Ready Busy Printer Handshaking SIMATIC 545 555 575 System Manual Cabling and Wiring the System 635 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Chapter 7 Using EEPRO Ms for Program Storage 7 1 Program Storage Options 0ccceec cece cence cere eee eee 7 2 old xL 7 2 On Board Flash EEPROM Program Storage scene eens 7 2 Optional Portable EEPROM Program Storage eee eee eens 7 2 EEPROM Porta Dulity 1x Vnde he ree der e ea Oe eee ae sea Pea Sova devs dp E 7 3 Using an EEPROM ege de etd iad ose Ur do Rad eid Meds Me dada RR P Rs 7 3 Using AM EPRO M ubera e tede Le le der dien coe Soc dtl a Ie le Ari dete 7 3 What is Stored in Non Volatile Memory sssessssss III 7 4 Program Storage Operations 6c cece 7 5 Memory and Mode Status at POWEIUD sssssssseeesee eee 7 5 7 2 Configuring the CPU for Non Volatile EEPROM Program Storage 7 6 Configuring the CPU for Portable EEPROM Usage sssseeeen nn 7 6 Configuring the CPU for On Board EEPROM Usage sssseeee n 7 8 7 3 Copying a Program into an EEPROM ccc eee eee nnn nn nm mmm 7 10 7 4 Editing a Program Stored in an EEPROM
74. On position the CPU isin the AUTO CONHGURED mode e n the AUTO CONHGURED mode the 575 Release 5 0 is compatible with 575 Releases 2 0 through 3 1 e In AUTO CONHGURED mode a 575 CPU must be located in slot 1 During FAULT recovery the 575 CPU in slot 1issues SYSRESET NOTE If any 575 2104 CPU in your system does not have a remote I O annex card then the entire system must operate in the AUTO CONHGURED mode Verify that the 575 2104 CPUs in your system that do have an annex card have SW6 set to the On position you do not need to do anything to the rest of the switches Using the To select the USER C ONHGURED mode you must ensure that SW6 is in the USER C ONHG URED Off position for every dipswitch and that SW3 through SW6 are set to the Mode same positions for every 575 in the system 575 2104 CPUs require an I O annex card in order to select user configured mode Configuring the 575 In the USE CONRGURED mode the position of switch SW7 determines Primary and whether the CPU is a primary or secondary 575 Setting SW7 to the On Secondaries position indicates that the CPU is the primary 575 in the system setting SW7 tothe Off position indicates that the CPU is a secondary 575 Only one 575 can bethe primary 575 in a system If a 575 CPU resides in slot 1 the system controller slot then it is automatically configured as the primary 575 CPU regardless of the position of SW7 Do not configure any other 575 as your primary Enablin
75. RS 232 1 RS 232 1 RS 232 2 RS 232 Local Comm Ports 1RS 232 422 1RS 232 422 1RS 232 422 1 RS 232 422 1RS 422 485 485 485 485 Baud Rates up to 38 400 up to 38 400 up to 38 400 up to 38 400 up to 38 400 PortableEEPROM 128K 256K 128K 256K 128K 256K 128K 256K On board EEPROM 1105 96K 1106 192 K Multiple CPUs No No No No Yes Fault Relay No No No No Yes Real Time Clock 10 ms 10 ms 10 ms 10 ms 100 ms Resolution Accuracy 5 min mo 2 2 min mo 2 2 min mo 2 2 min mo 2 2 min mo ps s Pront al ne Pront al Yes internal Yes internal On chassis Requires optional PPX 575 2126 Series 505 remote I O annex card The number for devices supported includes both masters and slaves The actual number that you can connect may be less depending on the type of slave and the memory requirements of each Requires optional PPX 505 CP5434 DP PROFIBUS DP I O annex card The 575 CPU does not support simultaneous use of 505 Remote I O and PROFIBUS DP 1 0 1 6 Artisan Technology Group Quality Instrumentation System Overview SIMATIC 545 555 575 System Manual Guaranteed 888 88 SOURCE www artisantg com Table 1 2 lists memory capacity scan performance and other features for the newer model CPUs described in this manual Table 1 2 CPU Specifications User Memory 384 K bytes 1856 K bytes 832 K bytes 1856 K bytes Boolean Scan 0 07 ms K 0 07 ms
76. Rates sci pene eh ede pede pideeebbe eta hd obi ee bbe hades C 16 Using the Base Thumbwheel ssssssssseeeeee eee C 17 Resetting the RBG 22 ais used uen etri dedak ioti Kai de bed ok oe ee bee oad C 17 Assigning Base NUMbEDS 00 cece hm C 18 C 6 RS 485 RFI O Channel Converter cceee cece eee een nnn C 19 Introduction ic cei once xi DUX E e Be cade eed ec adek aden dae ge edd Eo aa C 19 Compatibility sec owt visit Deep RE E beled bien ey aod VE ae E REA Cds C 19 Installing the RS 485 RF I O Channel Converter ssssseee ee C 20 Removing the RS 485 RF I O Channel Converter ccccceee eee C 21 Cabling 2 ceseee n Id rel od kl be ere eae caedesv ew WR E REX YR EX AQ C 22 SIMATIC 545 555 575 System Manual Upgrading Existing Series 500 Installations C 1 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com C 1 Series 500 System Installations You can upgrade an existing Series 500 system by replacing the controller with a 545 1106 555 1105 or 555 1106 CPU or a 575 2105 or 575 2106 CPU with the 575 2126 annex card Thefollowing Series 500 systems can be connected as remote I O bases to a Series 505 CPU e SIMATIC 520 520C 530 530C and 530T systems e SIMATIC 560 560T 565 and 565P systems using twin axial RS 485 remote I O channels e SIMATIC 560 560T 565 and 565P systems using coaxial RF remote O channels Refer to Sec
77. SIMATIC 545 555 575 System Manual Figure 1 2 Typical 555 System System Overview 1 9 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com System Features continued 575 Only Features The 575 system offers the following additional features e Open VME system allowing real time communication across VME backplane to boards such as motion control vision host processors and special I O and to other 575 CPUs installed in the same base e Additional RLL instructions to support VME e Fault relay capability Figure 1 3 shows a typical 575 system D QD VME PLC SIMATIC g ire 575 6 O Run 515 6663 o eo MOB gg SYF 9 pco SERIAL PORT 1 c SYS RESET POWER SUPPLY 300 WATTS W FANS 100 WATTS W O FANS FAULT RELAY Q VO LINK 866Y LISTED REPLACE ONLY WITH o 9j MUR 10 AMP 250 VOLT INE SLOW BLOW FUSE SERIAL SERIAL PORTS 2 3 4 FUSE PROFIBUS LR44226 APPROVED Oo LINE CLASS I DIV2 O NEUTRAL T4A WIFANS GROUND T4 W O FANS 110 220 VAC 50 60 HZ 575 2105 575 2103 D D Figure 1 3 Typical 575 System 1 10 System Overview SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE
78. The545 1103 1105 CPUs support up to 32 PROFIBUS DP addresses for master and slave devices with the optional PROFIBUS annex card e Token passing to a programming device is supported e Baud rates are user selectable from 9600 baud to 12 M baud e All consistent data requirements of PROFIBUS DP slaves are supported Using consistent data however reduces the number of slaves you can connect due to increased memory requirements To configure PROFIBUS DP I O for Series 505 CPUs you must use the COM PROFIBUS configuration utility in conjunction with TISOFT consult the SIMATIC 505 TISOFT2 User Manual PROFIBUS user organizations exist in a number of countries to allow PROFIBUS users to exchange information The address of the organization in the U S A is as follows PROFIBUS Trade Organization Michael Bryant 5010 East Shea Boulevard Suite C 226 Scottsdale AZ 85254 Telephone 602 483 2456 Fax 602 483 7202 All controller systems can communicate through any of several networks For information about Ethernet H1 or TCP IP PROFIBUS FMS TIWAY or Modbus consult the documentation cited in the preface of this manual Figure 1 1 shows the I O architecture of the Series 505 system SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Series 505 Remote I O Channel
79. Upgrading 16 Slot and 8 Slot Bases Determine the number of O slots in the base to be upgraded For some bases a PPX 500 5840 adapter base must be installed The 14 slot 12 slot and 6 slot bases U pgrade Path A do not require an adapter base For a 16 slot or 8 slot base U pgrade Path B you need to install an adapter base A WARNING Do not attempt to install or remove modules from powered up bases Installing or removing any module from a powered up base could cause unexpected operation which could cause death or serious injury to personnel and or damage to equipment Disable all power to bases before installing or removing modules For 14 slot 12 slot and 6 slot bases follow these steps U pgrade Path A 1 Removethe existing control device s the CPU and IOCC if an I1OCC is present or the DBC 2 Ifthe power supply is in slot B move it to slot A of the I O base This makes slot B of the I O base available for an O module In your I O configuration the slot that was previously slot 1 becomes slot 2 For 16 slot and 8 slot bases follow these steps U pgrade Path B 1 Removethe existing control device s the CPU and IOCC if an I1OCC is present or the DBC 2 Install a PPX 500 5840 adapter base See user manual PPX 500 8140 for information about installing the adapter base 3 Install an AC PPX 500 2151A or DC PPX 500 2153 power supply in slot B of the adapter base Slot A is left empty
80. a network the network is identified e g TI WAY NETWORK or H1 NETWORK In the case of H1 the network connection name is displayed in quotation marks in a field tothe right e Scan Scan time reported by AUX 29 it is the highest scan time recorded since the last CPU reset PROGRAM RUN modetransition or user peak resets Status Word 10 STW10 contains a continuously updated report of the scan time 9 4 Troubleshooting SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com e Key Always unlocked the CPU does not have a key e Mode Showsthe CPU operating mode RUN PROGRAM or HOLD e SF Loop Mode Run indicates the system is running loops analog alarms and SF programs in the SF Loop M ode e SF Loop Follows PLC to Program Mode Informational comment e PLC Fatal Error Descriptions causes and corrective actions are listed in Section 9 3 e PLC Non fatal Error Descriptions causes and corrective actions are listed in Section 9 4 e Loop Fatal Error Status word 161 STW161 reports the causes and indicates the corrective actions e Loop Non fatal Error Status word 162 STW162 reports the causes and indicates the corrective actions e Battery On indicates the back up battery is switched on and good Off indicates the back up battery is switched off or bad e Download Selection switch is not user accessible and is always off e Pro
81. alternate choi ce components for use only in low baud rate applications ranging between 9 6 kbaud and 1 5 M baud Table 6 5 PRORBUS DP Components Low Baud Rates Hem Order Number Comment Connector 6ES5 762 2AA12 Connector 6ES5 762 2AA21 Indudes PG port Repeater 6GK 1 5100 ACOO 24 VDC Repeater 6GK 1 5100 ADOO SIMATIC 545 555 575 System Manual Cabling and Wiring the System 621 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Installing PRORBUS DP I O Cables continued PROHBUS DPCable Table 6 6 lists the PROFIBUS DIN 19245 cable line specifications and Connector specific ations Table 6 6 PRORBUS DP Cable Specifications Impedance 135 165 Ohm 3 20 MHz Capacitance 9 1 pF ft lt 30 nF km Resistance 33 5 Q 1000 ft 110 Ohm km Attenuati on 0 27 dB 100 ft 0 9 dB 100 m f 200kHz Conductor Area 20 22 AWG 0 3 mm 0 5 mm Cable Diameter 0 315 in 0 02in 8mm 0 5 mm PROABUS DP Line Up to 10 bus segments can be connected in series The distance between the Length Limits two most widely separated stations must not exceed the appropriate value shown in Table 6 7 Use repeaters between each cable segment Table 67 PROHBUS DP Line Length Limits Maximum Segment Maximum Installation Baud Rate Length Length 9 6 to 93 75 kbaud 3 930 ft 1 200 m 39 300 ft 12 000 m 187 5 kbaud 3 280 ft 1 000 m 32 800 ft 10 000 m 500 kbaud 1 310 ft
82. an installed EEPROM has a program which is invalid for the CPU The most likely cause of the error is that the memory configuration contained in theinstalled EEPROM is invalid For example an EEPROM that was created by a 555 1104 has been installed in a 545 1103 and the 555 program requires memory that is not available on the 545 1103 SIMATIC 545 555 575 System Manual Troubleshooting 9 9 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Troubleshooting CPU Fatal Enors continued 575 Fatal Enors The following is a list of the 575 fatal errors e Board table system descriptor table or application table mismatch these tables do not match the power down configuration on the next BATTERY GOOD powerup e The configuration switches are inconsistent e VMEbus error the CPU receives a bus error while attempting to access a VMEbus address and you have not indicated that such errors should be ignored NOTE Release 3 0 and later provide recovery from VMEbus errors if the MOVE or XSUB instruction initiates the bus transaction Refer to the SIMATIC 545 555 575 Programming Reference User Manual for details 545 555 575 CPU Table 9 5 describes AU X 29 fatal error codes Fatal Enor Codes Table 9 5 Aux 29 Fatal Eror Codes 0001 Error creating the boot task 0002 Intertask message logic error 0003 Illegal
83. analog word output module that selection overrides the Off option on the RBC jumper NOTE If the RBC hardware watchdog timer is activated an RBC failure the state of the outputs is determined by the output module with no reference to the RBC s E1 Off F reeze jumper Discrete outputs go off toa value of zero Analog word outputs obey their own Zero H old Last Value selection If no Zero H old Last Value selection is available on the module the analog word outputs hold their last value Jumpers E2 E3 and The jumpers on headers E2 and E3 are for factory use only Header E4 is E4 shipped without a jumper Do not alter the default settings unless instructed to do so by a Siemens Technical Support technician SIMATIC 545 555 575 System Manual Installing Remote Base Controllers RBCs 5 15 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com PPX 505 6870 RBC continued Dipswitch Options You can select the RS 232 423 baud rate RBC station address and display mode of the RBC status display by setting a dipswitch that is accessible from the bezel of the RBC Figure 5 10 shows the location of the dipswitch 2 505 PROFIBUS DP REMOTE BASE CONTROLLER Status display Mian L STATUS 0 MODULE READY 1 DIAGNOSTIC FAILURE 2 MODULE MISMATCH 3 NO COMMUNICATIONS 4 NO OPERATIONAL FIRMWARE Set RS 232 423 Serial Port Baud Rate See Table 5 6
84. and Table B 4 in Appendix B list the requirements for the 575 CPU that you are using Note that if you connect 45 V STDBY to 45 V you will need to reload the user program in each of the installed 575 CPUs after every power cycle A WARNNG The 5 V STDBY power must be supplied to each 575 CPU A 575 CPU without this 5 V STDBY power supply may appear to operate properly nevertheless erratic and unpredictable operation can occur that could result in death or serious injury to personnel and or damage to equipment The 5 V STDBY power must meet the requirements for the 575 CPU See Table 4 5 in Section 4 15 and Table B 4 in Appendix B e TheVMEbus power monitor function must be supplied The power monitor must provide both SYSRESET and ACFAIL To use the 575 CPU as the slot 1 master that is as system controller in a third party base you must provide a means for the 575 to determine the condition of the battery A high 5 V signal on the slot 1 BGIN2 line indicates a charged battery a low ground signal indicates an absent or discharged battery You must provide a way to force a battery bad indication BGIN2 driven low in order to perform a battery bad restart NOTE If BGIN2 is left open then the battery test always indicates a charged battery and a battery bad restart is not possible The 575 CPU installed in slot 1 tests the condition of the battery once every minute it drives the BGINO and BGIN1 signals
85. artisantg com Table 3 2 Series 505 Base Dimensions AS G3 Siemens SIMATIC 505 PPX 505 6504 PPX 505 6508 PPX 505 6511 PPX 505 6516 Base PPX Dimension A inches mm Dimension B inches mm 505 6504 8 10 206 8 69 221 505 6508 11 29 287 11 93 303 505 6511 17 70 450 18 34 466 505 6516 17 70 450 18 34 466 SIMATIC 545 555 575 System Manual Installing 505 System Hardware 3 7 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 3 6 Installing Series 505 Power Supply Power Budget for The total power consumption of all 1 O modules including the CPU or RBC Series 505 Base drawing power from a Series 505 power supply must not exceed 55 0 W from the 5 VDC output and 3 75 W from the 5 VDC output Refer to Appendix B for power consumption listings for the CPU and all currently available Series 505 I O modules and RBCs Power Supply Figure 3 3 shows the placement of the power supply in Series 505 bases Placementin Bases The power supply must always be installed in the left most slot OQUIE CUO Figure 3 3 Placement of Power Supply in Series 505 Base
86. but its sources are common in industrial applications 2 12 Pre installation Guidelines SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 2 6 Corecting Noise Problems When potential noise sources are identified two methods are available to handle them noise snubbing and noise isolation These methods are described in the following sections Noise Snubbing Noise snubbing reduces noise at its source Applicable only to devices driven by mechanical contacts snubbing suppresses the arcing at electrical contacts that is caused by turnoff of inductive loads e g relays motors motor starters solenoids etc Load snubbing reduces voltage transients caused by the load preventing them from traveling back to the output where they would produce a showering arc and couple with adjacent wiring See Figure 2 8 r InputPower F InputPower Discrete Discrete Output Output Load Discrete Output Discrete Output Module Protection Module Protection RC snubbing MOV snubbing Figure 2 8 Load Noise Snubbing SIMATIC 545 555 575 System Manual Pre installation Guidelines 2 13 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Conecting Noise Problems continued You can also use contact snubbing shown in Figur
87. cece ccna 3 22 Enabling the Auto Recompile Function 00 eee 3 22 Setting Baud Ra tesem iiaiai aaa nma aa aaa a aiia e nn 3 23 CommunicationsPort 1 ssuuusseesssssssss essere nn 3 24 COMMUNICATIONS POM 2 o eb PubepIeRRRE teed s lebe ge RI wea RUPEE RE 3 24 VO Potts eeleeexu e kk x Exi REIR be ees PR bee eRe E MEY eee dee ENE ERG Oba EES 3 25 3 11 Installing Series 505 I O Modules eeeeeee nnn nnn nnn nnn 3 26 Mixing VO Modules assasi iaiia aaia aaa hh hh 3 26 Installing and Removing I O Modules sssssseeeee enm m e eee 3 26 SIMATIC 545 555 575 System Manual Installing 505 System Hardware 3 1 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 3 1 Overview of Installation Proc edures Thefollowing charts identify the tasks for installing Series 505 system hardware Toinstall a CPU Toinstall an RBC Install Base Install Base e Rack mounting e Rack mounting e Panel mounting e Panel mounting Install Power Supply Install Power Supply Optional Install Annex Card Install RBC Install 545 555 CPU Install I O Modules Install I O Modules 1 The PROFIBUS DP annex card PPX 505 CP5434 DP is a user installed option for the 545 1103 1105 CPU Chapter 5 describes the RBCs which can be installed in Series 505 bases
88. cece eee ee eee ees B 4 Series 505 Module Power Requirements continued ccc eee ee ee eens B 5 DC Current Requirementsfor575 Devices ssssssssssssessseee seen B 6 Analog Word Output States 0 essen rn C 15 Series 500 RBC LED Messages 11 cece eect ttt tents C 16 Base Numbers 2 Sees Oh ROI e Ur eee oe dae bie Phe der obser ok es C 18 Pinout Specifications eserci conr cece eee C 22 Series 505 System Components 0 cece eect e nnn D 2 5 5 System Components i a ar vaa danas a ad x eee ee ee aes D 5 Discrete AC Input Module Specifications 0 0 0 E 2 Discrete AC Input Module ConnectorPinouts 02 cee eee E 3 24 VDC I O Module Isolation ssssssssen RII Mh E 4 16 Input 16 Output Module Specifications 0 E 5 16 Input 16 Output Module Connector Pinouts ccc eee eae E 6 Discrete AC Output Module Specifications 00a E 7 Discrete AC 16 point Output Module ConnectorPinouts 00000 2 eee E 8 Disc rete Relay Output Module Specifications 0c E 9 Disc rete Relay Output Module Connector Pinouts eee eee E 10 PPX 575 4532 Specifications 0 ccc ccc E 12 PPX 575 4732 Specifications 0 ccc cece E 13 Discrete DC Output Module Connector Pinouts 000 E 14 Discrete DC Input Module Specifications 0 0 eee E 15 Discrete DC Input Module ConnectorPinouts
89. cece reece eee E 2 E2 16 Input 16 Output 24 VDC Module 0 ccce cece eee eee eee E 4 E3 Disc rete AC Output Module cccceccee cece eee eee eee E 7 EA Disc rete Relay Output Module 0cccccceee cece e cece E 9 E5 Disc rete DC Output Module cccccece cece eee eee eee E 12 E6 Disc rete DC Input Module cccccceeeee cece reece E 15 SIMATIC 545 555 575 System Manual 575 I O Module Specification amp Pinouts E 1 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com E 1 Disc rete AC Input Module The discrete AC input module PP X 575 4232 enables the CPU to monitor 110 VAC field inputs Table E 1 lists the specifications of the discrete AC input module See Table E 2 for connector pinouts Table E 1 Discrete AC Input Module Specifications Feature Depto Optical isolation 1500 Vrms Cmn E 79 0 VAC UH minimum On voltage 132 0 VAC UH maximum 0 0 VAC UL minimum Off voltage 20 0 VAC UL maximum dis 4 0 mA IH minimum On input current limits 15 0 mA IH maximum 4 ms minimum Operating frequency 47 63Hz Vbatt Current consumption 45 V STDBY None On state indicators one per channel No fuses so blown fuse indicators are not used E 2 575 O Module Specification amp Pinouts SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Table E 2 shows connector p
90. channel If the existing Series 500 system has more than 15 bases multiple VME 575 CPUs each with its own I O channel can be used However significant program modifications may be necessary in order to divide the 565 program and redistribute the program among multi ple 575 CPUs Another option is to rewire using a PROFIBUS DP channel with up to 112 master and slave devices 2 Renumber your bases so that no two bases have the same number and so that base number 0 is not used 3 Modify the controller s I O configuration to reflect the channel number and base number changes 4 Movejumper E8 on the 575 2126 annex card from the U position to the T position This ensures that the I O channel data lines are properly terminated 5 Install a Series 505 base with power supply and PPX 505 6860 converter as described in Section C 6 6 Connect the RS 485 I O port on the 575 CPU to the RS 485 I O port on the PP X 505 6860 converter and ensure that the VM E bus base is electrically bonded tothe Series 505 base as described in Section C 6 7 Connect the RF coaxial cable of the Series 500 I O channel to the PPX 505 6860 port that is labeled RF Tol O BASES See Section C 6 C 10 Upgrading Existing Series 500 Installations SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com
91. copy a program into the on board flash EEPROM If you have changed the board configuration at any time follow these instructions to configure the CPU for on board EEPROM program storage NOTE Ensure that the back up battery is enabled and good BATT GOOD LED is on Power to the base must be turned off and without a functioning back up battery your program may be lost when power is restored You may want to use TISOFT AUX 60 SAVE PLC ALL or the corresponding function in SoftShop to save your program to disk before proceeding 1 Placethe CPU in PROGRAM Mode 2 Ensurethat switch 9 on the CPU dipswitch is turned On tothe left This enables the back up batter y 3 Turn off all user supplied power to the 545 555 base CAUTION The CPU is sensitive to and can be damaged by electrostatic discharge Personnel must make contact with a static dissipative pad and or wear a grounded wrist strap when handling the CPU 4 Removethe CPU from the base assembly and place the CPU component side up on a static dissipative surface 5 Ifa portable EEPROM is installed in the socket on the CPU you must remove it in order to select on board EEPROM program storage 6 Set the jumper on header E20 to strap the pins marked ON BRD FLASH on board flash memory as shown in Figure 7 3 7 Reinstall the CPU in the base and turn the base power On Refer to Chapter 9 of this manual if the E EPROM fails to function correctly To
92. copy a program into the on board flash EEPROM see Section 7 3 7 8 Using EEPROMsfor Program Storage SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Figure 7 3 Jumper Pin Settings for On Board Memory Program Storage SIMATIC 545 555 575 System Manual Using EEPROMsfor Program Storage 7 9 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 7 3 Copying a Program into an EEPROM Ensure that you have configured the CPU to select the desired EEPROM portable or on board refer to Section 7 2 and then continue with the steps listed below 1 Enter the program into the CPU Verify that your program is correct and save your program to your programming unit hard disk 2 Setthe CPU toPROGRAM mode 3 Select the TISOFT auxiliary function AU X 84 or select the menu command PLC Utilities PLC Operations in SoftShop 4 Usethe Source Toggle option to select RAM as your program source 5 Make any desired changes to the source program which is located in RAM 6 Usethe Erase option to erase program data on the EEPROM 7 Usethe Copy option to copy the program from RAM tothe EEPROM NOTE The CPU does not allow changes to program memory during the programming of the EEPROM 8 Usethe Source Toggle option to select either RAM or EEPROM as the program source Refer to Table 7 3 for mode an
93. e RS 485 cables e Taps terminal blocks e 9 pin D connectors male and shell e Terminal lugs Mounting Taps or Installation procedures for mounting taps or terminal blocks depend upon Terminal Bloc ks the cable installation technique used Refer to mounting instructions provided by the tap or terminal block vendor 6 4 Cabling and Wiring the System SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Tunk and Drop Lines Figure 6 1 Local Base l4 Drop Line Use RS 485 cabling for the trunk and drop lines that connect the various hardware items in your system Trunk line refers to the cable that is used to connect terminal blocks to one another drop line refers to the cable that connects a CPU or RBC tothe trunk line by means of a terminal block See Remote Base T Terminal Block T Trunk Lines Drop Lines Remote Base Figure 6 1 Trunk and Drop Line Example SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Cabling and Wiring the System 6 5 Installing Series 505 Remote I O Cables continued Selecting Cable Three commercially available cables provide an acceptable level of I O communication in an industrial environment e Belden cable
94. eek eet ein wb onk Bead et ieu tee e PD Gee DE Br gored 5 6 Output State Selection 0 eee nnn 5 6 Dipswitch O ptlOns xi easet etie Linde er ben tet Dac RU Fest ua base e ed 5 8 Series 505 Base Numbers ssssseeesseesss en nnn 5 9 Changing the RBC Base Number 0 0 00 cece eee nnn 5 9 Resetting the RBC ccc cece te tee 5 11 Status Display aes 9 Locas ehe Crus s dads ode dace eed oe See ee ee ea ine ek 5 12 5 5 PPX 505 6870 RBC ccc cece cece cece eee ee 5 14 UserO PUOMS ee toten qtd oe de Hah hh Fon lt ers Alin e AH ens dc 5 14 Output State Selection ssussuuuseeessseelslsesss sn nnn 5 14 J mpersE2 E3and E4 230 ccci avi e ee ket pde he ee ee E EE Er ERAS 5 15 Dipswitch Options 0c cece ccc 5 16 Baud Rate forthe RS 232 Port cece ee 5 17 Assigning the RBC Station Address 6 ceca 5 17 Reset Pushbutton 00 ccc ehh heh 5 20 Resetting the RBC vessat irnia kiaia ele i C aA ROI aU EE XE EE 5 20 Status Display Mode ssssssssssseee s nn 5 22 Setting User Pa ra meters forthe 505 PROFIBUS DP RBC 0c cece cece teens 5 24 Discrete I O Interval 0 ccc cect tee 5 24 Word O Update Factor 2 rodent tret dette ere tea ale dad 5 24 50X Ignore Mismatch Mode 0 cc cece e nnn 5 24 50X RS 232 COMM POM 4 pore dees 04d dk dae ee ele dee a eee dee da s 5 24 SIMATIC 545 555 575 System Manual Installing Remote Base Controllers
95. execute AUX 12 PLC Complete Restart If the fatal error persists ensure that the battery backup is enabled and execute the AUX 10 PLC Power up Restart f you have been unable to clear the fatal error to this point you must re initialize the CPU This clears the CPU memory Disable the battery backup disconnect the battery and cycle power to the base If the PCG LED comes on restore the battery backup by reconnecting the battery You must now use your programming unit to restore your program If the PCG LED does not turn on at this time your CPU may havea hardware failure Calling for Refer to the Preface for information on obtaining technical assistance Assistance Before calling for assistance havethe following information at hand List of fatal and non fatal errors Model number CPU serial number CPU software revision execute AU X 15 or check the EPROM label Sequence of events leading up tothe failure SIMATIC 545 555 575 System Manual Troubleshooting 9 15 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 9 4 9 16 Toubleshooting CPU Non Fatal Enors Troubleshooting Definitions of non fatal errors and suggested courses of action are as follows Scan overrun The CPU fixed scan time is not sufficient to execute the user program I O base failure A configured base is not connected or has failed Check the I O cabling and the O configurati
96. faster when you install the module in the local base versus a remote base You can improve SF module performance and scan performance by replacing your Series 500 SF modules with Series 505 SF modules and installing them in the 545 555 local base If all SF modules cannot be installed in the local base consider placing low activity SF modules such as the ASCII BASIC or DCP modules in a remote base Place high activity modules such as the NIM or Peerlink in thelocal base C 8 Upgrading Existing Series 500 Installations SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Upgrade Path Series 505 base Oco00 oc1ooc Oo Series 500 505 bases with RF RBCs Notes The 545 1104 545 1106 555 1103 1104 1105 and 1106 CPUs can be used in the Series 505 base
97. match with those of the first set of terminal lugs That is if a wire at a bottom terminal screw is blue the wire on the screw directly above it must also be blue 614 Cabling and Wiring the System SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 5 Tighten terminal block screws 6 If you arenot using another terminal block install a terminating resistor across the terminal screws securing the cable wires with the color coded insulation jacket See Figure 6 8 NOTE Theterminating resistor value depends on the type of cable being used See Table 6 3 Terminating Resistor Ly Drop line from CPU or RBC Figure 6 8 Adding a Terminating Resistor Table 6 3 Temninating Resistors Cable Type Resistor Value Color Code Belden 9860 120 Ohms 5 1 4 W Brown Red Brown Gold Belden 9271 120 Ohms 5 1 4 W Brown Red Brown Gold Belden 9182 150 Ohms 5 1 4 W Brown Green Brown Gold SIMATIC 545 555 575 System Manual Cabling and Wiring the Sytem 615 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Installing Series 505 Remote I O Cables continued Preparing Trunk Use the following procedure to prepare Series 505 trunk line cables Line Cables 1 Strip back 1 50 inches 38 mm of the sleeving on bot
98. no n o o m i jm i jm iIm jojojojo n n ijm jm jojojojo n n nm m nm iojojojo jn jn nm nm ijojo o o j o nm jm jojo n jn jojo n n jojo n jn jojo n jn joj joijnm in jojoijnm ijn jojoijnm m jni o 9 S PLolePl ole ol RPlof re of e of FPL of BJ Of FB Of BP Of BI Of FB Of BI Of BIL Of BP Of BP of eB Address not allowed when connecting to 545 555 575 CPUs 5 18 Installing Remote Base Controllers RBC s SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Table 5 7 Setting the RBC Station Address continued Switch Number State Station Switch Number State Station Address 5 6 7 8 9 10 Address P 5 6 7 8 9 6 Sta 66 Sta 67 Sta 68 Hn Bio PPR RPP Rt RyRy oO CO OF Of Of OF OF OF PJ RT RP RIT RI RIT_rR Oo Oo Of CO CO OF OF m ojo ojojo m o pal o m m m Sta 70 1 0 Sta 100 1 1 Sta 73 1 Sta 103 1 Pile Sta 106 Sta 112 Sta 118 Sta 121 Sta 123 Sta 124 1 Sta 125 Address not allowed when connecting to 545 555 575 CPUs Pile e 90 0 Oo oO OF O CO OF CO CO n Ol O FOI O FOl o Ta Pl Pile el ele e H CO oO CO CO CO OF CO CO OF CO CO CO H m m m Pl elPlelrelo m m eojojojo jo Bieo mo moijno no m m Pl e f ej e
99. o pa Table 5 7 Setting the RBC Station Address Switch Number State P 5 o ojo o l o Fol o o 6 7 8 9 10 Sta 9 o o ojojojo Sta 32 o o O Fol o Fol o FS o o o ojo oO CO CO OF eo eo B ieo meojeo eo no m o ea jmn jmnjnoeo o o 0 1 Oo CO CO CO CO CO O OF O CO OF o o ojojojol jo Pl ePlRPlel elo o oO oO CO CO o o PPR Rp Rp Rey Ret Rey ey o Of OF OF OF OF OF OF FY RIT RI RP RyRy Ret Ry oO O Oo OF OF OF CO CO Py RyRy rey ol Oo OF OF FJ RI _ Ry rR oO Of OF OF FI RIT RI e oO oO Of CO FJ RF RI rRy O Oo o o eje O O Try rR oO OF Fy FI OF OF FP FR OF OF FI FRI ol CO FIT FR oO OO FT RF OO OF FIT rRI O o e O e Oje Of ry OF RF Of FR OF RF OF FR OF FI OF RF OF FF OF FI OF FR OF RF OF RF Olej O 0 0 0 0 0 Station Address ojojo Hn ojojo oO O CO Hn Switch Number State P e Bio o o o ojo Hn 5 BPlele rR eo 6 7 8 eo Pl ele el Pelee ojo AN UA eric vv D V VVV V V L Aj gt N m ojojo oO OO CO CO CO CO CO OF CO OF CO O e m ojl ojlejejejejej ejejej ojojlojlojojojlojlolejejejejejejejejojlojojojojlojlo o Pl RePlelele Pl el elelele o Plelelelre CO Of PL RP Rey Py Rel ey Rel eleler o o meo jmo jmo
100. only Four base models are currently available e Model PPX 505 6504 41 0 slots e Model PPX 505 6508 8 I O slots e Model PPX 505 6511 111 O slots supports redundant power supply redundant RBCs and or dual media cabling e Model PPX 505 6516 16 I O slots Any Series 505 base may be used at any place in the system as either local or remote Select your base according to the number of I O points required including plans for future expansion Chapter 3 describes installation procedure for Series 505 system hardware and Chapter 5 is devoted to information about Series 505 RBCs including the DP RBC which is housed in a Series 505 base The 575 CPUs are housed in a VME bus base with slots for a power supply one or more CPUs VME I O and third party masters and slaves The PPX 575 2130 VME bus base has slots for 14 0 8 inch boards in addition to the power supply and system controller Chapter 4 describes installation procedures for the 575 local base SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Expansion I O Two 1 O channels are available for expansion I O e The Series 505 channel supports Series 505 and Series 500 remote I O NOTE To upgrade your Series 500 installation to a Series 505 system while keeping your Series 500 remote I O bases see Appendix C e ThePROFIBUS DP I O channel supports PROFIBUS DP 1 0 masters slav
101. required for an earth ground e Usethe shortest possible length of 8 gauge copper wire or equivalent braided cable to make the connection Figure 2 13 Grounding the 545 555 Controller Chassis Grounding the If the system is mounted in a cabinet or rack use the same grounding Cabinetor Rack procedure Ensure that a good cabinet or rack ground connection is achieved by removing existing paint and attaching a 8 gauge copper wire or equivalent using a bolt washers and nut as necessary SIMATIC 545 555 575 System Manual Pre installation Guidelines 2 19 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Grounding the Power System continued Cable Cabling at the rear of the unit can be routed in and out of the cabinet Managementfor through the two cable ducts at the bottom of the unit or by removing the the 575 break away tab on the rear panel Refer to Figure 4 31 for location of the break away tab Grounding the 575 A ground connector mounted on the side panel of the chassis provides an Controller Chassis earth ground connection to the chassis For an alternate location you can move the ground lug to the rear mounting bracket as shown in Figure 2 14 Optional Mounting Location Rear Mounting
102. system C 3 560 565 system C 6 560 565 to 545 555 C 8 560 565 to 575 C 10 RF based 560 565 system C 8 Series 500 system C 2 using RS 485 RF converter C 8 User configured mode 575 CPUs 4 26 V VMEbus base adding 575 secondary 4 36 installing 575 primary 4 35 4 38 installing 575 secondary 4 39 installing system controller 4 35 guidelines 4 34 over view 1 12 panel mounting 4 12 rack mounting 4 11 replacing 575 CPU 4 37 boards installing 4 32 daisy chain signals 4 53 1 0 installing 4 40 slot numbering 4 40 1 O modules installing 4 42 installation flowchart 4 2 modules power requirements B 6 power supply installing 4 17 Index 9 Guaranteed 888 88 SOURCE www artisantg com VMEbus power supply continued power consumption 4 15 replacing fuse 9 19 selecting voltage 4 16 troubleshooting 9 19 wiring guidelines 4 17 wiring procedure 4 18 requirements 4 50 spare parts D 5 system components D 5 Voltage selecting for fan assembly 4 7 selecting power supply input 4 16 Index 10 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com W Watchdog ti mer communications 9 24 hardware PROFIBUS DP RBC 5 15 Series 500 RBC C 15 Series 505 RBC 5 6 Wiring Seealso Cable planning for installation 2 16 Word I O update factor 5 24 SIMATIC and SINEC are registered trademarks of Siemens AG PowerMath SmarTune So
103. the RBC overrides the Zero selection on the analog word output module likewise when Hold Last Value is selected on the analog word output module that selection overrides the Off option on the RBC jumper NOTE If the RBC hardware watchdog timer is activated an RBC failure the state of the outputs is determined by the output module with no reference to the RBC s J P6 Off F reeze jumper Discrete outputs go off toa value of zero Analog word outputs obey their own Zero Hold Last Value selection If no Zero H old Last Value selection is available on the module the analog word outputs hold their last value 5 6 Installing Remote Base Controllers RBC s SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com JP6 Dipswitch SW2 for setting baud rate Outputs off default OFF FRZ Jumper JP6 Dipswitch S2 for setting baud rate OFF FRZ Jumper JP6 Baud Rate 19200 9600 7 2400 Outputs off 6 1200 default 300 Figure 5 5 Position of OFF FRZJ umper and Baud Rate Switch on the B Model RBCs SIMATIC 545 555 575 System Manual Installing Remote Base Controllers RBCs 5 7 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com PPX 505 6851 A B and PPX 505 6850 A B RBCs continued Dipswitch Options Dipswitch SW2 S2 on the B version is used to set RS 232 423 baud rates
104. the floating point coprocessor Installation of the math coprocessor PPX 2589739 8010 is illustrated in Figure 4 14 The 575 2105 and 575 2106 CPUs have the Motorola M C68882 floating point math coprocessor built onto the board which is automatically used in conjuction with PowerM ath Alignment notch on silkscreen Figure 4 14 Installing the Math Coprocessor on the 575 2104 C PU SIMATIC 545 555 575 System Manual Installing 575 System Hardware 4 23 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 4 10 Configuring the CPU Configuring the Before installing the 575 2105 or 575 2106 CPU board you must configure 575 2105 2106 the dipswitch on the 575 CPU board The configuration options override any CPU dipswitch settings that you may have made on an HSIO annex card or a PROFIBUS DP annex card Figure 4 15 shows the position of the configuration di pswitch on the 575 2105 and 575 2106 CPU boards Table 4 3 lists the dipswitch configuration options Dipswitch Figure 4 15 Position of Configuration Dipswitc h on 575 2105 and 2106 CPUs Configuring the If you are using a 575 2104 CPU you must configure the dipswitch located 575 2104 CPU on the HSIO or PROFIBUS DP annex card Refer to Section 4 11 Figure 4 16 shows the location of the dipswitch on the 575 2126 annex card Figure 4 17 shows the location of the dipswitch on the 505 CP5434 DP annex card Table 4
105. the front panel of the fan assembly To replace a fuse follow these steps A caution To minimize risk of shock hazard always turn off all power from the fan assembly before changing the fuse Failure to do so could cause death or serious injury and or damage to equipment Ensure that power to the base is turned off before changing the fuse 1 Disconnect power to the fan assembly 2 Inserta flat bladed screwdriver in the fuse holder slot and rotate counterclockwise about 16 turn until it pops out see Figure 4 3 3 Remove the fuse and insert a new fuse in the fuse holder 4 Insert the fuse holder into the slot push firmly against the spring and rotate clockwise until it locks in place 5 Reconnect power to the fan assembly Turn counterclockwise to remove A Front Panel of Fan Assembly Pd Fuse holder Figure 4 3 Replacing Fuse on Optional Fan Assembly SIMATIC 545 555 575 System Manual Installing 575 System Hardware 4 9 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 4 6 Installing the PPX 575 2130 VMEbus Base Mechanical Figure 4 4 shows the physical dimensions of the PPX 575 2130 VMEbus Outline base This baseis designed to be mounted and operated in the horizontal orientation only 19 0 483 gt lt 17 68 449 9 58 243 o E Optional fan assembly
106. the terminal block 4 Ifyou arenot using another terminal block install a terminating resistor across the terminal screws that secure the cable wires with the color coded insulation NOTE Theterminating resistor value depends on the type of cable being used and must match the characteristic impedance See Table 6 3 A terminating resistor must be installed on the end terminal block s Trunk line Terminating Resistor Figure 6 9 Connecting Trunk Line to Terminal Block SIMATIC 545 555 575 System Manual Cabling and Wiring the Sytem 617 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Installing Series 505 Remote I O Cables continued Extending Trunk Line Cables Thefollowing procedure assumes you have connected one segment of trunk linetoa terminal block and wish to add a second segment in order to extend your installation Refer to Figure 6 10 Loosen the three terminal screws on terminal block A and install the second set of cable terminal lugs onto the terminal block NOTE Ensurethat the wires of the second set of terminal lugs match with those of the first set e g if a wireat a terminal screw is blue the second wire installed on the same terminal screw must also be blue Tighten screws on terminal block A Loosen three screws on terminal block B Install theterminal lugs on
107. to connect by means of the RS 485 RF I O channel converter to the Series 500 remote I O No remote bases can be connected on the RS 485 link between the 545 555 CPU and the PPX 505 6860 Figure C 3 Upgrading an RF Based 560 560T 565 565P System to 545 555 SIMATIC 545 555 575 System Manual Upgrading Existing Series 500 Installations C 9 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Upgrading an RF Based 560 560T 565 565P System continued Upgrading an To upgrade an existing 560 560T 565 or 565P system to a 575 system you RF based System need to replace the existing programmable controller including its chassis to 575 power supply and all installed boards with the VME bus base power supply and 575 CPU You must also install a Series 505 base with an RS 485 RF O channel converter PPX 505 6860 within three feet of the VMEbus base and ensure that the bases are electrically bonded i e connected by a grounding strap The upgrade is shown graphically in Figure C 4 NOTE The 575 cannot directly replace a hot backup H BU configuration 1 Ifthe Series 500 remote I O installation consists of more than one coaxial RF remote I O channel combine these channels into a single remote I O channel Refer to the chapter entitled Cabling and Wiring the System in the SIMATIC 560T 565T System Manual for information about installation of a coaxial remote I O
108. voltage and with the fan assembly operating The load power supplied by the 12 or 12 volt output must not exceed the power supplied by the 45 volt output i e with a 5 A load on the 5 V the load current supplied by the 12 or 12 must not exceed 2 A V current draw must be reduced by the amount of V stapy current used The battery will maintain memory for a time inversely proportional to the current consumed e g 5 Ah 4 mA 52 days assuming a fully charged battery NOTE The backplane termination consumes 1 0 A 5 W from the 5 V supply NOTE f a given module exceeds 3 3 amps in the VM E bus backplane then aJ 2 connector PPX 2589739 8012 must be installed in that slot This assumes that the module has a P2 connector SIMATIC 545 555 575 System Manual Installing 575 System Hardware 4 15 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Installing the 575 Power Supply continued Selecting If you have a PPX 575 6663 power supply module ensure that your voltage Input Voltage selection matches your line voltage To configure the module for 110 VAC or PPX 575 6663 220 VAC operation use the jumper selector wire located on the power Only supply board SeeFigure 4 9
109. 0 A B Coax Dual Media RBC PPX 505 6851 A B RS 485 Dual Media RBC PPX 505 6870 505 PROFIBUS DP RBC 0 to 60 C 32to 140 F 40to 70 C 40 to 158 F 5 to 95 noncondensing 2 IEC 664 664A Vibration Sinusoidal IEC 68 2 6 Test Fc 0 15mm peak to peak 10 57 Hz 1 0g 57 150 Hz Random NAVMAT P 9492 or IEC 68 2 34 Test F dc with 0 04 g Hz 80 350 Hz and 3 dB octave rolloff 80 20 Hz and 350 2000 Hz at 10 min axis EC 68 2 27 Test Ea Half sine 15g 11 ms 1500 Vrms except where specified Operating temperature Storage temperature Relative humidity Pollution degree Impact Shock Isolation inputs to controller Corrosion protection All parts of corrosion resistant material or plated or painted as corrosion protection Electric Noise Immunity Conducted noise EC 801 Part 4 Level 3 MIL STD 461B Part 4 CSO1 CS0O2 CS06 EC 255 4 Appendix C EEC 4517 79 Com 78 766 Final Part 4 IEEE 472 2 5 kV Radiated noise EC 801 Part 3 Level 3 MIL STD 461B Part 4 RSO1 RS02 Electrostatic discharge EC 801 Part 2 Level 4 15 kV A 2 System Specifications SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com A 2 General Series 505 Specifications Table A 2 General Series 505 Specifications Input Power Provided by means of power supply module PPX 505 6660 for user supplied
110. 0 Adapter Base Install PPX 500 2151 A or PPX 500 2153 Power Supply in slot A 2 If power supply is in slot B move it to slot A This makes I O slot 1 available A for an I O module S3 Finish upgrade with these steps 1 Install PPX 500 5114 A RBC 8 Connect twin axial cable to RBC port 2 Set base address es 4 Configure 1 0 Series 505 I O 4 8 or 16 slots 545 555 or VMEbus 575 Local I O 545 1104 or 1106 CPU 555 1103 1104 1105 or 1106 CPU or 575 2104 2105 or 2106 CPU with 575 2126 annex card Series 505 remote O link Figure C 1 Upgrading a 520 520C 530 530C 530T System SIMATIC 545 555 575 System Manual Upgrading Existing Series 500 Installations C 5 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com C 3 Upgrading an RS 485 Based 560 560T 565 565P System To upgrade an existing RS 485 based 560 560T 565 or 565P system replace the existing programmable controller including its chassis power supply and all installed boards either with a Series 505 base power supply and CPU 545 1104 1106 555 1103 1104 1105 1106 or else with a VME bus base power supply and one or more 575 CPUs with 5
111. 11B Board table did not match 0124 U Memory checksum error 012B System descriptor table did not match 0134 CS Memory checksum error 013B Application table did not match 0208 Invalid SFPGM number received from RLL 0209 S Memory is inconsistent 020C Invalid control block 0300 Operating system fatal error 030A Debugger called but not present 030B Buffer not available 030C Task code processing logic error 030D Invalid task code request 030E System request queue is full 030F A_SF detected error from SF INIT 0310 Invalid state change request SIMATIC 545 555 575 System Manual Troubleshooting 911 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Troubleshooting CPU Fatal Enors continued Table 9 5 Aux 29 Fatal Enor Codes continued 0313 Power fail recovery error 0314 Invalid SYSRQUE request type 031B Invalid state change event posted 031D Non conformant slave board requesting login 031E Unexpected bus error 031F System I O configuration error 0320 Boolean processor FAULT 0321 GSDA data structure format incompatible 0322 Remote 1 O annex card switch mismatch with primary switch 0323 Board timed out during login 0324 Unexpected error reported by 505 CP5434 DP annex board 0325 CPU timed out requested 505 CP5434 DP annex board operation O3FE Breakpoint encountered
112. 1500 Vrms user circuits imme One 3A 250 V normal blow 5 x 20 mm Fuses fuse per output 16 fuses total Replace only with UL CSA listed fuse Output type Non latching unprotected Operating voltage range SEA Minimum load current per point 10 0 mA 12 V current consumption Vbatt Current consumption 45 V STDBY Dons Life cycles 1 Hz repetition rate Full rated current 100 000 905A 300 000 0 1A 1 000 000 Maximum total relay contact resistance at 0 5 A to 2 A load currents 2400 mOhms at 10 mA to 0 5 A load currents use the following equation max R ohms 4 5 V load current x 0 05 0 15 The relay output module may be damaged if more than one channel is overloaded at the same time or if the temporary overload specification is exceeded SIMATIC 545 555 575 System Manual 575 O Module Specification amp Pinouts E 9 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Disc rete Relay Output Module continued Table E 9 shows connector pinouts for the discrete relay output module Table E 9 Discrete Relay Output Module Connector Pinouts Pim Soma t9 AR OumuseHonA Eum Ac OuputsexiAuserpou SR Output section Braun d 4 output 9 pc oumutsenanBusrpaer o
113. 19 inch rack Depth of base is 9 6 inches 244 mm minimum depth required to install the baseis 12 inches 305 mm NOTE Leave dearance of at least 3 inches 76 mm above and below the base and a clearance of 2 5 inches 64 mm behind for cooling 3 Align two bracket slots with two screw holes located on each side of the 19 inch rack 4 Secure each bracket to the 19 inch rack with two screws installed through the bracket slots Jo60690000006909002902929020 Figure 4 6 Mounting Base to Standard 19 inch Rack SIMATIC 545 555 575 System Manual Installing 575 System Hardware 4 11 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Installing the PPX 575 2130 VMEbus Base continued NEMA Cabinet Figure 4 7 shows the measurements required for rear mounting in a NEMA Mounting cabinet or mounting against a wall Rear mounting brackets are induded Measurements for these mounting options The cabinet must provide a minimum depth of 12 inches to accommodate cabling from the front of installed modules Leave dearance of at least 3 inches above and below the base for proper cooling diameter Measurements in mm 0 272 6 9 ON 8 holes o 18 31 465 Hill 19 0 483 Figure 4 7 VMEbus Base Wall or Cabinet Mounting Measurements Panel Mounting the Usethefollowing steps for panel
114. 2 2 for more information on safety considerations Fault Relay Usage To help place the system in a safe state for both the operator user and the Examples process you can use the 575 fault relay in conjunction with the emergency stop switch es and with any interposing relays that you use for safety critical circuits NOTE Refer to Section 2 2 Safety Considerations for additional safety information There are several different ways to usethe 575 CPU fault relay You can use it to control the power to the safety critical outputs You can also use it to control the power to the entire electronic control system thereby controlling the safety critical outputs To use the fault relay to control the power to the safety critical outputs you must wire the relay so that it controls the interposing relays in these circuits An example of this is shown in Figure 2 5 NOTE Figure 2 5 is not a complete electrical diagram It is for illustration purposes only A qualified control engineer should be aware of any relevant regulations and design the system with these in mind The fault relay can be used in conjunction with the emergency stop switch es and with any interposing relays used for safety critical circuits Safety critical circuits include but are not limited to circuits controlling motion of equipment and or circuits controlling high voltage Any circuit that could potentially injure the operator user if the circuit is energized at an i
115. 2 must not exceed 2 A 3 45V current draw must be reduced by the amount of V stapy current used 4 The battery will maintain memory for a time inversely proportional to the current consumed e g 5 Ah 4 mA 52 days assuming a fully charged battery Dimensions A 4 System Specifications SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com A 4 Series 505 Power Supply Specifications Table A 4 Series 505 Power Supply Specifications MEER PPX 505 6660 PPX 505 6660 A PPX 505 6663 85 132 VAC 110 85 132 VAC 110 170 264 VAC 220 170 264 VAC 220 20 30 VDC 24 47 4 63Hz2 Hz 47 63Hz ee State 2Arms maximum 2A rms maximum 8A zeroto peak 5A DC maximum Input Current Peak inr sh 50 A maximum for 50 A maximum for 20 A maximum for up to 100 ms up to 100 ms up to 100 ms Fuse 3 0 A 250 V 3 0 A 250 V 8 0 A 250 V slow blow 3 AG slow blow 3 AG normal blow 3 AG Volt Amp Rating 200 V A 200 V A ee Wattage Rating 100 W maximum 5 VDC 3 75 W 5 VDC 3 75 W 5 VDC 3 75 W Output Voltage Current VDC 11 A VDC 11A 5 VDC 11A 5 VDC 0 75 A 5 VDC 0 75 A 5 VDC 0 75 A 1 The wattage ratings are based on nominal voltage In addition the system complies with applicable requirements of Verband Deutscher Elektrotechniker VDE 0160 Electrical Equipment except 220 VAC Input Modules No PPX 505 44XX
116. 26 Setting the Base Address 1 tnt tte n n nnn 4 27 ISSUING SYSRESET eL che etek bene edes eee aged du terr robs Pacte reor Ei 4 27 Installing a Remote I O Annex Card Optional seen n n n n n n nnn 4 28 Configuring Annex Card Dipswitch sssssssssssses II 4 28 Annex Card PowerConsumption sssssssseeeee eee 4 28 Installing the Series 505 Remote I O AnnexCard ccc ccc cece cece nee eens 4 29 Installing the PROFIBUS DP Annex Card sssssssseese eese 4 30 Installing VMEbus Boards 000ccccec cece cece e eee eee 4 32 Introduction sie xk MR EE ia nk Ee ee OEE bbe Shs ee EDE cade eee 4 32 GeneralGuldelines 045 cis Glas ete ee EREE HAE HERE RES be eee eee eed 4 34 Guidelines for Installing a 575 System Controllerora Primary 575 4 4 35 Guidelines for Installing or Adding a 575 Secondary to the System 4 36 Guidelinesfor Replacing a 575 System Controller ccc cece eee eee eens 4 37 Guidelines for Replacing a 575 Primary Notin Slot 1 0 ccc eee eee eee 4 38 Guidelinesfor Replacing a 575 Secondary ccc eens 4 39 Guidelinesfor Installing SIMATIC VMEbus I O and Third Party Boards 4 40 Setting the Daisy Chain Switches sssssssesss In 4 41 Sot Numbering adoun ai aaka goai iaai enn 4 41 Installing and Removing I O Modules sssssseenseennm m 4 42 Contents Artisan Technology Group Quality I
117. 2FO Network Components Manual order number 6GK 1 970 5CA00 0AA1 describes how to install glass and fiber optic PROFIBUS cable systems e SIMATIC S5 ET 200 Distributed I O System Manual order number 6ES5 998 3E S22 describes installation and use of ET 200 products and the I O configuration utility COM PROFIBUS Refer to material in these manuals as necessary for additional information about programmi ng and operating your 545 555 575 system XX Preface SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Agency Standards European Community CE Approval Technical Assistance Series 505 products have been developed with consideration of the draft standard of the International Electrotechnical Commission Committee proposed standard IE C 65A WG6 for programmable controllers released as IEC 1131 2 Programmable Controllers Part 2 Equipment Requirements and Tests First Edition 1992 09 The 575 controller system is designed to be compatible with ANSI IEEE Std 1014 1987 Contact Siemens Energy amp Automation Inc for information about regulatory agency approvals that have been obtained on Series 505 units Agency approvals arethe following UL Listed industrial control equipment CSA Certified process control equipment or cUL UL for Canada FM Class Div 2 Group A B C D Hazardous Locations All Series 505 products
118. 3 lists the dipswitch configuration options NOTE All switches have the same meaning for both annex cards except for switches 1 2 For the 575 2126 annex card these switches must be in the correct position On or the 575 CPU will not be able to communicate with the remote bases Table 4 3 identifies the correct switch settings for each annex card 4 24 Installing 575 System Hardware SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Table 4 3 lists the configuration options you can select using the dipswitch on the CPU board 575 2105 2106 CPUs or on an HSIO annex card or a PROFIBUS DP annex card when used with a 575 2104 CPU These options are explained in more detail on the following two pages Table 4 3 Dipswitch Configuration Options Switch LE On On Bn For 575 2126 annex card selects remote I O baud rate Do not change change EI Off For 505 CP5434 DP annex card reserved for factory use Do not change BASE ADDRESS selections These dipswitches select the base address for the 575 system tables A24 address space and global control and status registers A16 address space Section 4 15 describes how the 575 allocates VM E bus memory A24 Base Address A16 Base Address 00000016 000016 Assumed value if AUTO CONFIGURED Off Off C0000016 C00016 ASSERT MAIT FOR SYSRESEF to recover from FAULT If the primary 575 is
119. 4 Installing 575 System Hardware 4 1 4 2 4 3 4 4 4 5 Overview of Installation Procedures ssssnsnnnsannnnnnnsnnsnunnsnnnnnnnnnnn Features of the PPX 575 2130 VMEbus Base see ehh hh hh Ove MEW inam in a A AE D R E a E R AE EA a E RE Features Required of a Third Party VMEbus Base eee eee n n n n nn nnn VMEbus Base Requirements sssuuesseessseessssss seen Determining the Condition of the 575 CPU Battery 2 2 0 00 e eee eee eee Enclosure and Temperature Considerations eere Enclosure Selection ssesee RR rhe Temperature Considerations 0 ccc esee Installing the Fan Assembly 0cccccecceeeeeee eee een nnn nnn Operating With Fan Assembly 0 0 nn Operating Without Fan Assembly 000s Installation Sequence ssssssseeee II hmm Selecting Voltage for Fan Operation sssssssssse Ih Wiring the AC Power Terminals uiusussssssssssessses n Mounting the Fan Assembly sssssssssse era Replacing Fuse on the Fan Assembly sssssssssssssess eae Contents Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 4 6 4 7 4 8 4 9 4 10 4 11 4 12 Installing the PPX 575 2130 VMEbus Base ssseeen nennen nn nnn nnn nnn 4 10 Mechanical Outline 0 cece mh 4 10 Mounting Measurements
120. 400 m 13 100 ft 4 000 m 1 5 Mbaud 660 ft 200 m 6 600 ft 2 000 m 3 to 12 Mbaud 330 ft 100 m 3 300 ft 1 000 m 622 Cabling and Wiring the System SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Installing Therules for proper PROFIBUS DP installation follow PRORBUS DP Cable e Create a daisy chain arrangement not a star arrangement A daisy chain has two connectors with a single cable bus wire connection all other connectors if any have two cable bus wires connections e You can connect up to 32 devices on one cable segment Repeaters count as devices e Donot run the cables near power wires e Thecommunication cable consists of two color coded insulated wires that are twisted together and surrounded by a shield The cable is encased in an insulating jacket When wiring the system the same color of wire must be connected to the TX RX pin throughout the system e Donot cross the TX RX signals and the TX RX signals Wire all of the TX RX r pins terminal B on the Siemens connectors together on each slave device and on the PROFIBUS DP annex card Wire all of the TX RX pins terminal A on the Siemens connectors together to each slave device and to the PROFIBUS DP annex card Crossing the wires at any point in the system causes communication problems e Proper termination and bias of PROFIBUS DP cable is important for relia
121. 5 32 Input Simulator PPX 505 6010 and 32 Output Simulator PPX 505 6011 are also affected by this compatibility restriction NOTE Note 1 in Table B 3 identifies all affected modules Thefollowing modules are fully compatible with 545 555 and 575 CPUs regardless of the manufacturing date e All Series 500 I O and all non discrete for instance analog Series 505 1 O with the exception of the High Speed Counter as described on page B 8 e Series 505 8 Channel Word Input PPX 505 6308 and 8 Channel Word Output PPX 505 6408 The serial number found on each module contains the manufacturing date of the module The fifth through the eighth characters of the serial number determine the manufacturing date see Figure B 1 NOTE Units manufactured prior toJ anuary 1988 that have been modified havethe letter G immediately following the serial number Before you install Series 505 discrete modules into a 545 555 575 system check the serial number of each module to ensure it is compatible with the 545 555 575 CPU SIMATIC 545 555 575 System Manual Powerand Compatibility B 7 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Module Compatibility with CPUs continued Series 505 High Speed Counterfor 545 555 High Speed Counter modules PP X 505 7002 manufactured prior to May 1990 will not operate properly in a 545 555 controller s local base configuration If a High Spe
122. 545 555 and 575 CPUs can communicate through Port 1 RS 232 to an operator interface or programming station through a dedicated line or dial up phone modems Dedicated line operation is a line used exclusively to connect the modems Dial up phone operation connects the modems by telephone lines Refer to Figure 6 22 for a typical configuration 545 555 CPUs require 25 9 pin female adapter 25 9 pin female adapter INMAC 359 4 or equivalent INMAC 359 4 if needed EIA RS 232C EIA RS 232C connectors connector CPU RS 232 9 Pin Port for Programming 545 555 7 Device 25 Pin Port for 575 Cable Cable 2462553 0001 2462553 0001 Connect in accordance with the modem manual Figure 6 22 Modem Configuration NOTE The modems must provide an EIA RS 232C DTE interface to the controller and operator interface and must have a built in error correction capability Although the controller supports both full and half duplex communications TI SOFT only supports full duplex communications 632 Cabling and Wiring the System SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Dedicated Line Operation Dial up Phone Line Usethese procedures to establish communication between modems in a dedicated line configuration 1 Connect the modem configuration 2 Ensure
123. 575 system NOTE You must adhereto VME addressing requirements for all the products that you install in the system Refer tothe IEEE 1014 VMEbus Specification and the literature accompanying other vendors products for additional details required for installation A Warning Installing or removing a board from a powered up base disrupts your process Disruption of your process can cause death or serious injury to personnel and or damage to equipment Ensure that all power is disabled before installing or removing boards from your VMEbus base ACAUON E Disconnect the battery in addition to disabling power before installing or removing a third party board if that board makes a connection to the battery backup 5 V STDBY circuit of the VMEbus backplane Failure to follow this caution could result in damage to the 575 power supply Do not install or remove a third party board with connection to a 5 V STDBY unless the battery is first disconnected Section 4 8 describes how to disable the battery 4 32 Installing 575 System Hardware SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Figure 4 18 provides an example of how boards might be used on a sample 575 system Filler plate S99SS5 o0 pd pur party slave dd P 3rd party master P di VME I O Pd AT card Fan
124. 6 Installing the 575 Power Supply Module ssssseenn nm 4 17 Connecting Powerto the 575 Power Supply sseesseesseese 4 19 Mounting the Battery ssssssssseeseeee hh 4 21 Disconnecting Back up Battery Before Powerup 0 0 4 22 Installing the Math Coprocessoron the 575 2104 CPU s sees 4 23 Position of Configuration Dipswitch on 575 2105 and 2106 CPUs 4 24 Installing the Remote I O AnnexCard ssssssssese sees 4 29 Installing the PROFIBUS DP Annex Card sssssssseesee eese 4 31 575 Controller sasise seiiet ai rre Ep ER n Rl Dea a en ue C Le Prada 4 33 Location ofthe CPULEDsS ssssssssseeee ehh hh 4 35 Setting Daisy Chain Signal Dipswitcheson VMEbus Backplane Lue 4 41 Installing and Removing Modulesin a VMEbus Base seeeeeeeeese 4 43 Fault Relay Wiring suse esrb ed a et oct dub ea Pe a bo edd 4 44 Normally Open Contacts ssssssssssssseese eee 4 44 575 2104 CPU Front Bezel ssssssssessss e nnn 4 45 POrt E PIDOUtS rikanis saia RR RA Rr BUREAU RE bed RR pe ERU tga mend ey biden es Pis 4 46 Port 2 3 and 4 Pinouts rici aii ai nase a ai aad heh 4 46 Cable to Connect to 9 Pin PC Serial Port ee eens 4 47 Cable for XON XOFF PrinterHandshaking 00 cece eee 4 48 Cable for Ready Busy PrinterHandshaking 00 c cece e eee eee eens 4 48 Cable to Connect Port 3 to an RS 422 Progr
125. 6 SYM IPTE 9 7 Troubleshooting CPU Fatal Errors 0cccccc cece cence eee 9 8 545 555 CPU Fatal EmorIndications sssesesss teen eee rnrn 9 8 575 CPU Fatal Error Indications ccc ccc cece teen nee rnrn 9 8 Causesof CPU Fatal EM0rs ccc ccc cece cence eee n eee eeennnnnes 9 9 545 555 Fatal EMOS i eemlkkIe dd aad bb ews veda bee 34k REX C9 eee 46 EI EX DERE 9 9 575 Fatal BITOIS i decor d pias ann quoe oad dudes ieee ae ond deduc deed Eder inus 9 10 545 555 575 CPU Fatal ErorCodes sssssesesee en 9 10 545 555 CPU Responsesto Fatal ErOrsS 1 cece eee n 9 13 Stepsto Clear 545 555 Fatal ErOrs sess 9 13 575 CPU Responsesto Fatal Emors ccc cece cece n 9 14 Stepsto Clear575 Fatal Em0rs ccc cece ccc cece hh 9 15 Calling forAssistance 1 0 cece enna 9 15 Troubleshooting CPU Non Fatal Enors sssssssssnnsnnnnnnnnnnnnnnnnnnnnnnnnn 9 16 Troubleshooting by Using Status Words serene nn II nnn 9 17 Troubleshooting User EEPROMs or EPROMs eere nn nnn 9 18 Troubleshooting PowerSupplies erseeee een nmm nnn 9 19 Checking RS 485 Twisted Pair Cable Installation elueeeees 9 21 Using DigitalorAnalog Meter ccc cece cece cee HI 9 21 Resistance below Minimum 0 cece eee cette IH 9 21 Resistance above Maximum ssssseee n 9 22 Checking PROHBUS DP Cable Installation
126. 75 2126 annex card The upgrade is shown graphically in Figure C 2 NOTE A 545 555 575 cannot directly replace a hot backup HBU configuration 1 Ifthe Series 500 remote I O installation consists of more than one twin axial RS 485 remote I O channel combine these channels into a single remote I O channel Refer to Chapter 6 for information about installation of a twin axial remote I O trunk line 2 Renumber your bases so that no two bases have the same number and sothat base number 0 is not used 3 Modify the controller s I O configuration to reflect the channel number and base number changes 4 Connecthel O trunk line to the 545 555 575 remote I O connector Update ti me for a special function module is significantly faster when you install the module in the local base versus a remote base If you are upgrading to a 545 555 system you can improve SF module performance and scan performance by replacing the Series 500 SF modules with Series 505 SF modules and installing them in the 545 555 local base If all SF modules cannot be installed in the local base consider placing low activity SF modules such as the ASCII BASIC or DCP modules in a remote base Place high activity modules such as the NIM or Peerlink in thelocal base C 6 Upgrading Existing Series 500 Installations SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com
127. 8 slots PPX 505 6511 Bases Card Rack Redundant I O base 11 slots PPX 505 6516 O base 16 slots 2587705 8003 PPX 505 6660 Blank bezel 0 8 inch 110 220 VAC power supply 50 60 Hz Power Supplies PPX 505 6660 A B 110 220 VAC power supply 50 60 Hz PPX 505 6663 A PPX 505 6830 24 VDC power supply redundancy capable O channel controller IOCC PPX 505 6840 Distributed base controller DBC Remote Base pala PPX 505 6850 A B RF dual media RBC PPX 505 6851 A B RS 485 dual media RBC PPX 505 6870 PPX 505 5100 505 PROFIBUS DP RBC TurboPlastic PPX 505 5103 TurboParison PPX 505 5190 Series 505 to 6MT Interface PPX 505 7002 High Speed Counter Intelligent Modules PPX 505 7003 New High Speed Counter 100 KHz PPX 505 7101 BASIC Module PPX 505 7190 Series 505 to 7 MT l O Interface PPX 505 ATM 4120 PPX 505 5184 386 ATM Module 80C386SX 16 MHz Co processor Modbus Protocol NIM PPX 505 7201 Field Interface Device PROFIBUS DP PPX 505 7202 Field Interface Device PROFIBUS DP PPX 505 7339 TIWAY NIM 2 local line ports Network Interface Modiiles PPX 505 7340 TIWAY NIM 2 RS 232C ports PPX 505 7354 Peerlink dual local line ports PPX 505 CP2572 Ethernet TCP IP NIM PPX 505 CP1434TF Ethernet H1 CP NIM PPX 505 CP5434 FMS PPX 505 2571 PRO
128. 85 RF I O Channel Converter continued Installing the Use the following procedure to install the PPX 505 6860 RS 485 RF VO Channel 1 Remove the power from the base in which you are installing the Converter PPX 505 6860 A WARNING Disable all power to the base before installing or removing the PPX 505 6860 Installing or removing any module from a powered up base could cause unexpected operation which could cause death or serious injury to personnel and or damage to equipment To prevent disruption of the I O channel disconnect the I O channel cable before removing or installing the PPX 505 6860 2 In the case of a 545 1104 555 1103 or 555 1104 installation install the PPX 505 6860 in the same base as the CPU in the first double I O slot adjacent to the CPU In the case of a 575 2104 installation the PPX 505 6860 must be installed in a Series 505 base within three feet of the 575 base that is electrically bonded to the Series 505 base O CONUNON The PPX 505 6860 is sensitive to and can be damaged by electrostatic discharge Ensure that personnel make contact with a static dissipative pad and or wear a grounded wrist strap when handling the PPX 505 6860 3 Position the PPX 505 6860 so that the bezel is facing you 4 Grasp the top and bottom of the PPX 505 6860 5 Carefully push the PPX 505 6860 into the slot until it mates with the backplane connector 6 Tighten top and bottom bezel scre
129. AM modein order to execute self tests For 545 555s the CPU executes the equivalent of an AU X 20 at every powerup If any area fails a message detailing the failure is displayed AUX 20 makes the following tests e Valid RAM locations are verified e Pre coded ROM checksum values are checked e The hardware force function is checked e nternal timer operation is verified Display Failed I O AUX 25 Display Failed I O displays the locations of any failed 1 O modules that are capable of diagnosing and indicating failure Some modules such as word and analog modules report that they have failed if the user supplied voltage is not correct AUX 25 also displays I O mismatch es indicating that one or more installed module s do not agree with the I O configuration Verify that the configuration data for listed modules is correct before considering that the module may actually be malfunctioning PLC Operational AUX 29 PLC Operational Status checks the operational status of the CPU Status and displays the results The display provides the information illustrated in Figure 9 1 Field descriptions are listed below e Application ID 575 only Identifies the CPU currently selected e Communications dentifies port or network in use If you are using a communications port the port is identified followed by a space and the protocol e g P1 TBP or P2 NITP The current baud rate is displayed in a field to the right If you are using
130. BUS DP ConnectorSchematics lssssssssssssesseeess eee 6 26 Installing a PROFIBUS DP Connector ssssssssssse eene 6 28 PROFIBUS DP Port PlInoUb cesses kie ruv eee lee ceed E REX bee Xie tg kg TCI yates 6 31 6 4 Connecting Modems ssssess nnn nnnm 6 32 UU EC L 6 32 Dedicated Line Operation ssssssssssseeee eee 6 33 Dial up Phone Line Operation ssssssssseeeeeen II 6 33 6 5 Connecting to a Printer 0 cece eens 6 34 aluum cT 6 34 545 555 Printer CONNECTIONS ssssseessseessseee nnn 6 34 575 PrinterConnections sissies cece nett n n nnn 6 35 SIMATIC 545 555 575 System Manual Cabling and Wiring the System 6 1 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 6 1 Cable Routing Guidelines Follow these suggestions when planning your cable routing e Allow for system growth Provide for attachment of future I O bases by routing cable through all possible areas of plant expansion e Take steps to bypass or eliminate noise sources in order to reduce system data error rates The following are common sources of electrical noise Power distribution mains Arcing motors and motor starters Fluorescent lighting Undesired signal transfer between adjacent circuits Poor terminations of cable connector e Dono allow the trunk cable to come into contact with any
131. C 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 4 14 Establishing CPU Communication Default Port The 575 CPU has four serial communication ports and initializes all four Configurations ports to 9600 7 bits odd parity and 1 stop bit on battery bad powerup These communication ports remain in this configuration unless you change them Port configuration can be changed using TISOFT 4 3 or later Figure 4 24 shows the locations of the communication ports and the optional PROFIBUS DP connection D 575 VME CPU BAT No battery backup O O run Run Watchdog 0 onam Master on bus System failure 09 9 ST PLC good SERIAL PORT 1 Port 1 RS 232 25 pin female D connector See Figure 4 25 e 000000000000 0000000000000 Fault relay 9 pin male D connector Series 505 remote I O port 9 pin female D connector 3 4 PROFIBUS DP Ports 2 3 and 4 25 pin female D connector See Figure 4 26 PROFIBUS DP port 9 pin female D connector 000000000000 0000000000000 optional o 575 2104 CO Figure 4 24 575 2104 CPU Front Bezel SIMATIC 545 555 575 System Manual Installing 575 System Hardware 4 45 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Establishing CPU Communication continued P
132. CPU is switched back to RUN mode which could cause death or serious injury to personnel and or damage to equipment If you have to edit a program stored in EEPROM be sure to re enter all correct variables and other settings to memory as required by your process before going back to RUN mode 3 Select RAM as the program source 4 Edit the program source code in RAM memory as required 5 Select the TISOFT auxiliary function AUX 84 in your programming unit 6 Usethe Erase option to erase program data on the EEPROM 7 Usethe Copy option to copy the program from RAM tothe EEPROM 8 Select the EEPROM as the program source Although the CPU can copy a program from either an EEPROM or an EPROM into RAM the CPU cannot copy a program from RAM toan EPROM 7 12 Using EEPROMsfor Program Storage SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Chapter 8 Starting Up the System 8 1 Powering Up the System ccccccc cece cece cece eee eee 8 2 huc nia Bleed hte pe Hea anaes feta ven ese dares ain atare E D O gee ee eee eee 8 2 Start up Procedures 0 nent nnn 8 2 82 CPU Memory Configuration sssssssssees nennen 8 4 Memory Configuration sssssssssssssss ehh ea 8 4 Maximum Configurable Memory sssssseeee e mm 8 4 SIMATIC 545 555 575 System Manual Starting Up the System 8 1 Artisan Technology Group Quality
133. Changesin Memory EmorHandling ssseessseessII F 2 Using the Auto Recompile Function sssssssssseeees m F 3 Programming Support sssssssssssssss hh F 3 F2 Fast PROABUS DP I O Update Times 0cccceccee cece eee eee enhn nnn nnn nnn F4 CPUs with this Feature 2 8 6 der prem re yg xp eet dee eed eee pera F 4 Fast PROFIBUS DP I O Updates sssssssssssse eee I F 4 OW IE WOIKS crecer hatin pit pterea tokna e RERER CO Ob hy ek Gee hate F 4 Selecting Fast DP Update Mode 0 ccc cece cette nnn F 4 Changing a PROFIBUS DP Slave Configuration 0 0 cece cece eee eens F 5 Typical Update Time 0 samian iia iada ehh F 5 scjp dae r F 5 F3 Memory Capacity ofthe 555 1106 CPU ccccccce cece eee eee F6 Difference in Memory Capacity between the 555 1106 CPU and Earlier CPUs F 6 SIMATIC 545 555 575 System Manual Enhancements in Late Model CPUs F1 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com F 1 Enhancements to Enor Handling CPUs with Enhanced Firmware Fatal Enor Conditions Changes in Memory Enor Handling For the 555 1103 1104 CPUs Release 4 2 or greater 555 1105 1106 CPUs Release 5 2 or greater 545 1105 1106 CPUs Release 5 1 or greater and 575 2105 2106 CPUs Release 5 1 or greater the following changes in the firmware have been implemented to minimize problems caused by excess
134. Check the pins to make sure that they are all seated properly in the socket 7 Observe umper E18 If you intend to write to the EEPROM ensure that J umper E18 is strapped If you do not write to the EEPROM and want to disable this feature remove strap E18 For the new CPU models 1105 1106 set the jumper on header E 20 to strap the pins marked DIP EEPROM as shown in Figure 7 2 8 Reinstall the CPU in the base and turn the base power On Refer to Chapter 9 of this manual if the E EPROM fails to function correctly To copy a program into the EEPROM see Section 7 3 7 6 Using EEPROMsfor Program Storage SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Figure 7 2 E EPROM Socketand J umper Pins for 1105 1106 CPUs SIMATIC 545 555 575 System Manual Using EEPROMsfor Program Storage 7 7 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Configuring the CPU for Non Volatile EEPROM Program Storage continued Configuring the CPU forOn Board EEPROM Usage The 575 CPUs require no configuration to store programs in non volatile memory The 545 555 1105 and 1106 CPU models are configured at the factory to enable the permanent on board EEPROM as the default program storage option If you have not changed the board configuration skip this procedure and refer to Section 7 3 to
135. Discrete VM Ebus 16 input 16 output 24 V 0 5 A DC module PPX 575 4366 Discrete VM E bus 32 point 24 V 0 5 A DC output module PPX 575 4532 Discrete VMEbus 16 point 110 V 1 A AC output module PPX 575 4616 Discrete VM E bus 32 point 24 V 2 0 A DC output module PPX 575 4732 Discrete 16 point relay output module PPX 575 4916 Male to male programming cable 25 pin PPX VPU 200 3605 Support rail 9 slot 1 inch center base PPX 2589739 8001 Support rail 14 slot 1 inch center base PPX 2589739 8002 0 2 inch filler panel for 1 inch bases PPX 2589739 8004 0 4 inch filler panel for 1 inch bases PPX 2589739 8005 0 6 inch filler panel for all bases PPX 2589739 8015 0 8 inch filler panel for all bases PP X 2589739 8014 1 0 inch filler panel for 1 inch bases PPX 2589739 8003 Battery 4 V 5 Ah for all bases PPX 2589739 8006 O connector front access PP X 2589739 8007 MC68882 math co processor 12 5 mHz for 575 2104 CPU PPX 2589739 8010 Daisy chain jumper for 1 inch bases PPX 2589739 8011 Mounting rails for 0 8 inch base PPX 2589739 8016 575 J 2 power connector kit PPX 2589739 8012 SIMATIC 545 555 575 System Manual Series 505 and VME Components Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com D 5 D 3 Recommended Spare Parts Siemens Ene
136. EEPROMs or EPROMs Troubleshooting Portable EEPROMs and EPROMs cannot usually be repaired and must be replaced if they become defective Before replacement read Chapter 7 carefully and perform the foll owing checks Ensurethat the EEPROM programming enable strap is installed correctly on the jumper pin E18 See Figure 7 1 Ensurethat an E EPROM is installed depending on your use Ensure that all E EPROM pins are properly seated in the socket For CPUs that support both portable and on board EEPROM ensure that the jumper E 20 is configured to select your target EEPROM In addition if you select on board EEPROM for program storage ensure that the portable EEPROM is not installed Other possible causes for errors indudethe following The EEPROM may already have been programmed and not erased Usethe AUX 84 to erase program data on the EEPROM The size of the user program L K S and U memories that is being stored may exceed the size of the E EPROM NOTE To help ensurethat the user program is saved the total user memory space occupied by the user program must not exceed the size of the E EPROM minus 2 Kbytes If the total user memory not system memory space occupied by these user programs is greater than this value none of the data is saved and the error message OPERATION FAILED is displayed on the screen when attempting to save the data SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instru
137. FIBUS FMS Communications Processor module Programming port expander 4 Miscellaneous PPX 505 CP5434 DP PROFIBUS DP annex card PPX 505 6860 PPX 2587678 8005 Lithium battery for 1105 and 1106 CPUs also 545 1101 Lithium battery for 1103 and 1104 CPUs BASIC module Battery Kit PPX 2587678 8010 Series 505 and VME Components Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com RS 485 to RF coaxial O channel converter ATM module SIMATIC 545 555 575 System Manual D 2 575 VME System Components Table D 2 lists components used in 575 systems Table D 2 575 System Components Fart Number VMEbus CPU 832 Kbytes of user memory amp fault relay 12 5 MHz clock PPX 575 2104 VMEbus CPU 832 Kbytes built in math coprocessor and PowerMath 32 MHz dock PPX 575 2105 VMEbus CPU 1856 Kbytes built in math coprocessor and PowerM ath 32 MHz dock PPX 575 2106 Sixteen slot VM E bus base 0 8 inch centers PPX 575 2130 Fan kit for PPX 575 2130 base 115 230 VAC PPX 575 2131 VMEbus power supply 185 W 110 VAC only PPX 575 6660 VMEbus power supply 300 W 110 220 VAC PPX 575 6663 Series 505 Remote I O annex card PPX 575 2126 PROFIBUS DP annex card PPX 505 CP5434 DP Discrete VM E bus 32 point 110 V AC input module PPX 575 4232 Discrete VM E bus 32 point 24 V DC input module PPX 575 4332
138. Figure 4 4 VMEbus Base Physical Measurements Measurements in mm Mounting TheVME bus base conforms to DIN 41494 and IEC 297 standards which Measurements define the requirements for equi pment mounted in standard 19 inch rack cabinets The base is a 7U high 12 25 in unit Figure 4 5 shows the measurements required for front panel or 19 inch cabinet mounting Leave dearance of at least 3 inches above and below the base for cooling You must remove the rear mounting brackets and the ground lug in order to install theunit in a 19 inch rack or the front panel cutout shown in Figure 4 5 After installing the base re install the ground lugtothe side of the base to provide a proper grounding connection Refer to Chapter 2 Figure 2 14 for proper placement of the grounding lug cane Measurements in mm 6 9 8 holes lt x 17 72 450 18 31 465 Figure 4 5 19 Rack or Front Panel Mounting Measurements for Base 4 10 Installing 575 System Hardware SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Mounting a Base in Use the following steps for mounting a PPX 575 2130 base in a standard a 19 inch Rack 19 inch rack SeeFigure 4 6 1 Move brackets from wall mounting position back of chassis to front position 2 Position the basein the
139. Figure 5 6 shows the location of the baud rate dipswitch on the RBC card Dipswitch for JULLI setting baud rate A ea On Backplane connector b Figure 5 6 RBC Dipswitch Location Table 5 2 shows how to set the switches to select the desired baud rate Table 5 2 RS 232 Port Baud Rate Settings BL SE SION NOTE Dipswitch SW3 on the A version is for factory use only Do not change the settings on this dipswitch If the dipswitch setting is accidentally changed refer to Table 5 3 to reset your dipswitch to the proper setting Table 5 3 SW3 Factory Dipswitc h Setting A Version Only Switch swih2 swims swima On 1 off 0 Off 0 Off 0 5 8 Installing Remote Base Controllers RBC s SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Series 505 Base The base containing the Series 505 CPU and local I O is designated base 0 Numbers You can connect up to 15 remote bases to your Series 505 system numbered 1 through 15 If you are using more than one RBC each RBC must be uniquely numbered Figure 5 7 shows the location of the base number switch on the front of the RBC models e A thumbwheel switch on the A version RBC is used to assign the base number e A rotary switch on the B versi
140. G9 69 QO amp 9 amp 9 OQ ACAO 69 69 vojol CO SMS GK PV PGP SS S MSS SS S S S MS V8 rg y amp 9 G9 69 G9 Co 69 9 G9 G9 a q 90 Sd Od z3 GVGCGCGK SS MS MSS MS MS S VS 80 40 v0 2d cd I Figure 3 16 Input Output Terminal Bloc ks 3 28 Installing 505 System Hardware SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Chapter 4 Installing 575 System Hardware 4 1 Overview of Installation Procedures ssseeeees enne nnne nnn 4 2 4 2 Features of the PPX 575 2130 VMEbus Base sese nnn nn nnn 4 3 4 3 Features Required of a Third Party VMEbus Base een n n n n n n n nnn 4 4 4 4 Enclosure and Temperature Considerations eere 4 5 4 5 Installing the Fan Assembly 0ccccceceee cece eee eee eee eee 4 6 4 6 Installing the PPX 575 2130 VMEbus Base 0cccceeeeeeee eee eee eee e ee nnn nnn 4 10 4 7 Installing the 575 Power Supply 00cccccceeeecee eee ee eee eee eee eee 4 14 4 8 Installing the Battery cccccce cece cece ce
141. Installing and Use the following steps to install or remove a PPX 505 6660 Removing the PPX 505 6660 A or PPX 505 6663 power supply Power Supply AWARNNG 7 Do not install or remove any modules to or from a powered up base Installing or removing any module from a powered up base could cause unexpected operation which could cause death or serious injury to personnel and or damage to equipment Disable all power to the base before installing or removing any module 1 Disconnect power to the base O oon Attempting to operate the PPX 505 6660 or PPX 505 6660 A power supply at 220 VAC with 110 VAC selected or 110 VAC with 220 VAC selected results in damage to power supply Attempting to operate the PPX 505 6663 power supply outside the designed voltage range of 20 to 30 VDC may cause damage to the power supply Double check your power supply voltage before you attempt operation 3 8 Installing 505 System Hardware SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 2 Ifyou areinstalling the PPX 505 6660 or PPX 505 6660 A or B power supply connect the voltage selector as shown in Figure 3 4 Selecting voltage for the PPX 505 6660 power supply Selecting voltage for the Fm PPX 505 6660 A n power supply cu 7 ues JP3 110V 220V Selecting voltage for the
142. Instrumentation Guaranteed 888 88 SOURCE www artisantg com 8 1 Powering Up the System Overview This section provides general guidelines for powering up your system a WARNNG O You must be fully informed about safety procedures before you power up the system Failure to follow safety guidelines could result in death or serious injury to personnel and or damage to equipment Review and comply with the safety procedures listed in Chapter 2 before completing the following steps Start up Follow these procedures when powering up your system for the first time Procedures l Verify thefollowing items e Check input power to verify that it matches the voltage used by the power supply If necessary adjust the voltage selector on the power supply to correspond to input power e Check for correct switch settings on all configurable modules namely the CPU and annex card s if any and any RBC s If you intend to copy user programs into an installed EEPROM the jumper strap E 18 on your 545 555 CPU must be strapped and the CPU must be configured for EEPROM storage see Chapter 7 NOTE Do not install a programmed EEPROM when commissioning your system the EEPROM must not be programmed before you have verifi ed component functionality and system installation and design e f any of your system bases have empty I O slots use filler bezels and bezel screws to cover the openings in the base This prevents debris fro
143. MATIC and third party DP I O slaves with the optional PROFIBUS DP I O annex card Figure 1 1 Series 505 I O Architecture SIMATIC 545 555 575 System Manual System Overview 1 5 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 1 2 System Features Product Table 1 1 lists memory capacity scan performance and other features for Specifications the CPUs described in this manual Overview Table 1 1 CPU Specifications sensus sa noanos sss ssemor sez User Memory Memory 96 Kbytes 192 Kbytes 384 Kbytes 1920 Kbytes 832 Kbytes Boolean Scan 0 33 ms K 0 16 ms K 0 07 ms K 0 07 ms K 0 9 ms K Digital I O Points 1024 2048 8192 8192 8192 Analog I O Points 1024 1024 8192 8192 8192 Control Relays 4096 32768 32768 32768 23552 Timers Counters 1024 20480 20480 20480 20480 a Yes Yes Yes Yes Yes PID Loops 16 64 64 64 64 Analog Alarms 32 128 128 128 128 SFPGMs SFSUBs 64 64 1023 1023 1023 1023 1023 1023 1023 1023 Local I O Series 505 Series 505 Series 505 Series 505 VME 505 Remote I O 15 Bases 15 Bases 15 Bases 15 Bases 1 PROFIBUS DP 1 0 2 32 Devices 3 112 Devices 112 Devices 112 Devices 112 Devices 34 Ethernet H1 Ethernet H1 Ethernet H1 Ethernet H1 Ethernet H1 Communications TI o P Tl E P TI pnis P Tl ee P TI poc P PROFIBUS FMS PROFIBUS FMS PROFIBUS FMS PROFIBUS FMS PROFIBUS FMS 1 RS 232 1
144. OG orINCH Switch 0 ccc hes 2 5 575 Fault Relay Operation eeeeeeeeeeeere nnn nnn nnn nnn 2 6 OVEWIEW iis tava ative ei ke Meee hehe hoes OE Ge es een ese een een 2 6 Fault Relay Operation Details 0 0 cee 2 6 Time DERRY Ar 2 8 Fault Relay Usage Examples ssssssssssssesee eee 2 8 Contents iii Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 2 4 2 5 2 6 2 7 2 8 Guidelines for Fuses Circuit Breakers ssnnssnnnnansnnnnnnnnnunnnnnnnnunnnnnn 2 11 Fusing the Controllerand Remote I O Base ccc ccc cent nnn 2 11 Hectrical Noise 56i nhs ii aie inn RO wee nine OR Rn R8 DG mw 8 JR cR 8 RR a 2 12 Definition and Source sssssseeeeseee anann narrar nran 2 12 Correcting Noise Problems ceeee cece cence eee nnn nnnm 2 13 Noise Snub BING 34 pene Diere ee Tedre op dee Oa Seed Lie EE ee dis Pees 2 13 Noise Isolation llsssssseeeeee IIR hn 2 15 Wiring Guidelines ccccceee cece eee eee eee eee nnm 2 16 Grounding the Power System cece cece e eee eens 2 17 Eat GOUNA eer Tr 2 17 Ground Connections eee ees 2 18 Grounding the 545 555 ControlerChassis 0 ccc cece cence eee e 2 19 Grounding the Cabinet OrRack ccc ccc cece s 2 19 Cable Management forthe 575 ccc ccc cece arrra nrnna nrnna 2 20 Grounding th
145. PROFIBUS configuration utility software Refer tothe SIMATIC 505 505 PROABUS DP TISOFT2 User Manual and the SIMATIC S5 ET 200 Distributed O RBC System M anual for information about using COM PROFIBUS Table 5 9 describes the parameters used to set up the 505 PROFIBUS DP RBC in COM PROFIBUS You set these parameters by selecting the Parameterize dialog box in COM PROFIBUS Table 5 9 505 PROABUS DP REC Software Parameters Discrete I O interval 1 255 msec The RBC updates discrete I O modules at this rate Word I O 1 255 Determines the number of discrete I O updates performed Update F actor per I O word update Disable specifies DP Standard configuration mismatch 50X Ignore handling Mismatch Disable Enable Disable in i Mode Enable specifies Series 50X configuration mismatch handling 50X RS 232 e Comm Port Disable E nable Disable Disable or enable RS 232 port communications Discrete I O The Discrete I O Interval parameter defines the rate at which the Interval PROFIBUS DP RBC updates I O modules This parameter specifies the minimum time between updates of the discrete I O modules Word I O Update The Word I O Update F actor controls how often the word I O modules are Factor updated The Word I O Factor is the number of discrete I O updates performed per word update for example if the factor is 2 the word I O modules are updated on every second discrete I O update 50X Ignore The 50X Ignore Mismatch Mod
146. RCE www artisantg com 5 3 Communic ation Ports Series 505 RBCs including the 505 PROFIBUS DP RBC havetwo communication ports RS 232 Port The RS 232 port is an interface to programming devices that use software like TISOFT or other configuration tools To connect your RBC toa programming device modem use a standard 9 pin RS 232 serial cable that conforms at a minimum to the pinouts shown in Figure 5 3 A standard cable that conforms to the minimum requirements is available through Siemens specify part number 2601094 8001 Programming Device Modem RBC RS 232 423 Pinouts Pinouts 9 Pin Female pd D Connector Bc Signal Ground 5 90 5 Signal Ground Transmit Data 3 4 I O 3 Transmit Data Receive Data 2 1 5 leo 9 2 Receive Data TEEN Note The PPX 505 6851 A B and PPX 505 6850 A B RBCs require Pin 7 RTS and Pin 8 CTS to be connected together as shown above loopback Figure 5 3 RS 232 Serial Port Minimum Cable Pinouts I O Port Thel O port is used to connect the RBC to the PROFIBUS DP or Series 505 remote I O channel Chapter 6 describes how to connect a cable to the I O port SIMATIC 545 555 575 System Manual Installing Remote Base Controllers RBCs 5 5 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 5 4 PPX 505 6851 A B and PPX 505 6850 A B RBCs User Options Output State Selection The fol
147. S 232 RS 423 signaling protocol and an RS 232 pinout arrangement with an RS 423 5 V signal level extending up to 50 feet 15 m You can use a modem to extend this distance e Setting SW2 to the left selects Port 1 as a programming port e Setting SW2 to the right selects Port 1 as a printer port Figure 3 13 shows the locations of Port 1 and Port 2 on the front of the CPU Port 1 Port 2 1 Port 2 1 Port 2 2 RS 232 Port Pinouts RS 232 Port Pinouts RS 422 Port Pinouts RS 485 Port Pinouts Controller Controller Controller Controller Male 9 Pin D Type Male 9 Pin D Type Male 9 Pin D Type Male 9 Pin D Type I 5 Signal Pin Signal Pin Signal Pin Signal RSD 2 RCV m 3 DO UL 38 TXRX RCV XMT m9 DI L 8 TX RX XMT GND 5 GND 5 GND DTR SEL232 8 DO 6 SEL232 GND 2 D DSR 6 SEL232 RTS 1 Dipswitch 1 is On 120 Q termination resistors CTS 2 Dipswitch 1 is Off can be used for higher noise 3 User connection to select RS 232 operation immunity and more reliable long distance communication Cono Ofr o Il Port 2 oq 9c 3o ON Oar ORN Figure 3 13 545 555 CPU Port Locations Communications With the 545 and 555 CPUs your choice of cabling determines whether Port 2 Port 2 functions as an RS 232 RS 423 port or as an RS 422 RS 485 port Figure 3 13 describes the pinouts required for the various Port 2 options If you use RS 422 RS 485 cabling SW1 on the dipsw
148. S 485 RF I O Channel Converter cccccecencnceneneeueueseseenueueueuenesues C 19 IMO JUGON PPP C 19 COMPS Ub UY set Paina ao nitus pietre dud duca deo dort E RUE date die xe tel C 19 Installing the RS 485 RF I O Channel Converter ssssseee ee C 20 Removing the RS 485 RF I O Channel Converter cc cc ceee cece eee C 21 e puDM E C 22 Appendix D Series 505 and VME Components D 1 D 2 D 3 Series 505 System Components eeeeeeeee eee nnn nnn nnn nnn D 2 575 VME System Components sseseerses nnne nhanh haha D 5 Recommended Spare Parts 0ccccccceecee eee ee eee eee eee eee D 6 Spares for Series 505 System 1 keene nnn D 6 Sparesfor575 System 2 eee nnn D 7 Appendix E 575 I O Module Specifications amp Pinouts El E2 E3 EA E5 E6 Disc rete AC Input Module cccccceecee cece reece eee eee E 2 16 Input 16 Output 24 VDC Module 0 cece cece eee eee eee E 4 Discrete AC Output Module ccceeccee cece eee eee eee E 7 Disc rete Relay Output Module 00ccccceeeeeee eee ee eee eee eee E 9 Disc rete DC Output Module cccccece cece eee eee eee eee E 12 Disc rete DC Input Module 0cccecceeeee cece reece eee E 15 Appendix F Enhancements in Late Model CPUs F1 F 2 F 3 Index xii Enhancements to Enor Handling 00ccccceee cece e eee eee F 2 CPUs with Enhanced Firmware ssssssssssssss sess F 2 Fatal Emo
149. See the appropriate user manuals for information about the power supply Finish Upgrade with These steps finish the upgrade for both upgrade paths A and B These Steps 1 Install an RBC PPX 500 5114 A in the controller slot See Section C 5 for information about installing the RBC 2 Set the base address 1 15 using the thumbwheel on the RBC Base number O is reserved for the local base and cannot be used for an RBC 3 Connect the twin axial cable to the RS 485 port on the RBC s and to the remote I O port of the 545 555 575 CPU 4 UseAPT or TISOFT to set thel O configuration for the upgrade C 4 Upgrading Existing Series 500 Installations SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Series 500 Base is Series 500 Base is e PPX 500 5848 e PPX 500 5228 14 I O Slots 16 I O Slots or e PPX 500 5884 e PPX 500 5864 12 I O Slots or 8 I O Slots PPX 500 5892 Controlling Device is Controlling Device is 6 VO Slots e 530C 530T and IOCC if present e 530 and IOCC if present e 520C or e 520 or e PPX 500 2109 DBC e PPX 500 2103 DBC Upgrade Path A Upgrade Path B 1 Remove controlling device CPU and IOCC if present or DBC 1 Remove controlling device CPU and IOCC if present or DBC Install PPX 500 584
150. SnuD DING iiec d RR Rr ERR ERE PRTEE cnt Ride Rupe aUa gd RR dau 2 13 Noise Isolation cus seus t i ode os d ede Al ae efe o D edd 2 15 2 7 Wiring Guidelines ccccccee cece eee eee eee eens 2 16 2 8 Grounding the Power System 0 cece eee e eee nnnm 2 17 Earth Ground errenda ndanda ny de eae Pi ae oa EeR Oe RERICDELIC Fr pie dhe 2 17 Ground Connections eee nnn 2 18 Grounding the 545 555 Controller Chassis 0 0 cece cece eee eee e 2 19 Grounding the Cabinet or Rack 0 nena 2 19 Cable Management forthe 575 0 eee eee eee een eae 2 20 Grounding the 575 Controller Chassis 0 ccc cece ee 2 20 Grounding the Cabinet orRack 0 2 20 SIMATIC 545 555 575 System Manual Pre installation Guidelines 2 1 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 2 1 Planning Your Installation Preparing the site for installation of your CPU consists of the following tasks e Define control requirements e Determine the number of CPUs needed e Determine the panel and grounding layout NOTE Since no two applications are identical use these recommendations as general guidelines only Defining Control Usethe following considerations to define your control requirements Requirements e Definethe number and type of inputs and outputs you need e Calculate the number of I O modules and bases that you need e Determine the power requirements
151. TTL or low level wiring less than 24 V In these cases supplement the physical separation between control and noise prone wiring with shielded twisted pair wiring for the control signals Process transmitters should normally be grounded at thetransmitter end Use a single point shield ground as shown in Figure 2 10 Shielding Shielding a Twisted pair d Transmitter Single point ground To controller I O Figure 2 10 Grounding Shielded Twisted Pair Cables SIMATIC 545 555 575 System Manual Pre installation Guidelines 2 15 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 2 7 2 16 Wiring Guidelines Consider the following guidelines before installing any system or power wiring e Always use the shortest possible single length cable e Avoid placing system and field wiring in the vicinity of high energy and or high frequency wiring e Keep field input wiring output wiring and all other types of wiring in the panel physically separated when possible e Separate DC field wiring from AC field wiring wherever possible e Avoid sharp bends to power and data cables Use 3 in 76 mm radius minimum on all bends e Ensure that a good low earth ground impedance of 0 1 ohm or less exists for all components in the system e Use metal wireways and conduit when possible e Keepwirestrippings from falling into modules CPUs or bases
152. Technical Support In the U S A call 423 461 2522 Watchdog Time Out Standby RBC in dual media application is Standby Configuration ready to take over I O configuration is OK Action None No power to base or serious malfunction Action Check power to base If base power is Blank No Code Displayed OK place the system in a safe state and consult Siemens Technical Support In the U S A call 423 461 2522 SIMATIC 545 555 575 System Manual Installing Remote Base Controllers RBCs 513 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 5 5 PPX 505 6870 RBC User Options Output State Selection 5 14 User options switch settings status displays and base address configuration vary with RBC model The options for the 505 PROFIBUS DP RBC PPX 505 6870 are described in this section see Section 5 4 for a description of PPX 505 6851 A B and PPX 505 6850 A B options Series 505 Special Function modules cannot be used in a DP base Thefollowing features are user selectable e Thestate of the output points that are controlled by the RBC after remote I O channel communication is lost jumper selectable e RS 232 423 baud rate dipswitch selectable e RBC station address dipswitch selectable e Status display mode dipswitch selectable e Software parameters When I O channel communication to a base is lost the state of the outputs is determined by
153. V 11 W 2 2 A 16 W 3 2 A 12 V 600 mW 50 mA 600 mW 50 mA 12V 600 mW 50 mA 600 mW 50 mA V batt 600 mW 120 mA 600 mW 120 mA 45 V STDBY 1 mA in backup 1 mA in backup Note Power consumption given in watts amps in parentheses Power Supply All current Series 505 power supply modules can supply up to 55 watts of Loading power to the modules listed in Table B 3 You can increase the available power by using two power supplies in the 505 6511 Redundant Base for a total of 90 watts if the redundant mode is not required In this case if one power supply module fails the other power supply module trips off as well when the actual load is above its 55 watt capacity B 2 Powerand Compatibility SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Power Table B 3 shows the power requirements of the various Series 505 modules Requirements for Stee Modules Table B 3 Series 505 Module Power Requirements Maximum DC Power ii e Description s di Consumption Watts 505 2580 120 VAC ISO I nput 16 point w 1 0 505 2590 24 120 VAC ISO Output 16 point in 1 0 505 2555 Diff Analog Input 16 point w 5 0 505 2571 Program Port Expander 5 0 505 3508 24 VDC Output 8 point sinking w 2 5 505 3516 24 VDC Output 16 point
154. X RS 232 comm port 5 24 575 SeeVMEbus A Address range for Series 505 remote bases 5 9 Annex card PROFIBUS DP 1 4 installing in 545 1103 CPU 3 12 installing in 575 CPU 4 30 power consumption B 2 Series 505 installing in 575 CPU 4 29 power consumption B 2 when must install 1 13 Assistance technical xxi Auto Recompile function 3 22 4 25 4 26 F 3 Auto configured mode 575 CPU 4 26 Auxiliary functions Compare PLC to Disk 9 4 Display Failed I O 9 4 PLC Operational Status 9 4 9 8 list of error codes 9 10 restart clear described 9 2 list of 9 3 Run PLC Diagnostics 9 4 used in troubleshooting 9 2 Backplane connectors installing on 575 VME bus base 4 56 4 59 J 1pin assignments 4 54 Artisan Technology Group Quality Instrumentation Index Base models 1 12 Series 500 installing C 12 Series 505 address numbering 5 9 installing 545 555 CPU 3 14 installing PROFIBUS DP RBC 5 4 installing Series 505 RBC 5 4 list of RBCs 5 3 local vs remote 1 12 panel mounting 3 6 placement of power supply 3 8 placement of RBC 5 3 rack mounting 3 5 VMEbus installing 4 10 overview 1 12 panel mounting 4 12 rack mounting 4 11 third party 4 4 Battery backup for 545 555 CPU 3 20 3 21 for 575 CPU 4 20 for new 545 555 CPUs 3 17 installing in 545 555 CPUs 3 20 installing in new 545 555 CPUs 3 17 location in 545 555 CPUs 3 18 location in new 545 555 CPUs 3 16 status 4 51
155. a grounded wrist strap when handling the CPU cards or modules 4 Grasp the top and bottom of the I O module 5 Carefully push thel O module into the slot until it mates with the backplane connectors 6 Tighten top and bottom bezel screws To remove the I O module reverse procedures used during installation 4 42 Installing 575 System Hardware SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Figure 4 21 shows the installation of a module in a VME bus base Minimum torque 2 6 in lb 0 3 N m Maximum torque 5 2 in lb 0 6 N m Figure 4 21 Installing and Removing Modules in a VMEbus Base SIMATIC 545 555 575 System Manual Installing 575 System Hardware 4 43 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 4 13 Wiring the Fault Relay The fault relay on the 575 CPU is a male 9 pin D shell connector that can be used with a low voltage safety chain Port pinouts and wiring are shown in Figure 4 22 Circuit 1 Circuit 1 Circuit 2 Circuit 2 Figure 4 22 Fault Relay Wiring Two circuits are available as shown in Figure 4 23 1 2 gt ol Oo Circuit 1 3 4 iM Circuit 2 Figure 4 23 Normally Open Contacts See Section 2 3 for an explanation of the operation of the fault relay and application examples 4 44 Installing 575 System Hardware SIMATI
156. abinet with tightly sealed doors If Series 505 Remote I O channel cables to remote bases are run outside the cabinet they must either be run in a fully enclosed metal raceway or fitted with ferrite beads where they leave and or enter the cabinets Ferrites shall be Steward PN 28 A 2029 0 or equivalent When preparing your installation plan for an adequate air flow to ensure proper cooling of equipment Do not permit the convection cooling of the controller to be hindered Unless ambient temperatures are extremely high a fan or air conditioned cooling is unnecessary for keeping controllers below their maximum rated operating temperature of 60 C provided that the cabinet adequately dissi pates heat For onelocal base and one remote base located in the bottom half of a 7 foot 19 inch rack you can place equipment that dissi pates no more than 325 W in thetop half abovethe Series 505 bases assuming a 25 C external ambient temperature If you must exceed these guidelines or if the base is not installed with the vent screens at top and bottom positions use cooling equi pment to lower the equipment temperature to the recommended level SIMATIC 545 555 575 System Manual Installing 505 System Hardware 3 3 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 3 3 Series 505 Bases Desc ription The 545 555 CPU is housed in a Series 505 base A base has slots for the power supply the CPU or RBC
157. able controller SIMATIC 545 555 575 System Manual which could cause injury Figure 2 3 JOG orINCH Switch Pre installation Guidelines Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 2 5 2 3 575 Fault Relay Operation Overview Fault Relay Operation Details The 575 CPU provides a normally open NO relay output fault relay for use in a low voltage safety chain The CPU must successfully complete power up diagnostics before its fault relay is dosed If an error is detected by the software or the hardware then the fault relay does not dose During normal operation the fault relay remains closed The fault relay opens if a fatal error is detected by the 575 CPU See Figure 4 22 for fault relay pinouts Table 2 1 lists the electrical specifications of the fault relay output Table 2 1 FaultRelay Output Electrical Specifications Contact to contact breakdown voltage 120 VAC Contact to ground breakdown voltage 500 VAC Voltage rating 30 V AC or DC 500 mA resistive AC or DC Current rating 200 mA inductive DC L R 7 ms 100 mA inductive AC power factor gt 0 4 The 575 CPU fault relay is under software control The operating system software can be in one of three states Idle Normal or Fault The fault relay closes only when the software state is Normal The transitions to and from the various states are described in this section and are shown i
158. afety switches to help prevent operation during a system failure Although the specific steps depend on the application the general precautions indude the following considerations a WARNING Conirol devices can fail in an unsafe condition Unless proper safeguards are incorporated by the user malfunctions of these devices could lead to sudden equipment startup or shutdown Failure can also be exhibited as erratic or unexpected operation Such startup or shutdown or unexpected operation could result in death or serious injury to personnel and or damage to equipment If you or your company use any programmable controllers with equipment which requires an operator or attendant you should be aware that this potential safety hazard exists and take appropriate precautions The precautions below conform to the National Electrical Manufacturers Association guidelines for installation of programmable controllers as recommended in the NEMA ICS 3 304 Programmable Control Standards ICS 3 304 81 Safety Recommendations Consideration should be given to the use of an energency stop function which is independent of the programmable controller Where the operator is exposed to the machinery such as in loading or unloading a machine tool or wherethe machine cycles automatically consideration should be given to the use of an eectromechanical override or other redundant means independent of the programmable controller for starting and inte
159. amming Device 4 49 Rear Panel Disassembly for 2 Backplane Installation 00 ccc eee 4 56 Installing J 2 Backplane sssssseee RR 4 57 Installing J2 Connector issssssssssseeI hr 4 58 RBC Models Bases and I O Channels ssssssssseeee eese 5 2 Location of RBC in a Series505 Base ssssssssssssseeee eee 5 3 RS 232 Serial Port Minimum Cable Pinouts 0 0 eee 5 5 Off Freeze Jumper Location on the A Model RBCS cece cece eens 5 7 Position of OFF FRZJ umperand Baud Rate Switch on the BModelRBCs 5 7 RBC Dipswitch Location ssssssssssseee mna 5 8 RBC Status Display and Base Number Switch ssseseee ee 5 10 RBC Status Display i cose erre rere cere eb ek neben noxa Mend Da KA wae n 5 12 RBC JumperLocations ssssssssseeseeee ehh 5 15 505 PROFIBUS DP Remote Base Controller 0c cece 5 16 Trunk and Drop Line Example ssssssssssss eee 6 5 Maximum Trunk Length 0 ccc cece mh 6 8 LCOMIGQUIATION 5 ERE RR nin Ek Ree pon RR bead UR toc Dad dat Re pada 6 8 Multiple Tap Connectionsin Close Proximity 0c eee 6 10 Spacing between Taps cece ce ee c ne n nnn 6 11 OcLink PINQUE iei ake oat et ade ae tame ood NR RT oad Belus cbr Ree ein US 6 13 Contents Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 6
160. an RS 232 baud rate of 9600 PROFIBUS DP master and RBC did not complete I O channel initialization Probable causes The station address is incorrect or the I O modules installed in this base do not match the I O configuration 7 Nol O Configuration Not Ready expected by the PROFIBUS DP master Action Check for and if necessary select a valid station address Compare the actual configuration of the base against the configuration expected by the PROFIBUS DP master Hardware watchdog timeout that immediately resets the RBC Action Serious malfunction Place the 8 Watchdog Timer Expired None system in a safe state and consult Siemens Technical Support In the U S A call 423 461 2522 Serious malfunction C Consult Siemens Technical Not Read Action Place the system in a safe state and Support y consult Siemens Technical Support In the U S A call 423 461 2522 No power to base or serious malfunction Action Check power to base If base power is blank Blank No Code Displayed None OK place the system in a safe state and consult Siemens Technical Support In the U S A call 423 461 2522 SIMATIC 545 555 575 System Manual Installing Remote Base Controllers RBCS 523 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com PPX 505 6870 RBC continued Setting User The 505 PROFIBUS DP RBC has parameters that are specified using the Parameters forthe COM
161. and mounting space needed e Consider availability of space including growth potential This is particularly vital if several double wide modules are needed Calculating Power Calculate a power budget for each base prior to installation The power Needs requirements of all modules must be included in the calculations the CPUs and the base controllers as well as the I O modules The user supplied power to individual modules is not a part of the power budget calculation Refer to Appendix B for information about Series 505 and 575 VME module and annex card power consumption To help ensure reliable system operation the total power required for the controller and I O modules must not exceed the total power available from the system power supply Chapter 3 gives information about Series 505 power supplies Chapter 4 describes VM E power supplies For the 575 if a given module exceeds 3 3 amps in the VM E bus backplane then a J 2 connector PP X 2589739 8012 must be installed in that slot This assumes that the module has a P2 connector 2 2 Pre installation Guidelines SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 2 2 Safety Considerations Pre installation planning and site preparation must include consideration of hazards to personnel in the event of a system failure The equipment connected to the control system must indude interlocks and s
162. and the I O modules F our base models are currently available see Table 3 1 Table 3 1 Series 505 Base Models Number of I O Support for Slots Redundancy PPX 505 6504 505 6504 NEMA NEMA pana PPX 505 6508 8 No NEMA panel PPX 505 6511 11 Yes NEMA panel or rack PPX 505 6516 16 No NEMA panel or rack 1The PPX 505 6511 base supports redundant power supplies and or redundant RBCs The PPX 505 6660 A or B and the PPX 505 6663 or A power supplies can be used in either a redundant or a non redundant configuration You do not have to use redundant RBCs with dual power supplies you can use a single RBC or a single CPU Grounding the A good grounding system is essential for proper operation of the system Controller Chassis Follow the guidelines in Section 2 8 to ensure that the Series 505 base is properly grounded 3 4 Installing 505 System Hardware SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 3 4 Rack Mounting Series 505 Bases Use the following steps for mounting a PPX 505 6511 or PPX 505 6516 base in a standard 19 inch rack See Figure 3 1 1 Move brackets from wall mounting position back of chassis to front position 2 Position the base in the 19 inch rack Depth of base is 8 inches 205 mm NOTE There should be at least 6 inches 150 mm of clearance at the top and bottom of the base for ade
163. annex card to the CPU board because the di pswitch is inaccessible once the annex card is installed A Standoff RA 5 Ee Dipswitch ar SAL Figure 4 16 Installing the Remote I O Annex Card SIMATIC 545 555 575 System Manual Installing 575 System Hardware 4 29 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Installing a Remote I O Annex Card continued Installing the Toinstall the PROFIBUS DP annex card PPX 505 CP5434 DP follow the PROHBUS DP steps below Annex Card 1 Carefully set your CPU board on a static dissi pative surface and remove the PROFIBUS DP port cover from the bezel CAUTON Electronic equipment can be damaged by electrostatic discharge Ensure that personnel make contact with a static dissipative pad and or wear a grounded wrist strap when handling the CPU cards or modules 2 Removethe PROFIBUS DP port cover from the bezel The port cover is not reusable The port cover is secured by plastic pins that project through the bezel and are secured on the back side by damps First clip the pins off as close to the clamps as practicable then pry the camps loose and remove the port cover 3 Toattach the annex card tothe CPU board insert the 9 pin D connector of the annex card into the CPU bezel opening and align the annex connector with the connector on the CPU Apply pressure until the connectors are mated NOTE
164. ard Communication Specification PPX 575 8103 x Each 575 CPU uses one megabyte of VME bus A24 memory space and 16 bytes of A16 memory space Additionally each 575 VMEbus I O module uses two bytes of A16 memory space and 64 K bytes of A24 memory space Table 4 6 shows how each function uses memory SIMATIC 545 555 575 System Manual Installing 575 System Hardware 4 51 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Using Boards in the VMEbus Base continued Table 4 6 Use of VME Address Space Function AztAddremRange AisAd resRange Notes 12 Secondary 14 Application O E 0000016 EFFFFF16 OOE O16 OOEF 16 575 VMEbus I O Module 1 F 0000016 FOFFFF 1 010046 01016 575 VMEbus I O Module 2 F 1000016 F1FFFFig 010216 010316 3 575 VMEbus I O Module 16 FF 000016 FFFFFF16 O11E 16 011F 16 3 Reserved for 575 VMEbus I O po 3s 012036 0123416 3 4 Available 012446 FFFF 16 If the USER CONRGURED option has been selected see Section 4 10 add the configured A24 base address to the start and end addresses of the A24 address range and the configured A16 base address to the start and end address of the A16 address range Refer to Table 4 3 in Section 4 10 If after addition of the configured A24 base address the A24 address range for a 575 secondary would contain an address greater than EFFFFF 46 then that 575 secondary cannot be installed Addresses are fixed
165. are COM PROFIBUS 1 11 5 24 SoftShop 1 11 TISOFT 1 11 Configuring CPU for program storage 7 6 7 9 Connectors J 1 backplane pin assignments 4 54 J 2 backplane on VMEbus base 4 56 4 59 Coprocessor installing 4 23 CPU models compatibility with O modules B 7 described in manual 1 2 D Daisy chain cable layout PROFIBU S DP 6 23 switches VME bus backplane 4 41 VMEbus signals 4 53 Dipswitches annex card 575 CPU 4 28 back up battery switch 3 22 backplane 575 CPU 4 41 base address 575 CPU 4 27 surface duct 6 3 baud rates terminal block 6 4 CPU under floor 6 3 545 555 3 23 Checksum error handling F 2 F 3 aoe 4 25 Circuit breakers guidelines for 2 11 PROFIBUS DP 5 17 COM PROFIBUS 1 11 5 24 Series 505 5 8 setting RBC parameters 5 24 comm ports selecting 3 24 Index 2 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Dipswitches conti nued configuration of 575 CPU 4 24 4 29 daisy chain 575 CPU 4 41 operating parameters 545 555 CPU 3 22 Discrete AC input module connector pinouts E 3 isolation E 2 spedifications E 2 Discrete AC output module connector pinouts E 8 current vs temperature E 8 isolation E 7 spedifications E 7 Discrete DC 161 O module connector pinouts E 6 current vs temperature E 4 isolation E 4 spedifications E 5 Discrete DC input module connector pinouts E 16 isolation E 15 spedi
166. at is different from the format shown in Figure B 1 Any module with a serial number that does not begin with 86 is compatible with the current 545 555 575 CPUs SIMATIC 545 555 575 System Manual Powerand Compatibility B 9 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Appendix C Upgrading Series 500 Installations C 1 Series 500 System Installations eeeeeeeeeeee nnn nnn nnn nnn C 2 C 2 Upgrading a 520 520C 530 530C 530T System e eene nnn c 3 Check Base to Be Upgraded uuuuuusuesssessssesls sn C 4 Upgrading 14 Slot 12 Slot 6 Slot Bases 6 cece C 4 Upgrading 16 Slot and 8 Slot Bases ssssssssssess eese C 4 Finish Upgrade with These Steps cece eee C 4 C 3 Upgrading an RS 485 Based 560 5607 565 565P System serere C 6 C 4 Upgrading an RF Based 560 560T 565 565P System cccesceeeeeee eee n nnn C 8 Upgrading an RF based System to 545 555 ssssssssessssesse eee C 8 Upgrading an RF based System to 575 ssssssssssssseeee eh C 10 C 5 Installing a PPX 500 5114 A RBC ccccccccc cece cee eee eee C 12 Installing a Seres 500 RBC ssssssssseeeeeee IRI C 12 Output State Selection Switch cece ccc cece ene teen eee eeeneneees C 14 Status Display 2 e ese eeeue ered dR eR needa PETIERE cae he cde ew RE REEYAPREIRY RE eS C 16 Setting Baud
167. ation Block Allocation Size Total Memory Required for Maximum Size Default Allocation Memory Type Total memory 1856 Kbytes Ladder L lKbyte 3Kbytes 1 Kbyte 614 Kbytes 1842 Kbytes 32 Kbytes Variable V 1 Kbyte 1 Kbyte 1 Kbyte 1841 K bytes 1841 K bytes 52 Kbytes Constant K 1 Kbyte 1 Kbyte 0 Kbytes 1840 Kbytes 1840 Kbytes 0 Kbytes Special S 1 Kbyte 1 Kbyte 0 Kbytes 1840 Kbytes 1840 Kbytes 32 K bytes SES 1Kbyte 1Kbyte OKbytes 1840Kbytes 1840Kbytes OKbytes User U 1 Kbyte 1 Kbyte 0 Kbytes 1840 K bytes 1840 Kbytes 0 Kbytes Timer 1024 5 Kbytes 1024 20480 100 K bytes 1024 Drum 64 3Kbytes 64 2304 108 K bytes 64 Shift Register 1024 lKbyte 1024 16384 16 Kbytes 1024 Table Move 1024 2 Kbytes 1024 14336 28 Kbytes 1024 One Shot 1024 1 Kbyte 1024 32768 32 K bytes 1024 N umber per block Total Memory Required for Maximum Size Default Allocation Total memory 832 K bytes Ladder L 273 Kbytes 819 K bytes 64 K bytes Variable V 1 Kbyte 817 Kbytes 817 Kbytes 52 Kbytes Constant K 1 Kbyte 816 Kbytes 816 Kbytes 0 Kbytes Special S 1 Kbyte 816 Kbytes 816 Kbytes 32 Kbytes User U 1 Kbyte 816 Kbytes 816 Kbytes 0 Kbytes Timer 5 Kbytes 20480 100 K bytes 1024 Drum 3 Kbytes 2304 108 K bytes 64 Shift register 1 Kbyte 16384 16 Kbytes
168. ble communication The device at each extreme end of a PROFIBUS DP cable must be terminated and biased any connections made between extreme cable ends must not be terminated or biased See pages 6 24 and following for more information about terminati on and bias e Ground the chassis of each module to earth ground as described in Chapter 2 e All PROFIBUS DP cable connectors must be properly grounded With a Siemens PROFIBUS DP connector proper grounding is accomplished when the bare cable shield contacts the metal connector ground e Tighten screws on all PROFIBUS DP connectors throughout your system to a maximum torque of 8 in Ib 0 9 N m in order to ensure a good ground connection SIMATIC 545 555 575 System Manual Cabling and Wiring the System 6 23 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Installing PROABUS DP I O Cables continued Termination and The device at each extreme end of a PROFIBUS DP cable must be Bias terminated and biased any connections made between extreme cable ends must not be terminated or biased See the examples below If a CPU with PROFIBUS DP interface is located at an extreme end of the cable it must be terminated and biased The device at the other end of the cable must be terminated and biased See Figure 6 12 CPU with PROFIBUS DP N PROFIBUS DP Node I O interface Cable end must be NN terminated and biased
169. ble you select e A high uniform twist and spacing of conductors usually found in cables called twin axial e Shield coverage approaching 100 e DC resistance of the installed cable length smaller than the characteristic impedance e A jacket suitable for the installation NOTE When selecting cable connectors be aware that shells with strain relief provide the most dependable long term operation SIMATIC 545 555 575 System Manual Cabling and Wiring the System 6 7 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Installing Series 505 Remote I O Cables continued Planning Your Follow these guidelines when installing Series 505 RS 485 trunk and drop Installation line cabling e Measure the maximum length consult Table 6 2 from the CPU tothe most distant tap See Figure 6 2 Terminating lt _ Maximum Trunk Length Resistor T Terminal Block Terminating Resistor A terminating resistor shown in Figure 6 8 must be installed on the end terminal blocks If only one terminal block is used a terminating resistor must be installed on that terminal block Figure 6 2 Maximum Trunk Length e By usinga T configuration Figure 6 3 you can increase the total trunk line length to twice the length specified in Table 6 2 E E Terminat
170. bytes 176 Kbytes 32 Kbytes User U 176 Kbytes 176 Kbytes OKbytes Timer 20480 100 Kbytes 1024 Drum 2304 108 Kbytes 64 Shift Register 16384 16 Kbytes 1024 Table Move 14336 28 Kbytes 1024 One Shot Number per block 32768 32Kbytes Table 8 3 555 1103 CPU Memory Configuration Memory Required per Block Total memory 384 K bytes Total Memory Required for Maximum Size 1024 Default Allocation Ladder L 123 Kbytes 369 K bytes 32 Kbytes Variable V 369 K bytes 369 K bytes 52 Kbytes Constant K 368 K bytes 368 K bytes OKbytes Special S 368 K bytes 368 K bytes 32 Kbytes User U 368 K bytes 368 K bytes OKbytes Timer 20480 100 Kbytes 1024 Drum 2304 108 Kbytes 64 Shift Register 16384 16 Kbytes 1024 Table Move 14336 28 Kbytes 1024 One Shot Number per block SIMATIC 545 555 575 System Manual 32768 32Kbytes 1024 Starting Up the System 8 5 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com CPU Memory Configuration continued Table 8 4 555 1104 CPU Memory Configuration Memory Total Memory Required Required for per Block Maximum Size Default Allocation Total memory 1920 Kbytes Ladder L 635 Kbytes 1905 K bytes 32 Kbytes
171. ca 4 57 Installing Optional 2 DIN Connector ssssseeeee enm nrnna nnan 4 58 Chapter5 Installing Remote Base Controllers RBCs 5 1 52 5 3 5 4 JUI PEE m 5 2 Installation reeeeeeeee ee 5 3 Models Used in Series 505 Base ssssssssssseeees eee 5 3 RBC Placement in Base sssssssssess ee 5 3 Installing and Removing the RBC ssssssseeeee eene nanna 5 4 Communication Ports cece eee 5 5 RS 232 POI cce diede dur ooh odie Pheer hoes Chie elias che dee E L vis 5 5 VO Pott gi peeeciase tees agdene ERXGAAERURIERXIMERTLICCRECAPERDCRREIAYREGDAganE 5 5 PPX 505 6851 A B and PPX 505 6850 A B RBCS eeeennn n nnn 5 6 U iehnenrfctcc E 5 6 Output State Selection 0 Rn n nnn 5 6 Dipswitc h Options soas sgri iaiia aa aam oa a ERE Eb aes du e Pe ea be ads 5 8 Series 505 Base Numbers 1 cette nnn 5 9 Changing the RBC Base Number 0 000 cece eee eee eee eee eae 5 9 Resetting the RBC s i cfuc ccs easy db bee Seep ee RE eee wreck dab cay ee var od cae ae 5 11 Status Display i ese see cece cece eer Gee ee eed dee nee ER ORO EXC EX OR ee 5 12 Contents vii Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 55 PPX 505 6870 RBC ww cece cece eee cece nnn nnn eee eee eee 5 14 U dslnnafcpcE LEM 5 14 Output State Selection ssusuueusseeeseselllsessss nnn n 5 14 Jumpers E2
172. carry the CE Marking Low Voltage Directive 73 23 EEC and or Electro M agnetic Compatibility Directive 89 336 E EC A declaration of conformity is included with each CPU The SIMATIC 505 575 PLC Systems comply with the requirements of the EMC Directive 89 336 EEC when installed in accordance with the specifications in this manual and when installed in a grounded metal cabinet with tightly sealed doors If Series 505 Remote I O channel cables to remote bases are run outside the cabinet they must either be run in a fully enclosed metal raceway or fitted with ferrite beads where they leave and or enter the cabinets Ferrites shall be Steward PN 28 A 2029 0 or equivalent For SIMATIC 575 Systems a linefilter must be connected in the power lines to the system in order to comply with the EMC directive The line filter shall be Corcom part no 10VS1 or equivalent Filter Network connected ahead of each power supply For technical assistance contact your Siemens Energy amp Automation Inc distributor or sales office If you need assistance in contacting your sales agent or distributor in the United States call 1 800 964 4114 For additional technical assistance call the Siemens Technical Services Group in J ohnson City Tennessee at 423 461 2522 or contact them by e mail at simatic hotline sea siemens com F or technical assistance outside the United States call 49 911 895 7000 SIMATIC 545 555 575 System Manual Preface xxi Artisan Technol
173. ceeeecee eee eee eee eee hh 3 6 3 6 Installing Series 505 Power Supply 00cccceeeecee eee ee eee eee eee eee nnn nn nnn 3 8 Power Budget for Series 505 Base sssssssssssseese eee 3 8 Power Supply Placement in Bases issssssssssssseees eee 3 8 Installing and Removing the Power Supply eee m eee 3 8 Wiring the PowerSupply 0 eee eens 3 10 3 7 Installing the PROHBUS DP Annex Card Optional 0 ceeeeeee eee eee eeeeeee 3 12 3 8 Installing the 545 555 CPU cccccee cece cece cece eee 3 14 CPU RBC Location in a Base eee eens 3 14 Installing and Removing the CPU cece eae 3 14 3 9 Replacing and Handling the Battery sseeeseee eene nnne nnn nnn 3 16 Lithium Battery in the 545 and 555 1105 1106 CPUs cece eee eee 3 16 Replacing the Battery in 1105 1106 CPUs ccc ccc cece eens 3 17 Lithium Battery in the 545 and 555 1103 1104 CPUs cece eee eee 3 18 Indicators er ee 3 18 Using and Handling Batteries 2 cece eee 3 19 Transporting Batteries ccc ccc eee 3 19 Storing Batteries seisde cen nnn 3 19 Discarding Battenes cca vadend e ee ere erre rd sea Gd header Bb dean dir d 3 19 Replacing the Battery in 1103 1104 CPUS 0 00 3 20 3 10 Setting the CPU Dipswitches 0 ccc sce e eee eee nnn nnn 3 22 Dipswitch Location and Settings cece eee 3 22 Enabling Battery Backup 0
174. connect power before mounting the fan assembly 4 6 Installing 575 System Hardware SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Selecting Voltage for Fan Operation Wiring the AC Power Terminals The 16 slot VM E bus base provides space under the lower module guiderails toinstall the optional 575 fan assembly PPX 575 2131 The fan assembly has a switch located on the rear panel for selecting 110 or 220 VAC operation Before mounting the fan assembly ensure that the voltage setting on the fan assembly unit matches your input voltage and connect power lines to the AC terminals Follow these steps to ensure voltage setting matches input voltage NOTE Thefan assembly unit is shipped with the voltage selector switch set for 110 VAC operation If your input voltage is 220 VAC be sure to set the voltage selection on the unit as described below CAUTION Failure to match voltage selection to your input voltage can result in damage to the fan assembly unit Be sure that the voltage selector switch is set to match your input voltage 1 Ensurethat all power to the system is off before making any changes to the voltage selector switch shown in Figure 4 1 2 Tosetthe voltage use a flat bladed screwdriver to rotate the voltage selector switch to the required position Voltage Selector Switch AC Power Terminals 110 O
175. ctronic control system you must wire the relay so that it controls the interposing relays in the supply line An example of this is shown in Figure 2 6 NOTE Figure 2 6 is not a complete electrical diagram It is for illustration purposes only A qualified control engineer should be aware of any relevant regulations and design the system with these in mind SEU m frtev 24V 575 VME System Output Modules Master Stop Master Start PB ele Figure 2 6 Safety Chain Controlling Control System Power Example In Figure 2 6 relay CRM istheinterposing relay and FLT is a 24 volt relay in the low voltage safety chain TDR is a delay on relay with normally closed contacts Note the use of pushbutton switches for master stop normally dosed and master start normally open Power to the control system is applied when the master start switch is actuated If the time delay relay opens before the fault relay is dosed then the control system loses power If either the master stop switch is actuated or one of the fault relays opens then the control system is turned off 2 10 Pre installation Guidelines SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 2 4 Guidelines for Fuses C
176. d 1 Determine the fatal error condition by selecting AU X 29 from the Auxiliary Function Menu on your programming unit Record the fatal and non fatal error s listed along with the date time CPU serial number and software part number AU X 15 for later reference f communication errors occur ensure that the battery backup is enabled and then cycle power to the base If communication errors continue record No Communication as the fatal error and goto step 4 Execute AU X 11 CPU Partial Restart If this fails to dear the error execute AU X 12 CPU Complete Restart If thefatal error persists ensurethat the battery backup is enabled power cycle the CPU then reattempt step 2 and execute AUX 10 CPU Power up Restart f you have been unable to clear the fatal error to this point you must re initializethe CPU Disablethe battery backup turn off switch 9 of the dipswitch and cyde power to the CPU or execute AUX 10 This dears the CPU memory If the CPU GOOD LED comes on restore the battery backup by turning on switch 9 of the di pswitch You must now use your programming unit to restore your program If the CPU GOOD LED does not turn on at this time your CPU may have a hardware failure SIMATIC 545 555 575 System Manual Troubleshooting 9 13 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Troubleshooting CPU Fatal Enors continued 575 CPU Responses to Fata
177. d 1106 CPU Modules 0c ccc eens 3 17 Battery Location on 545 555 CPU Modules 00 ccc cece eee e 3 18 545 555 CPU Dipswitch Location ssssssssssseee III 3 22 545 555 CPU Por Locations ssssssssssssss ese 3 24 Installing and Removing Modulesin a Series505 Base cece cece eects 3 27 Wire Gauge and Stud Sizes for Input Output Terminal Blocks sse 3 27 Input Output Terminal BIOCKS sssssssssseeeee een 3 28 Fan Assembly RearPanel sssssssssesssse eee 4 7 Installing the Fan Assembly sssssseeeee RI 4 8 Replacing Fuse on Optional Fan Assembly 00 eee ee 4 9 VMEbus Base Physical Measurements susuuuesssseesssese essen 4 10 19 Rack or Front Panel Mounting MeasurementsforBase 0 cee eee eee 4 10 Mounting Base to Standard 19 inch Rack 0 ccc eee 4 11 VMEbus Base Wall orCabinet Mounting Measurements 00 scene eee 4 12 Mounting Base in NEMA Enclosure 0c e 4 13 Contents xiii Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 4 9 4 10 4 11 4 12 4 13 4 14 4 15 4 16 4 17 4 18 4 19 4 20 4 21 4 22 4 23 4 24 4 25 4 26 4 27 4 28 4 29 4 30 4 31 4 32 4 33 5 1 5 2 5 3 5 4 5 5 5 6 5 7 5 9 5 10 61 6 2 6 3 6 4 6 5 xiv Selecting Input Voltage on the PPX 575 6663 Power Supply sssssss 4 1
178. d checksum calculations must occur before another Auto Recompile is allowed If eight good checksum calculations are not accomplished or if there is already an L memory checksum error logged as described in item 2 then a fatal error is declared and the Program Memory Diagnostic Error will be displayed when the CPU is interrogated by TISOFT or SoftShop SoftShop Release 3 1 or greater and TISOFT Release 7 1 or greater provide support for new error messages associated with these enhancements It is possible however to use older versions to read the new status words and bits SIMATIC 545 555 575 System Manual Enhancements in Late Model CPUs F3 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com F 2 Fast PROABUS DP I O Update Times CPUs with this Feature Fast PROHBUS DP I O Updates How it Works Selecting Fast DP The 555 1105 1106 CPUs Release 5 2 or greater the 545 1105 1106 CPUs Release 5 1 or greater and the 575 2105 2106 CPUs Release 5 1 or greater support the new Fast PROFIBUS DP I O Update feature The CPUs listed above provide the ability to do faster PROFIBUS DP I O updates using I ORW box instructions immediate contacts and immediate coils Although these instructions existed previously in the CPU they only supported access to I O points installed in the local 505 base With this release these same instructions can now be used to access the memory ba
179. d memory status after powerup based on the battery status and program source selected 9 f you selected EEPROM as the program source use TISOFT AUX 17 to check the program carefully while the CPU is in PROGRAM mode before allowing the CPU to control equipment connected to the I O a WARNNG To minimize risk of potential injury to personnel or damage to equipment check the program before permitting a CPU to execute from an EEPROM program An incorrect program may cause unexpected operation of the process which can cause death or serious injury to personnel and or damage to equipment You must be absolutely certain that the EEPROM program is correct Take standard precautions associated with program development and debug 7 10 Using EEPROMsfor Program Storage SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com If an error occurs during the copy process it will be listed on the programming unit If an error occurs perform the following checks e Ensurethat the EEPROM jumper pin programming enable strap is installed correctly on the 545 or 555 CPUs e Ensure that an EEPROM not an EPROM is installed on the 545 or 555 CPUs e Ensure that all EEPROM pins are properly seated in the socket e For CPUs that support both portable and on board EEPROM ensure that the jumper E 20 is configured to select your target EEPROM In addition if y
180. d while the CPU is powered and running The battery is rated to retain program memory with the system powered off for 3 years at room temperature 25 C and for 6 months at elevated temperature 60 C The PROFIBUS DP port is now integrated on the board rather than on an annex card with the 545 1106 and 555 1105 1106 CPUs SIMATIC 545 555 575 System Manual System Overview 1 3 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Overview continued PRORBUS DP PRORBUS User Organizations Using Other Networks 1 4 System Overview Series 505 programmable control systems can now communicate with PROFIBUS DP I O and other devices that meet the PROFIBUS standard DIN 19245 Part 3 PROFIBUS DP is a token ring protocol in a master to slave configuration that is optimized for O exchange Some Series 505 CPUs contain a PROFIBUS DP annex card optional for 575 and 545 1103 1105 CPUs that supports all I O devices that conform to the PROFIBUS DP standard New model 545 1106 and 555 1105 1106 CPUs have the PROFIBUS DP I O port integrated on the board The PROFIBUS DP I O channel allows you to greatly expand the type and quantity of your remote I O as well as increase communication speed The following features are available on the PROFIBUS DP I O channel e All CPUs except the 545 1103 1105 can support up to 112 PROFIBUS DP addresses for master and slave devices e
181. der to select proper components and settings for your project SIMATIC 545 555 575 System Manual Enhancements in Late Model CPUs F5 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com F3 Memory Capacity of the 555 1106 CPU Difference in Memory Capacity between the 555 1106 CPU and Earlier C PUs Duetointernal CPU requirements it was previously necessary to reduce the amount of memory available to the user in a 505 1106 CPU by 64 Kbytes compared to the 555 1102 and 555 1104 1920 K bytes in the earlier model CPUs vs 1856 Kbytes in the 1106 CPU Now a method has been implemented to re allocate internal memory usage to allow the maximum Size 555 1102 4 RLL program to fit into a 555 1106 CPU This insures that a previous 555 1104 program will load into a 555 1106 but does not guarantee that it will have enough room to compile However an investigation into the memory usage of a number of large user programs indicates that the program will most likely compile as well but you will need totry it to be sure This change will not help in unusual situations where most of the memory is used as V Memory to store data or U Memory to store a compiled XSUB program F 6 Enhancements in Late Model CPUs SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Numbers 50X ignore mismatch mode 5 22 5 24 50
182. dic noises generally are easy to detect and remedy I ntermittent noise sources that produce short high energy bursts at irregular and widely spaced intervals create problems that can be harder to resolve The primary sources of noisein industry are those devices and their wiring that produce and switch high voltage and current Typical examples include large motors welders and contacts that switch heavily inductive loads such as brakes or clutches Noise can enter your control equipment by several routes t can be conducted through signal or power wiring or can be radiated by electromagnetic waves Conducted noise usually enters the system through the signal or power wiring The noise may couple into the wiring by electrostatic or magnetic means Electrostatic coupling occurs through parasitic capacitance between the noisy line and the signal power line This requires high voltage or high rate of change voltages in the noisy line and high parasitic capacitance between lines This can occur when you have long wire runs in the same conduit Magnetic coupling occurs through mutual inductances between lines This is the result of high currents or high rates of change of current as well as significant mutual inductance Electromagnetically radiated noise typically is high frequency radio waves The control system and its wiring may act as antennas in picking up noise signals This pathway is least likely to present problem levels of noise
183. ds which could Output cause injury module Loads which could not _ cause injury Output points from the programmable control system Figure 2 1 Operator Safety Switch Emergency Stop Provide a means for removing power from the output if an emergency Switch condition occurs with the machine during operation Disconnect output power with a non semiconductor switch or hardwired relay contact not through the programmable control system See Figure 2 2 Emergency Reset Guard stop ey limit switch Oo o uw e ND Electromechanical relay Contacts of electromechanical relay C1 C1 C1 e 4 User supplied critical loads el el which could cause injury Output module could not cause injury pus l Loads which Outputs from the programmable control system Figure 2 2 Emergency Stop Switch 2 4 Pre installation Guidelines SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com JOG orINCH Switch Switch or contact Jog closed in the JOG or INCH Oo Output module Bypass the programmable control system with an external J OG or INCH switch during machine loading or set up operations See Figure 2 3 User supplied critical loads Outputs from the da Switch or contact open in the JOG or INCH mode programm
184. e 2 9 as an alternative type of snubbing Both types of snubbing cause the physical devices to come on or go off more slowly The resistance capacitance RC and metal oxide varistor MOV elements should have minimal effect on system timing their time constants are substantially less than one millisecond M Input Power FM nput Power Discrete Discrete Output Load Output MOV Ea Discrete Output Discrete Output Module Protection Module Protection RC snubbing MOV snubbing Figure 2 9 Contact Noise Snubbing NOTE The noise snubbing shown in Figure 2 9 is built into the PPX 505 5518 relay output module 2 14 Pre installation Guidelines SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Noise Isolation The second approach to handling noise problems is to isolate the problem device and its wiring from the electronics and associated signal wiring You can accomplish this by increasing the physical distance from some types of noisy devices For extreme cases electrostatic metal shielding may be required This is truefor noise sources outside as well as insidethe mounting cabinet N EM A type recommended Two kinds of field wiring warrant special attention wiring that enters the harsh noise area to enable monitoring and control of devices and
185. e 575 Controller Chassis suse 2 20 Grounding the CabinetorRack ccc ccc cece eee eee s 2 20 Chapter3 Installing 505 System Hardware 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 Overview of Installation Procedures cece eee eee mmm 3 2 Enclosure and Temperature Considerations eere 3 3 Enclosure Selection sai ccc tdci ete h derer ctt aer Fs iae eR Ea doe wd 3 3 Temperature ConsiderationsS 00 ceca 3 3 Series 505 Bases 2 ccs e eee eee nna aaa nan 3 4 DESCHPHON i cin d dd pe bode oni shied re AS a wanes cie eR rixa ur 3 4 Grounding the ControllerChassis 0 c cece eee eee eas 3 4 Rack Mounting Series 505 Bases ccccecceeee cee ee eee eee 3 5 Panel Mounting Series 505 Bases 0ccccccceeeeeee eee eee eee e eee e nnn 3 6 Installing Series 505 Power Supply 00cccceeeecee eee ee eee eee nnn nnn nnn nnn nnn 38 Power Budget for Series 505 Base cece tee 3 8 Power Supply Placement in BaSeS anaana 3 8 Installing and Removing the Power Supply sseeesseennn m e eae 3 8 Wiring the Power Supply 0 eI In 3 10 Installing the PROHBUS DP Annex Card Optional 0 cceeeeeee eee eee eens 3 12 Installing the 545 555 CPU cccccccc cece cece 3 14 CPU RBC Location in a Base eee eens 3 14 Installing and Removing the CPU sssssseeeseeee e 3 14 Contents Artisan Technology Group Quality Instrumentatio
186. e RS 485 RF Coaxial O Channel Converter PP X 505 6860 allows you to use coaxial cables in a Series 505 system thereby extending the maximum cable distance to 4 km The converter connects a Series 505 RS 485 remote I O interface to an RF remote I O interface and makes it possible to go from a Series 505 local base either to a Series 500 remote base that has RF media or to a dual media remote base For more information about using dual media with Series 505 remote bases refer to the SIMATIC 505 Redundant I O Systems User Manual PPX 505 8125 x Your RBC must have firmware Rel 3 0 or later if you use either the dual media option or PCS 3 0 or later The RS 485 RF I O channel converter is compatible with the following CPUs e 545 1104 and 545 1106 CPUs e 555 1103 555 1104 555 1105 and 5550 1106 CPUs e 575 2104 575 2105 and 575 2106 CPUs with installed PPX 575 2126 annex card NOTE The RS 485 RF I O channel converter is compatible only with RBCs using the Series 505 remote I O channel and Series 505 Series 500 remote I O such as the PPX 505 6850 A and PPX 500 2114 A RF dual media compatible RBCs The converter is not compatible with the 505 PROFIBUS DP RBC or other products that use the PROFIBUS DP I O channel SIMATIC 545 555 575 System Manual Upgrading Existing Series 500 Installations C 19 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com RS 4
187. e bezel or battery door See Figure 3 12 To gain access lower the access door With the CPU in its normal vertical position dipswitches pushed to the left are On dipswitches pushed to the right are Off On E Off 0 e 4 gt Port 2 RS 485 Port 1 Printer port Port 2 RS 232 422 Port 1 Programming port L Port 1 Baud rate Dipswitch Port 2 Baud rate Battery On Auto Recompile Off Battery Off Auto Recompile On 0 68 29 Sv c The Auto Recompile option is available on CPU models 555 1103 1104 Release 4 2 or greater models 555 1105 1106 Release 5 2 or greater and models 545 1105 1106 Release 5 1 or greater Figure 3 12 545 555 CPU Dipswitc h Location Switch 9 is used to set the back up battery On or Off As Figure 3 12 indicates moving the switch to the left enables the back up battery setting the switch tothe right disables the back up battery NOTE When SW9 is set to the On position the battery LED indicates the state of the battery back up circuit If the battery LED isilluminated memory contents should be maintained if the LED is not illuminated memory contents will not be maintained Enabling the Switch 10 is used to allow the CPU to perform an Auto Recompile during Auto Recompile runtime Switch 10 is shipped in the disabled left position To activatethi
188. e or abuse If alithium battery short circuits disconnect it immediately and move it to a well ventilated area Wear safety glasses and other protective gear when handling a disabled battery Transportation of lithium batteries is regulated by the U S Department of Transportation Lithium batteries must be shipped under exemption DOT E 7502 e For international shipments IATA Regulation 2294 applies e Lithium batteries such as the one used in the 545 and 555 CPUs which contains less than 0 5 grams of lithium are not restricted in shipment according to DOT 173 206 f or IATA Section X Take precautions in storing batteries e Donct place batteries on a metal surface doing so could cause a potential short circuit e Donot store batteries loosely or in dump bins Store batteries in the original shipping container e Store batteries in a cool well ventilated area with a maximum temperature of 70 C 158 F Disc arding Batteries to be discarded may contain a significant amount of unused Batteries energy They must be packed for disposal and isolated electrically Batteries must be disposed of in accordance with all local state and federal regulations SIMATIC 545 555 575 System Manual Installing 505 System Hardware 3 19 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Replacing and Handling the Battery continued ATTENTION Danger of explosion if battery is
189. e parameter allows you to select the way I O Mismatch Mode configuration mismatches are handled With the default setting Disable the PROFIBUS DP RBC handles I O configuration mismatches according to DP Standard mode meaning that the configuration sent by the CPU tothe RBC must match the actual base configuration exactly or else no I O updates are performed If you enable 50X Ignore Mismatch Mode the RBC performs updates with all modules whose configuration matches omitting only those modules whose configuration does not match This mode of operation does not conform to the DP Standard 50X RS 232 Comm The default for RS 232 port communications is communications disabled Port When 50X RS 232 Comm Port is enabled the RBC is not operating in 100 compliance with the PROFIBUS DP Standard due to the additional network traffic caused by task code transfers 5 24 Installing Remote Base Controllers RBCs SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Chapter Cabling and Wiring the System 6 1 Cable Routing cccee cece eee eee eee eens 6 2 GU ldelinies 23 22 0 aon eae Seba shee DO VPE dried ee EA e 6 2 Cable Routing Methods iuuusuuussssssssslsssesss sen 6 2 Under FloorRouting lssssssssesese hh hh 6 3 In Ceiling ROUN esce iuh r t o eere eripe Cher iu per E E A Che ree 6 3 Surface Duct Routing 2 6 s n 6 3 6 2 I
190. e primary 575 asthe left most 575 in the chassis f you leave an open slot between boards set the dipswitches in the backplane to the appropriate values See Setting the Daisy Chain Switches on page 4 41 You can place third party VME bus boards between 575 CPUs but be sure to install any boards that do not pass daisy chain signals to the right side of boards that require them 4 34 Installing 575 System Hardware SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Guidelines for Installing a 575 System Controller ora Primary 575 Follow the guidelines and steps below when installing a 575 as system controller and or as primary NOTE Read and abide by the warnings and cautions at the beginning of this section Ensure that all power is disconnected from the VM E bus base If the 575 CPU isto perform as the VMEbus system controller install it in slot 1 If the 575 is not performing as the VM E bus system controller then install the 575 primary as the leftmost 575 CPU in the system according to the General Guidelines at the beginning of this section Install 575 secondary CPUs if any Follow the procedure on page 4 36 Power up the 575 system Reconnect the battery after the PCG LED lights up on the 575 system controller that is when the LED on the bottom right hand side turns on See Figure 4 19 for the location of the LEDs
191. e size of the terminal lug depends on the type of terminal block used Consult your vendor for the appropriate terminal lug size Remote I O Port Figure 6 6 shows the pinout for the I O Link port on Series 505 CPUs and Pinout RBCs Thel O Link port is a 9 pin female D connector Figure 6 6 I O Link Pinout SIMATIC 545 555 575 System Manual Cabling and Wiring the System 613 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Installing Series 505 Remote I O Cables continued Connecting a Use the following procedure to connect a drop line cable between a CPU or Drop Line RBC and the Series 505 terminal block 1 Prepare a cable as described on page 6 12 2 Plug the cable D connector into the I O connector of the CPU or RBC 3 Tighten the two cable connector screws to secure the cable D connector to the I O connector of the CPU or RBC 4 Loosenthreeterminal screws on the terminal block and install the cable lug terminals onto the terminal block See Figure 6 7 Drop line from CPU or RBC Figure 6 7 Connecting to a Series 505 Terminal Block NOTE Throughout your installation make connections carefully to prevent wire mismatches F or example if you have already connected one line such as a trunk line tothe terminal block when you attach the drop line you must ensure that the wires of the second set of terminal lugs
192. early model pre 1989 Series 505 1 O modules with a 545 555 or 575 CPU Refer to Appendix B for details about compatibility SIMATIC 545 555 575 System Manual System Overview 1 13 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Chapter 2 Pre installation Guidelines 2 1 Planning Your Installation seeeseeeene nennen hh hh 2 2 Defining Control Requirements sssssssseessee eee 2 2 Calculating PowerNeeds suuussusssssssssesss sen 2 2 22 Safety Considerations uuuueeeeeeeereeeern nnn nnn nnns 2 3 Operator Safety Switches ssuusueesssselsssees sn 2 4 Emergency Stop Switch sssssssssssseeee ehh 2 4 JOG orINCH Switc hi saci cia ieee eae nbd dee end cee Ere EXTA ERA EEG RR REG 2 5 2 3 575 Fault Relay Operation 0 cee seen eee eee nnn nnn nnn nnn 2 6 OVEWIEW sagasa odo fecu e ssi OP ooo da bat Teo utri i gud RU t pula genes hace 2 6 Fault Relay Operation Details lllslssssssssseeesseees I 2 6 WME Delay ATE 2 8 Fault Relay Usage Examples 0c cece 2 8 2 4 Guidelines for Fuses Circuit Breakers 0 cece eee eee eens 2 11 Fusing the Controllerand Remote I O Base 0 2 11 2 5 Hectrical Noise reueeeeeeeen nnn eee 2 12 Definition and Source sssssssssssseeee ehh 2 12 2 6 Corecting Noise Problems seseeee nen nnnm 2 13 Noise
193. eated on a CPU that had a Series 505 remote I O configuration the destination CPU must have the hardware to support such a configuration 545 1103 CPUs do not support the Series 505 remote I O channel Using an EEPROM If you install an EEPROM the CPU allows you to save your current program without using a separate EEPROM programming device The program can be downloaded directly from RAM to the EEPROM by using TISOFT auxiliary function 84 or the corresponding function in SoftShop select the menu command PLC Utilities PLC Operations See Section 7 2 for instructions on installing an EEPROM chip See Section 7 3 for instructions on storing a program using an EEPROM Using an EPROM If your operating program does not change you can store it permanently on an EPROM You can use an EPROM copier to copy your program from an EEPROM toan EPROM The EPROM cannot be programmed in the CPU This is a cost effective method for creating duplicate copies if you have additional CPUs running the same program SIMATIC 545 555 575 System Manual Using EEPROMsfor Program Storage 7 3 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Program Storage Options continued Whatis Stored in The EEPROM stores the following elements of the user program Non Volatile Memory e Relay ladder logic RLL e K memory e U memory e S memory PID loops analog alarms and SF programs e Memory configuration e
194. echnology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Program Storage You can manage operation of EEPROMs by using SoftShop select the menu Operations command PLC Utilities PLC Operations or TISOFT AUX 84 on your programming unit Your programming package allows you to do the following procedures e Copy RAM to EEPROM e Copy EEPROM toRAM e Select RAM as program source e Select EEPROM as program source e Erasethe program in EEPROM e Report source RAM OR EEPROM of program being executed Memory and Mode When you power up your system the CPU checks the status of the Status at Powerup E EPROM and the battery A clear un programmed E EPROM is equivalent to having no E EPROM installed Table 7 3 lists mode and memory status after powerup that result from various battery and E EPROM conditions Table 7 3 Mode and Memory Status after Powerup Conditions Results Programmed E EPROM and Program Source EEPROM Bad or Off No Cleared PROGRAM Battery Status CPU Memory Cleared then loaded Bad or Off Yes with program that is RUN in E EPROM Mode prior to Good and On No No change power loss Mode prior to Good and On Yes same program No change power loss Cleared then loaded Good and On Yes different program with program that is RUN in E EPROM SIMATIC 545 555 575 System Manual Using EEPROMs for Program Storage 7 5
195. ed Counter is placed in a 545 555 controller s local base configuration the WX inputs will intermittently set to FF s which could cause improper operation NOTE High Speed Counter modules manufactured prior to May 1990 that have been modified for 545 555 controller s local base compatibility have the letter A immediately following the serial number Before you install Series 505 High Speed Counter modules into a 545 555 local base check the serial number of each module to ensure that it is compatible with the 545 555 local base Refer to Figure B 1to understand how to read the serial number a Warning o Do not use an unmodified Series 505 High Speed Counter module manufactured prior to May 1990 in a 545 555 controller s local base In a Series 505 High Speed Counter WX inputs may change to FFs that could change the High Speed Counter outputs to an unsafe condition This could result in death or serious injury to personnel and or damage to equipment Refer to the Safety Considerations Guidelines PPX 2588015 0003 shipped with each 545 555 controller for details Follow the safety installation guidelines recommended by Siemens Energy amp Automation B 8 Powerand Compatibility SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Determining the Thefifth through the eighth characters of the serial number determine the Manufacturing ma
196. eee em 6 4 Tunk and Drop Nes snus cese reete erede er Fed i doe RA Eo oo Re dde 6 5 Selecting Cable vices satan aae eeu d be ox rc ioo c on daha db acts 6 6 Planning YourInstallation sssssssssee IR 6 8 Preparing Drop Line Cables ssssssseeeeeee 6 12 Remote I O Port PINU sesia citeai eieaa iaaa ehh 6 13 Connecting a Drop Line 0 esee n 6 14 Preparing Tunk Line Cables ssssssssse eee eae 6 16 Connecting Trunk Line Cables suuuussesssssssssess nne 6 17 Extending Trunk Line Cables ssssssssssseeeee ee 6 18 Installing PROHBUS DP I O Cables cccceeeecee eee ee eee eee nnn nnn nnn 6 20 Media Options i siecusxlsd n gk RIRER PIA ew eed Gwe ebay cade RIA ER IA ERIAM4R 6 20 Sysem Layout n evroexebep erp pube ib P edad Pine dre ex dde eg Ea aad 6 20 Equipment Needed sssssssssseeseeeee ehh 6 21 PROFIBUS DP Cable and Connector Specifications ssuuuseeeuueeeuse 6 22 PROFIBUS DP Line Length Limits lsssssssssseeseeen m I 6 22 Installing PROFIBUS DP Cable ssssseeee ee I 6 23 Termination and Bias iaai ae a e ea ehh 6 24 Using a Termination Selection Switch sssssssssseeeseeenm mm 6 25 PROFIBUS DP ConnectorSchematics lssssssssssssesse eae 6 26 Installing a PROFIBUS DP Connector 0 cece 6 28 PROFIBUS DP Port PINOUT viiendas aieea tee 6 31 Contents Artisan Technology Group Quality Instrumen
197. efer to Section 4 10 for details on configuration Figure 4 16 shows the location of the dipswitch on the 575 2126 annex card Figure 4 17 shows the location of the dipswitch on the 505 CP5434 DP annex card The installation of a remote I O annex card has an effect on the power consumption of the CPU See Table B 2 to calculate power requirements for Series 505 remote I O and PROFIBUS DP I O annex cards If you have made allowances for the effects of annex card power consumption on your system you are ready to install your Series 505 remote I O or PROFIBUS DP annex card 4 28 Installing 575 System Hardware SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Installing the Series Toinstall the Series 505 remote I O annex card PPX 575 2126 follow the 505 Remote I O steps below Annex Card 1 Carefully set your CPU board on a static dissipative surface CAUTION Electronic equipment can be damaged by electrostatic discharge Ensure that personnel make contact with a static dissipative pad and or wear a grounded wrist strap when handling the CPU cards or modules 2 Lowerthe annex card directly onto the CPU board as shown in Figure 4 16 applying pressure until all connectors and standoffs are mated NOTE If you are installing the annex card on a 575 2104 ensure that dipswitch settings are correct before you mate the
198. egister points which represent the inputs from this RBC s base Theimage register is zeroed out until the RBC completes reset and resumes communication with the CPU If this occurs whilethe system is operating depending on your RLL program turning these inputs off could affect other base outputs e Fromtheassertion of reset until the RBC completes the reset and resumes communication with the CPU the state of the outputs on this RBC s base is determined by the output module with no reference to the RBC s Off F reeze switch Discrete outputs go off to a value of zero Analog word outputs obey their own Zero Hold Last Value selection If no Zero Hold Last Value selection is available on the module the analog word outputs hold their last value e If the base number you assign to the RBC by setting the base thumbwheel inadvertently duplicates the number already in use by a second RBC on the O channel when the first RBC completes its reset and attempts to communicate identifying itself with the new base number the second RBC will be logged off the system The state of the second RBC s outputs is determined by the selection made on the RBC S Off F reeze switch The CPU image register containing the input points for the second RBC is zeroed Intermittent operation could occur as long as the two RBC base thumbwheels are set to the same number SIMATIC 545 555 575 System Manual Upgrading Existing Series 500 Installations C 17 Artisan Technol
199. el Support sssssssssssse eae 1 13 SIMATIC 545 555 575 System Manual System Overview 1 1 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 1 1 Overview Introduction This manual describes SI MATIC 545 555 and 575 programmable control systems and encompasses the following CPU models e PPX 545 1103 1104 1105 1106 e PPX 555 1103 1104 1105 1106 e PPX 575 2104 2105 2106 NOTE In this manual a feature unless it is explicitly restricted applies to all systems The CPU models are distinguished by capacity and speed and by various optional features The 1103 and 1104 models of the 545 and 555 CPUs are older models that will be superseded by the newer models 1105 and 1106 However all share the same programming standards and all offer access to PROFIBUS DP I O The systems that are described in this manual are designed for usein a broad range of applications induding those that require discrete and analog control Components indude the CPU and the support devices that provide operator interface communication I O control and power The CPUs and their support equipment comprise computer control led systems that are capable of controlling complex manufacturing systems These systems perform the same functions as relays static control or card logic control systems They can detect the change in state of input signals from such devices as pushbut
200. enclosure The SIMATIC 575 PLC System complies with the requirements of the EMC Directive 89 336 EEC when installed in accordance with the specifications in this manual and when installed in a grounded metal cabinet with tightly sealed doors If Series 505 Remote I O channel cables to remote bases are run outside the cabinet they must either be run in a fully enclosed metal raceway or fitted with ferrite beads where they leave and or enter the cabinets Ferrites shall be Steward PN 28 A 2029 0 or equivalent For SIMATIC 575 Systems a linefilter must be connected in the power lines to the system in order to comply with the EMC directive The line filter shall be Corcom part no 10VS1 or equivalent Filter Network connected ahead of each power supply The 575 2130 VME bus base can be operated with or without the optional fan assembly PPX 575 2131 The maximum rated operating temperature of the controller is 60 C In an environment where ambient temperatures do not exceed 40 C or where other means of cooling are available operating the VMEbus base without the fan assembly is a cost saving option When operating without the fan assembly additional derating of power supplies and I O modules is required For more information about the fan assembly option see Section 4 5 SIMATIC 545 555 575 System Manual Installing 575 System Hardware 4 5 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com
201. er including its chassis power supply and all installed boards with a Series 505 base power supply CPU 545 1104 545 1106 or 555 1103 1104 1105 or 1106 and PPX 505 6860 RS 485 RF I O channel converter The upgrade is shown graphically in Figure C 3 NOTE The 545 555 CPU cannot directly replace either a hot backup HBU configuration or a system with more than 15 bases 1 Ifthe Series 500 remote I O installation consists of more than one coaxial RF remote I O channel combine these channels into a single remote I O channel Refer to the chapter entitled Cabling and Wiring the System in the SIMATIC 560T 565T System Manual for information about installation of a coaxial remote I O channel 2 Renumber your bases as necessary Each base must use a unique address Base 0 is reserved for the local base remote bases can be numbered between 1 and 15 3 Modify the I O configuration in the 545 555 CPU to reflect the channel number and base number changes 4 Connect the Series 500 RF based I O channel to your 545 or 555 local base by installing a PPX 505 6860 converter in the slot next to the CPU Section C 6 describes how to install the converter in the Series 505 base and connect cabling 5 Connect a 120 ohm resistor between pins 3 and 8 on the RS 485 I O connector of your 545 or 555 CPU This ensures proper termination of thel O channel data lines U pdate ti me for a special function module is significantly
202. er optic media This section describes the twisted pair RS 485 cable If you are installing a glass or plastic fiber optic system follow the instructions in the SINEC L2 L2FO Network Components Manual order number 6GK 1 970 5CA00 0AA1 System Layout Figure 6 11 shows a simple I O system layout for the PROFIBUS DP interface On the PROFIBUS DP I O channel the CPU is a master and I O devices are slaves CPU with PROFIBUS DP C I O interface P S P Local I O U PROFIBUS DP I O link PROFIBUS DP E to RBC RBC T R PPX 505 6870 P S p Local I O CL slave 1 slave 2 slave 3 PROFIBUS DP __ field bus m slave 112 Up to 112 PROFIBUS DP devices with repeaters Figure 6 11 Sample System Layout for PROABUS DP 6 20 Cabling and Wiring the System SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Equipment Needed Standard PROFIBUS DP cable connectors and repeaters are available from Siemens to cable and wire your installation The components listed in Table 6 4 are recommended for all installations They support baud rates from 9 6 kbaud through 12 M baud Table 6 4 PRORBUS DP Components All Baud Rates item OrdeNumbe commet Cable 6XV1 830 0AH 10 Connector 6ES7 972 0BA10 0XAO0 Connector 6ES7972 O0BB10 OXAO Indudes PG port Repeater 6E S7 972 0AA00 0XAO0 Table 6 5 lists
203. ery indicator blinks or goes off the battery has dropped below the voltage required to maintain memory and should be replaced See page 3 20 Replacing the Battery A WARNNG Charging a primary lithium battery can cause the battery to explode An exploding lithium battery can result in death or serious injury to personnel and or damage to equipment Do not attempt to charge primary lithium batteries Instead replace your battery following the procedure on page 3 20 and dispose of the battery according to the instructions of its manufacturer 3 18 Installing 505 System Hardware SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Using and Handling Batteries Transporting Batteries Storing Batteries Use the following safety instructions to minimize the risk of personal injury or fire hazard when handling lithium batteries Lithium batteries contain flammable material Do not open puncture or crush the battery case Puncturing the battery case releases electrolyte and potentially flammable material Exposure to electrolyte can cause throat and or eye irritation If the electrolyte comes in contact with your skin or eyes flush the area thoroughly with large amounts of water Never use a lithium battery in a completely sealed container Containers must have a mechanism for relieving pressure if the battery is exposed to high temperatur
204. es and field devices and also Series 505 remote I O by means of the DP RBC PPX 505 6870 I O Channel Both I O channels are supported by the 545 1104 and all models of the 555 Support CPUs Annex cards are available to allow the 575 CPUs to access either channel the PPX 575 2126 is used with the Series 505 remote I O channel and the PPX 505 CP5434 DP is used with the PROFIBUS DP I O channel Only one annex card can be used per 575 CPU the annex card mounts on the CPU and does not require a separate VME slot One annex card the PPX 505 CP5434 DP is available for the 545 1103 CPU the 545 1103 can only access Series 505 remote I O by means of the 505 PROFIBUS DP RBC Table 1 3 offers a breakdown of the types of I O local and remote supported by the various CPU models Table 1 3 I O Options Local I O Expansion I O I O Type Max of Slots Series 505 PROFIBUS DP 545 1103 1105 Series 505 Not supported 32 devices 545 1104 1106 Series 505 15 bases 112 devices 555 1103 1104 Series 505 15 bases 112 devices 555 1105 1106 Series 505 15 bases 112 devices 575 2104 575 2105 2106 The number for devices supported includes both masters and slaves Optional for this system Requires installation of PP X 505 CP5434 DP annex card Assumes 2 slots taken for at least one 575 CPU Optional for this system Requires installation of PPX 575 2126 annex card VME 15 bases 4 112 devices 2 NOTE You cannot use some
205. f zero Analog word outputs obey their own Zero H old Last Value selection If no Zero Hold Last Value selection is available on the module the analog word outputs hold their last value e fthestation address you assign to the RBC by setting the dipswitch inadvertently duplicates an address already in use by a second slave on thel O channel then when the RBC completes its reset and attempts to communicate identifying itself with the new station address the second slave may be logged off the system Intermittent operation could occur as long as the two slaves are set to the same station address 5 20 Installing Remote Base Controllers RBC s SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com When the CPU logs an RBC off the system it sets a corresponding bit in one of the status words that are available to your RLL program Your RLL program can use these bits to detect the loss of the RBC and control the outputs of other bases as appropriate for your application For details about status words and more information about programming refer to the SIMATIC 545 555 575 Programming Reference U ser Manual SIMATIC 545 555 575 System Manual Installing Remote Base Controllers RBCS 521 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com PPX 505 6870 RBC continued Status Display Switch 11 on the d
206. fications E 15 Discrete DC output module connector pinouts E 14 current vs temperature E 12 isolation E 12 specifications E 12 Discretel O interval 5 24 Discrete relay output module connector pinouts E 10 current vs temperature E 11 field wiring E 11 isolation E 9 spedifications E 9 DP RBC SeePROFIBUS DP Drop line cableinstallations 6 5 connecting to CPU 6 14 connecting to RBC 6 14 preparing 6 12 terminating 6 15 Dual media base 1 12 3 4 power supplies 3 4 RBCs 5 3 C 19 RS 485 RF converter C 19 Artisan Technology Group Quality Instrumentation EEPROM See also EPROM configuring CPU for program storage 7 6 7 9 errors and corrections 7 11 fatal error 9 9 list of functions 7 5 on board flash 7 2 configuring CPU for program storage 7 8 program copying 7 10 editing 7 12 errors 7 11 Electrical noise avoiding 2 12 correcting 2 13 isolating from 2 15 Emergency stop switch 2 4 Enclosure planning for Series 505 base 3 3 VMEbus base 4 5 EPROM EEPROM compatibility 7 3 overview 7 2 troubleshooting 9 18 using 7 3 Errors checksum in L and CL memory F 2 F 3 controller fatal 9 8 non fatal 9 16 Expansion I O options 1 13 PROFIBUS DP 1 4 F Fast PROFIBUS DP I O update F 4 F 5 Fatal error codes 9 10 indications 9 8 Fault relay operation 2 6 pinouts 4 44 specifications 2 6 Fault restart troubleshooting 9 2 Index 3 Guaranteed
207. ftShop Series 505 Series 500 APT CVU1000 CVU10000 MODNIM Peerlink TISOFT TISOFT2 TIWAY PCS 386 ATM and 7MT are trademarks of Siemens Energy amp Automation Inc IBM and AT are registered trademarks of International Business Machines Corporation Belden is a registered trademark of Belden Wire amp Cable Company CSA is a registered trademark of the Canadian Standards Association MS DOS and Windows are registered trademarks of Microsoft Corporation Modbus is a registered trademark of New Modicon Incorporated Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com A rtisan Artisan Technology Group is your source for quality TecmoogyGroup new and certified used pre owned equipment FAST SHIPPING AND SERVICE CENTER REPAIRS WE BUY USED EQUIPMENT DELIVERY Experienced engineers and technicians on staff Sell your excess underutilized and idle used equipment TENS OF THOUSANDS OF at our full service in house repair center We also offer credit for buy backs and trade ins IN STOCK ITEMS www artisantg com WeBuyEquipment EQUIPMENT DEMOS HUNDREDS OF InstraV ea REMOTE INSPECTION LOOKING FOR MORE INFORMATION MANUFACTURERS Remotely inspect equipment before purchasing with Visit us on the web at www artisantg com 7 for more our interactive website at www instraview com 7 information on price quotations drivers technical LEASING MONTHLY specifications manuals and docu
208. g e Oneof the 9 pin connectors is connected to an RBC or CPU e Cableline wires are shorted to the shield SIMATIC 545 555 575 System Manual Troubleshooting 9 21 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Checking RS 485 Twisted Pair Cable Installation continued Resistance above Line to lineresistance that is above the maximum specified in Table 9 6 Maximum may be caused by the following e Incorrect termination resistors are installed e Fewer than two termination resistors are installed always use at least one termination resistor even with the simplest installation e Thecable is open between the point of measurement and one or both of the termination resistors 9 22 Troubleshooting SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 9 9 Checking PROHBUS DP Cable Installation Verify the PROFIBUS DP system cable installation using the following guidelines e Inspect system terminations too many not enough or incorrect placement See Section 6 3 for proper placement of termination connectors e Check for a short in the cable with an ohmmeter e Check for an open circuit in the cable between the point of measurement and one or both of the termination resistors with an ohmmeter Line to shield resistance that is generating errors may be caused by one of the follow
209. g a To install the PPX 500 5114 A RBC in a Series 500 base refer to Series 500 RBC Figure C 5 and follow the steps below AWARNNG Installing or removing a RBC from a powered up base disrupts your process Installing or removing an RBC from a powered up base could cause unexpected operation which could cause death or serious injury to personnel and or damage to equipment Ensure that all power is disabled before installing or removing the RBC CAUTION Ek The RBC is sensitive to and can be damaged by electrostatic discharge Ensure that personnel make contact with a static dissipative pad and or wear a grounded wrist strap when handling the RBC 1 Disconnect power to the base 2 Position the RBC so that the bezel is facing you 3 Grasp the top and bottom of the RBC 4 Carefully push the RBC into the slot until it mates with the backplane connectors 5 Tighten top and bottom bezel screws 6 Connect the RBC to the RS 485 drop or trunk line C 12 Upgrading Existing Series 500 Installations SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com E lt gt a Remote Base Controller Power Supply Pd Figure C 5 Installed Series 500 RBC SIMATIC 545 555 575 System Manual Upgrading Existing Series 500 Installations C 13 Artisan Technology Group Quality Instrumentation Guaranteed
210. g the Switch 8 is used to allow the CPU to perform an Auto Recompile during Auto Recompile runtime Switch 8 is shipped in the disabled left position To activate this Function feature set the switch tothe right enabled position Refer to Appendix F for more information about the Auto Recompile function 4 26 Installing 575 System Hardware SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Setting the Base Address Issuing SYSRESET The positions of the BASE ADDRESS switch pair SW3 and SWA determine the base address for the 575 system tables A24 space and the 575 Global Communication Status Registers or GCSRs A16 space SW5 controls whether the primary 575 CPU issues SY SRESET when changing from FAULT mode to PROGRAM mode When SW5 is set tothe Off position option DO NOTASSERT VAIT FOR SYSRESET the primary 575 CPU performs a coordinated state change from FAULT mode to PROGRAM mode without issuing SY SRESET When SW5 is set to the On position option ASSERT WAIT FOR SYSRESET and the primary 575 CPU is in slot 1 the primary issues SY SRESET to recover from FAULT mode If SW5 is set tothe On position but the primary 575 CPU is not in slot 1 then the primary 575 CPU cannot issue SYSRESET In this case to recover from FAULT mode you must follow the procedure below 1 Execute AUX 11 or AUX 12 from TISOFT 2 Wait at least three seconds
211. gical base has a unique base address By comparison the Series 505 remote base assembly addresses up to 16 contiguous slots with a single base address e To reduce down time for your process plan to install the new RS 485 twin axial cables for the I O trunkline before upgrading the hardware for each I O base e Update time for a special function module is significantly faster when you install the module in the local base rather than a remote base However 545 and 555 CPUs are installed in a Series 505 local base and Series 500 SF modules cannot be placed in a Series 505 local base Therefore if SF module updates are critical to your application consider replacing the Series 500 SF modules with Series 505 SF modules and installing them in the local base with the 545 555 If all SF modules cannot be installed in the local base consider placing low activity SF modules such as the ASCII BASIC or Dual Communication Port DCP modules in a remote base Place high activity modules such as the NIM or Peerlink in the local base To perform an upgrade follow the procedure on the next page and refer to Figure C 1 SIMATIC 545 555 575 System Manual Upgrading Existing Series 500 Installations C 3 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Upgrading a 520 520C 530 530C 530T System continued Check Base to Be Upgraded Upgrading 14 Slot 12 Slot 6 Slot Bases
212. gramin RAM or ROM RAM if system is operating from RAM memory ROM if system is operating from an E EPROM 575 OPERATIONAL STATUS APPLICATION ID B COMMUNICATIONS P1 TBP BAUD RATE 38400 SCAN 76 MSECS FIXED BATTERY GOOD KEY UNLOCKED DOWNLOAD OFF MODE PROGRAM PROGRAM IN RAM SF LOOP MODE PROGRAM SF LOOP FOLLOWS PLC TO PROGRAM MODE FATAL ERROR NONE LOOP FATAL ERROR NONE NON FATAL ERROR NONE LOOP NON FATAL ERROR NONE 575 NETDATA PG EXIT F1 Figure 9 1 Typical AUX 29 Screen SIMATIC 545 555 575 System Manual Troubleshooting 9 5 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 9 2 Toubleshooting by Reading LEDs 545 555 LEDs TheLEDs on the 545 555 CPUs arelabeled CPU GOOD RUN and BATT GOOD These LEDs provide CPU status as shown in Table 9 2 NOTE Sincethe CPU receives power from the base power supply module the power supply must be on and functioning correctly to turn the LEDs on f the base power supply module is defective or turned off all CPU indicators will be off Table 9 2 CPU Indicators indicator status Meaning OOO O O CPU GOOD CPU functioning with no fatal errors On CPU analog and discrete is in the RUN mode RUN Analog Loops Analog Alarms and SF programs is Flashing in the RUN mode and discrete RLL program is in the PROG mode On Battery is good and switch 9 is set to the On position Batte
213. h 545 555 CPUs Table 7 2 Program Storage Using E EPROM EEPROM 128 Kbytes 126 Kbytes 2587681 8022 EEPROM 256 Kbytes 254 K bytes 2587681 8030 EPROM 128 Kbytes 126 K bytes 2587681 8023 EPROM 256 Kbytes 254 K bytes 2587681 8031 The EPROM chips cannot be programmed on the CPU You must use an EPROM copier to copy your progam from an EEPROM tothe EPROM chip 7 2 Using EEPROMs for Program Storage SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com EEPROM Portability EEPROMS are portable if and only if they meet the following criteria e Thefirmware of the CPU on which the EEPROM was created is compatible with the firmware of the destination CPU EEPROMS created with firmware from Release 1 x through Release 3 x are compatible forward and backward However Release 4 0 is not backward compatible you can use EEPROMs created under earlier firmware on a Release 4 0 CPU but you cannot take an EEPROM created under Release 4 0 and transfer it to a CPU with firmware from Release 1 x through Release 3 x e The EEPROM program was created on a CPU that had a memory configuration smaller than or equal to the memory available on the destination CPU e Ifthe EEPROM program was created on a CPU that had a PROFIBUS DP I O configuration the destination CPU must have the hardware to support such a configuration e fthe EEPROM program was cr
214. h ends of the cable There arethree wires when the sleeving is stripped back two wires have color coded insulation jackets and one the shield is bare 2 At both ends of the cable remove 0 13 in 3 3 mm of each color coded insulation jacket both ends to expose the bare wires 3 At both ends of the cable install each of the three exposed wires onto terminal lugs according to directions provided by the manufacturer The size of the terminal lug depends on the type of terminal block used Consult your vendor for the appropriate terminal lug size 616 Cabling and Wiring the System SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Connecting Trunk To connect a trunk line cable to a terminal block follow the steps below Line Cables Refer to Figure 6 9 1 Loosen three terminal screws on the terminal block 2 Install the terminal lugs at the cable end onto the terminal screws NOTE Throughout your installation make connections carefully to prevent wire mismatches F or example if you have already connected one line such as a drop line tothe terminal block when you attach the trunk line you must ensure that the wires of the second set of terminal lugs match with those of the first set of terminal lugs That is if a wire at a bottom terminal screw is blue the wire on the screw directly above it must also be blue 3 Tighten the screws on
215. he position of the user accessi ble jumper selector Refer to Table 4 2 and Table B 4 to develop a system power budget 4 14 Installing 575 System Hardware SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Table 4 2 Power Supply Specifications Input Specifications PPX 575 6660 Power Supply PPX 575 6663 Power Supply Capacity 185 wi 300 w1 AC input voltage 110 VAC 85 132 VAC 110 220 VAC jumper selectable 85 132 170 264 VAC Input voltage frequency 47 to 63 Hz 47 to 63 Hz Input current maximum operating 5Arms 8A rms inrush 50 A peak for up to 100 ms 50 A peak for up to 100 ms overcurrent protection fuse provided fuse provided Input fusing 8 A 250 VAC slow blow 3 AG 10 A 250 VAC slow blow 3 AG fuse fuse Output Specifications Voltage Range Current Rating Power Current Rating Power 45 4 875 to 5 250 25 A 125 W 35 A 175 W 12 11 64 to 12 60 3 A 36 W 6 A 72 W i 12 11 64 to 12 60 2A 24W 4 A 48 W Vstdby Run mode 4 875 to 5 250 1A3 5 Ww 1 A3 5 Ww Vstdby Battery 3 to 5 volts 100 mA4 100 mA4 backup mode Dimensions 10 3 H x 6 3 D x 3 6 W 10 3 H x 6 3 D x 3 6 W 262 mm x 160 mm x 91 mm 262 mm x 160 mm x 91 mm Class Div 2 temperature rating No special restrictions T4A with fans T4 without fans The wattage ratings are based on nominal
216. his power supply requires 24 VDC SIMATIC 545 555 575 System Manual Installing 505 System Hardware 3 11 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 3 7 Installing the PROHBUS DP Annex Card Optional Toinstall the PROFIBUS DP annex card PPX 505 CP5434 DP on a 545 1103 or 545 1105 CPU follow the procedure described below and consult Figure 3 6 1 Carefully set your CPU board on a static dissipative surface CAUTION Electronic equipment is sensitive to and can be damaged by electrostatic discharge Ensure that personnel make contact with a static dissipative pad and or wear a grounded wrist strap when handling the CPU cards or modules 2 Removethe PROFIBUS DP port cover from the bezel The port cover is not reusable The port cover is secured by plastic pins that project through the bezel and are secured on the back side by clamps First clip the pins off as dose to the clamps as practicable then pry the camps loose and remove the port cover 3 Toattach the annex card tothe CPU board insert the 9 pin D connector of the annex card into the CPU bezel opening and align the annex connector with the connector on the CPU Apply pressureuntil the connectors are mated 4 Insert metal screws supplied into the screw holes of the PROFIBUS DP communication port and tighten to a maximum of 5 2 in Ib 0 6 N m torque 5 Insert plastic screws supplied
217. ial control equi pment CSA Certified process control equipment or CUL Canadian UL FM approved Class Div 2 Haz Loc CE Marking Low Voltage Directive 73 23 EEC and Electro Magnetic Compatibility Directive 89 336 E EC SIMATIC 545 555 575 System Manual System Specifications A 3 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com A 3 575 Power Supply Specific ations Table A 3 575 Power Supply Specifications a Loexmsses PPXBIRES 07 85 132 VAC 85 122VAC 110 Range 85 132 VAC 110 Input Current i i p Peak Inrush 50 A maximum for up to 50 A maximum for up to 100 ms 100 ms 8 0 A 250 V slow blow 3AG 10 0 A 250 V slow blow 3 AG 45 VDC 45 VDC 12 VDC 12 VDC 12 VDC 12 VDC Vstdby Run mode Vstdby Run mode Power Output Voltage 45 VDC A 45 VDC 12 VDC 12 VDC Current 12 VDC 12 VDC Vstdby Run mode Vstdby Run mode Vstdby Batt bckp Vstdby Batt bckp 10 3 H x 63 D x 3 6 W 10 3 H x 6 3 D x 3 6 W 262 mm x 160 mm x 91 mm 262 mm x 160 mm x 91 mm Class Division 2 temperature rating No special restrictions T4A with fans T4 without fans 1 The wattage ratings are based on nominal voltage 2 Theload power supplied by the 12 or 12 volt output must not exceed the power supplied by the 5 volt output i e with a 5 A load on the 45 V the load current supplied by the 12 or 1
218. iguration of the base against the configuration expected by the CPU No communication with the CPU within the allotted timeout period Probable causes The CPU is not powered or thel O channel wiring is incorrect Action Check CPU power and I O channel wiring Self Diagnostics Failure Module Mismatch O Communication Time Out 5 12 Installing Remote Base Controllers RBCs SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Table 5 4 RBC Status Codes continued The RBC has detected an internal RAM parity error Action Serious malfunction Placethe system in a safe state and consult Siemens Technical Support In the U S A call 423 461 2522 Standby RBC in dual media application has Standby N o Configuration no configuration Action Configure the RBC Address switch setting is incorrect Dual media RBCs need to have the same address switch setting Action In a dual media application set both address switches to the same address If they are at the same address consult Siemens Technical Support In theU S A call 423 461 2522 Communication Good No RBC has no configuration Configuration Action Configure the RBC RAM Parity Error Address Mismatch Hardware watchdog timeout that immediately resets the RBC Action Serious malfunction Place the system in a safe state and consult Siemens
219. in slot 1 only a 575 primary residing in slot 1 can issue SYSRESET it issues SYSRESET during FAULT recovery The 575 secondaries do not recover from 1 FAULT mode unless SYSRESET is issued AUTO CONFIGURED value DO NOTASSERT WAITFOR SYSRESEF to recover from FAULT The 575 primary coordinates FAULT recovery with the 575 secondaries without issuing SYSRESET AUTO CONAGURED SW3 through SW5 and SW7 are ignored This option allows compatibility with earlier releases that is with 575 Release 2 0 through 575 Release 3 0 USER C ONG URED configuration in SW3 through SW5 and SW7 If this option is selected then any 575 2104 CPU must have a remote I O annex card and switches SW3 through SW6 must be set to the same position PRIMARY 575 Only one 575 CPU can be configured as a primary All other 575s must be configured as secondaries If a 575 CPU isin slot 1 then it is configured as the primary regardless of the switch position SONDAS On AUTO RECOMPILE function disabled AUTO RECOMPILE function enabled Available on CPU models 575 2105 2106 Release 5 1 or greater Refer to Appendix F for more information about the Auto Recompile function SIMATIC 545 555 575 System Manual Installing 575 System Hardware 4 25 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Configuring the CPU continued Using the AUTO CONHGURED Mode When SW6 is set tothe
220. in one of the status words that are available to your RLL program Your RLL program can use these bits to detect the loss of the RBC and control the outputs of other bases as appropriate for your application For details about status words and more information about programming refer to the SIMATIC 545 555 575 Programming Reference U ser Manual SIMATIC 545 555 575 System Manual Installing Remote Base Controllers RBCs 511 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com PPX 505 6851 A B and PPX 505 6850 A B RBCs continued Status Display The display at the top of the module see Figure 5 8 indicates the status of the RBC See Table 5 4 for the definition of status displays 2 REMOTE BASE CONTROLLER STATUS RBC GOOD SELF DIAG FAILURE MODULE MISMATCH O COMM TIME OUT RAM PARITY ERROR STANDBY NO CONF ADDR MISMATCH COMM OK NO CONF WATCHDOG TIME OUT STANDBY CONF Q0 001 amp 0nmNo oO0 Figure 5 8 RBC Status Display Table 5 4 RBC Status Codes Communicati ons am Fully operational No errors detected operational No errors detected RBC Good Action None Serious malfunction Action Place the system in a safe state and consult Siemens Technical Support In the U S A call 423 461 2522 I O modules installed in the base do not match the expected configuration in the CPU Action Compare the actual conf
221. in supervisor mode O3FF Debug mode error 0400 _ Diagnostic failure 0401 Memory parity error 0402 Bus time out test failure 0403 Microprocessor test failure 0404 Watchdog test failure 0405 Error register test failure 0407 General outputs register test failure 0408 Imageregister RAM test failure 0409 Imageregister hardware test failure 040A Interval timer test failure 040B TM test failure 040C TOD test failure 040D Exception register test failure 040E UART test failure O40F Incorrect CPU ASIC 0501 Bus error in user defined external subroutine 0502 SYSFAIL asserted on VME 0504 Invalid firmware installed in annex board 9 12 Troubleshooting SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 545 555 CPU When a fatal error occurs the CPU attempts the following actions Responses to Fatal Enors e TheCPU GOOD LED is turned off e O ports are disabled discrete outputs are turned off and word outputs are held in their last valid state e Communication ports are cleared and re initialized e Pending or queued communication tasks are aborted Steps to Clear Attempt to clear the fatal error by following the steps listed below When the 545 555 Fatal Errors CPU GOOD LED turns on the fatal error has been cleare
222. incorrectly replaced Replace only with the sameor equivalent type recommended by the manufacturer Discard used batteries according to the manufacturer s instructi ons ATTENTION II y a danger d explosion s il y a remplacement incorrect dela batterie Remplacer uniquement avec une batterie du m metype ou d un type recommand par le constructeur M ettreau rebut les batteries usag es conformement aux instructions du fabricant Canadian standard CAN CSA C22 2 No 950 M 89 Replacing the Battery changes require advance planning For the 545 1103 1104 and Battery in 555 1103 1104 CPUs keep the following guidelines in mind 1103 1104 CPUs e n order to change the lithium battery you must power down the system e Memory can be lost if system power is removed from the CPU for longer than twenty minutes during a battery change e A good battery must bein place when power is restored or else the CPU goes through a battery bad powerup and all memory is lost NOTE As a safeguard consider using SoftShop TI SOFT or APT to save your program before you replace the battery Follow these steps to replace the lithium battery 1 Place your process in a safe state a WARNING Installing or removing a CPU from a powered up base disrupts your process Disruption of your process can cause death or serious injury to personnel and or damage to equipment Ensure that all power is disabled before installing or removing the CPU
223. indication of a hard memory chip failure and the conservative approach of dedaring a fatal error and shutting down the CPU was taken even for soft memory errors caused by noise spikes In addition the fatal error response was applied to all program memory whether or not it was being used to store program data Therefore to improve up time in the event of any soft memory errors Siemens has made the following changes in the SIMATIC CPUs 1 The checksums that are used to determine if there is an uncommanded memory change problem will be calculated only on the L ladder and CL compiled ladder memory that is actually used Errors discovered in unused portions of memory whether configured or unconfigured will be ignored Refer to the SIMATIC 545 555 575 Programming Reference User Manual for a more detailed discussion on SIMATIC 5X5 CPU memory architecture F2 Enhancements in Late Model CPUs SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Using the Auto Recompile Function Programming Support 2 Sincethe CPU actually runs on compiled code stored in CL memory the CPU will no longer declare a fatal error if an error in L memory is detected Instead the CPU will set a non fatal error and keep running Status Word 1 bit 16 STW1 16 indicates this condition and can only be cleared by reloading the RLL application program from your PC or
224. ing Terminating Resistor Resistor Max Trunk Length 7 Max Trunk Length CW T T T T T zi Total Trunk Line Length T Terminal Block A terminating resistor shown in Figure 6 8 must be installed on the end terminal blocks If only one terminal block is used a terminating resistor must be installed on that terminal block Figure 6 3 TConfiguration 6 8 Cabling and Wiring the System SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com e Drop lines should be no longer than 33 feet 10 m e Short drop lines of 3 3 feet 1 m do not measurably affect signal quality and do not have to be counted for the length reduction shown in Table 6 2 The maximum permissible trunk length depends on the cable type used and the number of terminal blocks in your installation See Table 6 2 Table 6 2 Maximum Cable Length for Trunk Lines Maximum Distance in Feet Meters Number of of Belden Cables T inal Block Eee 9860 cable 9271 cable 9182 cable 3300 1006 Figures in parentheses indicate distance in meters SIMATIC 545 555 575 System Manual Cabling and Wiring the System 6 9 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Installing Series 505 Remote I O Cables c
225. ing PROHBUS DP Cable Installation eee 9 23 9 10 PROHBUS DP Communications Watchdog Timer Lseeeee 9 24 9 11 Troubleshooting 575 Improperlogin seen mmm m mmm mmm 9 25 SIMATIC 545 555 575 System Manual Troubleshooting 9 1 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 9 1 Toubleshooting by Using Auxiliary Functions Overview Power up Restart Partial Restart and Complete Restart 575 Fault Restarts 9 2 Troubleshooting The troubleshooting information in this chapter is generic unless a specific CPU is stipulated The CPUs have self checking and diagnostic capabilities that can be used for troubleshooting The diagnostics and self checks are accessible through the Auxiliary Function menu on your TISOFT programming device When you display the Auxiliary Function menu the following functions are available for resetting the CPU initiating diagnostics or displaying diagnostic information e Power up Restart AUX 10 e Partial Restart AUX 11 e Complete Restart AUX 12 e Compare PLC to Disk AUX 17 e PLC Diagnostics AUX 20 545 555 CPUs only e Display Failed I O AUX 25 e PLC Operational Status AUX 29 AUX 10 Power up Restart AUX 11 Partial Restart and AUX 12 Complete Restart are restart clear functions See Table 9 1 for AUX 10 AUX 11 and AUX 12 restart states f config
226. ing from 2 15 load snubbing 2 13 Non fatal error indications 9 16 Non volatile memory program storage 7 4 O Off F reeze jumper PROFIBUS DP RBC 5 14 Series 500 RBC C 14 Series 505 RBC 5 6 On board flash EEPROM configuring CPU for program storage 7 8 7 9 program storage 7 2 Output state jumper position PROFIBUS DP RBC 5 14 Series 500 RBC C 14 Series 505 RBC 5 6 selection PROFIBUS DP RBC 5 14 Series 500 RBC C 14 Series 505 RBC 5 6 P Performance by CPU model overview 1 6 1 7 Pinouts 505 RBCs serial port 5 5 545 555 CPU Port 1 printer connections ready busy handshaking 6 34 XON XOFF handshaking 6 34 Port 1 2 3 24 575 CPU Port 1 4 46 Port 2 printer connections ready busy handshaking 4 48 6 35 XON XOFF handshaking 4 48 6 35 Port 3 connection programming device 4 49 Ports 2 3 4 4 46 Index 5 Guaranteed 888 88 SOURCE www artisantg com Pinouts 575 CPU continued serial port connection 4 47 VME backplane 4 54 575 fault relay 4 44 575 modules discrete AC input E 3 discrete AC output E 8 discrete DC 16 I O E 6 discrete DC input E 16 discrete DC output E 14 discrete relay output E 10 remote I O port PROFIBUS DP 6 31 Series 505 6 13 RS 485 RF converter C 22 Port pinouts 575 CPUs 4 46 4 49 Power consumption See Power requirements Power requirements calculating 2 2 remote I O annex cards B 2 Series 505 modules B 3 VMEbus modules B 6 Powe
227. ing situations e Oneof the 9 pin connectors is connected to an RBC or CPU e Cableline wires are shorted to the shield SIMATIC 545 555 575 System Manual Troubleshooting 9 23 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 9 10 PROHBUS DP Communications Watchdog Timer 9 24 Troubleshooting Most slaves have a communications watchdog timer that may be activated or deactivated by the user during initial configuration The communications watchdog timer is distinct from a hardware watchdog timer The communications watchdog timer monitors time between communications from the PROFIBUS DP annex card If the communications watchdog timer is activated and communication between the PROFIBUS DP annex card and the slave is broken the communications watchdog timer on the slave will expire and set the output points to a safe state The safe state may vary depending on the slave s design but most slaves zero the output points Refer to your slave manual s for more information about slave watchdog timer reaction The PROFIBUS DP annex card restarts communications to the slaves in the following events e fan error has been detected by the CPU when the error is cleared by theCPU e When communication between the PROFIBUS DP annex card and the CPU is restored SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE
228. inout for Serial Figure 4 25 shows the pinout for Port 1 on the 575 CPUs Port 1 Chassis GND TD RD RTS CTS Signal GND DCD Figure 4 25 Port 1 Pinouts Pinouts for Serial Figure 4 26 shows the pinouts for Ports 2 3 and 4 on the 575 CPUs Ports 2 3 and 4 Chassis GND CH2 TD CH2 RD CH2 RTS CH2 CTS gt 4 Signal GND CH2 DTR CH4 RD CH4 RD CH4 TD CH4 TD Signal GND CH2 DCD CH3 RD CH3 RD Signal GND CH3 TD CH3 TD Figure 4 26 Port2 3 and 4 Pinouts 4 46 Installing 575 System Hardware SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Of the four serial communication ports on the 575 CPU twoare modem compati ble RS 232 ports one for a printer and one for an operator interface and one is an RS 422 operator interface port The fourth RS 422 port is reserved for factory use Serial Port 1 Port 1isa DTE RS 232 port with modem control lines It is the primary programming port You can connect this port directly to most PC AT serial ports Refer to Figure 4 27 for connection information Use this port for distances of up to 50 feet You can set the baud rate of this port from 300 to 38 400 using TI SOFT Signal Ground 9 Pin Female D Connect
229. inouts for a discrete AC input module Table E 2 Discrete AC Input Module Connector Pinouts LULMSL LE FAR ImutsedimArdum O BR input section Breturn 1 B3 Input 11 B3 B4 mti T 56 ipti 86 B mptis 87 B8 B7 B8 OR mtse eum SSCS D4 Imptzg B4 p imput30 B6 ps frea e SIMATIC 545 555 575 System Manual 575 O Module Specification amp Pinouts E 3 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com E2 16 Input 16 Output 24 VDC Module The discrete DC 16 input 16 output module PP X 575 4366 lets you drive 24 VDC sinking loads and monitor 24 VDC source inputs Table E 3 shows the module isolation specifications Table E 3 24VDC I O Module Isolation Feature Beripion Optical isolation 1500 Vrms Isolation between commons 1000 Vrms Chassis to user circuits 1000 Vrms Figure E 1 illustrates the effect that temperature has on current output capabilities With fan cooling Without fan cooling 6 j_ 0 10 20 30 40 50 60 70 0 10 20 30 40 50 60 70 Temperature C Temperature C Figure E 1 Low Curent DC Output Curent Point vs Ambient emp E 4 575 O Module Specification amp Pinouts SIMATIC 545 555 575 System Man
230. interrupt 0005 Invalid SFOS service call code 0006 Task queue logic error 0007 Stack error 0008 Heap logic error 0009 Heap overflow 000B Lock sema logic error 000D Task management logic error 0011 Timer list processing logic error 0016 Specified task not an OCT 0017 Incompatible task attributes 0022 Dispatcher flags DSPFLG have been corrupted 0023 IOCB table is full 0024 1 0 already in progress 0025 Uninitialized 1 O 0026 1 0 processing logic error 0027 Invalid system stack pointer 0028 Invalid user stack pointer 0029 Total queue sizeis invalid 9 10 Troubleshooting SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Table 9 5 Aux 29 Fatal Enor Codes continued 002A BUS error 002B Address error 002C Illegal instruction 002D Divide by zero 002E CHK exception 002F TRAPV exception 0030 Privilege violation 0031 TRACE exception 0032 Privileged SFOS function 0033 Power fail recovery error 0034 A line exception 0035 F line exception 0036 Exception not claimable 0103 Hardware watchdog time out 0104 C Memory checksum error 0106 RAM error 0107 ROM error 010B Abnormal power loss O10D EEPROM restore error 0113 Scan watchdog time out 0114 L Memory checksum error Refer to Section F 1 for more information 0
231. ion 06 00 Third Edition 2804693 0003 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com LIST OF EFFECTIVE PAGES Pages Cover Copyright History Effective Pages iii xxi 1 1 1 13 2 1 2 20 3 1 3 28 4 1 4 58 5 1 5 24 6 1 6 35 7 1 7 12 8 1 8 8 9 1 9 25 A 1 A 5 B 1 B 9 C 1 C 23 D 1 D 7 E 1 E 16 F 1 F 6 Index 1 Index 10 Registration Description Third Edition Third Edition Third Edition Third Edition Third Edition Third Edition Third Edition Third Edition Third Edition Third Edition Third Edition Third Edition Third Edition Third Edition Third Edition Third Edition Third Edition Third Edition Third Edition Third Edition Pages Description Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Contents Preface Chapterl System Overview 1 1 JUI PEE 1 2 Introductio M PEPPER 1 2 Compatibility with Previous CPUS 2 ccc RII 1 2 Featureson New CPU Models sssssssseeeee eee 1 3 PROFIBUS DP 2 sagasa inmate dur erc a aeaa AA HR ERR RU on od mame RU UR Run RR RR IRR 1 4 PROFIBUS User Organizations sssssssssseeee eee 1 4 Using OtherNetworks 00 cece eae 1 4 12 System Features wo cece cece cece eee uaa hau uana hun n 1 6 Product SpecificationsOverview 6c cece eee 1 6
232. ipswitch controls the display mode of the RBC Status Mode Display to show either station address or module status e When switch 11 is set to 1 the station address of the RBC is displayed as a three digit number one digit at a time The display goes blank for a short period of time between each digit and for a long period after the last digit For example if the RBC station address is 18 it will be displayed according to this pattern O short pause 1 short pause 8 long pause O short pause 1 short pause 8 long pause The three digit pattern repeats until the mode is changed e When switch 11 is set to 0 the status of the RBC is displayed according to the codes shown in Table 5 8 NOTE When switch 11 is set to display the RBC status a decimal point on the status display indicates that the 50X Ignore Mismatch M ode parameter is enabled The point appears before the status code as shown below 50X Ignore Mismatch Iis 50X Ignore Mismatch Ii Mode Enabled L1 Mode Disabled LH If the 50X Ignore Mismatch Mode is disabled the default value that conforms to the DP standard the RBC status display does not show a decimal point For more information about this parameter see page 5 24 The Status Display mode switch is read periodically during operation The switch may be changed at any time Table 5 8 505 PRORBUS DP REC Status Codes Module Ready nce No errors detected Serious malfunction Acti
233. ircuit Breakers Fusing the Use the following guidelines for installing fuses circuit breakers see Contoller and Figure 2 7 The sizes and types of fuses circuit breakers depend on the Remote I O Base specified power distribution requirement e A circuit breaker before the isolation transformer Isolation transformers may not be required if your power distribution system does not havea high level of noise e Afuseafter the isolation transformer e An external fuse before each power supply Input Power Line 110 220 VAC Isolation Transformer Optional Grounds Np P S Line Neutral Ground P S Line Neutral Ground Controller Remote I O Base Figure 2 7 Fuse Circuit Breaker Placement NOTE In order to ensure a proper level of safety compliance observe local codes practices and guidelines SIMATIC 545 555 575 System Manual Pre installation Guidelines 2 11 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 2 5 Electric al Noise Definition and Electrical noise is defined as any unwanted electrical signal which enters Source the control equipment Noise signals cover the entire spectrum of frequencies and may have any wave shape A major difficulty with noise problems is that they can occur at random intervals Continuous or frequent perio
234. is not rechargeable The battery in these CPU models is accessible through the bezel door on the front of the module as shown in Figure 3 9 When the battery indicator blinks or goes off the battery has dropped below the voltage required to maintain memory and should be replaced Request battery kit replacement part number PPX 2587678 8005 for the appropriate replacement battery Refer to page 3 19 for guidelines on handling batteries NOTE As a good engineering practice design your user program to monitor Status Word 01 on a cydic basis and trigger an alarm if the battery low bit 15 is set Additionally you can usethe battery life specifications listed in Table A 2 to determine how often you routinely replace the battery a m Replaceable Lithium Battery Figure 3 9 Battery Location in 1105 and 1106 CPU Modules 3 16 Installing 505 System Hardware SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Replacing the Follow these steps to replace the battery Battery in 1105 1106 CPUs 1 Maintain power tothe CPU 2 Openthe battery cover 3 Pull out the old battery and disconnect the battery connectors 4 Connect the battery connectors to the replacement battery 5 Placethe new battery in the battery compartment making sure the connecting wires are fully inserted through the holes in the compartment and close the cover
235. itch allows you to select between RS 422 and RS 485 Use SW1 as follows e Set SW1 tothe left when you use RS 232 or RS 422 cabling e Set SW1totothe right when you use RS 485 cabling RS 485 uses a single twisted pair to transmit and receive data between the programming device and the 545 555 CPU Multiple CPUs or multiple programming devices on this RS 485 link are not supported and must not be used 3 24 Installing 505 System Hardware SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com For Communication Port 2 the maximum permissible cable length depends on the type of connection used e TheRS 232 RS 423 connection can extend a maximum of 50 feet 15 m e TheRS 422 RS 485 connection can extend a maximum of 3300 feet 1 km The cable installation for RS 485 or RS 422 can indude a 120 ohm termination resistor across the signal conductors at each end of the cable Theresistor provides a higher noise immunity and better long distance communication I O Ports The 545 1104 1106 and 555 CPUs have two remote I O ports e Thel O port is a 9 pin female port used to communicate directly with Series 505 RBCs by means of a shielded twisted pair RS 485 cable e ThePROFIBUS DP port is a 9 pin female port used to communicate to a variety of PROFIBUS DP slaves and field devices in daisy chain fashion across a shielded twisted pair RS 485 cable that
236. j e m m o o Pleyel ele relol of Of CO Of Of Of O BJ PI RIT RP RPI RPI RI rl o of of co of o Pl Rey RPlLolol of of PL RPL RPI Rl of oO Of CO BP BP BP RP Olol of Of BP BP RIL R olo ejoj oleje oO OF PT Rr OO OF FP RF OO OF FP RF OO Of PIL FR OF OF PIR oO CO PIR ojej OF ry oO Fe OF RF OO FR OF FR OF FI OF RF OO FR OF FR OF FB OF RF OF FR oO RIO m m m m H m m H H Bimeo mnb jmo n ojojojojo jo jo PlelePlelelelele Pl e Pie PlelePlelelelele m o m PlLrl OoO oO OO Of FP RP rR RIO OF OF OF FP RPT RI rR O CO OF OF FJ RIT_RI rR O OO CO oO O OF FIT rR O OF FIL FR O OF FTF O OF FLT rR O Ole rR O CO FTF ojl oleje ojo ej olje oje Of RF OF FF Of FR OF RF Of RF OF FR OF FJ OF FR OF FR OF RF OF FR OF RI oO PlePlePlelelel el ele m eo m m m m m m NOTE It is possible to select Station Addresses 126 or 127 on the dipswitch but these addresses are invalid SIMATIC 545 555 575 System Manual Installing Remote Base Controllers RBCs 519 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com PPX 505 6870 RBC continued Reset Pushbutton The RESET pushbutton on the front of the RBC is deliberately recessed to prevent accidental activation When you press this button a global reset is immediately performed on the RBC After completing rese
237. l Enors 9 14 Troubleshooting When a fatal error occurs the CPU causing the error attempts to do the following actions SY SFAIL is asserted on the VME bus This action causes all 575 CPUs in the system to enter the FAULT mode TheSYF LED is turned on The PCG LED is turned off Thefault relay is opened O ports are disabled discrete outputs are turned off and word outputs are held in their last valid state This action can be overruled by a remote base controller configuration option Communication ports are cleared and re initialized Applications are reconnected totheir local ports Pending or queued tasks are cleared SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Steps to Clear Try to clear the fatal error by following the steps listed below When the 575 Fatal Enors PCG LED turns on the fatal error has been cleared f communication errors occur ensure that the battery backup is enabled and then cyde power to the CPU If communication errors continue record No Communication as the fatal error and goto step 4 1 Determine the fatal error condition by selecting AUX 29 from the Auxiliary Function Menu on your programming unit Record the fatal and non fatal error s listed along with the date time and CPU serial number for later reference Execute AUX 11 PLC Partial Restart If this fails to clear the error
238. ling 3 26 installation flowchart 3 2 module power requirements B 3 power supply 24 VDC unit 3 11 installing 3 8 placement in base 3 8 power consumption 3 8 replacing fuse 9 19 selecting voltage 3 9 troubleshooting 9 19 wiring 3 10 RBC assigning base numbers 5 9 base number switch 5 9 hardware watchdog timer 5 6 installing in base 5 4 off freeze jumper 5 6 output state selection 5 6 Index 8 Artisan Technology Group Quality Instrumentation status display 5 12 remote I O channel overview 1 13 spare parts D 2 system components D 2 overview 1 8 specifications overview 1 6 1 7 Slaves number permitted 1 4 supported on PROFIBUS channel 1 4 configuring with COM PROFIBUS 1 11 5 24 SmarTune automatic PID loop tuning 1 3 SoftShop programming software 1 11 Spare parts 575 D 5 Series 505 D 2 Specifications general A 3 physical and environmental A 2 Series 505 1 6 1 7 Start up procedures 8 2 Station address assigning 5 17 Status display RBC PROFIBUS DP 5 22 Series 505 5 12 Status words using in troubleshooting 9 17 Switch emergency stop 2 4 Switches inch 2 5 jog 2 5 Safety 2 4 SYSRESET in 575 CPUs 4 27 System features of 1 8 System components 575 D 5 Series 505 D 2 System controller installing in VME bus base 4 34 4 35 replacing in VM E bus base 4 37 Guaranteed 888 88 SOURCE www artisantg com T Technical assistance xxi Tem
239. lity Instrumentation Guaranteed 888 88 SOURCE www artisantg com 2 Connect the RF coaxial cable to the PPX 505 6860 port that is labeled RF Tol O BASES See Figure C 8 RS 485 RF I O Channel Converter 22 RS 485 I O E From PLC RF To 1 O BASES 505 6860 NEN Figure C 8 RS 485 RF Connector Ports SIMATIC 545 555 575 System Manual Upgrading Existing Series 500 Installations C 23 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Appendix D Seres 505 and VME Components D 1 Series 505 System Components eeeeeeeeee een nnn nn nn nnn D 2 D 2 575 VME System Components ssssssssssnnnsnnnnsnnnnnnnnnnnnnsnnnnnnnnnnn D 5 D 3 Recommended Spare Parts cccccceeecee cece eee eee eee D 6 Spares for Series 505 System 1 knee nnn D 6 Sparesfor575 System 2 eee n nn D 7 SIMATIC 545 555 575 System Manual Series 505 and VME Components D 1 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com D 1 Series 505 System Components Table D 1 lists components used in Series 505 systems Table D 1 Series 505 System Components PPX 545 1103 1105 96 Kbyte RAM CPU w 12 MHz 68020 processor PPX 545 1104 1106 192 Kbyte RAM CPU w 12 MHz 68020 processor PPX 555 1103 384 K byte RAM CPU w 25 MHz 68020 processor PPX 555 1104 1920 Kbyte RAM CPU w 25 MHz
240. lity Instrumentation Guaranteed 888 88 SOURCE www artisantg com Table E 11 shows the module specifications and Figure E 6 shows the effect that temperature has on current output for the PPX 575 4732 Table E 11 PPX 575 4732 Specifications Optical isolation 1500 Vrms Isolation between commons 500 Vrms Isolation between chassis ground and 1000 Vrms user circuits 32 Outputs Commons One 8A 125 V normal blow 5 x 20 mm Fuses fuse per common 4 fuses total Replace only with UL CSA listed fuse Output type Non latching unprotected Operating voltage range 4 5 to 36 VDC Maximum off state leakage current 0 2 mA Maximum on state voltage drop 2 2 VDC Minimum load current per point 1 0 mA 24 VDC Maximum delay time through module with 5 mA load 2 ms off to on Inductive load kickback Diode protected Temporary overload 5 0 A for 1 ms User power current with no load With fan cooling Without fan cooling oc 4 on i cm 16 on ton 32 on 16 on 0 0 0 0 32 on 0 10 20 30 40 50 60 70 0 10 20 30 40 50 60 70 Temperature C Temperature C Figure E 6 PPX 575 4732 Current Point vs Ambient emp SIMATIC 545 555 575 System Manual 575 O Module Specification amp Pinouts E13 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Disc rete DC Output Module
241. low baud rates from 9600 baud to 1 5 M baud as listed in Table 6 5 Pin 6 BIAS SUPPLY 5V Bias Resistor 390 ohm 1 8 W 5 mene Internal Connection B _ Internal Connection B Termination Resistor 220 ohm 1 8 W 5 Internal Connection A Internal Connection A Bias Resistor 390 ohm 1 8 W 5 Pin 5 Pins 1 2 4 7 and 9 are not connected BIAS SUPPLY GND Figure 6 17 9600 baud to 1 5 Mbaud Connector Schematic PROFIBUS DP I O channel connection to some slaves cannot be accomplished with the standard Siemens connector Refer to the slave documentation for termination and bias options and ensure that every PROFIBUS DP device that requires termination and bias meets the schematics shown in Figure 6 16 and Figure 6 17 Connector schematics and mechanical features are subject to change without notice Check with your local Siemens Energy amp Automation Inc distributor for the latest version SIMATIC 545 555 575 System Manual Cabling and Wiring the Sytem 627 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Installing PROABUS DP I O Cables continued Installing a The following procedure describes how to attach a typical connector to your PROHBUS DP cable Also consult the instructions that come with your specific Siemens Connector connector 1 Open the connector housing by loosening both housing screws see Figure 6 18
242. lowing options for the PPX 505 6851 RBC A and B versions and PPX 505 6850 A and B RBCs are user selectable e Thestate of the output points that are controlled by the RBC after remote I O channel communication is lost jumper selectable e RS 232 423 baud rate dipswitch selectable e RBC station address thumbwheel selectable on the A model RBCs rotary switch selectable on the B model RBCs When I O channel communication to a base is lost the state of the outputs is determined by the selection made on the RBC jumper J P6 Off F reeze See Figure 5 4 for the location of the Off F reeze jumper on the A models and Figure 5 5 for the B models For discrete output modules the state of the outputs is determined solely by the position of the J P6 Off F reeze jumper For analog word output modules the state of the outputs is influenced not only by the position of the Off F reeze jumper but by the output module s Zero H old Last Value selection if the module has that option See Table 5 1 Table 5 1 Analog Word Output States Analog Word Module Analog Word Zero Hold Selection Output State off Zero Zero Off Hold Last Value Last Value Off no selection Last Value Freeze Zero Last Value Freeze Hold Last Value Last Value RBC Off Freeze Selection Freeze no selection Last Value See the user manual of your analog word output module for further details Notice that the Freeze option on
243. ly Since the battery is shaped like a coin it is easy for the screwdriver blade to make contact with both rim and underside which would cause a short CAUTION The positive contact of the battery socket is a thin metal strip easily bent If you deform the positive contact of the socket the socket is ruined Extract the battery gently so that you do not overflex the socket Follow the instructions given below e fyou pull the battery straight up from the socket you could spring the positive contact and ruin the socket Instead lift the battery up to the height of the socket rim and carefully slide it out making certain you do not bend the socket s positive contact 5 Slidea fresh battery into the socket being careful to observe polarity The battery and the socket are both marked with plus signs indicating positive contacts The positive contact is the upper contact 6 Reinstall the CPU in the chassis 7 Ensurethe battery is enabled SW9 is set to On See page 3 22 8 Restore power tothe chassis SIMATIC 545 555 575 System Manual Installing 505 System Hardware 3 21 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 3 10 Setting the CPU Dipswitc hes Dipswitch Location and Settings Enabling Battery Bac kup Dipswitches are used to set 545 555 CPU operating parameters The dipswitches are located near the front of the CPU behind th
244. m getting into the system it also helps prevent electrostatic discharge and other types of electrical noise interference e Ensure that all I O interface cables are properly connected to I O interface connectors e Ensure that all configured bases are properly connected that there are no crimps or breaks in the cable and that base addresses are correct e Ensurethat connector pins are not bent that all modules are securely plugged into the base s and that bezel screws are tightened 8 amp 2 Starting Up the System SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 2 Initializethe CPU by completing the following procedures e f you have not already done so disable the CPU battery For 545 555 CPUS turn off switch 9 on the CPU front dipswitch For 575 CPUs disconnect the battery e Turn on power to the base e With the battery disabled and an unprogrammed E EPROM the CPU clears memory and enters PROGRAM mode e Enable the battery backup circuit by turning on switch 9 The battery LED should light The CPU is now initialized NOTE If the battery LED does not come on the battery is low The LED should be lit when the system is powered and a good battery is installed and enabled 3 Connect your programming device to one of the CPU communication ports Placethe CPU in PROGRAM mode 4 Using your programming device enter the me
245. mal Termination Switch Connector Housing Connector Interior SIEMENS Internal Termination Switch Pit c m ON 1 lt gt OFF 0 YT Figure 6 15 Low Baud Rate Connector Intemal Termination Switch SIMATIC 545 555 575 System Manual Cabling and Wiring the Sytem 625 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Installing PROABUS DP I O Cables continued PROHBUS DP Figure 6 16 shows the schematic for PROFIBUS DP connectors designed to Connector handle all baud rates from 9600 baud to 12 M baud as listed in Table 6 4 Schematics Pin 6 j BIAS SUPPLY 5V Bias Resistor 390 ohm 1 8 W 5 Pin3 Internal Connection B TX RX ternal Gonne Internal Connection B Termination Resistor 220 ohm 1 8 W 5 On FL Internal Connection A i Internal Connection A Bias Resistor 390 ohm 1 8 W 596 Pin 5 BIAS SUPPLY GND Pins 1 2 4 7 and 9 are not connected Figure 6 16 9600 baud to 12 Mbaud Connector Schematic 6 26 Cabling and Wiring the System SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Figure 6 17 shows the schematic for connectors designed only to handle
246. meets PROFIBUS standards The 545 1103 CPU has the option of a PROFIBUS DP port if you install the PPX 505 CP5434 DP annex card SIMATIC 545 555 575 System Manual Installing 505 System Hardware 3 25 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 3 11 Installing Series 505 I O Modules Mixing I O A mix of I O modules can be used with one base you can combine input Modules output word input word output and intelligent modules in a single base Installing and Use the following steps for installing and removing Series 505 1 0 modules Removing in the base Refer to Figure 3 14 I O Modules a WARNING Do not install or remove any modules to or from a powered up base Installing or removing any module from a powered up base could cause unexpected operation which could cause death or serious injury to personnel and or damage to equipment Disable all power to the base before installing or removing any module 1 Disconnect power to the base 2 Usespecification sheets provided with the modules to install option and wiring selections for your application 3 Position thel O module so the bezel is facing you Electronic equipment is sensitive to and can be damaged by electrostatic discharge Ensure that personnel make contact with a static dissipative pad and or wear a grounded wrist strap when handling the CPU cards or modules 4 Grasp the top and bottom
247. mentation Guaranteed 888 88 SOURCE www artisantg com 9 7 Toubleshooting Power Supplies Completethe following steps when troubleshooting a power supply 1 Ensurethat the power budget has not been exceeded and that the power supply module is properly installed 2 Disable all power to the system for at least 90 seconds 3 Restore system power 4 Ifthe problem still exists turn off power to the system again and follow the steps below a WARNING To minimize risk of shock hazard always turn off power to the base before removing or installing a power supply module Failure to do so could cause death or serious injury and or damage to equipment Ensure that power to the base is turned off before removing or installing a power supply module 5 Toverify that voltage selection is correct remove the power supply module from the base This step is not required for the PPX 505 6663 or PPX 575 6660 power supplies a Ensurethat the power supply module is set to the correct line voltage b If the voltage has been set incorrectly wait at least one minute before touching the jumper Then move the jumper to the appropriate quick connect pin 6 If you removed the power supply module to check the voltage selection re install the power supply now 7 Ensurethat the wires attached to the terminal screws on the bezel are secure and that the user supplied power source is functional 8 Verify that the fuse located
248. mentation RENTALS ITAR CERTIFIED yop aed Contact us 888 88 SOURCE sales artisantg com www artisantg com
249. mmon PPX 505 4832 32 output 85 265 VAC 2A 8 outputs common PPX 505 4908 8 output Form C 20 265 VAC or 4 5 30 VDC PPX 505 4916 16 output NO 20 265 VAC or 4 5 30 VDC 8 outputs common PPX 505 4932 A 32 output NO 20 265 VAC or 4 5 30 VDC 8 outputs common PPX 505 5417 16 output Form C 120 VAC 10 125 VAC relay out PPX 505 5518 16 output Form C 120 VAC high current relay out PPX 505 6010 32 input simulator PPX 505 6011 PPX 505 2555 32 output simulator 16 input analog 14 bit differential PPX 505 2556 16 input Thermocouple with open T C detect PPX 505 2557 16 input RTD with open sensor detect PPX 505 6108 A B 8 input analog 12 bit singl e ended PPX 505 6208 A B 8 output analog 12 bit single ended PPX 505 6308 8 input BCD word PPX 505 6408 8 output BCD word PPX 505 7012 8 input 4 output analog PPX 505 7016 8 input 4 output analog bipolar voltage outputs PPX 505 7028 A 8 input Thermocouple isolated PPX 505 7038 8 input Resistance Temperature Detector Series 505 and VME Components D 3 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com D 4 Series 505 System Components continued Table D 1 Series 505 System Components continued Part Number PPX 505 6504 O base 4 slots PPX 505 6508 O base
250. mory and I O configuration Refer to Table 8 1 Table 8 2 Table 8 3 Table 8 4 or Table 8 7 as appropriate 5 Entertheuser program Seethe SIMATIC 545 555 575 Programming ReferenceU ser Manual for programming information 6 Useyour programming device to OG motors solenoids or other positioning devices one at a time to establish correct rotation or positioning After all the steps are performed and verified placethe CPU in RUN mode SIMATIC 545 555 575 System Manual Starting Up the System 8 3 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 8 2 CPU Memory Configuration Memory The CPU user memory is user configurable The actual ranges of memory Configuration types depend upon how the memory has been configured Ranges for memory types are listed by CPU model in Table 8 1 through Table 8 7 You can increase the memory allocated to a particular memory type a block at a time up tothe maxi mum listed Block sizes vary with the memory type Refer tothetable for your CPU For example when you increase L memory by one block from 16 K bytes to 17 K bytes system memory reserved for L memory increases from 48 K bytes to 51 Kbytes Maximum The size of configurable system memory is determined by the CPU model Configurable You cannot configure all memory types to their maximum allocation size Memory simultaneously For example on a 545 1103 if L memory is configured to 30
251. mounting in an NEMA cabinet Base 1 Open NEMA enclosure door 2 Drill four holes in sub panel of NEMA enclosure with a 21 drill bit Refer to Figure 4 7 for screw hole dimensions for each base Ensurethat chips from drilling do not contaminate other equipment 3 Position the baseinsidethe NEMA enclosure NOTE Besurethat the bracket holes and the tapped holes in the sub panel are aligned 4 12 Installing 575 System Hardware SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 4 Install 10 screws through each bracket hole to attach the base to the sub panel See Figure 4 8 Figure 4 8 Mounting Base in NEMA Enclosure Grounding the A good grounding system is essential for proper operation of the 575 system Controller Chassis Follow the guidelines in Section 2 8 to ensure that the VME bus baseis properly grounded SIMATIC 545 555 575 System Manual Installing 575 System Hardware 4 13 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 4 7 Installing the 575 Power Supply Overview Two power supplies are available for use in 575 bases The PPX 575 6660 power supply provides up to 185 W tothe VMEbus base and operates on 110 VAC input voltage The PPX 575 6663 power supply provides up to 300 W tothe VM Ebus base It operates on either 110 or 220 VAC input voltage depending on t
252. mpting to operate the power supply at 220 VAC with 110 VAC selected or 110 VAC with 220 VAC selected will result in damage to the power supply Double check your power supply voltage before you attempt the operation 4 Tighten screws to no more than 8 in Ib 0 9 N m torque 4 18 Installing 575 System Hardware SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 575 6660 575 6663 o POWER E GOOD 575 6660 SAEAVLT O35 12 12 GND AC FAIL 9 SYS RESET 85 WATT POWER SUPPLY REPLACE ONLY WITH 8AMP 250 VOLT SLOW BLOW FUSE Q FUSE APPROVED CLASS I DIV 10 VAC 2 HAZ LOC LINE 110 VAC POWER Q NEUTRAL 50 60 HZ 185 GROUND WATTS G 2 G Q SIEMENS O POWER SIMATIC GOOD 575 6663 FAULI Q 145 12 12 GND AC FAIL SYS RESET POWER SUPPLY 300 WATTS W FANS 100 WATTS W O FANS 866Y LISTED IND CONTROL EQUIP REPLACE ONLY WITH GR 10 AMP 250 VOLT SLOW BLOW FUSE LR44226 f O FUSE APPROVED CLASS DIV 2 HAZ LOC LINE NEUTRAL TAA WIEANS T4 W O FANS GROUND 110 220 VAC 50 60 HZ 2 Power connector screws Figure 4 11 Connecting Power to the 575 Power Supply SIMATIC 545 555 575 System Manual Installing 575 System Hardware Artisan Technology Group Quality Instrumentation
253. n Guaranteed 888 88 SOURCE www artisantg com 3 9 3 10 3 11 Replacing and Handling the Battery ssseesese eese nnn nnn nnn Lithium Battery in the 545 and 555 1105 1106 CPUs isusuuuuueeeeeeeees Replacing the Battery in 1105 1106 CPUs ssssssssssseeeee enses Lithium Battery in the 545 and 555 1103 1104 CPUs Liuuuuuueeeeeseeee hiscere pP Using and Handling Batteries ssssssssseeeseeee e Transporting Batteries 0 ieee mnn Stonng Batteries scons sorte etre ite Eo od doe ek QS e RA MR A Discarding Batteries iisissssssssssssssee ehh Replacing the Battery in 1103 1104 CPUS 0 0 Setting the CPU Dipswitc hes eeeeeeeeeeeeeern nnn nnn nnn nnns Dipswitch Location and Settings slssssssssssssseeese eee Enabling Battery Backup sssssseseee mma Enabling the Auto Recompile Function 00 eee Setting Baud RIES sexii iaa sa aaia nn tenet nnn COMMUNICATIONS POM sseni aviei samea ac ke cle p Rer Ohad Pee thee ER ea hee CommunicationsPort2 iia ia oaa a a a AAR E AR E AE O EAEE E E RA OPO MS o aiaiai i a ae Seiad Roe dati io eds ei tne ae A Installing Series 505 I O Modules sussnsnnsnnnnnnnnnnnnnunnnnnunnnnnnnnnnnnnn Mixing VO Modules css che d rete bt tee E n co o e De My te YR bae bun Installing and Removing I O Modules sssssseeese enn m Chapter
254. n ensure that there are no memory overlaps in board addresses SIMATIC 545 555 575 System Manual Installing 575 System Hardware 4 53 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Using Boards in the VMEbus Base continued Table 4 7 VMEbusj 1 Backplane Connector Pin Assignments 1 DOO BBSY D08 2 D01 BCLR D09 3 D02 ACFAIL D10 4 D03 BGOIN D11 5 D04 BGOOUT D12 6 D05 BG1IN D13 7 D06 BG1OUT D14 8 D07 BG2IN D15 9 GND BG2O0UT GND 10 SYSCLK BG3IN SYSFAIL 11 GND BG30UT BERR 12 DS1 BRO SYSRESET 13 DSO BRI LWORD 14 WRITE BR2 AM5 15 GND BR3 A23 16 DTACK AMO A22 17 GND AM1 A21 18 AS AM2 A20 19 GND AM3 A19 20 IACK GND A18 21 IACKIN SERCLK A17 22 IACKOUT SERDAT A16 23 AMA GND A15 24 A07 IRQ7 A14 25 A06 IRQ6 A13 26 A05 IRQ5 A12 27 A04 IRQ4 All 28 A03 IRQ3 A10 29 A02 IRQ2 A09 30 A01 IRQ1 A08 31 12V 15V STDBY 12V 32 V V V NOTE The asterisk designates an active low signal 4 54 Installing 575 System Hardware SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com VMEbus Access When using the 575 CPU and third party boards you must be aware of the Limitations following limitations e The575 CPU VMEbus data strobe timeout is 40 microseconds The thi
255. n Figure 2 4 Idle State Fault relay operation begins in the dle state and transitions to one of two states The fault relay transitions to the Fault state if a fault is detected during CPU initialization or if you perform a battery good powerup in fault mode Otherwise the fault relay transitions to the Normal state Normal State The fault relay can transition to either the Idle state or the Fault state from the Normal state If power is turned off the fault relay transitions to the Idle state If a fatal error is detected the fault relay transitions to the Fault state 2 6 Pre installation Guidelines SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com NORMAL closed Non fault 575 CPU Power off initialization Fault Detected Power up Reset AUX 11 or Fault Power off AUX12 Detected restart FAULT open Figure 2 4 Software State Diagram Fault State Thefault relay opens whenever the 575 CPU enters the FAULT mode or loses power To dose the fault relay after entering FAULT mode transition the 575 CPU to PROGRAM mode either by executing an AUX 11 or AUX 12 from TI SOF T or by performing a bad battery power cyde NOTE If a hardware watchdog timeout sends the CPU into FAULT mode WDG LED is illuminated when the 575 is configured as USER CONHGURED and DO NOTASSERT WAIT FOR SYSRESET in other words SW5 on the I O an
256. n a Series 505 base Removing the RBC A WARNING Installing or removing an RBC from a powered up base disrupts your process Installing or removing an RBC from a powered up base could cause unexpected operation which could cause death or serious injury to personnel and or damage to equipment Ensure that all power is disabled before installing or removing the RBC O ONUTON The RBC is sensitive to and can be damaged by electrostatic discharge Ensure that personnel make contact with a static dissipative pad and or wear a grounded wrist strap when handling the RBC l Verify that all jumper and dipswitch selections are correct 2 Disconnect power to the base 3 Position the RBC sothat the bezel is facing you 4 Grasp thetop and bottom of the RBC 5 Carefully push the RBC into the slot until it mates with the backplane connector 6 Tighten top and bottom bezel screws RBCs are not designed to be installed in VME bases Doing so results in damage to equipment Never attempt to install any RBC in a VME base To remove the RBC complete the following steps 1 If cables are attached remove them from the front of the RBC 2 Disconnect power to the base 3 Loosen top and bottom bezel screws B Carefully pull the RBC from the base 5 4 Installing Remote Base Controllers RBCs SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOU
257. n the PROFIBUS DP configuration as a parameter in an Immediate instruction Upon a transition from Program to Run the CPU s RLL compiler automatically searches the PROFIBUS DP configuration when compiling I ORW box instructions immediate contacts and immediate coils and generates special code if a match is found between an Immediate instruction operand and a DP configuration entry This code automatically implements logic that allows immediate program access to from the shared DP buffer FA Enhancements in Late Model CPUs SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Changing a PRORBUS DP Slave Configuration Typical Update Time Example NOTE Be careful not to enter duplicate I O references because the first reference found is the one that is used Due to the previously mentioned special code that is generated by the CPU s compiler the configuration of a DP slavethat has an associated immediate instruction can nolonger be changed while a PLC is in run mode If attempted the error message ILLEGAL REQUEST IN CURRENT OPERATIONAL MODE will be given You must make changes to the DP configuration in Program mode so that the required program to run transition occurs to cause an RLL compile Immediate instructions can be added or deleted at any timeto any correctly configured points using the run time edit function In order to estimate a t
258. n the VMEbus Base Communicating Refer to the SIMATIC 545 555 575 Programming Reference User Manual with the CPU for details concerning communication support between 575 CPUs and third party masters using VMEbus READ WRITE instructions Refer to the SIMATIC 575 Interboard Communication Specification PP X 575 8103 x for details on message support between 575 CPUs and third party masters Table 4 5 summarizes the VME bus specifications for the 575 CPUs Table 4 5 SIMATIC 575 CPU VMEbus Specifications Function Comments System Requirements SYSRESET 1 ACFAIL must be asserted at least 2 milliseconds before SYSRESET is asserted ACFAIL 1 ACFAIL must be asserted at least 2 milliseconds before SYSRESET is asserted 45V STDBY Must be powered with 5 V during normal operation and a minimum of 43 V during power off Services Provided by the System Controller Arbiter Prioritized PRI SYSRESET 1 Driven during fault recovery if configured See Section 4 11 VMEbus Timer 40 microseconds IACK Daisy chain driver Provided SYSCLK 16 MHz Local Bus Timer Limit to get on the 255 microseconds VMEbus Requester 2 Release When Done RWD and Request on No Request similar to FAIR requester The 575 requests on Level 3 Interrupter 34 Release on acknowledged ROAK DO8 O Address space supported A24 D16 DO8 EO A16 D16 DO8 EO Address modifiers supported 2916 Short non privileged access gt 2D1e Short supervis
259. nappropriate time should be considered safety critical The safety chain permits the system to be placed into a safe state for both the operator user and the process 2 8 Pre installation Guidelines SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com In Figure 2 5 relay CRM is theinterposing relay and FLT is a 24 volt relay in thelow voltage safety chain Note the use of pushbutton switches for master stop normally closed and master start normally open Power to the safety critical loads is not applied until the master start switch is turned on If the master stop switch is turned on then the safety critical loads are turned off If one of the fault relays opens then the safety critical loads are also turned off Refer to Section 2 2 for more information on safety considerations Es 115V zav m 575 VME System Output Modules P Master Stop Master Start PB PB l O oO e CRM Figure 2 5 Safety Chain Controlling Outputs Example SIMATIC 545 555 575 System Manual Pre installation Guidelines 2 9 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 575 Fault Relay Operation continued To use the fault relay to control the power to the ele
260. nd third party boards Save the controller memory with TI SOFT before you remove or install boards Do not leave any open slots between cards Any open slots must be on the far right side of the base unless you set the dipswitches on the backplane to bypass the empty slots See Figure 4 20 You can place third party boards between SIMATIC VMEbus I O modules but be sure to install any boards that do not pass daisy chain signals to the right side of the boards that require them Standard VMEbus modules have a 0 8 inch front bezel Modules with 0 8 inch wide front bezels can be installed directly adjacent to each other If you use SIMATIC 575 VME I O modules with a 1 inch front bezel in the 16 slot PP X 575 2130 base you need to install a 0 6 inch blank filler bezel PP X 2589739 8015 to ensure proper air flow in the base A 1 inch wide VME module takes two slots in the 16 slot base Some VMEbus modules use tab connectors to secure the front bezel to the base F ollow the instructions provided with your module for proper installation procedures To fill any gaps left by empty slots and to ensure proper air flow in the base install an 0 8 inch PPX 2589739 8014 or 0 6 inch PPX 2589739 8015 blank filler bezel as appropriate This also ensures that the system meets environmental safety and noise specifications 4 40 Installing 575 System Hardware SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation
261. nex card is set to the Off position the following procedure must be followed to re enable the fault relay e Execute a power cycle After the power cycle the 575 system is still in FAULT mode and the fault relay on each of the 575 2104 CPUs in the system is open e Execute AUX 11 or AUX 12 from TISOFT The 575 CPUs are now in PROGRAM mode and the fault relay on each of the 575 CPUs in the system is closed SIMATIC 545 555 575 System Manual Pre installation Guidelines 2 7 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 575 Fault Relay Operation continued Time Delay Thetime delay required for the fault relay to operate correctly is dependent on the modules in the system The fault relay doses within 10 seconds of power being applied to the system if no fault is detected and if only SIMATIC 575 VME equipment is used in the VME base If you usea third party master to log into the 575 system the fault relay is delayed Third party masters extend the time needed for a login only if they log into the 575 system or drive SYSFAIL for a longer time than the 575 CPUs If a third party board either master or slave drives the SYSFAIL then the fault relay does not close until the SY SFAIL signal is de asserted You may need to bypass the fault relay circuit during debug when a system fault is being tracked down the fault relay does not close until the fault is removed Refer to Section
262. ng a Program into an EEPROM eere nnn nnn nnn 7 10 Editing a Program Stored in an EEPROM sssssseeenn enhn nnn nnn 7 12 Chapter8 Starting Up the System 8 1 8 2 Powering Up the System 2 2 2 ccc cece cece cece eee eee 8 2 OVEWIEW eT 8 2 Start Up Procedure S siosar cte tete p te Ped eee be eee eee doe td e 8 2 CPU Memory Configuration ssssssesseee enne nnnm 8 4 Memory Configuration 00 cece ha 8 4 Maximum Configurable Memory sssssseeee e r nrnna 8 4 Contents ix Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Chapter9 Troubleshooting 9 1 9 2 9 3 9 4 9 5 9 6 9 7 9 8 9 9 9 10 9 11 Troubleshooting by Using Auxiliary Functions eres 9 2 OVelViQW atamaii iina op del od ree artis detto ne Ro doe oh e ie i 9 2 Power up Restart Partial Restart and Complete Restart 000000005 9 2 575 Fau lERestartts 2452 cx meae rese ie e ihr eae e uh eie dub dau te edo de bae 9 2 Compare PLC to Disk sesira ci adeps i decet dawee SP a Saee sun ce 9 4 Run 545 555 PLC Diagnostics sssssssssess eee 9 4 Display Failed VO ssssssssssee RII mna 9 4 PLC Operational Status tan tena herr Re ehm REF Fior Rei rr ud 9 4 Troubleshooting by Reading LEDs eeseeee enn mnn nh 9 6 545 555 LEDS 5s ixi niikeReueabte usus ASIDE LO RRLIUREE QUNERI NR OS ces RR 9
263. nk that is shared by both the main CPU and the PROFIBUS DP master coprocessor more often than once per RLL scan which is how it was previously The new Fast PROFIBUS DP I O feature provides the capability to do multiple updates of analog and discrete PROFIBUS DP I O points per RLL scan where a large program has increased the RLL scan to a point that it can no longer provide fast enough control for certain operations connected by PROFIBUS I O This is easily accomplished by placing these immediate instructions in a cydictask Task 2 that is scheduled to operate at a faster ratethan the RLL executes To be effective the fast PROFIBUS DP I O update feature requires the PROFIBUS DP channel update rate to be set sufficiently high For example at 12 M baud an asynchronous PROFIBUS DP I O channel will generally update and place new I O information in the shared memory buffer every 2 to 3 milliseconds Normally a large RLL program may require 100 or more milliseconds to execute E ven taking into consideration the small amount of time of most O points to activate and the time for the PLC to make reasonable calculations the fast PROFIBUS DP I O feature provides the opportunity for several O updates per RLL scan that could make a difference in whether or not the remote process could be properly controlled To use fast PROFIBUS DP I O update first set the PROFIBUS DP mode to Update Mode OPERATE ASYNCHRONOUS Then use any valid I O point i
264. noise as described below A few SIMATIC 505 customers have experienced an occasional CPU fatal error typically several months or more between failures on a specific CPU that usually results in a TISOFT or SoftShop message such as Program Memory Diagnostic Error These fatal errors generally occur in an environment that includes various equipment adjacent to the PLC such as UPS systems variable speed drives and battery chargers These types of equi pment often contain switching power supplies that can be sources of high frequency electrical noise spikes which may occasionally induce such a fatal memory error condition Whileit is preferred that this electrical noise be eliminated through suppression or dissipation in an adequate grounding system this may be difficult to effect in many cases At the same time there are many customers who place a high value on up time and cannot justify a fatal error unless it has a direct effect on the CPU operation The changes described in this section should provide a better solution for affected customers since this may reduce or even eliminate the problem for them without the need to make changes to their systems H owever for most of the customers who do not havethis type of environment and have never experienced a Program M emory Diagnostic Error there will be no noticeable change When the SIMATIC 505 CPU diagnostics were originally written it was assumed that any memory error found was an
265. nstalling Series 505 Remote I O Cables creer eren 6 4 Media Options cel rer ERR 6 TOv RIS EEX TI RRIDOTEXRPD PERO LER P Pb 6 4 Equipment Needed sssssssssseeseeeee ehh 6 4 Mounting TapsorTerminalBlocks ssssssseeeeen em 6 4 Trunk and Drop Lines ssssssssssssseese ehh 6 5 Selecting Cable 2 sot senda aa RR LAT AERI RR uk Re Rp ue RIDE ended 6 6 Planning YourInstallation sssssssssee IH 6 8 Preparing Drop Line Cables sssssssse ee I 6 12 Remote I O Port PiNOUt cece ccc hh 6 13 Connecting a Drop Line 0 ene n 6 14 Preparing Tunk Line Cables 0 cece eects 6 16 Connecting Trunk Line Cables 0 eens 6 17 Extending Trunk Line Cables 00 c cece eee 6 18 6 3 Installing PROHBUS DP I O Cables cccceeeccee eee ee eee eee eee eee 6 20 Media Options nimi teed ata eg loin tan de cul ele le en e Shia et dha Medea 6 20 Sysem EayOUE lirs ected pan RR aban OR CR RO doa d RR RU RO ER ed RU RUE nad weeks ar ak woes 6 20 Equipment Needed sssssssssesssseeee ehh 6 21 PROFIBUS DP Cable and Connector Specifications 00 e eee eee 6 22 PROFIBUS DP Line Length Limits nsanra nannan 6 22 Installing PROFIBUS DP Cable ssssseeeeeee RII 6 23 Termination and Bias ssssssssssssssssee hh 6 24 Using a Termination Selection Switch ssssssssssseesee m 6 25 PROFI
266. nstrumentation Guaranteed 888 88 SOURCE www artisantg com 4 13 4 14 4 15 4 16 Wiring the Fault Relay ccccceee cee eee eee eee mmn 4 44 Establishing CPU Communication 00ccceeccee cece eee eee eee 4 45 Default Port Configurations 0 cece 4 45 Pinout forSerial Port 1 serais measai isa ada a a Aa a ATR A A RE 4 46 Pinouts for Serial Ports 2 3 and 4 1 kk eae 4 46 Serial Port lI 2 22ssilzekslukkl deena Gk ARGEVILGERIRERVIAPEXTAFEXATRXIAY REE end 4 47 Senal Port 2 Printer POTE eset eee teEE UPOEDUDRRPCPEARRPRRR ERR EERA AMORES 4 48 SenalPort3 iekillizilikk elk edki e kGiRERESQORE4TAREXIRPEXIAREXG RE REE end 4 49 SenalPort 4 iios esee oem her Cura LIVRE IU TAE dae dates oh eee bee ERG ED 4 49 Using Boards in the VMEbus Base eeseen nnn nnn nnn 4 50 Communicating with the CPU 0 ses n 4 50 Battery Status feud ecee ed orati ende A ER DueERETIER CX a Rx Cad Ed DapRab E eR ER cakes 4 5 Using VMEbusAddressSpaCe cece ccc eese hh 4 51 Daisy Chain Signals ssssssssssssesee mna 4 53 Assigning Addressesto Third Party Slaves 0 cee eee aes 4 53 VMEbusAccessLimitations 00 00 s 4 55 Installing Additional Backplane Connectors Leeeeeeeeeeeerr 4 56 J 2 Backplati8s 5 pep Wale Rue ent Rae cedi ae desde tas 4 56 Optional 2 Mini Backplane Kit 2 0 0 ete eens 4 56 Installing Optional 2 Backplane 0 cece c
267. ntents Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 8 6 8 7 8 9 9 1 9 3 9 4 9 5 9 6 A 1 A 2 A 3 A 4 B 1 B 2 B 3 B 3 B 3 B 4 Ci 63 C3 C 4 D 1 D 2 E 1 E 2 E 4 E 5 E 6 E 7 E 8 E 9 E 10 E 11 E 12 E 13 E 14 555 1106 CPU Memory Configuration sssssssessse nh 8 7 575 2104 CPU Memory Configuration 0 0 c cece cece Ih 8 7 575 2105 CPU Memory Configuration sssssssssss Ih 8 8 575 2106 CPU Memory Configuration sssssssessse II 8 8 Effects of Using AUX 10 AUX 11 and AUX 12 sssssssessssess eee 9 3 CPU IndlIcators iiik rx Ret RLXEr Ree RLeERiseiRisebRERed Red EID a 9 6 575 C PU IndlCatOF acertado La ad metas Re OR ERR EUR alias 9 7 Power Supply LEDS 152238 Ri Rhe Rn RU en OR e osa UR eate RU ara RU Pa gf un 9 7 Aux29FatalEmorCodes ssssssssseeese een 9 10 RS 485 Cable Resistance cc cece ccc ehe 9 21 Physical and Environmental Specifications 0 eee A 2 General Series 505 Specifications 0 A 3 575 Power Supply Specifications 0 eects A 4 Series 505 Power Supply Specifications 0 cece eects A 5 545 555 CPU Power Consumption 00 cece ete nn B 2 575 2104 CPU PowerConsumption 0 ccc cece nnn B 2 Series 505 Module Power Requirements 0 0 cece B 3 Series 505 Module Power Requirements continued 0
268. ntilation These gases could explode if adequate ventilation is not available an explosion could result in death or serious injury to personnel and or damage to equipment Ensure that you install the battery in a well ventilated enclosure so that the explosive gases can dissipate 4 20 Installing 575 System Hardware SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Rear panel Battery connector Break away tab Figure 4 12 Mounting the Battery ACAUON Take care to avoid short circuiting the battery Use caution when working near the open terminals or cells when wearing metal rings or watchbands Shorting results in dangerously high current flow that could cause severe burns and is a potential fire hazard Placing metal articles such as rings or watchbands across shorted terminals could result in severe skin burns Handle the battery with utmost care to avoid the possibility of a short circuit a WARNING The battery contains toxic and corrosive materials which could be released if the battery is damaged Contact with the battery contents could cause serious injury or death if ingested to personnel and or damage to equipment Avoid personal or equipment contact with the battery contents SIMATIC 545 555 575 System Manual Installing 575 System Hardware 421 Artisan Technology Grou
269. nufacturing date Figure B 1 shows how to read the serial numbers Date Serial Number FF DD YY MM SSSSS CX _ Not present with initial serial number a G appears here if the Series 505 Discrete Module was manufactured prior to January 1988 but was modified for 545 555 compatibility Serial Number Checksum Unique Unit Identifier Month of Manufacture Last Two Digits of Year of Manufacture Device Indicator Family Indicator Figure B 1 Serial Number Definition The following examples demonstrate how to read the serial number on the modules 86ML8712020175 This module was manufactured in December 12 of 1987 87 This unit is not compatible with the 545 555 575 CPU because it was manufactured prior toJ anuary 1988 and the letter G designating that a modification occurred does not appear at the end of the serial number 86ML8712020175G This module was manufactured in December 12 of 1987 87 This unit is compatible with the 545 555 575 CPU because it was manufactured prior to J anuary 1988 and the letter G designating that a modification occurred appears at the end of the serial number 86ML8801041324 This module was manufactured in J anuary 01 of 1988 88 This unit is compatible with the 545 555 575 CPU because it was manufactured in J anuary 1988 Theletter G is not required if the module was manufactured in J anuary 1988 or later NOTE The current serial number form
270. ocation of Compiled Special CS memory for Special Function SF programs and SF subroutines Compiled SF programs and SF subroutines can be marked for in line execution within your relay ladder logic RLL program Refer to the SIMATIC 545 555 575 Programming Reference U ser Manual or the release notes that are shipped with your CPU for more information about PowerMath and other CPU specific features SmarTune built in automatic PID loop tuning is supported in the 555 1105 and 555 1106 CPUs The standard PID loops have increased from 64 to 128 on the 555 1105 and 555 1106 CPUs The 555 1105 and 555 1106 CPUs also support an additional 128 fast user scheduled PID loops Analog alarms have increased from 128 to 512 on the 555 1105 and 555 1106 CPUs Faster local port baud rates of 57 600 and 115 200 baud are supported in the 555 1105 1106 and 575 2105 2106 CPUs These baud rates allow faster program loading and operator panel updates Operating system firmware is stored in on board permanent flash memory which allows you to make future firmware release upgrades using floppy disks or file transfer over the Internet The 545 and 555 CPUs have the option of storing user program memory in larger capacity on board EEPROM in addition to the portable EEPROM option The new 575 CPUs support program storage in on board EEPROM The 545 and 555 CPUs now incorporate a front accessible back up battery which can be replace
271. ochange Nochange Downloaded Downloaded L V K S U Memory No change Cleared Nochange Nochange Nochange No change Memory Configuration No change Default value Nochange Nochange No change No change I O Configuration No change Cleared Nochange Nochange Nochange Nochange DP I O Mode No change STOP Nochange Nochange Nochange Nochange DP Sync Mode No change Async Nochange Nochange Nochange Nochange Scan Time No change Variable Nochange Nochange Nochange Nochange Time of Day No change No change Nochange Nochange Nochange Nochange Task Codes Scan Nochange 2 Nochange Nochange Nochange Nochange Watchdog Value No change 1 sec Nochange Nochange Nochange Nochange Port Lockout No change Unlocked Nochange Nochange Nochange Nochange Fatal Error No change Cleared Cleared Cleared Cleared Cleared 2 For 545 555 CPUs if programmed E EPROM is present then RUN mode using program in E EPROM 3 If fatal error was present then PROGRAM mode SIMATIC 545 555 575 System Manual Troubleshooting 9 3 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Toubleshooting by Using Auxiliary Functions continued Compare PLC AUX 17 Compare PLC to Disk compares the selected program on disk to to Disk data in the CPU Run 545 555 PLC AUX 20 PLC Diagnostics available only for 545 555 CPUs initiates the Diagnostics CPU self checks The CPU must bein PROGR
272. of the I O module 5 Carefully push thel O module into the slot until it mates with the backplane connectors 6 Tighten top and bottom bezel screws To remove the I O module reverse procedures used during installation 3 26 Installing 505 System Hardware SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Figure 3 14 shows the installation of a module in a Series 505 base Minimum torque 2 6 in lb 0 3 N m Maximum torque 5 2 in lb 0 6 N m Figure 3 14 Installing and Removing Modules in a Series 505 Base Two types of terminal block connectors are availablefor SIMATIC 505 input and output modules the front accessible 2587705 8011 terminal block and the side accessible 2587705 8010 terminal block as shown in Figure 3 16 Figure 3 15 shows the wire gauge and stud sizes you can use for the terminal blocks Note in particular the maximum torque specification for theterminal block screws of 5 0 in Ib 0 56 N m Stud Size 4 2 5mm Amp Parti 321462 Use with connector 2587705 8010 Wire Gauge 12 26 both connectors LL EC Max Width 5 54 mm 218 in it 1er Stud Size 4 2 5mm Amp Part 327891 Specify 2pt Connector L Use with connector 2587705 8010 C Max Width 4 62 mm 182 in PONE ESO Note When using small gauge
273. ogy Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Chapter 1 System Overview 1 1 OVEIVICW Pn 1 2 INCOCDUE TON PIC tae eee es ue ohare eek ok ee 1 2 Compatibility with Previous CPUS 0 eee eens 1 2 Featureson New CPU Models sssssssseeeee eee 1 3 PROFIBUS DP 5 ee beta gi eb es Ea esame eripe rige ries ES Fat md aad 1 4 PROFIBUSUserOrganizations ssssssssseeee eee 1 4 Using Other Networks ssssssssse hr 1 4 12 System Features wo cece cece ee eee eens 1 6 Product SpecificationsOverview 6c cece eae 1 6 Shared Features sirri iaaa eee nnn 1 8 545 555 Only Features sssesseeesseees n nnn 1 9 575 Only Featules 21x bes Res ddr RE CREER ER Eae deer AERE Rupe Pads 1 10 13 Programming Tools eeeeeeeeeenn eee eee eee 1 11 SOftSho p harsa e Races Rura RR ea e Rc Rud RU Ron OR daa aie Rnd Rees de hada 1 11 ucelppc 1 11 COM PROFIBUS 5 enhn ac ecu sd aly abe at ko ook e Rs RR D RR RC 1 11 Communicating with the CPU ssuuussssssssssss eee n 1 11 L4 Hardware Overview eeeueeeesee nnn nnn nuhuuuunuu uu nn uuu h uuu 1 12 Senes 505 Bases cose euer sete e tee tet Ee Ea D ED dL Er d d ane 1 12 MME Base asamara as aa dA dues eism E A dq bet AR mine tae E GO 1 12 Expansion dO minetan ais etn Sauk oie ii keena i eedi ia Dt adhered 1 13 VO Chann
274. ogy Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Installing a PPX 500 5114 A RBC continued When the CPU logs an RBC off the system it sets a corresponding bit in one of the status words that are available to your RLL program Your RLL program can use these bits to detect the loss of the RBC and control the outputs of other bases as appropriate for your application For details about status words and more information about programming refer to the SIMATIC 505 Programming Reference User Manual Assigning Base The base thumbwheel switch shown in Figure C 7 is used to assign a base Numbers number tothe RBC for system identification If you are using more than one RBC each RBC must be uniquely numbered Refer to Table C 3 when assigning base numbers Base number 0 is reserved for the local base Series 505 controller and must not be assigned to the RBC Table C 3 Base Numbers Thumbwheel Thumbwheel ume eR DM Do Not Use 1 1 9 2 2 10 10 3 3 1 1 4 4 12 12 5 5 13 13 6 6 14 14 7 7 15 15 Base Ois reserved for local base assignment Therefore do not assign base address 0 tothe Series 500 RBC C 18 Upgrading Existing Series 500 Installations SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com C 6 RS 485 RF I O Channel Converter Introduction Compatibility Th
275. on Special function port failure A communication port on an SF module has failed Check all SF modules I O module failure A configured module is not present or is reporting an error Run AUX 25 or see Appendix C to identify the module O table does not agree with modules installed The configured I O does not match what is installed in the base Check the I O configuration and or run AU X 25 Password warning The CPU has a password that has been disabled by an operator NOTE Series 505 I O modules with date codes before anuary 1988 cannot be used with a 545 555 CPU See Appendix B for details on compatibility SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 9 5 Toubleshooting by Using Status Words In addition to auxiliary functions the CPU provides operational information in the form of 16 bit status words Status words can be read with your programming device Status words can also be used within an RLL program thus allowing the system to execute diagnostics during run time conditions All status words that are supported by the CPU are described in detail in the SIMATIC 545 555 575 Programming Reference User Manual SIMATIC 545 555 575 System Manual Troubleshooting 9 17 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 9 6 9 18 Troubleshooting User
276. on Place the system in a safe state and consult Siemens Technical Support In the U S A call 423 461 2522 I O modules installed in this base do not match the expected configuration in the PROFIBUS DP master Action Compare the actual configuration of the base against the configuration expected by the PROFIBUS DP master Diagnostic Failure Module Mismatch 5 22 Installing Remote Base Controllers RBCs SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Table 5 8 505 PROABUS DP REC Status Codes continued The RBC detects no PROFIBUS DP I O channel activity Action Place the system in a safe state and 3 No Communications None check the connection to the PROFIBUS DP O channel Ensure that other PROFIBUS DP I O channel devices are powered and not reporting errors Firmwareis missing 4 No Operational Firmware None Action Download new firmware into Flash Memory J umper E1 is missing or not recognized Action Install jumper on header E 1 5 No Hold Mode Selection OK Default The RBC continues to operate with a missing jumper if communication is lost outputs will be driven to Off setting Improper dipswitch selection for RS 232 baud rate Action Set the dipswitch to valid RS 232 6 Invalid RS 232 423 Baud Rate OK baud rate Default The RBC continues to operate with an improper dipswitch setting it uses
277. on 4 10 for information about dipswitch configuration Install the 575 secondary Refer to General Guidelines at the beginning of this section for information about how slot placement affects the assignment of applications during powerup Power up the 575 system If you have added the 575 secondary to an existing installation the added 575 secondary performs a battery bad restart and then transitions to PROGRAM mode All other 575 CPUs transition to the state they were in prior to the powerdown Load your program in the new 575 secondary 4 36 Installing 575 System Hardware SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Guidelines for A 575 system controller is any 575 CPU installed in slot 1 If you want to Replacing a 575 replace a 575 system controller follow the steps below System Contoller NOTE Read and abide by the warnings and cautions at the beginning of this section 1 Before you remove the 575 system controller save the memory of the system controller any 575 secondaries and any third party masters 2 Ensurethat all power is disconnected from the VME bus base and that the battery is disconnected 3 Removethe 575 system controller 4 Ensurethat the dipswitch configuration is the same for the new 575 Refer to Section 4 10 for information about dipswitch configuration 5 Install the new 575 system controller 6 Po
278. on RBC is used to assign the base number Base numbers 10 through 15 are represented by the hexadecimal characters A through F See Figure 5 7 Changing the RBC To change the RBC base number you adjust the switch setting to the Base Number desired number If the system is operating when you change the setting the RBC will be reset The new base number takes effect when the RBC completes reset NOTE Do not select base 0 on an RBC Base 0 is reserved as the local base A WARNING If you reset the RBC when the system is operating the RBC is logged off the system When the RBC is logged off inputs and outputs associated with the base are affected as described below If you do not take the condition of your inputs and outputs into account logging the RBC off the system can cause unpredictable process operation Unpredictable process operation can cause death or serious injury to personnel and or damage to equipment Do not reset your RBC unless you understand and are prepared for the consequences see Resetting the RBC on page 5 11 If you want to usethe base number switch to reset the RBC whilethe system is operating momentarily change the switch to another number then quickly return it to the correct base address setting SIMATIC 545 555 575 System Manual Installing Remote Base Controllers RBCs 5 9 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com PPX 505 6851
279. on the bezel has not opened Follow steps 9 through 12 to replace the fuse if necessary with the appropriatefuse SeeFigure 9 2 A WARNING To minimize the risk of shock hazard always turn off power to the base before you replace a fuse Failure to do so could cause death or serious injury to personnel and or damage to equipment Ensure that power to the base is disabled before replacing a fuse SIMATIC 545 555 575 System Manual Troubleshooting 9 19 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Toubleshooting Power Supplies continued 10 11 12 13 14 Turn the fuse cap counterclockwise a half turn with a standard screwdriver Pull the fuse cap out of the fuse socket Remove and replace existing fuse with one of recommended type and rating see the lists of Series 505 and VME components in Appendix D Place the fuse cap in socket and turn it clockwise with a standard screwdriver Apply power to the system If the power supply continues to malfunction replace it Follow procedures established at your site for processing defective equipment If necessary contact your distributor or sales office in the United States or call Siemens Energy amp Automation Inc at 1 800 964 4114 for assistance in contacting your distributor or sales office 9 20 Troubleshooting Front Bezel Fuse Fuse Cap Figure 9 2
280. ontinued e Where several connections need to be made close together it is better to place a single terminal block in thetrunk line and connect all nearby equi pment to that terminal block See Figure 6 4 Make multiple connections like this Remote Base but not like this Figure 6 4 Multiple Tap Connections in Close Proximity 6 10 Cabling and Wiring the System SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com e Tap connections on the trunk line should be spaced on average so that the total length of trunk cable separating several taps is greater than the sum of the total length of drop cables connected at the taps See Figure 6 5 La gt L Le Figure 6 5 Spacing between Taps e Theideal cable installation is a single unbranched trunk line with short drop cables and a termination resistor at each end of the trunk NOTE For installations with five or fewer connections if the cable length between the controller and the most distant RBC is less than 100 feet 30m any cable configuration can be used Always use at least one termination resistor even with the simplest installation SIMATIC 545 555 575 System Manual
281. operations to access Global Configuration Status Registers If these operations are performed a VM Ebus error occurs e Accesses also address only bus cycles to VMEbus short supervisory space VMEbus address modifier 2D16 addresses A16 Base Address F 016 F 716 must be avoided If these operations are performed the 575 CPUs in the system wastetime servicing an unsupported location monitor interrupt Table 4 7 lists the signal mnemonics assigned to each pin in the 1 backplane connector as defined by the VME bus standard SIMATIC 545 555 575 System Manual Installing 575 System Hardware 4 55 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 4 16 Installing Additional Backplane Connectors J2 Backplanes Optional J 2 Mini Backplane Kit Rear panel retaining screws Certain VM Ebus modules require the use of a second connector on the backplane to supply the additional current required for operation J 2 backplanes that conform to VME bus standards can be installed in the PPX 575 2130 base Two suppliers of J 2 backplanes are the following BI CC Vero Electronics nc SCHROFF Inc 1000 Sherman Avenue 170 Commerce Drive Hamden CT 06514 1336 Warwick RI 02886 203 288 8001 or 800 BICC VME 401 732 3770 U S A U S A NOTE Theuse of non SIMATIC or non agency approved components in the system will affect the agency approvals for the installed system
282. or Serial Port PC AT oa 25 Pin Male D Connector Port 1 PPX 575 2104 Figure 4 27 Cable to Connectto 9 Pin PC Serial Port SIMATIC 545 555 575 System Manual Installing 575 System Hardware 4 47 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Establishing CPU Communication continued Serial Port 2 Port 2is a DTE RS 232C port with modem control lines Usethis port with Printer Port a serial printer The CPU can send information to a printer through the use of an SF program or SF subroutine You can set the baud rate of this port from 300 to 38 400 using TI SOFT You can wirethe port to use XON XOFF handshaking Figure 4 28 or READY BU SY handshaking Figure 4 29 O Oloo HOS N wo A oa N Serial Printer m oo RTS Not required for all printers CTS O00000 25 Pin Male D Connector Port 2 RS 232 m oa QU OO OT OVO O N a DOO OO O00 N Serial Printer nN ODO OOO 25 Pin Male D Connector Port 2 RS 232 OOO OO OO OO CU LU ED m oa Figure 4 29 Cable for Ready Busy Printer Handshaking 4 48 Installing 575 System Hardware SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Serial Port 3
283. or finely stranded wire tin the wire ends or use an appropriately sized pin contact ferrule for the best possible connection Do not exceed the specified maximum torque on the terminal block screws Figure 3 15 Wire Gauge and Stud Sizes for Input Output Terminal Blocks SIMATIC 545 555 575 System Manual Installing 505 System Hardware 3 27 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Installing Series 505 I O Modules continued Figure 3 16 shows the two types of terminal block connectors that are available for SIMATIC 505 input and output modules 2587705 8011 2587705 8010 Front accessible Side accessible C shipped with module order separately i IN QV SV OV oY da eV eV Gd 08 8V ZV g cd Maximum torque for terminal block screws 5 0 in Ib 0 56 N m eg 88 48 1198 Caution Applying excess torque or using a power screwdriver without torque limits may damage the connector yo L3 S9 691139 99
284. ory access 3916 Standard non privileged data access gt 3Aie Standard non privileged program access 3D1e Standard supervisory data access 3E16 Standard supervisory program access Address space supported A24 D16 DO8 EO Shared RAM 3 A16 DO8 E O Global Communication Status Registers GCSR 3 Access Time Shared RAM 300 nanoseconds no contention GCSR 4microseconds 1 During fault recovery ACFAIL is not driven 2 All third party masters must be Release When Done RWD 3 Refer tothe SIMATIC 575 Interboard Communication Specification 4 Interrupt processing by user programs is not supported at this time 5 Supported by RLL MOVE instruction 4 50 Installing 575 System Hardware SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Battery Status Using VMEbus Address Space If a 575 CPU is nat in slot 1 then the system controller is responsible for informing the primary 575 CPU about battery status The system controller writes a 255 FF 16 for battery good or 0 for battery bad to the battery status BATGOOD location at BASE ADDRESS44 where BASE ADDRESS is the base address of the 575 system tables Refer to Section 4 11 of this chapter for additional information on BASE ADDRESS This variable is an 8 bit integer byte For information about the 575 CPU s system tables refer to SIMATIC 575 Interbo
285. ot Numbering VME I O slot numbering is automatic for example to find the module TISOFT shows is in slot three count SIMATIC VMEbus I O modules from left to right to the third module f you want a 575 CPU to function as your system controller you must install the 575 CPU in theslot next to the power supply Board order for remaining cards including other CPUs is unimportant SIMATIC 545 555 575 System Manual Installing 575 System Hardware 4 41 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Installing VMEbus Boards continued Installing and Use the following steps for installing and removing SIMATIC VMEbus I O Removing modules in the base Refer to Figure 4 21 I O Modules To minimize risk of shock hazard always turn off power to the base before removing or installing a power supply module Installing or removing any module from a powered up base could cause unexpected operation which could cause death or serious injury to personnel and or damage to equipment Disconnect all power to the base before installing or removing I O modules 1 Disconnect power to the base 2 Usespecification sheets provided with the modules to install option and wiring selections for your application 3 Position thel O module so the bezel is facing you Electronic equipment can be damaged by electrostatic discharge Ensure that personnel make contact with a static dissipative pad and or wear
286. other electrical conductor e fcablingis installed inside a conduit the conduit should be grounded according to applicable electrical codes e Maintain a minimum of 3 feet 1 m between trunk lines and the following noise sources Power lines Electric motors and motor starters Generators Electric welders Cable Routing The type of routing is usually determined by the type of building in which Methods the cables are being installed Any combination of the following may be used to route the cables under floor in ceiling or surface duct A WARNING Electrical and fire safety must be considered in planning the installation To ensure safety compliance observe local installation code guidelines 6 2 Cabling and Wiring the System SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Under Hoor Routing In Ceiling Routing Surface Duct Routing In under floor routing the cable can be endosed in ducts or with raised flooring in the open air e Duct systems are better protected against unauthorized taps or terminal blocks but expansion is more difficult and expensive than with open air systems e Open air systems provide more freedom of access and allow maximum system expansion and flexibility For in ceiling routing cables are usually supported in troughs or with hooks and damps every 10 to 15 fee
287. other programming device to the PLC The corrupted L memory cannot be displayed or edited online 3 Ifthereis an error in CL memory you will now be able to clear this error from TISOFT or SoftShop with a restart Aux function 11 or 12 rather than by having to reload the program since all that is required is a recompile of the RLL code that already exists in L memor y If an error occurs in CL memory you now have the additional option to set DIP switch 10 switch 8 on 575 CPUs toallow the CPU to perform an Auto Recompile during run time Before you usethe Auto Recompile option you must determine if your process can accept a one scan bump of a few seconds for the recompile which is equivalent to a recompile following a run time edit on the ladder program In other words if you can perform a run time edit to your program without disrupting your process you should be able to use this feature without a problem Switch 10 switch 8 on 575 CPUs is shipped in the Auto Recompile disabled left position To activate Auto Recompile set the switch tothe right enabled position Status Word 243 indicates the following information e Status Word 243 indicates that Auto Recompile is enabled by setting bit 1 STW243 1 to 1 e Thelower byte of Status Word 243 counts the number of times an Auto Recompile has been accomplished since the last time the program was compiled by the CPU After an Auto Recompile has been performed at least eight goo
288. ou can Yes connect may be less depending on the type of slave and the memory requirements of each Requires optional PPX 505 CP5434 DP PROFIBUS DP I O annex card The 575 CPU does not support simultaneous use of 505 Remote I O and PROFIBUS DP 1 0 SIMATIC 545 555 575 System Manual System Overview Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 1 7 System Features continued Shared Features All CPUs offer the following features e Support for I O expansion using PROFIBUS DP 1 0 e Support for I O expansion using Series 505 remote I O Exception the 545 1103 1105 cannot use the Series 505 remote I O channel e Optional password protection for user programs e Full support for SIMATIC PCS e Immediate local base I O module updates that allow your application program to access an I O point multiple times during a CPU scan e Cyclic RLL that allows you to create an additional RLL program that runs independently from the main RLL program e External subroutines that allow your program to call externally developed programs written in high level languages such as C e Proportional I ntegral Derivative PI D loop functions for process and batch control e Analog alarms e Special Function Programs SFPGMs and Special Function Subroutines SF SU Bs that use a higher level statement driven programming language to ease the development of complex prog
289. ou select on board EEPROM for program storage ensure that the portable EEPROM is not installed Other possible causes for errors include the following e TheEEPROM may be defective e TheEEPROM may already have been programmed and not erased Usethe TISOFT auxiliary function AUX 84 to erase program data on the EEPROM e Thesize of your user program that is being stored may exceed the size of the installed EEPROM If you suspect a defective portable EEPROM power down remove the EEPROM install another EEPROM power up again and repeat the programming procedure SIMATIC 545 555 575 System Manual Using EEPROMsfor Program Storage 7 11 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 7 4 Editing a Program Stored in an EEPROM You can edit the program and data stored in an EEPROM by following the steps listed below NOTE f necessary refer to your SIMATIC 505 TISOFT2 User Manual for detailed instructions about executing TISOFT AUX functions 1 Setthe CPU to PROGRAM mode 2 Using your programming unit and the TISOFT auxiliary function AUX 84 option select EEPROM as the program source This will copy the EEPROM program to RAM A WARNING When you select EEPROM the CPU is cleared and then loaded with the contents of the EEPROM This clears V memory and resets all timers counters drums etc Therefore selecting EEPROM could cause unexpected operation when the
290. out how to enter a program The COM PROFIBUS configuration utility is a Windows based tool for configuring PROFIBUS DP I O slaves Refer tothe SIMATIC 505 TISOFT2 User Manual and the SIMATIC S5 ET 200 Distributed I O System Manual for information about using COM PROFIBUS You can communicate with the CPU by using the following devices e BM PC AT 386 or higher or a 10096 compatible computer using SoftShop or TISOFT software e Control Vision Unit CVU 1000 or CVU 10000 e PCS SIMATIC 545 555 575 System Manual System Overview 1 11 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 1 4 Hardware Overview Series 505 Bases VME Base 1 12 System Overview The base that contains a 545 555 or 575 CPU and I O modules is called the local base Expansion I O is also available in the form of Series 505 remote I O and or PROFIBUS DP I O slaves and field devices Special function SF O modules can be used in a Series 505 remote base however performance is improved when they are used in the local base SF I O cannot be used with the 505 PROFIBUS DP RBC PPX 505 6870 on the PROFIBUS DP channel See Table B 3 in Appendix B 545 and 555 CPUs are housed in a Series 505 base which has slots for a power supply a CPU or RBC and I O modules A local base can contain a mix of Series 505 I O normal and or immediate interrupt I O normal and or immediate and SF I O normal
291. p 022 e eee eee E 12 PPX 575 4732 Cument Point vs Ambient Temp 60 cee eee eee E 13 Contents xv Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com List of Tables 1 1 1 2 13 2 1 3 1 3 2 3 3 3 4 4 1 4 2 4 3 4 4 4 5 4 6 4 7 5 1 5 2 5 3 5 4 5 5 5 6 5 7 5 8 5 9 6 1 6 2 CPU Specifications iis aaia da ane iaaea aa aan ia eee rr nnn 1 6 CPU Specific atio NSaeia asaan ea aao Ana aek i ido ARR RR rr nnn 1 7 VO OptONS ereire a peta EI 1 13 Fault Relay Output Electrical Specifications 00 eee ee 2 6 Series 505 Base Models 00 ccc cece ence n nnn 3 4 Series 505 Base Dimensions sssssssessseee nnn 3 7 Port 1 Baud Rate SettingS 0 cece eer 3 23 Port 2 Baud Rate Seting S ies iaiia amea e cece ehh 3 23 Derating Requirements for Operation without Fan Assembly uuuuueue 4 6 Power Supply Specifications 0 cece e 4 15 Dipswitch Configuration Options issssssssseeese eee 4 25 575 CPU SW5 On During Fault Recovery sssssssse eh 4 27 SIMATIC 575 CPU VMEbus Specifications sssssseee 4 50 Use of VMEAddressSpace ssssssssssssess ehh 4 52 VMEbus 1 Backplane ConnectorPin Assignments 0000 cee cece ee eee eae 4 54 Analog Word Output States 0 0 5 6 RS 232 Port Baud Rate SettingS ceca 5 8 SW3 Factory Dips
292. p Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Installing the Battery continued Disabling the The battery cable has a polarized connector to allow easy disconnection and Battery re connection of the battery When you first power up your system the battery must be disabled To disable the battery disconnect the battery connector shown in Figure 4 13 by squeezing the locking tabs to release them and then pulling apart the connector plugs Battery connector Figure 4 13 Disconnecting Back up Battery Before Powerup Battery Fuse The in line battery fuse is a4 A 3 AG 14 in x 4 in normal blow fuse Replace with a UL approved fuse of the same rating PPX 2587679 8016 NOTE Comply with applicable federal state and local regulations when disposing of the battery The battery contains lead which is a hazardous waste material Dispose of batteries properly 4 22 Installing 575 System Hardware SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 4 9 Installing the Hoating Point Coprocessor Optional The 575 2104 CPU has a socket for a Motorola M C68882 floating point coprocessor 12 5 MHz or faster If you install a floating point coprocessor in this socket you may create external subroutines XSUBs to perform high speed floating point calculations the 575 2104 operating system does not otherwise use
293. p dde I NEUTRAL GROUND Figure 4 1 Fan Assembly Rear Panel To provide power to the fans follow these steps 1 Remove the terminal block shield from the AC terminals on the rear panel 2 Connect power lines to the AC terminals shown in Figure 4 1 3 Replacetheterminal block shield SIMATIC 545 555 575 System Manual Installing 575 System Hardware 4 7 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Installing the Fan Assembly continued Mounting the Fan Mount the fan assembly under the lower guiderails attaching it with three Assembly screws provided to each side panel as shown in Figure 4 2 Besureto orient the fan assembly with the replaceable fuse at the front and the AC power connection and voltage selector switch at the rear of the unit Front of Fan Assembly with Fuse Holder Figure 4 2 Installing the Fan Assembly 48 Installing 575 System Hardware SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Replacing Fuse on Thefan assembly is fused to protect the hardware from over voltage or the Fan Assembly other adverse power conditions If you need to replace the fuse use a 3 A 3 AG 1 in x 14 in 250 V slow blow fuse PP X 2587679 8002 The fuse holder is located on
294. perature planning for 4 6 Series 505 base 3 3 VME bus base 4 5 Termination and bias overview 6 24 Third party boards assigning addresses 4 53 installing 4 40 Thumbwheels assigning base numbers Series 500 RBC C 18 Series 505 RBC 5 9 TISOFT programming software 1 11 TIWAY support 1 4 Token ring PROFIBUS protocol 1 4 Torque specifications for CPUs 3 15 for Series 505 modules 3 27 for terminal block screws 3 27 3 28 Troubleshooting 575 power supply 9 19 575 fault restart 9 2 575 improper login 9 25 assistance 9 15 cable RS 485 9 21 EPROM EEPROM 9 18 fatal errors causes 9 9 causes 545 555 CPUs 9 9 causes 575 CPUs 9 10 clearing 545 555 CPUs 9 13 clearing 575 CPUs 9 15 determining 545 555 CPUs 9 8 determining 575 CPUs 9 8 responses 545 555 CPUs 9 13 responses 575 CPUs 9 14 non fatal errors list of 9 16 restart 9 2 Series 505 power supply 9 19 using auxiliary functions 9 2 Compare PLC to Disk 9 4 Display Failed I O 9 4 PLC Operational Status 9 4 9 8 list of error codes 9 10 Run PLC Diagnostics 9 4 Artisan Technology Group Quality Instrumentation Troubleshooting continued using LEDs 545 555 CPUs 9 6 575 CPUS 9 7 575 power supply 9 7 using status words 9 17 Trunk line cable installations 6 5 connecting to terminal block 6 17 extending 6 18 maximum length 6 9 preparing 6 16 terminating 6 18 U Upgrading 520 530
295. plane properly install a VME card that has a P2 connector in the base so that it mates with a J 2 backplane connector Existing J1 Backplane Chassis rail 8 Backplane spacer Optional J2 Backplane full backplane or individual backplane kit Chassis rail E M2 5 x 10mm screw i Backplane spacer Figure 4 32 Installing J 2 Backplane If you are using the single slot J 2 Backplane Kit connect the blue lead to the GND lug and the red lead to the 5 V lug on theJ 1 backplane refer to the 2 connector installation instructions Replace the rear panel and the battery assembly Installing 575 System Hardware 4 57 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Installing Additional Backplane Connectors continued Installing Optional You can also install individual J 2 DIN connectors to the backplane of the J2 DIN Connector 575 VMEbus base This allows you to provide J 2 connection using wire wrap technology or flat ribbon cables without a J 2 backplane assembly For this option you need to install VME Z Rails PPX 2589739 8016 Toinstall a J 2 connector follow these steps 1 Unplug the battery connector unscrew the two battery retaining screws and remove the battery from the rear of the unit 2 Removethe 6 screws 3 per side that hold the rear panel and remove the rear panel from
296. port and uses RS 232 protocol 545 555 Printer The 545 555 CPU uses Port 1 for printer operations and the two available Connections printer handshaking options are as follows 6 34 e XON XOFF printer handshaking see Figure 6 23 e READY BUSY printer handshaking see Figure 6 24 Serial Printer or Programming Device RTS Port 1 RS 232 423 CTS NOTE Setdipswitch 2 on the Not required for all printers CPU to the OFF position for printing Figure 6 23 545 555 XON XOFF Printer Handshaking Serial Printer Port 1 RS 232 423 NOTE Set dipswitch 2 on the CPU to the OFF position for printing Figure 6 24 545 555 READY BUSY Printer Handshaking Cabling and Wiring the System SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 575 Printer The 575 CPU uses Port 2 for printer operations You can set the baud rate of Connections this port using TI SOFT The two available printer handshaking options are as follows e XON XOFF printer handshaking see Figure 6 25 e READY BUSY printer handshaking see Figure 6 26 CODE qp N wo A a N Serial Printer bs RTS Not required for all rinters P CTS 25 Pin Male D Connector Port 2 RS 232 O00000
297. program the Series 505 CPU or to troubleshoot from a remote I O base A baud rate thumbwheel shown in Figure C 7 is used to set the baud rate for this port 3 O Communication Time 8 C 16 Upgrading Existing Series 500 Installations SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Using the Base Thumbwheel Resetting the RBC The base thumbwheel shown in Figure C 7 is used to reset the Series 500 RBC during system operation and to assign the base address A WARNING If you reset the RBC when the system is operating the RBC is logged off the system When the RBC is logged off inputs and outputs associated with the base are affected as described below If you do not take the condition of your inputs and outputs into account logging the RBC off the system can cause unpredictable process operation Unpredictable process operation can cause death or serious injury to personnel and or damage to equipment Do not reset your RBC unless you understand and are prepared for the consequences described below If you want to use the base thumbwheel switch to reset the Series 500 RBC whilethe system is operating momentarily change the switch to another number then quickly return it to the correct base address setting Thefollowing actions take place when an RBC is reset e TheCPU logsthe RBC off the system and zeros the image r
298. ps Analog alarms and SF programs is in RUN mode and discrete I O and RLL program is in PROGRAM mode BAT On Battery disconnected or bad BAT Off Battery connected and good BAT Flashing Remotel O annex card configuration dipswitch settings do not match the primary 575 CPU s remate I O CPU annex card dipswitch settings The 575 system is in fatal error mode The board with the flashing BAT LED is disabled WDG On CPU in watchdog fatal error MOB On CPU is the active VME bus master SYF On This CPU failed or is doing power up diagnostics After a CPU fails the SYF LED remains on until the next power cycle or until the problem is removed The LEDs on the 575 power supply module are listed in Table 9 4 Table 9 4 Power Supply LEDs indicator Status Meanings O POWER GOOD On Power is good Power supply is not regulating correctly SIMATIC 545 555 575 System Manual Troubleshooting 9 7 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 9 3 Troubleshooting CPU Fatal Enors NOTE Always execute AU X 29 PLC Operational Status and make a list of the errors before attempting to clear them If you dear errors before listing them it will be impossible to determine what errors occurred and difficult to identify the problem that caused them 545 555 CPU Fatal For 545 555s a fatal error is indicated when both of the following conditions Enor Indic ations are present e TheCPU GOOD LED i
299. quate airflow 3 Align two bracket slots with two screw holes located on each side of the 19 inch rack 4 Secure each bracket to the 19 inch rack with two screws installed through the bracket slots Joo669600000000000299020 Figure 3 1 Mounting Base to Standard 19 inch Rack SIMATIC 545 555 575 System Manual Installing 505 System Hardware 3 5 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 3 5 Panel Mounting Series 505 Bases Use the following steps for panel mounting in an NEMA enclosure NOTE There should be at least 6 inches 150 mm of clearance at the top and bottom of base for adequate airflow The base depth is 7 99 inches 203 mm 1 Open NEMA enclosure door 2 Drill four holes in sub panel of NEMA enclosure with a 21 drill bit Refer to Table 3 2 for screw hole dimensions for each base Ensurethat chips from drilling do not contaminate other equipment 3 Tapthedrilled holes with a 10 32 tap 4 Position the baseinsidethe NEMA enclosure NOTE Besurethat the bracket holes and the tapped holes in the sub panel are aligned 5 Install 10 screws through each bracket hole to attach the base to the sub panel See Figure 3 2 Figure 3 2 Mounting Base in NEMA Enclosure 3 6 Installing 505 System Hardware SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www
300. r that is when the LED on the bottom right hand side turns on See Figure 4 19 for the location of the LEDs When a 575 CPU is not in slot 1 then the system controller is responsible for informing the primary 575 CPU about battery status The system controller writes either 255 FF 16 for battery good or O for battery bad to the battery status BATGOOD location at address BASE ADDRESS 4 where BASE ADDRESS is the base address of the 575 system tables see Section 4 11 This variable is an 8 bit integer For information about the 575 CPU s system tables refer to the SIMATIC 575 Interboard Communication Specification PPX 575 8103 x 8 Load your program s 4 38 Installing 575 System Hardware SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Guidelines for Replacing a 575 Secondary A 575 secondary is any 575 that is not installed in slot 1 and is not configured by the dipswitch as a primary If you want to replace a 575 secondary follow the steps below NOTE Read and abide by the warnings and cautions at the beginning of this section If possible save the memory of your system Ensure that all power is disconnected from the VME bus base You do not have to disconnect the battery to replace a 575 secondary Remove the old 575 secondary Your new 575 secondary must conform to the dipswitch configuration established by your 575 primar
301. r Conditions once geii RD RHERRCHRPERE C RERUPPRE UERRCDLERUDPPRULRRRNCRU F 2 Changesin Memory EmorHandling 0 cece eee eens F 2 Using the Auto Recompile Function 0 0 cece F 3 Programming Support isssssssssssssss ehh F 3 Fast PRORBUS DP I O Update Times 00cceeecee cece eee eee eee eee F4 CPUs with this Feature 0 0 ene rr F 4 Fast PROFIBUS DP I O UpdateS 0 cece eae F 4 How It WOKS cscs vege See eek ree ee Re ER oe Ee lE PiMSRXEIASESIA ER A ee ean F 4 Selecting Fast DP Update Mode 0c ccc cece ttt n nnn F 4 Changing a PROFIBUS DP Slave Configuration 0 cece cece ences F 5 Typical Update Time ccc cece tee F 5 ncn ds ee e aa eee eee ee F 5 Memory Capacity of the 555 1106 CPU 2 ccc cece cece eee rene ee eee nnn F 6 Difference in Memory Capacity between the 555 1106 CPU and Earlier CPUs F 6 Contents Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com List of Figures 1 1 1 2 1 3 2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 2 9 2 10 2 11 2 12 2 13 2 14 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 3 9 3 10 3 11 3 12 3 13 3 14 3 15 3 16 Series 505 I O Architecture 2 6 e nn 1 5 Typical 555 System iili e ilg lime eed das bees bac edew dba aA 1 9 Tlypicalb75 System i i xd xr eed eee eee nd ETAT ERI dee 1 10 Operator Safety Switch ssssuuusssessssesss sees nnn 2
302. r supply 575 installing 4 17 overview 4 14 placement in base 4 17 power consumption 4 15 replacing fuse 9 19 selecting voltage 4 16 specifications 4 15 A 4 troubleshooting 9 19 wiring guidelines 4 17 wiring procedure 4 18 Series 505 24 VDC unit 3 11 installing 3 8 placement in base 3 8 power consumption 3 8 replacing fuse 9 19 selecting voltage 3 9 specifications A 5 troubleshooting 9 19 wiring guidelines 3 10 wiring procedure 3 10 Index 6 Artisan Technology Group Quality Instrumentation Power up memory and mode status 7 5 procedures 8 2 PowerMath 1 3 Primary 575 not in slot one 4 38 setting dipswitches 4 38 Printer connecting 4 48 6 34 handshaking 4 48 6 34 overview 6 34 PROFIBUS DP annex card installing in 545 1103 CPU 3 12 in 575 CPU 4 30 cable installations attaching connector 6 28 cable requirements 6 22 equipment needed 6 21 guidelines 6 23 maximum line length 6 22 media options 6 20 sample system 6 20 termination and bias 6 24 termination guidelines 6 24 termination schematics 6 26 termination selection switch 6 25 troubleshooting 9 23 twisted pair 6 20 communications watchdog timer 9 24 fast I O update F 4 F 5 1 O channel overview 1 4 supported by Series 505 CPUs 1 13 RBC assigning station address 5 17 configuring 5 24 hardware watchdog timer 5 15 installing in base 5 4 off freeze jumper 5 14 output state selection 5 14 overview
303. rading 560 565 system C 8 S Safety guidelines 2 3 inch switch 2 5 jog switch 2 5 operator safety switches 2 4 Scan time by CPU model overview 1 6 1 7 Secondary 575 adding to system 4 36 replacing 4 39 setting dipswitches 4 36 4 39 Series 500 base connecting to Series 505 system C 2 RBC assigning base numbers C 18 base thumbwheel C 18 hardware watchdog timer C 15 installing in base C 12 off freeze jumper C 14 output state selection C 14 setting baud rate C 16 status display C 16 upgrading C 2 Index 7 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Series 505 over view 5 6 annex card installing in 575 CPU 4 29 placement in base 5 3 base setting baud rate 5 8 installing 545 555 CPU 3 14 models available 1 12 3 4 panel mounting 3 6 models available 3 4 rack mounting 3 5 models available 3 4 cable installations cable requirements 6 7 connecting drop lineto CPU 6 14 connecting drop lineto RBC 6 14 connecting trunk line to terminal block 6 17 drop line 6 5 equipment needed 6 4 extending trunk line 6 18 guidelines 6 8 media options 6 4 preparing drop line 6 12 preparing trunk line 6 16 proper termination 6 15 6 18 selecting cable 6 6 terminal blocks 6 4 trunk line 6 5 twisted pair 6 4 dipswitch selecting comm ports 3 24 general specifications A 3 I O architecture overview 1 4 I O modules instal
304. rams e Tuneable scan timeline e Battery backup to maintain a real time clock and the dynamic state of user program variables and retentive control relays CRs in case of a power outage e Ethernet network connectivity using the H1 or TCP IP protocols The PPX 505 CP1434TF H1 module Rel 2 0 and later or PPX 505 CP2572 TCP IP module is required e PROFIBUS FMS network connectivity for master to master communications The PPX 505 CP5434 F MS module is required e A real time clock that keeps track of both date and time 1 8 System Overview SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 545 555 Only The 545 and 555 systems offer the following additional features Features e Local baseinterrupt I O that allows for fast reaction to external events e Non volatile program storage and execution portable EEPROM or EPROM to restore the initial state of your program e Series 505 footprint Figure 1 2 shows a typical 555 system Siemens SIMATIC 505 O DC POWER GOOD AC LINE AC NEUTRAL GROUND G Q Q SIMATIC 555 Q CPU GOOD run 247 coop a e PROFIBUS DP os joo
305. rd party VMEbus boards must respond to a 575 request in less than 40 microseconds or VMEbus error occurs Unless the MOVE instruction was used this causes a fatal error e VMEbus block transfers are not supported Third party boards may not use VME bus block transfers to or from the CPU shared memory All data transfers must be accomplished by VMEbus word or byte read write e The575 CPU reserves Address Modifier 2D1 address 12216 Any attempt to access this address Read Write Read M odify Write or address only cycle results in disabling the 575 VMEbus I O module outputs e The575 CPU does not perform D32 VMEbus cycles nor allow D32 VMEbus cycles to or from CPU shared memory Long word Read M odify Write operations are not indivisible across the backplane The Motorola 68K CAS L and CAS2 instructions should not have destinations on the VME bus e The575 CPU implements the Read M odify Write RM W cycle by maintaining control of the VME bus by using the BBSY signal This precludes the use of semaphores residing on dual ported memory on a third party master if the third party master does not acquire the VMEbus first before accessing its dual ported memory e Read and write operations to the Global Configuration Status Registers in the VMEbus short supervisory address space VM E bus address modifier 2D16 must be limited to byte transfers on odd addresses only The GCSR is a DO8 O slave Do not use word or long word read or write
306. re 4 20 49 Installing the Hoating Point Coprocessor Optional 0 cceeeeeee eee ee ee eeeeeees 4 23 4 10 Configuring the CPU ssssssnsnnnnnnunnennnnnnnnnnnnnnnnnnnunnnnnnnnnnnnnnn 4 24 4 11 Installing a Remote I O Annex Card Optional eere 4 28 4 12 Installing VMEbus Boards cece eee eee eee eee nmn 4 32 4 13 Wiring the Fault Relay cccee eee eee eee hnnc 4 44 4 14 Establishing CPU Communication 00cce eee e eee mmm 4 45 4 15 Using Boards in the VMEbus Base 00 ee cece e nnn nnnm 4 50 4 16 Installing Additional Backplane Connectors eeeeeeeeerrrrrrrnn 4 56 SIMATIC 545 555 575 System Manual Installing 575 System Hardware 4 1 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 4 1 Overview of Installation Proc edures Thefollowing chart identifies the tasks for installing 575 system hardware Optional Install Fan Assembly Install VMEbus Base Install Power Supply Optional Install 575 CPU Options e Series 505 Remote I O Annex e PROFIBUS DP Annex Floating Point Math Co processor Y Install 575 CPU s Y Install VME I O Modules 4 2 Installing 575 System Hardware SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 4 2 Features of the PPX
307. rgy amp Automation Inc recommends that you maintain a 1096 surplus of your system s I O modules as available spare parts Depending upon the number and type of CPUs that you have installed you may wish to stock an extra controller as well Additional spare parts depending upon your site configuration can include items like fuses back up batteries blank filler bezels and spare bases Spares for Series Thefollowing is the recommended list of spare parts for a Series 505 505 System system PPX 505 6504 base 4 1 O slots PPX 505 6508 base 8 1 O slots PPX 505 6511 base 19 inch rack compatible 11 1 O slots PPX 505 6516 base 19 inch rack compatible 16 I O slots PPX 505 6660A or PPX 505 6663 power supply module PPX 2587679 8015 3 0 A 250 V slow blow fuse 3AG for PPX 505 6660A qty 5 PPX 2587679 8018 8 0 A 250 V normal blow fuse 3AG for PPX 505 6663 qty 5 PPX 2601094 8001 RS 232 C RS 423 9 to 9 pin programming cable EEPROM 128K x 8 PPX 2587681 8022 EEPROM 256K x 8 PPX 2587681 8030 EPROM 128K x 8 PPX 2587681 8023 EPROM 256K x 8 PPX 2587681 8031 Battery Kit for 545 1103 1104 CPUs 555 1103 1104 CPUs 505 7101 BASIC Module and 505 ATM Module PPX 2587678 8010 Battery Kit for 545 1105 1106 CPUs 555 1105 1106 CPUs 545 1101 CPU 560 565 CPUs Series 500 CPUs PPX 2587678 8005 D 6 Series 505 and VME Components SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation
308. rnal toothed lock washers star washers to ensure good continuity and low impedance This practice should be used for all terminations lug to subpanel device to lug device to subpanel subpanel to conduit etc Examples of ground connections are shown in Figure 2 12 Equipment Subpanel Step 1 bt Ground braid copper lugs Star Step 2 a Nu Star washers Step 3 Subpanel X or user supplied Step 1 single point ground To ground equipment directly to the sub panel To attach ground leads to the sub panel follow these steps follow these steps 1 Remove the finish from the equipment at 1 Remove the finish from the equipment at areas of contact areas of contact 2 Tighten the first nut 2 Tighten the bolt 3 Tighten the second nut You may need a lock washer to prevent the nut in Step 3 from backing off Figure 2 12 Example of Ground Connections 2 18 Pre installation Guidelines SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Grounding the Ground your 545 555 controller by following the guidelines below to ensure 545 555 Controller that noiseis minimized Chassis e Usethe ground connection Figure 2 13 to attach one end of a ground wire attach the other end to a nearby grounding rod that meets all electrical specifications
309. roducts described in this manual For some PROFIBUS products these pins are used to provide 24 VDC for powering a programming or configuration tool Such tools are not powered by the products described in this manual It is acceptable for an externally powered PROFIBUS programming or configuration tool to drive pins 2 and 7 to 24 VDC Female 9 Pin D Connector Pin Signal D shell 1 CHASSIS GND or NC CHASSIS GND 2 NOCONNECT 8 TX RX RTS BIAS SUPPLY GND BIAS SUPPLY 5V NO CONNECT TX RX BIAS SUPPLY GND BIAS SUPPLY GND 5 TX RX 3 For Pin 3 Terminal B on Siemens connector For Pin 8 Terminal A on Siemens connector Figure 6 21 PROHBUS DP I O Port Pinouts CAUTION Pin 5 BIAS SUPPLY GND and Pin 6 BIAS SUPPLY 5V on the PROFIBUS DP connector are designed to support the PROFIBUS DP I O channel only These pins have a limited output power capability of approximately 0 45 W which greatly exceeds the typical PROFIBUS DP load however overloading these pins may cause internal component damage If the pins are overloaded the PROFIBUS DP port can be rendered non functional requiring the unit to be returned to the factory for repair Do not overload the pins on the PROFIBUS DP connector SIMATIC 545 555 575 System Manual Cabling and Wiring the System 631 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 6 4 Connecting Modems Overview
310. rrupting thecycle If provision is required for changing programs while the equipment is in operation consideration should be given to the use of locks or other means of assuring that such changes can be made only by authorized personnel These recommendations areintended as safeguards against the failure of critical components and the effects of such failures or the inadvertent errors that might be introduced if programs are changed while the equipment is in operation ThelCS 3 304 81 Safety Recommendations from NEMA ICS 3 304 Programmable Controller Standard Recommendations are reproduced by permission of the National Electrical Manufacturers Association SIMATIC 545 555 575 System Manual Pre installation Guidelines 2 3 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Safety Considerations continued Operator Safety Provide a means independent of the controller for disconnecting power Switc hes from the output loads when a machine is not operating or when it is necessary for the operator to reach into the machine Power must be removed by a non semi conductor switch or a physically wired relay contact placed to interrupt power to the output Do not rely solely on the programmable control system for this function Figure 2 1 shows an operator safety switch Relay contacts or limit switches open when operator must reach into machine Ne User supplied N critical loa
311. ry is marginal and switch 9 is set to the On Barr Goop F eshing position Off Battery is discharged or Switch 9 is set to the Off position Data in the CPU is backed up by a lithium battery Status of the battery LED is determined as follows e When the battery dipswitch is set to the On position a battery test is initiated within one second The battery status LED is updated with thetest result e Whilethe battery dipswitch is in the On position the battery is retested whenever the hour byte of the ti me of day dock changes value The battery status is reflected by the results of the last completed test e When the battery dipswitch is set to the Off position battery low status is indicated within approximately one second 9 6 Troubleshooting SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 575 LEDs TheLEDs on the 575 provide CPU status as listed in Table 9 3 NOTE Sincethe CPU receives power from the base power supply module the power supply must be on and functioning correctly to turn the LEDs on If the power supply module is defective or turned off all CPU indicators will be off Table 9 3 575 CPU Indicator PCG On CPU functioning with no fatal errors fault relay is closed PCG Off System has failed fault relay is open RUN On CPU analog and discrete is in the RUN mode RUN Flashing Analog Loo
312. ry to personnel and or damage to equipment Ensure that all power is disabled before attempting the wiring procedures 1 Disconnect power to the base 2 Loosen the three power connector screws A cavTion The PPX 505 6660 and PPX 505 6660 A power supplies have selectable voltage Ensure that the voltage selector is set to match the input power See Figure 3 4 for an example of how to set the voltage selector Attempting to operate the power supply at 220 VAC with 110 VAC selected or 110 VAC with 220 VAC selected results in damage to the power supply Double check your power supply voltage before you connect input power 3 10 Installing 505 System Hardware SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Insert wires as appropriate for your power supply module and tighten screws to no more than 5 in Ib 0 56 N m torque Figure 3 5 shows the location of the power connector screws on the module Consult Section 2 8 for grounding guidelines 2 Siemens SIMATIC 505 Dc POWER GOO AC LINE AC NEUT GROUND Power connector screws Figure 3 5 Series 505 Power Connector 4 Ifyou have the PPX 505 6663 power supply insert the chassis ground DC and DC line wires into the socket on the power supply T
313. s Function feature set the switch tothe right enabled position Refer to Appendix F for more information about the Auto Recompile function 3 22 Installing 505 System Hardware SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Setting Baud Rates Switches 3 through 8 are used to set baud rates for Ports 1 and 2 Switches 3 4 and 5 set Port 1 baud rates See Table 3 3 Switches 6 7 and 8 set Port 2 baud rates See Table 3 4 Table 3 3 Port 1 Baud Rate Settings 115200 57600 38400 19200 9600 2400 1200 300 O E o 5 O E o 5 o 5 O E ololelelelolel o ix ss eS cease van oc Po ood O 5 33a aa a a3 O E 115200 57600 38400 19200 9600 2400 1200 300 These baud rates are available only on the 555 1105 and 555 1106 CPUs NOTE The baud rates 115 200 and 57 600 are available only on the 555 1105 and 555 1106 CPUs SIMATIC 545 555 575 System Manual Installing 505 System Hardware 3 23 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Setting the CPU Dipswitc hes continued The 545 and 555 CPUs have two communications ports Both ports are configured as Data Terminal Equipment DTE Communications SW2 selects Port 1 as either a programming port or a printer port on a Port 1 545 555 CPU Port 1 uses an R
314. s PPX 575 4532 and PPX 575 4732 allow the controller to drive DC loads of various voltages These modules are sourcing output modules An LED indicator on the module faceplate signals a blown fusein the module Table E 10 shows the module specifications and Figure E 5 shows the effect that temperature has on current output for the PPX 575 4532 Table E 10 PPX 575 4532 Specifications Feature Description Optical isolation 1500 Vrms Isolation between commons 500 Vrms Isolation between chassis ground and 1000 Vrms user circuits Commons a One 5A 125 V normal blow 5 x 20 mm Fuses fuse per common 4 fuses total Replace only with UL CSA listed fuse Operating voltage range Maximum off state leakage current Maximum on state voltage drop Minimum load current per point Maximum delay time through module 2 ms on to off with 5 mA load 2 ms off to on Inductive load kickback Diode protected Temporary overload 2 0 A for 1 ms User power current with no load 3 0 mA maximum per common With fan cooling T Without fan cooling ETNI 0 5 Allon 0 4 EE z 0 3 TN 0 2 D 5 04 Oo 0 0 10 20 30 40 50 60 70 0 10 20 30 40 50 60 70 Temperature C Temperature C Figure E 5 PPX 575 4532 Current Point vs Ambient emp E 12 575 V O Module Specification amp Pinouts SIMATIC 545 555 575 System Manual Artisan Technology Group Qua
315. s formerly located in the SIMATIC TI575 System Manual has been moved to an appendix of the SIMATIC 545 555 575 Programming Reference User Manual SIMATIC 545 555 575 System Manual Preface xix Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Related Manuals Additional manuals that have relevant information include the following e SIMATIC 545 555 575 Programming Reference User M anual PPX 505 8204 x e SIMATIC 505 TISOFT2 User Manual PPX TS505 8101 x e SIMATIC 505 PROFIBUS FMS Communications Processor User Manual PPX 505 8129 x for information on operating and configuring the FMS CP module e SIMATIC 505 H1 Communication Processor User Manual PPX 505 8126 x e SIMATIC TIWAY I Unilink Host Adapter User Manual PPX TI WAY 8121 x e SIMATIC 505 500 MODNIM User Manual PPX 505 8122 x e SIMATIC 505Input Output Modules User Manual PPX 505 8105 x e SIMATIC 505 Analogl O Modules User Manual PPX 505 8120 x e SIMATIC 505 Isolated Interrupt Discretel nput Module User Manual PPX 505 4317 x provides information on configuring and installing the interrupt input module PPX 505 8123 x which is required for the operation of interrupt I O e SIMATIC 505 Redundant O Systems Users Manual PPX 505 8125 x e SIMATIC 575 Interboard Communication Specification PPX 575 8103 x e SIMATIC 575 Task Code Use Manual PPX 575 8104 x e SINECL2 L
316. s not illuminated e TheDC POWER GOOD LED on the power supply is illuminated 575 CPU Fatal Enor For 575s a fatal error is indicated when all of the following conditions are Indications present and a power cycle has not been performed since the fault condition e TheSYF LED isilluminated on the CPU that caused the error e ThePCGLED is not illuminated on the CPU that caused the error e ThePOWER GOOD LED on the power supply is on e n a system with more than one CPU both the SYF and the PCG LEDs on each 575 CPU that did not causethe error are off e f a secondary 575 CPU s configuration dipswitches on the PPX 575 2126 annex card are inconsistent with the configuration selected for the primary 575 CPU then the BAT LED on the secondary flashes and the SYF LED on the primary is lit One of twoerrors is indicated on the primary Error code 323 Board timed out during login Error code 11B Board table did not match 9 8 Troubleshooting SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Causes of CPU Fatal Errors 545 555 Fatal Errors The CPU enters a fatal error condition and ceases operation if one of the problems listed below occurs AU X 29 displays the problem that caused the CPU to enter the fatal error condition Hardware failure This error occurs if the power up or user requested diagnostics have detected a hardware problem o
317. s the image register points which represent the inputs from this RBC s base The image register is zeroed out until the RBC completes reset and resumes communication with the CPU If this occurs while the system is operating depending on your RLL program turning these inputs off could affect other base outputs From the assertion of reset until the RBC completes the reset and resumes communication with the CPU the state of the outputs on this RBC s base is determined by the output module with no reference to the RBC sJ P6 Off F reeze jumper Discrete outputs go off to a value of zero Analog word outputs obey their own Zero H old Last Value selection If no Zero H old Last Value selection is available on the module the analog word outputs hold their last value If the base number you assign to the RBC by setting the thumbwheel or rotary switch inadvertently duplicates the number already in use by a second RBC on thel O channel then when the first RBC completes its reset and attempts to communicate identifying itself with the new base number the second RBC will be logged off the system The state of the second RBC s outputs is determined by the selection made on jumper J P6 Off F reeze The CPU image register containing the input points for the second RBC is zeroed I ntermittent operation could occur as long as the two RBC base numbers are set to the same value When the CPU logs an RBC off the system it sets a corresponding bit
318. source follow these guidelines e Usel4to22 AWG solid or stranded wire If you use stranded wire the wire should be twisted and trimmed e Stripinsulation back 0 4 inches 10mm e Insert the wires fully into the terminal block so that the insulation butts against the block NOTE The power connector is rated for 50 wire insertions at a maximum torque of 8 in Ib 0 9 N m SIMATIC 545 555 575 System Manual Installing 575 System Hardware 4 17 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Installing the 575 Power Supply continued Wiring Procedure Refer to Figure 4 11 and follow the steps below to connect input power to the VME power supply module 1 Disconnect power to the base A WARNING To minimize risk of shock hazard always turn off all power to the base before attempting the wiring procedure Failure to turn off power could cause death or serious injury to personnel and or damage to equipment Ensure that all power is disabled before attempting the wiring procedure 2 Loosen the three power connector screws 3 Connect wires as appropriate for your power supply module Ensurethat you have followed the grounding guidelines in Section 2 8 CAUTION Ensure that PPX 575 6663 power supply is set to operate on 110 VAC or 220 VAC to match the input power Section 4 7 describes how to select input voltage for the PPX 575 6663 Atte
319. t 3 to 4 5 m Some advantages of in ceiling routing are listed below e Flexibility e Low cost installation e Accessibility of cabling Some disadvantages of in ceiling routing are listed below e Collection of dust and other debris in ceilings e Hazardous working conditions in ceilings e Impracticality for buildings without drop ceilings Surface ducting is usually installed along baseboards or attached to walls at desktop height While surface ducting ordinarily protects cables from both physical and electro magnetic EMI effects it usually requires I O bases to be positioned near a wall NOTE Consult your cable vendor for proper cable pulling techniques so that no kinks occur in the cable during installation SIMATIC 545 555 575 System Manual Cabling and Wiring the System 6 3 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 6 2 Installing Series 505 Remote I O Cables Media Options There are two media options for Series 505 remote I O cabling e Non redundant I O cabling using twisted pair RS 485 media e Redundant I O cabling using coaxial RF media This section describes the twisted pair media If you are installing a coaxial O system see the description of the RS 485 RF converter in Appendix C and follow the instructions in the SIMATIC 505 Redundant I O Systems User Manual PPX 505 8125 x Equipment Needed U ser supplied components are listed below
320. t the RBC assumes the RS 232 baud rate stipulated by the setting of switches 1 through 3 on the dipswitch and the station address indicated by switches 4 through 10 a WARNING Pressing the RESET button when the system is operating causes the RBC to be logged off the system When the RBC is logged off inputs and outputs associated with the base are affected as described below If you do not take the condition of your inputs and outputs into account logging the RBC off the system can cause unpredictable process operation Unpredictable process operation can cause death or serious injury to personnel and or damage to equipment Do not reset your RBC unless you understand and are prepared for the consequences described below Resetting the RBC The following actions take place when an RBC is reset e TheCPU logs the RBC off the system and sets the image register points which represent the inputs from this RBC s base to zero The image register is zeroed out until the RBC completes reset and resumes communication with the CPU If this occurs whilethe system is operating depending on your RLL program turning these inputs off could affect other base outputs e From the assertion of reset until the RBC completes the reset and resumes communication with the CPU the state of the outputs on this RBC s base is determined by the output module with no reference to the RBC S E1 Off F reeze jumper Discrete outputs go off to a value o
321. tation Guaranteed 888 88 SOURCE www artisantg com 6 4 6 5 Connecting Modems ss ss eee eee hnnc n 6 32 OVelvie W coii A RE RS REG GRE RIxGERIOUESEG D vale vas IC DxXeXqexk Cw CENE 6 32 Dedicated Line Operation 0 cc cece eese 6 33 Dial up Phone Line Operation ssssssssseeee e 6 33 Connecting to a Printer 0 6 34 OVelVIeW aooga a eed Seda k Senda SadeeGes aa whenever ae lee oie ae ee dus 6 34 545 555 Printer CONNECTIONS 1 isses IRR hn 6 34 575 Printer CONNECTIONS siese eredet eea RR mn 6 35 Chapter7 Using EEPROMs for Program Storage 7 1 7 2 73 7 4 Program Storage Options c cece ee cence seen eee eee eee eee eee eens 7 2 e c TK 7 2 On Board Flash EEPROM Program Storage see eee eens 7 2 Optional Portable EEPROM Program Storage cece eens 7 2 EEPROM Porta bility dus eie re Re dade dasa de Dridg er dade deine gena 7 3 Using AN EEPROM ccc ccc ccc ccc hah 7 3 Using ari EPROM agraris curie ide dein ee eda ee hd bea EP Edd EX Ee eis 7 3 What is Stored in Non Volatile Memory 6 0 eens 7 4 Program Storage Operations 0 cece cece eee n 7 5 Memory and Mode Status at POWEIUD 0 0 cece 7 5 Configuring the CPU for Non Volatile EEPROM Program Storage 7 6 Configuring the CPU for Portable EEPROM Usage sssseeee n 7 6 Configuring the CPU forOn Board EEPROM Usage 0c cece cent eee nens 7 8 Copyi
322. that the CPU and modem baud rates are set to the same value NOTE f the modems are auto bauding ensure that the CPU baud rate is set within the baud rate range of the modems 3 Power up the modems and verify that they are connected usually by consulting an indicator on the modems 4 Start TISOFT TISOFT auto bauds to the system s baud rate CPU and modem Usethese procedures to establish communication between modems in a Operation dial up phone line configuration 1 Connect the modem configuration 2 Ensurethat the CPU and modem baud rates are set to the same value 3 Depending on the type of modems being used the following are three ways to establish communication between the modems e Manually call from one modem station to the other modem station and then switch on both modems e Manually call from one modem station to an auto answer modem at the other station e UseTIDIAL dialing software installed with TISOFT Release 5 0 to call an auto answer modem at the CPU modem station 4 Start TISOFT TISOFT auto bauds to the system CPU and modems baud rate SIMATIC 545 555 575 System Manual Cabling and Wiring the System 633 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 6 5 Connecting to a Printer Overview 545 555 and 575 CPUs havethe capability to send information to a printer through the use of an SF program or SF subroutine The printer connects to a serial
323. the other cable end to the terminal screws in terminal block B Tighten screws on terminal block B If you are not using another terminal block install a terminating resistor across the terminal screws that securethe cable wires with the color coded insulation The terminating resistor value depends on the type of cable being used and must match the characteristic impedance See Table 6 3 A terminating resistor must be installed on the end terminal block s Refer to Chapter 9 for procedures to check for faulty cables 618 Cabling and Wiring the System SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Trunk line TX RX Trunk line Trunk line gt Terminating resistor Terminal AE Terminal Block A CC K Block B l O Link port TX RX l O Link port of CPU or RBC of CPU or RBC Drop line 9 TX RX TX RX Figure 6 10 Extending and Terminating Trunk Line SIMATIC 545 555 575 System Manual Cabling and Wiring the Sytem 619 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 6 3 Installing PROHBUS DP I O Cables Media Options The PROFIBUS DP I O channel provides serial communication over either of the following e Shielded twisted pair RS 485 cable media e Glass or plastic fib
324. the selection made on the RBC jumper E1 Off F reeze Figure 5 9 shows the location of the jumpers on the RBC NOTE You must make an E1 jumper selection The RBC Status Display reports an error if no jumper selection is made For discrete output modules the state of the outputs is determined solely by the position of the E1 Off F reeze jumper For analog word output modules the state of the outputs is influenced not only by the position of the E1 Off F reeze jumper but by the output module s Zero H old Last Value selection if the module has that option See Table 5 5 Table 5 5 Analog Word Output States x Analog Word Module Analog Word REC Off Freeze Selection Zero Hold Selection Output State Zero Zero Hold Last Value Last Value noselection Last Value Zero Last Value Hold Last Value Last Value noselection Last Value See the user manual of your analog word output module for further details Installing Remote Base Controllers RBC s SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com RESET pushbutton recessed Header E4 Jumper E1 for setting output state Off Freeze Jumper E2 Jumper E3 Figure 5 9 RBC Jumper Locations Notice in Table 5 5 that the Freeze option on the RBC overrides the Zero selection on the analog word output module likewise when Hold Last Value is selected on the
325. the unit see Figure 4 31 3 Removethe 10 M2 5 x 10mm screws that hold the backplane spacers Remove the spacers and discard or save them for future use 4 UsingM2 5 x 10mm screws mount the Z Rails onto the rear chassis rails directly without the backplane spacers as shown in Figure 4 33 5 Mount the 2 connector s to the Z Rails using M2 5 x 10mm screws as shown in Figure 4 33 6 Replacetherear panel and the battery assembly 4 Existing J1 Backplane M2 5 x 10mm screw Chassis rail zI 4 Optional J2 Connector Chassis rail Xd VY M2 5 x 10mm screw D Figure 4 33 Installing J2 Connector M2 5 x 10mm screws 4 58 Installing 575 System Hardware SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Chapter 5 Installing Remote Base Controllers RBC s 5 1 OVEIVICW MEE 5 2 52 Installation 212 hr Rr ene eee SERRA ee ee ee ee anaana 5 3 Models Used in Series505 Base 1 cece tenes 5 3 RBC PlaCeMENE in Base 2 pi eee he dad hp ded he dee ew ee de erga bee da reru 5 3 Installing and Removing the RBC eee eee eae 5 4 5 3 Communication Ports 0c eee eens 5 5 RS 232 POIE 22 ied icd EX RU Rin Cd a e RR RS RO d aon e lud ecc doled erg 5 5 Hog M ETT 5 5 5 4 PPX 505 6851 A B and PPX 505 6850 A B RBCS eeennn n nnn 5 6 UserOptlols 4
326. ther than those listed here Invalid control block S Memory is inconsistent An error has been detected in a control block being accessed by a loop analog alarm SF program or SF subroutine The most likely cause of this error is that S M emory has been corrupted Operating system fatal error The CPU has detected a logic error during execution of the operating system firmware RAM diagnostic failure O S RAM The system has detected a RAM error while running diagnostics on System RAM I mage Register RAM or Image Register Force RAM Thisis a hardware failure ROM diagnostic failure O S ROM The system has detected a ROM checksum error while running diagnostics on System EEPROM This is a hardware failure Watchdog timeout There are two possible reasons for this error First reason The scan watchdog expired during execution of the RLL scan Using AUX 14 check to verify that the scan watchdog has been set to a sufficient value Notethat an incorrectly tuned system may experience this error if the cyclic RLL task TASK 2 or theinterrupt RLL task TASK 8 consume a high percentage of available CPU time You may need to increase the scan watchdog increase the cyde time for TASK 2 reduce the amount of RLL executed in TASK 8 or some combination of these changes Second reason The hardware has failed in such a way as to prevent scan operation Fatal error dueto EEPROM This error occurs on a 545 or a 555 if
327. through the CPU into the annex card standoffs and tighten 3 12 Installing 505 System Hardware SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com O SIMATIC 545 CPU GOOD Q RUN BATT GOOD 0 PROFIBUS DP Q E Dipswitch s 545 1105 O Figure 3 6 Installing the PROHBUS DP Annex Card in 545 1103 1105 CPU SIMATIC 545 555 575 System Manual Installing 505 System Hardware 3 13 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 3 8 Installing the 545 555 CPU CPU REC Location The second slot from the left beside the power supply module is reserved in in a Base Series 505 bases for the CPU or RBC as shown in Figure 3 7 Figure 3 7 Location of CPU RBC in a Series 505 Base Installing and Refer to Figure 3 8 and follow the steps below to install the 545 555 CPU Removing the CPU A WARNING Installing or removing a CPU from a powered up base disrupts your process Disruption of your process can cause death or serious injury to personnel and or damage to equipment Ensure that all power is disabled before installing or removing the CPU 1 Disconnect power to the base 2 Position the CPU so that the be
328. tion C 2 for information about upgrading an existing 520 520C 530 530C or 530T system Refer to Section C 3 for information about upgrading an existing 560 560T 565 or 565P system that has one or more RS 485 remote I O channels Refer to Section C 4 for information about upgrading an existing 560 560T 565 or 565P system that has one or more coaxial remote I O channels C 2 Upgrading Existing Series 500 Installations SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com C 2 Upgrading a 520 520C 530 530C 530T System When you upgrade from a 520 520C 530 530C or 530T system all of your existing Series 500 bases whether local or remote must be converted to Series 500 remote bases The CPU and 1 O channel converter IOCC on the local base and the distributed base controller DBC on the remote base s are all replaced by the same unit the PPX 500 5114 A RBC In the case of a 520 530 CPU or a PPX 500 2103 DBC it is necessary to install an adapter base and modular power supply when you upgrade to the 500 5114 A RBC Consider these points when you prepare to upgrade your system e n the case of 520x 530x systems the Series 500 physical base assembly is composed of one or two logical bases A logical base is defined as a contiguous group of eight I O slots For example the 16 slot physical base assembly has two 8 slot logical bases Each lo
329. to a value of zero Analog word outputs obey their own Zero Hold Last Value selection If no Zero H old Last Value selection is available on the module the analog word outputs hold their last value NOTE The DBC being replaced and previous models of the RBC automatically set all discrete outputs to Off 0 and froze analog outputs unless the output module had a ZERO HOLD LAST VALUE option SIMATIC 545 555 575 System Manual Upgrading Existing Series 500 Installations C 15 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Installing a PPX 500 5114 A RBC continued Status Display As shown in Figure C 7 the display at the top of the module indicates the status of the Series 500 RBC RS 485 I O port 9 pin female a A LED display p Pase thumbwheel Thumbwheel Baud Number L Baud rate thumbwheel i RS 232 port 25 pin female Figure C 7 Series 500 Remote Base Controller and Baud Rate Settings Status is displayed in integer format see Table C 2 for definitions Table C 2 Series 500 RBC LED Messages e nemo C netiis 0 RBC Good NotUsed 1 Self Diagnostics Failure 6 Not U sed 2 Module Mismatch 7 Communication Good Not Configured Watchdog Timer Expired Out 4 RAM Parity Error Setting Baud Rates The RBC is equipped with a RS 232 port that allows you to
330. to the low state for 100 milliseconds and then examines the BGIN2 signal In the 575 VMEbus base this is used to place the battery under load sothat the battery status reflects the battery s true condition You can implement external circuitry to provide a similar capability for your third party base if desired 4 4 Installing 575 System Hardware SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 4 4 Enclosure and Temperature Considerations Enclosure Selection Temperature Considerations An enclosure should provide the following features e Easy access to components e A common ground potential on the cabinet e A secure vertical panel or rails e Conformance to electrical standards e An electromagnetic shield if needed to meet FCC or CE emission standards e Access restricted to authorized personnel only e Adequate cooling and heat dissipation e Protection from dust and dirt as required by the environment Mount the components in a dustproof and drip tight enclosure such as a NEMA enclosure The enclosure must provide a minimum depth of 12 inches 305 mm from the panel to the inside surface of the enclosure door The enclosure should be located so that the doors can be opened fully permitting easy access to the controller wiring and components If environmental conditions permit a 19 inch rack may be used instead of a NEMA
331. tons limit switches and analog sensors Acting on this information and executing a relay ladder logic RLL program stored in memory the CPU produces output signals to drive motor starters solenoids pilot lights modulating control valves etc These signals are used to regulate the operation of various pieces of equipment A full line of discrete analog word and intelligent I O modules are available for handling al most any input or output specification These I O modules are rugged plug in devices capable of functioning within operating specifications in harsh environments Compatibility with Current 545 and 555 CPUs are fully software compatible with previous 545 Previous C PUs and 555 CPUs However the early model 545 1101 has a female connector and a different electronic pinout on RS 232 port 2 compared to all other 545 and 555 CPU models which have a male connector 1 2 System Overview SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Features on New CPU Models The newer model 555 and 575 CPUs incorporate several new features and enhancements including the following The 555 1105 1106 CPUs and 575 2105 2106 CPUs indudea built in Motorola 68882 floating point math coprocessor The 555 1105 1106 and 575 2105 2106 CPUs support PowerM ath functionality which compiles high level math functions using the new memory type all
332. ual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Specifications for the discrete DC 16 input 16 output module are shown in Table E 4 See Table E 5 for the connector pinouts Table E4 16 Input 16 Output Module Specifications Feature Bexrpion OO O 45 V base current consumption 0 9 A maximum Veatt 45 V STDBY current None consumption ee One 5A 125 V normal blow 5x20 mm Fuses fuse per output common Replace only with UL CSA listed fuse TIR 3 0 mA maximum per common with On state indicators one per channel One blown fuse indicator which lights Indicators when any fuse blows user power and base power must be on 16 Input type IEC type 1 14 0 VDC UH min On voltage 36 0 VDC UH max 0 0 VDC UL min Off voltage 5 0 VDC UL max un 2 0 mA IH min On input current limits 15 0 mA IH max Off input current 0 5 mA max Module time delay ee On state indicators one par channa SIMATIC 545 555 575 System Manual 575 O Module Specification amp Pinouts E 5 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 16 Input 16 Output 24 VDC Module continued Table E 5 16 Input 16 Output Module Connector Pinouts Rw spnep 8 0 d PAR ImwtseHon amp dum SSS SR imutseHonBrdum B4 B4 C A CR c ci c C2 c3 C3 cc Output seton C usa pow
333. ubleshooting CPU Fatal Errors ccccc cece cece 9 8 545 555 CPU Fatal EmorIndications sssssssss renr r rnnr een nneenes 9 8 575 CPU Fatal Error IndicationS ccc ccc cee eee nee nee nnneenes 9 8 Causesof CPU Fatal ENOI 0 ccc ccc cent nee n een een nnennnnees 9 9 545 555 Fatal ETOS cc cece ccc ia aoia ra 9 9 575 Fatal EITOTS aa eR LER e s acie eee t ete n erase leu d daw RE dac See Dk Mok idee 9 10 545 555 575 CPU Fatal ErorCodes sssssseses nee rnnr rnrn 9 10 545 555 CPU Responsesto Fatal EMOrsS 1 ene nn 9 13 Stepsto Clear 545 555 Fatal ErOrsS cece ccc ccc cect nn 9 13 575 CPU Responsesto Fatal Emors 0 cece cece tte e nnn 9 14 Stepsto Clear575 Fatal ErOrs 0 ccc cece ttt ttt nnn 9 15 Calling for Assistanee 4c egre gost reem gb deere ee aa eee ee ee ETE ERREUR 9 15 9 4 Troubleshooting CPU Non Fatal Emors cece cece eee eere nnn nnn 9 16 9 5 Troubleshooting by Using Status Words eere nnm I nnn 9 17 9 6 Troubleshooting User EEPROMs or EPROMs seen nn nmn 9 18 9 7 Troubleshooting Power Supplies 00cccceeeeeeee ee eee eee eee eee eee eee 9 19 9 8 Checking RS 485 Twisted Pair Cable Installation euueereees 9 21 Using DigitalorAnalog Meter sssssssssssseee ee I 9 21 Resistance below Minimum 00 cece cece HI 9 21 Resistance above Maximum ssssseeee hn 9 22 9 9 Check
334. uld result in death or serious injury and or property damage r CAUTION indicates a potentially hazardous situation that if not avoided could result in minor or moderate injury and or damage to property CAUTION CAUTION without the safety alert symbol indicates a potentially hazardous situ ation that if not avoided could result in property damage Copyright 2000 by Siemens Energy amp Automation Inc All Rights Reserved Printed in USA Reproduction transmission or use of this document or contents is not permitted without express consent of Siemens Energy amp Automation Inc All rights including rights created by patent grant or registration of a utility model or design are reserved Since Siemens Energy amp Automation Inc does not possess full access to data concerning all of the uses and applications of customer s products we do not assume responsibility either for customer product design or for any infringements of patents or rights of others which may result from our assistance Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com MANUAL PUBLIC ATION HISTORY SIMATIC 545 555 575 System Manual OrderManual Number PPX 505 8201 3 Refer to this history in all correspondence and or discussion about this manual Event Date Description Original Issue 03 96 Original Issue 2804693 0001 Second Edition 08 98 Second Edition 2804693 0002 Third Edit
335. ured to do so a 575 that is acting as system controller asserts SYSRESET on the VMEbus on any fault restart i e AUX 11 or AUX 12 from TISOFT in FAULT mode If the 575 is executing in FAULT mode with a bad battery and an AUX 11 or AUX 12 is executed from TI SOFT the 575 performs a bad battery powerup all user memory is re initialized SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Table 9 1 shows the effects of using AUX 10 AUX 11 and AUX 12 Table 9 1 Effects of Using AUX 10 AUX 11 and AUX 12 Power up Restart Partial Restart Complete Restart 1 Ifin EDIT mode Goto PROGRAM mode prior to RUN mode AUX 10 AUX 11 AUX 12 Battery Battery Battery System Characteristic OFF OFF ON OFF AL D SN ROM T l ee i Program pele 3 ene 3 No change No change Loop Processing Mode No change iecit ae 3 DN 3 No change No change Loop Mode No change N A Nochange Nochange Manual Manual Discrete I O X s and Y s Cleared Cleared Cleared Cleared Cleared Cleared odd WY s No change Cleared Nochange Nochange Cleared Cleared Med Cleared Cleared Cleared Cleared Cleared Cleared Retentive Control Relays No change Cleared Nochange Nochange Cleared Cleared Forced Elements No change Cleared Nochange Nochange Nochange Nochange TMR CTR Drum Presets No change Cleared N
336. ut capabilities Table E 7 shows connector pinouts With fan cooling 15 Without fan cooling A O 10 20 30 40 50 60 70 10 20 30 40 50 60 70 Temperature C Temperature C Figure E 2 16 point AC Output Curent Point vs Ambient emp Table E 7 Discrete AC 16 point Output Module Connector Pinouts Fm Sa EP A OupuseHonA Eum xi out S fas Output CIA M qum IN Output section A user power BR Output section B return B1 Output 5 B1 pz fome SSCS pa outs te for c cc Outputsection Cuserpower DR OwmursetnD rdum pa Outmut18 P4 pe Output section Duser pow E8 575 V O Module Specification amp Pinouts SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com EA Disc rete Relay Output Module The discrete relay output module PP X 575 4916 allows the controller to drive AC and DC loads of various voltage and current ranges Theloads can be sourcing or sinking Table E 8 shows module specifications Table E 8 Discrete Relay Output Module Specific ations Optical isolation 1500 Vrms Isolation between commons 1500 Vrms sol ation between chassis ground and
337. utput 8 point in 5 0 505 6208 A Analog Output 8 point in 2 0 505 6308 Word Input a 4 0 505 6408 Word Output a 5 0 1 Modules that are affected by date code restrictions See Section B 2 for information B 4 Power and Compatibility SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Table B 3 Series 505 Module Power Requirements continued Special Maximum DC Power aar cud Description Function M ii Consumption Watts r Module 505 6850 A Coax Dual Media RBC 5 0 0 200 505 6850 B Coax Dual Media RBC 5 0 0 200 505 6851 A RS 485 Dual Media RBC 5 0 0 200 505 6851 B RS 485 Dual Media RBC 5 0 0 200 505 6870 505 PROFIBUS DP RBC 5 0 0 200 505 6860 RF to RS 485 Converter 2 0 0 200 505 7002 High Speed Counter amp Encoder a 2 0 505 7003 High Speed Counter Encoder a 2 0 505 7012 8 1 n 4 Out Analog al 3 0 0 030 505 7016 Bipolar 81n 4 Out Analog in 3 0 0 030 505 7028 Thermocouple Input al 2 2 0 01 505 7028 A Thermocouple Input in 3 0 0 01 505 7038 RTD Input al 2 2 0 505 7101 BASIC Module w 6 0 0 125 505 7190 7MT Channel Controller 4 0 505 7202 FIM Field Interface Module 2 5 505 7339 NIM Network Interface Module w 8 0
338. wer upthe 575 system 7 Reconnect the battery after the PCG LED lights up on the 575 system controller that is when the LED on the bottom right hand side turns on SeeFigure 4 19 for the location of the LEDs 8 Load your program s SIMATIC 545 555 575 System Manual Installing 575 System Hardware 4 37 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Installing VMEbus Boards continued Guidelines for If you want to replace a 575 primary that is not in slot 1 a 575 that has Replacing a 575 been configured as a primary by means of the primary switch SW7 as Primary Not in described in Section 4 10 follow the steps below Slot 1 NOTE Read and abide by the warnings and cautions at the beginning of this section 1 Before you remove the 575 primary save the memory of the 575 primary any 575 secondaries and any third party masters 2 Ensurethat all power is disconnected from the VM E bus base Do not omit this step 3 Removethe 575 primary CPU 4 Ensurethat dipswitch configuration of the new 575 primary is configured to match the dipswitch configuration of the previous primary Refer to Section 4 10 for information about dipswitch configuration 5 Install the new 575 primary 6 Power upthe system The 575 primary and all the 575 secondaries perform a battery bad powerup 7 Update the battery status after the PCG LED lights up on the 575 system controlle
339. wire resistance is less than 0 1 ohm e Ensure that the resistance to earth ground is 0 1 ohm or less Power company transformer Circuit Service breaker Base entrance Conduit panel Conduit power supply AC line AC neutral Ground TT Protective IH DH ground Power Earth company ground rod earth ground Figure 2 11 Isolating Ground and Neutral From Conduit SIMATIC 545 555 575 System Manual Pre installation Guidelines 2 17 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Grounding the Power System continued Ground Use particular care when establishing the ground connections The Connections following techniques will help to establish good electrical connections and decrease noise interference e Where possible terminate grounding braid and green wires at both ends with copper eye lugs to provide a good contact surface Lugs should be crimped and soldered e Use 10 copper bolts or equivalent for those fasteners providing electrical connections to the single point ground This applies to device mounting bolts and braid termination bolts for subpanel and user supplied single points Tapped holes for these fasteners are better than nut bolt arrangements e Paints coatings and corrosion can prevent good electrical contact at ground points Remove these impediments in the area of contact and use exte
340. witch Setting A Version Only 0c cece eee eee eens 5 8 RBC Status Codes edes sn tested t euet teda vat Farb Eu ur yee EE wur 5 12 Analog Word Output States sisssssssssssssssese eer 5 14 RS 232 Port Baud Rate SettingS 0 cece eee 5 17 Setting the RBC Station Address sssssssseeesssse nnn 5 18 505 PROFIBUS DP RBC StatusCodes 0 cc cece cette 5 22 505 PROFIBUS DP RBC Software Parameters 00 ccc ce cece ttt eens 5 24 Series505 Cable Characteristics cic cts 6 7 Maximum Cable Length for Trunk LineS 000 eee 6 9 Terminating Resistors 0 0 cece tae 6 15 PROFIBUS DP Components All Baud Rates cee eee 6 21 PROFIBUS DP Components Low Baud RateS e eee eee eee 6 21 PROFIBUS DP Cable Specifications 0 0 ccc cee 6 22 PROFIBUS DP Line Length Limits ssssssssssseeee eem I 6 22 Program Storage Capacities sssssssssssssesse eee 7 2 Program Storage Using EEPROM sssssssseeee eee 7 2 Mode and Memory StatusafterPowermp ssssssesee eee 7 5 545 1103 1105 CPU Memory Configuration 0 00 cece ccc ees 8 4 545 1104 1106 CPU Memory Configuration 0 c cece ees 8 5 555 1103 CPU Memory Configuration 00 ccc cece tte 8 5 555 1104 CPU Memory Configuration 00 ccc cece ttt eee 8 6 555 1105 CPU Memory Configuration 0 0c cece ttt tte 8 6 Co
341. ws O COAUNON The PPX 505 6860 is not designed to be installed in a VME base Doing so results in damage to equipment Never attempt to install the PPX 505 6860 in a VME base C 20 Upgrading Existing Series 500 Installations SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Removing the To remove the PP X 505 6860 complete the following steps RS 485 RF O Channel 1 If attached remove cables from the front of the PPX 505 6860 Converter 2 Disconnect power to the base A WARNING Disable all power to the base before installing or removing the PPX 505 6860 Installing or removing any module from a powered up base could cause unexpected operation which could cause death or serious injury to personnel and or damage to equipment To prevent disruption of the I O channel disconnect the I O channel cable before removing or installing the PPX 505 6860 3 Loosen top and bottom bezel screws 4 Carefully pull the PPX 505 6860 from the base 1 CAUTION j The PPX 505 6860 is sensitive to and can be damaged by electrostatic discharge Ensure that personnel make contact with a static dissipative pad and or wear a grounded wrist strap when handling the PPX 505 6860 SIMATIC 545 555 575 System Manual Upgrading Existing Series 500 Installations C 21 Artisan Technology Group Quality Instrumentation
342. y If the primary 575 CPU is set tothe USER C ONHGURED mode then all 575 secondaries must also be set to the USER C ONAG URED mode 575 2104 CPUs require an I O annex card in order to select user configured mode NOTE You must know the di pswitch configuration of your primary 575 before you can correctly configure your 575 secondary All primary and secondary CPUs must have the same dipswitch settings for switches SW3 through SW6 Refer to Section 4 10 for information about dipswitch configuration Install the new 575 secondary Power up the 575 system The new 575 secondary performs a battery bad restart and then transitions to FAULT mode The PCG LED does not light up The other 575 CPUs restart according to the battery status The primary 575 asserts SYSFAIL The SYF LED lights up on the primary 575 See Figure 4 19 for the location of the LEDs This allows you to reload the replaced CPU prior to starting control from other CPUs UseTISOFT to execute AUX 11 partial restart or AUX 12 complete restart to clear the fatal error Load your program in the new 575 secondary SIMATIC 545 555 575 System Manual Installing 575 System Hardware 4 39 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Installing VMEbus Boards continued Guidelines for Installing SIMATIC VMEbus I O and Third Party Boards The following guidelines apply when you install SIMATIC VMEbus I O a
343. ypical fast DP O update time for your application the following time components should be considered 1 Buffer access a DP buffer is accessed in less than 0 1 ms unless consistency is selected 2 DP data cycletime an estimate of DP data cycle time is given by the COM PROFIBUS software tool 3 DP RBC Remote Base Controller data cycle time a SIMATIC 505 DP RBC reads writes discrete modules every 2 ms and word analog modules every 4 ms This delay is not present for modules that connect directly to PROFIBUS DP 4 Module delay time module delay time is given in the SIMATIC 505 Input Output Modules User Manual for each SIMATIC 505 module Delay times for other slaves can usually be obtained from their documentation Given a 12 Mbaud network with a 53 slave configuration COM PROFIBUS estimates a typical data cycle time of 2 7 ms for the PROFIBUS DP channel For a SIMATIC 505 discrete AC module in the local base an ORW immediate requires 10 5 ms to complete Shifting the module to a DP base increases its update time to 17 5 ms The difference 7 ms is within the calculated typical update bounds of 4 7 ms 2 7 2 0 to 9 4 ms 5 4 4 0 of the DP and 505 DP RBC update cycles This is a worst case scenario Normally faster DC I O modules are used in applications where response speed is important and stand alone slaves do not have delays such as those created by the RBC Therefore use the considerations described above in or
344. zel is facing you O COAUION Electronic equipment is sensitive to and can be damaged by electrostatic discharge Ensure that personnel make contact with a static dissipative pad and or wear a grounded wrist strap when handling the CPU cards or modules 3 Grasp the top and bottom of the CPU module 3 14 Installing 505 System Hardware SIMATIC 545 555 575 System Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 4 Carefully push the module into the slot until it mates with the backplane connectors 5 Tighten top and bottom bezel screws Minimum torque 2 6 in lb 0 3 N m Maximum torque 5 2 in lb 0 6 N m Figure 3 8 Installing CPU Module in a Series 505 Base To remove the CPU complete the following steps 1 If cables are attached remove them from the front of the CPU 2 Disconnect power to the base 3 Loosen top and bottom bezel screws 4 Carefully pull the CPU from the base SIMATIC 545 555 575 System Manual Installing 505 System Hardware 3 15 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 3 9 Replacing and Handling the Battery Lithium Battery in The 545 1105 1106 and 555 1105 1106 CPUs use a lithium battery for the 545 and 555 maintaining CPU memory contents while power is not present The lithium 1105 1106 CPUs battery is a primary cell it

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