2500-RIO RS-485 Remote Base Controller
Contents
1. Cable Routing and Layout Guidelines Cables containing the following should be routed Bus signals e g Remote I O Data signals for PCs programming devices printers etc Screened analog inputs Unscreened DC voltages lt 60V in the same cable loom or cable duct Screened process signals lt 25 V Unscreened AC voltages lt 25V Coaxial cables for monitors DC voltages from 60 V to 400 V unscreened in separate cable looms or cable ducts AC voltages from 25V to 400 V unscreened without minimum spacing requirements DC and AC voltages gt 400 V unscreened Telephone cables For areas with explosion hazard in separate cable looms or cable ducts without minimum spacing requirements Laying Cables Outside of Control Cabinets All cable ducts should be constructed of electrically conducting material and connected to functional ground at regular intervals Cables should not be subject to mechanical loads which exceed the manufacturer s specifications If this cannot be avoided additional protective measures should be taken such as laying the cables in a steel pipe or rugged metal duct The pipe or duct should then be grounded at regular intervals and protected against corrosion 12 2500 RIO Installation and Operation Guide V1 1 SPECIFICATIONS General Module Size Double Wide SIMATIC 505 I O Backplane Power Consumption 2 5 wa2. 2 4 Configuring the Module Setting the RS232 Port Baud Rate Setting the Output State on Communication Loss 2 5 Physical STAN QMO ssiri En aa SEEE aaa EREE 2 6 Connecting to the RS232 Port 6 2 7 Connecting the Remote I O Cable 7 2 9 Operation of LED Display 8 APPENDIX A REMOTE I O INSTALLATION GUIDELINES Cable Layout Planning Cable Selection Cable Lengths Bus termination Cable Routing and Layout Guidelines Laying Cables Outside of Control Cabinets SPECIFICA HONS u u u u u uu u u usus eaea CTI 2500 RIO Installation and Operation Guide V1 0 CHAPTER 1 DESCRIPTION 1 1 Introduction The CTI 2500 RIO RS485 Remote Base Controller is a Eo member of Control Technology s family of I O modules 1 compatible with 505 programmable controllers from 0 Siemens and CTI 3 The 2500 RIO RS485 Remote Base Controller RBC allows a SIMATIC 505 I O base to function as a remote base on the 505 Remote I O channel The 2500 RIO is intended to be a replacement for the Siemens 505 6851 A RBC It provides the following functio
3. J 5 a O i TX RX 8 Figure 4 Remote I O Port CTI 2500 RIO Installation and Operation Guide V1 0 2 8 Operation of LED Display The LED Display is used to indicate the status of the 2500 RIO Remote Base Controller as shown in the following table Display Definition Communication Comment Action s to RBC Module Fully Operational online with Diagnostics Failure Serious malfunction Place system in safe state and contact CTI Technical Support Module Mismatch I O modules installed do not match the expected configuration in the CPU No Communications Failed There is no communication with the CPU Place the system in a safe state Check power cabling and connection to the CPU RAM Parity Error None The 2500 RIO has detected an internal RAM parity error Serious malfunction Place system in safe state and consult CTI Technical Support Standby No None Standby RBC in dual media application Configuration is not configured Configure module Address Mismatch Dual media RBC s must have identical station address If addresses are equal contact CTI Technical Support No Configuration 2500 RIO is not configured Configure RBC in CPU Watchdog Timeout None RBC reset by hardware watchdog timeout Serious malfunction Place system in safe state and consult Technical Support Standby Configured Sta
4. 2500 RIO RS485 REMOTE BASE CONTROLLER INSTALLATION AND OPERATION GUIDE Version 1 0 CTI Part 062 00366 010 2500RIO IOG 120805 Copyright 2005 Control Technology Inc All rights reserved This manual is published by Control Technology Inc 5734 Middlebrook Pike Knoxville TN 37921 This manual contains references to brand and product names which are trade names trademarks and or registered trademarks of Control Technology Inc Siemens and SIMATIC are registered trademarks of Siemens AG Other references to brand and product names are trade names trademarks and or registered trademarks of their respective holders DOCUMENT DISCLAIMER STATEMENT Every effort has been made to ensure the accuracy of this document however errors do occasionally occur CTI provides this document on an as 1s basis and assumes no responsibility for direct or consequential damages resulting from the use of this document This document 15 provided without express or implied warranty of any kind including but not limited to the warranties of merchantability or fitness for a particular purpose This document and the products it references are subject to change without notice If you have a comment or discover an error please call us toll free at 1 800 537 8398 or email us at sales controltechnology com REVISION HISTORY 12 08 05 ry s PREFACE This Installation and Operation Guide provides reference information for the CTI 2500
5. RIO RS485 Remote Base Controller The information in this manual 15 directed to individuals who will be installing the module and configuring it for use with a 505 CPU from Siemens or CTI We assume you are familiar with the installation and operation of SIMATIC 505 programmable controllers Please refer to the appropriate SIMATIC user documentation for specific information on SIMATIC 505 programmable controllers and I O modules 2500 RIO Installation and Operation Guide V1 0 USAGE CONVENTIONS NOTE Notes alert the user to special features or procedures CAUTION Cautions alert the user to procedures that could damage equipment WARNING Warnings alert the user to procedures that could damage equipment and endanger the user TABLE OF CONTENTS WW W 10 11 12 12 CHAPTER 1 DESCRIPTION As alt OCNIC ieh uuu uu 1 2 Communication Ports 1 2 1 Serial Port 1 2 2 Port CHAPTER 2 INSTALLATION 2 Ax T Lu lelaveds Choosing Remote I O Media Selecting a Remote Base Address Setting Module Hardware Options Connecting to Remote I O Cable 2 2 Power Requirements aa 2 3 Unpacking the Module
6. the module is fully seated in the slot tighten the captive screws at the top and bottom to hold the module in place To remove the module from the I O base loosen the captive screws and then pull the module from the base Take care not to damage the connector at the back of the module when inserting or removing the module 2 6 Connecting to the RS232 Port The RS232 port 15 provided to interface to PLC programming and configuration tools such as TISOFT The use of this port is optional A standard 9 pin PC RS232 serial cable can be used to connect to the programming device or modem The port details are shown in Figure 3 6 2500 RIO Installation and Operation Guide V1 1 9 Pin D Shell Male Connector Compatible with standard PC Serial Port RxD 2 TxD 3 SGND 5 N J lt Figure 3 RS232 Serial Port The I O Port connects the 2500 RIO to a SIMATIC 505 compatible RS485 Remote I O channel This enables the remote Siemens 505 CPU or CTI 2500 CPU to control the I O modules in the base where the RBC 1s located The Remote I O Port interface is a 9 pin D Shell connector with pinout as shown in Figure 3 Recommending wiring for the Remote I O cabling is detailed in Siemens 545 555 575 System Manual Figure 4 shows the pinout for the I O Port 2 Connecting the Remote I O Cable 9 Pin D Shell Female Connector GND 5 TXIRX 3 4 O O O O
7. 0 RIO Installation and Operation Guide V1 1 CHAPTER 2 INSTALLATION The installation of the Model 2500 RIO RS485 Remote Base Controller consists of the following Steps 1 Planning the installation 2 Verifying power requirements 3 Unpacking and configuring the module 4 Physical installation 5 Connecting cables 6 Checking the module operation 2 1 Installation Planning Choosing Remote I O Media The 2500 RIO attaches directly to the RS485 Remote I O cable using a DB9 connector We recommend using cable designed specifically for RS485 systems such as Belden 3105A See Appendix A for information related to cable specifications layout and installation Selecting a Remote Base Address Before proceeding you must determine what address you will assign to the RBC Remote Base addresses range from 1 to 15 In SIMATIC 505 systems address 0 is reserved for the local base where the CPU is installed Note that each Remote Base on the Remote I O channel must have a unique address Setting Module Hardware Options The RBC includes a hardware setting for selecting the state of the base discrete outputs in the event of a loss of communication with the CPU The module can be configured to set all outputs off or to leave outputs at their last states Connecting to Remote I O Cable The Remote I O connector should be wired as shown in Section 2 7 2 2 Power Requirements The CTI 2500 RIO module consumes 2 5 watts of 5 VDC powe
8. ANTY SET FORTH ABOVE IN THIS ARTICLE IS THE ONLY WARRANTY CTI GRANTS AND IT IS IN LIEU OF ANY OTHER IMPLIED OR EXPRESSED GUARANTY OR WARRANTY ON CTI PRODUCTS INCLUDING WITHOUT LIMITATION ANY WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE AND IS IN LIEU OF ALL OBLIGATIONS OR LIABILITY OF CTI FOR DAMAGES IN CONNECTION WITH LOSS DELIVERY USE OR PERFORMANCE OF CTI PRODUCTS OR INTERRUPTION OF BUSINESS LOSS OF USE REVENUE OR PROFIT IN NO EVENT WILL CTI BE LIABLE FOR SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES FOR CONSUMER PRODUCTS SO THE ABOVE LIMITATIONS OR EXCLUSIONS MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH MAY VARY FROM STATE TO STATE 14 2500 RIO Installation and Operation Guide V1 1 REPAIR POLICY In the event that the Product should fail during or after the warranty period a Return Material Authorization RMA number can be requested orally or in writing from CTI main offices Whether this equipment is 1 or out of warranty a Purchase Order number provided to CTI when requesting the RMA number will aid in expediting the repair process The RMA number that is issued and your Purchase Order number should be referenced on the returning equipment s shipping documentation Additionally if the product is under warranty proof of purchase date and se
9. Number of Installed Feet Meters Drop Lines Belden 3105 2360 _ _ 8 2000 610 x 9 H36 9 10 CTI 2500 RIO Installation and Operation Guide V1 1 Cable trunk length is measured from the CPU to the most distant base CPU Terminating Resistor Terminating Resistor Trunk Length gt a Max Trunk Length _ T T T T T T T lt Total Trunk Line Length gt T Terminal Block Figure 6 Trunk Length Measurement By using a T configuration as shown In Figure 7 the maximum trunk length can be extended to twice the length shown in the table on the previous page CPU Terminating Resistor Terminating Resistor Max Trunk Length gt 4 Max Trunk Length T T T T T T T Total Trunk Line Length T Terminal Block Figure 7 T Connection Trunk Length Bus termination In order to minimize cable reflections and ensure a defined noise level on the data lines the data transfer cable MUST be terminated at both ends with a terminating resistor approximating the characteristic impedance of the cable For Belden 3105A cable a termination resistor value of 120 ohms should be connected across the TX RX and TX RX signal lines 2500 RIO Installation and Operation Guide V1 0
10. cts 10 material and workmanship at any time during this 1 year warranty period CTI will repair or replace at its option parts or Products found to be defective and shipped prepaid by the customer to a designated CTI service location along with proof of purchase date and associated serial number Repair parts and replacement Product furnished under this warranty will be on an exchange basis and will be either reconditioned or new All exchanged parts or Products become the property of CTI Should any Product or part returned to CTI hereunder be found by CTI to be without defect CTI will return such Product or part to the customer This warranty does not include repair of damage to a part or Product resulting from failure to provide a suitable environment as specified in applicable Product specifications or damage caused by an accident disaster acts of God neglect abuse misuse transportation alterations attachments accessories supplies non CTI parts non CTI repairs or activities or to any damage whose proximate cause was utilities or utility like services or faulty installation or maintenance done by someone other than CTI Control Technology Inc reserves the right to make changes to the Product order to improve reliability function or design in the pursuit of providing the best possible Product CTI assumes no responsibility for indirect or consequential damages resulting from the use or application of this equipment THE WARR
11. n Switches Freeze Jumper 2500 RIO Installation and Operation Guide V1 1 1 Setting the RS232 Port baud rate 2 Setting the Remote Base Controller address 3 Setting the output state on communication loss Freeze Jumper Figure 2 indicates the location of the RS232 port baud rate selection switches the RBC station address thumbwheel and Freeze Jumper The remainder of this section describes the function of the individual settings Setting the RS232 Port Baud Rate Switches SW1 SW4 are used for setting the baud rate of the RS 232 serial port The supported baud rates are shown in the following table All other switch combinations are invalid Baud Rate SW1 SW2 SW3 SW4 19200 9600 2400 1200 300 RBC Station Address Setting Remote base Controller Station Address A thumbwheel switch is provided to set the base address to the 2500 RIO for Remote I O station identification A maximum of 15 remote bases can be connected to the CTI 2500 Series CPU or Siemens 545 555 575 CPU NOTE When connecting the 2500 RIO to a 2500 Series CPU or Siemens 545 555 575 CPU only addresses between 1 and 15 are valid Each installed 2500 RIO must have a unique station number Care should be taken to prevent circumstances which cause the CPU to lose communication with the 2500 RIO while the system is operating Loss of communication between the CPU and RBC will cause the base to be logged off from the CPU This can cause i
12. ndby RBC in dual media application configured and ready to control I O blank No Code Displayed None Serious condition 2500 RIO is not operational If power to base is OK contact Technical Support 8 2500 RIO Installation and Operation Guide V1 1 APPENDIX A REMOTE I O INSTALLATION GUIDELINES These Remote I O Installation Guidelines are based on standard RS485 wiring practices See Chapter 6 of the SIMATIC 505 545 555 575 System Reference Manual for further details The Remote I O cable system consists of a main trunk line and drop lines which connect the CPU Local Base and Remote Base s to the trunk line by means of terminal blocks as shown in Figure 5 CPU Terminating Resistor Terminating Resistor lt Trunk Length gt lt Max Trunk Length T T T T T T T lt Total Trunk Line Length gt T Terminal Block Figure 5 Remote I O Installation Cable Layout Planning Use the following guidelines for planning the Remote I O cable routing and locations e The ideal cable installation is a single unbranched trunk line with short drop lines and termination resistor at each end Maximum length of a drop line should not exceed 33 feet 10 m Drop lines less than 3 3 feet 1 m do not count toward cable length calculations The total length of all drop lines should be much less than the length of the trunk line When multi
13. ns Compatible with 505 CPUs from Siemens and CTI Can be used In currently available CTI and Siemens 4 8 and 16 slot bases Supports communication speeds 2Mbits sec and maximum cable distance of 1000 meters LED display which shows error and status codes Front panel thumbwheel switch for setting the station address On board RS232 port which can be used for PLC programming and configuration The 2500 RIO resides in SIMATIC 505 base It installs in the second slot from the left adjacent to the power supply module Figure 1 2500 RIO Front Panel 2500 RIO Installation and Operation Guide V1 0 1 1 2 Communication Ports The 2500 RIO RS485 RBC has two communication ports on the front panel 1 2 1 Serial Port The RS232 port 15 provided to interface to PLC programming and configuration tools such as TISOFT A standard 9 PC compatible RS232 serial cable is used to connect to the programming device or modem The port pinout 1s provided in Section 2 6 of this manual 1 2 2 YO Port The I O Port connects the 2500 RIO to a SIMATIC 505 compatible RS485 Remote I O channel This enables the remote 505 CPU to control the I O modules in the base where the RBC 15 located The Remote I O Port interface is a 9 pin D Shell connector as detailed in Section 2 7 of this manual Recommended guidelines for planning selection and installation of Remote I O system is included in Appendix A 2 250
14. ntermittent process operation WARNING The following events will cause loss of communication with the 2500 RIO and result in the base being logged off from the CPU 1 Duplication of the station address between RBC s attached to the same CPU except in dual media applications 2 Changing the thumbwheel switch station address while the system is operating These events could cause unpredictable process operation and result in damage to equipment and or serious injury to personnel When a base if logged off the CPU zeroes all image register input points associated with the base and all outputs go to the value determined by the installed output module Discrete outputs turn OFF 0 and Analog Word outputs are set according to the Zero Hold Last Value settings in each particular module Your program can monitor the CPU Status Words to detect this condition and control the outputs from other remote bases as appropriate for the application Details on the Status Words and programming examples can be found in the SIMATIC 545 555 575 Programming Reference User Manual Setting the Output State on Communication Loss When I O channel communication to a remote base is lost the state of the discrete outputs 15 determined by the selection made on the 2500 RIO jumper JP1 Off Freeze Figure 2 shows the location of the jumper on the 2500 RIO NOTE The 2500 RIO ships with the FREEZE jumper in the OFF setting If the jumper 1 is missing f
15. ple bases must be located in close proximity connect all bases in a daisy chain arrangement with a single drop line Cable Selection Data transfer in the Remote I O systems is based on a symmetrical RS485 bus system using shielded twisted pair cable The cable shield 15 used to improve the immunity to electromagnetic interference The ideal cable provides low signal attenuation for long trunk lines and flexibility for ease of installation The recommended cable should include the characteristics as shown in the following table 2500 RIO Installation and Operation Guide V1 0 Recommended 8 to 22AWG uniform 2 conductors 22A WG 030 twisted pair in 7 5mm 7x30 stranded copper braid plus drain wire Impedance lt 50 pF m Resistance of installed length lt characteristic impedance 1 0 dB 30 m 1MHz Velocity of Propagation gt 65 Operating Temperature 0 to 60 C 20 to 60 C Cable Lengths Maximum permissible cable length is dependent on cable characteristics and number of terminal blocks used in the installation Terminal blocks are used to connect drop lines and or extend Remote I O cable trunk line The following table contains the maximum recommended cable length Trunk Length Drop Lines for Belden 3105A cable It is possible to have longer cable runs if larger diameter wire is used Maximum Cable Length in
16. r from the backplane Before installing the RBC verify that your mounting base power budget can accommodate the required power A good tool for performing the verification is the CTI SIMATIC 505 Replacement Guide and Power Calculator available from our website at ftp ftp controltechnology com public Download tools 2500 RIO Installation and Operation Guide V1 0 3 2 3 Unpacking the Module Open the shipping carton and remove the special anti static bag that contains the module After discharging any static build up remove the module from the static bag Do not discard the static bag Always use this bag for protection against static damage when the module is not inserted into the I O base CAUTION The components on the 2500 RIO module printed circuit card can be damaged by static electricity discharge To prevent this damage the module is shipped in a special anti static bag Static control precautions should be followed when removing the module from the bag and when handling the printed circuit card during configuration 2 4 Configuring the Module There are three steps to configuring the module and making it fully operational Figure 2 Switch Locations 141665 p a Ret 2 R62 F pia C71 I 012 413 03 0 RS 232 BAUD SWI 512 SW3 4 w2 9600 1 2400 0 1200 1 300 C73 1 1 at Baud 6 Selectio
17. rial number must accompany the returned equipment The current repair and or exchange rates can be obtained by contacting CTI s main office at 1 800 537 8398 When returning any module to CTI follow proper static control precautions Keep the module away from polyethylene products polystyrene products and all other static producing materials Packing the module in its original conductive bag 15 the preferred way to control static problems during shipment Failure to observe static control precautions may void the warranty For additional information on static control precautions contact CTI at 1 800 537 8398 2500 RIO Installation and Operation Guide V1 0 15
18. rom the board the 2500 RIO defaults to the OFF setting For discrete output modules the state of the outputs is determined solely by the position of the Off Freeze jumper JP1 on the 2500 RIO 2500 RIO Installation and Operation Guide V1 0 5 For analog word output modules the state of the outputs is influenced not only by the position of the Off Freeze jumper but by the output module s Zero Hold Last Value selection if the module has that option See the table below RBC Off Freeze Analog Word Module Analog Word Output Selection Zero Hold Selection State Hold Last Value see the user manual of your analog word output module for details Notice 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 analog word output module that selection overrides the OFF option on the RBC jumper WARNING If the RBC fails or loses power during system operation all outputs will turn OFF 0 regardless of the Freeze Jumper setting This could result in damage to equipment and or serious injury to personnel 2 5 Physical Installation To insert the module into the I O base hold the top and bottom of the bezel and slide the module carefully into the slot pushing it all the way into the base If you have inserted the module correctly you will feel a slight increase in resistance as the module mates with the base backplane connector Once
19. tts Compatibility SIMATIC 505 and 2500 CPU s All currently available and Siemens 505 4 8 and 16 slot bases Single and Dual Media configurations Display Shows RBC status and error codes Output State Selection Determines state of outputs when I O channel communication is lost OFF All outputs are turned off FREEZE outputs hold their last value Hardware User Configuration Options RS232 Serial Port baud rate dipswitch RBC Station Address thumbwheel Diagnostic Data RBC Status Indication in CPU Status Word and Front Panel LED Display Ports Remote I O 9 Pin D Shell Female Connecter RS232 Serial 9 Pin D Shell Male Connecter PC compatible pinout Environmental Operating Temperature 0 to 60 C 32 to 185 F Storage Temperature 40 to 85 C 40 to 185 F Humidity 5 to 95 non condensing Agency Approvals Pending UL ULC CE Class Division 2 Hazardous Location Shipping Weight 1 5 Ib 0 68 Kg 2500 RIO Installation and Operation Guide V1 0 13 LIMITED PRODUCT WARRANTY CTI warrants that this CTI Industrial Product shall be free from defects in material and workmanship for a period of one 1 year after purchase from CTI or from an authorized CTI Industrial Distributor This CTI Industrial Product will be newly manufactured from new and or serviceable used parts which are equal to new in the Product Should this CTI Industrial Product fail to be free from defe
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