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SIMATIC TI525/TI535 Hardware and Installation User Manual

1. ae base Highest Switch position base 5 6 address ON ON OFF ON ON OFF OFF OFF ON ON OFF ON ON OFF OFF OFF ON ON OFF ON ON OFF OFF OFF ON ON OFF ON ON OFF OFF OFF OFF Front bezel Position selected Push down Position not A selected O OCO N OD O11 A Oo Po eo E eo A un un Dv un 99 AR E oa Position Position not Selected ff Selected Push left or right Switch position Front bezel L Left R Right on i PUSHLEFT PUSH RIGHT Baud 2 3 4 Batter Battery 300 enable MEI WM disable 1200 2400 9600 RS 422 Baud rate 19200 Position does not matter T Switch position RS 232 C 423 L Left R Right Baud rate gt Baud 5 6 7 300 gt L Memory L Memory Protect on Bl BM Protect off SUO 9600 19200 Position does not matter Figure 3 8 Locations of the Dipswitc hes for 11535 Models Hardware and Installation User Manual 3 10 INSTALLATION NOTE Switch 1 on the first dipswitch DIP 1 is used for factory testing and should be turned OF F Switches 2 and 3 are also reserved for
2. A system with distributed I O requires one I OCC located in the primary base Depending upon the cable used the line drivers of the DBC and the IOCC permit distributed I O to be up to 1300 feet 396 m from the PLC 3 21 Hardware and Installation User Manual INSTALLATION Both Series 500 and 505 I O can be connected to a T1525 TI535 PLC as distributed I O The Series 505 OCC PPX 505 6830 is capable of addressing the Series 500 DBCs PPX 2109 or PPX 505 2103 in a Series 500 base assembly If your application requires distributed I O you must install an IOCC in the primary base assembly You must also install the distributed bases with their power supplies DBCs I O modules and cabling See the installation instructions later in this chapter 3 6 1 Numbering Series 505 I O Points When you configure the I O you assign an I O point number to each point You do this from the I O Module Definition Chart on your programming device Local I O consisting of a maximum of 512 I O points can be configured when you assign the I O point numbers This is obtained by using base Model 505 6516 sixteen slots and 32 point I O modules The PLC permits a maximum number of 1023 points for a local and distributed system You need not assign the point numbers consecutively For example in a distributed system Base 2 can be assigned I O point numbers 897 960 However the highest point number that you can assign to a point is 1023 You do n
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4. 1 2 5 Ladder Memory Protection A memory protection dipswitch provides protection for the RLL program When the switch is in the ON position the program cannot be changed by a programming device that is connected to the PLC through one of the communication ports NOTE The memory protection dipswitch does not prevent forcing l O changing variable memory or switching the PLC from PROGRAM to RUN mode These actions may be made by a programming device connected to the PLC or a special function I O module designed for this type of interface to the PLC e g a Network Interface Module The RLL can also be changed through a special function module even when the memory protection is enabled Hardware and Installation User Manual 1 10 2 1 CHAPTER 2 PRE INSTALLATION PLANNING This chapter presents recommended installation practices and procedures Since no two applications are identical these recommendations are guidelines INTRODUCTION Preparing the site for installation of your TI525 TI 535 PLC consists of the following e Defining the control requirements e Determining the number of PLCs needed e Determining the panel and grounding layout You should define the control requirements in terms of the number and type of inputs and outputs Once the inputs and outputs have been defined calculate the number of I O modules and bases that are needed When the number of PLCs bases and I O modules is known determine the power re
5. 3 2 I O Module Point Assignments 0c cece cette een 3 31 4 1 Changesin Mode and Memory After PowerUp ssssssssse nh 4 3 Bl LED Indicato eriei einn iR tace ER ced bak Facice Pade Rad A baci etes 5 4 5 2 Effectsof Aux Functions on Memory Locations ssssssssseeee eee 5 7 C 1 Series505 Component Power Requirements 0 0 eet enn C 1 C 2 Series500 Component Power Requirements cette ees C 4 Contents vii PREFACE INTRODUCTION This manual gives detailed instructions for the installation and operation of the Series 505 family of programmable logic controllers PLCs Both the SIMATIC TI525 and the SIMATIC T1535 PLCs and their support equipment are discussed The topics are listed below by chapter e Chapter 1 describes the features of the various models of the T1525 and T1535 PLCs e Chapter 2 is a guide to pre installation planning to facilitate the establishment of a safe and efficient system of equipment control e Chapter 3 contains the details of installing the system components e Chapter 4 presents the installation and operation of EPROMs and EEPROMs e Chapter 5 describes the system start up procedure and gives information for troubleshooting e Appendix A lists the specifications for the T1525 and TI535 PLCs e Appendix B gives grounding and other electrical guidelines e Appendix C lists the power requirements for all currently available Series 505 and Series 500 1 O modules ix
6. 5 2 3 1 Status Word One SIW01 STWO1 provides information in the word format shown in Figure 5 2 STWOI shows the status good or failed of the PLC battery scan overrun communication port I O modules indirect table move overflow and special function modules A bit containing a 0 indicates no error while a 1 indicates a problem or failure LSB 12 34 5 6 7 8 910 11 12 13 14 15 16 Not used 1 battery low or off 1 scan overrun i e fixed scan time is too short to run RLL program 1 communication port failure 1 I O failure 1 indirect table move overflow 1 intelligent module com munication failure This applies to any I O module capable of diagnosing its own failure This bit is also set if there is an I O mismatch i e the I O configuration does not agree with the installed module for any I O slot in the system Figure 5 2 Format of Status Word One SIW01 Hardware and Installation User Manual 5 8 STARTUP TROUBLESHOOTING 5 2 3 2 Status Word Two STW02 As illustrated in Figure 5 3 below STWO2 shows the status of up to sixteen bases From right to left each bit in the word represents a base The bit is set to 1 when the base that it represents has failed or is not present and it contains a O if the base is good An empty base is reported with a 0 and bases 0 and 1 are always reported with a O LSB 34 5 6 78 910 11 12 13 14 15 16 sme qo
7. PPX 505 4216 PPX 505 4232 PPX 505 4308 PPX 505 4316 PPX 505 4317 PPX 505 4332 PPX 505 4408 PPX 505 4416 PPX 505 4432 PPX 505 4508 PPX 505 4516 PPX 505 4532 PPX 505 4608 PPX 505 4616 PPX 505 4632 PPX 505 4708 PPX 505 4716 PPX 505 4732 PPX 505 4808 PPX 505 4816 PPX 505 4832 PPX 505 4908 PPX 505 4916 PPX 505 4932 PPX 505 5417 INSIALLATION Table 3 2 I O Module Point Assignments Continued on next page Model Description 20 56 VAC Input 20 56 VAC Input 20 56 VAC Input 4 5 15 VDC Input 4 5 15 VDC Input 4 5 15 VDC Input 79 132 VAC Input 79 132 VAC Input 79 132 VAC Input 14 32 VDC Input 14 32 VDC Input 16 Isolated Inputs or 8 Interrupt Inputs 8 Isolated Inputs 14 32 VDC Input 164 256 VDO Input 164 256 VDO Input 164 256 VDO Input 4 5 34 VDC 0 5 Amp Output 4 5 34 VDC 0 5 Amp Output 4 5 34 VDC 0 5 Amp Output 20 132 VAC 0 5 Amp Output 20 132 VAC 0 5 Amp Output 20 132 VAC 0 5 Amp Output 4 5 34 VDC 2 0 Amp Output 4 5 34 VDC 2 0 Amp Output 4 5 34 VDC 2 0 Amp Output 85 256 VAC 2 0 Amp Output 85 256 VAC 2 0 Amp Output 85 256 VAC 2 0 Amp Output 20 256 VAC or 4 5 34 VDC Form C Output 20 256 VAC or 4 5 34 VDC Normally Open Output 20 256 VAC or 4 5 34 VDC Normally Open Output 115 VDC Relay Output 3 31 Points Used 8X 16X 32X 8X 16X 32X 8X 16X 32X 8X 16X 16X 32X 8X 16X 32X 8Y 16Y 32Y 8Y 16Y 32Y 8Y 16Y 32Y 8Y 16Y 32Y
8. 1101 Continued Max DC Power Required Model Description High Speed Counter amp Encoder 8 In 4 Out Analog Bipolar 8 In 4 Out Analog Thermocouple RTD BASIC Module NIM Network Interface Module Dual Media NIM Peerlink IBM AT Compatible Coprocessor IBM AT Compatible Coprocessor IBM AT Compatible Coprocessor IBM AT Compatible Coprocessor Programmable Logic Controller All models of T1525 CPUs All models of TI535 CPUs CPU in watts 5 V 5 V Hardware and Installation User Manual APPENDIX C I O POWER CONSUMPTION Table C 2 Series 500 Component Power Requirements Continued on next Page Power Available in watts 45V 5 V PPX 500 2151 AC Power Supply PPX 500 2153 DC Power Supply PPX 500 2103 Distributed Base Controller Power Supply included PPX 500 2108 PPX 500 2109 PPX 500 5001 PPX 500 5002 PPX 500 5003 PPX 500 5004 PPX 500 5005 PPX 500 5006 PPX 500 5007 PPX 500 5008 PPX 500 5009 PPX 500 5010 PPX 500 5011 PPX 500 5012 PPX 500 5013 PPX 500 5016 PPX 500 5018 PPX 500 5019 PPX 500 5020 PPX 500 5021 PPX 500 5022 PPX 500 5023 PPX 500 5024 PPX 500 5026 Hardware and Installation User Manual DC Power Required in watts Model Description 5 V 5 V IOCC Distributed Base Controller 110 VAC Input 220 VAC Input 110 VDC Input 220 VDC Input 24 V AC DC Input 48 V AC DC Input TTL Input 24 VDC Input Analog Input 24 48 V
9. 3 0 110 VAC Input 32 Point nn Density 3 0 110 VAC Output High current Relay 3 0 Low current Relay 3 0 Remote Base Controller 6 0 48 VDC Input 3 0 PPX 520C 530C All models of TI520C TI530C CPUs 11 0 PPX 530T All models of TI530T CPU 14 0 Some versions of the 500 5056 32 Point Output Module consume 3 3 watts of 5 VDC power These units are appropriately identified with labels C 5 Hardware and Installation User Manual A AUX Function B Base Assembl Installation Models 3 1 Slots Controller 3 27 I O M odules 3 29 Power Supply 3 25 Base Number Dipswitch T1535 3 10 3 13 Base Logical 3 13 3 19 Battery Backup Dipswitch T1525 3 5 3 7 T1535 3 10 3 14 Information Protected 1 9 1 9 3 7 3 14 Installation Baud Rate T1525 3 5 T1535 3 10 3 15 Boolean Symbolic Code 1 1 1 8 C Communication Ports Baud Rate T1525 3 5 T1535 3 10 3 15 Pinout 3 28 INDEX Configuration T1525 3 5H3 9 T1535 3 10 3 15 D Diagnostics See Status Word AUX Funcion Troubleshooting Dipswitches T1525 ES Battery E ae 3 5 3 7 Baud Rate EE M emory P rotect 3 8 Preset uec re 3 5 9 T1535 Battery Enable Baud Rate 3 10 3 15 Highest Numbered Base 3 10 3 13 Memory Protect 3 16 Preset download retain 3 10 3 12 Distributed Base 1 3 3 21 Distributed Base Controller DBC 1 3 3 21 i39 Distributed 1 O 1 3 3 21 E El
10. Base Assemblies ssseeeeenn mH mm mmm rn 3 11 Installing Base Hardware sssesssssses e 3 1 2 RackorPanel Mounting 00 0 ccc sns 3 2 Handling Series 505 Modules ccccecceeeceee eee eeee ee ee eee eeeeeeeeneeeae 3 3 Setting T1525 Dipswitt hes sse mms nna 3 3 1 Setting Port Baud Rate 1525 Models 0 0 0 c cece 3 3 2 Selecting Battery Backup 7525 Models ccc cece eee eens 3 3 3 Selecting Ladder Memory Protection TI525 Models 0 000 es 3 3 4 Downloading Preset Constants 1525 Models cc cece eee ees 3 4 Setting 11535 Dipswitt hes 0 cece nnm msnm 3 4 1 Selecting I O Type 1535 Models 6 cee 3 4 2 Downloading Preset Constants 1535 Models ccc e eee ees 3 4 3 Setting Highest I O Base Number 1535 Models 0 cece ees 3 4 4 Selecting Battery Backup 7535 Models cece cece eee eens 3 4 5 Setting Communication Port Baud Rate TI535 Models 3 4 6 Selecting Ladder Memory Protection 7535 Models sssse 3 5 Installing The Battery cccccece cee ee cece sneer e mmm Rmi 3 5 1 Model 11525 Battery Installation sisii rissani i aiui aeii ees Contents iii 3 6 4 1 4 2 4 3 4 4 4 5 3 5 2 Model 535 Battery Installation 2 0 0 eens Installing System Components cccceeeee nese eee eee eee eee eee 3 6 1 Numbering Series 505 I O Poin
11. Edition 2586652 0003 LIST OF EFFECTIVE PAGES Pages Cover Copyright History Effective Pages iii viii Preface ix x 1 1 1 10 2 1 2 7 3 1 3 32 4 1 4 13 5 1 5 19 A 1 A 2 B 1 B 7 C 1 C 5 Index 1 Index 3 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 Pages Description Contents Preface Chapterl Series 505 System Overview 1 1 Intioduction issiria LDE REEE EEEREN 1 2 Features Of The 11525 And T535 ssssssssssssnassnssnnnnnnnnnnnnnnnnnnnnnnnnn 1 2 1 Program SoftWare 4 isecrenenen er nOPeR ERR RENI E A ADR 1 2 2 Program Storage in EEPROM ssssesssss nns 1 2 3 Communication Ports 1 2 4 Battery Backup ck eE RR nuc eb E oiaoi FCIRE ACER dates edad eB 12 5 LadderMemory Protection 0 nnns Chapter2 Pre installation Planning 2 1 IntiodUc Ooh usi kc a7 ROC RR RR OR 4 7 DC RR RR EORR RU 28 8 RO RC RR RR 2 1 2 2 Safety Considerations s ssssssssssnnnsnnnnnsnnnnnsunnnnnnnunnnnnnnnnnnnnn 2 3 Enclosure Selection cc cc ccc cee eee cccee eee eee eee eee rr 2 4 Grounding And Wiring The Equipment s sssssssssssssnssnnunnnnnnnnnsnnnnn 2 7 2 5 Temperature Considerations ccc cece ee cece eee eee eee eee nnn 2 7 Chapter3 Installation 3 1 Installing The
12. PLC reports an I O mismatch an installed module does not agree with the I O configuration as a failed I O module The module has not actually failed You should re enter the I O configuration for the slot in question Bit Number Status Words 11 18 1 2 8 4 5 6 7 8 9 10 11 12 13 14 15 16 Slot Slot Slot Slot 5 1 5 1 Slot Slot Slot Slot 6 2 6 2 Slot Slot Slot Slot 7 3 7 3 Slot Slot Slot Slot 8 4 8 4 Logical Base B Logical Base A Status Word 11 12 13 14 15 16 17 18 Logical Base B Base Base Base Base Base Base Base Base Noo 9 11 13 15 Logical Base A Base Base Base Base Base Base Base Base 10 12 14 Figure 5 6 Formatof Status Words Eleven to Eighteen SIW11 18 Hardware and Installation User Manual 5 12 STARTUP TROUBLESHOOTING In Figure 5 7 the 1 in Bit 10 indicates that slot seven in Base O0 contains a malfunctioning or incorrectly configured module I O mismatch All other slots either contain a working module or no module at all Bits in Status Word 11 Bit 6 7 8 9 10 11 12 13 14 15 16 Value 0 0 0 0 0 0 0 0 1 0 0 0 0 Slot 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 Base Base 1 ES no ol A c1 Base 0 Figure 5 7 Example of a Status Word With a Bit Set NOTE When a distributed bas
13. PROGRAM mode If the battery is low and an EPROM EEPROM with a valid program is installed AUX Function 10 puts the PLC in RUN mode e AUX Function 10 downloads presets in either of the following situations a the battery is good and the download select switch is set or b the battery is low and a program isin EPROM EEPROM e AUX Function 10 also puts the PLC in PROGRAM mode if a the battery is good and a fatal error is present or b the battery is good with no error and the previous mode was PROGRAM Table 5 2 lists the effects on memory locations when AU X Functions 10 11 and 12 are executed Table 5 2 Effects of Aux Functions on Memory Locations Image Register Operation i Control Relay Forced TMR CTR Selected Discrete Word Retentive Non Retentive 1 0 P Input Output Input Output esets AUX 10 Cleared Cleared Note1 Note1 Note Note 2 No No No No No Note 1 No change if the battery is good otherwise cleared Note 2 Dependent on user selectable switch memory type and battery condition 5 7 Hardware and Installation User Manual STARTUP TROUBLESHOOTING 5 2 3 Troubleshooting with Status Words In addition to the auxiliary functions described above the TI525 TI535 PLCs provides operational information in the form of status words These status words can be read with the programming device Status words may also be contained within an RLL program so that diagnostics can be executed during run time conditions
14. Rate 11525 Models Figure 3 4 shows the baud rate switch assignments for the communication ports Switches 1 and 2 on the first switch bank DIP 1 set the baud rate for the RS 232 C 423 port Port 1 Switches 3 and 4 on DIP 1 set the baud rate for the RS 422 port Port 2 Switch position does not matter if a device is not connected to the port You need to set only switches 1 and 2 for PPX 525 1102 and PPX 505 1104 models which have only an RS 232 C RS 423 port ON RS 232 C 423 Baud rate Switch position r Baud 1 2 9600 ON ON 4 2400 OFF ON _ RS 422 1200 ON OFF Baud rale 300 OFF OFF Switch position Baud 3 4 9600 ON ON 2400 OFF ON 1200 ON OFF 300 OFF OFF Position Position not selected m selected Push down Figure 3 4 Switch Settings 11525 RS 232 C 423 and RS 422 Ports NOTE Switches 5 6 7 and 8 on the first bank DIP 1 are reserved for factory testing and should all be turned ON Hardware and Installation User Manual 3 6 3 3 2 INSIALLATION Selecting Battery Backup 11525 Models Switch 1 on the second dipswitch assembly DIP 2 enables or disables the battery backup function With the battery backup enabled cyding power does not alter the following information e RLL program e Timer counter preset and
15. alteringtheir value in the RLL program If you cycle power or execute AU X Function 10 or 11 while the battery is enabled switch 4 on DIP 1 determines whether values in preset memory are retained or downloaded from the RLL program If the battery is dead low or disabled the preset values are always downloaded from the RLL program in an EPROM EEPROM if oneis installed Refer to Figure 3 9 Turn switch 4 ON to have values downloaded from the RLL program Turn switch 4 OFF to have preset values retained Retain a Download presets presets DIP 1 Position m selected AN Position not selected Push down Figure 3 9 Switch Settings 11535 Download Retain Presets NOTE Executing AU X Function 12 PLC Complete Restart with your programming device causes the presets to be downloaded from the RLL program regardless of the state of this dipswitch Hardware and Installation User Manual 3 12 INSTALLATION 3 4 3 Setting Highest I O Base Number 11535 Models The base assembly holding the PLC also holds the local I O The local I O consists of the first two logical bases numbered 0 and 1 A logical base is defined as a group of eight I O slots As many as fourteen additional logical bases numbered from 2 to 15 may be connected to the system as distributed I O Switches 5 8 on DIP 1 are used to select the high
16. an EEPROM place jumpers on pins 1 2 and 3 4 Refer to Figure 4 2 6 The EPROM EEPROM socket is a zero insertion force socket and no pressure is required to insert the 28 pin EPROM EEPROM Use a small flat blade screwdriver to open the socket Turn the screw on the Socket counterdockwise one quarter turn until the socket pins have opened Hardware and Installation User Manual 4 6 EPRO M EEPROM OPERATION 7 Insert the EPROM EEPROM aligning the notch on the EPROM EEPROM with the socket screw Refer to Figure 4 2 8 Check the pins to make sure that they are all seated properly Tighten the socket by turning the screw dockwise 9 Replace the PLC in its base and enable power Refer to the Troubleshooting Chapter if the EPROM EEPROM fails to function correctly EPROM EEPROM jumper pins y Bezel edge Figure 4 2 11535 EPROM EEPROM Socket and J umper Pins 4 7 Hardware and Installation User Manual EPRO M EEPROM OPERATION 4 4 PROGRAMMING THE EEPROM To program the EEPROM you first must enter the RLL program into the PLC Verify that this program is correct and continue with the steps listed below 1 Make certain that the battery enable dipswitch is ON and that the jumper pins are set for EEPROM 2 Set the PLC toPROGRAM mode 3 Select Auxiliary Function 84 in your programming unit Use the Copy option to copy
17. current values e Drum preset preset and current values e Word 1 O values e Variable V memory values e Retentive control relay status e States of forced I O e Scantime e 1 0 Configuration data If you power up a T1525 without a good battery installed or with the battery backup dipswitch turned OFF the PLC clears memory To allow for battery replacement the T1525 is designed to retain memory for at least 10 minutes while powered down even with a bad battery If the PLC is powered down without a good battery for longer than 10 minutes at power up the PLC detects whether or not memory is valid If memory is not valid then the PLC dears memory upon power up Refer to Figure 3 5 Turn switch 1 ON to enable the battery backup Turn switch 1 OFF to disable battery backup OFF ON Battery disable mS C wm Battery enable Position Position not selected m selected Push down Figure 3 5 Switch Settings T1525 Battery Backup NOTE Switches 2 3 6 7 and 8 on DIP 2 are reserved for factory testing Switches 2 and 3 should be turned off The position of switches 6 7 and 8 do not matter for normal operation 3 7 Hardware and Installation User Manual INSTALLATION 3 3 3 Selecting Ladder Memory Protection 11525 Models Switch 4 on DIP 2 prevents modifications tothe RLL program in ladder memory Your programming un
18. dipswitch assembly DIP 2 enables or disables the battery backup function With the battery backup enabled cyding power does not alter the following information e RLL program e Timer counter preset and current values e Drum preset preset and current values e Word I O values e Variable V memory values e Retentive control relay status e States of forced I O e Scantime e O Configuration data If you power up a T1535 with the battery backup dipswitch turned OFF and have not installed an EPROM EEPROM the PLC clears memory NOTE If you are powering up a T1535 for the first time turn off the battery backup and do not install a programmed EPROM EEPROM This ensures that the PLC is properly initialized Refer to Figure 3 11 Push Switch 1 LEFT to enable the battery backup Push switch 1 RIGHT to disable battery backup PUSH LEFT PUSH RIGHT gt Battery Li a Battery enable disable Figure 3 11 Switch Settings 11535 Battery Backup Hardware and Installation User Manual 3 14 3 4 5 INSTALLATION Setting Communication Port Baud Rate 11535 Models Figure 3 12 shows the baud rate switch assignments for the communication ports Switches 2 4 on the second dipswitch assembly DIP 2 set the baud rate for the RS 422 9 pin port Port 2 Switches 5 7 set the baud rate for the RS 232 C 423 25 pin port Port 1 Switch pos
19. factory testing and should be turned ON 3 4 1 Selecting I O Type 11535 Models Some earlier Series 505 I O modules manufactured prior toJ anuary 1 1988 do not report module status to the CPU Modules built after this date do report status Complete the following steps to determine which type of I O you have 1 Disconnect all user supplied power from the base 2 Removethel O module 3 Findtheserial number label on the inside of the front bezel If you have a number greater than XXXX8801XXXXXX you have a module that reports status If you have a serial number less than or equal to XXXX8712XXXXXX you have a module that does not report status Switches 2 and 3 on DIP 1 determine whether the CPU expects the status to be reported If the switches are both ON the CPU expects the status to be reported If you install 1 O modules that do not report status the CPU reports an I O mismatch and I O failure If the switches are both OFF the CPU does not expect the status to be reported When both switches are off you can use either type of I O When the switches are mixed ON OFF or OFF ON the CPU is set for factory tests 3 11 Hardware and Installation User Manual INSTALLATION 3 4 2 Downloading Preset Constants 11535 Models The drum and timer counter instructions have reserved sections of memory where preset variables are stored These variables may be changed with an operator interface such as a TCAM or VPU without
20. 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 but its sources are common in industrial applications The primary sources of noise in industry are those devices and their wiring that produce and switch high voltage and current Typical examples indude large motors welders and contactors that switch heavily inductive loads such as brakes or clutches B 5 Hardware and Installation User Manual APPENDIX B GROUNDING GUIDELINES B 4 2 Conecting Noise Problems When potential noise sources are identified two general methods are available to correct them These methods are noise suppression and noise isolation B 4 2 1 Noise Suppression You can use noise suppression Snubbing to reduce noise at its source Applicable only to devices driven by mechanical contacts snubbing suppresses arcing at electrical contacts caused by turnoff of inductive loads e g relays motors motor starters solenoids etc Load side suppression reduces voltage transients at the load preventing them from traveling back to the contacts where they would produce a showering arc and couple with adjacent wiring You may achieve an alternative type of suppression by placing an RC or varistor circuit shown in Figure B 2 across the contacts parallel to the switch Both types of snubbing cause the physical devices to come on or go off
21. models provided the program is compatible with the system s capabilities An EPROM may also be used to execute a program in a T1525 or TI 535 PLC The program must be copied from an EEPROM described above or by an EPROM programmer before it is installed on the T1525 TI535 CPU board To ensure equipment compatibility use only the EPROM model supplied by your distributor PPX 2587681 8012 Hardware and Installation User Manual 1 8 FEATURES 1 2 3 Communication Ports Each 11525 T1535 PLC has a 25 pin RS 232 C RS 423 compatible port configured as Data Terminal Equipment DTE This port may be used for communicating with programming equipment such as the Timer Counter Access Module TCAM the VPU a CVU or amodem up to 50 feet 15 m away An RS 422 compatible port is also available on the PPX 535 1212 This port may be used for communicating with a modem and allows communication to a distance up to 1000 feet 305 m 1 2 4 Battery Backup A 3 0 V lithium battery PPX 2587678 8005 protects the following information during a power cycle e RLL program e Timer counter preset and current values e Drum preset preset and current values e Word 1 O values e Variable V memory values e Retentive control relay status e States of forced I O e Scan time e 1 0 Configuration data Battery memory backup typically lasts six months at temperatures ranging from 0 to 60 C 1 9 Hardware and Installation User Manual FEATURES
22. more slowly The RC and varistor elements should have minimal effect on system timing their time constants are substantially less than 1 millisecond m 120 VAG gt lt 120 VAG gt Discrete Discrete input input Load N ef Discrete input Discrete input module protection module protection RC type noise snubbing MOV snubbing Figure B 2 Examples of Noise Snubbing Hardware and Installation User Manual B 6 APPENDIX B GROUNDING GUIDELINES B 4 2 2 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 may accomplish this by increasing the physical distance from some types of noisy devices For extreme cases electrostatic metal shielding may be required This is true for noise sources outside as well as inside the mounting cabinet NEMA type recommended Two cases of field wiring warrant special attention Wiring which enters the harsh noise area to enable monitoring and control of those devices and TTL or low level less than 24 V wiring In these cases supplement the physical separation between control and noise prone wiring with shielded twisted pair wiring 12 twists ft for the control signals Ground the shield at the electronics side only to the single point ground B 7 Hardware and Installation User Manual APPENDIX C SERIES 500 505
23. on the programming unit Function 84 gives you the following options Copy RAM to EEPROM Copy EEPROM to RAM Select RAM as program source Select EEPROM as program source Erase program in EEPROM Report source RAM OR EEPROM of program being executed NOTE If you usean EPROM in a TI525 TI535 you cannot execute these AU X Function 84 options Copy RAM to EEPROM Erase program in EEPROM The EEPROM is automatically write protected on power up which prevents any accidental write operations This protective measure does not hinder the device operation in any way If you want to usethe device in equipment other than SIMATIC TI equipment you can deactivate this protective feature by erasing the EEPROM powering down the unit and removing the EEPROM Hardware and Installation User Manual 4 12 EPRO M EEPROM OPERATION You can edit an RLL program in an EEPROM by following the steps listed below Refer to the user s manual for your programming unit for detailed instructions about the execution of AU X Functions 1 Execute the AUX Function 84 option that copies EEPROM to RAM 2 Select RAM as the program source 3 Make changes in your program with a programming unit by editing the source code in RAM memory 4 Execute the AUX Function 84 option that copies RAM to EEPROM 5 Select the EEPROM as the program source Although the T1525 T1535 can copy a program from either an EPROM or an EEPROM into RAM the TI 525 TI 535 cann
24. the appropriate quick connect pin 6 Make sure the wires attached to the terminal screws on the bezel are secure and that the user supplied power source is functional 7 Check to see that the fuse located on the bezel has not opened Replace the fuse if necessary with the appropriate fuse a Using a flat blade screwdriver twist the fuse holder once counter d ockwise to remove the fuse holder b To replace the fuse holder insert push and turn clockwise to secure 8 Replacethe power supply and enable power to the system 9 Ifthe power supply continues to malfunction replace it If replacing the fuse does not solve the problem and the power source is correctly connected then the power supply module should be returned for repair Contact your local distributor for assistance Hardware and Installation User Manual 5 18 5 2 7 STARTUP TROUBLESHOOTING Spare Parts It is recommended that you keep on hand a 10 surplus of your system s I O modules Depending upon the number of PLCs that you have installed you may wish to stock an extra PLC as well The following is a list of other spare parts that you should have available PPX 505 6504 41 0 slots PPX 505 6508 8 I O slots PPX 505 6516 16 I O slots 19 inch rack compatible Power Supply Module PPX 505 6660 PPX 505 6660A or PPX 505 6663 3 V lithium battery PPX 2587678 8005 3 0 A 250 V slow blow fuse 3 AG for PPX 505 6660 8 0 A 250 V normal blow fus
25. to the PLC or a special function O module designed for this type of interface tothe PLC e g a Network Interface Module The RLL can also be changed through a special function module even when the memory protection is enabled with the keylock Do not depend upon this switch to prevent personnel from interrupting your process Hardware and Installation User Manual 3 16 INSTALLATION 3 5 INSTALLING THE BATIERY The TI525 TI535 PLCs are shipped with a lithium battery already installed This battery has a minimum storage lifetime of three years and a minimum backup lifetime of six months 0 to 60 C Follow the steps listed below to replace the battery 3 5 1 Model 11525 Battery Installation The TI 525 is capable of preserving system memory for at least ten minutes after the battery and power have been disconnected Complete the battery replacement within this period if you wish to save information 1 Disable all user supplied power to the base 2 Removethe PLC from the base Do not touch the components on the printed circuit board or short any etch lines or pins as this may disrupt system memory Do not place the PLC on a conductive surface 3 Check the battery backup switch DIP 2 switch 1 If it is off and you wish to retain system memory turn the switch on 4 Removethe battery from the clip and disconnect the leads 5 Thenew battery should be a 3 0 VDC UL Recognized lithium battery PPX 2587678 8005 Connect t
26. 12 enclosure The enclosure must provide a minimum depth of 25 4 cm 10 in from the panel to the inside surface of the enclosure door The endosure should be located so that the doors may be opened fully permitting easy access to the PLC wiring and components If environmental conditions permit a 19 inch rack may be used instead of a NEMA enclosure Use the 16 slot I O base PP X 505 6516 for 19 inch rack installations GROUNDING AND WIRING THE EQUIPMENT A good grounding system is essential for proper operation of a PLC system and should be one of the most important considerations in planning your installation The structural ground present in many industrial environments does not provide an adequate ground return where direct wire connection is not feasible Appendix B is a discussion of grounding electromagnetic interference EMI and other electrical considerations See the guidelines in Appendix B to be certain to meet all grounding and wiring requirements TEMPERATURE CONSIDERATIONS When preparing your installation plan for an adequate air flow to ensure proper cooling of equipment Do not permit the convective cooling of the PLC to be hindered Unless ambient temperatures are extremely high a fan or air conditioned cooling is unnecessary for keeping TI525 TI535 PLCs below their maximum rated operating temperature of 60 C For one local base and one distributed base located in the the bottom half of a 7 foot 19 inch rack place eq
27. 4832 PPX 505 4908 PPX 505 4916 PPX 505 4932 PPX 505 5100 PPX 505 5103 PPX 505 5184 PPX 505 5190 PPX 505 5417 PPX 505 6010 PPX 505 6011 PPX 505 6108 PPX 505 6108A PPX 505 6202 PPX 505 6204 PPX 505 6208 PPX 505 6208A PPX 505 6308 PPX 505 6408 PPX 505 6851A Hardware and Installation User Manual Continued Max DC Poer Required in watts Model Description 5V 5 V 24 VDC Output 8 point 24 VDC Output 16 point 24 VDC Output 32 point 110 VAC Output 8 point 110 VAC Output 16 point 110 VAC Output 32 point 24 VDC Output 8 point 24 VDC Output 16 point 24 VDC Output 32 point 220 VAC Output 8 point 220 VAC Output 16 point 220 VAC Output 32 point Relay Output Form C 8 point Relay Output Form A 16 point Relay Output Form A 32 point TurboPlastic TurboParison MODNIM Modbus NIM 6MTCC TI505 to 6MT I F 16 Output Relay 115 VDC Input Simulator Output Simulator Analog Input Analog Input Analog Output 2 point Analog Output 4 point Analog Output 8 point Analog Output 8 point Word Input Word Output Remote Base Controller APPENDIX C I O POWER CONSUMPTION Table C 1 Series 505 Component Power Requirements Model Number PPX 505 7002 PPX 505 7012 PPX 505 7016 PPX 505 7028 PPX 505 7038 PPX 505 7101 PPX 505 7339 PPX 505 7340 PPX 505 7354 PPX505 ATM 0220 0440 4120 PPX 545 1101 PPX 525 CPUs PPX 535 CPUs PPX 555
28. 525 TI535 Operational Status Scan 027 Milliseconds Variable Battery On Key Unlocked Download Off Mode RUN Program in RAM Fatal Error None Non fatal Error None Figure 5 1 Example of AUX Function 29 Screen The scan time reported by AU X Function 29 is the highest scan time recorded since the last PLC reset or PROGRAM RUN modetransition Status Word 10 STW10 contains a continuously updated report of the scan time 5 5 Hardware and Installation User Manual STARTUP TROUBLESHOOTING 5 2 2 2 AUX Function 25 Display Failed I O AUX Function 25 displays the locations of any failed I O modules which 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 Function 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 5 2 2 3 AUX Function 20 Run PLC Diagnostic s AUX Function 20 initiates the PLC self checks The PLC must be in PROGRAM mode in order to execute self tests The PLC executes the equivalent of an AUX Function 20 at every power up If any area fails a message detailing the failure is displayed AUX Function 20 makes the following tests e Valid RAM locations are verified e Pre coded
29. 6 12000 Physical 1 O 512 1023 1023 Discrete Word I O 1023 1023 1023 Control Relays 511 511 1023 V Memory words 1024 2048 5120 Timers Counters 256 256 400 Drums 30 30 30 One Shot SHRB SHRW MWTT MWFT J MP nested MCR nested SKP LBL Status Words RS 232 C 423 Ports RS 422 Ports These models are now obsolete Hardware and Installation User Manual 1 6 FEATURES Table 1 2 TI525 TI535 Instruction Set Program Control Instructions J ump J MP Label LBL Master Control Relay MCR End Conditional ENDC End Unconditional END Skip SKP Math Instructions Add ADD Subtract SUB Compare CMP Divide DIV Multiply MULT Square Root SQRT Bit Instructions Bit Clear BITC Bit Pick BITP Bit Set BITS Bit Shift Register SHRB Word Instructions Convert Binary to BCD CDB Convert BCD to Binary CBD Word AND WAND Word OR WOR Word Rotate WROT Word Exdusive OR WXOR Word Shift Register SHRW Move Instructions Load Data Constant LDC Move Discrete mage Register to Word MIRW Move Word To Table MWTT Move Word MOVW Move Word To Discrete I mage Register MWIR Move Word F rom Table MWFT Counter Timer Counter CTR Timer TMR U p Down Counter U DC One Shot O S Matrix Instructions Scan Matrix Compare SMC Index Matrix Compare IMC Drum Instructions Drum DRUM 1 7 Event Drum EDRUM Hardware and Ins
30. 8Y 16Y 32Y 16Y Slots Used Special Function ee h m b ee ee k ND NP PPP Add Hardware and Installation User Manual Model Slots Number PPX 505 6010 PPX 505 6011 PPX 505 6108 PPX 505 6108A PPX 505 6202 PPX 505 6204 PPX 505 6208 PPX 505 6208A PPX 505 6308 PPX 505 6408 PPX 505 7012 PPX 505 7016 PPX 505 7028 PPX 505 7038 PPX 505 7101 PPX 505 7339 PPX 505 7340 PPX 505 7354 INSIALLATION Table 3 2 Model Description 32 Point Input Simulator 32 Point Output Simulator 8 Channel Analog Input 8 Channel Analog Input 2 Channel Analog Output 4 Channel Analog Output 8 Channel Analog Output 8 Channel Analog Output 8 Channel Word Input 8 Channel Word Output 8 In 4 Out Analog Bipolar 8 In 4 Out Analog Thermocouple Input RTD Input BASIC Module TIWAY Network Interface Module Local Line Ports TIWAY Network Interface Module RS 232 C 423 Ports Peerlink 3 6 6 Installing the Base C ontollers Refer to the Series 500 505 IOCC and DBC User s Manual PP X 500 8143 for instructions on wiring and installing the IOCC PPX 505 6830 and the DBC PPX 505 6840 NOTE I O Module Point Assignments Continued Points Used Function 32X 32Y 8WX 8WX 2WY 4WY 8WY 8WY 8WX 8WY 12WX amp 4WY or 4WX amp 4WY or 6WX amp 2WY or 8WX 12WX amp 4WY or 20WX amp 4WY or 4WX amp 4WY or 8WX 8WX 8WX or 16WX 4WX amp 4WY 8WY 8WY 3WX amp
31. AC Output 110 VAC Output 220 VAC Output 24 48 VDC Output Analog Output Word Input Word Output Input Simulator Output Simulator ASCII High Speed Pulse Input SERVO AXIS Controller 24 VDC Latching Input Rapid Response Output APPENDIX C I O POWER CONSUMPTION Table C 2 Series 500 Component Power Requirements Model Number PPX 500 5027 PPX 500 5028 PPX 500 5029 PPX 500 5030 PPX 500 5031 PPX 500 5032 PPX 500 5033 PPX 500 5035 Continued DC Power Required in watts Model Description 45V 5 V 110 VAC Latching Input Rapid Response Output 120 VDC Latching Input Rapid Response Output Dual Communication Port 32 Point 24 VDC Input 32 Point 24 VDC Output 110 VAC Isolated Input 110 VAC Isolated Output BASIC PPX 500 5037A 8 Channel Analog Input PPX 500 5038 PPX 500 5039 PPX 500 5040 PPX 500 5041 PPX 500 5047 Network Interface RS 232 Local Line Ports Network Interface Dual Local Line Ports Network Interface Dual RS 232 Ports 110 VAC Redundant Output 8 Channel Analog Output PPX 500 5047A 8 Out Analog PPX 500 5048 PPX 500 5049 PPX 500 5051 PPX 500 5052 PPX 500 5053 PPX 500 5054 PPX 500 5055 PPX 500 5056 PPX 500 5061 PPX 500 5062 PPX 500 5114 PPX 500 5192 24 VDC Isolated Input 24 VDC Isolated Output Thermocouple Resistance Temperature Detector TIWAY Peerlink Redundant TIWAY Peerlink 32 Point High Density
32. Hardware and Installation User Manual PREFACE REFERENCES Consult the manuals listed below for further information on installing programming and troubleshooting your Series 505 hardware e SIMATIC TI505 Programming Reference Manual PPX 505 8104 3 e TIWAY Systems Manual TI WAY 8101 e CVU1000 amp CVU10000 User Reference M anual PPX CVU 10 8101 2 e Thel O module user manuals that are appropriate for your system e Theuser manuals for your release of TISOFT Hardware and Installation User Manual x 1 1 CHAPTER 1 SERIES 505 SYSTEM OVERVIEW INTRODUCTION The TI525 TI535 Programmable Controllers PLCs and their support equi pment are computer controlled systems that are capable of managing the operation of other systems These PLCs execute 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 pushbuttons limit switches and sensors Acting on this information and executing a Relay Ladder Logic RLL program stored in memory the T1525 T1535 PLCs produce output signals to drive motor starters solenoids and pilot lights etc that regulate the operation of various pieces of equipment The TI 535 is an enhanced version of the T1525 that offers the following features e The scan time for Boolean logic is reduced significantly from 4 milliseconds per K words of memory to less than 1 millisecond per K words o
33. I O POWER CONSUMPTION The power requirements for all currently available Series 505 and Series 500 I O modules are given in Table C 1 and Table C 2 respectively Table C 1 Series 505 Component Power Requirements Continued on next Page Power Available in watts PPX 505 6660 Power Supply PPX 505 6660A Power Supply PPX 505 6663 Power Supply Max DC Power Required in watts Model Description 45V 5 V PPX 505 6830 IOCC 5 0 PPX 505 6840 Distributed Base Controller 5 0 PPX 505 4008 24 VAC Input 8 point 2 0 PPX 505 4016 24 VAC Input 16 point 2 0 PPX 505 4032 24 VAC Input 32 point 2 0 PPX 505 4108 LVDC TTL 8 point 2 0 PPX 505 4116 LVDC TTL 16 point 2 0 PPX 505 4132 LVDC TTL 32 point 2 0 PPX 505 4208 110 VAC Input 8 point 2 0 PPX 505 4216 110 VAC Input 16 point 2 0 PPX 505 4232 110 VAC Input 32 point 2 0 PPX 505 4308 24 VDC Input 8 point 2 0 PPX 505 4316 24 VDC Input 16 point 2 0 PPX 505 4317 24 VDC Interrupt Input 16 32 point 1 0 PPX 505 4332 24 VDC Input 32 point 2 0 PPX 505 4408 220 VAC Input 8 point 2 0 PPX 505 4416 220 VAC Input 16 point 2 0 PPX 505 4432 220 VAC Input 32 point 2 0 C 1 Hardware and Installation User Manual APPENDIX C I O POWER CONSUMPTION Table C 1 Series 505 Component Power Requirements Model Number PPX 505 4508 PPX 505 4516 PPX 505 4532 PPX 505 4608 PPX 505 4616 PPX 505 4632 PPX 505 4708 PPX 505 4716 PPX 505 4732 PPX 505 4808 PPX 505 4816 PPX 505
34. ROM checksum values are checked e Thehardware force function is checked e Internal timer operation is verified e Operating system ROM cyclic redundancy check code is checked 5 2 2 4 AUX Function 11 Partial Restart AUX Function 11 clears the discrete and control relay image registers but does not affect forced elements retentive control relays preset values and word image registers AUX Function 11 puts the PLC in PROGRAM mode only if a fatal error is present or the previous mode was PROGRAM 5 2 2 5 AUX Function 12 Complete Restart AUX Function 12 clears the discrete control relay and word image registers and the retentive control relays but does not affect forced elements and word registers All preset values are downloaded at restart AUX Function 12 puts the PLC in PROGRAM mode only if a fatal error is present or the previous mode was PROGRAM Hardware and Installation User Manual 5 6 STARTUP TROUBLESHOOTING 5 2 2 6 AUX Function 10 Power up Restart AUX Function 10 clears all discrete and non retentive control relay image registers except those elements that are forced Other results of AUX Function 10 depend on the following conditions e Ifthe battery is low AUX Function 10 clears the RLL program I O configuration retentive control relays WXs WYs forced I O V memory and all timer counter and drum preset current values If the battery is low and a program is in RAM AUX Function 10 puts the PLC in
35. SIEMENS SIMATIC T1525 TI535 Hardware and Installation User Manual Order Number PPX 505 8103 3 Manual Assembly Number 2586546 0052 Third Edition Copyright 1993 by Siemens Industrial 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 Industrial Automation Inc All rights including rights created by patent grant or registration of a utility model or design are reserved Since Siemens Industrial 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 01 21 92 Technical data is subject to change We check the contents of every manual for accuracy at the time it is approved for printing however there may be undetected errors Any errors found will be corrected in subsequent editions Any suggestions for improvement are welcomed MANUAL PUBLIC ATION HISTORY SIMATIC 1525 1535 Hardware and Installation Manual Order Manual Number PPX 505 8103 3 Refer to this history in all correspondence and or discussion about this manual Event Date Description Original Issue 09 88 Original Issue 2586652 0001 Second Edition 11 90 Second Edition 2586652 0002 Third Edition 04 93 Third
36. SWY NN XY XN The DBCs are multi dropped from the IOCC If one distributed base becomes disabled all the remaining DBCs should continue to communicate with the PLC Hardware and Installation User Manual 3 32 Special Used NMONH NMNNH_DND 4 1 CHAPTER 4 EPROM EEPROM OPERATION INTRODUCTION The T1525 T1535 controllers offer the option of saving the RLL program to an Electrically Erasable Programmable Read Only Memory EEPROM without the use of a separate programming device The RLL program is downloaded directly from the PLC RAM toa 256 kbyte EEPROM PPX 2587681 8020 NOTE The EEPROM holds only the ladder logic program and the I O configuration Other information stored in memory is cleared if power is cycled without a battery backup Once an EEPROM is programmed you may use it in any of the TI525 TI535 or TI530T models The only limitation is program size The PLC must have enough memory to store and execute the program contained on the EEPROM You can erase an EEPROM with a programming device that is capable of executing Auxiliary AUX Function 84 A TI525 TI535 EEPROM cannot be used in SIMATIC TI520 SIMATIC TI530 SIMATIC TI520C or SIMATIC TI530C models If you choose you may program an EPROM in a TI520C or TI530C and usethe EPROM in any of the TI525 535 PLCs The PLC must have the memory capacity to execute the program Although they do not copy a program to an EPROM all TI525 TI 535 mo
37. T1535 12 5 W 5 VDC 0 2 W 5 VDC Battery Backup 3 0 V lithium battery PPX 2587678 8005 3 years typical storage 05 to 605C 6 months typical storage 05 to 605C Communication Ports RS 232 C RS 423 all models RS422 PPX 525 1208 PPX 525 1212 PPX 535 1204 PPX 535 1212 User Memory Capacity 2K 4K 8K or 12K of RLL memory depending on the model Memory Backup EEPROM PPX 2587681 8020 Battery backed up static RAM Corrosion Protection All parts are of corrosion resistant material or are plated or painted as corrosion protection Agency Approvals All PLC models and power supply UL Listed industrial control equipment CSA Certified process control equipment Hardware and Installation User Manual APPENDIX A SPECIHCATIONS Electrical Specifications Fuse Power Supply 3 0A 250 V slow blow 3AG PPX 505 6660 Input voltage select 8 0A 250 V normal blow 3 AGPPX 505 6663 110 or 220 VAC User selectable PPX 505 6660 General Voltage range Corrosion protection 85 132 VAC 110 PPX 505 6660 All parts are of corrosion resistant material 170 264 VAC 220 PPX 505 6660 or are plated or painted as corrosion 20 30 VDC 24 PPX 505 6663 protection Frequency 47 63 Hz PPX 505 6660 PPX 505 6660 Input current Peak inrush 50 A maximum PPX 505 6660 20 A maximum PPX 505 6663 Steady state 2 Arms maximum PPX 505 6660 8 Azero to peak PPX 505 6660 5 ADC maximum PPX 505 6663 Volt Amp rat
38. X 505 6504 4 slot base SESE rear mounted for panel installation Pee mm all models 7 69 in PPX 505 6508 8 slot base 273mm 10 75 in Brackets front mounted for rack installation PPX 505 6515 only PPX 505 6516 16 slot base 438 mm gt 17 25 in M 203 mm 7 99 in 266 mm 10 47 in l Side View All Models Figure 3 2 Mounting Dimensions for the Series 505 Bases Hardware and Installation User Manual 3 2 INSTALLATION 3 1 1 Installing Base Hardware For rack or panel mounting place the brackets in the desired position on the Series 505 base on the front for rack mounting or on the back for panel mounting as shown in Figure 3 2 Insert the endosed screws through the brackets into the predrilled holes in the base and tighten 3 1 2 Rack or Panel Mounting If you are mounting your base on a predrilled rack align the brackets with the rack then insert and tighten the screws Before mounting the base to a panel you need to measure for and drill screw holes Refer to Figure 3 2 for screw locations On the front of the base is a ground lug which you should connect to a single point earth ground Refer to Appendix B for further grounding guidelines CAUTION Each base has a plastic dustguard covering the top grill The dus
39. a ut s PUR aR E Appendix C Series 500 505 I O Power Consumption C 1 Contents v List of Figures 1 1 1 2 2 1 2 2 2 3 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 3 17 3 18 3 19 3 20 3 21 5 1 5 2 5 3 5 4 5 5 5 6 5 7 B 1 B 2 TS25aind 11535 Controllers esigi ere ra Eee ea er Rte E e RR e RR RERO RA RR RO d de Functional Relationship of Series 505 Components ssseuusesesssssseeeses Operator Safety Switch seiiet emenn inapina a Aaa menn Emergency Stop Switch 0c cece eae JOG Or INCH SWIEN ui iiie ht deeds ee etn e deese beats she Bees bebe rr beads Series 505 Bases coude ice diced d Ro mie decipi Pasion duis dati eae ieee Mounting Dimensions for the Series 505 Bases 0 06 ee Locations of the Dipswitches forthe 1525 Models cece cece eee e eens Switch Settings 11525 RS 232 C 423 and RS 422 Ponts cece cee ee eee nes Switch Settings 7525 Battery Backup 1 eens Switch Settings 1525 L Memory Protection 00000 Switch Settings 1525 Download Retain Presets ssssssssssssseeeeeeeses Locations of the Dipswitches for 1535 Models cece cette eee nn Switch Settings 1535 Download Retain Presets u s aua Switch Settings T1535 Highest Numbered Logical Base unusu cece cee ees Switch Settings 7535 Battery Backup 0 ett Switch Settings 15535 RS 232 C RS 423 and RS 422 P
40. am are executed immediately if the PLC isin RUN mode Hardware and Installation User Manual 5 2 STARTUP TROUBLESHOOTING 6 Using the programming device enter the I O configuration 7 Enter the RLL program See the SIMATIC TI505 Programming Reference manual for information about designing your RLL program 8 Use the programming device to JOG motors solenoids or other positioning devices one at a time to establish correct rotation or position After all the steps are performed and verified place the PLC in the RUN mode If you turn ON the L memory MEMORY PROTECT dipswitch your RLL program cannot be changed by a programming device that is connected to the PLC through one of the communication ports NOTE The MEMORY PROTECT dipswitch does not prevent forcing I O changing variable memory or switching the PLC from PROGRAM to RUN mode These actions may be made by a programming device connected to the PLC or a special function O module designed for this type of interface to the PLC e g a Network Interface Module The RLL can also be changed through a special function module even when the memory protection is enabled 5 3 Hardware and Installation User Manual STARTUP TROUBLESHOOTING 5 2 USING THE TROUBLESHOOTING TOOLS This section offers information and guidelines for troubleshooting TI 525 TI 535 PLCs If you cannot locate the source of the problem contact your Siemens Industrial Automation distributor or sales
41. ation planning and site preparation must include consideration of hazards to personnel during a system failure The equipment connected to the T1525 TI535 PLC should include interlocks and safety switches to prevent operation during a system failure Although the specific steps depend on the application the general precautions include the following e Provide a means for disconnecting power independent of the PLC 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 semiconductor switch or a physically wired relay contact placed to interrupt power to the output It is not sufficient to rely solely on the PLC for this function Figure 2 1 illustrates an operator safety switch Relay contacts or limit switches open when operator must reach into machine User supplied critical loads which could cause injury Output Module Loads which could not cause injury Output points from the programmable controller Figure 2 1 Operator Safety Switch Hardware and Installation User Manual 2 4 PRE INSTALLATION e Provide a means for removing power from the output if an emergency condition occurs with the machine during operation Do this by disconnecting output power with a non semiconductor switch or hard wired relay contact not through the programmable control system This type of switch is shown in Fig
42. dels can read and execute an EPROM program with which they are compatible You may also save a program to the EEPROM and then use an EPROM programmer to copy the program from EEPROM to EPROM To ensure equipment compatibility use only the EPROM model supplied by your distributor PP X 2587681 8012 4 1 Hardware and Installation User Manual EPRO M EEPROM OPERATION WARNING The older non compiled TI520 TI530 EPROMs are not compatible with any other Series 500 or Series 505 PLCs Attempting to interchange the EPROMs may cause injury to personnel or damage to equipment because of unexpected operation of the PLC When you power up a TI525 TI535 the PLC checks the status of the EPROM EEPROM and the battery A dear unprogrammed EPROM EEPROM is equivalent to there being no EPROM EEPROM installed Table 4 1 lists the effects on memory and the mode that the PLC enters after power up Hardware and Installation User Manual 4 2 EPRO M EEPROM OPERATION Table 4 1 Changes in Mode and Memory After Power Up Conditions Results Programmed Battery EPROM or System PLC Status EEPROM Memory Mode Present RUN PLC executes Cleared program in EPROM EEPROM No Change No Change No Change No Change RUN PLC executes program in EPROM EEPROM Disabled for PROGRAM 10 minutes while power to the PIC is off No Checksum No Checksum Errors Found Errors Found No Change No Change Cleared Checksum Checksum Er
43. discrete analog word and intelligent I O modules are available that can handle al most any input or output specifications These I O modules are rugged plugin devices capable of functioning in harsh environments I O modules are grouped into local and distributed I O categories depending upon their physical location The local I O consists of those modules installed in the same base assembly as the PLC The TI 525 1102 can support up to 512 local I O points You can create a distributed I O system for all other models by connecting up to 14 additional base assemblies All current versions of the TI525 and TI535 PLCs support up to 1023 I O points in both local and distributed bases When additional bases are connected to the system distributed I O is managed through communication between base controllers thel O Channel Controller IOCC and one or more Distributed Base Controllers DBC The DBC PPX 505 6840 in each distributed base assembly transmits data from the I O modules in that base assembly to the OCC PPX 505 6830 which occupies the same base assembly as the PLC Your TI1525 T1535 PLC can address distributed bases up to 1300 feet 396m away A diagram of the TI 525 TI 535 system which shows the functional relationship of all the system components is shown in Figure 1 2 1 3 Hardware and Installation User Manual FEATURES IBM PC XT with TISOFT DEC VAX VPU 200 Handheld Intelligent Terminal Prog
44. e Troubleshooting Chapter if the EPROM EEPROM fails to function correctly EPROM EEPROM jumper pins QQ anaes Bezel edge Figure 4 1 71525 EPROM EEPROM Socket and J umper Pins 4 5 Hardware and Installation User Manual EPRO M EEPROM OPERATION 4 3 INSTALLING AN EPROM EEPROM IN T1535 MODELS If you are powering up a T1535 for the first time you should initialize it before proceeding with the EPROM EEPROM installation Refer to the startup procedure in Chapter 5 To install the EPROM EEPROM follow these steps 1 Usingthe programming unit place the PLC in PROGRAM MODE NOTE The PLC mode RUN or PROGRAM on power up depends upon mode at power down the condition of the battery and the presence or absence of an EPROM EEPROM Refer to Table 4 1 2 Ensurethat the Battery Good LED is on If it is not turn on switch 1 on DIP 2 This enables battery backup If the Battery Good LED remains off replace the battery before continuing with the EPROM EEPROM installation NOTE If you power down the TI535 while the BATT GOOD LED is off you may lose the program stored in RAM 3 Turn off all user supplied power to the PLC base 4 Removethe PLC from the base 5 If you areinstallingan EPROM place jumpers on pins 2 3 and 4 5 If you are installing
45. e 3 AG for PPX 505 6663 You can order the following spare parts from your distributor EEPROM PPX 2587681 8020 525 12 Kbytes Upgrade Kit PPX 2586491 8003 5 19 Hardware and Installation User Manual Environmental Specifications All P C models and power supply Storage Temperature 405 to 705C 405 to 1585F Operating Temperature 05 to 605C 325 to 1405F Relative Humidity 5 to 95 noncondensing Vibration Sinusoidal IEC 68 2 6 Test Fc 0 15 mm peak to peak 10 57 Hz 1 0 g 57 150 Hz Random NAVMAT P 9492 or IEC 68 234 Test Fdc with 0 04g Hz 80 350 Hz and 3dB octave rolloff 80 20 Hz and 350 2000 Hz at 10 min axis Impact Shock IEC 68 2 27 Test Ea Half sine 15g 11 ms Pollution degree 2 IEC664 664A Electric Noise Immunity Conducted noise IEC 801 Part 4 Level 3 MIL STD 461B Part 4 CS01 CS02 CS06 IEC 255 4 Appendix E EEC 4517 79 Com 78 766 Final Part 4 IEEE 472 2 5 kV Radiated noise IEC 801 Part 3 Level 3 MIL STD 461B Part 4 RS01 RS02 Electrostatic discharge IEC 801 Part 2 Level 4 15 KV System Isolation Isolation user side to PLC side 1500 Vrms APPENDIX A SPECIHCATIONS General Specifications All P C models Input Power Provided by power supply module PPX 505 6660 for user supplied 110 220 VAC PPX 505 6663 for user supplied 24 VDC Maximum power drawn from base by T1525 10 W 5 VDC 0 5 W 5 VDC Maximum power drawn from base by
46. e bezel Do not over tighten The maximum torque that can be applied to the screw is 3 Kgf cm 2 60 in Ib NOTE For instructions on wiring I O modules and calculating I O power requirements check the appropriate manual for each I O module Complete the following steps to remove the modules into the base 1 Disable line and user supplied power 2 Loosen the screws at the top and bottom of the bezel NOTE Prior to removing I O modules you may remove the wiring terminal block without disturbing field wiring Use a Phillips head screwdriver to remove the screws at the top and bottom of the terminal block and pull the terminal block off the bezel 3 Grasp the bezel screws and carefully remove the module You may find it easier to loosen the module first by gently pulling the module up and down within the slot by the bezel screws Hardware and Installation User Manual 3 24 3 6 3 INSTALLATION Installing the Power Supply You may operate the PP X 505 6660 or PPX 505 6660A power supply at either 110 or 220 VAC The power supply is shipped preset for 220 VAC Use the jumper shown in Figure 3 18 to select the proper voltage for your application CAUTION To minimize the risk of personal injury disable all system power before changing the power supply jumper Attempts to operate the power supply with the line voltage jumper placed incorrectly may damage the power supply 7 Figure 3 18 Power Supply J
47. e loses communication with the PLC the appropriate bit in STWO2 shows a 1 and the corresponding bits in STW12 to STW18 show zeroes even if modules on that base have failed or been incorrectly configured That is modules do not show failures on a basethat is not present 5 13 Hardware and Installation User Manual STARTUP TROUBLESHOOTING 5 2 4 Clearing PLC Fatal Enors A fatal error has occurred when both the following conditions hold e PC GOOD LED is not lighted e TheDC GOOD LED on the power supply is on The PLC enters a fatal error condition and ceases operation if a problem listed below occurs e Watchdog time out The microprocessor does not reset a watchdog circuit periodically e llegal operation code The microprocessor receives an illegal instruction e Diagnostic test failure The PLC fails a diagnostic test e O fatal error The PLC detects a non recoverable I O error e ROM diagnostic failure The operating system EPROMs are found to be invalid e Operating system fatal error The PLC detects a non recoverable error during execution e Abnormal power loss Power tothe PLC is removed without proper warning e Dynamic Program Memory Diagnostics Error The PLC determines a checksum error in the user EPROM EEPROM or RAM When a fatal error occurs the PLC takes the following actions e ThePC GOOD LED is turned off e 1 0 ports are disabled Discrete outputs are turned off and word outputs are held in
48. ectrical Noise Definition Isolation B 7 Suppression B 6 Emergency Stop Switch 2 5 Endosures EPROM EEPROM AUX Function 84 and 4 1 4 8 4 12 Installation J umper Pins 4 444 9 5 17 Operation At Power Up Programming 4 8 Status Words and 4 10 Troubleshooting 4 94 4 11 5 17 Errors SeeFatal Errors Status Words INDEX 1 Hardware and Installation User Manual F Fatal Errors Clearing 5 15 Conditions 5 14 Grounding Guidelines 2 7 B 1B 4 Guidelines Grounding 2 7 B 1 Handling Modules Module Installation 3 23 Pre installation Safety Temperature I O selecting type of I O Channel Controller 1OCC 1 3 3 21 3 32 1 OM ismatch 5 6 5 13 O Module Base Power Budget and Handling Guidelines 3 4 Installation 3 29 Point Numbering 3 Power Budget 2 1 Status Words and Inch Switch 2 6 Initialization P C 5 1 Input Output I O eee pee ERE EPA Local Installation Base Assembly 3 2 Base Controllers 3 32 Battery 3 17 Communication Cables 3 27 EPROM EEPROM T1525 4 4 T1535 4 6 1 0 Madsies 529 PIC Power Supply 3 25 Instruction Set RLL 1 7 Hardware and Installation User Manual INDEX J J og Switch 2 6 J umper Pins EPROM EEPROM 4 44 9 L LED Indicators 5 4 Local 0 1 3 3 20 3 22 Logical Base 3 13 3 19 M Memory AUX Functions and Battery Backup 3 7 3 14 Features by mod
49. ed by the base power supply and the requirements of the particular modules used When determining the O system layout do not exceed the maximum power available from the power supply The total power requirement for all modules drawing power from a Series 505 base must beless than or equal 55 W at 45 VDC and 3 75 W at 5 VDC Hardware and Installation User Manual 3 26 INSTALLATION 3 6 4 Installing the PLC Complete the following steps to install the PLC in the base 1 Check dipswitches for correct configuration 2 Disable all user supplied power to the base 3 Insert the PLC into its slot adjacent to the power supply as shown in Figure 3 20 4 Tighten the bezel screws Bezel screws Figure 3 20 Location of PLC in Base 5 If you have equipment to connect to the ports attach the communication cables to the appropriate port s The RS 232 C RS 423 compatible port accepts a 25 pin male plug and allows communication with equipment up to 50 ft 15 2 m away The RS 422 compatible port accepts a 9 pin male plug and allows communication up to a distance of 1000 ft 305 m for all baud rates supported by the PLC model Both ports are configured as Data Terminal Equipment DTE The pin outs are listed in Table 3 1 3 27 Hardware and Installation User Manual INSTALLATION NOTE If you are powering up a T1535 for the first
50. el 1 Ladder Logic Memory by model 1 Memory Protect Dipswitch 5 3 T1525 Models 3 16 6 T1535 Models 3 Memory Protect Dipswitch 1 10 Modules Handling Guidelines 3 4 Installation Guidelines 3 23 NEMA Enclosures 2 7 O Operator Safety Switch 2 4 P P C Initialization 5 145 3 Installation Troubleshooting 5 14 Port Communication Baud Rate Dipswitch T1525 3 6 T1535 3 15 Pin Out 3 27 Power Budget INDEX 2 Power Consumption Series 500 Modules C 4 Series 505 Modules C 1 Power RORA l nstallation 3 25 M odels 1 5 gud Power Budget 2 1 Troubleshooting 5 18 Power Up AUX Functions and 5 7 5 7 Modes P C Initialization 5 1 Pre installation Guidelines 2 1 Preset Values AUX Functions and 3 9 3 12 5 6 Download Retain Dipswitch T1525 3 9 T1535 3 12 Primary Base 3 20 3 21 Programming EPROM EEPROM 4 8 Programming Devi ces 1 2 1 8 Programming Software 1 8 R RLL Instruction Set 1 7 S Safety Guideli nes 2 4 2 6 Safety Switch 2 4 Scan Time Boolean Logic 1 1 INDEX Status Word 10 and P C Power Supply 3 25 Software P rogramming 1 8 Spare Parts List 5 19 Specifi cations A 1 Start Up Procedure 5 11 5 3 Status Words STWO7 STWO09 4 11 5 11 STW10 STW11 STW18 Troubleshooting with 5 13 Stop Switch 2 5 T Temperature Guidelines TISOFT Programming Software 1 8 Troublesho
51. est numbered logical base in the system For example if your system consists of 5 logical bases numbered 0 through 5 then the dipswitches should be set for 5 Switches 5 8 reduce I O update time by preventing the PLC from attempting to communicate with distributed bases that are not present or which you may have shut down Although it increases scan time you can set the switches for 15 if you prefer regardless of the actual number of logical bases that are connected You may connect Series 500 bases to your system Number the Series 500 logical bases just as you would Series 505 bases however the total number of logical bases cannot exceed 16 Figure 3 10 lists the switch positions for each address Highest Switch position base 6 7 8 address ON ON ON ON ON ON OFF ON ON OFF ON ON ON OFF ON ON OFF ON OFF OFF ON OFF OFF ON ON ON OFF ON ON OFF OFF ON OFF OFF ON OFF ON OFF ON OFF OFF OFF OFF OFF En olola 1 O O1 S Oo Po O i N Position p selected ga POSition not C5 selected A Push down Em oa Figure 3 10 Switch Settings 11535 Highest Numbered Logical Base 3 13 Hardware and Installation User Manual INSIALLATION 3 4 4 Selecting Battery Backup 11535 Models Switch 1 on the second
52. et copy errors then the EEPROM may have failed You must power down remove the EEPROM and power up again to dear this error condition 4 9 Hardware and Installation User Manual EPRO M EEPROM OPERATION 4 5 REPORTING EEPROM STATUS EEPROM programming information is recorded in status words that can be read with the programming device These status words represent EEPROM programming information gathered on the last completed programming cycle They can be read any time except when you are in the process of programming If an error occurs while you are copying a program to an EEPROM you can examine the status words to evaluate the error condition Follow the steps below 1 Makecertain that the battery is enabled 2 Clear the error condition by cyding power 3 Examinethe status words with a programming unit 4 5 1 Status Word Six STWO6 As illustrated in Figure 4 3 below STWO6 reports the status of EEPROM programming MSB LSB Bt 1 2 34 5 6 78 910 11 12 13 14 15 16 Ge OD spare spare 1 programming complete no errors 1 programming complete error 1 the EPROM EEPROM was not initially clear 1 programming error Figure 4 3 Formatof Status Word Six STWO6 Hardware and Installation User Manual 4 10 EPRO M EEPROM OPERATION 4 5 2 Status Words Seven to Nine STWO07 STWO9 STWO7 gives the absolute address of the first error encountered while attempti
53. f memory e A communication port baud rate of 19 200 provides faster communication with the Video Programming Unit VPU and other operator interfaces 1 1 Hardware and Installation User Manual The Series 505 product line is designed for use in small to medium applications such as discrete word and analog control Components include the T1525 and T1535 PLCs shown in Figure 1 1 and the support devices that provide operator FEATURES D TI52 RUN SIMATIC 9 BATTERY GOOD P c GOOD 5 D 525 1102 D SIMATIC TI535 RUN BATT GOOD P c GOOD communication I O control and power Operator communication may take place through any of the following devices e BM PC XT Computer or a 10096 compatible computer with TI SOFT e Video Programming Unit VPU e Handheld Intelligent Terminal HIT 500 1101 e Control Vision Unit CVU Hardware and Installation User Manual 1 2 Figure 1 1 T1525 and T1535 Controllers FEATURES You may usea DEC VAX Computer to develop an RLL program that can be transferred to a T1525 T1535 PLC with a VPU You can provide communication between devices through the TI WAY industrial local area network See the references listed in the Preface of this manual for information on these systems I O control for the Series 505 takes place through individual Series 505 I O modules A full line of
54. for proper voltages Be surethe jumper in the back of the power supply is set for the appropriate voltage 5 1 Hardware and Installation User Manual STARTUP TROUBLESHOOTING e Besure that all I O interface cables are properly connected to I O interface connectors e All the configured bases are properly connected there are no crimps or breaks in the cable and base addresses are correct e Thecabletothe programming unit where applicable is secure e PLC battery polarity is correct 3 Initialize PLC For TI 535 models If you have not already done so disable the PLC battery by turning off switch 1 on DIP 2 Make certain that a programmed EPROM EEPROM is nct installed Turn on power tothe PLC With the battery disabled and no programmed EPROM EEPROM installed the TI 535 clears memory and enters PROGRAM mode Enable the battery by turning on DIP 2 switch 1 The Battery Good LED should light The T1535 is now initialized For TI 525 models Turn on power to the PLC The TI525 is initialized during power up 4 If you intend to use an EPROM EEPROM install the EPROM EEPROM according to the instructions given in Chapter 4 5 Connect the programming device to the RS 232 C RS 423 port of the PLC Place the PLC in PROGRAM mode If you have installed a pre programmed EPROM EE PROM go to step 8 NOTE The PLC should be in PROGRAM mode at this point not in RUN mode Instructions that you enter in the RLL progr
55. he following paragraphs provide information to help reduce the possibility of electrical noise problems B 4 1 Definition and Source Electrical noise is defined as any unwanted electrical signal which enters the control equipment Noise signals cover the entire spectrum of frequencies and may have any waveshape The largest single difficulty with noise is that it is not always present Continuous or frequent periodic noises generally are easy to detect and remedy Intermittent noise sources that produce short high energy bursts at irregular and widely spaced intervals cause the majority of difficulties Noise has a number of different pathways into control equipment It can be conducted through signal or power wiring or can be radiated by electromagnetic waves Conducted noise typically is coupled with the signal or power wiring either electrostatically or magnetically Electrostatic coupling occurs through parasitic capacitance between the noisy line and the signal power line This requires high voltage or high rate of change of voltages in the noisy line and high parasitic capacitance between lines This typically would be the case for long wire runs in the same conduit Magnetic coupling occurs through parasitic mutual inductances between lines This requires high currents or high rates of change of current as well as significant mutual inductance which may result from proximity of wiring Electromagnetically radiated noise typically is
56. he red wire to the positive pole and the black wire to the negative pole of the new battery Then insert the new battery into the battery holder 6 Insert the PLC into the base enable power and verify that the BATT GOOD LED comes on 3 17 Hardware and Installation User Manual INSIALLATION 3 5 2 Model 11535 Battery Installation Take the following steps to replace the battery 1 Ensure that the power to the PLC is on Replacing the battery with power off will result in memory loss 2 Open the battery door as shown in Figure 3 14 Figure 3 14 Battery Location for 11535 Models 3 Remove the battery from the compartment and disconnect the leads 4 Attach the leads to the new battery 3 0 VDC UL Recognized lithium battery PP X 2587678 8005 Connect the red wire to the positive pole and the black wire to the negative pole Push the new battery and leads back into the compartment 5 Set the battery dipswitch ON DIP 2 switch 1 if you wish to enable battery backup The BATT GOOD indicator should light 6 Close the battery door Hardware and Installation User Manual 3 18 INSTALLATION 3 6 INSTALLING SYSTEM COMPONENTS A base assembly is composed of one or two logical bases A logical baseis defined as a group of eight I O slots as shown in Figure 3 15 Therefore the PPX 505 6516 sixteen slot base assembly comprises two logical bases while the PPX 505 6508 eight slot base assembly contains one log
57. ic electricity touch a grounded piece of metal before touching the circuit board or any of its components e Wear non synthetic dothing e Handle all modules by the external casing and avoid contact with the circuit board or any of its components Hardware and Installation User Manual 3 4 INSTALLATION 3 3 SETTING 11525 DIPSWITC HES You determine operational parameters for the T1525 by setting switches on two dipswitches F or the T1525 PLCs these dipswitches are located on the printed circuit board PCB Refer to Figure 3 3 Switch position r Baud 1 RS 232 C 423 9600 ON Baud rate 2400 OFF 1200 ON RS 422 300 OFF Baud rate Switch position p Baud 3 Au a Factory test must be 9600 ON A set on 2400 OFF 1200 ON Am 300 OFF Position Position not Selected m Selected Push Down O zZ Battery enable Factory test switches must be set off for normatl operation L Memory protect on Download presets Factory test switches position does not matter fro normal use aaneaen Figure 3 3 Locations of the Dipswitc hes for the 11525 Models 3 5 Hardware and Installation User Manual INSTALLATION 3 3 1 Setting Port Baud
58. ical NOTE Identical RLL programs and identical I O configurations programmed in different machines may yield different checksums due to internal storage differences STWO9 shows the checksum generated from the EPROM EEPROM The checksum is a numerical calculation based on all data stored in the EPROM EEPROM including your RLL program and information contained in the I O configuration memory When you copy a program to several EPROM EEPROMs you can check STWO9 for every EPROM EEPROM to verify that the information contained in each is identical 5 2 3 5 Status Word Ten SIW10 STW10 shown in Figure 5 5 provides the PLC scan time in binary code If you display the integer value of the word the program scan time is given in milliseconds The PLC updates the word each scan MSB LSB Bit 1 2 34 5 6 7 8 9 10 11 12 13 14 15 16 stwo ololololo ojolojo ojo o t o olo Figure 5 5 Formatof Status Word Ten SIW10 5 11 Hardware and Installation User Manual 5 2 3 6 STARTUP TROUBLESHOOTING Status Words Eleven to Eighteen SIW11 SIW18 Status Words 11 through 18 report the status of the I O modules contained on the logical bases as shown in Figure 5 6 Each bit corresponds to one module in the base If the module is in proper working order or if there is no module in that slot the corresponding bit is 0 If the occupied slot contains a malfunctioning module the bit is 1 Seethe example shown in Figure 5 7 The
59. ical base The four slot PP X 505 6504 base also contains one logical base but slots 5 8 do not physically exist A system may consist of as many as 16 logical bases and up to 1023 I O points PPX 505 6508 8 slot base base Power TI525 TI535 8 slots supply PLC PPX 505 6516 16 slot base P d S Logical base Logical base Power TI525 TI535 8 slots 8 slots supply PLC PPX 505 6504 4 slot base P S One logical Power T1525 TI535 pase 4 Physical slots supply PLC 4 Non existent slots Figure 3 15 Definition of the Series 505 Logical Base 3 19 Hardware and Installation User Manual INSIALLATION O modules are grouped into local or distributed I O categories depending upon their physical location The local I O comprises those modules installed in the same base assembly as the PLC the primary base A system having local I O only consists of a single base assembly comprising a maximum of two logical bases A 16 slot base assembly contains two logical bases numbered 0 and 1 from left to right The 8 slot and 4 slot base assemblies each contain one logical base numbered 0 SeeFigure 3 16 NOTE Bases 0 and 1 are always on the local base Therefore any distributed base will always be numbered greater than 1 If your system has local I O only you need to install the power supply PLC and I O modu
60. ing 200 V A PPX 505 6660 Wattage Rating 100 W maximum PPX 505 6663 Output 55 W at 5 VDC 3 75 W at 5 VDC In addition the system complies with applicable requirements of Verband Deutscher Elektrotechniker VDE 0160 Electrical Equipment except 220 VAC Input Modules No 505 44XX 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 Information concerning product reliability and compliance to the IEC or other standards can be provided upon request Contact your Siemens Industrial Automation distributor or sales office If you need assistance in contacting your U S distributor or sales office call 1 800 964 4114 Hardware and Installation User Manual A 2 APPENDIX B GROUNDING AND ELECTRICAL GUIDELINES B 1 INTRODUCTION This appendix describes measures you can take to provide a good earth ground to your system lists steps you can perform to ensure that your system is not influenced by electrical noise and gives instructions for proper wiring B 2 GROUNDING A good grounding system is essential for proper operation of the Series 505 controllers All filtering devices internal to the 505 system require a good earth ground for reference The structural ground present in many industrial environments does not provide an adequate ground return when di
61. it refers to this switch as a keylock Refer to Figure 3 6 Turn switch 4 ON to prohibit changes to the program Turn switch 4 OFF to permit program editing L Memory AS A L Memory protect off protect on DIP 2 Position Position not Selected mm Selected Push Down Figure 3 6 Switch Settings T1525 L Memory Protection NOTE Turning the L memory protect switch on does not prevent forcing I O changing variable memory or switching the PLC from PROGRAM to RUN mode These actions may be initiated with a programming device connected to the PLC or a special function I O module designed for this type of interface to the PLC e g a Network Interface Module The RLL can also be changed through a special function module even when the memory protection is enabled with the keylock Do not depend upon this switch to prevent personnel from interrupting your process Hardware and Installation User Manual 3 8 INSTALLATION 3 3 4 Downloading Preset Constants 11525 Models The drum and timer counter instructions have reserved sections of memory where preset variables are stored These variables may be changed with an operator interface such as a TCAM or VPU or with an RLL instruction without altering their valuein the RLL program If you cycle power or execute AUX Function 10 while the battery is enabled switch 5
62. ition does not matter if a device is not to be connected to the port PUSH PUSH LEFT RIGHT Switch position L Left R Right RS 422 Baud rate RS 232 C 423 Baud rate Baud 2 3 4 300 1200 2400 9600 19200 Position does not matter Switch position L Left R Right 6 gt Baud 5 300 1200 2400 9600 19200 Position does not matter Figure 3 12 Switch Settings 11535 RS 232 C RS 423 and RS 422 Ports 3 15 Hardware and Installation User Manual INSTALLATION 3 4 6 Selecting Ladder Memory Protection 11535 Models Switch 8 on DIP 2 prevents changes to the RLL program in ladder memory Your programming unit refers to this switch as a keylock Refer to Figure 3 13 Push switch 8 LEFT to prohibit changes to the program Push switch 8 RIGHT to permit program editing Position Position not selected selected Push Left or Right L Memor m L Memor y v E protect on protect off Figure 3 13 Switch Settings 11535 L Memory Protection NOTE Turning the L memory protect switch on does not prevent forcing I O changing variable memory or switching the PLC from PROGRAM to RUN mode These actions may be made by a programming device connected
63. l devices These precautions conform to the guidelines for installation of Programmable Controllers as recommended in the NEMA ICS 3 304 Programmable Control Standards Hardware and Installation User Manual 9 2 PRE INSTALLATION ICS 3 304 81 Safety Recommendations Consideration should be given to the use of an emergency stop function which is independent of the programmable controller Wherethe operator is exposed to the machinery such as in loading or unloading a machine tool or where the machine cycles automatically consideration should be given to the use of an electromechanical override or other redundant means independent of the programmable controller for starting and interrupting the cycle 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 are intended as safeguards against the failure of critical components and the effects of such failures or theinadvertent errors that might be introduced if programs are changed while the equipment is in operati on The ICS 3 304 81 Safety Recommendations are reproduced by permission of the National Electrical Manufacturers Association from NEMA ICS 3 304 Programmable Controller Standard 9 3 Hardware and Installation User Manual PRE INSTALLATION 2 2 SAFETY CONSIDERATIONS Pre install
64. les in a single base assembly See the installation instructions later in this chapter TI525 TI535 PLC Logical Logical Power base 0 base 1 supply B Series 505 I O modules 4 Slot base 8 Slot base 16 Slot base Figure 3 16 System With Local I O Only Hardware and Installation User Manual 3 20 INSTALLATION You may connect up to 14 additional base assemblies to your system as shown in Figure 3 17 These additional bases constitute the distributed I O and are numbered from 2 to 15 TI525 TI535 PLC Logical Logical Power base0 base 1 supply TS Local I O PPX 505 6830 IOCC PPX 505 6840 PPX 505 6840 DBC DBC Logical Logical Logical Logical baseA base B baseC base D ge S Te ae Distributed I O To other bases To other bases The PPX 525 1102 does not support distributed I O Figure 3 17 Systems with Local and Distibuted I O The I O modules in the distributed bases communicate with the PLC through base controllers The Series 505 Distributed Base Controller DBC PPX 505 6840 in each distributed base assembly transmits all information from the I O modules in that base assembly to the I O Channel Controller LOCC PP X 505 6830
65. ng to program the EEPROM The value given is the memory address of the EEPROM memory STWOS shows the checksum calculated from the RLL program stored in the EEPROM The checksum is a numerical calculation based on your RLL program only When you copy a program to several EEPROMs you can check STWOS for every EEPROM to verify that the information contained in each is identical NOTE Identical RLL programs and identical I O configurations programmed in different machines may yield different checksums due to internal storage differences STWO9 shows the checksum generated from the EEPROM The checksum is a numerical calculation based on all data stored in the EEPROM including your RLL program and information contained in the I O configuration memory When you copy a program to several EEPROMs you can check STWOO for each EEPROM to verify that the information contained in each is identical WARNING Permitting a PLC to execute an EPROM EEPROM program without first checking the program may result in injury to personnel and damage to equipment due to unexpected operation by the PLC If you are not absolutely certain that the EPROM EEPROM program is correct disconnect all 1 O modules and the IOCC if necessary from the base before you power up 4 11 Hardware and Installation User Manual EPRO M EEPROM OPERATION 4 6 EDITING SAVING PROGRAMS USING AN EPROM EEPROM You manage operation of the EPROM EEPROM by executing AU X Function 84
66. ns and increasing system noise immunity e 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 710 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 external 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 B 1 Hardware and Installation User Manual B 2 APPENDIX B GROUNDING GUIDELINES Equipment Subpanel X Star washers To ground equipment directly to the subpanel follow these Steps 1 Remove the finish from the equipment at areas of contact 2 Tighten the bolt 3 Tighten the first nut 4 Tighten the second nut Ground braid copper lugs Step 2 NU NA Star washers Subpanel or user supplied single
67. office If you need assistance in contacting your U S sales office call 1 800 964 4114 5 2 1 Reading the LED Indicators The three LEDs on the PLC are labeled RUN BATTERY GOOD and PLC GOOD When the LEDs are on they indicate status as shown in Table 5 1 and can aid in locating the source of a problem The PLC LEDs are meaningful only when the DC POWER GOOD LED on the power supply is turned on Table 5 1 LED Indicators RUN ON PLC is in Run mode BATTERY GOOD ON Battery is good and battery dipswitch is on PLC GOOD ON PLC is functioning with no fatal errors Hardware and Installation User Manual 5 4 5 2 2 5 2 2 1 STARTUP TROUBLESHOOTING Executing the Auxiliary Functions The TI525 TI535 PLCs offer self checking and diagnostic capabilities for troubleshooting purposes The diagnostics and self checks are accessible through the Auxiliary Function menu on the programming device When you display the Auxiliary Function menu the following functions are available for resetting the PLC initiating diagnostics or displaying diagnostic information e AUX29 Show PLC diagnostic cell e AUX 25 Display failed I O e AUX20 RunPLC diagnostics e AUXI11 Partial restart e AUX12 Complete restart e AUXIO Power uprestart AUX Function 29 Show PLC Diagnostic Cell AUX Function 29 checks the operational status of the PLC and displays the results The display provides the information illustrated in Figure 5 1 TI
68. on DIP 2 determines whether the changed values in preset memory are retained or the original values are downloaded from the RLL program If the battery is dead low or disabled the preset values are always downloaded from the RLL program in an EPROM EEPROM if oneis installed Refer to Figure 3 7 Turn switch 5 ON to have values downloaded from the RLL program Turn switch 5 on DIP 2 OFF to have preset values retained Retain gas z Download presets presets DIP 2 Position Position not ud selected m selected Push down Figure 3 7 Switch Settings 11525 Download Retain Presets NOTE Executing AU X Function 12 PLC Complete Restart with your programming device causes the presets to be downloaded from the RLL program regardless of the state of this dipswitch 3 9 Hardware and Installation User Manual INSTALLATION 3 4 SETTING 11535 DIPSWITC HES You determine operational parameters for the T1535 by setting switches on two dipswitch block assemblies For the T1535 PLCs this is done with one block of dipswitches located on the printed circuit board PCB and a second block located inside the battery door Refer to Figure 3 8 OFF Switch position Factory test AN I O Type 2 3 selo Status ON ON I O type Test ON and factory test Test OFF ON Retain ga Cw Download No status OFF presets presets
69. orts suasusu Switch Settings 7535 L Memory Protection 0 cece ete Battery Location for 535 Models ssssssseees es Definition of the Series 505 Logical Base sssssseseeeee e System With Local l O Only cicer RR yee hd bee ke eee aie Ec E Systems with Local and Distributed I O 2 0 eet tenes Power Supply UMPC uere grim elisa EORR a pie einen engine Location of Power Supply in Base 1 ict Hn Location of PLC IN Base sii sata ees cated hee Sede ce a ea eh eae wed ates Location of O Modulesin Base ssssss He T1525 EPROM EEPROM Socket and JumperPins osuessaan 7115535 EPROM EEPROM Socket and JumperPins ssssssssssssee ne Format of Status Word Six SIWO6 ssssse Hn Example of AUX Function 29 Screen 6 eese esee Format of Status Word One SIWO1 ssssseee RR ra Format of Status Word Two SIWO2 sssse I ra Format of Status Word Six SIWO6 sssssse Ihn Format of Status Word Ten STW10 sssssssee Ia Format of Status Words Eleven to Eighteen STW11 18 usuau Example of a Status Word With a Bit Set 00 eee Sample Ground Connections s reri rinie eee Examplesof Noise Snubbing 6 nett nnn Contents List of Tables 1 1 ModeliDierences sessi bete ee edes Red ese ee eaa Gideon as 1 6 1 2 1525 1535 INSMUICLON SGre x e hae efc ade fe ehe e ec I Ra c even grad d 1 7 3 1 Pin outforthe RS 232 C RS 423 Port ssssssssssse een 3 28
70. ot copy a program from RAM to an EPROM NOTE AUX Function 84 affects only the RLL program and the I O configuration Timer counter and drum event drum variables and values in V memory are not affected by AUX Function 84 operati ons 4 13 Hardware and Installation User Manual CHAPTER 5 STARTUP TROUBLESHOOTING 5 1 START UP PROC EDURES Follow the steps outlined below before powering up your TI525 TI535 system for the first time 1 Befamiliar with the operation of the system components as discussed in this installation manual 2 Verify the following items e f any of your installed bases have empty I O slots use filler bezels PPX 2587705 8003 to cover the openings in the base This prevents debris from interfering with system operation and helps to guard against electrostatic discharge and electrical noise interference e After installation is complete remove the plastic dustguard on the top grill of every installed Series 505 base WARNING Failure to remove the dustguard may result in overheating and damage to equipment and could result in injury to personnel e Check for correct switch settings on all configurable modules e g the PLC and DBC s The L memory MEMORY PROTECT dipswitch on the PLC must be OFF if you intend to enter the RLL program with a programming device e All modules are securely plugged into the base connector pins are not bent and bezel screws are tightened e Check AC input power
71. ot need to assign I O point numbers to empty slots or to non existent slots in logical bases having fewer than eight slots O Module power consumption requirements may reduce the actual number of I O points that can be installed Hardware and Installation User Manual 3 22 INSIALLATION 3 6 2 Guidelines For Installing Series 505 Modules The Series 505 I O base controllers and PLCs are all open card modules in double Eurocard design The power supply is a partially encased module in double Eurocard design Follow the guidelines in the following paragraphs when inserting or removing the modules WARNING Do not insert or remove modules while power is enabled to the PLC Modules may be damaged if inserted while power is on and memory may be lost if the PLC is removed while power is on System 505 components are compatible with International standards double Eurocard DIN standard 41494 3 23 Hardware and Installation User Manual INSTALLATION Complete the following steps to insert the modules into the base 1 Disable all user supplied power before inserting modules 2 Holding the module by the bezel position the printed circuit board in the upper and lower card guides 3 Insert the module and push until it is plugged into the backplane connector The bezel should be tight against the base 4 The bezel screws provide the ground Use a flat blade screwdriver to tighten the screws at the top and the bottom of th
72. oting AUX Functions and EPROM EEPROM 4 914 11 5 17 LED Indicators and 5 4 Status Words and W Wiring Rules B 4 INDEX 3 Hardware and Installation User Manual SIMATIC is a registered trademark of Siemens AG Series 500 Series 505 TISOFT1 TISOFT2 TISOFTS TIWAY CVU VPU are trademarks of Siemens Industrial Automation Inc T1505 T1520 TI520C T1525 TI530 TI530C TI530T and T1535 are trademarks of Texas Instruments Incorporated IBM is a registered trademark of International Business Machines Incorporated DEC is a registered trademark and VAX is a trademark of Digital Equipment Corporation Customer Registration We would like to know what you think about our user manuals so that we can serve you better How would you rate the quality of our manuals Excellent Good Fair Poor Accuracy Organization Clarity Completeness Overall design Size Index Would you be interested in giving us more detailed comments about our manuals Yes Please send me a questionnaire No Thanks anyway Your Name Title Telephone Number Company Name Company Address Manual Name SIMATIC TI505 TI535 Hardware and Installation User Manual Edition Manual Assembly Number 2586546 0052 Date Order Number PPX 505 8 103 3 Thrid 04 93 FOLD BUSINESS REPLY MAIL FIRSTCLASS PERMITNO 3 JOHNSON CMY TN POSIAGE WILL BE PAID BY ADDRESSEE SIEMENS INDUSTRIAL AUTOMATION INC
73. p uper p d T d d 4 Base 0 always 0 Base 1 always 0 1 base 2 has failed or is not present 1 base 15 has failed or is not present Figure 5 3 Formatof Status Word Two SIW02 NOTE Status words three through five are not used by the T1525 TI535 5 9 Hardware and Installation User Manual STARTUP TROUBLESHOOTING 5 2 3 3 Status Word Six STWO6 As illustrated in Figure 5 4 below STWO6 reports the status of EEPROM programming Only one bit is set at a time MSB LSB Bt 1 2 34 5 6 78 910 11 12 13 14 15 16 sop TT TT TT TT TE TT spare spare 1 programming complete no errors 1 programming complete error 1 2 the EPROM EEPROM is not initially clear 1 programming error Figure 5 4 Formatof Status Word Six STWO6 Hardware and Installation User Manual 5 10 STARTUP TROUBLESHOOTING 5 2 3 4 Status Words Seven to Nine SIW07 STW09 STWO7 gives the absolute address of the first error encountered while attempting to program the EPROM EEPROM The value given is the memory address of the EPROM EEPROM memory STWOS shows the checksum calculated from the RLL program stored in the EPROM EEPROM The checksum is a numerical calculation based on your RLL program only When you copy a program to several EPROM EEPROMs you can check STWOS for every EPROM EEPROM to verify that the information contained in each is ident
74. peint groun To attach ground leads to the subpanel follow these steps 1 Remove the finish from the equipment at areas of contact 2 Tighten the bolt Figure B 1 Sample Ground Connections B 3 Hardware and Installation User Manual APPENDIX B GROUNDING GUIDELINES B 3 WIRING GUIDELINES Consider the following guidelines before installing any system or power wiring Always usethe shortest possible cable Use a single length of cable between components Do not connect short pieces of cable to obtain additional length Avoid placing system and field wiring in the vicinity of high energy wiring Keep field input wiring output wiring and all other types of wiring in the panel physically separated Consider separating DC field wiring from AC field wiring wherever possible Avoid sharp bends to power and data cables Use 7 6 cm 3 inch radius on all bends A good low ground impedance of 0 1 ohm or less must exist for all components in the system Use wireways for wire and cable routing when possible Keep wire strippings from falling into modules controllers or bases 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 Hardware and Installation User Manual B 4 APPENDIX B GROUNDING GUIDELINES B 4 MINIMIZING ELECTRIC AL NOISE T
75. quirements and mounting space needed Space in the base assembly may be a limiting factor that you should consider as you plan your system This is particularly true if several doubl e wide modules are needed It is useful to calculate a power budget for each base prior to installation The power requirements of all modules must be induded in the calculations the PLC the base controllers as well as the I O modules The user supplied power toindividual modules is not a part of the power budget calculation To help ensure reliable system operation the total power required for the PLC the I O controllers and the I O modules must not exceed the total power available from the system power supply WARNING Control devices can fail in an unsafe condition This means that unless proper safeguards are incorporated by the user certain malfunctions of these devices could lead to a sudden equipment startup Such a startup could result in property damage and or severe physical injury to the equipment operator 2 1 Hardware and Installation User Manual PRE INSTALLATION 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 Although the specific design steps depend on your particular application the following precautions generally apply to installation of solid state programmable contro
76. ramming Unit TI525 Series 505 I O Series 505 I O TI535 4 8 and 16 slots 4 8 and 16 slots Distributed y o Series 505 I O 4 8 and 16 slots Additonal I O may be connected up to a total of 14 base assemblies The PPX 525 1102 does not support distributed I O Figure 1 2 Functional Relationship of Series 505 Components Hardware and Installation User Manual 1 4 FEATURES The power supply provides up to 55 watts at 5 VDC and 3 75 watts at 5 VDC for use by the PLC the base controllers and the I O modules The PPX 505 6660 power supply operates at either 110 V or 220 VAC on user supplied power A jumper on the inside of the back of the module is used to select voltage The PPX 505 6663 power supply operates on 24 VDC user supplied power All Series 505 hardware is compatible with International Standards double E urocard DIN standard 41494 1 5 Hardware and Installation User Manual FEATURES 1 2 FEATURES OF THE 11525 AND 11535 Two models of the T1525 and one of the TI535 are currently available Differences between these models are given in Table 1 1 The T1525 TI 535 RLL instruction set is listed in Table 1 2 Table 1 1 Model Differences Features PLC Model PPX 525 PPX 525 PPX 525 PPX 525 PPX 535 PPX 535 1102 1104 1208 1212 1204 1212 Ladder LogicSize 2048 409
77. rect wire connection to the power system is not feasible As a minimum use 12 AWG stranded copper wire for the ground return Minimum wire sizes color coding and general safety practices should comply with all appropriate electrical standards and codes Screw connections between bezels and bases as well as between enclosures and bases provide grounds and should be tightened properly B 2 1 Single Point Grounding Connect any Series 505 component with an external chassis or external ground terminal on its power connectors to the subpanel ground bus This connection should exhibit very low DC resistance 0 05 ohm and low high frequency impedance Connect the subpanel ground bus to a single point ground such as a copper bus bar to a good earth ground reference The single point ought to be the center of a star configuration to minimize device to ground distances B 1 Hardware and Installation User Manual APPENDIX B GROUNDING GUIDELINES To achieve low impedance from device to single point termination 0 65 centimeter or larger ground braid should be used A good rule of thumb is to require less than 0 1 ohm of DC resistance between device and single point ground This is accomplished by removing the anodized finish and using copper lugs and star washers B 2 2 Guidelines for Ground Connections Use particular care when establishing the ground connections The following techniques will help in establishing good electrical connectio
78. rors Found Errors Found Cleared PROGRAM 4 3 Hardware and Installation User Manual EPRO M EEPROM OPERATION 4 2 INSTALLING AN EPROM EEPROM IN 11525 MODELS Before beginning installation you must disable power to the PLC If you intend to download a program in RAM memory to an EEPROM you should ensure that a good battery is installed and enabled or the program may be lost when power is restored Follow the steps listed below 1 Placethe PLC in PROGRAM MODE NOTE The PLC mode RUN or PROGRAM on power up depends upon mode at power down the condition of the battery and the presence or absence of an EPROM EEPROM Refer to Table 4 1 2 Turn off all user supplied power to the PLC base 3 Removethe PLC from the base assembly 4 Ensurethat switch 1 on the second dipswitch DIP 2 is turned ON This enables battery backup NOTE If the battery backup is disabled and you take longer than 10 minutes to install the EPROM EEPROM you may lose the program stored in RAM 5 Refer toFigure 4 1 If you are installing an EPROM place jumpers on pins 2 3 and 4 5 If you are installing an EEPROM place jumpers on pins 1 2 and 3 4 6 Insert the EPROM EEPROM aligning the notches on the EPROM EEPROM and the socket 7 Check the pins to make sure that they are all seated properly in the socket Hardware and Installation User Manual 4 4 EPRO M EEPROM OPERATION 8 Place the PLC in the base and enable power Refer to th
79. rtial Restart 2 0 ccc eee teens 5 2 2 5 AUX Function 12 Complete Restart 0 ccc ccc cece ne 5 2 2 6 AUX Function 10 Power up Restart 0 cece eee 5 2 3 Troubleshooting with Status Words cette 5 2 3 1 Status Word One SIWOL1 0 ccs 5 2 3 2 Status Word Two SIWO2 0 ccc ccc RH 5 2 3 3 Status Word Six SIWO6 ssseeee n teen In 5 2 3 4 Status Words Seven to Nine STWO7 STWO9 sssssesseeeeeeeeeee 5 2 3 5 Status Word Ten SIW10 sssssen RII 5 2 3 6 Status Words Eleven to Eighteen STW11 STW18 5 2 4 Clearing PLC Fatal Errors ssssesssssse em 5 2 5 Troubleshooting the EPROM EEPROM sssssss e 5 2 6 Troubleshooting the Power Supply ssssssss tees 5 2 7 Spare PANS Pr Appendix A Specifications hws hn aa cw Appendix B Grounding And Electrical Guidelines B l Introd ction htc E eek cid eR Q6 E43 eR Ha ED EURO EORR tame dae iv Contents B 2 GIOUNGING Mov B 2 1 Single Point CASE FIO 2c cert EE CDI EPI Feb FEE de a RP B 2 2 Guidelinesfor Ground Connections sss seee B 3 Wiring Guidelines usse nennen B 4 Minimizing Electrical Noise ssssssnnnnnnnnnnnnnnnusnnnnnnnnnnnnnnnnnnnnnn B 4 1 Defihiton and SOUC eistis riteriai i a a d d B 4 2 Correcting Noise Problems uis rd i OG une e en eR CECI PG acies B 6 B421 _ Noise Suppression sucia ikdrtiidots deiecta ta Ede D dc ERR Ed E SUR B 6 B422 INDE aitecd n E ernie padre nse ee RR
80. tallation User Manual FEATURES 1 2 1 Program Software The TI525 TI 535 PLCs are programmed in standard relay ladder logic and TISOFT programming software provides a means of entering debugging and documenting your RLL program TISOFT is menu driven provides both RLL and advanced program special functions language and permits you to add comments to instructions Different versions of TISOFT are available TISOFT1 operates on the VPU 200 TISOFT2 is executed on an IBM PC XT and TISOFT3 runs in an off line mode on a DEC VAX computer You may also fully program the TI525 T1535 in Boolean symbolic code using the Handheld Intelligent Terminal In addition to the standard relay ladder logic the T1525 TI 535 programming instruction set offers more than 30 high level user oriented operations The box instructions replace programming steps that once required hundreds of words of memory More importantly these instructions permit you to use the power of the PLC to perform complex functions which makes program development and debugging faster and easier 1 2 2 Program Storage in EEPROM The TI525 TI 535 PLCs offer the option of saving your RLL program in a non volatile form by downloading it to an Electrically Erasable Programmable Read Only Memory EEPROM PPX 2587681 8020 integrated circuit A separate programming device is not necessary Once programmed an EEPROM may be removed and used in any of the T1525 T1535 or SIMATIC TI530T
81. termining the I O system layout take care not to exceed the maximum power available from the power supply The total power requirement for all modules drawing power from a Series 505 base must be less than or equal 55 W at 45 VDC and 3 75 W at 5 VDC 3 29 Hardware and Installation User Manual INSIALLATION NOTE Do not install more than four word modules in a physical base This may cause a DC loading problem in the PLC which could result in unexpected disabling of output modules induding discrete output modules For example even though a 16 slot base contains two logical bases you can only have a total of four modules Appendix C gives the power requirements for many of the currently available Series 505 and Series 500 modules For other modules not listed see the manual for that module All the T1525 and T1535 controllers use the Series 505 I O modules These I O modules have different numbers and types of I O points For example an eight point discrete input requires eight inputs Xs be assigned while an eight point analog output module requires assignment of eight word outputs WY s Table 3 2 lists the number and type of points required to log in the Series 505 I O modules Additional information on particular modules is given in the manual included with each module Hardware and Installation User Manual 3 30 Model Number PPX 505 4008 PPX 505 4016 PPX 505 4032 PPX 505 4108 PPX 505 4116 PPX 505 4132 PPX 505 4208
82. tguard prevents debris from falling into the base during installation After the entire system installation is complete and BEFORE ENABLING POWER TO THE SYSTEM be sure to remove the dustguard from each base This will allow proper air flow and prevent serious complications due to overheating 3 3 Hardware and Installation User Manual INSTALLATION 3 2 HANDLING SERIES 505 MODULES Many integrated circuit IC devices are susceptible to damage by the discharge of static electricity Follow the suggestions listed below to reduce the probability of damage to these devices when you are handling a PLC an I O controller or any of the I O modules To minimize risk of shock hazard make certain power to the PLC system is turned off WARNING To minimize the risk of shock hazard make certain power to the PLC system is turned off Both the module and the person handling the module should be at the same ground potential To accomplish this ensure that e The module is transported in an antistatic container or antistatic material e The work area has a conducive pad with a lead connecting it to a common ground e You are grounded by making contact with the conductive pad and or by wearing a grounded wrist strap CAUTION The following precautions although less effective may be taken to minimize the possibility of component damage resulting from electrostatic discharge See Appendix B for grounding guidelines e To discharge stat
83. their last valid state e Communication ports are cleared and re initialized e Pending or queued tasks are cleared Hardware and Installation User Manual 5 14 STARTUP TROUBLESHOOTING Attempt to clear the fatal error by following the steps listed below When the PC GOOD LED turns on the fatal error has been cleared 1 Determine the fatal error condition by selecting AU X Function 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 PLC serial number for later reference NOTE Always execute AU X Function 29 and make a list of the errors before attempting to clear them If you dear errors before listing them it will beimpossible to determine what errors occurred and difficult to identify the problem that caused them If communication errors occur cycle power to the PLC If communication errors continue record No Communication as the fatal error and goto step 4 2 Execute AUX Function 11 PLC partial restart If this fails to clear the error execute AU X Function 12 PLC complete restart 3 If the fatal error persists make certain that the battery backup is enabled and execute AU X Function 10 PLC power up restart 4 f you have been unable to clear the fatal error to this point you must re initializethe PLC This clears the PLC memory For a T1535 disable the battery backup turn off switch 1 of DIP 2 and cycle po
84. time turn off the battery backup This ensures that the T1535 PLC is properly initialized Refer tothe startup procedure in Chapter 5 6 Enable power Table3 1 Pin out for the RS 232 C RS 423 Port RS 232 C 423 Port RS 422 Port Signal i Signal Transmitted data Data out Received data Data in Request to send Ground Clear to send Data out inverted Data set ready Data in inverted Signal ground Received line signal detector Data terminal ready All others no connection All others no connection Hardware and Installation User Manual 3 28 INSTALLATION 3 6 5 Installing the I O Modules The wiring for the different I O module terminal blocks may vary You should read the user s manual for an individual module before wiring and installing the module Insert the I O modules into the base starting with the slot adjacent tothe PLC as shown in Figure 3 21 CAUTION Use supply wires suitable for at least 75 C Signal wiring connected in this box must be rated at least 300 V ATTENTION Employer des fils d alimentation pour au moins 75 C Le cablage de signalisation raccorde dans cette boite doit convenir pour une tension nominale d au moins 300 V I O module I O slots Figure 3 21 Location of I O Modules in Base The base power budget is determined from the power provided by the base power supply and the requirements of the particular modules used When de
85. ts 0 cece eens 3 6 2 Guidelines For Installing Series 505 Modules 3 6 3 Installing the Power Supply ccc M 3 6 4 Installing the PLC ck rect pee eet mr thud Pw ee Cit Roca C Oa as 3 6 5 Installing the VO Modules 0 ccc csc eee deie detA aa 3 6 6 Installing the Base Controllers 2 nee Chapter4 EPROM EEPROM Operation Intiod ctioni forded ol2rci1ox rel E Minissha Seer RS beri KR ENSE Er aes Installing An EPROM EEPROM In 1525 Models esee Installing An EPROM EEPROM In T1535 Models cene Programming The EEPROM eseseeee nnn Ins Reporting EEPROM Status seessees nnne nan n nr nnn 4 5 1 Status Word Six SIWOO6 occ cee rim eee ca ee e C ace 4 10 4 5 2 Status Words Seven to Nine STWO7 STWO9 00 0 ccc eee 4 11 Editing Saving Programs Using An EPROM EEPROM ennnn n n n n n n n n n n n 4 6 Chapter5 Startup Toubleshooting 5 1 Start up Procedures isissssssssssssessse nennen aha aaa aai a n n an 5 2 Using The Troubleshooting Tools 00cccceeeeee cece nnn nnn nnn nn 5 2 1 Reading the LED Indicators iisissssssssssseee 5 2 2 Executing the Auxiliary Functions sises siras maneia eee 5 2 2 1 AUX Function 29 Show PLC Diagnostic Cell 02 eee eee 5 2 2 2 AUX Function 25 Display Failed I O ccc ccc cece cent n 5 2 2 3 AUX Function 20 Run PLC Diagnostics ccc cece eee eens 5 2 2 4 AUX Function 11 Pa
86. uipment that dissipates no more than 325 W in the top half above the Series 505 bases assuming a 25 C external ambient temperature If you must exceed these guidelines use cooling equipment to lower the equipment temperature to the recommended level 2 7 Hardware and Installation User Manual 3 1 CHAPTER 3 INSALLATION INSTALLING THE BASE ASSEMBLIES The PLC I O controllers power supply and I O modules are mounted in Series 505 base assemblies Three Series 505 base assembly models are currently available e PPX 505 6504 41 O slots e PPX 505 6508 81 O slots e PPX 505 6516 16 I O slots 19 inch rack compatible Each base has slots reserved for the power supply and for the PLC and 4 8 or 16 I O module slots depending upon the base model Refer to Figure 3 1 PPX 505 6504 4 Slot Base Power Supply sme TI525 TI53 PLC Series 505 I O PPX 505 6508 8 Slot Base Power Supply p TI525 TI53 PLC Series 505 I O PPX 505 6516 16 Slot Base Se Series 505 I O TI525 TI53 PLC Figure 3 1 Series 505 Bases 3 1 Hardware and Installation User Manual INSTALLATION All Series 505 bases may be panel mounted The PP X 505 6516 base may also be mounted in a 19 inch rack The mounting brackets are included with the Series 505 base assembly Figure 3 2 shows the dimensions and screw positions Front view PP
87. umper Follow the steps listed below to install the power supply 1 Removethe strip of paper covering the wire connectors on the terminal block 2 Select the proper operating voltage by placing the jumper on the appropriate quick connect as shown in Figure 3 18 Not required for the PPX 505 6663 power supply 3 Disable all user supplied power to the base 4 Insert the power supply into the far left slot of the base as shown in Figure 3 19 5 Tighten the bezel screws 3 25 Hardware and Installation User Manual INSTALLATION 6 Use14 AWG solid or stranded wire for connection to the power source use of smaller wire is not recommended If stranded wire is used the wire should be twisted and tinned 7 Insert the green ground wire into the connector labeled ground 8 Insert the black AC line and white AC neutral wires into the power supply wire connectors labeled AC line and AC neutral respectively WARNING Connecting the power supply leads to the wrong terminals creates a potential shock hazard that could cause damage to equipment or injury to personnel Be sure that the polarity on all power supply leads is correct 9 After inserting the wires secure them by tightening the terminal block screws 10 Enable power Bezel screws Figure 3 19 Location of Power Supply in Base The base power budget is determined from the power provid
88. ure 2 2 Emergency Reset Guard C1 stop limit switch olo e NES C C1 Electromechanical I Relay Contacts of electromechanical relay C1 user supplied critical loads which could cause injury Output Module loads which could not cause injury Outputs from the programmable controller Figure 2 2 Emergency Stop Switch 9 5 Hardware and Installation User Manual PRE INSTALLATION e Bypass the programmable control system with an external J OG or INCH switch during machine loading or setup operations See Figure 2 3 Switch or contact Jog closed in the jog or inch mode User supplied Mt e critical loads which could cause injury Switch or contact open in the JOG Output or INCH mode Module Outputs from the programmable controller Figure 2 3 JOG orINCH Switch 2 3 ENCLOSURE SELECTION As a minimum an endosure for a PLC should provide the following 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 e Access restricted to authorized personnel only e Protection from dust dirt and moisture in an industrial environment Hardware and Installation User Manual 2 6 2 4 2 5 PRE INSTALLATION Mount the TI525 TI 535 components in a dustproof and drip tight enclosure such as the NEMA Type
89. used in a T1525 T1535 however e If you transfer an EPROM EEPROM from one TI 525 TI 535 model to another remember that the program in the EPROM EEPROM has to be compatible with the model in which it is used e fthe program that you loaded in RAM fails to copy to the EEPROM check the EPROM EEPROM jumpers to be sure that you have them set for an EEPROM not an EPROM Refer to Chapter 4 of this manual for instructions on installing and programming the EPROM EEPROM 5 17 Hardware and Installation User Manual STARTUP TROUBLESHOOTING 5 2 6 Troubleshooting the Power Supply Complete the following steps when troubleshooting the power supply 1 Determine that the power budget has not been exceeded and that the module is properly installed 2 After making sure the battery is on so the program will not be lost disable all power to the system for at least 90 seconds 3 Restore system power 4 fthe problem still exists turn off power to the system WARNING To avoid the potential risk of damage to equipment or injury to personnel always turn off power to the system before removing the power supply from the base 5 Remove the power supply from the base This step is not required for the PPX 505 6663 power supply a Makesurethe jumper in the back of the 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
90. wer tothe PLC or execute AU X Function 10 For a TI525 power down and remove the PLC from the base Disable the battery backup turn off switch 1 of DIP 2 insert the PLC in the base and power up 5 Ifthe PC GOOD LED comes on restore the battery backup by turning on switch 1 of DIP 2 For a TI 525 you must power down again and remove the PLC from the base to re enable battery backup You must now use your programming unit to restore your program 5 15 Hardware and Installation User Manual STARTUP TROUBLESHOOTING 6 IfthePC GOOD LED does not turn on at this time your PLC may have a hardware failure Contact your Siemens Industrial Automation distributor or sales office If you need assistance in contacting your U S sales office call 1 800 964 4114 Have the following information available before you call e List of fatal and non fatal errors e PLC serial number e PLC softwarerevision execute AUX Function 15 or check the PLC label e Sequence of events leading up to the failure Hardware and Installation User Manual 5 16 STARTUP TROUBLESHOOTING 5 2 5 Troubleshooting the EPROM EEPROM From the Status Chart or WORDS display of the programming device you can check the values in the status words STW06 STWO7 STWO8 and STWOO for problems with the EPROM EEPROM You should also check for the following e TheEPROM used in the TI520 TI 530 PLCs is not compatible with the TI525 TI 535 A TI520C TI 530C EPROM may be
91. your RLL program to the EEPROM The programming unit displays messages indicating the progress of the copy operation The PLC completes all current and pending communication processes and turns off the communication ports before beginning the copy operation NOTE The TI525 TI 535 PLCs copy data to the EEPROM very rapidly The entire copy process takes approximately 5 seconds or less The PLC enters PROGRAM mode when the copy process is completed Hardware and Installation User Manual 4 8 EPRO M EEPROM OPERATION 4 When you are finished making copies of your program go to step 5 If you wish to copy the program to another EEPROM power down the PLC replace the EEPROM with another and power up again Repeat Step 3 to copy the program to this second EEPROM This procedure can be repeated to program several EEPROMs 5 Check the program carefully while the PLC is in the PROGRAM mode before allowing the PLC to control equipment connected to the I O WARNING Do not place the PLC in RUN mode without first verifying the EPROM EEPROM program If the program is incorrect unexpected operation by the PLC may result in injury to personnel and or damage to equipment Any errors that occur during the copy process are listed on the programming unit Check the EPROM EEPROM jumper pins and make certain that an EEPROM not an EPROM is installed Make certain that all IC pins are properly seated in the socket If you continue to g

SIMATIC TI525/TI535 Hardware and Installation User Manual

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