2500-RIO-A RS-485 Remote Base Controller
Contents
1. CPU Terminating Resistor Terminating Resistor Max Trunk Length gt a Max Trunk Length gt E Total Trunk Line Length T Terminal Block Figure 7 T Connection Trunk Length Bus termination In order to minimize cable reflections and ensure a defined noise level on the data lines the data transfer cable MUST be terminated at both ends with a terminating resistor approximating the characteristic impedance of the cable For Belden 3105A cable a termination resistor value of 120 ohms should be connected across the TX RX and TX RX signal lines CTI 2500 RIO A Installation and Operation Guide V2 0 Cable Routing and Layout Guidelines Cables containing the following should be routed Bus signals e g Remote I O Data signals for PCs programming devices printers etc Screened analog inputs Unscreened DC voltages lt 60V in the same cable loom or cable duct Screened process signals lt 25 V Unscreened AC voltages lt 25V Coaxial cables for monitors DC voltages from 60 V to 400 V unscreened in separate cable looms or cable ducts AC voltages from 25V to 400 V unscreened without minimum spacing requirements DC and AC voltages gt 400 V unscreened Telephone cables For areas with explosion hazard in separate cable looms or cable ducts without minimum spacing requirements Laying Cables Outside of Control Cabinets All cable ducts shoul2. PREFACE This Installation and Operation Guide provides reference information for the CTI 2500 RIO A RS485 Remote Base Controller The information in this manual is directed to individuals who will be installing the module and configuring it for use with a CTI 2500 Series or Simatic 505 Processor We assume you are familiar with the installation and operation of 2500 Series programmable controllers Please refer to the appropriate SIMATIC user documentation for specific information on SIMATIC 505 programmable controllers and I O modules CTI 2500 RIO A Installation and Operation Guide V2 0 USAGE CONVENTIONS NOTE Notes alert the user to special features or procedures CAUTION Cautions alert the user to procedures that could damage equipment WARNING Warnings alert the user to procedures that could damage equipment and endanger the user CTI 2500 RIO A Installation and Operation Guide V2 0 TABLE OF CONTENTS CHAPTER 1 DESCRIPTION nnn nennen nnn nnn nnus 1 NP EEOC HO 1 1 1 2 Communication Ports eesesseeeeenn mene eene nnns rsen rre rss 2 1 2 1 Serial Port 1 2 2 I O Port CHAPTER 2 INSTALLATION 3 2 1 Installation Planning eeeeeeeeieieeeeeeeeee esee eessessee eene 3 Choosing Remote I O Media Selecting a Remote Base Address Setting Module
3. modules compatible with programmable controllers from Siemens and CTI The 2500 RIO A RS485 Remote Base Controller RBC allows a 2500 Series I O base to function as a remote base The 2500 RIO A 15 intended to be a replacement for the Siemens 505 6851 A RBC It provides the following functions Compatible with CTI 2500 Series and Simatic 505 CPUs Can be used in currently available CTI and Siemens 4 8 11 and 16 slot bases Supports communication speeds 1 Mbits sec and maximum cable distance of 1000 meters LED display which shows error and status codes Front panel thumbwheel switch for setting the station address On board RS232 port which can be used for PLC programming and configuration The 2500 RIO A resides in 2500 Series base It installs in the second slot from the left adjacent to the power supply module When used in a 2500 R11 A Redundant Base two 2500 RIO A units can be installed in the third and fourth slots from the left adjacent to the second power supply Do not install this module into a normal I O slot as damage can occur CTI 2500 RIO A Installation and Operation Guide V2 0 Figure 1 2500 RIO A Front Panel 1 2 Communication Ports The 2500 RIO A RS485 RBC has two communication ports on the front panel 1 2 1 Serial Port The RS232 port is provided to interface to PLC programming and configuration tools such as TISOFT A standard 9 pin PC compatible RS232 serial cable is used
4. state and contact CTI Technical Support Module Mismatch OK modules installed do not match the expected configuration in the CPU I O Communications Failed There is no communication with the CPU timeout Place the system in a safe state Check power cabling and connection to the CPU K K Ram Parity Error Failed Serious malfunction Place system in safe state and contact CTI Technical Support Standby No None Standby RBC in dual media application is Configuration not configured Configure module Address Mismatch Dual media RBC s must have identical O station address If addresses are equal contact CTI Technical Support O Communications 2500 RIO A is not configured Configure RBC in CPU Configuration Watchdog timeout Failed Serious malfunction Place system in safe state and contact CTI Technical Support No Code Displayed None Serious condition 2500 RIO A is not operational If power to base is OK contact CTI Technical Support C Standby unit OK Standby unit of a redundant pair is configured configured and communicating Following power up of a redundant RBC pair the unit on the left becomes the primary and displays a 0 The unit on the right becomes the standby unit and displays a 8 CTI 2500 RIO A Installation and Operation Guide V2 0 APPENDIX A REMOTE 1 0 INSTALLATION GUIDELINES These Remote I O Installation Guidelines are based on standard RS485 wiring practices See Chapter 6 of the SI
5. outputs turn OFF 0 and Analog Word outputs are set according to the Zero Hold Last Value settings in each particular module Your program can monitor the CPU Status Words to detect this condition and control the outputs from other remote bases as appropriate for the application Details on the Status Words and programming examples can be found in the SIMATIC 545 555 575 Programming Reference User Manual Setting the Output State on Communication Loss When I O channel communication to a remote base is lost the state of the discrete outputs is determined by the selection made on the 2500 RIO A jumper JP1 Off Freeze Figure 2 shows the location of the jumper on the 2500 RIO A NOTE The 2500 HIO A ships with the FREEZE jumper in the OFF setting If the jumper JP1 is missing from the board the 2500 HIO A defaults to the OFF setting For discrete output modules the state of the outputs 1s determined solely by the position of the Off Freeze jumper JP1 on the 2500 RIO A CTI 2500 RIO A Installation and Operation Guide V2 0 5 For analog word output modules the state of the outputs is influenced not only by the position of the Off Freeze jumper but by the output module s Zero Hold Last Value selection if the module has that option See the table below Selection Zero Hold Selection State Off Zero Off Last Value Off Last Value Freeze Last Value Freeze Last Value Freeze Last Value see the user manual of your analog word
6. to connect to the programming device or modem The port pinout 1s provided in Section 2 6 of this manual 1 2 2 I O Port The I O Port connects the 2500 RIO A to a SIMATIC 505 compatible RS485 Remote I O channel This enables the remote CPU to control the I O modules in the base where the RBC is located The Remote I O Port interface is a 9 pin D Shell connector as detailed in Section 2 7 of this manual Recommended guidelines for planning selection and installation of Remote I O system 1s included in Appendix A 2 CTI 2500 RIO A Installation and Operation Guide V2 0 CHAPTER 2 INSTALLATION The installation of the Model 2500 RIO A RS485 Remote Base Controller consists of the following Steps 1 Planning the installation 2 Verifying power requirements 3 Unpacking and configuring the module 4 Physical installation 5 Connecting cables 6 Checking the module operation 2 1 Installation Planning Choosing Remote I O Media The 2500 RIO A attaches directly to the RS485 Remote I O cable using a DB9 connector We recommend using cable designed specifically for RS485 systems such as Belden 3105A See Appendix A for information related to cable specifications layout and installation Selecting a Remote Base Address Before proceeding you must determine what address you will assign to the RBC Remote Base addresses range from 1 to 15 In CTI 2500 Series and Simatic 505 systems address 0 is reserved for the local bas
7. Address 4 CTI 2500 RIO A Installation and Operation Guide V2 0 Setting Remote Base Controller Station Address A thumbwheel switch is provided to set the base address to the 2500 RIO A for Remote I O station identification A maximum of 15 remote bases can be connected to the CTI 2500 Series CPU or Siemens 545 555 575 CPU NOTE When connecting the 2500 RIO A to a CTI 2500 Series CPU or Siemens 545 555 575 CPU only addresses between 1 and 15 are valid Each installed 2500 HIO A must have a unique station number Care should be taken to prevent circumstances which cause the CPU to lose communication with the 2500 RIO A while the system is operating Loss of communication between the CPU and RBC will cause the base to be logged off from the CPU This can cause intermittent process operation WARNING The following events will cause loss of communication with the 2500 RIO A and result in the base being logged off from the CPU 1 Duplication of the station address between RBC s attached to the same CPU except in dual media applications 2 Changing the thumbwheel switch station address while the system is operating These events could cause unpredictable process operation and result in damage to equipment and or serious injury to personnel When a base if logged off the CPU zeroes all image register input points associated with the base and all outputs go to the value determined by the installed output module Discrete
8. CTI 2500 RIO A RS485 REMOTE BASE CONTROLLER INSTALLATION AND OPERATION GUIDE Version 2 0 CTI Part 062 00366 020 062 00366 010 2500 RIO A 10G 032008 Copyright 2008 Control Technology Inc All rights reserved This manual is published by Control Technology Inc 5734 Middlebrook Pike Knoxville TN 37921 This manual contains references to brand and product names which are trade names trademarks and or registered trademarks of Control Technology Inc Siemens and SIMATIC are registered trademarks of Siemens AG Other references to brand and product names are trade names trademarks and or registered trademarks of their respective holders DOCUMENT DISCLAIMER STATEMENT Every effort has been made to ensure the accuracy of this document however errors do occasionally occur CTI provides this document on an as 1s basis and assumes no responsibility for direct or consequential damages resulting from the use of this document This document is provided without express or implied warranty of any kind including but not limited to the warranties of merchantability or fitness for a particular purpose This document and the products it references are subject to change without notice If you have a comment or discover an error please call us toll free at 1 800 537 8398 or email us at sales controltechnology com __ 07 25 07 Corrected errors LED display chart CTI 2500 RIO A Installation and Operation Guide V2 0
9. Hardware Options Connecting to Remote I O Cable 2 2 eT diziss PERIERE OO 3 2 3 Unpacking the 4 2 4 Configuring the Module 4 Setting the RS232 Port Baud Rate Setting Remote Base Controller Station Address Setting the Output State on Communication Loss 9 My SICAWING TROU TT 6 2 6 Connecting to the RS232 6 2 7 Connecting the Remote I O 7 2 8 Operation of LED Display esesssssessseeeesee enne 8 APPENDIX A REMOTE I O INSTALLATION GUIDELINES 9 Cable Layout Planning Cable Selection Cable Lengths Bus termination Laying Cables Outside of Control Cabinets SPECIFICATIONS 028 13 GENES Al ce cecccceccccscccscccscccaucccueccaucececcauecauceseccueenaeceusecsaacensecsaueesseesaueenseeeauesaueenaeees 13 mo M E 13 mM Ee RIBBON 13 LIMITED PRODUCT WARRANT Y 14 REPAIR POLICY d aa a a A 15 CTI 2500 RIO A Installation and Operation Guide V2 0 Co CO CO CO 10 11 12 CHAPTER 1 DESCRIPTION 1 1 Introduction The CTI 2500 RIO A RS485 Remote Base Controller is a member of Control Technology s family of I O
10. MATIC 505 545 555 575 System Reference Manual for further details The Remote I O cable system consists of a main trunk line and drop lines which connect the CPU Local Base and Remote Base s to the trunk line by means of terminal blocks as shown in T Remote Base Figure 5 Local Base T Terminal Block Drop Line N E T Trunk Lines Drop Lines Remote Base Figure 5 Remote I O Installation Cable Layout Planning Use the following guidelines for planning the Remote I O cable routing and locations e The ideal cable installation is a single unbranched trunk line with short drop lines and termination resistor at each end arrangement with a single drop line Cable Selection Maximum length of a drop line should not exceed 33 feet 10 m Drop lines less than 3 3 feet 1 m do not count toward cable length calculations The total length of all drop lines should be much less than the length of the trunk line When multiple bases must be located in close proximity connect all bases in a daisy chain 9 Data transfer in the Remote I O systems is based on a symmetrical RS485 bus system using shielded twisted pair cable The cable shield is used to improve the immunity to electromagnetic interference The ideal cable provides low signal attenuation for long trunk lines and flexibility for ease of installation The recommended cable shou
11. d be constructed of electrically conducting material and connected to functional ground at regular intervals Cables should not be subject to mechanical loads which exceed the manufacturer s specifications If this cannot be avoided additional protective measures should be taken such as laying the cables in a steel pipe or rugged metal duct The pipe or duct should then be grounded at regular intervals and protected against corrosion 12 CTI 2500 RIO A Installation and Operation Guide V2 0 SPECIFICATIONS General Module Size Double Wide Backplane Power Consumption 2 5 watis Compatibility 2500 Series and Simatic 505 CPU s All currently available CTI and Siemens 505 4 8 11 and 16 slot bases Single and Dual Media configurations Display Shows RBC status and error codes Output State Selection Determines state of outputs when I O channel communication is lost OFF All outputs are turned off FREEZE All outputs hold their last value Hardware User Configuration Options RS232 Serial Port baud rate dipswitch RBC Station Address thumbwheel Diagnostic Data RBC Status Indication in CPU Status Word and Front Panel LED Display Ports Remote 1 0 9 Pin D Shell Female Connecter RS232 Serial 9 Pin D Shell Male Connecter PC compatible pinout Environmental Operating Temperature 0 to 60 C 32 to 185 F Storage Temperature 40 to 85 C 40 to 185 F Humidity 5 to 95 non condensing Agenc
12. e where the CPU 1s installed Note that each Remote Base on the Remote I O channel must have a unique address If two RBCs are installed in a 2500 R11 A Redundant Base they must both be set to the same address Setting Module Hardware Options The RBC includes a hardware setting for selecting the state of the base discrete outputs in the event of a loss of communication with the CPU The module can be configured to set all outputs off or to leave outputs at their last states If two RBCs are installed in a 2500 R11 A Redundant Base they must both have the same configuration Connecting to Remote I O Cable The Remote I O connector should be wired as shown in Section 2 7 2 2 Power Requirements The CTI 2500 RIO A module consumes 2 5 watts of 5 VDC power from the backplane Before installing the RBC verify that your mounting base power budget can accommodate the required power A good tool for performing the verification is the CTI Replacement Guide and Power Calculator available from our website at ftp ftp controltechnology com public Download tools CTI 2500 RIO A Installation and Operation Guide V2 0 3 2 3 Unpacking the Module Open the shipping carton and remove the special anti static bag that contains the module After discharging any static build up remove the module from the static bag Do not discard the static bag Always use this bag for protection against static damage when the module is not inserted into the I O ba
13. ld include the characteristics as shown in the following table CTI 2500 RIO A Installation and Operation Guide V2 0 twisted pair in 7 5mm 7x30 stranded copper braid plus drain wire Impedance lt characteristic impedance 1 0 dB 30 m 1MHz Cable Lengths Maximum permissible cable length is dependent on cable characteristics and number of terminal blocks used in the installation Terminal blocks are used to connect drop lines and or extend Remote I O cable trunk line The following table contains the maximum recommended cable length Trunk Length Drop Lines for Belden 3105A cable It is possible to have longer cable runs if larger diameter wire is used Maximum Cable Length in Number of Installed Feet Meters CROP Lanes Belden 3105A 2133 650 8 2000 610 9 1933 68 10 CTI 2500 RIO A Installation and Operation Guide V2 0 Cable trunk length is measured from the CPU to the most distant base CPU Terminating Resistor Terminating m Max Trunk Length gt Resistor T Terminal Block Figure 6 Trunk Length Measurement By using a T configuration as shown in Figure 7 the maximum trunk length can be extended to twice the length shown in the table on the previous page
14. output module for details Notice that the FREEZE option on the RBC overrides the Zero selection on the analog word output module likewise when Hold Last Value is selected on the analog word output module that selection overrides the OFF option on the RBC jumper WARNING If the RBC fails or loses power during system operation all outputs will turn OFF 0 regardless of the Freeze Jumper setting This could result in damage to equipment and or serious injury to personnel 2 5 Physical Installation To insert the module into the I O base hold the top and bottom of the bezel and slide the module carefully into the slot pushing it all the way into the base If you have inserted the module correctly you will feel a slight increase in resistance as the module mates with the base backplane connector Once the module is fully seated in the slot tighten the captive screws at the top and bottom to hold the module in place To remove the module from the I O base loosen the captive screws and then pull the module from the base Take care not to damage the connector at the back of the module when inserting or removing the module 2 6 Connecting to the RS232 Port The RS232 port is provided to interface to PLC programming and configuration tools such as TISOFT The use of this port is optional A standard 9 pin PC RS232 serial cable can be used to connect to the programming device or modem The port details are shown in Figure 3 Note tha
15. se CAUTION The components on the 2500 RIO A module printed circuit card can be damaged by static electricity discharge To prevent this damage the module is shipped in a special anti static bag Static control precautions should be followed when removing the module from the bag and when handling the printed circuit card during configuration 2 4 Configuring the Module There are three steps to configuring the module and making it fully operational 1 Setting the RS232 Port baud rate 2 Setting the Remote Base Controller address 3 Setting the output state on communication loss Freeze Jumper Figure 2 Switch Locations 4 3 il Figure 2 indicates the location of RS232 port baud Na m Gives rate selection switches the RBC station address a pi thumbwheel and Freeze Jumper The remainder of this section describes the function of individual settings om O13 05 r Ro 2J32 BAUD RATE SW2 5W3 5 Setting the RS232 Port Baud Rate L SENE Switches SW1 SW4 are used for setting the baud rate 1200 19 a of the RS 232 serial port The supported baud rates are f y P A shown in the following table All other switch combinations are invalid Baud Rate SW SW2 Eu e a a m E a m E 1200 so o NN pa fa zo o 4 ESTARS po Baud Rate RBC Station Selection Switches Freeze Jumper
16. t the serial port on the standby unit in a redundant RBC pair is inoperative This 1s normal the CPU makes no attempt to communicate with the serial port of the standby RBC The standby unit is the one displaying a on the front panel LED display 6 CTI 2500 RIO A Installation and Operation Guide V2 0 9 Pin D Shell Male Connector Compatible with standard PC Serial Port DSR 6 RTS 7 CTS 8 Figure 3 RS232 Serial Port 2 Connecting the Remote I O Cable The I O Port connects the 2500 RIO A to a SIMATIC 505 compatible RS485 Remote I O channel This enables the remote CTI 2500 Series or Simatic 505 CPU to control the I O modules in the base where the RBC is located The Remote I O Port interface is a 9 pin D Shell connector with pinout as shown in Figure 3 Recommending wiring for the Remote I O cabling is detailed in Siemens 545 555 575 System Manual Figure 4 shows the pinout for the I O Port 9 Pin D Shell Female Connector x GND 5 TX RX 8 PTEE Figure 4 Remote I O Port CTI 2500 RIO A Installation and Operation Guide V2 0 7 2 8 Operation of LED Display The LED Display is used to indicate the status of the 2500 RIO A Remote Base Controller as shown in the following table Display Definition Communication Comment Action s to RBC Module Ready Fully Operational and online with CPU Diagnostics Failure None Serious malfunction Place system in safe
17. y Approvals Pending UL ULC CE Class Division 2 Hazardous Location Shipping Weight 1 5 lb 0 68 Kg CTI 2500 RIO A Installation and Operation Guide V2 0 13 LIMITED PRODUCT WARRANTY For product Warranty information please see our standard product warranty at http www controltechnology com support warranty CTI 2500 RIO A Installation and Operation Guide V2 0 REPAIR POLICY In the event that the Product should fail during or after the warranty period a Return Material Authorization RMA number can be requested orally or in writing from CTI main offices Whether this equipment is in or out of warranty a Purchase Order number provided to CTI when requesting the RMA number will aid in expediting the repair process The RMA number that is issued and your Purchase Order number should be referenced on the returning equipment s shipping documentation Additionally if the product is under warranty proof of purchase date and serial number must accompany the returned equipment The current repair and or exchange rates can be obtained by contacting CTT s main office at 1 800 537 8398 When returning any module to CTI follow proper static control precautions Keep the module away from polyethylene products polystyrene products and all other static producing materials Packing the module in its original conductive bag is the preferred way to control static problems during shipment Failure to observe static control precautions ma
18. y void the warranty For additional information on static control precautions contact CTI at 1 800 537 8398 CTI 2500 RIO A Installation and Operation Guide V2 0 15
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