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CTI 2500-RBC Installation and Operation Guide V1.6

SPECIFICATIONS

General

Module Size:

Double-Wide CTI 2500 Series® or Simatic

505 I/O

Backplane Power Consumption:

2.5 watts

Compatibility

: CTI 2500 Series® ,

Simatic®

505, Siemens

S5 and S7 masters

Compatibility

: all currently-available CTI and Siemens

4-, 8-, and 16-slot bases

Display:

shows errors codes and Profibus address

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

Dipswitch Options:

Serial port baud rate (future use)

RBC station address

Status display mode

Software-Set Parameters:

Discrete I/O interval

Word I/O update factor

Ignore mismatch mode

RS232 port enable/disable

Diagnostic Data:

Station status (3 bytes)

Master address (1 byte)

Ident number (1 byte)

Extended diagnostics (9 bytes)

Ports

Profibus:

9-pin female,

pins 2,7 “no connect”

Communication Speeds Supported:

9600, 19.2K, 93.75K, 187.5K, 1.5M, 3.0M, 6.0M, 12M

RS232C:

9-pin male, future use

Profibus Port Isolation:

1500VDC

Environmental

Operating Temperature:

0º to 60º C (32º to 185º F)

Summary of Contents for 2500 Series

Page 1: ...2500 Series CTI 2500 RBC PROFIBUS REMOTE BASE CONTROLLER INSTALLATION AND OPERATION GUIDE Version 1 7 2500RBCIOG 1062016 ...

Page 2: ...rranties of merchantability or fitness for a particular purpose This document and the products it references are subject to change without notice If you have a comment or discover an error please call us toll free at 1 800 537 8398 or email us at sales controltechnology com REVISION HISTORY V1 0 04 30 04 Original Issue V1 1 08 25 04 Changed Profibus address switch open close labeling 05 03 07 Fixe...

Page 3: ...cted to individuals who will be installing the module and configuring it for use with a Profibus Master We assume you are familiar with the installation and operation of 1 CTI 2500 Series and Simatic 505 programmable controllers 2 PLC WorkShop for Siemens 505 or Com Profibus Configuration Software Please refer to the appropriate user documentation for specific information on your programmable cont...

Page 4: ...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 ...

Page 5: ...ical Installation 10 2 6 Connecting the Profibus Cable 11 2 7 Diagnostics 12 2 8 Base Mismatch Handling in the 2500 RBC 12 2 9 Differences Between the 2500 RBC and the 505 6870 12 2 10 Diagnostics 13 PLC Status Words 13 Diagnostic Bytes from the 2500 RBC 14 CHAPTER 3 SETTING UP THE 2500 RBC USING COM PROFIBUS 17 3 1 Overview 17 3 2 Startup Com Profibus 17 3 3 Import the 2500R gsd file into Com Pro...

Page 6: ...ations 37 Cable Type 37 Cable Lengths 37 Bus termination 38 Bus connectors and PROFIBUS DP FMS interface 38 Cable laying guidelines 40 Laying of copper cable 40 Laying cables within control cabinets 41 Laying cables outside of control cabinets 42 SPECIFICATIONS 43 General 43 Ports 43 Environmental 43 LIMITED PRODUCT WARRANTY 45 REPAIR POLICY 46 ...

Page 7: ...emens 505 6870 RBC It provides the following functions Compatible with CTI 2500 Series Simatic 505 Siemens S5 and S7 masters Can be used in currently available CTI and Siemens 4 8 and 16 slot bases Supports communication speeds from 9 6 Kbaud maximum cable distance per segment 1200 m up to 12 Mbaud maximum cable distance per segment 100 m Includes an LED display which shows error codes or current ...

Page 8: ......

Page 9: ...n EN 50170 part 8 2 and Cable Type A and should comply with the parameters below An example cable of this type would be Belden 3079A For more information on Profibus installation guidelines see Appendix A Wiring the Profibus Connector The Profibus connector should be wired as shown in Section 2 6 For more information refer to Appendix A Selecting a Profibus Address Before proceeding you must deter...

Page 10: ... the required power A good tool for performing the verification is the CTI Replacement Guide and Power Calculator available from our website at www controltechnology com On the main page you will find a selection for the Selection to CTI Replacement Calculator This is an excel file Once downloaded you will open the file as a spread sheet At the bottom of the spread sheet you will find tabs for Ins...

Page 11: ...ormation on using Com Profibus to configure a remote base with the 2500 RBC refer to Chapter 3 Setting the Module Option Switches Switches on the 2500 RBC are used to select the following Serial Port Baud Rate Profibus Address Display mode Figure 2 indicates the location of the option switches and freeze jumper The remainder of this section describes the function of the individual switches SW1 thr...

Page 12: ... 0 3 0 0 0 0 0 1 1 35 0 1 0 0 0 1 1 4 0 0 0 0 1 0 0 36 0 1 0 0 1 0 0 5 0 0 0 0 1 0 1 37 0 1 0 0 1 0 1 6 0 0 0 0 1 1 0 38 0 1 0 0 1 1 0 7 0 0 0 0 1 1 1 39 0 1 0 0 1 1 1 8 0 0 0 1 0 0 0 40 0 1 0 1 0 0 0 9 0 0 0 1 0 0 1 41 0 1 0 1 0 0 1 10 0 0 0 1 0 1 0 42 0 1 0 1 0 1 0 11 0 0 0 1 0 1 1 43 0 1 0 1 0 1 1 12 0 0 0 1 1 0 0 44 0 1 0 1 1 0 0 13 0 0 0 1 1 0 1 45 0 1 0 1 1 0 1 14 0 0 0 1 1 1 0 46 0 1 0 1 1 ...

Page 13: ...0 1 1 0 0 78 1 0 0 1 1 1 0 109 1 1 0 1 1 0 1 79 1 0 0 1 1 1 1 110 1 1 0 1 1 1 0 80 1 0 1 0 0 0 0 111 1 1 0 1 1 1 1 81 1 0 1 0 0 0 1 112 1 1 1 0 0 0 0 82 1 0 1 0 0 1 0 113 Invalid Addresses 83 1 0 1 0 0 1 1 114 84 1 0 1 0 1 0 0 115 85 1 0 1 0 1 0 1 116 86 1 0 1 0 1 1 0 117 87 1 0 1 0 1 1 1 118 88 1 0 1 1 0 0 0 119 89 1 0 1 1 0 0 1 120 90 1 0 1 1 0 1 0 121 91 1 0 1 1 0 1 1 122 92 1 0 1 1 1 0 0 123 9...

Page 14: ...master Place the system in a safe state Check cabling and connection to the master 7 No Configuration OK Enter a Profibus Configuration a Module Mismatch wrong module Rev 6 0 and OK The wrong module is inserted into a configured slot with Simatic 505 mismatch mode disabled A Diagnostic failure Serious malfunction Place system in safe state and consult CTI technical support b RBC in wrong Slot Rev ...

Page 15: ...e output module s Zero Hold Last Value selection if the module has that option See the table below RBC Off Freeze Selection Analog Word Module Zero Hold Selection Analog Word Output State Off Zero Zero Off Hold Last Value Last Value Off No selection Last Value Freeze Zero Last Value Freeze Hold Last Value Last Value Freeze No selection Last Value see the user manual of your analog word output modu...

Page 16: ... Profibus Master which I O modules are installed In Com Profibus this configuration is done using the Properties Configure Module dialog For each slot in the base simply select the installed CTI or Siemens I O module from the list For more information or if you re using WorkShop see Chapter 4 Exporting a Binary Configuration File from Com Profibus Once the RBC has been parameterized and configured...

Page 17: ...red PROFIBUS programming or configuration tool to drive pins 2 and 7 to 24 VDC 1 2 3 4 5 9 8 7 6 BIAS SUPPLY GND TX RX TX RX D shell CHASSIS GND Female 9 Pin D Connector Pin Signal 1 CHASSIS GND 2 NO CONNECT 3 TX RX 4 RTS 5 BIAS SUPPLY GND 6 BIAS SUPPLY 5V 7 NO CONNECT 8 TX RX 9 BIAS SUPPLY GND for Pin 3 Terminal B on Siemens connector for Pin 8 Terminal A on Siemens connector BIAS SUPPLY 5V CAUTI...

Page 18: ...t is that Bytes 5 and 6 equal 0xBC and 0xD0 respectively 2 8 Base Mismatch Handling in the 2500 RBC The 2500 RBC automatically detects mismatches between the Profibus configuration expected by the Profibus Master and the actual remote base configuration Depending on the type of mismatch and the configuration settings the 2500 RBC can operate normally or go offline and indicate a mismatch The table...

Page 19: ...s the base offline and sets outputs based on the freeze jumper setting The 505 6870 displays a 2 and takes the base offline When 50X Ignore Mismatch is enabled and a module is inserted into an empty slot the 2500 RBC ignores the inserted module and continues normal operation The 505 6870 displays a 2 ignores the inserted module and continues normal operation When Profibus is stopped from the PLC t...

Page 20: ...read by an RSD instruction The slave s bit is a 1 if a diagnostic has been signaled and not yet read Diagnostic Bytes from the 2500 RBC When an RSD instruction is executed the 2500 RBC returns 15 bytes of information which is stored according to the settings in the RSD instruction In each byte bit 7 is the MSB and bit 0 is the LSB Byte 1 Station_Status_1 Bit 7 RBC parameterized from another master...

Page 21: ...t_Diag_Data Device related diagnostic header value is 0x06 Byte 8 Ext_Diag_Data Bit 7 Reserved Bit 6 Reserved Bit 5 Reserved Bit 4 Reserved Bit 3 Reserved Bit 2 Reserved Bit 1 Reserved Bit 0 Remote port request pending Bytes 9 10 Ext_Diag_Data Reserved Byte 11 Ext_Diag_Data Bit 7 Slot 8 is mismatched type Bit 6 Slot 7 is mismatched type Bit 5 Slot 6 is mismatched type Bit 4 Slot 5 is mismatched ty...

Page 22: ...tched type Bit 3 Slot 4 contains failed module or is mismatched type Bit 2 Slot 3 contains failed module or is mismatched type Bit 1 Slot 2 contains failed module or is mismatched type Bit 0 Slot 1 contains failed module or is mismatched type Byte 15 Ext_Diag_Data Bit 7 Slot 16 contains failed module or is mismatched type Bit 6 Slot 15 contains failed module or is mismatched type Bit 5 Slot 14 con...

Page 23: ...s is used to setup the 2500 RBC for operation with a CTI 2500 Series or Simatic 505 PLC or other Profibus master Steps for configuration include 1 Startup Com Profibus 2 Import 2500 RBC gsd file into Com Profibus 3 Set bus parameters 4 Add a master CTI 2500 Cxxx or 505 CP1434 DP to the system and set Profibus address 5 Add a 2500 RBC to the system 6 Configure the 2500 RBC a Set address b Set stati...

Page 24: ...installed on your hard drive You can obtain the file from the CTI web site at www controltechnology com On the main page go to the Download tab once you have clicked on the tab scroll down the page and you will come to 2500 RBC Classic heading Under this heading will be a list of gsd files Select the latest version to download Once the file is copied into the gsd subfolder use File Read in GSD Fil...

Page 25: ...CTI 2500 RBC Installation and Operation Guide V1 6 19 3 4 Set Bus Parameters Next set the Profibus speed for this installation using Configure Set Bus Parameters ...

Page 26: ...us DP Set the baud rate to your desired value 3 5 Add a Master to the System and Set the Profibus Address Next add a master CTI 2500 Cxxx or 505 CP1434 DP to the system and set Profibus address Select the proper master from the list Click your selection and drag it over into the graphics window ...

Page 27: ...CTI 2500 RBC Installation and Operation Guide V1 6 21 Next highlight the PLC master and right click Then click Properties to set properties for this master ...

Page 28: ...stallation and Operation Guide V1 6 22 Now enter the Profibus address for this master and a station name Press OK when finished Next add the 2500 RBC to the system Go to the DP Slave I O CTI list and find the 2500 RBC ...

Page 29: ...allation and Operation Guide V1 6 23 3 6 Add the 2500 RBC to the System Click on the 2500 RBC and drag it into the graphics window 3 7 Configure the 2500 RBC Now configure the 2500 RBC Highlight the RBC and right click ...

Page 30: ...eterize button In the parameterize dialog box enter your desired settings for the parameters For more information see Setting Software Parameters in Com Profibus in Chapter 2 Press OK when finished Next press the Configure button to set up the I O slots For each slot select the installed CTI or Siemens module from the list For blank slots use the blank panel selection Note that some CTI ...

Page 31: ...s Next press OK to exit the Configure screen and OK to exit the Slave Properties screen 3 8 Save the Profibus Configuration and Export the Binary File Make sure the Master is highlighted as show below by clicking on it then use File Save to save your project Then use Export Binary File to export a binary file for merging into the PLC Save the file in a place where you can access it later with Work...

Page 32: ... Operation Guide V1 6 26 3 9 Merge the Binary File in Workshop Next start Workshop and go online with your PLC Use PLC Utilities PLC Configuration to get to the configuration menu Press the Profibus I O button to configure Profibus ...

Page 33: ...you have no slaves installed yet your Slave Status area will be blank To merge in your binary file and add the base to your configuration click the Merge button then select the 2bf file that your created with Com Profibus Export Binary File Press OK and Workshop will read your file from disk and merge it into the PLC configuration ...

Page 34: ... so use the Edit Slave button to set the starting addresses of the slots in the base Once all the I O is addressed use the Write All button again You may also need to Enable and Slaves that are showing Disabled in the status list 3 11 Select Synchronous or Asynchronous and Start Profibus Finally use the Profibus Ops button to start Profibus Operate and set Synchronous or Asynchronous mode as desir...

Page 35: ...CTI 2500 RBC Installation and Operation Guide V1 6 29 ...

Page 36: ... Run the PLC configuration utility 4 Add a 2500 RBC to the system 5 Configure the 2500 RBC a Set address b Set station name c Configure I O Slots d Set memory offsets for each slot 4 2 Download GSD file from the CTI Website To begin configuration of the 2500 RBC download the GSD file from the Control Technology Website www controltechnology com On the main page go to the Download tab once you have...

Page 37: ...figure the Profibus I O 4 4 Profibus Configuration To open the PLC Configuration screen click on the PLC Utilities Tab and then click on PLC Configuration The following box should appear Click on the Profibus I O button to get the following box Click on the PROFIBUS address box and enter the PROFIBUS address of the slave you are adding You can also enter a Station Name and a Host Name at this time...

Page 38: ...o not have a CTI folder with the 2500 Series RBC GSD V File as shown below Click on the Add Hardware Button Go to the HDGSDBMP folder and select CTI2500 gsd file you down loaded from CTI Then Click on the Open Button The Box should now look like this Click on 2500 Series RBC GSD V then Click on Add Slave You should get the following box ...

Page 39: ...peration Guide V1 6 33 Select the Slave you just added by clicking on in it in the left hand box The box should change to look like the box below You are now ready to configure the I O slots in your remote base Click on Insert Module ...

Page 40: ...slot does not have to have a Blank entry Each module in the remote base needs a unique starting I O address You can enter the starting I O address of a module by clicking on the address field on the module row Modules that use X and Y memory must have unique addresses because X and Y variables share the same memory table on the CPU An X32 and a Y32 cannot coexist in the same program Likewise modul...

Page 41: ...he first remote base must have a starting address of a least 33 and will use memory addresses 33through 40 The next 8pt digital card will need a starting address of 41 4 7 Setting Profibus Slave Parameters The following Profibus parameters can be set for each profibus slave Discrete I O Update Interval Word I O Update Factor and 505 Mismatch Mode These parameters are defined in section 2 4 Click o...

Page 42: ...ation Guide V1 6 36 After configuring each of your Profibus slaves you may click OK and then Close to exit the Profibus and PLC configuration screens The Profibus RBC s will be initialized when you download the program to the system CPU ...

Page 43: ...19 2 45 45 93 75 187 5 500 1500 3000 6000 12000 According to EN 50170 a maximum of 4 repeaters are allowed between any two stations Dependent on the repeater type and manufacturer more than 4 repeaters are allowed in some cases Refer to the manufacturer s technical specification for details Cable Type The bus cable is specified in EN 50170 part 8 2 as Cable Type A and should comply with the parame...

Page 44: ...ter type 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 combination as follows Bus connectors and PROFIBUS DP FMS interface A bus connector is used to connect the bus cable to the PROFIBUS device Bus connectors are available with a variety of protection cla...

Page 45: ...mpedance connection to the cable shield The data transfer technology of the serial bus system which uses a shielded twisted pair data cable is described in the specification of the interference immune RS 485 interface standard To allow correct bus termination each station must connect the signals DGND and VP 5 V to pins 5 and 6 of the connector respectively The 5 V supply for the terminating resis...

Page 46: ...voided with appropriate EMC measures such as EMC compliant system installation EMC compliant cable laying and measures that avoid large ground potential differences Electromagnetic interference from sources such as switching processes rectifiers and circuit breakers can cause equipment faults to occur In addition overvoltage and lightning strikes can destroy electronic components in fieldbus devic...

Page 47: ...the sole requirement is to ensure that the same core color is connected to the same terminal A or B for all stations throughout the entire system across all stations and bus segments If the data transfer cable has data wires with red and green insulation then the following assignment should be used Data cable wire A green Data cable wire B red Thisruleapplies toboththe incomingand theoutgoingdata ...

Page 48: ... spacing requirements DC and AC voltages 400 V unscreened Telephone cables For areas with explosion hazard in separate cable looms or cable ducts without minimum spacing requirements Laying cables outside of control cabinets All cable ducts should be constructed of electrically conducting material and connected to functional ground at regular intervals Bus cables should not be subject to mechanica...

Page 49: ...ion is lost off all outputs are turned off freeze all outputs hold their last value Dipswitch Options Serial port baud rate future use RBC station address Status display mode Software Set Parameters Discrete I O interval Word I O update factor Ignore mismatch mode RS232 port enable disable Diagnostic Data Station status 3 bytes Master address 1 byte Ident number 1 byte Extended diagnostics 9 bytes...

Page 50: ...CTI 2500 RBC Installation and Operation Guide V1 6 44 Storage Temperature 40º to 85º C 40º to 185º F Humidity 5 to 95 non condensing Agency Approvals Pending UL ULC CE Shipping Weight 1 5 lb 0 68 Kg ...

Page 51: ...specifications or damage caused by an accident disaster acts of God neglect abuse misuse transportation alterations attachments accessories supplies non CTI parts non CTI repairs or activities or to any damage whose proximate cause was utilities or utility like services or faulty installation or maintenance done by someone other than CTI Control Technology Inc reserves the right to make changes to...

Page 52: ...pment 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 CTI s main office at 1 800 537 8398 When returning any module to CTI follow proper static control precautions Keep the module away from polyethylene products polystyrene pro...

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