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CTI 2500 Installation and Operation Guide V2.8

1.9

2500 Series Compact Con

troller Front Panel

1. Status LEDs

CPU GOOD

RUN

BATTERY GOOD

2. Multi-Segment Display` (MSD)

3. USB Port

4. SD Card Slot

5. Network LEDs

LS – Link Status

NS- Network Status

6. Battery Holder

7. Ethernet Port

XMT LED – Flashes when transmitting

RCV LED – Flashes when receiving

8. Serial Communications Port

RS-232/RS-422)

9. Profibus DP Port

10. Remote I/O Port

Summary of Contents for 2500-C100

Page 1: ...CTI 2500 Series Controller INSTALLATION AND OPERATION GUIDE Version 2 8 CTI Part 062 00370 2500IOG...

Page 2: ...il us at sales controltechnology com REVISION HISTORY V 1 0 6 28 07 Initial Release V 1 1 10 30 07 Defined additional Profibus status bits for STW231 Added fatal error code for hardware watchdog event...

Page 3: ...11 Added new error code 102 to the list of fatal errors Corrected a corrupted cross reference on page 47 V1 19 9 20 11 Added documentation for dual RBC support Revised remote I O topology drawings to...

Page 4: ...3 2017 Corrected version support for TISOFT V2 2 1 26 17 Corrected illustration of user jumper p26 Updated copyright date V2 3 2 6 2017 Modified properties of user jumper illustration to correct text...

Page 5: ...ntrollers and CTI 2500 Series Compact controllers The information in this manual is directed to individuals who will be installing and operating the controller as well as those who will be designing s...

Page 6: ...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 t...

Page 7: ...tus Indicators 16 1 16 Ethernet Port 17 1 17 RS 232 RS 422 Serial Port 17 1 18 Profibus DP Port 17 1 19 I O Port 17 1 20 Product Models 18 CHAPTER 2 INSTALLATION 19 2 1 Installation Planning 19 2 2 Un...

Page 8: ...64 CHAPTER 9 TROUBLESHOOTING 65 9 1 Troubleshooting Aids 65 9 2 Startup Errors 65 9 3 Fatal Errors 66 9 4 Non Fatal Errors 70 CHAPTER 10 UPDATING FIRMWARE 73 10 1 Overview 73 10 2 Serial Port Method...

Page 9: ...PLACEMENT 105 APPENDIX F PRODUCT SPECIFICATIONS 107 Hardware Specifications 107 Serial Port Pinout 107 I O Port Pinout 108 Profibus Port Pinout 108 APPENDIX G SD CARD REQUIREMENTS 109 CTI 2500 Series...

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Page 11: ...ntroller Features 1 3 User Program Support User Program components include Relay Ladder Logic RLL Special Function programs Analog Loops and Analog Alarms The User Program is stored in battery backed...

Page 12: ...iemens modules The CTI 2500 controller also permits the attachment of remote bases using CTI 2500 RIO or CTI 2500C RIO remote base controllers or Siemens Series 505 or Series 500 remote base controlle...

Page 13: ...ly the User Program stored in the controller memory Alternately you can program off line and then download the program to the controller 1 7 Serial and USB Connectivity The CTI 2500 controller provide...

Page 14: ...us LEDs CPU GOOD RUN BATTERY GOOD 2 Multi Segment Display MSD 3 Battery Holder 4 SD Card Slot 5 USB Port 6 Network LEDs LS Link Status NS Network Status 7 Ethernet Port XMT LED Flashes when transmitti...

Page 15: ...s CPU GOOD RUN BATTERY GOOD 2 Multi Segment Display MSD 3 USB Port 4 SD Card Slot 5 Network LEDs LS Link Status NS Network Status 6 Battery Holder 7 Ethernet Port XMT LED Flashes when transmitting RCV...

Page 16: ...mat 1 12 Battery Holder The battery holder contains the battery that maintains the User Program and related data when the controller is not powered The battery may be replaced while the controller is...

Page 17: ...22 electrical interface which is supported by some operator interface equipment The electrical interface and port baud rate via a set of user switches on the controller circuit board See Section 2 3 f...

Page 18: ...clic PID Loops 16 64 128 128 RLL Initiated PID Loops Fast Loops 0 0 384 384 Analog Alarms 32 128 512 512 Special Function Programs 64 1023 1023 1023 Special Function Subroutines 64 1023 1023 1023 Remo...

Page 19: ...ontrollers with equipment that requires the presence of a person such as an operator or attendant you should be aware of this potential safety hazard and take appropriate precautions The precautions b...

Page 20: ...the source of the electrical interference and employ suitable techniques to eliminate it 2 1 3 Grounding It is very important that the all equipment is properly grounded Lack of proper grounding may...

Page 21: ...4 for additional information 2 1 5 Power Requirements The CTI 2500 module consumes 5 5 watts of 5 VDC power To calculate the total power required for the base you need to add the power requirements fo...

Page 22: ...isplay board behind the front panel on the switchblock labelled ENC1 See accompanying picture 2 3 2 User Switch Functions SW1 Battery Switch The battery switch is used to connect and disconnect the ba...

Page 23: ...Port 4452 can be used to modify the user program via the local Ethernet port Requests from TCP ports 1505 or 4450 can display the user program but attempts to modify the User Program will be rejected...

Page 24: ...bled but unconfigured This capability is especially important for APT users needing to reduce scan time since APT programming software does not provide a means to manually disable a base When Switch 8...

Page 25: ...ality or correct problems Switch 12 is used to enter the firmware update state When the switch is in the OPEN OFF position the controller will start up in the normal operating mode When the switch is...

Page 26: ...the user from inadvertently selecting the modified behavior The user jumpers are located next to the user switches labeled as J20 A jumper is OPEN when the jumper is not installed or is located in the...

Page 27: ...rossover is Disabled The port uses MDI mode Auto Crossover is enabled The Ethernet port operates most reliably in MDI mode In MDI mode the port can connect to switches and hubs using a standard straig...

Page 28: ...mplete the startup sequence When this is complete the status indicators should be in the following state Indicator State Comments CPU Good ON If the CPU Good LED is off check the Multi Segment Display...

Page 29: ...tically generate a temporary IP address You can connect to this address to set a permanent IP address The address will be selected from a range of Link Local addresses reserved for this purpose 169 25...

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Page 31: ...g setting and clearing bits as well as performing logical AND OR operations BCD Conversions The BCD instructions allow you to convert numbers between binary and binary coded decimal formats Word Move...

Page 32: ...lutions that cannot be done in RLL or would require complex RLL programming SF programs can be called from an RLL program or from analog loop or alarm tasks SF subroutines can be called from RLL SF pr...

Page 33: ...llowed by a period that the setpoint will remain the same Soak Using a series of ramp soak steps you can control most batch processes Loops are typically executed on a cyclic basis independent of the...

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Page 35: ...utput associated with discrete register address 20 would be designated as WY20 The I O register output values represent the last value set by the user logic or by programming software Unless changed b...

Page 36: ...s 505 discrete and analog I O modules In addition the controller will also interoperate with designated non CTI Special Function modules See the CTI Web Site for a list of supported Siemens Series 505...

Page 37: ...nes It may also be used for drop lines with Belden 9860 or Belden 9271 trunk lines Belden 9271 which is smaller and more flexible is suitable for use as drop lines as well as short trunk lines For tru...

Page 38: ...ft 569 m 933 ft 284 m 2800 ft 853 m 11 1800 ft 548 m 900 ft 274 m 2700 ft 823 m 12 1733 ft 528 m 867 ft 264 m 2600 ft 792 m 13 1677 ft 508 m 833 ft 254 m 2500 ft 762 m 14 1600 ft 488 m 800 ft 244 m 24...

Page 39: ...ve includes support for dual Remote Base Controller RBC configurations using an RS 485 network Coaxial dual media cabling is not supported A dual RBC configuration consists of two remote base controll...

Page 40: ...previously active RBC RBC status is reported in STW168 An RBC that has been disabled can be re enabled by temporarily changing the address switch to a different address then changing it back to the or...

Page 41: ...ave The total amount of data that can be exchanged is limited by the I O capability of the controller model Network data rates may be limited by the network configuration 4 4 1 Connecting the Profibus...

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Page 43: ...monly available from your distributor or other industrial suppliers Profibus Topology Profibus slave devices are connected in a daisy chain arrangement as indicated in the following illustration Up to...

Page 44: ...12 slaves and a maximum of 64 module slots per slave PLC Workshop The Profibus configuration tool is integrated into PLC Workshop V 4 52 and above 1 Select the PLC Utilities PLC Configuration menu ite...

Page 45: ...flag is set to 1 and the configuration tool supports DPV1 PLC Workshop V4 52 and above the outputs will not be cleared The status of the slave output will remain the same or transition to a state def...

Page 46: ...roller user logic and saved in V memory table by using the RLL Read Slave Diagnostic RSD instruction The saved information can then be processed in user logic or read by HMI workstations See the CTI 2...

Page 47: ...er Program Elements The following User Program elements are stored in battery backed memory Relay Ladder Logic RLL Program Special Function Programs Special Function Subroutines Loop Parameters Analog...

Page 48: ...annot access the additional control relays 5 2 4 Status Words Status Words are used to provide information about the controller operation Because Status Words can be read by user logic they can be use...

Page 49: ...tore the operating firmware for the controller The operating firmware can be updated in the field See CHAPTER 10 for more information 5 4 High Speed DRAM Because the DRAM Dynamic Random Access Memory...

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Page 51: ...nalog alarms Figure 1 Controller Scan 6 1 1 Discrete Scan The discrete scan consists of three tasks These tasks always run to completion Normal I O During the Normal I O task I O register output value...

Page 52: ...are further specified in the following sections Cyclic Analog Tasks Cyclic tasks execute on a time interval basis based on a user specified sample rate Cyclic tasks include Analog Loops Analog Alarms...

Page 53: ...rt local Ethernet port or from Special Function modules Priority Communications This task processes all requests from the serial and USB ports that can be processed in a single scan Network Communicat...

Page 54: ...en this option is selected the controller shall execute the discrete scan once and then begin executing analog tasks Each analog task will be guaranteed execution at least once during scan The PLC wil...

Page 55: ...ect the following Analog Scan Modes Mode Description PROGRAM When the Analog scan is placed in PROGRAM mode the Loop Alarm and Special Function Program Subroutine tasks do not execute Nothing will be...

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Page 57: ...ise immunity See APPENDIX F PRODUCT SPECIFICATIONS for the pinout of the serial port connector 7 3 USB Communications The USB port connector is identical to the port you find on peripheral devices suc...

Page 58: ...en using Workshop you will be able to select the assigned COM port as a serial port connection in the Fast PLC Setup option under the File menu Once the port is selected you will be able to access the...

Page 59: ...st be unique even between the local Ethernet port and an Ethernet module in the same base Duplicating IP addresses can cause unpredictable problems including loss of communications with the Ethernet p...

Page 60: ...o the network while the Ethernet link is connected and operating normally Also some older devices may not respond to a duplicate IP address probe message 7 4 5 TCP Port Number Support TCP IP provides...

Page 61: ...ow the user program to be displayed but not modified By default the Data Access port will reject commands that attempt to alter the User Program returning a port lockout error Some legacy network prog...

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Page 63: ...imary difference in the restart options is the state of the controller after the restart procedure has completed The power up restart procedure places the controller in the same state as cycling power...

Page 64: ...l Relays Cleared Cleared N C N C Cleared Forced Elements Cleared Cleared N C N C N C TMR CNTR Drum Presets Restore from User Program Flash RLL Cleared N C N C Restore from ladder V Memory Cleared Clea...

Page 65: ...ics The event log and diagnostics can be accessed by the controller web pages You can access the web pages using a standard web browser by entering the controller IP address in the browser URL field T...

Page 66: ...er program execution will be halted I O update will be discontinued and Output Disable will be asserted Serial USB and Ethernet port buffers will be cleared Pending requests from SF modules and the lo...

Page 67: ...time exceeded the watchdog setting The most common cause of the problem is setting the cyclic RLL cycle too small so that other scan elements do not get enough time to run If errors persist you may n...

Page 68: ...es the Special Function source is invalid and cannot be compiled After clearing the fatal error using Partial or Complete Restart you must reload the User Program to prevent this error from re occurri...

Page 69: ...ction evaluation data is invalid After clearing the error using Partial or Complete Restart try reloading the program If the error persists contact CTI Product Support 0703 Expression evaluation faile...

Page 70: ...al base configuration does not match the I O configuration in the User Program Use STW 11 STW 26 to determine which slots are mismatched Change the I O configuration to match the actual configuration...

Page 71: ...r than they can be executed Increase the Priority SF time slice Cyclic SF Queue is full STW 162 8 Indicates that that you are requesting Priority SF execution faster than they can be executed Error oc...

Page 72: ...nction Program If fails to compile correct problem s and re enable SFP Type is not Normal or Priority STW 200 error 10 Reported when the RLL attempts to call an in line SFP that is a restricted or cyc...

Page 73: ...Version 5 0 and above You can update the firmware using an SD card containing the firmware update file See APPENDIX G SD CARD REQUIREMENTS 10 2 Serial Port Method 10 2 1 Firmware Update Planning Seria...

Page 74: ...the base and apply power The controller should display U01 on the multi segment display indicating it is waiting for you to transfer the firmware update file to the controller 5 Connect the serial cab...

Page 75: ...CTI 2500 Installation and Operation Guide V2 8 75 7 Go to the Transfer Send File menu to select the firmware upgrade file and the Zmodem protocol See the following example...

Page 76: ...lete or missing firmware components making the controller inoperable Should you inadvertently lose power rerunning the firmware update procedure and successfully completing it will allow you to use th...

Page 77: ...opy the file to the root directory of the SD card NOTE The SD card must contain one and ONLY one firmware update file Firmware update files have a suffix of plc This file must be located in the root d...

Page 78: ...ten 8 Disconnect power from the base and remove the controller from the base 9 Set the firmware update switch to the Normal position See Section 2 3 Reinstall the controller in the base and apply powe...

Page 79: ...on and boot code to FPGA flash 10 5 Firmware Update Errors If an error occurs during the firmware update procedure the procedure will stop and wait for corrective action An error code will be displaye...

Page 80: ...a valid Firmware Update File Ensure that the file you transferred is a firmware update file If so retry the firmware update procedure If not obtain a valid firmware update file and repeat the firmware...

Page 81: ...executed The following User Program elements are stored in flash memory Relay Ladder Logic Special Function Programs and Subroutines Analog Loops Analog Alarms I O Configuration Memory Configuration...

Page 82: ...If a User Program is already stored in flash memory you must erase the User Program flash area before another program can be written to it This action is required to maintain compatibility with legacy...

Page 83: ...h to RAM Start up in RUN mode See following note NOTE When the User Program is copied from Flash to RAM timer counter presets drum presets loop parameters and alarm parameters will be restored to the...

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Page 85: ...his is likely a hardware problem Cycle power If the problem persists contact CTI Product Support E10 The battery backed RAM could not be partitioned This is likely a hardware problem E11 The battery b...

Page 86: ...is setting the cyclic RLL cycle time too small so that other scan elements do not get enough time to run If you are using cyclic RLL try increasing the cycle time This can also be caused by a Special...

Page 87: ...e power to the controller If the problem persists contact CTI Product Support 0611 RLL Source checksum error detected during power up start Indicates that the RLL is invalid and cannot be compiled Aft...

Page 88: ...sk Code Errors To aid in diagnosing errors the following table provides a list of all task code error codes returned in a task code 00 error reply Error Code Hexadecimal Description 01 Reset Current T...

Page 89: ...trol Block already exists 46 Offset out of range 47 Arithmetic error detected while writing Loop or Loop Alarm parameters 48 Invalid SF program type 49 Instruction number or RAMP SOAK step number out...

Page 90: ...3 67 Unused 68 Data cache full ECC1 module 69 CAMP server not enabled ECC1 module 70 NITP message count error 71 NITP invalid character error 72 NITP message too long 73 NITP Checksum error 74 8F Rese...

Page 91: ...or Flag RLL See STW 200 for error code Bit 7 RLL Subroutine Stack Overflow Bit 8 Time of Day Clock Failure Bit 9 Unused Bit 10 SF Module Communications Failure Bit 11 Previous RLL Instruction Failed B...

Page 92: ...7 6 5 4 3 2 1 A bit is set to 0 if the module status is good It is set to 1 if any of the following conditions is true Installed module does not match configuration for the slot The slot is configure...

Page 93: ...rors on the Profibus Channel This includes timeouts etc STW 148 Number of token related errors Counts the token related errors on the Profibus channel STW 149 STW 161 Not used STW 162 Analog Non Fatal...

Page 94: ...e least significant bit 16 represents the local base 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 15 14 13 12 11 10 9 8 7 6 5 4 3 3 1 0 STW 177 STW 183 Unused STW 184 Module Mismatch or Unclaimed MODFAIL...

Page 95: ...m RLL First Scan Flags Bit 1 First Scan After Compile Bit 2 First scan after Program Mode Bit 3 First scan after Edit Mode Bit 4 First scan after Auto Recompile Bit 5 8 Unused Bit 9 First Scan followi...

Page 96: ...20 STW 222 Unused STW 223 STW 224 Binary Time of Day Contains the relative millisecond of the current day expressed as a 32 bit unsigned integer STW 225 Binary Relative Day Contains the relative day w...

Page 97: ...xed Bit 3 User Program Source 0 RAM 1 Flash Bit 4 Ethernet Port Link Status 1 Connected Bit 5 TCP IP Network Status 1 TCP IP Stack is Operational Bit 6 Duplicate IP Address Status 1 Duplicate Detected...

Page 98: ...Execution msec STW329 Total Cyclic RLL Time Last Scan msec STW330 Total Cyclic RLL Execution Peak Time msec STW 331 STW 454 CTI Internal Support Statistics Subject to change STW 455 STW 469 Remote Ba...

Page 99: ...on a particular IP network must use must have unique Host ID The IP protocol sends messages with a destination IP address that is not on the host s IP network to the designated router gateway Address...

Page 100: ...00000000 00000000 00000000 255 0 0 0 8 1111111 1 11111111 11110000 00000000 255 255 240 0 20 1111111 1 11111111 11111111 00000000 255 255 255 0 24 For example when the IP address is 128 54 177 97 and...

Page 101: ...55 255 Class A 172 16 0 0 through 172 31 255 255 Class B 192 168 0 0 through 192 168 255 255 Class C These addresses will not be forwarded by the Internet backbone routers therefore you are free to us...

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Page 103: ...routine is enabled if the SF program has been modified During a Power Up start following the application of power When using Partial or Complete Restart to recover from a compiled checksum error Progr...

Page 104: ...Report by Exception RBE is not supported The CTI 2500 controller does not support RBE 4 A new time slice Network Communications has been added to support the local Ethernet port I O Support The I O su...

Page 105: ...pt to charge the lithium battery Charging a lithium battery can cause the battery to explode resulting in serious injury or death and or damage to equipment Replace the battery as shown above Lithium...

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Page 107: ...Temperature 0 to 60 C 32 to 185 F Typical Battery Storage Life 5 Years not connected Typical Battery Continuous Use Life 3 years 25 C 6 months 60 C Serial Port Pinout The serial port supports both th...

Page 108: ...nnector Connect the conductor without the shielding to pin 5 of the mating connector Connect one of the color coded conductors to pin 8 and the other to pin 3 It does not matter which color you choose...

Page 109: ...ts gigabytes The smallest capacity 4GB is more than adequate for use with the 2500 series controller However you can use SDHC cards with a larger capacity if you wish If you must use a standard capaci...

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Page 111: ...part to the customer The foregoing will be the exclusive remedies for any breach of warranty or breach of contract arising therefrom 3 General This warranty is only available if a the customer provide...

Page 112: ...ed herein and shall have no others for a nonconformity in the Product The customer agrees that these remedies provide the customer with a minimum adequate remedy and are its exclusive remedies whether...

Page 113: ...n 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 o...

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