Related Manuals for Control Technology CTI 2500 Series
Summary of Contents for Control Technology CTI 2500 Series
- Page 1 ® CTI 2500 Series REMOTE I/O SYSTEM DESIGN, INSTALLATION & TROUBLESHOOTING GUIDE Version 2.0...
- Page 2 Copyright© 2018-2020 Control Technology Inc. All rights reserved. This manual is published by Control Technology Inc. (CTI) 5734 Middlebrook Pike, Knoxville, TN 37921. This manual contains references to brand and product names which are tradenames, trademarks, and/or registered trademarks of Control Technology Inc.
- Page 3 ® For comprehensive processor information, you should also obtain the CTI 2500 Series Controller Installation and Operation Guide (CTI Part # 062 -00370-010) or CTI 2500P-Jxxx Janus Programmable Automation Controller Installation and Operation Guide.
- Page 4 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.
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Page 5: Table Of Contents
TABLE OF CONTENTS CHAPTER 1 OVERVIEW ..........................1 ............................1 NTRODUCTION ..........................1 ETWORK EATURES 1.2.1 Electrical Interface ..........................1 1.2.2 I/O Protocol ............................1 1.2.3 Compatibility ............................. 1 ..........................1 YSTEM OMPONENTS 1.3.1 2500 Series® Classic Processor ......................2 1.3.2 2500 Series®... - Page 6 ......................33 SETUP AND STATUS INDICATORS I/O S .................... 34 ROUBLESHOOTING TATUS IN ORKSHOP 4.3.1 System status words ........................34 4.3.2 Fatal and Non-Fatal Error Codes ....................35 I/O S ................. 35 ROUBLESHOOTING TATUS IN ANUS ORKBENCH 4.4.1 Janus Processor I/O Error Codes ....................35 4.4.2 Errors for Individual Remote Bases and I/O Modules ..............
- Page 7 TABLE OF FIGURES Figure 2 Linear Network Configuration .................. 6 Figure 1 "T" Network Configuration ..................6 Figure 3 Typical Redundant Dual Media Layout ..............8 Figure 4 Alternate Redundant Dual Media Layout ..............9 Figure 5 Remote I/O Connector Pinout................15 Figure 6 2500-RIO-B Switch and Jumper Location ..............
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Page 9: Chapter 1 Overview
CHAPTER 1 OVERVIEW 1.1 Introduction ® The CTI 2500 Series Remote I/O System provides I/O ® networking of up to 15 remote bases to 2500 Series Processors. Both Classic (2500-C200/C300/C400) and Janus (2500P-J750) Processors support Remote I/O. The system employs a standard RS-485 electrical interface and a specialized communications protocol to communicate with the remote bases and operate process I/O. -
Page 10: 2500 Series® Classic Processor
Installation and Operation Guide http://www.controltechnology.com/Files/Products/2500- (Classic)/2500-Cxxx/manuals/CTI-2500-IOG-(62-370) ® 1.3.2 2500 Series Janus Processor The new “JANUS” Processor brings completely new capabilities to the CTI 2500 Series ® ® ® System. Designed to work seamlessly with existing 2500 Series and Simatic /TI 505 Systems as well as to look to the future with state-of-the-art programming, protocols and capabilities, including direct access to the Industrial Internet of Things (IIoT) using MQTT. -
Page 11: 2500 Series® Remote Base Controller
Complete specifications and user guide for the 2500-TAP can be found on the CTI web site: 2500-TAP Product Bulletin http://www.controltechnology.com/Files/Products/2500- (Classic)/2500-TAP/product-bulletin/06200382_010 ® CTI 2500 Series Remote I/O System Design, Installation & Troubleshooting Guide Revision 2.0... -
Page 12: Network Terminations
Remote I/O networks must be properly terminated to ensure reliable operation. Guidelines for network termination are included in Section 2.4 below. For best results, use CTI 2500-TAP network taps with built-in terminations. ® CTI 2500 Series Remote I/O System Design & Troubleshooting Guide Revision 2.0... -
Page 13: Chapter 2 Design & Installation
CHAPTER 2 DESIGN & INSTALLATION ® The design and installation of the CTI 2500 Series Remote I/O network consists of the following steps: 1. Plan and specify I/O network requirements 2. Specify and design the network topology 3. Specify cable type 4. -
Page 14: Figure 2 Linear Network Configuration
Maximum Trunk Length Figure 2 Linear Network Configuration TB = Terminal Block Maximum Trunk Length Maximum Trunk Length Terminating Resistor Terminating Resistor Figure 1 "T" Network Configuration ® CTI 2500 Series Remote I/O System Design & Troubleshooting Guide Revision 2.0... -
Page 15: Placing Taps And Designing Droplines
In the illustration below, L1 must be greater than the sum of L2 + L3. Remote Remote Base Base ® CTI 2500 Series Remote I/O System Design, Installation & Troubleshooting Guide Revision 2.0... -
Page 16: Dual Media And Hardware Redundancy Installations
The 2500-TAP RS-485 Remote I/O Tap and Terminator is required for dual media applications. Remote Bases 2500-TAP Termination Local Base Figure 3 Typical Redundant Dual Media Layout ® CTI 2500 Series Remote I/O System Design & Troubleshooting Guide Revision 2.0... -
Page 17: Figure 4 Alternate Redundant Dual Media Layout
Alternate Redundant Dual Media Layout. The resistor value required depends on the trunk cable as specified in section 2.4. The terminating resistor is installed between terminal numbers 3 and 8, the transmit and receive lines. ® CTI 2500 Series Remote I/O System Design, Installation & Troubleshooting Guide Revision 2.0... -
Page 18: Specify Cable Type
High uniform twist and spacing of conductors (twinaxial cable) • Shield coverage approaching 100% • DC resistance smaller than the characteristic impedance • Jacket suitable for the installation ® CTI 2500 Series Remote I/O System Design & Troubleshooting Guide Revision 2.0... -
Page 19: Specify Terminations
Do not allow the trunk cable to come into contact with any other electrical conductor. If cabling is installed inside a conduit, the conduit should be grounded according to applicable electrical codes. ® CTI 2500 Series Remote I/O System Design, Installation & Troubleshooting Guide Revision 2.0... -
Page 20: Constructing Trunk Line Cables
(the shield) is bare. 2. At both ends of the cable, remove 3.3mm (0.13 in) of each color-coded insulation jacket (both ends) to expose the bare wires. ® CTI 2500 Series Remote I/O System Design & Troubleshooting Guide Revision 2.0... -
Page 21: Connecting Trunk Lines To Taps
As outlined in Section 2.4. PROPER TRUNKLINE CONNECTION TO TAP NOTE CORRECT STRIP LENGTH AND ATTACHMENT OF WIRES. NOTE TERMINATION SWITCH IN THE “OFF” POSITION ® CTI 2500 Series Remote I/O System Design, Installation & Troubleshooting Guide Revision 2.0... -
Page 22: Constructing Drop Line Cables
2. At both ends of the cable, remove 0.13 in. (3.3 mm) of each color-coded insulation to expose the bare wires. Strip wire insulation Strip outer jacket and 3.3mm (0.13in) shield 38mm (1.5in) ® CTI 2500 Series Remote I/O System Design & Troubleshooting Guide Revision 2.0... -
Page 23: Connecting Drop Lines To Taps
#3 or #8, but all connectors must be installed identically and must follow the +/- color code you selected at the beginning of the installation. Figure 5 Remote I/O Connector Pinout ® CTI 2500 Series Remote I/O System Design, Installation & Troubleshooting Guide Revision 2.0... -
Page 24: Commission The I/Onetwork
Resistance of “+” to “-“ measures too low Incorrect termination resistance installed More than two termination resistors installed Short in the cable ® CTI 2500 Series Remote I/O System Design & Troubleshooting Guide Revision 2.0... - Page 25 Connect battery to processor vii) Download program including I/O configuration viii) On completion of download, all RBCs should change reading to “0” (if configurations of bases match program) ® CTI 2500 Series Remote I/O System Design, Installation & Troubleshooting Guide Revision 2.0...
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Page 27: Chapter 3 System Configuration
2. Set the configuration and starting I/O address of each slot in each base 3.1.1 Setting the Enable/Disable status of each base ® CTI 2500 Series systems support up to 15 remote I/O bases. In Workshop each base number can be set in either a “disabled” or “enabled” status. The processor attempts to communicate every scan with all bases that are set to “enabled”... -
Page 28: Set Slot Configuration And Starting I/O Address
Y, WX, WY addresses) and the starting address of the I/O slot. To set the slot configuration from PLC Workshop, use PLC UTILITIES – PLC CONFIGURATION – 505 I/O – EDIT BASE – EDIT SLOT. EDIT I/O BASE DIALOG BOX ® CTI 2500 Series Remote I/O System Design & Troubleshooting Guide Revision 2.0... -
Page 29: Configuring The 2500 Series Janus Processor
3.2.1 Add the Remote I/O Configuration To open the Fieldbus Configurator, make sure you have selected the desired Startup Project, then click the “Open Fieldbus Configuration” icon. ® CTI 2500 Series Remote I/O System Design, Installation & Troubleshooting Guide Revision 2.0... - Page 30 Click the “Insert Configuration” icon on the Fieldbus Editor toolbar. The “Add Configuration” dialog will come up. Expand the “All” selection and then click “CTI PLC Remote I/O”. ® CTI 2500 Series Remote I/O System Design & Troubleshooting Guide Revision 2.0...
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Page 31: Add The Remote Base(S)
3.2.2 Add the Remote Base(s) Next, we’ll add a remote base. Highlight the “CTI PLC Remote I/O” item you just created, and click the “Insert Master/Port” icon. ® CTI 2500 Series Remote I/O System Design, Installation & Troubleshooting Guide Revision 2.0... - Page 32 Highlight Remote Base 1. In the details pane to the right, tic the desired boxes to indicate whether this base is enabled, has dual RBCs (dual media), and has dual power supplies. ® CTI 2500 Series Remote I/O System Design & Troubleshooting Guide Revision 2.0...
- Page 33 Double click on the “Remote Base 1” value field, to edit the base number. From the drop-down box, select your remote base address (1-15). ® CTI 2500 Series Remote I/O System Design, Installation & Troubleshooting Guide Revision 2.0...
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Page 34: Add I/O Module(S) To The Remote Base(S)
3.2.3 Add I/O module(s) to the Remote Base(s) To add a module, highlight the Remote Base 1 we just added, and click “Insert Slave/Data Block” icon. The “Select Module” dialog box will be displayed. ® CTI 2500 Series Remote I/O System Design & Troubleshooting Guide Revision 2.0... - Page 35 2558 8CH Analog Input”. Enter a description, which slot, and how many slots the module takes. Check the boxes to fill in I/O mappings and create variables. Enter a prefix for the variables that will be created. Click OK. ® CTI 2500 Series Remote I/O System Design, Installation & Troubleshooting Guide Revision 2.0...
- Page 36 You can also choose to not create variables and/or not automatically fill in the I/O mapping. In this case, you would manually create variables and manually attach them to the I/O module in Workbench. ® CTI 2500 Series Remote I/O System Design & Troubleshooting Guide Revision 2.0...
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Page 37: Configuring The 2500-Rio-B Remote Base Controller
Jumper. The remainder of this section describes the function of the individual settings. Baud Rate Selection Switches RBC Station Address Freeze Jumper Figure 6 2500-RIO-B Switch and Jumper Location ® CTI 2500 Series Remote I/O System Design, Installation & Troubleshooting Guide Revision 2.0... -
Page 38: Setting The Rs232 Port Baud Rate
CPU or Siemens 545/555/575 CPU. NOTE: ® ® When connecting the 2500-RIO-B to a CTI 2500 Series CPU or Siemens 545/555/575 CPU, only base addresses between 1 and 15 are valid. Each installed 2500-RIO-B must have a unique station number. -
Page 39: Setting The Output State On Communication Loss
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 CTI 2500 Series Processor Programmers Reference Guide. - Page 40 ® CTI 2500 Series Remote I/O System Design & Troubleshooting Guide Revision 2.0...
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Page 41: Chapter 4 Troubleshooting
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. ® CTI 2500 Series Remote I/O System Design, Installation & Troubleshooting Guide Revision 2.0... -
Page 42: Troubleshooting I/O Status In Workshop
I/O module mismatch STW210 Remote I/O base poll enable flags ® Note: Addresses above STW242 are only supported by the CTI 2500 Series CPUs. STW455-461 Remote base receive errors STW471-485 Remote base abnormal logoff counts STW487-501 Remote base timeout counts ®... -
Page 43: Fatal And Non-Fatal Error Codes
4.4.1 Janus Processor I/O Error Codes The front panel display on Janus Processors displays system error codes, including the follow errors for local and remote I/O. ® CTI 2500 Series Remote I/O System Design, Installation & Troubleshooting Guide Revision 2.0... -
Page 44: Errors For Individual Remote Bases And I/O Modules
DualPow – If TRUE, indicates Dual Power Supplies are present and operational In addition, each I/O module has Module Status object (see Section 3.2.3). Status=0 No error Status=1 Module error Status=2 Slot is unconfigured Status=3 Status unavailable ® CTI 2500 Series Remote I/O System Design & Troubleshooting Guide Revision 2.0...
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