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Control Technology 2500 Series Installation And Operation Manual

Profibus remote base controller
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2500 Series
CTI 2500-RBC
PROFIBUS REMOTE BASE CONTROLLER
INSTALLATION AND OPERATION GUIDE
Version 1.7
2500RBCIOG 1062016

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Summary of Contents for Control Technology 2500 Series

  • Page 1 ® 2500 Series CTI 2500-RBC PROFIBUS REMOTE BASE CONTROLLER INSTALLATION AND OPERATION GUIDE Version 1.7 2500RBCIOG 1062016...
  • Page 2 Copyright ©2015 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 tradenames, trademarks, and/or registered trademarks of Control Technology Inc. Siemens® and Simatic® are registered trademarks of Siemens AG.
  • Page 3 Profibus Master. We assume you are familiar with the installation and operation of: 2500 Series® and Simatic® 505® programmable controllers, PLC WorkShop™ for Siemens 505™ or Com Profibus Configuration Software Please refer to the appropriate user documentation for specific information on your programmable controllers and I/O modules.
  • 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.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS CHAPTER 1. DESCRIPTION ..................1 1.1. Introduction ......................1 CHAPTER 2. INSTALLATION .................3 2.1. Installation Planning....................3 Choosing Profibus Media Wiring the Profibus Connector Selecting a Profibus Address Selecting a Profibus Speed Selecting Slave Parameters Setting Module Hardware Options 2.2. Power Requirements ....................4 2.3.
  • Page 6 4.7 Setting Profibus Slave Parameters ..............35 APPENDIX A. PROFIBUS INSTALLATION GUIDELINES .........37 General Installation Information ................37 Maximum number of stations Cable Type Cable Lengths Bus termination Bus connectors and PROFIBUS-DP/FMS interface Cable laying guidelines....................40 Laying of copper cable Laying cables within control cabinets Laying cables outside of control cabinets SPECIFICATIONS ....................43...

  • Page 7: Chapter 1. Description

    CHAPTER 1. DESCRIPTION 1.1. Introduction The CTI 2500-RBC Profibus Remote Base Controller is a member of Control Technology's family of I/O modules compatible with the programmable controllers. The 2500-RBC Profibus Remote Base Controller (RBC) ® allows a CTI 2500 Series or Simatic®...

  • Page 9: Chapter 2. Installation

    Before proceeding, you must determine what Profibus address you will assign to the module. ® Profibus addresses range from 0 to 127. In CTI 2500 Series and Simatic® 505 systems, address 0 and addresses 113-127 are not valid. Therefore, any address between 1 and 112 is valid for the RBC when installed in these systems.

  • Page 10: Selecting A Profibus Speed

    Selecting a Profibus Speed The 2500-RBC supports Profibus speed from 9.6K bits/s to 12M bits/s. For more information on selecting Profibus speed see Appendix A. Selecting Slave Parameters The 2500-RBC supports four parameterization options. These options are set using WorkShop, or using the “properties”...

  • Page 11: Configuring The Module

    2.4. Configuring the Module There are six steps to configuring the module and option switches freeze jumper setting getting it operational on a Profibus network: 1. Setting the module option switches 2. Setting the output state on communication loss (freeze jumper) 3.
  • Page 12 SW4 through SW10 - Profibus Address Switches 4 through 10 are used to assign a station address to the RBC for identification on the Profibus-DP I/O channel. Each station in the Profibus network must be uniquely numbered. The station address is assigned as a binary number, with SW4 and the most significant bit (MSB) and SW10 as the least significant (LSB).
  • Page 13 Switch Number / State Switch Number / State Station Address Station Address 113* 114* 115* 116* 117* 118* Invalid Addresses 119* 120* 121* 122* 123* 124* 125* NOTE: The address setting on the 2500-RBC switches must match the address set for the base in WorkShop or Com Profibus for proper operation NOTE: When connecting the 2500-RBC to a CTI 2500 CPU or a 545/555/575 CPU, only addresses between...
  • Page 14 • When switch 11 is set to 1 (closed), the station address of the RBC is displayed as a three digit number, one digit at a time. There is a short pause after each digit, then a long pause after the last digit. •...

  • Page 15: Setting The Output State On Communications Loss

    Setting the Output State on Communications 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-RBC jumper JP1 (Off/Freeze). Figure 2 shows the location of the jumper on the 2500-RBC. NOTE: The 2500-RBC ships with the FREEZE jumper in the OFF setting.

  • Page 16: Configuring The Remote Base In Workshop Or Com Profibus

    The exported binary file must be merged with the Profibus Master to bring in the I/O configuration of the remote base. For more information about Merging the configuration file in Workshop (when using the 2500-RBC with CTI 2500 Series® or Simatic® 505 PLC’s), see Chapter 3. This merge step is not required when using WorkShop.

  • Page 17: Connecting The Profibus Cable

    2.6. Connecting the Profibus Cable The Profibus port is used to connect the 2500-RBC to a Profibus DP network. Appendix A describes how to connect a 12 Mbaud RS-485 cable to the PROFIBUS-DP port. The figure below shows the required pinout for the DB9 Profibus port. NOTE: NOTE: Pins 2 and 7 are “No Connect”...

  • Page 18: Diagnostics

    (LSB). This may or may not correspond to the bit numbering scheme used in your master system. For example, CTI 2500 Series® and Simatic® 505/500 controllers identify the MSB of a byte as Bit 1, and the LSB of a byte as Bit 8. A DP diagnostic consists of two parts. The first part (Bytes 1 through 6) is standardized for all DP slaves.

  • Page 19: Diagnostics

    The 2500-RBC provides diagnostic information in the PLC available in status words and through execution of the RSD instruction in the ladder logic. PLC Status Words NOTE: For more information on STW diagnostics, see the CTI 2500 Series® Programming Reference Manual, Appendix A. STW147: This PLC status word records the number of times, since the most recent start, that the Profibus-DP slaves have failed to respond to a request from the CPU.

  • Page 20: Diagnostic Bytes From The 2500-Rbc

    These 7 status words give the status for Profibus-DP slaves. Each bit corresponds to a particular Profibus address, with STW03 Bit 16 being address 1 and STW09 Bit 1 being address 112. Each bit = 0 if the address is present and operating. The bit = 1 if the address is not present or failed. When the 2500-RBC loses communication or goes offline due to a mismatch, the corresponding bit for that address is set = 1.
  • Page 21 Bit 5 = Reserved Bit 4 = Reserved Bit 3 = Reserved Bit 2 = Reserved Bit 1 = Reserved Bit 0 = Reserved Byte 4: Diag.Master_Add Bits 7-0 contain the address of the master that has parameterized the RBC. If none of the masters has parameterized the RBC, then the RBC inserts the address 255 in this byte.
  • Page 22 Bit 4 = Slot 13 is mismatched type Bit 3 = Slot 12 is mismatched type Bit 2 = Slot 11 is mismatched type Bit 1 = Slot 10 is mismatched type Bit 0 = Slot 9 is mismatched type Byte 13: Ext_Diag_Data Identifier-related diagnostic header;...

  • Page 23: Chapter 3. Setting Up The 2500-Rbc Using Com Profibus

    CHAPTER 3. SETTING UP THE 2500-RBC USING PROFIBUS 3.1. Overview Configuration of the Profibus network can be accomplished using either PLC WorkShop™ for Siemens 505™ (version 4.32 or above) or the Com Profibus configuration utility. If you’re using PLC WorkShop™ for Siemens 505™, please refer to the “PLC Memory and I/O Configuration”...

  • Page 24: Import The 2500R.gsd File Into Com Profibus

    3.3. Import the 2500R.gsd file into Com Profibus The next step is to copy the “2500.gsd” file into the Com Profibus directory. This file must be placed in the “gsd” subfolder where Com Profibus is 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”...

  • Page 25: Set Bus Parameters

    3.4. Set Bus Parameters Next, set the Profibus speed for this installation using “Configure / Set Bus Parameters”. CTI 2500-RBC Installation and Operation Guide V1.6...

  • Page 26: Add A Master To The System And Set The Profibus Address

    The “Bus Profile” setting should be “Profibus 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.
  • Page 27 Next, highlight the PLC master and right click. Then click “Properties” to set properties for this master. CTI 2500-RBC Installation and Operation Guide V1.6...
  • Page 28 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. CTI 2500-RBC Installation and Operation Guide V1.6...

  • Page 29: Add The 2500-Rbc To The System

    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. CTI 2500-RBC Installation and Operation Guide V1.6...
  • Page 30 Then click on “Properties” to bring up the configuration dialog. Enter the desired Profibus address and station name. Then click the “Parameterize” 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”...

  • Page 31: Save The Profibus Configuration And Export The Binary File

    discrete I/O modules support multiple login configurations for 32, 18, or 8 points. Be sure that you select the desired configuration if you’re using these modules. Next, press OK to exit the Configure screen and OK to exit the Slave Properties screen. 3.8.

  • Page 32: Merge The Binary File In Workshop

    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. CTI 2500-RBC Installation and Operation Guide V1.6...
  • Page 33 The system used in this example already has one Profibus slave installed. If 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”.

  • Page 34: Write The Configuration To The Base(S)

    3.10. Write the Configuration to the Base(s) You should already have installed the base and connected it to the Profibus. Next, click the “Write All” button to write the configuration out to the RBC on Profibus. You may get a notification that the I/O is not configured. If so, use the “Edit Slave” button to set the starting addresses of the slots in the base.
  • Page 35 CTI 2500-RBC Installation and Operation Guide V1.6...

  • Page 36: Chapter 4. Setting Up The 2500-Rbc Using Workshop 4.32 Or Later

    WorkShop/HDGSDBMP folder. It will be necessary to log in on the Control Technology website in order to download this GSD file. If you are not currently a registered user on the CTI website, then you must first complete a new user registration before being able to download your file.

  • Page 37: Start Workshop

    4.3 Start Workshop Start Workshop and open your new or existing program. You will need to be using Workshop version 4.32 or higher in order to configure 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.
  • Page 38 Click on the Add Slave Button to get the following box. Open the I/O folder. If you do 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.
  • Page 39 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. CTI 2500-RBC Installation and Operation Guide V1.6...
  • Page 40 Scroll through the module list to find the 2500 or 505 series devices. Select the desired module for I/O slot #1 and then press the Add Module button. Then select the module for each of the remaining slots and add them in like manner. Note: All empty slots before an occupied slot must be filled with a “Blank”...

  • Page 41: Setting Profibus Slave Parameters

    NOTE: The local base is defined as the rack that contains the CPU. Be careful that you do not overlap memory addresses with modules in your local base or other remote bases. Example: If the local base rack uses addresses 1-32 of X/Y memory, the 8pt digital input card in slot #1 of the first remote base must have a starting address of a least ‘33’...
  • Page 42 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. CTI 2500-RBC Installation and Operation Guide V1.6...

  • Page 43: Appendix A. Profibus Installation Guidelines

    APPENDIX A. PROFIBUS INSTALLATION GUIDELINES These Profibus Installation Guidelines are based on the PNO Profibus Guideline, September 1998. General Installation Information Maximum number of stations Maximum number of stations participating in DP: 126 (addresses from 0 .. 125) the exchange of user data FMS: 127 (addresses from 0 ..

  • Page 44: Bus Termination

    9.6 19.2 45.45 93.75 187.5 500 1500 3000 6000 Data transfer rate in kbit/s Max segment 1200 1200 1200 1000 length in meters Important: In a PROFIBUS-DP/FMS installation, you must choose a data transfer rate which is supported by all devices connected to the bus. The chosen data transfer rate then determines the maximum segment lengths as shown above.
  • Page 45 Pin no. Signal Significance Shield Shield/functional ground Ground for +24 V output voltage Receive/Transmit data – plus (B wire) RxD/TxD-P *) CNTR-P Repeater control signal (direction control), RTS signal DGND *) Data ground (reference potential for VP) VP *) Supply voltage - plus (P5V) Output voltage +24 V Receive/Transmit data –...

  • Page 46: Cable Laying Guidelines

    Cable laying guidelines Laying of copper cable Data transfer in PROFIBUS systems is based on an interference-immune symmetrical bus system to the RS 485 specification using shielded twisted pair cable. With correct system installation, small external sources of interference are led to ground through the cable shield without causing interference in the data lines.

  • Page 47: Laying Cables Within Control Cabinets

    Shielding. In addition, electronic starters should be used if fluorescent lamps are installed within control cabinets. The following cable laying instructions apply to shielded twisted pair cables. The cable shield is used to improve the immunity to electromagnetic interference. PROFIBUS cables should be shielded with a combination of both conductive braid and conductive foil.

  • Page 48: Laying Cables Outside Of Control Cabinets

    PROFIBUS cables ... and cables for ... must be laid ... • in the same cable loom or cable duct. Bus signals, e.g. PROFIBUS • Data signals for PC´s, programming devices, printers etc. • Screened analog inputs • Unscreened DC voltages (<= 60V) •...

  • Page 49: Specifications

    SPECIFICATIONS General ® Module Size: Double-Wide CTI 2500 Series® or Simatic 505 I/O Backplane Power Consumption: 2.5 watts Simatic® ® Compatibility: CTI 2500 Series® , 505, Siemens S5 and S7 masters Compatibility: all currently-available CTI and Siemens ® 4-, 8-, and 16-slot bases...
  • Page 50 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) CTI 2500-RBC Installation and Operation Guide V1.6...

  • Page 51: Limited Product Warranty

    CTI. Control Technology Inc. reserves the right to make changes to the Product in order to improve reliability, function, or design in the pursuit of providing the best possible Product. CTI assumes no responsibility for indirect or consequential damages resulting from the use or application of this equipment.

  • Page 52: Repair Policy

    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.

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