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! DANGER DANGER indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury. DANGER is limited to the most extreme situations. ! WARNING WARNING indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury, and/or property damage. ! CAUTION CAUTION indicates a potentially hazardous situation that, if not avoided, could result in minor or moderate injury, and/or damage to property.
MANUAL PUBLICATION HISTORY SIMATIC 545/555/575 System Manual Order Manual Number: PPX:505–8201–3 Refer to this history in all correspondence and/or discussion about this manual.
LIST OF EFFECTIVE PAGES Pages Description Cover/Copyright History/Effective Pages iii — xxi 1-1 — 1-13 2-1 — 2-20 3-1 — 3-28 4-1 — 4-58 5-1 — 5-24 6-1 — 6-35 7-1 — 7-12 8-1 — 8-8 9-1 — 9-25 A-1 — A-5 B-1 — B-9 C-1 — C-23 D-1 — D-7 E-1 — E-16 F-1 — F-6 Index-1 — Index-10 Registration Third Edition Third Edition Third Edition Third Edition Third Edition Third Edition Third Edition Third Edition Third Edition Third Edition Third Edition Third Edition Third Edition Third Edition Third Edition Third Edition T
Contents Preface Chapter 1 1.1 1.2 1.3 1.4 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compatibility with Previous CPUs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Features on New CPU Models . .
2.4 Guidelines for Fuses/Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Fusing the Controller and Remote I/O Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Electrical Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Definition and Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.9 3.10 3.11 Replacing and Handling the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Lithium Battery in the 545 and 555 –1105/–1106 CPUs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the Battery in –1105/–1106 CPUs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lithium Battery in the 545 and 555 –1103/–1104 CPUs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Indicators . . . .
4.6 Installing the PPX:575–2130 VMEbus Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Mechanical Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mounting Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mounting a Base in a 19-inch Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.13 Wiring the Fault Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44 4.14 Establishing CPU Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45 Default Port Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pinout for Serial Port 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5 PPX:505–6870 RBC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . User Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output State Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Jumpers E2, E3 and E4 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4 6.5 Connecting Modems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dedicated Line Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dial-up Phone Line Operation . . . . . . . . . . . . . . . . . . . . . . .
Chapter 9 9.1 Troubleshooting Troubleshooting by Using Auxiliary Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power-up Restart, Partial Restart, and Complete Restart . . . . . . . . . . . . . . . . . . . . . . . . . . 575 Fault Restarts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix A System Specifications A.1 Physical and Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 A.2 General Series 505 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3 A.3 575 Power Supply Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4 A.4 Series 505 Power Supply Specifications . . . . . . . . . .
C.6 RS-485/RF I/O Channel Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-19 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing the RS-485/RF I/O Channel Converter . . . . . . . . . . . . . . .
List of Figures 1-1 1-2 1-3 Series 505 I/O Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Typical 555 System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Typical 575 System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9 4-10 4-11 4-12 4-13 4-14 4-15 4-16 4-17 4-18 4-19 4-20 4-21 4-22 4-23 4-24 4-25 4-26 4-27 4-28 4-29 4-30 4-31 4-32 4-33 Selecting Input Voltage on the PPX:575–6663 Power Supply . . . . . . . . . . . . . . . . . . . . . . . Installing the 575 Power Supply Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting Power to the 575 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mounting the Battery . . . . . . . . . . . .
6-7 6-8 6-9 6-10 6-11 6-12 6-13 6-14 6-15 6-16 6-17 6-18 6-19 6-20 6-21 6-22 6-23 6-24 6-25 6-26 Connecting to a Series 505 Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adding a Terminating Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting Trunk Line to Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
List of Tables 1-1 1-2 1-3 CPU Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CPU Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I/O Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-6 8-7 8-8 8-9 555–1106 CPU Memory Configuration 575–2104 CPU Memory Configuration 575–2105 CPU Memory Configuration 575–2106 CPU Memory Configuration ............................................ ............................................ ............................................ ............................................ 8-7 8-7 8-8 8-8 9-1 9-2 9-3 9-4 9-5 9-6 Effects of Using AUX 10, AUX 11, and AUX 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preface About This Manual This SIMATIC 545/555/575 System Manual includes requirements and specifications for preparing your control site and installing a SIMATICr 545, 555, or 575 programmable logic controller system.
Related Manuals Additional manuals that have relevant information include the following: • SIMATIC 545/555/575 Programming Reference User Manual (PPX:505–8204–x). • SIMATIC 505 TISOFT2t User Manual (PPX:TS505–8101–x). • SIMATIC 505 PROFIBUS-FMS Communications Processor User Manual, (PPX:505–8129–x) for information on operating and configuring the FMS CP module. • SIMATIC 505 H1 Communication Processor User Manual (PPX:505–8126–x).
Agency Standards Series 505 products have been developed with consideration of the draft standard of the International Electrotechnical Commission Committee proposed standard (IEC–65A/WG6) for programmable controllers (released as IEC 1131–2, Programmable Controllers, Part 2: Equipment Requirements and Tests, First Edition, 1992–09). The 575 controller system is designed to be compatible with ANSI/IEEE Std. 1014–1987. Contact Siemens Energy & Automation, Inc.
Chapter 1 System Overview 1.1 1.2 1.3 1.4 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compatibility with Previous CPUs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Features on New CPU Models . .
1.1 Overview Introduction This manual describes SIMATIC 545, 555, and 575 programmable control systems and encompasses the following CPU models: • PPX:545–1103, –1104, –1105, –1106 • PPX:555–1103, –1104, –1105, –1106 • PPX:575–2104, –2105, –2106 NOTE: In this manual, a feature, unless it is explicitly restricted, applies to all systems. The CPU models are distinguished by capacity and speed and by various optional features.
Features on New CPU Models The newer model 555 and 575 CPUs incorporate several new features and enhancements, including the following: • The 555–1105/–1106 CPUs and 575–2105/–2106 CPUs include a built-in Motorola 68882 floating-point math coprocessor. • The 555–1105/–1106 and 575–2105/–2106 CPUs support PowerMatht functionality, which compiles high-level math functions using the new memory type allocation of Compiled Special (CS) memory for Special Function (SF) programs and SF subroutines.
Overview (continued) PROFIBUS-DP Series 505 programmable control systems can now communicate with PROFIBUS-DP I/O and other devices that meet the PROFIBUS standard (DIN 19245, Part 3). PROFIBUS-DP is a token ring protocol in a master-to-slave configuration that is optimized for I/O exchange. Some Series 505 CPUs contain a PROFIBUS-DP annex card (optional for 575 and 545–1103/–1105 CPUs) that supports all I/O devices that conform to the PROFIBUS-DP standard.
545/555/575 C P U PROFIBUS-DP I/O Channel (12 Mbaud) Series 505 Remote I/O Channel (1 Mbaud) R B C Series 505 Base with RBC (PPX:505–6851–A/B RBC) R B C Series 505 Base with 505 PROFIBUS-DP RBC (PPX:505–6870 RBC) ET200U R B C Series 500 Base with RBC (PPX:500–5114–A RBC) 95U/PROFIBUS-DP Series 500 Base with 500 PROFIBUS-DP RBC R B C (PPX:500–6870 RBC) ET200B Block I/O ET200C AS-Interface Master S7 I/O AS-Interface Bus Limit SW P/B Solenoid PE Cell Siemens AC/DC Motors and Drives Allen-Bradle
1.2 System Features Product Specifications Overview Table 1-1 lists memory capacity, scan performance, and other features for the CPUs described in this manual. Table 1-1 CPU Specifications Feature 545–1103/1105 545–1104/1106 555–1103 555–1104 575–2104 User Memory 96 Kbytes 192 Kbytes 384 Kbytes 1920 Kbytes 832 Kbytes Boolean Scan 0.33 ms/K 0.16 ms/K 0.07 ms/K 0.07 ms/K 0.
Table 1-2 lists memory capacity, scan performance, and other features for the newer model CPUs described in this manual. Table 1-2 CPU Specifications Feature 555–1105 555–1106 575–2105 575–2106 User Memory 384 Kbytes 1856 Kbytes 832 Kbytes 1856 Kbytes Boolean Scan 0.07 ms/K 0.07 ms/K 0.45 ms/K 0.
System Features (continued) Shared Features 1-8 System Overview All CPUs offer the following features: • Support for I/O expansion using PROFIBUS-DP I/O. • Support for I/O expansion using Series 505 remote I/O. (Exception: the 545–1103/–1105 cannot use the Series 505 remote I/O channel.) • Optional password protection for user programs. • Full support for SIMATIC PCSt.
545/555-Only Features The 545 and 555 systems offer the following additional features: • Local-base interrupt I/O that allows for fast reaction to external events. • Non-volatile program storage and execution (portable EEPROM or EPROM) to restore the initial state of your program. • Series 505 footprint. Figure 1-2 shows a typical 555 system.
System Features (continued) 575-Only Features The 575 system offers the following additional features: • Open VME system allowing real-time communication across VME backplane to boards, such as motion control, vision, host processors, and special I/O, and to other 575 CPUs installed in the same base. • Additional RLL instructions to support VME. • Fault relay capability. Figure 1-3 shows a typical 575 system.
1.3 Programming Tools SoftShop SIMATIC 505 SoftShopt for Windowsr is a Windows-based programming software that supports all SIMATIC 505 series as well as previous generation Series 500 programmable controllers. SoftShop also reads in and automatically converts all your Series 505/500 TISOFT program files. SoftShop provides familiar Windows features such as menu-driven commands, tool bars, and point-and-click functions to help simplify creating and editing your application program.
1.4 Hardware Overview The base that contains a 545, 555, or 575 CPU and I/O modules is called the local base. Expansion I/O is also available, in the form of Series 505 remote I/O and/or PROFIBUS-DP I/O slaves and field devices. Special function (SF) I/O modules can be used in a Series 505 remote base; however, performance is improved when they are used in the local base. SF I/O cannot be used with the 505 PROFIBUS-DP RBC (PPX:505–6870) on the PROFIBUS-DP channel. See Table B-3 in Appendix B.
Expansion I/O Two I/O channels are available for expansion I/O. • The Series 505 channel supports Series 505 and Series 500 remote I/O. NOTE: To upgrade your Series 500 installation to a Series 505 system while keeping your Series 500 remote I/O bases, see Appendix C. • I/O Channel Support The PROFIBUS-DP I/O channel supports PROFIBUS-DP I/O masters, slaves, and field devices, and also Series 505 remote I/O (by means of the DP RBC, PPX:505–6870).
Chapter 2 Pre-installation Guidelines 2.1 Planning Your Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Defining Control Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Calculating Power Needs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 2-2 Safety Considerations . . . . . . . . . . . . . .
2.1 Planning Your Installation Preparing the site for installation of your CPU consists of the following tasks: • Define control requirements. • Determine the number of CPUs needed. • Determine the panel and grounding layout. NOTE: Since no two applications are identical, use these recommendations as general guidelines only.
2.2 Safety Considerations Pre-installation planning and site preparation must include consideration of hazards to personnel in the event of a system failure. The equipment connected to the control system must include interlocks and safety switches to help prevent operation during a system failure. Although the specific steps depend on the application, the general precautions include the following considerations. ! WARNING Control devices can fail in an unsafe condition.
Safety Considerations (continued) Operator Safety Switches Provide a means—independent of the controller—for disconnecting power from the output loads when a machine is not operating, or when it is necessary for the operator to reach into the machine. Power must be removed by a non-semiconductor switch or a physically-wired relay contact, placed to interrupt power to the output. Do not rely solely on the programmable control system for this function. Figure 2-1 shows an operator safety switch.
JOG or INCH Switch Bypass the programmable control system with an external JOG or INCH switch during machine loading or set-up operations. See Figure 2-3.
2.3 575 Fault Relay Operation Overview The 575 CPU provides a normally open (NO) relay output (fault relay) for use in a low-voltage safety chain. The CPU must successfully complete power-up diagnostics before its fault relay is closed. If an error is detected by the software or the hardware, then the fault relay does not close. During normal operation, the fault relay remains closed. The fault relay opens if a fatal error is detected by the 575 CPU. See Figure 4-22 for fault relay pinouts.
NORMAL (closed) Non-fault 575 CPU initialization Power-up Reset Power-off Fault Detected IDLE (open) Power-off AUX 11 or Fault AUX 12 Detected restart FAULT mode FAULT (open) Figure 2-4 Software State Diagram Fault State The fault relay opens whenever the 575 CPU enters the FAULT mode or loses power. To close the fault relay after entering FAULT mode, transition the 575 CPU to PROGRAM mode either by executing an AUX 11 or AUX 12 from TISOFT, or by performing a bad-battery power cycle.
575 Fault Relay Operation (continued) Time Delay The time delay required for the fault relay to operate correctly is dependent on the modules in the system. The fault relay closes within 10 seconds of power being applied to the system if no fault is detected, and if only SIMATIC 575 VME equipment is used in the VME base. If you use a third-party master to log into the 575 system, the fault relay is delayed.
In Figure 2-5, relay CRM is the interposing relay, and FLT is a 24-volt relay, in the low-voltage safety chain. Note the use of pushbutton switches for master stop (normally closed) and master start (normally open). Power to the safety-critical loads is not applied until the master start switch is turned on. If the master stop switch is turned on, then the safety-critical loads are turned off. If one of the fault relays opens, then the safety-critical loads are also turned off. Refer to Section 2.
575 Fault Relay Operation (continued) To use the fault relay to control the power to the electronic control system, you must wire the relay so that it controls the interposing relays in the supply line. An example of this is shown in Figure 2-6. NOTE: Figure 2-6 is not a complete electrical diagram. It is for illustration purposes only. A qualified control engineer should be aware of any relevant regulations and design the system with these in mind.
2.4 Guidelines for Fuses/Circuit Breakers Fusing the Controller and Remote I/O Base Use the following guidelines for installing fuses/circuit breakers; see Figure 2-7. The sizes and types of fuses/circuit breakers depend on the specified power distribution requirement. • A circuit breaker before the isolation transformer. Isolation transformers may not be required if your power distribution system does not have a high level of noise. • A fuse after the isolation transformer.
2.5 Electrical Noise Definition and Source Electrical noise is defined as any unwanted electrical signal which enters the control equipment. Noise signals cover the entire spectrum of frequencies and may have any wave shape. A major difficulty with noise problems is that they can occur at random intervals. Continuous or frequent, periodic noises generally are easy to detect and remedy.
2.6 Correcting Noise Problems When potential noise sources are identified, two methods are available to handle them: noise snubbing and noise isolation. These methods are described in the following sections. Noise Snubbing Noise snubbing reduces noise at its source. Applicable only to devices driven by mechanical contacts, snubbing suppresses the arcing at electrical contacts that is caused by turnoff of inductive loads (e.g., relays, motors, motor starters, solenoids, etc.).
Correcting Noise Problems (continued) You can also use contact snubbing (shown in Figure 2-9) as an alternative type of snubbing. Both types of snubbing cause the physical devices to come on or go off more slowly. The resistance-capacitance (RC) and metal oxide varistor (MOV) elements should have minimal effect on system timing; their time constants are substantially less than one millisecond.
Noise Isolation The second approach to handling noise problems is to isolate the problem device and its wiring from the electronics and associated signal wiring. You can accomplish this by increasing the physical distance from some types of noisy devices. For extreme cases, electrostatic (metal) shielding may be required. This is true for noise sources outside as well as inside the mounting cabinet (NEMA-type recommended).
2.7 Wiring Guidelines Consider the following guidelines before installing any system or power wiring: 2-16 • Always use the shortest possible single-length cable. • Avoid placing system and field wiring in the vicinity of high-energy and/or high-frequency wiring. • Keep field input wiring, output wiring, and all other types of wiring in the panel physically separated when possible. • Separate DC field wiring from AC field wiring wherever possible. • Avoid sharp bends to power and data cables.
2.8 Grounding the Power System WARNING ! A good grounding system is essential for proper operation of the system. It is one of the most important considerations in planning your installation. Failure to provide a good grounding system could lead to erratic operation of the equipment, which could result in death or serious injury to personnel, and/or damage to equipment. Ensure that you have a good grounding system when you install your equipment.
Grounding the Power System (continued) Ground Connections Use particular care when establishing the ground connections. The following techniques will help to establish good electrical connections and decrease noise interference: • Where possible, terminate grounding braid and green wires at both ends with copper eye lugs to provide a good contact surface. Lugs should be crimped and soldered.
Grounding the 545/555 Controller Chassis Ground your 545/555 controller by following the guidelines below to ensure that noise is minimized. • Use the ground connection (Figure 2-13) to attach one end of a ground wire; attach the other end to a nearby grounding rod that meets all electrical specifications required for an earth ground. • Use the shortest possible length of #8-gauge copper wire, or equivalent braided cable, to make the connection.
Grounding the Power System (continued) Cable Management for the 575 Cabling at the rear of the unit can be routed in and out of the cabinet through the two cable ducts at the bottom of the unit or by removing the break-away tab on the rear panel. (Refer to Figure 4-31 for location of the break-away tab.) Grounding the 575 Controller Chassis A ground connector mounted on the side panel of the chassis provides an earth-ground connection to the chassis.
Chapter 3 Installing 505 System Hardware 3.1 Overview of Installation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 3.2 Enclosure and Temperature Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Enclosure Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Temperature Considerations . . . . . . . . . . . . . . . . . . . .
3.1 Overview of Installation Procedures The following charts identify the tasks for installing Series 505 system hardware.
3.2 Enclosure and Temperature Considerations Enclosure Selection An enclosure should provide the following features: • Easy access to components. • A common ground potential on the cabinet. • A secure vertical panel or rails. • Conformance to electrical standards. • An electromagnetic shield, if needed to meet FCC or CE emission standards. • Access restricted to authorized personnel only. • Adequate cooling and heat dissipation.
3.3 Series 505 Bases Description The 545/555 CPU is housed in a Series 505 base. A base has slots for the power supply, the CPU or RBC, and the I/O modules. Four base models are currently available; see Table 3-1.
3.4 Rack Mounting Series 505 Bases Use the following steps for mounting a PPX:505–6511 or PPX:505–6516 base in a standard 19-inch rack. See Figure 3-1. 1. Move brackets from wall-mounting position (back of chassis) to front position. 2. Position the base in the 19-inch rack. Depth of base is 8 inches (205 mm). NOTE: There should be at least 6 inches (150 mm) of clearance at the top and bottom of the base for adequate airflow. 3.
3.5 Panel Mounting Series 505 Bases Use the following steps for panel mounting in an NEMA enclosure. NOTE: There should be at least 6 inches (150 mm) of clearance at the top and bottom of base for adequate airflow. The base depth is 7.99 inches (203 mm). 1. Open NEMA enclosure door. 2. Drill four holes in sub-panel of NEMA enclosure with a #21 drill bit. Refer to Table 3-2 for screw-hole dimensions for each base. Ensure that chips from drilling do not contaminate other equipment. 3.
Table 3-2 Series 505 Base Dimensions 0.85 (22) 0.85 (22) A Siemens PPX:505–6504 PPX:505–6508 PPX:505–6511 PPX:505–6516 10.47 (266) 8.97 (228) PROFIBUS-DP 1.47 (37) Measurements: in. (mm) B Base PPX: Dimension A inches/(mm) Dimension B inches/(mm) 505–6504 8.10 (206) 8.69 (221) 505–6508 11.29 (287) 11.93 (303) 505–6511 17.70 (450) 18.34 (466) 505–6516 17.70 (450) 18.
3.6 Installing Series 505 Power Supply Power Budget for Series 505 Base The total power consumption of all I/O modules (including the CPU or RBC) drawing power from a Series 505 power supply must not exceed 55.0 W from the +5 VDC output and 3.75 W from the –5 VDC output. Refer to Appendix B for power consumption listings for the CPU and all currently available Series 505 I/O modules and RBCs. Power Supply Placement in Bases Figure 3-3 shows the placement of the power supply in Series 505 bases.
2. If you are installing the PPX:505–6660 or PPX:505–6660–A or –B power supply, connect the voltage selector as shown in Figure 3-4. Selecting voltage for the PPX:505–6660 power supply. TAB2 TAB1 220 V 110 V Selecting voltage for the PPX:505–6660–A power supply. JP5 JP3 110V 220V Selecting voltage for the PPX:505–6660–B power supply. 110V 220V Figure 3-4 Input Voltage Selectors 3. Position the power supply so that the bezel is facing you. 4. Grasp the top and bottom of the power supply. 5.
Installing Series 505 Power Supply (continued) Wiring the Power Supply After installing the power supply, you are ready to connect your power supply to an external power source. Observe these guidelines as you carry out the procedure below. • Use 14 to 22 AWG solid or stranded wire. If you use stranded wire, the wire should be twisted and trimmed. • Strip insulation back 0.4 inches (10 mm). • Insert the wires fully into the terminal block so that the insulation butts against the block.
3. Insert wires as appropriate for your power supply module, and tighten screws to no more than 5 in–lb (0.56 N–m) torque. Figure 3-5 shows the location of the power connector screws on the module. (Consult Section 2.8 for grounding guidelines.) Siemens SIMATIC 505 DC POWER GOOD AC LINE AC NEUTRAL GROUND Power connector screws 505-6660 Figure 3-5 Series 505 Power Connector 4.
3.7 Installing the PROFIBUS-DP Annex Card (Optional) To install the PROFIBUS-DP annex card, PPX:505–CP5434–DP, on a 545–1103 or 545–1105 CPU, follow the procedure described below and consult Figure 3-6. 1. Carefully set your CPU board on a static-dissipative surface. CAUTION Electronic equipment is sensitive to, and can be damaged by, electrostatic discharge. Ensure that personnel make contact with a static-dissipative pad and/or wear a grounded wrist strap when handling the CPU cards or modules. 2.
SIMATIC 545 CPU GOOD RUN BATT GOOD PROFIBUS-DP Dipswitch 545–1105 Figure 3-6 Installing the PROFIBUS-DP Annex Card in 545–1103/–1105 CPU SIMATIC 545/555/575 System Manual Installing 505 System Hardware 3-13
3.8 Installing the 545/555 CPU CPU/RBC Location in a Base The second slot from the left (beside the power supply module) is reserved in Series 505 bases for the CPU or RBC, as shown in Figure 3-7. C P U / R B C P / S I I I I I I I I / / / / / / / / O O O O OO O O Figure 3-7 Location of CPU/RBC in a Series 505 Base Installing and Removing the CPU Refer to Figure 3-8 and follow the steps below to install the 545/555 CPU.
4. Carefully push the module into the slot until it mates with the backplane connectors. 5. Tighten top and bottom bezel screws. Minimum torque: 2.6 in–lb (0.3 N–m) Maximum torque: 5.2 in–lb (0.6 N–m) Figure 3-8 Installing CPU Module in a Series 505 Base To remove the CPU, complete the following steps. 1. If cables are attached, remove them from the front of the CPU. 2. Disconnect power to the base. 3. Loosen top and bottom bezel screws. 4. Carefully pull the CPU from the base.
3.9 Replacing and Handling the Battery Lithium Battery in the 545 and 555 –1105/–1106 CPUs The 545–1105/1106 and 555–1105/1106 CPUs use a lithium battery for maintaining CPU memory contents while power is not present. The lithium battery is a primary cell; it is not rechargeable. The battery in these CPU models is accessible through the bezel door on the front of the module, as shown in Figure 3-9.
Replacing the Battery in –1105/–1106 CPUs Follow these steps to replace the battery: 1. Maintain power to the CPU. 2. Open the battery cover. 3. Pull out the old battery and disconnect the battery connectors. 4. Connect the battery connectors to the replacement battery. 5. Place the new battery in the battery compartment, making sure the connecting wires are fully inserted through the holes in the compartment, and close the cover. 6.
Replacing and Handling the Battery (continued) Lithium Battery in the 545 and 555 –1103/–1104 CPUs The 545–1103/1104 and 555–1103/1104 CPUs use a lithium coin battery for maintaining CPU memory contents while power is not present. The battery is a Panasonic BR2325, PPX:2587678–8010, or equivalent, 23 mm diameter, with a nominal capacity of 165 mAh. The lithium battery is a primary cell; it is not rechargeable. Figure 3-11 shows the location of the battery on the CPU card.
Use the following safety instructions to minimize the risk of personal injury or fire hazard when handling lithium batteries. Using and Handling Batteries Lithium batteries contain flammable material. Do not open, puncture, or crush the battery case. Puncturing the battery case releases electrolyte and potentially flammable material. Exposure to electrolyte can cause throat and/or eye irritation.
Replacing and Handling the Battery (continued) ATTENTION: Danger of explosion if battery is incorrectly replaced. Replace only with the same or equivalent type recommended by the manufacturer. Discard used batteries according to the manufacturer’s instructions. ATTENTION: Il y a danger d’explosion s’il y a remplacement incorrect de la batterie. Remplacer uniquement avec une batterie du même type ou d’un type recommandé par le constructeur.
3. Remove the CPU from the chassis and place the CPU, component-side up, on a static-dissipative surface. The components in the CPU card can be degraded or destroyed by electrostatic discharge (ESD). Follow proper handling precautions in order to prevent ESD damage. 4. Remove the battery from the socket, observing the following precautions: ! WARNING The terminals of the lithium coin cell are extremely close together. In the course of removing the battery, it is possible for you to short the battery.
3.10 Setting the CPU Dipswitches Dipswitch Location and Settings Dipswitches are used to set 545/555 CPU operating parameters. The dipswitches are located near the front of the CPU, behind the bezel or battery door. See Figure 3-12. To gain access, lower the access door. With the CPU in its (normal) vertical position, dipswitches pushed to the left are On; dipswitches pushed to the right are Off.
Setting Baud Rates Switches 3 through 8 are used to set baud rates for Ports 1 and 2. Switches 3, 4, and 5 set Port 1 baud rates. See Table 3-3. Switches 6, 7, and 8 set Port 2 baud rates. See Table 3-4.
Setting the CPU Dipswitches (continued) The 545 and 555 CPUs have two communications ports. Both ports are configured as Data Terminal Equipment (DTE). Communications Port 1 SW2 selects Port 1 as either a programming port or a printer port on a 545/555 CPU. Port 1 uses an RS-232/RS-423 signaling protocol and an RS-232 pinout arrangement with an RS-423 (+5 V) signal level extending up to 50 feet (15 m). You can use a modem to extend this distance.
For Communication Port 2, the maximum permissible cable length depends on the type of connection used: • The RS-232/RS-423 connection can extend a maximum of 50 feet (15 m). • The RS-422/RS-485 connection can extend a maximum of 3300 feet (1 km). The cable installation for RS-485 or RS-422 can include a 120-ohm termination resistor across the signal conductors at each end of the cable. The resistor provides a higher noise immunity and better long-distance communication.
3.11 Installing Series 505 I/O Modules Mixing I/O Modules A mix of I/O modules can be used with one base: you can combine input, output, word input, word output, and intelligent modules in a single base. Installing and Removing I/O Modules Use the following steps for installing and removing Series 505 I/O modules in the base. (Refer to Figure 3-14.) ! WARNING Do not install or remove any modules to or from a powered-up base.
Figure 3-14 shows the installation of a module in a Series 505 base. Minimum torque: 2.6 in–lb (0.3 N–m) Maximum torque: 5.2 in–lb (0.6 N–m) Figure 3-14 Installing and Removing Modules in a Series 505 Base Two types of terminal block connectors are available for SIMATIC 505 input and output modules: the front-accessible 2587705–8011 terminal block and the side-accessible 2587705–8010 terminal block, as shown in Figure 3-16.
Installing Series 505 I/O Modules (continued) Figure 3-16 shows the two types of terminal block connectors that are available for SIMATIC 505 input and output modules. 2587705–8011 Front-accessible (shipped with module) 2587705–8010 Side-accessible (order separately) Maximum torque for terminal block screws: 5.0 in-lb (0.56 N-m) Caution: Applying excess torque or using a power screwdriver without torque limits may damage the connector.
Chapter 4 Installing 575 System Hardware 4.1 Overview of Installation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4.2 Features of the PPX:575–2130 VMEbus Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 4.3 Features Required of a Third-Party VMEbus Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 4.4 Enclosure and Temperature Considerations . . . . . . . . . . . . . . .
4.1 Overview of Installation Procedures The following chart identifies the tasks for installing 575 system hardware.
4.2 Features of the PPX:575–2130 VMEbus Base Overview The 575–2104, –2105, and –2106 CPUs are compatible with the PPX:575–2130 base, which accommodates any of the 575 power supply modules and up to sixteen 0.8-inch-wide VMEbus modules (including the system controller). The VMEbus 16-slot base also supports all of the 575 CPU and I/O modules. The PPX:575–2130 base conforms to the DIN 41494, IEC 297, and ANSI/IEEE 1014 standards that define the requirements for a VMEbus chassis.
4.3 Features Required of a Third-Party VMEbus Base VMEbus Base Requirements In order to use a 575 CPU in a third-party VMEbus base, the base must conform to the following requirements: • Each 575 CPU must be supplied with +5 V STDBY power, in order to avoid unpredictable operation. Table 4-5 in Section 4.15 and Table B-4 in Appendix B list the requirements for the 575 CPU that you are using.
4.4 Enclosure and Temperature Considerations Enclosure Selection An enclosure should provide the following features: • Easy access to components. • A common ground potential on the cabinet. • A secure vertical panel or rails. • Conformance to electrical standards. • An electromagnetic shield, if needed to meet FCC or CE emission standards. • Access restricted to authorized personnel only. • Adequate cooling and heat dissipation.
4.5 Installing the Fan Assembly Operating With Fan Assembly You can operate the PPX:575–2130 base with the fan assembly at standard rated power of each I/O module and the power supply at any ambient temperature up to 60°C. Refer to Appendix E for I/O module derating charts with and without forced air flow. Operating Without Fan Assembly Table 4-1 lists the requirements that apply when you set up your system without the fan assembly.
The 16-slot VMEbus base provides space under the lower module guiderails to install the optional 575 fan assembly (PPX:575–2131). The fan assembly has a switch, located on the rear panel, for selecting 110 or 220 VAC operation. Before mounting the fan assembly, ensure that the voltage setting on the fan assembly unit matches your input voltage, and connect power lines to the AC terminals. Selecting Voltage for Fan Operation Follow these steps to ensure voltage setting matches input voltage.
Installing the Fan Assembly (continued) Mounting the Fan Assembly Mount the fan assembly under the lower guiderails, attaching it with three screws (provided) to each side panel, as shown in Figure 4-2. Be sure to orient the fan assembly with the replaceable fuse at the front and the AC power connection and voltage selector switch at the rear of the unit.
Replacing Fuse on the Fan Assembly The fan assembly is fused to protect the hardware from over-voltage or other adverse power conditions. If you need to replace the fuse, use a 3 A, 3 AG, 11@4-in. x 1@4-in., 250 V, slow-blow fuse (PPX:2587679–8002). The fuse holder is located on the front panel of the fan assembly. To replace a fuse, follow these steps. ! CAUTION To minimize risk of shock hazard, always turn off all power from the fan assembly before changing the fuse.
4.6 Installing the PPX:575–2130 VMEbus Base Mechanical Outline Figure 4-4 shows the physical dimensions of the PPX:575–2130 VMEbus base. This base is designed to be mounted and operated in the horizontal orientation only. 19.0 (483) 17.68 (449) 9.58 (243) 12.22 (310) Measurements: in.
Mounting a Base in a 19-inch Rack Use the following steps for mounting a PPX:575–2130 base in a standard 19-inch rack. See Figure 4-6. 1. Move brackets from wall-mounting position (back of chassis) to front position. 2. Position the base in the 19-inch rack. Depth of base is 9.6 inches (244 mm); minimum depth required to install the base is 12 inches (305 mm). NOTE: Leave clearance of at least 3 inches (76 mm) above and below the base, and a clearance of 2.5 inches (64 mm) behind, for cooling. 3.
Installing the PPX:575–2130 VMEbus Base (continued) NEMA Cabinet Mounting Measurements Figure 4-7 shows the measurements required for rear mounting in a NEMA cabinet or mounting against a wall. Rear mounting brackets are included for these mounting options. The cabinet must provide a minimum depth of 12 inches to accommodate cabling from the front of installed modules. Leave clearance of at least 3 inches above and below the base for proper cooling. diameter 0.272 (6.9) 8 holes Measurements: in. (mm) 3.
4. Install #10 screws through each bracket hole to attach the base to the sub-panel. See Figure 4-8. Figure 4-8 Mounting Base in NEMA Enclosure Grounding the Controller Chassis A good grounding system is essential for proper operation of the 575 system. Follow the guidelines in Section 2.8 to ensure that the VMEbus base is properly grounded.
4.7 Installing the 575 Power Supply Overview Two power supplies are available for use in 575 bases: • The PPX:575–6660 power supply provides up to 185 W to the VMEbus base, and operates on 110 VAC input voltage. • The PPX:575–6663 power supply provides up to 300 W to the VMEbus base. It operates on either 110 or 220 VAC input voltage, depending on the position of the user-accessible jumper selector. Refer to Table 4-2 and Table B-4 to develop a system power budget.
Table 4-2 Power Supply Specifications Input Specifications PPX:575–6660 Power Supply PPX:575–6663 Power Supply Capacity 185 W1 300 W1 AC input voltage 110 VAC (85–132 VAC) 110/220 VAC, jumper selectable (85–132, 170–264 VAC) Input voltage frequency 47 to 63 Hz 47 to 63 Hz Input current maximum operating inrush overcurrent protection 5 A rms 50 A peak for up to 100 ms fuse provided 8 A rms 50 A peak for up to 100 ms fuse provided 8 A, 250 VAC, slow-blow, 3 AG fuse 10 A, 250 VAC, slow-blow 3 A
Installing the 575 Power Supply (continued) Selecting Input Voltage (PPX:575–6663 Only) If you have a PPX:575–6663 power supply module, ensure that your voltage selection matches your line voltage. To configure the module for 110 VAC or 220 VAC operation, use the jumper selector wire located on the power supply board. See Figure 4-9.
Installing the 575 Power Supply The 16-slot VMEbus base accepts either one of the 575 power supply modules, PPX:575–6660 and PPX:575–6663. To install a power supply module, align the metal backplate of the module in the metal guiderails on the left side of the chassis, as shown in Figure 4-10. Push firmly until the module is properly seated in the backplane connector and tighten the four securing screws at the corners of the faceplate.
Installing the 575 Power Supply (continued) Wiring Procedure Refer to Figure 4-11 and follow the steps below to connect input power to the VME power supply module. 1. Disconnect power to the base. ! WARNING To minimize risk of shock hazard, always turn off all power to the base before attempting the wiring procedure. Failure to turn off power could cause death or serious injury to personnel, and/or damage to equipment. Ensure that all power is disabled before attempting the wiring procedure. 2.
575–6663 575–6660 POWER GOOD SIMATIC 575 FAULT 575–6660 SIMATIC 575 575–6663 POWER GOOD FAULT +5 +12 –12 GND AC FAIL SYS RESET +5 +12 –12 GND AC FAIL SYS RESET POWER SUPPLY 185 WATT POWER SUPPLY 300 WATTS (W/FANS) 100 WATTS (W/O FANS) . UL 866Y LISTED IND CONTROL EQUIP . UL REPLACE ONLY WITH 8 AMP 250 VOLT SLOW BLOW FUSE APPROVED CLASS I DIV 2 HAZ. LOC.
4.8 Installing the Battery Battery Backup for the 575 For the 575 controller, a 4 V, 5 amp-hour (Ah) maintenance-free gel cell battery and cable are included with the base. The battery is continuously recharged by the power supply and maintains user memory and programming during a power loss. The 5 Ah battery will maintain the memory until the battery is depleted.
Rear panel Battery connector Break-away tab Figure 4-12 Mounting the Battery ! CAUTION Take care to avoid short-circuiting the battery. Use caution when working near the open terminals or cells when wearing metal rings or watchbands. Shorting results in dangerously high current flow that could cause severe burns and is a potential fire hazard. Placing metal articles (such as rings or watchbands) across shorted terminals could result in severe skin burns.
Installing the Battery (continued) Disabling the Battery The battery cable has a polarized connector to allow easy disconnection and re-connection of the battery. When you first power up your system, the battery must be disabled. To disable the battery, disconnect the battery connector shown in Figure 4-13 by squeezing the locking tabs to release them and then pulling apart the connector plugs.
4.9 Installing the Floating-Point Coprocessor (Optional) The 575–2104 CPU has a socket for a Motorola MC68882 floating-point coprocessor (12.5 MHz or faster). If you install a floating-point coprocessor in this socket, you may create external subroutines (XSUBs) to perform high speed floating-point calculations; (the 575–2104 operating system does not otherwise use the floating-point coprocessor). Installation of the math coprocessor (PPX:2589739–8010) is illustrated in Figure 4-14.
4.10 Configuring the CPU Configuring the 575–2105/–2106 CPU Before installing the 575–2105 or 575–2106 CPU board, you must configure the dipswitch on the 575 CPU board. The configuration options override any dipswitch settings that you may have made on an HSIO annex card or a PROFIBUS-DP annex card. Figure 4-15 shows the position of the configuration dipswitch on the 575–2105 and 575–2106 CPU boards. Table 4-3 lists the dipswitch configuration options.
Table 4-3 lists the configuration options you can select using the dipswitch on the CPU board (575–2105/–2106 CPUs) or on an HSIO annex card or a PROFIBUS-DP annex card when used with a 575–2104 CPU. These options are explained in more detail on the following two pages. Table 4-3 Dipswitch Configuration Options Switch 1–2 Switch Position Description On – On For 575–2126 annex card, selects remote I/O baud rate. Do not change. Off – Off For 505–CP5434–DP annex card, reserved for factory use.
Configuring the CPU (continued) Using the AUTO-CONFIGURED When SW6 is set to the On position, the CPU is in the AUTO-CONFIGURED mode. Mode • In the AUTO-CONFIGURED mode, the 575 Release 5.0 is compatible with 575 Releases 2.0 through 3.1. • In AUTO-CONFIGURED mode, a 575 CPU must be located in slot 1. During FAULT recovery, the 575 CPU in slot 1 issues SYSRESET*.
Setting the Base Address The positions of the BASE-ADDRESS switch pair, SW3 and SW4, determine the base address for the 575 system tables (A24 space) and the 575 Global Communication Status Registers, or GCSRs (A16 space). Issuing SYSRESET SW5 controls whether the primary 575 CPU issues SYSRESET* when changing from FAULT mode to PROGRAM mode.
4.11 Installing a Remote I/O Annex Card (Optional) There are two ways to connect your 575 CPU to remote I/O: • Use a PPX:575–2126 remote I/O annex card to connect the 575 CPU to Series 505 remote I/O by means of the Series 505 remote I/O channel. • Alternatively, you can use a PPX:505–CP5434–DP PROFIBUS-DP annex card to connect the 575 CPU to DP and Series 505 I/O by means of the PROFIBUS-DP I/O channel. You can only use one remote I/O annex card per 575 CPU.
Installing the Series 505 Remote I/O Annex Card To install the Series 505 remote I/O annex card (PPX:575–2126), follow the steps below. 1. Carefully set your CPU board on a static-dissipative surface. CAUTION Electronic equipment can be damaged by electrostatic discharge. Ensure that personnel make contact with a static-dissipative pad and/or wear a grounded wrist strap when handling the CPU cards or modules. 2.
Installing a Remote I/O Annex Card (continued) Installing the PROFIBUS-DP Annex Card To install the PROFIBUS-DP annex card (PPX:505–CP5434–DP), follow the steps below. 1. Carefully set your CPU board on a static-dissipative surface, and remove the PROFIBUS-DP port cover from the bezel. CAUTION Electronic equipment can be damaged by electrostatic discharge. Ensure that personnel make contact with a static-dissipative pad and/or wear a grounded wrist strap when handling the CPU cards or modules. 2.
575 VME CPU BAT RUN WDG MOB SYF PCG SERIAL PORT 1 FAULT RELAY I/O LINK SERIAL PORTS 2, 3, 4 Dipswitch PROFIBUS-DP 575–2104 Figure 4-17 Installing the PROFIBUS-DP Annex Card SIMATIC 545/555/575 System Manual Installing 575 System Hardware 4-31
4.12 Installing VMEbus Boards Introduction The guidelines in this section apply when you install boards into the local VMEbus base. CAUTION Never attempt to install Series 505 I/O in a VMEbus base. Doing so results in damage to equipment. Series 505 I/O is only available as an option for the remote bases in your 575 system. NOTE: You must adhere to VME addressing requirements for all the products that you install in the system.
Figure 4-18 provides an example of how boards might be used on a sample 575 system.
Installing VMEbus Boards (continued) General Guidelines 4-34 The following guidelines apply when installing the 575 CPU into the VMEbus base. • If you are using a 575–2105/–2106, ensure that you have correctly configured the dipswitch on the CPU board before installing the board into the VMEbus base. Refer to Section 4.10 for the configuration settings.
Guidelines for Installing a 575 System Controller or a Primary 575 Follow the guidelines and steps below when installing a 575 as system controller and/or as primary. NOTE: Read and abide by the warnings and cautions at the beginning of this section. 1. Ensure that all power is disconnected from the VMEbus base. 2. If the 575 CPU is to perform as the VMEbus system controller, install it in slot 1.
Installing VMEbus Boards (continued) Guidelines for Installing or Adding a 575 Secondary to the System A 575 secondary is any 575 CPU other than the primary 575 CPU. If you want to add a 575 secondary to your system, follow the steps below. NOTE: Read and abide by the warnings and cautions at the beginning of this section. 1. Ensure that all power is disconnected from the VMEbus base. It is not necessary to disconnect the battery to add a 575 secondary. 2.
Guidelines for Replacing a 575 System Controller A 575 system controller is any 575 CPU installed in slot 1. If you want to replace a 575 system controller, follow the steps below. NOTE: Read and abide by the warnings and cautions at the beginning of this section. 1. Before you remove the 575 system controller, save the memory of the system controller, any 575 secondaries, and any third-party masters. 2. Ensure that all power is disconnected from the VMEbus base and that the battery is disconnected.
Installing VMEbus Boards (continued) Guidelines for Replacing a 575 Primary Not in Slot 1 If you want to replace a 575 primary that is not in slot 1 (a 575 that has been configured as a primary by means of the primary switch (SW7) as described in Section 4.10), follow the steps below: NOTE: Read and abide by the warnings and cautions at the beginning of this section. 1. Before you remove the 575 primary, save the memory of the 575 primary, any 575 secondaries, and any third-party masters. 2.
Guidelines for Replacing a 575 Secondary A 575 secondary is any 575 that is not installed in slot 1 and is not configured by the dipswitch as a primary. If you want to replace a 575 secondary, follow the steps below: NOTE: Read and abide by the warnings and cautions at the beginning of this section. 1. If possible, save the memory of your system. 2. Ensure that all power is disconnected from the VMEbus base. You do not have to disconnect the battery to replace a 575 secondary. 3.
Installing VMEbus Boards (continued) Guidelines for Installing SIMATIC VMEbus I/O and Third-Party Boards 4-40 The following guidelines apply when you install SIMATIC VMEbus I/O and third-party boards: • Save the controller memory with TISOFT before you remove or install boards. • Do not leave any open slots between cards. Any open slots must be on the far right side of the base, unless you set the dipswitches on the backplane to bypass the empty slots. See Figure 4-20.
Setting the Daisy-Chain Switches VMEbus bases provide a daisy-chain interrupt feature which passes through every module installed in the base. When a base slot is skipped (i.e., left empty), this daisy chain is broken, unless provision is made to pass the signals across the empty slot. For this reason, the PPX:575–2130 16-slot VMEbus base provides a set of daisy-chain dipswitches to the immediate left of connectors J1 through J15 on the backplane.
Installing VMEbus Boards (continued) Installing and Removing I/O Modules Use the following steps for installing and removing SIMATIC VMEbus I/O modules in the base. (Refer to Figure 4-21.) ! WARNING To minimize risk of shock hazard, always turn off power to the base before removing or installing a power supply module. Installing or removing any module from a powered-up base could cause unexpected operation which could cause death or serious injury to personnel, and/or damage to equipment.
Figure 4-21 shows the installation of a module in a VMEbus base. Minimum torque: 2.6 in–lb (0.3 N–m) Maximum torque: 5.2 in–lb (0.
4.13 Wiring the Fault Relay The fault relay on the 575 CPU is a male 9-pin, D-shell connector that can be used with a low-voltage safety chain. Port pinouts and wiring are shown in Figure 4-22. 1 Circuit 1 2 Circuit 1 3 Circuit 2 4 Circuit 2 6 7 8 9 5 Figure 4-22 Fault Relay Wiring Two circuits are available, as shown in Figure 4-23. 1 2 Circuit 1 3 4 Circuit 2 Figure 4-23 Normally Open Contacts See Section 2.3 for an explanation of the operation of the fault relay and application examples.
4.14 Establishing CPU Communication Default Port Configurations The 575 CPU has four serial communication ports and initializes all four ports to 9600, 7 bits, odd parity, and 1 stop bit on battery-bad powerup. These communication ports remain in this configuration unless you change them. Port configuration can be changed using TISOFT 4.3 or later. Figure 4-24 shows the locations of the communication ports, and the optional PROFIBUS-DP connection.
Establishing CPU Communication (continued) Pinout for Serial Port 1 Figure 4-25 shows the pinout for Port 1 on the 575 CPUs. 14 15 16 17 18 19 DTR 20 21 22 23 24 25 1 2 3 4 5 Chassis GND TD RD RTS CTS 6 7 8 Signal GND DCD 9 10 11 12 13 Figure 4-25 Port 1 Pinouts Pinouts for Serial Ports 2, 3, and 4 Figure 4-26 shows the pinouts for Ports 2, 3, and 4 on the 575 CPUs.
Of the four serial communication ports on the 575 CPU, two are modem-compatible RS-232 ports (one for a printer and one for an operator interface), and one is an RS-422 operator interface port. The fourth RS-422 port is reserved for factory use. Serial Port 1 Port 1 is a DTE RS-232 port with modem control lines. It is the primary programming port. You can connect this port directly to most PC/AT serial ports. Refer to Figure 4-27 for connection information. Use this port for distances of up to 50 feet.
Establishing CPU Communication (continued) Serial Port 2/ Printer Port Port 2 is a DTE RS-232C port with modem control lines. Use this port with a serial printer. The CPU can send information to a printer through the use of an SF program or SF subroutine. You can set the baud rate of this port from 300 to 38,400 using TISOFT. You can wire the port to use XON/XOFF handshaking (Figure 4-28) or READY/BUSY handshaking (Figure 4-29).
Serial Port 3 Port 3 is an RS-422 port. This is the alternate programming port. You can connect it to a programming device that has an RS-422 interface, or you can use an RS-422-to-RS-232 converter and connect it to an RS-232 programming device. This port allows the programming device to be separated from the 575 by 100 meters.
4.15 Using Boards in the VMEbus Base Communicating with the CPU Refer to the SIMATIC 545/555/575 Programming Reference User Manual for details concerning communication support between 575 CPUs and third-party masters using VMEbus READ/WRITE instructions. Refer to the SIMATIC 575 Interboard Communication Specification (PPX:575–8103–x) for details on message support between 575 CPUs and third-party masters. Table 4-5 summarizes the VMEbus specifications for the 575 CPUs.
Battery Status If a 575 CPU is not in slot 1, then the system controller is responsible for informing the primary 575 CPU about battery status. The system controller writes a 255 (FF16), for battery good, or 0, for battery bad, to the battery status (BATGOOD) location at BASE-ADDRESS+4, where BASE-ADDRESS is the base address of the 575 system tables. (Refer to Section 4.11 of this chapter for additional information on BASE-ADDRESS.) This variable is an 8-bit integer (byte).
Using Boards in the VMEbus Base (continued) Table 4-6 Use of VME Address Space Function A24 Address Range A16 Address Range Notes Primary 575 (Application A) 00000016 – 0FFFFF16 000016 – 000F16 1 Secondary 1 (Application B) 10000016 – 1FFFFF16 001016 – 001F16 1 Secondary 2 (Application C) 20000016 – 2FFFFF16 002016 – 002F16 1 Secondary 3 (Application D) 30000016 – 3FFFFF16 003016 – 003F16 1, 2 . . . . . . . . .
Daisy-Chain Signals All VMEbus masters (including the 575 CPUs) require access to the VMEbus daisy-chain control signals, including the bus grant and interrupt acknowledge signals: • • • • IACKIN* IACKOUT* BG0IN* BG0OUT* • BG1IN* • BG1OUT* • BG2IN* • BG2OUT* • BG3IN* • BG3OUT* Refer to Table 4-7 for pinouts. Place any board that does not provide the BGxOUT* signals to the right of any board that requires these signals. All of the 575 boards (CPUs and I/O modules) pass through the daisy-chain signals.
Using Boards in the VMEbus Base (continued) Table 4-7 VMEbus J1 Backplane Connector Pin Assignments Pin Number Row A Row B Row C 1 D00 BBSY* D08 2 D01 BCLR* D09 3 D02 ACFAIL* D10 4 D03 BG0IN* D11 5 D04 BG0OUT* D12 6 D05 BG1IN* D13 7 D06 BG1OUT* D14 8 D07 BG2IN* D15 9 GND BG2OUT* GND 10 SYSCLK BG3IN* SYSFAIL* 11 GND BG3OUT* BERR* 12 DS1* BR0* SYSRESET* 13 DS0* BR1* LWORD* 14 WRITE* BR2* AM5 15 GND BR3* A23 16 DTACK* AM0 A22 17 GND AM1 A21
VMEbus Access Limitations When using the 575 CPU and third-party boards, you must be aware of the following limitations. • The 575 CPU VMEbus data strobe timeout is 40 microseconds. The third-party VMEbus boards must respond to a 575 request in less than 40 microseconds or VMEbus error occurs. Unless the MOVE instruction was used, this causes a fatal error. • VMEbus block transfers are not supported. Third-party boards may not use VMEbus block transfers to or from the CPU shared memory.
4.16 Installing Additional Backplane Connectors J2 Backplanes Certain VMEbus modules require the use of a second connector on the backplane to supply the additional current required for operation. J2 backplanes that conform to VMEbus standards can be installed in the PPX:575–2130 base. Two suppliers of J2 backplanes are the following: BICC-Vero Electronics, Inc. 1000 Sherman Avenue Hamden, CT 06514–1336 (203) 288–8001 or 800–BICC–VME U.S.A. SCHROFF, Inc.
Installing Optional J2 Backplane To install a J2 backplane, follow these steps: 1. Unplug the battery connector, unscrew the two battery retaining screws, and remove the battery from the rear of the unit. 2. Remove the 6 screws (3 per side) that hold the rear panel, and remove the rear panel from the unit (see Figure 4-31). 3. Remove the M2.5 x 10mm screws that hold the backplane spacers. 4. Mount the backplane with the spacers between the chassis rails and the backplane, using the M2.
Installing Additional Backplane Connectors (continued) Installing Optional J2 DIN Connector You can also install individual J2 DIN connectors to the backplane of the 575 VMEbus base. This allows you to provide J2 connection using wire wrap technology or flat ribbon cables without a J2 backplane assembly. For this option, you need to install VME Z-Rails (PPX:2589739–8016). To install a J2 connector, follow these steps: 1.
Chapter 5 Installing Remote Base Controllers–RBCs 5.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 5.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Models Used in Series 505 Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Overview Through the Series 505 remote I/O channel, your CPU can communicate to Series 505/Series 500 remote I/O modules by means of an RBC. The PROFIBUS-DP I/O channel allows you to communicate not only to SIMATIC and third-party DP I/O, but to Series 505 remote I/O modules in a Series 505 base by means of a DP RBC, the PPX:505–6870. Figure 5-1 shows the RBC models available for each I/O channel and base type.
5.2 Installation Models Used in Series 505 Base RBC Placement in Base The following RBCs can be installed in a Series 505 base. • PPX:505–6870, communicates over PROFIBUS-DP I/O channel using 12 Mbaud RS-485 cable. (Note: Series 505 Special Function modules cannot be used in a DP base.) • PPX:505–6851–A/B, communicates over Series 505 remote I/O channel using 1 Mbaud RS-485 cable. This RBC can be used in a redundant configuration (i.e.
Installation (continued) Installing and Removing the RBC Use the following steps to install an RBC in a Series 505 base. ! WARNING Installing or removing an RBC from a powered-up base disrupts your process. Installing or removing an RBC from a powered-up base could cause unexpected operation which could cause death or serious injury to personnel, and/or damage to equipment. Ensure that all power is disabled before installing or removing the RBC.
5.3 Communication Ports Series 505 RBCs, including the 505 PROFIBUS-DP RBC, have two communication ports. RS-232 Port The RS-232 port is an interface to programming devices that use software like TISOFT or other configuration tools. To connect your RBC to a programming device/modem, use a standard 9-pin RS-232 serial cable that conforms at a minimum to the pinouts shown in Figure 5-3.
5.
JP6 Freeze Dipswitch (SW2) for setting baud rate Outputs off (default) OFF/FRZ Jumper (JP6) Figure 5-4 Off/Freeze Jumper Location on the –A Model RBCs Dipswitch (S2) for setting baud rate OFF/FRZ Jumper (JP6) JP6 Baud Rate 19200 9600 2400 1200 300 Switch 1234 1101 1111 0111 1011 0011 Freeze Outputs off (default) Figure 5-5 Position of OFF/FRZ Jumper and Baud Rate Switch on the –B Model RBCs SIMATIC 545/555/575 System Manual Installing Remote Base Controllers—RBCs 5-7
PPX:505–6851–A/B and PPX:505–6850–A/B RBCs (continued) Dipswitch Options Dipswitch SW2 (S2 on the –B version) is used to set RS-232/423 baud rates. Figure 5-6 shows the location of the baud rate dipswitch on the RBC card. Off Dipswitch for setting baud rate On 1 2 3 Bezel 4 Backplane connector Figure 5-6 RBC Dipswitch Location Table 5-2 shows how to set the switches to select the desired baud rate.
Series 505 Base Numbers Changing the RBC Base Number The base containing the Series 505 CPU and local I/O is designated base 0. You can connect up to 15 remote bases to your Series 505 system, numbered 1 through 15. If you are using more than one RBC, each RBC must be uniquely numbered. (Figure 5-7 shows the location of the base number switch on the front of the RBC models.) • A thumbwheel switch on the –A version RBC is used to assign the base number.
PPX:505–6851–A/B and PPX:505–6850–A/B RBCs (continued) REMOTE BASE CONTROLLER REMOTE BASE CONTROLLER Status display STATUS STATUS 0 - RBC GOOD 1 - SELF DIAG FAILURE 2 - MODULE MISMATCH 3 - I/O COMM TIME OUT 4 - RAM PARITY ERROR 5 - STANDBY, NO CONF 6 - ADDR MISMATCH 7 - COMM OK, NO CONF 8 - WATCHDOG TIME OUT C - STANDBY, CONF 0 - RBC GOOD 1 - SELF DIAG FAILURE 2 - MODULE MISMATCH 3 - I/O COMM TIME OUT 4 - RAM PARITY ERROR 5 - STANDBY, NO CONF 6 - ADDR MISMATCH 7 - COMM OK, NO CONF 8 - WATCHDOG TIME OU
Resetting the RBC The following actions take place when an RBC is reset. • The CPU logs the RBC off the system and zeroes the image register points which represent the inputs from this RBC’s base. The image register is zeroed out until the RBC completes reset and resumes communication with the CPU. If this occurs while the system is operating, depending on your RLL program, turning these inputs off could affect other base outputs.
PPX:505–6851–A/B and PPX:505–6850–A/B RBCs (continued) Status Display The display at the top of the module (see Figure 5-8) indicates the status of the RBC. See Table 5-4 for the definition of status displays.
Table 5-4 RBC Status Codes (continued) Display Definition 4 RAM Parity Error 5 Standby, No Configuration Communications to this RBC Comment/Action None The RBC has detected an internal RAM parity error. Action: Serious malfunction. Place the system in a safe state and consult Siemens Technical Support. (In the U.S.A., call 423–461–2522.) OK Standby RBC in dual-media application has no configuration. Action: Configure the RBC. 6 Address Mismatch OK Address switch setting is incorrect.
5.5 PPX:505–6870 RBC User options, switch settings, status displays, and base address configuration vary with RBC model. The options for the 505 PROFIBUS-DP RBC, PPX:505–6870, are described in this section; see Section 5.4 for a description of PPX:505–6851–A/B and PPX:505–6850–A/B options. (Series 505 Special Function modules cannot be used in a DP base.
Freeze Outputs off (default) Dipswitch Jumper E1 for setting output state (Off/Freeze) RESET pushbutton (recessed) Jumper E2 Header E4 Jumper E3 Figure 5-9 RBC Jumper Locations Notice, in Table 5-5, 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.
PPX:505–6870 RBC (continued) Dipswitch Options You can select the RS-232/423 baud rate, RBC station address, and display mode of the RBC status display by setting a dipswitch that is accessible from the bezel of the RBC. Figure 5-10 shows the location of the dipswitch.
Baud Rate for the RS-232 Port Switches 1 through 3 on the dipswitch control the baud rate of the RS-232/423 port. Table 5-6 lists the baud rates available. Invalid selections cause the RBC to report an error on the Status Display and cause the RS-232/423 port to default to 9600 baud. The RS-232/423 baud rate switch settings are read only on power-up or after pressing the reset button. NOTE: The RS-232 port is disabled by default.
PPX:505–6870 RBC (continued) Table 5-7 Setting the RBC Station Address Switch Number/State Station Address 4 5 6 7 8 9 Sta. 0* 0 0 0 0 0 Sta. 1 0 0 0 0 Sta. 2 0 0 0 Sta. 3 0 0 Sta. 4 0 Sta. 5 Switch Number/State 10 Station Address 4 5 6 7 8 9 10 0 0 Sta. 33 0 1 0 0 0 0 1 0 0 1 Sta. 34 0 1 0 0 0 1 0 0 0 1 0 Sta. 35 0 1 0 0 0 1 1 0 0 0 1 1 Sta. 36 0 1 0 0 1 0 0 0 0 0 1 0 0 Sta.
Table 5-7 Setting the RBC Station Address (continued) Switch Number/State Station Address 4 5 6 7 8 9 Sta. 66 1 0 0 0 0 Sta. 67 1 0 0 0 Sta. 68 1 0 0 Sta. 69 1 0 Sta. 70 1 Sta. 71 Switch Number/State 10 Station Address 4 5 6 7 8 9 10 1 0 Sta. 96 1 1 0 0 0 0 0 0 1 1 Sta. 97 1 1 0 0 0 0 1 0 1 0 0 Sta. 98 1 1 0 0 0 1 0 0 0 1 0 1 Sta. 99 1 1 0 0 0 1 1 0 0 0 1 1 0 Sta. 100 1 1 0 0 1 0 0 1 0 0 0 1 1 1 Sta.
PPX:505–6870 RBC (continued) Reset Pushbutton The RESET pushbutton on the front of the RBC is deliberately recessed to prevent accidental activation. When you press this button, a global reset is immediately performed on the RBC. After completing reset, the RBC assumes the RS-232 baud rate stipulated by the setting of switches 1 through 3 on the dipswitch, and the station address indicated by switches 4 through 10.
When the CPU logs an RBC off the system, it sets a corresponding bit in one of the status words that are available to your RLL program. Your RLL program can use these bits to detect the loss of the RBC and control the outputs of other bases as appropriate for your application. For details about status words and more information about programming, refer to the SIMATIC 545/555/575 Programming Reference User Manual.
PPX:505–6870 RBC (continued) Status Display Mode Switch 11 on the dipswitch controls the display mode of the RBC Status Display to show either station address or module status. • When switch 11 is set to 1, the station address of the RBC is displayed as a three-digit number, one digit at a time. The display goes blank for a short period of time between each digit and for a long period after the last digit.
Table 5-8 505 PROFIBUS-DP RBC Status Codes (continued) Display Definition Communications to This RBC Comment/Action 3 No Communications None The RBC detects no PROFIBUS-DP I/O channel activity. Action: Place the system in a safe state and check the connection to the PROFIBUS-DP I/O channel. Ensure that other PROFIBUS-DP I/O channel devices are powered and not reporting errors. 4 No Operational Firmware None Firmware is missing. Action: Download new firmware into Flash Memory.
PPX:505–6870 RBC (continued) Setting User Parameters for the 505 PROFIBUS-DP RBC The 505 PROFIBUS-DP RBC has parameters that are specified using the COM PROFIBUS configuration utility software. Refer to the SIMATIC 505 TISOFT2 User Manual and the SIMATIC S5 ET 200 Distributed I/O System Manual for information about using COM PROFIBUS. Table 5-9 describes the parameters used to set up the 505 PROFIBUS-DP RBC in COM PROFIBUS.You set these parameters by selecting the “Parameterize” dialog box in COM PROFIBUS.
Chapter 6 Cabling and Wiring the System 6.1 6.2 6.3 6.4 6.5 Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cable Routing Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Cable Routing Guidelines Cable Routing Methods Follow these suggestions when planning your cable routing. • Allow for system growth. Provide for attachment of future I/O bases by routing cable through all possible areas of plant expansion. • Take steps to bypass or eliminate noise sources in order to reduce system data error rates. The following are common sources of electrical noise.
Under-Floor Routing In-Ceiling Routing In under-floor routing, the cable can be enclosed in ducts or, with raised flooring, in the open air. • Duct systems are better protected against unauthorized taps or terminal blocks, but expansion is more difficult and expensive than with open air systems. • Open air systems provide more freedom of access, and allow maximum system expansion and flexibility.
6.2 Installing Series 505 Remote I/O Cables Media Options There are two media options for Series 505 remote I/O cabling: • Non-redundant I/O cabling using twisted pair (RS-485) media • Redundant I/O cabling using coaxial (RF) media This section describes the twisted pair media. If you are installing a coaxial I/O system, see the description of the RS-485/RF converter in Appendix C, and follow the instructions in the SIMATIC 505 Redundant I/O Systems User Manual, PPX:505–8125–x.
Trunk and Drop Lines Use RS-485 cabling for the trunk and drop lines that connect the various hardware items in your system. Trunk line refers to the cable that is used to connect terminal blocks to one another; drop line refers to the cable that connects a CPU or RBC to the trunk line by means of a terminal block. See Figure 6-1.
Installing Series 505 Remote I/O Cables (continued) Selecting Cable Three commercially available cables provide an acceptable level of I/O communication in an industrial environment. • Beldenr cable 9860 is a large conductor cable that provides a low attenuation and distortion for long trunk lines. • Belden cable 9271 is a smaller and more flexible cable suitable for short trunk lines and all drop line cables. • Belden cable 9182 provides an intermediate level of size, flexibility, and useful length.
Table 6-1 lists the characteristics of the Belden cables recommended for Series 505 installations. Table 6-1 Series 505 Cable Characteristics Belden Cable Type Center Conductor Outside Impedance Capacitance Velocity Diameter 9860 16 AWG solid 13.8 ohm/km 0.44 in. 11.2 mm 124 ohms 35.8 pf/m 0.78 c 9271 25 AWG 7x33 104.3 ohm/km 0.24 in. 6.1 mm 124 ohms 40 pf/m 0.66 c 9182 (89182) 22 AWG 19x34 46 ohm/km 0.35 in. 8.9 mm 150 ohms 28.9 pf/m 0.
Installing Series 505 Remote I/O Cables (continued) Planning Your Installation Follow these guidelines when installing Series 505 RS-485 trunk and drop line cabling. • Measure the maximum length (consult Table 6-2) from the CPU to the most distant tap. See Figure 6-2. C P U *Terminating Resistor *Terminating Resistor Maximum Trunk Length T T T T T = Terminal Block *A terminating resistor (shown in Figure 6-8) must be installed on the end terminal blocks.
• Drop lines should be no longer than 33 feet (10 m). • Short drop lines of 3.3 feet (1 m) do not measurably affect signal quality and do not have to be counted for the length reduction shown in Table 6-2. The maximum permissible trunk length depends on the cable type used and the number of terminal blocks in your installation. See Table 6-2.
Installing Series 505 Remote I/O Cables (continued) • Where several connections need to be made close together, it is better to place a single terminal block in the trunk line and connect all nearby equipment to that terminal block. See Figure 6-4. Make multiple connections like this... ... or this... T Remote Base Remote Base Remote Base T Remote Base Remote Base Remote Base T T T Remote Base Remote Base Remote Base ... but not like this.
• Tap connections on the trunk line should be spaced, on average, so that the total length of trunk cable separating several taps is greater than the sum of the total length of drop cables connected at the taps. See Figure 6-5. L3 T T L1 L2 Remote Base Remote Base L3 > (L1 + L2) Figure 6-5 Spacing between Taps • The ideal cable installation is a single, unbranched trunk line with short drop cables and a termination resistor at each end of the trunk.
Installing Series 505 Remote I/O Cables (continued) Preparing Drop Line Cables Use the following procedures to attach a D-connector and terminal lugs to your drop line cable: 1. Strip back 1.50 inches (38 mm) of the sleeving on one end of the cable. There are three wires when the sleeving is stripped back; two wires have color-coded insulation jackets and one (the shield) is bare. 2. Remove 0.13 in. (3.3 mm) of each color-coded insulation jacket to expose the bare wires. 3.
4. Strip back 1.50 in. (38 mm) of the sleeving on the other end of the cable. 5. Remove 0.13 in. (3.3 mm) of each color-coded insulation to expose the bare wires. 6. Install each wire end onto a terminal lug according to directions provided by the vendor. The size of the terminal lug depends on the type of terminal block used. Consult your vendor for the appropriate terminal lug size. Remote I/O Port Pinout Figure 6-6 shows the pinout for the I/O Link port on Series 505 CPUs and RBCs.
Installing Series 505 Remote I/O Cables (continued) Connecting a Drop Line Use the following procedure to connect a drop line cable between a CPU or RBC and the Series 505 terminal block. 1. Prepare a cable as described on page 6-12. 2. Plug the cable D-connector into the I/O connector of the CPU or RBC. 3. Tighten the two cable connector screws to secure the cable D-connector to the I/O connector of the CPU or RBC. 4.
5. Tighten terminal block screws. 6. If you are not using another terminal block, install a terminating resistor across the terminal screws securing the cable wires with the color-coded insulation jacket. See Figure 6-8. NOTE: The terminating resistor value depends on the type of cable being used. See Table 6-3.
Installing Series 505 Remote I/O Cables (continued) Preparing Trunk Line Cables Use the following procedure to prepare Series 505 trunk line cables. 1. Strip back 1.50 inches (38 mm) of the sleeving on both ends of the cable. There are three wires when the sleeving is stripped back; two wires have color-coded insulation jackets and one (the shield) is bare. 2. At both ends of the cable, remove 0.13 in. (3.3 mm) of each color-coded insulation jacket (both ends) to expose the bare wires. 3.
Connecting Trunk Line Cables To connect a trunk line cable to a terminal block, follow the steps below. Refer to Figure 6-9. 1. Loosen three terminal screws on the terminal block. 2. Install the terminal lugs at the cable end onto the terminal screws. NOTE: Throughout your installation, make connections carefully to prevent wire mismatches.
Installing Series 505 Remote I/O Cables (continued) Extending Trunk Line Cables The following procedure assumes you have connected one segment of trunk line to a terminal block, and wish to add a second segment in order to extend your installation. Refer to Figure 6-10. 1. Loosen the three terminal screws on terminal block A and install the second set of cable terminal lugs onto the terminal block. NOTE: Ensure that the wires of the second set of terminal lugs match with those of the first set: e.g.
Trunk line Trunk line TX/RX+ Trunk line TX/RX+ TX/RX+ Terminal Block A Terminating resistor Terminal Block B TX/RX+ I/O Link port of CPU or RBC Drop line TX/RX+ I/O Link port of CPU or RBC Drop line TX/RX+ TX/RX+ Figure 6-10 Extending and Terminating Trunk Line SIMATIC 545/555/575 System Manual Cabling and Wiring the System 6-19
6.3 Installing PROFIBUS-DP I/O Cables Media Options The PROFIBUS-DP I/O channel provides serial communication over either of the following: • Shielded twisted pair (RS-485) cable media • Glass or plastic fiber optic media This section describes the twisted pair RS-485 cable. If you are installing a glass or plastic fiber optic system, follow the instructions in the SINEC L2/L2FO Network Components Manual, order number 6GK1 970–5CA00–0AA1.
Equipment Needed Standard PROFIBUS-DP cable, connectors, and repeaters are available from Siemens to cable and wire your installation. The components listed in Table 6-4 are recommended for all installations. They support baud rates from 9.6 kbaud through 12 Mbaud.
Installing PROFIBUS-DP I/O Cables (continued) PROFIBUS-DP Cable and Connector Specifications Table 6-6 lists the PROFIBUS DIN 19245 cable line specifications. Table 6-6 PROFIBUS-DP Cable Specifications Parameter PROFIBUS-DP Line Length Limits Value Impedance 135–165 Ohm (3–20 MHz) Capacitance 9.1 pF/ft. Resistance 33.5 W/1000 ft. Attenuation 0.27 dB/100 ft. (0.9 dB/100 m (f=200kHz)) Conductor Area 20–22 AWG Cable Diameter 0.315 in. " 0.02 in. (<30 nF/km) (<110 Ohm/km) (0.3 mm2 ... 0.
Installing PROFIBUS-DP Cable The rules for proper PROFIBUS-DP installation follow: • Create a daisy-chain arrangement, not a star arrangement. A daisy chain has two connectors with a single cable (bus wire) connection; all other connectors (if any) have two cable (bus wires) connections. • You can connect up to 32 devices on one cable segment. Repeaters count as devices. • Do not run the cables near power wires.
Installing PROFIBUS-DP I/O Cables (continued) Termination and Bias The device at each extreme end of a PROFIBUS-DP cable must be terminated and biased; any connections made between extreme cable ends must not be terminated or biased. See the examples below. If a CPU with PROFIBUS-DP interface is located at an extreme end of the cable, it must be terminated and biased. The device at the other end of the cable must be terminated and biased. See Figure 6-12.
Using a Termination Selection Switch Siemens PROFIBUS-DP connectors have selectable termination and bias built in. The connectors designed to handle baud rates from 9600 baud to 12 Mbaud (see Table 6-4) have an external switch: see Figure 6-14. The low baud-rate connectors (9600 baud to 1.5 Mbaud; Table 6-5) have an internal switch: see Figure 6-15. In both cases, you set the selection switch to the On position to enable termination and bias, or Off to disable termination and bias.
Installing PROFIBUS-DP I/O Cables (continued) PROFIBUS-DP Connector Schematics Figure 6-16 shows the schematic for PROFIBUS-DP connectors designed to handle all baud rates, from 9600 baud to 12 Mbaud (as listed in Table 6-4).
Figure 6-17 shows the schematic for connectors designed only to handle low baud rates, from 9600 baud to 1.5 Mbaud (as listed in Table 6-5).* Pin 6 (BIAS SUPPLY +5V) Bias Resistor, 390 ohm, 1/8 W, 5% Pin 3 (TX/RX+) Internal Connection B Internal Connection B Termination Resistor, 220 ohm, 1/8 W, 5% Pin 8 (TX/RX–) Internal Connection A Internal Connection A Bias Resistor, 390 ohm, 1/8 W, 5% Pin 5 (BIAS SUPPLY GND) Pins 1, 2, 4, 7, and 9 are not connected. Figure 6-17 9600 baud to 1.
Installing PROFIBUS-DP I/O Cables (continued) Installing a PROFIBUS-DP Connector The following procedure describes how to attach a typical connector to your cable. Also consult the instructions that come with your specific Siemens connector. 1. Open the connector housing by loosening both housing screws (see Figure 6-18). 9-pin D-connector External Termination Switch ON OFF Cable guide Housing screws Figure 6-18 Typical PROFIBUS-DP Connector 2. Remove the cover of the housing. 3. Remove 1.
4. Remove a 0.75-inch (19 mm) portion of the cable shielding to expose the two signal wires. To ensure that the connection is properly grounded, you must leave enough exposed cable shielding (0.5 inches, 13 mm) to make a proper contact with the metal cable guide on the connector. See Figure 6-19. 5. Remove 0.25 inches (6 mm) of insulation at the wire ends. 6. Insert the signal wires into the cable terminals.
Installing PROFIBUS-DP I/O Cables (continued) 8. Put the cover back on the connector housing. Be sure that the bare cable shielding makes contact with the metal cable guide on the connector, to ensure proper grounding for the connection. 9. 6-30 Tighten the connector housing screws to a maximum torque of 8 in–lb (0.9 N–m) in order to ensure a good connection.
PROFIBUS-DP Port Pinout Figure 6-21 shows the pinout for the PROFIBUS-DP port for the products (e.g., CPUs, RBCs) that are described in this manual. NOTE: Pins 2 and 7 are “No Connect” for the products described in this manual. For some PROFIBUS products, these pins are used to provide 24 VDC for powering a programming or configuration tool. Such tools are not powered by the products described in this manual.
6.4 Connecting Modems Overview 545, 555, and 575 CPUs can communicate through Port 1 (RS-232) to an operator interface or programming station through a dedicated line or dial-up phone modems. Dedicated line operation is a line used exclusively to connect the modems. Dial-up phone operation connects the modems by telephone lines. Refer to Figure 6-22 for a typical configuration.
Dedicated Line Operation Use these procedures to establish communication between modems in a dedicated line configuration. 1. Connect the modem configuration. 2. Ensure that the CPU and modem baud rates are set to the same value. NOTE: If the modems are auto-bauding, ensure that the CPU baud rate is set within the baud rate range of the modems. Dial-up Phone Line Operation 3. Power up the modems and verify that they are connected, usually by consulting an indicator on the modems. 4.
6.5 Connecting to a Printer Overview 545, 555, and 575 CPUs have the capability to send information to a printer through the use of an SF program or SF subroutine. The printer connects to a serial port and uses RS-232 protocol. 545/555 Printer Connections The 545/555 CPU uses Port 1 for printer operations and the two available printer handshaking options are as follows: • XON/XOFF printer handshaking; see Figure 6-23. • READY/BUSY printer handshaking; see Figure 6-24.
575 Printer Connections The 575 CPU uses Port 2 for printer operations. You can set the baud rate of this port using TISOFT. The two available printer handshaking options are as follows: • XON/XOFF printer handshaking; see Figure 6-25. • READY/BUSY printer handshaking; see Figure 6-26. 1 14 2 TD RD 3 RD TD RTS 4 CTS 5 7 DTR Serial Printer GND 20 8 DCD RTS Not required for all printers.
Chapter 7 Using EEPROMs for Program Storage 7.1 Program Storage Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . On-Board Flash EEPROM Program Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Optional Portable (E)EPROM Program Storage . . . . .
7.1 Program Storage Options Overview You can download your program into a non-volatile, read-only memory chip for additional program security. Program storage options include portable Electrically Erasable Programmable Read-Only Memory (EEPROM) or Erasable Programmable Read-Only Memory (UV-erasable EPROM) chips and permanent on-board EEPROMs. On-Board Flash EEPROM Program Storage The CPUs listed in Table 7-1 provide on-board, permanent, non-volatile flash EEPROM memory for program storage.
EEPROM Portability EEPROMS are portable if, and only if, they meet the following criteria: • The firmware of the CPU on which the EEPROM was created is compatible with the firmware of the destination CPU. EEPROMs created with firmware from Release 1.x through Release 3.x are compatible forward and backward. However, Release 4.0 is not backward-compatible; you can use EEPROMs created under earlier firmware on a Release 4.0 CPU, but you cannot take an EEPROM created under Release 4.
Program Storage Options (continued) What is Stored in Non-Volatile Memory The EEPROM stores the following elements of the user program: • Relay ladder logic (RLL) • K-memory • U-memory • S-memory (PID loops, analog alarms, and SF programs) • Memory configuration • I/O configuration • Password, if installed • Scan configuration NOTE: The current values for timer, counter, and drum presets (TCP, DSP, and DCP) are not copied to the EEPROM.
Program Storage Operations Memory and Mode Status at Powerup You can manage operation of EEPROMs by using SoftShop (select the menu command PLC Utilities → PLC Operations) or TISOFT AUX 84 on your programming unit. Your programming package allows you to do the following procedures: • Copy RAM to EEPROM. • Copy EEPROM to RAM. • Select RAM as program source. • Select EEPROM as program source. • Erase the program in EEPROM. • Report source (RAM OR EEPROM) of program being executed.
7.2 Configuring the CPU for Non-Volatile EEPROM Program Storage Configuring the CPU for Portable EEPROM Usage Follow the instructions in this section to configure and install an EEPROM in your 545 or 555 CPU. (The 575 CPUs do not support this option.) NOTE: If you are installing an EEPROM and intend to download a program (from RAM memory), ensure that the back-up battery is enabled and good (BATT GOOD LED is on).
Note location of notches Figure 7-1 (E)EPROM Socket and Jumper Pins for –1103/–1104 CPUs E16 E20 E18 Note location of notches Figure 7-2 (E)EPROM Socket and Jumper Pins for –1105/–1106 CPUs SIMATIC 545/555/575 System Manual Using EEPROMs for Program Storage 7-7
Configuring the CPU for Non-Volatile EEPROM Program Storage (continued) Configuring the CPU for On-Board EEPROM Usage The 575 CPUs require no configuration to store programs in non-volatile memory. The 545/555–1105 and –1106 CPU models are configured at the factory to enable the permanent on-board EEPROM as the default program storage option. If you have not changed the board configuration, skip this procedure, and refer to Section 7.3 to copy a program into the on-board flash EEPROM.
E16 E20 E18 Figure 7-3 Jumper Pin Settings for On-Board Memory Program Storage SIMATIC 545/555/575 System Manual Using EEPROMs for Program Storage 7-9
7.3 Copying a Program into an EEPROM Ensure that you have configured the CPU to select the desired EEPROM, portable or on-board (refer to Section 7.2), and then continue with the steps listed below. 1. Enter the program into the CPU. Verify that your program is correct, and save your program to your programming unit hard disk. 2. Set the CPU to PROGRAM mode. 3. Select the TISOFT auxiliary function AUX 84 (or select the menu command PLC Utilities → PLC Operations in SoftShop). 4.
If an error occurs during the copy process it will be listed on the programming unit. If an error occurs, perform the following checks: • Ensure that the EEPROM jumper pin programming enable strap is installed correctly (on the 545 or 555 CPUs). • Ensure that an EEPROM, not an EPROM, is installed (on the 545 or 555 CPUs). • Ensure that all EEPROM pins are properly seated in the socket.
7.4 Editing a Program Stored in an EEPROM You can edit the program and data stored in an EEPROM by following the steps listed below. NOTE: If necessary, refer to your SIMATIC 505 TISOFT2 User Manual for detailed instructions about executing TISOFT AUX functions. 1. Set the CPU to PROGRAM mode. 2. Using your programming unit and the TISOFT auxiliary function AUX 84 option, select EEPROM as the program source. This will copy the EEPROM program to RAM.
Chapter 8 Starting Up the System 8.1 8.2 Powering Up the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Start-up Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1 Powering Up the System Overview This section provides general guidelines for powering up your system. ! WARNING You must be fully informed about safety procedures before you power up the system. Failure to follow safety guidelines could result in death or serious injury to personnel, and/or damage to equipment. Review and comply with the safety procedures listed in Chapter 2 before completing the following steps.
2. Initialize the CPU by completing the following procedures: • If you have not already done so, disable the CPU battery. (For 545/555 CPUs, turn off switch 9 on the CPU front dipswitch. For 575 CPUs, disconnect the battery.) • Turn on power to the base. • With the battery disabled and an unprogrammed (E)EPROM, the CPU clears memory and enters PROGRAM mode. • Enable the battery backup circuit by turning on switch 9. The battery LED should light. The CPU is now initialized.
8.2 CPU Memory Configuration Memory Configuration The CPU user memory is user configurable. The actual ranges of memory types depend upon how the memory has been configured. Ranges for memory types are listed by CPU model in Table 8-1 through Table 8-7. You can increase the memory allocated to a particular memory type, a block at a time, up to the maximum listed. Block sizes vary with the memory type. Refer to the table for your CPU.
Table 8-2 545–1104/–1106 CPU Memory Configuration Block Allocation Size Memory Required per Block Minimum Size Maximum Size Total Memory Required for Maximum Size Default Allocation — — — 192 Kbytes — — Ladder (L) 1 Kbyte 3 Kbytes 1 Kbyte 59 Kbytes 177 Kbytes 32 Kbytes Variable (V) 1 Kbyte 1 Kbyte 1 Kbyte 177 Kbytes 177 Kbytes 52 Kbytes Constant (K) 1 Kbyte 1 Kbyte 0 Kbytes 176 Kbytes 176 Kbytes 0 Kbytes Special (S) 1 Kbyte 1 Kbyte 0 Kbytes 176 Kbytes 176 Kbytes 32 Kby
CPU Memory Configuration (continued) Table 8-4 555–1104 CPU Memory Configuration Block Allocation Size Memory Required per Block Minimum Size Maximum Size Total Memory Required for Maximum Size Default Allocation — — — 1920 Kbytes — — Ladder (L) 1 Kbyte 3 Kbytes 1 Kbyte 635 Kbytes 1905 Kbytes 32 Kbytes Variable (V) 1 Kbyte 1 Kbyte 1 Kbyte 1905 Kbytes 1905 Kbytes 52 Kbytes Constant (K) 1 Kbyte 1 Kbyte 0 Kbytes 1904 Kbytes 1904 Kbytes 0 Kbytes Special (S) 1 Kbyte 1 Kbyte 0
Table 8-6 555–1106 CPU Memory Configuration Block Allocation Size Memory Required per Block Minimum Size Maximum Size Total Memory Required for Maximum Size Default Allocation — — — 1856 Kbytes — — Ladder (L) 1 Kbyte 3 Kbytes 1 Kbyte 614 Kbytes 1842 Kbytes 32 Kbytes Variable (V) 1 Kbyte 1 Kbyte 1 Kbyte 1841 Kbytes 1841 Kbytes 52 Kbytes Constant (K) 1 Kbyte 1 Kbyte 0 Kbytes 1840 Kbytes 1840 Kbytes 0 Kbytes Special (S) 1 Kbyte 1 Kbyte 0 Kbytes 1840 Kbytes 1840 Kbytes 32
CPU Memory Configuration (continued) Table 8-8 575–2105 CPU Memory Configuration Block Allocation Size Memory Required per Block Minimum Size Maximum Size Total Memory Required for Maximum Size Default Allocation — — — 832 Kbytes — — Ladder (L) 1 Kbyte 3 Kbytes 1 Kbyte 273 Kbytes 819 Kbytes 64 Kbytes Variable (V) 1 Kbyte 1 Kbyte 1 Kbyte 817 Kbytes 817 Kbytes 52 Kbytes Constant (K) 1 Kbyte 1 Kbyte 0 Kbytes 816 Kbytes 816 Kbytes 0 Kbytes Special (S) 1 Kbyte 1 Kbyte 0 Kbytes
Chapter 9 Troubleshooting 9.1 Troubleshooting by Using Auxiliary Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power-up Restart, Partial Restart, and Complete Restart . . . . . . . . . . . . . . . . . . . . . . . . . . 575 Fault Restarts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.1 Troubleshooting by Using Auxiliary Functions Overview The troubleshooting information in this chapter is generic unless a specific CPU is stipulated. The CPUs have self-checking and diagnostic capabilities that can be used for troubleshooting. The diagnostics and self-checks are accessible through the Auxiliary Function menu on your TISOFT programming device.
Table 9-1 shows the effects of using AUX 10, AUX 11, and AUX 12.
Troubleshooting by Using Auxiliary Functions (continued) Compare PLC to Disk AUX 17 (Compare PLC to Disk) compares the selected program on disk to data in the CPU. Run 545/555 PLC Diagnostics AUX 20 (PLC Diagnostics), available only for 545/555 CPUs, initiates the CPU self-checks. The CPU must be in PROGRAM mode in order to execute self-tests. For 545/555s, the CPU executes the equivalent of an AUX 20 at every powerup. If any area fails, a message detailing the failure is displayed.
• Key Always unlocked; the CPU does not have a key. • Mode Shows the CPU operating mode: RUN, PROGRAM, or HOLD. • SF/Loop Mode Run indicates the system is running loops, analog alarms, and SF programs in the SF/Loop Mode. • SF/Loop Follows PLC to Program Mode Informational comment. • PLC Fatal Error Descriptions, causes, and corrective actions are listed in Section 9.3. • PLC Non-fatal Error Descriptions, causes, and corrective actions are listed in Section 9.4.
9.2 Troubleshooting by Reading LEDs 545/555 LEDs The LEDs on the 545/555 CPUs are labeled CPU GOOD, RUN, and BATT GOOD. These LEDs provide CPU status as shown in Table 9-2. NOTE: Since the CPU receives power from the base power supply module, the power supply must be on and functioning correctly to turn the LEDs on. If the base power supply module is defective or turned off, all CPU indicators will be off.
575 LEDs The LEDs on the 575 provide CPU status as listed in Table 9-3. NOTE: Since the CPU receives power from the base power supply module, the power supply must be on and functioning correctly to turn the LEDs on. If the power supply module is defective or turned off, all CPU indicators will be off. Table 9-3 575 CPU Indicator Indicator Status Meaning PCG On CPU functioning with no fatal errors; fault relay is closed. PCG Off System has failed; fault relay is open.
9.3 Troubleshooting CPU Fatal Errors NOTE: Always execute AUX 29 (PLC Operational Status) and make a list of the errors before attempting to clear them. If you clear errors before listing them, it will be impossible to determine what errors occurred and difficult to identify the problem that caused them. 545/555 CPU Fatal Error Indications 575 CPU Fatal Error Indications For 545/555s, a fatal error is indicated when both of the following conditions are present. • The CPU GOOD LED is not illuminated.
Causes of CPU Fatal Errors The CPU enters a fatal error condition and ceases operation if one of the problems listed below occurs. AUX 29 displays the problem that caused the CPU to enter the fatal error condition. • Hardware failure — This error occurs if the power-up or user-requested diagnostics have detected a hardware problem other than those listed here.
Troubleshooting CPU Fatal Errors (continued) 575 Fatal Errors The following is a list of the 575 fatal errors: • Board table, system descriptor table, or application table mismatch — these tables do not match the power-down configuration on the next BATTERY GOOD powerup. • The configuration switches are inconsistent. • VMEbus error — the CPU receives a bus error while attempting to access a VMEbus address, and you have not indicated that such errors should be ignored. NOTE: Release 3.
Table 9-5 Aux 29 Fatal Error Codes (continued) Code Description 002A BUS error 002B Address error 002C Illegal instruction 002D Divide by zero 002E CHK exception 002F TRAPV exception 0030 Privilege violation 0031 TRACE exception 0032 Privileged SFOS function 0033 Power–fail recovery error 0034 A-line exception 0035 F-line exception 0036 Exception not claimable 0103 Hardware watchdog time-out 0104 C-Memory checksum error 0106 RAM error 0107 ROM error 010B Abnormal power l
Troubleshooting CPU Fatal Errors (continued) Table 9-5 Aux 29 Fatal Error Codes (continued) 9-12 Troubleshooting Code Description 0313 Power-fail recovery error 0314 Invalid SYSRQUE request type 031B Invalid state change event posted 031D Non-conformant slave board requesting login 031E Unexpected bus error 031F System I/O configuration error 0320 Boolean processor FAULT 0321 GSDA data structure format incompatible 0322 Remote I/O annex card switch mismatch with primary switch 0323 B
545/555 CPU Responses to Fatal Errors Steps to Clear 545/555 Fatal Errors When a fatal error occurs, the CPU attempts the following actions: • The CPU GOOD LED is turned off. • I/O ports are disabled, discrete outputs are turned off, and word outputs are held in their last valid state. • Communication ports are cleared and re-initialized. • Pending or queued communication tasks are aborted. Attempt to clear the fatal error by following the steps listed below.
Troubleshooting CPU Fatal Errors (continued) 575 CPU Responses to Fatal Errors 9-14 Troubleshooting When a fatal error occurs, the CPU causing the error attempts to do the following actions: • SYSFAIL* is asserted on the VMEbus. This action causes all 575 CPUs in the system to enter the FAULT mode. • The SYF LED is turned on. • The PCG LED is turned off. • The fault relay is opened. • I/O ports are disabled, discrete outputs are turned off, and word outputs are held in their last valid state.
Steps to Clear 575 Fatal Errors Try to clear the fatal error by following the steps listed below. When the PCG LED turns on, the fatal error has been cleared. If communication errors occur, ensure that the battery backup is enabled and then cycle power to the CPU. If communication errors continue, record “No Communication” as the fatal error and go to step 4. 1. Determine the fatal error condition by selecting AUX 29 from the Auxiliary Function Menu on your programming unit.
9.4 Troubleshooting CPU Non-Fatal Errors Definitions of non-fatal errors and suggested courses of action are as follows. • Scan overrun — The CPU fixed scan time is not sufficient to execute the user program. • I/O base failure — A configured base is not connected or has failed. Check the I/O cabling and the I/O configuration. • Special function port failure — A communication port on an SF module has failed. Check all SF modules.
9.5 Troubleshooting by Using Status Words In addition to auxiliary functions, the CPU provides operational information in the form of 16-bit status words. Status words can be read with your programming device. Status words can also be used within an RLL program, thus allowing the system to execute diagnostics during run-time conditions. All status words that are supported by the CPU are described in detail in the SIMATIC 545/555/575 Programming Reference User Manual.
9.6 Troubleshooting User EEPROMs or EPROMs Portable EEPROMs and EPROMs cannot usually be repaired and must be replaced if they become defective. Before replacement, read Chapter 7 carefully and perform the following checks: • Ensure that the EEPROM programming enable strap is installed correctly on the jumper pin E18. (See Figure 7-1.) • Ensure that an (E)EPROM is installed, depending on your use. • Ensure that all (E)EPROM pins are properly seated in the socket.
9.7 Troubleshooting Power Supplies Complete the following steps when troubleshooting a power supply. 1. Ensure that the power budget has not been exceeded and that the power supply module is properly installed. 2. Disable all power to the system for at least 90 seconds. 3. Restore system power. 4. If the problem still exists, turn off power to the system again and follow the steps below.
Troubleshooting Power Supplies (continued) 9. Turn the fuse cap counterclockwise a half-turn with a standard screwdriver. 10. Pull the fuse cap out of the fuse socket. 11. Remove and replace existing fuse with one of recommended type and rating; see the lists of Series 505 and VME components in Appendix D. 12. Place the fuse cap in socket and turn it clockwise with a standard screwdriver. 13. Apply power to the system. 14. If the power supply continues to malfunction, replace it.
9.8 Checking RS-485 (Twisted Pair) Cable Installation Using Digital or Analog Meter To locate problems with RS-485 communication links, use a digital or analog meter capable of measuring resistance between 0 and 150 ohms. Measure the line-to-line and line-to-shield resistance as follows: 1. Remove power from the local base and all remote bases. 2. Disconnect the CPU and all RBCs from the cable by removing the 9-pin D-connector. 3.
Checking RS-485 (Twisted Pair) Cable Installation (continued) Resistance above Maximum 9-22 Troubleshooting Line-to-line resistance that is above the maximum specified in Table 9-6 may be caused by the following: • Incorrect termination resistors are installed. • Fewer than two termination resistors are installed: always use at least one termination resistor, even with the simplest installation. • The cable is open between the point of measurement and one or both of the termination resistors.
9.9 Checking PROFIBUS-DP Cable Installation Verify the PROFIBUS-DP system cable installation using the following guidelines: • Inspect system terminations (too many, not enough or incorrect placement.) See Section 6.3 for proper placement of termination connectors. • Check for a short in the cable with an ohmmeter. • Check for an open circuit in the cable between the point of measurement and one or both of the termination resistors with an ohmmeter.
9.10 PROFIBUS-DP Communications Watchdog Timer Most slaves have a communications watchdog timer that may be activated or deactivated by the user during initial configuration. The communications watchdog timer is distinct from a hardware watchdog timer. The communications watchdog timer monitors time between communications from the PROFIBUS-DP annex card.
9.11 Troubleshooting 575 Improper Login If the 575 CPU does not log in to the local I/O properly, or if other vendors’ modules are not communicating properly, first check to make certain that the daisy-chain backplane dipswitches are set correctly. Switches immediately to the left of installed modules should all be set to the left (Off) position. All unused slots should have their associated switches set to the right (On) position.
Appendix A System Specifications A.1 Physical and Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 A.2 General Series 505 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3 A.3 575 Power Supply Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4 A.4 Series 505 Power Supply Specifications . . . . . . . . . . .
A.
A.2 General Series 505 Specifications Table A-2 General Series 505 Specifications Input Power Provided by means of power supply module: PPX:505–6660 for user-supplied 110/220 VAC PPX:505–6660–A for user-supplied 110/220 VAC PPX:505–6663 for user-supplied 24 VDC PPX:575–6660 for user-supplied 110 VAC PPX:575–6663 for user-supplied 110/220 VAC 545/555–1103/–1104 Battery Backup 3.
A.3 575 Power Supply Specifications Table A-3 575 Power Supply Specifications PPX:575–6660 PPX:575–6663 Range 85–132 VAC (110) 85–132 VAC (110); 170–264 VAC (220) Frequency 47–63 Hz 47–63 Hz Steady State 5 A rms maximum 8 A rms maximum Peak Inrush 50 A maximum for up to 100 ms 50 A maximum for up to 100 ms 8.0 A/250 V, slow-blow, 3 AG 10.
A.4 Series 505 Power Supply Specifications Table A-4 Series 505 Power Supply Specifications PPX:505–6660 PPX:505–6660–A PPX:505–6663 Range 85–132 VAC (110); 170–264 VAC (220) 85–132 VAC (110); 170–264 VAC (220) 20–30 VDC (24) Frequency 47–63 Hz 47–63 Hz — Steady State 2 A rms maximum 2 A rms maximum 8 A zero to peak; 5 A DC maximum Peak Inrush 50 A maximum for up to 100 ms 50 A maximum for up to 100 ms 20 A maximum for up to 100 ms 3.0 A/250 V, slow-blow, 3 AG 3.
Appendix B Power and Compatibility B.1 B.2 Power Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2 Influence of Annex Cards on CPU Power Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Supply Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Requirements for Series 505 Modules . . . . . . . . . . . . . . . . . . . .
B.1 Power Consumption Influence of Annex Cards on CPU Power Consumption Table B-1 shows the power consumption of 545 and 555 CPUs, with and without PROFIBUS-DP annex cards. Table B-2 shows the power consumption of 575 CPUs, with or without an annex card. (The Series 505 remote I/O and PROFIBUS-DP I/O annex cards have the same effect on power consumption.
Power Requirements for Series 505 Modules Model Number PPX: Table B-3 shows the power requirements of the various Series 505 modules. Table B-3 Series 505 Module Power Requirements Description Special Function Module Immediate I/O Maximum DC Power Consumption (Watts) +5 V –5 V 505–2580 120 VAC ISO Input (16-point) — n 1.0 — 505–2590 24–120 VAC ISO Output (16-point) — n 1.0 — 505–2555 Diff. Analog Input (16-point) — n 5.0 — 505–2571 Program Port Expander — — 5.
Power Consumption (continued) Table B-3 Series 505 Module Power Requirements (continued) Model Number PPX: Description Special Function Module Immediate I/O Maximum DC Power Consumption (Watts) +5 V –5 V n 2.5 — — n 2.5 — 24 VDC Output (32-point) — n 2.5 — 110 VAC Output (8-point) — n 2.5 — 110 VAC Output (16-point) — n 2.5 — 110 VAC Output (32-point) — n 2.5 — 24 VDC Output (8-point) — n 5.0 — 24 VDC Output (16-point) — n 5.0 — 24 VDC Output (32-point) — n 5.
Table B-3 Series 505 Module Power Requirements (continued) Model Number PPX: Description Special Function Module Immediate I/O Maximum DC Power Consumption (Watts) +5 V –5 V 505–6850-A Coax, Dual Media RBC — — 5.0 0.200 505–6850-B Coax, Dual Media RBC — — 5.0 0.200 505–6851-A RS-485, Dual Media RBC — — 5.0 0.200 505–6851-B RS-485, Dual Media RBC — — 5.0 0.200 505–6870 505 PROFIBUS-DP RBC — — 5.0 0.200 505–6860 RF to RS-485 Converter — — 2.0 0.
Power Consumption (continued) Power Requirements for 575 Devices Table B-4 shows the DC current requirements for 575 VME devices. Table B-4 DC Current Requirements for 575 Devices DC Current Model Number PPX: Description +5 V +12 V –12 V V Batt (+5 V STDBY) 575–2104 VME CPU 2.2 A1 50 mA 50 mA 120 mA (1 mA in backup) 575–2105 VME CPU 2.2 A1 50 mA 50 mA 120 mA (1 mA in backup) 575–2106 VME CPU 2.2 A1 50 mA 50 mA 120 mA (1 mA in backup) 575–2124 9-slot 1-inch VMEbus base 1.
B.2 Module Compatibility with CPUs I/O Modules Not Compatible with CPUs Unmodified Series 505 discrete I/O modules manufactured prior to January, 1988 are unable to report module status and, therefore, cannot be recognized by the 545, 555, or 575 CPU (that is, inputs are not read and outputs are not written).
Module Compatibility with CPUs (continued) Series 505 High Speed Counter for 545/555 High Speed Counter modules (PPX:505–7002) manufactured prior to May 1990 will not operate properly in a 545/555 controller’s local base configuration. If a High Speed Counter is placed in a 545/555 controller’s local base configuration, the WX inputs will intermittently set to FFs, which could cause improper operation.
Determining the Manufacturing Date The fifth through the eighth characters of the serial number determine the manufacturing date. Figure B-1 shows how to read the serial numbers. Serial Number FF DD YY MM SSSSS C X Not present with initial serial number; a G appears here if the Series 505 Discrete Module was manufactured prior to January, 1988 but was modified for 545/555 compatibility.
Appendix C Upgrading Series 500 Installations C.1 Series 500 System Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2 C.2 Upgrading a 520/520C/530/530C/530T System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3 Check Base to Be Upgraded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Upgrading 14-Slot, 12-Slot, 6-Slot Bases . . . . . . . . . . . . .
C.1 Series 500 System Installations You can upgrade an existing Series 500 system by replacing the controller with a 545–1106, 555–1105, or 555–1106 CPU, or a 575–2105 or 575–2106 CPU with the 575–2126 annex card. The following Series 500 systems can be connected as remote I/O bases to a Series 505 CPU: • SIMATIC 520, 520C, 530, 530C, and 530T systems. • SIMATIC 560, 560T, 565, and 565P systems using twin axial (RS-485) remote I/O channels.
C.2 Upgrading a 520/520C/530/530C/530T System When you upgrade from a 520, 520C, 530, 530C, or 530T system, all of your existing Series 500 bases, whether local or remote, must be converted to Series 500 remote bases. The CPU and I/O channel converter (IOCC) on the local base, and the distributed base controller (DBC) on the remote base(s), are all replaced by the same unit, the PPX:500–5114–A RBC.
Upgrading a 520/520C/530/530C/530T System (continued) Check Base to Be Upgraded Determine the number of I/O slots in the base to be upgraded. For some bases, a PPX:500–5840 adapter base must be installed. The 14-slot, 12-slot and 6-slot bases (Upgrade Path A) do not require an adapter base. For a 16-slot or 8-slot base (Upgrade Path B), you need to install an adapter base. ! WARNING Do not attempt to install or remove modules from powered-up bases.
Series 500 Base is: Series 500 Base is: • PPX:500–5848 (14 I/O Slots) • PPX:500–5228 (16 I/O Slots) or • PPX:500–5884 (12 I/O Slots) or • PPX:500–5864 (8 I/O Slots) • PPX:500–5892 (6 I/O Slots) Controlling Device is: • 530 (and IOCC if present) • 520 or • PPX:500–2103 DBC Controlling Device is: • 530C/530T (and IOCC if present) • 520C or • PPX:500–2109 DBC Upgrade Path A Upgrade Path B 1 Remove controlling device: CPU (and IOCC, if present) or DBC.
C.3 Upgrading an RS-485-Based 560/560T/565/565P System To upgrade an existing RS-485 based 560, 560T, 565, or 565P system, replace the existing programmable controller, including its chassis, power supply and all installed boards, either with a Series 505 base, power supply, and CPU (545–1104, –1106, 555–1103, –1104, –1105, –1106), or else with a VMEbus base, power supply, and one or more 575 CPUs (with 575–2126 annex card). The upgrade is shown graphically in Figure C-2.
P/S 560 565 R C C 1 2 R C C 3 Upgrade Path 545 P/S 555 or 575* Series 505 I/O 4, 8, or 16 slots [545/555] or VMEbus [575] Local I/O *545–1104 or –1106 CPU 555–1103, –1104, –1105, or –1106 CPU, or 575–2104, –2105, or –2106 CPU with 575–2126 annex card (Series 505 remote I/O link).
C.4 Upgrading an RF-Based 560/560T/565/565P System Installing an RS-485/RF I/O channel converter allows you to update an existing 560, 560T, 565, or 565P system that uses coaxial (RF) cables with 545, 555, or 575 CPUs, providing the advantages of greater speed and greater remote distance, and the option of dual media.
P/S 560 565 R C C 1 2 R C C 3 coax coax coax Upgrade Path P/S 545 or 555 5 0 5 – 6 8 6 0 Series 505 base coax Series 500/505 bases with RF RBCs. Notes: — The 545–1104, 545–1106, 555–1103, –1104, –1105, and –1106 CPUs can be used in the Series 505 base to connect (by means of the RS-485/RF I/O channel converter) to the Series 500 remote I/O. — No remote bases can be connected on the RS-485 link between the 545/555 CPU and the PPX:505–6860.
Upgrading an RF-Based 560/560T/565/565P System (continued) Upgrading an RF-based System to 575 To upgrade an existing 560, 560T, 565, or 565P system to a 575 system, you need to replace the existing programmable controller, including its chassis, power supply and all installed boards, with the VMEbus base, power supply, and 575 CPU.
P/S 560 R C C R C C 1 2 3 4 565 coax coax coax coax Upgrade Path #8 Copper Ground Strap P/S 575 A VMEbus 575 B VME Base Local I/O R S 4 8 5 P/S R S 4 8 5 5 0 5 – 6 8 6 0 C o a x Bases must be within three feet of each other and connected by a #8 copper ground strap.
C.5 Installing a PPX:500–5114–A RBC Installing a Series 500 RBC To install the PPX:500–5114–A RBC in a Series 500 base, refer to Figure C-5 and follow the steps below. ! WARNING Installing or removing a RBC from a powered-up base disrupts your process. Installing or removing an RBC from a powered-up base could cause unexpected operation which could cause death or serious injury to personnel, and/or damage to equipment. Ensure that all power is disabled before installing or removing the RBC.
Remote Base Controller Power Supply Figure C-5 Installed Series 500 RBC SIMATIC 545/555/575 System Manual Upgrading Existing Series 500 Installations C-13
Installing a PPX:500–5114–A RBC (continued) Output State Selection When I/O channel communication to a base is lost, the state of the outputs is determined by the selection made on the RBC (Off/Freeze) switch. See Figure C-6. FREEZE OFF (factory set) Figure C-6 Series 500 RBC Switch Selection For discrete output modules, the state of the outputs is determined solely by the position of the RBC (Off/Freeze) switch.
Table C-1 Analog/Word Output States 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 module for further details.
Installing a PPX:500–5114–A RBC (continued) Status Display As shown in Figure C-7, the display at the top of the module indicates the status of the Series 500 RBC. RS-485 I/O port 9-pin female LED display Base thumbwheel Baud rate thumbwheel Remote Base Controller Thumbwheel Baud Number Rate 0 . . . . . . . . 9600 1 . . . . . . . . 2400 2 . . . . . . . . 1200 3 . . . . . . . . . 300 4 . . . . . . . 19200 5 . . . . . . . 19200 6 . . . . . . . 19200 7 . . . . . . . 19200 8 . . . . . . . . 9600 9 . . . .
Using the Base Thumbwheel The base thumbwheel shown in Figure C-7 is used to reset the Series 500 RBC during system operation and to assign the base address. ! WARNING If you reset the RBC when the system is operating, the RBC is logged off the system. When the RBC is logged off, inputs and outputs associated with the base are affected, as described below. If you do not take the condition of your inputs and outputs into account, logging the RBC off the system can cause unpredictable process operation.
Installing a PPX:500–5114–A RBC (continued) When the CPU logs an RBC off the system, it sets a corresponding bit in one of the status words that are available to your RLL program. Your RLL program can use these bits to detect the loss of the RBC and control the outputs of other bases as appropriate for your application. For details about status words and more information about programming, refer to the SIMATIC 505 Programming Reference User Manual.
C.6 RS-485/RF I/O Channel Converter Introduction The RS-485/RF (Coaxial) I/O Channel Converter, PPX:505–6860, allows you to use coaxial cables in a Series 505 system, thereby extending the maximum cable distance to 4 km. The converter connects a Series 505 RS-485 remote I/O interface to an RF remote I/O interface, and makes it possible to go from a Series 505 local base either to a Series 500 remote base that has RF media or to a dual media remote base.
RS-485/RF I/O Channel Converter (continued) Installing the RS-485/RF I/O Channel Converter Use the following procedure to install the PPX:505–6860. 1. Remove the power from the base in which you are installing the PPX:505–6860. ! WARNING Disable all power to the base before installing or removing the PPX:505–6860. Installing or removing any module from a powered-up base could cause unexpected operation which could cause death or serious injury to personnel, and/or damage to equipment.
Removing the RS-485/RF I/O Channel Converter To remove the PPX:505–6860, complete the following steps. 1. If attached, remove cables from the front of the PPX:505–6860. 2. Disconnect power to the base. ! WARNING Disable all power to the base before installing or removing the PPX:505–6860. Installing or removing any module from a powered-up base could cause unexpected operation which could cause death or serious injury to personnel, and/or damage to equipment.
RS-485/RF I/O Channel Converter (continued) Cabling Use the following instructions to install cables for the PPX:505–6860: NOTE: Since 545–1104, –1106, 555–1103, –1104, –1105, –1106 and 575–2104, –2105, –2106 CPUs use RS-485 cabling, the RS-485/RF I/O channel converter is only needed if you are connecting the CPU to an RF remote base. The CPU can be connected directly to an RS-485 remote base. 1. Use an RS-485 cable to connect the CPU’s RS-485 I/O port to the converter’s RS-485 I/O port.
2. Connect the RF (coaxial) cable to the PPX:505–6860 port that is labeled RF To I/O BASES. See Figure C-8.
Appendix D Series 505 and VME Components D.1 Series 505 System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2 D.2 575 VME System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-5 D.3 Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-6 Spares for Series 505 System . . . . . . . . . . .
D.1 Series 505 System Components Table D-1 lists components used in Series 505 systems.
Table D-1 Series 505 System Components (continued) Component Discrete I/O Modules Analog & Word I/O Modules Part Number Description PPX:505–4516 16 output, 4.5–34 VDC, 0.5 A, 4 outputs/common PPX:505–4532 32 output, 4.5–34 VDC, 0.5 A, 8 outputs/common PPX:505–4608 8 output, 20–132 VAC, 0.5 A, 2 outputs/common PPX:505–4616 16 output, 20–132 VAC, 0.5 A, 4 outputs/common PPX:505–4632 32 output, 20–132 VAC, 0.5 A, 8 outputs/common PPX:505–4708 8 output, 4.
Series 505 System Components (continued) Table D-1 Series 505 System Components (continued) Component Bases (Card Rack) Power Supplies Remote Base Controllers Intelligent Modules Network Interface Modules Miscellaneous Battery Kit D-4 Part Number Description PPX:505–6504 I/O base, 4 slots PPX:505–6508 I/O base, 8 slots PPX:505–6511 Redundant I/O base, 11 slots PPX:505–6516 I/O base, 16 slots 2587705–8003 Blank bezel, 0.
D.2 575 VME System Components Table D-2 lists components used in 575 systems. Table D-2 575 System Components Component Part Number VMEbus CPU: 832 Kbytes of user memory & fault relay; 12.5 MHz clock PPX:575–2104 VMEbus CPU: 832 Kbytes; built-in math coprocessor and PowerMath; 32 MHz clock PPX:575–2105 VMEbus CPU: 1856 Kbytes; built-in math coprocessor and PowerMath; 32 MHz clock PPX:575–2106 Sixteen-slot VMEbus base, 0.
D.3 Recommended Spare Parts Siemens Energy & Automation, Inc., recommends that you maintain a 10% surplus of your system’s I/O modules as available spare parts. Depending upon the number and type of CPUs that you have installed, you may wish to stock an extra controller as well. Additional spare parts, depending upon your site configuration, can include items like fuses, back-up batteries, blank filler bezels, and spare bases.
Spares for 575 System The following is the recommended list of spare parts for a 575 system: • PPX:575–2130, 16-slot VME base with 0.8-inch spacing • PPX:575–2131, 115/230 VAC fan kit for 751–2130 base • PPX:575–6660, 185-watt power supply module • PPX:575–6663, 300-watt power supply module • PPX:2587679–8016, 4.0 A fuse kit for battery on all VME bases • PPX:2589739–8008, 8.0 A/250 V, slow-blow fuse (3 AG) for PPX:575–6660, qty. 5 • PPX:2589739–8013, 10.
Appendix E 575 I/O Module Specifications & Pinouts E.1 Discrete AC Input Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2 E.2 16 Input/16 Output 24 VDC Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-4 E.3 Discrete AC Output Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-7 E.4 Discrete Relay Output Module .
E.1 Discrete AC Input Module The discrete AC input module (PPX:575–4232) enables the CPU to monitor 110 VAC field inputs. Table E-1 lists the specifications of the discrete AC input module. See Table E-2 for connector pinouts. Table E-1 Discrete AC Input Module Specifications Feature E-2 Description Optical isolation 1500 Vrms Isolation between commons 1500 Vrms Chassis-to-user circuits 1500 Vrms Inputs 32 Commons 4 Input type IEC type 1 On voltage 79.0 VAC UH minimum 132.
Table E-2 shows connector pinouts for a discrete AC input module.
E.2 16 Input/16 Output 24 VDC Module The discrete DC 16 input/16 output module (PPX:575–4366) lets you drive 24 VDC sinking loads and monitor 24 VDC source inputs. Table E-3 shows the module isolation specifications. Table E-3 24 VDC I/O Module Isolation Feature Description Optical isolation 1500 Vrms Isolation between commons 1000 Vrms Chassis-to-user circuits 1000 Vrms Figure E-1 illustrates the effect that temperature has on current output capabilities. With fan cooling 0.6 0.5 0.5 0.4 0.
Specifications for the discrete DC 16 input/16 output module are shown in Table E-4. See Table E-5 for the connector pinouts. Table E-4 16 Input/16 Output Module Specifications Feature Description +5 V base current consumption 0.9 A (maximum) ±12 V current consumption None VBatt (+5 V STDBY) current consumption None Outputs 16 Commons 2 Fuses One 5 A, 125 V, normal-blow, 5 x 20 mm fuse per output common. Replace only with UL/CSAr-listed fuse.
16 Input/16 Output 24 VDC Module (continued) Table E-5 16 Input/16 Output Module Connector Pinouts Pin Signal LED AR Input section A return — A1 Input 1 A1 A2 Input 2 A2 A3 Input 3 A3 A4 Input 4 A4 A5 Input 5 A5 A6 Input 6 A6 A7 Input 7 A7 A8 Input 8 A8 BR Input section B return — B1 Input 9 B1 B2 Input 10 B2 B3 Input 11 B3 B4 Input 12 B4 B5 Input 13 B5 B6 Input 14 B6 B7 Input 15 B7 B8 Input 16 B8 CR Output section C return — C1 Output 1 C1 C2
E.3 Discrete AC Output Module The discrete AC output module (PPX:575–4616) allows the controller to drive 110 VAC loads. Table E-6 shows module specifications, and Figure E-2 illustrates the effect that temperature has on current output capabilities. Table E-7 shows connector pinouts.
Discrete AC Output Module (continued) Figure E-2 illustrates the effect that temperature has on current output capabilities. Table E-7 shows connector pinouts. Without fan cooling 1.2 1.0 1.0 0.8 0.8 0.6 16 on 0.4 0.2 0.0 Current (A) Current (A) With fan cooling 1.2 0.6 8 on 0.4 16 on 0.2 0.0 0 10 20 30 40 50 60 70 Temperature (°C) 0 10 20 30 40 50 60 70 Temperature (°C) Figure E-2 16-point AC Output: Current/Point vs.
E.4 Discrete Relay Output Module The discrete relay output module (PPX:575–4916) allows the controller to drive AC and DC loads of various voltage and current ranges. The loads can be sourcing or sinking. Table E-8 shows module specifications.
Discrete Relay Output Module (continued) Table E-9 shows connector pinouts for the discrete relay output module.
Figure E-3 shows a sample of field wiring for the discrete relay output module. Terminal Block Module Field AC A1 A2 A3 A4 AR Figure E-3 Field Wiring for Relay Output Module Figure E-4 illustrates the effect that temperature has on current output capabilities. With fan cooling Without fan cooling 2.5 2.0 8 on 2.0 1.5 16 on 1.5 Current (A) Current (A) 2.5 1.0 0.5 0.0 8 on 1.0 16 on 0.5 0.
E.5 Discrete DC Output Module The discrete DC output modules (PPX:575–4532 and PPX:575–4732) allow the controller to drive DC loads of various voltages. These modules are sourcing output modules. An LED indicator on the module faceplate signals a blown fuse in the module. Table E-10 shows the module specifications, and Figure E-5 shows the effect that temperature has on current output, for the PPX:575–4532.
Table E-11 shows the module specifications, and Figure E-6 shows the effect that temperature has on current output, for the PPX:575–4732. Table E-11 PPX:575–4732 Specifications Feature Description Optical isolation 1500 Vrms Isolation between commons 500 Vrms Isolation between chassis ground and user circuits 1000 Vrms Outputs 32 Commons 4 Fuses One 8 A, 125 V normal-blow, 5 x 20 mm fuse per common (4 fuses total). Replace only with UL/CSA-listed fuse.
Discrete DC Output Module (continued) Table E-12 shows connector pinouts for both discrete DC output modules.
E.6 Discrete DC Input Module The discrete low-voltage DC input module (PPX:575–4332) allows the controller to monitor user inputs of various DC voltages. An LED indicator on the module faceplate signals a blown fuse in the module. Table E-13 shows the module specifications.
Discrete DC Input Module (continued) Table E-14 shows connector pinouts for the discrete DC input module.
Appendix F Enhancements in Late Model CPUs F.1 F.2 F.3 Enhancements to Error Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-2 CPUs with Enhanced Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fatal Error Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changes in Memory Error Handling . . . . . . . .
F.1 Enhancements to Error Handling CPUs with Enhanced Firmware For the 555–1103/–1104 CPUs Release 4.2 or greater, 555–1105/–1106 CPUs Release 5.2 or greater, 545–1105/–1106 CPUs Release 5.1 or greater, and 575–2105/–2106 CPUs Release 5.1 or greater, the following changes in the firmware have been implemented to minimize problems caused by excess noise, as described below.
Using the Auto Recompile Function 2. Since the CPU actually runs on compiled code stored in CL-memory, the CPU will no longer declare a fatal error if an error in L-memory is detected. Instead, the CPU will set a non-fatal error and keep running. Status Word 1, bit 16 (STW1.16) indicates this condition and can only be cleared by reloading the RLL application program from your PC (or other programming device) to the PLC. The corrupted L-memory cannot be displayed or edited online. 3.
F.2 Fast PROFIBUS-DP I/O Update Times CPUs with this Feature The 555–1105/–1106 CPUs Release 5.2 or greater, the 545–1105/–1106 CPUs Release 5.1 or greater, and the 575–2105/–2106 CPUs Release 5.1 or greater, support the new Fast PROFIBUS-DP I/O Update feature. Fast PROFIBUS-DP I/O Updates The CPUs listed above provide the ability to do faster PROFIBUS-DP I/O updates using IORW box instructions, immediate contacts, and immediate coils.
NOTE: Be careful not to enter duplicate I/O references, because the first reference found is the one that is used. Changing a PROFIBUS-DP Slave Configuration Due to the previously mentioned special code that is generated by the CPU’s compiler, the configuration of a DP slave that has an associated immediate instruction can no longer be changed while a PLC is in run mode. If attempted, the error message “ILLEGAL REQUEST IN CURRENT OPERATIONAL MODE” will be given.
F.3 Memory Capacity of the 555–1106 CPU Difference in Memory Capacity between the 555–1106 CPU and Earlier CPUs Due to internal CPU requirements, it was previously necessary to reduce the amount of memory available to the user in a 505–1106 CPU by 64 Kbytes compared to the 555–1102 and 555–1104 (1920 Kbytes in the earlier model CPUs vs. 1856 Kbytes in the –1106 CPU).
Index Numbers 50X ignore mismatch mode, 5-22, 5-24 50X RS-232 comm port, 5-24 575.
C Cable connecting modems, overview, 6-32 PROFIBUS-DP installations attaching connector, 6-28 cable requirements, 6-22 equipment needed, 6-21 guidelines, 6-23 maximum line length, 6-22 media options, 6-20 sample system, 6-20 termination and bias, 6-24 termination guidelines, 6-24 termination schematics, 6-26 termination selection switch, 6-25 troubleshooting, 9-23 twisted pair, 6-20 resistance of line-to-line, 9-21 RS-485, measuring resistance, 9-21 Series 505 installations cable requirements, 6-7 connectin
Dipswitches, continued configuration of 575 CPU, 4-24–4-29 daisy chain, 575 CPU, 4-41 operating parameters, 545/555 CPU, 3-22 Discrete AC input module connector pinouts, E-3 isolation, E-2 specifications, E-2 Discrete AC output module connector pinouts, E-8 current vs.
Features 545/555-only, 1-9 575-only, 1-10 shared system, 1-8 Floating point coprocessor, installing, 4-23 Fuse replacing 575 battery fuse, 4-22 replacing on fan assembly, 4-9 replacing on power supply, 9-20 Fuses, guidelines for, 2-11 G Global reset, PROFIBUS-DP RBC, 5-20 Grounding 545/555 chassis, 2-19 575 chassis, 2-20 cabinet or rack 545/555, 2-19 575, 2-20 chassis connections 545/555, 2-19 575, 2-20 earth, 2-17 planning for, 2-17 H H1 support, 1-4 Hardware, overview, 1-12 Hot backup, C-8, C-10 Hotline
J J1 Backplane connectors, pin assignments, 4-54 J2 Backplane connectors, installing on 575 VMEbus base, 4-56–4-59 Jog switch, location, 2-5 Jumper, Off/Freeze PROFIBUS-DP RBC, 5-14 Series 500 RBC, C-14 Series 505 RBC, 5-6 N Noise avoiding electrical, 2-12 contact snubbing, 2-14 isolating from, 2-15 load snubbing, 2-13 Non-fatal error indications, 9-16 Non-volatile memory, program storage, 7-4 O L LED indicators Series 500 RBC, C-16 troubleshooting 545/555 CPUs, 9-6 575 CPUs, 9-7 575 power supply, 9-7 Loc
Pinouts, 575 CPU, continued serial port connection, 4-47 VME backplane, 4-54 575 fault relay, 4-44 575 modules discrete AC input, E-3 discrete AC output, E-8 discrete DC 16 I/O, E-6 discrete DC input, E-16 discrete DC output, E-14 discrete relay output, E-10 remote I/O port PROFIBUS-DP, 6-31 Series 505, 6-13 RS-485/RF converter, C-22 Port pinouts, 575 CPUs, 4-46–4-49 Power consumption.
Program copying into EEPROM, 7-10 editing in EEPROM, 7-12 software SoftShop, 1-11 TISOFT, 1-11 Program storage configuring CPU, 7-6–7-9 EPROM/EEPROM, 7-2–7-5 R RBC 505 PROFIBUS-DP assigning station address, 5-17 hardware watchdog timer, 5-15 installing in base, 5-4 overview, 5-14 placement in base, 5-3 reset button, 5-20 setting baud rate, 5-17 station address dipswitch, 5-17 status display, 5-22 PROFIBUS-DP, configuring, 5-24 Series 500 assigning base numbers, C-18 base thumbwheel, C-18 hardware watchdog
Series 505 annex card, installing, in 575 CPU, 4-29 base installing 545/555 CPU, 3-14 models available, 1-12, 3-4 panel mounting, 3-6 models available, 3-4 rack mounting, 3-5 models available, 3-4 cable installations cable requirements, 6-7 connecting drop line to CPU, 6-14 connecting drop line to RBC, 6-14 connecting trunk line to terminal block, 6-17 drop line, 6-5 equipment needed, 6-4 extending trunk line, 6-18 guidelines, 6-8 media options, 6-4 preparing drop line, 6-12 preparing trunk line, 6-16 prope
T Technical assistance, xxi Temperature, planning for, 4-6 Series 505 base, 3-3 VMEbus base, 4-5 Termination and bias, overview, 6-24 Third-party boards assigning addresses, 4-53 installing, 4-40 Thumbwheels, assigning base numbers Series 500 RBC, C-18 Series 505 RBC, 5-9 TISOFT, programming software, 1-11 TIWAY, support, 1-4 Token ring, PROFIBUS protocol, 1-4 Torque specifications for CPUs, 3-15 for Series 505 modules, 3-27 for terminal block screws, 3-27, 3-28 Troubleshooting 575, power supply, 9-19 575 f
VMEbus, power supply, continued power consumption, 4-15 replacing fuse, 9-19 selecting voltage, 4-16 troubleshooting, 9-19 wiring guidelines, 4-17 wiring procedure, 4-18 requirements, 4-50 spare parts, D-5 system components, D-5 Watchdog timer communications, 9-24 hardware PROFIBUS-DP RBC, 5-15 Series 500 RBC, C-15 Series 505 RBC, 5-6 Voltage selecting for fan assembly, 4-7 selecting power supply input, 4-16 Word I/O update factor, 5-24 Index-10 W Wiring See also Cable planning for installation, 2-16
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