Control Technologies 5250-TI5 Operating instructions

CTI Model 5250-TI5
CTI Model 5251-TI5
Access Modules
INSTALLATION AND OPERATION GUIDE
Version 4.2
CTI Part #062-00109
*062-00100*
5250-TI5IOG051403 $25

ii CTI 5250-TI5 and 5251-TI5 Installation and Operation Guide
Copyright © 2005 Control Technology Inc.
All rights reserved.
This manual is published by Control Technology Inc., 5734 Middlebrook Pike, Knoxville, TN 37921.
This manual contains references to brand and product names which are tradenames, trademarks,
and/or registered trademarks of Control Technology Inc. Siemens® and SIMATIC® are registered
trademarks of Siemens AG. Other references to brand and product names are tradenames,
trademarks, and/or registered trademarks of their respective holders.
DOCUMENT DISCLAIMER STATEMENT
Every effort has been made to ensure the accuracy of this document; however, errors do occasionally
occur. CTI provides this document on an "as is" basis and assumes no responsibility for direct or
consequential damages resulting from the use of this document. This document is provided without
express or implied warranty of any kind, including but not limited to the warranties of
merchantability or fitness for a particular purpose. This document and the products it references are
subject to change without notice. If you have a comment or discover an error, please call us toll-free
at 1-800-537-8398.

CTI 5250-TI5 and 5251-TI5 Installation and Operation Guide iii
Figure 1 The 5250-TI5 and 5251-TI5 Access Modules
PREFACE
This Installation and Operation Guide provides installation and operation instructions for the CTI
Model 5250-TI5 and Model 5251-TI5 Access Modules for SIMATIC® Series 500 and 505
programmable controllers. The two models function identically with differences only in the data
display technology. The Model 5250-TI5 has a Liquid Crystal Display (LCD), while the Model
5251-TI5 contains a Vacuum Fluorescent Display (VFD).
This document assumes familiarity with the operation of SIMATIC® Series 500 and 505
programmable controllers. Refer to the appropriate SIMATIC® user documentation for specific
information on the SIMATIC® Series 500 and 505 programmable controllers and I/O modules.
This Installation and Operation Guide contains two main parts:
I. Access Module Installation and Operation gives an overview of the Access Module,
provides installation instructions, and covers operation (Chapters 1-3).
II. Configuration Program Installation and Operation provides instructions for the use of
the Software Configuration Program.

iv CTI 5250-TI5 and 5251-TI5 Installation and Operation Guide

CTI 5250-TI5 and 5251-TI5 Installation and Operation Guide v
NOTE:
Notes alert the user to special features or procedures.
CAUTION:
Cautions alert the user to procedures which could damage equipment.
WARNING:
Warnings alert the user to procedures which could damage equipment and endanger the user.
USAGE CONVENTIONS

vi CTI 5250-TI5 and 5251-TI5 Installation and Operation Guide

CTI 5250-TI5 and 5251-TI5 Installation and Operation Guide vii
TABLE OF CONTENTS
PREFACE ......................................................................iii
USAGE CONVENTIONS ........................................................ v
TABLE OF FIGURES ............................................................ ix
CHAPTER 1. DESCRIPTION ..................................................... 1
1.1 Features ............................................................. 1
1.2 Theory of Operation .................................................... 2
1.3 Battery Replacement ................................................... 2
1.4 Front Panel Description ................................................. 3
1.5 LCD Brightness Control ................................................. 4
1.6 Communications ....................................................... 4
1.6.1 Access Module to Personal Computer .............................. 4
1.6.2 Access Module to PLC .......................................... 4
1.6.3 Access Module Output through AUX Port .......................... 4
CHAPTER 2. INSTALLATION ................................................... 5
2.1 Access Module Mounting ............................................... 5
2.2 Connecting Power to the Access Module ................................... 7
2.3 Connecting the Access Module to a Series 500/505 PLC ....................... 9
2.4 Connecting the AUX Port to a Serial Device ................................. 11
2.5 Cleaning the Front Panel ................................................ 11
CHAPTER 3. OPERATION ...................................................... 13
3.1 Initial Power Up ....................................................... 13
3.2 Keypad Entry ......................................................... 14
3.2.1 SHIFT Key ................................................... 14
3.2.2 PRE/NEXT Key ............................................... 15
3.3 Reading PLC Memory Locations .......................................... 16
3.3.1 Direct Memory Address Number .................................. 16
3.3.2 Accessing Memory by Tag Names ................................. 17
3.3.3 Discrete I/O Points (X/Y) ........................................ 19
3.3.4 Control Relays (CR) ............................................ 20
3.3.5 Timer/Counter ................................................ 21
3.3.6 Variable (V) Memory ........................................... 22
3.3.7 Word Input/Output (WX/WY) .................................... 23
3.3.8 Drums/Event Drums ............................................ 24
3.4 Editing a PLC Memory Location .......................................... 26
3.4.1 Entering Negative Numbers ...................................... 27
3.4.2 Variable Minimum/Maximum Limits .............................. 27
3.4.3 Changing a Discrete Variable (X/Y, CR) ........................... 28
3.4.4 Changing a Timer/Counter ....................................... 30
3.4.5 Changing WX/WY and V Memory Locations ........................ 31
3.4.6 Changing Drum Parameters ...................................... 31

viii CTI 5250-TI5 and 5251-TI5 Installation and Operation Guide
3.5 Auxiliary Commands ................................................... 34
3.5.1 Status Display - SHIFT 0 ........................................ 34
3.5.2 Date/Time Set - SHIFT 1 ........................................ 34
3.5.3 Custom 4-Variable Screen - SHIFT 2 ............................... 35
3.5.4 Download Configuration File - SHIFT 3 ............................ 38
3.5.5 Version Information - SHIFT 4 ................................... 38
3.5.6 Upload Configuration File - SHIFT 5 ............................... 39
3.5.7 PLC Communication Baud Rate - SHIFT 6 .......................... 39
3.5.8 VFD Screen Saver Setup - SHIFT 7 (5251-TI5 only) .................. 40
3.6 Using the HELP Key ................................................... 41
3.7 Alarms ............................................................... 42
3.8 Event Messaging ....................................................... 44
3.9 PLC Errors ........................................................... 45
CHAPTER 4. TI5 CONFIG PROGRAM SETUP AND OPERATION ...................... 47
SPECIFICATIONS .............................................................. 51
APPENDIX A: COMMUNICATIONS ERROR CODES ................................ 53
APPENDIX B: PLC ERROR CODES ............................................... 55
APPENDIX C: OPERATION WITH REMOTE BASE CONTROLLERS ................... 57
LIMITED PRODUCT WARRANTY ................................................ 59
REPAIR POLICY ............................................................... 61

CTI 5250-TI5 and 5251-TI5 Installation and Operation Guide ix
TABLE OF FIGURES
Figure 1 The 5250-TI5 and 5251-TI5 Access Modules ...................................iii
Figure 2 Front Panel Description .................................................. 3
Figure 3 Panel Cut-out and Stud Torque Sequence .................................... 5
Figure 4 Module Outside Dimensions ............................................... 6
Figure 5 Rear View of Access Module ............................................... 6
Figure 6 5250-TI5 / 5251-TI5 Printed Circuit Board ................................... 8
Figure 7 Cable Matrix ........................................................... 9
Figure 8 RS232 to 500/505 PLC Cable .............................................. 10
Figure 9 RS232 to 545 PLC Cable .................................................. 10
Figure 10 RS422 to PLC Cable .................................................... 10
Figure 11 Auxiliary Port Pin-out ................................................... 11
Figure 12 Power Up Screen A ..................................................... 13
Figure 13 Power Up Screen B ..................................................... 13
Figure 14 Power Up Screen C .................................................... 13
Figure 15 SHIFT Key ............................................................ 14
Figure 16 Use of SHIFT Key to Select WX/WY ........................................ 14
Figure 17 NEXT Key ............................................................. 15
Figure 18 PRE Key .............................................................. 16
Figure 19 Scrolling Sequence ...................................................... 17
Figure 20 Accessing Memory by Tag Name ........................................... 18
Figure 21 Reading a Discrete I/O by PLC Address ..................................... 19
Figure 22 Reading a Discrete I/O by Tag Name ....................................... 19
Figure 23 Reading Control Relay Status by PLC Address ................................ 20
Figure 24 Reading Control Relay Status by Tag Name .................................. 20
Figure 25 Reading Timer/Counter by PLC Address .................................... 21
Figure 26 Reading a Timer/Counter by Tag Name ..................................... 21
Figure 27 Reading V-Memory by PLC Address ....................................... 22
Figure 28 Reading V-Memory by Tag Name .......................................... 22
Figure 29 Reading WX/WY Location by PLC Address .................................. 23
Figure 30 Reading WX/WY Location by Tag Name ..................................... 23
Figure 31 Reading Drum by PLC Address ............................................ 24
Figure 32 Reading Drum by Tag Name .............................................. 24
Figure 33 Reading Event Drum DCP Values .......................................... 25
Figure 34 Changing Discrete Variable Value ......................................... 28
Figure 35 Changing Discrete Variable Forced State .................................... 29
Figure 36 Changing Timer/Counter CURRENT Value .................................. 30
Figure 37 Changing Timer/Counter PRESET Value .................................... 30
Figure 38 Changing WX/WY and V-Memory Values.................................... 31
Figure 39 Changing Drum DSP Parameter ........................................... 31
Figure 40 Changing Drum DSC/Time Base Values .................................... 32
Figure 41 Changing Drum DCP Values .............................................. 33
Figure 42 5250/5251 Status Screen ................................................ 34
Figure 43 5250/5251 Real Time Clock Edit Screen .................................... 34
Figure 44 Custom 4-Variable Screen Definition ....................................... 36
Figure 45 Editing Custom 4-Variable Screen ......................................... 37

xCTI 5250-TI5 and 5251-TI5 Installation and Operation Guide
Figure 46 Configuration File Download ............................................. 38
Figure 47 5250/5251 Version Information ............................................ 38
Figure 48 Configuration File Upload ................................................ 39
Figure 49 PLC Communication Baud Rate Edit Screen .................................. 39
Figure 50 VFD Screen Saver Setup ................................................. 40
Figure 51 Using HELP Function .................................................. 41
Figure 52 Alarm Queue Message Examples ........................................... 42
Figure 53 PC 25-Pin COM Port to Access Module ..................................... 49
Figure 54 PC 9-Pin COM Port to Access Module ...................................... 49

CTI 5250-TI5 and 5251-TI5 Installation and Operation Guide 1
CHAPTER 1. DESCRIPTION
The Model 5250-TI5 and Model 5251-TI5 Access Modules provide a simple, yet flexible, interface
to the SIMATIC® Series 500 and 505 Programmable Controllers. The Access Modules are
designed to monitor and (optionally) modify Discrete I/O (X/Y), Control Relays (CR),
Timers/Counters (TCP/TCC), V-memory (V), Word I/O (WX/WY), and Drums/Event Drums. PLC
memory locations are continuously monitored to detect internal PLC errors and user configured
alarms and event messages.
The Access Modules provide a rugged, compact panel for the operator, technician, and engineer who
need to access PLC memory locations without using a VPU or TISOFT. This interface provides the
ease of use and flexibility needed for numerous operation, diagnostic, and maintenance applications.
Included with each module is a menu-driven software configuration program which runs on IBM-
compatible computers. (The configuration package is covered in Chapter 4 of this Installation and
Operation Guide.) By following simple command prompts, users can assign custom tag names to
PLC memory locations, define alarms and messages, select operator password, designate read-only
memory locations, and specify V memory locations for the transfer of real-time clock data. Once
created, the configuration file can be transferred to or from the battery-backed memory in the Access
Module.
1.1 Features
Compact, industrial panel mount design including NEMA 4 rated (water-tight) front panel
and convenient plug-in communications and power cables
Access to SIMATIC® 500 and 505 PLC memory locations by address or tag names
Password protection for individual memory locations prevents unauthorized changes while
allowing all monitoring functions
Read-only option prevents altering critical data
Flexible alarm handling permits selection of partial or complete display interruption, alarm
storage, and event logging
Context-sensitive Help screens
Real time clock that can be transferred to user-specified V memory locations
Displays and dynamically updates PLC memory locations (tag names) embedded in user
defined messages

2CTI 5250-TI5 and 5251-TI5 Installation and Operation Guide
1.2 Theory of Operation
The executable program and commands which allow the Access Module to interact with the
SIMATIC® 500 and 505 Series Controllers are permanently stored in internal ROM (Read Only
Memory). Custom configuration parameters, including user-assigned tag names, alarms, and
messages, are stored in battery-backed RAM.
The Access Module software provides two command sets for the operator. The primary command
set allows the user to monitor PLC status and monitor/change X/Y, WX/WY, V memory, Drums,
Timer/Counter, and Control Relay (CR) locations. The auxiliary command set displays the status of
the Access Module, display and edit the Real Time Clock, create a screen to dynamically display
four (4) data points, set PLC communications baud rate, and upload/download a configuration file
to/from a PC running the TI5 Configuration Software program. Additionally, the Model 5251-TI5
permits the user to specify the time delay before the VFD Screen Saver is activated.
Procedures for using each of these commands are described in the Chapter 3.
1.3 Battery Replacement
The Access Module is equipped with an internal 3.6V Lithium battery that should provide memory
backup for approximately 8 years when operated in normal environments. Battery life can diminish
if the unit is subjected to extreme temperatures or frequent temperature cycles.
It is recommended that the unit be returned to CTI for service when battery replacement is required.
However, a qualified technician can access the battery by removing the rear panel. A replacement
battery can be ordered from CTI (Part #075-00009).

CTI 5250-TI5 and 5251-TI5 Installation and Operation Guide 3
Figure 2 Front Panel Description
1.4 Front Panel Description
The Access Module front panel contains a data display (LCD or VFD), 20 key membrane keypad,
and four (4) status LEDs, as shown below.
An 80 character (4 Line by 20 Characters) Data Display is provided with each unit. Model 5250-TI5
contains a 1" by 3" LCD with wide viewing angle. Model 5250-TI5 includes a VFD with 5mm by
3mm character size.
The Keypad is used to access PLC memory locations, edit values, and specify the Auxilliary
Command set (described in Section 3.5).
The "SHIFT" LED is illuminated when the "SHIFT" mode is active. The next key pressed causes
the alternate (Blue-labelled) function to be called.
The "MESSAGE ACTIVE" LED is illuminated when an Event Message appears on one or more
lines of the data display. An Event Message is a special type of alarm that interrupts the data display
but does not create an entry in the Alarm Storage Queue. See Section 3.8 for details on messaging.
The "ALARM ACTIVE" LED is illuminated whenever one or more "unacknowledged" alarm
messages exist in the Alarm Storage Queue. Alarm Queue messages are created when the Access
Module detects an alarm condition configured for this action. See Section 3.7 for a description of
alarms.
The "UNIT OK" LED indicates that the Access Module is properly powered and operating
normally. If this LED is ON steady, the unit is communicating with the PLC. If the PLC is not
responding, this LED is flashing.

4CTI 5250-TI5 and 5251-TI5 Installation and Operation Guide
1.5 LCD Brightness Control
The Model 5250-TI5 Access Module contains an adjustment screw that allows contrast control for
the Liquid Crystal Display (LCD). This contrast control is located in the left side panel below the
LCD.
A small screwdriver of approximately 1/8 inch diameter may be used to adjust the contrast setting.
The range of control is slightly less than one full turn with factory setting about 50%. DO NOT
PUSH on the adjustment screw with the screwdriver.
1.6 Communications
1.6.1 Access Module to Personal Computer
The Access Module communicates with an IBM-compatible PC to provide upload/download of
custom configuration files to/from the PC. The PC must be running the TI5 Configuration Program
provided with the unit.
A cable must be connected between the Access Module PROGRAM Port on the rear panel and a
serial port (COM1 or COM2) on the PC. Communication cables may be purchased from CTI or
constructed according to the specifications described in Chapter 4 of this manual.
1.6.2 Access Module to PLC
The Access Module can be connected directly to Siemens® Series 500 and 505 PLC Programming
Port via a standard communications cable. Cables required to interface to all Series 500 and 505
PLC's are available from CTI or can be constructed as described in Section 2.3.
The Access Module can communicate to the PLC through the PROGRAM Port by either RS-232 or
RS-422. This choice is determined by the selection of the proper communication cable. No internal
switching is required to select RS-232 or RS-422 operation.
PLC Communications Baud Rate can be set through the TI5 Configuration Program as well as
directly from the keypad using an auxilliary command function. Choices are 9600 or 19.2K baud.
The other communication parameters (7 data bits, odd parity, 1 stop bit) are fixed and cannot be
altered.
If communications with the PLC is disconnected or interrupted by excessive noise, the Access
Module UNIT OK LED flashes approximately once per second to indicate the problem.
1.6.3 Access Module Output through AUX Port
The AUX Port on the Access Module rear panel can be used for a second serial connection to a log
printer or message display. The pinout for this port is described in Section 2.4.
The AUX Port is configured as RS-232 DTE (Data Terminal Equipment) operation. This port can be
used for output only; serial input is not supported. AUX Port communications settings are fixed at
9600 baud, 8 data bits, no parity, 1 stop bit and cannot be altered.

CTI 5250-TI5 and 5251-TI5 Installation and Operation Guide 5

6CTI 5250-TI5 and 5251-TI5 Installation and Operation Guide

CTI 5250-TI5 and 5251-TI5 Installation and Operation Guide 7
Figure 3 Panel Cut-out and Stud Torque Sequence
CHAPTER 2. INSTALLATION
2.1 Access Module Mounting
To comply with NEMA 4 specifications, the Access Module must be installed in a NEMA 4 rated
enclosure according to the following procedure:
Step 1. Ensure that there is adequate panel and depth clearance in the NEMA 4 enclosure
where the module is to be mounted. Refer to the following figure for overall
clearances.
Step 2. Cut an opening and drill 10 mounting holes in the enclosure panel as shown in the
figure below.
Step 3. Line up the studs on the module with the holes in the enclosure panel. Do not remove
the gasket from the studs. Insert the module into the cut-out through the front of the
panel. The gasket should be between the module and the front of the panel.
Step 4. Remove the nuts from the packing envelope and install them onto the studs from the
rear of the panel. Tighten the nuts in the sequence and to the torque specifications
shown in the figure below.

8CTI 5250-TI5 and 5251-TI5 Installation and Operation Guide
Figure 4 Module Outside Dimensions
Figure 5 Rear View of Access Module

CTI 5250-TI5 and 5251-TI5 Installation and Operation Guide 9
WARNING:
Ensure that the GND pin (top pin on the 3 pin connector) is connected to a suitable ground to
prevent personal injury.
WARNING:
Ensure that line power is off when connecting the supply wires to the screw terminals to
prevent personal injury.
2.2 Connecting Power to the Access Module
110V AC power is supplied to the Access Module by connecting the appropriate lines to the screw
terminals of the power connector located on the rear panel. The screw terminal connector is a two-
piece part that can be removed from the unit to assist in wiring.
This connector supports wires ranging from 14-18 AWG.

10 CTI 5250-TI5 and 5251-TI5 Installation and Operation Guide
Figure 6 5250-TI5 / 5251-TI5 Printed Circuit Board
WARNING:
Ensure that the voltage select switch is in the correct position before connecting 220VAC.
Equipment damage can occur which will void the product warranty. The unit is factory
configured for 100VAC.
For 220V AC operation, remove the 4 screws from the back panel, change the voltage select switch
(see above figure) from the 110V to the 220V position. Reinstall the back panel before connecting
power to the unit.
Power voltages other than 110/220V AC are available by special request. Contact CTI for special
voltage requirements.
The Access Module is protected by a 125mA 250V fuse located directly above the screw terminal
connector. To remove the fuse, insert a flat-blade screwdriver into the fuse holder and turn
counter-clockwise. The replacement fuses should be Littlefuse #218.125 or equivalent. Fuse
replacement is accomplished by inserting a new fuse in the holder, place the fuse and holder into the
fuse hole, and turn clockwise using a flat-blade screwdriver.