Control Technologies CTI 2500 Series User manual

CTI 2500 Series®
REMOTE I/O SYSTEM
DESIGN, INSTALLATION
& TROUBLESHOOTING GUIDE
Version 2.0

Copyright© 2018-2020 Control Technology Inc.
All rights reserved.
This manual is published by Control Technology Inc. (CTI) 5734 Middlebrook Pike,
Knoxville, TN 37921. This manual contains references to brand and product names which
are tradenames, trademarks, and/or registered trademarks of Control Technology Inc.
Siemens®, SIMATIC®, and Series 505®, and 505®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 or email us at
[e-mail].
REVISION HISTORY
V1.0
08OCT2008
Initial Release
V1.1
03MAY2013
Added note about Belden cable compatibility
V1.2
11JLY2013
Added section on redundant topology, Add manual links to new
Website, Replace RIO-A references with RIO-B
V1.3
17SEP2013
Added alternate redundant topology and new Belden cable spec
V1.4
24APR2018
Added note “Note: Addresses above STW242 are only
supported by the CTI 2500 Series®CPUs in Section 4.4.(pdb)
V2.0
24JUL2020
Extensive additions to support Janus processors (rdp)

CTI 2500 Series®Remote I/O System Design, installation & Troubleshooting Guide V2.0
i
PREFACE
This Remote I/O System Design & Troubleshooting Guide provides reference
information for constructing and operating CTI 2500 Series®Remote I/O networks. The
information in this manual is directed to individuals who will be installing and operating the
processor as well as those who will be designing systems that use it.
For comprehensive processor information, you should also obtain the CTI 2500 Series®
Controller Installation and Operation Guide (CTI Part # 062 -00370-010) or CTI 2500P-Jxxx
Janus Programmable Automation Controller Installation and Operation Guide.

USAGE CONVENTIONS
NOTE:
Notes alert the user to special features or procedures.
CAUTION:
Cautions alert the user to procedures that could damage equipment.
WARNING:
Warnings alert the user to procedures that could damage equipment and endanger the user.

iii
TABLE OF CONTENTS
CHAPTER 1 OVERVIEW .............................................................................................................................1
1.1 INTRODUCTION..........................................................................................................................................1
1.2 NETWORK FEATURES ..................................................................................................................................1
1.2.1 Electrical Interface ............................................................................................................................1
1.2.2 I/O Protocol.......................................................................................................................................1
1.2.3 Compatibility.....................................................................................................................................1
1.3 SYSTEM COMPONENTS................................................................................................................................1
1.3.1 2500 Series® Classic Processor..........................................................................................................2
1.3.2 2500 Series® Janus Processor ...........................................................................................................2
1.3.3 2500 Series® Remote Base Controller ...............................................................................................3
1.3.4 Network Cabling & Taps ...................................................................................................................3
1.3.5 Network Terminations ......................................................................................................................4
CHAPTER 2 DESIGN & INSTALLATION .......................................................................................................5
2.1PLAN AND SPECIFY I/O NETWORK REQUIREMENTS...........................................................................................5
2.2 SPECIFY AND DESIGN THE NETWORK TOPOLOGY................................................................................................5
2.2.1 Select Basic Network Topology.........................................................................................................5
2.2.2 Placing Taps and Designing Droplines ..............................................................................................7
2.2.3 Dual Media and Hardware Redundancy Installations ......................................................................8
2.3 SPECIFY CABLE TYPE..................................................................................................................................10
2.4 SPECIFY TERMINATIONS.............................................................................................................................11
2.5 DOCUMENT THE I/O NETWORK ..................................................................................................................11
2.6 CONSTRUCT THE I/O NETWORK ..................................................................................................................11
2.6.1 General Cabling Guidelines.............................................................................................................11
2.6.2 Constructing Trunk Line Cables.......................................................................................................12
2.6.3 Connecting Trunk Lines to Taps ......................................................................................................13
2.6.4 Constructing Drop Line Cables ........................................................................................................14
2.6.5 Connecting Drop Lines to Taps .......................................................................................................15
2.6.6 Attach D-connector to Drop Line for Connection to 2500 Series® Processor or RBC ......................15
2.7 COMMISSION THE I/O NETWORK ................................................................................................................16
CHAPTER 3 SYSTEM CONFIGURATION .................................................................................................... 19
3.1 CONFIGURING THE 2500 SERIES®CLASSIC PROCESSOR...................................................................................19
3.1.1 Setting the Enable/Disable status of each base..............................................................................19
3.1.2 Set Slot Configuration and Starting I/O Address.............................................................................20
3.2 CONFIGURING THE 2500 SERIES®JANUS PROCESSOR .....................................................................................21
3.2.1 Add the Remote I/O Configuration .................................................................................................21
3.2.2 Add the Remote Base(s)..................................................................................................................23
3.2.3 Add I/O module(s) to the Remote Base(s) ......................................................................................26
3.3 CONFIGURING THE 2500-RIO-B REMOTE BASE CONTROLLER..........................................................................29
3.3.1 Setting the RS232 Port Baud Rate ..................................................................................................30
3.3.2 Setting Remote Base Controller Station Address ............................................................................30
3.3.3 Setting the Output State on Communication Loss ..........................................................................31
CHAPTER 4 TROUBLESHOOTING............................................................................................................. 33
4.1 COMMISSIONING INSTRUCTIONS .................................................................................................................33

4.2RBC SETUP AND STATUS INDICATORS .......................................................................................................... 33
4.3 TROUBLESHOOTING I/O STATUS IN WORKSHOP............................................................................................ 34
4.3.1 System status words ...................................................................................................................... 34
4.3.2 Fatal and Non-Fatal Error Codes.................................................................................................... 35
4.4 TROUBLESHOOTING I/O STATUS IN JANUS WORKBENCH................................................................................. 35
4.4.1 Janus Processor I/O Error Codes .................................................................................................... 35
4.4.2 Errors for Individual Remote Bases and I/O Modules .................................................................... 36

v
TABLE OF FIGURES
Figure 2 Linear Network Configuration..................................................................................6
Figure 1 "T" Network Configuration.......................................................................................6
Figure 3 Typical Redundant Dual Media Layout....................................................................8
Figure 4 Alternate Redundant Dual Media Layout.................................................................9
Figure 5 Remote I/O Connector Pinout................................................................................15
Figure 6 2500-RIO-B Switch and Jumper Location..............................................................29

CTI 2500 Series®Remote I/O System Design, Installation & Troubleshooting Guide Revision 2.0
1
CHAPTER 1 OVERVIEW
1.1 Introduction
The CTI 2500 Series®Remote I/O System provides I/O
networking of up to 15 remote bases to 2500 Series®
Processors. Both Classic (2500-C200/C300/C400) and Janus
(2500P-J750) Processors support Remote I/O.
The system employs a standard RS-485 electrical interface and
a specialized communications protocol to communicate with the
remote bases and operate process I/O. Error detection,
correction, and recovery is automatically handled, eliminating
any need to perform these operations in the user program.
Two 2500-RIO-B base controllers can be installed as a pair in a
redundant base (2500-R11-A) to achieve media and hardware
redundancy.
1.2 Network Features
1.2.1 Electrical Interface
The electrical interface is standard RS-485, differential signaling,
unbiased. This standards-based approach allows many choices
for selection of cabling and other network components.
1.2.2 I/O Protocol
The I/O protocol uses Miller Encoding to minimize signal
bandwidth required and maximize reliability.
1.2.3 Compatibility
The CTI 2500 Series®Remote I/O System is compatible with
Simatic® 505 remote I/O components. Users can freely combine Processors and Remote
Base Controllers (RBCs) from both CTI and Siemens®on the same network.
1.3 System Components
The following components are required to make an operating 2500 Series®Remote I/O
system:
•2500 Series®Processor supporting Remote I/O
•One or more 2500 Series®Remote Base Controllers (RBCs)
•Network cabling and taps

CTI 2500 Series®Remote I/O System Design & Troubleshooting Guide Revision 2.0
2
•Network connectors
•Network terminations
1.3.1 2500 Series®Classic Processor
The CTI 2500 Series®Processor is available in four models. All models except the 2500-
C100 support operation of a remote I/O network.
Complete specifications and user guide for the 2500
Series®Processors can be found on the CTI web site:
Product Bulletin
http://www.controltechnology.com/Files/Products/2500-
(Classic)/2500-Cxxx/bulletin/ProductBulletin
Installation and Operation Guide
http://www.controltechnology.com/Files/Products/2500-
(Classic)/2500-Cxxx/manuals/CTI-2500-IOG-(62-370)
1.3.2 2500 Series®Janus Processor
The new “JANUS” Processor brings completely new capabilities to the CTI 2500 Series®
System. Designed to work seamlessly with existing 2500 Series®and Simatic®/TI 505
Systems as well as to look to the future with state-of-the-art programming, protocols and
capabilities, including direct access to the Industrial Internet of Things (IIoT) using MQTT.
Complete specifications and user guide for the 2500
Series®Janus Processors can be found on the CTI web
site:
Product Bulletin
http://www.controltechnology.com/Files/Products/2500-
Classic/2500P-Jxxx/product-bulletin/2500P-Jxxx-CPU-
ProductBulletin-FINAL
Installation and Operation Guide
http://www.controltechnology.com/Files/Products/2500-
Classic/2500P-Jxxx/manuals/Janus-Controller-Installation-
and-Operation-Guide

CTI 2500 Series®Remote I/O System Design, Installation & Troubleshooting Guide Revision 2.0
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1.3.3 2500 Series®Remote Base Controller
Each remote base in the system connects to the I/O network using a Remote Base
Controller (RBC). The 2500-RIO-B RBC operates the I/O in the remote base and
communicates to the processor.
Complete specifications and user guide for the 2500-RIO-B
can be found on the CTI web site:
2500-RIO-B Product Bulletin
http://www.controltechnology.com/Files/Products/2500-
(Classic)/2500-RIO-B/product-bulletin/2500-RIO-B product
bulletin
2500-RIO-B Installation and Operation Guide
http://www.controltechnology.com/Files/Products/2500-
(Classic)/2500-RIO-B/manuals/6200428-010
Although we recommend the use of 2500-RIO-B Remote
Base Controllers, the use of Siemens®505-6851-A and
505-6851-B is also permitted. Additionally, Texas
Instruments 500-5114-A RBCs can be used.
1.3.4 Network Cabling & Taps
Standard RS-485 cabling is used to construct the network. All cabling should use high
quality industrial-grade cable. Specific recommendations for cable types is included in
Section 2.3.
For best results, use CTI 2500-TAP RS-485 network taps
for attaching trunkline sections and droplines. These taps
use an impedance-controlled design for highest noise
immunity and include built-in termination resistance which
can be easily switched in- or out- of the circuit using a
toggle switch. They also include an electrical noise bleed
path to chassis ground which can improve the noise
immunity of your network.
Complete specifications and user guide for the 2500-TAP
can be found on the CTI web site:
2500-TAP Product Bulletin
http://www.controltechnology.com/Files/Products/2500-
(Classic)/2500-TAP/product-bulletin/06200382_010

CTI 2500 Series®Remote I/O System Design & Troubleshooting Guide Revision 2.0
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1.3.5 Network Terminations
2500 Series®Remote I/O networks must be properly terminated to ensure reliable
operation. Guidelines for network termination are included in Section 2.4 below. For best
results, use CTI 2500-TAP network taps with built-in terminations.

CTI 2500 Series®Remote I/O System Design, Installation & Troubleshooting Guide Revision 2.0
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CHAPTER 2 DESIGN & INSTALLATION
The design and installation of the CTI 2500 Series®Remote I/O network consists of the
following steps:
1. Plan and specify I/O network requirements
2. Specify and design the network topology
3. Specify cable type
4. Specify terminations
5. Document the I/O network
6. Construct the I/O network
7. Commission the I/O network
2.1 Plan and Specify I/O Network Requirements
Before you begin design the network and selecting components, be sure you have collected
all requirements of the network:
How many remote I/O bases will be included?
Where will the 2500 Series®Processor be installed?
Where will each I/O base be installed?
What is the distance between each I/O base and the processor?
Are there allowances made for routing I/O cables properly (see Section 2.6.1)?
Is space allocated for mounting network taps?
2.2 Specify and design the network topology
With information about the number of bases, distances from the processor to each base,
and possible routing paths, you can begin to select and design the network topology. Read
the information below on topology and design considerations. Then, following the guidelines
included here and the constraints of your cable routing paths, develop a network
configuration using trunklines and droplines which interconnects your I/O bases.
2.2.1 Select Basic Network Topology
The first step in designing the network is to select the basic network topology, based on
location of equipment and maximum length between the processor and the most distant
base, as shown in Figure 2.1 below. The maximum allowable trunk length depends on the
number of bases (taps) in the network and the cable type being used. The table below
shows maximum trunk length for each cable type.

CTI 2500 Series®Remote I/O System Design & Troubleshooting Guide Revision 2.0
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Number of
Terminal Blocks
Maximum Distance
Belden 9182
Belden 9271
Belden 9860
2 - 5
2200 ft (670 m)
1100 ft (335 m)
3300 ft (1006 m)
6
2133 ft (650 m)
1067 ft (325 m)
3200 ft (975 m)
7
2067 ft (630 m)
1033 ft (315 m)
3100 ft (945 m)
8
2000 ft (610 m)
1000 ft (305 m)
3000 ft (914 m)
9
1933 ft (589 m)
967 ft (295 m)
2900 ft (884 m)
10
1827 ft (569 m)
933 ft (284 m)
2800 ft (853 m)
11
1800 ft (548 m)
900 ft (274 m)
2700 ft (823 m)
12
1733 ft (528 m)
867 ft (264 m)
2600 ft (792 m)
13
1677 ft (508 m)
833 ft (254 m)
2500 ft (762 m)
14
1600 ft (488 m)
800 ft (244 m)
2400 ft (732 m)
15
1533 ft (476 m)
767 ft (234 m)
2300 ft (701 m)
16
1400 ft (427 m)
733 ft (223 m)
2200 ft (671 m)
Table 2-1 Maximum Trunk Length
Based on the maximum trunk length from the table, and requirements of your installation,
select either the “Linear Network Configuration” or “T Network Configuration”. Examples are
found in Figure 2 Linear Network Configuration and Figure 1 "T" Network Configuration
below. Note that the “T” network configuration allows you to double the maximum allowable
trunk length.
Figure 2 Linear Network Configuration
TB
TB
TB
TB = Terminal Block
C
P
U
TB
TB
Terminating Resistor
Maximum Trunk Length
TB
TB = Terminal Block
C
P
U
TB
TB
TB
TB
Maximum Trunk Length
TB
TB
Maximum Trunk Length
Terminating Resistor
Terminating Resistor
Figure 1 "T" Network Configuration

CTI 2500 Series®Remote I/O System Design, Installation & Troubleshooting Guide Revision 2.0
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Example:
The I/O network will have 11 total bases and will use Belden 9271 cable. From Table 2-1,
the maximum allowable trunk length is 274m. Therefore, as long as the distance from the
CPU to the farthest base is less than 274m, then the “Linear” configuration of Figure 2
Linear Network Configuration can be used. If the distance is between 274m and 548m, then
the “T” configuration shown in Figure 1 "T" Network Configuration must be used. If the
distance is more than 548m, then Belden 9271 cable is not adequate for this installation,
and you must use a higher grade of cable.
2.2.2 Placing Taps and Designing Droplines
Drop lines attached to each tap must be less than 10m (33 feet) in length. Any droplines
longer than 1m (3.3 feet) must be added to the total trunk length, and the resulting trunk size
must be within the limits of Table 6-2 for your network configuration and cable type.
When multiple connections are required in close proximity, you should connect the
equipment to a single terminal block instead of dedicating a terminal block to each
connection. See the figure below for connection options.
Terminal Block connections to the trunk line must be spaced so that the total length of the
trunk line separating the taps is greater than the sum of the drop line lengths at the taps. In
the illustration below, L1 must be greater than the sum of L2 + L3.
TB = Terminal Block
Remote
Base
Remote
Base
TB
Remote
Base
TB
Remote
Base
OR
Remote
Base
TB
Remote
Base
TB
L1
L2
L3

CTI 2500 Series®Remote I/O System Design & Troubleshooting Guide Revision 2.0
8
T
T
2500-TAP
T
Termination
2.2.3 Dual Media and Hardware Redundancy Installations
A pair of 2500-RIO-B RBC’s may be installed in a 2500-R11-A or 505-6511 redundant base
to provide dual media as well as hardware redundancy. In a redundant configuration, two
2500-RIO-B units are installed in the base and separate cable runs are used to provide
redundancy in both the hardware and communications cabling between the CPU and the
remote base. The dual RBCs function in an active/standby configuration. A loss of
communications to the active RBC will result in switching to the standby RBC with no
change to system outputs.
Dual media / Dual RBC configurations are supported by Classic as well as Janus
Processors.
Pictured in Figure 3 Typical Redundant Dual Media Layout is an example of a typical
hardware and cabling layout for achieving dual media redundancy. The 2500-TAP RS-485
Remote I/O Tap and Terminator is required for dual media applications.
Figure 3 Typical Redundant Dual Media Layout
Local Base
A
B
A
B
Remote Bases
KEY

CTI 2500 Series®Remote I/O System Design, Installation & Troubleshooting Guide Revision 2.0
9
Pictured in Figure 4 Alternate Redundant Dual Media Layout, is an example of the
recommended hardware and cabling layout for achieving optimum dual media redundancy.
The recommended RIO connector is made by Phoenix Contact and the model number is
2761826.
Figure 4 Alternate Redundant Dual Media Layout
Termination resistors must be installed at the ends of the trunk line, as shown in Figure 4
Alternate Redundant Dual Media Layout. The resistor value required depends on the trunk
cable as specified in section 2.4. The terminating resistor is installed between terminal
numbers 3 and 8, the transmit and receive lines.

CTI 2500 Series®Remote I/O System Design & Troubleshooting Guide Revision 2.0
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2.3 Specify cable type
Based on your topology selection and distances, specify the cable type to be used based on
the information included below.
The following cables (or equivalent) are acceptable for use for remote I/O connections.
Belden
Cable
Type
Outside
Diameter
Impedance
Capacitance
Velocity
Center
Conductor
3105A
.281 in.
7.1 mm
120 ohms
36 pf/m
0.78c
22AWG 7x30
48.2 ohms/km
9182
0.35 in.
8.9 mm
150 ohms
28.9 pf/m
0.78c
22 AWG 19x34
46 ohm/km
9271
0.24 in
6.1 mm
124 ohms
40 pf/m
0.66c
25 AWG 7x33
104.3 ohm/km
9860
0.44 in.
11.2.mm
124 ohms
35.8 pf/m
0.78c
16 AWG Solid
13.8.ohm/km
Belden 9182 and 3105A are suitable for intermediate length trunk lines. These cables
cannot be intermixed with other cables for trunk lines. In addition, if either of these cables
are used for a trunk line, they must also be used for all drop lines. It may also be used for
drop lines with Belden 9860 or Belden 9271 trunk lines.
NOTE: If the trunk line is Belden 9182, then the droplines must also be Belden 9182. If the
trunk line is Belden 9860 or 9271, then the droplines can be 9271 or 9182.
Belden 9271, which is smaller and more flexible, is suitable for use as drop lines as well as
short trunk lines. For trunk lines, this cable may be intermixed with Belden 9860.
Belden 9860 cable, which provides low attenuation and distortion, should be used for long
trunk lines.
If you use cable types other than these, you should ensure the following requirement are
met:
•Characteristic impedance between 100 and 150 ohms (124 ohms optimum)
•High uniform twist and spacing of conductors (twinaxial cable)
•Shield coverage approaching 100%
•DC resistance smaller than the characteristic impedance
•Jacket suitable for the installation

CTI 2500 Series®Remote I/O System Design, Installation & Troubleshooting Guide Revision 2.0
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2.4 Specify terminations
Termination resistors must be installed at the ends of the trunk line, as shown in Figure 2
Linear Network Configuration and Figure 1 "T" Network Configuration. The resistor value
required depends on the trunk cable as specified in the table below:
.
Cable Type
Resistor Value
Belden®3105A
120 ohms, 5%, ¼ W
Belden®9182
150 ohms, 5%, ¼ W
Belden®9860 or 9271
120 ohms, 5%, ¼ W
2.5 Document the I/O network
Before beginning construction of your network, it is important to make a detailed drawing of
the network. During construction and commissioning, keep this drawing updated to reflect
the “as built” configuration. Should you require technical support due to difficulties in
network operation, this information will be need by CTI support representatives to help you.
As a minimum, the drawing should include:
•Location of the processor and each remote base in the network
•Location of network taps
•Cable type and length for each segment of trunk line and drop line
•Location of value of network terminations
2.6 Construct the I/O network
2.6.1 General Cabling Guidelines
For highest reliability in remote I/O communications, it is important to observe proper cabling
guidelines when constructing your network.
Take steps to bypass or eliminate noise sources in order to reduce system data error rates.
The following are common sources of electrical noise.
•Power distribution mains
•Arcing motors and motor starters
•Fluorescent lighting
•Undesired signal transfer between adjacent circuits
•Poor terminations of cable connector
Do not allow the trunk cable to come into contact with any other electrical conductor. If
cabling is installed inside a conduit, the conduit should be grounded according to applicable
electrical codes.

CTI 2500 Series®Remote I/O System Design & Troubleshooting Guide Revision 2.0
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IMPORTANT: Maintain a minimum of 3 feet (1 m) between trunk lines and the
following noise sources.
•Power lines
•Electric motors and motor starters
•Variable speed drives
•Generators
•Electric welders
The type of routing is usually determined by the type of building in which the cables are
being installed. Any combination of the following may be used to route the cables: under-
floor, in-ceiling, or surface duct.
Consider the following general guidelines before installing any system or power wiring.
•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. Use 7.6 cm (3 inches) radius on all
bends.
•Ensure that a good low earth ground impedance of 0.1 ohm or less exists for all
components in the system.
•Use metal wireways and conduit when possible.
•Keep wire strippings from falling into modules, controllers, or bases.
•For long return lines to the power supply, do not use the same wire for input and
output modules. Using separate return wiring for these modules minimizes the
voltage drop on the return lines of the input connections.
2.6.2 Constructing Trunk Line Cables
Use the following procedure to prepare trunk line cables.
1. Strip back 38mm (1.5 in) of the sleeving on both ends of the cable. There are three
wires exposed 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 3.3mm (0.13 in) of each color-coded insulation
jacket (both ends) to expose the bare wires.