CTI 2500-C100 Instruction Manual

CTI 2500 Series®Controller
INSTALLATION AND OPERATION GUIDE
Version 2.8
CTI Part # 062-00370
2500IOG

CTI 2500 Installation and Operation Guide V2.8 ii
Copyright 2018 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
REVISION HISTORY
V 1.0
6/28/07
Initial Release
V 1.1
10/30/07
Defined additional Profibus status bits for STW231.
Added fatal error code for hardware watchdog event.
Added information regarding the IPSET utility.
Added a caution to avoid duplicate IP addresses.
Changed fatal error section to reflect that the fatal error code will be
displayed on the MSD.
V1.2
Corrected error describing STW162 bit 12.
V1.3
4/29/08
Documented STW 455 – STW 501.
Revised Section regarding Ethernet TCP/IP to improve clarity.
Revised Appendix C to improve clarity.
Revised description of SW6 usage to improve clarity.
V1.4
6/30/08
Added section for user flash operation
V1.5
10/8/08
Corrected erroneous status word bit reference in non-fatal error table.
Added instructions for selecting PRINT jumper
Added STW191 use for serial port print error reporting.
V1.6
12/1/08
Changed error codes containing a B or D to lower case b or d to
correspond to multi-segment display.
Added firmware update status code table.
V1.7
2/25/09
Added a comment requiring all reserved switches to be set to the closed
position.
V1.8
5/11/09
Added specification of serial port parity, data bits, and stop bits.
Added instructions for upgrading firmware using the SD card.
Added description of the duplicate IP detection feature.
V1.9
6/11/09
Added specifications and handling instructions for the lithium battery

CTI 2500 Installation and Operation Guide V2.8 iii
REVISION HISTORY
V1.10
9/16/09
Revised Profibus DP cabling specifications to be expressed in meters
rather than feet.
Added Belden Hi-Flex cable to recommended Profibus DP cabling.
Added specifications for maximum number of DP Profibus slaves and
maximum number of slots per slave.
V1.11
11/10/09
Added specifications for the amount of data per Profibus slave and slots
per Profibus slave supported by the 2500 controller.
V1.12
11/30/09
Corrected specifications for STW191.
V1.13
2/15/10
Added warning for use of USB port in hazardous environments.
Added section describing system restart options.
V1.14
3/16/10
Revised text to reflect new features introduced in firmware V6.07.
•new status bits in STW244 and STW245,
•fatal error code in STW246,
•automatic IP address assignment,
•capability to change IP address in Run mode,
•expansion of modular slave slots supported from 64 to 128,
Added a section on Profibus operation to explain Profibus operational and
synchronization modes and to highlight diagnostic capabilities.
Corrected serial port pinout diagram in Appendix E.
V1.15
9/21/10
Revised text to reflect new Profibus slave status bit in STW321 (added in
firmware V6.11).
V1.16
11/17/10
Provided more detail regarding startup errors E9 – E14
V1.17
1/10/10
Corrected error specifying status words for product serial number.
V1.18
5/5/11
Added new error code 102 to the list of fatal errors.
Corrected a corrupted cross-reference on page 47.
V1.19
9/20/11
Added documentation for dual RBC support
Revised remote I/O topology drawings to better illustrate dual RBC
connectivity.
Updated product pictures to reflect latest front panel overlay.
Enhanced battery specifications in Appendix B.
Deleted battery specification in product model table.
V1.20
4/21/13
Added documentation for new functionality enabled by Switch 7 and 8.
Revised text regarding switches and jumpers to improve clarity.
V1.21
4/25/14
Modified switch drawing to include SW7 and SW8
Revised text to correct typographic errors and improve clarity
Updated SD card documentation
V1.22
6/26/14
Added documentation regarding support of additional control relays.
Added table indicating retentive and non-retentive control relay
addresses.
Modified installation instructions to reflect that the controller battery is now
shipped with the battery installed.
Created a Battery Replacement appendix.
V1.23
7/28/14
Clarified SD card requirements. Added an SD Requirements appendix.
V1.24
4/8/15
Added a list of all task code errors.
V1.25
6/23/15
Revised the description of the serial port (section 7.2) to include use as a
printer port.
V1.26
9/10/15
Revised documentation to include new features added in firmware version
8.02. (Ethernet port IP address change, embedded web server IP
configuration page, reset to factory default, display subnet in CIDR
format).
Added sections to Installation chapter regarding setting IP address and
automatic IP address assignment.

CTI 2500 Installation and Operation Guide V2.8 iv
REVISION HISTORY
V1.27
9/17/15
Corrected error in Appendix C; CIDR notation for subnet mask
255.255.240.0.
V1.28
11/30/15
Corrected error in firmware update error table for error E30
Revised text for firmware update error E31 to improve clarity.
V1.29
3/1/2016
Expanded firmware update status codes to include Profibus FPGA (Rev
G and above)
Expanded firmware update error codes to include Profibus FPGA (Rev G
and above)
V2.0
8/25/2016
Added compact PLC (2500C-Cxxx)
Implemented table of contents hyperlinks
V2.1
1/3/2017
Corrected version support for TISOFT.
V2.2
1/26/17
Corrected illustration of user jumper (p26)
Updated copyright date
V2.3
2/6/2017
Modified properties of user jumper illustration to correct text positioning.
Added caption to open Jumper illustration.
V2.4
2/14/2017
Added inline SFP to the potential causes of fatal error 113 in Section
9.3.2.
V2.5
2/27/2017
Revised description for error E30.
V2.6
8/23/2017
Replaced dipswitch position picture for compact controller models
V2.7
12/11/2017
Added documentation for STW300 – STW330
V2.8
4/24/2018
Added a note to Appendix B stating that status words 243 and above are
not supported by Siemens 505 controllers.
Revised note in Firmware Update section that appeared to limit supported
SD cards to 4GB and below

CTI 2500 Installation and Operation Guide V2.8 5
PREFACE
This Installation and Operation Guide provides reference information for CTI 2500 Series
Classic controllers and CTI 2500 Series Compact controllers. The information in this manual is
directed to individuals who will be installing and operating the controller as well as those who
will be designing systems that use the controller.
For comprehensive programming information, you should also obtain the CTI 2500
Programming Reference Manual (CTI Part # 062 -00371).

CTI 2500 Installation and Operation Guide V2.8 6
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.

CTI 2500 Installation and Operation Guide V2.8 7
TABLE OF CONTENTS
CHAPTER 1 OVERVIEW................................................................................................11
1.1 Introduction .................................................................................................................. 11
1.2 Controller Features......................................................................................................11
1.3 User Program Support................................................................................................. 11
1.4 I/O Support................................................................................................................... 12
1.5 Ethernet TCP/IP Connectivity ..................................................................................... 12
1.6 Programming Support .................................................................................................12
1.7 Serial and USB Connectivity....................................................................................... 13
1.8 2500 Series Classic Controller Front Panel................................................................ 14
1.9 2500 Series Compact Controller Front Panel.............................................................15
1.10 Operational Status LEDs.............................................................................................16
1.11 Multi-Segment Display................................................................................................. 16
1.12 Battery Holder.............................................................................................................. 16
1.13 SD Flash Card Slot...................................................................................................... 16
1.14 USB Port...................................................................................................................... 16
1.15 Ethernet Status Indicators........................................................................................... 16
1.16 Ethernet Port................................................................................................................ 17
1.17 RS-232/ RS-422 Serial Port........................................................................................17
1.18 Profibus-DP Port.......................................................................................................... 17
1.19 I/O Port......................................................................................................................... 17
1.20 Product Models............................................................................................................ 18
CHAPTER 2 INSTALLATION.........................................................................................19
2.1 Installation Planning.....................................................................................................19
2.2 Unpacking the Controller............................................................................................. 21
2.3 Setting the User Switches ........................................................................................... 22
2.4 Setting the User Jumpers or Auxiliary Switches......................................................... 26
2.5 Physical Installation ..................................................................................................... 28
2.6 Initial Power On............................................................................................................28
2.7 Setting the Controller IP Parameters .......................................................................... 29
2.8 Automatic IP Address Assignment.............................................................................. 29
CHAPTER 3 USER PROGRAMMING............................................................................31
3.1 Overview ...................................................................................................................... 31
3.2 Relay Ladder Programming ........................................................................................ 31
3.3 Special Function Programs and Subroutines............................................................. 32
3.4 Analog Loops............................................................................................................... 33
3.5 Analog Alarms.............................................................................................................. 33
CHAPTER 4 I/O SUPPORT ............................................................................................35
4.1 I/O Concepts................................................................................................................ 35
4.2 I/O Support................................................................................................................... 36
4.3 Dual RBC Support....................................................................................................... 39
4.4 Profibus DP I/O............................................................................................................ 41

CTI 2500 Installation and Operation Guide V2.8 8
CHAPTER 5 CONTROLLER MEMORY.........................................................................47
5.1 Overview ...................................................................................................................... 47
5.2 User Program RAM.....................................................................................................47
5.3 Flash Memory..............................................................................................................49
5.4 High Speed DRAM ...................................................................................................... 49
CHAPTER 6 SCAN TIMELINE .......................................................................................51
6.1 Scan Overview............................................................................................................. 51
6.2 PLC Scan Types.......................................................................................................... 53
6.3 Scan Modes................................................................................................................. 54
CHAPTER 7 COMMUNICATIONS..................................................................................57
7.1 Overview ...................................................................................................................... 57
7.2 Serial Communications................................................................................................ 57
7.3 USB Communications .................................................................................................57
7.4 Ethernet Communications........................................................................................... 58
CHAPTER 8 SYSTEM RESTART OPTIONS .................................................................63
8.1 Overview ...................................................................................................................... 63
8.2 Restart Options............................................................................................................63
8.3 System Restart Table.................................................................................................. 64
CHAPTER 9 TROUBLESHOOTING...............................................................................65
9.1 Troubleshooting Aids...................................................................................................65
9.2 Startup Errors............................................................................................................... 65
9.3 Fatal Errors .................................................................................................................. 66
9.4 Non-Fatal Errors .......................................................................................................... 70
CHAPTER 10 UPDATING FIRMWARE............................................................................73
10.1 Overview...................................................................................................................... 73
10.2 Serial Port Method....................................................................................................... 73
10.3 SD Card Method.......................................................................................................... 77
10.4 Firmware Update Status Codes.................................................................................. 78
10.5 Firmware Update Errors.............................................................................................. 79
CHAPTER 11 USER PROGRAM FLASH STORAGE......................................................81
11.1 Overview...................................................................................................................... 81
11.2 Using Flash Memory.................................................................................................... 82
11.3 Power-On Start Operation........................................................................................... 83
11.4 Restrictions When the Program Source is Flash........................................................ 83
APPENDIX A. - ERROR CODES ......................................................................................85
Startup Error Codes................................................................................................................ 85
Fatal Error Codes ................................................................................................................... 86
Task Code Errors.................................................................................................................... 88
APPENDIX B. – SYSTEM STATUS WORDS ...................................................................91
APPENDIX C. – IP ADDRESS INFORMATION................................................................99
IP Address Nomenclature ...................................................................................................... 99
Selecting IP Addresses ........................................................................................................100

CTI 2500 Installation and Operation Guide V2.8 9
APPENDIX D. – COMPATIBILITY ..................................................................................103
Overview...............................................................................................................................103
Relay Ladder Logic...............................................................................................................103
Special Function Programs..................................................................................................103
User Configuration................................................................................................................104
I/O Support............................................................................................................................104
APPENDIX E. – BATTERY REPLACEMENT.................................................................105
APPENDIX F. – PRODUCT SPECIFICATIONS..............................................................107
Hardware Specifications.......................................................................................................107
Serial Port Pinout..................................................................................................................107
I/O Port Pinout ......................................................................................................................108
Profibus Port Pinout..............................................................................................................108
APPENDIX G. – SD CARD REQUIREMENTS................................................................109
CTI 2500 Series Classic Controller SD Card Requirements ..............................................109
CTI 2500 Series Compact Controller SD Card Requirements ...........................................109
Data Storage Capacity.........................................................................................................109
Physical Size.........................................................................................................................109
Speed109
LIMITED PRODUCT WARRANTY ..................................................................................111
REPAIR POLICY .............................................................................................................113


CTI 2500 Installation and Operation Guide V2.8 11
CHAPTER 1
OVERVIEW
1.1 Introduction
Providing the capabilities of a programmable logic controller and a loop controller, the CTI 2500
Series®controllers offer solutions for a wide range of process control applications. The CTI
2500 Series includes two families, CTI 2500 Series Classic and CTI 2500 Series Compact.
•Classic: 2500 Series Classic controllers (2500-Cxxx) are physically compatible with the
Siemens SIMATIC 505 product line and may be installed in a CTI 2500 Series base or a
Siemens SIMATIC 505 base, along with CTI 2500 Series Classic I/O and SIMATIC 505
I/O.
CTI 2500 Series Classic controllers are also operationally compatible. They can run
most user programs that were originally developed for Siemens SIMATIC 505 controllers
(see APPENDIX D. – COMPATIBILITY for exceptions) and can communicate with
remote bases using SIMATIC 505 or CTI 2500 Series remote base controllers.
•Compact: CTI 2500 Series Compact controllers (2500C-Cxxx) are physically smaller
than the Classic controllers but are otherwise operationally identical to the 2500 Series
Classic controllers.
1.2 Controller Features
1.3 User Program Support
User Program components include Relay Ladder Logic (RLL), Special Function programs,
Analog Loops, and Analog Alarms. The User Program is stored in battery backed RAM and is
preserved when power is removed from the controller, assuming the battery is good. See
CHAPTER 3 for more information about user programming.
Relay Ladder Logic
CTI 2500 Series controllers incorporate a powerful RLL programming language that is
compatible with the RLL used in the Siemens SIMATIC®505 PLC. The RLL program is
compiled in the controller before execution.
Special Function Programs and Subroutines
Special Function programs and subroutines introduce the capability to program in a procedural
language, similar to Basic or Structured Text. This capability can be used to implement control
processes that would be difficult or impossible to program in RLL.
All Special Function programs and subroutines are compiled on the controller. Where
applicable, they make use of the double-precision floating point unit provided by the CTI 2500
hardware.
Special Function programs and subroutines may be called from RLL for in-line execution or
queued for subsequent execution in the analog portion of the scan. Special Function programs
can also be called from PID loops or Analog alarms or executed on a cyclic basis.

CTI 2500 Installation and Operation Guide V2.8 12
Analog Loops
CTI 2500 Series controllers incorporate a comprehensive, parameter-driven PID loop algorithm.
PID loop calculations make use of a double-precision floating point processor. Loop
calculations can be automatically executed on a specified time interval or called directly from
RLL (Models 300 and 400 only). The number of PID loops supported depends on the controller
model. See Section 1.20.
Coupled with the loop processing is an extensive alarm reporting capability.
Analog Alarms
The CTI 2500 controller includes analog alarm functions that can monitor the process variable
and the set point. Absolute values, deviation, and rate of change can be monitored. The number
of analog alarms supported varies with the controller model. See Section 1.20
1.4 I/O Support
The CTI 2500 Series controller supports CTI 2500 Series Classic I/O, CTI 2500 Series Compact
I/O, Siemens SIMATIC®505 compatible I/O and Profibus DP I/O.
SIMATIC®505 Compatible I/O
The CTI 2500 controller supports all CTI 2500 series modules and most Siemens SIMATIC®
505 discrete and analog modules. In addition, the controller will communicate with designated
Siemens SIMATIC®505 Special Function modules. See the CTI Web site
(www.controltechnology.com) for a list of supported Siemens modules.
The CTI 2500 controller also permits the attachment of remote bases using CTI 2500-RIO or
CTI 2500C-RIO remote base controllers or Siemens Series 505®or Series 500®remote base
controllers. See Section 4.2 for more information.
Profibus DP I/O
The CTI 2500 controller supports I/O that conforms to the Profibus DP standard, including the
CTI 2500-RBC and the Siemens®505-6870. The Profibus network can be configured using
software tool shipped with your programming software.
1.5 Ethernet TCP/IP Connectivity
The CTI 2500 controller provides a local 10/100 Mb Ethernet port, allowing it to be connected to
plant floor networks. Programming software that supports the TCP/IP protocol, such as FasTrak
Softworks Workshop®, can be used to program the CTI 2500 via the network.
Although the primary purpose of the Ethernet port is to provide network access for programming
and operating the controller, it also may be used by Supervisory Control and Data Access
(SCADA) applications. Software with drivers that support the CTI 2572 or 2572-A network
modules can be used with the local Ethernet port. See CHAPTER 7 for additional information.
1.6 Programming Support
To access all the features of the CTI 2500 controller, you must use PLC Workshop Version 4.11
or greater. Contact FasTrak Softworks, Inc. (262) 238-8088 to obtain this software.
The following programming software can be used; however, certain features, such as additional
memory, may not be accessible:
•Siemens TISOFT®V7.1
•Siemens APT®V1.9

CTI 2500 Installation and Operation Guide V2.8 13
See the CTI 2500 Programming Reference Manual for additional details.
Using suitable programming software, you may edit directly the User Program stored in the
controller memory. Alternately, you can program off-line and then download the program to the
controller.
1.7 Serial and USB Connectivity
The CTI 2500 controller provides a traditional 9 pin serial port and a USB (Universal Serial Bus)
port which may be used to program the controller and control its operation. See CHAPTER 7 for
more information.

CTI 2500 Installation and Operation Guide V2.8 14
1.8 2500 Series Classic Controller Front Panel
1. Operational Status LEDs
CPU GOOD
RUN
BATTERY GOOD
2. Multi-Segment Display` (MSD)
3. Battery Holder
4. SD Card Slot
5. USB Port
6. Network LEDs
LS – Link Status
NS- Network Status
7. Ethernet Port
XMT LED – Flashes when transmitting
RCV LED – Flashes when receiving
8. Serial Communications Port
RS-232/RS-422)
9. Profibus DP Port
10. Remote I/O Port

CTI 2500 Installation and Operation Guide V2.8 15
1.9 2500 Series Compact Controller Front Panel
1. Status LEDs
CPU GOOD
RUN
BATTERY GOOD
2. Multi-Segment Display` (MSD)
3. USB Port
4. SD Card Slot
5. Network LEDs
LS – Link Status
NS- Network Status
6. Battery Holder
7. Ethernet Port
XMT LED – Flashes when transmitting
RCV LED – Flashes when receiving
8. Serial Communications Port
RS-232/RS-422)
9. Profibus DP Port
10. Remote I/O Port

CTI 2500 Installation and Operation Guide V2.8 16
1.10 Operational Status LEDs
The following LEDs provide status information:
CPU
Good
When this LED is on, the controller is operational.
When this LED is off, power is not present or a startup or fatal error exists. See
CHAPTER 9.
Run
When this LED is on, the controller is in RUN mode.
When this LED is off, the controller is in PROGRAM mode.
When this LED is blinking, the RLL execution is in PROGRAM mode and the Analog
execution is in RUN mode.
Battery
Good
When this LED is on, the battery is good.
When this LED is off, the battery is bad or missing or the battery switch is Off.
When this LED is blinking, this LED indicates that the battery is marginal and should be
replaced.
1.11 Multi-Segment Display
The Multi-Segment Display (MSD) is used to display status and error codes (see CHAPTER 9).
During normal operation it will display the TCP/IP address, one octet at a time. Firmware
Version 8.02 and above firmware also displays the network mask in CIDR (Classless Inter-
Domain Routing) format following the IP Address. See APPENDIX C. – IP ADDRESS
INFORMATION for more information about CIDR format.
1.12 Battery Holder
The battery holder contains the battery that maintains the User Program and related data when
the controller is not powered. The battery may be replaced while the controller is installed and
powered, eliminating the need to re-program the controller after swapping the battery.
1.13 SD Flash Card Slot
2500 Series Classic controllers accommodate a standard SD or SDHC card. 2500 Series
Compact controllers accommodate a micro SD or micro SDHC card, The SD card may be used
to upgrade the controller firmware. See APPENDIX G. – SD CARD REQUIREMENTS.
1.14 USB Port
The CTI 2500 controller provides a type B USB (Universal Serial Bus) connector. The port can
be used to program the controller. A special PC driver that emulates a standard COM port is
required. See Section 7.3 for additional information.
WARNING
The USB Port is for temporary connection only.
Do not use, connect, or disconnect the USB cable unless area is known to be non-hazardous.
Connection or disconnection in an explosive atmosphere could result in an explosion.
1.15 Ethernet Status Indicators
LS – Link Status
When this LED is on, an Ethernet link has been established.
NS – Network
Status
When the network is operating normally, the LED color will be GREEN. If a
network device with the same IP address as the Ethernet port is detected,
this LED will be RED.

CTI 2500 Installation and Operation Guide V2.8 17
1.16 Ethernet Port
The Ethernet port allows you to connect the controller directly to an Ethernet network using a
standard RJ-45 connector. The port automatically selects between 10bT and 100bTX Ethernet
and between half or full duplex, depending on speed of the device to which it is connected. Two
status indicators that display Ethernet traffic are embedded into the connector.
TX- Transmit
Flashes when the port transmits an Ethernet packet.
RX- Receive
Flashes when the port receives an Ethernet packet. *
*Ethernet packets received by the port do not necessarily contain data for the controller.
See Section 7.4 for information regarding use of the Ethernet port.
1.17 RS-232/ RS-422 Serial Port
The serial port can support either an RS-232 or an RS-422 electrical interface. When the RS-
232 electrical interface is selected, you can connect to the RS-232 serial port on your PC using
a standard null modem cable or cables that are currently used with the Siemens Series 505®
controllers. For longer cable runs, you can select the RS-422 electrical interface, which is
supported by some operator interface equipment.
The electrical interface and port baud rate via a set of user switches on the controller circuit
board. See Section 2.3 for further information regarding the user switches. The other port
parameters have constant values: Parity = Odd, Data Bits = 7, and Stop Bits = 1.
Normally, the serial port is used for programming and data access. However, you can change
the function of the port to a printer port (output only) by repositioning a jumper on the printed
circuit board (see Section 2.4). You can then use the PRINT statement to send a character
string to the printer our output device. See the CTI 2500 Series Programming Reference Manual
for additional information.
If your application requires a custom cable, see APPENDIX F. – PRODUCT SPECIFICATIONS
for the port pinout.
1.18 Profibus-DP Port
This port allows you to connect the controller to a standard Profibus-DP network. See
CHAPTER 4 for more information on using Profibus and APPENDIX F. – PRODUCT
SPECIFICATIONS for the port pinout.
1.19 I/O Port
The I/O port enables you to connect CTI 2500 Series and SIMATIC Series 505®Remote I/O.
See CHAPTER 4 for additional information regarding remote I/O support and APPENDIX F. –
PRODUCT SPECIFICATIONS for the port pinout.

CTI 2500 Installation and Operation Guide V2.8 18
1.20 Product Models
The CTI 2500 Classic controller (2500-Cxxx) is available in four models. The CTI 2500 Compact
(2500C-Cxxx) controller is available in three models. The following table lists the model
characteristics.
Feature
2500-C100
2500C-C100
2500-C200
2500C-C200
2500-C300
2500C-C300
2500-C400
User Program RAM
128K
256K
512K
3072K
Discrete I/O Points
1024
2048
8192
8192
Word I/O Points
1024
1024
8192
8192
Control Relays
4096
32,768
32,768
32,768 See Note 1
Retentive Control
Relays
1024
4096
4096
4096
Timers/Counters
1024
20,480
20,480
20,480
Compiled SF
Yes
Yes
Yes
Yes
Cyclic PID Loops
16
64
128
128
RLL Initiated PID
Loops (Fast Loops)
0
0
384
384
Analog Alarms
32
128
512
512
Special Function
Programs
64
1023
1023
1023
Special Function
Subroutines
64
1023
1023
1023
Remote IO
None
15 bases
15 bases
15 bases
Profibus I/O
None
Up to 112
devices
Up to 112
devices
Up to 112
devices
Maximum Serial Port
Data Rate
115,200 baud
115,200 baud
115,200 baud
115,200 baud
Flash O/S
Yes
Yes
Yes
Yes
Removable User
Storage
SDHC Card -
Up to 32GB
SDHC Card -
Up to 32GB
SDHC Card -
Up to 32GB
SDHC Card -
Up to 32GB
On Board User Flash
Yes
Yes
Yes
Yes
Local Ethernet Port
Yes
Yes
Yes
Yes
USB Port
Yes
Yes
Yes
Yes
Remote I/O
No
Yes
Yes
Yes
Profibus I/O
No
Yes
Yes
Yes
Note 1: CTI 2500 Classic controller model C400 with firmware version 8.01 and above support
56,320 control relays. See Section 5.2.3 for more information.

CTI 2500 Installation and Operation Guide V2.8 19
CHAPTER 2
INSTALLATION
The installation of the CTI 2500 Controller consists of the following steps:
1) Reading this Chapter
2) Planning the installation,
3) Unpacking and configuring the module,
4) Physical installation,
5) Connecting cables,
6) Checking the controller operation.
2.1 Installation Planning
2.1.1 Safety Considerations
Before installing the controller, you must identify the personnel hazards that may be created in
the event of a system failure and provide interlocks and safety switches to prevent operation
during a system failure. Refer to the NEMA ICS 3-304 Programmable Control Standards.
WARNING
As a system designer, you should be aware that Control devices can fail in an unsafe condition. Unless you
incorporate proper safeguards, malfunction of the controller or associated devices, such as operator
interface equipment, could cause sudden equipment startup, shutdown, or other unexpected operation.
Such startup or shutdown or unexpected operation could result in death or serious injury to personnel,
and/or damage to equipment.
If you or your company are using CTI controllers with equipment that requires the presence of a person
(such as an operator or attendant), you should be aware of this potential safety hazard and take appropriate
precautions.
The precautions below conform to the National Electrical Manufacturers Association guidelines
for installation of programmable controllers as recommended in the NEMA ICS 3–304
Programmable Control Standards.
ICS 3-304.81 Safety Recommendations:
Consideration should be given to the use of an emergency stop function which is independent of
the programmable controller. Where the operator is exposed to the machinery, such as in
loading or unloading a machine tool, or where the machine cycles automatically, consideration
should be given to the use of an electromechanical override or other redundant means,
independent of the programmable controller, for starting and interrupting the cycle. If provision is
required for changing programs while the equipment is in operation, consideration should be
given to the use of locks or other means of assuring that such changes can be made only by
authorized personnel. These recommendations are intended as safeguards against the failure
of critical components and the effects of such failures or the inadvertent errors that might be
introduced if programs are changed while the equipment is in operation.

CTI 2500 Installation and Operation Guide V2.8 20
Operator Safety Switches
Power should be configured so that it can be manually removed from all output devices. You
must provide a method that is independent of the control system for disconnecting power from
the outputs when a machine is not operating or the operator must reach into the machine. A
non-electronic switch or directly wired relay must be used to disconnect the power.
Emergency Stop Switch
You must provide a method for disconnecting power from the outputs if an emergency situation
is encountered with the machine operation. Use a non-electronic switch or relay that is wired
external to the controller and that is easily accessible.
2.1.2 Electrical Interference
Electrical interference can adversely affect the operation of control equipment. The major
sources of electrical interference in an industrial environment are devices that use high voltages
and current, such as motors and welders. Electrical interference can be conducted directly
through wiring or inducted via electromagnetic coupling.
To ensure a reliable control system, you will need to determine the source of the electrical
interference and employ suitable techniques to eliminate it.
2.1.3 Grounding
It is very important that the all equipment is properly grounded. Lack of proper grounding may
cause intermittent or erratic operation or may cause the control system to fail. A properly
installed grounding system will provide a low-impedance path to earth ground, which will give all
PLC internal filtering devices a good ground return for reference. The earth ground of the
building site typically provides reliable grounding; however, if excessive ground current is
present, a separate grounding electrode should be installed.
A common practice is to provide a central ground bus bar as a single point of reference within
each enclosure, connecting all chassis and power supply components to the bus bar. The bus
bar is then connected to earth ground. When connecting to the bus bar, use 1 inch copper braid
or No. 8 AWG wire. To ensure good connections, scrape paint or other non-conductive coatings
away from mounting studs and from enclosure surfaces where mounting bolts and washers
make contact.
In addition to connecting the controller rack and power supply to earth ground, you must ensure
that the power supply, controller and all modules installed in the base are installed securely and
that the thumbscrews are tightened.
This manual suits for next models
6
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