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CTI 2500-C100 Application Notes

Application Notes

• Capturing Diagnostic Information on CTI 2500 Series CPUs (YouTube Video)

• Redundancy and Backup Solutions (MS-Powerpoint)

• Understanding CIDR Notation Used for IP Address Display on 2500 Series®

Processors

• Connecting CTI 2500 Series® Processors to Siemens® COROS® OP/TP HMI

Units using Profibus – Driver Files & Documentation

• Providing Diagnostic Data for Support on CTI 2500 Series® Processors and

Coprocessors

• What causes a CPU to go into Fatal Error and how do I recover?

• Adding Serial Ports to 2500 Series® Processors using GridConnect NET232 Adapter

• Configuration of Serial Ports on CTI 2500 Series® and Simatic® 545/555 Processors

• Identifying Hardware Revision Level on 2500 Series® Processors

• Accessing Memory Above 1856K on 2500-C400 Processors using APT®

• Optimizing Performance Using the 2500 Series® Processor

• Connecting to a 2500 Series® Processors using PLC Workshop

• 2500 Series® Redundancy Options

• Guide to Upgrading TI560/565 to CTI 2500 Series® System

• Guide to Upgrading TI520C& 530T to CTI 2500 Series® System

• Recovering the Event Log from a CTI 2500 Series® Processor

• 2500 Series Processor V6.02 Firmware Enhancements

• Using the Port Lockout Feature on 2500 Series® Processor to prevent simultaneous

program edits

• CPU Redundancy with 2541 and 2500P-ACP1/JACP (pdf application note)

• Setting Up S7-1500 as a Profibus-DP Slave on CTI 2500 Series® Processors

• CPU Redundancy with 2541 and 2500P-ACP1/JACP (sample program files for CPU,

2541. ACP1/JACP)

• Setting Up S7-1500 as a Profibus-DP Slave on CTI 2500 Series® Processors- Sample

Files

• Recovering Diagnostic Data from a CTI 2500 Series® Processor

• E89 Error on 2500-Cxxx Family Processors

• PID Loop Bumpless Transfer with CTI and Simatic/TI PLCs

CTI 2500-C100 CPU with 128K User Memory

The 2500-C100 CPU provides discrete, analog, loop, advanced mathematical

and high-speed sequential control capability for your CTI 2500 Series® or

Simatic® 505 control system.

Features

• Replaces Siemens® 545-1103 and 545-1105 with no rewiring

• Note that if the Siemens® processor includes a Profibus-DP annex card,

then 2500-C200 must be used

• 128K user memory

• 1024 digital / 1024 analog I/O

• 16 loops / 32 alarms

• Built-in Ethernet for programming and MMI

• Built-in USB for programming

• Built-in SD flash card slot for firmware update

Beckhoff EL3072 | EtherCAT Terminal, 2-channel analog input, multi-function

The EL3072. EL3074. and EL3078 analog input terminals are universal

10 V/20 mA input modules in the 16-bit class for simple control tasks.

Input signals in the -10/0…+10 V or -20/0/+4…+20 mA ranges can

be processed per channel. Voltage and current signals are connected

to different terminal points. CoE can be used to set each channel to U

or I mode in TwinCAT or from the controller.

The voltage and current inputs are single-ended. This means that one

connection point of each channel is connected to +24 V or 0 V

(power contacts) in the terminal. All inputs are digitized with a 16-bit

resolution and transmitted to the superordinate automation system

under electrical isolation. With a technical measuring range of ±107%

of the nominal range, the terminal also supports commissioning with

sensor values in the limit range and evaluation in accordance with

NAMUR NE43.

The EL3072 has two individually parameterizable inputs and supports

2-, 3-, and 4-wire connection. It can supply sensors with +24 V directly.

Special features:

• combined input terminal: 10 V/20 mA

• ±107% measuring range

• 2 ksps conversion rate per channel for standard automation tasks

Beckhoff EL/ED3xxx Calibration to control the measurement chain

Advantages:

robust measurement of analog signals with long-term availability fine scalability

of channel density and functional scope extensive adjustment and diagnostic

options in the terminals via the EtherCAT bus distributed clocks for the precise

acquisition of the timestamp of an input signal and synchronization of the network

optionally calibrated terminals for precise acquisition of the measurement uncertainty

Areas of application:

production machines

test systems

condition monitoring

energy generation systems

Calibration to control the measurement chain

Calibration certificates (factory calibration or calibration to ISO 17025/DAkkS)

are also available for some EtherCAT analog input terminals. If Beckhoff 

EtherCAT Terminals are part of a measurement chain and therefore subject

to special requirements for the reproducibility and traceability of measurement

results, a calibration certificate can be issued to the user for certain terminal

types for quality assurance purposes. The certificate is issued for individual

terminals, enabling a more precise definition of the entire measurement chain

as proof of the exact measurement deviation of the terminal and thus reducing

the measurement uncertainty. In the context of the uncertainty assessment of

a measurement, the possible influence of the Beckhoff terminal can be reduced

in this way.

Beckhoff EL/ED3xxx Distributed clocks and XFC for speed and precision

Distributed clocks and XFC for speed and precision

Some analog EtherCAT Terminals support the XFC technology (eXtreme

Fast Control), which enables rapid, deterministic reactions in the µs range.

This technology enables fast I/O response times, oversampling of the input

signal and precise time measurement for events at the input with a

resolution of 1 ns. Highly accurate synchronization of all distributed clocks

-capable devices in the network is attainable with a synchronization accuracy

of << 1 µs with the EtherCAT distributed clocks, which are implemented in

many EtherCAT analog terminals.

Calibration to control the measurement chain

Calibration certificates (factory calibration or calibration to ISO 17025/DAkkS)

are also available for some EtherCAT analog input terminals. If Beckhoff 

EtherCAT Terminals are part of a measurement chain and therefore subject

to special requirements for the reproducibility and traceability of measurement

results, a calibration certificate can be issued to the user for certain terminal

types for quality assurance purposes. The certificate is issued for individual

terminals, enabling a more precise definition of the entire measurement chain

as proof of the exact measurement deviation of the terminal and thus reducing

the measurement uncertainty. In the context of the uncertainty assessment of

a measurement, the possible influence of the Beckhoff terminal can be reduced

in this way.

Beckhoff EL/ED3xxx | EtherCAT Terminals, analog input

The EtherCAT Terminals from the EL/ED3xxx, ES3xxx, ELM3xxx, ELX3xxx

and EM3xxx series process the most diverse analog signals. 

The typical standard signals encountered in the automation industry, such

as 0 to 10 V, ±10 V, 0 to 20 mA and 4 to 20 mA, are supported and pre-

processed along with other measured variables such as resistance,

pressure or temperature. The product portfolio additionally includes analog

EtherCAT Terminals for the connection and evaluation of special sensors

such as strain gauges, thermocouples, resistance thermometers and

accelerometers. Special analog EtherCAT Terminals are also available for

measurement tasks in energy and power measurement.

Beckhoff offers the right product for every application in its product

portfolio of analog EtherCAT input terminals. Due to a comprehensive

selection of terminals with different numbers of channels, resolutions

and measuring accuracies, the right product is available for every

application, from simple industrial applications to high-precision

measurement technology. There are also different product categories for

some application areas. For example, the analog input terminals from the

ELX3xxx series are specially designed for potentially explosive atmospheres

and the products from the ELM3xxx series with their low measurement

uncertainty are especially designed for measurement applications with

high requirements.

Beckhoff ELM2644-0000 | EtherCAT Terminal, 4-channel reed output, multiplexer

With the EL/ELM264x (Reed) and ELM274x (Solid-State) Beckhoff

is considerably extending the usage possibilities of the integrated

measurement technology of the ELM3xxx series as well as the

normal EL3xxx/EL4xxx analog inputs and outputs, because several

sensors or sources can now be connected at the same time to one

analog input channel.

To this end, the ELM2642 and ELM2644 are equipped with Reed

relays as switching elements, allowing fast switching cycles and

a long lifetime. The electrical isolation and the constant contact

resistance of the reed switch allows the measurement of even

sensitive signals up to fast scanning operation.

Due to the double input connectors X the channels can easily be

connected to 1 x 8 multiplexers and more.

The multi-channel recording of analog signals as well as the flexible

switching of various test states in production-integrated test

stations is easily possible through the integration of the often

necessary switches into the EtherCAT system.

Beckhoff ELM2642-0000 | EtherCAT Terminal, 2-channel reed output

With the EL/ELM264x (Reed) and ELM274x (Solid-State) Beckhoff

is considerably extending the usage possibilities of the integrated

measurement technology of the ELM3xxx series as well as the

normal EL3xxx/EL4xxx analog inputs and outputs, because several

sensors or sources can now be connected at the same time to one

analog input channel.

To this end, the ELM2642 and ELM2644 are equipped with Reed

relays as switching elements, allowing fast switching cycles and a

long lifetime. The electrical isolation and the constant contact

resistance of the reed switch allows the measurement of even

sensitive signals up to fast scanning operation.

Due to the double input connectors X the channels can easily be

connected to 1 x 8 multiplexers and more.

The multi-channel recording of analog signals as well as the flexible

switching of various test states in production-integrated test stations

is easily possible through the integration of the often necessary

switches into the EtherCAT system.

Beckhoff EL2912 | EtherCAT Terminal, 2-channel digital output, 24 V DC, 2 A

The safety parameters are not stored directly on the component, but are

transmitted to the input terminal via a TwinSAFE Logic capable component

when the safety application is started. This simplifies service procedures,

because in this case the component can simply be replaced.

The safety-relevant parameters are transferred to the new component

when the safety application is restarted.

A further highlight of the EL2912 is the integration of the functionality of

the EL6910 TwinSAFE Logic. The EL2912 can thus also be used as a safety

controller at any time. Thus, for example, the output signals can be prepared

directly on the EL2912 before they are actually output.

The range of functions corresponds to that of the EL6910.

The only difference at this point is the limitation of the number of possible

safe connections to 128. Apart from that, all the advantages of the new

generation of safety controllers can be used (see EL6910 customizing,

incremental download, analog value processing, etc.).

Special features EL2912:

• 2 safe outputs with 2 A

• integrated TwinSAFE Logic (functionality similar to the EL6910)

• up to 128 safe connections

• fine granular configuration of the test pulses of the individual output channels

• standard outputs can be activated with automatic ANDing with a safe output signal.

Beckhoff EL2912 TwinSAFE component is a digital output terminal

The EL2912 TwinSAFE component is a digital output terminal.

It has two fail-safe outputs with up to 2 A. The outputs are controlled

by a TwinSAFE Logic-capable component via FSoE.

The EL2912 has safety parameters to specifically adapt the functionality

to the respective safety requirements. Thus, for example, a test of the

outputs can be configured with fine granularity in order to be able to

detect cross-circuits among other things and to react appropriately.

In addition, standard outputs can be activated for the EL2912.

As a result, corresponding standard outputs are available in parallel

and internally ANDed with the safe outputs of the EL2912.

The safe output signals, which are controlled by a TwinSAFE Logic, thus

issue the safe release for the standard signals, which can then be

triggered by the non-safety oriented control system independently of the

cycle of the safety controller and FSoE. This allows faster switching times

of the outputs, provided that the safety controller issues the necessary

release for the output.

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