Plant Floor Network Levels

1
THE FUTURE OF 505
CTI Product Training Breda, Netherlands October
2003
2
Agenda

• CTI Product Overview
• 505 business strategy
• SuperSavers
• Other 505 I/O products
• 505 communications products
• 2541 redundant processor manager
• 2505 vibration sensor interface module
• 3570 Ethernet switch 
• Ethernet on the Factory Floor
• Introduction to Ethernet on the factory floor -
  not sure how much of this I'll have time for
• Using the CTI 2572-A
• Demonstration of the 2572-A
• Product Roadmap and Strategy

3
CTI Product Overview
4
Introduction to CTI

• CTI - A Brief History
• CTI 505 Business Strategy
• Product overview
• Supersavers
• Other 505 I/O products
• Communications products
• Warm Backup
• Ethernet
• Modbus
• Profibus
• Virbation Monitoring Module
• Support for Siemens Mature Products
• 3570 Ethernet Switch

5
CTI A Brief History

• 1980 Founded as a spin-off from Computer Concepts
  Corporation - roots from the dairy and meat
  packing process control industry
• 1983 First industrial products for TI and Allen
  Bradley
• 1985 1771-DB Basic Module (Allen-Bradley)
• 1990 Isolated analog and discrete modules for TI
  500 I/O
• 1991 First TI505 I/O products
• 1993 2553 High Speed Counter
• 1995 2572 Ethernet Module
• 1996 1771-IFMS module (Allen-Bradley
• 1997 Siemens private labeled analog, discrete,
  and communications modules
• 1999 2576 DeviceNet Scanner
• SuperSavers I/O Modules
• 3570 Ethernet Switch
• 2003 2572-A Fast Ethernet Module

6
CTI Corporate Headquarters

• Corporate Offices
• Product Development
• Manufacturing
• Sales Marketing

7
International Distribution Locations
8
U.S. Distribution Locations
9
CTI 505 Business Strategy

• Be the leading supplier of specialized I/O and
  communications solutions (1990 - 2000)
• Develop isolated I/O solutions and
  special-purpose I/O and communications products
• Lower the cost of using 505 (2001 - 2003)
• Develop replacement I/O products with better
  performance and lower prices
• Pick up the 505 where Siemens leaves off (2003
  forward)
• Develop RBC, racks, CPUs
• Develop application I/O

10
CTI 505 SuperSavers

• Lower the total cost of using 505
• Performance equal or greater than Siemens
• 25 to 50 lower price
• Fewer products needed
• new designs longer availability
• Directly replace Siemens I/O products
• Super specs Saver prices SuperSavers

11
What SuperSavers are Available?

• Mounting Bases
• 2500-R16 Sixteen Slot Base
• Power Supplies
• 2512 75W Power Supply
• Digital Modules
• 2531,2532,2534
• 8, 16, 32-Point Relay Outputs
• 2589-A
• 16/32-Point Universal Input
• 2596, 2597
• 16, 32-Point DC Output
• 2598, 2599
• 16, 32 Point AC Output
• Analog Modules
• 2501 8in/4out Analog
• 2558 8-Channel Analog Input
• 2562 8-Channel Analog Output
• 2559-TC 8-Channel Thermocouple

12
What SuperSavers are in Development?

• Digital Modules
• 2588-8 8-Point Universal Input
• 2596-8 8-Point DC Output
• 2598-8 8-Point AC Output
• Analog Modules
• 2559-RTD 8-Channel RTD
• Mounting Base
• 2500-R08 Eight Slot Base
• Remote Base Controller
• 2500-RBC Profibus RBC

13
2500-R16Sixteen Slot Base

• Direct replacement for Siemens 505-6516

14
2500-R8Eight Slot Base (in development)

• Direct replacement for Siemens 505-6508
• Availability January 2004

15
2500-RBCProfibus RBC - 983 (in development)

• Direct replacement for Siemens 505-6870 - 1,292
• Availability early 2004

16
2512 75W Power Supply - 302

• Replacement for 505-6660 - 353, but provides 50
  more power
• Longer ride-through for better operation in
  brownouts

17
2531 Relay Output Module - 385

• 32 Form-A relay output points
• Isolation in groups of 8
• Voltage Range 12VDC to 30VDC,12VAC to 250V AC
• 4A per channel, 8A per group, 32A per module
• Each channel individually fused
• Replacement for 505-4932 - 595
• 2531 advantages
• individually fused outputs!
• more output current (4A vs 2A)
• up to 10X contact life
• less expensive

18
2532 Relay Output Module - 324

• 16 Form-A relay output points
• Isolation in groups of 4
• Voltage Range 12VDC to 30VDC,12VAC to 250V AC
• 4A per channel, 8A per group, 32A per module
• Each channel individually fused
• Replacement for 505-4916-A - 420
• 2532 advantages
• individually fused outputs!
• more output current (4A vs 2A)
• up to 10X contact life
• less expensive

19
2534 Relay Output Module - 231

• 8 Form-C relay output points
• Individually isolated
• Voltage Range 12VDC to 30VDC,12VAC to 250V AC
• 4A per channel, 32A per module
• Each channel individually fused
• Replacement for 505-4908 - 270
• 2534 advantages
• individually fused outputs!
• more output current (4A vs 2A)
• up to 10X contact life

20
2589-A Universal Digital Input Modules - 274

• 16/32 universal input points
• Isolation in groups of 4 or 8 (selectable)
• Voltage Range 11V to 250V AC or DC, selectable by
  group
• Logs in as 16pt or 32pt
• Replacement for 505-4032(515), 4232(396),
  4332(349), 4432-A(461), 4216(278),
  4316-A(292), 4416-A(334), 505-4016 (n/a),
  4116(n/a), 4132(n/a)
• 2589-A advantages
• Wide AC / DC voltage range
• less expensive
• one module replaces 10!

21
2588-8 Universal Digital Input(in development)

• 8 universal input points
• Voltage Range 11V to 250V AC or DC
• Replacement for 4208(208), 4308(197),
  505-4008(n/a), 4408(n/a)
• 2588-8 advantages
• Wide AC / DC voltage range
• less expensive
• one module replaces 4!

22
2597 DC Output Module - 373

• 32 DC output points, sourcing
• Isolation in groups of 4 or 8 (selectable)
• Voltage Range 11V to 125V DC
• 2A per channel, 32A per module
• Each channel individually fused
• Replacement for 505-4532(443 ),
  505-4732(557 )
• 2597 advantages
• individually fused outputs!
• 2A/pt in a single wide module
• better isolation
• more output current (2A vs 0.5A)
• less expensive

23
2596 DC Output Module - 310

• 16 DC output points, sourcing
• Isolation in groups of 4
• Voltage Range 11V to 125V DC
• 2A per channel, 32A per module
• Each channel individually fused
• Replacement for 505-4516(330),
  505-4716(389)
• 2596 advantages
• individually fused outputs!
• 2A/pt in a single wide module
• better isolation
• more output current (2A vs 0.5A)
• less expensive

24
2596-8 DC Output Module(in development)

• 8 DC output points, sourcing
• Voltage Range 11V to 125V DC
• 2A per channel, 16A per module
• Each channel individually fused
• Replacement for 505-4508(n/a), 505-4708(n/a)
• 2596-8 advantages
• individually fused outputs!
• 2A/pt in a single wide module
• more output current (2A vs 0.5A)
• less expensive

25
2599 AC Output Module - 373

• 32 AC output points
• Isolation in groups of 4 or 8 (selectable)
• Voltage Range 11V to 240V AC
• 2A per channel, 32A per module
• Each channel individually fused
• Replacement for 505-4632(581),
  505-4832(595)
• 2599 advantages
• individually fused outputs!
• 2A/pt in a single wide module
• better isolation
• more output current (2A vs 0.5A)
• less expensive

26
2598 AC Output Module - 310

• 16 AC output points
• Isolation in groups of 4
• Voltage Range 11V to 240V AC
• 2A per channel, 32A per module
• Each channel individually fused
• Replacement for 505-4616(347),
  505-4816(340)
• 2598 advantages
• individually fused outputs!
• 2A/pt in a single wide module
• better isolation
• more output current (2A vs 0.5A)
• less expensive

27
2598-8 AC Output Module(in development)

• 8 AC output points
• Voltage Range 11V to 240V AC
• 2A per channel, 16A per module
• Each channel individually fused
• Replacement for 505-4608(280),
  505-4808(246)
• 2598-8 advantages
• individually fused outputs!
• 2A/pt in a single wide module
• more output current (2A vs 0.5A)
• less expensive

28
2558 Analog Input Module - 359

• 8 channels 0-5V, 0-10V, 0-20mA unipolar and
  bipolar, ranges set individually per channel
• True differential inputs
• 16 bits resolution
• 140Vrms isolation between channels (equivalent to
  505-2555)
• Update time 4msec all channels
• Replacement for 505-6108-A(n/a),
  505-6108-B(533)
• 2558 advantages
• better resolution / accuracy
• individual range settings
• faster (4msec vs 250msec)
• isolation between input channels
• less expensive

29
2562 Analog Output Module - 498

• 8 channels 0-5V, 0-10V, 0-20mA unipolar and
  bipolar, ranges set individually per channel
• 12 bits resolution
• Update time 4msec all channels
• Replacement for 505-6208-A(n/a),
  505-6208-B(1,146)
• 2562 advantages
• individual range settings
• faster (4msec vs 30msec)
• less expensive

30
2501 8in/4out Analog Module - 1,123

• 8 differential bipolar analog input points
• 140Vrms isolation between channels (equivalent to
  505-2555)
• 4 isolated bipolar analog output points
• Resolution 16-bits in / 12-bits out
• Update time 7msec all channels
• Compatibility 505-7012-A(1,823) ,
  505-7016(1,926)
• 2501 advantages
• better resolution / accuracy
• faster (7msec vs 180msec)
• isolation between input channels
• only 1 user 24vdc required
• less expensive

31
2559-TC Thermocouple Input Module - 771

• 8 channels
• Supports J, K, T, E, R, S, N, and mV
• Update time 9msec all channels
• Replacement for 505-7028-A(1,222)
• 2559-TC advantages
• better resolution / accuracy
• individual range settings
• faster (4msec vs 250msec)
• less expensive

32
2559-RTD Input Module(in development)

• 8 channels
• Supports 505-7038 RTD types
• Update time 9msec all channels
• Replacement for 505-7038(1,222)
• 2559-RTD advantages
• better resolution / accuracy
• individual range settings
• faster (4msec vs 250msec)
• less expensive

33
SuperSavers Replacement Guide V1.5
34
Other 505 Digital I/O Products

• 2515 100-Watt Power Supply(550)
• 2564 4-Channel Pulse Output(1,102)
• 2530 8pt Relay Output(373)
• 2580 16pt Isolated AC Input(345)
• 2581 16pt Isolated DC Input(359)
• 2582 16pt Isolated 125VDC Input(359)
• 2585 16pt TTL Input(359)
• 2590-A 16pt Isolated AC Output(442)
• 2590-EF 16pt Isolated AC Output with Front Panel
  Fuses(517)
• 2591-A 16pt Isolated DC Output(442)
• 2591-EF 16pt Isolated DC Output with Front Panel
  Fuses(517)
• 2595 16pt TTL Output(331)

35
Other 505 Analog I/O Products

• 2550-A 8-Ch. Isolated Analog Input(1,050)
• 2551-A 8-Ch. Isolated Thermocouple Input(1,061)
• 2552-A 8-Ch. Isolated RTD Input(1,061)
• 2553-A 4-Ch. Magnetic Meter Input(777)
• 2554-A 4-Ch. High Speed Counter(1,036)
• 2555-A 16-Ch. Analog Input(1,102)
• 2556 16-Ch. Isolated Thermocouple Input(1,464)
• 2557 16-Ch. Isolated RTD Input(1,464)
• 2560-A 8-Ch. Isolated Analog Output(1,105)

36
505 Communications Products

• 2541 Redundant Processor Manager(5,587)
• 2572 Ethernet Adapter(1,194)
• 2573 Modbus Adapter(1,465)
• 2576 DeviceNet Scanner(1,405)
• 2577 Profibus DP Slave Adapter(1,056)

37
2573 Modbus Adapter - 1,465

• 4 serial ports, each with RS-422, RS-485, and
  RS-232 electrical interfaces
• 2 ports can be Modbus master/slave
• 2 ports can be NITP master/slave
• additional program ports for the PLC
• peer-peer support to other 2573 modules
• General ASCII protocol manager can be configured
  to communicate with many kinds of devices

38
2576 DeviceNet Scanner - 1,405

• Connects a DeviceNet network to 505 PLC
• DeviceNet nodes appear as standard 505 I/O
• Up to 63 devices per network
• Multiple scanners can be installed
• Use standard PLC logic
• Configuration ports provide access to configure
  DeviceNet nodes as well as the module
• Power tap can be used to supply DeviceNet power

39
2577 Profibus Slave Adapter - 1,056

• Interfaces existing installations to new S7
  systems
• No configuration, program, or I/O changes
  required
• Transfers 110 words in and 110 words out

40
2572 Ethernet Module - 1,194

• 10 Mbit support
• RJ-45 and AUI interface
• IP addressing from serial port or PLC
• Serial port for configuration and PLC programming
• Supports external power for transceiver
• 100 compatibility with 505-CP2572
• Server mode for supporting MMIs
• 2 Client modes for peer-peer
• Email capability
• S7 send/receive support

41
2572-A Ethernet Module - 1,546

• 10/100 Mbit support
• More throughput ( 2X 3X)
• Enhanced PLC access
• Additional protocol support (Modbus TCP,
  EtherNet/IP coming soon)
• Web server access for diagnostics and
  configuration
• Enhanced event logging for troubleshooting
• DHCP with module ID
• Flash upgradeable
• 100 compatibility with 2572 / 505-CP2572

42
Comparing Ethernet Solutions
43
2541 Redundant Processor Manager - 5,587

• Provides Warm Backup for Simatic TI505 PLCs
• Hot Backup
• Synchronous program execution
• Instantaneous transfer of control
• Warm Backup (RPM)
• Asynchronous program execution
• Transfer within 100ms or 2 scans
• Bumpless transfer
• Transfer of control without significantly
  changing the outputs

44
2505 Vibration Sensor Interface Module - 2,817

• 4 transducer channels tachometer channel
• Each transducer channel supports proximity,
  velocity, or accelerometer transducers
• Includes front panel BNCs for buffered outputs
  to other monitoring equipment
• Reports RMS and peak vibration to PLC, along with
  speed
• Monitors and reports alarm conditions

45
3570 Series Ethernet Switch - from 357

• Provides network access to small clusters of
  factory floor equipment
• Industrially hardened
• Space-saver DIN rail mounting
• Support for redundant power
• 5 ports / 4 variations of copper and fiber
• 10/100 Mbit with auto-sense, auto-negotiation,
  auto-crossover
• Broadcast storm protection

46
Summary

• CTI remains committed to the 505. Our plan is to
  pick up the 505 where Siemens leaves off.
• SuperSavers are now available to replace almost
  all Siemens I/O modules
• We will continue to add products to our
  SuperSavers line to provide a complete set of
  100 compatible 505 products

47
Ethernet on the Factory Floor
48
Why Are We Talking About Ethernet?
49
Why Are We Talking About Ethernet?
50
What is Ethernet?

• Ethernet is the most widely used LAN technology
• Ethernet is a packet-switched network
• a direct electrical connection between computers
  is not needed
• Ethernet defines only
• the appearance of the packet
• the method of gaining access to the network
• the physical media of the network

51
The Ethernet Framepacket
Preamble (7 bytes)
Start Frame Delimiter (1 byte)
Dest MAC Address (6 bytes)
Source MAC Address (6 bytes)
Type (2 bytes)
Data (0 - 1500 bytes)
Pad (0 - n bytes)
Frame Check Sequence (4 bytes)
Error check Padding
Data to be delivered
Source and destination hardware address.
Used for hardware synchronization
Type
52
Popular Ethernet Physical Layer Standards
53
Bus Topology
54
Star Topology
Ethernet Hub or Switch
55
Cabling and Connectors

• 10Base2 - RG58 coaxial cable
• use BNC connectors, Ts, and terminators to
  create the bus topology
• 185m maximum segment length, max 30 nodes per
  segment, 0.5m minimum spacing between nodes

BNC connector
Connection T
Connection T with termination
56
Cabling and Connectors

• 10BaseT - unshielded twisted pair cable
• available in Category 3, 4, 5 (cost vs
  performance)
• use plastic RJ45 connectors and hubs to create
  the star topology
• maximum segment length 100m maximum length
  between two nodes 200m
• maximum hubs between two nodes is 2

UTP patch cords
RJ45 connector
Typical CAT5 cable
57
Cabling and Connectors

• 10BaseFL - fiber optic cable
• 62.5/125 multimode fiber with ST style
  connectors is common
• SC connectors also used
• MTRJ connectors are gaining acceptance
• Patch cords can convert from one style to another

ST connector
MTRJ connector
MTRJ patch cord
MTRJ ST patch cord
SC patch cord
58
NICS MAUs

• NIC (Network Interface Card) - connects a PC to
  Ethernet

• MAU (Medium Attachment Unit) - connects the
  Ethernet medium to a generic Attachment Unit
  Interface port

15 pin AUI port (connects to device)
10BT port
59
Media Converters

• Media Converters - change the Ethernet medium
  in-line

Fiber to UTP
Coax to UTP
60
Hubs and Switches

• Both connect Ethernet segments together
• In a hub, all messages are sent to all ports
• every device sees all the network traffic
• In a switch, messages are sent only to the port
  of the destination device
• the switch learns what hardware addresses are
  connected to each port
• every device see only the traffic intended for it
• Switches are usually a better solution because
  they reduce segment loading and collisions

61
Why Should I Use Ethernet?

• Ethernet defines the physical media, how the
  network is accessed, and the appearance of the
  packet - the higher level protocol choice is up
  to you
• Ethernet is a fully specified, open industry
  standard - your future is not tied to one company
• Multiple choices for cabling, topology, and
  support devices - lets you pick the best
  solution
• Availability of expertise and tools - reduces
  your implementation and support cost
• Performance is going up, cost is going down

62
What is TCP/IP?

• TCP/IP stands for Transmission Control Protocol /
  Internet Protocol
• TCP/IP is a suite of protocols that provide
  reliable exchange of information within a network
  or between networks

TCP/IP is embedded in the Ethernet data field
63
IP

• IP (Internet Protocol) is like the Postal Service
• Its job is deliver packets between networks
• Provides connectionless, best-effort packet
  delivery
• Does not guarantee delivery of packets, or that
  theyll be delivered in a specific order
• It is the job of higher-level protocols (ie TCP,
  UDP) to guarantee delivery, ordering, flow
  control, and error handling
• The design of IP was driven by the need to
  deliver packets in a military network, where
  specific network paths could be lost or destroyed

64
TCP

• Transmission Control Protocol (TCP)
• Provides a connection-oriented service which
  reliably delivers a data stream
• Handles sequencing, flow control and error
  recovery
• May require additional time (because of retries)
• Requires more resources (ie memory, processing
  and network bandwidth) for delivering data
• Use TCP for delivery of a specific piece of data
  or for file transfer

65
UDP

• User Datagram Protocol (UDP)
• Does not provide reliability, flow control, or
  error recovery - the application must provide
  these features if necessary
• Extremely low overhead
• Use UDP where data is being sent repeatedly (ie
  I/O scan), and where you need only the latest
  data

66
IP Addressing

• A unique IP address identifies each host on the
  network
• The address is a 32 bit entity
• Represented in dotted decimal format
• Example 199.184.177.20 (CTI Web Server)
• IP address contains a network ID and a host ID
• Network ID identifies the network (for routing)
• Host ID identifies the individual node on the
  network

32 Bit IP Address
Network ID
Host ID
67
IP Address Concepts

• Network Class
• Determined by first bits of IP address
• Class A first octet is network ID, rest is Host
  ID
• 1.X.X.X - 126.X.X.X
• Class B first two octets are network ID,
  remaining is host ID
• 128.1.X.X - 191.254.X.X
• Class C first three octets are network ID, last
  octet is host ID
• 192.0.1.X - 223.255.254.X
• Class D (Multicast) first three octets are
  network ID, last octet is host ID
• 224.X.X.X - 239.X.X.X

68
DHCP - Dynamic Host Configuration Protocol

• Used for automatic assignment of IP addresses,
  and other configuration parameters such as subnet
  mask and default router

69
Routers

• Interconnect networks at the IP level and
  transfers packets between them
• Understand the addressing structure of IP and
  make decisions on whether and how to forward
  packets
• Select the best transmission path and optimal
  packet size

70
Using Ethernet TCP/IP in the Factory

• Plant Control Engineer must assume an active role
• Includes network design and troubleshooting
• IT/MIS may be of limited help
• Education/Training is a must
• Network Components and Protocols
• Problem Analysis and Resolution
• Troubleshooting Aids
• Network Analyzer software
• Allows you to view traffic on the network
• Diagnostic Data built-in to devices

71
Broadcast Issues

• What is a Broadcast?
• Message sent to Ethernet Broadcast address
• Passed by hubs and switches to all ports
• Passed by all Ethernet controllers to their
  processors
• Required for proper TCP/IP operation
• Address resolution
• Router inter-communication
• Result of Excessive Broadcasts
• Performance degradation due to congestion at the
  network interface
• Additional network loading

72
Broadcast Example

• Problem
• Customer reported periodic slowdown in PLC update
  to the HMI
• Problem Analysis
• Used Network Analyzer to capture traffic during
  slowdown
• Obtained statistics from 2572
• Result
• Diagnostic statistics indicated high level of
  broadcast traffic
• Network Analyzer confirmed problem, traced to a
  PC on the network.
• Internet Radio application was generating high
  rate of broadcasts
• Solution
• Removed application from PC

73
Power Problem

• Problem
• Existing network had been working fine for
  several months
• Network suddenly stopped working near end of day
  shift every day.
• Problem Analysis
• Unable to get a network capture
• 2572 diagnostic statistics indicated high level
  of network errors
• Result
• Finally discovered a network hub was on same
  power as an area heater
• When heater kicked in, the hub failed to work
  properly.
• Solution
• Reconfigured power connection to hub

74
Network Interface Flooding

• Problem
• Customer reporting poor performance on new SCADA
  system
• Problem Analysis
• Obtained diagnostic log from SCADA I/O server
  which indicated numerous timeouts
• 2572 diagnostic statistics indicated input queue
  overflow
• Result
• Discovered several SCADA systems polling the same
  PC interface as rapidly as possible. This was
  flooding the network interface input queue
  increasing response time and dropping packets
• Solution
• Reduce polling rate on SCADA systems to reduce
  load on system while maintaining desired response
  time

75
Design Recommendations

• Limit access to the control and I/O network.
• Avoid temptation to use an existing network by
  default
• Interconnect to other networks using routers
• Use firewall techniques to provide security
• Pay attention to network configuration
• Understand the topology rules
• Ensure routers are configured properly
• Evaluate power sources for network components
• Be alert to network interface congestion
• Use appropriate network components
• Switching hubs can reduce configuration
  complexity
• Use proper cabling
• Cat 5 UTP cabling for normal environment
• Fiber optic or shielded twisted pair for noisy
  environment

76
Summary

• Ethernet TCP/IP can provide significant benefits
  for plant floor networking
• It can address all plant floor networking
  requirements
• It facilitates rapid access to data distributed
  throughout plant
• Tools and hardware are widely available
• Successful Implementation requires proper design
• Network topologies and protocol use
• Network interconnection
• Security
• Plant Engineering must take charge
• Requires training
• Requires troubleshooting tools

77
Using the 2572-A Ethernet Module
78
2572-A features

• 2572 compatibility
• Better performance (2x)
• 100Mb support
• New startup option to use DHCP for addressing
• Enhanced diagnostics stored in non-volatile RAM
• Web server for configuration and diagnostics
• Better security for configuration changes
• Password control
• Hardware lockout

79
2572-A Front Panel - Status LEDs

• MS (Module Status)
• Steady Green module hardware and software is
  operational
• Flashing green module is starting up
• Steady red or flashing red error conditions.
• NS (Network Status)
• Steady Green network server is operational (IP
  address has been set)
• Steady red or flashing red error conditions
• Off network server has not been started.
• LS (Link Status)
• Steady Green a link exists between the module
  and the Ethernet hub or switch
• Off no cable connected, or cable fault
• COL (Collision)
• Lights when a collision is detected

80
2572-A Front Panel - Status LEDs

• FDX (Full-Duplex)
• Steady green full duplex mode. 100 (100 Mb)
• Steady Green 100Mb
• Off 10Mb
• XMT-S, XMIT-E (Transmit)
• Lights when data is transmitted on serial or
  Ethernet ports
• RCV-S, RCV-E (Receive)
• Lights when data is received on serial or
  Ethernet ports

81
2572-A Front Panel

• Reset button
• Recessed to avoid accidental press
• Causes a hardware reset (like removing the module
  and reinstalling)
• Module ID switches
• Set the module ID for use with DHCP
  auto-addressing

82
2572-A Front Panel

• Serial port
• RS232
• Works with PLC programming cables
• For module configuration only
• Ethernet port
• Supports 10Mb or 100Mb
• Shielded or unshielded cable

83
Ethernet Module Functions

• PLC server allows external clients to read and
  write PLC memory (HMI)
• Client sends request to the module using NITP or
  CAMP command embedded in TCP/IP packet
• Module sends the command to the PLC over the
  backplane
• PLC responds over the backplane
• Module returns data or acknowledgement to the
  client
• Up to 16 requests (2572-A) allowed per PLC scan
• PLC client (peer-peer)
• Under control of PLC logic
• Sends messages to other nodes
• Processes messages from other nodes
• Can support multiple connections simultaneously

84
PLC command interface

• A command interface is used to trigger the module
  to send and receive data
• Not required for simple HMI operation
• Module logs in as 2WX, 6WY
• Command process
• Place a command block in V-memory
• Put the starting address of the command block in
  WY
• Trigger a bit in WY4
• Monitor command status in WX2
• Up to 4 commands can be processed simultaneously

85
PLC command interface

• Logs in as 2WX and 6WY words

86
Module Status Word (WX1)
   
1
2
3
4
5
6
7
8 - 15
16
MOD STATUS
RSVD
NET CFG
RSVD
RSVD
LINK STATUS
RSVD
RSVD
HEART BEAT
87
Module Control Word (WY3)
1
2
3
4
5
6
7
8
9 - 16
MOD RESET
RSVD
RSVD
RSVD
RSVD
RSVD
RSVD
RSVD
RSVD

• To perform a module reset, set MOD RESET AND set
  all 4 abort triggers in the Command Control word
  (WY4).

88
Command Control Word (WY4)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
ERR Ack
CMD Mode
CMD Trig
Abort Trig
ERR Ack
CMD Mode
CMD Trig
Abort Trig
ERR Ack
CMD Mode
CMD Trig
Abort Trig
ERR Ack
CMD Mode
CMD Trig
Abort Trig
Command 1
Command 2
Command 3
Command 4

• CMD Mode
• 0 uncoupled mode (command runs continuously as
  long as CMD Trig is high)
• 1 coupled mode (command runs once, then CMD
  Trig must go low and high to run command again)

89
Command Status Word (WX2)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
CMDERR
PLC Err
CMD Busy
Abort Busy
CMDERR
PLC Err
CMD Busy
Abort Busy
CMDERR
PLC Err
CMD Busy
Abort Busy
CMDERR
PLC Err
CMD Busy
Abort Busy
Command 1
Command 2
Command 3
Command 4

• CMD Err error in executing command
• Error code is written into first word of command
  block in V-memory
• PLC Err no valid command block at specified
  V-memory address
• No error code is written

90
Command Block in V-Memory
Offset
Contents

• Common Command Codes
• 4 start network server
• 3 create connection
• 2 close connection
• 513 write remote
• 514 read remote
• 515 memory exchange

Error Word
0
Command Code
1
Connection Number
2
Command Parameter 1
3
Additional parameters
4-15

• Command block is 16 contiguous words in V-Memory
• If error in processing, Error Word contains the
  code of the error
• Command code type of command
• Connection Number which protocol manager
  executes the command
• High byte of Connection Number must 4B

91
Sample Command BlockStart Network Server
 
92
Getting Started Using the 2572-A

• Determine IP address
• Choose network startup mode
• Set up switches
• Install 2572-A and connect network cable
• Enter startup ladder logic if PLC-start
  selected or enter IP address into module if
  auto-start selected
• Verify PC address is on the same network as the
  2572-A
• Test connection using ping or browser

93
Getting Started Using the 2572-A

• Choose network startup mode
• Automatically starting the network server
• Starts the network server from onboard EEPROM
• The IP address must be pre-assigned using serial
  port with CTIDiag program
• Requires no PLC logic
• Starting the network server from PLC logic
• Requires PLC logic to trigger start network
  server command block
• Ensures that any 2572 plugged into that slot will
  get the same IP address
• Easy replacement of modules
• Automatic start with DHCP server
• Ensures a replacement module will get the same
  address as the old module
• Does not require any PLC logic
• Requires a DHCP server on the network which must
  be configured to support Module ID

94
Getting Started Using the 2572-A

• Set switches
• Serial port baud rate
• Diagnostic start
• Interface mode
• Password bypass
• Download lock
• Configuration lock
• Network startup mode

95
Setting Switches
2572-A
SW1
96
Setting Switches (2572-A)
SW1
1 2 3 4 5 6 7 8 9
10 11 12
OPEN
97
Starting the Network Server from PLC Logic

• Select PLC-Start on switches
• SW1 position 4
• Setup the Start Network Server command block in
  V-memory
• Enter the example logic for triggering the
  command block
• Start the program
• Verify communication with the module using ping

98
Start Network Server Command Block
 
99
Starting the Network Server from PLC Logic

• Example ladder logic

100
CTI 2572-DDS2 DDE I/O Server

• Software package that runs on a PC
• Can read / write data from the PLC and make it
  available to any application that supports DDE
  (Wonderware, MS-Excel, etc)

Start DDE Server
101
Making a Simple Display Using Excel

• Install 2572 and start network server
• Start DDE server
• Create topic in DDE server
• Select Configure / Topic
• Enter a topic name
• Enter the IP address of the 2572
• Start Excel
• Enter formulas using the syntax
• Application_nametopic_name!item_name
• Application_name is the name of the CTI I/O
  server
• Topic_name is the topic you created
• Item_name is a valid 505 memory reference
• Example cti2572testplc!wx1
• Demonstration

Start Excel
102
2572 Application notes

• IP Addressing and the 505-CP2572
• Getting Started with Networking and the
  505-CP2572
• Using CTIDiag with the 505-CP2572
• Starting the 505-CP2572 Network Server from PLC
  Logic
• Reading Values into Excel Spreadsheets Using the
  505-CP2572
• Using the 505-CP2572 with Wonderware 7.0
• Creating a Client/Server Memory Transfer between
  Two 505-CP2572 Modules
• Using the 505-CP2572 UDP "Send To" Feature to
  Exchange Memory with Multiple PLCs

103
2572-A IP Address Assignment using DHCP

• Allows use of auto-start while still guaranteeing
  correct IP address in case of a module
  replacement
• How it works
• If auto-start is selected and settings of module
  ID switches are non-zero, the module ID value is
  sent to the DHCP server as a client identifier
• DHCP server is set up to assign IP addresses
  based on client identifier
• At CTI, we set up our server to assign the last
  part of the IP address based on the switch
  assignment
• Example
• Switch setting of 70 receives IP address of
  199.184.177.70
• Complete information on setting up DHCP server in
  Appendix E of 2572-A user manual

104
2572-A Built-In Web Server

• Web server features
• Module diagnostics
• Module configuration
• Firmware download
• Security services
• Product support
• Just point your browser at the IP address of the
  module
• Demonstration

Start Web Browser
105
2572-A Security Features

• Password protection for
• Module configuration changes
• Module firmware download
• Bypass password protection using SW1-7
• Hardware lockout for
• Module configuration changes
• Module firmware download
• Set on SW1-5 and SW1-6

106
2572-A Firmware Upgrade

• Firmware updates can be re-flashed in-place using
  the web server interface
• Install a free TFTP server on your network
• Download and copy the upgrade file to the TFTP
  server
• Go to the firmware download section of the
  2572-A web server interface
• Enter the IP address of the TFTP server
• Complete information in Appendix F of the user
  manual

107
CTI Product Roadmap and Strategy
108
THE FUTURE OF 505
Thank you for coming!