Q 2586652

SIMATIC TI525/TI535
Hardware and Installation

User Manual
Order Number: PPX:50581033
Manual Assembly Number: 25865460052
Third Edition
01/21/92
Copyright 1993 by Siemens Industrial Automation, Inc.
All Rights Reserved Printed in USA
Reproduction, transmission or use of this document or
contents is not permitted without express consent of
Siemens Industrial Automation, Inc. All rights, including rights
created by patent grant or registration of a utility model or
design, are reserved.
Since Siemens Industrial Automation, Inc. does not possess
full access to data concerning all of the uses and applications
of customers products, we do not assume responsibility either
for customer product design or for any infringements of patents
or rights of others which may result from our assistance.
Technical data is subject to change.
We check the contents of every manual for accuracy at the
time it is approved for printing; however, there may be
undetected errors. Any errors found will be corrected in
subsequent editions. Any suggestions for improvement are
welcomed.

M ANUAL PUBLIC ATIO N HISTO RY
SIMATIC TI525/TI535 Hardware and Installation Manual
Order Manual Number: PPX:50581033
Refer to this history in all correspondence and/ or discussion about this manual.
Event Date Description
Original Issue 09/88 Original Issue (25866520001)
Second Edition 11/90 Second Edition (25866520002)
Third Edition 04/93 Third Edition (25866520003)

LIST O F EFFEC TIVE PAG ES
Pages Description Pages Description
Cover/Copyright Third Edition
History/Effective Pages Third Edition
iii viii Third Edition
Preface ixx Third Edition
1-1 1-10 Third Edition
A-1 A-2 Third Edition
B-1 B-7 Third Edition
C-1 C-5 Third Edition
Index-1 Index-3 Third Edition
Registration Third Edition

Contents iii
Contents
Pre fa c e
C ha p te r 1 Se rie s 505 Syste m O ve rvie w
1.1 Introd uc tion 1- 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 Fe a ture s O f The TI525 And TI535 1- 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2.1 Program Software 1-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2.2 Program Storage in EEPROM 1-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2.3 Communication Ports 1-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2.4 Battery Backup 1-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2.5 Ladder Memory Protection 1-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C ha p te r 2 Pre - insta lla tion Pla nning
2.1 Introd uc tion 2- 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Sa fe ty C onsid e ra tions 2- 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 Enc losure Se le c tion 2- 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4 G round ing And Wiring The Eq uip me nt 2- 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5 Te mp e ra ture C onsid e ra tions 2- 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C ha p te r 3 Insta lla tion
3.1 Insta lling The Ba se Asse mb lie s 3- 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.1 Installing Base Hardware 3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.2 Rack or Panel Mounting 3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Ha nd ling Se rie s 505 M od ule s 3- 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 Se tting TI525 Dip switc he s 3- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.1 Setting Port Baud Rate TI525 Models 3-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.2 Selecting Battery Backup TI525 Models 3-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.3 Selecting Ladder Memory Protection TI525 Models 3-8 . . . . . . . . . . . . . . . . . . .
3.3.4 Downloading Preset Constants TI525 Models 3-9 . . . . . . . . . . . . . . . . . . . . . . . . .
3.4 Se tting TI535 Dip switc he s 3- 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4.1 Selecting I/O Type TI535 Models 3-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4.2 Downloading Preset Constants TI535 Models 3-12 . . . . . . . . . . . . . . . . . . . . . . . . .
3.4.3 Setting Highest I/O Base Number TI535 Models 3-13 . . . . . . . . . . . . . . . . . . . . . . .
3.4.4 Selecting Battery Backup TI535 Models 3-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4.5 Setting Communication Port Baud Rate TI535 Models 3-15 . . . . . . . . . . . . . . . . .
3.4.6 Selecting Ladder Memory Protection TI535 Models 3-16 . . . . . . . . . . . . . . . . . . .
3.5 Insta lling The Ba tte ry 3- 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5.1 Model TI525 Battery Installation 3-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
iv Contents
3.5.2 Model TI535 Battery Installation 3-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.6 Insta lling Syste m C omp one nts 3- 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.6.1 Numbering Series 505 I/O Points 3-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.6.2 Guidelines For Installing Series 505 Modules 3-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.6.3 Installing the Power Supply 3-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.6.4 Installing the PLC 3-27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.6.5 Installing the I/O Modules 3-29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.6.6 Installing the Base Controllers 3-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C ha p te r 4 EPRO M / EEPRO M O p e ra tion
4.1 Introd uc tion 4- 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Insta lling An EPRO M / EEPRO M In TI525 M od e ls 4- 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Insta lling An EPRO M / EEPRO M In TI535 M od e ls 4- 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 Prog ra mming The EEPRO M 4- 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5 Re p orting EEPRO M Sta tus 4- 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5.1 Status Word Six (STW06) 4-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5.2 Status Words Seven to Nine (STW07STW09) 4-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6 Ed iting / Sa ving Prog ra ms Using An EPRO M / EEPRO M 4- 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C ha p te r 5 Sta rtup / Troub le shooting
5.1 Sta rtup Proc e d ure s 5- 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Using The Troub le shooting Tools 5- 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.1 Reading the LED Indicators 5-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.2 Executing the Auxiliary Functions 5-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.2.1 AUX Function 29 (Show PLC Diagnostic Cell) 5-5 . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.2.2 AUX Function 25 (Display Failed I/O) 5-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.2.3 AUX Function 20 (Run PLC Diagnostics) 5-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.2.4 AUX Function 11 (Partial Restart) 5-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.2.5 AUX Function 12 (Complete Restart) 5-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.2.6 AUX Function 10 (Power-up Restart) 5-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.3 Troubleshooting with Status Words 5-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.3.1 Status Word One (STW01) 5-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.3.2 Status Word Two (STW02) 5-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.3.3 Status Word Six (STW06) 5-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.3.4 Status Words Seven to Nine (STW07STW09) 5-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.3.5 Status Word Ten (STW10) 5-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.3.6 Status Words Eleven to Eighteen (STW11STW18) 5-12 . . . . . . . . . . . . . . . . . . . . . . . .
5.2.4 Clearing PLC Fatal Errors 5-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.5 Troubleshooting the EPROM/EEPROM 5-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.6 Troubleshooting the Power Supply 5-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.7 Spare Parts 5-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ap p e nd ix A Sp e c ific a tions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A- 1
Ap p e nd ix B G round ing And Ele c tric a l G uid e line s
B.1 Introd uc tion B- 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contents v
B.2 G round ing B- 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B.2.1 Single Point Grounding B-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B.2.2 Guidelines for Ground Connections B-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B.3 Wiring G uid e line s B- 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B.4 M inimizing Ele c tric a l Noise B- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B.4.1 Definition and Source B-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B.4.2 Correcting Noise Problems B-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B.4.2.1 Noise Suppression B-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B.4.2.2 Isolation B-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ap p e nd ix C Se rie s 500/ 505 I/ O Powe r C onsump tion . . . . . . . . . . . . . . . . . . . C - 1
vi Contents
List of Fig ure s
1-1 TI525 and TI535 Controllers 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2 Functional Relationship of Series 505 Components 1-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1 Operator Safety Switch 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2 Emergency Stop Switch 2-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3 J OG or INCH Switch 2-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1 Series 505 Bases 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2 Mounting Dimensions for the Series 505 Bases 3-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3 Locations of the Dipswitches for the TI525 Models 3-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4 Switch Settings TI525 RS-232-C/423 and RS-422 Ports 3-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5 Switch Settings TI525 Battery Backup 3-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6 Switch Settings TI525 L-Memory Protection 3-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7 Switch Settings TI525 Download/Retain Presets 3-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8 Locations of the Dipswitches for TI535 Models 3-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-9 Switch Settings TI535 Download/Retain Presets 3-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-10 Switch Settings TI535 Highest-Numbered Logical Base 3-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-11 Switch Settings TI535 Battery Backup 3-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-12 Switch Settings TI535 RS-232-C/RS-423 and RS-422 Ports 3-15 . . . . . . . . . . . . . . . . . . . . . . . . . .
3-13 Switch Settings TI535 LMemory Protection 3-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-14 Battery Location for TI535 Models 3-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-15 Definition of the Series 505 Logical Base 3-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-16 System With Local I/O Only 3-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-17 Systems with Local and Distributed I/O 3-21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-18 Power Supply J umper 3-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-19 Location of Power Supply in Base 3-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-20 Location of PLC in Base 3-27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-21 Location of I/O Modules in Base 3-29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1 TI525 EPROM/EEPROM Socket and J umper Pins 4-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2 TI535 EPROM/EEPROM Socket and J umper Pins 4-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3 Format of Status Word Six (STW06) 4-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1 Example of AUX Function 29 Screen 5-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2 Format of Status Word One (STW01) 5-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3 Format of Status Word Two (STW02) 5-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4 Format of Status Word Six (STW06) 5-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5 Format of Status Word Ten (STW10) 5-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6 Format of Status Words Eleven to Eighteen (STW1118) 5-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7 Example of a Status Word With a Bit Set 5-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-1 Sample Ground Connections B-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-2 Examples of Noise Snubbing B-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contents vii
List of Ta b le s
1-1 Model Differences 1-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2 TI525/TI535 Instruction Set 1-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1 Pin-out for the RS-232-C/RS-423 Port 3-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2 I/O Module Point Assignments 3-31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1 Changes in Mode and Memory After Power Up 4-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1 LED Indicators 5-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2 Effects of Aux Functions on Memory Locations 5-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-1 Series 505 Component Power Requirements C-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-2 Series 500 Component Power Requirements C-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ix
Hardware and Installation User Manual
PREFAC E
INTRO DUC TIO N
Thi s manual gi ves detai l ed i nstructi ons for the i nstal l ati on and operati on of
the Seri es 505
fami l y of programmabl e l ogi c control l ers (PLCs). Both the

SI MATI C
TI 525
and the SI MATI C
TI 535
PLCs and thei r support

equi pment are di scussed. The topi cs are l i sted bel ow by chapter.
D Chapter 1 descri bes the features of the vari ous model s of the TI 525
and TI 535 PLCs.
D Chapter 2 i s a gui de to pre-i nstal l ati on pl anni ng to faci l i tate the
establ i shment of a safe and effi ci ent system of equi pment control .
D Chapter 3 contai ns the detai l s of i nstal l i ng the system components.
D Chapter 4 presents the i nstal l ati on and operati on of EPROMs and
EEPROMs.
D Chapter 5 descri bes the system start-up procedure and gi ves
i nformati on for troubl eshooti ng.
D Appendi x A l i sts the speci fi cati ons for the TI 525 and TI 535 PLCs.
D Appendi x B gi ves groundi ng and other el ectri cal gui del i nes.
D Appendi x C l i sts the power requi rements for al l currentl y avai l abl e
Seri es 505 and Seri es 500
I /O modul es.
PREFAC E
x
REFERENC ES
Consul t the manual s l i sted bel ow for further i nformati on on i nstal l i ng,
programmi ng, and troubl eshooti ng your Seri es 505 hardware.
D SI MATI C
TI 505
Programming Reference Manual

(PPX:50581043)
D TI WAY
Systems Manual (TI WAY8101)

D CVU1000
& CVU10000
User Reference Manual

(PPX:CVU1081012)
D The I /O modul e user manual s that are appropri ate for your system.
D The user manual s for your rel ease of TI SOFT
.
1-1
C HAPTER 1
SERIES 505 SYSTEM O VERVIEW
1.1 INTRO DUC TIO N
The TI 525/TI 535 Programmabl e Control l ers (PLCs) and thei r support
equi pment are computer-control l ed systems that are capabl e of managi ng the
operati on of other systems. These PLCs execute the same functi ons as rel ays,
stati c control , or card l ogi c control systems. They can detect the change i n state
of i nput si gnal s from such devi ces as pushbuttons, l i mi t swi tches, and sensors.
Acti ng on thi s i nformati on and executi ng a Rel ay Ladder Logi c (RLL) program
stored i n memory, the TI 525/TI 535 PLCs produce output si gnal s to dri ve motor
starters, sol enoi ds, and pi l ot l i ghts, etc., that regul ate the operati on of vari ous
pi eces of equi pment.
The TI 535 i s an enhanced versi on of the TI 525 that offers the fol l owi ng features:
D The scan ti me for Bool ean l ogi c i s reduced si gni fi cantl y (from 4
mi l l i seconds per K words of memory to l ess than 1 mi l l i second per K
words of memory).
D A communi cati on port baud rate of 19,200 provi des faster
communi cati on wi th the Vi deo Programmi ng Uni t (VPU
) and other
operator i nterfaces.
FEATURES
1-2
SIMATIC
TI525
PORT
1
RS232
5251102
SIMATIC
TI535
RUN
BATT GOOD
P/C GOOD
RUN
BATTERY GOOD
P/C GOOD
PORT
1
RS232
PORT
2
RS422
5351212
Figure 1-1 TI525 and TI535 Controllers
The Seri es 505 product l i ne i s desi gned for use i n smal l to medi um appl i cati ons
such as di screte, word, and anal og control . Components i ncl ude the TI 525 and
TI 535 PLCs, shown i n Fi gure 1-1, and the support devi ces that provi de operator
communi cati on, I /O control , and power.
Operator communi cati on may take pl ace through any of the fol l owi ng devi ces:
D I BM
PC/XT Computer or a 100% compati bl e computer wi th TI SOFT

D Vi deo Programmi ng Uni t (VPU)
D Handhel d I ntel l i gent Termi nal (HI T 5001101)
D Control Vi si on Uni t (CVU)
FEATURES
1-3
You may use a DEC
VAX
Computer to devel op an RLL program that can be

transferred to a TI 525/TI 535 PLC wi th a VPU. You can provi de communi cati on
between devi ces through the TI WAY i ndustri al l ocal area network.
See the references l i sted i n the Preface of thi s manual for i nformati on
on these systems.
I /O control for the Seri es 505 takes pl ace through i ndi vi dual Seri es 505 I /O
modul es. A ful l l i ne of di screte, anal og, word, and i ntel l i gent I /O modul es are
avai l abl e that can handl e al most any i nput or output speci fi cati ons. These I /O
modul es are rugged, pl ug-i n devi ces capabl e of functi oni ng i n harsh
envi ronments.
I /O modul es are grouped i nto l ocal and di stri buted I /O categori es dependi ng
upon thei r physi cal l ocati on. The l ocal I /O consi sts of those modul es i nstal l ed i n
the same base assembl y as the PLC. The TI 5251102 can support up to 512 l ocal
I /O poi nts. You can create a di stri buted I /O system for al l other model s by
connecti ng up to 14 addi ti onal base assembl i es. Al l current versi ons of the
TI 525 and TI 535 PLCs support up to 1023 I /O poi nts, i n both l ocal and
di stri buted bases.
When addi ti onal bases are connected to the system, di stri buted I /O i s managed
through communi cati on between base control l ers the I /O Channel Control l er
(I OCC) and one or more Di stri buted Base Control l ers (DBC). The DBC
(PPX:5056840) i n each di stri buted base assembl y transmi ts data from the I /O
modul es i n that base assembl y to the I OCC (PPX:5056830) , whi ch occupi es the
same base assembl y as the PLC. Your TI 525/TI 535 PLC can address di stri buted
bases up to 1300 feet (396m) away.
A di agram of the TI 525/TI 535 system whi ch shows the functi onal rel ati onshi p
of al l the system components i s shown i n Fi gure 1-2.
FEATURES
1-4
IBM PC/XT with TISOFT
DEC VAX
VPU200
Programming Unit
Local
I/O
Additonal I/O may be connected
up to a total of 14 base assemblies.
Distributed
I/O
P/S Series 505 I/O
4, 8, and 16 slots
I
O
C
C
P/S Series 505 I/O
4, 8, and 16 slots
P/S Series 505 I/O
4, 8, and 16 slots
Handheld
Intelligent Terminal
*The PPX:5251102 does not support distributed I/O.
PPX:
505
6830
TI525
TI535
TI525*
TI535
D
B
C
PPX:
505
6840
Figure 1-2 Functional Relationship of Series 505 Components
FEATURES
1-5
The power suppl y provi des up to 55 watts at +5 VDC and 3.75 watts at 5 VDC
for use by the PLC, the base control l ers, and the I /O modul es. The
PPX:5056660 power suppl y operates at ei ther 110 V or 220 VAC on
user-suppl i ed power. A jumper on the i nsi de of the back of the modul e i s used to
sel ect vol tage. The PPX:5056663 power suppl y operates on 24 VDC
user-suppl i ed power.
Al l Seri es 505 hardware i s compati bl e wi th I nternati onal Standards
doubl e-Eurocard (DI N standard 41494).
FEATURES
1-6
1.2 FEATURES O F THE TI525 AND TI535
Two model s of the TI 525 and one of the TI 535 are currentl y avai l abl e.
Di fferences between these model s are gi ven i n Tabl e 1-1. The TI 525/TI 535 RLL
i nstructi on set i s l i sted i n Tabl e 1-2.
Table 1-1 Model Differences
Ladder Logi c Si ze
Physi cal I /O
Di screte/Word I /O
Control Rel ays
V Memory (words)
Ti mers/Counters
Drums
One Shot
SHRB/SHRW
MWTT/MWFT
JMP (nested)
MCR (nested)
SKP/LBL
Status Words
PPX:525
1102 1104 1208* 1212*
2048 4096 8192 12000
512 1023 1023 1023
1023 1023 1023 1023
511 511 511 1023
1024 2048 4096 5120
256 256 256 400
30 30 30 30
128 128 256 400
30 45 60 75
30 45 60 75
8 8 8 8
8 8 8 8
255 255 255 255
11 18 18 18
Features
1204* 1212
12000
1023
1023
1023
5120
400
30
400
75
75
8
8
255
18
4096
1023
1023
511
2048
256
30
128
45
45
8
8
255
18
RS-232-C/423 Ports
RS-422 Ports
1 1 1
0 0 1
1
1
1
1
1
1
PLC Model
* These model s are now obsol ete.
PPX:525 PPX:525 PPX:525 PPX:535 PPX:535
FEATURES
1-7
Table 1-2 TI525/TI535 Instruction Set
Program Control Instructions
Jump (JMP)
Master Control Rel ay (MCR)
End, Condi ti onal (ENDC)
End, Uncondi ti onal (END)
Ski p (SKP)
Label (LBL)
Math Instructions
Add (ADD)
Subtract (SUB)
Compare (CMP)
Di vi de (DI V)
Mul ti pl y (MULT)
Square Root (SQRT)
Bit Instructions
Bi t Cl ear (BI TC)
Bi t Pi ck (BI TP)
Bi t Set (BI TS)
Bi t Shi ft Regi ster (SHRB)
Word Instructions
Convert Bi nary to BCD (CDB)
Convert BCD to Bi nary (CBD)
Word AND (WAND)
Word OR (WOR)
Word Rotate (WROT)
Word Excl usi ve OR (WXOR)
Word Shi ft Regi ster (SHRW)
Move Instructions
Load Data Constant (LDC)
Move Di screte I mage Regi ster
to Word (MI RW)
Move Word To Tabl e (MWTT)
Move Word (MOVW)
Move Word To Di screte
I mage Regi ster (MWI R)
Move Word From
Tabl e (MWFT)
Counter/Timer
Counter (CTR)
Ti mer (TMR)
Up/Down Counter (UDC)
One Shot (O/S)
Matrix Instructions
Scan Matri x Compare (SMC) I ndex Matri x Compare (I MC)
Drum Instructions
Drum (DRUM) Event Drum (EDRUM)
FEATURES
1-8
1.2.1 Prog ra m Softwa re
The TI 525/TI 535 PLCs are programmed i n standard rel ay l adder l ogi c, and
TI SOFT programmi ng software provi des a means of enteri ng, debuggi ng, and
documenti ng your RLL program. TI SOFT i s menu-dri ven, provi des both RLL
and advanced program speci al functi ons l anguage, and permi ts you to add
comments to i nstructi ons. Di fferent versi ons of TI SOFT are avai l abl e.
TI SOFT1
operates on the VPU200; TI SOFT2
i s executed on an I BM PC/XT,
and TI SOFT3
runs i n an off-l i ne mode on a DEC VAX computer.

You may al so ful l y program the TI 525/TI 535 i n Bool ean symbol i c code usi ng the
Handhel d I ntel l i gent Termi nal .
I n addi ti on to the standard rel ay l adder l ogi c, the TI 525/TI 535 programmi ng
i nstructi on set offers more than 30 hi gh-l evel , user-ori ented operati ons. The
box i nstructi ons repl ace programmi ng steps that once requi red hundreds of
words of memory. More i mportantl y, these i nstructi ons permi t you to use the
power of the PLC to perform compl ex functi ons, whi ch makes program
devel opment and debuggi ng faster and easi er.
1.2.2 Prog ra m Stora g e in EEPRO M
The TI 525/TI 535 PLCs offer the opti on of savi ng your RLL program i n a
non-vol ati l e form by downl oadi ng i t to an El ectri cal l y Erasabl e Programmabl e
Read Onl y Memory (EEPROM; PPX:25876818020) i ntegrated ci rcui t. A
separate programmi ng devi ce i s not necessary. Once programmed, an
EEPROM may be removed and used i n any of the TI 525/TI 535 or SI MATI C
TI 530T
model s, provi ded the program i s compati bl e wi th the systems

capabi l i ti es.
An EPROM may al so be used to execute a program i n a TI 525 or TI 535 PLC. The
program must be copi ed from an EEPROM descri bed above or by an EPROM
programmer before i t i s i nstal l ed on the TI 525/TI 535 CPU board.
To ensure equi pment compati bi l i ty use onl y the EPROM model suppl i ed by
your di stri butor: (PPX:25876818012).
FEATURES
1-9
1.2.3 C ommunic a tion Ports
Each TI 525/TI 535 PLC has a 25-pi n RS-232-C/RS-423 compati bl e port
confi gured as Data Termi nal Equi pment (DTE). Thi s port may be used for
communi cati ng wi th programmi ng equi pment such as the Ti mer/Counter
Access Modul e (TCAM), the VPU, a CVU, or a modem up to 50 feet (15 m) away.
An RS-422 compati bl e port i s al so avai l abl e on the PPX:5351212. Thi s port
may be used for communi cati ng wi th a modem and al l ows communi cati on to a
di stance up to 1000 feet (305 m).
1.2.4 Ba tte ry Ba c kup
A 3.0 V l i thi um battery (PPX:25876788005) protects the fol l owi ng i nformati on
duri ng a power cycl e:
D RLL program
D Ti mer/counter preset and current val ues
D Drum preset preset and current val ues
D Word I /O val ues
D Vari abl e (V) memory val ues
D Retenti ve control rel ay status
D States of forced I /O
D Scan ti me
D I /O Confi gurati on data
Battery memory backup typi cal l y l asts si x months at temperatures rangi ng
from 0_to 60_C.
FEATURES
1-10
1.2.5 La d d e r M e mory Prote c tion
A memory protecti on di pswi tch provi des protecti on for the RLL program. When
the swi tch i s i n the ON posi ti on, the program cannot be changed by a
programmi ng devi ce that i s connected to the PLC through one of the
communi cati on ports.
NOTE
The memory protection dipswitch does not prevent forcing I/O,
changing variable memory, or switching the PLC from PROGRAM
to RUN mode. These actions may be made by a programming
device connected to the PLC, or a special function I/O module
designed for this type of interface to the PLC, e.g., a Network
Interface Module. The RLL can also be changed through a special
function module, even when the memory protection is enabled.
2-1
C HAPTER 2
PRE- INSTALLATIO N PLANNING
Thi s chapter presents recommended i nstal l ati on practi ces and procedures.
Si nce no two appl i cati ons are i denti cal , these recommendati ons are gui del i nes.
2.1 INTRO DUC TIO N
Prepari ng the si te for i nstal l ati on of your TI 525/TI 535 PLC consi sts of the
fol l owi ng:
D Defi ni ng the control requi rements
D Determi ni ng the number of PLCs needed
D Determi ni ng the panel and groundi ng l ayout
You shoul d defi ne the control requi rements i n terms of the number and type of
i nputs and outputs. Once the i nputs and outputs have been defi ned, cal cul ate
the number of I /O modul es and bases that are needed. When the number of
PLCs, bases, and I /O modul es i s known, determi ne the power requi rements and
mounti ng space needed. Space i n the base assembl y may be a l i mi ti ng factor
that you shoul d consi der as you pl an your system. Thi s i s parti cul arl y true i f
several doubl e-wi de modul es are needed.
I t i s useful to cal cul ate a power budget for each base pri or to i nstal l ati on. The
power requi rements of al l modul es must be i ncl uded i n the cal cul ati ons the
PLC, the base control l ers, as wel l as the I /O modul es. The user-suppl i ed power
to i ndi vi dual modul es i s not a part of the power budget cal cul ati on.
To hel p ensure rel i abl e system operati on, the total power requi red for the PLC,
the I /O control l ers, and the I /O modul es must not exceed the total power
avai l abl e from the system power suppl y.
WARNING
Control devices can fail in an unsafe condition. This means
that, unless proper safeguards are incorporated by the
user, certain malfunctions of these devices could lead to a
sudden equipment startup. Such a startup could result in
property damage and/or severe physical injury to the
equipment operator.
PRE- INSTALLATIO N
2-2
If you, or your company, use any programmable
controllers with equipment which requires an
operator or attendant, you should be aware that
this potential safety hazard exists and take
appropriate precautions. Although the specific
design steps depend on your particular
application, the following precautions generally
apply to installation of solid-state programmable
control devices.
These precautions conform to the guidelines for
installation of Programmable Controllers as
recommended in the NEMA ICS 3304
Programmable Control Standards.
PRE- INSTALLATIO N
2-3
ICS 3304.81 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.
I f 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.*
*The I CS 3304.81 Safety Recommendati ons are reproduced by permi ssi on of
the Nati onal El ectri cal Manufacturers Associ ati on from NEMA I CS 3304,
Programmabl e Control l er Standard.
PRE- INSTALLATIO N
2-4
2.2 SAFETY C O NSIDERATIO NS
Pre-i nstal l ati on pl anni ng and si te preparati on must i ncl ude consi derati on of
hazards to personnel duri ng a system fai l ure. The equi pment connected to the
TI 525/TI 535 PLC shoul d i ncl ude i nterl ocks and safety swi tches to prevent
operati on duri ng a system fai l ure. Al though the speci fi c steps depend on the
appl i cati on, the general precauti ons i ncl ude the fol l owi ng:
D Provi de a means for di sconnecti ng poweri ndependent of the
PLCfrom the output l oads when a machi ne i s not operati ng, or when
i t i s necessary for the operator to reach i nto the machi ne. Power must be
removed by a non-semi conductor swi tch or a physi cal l y-wi red rel ay
contact, pl aced to i nterrupt power to the output. I t i s not suffi ci ent to
rel y sol el y on the PLC for thi s functi on. Fi gure 2-1 i l l ustrates an
operator safety swi tch.
Output
Module
Relay contacts or limit switches
open when operator must
reach into machine.
User-supplied
critical loads
which could
cause injury
Loads which
could not
cause injury
Output points from
the programmable controller
Fig ure 2- 1 O p e ra tor Sa fe ty Switc h
PRE- INSTALLATIO N
2-5
D Provi de a means for removi ng power from the output i f an emergency
condi ti on occurs wi th the machi ne duri ng operati on. Do thi s by
di sconnecti ng output power wi th a non-semi conductor swi tch or
hard-wi red rel ay contact, not through the programmabl e control
system. Thi s type of swi tch i s shown i n Fi gure 2-2.
Output
Module
Contacts of
electromechanical relay C1
usersupplied
critical loads
which could
cause injury
loads which
could not
cause injury
Outputs from the
programmable controller
C1
C1
Emergency
stop
Reset
C1
Electromechanical
Relay
Guard
limit switch
C1
Fig ure 2- 2 Eme rg e nc y Stop Switc h
PRE- INSTALLATIO N
2-6
D Bypass the programmabl e control system wi th an external JOG or
I NCH swi tch duri ng machi ne l oadi ng or setup operati ons. See
Fi gure 2-3.
Output
Module
User-supplied
critical loads
which could
cause injury
Outputs from the
programmable controller
Jog
Switch or contact
open in the JOG
or INCH mode
Switch or contact
closed in the jog
or inch mode
Fig ure 2- 3 JO G or INC H Switc h
2.3 ENC LO SURE SELEC TIO N
As a mi ni mum, an encl osure for a PLC shoul d provi de the fol l owi ng:
D Easy access to components
D A common ground potenti al on the cabi net
D A secure verti cal panel or rai l s
D Conformance to el ectri cal standards
D An el ectromagneti c shi el d
D Access restri cted to authori zed personnel onl y
D Protecti on from dust, di rt and moi sture i n an i ndustri al envi ronment
PRE- INSTALLATIO N
2-7
Mount the TI 525/TI 535 components i n a dustproof and dri p ti ght encl osure
such as the NEMA Type 12 encl osure. The encl osure must provi de a mi ni mum
depth of 25.4 cm (10 i n) from the panel to the i nsi de surface of the encl osure door.
The encl osure shoul d be l ocated so that the doors may be opened ful l y,
permi tti ng easy access to the PLC, wi ri ng, and components. I f envi ronmental
condi ti ons permi t, a 19-i nch rack may be used i nstead of a NEMA encl osure.
Use the 16-sl ot I /O base PPX:5056516 for 19-i nch rack i nstal l ati ons.
2.4 G RO UNDING AND WIRING THE EQ UIPM ENT
A good grounding system is essential for proper operation of a PLC
system and should be one of the most important considerations in
planning your installation. The structural ground present i n many
i ndustri al envi ronments does not provi de an adequate ground return where
di rect wi re connecti on i s not feasi bl e. Appendi x B i s a di scussi on of groundi ng,
el ectromagneti c i nterference (EMI ), and other el ectri cal consi derati ons. See
the gui del i nes i n Appendi x B to be certai n to meet al l groundi ng and wi ri ng
requi rements.
2.5 TEM PERATURE C O NSIDERATIO NS
When prepari ng your i nstal l ati on, pl an for an adequate ai r fl ow to ensure
proper cool i ng of equi pment. Do not permi t the convecti ve cool i ng of the PLC to
be hi ndered. Unl ess ambi ent temperatures are extremel y hi gh, a fan or
ai r-condi ti oned cool i ng i s unnecessary for keepi ng TI 525/TI 535 PLCs bel ow
thei r maxi mum-rated operati ng temperature of 60_C.
For one l ocal base and one di stri buted base l ocated i n the the bottom hal f of a
7-foot, 19-i nch rack, pl ace equi pment that di ssi pates no more than 325 W i n the
top hal f, above the Seri es 505 bases, assumi ng a 25_C external ambi ent
temperature. I f you must exceed these gui del i nes, use cool i ng equi pment to
l ower the equi pment temperature to the recommended l evel .
3-1
C HAPTER 3
INSTALLATIO N
3.1 INSTALLING THE BASE ASSEM BLIES
The PLC, I /O control l ers, power suppl y, and I /O modul es are mounted i n Seri es
505 base assembl i es. Three Seri es 505 base assembl y model s are currentl y
avai l abl e:
D PPX:5056504, 4 I /O sl ots
D PPX:5056508, 8 I /O sl ots
D PPX:5056516, 16 I /O sl ots (19-i nch rack compati bl e)
Each base has sl ots reserved for the power suppl y and for the PLC, and 4, 8, or
16 I /O modul e sl ots, dependi ng upon the base model . Refer to Fi gure 3-1.
Power
Supply
PPX:5056504 4Slot Base
Series 505 I/O
Series 505 I/O
Power
Supply
Power
Supply
Series 505 I/O
TI525/TI53 PLC
TI525/TI53 PLC
TI525/TI53 PLC
Fig ure 3- 1 Se rie s 505 Ba se s
INSTALLATIO N
3-2
Al l Seri es 505 bases may be panel -mounted. The PPX:5056516 base may al so
be mounted i n a 19-i nch rack. The mounti ng brackets are i ncl uded wi th the
Seri es 505 base assembl y. Fi gure 3-2 shows the di mensi ons and screw posi ti ons.
438 mm
273 mm
195 mm
203 mm
All Models
Front view
Side View
(7.69 in)
(10.75 in)
(17.25 in)
(7.99 in)
266 mm
(10.47 in)
22 mm
(0.87 in)
9 mm
(0.35 in)
191 mm
37.8 mm
(7.52 in)
(1.49 in)
PPX:5056504 4-slot base
Brackets rear-mounted
for panel installation
(all models)
Brackets front-mounted
for rack installation
(PPX:5056515 only)
Fig ure 3- 2 M ounting Dime nsions for the Se rie s 505 Ba se s
INSTALLATIO N
3-3
3.1.1 Insta lling Ba se Ha rd wa re
For rack or panel mounti ng, pl ace the brackets i n the desi red posi ti on on the
Seri es 505 base (on the front for rack mounti ng, or on the back for panel
mounti ng) as shown i n Fi gure 3-2. I nsert the encl osed screws through the
brackets i nto the predri l l ed hol es i n the base and ti ghten.
3.1.2 Ra c k or Pa ne l M ounting
I f you are mounti ng your base on a predri l l ed rack, al i gn the brackets wi th the
rack, then i nsert and ti ghten the screws.
Before mounti ng the base to a panel , you need to measure for and dri l l screw
hol es. Refer to Fi gure 3-2 for screw l ocati ons.
On the front of the base i s a ground l ug whi ch you shoul d connect to a
si ngl e-poi nt earth ground. (Refer to Appendi x B for further groundi ng
gui del i nes.)
CAUTION
Each base has a plastic dustguard covering the top grill.
The dustguard prevents debris from falling into the base
during installation. After the entire system installation
is complete, and BEFORE ENABLING POWER TO THE
SYSTEM, be sure to remove the dustguard from each
base. This will allow proper air flow and prevent serious
complications due to overheating.
INSTALLATIO N
3-4
3.2 HANDLING SERIES 505 M O DULES
Many i ntegrated ci rcui t (I C) devi ces are suscepti bl e to damage by the di scharge
of stati c el ectri ci ty. Fol l ow the suggesti ons l i sted bel ow to reduce the probabi l i ty
of damage to these devi ces when you are handl i ng a PLC, an I /O control l er, or
any of the I /O modul es. To minimize risk of shock hazard, make certain
power to the PLC system is turned off.
WARNING
To minimize the risk of shock hazard, make
certain power to the PLC system is turned off.
Both the modul e and the person handl i ng the modul e shoul d be at the same
ground potenti al . To accompl i sh thi s, ensure that:
D The modul e i s transported i n an anti stati c contai ner or anti stati c
materi al .
D The work area has a conducti ve pad wi th a l ead connecti ng i t to a
common ground.
D You are grounded by maki ng contact wi th the conducti ve pad and/or by
weari ng a grounded wri st strap.
CAUTION
The following precautions, although less
effective, may be taken to minimize the
possibility of component damage resulting from
electrostatic discharge. See Appendix B for
grounding guidelines.
D To di scharge stati c el ectri ci ty, touch a grounded pi ece of metal before
touchi ng the ci rcui t board or any of i ts components.
D Wear non-syntheti c cl othi ng.
D Handl e al l modul es by the external casi ng, and avoi d contact wi th the
ci rcui t board or any of i ts components.
INSTALLATIO N
3-5
3.3 SETTING TI525 DIPSWITC HES
You determi ne operati onal parameters for the TI 525 by setti ng swi tches on two
di pswi tches. For the TI 525 PLCs, these di pswi tches are l ocated on the pri nted
ci rcui t board (PCB). Refer to Fi gure 3-3.
DIP 1
ON OFF
RS-232-C/423
Baud rate
RS-422
Baud rate
DIP 2
ON OFF
Position not
Selected
Position
Selected
Push Down
L-Memory
3 4 Baud
9600
2400
1200
300
ON ON
OFF ON
ON OFF
OFF OFF
1 2 Baud
9600
2400
1200
300
ON ON
OFF ON
ON OFF
OFF OFF
Factory test
must be
set on
Switch position
Switch position
Battery enable
Factory test switches
must be set off
for normatl operation
L- Memory protect on
Download presets
Factory test switches
position does not matter
fro normal use
Fig ure 3- 3 Loc a tions of the Dip switc he s for the TI525
M od e ls
INSTALLATIO N
3-6
3.3.1 Se tting Port Ba ud Ra te TI525 M od e ls
Fi gure 3-4 shows the baud rate swi tch assi gnments for the communi cati on
ports. Swi tches 1 and 2 on the fi rst swi tch bank (DI P 1) set the baud rate for the
RS-232-C/423 port (Port 1). Swi tches 3 and 4 on DI P 1 set the baud rate for the
RS-422 port (Port 2). Swi tch posi ti on does not matter i f a devi ce i s not connected
to the port.
You need to set onl y swi tches 1 and 2 for PPX:5251102 and PPX:5051104
model s whi ch have onl y an RS-232-C/RS-423 port.
DIP 1
Position not
selected
Position
selected
ON OFF
RS-232-C/423
Baud rate
RS-422
Baud rate
3 4 Baud
9600
2400
1200
300
ON ON
OFF ON
ON OFF
OFF OFF
1 2 Baud
9600
2400
1200
300
ON ON
OFF ON
ON OFF
OFF OFF
Push down
Switch position
Switch position
Fig ure 3- 4 Switc h Se tting s TI525 RS- 232- C / 423 a nd RS- 422
Ports
NOTE
Swi tches 5, 6, 7, and 8 on the fi rst bank (DI P 1) are reserved for
factory testi ng and shoul d al l be turned ON.
INSTALLATIO N
3-7
3.3.2 Se le c ting Ba tte ry Ba c kup TI525 M od e ls
Swi tch 1 on the second di pswi tch assembl y (DI P 2) enabl es or di sabl es the
battery backup functi on. Wi th the battery backup enabl ed, cycl i ng power does
not al ter the fol l owi ng i nformati on:
D RLL program
D Word I /O val ues
D Scan ti me
I f you power up a TI 525 wi thout a good battery i nstal l ed or wi th the battery
backup di pswi tch turned OFF, the PLC cl ears memory.
To al l ow for battery repl acement, the TI 525 i s desi gned to retai n memory for at
l east 10 mi nutes whi l e powered down, even wi th a bad battery. I f the PLC i s
powered down wi thout a good battery for l onger than 10 mi nutes, at power-up
the PLC detects whether or not memory i s val i d. I f memory i s not val i d, then the
PLC cl ears memory upon power-up.
Refer to Fi gure 3-5. Turn swi tch 1 ON to enabl e the battery backup. Turn swi tch
1 OFF to di sabl e battery backup.
DIP 2
ON OFF
Battery enable Battery disable
Position not
selected
Position
selected
Push down
Fig ure 3- 5 Switc h Se tting s TI525 Ba tte ry Ba c kup
NOTE
Swi tches 2, 3, 6, 7, and 8 on DI P 2 are reserved for factory
testi ng. Swi tches 2 and 3 shoul d be turned off. The posi ti on of
swi tches 6, 7, and 8 do not matter for normal operati on.
INSTALLATIO N
3-8
3.3.3 Se le c ting La d d e r M e mory Prote c tion TI525 M od e ls
Swi tch 4 on DI P 2 prevents modi fi cati ons to the RLL program i n l adder memory.
Your programmi ng uni t refers to thi s swi tch as a keyl ock.
Refer to Fi gure 3-6. Turn swi tch 4 ON to prohi bi t changes to the program. Turn
swi tch 4 OFF to permi t program edi ti ng.
DIP 2
ON OFF
Position not
Selected
Position
Selected
Push Down
L-Memory
protect off
L-Memory
protect on
Fig ure 3- 6 Switc h Se tting s TI525 L- M e mory Prote c tion
NOTE
Turni ng the L-memory protect swi tch on does not prevent
forci ng I /O, changi ng vari abl e memory, or swi tchi ng the PLC
from PROGRAM to RUN mode. These acti ons may be i ni ti ated
wi th a programmi ng devi ce connected to the PLC, or a speci al
functi on I /O modul e desi gned for thi s type of i nterface to the
PLC, e.g., a Network I nterface Modul e.
The RLL can al so be changed through a speci al functi on
modul e, even when the memory protecti on i s enabl ed wi th the
keyl ock. Do not depend upon thi s swi tch to prevent personnel
from i nterrupti ng your process.
INSTALLATIO N
3-9
3.3.4 Downloa d ing Pre se t C onsta nts TI525 M od e ls
The drum and ti mer/counter i nstructi ons have reserved secti ons of memory
where preset vari abl es are stored. These vari abl es may be changed wi th an
operator i nterface, such as a TCAM or VPU, or wi th an RLL i nstructi on,
wi thout al teri ng thei r val ue i n the RLL program. I f you cycl e power or execute
AUX Functi on 10 whi l e the battery i s enabl ed, swi tch 5 on DI P 2 determi nes
whether the changed val ues i n preset memory are retai ned or the ori gi nal
val ues are downl oaded from the RLL program. I f the battery i s dead, l ow, or
di sabl ed, the preset val ues are al ways downl oaded from the RLL program i n an
EPROM/EEPROM, i f one i s i nstal l ed.
Refer to Fi gure 3-7. Turn swi tch 5 ON to have val ues downl oaded from the RLL
program. Turn swi tch 5 on DI P 2 OFF to have preset val ues retai ned.
DIP 2
ON OFF
Position not
selected
Position
selected
Push down
Retain
presets
Download
presets
Fig ure 3- 7 Switc h Se tting s TI525 Downloa d / Re ta in Pre se ts
NOTE
Executi ng AUX Functi on 12 (PLC Compl ete Restart) wi th your
programmi ng devi ce causes the presets to be downl oaded from
the RLL program, regardl ess of the state of thi s di pswi tch.
INSTALLATIO N
3-10
3.4 SETTING TI535 DIPSWITC HES
You determi ne operati onal parameters for the TI 535 by setti ng swi tches on two
di pswi tch bl ock assembl i es. For the TI 535 PLCs, thi s i s done wi th one bl ock of
di pswi tches l ocated on the pri nted ci rcui t board (PCB) and a second bl ock
l ocated i nsi de the battery door. Refer to Fi gure 3-8.
DIP 1
DIP 2
Front bezel
Position not
selected
Position
selected
Push down
ON OFF
Factory test
I/O type
and factory test
Highest base
set off
Retain
presets
Download
presets
L = Left R = Right
base
address
5 6 7 8
0 ON ON ON ON
1 OFF ON ON ON
2 ON OFF ON ON
3 OFF OFF ON ON
4 ON ON OFF ON
5 OFF ON OFF ON
6 ON OFF OFF ON
7 OFF OFF OFF ON
8 ON ON ON OFF
9 OFF ON ON OFF
10 ON OFF ON OFF
11 OFF OFF ON OFF
12 ON ON OFF OFF
13 OFF ON OFF OFF
14 ON OFF OFF OFF
15 OFF OFF OFF OFF
.
Highest
2 3 Baud
1200
2400
9600
19200
L R
R L
L L
* *
Switch position
4
R
R
R
L
300 R R R
L = Left R = Right
5 6 Baud
1200
2400
9600
19200
L R
R L
L L
* *
Switch position
7
R
R
R
L
300 R R R
address
* Position does not matter
Battery Battery
enable disable
L-Memory
Protect off
L Memory
Protect on
Position not
Selected
Position
Selected
Push left or right
PUSH LEFT PUSH RIGHT
RS-422
Baud rate
RS-232-C/423
Baud rate
2 3 I/O Type
Test
Test
No status
ON OFF
OFF ON
OFF OFF
Switch position
Status ON ON
Switch position
Front bezel
Fig ure 3- 8 Loc a tions of the Dip switc he s for TI535
M od e ls
INSTALLATIO N
3-11
NOTE
Swi tch 1 on the fi rst di pswi tch (DI P 1) i s used for factory testi ng
and shoul d be turned OFF. Swi tches 2 and 3 are al so reserved
for factory testi ng and shoul d be turned ON.
3.4.1 Se le c ting I/ O Typ e TI535 M od e ls
Some earl i er Seri es 505 I /O modul es (manufactured pri or to January 1, 1988) do
not report modul e status to the CPU. Modul es bui l t after thi s date do report
status. Compl ete the fol l owi ng steps to determi ne whi ch type of I /O you have.
1. Disconnect all user-supplied power from the base.
2. Remove the I /O modul e.
3. Fi nd the seri al number l abel on the i nsi de of the front bezel . I f you have
a number greater than XXXX8801XXXXXX, you have a modul e that
reports status. I f you have a seri al number l ess than or equal to
XXXX8712XXXXXX, you have a modul e that does not report status.
Swi tches 2 and 3 on DI P 1 determi ne whether the CPU expects the status to be
reported.
I f the swi tches are both ON, the CPU expects the status to be reported. I f you
i nstal l I /O modul es that do not report status, the CPU reports an I /O mi smatch
and I /O fai l ure.
I f the swi tches are both OFF, the CPU does not expect the status to be reported.
When both swi tches are off, you can use ei ther type of I /O.
When the swi tches are mi xed (ON/OFF or OFF/ON), the CPU i s set for factory
tests.
INSTALLATIO N
3-12
3.4.2 Downloa d ing Pre se t C onsta nts TI535 M od e ls
The drum and ti mer/counter i nstructi ons have reserved secti ons of memory
where preset vari abl es are stored. These vari abl es may be changed wi th an
operator i nterface, such as a TCAM or VPU, wi thout al teri ng thei r val ue i n the
RLL program. I f you cycl e power or execute AUX Functi on 10 or 11 whi l e the
battery i s enabl ed, swi tch 4 on DI P 1 determi nes whether val ues i n preset
memory are retai ned or downl oaded from the RLL program. I f the battery i s
dead, l ow, or di sabl ed, the preset val ues are al ways downl oaded from the RLL
program i n an EPROM/EEPROM, i f one i s i nstal l ed.
Refer to Fi gure 3-9. Turn swi tch 4 ON to have val ues downl oaded from the RLL
program. Turn swi tch 4 OFF to have preset val ues retai ned.
DIP 1
ON OFF
Retain
presets
Download
presets
Position not
selected
Position
selected
Push down
Fig ure 3- 9 Switc h Se tting s TI535 Downloa d / Re ta in Pre se ts
NOTE
Executi ng AUX Functi on 12 (PLC Compl ete Restart) wi th your
programmi ng devi ce causes the presets to be downl oaded from
the RLL program, regardl ess of the state of thi s di pswi tch.
INSTALLATIO N
3-13
3.4.3 Se tting Hig he st I/ O Ba se Numb e r TI535 M od e ls
The base assembl y hol di ng the PLC al so hol ds the l ocal I /O. The l ocal I /O
consi sts of the fi rst two l ogi cal bases, numbered 0 and 1. A l ogi cal base i s defi ned
as a group of ei ght I /O sl ots. As many as fourteen addi ti onal l ogi cal bases,
numbered from 2 to 15, may be connected to the system as di stri buted I /O.
Swi tches 58 on DI P 1 are used to sel ect the hi ghest-numbered l ogi cal base i n
the system. For exampl e, i f your system consi sts of 5 l ogi cal bases numbered 0
through 5, then the di pswi tches shoul d be set for 5.
Swi tches 58 reduce I /O update ti me by preventi ng the PLC from attempti ng to
communi cate wi th di stri buted bases that are not present or whi ch you may
have shut down. Al though i t i ncreases scan ti me, you can set the swi tches for 15
i f you prefer, regardl ess of the actual number of l ogi cal bases that are connected.
You may connect Seri es 500 bases to your system. Number the Seri es 500 l ogi cal
bases just as you woul d Seri es 505 bases; however, the total number of l ogi cal
bases cannot exceed 16.
Fi gure 3-10 l i sts the swi tch posi ti ons for each address.
base
address
5 6 7 8
0 ON ON ON ON
1 OFF ON ON ON
2 ON OFF ON ON
3 OFF OFF ON ON
4 ON ON OFF ON
5 OFF ON OFF ON
6 ON OFF OFF ON
7 OFF OFF OFF ON
8 ON ON ON OFF
9 OFF ON ON OFF
10 ON OFF ON OFF
11 OFF OFF ON OFF
12 ON ON OFF OFF
13 OFF ON OFF OFF
14 ON OFF OFF OFF
15 OFF OFF OFF OFF
.
Switch position Highest
DIP 1
Position not
selected
Position
selected
Push down
ON OFF
Fig ure 3- 10 Switc h Se tting s TI535 Hig he st- Numb e re d
Log ic a l Ba se
INSTALLATIO N
3-14
3.4.4 Se le c ting Ba tte ry Ba c kup TI535 M od e ls
Swi tch 1 on the second di pswi tch assembl y (DI P 2) enabl es or di sabl es the
battery backup functi on. Wi th the battery backup enabl ed, cycl i ng power does
not al ter the fol l owi ng i nformati on:
D RLL program
D Word I /O val ues
D Scan ti me
I f you power up a TI 535 wi th the battery backup di pswi tch turned OFF and
have not i nstal l ed an EPROM/EEPROM, the PLC cl ears memory.
NOTE
I f you are poweri ng up a TI 535 for the fi rst ti me, turn off the
battery backup and do not i nstal l a programmed
EPROM/EEPROM. Thi s ensures that the PLC i s properl y
i ni ti al i zed.
Refer to Fi gure 3-11. Push Swi tch 1 LEFT to enabl e the battery backup. Push
swi tch 1 RI GHT to di sabl e battery backup.
DIP 2
PUSH LEFT PUSH RIGHT
Battery Battery
enable disable
Fig ure 3- 11 Switc h Se tting s TI535 Ba tte ry Ba c kup
INSTALLATIO N
3-15
3.4.5 Se tting C ommunic a tion Port Ba ud Ra te TI535 M od e ls
Fi gure 3-12 shows the baud rate swi tch assi gnments for the communi cati on
ports. Swi tches 24 on the second di pswi tch assembl y (DI P 2) set the baud rate
for the RS-422 9-pi n port (Port 2). Swi tches 57 set the baud rate for the
RS-232-C/423 25-pi n port (Port 1). Swi tch posi ti on does not matter i f a devi ce i s
not to be connected to the port.
DIP 2
L = Left R = Right
RS422
Baud rate
2 3 Baud
1200
2400
9600
19200
L R
R L
L L
* *
Switch position
4
R
R
R
L
300 R R R
RS232C/423
Baud rate
L = Left R = Right
5 6 Baud
1200
2400
9600
19200
L R
R L
L L
* *
Switch position
7
R
R
R
L
300 R R R
PUSH
LEFT
PUSH
RIGHT
Fig ure 3- 12 Switc h Se tting s TI535 RS- 232- C / RS- 423 a nd
RS- 422 Ports
INSTALLATIO N
3-16
3.4.6 Se le c ting La d d e r M e mory Prote c tion TI535 M od e ls
Swi tch 8 on DI P 2 prevents changes to the RLL program i n l adder memory. Your
programmi ng uni t refers to thi s swi tch as a keyl ock.
Refer to Fi gure 3-13. Push swi tch 8 LEFT to prohi bi t changes to the program.
Push swi tch 8 RI GHT to permi t program edi ti ng.
DIP 2
PUSH PUSH
L-Memory L-Memory
protect on protect off
Position not
selected
Position
selected
Push Left or Right
LEFT RIGHT
Fig ure 3- 13 Switc h Se tting s TI535 LM e mory Prote c tion
NOTE
Turni ng the L-memory protect swi tch on does not prevent
forci ng I /O, changi ng vari abl e memory, or swi tchi ng the PLC
from PROGRAM to RUN mode. These acti ons may be made by a
programmi ng devi ce connected to the PLC, or a speci al functi on
I /O modul e desi gned for thi s type of i nterface to the PLC, e.g., a
Network I nterface Modul e.
The RLL can al so be changed through a speci al functi on
modul e, even when the memory protecti on i s enabl ed wi th the
keyl ock. Do not depend upon thi s swi tch to prevent personnel
from i nterrupti ng your process.
INSTALLATIO N
3-17
3.5 INSTALLING THE BATTERY
The TI 525/TI 535 PLCs are shi pped wi th a l i thi um battery al ready i nstal l ed.
Thi s battery has a mi ni mum storage l i feti me of three years and a mi ni mum
backup l i feti me of si x months (0_to 60_C). Fol l ow the steps l i sted bel ow to
repl ace the battery.
3.5.1 M od e l TI525 Ba tte ry Insta lla tion
The TI 525 i s capabl e of preservi ng system memory for at l east ten mi nutes after
the battery and power have been di sconnected. Compl ete the battery
repl acement wi thi n thi s peri od i f you wi sh to save i nformati on.
1. Disable all user-supplied power to the base.
2. Remove the PLC from the base. Do not touch the components on the
pri nted ci rcui t board or short any etch l i nes or pi ns as thi s may
di srupt system memory. Do not pl ace the PLC on a conducti ve
surface.
3. Check the battery backup swi tch (DI P 2, swi tch 1). I f i t i s off and you
wi sh to retai n system memory, turn the swi tch on.
4. Remove the battery from the cl i p and di sconnect the l eads.
5. The new battery shoul d be a 3.0 VDC UL Recogni zed l i thi um battery
(PPX:25876788005). Connect the red wi re to the posi ti ve pol e and
the bl ack wi re to the negati ve pol e of the new battery. Then i nsert
the new battery i nto the battery hol der.
6. I nsert the PLC i nto the base, enabl e power, and veri fy that the BATT
GOOD LED comes on.
INSTALLATIO N
3-18
3.5.2 M od e l TI535 Ba tte ry Insta lla tion
Take the fol l owi ng steps to repl ace the battery.
1. Ensure that the power to the PLC is on. Replacing the
battery with power off will result in memory loss.
2. Open the battery door as shown i n Fi gure 3-14.
Battery
Fig ure 3- 14 Ba tte ry Loc a tion for TI535 M od e ls
3. Remove the battery from the compartment and di sconnect the l eads.
4. Attach the l eads to the new battery (3.0 VDC UL Recogni zed l i thi um
battery (PPX:25876788005). Connect the red wi re to the posi ti ve
pol e and the bl ack wi re to the negati ve pol e. Push the new battery
and l eads back i nto the compartment.
5. Set the battery di pswi tch ON (DI P 2, swi tch 1) i f you wi sh to enabl e
battery backup. The BATT GOOD i ndi cator shoul d l i ght.
6. Cl ose the battery door.
INSTALLATIO N
3-19
3.6 INSTALLING SYSTEM C O M PO NENTS
A base assembl y i s composed of one or two l ogi cal bases. A l ogi cal base i s defi ned
as a group of ei ght I /O sl ots, as shown i n Fi gure 3-15. Therefore, the
PPX:5056516 si xteen-sl ot base assembl y compri ses two l ogi cal bases, whi l e
the PPX:5056508 ei ght-sl ot base assembl y contai ns one l ogi cal base. The
four-sl ot PPX:5056504 base al so contai ns one l ogi cal base, but sl ots 58 do not
physi cal l y exi st. A system may consi st of as many as 16 l ogi cal bases and up to
1023 I /O poi nts.
Power
supply
One Logical
base
8 slots
Logical base
8 slots
One logical
base
.
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.
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. . . . . . . .
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. . . . .
. . . . . . . .
4 Physical slots
4 Nonexistent slots
Logical base
8 slots Power
supply
Power
supply
TI525/TI535
PLC
TI525/TI535
PLC
TI525/TI535
PLC
PPX:5056508 8slot base
Fig ure 3- 15 De finition of the Se rie s 505 Log ic a l Ba se
INSTALLATIO N
3-20
I /O modul es are grouped i nto l ocal or di stri buted I /O categori es dependi ng upon
thei r physi cal l ocati on. The l ocal I /O compri ses those modul es i nstal l ed i n the
same base assembl y as the PLC the pri mary base.
A system havi ng l ocal I /O onl y consi sts of a si ngl e base assembl y compri si ng a
maxi mum of two l ogi cal bases. A 16-sl ot base assembl y contai ns two l ogi cal
bases, numbered 0 and 1 from l eft to ri ght. The 8-sl ot and 4-sl ot base assembl i es
each contai n one l ogi cal base, numbered 0. See Fi gure 3-16.
NOTE
Bases 0 and 1 are al ways on the l ocal base. Therefore, any
di stri buted base wi l l al ways be numbered greater than 1.
I f your system has l ocal I /O onl y, you need to i nstal l the power suppl y, PLC and
I /O modul es i n a si ngl e base assembl y. See the i nstal l ati on i nstructi ons l ater i n
thi s chapter.
Power
4-Slot base
supply
8-Slot base
16-Slot base
Series 505
Logical
base 0
Logical
base 1
I/O modules
TI525/TI535 PLC
Fig ure 3- 16 Syste m With Loc a l I/ O O nly
INSTALLATIO N
3-21
You may connect up to 14 addi ti onal base assembl i es to your system, as shown i n
Fi gure 3-17. These addi ti onal bases consti tute the di stri buted I /O and are
numbered from 2 to 15.
Local I/O
Distributed
I/O
To other bases To other bases
Power
supply
Logical
base 0
Logical
base 1
Logical
base A
Logical
base B
Logical
base C
Logical
base D
TI525/TI535 PLC
* The PPX:5251102 does not support distributed I/O.
PPX:5056830
IOCC
PPX:5056840
DBC
PPX:5056840
DBC
Fig ure 3- 17 Syste ms with Loc a l a nd Distrib ute d I/ O
The I /O modul es i n the di stri buted bases communi cate wi th the PLC through
base control l ers. The Seri es 505 Di stri buted Base Control l er (DBC)
(PPX:5056840) i n each di stri buted base assembl y transmi ts al l i nformati on
from the I /O modul es i n that base assembl y to the I /O Channel Control l er
(I OCC) (PPX:5056830) .
A system wi th di stri buted I /O requi res one I OCC, l ocated i n the pri mary base.
Dependi ng upon the cabl e used, the l i ne dri vers of the DBC and the I OCC
permi t di stri buted I /O to be up to 1300 feet (396 m) from the PLC.
INSTALLATIO N
3-22
Both Seri es 500 and 505 I /O can be connected to a TI 525/TI 535 PLC as
di stri buted I /O. The Seri es 505 I OCC (PPX:5056830) i s capabl e of addressi ng
the Seri es 500 DBCs (PPX:2109 or PPX:5052103) i n a Seri es 500 base
assembl y.
I f your appl i cati on requi res di stri buted I /O, you must i nstal l an I OCC i n the
pri mary base assembl y. You must al so i nstal l the di stri buted bases wi th thei r
power suppl i es, DBCs, I /O modul es, and cabl i ng. See the i nstal l ati on
i nstructi ons l ater i n thi s chapter.
3.6.1 Numb e ring Se rie s 505 I/ O Points
When you confi gure the I /O, you assi gn an I /O poi nt number to each poi nt. You
do thi s from the I /O Modul e Defi ni ti on Chart on your programmi ng devi ce.
Local I /O consi sti ng of a maxi mum of 512* I /O poi nts can be confi gured when
you assi gn the I /O poi nt numbers. Thi s i s obtai ned by usi ng base Model
5056516 (si xteen sl ots) and 32-poi nt I /O modul es.
The PLC permi ts a maxi mum number of 1023 poi nts for a l ocal and di stri buted
system. You need not assi gn the poi nt numbers consecuti vel y. For exampl e, i n a
di stri buted system, Base 2 can be assi gned I /O poi nt numbers 897960.
However, the hi ghest poi nt number that you can assi gn to a poi nt i s 1023.
You do not need to assi gn I /O poi nt numbers to empty sl ots or to non-exi stent
sl ots i n l ogi cal bases havi ng fewer than ei ght sl ots.
* I/O Module power consumption requirements may reduce the actual number of I/O points
that can be installed.
INSTALLATIO N
3-23
3.6.2 G uid e line s For Insta lling Se rie s 505 M od ule s
The Seri es 505 I /O, base control l ers, and PLCs are al l open-card modul es i n
doubl e Eurocard desi gn*. The power suppl y i s a parti al l y encased modul e i n
doubl e Eurocard desi gn. Fol l ow the gui del i nes i n the fol l owi ng paragraphs
when i nserti ng or removi ng the modul es.
WARNING
Do not insert or remove modules while power is enabled
to the PLC. Modules may be damaged if inserted while
power is on, and memory may be lost if the PLC is
removed while power is on.
* System 505 components are compatible with International standards double-Eurocard (DIN standard 41494)
INSTALLATIO N
3-24
Compl ete the fol l owi ng steps to i nsert the modul es i nto the base.
1. Disable all user-supplied power before inserting modules.
2. Hol di ng the modul e by the bezel , posi ti on the pri nted ci rcui t board i n
the upper and l ower card gui des.
3. I nsert the modul e and push unti l i t i s pl ugged i nto the backpl ane
connector. The bezel shoul d be ti ght agai nst the base.
4. The bezel screws provi de the ground. Use a fl at-bl ade screwdri ver to
ti ghten the screws at the top and the bottom of the bezel . Do not
over-ti ghten. The maxi mum torque that can be appl i ed to the screw i s 3
Kg
p
cm (2.60 i nl b).
NOTE
For i nstructi ons on wi ri ng I /O modul es and
cal cul ati ng I /O power requi rements, check the
appropri ate manual for each I /O modul e.
Compl ete the fol l owi ng steps to remove the modul es i nto the base.
1. Disable line and user-supplied power.
2. Loosen the screws at the top and bottom of the bezel .
NOTE
Pri or to removi ng I /O modul es, you may remove the
wi ri ng termi nal bl ock wi thout di sturbi ng fi el d
wi ri ng. Use a Phi l l i ps-head screwdri ver to remove
the screws at the top and bottom of the termi nal
bl ock and pul l the termi nal bl ock off the bezel .
3. Grasp the bezel screws and careful l y remove the modul e. You may fi nd
i t easi er to l oosen the modul e fi rst by gentl y pul l i ng the modul e up and
down wi thi n the sl ot by the bezel screws.
INSTALLATIO N
3-25
3.6.3 Insta lling the Powe r Sup p ly
You may operate the PPX:5056660 or PPX:5056660A power suppl y at ei ther
110 or 220 VAC. The power supply is shipped preset for 220 VAC. Use the
jumper shown i n Fi gure 3-18 to sel ect the proper vol tage for your appl i cati on.
CAUTION
To minimize the risk of personal injury, disable all
system power before changing the power supply jumper.
Attempts to operate the power supply with the line
voltage jumper placed incorrectly may damage the
power supply.
220V 110V
TAB1 TAB2
Fig ure 3- 18 Powe r Sup p ly Jump e r
Fol l ow the steps l i sted bel ow to i nstal l the power suppl y.
1. Remove the stri p of paper coveri ng the wi re connectors on the
termi nal bl ock.
2. Sel ect the proper operati ng vol tage by pl aci ng the jumper on the
appropri ate qui ck-connect as shown i n Fi gure 3-18. (Not requi red for
the PPX:5056663 power suppl y.)
4. I nsert the power suppl y i nto the far l eft sl ot of the base as shown i n
Fi gure 3-19.
5. Ti ghten the bezel screws.
INSTALLATIO N
3-26
6. Use 14 AWG sol i d or stranded wi re for connecti on to the power
source; use of smal l er wi re i s not recommended. I f stranded wi re i s
used, the wi re shoul d be twi sted and ti nned.
7. I nsert the green ground wi re i nto the connector l abel ed ground.
8. I nsert the bl ack AC l i ne and whi te AC neutral wi res i nto the power
suppl y wi re connectors l abel ed AC l i ne and AC neutral ,
respecti vel y.
WARNING
Connecting the power supply leads to the
wrong terminals creates a potential shock
hazard that could cause damage to
equipment or injury to personnel. Be sure
that the polarity on all power supply leads is
correct.
9. After i nserti ng the wi res, secure them by ti ghteni ng the termi nal
bl ock screws.
10. Enabl e power.
Bezel screws
Fig ure 3- 19 Loc a tion of Powe r Sup p ly in Ba se
The base power budget i s determi ned from the power provi ded by the base
power suppl y and the requi rements of the parti cul ar modul es used. When
determi ni ng the I /O system l ayout, do not exceed the maxi mum power avai l abl e
from the power suppl y. The total power requi rement for al l modul es drawi ng
power from a Seri es 505 base must be l ess than or equal : 55 W at +5 VDC and
3.75 W at 5 VDC.
INSTALLATIO N
3-27
3.6.4 Insta lling the PLC
Compl ete the fol l owi ng steps to i nstal l the PLC i n the base.
1. Check di pswi tches for correct confi gurati on.
3. I nsert the PLC i nto i ts sl ot adjacent to the power suppl y as shown i n
Fi gure 3-20.
4. Ti ghten the bezel screws.
Bezel screws
Fig ure 3- 20 Loc a tion of PLC in Ba se
5. I f you have equi pment to connect to the ports, attach the
communi cati on cabl es to the appropri ate port(s). The RS-232-C/RS-423
compati bl e port accepts a 25-pi n mal e pl ug and al l ows communi cati on
wi th equi pment up to 50 ft (15.2 m) away. The RS-422 compati bl e port
accepts a 9-pi n mal e pl ug and al l ows communi cati on up to a di stance of
1000 ft (305 m) for al l baud rates supported by the PLC model . Both
ports are confi gured as Data Termi nal Equi pment (DTE). The pi n-outs
are l i sted i n Tabl e 3-1.
INSTALLATIO N
3-28
NOTE
I f you are poweri ng up a TI 535 for the fi rst ti me, turn off the
battery backup. Thi s ensures that the TI 535 PLC i s properl y
i ni ti al i zed. Refer to the startup procedure i n Chapter 5.
6. Enabl e power.
Table 31Pinout for the RS232C/RS423 Port
Pin Signal
2
3
4
5
6
7
8
20
Transmitted data
Received data
Request to send
Clear to send
Data set ready
Signal ground
Received line signal
Data terminal ready
All othersno connection
RS232C/423 Port
Pin Signal
1
5
6
7
8
Data out
Data in
Ground
Data out, inverted
Data in, inverted
RS422 Port
detector
All othersno connection
INSTALLATIO N
3-29
3.6.5 Insta lling the I/ O M od ule s
The wi ri ng for the di fferent I /O modul e termi nal bl ocks may vary. You shoul d
read the user s manual for an i ndi vi dual modul e before wi ri ng and i nstal l i ng
the modul e. I nsert the I /O modul es i nto the base, starti ng wi th the sl ot adjacent
to the PLC as shown i n Fi gure 3-21.
CAUTION
Use supply wires suitable for at least 75_C. Signal wiring
connected in this box must be rated at least 300 V.
ATTENTION
Employer des fils dalimentation pour au moins 75_C. Le
cablage de signalisation raccorde dans cette boite doit
convenir pour une tension nominale dau moins 300 V.
I/O slots
I/O module
Fig ure 3- 21 Loc a tion of I/ O M od ule s in Ba se
The base power budget i s determi ned from the power provi ded by the base
power suppl y and the requi rements of the parti cul ar modul es used. When
determi ni ng the I /O system l ayout, take care not to exceed the maxi mum power
avai l abl e from the power suppl y.
The total power requi rement for al l modul es drawi ng power from a Seri es 505
base must be l ess than or equal : 55 W at +5 VDC and 3.75 W at 5 VDC.
INSTALLATIO N
3-30
NOTE
Do not i nstal l more than four word modul es i n a physi cal base.
Thi s may cause a DC l oadi ng probl em i n the PLC whi ch coul d
resul t i n unexpected di sabl i ng of output modul es (i ncl udi ng
di screte output modul es). For exampl e, even though a 16-sl ot
base contai ns two l ogi cal bases, you can onl y have a total of four
modul es.
Appendi x C gi ves the power requi rements for many of the currentl y avai l abl e
Seri es 505 and Seri es 500 modul es. For other modul es not l i sted see the manual
for that modul e.
Al l the TI 525 and TI 535 control l ers use the Seri es 505 I /O modul es. These I /O
modul es have di fferent numbers and types of I /O poi nts. For exampl e, an
ei ght-poi nt di screte i nput requi res ei ght i nputs (Xs) be assi gned, whi l e an
ei ght-poi nt anal og output modul e requi res assi gnment of ei ght word outputs
(WYs). Tabl e 3-2 l i sts the number and type of poi nts requi red to l og i n the Seri es
505 I /O modul es. Addi ti onal i nformati on on parti cul ar modul es i s gi ven i n the
manual i ncl uded wi th each modul e.
INSTALLATIO N
3-31
Ta b le 3- 2 I/ O M od ule Point Assig nme nts
(Continued on next page)
Model Model Points Special Slots
Number Description Used Function Used
PPX:5054008 2056 VAC Input 8X 1
PPX:5054016 2056 VAC Input 16X 1
PPX:5054032 2056 VAC Input 32X 1
PPX:5054108 4.515 VDC Input 8X 1
PPX:5054116 4.515 VDC Input 16X 1
PPX:5054132 4.515 VDC Input 32X 1
PPX:5054208 79132 VAC Input 8X 1
PPX:5054216 79132 VAC Input 16X 1
PPX:5054232 79132 VAC Input 32X 1
PPX:5054308 1432 VDC Input 8X 1
PPX:5054316 1432 VDC Input 16X 1
PPX:5054317 16 Isolated Inputs or
8 Interrupt Inputs/8 Isolated Inputs 16X 1
PPX:5054332 1432 VDC Input 32X 1
PPX:5054408 164256 VDC Input 8X 2
PPX:5054416 164256 VDC Input 16X 1
PPX:5054432 164256 VDC Input 32X 1
PPX:5054508 4.534 VDC, 0.5 Amp Output 8Y 1
PPX:5054608 20132 VAC, 0.5 Amp Output 8Y 1
PPX:5054908 20256 VAC or 4.534 VDC
Form C Output 8Y 1
PPX:5054916 20256 VAC or 4.534 VDC
Normally Open Output 16Y 1
PPX:5054932 20256 VAC or 4.534 VDC
Normally Open Output 32Y 2
PPX:5055417 115 VDC, Relay Output 16Y 1
INSTALLATIO N
3-32
Ta b le 3- 2 I/ O M od ule Point Assig nme nts
(Continued)
Model Model Points Special
Slots
Number Description Used Function Used
PPX:5056010 32-Point Input Simulator 32X 1
PPX:5056011 32-Point Output Simulator 32Y 1
PPX:5056108 8-Channel Analog Input 8WX 2
PPX:5056108A 8-Channel Analog Input 8WX 1
PPX:5056202 2-Channel Analog Output 2WY 2
PPX:5056208A 8-Channel Analog Output 8WY 1
PPX:5056308 8-Channel Word Input 8WX 2
PPX:5056408 8-Channel Word Output 8WY 2
PPX:5057012 8 In/4 Out Analog 12WX & 4WY or 1
4WX & 4WY or
6WX & 2WY or
8WX
PPX:5057016 Bipolar 8 In/4 Out Analog 12WX & 4WY or 1
20WX & 4WY or
4WX & 4WY or
8WX
PPX:5057028 Thermocouple Input 8WX 1
PPX:5057038 RTD Input 8WX or 16WX 1
PPX:5057101 BASIC Module 4WX & 4WY n 1
PPX:5057339 TIWAY Network Interface Module
Local Line Ports 8WY n 1
PPX:5057340 TIWAY Network Interface Module
RS-232-C/423 Ports 8WY n 1
PPX:505-7354 Peerlink 3WX & 5WY n 1
3.6.6 Insta lling the Ba se C ontrolle rs
Refer to the Series 500/ 505 I OCC and DBC Users Manual (PPX:5008143) for
i nstructi ons on wi ri ng and i nstal l i ng the I OCC (PPX:5056830) and the DBC
(PPX:5056840).
NOTE
The DBCs are mul ti -dropped from the I OCC. I f one di stri buted
base becomes di sabl ed, al l the remai ni ng DBCs shoul d conti nue
to communi cate wi th the PLC.
4-1
C HAPTER 4
EPRO M / EEPRO M O PERATIO N
4.1 INTRO DUC TIO N
The TI 525/TI 535 control l ers offer the opti on of savi ng the RLL program to an
El ectri cal l y Erasabl e Programmabl e Read Onl y Memory (EEPROM) wi thout
the use of a separate programmi ng devi ce. The RLL program i s downl oaded
di rectl y from the PLC RAM to a 256 kbyte EEPROM (PPX:25876818020).
NO TE
The EEPROM hol ds onl y the l adder l ogi c program and the I /O
confi gurati on. Other i nformati on stored i n memory i s cl eared i f
power i s cycl ed wi thout a battery backup.
Once an EEPROM i s programmed, you may use i t i n any of the TI 525/TI 535 or
TI 530T model s. The onl y l i mi tati on i s program si ze. The PLC must have enough
memory to store and execute the program contai ned on the EEPROM. You can
erase an EEPROM wi th a programmi ng devi ce that i s capabl e of executi ng
Auxi l i ary (AUX) Functi on 84. A TI 525/TI 535 EEPROM cannot be used i n
SI MATI C
TI 520
, SI MATI C
TI 530
, SI MATI C
TI 520C
, or SI MATI C
TI 530C
model s.
I f you choose, you may program an EPROM i n a TI 520C or TI 530C and use the
EPROM i n any of the TI 525/535 PLCs. The PLC must have the memory
capaci ty to execute the program. Al though they do not copy a program to an
EPROM, al l TI 525/TI 535 model s can read and execute an EPROM program
wi th whi ch they are compati bl e. You may al so save a program to the EEPROM
and then use an EPROM programmer to copy the program from EEPROM to
EPROM.
To ensure equi pment compati bi l i ty use onl y the EPROM model suppl i ed by
your di stri butor: (PPX:25876818012).
4-2
WARNING
The older non-compiled TI520/TI530 EPROMs are not
compatible with any other Series 500 or Series 505 PLCs.
Attempting to interchange the EPROMs may cause
injury to personnel or damage to equipment because of
unexpected operation of the PLC.
When you power up a TI 525/TI 535, the PLC checks the status of the
EPROM/EEPROM and the battery. A cl ear (unprogrammed)
EPROM/EEPROM i s equi val ent to there bei ng no EPROM/EEPROM i nstal l ed.
Tabl e 4-1 l i sts the effects on memory and the mode that the PLC enters after
power up.
4-3
Ta b le 4- 1 C ha ng e s in M od e a nd M e mory Afte r Powe r Up
Battery
Status
Programmed
EPROM or System
Memory
PLC
Mode
Conditions Results
Bad No Cleared PROGRAM
Present
Bad Yes Cleared
PLC executes
program in
EPROM/EEPROM
Good No No Change No Change
Good Yes No Change No Change
RUN
Disabled for
10+ minutes
Yes
No
Cleared
525
PLC executes
program in
EPROM/EEPROM
RUN
Cleared PROGRAM
535
Checksum
Cleared PROGRAM
Errors Found:
No Checksum
No Change No Change
Errors Found:
No Checksum
Errors Found:
Checksum
Errors Found:
EEPROM
while power to
the PLC is off.
4-4
4.2 INSTALLING AN EPRO M / EEPRO M IN TI525 M O DELS
Before begi nni ng i nstal l ati on, you must di sabl e power to the PLC. I f you i ntend
to downl oad a program i n RAM memory to an EEPROM, you shoul d ensure that
a good battery i s i nstal l ed and enabl ed, or the program may be l ost when power
i s restored. Fol l ow the steps l i sted bel ow.
1. Pl ace the PLC i n PROGRAM MODE.
NO TE
The PLC mode (RUN or PROGRAM) on power-up
depends upon mode at power-down, the condi ti on of
the battery, and the presence or absence of an
EPROM/EEPROM. Refer to Tabl e 4-1.
2. Turn off all user-supplied power to the PLC base.
3. Remove the PLC from the base assembl y.
4. Ensure that swi tch 1 on the second di pswi tch (DI P 2) i s turned ON. Thi s
enabl es battery backup.
NO TE
I f the battery backup i s di sabl ed and you take
l onger than 10 mi nutes to i nstal l the
EPROM/EEPROM, you may l ose the program
stored i n RAM.
5. Refer to Fi gure 4-1. I f you are i nstal l i ng an EPROM, pl ace jumpers on
pi ns 23 and 45. I f you are i nstal l i ng an EEPROM, pl ace jumpers on
pi ns 12 and 34.
6. I nsert the EPROM/EEPROM, al i gni ng the notches on the
EPROM/EEPROM and the socket.
7. Check the pi ns to make sure that they are al l seated properl y i n the
socket.
4-5
8. Pl ace the PLC i n the base and enabl e power. Refer to the
Troubl eshooti ng Chapter i f the EPROM/EEPROM fai l s to functi on
correctl y.
Bezel edge
EPROM/EEPROM
jumper pins
1 2 3 4 5
EEPROM
4 3 2 1
EPROM
5 4 3 2
Fig ure 4- 1 TI525 EPRO M / EEPRO M Soc ke t a nd Jump e r Pins
4-6
4.3 INSTALLING AN EPRO M / EEPRO M IN TI535 M O DELS
I f you are poweri ng up a TI 535 for the fi rst ti me you shoul d i ni ti al i ze i t before
proceedi ng wi th the EPROM/EEPROM i nstal l ati on. Refer to the startup
procedure i n Chapter 5.
To i nstal l the EPROM/EEPROM, fol l ow these steps.
1. Usi ng the programmi ng uni t, pl ace the PLC i n PROGRAM MODE.
NO TE
The PLC mode (RUN or PROGRAM) on power-up
depends upon mode at power-down, the condi ti on of
the battery, and the presence or absence of an
EPROM/EEPROM. Refer to Tabl e 4-1.
2. Ensure that the Battery Good LED i s on. I f i t i s not, turn on swi tch 1 on
DI P 2. Thi s enabl es battery backup. I f the Battery Good LED remai ns
off, repl ace the battery before conti nui ng wi th the EPROM/EEPROM
i nstal l ati on.
NO TE
I f you power down the TI 535 whi l e the BATT
GOOD LED i s off, you may l ose the program stored
i n RAM.
3. Turn off all user-supplied power to the PLC base.
4. Remove the PLC from the base.
5. I f you are i nstal l i ng an EPROM, pl ace jumpers on pi ns 23 and 45. I f
you are i nstal l i ng an EEPROM, pl ace jumpers on pi ns 12 and 34.
Refer to Fi gure 4-2.
6. The EPROM/EEPROM socket i s a zero i nserti on force socket, and no
pressure i s requi red to i nsert the 28-pi n EPROM/EEPROM. Use a
smal l , fl at-bl ade screwdri ver to open the socket. Turn the screw on the
socket countercl ockwi se one quarter turn unti l the socket pi ns have
opened.
4-7
7. I nsert the EPROM/EEPROM, al i gni ng the notch on the
EPROM/EEPROM wi th the socket screw. Refer to Fi gure 4-2.
8. Check the pi ns to make sure that they are al l seated properl y. Ti ghten
the socket by turni ng the screw cl ockwi se.
9. Repl ace the PLC i n i ts base and enabl e power. Refer to the
Troubl eshooti ng Chapter i f the EPROM/EEPROM fai l s to functi on
correctl y.
Bezel edge
EPROM/EEPROM
jumper pins
5
4
3
2
1
Fig ure 4- 2 TI535 EPRO M / EEPRO M Soc ke t a nd Jump e r Pins
4-8
4.4 PRO G RAM M ING THE EEPRO M
To program the EEPROM, you fi rst must enter the RLL program i nto the PLC.
Veri fy that thi s program i s correct and conti nue wi th the steps l i sted bel ow.
1. Make certai n that the battery enabl e di pswi tch i s ON, and that the
jumper pi ns are set for EEPROM.
2. Set the PLC to PROGRAM mode.
3. Sel ect Auxi l i ary Functi on 84 i n your programmi ng uni t. Use the Copy
opti on to copy your RLL program to the EEPROM. The programmi ng
uni t di spl ays messages i ndi cati ng the progress of the copy operati on.
The PLC compl etes al l current and pendi ng communi cati on processes
and turns off the communi cati on ports before begi nni ng the copy
operati on.
NO TE
The TI 525/TI 535 PLCs copy data to the EEPROM
very rapi dl y. The enti re copy process takes
approxi matel y 5 seconds or l ess.
The PLC enters PROGRAM mode when the copy process i s compl eted.
4-9
4. When you are fi ni shed maki ng copi es of your program, go to step 5.
I f you wi sh to copy the program to another EEPROM, power down the
PLC, repl ace the EEPROM wi th another, and power up agai n. Repeat
Step 3 to copy the program to thi s second EEPROM. Thi s procedure can
be repeated to program several EEPROMs.
5. Check the program careful l y, whi l e the PLC i s i n the PROGRAM mode,
before al l owi ng the PLC to control equi pment connected to the I /O.
WARNING
Do not place the PLC in RUN mode without
first verifying the EPROM/EEPROM
program. If the program is incorrect,
unexpected operation by the PLC may result
in injury to personnel and/or damage to
equipment.
Any errors that occur duri ng the copy process are l i sted on the programmi ng
uni t. Check the EPROM/EEPROM jumper pi ns and make certai n that an
EEPROM, not an EPROM, i s i nstal l ed. Make certai n that al l I C pi ns are
properl y seated i n the socket.
I f you conti nue to get copy errors, then the EEPROM may have fai l ed. You must
power down, remove the EEPROM, and power up agai n to cl ear thi s error
condi ti on.
4-10
4.5 REPO RTING EEPRO M STATUS
EEPROM programmi ng i nformati on i s recorded i n status words that can be
read wi th the programmi ng devi ce. These status words represent EEPROM
programmi ng i nformati on gathered on the l ast compl eted programmi ng cycl e.
They can be read any ti me except when you are i n the process of programmi ng.
I f an error occurs whi l e you are copyi ng a program to an EEPROM, you can
exami ne the status words to eval uate the error condi ti on. Fol l ow the steps
bel ow:
1. Make certai n that the battery i s enabl ed.
2. Cl ear the error condi ti on by cycl i ng power.
3. Exami ne the status words wi th a programmi ng uni t.
4.5.1 Sta tus Word Six ( STW06)
As i l l ustrated i n Fi gure 4-3 bel ow, STW06 reports the status of EEPROM
programmi ng.
STW06
Bit 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Spare
spare
1 = programming
complete
no errors
1 = programming
complete error
1 = the EPROM/
EEPROM was not
initially clear
1 = programming
error
MSB LSB
spare
Fig ure 4- 3 Forma t of Sta tus Word Six ( STW06)
4-11
4.5.2 Sta tus Word s Se ve n to Nine ( STW07STW09)
STW07 gi ves the absol ute address of the fi rst error encountered whi l e
attempti ng to program the EEPROM. The val ue gi ven i s the memory address of
the EEPROM memory.
STW08 shows the checksum cal cul ated from the RLL program stored i n the
EEPROM. The checksum i s a numeri cal cal cul ati on based on your RLL
program onl y. When you copy a program to several EEPROMs, you can check
STW08 for every EEPROM to veri fy that the i nformati on contai ned i n each i s
i denti cal .
NO TE
I denti cal RLL programs and i denti cal I /O confi gurati ons
programmed i n di fferent machi nes may yi el d di fferent
checksums due to i nternal storage di fferences.
STW09 shows the checksum generated from the EEPROM. The checksum i s a
numeri cal cal cul ati on based on al l data stored i n the EEPROM, i ncl udi ng your
RLL program and i nformati on contai ned i n the I /O confi gurati on memory.
When you copy a program to several EEPROMs, you can check STW09 for each
EEPROM to veri fy that the i nformati on contai ned i n each i s i denti cal .
WARNING
Permitting a PLC to execute an EPROM/EEPROM
program without first checking the program may result
in injury to personnel and damage to equipment due to
unexpected operation by the PLC. If you are not
absolutely certain that the EPROM/EEPROM program
is correct, disconnect all I/O modules and the IOCC (if
necessary) from the base before you power up.
4-12
4.6 EDITING / SAVING PRO G RAM S USING AN EPRO M / EEPRO M
You manage operati on of the EPROM/EEPROM by executi ng AUX Functi on 84
on the programmi ng uni t. Functi on 84 gi ves you the fol l owi ng opti ons:
D Copy RAM to EEPROM
D Copy EEPROM to RAM
D Sel ect RAM as program source
D Sel ect EEPROM as program source
D Erase program i n EEPROM
D Report source (RAM OR EEPROM) of program bei ng executed
NO TE
I f you use an EPROM i n a TI 525/TI 535, you cannot
execute these AUX Functi on 84 opti ons:
Copy RAM to EEPROM
Erase program i n EEPROM
The EEPROM i s automati cal l y wri te protected on
power-up, whi ch prevents any acci dental wri te
operati ons. Thi s protecti ve measure does not
hi nder the devi ce operati on i n any way. I f you want
to use the devi ce i n equi pment other than SI MATI C
TI equi pment, you can deacti vate thi s protecti ve
feature by erasi ng the EEPROM, poweri ng down
the uni t, and removi ng the EEPROM.
4-13

You can edi t an RLL program i n an EEPROM by fol l owi ng the steps l i sted bel ow.
Refer to the user s manual for your programmi ng uni t for detai l ed i nstructi ons
about the executi on of AUX Functi ons.
1. Execute the AUX Functi on 84 opti on that copi es EEPROM to RAM.
2. Sel ect RAM as the program source.
3. Make changes i n your program wi th a programmi ng uni t by edi ti ng the
source code i n RAM memory.
4. Execute the AUX Functi on 84 opti on that copi es RAM to EEPROM.
5. Sel ect the EEPROM as the program source.
Al though the TI 525/TI 535 can copy a program from ei ther an EPROM or an
EEPROM i nto RAM, the TI 525/TI 535 cannot copy a program from RAM to an
EPROM.
NO TE
AUX Functi on 84 affects onl y the RLL program and the I /O
confi gurati on. Ti mer/counter and drum/event drum vari abl es
and val ues i n V memory are not affected by AUX Functi on 84
operati ons.
5-1
C HAPTER 5
STARTUP / TRO UBLESHO O TING
5.1 START- UP PRO C EDURES
Fol l ow the steps outl i ned bel ow before poweri ng up your TI 525/TI 535 system
for the fi rst ti me.
1. Be fami l i ar wi th the operati on of the system components as di scussed i n
thi s i nstal l ati on manual .
2. Veri fy the fol l owi ng i tems:
D I f any of your i nstal l ed bases have empty I /O sl ots, use fi l l er bezel s
(PPX:25877058003) to cover the openi ngs i n the base. Thi s
prevents debri s from i nterferi ng wi th system operati on and hel ps to
guard agai nst el ectrostati c di scharge and el ectri cal noi se
i nterference.
D After i nstal l ati on i s compl ete, remove the pl asti c dustguard on the
top gri l l of every i nstal l ed Seri es 505 base.
WARNING
Fai l ure to remove the dustguard may resul t i n
overheati ng and damage to equi pment, and coul d
resul t i n i njury to personnel .
D Check for correct swi tch setti ngs on al l confi gurabl e modul es, e.g.,
the PLC and DBC(s). The L-memory MEMORY PROTECT
di pswi tch on the PLC must be OFF i f you i ntend to enter the RLL
program wi th a programmi ng devi ce.
D Al l modul es are securel y pl ugged i nto the base, connector pi ns are
not bent, and bezel screws are ti ghtened.
D Check AC i nput power for proper vol tages. Be sure the jumper i n the
back of the power suppl y i s set for the appropri ate vol tage.
5-2
D Be sure that al l I /O i nterface cabl es are properl y connected to I /O
i nterface connectors.
D Al l the confi gured bases are properl y connected, there are no cri mps
or breaks i n the cabl e, and base addresses are correct.
D The cabl e to the programmi ng uni t (where appl i cabl e) i s secure.
D PLC battery pol ari ty i s correct.
3. I ni ti al i ze PLC.
For TI535 models
I f you have not al ready done so, di sabl e the PLC battery by turni ng
off swi tch 1 on DI P 2. Make certai n that a programmed
EPROM/EEPROM i s not i nstal l ed.
Turn on power to the PLC.
Wi th the battery di sabl ed and no programmed EPROM/EEPROM
i nstal l ed, the TI 535 cl ears memory and enters PROGRAM mode.
Enabl e the battery by turni ng on DI P 2, swi tch 1. The Battery Good
LED shoul d l i ght. The TI 535 i s now i ni ti al i zed.
For TI525 models
Turn on power to the PLC. The TI 525 i s i ni ti al i zed duri ng
power-up.
4. I f you i ntend to use an EPROM/EEPROM, i nstal l the
EPROM/EEPROM accordi ng to the i nstructi ons gi ven i n Chapter 4.
5. Connect the programmi ng devi ce to the RS-232-C/RS-423 port of the
PLC. Pl ace the PLC i n PROGRAM mode. I f you have i nstal l ed a
pre-programmed EPROM/EEPROM, go to step 8.
NO TE
The PLC shoul d be i n PROGRAM mode at thi s
poi nt, not i n RUN mode. I nstructi ons that you enter
i n the RLL program are executed i mmedi atel y i f the
PLC i s i n RUN mode.
5-3
6. Usi ng the programmi ng devi ce, enter the I /O confi gurati on.
7. Enter the RLL program. See the SI MATI C TI 505 Programming
Reference manual for i nformati on about desi gni ng your RLL program.
8. Use the programmi ng devi ce to JOG motors, sol enoi ds, or other
posi ti oni ng devi ces one at a ti me to establ i sh correct rotati on or
posi ti on.
After al l the steps are performed and veri fi ed, pl ace the PLC i n the RUN mode.
I f you turn ON the L-memory MEMORY PROTECT di pswi tch, your RLL
program cannot be changed by a programmi ng devi ce that i s connected to the
PLC through one of the communi cati on ports.
NO TE
The MEMORY PROTECT di pswi tch does not prevent forci ng
I /O, changi ng vari abl e memory, or swi tchi ng the PLC from
PROGRAM to RUN mode. These acti ons may be made by a
programmi ng devi ce connected to the PLC, or a speci al functi on
I /O modul e desi gned for thi s type of i nterface to the PLC, e.g., a
Network I nterface Modul e. The RLL can al so be changed
through a speci al functi on modul e, even when the memory
protecti on i s enabl ed.
5-4
5.2 USING THE TRO UBLESHO O TING TO O LS
Thi s secti on offers i nformati on and gui del i nes for troubl eshooti ng TI 525/TI 535
PLCs. I f you cannot l ocate the source of the probl em, contact your Si emens
I ndustri al Automati on di stri butor or sal es offi ce. I f you need assi stance i n
contacti ng your U.S. sal es offi ce, cal l 18009644114.
5.2.1 Re a d ing the LED Ind ic a tors
The three LEDs on the PLC are l abel ed RUN, BATTERY GOOD, and PLC
GOOD. When the LEDs are on, they i ndi cate status as shown i n Tabl e 5-1 and
can ai d i n l ocati ng the source of a probl em. The PLC LEDs are meani ngful onl y
when the DC POWER GOOD LED on the power suppl y i s turned on.
Ta b le 5- 1 LED Ind ic a tors
RUN
BATTERY GOOD
PLC GOOD
ON = Battery is good and
battery dipswitch
is on
ON = PLC is functioning
with no fatal errors
ON = PLC is in Run mode
5-5
5.2.2 Exe c uting the Auxilia ry Func tions
The TI 525/TI 535 PLCs offer sel f-checki ng and di agnosti c capabi l i ti es for
troubl eshooti ng purposes. The di agnosti cs and sel f-checks are accessi bl e
through the Auxi l i ary Functi on menu on the programmi ng devi ce.
When you di spl ay the Auxi l i ary Functi on menu, the fol l owi ng functi ons are
avai l abl e for resetti ng the PLC, i ni ti ati ng di agnosti cs or di spl ayi ng di agnosti c
i nformati on:
D AUX 29 Show PLC di agnosti c cel l
D AUX 25 Di spl ay fai l ed I /O
D AUX 20 Run PLC di agnosti cs
D AUX 11 Parti al restart
D AUX 12 Compl ete restart
D AUX 10 Power-up restart
5.2.2.1 AUX Func tion 29 ( Show PLC Dia g nostic C e ll)
AUX Functi on 29 checks the operati onal status of the PLC and di spl ays the
resul ts. The di spl ay provi des the i nformati on i l l ustrated i n Fi gure 5-1.
Scan = 027 Milliseconds/Variable
Key = Unlocked
Mode = RUN
Fatal Error = None
Nonfatal Error = None
Battery = On
Download = Off
Program in RAM
TI525/TI535 Operational Status
Fig ure 5- 1 Exa mp le of AUX Func tion 29 Sc re e n
The scan ti me reported by AUX Functi on 29 i s the hi ghest scan ti me recorded
si nce the l ast PLC reset or PROGRAMRUN mode transi ti on. Status Word 10
(STW10) contai ns a conti nuousl y updated report of the scan ti me.
5-6
5.2.2.2 AUX Func tion 25 ( Disp la y Fa ile d I/ O )
AUX Functi on 25 di spl ays the l ocati ons of any fai l ed I /O modul es whi ch are
capabl e of di agnosi ng and i ndi cati ng fai l ure. Some modul es, such as word and
anal og modul es, report that they have fai l ed i f the user-suppl i ed vol tage i s not
correct.
AUX Functi on 25 al so di spl ays I /O mi smatch(es), i ndi cati ng that one or more
i nstal l ed modul e(s) do not agree wi th the I /O confi gurati on. Veri fy that the
confi gurati on data for l i sted modul es i s correct before consi deri ng that the
modul e may actual l y be mal functi oni ng.
5.2.2.3 AUX Func tion 20 ( Run PLC Dia g nostic s)
AUX Functi on 20 i ni ti ates the PLC sel f-checks. The PLC must be i n PROGRAM
mode i n order to execute sel f-tests. The PLC executes the equi val ent of an AUX
Functi on 20 at every power-up. I f any area fai l s, a message detai l i ng the fai l ure
i s di spl ayed. AUX Functi on 20 makes the fol l owi ng tests:
D Val i d RAM l ocati ons are veri fi ed.
D Pre-coded ROM checksum val ues are checked.
D The hardware force functi on i s checked.
D I nternal ti mer operati on i s veri fi ed.
D Operati ng system ROM cycl i c redundancy check code i s checked.
5.2.2.4 AUX Func tion 11 ( Pa rtia l Re sta rt)
AUX Functi on 11 cl ears the di screte and control rel ay i mage regi sters, but does
not affect forced el ements, retenti ve control rel ays, preset val ues, and word
i mage regi sters. AUX Functi on 11 puts the PLC i n PROGRAM mode onl y i f a
fatal error i s present or the previ ous mode was PROGRAM.
5.2.2.5 AUX Func tion 12 ( C omp le te Re sta rt)
AUX Functi on 12 cl ears the di screte, control rel ay, and word i mage regi sters
and the retenti ve control rel ays, but does not affect forced el ements and word
regi sters. Al l preset val ues are downl oaded at restart. AUX Functi on 12 puts
the PLC i n PROGRAM mode onl y i f a fatal error i s present or the previ ous mode
was PROGRAM.
5-7
5.2.2.6 AUX Func tion 10 ( Powe r- up Re sta rt)
AUX Functi on 10 cl ears al l di screte and non-retenti ve control rel ay i mage
regi sters except those el ements that are forced. Other resul ts of AUX Functi on
10 depend on the fol l owi ng condi ti ons:
D I f the battery i s l ow, AUX Functi on 10 cl ears the RLL program, I /O
confi gurati on, retenti ve control rel ays, WXs, WYs, forced I /O,
V memory, and al l ti mer, counter, and drum preset/current val ues.
I f the battery i s l ow and a program i s i n RAM, AUX Functi on 10 puts
the PLC i n PROGRAM mode. I f the battery i s l ow and an
EPROM/EEPROM wi th a val i d program i s i nstal l ed, AUX Functi on
10 puts the PLC i n RUN mode.
D AUX Functi on 10 downl oads presets i n ei ther of the fol l owi ng
si tuati ons: (a) the battery i s good and the downl oad sel ect swi tch i s
set, or (b) the battery i s l ow and a program i s i n EPROM/EEPROM.
D AUX Functi on 10 al so puts the PLC i n PROGRAM mode i f (a) the
battery i s good and a fatal error i s present or (b) the battery i s good wi th
no error and the previ ous mode was PROGRAM.
Tabl e 5-2 l i sts the effects on memory l ocati ons when AUX Functi ons 10, 11, and
12 are executed.
Ta b le 5- 2 Effe c ts of Aux Func tions on M e mory
Loc a tions
Operation
Selected
Discrete Word
Image Register
Control Relay
Retentive NonRetentive
TMR/CTR
DRUM
Presets
Forced
I/O
AUX 10 Cleared Note 1 Cleared Note 2 Note 1
AUX 11 Cleared Cleared
No
Change
No
Change
No
Change
AUX 12 Cleared Cleared Download
No
Change
Cleared
Input
Cleared
Cleared
Cleared
Output
Note 1
Input
Note 1
Cleared
Output
Cleared
No
Change
No
Change
Note 1 No change if the battery is good; otherwise, cleared.
Note 2 Dependent on user-selectable switch, memory type, and battery condition.
5-8
5.2.3 Troub le shooting with Sta tus Word s
I n addi ti on to the auxi l i ary functi ons descri bed above, the TI 525/TI 535 PLCs
provi des operati onal i nformati on i n the form of status words. These status
words can be read wi th the programmi ng devi ce. Status words may al so be
contai ned wi thi n an RLL program so that di agnosti cs can be executed duri ng
run-ti me condi ti ons.
5.2.3.1 Sta tus Word O ne ( STW01)
STW01 provi des i nformati on i n the word format shown i n Fi gure 5-2. STW01
shows the status (good or fai l ed) of the PLC battery, scan overrun,
communi cati on port, I /O modul es, i ndi rect tabl e move overfl ow, and speci al
functi on modul es. A bi t contai ni ng a 0 i ndi cates no error, whi l e a 1 i ndi cates a
probl em or fai l ure.
STW01
Bit 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Not used
1 = battery low
or off
1 = scan overrun
i.e., fixed
scan time is
too short to
run RLL
program
1 = communication
port failure
1 = I/O failure *
1 = indirect table
move overflow
1 = intelligent
module com
munication
failure
Spare
*This applies to any I/O module capable of diagnosing its own failure.
MSB LSB
This bit is also set if there is an I/O mismatch, i.e., the I/O configuration
does not agree with the installed module for any I/O slot in the system.
Fig ure 5- 2 Forma t of Sta tus Word O ne ( STW01)
5-9
5.2.3.2 Sta tus Word Two ( STW02)
As i l l ustrated i n Fi gure 5-3 bel ow, STW02 shows the status of up to si xteen
bases. From ri ght to l eft, each bi t i n the word represents a base. The bi t i s set to 1
when the base that i t represents has fai l ed or i s not present, and i t contai ns a 0 i f
the base i s good. An empty base i s reported wi th a 0, and bases 0 and 1 are
al ways reported wi th a 0.
STW02
Bit 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 = base 15 has
failed or is
not present
D
D
D
MSB LSB
1 = base 2 has
failed or is
not present
Base 0: always 0
Base 1: always 0
Fig ure 5- 3 Forma t of Sta tus Word Two ( STW02)
NO TE
Status words three through fi ve are not used by the
TI 525/TI 535.
5-10
5.2.3.3 Sta tus Word Six ( STW06)
As i l l ustrated i n Fi gure 5-4 bel ow, STW06 reports the status of EEPROM
programmi ng. Onl y one bi t i s set at a ti me.
STW06
Bit 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
spare
Spare
1 = programming
complete
no errors
1 = programming
complete error
1 = the EPROM/
EEPROM is not
initially clear
1 = programming
error
MSB LSB
spare
Fig ure 5- 4 Forma t of Sta tus Word Six ( STW06)
5-11
5.2.3.4 Sta tus Word s Se ve n to Nine ( STW07STW09)
STW07 gi ves the absol ute address of the fi rst error encountered whi l e
attempti ng to program the EPROM/EEPROM. The val ue gi ven i s the memory
address of the EPROM/EEPROM memory.
STW08 shows the checksum cal cul ated from the RLL program stored i n the
EPROM/EEPROM. The checksum i s a numeri cal cal cul ati on based on your
RLL program onl y. When you copy a program to several EPROM/EEPROMs,
you can check STW08 for every EPROM/EEPROM to veri fy that the
i nformati on contai ned i n each i s i denti cal .
NO TE
I denti cal RLL programs and i denti cal I /O confi gurati ons
programmed i n di fferent machi nes may yi el d di fferent
checksums due to i nternal storage di fferences.
STW09 shows the checksum generated from the EPROM/EEPROM. The
checksum i s a numeri cal cal cul ati on based on al l data stored i n the
EPROM/EEPROM, i ncl udi ng your RLL program and i nformati on contai ned i n
the I /O confi gurati on memory. When you copy a program to several
EPROM/EEPROMs, you can check STW09 for every EPROM/EEPROM to
veri fy that the i nformati on contai ned i n each i s i denti cal .
5.2.3.5 Sta tus Word Te n ( STW10)
STW10, shown i n Fi gure 5-5, provi des the PLC scan ti me i n bi nary code. I f you
di spl ay the i nteger val ue of the word, the program scan ti me i s gi ven i n
mi l l i seconds. The PLC updates the word each scan.
STW10
Bit 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0
= 8 ms P/C
scan time
MSB LSB
Fig ure 5- 5 Forma t of Sta tus Word Te n ( STW10)
5-12
5.2.3.6 Sta tus Word s Ele ve n to Eig hte e n ( STW11STW18)
Status Words 11 through 18 report the status of the I /O modul es contai ned on
the l ogi cal bases, as shown i n Fi gure 5-6. Each bi t corresponds to one modul e i n
the base. I f the modul e i s i n proper worki ng order or i f there i s no modul e i n that
sl ot, the correspondi ng bi t i s 0. I f the occupi ed sl ot contai ns a mal functi oni ng
modul e, the bi t i s 1. See the exampl e shown i n Fi gure 5-7.
The PLC reports an I /O mi smatch an i nstal l ed modul e does not agree wi th
the I /O confi gurati on as a fai l ed I /O modul e. The modul e has not actual l y
fai l ed. You shoul d re-enter the I /O confi gurati on for the sl ot i n questi on.
1 2 3 4 5 6 7 8 9 10 11 13 14 15 16
Bit Number (Status Words 1118)
12
Slot
Slot
Slot
8
7
6
Slot
5
Slot
Slot
Slot
4
3
2
Slot
1
Slot
Slot
Slot
8
7
6
Slot
5
Slot
Slot
Slot
4
3
2
Slot
1
Logical Base B Logical Base A
Status Word Logical Base B Logical Base A
Base
Base
Base
Base
Base
Base
Base
Base
Base
Base
Base
Base
Base
Base
Base
Base
11
12
13
14
15
16
17
18 15
13
11
9
7
5
3
1
14
10
12
8
6
4
2
0
Fig ure 5- 6 Forma t of Sta tus Word s Ele ve n to Eig hte e n
( STW1118)
5-13
I n Fi gure 5-7, the 1 i n Bi t 10 i ndi cates that sl ot seven i n Base 0 contai ns a
mal functi oni ng or i ncorrectl y confi gured modul e (I /O mi smatch). Al l other sl ots
ei ther contai n a worki ng modul e or no modul e at al l .
0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
8 7 6 5 4 3 2 1
Bits in Status Word 11
Base 1 Base 0
8 7 6 5 4 3 2 1
Bit #
Value
Slot #
Base
Fig ure 5- 7 Exa mp le of a Sta tus Word With a Bit Se t
NO TE
When a di stri buted base l oses communi cati on wi th the PLC, the
appropri ate bi t i n STW02 shows a 1, and the correspondi ng bi ts
i n STW12 to STW18 show zeroes, even i f modul es on that base
have fai l ed or been i ncorrectl y confi gured. That i s, modul es do
not show fai l ures on a base that i s not present.
5-14
5.2.4 C le a ring PLC Fa ta l Errors
A fatal error has occurred when both the fol l owi ng condi ti ons hol d:
D PC GOOD LED i s not l i ghted.
D The DC GOOD LED on the power suppl y i s on.
The PLC enters a fatal error condi ti on and ceases operati on i f a probl em l i sted
bel ow occurs:
D Watchdog ti me-out: The mi croprocessor does not reset a watchdog
ci rcui t peri odi cal l y.
D I l l egal operati on code: The mi croprocessor recei ves an i l l egal
i nstructi on.
D Di agnosti c test fai l ure: The PLC fai l s a di agnosti c test.
D I /O fatal error: The PLC detects a non-recoverabl e I /O error
D ROM di agnosti c fai l ure: The operati ng system EPROMs are found to
be i nval i d.
D Operati ng system fatal error: The PLC detects a non-recoverabl e
error duri ng executi on.
D Abnormal power l oss: Power to the PLC i s removed wi thout proper
warni ng.
D Dynami c Program Memory Di agnosti cs Error: The PLC determi nes a
checksum error i n the user EPROM/EEPROM or RAM.
When a fatal error occurs, the PLC takes the fol l owi ng acti ons:
D The PC GOOD LED i s turned off.
D I /O ports are di sabl ed. Di screte outputs are turned off, and word
outputs are hel d i n thei r l ast val i d state.
D Communi cati on ports are cl eared and re-i ni ti al i zed.
D Pendi ng or queued tasks are cl eared.
5-15
Attempt to cl ear the fatal error by fol l owi ng the steps l i sted bel ow. When the PC
GOOD LED turns on, the fatal error has been cl eared.
1. Determi ne the fatal error condi ti on by sel ecti ng AUX Functi on 29 from
the Auxi l i ary Functi on Menu on your programmi ng uni t. Record the
fatal and non-fatal error(s) l i sted al ong wi th the date, ti me, and PLC
seri al number for l ater reference.
NO TE
Al ways execute AUX Functi on 29 and make a l i st of
the errors before attempti ng to cl ear them. I f you
cl ear errors before l i sti ng them, i t wi l l be i mpossi bl e
to determi ne what errors occurred and di ffi cul t to
i denti fy the probl em that caused them.
I f communi cati on errors occur, cycl e power to the PLC. I f
communi cati on errors conti nue, record No Communi cati on as the
fatal error and go to step 4.
2. Execute AUX Functi on 11 PLC parti al restart. I f thi s fai l s to cl ear the
error, execute AUX Functi on 12 PLC compl ete restart.
3. I f the fatal error persi sts, make certai n that the battery backup i s
enabl ed and execute AUX Functi on 10 PLC power-up restart.
4. I f you have been unabl e to cl ear the fatal error to thi s poi nt, you must
re-i ni ti al i ze the PLC. This clears the PLC memory.
For a TI 535, di sabl e the battery backup (turn off swi tch 1 of DI P 2) and
cycl e power to the PLC (or execute AUX Functi on 10).
For a TI 525, power down and remove the PLC from the base. Di sabl e
the battery backup (turn off swi tch 1 of DI P 2), i nsert the PLC i n the
base, and power up.
5. I f the PC GOOD LED comes on, restore the battery backup by turni ng
on swi tch 1 of DI P 2. (For a TI 525, you must power down agai n and
remove the PLC from the base to re-enabl e battery backup.) You must
now use your programmi ng uni t to restore your program.
5-16
6. I f the PC GOOD LED does not turn on at thi s ti me, your PLC may have
a hardware fai l ure. Contact your Si emens I ndustri al Automati on
di stri butor or sal es offi ce. I f you need assi stance i n contacti ng your U.S.
sal es offi ce, cal l 18009644114. Have the fol l owi ng i nformati on
avai l abl e before you cal l :
D Li st of fatal and non-fatal errors
D PLC seri al number
D PLC software revi si on (execute AUX Functi on 15 or check the PLC
l abel )
D Sequence of events l eadi ng up to the fai l ure
5-17
5.2.5 Troub le shooting the EPRO M / EEPRO M
From the Status Chart or WORDS di spl ay of the programmi ng devi ce, you can
check the val ues i n the status words STW06, STW07, STW08, and STW09 for
probl ems wi th the EPROM/EEPROM. You shoul d al so check for the fol l owi ng:
D The EPROM used i n the TI 520/TI 530 PLCs i s not compati bl e wi th
the TI 525/TI 535. A TI 520C/TI 530C EPROM may be used i n a
TI 525/TI 535, however.
D I f you transfer an EPROM/EEPROM from one TI 525/TI 535 model to
another, remember that the program i n the EPROM/EEPROM has to
be compati bl e wi th the model i n whi ch i t i s used.
D I f the program that you l oaded i n RAM fai l s to copy to the EEPROM,
check the EPROM/EEPROM jumpers to be sure that you have them set
for an EEPROM, not an EPROM.
Refer to Chapter 4 of thi s manual for i nstructi ons on i nstal l i ng and
programmi ng the EPROM/EEPROM.
5-18
5.2.6 Troub le shooting the Powe r Sup p ly
Compl ete the fol l owi ng steps when troubl eshooti ng the power suppl y:
1. Determi ne that the power budget has not been exceeded and that the
modul e i s properl y i nstal l ed.
2. After maki ng sure the battery i s on (so the program wi l l not be l ost),
di sabl e al l power to the system for at l east 90 seconds.
3. Restore system power.
4. I f the probl em sti l l exi sts, turn off power to the system.
WARNING
To avoid the potential risk of damage to equipment
or injury to personnel, always turn off power to the
system before removing the power supply from the
base.
5. Remove the power suppl y from the base. Thi s step i s not requi red for the
PPX:5056663 power suppl y.
a. Make sure the jumper i n the back of the modul e i s set to the correct
l i ne vol tage.
b. I f the vol tage has been set i ncorrectl y, wai t at l east one mi nute
before touchi ng the jumper. Then move the jumper to the
appropri ate qui ck-connect pi n.
6. Make sure the wi res attached to the termi nal screws on the bezel are
secure and that the user-suppl i ed power source i s functi onal .
7. Check to see that the fuse (l ocated on the bezel ) has not opened. Repl ace
the fuse, i f necessary, wi th the appropri ate fuse.
a. Usi ng a fl at-bl ade screwdri ver, twi st the fuse hol der once,
counter-cl ockwi se, to remove the fuse hol der.
b. To repl ace the fuse hol der, i nsert, push, and turn cl ockwi se to
secure.
8. Repl ace the power suppl y and enabl e power to the system.
9. I f the power suppl y conti nues to mal functi on, repl ace i t.
I f repl aci ng the fuse does not sol ve the probl em, and the power source i s
correctl y connected, then the power suppl y modul e shoul d be returned for
repai r. Contact your l ocal di stri butor for assi stance.
5-19
5.2.7 Sp a re Pa rts
I t i s recommended that you keep on hand a 10% surpl us of your systems I /O
modul es. Dependi ng upon the number of PLCs that you have i nstal l ed, you may
wi sh to stock an extra PLC as wel l . The fol l owi ng i s a l i st of other spare parts
that you shoul d have avai l abl e.
D PPX:5056504, 4 I /O sl ots
D PPX:5056508, 8 I /O sl ots
D PPX:5056516, 16 I /O sl ots (19-i nch rack compati bl e)
D Power Suppl y Modul e, PPX:5056660, PPX:5056660A or
PPX:5056663
D 3 V l i thi um battery, PPX:25876788005
D 3.0 A/250 V, sl ow-bl ow fuse 3 AG for PPX:5056660
D 8.0 A/250 V, normal -bl ow fuse 3 AG for PPX:5056663
You can order the fol l owi ng spare parts from your di stri butor.
D EEPROM, PPX:25876818020
D 525 12 Kbytes Upgrade Ki t, PPX:25864918003
A-1
APPENDIX A
SPEC IFIC ATIO NS
Environmental Specifications
Operating Temperature
Relative Humidity
5% to 95% noncondensing
Vibration
Sinusoidal: IEC 6826, Test Fc;
Random: NAVMAT P9492 or
Impact Shock
IEC, 68227, Test Ea; Half sine, 15g, 11 ms
Pollution degree
2, IEC664, 664A
Corrosion Protection
All parts are of corrosion-resistant material
or are plated or painted as corrosion
protection.
User Memory Capacity
2K, 4K, 8K, or 12K of RLL memory,
depending on the model.
General Specifications
Input Power
Provided by power supply module
10 W @ +5 VDC, 0.5 W @ 5 VDC
Electric Noise Immunity
Conducted noise: IEC 801, Part 4, Level 3
MILSTD461B, Part 4; CS01, CS02, CS06
IEC 2554, Appendix E
IEEE 472, 2.5 kV
Radiated noise: IEC 801 Part 3, Level 3
MILSTD461B, Part 4; RS01, RS02
Electrostatic discharge:IEC 801, Part 2,
(15 KV)
Battery Backup
3.0 V lithium battery (PPX:25876788005)
Communication Ports
RS-232-C/RS-423: all models
0.15 mm peak to peak, 1057 Hz;
1.0 g, 57150 Hz
2
/Hz, 80350 Hz, and
IEC 68234,
0.04g
3dB/octave rolloff, 8020 Hz and
3502000 Hz at 10 min/axis
Test Fdc with
Storage Temperature
EEC 4517/79 Com(78) 766 Final, Part 4
Level 4
(All P/C models and power supply) (All P/C models)
Isolation (user-side to PLC-side): 1500 Vrms
UL Listed (industrial control equipment)
CSA Certified (process control equipment)
Agency Approvals
(All PLC models and power supply)
System Isolation
Maximum power drawn from base by TI525:
12.5 W @ +5 VDC, 0.2 W @ 5 VDC
Maximum power drawn from base by TI535:
Memory Backup
EEPROM (PPX:25876818020)
Battery backed-up static RAM
PPX:5056660 for user-supplied 110/220 VAC.
PPX:5056663 for user-supplied 24 VDC.
405 to 705C; 405 to 1585F
05 to 605C; 325 to 1405F
3 years typical storage (05 to 605C)
6 months typical storage (05 to 605C)
RS422: PPX:5251208, PPX:5251212
PPX:5351204, PPX:5351212
APPENDIX A SPEC IFIC ATIO NS
A-2
Power Supply
Input voltage select
Voltage range
110 or 220 VAC
85132 VAC (110)
170264 VAC (220)
Frequency
4763 Hz PPX:5056660
Input current
Peak inrush:
Output
55 W at +5 VDC
3.75 W at 5 VDC
Electrical Specifications
All parts are of corrosion-resistant material
or are plated or painted as corrosion
protection.
General
Corrosion protection
(Userselectable)
50 A maximum
Steady state: 2 A rms maximum
VoltAmp rating: 200 VA
Fuse
3.0A/250 V, slow-blow, 3 AG
8 A zero to peak
2030 VDC (24)
PPX:5056660
Wattage Rating: 100 W maximum
5 ADC maximum
20 A maximum
8.0A/250 V, normal-blow, 3 AG
PPX:5056660
PPX:5056663
PPX:5056660
PPX:5056660
PPX:5056663
PPX:5056660
PPX:5056660
PPX:5056663
PPX:5056660
PPX:5056660
PPX:5056663
PPX:5056660
PPX:5056663
I n addi ti on, the system compl i es wi th appl i cabl e requi rements of Verband
Deutscher El ektrotechni ker (VDE) 0160: El ectri cal Equi pment, except 220
VAC I nput Modul es (No. 50544XX)
Seri es 505 products have been devel oped wi th consi derati on of the draft
standard for programmabl e control l ers as descri bed i n the proposed standard of
the I nternati onal El ectrotechni cal Commi ssi on Commi ttee (I EC65A/WG6,
Part 2).
I nformati on concerni ng product rel i abi l i ty and compl i ance to the I EC or other
standards can be provi ded upon request. .Contact your Si emens I ndustri al
Automati on di stri butor or sal es offi ce. I f you need assi stance i n contacti ng your
U.S. di stri butor or sal es offi ce, cal l 18009644114.
B-1
APPENDIX B
G RO UNDING AND ELEC TRIC AL
G UIDELINES
B.1 INTRO DUC TIO N
Thi s appendi x descri bes measures you can take to provi de a good earth ground
to your system, l i sts steps you can perform to ensure that your system i s not
i nfl uenced by el ectri cal noi se, and gi ves i nstructi ons for proper wi ri ng.
B.2 G RO UNDING
A good groundi ng system i s essenti al for proper operati on of the Seri es 505
control l ers. Al l fi l teri ng devi ces i nternal to the 505 system requi re a good earth
ground for reference. The structural ground present i n many i ndustri al
envi ronments does not provi de an adequate ground return when di rect wi re
connecti on to the power system i s not feasi bl e. As a mi ni mum, use #12 AWG
stranded copper wi re for the ground return. Mi ni mum wi re si zes, col or codi ng,
and general safety practi ces shoul d compl y wi th al l appropri ate el ectri cal
standards and codes. Screw connecti ons between bezel s and bases, as wel l as
between encl osures and bases, provi de grounds and shoul d be ti ghtened
properl y.
B.2.1 Sing le Point G round ing
Connect any Seri es 505 component wi th an external chassi s or external ground
termi nal on i ts power connectors to the subpanel ground bus. Thi s connecti on
shoul d exhi bi t very l ow DC resi stance (0.05 ohm) and l ow hi gh-frequency
i mpedance.
Connect the subpanel ground bus to a si ngl e-poi nt ground, such as a copper bus
bar to a good earth ground reference. The si ngl e poi nt ought to be the center of a
star confi gurati on to mi ni mi ze devi ce-to-ground di stances.
APPENDIX B G RO UNDING G UIDELINES
B-2
To achi eve l ow i mpedance from devi ce to si ngl e-poi nt termi nati on, 0.65
centi meter or l arger ground brai d shoul d be used. A good rul e of thumb i s to
requi re l ess than 0.1 ohm of DC resi stance between devi ce and si ngl e-poi nt
ground. Thi s i s accompl i shed by removi ng the anodi zed fi ni sh and usi ng copper
l ugs and star washers.
B.2.2 G uid e line s for G round C onne c tions
Use parti cul ar care when establ i shi ng the ground connecti ons. The fol l owi ng
techni ques wi l l hel p i n establ i shi ng good el ectri cal connecti ons and i ncreasi ng
system noi se i mmuni ty:
D Termi nate groundi ng brai d and green wi res at both ends wi th copper
eye l ugs to provi de a good contact surface. Lugs shoul d be cri mped and
sol dered.
D Use #10 copper bol ts (or equi val ent) for those fasteners provi di ng
el ectri cal connecti ons to the si ngl e-poi nt ground. Thi s appl i es to
devi ce-mounti ng bol ts and brai d termi nati on bol ts for subpanel and
user-suppl i ed si ngl e poi nts. Tapped hol es for these fasteners are better
than nut-bol t arrangements.
D Pai nts, coati ngs, and corrosi on can prevent good el ectri cal contact at
ground poi nts. Remove these i mpedi ments i n the area of contact and
use external toothed l ock washers (star washers) to ensure good
conti nui ty and l ow i mpedance. Thi s practi ce shoul d be used for al l
termi nati ons l ug to subpanel , devi ce to l ug, devi ce to subpanel ,
subpanel to condui t, etc. Exampl es of ground connecti ons are shown i n
Fi gure B-1.
B-3
To ground equipment directly
to the subpanel, follow these
steps:
1. Remove the finish from the
equipment at areas of contact.
2. Tighten the bolt.
3. Tighten the first nut.
4. Tighten the second nut.
To attach ground leads to
the subpanel, follow these
steps:
1. Remove the finish from the
equipment at areas of contact.
2. Tighten the bolt.
Equipment Subpanel
Star
Step 2
Step 1
Step 4
Step 3
washers
Ground braid
copper lugs
Star
washers
Subpanel
or usersupplied
single point
ground
Step 1 Step 2
Fig ure B- 1 Sa mp le G round C onne c tions
B-4
B.3 WIRING G UIDELINES
Consi der the fol l owi ng gui del i nes before i nstal l i ng any system or power wi ri ng.
D Al ways use the shortest possi bl e cabl e.
D Use a si ngl e l ength of cabl e between components.
D Do not connect short pi eces of cabl e to obtai n addi ti onal l ength.
D Avoi d pl aci ng system and fi el d wi ri ng i n the vi ci ni ty of hi gh-energy
wi ri ng.
D Keep fi el d i nput wi ri ng, output wi ri ng, and al l other types of wi ri ng i n
the panel physi cal l y separated.
D Consi der separati ng DC fi el d wi ri ng from AC fi el d wi ri ng wherever
possi bl e.
D Avoi d sharp bends to power and data cabl es. Use 7.6 cm (3 i nch) radi us
on al l bends.
D A good l ow ground i mpedance of 0.1 ohm or l ess must exi st for al l
components i n the system.
D Use wi reways for wi re and cabl e routi ng when possi bl e.
D Keep wi re stri ppi ngs from fal l i ng i nto modul es, control l ers, or bases.
D For l ong return l i nes to the power suppl y, do not use the same wi re for
i nput and output modul es. Usi ng separate return wi ri ng for these
modul es mi ni mi zes the vol tage drop on the return l i nes of the i nput
connecti ons.
B-5
B.4 M INIM IZING ELEC TRIC AL NO ISE
The fol l owi ng paragraphs provi de i nformati on to hel p reduce the possi bi l i ty of
el ectri cal noi se probl ems.
B.4.1 De finition a nd Sourc e
El ectri cal noi se i s defi ned as any unwanted el ectri cal si gnal whi ch enters the
control equi pment. Noi se si gnal s cover the enti re spectrum of frequenci es and
may have any waveshape. The l argest si ngl e di ffi cul ty wi th noi se i s that i t i s not
al ways present. Conti nuous, or frequent, peri odi c noi ses general l y are easy to
detect and remedy. I ntermi ttent noi se sources that produce short, hi gh-energy
bursts at i rregul ar and wi del y spaced i nterval s cause the majori ty of
di ffi cul ti es.
Noi se has a number of di fferent pathways i nto control equi pment. I t can be
conducted through si gnal or power wi ri ng or can be radi ated by el ectromagneti c
waves. Conducted noi se typi cal l y i s coupl ed wi th the si gnal or power wi ri ng,
ei ther el ectrostati cal l y or magneti cal l y. El ectrostati c coupl i ng occurs through
parasi ti c capaci tance between the noi sy l i ne and the si gnal /power l i ne. Thi s
requi res hi gh vol tage or hi gh rate of change of vol tages i n the noi sy l i ne and
hi gh parasi ti c capaci tance between l i nes. Thi s typi cal l y woul d be the case for
l ong wi re runs i n the same condui t.
Magneti c coupl i ng occurs through parasi ti c mutual i nductances between l i nes.
Thi s requi res hi gh currents or hi gh rates of change of current, as wel l as
si gni fi cant mutual i nductance, whi ch may resul t from proxi mi ty of wi ri ng.
El ectromagneti cal l y radi ated noi se typi cal l y i s hi gh frequency (radi o waves).
The control system and i ts wi ri ng may act as antennas i n pi cki ng up noi se
si gnal s. Thi s pathway i s l east l i kel y to present probl em l evel s of noi se, but i ts
sources are common i n i ndustri al appl i cati ons.
The pri mary sources of noi se i n i ndustry are those devi ces (and thei r wi ri ng)
that produce and swi tch hi gh vol tage and current. Typi cal exampl es i ncl ude
l arge motors, wel ders and contactors that swi tch heavi l y i nducti ve l oads such
as brakes or cl utches.
B-6
B.4.2 C orre c ting Noise Prob le ms
When potenti al noi se sources are i denti fi ed, two general methods are avai l abl e
to correct them. These methods are noi se suppressi on and noi se i sol ati on.
B.4.2.1 Noise Sup p re ssion
You can use noi se suppressi on (snubbi ng) to reduce noi se at i ts source.
Appl i cabl e onl y to devi ces dri ven by mechani cal contacts, snubbi ng suppresses
arci ng at el ectri cal contacts caused by turnoff of i nducti ve l oads (e.g., rel ays,
motors, motor starters, sol enoi ds, etc.). Load si de suppressi on reduces vol tage
transi ents at the l oad, preventi ng them from travel i ng back to the contacts
where they woul d produce a showeri ng arc and coupl e wi th adjacent wi ri ng.
You may achi eve an al ternati ve type of suppressi on by pl aci ng an RC or vari stor
ci rcui t (shown i n Fi gure B-2) across the contacts, paral l el to the swi tch.
Both types of snubbi ng cause the physi cal devi ces to come on or go off more
sl owl y. The RC and vari stor el ements shoul d have mi ni mal effect on system
ti mi ng: thei r ti me constants are substanti al l y l ess than 1 mi l l i second.
Discrete
input Load
C R
Discrete input
module protection
RC type noise snubbing
120 VAC
Discrete
input Load
Discrete input
module protection
MOV snubbing
120 VAC
MOV
Fig ure B- 2 Exa mp le s of Noise Snub b ing
B-7
B.4.2.2 Isola tion
The second approach to handl i ng noi se probl ems i s to i sol ate the probl em devi ce
and i ts wi ri ng from the el ectroni cs and associ ated si gnal wi ri ng. You may
accompl i sh thi s by i ncreasi ng the physi cal di stance from some types of noi sy
devi ces. For extreme cases, el ectrostati c (metal ) shi el di ng may be requi red.
Thi s i s true for noi se sources outsi de as wel l as i nsi de the mounti ng cabi net
(NEMA-type recommended).
Two cases of fi el d wi ri ng warrant speci al attenti on: Wi ri ng whi ch enters the
harsh-noi se area to enabl e moni tori ng and control of those devi ces, and TTL or
l ow-l evel (l ess than 24 V) wi ri ng. I n these cases, suppl ement the physi cal
separati on between control and noi se-prone wi ri ng wi th shi el ded, twi sted-pai r
wi ri ng (12 twi sts/ft) for the control si gnal s.
Ground the shi el d at the el ectroni cs si de onl y to the si ngl e-poi nt ground.
C-1
APPENDIX C
SERIES 500/ 505 I/ O
PO WER C O NSUM PTIO N
The power requi rements for al l currentl y avai l abl e Seri es 505 and Seri es 500
I /O modul es are gi ven i n Tabl e C-1 and Tabl e C-2, respecti vel y.
Ta b le C - 1 Se rie s 505 C omp one nt Powe r Re q uire me nts
(Continued on next Page)
Model Description
Max. DC Power Required
(in watts)
+5 V 5 V
IOCC 5.0 0.1
5056840
5054008
5054016 2.0
5054032 2.0
5054108 2.0
5054116 2.0
5054132 2.0
5054208 2.0
5054216 2.0
5.0 0.1
2.0
Number
5056830
Distributed Base Controller
24 VAC Input (8 point)

LVDC/TTL (8 point)
LVDC/TTL (16 point)
LVDC/TTL (32 point)
110 VAC Input (32 point) 2.0
5054308
5054316
5054332 2.0
5054408 2.0
5054416 2.0
5054432 2.0
2.0
2.0
5054232
24 VDC Input (8 point)

Power Supply
55 3.75
+5 V 5 V
Power Available
(in watts)
PPX:5056663
Power Supply PPX:5056660
55 3.75
55 3.75 Power Supply PPX:5056660A
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
5054317 1.0 24 VDC Interrupt Input (16/32 point) PPX:
Model
APPENDIX C I/ O PO WER C O NSUM PTIO N
C-2
(Continued)
Model Description
Max. DC Poer Required
(in watts)
+5 V 5 V Number
5054508 2.5
5054516 2.5
5054532 2.5
24 VDC Output (8 point)

5054608 2.5
5054616 2.5
110 VAC Output (8 point)

5054632 2.5 110 VAC Output (32 point)
5054708
5054716 5.0
5054732 5.0
5054808 5.0
5054816 5.0
5054832 5.0
5054908 2.5
5054916 2.5
5.0 24 VDC Output (8 point)

Relay Output Form C (8 point)
Relay Output Form A (16 point)
Relay Output Form A (32 point) 2.5
5056010
5056011
5056108 4.0
5056202 2.5
5056204 5.0
5056208 5.0
2.0
2.5
5054932
Input Simulator
Output Simulator
Analog Input
Analog Output (2 point)

5056308 4.0
5056408 5.0
Word Input
Word Output
TurboPlastic 7.0 0 5055100
TurboParison 7.0 0 5055103
5056208A 2.0 Analog Output (8 point)
5056851A 5.0 0.200 Remote Base Controller
5055417 3.0 16 Output Relay, 115 VDC
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
MODNIM (Modbus NIM) 8.0 5055184 PPX:
Model
5056108A 4.0 Analog Input PPX:
6MTCC: TI505 to 6MT I/F 4.0 5055190 PPX:
C-3
(Continued)
Model Description
Max. DC Power Required
(in watts)
+5 V 5 V Number
525 CPUs All models of TI525 CPUs 10.0 0.5
535 CPUs All models of TI535 CPUs 12.5 0.2
5057038 RTD 2.2 0
5057101 BASIC Module 6.0 0.125
5057339 NIM (Network Interface Module) 8.0
5057340 Dual Media NIM 8.0
5057354 Peerlink 8.0

505ATM IBM AT Compatible Coprocessor 11.0 0.2
0220
0440
4120
5451101 Programmable Logic Controller 4.0 0.200
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
5057028 2.2 0.01 Thermocouple PPX:
Model
IBM AT Compatible Coprocessor 11.0 0.2
PPX:
PPX:
5057012 3.0 8 In/4 Out Analog
5057002 2.5 High Speed Counter & Encoder PPX:
PPX:
5057016 6.5 Bipolar 8 In/4 Out Analog PPX:
5551101 CPU 4.0 0.200 PPX:

C-4
(Continued on next Page)
Model Description
DC Power Required
(in watts)
+5 V 5 V
IOCC 5.0 0.1
5002109
5005001
5005002 1.0
5005005 1.0
5005006 1.0
5005007 1.0
5005008 1.0
5005009 3.0
5005010 1.4
5.0 0.1
1.0
Number
5002108
Distributed Base Controller
110 VAC Input
220 VAC Input
24 V AC/DC Input
48 V AC/DC Input
TTL Input
24 VDC Input
Analog Input
24/48 VAC Output
110 VAC Output 1.4
5005012
5005013
5005016 3.0
5005018 2.0
5005019 2.0
5005020 1.0
5005021 1.4
5005022 8.5
5005023 6.0
1.4
1.4
5005011
220 VAC Output
24/48 VDC Output
Analog Output
0.125
0.05
Word Input
Word Output
Input Simulator
Output Simulator
ASCII
High Speed Pulse Input
+5 V 5 V
Power Available
(in watts)
5005024 7.5
5005026 2.0
0.15
SERVO AXIS Controller

24 VDC Latching Input
Rapid Response Output
5002151 AC Power Supply 54 3.75
56 3.75 5002153 DC Power Supply
45 2.50 5002103 Distributed Base Controller
(Power Supply included)
5005003 1.0 110 VDC Input
5005004 1.0 220 VDC Input
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
Model
C-5
(Continued)
Model Description
DC Power Required
(in watts)
+5 V 5 V
110 VAC Latching Input 2.0
5005028
5005029
5005030 3.0
5005031 3.0
5005032 1.0
5005033 1.4
5005035 8.5
5005037A 2.0
5005038 8.0
2.0
8.5 0.125
Number
5005027
120 VDC Latching Input
Dual Communication Port
32-Point 24 VDC Input
0.125
0.625
32-Point 24 VDC Output
110 VAC Isolated Input
110 VAC Isolated Output
BASIC
8-Channel Analog Input
Network InterfaceRS-232/Local
110 VAC Redundant Output 2.5
5005047A
5005048
5005049 1.4
5005052 3.5
5005053 6.5
5005054 6.9
5005055 3.0
2.0
1.0
5005041
8 Out, Analog
24 VDC Isolated Input
24 VDC Isolated Output
0.625
1.25
Resistance Temperature Detector

TIWAY Peerlink
Redundant TIWAY Peerlink
32-Point High Density
Line Ports
5005039 8.0 1.25 Network InterfaceDual Local
Line Ports
5005040 8.0 0.06 Network InterfaceDual RS-232
Ports
110 VAC Input
5005056 3.0* 32-Point High Density
110 VAC Output
* Some versions of the 5005056 32Point Output Module
consume 3.3 watts of +5 VDC power. These units are
appropriately identified with labels.
5005051 4.75 Thermocouple
520C/530C All models of TI520C/TI530C CPUs 11.0 0.3
530T All models of TI530T CPU 14.0 0.2
5005047 2.0 8-Channel Analog Output
5005061 3.0 High-current Relay
5005062 3.0 Low-current Relay
5005114 6.0 0.200 Remote Base Controller
5005192 3.0 48 VDC Input
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
PPX:
Model
INDEX-1
INDEX
A
AUX Functi on
AUX 10, 3-9, 3-12, 5-7, 5-15
AUX 11, 5-6, 5-15
AUX 12, 3-9, 3-12, 5-6, 5-15
AUX 20, 5-6
AUX 25, 5-6
AUX 29, 5-5, 5-15
AUX 84, 4-1, 4-8, 4-12
Troubl eshooti ng wi th, 5-55-7, 5-15
B
Base Assembl y
I nstal l ati on, 3-2
Model s, 3-1
Sl ots
Control l er, 3-27
I /O Modul es, 3-29
Power Suppl y, 3-25
Base Number Di pswi tch, TI 535, 3-10, 3-13
Base, Logi cal , 3-13, 3-19
Battery
Backup Di pswi tch
TI 525, 3-5, 3-7
TI 535, 3-10, 3-14
I nformati on Protected, 1-9, 3-7, 3-14
Baud Rate
TI 525, 3-5, 3-6
TI 535, 3-10, 3-15
Bool ean Symbol i c Code, 1-1, 1-8
C
Communi cati on Ports
Baud Rate
TI 525, 3-5, 3-6
TI 535, 3-10, 3-15
Pi nout, 3-28
Confi gurati on
TI 525, 3-53-9
TI 535, 3-103-15
D
Di agnosti cs. See Status Word, AUX Functi on,
Troubl eshooti ng
Di pswi tches
TI 525
Battery Enabl e, 3-5, 3-7
Baud Rate, 3-5, 3-6
Memory Protect, 3-8
Preset (downl oad/retai n), 3-5, 3-9
TI 535
Battery Enabl e, 3-10, 3-14
Baud Rate, 3-10, 3-15
Hi ghestNumbered Base, 3-10, 3-13
Memory Protect, 3-16
Preset (downl oad/retai n), 3-10, 3-12
Di stri buted Base, 1-3, 3-21
Di stri buted Base Control l er (DBC), 1-3, 3-21,
3-32
Di stri buted I /O, 1-3, 3-21
E
El ectri cal Noi se
Defi ni ti on, B-5
I sol ati on, B-7
Suppressi on, B-6
Emergency Stop Swi tch, 2-5
Encl osures, 2-6
EPROM/EEPROM
AUX Functi on 84 and, 4-1, 4-8, 4-12
Jumper Pi ns, 4-44-9, 5-17
Operati on At Power Up, 4-2
Programmi ng, 4-8
Status Words and, 4-10
Troubl eshooti ng, 4-94-11, 5-17
Errors. See Fatal Errors, Status Words
INDEX
INDEX-2
F
Fatal Errors
Cl eari ng, 5-15
Condi ti ons, 5-14
G
Groundi ng Gui del i nes, 2-7, B-1B-4
Gui del i nes
Groundi ng, 2-7, B-1B-4
Handl i ng Modul es, 3-4
Modul e I nstal l ati on, 3-23
Prei nstal l ati on, 2-1
Safety, 2-42-6
Temperature, 2-7
I
I /O, sel ecti ng type of, 3-11
I /O Channel Control l er (I OCC), 1-3, 3-21, 3-32
I /O Mi smatch, 5-6, 5-13
I /O Modul e
Base Power Budget and, 3-29
Handl i ng Gui del i nes, 3-4
Poi nt Numberi ng, 3-22, 3-30
Power Budget, 2-1
Status Words and, 5-12
I nch Swi tch, 2-6
I ni ti al i zati on (P/C), 5-15-3
I nput/Output (I /O)
Di stri buted, 1-3, 3-13, 3-21
Local , 1-3, 3-13, 3-20, 3-22
I nstal l ati on
Base Assembl y, 3-2
Base Control l ers, 3-32
Battery, 3-17
Communi cati on Cabl es, 3-27
EPROM/EEPROM
TI 525, 4-4
TI 535, 4-6
I /O Modul es, 3-29
P/C, 3-27
Power Suppl y, 3-25
I nstructi on Set (RLL), 1-7
J
Jog Swi tch, 2-6
Jumper Pi ns, EPROM/EEPROM, 4-44-9
L
LED I ndi cators, 5-4
Local I /O, 1-3, 3-20, 3-22
Logi cal Base, 3-13, 3-19
M
Memory
AUX Functi ons and, 5-7
Battery Backup, 3-7, 3-14
Features (by model ), 1-6
Ladder Logi c Memory (by model ), 1-6
Memory Protect Di pswi tch, 5-3
TI 525 Model s, 3-8
TI 535 Model s, 3-16
Memory Protect Di pswi tch, 1-10
Modul es
Handl i ng Gui del i nes, 3-4
I nstal l ati on Gui del i nes, 3-23
N
NEMA Encl osures, 2-7
O
Operator Safety Swi tch, 2-4
P
P/C
I ni ti al i zati on, 5-15-3
Troubl eshooti ng, 5-145-16
Port (Communi cati on)
Baud Rate Di pswi tch
TI 525, 3-6
TI 535, 3-15
Pi nOut, 3-27
Power Budget, 2-1, 3-26, 5-18
INDEX
INDEX-3
Power Consumpti on
Seri es 500 Modul es, C-4
Seri es 505 Modul es, C-1
Power Suppl y
Model s, 1-5
Power Budget, 2-1, 3-26, 5-18
Troubl eshooti ng, 5-18
Power Up
AUX Functi ons and, 5-7
Modes, 4-3
P/C I ni ti al i zati on, 5-15-3
Prei nstal l ati on Gui del i nes, 2-1
Preset Val ues
AUX Functi ons and, 3-9, 3-12, 5-6
Downl oad/Retai n Di pswi tch
TI 525, 3-9
TI 535, 3-12
Pri mary Base, 3-203-21
Programmi ng, EPROM/EEPROM, 4-8
Programmi ng Devi ces, 1-2, 1-8
Programmi ng Software, 1-8
R
RLL I nstructi on Set, 1-7
S
Safety Gui del i nes, 2-42-6
Safety Swi tch, 2-4
Scan Ti me
Bool ean Logi c, 1-1
Status Word 10 and, 5-11
Sl ots
I /O, 3-29
P/C, 3-27
Power Suppl y, 3-25
Software (Programmi ng), 1-8
Spare Parts Li st, 5-19
Speci fi cati ons, A-1
StartUp Procedure, 5-15-3
Status Words
STW01, 5-8
STW02, 5-9
STW06, 4-10, 5-10
STW07STW09, 4-11, 5-11
STW10, 5-11
STW11STW18, 5-12
Troubl eshooti ng wi th, 4-10, 5-85-13
Stop Swi tch, 2-5
T
Temperature Gui del i nes, 2-7
TI SOFT Programmi ng Software, 1-8
Troubl eshooti ng
AUX Functi ons and, 5-55-7, 5-15
EPROM/EEPROM, 4-94-11, 5-17
LED I ndi cators and, 5-4
P/C, 5-145-16
Power Suppl y, 5-18
Status Words and, 4-10, 5-85-13
W
Wi ri ng Rul es, B-4
SIMATIC is a registered trademark of Siemens AG.
Series 500, Series 505, TISOFT1, TISOFT2, TISOFT3, TIWAY, CVU, VPU are trademarks of Siemens Industrial Automation, Inc.
TI505, TI520, TI520C, TI525, TI530, TI530C, TI530T and TI535 are trademarks of Texas Instruments Incorporated.
IBM is a registered trademark of International Business Machines, Incorporated.
DEC is a registered trademark and VAX is a trademark of Digital Equipment Corporation.
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Manual Name: SIMATIC TI505/TI535 Hardware and Installation User Manual Edition: Thrid
Manual Assembly Number: 25865460052 Date: 04/93
Order Number: PPX:50581033
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SIMATIC TI525/TI535

Hardware and Installation

fami l y of programmabl e l ogi c control l ers (PLCs). Both the

and the SI MATI C

PLCs and thei r support

Programming Reference Manual

Systems Manual (TI WAY8101)

User Reference Manual

PC/XT Computer or a 100% compati bl e computer wi th TI SOFT

Computer to devel op an RLL program that can be

operates on the VPU200; TI SOFT2

runs i n an off-l i ne mode on a DEC VAX computer.

model s, provi ded the program i s compati bl e wi th the systems

24 VAC Input (32 point)

220 VAC Input (8 point)

24 VDC Output (8 point)

110 VAC Output (8 point)

24 VDC Output (32 point)

Analog Output (2 point)

5057354 Peerlink 8.0

5551101 CPU 4.0 0.200 PPX:

SERVO AXIS Controller

Resistance Temperature Detector

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