SIMATIC TI545/TI555

System Manual

Order Number: PPX:545/555–8101–2

Manual Assembly Number: 2586546–0084
Second Edition
 Copyright 1994 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 customer’s 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.
MANUAL PUBLICATION HISTORY
SIMATIC TI545/TI555 System Manual
Order Manual Number: PPX:545/555–8101-2
Refer to this history in all correspondence and/or discussion about this manual.

Event Date Description

Original Issue 02/93 Original Issue (2801030-0001)

Second Edition 10/94 Second Edition (2801030-0002)
LIST OF EFFECTIVE PAGES

Pages Description Pages Description

Cover/Copyright Second
History/Effective Pages Second
iii — xii Second
1-1 — 1-8 Second
2-1 — 2-15 Second
3-1 — 3-21 Second
4-1 — 4-20 Second
5-1 — 5-10 Second
6-1 — 6-5 Second
7-1 — 7-16 Second
A-1 — A-4 Second
B-1 — B-4 Second
C-1 — C-4 Second
D-1 — D-13 Second
Index-1 — Index-4 Second
Registration Second
 Contents
Preface
Chapter 1 System Overview
1.1 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.2 Hardware Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Series 505 Base Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Local and Remote I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Series 505 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Communication Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
I/O Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Battery Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Real-time Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Programming Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Program Storage in EEPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Program Storage in EPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Chapter 2 Pre-installation Guidelines

2.1 Planning Your Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Defining Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Calculating Power Needs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2 Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Operator Safety Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Emergency Stop Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
JOG or INCH Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.3 Enclosure and Temperature Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Enclosure Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Temperature Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.4 Guidelines for Fuses/Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Fusing the Controller and Remote I/O Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.5 Definition and Source of Electrical Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Electrical Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2.6 Correcting Noise Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Noise Snubbing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Noise Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.7 Wiring Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Contents iii
2.8 Power System Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Earth Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Grounding the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Grounding the Cabinet or Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Ground Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Chapter 3 Installing Series 505 System Hardware

3.1 Overview of Installation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3.2 Series 505 Bases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Connecting Series 500 Bases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.3 Rack Mounting Series 505 Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

PPX:505–6516, 16-Slot Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.4 Panel Mounting Series 505 Bases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Series 505 Bases PPX:505–6516, PPX:505–6508, PPX:505–6504 . . . . . . . . . . . . . . . . . . . . . . . 3-5

3.5 Installing Series 505 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Power Budget for Series 505 Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Power Supply Placement in Bases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Installing and Removing the Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

3.6 Installing the TI545/TI555 CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

CPU/RBC Location in a Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Installing and Removing the CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
CPU Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Setting CPU Dipswitches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Using Port 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Using Port 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Setting Baud Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Enabling Battery Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

3.7 Installing Series 505 Remote Base Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

RBC Placement in Bases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Dipswitches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Setting RS-232 Port Baud Rates (SW 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Series 505 RBC SW 3 (Factory) Dipswitch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Output State Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Installing and Removing Series 505 RBC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Assigning RBC Base Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Series 505 RBC LED Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

3.8 Installing Series 505 I/O Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Mixing I/O Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Installing and Removing I/O Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

iv Contents
Chapter 4 Cabling and Wiring the System
4.1 Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Wiring Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2 Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Cable Routing Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Under-Floor Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
In-Ceiling Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Surface Duct Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Mounting the Tap or Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.3 Installing Remote I/O Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Cabling Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Trunk and Drop Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
User-Supplied Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Mounting the Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Programmable Controller and RBC Drop Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Preparing Cables (for Drop Lines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Connecting a CPU Drop Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Connecting the RBC Drop Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Connecting Terminal Block Trunk Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Alternate Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Configuration Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Preparing Trunk Line Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Connecting Trunk Line to Terminal Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4.4 Connecting Modems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Dedicated Line Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Dial-up Phone Line Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4.5 Connecting a Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

Chapter 5 Using an EEPROM or EPROM

5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Program Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Using an EEPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Using an EPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
EEPROM Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.2 TI545/TI555 Memory and Mode Status at Power-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

5.3 Installing EEPROMs and EPROMs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5.4 Copying a Program into an EEPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

5.5 Editing a Program Stored in EEPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Contents v
Chapter 6 Starting Up the TI545/TI555 System
6.1 Powering Up the TI545/TI555 System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Start-up Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2 TI545 CPU Memory Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Memory Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Maximum Configurable Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.3 TI555 CPU Memory Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Memory Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Maximum Configurable Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Chapter 7 Troubleshooting
7.1 Troubleshooting by Using Auxiliary Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Power-up Restart, Partial Restart, and Complete Restart . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Compare PLC to Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Run PLC Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Display Failed I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Show PLC Diagnostic Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.2 Troubleshooting by Reading LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

7.3 Troubleshooting Controller Fatal Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

CPU Fatal Error Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Causes of CPU Fatal Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Controller Responses to Fatal Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Steps to Clear Fatal Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Calling for Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.4 Troubleshooting Controller Non-Fatal Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

7.5 Troubleshooting by Using Status Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

7.6 Troubleshooting EEPROMs or EPROMs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

7.7 Troubleshooting the Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

7.8 Checking RS-485 (Twisted Pair) Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

Using Digital or Analog Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Resistance Below Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Resistance Above Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
7.9 Recommended Spare Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16

vi Contents
Appendix A System Specifications
A.1 Series 505 System Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

Appendix B Module Power Consumption

B.1 Series 505 Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

Appendix C TI545/TI555 CPU and I/O Compatibility

C.1 I/O Module Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
I/O Modules not Compatible with TI545/TI555 CPUs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Determining the Compatibility of a Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Series 505 High Speed Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
C.2 Reading the Serial Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
Determining the Manufacturing Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
86ML8712020175_ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
86ML8712020175G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
86ML8801041324_ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4

Appendix D Upgrading Series 500 Installations

D.1 Series 500 System Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2

D.2 Upgrading a TI520/TI520C/TI530/TI530C/TI530T System . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-3

Install RS-485 Twin Axial Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-3
Check Base to be Upgraded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-4
Upgrading 14-Slot, 12-Slot, 6-Slot Bases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-4
Upgrading 16-Slot and 8-Slot Bases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-4
Finish Upgrade with these Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-4
D.3 Upgrading an RS-485 Based TI560/TI565/TI560T/TI565P System . . . . . . . . . . . . . . . . . . . . . D-6

D.4 Upgrading an RF Based TI560/TI565/TI560T/TI565P System . . . . . . . . . . . . . . . . . . . . . . . . . . D-8

D.5 Installing a PPX:500-5114A RBC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-10

Output State Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-10
Installing a Series 500 RBC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-11
Setting Baud Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-12
Assigning Base Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-12
Series 500 RBC LED Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-13

Contents vii
List of Figures

Figure 1-1 Typical TI555-1102 Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Figure 1-2 TI545/TI555 System Using Series 500 and Series 505 Components . . . . . . . . . . . . . . . 1-5

Figure 2-1 Operator Safety Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Figure 2-2 Emergency Stop Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Figure 2-3 JOG or INCH Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Figure 2-4 Fuse/Circuit Breaker Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Figure 2-5 Load Noise Snubbing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Figure 2-6 Contact Noise Snubbing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Figure 2-7 Grounding Shielded, Twisted Pair Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Figure 2-8 Isolating Ground and Neutral From Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Figure 2-9 Grounding the TI545/TI555 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Figure 2-10 Example of Ground Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Figure 3-1 Mounting Base to Standard 19-inch Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Figure 3-2 Screw-hole Dimensions for PPX:505–6516/6511 Bases . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Figure 3-3 Screw-hole Dimensions for PPX:505–6504 Bases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Figure 3-4 Screw-hole Dimensions for PPX:505-6508 Bases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Figure 3-5 Mounting Brackets to Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Figure 3-6 Mounting Base in NEMA Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Figure 3-7 Series 505 Module Placement in Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Figure 3-8 Selecting Input Voltage—PPX:505–6660 Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Figure 3-9 Location of CPU/RBC in a Series 505 Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Figure 3-10 Installing CPU Module in a Series 505 Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Figure 3-11 CPU Dipswitch Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Figure 3-12 TI545/TI555 CPU Port Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Figure 3-13 RBC Dipswitch Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Figure 3-14 Series 505 RBC Jumper Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Figure 3-15 Series 505 Remote Base Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Figure 3-16 Installing and Removing Modules in a Series 505 Base . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Figure 4-1 Supplying Power with the PPX:505–6660A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Figure 4-2 Trunk and Drop Line Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Figure 4-3 9-Pin I/O Female D-Connector Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Figure 4-4 Connecting to Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Figure 4-5 Adding a Terminating Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Figure 4-6 Attaching RBC to Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Figure 4-7 Maximum Trunk Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Figure 4-8 T Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Figure 4-9 Multiple Tap Connections in Close Proximity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Figure 4-10 Spacing between Taps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Figure 4-11 Connecting Terminal Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Figure 4-12 Modem Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

viii Contents
Figure 4-13 XON/XOFF Printer Handshaking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Figure 4-14 READY/BUSY Printer Handshaking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

Figure 5-1 EEPROM (EPROM) Socket and Jumper Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Figure 7-1 Typical AUX Function 29 Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Figure 7-2 Replacing PPX:505–6660 Power Supply Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

Figure C-1 Serial Number Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4

Figure D-1 Upgrading a TI520/TI520C/TI530/TI530C/TI530T System . . . . . . . . . . . . . . . . . . . . . . . . D-5

Figure D-2 Upgrading an RS-485 Based TI560/TI565/TI560T/TI565P System . . . . . . . . . . . . . . . . . . D-7
Figure D-3 Upgrading an RF Based TI560/TI565/TI560T/TI565P System . . . . . . . . . . . . . . . . . . . . . . D-9
Figure D-4 Series 500 RBC Switch Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-10
Figure D-5 Installed Series 500 RBC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-11
Figure D-6 Series 500 Remote Base Controller and Baud Rate Settings . . . . . . . . . . . . . . . . . . . . D-12

Contents ix
List of Tables

Table 1-1 TI545/TI555 Capacity/Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Table 1-2 Program Storage Using EEPROM and EPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Table 3-1 Base Assembly Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Table 3-2 Port 1 Baud Rate Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Table 3-3 Port 2 Baud Rate Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Table 3-4 RBC SW 2 (RS-232 Port) Baud Rate Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Table 3-5 Series 505 RBC SW 3 (Factory) Dipswitch Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Table 3-6 Series 505 RBC LED Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Table 4-1 Terminating Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Table 4-2 Maximum Cable Length for Trunk Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Table 4-3 Cable Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Table 5-1 Program Storage Using EEPROM and EPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Table 5-2 EEPROM/EPROM Portability Between Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Table 5-3 TI545/TI555 Mode and Memory Status After Power-up . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Table 6-1 TI545-1102 CPU Memory Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Table 6-2 TI555-1101/1102 CPU Memory Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Table 7-1 Effects of Using AUX Functions 10, 11, and 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Table 7-2 CPU Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Table 7-3 Cable Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

Table A-1 Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

Table A-2 General Series 505 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Table A-3 Power Supply Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4

Table B-1 Series 505 Module Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

Table D-1 Base Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-13

Table D-2 Series 500 RBC LED Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-13

x Contents
 Preface
About this Manual This SIMATIC
TI545/TI555 System Manual includes requirements and
specifications for preparing your control site and installing a
SIMATIC TI545/TI555 Programmable Logic Controller (PLC) system.

NOTE: This manual describes the SIMATIC TI545-1102 CPU, and both the
SIMATIC TI555-1101 and -1102 CPUs. Information in this manual does not
apply to the SIMATIC TI545-1101 CPU. For the information concerning the
SIMATIC TI545-1101 CPU refer to SIMATIC TI545 System Manual:
PPX:545-8101-x.

The following major topics are covered.

• Site preparation including power and grounding requirements and

other safety considerations.

• Hardware installation including Series 505 bases, power supplies,

TI545/TI555 CPUs, Remote Base Controllers (RBCs), and I/O modules.

• Upgrade of Series 500 bases for connection to the TI545/TI555.

• System cable and wiring procedures.

• Using EEPROMs or EPROMs.

• System startup, including modem operation.

• System troubleshooting, including use of AUX functions, status words,

and other diagnostic aids.

• General maintenance procedures such as changing power supply fuses.

TI545/TI555 System Manual Preface xi

Related Manuals Additional manuals that have relevant information include the following:

• SIMATIC
TI505 Programming Reference Manual (PPX:505–8104-5).

• SIMATIC
TI505/TI500 TISOFT Release 5.0 User Manual

(PPX:TS505–8101-x).

• SIMATIC TI505 Input/Output Modules User Manual

(PPX:505–8105-x).

• SIMATIC TI505 Analog I/O Modules User Manual (PPX:505–8120-x).

• SIMATIC TI505 H1 Communication Processor User Manual

(PPX:505–8126–2 or later).

• SIMATIC TI505 Redundant I/O Systems Users Manual,

(PPX:505-8125-x).

• SIMATIC TI505 Isolated Interrupt Discrete Input Module User Manual

(PPX:505-4317–x) provides information on configuring and installing
the Interrupt Input module (PPX:505–8123-x) which is required for the
operation of interrupt I/O.

Refer to material in these manuals as necessary for additional information

about programming and operating your TI545/TI555 system.

Agency Standards Series 505 products have been developed with consideration of the draft
standard of the International Electrotechnical Commission Committee
proposed standard (IEC-65A/WG6) for programmable controllers (released
as IEC 1131–2, Programmable Controllers Part 2: Equipment Requirements
and Tests, First Edition, 1992–09). Contact Siemens Industrial Automation,
Inc., for information about regulatory agency approvals that have been
obtained on the TI545/555 systems and Series 505 units.

Agency Approvals are the following:

– UL Listed (industrial control equipment)

– CSA Certified (process control equipment)
– FM (Class I, Div. 2, Group A, B, C, D Hazardous Locations)

Technical For technical assistance, contact your Siemens Industrial Automation, Inc.
Assistance distributor or sales office. If you need assistance in contacting your sales
agent or distributor in the United States, call 1–800–964–4114.

xii Preface TI545/TI555 System Manual

 Chapter 1
System Overview

Chapter 1 System Overview

1.1 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.2 Hardware Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Series 505 Base Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Local and Remote I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Series 505 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Communication Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
I/O Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Battery Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Real-time Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Programming Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Program Storage in EEPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Program Storage in EPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

TI545/TI555 System Manual System Overview 1-1

1.1 Features

The TI545/TI555 CPUs and support equipment comprise a

computer-controlled system that is capable of controlling complex
manufacturing systems. This system performs the same functions as relays,
static control, or card logic control systems. It can detect the change in state
of input signals from such devices as pushbuttons, limit switches, and
analog sensors.

Acting on this information and executing a Relay Ladder Logic (RLL)

program stored in memory, the TI545/TI555 CPU produces output signals to
drive motor starters, solenoids, pilot lights, modulating control valves, etc.
These signals are used to regulate the operation of various pieces of
equipment.

Features The TI545/TI555 systems offer the following features:

• Memory and I/O capacities and scan performance are summarized in

Table 1-1.

Table 1-1 TI545/TI555 Capacity/Performance

TI545 TI555
Feature –1102 –1101 –1102
User Memory (bytes) 192K 384K 1920K
EEPROM (EPROM) (bytes) 256K
Discrete I/O Points 2048 1
8192 2
Word I/O Points 1024 1
Control Relays 32,768
Scan Performance
(milliseconds/KW, best case) .67 .07
Notes:
1 Total I/O count may not exceed 2,048 points.
2 Total I/O count may not exceed 8,192 points.

• Optional password protection for user programs.

• Support for Report By Exception (RBE) when used as a control element

in a SIMATIC
PCS System (Release 3.0 or later).

1-2 System Overview TI545/TI555 System Manual

 • Interrupt I/O allows for fast reaction to external events.

• Support for Redundant Remote Base Controller.

• Immediate I/O Updates allow your application program to access an I/O

point multiple times during a controller scan.

• Cyclic RLL allows you to create an additional RLL program that runs
independently of the main RLL program.

• External subroutines allows your program to call externally developed

programs written in high-level languages such as C.

• Proportional-Integral-Derivative (PID) loop functions for process and

batch control.

• Special Function Programs (SFPGMs) and Special Function

Subroutines (SFSUBs) that use a higher level statement-driven
programming language to ease the development of complex programs.

• Up to 256 SF modules can be used in the TI545/TI555 system.

• A communication port baud rate of up to 19,200 baud to provide fast

communication with your (programming) operator interfaces.

• Ethernet connectivity using H1 protocol and the CP1434TF H1 module

(Rel. 2.0 and later).

• Adjustable processor scan time by using the configurable timeline

function.

• Analog alarm functionality.

• Non-volatile program storage and execution (EEPROM or EPROM).

• Series 505 footprint.

TI545/TI555 System Manual System Overview 1-3

Features (continued)

Siemens
SIMATIC
SIMATIC TI555
TI505 CPU GOOD
RUN
BATT GOOD

R
S
2
3
2
#
1

I
/
O

R
S
2
3
2
#
2

555–1102

Figure 1-1 Typical TI555–1102 Control System

TI545/TI555 systems (see Figure 1-1) are designed for use in applications
that require discrete and analog control. Components include the CPU and
the support devices that provide operator communication, I/O control, and
power (see Figure 1-2).

You can communicate with the CPU by using the following devices:

• IBM
PC/AT
(386 or higher) or a 100% compatible computer, using the

SIMATIC
APT or TISOFT software.

• Control Vision Unit (CVU100, CVU1000, or CVU10000).

• SIMATIC PCS.

1-4 System Overview TI545/TI555 System Manual

 The TI545/TI555 controller system uses individual Series 505 or Series 500
I/O modules for I/O interfaces. A full line of discrete, analog, word, and
intelligent I/O modules are available for handling almost any input or
output specification. These I/O modules are rugged, plug-in devices capable
of functioning in harsh environments within the operating specifications.

The controllers can also communicate with other devices through the
SINECr H1 or SIMATICr TIWAY Local Area Networks. See documents
listed in the Preface of this manual for information on these systems.

Programming Unit

CVU100 TISOFT CVU1000/10000 SIMATIC PCS

TIWAY SINEC H1

Series 505 I/O N CP

P/S CPU 4, 8, and 16 I 1434 Local I/O up to
Slots M TF 16 I/O Slots

RBC Series 505

P/S PPX:
Remote I/O up 505– I/O 4, 8, and
to 15 additional 6851 16 Slots
bases.

Series 505 and

Series 500 I/O
can be used. RBC
Series 500
6, 8*, 12, 14, &
P/S PPX:
500–
16* I/O slots 5114

*The 8-slot and 16-slot I/O bases operate with the PPX:500–5840 Adapter.

Figure 1-2 TI545/TI555 System Using Series 500 and Series 505
Components

TI545/TI555 System Manual System Overview 1-5

1.2 Hardware Description

Series 505 Base The CPUs are housed in a Series 505 base assembly. A base assembly has
Assemblies slots for the CPU or remote base controller (RBC), a power supply, and the
I/O modules. Three base assembly models are currently available. Each has
the following number of slots for I/O modules.

• Model PPX:505–6504, 4 slots.

• Model PPX:505–6508, 8 slots.

• Model PPX:505–6511, 11 slots (redundant). Power supply and media.

• Model PPX:505–6516, 16 slots.

Any base assembly may be used at any point in the system, depending upon
the number of I/O points required.

Local and Remote I/O modules are grouped into local and remote I/O categories depending
I/O upon their physical location. The local I/O comprises those modules located
in the same base assembly as the CPU. If you install the CPU in base
assembly Model PPX:505–6516, the local I/O may consist of as many as 16
I/O modules. The base assembly containing the local I/O is designated 0.

You can connect up to 15 additional base assemblies to the system,

numbered 1–15. The I/O modules in these bases make up the remote I/O as
shown in Figure 1-2.

Individual I/O modules in the remote bases communicate with the CPU
through RBCs. The RBC in each remote base transmits information from
the I/O modules in that base directly to the CPU.

Series 505 The power supply provides up to 55 W at +5 VDC and 3.75 W at –5 VDC for
Power Supply use by the CPU and the I/O modules. The PPX:505–6660 power supply
operates at either 110 VAC or 220 VAC on user-supplied power. A jumper on
the inside of the back of the module is used to select voltage. The model
PPX:505–6663 power supply operates on 24 VDC user-supplied power.

1-6 System Overview TI545/TI555 System Manual

Communication The CPU has two communications ports; features and descriptions are
Ports listed below. Both ports are configured as Data Terminal Equipment (DTE).
• Port 1 — RS-232 (9-pin male) is used to either program the CPU by an
IBM PC/AT compatible computer with APT or TISOFT, or to attach
equipment such as the Timer/Counter Access Module (TCAM), a
CVU100, or other operator interface using RS-232. The operator
interface can be up to 50 feet (15 m) away. A user supplied modem can
be used to extend this distance. Port 1 can also be used to attach a
printer.

• Port 2 — RS-232/RS-423 or RS-422/RS-485 (9-pin male) is used to

communicate with operator interface equipment. Selection between
RS-232/423 and RS-422/485 is done with cabling options. Dipswitch 1
selects between RS-422 and RS-485 if 422/485 cabling is used. See
Chapter 3, Making Port Selection. Distance constraints are listed
below.
• RS-232/RS-423 connection for operator interface up to 50 feet.

• RS-422/RS-485 connection to 1000 feet.

I/O Port The CPU has one Remote I/O port, (9-pin female) used to communicate
directly with remote base controllers (RBCs). This port uses a twisted,
shielded-pair RS-485 cable to communicate with RBCs.
Both Series 505 (see NOTE and Appendix C) and Series 500 I/O modules can
be connected to the TI545/TI555 CPU as remote I/O. The CPU is capable of
directly addressing the PPX:505–6851–A RBC in a Series 505 base
assembly, or the PPX:500–5114–A RBC in a Series 500 base assembly
intermixed in the same system. Both RBC models use shielded twisted-pair
cable. They can be placed up to 3300 feet from the CPU.

NOTE: You cannot use some early model Series 505 I/O modules with a
TI545/TI555 CPU. Refer to Appendix C for details.

Battery Backup A permanent, rechargeable battery protects user memory and programming
during a power outage. Battery memory backup typically lasts six months
at temperatures ranging from 0° to 60°C.

! CAUTION Battery Damage: If the TI545/TI555 unit is left without power and
with the battery switch on for longer than six months, the battery
may be damaged to the point that it cannot be recharged.

Be aware that the battery will appear to charge, but the memory
backup time will be seriously degraded.

Return a unit in this condition to the factory for battery

replacement.

TI545/TI555 System Manual System Overview 1-7

Hardware Description (continued)

Real-time Clock The CPU contains a real-time clock which includes the following
information:
• Year (two digits), Month, Day of month, and Day of week.
• Hour, minute, second, tenths and hundredths of a second.

Programming You can use APT to program the CPU. APT is a graphic programming
Software environment that eliminates the need for you to work in relay ladder logic
when you create your application program. APT presents a familiar
structure for process engineers, allowing them to become more closely
involved in up-front design work. When the APT program is compiled, an
RLL program code is produced, generating the language with which the
electrician or maintenance person is already familiar. Refer to the APT
manual set for more information.
You can use the TISOFT programming software to create and edit your
application program. TISOFT allows you to work directly in the ladder logic
environment as you design the RLL program. For loops, analog alarms, and
SF programs, TISOFT presents menu-driven programming tools.

To program the latest features that are described in the Preface of this
manual, you need TISOFT Release 5.0, which runs on an IBM PC/AT (386
or higher) compatible personal computer running MS-DOS
3.3 or later.

Refer to your TISOFT manual for detailed instructions about how to enter a
program.

Program Storage The CPU offers the option of saving your RLL program in a non-volatile
in EEPROM form by downloading it to an EEPROM integrated circuit as shown in
Table 1-2. A separate programming device is not necessary. Once
programmed, an EEPROM can be removed and used in any Release 3.0 or
higher CPU as required. To help ensure equipment compatibility, use only
the EEPROM model supplied by your distributor.

Program Storage If your operating program does not change, you can store it permanently on
in EPROM EPROM(s) as shown in Table 1-2. By copying your program from an
EEPROM to an EPROM (using an EPROM copier), you can create
additional copies for CPUs that are running the same program.

Table 1-2 Program Storage Using EEPROM and EPROM

Storage Type Size Order Number

EEPROM 128K bytes 2587681–8022
EEPROM 256K bytes 2587681–8030
EPROM 128K bytes 2587681–8023
EPROM 256K bytes 2587681–8031

1-8 System Overview TI545/TI555 System Manual

 Chapter 2
Pre-installation Guidelines
Chapter 2 Pre-installation Guidelines
2.1 Planning Your Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Defining Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Calculating Power Needs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2 Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Operator Safety Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Emergency Stop Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
JOG or INCH Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.3 Enclosure and Temperature Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Enclosure Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Temperature Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.4 Guidelines for Fuses/Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Fusing the Controller and Remote I/O Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.5 Definition and Source of Electrical Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Electrical Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2.6 Correcting Noise Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Noise Snubbing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Noise Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.7 Wiring Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.8 Power System Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Earth Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Grounding the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Grounding the Cabinet or Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Ground Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

TI545/TI555 System Manual Pre-installation Guidelines 2-1

2.1 Planning Your Installation

Preparing the site for installation of your TI545/TI555 controller consists of

the following tasks.

• Defining control requirements

• Determining the number of controllers needed

• Determining the panel and grounding layout

NOTE: Since no two applications are identical, use these recommendations

as general guidelines only.

Defining Control Use the following steps to define your control requirements:

• Define the number and type of inputs and outputs you need.

• Calculate the number of I/O modules and bases that you need.

• Determine the power requirements and mounting space needed.

• Consider availability of space (including growth potential). This is

particularly true if several double-wide modules are needed.

Calculating Power Calculate a power budget for each base prior to installation. The power
Needs requirements of all modules must be included in the calculations — the
controller, the base controllers, as well as the I/O modules. The
user-supplied power to individual modules is not a part of the power budget
calculation. Refer to Appendix B for Series 505 module power consumption
information.

To help ensure reliable system operation, the total power required for the
controller and I/O modules must not exceed the total power available from
the system power supply. Refer to Chapter 3 for Series 505 power budget.

2-2 Pre-installation Guidelines TI545/TI555 System Manual

2.2 Safety Considerations

Pre-installation planning and site preparation must include consideration of

hazards to personnel in the event of a system failure. The equipment
connected to the control system must include interlocks and safety switches
to help prevent operation during a system failure. Although the specific
steps depend on the application, the general precautions include the
following data.

! WARNING Control devices can fail in an unsafe condition. This means that,
unless you incorporate proper safeguards, certain malfunctions of
these devices could lead to a sudden equipment startup or
shutdown. Such a startup or shutdown could result in property
damage and/or death or severe physical injury to the equipment
operator. Failure can also be exhibited as erratic or unexpected
operation.

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 3–304
Programmable Control Standards.

ICS 3-304.81 Safety Recommendations:

Consideration should be given to the use of an emergency stop function which is

independent of the programmable controller.

Where the operator is exposed to the machinery, such as in loading or unloading a

machine tool, or where the machine cycles automatically, consideration should be
given to the use of an electromechanical override or other redundant means,
independent of the programmable controller, for starting and interrupting the cycle.

If provision is required for changing programs while the equipment is in operation,

consideration should be given to the use of locks or other means of assuring that such
changes can be made only by authorized personnel.

These recommendations are intended as safeguards against the failure of critical

components and the effects of such failures or the inadvertent errors that might be
introduced if programs are changed while the equipment is in operation.

The ICS 3-304.81 Safety Recommendations from NEMA ICS 3-304, Programmable Control-
ler Standard. Recommendations are reproduced by permission of the National Electrical
Manufacturers Association.

TI545/TI555 System Manual Pre-installation Guidelines 2-3

Safety Considerations (continued)

Operator Safety Provide a means for disconnecting power — independent of the controller —
Switches from the output loads when a machine is not operating, or when it is
necessary for the operator to reach into the machine. Power must be
removed by a non-semiconductor switch or a physically-wired relay contact,
placed to interrupt power to the output. It is not sufficient to rely solely on
the controller for this function. Figure 2-1 shows an operator safety switch.

Relay contacts or limit switches

open when operator must
reach into machine.

User-supplied
critical loads
which could
Output cause injury
Module
Loads which
could not
cause injury

Output points from

the programmable control system

Figure 2-1 Operator Safety Switch

Emergency Stop Provide a means for removing power from the output if an emergency
Switch condition occurs with the machine during operation. Do this by
disconnecting output power with a non-semiconductor switch or hardwired
relay contact, not through the programmable control system (Figure 2-2).

Emergency Reset Guard

stop limit switch C1

C1 Electromechanical
Relay

Contacts of
electromechanical relay C1

C1
User-supplied
critical loads
C1 which could
Output cause injury
Module
Loads which
could not
cause injury

Outputs from the

programmable control system

Figure 2-2 Emergency Stop Switch

2-4 Pre-installation Guidelines TI545/TI555 System Manual

JOG or INCH Bypass the programmable control system with an external JOG or INCH
Switch switch during machine loading or setup operations. See Figure 2-3.

Switch or contact
Jog closed in the jog
or inch mode

User-supplied
critical loads
which could
Switch or contact cause injury
open in the JOG
Output or INCH mode
Module

Outputs from the

programmable controller

Figure 2-3 JOG or INCH Switch

TI545/TI555 System Manual Pre-installation Guidelines 2-5

2.3 Enclosure and Temperature Considerations

Enclosure Selection An enclosure should provide the following features:

• Easy access to components.

• A common ground potential on the cabinet.

• A secure vertical panel or rails.

• Conformance to electrical standards.

• An electromagnetic shield.

• Access restricted to authorized personnel only.

• Cooling and heat dissipation.

• Protection from dust and dirt as required by the environment.

Mount the components in a dustproof and drip tight enclosure such as the
NEMA Type enclosure. The enclosure must provide a minimum depth of
10 in. (25.4 cm) from the panel to the inside surface of the enclosure door.
The enclosure should be located so that the doors may be opened fully,
permitting easy access to the controller, wiring, and components. If
environmental conditions permit, a 19-inch rack may be used instead of a
NEMA enclosure. Use the 16-slot PPX:505–6516 I/O base for 19-inch rack
installations.

Temperature When preparing your installation, plan for an adequate air flow to ensure
Considerations proper cooling of equipment. Do not permit the convection cooling of the
controller to be hindered. Unless ambient temperatures are extremely high,
a fan or air-conditioned cooling is unnecessary for keeping controllers below
their maximum-rated operating temperature of 60°C provided that the
cabinet adequately dissipate heat.

For one local base and one remote base located in the bottom half of a 7-foot,
19-inch rack, place equipment that dissipates no more than 325 W in the
top half, above the System 505 bases, assuming a 25°C external ambient
temperature. If you must exceed these guidelines, use cooling equipment to
lower the equipment temperature to the recommended level.

2-6 Pre-installation Guidelines TI545/TI555 System Manual

2.4 Guidelines for Fuses/Circuit Breakers

Fusing the Use the following guidelines for installing fuses/circuit breakers; see
Controller and Figure 2-4. The sizes and types of fuses/circuit breakers depend on the
Remote I/O Base specified power distribution requirement.

• A circuit breaker before isolation transformer (isolation transformers

may not be required if your power distribution system does not have a
high level of noise).

• A fuse after isolation transformer.

• An external fuse before each power supply.

Input Power Line 110/220 VAC

Isolation
Transformer

Optional
Grounds

P/S
(Line)
(Neutral) Controller
(Ground)

P/S
(Line)
(Neutral) Remote I/O Base
(Ground)

Figure 2-4 Fuse/Circuit Breaker Placement

NOTE: In order to ensure a proper level of safety compliance, observe local

installation code practices and guidelines.

TI545/TI555 System Manual Pre-installation Guidelines 2-7

2.5 Definition and Source of Electrical Noise

Electrical Noise Electrical noise is defined as any unwanted electrical signal which enters
the control equipment. Noise signals cover the entire spectrum of
frequencies and may have any wave shape.

A major difficulty with noise problems is that they can occur at random
intervals. Continuous, or frequent, periodic noises generally are easy to
detect and remedy. Intermittent noise sources that produce short,
high-energy bursts at irregular and widely spaced intervals create problems
that can be harder to resolve.

The primary sources of noise in industry are those devices (and their wiring)
that produce and switch high voltage and current. Typical examples include
large motors, welders and contacts that switch heavily inductive loads such
as brakes or clutches.

Noise can enter your control equipment by several routes. It can be

conducted through signal or power wiring or can be radiated by
electromagnetic waves. Conducted noise typically is coupled with the signal
or power wiring, either electrostatically or magnetically.

Electrostatic coupling occurs through parasitic capacitance between the

noisy line and the signal/power line. This requires high voltage or high rate
of change voltages in the noisy line and high parasitic capacitance between
lines. This can occur when you have long wire runs in the same conduit.

Magnetic coupling occurs through mutual inductances between lines. This

requires high currents or high rates of change of current, as well as
significant mutual inductance.

Electromagnetically radiated noise typically is high frequency (radio waves).

The control system and its wiring may act as antennas in picking up noise
signals. This pathway is least likely to present problem levels of noise, but
its sources are common in industrial applications.

2-8 Pre-installation Guidelines TI545/TI555 System Manual

2.6 Correcting Noise Problems

When potential noise problem sources are identified, two general methods
are available to handle them. These methods are described in the following
sections.

• Noise snubbing.

• Noise isolation.

These methods are described in the following sections.

Noise Snubbing Noise snubbing reduces noise at its source. Applicable only to devices driven
by mechanical contacts, snubbing suppresses arcing at electrical contacts
caused by turnoff of inductive loads (e.g., relays, motors, motor starters,
solenoids, etc.).

Load snubbing (shown in Figure 2-5) reduces voltage transients at the load,
preventing them from traveling back to the contacts where they would
produce a showering arc and couple with adjacent wiring.

Input Power Input Power

Discrete Discrete
input Load input Load

C R MOV

Discrete input Discrete input

module protection module protection

RC snubbing MOV snubbing

Figure 2-5 Load Noise Snubbing

TI545/TI555 System Manual Pre-installation Guidelines 2-9

Correcting Noise Problems (continued)

You can also use contact snubbing (shown in Figure 2-6) as an alternative
type of snubbing.

Both types of snubbing cause the physical devices to come on or go off more
slowly. The resistance-capacitance (RC) and metal oxide varistor (MOV)
elements should have minimal effect on system timing; their time constants
are substantially less than one millisecond.

Input Power Input Power

Discrete Discrete
input Load input Load

R C MOV

Discrete input Discrete input

module protection module protection

RC snubbing MOV snubbing

Figure 2-6 Contact Noise Snubbing

NOTE: Noise snubbing shown in Figure 2-6 is built into the PPX:505-5518
Relay Output module.

2-10 Pre-installation Guidelines TI545/TI555 System Manual

Noise Isolation The second approach to handling noise problems is to isolate the problem
device and its wiring from the electronics and associated signal wiring. You
may accomplish this by increasing the physical distance from some types of
noisy devices. For extreme cases, electrostatic (metal) shielding may be
required. This is true for noise sources outside as well as inside the
mounting cabinet (NEMA-type recommended).

Two cases of field wiring warrant special attention; wiring which enters the
harsh noise area to enable monitoring and control of those devices, and TTL
or low-level (less than 24 V) wiring. In these cases, supplement the physical
separation between control and noise-prone wiring with shielded,
twisted-pair wiring (12 twists/ft) for the control signals.

Process transmitters should normally be grounded at the transmitter end.

Use a single-point, shield ground as shown in Figure 2-7.

Shielding Shielding

Twisted Pair

Transmitter

Single-point ground To Controller I/O

Figure 2-7 Grounding Shielded, Twisted Pair Cables

TI545/TI555 System Manual Pre-installation Guidelines 2-11

2.7 Wiring Considerations

Guidelines Consider the following guidelines before installing any system or power
wiring.

• Always use the shortest possible single length cable.

• Avoid placing system and field wiring in the vicinity of high-energy

and/or high frequency wiring.

• Keep field input wiring, output wiring, and all other types of wiring in
the panel physically separated when possible.

• Consider separating DC field wiring from AC field wiring wherever

possible.

• Avoid sharp bends to power and data cables. Use 7.6 cm (3 inches)
radius on all bends.

• Ensure that a good low earth ground impedance of 0.1 ohm or less
exists for all components in the system.

• Use metal wireways and conduit when possible.

• Keep wire strippings from falling into modules, controllers, or bases.

• For long return lines to the power supply, do not use the same wire for
input and output modules. Using separate return wiring for these
modules minimizes the voltage drop on the return lines of the input
connections.

2-12 Pre-installation Guidelines TI545/TI555 System Manual

2.8 Power System Grounding

Earth Ground In some installations, a metal conduit that connects to the neutral phase at
the circuit-breaker box supplies the earth ground of the power receptacle.
Depending on site conditions, this metal conduit may conduct current from
other sources that can interfere with the operation of the equipment.

To reduce this possibility, isolate earth ground and neutral from the conduit
(except at the service entrance housing); see Figure 2-8. Ensure that system
power is wired in accordance with National Electrical Manufacturers
Association specifications. Also comply with the following:

• Ensure that the protective ground wire resistance is less than 0.1 ohm.

• Ensure that the resistance to earth ground is 0.1 ohm or less.

Power
company
transformer Circuit
Service breaker TI545/TI555
entrance Conduit panel Conduit Base
power supply
AC line

AC neutral

Ground

Protective
Ground
Power Earth
company ground rod
earth ground

Figure 2-8 Isolating Ground and Neutral From Conduit

TI545/TI555 System Manual Pre-installation Guidelines 2-13

Power System Grounding (continued)

Grounding the When installing the controller, ensure that noise is minimized by following
Controller these guidelines. Use the ground connection (Figure 2-9) to attach one end
of a ground wire; attach the other end to a nearby grounding rod that meets
all electrical specifications required for an earth ground. Use the shortest
possible length of #8-gauge copper wire, or equivalent braided cable to make
the connection.

Figure 2-9 Grounding the TI545/TI555 Controller

Grounding the If the controller is mounted in a cabinet or rack, use the same grounding
Cabinet or Rack procedure. Ensure that a good cabinet or rack ground connection is achieved
by removing existing paint and attaching a #8-gauge copper wire (or
equivalent) using a bolt, washers, and nut as necessary. You can attach the
other end of the wire to the same ground rod used to ground the controller.
Ground Use particular care when establishing the ground connections. The
Connections following techniques will help to establish good electrical connections and
decrease noise interference:
• Terminate grounding braid and green wires at both ends with copper
eye lugs to provide a good contact surface. Lugs should be crimped and
soldered.
• Use #10 copper bolts (or equivalent) for those fasteners providing
electrical connections to the single-point ground. This applies to
device-mounting bolts and braid termination bolts for subpanel and
user-supplied single points. Tapped holes for these fasteners are better
than nut-bolt arrangements.
• Paints, coatings, and corrosion can prevent good electrical contact at
ground points. Remove these impediments in the area of contact and
use external toothed lock washers (star washers) to ensure good
continuity and low impedance. This practice should be used for all
terminations — lug to subpanel, device to lug, device to subpanel,
subpanel to conduit, etc. Examples of ground connections are shown in
Figure 2-10.

2-14 Pre-installation Guidelines TI545/TI555 System Manual

 ! CAUTION A good grounding system is essential for proper operation of the
system. It is one of the most important considerations in planning
your installation.

Failure to provide a good grounding system could result in death or

serious injury to personnel and/or damage to equipment.

Ensure that you have a good grounding system when you install
your equipment.

Equipment Subpanel Step 1

Ground
braid
copper lugs
Star
washers Step 2

Star
washers
Step 2 Step 3 Subpanel
or user-supplied
Step 1 single point
ground

To ground equipment directly to the sub-panel, To attach ground leads to the sub-panel,
follow these steps: follow these steps:
1. Remove the finish from the equipment at 1. Remove the finish from the equipment at
areas of contact. areas of contact.
2. Tighten the first nut. 2. Tighten the bolt.
3. Tighten the second nut.
You may need a lock washer to prevent the nut
in Step 3 from backing off.

Figure 2-10 Example of Ground Connection

TI545/TI555 System Manual Pre-installation Guidelines 2-15

 Chapter 3
Installing Series 505 System Hardware
3.1 Overview of Installation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3.2 Series 505 Bases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Connecting Series 500 Bases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.3 Rack Mounting Series 505 Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
PPX:505–6516, 16-Slot Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.4 Panel Mounting Series 505 Bases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Series 505 Bases PPX:505–6516, PPX:505–6508, PPX:505–6504 . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.5 Installing Series 505 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Power Budget for Series 505 Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Power Supply Placement in Bases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Installing and Removing the Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.6 Installing the TI545/TI555 CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
CPU/RBC Location in a Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Installing and Removing the CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
CPU Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Setting CPU Dipswitches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Using Port 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Using Port 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Setting Baud Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Enabling Battery Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.7 Installing Series 505 Remote Base Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
RBC Placement in Bases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Dipswitches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Setting RS-232 Port Baud Rates (SW 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Series 505 RBC SW 3 (Factory) Dipswitch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Output State Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Installing and Removing Series 505 RBC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Assigning RBC Base Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Series 505 RBC LED Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3.8 Installing Series 505 I/O Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Mixing I/O Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Installing and Removing I/O Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

TI545/TI555 System Manual Installing Series 505 System Hardware 3-1

3.1 Overview of Installation Procedures

The following chart identifies the tasks for installing Series 505 system
hardware.

Install Base
• Rack mounting (Section 3.3)
• Panel mounting (Section 3.4)

Install Power Supply (Section 3.5)

Install TI545/TI555 Controller (Section 3.6)

Install Remote Base Controller (Section 3.7)

Install I/O Modules (Section 3.8)

3-2 Installing Series 505 System Hardware TI545/TI555 System Manual

3.2 Series 505 Bases

Description The controller is housed in a Series 505 base assembly. A base assembly has
slots for the programmable controller or remote base controller (RBC),
power supply, and the I/O modules. Four base assembly models are
currently available (see Table 3-1).

Table 3-1 Base Assembly Models

Model Number of Slots Mounting

PPX:505–6504 4 NEMA panel
PPX:505–6508 8 NEMA panel
PPX:505–6511 11 NEMA panel or rack
PPX:505–6516 16 NEMA panel or rack

Connecting Series Series 500 bases can be connected to a TI545/TI555 PLC system as a remote
500 Bases I/O base assembly. The TI545/TI555 controller is capable of addressing the
Series 500 base assembly through the RBC (PPX:500–5114–A). See
Appendix D for information about upgrading Series 500 bases.

Using the PPX:505–6860 RS-485/RF Converter the TI545/TI555 controller

can connect to the TI545/TI555 Bases in an RF I/O Channel using the
PPX:500–2114A or the TI505–6850–A RBCs. Refer to the SIMATIC TI505
Redundant I/O Systems User Manual, PPX:505–8125–x for additional
information.

TI545/TI555 System Manual Installing Series 505 System Hardware 3-3

3.3 Rack Mounting Series 505 Base

PPX:505–6516, Use the following steps, and Figure 3-1, for mounting the base in a standard
16-Slot Base 19-inch rack.

1. Align two bracket holes with two screw holes located on the sides of
base.

2. Secure each bracket to base with two screws installed through the
bracket holes.

3. Position the base in the 19-inch rack. Depth of base is 7.99 inches
(20.3 cm).

NOTE: There should be at least 6 inches (15.24 cm.) of clearance at the top
and bottom of base for adequate airflow.

4. Align two bracket slots with two screw holes located on each side of the
19-inch rack. See Figure 3-1.

5. Secure each bracket to the 19-inch rack with two screws installed
through the the bracket slots. See Figure 3-1.

Figure 3-1 Mounting Base to Standard 19-inch Rack

3-4 Installing Series 505 System Hardware TI545/TI555 System Manual

3.4 Panel Mounting Series 505 Bases

Series 505 Bases Use the following steps for panel mounting in an NEMA enclosure.
PPX:505–6516,
PPX:505–6508, 1. Open NEMA enclosure door.
PPX:505–6504
2. Drill four holes in sub-panel of NEMA enclosure with a #21 drill bit.
Refer to Figure 3-2 through Figure 3-4 for screw-hole dimensions for
each base.

NOTE: There should be at least 6 inches (15.24 cm.) of clearance at the top
and bottom of base for adequate airflow. The base depth is 7.99 inches
(20.3 cm.).

0.64 17.70 0.64

(16.26) (449.58) (16.26)

10.47
(265.94)
8.97
(227.81)

1.47
(37.31)

18.34
(465.84)

PPX:505–6516 and PPX:505–6511

Note: in.
(mm)

Figure 3-2 Screw-hole Dimensions for PPX:505–6516/6511 Bases

TI545/TI555 System Manual Installing Series 505 System Hardware 3-5

Panel Mounting Series 505 Bases (continued)

0.64 8.10 0.64

(16.26) (205.74) (16.26)

10.47
(265.94)
8.97
(227.81)

1.47
(37.31)

8.69
(220.79)
Note: in.
PPX:505–6504 (mm)

Figure 3-3 Screw-hole Dimensions for PPX:505–6504 Bases

3-6 Installing Series 505 System Hardware TI545/TI555 System Manual

 0.64 11.29 0.64
(16.26) (286.77) (16.26)

10.47
(265.94)
8.97
(227.81)

1.47
(37.31)

11.93
(303.2)
PPX:505–6508
Note: in.
(mm)

Figure 3-4 Screw-hole Dimensions for PPX:505–6508 Bases

TI545/TI555 System Manual Installing Series 505 System Hardware 3-7

Panel Mounting Series 505 Bases (continued)

3. Tap the drilled holes with a #10-32 tap.

4. Align two bracket holes with two screw holes located on each side of
base. See Figure 3-5.

5. Secure each bracket to base with two screws installed through the
bracket holes. See Figure 3-5.

Figure 3-5 Mounting Brackets to Base

6. Position the base inside the NEMA enclosure.

NOTE: Be sure that the bracket holes and the tapped holes in the sub-panel
are aligned.

7. Install #10 screws through each bracket hole to attach the base to the
sub-panel. See Figure 3-6.

Figure 3-6 Mounting Base in NEMA Enclosure

3-8 Installing Series 505 System Hardware TI545/TI555 System Manual

3.5 Installing Series 505 Power Supply

Power Budget for The total power consumption of all I/O modules (including the
Series 505 Base programmable controller and RBC) drawing power from a Series 505 power
supply must not exceed 55.0 W from the +5 VDC output and 3.75 W from
the –5 VDC output. Refer to Appendix B for power consumption listings for
the controller and all currently available Series 505 I/O modules and RBCs.

Power Supply See Figure 3-7 for power supply placement in Series 505 bases. The power
Placement in Bases supply must always be installed in the left-most slot.

C
P
P U I I I I I I I I
/ / / / / / / / / /
S R O O O O OO O O
B
C

Figure 3-7 Series 505 Module Placement in Base

Installing and Use the steps that follow to install or remove the Series 505 base power
Removing the supply.
Power Supply
1. Disconnect power to the base.

! WARNING Disable all power to the base before installing or removing any
module.

Failure to do so could cause death or serious injury and/or damage

to equipment.

Ensure that all power is disabled before you install or remove any
module.

TI545/TI555 System Manual Installing Series 505 System Hardware 3-9

Installing Series 505 Power Supply (continued)

! CAUTION Attempting to operate the PPX:505–6660 power supply at 220 VAC

with 110 VAC selected, or 110 VAC with 220 VAC selected, results in
damage to power supply.

Attempting to operate the PPX:505–6663 power supply outside the

designed voltage range of 20 to 30 VDC may cause damage to the
power supply.

Double check your power supply voltage before you attempt

operation.

2. Connect the voltage selector connector to TAB1 for 110 VAC input
power or TAB2 for 220 VAC input power when installing the
PPX:505–6660 power supply only. See Figure 3-8.

TAB2 TAB1

220 V 110 V

Figure 3-8 Selecting Input Voltage—PPX:505–6660 Only

3. Position the power supply so that the bezel is facing you.

4. Grasp the top and bottom of the power supply.

5. Carefully push the power supply into the slot until it mates with the
backplane connectors.

6. Tighten top and bottom bezel screw. (Refer also to Figure 3-10.)

To remove the Series 505 Power Supply, simply reverse the procedures used
during installation.

3-10 Installing Series 505 System Hardware TI545/TI555 System Manual

3.6 Installing the TI545/TI555 CPU

CPU/RBC Location The CPU/RBC must always be installed in the second slot from the left
in a Base (beside the power supply module), as shown in Figure 3-9.

C
P
P U I I I I I I I I
/ / / / / / / / / /
S R O O O O OO O O
B
C

Figure 3-9 Location of CPU/RBC in a Series 505 Base

! CAUTION Electronic equipment can be damaged by electrostatic discharge.

Ensure that personnel make contact with a grounded conductive

pad and/or wear a grounded wrist strap when handling the
controller cards or modules.

TI545/TI555 System Manual Installing Series 505 System Hardware 3-11

Installing the TI545/TI555 CPU (continued)

Installing and Refer to Figure 3-10 and follow the steps below to install the CPU.
Removing the CPU
1. Disconnect power to the base.

! WARNING Disable all power before installing or removing the CPU.

Failure to do so could cause death or serious injury and/or damage
to equipment.
Ensure that all power is disabled before installing or removing the
CPU.

2. Position the CPU so that the bezel is facing you.

3. Grasp the top and bottom of the CPU module.

4. Carefully push the module into the slot until it mates with the back
plane connectors.

5. Tighten top and bottom bezel screws.

To remove the CPU, disconnect the RS-485 cable from the I/O port, if it is
connected, and reverse the installation procedure.

Minimum torque: 2.61 in-lb (0.3 N-m)

Maximum torque: 5.22 in-lb (0.6 N-m)

Figure 3-10 Installing CPU Module in a Series 505 Base

3-12 Installing Series 505 System Hardware TI545/TI555 System Manual

CPU Battery A permanent, rechargeable battery protects user memory and programs
during a power cycle. Battery backup typically lasts six months at
temperatures ranging from 0° to 60°C provided the battery was fully
charged.
If the battery LED does not light, the battery may be discharged. A blinking
LED indicates a marginal charge. The LED lights steadily when the battery
is sufficiently charged with the switch enabled and power applied. The
battery will be only be fully charged following 36 hours of being powered
after the LED first lights steadily.
Because the CPU contains a 3 V lithium battery that is soldered in the CPU
module, the CPU must be sent to the factory to replace the battery. Refer
also to Section 7.2 for more information on the battery LED.

! CAUTION Battery Damage: Do not leave the unit powered down with the
battery switch on for longer than six months.
Doing so could damage the battery to the point it cannot be
recharged.
Return a unit in this condition to the factory for battery
replacement.

Setting CPU Dipswitches are used to set CPU operating parameters. The dipswitches are
Dipswitches located near the front of the CPU behind the bezel door; see Figure 3-11. To
gain access, lower the access door. With the CPU in its (normal) vertical
position, dipswitches pushed to the left are On; dipswitches pushed to the
right are Off.

ON OFF

Port 2 = RS-232/422 Port 2 = RS-485

Port 1 = Programming port Port 1 = Printer port

Port 1
Baud rate

Dipswitch
Port 2
Baud rate

Battery ON Battery OFF

Not used

Figure 3-11 CPU Dipswitch Location

TI545/TI555 System Manual Installing Series 505 System Hardware 3-13

Installing the TI545/TI555 CPU (continued)

Using Port 1 Switch 2 selects Port 1 as, either a programming port, or a printer port; see
Figure 3-12 for port locations. This port uses a RS-232/RS-423 signaling
protocol and uses a RS-232 pinout arrangement with a RS-423 (+5 V) signal
level extending up to 50 feet. A modem may be used to increase the cable
distance.
• Setting Switch 2 to the left selects Port 1 as a programming port.
• Setting Switch 2 to the right selects Port 1 as a printer port.

Using Port 2 Selection between RS-232/RS423 or RS-422/RS-485 is accomplished by

cabling. If RS-422/RS-485 cabling is used, then dipswitch 1 selects between
RS-422 and RS-485 (see Figure 3-11). The cable installation for RS-485 or
RS-422 can include a 120-ohm termination resistor across the signal
conductors at each end of the cable. The resistor provides a higher noise
immunity and better long-distance communication (see Figure 3-12).

• RS-232/RS-423 connection for Operator Interface up to 50 feet.

• RS-422/RS-485 connection to 3300 feet (1 km).

Switch 1 is used as follows:

• When RS-232 or RS-422 cabling is used, set Switch 1 to the left.
• When RS-485 cabling is used, set Switch 1 to to the right. RS-485 uses
a single twisted pair to transmit and receive data between the
programming device and the CPU. Multiple CPUs or multiple
programming devices (on this RS-485 link) are currently not supported
and should not be used.

Port 1 Port 2 (1) Port 2 (1) Port 2 (2)

RS-232 Port Pinouts RS-232 Port Pinouts RS-422 Port Pinouts RS-485 Port Pinouts
Controller Controller Controller Controller
Male 9-Pin D Type Male 9-Pin D Type Male 9-Pin D Type Male 9-Pin D Type

Pin Signal Pin Signal Pin Signal Pin Signal

1 RSD 2 RCV 3 DO+ 3 TX/RX+
2 RCV 3 XMT 9 DI+ 8 TX/RX–
Port 1
3 XMT 5 GND 5 GND 5 GND
4 DTR 8 DO–
5 GND 2 DI–
Port 2 6 DSR
7 RTS Termination resistors can be
(1) Dipswitch 1 is ON used for higher noise immunity
8 CTS (2) Dipswitch 1 is OFF and better long-distance
communication.

Figure 3-12 TI545/TI555 CPU Port Locations

3-14 Installing Series 505 System Hardware TI545/TI555 System Manual

Setting Baud Rates Switches 3 through 8 are used to set baud rates for Ports 1 and 2. Switches
3, 4, and 5 set Port 1 baud rates (Table 3-2). Switches 6, 7, and 8 set Port 2
baud rates (Table 3-3).

Table 3-2 Port 1 Baud Rate Settings

Dipswitches
Baud Rate 3 4 5
19200 On On On
9600 Off On On
2400 Off Off On
1200 Off On Off
300 Off Off Off

Table 3-3 Port 2 Baud Rate Settings

Dipswitches
Baud Rate 6 7 8
19200 On On On
9600 Off On On
2400 Off Off On
1200 Off On Off
300 Off Off Off

Enabling Battery Switch 9 is used to set the backup battery On or Off; see Figure 3-11.
Backup Moving the switch to the left sets the backup battery On; setting the switch
to the right sets the backup battery Off.

NOTE: The battery in the CPU is rechargeable. The battery LED indicates
the state of the battery backup circuit (when switch 9 is ON) as follows:

OFF Low Battery backup will not work

FLASHING Marginal or charging backup may work
ON Good battery backup should work

TI545/TI555 System Manual Installing Series 505 System Hardware 3-15

3.7 Installing Series 505 Remote Base Controller

RBC Placement in The RBC must always be installed in the second slot from the left (adjacent
Bases to the power supply module) in a remote base.

Dipswitches There are two dipswitches, SW 2 and SW 3, located on the components side
of the RBC. SW 2 (Figure 3-13) is used to set baud rates. SW 3 is a
factory-use-only switch.

Off
SW 2 Front bezel

1 2 3 4
On

Figure 3-13 RBC Dipswitch Location

Setting RS-232 Port Dipswitch SW 2 is used to set baud rates for the RBC RS-232 port. The
Baud Rates (SW 2) RS-232 port is used to program the controller or to troubleshoot from a
remote I/O base.

See Figure 3-13 for positions of SW 2 on the board; refer to Table 3-4 for
individual dipswitch settings.

Table 3-4 RBC SW 2 (RS-232 Port) Baud Rate Settings

Dipswitch
Baud Rate 1 2 3 4

19200 On (1) On (1) Off (0) On (1)

9600 On (1) On (1) On (1) On (1)
2400 Off (0) On (1) On (1) On (1)
1200 On (1) Off (0) On (1) On (1)
300 Off (0) Off (0) On (1) On (1)

3-16 Installing Series 505 System Hardware TI545/TI555 System Manual

Series 505 RBC The factory dipswitch, labeled SW 3 on the board is for factory use only. Do
SW 3 (Factory) not change the settings on this dipswitch. If the dipswitch setting is
Dipswitch Settings accidentally changed, or you are installing a new RBC, refer to Table 3-5 for
the proper dipswitch settings.

Table 3-5 Series 505 RBC SW 3 (Factory) Dipswitch Setting

Dipswitch
1 2 3 4
On Off Off Off

Output State You can select the state you want the outputs, controlled by the RBC, to be
Selection set to whenever a communication error occurs. Previous models of the RBC
automatically set all outputs to off (0) when communication is lost. The A
version of RBCs allow you to either freeze the outputs in the state they were
in when communication was lost, or have the outputs set to off (0).

! WARNING Energized parts could fail in an unsafe condition.

If the RBC fails or the system loses power, the outputs will go off (0)
regardless of the jumper selection.

This could cause damage to equipment or death or injury to

personnel.

TI545/TI555 System Manual Installing Series 505 System Hardware 3-17

Installing Series 505 Remote Base Controller (continued)

The RBC has a jumper to select the output state during a communication
loss (Figure 3-14). If the output modules in the remote base have a selection
switch, the freeze selection will override the output module’s selection.

Outputs off
(default)
OFF FRZ

Freeze

OFF FRZ

Figure 3-14 Series 505 RBC Jumper Locations

3-18 Installing Series 505 System Hardware TI545/TI555 System Manual

Installing and Use the following steps to install and remove a Series 505 RBC.
Removing
Series 505 RBC
! CAUTION The RBC can be damaged by electrostatic discharge.

Ensure that personnel make contact with a grounded conductive

pad and/or wear a grounded wrist strap when handling the RBC.

1. Disconnect power to the base.

! WARNING Disable all power to the base before installing or removing the
RBC.

Failure to do so could cause death or serious injury and/or damage

to equipment.

To prevent disruption of the I/O channel, disconnect the RS-485

cable before removing or installing an RBC.

2. Position the RBC so that the bezel is facing you.

3. Grasp the top and bottom of the RBC.

4. Carefully push the RBC into the slot until it mates with the back plane
connectors.

5. Tighten top and bottom bezel screws.

To remove the RBC module, complete these steps.

1. If attached, remove cables from the front of the RBC.

2. To complete the removal of the RBC module, simply reverse procedures

used during installation.

Assigning RBC A base thumbwheel is used to assign a base number to the RBC for system
Base Numbers identification. If you are using more than one RBC, each RBC must be
uniquely numbered. Base numbers are the same as the thumbwheel
number except for base 0, which is reserved for local base assignment and
cannot be used by Series 505 RBCs.

TI545/TI555 System Manual Installing Series 505 System Hardware 3-19

Installing Series 505 Remote Base Controller (continued)

! WARNING Control devices can fail in an unsafe condition that could result in
death or serious injury and/or damage to equipment.
Do not change the base thumbwheel numbers when the system is
operating. This may cause the base to be logged off the system.
When the base is logged off the system, all discrete outputs will be
turned off, analog outputs will be frozen, and word and discrete
inputs will go to 0.

Series 505 RBC The display at the top of the module (see Figure 3-15) indicates the status of
LED Display the Series 505 RBC. Status is displayed in integer format; see Table 3-6 for
definitions of the displays.

Table 3-6 Series 505 RBC LED Messages

Display Definitions
0 RBC Good
1 Self Diagnostics Failure
2 Module Mismatch
3 I/O Communication Time Out
4 RAM Parity Error
5 Standby, No Configuration
6 Address Mismatch
7 Communication Good, No Configuration
8 Watchdog Time Out
C Standby, Configuration

LED Display

Base Thumbwheel

RS-232 port (male)

I/O port (female)

Figure 3-15 Series 505 Remote Base Controller

3-20 Installing Series 505 System Hardware TI545/TI555 System Manual

3.8 Installing Series 505 I/O Modules

Mixing I/O A mix of I/O modules can be used with one base; you can combine input,
Modules output, word input, word output, and intelligent modules in a single base.

Installing and Use the following steps for installing and removing Series 505 I/O modules
Removing in the base. (Refer to Figure 3-16.)
I/O Modules
1. Disconnect power to the base.

! WARNING Disable all power to the base before installing or removing I/O
modules.
Failure to do so could cause death or serious injury and/or damage
to equipment.
Ensure that all power is disabled before you install or remove I/O
modules.

2. Use specification sheets provided with the modules to install option and
wiring selections for your application.
3. Position the I/O module so the bezel is facing you.
4. Grasp the top and bottom of the I/O module.
5. Carefully push the I/O module into the slot until it mates with the back
plane connectors.
6. Tighten top and bottom bezel screws.

Minimum torque: 2.61 in-lb (0.3 N-m)

Maximum torque: 5.22 in-lb (0.6 N-m)

Figure 3-16 Installing and Removing Modules in a Series 505 Base

To remove the I/O module, reverse procedures used during installation.

TI545/TI555 System Manual Installing Series 505 System Hardware 3-21

 Chapter 4
Cabling and Wiring the System
4.1 Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Wiring Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2 Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Cable Routing Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Under-Floor Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
In-Ceiling Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Surface Duct Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Mounting the Tap or Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.3 Installing Remote I/O Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Cabling Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Trunk and Drop Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
User-Supplied Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Mounting the Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Programmable Controller and RBC Drop Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Preparing Cables (for Drop Lines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Connecting a CPU Drop Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Connecting the RBC Drop Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Connecting Terminal Block Trunk Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Alternate Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Configuration Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Preparing Trunk Line Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Connecting Trunk Line to Terminal Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4.4 Connecting Modems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Dedicated Line Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Dial-up Phone Line Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4.5 Connecting a Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

TI545/TI555 System Manual Cabling and Wiring the System 4-1

4.1 Connecting Input Power

Guidelines To connect the Series 505 power supply, and the Series 500 remote I/O base
to the external power source, follow these guidelines.

• Use 14 AWG solid or stranded wire. If you use stranded wire, the wire
should be twisted and trimmed.

• Strip insulation back 0.40 inches (10mm).

• Insert the wires fully into the terminal block so that the insulation
butts against the block.

Wiring Use the following steps for connecting input power to the power supply. See
Power Supply Figure 4-1.

1. Disconnect power to the base.

! WARNING Disable all power before attempting the wiring procedures.

Failure to do so could cause death or serious injury and/or damage
to equipment.
Ensure that all power is disabled before attempting the wiring
procedures.

2. Loosen three power connector screws.

3. Connect wires as appropriate for your power supply module.

Model PPX:505–6660A: insert ground, neutral, and AC line wires into

socket on the power supply. This power supply requires 110 or 220 VAC.

! CAUTION Ensure that PPX:505–6660A power supply is set to operate on 110

VAC or 220 VAC to match the input power. See Chapter 3 for
selecting voltage for this power supply.
Attempting to operate the power supply at 220 VAC with 110 VAC
selected, or 110 VAC with 220 VAC selected, will result in damage to
the power supply.
Double check your power supply voltage before you attempt the
operation.

Model PPX:505–6663: insert chassis ground, DC–, and DC+ line wires
into socket on the power supply. This power supply requires 24 VDC.

4-2 Cabling and Wiring the System TI545/TI555 System Manual

 4. Tighten screws.

5. Refer to Chapter 2 for grounding guidelines.

Siemens
SIMATIC
TI505
DC POWER GOOD

AC LINE
AC NEUTRAL
GROUND

Figure 4-1 Supplying Power with the PPX:505–6660A

TI545/TI555 System Manual Cabling and Wiring the System 4-3

4.2 Cable Routing

Guidelines Follow these suggestions when planning your cable routing.

• Allow for system growth. Provide for attachment of future I/O bases by
routing cable through all possible areas of plant expansion.

• The TI545/TI555 can have a trunk line (attached to its I/O) that
extends up to 3300 feet (1000 m) using RS-485 (twisted pair) cables.

• Take steps to bypass or eliminate noise sources to reduce system data

error rates. The following are common sources of electrical noise.

V Power distribution mains

V Arcing motors
V Fluorescent lighting
V Undesired signal transfer between adjacent circuits
V Poor terminations of cable connector

• Do not allow the trunk cable to come into contact with any other
electrical conductor.

• If cabling is installed inside a conduit, the conduit should be grounded

according to applicable electrical codes.

• Maintain a minimum of 3 feet (0.91 m) between trunk lines and the

following noise sources.

V Power lines
V Electric motors and motor starters
V Generators
V Electric welders

Cable Routing The type of routing is usually determined by the type of building in which
Methods the cables are being installed. Any combination of the following may be used
to route the cables: under-floor, in-ceiling, or surface duct.

NOTE: Electrical and fire safety must be considered in planning the

installation. Modern codes seek to limit the hazard of cable installations as
a means of propagating fire and smoke. In order to ensure a proper level of
safety compliance, observe local installation code practices and guidelines.

4-4 Cabling and Wiring the System TI545/TI555 System Manual

Under-Floor In under-floor routing, the cable can be enclosed in ducts or, with raised
Routing flooring, in the open air.

• Duct systems are better protected against unauthorized taps or

terminal blocks, but expansion is more difficult and expensive than
with open air systems.

• Open air systems provide more freedom of access, and allow maximum
system expansion and flexibility.

In-Ceiling Routing For in-ceiling routing, cables are usually supported in troughs or with hooks
and clamps every 10 or 15 feet (3.05 or 4.57 m).

Some advantages of in-ceiling routing follow:

• Flexibility.

• Low cost installation.

• Accessibility of cabling.

Some disadvantages of in-ceiling routing are:

• Collection of dust and other debris in ceilings.

• Hazardous working conditions in ceilings.

• Impracticality for buildings without drop ceilings.

Surface Duct Surface ducting is usually installed along baseboards or attached to walls at
Routing desktop height. While surface ducting ordinarily protects cables from both
physical and electro-magnetic (E/M) effects, it usually requires I/O bases to
be positioned near a wall.

NOTE: Consult your cable vendor for proper cable-pulling techniques so that
no kinks occur in the cable during installation.

Mounting the Tap Installation procedures for mounting the tap or terminal block depend upon
or Terminal Block the cable installation technique used. Refer to mounting instructions
provided by the tap or terminal block vendor.

TI545/TI555 System Manual Cabling and Wiring the System 4-5

4.3 Installing Remote I/O Cables

Cabling Options Effective with Firmware Release 3.0 the TI545/TI555 provides two cabling
options for the remote I/O system:

• Non-redundant I/O cabling using twisted pair (RS-485) media.

• Redundant I/O cabling using coaxial (RF) media.

This manual describes the twisted pair media. If you are installing a
Redundant I/O system follow the instructions in the SIMATIC TI505
Redundant I/O Systems User Manual, PPX:505–8125–2.

Trunk and Drop Use RS-485 cabling to install your trunk and drop lines after you have
Lines installed other system hardware items.
Figure 4-2 shows a typical application. The following sections provide
information on cabling the TI545/TI555 controller and RBCs designed for
RS-485 cables. These models are as follows:

• Programmable Controller — PPX:545–1102, PPX:555–1101, or

PPX:555–1102.

• RBC — PPX:505–6851–A for Series 505 bases.

• RBC — PPX:500–5114–A for Series 500 bases (see Appendix D).

Local
Base
Drop Line

T T T

Trunk Lines

Remote Remote
Base Base
Drop Lines
T = Terminal Block

Figure 4-2 Trunk and Drop Line Example

4-6 Cabling and Wiring the System TI545/TI555 System Manual

User-Supplied User-supplied components are listed below:
Equipment
• RS-485 cables.

• Taps (terminal blocks).

• 9-Pin D-connectors (male) and shell.

• Terminal lugs.

Mounting the Installation procedures for mounting the terminal block depend upon the
Terminal Block cable installation technique used. Refer to mounting instructions provided
by the terminal block vendor for additional information.

Programmable The cable that connects the programmable controller and RBC to a terminal
Controller and block is called a drop line (Figure 4-2). Belden
cable type 9271 and 9182
RBC Drop Lines should be used for all drop lines.

NOTE: If the trunk line is Belden cable type 9182, the drop line must be
Belden cable type 9182.
If the trunk line is Belden cable type 9860 or 9271, the drop line can be
Belden cable type 9271 or 9182.

TI545/TI555 System Manual Cabling and Wiring the System 4-7

Installing Remote I/O Cables (continued)

Preparing Cables Use the following procedures to prepare drop line cables to connect the
(for Drop Lines) programmable controller and RBC to terminal blocks:

1. Strip back 1.50 inches (3.8 cm) of the sleeving on one end of the cable.
There are three wires when the sleeving is stripped back; two wires
have color coded insulation jackets and one is bare.

2. Remove 0.13 in. (0.33 cm) of each color coded insulation jacket to
expose the bare wires.

NOTE: One wire should already be bare.

3. Install the cable wires to a 9-pin D-connector according to directions

provided by the connector vendor.

NOTE: Install the wire without insulation to pin #5 of the 9-pin D-connector.
Install the wires with the color-coded insulation to pins #3 and #8.
It does not matter which wire is installed to pin #3 or #8, but all connectors
must be installed identically. See Figure 4-3 for pin-out information.

5
9 Ground (5)
Signal (8) Signal (3)

6 1

Figure 4-3 9-Pin I/O Female D-Connector Pinout

4-8 Cabling and Wiring the System TI545/TI555 System Manual

 4. Strip back 1.50 in. (3.8 cm) of the sleeving on the other end of the cable.

5. Remove 0.13 in. (0.33 cm) of each color-coded insulation to expose the
bare wires.

6. Install each wire end onto a terminal lug according to directions

provided by the vendor.

NOTE: The size of the terminal lug depends on the type of terminal block
used. Consult your vendor for the appropriate terminal lug size.

Connecting a CPU Use the following procedure to connect a drop line cable between the
Drop Line programmable controller and terminal block.
1. Ensure that the cable has been prepared as described on page 4-8.

2. Plug the cable D-connector onto the CPU I/O connector.

3. Tighten two cable connector screws to secure the cable D-connector to

the CPU I/O connector.

4. Loosen three terminal screws on the terminal block and install the
cable lug terminals onto the terminal block. See Figure 4-4.

From TI545/TI555

Figure 4-4 Connecting to Terminal Block

5. Tighten terminal block screws.

TI545/TI555 System Manual Cabling and Wiring the System 4-9

Installing Remote I/O Cables (continued)

6. If you are not using another terminal block, install a terminating

resistor across the terminal screws securing the cable wires with the
colored coded insulation jacket. See Figure 4-5.

NOTE: The terminating resistor value depends on the type of cable being
used. See Table 4-1.

From CPU
Terminating
Resistor

Figure 4-5 Adding a Terminating Resistor

Table 4-1 Terminating Resistors

Cable Type Resistor Value Color Code

9860 120 Ohms Brown-Red-Brown-Gold
9271 120 Ohms Brown-Red-Brown-Gold
9182 150 Ohms Brown-Green-Brown-Gold

4-10 Cabling and Wiring the System TI545/TI555 System Manual

Connecting the Use the following procedure to connect a cable between the RBC and
RBC Drop Line terminal block.

1. Prepare another cable as described on page 4-8.

2. Place the cable D-connector onto the RBC RS-485 connector.

3. Tighten two cable connector screws to secure the cable D-connector to

the RBC RS-485 connector.

4. Loosen three terminal screws on the terminal block and install the
cable terminal lugs onto the terminal block. See Figure 4-6.

NOTE: Ensure that the RBC cable wires match with the CPU cable wires at
the terminal block. For example, if a wire at a bottom terminal screw is
blue, the wire directly above it must also be blue.

From CPU

To RBC

Figure 4-6 Attaching RBC to Terminal Block

TI545/TI555 System Manual Cabling and Wiring the System 4-11

Installing Remote I/O Cables (continued)

Connecting The cable that connects the terminal blocks is called a trunk line. See
Terminal Figure 4-2. The maximum trunk length depends on the cable type and
Block Trunk Lines number of terminal blocks used in your installation. See Table 4-2.

Table 4-2 Maximum Cable Length for Trunk Lines

Maximum Distance in Feet (Meters)*

Number of (Belden Cables)
Terminal Blocks
9860 cable 9271 cable 9182 cable

2–5 3300 (1006) 1100 (335) 2200 (670)

6 3200 (975) 1067 (325) 2133 (650)
7 3100 (945) 1033 (315) 2067 (630)
8 3000 (914) 1000 (305) 2000 (610)
9 2900 (884) 967 (295) 1933 (589)
10 2800 (853) 933 (284) 1867 (569)
11 2700 (823) 900 (274) 1800 (548)
12 2600 (792) 867 (264) 1733 (528)
13 2500 (762) 833 (254) 1667 (508)
14 2400 (732) 800 (244) 1600(488)
15 2300 (701) 767 (234) 1533 (467)
16 2200 (671) 733 (223) 1467 (447)
17 2100 (640) 700 (213) 1400 (427)
*Figures in parentheses indicate distance in meters.

NOTE: Cable types 9860 and 9271 can be mixed on the trunk line, but cable
type 9182 must be used alone.

4-12 Cabling and Wiring the System TI545/TI555 System Manual

Alternate Cables Three commercially available cables provide an acceptable level of I/O
communication in an industrial environment when used in accordance with
Table 4-2.

• Belden cable 9860 is a large conductor cable that provides a low

attenuation and distortion for long trunk lines.

• Belden cable 9271 is a smaller and more flexible cable suitable for short
trunk lines and all drop line cables.

• Belden cable 9182 provides an intermediate level of size, flexibility, and

useful length. The 9182 cable is also available in a version (89182)
rated for a higher level of fire resistance and low smoke producing
properties.

Alternate cables should have a specified characteristic impedance between

100 and 150 ohms; 124 ohms being optimum. Other considerations for
alternate cables include: a high uniform twist and spacing of conductors
(usually found in cables called “twinaxial”), shield coverage approaching
100%, DC resistance of the installed cable length smaller than the
characteristic impedance, and a jacket suitable for the installation.

Characteristics of the cables listed in Table 4-2 are provided in Table 4-3 as
a guide for selecting alternate cables.

Table 4-3 Cable Characteristics

Belden Center Outside

Impedance Capacitance Velocity
Cable Type Conductor Diameter
16 AWG solid
9860 11.18 mm 124 ohms 35.8 pf/m 0.78 c
13.8 ohm/km
25 AWG 7x33
9271 6.15 mm 124 ohms 40 pf/m 0.66 c
104.3ohm/km
9182 22 AWG 19x34
8.89 mm 150 ohms 28.9 pf/m 0.78 c
(89182) 46 ohm/km

TI545/TI555 System Manual Cabling and Wiring the System 4-13

Installing Remote I/O Cables (continued)

Configuration Follow these guidelines when installing RS-485 trunk line cabling.
Requirements
• Measure the maximum length (listed in Table 4-2) from the CPU to the
most distant tap. See Figure 4-7.

P
L
C
*Terminating
*Terminating Resistor
Resistor Maximum Trunk Length

T T T T

T = Terminal Block

*A terminating resistor must be installed on the end terminal blocks. If only one terminal block is
used, a terminating resistor must be installed on that terminal block. See Figure 4-11 for details.

Figure 4-7 Maximum Trunk Length

• By using a T configuration (Figure 4-8), you can increase the total

trunk line length to twice the length specified in Table 4-2.

P
L
C
*Terminating
*Terminating Resistor
Resistor Max. Trunk Length Max. Trunk Length

T T T T T T T

Total Trunk Line Length

T = Terminal Block
*A terminating resistor must be installed on the end terminal blocks. If only one terminal block is
used, a terminating resistor must be installed on that terminal block. See Figure 4-11 for details.

Figure 4-8 T Configuration

• Drop lines should be no longer than 10 m (33 feet).

• Short drop lines of 1 m (3.3 feet) do not measurably affect signal quality
and do not have to be counted for the length reduction shown in
Table 4-2.

4-14 Cabling and Wiring the System TI545/TI555 System Manual

 • Where several connections need to be made close together, it is better to
place a single terminal block in the trunk line and connect all nearby
equipment to that terminal block (Figure 4-9).

Make multiple connections like this... ... or this...

T
Remote
Base
Remote
Base
Remote
Base T
Remote
Base
Remote
Base
Remote
Base

T T T
... but not like this.

Remote Remote Remote

Base Base Base

Figure 4-9 Multiple Tap Connections in Close Proximity

• Tap connections on the trunk line should be spaced, on average, so that

the total length of trunk cable separating several taps is greater than
the sum of the total length of drop cables connected at the taps
(Figure 4-10).

L3

T T

L1 L2

Remote Remote
Base Base

L3 > (L1 + L2)

Figure 4-10 Spacing between Taps

TI545/TI555 System Manual Cabling and Wiring the System 4-15

Installing Remote I/O Cables (continued)

• The ideal cable installation is a single, unbranched trunk line with

short drop cables and a termination resistor at each end of the trunk.

NOTE: For installations with five connections or less that have a cable
length between the controller and the most distant RBC less than 30m
(100 feet), any cable configuration can be used. Always use at least one
termination resistor, even with the simplest installation.

Preparing Trunk Use the following procedures to prepare trunk-line cables for connecting
Line Cables terminal blocks.

1. Strip back 1.50 in. (3.8 cm) of the sleeving on both ends of the cable.

NOTE: You will see three wires when the sleeving is stripped back. Two
wires have color coded insulation jackets and one is bare.

2. Remove 0.13 in. (0.33 cm) of each color-coded insulation jacket (both
ends) to expose the bare wires.

NOTE: One wire is already bare.

3. Install each wire (both cable ends) onto a terminal lug according to
directions provided by the vendor.

NOTE: The size of the terminal lug depends on the type of terminal block
used. Consult your vendor for the appropriate terminal lug size.

4-16 Cabling and Wiring the System TI545/TI555 System Manual

Connecting Trunk Use the following procedures to connect two terminal blocks. See
Line to Terminal Figure 4-11.
Blocks
1. Loosen three terminal screws on terminal block A and install second
set of cable terminal lugs onto the terminal block.

NOTE: Ensure that the wires of the second set of terminal lugs match with
those of the first set of terminal lugs. For example, if a wire at a terminal
screw is blue, the second wire installed with it on the same terminal screw
must also be blue.

First set of terminal lugs were previously installed

Second set of terminal lugs

Terminating
resistor

Terminal Block A Terminal Block B

Figure 4-11 Connecting Terminal Blocks

2. Tighten screws on terminal block A.

3. Loosen three screws on terminal block B.

4. Install the terminal lugs on the other cable end to the terminal screws
in terminal block B.

5. Tighten screws on terminal block B.

6. If you are not using another terminal block, install a terminating

resistor across the terminal screws that secure the cable wires with the
colored coded insulation.

NOTE: The terminating resistor value depends on the type of cable being
used; see Table 4-1. A terminating resistor must be installed on the end
terminal blocks.

Refer to Chapter 7 for procedures to check for faulty cables.

TI545/TI555 System Manual Cabling and Wiring the System 4-17

4.4 Connecting Modems

Overview The CPU can communicate through Port 1 to an operator interface via
dedicated line or dial-up phone modems. Dedicated line operation is a line
used exclusively to connect the modems. Dial-up phone operation connects
the modems by telephone lines. Refer to Figure 4-12 for a typical
configuration.

NOTE: The modems must provide an EIA RS-232C DCE interface to the
TI545/TI555 controller and operator interface and must have a built-in V.32
error correction capability.

Although the TI545 and TI555 controllers support both full- and half-duplex
communications, TISOFT only supports full-duplex communications.

25-9 Pin female adapter, 25-9 Pin female adapter,

INMAC 359–4 (or equivalent) INMAC 359–4 (if needed)

EIA RS-232C EIA RS-232C

connector connector
TI555

RS-232 Modem Modem Programming

(9-Pin Port) Device

Cable Cable
(2462553–0001) (2462553–0001)
Connect in accordance
with the modem manual

Figure 4-12 Modem Configuration

4-18 Cabling and Wiring the System TI545/TI555 System Manual

Dedicated Line Use these procedures to establish communication between modems in a
Operation dedicated line configuration.

1. Connect the modem configuration.

2. Ensure that the CPU controller and modem baud rates are set to the
same value.

NOTE: If the modems are auto-bauding, ensure that the controller baud rate
is set within the baud rate range of the modems.

3. Power up the modems and verify that they are connected—usually by

an indicator on the modems.

4. Execute TISOFT; TISOFT auto-bauds to the system’s baud rate (CPU

and modem).

Dial-up Phone Line Use these procedures to establish communication between modems in a
Operation dial-up phone line configuration.

1. Connect the modem configuration.

2. Ensure that the CPU controller and modem baud rates are set to the
same value.

3. Depending on the type of modems being used, the following are three
ways to establish communication between the modems.

• Manually call from one modem station to the other modem station
and then switch on both modems.

• Manually call from one modem station to an auto-answer modem

at the other station.

• Use TIDIAL dialing software installed with TISOFT Release 5.0 to

call an auto-answer modem at the PLC modem station.

4. Execute TISOFT; TISOFT auto-bauds to the system’s baud rate (CPU

and modems).

TI545/TI555 System Manual Cabling and Wiring the System 4-19

4.5 Connecting a Printer

Overview The CPU has the capability to send information to a printer through the use
of an SF program or SF subroutine. The printer connects to Port 1 and uses
RS-232 protocol. Cabling for the two available handshaking options are as
follows:

• XON/XOFF printer handshaking; see Figure 4-13.

• READY/BUSY printer handshaking; see Figure 4-14.

RSD 1
DSR RCV XMT
RTS 6
XMT RCV
Serial Printer
CTS or
DTR
GND Programming
9 Device
5
RTS

CTS
Port 1 (RS-232/423)

NOTE: Set dipswitch 2 on the Not required for all printers

CPU to the OFF
position for printing.

Figure 4-13 XON/XOFF Printer Handshaking

RSD 1
DSR
6
XMT RCV
Serial Printer
DTR CTS CTS
9 GND
5

Port 1 (RS-232/423)

NOTE: Set dipswitch 2 on the

CPU to the OFF
position for printing.

Figure 4-14 READY/BUSY Printer Handshaking

4-20 Cabling and Wiring the System TI545/TI555 System Manual

 Chapter 5
Using an EEPROM or EPROM
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Program Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Using an EEPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Using an EPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
EEPROM Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.2 TI545/TI555 Memory and Mode Status at Power-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

5.3 Installing EEPROMs and EPROMs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5.4 Copying a Program into an EEPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

5.5 Editing a Program Stored in EEPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

TI545/TI555 System Manual Using an EEPROM or EPROM 5-1

5.1 Introduction

Program Storage The CPU offers the option of storing your application program in
non-volatile form. Using Electrically Erasable Programmable Read-Only
Memory (EEPROM), or Erasable Programmable Read-Only Memory
(EPROM [UV-EPROM]), is discussed in the following sections. See Table 5-1
for a description of available EEPROMs and EPROMs.

Table 5-1 Program Storage Using EEPROM and EPROM

Storage Type Size Order Number

EEPROM 128K bytes 2587681–8022
EEPROM 256K bytes 2587681–8030
EPROM 128K bytes 2587681–8023
EPROM 256K bytes 2587681–8031

After your EEPROM has been programmed, it is portable; that is, it can be
used in any other TI545–1102 or TI555 controller.

Using an EEPROM If you install an EEPROM, the CPU allows you to save your current
program without using a separate EEPROM programming device. The
program can be downloaded directly from RAM to a 128K byte or 256K byte
EEPROM by using Auxiliary Function 84. Complete instructions on storing
a program using an EEPROM appear later in this chapter. Refer to
Table 5-2 for EEPROM compatibility.

Table 5-2 EEPROM/EPROM Portability Between Controllers

Controller / Firmware Release Can Use EEPROM / EPROM From:

TI545–1102* or TI555 with

TI545, TI555 with any firmware release.
Firmware Release 3.0 or later.
TI545–1101 with any firmware release.
TI555 with Release 1.1.2. or earlier.
TI555 with Release 1.1.2 or earlier.
Note: * Due to the inclusion of password-related information in the (E)EPROM,
an EEPROM generated by Release 3.0 or later on the TI545–1102 or TI555 cannot
be used in the TI545–1101. If you require an (E)EPROM for use on the both the
TI545–1101 and the TI545–1102 (TI555), create the EEPROM on the TI545–1101.

5-2 Using an EEPROM or EPROM TI545/TI555 System Manual

 The EEPROM stores the user program including the following:

• Relay ladder logic (RLL).

• K memory.
• U memory.
• S memory (PID loops, analog alarms, and SF programs).
• Memory configuration.
• I/O configuration.
• Password , if installed.
• Scan configuration.

After storage in the EEPROM, this data is saved even if power is cycled
without a backup battery. However, other data in memory will be lost if you
do not have a backup battery.

NOTE: To help ensure that the data listed above is saved, the total user
memory space to be stored in the EEPROM must not exceed 126K bytes or
254K bytes. If the total user memory (not system memory) space occupied
by these areas is greater than 126K bytes or 254 K bytes, no data is saved.
The error message, OPERATION FAILED, is displayed on the screen if the
user memory exceeds the applicable size when attempting to save the data.

Using an EPROM If your operating program does not change, you can store it permanently on
an EPROM. You can use an EPROM copier to copy your program from an
EEPROM to an EPROM. (The EPROM cannot be programmed in the CPU.)
This is a cost-effective method for creating duplicate copies if you have
additional CPUs running the same program.

TI545/TI555 System Manual Using an EEPROM or EPROM 5-3

Introduction (continued)

EEPROM Functions After your EPROM has been programmed, it is portable and can be used
in any other TI545–1102 or TI555 CPU of compatible or newer software
revision. EPROMS are available from your distributor for EPROM
applications.

You can manage operation of EEPROMs by using AUX Function 84 on your

programming unit. If necessary, refer to your SIMATIC TI505 Programming
Reference manual for detailed instructions about executing AUX Functions.
AUX Function 84 allows you to do the following procedures:

• Copy RAM to EEPROM.

• Copy EEPROM to RAM.

• Select RAM as program source.

• Select EEPROM as program source.

• Erase the program in EEPROM.

• Report source (RAM OR EEPROM) of program being executed.

NOTE: The EEPROM is automatically write protected on power up, which

helps to prevent any accidental write operations.

5-4 Using an EEPROM or EPROM TI545/TI555 System Manual

5.2 TI545/TI555 Memory and Mode Status at Power-up

When you power up a TI545/TI555 system, the CPU checks the status of the
EEPROM (EPROM) and the battery. A clear (un-programmed) EEPROM
(EPROM) is equivalent to having no EEPROM (EPROM) installed.
Table 5-3 lists mode and memory status (after power up) that result from
various battery and EEPROM (EPROM) conditions.

Table 5-3 TI545/TI555 Mode and Memory Status After Power-up

Conditions Results
Programmed
Battery Controller
EEPROM (or EPROM) Controller Memory
Status Mode
Installed and Selected
Bad or Off No Cleared PROGRM
Cleared, then loaded with
Bad or Off Yes program that is in RUN
EEPROM (EPROM)
Mode prior
Good and
No No change to power
On
loss
Mode prior
Good and
Yes (same program) No change to power
On
loss
Cleared, then loaded with
Good and
Yes (different program) program that is in RUN
On
EEPROM (EPROM)

TI545/TI555 System Manual Using an EEPROM or EPROM 5-5

5.3 Installing EEPROMs and EPROMs

Follow instructions in this section to install an EEPROM or EPROM in your

CPU.

NOTE: If you are installing an EEPROM and intend to download a program

(from RAM memory), ensure that the good back-up battery is fully charged
and enabled. Controller power must be turned off and, without a
functioning back-up battery, your program may be lost when power is
restored.

1. Place the CPU in PROGRAM Mode. You may want to use TISOFT AUX
60 (SAVE PLC
ALL) to save program to disk before proceeding.

2. Ensure that switch 9 on the CPU dipswitch is turned On (to the left).
This enables backup battery.

3. Turn off all user-supplied power to the TI545/TI555 base.

! CAUTION Electrostatic discharge can damage the CPU.

Personnel must make contact with a grounded conductive pad

and/or wear a grounded wrist strap when handling the CPU.

4. Remove the CPU from the base assembly and place component-side up
on a non-conductive surface.

5. Insert the EEPROM (EPROM), aligning the notches on the EEPROM

(EPROM) and the socket (Figure 5-1).

6. Check the pins to make sure that they are all seated properly in the
socket.

7. Observe Jumper E18. If you intend to write to the EEPROM, ensure

that Jumper E18 is strapped. If you do not write to the EEPROM and
want to disable this feature, remove strap E18.

8. Re-install the CPU in the base and turn the base power On. Refer to
the Troubleshooting chapter if the EEPROM (EPROM) fails to function
correctly.

5-6 Using an EEPROM or EPROM TI545/TI555 System Manual

 Note location of notches

Figure 5-1 EEPROM (EPROM) Socket and Jumper Pins

TI545/TI555 System Manual Using an EEPROM or EPROM 5-7

5.4 Copying a Program into an EEPROM

To copy a program into your EEPROM, you must first enter the program
into the CPU. Verify that your program is correct, save your program to
your programming unit hard disk, and then continue with the steps listed
below.

1. Ensure that the battery enable dipswitch is On, and that jumper pins
(E18) are strapped to enable programming.

2. Set the CPU to PROGRAM mode.

3. Select Auxiliary Function 84 in your programming unit.

4. Use the Source Toggle option to select RAM as your program source.

5. Use the AUX Function 84 to erase program data on the EEPROM.

6. Use the Copy option to copy the program from RAM to the EEPROM.

NOTE: The CPU does not allow changes to program memory during the
programming of the EEPROM.

The CPU returns to the PROGRAM mode when the copy process is
completed.

7. If you are finished copying the program, go to step 8.

To copy the program to another EEPROM, turn off controller power,

replace the EEPROM with another, and power up again. Repeat Steps
5 and 6 to copy the program to another EEPROM; continue the process
to program additional EEPROMs.

! WARNING To minimize risk of potential injury to personnel or damage to

equipment check the program before permitting a CPU to execute
from an EEPROM program.
An incorrect program can cause death or serious injury and/or
damage to equipment.
You must be absolutely certain that the EEPROM program is
correct. Take standard precautions associated with program
development and debug.

5-8 Using an EEPROM or EPROM TI545/TI555 System Manual

 8. If the program is correct and you want to run the program from
EEPROM, use the Source Toggle option to select EEPROM as the
program source.

! WARNING Electronic devices can operate in an unsafe condition that can

cause death or serious injury and/or damage to equipment.
When you select EEPROM, the controller is cleared and then
loaded with the EEPROM content. This clears V-memory and resets
all timers, counters, and drums, etc.
Be sure that you really want to select EEPROM.

9. Use AUX 17 to check the program carefully, while the CPU is in the
PROGRAM mode, before allowing the CPU to control equipment
connected to the I/O.

If an error occurs during the copy process it will be listed on the

programming unit. If an error occurs, perform the following checks:

• Ensure that the EEPROM jumper pin programming enable strap is

installed correctly.

• Ensure that an EEPROM, not an EPROM, is installed.

• Ensure that all EEPROM pins are properly seated in the socket.

Other possible causes for errors include the following:

• The EEPROM may be defective.

• The EEPROM may already have been programmed (and not erased).
Use the AUX Function 84 to erase program data on the EEPROM.

• The size of your user program that is being stored may exceed the size
of the installed EEPROM (126K bytes or 254K bytes).

If you suspect a defective EEPROM, power down, remove the EEPROM,

install another EEPROM, power up again and repeat the programming
procedure.

TI545/TI555 System Manual Using an EEPROM or EPROM 5-9

5.5 Editing a Program Stored in EEPROM

You can edit the program and data stored in an EEPROM by following the
steps listed below.

NOTE: If necessary, refer to your SIMATIC TI505 Programming Reference

manual for detailed instructions about executing AUX Functions.

1. Using your programming unit and the AUX Function 84 option, select
EEPROM as the program source. This will copy the EEPROM program
to RAM.

! WARNING Electronic devices can operate in an unsafe condition that can

cause death or serious injury and/or damage to equipment.
When you select EEPROM, the controller is cleared and then
loaded with the EEPROM content. This clears V-memory and resets
all timers, counters, and drums, etc.
Be sure that you really want to select EEPROM.

2. Select RAM as the program source.

3. Edit the program source code (in RAM memory) as required.

4. Use the AUX Function 84 to erase program data on the EEPROM.

5. Copy the RAM program back to EEPROM.

6. Select the EEPROM as the program source.

Although the CPU can copy a program from either an EEPROM or an

EPROM into RAM, the CPU cannot copy a program from RAM to an
EPROM.

NOTE: AUX Function 84 will not download timer/counter and drum/event

presets, and values in V-memory.

5-10 Using an EEPROM or EPROM TI545/TI555 System Manual

 Chapter 6
Starting Up the TI545/TI555 System
6.1 Powering Up the TI545/TI555 System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Start-up Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2 TI545 CPU Memory Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Memory Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Maximum Configurable Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.3 TI555 CPU Memory Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Memory Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Maximum Configurable Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

TI545/TI555 System Manual Starting Up the TI555 System 6-1

6.1 Powering Up the TI545/TI555 System

Overview This section provides general guidelines for powering up your TI545/TI555
system system.

! WARNING You must be fully informed about safety procedures before you
power up the TI545/TI555 system.

Not knowing so could result in death or serious injury and/or

damage to equipment.

Review and comply with safety procedures listed in Chapter 2

before completing the following steps.

Start-up Follow these procedures when powering up your TI545/TI555 system for the
Procedures first time.

1. Be familiar with the operation of your system components.

2. Verify the following items.

• Power Supply PPX:505-6660 requires 110 or 220 VAC input power.

• If any of your installed 505 bases have empty I/O slots, use
filler bezels (part #2587705-8003) and bezel screws
(part #2587705–8001) to cover the openings in the base. This
prevents debris from getting into the system; it also helps prevent
electrostatic discharge and other types of electrical noise
interference.

• After installation is complete, remove the plastic dust guard on the

top grill of every installed Series 505 base.

! WARNING You must remove the dustguard from the base.

Failure to remove the dustguard may result in overheating and
damage to equipment.
This could result in death or serious injury and/or damage to
equipment.

• Check for correct switch settings on all configurable modules, e.g.,

the programmable controller and RBC(s). The jumper strap (E18)
on the CPU must be strapped if you intend to copy user programs
into an installed EEPROM.

• Ensure that all modules are securely plugged into the base(s),
connector pins are not bent, and bezel screws are tightened.

6-2 Starting Up the TI555 System TI545/TI555 System Manual

 • Check AC input power for proper voltages. Ensure that the jumper
in the back of the power supply is set for the correct voltage.

• Ensure that all I/O interface cables are properly connected to I/O
interface connectors.

• Ensure that all configured bases are properly connected, there are
no crimps or breaks in the cable, and base addresses are correct.

3. If you intend to use an EEPROM (EPROM), install the EEPROM

(EPROM) according to the instructions given in Chapter 5.

4. Initialize the CPU by completing the following procedures:

• If you have not already done so, disable the CPU battery by
turning off switch 9 on the dipswitch. Ensure that a programmed
EEPROM (EPROM) is not installed.

• Turn on power to the controller.

• With the battery disabled and no programmed EEPROM (EPROM)

installed, the CPU clears memory and enters PROGRAM mode.

• Enable the battery backup circuit by turning on switch 9. The

Battery Good LED should light. The CPU is now initialized.

NOTE: If the battery LED does not come on, the battery may be discharged.
The LED should light when fully charged with the switch enabled and
power applied. A blinking light means marginal charge. The battery will be
fully charged after 24 hours of operation.

5. Connect your programming device to one of the CPU communication

ports. Place the CPU in PROGRAM mode. If you have installed a
pre-programmed EEPROM (EPROM), go to step 8.

6. Using your programming device, enter the memory (refer to Table 6-1
and Table 6-2) and I/O configuration.

7. Enter the user program. See the SIMATIC TI505 Programming

Reference Manual (PPX:505–8104) for programming information.

8. Use your programming device to JOG motors, solenoids, or other

positioning devices one at a time to establish correct rotation or
positioning.

After all the steps are performed and verified, place the controller in RUN
mode.

TI545/TI555 System Manual Starting Up the TI555 System 6-3

6.2 TI545 CPU Memory Configuration

Memory The TI545 CPU memory is user configurable. The actual ranges of memory
Configuration types depend upon how the memory has been configured. Ranges for
memory types are listed in Table 6-1.

You can increase the memory allocated to a particular memory type, a block
at a time, up to the maximum listed in Table 6-1. Block sizes vary with the
memory type as shown in Table 6-1.

Some overhead is associated with certain memory types. For example, each
K byte of L-memory uses a total of 3K bytes of system memory. Each
timer/counter uses 5 bytes of system memory. A drum uses 48 bytes.

When you increase L-memory by one block, from 16K bytes to 20K bytes,
system memory reserved for L-memory increases from 48K bytes to
60K bytes. When you increase the number of drums by one block, from 64 to
128, system memory reserved for drums increases from 3K bytes to
6K bytes.

Maximum Up to 192K bytes of configurable system memory are available on the TI545
Configurable CPU. You cannot configure all memory types to their maximum allocation
Memory size simultaneously. For example, if V-memory is configured to 177K bytes,
then S memory cannot be configured to 176K bytes because the 192K bytes
of system memory would be exceeded.

Refer to your TISOFT manual and SIMATIC TI505 Programming Reference

manual for additional information on memory configuration and configuring
I/O.

Table 6-1 TI545-1102 CPU Memory Configuration

Block Memory Total Memory

Minimum Maximum
Memory Type Allocation Required Required for
Size Size
Size per Block Maximum Size
Ladder (L) 1K bytes 3K bytes 1K bytes 59K bytes 177K bytes
Variable (V) 1K bytes 1K bytes 1K bytes 177K bytes 177K bytes
Constant (K) 1K bytes 1K bytes 0K bytes 176K bytes 176K bytes
Special (S) 1K bytes 1K bytes 0K bytes 176K bytes 176K bytes
User (U) 1K bytes 1K bytes 0K bytes 176K bytes 176K bytes
Timer 1024* 5K bytes 1024* 4096 20K bytes
Drum 64* 3K bytes 64 512 24K bytes
Shift Register 1024* 1K bytes 1024* 3072 3K bytes
Table Move 1024* 2K bytes 1024* 3072 6K bytes
One Shot 1024* 1K bytes 1024* 7168 7K bytes
*Number per block.

6-4 Starting Up the TI555 System TI545/TI555 System Manual

6.3 TI555 CPU Memory Configuration

Memory The TI555 CPU memory is user configurable. The actual ranges of memory
Configuration types for each model of the CPU depend upon how the memory has been
configured. Ranges for memory types are listed in Table 6-2.

You can increase the memory allocated to a particular memory type, a block
at a time, up to the maximum listed in Table 6-2. Block sizes vary with the
memory type as shown in Table 6-2.

Some overhead is associated with certain memory types. For example, each
K-byte of L-memory uses a total of 3K bytes of system memory. Each
timer/counter uses 5 bytes of system memory. A drum uses 48 bytes. When
you increase L-memory by one block, from 16K bytes to 20K bytes, system
memory reserved for L-memory increases from 48K bytes to 60K bytes.
When you increase the number of drums by one block, from 64 to 128,
system memory reserved for drums increases from 3K bytes to 6K bytes.

Maximum Up to 384K bytes of system memory are available on the PPX:555–1101

Configurable CPU, and up to 1920K bytes on the PPX:555–1102 CPU. You cannot
Memory configure all memory types to their maximum allocation size
simultaneously. For example, (for the TI555–1101) if you configure
V-memory to 369K bytes, then you cannot configure S-memory to 368K
bytes because the 384K bytes of system memory would be exceeded.

Refer to your TISOFT manual and SIMATIC TI505 Programming Reference

manual for additional information on memory configuration.

Table 6-2 TI555-1101/1102 CPU Memory Configuration

Total Memory
Block Memory Required for
Minimum Maximum
Memory Type Allocation Required Maximum Size
Size Size
Size per Block
–1101 –1102 –1101 –1102
Ladder (L) 1K bytes 3K bytes 1K bytes 123K bytes 635K bytes 369K bytes 1905K bytes
Variable (V) 1K bytes 1K bytes 1K bytes 369K bytes 1905K bytes 369K bytes 1905K bytes
Constant (K) 1K bytes 1K bytes 0K bytes 368K bytes 1904K bytes 368K bytes 1904K bytes
Special (S) 1K bytes 1K bytes 0K bytes 368K bytes 1904K bytes 368K bytes 1904K bytes
User (U) 1K bytes 1K bytes 0K bytes 368K bytes 1904K bytes 368K bytes 1904K bytes
Timer 1024* 5K bytes 1024* 20480 20480 100K bytes 100K bytes
Drum 64* 3K bytes 64* 2304 2304 108K bytes 108K bytes
Shift Register 1024* 1K bytes 1024* 16384 16384 16K bytes 16K bytes
Table Move 1024* 2K bytes 1024* 14336 14336 28K bytes 28K bytes
One Shot 1024* 1K bytes 1024* 32768 32768 32K bytes 32K bytes
*Number per block.

TI545/TI555 System Manual Starting Up the TI555 System 6-5

 Chapter 7
Troubleshooting
7.1 Troubleshooting by Using Auxiliary Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Power-up Restart, Partial Restart, and Complete Restart . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Compare PLC to Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Run PLC Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Display Failed I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Show PLC Diagnostic Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.2 Troubleshooting by Reading LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

7.3 Troubleshooting Controller Fatal Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

CPU Fatal Error Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Causes of CPU Fatal Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Controller Responses to Fatal Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Steps to Clear Fatal Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Calling for Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.4 Troubleshooting Controller Non-Fatal Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

7.5 Troubleshooting by Using Status Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

7.6 Troubleshooting EEPROMs or EPROMs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

7.7 Troubleshooting the Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

7.8 Checking RS-485 (Twisted Pair) Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

Using Digital or Analog Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Resistance Below Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Resistance Above Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
7.9 Recommended Spare Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16

TI545/TI555 System Manual Troubleshooting 7-1

7.1 Troubleshooting by Using Auxiliary Functions

Overview The TI545/TI555 CPU has self-checking and diagnostic capabilities that can
be used for troubleshooting purposes. The diagnostics and self-checks are
accessible through the Auxiliary Function menu on your programming
device.

When you display the Auxiliary Function menu, the following functions are
available for resetting the CPU, initiating diagnostics or displaying
diagnostic information:

• Power-up restart — AUX 10.

• Partial restart — AUX 11.

• Complete restart — AUX 12.

• Compare PLC to Disk — AUX 17.

• Run PLC diagnostics — AUX 20.

• Display failed I/O — AUX 25.

• Show PLC diagnostic cell — AUX 29.

Power-up Restart, AUX Function 10 (power-up restart), AUX Function 11 (partial restart), and
Partial Restart, and AUX Function 12 (complete restart) are restart/clear functions. See
Complete Restart Table 7-1 for AUX Function 10, 11, and 12 restart states.

7-2 Troubleshooting TI545/TI555 System Manual

 Table 7-1 Effects of Using AUX Functions 10, 11, and 12

Power-up Restart Partial Restart Complete Restart

AUX 10 AUX 11 AUX 12
Battery Battery Battery
System Characteristic ON OFF ON OFF ON OFF
Controller Mode (RUN,
PGM HOLD, RAM, No change Program** No change* No change* No change* No change*
ROM)
Program/
Loop Processing Mode No change No change* No change* No change* No change*
LOCK**
Loop Mode No change N/A No change No change Manual Manual
Discrete I/O
Cleared Cleared Cleared Cleared Cleared Cleared
(X’s and Y’s)
Word I/O
No change Cleared No change No change Cleared Cleared
(WX’s and WY’s)
Non-Retentive
Cleared Cleared Cleared Cleared Cleared Cleared
Control Relays
Retentive Control Relays No change Cleared No change No change Cleared Cleared
Forced Elements No change Cleared No change No change No change No change
TMR/CTR/Drum Presets No change Cleared No change No change Downloaded Downloaded
L, V, K, S, U Memory No change Cleared No change No change No change No change
Memory Configuration No change Default value No change No change No change No change
I/O Configuration No change Cleared No change No change No change No change
Scan Time No change Variable No change No change No change No change
Time of Day No change No change No change No change No change No change
Task Codes/Scan No change 2 No change No change No change No change
Watchdog Value No change 1 sec No change No change No change No change
Port Lockout No change Unlocked No change No change No change No change
Fatal Error No change Cleared Cleared Cleared Cleared Cleared
* If fatal error was present, then Program Mode
** If programmed EEPROM (EPROM) is present, then Run Mode using program in EEPROM (EPROM)

TI545/TI555 System Manual Troubleshooting 7-3

Troubleshooting by Using Auxiliary Functions (continued)

Compare PLC AUX Function 17 (Compare PLC to Disk) compares program disk and
to Disk controller data. It allows you to save and load your VERIFY options to and
from the disk or directory.

Run PLC AUX Function 20 (run PLC diagnostics) initiates the CPU self-checks. The
Diagnostics CPU must be in PROGRAM mode in order to execute self-tests. The CPU
executes the equivalent of an AUX Function 20 at every power up. If any
area fails, a message detailing the failure is displayed. AUX Function 20
makes the following tests.

• Valid RAM locations are verified.

• Pre-coded ROM checksum values are checked.

• The hardware force function is checked.

• Internal timer operation is verified.

Display Failed I/O AUX Function 25 (display failed I/O) displays the locations of any failed I/O
modules which are capable of diagnosing and indicating failure. Some
modules, such as word and analog modules, report that they have failed if
the user-supplied voltage is not correct.

AUX Function 25 also displays I/O mismatch(es), indicating that one or

more installed module(s) do not agree with the I/O configuration. Verify that
the configuration data for listed modules is correct before considering that
the module may actually be malfunctioning.

Show PLC AUX Function 29 checks the operational status of the CPU and displays the
Diagnostic Cell results. The display provides the information illustrated in Figure 7-1. Field
descriptions are listed below.

• Scan = scan time reported by AUX Function 29; it is the highest scan
time recorded since the last CPU reset, PROGRAM–RUN mode
transition, or user peak resets. Status Word 10 (STW10) contains a
continuously updated report of the scan time.

• Key = always unlocked; the CPU does not have a key.

• Mode = Run, Program, or Hold; shows the CPU operating mode.

• SF/Loop Mode = Run indicates the system is running loops, analog

alarms, and SF programs in the SF/Loop Mode.

7-4 Troubleshooting TI545/TI555 System Manual

 • SF/Loop Follows PLC to Program Mode — informational comment.

• PLC Fatal Error = a description, causes, and corrective actions are

listed in Section 7.3.

• PLC Non-fatal Error = a description, causes, and corrective actions are

listed in Section 7.4.

• Loop Fatal Error = status word 161 (STW161) reports the causes and
indicates the corrective actions.

• Loop Non-fatal Error = status word 162 (STW162) reports the causes
and indicates the corrective actions.

• Battery = On indicates the backup battery is switched On and good;

Off indicates the backup battery is switched Off or bad.

• Download select switch is not user accessible and is always Off.

• Program in [RAM or ROM]; RAM if system is operating from RAM

memory; ROM if system is operating from an EEPROM (EPROM).

TI545/TI555 Operational Status

Scan = 027 milliseconds Battery = On

Key = Unlocked Download = Off

Mode = Run Program in RAM

SF/Loop Mode = Run

SF/Loop Follows P/C to Program Mode

Fatal Error = None

Loop Fatal Error = None
Non Fatal Error = None
Loop Non Fatal Error = None

Figure 7-1 Typical AUX Function 29 Screen

TI545/TI555 System Manual Troubleshooting 7-5

7.2 Troubleshooting by Reading LEDs

Three LEDs on the CPU are labeled CPU GOOD, RUN, and BATT GOOD.
These LEDs provide CPU status as shown in Table 7-2.

NOTE: Since the CPU receives power from the base power supply module,
the power supply must be on and functioning correctly to turn the LEDs on.
Obviously, if the base power supply module is defective or Off, all CPU
indicators will be Off.

Table 7-2 CPU Indicators

Indicator Status Meaning

CPU GOOD On Controller functioning with no fatal errors.
On Controller (analog and discrete) is in the RUN mode.

RUN Analog (Loops, Analog Alarms, and SF programs) is

Flashing in the RUN mode and discrete (RLL program) is in
the PROG mode.
On Battery is good and switch 9 is On.
BATT GOOD Flashing Battery is marginally charged and switch 9 is On.
Off Battery is discharged or Switch 9 is Off.

Data in the CPU is backed up by a rechargeable lithium battery. Status of

the battery LED is determined as follows:

• When the battery dipswitch is set to the ON position, a 250-ms battery

test is initiated within one second. At the end of the test, the battery
status LED is updated with the test result.

• While the battery dipswitch is in the ON position, the battery is

retested whenever the hour byte of the time-of-day clock changes value.
The battery status is reflected by the results of the last completed test.

• When the battery dipswitch is set to the OFF position, battery-low

status is indicated within approximately one second.

NOTE: The situation may occur when the battery dipswitch is on and the
battery is marginally charged, i.e., the battery is okay when not under load,
but is low when under load. In this case, the battery test is still done hourly,
but the battery LED flashes. This indicates that the battery is charging (or
discharging, if it was good). While in this state, a power-up restart following
a brief power outage will probably result in a battery-good restart.

7-6 Troubleshooting TI545/TI555 System Manual

7.3 Troubleshooting Controller Fatal Errors

CPU Fatal Error A fatal error is indicated when both the following conditions are present.
Indications
• CPU GOOD LED is not lighted.

• The DC POWER GOOD LED on the power supply is on.

Causes of CPU The CPU enters a fatal error condition and ceases operation if one of the
Fatal Errors problems listed below occurs. AUX Function 20 or 29 displays the problem
that caused the CPU to enter the fatal error condition.

• ROM diagnostic failure — the operating system EPROMs are found to

be invalid.

• Watchdog time-out — the microprocessor does not reset a watchdog

circuit periodically.

• Illegal operation code — the microprocessor receives an illegal

instruction.

• Diagnostic test failure — the CPU fails a diagnostic test.

• Operating system fatal error — the CPU detects a non-recoverable

error during execution.

• Abnormal power loss — the CPU detects DC power failure without

advance warning from the power supply.

• Dynamic Program Memory Diagnostics Error — the CPU determines a

checksum error in the user program memory (ladder or external
subroutine)

• Fatal error due to EEPROM (EPROM) — the EEPROM (EPROM) is

bad.

Controller When a fatal error occurs, the CPU attempts the following actions.
Responses to Fatal
Errors • The CPU GOOD LED is turned off.

• I/O ports are disabled, discrete outputs are turned off, and word
outputs are held in their last valid state.

• Communication ports are cleared and re-initialized.

• Pending or queued communication tasks are aborted.

TI545/TI555 System Manual Troubleshooting 7-7

Troubleshooting Controller Fatal Errors (continued)

Steps to Attempt to clear the fatal error by following the steps listed below. When the
Clear Fatal Errors CPU GOOD LED turns on, the fatal error has been cleared.

1. Determine the fatal error condition by selecting AUX Function 29 from

the Auxiliary Function Menu on your programming unit. Record the
fatal and non-fatal error(s) listed along with the date, time, controller
serial number and software part number (AUX 15) for later reference.

NOTE: Always execute AUX Function 29 and make a list of the errors before
attempting to clear them. If you clear errors before listing them, it will be
impossible to determine what errors occurred and difficult to identify the
problem that caused them.

If communication errors occur, ensure that the battery backup is enabled

and then cycle power to the controller. If communication errors continue,
record No Communication as the fatal error, and go to step 4.

2. Execute AUX Function 11 — CPU partial restart. If this fails to clear

the error, execute AUX Function 12 — CPU complete restart.

3. If the fatal error persists, ensure that the battery backup is enabled,
power cycle the CPU, then reattempt step 2 and execute the AUX
Function 10 — CPU power-up restart.

4. If you have been unable to clear the fatal error to this point, you must
re-initialize the CPU. Disable the battery backup (turn off switch 9 of
the dipswitch) and cycle power to the CPU (or execute AUX
Function 10). This clears the CPU memory.

5. If the CPU GOOD LED comes on, restore the battery backup by
turning on switch 9 of the dipswitch. You must now use your
programming unit to restore your program.

6. If the CPU GOOD LED does not turn on at this time, your CPU may
have a hardware failure.

Calling for Before calling for assistance, be sure that you have the following
Assistance information available.
• List of fatal and non-fatal errors

• Model number

• CPU serial number

• CPU software revision (execute AUX Function 15 or check the EPROM

label)

• Sequence of events leading up to the failure

7-8 Troubleshooting TI545/TI555 System Manual

7.4 Troubleshooting Controller Non-Fatal Errors

Definitions of non-fatal errors are listed in this section along with suggested
courses of action.

• Scan overrun — The CPU scan time is not sufficient to execute the user
program.

• I/O base failure — A configured base is not connected or has failed.

Check the I/O cabling and/or I/O configuration.

• Special function port failure — A communication port on an SF module

has failed. Check all SF modules.

• I/O module failure — A configured module is not present or is reporting

an error. Run AUX 25 or see Appendix C to identify the module.

• I/O table does not agree with modules installed — The configured I/O
does not match what is installed in the base. Check the I/O
configuration and/or run AUX 25.

NOTE: Series 505 I/O modules with date codes before January 1988 cannot
be used with a TI545/TI555 CPU. See Appendix C for details.

TI545/TI555 System Manual Troubleshooting 7-9

7.5 Troubleshooting by Using Status Words

In addition to auxiliary functions, the CPU provides operational information

in the form of 16-bit status words. Status words can be read with your
programming device. Status words can also be used within a RLL program
thus allowing the system to execute diagnostics during run-time conditions.

Status words supported by the CPU are described in detail in the SIMATIC
TI505 Programming Reference Manual.

7-10 Troubleshooting TI545/TI555 System Manual

7.6 Troubleshooting EEPROMs or EPROMs

EEPROMs and EPROMs are generally not serviceable and must be replaced
if they become defective. Before replacement however, review material in
Chapter 5, Using an EEPROM or EPROM, and perform the following
checks.

• Ensure that the EEPROM programming enable strap is installed

correctly on the jumper pin E18. (See Figure 5-1.)

• Ensure that an EEPROM or EPROM is installed, depending on your

use.

• Ensure that all EEPROM (EPROM) pins are properly seated in the
socket.

Other possible causes for errors include the following.

• The EEPROM may already have been programmed (and not erased).
Use the AUX Function 84 to erase program data on the EEPROM.

• The size of your user program (L, K, S, and U memories) that is being
stored may exceed the size of the (E)EPROM (126 or 254K bytes).

NOTE: To help ensure that the user program will be saved, the total user
memory space occupied by the user program must not exceed the size of the
(E)EPROM minus 2K bytes (126K or 254K bytes). If the total user memory
(not system memory) space occupied by these user programs is greater than
this value, none of the data is saved and the error message, OPERATION
FAILED, is displayed on the screen when attempting to save the data.

TI545/TI555 System Manual Troubleshooting 7-11

7.7 Troubleshooting the Power Supply

Complete the following steps when troubleshooting the power supply.

1. Ensure that the power budget has not been exceeded and that the
module is properly installed.

2. After making sure the backup battery is on (so the program will not be
lost), disable all power to the system for at least 90 seconds.

3. Restore system power.

4. If the problem still exists, turn off power to the system.

! WARNING To minimize risk of shock hazard, always turn off the controller
before removing or installing a CPU or I/O module.
Failure to do so could cause death or serious injury and/or damage
to equipment.
Ensure that controller power is turned off before removing or
installing a CPU or I/O module.

5. Remove the power supply module from the base. This step is not
required for the PPX:505–6663 power supply.

a. Ensure that the jumper in the back of the power supply module is
set to the correct line voltage.

b. If the voltage has been set incorrectly, wait at least one minute
before touching the jumper. Then move the jumper to the
appropriate quick-connect pin.

6. Ensure that the wires attached to the terminal screws on the bezel are
secure and that the user-supplied power source is functional.

7. Verify that the fuse (located on the bezel) has not opened. Follow steps
8. through 12. to replace the fuse, if necessary, with the appropriate
fuse. See Figure 7-2 .

! WARNING Before you replace a fuse, disable all power to the base .
Failure to do so could cause death or serious injury and/or damage
to equipment.
Disable all power to the base before replacing a fuse.

7-12 Troubleshooting TI545/TI555 System Manual

 8. Turn off power to the power supply module.

9. Turn the fuse cap counterclockwise a half-turn with a standard

screwdriver.

10. Pull the fuse cap out of the fuse socket.

11. Remove and replace fuse.

NOTE: PPX:505–6660A requires a 3 A, 250 V, slow-blow fuse. PPX:505–6663

requires an 8 A, 250 V, normal-blow fuse.

12. Place the fuse cap in socket and turn it clockwise with a standard
screwdriver.

Front Bezel

Fuse

Fuse Cap

Figure 7-2 Replacing PPX:505–6660 Power Supply Fuse

13. Re-install the power supply and apply power to the system.

14. If the power supply continues to malfunction, replace it.

Follow procedures established at your site for processing defective

equipment. If necessary, contact your distributor or sales office in the
United States or call Siemens Industrial Automation, Inc., at (800)
964–4114 for assistance in contacting your distributor or sales office.

TI545/TI555 System Manual Troubleshooting 7-13

7.8 Checking RS-485 (Twisted Pair) Cable Installation

Using Digital or To locate problems with RS-485 communication links, use a digital or analog
Analog Meter meter capable of measuring resistance between 0 and 150 ohms.

Measure the line-to-line and line-to-shield resistance as follows:

1. Remove power from the controller and all bases.

2. Disconnect the CPU and all RBCs from the cable by removing the 9-pin
D-connector.

3. Measure the resistance from either isolated wire to the other isolated
wire (line-to-line) and record this value.

4. Measure the resistance from one line to the shield wire and record this
value.

5. Measure the resistance from the other line to the shield wire and
record this value.

6. Compare the values you recorded with those in Table 7-3.

Table 7-3 Cable Resistance

9860 or 9271 9182

Trunk Cable Type
Min Max Min Max

Line-to-line 52 ohms 70 ohms 63 ohms 87 ohms

Line-to-shield 100K ohms – 100K ohms –

7-14 Troubleshooting TI545/TI555 System Manual

Checking RS-485 (Twisted Pair) Cable Installation (continued)

Resistance Below Line-to-line resistance that is below the minimum specified in Table 7-3
Minimum may be caused by the following:

• Incorrect termination resistors are installed.

• More than two termination resistors are installed.

• There is a short in the cable.

Line-to-shield resistance that is below the minimum specified in Table 7-3

may be caused by the following:

• One of the 9-pin connectors is connected to an RBC or CPU.

• Cable line wires are shorted to the shield.

Resistance Above Line-to-line resistance that is above the maximum specified in Table 7-3
Maximum may be caused by the following:

• Incorrect termination resistors are installed.

• Fewer than two termination resistors are installed.

• The cable is open between the point of measurement and one or both of
the termination resistors.

TI545/TI555 System Manual Troubleshooting 7-15

7.9 Recommended Spare Parts List

Siemens Industrial Automation, Inc., recommends that you maintain a 10%

surplus of your system’s I/O modules as available spare parts. Depending
upon the number of CPUs that you have installed, you may wish to stock an
extra controller as well. Additional spare parts, depending upon your site
configuration, include the following:

• PPX:505–6504, 4 I/O slots base.

• PPX:505–6508, 8 I/O slots base.

• PPX:505–6511, 11 I/O slots base.

• PPX:505–6516, 16 I/O slots base (19-inch rack compatible).

• PPX:505–6660A or PPX:505–6663, Power Supply Module.

• 3.0A/250 V, slow-blow fuse (3AG) for PPX:505–6660A,

PPX:2587679–8015, Qty 5.

• 8.0A/250 V, normal-blow fuse (3AG) for PPX:505–6663,

PPX:2587679–8018, Qty 5.

Order the following spare parts as needed from your supplier or Siemens
Industrial Automation:

• EEPROM, 128K x 8, PPX:2587681–8022

EEPROM, 256K x 8, PPX:2587681–8030.

• EPROM, 128K x 8, PPX:2587681–8023

EPROM, 256K x 8, PPX:2587681–8031.

• RS-232-C/RS-423 9-to-9 Pin Programming Cable, Part #2601094–8001.

7-16 Troubleshooting TI545/TI555 System Manual

 Appendix A
System Specifications
A.1 Series 505 System Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

TI545/TI555 System Manual System Specifications A-1

A.1 Series 505 System Specifications

Table A-1 Environmental Specifications

PPX:545–1102 Controller
PPX:555–1101 Controller
PPX:555–1102 Controller
Models
PPX:505–6851 Remote Base Controller
PPX:505–6660A Power Supply
PPX:505–6663 Power Supply
Storage Temperature –40° to 70°C; –40° to 158°F
Operating Temperature 0° to 60°C; 32° to 140°F
Relative Humidity 5% to 95% noncondensing
Vibration
Sinusoidal: IEC 68-2-6, Test Fc;
0.15 mm peak-to-peak, 10–57 Hz;
1.0 g, 57–150 Hz

Random: NAVMAT P–9492 or IEC 68–2–34,

Test Fdc with 0.04 g2 /Hz, 80–350 Hz, and
3 dB/octave rolloff, 80–20 Hz and
350–2000 Hz at 10 min/axis
Impact Shock IEC, 68–2–27, Test Ea; Half sine, 15 g 11 ms
Pollution Degree 2, IEC664, 684A
Electric Noise Immunity
Conducted noise: IEC 801, Part 4, Level 3
MIL-STD-461B, Part 4; CS01, CS02, CS06
IEC 255–4, Appendix C
EEC 4517/79 Com(78) 766 Final, Part 4
IEEE 472, 2.5 kV

Radiated noise: IEC 801 Part 3, Level 3

MIL-STD-461B, Part 4; RS01, RS02

Electrostatic discharge: IEC 801, Part 2, Level 4 (15 kV)

System Isolation 1500 Vrms (user-side to controller-side)

A-2 System Specifications TI545/TI555 System Manual

 Table A-2 General Series 505 Specifications

Provided by power supply module

Input Power PPX:505–6660A for user-supplied 110/220 VAC
PPX:505–6663 for user-supplied 24 VDC
Maximum power drawn
4 W @ +5 VDC,
from base by
0.2 W @ –5 VDC
TI545/TI555 controller
Maximum power drawn 5 W @ +5 VDC
from base by RBC: 0.2 W @ –5 VDC
3.0 V rechargeable lithium battery
Battery Backup 3 years typical storage (0° to 60°C)
6 months typical continuous life (0° to 60°C)
Communication Ports RS-232-C/RS-423 RS-232/422
Remote: RS-485
I/O Port
Local: back-plane connectors
RAM for 545-1102: 192K bytes (user-configurable)
RAM for 555-1101: 384K bytes (user-configurable)
User Memory Capacity RAM for 555-1102: 1920K bytes (user-configurable)
TI545/TI555 EEPROM(EPROM): 126K bytes (total), or
TI555 EEPROM(EPROM): 254K bytes (total)
EEPROM, 128K bytes (Part #2587681–8022)
EEPROM, 256K bytes (Part #2587681–8030)
Memory Backup EPROM, 128K bytes (Part #25587681–8023)
EPROM, 256K bytes (Part #2587681–8031)
Battery backed-up static RAM
All parts are of corrosion-resistant material or are
Corrosion Protection
plated or painted as corrosion protection.
Agency Approvals UL Listed (industrial control equipment)
(All controller models CSA Certified (process control equipment)
and power supply) FM approved (Class I, Div. 2, Haz. Loc.)

TI545/TI555 System Manual System Specifications A-3

Series 505 System Specifications (continued)

Table A-3 Power Supply Electrical Specifications

Input Voltage Select, PPX:505–6660 110/220 VAC (User-selectable)

Voltage Range 85–132 VAC (110), or
PPX:505–6660A 170–264 VAC (220)
PPX:505–6663 20–30 VDC (24)
Frequency PPX:505–6660A 47–63 Hz
Input Current
Peak Inrush – PPX:505–6660A 50 A maximum
Peak Inrush – PPX:505–6663 20 A maximum

Steady state – PPX:505–6660A 2 A rms maximum

Steady state – PPX:505–6663 8 A zero to peak
5 A DC maximum

Volt-Amp rating – PPX:505–6660A 200 V-A

Wattage rating – PPX:505–6663 100 W maximum
55 W at +5 VDC
Output
3.75 W at –5 VDC
Fuse
PPX:505–6660A 3.0A/250 V, slow-blow, 3 AG
PPX:505–6663 8.0A/250 V, normal-blow, 3 AG

In addition, the system complies with applicable requirements of Verband

Deutscher Elektrotechniker (VDE) 0160: Electrical Equipment, except 220
VAC Input Modules (No. PPX:505-44XX).

Series 505 products have been developed with consideration of the draft
standard for programmable controllers as described in the proposed
standard of the International Electrotechnical Commission Committee
(IEC-65A/WG6, Part 2).

Information concerning product reliability and compliance to the IEC or

other standards can be provided upon request. Contact Siemens Industrial
Automation at the following address.

Siemens Industrial Automation Incorporated

3000 Bill Garland Road
P.O. Box 1255,
Johnson City, TN. 37605-1255

A-4 System Specifications TI545/TI555 System Manual

 Appendix B
Module Power Consumption
B.1 Series 505 Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

T545/TI555 System Manual Module Power Consumption B-1

B.1 Series 505 Modules

Table B-1 Series 505 Module Power Requirements

Special Maximum DC Power

Model Immediate Consumption (Watts)
Description Function
Number
umber I/O
I/
Module +5 V –5 V

PPX:505–40081 24 VAC Input (8 point) – n 2.0 –

PPX:505–40161 24 VAC Input (16 point) – n 2.0 –
PPX:505–40321 24 VAC Input (32 point) – n 2.0 –
PPX:505–41081 LVDC/TTL (8 point) – n 2.0 –
PPX:505–41161 LVDC/TTL (16 point) – n 2.0 –
PPX:505–41321 LVDC/TTL (32 point) – n 2.0 –
PPX:505–42081 110 VAC Input (8 point) – n 2.0 –
PPX:505–42161 110 VAC Input (16 point) – n 2.0 –
PPX:505–42321 110 VAC Input (32 point) – n 2.0 –
PPX:505–43081 24 VDC Input (8 point) – n 2.0 –
PPX:505–43161 24 VDC Input (16 point) – n 2.0 –
PPX:505–4317 24 VDC Interrupt Input (16/32) – n2 2.0 –
PPX:505–4318 48 VDC Interrupt Input (16/32) – n 2.0 –
PPX:505–4319 125 VDC Interrupt Input (16/32) – n 2.0 –
PPX:505–43321 24 VDC Input (32 point) – n 2.0 –
PPX:505–44081 220 VAC Input (8 point) – n 2.0 –
PPX:505–44161 220 VAC Input (16 point) – n 2.0 –
PPX:505–44321 220 VAC Input (32 point) – n 2.0 –
PPX:505–45081 24 VDC Output (8 point) – n 2.5 –
PPX:505–45161 24 VDC Output (16 point) – n 2.5 –
PPX:505–45321 24 VDC Output (32 point) – n 2.5 –
PPX:505–46081 110 VAC Output (8 point) – n 2.5 –
PPX:505–46161 110 VAC Output (16 point) – n 2.5 –
PPX:505–46321 110 VAC Output (32 point) – n 2.5 –
PPX:505–47081 24 VDC Output (8 point) – n 5.0 –
PPX:505–47161 24 VDC Output (16 point) – n 5.0 –
PPX:505–47321 24 VDC Output (32 point) – n 5.0 –
1 Modules that are affected by date code restrictions. See Appendix C.
2 Interrupt mode operation requires TI545 with Firmware Release 2.1 or later, or TI555 with Firmware Release 1.1 or later.

B-2 Module Power Consumption TI545/TI555 System Manual

 Table B-1 Series 505 Module Power Requirements (continued)

Special
Immediate Maximum DC Power
Model Number Description Function
I/O Consumption (Watts)
Module
PPX:505–48081 220 VAC Output (8 point) – n 5.0 –
PPX:505–48161 220 VAC Output (16 point) – n 5.0 –
PPX:505–48321 220 VAC Output (32 point) – n 5.0 –
PPX:505–49081 Relay Output Form C (8 point) – n 2.5 –
PPX:505–49161 Relay Output Form A (16 point) – n 2.5 –
PPX:505–49321 Relay Output Form A (32 point) – n 2.5 –
PPX:505–5100 TurboPlastic n 7.0 0
PPX:505–5103 TurboParison n 7.0 0
PPX:505–5184 MODNIM (Modbus NIM) n 8.0 –
PPX:505–5190 6MTCC: TI505-to-6MT Interface n 4.0 –
PPX:505–54171 Relay Output, 115 VDC (16 point) n 3.0 –
PPX:505–60101 Input Simulator n 2.0 –
PPX:505–60111 Output Simulator n 2.5 –
PPX:505–6108 Analog Input n3 4.0 –
PPX:505–6108A Analog Input n3 4.0 –
PPX:505–6202 Analog Output (2 point) n3 2.5 –
PPX:505–6204 Analog Output (4 point) n3 5.0 –
PPX:505–6208 Analog Output (8 point) n3 5.0 –
PPX:505–6208A Analog Output (8 point) n3 2.0 –
PPX:505–6308 Word Input n3 4.0 –
PPX:505–6408 Word Output n3 5.0 –
1 Modules that are affected by date code restrictions. See Appendix C.
2 Interrupt mode operation requires TI545 with Firmware Release 2.1 or later, or TI555 with Firmware Release 1.1 or later.
3 Supported by TI555 Release 3.0 or TI545–1102 Release 3.0.

T545/TI555 System Manual Module Power Consumption B-3

Series 505 Modules (continued)

Table B-1 Series 505 Module Power Requirements (continued)

Special Maximum DC Power

Immediate Consumption (Watts)
Model Number Description Function
I/O
I/
Module +5 V –5 V

PPX:505–6851A Remote Base Controller (RBC) 5.0 0.200

PPX:505–6860 RF to RS-485 Converter 4 4

PPX:505–7002 High Speed Counter & Encoder n3 2.0 –

PPX:505–7003 High Speed Counter Encoder n3 2.0 –
PPX:505–7012 8 In/4 Out Analog n2 3.0 0.030
PPX:505–7016 Bipolar 8 In/4 Out Analog n 3.0 0.030
PPX:505–7028 Thermocouple Input n 2.2 0.01
PPX:505–7038 RTD Input n 2.2 0
PPX:505–7101 BASIC Module n 6.0 0.125
PPX:505–7190 7MT Channel Controller 4.0 –
PPX:505–7201 FIM (Field Inteface Module) 2.5 –
PPX:505–7339 NIM (Network Interface Module) n 8.0 –
PPX:505–7340 Dual Media NIM n 8.0 –
PPX:505–7354 Peerlink n 8.0 –
PPX:505–ATM
386/ATM Coprocessor Module
–0220 n 11.0 0.2
(IBM AT-Compatible Coprocessor)
–0440, –4120
PPX:545–1102
PPX:555–1101 Programmable Logic Controller 4.0 0.200
PPX:555–1102
Notes:
1 Modules that are affected by date code restrictions. See Appendix C.
2 Only inputs should be used for immediate I/O when using Release 1.1.x of TI555. No restriction with Release 3.0.
3 Supported by TI555 Release 3.0 or TI545–1102 Release 3.0.
4 Refer to TI555 Release 3.0 Notes.

For any module not listed here, see the manual for that module.

B-4 Module Power Consumption TI545/TI555 System Manual

 Appendix C
TI545/TI555 CPU and I/O Compatibility
C.1 I/O Module Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
I/O Modules not Compatible with TI545/TI555 CPUs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Determining the Compatibility of a Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Series 505 High Speed Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
C.2 Reading the Serial Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
Determining the Manufacturing Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
86ML8712020175_ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
86ML8712020175G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
86ML8801041324_ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4

TI545/TI555 System Manual TI545/TI555 Controller and I/O Compatibility C-1

C.1 I/O Module Compatibility

I/O Modules not Unmodified Series 505 discrete I/O modules manufactured prior to
Compatible with January, 1988 are unable to report module status and, therefore, cannot be
TI545/TI555 CPUs recognized by the TI545/TI555 CPU (that is, inputs are not read and
outputs are not written). Series 505 discrete I/O modules manufactured in
January, 1988 or later and those manufactured prior to this date that have
been modified contain the status reporting mechanism and are compatible
with the TI545/TI555 CPU.

The Series 505 Simulators (PPX:505–6010, 32-Input Simulator and

PPX:505–6011, 32-Output Simulator) are also affected by this compatibility
restriction.

NOTE: Note1 in Table B-1 indentifies all affected modules.

The following modules are fully compatible with the TI545/TI555 CPU,
regardless of the manufacturing date.

• All Series 500 I/O and all non-discrete Series 505 I/O, such as analog
modules (except for the High Speed Counter, as described on page C-3)

• Series 505 Word modules (PPX:505–6308, 8-Channel Word Input and

PPX:505–6408, 8-Channel Word Output)

C-2 TI545/TI555 Controller and I/O Compatibility TI545/TI555 System Manual

Determining the The serial number found on each module contains the manufacturing date
Compatibility of a of the module. The fifth through the eighth characters of the serial number
Module determines the manufacturing date; see Figure C-1.

NOTE: Units manufactured prior to January, 1988 that have been modified
have the letter G immediately following the serial number.

Before you install Series 505 discrete modules into a TI545/TI555 system,
check the serial number of each module to ensure it is compatible with the
TI545/TI555 CPU.

Series 505 High High Speed Counter modules (PPX:505-7002) manufactured prior to May
Speed Counter 1990 will not operate properly in a TI545/TI555 controller’s local base
configuration. If a High Speed Counter is placed in a TI545/TI555
controller’s local base configuration, the WX inputs will intermittently set to
FFs, which could cause improper operation.

NOTE: High Speed Counter modules manufactured prior to May 1990 that
have been modified for TI545/TI555 controller’s local base compatibility
have the letter A immediately following the serial number.

Before you install Series 505 High Speed Counter modules into a
TI545/TI555 local base, check the serial number of each module to ensure
that it is compatible with the TI545/TI555 local base.

! WARNING Do not use an unmodified Series 505 High Speed Counter module
manufactured prior to May 1990 in a TI545/TI555 controller’s local
base.
In a Series 505 High Speed Counter, WX inputs may change to FFs
that could change the High Speed Counter outputs to an unsafe
condition. This could result in death or serious injury and/or
damage to equipment.
Refer to the Safety Considerations Guidelines, part no.
2588015-0003 (shipped with each TI545/TI555 controller), for details.
Follow Siemens Industrial Automation, Inc.’s recommended safety
installation guidelines.

TI545/TI555 System Manual TI545/TI555 Controller and I/O Compatibility C-3

C.2 Reading the Serial Numbers

Determining the The fifth through the eighth characters of the serial number determines the
Manufacturing manufacturing date. Figure C-1 shows how to read the serial numbers.
Date

Serial Number
FF DD YY MM SSSSS C X

Not present with initial serial number;

a G appears here if the Series 505
Discrete Module was manufactured
prior to January, 1988 but was modified
for TI545/TI555 compatibility.

Serial Number Checksum

Unique Unit Identifier

Month of Manufacture

Last Two Digits of Year of Manufacture

Device Indicator

Family Indicator

Figure C-1 Serial Number Definition

Examples The following examples demonstrate how to read the serial number on the
modules.

86ML8712020175_ This module was manufactured in December (12) of 1987 (87). This unit is
not compatible with the TI545/TI555 controller because it was
manufactured prior to January, 1988 and the letter G (designating that a
modification occurred) does not appear at the end of the serial number.

86ML8712020175G This module was manufactured in December (12) of 1987 (87). This unit is
compatible with the TI545/TI555 controller because it was manufactured
prior to January, 1988 and the letter G (designating that a modification
occurred) appears at the end of the serial number.

86ML8801041324_ This module was manufactured in January (01) of 1988 (88). This unit is
compatible with the TI545/TI555 controller because it was manufactured in
January, 1988. (The letter G is not required if the module was
manufactured in January, 1988 or later.)

C-4 TI545/TI555 Controller and I/O Compatibility TI545/TI555 System Manual

 Appendix D
Upgrading Series 500 Installations

D.1 Series 500 System Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2

D.2 Upgrading a TI520/TI520C/TI530/TI530C/TI530T System . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-3

Install RS-485 Twin Axial Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-3
Check Base to be Upgraded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-4
Upgrading 14-Slot, 12-Slot, 6-Slot Bases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-4
Upgrading 16-Slot and 8-Slot Bases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-4
Finish Upgrade with these Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-4
D.3 Upgrading an RS-485 Based TI560/TI565/TI560T/TI565P System . . . . . . . . . . . . . . . . . . . . . D-6

D.4 Upgrading an RF Based TI560/TI565/TI560T/TI565P System . . . . . . . . . . . . . . . . . . . . . . . . . . D-8

D.5 Installing a PPX:500–5114A RBC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-10

Output State Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-10
Installing a Series 500 RBC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-11
Setting Baud Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-12
Assigning Base Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-12
Series 500 RBC LED Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-13

TI545/TI555 System Manual Upgrading Existing Series 500 Installations D-1

D.1 Series 500 System Installations

You can upgrade an existing Series 500 system, by replacing the controller
with a TI545–1102 or a TI555. The following Series 500 systems can be
upgraded:

• SIMATIC TI520, TI520C, TI530, TI530C, and TI530T systems.

• SIMATIC TI560, TI560T, TI565, and TI565P systems using twin

axial (RS-485) remote I/O channels.

• SIMATIC TI560, TI560T, TI565, and TI565P systems using coaxial

(RF) remote I/O channels.

Refer to Section D.2 for information about upgrading an existing TI520,

TI520C, TI530, TI530C, or TI530T systems.

Refer to Section D.3 for information about upgrading an existing TI560,

TI560T, TI565, or TI565P system with one or more RS-485 remote I/O
channels.

Refer to Section D.4 for information about upgrading an existing TI560,

TI560T, TI565, or TI565P system with one or more coaxial remote I/O
channels.

D-2 Upgrading Existing Series 500 Installations TI545/TI555 System Manual

D.2 Upgrading a TI520/TI520C/TI530/TI530C/TI530T System

To upgrade a TI520, TI520C, TI530, TI530C, or TI530T system to the

TI545/TI555 you must install a twin axial (RS-485) remote I/O channel to
connect the Series 500 bases to the TI545/TI555.

You must also convert each of the existing series 500 bases to a series 500
remote base by replacing the existing programmable controller (and I/O
channel controller, if present) or the existing distributed base controller
with a PPX:500–5114A (RS-485) Remote Base Controller (RBC). If the base
contains a TI520, TI530, or a PPX:500–2103 distributed base controller you
must install an adapter base and modular power supply before you can
install the RBC in the Series 500 base.

Consider these points as you do the upgrade:

• The Series 500 physical base assembly is composed of one or two logical
bases. A logical base is defined as a contiguous group of eight I/O slots.
For example, the 16-slot physical base assembly has two 8-slot logical
bases. Each logical base has a unique base address.

By comparison, the TI545/TI555 remote base assembly addresses up to

16 contiguous slots with a single base address.

• To reduce down time for your process, plan to install the new RS-485
twin axial cables for the I/O trunkline before upgrading the hardware
for each I/O base.

• Update time for a special function module is significantly faster when

you install the module in the local base, versus a remote base. Because
the TI545/TI555 is installed in a Series 505 local base, Series 500 SF
modules cannot be located in the TI545/TI555 local base. Therefore, if
SF module updates are critical to your application, consider replacing
the Series 500 SF modules with Series 505 SF modules and installing
them in the TI545/TI555 local base.

If all SF modules cannot be installed in the local base, consider placing

low-activity SF modules, such as the ASCII, BASIC, or Dual Comm
Port (DCP) modules, in a remote base. Place high-activity modules,
such as the NIM or Peerlink, in the local base.

To do an upgrade, refer to Figure D-1 and follow the procedure below.

Install RS-485 Twin Refer to Chapter 4 “Cabling and Wiring the System,” for information about
Axial Cabling installing RS-485 twin axial cabling for the I/O trunk line. To reduce the
down time for your process, install the cabling before installing new
hardware in each I/O base.

TI545/TI555 System Manual Upgrading Existing Series 500 Installations D-3

Upgrading a TI520/TI520C/TI530/TI530C/TI530T System (continued)

Check Base to be Determine the number of I/O slots in the base to be upgraded. For some
Upgraded bases, a PPX:500–5840 adapter base must be installed. The 14-slot, 12-slot
and 6-slot bases (Upgrade Path A) do not require an adapter base. For a
16-slot or 8-slot base (Upgrade Path B), you need to install an adapter base.

! WARNING Disable all power to bases before installing or removing modules.

Failure to do so could cause death or serious injury and/or damage
to equipment.
Ensure that all power is disabled before installing or removing
modules.

Upgrading 14-Slot, For 14-slot, 12-slot and 6-slot bases follow these steps (Upgrade Path A):
12-Slot, 6-Slot
Bases 1. Remove the existing controlling device(s): the controller and IOCC (if
an IOCC is present), or the DBC.

2. If the power supply is in slot B, move it to slot A of the I/O base. This
makes slot B of the I/O base available for an I/O module. In your I/O
configuration, the slot that was previously slot #1 becomes slot #2.

Upgrading 16-Slot For 16-slot and 8-slot bases follow these steps (Upgrade Path B):
and 8-Slot Bases
1. Remove the existing controlling device(s): the controller and IOCC (if
an IOCC is present), or the DBC.

2. Install a PPX:500–5840 adapter base. See user manual PPX:500–8140

for information about installing the adapter base.

3. Install an AC (PPX:500–2151A) or DC (PPX:500–2153) power supply in

Slot B of the adapter base. Slot A is left empty. See the appropriate
user manuals for information about the power supply.

Finish Upgrade with These steps finish the upgrade for both Upgrade Paths A and B.
these Steps
1. Install an RBC (PPX:500–5114A) in the controller slot. See Section D.5
for information about installing the RBC.

2. Set the base address (1–15) using the thumbwheel on the RBC. Base
number 0 is reserved for the local base and cannot be used for an RBC.

3. Connect the twin axial cable to the RS-485 port on the RBC(s) and to
the I/O port of the TI545/TI555.

4. Use APT or TISOFT to set the I/O configuration for the upgrade.

D-4 Upgrading Existing Series 500 Installations TI545/TI555 System Manual

 Series 500 Base is: Series 500 Base is:
• PPX:500–5848 • PPX:500–5228
(14 I/O Slots) (16 I/O Slots) or
• PPX:500–5884 • PPX:500–5864
(12 I/O Slots) or (8 I/O Slots)
• PPX:500–5892 Controlling Device is: Controlling Device is:
(6 I/O Slots) • TI530C/TI530T (and IOCC if present) • TI530 (and IOCC if present)
• TI520C or • TI520 or
• PPX:500–2109 DBC • PPX:500–2103 DBC

Upgrade Path A Upgrade Path B

1 Remove controlling device: controller
(and IOCC, if present) or DBC.

1 Remove controlling device: controller

(and IOCC, if present) or DBC.

2 If power supply is in slot B, move it to 2 Install PPX:500–5840 Adapter Base.

slot A. This makes I/O slot #1 available 3 Install PPX:500–2151A or
for an I/O module.
PPX:500–2153 Power Supply in slot A.

Finish upgrade with these steps:

1 Install PPX:500–5114/A RBC. 3 Connect twin axial cable to RBC port.
2 Set base address(es). 4 Configure I/O.

TI545
P/S or Series 505 I/O
TI555 4, 8, or 16 slots
Local I/O

Figure D-1 Upgrading a TI520/TI520C/TI530/TI530C/TI530T System

TI545/TI555 System Manual Upgrading Existing Series 500 Installations D-5

D.3 Upgrading an RS-485 Based TI560/TI565/TI560T/TI565P System

To upgrade an existing RS-485 based TI560, TI560T, TI565, TI565P system,

replace the existing programmable controller, including its chassis, power
supply and all installed boards with the TI505 base, power supply, and
TI545/TI555 controller. The upgrade is shown graphically in Figure D-2.

NOTE: Note that the TI545/TI555 cannot directly replace an hot backup
HBU configuration.

1. If the series 500 remote I/O installation consists of more than one
twin-axial (RS-485) remote I/O channel, combine these channels into a
single remote I/O channel. Refer to Section 4, “Cabling and Wiring the
System,” for information about installation of a twin axial remote I/O
trunk line.

2. Renumber your bases so that no two bases have the same number and
so that base number 0 is not used.

3. Modify the controller’s I/O configuration to reflect the channel number

and base number changes.

4. Connect the I/O trunk line to the TI545/TI555 I/O connector.

Update time for a special function module is significantly faster when you
install the module in the local base, versus a remote base. You can improve
SF module performance, and scan performance, by replacing the Series 500
SF modules with Series 505 SF modules and installing them in the
TI545/TI555 local base.

If all SF modules cannot be installed in the local base, consider placing

low-activity SF modules, such as the ASCII, BASIC, or DCP modules, in a
remote base. Place high-activity modules, such as the NIM or Peerlink, in
the local base.

D-6 Upgrading Existing Series 500 Installations TI545/TI555 System Manual

 R R
P/S TI560 TI565 C C
C C

1 2 3

Upgrade Path

TI545
P/S or Series 505 I/O
TI555 4, 8, or 16 slots
Local I/O

Figure D-2 Upgrading an RS-485 Based TI560/TI565/TI560T/TI565P System

TI545/TI555 System Manual Upgrading Existing Series 500 Installations D-7

D.4 Upgrading an RF Based TI560/TI565/TI560T/TI565P System

To upgrade an existing RF based TI560, TI560T, TI565, TI565P system,

replace the existing programmable controller, including its chassis, power
supply and all installed boards with the TI505 base, power supply,
TI545/TI555 controller, and RF/RS-485 converter. The upgrade is shown
graphically in Figure D-3.

NOTE: Note that the TI545/TI555 cannot directly replace an hot backup
HBU configuration.

1. If the series 500 remote I/O installation consists of more than one
coaxial (RF) remote I/O channel, combine these channels into a single
remote I/O channel. Refer to your existing controller’s documentation
for information about installation of a coaxial remote I/O channel.

2. Renumber your bases so that no two bases have the same number and
so that base number 0 is not used.

3. Modify the controller’s I/O configuration to reflect the channel number

and base number changes.

4. Connect the resulting I/O channel to the TI545/TI555 system using the
PPX:505–6860 RF to RS-485 converter.

Update time for a special function module is significantly faster when you
install the module in the local base, versus a remote base. You can improve
SF module performance, and scan performance, by replacing the Series 500
SF modules with Series 505 SF modules and installing them in the
TI545/TI555 local base.

If all SF modules cannot be installed in the local base, consider placing

low-activity SF modules, such as the ASCII, BASIC, or DCP modules, in a
remote base. Place high-activity modules, such as the NIM or Peerlink, in
the local base.

D-8 Upgrading Existing Series 500 Installations TI545/TI555 System Manual

 R R
P/S TI560 TI565 C C
C C

1 2 3

Upgrade Path

5
0
TI545
5 Series 505 I/O
P/S or –
TI555 4, 8, or 16 slots
6
8 Local I/O
6
0

Figure D-3 Upgrading an RF Based TI560/TI565/TI560T/TI565P System

TI545/TI555 System Manual Upgrading Existing Series 500 Installations D-9

D.5 Installing a PPX:500–5114A RBC

Output State With the PPX:500–5114A RBC you can select the state of the outputs
Selection whenever a communication error occurs. Previous models of the RBC
automatically set all outputs to off (0) when communication is lost. You
must configure the RBC to freeze outputs in the state they were in when
communication was lost, or to have them set to off (0).

The Series 500 output modules in the remote base have a selection switch
for the state of the outputs during a communication loss (Figure D-4). If the
output modules in the remote base have a selection switch, the freeze
selection will override the output module’s selection.

NOTE: If the RBC fails or the system loses power, the outputs will go off (0)
regardless of the jumper selection.

FREEZE

OFF
(Factory Set)

Figure D-4 Series 500 RBC Switch Selection

D-10 Upgrading Existing Series 500 Installations TI545/TI555 System Manual

Installing a To install the RBC, refer to Figure D-5 and follow the steps below.
Series 500 RBC
1. Position the RBC so that the bezel is facing you.

2. Grasp the top and bottom of the RBC.

3. Carefully push the RBC into the slot until it mates with the back plane
connectors.

4. Tighten top and bottom bezel screws.

5. Connect the RBC to the RS-485 trunkline.

Remote Base Controller

Power Supply

Figure D-5 Installed Series 500 RBC

TI545/TI555 System Manual Upgrading Existing Series 500 Installations D-11

Installing a PPX:500–5114A RBC (continued)

Setting Baud Rates The RBC is equipped with a RS-232 port to program the TI545/TI555 CPU
or, to troubleshoot from a remote I/O base. A baud rate thumbwheel (see
Figure D-6) is used to set the baud rate for this port.

RS-485 I/O port 9-pin female

LED Display

Base Thumbwheel
Thumbwheel Baud
Number Rate
Baud Rate Thumbwheel
0 . . . . . . . . 9600
1 . . . . . . . . 2400
2 . . . . . . . . 1200
3 . . . . . . . . . 300
Remote
Base
4 . . . . . . . . 9600
Controller 5 . . . . . . . . 2400
6 . . . . . . . . 1200
7 . . . . . . . . . 300
8 . . . . . . . . 9600
9 . . . . . . . . 2400
10 . . . . . . . . 1200
11 . . . . . . . . . 300
12 . . . . . . . . 9600
13 . . . . . . . . 2400
14 . . . . . . . . 1200
15 . . . . . . . . . 300

RS-232 port 25-pin female

Figure D-6 Series 500 Remote Base Controller and Baud Rate Settings

Assigning Base The base thumbwheel (Figure D-6) is used to assign a base number to the
Numbers RBC for system identification. If you are using more than one RBC, each
RBC must be uniquely numbered. Refer to Table D-1 for assigning base
numbers. Base number 0 is reserved for the TI545/TI555 and must not be
assigned to the RBC.

D-12 Upgrading Existing Series 500 Installations TI545/TI555 System Manual

 Table D-1 Base Numbers

Thumbwheel Thumbwheel
Base Number Base Number
Number Number
Do Not Use 0* 8 8
1 1 9 9
2 2 10 10
3 3 11 11
4 4 12 12
5 5 13 13
6 6 14 14
7 7 15 15
Notes: *Base 0 is reserved on the model TI545/TI555 controller for local base
assignment. Therefore, do not select number 0 on the Series 500 RBC.

Series 500 RBC The display at the top of the module (refer to Table D-2) indicates the status
LED Display of the Series 500 RBC. Status is displayed in integer format; see Table D-2
for definitions of the displays.

Table D-2 Series 500 RBC LED Messages

Display Definitions
0 RBC Good
1 Self Diagnostics Failure
2 Module Mismatch
3 I/O Communication Time Out
4 RAM Parity Error
5 Not used
6 Not used
7 Communication Good, Not Configured
8 Watchdog Timer Expired

TI545/TI555 System Manual Upgrading Existing Series 500 Installations D-13

 Index
connecting terminal blocks, 4-17
A measuring resistance, 7-14
Assistance, calling for, 7-8 preparing trunk line, 4-16
user-supplied equipment, 4-6
Auxiliary functions
display failed I/O, 7-4 Cable routing
restarting, 7-2 in-ceiling, 4-5
run diagnostics, 7-4 methods, 4-4
show diagnostic cell, 7-4 mounting tap, 4-5
used in troubleshooting, 7-2 surface duct, 4-5
terminal block, 4-5
under-floor, 4-5

B Circuit breaker, guidelines for fuses/circuit

breakers, 2-7
Base Clock (real-time), 1-7
series 500, RBC, installing and removing,
D-11 Communicating with controller, devices to use,
series 505 1-5
installing controller, 3-11–3-15 Communication ports, description, 1-7
installing RBC, 3-19
panel mounting, 3-5
rack mounting, 3-4
D
Battery, backup
description, 1-7 Dipswitches
replacing, 3-13 back-up battery switch, 3-15
baud rates, 3-15
Baud rates
port selections, 3-14
series 500, RBC, setting thumbwheel, D-12
series 505 RBC, setting baud rate, 3-16
series 505, 3-15
setting controller, 3-13
series 505 RBC, 3-16
setting, 3-15

E
C EEPROM
errors and corrections, 5-9
Cable
installing, 5-6
alternate cables, 4-13
list of functions, 5-4
characteristics, 4-13
overview, 5-2
connecting drop line, 4-9, 4-12, 4-14, 4-16
program
connecting modems, overview, 4-18
copying, 5-8
connecting to terminal block, 4-8, 4-10
editing, 5-10
installing drop lines, 4-8, 4-10
errors, 5-9
overview, 4-6
resistance of line-to-line, 7-15 Electrical noise
routing guidelines, 4-4 avoiding, 2-8
RS-485 correcting, 2-9
connecting drop line, 4-8, 4-10 isolating from, 2-11

Index-1
Emergency, stop switch, 2-4 controller compatibility, C-2
Enclosure, planning for PLC, 2-6 local, overview, 1-6
mismatches, troubleshooting, 7-4
EPROM remote, overview, 1-6
installing, 5-6 serial number, C-4
overview, 5-3 series 505
EPROM/EEPROM installing and removing, 3-21
compatability, 5-2 mixing, 3-21
troubleshooting, 7-11 troubleshooting, 7-4
using, 5-2 I/O port, description, 1-7
Errors Inch switch, location, 2-5
correcting fatal errors, 7-7
troubleshooting fatal, 7-7 Installing
EEPROM and EPROM, 5-6
planning for, 2-2
F series 500 RBC
in adapters, D-11
Fatal errors, steps to clear, 7-8 in bases, D-11
series 505, 3-4
Features, 1-2 power supply, 3-9
Fuse series 505 RBC, 3-19
guidelines for fuses/circuit breakers, 2-7 Installing and removing
series 505, replacing in power supply, 7-12
series 500 RBC, D-11
series 505
I/O modules, 3-21
G power supply, 3-9
RBC, 3-19
Grounding
cabinet or rack, 2-14
connections, 2-14
controller, 2-14 J
earth, 2-13
planning for, 2-13 Jog switch, location, 2-5
sample connection, 2-15

L
H
Local area networks, supported, 1-5
H1 support, 1-5
Hardware, description, 1-6
Hot backup, D-8 M
Memory, configuration, list of types, 6-4, 6-5
I Modem
connecting, overview, 4-18
I/O modules dedicated line operation, 4-18, 4-19
compatibility, determing of module, C-2 dial-up phone line, 4-19

Index-2
 setting baud rate, 3-16
N
RBE, support, 1-2
Noise
avoiding electrical, 2-8 Restart
isolating from, 2-11 list of auxiliary functions, 7-3–7-16
snubbing, contact noise, 2-9 using auxiliary functions, 7-2
RF to RS-485 converter, D-8

P
Power needs, planning for, 2-2
S
Power supply Safety
connecting input, 4-2 guidelines, 2-3
series 505, 1-7 inch switch, 2-5
installing, 3-9 jog switch, 2-5
installing and removing, 3-9 operator safety switches, 2-4
power consumption, 3-9 Series 500, base numbers, assigning, D-12
replacing fuse, 7-12
troubleshooting, 7-12 Series 500 RBC
installing and removing, D-11
Power-up LED messages, D-13
memory and mode status, 5-5
placing in bases, D-11
procedures, 6-2
setting baud rates, D-12
Printer
Series 505
connecting, 4-20
base
handshaking, 4-20
installing controller, 3-11–3-15
overview, 4-20
models available, 3-3
Program panel mounting, 3-5
copying into EEPROM, 5-8 models available, 3-3
editing in EEPROM, 5-10 rack mounting, 3-4
software, 1-8 models available, 3-3
storage in EEPROM, 1-8 connecting base, 3-3
storage in EPROM, 1-8 dipswitch, ports, 3-14
environmental specifications, A-2
general specifications, A-3
I/O modules, installing and removing, 3-21
R installing, flowchart, 3-2
module power requirements, B-2
RBC
power supply
series 500
installing and removing, 3-9
assigning base numbers, D-12
replacing fuse, 7-12
installing and removing, D-11
specifications, power supply electrical, A-4
placing in bases, D-11
setting baud rate, D-12 Series 505 RBC
series 505 base, installing, 3-19
assigning base numbers, 3-19 base numbers, assigning, 3-19
description, 3-3 dipswitch (factory), 3-17
installing and removing, 3-19 installing and removing, 3-19
installing in base, 3-19 LED messages, 3-20

Index-3
Spare parts, list of, 7-16 Troubleshooting
Specifications, series 505 cable, RS-485, 7-14
general, A-3 compare disk to PLC, 7-4
power supply electrical, A-4 EPROM/EEPROM, 7-11
system specifications, A-2 fatal errors, 7-7
non-fatal errors, list of, 7-9
Start-up, procedures, 6-2 reading LEDs, 7-6
Status words, using in troubleshooting, 7-10 restart, 7-2
series 505, power supply, 7-12
Switch, emergency stop, 2-4
using auxiliary functions, 7-2
Switches using status words, 7-10
inch, 2-5
jog, 2-5
safety, 2-4
U
Upgrading
T series 500 system, D-3–D-5
TI560/TI565 system, D-6–D-7, D-8–D-9
Temperature, planning for PLC, 2-6
Thumbwheels
series 500 RBC
assigning base numbers, D-12
W
setting baud rate, D-12 Wiring
series 505 RBC, assigning base numbers, 3-19 connecting input power, 4-2
TIWAY, support, 1-5 planning for installation, 2-12

Index-4
SIMATIC and SINEC are trademarks of Siemens AG.

Series 505, Series 500, APT, CVU100, CVU1000, CVU10000, Peerlink, TISOFT, TIWAY, PCS, 386/ATM, and 7MT are trademarks of
Siemens Industrial Automation, Inc.
IBM and AT are registered trademarks of International Business Machines Incorporated.
MS-DOS is a registered trademark of Microsoft corporation.
Belden is a registered trademark of Cooper Industries, Inc.
TI505, TI520, TI520C, TI530, TI530C, TI530T, TI545, TI555, TI560, TI565, TI560T, and TI565P are trademarks of Texas Instruments
Incorporated.
CSA is a registered trademark of the Canadian Standards Association.
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Manual Name: SIMATIC TI545/555 System Manual Edition: Second

Manual Assembly Number: 2586546–0084 Date: 10/94
Order Number: PPX:545/555–8101-2
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