Advantech ADAM-5560 User Manual

User Manual

ADAM-5560 Series

Programmable Automation
Controllers

Copyright

Part No. XXXXXXXXXX Edition 1
Printed in Taiwan February 2014

The documentation and the software included with this product are copyrighted 2012
by Advantech Co., Ltd. All rights are reserved. Advantech Co., Ltd. reserves the right
to make improvements in the products described in this manual at any time without
notice. No part of this manual may be reproduced, copied, translated or transmitted
in any form or by any means without the prior written permission of Advantech Co.,
Ltd. Information provided in this manual is intended to be accurat e and reliable. How­ever, Advantech Co., Ltd. assumes no responsibility for its use, nor for any infringe­ments of the rights of third parties, which may result from its use.

Acknowledgements

ADAM is a trademark of Advantech Co., Ltd.
IBM and PC are trademarks of International Business Machines Corporation.
MULTIPROG is a trademark of KW-Software Gmbh.
All other product names or trademarks are properties of their respective owners.

Product Warranty (2 years)

Advantech warrants to you, the original purchaser, that each of its products will be
free from defects in materials and workmanship for two years from the date of pur­chase.

This warranty does not apply to any products which have been repaired or altered by
persons other than repair personnel authorized by Advantech, or which have been
subject to misuse, abuse, accident or improper installation. Advantech assumes no
liability under the terms of this warranty as a consequence of such events.

Because of Advantech’s high quality-control standards and rigorous testing, most of
our customers never need to use our repair service. If an Advantech product is defec­tive, it will be repaired or replaced at no charge during the warranty period. For out­of-warranty repairs, you will be billed according to the cost of replacement materials,
service time and freight. Please consult your dealer for more details.

If you think you have a defective product, follow these steps:

1. Collect all the information about the problem encountered. (For example, CPU

speed, Advantech products used, other hardware and software used, etc.) Note
anything abnormal and list any onscreen messages you get when the problem
occurs.

2. Call your dealer and describe the problem. Please have your manual, product,

and any helpful information readily available.

3. If your product is diagnosed as defective, obtain an RMA (return merchandize

authorization) number from your dealer. This allows us to process your return
more quickly.

4. Carefully pack the defective product, a fully-completed Repair and Replacement

Order Card and a photocopy proof of purchase date (such as your sales receipt)
in a shippable container. A product returned without proof of the purchase date
is not eligible for warranty service.

5. Write the RMA number visibly on the outside of the package and ship it prepaid

to your dealer.

ADAM-5560 Series User Manual ii

Declaration of Conformity

CE

This product has passed the CE test for environmental specifications when shielded
cables are used for external wiring. We recommend the use of shielded cables. This
kind of cable is available from Advantech. Please contact your local supplier for
ordering information.

FCC Class A

Note: This equipment has been tested and found to comply with the limit s for a Class
A digital device, pursuant to part 15 of the FCC Rules. These limits are designed to
provide reasonable protection against harmful interference when the equipment is
operated in a commercial environment. This equipment generates, uses, and can
radiate radio frequency energy and, if not installed and used in accordance with the
instruction manual, may cause harmful interference to radio communications. Opera­tion of this equipment in a residential area is likely to cause harmful interference in
which case the user will be required to correct the interference at his own expense.

Technical Support and Assistance

1. Visit the Advantech web site at www .ad vantech.com/support where you can find

the latest information about the product.

2. Contact your distributor, sales representative, or Advantech's customer service

center for technical support if you need additional assistance. Please have the
following information ready before you call:

– Product name and serial number
– Description of your peripheral attachments
– Description of your software (OS, version, application software, etc.)
– A complete description of the problem
– The exact wording of any error messages

Safety Precaution - Static Electricity

Follow these simple precautions to protect yourself from harm and the products from
damage.

 To avoid electrical shock, always disconnect the power from your PC chassis

before you work on it. Don't touch any components on the CPU card or other
cards while the PC is on.

 Disconnect power before making any configuration changes. The sudden rush

of power as you connect a jumper or install a card may damage sensitive elec­tronic components.

iii ADAM-5560 Series User Manual

Safety Instructions

1. Read these safety instructions carefully.

2. Keep this User Manual for later reference.

3. Disconnect this equipment from any AC outlet before cleaning. Use a damp

cloth. Do not use liquid or spray detergents for cleaning.

4. For plug-in equipment, the power outlet socket must be located near the equip-

ment and must be easily accessible.

5. Keep this equipment away from humidity.

6. Put this equipment on a reliable surface during installation. Dropping it or letting

it fall may cause damage.

7. The openings on the enclosure are for air convection. Protect the equipment

from overheating. DO NOT COVER THE OPENINGS.

8. Make sure the voltage of the power source is correct before connecting the

equipment to the power outlet.

9. Position the power cord so that people cannot step on it. Do not place anything

over the power cord.

10. All cautions and warnings on the equipment should be noted.

11. If the equipment is not used for a long time, disconnect it from the power source

to avoid damage by transient overvoltage.

12. Never pour any liquid into an opening. This may cause fire or electrical shock.

13. Never open the equipment. For safety reasons, the equipment should be

opened only by qualified service personnel.

14. If one of the following situations arises, get the equipment checked by service

personnel:

15. The power cord or plug is damaged.

16. Liquid has penetrated into the equipment.

17. The equipment has been exposed to moisture.

18. The equipment does not work well, or you cannot get it to work according t o the

user's manual.

19. The equipment has been dropped and damaged.

20. The equipment has obvious signs of breakage.

21. DO NOT LEAVE THIS EQUIPMENT IN AN ENVIRONMENT WHERE THE

STORAGE TEMPERATURE MAY GO BELOW -20° C (-4° F) OR ABOVE 60° C
(140° F). THIS COULD DAMAGE THE EQUIPMENT. THE EQUIPMENT
SHOULD BE IN A CONTROLLED ENVIRONMENT.

22. CAUTION: DANGER OF EXPLOSION IF BATTERY IS INCORRECTLY

REPLACED. REPLACE ONLY WITH THE SAME OR EQUIVALENT TYPE
RECOMMENDED BY THE MANUFACTURER, DISCARD USED BATTERIES
ACCORDING TO THE MANUFACTURER'S INSTRUCTIONS.

23. The sound pressure level at the operator's position according to IEC 704-1:1982

is no more than 70 dB (A).

DISCLAIMER: This set of instructions is given according to IEC 704-1. Advantech
disclaims all responsibility for the accuracy of any statements contained herein.

ADAM-5560 Series User Manual iv

Contents

Chapter 1 Overview...............................................1

1.1 Introduction ...............................................................................................2

1.2 Features....................................................................................................2

Table 1.1: Programming Languages Table................ .... ... ... ... ... . 4

Figure 1.1 Cross-Language Programming . ... .... ... ... ... .... ... ... ... ... . 4

Table 1.2: I/ O Module Support List....... ... ... ... .... ... ... ... .... ... ... ... ... . 6

Figure 1.2 ADAM-5560 Communication Ports.............................7

1.3 Specifications............................................................................................8

1.3.1 System.......................................................................................... 8

1.3.2 USB Ports.....................................................................................8

1.3.3 VGA Port.......................................................................................8

1.3.4 Ethernet Ports ............................................................. .... ... ... ... ... . 8

1.3.5 RS-232/485 interface (COM1)...................................................... 8

1.3.6 RS-485 interface (COM2)................................... ... .......................9

1.3.7 ES-232/485 interface (COM3) (Suitable for touchscreen)............9

1.3.8 RS-232/485 interface (COM4)......................................................9

1.3.9 Isolation.........................................................................................9

1.3.10 Power............................................................................................ 9

1.3.11 Mechanical..................................................................................10

1.3.12 Environment................................................................................10

1.3.13 Software Specifications...............................................................10

1.4 Dimensions .............................................................................................10

Figure 1.3 ADAM-5560 Dimensions ..........................................10

1.5 LED Status.............................................................................................. 10

1.6 Limitations............................................................................................... 11

1.6.1 Remote I/O Quantity................................................................... 11

1.6.2 Modbus/RTU Slave Function......................................................11

1.6.3 TCP/IP Connections ...................................................................11

1.6.4 Firmware Upgrade Notice........................................................... 11

1.6.5 Boot-up Time .............................................................................. 11

Chapter 2 Installation..........................................13

2.1 Overview ................................................................................................. 14

2.2 System Requirements.............................................................................14

2.2.1 Host Computer Requirements ....................................................14

2.2.2 ADAM-5560 Series Requirements..............................................14

2.2.3 I/O Module Requirements...........................................................14

2.3 Hardware Installation .............................................................................. 15

2.3.1 Selecting I/O Module...................................................................15

Table 2.1: Discrete and Analog I/O Selection Guidelines..........15

2.3.2 Selecting Power Supply Module.................................................18

Table 2.2: Power Consumption of ADAM-5000 series (Main Units)

18

Table 2.3: Power Consumption of ADAM-5000 series (IO Mod-

ules).......................................................................... 19

Table 2.4: Power Supply Specification Table............................ 20

2.3.3 Install Main Unit and Modules.....................................................20

2.3.4 I/O Slots and I/O Channel Numbering ........................................ 20

2.3.5 Mounting.....................................................................................21

Figure 2.1 Panel Mount for ADAM-5560 Series ........................ 21

Figure 2.2 DIN-rail Mounting...................................................... 21

2.3.6 Jumper and DIP Switch Settings ................................................ 22

Figure 2.3 COM Port Location................................................... 22

v ADAM-5560 Series User Manual

Figure 2.4 COM1/COM4 RS-232/485 Settings ......................... 22

Figure 2.5 COM1 RS-232/485 and Terminal Resistor Settings. 23
Figure 2.6 COM3 RS-232/485 and Terminal Resistor Settings. 23
Figure 2.7 COM4 RS-232/485 and Terminal Resistor Settings. 23

Figure 2.8 ADAM-5560 Series DIP Switch................................ 24

Table 2.5: Device ID DIP Switch Table..................................... 24

2.3.7 COM Port Pin Assignments........................................................ 25

Figure 2.9 RS-232 Port Pin Assignment.................. ... ... ... .... ... .. 25

Figure 2.10RS-485 Port Pin Assignment.................................... 25

2.4 System Wiring and Connections............................................................. 26

2.4.1 Power Supply Wiring ............ .... ... ... ... ... .... ... ............................... 26

Figure 2.11ADAM-5560 Series Controller Power Wiring............ 26

2.4.2 I/O Module Wiring........................ ... ... ... .... ... ... ... .... ... ... ... ... .... ... .. 26

2.4.3 Connection of Communication Ports.......................................... 26

Figure 2.12Remote I/O Wiring........... ... .... ... ... ... .... ... ... ... ... .... ... .. 27

2.4.4 Ethernet Network Connection..................................................... 27

Figure 2.13Ethernet Network Connection ................ ... ...... .... ... .. 27

Chapter 3 Quick Start......................................... 29

3.1 Set IP Address to ADAM-5560KW........................... ... ... .... ... ... ... ... .... ... .. 31

3.2 Configure ADAM-5000 Local I/O ................................................... .... ... .. 35

3.3 Multiprog Installation............................................................................... 39

3.4 Create a Project and Test the System.................................................... 39

3.5 Special Module Support in KW............................................................... 59

Chapter 4 Modbus Functions............................61

4.1 Introduction............................................................................................. 62

4.2 Modbus/TCP Client Function... ... ... ... .... ... ... ... ... .... ... ... ............................ 62

4.2.1 An example to demonstrate how to connect to ADAM-6050 for

Modbus/TCP client function........................................................ 63

4.3 Modbus/RTU Master Function................................................. ... ... .... ... .. 80

4.3.1 Modbus/RTU Master Function Example..................................... 80

4.4 Modbus/TCP Server Functions................................... ... .... ... ... ... ... .... ... 107

4.4.1 Modbus Address Mapping........................................................ 107

4.4.2 Example.................................................................................... 108

Chapter 5 Network Functions.......................... 123

5.1 Web Server Functions .......................................................................... 124

5.1.1 Configure Web Server.............................................................. 124

5.2 FTP Server Function............................................................................. 131

5.3 Email Alarm Function............................................................................ 143

5.4 SQL Server Function ............................................................................ 145

Chapter 6 Miscellaneous Functions............... 149

6.1 Advantech Utilities ......................................... ... .... ... ... ... .... ... ... ............. 150

6.2 Change Language Interface of CE ....................................................... 151

6.3 Example of Configuring Touch Screen................................................. 154

6.4 Save and Upload Project Source.......................................................... 160

6.5 Changing the Language Interface......................................................... 163

Chapter A RS-485 Networks............................. 167

ADAM-5560 Series User Manual vi

A.1 RS-485 Networks..................................................... ... .... ......................168

A.2 Basic Network Layout ...........................................................................168

Figure A.1 Daisychaining......................................................... 169

Figure A.2 Star Structure .........................................................169

Figure A.3 Random structure................................................... 170

A.3 Line Termination .................................................................................. 170

Figure A.4 Signal Distortion .....................................................170

Figure A.5 Termination Resistor Locations..............................171

A.4 RS-485 Data Flow Control ....................................................................172

Figure A.6 RS-485 Data Flow Control with RTS......................172

Chapter B Grounding Reference......................173

B.1 Field Grounding and Shielding Applications .........................................174

B.2 Grounding ............................................................................................. 174

B.2.1 The ‘Earth’ for reference...........................................................174

Figure B.1 Think the EARTH as GROUND.............................. 174

B.2.2 The ‘Frame Ground’ and ‘Grounding Bar’.... ... .... ... ... ... .... ... ... ... 175

Figure B.2 Grounding Bar........................................................175

Figure B.3 Normal and Common Modes..................................175

B.2.3 Normal Mode and Common Mode............ ... ... .... ... ... ... .... ... ... ... 176

Figure B.4 Normal and Common Modes..................................176

B.2.4 Wire Impedance........................................................................176

Figure B.5 High Voltage Transmissions................................... 176

Figure B.6 Wire Impedance .....................................................177

B.2.5 Single Point Grounding............................................................. 177

Figure B.7 Single Point Grounding (1).....................................177

Figure B.8 Single Point Grounding (2).....................................178

B.3 Shielding ...............................................................................................178

B.3.1 Cable Shield.............................................................................. 178

Figure B.9 Single Isolated Cable..............................................178

Figure B.10Double Isolated Cable............................................ 179

B.3.2 System Shielding...................................................................... 180

Figure B.11System Shielding.................................................... 180

Figure B.12Cable Characteristics.............................................180

Figure B.13System Shielding (1)..............................................181

Figure B.14System Shielding (2)..............................................181

B.4 Noise Reduction Techniques................................................................ 182

Figure B.15Noise Reduction Techniques ................................. 182

B.5 Check Point List ....................................................................................182

Chapter C Reference Documents.....................183

C.1 Reference Documents .......................................................................... 184

C.2 Topics for Getting Familiar with Multiprog.............................................184

vii ADAM-5560 Series User Manual

ADAM-5560 Series User Manual viii

Chapter 1

1 Overview

1.1 Introduction

ADAM-5560 Series Controller is Programmable Automation Controller designed for
control tasks which require Industrial PC computing performance with the PLC’s
robustness. ADAM-5560 Series Controller offers Intel ATOM Z510P CPU along with
control specific features such as watchdog timer, battery backup RAM and determin­istic I/O.

ADAM-5560KW Controller features 5 standard IEC61131-3 programming languages
in CE 5.0, so PLC users can develop control strategies with their own familiar pro­gramming languages. The powerful Multiprog KW Software and stable ProCon OS
have allowed ADAM-5560KW Controller to become the best choice for a Program­mable Automation Controller on the market today. With the optional HMI Software
and built-in VGA port. User will no longer be required to build up additional SCADA
PC’s in their applications. This compact and powerful PAC is ideal for a variety of
applications ranging from Machine Automation to SCADA applications.

The ADAM-5560 Series Controller includes two models as following:

ADAM-5560CE 7-slot PC-based Programmable Controller
ADAM-5560KW 7-slot Programmable Automation Controller

1.2 Features

The hardware system of ADAM-5560 Series Controller consists of two major compo­nents: the main unit and I/O modules. The main unit includes a CPU card, a power
module, an 7-slot backplane and four serial communication ports. ADAM-5560
Series Controller also embeds two Ethernet ports, two USB ports and VGA port. The
.NET class Library is needs for developing the program for ADAM-5560CE. The
Multiprog software is also needed for developing the control program for ADAM-5560
Series Controller. Following are the major features:

 Designed for control tasks that meet robust and computing performance

requirements of PLC and Industrial PC’s

 Built-in VGA Port
 Support Storage Function by Battery Backup RAM and SD Card I/O Module
 Built-in real-time clock and watchdog timer
 Support .NET class library (For ADAM-5560CE)
 SoftLogic support in CE 5.0
 Process IEC-61131-3 standard with rich development environment (For ADAM-

5560KW)

 Cross-Language programming (For ADAM-5560KW)
 Deterministic I/O
 Real time multi-task engine
 Custom Function Block (For ADAM-5560KW)
 Pre-defined function library (For ADAM-5560KW)
 Powerful debug / diagnostic / simulation / force tools
 Online editing & partial download
 Rich support to ADAM-5560 I/O Modules
 Dual Ethernet Ports
 Remote maintenance via FTP Server
 Built-in SQL Mobile Server
 RS-232/485 communication ability
 Remote I/O expansibility

ADAM-5560 Series User Manual 2

Designed for control tasks that meet robust and computing performance
requirements of PLC and Industrial PC’s

ADAM-5560 Series Controller is designed for control tasks which need Industrial
PC’s computing performance and PLC’s robustness. Its multiple functionalities
include discrete, analog and motion functions. The well-integrated programming tool
and optional HMI software provide a flexible and easy-to-use software solution for
versatile applications.

Built-in VGA port

ADAM-5560 Series Controller has a built-in VGA port which can directly connect to a
display. So HMI function can be integrated into this controller. ADAM-5560 Series
Controller can be operated with or without display and/or keyboard/mouse which can
meet different requirements of applications.

Support atorage function by battery backup rAM and SD card I/O module

ADAM-5560 Series Controller has built-in 1GB DDR2 SDRAM with 1MB battery
backup RAM for saving important data. The ADAM-5030 I/O Module supports two
SD cards and two USB ports. So users can use SD cards or USB sticks for large
amount of data storage requirement.

Chapter 1 Overview

Built-in real-time clock and watchdog timer

The ADAM-5560 Series Controller also includes a real-time clock and watchdog
timer. The real-time clock records events while they occur. The watchdog timer is
designed to automatically reset the microprocessor if the system fails. ADAM-5560
Series Controller provides two types of watchdog timers. They are Operating System
Watchdog and KW application watchdog. It will increase the reliability of system and
make the ADAM-5560 Series Controller ideal for use in applications which require
high system stability.

SoftLogic Support in Windows CE 5.0

ADAM-5560KW Controller supports IEC-61131-3 programming in WinCE 5.0. The
five programming languages of Ladder Diagram, Function Block, Sequential Func­tion Chart, Structured Text and Instruction List cover most of the PLC programming
languages in the market. The reliable PROCONOS runtime engine and powerful
MULTIPROG software from KW-Software empower ADAM-5560KW Controller as
the best solution of Programmable Automation Controller.

Process IEC 61131-3 standard with rich development environment

The standard IEC 61131-3 has been established to standardize the multiple lan­guages, sets of instructions and different concepts existing in the field of automation
systems. The great variety of control concepts has led to an incompatibility between
the different control platforms and manufacturers. The result was a great effort to be
made for training, hardware and software investments.

IEC 61 131-3 defines the synt ax of 5 programming languages, defines a cert ain repre­sentation and describes the different elements which can be used in the language.

The programming languages can be differentiated by the physical appearance into 2
textual languages and 3 graphical languages.

3 ADAM-5560 Series User Manual

Table 1.1: Programming Languages Table

Textual Languages Graphical Languages

Instruction List (IL)
Structured Text (ST)

Function Block Diagram (FBD)
Ladder Diagram (LD)
Sequential Function Chart (SFC)

Cross-Language Programming

For some project integrate and scalable issues, cross-language can help you to
choose the different language for your project. For example, you can use ladder (LD)
on the simple I/O module control or simple logical expression and use Function Block
(FB) on process control for more advanced expression and use Sequential Function
Chart (SFC) for system configuration in hybrid control system such as Water Treat­ment.

Figure 1.1 Cross-Language Programming

Deterministic I/O

ADAM-5560 Series Controller can guarantee deterministic I/O at 1ms. The feature
guarantees control and response speed at I/O level so HMI software or operations of
other application programs cannot affect the I/O control performance.

ADAM-5560 Series User Manual 4

Real time multi-task engine

ADAM-5560 Series Controller provides the multi-task and multi-program environ­ment. ADAM-5560 Series Controller’s communication, data process and I/O access
tasks are working independent, so the system performance and efficiency are better
than traditional PLC.

Custom Function Block for complex control

ADAM-5560KW Controller allows custom function block for advanced control algo­rithm such as fuzzy logic control or neural network control function. Users can define
their own function block for common use function or special domain know-how. The
control kernel also provides powerful floating point calculation and rich memory for
complex control.

Pre-defined function library

Advantech Multiprog provides many pre-defined function library such as maximum of
strings as string function block, Convert REAL to INT as type convert function block.
It helps you to build up your program more conveniently. It is more convenient than
the traditional control programming tools. With this pre-defined function, you can
make your project easier in timer control, variable type conversion or strings conver­sion, etc.

Chapter 1 Overview

Powerful debug / diagnostic / simulation / force tools

Advantech Multiprog provides lots of powerful tools for debug, diagnostic, simulation
and force function. It shows friendly interfaces when you use these tools. With debug
/ diagnostic tools, you can make it easier on trouble-shooting. Advantech Multiprog
simulator supports program verification offline directly on your PC. This is great in
case you are developing logic and you do not have access to a controller. To activate
an I/O simply click on the LED you want to energize and your logic executes as if it
was a real I/O. The program operation is the same as if you actually were connected
to the controller, so all the debug tools are fully functional: power and logic flow, I/O
force and overwriting. With force tools, you can check more exception situations and
check if the project handling right or wrong. It prevents the damage for you.

Online editing & partial download

Online editing is a MUST even though many packages do not support it. It is unac­ceptable to shut down the machine or process to perform maintenance, not to men­tion how difficult it is to debug when you have to switch back and forth from program
to run mode. Multiprog supports online editing so you can make changes and then
download the changes to the controller WITHOUT stopping the machine or process.
It helps you to maintain your system easier and save the cost for your system pro­cess.

Rich support to ADAM-5560 I/O Modules

Most of the ADAM-5560 I/O modules are supported by ADAM-5560 Series Controller
including analog I/O modules, digital I/O modules and motion control module. All the
operations of supported modules are the same with the operations of ADAM-5510
series.

The ADAM-5560 Series Controller uses a convenient backplane system for
supporting versatile I/O modules. Advantech's complete line of ADAM-5560 I/O mod­ules integrates with the ADAM-5560 Series Controller to support your applications.
Following table is the latest I/O module support list we provided for user’s choice.

5 ADAM-5560 Series User Manual

Table 1.2: I/O Module Support List

Function Module Description Reference

ADAM-5013 3 -c h RTD Input Isolated
ADAM-5017 8 -c h AI Isolated
ADAM-5017P 8-ch AI w/Independent Input Range Isolated

Analog Input

Analog Output ADAM-5024 4-ch AO Isolated

Digital Input

Digital Output

Digital I/O

Relay Output
Counter/

Frequency
Communication
Storage ADAM-5030 2-slot SD Storage Module Non-isolated

Motion

ADAM-5017H 8-ch High Speed AI (1 KHz) Isolated
ADAM-5017UH 8-ch Ultra High Speed AI (200KHz) Isolated
ADAM-5018 7 -c h TC Input Isolated
ADAM-5018P 7-ch TC Input w/Independent Input Range Isolated

ADAM-5051 16-ch DI Non-isolated
ADAM-5051D 16-ch DI w/LED Non-isolated
ADAM-5051S 16-ch Isolated DI w/LED Isolated
ADAM-5052 8-ch Isolated DI w/LED Isolated
ADAM-5053S 32-ch Isolated DI Isolated
ADAM-5056 16-ch DO Non-isolated
ADAM-5056D 16-ch DO w/LED Non-isolated
ADAM-5056S 16-ch Isolated DO w/LED Isolated
ADAM-5056SO 16-ch Source Type Isolated DO w/LED Isolated
ADAM-5057S 32-ch Isolated DO Isolated
ADAM-5050 16-ch DI/O Non-isolated
ADAM-5055S 16-ch Isolated DI/O w/LED Isolated
ADAM-5060 6-ch Relay Output Isolated
ADAM-5069 8-ch Power Relay Output w/LED Isolated

ADAM-5081 4 -c h/ 8- ch High Speed Counter/Frequen cy Isolated
ADAM-5091 4-port RS-232 Module Non-isolated

ADAM-5095 2-port CAN Module Isolated

ADMA-5202 2-port AMONet Master Module Isolated
ADAM-5240

4-axis Stepping/Servo Motor Control
Module

Isolated

Note! For details, refer to ADAM-5000 I/O Module User’s Manual.

Dual Ethernet Ports

ADAM-5560 Series Controller provides two Ethernet ports for different application
requirements such as redundant Ethernet connection for reliability concern or sepa­rated network connections for security concern. Both of the functions are possible to
be implemented by customer’s application program.

ADAM-5560 Series User Manual 6

Remote maintenance via FTP Server and DiagAnywhere Software

For remote maintenance function, the built-in FTP server provides service for upload­ing application program or downloading data logging files. DiagAnywhere Software is
also supported for remote control, download and upload functions.

Built-in SQL Mobile Server

ADAM-5560KW Controller embeds SQL server so it is very easy to exchange data
between enterprise database/local HMI software and SQL server by SQL query func­tions. Following is the Architecture of ADAM-5560KW Controller Kernel.

Chapter 1 Overview

RS-232/485 communication ability

The ADAM-5560 Series Controller has four serial communication ports, giving it
excellent communication abilities. This facilitates its ability to control networked
devices. ADAM-5560 Series Controller COM1/COM3/COM4 are RS-232/485
selectable port and COM2 is a dedicated RS-485 por. These four ports allow the
ADAM-5560 Series Controller to satisfy diverse communication and integration
demands. With this communication ports, you should not buy more I/O communica­tion device and save more costs. You can also extend your system by using these
communication ports. Please refer to following figure and check the location of COM
ports.

Figure 1.2 ADAM-5560 Communication Ports

7 ADAM-5560 Series User Manual

Remote I/O Expansibility

ADAM-5560 Series Controller supports not only Modbus/RTU Master function via
serial ports, but also the Modbus/TCP Client to retrieve data from remote I/O, and
Modbus/TCP Server to exchange data with other Modbus devices via Ethernet port.
This Modbus features are very useful when the control system needs expand the
remote I/O modules or connect to other controllers.

1.3 Specifications

1.3.1 System

 CPU: Intel ATOM Z510P Processor
 Operating system: Windows CE 5.0
 Memory: 1 GB DDR2 SDRAM with 1MB Battery Backup

One CompactFlash® Card (Internal)

 Real-time clock: Yes
 Watchdog timer: Yes

– Operating System Watchdog
– KW application watchdog
– Modbus server communication watchdog

 USB Port: USB 2.0 ports * 2
 VGA Port: 1024 X 768 Resolution
 Ethernet Port: 10M/100M bps * 2

RJ-45 connectors

 COM1: RS-232/485 selectable, DB-9 connector
 COM2: RS-485, Terminal Block
 COM3: RS-232/485 selectable, DB-9 connector
 COM4: RS-232/485 selectable, DB-9 connector
 I/O capacity: 7 slots
 Maximum number of nodes: 256 nodes
 System power consumption: 17 W (without I/O modules)

1.3.2 USB Ports

 USB 2.0

1.3.3 VGA Port

 1024 X 768 Resolution

1.3.4 Ethernet Ports

 10M/100M bps x 2
 RJ-45 connectors
 Transmission Speed 10M/100M bps (10/100 Base-T)

1.3.5 RS-232/485 interface (COM1)

 RS-232/485 Mode selectable by jumper
 RS-232 Mode: Asynchronous full duplex, point to point

Signals: TxD, RxD, RTS, CTS, DTR, DSR, DCD, RI, GND

 RS-485 Mode: Half duplex, multi-drop

Signal: DATA+, DATA-

ADAM-5560 Series User Manual 8

 Connector: DB-9 pin
 Transmission speed: Up to 115.2 Kbps
 Max transmission distance:

– RS-232: 50 feet (15.2 m)
– RS-485: 4,000 feet (1220 m)

1.3.6 RS-485 interface (COM2)

 Signals: DATA+, DATA-
 Mode : Half duplex, multi-drop
 Connector: Screw terminal
 Transmission speed: Up to 115.2K bps
 Max transmission distance: 4000 feet (1220 m)

1.3.7 ES-232/485 interface (COM3) (Suitable for touchscreen)

 RS-232/485 Mode selectable by jumper

RS-485 Signal: DATA+, DATA-

 RS-232 Mode: Asynchronous full duplex, point to point

Signals: TxD, RxD, RTS, CTS, DTR, DSR, DCD, RI, GND

 RS-485 Mode: Half duplex, multi-drop

RS-485 Signal: DATA+, DATA-

 Connector: DB-9
 Transmission speed: Up to 115.2K bps
 Max transmission distance:

– RS-232: 50 feet (15.2 m)
– RS-485: 4000 feet (1220 m)

Chapter 1 Overview

1.3.8 RS-232/485 interface (COM4)

 RS-232/485 Mode selectable by jumper

RS-485 Signal: DATA+, DATA-

 RS-232 Mode: Asynchronous full duplex, point to point

Signals: TxD, RxD, RTS, CTS, DTR, DSR, DCD, RI, GND

 RS-485 Mode: Half duplex, multi-drop

RS-485 Signal: DATA+, DATA-

 Connector: DB-9
 Transmission speed: Up to 115.2K bps
 Max transmission distance:

– RS-232: 50 feet (15.2 m)
– RS-485: 4000 feet (1220 m)

1.3.9 Isolation

 COM2: 2500 Vrms
 COM1/COM3/COM4: 1000 Vrms (RS-485 only)

1.3.10 Power

 Unregulated +10 to +30 VDC
 Protected against power reversal
 Power consumption: 17 W (not including I/O modules)

9 ADAM-5560 Series User Manual

1.3.11 Mechanical

 Case: ABS+PC with captive mounting hardware
 Plug-in screw terminal block:

Accepts 0.5 mm2 to 2.5 mm2, 1 - #12 or 2 - #14 to #22 AWG

1.3.12 Environment

 Operating temperature: 0 ~ 55° C (32 ~ 122° F)
 Storage temperature: -25° to 85° C (-13° to 185° F)
 Humidity: 5 to 95 %, non-condensing
 Atmosphere: No corrosive gases

Note! Equipment will operate below 30% humidity. However, static electricity

problems occur much more frequently at lower humidity levels. Make
sure you take adequate precautions when you touch the equipment.
Consider using ground straps, anti-static floor coverings, etc. if you use
the equipment in low humidity environments.

1.3.13 Software Specifications

 Real Time O.S: KW ProConOS (Up to 16 cycle tasks)
 Programmable Code/Data Size: up to 710 KB

1.4 Dimensions

The following diagrams show the dimensions of the system unit and an I/O unit. All
dimensions are in millimeters.

Figure 1.3 ADAM-5560 Dimensions

1.5 LED Status

There are two LEDs on the front panel of ADAM-5560 Series Controller. The LEDs
indicate operating status, as explained below:

PWR: Power indicator. This LED is on whenever the ADAM-5560 Series Controller is
powered on.

RUN: Blinking while project is running, off while project is stopped.

ADAM-5560 Series User Manual 10

There are two LEDs besides each Ethernet port. The LEDs indicate operating status,
as explained below:

TX (Green): This LED blinks whenever the ADAM-5560 Series Controller
transmitting data to Ethernet.

Link (Orange): This LED is on whenever the ADAM-5560 Series Controller
connecting to Ethernet.

1.6 Limitations

1.6.1 Remote I/O Quantity

ADAM-5560 Series Controller can connect to ADAM-4000 Modbus I/O modules
through COM1/COM2/COM3/COM4 RS-485 port by Modbus protocol. (COM2 is also
workable if a RS-232 to RS-485 converter is used.) The typical quantity of remote I/O
connection is 128.

1.6.2 Modbus/RTU Slave Function

ADAM-5560 Series Controller support Modbus/RTU slave function.

1.6.3 TCP/IP Connections

Chapter 1 Overview

 Multiprog via Ethernet connection: maximum 4 connections
 Modbus/TCP Server connection: maximum 64 connections
 Modbus/TCP Client connection: maximum 128 connections

1.6.4 Firmware Upgrade Notice

When you would like to upgrade the firmware of ADAM-5560 Series Controller,
please do contact with Advantech Technical Support Team for support. Wrong proce­dures will possibly cause potential problem to your system.

1.6.5 Boot-up Time

The boot-up time of ADAM-5560 Series Controller is around 40 seconds.

11 ADAM-5560 Series User Manual

ADAM-5560 Series User Manual 12

Chapter 2

2 Installation

2.1 Overview

This chapter describes how to install an ADAM-5560 Series Controller. A quick
hookup scheme is provided that let you easily configure your system before imple­menting it into your application.

2.2 System Requirements

Before you start installing the ADAM-5560 Series Controller, make sure the system
requirements are met as below:

2.2.1 Host Computer Requirements

1. IBM PC compatible computer with Pentium II 350MHz processor.

2. Microsoft Windows 95/98/NT4.0 SP5/Windows 2000 SP2 or Windows XP.

3. At least 64 MB RAM.

4. 200 MB of hard disk space available

5. VGA 256 colors monitor, 800x600 resolutions

6. CD-ROM.

7. Mouse or other pointing devices.

8. One Ethernet port

2.2.2 ADAM-5560 Series Requirements

1. 1 x ADAM-5560 Series main unit, i.e., ADAM-5560CE or ADAM-5560KW

2. ADAM-5560 Series User’s Manual

3. One Advantech Multiprog CD.

4. Power supply for ADAM-5560 Series (+10 to +30 VDC unregulated)

5. One Ethernet Hub or Switch like ADAM-6520 or ADAM-6510

2.2.3 I/O Module Requirements

At least one I/O module is needed to use the system. A variety of I/O modules are
available to meet different application requirements. Table 1.2 gives a current listing
of these modules for your reference. In following example, we will use ADAM-5051D
in Slot 0 and ADAM-5056D in Slot 1 on ADAM-5560KW.

ADAM-5560 Series User Manual 14

2.3 Hardware Installation

2.3.1 Selecting I/O Module

To organize an ADAM-5560 Series control system, you need to select I/O modules to
interface the main unit with field devices or processes that you have previously deter­mined. There are several things should be considered when you select the I/O mod­ules.

 What type of I/O signal is applied in your system?
 How many I/O is required to your system?
 How will you concentrate the I/O points of an entire process?
 What is the required voltage range for each I/O module?
 What isolation environment is required for each I/O module?
 What are the noise and distance limitations for each I/O module?

Refer to discrete & analog I/O module selection guidelines as below.

Table 2.1: Discrete and Analog I/O Selection Guidelines

Choose this type of I/O
module:

Discrete input module
and block I/O module

Discrete output module
and block I/O module

Analog input module

Analog output module

For these types of field devices or
operations (examples):

Selector switches, push buttons,
photoelectric eyes, limit switches,
circuit breakers, proximity switches,
level switches, motor starter con­tacts, relay contacts, thumbwheel
switches

Alarms, control relays, fans, lights,
horns, valves, motor starters, sole­noids

Thermocouple signals, RTD signals,
temperature transducers, pr ess ur e
transducers, load cell transducers,
humidity transducers, flow transduc­ers, potentiometers.

Analog valves, actuators, chart
recorders, electric motor drives,
analog meters

Chapter 2 Installation

Explanation:

Input modules sense ON/OFF
or OPENED/CLOSED sig­nals. Discrete signals can be
either AC or DC.

Output module signals inter­face with ON/OFF or
OPENED/CLOSED devices.
Discrete signals can be either
AC or DC.

Convert continuous analog
signals into input values

Interpret output value to ana­log signals (generally through
transducers) for field devices.

Advantech provides 28 types of ADAM-5560 I/O modules for various applications so
far. The Table 1.2 will help you to select the ADAM-5560 I/O modules quickly and
easily.

15 ADAM-5560 Series User Manual

Module

Resolution 16 bit 16 bit 12 bit 16 bit ­Input Channel 3 8 8 7 ­Sampling Rate 10 10 8K (Total) 10 -

Analog Input

Analog

Output

Digital Input
and Digital
Output

Counter
(32-bit)

Isolation 3000 VDC 3000 VDC 3000 VDC 3000 VDC 3000 VDC

Voltage Input -

Current Input - ±20 mA 4~20mA ±20 mA ­Direct Sensor Input
Resolution - - - - 12 bit

Voltage Output - - - - 0~10 V
Current Output - - - ­Digital Input

Channels
Digital Output

Channels
Channels - - - - ­Input Frequency - - - - ­Mode ---- -

ADAM­5013

Pt or Ni
RTD

---- -

---- -

ADAM­5017

±150 mV
±500 mV
±1 V
±5 V
±10 V

--

ADAM­5017UH

±10 V
0~10V
0~20mV

ADAM­5018

±15 mV
±50 mV
±100 mV
±500 mV
±1 V
±2.5 V

J, K, T, E,
R, S, B

ADAM­5024

-

-

0~20 mA
4~20 mA

Module

Resolution - - - ­Input Channel - - - -

Analog Input

Analog

Output

Digital Input and
Digital Output

Count-er (32-bit)

Isolation - - - 2500 VDC

Sampling Rate - - - ­Voltage Input - - - ­Current Input - - - ­Direct Sensor Input - - - ­Resolution - - - ­Voltage Output - - - ­Current Output - - - ­Digital Input

Channels
Digital Output

Channels
Channels - - - ­Input Frequency - - - ­Mode - - - -

ADAM­5050

16 DIO
(bit-wise
selectable)

ADAM­5051

16 16 W/LED 16 W/LED

-- -

ADAM­5051D

ADAM­5051S

ADAM-5560 Series User Manual 16

Chapter 2 Installation

Module

Analog Input

Analog Output

Digital Input and
Digital Output

Count-er (32-bit)

Isolation

ADAM­5052

Resolution - - - - ­Input

Channel
Sampling

Rate
Voltage Input - - - - ­Current

Input
Direct

Sensor
Input

Resolution - - - - ­Voltage Output - - - - ­Current

Output
Digital Input

Channels
Digital Output

Channels
Channels - - - - ­Input

Frequency
Mode -- -- -

-- -- -

-- -- -

-- -- -

-- -- -

-- -- -

8 8 W/LED - - -

- 8 W/LED 16 16 W/LED 16 W/LED

-- -- -

5000
V

RMS

ADAM­5055S

2500 V

ADAM­5056

--

DC

ADAM­5056D

ADAM­5056S /
5056SO

2500V

DC

Module ADAM-5060 ADAM-5069

Resolution - ­Input Channel - ­Sampling Rate - -

Analog Input

Analog Output

Digital Input and
Digital Output

Counter (32-bit)

RS-232 Channels - ­Isolation - -

Voltage Input - ­Current Input - ­Direct Sensor

Input
Resolution - ­Voltage Output - ­Current Output - ­Digital Input Channels - -

Digital Output Channels
Channels - -

Input Frequency - ­Mode - -

--

6 relay
(2 form A/ 4 form C)

8 power relay
(8 form A)

17 ADAM-5560 Series User Manual

Module ADAM-5030
SD Card Slot 2
USB 2.0 Slot 2

2.3.2 Selecting Power Supply Module

ADAM-5560 Series Controller works under unregulated power source between +10
and +30 VDC. When you arrange different I/O modules on ADAM-5560 Series Con­troller’s backplane, it may require comparable power supply. Use the following steps
as guidelines for selecting a power supply for your ADAM-5000 Series control sys­tem.

Refer to Table 2.2 to check the power consumption of ADAM-5000 Series Controller
and each I/O module.

Table 2.2: Power Consumptio n of ADAM-5000 series (Main Units)

Main Units Description

ADAM-5000/485

ADAM-5000

ADAM-5000/TCP

ADAM-5510

ADAM-5510M
ADAM-5511 PC-Based Programmable Controller with Modbus 1.0 W

ADAM-5510E 8-slot PC-Based Programmable Controller 1.2 W
ADAM-5510/TCP

ADAM-5510E/TCP
ADAM-5510KW PC-based SoftLogic Controller 1.2 W

ADAM-5510EKW 8-slot PC-based SoftLogic Controller 1.2 W
ADAM-5510EKW/TP 8-slot Ethernet-enabled SoftLogic Controller 2.0 W
ADAM-5560 8-slot Programmable Automation Controller 17 W

Distributed Data Acquisition and Control System
based on RS-485

Distributed Data Acquisition and Control System
based on RS-485

Distributed Data Acquisition and Control System
based on Ethernet

PC-Based Programmable Controller (With Battery
Backup)

Enhanced PC-Based Programmable Controller (With
Battery Backup)

Ethernet-enabled PC-Based Programmable
Controller

8-slot Ethernet-enabled PC-Based Programmable
Controller

Power
Consumption

1.0 W

4.0 W

5.0 W

1.0 W

1.2 W

2.0 W

2.0 W

ADAM-5560 Series User Manual 18

Table 2.3: Power Consumption of ADAM-5000 series (IO Modules)

ADAM-5013 3-Channel RTD Input Module 1.1 W
ADAM-5017 8-Ch Analog Input Module (mV, mA or High Voltage) 1.25 W

ADAM-5017UH

ADAM-5018
ADAM-5024 4-Channel Analog Output Module (V, mA) 2.9 W

ADAM-5050 16-Channel Universal DIO 1.2 W
ADAM-5051 16-Channel Digital Input Module 0.53 W
ADAM-5051D 16-Channel Digital Input w/LED Module 0.84 W
ADAM-5056S 16-Channel Isolated Digital Input w/LED Module 0.8 W
ADAM-5056SO 16-Channel Digital Input w/LED Module 0.84 W
ADAM-5052 8-Channel Isolated DI 0.27 W
ADAM-5055S 16-Channel Isolated DIO w/LED Module 0.68 W
ADAM-5056 16-Channel Digital Output Module 0.53 W
ADAM-5056D 16-Channel Digital Output w/LED Module 0.84 W
ADAM-5056S 16-Channel Isolated Digital Output w/LED Module 0.6 W

ADAM-5060
ADAM-5068 8-Channel Relay Output Module ( 8 Form A) 1.8 W

ADAM-5069 8-Channel Power Relay Output Module ( 8 Form A) 2.2 W
ADAM-5202 2-Ring AMONet Motion Control Module 2.5 W

8-CH Ultra High speed Analog Input Module (mV, mA
or High Voltage)

7-Channel Thermocouple Input Module (mV, V, mA,
Thermocopule)

6-Ch Relay Output Module ( 2 of Form A, 4 of Form
C)

2.2 W

0.63 W

1.8 W

Chapter 2 Installation

Calculate the Summary of the whole system’s power consumption.
For example, there are following items in your system.
ADAM-5550KW * 3 & ADAM-5024 * 2 & ADAM-5017 * 4 &
ADAM-5068 * 2 & ADAM-5056D * 2
The power consumption is:
17 W * 3 + 2.9 W * 2 + 1.25 * 4 + 1.8 W * 2 + 0.84 W * 2 = 67.08 W

19 ADAM-5560 Series User Manual

Select a suitable power supply from Table 2.4 or other comparable power resource
for system operation.

Table 2.4: Power Supply Specification Table

Specification PWR-242 PWR-243 PWR-244

Input

Input Voltage 90 ~ 264 V
Input Frequency 47 ~ 63 Hz 47 ~ 63 Hz 47 ~ 63 Hz

Input Current 1.2 A max. 1.4 A max

Short Protection Yes Yes Yes

Output

AC

85 ~ 132 V AC
170 ~ 264 VAC

100 ~ 240 VAC

25 A/110 V
50 A/220 VAC
(Inrush current)

AC

Output Voltage +24 V
Output Current 2.1 A 3 A 4.2 A
Overload Protection Yes Yes Yes

General

Dimension

Operating Temperature 0 ~ 50C (32 ~ 122F) 0 ~ 50C (32 ~ 122F) 0 ~ 50C (32 ~ 122F)
DIN-rail Mountable Yes No No

DC +24 VDC +24 VDC

181mm x 113 mm x
60 mm
(L x W x H)

181mm x 113 mm x
60 mm
(L x W x H)

2.3.3 Install Main Unit and Modules

While inserting modules into the system, align the PC board of the module with the
grooves on the top and bottom of the system. Push the module straight into the sys­tem until it is firmly seated in the backplane connector. Once the module is inserted
into the system, push in the retaining clips (located at the top and bottom of the mod­ule) to firmly secure the module to the system.

2.3.4 I/O Slots and I/O Channel Numbering

The ADAM-5560 Series provides 7 slots for I/O modules. The I/O slot s are numbered
0 through 6, and the channel numbering of any I/O module in any slot starts from 0.
For example, the ADAM-5017 is an 8-channel analog input module. Its input channel
numbering is 0 through 7.

181mm x 113 mm x
60 mm
(L x W x H)

ADAM-5560 Series User Manual 20

2.3.5 Mounting

The ADAM-5560 Series Controller can be installed on a panel or on a DIN rail.

2.3.5.1 Panel Mount

Mount the system on the panel horizontally to provide proper ventilation. You cannot
mount the system vertically, upside down or on a flat horizontal surface. A standard
#7 tatting screw (4 mm diameter) should be used.

Chapter 2 Installation

2.3.5.2 DIN-rail Mounting

Figure 2.1 Panel Mount for ADAM-5560 Series

Figure 2.2 DIN-rail Mounting

21 ADAM-5560 Series User Manual

The system can also be secured to the cabinet by using mounting rails. If you mount
the system on a rail, you should also consider using end brackets at each end of the
rail. The ended brackets help keep the system from sliding horizo ntally along the rail.
This minimizes the possibility of accidentally pulling the wiring loose. If you examine
the bottom of the system, you will notice two small retaining clips. To secure the sys­tem to a DIN rail, place the system on to the rail and gently push up on the retaining
clips. The clips lock the system on the rail. To remove the system, pull down on the
retaining clips, lift up on the base slightly, and pull it away from the rail.

2.3.6 Jumper and DIP Switch Setting s

This section tells you how to set the jumpers and DIP switches to configure your
ADAM-5560 Series Controller. It gives the system default configuration and your
options for each jumper and dip switch. The backplane has one 8-pin DIP switch and
twelve jumpers on it.

2.3.6.1 RS-232/485 Selectable Jumper Setting

Following figure shows the COM1 to COM4 location.

Figure 2.3 COM Port Location

The Communication mode of COM1, COM3 and COM4 are set by jumpers on the
backplane. Please refer to Figure 2.4 to get the jumper locations.

Figure 2.4 COM1/COM4 RS-232/485 Settings

ADAM-5560 Series User Manual 22