Advantech ADAM-5560 User Manual

User Manual

ADAM-5560 Series

Programmable Automation

Controllers

Copyright

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 accurate 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 out- of-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.

Part No. XXXXXXXXXX	Edition 1
Printed in Taiwan	February 2014

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 limits 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.advantech.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 equipment 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 to 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 ADAM5560KW)

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.

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 61131-3 defines the syntax of 5 programming languages, defines a certain 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.

Overview 1 Chapter

3	ADAM-5560 Series User Manual

Table 1.1: Programming Languages Table

	Textual Languages	Graphical Languages
	Instruction List (IL)	Function Block Diagram (FBD)
		Ladder Diagram (LD)
	Structured Text (ST)
		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.

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.

Overview 1 Chapter

5	ADAM-5560 Series User Manual

Table 1.2: I/O Module Support List

	Function	Module	Description	Reference
		ADAM-5013	3-ch RTD Input	Isolated
		ADAM-5017	8-ch AI	Isolated
		ADAM-5017P	8-ch AI w/Independent Input Range	Isolated
	Analog Input	ADAM-5017H	8-ch High Speed AI (1KHz)	Isolated
		ADAM-5017UH	8-ch Ultra High Speed AI (200KHz)	Isolated
		ADAM-5018	7-ch TC Input	Isolated
		ADAM-5018P	7-ch TC Input w/Independent Input Range	Isolated
	Analog Output	ADAM-5024	4-ch AO	Isolated
		ADAM-5051	16-ch DI	Non-isolated
		ADAM-5051D	16-ch DI w/LED	Non-isolated
	Digital Input	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
	Digital Output	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
	Digital I/O	ADAM-5050	16-ch DI/O	Non-isolated
		ADAM-5055S	16-ch Isolated DI/O w/LED	Isolated
	Relay Output	ADAM-5060	6-ch Relay Output	Isolated
		ADAM-5069	8-ch Power Relay Output w/LED	Isolated
	Counter/	ADAM-5081	4-ch/8-ch High Speed Counter/Frequency	Isolated
	Frequency
	Communication	ADAM-5091	4-port RS-232 Module	Non-isolated
		ADAM-5095	2-port CAN Module	Isolated
	Storage	ADAM-5030	2-slot SD Storage Module	Non-isolated
		ADMA-5202	2-port AMONet Master Module	Isolated
	Motion	ADAM-5240	4-axis Stepping/Servo Motor Control	Isolated
			Module

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.

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

Overview 1 Chapter

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

1.3.1System

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)

1.3.2USB Ports

USB 2.0

1.3.3VGA Port

1024 X 768 Resolution

1.3.4Ethernet Ports

10M/100M bps x 2

RJ-45 connectors

Transmission Speed 10M/100M bps (10/100 Base-T)

1.3.5RS-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)

1.3.6RS-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)

1.3.7ES-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)

1.3.8RS-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)

1.3.9Isolation

COM2: 2500 Vrms

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

1.3.10Power

Unregulated +10 to +30 VDC

Protected against power reversal

Power consumption: 17 W (not including I/O modules)

Overview 1 Chapter

9	ADAM-5560 Series User Manual

1.3.11Mechanical

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

1.3.12Environment

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.

1.3.13Software 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.

1.6.3TCP/IP Connections

Multiprog via Ethernet connection: maximum 4 connections

Modbus/TCP Server connection: maximum 64 connections

Modbus/TCP Client connection: maximum 128 connections

1.6.4Firmware 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.

Overview 1 Chapter

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:

2.2.1Host 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

2.2.2ADAM-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

2.2.3I/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	For these types of field devices or	Explanation:
	module:	operations (examples):
		Selector switches, push buttons,	Input modules sense ON/OFF
		photoelectric eyes, limit switches,
	Discrete input module	circuit breakers, proximity switches,	or OPENED/CLOSED sig-
	and block I/O module	level switches, motor starter con-	nals. Discrete signals can be
		tacts, relay contacts, thumbwheel	either AC or DC.
		switches
			Output module signals inter-
	Discrete output module	Alarms, control relays, fans, lights,	face with ON/OFF or
		horns, valves, motor starters, sole-	OPENED/CLOSED devices.
	and block I/O module	noids	Discrete signals can be either
			AC or DC.
		Thermocouple signals, RTD signals,
		temperature transducers, pressure	Convert continuous analog
	Analog input module	transducers, load cell transducers,
			signals into input values
		humidity transducers, flow transduc-
		ers, potentiometers.
		Analog valves, actuators, chart	Interpret output value to ana-
	Analog output module	recorders, electric motor drives,	log signals (generally through
		analog meters	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.

Installation 2 Chapter

15	ADAM-5560 Series User Manual

Module			ADAM-		ADAM-		ADAM-			ADAM-		ADAM-
			5013		5017		5017UH			5018		5024
	Resolution		16 bit		16 bit		12 bit			16 bit		-
	Input Channel		3		8		8			7		-
	Sampling Rate		10		10		8K (Total)			10		-
					±150 mV					±15 mV
							±10 V			±50 mV
					±500 mV
Analog Input										±100 mV		-
	Voltage Input		-		±1 V		0~10V
										±500 mV
					±5 V		0~20mV
										±1 V
					±10 V
										±2.5 V
	Current Input		-		±20 mA		4~20mA			±20 mA		-
	Direct Sensor Input		Pt or Ni		-		-			J, K, T, E,		-
			RTD							R, S, B
	Resolution		-		-		-			-		12 bit
Analog	Voltage Output		-		-		-			-		0~10 V
Output
	Current Output		-		-		-			-		0~20 mA
												4~20 mA
Digital Input	Digital Input		-		-		-			-		-
	Channels
and Digital
	Digital Output
Output			-		-		-			-		-
	Channels
Counter	Channels		-		-		-			-		-
	Input Frequency		-		-		-			-		-
(32-bit)
	Mode		-		-		-			-		-
Isolation			3000 VDC		3000 VDC		3000 VDC			3000 VDC		3000 VDC
Module				ADAM-		ADAM-			ADAM-		ADAM-
				5050		5051			5051D		5051S
		Resolution		-		-			-		-
		Input Channel		-		-			-		-
Analog Input		Sampling Rate		-		-			-		-
		Voltage Input		-		-			-		-
		Current Input		-		-			-		-
		Direct Sensor Input		-		-			-		-
Analog		Resolution		-		-			-		-
		Voltage Output		-		-			-		-
Output
		Current Output		-		-			-		-
		Digital Input		16 DIO		16			16 W/LED		16 W/LED
Digital Input and		Channels
				(bit-wise
Digital Output		Digital Output
				selectable)		-			-		-
		Channels
		Channels		-		-			-		-
Count-er (32-bit)		Input Frequency		-		-			-		-
		Mode		-		-			-		-
Isolation				-		-			-		2500 VDC

ADAM-5560 Series User Manual

16

			ADAM-	ADAM-	ADAM-	ADAM-		ADAM-
Module								5056S /
			5052	5055S	5056	5056D
								5056SO
		Resolution	-	-	-	-		-
		Input	-	-	-	-		-
		Channel
		Sampling	-	-	-	-		-
		Rate
Analog Input		Voltage Input	-	-	-	-		-
		Current	-	-	-	-		-
		Input
		Direct
		Sensor	-	-	-	-		-
		Input
		Resolution	-	-	-	-		-
Analog Output		Voltage Output	-	-	-	-		-
		Current	-	-	-	-		-
		Output
		Digital Input	8	8 W/LED	-	-		-
Digital Input and		Channels
Digital Output		Digital Output	-	8 W/LED	16	16 W/LED		16 W/LED
		Channels
		Channels	-	-	-	-		-
Count-er (32-bit)		Input	-	-	-	-		-
		Frequency
		Mode	-	-	-	-		-
Isolation			5000	2500 VDC	-	-		2500VDC
			VRMS
Module				ADAM-5060			ADAM-5069
	Resolution			-			-
	Input Channel			-			-
	Sampling Rate			-			-
Analog Input	Voltage Input			-			-
	Current Input			-			-
	Direct Sensor			-			-
	Input
	Resolution			-			-
Analog Output	Voltage Output			-			-
	Current Output			-			-
Digital Input and	Digital Input Channels			-			-
				6 relay			8 power relay
Digital Output	Digital Output Channels
				(2 form A/ 4 form C)			(8 form A)
	Channels			-			-
Counter (32-bit)	Input Frequency			-			-
	Mode			-			-
RS-232	Channels			-			-
Isolation				-			-

Installation 2 Chapter

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 Consumption of ADAM-5000 series (Main Units)

	Main Units	Description	Power
			Consumption
	ADAM-5000/485	Distributed Data Acquisition and Control System	1.0 W
		based on RS-485
	ADAM-5000	Distributed Data Acquisition and Control System	4.0 W
		based on RS-485
	ADAM-5000/TCP	Distributed Data Acquisition and Control System	5.0 W
		based on Ethernet
	ADAM-5510	PC-Based Programmable Controller (With Battery	1.0 W
		Backup)
	ADAM-5510M	Enhanced PC-Based Programmable Controller (With	1.2 W
		Battery Backup)
	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	Ethernet-enabled PC-Based Programmable	2.0 W
		Controller
	ADAM-5510E/TCP	8-slot Ethernet-enabled PC-Based Programmable	2.0 W
		Controller
	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

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	8-CH Ultra High speed Analog Input Module (mV, mA	2.2 W
		or High Voltage)
	ADAM-5018	7-Channel Thermocouple Input Module (mV, V, mA,	0.63 W
		Thermocopule)
	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	6-Ch Relay Output Module ( 2 of Form A, 4 of Form	1.8 W
		C)
	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

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

Installation 2 Chapter

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 VAC	85 ~ 132 VAC	100 ~ 240 VAC
			170 ~ 264 VAC
	Input Frequency	47 ~ 63 Hz	47 ~ 63 Hz	47 ~ 63 Hz
	Input Current	1.2 A max.	1.4 A max	25 A/110 VAC
				50 A/220 VAC
				(Inrush current)
	Short Protection	Yes	Yes	Yes
	Output
	Output Voltage	+24 VDC	+24 VDC	+24 VDC
	Output Current	2.1 A	3 A	4.2 A
	Overload Protection	Yes	Yes	Yes
	General
		181mm x 113 mm x	181mm x 113 mm x	181mm x 113 mm x
	Dimension	60 mm	60 mm	60 mm
		(L x W x H)	(L x W x H)	(L x W x H)
	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

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 slots 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.

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.

2.3.5.1Panel 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.

Figure 2.1 Panel Mount for ADAM-5560 Series

2.3.5.2 DIN-rail Mounting

Figure 2.2 DIN-rail Mounting

Installation 2 Chapter

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 horizontally 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 Settings

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.

2.3.6.1RS-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