Description
Product Introduction
The CTI 2500-C200 is a compact, high-speed central processing unit designed as a form-fit-function replacement for legacy Siemens Simatic 545 and 555 processors. Featuring 256K of battery-backed user memory and executing ladder logic at speeds significantly faster than original legacy hardware, the 2500-C200 upgrades aging Texas Instruments / Siemens 505 control systems without requiring panel rewiring or program rewrites.
Unlike older legacy CPUs that required dedicated co-processor cards for network access, the 2500-C200 includes onboard 10/100 Ethernet (supporting TCP/IP CAMP and Modbus-TCP), USB configuration ports, an RS-232 serial interface, a Profibus-DP Master port, and a Remote I/O controller port right on the front bezel.
Key Technical Specifications
| Parameter | Value |
| Part Number | 2500-C200 |
| Manufacturer | Control Technology Inc. (CTI) |
| System Compatibility | CTI 2500 Series and Siemens / TI 505 Bases |
| User Memory | 256 KB (User Program & Data Space) |
| Digital I/O Points | Up to 2,048 Inputs / 2,048 Outputs |
| Analog I/O Points | Up to 1,024 Inputs / 1,024 Outputs |
| PID Loop Capacity | 64 PID Process Loops |
| Communications | Onboard 10/100M Ethernet, USB Type-B, RS-232, Profibus-DP Master, 500 Series Remote I/O |
| Firmware Storage | Onboard SD Flash Card Slot (Firmware updates & backup) |
| Battery Backup | Front-accessible 3V Lithium Cell (CR2032 / 2500-BAT) |
| Operating Temp | 0°C to +60°C (32°F to 140°F) |
Application Scenarios & The “Trench” Experience
Imagine an aging chemical batching facility operating on a 1990s Siemens 545 CPU inside a TI 505 rack chassis. The CPU experiences intermittent memory parity errors, and the original serial programming cable setup fails regularly. Upgrading to a completely new PLC platform would mean weeks of offline downtime, rewiring thousands of point-to-point terminations, and re-validating critical PID loops. Dropping in a CTI 2500-C200 resolves the hardware instability immediately—allowing engineers to migrate the existing Workshop / TISOFT logic file directly into the CTI CPU in under an hour.
- Chemical & Specialty Batch Processing – Maintains tight temperature and flow curves using 64 built-in PID loops.
- Oil & Gas Pipeline Stations – Connects long-distance telemetry via onboard Modbus-TCP and CAMP protocols.
- Grain Handling & Food Processing – Controls multi-deck conveyors and elevator safety interlocks across local and remote 505 I/O bases.
Field Case Study
A water treatment utility in Ohio ran four remote pump stations driven by Siemens 545-1102 CPUs. When one unit failed during a seasonal storm surge, finding an exact OEM Siemens replacement proved slow and cost-prohibitive. We dispatched a CTI 2500-C200 CPU configured to emulate the 545 memory map. The plant technician inserted the unit into Slot 1, uploaded the backup file via the front USB port, and restored full station pump automation before tank levels breached limits.
2500-C200
2500-C200
Transparency SOP: Quality Assurance & Testing
Every unit undergoes rigorous functional verification on a CTI 2500-A200 base rack:
- Physical & Mechanical Audit: Check front bezel levers, status LEDs, battery clip, SD slot, and backplane edge connector pins.
- Backplane & Bus Test: Mount in a live 2500 rack; verify power-up sequencing and front status LEDs (CPU GOOD, RUN, BATTERY GOOD).
- Communication Sweep: Test data transfer across Ethernet (CAMP & Modbus-TCP), RS-232, USB, and Profibus-DP channels using CTI WorkShop software.
- I/O Expansion Stress Test: Execute complex ladder logic routines while scanning 2500 series local discrete and 2562 analog cards.
- Memory & Battery Retain Test: Verify program retention during simulated main power outages using a fresh lithium battery.
- Packaging: Flash latest stable firmware revision, apply ESD protection, and ship in custom foam-padded containers.
The Veteran’s Tech Trap Guide
- ⚠️ Check Dip Switch 1 Settings: DIP switches on the bottom or side of the module set startup modes, memory retention, and default IP behavior. Ensure Dip Switch 1 is properly set before powering up, or the CPU may default to a cleared memory state upon reboot.
- ❗ Verify Program File Memory Offsets: When uploading legacy TISOFT or APT logic into the 2500-C200, double-check your V-Memory allocation blocks. The 2500-C200 provides expanded memory space, but legacy logic must respect original boundary addresses to avoid pointer overlaps.
- ⚠️ Do Not Hot-Swap in 505 Racks: Always shut off the rack power supply (e.g., 2500-PS-120V) before pulling or installing the CPU module. Hot-swapping can damage the backplane bus controller chips.
Frequently Asked Questions
Q: Is the CTI 2500-C200 compatible with original Siemens Simatic 505 I/O modules?
A: Yes. The 2500-C200 operates directly in both CTI 2500 Series bases and original Siemens/TI 505 chassis, supporting existing discrete, analog, and specialty cards seamlessly.
Q: What programming software is used with the CTI 2500-C200?
A: It can be programmed using CTI WorkShop for 2500 Series, as well as legacy software packages like Siemens SoftShop, TISOFT, or FasTrak Workshop.
Q: How does the 2500-C200 compare to the 2500-C100 or 2500-C300 models?
A: The primary differences are user memory size and execution speeds. The 2500-C100 offers 128K memory, the C200 provides 256K memory, and the higher-tier C300 or C400 models offer up to 512K/3MB memory for larger applications.
Q: What battery does the 2500-C200 use?
A: It uses a standard front-accessible 3V lithium coin cell battery (CR2032 or CTI part number 2500-BAT) to maintain volatile RAM during power outages.
Q: What warranty is provided with this unit?
A: All CTI 2500-C200 processors—whether New or bench-tested Refurbished—come backed by a full 12-month operational warranty covering memory, logic execution, and onboard communication interfaces.
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