Installation and Operation Guide
Contents
1. 125 and divide the product by 100 This yields the following equation WX 6400 x 125 100 20 offset data word Consult your PLC programming manual or program design guide for information about RLL instructions used in the conversion 1 7 Using the Module with 20 Offset If all eight inputs are used in offset mode the Model 2558 may be configured to perform the offset calculation automatically see Figure 2 2 Configuration Jumper Board Locations Jumper JP40 when enabled will configure the module such that all inputs will be scaled for 1 5VDC or 4 20mA operation No further relay ladder logic is required for input processing 2 CTI 2558 Installation and Operation Guide 1 8 Digital Word Map 13 Bit Mode A unipolar analog input signal is translated into a 13 bit plus sign bit digital word Since the PLC requires a 16 bit input word the 13 bit value from the converter is placed into a 16 bit word for transmittal to the PLC As shown in the following figure of the two bits not used for the digital word one is used to show the sign of the word and one is used to note values which are overrange BIT 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 MSB TRANSLATED UNUSED LSB SIGN 1 DIGITAL WORD SETTOO F OVERRANGE SETTO 1 UNIPOLAR WORD MAP Figure 1 2 13 Bit Word Input to the PLC from the Module 1 9 Analog to Digital Conversions 13 Bit Mode 1 9 1 Unipolar Mode Conversion The followin2. 5 05V ov 5 05V 200V 200V 10 10V ov 10 10V 200V sees Module not Underrange Accuracy Overrange Module not protected Code within Code protected damage ee 32 758 specification Oveirang 32 759 damage might occur might occur Math Ovario Math A 32 756 32 756 32 763 32 750 BIPOLAR MODE Figure 1 14 16 Bit Voltage Input Limits Bipolar Figures 1 15 and 1 16 show the binary values of typical overrange and underrange conditions for Bipolar Mode Typical Digital Word Map for Overrange Digital Word TRANSLATED VALUE Overrange 32 759 or 16 384 64 32 16 Math Overflow 32 756 BIT BIT 0 1 1 1 1 1 1 1 1 0 1 1 1 16 MSB TRANSLATED SIGN 4 DIGITAL WORD 0 BIPOLAR MODE Figure 1 15 16 Bit Overrange Word Value Bipolar Typical Digital Word Map for Underrange Digital Word TRANSLATED VALUE Underrange 32 758 or 16 384 64 32 16 Math Overflow 32 756 BIT 0 1 1 1 1 1 1 1 1 1 0 1 1 0 MSB TRANSLATED SIGN 1 DIGITAL WORD gar BIPOLAR MODE Figure 1 16 16 Bit Underrange Word Value Bipolar CTI 2558 Installation and Operation Guide 11 1 15 Resolution 16 Bit The module has a resolution of 1 count out of 32000 This is the smallest unit into which the module will divide an input and is 1 part out of 32000 This relationship can be shown as 1 count per step 32000 counts full scale 1 32000 The chart bel
3. Bit 15 is always returned as a zero and bit 16 is employed as an over underrange bit Consequently returned data values change by four 1 10 Effect of Out of Range Input Signals 13 Bit Mode The Model 2558 utilizes the overrange and underrange bit to indicate when a channel has reached individual limits The value of the overrange or underrange condition varies from channel to channel The reason for this is that as a channel is calibrated all of the gains and offsets and dynamic ranges of the analog to digital converter of the system are compensated for in each analog input channel Therefore the point at which the analog to digital converter reaches a saturation point and can no longer produce a change in counts for corresponding change in input signal is called the overrange or underrange limit of the channel This level is different for every channel In Figures 1 3 and 1 6 the limits for the overrange and underrange values are the minimum limits for a given channel The actual limits for an individual channel may be greater 4 CTI 2558 Installation and Operation Guide 1 10 1 Unipolar Mode Signals falling below the lower limits in 0 to 5V Input Mode or 0 to 10V Input Mode are translated into a digital word that includes the addition of Bit 16 to indicate an overrange or underrange condition The underrange capability of any channel in Unipolar Mode may produce a negative value to the PLC for a number of counts before the underrange bi
4. CTI will return such Product or part to the customer This warranty does not include repair of damage to a part or Product resulting from failure to provide a suitable environment as specified in applicable Product specifications or damage caused by an accident disaster acts of God neglect abuse misuse transportation alterations attachments accessories supplies non CTI parts non CTI repairs or activities or to any damage whose proximate cause was utilities or utility like services or faulty installation or maintenance done by someone other than CTI Control Technology Inc reserves the right to make changes to the Product in order to improve reliability function or design in the pursuit of providing the best possible Product CTI assumes no responsibility for indirect or consequential damages resulting from the use or application of this equipment THE WARRANTY SET FORTH ABOVE IN THIS ARTICLE IS THE ONLY WARRANTY CTI GRANTS AND IT IS IN LIEU OF ANY OTHER IMPLIED OR EXPRESSED GUARANTY OR WARRANTY ON CTI PRODUCTS INCLUDING WITHOUT LIMITATION ANY WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE AND IS IN LIEU OF ALL OBLIGATIONS OR LIABILITY OF CTI FOR DAMAGES IN CONNECTION WITH LOSS DELIVERY USE OR PERFORMANCE OF CTI PRODUCTS OR INTERRUPTION OF BUSINESS LOSS OF USE REVENUE OR PROFIT IN NO EVENT WILL CTI BE LIABLE FOR SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITA
5. Filtering Time Constant DC Input Resistance DC Accuracy Resolution 8WX Mode Common Mode Rejection Normal Mode Rejection Connector Wire Gauge Input Protection Isolation Module Size Backplane Power Consumption Operating Temperature CTI 2558 Installation and Operation Guide 8 analog input channels Unipolar 0 to 5VDC 0 to 10VDC or 0 to 20mA Bipolar 5 to 5 VDC 10 to 10VDC or 20 to 20mA 8WX mode 5 mSec all channels 0 3 Sec Voltage Mode 780kQ Current Mode 250Q Voltage Mode 0 125 of full scale from 0 to 60 C Current Mode 0 225 of full scale from 0 to 60 C Unipolar 15 bits plus sign 0 5 VDC range 156uV step 0 10VDC range 312uV step 0 20mA range 0 625uA step Bipolar 15 bits plus sign 5 to S VDC 156uV step 10 to 10VDC range 312uV step 20 to 20mA range 0 625uA step gt 120db E 60Hz digital filtering disabled gt 40db E 500 Hz digital filtering enabled Removable 14 22 AWG Input ESD Protection 20 000V IEC 1000 4 2 level 4 Overrange Protection 300VDC 1500VDC channel to PLC Single wide 3 0 Watts maximum 0 to 60 C 32 to 140 F 25 Storage Temperature 40 to 85 C 40 to 185 F Humidity 5 to 95 non condensing Agency Approvals Pending UL ULC FM Class 1 Div 2 CE Shipping Weight 1 5 lb 0 68 Kg Specifications subject to change without notice 26 CTI 2558 Installation and Operation Guide APPENDIX A COMPATIBIL
6. RANGE GE OTO 10V 200V 0 02V 10 10V 200V Module not Underrange Accuracy Overrange Module not protected Code within Codes protected damage 32 758 specification Overrange 32 759 damage might occur or might occur Math Overflow 32 756 Approximately 300 32 750 UNIPOLAR MODE Figure 1 11 16 Bit Voltage Input Limits Unipolar Figures 1 12 and 1 13 show the binary values of typical overrange and underrange conditions for Unipolar mode Typical Digital Word Map for Overrange Digital Word TRANSLATED VALUE Overrange 32 759 or 16 384 64 32 16 8 Math Overflow 32 756 BIT 0 1 1 1 1 1 1 1 1 1 1 0 1 1 a 1 MSB TRANSLATED SIGN 1 DIGITAL WORD 0 UNIPOLAR MODE Figure 1 12 16 Bit Overrange Word Value Unipolar Typical Digital Word Map for Underrange Digital Word TRANSLATED VALUE Underrange 32 758 or 16 384 64 32 16 Math Overflow 32 756 BIT BIT 1 1 1 1 1 1 1 1 1 1 1 1 0 1 0 Hi 1 MSB TRANSLATED SIGN 1 DIGITAL WORD 0 UNIPOLAR MODE Figure 1 13 16 Bit Underrange Word Value Unipolar 1 14 2 Bipolar Mode In Bipolar Mode signals above or below the upper and lower limits in the 5 to 5 VDC or 10 to 10 VDC range are translated to a digital word and also utilize the overrange and underrange values The actual limit for each channel will vary from channel to channel as described in the previous section 10 CTI 2558 Installation and Operation Guide VOLTAGE gt TO 8V RANGE 10 TO 10V 200V
7. oe gp E co ca co Da a eg 23 22 cs Sie Ss cs eis ees 2 CD oem as lt amp Zz o EE N 3 S 5 3 5 3 y 2 O m cub cuz 2S ces can 22 cer can 2 5 ai Z e gt em gt m 5 Il e gt e JLS Os OE o gy r u had 8 es S 8 ON BACKPLANE CONNECTOR Figure 2 2 Configuration Jumper Board Locations jumper settings shown as shipped 2 3 4 Selecting Digital Filtering Locate the Digital Filtering Jumper DIG FILTER JP25 see Figure 2 2 To enable digital filtering set the jumper in the EN position to disable set to the DIS position Since many analog input signals contain noise CTI recommends using digital filtering unless maximum response time is required As shipped digital filtering is enabled for all 8 analog inputs CTI 2558 Installation and Operation Guide 17 2 3 5 Selecting Offset Scaling Locate the Offset Scaling OFFSET jumper JP40 see Figure 2 2 To enable offset scaling for all 8 inputs set the jumper to the EN position to disable set to the DIS position 2 3 6 Selecting Compatibility Mode Locate the Compatibility Mode CMPBTY MODE jumper JP26 see Figure 2 2 To enable 16 bit compatibility mode for all 8 inputs set the jumper to the 16BIT position As shipped the 13 bit compatibility mode is enabled 2 3 7 Configuring Switches to Report Hardware Conf
8. to Digital Conversions 16 Bit Mode 1 13 1 Unipolar Mode Conversion The following equations may be used to calculate the digital word which will result from a particular voltage or current input in the Unipolar Input Mode 0 to 5VDC range Digital Word WX Input voltage x 32000 5 volts example to generate an input voltage of 2 5 VDC the WX value input to the PLC is calculated as follows WX 2 5 x 32000 5 16000 0 to 10VDC range Digital Word WX Input voltage x 32000 10 volts example 7 5VDC input WX 7 5 x 32000 10 24000 0 to 20mA range Digital Word WX Input current x 32000 20 mA example 10mA input WX 10 x 32000 20 16000 8 CTI 2558 Installation and Operation Guide 1 13 2 Bipolar Mode Conversion The following equations may be used to calculate the digital word which will result from a particular voltage or current input in the Bipolar Input Mode 5 to 5 VDC range Digital Word WX Input voltage x 32000 5 volts example to generate an input voltage of 2 5 VDC the WX value input from the PLC is calculated as follows WX 2 5 x 32000 5 16000 10 to 10V range Digital Word WX Input voltage x 32000 10 volts example 10 VDC input WX 10 x 32000 10 32000 20 to 20mA range Digital Word WX Input current x 32000 20 mA example 15mA input WX 15 x 32000 20 24000 1 14 Effect of Out of Range Input Signals 16 Bit Mode The Model 255
9. 255810G CTI 2558 EIGHT CHANNEL ANALOG INPUT MODULE INSTALLATION AND OPERATION GUIDE Version 1 2 CTI Part 062 00331 012 25 Copyright 2005 Control Technology Inc All rights reserved This manual is published by Control Technology Inc 5734 Middlebrook Pike Knoxville TN 37921 This manual contains references to brand and product names which are tradenames trademarks and or registered trademarks of Control Technology Inc and Siemens AG Other references to brand and product names are tradenames trademarks and or registered trademarks of their respective holders DOCUMENT DISCLAIMER STATEMENT Every effort has been made to ensure the accuracy of this document however errors do occasionally occur CTI provides this document on an as is basis and assumes no responsibility for direct or consequential damages resulting from the use of this document This document is provided without express or implied warranty of any kind including but not limited to the warranties of merchantability or fitness for a particular purpose This document and the products it references are subject to change without notice If you have a comment or discover an error please call us toll free at 1 800 537 8398 REVISION HISTORY Version 1 0 4 30 01 Original Release Version 1 1 5 30 01 Add 1 bit of resolution to 16 bit compatibility Version 1 2 4 3 03 Add return common jumpers CTI 2558 Installation and Operatio
10. 8 utilizes the overrange and underrange code of 32757 and 32758 respectively to indicate when a channel has reached individual limits The value of the overrange or underrange condition varies from channel to channel The reason for this is that as a channel is calibrated all of the gains and offsets and dynamic ranges of the analog to digital converter of the system are compensated for in each analog input channel Therefore the point at which the analog to digital converter reaches a saturation point and can no longer produce a change in counts for corresponding change in input signal is called the overrange or underrange limit of the channel This level is different for every channel In Figures 1 11 and 1 14 the limits for the overrange and underrange values are the minimum limits for a given channel The actual limits for an individual channel may be greater 1 14 1 Unipolar Mode Signals falling below the lower limits in 0 to 5V Input Mode or 0 to 10V Input Mode are translated into a digital word that outputs a specific code to indicate an overrange or underrange condition The underrange capability of any channel in Unipolar Mode may produce a negative value to the PLC for a number of counts before the underrange code is produced CTI 2558 Installation and Operation Guide 9 VOLTAGE 0 TO 5V 200V 0 01V 5 05V 200V
11. CORRECTIVE ACTION Indicator is not lit Indicator is blinking Incorrect inputs Base power is off Defective module Calibration data no longer stored in memory Blown fuse Wrong addresses for word input Not logged in Incorrect jumper settings Incorrectly calibrated Noisy signal Offset scale enabled Figure 3 1 Troubleshooting Matrix CAUTION Turn base on Return the module to CTI for repair Return the module to CTI for calibration Return the module to CTI for repair Check program for correct word input addresses Read I O configuration Refer to Section 2 3 of this Installation amp Operation Guide for jumper settings Return the module to CTI for recalibration Check for proper shield termination at input connectors If JP40 is enabled all inputs are scaled for 4 20mA offset operation The module fuse F2 is not user serviceable If this fuse is blown the module has a serious component failure and should be returned to CTI for repair When it is inconvenient to visually check the status indicator use the TISOFT Display Failed I O or Show PLC Diagnostics support functions If after consulting the chart above you are unable to diagnose or solve the problem contact your local distributor or CTI at 1 800 537 8398 for further assistance CTI 2558 Installation and Operation Guide 23 HARDWARE SPECIFICATIONS Input Channels Signal Range Update Time Digital
12. ITY WITH SIEMENS 505 6108A B Overview The CTI 2558 Analog Input Module was designed to be a drop in replacement for the Siemens models 505 6108 A and 505 6108 B From set up of the module to wiring and PLC reporting the user will find many similarities between the CTI and Siemens models Using the CTI 2558 in a 505 6108 A and or 505 6108 B application The CTI 2558 should fulfill all the following requirements for the 505 6108 A and 505 6108 B replacement s as outlined below Module setup Since the CTI 2558 allows for both Unipolar and Bipolar setup the module does have a slightly different module setup See Chapter 2 3 Configuring the Module for Operation to determine the details in module setup Wiring The wiring of the input connector is the same between the module See Chapter 2 5 Wiring the Output Connector for a detailed explanation of how this is accomplished PLC Reporting The word format is the same between the modules See Chapter 1 for a more detailed explanation on PLC reporting CTI 2558 Installation and Operation Guide 27 28 CTI 2558 Installation and Operation Guide APPENDIX B JUMPER SETTINGS LOG SHEET Voltage Current Voltage Range Unipolar Bipolar Return Path Channel Jumper Jumper Jumper Compatibility Jumper Number 20mA or V 5V or 10V UNI or BI COM or ISO 1 JP1 JP3 JP2 JP24 2 JP4 JP27 JPS JP28 3 JP10 JP6 JP8 JP29 4 JP13 JP9 JP11
13. JP30 5 JP16 JP12 JP14 JP31 6 JP7 JP15 JP17 JP32 7 JP19 JP18 JP20 JP33 8 JP22 JP21 JP23 JP34 Offset Digital All Scaling Jumper Filtering Jumper Compatibility Jumper Channels Jumper Position Jumper Position Mode Jumper Position 1 8 JP40 JP25 JP26 Record the configuration jumper settings on this log for future reference Make additional copies if necessary CTI 2558 Installation and Operation Guide 29 LIMITED PRODUCT WARRANTY CTI warrants that this CTI Industrial Product shall be free from defects in material and workmanship for a period of one 1 year after purchase from CTI or from an authorized CTI Industrial Distributor This CTI Industrial Product will be newly manufactured from new and or serviceable used parts which are equal to new in the Product Should this CTI Industrial Product fail to be free from defects in material and workmanship at any time during this 1 year warranty period CTI will repair or replace at its option parts or Products found to be defective and shipped prepaid by the customer to a designated CTI service location along with proof of purchase date and associated serial number Repair parts and replacement Product furnished under this warranty will be on an exchange basis and will be either reconditioned or new All exchanged parts or Products become the property of CTI Should any Product or part returned to CTI hereunder be found by CTI to be without defect
14. OCATED ON SIDE OF RACK AND USE TO CONNECT ALL SHIELD WIRES AT THAT POINT Star Washer Ground Lugs y N km IH oye Screw S835 ho of Sho oF ho EARTH GROUND Figure 2 4 Shield Wire Termination 2 6 Installing the Screw Terminal Connector When all the input signal wires are connected to the screw terminal connector carefully install the connector on the front of the module _7 PRINTED CIRCUIT CARD PCB CAPTIVE SCREWS Q 7 y a one 0 INDIVIDUAL CAPTIVE SCREW a f INPUT SIGNAL WIRES PX SSSSS 0 FRONT FACE CONNECTOR a 77 WSSPSSSHSHSSS En Figure 2 5 Input Connector Assembly CTI 2558 Installation and Operation Guide 21 2 7 Checking Module Operation First turn on the base power If the module diagnostics detect no problems the status indicator on the front of the module will light If the status indicator does not light begins blinking or goes out during operation the module has detected a failure For information on viewing failed module status refer to your TISOFT user manual To diagnose and correct a module failure refer to the next section on troubleshooting You must also check that the module is configured in the memory of the PLC This is important because the module will appear to be functioning regardless of whether it is communicating with the PLC To view the PLC memory configuration chart listin
15. TION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES FOR CONSUMER PRODUCTS SO THE ABOVE LIMITATIONS OR EXCLUSIONS MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH MAY VARY FROM STATE TO STATE CTI 2558 Installation and Operation Guide 31 32 CTI 2558 Installation and Operation Guide REPAIR POLICY In the event that the Product should fail during or after the warranty period a Return Material Authorization RMA number can be requested orally or in writing from CTI main offices Whether this equipment is in or out of warranty a Purchase Order number provided to CTI when requesting the RMA number will aid in expediting the repair process The RMA number that is issued and your Purchase Order number should be referenced on the returning equipment s shipping documentation Additionally if the product is under warranty proof of purchase date and serial number must accompany the returned equipment The current repair and or exchange rates can be obtained by contacting CTI s main office at 1 800 537 8398 When returning any module to CTI follow proper static control precautions Keep the module away from polyethylene products polystyrene products and all other static producing materials Packing the module in its original conductive bag is the preferred way to control static problems during shipment Failure to observe static control precautions may void the warranty For additional informati
16. aling Jumper Filtering Jumper Compatibility Jumper Channels Jumper Position Jumper Position Mode Jumper Position 1 8 JP40 DISABLED JP25 ENABLE JP26 13 BIT 16 Figure 2 1 Shipping Jumper Configuration Locations CTI 2558 Installation and Operation Guide 2 3 3 Selecting Unipolar or Bipolar Input Mode Locate the Unipolar Bipolar Jumpers for each channel see Figure 2 2 Set each jumper to UNI for unipolar operation or BI for bipolar operation for each input channel m FIELD WIRING CONNECTOR mH MH O O oO O O O Q O T T x E E x X T o 5 022 py Pi Bd Bd gy PI py SP y is y PI 9 25 aieas se a Be dEl ze zum ze E se JPA BE D S al S NZ gt gt gt gt gt gt gt Pal 55 56 56 5 5 56 5 a m m A A m m A m ar Q Q Q Q Q Q Q Q LO le fe e e e fe fe e da m rs a D a a a g Im Om NT NA a Ed sl M m 2m Q 4 u a u re u a vV 2 u 2 u v 5 d a 2 els alls Sos SUS SH S NES gas RLS el pa m amp amp B 2 Sm eZ eZ e Z Sel Z Me 2 2 iz el 5 A O oa A NS Ww a ZN _a es X mS 6 6 3 6 6 6 6 6 r Zz z Y O 2 0 5 FR 3 2 amp 2s amp amp 3 O a R 5 2 5 E N a S om G O ogee aa
17. cribed in the previous section VOLTAGE 5 TO 5V 200V 5 05V OV 5 05V 200V RANGE a 10 10 LOTO 0V ib rn i sti lt a gt Module not Underrange Accuracy Overrange Module not protected output data within bit set protected damage specification damage might occur might occur 32 767 32 765 BIPOLAR MODE Figure 1 6 13 Bit Voltage Input Limits Bipolar Figures 1 7 and 1 8 show the binary values of typical overrange and underrange conditions for Bipolar Mode Typical Digital Word Map for Overrange Digital Word TRANSLATED 16 384 4 32 16 VALUE 32 765 BIT y 1 1 1 1 1 1 1 1 1 1 1 1 1 0 hes 1 UNUSED MSB TRANSLATED a LSB SIGN 1 DIGITAL WORD IFOVERRANGE 0 OR UNDERRANGE BIPOLAR MODE SETTO 1 Figure 1 7 13 Bit Overrange Word Value Bipolar 6 CTI 2558 Installation and Operation Guide Typical Digital Word Map for Underrange Digital Word TRANSLATED 16 384 64 32 16 VALUE 32 763 BIT 1 0 0 0 0 0 0 0 0 0 0 0 0 1 UNUSED SET TO MSB TRANSLATED ZERO LSB SIGN 1 DIGITAL WORD IF OVERRANGE ves BIPOLAR MODE SETTO 1 Figure 1 8 13 Bit Underrange Word Value Bipolar 1 11 Resolution 13 Bit Mode The module has a resolution of 4 counts out of 32000 This is the smallest unit into which the module will divide an input and is 1 part out of 8000 This relationship can be shown as 4 counts per step 32000 counts
18. cted and radiated interference from other energy sources Standard practices usually require that all shields be tied together and grounded at a single point Note the following general considerations when wiring the module e Always use the shortest possible cables e Avoid placing low voltage wire parallel to high energy wire if the two wires must meet cross them at a right angle e Avoid bending the wire into sharp angles e Use wireways for wire routing e Avoid placing wires on any vibrating surface CTI 2558 Installation and Operation Guide 13 2 2 Unpacking the Module Open the shipping carton and remove the special anti static bag which contains the module CAUTION HANDLING STATIC SENSITIVE DEVICES The components on the Model 2558 module printed circuit card can be damaged by static electricity discharge To prevent this damage the module is shipped in a special anti static bag Static control precautions should be followed when removing the module from the bag when opening the module and when handling the printed circuit card during configuration After discharging any static build up remove the module from the static bag Do not discard the static bag Always use this bag for protection against static damage when the module is not inserted into the I O backplane 14 CTI 2558 Installation and Operation Guide 2 3 Configuring the Module The Model 2558 must be configured for voltage or current inputs voltage rang
19. d input sampling of the module do not occur at the same time Instead the module will translate all analog inputs in one module update 5 milliseconds maximum and store the translated words in buffer memory The PLC retrieves the stored words from the module buffer memory at the start of the I O scan 1 3 Immediate I O The Model 2558 Analog Input Module is fully compatible with the immediate input instruction for the TI545 and 555 PLCs 1 4 Unipolar or Bipolar Mode Each input channel may be configured to accept either bipolar or unipolar input signals Selection of unipolar of bipolar mode is made via an internal jumper see Section 2 3 3 1 5 Voltage or Current Mode Each of the module s eight channels may be configured to receive either voltage or current analog input signals For unipolar input signals the range is 0 to 5 VDC 0 to 10 VDC or 0 to 20 mA For bipolar input signals the signal range is 5 to 5 VDC 10 to 10 VDC or 20 to 20 mA Selection of voltage or current mode and voltage range are made via internal jumpers see Sections 2 3 1 and 2 3 2 1 6 Using an Input with 20 Offset Some applications use transducers that provide 1 to 5 volts 4 to 20mA input signals instead of 0 to 5 volt 0 to 20mA input signals You can allow for this 20 offset by including some additional instructions in your RLL Relay Ladder Logic program First subtract 6400 from the input data word WX Then multiply the result by
20. e unipolar bipolar mode digital filtering no filtering mode return commonality and 13 or 16 bit compatibility before wiring the input connectors and inserting the module into the I O base As shipped all input channels are configured for current inputs 5V range see note below unipolar mode digital filtering enabled offset scaling disabled a common return and 13 bit compatibility see Figure 2 1 NOTE The 5V input signal range configuration is used for both 0 to 5VDC and I to 5VDC or 0 to 20mA and 4 to 20mA input signal ranges Changing the module input channel configuration involves the following steps notations in parenthesis are actual printed board titles described in the following sections Selecting voltage VOLTAGE or current 20MA input mode for each channel Selecting 0 to 5V 5V or 0 to 10V 10V voltage range for each channel Selecting unipolar UND or bipolar BI input mode for each channel Selecting digital filtering EN or no filtering DIS for the module Selecting offset scaling EN or no offset DIS for the module Selecting the 13 bit 13BIT or 16 bit 16BIT compatibility for the module Configuring DIP switches to report the hardware selections to the microcomputer Selecting channel return path as common COM or isolated ISO Logging the configuration jumper settings for future reference SOOO Oe ONS 2 3 1 Selecting Voltage or Current Input Mode Locate the 8 Voltage Current Jumpers correspond
21. eenenenenennenenenonnenennnonnenenenennnenonnenenenonneenenonane 2 LS Voltage or Current Modernas ips 2 1 6 Using an Input with 20 Offset u euesessnenenenennenennneneenennnenonennnenonneneenonene nennen nenn 2 1 7 Using the Module with 20 Offset u uenneneseseseneneneneeneneneneenennnenonnenenenenenenenennenen nenn 2 1 8 Digital Word Map 13 Bit Mode ee esesesceesseseseeeeseseseeeeecscseseeesscseeeeerscseseeessneeesaeees 3 1 9 Analog to Digital Conversions 13 Bit Mode 222nesesenenenenenennenenenennenennnenenen nen 3 1 10 Effect of Out of Range Input Signals 13 Bit Mode unenesnenenessennenenenennenenenen 4 1 11 Res l tion T3 Bit Mode en nern eines 7 1 12 Digital Word Map 16 Bit Mode 22eeseneneneneneneenenenenennenenenonenenenonneneenennenen nenn 8 1 13 Analog to Digital Conversions 16 Bit Mode neesesenenenenenennenenenennenennneneneenen 8 1 14 Effect of Out of Range Input Signals 16 Bit Mode unnesessenenesenennenennennenenenen 9 1 15 Resolution 16 Bites re ee ee ie sehn 12 CHAPTER2 INSTALLATION 2 22 02 ee ma Iris las 13 2 1 Pl nnms theTnistallati n 2 2 222 a ire 13 2 2 Unpacking the Module id 14 2 3 Contisurins the Module 2 is 15 2 4 Inserting the Module into the VO Base u uenenenenesesesenenenenennenennnenonenenenenene nenne 19 2 5 Wiring the Input COnnectors arteae hid detent tdt 19 2 6 Installing the Screw Term
22. full scale 1 8000 When using the module with 20 offset module resolution remains at 4 counts out of 32000 but offset resolution increases to 5 counts out of 32000 as a result of the multiplication and division of the incoming data word The chart below shows the corresponding input resolution per step for each of the input configuration modes UNIPOLAR UNIPOLAR WITH __ 20 OFFSET BIPOLAR RANGE DIGITAL INPUT RESOLUTION CONFIGURATION COUNTS STEP PER STEP 0 5 VDC 4 0 625 mV 0 10 VDC 4 1 25 mV 0 20mA 4 2 5 pA 1 5 VDC 5 0 625 mV 4 20 mA 5 2 5 pA 5 10 5 V 4 0 625 mV 10 TO 10 V 4 1 25 mV 20 to 20mA 4 2 5 pA Figure 1 9 Input Resolution 13 Bit CTI 2558 Installation and Operation Guide 1 12 Digital Word Map 16 Bit Mode An analog input signal is translated into a 15 bit plus sign bit digital word Since the PLC requires a 15 bit input word the 15 bit plus sign value from the converter is placed into a 16 bit word for transmittal ta the PT Ac chawn in the fallawing fionre ane hit ic need ta chaw the cian af the ward Translated Values for Overrange Math Overflow amp Underrange Conditions 32 16 8 4 2 1 BIT 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 MSB TRANSLATED SIGN 1 DIGITAL WORD 0 WORD MAP Figure 1 10 16 Bit Word Input to the PLC from the Module 1 13 Analog
23. g all slots on the base and the inputs or outputs associated with each slot refer to your TISOFT Programming Manual An example chart is shown in the following figure 1 0 MODULE DEFINITION FOR CHANNEL 1 BASE 00 1 0 NUMBER OF BIT AND WORD I O SPECIAL SLOT ADDRESS X Y WX WY FUNCTION 01 0001 00 00 08 00 NO 02 0000 00 00 00 00 NO 15 0000 00 00 00 00 NO 16 0000 00 00 00 00 NO Figure 2 6 Example I O Configuration Chart In this example the Model 2558 module is inserted in slot 1 in I O base 0 Data for channel 1 appears in word location WX1 data for channel 2 appears in word location WX2 etc For your particular module look in the chart for the number corresponding to the slot occupied by the module If word memory locations appear on this line then the module is registered in the PLC memory and the module is ready for operation If the line is blank or erroneous re check the module to ensure that it is firmly seated in the slots Generate the PLC memory configuration chart again If the line is still incorrect contact your local distributor or CTI at 1 800 537 8398 for further assistance 22 CTI 2558 Installation and Operation Guide CHAPTER 3 TROUBLESHOOTING If the module provides improper readings or the status indicator is not on use the following chart to determine the appropriate corrective action SYMPTOM PROBABLE CAUSE
24. g equations may be used to calculate the digital word which will result from a particular voltage or current input in the Unipolar Input Mode 0 to 5VDC range Digital Word WX Input voltage x 32000 5 volts example to generate an input voltage of 2 5 VDC the WX value input to the PLC is calculated as follows WX 2 5 x 32000 5 16000 0 to 10VDC range Digital Word WX Input voltage x 32000 10 volts example 7 5VDC input WX 7 5 x 32000 10 24000 0 to 20mA range Digital Word WX Input current x 32000 20 mA example 10mA input WX 10 x 32000 20 16000 Note Bit 15 is always returned as a zero and bit 16 is employed as an over underrange bit Consequently returned data values change by four CTI 2558 Installation and Operation Guide 1 9 2 Bipolar Mode Conversion The following equations may be used to calculate the digital word which will result from a particular voltage or current input in the Bipolar Input Mode 5 to 5 VDC range Digital Word WX Input voltage x 32000 5 volts example to generate an input voltage of 2 5 VDC the WX value input from the PLC is calculated as follows WX 2 5 x 32000 5 16000 10 to 10VDC range Digital Word WX Input voltage x 32000 10 volts example 10 VDC input WX 10 x 32000 10 32000 20 to 20mA range Digital Word WX Input current x 32000 20 mA example 15mA input WX 15 x 32000 20 24000 Note
25. he module from the I O base Be careful not to damage the edge card at the back of the module when inserting or removing the module 2 5 Wiring the Input Connectors Input signals are accepted through a connector assembly located on the front of the module The connector assembly consists of a standard Siemens front panel edge connector that mates with the printed circuit board Wiring is connected to the front connector via recessed screw terminals The screw terminals can accept wire sizes up to single stranded 14 gauge wire The actual size used depends on the external device providing the input signal Consult the device manufacturer s recommendations for selecting the input wire size To assign an input to a specific channel locate the appropriate channel position on the screw terminal connector as shown in the following figure NOT USED 4 NOT USED A PA MIN 198 i 2 in V1 IN 1 HE RETURN 1 1 Aig HO RETURN 5 NOT USED fl ac H NOT USED NOT usED L OP TF NOT USED rin 16 L 16 IN van 159407 V6 IN RETURN Afel RETURN 6 NOTUSED Dial NOT USED NOT USED 2 NOT USED BN Afl VIN van Ail WN RETURN 3 Afel RETURN NOT USED AE n NOTUSED NOT USED DA E Den USED 14 IN vain LO HOT V8 IN RETURN 4 LAF L T RETURN 8 chassis tAE CHASSIS Figure 2 3 Screw Terminal Connector Wiring CTI 2558 Installation and Operation Guide 19 2 5 1 Connecting Voltage Inpu
26. iguration Once the hardware jumpers are selected this information needs to be reported to the microcomputer The information is reported via DIP switches SW1 and SW2 see Figure 2 2 Each output channel uses 2 switches with a BCD code to indicate the state of the hardware jumpers 2 MSB 1 LSB Range Md S S OFF OFF Unipolar 5VDC BB OFF OFF ON Unipolar 10VDC ON OFF Bipolar SVDC ON ON ON Bipolar 1OVDC CH 1 NOTE The OFF position is selected by actuating the switch in the direction of the center of the printed circuit board 2 3 8 Selecting Channel Return Path as Common or Isolated Locate the return jumpers 1 8 see Figure 2 2 To enable a common channel 1 8 return path select the COM common position To isolate individual channels choose the ISO isolated position As shipped all 8 channels are in COM common mode 2 3 9 Jumper Settings for Future Reference See Appendix B Jumper Settings Log Sheet to record any changes to the module s jumper settings 18 CTI 2558 Installation and Operation Guide 2 4 Inserting the Module into the I O Base Insert the module into the I O base by carefully pushing the module into the slot When the module is fully seated in the slot and backplane connector tighten the captive screws at the top and bottom to hold the module in place To remove the module from the I O base loosen the captive screws then remove t
27. inal Connector ueuesesenesenesennenenenennenenenenennenenenennenenenenane 21 2 7 Checking Mod le Operation sb 22 CHAPTER 3 TROUBLESHOOTING fs ees nenne nee an 23 HARDWARE SPECIFICATIONS icccccscscesesiteccccseessesegecenosesustsncesedeeeeadusscocesessessececseecesetecsnes 25 APPENDIX A COMPATIBILITY WITH SIEMENS 505 6108A B nosses 27 APPENDIX B JUMPER SETTINGS LOG SHEET c esesssensennenennsennennenennenne 29 LIMITED PRODUCT WARRANTY cennere earna EE E aia ES 31 REPAIR POLICY i 2282368 Roa ni n in dn eR Un a le 33 CTI 2558 Installation and Operation Guide TABLE OF FIGURES E sgure 1 1 CTL2558 Eront Panelis irine 2408 ki He Ace lieh 1 Figure 1 2 13 Bit Word Input to the PLC from the Module oonocononcnoccconcconnconcnonnnonnonanononcnnnccnnocno ns 3 Figure 1 4 13 Bit Overrange Word Value Unipolar cc ceecceecscceesceceeeeeceeceeaaeceeaeeceeeeeaeceeaeeceeeeees 5 Figure 1 5 13 Bit Underrange Word Value Unipolar 0 ccc ecccceecceceeeceeececeeaceceeneecsaeeeeaaeceeaeeceeeeees 6 Figure 1 6 13 Bit Voltage Input Limits Bipolar eee eee ceseceseceseceeceseeeseeeseeeeaeeeaeeeaeesaeeenaeenaee 6 Figure 1 7 13 Bit Overrange Word Value Bipolar 0 eee eseessecsseceseceseceseeeseceseeeeeeeeeeeeaeeeaeeeaecaeens 6 Figure 1 8 13 Bit Underrange Word Value Bipolar ooooncononcnnonnnocononononononaconaconaconncnn nono nonn ccoo nc nnnccona ns 7 Figure 1 9 Input Resolution 13 Bi
28. ing to input channels 1 through 8 See Figure 2 2 for the location of these jumpers For each input channel select current mode by placing the jumper in the 20MA position or voltage mode by placing the jumper in the VOLTAGE position For each input channel set to current mode you must set the corresponding Voltage Range Jumper to the 5V position as described in the following section 2 3 2 Selecting Voltage Range Locate the Voltage Range Jumpers corresponding to input channels 1 through 8 see Figure 2 2 For each input channel operating in current mode set the corresponding Voltage Range Jumper to 5V CAUTION For each input channel configured for current mode the corresponding Voltage Range Jumper must be set to 5V For each input channel operating in voltage mode set the corresponding Voltage Range Jumper to SV for 0 to 5V or 5 to 5V input range or 10V for 0 to 10V or 10 to 10V input range As shipped the 2558 is in 5V range CTI 2558 Installation and Operation Guide 15 Voltage Current Voltage Range Unipolar Bipolar Return Path Channel Jumper Jumper Jumper Compatibility Jumper Number Default 20mA Default 5V Default UND Default COM 1 JP1 JP3 JP2 JP24 2 JP4 JP27 JP5 JP28 3 JP10 JP6 JP8 JP29 4 JP13 JP9 JP11 JP30 5 JP16 JP12 JP14 JP31 6 JP7 JP15 JP17 JP32 7 JP19 JP18 JP20 JP33 8 JP22 JP21 JP23 JP34 Offset Digital All Sc
29. n 19 Figure 2 4 Shield Wire Termination ooococcnnncnonnconnconnninnnonnnonnnonononn nono no nono nono nono i rra essen 21 Figure 2 5 Input Connector Assembly ui ii te en tieren 21 Figure 2 6 Example I O Configuration Chalt oooncnnnccnnncnocnnnonnnnncnnnconncnononnoconocnnccnnnnnnn cnn cnn cra cra conos 22 Figure 3 1 Troubleshooting Matrix 0 0 eee cesecesecssecssecssecesecsseeseeeseseeeseeeseecaecaecsaeceaeesseesseeeseeeeeeeees 23 CTI 2558 Installation and Operation Guide Xi CHAPTER 1 OVERVIEW 1 0 Product Summary The CTI 2558 Eight Channel Analog Input Module is a member of Control Technology s family of T O modules compatible with the SIMATIC 505 programmable controllers It is designed to translate an analog input signal into an equivalent digital word which is then sent to the programmable controller PLC 1 1 Front Panel Description ACTIVE LED CHANNELS 1 8 Figure 1 1 CTI 2558 Front Panel 1 1 1 Active LED The Active LED will be illuminated when the module is functioning normally If the Active LED is not lit or if it is blinking refer to Chapter 3 for troubleshooting 1 1 2 Input Connector for Channels 1 8 This connector provides wiring terminals for Channels 1 8 for either voltage or current inputs The wiring connector accepts 14 22 AWG wire CTI 2558 Installation and Operation Guide 1 2 Asynchronous Operation The module operates asynchronously with respect to the PLC a scan of the PLC an
30. n Guide iii PREFACE This Installation and Operation Guide provides installation and operation instructions for the CTI 2558 Eight Channel Isolated Analog Input Model for SIMATIC 505 programmable controllers We assume you are familiar with the operation of SIMATIC 505 series programmable controllers Refer to the appropriate 505 user documentation for specific information on the SIMATIC 505 programmable controllers and I O modules This Installation and Operation Guide is organized as follows Chapter 1 provides a description of the module Chapter 2 covers installation and wiring Chapter 3 is a guide to troubleshooting Appendix A details compatibility between the 2558 and the Siemens505 6108 A and 505 6108 B s s vecu u sve The Model 2558 8 Channel Analog Input Module CTI 2558 Installation and Operation Guide v USAGE CONVENTIONS NOTE Notes alert the user to special features or procedures CAUTION Cautions alert the user to procedures that could damage equipment WARNING Warnings alert the user to procedures that could damage equipment and endanger the user CTI 2558 Installation and Operation Guide Vii TABLE OF CONTENTS CHAPTER OVERVIEW unas pleasant 1 1 0 Product Summary cidos ido 1 1 1 Front Panel Description sieren ne ies ae aa a ae REE AE E AARE 1 1 2 Asynchronous Operation iis nei a A E EEE E A N RSE 2 A OS 2 1 4 Unipolar or Bipolar Mode ueueseseneseses
31. om the terminal strip to the PLC act as antennas and are susceptible to radiated and conducted emissions in the cabinet Unprotected cables may introduce measurement errors in the module The front connector on the module contains a CHASSIS terminal which may be used for the shield wire if the installation is in a noise free environment If the installation is in an extremely noisy environment CTI strongly recommends that the shielded wires terminated to the PLC chassis ground CTI has exhaustively tested this product to maximize its ability to reject noise from inductive sources as well as showering arcs fast transients and other high frequency generators and has determined that the best performance results from connecting all shield wires together at the PLC module and terminating this single wire to the chassis ground with a large current capacity conductor CTI recommends using a 8 gauge wire are larger from the PLC chassis to the earth ground connection 20 CTI 2558 Installation and Operation Guide CABLE GROUNDING Remove a length of cable Pull the foil shield and bare Twist the foil shield and drain Attach a ground lug jacket from the cable drain wire from the insulated wire together to form a single wires adh strand Bare drain wire 43 AAA ATL Zi LEE g E Insulated a Foil wires shield 21 Siemens SIMATIC SIMATIC TI 505 T1545 O no sooo O O so row sono ae CHASSIS GROUND REMOVE SCREW L
32. on on static control precautions contact CTI s office at 1 800 537 8398 CTI 2558 Installation and Operation Guide 33
33. ow shows the corresponding input resolution per step for each of the input configuration modes UNIPOLAR UNIPOLAR WITH 20 OFFSET BIPOLAR 12 RANGE DIGITAL INPUT RESOLUTION CONFIGURATION COUNTS STEP PER STEP 0 5 VDC 1 156 pV 0 10 VDC 1 312 pV 0 20 mA 1 0 625 pA 1 5 VDC 1 156 uV 4 20 mA 1 0 625 pA 5 TO 5 V 1 156 uV 10 TO 10 V 1 312 pV 20 to 20mA 1 0 625 pA Figure 1 17 Input Resolution 16 Bit CTI 2558 Installation and Operation Guide CHAPTER 2 INSTALLATION The installation of the Eight Channel Analog Module involves the following steps Planning the installation Unpacking and configuring the module Inserting the module into the I O base Wiring and connecting the module input connectors MR WN Checking module operation The steps listed above are explained in detail in the following pages 2 1 Planning the Installation Planning is the first step in the installation of the module This involves calculating the I O base power budget and routing the input signal wiring to minimize noise The following sections discuss these important considerations 2 1 1 Calculating the I O Base Power Budget The Model 2558 requires 3 0 watts maximum of power from the I O base Use this value to verify that the base power supply is not exceeded 2 1 2 Input Signal Wiring Input signal wiring must be shielded twisted pair cable A twisted pair will aid in the rejection of condu
34. t oooonccnnncniccnooccnoccnonoconoconoconoconccnnn nono nono nono AA nc none conan nn cnn anno ne n 7 Figure 1 10 16 Bit Word Input to the PLC from the Module ooooconcnincnnnccnocnnocnconncnoncnncnn nono nononocnacns 8 Figure 1 11 16 Bit Voltage Input Limits Unipolar oooonnccninncicanocononcnononacononanononononcnnnnnocnnn cc nnncccnnnnos 10 Figure 1 12 16 Bit Overrange Word Value Unipolar ooooonnccnocccoccconnnonnnonnconncnn nono noconononoconccnnncnnncnnos 10 Figure 1 13 16 Bit Underrange Word Value Unipolar oconcnnncnnnconoconococoncconaconoconncnnncnnncnnononacrnn conan 10 Figure 1 14 16 Bit Voltage Input Limits Bipolar oonocnncnnnccnncanocanacnnananonnconncon nono noconononocnnccnnccnncannos 11 Figure 1 15 16 Bit Overrange Word Value Bipolar oonconncnnnncnnnonnocnooncnoncnononn nono nonnncnnncnnn crac esse conan 11 Figure 1 16 16 Bit Underrange Word Value Bipolar ursuessesnesnnesnnesnnennnnnnnnnnnennnennnennnen 11 Figure 1 17 Input Resolution 16 Bit ursuesssessnersnessnnesnnesnnesnnesnennnnnnnnnnnnennonnnnennnennnen nassen 12 Figure 2 1 Shipping Jumper Configuration Locations u e22uessessensensensnensnensnnesnnesnnesnnennennnnnnn 16 Figure 2 2 Configuration Jumper Board Locations 22u22200220ssnensnersnersnnennnesnnesnnesnnennnennsn nme nn 17 Figure 2 3 Screw Terminal Connector Wiring uusueessesssessnesnnesnnnsnnnnnnnennnennnennennnennnonnnnennnennnennnenna
35. t Wiring For voltage input circuits connect the signal wire to the V In screw terminal and the return wire to the Return screw terminal Insert the wires in the appropriate holes on the front of the connector When the wires are inserted tighten the screws Repeat this procedure for the remaining voltage input channels 2 5 2 Connecting Current Input Wiring For current input circuits connect the signal wire to the I screw terminal and the return wire to the Return screw terminal Insert the wires in the appropriate holes on the front of the connector When the wires are inserted tighten the screws Repeat this procedure for the remaining current input channels 2 5 3 Connecting the Shield Wiring Control Technology Inc recommends that all wires be shielded twisted pair with a foil wrap shield and a separate drain wire and that they be installed in a metallic conduit Use Belden cable 8761 or equivalent which contains a foil wrap shield and a separate drain wire The shield and the foil wrap should be twisted together and should be terminated at only one end The other end should be left in an open circuit condition CTI recommends that the shield be terminated at the PLC end of the signal wire Special components are installed on the module to aid in the rejection of noise When entering the industrial cabinet the shield should be routed from the main terminal strip all the way to the PLC Signal leads that do not maintain a shield fr
36. t is set VOLTAGE RANGE m OTOSV 0TO10V 200V 0 01V 5 05V 200V 200V 0 02V 10 10V 200V me Module not Underrange Accuracy Overrange Module not protected output data within bit set protected damage specification damage might occur might occur lt 0 32 765 UNIPOLAR MODE Figure 1 3 13 Bit Voltage Input Limits Unipolar Figures 1 4 and 1 5 show the binary values of typical overrange and underrange conditions for Unipolar mode BIT 1 Typical Digital Word Map for Overrange Digital Word UNIPOLAR MODE Figure 1 4 13 Bit Overrange Word Value Unipolar CTI 2558 Installation and Operation Guide TRANSLATED 16 384 6 32 16 8 VALUE 42 765 0 1 1 1 1 1 1 1 1 1 1 1 1 0 1 I UNUSED SETTO MSB TRANSLATED ZERO LSB SIGN 1 DIGITAL WORD IF OVERRANGE 0 SETTO 1 Typical Digital Word Map for Underrange Digital Word TRANSLATED 16 384 64 32 46 VALUE 403 BIT 1 a a 1 0 rajo a oa a 1 Pp UNUSED MSB TRANSLATED ena LSB SIGN 1 DIGITAL WORD IF UNDERRANGE 0 SETTO1 UNIPOLAR MODE Figure 1 5 13 Bit Underrange Word Value Unipolar 1 10 2 Bipolar Mode In Bipolar Mode signals above or below the upper and lower limits in the 5 to 5 VDC or 10 to 10 VDC range are translated to a digital word and also utilize the overrange and underrange bit The actual limit for each channel will vary from channel to channel as des
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