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Installation and Operation Guide

1. 1 7 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 Input voltage V x 32000 5 to 5 V Input Range Mode Digital Word WX 10 to 10 V Input Range Mode Digital Word WX __ 10 volts Input current mA x 32000 20 to 20 mA Input Range Mode Digital Word WX 4 CTI 2555 Installation and Operation Guide 1 7 3 Example Conversion As an example the following figure illustrates the effects of a change in input level going from 3125 to 625 mV in the 0 to SV Unipolar Input Mode For the 0 to 10V and 0 to 20mA Unipolar Input Modes or the Bipolar Modes refer to the formulas given in Sections 1 7 1 and 1 7 2 to determine the digital word which results from a particular input LSB HEM x 32000 2 o o olol o o o olojo o 0 0 011 0 8216 8 4 2 1 MSB SIGN 4 0 LSB SE x32000 4 o o 0 0 00 00 000004 8216 8 4 2 1 o o MSB SIGN 1 O 16 384 LSB L 287 x32000 6400 ojo o 110 01o o ojojo ojojo 2 3216 8 4 2 1 MSB SIGN 1 O Figure 5 Example of Change in
2. SHIELD Y Figure 16 Typical Internal Circuit Voltage Mode For current input circuits connect the signal wire to the positive screw terminal and the return wire to the negative screw terminal The ground terminals labeled SHIELD provide a convenient location to terminate the shield Insert the wires in the appropriate holes on the front of the connector adjacent to the corresponding screw When the wires are inserted tighten the screws Repeat this procedure for the remaining current input channels NOTE No external current resistor is required in current mode V 250 gt OHM gt NA SHIELD Y Figure 17 Typical Internal Circuit Current Mode 16 CTI 2555 Installation and Operation Guide 2 6 Inserting the Screw Terminal Connector When all the input signal wires are connected to the screw terminal align the edge of the printed circuit board with the corresponding edge of the wiring connector and press the connector on the circuit board until the connector is fully seated Next align the captive screws on the top and bottom of the connector with the front panel and tighten until the module connector is fully seated we PRINTED CIRCUIT CARD PCB CAPTIVE SCREWS BB r INDIVIDUAL CAPTIVE SCREW E INPUT SIGNAL WIRES Ss R mn D 2 a 3 m gt a TUT O 2 pra oat m E 4 o o SSSSS8SSSS8SSsssssssss je Fig
3. pe Z SHIELD SHIELD A J ec lt ied Z CHANNEL 5 CHANNEL 5 2 poa L 4 CHANNEL 6 CHANNEL 6 2 Z CHANNEL 7 CHANNEL 7 M y z Z CHANNEL 8 CHANNEL 8 7 SHIELD SHIELD z gt Z CHANNEL 9 CHANNEL 9 z oe 2 CHANNEL 10 CHANNEL 10 2 z Z 7 CHANNEL 11 CHANNEL 11 A E z H CHANNEL 12 CHANNEL 12 e SHIELD SHIELD 7 M oc H CHANNEL 13 CHANNEL 13 5 H CHANNEL 14 CHANNEL 14 be Z CHANNEL 15 CHANNEL 15 M 07 p CHANNEL 16 CHANNEL 16 zs SHIELD Figure 15 Screw Terminal Plug Wiring CTI 2555 Installation and Operation Guide 15 2 5 1 Connecting Voltage Input Wiring For voltage input circuits connect the signal wire to the positive screw terminal and the return wire to the negative screw terminal The ground terminals labeled SHIELD provide a convenient location to terminate the shield Insert the wires in the appropriate holes on the front of the connector adjacent to the corresponding screw When the wires are inserted tighten the screws Repeat this procedure for the remaining voltage input channels The 2555 inputs are full differential input amplifiers that may be driven in a differential or single ended mode 2 5 2 Connecting Current Input Wiring V
4. For each channel select UNI or BIP for Unipolar or Bipolar mode Next set DIP switches SW7 and SW8 for each channel to the same selection as the corresponding jumpers JP5 JP20 CTI 2555 Installation and Operation Guide 13 Ml JP20 JP18 JP16 JP14 JP12 JP10 JP8 JP6 JP19 JP17 JP15 JP13 JP11 JP9 JP7 JP5 go OO do 00 00 00 00 go 0 00 00 A l Sw8 OTTO SW7 JP121 iii SW6 SW5 OO TO 2 3 4 Selecting Digital Filtering DIGITAL FILTERING ENABLED Figure 14 Configuration Jumper Locations gt Locate the Digital Filtering No Filtering Jumper JP121 see Figure 14 To enable digital filtering set the jumper in the FIL position Since many analog input signals contain noise CTI recommends using digital filtering unless maximum response time is required Digital Filter Time Constant The time constant for the Model 2555 is 25 milliseconds An input signal from zero to full scale will require 4 to 5 time constants to reach a final value Therefore the effect of digital filtering will slow the response of the module to 100 milliseconds 14 CTI 2555 Installation a
5. Then multiply the result by 125 and divide the product by 100 This yields the following equation WX 6400 x 125 rd ae aE 20 offset data word Consult your PLC programming manual or program design guide for information about the RLL instructions used in the conversion 1 10 Resolution In the Unipolar Input Mode the module has a resolution of 2 counts out of 32000 That is the smallest unit into which the module will divide an input is 1 part out of 16000 This relationship can be shown as 2 counts per step 1 32000 counts full scale 16000 In Bipolar Mode the resolution is 4 counts out of 32000 so that the smallest unit into which the module will divide an input is 1 part out of 8000 This relationship can be shown as 4 counts per step 1 32000 counts full scale 8000 When using the module with 20 offset module resolution remains at 2 counts out of 32000 but offset resolution becomes 4 counts out of 32000 as a result of the multiplication and division of the incoming data word 8 CTI 2555 Installation and Operation Guide The chart below shows the corresponding input resolution per step for each of the input configuration modes RANGE DIGITAL INPUT RESOLUTION CONFIGURATION COUNTS STEP PER STEP 0 5 VDC 2 0 3125 mV UNIPOLAR 0 10 VDC 2 0 625 mV L 0 20mA 2 1 25 pA UNIPOLAR 1 5 VDC 4 0 625 mV WITH 20 OFFSET L 4 20mA 4 2 50 pA 5 TO 5 VDC 4 0 625 mV BIPOLAR 10 TO 10
6. NOTE The 5V input signal range configuration is used for both 0 to 5 VDC and 1 to 5 VDC or 4 to 20 mA and 0 to 20 mA input signal ranges Changing the module input channel configuration involves the following steps 1 Selecting voltage V or current I input mode for each channel 2 Selecting 0 to 5V or 0 to 10V voltage range for each channel 3 Selecting unipolar or bipolar input mode for each channel 4 Selecting digital filtering or no filtering for the module 5 Logging the configuration jumper settings for future reference Each of these steps is described in the following sections 2 3 1 Selecting Voltage or Current Input Mode JP1 JP2 JP3 JP4 Locate the 16 Voltage Current Jumpers corresponding to input channels through 16 See Figure 14 for the location of these jumpers For each input channel select current mode by placing the jumper in the Current 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 The silkscreen on the printed circuit board is clearly marked to indicate the voltage or current position for each channel NOTE Each channel utilizes jumpers to configure the hardware and DIP switches to configure the microcomputer 12 CTI 2555 Installation and Operation Guide 2 3 2 Selecting Voltage Range JP5 JP20 Locate
7. TRANSLATED 16 384 64 32 16 8 VALUE 32309 BIT 1 BIT 1 16 p MSB TRANSLATED LSB SIGN DIGITAL WORD IF OVERRANGE SET TO 1 1 a D UNIPOLAR MODE Figure 8 Typical Unipolar Overrange Word Value Typical Digital Word Map for Underrange Digital Word TRANSLATED 16 384 64 32 16 VALUE 403 Ba lo fo afro op BT SB TRANSLATED LSB SIGN 1 DIGITAL WORD IF UNDERRANGE O SET TO 1 UNIPOLAR MODE Figure 9 Typical Unipolar Underrange Word Value mode Typical Digital Word Map for Overrange Digital Word TRANSLATED 16 384 64 32 16 VALUE 32687 Bo 1 aa faja jajaa o 1 o 111 fa Bie a MSB TRANSLATED LSB DIGITAL WORD IF OVERRANGE SET TO 1 BIPOLAR MODE Figure 10 Typical Bipolar Overrange Word Value CTI 2555 Installation and Operation Guide Typical Digital Word Map for Underrange Digital Word TRANSLATED VALUE 32767 16 384 64 32 16 BIT 4 4 BIT 1 16 E a MSB TRANSLATED LSB SIGN 1 DIGITAL WORD IF UNDERRANGE O SET TO 1 BIPOLAR MODE Figure 11 Typical Bipolar Underrange Word Value 1 9 Using the Module with 20 Offset Most applications use transducers that provide 1 to 5 volt 4 to 20 mA input signals instead of 0 to 5 volt 0 to 20 mA 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
8. 00 00 NO 16 0000 00 00 00 00 NO Figure 19 Example I O Configuration Chart 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 18 CTI 2555 Installation and Operation Guide If the module provides improper readings or the status indicator is not on use the following chart to determine the appropriate corrective action CHAPTER 3 TROUBLESHOOTING SYMPTOM Indicator is not lit Blinking indicator Incorrect inputs PROBABLE CAUSE Base or PLC power is off Defective module EEPROM failure Blown fuse Wrong addresses for word input Not logged in Incorrect jumper settings CORRECTIVE ACTION Turn base or PLC on Return the module to CTI for repair Return the module to CTI for repair Return the module to CTI for repair Check program for correct word input addresses Read I O configuration Refer to proper section of this Installation amp Operation guide for jumper settings Return the module to CTI for recalibration Incorrectly calibra
9. I O Base Power Budget 0 0 0 e eee eee eee 10 2 1 2 Input Signal WINE A ANA teh dees le ae ney 10 2 2 Unpacking the Modules 03 95 iia 11 2 3 Configuring the Module sepiaria ania eee nee eee eens 12 2 3 1 Selecting Voltage or Current Input Mode JP1 JP2 JP3 JP4 12 2 3 2 Selecting Voltage Range JP5 JP20 0 0 2 eee eee 13 2 3 3 Selecting Unipolar or Bipolar Input Mode 0 0 0 eee eee eee 13 2 3 4 Selecting Digital Filtering oooooooccoocoooooo a 14 2 4 Inserting the Module Into the I O Base 0 0 eee eens 15 2 5 Wiring the Input Connectors A I a 15 2 5 1 Connecting Voltage Input Wiring 6 ee eee 16 2 5 2 Connecting Current Input Wiring 6 eee 16 2 6 Inserting the Screw Terminal Connector 0 0 0 cee ee eee eens 17 2 7 Checking Modules Operation io cowie e aed 18 CHAPTER 3 TROUBLESHOOTING essex pipe bee A OE Ee 19 SPECIFICATIONS a A AAA A pv aia RA AAA 21 JUMPER SETTINGS LOG SHEET 205 A A AA AAA AR 23 USERNOTES Margret eae A A E ad Di ic 25 LIMITED PRODUCT WARRANTY eei a a e E eee eee 27 REPAIRPROLIC td td td tb OS 29 CTI 2555 Installation and Operation Guide ix CTI 2555 Installation and Operation Guide Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 TABLE OF FIGURES The Mo
10. 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 CTI will return such Product or part to the customer This warranty does not include repair of damage to a part or the 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
11. fully compatible with the Immediate Input function in the SIMATIC TI545 and 555 PLC 1 4 Unipolar or Bipolar Mode The module may be configured to accept either bipolar or unipolar input signals Selection of unipolar or bipolar mode is made via one internal jumper per channel see Section 2 3 3 1 5 Voltage or Current Mode Each of the module s sixteen 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 Digital Word Map A unipolar analog input signal is translated into a 14 bit digital word A bipolar input signal is translated into a 13 bit digital word plus 1 bit for the polarity sign Since the PLC requires a 16 bit input word the 14 bit value from the converter is placed into a 16 bit word for transmittal to the PLC 2 CTI 2555 Installation and Operation Guide 1 6 1 Unipolar Presentation 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 one is used to note values which are overrange underrange so 3216 8 4 2 1 beef eee ea ell ie ell Pi MSB TRANSLATED LSB DIGITAL WORD IF OVERRANGE UNDERRANGE SET TO 1 UNIPOLAR WO
12. CTI 2555 SIXTEEN CHANNEL DIFFERENTIAL ANALOG INPUT MODULE INSTALLATION AND OPERATION GUIDE Version 1 0 CTI Part 062 00157 255510G 092205 25 ii CTI 2555 Installation and Operation Guide 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 Siemens and SIMATIC are registered trademarks of 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 merchantablility 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 CTI 2555 Installation and Operation Guide iii iv CTI 2555 Installation and Operation Guide PREFACE This Installation an
13. ENTS PREFACIO A A v USAGECONVENTIONS to en vil TABLE OF FIGURES dia SA EU E EOE xi CHAPTER LL DESCRIPTION de de e aldo endl 1 1 1 Front Panel Description sessen owe ee wee A A Re awe ae eS 1 diel Active LEDs 2 22 Snceo e yg Es 1 1 1 2 Input Connector for Channels 1 16 2 0 0 0 eee eee 2 1 2 Asynchronous Operation ioe A ed aes aged aoe ed S 2 1 3 Immediate VO a pag wed Relies o Meee a Mena goes 2 1 4 Unipolar or Bipolar Mode 0 6 eet n teens 2 1 5 Voltage or Current Mode 0 ccc eee e nen eens 2 1 6 Digital Word Mapes fies csnlea A EA veins Sis eet ate ibe 2 1 6 1 Unipolar Presentation s 0 00 00 6378 A a Ree ERR a wee eee 3 16 2 Bipolar Presentation 3 51 04 300 5 See is 3 1 7 Analog to Digital Conversion poesien aea a a O A en enn eee nee 4 1 7 1 Unipolar Mode Conversion 0 0c cece ete e nes 4 1 7 2 Bipolar Mode Conversion 0 0 0 cece eee tenes 4 1 7 3 Example Conversion ipene ti en e cece cen ene tenn ee ene nena 5 1 8 Effect of Out of Range Input Signals 2 0 0 0 0 cee eens 6 1 81 Unipolar Mode Ia celta ele an lei oles ae tlle as ley 6 8 2 Bipolar Mode consabido 6 1 9 Using the Module with 20 Offset 2 0 0 0 cen nen ees 8 LLO Resol 2 oser in daw es wey rinia A a DR ec Be Denn vey he aaa foe 8 CHAPTER 2 INSTALLATION us a post Sous Bed arda ol E ne ais eg tsa shin antag dx gta ao 10 2 1 Planning the Installation ise eenige a ee ttt teen nes 10 2 1 1 Calculating the
14. Input Level CTI 2555 Installation and Operation Guide 3 1 8 Effect of Out of Range Input Signals The Model 2555 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 a corresponding change in input signal is called the overrange or underrange limit of the channel This level is different for every channel In the figures below 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 8 1 Unipolar Mode Signals falling above or below the upper and 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 Note that although the digital word may approach zero as the analog input signal approaches the minimum for a given range the digital word will never actually be zero In fact the underrange capability of any channel in Unipolar Mode may produce a negative value to the PLC f
15. 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 LIMITATION 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 2555 Installation and Operation Guide 27 28 CTI 2555 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 verbally 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 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 mod
16. OIN OD oR ow lm JP 12 JP 12 O CO N O oO A w lm o P 13 JP 13 o o P14 JP 14 P15 JP 15 P16 JP 16 P17 JP 17 P18 JP 18 P19 JP 19 UNIPOLAR ALL BIPOLAR CHANNELS SWITCHES P 20 VOLTAGE RANGE SWITCHES DIGITAL FILTERIN JUMPER JP 20 JUMPER POSITION FIL none SW7 SW 8 SW5 SW 6 JP 121 Figure 21 Jumper Settings Log FIL Record the configuration jumper settings on this log for future reference Make additional copies if necessary CTI 2555 Installation and Operation Guide 23 24 CTI 2555 Installation and Operation Guide CTI 2555 Installation and Operation Guide USER NOTES 26 CTI 2555 Installation and Operation Guide 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 one 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
17. RD MAP Figure 3 Word Input to the PLC from the Module Unipolar 1 6 2 Bipolar Presentation As shown in the following figure of the three bits not used for the digital word one is used to show the sign of the word one is used to note values which are overrange and the remaining bit is not used and set to zero 8216 8 4 2 1 ir i ae Sea a ajajaja aja e Ml MSB TRANSLATED LSB SIGN 1 DIGITAL WORD IF OVERRANGE UNDERRANGE Oi SET TO 1 UNUSED BIPOLAR WORD MAP SET T00 Figure 4 Word Input to the PLC from the Module Bipolar NOTE In the Bipolar Word Map bit 15 is unused There will however be cases where bit 15 will not be zero as indicated Bipolar Mode consists of 13 bits plus a sign bit When this data is transformed to a 16 bit word space to the PLC some codes will result that will include bit 15 CTI 2555 Installation and Operation Guide 3 1 7 Analog to Digital Conversion 1 7 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 Input voltage V x 32000 0 to 5 V Input Range Mode Digital Word WX 5 volts Input voltage V x 32000 0 to 10 V Input Range Mode Digital Word WX 10 volts Input current mA x 32000 0 to 20 mA Input Range Mode Digital Word WX __
18. VDC 4 1 25 mV Ll 0 20mA 4 2 50 pA Figure 12 Input Resolution CTI 2555 Installation and Operation Guide 9 CHAPTER 2 INSTALLATION The installation of the Sixteen Channel Analog Input Module involves the following steps Planning the installation Configuring the module Inserting the module into the I O base Wiring and connecting the module input connectors Checking module operation Sch ee at cri ae 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 2555 requires 5 0 watts of 5 VDC power from the I O base Use this value to verify that the base power supply capacity is not exceeded 2 1 2 Input Signal Wiring Input signal wiring must be shielded twisted pair cable The shielding for the cable should always be terminated at the Model 2555 Each group of four input channels contain two termination points for the shield wire The shield wire should be terminated at the designated shield terminals only to minimize the effects of noise on the measuring system 10 CTI 2555 Installation and Operation Guide Note the following general considerations when wiring the module Always use the shortest po
19. change without notice CTI 2555 Installation and Operation Guide Unipolar 0 to 5 VDC 0 to 10 VDC or 0 to 20 mA Bipolar 5 to 5 VDC 10 to 10 VDC or 20 to 20 mA 5 9 mSec no filtering 8 2 mSec digital filtering enabled 25 mSec Voltage Mode 680 kQ Current Mode 250 Q 0 008 Voltage Mode 0 10 of full scale at 25 C 0 30 of full scale at 0 60 C Current Mode 0 20 of full scale at 25 C 0 40 of full scale at 0 60 C Unipolar 14 bit plus sign 0 5 VDC range 0 3125 mV step 0 10 VDC range 0 625 mV step 0 20 mA range 1 25 pA step Bipolar 13 bit plus sign 5 to 5 VDC 0 625 mV step 10 to 10 VDC range 1 25 mV step 20 to 20 mA range 2 5 pA step gt 86db 60Hz digital filtering disabled gt 45db 60Hz digital filtering enabled Input ESD Protection 4 000 V Overrange Protection 500 V 1500 VDC channel to PLC Single wide 5 0 Watts 0 to 60 C 32 to 140 F 40 to 85 C 40 to 185 F 5 to 95 non condensing 1 5 lbs 0 68 Kg UL UL for Canada FM Class I Div 2 21 22 CTI 2555 Installation and Operation Guide JUMPER SETTINGS LOG SHEET CHANNEL VOLTAGE NUMBER CURRENT JUMPER JUMPER VOLTAGE POSITION RANGE Vorl JUMPER JUMPER POSITION 5V or 10V UNIPOLAR JUMPER BIPOLAR JUMPER POSITION UNI or BIP JP5 JP5 JP6 JP 6 JP7 JP7 JP8 JP 8 JP 9 JP 9 JP 10 JP 10 JP 11 JP 11 C
20. d Operation Guide provides installation and operation instructions for the CTI 2555 Sixteen Channel Differential Analog Input Module for SIMATIC TI Series 505 programmable controllers We assume you are familiar with the operation of SIMATIC TI Series 505 programmable controllers Refer to the appropriate SIMATIC TI user documentation for specific information on the SIMATIC TI Series 505 programmable controllers and I O modules This Installation and Operation Guide is organized as follows Chapter provides a description of the module Chapter 2 covers installation and wiring Chapter 3 is a guide to troubleshooting ACTIVE Figure 1 The Model 2555 16 Channel Differential Analog Input Module CTI 2555 Installation and Operation Guide v vi CTI 2555 Installation and Operation Guide USAGE CONVENTIONS NOTE Notes alert the user to special features or procedures CAUTION Cautions alert the user to procedures which could damage equipment WARNING Warnings alert the user to procedures which could damage equipment and endanger the user STATEMENT OF PRODUCT COMPATIBILITY The 255X 16 point I O module is compatible with all of the SIMATIC TI PLCs including 535 545 and 555 except for the Model 525 The Model 525 will not support the high density WX 16 mode that is required for operation CTI 2555 Installation and Operation Guide vii viii CTI 2555 Installation and Operation Guide TABLE OF CONT
21. del 2555 16 Channel Differential Analog Input Module 0 00000 000s v Front Panel Description sems s oeseri A A A A E A EA a ia EEE A 1 Word Input to the PLC from the Module Unipolar 0 0 00 00 cee 3 Word Input to the PLC from the Module Bipolar 1 0 0 0 06 ees 3 Example of Change in Input Level oo cee ene eens 5 Voltage Input Limits Unipolar evire cessisse iier cece eens 6 Voltage Input Limits Bipolar ersen oes moete ee enn eens 6 Typical Unipolar Overrange Word Value 0 ccc ce ene nes 7 Typical Unipolar Underrange Word Value 0 00 cc ten eens 7 Typical Bipolar Overrange Word Value 0 0 eee nes 7 Typical Bipolar Underrange Word Value 0 0 ct ees 8 Input Resolution A BONA iain OS A E aE RA TN A REE BAIS 9 Factory Configuration Jumper Settings 0 0 0 0 0c eee eens 13 Configuration Jumper Locations 0 0 eee e teens 14 Screw Terminal Plug Wiring sssi en ccc ee cent ne ee nnn 15 Typical Internal Circuit Voltage Mode 1k cnet nen 16 Typical Internal Circuit Current Mode 0 00 eee ens 16 Input Connector ASSCMDIY acc sera A Mong RR Ao AA RS ha Babs Raa RS Ka 17 Example I O Configuration Chart 0 0 00 eee eee es 18 Troubleshooting Matrix ia SS OEE MOLT RR EER ORI SA RE BRA Os 19 Jumper Settings LOS A OEY EE es es ee 23 CTI 2555 Installation and Operation Guide xi xii CTI 2555 Installation and Operation Guide CHAPTER 1 DESCRIPTION The Sixteen Channel Analog Input Module is a member of the Control Technol
22. nd Operation Guide 2 4 Inserting the Module Into the I O Base WARNING The module must not be inserted into the I O rack while rack power is applied 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 the module from the I O base Be careful not to damage the DIN connector 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 SIMATIC TI505 wiring connector see Figure 18 Wiring is connected through the screw terminal plug The screw terminals can accept wire sizes up to single stranded 14 gauge wire The actual size wire 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 plug as shown in the following figure 7 CHANNEL 1 CHANNEL 1 7 J as Z CHANNEL 2 CHANNEL 2 M 16 2 CHANNEL 3 CHANNEL 3 7 M 3 ise 4 CHANNEL 4 CHANNEL 4
23. ogy Inc CTI family of Input Output I O modules for SIMATIC TI Series 505 programmable controllers The Model 2555 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 STATEMENT OF PRODUCT COMPATIBILITY The 255X 16 point I O module is compatible with all of the SIMATIC TI PLCs including 535 545 and 555 except for the Model 525 The Model 525 will not support the high density WX 16 mode that is required for operation 1 1 1 Active LED The active LED will be illuminated when the module is functioning normally If the Active LED is not lit refer to Chapter 3 for troubleshooting 2 ACTIVE LED CONNECTOR HQYHEYT EYP HOP HSNO OEYPS N Figure 2 Front Panel Description CTI 2555 Installation and Operation Guide 1 1 1 2 Input Connector for Channels 1 16 This connector provides wiring terminals for channels 1 16 1 2 Asynchronous Operation The module operates asynchronously with respect to the PLC a scan of the PLC and input sampling of the module do not occur at the same time Instead the module will translate all analog inputs in one module update approximately 6 milliseconds 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 2555 Differential Analog Input Module is
24. or a number of counts before the underrange bit is set 1 8 2 Bipolar Mode In Bipolar Mode signals above or below the upper and lower limits in the 5 to 5 VDC or 10 to 10VDC range are translated to a digital word and also utilize the overrange or underrange bit The actual limit for VOLTAGE M 0 TO5V 0 05V 5 05V RANGE L 9 TO 10V 200V 0 10V 10 10V 200V E E Module not Underrange Accuracy Overrange Module not protected output data within bit set protected damage specification damage might occur might occur 32 320 NOTE LIMITS WILL NOT BE LESS THAN THOSE LISTED BUT CAN BE GREATER UNIPOLAR MODE Figure 6 Voltage Input Limits Unipolar each channel will vary from channel to channel as described above VOLTAGE m 5 TO 5V 5 05V ov 5 05V RANGE 10 TO 10V 200V 10 10V ov 10 10V 200V y 5 Module not Underrange Accuracy Overrange Module not protected output data within bit set protected damage specification damage might occur might occur 32 320 32 320 NOTE LIMITS WILL NOT BE LESS THAN THOSE LISTED BUT CAN BE GREATER BIPOLAR MODE Figure 7 Voltage Input Limits Bipolar 6 CTI 2555 Installation and Operation Guide Figures 8 and 9 show the binary values of typical overrange and underrange conditions for Unipolar mode Figures 10 and 11 show the binary values of typical overrange and underrange conditions for Bipolar Typical Digital Word Map for Overrange Digital Word
25. ssible cables Avoid placing low voltage wire parallel to high energy wire if the two wires must meet cross them at a right angle Avoid bending the wire into sharp angles Use wireways for wire routing Avoid placing wires on any vibrating surface 2 2 Unpacking the Module Open the shipping carton and remove the special anti static bag which contains the module 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 CAUTION HANDLING STATIC SENSITIVE DEVICES The components on the Model 2555 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 the I O backplane CTI 2555 Installation and Operation Guide del 2 3 Configuring the Module The Model 2555 must be configured for voltage or current inputs voltage range unipolar bipolar mode and digital filtering no filtering mode before wiring the input connector 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 and digital filtering enabled see Figure 13
26. ted Noisy signal Check for proper shield termination at input connectors Figure 20 Troubleshooting Matrix When it is inconvenient to visually check the status indicator use the TISOFT Display Failed I O or Show PLC Diagnostics support functions Note that if the module power supply fails the module will still be logged into the PLC even though it is not operating In this case Display Failed I O will not provide the information to accurately diagnose the problem 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 CAUTION The module fuse F1 is not user serviceable If this fuse is blown the module has a serious component failure and should be returned to CTI for repair CTI 2555 Installation and Operation Guide 19 20 CTI 2555 Installation and Operation Guide Input Channels SPECIFICATIONS 16 differential input channels 140 VRMS channel to channel common mode rejection CMR Signal Range Update Time Digital Filtering Time Constant DC Input Resistance Repeatability Accuracy Resolution Common Mode Rejection Normal Mode Rejection Input Protection Isolation Module Size Backplane Power Consumption Operating Temperature Storage Temperature Humidity Relative Shipping Weight Agency Approvals Pending Specifications subject to
27. the Voltage Range Jumpers corresponding to input channels 1 through 16 see Figure 14 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 or damage will result to the module For each input channel operating in voltage mode set the corresponding Voltage Range Jumper to 5V for 0 to 5VDC input range or 10V for 0 to 10VDC or 10 to 10VDC input range Locate DIP switches SW5 and SW6 and for each channel select the voltage range as previously selected with the jumpers CHANNEL VOLTAGE JUMPER VOLTAGE JUMPER UNIPOLAR JUMPER NUMBER CURRENT POSITION RANGE POSITION BIPOLAR POSITION JUMPER Vorl JUMPER 5Vor10V JUMPER UNI or BIP JP 5 5V JP 5 JP 6 5V JP 6 JP7 5V JP7 JP 8 5V JP 8 JP 9 5V JP 9 JP 10 5V JP 10 JP 11 5V JP 11 JP 12 5V JP 12 JP 13 5V JP 13 JP 14 5V JP 14 JP 15 5V JP 15 JP 16 5V JP 16 JP 17 5V JP 17 JP 18 5V JP 18 JP 19 5V JP 19 JP 20 5V JP 20 ojn jor jv frm ALL UNIPOLAR DIGITAL JUMPER CHANNELS BIPOLAR FILTERI POSITIO SWITCHES JUMPER FiL none SW7 SW8 JP 121 FIL Figure 13 Factory Configuration Jumper Settings 2 3 3 Selecting Unipolar or Bipolar Input Mode Locate the Unipolar Bipolar Jumpers JP5 through JP20 see Figure 14
28. ule 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 it s 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 information on static control precautions contact CTI s main office at 1 800 537 8398 CTI 2555 Installation and Operation Guide 29
29. ure 18 Input Connector Assembly CTI 2555 Installation and Operation Guide 17 2 7 Checking Module Operation First turn on the base power supply Ifthe module diagnostics detect no problems the status indicator on the front of the module will light If the status indicator does not light blinks or goes out during operation the module has detected a failure For information on viewing failed module status refer to your SIMATIC 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 listing all slots on the base and the inputs or outputs associated with each slot refer to your SIMATIC TISOFT Programming Manual An example chart is shown in the following figure The Model 2555 logs in to the PLC as 16 WX inputs In this example the Model 2555 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 1 0 MODULE DEFINITION FOR CHANNEL 1 BASE 00 0 NUMBER OF BIT AND WORD I O SPECIAL SLOT ADDRESS X Y WX WY FUNCTION 01 0001 00 00 16 00 NO 02 0000 00 00 00 00 NO 15 0000 00 00

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