2500 Series ™ Compact IO System Control Technology Inc.

2500 Series ™ Compact IO System Control Technology Inc.
Control Technology Inc.
5734 Middlebrook Pike
Knoxville, Tennessee 37921
www.controltechnology.com
Toll Free: 800-537-8398
2500 Series ™
Compact IO System
2500C-8-AO
8-CHANNEL ANALOG OUTPUT MODULE
2500 SERIES® COMPACT I/O
INSTALLATION AND OPERATION GUIDE
Version 1.4
Copyright© 2016 Control Technology Inc.
All rights reserved.
This manual is published by Control Technology Inc. (CTI) 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 , SIMATIC , and
®
®
Series 505 , and 505 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 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 or email us at [email protected]
V 1.0
V1.1
V1.2
V 1.3
V1.4
1 Nov 2013
20 Nov 2013
26 March 2014
17 April 2014
18 January
2016
REVISION HISTORY
Initial Release
Corrected Section 1.9 Error Code Reporting
Corrected Module Pictures
Corrected Section 1.4 reference to Classic Output Range
Corrected Accuracy Rating from .1% to .15%.
PREFACE
This Installation and Operation Guide provides reference information for the CTI 2500 2500C-8-AO
8-Channel Analog Output Model for 2500 Series® Compact I/O. We assume you are familiar with the
operation of CTI 2500 Series® programmable controllers. Refer to the appropriate user
documentation for specific information on the 2500 Series® 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, setup, and wiring.
2500C-8-AO Installation and Operation Guide
www.controltechnology.com
i
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.
TABLE OF CONTENTS
CHAPTER 1 ....................................................................................................... OVERVIEW .......... 5
1.1
Introduction .....................................................................................................5
1.2
Front Panel Description .................................................................................5
1.3
Asynchronous Operation ...............................................................................6
1.4
Modes of Operation........................................................................................6
1.5
Output Resolution ..........................................................................................7
1.6
Accuracy .........................................................................................................7
1.7
Digital to Analog Conversion .........................................................................8
1.8
Module Setup from the PLC in Classic Plus Mode .......................................8
1.9
Error conditions reported: ..............................................................................9
1.10
Using the Module with a Built-In 20% Offset Calculation .......................... 10
CHAPTER 2 ................................................................................ INSTALLATION & SETUP ........ 11
2.1
Installation Planning .................................................................................... 11
2.2
Unpacking the Module ................................................................................ 15
2.3
Configuring the Module ............................................................................... 15
2.4
Physical Installation ..................................................................................... 17
2.5
Connecting Field Wiring .............................................................................. 18
2.6
Initial Power On ........................................................................................... 19
APPENDIX 1 2500C-8-AO PRODUCT SPECIFICATIONS ................................................ 21
CTI WARRANTY .................................................................................................................... 23
REPAIR POLICY ................................................................................................................... 25
iii
TABLE OF FIGURES
Figure 1 2500C-8-AO Front Panel .......................................................................................................... 6
Figure 2 Asynchronous Operation Diagram ............................................................................................ 6
Figure 3 2500C-8-AO JP11 location on PCB........................................................................................16
Figure 4 Physical Installation Picture ....................................................................................................17
Figure 5 2500C-8-AO Wiring Connector Diagram ................................................................................18
CHAPTER 1
1.1
OVERVIEW
Introduction
The CTI 2500C-8-AO 8-Channel Analog Output Module is a member of Control Technology’s 2500C
Compact I/O modules compatible with the 2500 Series® and 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).
Features
 8 analog outputs
 Output ranges 0-5V, 0-10V, 0-20mA, +/-5V, +/-10V, +/-20mA
 7 Segment Display for Module Status indication
 No user calibration
 Software Configurable Range Selection
 Uses 2500C-32F removable wiring connector
 Module supports hot swapping (See Section 2.5)
1.2
Front Panel Description
The module front panel includes a 7-segment status display for showing module status, and a 32-pin
removable I/O wiring connector.
Status display
I/O wiring connector
2500C-8-AO Installation and Operation Guide
5
Figure 1 2500C-8-AO Front Panel
1.2.1 Status Display
The Status Display will be illuminated with a “0” when the module is functioning normally. If the Status
Display is not lit, or if it displaying something other than “0”, refer to Chapter 3 for troubleshooting.
1.2.2 I/O Wiring Connector
The 2500C-8-AO module uses the standard 2500C-32F Field Wiring Connector. This connector
provides 32 connections and accepts 14-22 AWG wires.
1.3
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 (3.5 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.
Figure 2 Asynchronous Operation Diagram
1.4
Modes of Operation
The 2500C-8-AO supports two modes of operation: Classic mode and Classic Plus mode. These two
modes are selected by jumper JP11 located at the top of the card. Refer to diagram xx for the
location of this jumper. Classic Mode is the default shipping selection.
1.4.1 Classic Mode
In Classic mode (or Low Density) operation, the 2500C-8-AO operates logs in to the PLC as an 8
word Output (8WX) module. Analog values for each channel are reported to the PLC in the
corresponding input word. In Classic mode, the module only operates in the 0-20mA range (for
current outputs). To operate the module in voltage or other ranges, you must change to Classic Plus
mode.
6
2500C-8-AO Installation and Operation Guide
1.4.2 Classic Plus Mode
In Classic Plus mode (or High Density) operation, the 2500C-8-AO operates logs in to the PLC as an
8 word input / 16 word output (8WX/16WY) module. Analog values for each channel are reported to
the PLC in the corresponding input word. The WY output words are used to allow the PLC to select
the output signal range for the module.
For example, if the module is in Classic Plus mode and is logged in at address 1:
WX1 = Channel 1 Status Word
WX2 = Channel 2 Status Word
WX3 = Channel 3 Status Word
WX4 = Channel 4 Status Word
WX5 = Channel 5 Status Word
WX6 = Channel 6 Status Word
WX7 = Channel 7 Status Word
WX8 = Channel 8 Status Word
WY9 = Channel 1 DAC data out
WY10 = Channel 2 DAC data out
WY11 = Channel 3 DAC data out
WY12 = Channel 4 DAC data out
WY13 = Channel 5 DAC data out
WY14 = Channel 6 DAC data out
WY15 = Channel 7 DAC data out
WY16 = Channel 8 DAC data out
WY17 = Channel 1 Configuration
WY18 = Channel 2 Configuration
WY19 = Channel 3 Configuration
WY20 = Channel 4 Configuration
WY21 = Channel 5 Configuration
WY22 = Channel 6 Configuration
WY23 = Channel 7 Configuration
WY24 = Channel 8 Configuration
In Classic Plus mode, the PLC can select range operation from any of the following by setting the
appropriate bits in the corresponding WY word for each channel. In addition, the PLC can enable or
disable digital filtering for each channel, Offset enable or disable, Unipolar or Bipolar and 5V or 10V
range.
1.5
Voltage Ranges
Current Ranges
0-5V
0-10V
+5V
+10V
0-20mA
+20mA
4-20mA
Output Resolution
Basic resolution of the 2500C-8-AO is 16 bits. Since it can be configured for bipolar operation, the
resolution reported to the PLC is 15 bits + sign.
The table below shows the resolution of the module for each scale, and the maximum converted
value.
Range
0-5V, +5V
0-10V, +10V
0-20mA, +20mA
1.6
Resolution, per step
156uV
312.5uV
625uA
Maximum Converted Value
5.12V
10.24
20.24mA
Accuracy
The module accuracy is 0.15% of full scale (current mode) and 0.15% of full scale (voltage mode)
2500C-8-AO Installation and Operation Guide
7
1.7
Digital to Analog Conversion
The digital value representing the desired analog output is written to the module. The module
converts the digital value to the analog value for each channel from the corresponding WY word. The
digital value is scaled according to the “0-32000” convention usually used in 2500 Series® PLC
applications. A “0” indicates 0V or 0mA. A “32000” indicates full scale volts or mA, with the level
depending on the range being used.
The digital value is sent from the PLC in the format shown below:
Sign bit
16,384
8192
4096
2048
1024
512
256
128
64
32
16
8
4
2
1
In addition to applying a basic scale of 0-32000, the module provides a small overrange capability to
convert voltages above the full scale. The maximum valid reading is +32749. Values above +32749
or below -32749 indicate error conditions.
1.8
Module Setup from the PLC in Classic Plus Mode
When operating in Classic Plus Mode, the module reads setup information that the PLC has stored in
the WY word corresponding to each channel.
WYn
Bit 1
Bit 2
Bit 3
Bit 4
Bits 5-16
Function
0 = Voltage
1 = Current
0 = normal
1 = Offset
Enabled
0 = Unipolar
1 = Bipolar
0 = 5V Range
1 = 10V Range
unused




Bit 1 – sets the channel output to voltage or current ranges
Bit 2 – sets the channel to a normal or to the Built-in Offset
Bit 3 – sets the channel ranges to either unipolar or bipolar
Bit 4 – sets the Voltage Ranges for the channel to either 5V or 10V
Binary Examples of the Configuration Word for WY17 (Channel 1) X represents a null location
0000 xxxx xxxx xxxx
0001 xxxx xxxx xxxx
0010 xxxx xxxx xxxx
0011 xxxx xxxx xxxx
0100 xxxx xxxx xxxx to 0111 xxxx xxxx xxxx
1000 xxxx xxxx xxxx
1001 xxxx xxxx xxxx
1010 xxxx xxxx xxxx
1011 xxxx xxxx xxxx
1100 xxxx xxxx xxxx
1101 xxxx xxxx xxxx to 1111 xxxx xxxx xxxx
8
5 Volt Unipolar
10 Volt Unipolar
5 Volt Bipolar
10 Volt Polar
Invalid Configuration, channel output goes to 0 to -1 volt
32752 Error Code is returned in WX1(Module Status Word
for Channel 1)
20 milliamp Unipolar Current
24 milliamp Unipolar Current
20 milliamp Bipolar Current
24 milliamp Bipolar Current
4 to milliamp Offset Current
Invalid Configuration, channel output goes to 0 to -1 volt
32752 Error Code is returned in WX1 (Module Status Word
for Channel 1)
2500C-8-AO Installation and Operation Guide
1.9
Error conditions reported:
When in Classic Plus Mode the first 8 WX addresses will report 4 different error codes on a channel
by channel basis.
Overrange – means the value written to the module is higher than the maximum that can be
converted (example: 5.12V for the 0-5V range). For this error, a value of “32755” is reported. Note:
No overrange error is reported for Bipolar Ranges.
Underrange - means the value written to the module is lower than the minimum that can be
converted. (example: any negative value for any unipolar range). For this error, a value of “32754” is
reported. Note: No underrange error is reported for Bipolar Ranges.
Invalid Configuration – means there is configuration error in the WY configuration data given to the
module. This error is detected and reported on each channel. For this error, a value of “32752” is
reported.
24V Power Supply Failure – means the user supplied 24VDC power has gone below 19VDC or
above 30VDC. When this occurs the module cannot supply a control signal output on any channel.
For this error, a value of “32753” will be reported on all channels.
The table below shows how the module reports for various input signals and range selections.
Error Codes
Range
Selection
All Ranges
0-5V
Output Signal
Value Reported
Comment
5.12V
0V
00000
32755
32754
No errors reported
overrange
underrange
0-10V
10.24V
0V
32755
32754
overrange
underrange
+5V
+5.12V
-5.12V
No overrange
No underrange
+10V
+10.24V
-10.24V
No overrange
No underrange
0-20mA
+20.24mA
0 mA
+20mA
+20.24mA
-20.24mA
These Error Codes are returned
in the Channel Status Word
regardless of Range or
Configuration Selections
2500C-8-AO Installation and Operation Guide
32755
32754
overrange
underrange
No overrange
No underrange
32752
Invalid Configuration
32753
24VDC Power Supply Failure
9
1.9.1 Application Note for 24VDC User Supplied Power Monitoring
The 2500C-8-AO constantly monitors the health of the 24VDC user supplied power source, if the
power source drops below 19VDC or goes above 30VDC the module reports 32753 back to PLC in
all the channel status words or WX addresses. This feature can be very useful in tracking power
supply problems by trapping for the error code in the PLC program, recording the time and number of
occurrences. When power supplies fail especially on an intermittent basis it can be very difficult to
determine exactly what happened, but using this feature can help determine the cause in an easy to
implement fashion.
Once power is restored within the acceptable ranges the 2500C-8-AO will automatically clear the
error code in the Channel Status Word and return to normal operation.
1.10 Using the Module with a Built-In 20% Offset Calculation
You may enable Offset Mode for any channel using bit 3 in the Channel Configuration Word, i.e., 4 to
20 mA or 1 to 5 VDC operation, the 2500C-8-AO will then be configured to automatically scale the
digital word from the PLC. Offset Enabled may only be used in Unipolar mode.
4 to 20 mA range
Digital WY = ((Output current - 4) x 32000) ÷ 16 mA
WY = ((Desired Output Current - 4) x 32000) ÷ 16 for example, to generate
an output voltage of 12 mA the WY value output from the PLC is
calculated as follows: WY= ((12-4)x32000) ÷ 16 = 16000
10
2500C-8-AO Installation and Operation Guide
CHAPTER 2
INSTALLATION & SETUP
The installation of the 2500C-8-AO consists of the following steps:
1)
2)
3)
4)
5)
6)
7)
2.1
Reading this Chapter
Installation planning
Unpacking and configuring the module,
Inserting the module into the I/O Base
Wiring the module output screw terminal connector to the Field Wiring
Choosing and Connecting the 24VDC user power supply
Checking module operation.
Installation Planning
Planning is the first step in the installation of the module. This involves:
1. Calculating the I/O base power budget
2. Selecting a proper user power supply and wiring
3. Routing the wiring to minimize noise
4. Selecting the proper wiring method for the type of output you will use.
The following sections discuss these important considerations of the installation.
2.1.1 Safety Considerations
Before installing the module, you must identify the personnel hazards that may be created in the
event of a system failure and provide interlocks and safety switches and backup control to prevent
unsafe operation during a system failure. Refer to the NEMA ICS 3-304 Programmable Control
Standards.
WARNING
As a system designer, you should be aware that Control devices can fail in an unsafe condition. Unless
you incorporate proper safeguards, malfunction of the controller or associated devices, such as
operator interface equipment, could cause sudden equipment startup, shutdown, or other unexpected
operation. Such startup or shutdown or unexpected operation could result in death or serious injury to
personnel, and/or damage to equipment.
If you or your company are using CTI controllers with equipment that requires the presence of a person
(such as an operator or attendant), you should be aware of this potential safety hazard and take
appropriate precautions.
2500C-8-AO Installation and Operation Guide
11
The precautions below conform to the National Electrical Manufacturers Association guidelines for
installation of programmable controllers as recommended in the NEMA ICS 3–304 Programmable
Control Standards.
ICS 3-304.81 Safety Recommendations:
Consideration should be given to the use of an emergency stop function which is independent of the
programmable controller. Where the operator is exposed to the machinery, such as in loading or
unloading a machine tool, or where the machine cycles automatically, consideration should be given
to the use of an electromechanical override or other redundant means, independent of the
programmable controller, for starting and interrupting the cycle. If provision is required for changing
programs while the equipment is in operation, consideration should be given to the use of locks or
other means of assuring that such changes can be made only by authorized personnel. These
recommendations are intended as safeguards against the failure of critical components and the
effects of such failures or the inadvertent errors that might be introduced if programs are changed
while the equipment is in operation.
Operator Safety Switches
Power should be configured so that it can be manually removed from all output devices. You must
provide a method that is independent of the control system for disconnecting power from the outputs
when a machine is not operating or the operator must reach into the machine. A non-electronic switch
or directly wired relay must be used to disconnect the power.
Emergency Stop Switch
You must provide a method for disconnecting power from the outputs if an emergency situation is
encountered with the machine operation. Use a non-electronic switch or relay that is wired external to
the controller and that is easily accessible.
2.1.2 Power Requirements
The 2500C-8-AO module consumes 0.75 watts of +5VDC power. To calculate the total power
required for the base, you need to add the power requirements for the other modules you will install in
the base.
2.1.3 Choosing a Power Supply
The 2500C-8-AO requires an external power supply to provide power for the analog outputs. The
power supply should be a single voltage, 20-28 VDC nominal 2.0 amp, UL Class 2 device. The
compliance of the output circuits is directly related to the output voltage. The drive voltage and current
are specified at 24 VDC.
2.1.4 Electrical Interference
Electrical interference can adversely affect the operation of control equipment. The major sources of
electrical interference in an industrial environment are devices that use high voltages and current,
such as motors and welders. Electrical interference can be conducted directly through wiring or
inducted via electromagnetic coupling.
To ensure a reliable control system, you will need to determine the source of the electrical
interference and employ suitable techniques to eliminate it.
12
2500C-8-AO Installation and Operation Guide
2.1.5 Grounding
It is very important that the all equipment is properly grounded. Lack of proper grounding may cause
intermittent or erratic operation or may cause the control system to fail. A properly installed grounding
system will provide a low-impedance path to earth ground, which will give all PLC internal filtering
devices a good ground return for reference. The earth ground of the building site typically provides
reliable grounding; however, if excessive ground current is present, a separate grounding electrode
should be installed.
A common practice is to provide a central ground bus bar as a single point of reference within each
enclosure, connecting all chassis and power supply components to the bus bar. The bus bar is then
connected to earth ground. When connecting to the bus bar, use 1 inch copper braid or No. 8 AWG
wire. To ensure good connections, scrape paint or other non-conductive coatings away from
mounting studs and from enclosure surfaces where mounting bolts and washers make contact.
In addition to connecting the controller rack and power supply to earth ground, you must ensure that
the power supply, controller and all modules installed in the base are installed securely and that the
thumbscrews are tightened.
2.1.6 Requirements for Signal Wire Carrying Current
You must calculate the loop wiring resistance for any current output circuits. The loop resistance is
determined by the length and type of wire, as well as the field device series resistance.
The circuit resistance must not exceed 1000 ohms. If a separate 20 volt power supply is used in the
loop, the minimum resistance increases 1000 ohms, and the maximum resistance becomes 2000
ohms. Any value over 1000 ohms prevents the module from operating accurately. The following figure
provides a schematic for wiring a loop with a resistance of less than 1000 ohms. It also shows a
schematic for adding a power supply to allow loop resistances up to 2000 ohms. Use the following
equation to determine the resistance of an output loop for a channel:
Resistance = (2 x CL x RFT) + TFL
where: CL is the cable length
RFT is the conductor resistance (ohms/unit length)
TFL is the resistance of the field device
2500C-8-AO Installation and Operation Guide
13
2.1.7 Requirements for Signal Wire Providing Voltage
Applications using voltage signals require some special considerations to ensure the module's
accuracy. Two additional parameters must be considered:

Resistive load of the field device

Capacitance of the cable wiring
The resistive load of the field device must be no lower than 1K ohms. The cable capacitance must be
less than 0.01 microfarad.
The cable capacitance is a function of the cable length. To determine the maximum cable length
allowed, find the nominal value of cable capacitance per unit length as given by the manufacturer.
Use this value in the following equation to determine the maximum cable length:
0.01 microfarads
Maximum Cable Length = Nominal Cable Capacitance (per unit length)
NOTE:
Nominal capacitance is measured between the conductors. However, if one conductor is
connected to the shield via a grounded power supply, then the nominal value will usually double
in value.
The length of a cable and the cable conductor resistance are used to find the fixed error which would
appear at the field device. Use the following equation to determine the fixed error:
Fixed Error (%) =
[1-R1] x 100
[R1 + 2 x CL x RC]
where: R1 is the field device resistive load
CL is the cable length
RC is the conductor resistance per unit length
The following figure provides a schematic for a voltage output circuit.
14
2500C-8-AO Installation and Operation Guide
2.1.8 Defining Operation Mode and Range Selections
Before you can install the module, you must review your planned input signals by channel and decide
on both the operation modes (Classic or Classic Plus), and the range selections (Voltage or Current)
for each output. If your application needs only 0-5V or 0-20mA for every channel, then you may use
Classic mode. All other ranges require the selection of Classic Plus mode.
2.2
Unpacking the Module
Open the shipping carton and remove the special anti-static bag that contains the controller.
After discharging any static build-up, remove the unit from the static bag. Do not discard the static
bag; use it for protection against static damage when the module is not inserted into the I/O base.
CAUTION
The components on the 2500C-8-AO 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 and when
handling the printed circuit card during configuration.
2.3
Configuring the Module
Prior to inserting the module in the base, you must first configure it for operation based on your
requirements identified in Section 2.1.7 above. Configuration includes selecting operation mode and
selecting voltage or current for each channel. In addition, if you have selected Classic Plus mode,
you must configure your PLC program to set the necessary bits in the WY word for the module.
2.3.1 Default Factory Configuration
The default setting can only be changed by placing the module in Classis Plus Operation Mode and
setting the Channel Configuration Word bits (see Section 1.8).
Classic Operation Mode JP11 is in the LD or C position
0 to 20mA Signal Range
Offset Disabled
Unipolar Range
2500C-8-AO Installation and Operation Guide
15
2.3.2 Selecting Operation Mode
The operational mode selection is the only jumper to set according to the application requirements.
This jumper is JP11 and the selectable positions are Classic labeled as either LD or C or Classic Plus
labeled as either HD or CP. The 2500C-8-AO is shipped with the jumper in LD or C.
See Section 1.4 for more information on Classic Mode and Classic Plus Mode.
JP 11
Backplane
Connector
JP 11
Front of the
Module
Figure 3 2500C-8-AO JP11 location on PCB
16
2500C-8-AO Installation and Operation Guide
2.4
Physical Installation
Remove AC power from the rack. Align the circuit board with the connector next to the power supply.
Slide the controller into the rack until the connector seats. Use the thumbscrews to secure the module
in the rack.
Figure 4 Physical Installation Picture
IMPORTANT NOTE:
The 2500-8-AO is designed to allow “hot-swapping” the module under power in the event
that a replacement is needed. When “hot-swapping” the module, use the following
procedure:
1.
2.
3.
4.
5.
6.
7.
8.
Make sure all field devices connected to the module are placed into a “safe” state
Remove the I/O connector from the front of the module
Loosen the module retaining screws and remove it from the base
Ensure the jumper configuration of the replacement module matches the one just
removed
Install the replacement module and tighten the retaining screws. The replacement
module must be the same model number as the one removed.
Reattach the I/O connector to the module
Ensure the replacement module is operating properly
Remove the field devices from “safe” state
2500C-8-AO Installation and Operation Guide
17
2.5
Connecting Field Wiring
Field wiring is connected to the 2500C-8-AI as shown in the connector wiring diagram below. NOTE:
For current (0-20mA or 4-20mA) outputs you must wire to the “I+” output terminals. For voltage, wire
to the “V+” output terminals. The “Return” or “Common” for each channel is wired to the “Return”
terminal and the shield (if any) is wired to the “Earth” terminal.
Channel 1
V Out
A1
B1
I Out
Earth
A2
B2
Return
V Out
A3
B3
I Out
Earth
A4
B4
Return
V Out
A5
B5
I Out
Earth
A6
B6
Return
V Out
A7
B7
I Out
Earth
A8
B8
Return
Channel 5
V Out
A9
B9
I Out
Earth
A10
B10
Return
Channel 6
V Out
A11
B11
I Out
Earth
A12
B12
Return
Channel 7
V Out
A13
B13
I Out
Module
Power
+24V
A14
B14
Return
Channel 8
V Out
A15
B15
I Out
Module Power
24V
Return
A16
B16
Return
Channel 2
Channel 3
Channel 4
Channel 1
Channel
2
Channel 3
Channel 4
Channel 5
Channel 6
Channel 7
Channel 8
2500C-8-AO Wiring Connection Diagram
Figure 5 2500C-8-AO Wiring Connector Diagram
18
2500C-8-AO Installation and Operation Guide
2.6
Initial Power On
Apply power to the base power supply. The Power Good LED on the power supply should illuminate,
indicating that power is being supplied to the base connectors. The 2500C-8-AO 7 Segment LED will
display 0 indicating the module has passed it’s internal diagnostics and that no fault conditions exist.
The 2500C-8-AO runs it’s own diagnostics and when this complete, the status indicators should be in
one of the following state:
Indicator
Module Good
State
0
Lost or no
24VDC User
Supplied
Power
P
Comments
Once the module completes it’s internal diagnostics and the 24VDC user
supplied power is connected and turned ON, the 7 segment LED will
display 0.
The 7 segment LED will display P if there is no 24VDC User Supplied
Power connected or if the 24VDC Power Source fails during operation.
The health of the 24VDC power source is monitored constantly by the
2500C-8-AO.
2500C-8-AO Installation and Operation Guide
19
Appendix 1 2500C-8-AO Product Specifications
Output Specifications
Operation Mode Support
(See Note 1)
Classic Mode
Classic Plus
Mode
8 Analog
Output Channels
Supported
Supported
Module Logon
8WY
8WX/16WY
Unipolar Ranges
0 to 5.12 VDC,
0 to 20.24 mA
0 to 10.24
VDC,
0 to 5.12 VDC,
0 to 20.24 mA
Bipolar Ranges
NA
+/- 5.12 VDC
+/- 10.24 VDC
+/- 20.24 mA
Module Response Time
Signal Range( Note 2):
Resolution ( 15 bits plus sign)
0 to +5.12 VDC or +/- 5.12 VDC
156µV per bit
0 to +10 VDC or +/-10VDC
312.50µV per bit
0 to +20mA or +/-20mA
.625µA per bit
Accuracy 0º to 60 ºC
Voltage Mode
Load Resistance
(See Note 2)
User supplied Loop Power
Current Mode
Voltage Mode
0.15% @25ºC
0.15% @ 25ºC
Min - 250Ω
Max - 1kΩ
Min - 1kΩ
Max - 0Ω
20 to 30VDC @ 0.50 Amps max
Maximum Ripple of 0.4V
Backplane Power (MAX)
.312 watts
Input ESD Protection
IEC 1000-4-2 level 4
Isolation
24VDC IN - 500VDC
Connector
2500C-32F
Agency Approvals Pending
Shipping Dimensions and
Weight
UL, ULC, UL Class 1, Div 2, CE
223.84mm x 109.86mm x
34.93mm, 0.234kg
Note 1:
Classic or Classic Plus modes are jumper
selectable for the module.
Note 2:
In current mode for 600Ωto 1KΩ load user
must have a 24V to 30 V Power Supply.
2500C-8-AO Installation and Operation Guide
21
CTI WARRANTY
Warranty. Control Technology Inc. ("CTI")
warrants that this CTI Industrial Product (the
"Product") shall be free from defects in
material and workmanship for a period of one
(1) year from the date of purchase from CTI or
from an authorized CTI Industrial Distributor,
as the case may be. Repaired or replacement
CTI products provided under this warranty are
similarly warranted for a period of 6 months
from the date of shipment to the customer or
the remainder of the original warranty term,
whichever is longer. This Product and any
repaired or replacement products will be
manufactured from new and/or serviceable
used parts which are equal to new in the
Product. This warranty is limited to the initial
purchaser of the Product from CTI or from an
authorized CTI Industrial Distributor and may
not be transferred or assigned.
2. Remedies. Remedies under this warranty
shall be limited, at CTI's option, to the
replacement or repair of this Product, or the
parts thereof, only after shipment by the
customer at the customer's expense to a
designated CTI service location along with
proof of purchase date and an associated
serial number. Repair parts and replacement
products furnished under this warranty will be
on an exchange basis and 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. The foregoing will be the
exclusive remedies for any breach of warranty
or breach of contract arising therefrom.
3. General. This warranty is only available if
(a) the customer provides CTI with written
notice of a warranty claim within the warranty
period set forth above in Section 1 and (b)
CTI's examination of the Product or the parts
thereof discloses that any alleged defect has
not been caused by a failure to provide a
2500C-8-AO Installation and Operation Guide
suitable environment as specified in the CTI
Standard Environmental Specification and
applicable Product specifications, or damage
caused by 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.
4. Product Improvement. CTI 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 products.
5. Exclusive Warranty. THE WARRANTIES
SET FORTH HEREIN ARE CUSTOMER'S
EXCLUSIVE WARRANTIES. CTI HEREBY
DISCLAIMS ALL OTHER WARRANTIES,
EXPRESS OR IMPLIED. WITHOUT LIMITING
THE FOREGOING, CTI SPECIFICALLY
DISCLAIMS THE IMPLIED WARRANTIES OF
MERCHANTABILITY, FITNESS FOR A
PARTICULAR PURPOSE, NONINFRINGEMENT, COURSE OF DEALING
AND USAGE OF TRADE.
6. Disclaimer and Limitation of Liability. TO
THE FULLEST EXTENT PERMITTED BY
APPLICABLE LAW, CTI WILL NOT BE
LIABLE FOR ANY BUSINESS
INTERRUPTION OR LOSS OF PROFIT,
REVENUE, MATERIALS, ANTICIPATED
SAVINGS, DATA, CONTRACT, GOODWILL
OR THE LIKE (WHETHER DIRECT OR
INDIRECT IN NATURE) OR FOR ANY
OTHER FORM OF INCIDENTAL, INDIRECT
OR CONSEQUENTIAL DAMAGES OF ANY
KIND. CTI'S MAXIMUM CUMULATIVE
LIABILITY RELATIVE TO ALL OTHER
CLAIMS AND LIABILITIES, INCLUDING
OBLIGATIONS UNDER ANY INDEMNITY,
WHETHER OR NOT INSURED, WILL NOT
EXCEED THE COST OF THE PRODUCT(S)
GIVING RISE TO THE CLAIM OR LIABILITY.
CTI DISCLAIMS ALL LIABILITY RELATIVE
TO GRATUITOUS INFORMATION OR
ASSISTANCE PROVIDED BY, BUT NOT
REQUIRED OF CTI HEREUNDER. ANY
ACTION AGAINST CTI MUST BE BROUGHT
23
WITHIN EIGHTEEN (18) MONTHS AFTER
THE CAUSE OF ACTION ACCRUES. THESE
DISCLAIMERS AND LIMITATIONS OF
LIABILITY WILL APPLY REGARDLESS OF
ANY OTHER CONTRARY PROVISION
HEREOF AND REGARDLESS OF THE
FORM OF ACTION, WHETHER IN
CONTRACT, TORT (INCLUDING
NEGLIGENCE AND STRICT LIABILITY) OR
OTHERWISE, AND FURTHER WILL
EXTEND TO THE BENEFIT OF CTI'S
VENDORS, APPOINTED DISTRIBUTORS
AND OTHER AUTHORIZED RESELLERS AS
THIRD-PARTY BENEFICIARIES. EACH
PROVISION HEREOF WHICH PROVIDES
FOR A LIMITATION OF LIABILITY,
DISCLAIMER OF WARRANTY OR
CONDITION OR EXCLUSION OF DAMAGES
IS SEVERABLE AND INDEPENDENT OF
ANY OTHER PROVISION AND IS TO BE
ENFORCED AS SUCH.
9. Governing Law. The laws of the State of
Tennessee shall govern the validity,
interpretation and enforcement of this
warranty, without regard to its conflicts of law
principles. The application of the United
Nations Convention on Contracts for the
International Sale of Goods shall be excluded.
7. Adequate Remedy. The customer is limited
to the remedies specified herein and shall
have no others for a nonconformity in the
Product. The customer agrees that these
remedies provide the customer with a
minimum adequate remedy and are its
exclusive remedies, whether based on
contract, warranty, tort (including negligence),
strict liability, indemnity, or any other legal
theory, and whether arising out of warranties,
representations, instructions, installations, or
non-conformities from any cause. The
customer further acknowledges that the
purchase price of the Product reflects these
warranty terms and remedies.
8. Force Majeure. CTI will not be liable for any
loss, damage or delay arising out of its failure
(or that of its subcontractors) to perform
hereunder due to causes beyond its
reasonable control, including without limitation,
acts of God, acts or omissions of the
customer, acts of civil or military authority,
fires, strikes, floods, epidemics, quarantine
restrictions, war, riots, acts of terrorism, delays
in transportation, or transportation embargoes.
In the event of such delay, CTI's performance
date(s) will be extended for such length of time
as may be reasonably necessary to
compensate for the delay.
24
2500C-8-AO 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 or go to
www.controltechnology.com/support/repairs/.
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.
2500C-8-AO Installation and Operation Guide
25
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