Figure 13 2500C-8-TC Effect of Voltage Input on Type J

Figure 13 2500C-8-TC Effect of Voltage Input on Type J
Control Technology Inc.
5734 Middlebrook Pike
Knoxville, Tennessee 37921
www.controltechnology.com
Toll Free: 800-537-8398
2500 Series ™
Compact I/O System
2500C-8-TC
8-CHANNEL THERMOCOUPLE INPUT MODULE
2500 SERIES® COMPACT I/O
INSTALLATION AND OPERATION GUIDE
Version 1.0
Copyright© 2014 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 trade names, 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 trade names, 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]
Revision
1.0
Date
4/15/2014
REVISION HISTORY
Description
Initial Release
PREFACE
This Installation and Operation Guide provides reference information for the CTI 2500C-8TC 8-Channel Thermocouple Module for 2500 Series® Compact I/O system. 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-TC Installation and Operation Guide
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
USAGE CONVENTIONS .........................................................................................II
TABLE OF FIGURES ..............................................................................................5
CHAPTER 1 OVERVIEW ......................................................................................6
1.1
1.2
Introduction .....................................................................................................6
Front Panel Description .................................................................................6
1.2.1
1.2.2
1.3
1.4
Asynchronous Operation ...............................................................................7
Modes of Operation........................................................................................7
1.4.1
1.4.2
1.5
1.6
1.7
1.8
1.9
Classic Mode .................................................................................. 8
Classic Plus Mode .......................................................................... 8
Input Signal Ranges .......................................................................................9
Measurement Resolution ...............................................................................9
Accuracy ...................................................................................................... 10
Digital Word map ......................................................................................... 10
Thermocouple Input to Digital Conversion ................................................. 11
1.9.1
1.9.2
1.10
1.11
1.12
Status Display................................................................................. 7
I/O Wiring Connector ...................................................................... 7
Engineering Units ........................................................................... 11
Scale Units...................................................................................... 11
Effect of Out-of-Range Input Signals .......................................................... 12
Error Code Values Reported to the PLC .................................................... 15
Module Setup from the PLC in Classic Plus Mode .................................... 16
CHAPTER 2 INSTALLATION & SETUP.............................................................17
2.1
Installation Planning .................................................................................... 17
2.1.1
2.1.2
2.1.3
2.2
2500C-8-TC Board Layout.......................................................................... 19
2.2.1
2.2.2
2.3
2.4
Operation Mode Jumpers - Selecting Operation Mode ................. 21
Selecting millivolt or Thermocouple Types for Each Channel ...... 22
Factory Default Settings ................................................................. 22
Physical Installation ..................................................................................... 23
Connecting Field Wiring .............................................................................. 24
2.6.1
2.6.2
2.6.3
2.7
Defining Operation Mode and Range Selections .......................... 20
Power Requirements ...................................................................... 20
Unpacking the Module ................................................................................ 20
Configuring the Module ............................................................................... 20
2.4.1
2.4.2
2.4.3
2.5
2.6
Safety Considerations .................................................................... 17
Electrical Interference ..................................................................... 18
Grounding ....................................................................................... 18
Understanding the Modified Front Panel Connector ..................... 25
Connecting Thermocouple Input Wiring ........................................ 25
Connecting the Shield Wiring ......................................................... 26
Installing the Screw Terminal Connector ................................................... 26
2500C-8-TC Installation and Operation Guide
3
2.8
2.9
Calibration of the Module .............................................................................26
Checking Module Operation ........................................................................27
CHAPTER 3 ................................................................................ TROUBLESHOOTING........28
APPENDIX A MODULE SPECIFICATIONS..........................................................31
CTI WARRANTY....................................................................................................33
REPAIR POLICY ...................................................................................................35
4
2500C-8-TC Installation and Operation Guide
Table of Figures
Figure 1 2500C-8-TC Front Panel ......................................................................................... 6
Figure 2 Asynchronous Operation Diagram ........................................................................... 7
Figure 3 2500C-8-TC Default Configuration Table ................................................................ 8
Figure 4 2500C-8-TC Classic Plus Login Table ..................................................................... 8
Figure 5 2500C-8-TC Classic Plus Configuration Options ..................................................... 9
Figure 6 2500C-8-TC Thermocouple Measurement Ranges ................................................. 9
Figure 7 2500C-8-TC Thermocouple Measurement Resolution Table ................................... 9
Figure 8 2500C-8-TC Accuracy Rating Table ...................................................................... 10
Figure 9 2500C-8-TC Digital Word Map Diagram ................................................................ 10
Figure 10 2500C-8-TC Example of Change in Input Level .................................................. 11
Figure 11 2500C-8-TC Example of Change in Input Level .................................................. 12
Figure 12 2500C-8-TC Effect of Voltage Input on Type J Thermocouple ............................. 12
Figure 13 2500C-8-TC Effect of Voltage Input on Type J Thermocouple ............................ 13
Figure 14 2500C-8-TC Effect of Voltage Input on Type T Thermocouple ........................... 13
Figure 15 2500C-8-TC Effect of Voltage Input on Type E Thermocouple ........................... 13
Figure 16 2500C-8-TC Effect of Voltage Input on Type R Thermocouple ........................... 13
Figure 17 2500C-8-TC Effect of Voltage Input on Type S Thermocouple ........................... 14
Figure 18 2500C-8-TC Effect of Voltage Input on Type N Thermocouple ........................... 14
Figure 19 2500C-8-TC Effect of Voltage Input on mV Input ................................................ 14
Figure 20 2500C-8-TC Error Code Table ........................................................................... 15
Figure 21 2500C-8-TC Word Map for Configuration Data ................................................... 16
Figure 22 2500C-8-TC Binary Example of Module Configuration Word .............................. 16
Figure 23 2500C-8-TC Board Layout Picture...................................................................... 19
Figure 24 2500C-8-TC Operation Mode Jumpers Picture ................................................... 21
Figure 25 2500C-8-TC Jumper Signal Selection Table ....................................................... 22
Figure 26 2500C-8-TC Binary Example of Module Configuration Word .............................. 22
Figure 27 2500C-8-TC Binary Example of Module Configuration Word .............................. 22
Figure 28 2500C-8-TC Default Factory Settings ................................................................. 22
Figure 29 2500C-8-TC Module Physical Installation Picture ............................................... 23
Figure 30 2500C-8-TC Wiring Connector Diagram ............................................................. 24
Figure 31 Millivolt Wiring Connector Diagram .................................................................... 25
Figure 32 Thermocouple Wiring Connector Diagram ......................................................... 25
Figure 33 2500C-8-TC Thermocouple Type and Wire Descriptions .................................... 25
Figure 34 2500C-8-TC LED Error Code Table.................................................................... 27
2500C-8-TC Installation and Operation Guide
5
CHAPTER 1
1.1
OVERVIEW
Introduction
The CTI 2500C-8-TC Eight-Point Thermocouple Input Module is a member of Control
Technology’s family of I/O modules compatible with the Compact System Chassis. It is
designed to translate a J, K, T, E, R, S, N thermocouple or millivolt input signal from the field
device into an equivalent digital word which is then sent to the programmable controller
(PLC).
Features
 8 Thermocouple inputs
 Supports Classic and Classic Plus Modes
 7 Segment Display for Module Status indication
 No user calibration
 Supports J, K, T, E, R, S, & N thermocouples and millivolt inputs
 Software Configurable Range Selection
 Uses 2500C-32F-CJC removable wiring connector(sold separately)
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
with built in CJC
Figure 1 2500C-8-TC Front Panel
6
2500C-8-TC Installation and Operation Guide
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-TC utilizes a modified 32 pin connector, part number 2500C-32F-CJC (a
standard connector is NOT interchangeable) to provide wiring terminals for Channels 1-8
thermocouple inputs and two temperature (cold junction compensation) sensors. The wiring
connector accepts 14-22 AWG wire.
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-TC 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
Figure 23 2500C-8-TC Board Layout Picture for the location of this jumper. Classic Mode is
the default shipping selection.
2500C-8-TC Installation and Operation Guide
7
1.4.1 Classic Mode
In Classic mode (or Low Density) operation, the 2500C-8-TC operates logs in to the PLC as
an 8 word Input (8WX) module. Temperature values for each channel are reported to the
PLC in the corresponding input word. In Classic mode, the module accepts Type J
Thermocouple range. To operate the module in other ranges, you must change to Classic
Plus mode.
1.4.1.1 Classic Mode Module Default Configuration
The 2500C-8-TC ships in a default configuration which matches a common set of
application requirements.
2500-8-TC Default Shipment Settings
Operation Mode
Classic Mode
Logon
8WX
Thermocouple
J
Digital Filtering
Enabled
Offset Scaling
Disabled
Temperature Units
Degrees C
Figure 3 2500C-8-TC Default Configuration Table
1.4.2 Classic Plus Mode
In Classic Plus mode (or High Density) operation, the 2500-8-TC operates logs in to the PLC
as an 8 word input / 8 word output (8WX/8WY) module. Thermocouple or millivolt signal
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 input 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 TC/mV Input
WX2 = Channel 2 TC/mV Input t
WX3 = Channel 3 TC/mV Input
WX4 = Channel 4 TC/mV Input
WX5 = Channel 5 TC/mV Input
WX6 = Channel 6 TC/mV Input
WX7 = Channel 7 TC/mV Input
WX8 = Channel 8 TC/mV Input
WY9 = Channel 1 Configuration
WY10 = Channel 2 Configuration
WY11 = Channel 3 Configuration
WY12 = Channel 4 Configuration
WY13 = Channel 5 Configuration
WY14 = Channel 6 Configuration
WY15 = Channel 7 Configuration
WY16 = Channel 8 Configuration
Figure 4 2500C-8-TC Classic Plus Login Table
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, Scaling enable or disable, Degrees C or Degrees
F for each channel.
8
2500C-8-TC Installation and Operation Guide
Thermocouple
mVolt
J, K, N, R
0-55mV
S*, T*, E*
*Note: S, T, E also require a jumper selection change from
the shipped jumper configuration per channel.
Figure 5 2500C-8-TC Classic Plus Configuration Options
1.5
Input Signal Ranges
Thermocouple Measurement Ranges
J: -210ºC to 760ºC (-350ºF to 1400ºF)
K: -270ºC to 1372ºC (-450ºF to 2500ºF)
T: -270ºC to 400ºC (-454ºF to 752ºF)
E: -270ºC to 1000ºC (-454ºF to 1832ºF)
R: 0ºC to 1768ºC (32ºF to 3214ºF)
S: 0ºC to 1768ºC (32ºF to 3214ºF)
N: -260ºC to 1300ºC (-436ºF to 2372ºF)
mV: -55 to +55mV
Figure 6 2500C-8-TC Thermocouple Measurement Ranges
1.6
Measurement Resolution
The module has a resolution of approximately 0.1oC, 0.1oF or exactly .01 millivolts.
The chart below shows the corresponding input resolution per step for each of the input
configuration modes:
Units
Temp: oC
Temp: oF
Millivolts
Input Resolution / Step
~0.05oC
~0.09oF
0.0017 millivolts
Figure 7 2500C-8-TC Thermocouple Measurement Resolution Table
2500C-8-TC Installation and Operation Guide
9
1.7
Accuracy
The module measurement accuracy is listed below for each Thermocouple Type and
millivolt signals:
Accuracy :
J : +/-1ºC from 0ºC to 60ºC
K: +/-1ºC from 0ºC to 60ºC
T: +/-1ºC from 0ºC to 60ºC
E: +/-1ºC from 0ºC to 60ºC
R: +/-2ºC from 0ºC to 60ºC*
S: +/-2ºC from 0ºC to 60ºC*
N: +/-1ºC from 0ºC to 60ºC
mV: +/-0.5% full scale or +/- 500µV
* reduced accuracy for measurements
below 500ºC
Thermocouple Types and mV
Figure 8 2500C-8-TC Accuracy Rating Table
1.8
Digital Word map
Thermocouple and/or millivolt signals are translated into a 15-bit plus sign digital word.
Since the PLC requires a 16-bit input word, the 15-bit value from the converter is placed into
a 16-bit word for transmittal to the PLC, the extra bit being used to show the sign of the
value.
The data is reported to 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
Figure 9 2500C-8-TC Digital Word Map Diagram
In addition to applying a basic scale of 0-32000, the module provides a over-range error
value of 32765 or under-range error value of 32766.
10
2500C-8-TC Installation and Operation Guide
1.9
Thermocouple Input to Digital Conversion
1.9.1 Engineering Units
When module SCALING is disabled, data is reported as engineering units to the PLC as
follows:
Thermocouple Mode, digital word (WX) = Degrees x 10
Millivolt Mode, digital word (WX) = -10,000 to +10,000
As an example, the following Figure 1.3 illustrates the effects of a change in input level
going from 0 to 102.4oF in the Thermocouple Input Mode.
Example 1:
o
0.0 F = (Digital Word (WX))/10
MSB
1 2
0
.
0
.
3
4
5
6
7
8
9
LSB
10 11 12 13 14 15 16
0
.
0
0
0
0
0
0
0
0
0
0
0
.
.
.
0
.
0
.
.
.
32 16
8
4
2
1
Example 2:
o
102.4 F = (Digital Word (WX))/10
MSB
1 2
0
.
0
.
3
4
5
0
.
0
0
.
6
7
8
9
LSB
10 11 12 13 14 15 16
1
0
0
.
0
0
0
0
0
0
0
0
.
.
32 16
8
4
2
1
1024
Figure 10 2500C-8-TC Example of Change in Input Level
1.9.2 Scale Units
When data format is selected as SCALING enabled the full temperature range of the
thermocouple is scaled as an unsigned integer from 0 to 32000 for thermocouple units or
–32,000 to +32,000 for mV units (range of +/-55mV). The following formulas may be used to
calculate the scaled integer value for temperature and mV.
Temperature: Scaled Integer = (measured temp - min temp) / (max temp - min temp) x
32000
example: the scaled integer offset at 0oC for a Type J thermocouple is:
Scaled integer = (0 - (-210)) / (760 - (-210)) x 32000 = 6928
example: the scaled integer overrange at 770oC for a Type J thermocouple is:
Scaled integer = (770 - (-210)) / (760 - (-210)) x 32000 = 32330
mV:
Scaled Integer = mV x (32,000 ÷ 55)
example: the scaled integer offset at 20 mV is:
Scaled Integer = 20 x (32,000 ÷ 55) = ~11636.36
2500C-8-TC Installation and Operation Guide
11
The table below shows the scaling temperature ranges of each probe type.
Probe Type
J
K
T
E
R
S
N
Temperature Range
o
C
F
-210 to 760
-346 to 1400
-220 to 1320
-364 to 2408
-230 to 400
-382 to 752
-240 to 700
-400 to 1292
0 to 1768
32 to 3214
0 to 1768
32 to 3214
-200 to 1300
-328 to 2372
o
Figure 11 2500C-8-TC Example of Change in Input Level
1.10 Effect of Out-of-Range Input Signals
The 2559-TC utilizes the underrange and overrange codes of 32766 and 32765,
respectively, to indicate when a channel has reached individual limits. Thermocouple inputs
exceeding the ANSI standard for the different types of thermocouples (listed on the following
pages in Figures 1.4-1.11) will cause the overrange value, 32765, to be displayed and the
maximum temperature for that thermocouple type to be returned. Open thermocouples
report temperatures that are out of the allowable range. This condition may occur due to
failure of the thermocouple or due to the thermocouple wire being cut or disconnected. The
2559-TC will report an open thermocouple condition within 200 milliseconds.
NOTE:
The 2559-TC uses the overrange error code, 32765, to indicate an open thermocouple. An open
thermocouple condition will report within 200 milliseconds.
Figure 12 2500C-8-TC Effect of Voltage Input on Type J Thermocouple
12
2500C-8-TC Installation and Operation Guide
Figure 13 2500C-8-TC Effect of Voltage Input on Type J Thermocouple
Figure 14 2500C-8-TC Effect of Voltage Input on Type T Thermocouple
Figure 15 2500C-8-TC Effect of Voltage Input on Type E Thermocouple
Figure 16 2500C-8-TC Effect of Voltage Input on Type R Thermocouple
2500C-8-TC Installation and Operation Guide
13
Figure 17 2500C-8-TC Effect of Voltage Input on Type S Thermocouple
Figure 18 2500C-8-TC Effect of Voltage Input on Type N Thermocouple
Figure 19 2500C-8-TC Effect of Voltage Input on mV Input
14
2500C-8-TC Installation and Operation Guide
1.11 Error Code Values Reported to the PLC
The ‘temperature sensor bad’ code is reported to the PLC when either of the two
temperature sensors encapsulated in front panel connector goes bad. This is a rare
occurrence, but would yield code 32,761 if it does occur.
The math overflow code of 32,763 occurs when the thermocouple type mV and SCALE
modes are chosen, and the units tries to report a value under –32,000.The following chart
summarizes the 2500C-8-TC error codes:
Error Code
32761
Error
Bad Temperature
Sensor(s)
32763
Math Overflow
32764
32765
EEPROM Error
Channel Overrange
32766
Channel Underrange
Comment; Corrective Action
A temperature sensor (s) in front panel
connector is faulty/defective; call CTI for
replacement 2500C-8-TC connector, P/N:
2500C-32F-CJC.
Low end range of mV/SCALE exceeded;
Check process to determine if input is actually
low. Determine if mV transmitter is defective.
EEPROM Storage Error
Input level is above normal input range (see
Figures 1.4-1.11 for each thermocouple type);
Check process to determine if input is actually
high or if the transmitter is defective.
Input level is above below input range (see
Figures 1.4-1.11 for each thermocouple type);
Check process to determine if input is actually
low or if the transmitter is defective.
Figure 20 2500C-8-TC Error Code Table
2500C-8-TC Installation and Operation Guide
15
1.12 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. See Section 1.4.2 for module log on
example.
MSB
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
LSB
16
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
.
.
.
.
.
.
Not Used
Bit 9 through 16 Not Used
Figure 21 2500C-8-TC Word Map for Configuration Data
Bit 1 – Sets Temperature Measurement Range to Degrees Centigrade or Fahrenheit
0=Centigrade 1=Fahrenheit
Bit 2 – Sets Digital Filtering Enabled or disabled
0=Enabled
1=Disabled
Bit 3 – Sets Scaling Mode Enabled or Disabled
0=Enabled
1=Disabled
Bit 4 and Bit 5 are not used
Bit 6 through Bit 8 are used to set the input channel to millivolt ranges or select the
Thermocouple Type
000 = 55 millivolts
001 = Type E Thermocouple
010 = Type J Thermocouple
011 = Type K Thermocouple
100 = Type N Thermocouple
101 = Type R Thermocouple
110 = Type S Thermocouple
111 = Type T Thermocouple
Binary Examples of the Configuration Word for WY9 (Channel 1) X represents a null location
000x x000 xxxx xxxx
100x x001 xxxx xxxx
100x x010 xxxx xxxx
Module is set for ºC, Digital Filtering, Scaling Enable, 55mV
Module is set for ºF, Digital Filtering, Scaling Enable, Type E
Module is set for ºF, Digital Filtering, Scaling Enable, Type J
Figure 22 2500C-8-TC Binary Example of Module Configuration Word
16
2500C-8-TC Installation and Operation Guide
CHAPTER 2
INSTALLATION & SETUP
The installation of the 2500C-8-TC consists of the following steps:
1)
2)
3)
4)
5)
6)
7)
2.1
Reading this Chapter
Installation planning
Unpacking the module
Configuring the module
Physical installation
Connecting field wiring
Checking operation
Installation Planning
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 to prevent 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.
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
2500C-8-TC Installation and Operation Guide
17
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 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.
2.1.3 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 nonconductive 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.
18
2500C-8-TC Installation and Operation Guide
2.2
2500C-8-TC Board Layout
Top of the Module
Operation Mode
Selection Jumpers
LED Display
Module Front Panel
Backplane Connector
Wiring Connector
Plug in
Channel Range
Selection Jumpers
Figure 23 2500C-8-TC Board Layout Picture
2500C-8-TC Installation and Operation Guide
19
2.2.1
Defining Operation Mode and Range Selections
Before you can install the module, you must review your planned input signals by channel
and decide on one the operation modes (Classic or Classic Plus), and the range selections
and settings for each input. If your application needs only Type J Thermocouple digital
filtering enabled and degree measurements in Centigrade for every channel, then you may
use Classic mode. All other ranges and options require the selection of Classic Plus mode
and will be configured in your PLC logic.
2.2.2 Power Requirements
The 2500C-8-TC 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.
2.3
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-TC 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.
2.4
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 2.2.1 above. Configuration includes selecting
operation mode and selecting signal type, digital filtering, scaling and degrees F or C
reporting 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.
NOTE
Remember the module configuration must be reflected not only in the jumper selections but also in
the Channel Configuration Words that is written to the module from the CPU. This requires logic in
the application program to make this happen.
See section 1.12 Module Setup from the PLC in Classic Plus Mode
20
2500C-8-TC Installation and Operation Guide
2.4.1 Operation Mode Jumpers - Selecting Operation Mode
The module operational mode is selecting using the jumper at JP11. For Classic mode, the
jumper should be installed at the “C” position. For Classic Plus mode it should be installed
at the “CP” position. The module ships from the factory set for Classic mode operation.
Figure 24 2500C-8-TC Operation Mode Jumpers Picture
NOTE
JP1 is used for factory test purposes and should not be populated. If your module has a jumper at
JP1 PROGRAM position please remove before inserting the module.
2500C-8-TC Installation and Operation Guide
21
2.4.2 Selecting millivolt or Thermocouple Types for Each Channel
Millivolt or Thermocouple Type is set for each channel using the set of jumpers located on
the printed circuit board refer to Figure 23 2500C-8-TC Board Layout Picture for the jumper
locations. The module ships with the jumpers in “Type J, K, N, MV” position. For Type R, S,
T, and E Thermocouples, place the jumper in the position shown in the table below.
Note: Each Channel must be configured for the
desired range.
Jumper
Thermocouple
Position
Type Selection
E
E
J,K,N,MV
J, K, N
R,S,T
R*, S*, T*
mVolt
0-55mV
Figure 25 2500C-8-TC Jumper Signal Selection Table
Figure 26 2500C-8-TC Binary Example of Module Configuration Word
Top of the Module
Figure 27 2500C-8-TC Binary Example of Module Configuration Word
2.4.3 Factory Default Settings
The 2500C-8-TC default configuration as shipped from the factory is listed in the table
below:
2500-8-TC Default Shipment Settings
Operation Mode
Classic Mode
Logon
8WX
Thermocouple
J
Digital Filtering
Enabled
Offset Scaling
Disabled
Temperature Units
Degrees C
Figure 28 2500C-8-TC Default Factory Settings
22
2500C-8-TC Installation and Operation Guide
2.5
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 controller in the rack.
Figure 29 2500C-8-TC Module Physical Installation Picture
IMPORTANT NOTE:
The 2500-8-TC 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-TC Installation and Operation Guide
23
2.6
Connecting Field Wiring
Field wiring is connected to the 2500C-8-TC as shown in the connector wiring diagram
below. NOTE: For millivolt inputs you may wire to the “TC+” and the “TC-“ connections or
use the COM connections to reduce wiring. The “GND” connection is provided for the
shield. See 2.6.1 Understanding the Modified Front Panel Connector for a more detailed
explanation of the built CJC references.
+TC CH1
A1
B1
CJC+
-TC CH1
A2
B2
CJC-
+TC CH2
A3
B3
Not Used
-TC CH2
A4
B4
GND
+TC CH3
A5
B5
Not Used
-TC CH3
A6
B6
GND
+TC CH4
A7
B7
Not Used
-TC CH4
A8
B8
GND
+TC CH5
A9
B9
Not Used
-TC CH5
A10
B10
GND
+TC CH6
A11
B11
Not Used
-TC CH6
A12
B12
GND
+TC CH7
A13
B13
Not Used
-TC CH7
A14
B14
GND
+TC CH8
A15
B15
CJC+
-TC CH8
A16
B16
CJC-
2500C-8-TC Wiring Connection Diagram
Figure 30 2500C-8-TC Wiring Connector Diagram
24
2500C-8-TC Installation and Operation Guide
2.6.1 Understanding the Modified Front Panel Connector
In order to provide the most accurate cold junction compensation and to avoid CJC
calibration, the 2500C-8-TC utilizes a modified front panel connector which has two
temperature sensors directly set into the connector. These two temperature sensors are
encapsulated in connector locations B1 and B2 and B15 and B16 , and are not user
serviceable.
NOTE:
If either of the two temperature sensors fail, an error code of 32,761 will be reported to the PLC and
the module front panel LED will display the error code of “F” the modified connector needs replacing.
In the unlikely event this occurs, contact CTI for replacement connector part number ‘”2500C-32FCJC” for your replacement front panel connector.
2.6.2 Connecting Thermocouple Input Wiring
For thermocouple input circuits, connect the thermocouple wires to the screw terminals, as
indicated in Figure 30 2500C-8-TC Wiring Connector Diagram. Insert the wires in the
appropriate wiring connections on the front of the connector. When the wires are inserted,
tighten the screws. Repeat this procedure for the all thermocouple input channels. Ensure
that the proper wire polarity is followed for each of the seven supported thermocouple probe
types, as shown in Figure 33 2500C-8-TC Thermocouple Type and Wire Descriptions. See
also Appendix C for more detailed information on different thermocouple types.
Figure 32 Thermocouple Wiring Connector Diagram
Thermocouple
Type
J
K
T
E
R
S
N
Negative (-)
Lead
Copper-Nickel (Red)
Nickel-Aluminum (Red)
Copper-Nickel (Red)
Copper-Nickel (Red)
Platinum (Red)
Platinum (Red)
Nisil (Red)
Figure 31 Millivolt Wiring Connector Diagram
Positive (+)
Lead
Iron (White)
Nickel-Chromium (Yellow)
Copper (Blue)
Nickel-Chromium (Purple)
Platinum-13% Rhodium (Black)
Platinum-10% Rhodium (Black)
Nicrosil (Orange)
Figure 33 2500C-8-TC Thermocouple Type and Wire Descriptions
2500C-8-TC Installation and Operation Guide
25
2.6.3 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. For millivolt
applications, 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 from 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.
If the installation is in an extremely noisy environment CTI strongly recommends that the
shielded wires be 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 or larger from the PLC chassis
to the earth ground connection.
2.7
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.
2.8
Calibration of the Module
The 2500C-8-TC Thermocouple Input Module is calibrated at the factory. No further
calibration is required. All calibration parameters are stored in non-volatile memory. There
are no user adjustments on this product..
26
2500C-8-TC Installation and Operation Guide
2.9
Checking Module Operation
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 Remote Base
Controller will take a few seconds to complete the startup sequence. When this is complete,
the status indicator on the 2500-8-TC should display a “0”. Any other value displayed
indicates the module has detected a problem or error.
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.
Status
Indicator
0
A
B
C
D
E
F
Comments
Normal operation
Defective Internal RAM – contact CTI for assistance
Defective Flash memory failure – contact CTI for assistance
Defective internal MovX – contact CTI for assistance
Shared RAM failure – contact CTI for assistance
Defective EEPROM contents Calibration Record lost or corrupted
Contact CTI for assistance
Front Panel Sensor Error or there is no 2500C-32F-CJC installed –
Corrective action is to install the CJC wiring connector or if installed
replace with a new CJC wiring connector
Figure 34 2500C-8-TC LED Error Code Table
NOTE:
Refer to Hewlett-Packard Applications Note 290 or Omega Temperature Handbook, Volume 26,
Section T, for “practical thermocouple measurement” applications.
CAUTION:
For proper operation, ensure that the 2500C-8-TC and the thermocouple wires are not subjected to
drafts or large temperature gradients during operation.
NOTE:
In the event the 2500C-8-TC detects an onboard module failure, the module will assert the module
fail line and report the module failure in the I/O Status Word, which is reported to the PLC CPU. CTI
strongly recommends the user application monitor the I/O Module Status Words which are Status
Words 11-26. The I/O Module Status Word can be used to report a module failure for an I/O Module
in any of the 2500C I/O slots. If a module failure is reported by the status word, the module should be
replaced with a working unit and the failed module sent in for repair.
NOTE:
It may take 15-30 minutes after initial installation for temperature readings to stabilize.
2500C-8-TC Installation and Operation Guide
27
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. See Figure 34 2500C-8-TC LED Error
Code Table for additional diagnostic information.
Symptom
Indicator is not lit.
Probable Cause
Base or PLC power is off.
Corrective Action
Turn base or PLC on.
Incorrect inputs.
Wrong addresses for word
input.
Check program for correct work
input addresses.
Read I/O configuration.
Not logged in.
Calibration Error
Input does not work with PID
loop or analog alarm block.
Value is not reported as integer
0-32,000.
Value is too large.
Temperature is reported to PLC
as value x10.
Incorrect values to PLC.
(values off by 10-15 degrees)
Incorrect configuration
Return the module to CTI for
calibration.
Select SCALE format
Divide value by 10 in PLC.
Verify channel configuration
word
Wrong thermocouple type
selected by jumpers.
28
2500C-8-TC Installation and Operation Guide
2500C-8-TC Installation and Operation Guide
29
Appendix A Module Specifications
Input Specifications
Operation Mode Support (See Note 1)
Module Logon
Classic Mode
8WX
8WX/8WY
Module Update Time all modes
Digital Filtering Time Constant
Classic Plus Mode
9mS
80mS
80mS
Thermocouple Measurement Ranges
J: -210ºC to 760ºC (-350ºF to 1400ºF)
K: -270ºC to 1372ºC (-450ºF to 2500ºF)
T: -270ºC to 400ºC (-454ºF to 752ºF)
E: -270ºC to 1000ºC (-454ºF to 1832ºF)
R: 0ºC to 1768ºC (32ºF to 3214ºF)
S: 0ºC to 1768ºC (32ºF to 3214ºF)
N: -260ºC to 1300ºC (-436ºF to 2372ºF)
mV: -55 to +55mV
Accuracy :
J : +/-1ºC from 0ºC to 60ºC
K: +/-1ºC from 0ºC to 60ºC
T: +/-1ºC from 0ºC to 60ºC
E: +/-1ºC from 0ºC to 60ºC
R: +/-2ºC from 0ºC to 60ºC*
S: +/-2ºC from 0ºC to 60ºC*
N: +/-1ºC from 0ºC to 60ºC
mV: +/-0.5% full scale or +/- 500µV
* reduced accuracy for measurements below 500ºC
Thermocouple Types and mV
Open Thermocouple Detection
mV input impedance
Repeatability
Measurement Units
Resolution
Less than 1 second
4.4MΩ DC, >10kΩ @ 60Hz
±1ºC, ±2ºF for all Thermocouple Types
Degrees C or Degrees F selectable
16 bits (15 bits plus sign)
Data Presentation w/scaling enabled
0-32000(temp)
-32000 to +32000(mV)
Data Presentation w/scaling disabled
ºC or ºF x 10 (temp)
-10000 to +10000 (mV)
Common Mode Rejection
Normal Mode Rejection
Backplane Power (MAX)
Input ESD Protection
Isolation
Operating Temperature Range
Agency Approvals Pending
Shipping Dimensions and Weight
Storage Temperature Range
Relative Humidity
2500C-8-TC Installation and Operation Guide
>110db @ 60Hz
>60db @ 60Hz, >50db @ 50 Hz
1.25 watts
IEC 1000-4-2 Level 4
Channel to Channel 200V±
Channel to Backplane 1500VDC
0ºC to 60ºC (32ºF to 140ºF)
UL, ULC, UL Class 1, Div 2, CE
223.84mm x 109.86mm x 34.93mm, 0.45kg
-40ºC to 85ºC (-40ºF to 185ºF)
5% to 95% (non-condensing)
31
32
2500C-8-TC Installation and Operation Guide
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 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
2500C-8-TC Installation and Operation Guide
33
RELATIVE TO GRATUITOUS INFORMATION OR ASSISTANCE PROVIDED BY, BUT NOT
REQUIRED OF CTI HEREUNDER. ANY ACTION AGAINST CTI MUST BE BROUGHT 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.
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.
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.
34
2500C-8-TC 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-TC Installation and Operation Guide
35
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