Installation and Operation Guide

Installation and Operation Guide
CTI 2555 SIXTEEN CHANNEL
DIFFERENTIAL ANALOG INPUT MODULE
INSTALLATION AND OPERATION GUIDE
Version 1.0
CTI Part #062-00157
2555IOG 092205
$25
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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.
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PREFACE
This Installation and 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 1 provides a description of the module.
Chapter 2 covers installation and wiring.
Chapter 3 is a guide to troubleshooting.
Figure 1 The Model 2555 16-Channel Differential Analog Input Module
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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.
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TABLE OF CONTENTS
PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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USAGE CONVENTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
TABLE OF FIGURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
CHAPTER 1. DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 Front Panel Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1.1 Active LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1.2 Input Connector for Channels 1-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 Asynchronous Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 Immediate I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 Unipolar or Bipolar Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.5 Voltage or Current Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6 Digital Word Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6.1 Unipolar Presentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6.2 Bipolar Presentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.7 Analog to Digital Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.7.1 Unipolar Mode Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.7.2 Bipolar Mode Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.7.3 Example Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8 Effect of Out-of-Range Input Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8.1 Unipolar Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8.2 Bipolar Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.9 Using the Module with 20% Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.10 Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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CHAPTER 2. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 Planning the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1.1 Calculating the I/O Base Power Budget . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1.2 Input Signal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Unpacking the Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 Configuring the Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.1 Selecting Voltage or Current Input Mode (JP1, JP2, JP3, JP4) . . . . . . . . . . . . . .
2.3.2 Selecting Voltage Range JP5-JP20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.3 Selecting Unipolar or Bipolar Input Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.4 Selecting Digital Filtering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4 Inserting the Module Into the I/O Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5 Wiring the Input Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5.1 Connecting Voltage Input Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5.2 Connecting Current Input Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6 Inserting the Screw Terminal Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7 Checking Module Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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CHAPTER 3. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
JUMPER SETTINGS LOG SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
USER NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
LIMITED PRODUCT WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
REPAIR POLICY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
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TABLE OF FIGURES
Figure 1 The Model 2555 16-Channel Differential Analog Input Module . . . . . . . . . . . . . . . . . . . . .
Figure 2 Front Panel Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 3 Word Input to the PLC from the Module (Unipolar) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4 Word Input to the PLC from the Module (Bipolar) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5 Example of Change in Input Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 6 Voltage Input Limits (Unipolar) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7 Voltage Input Limits (Bipolar) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8 Typical Unipolar Overrange Word Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 9 Typical Unipolar Underrange Word Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10 Typical Bipolar Overrange Word Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11 Typical Bipolar Underrange Word Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 12 Input Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 13 Factory Configuration Jumper Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 14 Configuration Jumper Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 15 Screw Terminal Plug Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 16 Typical Internal Circuit - Voltage Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 17 Typical Internal Circuit - Current Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 18 Input Connector Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 19 Example I/O Configuration Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 20 Troubleshooting Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 21 Jumper Settings Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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CHAPTER 1. DESCRIPTION
The Sixteen Channel Analog Input Module is a member of the Control Technology 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.
Figure 2 Front Panel Description
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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 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.
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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”.
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.
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.
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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:
0 to 5 V Input Range Mode, Digital Word (WX) =
+Input voltage (V) x 32000
------------------------------------5 volts
0 to 10 V Input Range Mode, Digital Word (WX) =
+Input voltage (V) x 32000
-----------------------------------10 volts
0 to 20 mA Input Range Mode, Digital Word (WX) =
+Input current (mA) x 32000
------------------------------------20 mA
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:
-5 to +5 V Input Range Mode, Digital Word (WX) =
±Input voltage (V) x 32000
------------------------------------5 volts
-10 to +10 V Input Range Mode, Digital Word (WX) =
±Input voltage (V) x 32000
-----------------------------------10 volts
-20 to +20 mA Input Range Mode, Digital Word (WX) =
4
±Input current (mA) x 32000
------------------------------------20 mA
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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 5V 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.)
Figure 5 Example of Change in Input Level
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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 for 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 +5VDC or -10 to +10VDC
range are translated to a digital word and also utilize the overrange or underrange bit. The actual limit for
Figure 6 Voltage Input Limits (Unipolar)
each channel will vary from channel to channel as described above.
Figure 7 Voltage Input Limits (Bipolar)
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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
Figure 8 Typical Unipolar Overrange Word Value
Figure 9 Typical Unipolar Underrange Word Value
mode.
Figure 10 Typical Bipolar Overrange Word Value
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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). Then, multiply the result by 125 and divide the
product by 100. This yields the following equation:
(WX-6400) x 125
---------------------- = 20% offset data word
100
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.
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The chart below shows the corresponding input resolution per step for each of the input configuration
modes:
Figure 12 Input Resolution
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CHAPTER 2. INSTALLATION
The installation of the Sixteen Channel Analog Input Module involves the following steps:
1.
2.
3.
4.
5.
Planning the installation
Configuring the module
Inserting the module into the I/O base
Wiring and connecting the module input connectors
Checking module operation
The steps listed above are explained in detail in the following pages.
2.1 Planning the Installation
Planning is the first step in the installation of the module. This involves calculating the I/O base power
budget and routing the input signal wiring to minimize noise. The following sections discuss these
important considerations.
2.1.1 Calculating the I/O Base Power Budget
The Model 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.
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Note the following general considerations when wiring the module:
Always use the shortest possible 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.
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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).
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 1 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.
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CT I 2555 Installation and O peration G uide
2.3.2 Selecting Voltage Range JP5-JP20
Locate 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.
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). 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.
CT I 2555 Installation and O peration G uide
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Figure 14 Configuration Jumper Locations
2.3.4 Selecting Digital Filtering
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.
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CT I 2555 Installation and O peration G uide
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:
Figure 15 Screw Terminal Plug Wiring
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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
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.
Figure 17 Typical Internal Circuit - Current Mode
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CT I 2555 Installation and O peration G uide
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.
Figure 18 Input Connector Assembly
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2.7 Checking Module Operation
First turn on the base power supply. If the module diagnostics detect no problems, the status indicator on
the front of the module will light. If the status indicator does not light, 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,
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.
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CT I 2555 Installation and O peration G uide
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.
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.
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CT I 2555 Installation and O peration G uide
SPECIFICATIONS
Input Channels:
Signal Range:
16 differential input channels (140 VRMS channel-to-channel
common mode rejection CMR)
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
Update Time:
5.9 mSec no filtering
8.2 mSec digital filtering enabled
Digital Filtering Time Constant:
25 mSec
DC Input Resistance:
Voltage Mode: 680 kS
Current Mode: 250 S
Repeatability:
0.008%
Accuracy:
Voltage Mode:
Current Mode:
0.10% of full scale at 25/C
0.30% of full scale at 0-60/C
0.20% of full scale at 25/C
0.40% of full scale at 0-60/C
Resolution:
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 :A/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 :A/step
Common Mode Rejection:
>86db @ 60Hz (digital filtering disabled)
Normal Mode Rejection:
>45db @ 60Hz (digital filtering enabled)
Input Protection:
Input ESD Protection: 4,000 V
Overrange Protection: 500 V
Isolation:
1500 VDC channel-to-PLC
Module Size:
Single wide
Backplane Power Consumption:
Operating Temperature:
Storage Temperature:
Humidity, Relative:
Shipping Weight:
Agency Approvals Pending:
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)
Specifications subject to change without notice.
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CT I 2555 Installation and O peration G uide
JUMPER SETTINGS LOG SHEET
Figure 21 Jumper Settings Log
Record the configuration jumper settings on this log for future reference. Make additional copies if
necessary.
CT I 2555 Installation and O peration G uide
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CT I 2555 Installation and O peration G uide
USER NOTES
CT I 2555 Installation and O peration G uide
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CT I 2555 Installation and O peration G uide
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 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 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.
CT I 2555 Installation and O peration G uide
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CT I 2555 Installation and O peration G uide
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 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 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.
CT I 2555 Installation and O peration G uide
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