CTI 2562 EIGHT CHANNEL ANALOG OUTPUT MODULE INSTALLATION AND OPERATION GUIDE

CTI 2562 EIGHT CHANNEL ANALOG OUTPUT MODULE INSTALLATION AND OPERATION GUIDE
CTI 2562 EIGHT CHANNEL
ANALOG OUTPUT MODULE
INSTALLATION AND OPERATION GUIDE
Version 1.1
CTI Part # 062-00332-011
2562IOG 12MAR09
$25
Copyright © 2005 Control Technology Inc.
All rights reserved.
This manual is published by Control Technology Inc., 5734 Middlebrook Pike, Knoxville, TN
37921. This manual contains references to brand and product names that 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
merchantability or fitness for a particular purpose. This document and the products it references are
subject to change without notice. If you have a comment or discover an error, please call us toll-free
at 1-800-537-8398.
REVISION HISTORY
Version 1.0
Version 1.1
4/10/01
5/30/01
03/12/09
Original Release
Update to reflect addition of ‘last value’ in power cycling, module
configuration updates, miscellaneous typos corrected.
Added note about zero/last value jumper in 2.3.5, 2.9
CTI 2562 Installation and Operation Guide
iii
PREFACE
This Installation and Operation Guide provides installation and operation instructions for the
CTI 2562 8-Channel Analog Output Module for SIMATIC® 505 programmable controllers. We
assume you are familiar with the operation of SIMATIC® 505 programmable controllers. Refer to
the appropriate SIMATIC® user documentation for specific information on the SIMATIC® 505
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 and wiring.
Chapter 3 is a guide to troubleshooting.
Appendix A details compatibility between the 2562 and the Siemens® 505-6208-A and 505-6208-B.
The 2562 8-Channel Analog Output Module
CTI 2562 Installation and Operation Guide
v
USAGE CONVENTIONS
NOTE:
Notes alert the user to special features or procedures.
CAUTION:
Cautions alert the user to procedures that could damage equipment.
WARNING:
Warnings alert the user to procedures that could damage equipment and endanger the user.
CTI 2562 Installation and Operation Guide
vii
TABLE OF CONTENTS
CHAPTER 1. OVERVIEW...................................................................................................... 1
1.0. Product Summary .............................................................................................................. 1
1.1. Front Panel Description..................................................................................................... 1
1.2. Asynchronous Operation................................................................................................... 2
1.3. Output Signal Description ................................................................................................. 2
1.4. Immediate I/O .................................................................................................................... 3
1.5. Unipolar or Bipolar Mode ................................................................................................. 3
1.6. Voltage or Current Output ................................................................................................ 3
1.7. Digital to Analog Conversion ........................................................................................... 4
1.8. Output Resolution ............................................................................................................ 4
1.9. Using the Module with a Built-In 20% Offset Calculation .............................................. 5
CHAPTER 2. INSTALLATION.............................................................................................. 7
2.1. Planning the Installation .................................................................................................... 7
2.2. Unpacking the Module .................................................................................................... 11
2.3. Configuring the Module for Operation ........................................................................... 12
2.4. Inserting the Module into the I/O Base ........................................................................... 15
2.5. Wiring the Output Connector.......................................................................................... 15
2.6. Inserting the Screw Terminal Plug.................................................................................. 17
2.7. Connecting the 24 VDC User Power Supply ................................................................. 17
2.8. Checking Module Operation ........................................................................................... 18
2.9. Power Cycling ................................................................................................................. 19
CHAPTER 3. TROUBLESHOOTING.................................................................................. 21
SPECIFICATIONS................................................................................................................. 23
APPENDIX A. COMPATIBILITY WITH SIEMENS® 505-6208-A/B ............................. 25
APPENDIX B: JUMPER SETTINGS LOG SHEET ............................................................ 27
LIMITED PRODUCT WARRANTY.................................................................................... 29
REPAIR POLICY ................................................................................................................... 31
CTI 2562 Installation and Operation Guide
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TABLE OF FIGURES
Figure 1.1 CTI 2562 Front Panel .......................................................................................................... 1
Figure 1.2 Relation of Update Time Change in Signal Output ............................................................. 2
Figure 1.3 Word Output from the PLC to the Module .......................................................................... 3
Figure 1.4 Bipolar Word Output from the PLC to the module ............................................................. 3
Figure 1.5 Output Resolution. ............................................................................................................... 5
Figure 2.1 Current Output Circuits ....................................................................................................... 9
Figure 2.2 Voltage Output Circuit ..................................................................................................... 10
Figure 2.3 Configuring the Module .................................................................................................... 12
Figure 2.4 Output Screw Terminal Plug Wiring ................................................................................. 15
Figure 2.5 Connecting the Shield Wiring ........................................................................................... 16
Figure 2.6 Attaching the Screw Terminal Plug ................................................................................... 17
Figure 2.7 Power Supply Connections ................................................................................................ 17
Figure 2.8 I/O Configuration Chart .................................................................................................... 18
Figure 2.9 Last Value Mode Module Reactions ................................................................................. 19
Figure 2.10 Zero Mode Module Reactions ......................................................................................... 19
Figure 3.1 Troubleshooting Matrix .................................................................................................... 21
CTI 2562 Installation and Operation Guide
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CHAPTER 1. OVERVIEW
1.0. Product Summary
The CTI 2562 Eight Channel Analog Output Module is a member of Control Technology's family of I/O
modules compatible with the SIMATIC® 505 programmable controllers. The 2562 is designed to
translate a digital word from the programmable controller (PLC) into an equivalent analog voltage and
current signal.
1.1. Front Panel Description
Figure 1.1 CTI 2562 Front Panel
1.1.1. Active LED
The Active LED will be illuminated when the module is functioning normally. If the Active LED is not
lit, the user 24V is not present or a serious problem exists with the module. If the LED is blinking the
module requires calibration. Refer to Chapter 3 for troubleshooting.
1.1.2. Input Connector for Channels 1-8
This connector provides wiring terminals for channels 1-8 and for user supplied 24 VDC power supply.
The wiring connector accepts 14-22 AWG wire.
CTI 2562 Installation and Operation Guide
1
1.2. Asynchronous Operation
The module operates asynchronously with respect to the PLC so that a scan of the PLC and a module
output scan cycle do not occur at the same time. Note also that how an output signal changes is dependent
on the update time of the module. The following figure illustrates this relationship:
Figure 1.2 Relation of Update Time Change in Signal Output
1.3. Output Signal Description
Each of the eight channels independently provide output signals that are either Unipolar or Bipolar.
Ranges supported include 0 to +5 VDC, 0 to +10 VDC, 0 to +20mA, -5 to +5 VDC, -10 to +10 VDC, and
-20 to +20 mA. Both voltage and current outputs are available simultaneously so that either may be used
for a particular channel.
1.3.1. Unipolar Operation
In the Unipolar mode the PLC sends a 16-bit word to the module for translation to an analog signal. Data
to be translated occupies 12 bits. The four remaining bits are unused. The following figure illustrates a
16-bit word sent from the PLC to the module.
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CTI 2562 Installation and Operation Guide
Figure 1.3 Word Output from the PLC to the Module
1.3.2. Bipolar Operation
In the Bipolar mode data to be translated occupies 11 bits plus a sign bit. The four remaining bits are
unused.
Figure 1.4 Bipolar Word Output from the PLC to the module
1.4. Immediate I/O
The 2562 Analog Output Module is fully compatible with the Immediate output instructions for the
SIMATIC® 545 and 555 PLCs.
1.5. Unipolar or Bipolar Mode
Each output channel may be configured to provide either a bipolar or unipolar output signal.
1.6. Voltage or Current Output
Voltage and current output signals are both available simultaneously. For Unipolar output signals the
ranges supported are 0 to +5 VDC, 0 to +10 VDC, and 0 to 20mA. For Bipolar outputs the ranges
supported are -5 to +5 VDC, -10 to +10 VDC, and -20 to +20 mA. Selection of voltage ranges and
Unipolar and Bipolar operation are made via internal jumpers and DIP switches. (See Figure 2.3.)
CTI 2562 Installation and Operation Guide
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1.7. Digital to Analog Conversion
1.7.1. Unipolar Mode Conversion
The following equations are used to calculate the digital word used to generate a Unipolar output signal:
0 to +5 VDC range
Digital WY = (Output voltage x 32000) ÷ 5 volts
WY = (Desired Output Voltage x 32000) ÷ 5
for example, to generate an output voltage of 2.5 VDC the WY value output
from the PLC is calculated as follows: WY= (2.5x32000) ÷ 5 = 16000
0 to +10 VDC range
Digital WY = (Output voltage x 32000) ÷ 10 volts
0 to +20 mA range
Digital WY = (Output current x 32000) ÷ 20 mA
1.7.2. Bipolar Mode Conversion
The following equations are used to calculate the digital word used to generate a Bipolar output signal.
-5 to +5 VDC range
WY = (Desired output voltage x 32000) ÷ 5 volts
Example: -5 volts output
WY = (-5 x 32000) ÷ 5 = -32000
-10 to +10 VDC range
WY = (Desired output voltage x 32000) ÷ 10 volts
Example: -5 volts output
WY = (-5 x 32000) ÷ 10 = -16000
-20 to +20 mA range
WY = (Desired output current x 32000) ÷ 20 mA
Example: 4 mA output
WY = (4 x 32000) ÷ 20 = 6400
1.8. Output Resolution
1.8.1. Unipolar Mode
In Unipolar mode the module has a resolution of 8 counts out of 32000, or 1 part out of 4000. For the
voltage range 0 to +5 VDC the minimum step is 1.25 mV. For the range 0 to +10 VDC the minimum step
is 2.5 mV and for 0 to 20 mA output the minimum step is 5 microamps.
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CTI 2562 Installation and Operation Guide
1.8.2. Bipolar Mode
In Bipolar mode the module has a resolution of 16 counts out of 32000 or 1 part out of 2000. For the
voltage range -5 to +5 VDC the minimum step is 2.5 mV. For the range -10 to +10 VDC the minimum
step is 5.0 mV and for -20 to +20 mA output the minimum step is 10 microamps.
Figure 1.5 Output Resolution.
1.9. Using the Module with a Built-In 20% Offset Calculation
If all 8 outputs are used in Offset Mode, i.e., 4 to 20 mA or 1 to 5 VDC operation, the 2562 may be
configured to automatically scale the digital word from the PLC. This is to be used in Unipolar mode
only. Jumper JP40, when enabled, will configure all eight outputs for offset operation. No relay ladder
logic is required for output processing.
1 to 5 VDC range
Digital WY = ((Output voltage-1) x 32000) ÷ 4 volts
WY = ((Desired Output Voltage-1) x 32000) ÷ 4
for example, to generate an output voltage of 3.0 VDC the WY value output
from the PLC is calculated as follows: WY= ((3-1)x32000) ÷ 4 = 16000
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
NOTE:
Jumper JP40 is labeled on the printed circuit board as Offset (En(able)/Dis(able)).
CTI 2562 Installation and Operation Guide
5
CHAPTER 2. INSTALLATION
The installation of the Eight Channel Analog Output Module involves the following steps:
1. Planning the installation
2. Configuring the module
3. Inserting the module into the I/O base
4. Wiring the module output screw terminal connector
5. Connecting the 24 VDC user power supply
6. 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:
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.
1.1.1. Calculating the I/O Base Power Budget
The 2562 requires 2.0 watts of +5 VDC power from the I/O base. Before inserting the module into the I/O
base, ensure that the base power supply capacity is not exceeded.
CTI 2562 Installation and Operation Guide
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2.1.2. Choosing a Power Supply
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.
2.1.3. Wiring Consideration
The module requires separate wiring for the power supply and for the output signals. Power and signal
wiring must be separated to prevent noise in the signal wiring. Output signal wiring must be shielded,
twisted-pair cable, with 14 to 22 gauge stranded conductors. The cable shield should always be
terminated to earth ground at the I/O base. It should not be terminated at the output connector. Use the
following guidelines when wiring the module:
•
•
•
•
•
•
•
Always use the shortest possible cables
Avoid placing power supply wires and signal wires near sources of high energy
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 wires into sharp angles
Use wireways for wire routing
Be sure to provide a proper earth ground for the cable shield at the I/O base
Avoid placing wires on any vibrating surfaces
2.1.4. 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
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CTI 2562 Installation and Operation Guide
Figure 2.1 Current Output Circuits
2.1.5. 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.
CTI 2562 Installation and Operation Guide
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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.
Figure 2.2 Voltage Output Circuit
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CTI 2562 Installation and Operation Guide
2.2. Unpacking the Module
CAUTION:
HANDLING STATIC SENSITIVE DEVICES
The components on the 2562 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.
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 the
I/O backplane.
WARNING:
Ensure that the power supply is turned OFF before connecting the wires to the I/O base.
CTI 2562 Installation and Operation Guide
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2.3. Configuring the Module for Operation
The 2562 must be configured for voltage output range, unipolar or bipolar mode, offset mode, and
zero/last value mode before wiring the output connectors and inserting the module into the I/O base. As
shipped, all output channels are configured for the 5V output range, unipolar outputs, disabled offset
mode, and last value output at power up (see Table 2.1).
Configuring the 2562 for operation consists of the following steps (notations in parenthesis are actual
printed board titles):
1. Selecting 0-5V (5V) or 0-10V (10V) output voltage range for each channel.
2. Selecting unipolar (UNI) or bipolar (BI) mode for each output channel.
3. Setting DIP switches for each channel to match the hardware configuration.
4. Selecting offset scaling enabled (EN) or disabled (DIS) for the entire module.
5. Selecting either zero (ZERO) or last value (LAST VALUE) at power up for the module.
Figure 2.3 Configuring the Module
(jumper settings shown as shipped)
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CTI 2562 Installation and Operation Guide
Channel
Number
1
2
3
4
5
6
7
8
Voltage Range
Jumper
JP28
JP6
JP2
JP12
JP8
JP4
JP10
JP14
Jumper Position
All
Channels
1-8
Jumper Position
5V
5V
5V
5V
5V
5V
5V
5V
Unipolar/Bipola
r Jumper
JP24
JP5
JP1
JP11
JP7
JP3
JP9
JP13
Offset Mode
Jumper
Offset Mode
Jumper Position
Outputs at Power
Up Jumper
Outputs at Power Up
Jumper Position
JP40
DISABLED
JP25
LAST VALUE
5V or 10V
Uni or Bi
UNI
UNI
UNI
UNI
UNI
UNI
UNI
UNI
Table 2.1 Jumper Configuration as Shipped
2.3.1. Selecting Either 5 VDC or 10 VDC Range for Each Channel
The 2562 is capable of supporting Unipolar or Bipolar applications with an output range of 0 to +5 VDC,
0 to +10 VDC, -5 to +5 VDC or -10 to +10 VDC. For each channel a hardware jumper selects the range
for that output circuit. (See Figure 2.3.) Select 5 VDC range for all current applications. As shipped, the
5V range is selected.
2.3.2. Selecting Unipolar or Bipolar Output
Each output channel on the 2562 supports Unipolar or Bipolar output operation. Hardware jumpers select
operation of the output. (See Figure 2.3.) Select Bipolar for applications that drive the outputs from -5 to
+5 VDC, -10 to +10 VDC, or -20 to +20 mA. As shipped, Unipolar range is selected.
CTI 2562 Installation and Operation Guide
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2.3.3. Setting DIP Switches to Match the Hardware Selections
Once the hardware jumpers are selected this information needs to be reported to the microcomputer. The
information is reported via DIP switches SW1 and SW2. Each output channel uses 2 switches with a BCD
code to indicate the state of the hardware jumpers. As shipped, Unipolar 5VDC is selected.
2 (MSB)
1 (LSB)
Range
OFF
OFF
Unipolar 5VDC
OFF
ON
Unipolar 10VDC
ON
OFF
Bipolar 5VDC
ON
ON
Bipolar 10VDC
2.3.4. Selecting Automatic Offset Mode for the Entire Module
Some applications require an Offset mode of 4-20 mA or 1-5 VDC. The SIMATIC® TI PLC can adjust
an output loop calculation to provide an offset output. If the application does not use the PID control
block then the processing must be done in relay ladder logic. The 2562 can perform this offset calculation
and output an offset signal independent of the PLC. Selecting this function with JP40 causes all eight
outputs to be scaled. Move the jumper to the ENABLED position to select this function. As shipped the
module offset is DISABLED.
2.3.5. Selecting Either Zero or Last Value Output at Power Up
Upon power up of the base power, the 2562 allows the user to choose between either a zero output value
or last output value when transitioning to the next update. A hardware JP25 jumper setting (see Figure
2.3) sets the entire module for the mode chosen. Section 2.9. Power Cycling explains the details of each
selection. As shipped the module power up mode is LAST VALUE. Note: this jumper only has effect
when power is lost from the base.
2.3.6. Jumper Settings for Future Reference
See Appendix B. Jumper Settings Log Sheet to record any changes to the module’s factory jumper
settings.
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CTI 2562 Installation and Operation Guide
2.4. Inserting the Module into the I/O Base
When the module is fully seated in the slot, captive screws at the top and bottom will hold the module in
place. To remove the module from the I/O base, loosen these captive screws, and then remove the module
from the I/O base. Do not damage the edge connector at the back of the module when inserting or
removing the module.
2.5. Wiring the Output Connector
Output signals are provided through a connector assembly located on the front of the module. The
connector assembly consists of a header attached to the printed circuit card and a mating removable screw
terminal plug (see Figure 2.4). Wiring is connected through the removable screw terminal plug.
Figure 2.4 Output Screw Terminal Plug Wiring
2.5.1. Connecting Voltage Output Wiring
First, loosen the wire locking screws on the output screw terminal plug. For voltage output circuits,
connect the signal wire to the VO screw terminal, and the return wire to the Return (channel ground)
screw terminal. Insert the wires in the appropriate holes next to the screws. When the wires are inserted,
tighten the screws. Repeat this procedure for the remaining voltage output channels.
CTI 2562 Installation and Operation Guide
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2.5.2. Connecting Current Output Wiring
For current output circuits, connect the signal wire to the IO screw terminal, and the return wire to the
Return (channel ground) screw terminal. Insert the wires in the appropriate holes next to the screws.
When the wires are inserted, tighten the screws. Repeat this procedure for the remaining current output
channels.
2.5.3. Connecting the Shield Wiring
See Figure 2.5 below that describes cable grounding and chassis ground.
Figure 2.5 Connecting the Shield Wiring
Note:
A static drain is recommended on the 2562 to prevent a static charge buildup from occurring. A 10K to
1M resistor from any analog common to earth ground (chassis ground is front panel output connector
pins D4 or D8) is sufficient for protection.
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CTI 2562 Installation and Operation Guide
2.6. Inserting the Screw Terminal Plug
When all the output signal wires are connected to the screw terminal plug, carefully insert the plug into its
header. Both the plug and header are keyed to prevent reverse wiring. When the screw terminal is fully
inserted onto the header, use the captive screws to secure the plug to the front panel.
Figure 2.6 Attaching the Screw Terminal Plug
WARNING:
Always remove power from the I/O base before inserting a module to minimize the risk of
injury of damage to equipment. Never insert a module into a powered I/O base.
2.7. Connecting the 24 VDC User Power Supply
The power supply is connected to the top 2 positions of the top connector on the front of the module as
shown in Figure 2.7 below. Be sure to check that the 24V fuse is present and intact. See Chapter 3
Troubleshooting recommendations for replacement fuses.
Figure 2.7 Power Supply Connections
CTI 2562 Installation and Operation Guide
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2.8. Checking Module Operation
First turn on the base supply power. If diagnostics detects no problems, the front panel status indicator
will light. If the indicator does not light (or goes out during operation), the user 24VDC is not present or
the module has detected a different failure. For information on viewing failed module status, refer to your
SIMATIC® TISOFT Programming Manual. To diagnose and correct a module failure, refer to the next
section on troubleshooting.
NOTE:
If 24 VDC power fails or is removed and then later restored, the module will automatically resume
normal operation. No external reset is required after power is restored.
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.
In this example, the 2562 Module is inserted in slot 1 in I/O base 0. Data for channel 1 appears in word
location WY1, data for channel 2 appears in word location WY2, etc. For your particular module, look in
the chart for the number corresponding to the slot occupied by the module. If word memory locations
appear on this line, then the module is registered in the PLC memory and the module is ready for
operation.
Figure 2.8 I/O Configuration Chart
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.
NOTE:
In the event a CTI analog module detects no user 24VDC or 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 and apply to SIMATIC® Controllers TI/545, TI/555,
TI/560 & 565, and the TI/575. The I/O Module Status Word can be used to report a module failure
for an I/O Module in any of the SIMATIC® 505 I/O slots. Please refer to Siemens® SIMATIC® 505
Programming Reference Manual for more information. 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.
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CTI 2562 Installation and Operation Guide
2.9. Power Cycling
The 2562 reacts the following ways upon various power cycling scenarios:
Base Power
(5V)
On
User Power
(24V)
Transition off
2562 in Last Value Mode
Unipolar Mode*
Bipolar Mode*
Output to zero.
Output to zero.
On
Transition on
Transition off
On
Output from zero to PLC
value.
Maintains last value.
Output from zero to full
scale (+), then PLC value.
Maintains last value.
Transition on
On
Maintains last value.
Maintains last value.
Off
Transition on
Output stays at zero.
Output to full scale.
Figure 2.9 Last Value Mode Module Reactions
Base Power
(5V)
On
User Power
(24V)
Transition off
2562 in Zero Mode
Unipolar Mode*
Bipolar Mode*
Output to zero.
Output to zero.
On
Transition on
Output from zero to PLC
value.
Transition off
On
Maintains last value.
Transition on
On
Off
Transition on
Output to zero for several
seconds, then to PLC
value.
Output stays at zero.
Output from zero to full
scale (+), then to zero,
then to PLC value.
Maintains last value.
Output to zero, then to
PLC value.
Output from zero to full
scale (+).
Figure 2.10 Zero Mode Module Reactions
*see Section 2.3.5. Selecting Either Zero or Last Value Output at Power Up for further explanation.
Note: the zero/last value setting only has effect when power is lost from the base. It does not control
what happens when the PLC is put in PROGRAM mode. The PLC always continues to update I/O
modules when in PROGRAM mode.
CTI 2562 Installation and Operation Guide
19
CHAPTER 3. TROUBLESHOOTING
Figure 3.1 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 (user supply) fails, the
module will still be logged into the PLC even though it is not operating.
In the event the user serviceable fuse blows, its replacement should be a 1 A, 250V Fast Blow 5x20mm
fuse (Littelfuse 217-001 or equivalent).
If after consulting the chart above, you are unable to diagnose or solve the problem, contact your local
distributor or CTI at 1-800-537-8398 for further assistance.
CTI 2562 Installation and Operation Guide
21
SPECIFICATIONS
Output Channels:
8 analog output channels
Response Time:
4 mSec total module (includes settling time)
Output Range:
Unipolar:
Bipolar:
0 to +5.12 VDC
0 to +10.24 VDC
0 to +20 mA
-5.12 to +5.12 VDC
-10.24 to +10.24 VDC
-20 to +20 mA
Resolution 12 bits:
0-5 VDC range = 1.25 mV/step
0-10 VDC range = 2.5 mV/step
0-20 mA range = 5 μA/step
-5 to +5 VDC range = 2.5mV/step
-10 to +10 VDC range = 5.0 mV/step
-20 to +20 mA range = 10 μA/step
Isolation:
1500 VDC channel-to-PLC
Capacitance Drive:
0.01 microfarads
Load Resistance:
Voltage: 1KΩ minimum, no maximum
Current: 0Ω to 1KΩ max. @ 24VDC or greater
Voltage Accuracy:
0.125% of full scale from 0° to 60°C
over total load range
Current Accuracy:
0.225% of full scale from 0° to 60°C
over total load range
User Supply:
20 to 30 VDC @ 0.50 Amps
(maximum ripple of 0.4 V)
UL Class 2 power supply
Backplane Power Consumption:
1.7 Watts
Module Size:
Single-wide
Operating Temperature:
0° to 60°C (32° to 140°F)
Storage Temperature:
-40° to 85°C (-40° to 185°F)
Humidity, Relative:
5% to 95% non-condensing
Agency Approvals:
UL, UL-C
Specifications subject to change without notice.
CTI 2562 Installation and Operation Guide
23
APPENDIX A. COMPATIBILITY WITH SIEMENS® 505-6208-A/B
Overview
The CTI 2562 Analog Output Module was designed to be a drop-in replacement for the Siemens® models
505-6208-A and 505-6208-B. From set up of the module to wiring and PLC reporting, the user will find
many similarities between the CTI and Siemens® models.
Using the CTI 2562 in a 505-6208-A and/or 505-6208-B application
The CTI 2562 should fulfill all the following requirements for the 505-6208-A and 505-6208-B
replacement(s), as outlined below:
Module setup
Since the CTI 2562 allows for both Unipolar and Bipolar setup, the module does have a slightly different
module setup. See Chapter 2.3 Configuring the Module for Operation to determine the details in module
setup.
Wiring
The wiring of the output connector is the same between the modules. See Chapter 2.5. Wiring the Output
Connector for a detailed explanation of how this is accomplished.
If the module is used to supply voltage, the requirements of the input voltage to the module (20-30VDC)
remains the same in order to supply the resistive load of the field device (>1000Ω). However, the
maximum load resistance for current output drops to 600Ω at 20VDC and then climbs linearly to 1000Ω
at 24-30VDC.
Also noteworthy is the isolation achieved module to module with the same power supply by using the
CTI 2562 versus the Siemens® modules. With the 2562, each module is dielectrically isolated from a
common 24V power supply.
PLC Reporting
The word format is the same between the modules. See Chapter 1.3 for a more detailed explanation on
PLC reporting.
Power Cycling
When the user power is supplied and the base power is transitioning on, the 2562 has the option to either
transition to hold the last output value until the next PLC update, as the Siemens® modules do, or to go to
zero until the next PLC update. See section 2.3.5. Selecting Either Zero or Last Value Output at Power
Up for further details.
CTI 2562 Installation and Operation Guide
25
APPENDIX B: JUMPER SETTINGS LOG SHEET
Channel
Number
1
2
3
4
5
6
7
8
Voltage Range
Jumper
JP28
JP6
JP2
JP12
JP8
JP4
JP10
JP14
Jumper Position
All
Channels
1-8
Offset Mode
Jumper
Offset Mode
Jumper Position
JP40
5V or 10V
Unipolar/Bipolar
Jumper
JP24
JP5
JP1
JP11
JP7
JP3
JP9
JP13
Jumper Position
Outputs at Power
Up Jumper
Outputs at Power
Up Jumper Position
Uni or Bi
JP25
Record the configuration jumper settings on this log for future reference. Make additional copies if
necessary.
CTI 2562 Installation and Operation Guide
27
LIMITED PRODUCT WARRANTY
CTI warrants that this CTI Industrial Product shall be free from defects in material and workmanship
for a period of one (1) year after purchase from CTI or from an authorized CTI Industrial Distributor.
This CTI Industrial Product will be newly manufactured from new and/or serviceable used parts
which are equal to new in the Product.
Should this CTI Industrial Product fail to be free from defects in material and workmanship at any
time during this (1) year warranty period, CTI will repair or replace (at its option) parts or Products
found to be defective and shipped prepaid by the customer to a designated CTI service location along
with proof of purchase date and associated serial number. Repair parts and replacement Product
furnished under this warranty will be on an exchange basis and will be either reconditioned or new.
All exchanged parts or Products become the property of CTI. Should any Product or part returned to
CTI hereunder be found by CTI to be without defect, CTI will return such Product or part to the
customer.
This warranty does not include repair of damage to a part or Product resulting from: failure to
provide a suitable environment as specified in applicable Product specifications, or damage caused
by an accident, disaster, acts of God, neglect, abuse, misuse, transportation, alterations, attachments,
accessories, supplies, non-CTI parts, non-CTI repairs or activities, or to any damage whose
proximate cause was utilities or utility like services, or faulty installation or maintenance done by
someone other than CTI.
Control Technology Inc. reserves the right to make changes to the Product in order to improve
reliability, function, or design in the pursuit of providing the best possible Product. CTI assumes no
responsibility for indirect or consequential damages resulting from the use or application of this
equipment.
THE WARRANTY SET FORTH ABOVE IN THIS ARTICLE IS THE ONLY WARRANTY CTI
GRANTS AND IT IS IN LIEU OF ANY OTHER IMPLIED OR EXPRESSED GUARANTY OR
WARRANTY ON CTI PRODUCTS, INCLUDING WITHOUT LIMITATION, ANY WARRANTY
OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE AND IS IN LIEU
OF ALL OBLIGATIONS OR LIABILITY OF CTI FOR DAMAGES IN CONNECTION WITH
LOSS, DELIVERY, USE OR PERFORMANCE OF CTI PRODUCTS OR INTERRUPTION OF
BUSINESS, LOSS OF USE, REVENUE OR PROFIT. IN NO EVENT WILL CTI BE LIABLE
FOR SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES.
SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR
CONSEQUENTIAL DAMAGES FOR CONSUMER PRODUCTS, SO THE ABOVE
LIMITATIONS OR EXCLUSIONS MAY NOT APPLY TO YOU.
THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE
OTHER RIGHTS WHICH MAY VARY FROM STATE TO STATE.
CTI 2562 Installation and Operation Guide
29
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 office at 1-800-537-8398.
When returning any module to CTI, follow proper static control precautions. Keep the module away
from polyethylene products, polystyrene products and all other static producing materials. Packing
the module in its original conductive bag is the preferred way to control static problems during
shipment. Failure to observe static control precautions may void the warranty. For additional
information on static control precautions, contact CTI's office at 1-800-537-8398.
CTI 2562 Installation and Operation Guide
31
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