Control Technologies CTI 2554-A Operating instructions

CTI 2554-A FOUR CHANNEL
HIGH SPEED COUNTER MODULE
INSTALLATION AND OPERATION GUIDE
Version 1.0
CTI Part #062-00223
2554-A IOG 13JUL2017 $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
merchantiblility 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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Figure 1 The Model 2554-A Four-Channel High Speed Counter Module
PREFACE
This Installation and Operation Guide provides installation and operation instructions for the CTI
Model 2554-A Four-Channel High Speed Counter Module for SIMATIC® 505 programmable
controllers. We assume you are familiar with the operation of SIMATIC® 505 Series programmable
controllers. Refer to the appropriate SIMATIC® user documentation for specific information on the
SIMATIC® 505 programmable controllers and I/O modules.
This Installation and Operation Guide is organized as follows:
Chapter 1 provides a general description of the module and operating modes.
Chapter 2 covers Mode 3 (General Counter Mode) operation.
Chapter 3 covers installation and wiring.
Chapter 4 covers module configuration.
Chapter 5 is a PLC programming example.
Chapter 6 is a guide to troubleshooting.
Chapter 7 covers Quadrature Mode operation.
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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.
WARNING:
The CTI Model 2554-A High Speed Counter controls its four discrete outputs. If the PLC is
switched from RUN mode to PROGRAM mode the module will continue to function as
programmed and the outputs may be activated by the module.
USAGE CONVENTIONS
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TABLE OF CONTENTS
PREFACE....................................................................... v
USAGECONVENTIONS. ........................................................ vii
TABLEOFFIGURES..............................................................xi
CHAPTER1. DESCRIPTION....................................................... 1
1.1TheoryofOperation...................................................... 1
1.2 Mode 0 - Period Measurement (microseconds). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Mode 1 - Period Measurement (Hz).. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Mode 2 - Frequency Measurement (Hz). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5Mode3-EventCounter................................................... 2
1.6QuadratureCounterMode................................................. 2
1.7 Compatibility with Immediate I/O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.8FrontPanelDescription................................................... 3
CHAPTER2. MODE3OPERATION................................................. 5
2.1ControlWord........................................................... 5
2.1.1 Loading Preset Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2StatusWord. ........................................................... 8
2.3PresetTargetValues. .................................................... 9
2.4AutomaticReset......................................................... 9
2.4.1 Minimum Preset Target Values With Automatic Reset.. . . . . . . . . . . . . . . . . 10
2.5OutputControl......................................................... 11
2.6GatingandReset. ...................................................... 11
CHAPTER3. INSTALLATION.................................................... 13
3.1PlanningtheInstallation.................................................. 13
3.1.1 Calculating the I/O Base Power Budget.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.2UnpackingtheModule................................................... 13
3.3 Inserting the Module into the I/O Base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.4 Wiring the Input Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.4.1 Connecting the Shield Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.4.2 Connecting to the Counter Inputs.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.4.3 Connecting I/O Wiring.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.4.4 Wiring the Gate Inputs:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.4.5 Wiring the Reset Input:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.4.6WiringtheOutputs:............................................. 19
3.5 Checking Module Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
CHAPTER 4. CONFIGURING THE MODULE.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.1 Selecting Counter Mode or Quadrature Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.2InputSignalConditioning. ............................................... 23
4.3 Mode Select Switches and Jumpers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.4 Gate, Reset, and Output Jumpers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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CHAPTER 5. PLC Programming Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.1AProgrammingExample................................................. 29
CHAPTER6. TROUBLESHOOTING................................................ 35
CHAPTER 7. Quadrature Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.1 Quadrature Mode Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.2 Quadrature Data Presentation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.3 Wiring for Quadrature Mode Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
SPECIFICATIONS. .............................................................. 41
LIMITEDPRODUCTWARRANTY................................................. 43
REPAIRPOLICY. ............................................................... 45
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TABLE OF FIGURES
Figure 1 The Model 2554-A Four-Channel High Speed Counter Module..................... v
Figure 2 Module PLC Interface...................................................... 1
Figure 3 Front Panel Description. ................................................... 3
Figure 4 Bit Number Assignments.................................................... 5
Figure 5 Control Word Bit Assignments................................................ 6
Figure 6 Loading Preset Values...................................................... 7
Figure 7 Selecting Input Channel for Target Presets...................................... 7
Figure 8 Status Word Bit Assignments................................................. 8
Figure 9 Minimum Preset Target Value vs. PLC Scan Time ............................... 10
Figure 10 Shield Wire Termination. ................................................. 15
Figure 11 (AC) Sine Wave Counter Inputs............................................. 16
Figure 12 TTL Counter Inputs (Negative Transition). ................................... 16
Figure 13 TTL Counter Inputs (Positive Transition)..................................... 16
Figure 14 Open Collector Counter Inputs............................................. 17
Figure 15 Model 2554-A Wiring Connector............................................ 17
Figure 16 TTL Sourcing Application................................................. 18
Figure 17 Open Collector Sinking Application. ........................................ 18
Figure 18 Wiring the Outputs....................................................... 19
Figure 19 Model 2554-A I/O Configuration Chart...................................... 20
Figure 20 Model 2554-A Counter Mode or Quadrature Mode Jumpers. .................... 22
Figure 21 Model 2554-A Input Signal Conditioning Jumpers. ............................ 23
Figure 22 Model 2554-A Mode Jumpers.............................................. 24
Figure 23 SW1 and SW2 Settings.................................................... 25
Figure 24 Model 2554-A Gate, Reset, and Output Jumpers. .............................. 26
Figure 25 Model 2554-A Default Shipping Configuration................................. 27
Figure 26 Reset and Disable Input Counter Channels.................................... 29
Figure 27 Control Word for Sample Application........................................ 30
Figure 28 Loading Preset Values for Channel 1........................................ 32
Figure 29 PLC Interface........................................................... 38
Figure 30 Quadrature Increment.................................................... 38
Figure 31 Quadrature Decrement. .................................................. 38
Figure 32 Quadrature Wiring Example............................................... 39
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Figure 2 Module PLC Interface
CHAPTER 1. DESCRIPTION
The Model 2554-A Four-Channel High Speed Counter Module is a member of Control Technology's
family of I/O modules compatible with the SIMATIC® 505 Series programmable controllers.
1.1 Theory of Operation
The Model 2554-A High Speed Counter provides four channels which are designed to count input
pulses and translate them into an equivalent digital word. There are several different counting modes
which can be chosen on a per-channel basis. The module operates asynchronously with respect to the
PLC, i.e. a PLC scan and the module's input sampling are concurrent. The Model 2554-A translates
all counter inputs in one module update and stores the translated words in a buffer which the PLC
retrieves at the start of an I/O scan. To provide tight control in applications where this delay is
critical, the Model 2554-A can actuate its outputs based on preset counter values and auto-reset such
as that no input pulses are missed.
Each input channel utilizes a control word WY and a status word WX to interact with the PLC ladder
logic. These interfaces are only used in Mode 3 operation. The control word allows the PLC to start,
stop, configure, and reset the counter channel. Status information such as counter overflow or if a
preset value has been reached is provided to the PLC via the status word. The module logs into the
PLC as 4WX and 4WY registers. The WX registers return either data or status depending on whether
enabled in the control word.
For Modes 0, 1, and 2 (everything except Mode 3), the WY control word for the respective channel
should be 0. This will enable the WX data/status word to report data to the PLC. An 8 in the WY
control word will send status back in the associated WX word. (The status will report the mode
which the channel's jumpers/dip switches are set for, i.e. either a 0, 1, or 2.) Refer to Sections 2.1 and
2.2 for a complete discussion of Control and Status words.
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1.2 Mode 0 - Period Measurement (microseconds)
The period measurement mode provides good accuracy at low frequencies by counting the number of
internal clock cycles between external input pulses. The internal clock is generated by a 1 MHz
crystal oscillator. The data is reported to the PLC as microseconds and represents the period of the
input signal. 17 Hz is the lowest frequency measurable. The accuracy of Mode 0 decreases as
frequency increases. Update time of period mode is 100 milliseconds.
1.3 Mode 1 - Period Measurement (Hz)
Mode 1 operates the same as Mode 0 except that the data is reported as Hertz and represents the
frequency of the input signal.
1.4 Mode 2 - Frequency Measurement (Hz)
For high frequencies (up to 65 kHz input limit), Mode 2 is a better choice than Modes 0 and 1. In
frequency measurement mode, the Model 2554-A counts the number of external input pulses
between internal clock cycles. The internal clock in this mode runs a 1 Hz, therefore the update time
of frequency mode is 1 second. Data is reported to the PLC as Hertz.
1.5 Mode 3 - Event Counter
This is the general counter mode which allows absolute counting of input pulses. The current value
of the counter is updated into the buffer once per PLC scan. See Chapter 2 for a detailed description
of Mode 3.
1.6 Quadrature Counter Mode
The module can also be configured to operate in Quadrature Mode. Modes 0 through 3 are selectable
on a per-channel basis, but Quadrature Mode requires all four channels. Quadrature Mode examines
the phase relationship between two inputs, A and B. If A leads B, the counter will count up. If B
leads A, the counter counts down. This form of operation is useful for incremental encoders.
Channels 1 and 2 correspond to inputs A and B for Quadrature Channel 1. Channels 3 and 4 are A
and B for Quadrature Channel 2. The limitation on counting is +32,767 to -32,767.
1.7 Compatibility with Immediate I/O
The Model 2554-A has been tested and is compatible with the Immediate read function of the
SIMATIC® 545 and 555 PLC.
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Front Panel Description
ACT
The Active LED signifies a normally functioning module. If this is not lit, refer to the Chapter 6
Troubleshooting section.
GATE
There is a Gate LED for each channel which indicates the state of the external gate input. This will
illuminate when a signal greater than a TTL high level is present on the gate input terminal for that
channel. If external gating is selected (see Sections 2.4 and 4.4), the associated channel counter will
be enabled.
RESET
Each channel also has a Reset LED which indicates the state of the external reset input. If the
external level reset is selected (see Sections 2.4 and 4.4), the channel will not count (it is continually
reset) as long as the reset signal is greater than a TTL high level. If external edge reset is selected, the
channel counter will reset to zero when the signal exceeds a TTL high level and then resume
counting even though the LED may still be illuminated.
OUT
The Output LEDs report the state of the channel output circuit. This is the field side of the output,
not the logic side.
PULSE
The Pulse LED will be illuminated when there is a signal present on the logic side of the associated
input. This LED is dependent on the signal conditioning selected (negative, positive, or bipolar).
Refer to Section 4.2.
BF
The Blown Fuse LED will turn on if there is a blown fuse in any of the output circuits. This LED is
common to all four channels. The replacement fuse type is listed in the module specifications in the
back of this manual.
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Figure 4 Bit Number Assignments
NOTE:
Some control word bits are level-sensitive where others are edge-sensitive. An edge-sensitive bit
is only effective on a 0-to-1 transition; a constant 0 or 1 or a transition from 1-to-0 does not
cause ay action to take place. Where a bit is edge-sensitive it will be denoted, otherwise it is
level-sensitive.
CHAPTER 2. MODE 3 OPERATION
2.1 Control Word
The PLC ladder program maintains control over each input channel with a WY register control word.
This word is used to load presets, reset the counter, stop the counter and enable the discrete outputs.
The WY words, e.g. WY5, WY6, WY7, WY8, from the PLC to the module are control words which
program the various options, such as preset values, auto reset, output enable, etc:
The 16-bit word is in the following format:
CTI 2554-A Installation and Operation Guide 5

Figure 5 Control Word Bit Assignments
NOTE:
Bit 5 is only looked at when a reset signal is active. It must be present before an edge-triggered
reset comes active.You do not want to use this bit if the external reset is level-triggered because
the preset will get toggled continuously with no user control over its final state when the reset
signal is removed.
NOTE:
The only edge-sensitive bits are bit 1 (turn output on or off), bit 6 (internal reset),
and bit 7 (clear preset status latch).
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Figure 6 Loading Preset Values
Figure 7 Selecting Input Channel for Target Presets
2.1.1 Loading Preset Values
Preset values are loaded for each channel by setting WY5:14 and addressing the specific channel
with WY5:15 and WY5:16.
WY5:14
Bit 14 of WY5 determines the meaning of the other WY words:
If bit 14 is a 1, then WY6 and WY7 contain the preset values 1 and 2 for the channel number
designated by bits 15 and 16:
If bit 14 is a 0, then WY5 through WY8 are control words for channels 1 through 4, respectively. In
this case, bits 15 and 16 have no meaning.
NOTE:
If bit WY5:14 is a 1, the module ignores all other bits in WY5, and the whole WY8 word.
The following figure illustrates channel addressing with bits WY5:15 and WY5:16.
CTI 2554-A Installation and Operation Guide 7

2.2 Status Word
Under normal operation the count value is returned in the WX register for each input channel. When
enabled a status word is reported. By setting WY:13 to a 1 (assuming WY5:14 is a 0), each channel
can report status to the PLC instead of its current counter value. The first WX word (WX1 in this
manual) corresponds to channel 1, and so on. The status word is used to detect that an input channel
reached a preset value, or if an overflow condition has occurred. The status bit definitions are :
Bit 1 is the underflow flag. In Quadrature Mode a count <-32767 has been detected.
Bit 2 is the counter status: 0 indicates a count <65535, 1 indicates an overflow condition.
Bit 3 reflects the true output state. It will be zero if the output is disabled (WY:12=0) or the hardware
jumper is on "output disable" even if logic is commanding the channel to be on.
Bit 4 indicates that a preset has been reached when the channel is in auto-reset mode. This bit must
be reset from the control word (WY:7).
Bit 5 shows where the counter is with respect to the preset target.
Bit 6 indicates which preset is the current target (the preset value which the microprocessor is
comparing the counter value against).
Bit 7 indicates the direction for counting in Quadrature Mode, 1 indicates upward count.
Bit 8 is a 1 if the counter is inhibited by either the internal or external gate signal.
Bit 9 not used.
Bit 10 indicates that a preset target value has been missed by the counter.
Bit 11 indicates that a preset target value is loaded for the channel. This bit can be examined after
loading presets at start up to verify download procedure.
Bit 12 indicates that the preset latch bit was not cleared by the PLC ladder logic before another
preset condition was reached. This bit is cleared by the control word WY:7.
Bit 13 definition depends on bit 14. If in quadrature mode, it represents the maximum count. If in
counter mode (Modes 0, 1, 2, or 3) it represents the status of the digital filter.
Bit 14 is only used in Quadrature Mode. 1 indicates module is configured for Quadrature operation.
Bits 15 and 16 also depend on bit 14. If it is 0 (counter mode), then they indicate which variety of
counter mode. They return the counter mode, i.e 0, 1, 2 or 3.
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