Control Technologies CTI 2558 Owner's manual

CTI 2558
EIGHT CHANNEL ANALOG INPUT MODULE
INSTALLATION AND OPERATION GUIDE
Version 1.6
CTI Part # 062-00331-016
*062-00331-012*
2558IOG $25

CTI 2558 Installation and Operation Guide
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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. and 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
4/30/01
Original Release
Version 1.1
5/30/01
Add 1 bit of resolution to 16 bit compatibility.
Version 1.2
4/3/03
Add return-common jumpers
Version 1.3
7/8/14
Corrected typo “output” in section 2.3.7
Version 1.4
7/11/14
Replaced connector pinout diagram with a new high-resolution
diagram
Version 1.5
2/7/2017
Fixed Document Title and barcode font
Version 1.6
2/20/2018
Fixed readability of Figures 1.2 –1.17

CTI 2558 Installation and Operation Guide
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PREFACE
This Installation and Operation Guide provides installation and operation instructions for the CTI
2558 Eight Channel Isolated Analog Input Model for SIMATIC® 505 programmable controllers. We
assume you are familiar with the operation of SIMATIC® 505 series programmable controllers.
Refer to the appropriate 505 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 description of the module.
Chapter 2 covers installation and wiring.
Chapter 3 is a guide to troubleshooting.
Appendix A details compatibility between the 2558 and the Siemens505-6108-A and 505-6108-B.
The Model 2558 8-Channel 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 that could damage equipment.
WARNING:
Warnings alert the user to procedures that could damage equipment and endanger the user.

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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. Immediate I/O.................................................................................................................... 2
1.4. Unipolar or Bipolar Mode................................................................................................. 2
1.5. Voltage or Current Mode .................................................................................................. 2
1.6. Using an Input with 20% Offset........................................................................................ 2
1.7. Using the Module with 20% Offset................................................................................... 2
1.8. Digital Word Map: 13 Bit Mode....................................................................................... 3
1.9. Analog to Digital Conversions: 13 Bit Mode ................................................................... 3
1.10. Effect of Out-of-Range Input Signals: 13 Bit Mode....................................................... 4
1.11. Resolution: 13 Bit Mode................................................................................................. 7
1.12. Digital Word Map: 16 Bit Mode..................................................................................... 8
1.13. Analog to Digital Conversions: 16 Bit Mode ................................................................. 8
1.14. Effect of Out-of-Range Input Signals: 16 Bit Mode....................................................... 9
1.15. Resolution: 16 Bit.......................................................................................................... 12
CHAPTER 2. INSTALLATION............................................................................................13
2.1. Planning the Installation.................................................................................................. 13
2.2. Unpacking the Module.................................................................................................... 14
2.3. Configuring the Module.................................................................................................. 15
2.4. Inserting the Module into the I/O Base........................................................................... 19
2.5. Wiring the Input Connectors........................................................................................... 19
2.6. Installing the Screw Terminal Connector........................................................................ 21
2.7. Checking Module Operation........................................................................................... 21
CHAPTER 3. TROUBLESHOOTING..................................................................................23
HARDWARE SPECIFICATIONS........................................................................................25
APPENDIX A. COMPATIBILITY WITH SIEMENS505-6108A/B..............................27
APPENDIX B. JUMPER SETTINGS LOG SHEET............................................................29
LIMITED PRODUCT WARRANTY ...................................................................................31
REPAIR POLICY...................................................................................................................33

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TABLE OF FIGURES
Figure 1.1 CTI 2558 Front Panel..........................................................................................................1
Figure 1.2 13 Bit Word Input to the PLC from the Module .................................................................3
Figure 1.4 13 Bit Overrange Word Value (Unipolar)...........................................................................5
Figure 1.5 13 Bit Underrange Word Value (Unipolar).........................................................................6
Figure 1.6 13 Bit Voltage Input Limits (Bipolar).................................................................................6
Figure 1.7 13 Bit Overrange Word Value (Bipolar).............................................................................6
Figure 1.8 13 Bit Underrange Word Value (Bipolar)...........................................................................7
Figure 1.9 Input Resolution: 13 Bit ......................................................................................................7
Figure 1.10 16 Bit Word Input to the PLC from the Module ...............................................................8
Figure 1.11 16 Bit Voltage Input Limits (Unipolar)...........................................................................10
Figure 1.12 16 Bit Overrange Word Value (Unipolar).......................................................................10
Figure 1.13 16 Bit Underrange Word Value (Unipolar).....................................................................10
Figure 1.14 16 Bit Voltage Input Limits (Bipolar).............................................................................11
Figure 1.15 16 Bit Overrange Word Value (Bipolar).........................................................................11
Figure 1.16 16 Bit Underrange Word Value (Bipolar).......................................................................11
Figure 1.17 Input Resolution: 16 Bit ..................................................................................................12
Figure 2.1 Shipping Jumper Configuration Locations........................................................................16
Figure 2.2 Configuration Jumper Board Locations ............................................................................17
Figure 2.3 Screw Terminal Connector Wiring ...................................................................................19
Figure 2.4 Shield Wire Termination...................................................................................................21
Figure 2.5 Input Connector Assembly................................................................................................21
Figure 2.6 Example I/O Configuration Chart .....................................................................................22
Figure 3.1 Troubleshooting Matrix.....................................................................................................23

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CHAPTER
1.
OVERVIEW
1.0. Product Summary
The CTI 2558 Eight Channel Analog Input Module is a member of Control Technology’s family of
I/O modules compatible with the SIMATIC® 505 programmable controllers. It is designed to
translate an analog input signal into an equivalent digital word which is then sent to the
programmable controller (PLC).
1.1. Front Panel Description
Figure 1.1 CTI 2558 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, or if it is blinking, refer to Chapter 3 for troubleshooting.
1.1.2. Input Connector for Channels 1-8
This connector provides wiring terminals for Channels 1-8 for either voltage or current inputs. The
wiring connector accepts 14-22 AWG wire.
CHANNELS 1 - 8
ACTIVE LED

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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 (5 milliseconds maximum) and store the translated words in buffer memory. The
PLC retrieves the stored words from the module buffer memory at the start of the I/O scan.
1.3. Immediate I/O
The Model 2558 Analog Input Module is fully compatible with the immediate input instruction for
the TI545 and 555 PLCs.
1.4. Unipolar or Bipolar Mode
Each input channel may be configured to accept either bipolar or unipolar input signals. Selection of
unipolar of bipolar mode is made via an internal jumper (see Section 2.3.3).
1.5. Voltage or Current Mode
Each of the module’s eight 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. Using an Input with 20% Offset
Some applications use transducers that provide 1 to 5 volts (4 to 20mA) input signals instead of 0 to
5 volt (0 to 20mA) 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  100 = 20% offset data word
Consult your PLC programming manual (or program design guide) for information about RLL
instructions used in the conversion.
1.7. Using the Module with 20% Offset
If all eight inputs are used in offset mode the Model 2558 may be configured to perform the offset
calculation automatically (see Figure 2.2 Configuration Jumper Board Locations). Jumper JP40
when enabled will configure the module such that all inputs will be scaled for 1-5VDC or 4-20mA
operation. No further relay ladder logic is required for input processing.

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1.8. Digital Word Map: 13 Bit Mode
A unipolar analog input signal is translated into a 13-bit plus sign bit digital word. Since the PLC
requires a 16-bit input word, the 13-bit value from the converter is placed into a 16-bit word for
transmittal to the PLC. 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 and one is used to note values which are “overrange”.
Figure 1.2 13 Bit Word Input to the PLC from the Module
1.9. Analog to Digital Conversions: 13 Bit Mode
1.9.1. 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 +5VDC range Digital Word (WX) = (Input voltage x 32000) 5 volts
example: to generate an input voltage of 2.5 VDC, the WX value input to
the PLC is calculated as follows: WX = (2.5 x 32000) 5 = 16000
0 to +10VDC range Digital Word (WX) = (Input voltage x 32000) 10 volts
example: 7.5VDC input
WX = (7.5 x 32000) 10 = 24000
0 to +20mA range Digital Word (WX) = (Input current x 32000) 20 mA
example: 10mA input
WX = (10 x 32000) 20 = 16000
Note:
Bit 15 is always returned as a zero, and bit 16 is employed as an over/underrange bit. Consequently,
returned data values change by four.

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1.9.2. 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 +5VDC range Digital Word (WX) = (Input voltage x 32000) 5 volts
example: to generate an input voltage of -2.5 VDC, the WX value input
from the PLC is calculated as follows: WX = (-2.5 x 32000) 5 = -16000
-10 to +10VDC range Digital Word (WX) = (Input voltage x 32000) 10 volts
example: 10 VDC input
WX = (10 x 32000) 10 = 32000
-20 to +20mA range Digital Word (WX) = (Input current x 32000) 20 mA
example: -15mA input
WX = (-15 x 32000) 20 = -24000
Note:
Bit 15 is always returned as a zero, and bit 16 is employed as an over/underrange bit. Consequently,
returned data values change by four.
1.10. Effect of Out-of-Range Input Signals: 13 Bit Mode
The Model 2558 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 corresponding change in input signal is called the
overrange or underrange limit of the channel. This level is different for every channel. In Figures 1.3
and 1.6, 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.

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1.10.1. Unipolar Mode
Signals falling below the 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. 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.
Figures 1.4 and 1.5 show the binary values of typical overrange and underrange conditions for
Unipolar mode.
Figure 1.4 13 Bit Overrange Word Value (Unipolar)
Figure 1.3 13 Bit Voltage Input Limits (Unipolar)

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Figure 1.5 13 Bit Underrange Word Value (Unipolar)
1.10.2 Bipolar Mode
In Bipolar Mode signals above or below the upper and lower limits in the -5 to +5 VDC or -10 to
+10 VDC range are translated to a digital word and also utilize the overrange and underrange bit.
The actual limit for each channel will vary from channel to channel as described in the previous
section.
Figure 1.6 13 Bit Voltage Input Limits (Bipolar)
Figures 1.7 and 1.8 show the binary values of typical overrange and underrange conditions for
Bipolar Mode.
Figure 1.7 13 Bit Overrange Word Value (Bipolar)

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Figure 1.8 13 Bit Underrange Word Value (Bipolar)
1.11. Resolution: 13 Bit Mode
The module has a resolution of 4 counts out of 32000. This is the smallest unit into which the
module will divide an input and is 1 part out of 8000. This relationship can be shown as:
4 counts per step
 32000 counts full scale = 1/8000
When using the module with 20% offset, module resolution remains at 4 counts out of 32000, but
offset resolution increases to 5 counts out of 32000 as a result of the multiplication and division of
the incoming data word.
The chart below shows the corresponding input resolution per step for each of the input
configuration modes:
Figure 1.9 Input Resolution: 13 Bit

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1.12. Digital Word Map: 16 Bit Mode
An analog input signal is translated into a 15-bit plus sign bit digital word. Since the PLC requires a
15-bit input word, the 15-bit plus sign value from the converter is placed into a 16-bit word for
transmittal to the PLC. As shown in the following figure one bit is used to show the sign of the
word.
Figure 1.10 16 Bit Word Input to the PLC from the Module
1.13. Analog to Digital Conversions: 16 Bit Mode
1.13.1. 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 +5VDC range Digital Word (WX) = (Input voltage x 32000) 5 volts
example: to generate an input voltage of 2.5 VDC, the WX value input to
the PLC is calculated as follows: WX = (2.5 x 32000) 5 = 16000
0 to +10VDC range Digital Word (WX) = (Input voltage x 32000) 10 volts
example: 7.5VDC input
WX = (7.5 x 32000) 10 = 24000
0 to +20mA range Digital Word (WX) = (Input current x 32000) 20 mA
example: 10mA input
WX = (10 x 32000) 20 = 16000