Control Technologies 2600XM User manual
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This document is current as of the following revision levels:
Controller Firmware - 2.0
Controller Hardware - C
This guide contains installation and applications information for the model 2600 M Automation Con-
troller. The Model 2600 M has a flexible plug-in architecture, which supports a variety of modules, and
comes in two sizes:
The 2600 M-5, the base model, containing slots for five modules and a plug-in CPU
The 2600 M-10, containing slots for ten modules and a plug-in CPU
You program the 2600 M controller using CTCs state programming language, Quickstep for Win-
dows. You run all programming and diagnostic functions for the controller using an RS-232 interface,
which you can also use as a computer communications port.
This guide is divided into the following sections:
Specifications ............................................................................................................................................... 2
Dimensions and Mounting Instructions for the Model 2600 M ................................................................. 3
Inserting Modules into the Controller .......................................................................................................... 4
Model 2600 M Power Connections ............................................................................................................ 6
Connecting AC Power............................................................................................................................ 6
Using Step-down or Isolation Transformers .......................................................................................... 6
The Importance of Proper Grounding .................................................................................................... 6
The Controllers Power System ............................................................................................................. 7
Using External Power Supplies ............................................................................................................. 7
Status Light Description ............................................................................................................................... 8
Setting-up Controller Communications ........................................................................................................ 9
Using the RS-232 Port for Controller Communications ........................................................................ 9
Using Ethernet for Controller Communications .................................................................................. 11
Control Technology Corporation, 25 South Street, Hopkinton, MA 01748
© 2000 Control Technology Corporation
All Rights Reserved. Printed in USA
Doc. No. 2600 M-IG
Rev. C 6/00
Model 2600XM
Automation
Controller Installation Guide
Control
Technology
Corporation
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2Model 2600XM Controller Installation Guide
Temperature Ratings Min Typ Max
Ambient Temperature
operating 0 50 ºC
storage -20 80 ºC
AC Power Supply Requirements Min Typ Max
AC Voltage Range
120 Volt mode 90.0 120.0 132 VAC
240 Volt mode 190.0 240.0 264.0 VAC
Current Requirements
120 Volt mode 0.1 0.9 Amp AC
240 Volt mode 0.05 0.45 Amp AC
Internal Power Supply Capacities Min Typ Max
+5 Volt Logic Supply
Current Capability 3.0 Amp DC
CPU Requirement 0.2 0.25 Amp DC
+24 Volt I/O Supply
Current Capability (continuous) 1.5 Amp DC
Controller Resource Summary
Multi-Tasking (number of tasks) 28
Volatile Registers (32-bit) 488
Non-Volatile Registers (32-bit) 500
Data Table Elements (16-bit, Nonvolatile) 8000
Input-linkable Counters 8
Flags 32
Program Steps 1024
Controller Capacities * 2600 M-5 2600 M-10
Module Slot Capacity 5 10
Inputs 128 320
Outputs 120 320
Analog Inputs 64 160
Analog Outputs 40 80
Thumbwheels
4-digit 16 16
8-digit 8 8
Numeric Displays
4-digit 16 16
8-digit 8 8
Stepping Motor Axes 5 10
Servo Motor Axes 10 16
Relay Outputs 40 80
RS-232 Channels 1 1
For controller performance specifications and information on individual modules, refer to their respec-
tive data sheets and installation and applications guides.
* Not mutually inclusive.
Specifications
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3
Control Technology Corporation
Control Technology Corporation proprietary, Reproduction or distribution forbidden.
The Model 2600 M Automation Controller is provided with mounting ears, allowing
them to be easily mounted to a flat surface (for example, an NEMA-rated electrical
enclosure) with four mounting bolts. You should follow the guidelines described in this
installation guide to ensure a successful design.
Mounting Considerations
When selecting a mounting location for the controller, care should be taken to provide
protection against various environmental factors:
The controller should not be exposed to flying metal chips (be careful during instal-
lation and subsequent machine construction work!), conductive dusts, liquids or
condensing humidity. In environments where these hazards may be present, the
controller should be housed in a NEMA 4 or NEMA 12 rated enclosure, as appropri-
ate.
The controller is not intended for mounting in an environment requiring explosion-
proof practices.
If possible, the controller should be mounted physically distant from devices produc-
ing Electromagnetic Interference (EMI) or Radio Frequency Interference (RFI).
This includes motor starters, relays, large power transformers, ultrasonic welding
apparatus, etc.
Dimensions and Mounting Instructions for the Model 2600XM
On
Power
I/O Supply
Fuse
115V-1A.
230V-1/2A
Control Technology Corporation
Model 2600 Automation Controller
COMM FAULT
2203
1
5
9
13
I
N
P
U
T
S
1
5
9
13
O
U
T
P
U
T
S
16IN/16OUT
Logic Supply
2600F1
Side View
Overall Length (including mounting ears):
5 slot model - 10.9 in. (276.9 mm)
10 slot model - 15.9 in. (403.9 mm)
Mounting Dimensions:
5 slot model - 10.3 in. (261.6 mm)
10 slot model - 15.3 in. (388.6 mm)
5.8 in. (147.3 mm)
4.0 in. (101.6 mm)
5.4 in. (137.2 mm)
Allow 1.5 in. (38.1 mm) clearance
for power connector
24V Buss
24V (Internal)
24V Return
Power Switch
Indicators:
+5 Volts
+24 Volts
Fuse Holder
AC Line Cord
Connector
(See Side View)
RS-232
Connector
Line Voltage
Selector Switch
AC Power Input
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Model 2600XM Controller Installation Guide
Inserting Modules into the Controller
The Model 2600 M controller accepts a variety of plug-in modules. You insert the
modules into one of the slots of your Model 2600 M controller. Any combination of
modules, subject to system limits, may be inserted into the controller.
You may insert modules in any order; the controllers CPU dynamically assigns motor
number, input number, output numbers, etc., each time power is reapplied to the control-
ler. These numbers are assigned from left to right across the controller, from slot one to
slot ten in a Model 2600 M-10.
To install a module into the controller:
1. Remove all AC and DC power to the controller. This includes any external power
supplies connected to the controller.
2. Remove the retaining screws from the top and bottom of the cover plate at the
location where you are inserting the new module. Save these screws to reinstall the
new module.
3. To orient the module properly, make sure the labeling on the module reads right-side
up. See illustration on page 2.
4. Slide the module into the slot, insuring that the circuit board slides into the nylon
guides at the top and bottom of the slot.
5. Press the module firmly into the controller. When properly seated, the faceplate of
the module is flush with the adjacent sheet metal surface.
6. Reinstall the retaining screws in the top and bottom of the new module.
7. Wire the module according to the instructions in its installation guide.
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5
Control Technology Corporation
Control Technology Corporation proprietary, Reproduction or distribution forbidden.
Some modules provide one or more connectors on their faceplates. To keep their wires
from becoming accidently unplugged and from tangling together, CTC manufactures a
bracket to hold the wires. The Model 2699 bracket attaches to the controller as shown
below. Once the bracket is installed, you can attach connector wires to it.
1. Remove the retaining screws from the top of the module. Save these screws to
secure the bracket.
2. Place the bracket on the controller, making sure you line up the holes on the bracket
with the holes for the retaining screws.
3. Reinstall the retaining screws.
4. Wire the module according to the instructions in its installation guide.
5. Use tywraps to fasten the wires to the holes in the bracket.
Retaining Screw
Retaining Screw
2600-2
2700-2
The Model 2699 bracket requires an additional 2 in of clearance for the front of the
controller.
Inserting Modules into the Controller
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6Model 2600XM Controller Installation Guide
Connecting AC Power
The Model 2600 M contains an internal power supply which provides two mutually-
isolated voltages (+5 VDC and +24 VDC) for the operation of the controller. Also
included are two LED indicators for these voltages and a power ON-OFF switch.
The controllers power supply requires AC power, either 120 VDC or 240 VAC nominal
for proper operation. Power is applied to the controller via the standard IEC-type power
connector on the side of the controller. A US-standard three-prong power cord is pro-
vided with the controller for this purpose.
The supply voltage required is determined by a voltage selector on the side of the unit
(see diagram below). A fuse of the appropriate rating must also be installed in the fuse
holder on the front of the controller.
Voltage Range Fuse
120 VAC 90-132 1 Amp
240 VAC 190-264 1/2 Amp
Using Step-down or Isolation Transformers
When using a step-down or isolation transformer to supply power to the controller, be
aware of the following potential issues, all of which are drawn from experience:
Step-down transformers are typically derive 120 VAC from much higher voltage
lines that are also being used to power heavy equipment. Often, when motors are
first energized in heavy equipment, the stall currents that result can cause the voltage
supplied to the step-down transformer to drop by as much as 50%. Because step-
down transformers are ratio-metric devices, the voltage supplied to the controller
drops proportionately, causing a potential system malfunction.
The relatively light load imposed by the controller on the transformer secondary may
result in excessive voltage being present, representing a potential hazard to the
system.
Neither type of transformer represents ideal protection against electrical noise.
Inter-winding capacitances can result in noise transference among windings, and
differential noise may still be electromagnetically coupled to the secondary.
Adequate grounding of the controller is still critical to its proper performance. For
more information, see the section on The Importance of Proper Grounding.
These issues often point to the use of an independent power feed (120 or 240 VAC) for
the controller and associated components. The resulting additional stability and design
integrity are often well worth the slight additional cost.
The Importance of Proper Grounding
The controller is outfitted with an integral line filter to protect against electrical noise
carried on the AC power line. This line filter, along with the shielding provided by the
controller enclosure itself, depend on the presence of a good ground connection for
effectiveness. This is normally accomplished by connecting the controllers power cord
to a well-grounded outlet.
As with any electronic equipment, the controllers ground should follow a direct, low-
impedance path to the plants power source. If possible, this path should not be shared
by any machinery which injects a large amount of electrical noise into the ground.
In instances where step-down or isolation transformers are being used to power the
controller, the ground connection should still be made directly to the controller.
For further consideration regarding noise protection, refer to the Application Note,
Reducing Noise Susceptibility. Application notes may be obtained at no charge from
your distributor or directly from CTC.
Model 2600XM Power Connections
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7
Control Technology Corporation
Control Technology Corporation proprietary, Reproduction or distribution forbidden.
The Controllers Power S stem
The controllers power system provides two operating voltages, electrically isolated
from one another:
+5 VDC: Powers the controllers internal circuitry, including the CPU and the
logic-level circuitry on the various modules.
+24 VDC: Available with a current capacity of up to 1.0 Amp (maxium), to power
external control devices, such as solenoid valves, relays, sensors. You can also use
this power supply with some modules to power circuitry on the outbound side of any
on-board isolation.
The +5 V supply is not usually made available at any of the module connectors.
NOTE: Do not make any external connections to either the +5 V power supply or its common, as
an increased susceptibility to electrical noise may result.
Using External Power Supplies
Many of the modules available for this series of controllers allow the use of an external
power supply for powering actuators and other devices, in place of using the controllers
+24 V supply. The individual installation guides for these modules provide additional
details in this regard.
Pin 1 -
Pin 2 -
Pin 3 -
External 24 VDC connector
backplane 24 VDC input
internal +24 VDC supply
source
backplane and 24 VDC
supply common
2700-5
It is possible to connect an external +24 V power supply (with a capacity not in excess
of 10 Amps) to the controllers backplane, taking the place of the controllers internal
+24 V supply. A nylon 3-pin connector is provided on the side of the controller for this
purpose. This connector, as supplied by CTC, is fitted with a mating plug wired with a
jumper. The jumper carries +24 V from the internal power supply to the I/O power bus
extending across the controllers backplane.
If you remove the jumper plug, you may use the connector to attach an external power
supply to the I/O power bus and to the I/O common, pins 1 and 3. An extra mating
connector with pins is included with each controller, or you can order a plug with a
pigtail wires (Model 2885) from CTC for this purpose.
WARNING: Do not connect an external supply with a voltage rating other than +2 V to this connec-
tor, as potential incompatibilities may exist with the modules installed in the controller.
Consult CTC for further information.
Model 2600XM Power Connections
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8Model 2600XM Controller Installation Guide
Status Light Description
The status light on the Model 2600 M can indicate one of the following conditions:
Software fault: A periodic flashing light on the 2600 M indicates a program
software fault. This means the controller was unable to execute due to an applica-
tion problem within the program. To determine what type of software fault has
occurred, you can view the program status using Quickstep for Windows program
monitoring utility, CTCMON.
If a program software fault occurs, the controller is idle and all setable resources,
such as outputs, registers or flags, are left in the state they were in prior to the
software fault. You can program register 13009 to turn off a specific output in the
event of a software fault. Refer to the list of special purpose registers for more
information.
Hardware fault: A steady red light indicates that the internal watch dog timer has
disabled the controllers CPU. If this occurs, the controllers outputs are also
disabled. Try cycling the power, re-downloading your Quickstep program, or both.
If the fault continues, your controller may have to be returned to Control Technology
Corp. for repair. For further details, contact our Technical Support department
before returning your controller.
When powering-up the controller, the status light is a steady red light during the first
second of operation.
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9
Control Technology Corporation
Control Technology Corporation proprietary, Reproduction or distribution forbidden.
Your controller can be set up to communicate with a computer or with other controllers
through an RS-232 port or on an Ethernet network.
Using the RS-232 Port for Controller Communications
The RS-232 port on your Model 2600 M controller provides a means for both program-
ming and data communications via a personal computer using Quickstep. The controller
is also equipped with a built-in protocol allowing direct computer communications with
the controllers RS-232 port. This protocol is described in the Guide to CTC Serial Data
Communications available in the customer section of our web site. It allows an external
computer to directly interact with many of the controllers resources such as, counters,
registers, I/O, flags, without modifying the controllers program.
You can also use RS-232 communications when monitoring a controller using
CTCMON.
RS-232 Connections
Connections to the controllers RS-232 port is made via a
modular jack on the controller (labelled COMM). This jack
carries the receive signal, two commons (ground), and the
transmit signal for the communications channel. The pin
connection diagram illustrates the wiring of the jack. Only the
center four connectors of a six- or eight-conductor jack are used.
A series of standard CTC cables are available for making
connections to this jack. See the illustrations below and on the
following page. As an alternative, many commonly-available
telephone cables may be substituted.
NOTE: Do not connect the controller to a telephone line.
Connecting to a D Connector
RS-232 ports on computers are frequently brought out through 25- or 9-pin D type
connectors. There is a standard for wring such connectors followed by most PC
manufacturers.
Communications cable:
Model 2881 - 5 feet
Model 2882 - 15 feet
Model 2883 - 25 feet
Personal computer with RS-232
asynchronous communications board
D-connector to modular Jack adapter:
Model 2280A for 25-pin D-connectors
Model 2280B for 9-pin D-connectors
Controller's COMM port
2600-3
On
Power
I/O Supply
Fuse
115V-1A.
230V-1/2A
COMM FAULT
2203
1
5
9
13
I
N
P
U
T
S
1
5
9
13
O
U
T
P
U
T
S
16IN/16OUT
Logic Supply
Setting-up Controller Communications
165432
2600P1
1 - +5 VDC
2 - TxD Outbound
3 - Common
4 - Common
5 - RxD Inbound
6 - Ground
Modular Jack
Pin Connections
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10 Model 2600XM Controller Installation Guide
Control tech has adapters available that connect directly to a male 25-pin (Model
2880A) or 9-pin (2880B) D connector. These adapters provide a modular jack wired for
compatibility with the COMM port. To be fully compatible when using this adapter, the
computers communications port should be wired as a DTE device.
1
2
3
4
5
6
7
8
Tx
Comm
Rx
1
2
3
4
5
6
7
8
9
Rx
Tx
Modular Jack DB-9 Connector
Black
Yellow Red Common
DB9-232
1
2
3
4
5
6
7
8
Tx
Comm
Rx
1
2
3
4
5
6
7
8
9
Rx
Tx
Modular Jack DB-25 Connector
Black
Yellow Red Common
DB25-232
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
Common
Comm
Green
Setting-up Controller Communications
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11
Control Technology Corporation
Control Technology Corporation proprietary, Reproduction or distribution forbidden.
Setting-up Controller Communications
Using Ethernet for Controller Communications
Your 2600XM controller can access an ethernet network for controller-computer com-
munications using a Model 2217 or 2717 Ethernet Module. he 2217 or 2717 contains
both 10/100Base connections, as well as two RS-232 ports. he connections to the
controller Ethernet port use Ethernet IEEE 802.3 standard 10Base connections. For
additional information about setting up Ethernet communications, refer to the installa-
tion and applications guide for the 2217 or 2717 modules.
he following illustration shows computer-controller connections using an Ethernet
connection and list the part numbers for 10Base2 connectors.
Personal computer connected
to Ethernet network 2600XM-5 Controllers
containing Model 2217
Ethernet module
Ethernet Hub
Ethernet connection
computer Ethernet connection
to controllers
2600-4
On
Power
I/O Supply
Fuse
115V-1A.
230V-1/2A
COMM FAULT
2203
1
5
9
13
I
N
P
U
T
S
1
5
9
13
O
U
T
P
U
T
S
16IN/16OUT
Logic Supply
On
Power
I/O Supply
Fuse
115V-1A.
230V-1/2A
COMM FAULT
2203
1
5
9
13
I
N
P
U
T
S
1
5
9
13
O
U
T
P
U
T
S
16IN/16OUT
Logic Supply
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