Control Technologies 2553 Operating instructions

CTI 2553 TWO CHANNEL
ISOLATED MAG METER INPUT MODULE
INSTALLATION AND OPERATION GUIDE
Version 2.4
CTI Part #062-00120-024
2553IOG 092205 $25

CTI 2553 Installation and Operation Guide iii
Copyright © 2005 Control Technology Inc.
All rights reserved.
This manual is published by Control Technology Inc., 5734 Middlebrook Pike, Knoxville, TN 37921.
This manual contains references to brand and product names which are tradenames, trademarks, and/or
registered trademarks of Control Technology Inc. Siemens® and SIMATIC® are registered trademarks
of Siemens AG. Other references to brand and product names are tradenames, trademarks, and/or
registered trademarks of their respective holders.
DOCUMENT DISCLAIMER STATEMENT
Every effort has been made to ensure the accuracy of this document; however, errors do occasionally
occur. CTI provides this document on an "as is" basis and assumes no responsibility for direct or
consequential damages resulting from the use of this document. This document is provided without
express or implied warranty of any kind, including but not limited to the warranties of merchantablility
or fitness for a particular purpose. This document and the products it references are subject to change
without notice. If you have a comment or discover an error, please call us toll-free at 1-800-537-8398.

iv CTI 2553 Installation and Operation Guide

CTI 2553 Installation and Operation Guide v
Figure 1 The Model 2553 2-Channel Isolated MAG METER Input
PREFACE
This Installation and Operation Guide provides installation and operation instructions for the
CTI 2553 Two Channel Isolated MAG METER Module for SIMATIC® 505 Series 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 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.

vi CTI 2553 Installation and Operation Guide

CTI 2553 Installation and Operation Guide vii
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.
USAGE CONVENTIONS

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CTI 2553 Installation and Operation Guide ix
TABLE OF CONTENTS
PREFACE ................................................................... v
USAGECONVENTIONS....................................................... vii
TABLEOFFIGURES ......................................................... xi
CHAPTER1. DESCRIPTION.................................................... 1
1.1 AsynchronousOperation ............................................... 1
1.2 OperatingModes ..................................................... 1
1.2.1 NormalCountMode........................................... 1
1.2.2 N-ToothCountMode .......................................... 2
1.3DigitalWordMap..................................................... 2
1.4 Overrange/UnderrangeReporting ......................................... 3
1.5Resolution........................................................... 3
CHAPTER2. INSTALLATION .................................................. 5
2.1 PlanningtheInstallation ................................................ 5
2.2 CalculatingtheI/OBasePowerBudget .................................... 5
2.3UnpackingtheModule.................................................. 5
2.4 ConfiguringtheModule ................................................ 6
2.4.1 Selecting Normal Count Mode or N-Tooth Count Mode . . . . . . . . . . . . . . . . . 7
2.4.2 Selecting the Number of Teeth on the Wheel (N-Tooth Mode Only) . . . . . . . . 7
2.4.3 Selecting the Frequency or Period Reporting . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4.4SelectingDigitalFiltering........................................ 7
2.4.5 Selecting Input Signal Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4.6OpenCollectorConditioning ..................................... 8
2.4.7 Standard Shipping Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.5InsertingtheModuleintotheI/OBase...................................... 9
2.6WiringtheInputConnectors ............................................ 10
2.6.1ConnectingtheShieldWiring.................................... 11
2.7CheckingModuleOperation ............................................ 13
CHAPTER3. TROUBLESHOOTING............................................. 15
SPECIFICATIONS............................................................ 17
LIMITEDPRODUCTWARRANTY .............................................. 19
REPAIRPOLICY............................................................. 21

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CTI 2553 Installation and Operation Guide xi
TABLE OF FIGURES
Figure 1 The Model 2553 2-Channel Isolated MAG METER Input ........................ v
Figure 2 Word Map ............................................................ 2
Figure 4 Overrange/Underrange Truth Table ........................................ 3
Figure 3 Overrange/Underrange Bits ............................................... 3
Figure 5 Jumper Locations ...................................................... 6
Figure 6 Dip Switch Settings ..................................................... 7
Figure 7 Jumper Locations ....................................................... 8
Figure 8 Open Collector Selection ................................................. 8
Figure 9 Open Collector External Device ............................................ 9
Figure 10 Input Connectors ..................................................... 10
Figure 11 Shield Wire Termination ................................................ 11
Figure 12 Typical Wiring Diagram ............................................... 12
Figure 13 Typical Application ................................................... 12
Figure 14 I/O Configuration .................................................... 13

xii CTI 2553 Installation and Operation Guide

CTI 2553 Installation and Operation Guide 1
CHAPTER 1. DESCRIPTION
The Two Channel MAG METER Input Module is a member of Control Technology's family of I/O
modules compatible with the SIMATIC® 505 Series programmable controllers. The Model 2553 is
designed to measure the frequency or period of Mag Meter or Turbine Meter pulses and convert the
frequencies into equivalent digital words which are then sent to the programmable controller (PLC).
1.1 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 inputs in one module
update (7 mSec - in normal pulse count mode) and store the translated words in a buffer memory. The
PLC retrieves the stored words from the module buffer memory at the start of the I/O scan.
1.2 Operating Modes
1.2.1 Normal Count Mode
In normal count mode, the 2553 precisely measures the amount of time between teeth (or blades) of the
device being monitored. Normal count mode uses a measurement technique called "Reflex Counter" to
achieve the high accuracy and high speed of the measurement. A reflex counter is basically an auto-
ranging counter. Each input channel consists of an incoming pulse counter, a 5 MHz clock counter and
appropriate gating and reset circuits. The following paragraph describes a typical measurement.
The first incoming pulse enables both the pulse counter and 5 MHz clock counter. The 2553 counts
pulses and clocks until the clock counter is half full. On the next pulse input, the 2553 computes the
frequency based on the number of 5 MHz clock pulses counted and the number of incoming pulses
counted and outputs the value to the PLC. The frequency is derived by the following formula:
Number of Input Pulses x Clock Frequency (Hz)
Frequency (Hz) =
Number of Clock Counts

2CTI 2553 Installation and Operation Guide
Figure 2 Word Map
If an overflow is detected on the incoming pulse counter, the overrange/underrange bit will be set and
65535 will be reported to the PLC (see Section 1.4). If an overflow is detected on the 5 MHz clock
counter, the overrange/underrange bit will be set and 0 will be reported to the PLC (see Section 1.4).
1.2.2 N-Tooth Count Mode
In N-Tooth count mode, the 2553 measures the amount of time of a full revolution of the wheel (based
on the number of teeth entered in dip switch). The N-Tooth count mode is useful for compensating for
errors introduced by wheel wobble (an effect that occurs when the wheel being measured is not
perfectly round). Each input channel consists of an incoming pulse counter, a 5 MHz clock counter, a
scaling dip switch, and appropriate gating and reset circuits. The following paragraph describes a
typical measurement.
The first incoming pulse enables both the pulse counter and 5 MHz clock counter. The 2553 counts
pulses and clocks until the pulse counter overflows. The 2553 computes the frequency based on the
number of 5 MHz clock counts and the value entered in the dip switch (see Section 2.4.2).
1.3 Digital Word Map
Frequencies or period measurements are translated into a 16-bit digital word. The following figure
shows the bit positions and magnitudes in a typical digital word.

CTI 2553 Installation and Operation Guide 3
NOTE:
A failed pickup or an open circuit may be detected by examining the data register and the
overrange/underrange bit. If both are zero then there is no longer any input signal on the 2553
connector.
Figure 4 Overrange/Underrange Truth Table
Figure 3 Overrange/Underrange Bits
1.4 Overrange/Underrange Reporting
With no frequency input, the 2553 will report 0 in the data register (see Figure 2). The
overrange/underrange bit (see Figure 3) will be set to 0.
For frequencies under 76 Hz, the 2553 will report 0 in the data register (see Figure 2). The
overrange/underrange bit (see Figure 5) will be set to 1.
For frequencies between 76 Hz and 65535 Hz, the 2553 will report the correct frequency (or period if
set for period mode) in the data register (see Figure 2). The overrange/underrange bit (see Figure 4)
will set to 0.
For frequencies over 65535 Hz, the 2553 will report 65535 in the data register (see Figure 2). The
overrange/underrange bit (see Figure 5) will be set to 1.
1.5 Resolution
The 2553 has a resolution of ±1 Hz.

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CTI 2553 Installation and Operation Guide 5
CAUTION:
HANDLING STATIC SENSITIVE DEVICES
The components on the Model 2553 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.
CHAPTER 2. INSTALLATION
The installation of the Two Channel MAG METER Input Module involves the following steps:
1. Planning the installation
2. Configuring the module
3. Inserting the module into the base
4. Wiring the module input connector
5. Checking module operation
The steps listed above are explained in detail in the following pages.
2.1 Planning the Installation
Planning is the first step in the installation of the module. This involves calculating the I/O base power
budget and routing the input signal wiring to minimize noise. The following sections discuss these
important considerations.
2.2 Calculating the I/O Base Power Budget
The 2553 requires 2.5 watts of +5V power from the I/O base. Use this figure to verify that the base
power supply capacity is not exceeded.
2.3 Unpacking the Module
Open the shipping carton and remove the special anti-static bag which contains the module.

6CTI 2553 Installation and Operation Guide
Figure 5 Jumper Locations
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.
2.4 Configuring the Module
The Model 2553 must be configured to operate in normal counting mode or N-Tooth counting mode.
The module must also be configured to report the measurements in "Frequency" or "Period" and digital
filtering/no filtering mode before inserting the module into the I/O base. As shipped, the module is
configured for normal counting mode, "Frequency" and digital filtering disabled
(see Figure 5).
Changing the module input channel configuration involves the following steps:
1. Select Normal or N-Tooth Counting mode for each channel.
2. Select the number of teeth on the wheel (N-Tooth mode only).
3. Select frequency or period measurement for the module.
4. Select digital filtering or no filtering for the module.
5. Select proper input signal conditioning.
Each of these steps is described in the following sections.

CTI 2553 Installation and Operation Guide 7
Figure 6 Dip Switch Settings
2.4.1 Selecting Normal Count Mode or N-Tooth Count Mode
Locate the Normal/N-Tooth jumpers (see Figure 5). Each channel can be independently configured for
either counting mode. Jumper JP3 is used for channel 1, jumper JP4 is used for channel 2.
2.4.2 Selecting the Number of Teeth on the Wheel (N-Tooth Mode Only)
Dip switches SW1 and SW2 are used to tell the module how many teeth are on the wheel being
measured. For proper internal scaling in the module, enter 1 less than the number of teeth on the
wheel. Dip switch SW1 is used for channel 1, dip switch SW2 is used for channel 2.
2.4.3 Selecting the Frequency or Period Reporting
Locate the Period/Frequency jumper JP2 (see Figure 5). To select frequency measurement, set the
jumper in the FREQ position. To select period measurement, set the jumper in the PERIOD position.
2.4.4 Selecting Digital Filtering
Locate the Digital Filtering jumper JP1 (see Figure 5). To enable digital filtering, set the jumper in the
ENABLED position. Since many signals have timing jitter, CTI recommends using digital filtering
unless maximum response is required.
2.4.5 Selecting Input Signal Conditioning
Each of the inputs of the Model 2553 may be configured to support bipolar, positive pulse, negative
pulse or open collector applications. Jumpers JP5 for Channel 1 and JP7 for Channel 2 allow each
channel to be independently configured.

8CTI 2553 Installation and Operation Guide
Figure 7 Jumper Locations
Figure 8 Open Collector
Selection
-P, Negative Pulse: Devices that generate a negative pulse between ground and a negative voltage.
+P, Positive Pulse: Devices that generate a positive pulse between ground and a positive voltage.
BP, Bipolar: Devices that generate a sinusoidal or bipolar (square wave) output.
2.4.6 Open Collector Conditioning
Each input channel may be driven by an external device with open collector output drive. Jumpers JP8
and JP9 are used to configure the input channels for open collector operation.