Control Technology Inc. CTI 2559-TC Operating instructions

CTI 2559-TC
EIGHT POINT THERMOCOUPLE MODULE
INSTALLATION AND OPERATION GUIDE
Version 1.1
CTI Part #
062-00336-011
*062-00336-010*
2559TCIOG $25

CTI 2559-TC 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. 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 8/14/02 Original Release
Version 1.1 9/23/04 Changed manual to reflect changes in scaling operation

CTI 2559-TC Installation and Operation Guide
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PREFACE
This Installation and Operation Guide provides installation and operation instructions for the CTI
2559-TC Eight-Point Thermocouple Input Model for SIMATIC® 505 programmable controllers. We
assume you are familiar with the operation of SIMATIC® 505 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 2559-TC and the Siemens®505-7028-A.
The Model 2559-TC 8-Pt Thermocouple 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
PREFACE...........................................................................................................................................................V
USAGE CONVENTIONS..............................................................................................................................VII
TABLE OF CONTENTS.................................................................................................................................IX
TABLE OF FIGURES.....................................................................................................................................XI
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. J, K, T, E, R, S, N, and mV Thermocouples..............................................................................................2
1.5. Digital Word Map......................................................................................................................................2
1.6. Thermocouple Input to Digital Conversion...............................................................................................2
1.7. Effect of Out-of-Range Input Signals........................................................................................................4
1.8. Additional Error Codes..............................................................................................................................6
1.9. Resolution..................................................................................................................................................6
CHAPTER 2. INSTALLATION .......................................................................................................................9
2.1. Planning the Installation............................................................................................................................9
2.2. Unpacking the Module ............................................................................................................................10
2.3. Configuring the Module ..........................................................................................................................11
2.4. Inserting the Module into the I/O Base....................................................................................................13
2.5. Wiring the Input Connectors ...................................................................................................................13
2.6. Installing the Screw Terminal Connector................................................................................................16
2.7. Calibration of the Module........................................................................................................................17
2.8. Checking Module Operation ...................................................................................................................17
CHAPTER 3. TROUBLESHOOTING...........................................................................................................19
HARDWARE SPECIFICATIONS .................................................................................................................21
APPENDIX A. COMPATIBILITY WITH SIEMENS®505-7028-A.........................................................23
APPENDIX B. JUMPER SETTINGS LOG SHEET.....................................................................................25
APPENDIX C. THERMOCOUPLE WIRE GUIDE.....................................................................................27
LIMITED PRODUCT WARRANTY.............................................................................................................29
REPAIR POLICY.............................................................................................................................................31

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TABLE OF FIGURES
Figure 1.1 CTI 2559-TC Front Panel....................................................................................................1
Figure 1.2 Word Input to the PLC from the Module ............................................................................2
Figure 1.3 Example Change in Input Level ..........................................................................................3
Figure 1.4 Effect of Voltage Input on Type J Thermocouple...............................................................4
Figure 1.5 Effect of Voltage Input on Type K Thermocouple..............................................................4
Figure 1.6 Effect of Voltage Input on Type T Thermocouple..............................................................5
Figure 1.7 Effect of Voltage Input on Type E Thermocouple..............................................................5
Figure 1.8 Effect of Voltage Input on Type R Thermocouple..............................................................5
Figure 1.9 Effect of Voltage Input on Type S Thermocouple ..............................................................5
Figure 1.10 Effect of Voltage Input on Type N Thermocouple............................................................5
Figure 1.11 Effect of Voltage Input on Type mV Input........................................................................6
Figure 1.12 Error Codes........................................................................................................................6
Figure 1.13 Input Resolution ................................................................................................................7
Figure 2.1 Shipping Jumper Configuration Locations........................................................................11
Figure 2.2 Configuration Jumper Board Locations.............................................................................12
Figure 2.3 Screw Terminal Connector Wiring....................................................................................14
Figure 2.4 Thermocouple wiring application......................................................................................15
Figure 2.5 Millivolt wiring application...............................................................................................15
Figure 2.6 Thermocouple type and wire descriptions.........................................................................15
Figure 2.7 Shield Wire Termination ...................................................................................................16
Figure 2.8 Input Connector Assembly................................................................................................17
Figure 2.9 Example I/O Configuration Chart......................................................................................18
Figure 3.1 Troubleshooting Matrix.....................................................................................................19

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CHAPTER 1. OVERVIEW
1.0. Product Summary
The CTI 2559-TC Eight-Point Thermocouple 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 a J, K, T, E, R, S, N thermocouple or millivolt input signals from the thermocouple element
into an equivalent digital word which is then sent to the programmable controller (PLC).
1.1. Front Panel Description
Figure 1.1 CTI 2559-TC 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
The 2559-TC utilizes a modified 505 connector (a standard 505 connector is NOT interchangeable –
see section 2.5 for details) to provide wiring terminals for Channels 1-8 thermocouple inputs and two
temperature (cold junction compensation) sensors. The wiring connector accepts 14-22 AWG wire.
CHANNELS 1 - 8
ACTIVE LED
TEMPERATURE
SENSOR A
TEMPERATURE
SENSOR B

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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 thermocouple
inputs in one module update (9 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 2559-TC has been tested and is fully compatible with the immediate input instruction for the
TI545 and 555 PLCs.
1.4. J, K, T, E, R, S, N, and mV Thermocouples
Each of the module’s 8 channels may be configured to receive either J, K, T, E, R, S, N, or mV
thermocouple input signals. Selection of thermocouple type or millivolts is made via internal dip
switch settings and hardware jumpers (see Section 2.3 Configuring the Module).
1.5. Digital Word Map
Thermocouple and/or millivolt signals are translated into a 15-bit plus sign digital word. Since the
PLC requires a 16-bit input word, the 15-bit value from the converter is placed into a 16-bit word for
transmittal to the PLC, the extra bit being used to show the sign of the word.
Figure 1.2 Word Input to the PLC from the Module
1.6. Thermocouple Input to Digital Conversion
1.6.1. Engineering Units
When module SCALING is disabled, data is reported as engineering units to the PLC as follows:
Thermocouple Mode, digital word (WX) = Degrees x 10
Millivolt Mode, digital word (WX) = -10,000 to +10,000

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As an example, the following Figure 1.3 illustrates the effects of a change in input level going from 0
to 102.4oF in the Thermocouple Input Mode.
Example 1: 0.0oF = (Digital Word (WX))/10
MSB LSB
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
. . . . . . . . . .
32 16 8 4 2 1
Example 2: 102.4oF = (Digital Word (WX))/10
MSB LSB
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0
. . . . 1024 . . .
32 16 8 4 2 1
Figure 1.3 Example Change in Input Level
1.6.2. Scale Units
When data format is selected as SCALING enabled the full temperature range of the thermocouple is
scaled as an unsigned integer from 0 to 32000 for thermocouple units or –32,000 to +32,000 for mV
units (range of +/-55mV). The following formulas may be used to calculate the scaled integer value
for temperature and mV.
Temperature: Scaled Integer = (measured temp - min temp) / (max temp - min temp) x 32000
example: the scaled integer offset at 0oC for a Type J thermocouple is:
Scaled integer = (0 - (-210)) / (760 - (-210)) x 32000 = 6928
example: the scaled integer overrange at 770oC for a Type J thermocouple is:
Scaled integer = (770 - (-210)) / (760 - (-210)) x 32000 = 32330
mV: Scaled Integer = mV x (32,000 ÷ 55)
example: the scaled integer offset at 20 mV is:
Scaled Integer = 20 x (32,000 ÷ 55) = ~11636.36
The table below shows the scaling temperature ranges of each probe type.
Temperature Range
Probe Type oC oF
J -210 to 760 -346 to 1400
K -220 to 1320 -364 to 2408
T -230 to 400 -382 to 752
E -240 to 700 -400 to 1292
R 0 to 1768 32 to 3214
S 0 to 1768 32 to 3214
N -200 to 1300 -328 to 2372

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1.7. Effect of Out-of-Range Input Signals
The 2559-TC utilizes the underrange and overrange codes of 32766 and 32765, respectively, to
indicate when a channel has reached individual limits. Thermocouple inputs exceeding the ANSI
standard for the different types of thermocouples (listed on the following pages in Figures 1.4-1.11)
will cause the overrange value, 32765, to be displayed and the maximum temperature for that
thermocouple type to be returned. Open thermocouples report temperatures that are out of the
allowable range. This condition may occur due to failure of the thermocouple or due to the
thermocouple wire being cut or disconnected. The 2559-TC will report an open thermocouple
condition within 200 milliseconds.
NOTE:
The 2559-TC uses the overrange error code, 32765, to indicate an open thermocouple. An open
thermocouple condition will report within 200 milliseconds.
Figure 1.4 Effect of Voltage Input on Type J Thermocouple
Figure 1.5 Effect of Voltage Input on Type K Thermocouple

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Figure 1.6 Effect of Voltage Input on Type T Thermocouple
Figure 1.7 Effect of Voltage Input on Type E Thermocouple
Figure 1.8 Effect of Voltage Input on Type R Thermocouple
Figure 1.9 Effect of Voltage Input on Type S Thermocouple
Figure 1.10 Effect of Voltage Input on Type N Thermocouple

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Figure 1.11 Effect of Voltage Input on Type mV Input
1.8. Additional Error Codes
In addition to input underrange and overrange error codes (see previous section 1.7.), there exists
two other error codes to be aware of, namely the temperature sensor bad and math overflow codes.
The ‘temperature sensor bad’ code is reported to the PLC when either of the two temperature sensors
encapsulated in front panel connector goes bad. This is a rare occurrence, but would yield code
32,761 if it does occur.
The math overflow code of 32,763 occurs when the thermocouple type mV and SCALE modes are
chosen, and the units tries to report a value under –32,000.
The following chart summarizes the 2559-TC error codes:
Error Code Error Comment; Corrective Action
32761 Bad Temperature Sensor(s) A temperature sensor (s) in front panel connector
is faulty/defective; call CTI for replacement 2559-
TC connector, P/N: 2559-FPC.
32763 Math Overflow Low end range of mV/SCALE exceeded; Check
process to determine if input is actually low.
Determine if mV transmitter is defective.
32765 Channel Overrange Input level is above normal input range (see
Figures 1.4-1.11 for each thermocouple type);
Check process to determine if input is actually
high or if the transmitter is defective.
32766 Channel Underrange Input level is above below input range (see Figures
1.4-1.11 for each thermocouple type); Check
process to determine if input is actually low or if
the transmitter is defective.
Figure 1.12 Error Codes
1.9. Resolution
The module has a resolution of approximately 0.1oC, 0.1oF or exactly .01 millivolts.
The chart below shows the corresponding input resolution per step for each of the input
configuration modes:

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Units Input Resolution / Step
Temp: oC ~0.05oC
Temp: oF ~0.09oF
Millivolts 0.0017 millivolts
Figure 1.13 Input Resolution