CTC Union 2203 User manual

[phone] | [email protected] | artisantg.com
-~
ARTISAN
®
~I
TECHNOLOGY
GROUP
Your definitive source
for
quality
pre-owned
equipment.
Artisan Technology
Group
Full-service,
independent
repair
center
with
experienced
engineers
and
technicians
on staff.
We
buy
your
excess,
underutilized,
and
idle
equipment
along
with
credit
for
buybacks
and
trade-ins
.
Custom
engineering
so
your
equipment
works
exactly as
you
specify.
•
Critical
and
expedited
services
•
Leasing
/
Rentals/
Demos
• In
stock/
Ready-to-ship
•
!TAR-certified
secure
asset
solutions
Expert
team
ITrust
guarantee
I
100%
satisfaction
All
tr
ademarks,
br
a
nd
names, a
nd
br
a
nd
s a
pp
earing here
in
are
th
e property of
th
e
ir
r
es
pecti
ve
ow
ner
s.
Find the Control Technology 2203 at our website: Click HERE

Copyright © 2001 - 2007 Control Technology Corporation.
All Rights Reserved.
Printed in USA.
1
5
9
13
1
5
9
13
16IN / 16OUT
2203
I
N
P
U
T
S
O
U
T
P
U
T
S
Model 2203 Combination 16 Input / 16
Output Module Installation Guide
Doc. No. 2203IG
Revision C
July 2007

Control Technology Corporation proprietary. Reproduction or distribution forbidden.
The information in this document is subject to change without notice. The software described in this
document is provided under license agreement and may be used or copied only in accordance with the
terms of the license agreement.
The information, drawings, and illustrations contained herein are the property of Control Technology
Corporation. No part of this manual may be reproduced or distributed by any means, electronic or
mechanical, for any purpose other than the purchaser’s personal use, without the express written consent of
Control Technology Corporation.
The following are trademarks of Control Technology Corporation:
• Quickstep
• CTC Monitor
• CTC Utilities
Windows is a trademark of Microsoft Corporation.

iii
Control Technology Corporation proprietary. Reproduction or distribution forbidden.
Notes to Readers ................................................................................................. 1
Related Documents ........................................................................................ 2
Formatting Conventions ................................................................................. 2
Contacting Control Technology Corporation .................................................. 3
Your Comments ............................................................................................. 3
System Overview ................................................................................................. 5
Self-Powered Inputs ....................................................................................... 5
Open-Collector Outputs .................................................................................. 5
2203 Description .................................................................................................. 6
2203 Connection Diagrams .................................................................................. 7
Specifications ....................................................................................................... 8
Board Handling Precautions ............................................................................... 10
Installing the 2203 Module ................................................................................. 11
Connecting a Digital Input .................................................................................. 12
Using Solid-State Sensors ........................................................................... 12
Connecting Digital Outputs ................................................................................. 14
Using Open-Collector Outputs ..................................................................... 14
Connecting Multiple Devices ........................................................................ 16
Connecting to a Second External Supply ..................................................... 16
Contents

Contents
iv
Control Technology Corporation proprietary. Reproduction or distribution forbidden.
This page is intentionally left blank.

1
Control Technology Corporation proprietary. Reproduction or distribution forbidden.
The Model 2203 Installation Guide provides the following information:
• System Overview -- describes the 2203’s basic features.
• Description and Connection Diagrams -- an overview of the 2203’s basic functions; pinout
diagrams for its input and output connectors.
• Specifications -- general specifications; hardware and firmware revision levels.
• Board Handling Precautions-- contains general guidelines on handling printed circuit
boards with ESD devices.
• Installation -- describes how to install the 2203 module in a CTC controller.
• Applications Guide -- contains technical information on the 2203’s input and output
features.
Notes to Readers

2
Control Technology Corporation proprietary. Reproduction or distribution forbidden.
Notes to Readers
Related Documents
The following documents contain additional information:
• For information on Quickstep, refer to the QuickstepTM Language and Programming Guide
or the QuickstepTM User Guide.
• For information on the registers in your controller, refer to the Register Reference Guide
(available at www.ctc-control.com).
• For information on Microsoft Windows or your PC, refer to the manuals provided by the
vendor.
Formatting Conventions
The following conventions are used in this book:
ALL CAPS BOLDFACE Identifies DOS, Windows, and installation program
names.
Boldface Indicates information you must enter, an action you
must perform, or a selection you can make on a dialog
box or menu.
Italics Indicates a word requiring an appropriate substitution.
For example, replace filename with an actual file name.
Text_Connected_With_Underlines Indicates symbolic names used in Quickstep programs.
Step Names are ALL_CAPITALS. Other symbolic
names can be Initial_Capitals or lower_case.
SMALL CAPS Identifies the name of Quickstep instructions in text.
Courier font Identifies step names, comments, output changes, and
Quickstep instructions appearing in the Quickstep edi-
tor.
Art Code Identifies the file name of a particular graphic image.
2217F
1
2217F
1

3
Control Technology Corporation proprietary. Reproduction or distribution forbidden.
Model 2203 Combination 16 Input / 16 Output Module Installation Guide
Contacting Control Technology Corporation
Control Technology Corporation is located in Massachusetts. Our business hours are
8:30 AM to 5:00 PM. EST (Eastern Standard Time).
Your Comments
Suggestions and comments about this or any other Control Tech document can be e-mailed to
the Technical Publications Group at [e-mail].
Contact Method Address or Number
E-Mail:
Technical Support: [e-mail]
Technical Publications: [e-mail]
Website: www.ctc-control.com
Telephone: [phone] and 800.282.5008
FAX: [phone]
Mail: Control Technology Corporation
25 South Street
Hopkinton, MA 01748

4
Control Technology Corporation proprietary. Reproduction or distribution forbidden.
Notes to Readers
This page is intentionally left blank.

5
Model 2203 Combination 16 Input / 16 Output Module Installation Guide
Control Technology Corporation proprietary. Reproduction or distribution forbidden.
System Overview
The Model 2203 I/O module has 16 digital input and output channels. Self-powered inputs
make it easy to interface with many types of sensors and open-collector outputs can drive
solenoid valves and similar loads. The controller’s +24 V supply is available on each I/O
channel for supplying power to output devices and electronic sensors used on the 2203’s
inputs. Each channel also has an independent LED status indicator that simplifies
troubleshooting and setup.
Self-Powered Inputs
The module’s 16 input channels are self-powered. Each input is resistively pulled-up to the
controller’s 24V supply and is activated by an external switch closure to the common for this
supply. This feature allows easy connection to such components as Hall-effect sensors,
proximity sensors (when outfitted with sinking outputs), external electronic sensors that
possess open-collector outputs, and mechanical switches.
Open-Collector Outputs
The module’s 16 output channels are open-collectors and can accommodate many types of 24
VDC load devices. To use these outputs, connect one side of each load device to +24 V and
connect the other side to the open-collector output. When the output is activated under pro-
gram control, it switches to common, completes the circuit, and actuates the device. This
makes it easy to interface with loads such as solenoid valves, indicator lights, small motors,
and motor installers. The current level is limited to 500 mA/output and a total limit of 5A for
the module.

Control Technology Corporation
6
Control Technology Corporation proprietary. Reproduction or distribution forbidden.
2203 Description
Figure 1 shows the 2203’s faceplate and describes its different features.
Figure 1. 2203 Faceplate and Features
1
5
9
13
1
5
9
13
16IN / 16OUT 2203F2
2203
I
N
P
U
T
S
O
U
T
P
U
T
S
Module Extraction Handle (2 places) - Do not detach!
Digital Input Connector - Provides access to 16
digital inputs. Connection accessories include a
Model 2276 pigtail cable, which consists of a mating
connector with 6-foot unterminated wires. Alternatively,
you can create your own cable with an AMP housing
(PN 1-87733-8) and contacts (PN 1-87523-6). You
can also use a 3M ribbon cable connector(PN 3414-6000)
to mate with this connector.
Digital Output Connector - Provides access to 16
digital inputs. Connection accessories include a
Model 2275 pigtail cable, which consists of a mating
connector with 6-foot unterminated wires. Alternatively,
you can create your own cable with an AMP housing
(PN 1-87733-4) and contacts (PN 1-87523-6). You
can also use a 3M ribbon cable connector(PN 3399-6000)
to mate with this connector.
LED Indicators- Each
digital input and output
has an LED indicator.
An LED indicator lights
up when its associated
input or output is active.

7
Model 2203 Combination 16 Input / 16 Output Module Installation Guide
Control Technology Corporation proprietary. Reproduction or distribution forbidden.
2203 Connection Diagrams
Table 1. Connection Diagram - Digital Input Connector
Digital Input Connector Pin # Signal Pin # Signal
1 Input 1 2 Return
3 Input 2 4 Return
5 Input 3 6 Return
7 Input 4 8 Return
9 Input 5 10 Return
11 Input 6 12 Return
13 Input 7 14 Return
15 Input 8 16 Return
17 Input 9 18 Return
19 Input 10 20 Return
21 Input 11 22 Return
23 Input 12 24 Return
25 Input 13 26 Return
27 Input 14 28 Return
29 Input 15 30 Return
31 Input 16 32 Return
33 +24 VDC 34 Return
Table 2. Connection Diagram - Digital Output Connector
Digital Output Connector Pin # Signal Pin # Signal
1 Output 1 2 Output 14
3 Output 2 4 Output 15
5 Output 3 6 Output 16
7 Output 4 8 Return
9 Output 5 10 Return
11 Output 6 12 Return
13 Output 7 14 Return
15 Output 8 16 No pin
17 Output 9 18 +24 VDC
19 Output 10 20 +24 VDC
21 Output 11 22 +24 VDC
23 Output 12 24 +24 VDC
25 Output 13 26 NC
Pin 1 Pin 2
Pin 33 Pin 34
2647P1
Pin 1 Pin 2
Pin 25 Pin 26
2647P2

Control Technology Corporation
8
Control Technology Corporation proprietary. Reproduction or distribution forbidden.
Specifications
Table 3. Digital I/O Specifications
Description Min. Typical Max. Units
Absolute Maximum Ratings
Ambient Temperature
Operating 0+50°C
Storage -20 +80 °C
Applied input voltage 10 27.0 VDC
Applied output voltage 20 24.0 VDC
Output current
Single output 500 mA DC
Total limit 5A
Operating Characteristics
Output on voltage (Io= 500 mA) 0.8 1.8 VDC
Output off leakage (applied voltage = 24V) 3200 µA
Input off voltage (Ii= 0 mA) 24.0 26.4 VDC
Input on current (Vi= 0 V) -2.10 -2.85 mA
Input on current threshold (Vi= 8 V typical) -1.0 -1.85 mA
Input off current
(typical leakage current allowable) -250 µA
Power Requirements (from controller) 4
Logic supply (5 VDC) 135 200 mA
Auxiliary supply (24 VDC) 95 110 mA
1. Under normal operation, no external input voltage is applied. Inputs should be externally switched to the input common.
2. An on-board protection diode returns to +24 V from each output.
3. In the off state, unconnected outputs are internally pulled to +5 V through a diode and an LED indicator.
4. Power requirements are worst-case; all inputs and outputs are activated.
5. Specifications are at 25°C unless otherwise specified.

9
Model 2203 Combination 16 Input / 16 Output Module Installation Guide
Control Technology Corporation proprietary. Reproduction or distribution forbidden.
Table 4. Hardware / Firmware Revision Levels
Model Numbers Hardware Revision Level Firmware Revision Level 12
2203 CN/A
2200 Series 01.0
2600 Series C1.0
2700 Series C2.10
1. You can confirm firmware revision levels by doing a register read in Quickstep’s monitor program. Use register 13003 to
confirm the firmware revision in a 2600/2700 series controller.
2. Firmware revision levels are not equivalent to standard decimal numbers. For example, firmware revision level 2.10
translates to:
Major Revision Level 2
Major Revision Level 10
If this value changes to 2.20, it translates to
:
Major Revision Level 2
Major Revision Level 20 (not revision level 2)

Control Technology Corporation
10
Control Technology Corporation proprietary. Reproduction or distribution forbidden.
Board Handling Precautions
The module’s printed circuit board contains electrostatic discharge sensitive (ESD) devices.
Improper board handling could result in damage to the board. The following precautions are
recommended when handling the board or before inserting it into the controller:
• Make sure you are grounded electrically by using a wrist strap connected to an electri-
cally grounded workstation or by physically touching the controller case or something
electrically connected to the controller case.
• Avoid touching the leads or contacts of the circuit board and handle the board by its
edges only.
• Transport circuit boards in protective, anti-static bags, bins, or totes. Do not insert
boards into materials such as plastic, polystyrene foam, clear plastic bags, bubble
wrap, or plastic trays.

11
Model 2203 Combination 16 Input / 16 Output Module Installation Guide
Control Technology Corporation proprietary. Reproduction or distribution forbidden.
Installing the 2203 Module
The module fits into one of the slots of your automation controller (Figure 1). You can insert
any combination of modules into the controller (subject to system limits) and can install them
in any order. This is possible because the controller’s CPU dynamically assigns such items as
motor numbers, input numbers, and output numbers each time power is re-applied to the con-
troller. These numbers are assigned from left-to-right across the controller. To install a module
into the automation controller:
Note
Retain all hardware removed during this procedure.
1. Remove all AC and DC power, including any external supplies connected to the con-
troller.
2. Locate an unused slot and remove two retaining screws from the top and bottom of its
cover plate.
3. Slide the module into the slot and make sure that the circuit board slides into the nylon
guides at the top and bottom of the controller case. Make sure that the card is oriented
properly so that its labels are right-side-up.
4. Press the module firmly into the controller. Make sure that the module’s faceplate is
flush with the adjacent sheet metal surface.
5. Re-install two retaining screws in the top and bottom of the new module.
Figure 1. 2700 Series Controller with the 2203 module installed in the right-hand slot
2203-1
Retaining Screw
Retaining Screw
2700 Series
Automation
Controller
2203
16IN/16OUT
1
5
9
13
I
N
P
U
T
S
1
5
9
13
O
U
T
P
U
T
S
R2A
CPU
Digital I/O
R1B
+24
O1
In1
Flt
In4
O4
+5
Stat
RS-232
2703AP

Control Technology Corporation
12
Control Technology Corporation proprietary. Reproduction or distribution forbidden.
Connecting a Digital Input
The Model 2203 has 16 digital inputs that you can activate with a switch closure (Figure 2) to
Return (the common for the controller’s 24 V supply). Each input is opto-isolated from the
controller’s logic circuitry and is internally self-powered by the 24 V supply through a
current-limiting resistor.
Figure 2. Digital Input Activation
The controller senses when an input is pulled down to Return by a switch closure. A MONITOR
instruction or any other programmed instruction referring to a general purpose input can use
this information.
Using Solid-State Sensors
You can connect many types of electronic sensors such as three-wire Hall-effect sensors,
proximity sensors, and phototransistors to the inputs without any additional circuitry. These
devices must have sinking type open-collector outputs (NPN) and must be able to withstand at
least +24 V on their output terminals when they are in the OFF state. The sensor must also be
able to sink the required input current (i.e.- 2.1 mA) when ON.
Note
Do not use two-wire, solid-state sensors.
Input
Input
Input
Model 2203
2203-2
Return

13
Model 2203 Combination 16 Input / 16 Output Module Installation Guide
Control Technology Corporation proprietary. Reproduction or distribution forbidden.
Electronic sensors have internal circuitry that generally requires an external power source.
However, if the desired sensor has voltage requirements that equal the controller’s built-in
auxiliary supply (24 V), you can use the controller directly and do not need an external supply.
Figure 3 shows how to connect a solid-state sensor to a digital input.
Figure 3. Connecting a Solid-State Sensor to a Digital Input
Model 2203
Hall-Effect
Sensor
+ 24 VDC
Return
Input
Out
+
-
2203-3

Control Technology Corporation
14
Control Technology Corporation proprietary. Reproduction or distribution forbidden.
Connecting Digital Outputs
This section describes the digital outputs and how to connect devices to these inputs.
Using Open-Collector Outputs
The Model 2203 has 16 outputs for driving external loads such as solenoid valves, indicators,
solid-state relays and other low-power DC loads. These outputs are configured as
open-collector transistors that can switch loads up to 0.5 Amps DC. Open-collector outputs
are transistors whose collector terminal is left unconnected to allow greater flexibility in its
use.
An open-collector output, which is shown in Figure 4, performs roughly the same function as a
switch contact with one side of the switch connected to ground. When the output is turned
OFF, no current can flow through the transistor. This is equivalent to an open switch contact
because the device being controlled is turned OFF.
Note
Control Tech recommends that you place a suppression diode across inductive loads. Use a
1N4004 diode or its equivalent. Locate the diode as close to the load as possible. Refer to
Figure 4 for more information.
Figure 4. Open-Collector Output
When the output is turned on, current flows through the transistor, which is equivalent to a
closed switch contact. The controlled device turns on in response to the flow of current.
Connect a device to an open-collector output by connecting one of the device’s terminals to
the output and the other terminal to the positive side of the power supply. If the device is
polarized, connect its negative [-] terminal to the output.
Do not exceed the rated current of the power supply in use. If this supply is the controller’s
internal power supply, you should check the controller’s specifications for the maximum
current rating of its 24 V power system. This rating must include any current required by the
modules installed in the controller. However, when you calculate your system’s current
Open-Collector
Transistor
Solenoid
Valve
+ 24 VDC
Output
Base
2203-4
Controller with Output Board
Emitter
Collector
Internal 24 VDC
Power Supply
+
-
Internal Protection Diode
1N4004
Diode

15
Model 2203 Combination 16 Input / 16 Output Module Installation Guide
Control Technology Corporation proprietary. Reproduction or distribution forbidden.
requirements, you only need to consider the maximum number of output devices that will be
turned on simultaneously. Refer to Figure 5 if your system’s current requirements exceed the
capacity of the controller’s internal supply or you need a voltage other than 24 V.
Figure 5. External Power Supply Connection Diagram
Note
Do not use an external power supply with an output voltage that exceeds the voltage rating of
the 2203’s outputs.
Caution
Each output has a protection diode with its cathode connected to the +24 VDC power supply
through the input connector. This diode prevents damage to the output when it is connected to
an inductive load. If you use an external supply as shown in Figure 5, a current path exists
between the two supplies through the devices being controlled. Under normal circumstances,
this practice is acceptable. However, some power supplies offer low impedance with respect to
the power supply return when you turn them OFF. For example, in Figure 5, the main supply is
turned OFF and the external supply is ON. Current from the external supply can energize the
device connected to the output and turn it ON.To prevent this situation, make sure that both
supplies are turned ON and OFF at the same time.
Caution
Do not connect the positive [+] terminals of the power supplies together! Damage to one of the
supplies may result. Figure 5 shows the connection between the external supply’s negative
terminal and the output connector’s return terminal. This provides a complete path for the cur-
rent traveling through the device being controlled.
-+
Solenoid Valve
Output
External
Power Supply
Return
2203-5
Controller with Output Board
Internal 24 VDC
Power Supply
+
-
1N4004 Diode