CTI 2550 Operating instructions

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CTI 2550 EIGHT CHANNEL
ISOLATED ANALOG INPUT MODULE
INSTALLATION AND OPERATION GUIDE
Version 2.0
CTI Part #062-00102
2452IOG 092205 $25
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ii CTI 2550 Installation and Operation Guide
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CTI 2550 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.
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iv CTI 2550 Installation and Operation Guide
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CTI 2550 Installation and Operation Guide v
Figure 1 The Model 2550 8-Channel Isolated Analog Input Module
PREFACE
This Installation and Operation Guide provides installation and operation instructions for the CTI
2550 Eight Channel Isolated Analog Input Module for SIMATIC® 505 programmable controllers.
We assume you are familiar with the operation of the SIMATIC® 505 programmable controllers.
Refer to the appropriate SIMATIC® 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.
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vi CTI 2550 Installation and Operation Guide
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CTI 2550 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 2550 Installation and Operation Guide ix
TABLE OF CONTENTS
PREFACE .................................................................. v
USAGECONVENTIONS....................................................... vii
TABLEOFFIGURES ......................................................... xi
CHAPTER1. DESCRIPTION................................................... 1
1.1FrontPanelDescription................................................ 1
1.1.1ActiveLED ................................................. 1
1.1.2InputConnectorforChannels1-4................................. 2
1.1.3InputConnectorforChannels5-8................................. 2
1.2AsynchronousOperation ............................................... 2
1.3UnipolarorBipolarMode .............................................. 2
1.4VoltageorCurrentMode............................................... 2
1.5DigitalWordMap.................................................... 2
1.6AnalogtoDigitalConversion............................................ 3
1.6.1UnipolarModeConversion ..................................... 3
1.6.2BipolarModeConversion ...................................... 5
1.6.3ExampleConversion .......................................... 6
1.7EffectofOut-of-RangeInputSignals...................................... 7
1.8UsingtheModulewith20%Offset ....................................... 9
1.9Resolution.......................................................... 9
CHAPTER2. INSTALLATION ................................................ 11
2.1PlanningtheInstallation .............................................. 11
2.1.1 Calculating the I/O Base Power Budget . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1.2InputSignalWiring .......................................... 11
2.2UnpackingtheModule................................................ 12
2.3ConfiguringtheModule............................................... 13
2.3.1 Selecting Voltage or Current Input Mode . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.3.2SelectingVoltageRange ...................................... 14
2.3.3 Selecting Unipolar or Bipolar Input Mode . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.3.4SelectingDigitalFiltering...................................... 15
2.4InsertingtheModuleIntotheI/OBase.................................... 16
2.5WiringtheInputConnectors ........................................... 16
2.5.1 Connecting Voltage Input Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.5.2 Connecting Current Input Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.6InsertingtheScrewTerminalPlug ....................................... 17
2.7CheckingModuleOperation ........................................... 18
CHAPTER3. TROUBLESHOOTING............................................ 19
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xCTI 2550 Installation and Operation Guide
SPECIFICATIONS ........................................................... 21
JUMPERSETTINGSLOGSHEET .............................................. 23
USERNOTES .............................................................. 25
LIMITEDPRODUCTWARRANTY ............................................. 27
REPAIRPOLICY ............................................................ 29
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CTI 2550 Installation and Operation Guide xi
TABLE OF FIGURES
Figure 1 The Model 2550 8-Channel Isolated Analog Input Module ...................... v
Figure 2 2550 Front Panel ...................................................... 1
Figure 3 Word Input to the PLC from the Module (Unipolar) ........................... 3
Figure 4 Word Input to the PLC from the Module (Bipolar) ............................. 3
Figure 5 Maximum Non-Overrange Word Value (Unipolar) ............................ 4
Figure 6 Minimum Non-Underrange Word Value (Unipolar) ............................ 4
Figure 7 Maximum Non-Overrange Word Value (Bipolar) .............................. 5
Figure 8 Minimum Non-Underrange Word Value (Bipolar) ............................. 6
Figure 9 Example of Change in Input Level ......................................... 6
Figure 10 Voltage Input Limits (Unipolar) .......................................... 7
Figure 11 Voltage Input Limits (Bipolar) ........................................... 7
Figure 12 Overrange Word Value (Unipolar) ....................................... 8
Figure 13 Underrange Word Value (Unipolar) ...................................... 8
Figure 14 Overrange Word Value (Bipolar) ......................................... 8
Figure 15 Underrange Word Value (Bipolar) ........................................ 9
Figure 16 Input Resolution .................................................... 10
Figure 17 Factory Configuration Jumper Settings ................................... 14
Figure 18 Configuration Jumper Locations ........................................ 15
Figure 19 Screw Terminal Plug Wiring ........................................... 16
Figure 20 Input Connector Wiring ............................................... 17
Figure 21 Example I/O Configuration Chart ....................................... 18
Figure 22 Troubleshooting Matrix ............................................... 19
Figure 23 Jumper Settings Log ................................................. 23
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CTI 2550 Installation and Operation Guide 1
Figure 2 2550 Front Panel
CHAPTER 1. DESCRIPTION
The Eight Channel Analog Input Module is a member of Control Technology's family of I/O modules
compatible with the SIMATIC® 505 programmable controllers. The Model 2550 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
1.1.1 Active LED
The active LED will be illuminated when the module is functioning normally. If the Active LED is not
lit, refer to Chapter 3 for troubleshooting.
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2CTI 2550 Installation and Operation Guide
1.1.2 Input Connector for Channels 1-4
This connector provides wiring terminals for channels 1-4.
1.1.3 Input Connector for Channels 5-8
This connector provides wiring terminals for channels 5-8.
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 (2 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 Unipolar or Bipolar Mode
The module may be configured to accept either bipolar or unipolar input signals. Selection of unipolar
or bipolar mode is made via two internal jumpers (see Section 2.3.3).
1.4 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).
1.5 Digital Word Map
A unipolar analog input signal is translated into a 12-bit plus sign bit digital word. A bipolar input
signal is translated into an 11-bit digital word plus 1-bit for the polarity sign. Since the PLC requires a
16-bit input word, the 12-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 four bits not used for the digital word, one is used to
show the sign of the word, one is used to note values which are “overrange”, and the remaining bits are
not used and are set to zero.
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CTI 2550 Installation and Operation Guide 3
Figure 3 Word Input to the PLC from the Module (Unipolar)
Figure 4 Word Input to the PLC from the Module (Bipolar)
As shown in the following figure, of the four bits not used for the digital word, one is used to show the
sign of the word, one is used to note values which are “overrange”, and the remaining bits are not used
and are set to zero.
1.6 Analog to Digital Conversion
1.6.1 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:
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4CTI 2550 Installation and Operation Guide
Figure 5 Maximum Non-Overrange Word Value (Unipolar)
Figure 6 Minimum Non-Underrange Word Value (Unipolar)
0 to 5V Input Range Mode, Digital Word (WX) = Input voltage (V) x 32000 ÷ 5 volts
Note: Maximum digital word (WX) is +32,761 for voltages > 5.11V
0 to 10V Input Range Mode, Digital Word (WX) = Input voltage (V) x 32000 ÷ 10 volts
Note: Maximum digital word (WX) is +32,761 for voltages > 10.23V
0 to 20 mA Input Range Mode, Digital Word (WX) = Input current (mA) x 32000 ÷ 20 mA
Note: Maximum digital word (WX) is +32,761 for current > 20.47mA
The following figures show the bit conditions for the maximum and minimum non-overrange values in
unipolar mode:
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CTI 2550 Installation and Operation Guide 5
Figure 7 Maximum Non-Overrange Word Value (Bipolar)
1.6.2 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 +5V Input Range Mode, Digital Word (WX) = + Input voltage (V) x 32000 ÷ 5 volts
Note: Maximum digital word (WX) is +32,753 for voltages > 5.11V
Minimum digital word (WX) is -32,767 for voltages <-5.12V
-10 to +10V Input Range Mode, Digital Word (WX) = + Input voltage (V) x 32000 ÷ 10 volts
Note: Maximum digital word (WX) is +32,753 for voltages > +10.23V
Minimum digital word (WX) is -32,767 for voltages < -10.24V
-20 to +20 mA Input Range Mode, Digital Word (WX) = + Input current (mA) x 32000 ÷ 20 mA
Note: Maximum digital word (WX) is +32,753 for current > +20.46mA
Minimum digital word (WX) is -32,767 for current < -20.47mA
The following figures show the bit conditions for the maximum and minimum non-overrange values in
bipolar mode:
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6CTI 2550 Installation and Operation Guide
Figure 8 Minimum Non-Underrange Word Value (Bipolar)
Figure 9 Example of Change in Input Level
1.6.3 Example Conversion
As an example, the following figure illustrates the effects of a change in input level going from 1.25 to
2.5 mV in the 0 to 5V Unipolar Input Mode. (For the 0 to 10V and 0 to 20mA Unipolar Input Modes,
or the Bipolar Modes, refer to the formulas given in Sections 1.6.1 and 1.6.2 to determine the digital
word which results from a particular input.)
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CTI 2550 Installation and Operation Guide 7
Figure 10 Voltage Input Limits (Unipolar)
Figure 11 Voltage Input Limits (Bipolar)
1.7 Effect of Out-of-Range Input Signals
In Unipolar Mode, when the analog signal exceeds the positive limit, the translated digital word will
exceed 32000 to a maximum of +32760 (See Figure 5). Above this point the overrange bit will be set
giving an overrange reading of +32761 (See Figure 12).
Signals falling below the lower limits in 0 to 5V Input Mode or 0 to 10V Input Mode are translated
into a digital word equivalent to -1 (See Figure 13). Note that although the digital word may approach
zero as the analog input signal approaches the minimum for a given range, the digital word will never
actually be 0 (See Figure 6). Thus, in the 0 to 5V Input Mode, input signals below the 0.00125V
minimum result in a translated digital word of -1 (all 1's). Similarly, in the 0 to 10V Input Mode, input
signals below the 0.00250V minimum are translated into a digital word equivalent to -1 (all 1's).
In Bipolar Mode, when the analog input signal is outside the normal operating range, the translated
digital word will exceed 32000 to a maximum of +32753 for positive going signals or -32767 for
negative going signals. The following figure shows the effects of excessive voltage on the module. See
Figures 7 and 8 for maximum and minimum bipolar word values. See Figures 14 and 15 for overrange
and underrange bipolar word values.
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