CTI 2559-TC Eight-Point Thermocouple Module
Contents
1. CHANNEL THERMO JUMPER POSITION DIP SWITCH NUMBER TYPE JUMPER E or J K N mV or R S T SETTING 1 JP6 4 5 2 JP14 12 13 3 JP18 16 17 4 JP22 20 21 5 JP26 24 25 6 JP30 28 29 7 JP34 32 33 8 JP38 36 37 SCALING JUMPER DIGITAL JUMPER TEMP UNITS JUMPER POSITION FILTERING POSITION JUMPER POSITION JP1 JP2 JP3 Record the configuration jumper settings on this log for future reference Make additional copies if necessary NOTE The 2559 TC Thermocouple Input Module is calibrated at the factory No further calibration is required All calibration parameters are stored in non volatile memory There are no user adjustments on this product As shipped there is no jumper required on the CAL input CTI 2559 TC Installation and Operation Guide 25 APPENDIX C THERMOCOUPLE WIRE GUIDE Maximum Useful on EN gt Temperature Range 01 42283 5973 TO 50 53 5 802 lo 17 818 CONSTANTAN OMEGA f D NISIL NONE Thermocougie rade 4 345 lo 47 502 N S 0 200 C Extension Grado PLATINUM Ga NONE T R Al MN C Oto 16741 Extorson Grade BLACK PLATINUM PLATINUM S euo BENE 10 RHCDIUM Pt NONE Ped GREEN AED PLATE Rh NONI PLATINUM PLATINUM B 30 RHODIUM 6 RHODIUM 05012426 IKE Rh Pto Rh gt TUNGSTEN G ESTABLISHED i Van Aen 25 RHENIUM TE W28 Re bela EECHER D ITE NONE SC TUNGSTEN TUNGSTEN ade EB 5 RHENUM 28 RHENIUM gedet ware RD N 53 Re2. eeeeeeeeee esteso es tn sn sosta suse ns tn conoscan conoscan suse seen enses en censos sn sensesen se ZO CTI 2559 TC Installation and Operation Guide ix TABLE OF FIGURES Figure 1 1CTI2559 TC Front Panel iu ee ege Hei 1 Figure 1 2 Word Input to the PLC from the Module 2 Figure 1 3 Example Change in Input Level eese ener 3 Figure 1 4 Effect of Voltage Input on Type J Thermocouple eene 4 Figure 1 5 Effect of Voltage Input on Type K Thermocouple erre 4 Figure 1 6 Effect of Voltage Input on Type T Thermocouple esee 5 Figure 1 7 Effect of Voltage Input on Type E Thermocouple eene 5 Figure 1 8 Effect of Voltage Input on Type R Thermocouple eene 5 Figure 1 9 Effect of Voltage Input on Type S Thermocouple seen 5 Figure 1 10 Effect of Voltage Input on Type N Thermocouple eere 5 Figure 1 11 Effect of Voltage Input on Type mV Input 6 Figure 1 12 Error Codes ie EHER RR 6 Figure 1 13 Input Resolution odia eee SAUREN Eden 7 Figure 2 1 Shipping Jumper Configuration Locations nennen nennen 11 Figure 2 2 Configuration Jumper Board Locations eese nennen nennen 12 Figure 2 3 Screw Terminal Connector Wang 14 Figure 2 4 Thermocouple wiring appltcapon nennen enne enne ens 15 Figure 2 5 Millivolt wiring applicapon re nennen nennen nennen nnne 15 Figure 2 6 Thermocouple type and wire descriptions eese 15 Figure 2 7 Shield Wire Terminati
3. Temperature sensor s damaged Corrective Action Turn base or PLC on Return to CTI for calibration Check program for correct work input addresses Read I O configuration Return the module to CTI for calibration DO NOT ATTEMPT TO CALIBRATE Measure F1 for continuity Short all inputs and verify ambient temperature measurement Select SCALE format with jumper JP1 by placing in EN position Divide value by 10 in PLC Verify position of DIP switch Verify position s of jumpers Order special front panel connector from CTI P N 2559 FPC see section 2 5 1 CAUTION Figure 3 1 Troubleshooting Matrix The module fuse Fl is not user serviceable If this fuse is blown the module has a serious component failure and should be returned to CTI for repair CTI 2559 TC Installation and Operation Guide 19 When it is inconvenient to visually check the status indicator use the TISOFT Display Failed I O or Show PLC Diagnostics support functions If after consulting the chart above you are unable to diagnose the problem contact your local distributor or CTI at 1 800 537 8398 for further assistance 20 CTI 2559 TC Installation and Operation Guide HARDWARE SPECIFICATIONS Input Channels Thermocouple Types Isolation Input Overrange Protection Measurement Ranges Millivolt Input Impedance Data Presentation Measurement Units Digital Filtering Time Const
4. connector via recessed screw terminals The screw terminals can accept wire sizes up to single stranded 14 gauge wire The actual size used depends on the thermocouple wire providing the input signal To assign an input to a specific channel locate the appropriate channel position on the screw terminal connector as shown in the following figure CTI 2559 TC Installation and Operation Guide 13 Temp Sensor A Temp Sensor A SE ot use Not used Ei A N CH 1 IN Not used Not used Spain 2 IN CH 2 IN Not used Not used CH 3 IN CH 3 IN Not used Not used CH 4 1N CH 4 IN l Not used Not used SASi 5 N CH 5 IN Not used Not used CH 6 IN CH 6 IN l Not used Not used Elali 7IN CH 7 IN Temp Sensor B Temp Sensor B CH 8 IN CH 8 IN d Not used Not used Not used Not used Chassis GND Chassis GND Figure 2 3 Screw Terminal Connector Wiring 2 5 1 Understanding the Modified Front Panel Connector In order to provide the most accurate cold junction compensation and to avoid CJC calibration the 2559 TC utilizes a modified front panel connector which has two temperature sensors directly set into the connector These two temperature sensors are encapsulated in connector locations AR AC and DR DC and are not user serviceable NOTE If either of the two temperature sensors fail an error code of 32 761 will be reported to the PLC and the modified connector needs replacing In the unlikely event t
5. other high frequency generators and has determined that the best performance results from connecting all shield wires together at the PLC module and terminating this single wire to the chassis ground with a large current capacity conductor CTI recommends using a 8 gauge wire or larger from the PLC chassis to the earth ground connection CABLE GROUNDING Remove a length of cable Pull the foil shield and bare Twist the foil shield and drain Attach a ground lug jacket from the cable drain wire from the insulated wire together to form a single wires strand Bare drain wire rn EE _ ZZ qr pd g c pee 30 M E Ca e A JU Insulated Foi I wires shield Ji Siemens SIMATIC SIMATIC TI 505 71545 O mo coon q Ow CHASSIS GROUND REMOVE SCREW LOCATED ON SIDE OF RACK AND USE TO 7 CONNECT ALL SHIELD WIRES Si AT THAT POINT a A 5 Star Washer round Lugs o Dm 2 29 Screw d E o 2 EARTH GROUND Figure 2 Shield Wire Lermination 2 6 Installing the Screw Terminal Connector When all the input signal wires are connected to the screw terminal connector carefully install the connector on the front of the module 16 CTI 2559 TC Installation and Operation Guide _7 PRINTED CIRCUIT CARD PCB 7 CAPTIVE SCREWS gt _ TEMP SENSOR A INDIVIDUAL CAPTIVE SCREW IN
6. selection on a per channel basis The jumpers per channel can be set on one of three posts available used to determine thermocouple type The three posts refer to groupings of thermocouple types E J K N mV and R S T Choose the post for the thermocouple type used As shipped each channel is set for thermocouple types J K N mV Once the hardware jumpers are selected this information needs to be reported to the microcomputer The information is reported via DIP switches SW1 and SW2 see Figure 2 2 Each output channel uses 3 switches with a BCD code to indicate the state of the hardware jumpers The following chart illustrates the BCD which is needed to achieve the desired thermocouple type CTI 2559 TC Installation and Operation Guide 11 Type MV E J K N R S T BCD code 000 001 010 011 100 101 110 111 3 MSB 2 1 LSB Type M L S S OFF OFF OFF mV Bo B OFF OFF ON E OFF ON OFF J OFF ON ON K ON OFF OFF N ON OFF ON R cla ON ON OFF S ON ON ON T m FIELD WIRING CONNECTOR IT II Q o o o Q Q Q Q E I I I T I I I I oo N o q w
7. wireways for wire routing e Avoid placing wires on any vibrating surface CTI 2559 TC Installation and Operation Guide 9 2 2 Unpacking the Module Open the shipping carton and remove the special anti static bag which contains the module CAUTION HANDLING STATIC SENSITIVE DEVICES The components on the Model 2559 TC 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 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 The 505 front panel connector supplied with the 2559 TC is a modified connector with temperature sensors built in Do not attempt to use a standard connector as the thermocouple measurements will not be recognized and an error code will be reported on all channels 10 CTI 2559 TC Installation and Operation Guide 2 3 Configuring the Module The Model 2559 TC must be configured for the thermocouple type scaling digital filtering and temperature units before wiring the input connectors and inserting the module into the I O base As shipped all channels are configured for the ty
8. 2559TCIOG CTI 2559 TC EIGHT POINT THERMOCOUPLE MODULE INSTALLATION AND OPERATION GUIDE Version 1 1 CTI Part 062 00336 011 WII 25 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 111 PREFACE This
9. 59 TC Installation and Operation Guide 29 REPAIR POLICY In the event that the Product should fail during or after the warranty period a Return Material Authorization RMA number can be requested orally or in writing from CTI main offices Whether this equipment is in or out of warranty a Purchase Order number provided to CTI when requesting the RMA number will aid in expediting the repair process The RMA number that is issued and your Purchase Order number should be referenced on the returning equipment s shipping documentation Additionally if the product is under warranty proof of purchase date and serial number must accompany the returned equipment The current repair and or exchange rates can be obtained by contacting CTI s main office at 1 800 537 8398 When returning any module to CTI follow proper static control precautions Keep the module away from polyethylene products polystyrene products and all other static producing materials Packing the module in its original conductive bag is the preferred way to control static problems during shipment Failure to observe static control precautions may void the warranty For additional information on static control precautions contact CTI s office at 1 800 537 8398 CTI 2559 TC Installation and Operation Guide 31
10. C 40 to 185 F 5 to 95 non condensing UL ULC Class 1 Div 2 CE 1 5 lbs 0 68 Kg tom specifications subject to change without notice CTI 2559 TC Installation and Operation Guide 21 22 CTI 2559 TC Installation and Operation Guide APPENDIX A COMPATIBILITY WITH SIEMENS 505 7028 A Overview The CTI 2559 TC Thermocouple Module was designed to be a drop in replacement for the Siemens Model 505 7028 A From set up of the module to wiring and PLC reporting the user will find many similarities between the CTI and Siemens models Using the CTI 2559 TC in a 505 7028 A application The CTI 2559 TC should fulfill all the following requirements for the 505 7028 A replacement as outlined below Module setup The CTI 2559 TC sets up the same as its Siemen s counterpart without any input or CJC calibration needed See Chapter 2 3 Configuring the Module for Operation to determine the details in module setup Wiring The wiring of the input connector is the same between the modules although the 2559 TC utilizes a modified 505 front panel connector See Section 2 5 for details on the modified connector and a detailed explanation of how proper wiring is accomplished PLC Reporting The word format is the same between the modules See Chapter 1 for a more detailed explanation on PLC reporting CTI 2559 TC Installation and Operation Guide 23 APPENDIX B JUMPER SETTINGS LOG SHEET
11. 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 CTI 2559 TC Installation and Operation Guide v 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 CTI 2559 TC Installation and Operation Guide Vii TABLE OF CONTENTS 1 0 Product Summary or e e pi 1 1 1 Front Panel Description en BES In eee E aed nennen 1 1 2 Asynchronous Operations 5 2 enean EI on ER AU Bits ba cd EE EES 2 1 3 Immediate T O is a serch RA Heu edite A Gn acepte nitet E 2 14 J KL ER S Nand mV Fhermocouples vier eret eter nein Krebse 2 LS Digital Word Map c
12. LING 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 2 CTI 2559 TC Installation and Operation Guide As an example the following Figure 1 3 illustrates the effects of a change in input level going from 0 to 102 4 F in the Thermocouple Input Mode Example 1 0 0 F Digital Word WX 10 MSB LSB 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 O 0 0 0 0 0 0 0 0 0 0 0 0 0 070 32 16 8 4 2 Example 2 102 4 F Digital Word WX 10 MSB LSB 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 0O10 0 0 0 1 0 0 0 0 0 0 0 0 0 0 1004 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 O 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 0 C for a Type J thermocouple is Scaled integer 0 210 760 210 x 32000 6928 example the scaled integer overrange at 770 C for a Type J thermocou
13. PUT SIGNAL WIRES FRONT FACE CONNECTOR 727 HmnGQ d q 231 77VWAIPHORGIRERABK LLL LLL LL LL E TEMP SENSOR B 0 0 0 Leal GE Figure 2 8 Input Connector Assembly 2 7 Calibration of the Module Unlike its Siemens counterpart the CTI 2559 TC needs no calibration of inputs or cold junction compensation NOTE The 2559 TC Thermocouple Input Module is calibrated at the factory No further calibration is required All calibration parameters are stored in non volatile memory There are no user adjustments on this product As shipped there is no jumper required on the CAL input 2 8 Checking Module Operation First turn on the base power If the module diagnostics detect no problems the status indicator on the front of the module will light If the status indicator does not light begins blinking or goes out during operation the module has detected a failure For information on viewing failed module status refer to your TISOFT user manual To diagnose and correct a module failure refer to the next section on troubleshooting You must also check that the module is configured in the memory of the PLC This is important because the module will appear to be functioning regardless of whether it is communicating with the PLC To view the PLC memory configuration chart listing all slots on the base and the inputs or outputs associated with each slot refer to your TISOFT Programming Manual An example c
14. TI 2559 TC Installation and Operation Guide CHAPTER 2 INSTALLATION The installation of the Eight Point Thermocouple Module involves the following steps Planning the installation Unpacking and configuring the module Inserting the module into the I O base Wiring and connecting the module input connectors MR WN n 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 1 1 Calculating the I O Base Power Budget The Model 2559 TC requires 1 0 watt maximum of power from the I O base Use this value to verify that the base power supply is not exceeded 2 1 2 Input Signal Wiring Input signal wiring must be shielded twisted pair cable A twisted pair will aid in the rejection of conducted and radiated interference from other energy sources Standard practices usually require that all shields be tied together and grounded at a single point Note the following general considerations when wiring the module e Always use the shortest possible cables e Avoid placing low voltage wire parallel to high energy wire if the two wires must meet cross them at a right angle e Avoid bending the wire into sharp angles e Use
15. W20 Re RED TRAGE Dl eto Cos ME ees ESTABUSIED de RE 01030508 YELLOW TRACE Chart used with permission from Omega Engineering Inc CTI 2559 TC Installation and Operation Guide 27 LIMITED PRODUCT WARRANTY CTI warrants that this CTI Industrial Product shall be free from defects in material and workmanship for a period of one 1 year after purchase from CTI or from an authorized CTI Industrial Distributor This CTI Industrial Product will be newly manufactured from new and or serviceable used parts which are equal to new in the Product Should this CTI Industrial Product fail to be free from defects in material and workmanship at any time during this 1 year warranty period CTI will repair or replace at its option parts or Products found to be defective and shipped prepaid by the customer to a designated CTI service location along with proof of purchase date and associated serial number Repair parts and replacement Product furnished under this warranty will be on an exchange basis and will be either reconditioned or new All exchanged parts or Products become the property of CTI Should any Product or part returned to CTI hereunder be found by CTI to be without defect CTI will return such Product or part to the customer This warranty does not include repair of damage to a part or Product resulting from failure to provide a suitable environment as specified in applicable Product specifications or damage caused by an ac
16. ant Update Time Repeatability Accuracy ADC Resolution Common Mode Rejection Normal Mode Rejection Connector Wire Gauge Backplane Power Module size Operating Temperature Storage Temperature Relative Humidity Agency Approvals Pending Shipping Weight 8 thermocouple inputs J K T E R S N and mV 1500V channel to backplane 30 VDC or VAC continuous 120VAC for 10 sec J 210 C to 760 C 350 F to 1400 F K 270 C to 1372 C 450 F to 2500 F 270 C to 400 C 454 F to 752 F 270 C to 1000 C 454 F to 1832 F O C to 1768 C 32 F to 3214 F O C to 1768 C 32 F to 3214 F 260 C to 1300 C 436 F to 2372 F mV 55 to 55mV 4 4MQ DC gt 10KQ 060 Hz Scaling Enabled 0 to 32 000 temperature 32 000 to 32 000 mV Scaling Disabled C x10 or F x10 temperature 10 000 to 10 000 mV C or F selectable by module 80 mSec 9 mSec all channels 1 C 2 F for all thermocouple types J 1 C at 25 C ambient K 1 C at 25 C ambient T 1 C at 25 C ambient E 1 C at 25 C ambient R 2 C at 25 C ambient S 2 C at 25 C ambient N 1 C at 25 C ambient mV 0 5 full scale or 500u V reduced accuracy for measurements below 500 C 16 bits gt 110 dB 60 Hz gt 60 dB 60 Hz gt 50 dB 50 Hz Removable 14 22 AWG 1 0 Watt maximum Single wide 0 to 60 C 32 to 140 F 40 to 85
17. cident disaster acts of God neglect abuse misuse transportation alterations attachments accessories supplies non CTI parts non CTI repairs or activities or to any damage whose proximate cause was utilities or utility like services or faulty installation or maintenance done by someone other than CTI Control Technology Inc reserves the right to make changes to the Product in order to improve reliability function or design in the pursuit of providing the best possible Product CTI assumes no responsibility for indirect or consequential damages resulting from the use or application of this equipment THE WARRANTY SET FORTH ABOVE IN THIS ARTICLE IS THE ONLY WARRANTY CTI GRANTS AND IT IS IN LIEU OF ANY OTHER IMPLIED OR EXPRESSED GUARANTY OR WARRANTY ON CTI PRODUCTS INCLUDING WITHOUT LIMITATION ANY WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE AND IS IN LIEU OF ALL OBLIGATIONS OR LIABILITY OF CTI FOR DAMAGES IN CONNECTION WITH LOSS DELIVERY USE OR PERFORMANCE OF CTI PRODUCTS OR INTERRUPTION OF BUSINESS LOSS OF USE REVENUE OR PROFIT IN NO EVENT WILL CTI BE LIABLE FOR SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES FOR CONSUMER PRODUCTS SO THE ABOVE LIMITATIONS OR EXCLUSIONS MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH MAY VARY FROM STATE TO STATE CTI 25
18. e 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 UO 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 modules 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 TRANSLATED VALUES OVERRANGE 32 765 64 32 16 8 UNDERRANGE 32 766 BIT 1 0 1 1 1 q 1 a 1 1 1 1 1 1 1 1 1 MSB TRANSLATED SIGN 1 DIGITAL WORD 0 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 SCA
19. econds Type J 8 Millivolts 43 Millivolts SN 210 to 760 C SCH P S Module not Reports Accuracy Reports Module not protected underrange within overrange protected damage error code specification error code damage might occur might occur Figure 1 4 Effect of Voltage Input on Type J Thermocouple Type K 6 Millivolts 55 Millivolts 60V 270 to 1372 C TOU a 2 Module not Reports Accuracy Reports Module not protected underrange within overrange protected damage error code specification error code damage might occur might occur Figure 1 5 Effect of Voltage Input on Type K Thermocouple Type T 6 Millivolts 21 Millivolts d 270 to 400 C N gt Module not Reports Accuracy Reports Module not protected overrange within underrange protected damage error code specification error code damage might occur might occur 4 Figure 1 6 Effect of Voltage Input on Type T Thermocouple Type E 9 Millivolts 77 Millivolts 60V 60V 270 to 1000 C lt Module not Reports Accuracy Reports Module not protected underrange within overrange protected damage error code specification error code damage might occur might occur Type R 0 Millivolts 21 1 Millivolts SSC 0 to 1768 C SE P Module not Reports Accuracy Reports Module not protected underrange within overrange protected damage error code specification error code damage might occur might occu
20. es 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 1 C 0 1 F or exactly 01 millivolts The chart below shows the corresponding input resolution per step for each of the input configuration modes 6 CTI 2559 TC Installation and Operation Guide Units Input Resolution Step Temp C 0 05 C Temp F 0 09 F Millivolts 0 0017 millivolts Figure 1 13 Input Resolution C
21. g Control Technology Inc recommends that all wires be shielded twisted pair with a foil wrap shield and a separate drain wire and that they be installed in a metallic conduit For millivolt applications use Belden cable 8761 or equivalent which contains a foil wrap shield and a separate drain wire The shield and the foil wrap should be twisted together and should be terminated at only one end The other end should be left in an open circuit condition CTI recommends that the shield be terminated CTI 2559 TC Installation and Operation Guide 15 at the PLC end of the signal wire Special components are installed on the module to aid in the rejection of noise When entering the industrial cabinet the shield should be routed from the main terminal strip all the way to the PLC Signal leads that do not maintain a shield from the terminal strip to the PLC act as antennas and are susceptible to radiated and conducted emissions in the cabinet Unprotected cables may introduce measurement errors in the module The front connector on the module contains a CHASSIS terminal which may be used for the shield wire if the installation is in a noise free environment If the installation is in an extremely noisy environment CTI strongly recommends that the shielded wires be terminated to the PLC chassis ground CTI has exhaustively tested this product to maximize its ability to reject noise from inductive sources as well as showering arcs fast transients and
22. hart is shown in the following figure I O Module Definition for Channel 1 Base 00 Number of Bit and Word I O VO Address Special Slot X Y WX WY Function 1 0001 00 00 08 00 NO 2 0000 00 00 00 00 NO CTI 2559 TC Installation and Operation Guide 17 15 0000 00 00 00 00 NO 16 0000 00 00 00 00 NO Figure 2 9 Example I O Configuration Chart In this example the 2559 TC module is inserted in slot 1 in I O base 0 Data for channel 1 appears in word location WX1 data for channel 2 appears in word location WX2 etc For your particular module look in the chart for the number corresponding to the slot occupied by the module If word memory locations appear on this line then the module is registered in the PLC memory and the module is ready for operation If the line is blank or erroneous re check the module to ensure that it is firmly seated in the slots Generate the PLC memory configuration chart again If the line is still incorrect contact your local distributor or CTI at 1 800 537 8398 for further assistance NOTE Refer to Hewlett Packard Applications Note 290 or Omega Temperature Handbook Volume 26 Section T for practical thermocouple measurement applications CAUTION For proper operation ensure that the 2559 TC and the thermocouple wires are not subjected to drafts or large temperature gradients during operation NOTE In the event the 2559 TC detects an onboard module failure the m
23. his occurs contact CTI for replacement connector part number 2559 FPC for your replacement front panel connector 14 CTI 2559 TC Installation and Operation Guide 2 5 2 Connecting Thermocouple Input Wiring For thermocouple input circuits connect the thermocouple wires to the screw terminals as indicated in Figure 2 3 Screw Terminal Connector Wiring Insert the wires in the appropriate holes on the front of the connector see Figure 2 4 and 2 5 When the wires are inserted tighten the screws Repeat this procedure for the remaining thermocouple input channels Ensure that the proper wire polarity is followed for each of the seven supported thermocouple probe types as shown in Figure 2 6 See also Appendix C for more detailed information on different thermocouple types CH 1 Wa lt _ CH 1 IN Thermocouple SHIELD 2 Wire Figure 2 4 Thermocouple wiring application CH 1 IN CH 1 IN 55 to 55mV SHIELD Figure 2 5 Millivolt wiring application Thermocouple Negative Positive 4 Type Lead Lead J Copper Nickel Red Iron White K Nickel Aluminum Red Nickel Chromium Yellow T Copper Nickel Red Copper Blue E Copper Nickel Red Nickel Chromium Purple R Platinum Red Platinum 13 Rhodium Black S Platinum Red Platinum 10 Rhodium Black N Nisil Red Nicrosil Orange Figure 2 6 Thermocouple type and wire descriptions 2 5 3 Connecting the Shield Wirin
24. n re rtr Ru eoe PRU RC fe a o eR dad peo rond 2 1 6 Thermocouple Input to Digital Conversion esee nennen 2 1 7 Effect of Out of Range Input Senge 4 1 8 Additiorial Error EE 6 1 9 Resol ti n EE 6 2 1 Planmmg the Trstall tion ss oco eo ie a e eek 9 2 2 Unpacking the Mod le nsir naine hale Age ee Ae ee In rm dip 10 2 3 Configuring the Module 2 I Ba eite e en er i yg fe e D e Baba 11 2 4 Inserting the Module into the VO Base 13 2 5 Wiring the Input COBD CtOrs o guided Etre bt DT e e a UR Eee 13 2 6 Installing the Screw Terminal Connector ueuersesssesersnesensesnersernnnsonsernnnsonnnenensennorsnnnonsonnnenennsnensnsnane 16 2 7 Calibration of the Module 17 2 8 Checking Module Operation neiii re e E E EE EE AEE E AERE EEEa aeS 17 CHAPTER 3 TROUBLESHOOTING sssssssssssssssssessessrsessessrsessessssessessssessessssessessssessessssessessssessessssesees LD HARDWARE SPECIFICATIONS csssssssssssssssessssssessessrsessessssessessssessessssessessssessessssessessssessessssessessssessesee Al APPENDIX A COMPATIBILITY WITH SIEMENS 505 7028 A esscccssssscsssssssscssssccsssnsescsssnscsssnsessssseeee 23 APPENDIX B JUMPER SETTINGS LOG SHEET scssssssssssssssesssssssessessssessessssssessssessessssessessssessesss ZO APPENDIX C THERMOCOUPLE WIRE GUIDE eese reete en eren tn enean suse en en sse seen senses en sese seen sees 27 LIMITED PRODUCT WARRANTY
25. o N grs grs ale DIO Ze gi Ze gi 3c Xe e o 2 a z fece WE 5 NE fe fece TYPE fee TPE fee TPE fee TPE Gs E a E Ja E JP JP26 E Jr E Jg E JP DAS TYPE TYPE TYPE TYPE TYPE TYPE aes L2 JP36 K N mV 3532 4 K N mV pag Y KN mV JP24 J K N mV Jp20 J K N mV Jp16 K N mV Jp12 J K N mV JP4 ai m2 to e e B fece WE Gei ME Gs Poe TPE Gei TYPE ai TYPE WE Ge s p p JP37 RST a RST Jpoo JP25 RST Pm RST Jm RST RST Ip 3 oz No a S 2 CN5 un O os m o x z e o B Q OFF 0 OFF 0 Sw2 sm e ON 1 ON 1 EET O A BACKPLANE CONNECTOR 12 Figure 2 2 Configuration Jumper Board Locations shown as shipped from factory CTI 2559 TC Installation and Operation Guide 2 3 2 Selecting Digital Filtering Locate the Digital Filtering Jumper DIG FILTER JP2 see Figure 2 2 To enable digital filtering set the jumper in the EN position to disable set to the DIS position Since many analog input signals contain noise CTI recommends using digital filtering unless maximum response time is required As shipped digital filtering is enabled for all 8 thermocouple inputs 2 3 3 Selecting Offset Scaling Locate the Offset Scaling SCALING jumper JP1 see Figure 2 2 To enable offset scaling for all eight inputs set the jumper to the EN position The module will provide the formatted data range as 0 32000 for thermocouples and 32 000 to 32 000 for mV To disable scaling and use Engineering units se
26. odule will assert the module fail line and report the module failure in the I O Status Word which is reported to the PLC CPU CTI strongly recommends the user application monitor the I O Module Status Words which are Status Words 11 26 and apply to Controllers TI 545 TI 555 TI 560 amp 565 and the TI 575 The I O Module Status Word can be used to report a module failure for an I O Module in any of the 505 I O Slots Please refer to Siemens SIMATIC TI505 Programming Reference Manual for more information If a module failure is reported by the status word the module should be replaced with a working unit and the failed module sent in for repair 18 CTI 2559 TC Installation and Operation Guide CHAPTER 3 TROUBLESHOOTING If the module provides improper readings or the status indicator is not on use the following chart to determine the appropriate corrective action Symptom Indicator is not lit Indicator is blinking Incorrect inputs Input does not work with PID loop or analog alarm block Value is too large Incorrect values to PLC values off by 10 15 degrees Probable Cause Base or PLC power is off No calibration data Wrong addresses for word input Not logged in Incorrectly calibrated Blown fuse Value is not reported as integer 0 32 000 Temperature is reported to PLC as value x10 DIP switch not set in correct position Wrong thermocouple type selected by jumpers
27. on eese rennen a nnne enne 16 Figure 2 8 Input Connector Assembly AAA 17 Figure 2 9 Example I O Configuration Chart 18 Figure 3 1 Troubleshooting Mam 19 CTI 2559 TC Installation and Operation Guide xi 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 ACTIVE LED TEMPERATURE SENSOR A CHANNELS 1 8 TEMPERATURE z SENSOR B e 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 CTI 2559 TC Installation and Operation Guide 1 1 2 Asynchronous Operation The module operates asynchronously with respect to th
28. pe J thermocouple scaling disabled digital filtering enabled and Fahrenheit F units see Figure 2 1 CHANNEL THERMOCOUPLE JUMPER POSITION DIP SWITCH NUMBER TYPE JUMPER E or J K N mV or R S T SETTING 1 JP6 4 5 JP4 type J K N mV CH 1 010 type J 2 JP14 12 13 JP12 type J K N mV CH 2 010 type J 3 JP18 16 17 JP16 type J K N mV CH 3 010 type J 4 JP22 20 21 JP20 type J K N mV CH 4 010 type J 5 JP26 24 25 JP24 type J K N mV CH 5 010 type J 6 JP30 28 29 JP28 type J K N mV CH 6 010 type J 7 JP34 32 33 JP32 type J K N mV CH 7 010 type J 8 JP38 36 37 JP26 type J K N mV CH 8 010 type J SCALING JUMPER DIGITAL JUMPER TEMP UNITS JUMPER POSITION FILTERING POSITION JUMPER POSITION JP1 Dis JP2 En JP3 F Figure 2 1 Shipping Jumper Configuration Locations Changing the configuration involves the following steps notations in parenthesis are actual printed board titles described in the following sections 1 Selecting thermocouple type E or J K N mV or R S or T for each channel 2 Selecting digital filtering Enable EN or Disable DIS for the module 3 Selecting scaling Enable EN or Disable DIS for the module 4 Selecting temperature units Fahrenheit F or Celsius C for the module 2 3 1 Selecting Thermocouple Type This selection involves both changing the jumpers on a per channel basis as well as dip switch
29. ple 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 Probe Type coe Range 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 O to 1768 32 to 3214 S 0 to 1768 32 to 3214 N 200 to 1300 328 to 2372 CTI 2559 TC Installation and Operation Guide 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 millis
30. r Figure 1 8 Effect of Voltage Input on Type R Thermocouple Type S 0 Millivolts 18 7 Millivolts ey 0 to 1768 C eum lt Module not Reports Accuracy Reports Module not protected underrange within overrange protected damage error code specification error code damage might occur might occur Figure 1 9 Effect of Voltage Input on Type S Thermocouple Type N 4 3 Millivolts 47 5 Millivolts 60V 60V 270 to 1300 C lt gt Module not Reports Accuracy Reports Module not protected underrange within overrange protected damage error code specification error code damage might occur might occur Figure 1 10 Effect of Voltage Input on Type N Thermocouple CTI 2559 TC Installation and Operation Guide 56 6 Millivolts 56 6 Millivolts 60V 60V 56 to 56mV gt Module not Reports Accuracy Reports Module not protected underrange within overrange protected damage error code specification error code damage might occur might occur 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 do
31. t the jumper to the DIS position The module will then format the data range as C x10 or F x10 for thermocouples and mV from 10 000 to 10 000 As shipped the jumper is in the DIS disable position 2 3 4 Selecting Temperature Units Locate the Temperature Units TEMP UNITS jumper JP3 see Figure 2 2 To enable Fahrenheit units set the jumper to the F position to enable Celsius units set the jumper to the C position As shipped the jumper is in the F Fahrenheit position 2 3 5 Jumper Settings for Future Reference See Appendix B Jumper Settings Log Sheet to record any changes to the module s jumper settings 2 4 Inserting the Module into the UO Base Insert the module into the I O base by carefully pushing the module into the slot When the module is fully seated in the slot and backplane connector tighten the captive screws at the top and bottom to hold the module in place To remove the module from the I O base loosen the captive screws then remove the module from the I O base Be careful not to damage the edge card at the back of the module when inserting or removing the module 2 5 Wiring the Input Connectors Input signals are accepted through a connector assembly located on the front of the module The connector assembly consists of a modified Siemens front panel edge connector with built in temperature sensors that mates with the printed circuit board Wiring is connected to the front
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