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Control Technology CTI 2557-A, Installation And Operation Manual

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CTI 2557-A Installation and Operation Guide 

iii 

 

 

 

PREFACE 

 

 

 

This 

Installation and Operation Guide 

provides installation and operation instructions for the CTI 

2557-A Sixteen Channel Isolated Thermocouple Input Module for CTI’s 2500 Series 2500® 
Processors as well as the legacy SIMATIC® 505 programmable controllers. We assume you are 
familiar with the operation of CTI’s 2500 Series 2500® Processors and SIMATIC® Series 505 
programmable controllers. Refer to the appropriate CTI’s Series 2500® documentation for Processors 
and I/O module operation. 

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. 

 
 
 
 

 

 

 

Figure 1 The 2557-A 16 Channel RTD Input Module

Summary of Contents for CTI 2557-A

Page 1: ...CTI 2557 A SIXTEEN CHANNEL ISOLATED RTD INPUT MODULE INSTALLATION AND OPERATION GUIDE Ver 1 0 2557 AIOG 05 26 2021 25 ...

Page 2: ...s 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 war...

Page 3: ...ogrammable controllers We assume you are familiar with the operation of CTI s 2500 Series 2500 Processors and SIMATIC Series 505 programmable controllers Refer to the appropriate CTI s Series 2500 documentation for Processors and I O module operation This Installation and Operation Guide is organized as follows Chapter 1 provides a description of the module Chapter 2 covers installation and wiring...

Page 4: ... the Installation 6 2 2 Calculating the I O Base Power Budget 6 2 3 Unpacking the Module 6 2 4 Configuring the Module 7 2 4 1 Selecting Temperature or Millivolt Input 7 2 4 2 Selecting 2 and 3 Wire or 4 Wire Operation 8 2 4 3 Selecting 10 Ohm RTD Inputs 8 2 4 4 Selecting PLC Login Mode 8 2 4 5 Selecting Digital Filtering 8 2 4 6 Select Degrees Celsius or Fahrenheit 8 2 4 7 Selecting Data Scaling 9...

Page 5: ... 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 23 ...

Page 6: ...Figure 7 Effect of Voltage Input 10 Ohm Copper 5 Figure 8 Effect of Voltage Input Millivolts 5 Figure 9 Input Resolution 5 Figure 10 Factory Configuration Jumper Settings 9 Figure 11 Configuration Jumper Locations 10 Figure 12 2557 A Module PCB Layout 11 Figure 13 Copper Wire Table at 25 Degrees Celsius 12 Figure 14 Removable Wiring Connector Wiring Diagram 13 Figure 15 Wiring Diagram for 2 3 4 Wi...

Page 7: ...USAGE CONVENTIONS 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 ...

Page 8: ......

Page 9: ...rammable controllers and I O modules The Model 2557 A is designed to translate 10 Ohm copper 100 Ohm platinum and 120 Ohm nickel RTDs or millivolt input signals into scaled digital words which are then sent to the programmable controller PLC The 2557 A RTD Input Module features built in independent two three or four lead compensation for each RTD input The 2557 A uses 8 8 point removable wiring co...

Page 10: ...Inputs Each of the module s 16 channels may be configured to receive either a 100 Ohm platinum RTD or a 120 Ohm nickel RTD or a 10 Ohm copper RTD input signal two three or four wire or a DC voltage signal ranging from 0 to 100 millivolts Selection of 10 Ohm 100 Ohm or 120 Ohm RTDs or millivolts are made via internal switch and jumper settings 1 3 Digital Word Map RTD and or millivolt signals are t...

Page 11: ...illustrates the effects of a change in input level going from 0 to 102 4 degrees in the RTD Input Mode Figure 4 Example Change Input Level 1 4 2 Scale Units When data format is selected as SCALE the full temperature range of the RTD is scaled as an unsigned integer from 0 32000 The following formula may be used to calculate the scaled integer value Scaled Integer measured temp min temp max temp mi...

Page 12: ...1 degrees C for 120 Ohm nickel and 10 Ohm copper will be returned for any positive overrange input Similarly an input below 199 8 degrees C for 100 Ohm platinum or 79 8 degrees C for 120 Ohm nickel or 100 degrees C for 10 Ohm copper will cause the underrange bit to be set Figure 5 Effect of Voltage Input 100 Ohm Platinum Figure 6 Effect of Voltae Input 120 Ohm Nickel NOTE The Model 2557 A uses the...

Page 13: ...be returned for any positive over range input Similarly a millivolt input below 0 millivolts will cause the under range bit to be set A reading of 1 millivolt will be returned for any negative under range input 1 6 Resolution The module has a resolution of approximately 0 1 degrees C 0 2 degrees F or exactly 0 01 millivolts The chart below shows the corresponding input resolution per step for each...

Page 14: ...verify that the base power supply capacity is not exceeded 2 3 Unpacking the Module Open the shipping carton and remove the special anti static bag which contains the module After discharging any static build up remove the module from the static bag Do not discard the static bag You will need it for the following configuration procedure CAUTION HANDLING STATIC SENSITIVE DEVICES The components on t...

Page 15: ...lecting standard login mode 16WX or Advanced Operating Mode 5 Selecting digital filtering or no filtering for the module 6 Selecting degrees C or F for the module 7 Selecting Engr units or SCALE units for module 8 Logging the configuration jumper settings for future reference Each of these steps is described in the following sections 2 4 1 Selecting Temperature or Millivolt Input No hardware chang...

Page 16: ...changes are required to select 100 2 4 4 Selecting PLC Login Mode Locate JP67 on the printed circuit board to select PLC Login Mode See Figure 10 Standard login is 16 WX registers in the PLC Advanced Operating Mode logs in as 16 X 16 Y 32 WX and 32 WY registers Consult the CTI 255x Sixteen Channel Advanced Function Programming Reference Manual part 62 177 if the advanced operating mode is to be se...

Page 17: ... to present data to the PLC as temperature X10 or millivolts X100 Select ENABLE to scale and present the data as an unsigned integer from 0 32000 Figure 10 Factory Configuration Jumper Settings NOTE In the sample chart above the standard shipping configuration is indicated as 3 wire 1000 Pt 16 WX filtering enabled degrees C and scaling disabled ...

Page 18: ...10 CTI 2557 A Installation and Operation Guide Figure 11 Configuration Jumper Locations ...

Page 19: ...old 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 connector card at the back of the module when inserting or removing the module WARNING Remove power from the I O base before inserting or removing a module Removable Wiring Connectors Channel Measurement Selection DIP Switches 2 3 and 4 Wire...

Page 20: ...accuracy of the measurement CTI has carefully selected a connector that minimizes this effect Refer to Figure 13 for correct wiring for 2 3 or 4 wire RTDs to the Model 2557 A Each channel consists of four press in terminals Insert wire by using a small screw driver to depress the spring tension lever and then insert the wire Solid core wires may be pushed in without depressing lever Remove wire by...

Page 21: ...proper lead length compensation Removable Block 1 for Channels 1 Removable Block 2 for Channels 3 4 Removable Block 3 for Channels 5 6 Removable Block 4 for Channels 7 8 Removable Block 5 for Channels 9 10 Removable Block 6 for Channels 11 12 Removable Block 7 for Channels 13 14 Removable Block 8 for Channels 15 16 The same inputs are repeated on each of the each of the 8 wiring blocks ...

Page 22: ...Installation and Operation Guide Figure 15 Wiring Diagram for 2 3 4 Wire RTDs and Millivolt Signals CAUTION For proper operation ensure that the 2557 A is not subjected to large temperature gradients during operation ...

Page 23: ... 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 G 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 r...

Page 24: ...roubleshooting 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 SIMATIC or TISOFT Programming Manual An example c...

Page 25: ...r further assistance NOTE In advanced Operating Mode the module logs in to the PLC as 16X 16Y 32WX and 32WY Because Profibus will not allow a mixed X Y WX WY slave configuration the Advanced Operating Mode is not supported over Profibus NOTE In the event a CTI analog detects an onboard module failure the module will assert the module fail line and report the module failure in the I O Status Word w...

Page 26: ...en 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 or solve the problem contact your local distributor or CTI at 1 800 537 8398 for further assistance CAUTION The module fuse F1 is not user serviceable If this fuse is blown the module has a serious co...

Page 27: ...n 200 per lead wire Input Overrange Protection 30 VDC or VAC continuous Measurement Ranges 100 Cu 100 C to 260 C 148 F to 500 F F F to 500 F ADC Resolution 16 Bits Data Presentation Measurement returned in 0 2 degree resolution as temperature X10 or as an integer 0 32000 16WX mode Data word includes sign bit and overrange underange bit Millivolts returned as millivolts X100 16WX mode 0 1 degree in...

Page 28: ...ction 180 db 60 Hz Connector 64 position fixed wire press in Wire Gauge 18 to 30 AWG Module Size Single wide Backplane Power Consumption 4 75 Watts Standard Shipping Configuration 3 wire 100 Ohm Pt RTD Digital filtering enabled Degrees Centigrade Standard mode 16 WX Scale disabled Isolation 1500 VDC channel group to channel group 1500 VDC channel to backplane OperatingTemperature 0 to 60 C 32 to 1...

Page 29: ...557 A Installation and Operation Guide 21 JUMPER SETTINGS LOG SHEET Record the configuration jumper settings on this log and circle RTD type selected for future reference Make additional copies if necessary ...

Page 30: ...22 CTI 2557 A Installation and Operation Guide USER NOTES ...

Page 31: ... specifications or damage caused by an accident 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 t...

Page 32: ...ent s shipping documentation Additionally if 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 oth...

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