Control Technology 2500 Series Installation And Operation Manual
8-channel thermocouple input module
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- Page 1 Control Technology Inc. 5734 Middlebrook Pike Knoxville, Tennessee 37921 www.controltechnology.com Toll Free: 800-537-8398 2500 Series ™ Compact I/O System 2500C-8-TC 8-CHANNEL THERMOCOUPLE INPUT MODULE 2500 SERIES® COMPACT I/O INSTALLATION AND OPERATION GUIDE Version 1.2...
- Page 2 Copyright© 2021 Control Technology Inc. All rights reserved. This manual is published by Control Technology Inc. (CTI) 5734 Middlebrook Pike, Knoxville, TN 37921. This manual contains references to brand and product names which are trade names, trademarks, and/or registered trademarks of Control Technology Inc.
- Page 3 This Installation and Operation Guide provides reference information for the CTI 2500C-8- TC 8-Channel Thermocouple Module for 2500 Series® Compact I/O system. We assume you are familiar with the operation of CTI 2500 Series® programmable controllers. Refer to the appropriate user documentation for specific information on the 2500 Series®...
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Page 4: Usage Conventions
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. -
Page 5: Table Of Contents
TABLE OF CONTENTS USAGE CONVENTIONS ..................II TABLE OF FIGURES ....................5 CHAPTER 1 ....................OVERVIEW..6 Introduction .....................6 Front Panel Description .................6 Status Display ................. ………..7 1.2.1 1.2.2 I/O Wiring Connector…………………………………………………………..7 Asynchronous Operation ................7 Modes of Operation ..................7 Classic Mode .................. ………..8 1.4.1 Classic Plus Mode ................ - Page 6 Calibration of the Module ................26 Checking Module Operation ................ 27 CHAPTER 3 TROUBLESHOOTING ..............28 APPENDIX A MODULE SPECIFICATIONS............29 CTI WARRANTY ....................31 REPAIR POLICY ....................33 2500C-8-TC Installation and Operation Guide...
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Page 7: Table Of Figures
Table of Figures Figure 1 2500C-8-TC Front Panel ..................6 Figure 2 Asynchronous Operation Diagram ................7 Figure 3 2500C-8-TC Default Configuration Table ..............8 Figure 4 2500C-8-TC Classic Plus Login Table ..............8 Figure 5 2500C-8-TC Classic Plus Configuration Options ............. 9 Figure 6 2500C-8-TC Thermocouple Measurement Ranges .......... -
Page 8: Chapter 1
CHAPTER 1 OVERVIEW 1.1 Introduction The CTI 2500C-8-TC Eight-Point Thermocouple Input Module is a member of Control Technology’s family of I/O modules compatible with the Compact System Chassis. It is designed to translate a J, K, T, E, R, S, N thermocouple or millivolt input signal from the field device into an equivalent digital word which is then sent to the programmable controller (PLC). -
Page 9: Status Display
1.2.1 Status Display The Status Display will be illuminated with a “0” when the module is functioning normally. If the Status Display is not lit or if it displaying something other than “0”, refer to Chapter 3 for troubleshooting. 1.2.2 I/O Wiring Connector The 2500C-8-TC utilizes a modified 32 pin connector, part number 2500C-32F-CJC (a standard connector is NOT interchangeable) to provide wiring terminals for Channels 1-8 thermocouple inputs and two temperature (cold junction compensation) sensors. -
Page 10: Classic Mode
1.4.1 Classic Mode In Classic mode (or Low Density) operation, the 2500C-8-TC operates logs in to the PLC as an 8 word Input (8WX) module. Temperature values for each channel are reported to the PLC in the corresponding input word. In Classic mode, the module accepts Type J Thermocouple range. -
Page 11: Input Signal Ranges
Thermocouple mVolt J, K, N, R 0-55mV S*, T*, E* *Note: S, T, E also require a jumper selection change from the shipped jumper configuration per channel. Figure 5 2500C-8-TC Classic Plus Configuration Options 1.5 Input Signal Ranges Thermocouple Measurement Ranges J: -210ºC to 760ºC (-350ºF to 1400ºF) K: -270ºC to 1372ºC (-450ºF to 2500ºF) T: -270ºC to 400ºC (-454ºF to 752ºF) -
Page 12: Accuracy
1.7 Accuracy The module measurement accuracy is listed below for each Thermocouple Type and millivolt signals: Accuracy : J : +/-1ºC from 0ºC to 60ºC K: +/-1ºC from 0ºC to 60ºC Thermocouple Types and mV T: +/-1ºC from 0ºC to 60ºC E: +/-1ºC from 0ºC to 60ºC R: +/-2ºC from 0ºC to 60ºC* S: +/-2ºC from 0ºC to 60ºC*... -
Page 13: Thermocouple Input To Digital Conversion
1.9 Thermocouple Input to Digital Conversion 1.9.1 Scaling Enabled When module SCALING is enabled, 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 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. -
Page 14: Effect Of Out-Of-Range Input Signals
The table below shows the scaling temperature ranges of each probe type. Temperature Range Probe Type -210 to 760 -346 to 1400 -220 to 1320 -364 to 2408 -230 to 400 -382 to 752 -240 to 700 -400 to 1292 0 to 1768 32 to 3214 0 to 1768... -
Page 15: Figure 12 2500C-8-Tc Effect Of Voltage Input On Type J Thermocouple
Figure 12 2500C-8-TC Effect of Voltage Input on Type J Thermocouple Figure 13 2500C-8-TC Effect of Voltage Input on Type T Thermocouple Figure 14 2500C-8-TC Effect of Voltage Input on Type E Thermocouple Figure 15 2500C-8-TC Effect of Voltage Input on Type R Thermocouple 2500C-8-TC Installation and Operation Guide... -
Page 16: Figure 16 2500C-8-Tc Effect Of Voltage Input On Type S Thermocouple
Figure 16 2500C-8-TC Effect of Voltage Input on Type S Thermocouple Figure 17 2500C-8-TC Effect of Voltage Input on Type N Thermocouple Figure 18 2500C-8-TC Effect of Voltage Input on mV Input 2500C-8-TC Installation and Operation Guide... -
Page 17: Error Code Values Reported To The Plc
1.11 Error Code Values Reported to the PLC 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 2500C-8-TC error codes:... -
Page 18: Module Setup From The Plc In Classic Plus Mode
1.12 Module Setup from the PLC in Classic Plus Mode When operating in Classic Plus Mode, the module reads setup information that the PLC has stored in the WY word corresponding to each channel. See Section 1.4.2 for module log on example. -
Page 19: Chapter 2 Installation & Setup
CHAPTER 2 INSTALLATION & SETUP The installation of the 2500C-8-TC consists of the following steps: 1) Reading this Chapter 2) Installation planning 3) Unpacking the module 4) Configuring the module 5) Physical installation 6) Connecting field wiring 7) Checking operation 2.1 Installation Planning 2.1.1 Safety Considerations Before installing the module, you must identify the personnel hazards that may be created in... -
Page 20: Electrical Interference
intended as safeguards against the failure of critical components and the effects of such failures or the inadvertent errors that might be introduced if programs are changed while the equipment is in operation. Operator Safety Switches Power should be configured so that it can be manually removed from all output devices. You must provide a method that is independent of the control system for disconnecting power from the outputs when a machine is not operating or the operator must reach into the machine. -
Page 21: 2500C-8-Tc Board Layout
2.2 2500C-8-TC Board Layout Top of the Module Operation Mode Selection Jumpers LED Display Module Front Panel Backplane Connector Wiring Connector Plug in Channel Range Selection Jumpers Figure 22 2500C-8-TC Board Layout Picture 2500C-8-TC Installation and Operation Guide... -
Page 22: Defining Operation Mode And Range Selections
2.2.1 Defining Operation Mode and Range Selections Before you can install the module, you must review your planned input signals by channel and decide on one the operation modes (Classic or Classic Plus), and the range selections and settings for each input. If your application needs only Type J Thermocouple digital filtering enabled and Engindegree measurements in Centigrade for every channel, then you may use Classic mode. -
Page 23: Operation Mode Jumpers - Selecting Operation Mode
2.4.1 Operation Mode Jumpers - Selecting Operation Mode The module operational mode is selecting using the jumper at JP11. For Classic mode, the jumper should be installed at the “C” position. For Classic Plus mode it should be installed at the “CP” position. The module ships from the factory set for Classic mode operation. Figure 23 2500C-8-TC Operation Mode Jumpers Picture NOTE JP1 is used for factory test purposes and should not be populated. -
Page 24: Selecting Millivolt Or Thermocouple Types For Each Channel
2.4.2 Selecting millivolt or Thermocouple Types for Each Channel Millivolt or Thermocouple Type is set for each channel using the set of jumpers located on the printed circuit board refer to Figure 22 2500C-8-TC Board Layout Picture for the jumper locations. -
Page 25: Physical Installation
2.5 Physical Installation Remove AC power from the rack. Align the circuit board with the connector next to the power supply. Slide the controller into the rack until the connector seats. Use the thumbscrews to secure the controller in the rack. Figure 28 2500C-8-TC Module Physical Installation Picture IMPORTANT NOTE: The 2500-8-TC is designed to allow “hot-swapping”... -
Page 26: Connecting Field Wiring
2.6 Connecting Field Wiring Field wiring is connected to the 2500C-8-TC as shown in the connector wiring diagram below. NOTE: For millivolt inputs you may wire to the “TC+” and the “TC-“ connections or use the COM connections to reduce wiring. The “GND” connection is provided for the shield. -
Page 27: Understanding The Modified Front Panel Connector
2.6.1 Understanding the Modified Front Panel Connector In order to provide the most accurate cold junction compensation and to avoid CJC calibration, the 2500C-8-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 B1 and B2 and B15 and B16 , and are not user serviceable. -
Page 28: Installing The Screw Terminal Connector
2.6.3 Connecting the Shield Wiring 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. -
Page 29: Checking Module Operation
2.9 Checking Module Operation Apply power to the base power supply. The Power Good LED on the power supply should illuminate, indicating that power is being supplied to the base connectors. The Remote Base Controller will take a few seconds to complete the startup sequence. When this is complete, the status indicator on the 2500-8-TC should display a “0”. -
Page 30: Chapter 3 Troubleshooting
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. See Figure 33 2500C-8-TC LED Error Code Table for additional diagnostic information. Symptom Probable Cause Corrective Action Indicator is not lit. -
Page 31: Appendix A Module Specifications
Appendix A Module Specifications Input Specifications Operation Mode Support (See Note 1) Classic Mode Classic Plus Mode Module Logon 8WX/8WY Module Update Time all modes Digital Filtering Time Constant 80mS 80mS Thermocouple Measurement Ranges º º º J: -210 C to 760ºC (-350 F to 1400 º... - Page 32 2500C-8-TC Installation and Operation Guide...
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Page 33: Cti Warranty
CTI WARRANTY Warranty. Control Technology Inc. ("CTI") warrants that this CTI Industrial Product (the "Product") shall be free from defects in material and workmanship for a period of one (1) year from the date of purchase from CTI or from an authorized CTI Industrial Distributor, as the case may be. Repaired or replacement CTI products provided under this warranty are similarly warranted for a period of 6 months from the date of shipment to the customer or the remainder of the original warranty term, whichever is longer. - Page 34 RELATIVE TO GRATUITOUS INFORMATION OR ASSISTANCE PROVIDED BY, BUT NOT REQUIRED OF CTI HEREUNDER. ANY ACTION AGAINST CTI MUST BE BROUGHT WITHIN EIGHTEEN (18) MONTHS AFTER THE CAUSE OF ACTION ACCRUES. THESE DISCLAIMERS AND LIMITATIONS OF LIABILITY WILL APPLY REGARDLESS OF ANY OTHER CONTRARY PROVISION HEREOF AND REGARDLESS OF THE FORM OF ACTION, WHETHER IN CONTRACT, TORT (INCLUDING NEGLIGENCE AND STRICT LIABILITY) OR OTHERWISE, AND FURTHER WILL EXTEND TO THE BENEFIT OF CTI'S VENDORS, APPOINTED DISTRIBUTORS AND OTHER...
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Page 35: Repair Policy
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.
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