SIMATIC 505 505–2557 Sixteen Channel Isolated RTD Input Module Installation and Operation Guide Order Number: PPX:505–8134–1 Manual Assembly Number: 2807060–0001 Original Edition
! DANGER DANGER indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury. DANGER is limited to the most extreme situations. ! WARNING WARNING indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury, and/or property damage. ! CAUTION CAUTION indicates a potentially hazardous situation that, if not avoided, could result in minor or moderate injury, and/or damage to property.
MANUAL PUBLICATION HISTORY SIMATIC 505–2557 RTD Input Module Installation and Operation Guide Order Manual Number: PPX:505–8134–1 Refer to this history in all correspondence and/or discussion about this manual.
LIST OF EFFECTIVE PAGES Pages Cover/Copyright History/Effective Pages iii —viii 1-1 — 1-7 2-1 — 2-13 3-1 — 3-31 A-1 — A-1 B-1 — B-2 C-1 — C-1 Description Original Original Original Original Original Original Original Original Original Pages Description
Contents Preface Chapter 1 1.1 1.2 Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Asynchronous Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compatability with Immediate I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Ohm, 10 Ohm, 120 Ohm RTDs, or Millivolt Inputs . . . . . . .
3.2 Internal Register Structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Description of the I/O Registers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Input Registers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output Registers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
List of Figures 1-1 1-2 1-3 1-4 1-5 1-6 1-7 2-1 2-2 2-3 2-4 2-5 2-6 2-7 2-8 3-1 3-2 3-3 3-4 3-5 3-6 3-7 3-8 3-9 3-10 3-11 3-12 3-13 3-14 3-15 3-16 3-17 3-18 A-1 C-1 Word Input to the PLC from the Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Example Change Input Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Effectof Voltage Input - 100 Ohm Platinum . . . . . . . . . . . . . . . . . .
List of Tables 3-1 3-2 3-3 3-4 3-5 3-6 3-7 3-8 3-9 3-10 B-1 vi Input and Output Register Offsets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Input Channel Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Peak/Valley Hold Input Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output Data Registers . . . . .
Preface This Installation and Operation Guide provides installation and operation instructions for the SIMATIC 505–2557 Sixteen Channel Isolated RTD Input Module for SIMATIC 505 programmable controllers. We assume you are familiar with the operation of SIMATIC 505 series programmable controllers. Refer to the appropriate SIMATIC user documentation for specific information on the SIMATIC 505 programmable controllers and I/O modules.
Related Manuals Additional manuals that have relevant information include the following: • SIMATIC 545/555/575 System Manual (PPX:505–8201–x). • SIMATIC 545/555/575 Programming Reference User Manual (PPX:505–8204–x). • SIMATIC 505 TISOFT2t User Manual (PPX:TS505–8101–x). Refer to material in these manuals as necessary for additional information about programming and operating your 545/555/575 system.
Chapter 1 Description 1.1 1.2 Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Asynchronous Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compatability with Immediate I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Ohm, 10 Ohm, 120 Ohm RTDs, or Millivolt Inputs . . . . . . . . .
1.1 Operating Modes The SIMATIC 505–2557 Sixteen Channel RTD Input Module is a member of Siemens’s family of I/O modules compatible with the SIMATIC 505 series programmable controllers. The SIMATIC 505–2557 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).
Digital Word Map RTD and/or millivolt signals are translated into a 14–bit digital word. Since the PLC requires a 16–bit input word, the 14–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 two bits not used for the digital word, one is used to show the sign of the word, while the other is used to note values which are “overrange or underrange.
1.2 RTD Input to Digital Conversion Engineering Units The following equations may be used to calculate the digital word in decimal format which will result from a particular RTD input: RTD Mode, Digital Word (WX) = Degrees X 10 Millivolt Mode, Digital Word (WX) = Millivolts X 100 As an example, the following figure illustrates the effects of a change in input level going from 0 degrees to 102.4 degrees in the RTD Input Mode.
Effect of Out-of-Range Input Signals RTD inputs exceeding 849.8 degrees C for 100 Ohm platinum or 260.0 degrees C for 120 Ohm nickel and 10 Ohm copper will cause the overrange bit to be set. A maximum temperature of 849.9 degrees C for 100 Ohm platinum or 260.1 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.
RTD Input to Digital Conversion (continued) Figure 1-5 Effect of Voltage Input - 10 Ohm Copper Millivolt inputs exceeding 103.04 millivolts will cause the overrange bit to be set. A reading of 103.05 millivolts will be returned for any positive overrange input. Similarly a millivolt input below 0 millivolts will cause the underrange bit to be set. A reading of 1 millivolt will be returned for any negative underrange input.
Resolution The module has a resolution of approximately 0.1 degrees C, 0.2 degrees F or exactly 0.01 millivolts.
Chapter 2 Installation 2.1 2.2 Installing and Configuring the Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Planning the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Calculating the I/O Base Power Budget . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unpacking the Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 Installing and Configuring the Module The installation of the SIMATIC 505–2557 Sixteen Channel RTD Input Module involves the following steps: 1. Planning the installation 2. Configuring the module 3. Inserting the module into the I/O base 4. Wiring the module input connector 5. Checking module operation The steps listed above are explained in detail in the following pages. Planning the Installation Planning is the first step in the installation of the module.
Configuring the Module The SIMATIC 505–2557 must be configured for 10 Ohm copper, 100 Ohm platinum or 120 Ohm nickel RTDs (2, 3 or 4 wire) or millivolt range and digital filtering/no filtering mode before wiring the input connectors and inserting the module into the I/O base. NOTE: As shipped, all input channels are configured 100 Ohm platinum, 3 wire RTDs, degrees Centigrade and digital filtering enabled. Configuring the module is a two step process.
Installing and Configuring the Module (continued) Selecting Temperature or Millivolt Input No hardware changes are required for millivolt inputs. To select millivolt input mode for an input turn OFF the M and L switch for the input channel. (See Figure 2-2.) To select a particular RTD probe for each channel configure the M and L switch. M 0 0 1 1 L 0 1 0 1 Millivolt 10 Cu 100 Pt 120 Ni NOTE: Each channel contains a jumper to select between 2, 3 and 4 wire RTD elements. (See Figure 2-2, JP68).
Selecting Degrees Celsius or Fahrenheit Locate the temperature scaling jumper JP66 on the right hand side of the module (See Figure 2-2) and select either degrees Fahrenheit or Celsius by positioning the jumper in the DEG F or DEG C position. Selecting Data Scaling Locate JP90 on the printed circuit board (See Figure 2-2). Select DISABLE 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.
Installing and Configuring the Module (continued) Figure 2-2 Configuration Jumper Locations 2-6 Installation SIMATIC 505–2557 Installation and Operation Guide
Inserting the Module Into the I/O 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, 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 connector card at the back of the module when inserting or removing the module.
2.2 Wiring the Input Connectors RTD input signals are accepted through a 64 position fixed connector with wire press in terminals located on the front of the module. Consult the RTD manufacturer’s recommendations for selecting the input wire type and size. The connector will accept 18 to 30 AWG wire. The SIMATIC 505–2557 uses a fixed connector to terminate field wiring. This is used because the chemistry of a removable connector may have an adverse effect on the accuracy of the measurement.
To assign an input to a specific channel, locate the appropriate channel position on the press in connector block as shown in the following figure (each channel consists of 4 positions). Figure 2-4 Press In Wiring Connector NOTE: RTD wires must be of the same gauge for proper lead length compensation.
Wiring the Input connectors (continued) Ground at One End Only Figure 2-5 Wiring Diagram for 2, 3, or 4 Wire RTD NOTE: For proper operation, ensure that the SIMATIC 505–2557 is not subjected to large temperature gradients during operation.
Ground at One End Only Figure 2-6 Wiring Diagram for Millivolt Measurements Connecting the Shield Wiring Siemens Energy & Automation, Inc. recommends that all signal wires be shielded twisted–pair with a foil wrap shield and a separate drain wire and that they be installed in a metallic conduit. Use Belden cable 8761 or equivalent which contains 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.
Wiring the Input connectors (continued) Earth Ground Figure 2-7 Cable Grounding NOTE: The SIMATIC 505–2557 is isolated channel group to channel group. Each group consist of 2 input channels. Shields within a channel group may be terminated together at either G terminal. Siemens recommends that the shield wire be soldered or crimped to the wire connected to the G terminal.
Checking Module Operation First turn on the base supply 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, blinks, (or goes out during operation), the module has detected a failure. For information on viewing failed module status, refer to your SIMATIC TISOFT or SoftShop user manual. To diagnose and correct a module failure, refer to the next section on troubleshooting.
Chapter 3 Advanced Function Programming 3.1 Advanced Software Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview of the Advanced Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting the Module Configuration Jumper . . . . . . . . .
3.1 Advanced Software Functions Introduction As PLC control systems become more complex, the need for real-time processing of analog signals is needed at the I/O level. Current implementations using the 505 controllers utilize analog alarm blocks and/or special function programs within the controller. The SIMATIC 505–2557 analog input module from Siemens Energy & Automation, Inc., can reduce the program complexity and scan time by performing this signal processing in the module.
All of these advanced function options are designed to be stored in the controller in a V-memory or K-memory table and downloaded to the module. The advantages of this method over a communications port on the module are greater flexibility, easier maintenance, and reduced documentation. The controller can change any function “on the fly” if changing process conditions require (for example, a process needs tighter control, therefore narrower alarm limits).
Advanced Software Functions (continued) Logging the Module in the Controller I/O Configuration Memory First turn on the base power supply. 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, blinks (or goes out during operation), the module has detected a failure. For information on viewing failed module status, refer to your SIMATIC 505 TISOFT2 User Manual (PPX:TS505–8101–x).
3.2 Internal Register Structures Description of the I/O Registers The SIMATIC 505–2557 module in the high-density mode logs in to the controller as 32 WX input registers, 32 WY output registers and 16 X and 16 Y discrete inputs and outputs. This high-density configuration provides support for reading the raw data and the processed data, and for writing the configuration data to the module. Refer to section 3.7 for a one-page summary of I/O assignments.
Internal Register Structures (continued) Input registers WX49 – WX54 consist of special flag bits that may be interrogated in the controller ladder program to detect alarm conditions, overrange or underrange conditions, or arithmetic overflow conditions due to scaling operations. See Figure 3-3.
Output Registers The SIMATIC 505–2557 module also utilizes 32 WY registers. These registers are used to transfer the scaling values, the alarm setpoints, the filtering time constants, and the averaging count values to each of the sixteen channels. After the data is loaded into the module, these registers then enable each of the functions on a channel-by-channel basis. These WY registers become control words for enabling each channel for special operations (Table 3-4).
Internal Register Structures (continued) After the values are loaded to the module, WY registers are used like those shown in Table 3-5.
Before any transfers are made to the module, the relay ladder program should examine the state of this input. (Only when the input is true), can the loading operation begin.
Internal Register Structures (continued) Outputs The discrete output points consist of Y17 – Y32. Y17 – Y19 are used to identify the data being transferred. As data is loaded to the module, the state of these bits identifies the type of data being transferred (see Table 3-6). The SIMATIC 505–2557 module decodes these bits and processes the data accordingly.
Loading Data into the SIMATIC 505–2557 Module The process by which data is loaded into the SIMATIC 505–2557 module is shown in Figure 3-6.
Internal Register Structures (continued) The following steps explain how data is loaded into the SIMATIC 505–2557 module. 1. V- or K-memory tables are constructed with the scaling, alarm setpoints, filtering and averaging units. In the example below, low alarm and high alarm setpoints are loaded for each channel from V1 through V32. V1 – V16 contain the low alarm setpoints for channels 1–16, and V17 – V32 contain the high alarm setpoints for channels 1–16. See Figure 3-7.
3. The data identification outputs Y19 – Y17 are set according to the data being transferred. These are decoded by the module in order to distinguish the type of data being loaded (see Figure 3-9). MWIR A V300 B Y17 N=3 C1 Specified word V300=2 C2 LSB 14 15 16 17 18 19 Figure 3-9 Identifying the Data Being Transferred 4. Y32 Data_Ready is energized to transfer the word data into the module (see Figure 3-10).
Internal Register Structures (continued) 5. The functions are enabled with the enable bits. WY65 and WY66 are set to all 1’s with a MOVW instruction (see Figure 3-11). MOVW X16 C2 A V301 B WY65 N=2 V301=65,535 V302=65,535 C3 Figure 3-11 Enabling the Functions Loaded 6. With the Data_Ready bit, data is transferred with Y32 (see Figure 3-12).
3.3 Loading Programs into the I/O Module Before entering relay ladder logic in the controller, utilize the worksheets in sections 3.8 and 3.9, to ensure a successful installation and start-up. The following sample ladder program is provided to demonstrate how the data is loaded into the SIMATIC 505–2557 module. Each channel is enabled for all functions supported. This sample RLL loads the module with alarm, scaling, filtering, averaging, and function enable bits.
Loading Programs into the I/O Module (continued) Data_Ready Y32 RSTI Y32 1 X16 C2 CTR1 5 C10 10 TCC1 +0 = INT P= 4 Module_Ready X16 MOVW Y17 RSTI A:V1 B:WY65 N=32 Y18 SETI Y19 RSTI Y32 SETI 31 TCC1 +1 = INT Module_Ready MOVW X16 Y17 RSTI A:V33 B:WY65 N=32 Y18 SETI Y19 RSTI Y32 SETI 52 TCC1 +2 = INT Module_Ready MOVW X16 Y17 RSTI A:V65 B:WY65 N=32 Y18 SETI Y19 RSTI Y32 SETI 73 TCC1 +3 = INT Module_Ready MOVW X16 Y17 RSTI A:V97 B:WY65 N=32 Y18 SETI Y19 RSTI Y32 SETI Figure 3-13
The configuration example ladder program sequences through the transfer of all configuration data to the module. The first rung in the example resets Y32 if Y32 was turned ON on the previous scan. This should be done at the beginning of the ladder scan. The second rung is a counter that controls loading of the WY registers with configuration data. When the counter is reset, the current count is equal to zero. If X16 is ON, the WY registers are loaded with Low and High Alarm data from V1 through V32.
3.4 Timing Considerations Without any of the advanced features enabled, the SIMATIC 505–2557 module will update all 16 points in less than 6 msec. With all functions enabled for all 16 points, the module will update all 16 channels in less than 56 msec. Each function has a specific overhead associated with it and your application should consider the time delays to ensure that there is adequate time allowed for the processing of data.
3.5 Additional Information about Each Function Default Values There are default values for every function that is supported. If no data is transferred to the module and the enable bits for a function are set and written to the module, then the default values will be used. See Table 3-8. NOTE: No matter what functions are enabled, the actual hardware data from the I/O channel is always present in WX33 – WX48.
Additional Information about Each Function (continued) Degrees Centigrade or Degrees Fahrenheit In advanced mode the selection of degrees C or F is controlled by the information stored and transferred to the module at WY72. The default parameters are all zeroes which will cause the SIMATIC 505–2557 module to return the value in degrees Centigrade x10.
Digital Filtering Digital filtering time is the settling time to within 1 LSB of the analog-to-digital converter on the module. (Often digital filtering is specified as a time constant in milliseconds. With a time constant specification, it will take the input 4 to 5 time constants to reach 99% of the final value.) The value entered is the actual settling time.
Additional Information about Each Function (continued) Averaging Exclusivity If averaging and filtering are both enabled, alarming is exclusive of averaging. This means that after the data is filtered it is compared against alarm setpoints and then averaged. Numerical Range Values loaded into the module for averaging are expressed as 16-bit unsigned integers 1 to 65535 in units of number of samples. Signed integers will be interpreted as unsigned values.
Peak and Valley Hold Reset Outputs Y28 and Y29 are used to reset the valley or peak hold functions. The operation during reset is dependent on whether the hold function is enabled for each individual channel. Figure 3-15 shows how the peak value and the valley value react during reset.
Additional Information about Each Function (continued) Overrange/Underrange flags The overrange (WX52) and underrange (WX53) flag bits are set any time the analog-to-digital converter (ADC) saturates and cannot produce any higher value for positive inputs or lower value for negative inputs. NOTE: A zero input value is a reasonable input level of signal. It is not uncommon for the input to go below zero and the sign bit to change. The ADC will function below a value of zero until saturation.
3.6 Troubleshooting Troubleshooting the System Use the following procedures and Table 3-10 to troubleshoot your system. • First examine your V- or K-memory tables to ensure that the data to be loaded into the module makes sense. • Utilize the worksheets located at the end of this chapter to calculate key address locations. • Examine the relay ladder program to verify that the V-memory tables are being loaded into the correct WY65 – WY96 output registers.
Troubleshooting (continued) Table 3-10 Troubleshooting Flow Diagram Symptom Probable Cause Corrective Action Wrong values Not logged in Login to controller Not logged in correctly Verify log-in Ladder program did not execute Debug ladder program. Verify V-memory tables.
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SIMATIC 505–2557 Installation and Operation Guide Advanced Function Programming 3-29
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3.10 Items Unique to the SIMATIC 505–2557 Module Items unique to the SIMATIC 505–2557 RTD Input Module. Open RTD Status Bits: WX55 Figure 3-18 Open RTD Status Bits The bits returned in WX 55 indicate an open RTD for a particular channel. Floating Inputs If no RTD is connected to an input channel the value returned to the PLC is unpredictable.
Appendix A Troubleshooting If the module provides improper readings or the status indicator is not on, use the following chart to determine the appropriate corrective action. Figure A-1 Troubleshooting Matrix ! CAUTION The module fuse (F1) is not user servicable. If this fuse is blown, the module has a serious component failure. Do not attempt to repair or replace fuse (F1). Return the module to your nearest Siemens distributor or Siemens Energy & Automation, Inc. for repair.
Appendix B Specifications Table B-1 Specifications Input Channels 16 RTD or Millivolt Inputs (2 inputs per channel group) RTD Types 10W Cu (TCR=0.00427 W/W/_C) 100W Pt (TCR=0.003850 W/W/_C) European DIN 43760 120W Ni (TCR=0.00672 W/W/_C) 2, 3, and 4 wire modes RTD Excitation Current 250 micro Amp Millivolt Input Range 0 to 100 mV Millivolt Input Impedance >10KW @ 60 Hz >1000MW @ DC Absolute Millivolt Accuracy ±0.
Table B-1 Specifications (continued) Accuracy 10W Cu (0.5_C at 25_C) (1_C from 0_ to 60_C) 100W Pt (1_F at 25_C) (2_F from 0_ to 60_C) (0.5_C at 25_C) (1_C from 0_ to 60_C) 120W Ni (1_F at 25_C) (2_F from 0_ to 60_C) (0.
Appendix C Jumper Settings Log Sheet Figure C-1 Jumper Settings Log Sheet SIMATIC 505–2557 Installation and Operation Guide Jumper Settings Log Sheet C-1
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