ED-2002-016 8 Channel Thermocouple Input Module (4310) PDF

Messung Systems
NEXGEN PLC I/O Modules
NEXGEN PLC
8 Channel, Thermocouple Input Module (Ordering Code 4310)
Document No.:ED-2002-016
Version: 1.0
MESSUNG SYSTEMS EL-2, J- Block MIDC Bhosari, Pune 411026.(INDIA) Tel: (+91)-020-712 0807, 712 2807. Email : marketing@ms.messung.com WEB: www.messung.com
SD-2002-016 8 Channel Thermocouple Input Module(4310)mod.doc Document No.: ED-2002-006/V1.0
Published July 2002 Page 1 of 53
NEXGEN PLC I/O Modules Revision Version Date Description
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1.0
22 May 2004
8 Channel, Thermocouple Input Module (Ordering Code 4310) NEXGEN Series of PLCs.
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INDEX
1. 1.1 1.2 1.3 2. MODULE OVERVIEW........................................................................................................................................ 6 THERMOCOUPLE INPUT MODULE OVERVIEW ...................................................................................................... 6 LED INDICATIONS ............................................................................................................................................. 8 GENERAL SPECIFICATIONS ................................................................................................................................ 9 MODULE OPERATION.................................................................................................................................... 10 2.1 BLOCK DIAGRAM............................................................................................................................................. 10 2.2 THERMOCOUPLE TYPES AND RANGE OF TEMPERATURES ................................................................................... 12 2.3 ON-BOARD PROCESSOR OPERATIONS............................................................................................................. 12 2.3.1 Power On Operations ............................................................................................................................ 12 2.3.2 Analog to Digital Conversion ................................................................................................................. 13 2.3.3 Cold Junction Compensation................................................................................................................. 14 2.3.4 Scaling ................................................................................................................................................... 14 2.3.5 Linearization .......................................................................................................................................... 14 2.3.6 Averaging .............................................................................................................................................. 15 2.4 MODULE INFORMATION ................................................................................................................................... 15 2.4.1 Input Output Image Mapping ................................................................................................................. 15 2.4.2 Memory Mapping ................................................................................................................................... 16 2.4.3 Commands ............................................................................................................................................ 17 2.4.4 Module Status Bits................................................................................................................................. 18 3. 3.1 3.2 3.3 4. INSTALLATIONS AND WIRING...................................................................................................................... 19 MODULE INSTALLATION ................................................................................................................................... 19 CONNECTION DETAILS .................................................................................................................................... 19 PRECAUTIONS TO BE TAKEN ............................................................................................................................ 21 CONFIGURATION AND PROGRAMMING ..................................................................................................... 22 4.1 SLOT CONFIGURATION .................................................................................................................................... 22 4.2 CHANNEL CONFIGURATION .............................................................................................................................. 23 4.2.1 Static Configuration ............................................................................................................................... 23 4.2.2 Dynamic Configuration .......................................................................................................................... 25 4.3 CHANNEL INFORMATION .................................................................................................................................. 27 4.3.1 Channel Data......................................................................................................................................... 27 4.3.2 Channel Status ...................................................................................................................................... 27 4.4 PROGRAMMING WITH NEXGEN 4000 CPU ....................................................................................................... 30 4.5 PROGRAMMING WITH NEXGEN 5000 CPU ....................................................................................................... 37 5. 5.1 5.2 6. TROUBLESHOOTING ..................................................................................................................................... 42 LED INDICATIONS FOR DIAGNOSTICS............................................................................................................... 42 FAULT DIAGNOSTIC ......................................................................................................................................... 42 APPENDIX 1 .................................................................................................................................................... 46 6.1 REFERENCE TABLE - T TYPE THERMOCOUPLE (COPPER VS. COPPER-NICKEL) ................................................. 47 6.2 REFERENCE TABLE - E TYPE THERMOCOUPLE (NICKEL-CHROMIUM VS. COPPER-NICKEL)................................. 48 6.3 REFERENCE TABLE - R TYPE THERMOCOUPLE (PLATINUM-13% RHODIUM VS. PLATINUM) ................................ 48 6.4 REFERENCE TABLE - S TYPE THERMOCOUPLE (PLATINUM-10% RHODIUM VS. PLATINUM)................................. 49 6.5 REFERENCE TABLE - B TYPE THERMOCOUPLE (PLATINUM-30% RHODIUM VS. PLATINUM-6% RHODIUM) ........... 50 6.6 REFERENCE TABLE - N TYPE THERMOCOUPLE (NICKEL-14.2% CHROMIUM-1.4% SILICON VS. NICKEL-4.4% SILICON- 0.1% MAGNESIUM) ................................................................................................................................... 51
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INDEX OF FIGURES
FIGURE 1 : FRONT VIEW OF THERMOCOUPLE INPUT MODULE.........................................................7 FIGURE 2 : BLOCK DIAGRAM OF THERMOCOUPLE INPUT MODULE..................................................11 FIGURE 3 : ADC CONVERSION CYCLE ........................................................................................13 FIGURE 4 : INPUT OUTPUT IMAGE MAPPING OF THERMOCOUPLE INPUT MODULE .........................16 FIGURE 5 : MEMORY MAPPING OF THERMOCOUPLE INPUT MODULE .............................................16 FIGURE 6 : CONNECTION DIAGRAM OF THERMOCOUPLE INPUT MODULE .......................................20
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a)
Guidelines for the Safety of the user and protection of I/O Modules. This manual provides information for the use of the I/O Modules . The manual has been written to be used by trained and competent personnel. The definition of such a person or persons is as follows: Any engineer who is responsible for the planning, design and construction of automatic equipment using the product associated with this manual should be of a competent nature, trained and qualified to the local and national standards required to fulfill that role. These engineers should be fully aware of all aspects of safety with regards to automated equipment. Any commissioning or service engineer must be of a competent nature, trained and qualified to the local and national standards required to fulfill that job. These engineers should also be trained In the use and maintenance of the completed product. This Includes being completely familiar with all associated documentation for the said product. All maintenance should be carried out in accordance with established safety practices. All operators of the completed equipment should be trained to use that product in a safe and coordinated manner in compliance to established safety practices. The operators should also be familiar with documentation, which is connected with the actual operation of the completed equipment. Note: The term-completed equipment refers to a third party constructed device, which contains or uses the product associated with this manual. Note on the Symbol used in this Manual At various times through out this manual certain symbols will be used to highlight points of Information, which are Intended to ensure the users personal safety and protect the integrity of equipment. Whenever any of the following symbols are encountered its associated. Note must be read and understood. Each of the symbols used is listed below; with a brief description of its meaning.
b)
c)
Warning !
This product can only function correctly and safely if it is transported, stored, setup, and installed correctly, and operated and maintained as recommended.
Warning !
The specifications of product and contents of manual are subject to change without notice.
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1. Module Overview
This chapter describes the following Thermocouple Input Module Overview LED Indications General Specifications
1.1 Thermocouple Input Module Overview

This thermocouple input module converts thermocouple input mV values into equivalent temperature values of 0.1C resolution with cold junction compensation and linearization. This is sigma - delta type A/D conversion. It provides 8 non-isolated channels, 16-bit resolution ADC. The individual channel can be configured for specific type of thermocouple input. The thermocouple types along with temperature ranges are given in below table.
Thermocouple Type
J K T E R S B N
C Temperature range -210.0 to +760.0 -270.0 to +1370.0 -270.0 to +400.0 -270.0 to +1000.0 0.0 to +1760.0 0.0 to +1760.0 0.0 to +1820.0 -270.0 to +1300.0
The parameters and commands those are transferred to the module for advanced processing are Thermocouple input type Return value in case of open circuit Averaging Channel enable / disable Maximum minimum set points Static configuration write The module provides diagnostic information for each channel. It includes Maximum / minimum set points exceeded Invalid configuration Out of range Open circuit detection CJC fault This is an intelligent module with on-board processor and memory. The data transfer between CPU module and thermocouple input module takes place by 'READ_W' and 'WRITE_W' functions in application program. The module status is available in input image and commands can be issued through output image.
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The figure 1 on next page shows front view of 8 channels thermocouple input module
4310
Terminal Block Fixing Screw
ANALOG INTPUT 8 CH T/C
LM35 CJC Sensor PCB
01 02 03 04 05 06 07 08 09 10
NO 24 V SUPPLY CPU FAULT CJC FAULT
Module Status LEDs
CH0 11 TC0+ TC1+ TC0CH1 CH2 CH3 CH4 CH5 CH6 CH7
Front Shield Plate
12 13 14 16
TC115 SHIELD0 17 SHIELD1 TC2+
Channel Status LEDs
Pin Removable Terminal Block
18 20 22
TC3+ 19 TC221 23 TC3SHIELD2 SHIELD3 TC4+ TC5+ TC4-
24 25 26 28 30 31 32 33 34 35
TC527 SHIELD4 29 SHIELD5 TC6+ TC7+ TC6TC7SHIELD6 SHIELD7 + 24 V 0V EARTH
IO Label
Terminal Block Fixing Screw
36 37 38
LED Indications
Connection Details Label
Front Door
Figure 1 : Front View of Thermocouple Input Module The module provides LED indications on the front. Brief information about channel can be written on the front door. Behind front door, 38-pin removable terminal block is provided for interfacing. The wiring details are shown on backside of front door.
SD-2002-016 8 Channel Thermocouple Input Module(4310)mod.doc Document No.: ED-2002-006/V1.0 Published July 2002 Page 7 of 53
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The thermocouple input module can be configured in any IO slot of the PLC. The number of thermocouple input modules is limited by back panel current capacity. In general a channel requires following information Dynamic configuration information Static configuration information Data and Status information In all, 22 words information per module is available.
1.2 LED Indications

The following table explains significance of 11 numbers of LEDs provided on the module. No.
1
LED
No 24 V Supply
Color
Orange
Status
OFF ON OFF
Description
24 VDC supply to module healthy 24 VDC supply to module absent 24 VDC circuit on-board glass fuse blown Module hardware healthy and module is ready Module in self test CPU watchdog faulty Module busy CJC sensor OK. CJC sensor short CJC sensor open Channel not enabled Channel enabled and healthy Parameter mismatch Invalid configuration Over range Under range Open circuit CJC fault
CPU fault
Orange
ON OFF
CJC Fault
Orange
ON OFF ON
Channel Status (Eight for eight channels)
Green
Flashing with 10 Hz frequency
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1.3 General Specifications

General specifications of 8 channels thermocouple input module are as given below.
Number of Input channels Conversion Method J K T Thermocouple E input types and R output range S B N Temperature resolution Accuracy Input filter frequency Conversion time Thermocouple linearization Cold junction compensation Isolation Input Impedance External supply requirement External supply protection Indications Back-plane current (5 V consumption) IO points consumed Termination / Connection Ordering code Channel to internal circuit Channel to channel 8 Sigma delta with digital filter
-210.0 C to +760.0 C -270.0 C to +1370.0 C -270.0 C to +400.0 C -270.0 C to +1000.0 C 0.0 to +1760.0 C 0.0 to +1760.0 C 0.0 to +1820.0 C -270.0 C to +1300.0 C
0.1 C 0.5 % of full scale 50 Hz 60 ms per channel In steps of 10 C LM 35 IC sensor mounted on terminal block itself 1.5 kV optical Nil 1 M Ohms 24 V DC, 100 mA (18 30 VDV including ripple) 315 mA miniature glass fuse on module Reverse polarity protection No 24 V Supply CPU fault CJC fault Channel status (8) 250 mA 8 input bits and 8 output bits Removable 38 pin terminal block 4310
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2. Module Operation
This chapter helps in getting started with the thermocouple input module. It describes the basic operation of the module. This chapter explains operational details of: Block Diagram Thermocouple Types and Range of Temperatures On-Board Processor Operations Module Information
At the time of application program development, the module can be configured using the programming software DOXMINI+ so that above special features can be used. Refer chapter 4 for configuration and programming details.
2.1 Block Diagram

Block diagram of thermocouple input module is shown below.
On board / Analog to Digital Converter O P T I C A L I S O L A T I O N Module Interface Circuit +5V GND PCB with LM35 as CJC Sensor Cold junction Compensation Input Circuit Channel 0 Input Circuit Channel 7 Input Circuit
Processor
Watch Dog
TC0+ TC0SHIELD0
Amplifier
Memory for Configuration, Data, Status
Information
Multiplexer
TC7+ TC7SHIELD7
CPU Module
No 24 V Supply Signal +15 V -15 V Supply for ADC Circuit +5 V -5 V GND
ature Glass Fuse
+ 24 VDC 24 V GND Earth
DC-to-DC Converter
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Figure 2 : Block diagram of Thermocouple Input module The module provides eight analog to digital channels for thermocouple input. CPU bus is optically isolated from ADC circuit. The analog to digital converter operates on serial data from the channels. The cold junction compensation sensor signal and enabled channel input signals are multiplexed and then amplified for ADC input. Thus sigma-delta (/ ) ADC converts only enabled analog channels to digital value one by one. The converted count for each channel is manipulated by on-board processor. It has following functions. Cold junction compensation Scaling Linearization Averaging
Thus cold junction compensated, scaled and linearized temperature reading is transferred to module memory, which holds channel data information. If averaging is required, depending on the averaging count, on-board processor performs averaging of those many previous readings and updates channel data information. The channels can be independently enabled or disabled. Each channel input circuit has open circuit detection mechanism. On-board processor detects signals, which are out of range of selected input type. The CJC sensor faults are detected by module. All this information is available to main CPU. The dynamic configuration, static configuration, data, status information is available in dual port RAM on the module. The configuration of all channels is transferred to the module memory using WRITE_W function in the application program. Similarly data and status of all channels can be read by READ_W function in the application program. The module requires external 24 V for ADC circuit operation. Internally DCto-DC converter generates 15 VDC and 5 VDC as required by each channel. If 24 VDC is absent or on-board glass fuse is blown, module generates 'No 24 V Supply' signal for main CPU. The fuse protection for external 24 VDC supply is provided on module.
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2.2 Thermocouple types and range of temperatures

This section describes the thermocouple types and data range of temperatures supported by module.
Type Material mV signal C temperature range
J K T E R S B N
Iron Vs Constantan (Copper-Nickel) Chromel (Nickel-Chromium Vs Alumel (Nickel-Aluminium) Copper Vs Constantan (Copper-Nickel) Chromel (Nickel-Chromium) Vs Constantan (Copper-Nickel) Platinum Vs Platinum-13% Rhodium Platinum Vs Platinum-10% Rhodium Platinum- 6% Rhodium Vs Platinum-30% Rhodium Nickel-14.2% Chromium-1.4% Silicon Vs Nickel-4.4% Silicon-0.1% Magnesium
-8.096 to 42.922 -6.458 to 54.807 -6.258 to 20.869 -9.835 to 76.358 0.000 to 21.108 0.000 to 18.698 0.000 to 13.814 -3.990 to 47.502
-210.0 to +760.0 -270.0 to +1370.0 -270.0 to +400.0 -270.0 to +1000.0 0.0 to +1768.0 0.0 to +1768.0 0.0 to +1820.0 -200.0 to +1300.0
2.3 On-Board Processor Operations

The thermocouple input module is intelligent module with on-board processor. The functions of on-board processor are explained below. 2.3.1 Power On Operations After power ON, if 24 V supply to module is absent or on-board fuse is blown then on-board processor sets Ix.1 bit of input image. After power ON, this processor checks the hardware called as self test. During self-test and if hardware error is detected, Ix.1 bit is set. Also CPU fault LED on front panel is put ON indicating that module is not accessible. During module operation, if module hardware is found faulty or watchdog error is detected, Ix.1 bit is set. If the module hardware is OK, Ix.1 bit is cleared. Module starts CJC sensor signal conversion by default and waits for static and dynamic configuration from the CPU module. After reception of valid configuration of thermocouple input channels, the module starts sampling and digital conversion cycle of enabled channels. For more details of IO image of module, refer chapter 2.9. The module continues sampling, converting the channels and updating module memory even after the PLC is put in STOP mode. But In this case, CPU module does not read the channel data and status.
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2.3.2
Analog to Digital Conversion The module samples a thermocouple input channel and converts mV input to its digital value one by one. After power on, first CJC sensor signal is sampled and conversion is started. After that as shown in the figure below, only enabled channels are converted. If any error like invalid configuration is detected, channel is not converted. The disabled channels or channels with error detected are bypassed retaining earlier values. After one channel conversion, module initiates next channel conversion. During this conversion period, module processes converted data of previous channel. This process includes applying CJC compensation, scaling, linearization and averaging. Thus the processed data for previous channel is made available during this period. After converting all healthy channels, processed data and status information of all the channels is transferred to respective memory area on the module. This cycle continues. Thus when the processor module performs READ_W operation, it reads either old or new information i.e. data and status of channels.
Channel 0 disabled / error detection
CJC Channel Conversion Update all channel data and status Channel 0 Conversion Channel 7 Conversion

Channel 1 Conversion Channel 6 Conversion


Figure 3 : ADC Conversion Cycle The module takes certain time to sample all enabled channels and convert into digital value. The required time is the module update time. The factors affecting module update time is number of channels enabled. The module update time is minimum when only one channel is enabled. Likewise the module update time is maximum when all channels are enabled. The module incorporates a digital low pass filter to reject noise on the input signal. For thermocouple inputs, it is fixed to 50 Hz. It provides better noise rejection for low filter frequencies.
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2.3.3
Cold Junction Compensation Cold Junction Compensation (CJC) is necessary when making temperature measurements using thermocouples. The thermocouple itself works on the principle that an electrical potential exists at the junction of two dissimilar metals. The amount of this potential varies with temperature. When using a thermocouple, the voltage across the thermocouple is measured and accordingly the temperature is calculated. CJC becomes necessary because the junction between each end of the thermocouple and thermocouple input module (terminal block) also adds a potential difference to the actual thermocouple voltage. When the thermocouple wires are connected to the terminal block, two more thermocouple junctions are formed, because the terminals are made of a different material (copper) than the thermocouple wires. These extra junctions (called cold junctions), develop their own voltage, which alters the voltage generated by the actual thermocouple. To compensate for this added potential, it is necessary to know the temperature at the junction between the thermocouple and terminal block. This temperature is measured using an extra CJC sensor. This is a temperature sensor other than a thermocouple. The sensors used here is IC (integrated circuit) sensors LM 35, which is directly, mounted on terminal block between terminal numbers 4, 6 and 8 as shown in chapter 3.2. 15 VDC for the sensor LM35 is provided by thermocouple input module. The sensor provides 0 to 70 mV for 0 to 70 C temperature. To make actual thermocouple temperature measurement, the voltage from the thermocouple and CJC sensor is measured considering them as different channel inputs as explained in chapter 2.3.2. Then CJC sensor temperature reading is compensated from thermocouple channel temperature reading. Thus the effect of cold junctions is negated. This compensated reading is then scaled and linearized to get actual temperature.
2.3.4
Scaling The mV signal from thermocouples is scaled for equivalent temperature as per reference tables provided by standards. For the same, refer appendix 1.
2.3.5
Linearization Thermocouple signals are not linear e.g. 10 percent change in a thermocouple voltage does not correspond to a 10 percent change in its temperature. Therefore linearization of thermocouple signal is necessary to get equivalent temperature. Also, each thermocouple type requires different linearization. In thermocouple input module linearization is performed by flexible software methods. This is done with look up table in steps of 10 C for each thermocouple type. ADC count is mapped within its 10 C temperature range and equivalent temperature is calculated considering line equation.
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2.3.6
Averaging The module provides user selectable averaging facility so that stable value is available for processing and necessary control action. The module samples and converts enabled channels one by one. The module keeps digital value into different memory locations. Depending on the averaging count, the module performs averaging of those many previous readings and updates channel data information. Thus if the averaging counts of channel 0, 1 and 2 are 0, 4 and 8 respectively, then initially data of channel 0, 1 and 2 are updated after 1, 4 and 8 conversion cycles respectively. After that, it gets updated in every cycle. One conversion cycle means sampling and converting all enabled channels as explained in chapter 2.3.2. Thus combination of filter frequency and averaging count can be selected to get optimum channel update time and stable temperature reading.
2.4 Module Information

This section explains the entire information required and available with thermocouple input module. The following points are discussed 2.4.1 Input Output Image Mapping Memory Mapping Commands Module Status Bits
Input Output Image Mapping

Input output image mapping related to thermocouple input module is shown below.
CPU module Input Image 1.1.1.1.1

No 24 V Supply Invalid Configuration Set Points Exceeded Out of Range Open Circuit CJC Fault Ix.0 Ix.1 Ix.2 Ix.3 Ix.4 Ix.5 Ix.7 Input Scan Logic Scan IMM_IN ENO EN SLOT Output Scan
Thermocouple Input module Channel 0 Channel 1 Channel 2 Channel 3 Channel 4
CPU Fault
Output Image
Static Configuration Write Qx.0
Logic Scan IMM_OUT ENO EN SLOT
Channel 5 Channel 6
Module Interface circuit
Channel 7
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Figure 4 : Input Output Image Mapping of Thermocouple Input Module The module consumes 8 input bits (1 byte) of input image and 8 output bits (1 byte) of output image in the CPU module. CPU reads the status of module in input scan. CPU writes user commands to module in output scan. For immediate updation of input and output image in application program, IMM_IN and IMM_OUT functions can be used in application program whenever required. For the details refer chapter 2.4.3 and 2.4.4. 2.4.2 Memory Mapping The memory mapping related to thermocouple input module is shown in figure below.
CPU module Thermocouple Input module
Logic Scan WRITE W ENO EN SLOT DATA LEN ADDR Logic Scan READ W ENO EN SLOT DATA MW118 MW120 MW122 MW124 MW126 LEN ADDR 17 words hold channel dynamic information of 8 channels Channel Enable Word MMW00 Channel 0 High Set Point MMW02 Channel 0 Low Set Point MMW04
17 words hold channel dynamic information of 8 channels Channel Enable Word MW66 Channel 0 High Set Point MW68 Channel 0 Low Set Point MW70
Channel 7 High Set Point Channel 7 Low Set Point
MW96 MW98
8 words hold channel static information of 8 channels Channel 0 Static Configuration MW50 Channel 7 Static Configuration MW64 9 words hold data for 8 channels and CJC Channel 0 Data MW100 Channel 7 Data CJC Data 5 words hold status of 8 channels Channel Set Point Status Channel Configuration Status Channel Input Range Status Channel Open Circuit Status CJC Sensor Status MW114 MW116
Channel 7 High Set Point Channel 7 Low Set Point
MMW30 MMW32
8 words hold channel static information of 8 channels Channel 0 Static Configuration MMW96 Channel 7 Static Configuration MMW110 9 words hold data for 8 channels and CJC Channel 0 Data MMW128 Channel 7 Data CJC Data 5 words hold status of 8 channels Channel Set Point Status Channel Configuration Status Channel Input Range Status Channel Open Circuit Status CJC Sensor Status MMW142 MMW144 MMW146 MMW148 MMW150 MMW152 MMW154
Figure 5 : Memory Mapping of Thermocouple Input Module The configuration (grouped as static and dynamic) from PLC variable area e.g. memory or page is transferred to module memory when WRITE_W function gets executed in application program i.e. in logic scan. The module
Published July 2002 Page 16 of 53 SD-2002-016 8 Channel Thermocouple Input Module(4310)mod.doc Document No.: ED-2002-006/V1.0
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takes action on static configuration information only when static configuration write command is issued. This can be issued by setting Qx.0 bit of output image. In case of dynamic configuration information, the module detects any change in configuration cyclically and if any valid change is detected, it takes appropriate action. After power on, the module starts converting CJC sensor input channel. The module starts its channel conversion operation only after receiving valid configuration. If channel configuration is modified or channel is enabled / disabled, it takes effect only in the subsequent conversion cycle. The channel configuration can be modified using WRITE_W function. Similarly channel can be enabled or disabled during normal operation for optimum results. The channel temperature readings and CJC reading (ambient temperature) and status information can be read from the module using READ_W function. 2.4.3 Commands As discussed in chapter 2.4.1, output image bits are used as user commands to module. User can issue various commands to module through application program. CPU writes commands in output image area of module in output scan. The module reads output image area cyclically and takes appropriate action. If 'IMM_OUT' function is executed in logic scan for a particular slot, it stops current logic scan, executes output scan for defined slot and resumes logic scan again. This is useful when ever immediate updation of output image is needed. The functions of output image bits are given below No. Bit Address Command Write static configuration OFF Status ON 1 Qxx.0 Description It gives command to module to accept static configuration or change static configuration as per contents of module memory words MMW #96 to MMW#110. Write static command is OFF.
Note xx is slot number in which module is fixed. Qxx.1 to Qxx.7 are reserved and should not be used.
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2.4.4
Module Status Bits As discussed in chapter 2.4.1, input image bits are used as module status indications. User can check the module status through application program. The module writes status in its input image area cyclically. The CPU reads this input image area in input scan. If 'IMM_IN' function is executed in logic scan for a particular slot, it stops current logic scan, executes input scan for defined slot and resumes logic scan again. This is useful when ever immediate updation of input image is needed. The functions of input image bits are given below
No.
Bit Address
Module Status
Statu s
ON OFF
Description
24 VDC supply to module absent 24 VDC circuit fuse blown. Module CPU watch dog fault. Module not ready. 24 VDC Supply to module healthy Module healthy and ready Invalid static configuration Parameter mismatch Valid static configuration Valid parameters Any channel temperature reading above high set point Any channel temperature reading below low set point All channel temperature readings within high and low set points Over range for any enabled channels/s. Under range for any enabled channels/s. All enabled channel inputs are within specified range Open circuit for any enabled channels/s. All enabled channel inputs are connected CJC sensor open CJC sensor short CJC sensor healthy Module CPU watch dog fault Module not ready Module healthy and ready
MMW for storing the details
Ixx.0
Module Not Ready
Not Applicable
Ixx.1
Invalid Configuration
ON OFF ON OFF ON
MMW #148
Ixx.2
Set point exceeded
MMW #146
Ixx.3
Out of Range OFF ON
MMW #150
Ixx.4
Open Circuit OFF ON
MMW #152
Ixx.5
CJC fault OFF
MMW #154 Not Applicable
Ixx.6
CPU Fault
ON OFF
Note xx is slot number in which module is fixed. Ixx.6 is reserved and should not be used. Whenever accessing the module, user must check the module status bit Ix.0. If any error condition is detected in input image, check corresponding module memory word to get more details to locate exact problem.
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3. Installations and Wiring

This chapter provides the following information Module Installation Connection Details Precautions to be taken
3.1 Module Installation

The installation procedure for thermocouple input module is same as any other discrete I/O module. Put the module in to the desired slot of the PLC. Tighten the screw provided at the top of the module. Connect the terminal block at the front of the module and tighten it.
3.2 Connection Details

The figure shows the connection diagram of thermocouple input module
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01 02 03 04 05 06
Thermocouple 1
07 08 09 10 11 12 13 14 16 TC0+ TC1+ TC0-
TC115 SHIELD0 17 SHIELD1 TC2+ TC3+ TC2TC3SHIELD2 SHIELD3 TC4+ TC5+ TC4-
nect this shield to Earth busbar.
Connect this shield to SHIELD terminal.
18 19 20 21 22 23 24 25
Thermocouple 8
26 28 30
TC527 SHIELD4 29 31 SHIELD5 TC6+ TC7+ TC6TC7SHIELD6 SHIELD7 + 24 V 0V EARTH
32
+ 24 VDC GND EARTH
33 34 35 36 37 38
Figure 6 : Connection diagram of Thermocouple Input Module
In figure, thermocouples are connected to channel 0 and 7. For interfacing thermocouples, 38-pin terminal block is provided. Thermocouple input is connected to TCn+ and TCn- terminals, where n is a channel number. For healthy working, ensure correct polarity of thermocouple element. It is ensured that all the three connections of a thermocouple element come in line on terminal block for easy connectivity. Thermocouple 1 is connected to terminal cumbers 12, 14 and 16. Thermocouple 2 is to be connected to terminal numbers 13, 15 and 17. Thermocouple 8 is to be connected to
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terminal numbers 31, 33 and 35. Ensure that thermocouple element is isolated tip type only. Being susceptible to industrial noise, mill volt signal from thermocouple is to be carried out on the field through shielded cable. Connect shield on module side to 'SHIELDn' terminal provided on terminal block. For each thermocouple input separate 'SHIELDn' terminal is provided. Other end of shield should be earthed. For functioning of thermocouple input module, external 24 VDC supply is required. Connect 24 VDC supply between terminals 36 (+ 24 V) and 37 (0 V). Connect terminal 38 to earth busbar in control panel.
3.3 Precautions to be taken

All the normal precautions concerning the wiring and protection of an electronic equipment in an industrial environment should be observed. To guard against coupling noise from one conductor to another, follow the guidelines given below. Inside control panel Following guidelines to be observed inside control panel. All power circuit wiring e.g. connected to Power Supply Module, power contactors, etc i.e. high voltage wiring should be kept separate and apart from thermocouple signals. Digital Input wiring and Digital Output wiring (especially, relay output and AC output) should be separately bundled and kept as apart as possible from thermocouple signals. Thermocouple signals should be carried through shielded cables.
Outside control panel Following guidelines to be observed outside control panel. Depending upon the type of modules used in PLC, separate ducts should be provided for Power circuit wiring and power cables. Input cables Output cables All cables carrying low level signals for analog IO modules, thermocouple/ RTD input modules and for communication.
Wherever possible, it is recommended to Avoid parallel routing of cables carrying analog signals and power cables, etc over long distances Ensure that cables carrying analog signals cross at right angles to power cables so that minimum length of cable will be in close vicinity of power cables. Run cables on metallic surfaces Avoid number of joints Keep cable lengths as short as possible.
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4. Configuration and Programming

This chapter explains configuration of thermocouple input module and transferring information with thermocouple input module. This information is useful for application program development. The module configuration consists of Slot configuration and Channel configuration
4.1 Slot Configuration

The thermocouple input module provides 8 thermocouple input channels, which can be independently operated. Configuring the slot for thermocouple input module is just like any other discrete IO module only. The programming and documentation software DOXMINI+ is used for configuration and programming. The module consumes 1 byte of input image and 1 byte of output image. The input image is used for reading status of module. The output image is used for writing user commands to module. For more details, refer chapter 2.4.3 and 2.4.4. The IO byte consumption along with configuration of Nexgen PLC is shown below.
Power Supply Module CPU Module Slot 0 32 DC Input Module I0.0 to I0.7 I1.0 to I1.7 I2.0 to I2.7 I3.0 to I3.7 Slot 1 32 DC Output Module Q4.0 toQI4.7 Q5.0 to Q5.7 Q6.0 to Q6.7 Q7.0 to Q7.7 Slot 2 Thermocouple Input Module I8.0 to I8.7 Q8.0 to Q8.7 Slot 3 16 DC Output Module Q9.0 to Q9.7 Q10.0 to Q10.7
Input module in first slot 0 consumes IB0 to IB3 of input image. Output module in slot 1 consumes QB4 to QB7 of output image. Thermocouple input module consumes IB8 of input image and QB8 of output image.16 DC Output module in slot 3 consumes QB9 and QB10 of output image. The IO byte consumption along with configuration of Nexgen5000 PLC is shown below.
Power Supply Module Nexgen5000 CPU Module Slot 0 32 DC Input Module (4632) %IX0.0 - %IX0.7 %IX1.0 - %IX1.7 %IX2.0 - %IX2.7 %IX3.0 - %IX3.7 Slot 1 32 DC Output Module (4732) Slot 2 Thermocouple Input Module (4310) Slot 3 16 DC Output Module (4716)
%QX0.0 - %QX0.7 %QX5.0 - %QX5.7 %QX1.0 - %QX1.7 %IX4.0 - %IX4.7 %QX6.0 - %QX6.7 %QX2.0 - %QX2.7 %QX4.0 - %QX4.7 %QX3.0 - %QX3.7
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Input module in first slot 0 consumes IB0 to IB3 of input image. Output module in slot 1 consumes QB0 to QB3 of output image. The analog input module consumes IB4 of input image and QB4 of output image.16 DC Output module in slot 3 consumes QB5 and QB6 of output image.
4.2 Channel Configuration

The thermocouple input module can be configured in any slot of PLC. It provides 8 non-isolated channels. These channels can be independently configured for different types of thermocouple inputs. The channel configuration is grouped in two types Static configuration This information decides basic functioning of a channel. Normally, this information is not altered in run time e.g. type of thermocouple. Dynamic configuration This information does not affect basic functioning of channel. This information is changed during run time e.g. high and low limit for temperature reading. 4.2.1 Static Configuration After power ON the configuration of one or more channels can be transferred to the module using WRITE_W function. The global variables, memory or page can be used to hold channel configuration. The channel static configuration information includes Thermocouple input type Filter frequency (fixed to 50 Hz for thermocouple inputs) Return value on open circuit and Averaging This information is transferred to module memory by using 'WRITE_W function. The module takes action on this information when static configuration write command is issued (on rising edge of Qx.0 bit). After that only static configuration or change in static configuration is effective. This static configuration information is to be stored in bit form in one word for each channel. The following table gives information to be stored. The valid combination of bits must be set. Module memory words MMW #96 to MMW #110 are module memory words for static configuration. MMW #96 - Channel 0 Static Configuration Word
Item Description Input type J thermocouple K thermocouple T thermocouple E thermocouple R thermocouple S thermocouple 15 14 13 12 11 10 9 8 7 6 5 4 0 0 0 0 0 0 3 0 0 0 0 0 0 2 0 0 0 0 1 1 1 0 0 1 1 0 0 0 0 1 0 1 0 1
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Item
Description B thermocouple N thermocouple Invalid Invalid 50 Hz Invalid Invalid Zero Upper Scale Lower Scale Invalid 16 8 4 1 --
15 14 13 12 11 10
4 3 2 1 0 0 0 1 1 0 0 0 1 1 1 0 1 0 0 0 1 1 1 1 1
Filter Return value on Open circuit & CJC fault Avg. Samples Res.
0 0 1 0 0 1 1 0 0 1 1 0 0 0 0 0 1 0 1 0 1 0 1
0 0 1
0 1 1
MMW #98 to MMW #110 Channel 1 to 7 static configuration words.

MMW #98 MMW #110 Channel 1 static configuration word Channel 7 static configuration word
Input type The thermocouple input module supports different types of inputs. The inputs include J type thermocouple K type thermocouple T type thermocouple E type thermocouple R type thermocouple S type thermocouple B type thermocouple N type thermocouple Bit 0 to bit 4 hold input type information. Filter frequency Next three Bits, Bit 5 to bit 7 defines the low-pass filter frequency. One out of four filter frequencies can be selected.
Bit 7 0 0 0 0 0 0 1 1 Bit 6 0 1 0 1 Bit 5 Filter Frequency 50 Hz 60 Hz 250 Hz 500 Hz Update time for a Channel 60 ms 50 ms 12 ms 6 ms
This is in built function of ADC. The filter frequency affects noise rejection on incoming thermocouple milli- volt signal. A lower filter frequency increases
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noise rejection. Also it affects channel update time. So select a filter frequency considering acceptable noise and channel update time. Return value on open circuit and CJC fault Next two bits, bit 8 and bit 9 define the value of the channel temperature reading when the open circuit is detected for that channel or CJC fault (CJC sensor open or short) is detected.
Bit9 Bit8 Open Circuit value
0 0 1 1
0 1 0 1
Zero Upper scale Lower scale Invalid
In such open circuit condition, the channel value can be set to any one of above options considering safety in control action. Averaging Next two Bits, Bit10 and Bit 10 define the selection of sampling value for averaging.
Bit10 Bit11 Averaging Samples
0 0 1 1
0 1 0 1
16 8 4 No
If the averaging counts of channel 0, 1 and 2 are 0, 4 and 8 respectively, then initially data of channel 0, 1 and 2 are updated after 8, 4 and 1 conversion cycles respectively. After that, it gets updated in every cycle. One conversion cycle means sampling and converting all enabled channels as explained in chapter 2.3.2. Thus combination of filter frequency and averaging count can be selected to get optimum channel update time and stable temperature reading. Module memory words MMW #0 to MMW #32 are module memory words for dynamic configuration. MMW #0 is a channel enable / disable word. MMW #2 to MMW #32 provides high and low set points for individual channels. 4.2.2 Dynamic Configuration The channel dynamic configuration information includes Channel enable/ disable Channel high and low set points This information is transferred to module memory by using 'WRITE_W function. The module detects change in dynamic configuration information in its own scan. If valid change is detected, appropriate action is initiated and dynamic configuration or change in dynamic configuration is effective immediately. Channel Enable
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The eight bits in module memory word MMW #0 defines the enable status of the all the channels. If it is 0 channel is disabled and if it is 1 channel is enable. The module samples only enabled channels and converts into digital value. Thus enabling only used channels can minimize the channel update time. If a particular channel is important at particular instance, all other channels can be disabled temporarily and only one channel conversion can be carried out to get fast response. MMW #0 Channel enable / disable word
Item Ch 0 Description Disable Enable Disable Enable 0 0 0 0 0 0 0 0 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 0 1
Ch 7 Res
0 1
Bit 0 of MMW #0 is enable / disable bit for channel 1. Bit 7 of MMW #0 is enable / disable bit for channel 8. Bits 8 to 15 are reserved and should not be used. Channel High and Low set points User can define high and low set points for individual channel temperature readings available in 0.1 C resolution. If channel temperature is above high set point, corresponding high bit in MMW #146 is set. If channel temperature is below low set point, corresponding bit in MMW # 146 is set. MMW #2 to MMW #32 - Channel High and Low set points MMW #2 MMW #4 MMW #30 MMW #32 Channel 0 high set point (in 0.1 C resolution) Channel 0 low set point (in 0.1 C resolution) Channel 7 high set point (in 0.1 C resolution) Channel 7 low set point (in 0.1 C resolution)
Valid range for high and low set points is changed as per input type selection. These user settings are compared with input type selected for a channel. If settings are not within range of that input type, Ixx.1 bit is made ON indicating invalid configuration. Refer MMW #148 to point out faulty channel configuration. If high set point for a channel is less than that of low set point and vice versa, Ixx.1 bit is made ON indicating parameter mismatch. Refer MMW #148 to point out faulty channel configuration. MMW #34 to MMW #94 are reserved and should not be used.
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4.3
Channel Information For the configured channels, necessary information is available as channel data and status bits. This is explained in details below
4.3.1
Channel Data Module memory words MMW #128 to MMW #142 are module memory words for channel temperature readings. MMW #144 holds CJC sensor reading. This is nothing but ambient temperature. The temperature reading resolution is 0.1 C. For enabled channels, this information is updated cyclically in module. The data is read and stored using READ_W function in application program. Thermocouple Type J K T E R S B N C Temperature range -210.0 to +760.0 -270.0 to +1370.0 -270.0 to +400.0 -270.0 to +1000 0.0 to +1768.0 0.0 to +1768.0 0.0 to +1820.0 -200.0 to +1300.0
4.3.2
Channel Status Channel status information is available in MMW #146 to MMW #154 in bit form as follows. Channel high and low set point status MMW #146 stores high and low limit status of individual channels.
Item Ch 0
Description < Max. limit > Max. limit > Min. limit < Min. limit < Max. limit > Max. limit > Min. limit < Min. limit
15 14 13 12 11 10
1 0 1
0 0 1
Ch 7
0 1 0 1
First two bits bit 0 and bit 1 holds high and low point status of channel 0 comparing high and low set points in MMW #2 and MMW #4 respectively. Channel 0 high bit, bit 0 becomes ON when temerature reading is above high set point. It becomes OFF when temprature reading is below high set point. Low bit becomes ON when temerature reading is below low set point. It becomes OFF when temprature reading is above low set point.
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Similarly next two bits gives high and low point status of cahnnel 1 and so on. Channel configuration status Module memory word MMW #148 holds status of validity of configuration and parameters for all the channels. MMW #148 Channel configuration and parameter mismatch status
Item Ch 0 Description Config. valid Config. Invalid 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 0 1
Ch 7 Res -
Config. valid Config. Invalid 0 0 0 0 0 0 0 0
0 1
Bit 0 of MMW #148 gives channel 0 configuration status and bit 7 of MMW #148 gives channel 7 configuration status. Configuration bit is ON when Static configuration for a channel is invalid i.e. if bit 4 to bit 0 are 01000 to 11111 if bit 5 to bit 7 are 100 to 111 In dynamic configuration if high set point is not within specified input range if low set point is not within specified input range if high set point < low set point In all these cases, Ixx.1 bit becomes ON. Corresponding green channel LED starts flashing. Channel out of range status MMW #150 stores over range and under range status of individual channels.
Item Ch 0 Description < Over range Over range > Under range Under range < Over range Over range > Under range Under range 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 1 0 1 0 1 0 0 1
Ch 7
First two bits bit 0 and bit 1 gives over range and under range status of channel 0 depending on input type selected. Next two bits give over range and under range status of channel 1 and so on. The input ranges are as given below.
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Thermocouple Type J K T E R S B N
mV signal C Temperature range -8.096 to 42.922 -210 to +760 -6.458 to 54.807 -270 to +1370 -6.258 to 20.869 -270 to 400 -9.835 to 76.358 -270 to 1000 0.000 to 21.108 0 to 1768 0.000 to 18.698 0 to 1768 0.000 to 13.814 0 to 1820 -3.990 to 47.502 -200 to 1300
Over range bit becomes ON when thermocouple input is above specified input signal. Under range bit becomes ON when thermocouple input is below specified input signal. In all these cases, corresponding green channel LED starts flashing. Open Circuit Error MMW #152 stores open circuit status of individual channels.
Item Ch 0 Description Input connected Open circuit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 0 1
Ch 7 Res
Input connected Open circuit 0
0 1 0 0 0 0 0 0 0
Bit 0 of MMW #152 holds status of channel 0. It becomes ON if channel 0 is configured and input signal is not connected. Bit 1 of MMW #152 holds status of channel 1. In ADC conversion cycle, first open circuit status for configured channel is checked. If open circuit is detected, channel is bypassed and return value in case of open circuit is stored as channel temperature reading. Bit 9 and bit 8 of static configuration word of a channel decides return value as zero, upper scale or lower scale considering safety in control action. If open circuit error bit is set for a channel, corresponding channel LED (green color) on module starts flashing. CJC status MMW #154 stores cold junction compensation sensor channel status of individual channels.
Item Short Circuit Open Circuit Res Description 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Sensor not shorted 0 Sensor shorted 1 Sensor Connected 0 CJC Sensor Open 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Bit 0 of MMW #154 is CJC sensor short circuit bit Bit 1 of MMW #154 is open circuit status bit
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The behavior in case of CJC fault is similar to that of any thermocouple input channel. In case of fault, 'CJC fault' indication (yellow) on front side of module becomes ON.
4.4 Programming with Nexgen 4000 CPU

The data in PLC variables is transferred to the thermocouple input module when 'WRITE_W' function is executed. The data in the PLC variables can be updated using functions like 'MOV_W', arithmetic or any other functions. The data from thermocouple input module memory can be transferred to PLC variables when 'READ_W' function is executed. The WRITE_W function below shows data transfer from the CPU module's memory to thermocouple input module memory. The details of transfer are Thermocouple input module is configured in slot 2 of PLC Start address of memory on the CPU module is MW50 Length of data area to be transferred is 8 words Address on the thermocouple input module in slot 2 is #96
'WRITE_W' function gets executed when condition for enable 'EN' is ON. 'ENO' output becomes ON, when EN is ON and function is executed successfully. ENO is OFF if Parameters of function are invalid or not within specified range. Thermocouple input module is not accessible to CPU module M0.0 --- WRITE_W -M0.1
+---| |---+--------- |EN | #2 -|SLOT | MW50 -|DATA
ENO|-+---------+---( )--| | | |
|
#8 #96
-|LEN | | | -|ADDR | | | -------------------
So 8 words (MW50 to MW64) information from CPU memory is transferred to the memory at address #96 onwards of thermocouple input module fitted in slot 2. The 'READ_W' function below shows data transfer from the Thermocouple input module memory to CPU memory. The details of transfer are Thermocouple input module is configured in slot 2 of PLC Address on the thermocouple input module in slot 2 is #128 Start address of memory on the CPU module is MW100 Length of data area to be transferred is 8 words 'READ_W' function gets executed when condition for enable 'EN' is ON. 'ENO' output becomes ON, when EN is ON and function is executed successfully. ENO is OFF if Parameters of function are invalid or not within specified range. Thermocouple input module is not accessible to CPU module
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M0.2 ------ READ_W ----M0.3 +---| |---+--------- |EN ENO|-+---------+---( )--| | #2 -|SLOT | | | #128 -|ADDR | | | #8 -|LEN | | | MW100-|DATA | | | ------------------So 8 words (MMW128 to MMW142) information on thermocouple input module fitted in slot #2 are transferred to the CPU memory words (MW100 to MW114). Example of basic application program is given below. For the same, refer Nexgen PLC configuration shown in chapter 4.1. In the configuration, following points are to be noted. I 8.0 is a module status bit as 'Module Not OK' bit. I8.0 is set if 24 VDC supply to module is not healthy and / or hardware fault, watchdog fault is observed on module. I 8.1 is a configuration status bit as 'Invalid Configuration' bit. I 8.1 is set if for one or more channels, configuration is invalid. I 8.2 is a maximum minimum set point status bit as 'Set point Exceeded' bit. I 8.2 is set if for one or more configured channels, input signal is below or above limits set. I 8.3 is a thermocouple input range status bit as 'Out of Range' bit. I 8.3 is set if for one or more configured channels, input signal is below or above specified range. I 8.4 is a open circuit status bit as 'Open Circuit ' bit. I 8.4 is set if for one or more configured channels, input is not connected. I 8.5 is a CJC status bit as 'CJC Fault ' bit. I 8.5 is set if CJC sensor mounted directly on top side of terminal block is open or short. Q 8.0 is a command for 'Static Configuration Write'. When this bit is set by user, thermocouple input module accepts static configuration available in module memory words MMW#96 to MMW#110 and configures the module accordingly for input type, filter, return value for open circuit and number of averaging samples.
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S 4.2 is a 'Module Error' bit for the module fitted in slot 2. While developing application program, first check whether the module is healthy. For the same, check 'Module Error' bit S 4.2 and 'Module Not Ok' bit I8.0. If any bit is set, declare respective fault. In this case, module is not accessible. If both are OFF, then only enable 'WRITE_W' and 'READ_W' functions for thermocouple input module. The static configuration information consists of basic attributes like input type (J, K, T, E, R, S, B and N), filter (50 Hz, 60 Hz, 250 Hz, 500 Hz), return value in case of open circuit of input signal (zero, upper scale, lower scale) and no. of averaging samples ( 1, 4, 8, 16 ). This configuration is to be transferred to module memory MMW#96 to MMW#110, if all the 8 channels are used. In this example, channels are configured for T type of thermocouple 50 Hz filter Return value is of upper scale in case of open circuit of input signal No. of averaging samples is 8 For this configuration, the value $0902 should be written to respective module memory word.
Static Configuration Word
15 0
$0902
14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 0 0 0 1 0 0 1 0 0 0 0 0 0 1 0
Reserved Avg. of 4 Samples
Return value of upper scale
50 Hz Filter
T type Thermocouple input
So MW50 to MW 64 should contain $0902, for the configuration required. This information is transferred to thermocouple module memory MMW#96 to MMW#110, when 'WRITE_W' function is executed. When 'WRITE_W' function is executed successfully, ENO output becomes ON, When ENO is ON, set 'Static Configuration Write' command bit informing the module to accept the static configuration or change in configuration. Once this information is transferred to module, it is valid as long as PLC power is present. It is recommended to enable 'WRITE_W function when Warm start is observed i.e. System bit S0.6 is ON Cold start is observed i.e. System bit S0.7 is ON Module Error bit becomes OFF i.e. System bit S4.2 is ON Module Not OK bit becomes OFF i.e. Input bit I8.0 is ON and Any other condition as per requirement of application program e.g. memory bit M2.0 is ON.
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S0.6 ------ WRITE_W ---Q8.0 +---| |---+---------+---------|EN ENO|-+---( )--| | | S0.7 | | | +---| |---+---------| #2 -|SLOT | | | | S4.2 M0.4 | | | +---| |---+---|N|---| MW50 -|DATA | | | | I8.0 M0.5 | | | +---| |---+---|N|---+ #8 -|LEN | | | | M2.0 M2.1 | | | +---| |---+---|P|---+ #96 -|ADDR | | | ------------------If 'WRITE_W' function is executed successfully, Q8.0 bit becomes ON for one scan duration. If this bit is not ON even if function enable conditions are ON, declare fault and take appropriate action. Once, static configuration is written, channels are enabled as per requirement. To enable all the channels, memory word MW166 should contain $00FF value. Enable 'WRITE_W' function with any condition M0.6 with interlocks of Module Error bit S4.2 and 'Module Not Ok' bit I8.0. When 'WRITE_W' function is executed, the data $00FF is transferred to module memory MMW#00. The maximum and minimum set points for each channel is transferred to module memory words MMW#02 to MMW#32 If 'WRITE_W' function is executed successfully, M0.7 bit becomes ON. If this bit is not ON even if function enable conditions are ON, declare fault and take appropriate action. M0.6 S4.2 I8.0 ------ WRITE_W ---M0.7 +---| |---+---|/|---+---|/|---|EN ENO|-+---( )--| | | | #2 -|SLOT | | | | | MW166 -|DATA | | | | | #17 -|LEN | | | | | #0 -|ADDR | | | ------------------SD-2002-016 8 Channel Thermocouple Input Module(4310)mod.doc Document No.: ED-2002-006/V1.0 Published July 2002 Page 33 of 53
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After transferring static and dynamic configuration information to thermocouple module memory, module starts functioning. Enable 'READ_W' function with any condition M1.0 with interlocks of Module Error bit S4.2 and 'Module Not Ok' bit I8.0. When 'READ_W' function is executed, the temperature readings (0.1 C resolution) stored in module memory MMW#128 to MMW#142 are transferred to CPU memory MW100 to MW#114 respectively. CJC data i.e. ambient temperature reading is available in memory word MW#116. If 'READ_W' function is executed successfully, M1.1 bit becomes ON. If this bit is not ON even if function enable conditions are ON, declare fault and take appropriate action. M1.0 S4.2 I8.0 ------ READ_W ----M1.1 +---| |---+---|/|---+---|/|---|EN ENO|-+---( )--| | | | #2 -|SLOT | | | | | #128 -|ADDR | | | | | #9 -|LEN | | | | | MW100 -|DATA | | | ------------------To read the status of temperature readings for maximum and minimum set points, it is necessary to read MMW#146 when I8.2 bit 'Set point Exceeded' in ON. I8.2 S4.2 I8.0 ------ READ_W ----M1.5 +---| |---+---|/|---+---|/|---|EN ENO|-+---( )--| | | | #2 -|SLOT | | | | | #146 -|ADDR | | | | | #1 -|LEN | | | | | MW126 -|DATA | | | ------------------Here M126.0 is over range bit for channel 0 and M126.1 is for under range for channel 0. Similarly, M127.6 is over range bit for channel 7 and M127.7 is
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for under range for channel 7. With this status, appropriate action can be taken for temperature control. To read the status of each channel, read the status information when ever corresponding input image bit is ON. This is depicted below. 'Invalid Configuration bit I8.1 becomes ON, if one or more channel configuration data is invalid. To find out exact faulty channel/s, read MMW#148 from module. I8.1 S4.2 I8.0 ------ READ_W ----M1.2 +---| |---+---|/|---+---|/|---|EN ENO|-+---( )--| | | | #2 -|SLOT | | | | | #148 -|ADDR | | | | | #1 -|LEN | | | | | MW118 -|DATA | | | ------------------When this 'READ_W' function is executed successfully, check CPU memory bits M118.0 to M118.7. M118.0 bit is ON if channel 0 configuration is invalid, M118.1 bit is ON if channel 1 configuration is invalid and so on. In this correct the configuration of faulty channel. In case of invalid configuration for particular channel, channel temperature reading becomes #0. 'Out of Range' bit I8.3 becomes ON, if one or more channel input signal/s is/are below or above specified range for selected input type. To find out exact faulty channel/s, read MMW#150 from module. I8.3 S4.2 I8.0 ------ READ_W ----M1.3 +---| |---+---|/|---+---|/|---|EN ENO|-+---( )--| | | | #2 -|SLOT | | | | | #150 -|ADDR | | | | | #1 -|LEN | | | | | MW120 -|DATA | | | -------------------
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When this 'READ_W' function is executed successfully, check CPU memory bits M120.0 to M121.7 for over range and under range status. M120.0 bit is ON if channel 0 input signal is above specified range, M120.1 bit is ON if channel 0 input signal is below specified range and so on. In this case, take proper action. For a particular channel, if input signal is above specified range, channel temperature reading remains at maximum value. For T type thermocouple input, this is 400.0 C. For a particular channel, if input signal is below specified range, channel temperature reading remains at minimum value. For T type thermocouple input, this is -270.0 C. 'Open Circuit' bit I8.4 becomes ON, if one or more channel input is disconnected. To find out exact faulty channel/s, read MMW#152 from module. I8.4 S4.2 I8.0 ------ READ_W ----M1.4 +---| |---+---|/|---+---|/|---|EN ENO|-+---( )--| | | | #2 -|SLOT | | | | | #152 -|ADDR | | | | | #1 -|LEN | | | | | MW122 -|DATA | | | ------------------When this 'READ_W' function is executed successfully, check CPU memory bits M122.0 to M122.7 for open circuit status. M122.0 bit is ON if channel 0 input is open, M122.1 bit is ON if channel 1 input is open and so on. In this case, take proper action. For a particular channel, in case of open circuit, channel temperature reading is forced to value selected by user. In this case, it is upper scale value, which is 400.0 C for T type of thermocouple input type. 'CJC Fault' bit I8.5 becomes ON, if CJC sensor is open or short. This CJC sensor is mounted directly on terminal block and terminal no. 4,6,8 are used for the same. To find out exact reason, read MMW#154 from module. I8.5 S4.2 I8.0 ------ READ_W ----M1.5 +---| |---+---|/|---+---|/|---|EN ENO|-+---( )--| | | | #2 -|SLOT | | | | | #154 -|ADDR | | | | | #1 -|LEN | | | | | MW124 -|DATA | | | ------------------Published July 2002 Page 36 of 53 SD-2002-016 8 Channel Thermocouple Input Module(4310)mod.doc Document No.: ED-2002-006/V1.0
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When this 'READ_W' function is executed successfully, check CPU memory bits M124.0 and M124.1 for CJC sensor status. M124.0 bit is ON if CJC sensor is short and M122.1 bit is ON if CJC sensor is open. In this case, take proper action. If CJC sensor fault is detected, all the channel temperature readings are forced to user selected value (the return value in case of open circuit). In this case, it is upper scale value, which is 400.0 C for T type of thermocouple input type.
4.5 Programming with Nexgen 5000 CPU

The configuration data in PLC variables is transferred to the Thermocouple input module when 'IM_Write function is executed. The data in the PLC variables can be updated using operators like 'MOVE', arithmetic or any other functions. The data from analog input module memory can be transferred to PLC variables when 'IM_Read' function is executed. The IM_Write function below shows data transfer from the CPU module's memory to Thermocouple input module memory. The details of transfer are The Thermocouple input module is configured in slot 2 of PLC The configuration information is stored in an 8 word array Static_Config & in 17 word array Dynamic_Config. Length of data area to be transferred is 16 bytes at MMW96 for Static_Config & 34 bytes at MMW0 for Dynamic_Config. 'IM_Write' function gets executed when BOOLean input 'Config_Dn' & Wr_Delay.Q is TRUE. BOOLean output 'Config_Dn' becomes TRUE, when function is executed successfully. It is FALSE if Parameters of function are invalid or not within specified range. Thermocouple input module is not accessible to CPU module
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So 8 words configuration information ( Static ) from CPU memory is transferred to the memory at address 96 onwards & 17 words configuration information ( Dynamic) from CPU memory is transferred to memory 0 onwars of Thermocouple input module fitted in slot 2. The 'IM_Read function shows data transfer from the Theromocouple input module memory to CPU memory. The details of transfer are The Thermocouple input module is configured in slot 2 of PLC Address on the Thermocouple input module in slot 2 is 128 The data to be stored in PLC variable array Thermocouple_Data & AIStatus array. Length of data area to be transferred is 16 bytes for Thermocouple_data & 8 bytes for AIstatus . 'IM_Read' function gets executed when ' Rd_Delay.Q ' is ON. 'Rd_Dn' & Stat_Rdy output becomes ON, when EN is ON and function is executed successfully. ENO is OFF if Parameters of function are invalid or not within specified range. The module is not accessible to CPU module
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Example of basic application program is given below. For the same, refer Nexgen PLC configuration shown in chapter 4.1. In the configuration, following points are to be noted. %IX4.0 is a module status bit as 'Module Not OK' bit. %IX4.0 is set if 24 VDC supply to module is not healthy and / or hardware fault, watchdog fault is observed on module. %IX4.1 is a channel status bit as. %IX4.1 is set if for one or more channels, configuration is invalid and / or any channel error like open circuit is observed. _BRACK_0_IOERR.2 is a 'Module Error' bit for the module fitted in slot 2. While developing application program, first check whether the module is healthy. For the same, check 'Module Error' bit _BRACK_0_IOERR.2 and 'Module Not Ok' bit %IX4.0. If any bit is set, declare respective fault. In this case, module is not accessible. If both are OFF, then only enable 'IM_Write' and 'IM_Read functions for Thermocouple module. Once Thermocouple input data is read successfully, the data can be processed as the application requirement. If anaolg input data read is to be displayed on HMI or SCADA, the varaible AIData should be mapped to any memory varaible while declaration like
Thermocouple_Data AT%MW100: ARRAY [0..7] OF INT;
Here the Thermocouple data for the channels is stored in memory variable %MW100 to %MW116 in integer format. Channel 0 data is stored in %MW100 while channel 7 data is stored in %MW16. If input image bit %IX4.0 or %IX4.1 is TRUE, the appropriate error should be declared and further processing of anaolg input data read should be hold. If input image bit %IX4.1 is TRUE, the status of all the channels can be read and individual channel error and exact cause can be located with the help of an application program as shown below.
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5. Troubleshooting
In this chapter, following points related to thermocouple input module are discussed. LED Indications for diagnostics Fault Diagnostic
5.1 LED Indications for Diagnostics

The following table explains significance of LED provided for module status and diagnostic purpose on the module.
No. LED Color Status Description
No 24 V Supply
OFF Orange ON OFF
CPU fault
Orange ON OFF
CJC Fault
Orange
ON OFF ON
Channel Status (Eight for eight channels)
Green
Flashing with 10 Hz frequency
24 VDC supply to module healthy 24 VDC supply to module absent 24 VDC circuit on-board glass fuse blown Module hardware healthy and module is ready Module in self test CPU watchdog faulty Module busy CJC sensor OK. CJC sensor short CJC sensor open Channel not enabled Channel enabled and healthy Parameter mismatch Invalid configuration Over range Under range Open circuit CJC fault
5.2 Fault Diagnostic

This section explains various possibilities of faults related to thermocouple Input Module and external interface and corrective action to be taken. Faults may occur in Modules as a whole Specific channel only Application Program.
In first two cases, replacement of module is required where as third case can be sorted out by on line monitoring of application program.
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Equipments required The following equipments are required for fault diagnosis of thermocouple input module Screw driver Digital Multi meter with measuring facility for mV DC voltage. Continuity and resistance. Set up for on line monitoring of application program as follows. PC with DOXMINI+ software PC to Nexgen PLC Cable The following diagnostic flow chart shows various possibilities of faults if thermocouple module is not in operation as per requirement and corrective action to be taken.
Module not working
ON
No 24V Supply LED status?
OFF
Confirm 24 VDC supply at terminals 36 & 37. Take proper action.
ON
OFF
Check on-board glass fuse. * If blown, replace it by same type.
YES
Module working OK?
NO
ON Replace Module
OFF
Diagnosis Over ON CPU Fault LED Status? OFF
Module Hardware faulty ON CJC Fault LED Status? OFF
Replace Module
CJC sensor short or open. All enabled channel LEDs will start flashing
Replace Module
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Diagnostic flow chart continue.
ON
IO ERR LED Status?
OFF
ON
Module Error System bit Status ?
OFF
Fix module properly. Check expansion cable if it i9s in expansion rack. Check configuration of PLC. Take proper action.
ON Replace Module
Module Error System bit Status? YES
OFF
Module working OK?
NO
Diagnosis Over
Flashing
Channel LED Status?
ON
OFF Check module input image bits Ix.1 to Ix.4 Check application program. Enable channel.
Invalid configuration or parameter Mismatch. Take proper action. Temperature reading beyond Maximum - minimum set points. Take proper action. Temperature reading out of range of input type configured. Take proper action. Thermocouple element connections open circuit. Take proper action.
Ix.1 is set
OFF
Channel LED Status?
ON
Ix.2 is set
Replace Module
Ix.3 is set
Ix.4 is set C
Diagnostic flow chart continue.
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NO
Temperature reading Ok?
YES
Remove thermocouple element and short the terminals. Now module should show ambient temperature.
Diagnosis Over
NO Check application program. Check for JMP, MCR-ME interlocks if any. . NO
YES
Monitor binary data value for channel with PC based Programming Software YES
* The fuse should type strictly Rating - 315 mA, 250 V
Sub- miniature fuse link no. 372

Make WICKMANN
Probably problem is on thermocouple element side. Take proper action.

Connect wires to terminal block
be replaced by same
Note For healthy operation of module always ensure specified range i.e. 18 VDC to 30 VDC YES ripple. Always ensure that thermocouple elements are of isolated Diagnosis Over
that supply to module is within Temperature reading Ok? NO including
Contact MESSUNG SYSTEMS
tip type.
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6. Appendix 1
This section shows the reference tables for each thermocouple type. Each table gives mV signal from thermocouple and equivalent temperature. Reference Table - J Type Thermocouple (Iron vs. Copper-Nickel)
C -210 -200 -190 -180 -170 -160 -150 -140 -130 -120 -110 -100 -90 -80 -70 -60 -50 mV -8.096 -7.890 -7.659 -7.403 -7.123 -6.821 -6.500 -6.159 -5.801 -5.426 -5.037 -4.633 -4.215 -3.786 -3.344 -2.893 -2.431 C -40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 mV -1.961 -1.482 -0.995 -0.501 0.000 0.507 1.019 1.537 2.059 2.585 3.116 3.650 4.187 4.726 5.269 5.814 6.360 C 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 280 290 mV 6.909 7.459 8.010 8.562 9.115 9.669 10.224 10.779 11.334 11.889 12.445 13.000 13.555 14.110 14.665 15.219 15.773 C 300 310 320 330 340 350 360 370 380 390 400 410 420 430 440 450 460 mV 16.327 16.881 17.434 17.986 18.538 19.090 19.642 20.194 20.745 21.297 21.848 22.400 22.952 23.504 24.057 24.610 25.164 C 470 480 490 500 510 520 530 540 550 560 570 580 590 600 610 620 630 mV 25.720 26.276 26.834 27.393 27.953 28.516 29.080 29.647 30.216 30.788 31.362 31.939 32.519 33.102 33.689 34.279 34.873 C 640 650 660 670 680 690 700 710 720 730 740 750 760 770 mV 35.470 36.071 36.675 37.284 37.896 38.512 39.132 39.755 40.382 41.012 41.645 42.281 42.919 43.559
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Reference Table - K Type Thermocouple (Nickel-Chromium vs. Nickel-Aluminum) C -270 -260 -250 -240 -230 -220 -210 -200 -190 -180 -170 -160 -150 -140 -130 -120 -110 -100 -90 -80 -70 -60 -50 -40 -30 -20 -10 0 mV -6.458 -6.441 -6.404 -6.344 -6.262 -6.158 -6.035 -5.891 -5.730 -5.550 -5.354 -5.141 -4.913 -4.669 -4.411 -4.138 -3.852 -3.554 -3.243 -2.920 -2.587 -2.243 -1.889 -1.527 -1.156 -0.778 -0.398 0.000 C 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 280 mV 0.397 0.798 1.203 1.612 2.023 2.436 2.851 3.267 3.682 4.096 4.509 4.920 5.328 5.735 6.138 6.540 6.941 7.340 7.739 8.138 8.539 8.940 9.343 9.747 10.153 10.561 10.971 11.382 C 290 300 310 320 330 340 350 360 370 380 390 400 410 420 430 440 450 460 470 480 490 500 510 520 530 540 550 560 mV 11.795 12.209 12.624 13.040 13.457 13.874 14.293 14.713 15.133 15.554 15.975 16.397 16.820 17.243 17.667 18.091 18.516 18.941 19.366 19.792 20.218 20.644 21.071 21.497 21.924 22.350 22.776 23.203 C 570 580 590 600 610 620 630 640 650 660 670 680 690 700 710 720 730 740 750 760 770 780 790 800 810 820 830 840 mV 23.629 24.055 24.480 24.905 25.330 25.755 26.179 26.602 27.025 27.447 27.869 28.289 28.710 29.129 29.548 29.965 30.382 30.798 31.213 31.628 32.041 32.453 32.865 33.275 33.685 34.093 34.501 34.908 C 850 860 870 880 890 900 910 920 930 940 950 960 970 980 990 1000 1010 1020 1030 1040 1050 1060 1070 1080 1090 1100 1110 1120 mV 35.313 35.718 36.121 36.524 36.925 37.326 37.725 38.124 38.522 38.918 39.314 39.708 40.101 40.494 40.885 41.276 41.665 42.053 42.440 42.826 43.211 43.595 43.978 44.359 44.740 45.119 45.497 45.873 C 1130 1140 1150 1160 1170 1180 1190 1200 1210 1220 1230 1240 1250 1260 1270 1280 1290 1300 1310 1320 1330 1340 1350 1360 1370 mV 46.249 46.623 46.995 47.367 47.737 48.105 48.473 48.838 49.202 49.565 49.926 50.286 50.644 51.000 51.355 51.708 52.060 52.410 52.759 53.106 53.451 53.795 54.138 54.479 54.819
6.1 Reference Table - T Type Thermocouple (Copper vs. Copper-Nickel)

Monograph, mV C -270 -260 -250 -240 -230 -220 -210 -200 -190 -180 -170 -160 -6.258 -6.232 -6.180 -6.105 -6.007 -5.888 -5.753 -5.603 -5.439 -5.261 -5.070 -4.865 C -150 -140 -130 -120 -110 -100 -90 -80 -70 -60 -50 -40 mV -4.648 -4.419 -4.177 -3.923 -3.657 -3.379 -3.089 -2.788 -2.476 -2.153 -1.819 -1.475 C -30 -20 -10 0 10 20 30 40 50 60 70 80 mV -1.121 -0.757 -0.383 0.000 0.391 0.790 1.196 1.612 2.036 2.468 2.909 3.358 C 90 100 110 120 130 140 150 160 170 180 190 200 mV 3.814 4.279 4.750 5.228 5.714 6.206 6.704 7.209 7.720 8.237 8.759 9.288 C 210 220 230 240 250 260 270 280 290 300 310 320 mV 9.822 10.362 10.907 11.458 12.013 12.574 13.139 13.709 14.283 14.862 15.445 16.032 C 330 340 350 360 370 380 390 400 mV 16.624 17.219 17.819 18.422 19.030 19.641 20.255 20.872
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6.2 Reference Table - E Type Thermocouple (Nickel-Chromium vs. Copper-Nickel)

C -270 -260 -250 -240 -230 -220 -210 -200 -190 -180 -170 -160 -150 -140 -130 -120 -110 -100 -90 -80 -70 -60 mV -9.835 -9.797 -9.718 -9.604 -9.455 -9.274 -9.063 -8.825 -8.561 -8.273 -7.963 -7.632 -7.279 -6.907 -6.516 -6.107 -5.681 -5.237 -4.777 -4.302 -3.811 -3.306 C -50 -40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 mV -2.787 -2.255 -1.709 -1.152 -0.581 0.000 0.591 1.192 1.801 2.420 3.048 3.685 4.330 4.985 5.648 6.319 6.998 7.685 8.379 9.081 9.789 10.503 C 170 180 190 200 210 220 230 240 250 260 270 280 290 300 310 320 330 340 350 360 370 380 mV 11.224 11.951 12.684 13.421 14.164 14.912 15.664 16.420 17.181 17.945 18.713 19.484 20.259 21.036 21.817 22.600 23.386 24.174 24.964 25.757 26.552 27.348 C 390 400 410 420 430 440 450 460 470 480 490 500 510 520 530 540 550 560 570 580 590 600 mV 28.146 28.946 29.747 30.550 31.354 32.159 32.965 33.772 34.579 35.387 36.196 37.005 37.815 38.624 39.434 40.243 41.053 41.862 42.671 43.479 44.286 45.093 C 610 620 630 640 650 660 670 680 690 700 710 720 730 740 750 760 770 780 790 800 810 820 mV 45.900 46.705 47.509 48.313 49.116 49.917 50.718 51.517 52.315 53.112 53.908 54.703 55.497 56.289 57.080 57.870 58.659 59.446 60.232 61.017 61.801 62.583 C 830 840 850 860 870 880 890 900 910 920 930 940 950 960 970 980 990 1000 mV 63.364 64.144 64.922 65.698 66.473 67.246 68.017 68.787 69.554 70.319 71.082 71.844 72.603 73.360 74.115 74.869 75.621 76.373
6.3 Reference Table - R Type Thermocouple (Platinum-13% Rhodium vs. Platinum)

C 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 280 290 mV 0.000 0.054 0.111 0.171 0.232 0.296 0.363 0.431 0.501 0.573 0.647 0.723 0.800 0.879 0.959 1.041 1.124 1.208 1.294 1.381 1.469 1.558 1.648 1.739 1.831 1.923 2.017 2.112 2.207 2.304 C 300 310 320 330 340 350 360 370 380 390 400 410 420 430 440 450 460 470 480 490 500 510 520 530 540 550 560 570 580 590 mV 2.401 2.498 2.597 2.696 2.796 2.896 2.997 3.099 3.201 3.304 3.408 3.512 3.616 3.721 3.827 3.933 4.040 4.147 4.255 4.363 4.471 4.580 4.690 4.800 4.910 5.021 5.133 5.245 5.357 5.470 C 600 610 620 630 640 650 660 670 680 690 700 710 720 730 740 750 760 770 780 790 800 810 820 830 840 850 860 870 880 890 mV 5.583 5.697 5.812 5.926 6.041 6.157 6.273 6.390 6.507 6.625 6.743 6.861 6.980 7.100 7.220 7.340 7.461 7.583 7.705 7.827 7.950 8.073 8.197 8.321 8.446 8.571 8.697 8.823 8.950 9.077 C 900 910 920 930 940 950 960 970 980 990 1000 1010 1020 1030 1040 1050 1060 1070 1080 1090 1100 1110 1120 1130 1140 1150 1160 1170 1180 1190 mV 9.205 9.333 9.461 9.590 9.720 9.850 9.980 10.111 10.242 10.374 10.506 10.638 10.771 10.905 11.039 11.173 11.307 11.442 11.578 11.714 11.850 11.986 12.123 12.260 12.397 12.535 12.673 12.812 12.950 13.089 C 1200 1210 1220 1230 1240 1250 1260 1270 1280 1290 1300 1310 1320 1330 1340 1350 1360 1370 1380 1390 1400 1410 1420 1430 1440 1450 1460 1470 1480 1490 mV 13.228 13.367 13.507 13.646 13.786 13.926 14.066 14.207 14.347 14.488 14.629 14.770 14.911 15.052 15.193 15.334 15.475 15.616 15.758 15.899 16.040 16.181 16.323 16.464 16.605 16.746 16.887 17.028 17.169 17.310 C 1500 1510 1520 1530 1540 1550 1560 1570 1580 1590 1600 1610 1620 1630 1640 1650 1660 1670 1680 1690 1700 1710 1720 1730 1740 1750 1760 mV 17.451 17.591 17.732 17.872 18.012 18.152 18.292 18.431 18.571 18.710 18.849 18.988 19.126 19.264 19.402 19.540 19.677 19.814 19.951 20.087 20.222 20.356 20.488 20.620 20.749 20.877 21.003
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6.4 Reference Table - S Type Thermocouple (Platinum-10% Rhodium vs. Platinum)

C 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 280 290 mV 0.000 0.055 0.113 0.173 0.235 0.299 0.365 0.433 0.502 0.573 0.646 0.720 0.795 0.872 0.950 1.029 1.110 1.191 1.273 1.357 1.441 1.526 1.612 1.698 1.786 1.874 1.962 2.052 2.141 2.232 C 300 310 320 330 340 350 360 370 380 390 400 410 420 430 440 450 460 470 480 490 500 510 520 530 540 550 560 570 580 590 mV 2.323 2.415 2.507 2.599 2.692 2.786 2.880 2.974 3.069 3.164 3.259 3.355 3.451 3.548 3.645 3.742 3.840 3.938 4.036 4.134 4.233 4.332 4.432 4.532 4.632 4.732 4.833 4.934 5.035 5.137 C 600 610 620 630 640 650 660 670 680 690 700 710 720 730 740 750 760 770 780 790 800 810 820 830 840 850 860 870 880 890 mV 5.239 5.341 5.443 5.546 5.649 5.753 5.857 5.961 6.065 6.170 6.275 6.381 6.486 6.593 6.699 6.806 6.913 7.020 7.128 7.236 7.345 7.454 7.563 7.673 7.783 7.893 8.003 8.114 8.226 8.337 C 900 910 920 930 940 950 960 970 980 990 1000 1010 1020 1030 1040 1050 1060 1070 1080 1090 1100 1110 1120 1130 1140 1150 1160 1170 1180 1190 mV 8.449 8.562 8.674 8.787 8.900 9.014 9.128 9.242 9.357 9.472 9.587 9.703 9.819 9.935 10.051 10.168 10.285 10.403 10.520 10.638 10.757 10.875 10.994 11.113 11.232 11.351 11.471 11.590 11.710 11.830 C 1200 1210 1220 1230 1240 1250 1260 1270 1280 1290 1300 1310 1320 1330 1340 1350 1360 1370 1380 1390 1400 1410 1420 1430 1440 1450 1460 1470 1480 1490 mV 11.951 12.071 12.191 12.312 12.433 12.554 12.675 12.796 12.917 13.038 13.159 13.280 13.402 13.523 13.644 13.766 13.887 14.009 14.130 14.251 14.373 14.494 14.615 14.736 14.857 14.978 15.099 15.220 15.341 15.461 C 1500 1510 1520 1530 1540 1550 1560 1570 1580 1590 1600 1610 1620 1630 1640 1650 1660 1670 1680 1690 1700 1710 1720 1730 1740 1750 1760 mV 15.582 15.702 15.822 15.942 16.062 16.182 16.301 16.420 16.539 16.658 16.777 16.895 17.013 17.131 17.249 17.366 17.483 17.600 17.717 17.832 17.947 18.061 18.174 18.285 18.395 18.503 18.609
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6.5 Reference Table - B Type Thermocouple (Platinum-30% Rhodium vs. Platinum-6%

Rhodium)
C 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 280 290 300 mV 0.000 -0.002 -0.003 -0.002 0.000 0.002 0.006 0.011 0.017 0.025 0.033 0.043 0.053 0.065 0.078 0.092 0.107 0.123 0.141 0.159 0.178 0.199 0.220 0.243 0.267 0.291 0.317 0.344 0.372 0.401 0.431 C 310 320 330 340 350 360 370 380 390 400 410 420 430 440 450 460 470 480 490 500 510 520 530 540 550 560 570 580 590 600 610 mV 0.462 0.494 0.527 0.561 0.596 0.632 0.669 0.707 0.746 0.787 0.828 0.870 0.913 0.957 1.002 1.048 1.095 1.143 1.192 1.242 1.293 1.344 1.397 1.451 1.505 1.561 1.617 1.675 1.733 1.792 1.852 C 620 630 640 650 660 670 680 690 700 710 720 730 740 750 760 770 780 790 800 810 820 830 840 850 860 870 880 890 900 910 920 mV 1.913 1.975 2.037 2.101 2.165 2.230 2.296 2.363 2.431 2.499 2.569 2.639 2.710 2.782 2.854 2.928 3.002 3.078 3.154 3.230 3.308 3.386 3.466 3.546 3.626 3.708 3.790 3.873 3.957 4.041 4.127 C 930 940 950 960 970 980 990 1000 1010 1020 1030 1040 1050 1060 1070 1080 1090 1100 1110 1120 1130 1140 1150 1160 1170 1180 1190 1200 1210 1220 1230 mV 4.213 4.299 4.387 4.475 4.564 4.653 4.743 4.834 4.926 5.018 5.111 5.205 5.299 5.394 5.489 5.585 5.682 5.780 5.878 5.976 6.075 6.175 6.276 6.377 6.478 6.580 6.683 6.786 6.890 6.995 7.100 C 1240 1250 1260 1270 1280 1290 1300 1310 1320 1330 1340 1350 1360 1370 1380 1390 1400 1410 1420 1430 1440 1450 1460 1470 1480 1490 1500 1510 1520 1530 1540 mV 7.205 7.311 7.417 7.524 7.632 7.740 7.848 7.957 8.066 8.176 8.286 8.397 8.508 8.620 8.731 8.844 8.956 9.069 9.182 9.296 9.410 9.524 9.639 9.753 9.868 9.984 10.099 10.215 10.331 10.447 10.563 C 1550 1560 1570 1580 1590 1600 1610 1620 1630 1640 1650 1660 1670 1680 1690 1700 1710 1720 1730 1740 1750 1760 1770 1780 1790 1800 1810 1820 mV 10.679 10.796 10.913 11.029 11.146 11.263 11.380 11.497 11.614 11.731 11.848 11.965 12.082 12.199 12.316 12.433 12.549 12.666 12.782 12.898 13.014 13.130 13.246 13.361 13.476 13.591 13.706 13.820
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6.6 Reference Table - N Type Thermocouple (Nickel-14.2% Chromium-1.4% Silicon vs.

Nickel-4.4% Silicon- 0.1% Magnesium)
C -270 -260 -250 -240 -230 -220 -210 -200 -190 -180 -170 -160 -150 -140 -130 -120 -110 -100 -90 -80 -70 -60 -50 -40 -30 -20 -10 mV -4.345 -4.338 -4.313 -4.277 -4.226 -4.162 -4.083 -3.990 -3.884 -3.766 -3.634 -3.491 -3.336 -3.171 -2.994 -2.808 -2.612 -2.407 -2.193 -1.972 -1.744 -1.509 -1.269 -1.023 -0.772 -0.518 -0.260 C 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 mV 0.000 0.261 0.525 0.793 1.065 1.340 1.619 1.902 2.189 2.480 2.774 3.072 3.374 3.680 3.989 4.302 4.618 4.937 5.259 5.585 5.913 6.245 6.579 6.916 7.255 7.597 7.941 C 270 280 290 300 310 320 330 340 350 360 370 380 390 400 410 420 430 440 450 460 470 480 490 500 510 520 530 mV 8.288 8.637 8.988 9.341 9.696 10.054 10.413 10.774 11.136 11.501 11.867 12.234 12.603 12.974 13.346 13.719 14.094 14.469 14.848 15.225 15.604 15.984 16.366 16.748 17.131 17.515 17.900 C 540 550 560 570 580 590 600 610 620 630 640 650 660 670 680 690 700 710 720 730 740 750 760 770 780 790 800 mV 18.286 18.672 19.059 19.447 19.835 20.224 20.613 21.003 21.393 21.784 22.175 22.556 22.958 23.350 23.742 24.134 24.527 24.919 25.312 25.705 26.098 26.491 26.883 27.276 27.669 28.062 28.455 C 810 820 830 840 850 860 870 880 890 900 910 920 930 940 950 960 970 980 990 1000 1010 1020 1030 1040 1050 1060 1070 mV 28.847 29.239 29.632 30.024 30.416 30.807 31.199 31.590 31.981 32.371 32.761 33.151 33.541 33.930 34.319 34.707 35.095 35.482 35.869 36.256 36.841 37.027 37.411 37.795 38.179 38.562 38.944 C 1080 1090 1100 1110 1120 1130 1140 1150 1160 1170 1180 1190 1200 1210 1220 1230 1240 1250 1260 1270 1280 1290 1300 mV 39.326 39.708 40.087 40.466 40.845 41.223 41.600 41.976 42.352 42.727 43.101 43.474 43.846 44.218 44.588 44.958 45.326 45.694 46.060 46.425 46.789 47.152 47.513
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MESSUNG SYSTEMS
EL 2, J - Block, MIDC, Bhosari, PUNE 411 026. INDIA Tel. (+91) 020 712 0807, 712 2807 Fax. (+91) 020 712 0391
NEXGEN PLC I/O Modules 8 Channels, Thermocouple Input Module (Ordering Code 4310) Document1 Document No.: ED-2002-016

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NEXGEN PLC I/O Modules

SD-2002-016 8 Channel Thermocouple Input Module(4310)mod.doc Document No.: ED-2002-006/V1.0

Published July 2002 Page 1 of 53

NEXGEN PLC I/O Modules Revision Version Date Description

Published July 2002 Page 2 of 53

SD-2002-016 8 Channel Thermocouple Input Module(4310)mod.doc Document No.: ED-2002-006/V1.0

NEXGEN PLC I/O Modules

SD-2002-016 8 Channel Thermocouple Input Module(4310)mod.doc Document No.: ED-2002-006/V1.0

Published July 2002 Page 3 of 53

NEXGEN PLC I/O Modules

Published July 2002 Page 4 of 53

SD-2002-016 8 Channel Thermocouple Input Module(4310)mod.doc Document No.: ED-2002-006/V1.0

NEXGEN PLC I/O Modules

SD-2002-016 8 Channel Thermocouple Input Module(4310)mod.doc Document No.: ED-2002-006/V1.0

Published July 2002 Page 5 of 53

NEXGEN PLC I/O Modules

1.1 Thermocouple Input Module Overview

Published July 2002 Page 6 of 53

SD-2002-016 8 Channel Thermocouple Input Module(4310)mod.doc Document No.: ED-2002-006/V1.0

NEXGEN PLC I/O Modules

ANALOG INTPUT 8 CH T/C

LM35 CJC Sensor PCB

NO 24 V SUPPLY CPU FAULT CJC FAULT

Module Status LEDs

Front Shield Plate

TC115 SHIELD0 17 SHIELD1 TC2+

Channel Status LEDs

Pin Removable Terminal Block

TC3+ 19 TC221 23 TC3SHIELD2 SHIELD3 TC4+ TC5+ TC4-

TC527 SHIELD4 29 SHIELD5 TC6+ TC7+ TC6TC7SHIELD6 SHIELD7 + 24 V 0V EARTH

Terminal Block Fixing Screw

Connection Details Label

NEXGEN PLC I/O Modules

1.2 LED Indications

Channel Status (Eight for eight channels)

Flashing with 10 Hz frequency

Published July 2002 Page 8 of 53

SD-2002-016 8 Channel Thermocouple Input Module(4310)mod.doc Document No.: ED-2002-006/V1.0

NEXGEN PLC I/O Modules

1.3 General Specifications

SD-2002-016 8 Channel Thermocouple Input Module(4310)mod.doc Document No.: ED-2002-006/V1.0

Published July 2002 Page 9 of 53

NEXGEN PLC I/O Modules

2.1 Block Diagram

Memory for Configuration, Data, Status

No 24 V Supply Signal +15 V -15 V Supply for ADC Circuit +5 V -5 V GND

ature Glass Fuse

+ 24 VDC 24 V GND Earth

Published July 2002 Page 10 of 53

SD-2002-016 8 Channel Thermocouple Input Module(4310)mod.doc Document No.: ED-2002-006/V1.0

NEXGEN PLC I/O Modules

SD-2002-016 8 Channel Thermocouple Input Module(4310)mod.doc Document No.: ED-2002-006/V1.0

Published July 2002 Page 11 of 53

NEXGEN PLC I/O Modules

2.2 Thermocouple types and range of temperatures

2.3 On-Board Processor Operations

Published July 2002 Page 12 of 53

SD-2002-016 8 Channel Thermocouple Input Module(4310)mod.doc Document No.: ED-2002-006/V1.0

NEXGEN PLC I/O Modules

Channel 1 disabled / error detection

Channel 2 disabled / error detection

Channel 3 disabled / error detection