ABB SYN5202 Simultaneous grid connection of control instruments

Description

SYN5202 Thermocouples can be wired directly to the I/O Terminal Block on which the Thermocouple

module is installed, or wired to an optional Thermocouple Terminal Block (IC670CHS004).

If a Thermocouple Terminal Block is used, SYN5202 installing the Thermocouple Module itself on an I/O

Terminal Block with Wire to Board Connectors provides the simplest connection between terminal

blocks. However, the module can be installed on any Field Control I/O Terminal Block. Terminal

assignments for each type of Field Control I/O SYN5202 Terminal Block are shown below. Note that if a

thermistor is connected locally to the I/O Terminal Block on which the module is installed, to

achieve “local” cold junction compensation, SYN5202 the thermistor must be electronically identical to the

thermistor in the Thermocouple Terminal Block.

SYN5202 The Terminal Block with box terminals has 25 terminals for each module. Each terminal

accommodates one AWG #14 (avg 2.1mm2 cross section) to AWG #22 (avg 0.36mm2 cross

section) wire, or two wires up to AWG #18 (avg. 0.86mm2 cross section). When an external jumper

is used, wire capacity is reduced from AWG #14 (2.10mm2 ) to AWG #16 (1.32mm2 ).

The I/O Terminal Block with barrier terminals SYN5202 has 18 terminals per module. Each terminal can

accommodate one or two wires up to AWG #14 (avg 2.1mm2 cross section).

The I/O Terminal Block with Connectors has one 20-pin male connector per module.

SYN5202 Connect a Thermocouple Terminal Block (IC670CHS004) to the I/O Terminal block

(IC670CHS003) using an appropriate cable. The diagram below shows the pin assignments for

each Wire to Board connector on the Thermocouple Terminal Block (IC670CHS004).

Pins (catalog number IC670ACC003) must be installed on individual wires using a crimping tool.

The AMP Pro-Crimper II, Hand Tool Assembly 90546-1 is recommended. The tool must be

properly adjusted, as detailed in the instructions that come with the tool.

1. Strip the wire 3.96 to 4.75mm (0.156 to 0.187in), taking care not to nick or cut wire strands.
2. Hold the tool with the back (wire side) facing you. Squeeze tool handles together and allow

them to open fully.

3. Holding the contact by the mating end, insert the contact-insulation barrel first-through the

SYN5202 front of the tool into the appropriate crimp section. Position the contact with the mating end on

the locator side of the tool, so that the open “U” of the wire and insulation barrels face the top

of the tool. Place the contact up into the nest so that the movable locator drops into the slot in

the contact. Butt the front end of the wire barrel against the movable locator.

NOTE: Be sure both sides of the insulation barrel are started evenly into the crimping section.

DO NOT attempt to crimp an improperly-positioned contact.

4. Hold the contact in position and squeeze the tool handles together until ratchet engages enough

to hold the contact in position. DO NOT deform insulation barrel or wire barrel.

5. Insert stripped wire into contact until it is butted against wire stop as shown.
6. Holding wire in place, squeeze tool handles together until ratchet releases.
7. Check the contact’s crimp height as described in the tool instruction sheet. Adjust the crimp

height if necessary before continuing.

The Thermocouple module performs diagnostics and provides the diagnostic data to the Bus

Interface Unit’s discrete input (I) table.

The module sets the appropriate bit when a diagnostic condition is detected. The bit remains set

until it is cleared.

Alarm bits are set if the processed value for a channel exceeds its configured alarm limit.

Overrange bits are set if the millivolt value for an input exceeds the limits of its span.

Open circuit is checked every time a thermocouple input is read (unless Open TC checking is

disabled). If the circuit is open, the corresponding bit is set, and the input is not processed further.

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