DIGITAL CONTROLLER 5002U masibus

Ref No: m55A/om/101

Issue No: 08

Operator’s Manual

D I G I T A L C O N T R O L L ER 5 0 0 2 U

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DIGITAL CONTROLLER 5002U masibus
Ref No: m55A/om/101
Issue No: 08

CONTENTS

1. TECHNICAL DETAILS

2. SPECIFICATIONS

3. DIMENSIONS & PANEL CUTOUT

4. FRONT FASCIA

5. CONNECTIONS DETAIL

6. USER GUIDE

7. MODE OF OPERATION

8. MODBUS DETAIL (OPTIONAL)

9. COMMUNICATION PARAMETERS

10. TROUBLE SHOOTING

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DIGITAL CONTROLLER 5002U masibus
Ref No: m55A/om/101
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1. TECHNICAL DETAILS
Provision for zero and span setting is
This is a versatile microprocessor based made to restrict range of usage and
ON/OFF controller with a very high programming. This restricts accidental
performance to price ratio. The features wrong setting of set-point beyond the
offered in this product are better than range of interest. Outside this range the
any other controller available in similar unit will indicate temperature as 'OVER'
price range. for some abnormal condition. This zero
and span setting is used for linear inputs
The instrument is made in 96 x 96 x 180 for setting the range between -1999 to
mm³ size with standard cutout of 92 x 9999 counts.
92 mm². Front is sealed membrane type
to withstand dusty environment. On Also, the unit has an optional provision
back plate, PCB soldered terminals are for isolated linearzed retransmission
used. The programming and calibration signal or isolated serial
of the instrument is done by a 4-button communication using RS-485.
keypad, equipped with two independent Retransmission signal is useful for
displays for set point and process recorder or secondary display. The
variable. Set point display is kept 0.3” to output can be 4-20 mA for the
differentiate it from process variable programmed range or 1 mV/degree (1-
display. Status of control/alarm relays 5V) for thermocouple types so that an
and presently displayed set point are ordinary DPM can be connected to this
displayed by 3 mm red LED. signal for remote indication of
temperature.
The operation of the instrument is
menu- driven with user-friendly
prompts.

The product is made to accept all the

Ten standard thermocouple inputs,
PT100 RTD, 4 - 20 Ma, 0-5 VDC and 0-
2V inputs. It is available as a single
input version or field selectable
input version. In case of thermocouple
type of instrument, the type of input can
be changed in field itself. The calibration
of the unit is done without trimpots. The
unit can be calibrated in installed
condition itself by front panel keys at
any given point i.e. user need not feed a
fixed signal. All thermocouples and RTD
inputs are linearized for 0.1% accuracy
through out range. RTD input comes
with 0.1 degree indication for entire
range.

Three set-points with individual

Hysteresis are provided with separate
relays. The set-points can be
programmed as control or alarm type,
relay on below or above set-point , as
deviation from main set-point and
control outside band or control
inside band. This entire configuration
can be done on-line without opening the
unit.

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+
2. SPECIFICATIONS If Input type is fixed [Factory set]
to 0-2V dc then other input type are
not applicable.
DISPLAY
[for O 2 measurement]
• 4 digit 0.56" Red LEDs for Process CONTROL/ALARM OUTPUT
Variable
• 4 digit 0.3" Red LEDs for Set Point • Up to three set-points with individual
• Individual discrete Red LEDs to relay output rated for 2A@230V ac;
indicate relay status, set point selectable for alarm or control. Set-
selection, and serial transmit and point 2 and 3 can be absolute or
receive indication. deviation type.
• Individual Hysteresis setting: 0 to 99
INPUT
• Relays: configurable to energize or
• Thermo-couple types B,C E, J, G, K, de-energize above set-points
N, R, S & T (ANSI standard)
• RTD - PT100 3-wire Calibration
• 4-20mA & 0-20mA linear
• 1-5 V dc & 0-5 V dc linear • Ambient, Zero and Span adjusted by
• 0-100 mV dc linear digital calibration through front
• 0-2V dc linear panel keys
• Input field selectable. • One shot calibration of both input
• Other types on request and output
• Cold junction compensation
automatic for thermocouples CONTROL KEYS AND TERMINALS
• Accuracy: +/- 1 Count @ +/- 0.1%
of Span • Set, Increase, Decrease and Enter
• Input open protection – upscale keys for operation, programming
• Input Impedance: >1MΩ (for DC and calibration
Volt/mV input)
GENERAL
• Input Impedance : <100 Ω (for DC
Current input)
• Power supply:
110V/230V ac 50Hz
RANGE
(Internal Jumper selectable),
24V DC (optional) or
E -200 to 1000 ºC
24V AC (optional)
J -200 to 1200 ºC
• Ambient Temperature:
K -200 to 1372 ºC 0 to 55 °C
T -200 to 400 ºC • Humidity:
B 450 to 1820 ºC 20% to 95% RH non-condensing
R 0 to 1768 ºC • Power consumption:
S 0 to 1768 ºC Less than 10 VA
N -200 to 1300 ºC
G 0 to 2320 ºC PHYSICAL
C 0 to 2320 ºC
PT100 -199.9 to 850.0 ºC • Case:
4-20 mA dc -1999 to 9999 M.S. powder coated with ABS
0-20 mA dc -1999 to 9999 molded bezel
1-5 V dc -1999 to 9999 • Terminals:
0-5 V dc -1999 to 9999 PCB type terminal block can accept
0-100 mV dc -1999 to 9999 up to 2.5 mm² wire
0-2V dc
+
0 to 2000 • Bezel size:
[Configurable Input Voltage Scale] 96 X 96 mm²
• Depth behind Panel:
200 mm maximum including

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terminals 3. DIMENSIONS &

• Panel cutout:
92 X 92 mm² PANEL CUTOUT
Isolated Transmitted Power Supply

• No of Supply :1
• Voltage Rating : 24 V dc @ 20 mA
Isolated output
• Isolation : 500 V dc

Isolated Serial Communication

(Optional *)

• Communication standard:
RS-485
• Communication Protocol:
Modbus RTU
• Distance of Communication:
1200 meter (Twisted pair cable as
per EIA 485 standard)
• Maximum Slaves:
32 without repeaters
• Isolation:
500 V dc

Isolated Retransmission (Optional *)

• No of Output: 1.
• Output Type: 4-20 mA Isolated .
……. O/P**.
• Load Impedance: 250 ohms max.
• Accuracy: 0.25 % of Full scale.
• Isolation: 500 VDC

* Note: 5002u digital controller

will come with Isolated serial or
-
Isolated retransmission O/P.

** Note: 5002u digital controller

with 0-2V input type only has
facility of configurable RX output.
User can set zero and span for RX
output in configuration mode.

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4. FRONT FASCIA 5. CONNECTIONS

DETAIL
• PV : Process Value
• SV : Default Set-Point Value
• RL1,RL2,RL3:Relay Status On/Off
Some application RL1 is not used,
RL2 is used for Alert Operation &
RL3 is used for danger Operation
• RX,TX: Serial Data Transmit and
Receive Status
• SP1, SP2,SP3:Default Set-points
Displayed on SV Window
• SET: Indexing Parameter in Various
Modes
• ENTER: Saves Desired Parameter in
Various Mode
• INCR: Increments the Selected
Parameter Value to Desired Value
• DECR: Decrements the Selected
Parameter Value to Desired Value
The description of the Back Panel
terminals is as follows:
No. Description
1 Input IN+ Sensor Input
2 Input IN - ( T/C or RTD or
3 C+(Com of RTD I/P) Linear type )
4 +24V Output 24V D.C.
5 - 24V Output TPS o/p
6 + mA output Re-transmission
7 - mA output Output
8 + 24V / Line Mains
9 -24V / Neutral Supply
10 Earth
11 Common Relay 1 output
12 Normally Open rated for 230V
ac
13 Normally Close @ 2A
14 Common Relay 2 output
15 Normally Open rated for 230V
ac
16 Normally Close @ 2A
Note:
17 Common Relay 3 output
• Here Terminal Nos. are shown
18 Normally Open rated for 230V
(which are not marked on back
ac
plate), for the purpose of
19 Normally Close @ 2A
explanation only.
• Here some terminals may not be 20 TXD Serial
available, if they are not applicable Communication
as per Purchase order. 21 RXD RS485

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6. USER GUIDE Hys1 Hysteresis for first set-point

Sp2 Setpoint2
6.1 INTRODUCTION Hys2 Hysteresis for second set-point
Sp3 Setpoint3
DTC 5002U is an on-off controller user-
friendly key-pad and display for guiding Hys3 Hysteresis for Third set-point
the user with programming and
calibration operation. The manual covers After the last parameter display will go
all aspects of operation of the back to normal run mode. If no key is
instrument. Users are requested to go pressed for 20 seconds, the display will
read the instructions carefully before fall back to normal run mode.
altering any configuration.
To exit from any mode to normal run
6.2 POWER SUPPLY mode press select key for 3 seconds.

Before connecting power to the

instrument ensure that you are ENTER
connecting right input voltage to right
terminal. The instrument is having This key is used for entering into mode
terminals for both 110V ac and 230V ac (CALb Or ConF) and for entering the
or 24V dc. On application of correct value of the selected parameter. After
power supply, the instrument will display setting the data to proper value, if enter
input type set, for five seconds. key is pressed, the data will be
Once the input is applied, its value will permanently stored in non-volatile
be displayed in PV window and presently memory. On pressing of enter key,
selected set-points will be displayed in display shows the parameter which you
the SV display along with appropriate have entered. Now data change is not
set-point LED. possible until Enter key pressed once
again. On pressing of Enter key decimal
6.3 KEY BOARD point on last digit will glow and allow
changing data.
There are four keys for operation of the
instrument. INC (▲)
This key will increment the selected
SELECT (SET) parameter value by one count in all
operating mode. If the key is pressed
This key is used for programming set continuously than the rate of increment
points. Set-points data can be checked will be made five times faster. This
and reprogrammed by this key. facility is called dual speed increment
First press select key, it will display set- facility to allow faster data change for
point parameter. By pressing INC/DEC higher values. This key is also used to
keys value of the set-points and move into different mode (calibration
Hysteresis can be changed as desired. and configuration).

Bring the set-point at a desired value DEC (▼)

and press enter key for storing the value
permanently. On pressing of enter key This key is used to select the desired
the display shows the parameter operating mode and parameter in
prompt. On pressing of set key next various operating modes. On first press
parameter in sequence are selected and of this key in RUN mode for 3 second, it
changed by the same procedure. will display PASS in PV (Process value)
window.
The parameters in sequence are:
PASS
Sp1 Setpoint1

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Now, setting correct value of password various types of set-points and effect of
in SV (set value) window and pressing Hysteresis on relay operation.
enter key mode will be displayed.
mode 7.1 SET-POINTS &
HYSTERESIS EFFECTS
By pressing INC/DEC Key, user can view For set-points selection, there are three
operating modes (CALb Or ConF) in different options, which can be selected
for a particular set-point.
PV (Process value) window and by
pressing Enter key unit will enter into
On-Above/On-Below Set-point
that particular operating mode.
If user selects on above set-point option,
Conf the relay will be energized when the
Calb process variable is more than set
variable. In case of on below set-point
After Entering into operating mode operation of relay is reverse.
(CALb Or ConF), first parameter will be
displayed in SV window and by Pressing Control/ Alarm Set-point
select key subsequent parameter will be
displayed. Corresponding parameter In the case of control set-point the
values will be displayed in PV window. Hysteresis effect is different from alarm
By pressing INC/DEC Key, user can type. In case of alarm set-point, the
select desired value and by pressing relay can be acknowledged on pressing
ENTER Key, user can store selected of ENTER key in run mode. So, this
value. After the last parameter is selection should be done carefully
displayed, pressing of SEL key for 3 according to application.
second will bring the instrument in Run
mode. Absolute/ Deviation Set-point

This key will also decrement the selected Deviation option is applicable only for
parameter value by one count in all second and third set-points. In case of
operation modes. deviation set-point, it is added to the
If the key is pressed continuously than first set-point to derive the actual set-
the rate of decrement will be made five point.
times faster. This facility is called dual This set-point selection can be done by
speed decrement facility to allow faster changing the configuration. Refer to
data change for higher values. This key section on reconfiguration elsewhere in
is also used to move onto different mode this manual.
(calibration and configuration).
Now, let us see an example to illustrate
the effect of Hysteresis setting on relay
operation. For control set-point and
7. MODE OF alarm set-point the effect of Hysteresis
is little different so we will consider each
OPERATION case separately.

There are five modes of operations. Suppose you have selected a set-point
• Run mode of 200 and Hysteresis of 5. Also the
• Password mode setting is for control type and on below
• Program mode set-point. So in this case the Hysteresis
• Configuration mode effect is applicable while turning ON the
• Calibration mode relay. The relay will turn off exactly at
200 after being turned on. But it will not
Before looking into various modes of turn on once again until temperature
operations, it will be better to falls below 200 - 5 = 195. This provides
understand some fundamentals for a band of 5 around the set-point. In

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case of on above set-point type, the If either of the key is kept pressed
operation will be reverse. continuously for more than 10 counts
change in setting, it will start
Now suppose you have kept same set- incrementing or decrementing the data
point of 200 and Hysteresis of 5. Set- at a five time faster rate. Bring the set-
point type is alarm and on below set- point at a desired value and press enter
point. In this case the Hysteresis effect key for storing the value permanently.
will be applicable while turning OFF the On pressing of enter key the display
relay. The relay will turn ON when the shows the parameter prompt. On
process value goes below 200. But it will pressing of select key other parameter
not turn OFF until the temperature goes in sequence are selected and changed
beyond 200 + 5 = 205. This provides a by the same procedure.
band of 5 around the set-point. In case
of on above set-point type, the The parameters in sequence are:
operation will be reverse.
Sp1 Setpoint1
Band Set-point
Hys1 Hysteresis for first set-point
In case of band set point main set point Sp2 Setpoint2
is taken as a reference and band set Hys2 Hysteresis for second set-point
point is distributed both side of main set Sp3 Setpoint3
point equally.
Hys3 Hysteresis for Third set-point

7.2 RUN MODE

After the last parameter display will go
This is normal mode of display. From back to normal run mode. If no key is
other modes of operations, display falls pressed for 20 seconds, the display will
back to this mode if no key is pressed fall back to normal run mode.
for 20 seconds. In this mode PV display
will show value of input signal and SV 7.5 CONFIGURATION MODE
display will show the selected set-point
for normal display. This mode is useful for changing the
basic configuration of the unit. No
7.3 PASSWORD MODE hardware changes are necessary for
changing input type. It can be changed
In Run mode on first press of DEC key by just using front keys.
for 3 second, it shows password mode.
By setting correct password in SV(Set For entering this mode press DEC key
value) window and pressing enter key for 3 seconds, PASS will be displayed,
display will show menu mode. but if now enter correct password and press
password is wrong than it comes back to enter key to enter in menu mode. Now
the run mode. press INC ( ↑ ) and DEC ( ↓ ) for
selecting Configuration mode Conf.
7.4 PROGRAM MODE Now if Enter key is pressed the unit will
enter in the configuration mode and will
This mode is used for programming set- display input Inpt as first
points. In this mode set-points data can
configuration mode. These parameters
be checked and reprogrammed.
can be changed by increment,
decrement and enter keys as described
For entering this mode press select key,
earlier. User can select parameter to be
It will display first set-point parameter.
programmed by SET key.
By pressing INC/DEC keys value of the
The parameters which can be changed
set-points and Hysteresis can be
by this mode are described below in
changed as desired.
sequence in which they are displayed.

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First we will see the meaning of various N-tc input -200 to 1300.
prompts displayed.
G-tc input 0 to 2320.
Inpt Input type C-tc input 0 to 2320.
zerO Zero setting Rtd input 0.1 deg. Resolution
SpaN Span setting -199.9 to 850.0.
NOSP Number of set-point
4-20 mA input -1999 to 9999.
Tsp1 Type of first set-point
0-20 mA input -1999 to 9999.
Tsp2 Type of second set-point
1-5V input -1999 to 9999.
Tsp3 Type of third set-point
0-5V input -1999 to 9999.
D SP Default Display set-point
0-100 mV input -1999 to 9999.
dp Decimal point position
0-2V input 0 to 2000.
OPSE Open sensor For changing of input type, no internal
PASS Password hardware changes are required.
init Initialization When an input type is selected its
corresponding zero and span range is
SLOt Slot configuration
automatically adjusted as per its table.
Byps Bypass selection[used to However if user wants to change zero
bypass 3rd Relay and and span as required he can move to the
RL3 LED Indication in zero or span prompt and can change .
front]
srNo Serial No With this facility if the same input is
selected (i.e. ENTER key is pressed on
baud Baud Rate
the same input), its zero and span range
rt-Z RX zero setting [ Applicable is kept as it is. For setting the range as
for 0-2V input and Retransmission Option ] per the table one has to change the
rt-S RX span setting [ Applicable input type only. Refer corresponding
for 0-2V input and Retransmission Option ] range as per the inputs.

7.6 Input Type ZERO & SPAN

Type of input is displayed as code for These settings are for specifying
input type. The type of inputs available minimum and maximum range of
is E, J, K, T, B, R, S, N, G ,C, RTD, 4-20 operation. Although full sensor input
mA DC, 0-20 mA DC and 0-5 Volt DC, 1- range is supported, user can select his
5 Volt DC, 0-100 mV DC, 0-2 Volt DC range of operation. The set-point cannot
with display prompt shown below. be set below zero setting and above the
Input type can be selected by INC key or span setting. The reading will display
DEC key. Input type and each type of over when the input is below zero
input are displayed by prompt as setting by 5% or above span setting by
follows. 5%. This 5% is calculated for the
Inpt difference of zero and span settings.
Extreme limits for thermocouple and
E-tc input -200 to 1000. RTD types for the setting are sensor
limits.
J-tc input -200 to 1200
zerO
K-tc input –200 To 1372.
T-tc input -200 to 400
spaN
B-tc input 450 to 1820. Zero and span setting are used for
R-tc input 0 to 1768 selecting range for all inputs. This
S-tc input 0 to 1768 allows selecting any value between
-1999 to 9999 for the range of the all.

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This range can be changed any time, to

make instrument usable for any type of
4-20 mA output transmitters or such
other instrument.

Number of Set-points

Number of set-points is normally fixed at

factory to 1, 2 or 3 depending upon
specifications given while ordering.
However, user can reduce no. of set-
points from actual if all of them are not
used. The programmed no. of setpoint is
displayed in program modes.

Type of Set-point

The type of set-point is independently

programmable for each set-point. So, in
configuration mode you get three
different settings. This selection is
programmed by a code among 0 to 11.
For first set-point code available is 0 to 3
only as codes 4 to 11 are applicable for
deviation & band type. The table for
selection of set-point type is given
below:

0 -Absolute, control, on- above set-point

1 -Absolute, control, on- below set-point
2 -Absolute, alarm, on-above set-point
3 -Absolute, alarm, on-below set-point
4 -Deviation, control, on-above set-point
5 -Deviation, control, on-below set-point
6 -Deviation, alarm, on-above set-point
7 -Deviation, alarm, on-below set-point
8- Band, control, normal (On outside
band) set-point
9- Band, control, fail safe (On within
band) set-point
10-Band, alarm, normal (On outside
band) set-point
11-Band, alarm, fail safe (On within
band) set-point

For more details refer the below figures.

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pressing enter key again it goes to

initialization mode after initialization
instrument resets and all parameters will
be initialized.
Slot configuration

This parameter is used to select the

auxiliary output card and its parameters.
This parameter is configured for three
types of outputs.

Type of relay action for set-points can be Retransmission o/p

configured any time depending upon rtrC
application. Be careful in selecting
proper type as this decides final relay
action. Also refer description of Serial communication
Hysteresis effect in section 7.1 described
earlier for various set-point types. COMC
Default Display Set-point NO output
none
This option decides the set-point to be
displayed in normal run mode display.
User can select any of the set-point for
Serial Number
display.
This parameter is basically used for
Normally first set-point is considered
Modbus communication, to identify the
main set-point and that is displayed as
unit. Modbus communication is master
default.
and slave communication, in which
master will send query and slave will
Decimal Point Position
give response. If there are multiple
slaves connected, so to synchronies
This decides the decimal point position
communication, slave has its
for linear inputs (4-20 mA and voltage
identification no (serial no) and it
inputs). For other input types it is not
responds to only those query, which
having any effect on display. Decimal
have its serial no. Range of serial no is
point position can be programmed from
from 1 to 99.
0 to 3. Position of 0 means no decimal
point. Any non-zero number puts Srno
decimal point after that digit. For
example if decimal point position is set
0 to 99
to 2 and input reading is 1000, it will be
displayed as 10.00. Make sure to put This parameter is required while using
correct decimal point for linear inputs. the Serial Communication facility. It
represents the serial number or the ID
Password number of the Unit. It can be configured
between 1 and 99 by using INC/DEC
Password parameter can be set in the keys.
range of 0 to 9999 this mode.
Baud Rate
Initialization bd
This parameter is used for initialization 9600 19.2k
of all the parameters. By setting default
password for initialization and pressing
enter key it will display yes and by

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This parameter is used to set the BAUD Cals -Span Calibration

RATE for serial communication. Different
Cala -Ambient Calibration.
baud rates can be selected by using
INC/DEC keys. rtrz - Retransmission zero
In Asynchronous communication, master Calibration [ Applicable for
and slave has its separate clock source, Retransmission Option ]
for synchronizing, they must have same rtrs -Retransmission span
baud rate. Baud rate can be set from Calibration [ Applicable . ‘’’’
9600 and 19.2KB. …… for Retransmission Option]

RX ZERO & SPAN Calibration procedure for ANALOG

INPUT.
These setting are provided only for input
type 0-2V and retransmission card is [A] For T/C type
seleted. These settings are for specifying
minimum and maximum range of RX 1. Short the input terminals.
operation. Although full sensor input 2. Press the SET Key and then press
range is supported, user can select his INC/DEC Key to select CALb
range of RX operation. (Calibration mode) and press ENTER
key. Now press SET key twice SV
Rt-z window will indicate CALA. Now set
Rt-s the current ambient temperature
with the help of “INC” or “DEC” keys
and press ENTER key to calibrate
This allows selecting any value between
Ambient.
0 to 2000. This range can be changed
3. Feed the mV (Amb. subtracted
any time, to make instrument usable for
except for B type) according to the
any type of 4-20 mA output transmitters
T/C chart (For TC type) for ZERO
or such other instrument.
value.
4. Again go to Calibration mode by
CALIBRATION MODE
Pressing the SET Key and then press
The instrument is factory INC/DEC Key to select CALb
calibrated for the specified range, but (Calibration mode) and press ENTER
due to long term drift of components, key. SV window will indicate CALZ.
recalibration may be necessary in some Now set the ZERO (lower limit of
cases. For calibrating the instrument a range) with the help of “INC” or
reliable source is required. This source “DEC” keys and press ENTER key to
should be at least ten times accurate calibrate ZERO value.
compared to the range of the 5. Feed the mV (Amb. subtracted
instrument. except for B type) according to the
T/C chart (For TC type) for SPAN
The unit can be calibrated value.
without opening it and without trimpots. 6. Press the SET Key once. More, SV
For entering this mode press select key, window will indicate CALS. Now set
PASS will be displayed, now enter
the SPAN (higher limit of range) by
correct password and press enter key to
“INC” or “DEC” keys and press
enter in menu mode and then
ENTER key to calibrate SPAN (value
INCR/DECR to choose Calibration mode
is according to requirement & TC
and then press Enter key. It will display
type).
first calibration parameter. Now the
subsequent calibration parameter can be
Now check the linearity for the whole
viewed by pressing the select key. The
range.
parameters in sequence are as below.
[B] For RTD type
Calz - Zero Calibration

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1. Set the input resistance at 100.0 at output. Now Press ENTER key
ohm, get CALZ Prompt on the to calibrate O/P for 4 mA.
display and set it to 00.0 °C by 3. Now on pressing SET key SV
“INC” or “DEC” keys and press window will display rtrS
ENTER key to calibrate ZERO. (calibrate span) and PV will
2. Now set the input resistance at display “20.000.” and “2. .”
375.61 ohm. Get CALS Prompt on (20 mA). With help of “INC” or
the display and set 800.0 by “INC” “DEC” keys set this mA value
or “DEC” keys and press ENTER key exactly same as on Ampere-
to calibrate SPAN. meter reading connected at
output. Press ENT key to
Now check the linearity for the whole calibrate O/P for 20 mA.
range
Note: For input type 0-2V: rt-Z
[C] For Linear type parameter must be set to 0 and rt-S
parameter must be set to 2000 to
1. Set the input at 4.000 mA, get calibrate the unit for analog output.
CALZ Prompt on the display and After calibration user can set rt-Z
set it to Actual ZERO by “INC” or and rt-S parameter as per
“DEC” keys and press ENTER key to requirement.
calibrate ZERO.
2. Now set the input at 20.000 mA. • Now check the linearity for the
Get CALS Prompt on the display whole range.
and set it to Actual SPAN by “INC”
or “DEC” keys and press ENTER key
to calibrate SPAN. 7.7 SPECIAL NOTE

• Now check the linearity for the This controller is storing all data
programmed by user and calibration in
whole range.
EEPROM. There are lots of software and
hardware protections added for
ISOLATED RETRANSMISSION safeguarding against data corruptions.
SIGNAL There can be a very rare possibility of
data getting disturbed. The controller is
This is an optional feature. This output having unique algorithm to store data at
can be either 4-20 mA or voltage output multiple places. So, even if the data in
up to 5 volts. This output is proportional one place gets disturbed, it is
to the zero and span setting for input automatically over-ridden by other
type. For example, if you set zero and correct data values. It is also having
span at 0 deg. and 1200 deg. for K type software protections against accidental
thermocouple input, it will output 4 mA writing to EEPROM also.
for 0 deg. and 20 mA for 1200 Deg.
Even after all this, if the data gets
Calibration procedure for ANALOG corrupted by heavy transients on power
OUTPUT . line or noise on power line (for which
protections are already given in
1. Enter into calibration mode as hardware), the unit will display ‘dAtA
explained in the above
paragraph.
Err’ message on the display and will
2. Now SV window will display stop control action, keeping all relays in
OFF condition as safety. In this event,
rtrZ and PV window will programming mode will still continue
display 4.000 (4 mA). With working. User can go to program mode
help of “INC” or “DEC” keys set and check the data, which has changed.
this mA value exactly same as at Re-program the data if it is changed and
Ampere-meter reading connected still it shows data error message, select

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DIGITAL CONTROLLER 5002U masibus
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all entries of configuration and program When messages are transmitted on

modes and press ENTER key once for all standard Modbus serial networks, each
parameters. This is required because the character or byte is sent in this order
data displayed may be correct, but the (left to right):
same data at other positions might be Least Significant Bit (LSB)...Most
disturbed. Significant Bit (MSB) with RTU character
framing, the bit sequence is:
Even after this the data error message is i.e., 1 start bit,
not removed, calibration data would 2 stop bit and
have got disturbed. Re-calibrate the unit No parity.
as per the procedure stated earlier.

Even after all efforts to re-program data,

the error remains, the EEPROM might
have got damaged permanently. The
unit needs to be repaired in this case.
8.2.2 MESSAGE QUERY

8. MODBUS DETAIL

8.1 INTRODUCTION

The Digital controller 5002u can be

connected in RS-485 communication
data link either in multi drop or repeat
mode. Each Digital controller 5002u
must have unique Serial Number. No
two Digital controllers 5002u have the
same address. Entire range of addresses
(1 to 99) may be used.

Before starting any communication,

choose a baud rate and protocol
compatible to the host computer. Only 8.2.3 RTU FRAMING
two-pass protocol is available on Digital
controller 5002u and hence when using
the Digital controller 5002u, only two-
pass protocol is assumed. This speeds
up the total throughput.

8.2.4 START DELAY AND ADDRESS

8.2 COMMUNICATION PROTOCOL
Always contains the start of message
The communication protocol is a HEX with 3.5 null char delay followed by the
protocol. The host computer issues the address of the Digital controller 5002u to
commands to the Digital controller be addressed.
5002u that in turn respond to each
command. The entire protocol is based The address is represented by a HEX
on the command/answer protocol. character ranges from 00 to 99.
8.2.5 FUNCTION
8.2.1 SERIAL TRANSMISSION

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When a message is sent from a master CRC to the message. The receiving
to a slave device the function code field device recalculates a CRC during receipt
tells the slave what kind of action to of the message, and compares the
perform. calculated value to the actual value it
received in the CRC field. If the two
In Digital controller 5002u the functions values are not equal, an error is
implemented are encountered.

01 READ COIL STATUS The CRC is started by first pre loading a

(REFERENCE - 0x) 16-bit register to all 1's. Then a process
03 READHOLDING begins of applying successive eight-bit
REGISTERS bytes of the message to the current
(REFERENCE- 4x) contents of the register. Only the eight
06 PRESET SINGLE REGISTER bits of data in each character are used
(REFERENCE - 4x) for generating the CRC. Start and stop
bits, and the parity bit, do not apply to
Here Same Reference Functions are the CRC.
used for Reading and writing a
parameter, so only one Variable Tag is During generation of the CRC, each
required for reading and writing a eight-bit character is exclusive ORed
parameter. with the register contents. Then the
result is shifted in the direction of the
8.2.6 DATA FIELD least significant bit (LSB), with a zero
filled into the most significant bit (MSB)
Read position. The LSB is extracted and
examined. If the LSB was a 1, the
The query message specifies the starting register is then exclusive ORed with a
register and quantity of registers to be preset, fixed value. If the LSB was a 0,
read. Registers are addressed starting at no exclusive OR takes place.
zero- registers 1 ... 12 are addressed as
0 ... 11. This process is repeated until eight shifts
have been performed. After the last
Write (eighth) shift, the next eight-bit byte is
exclusive ORed with the register's
The query message specifies the register current value, and the process repeats
address and the data to be written in for eight more shifts as described above.
that register. Registers are addressed The final content of the register, after all
starting at zero- register 1 is addressed the bytes of the message have been
as 0. applied, is the CRC value.

8.2.7 CHECKSUM COMPUTATION When the CRC is appended to the

message, the low-order byte is
The error checking field contains a 16-bit appended first, followed by the high-
value implemented as two eight-bit order byte.
bytes. The error check value is the result
of a Cyclical Redundancy Check (CRC) 8.2.9 MESSAGE RESPONSE
calculation performed on the message
contents.

8.2.8 CRC CALCULATION

The CRC field checks the contents of the

entire message. It is applied regardless
of any parity check method used for the
individual characters of the message.
The CRC value is calculated by the
transmitting device, which appends the

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For a normal response, the Digital

controller 5002u Indicator simply echoes
the original function code. For an
exception response, the Digital controller
5002u Indicator returns a code that is
equivalent to the original function code
with its most significant bit set to logic
1.

9.3 Data Field

If no error occurs, the data field of a

response from a Digital controller 5002u
Indicator to a master contains the data
requested. The char will be the byte
count of data requested.

For the write command the response will

be an echo of the query.

If an error occurs, the field contains an

exception code that the master
application can use to determine the
next action to be taken.

9.4 CHECKSUM COMPUTATION

CRC of the message is calculated same

way as explained earlier and appended
to message.

9.5 EXCEPTION RESPONSE

9. COMMUNICATION
PROTOCOL The table explains the meaning of error
codes, if Digital controller 5002u
Indicator transmits error message.
9.1 DELAY AND ADDRESS
COD
Always contains the start of message
E MEANING
with 3.5 null char delay followed by the
address of the Digital controller 5002u to 1 Function code Invalid.
be addressed. The address is It must be 01, 05, 03 or
represented by a HEX character ranges 06.
from 00 to 99. 2 Illegal data starting address.
The range is specified for
different functions in the
9.2 FUNCTION Table below.
3 Illegal data value. The range
When the Digital controller 5002u
is specified for different
Indicator responds to the master, it uses
the function code field to indicate either Functions in the table below.
a normal (error-free) response or that 4 Check sum (CRC) error.
some kind of error occurred (called an Garbled message.
exception response).

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The table show Digital data to be 17 Open Read/ Int 40017

transmitted and its sequence. Sensor write
Sr Digital Type Typ Add 18 RX Zero Read/ Int 40018
No Paramete of e write
r Acces 19 RX Span Read/ Int 40019
s write
1 RELAY 1 Read Bit 00001
Note:
2 RELAY 2 Read Bit 00002
1. Display on Digital controller 5002u
3 RELAY 3 Read Bit 00003 will show ‘over’ when process value
is higher then 5 % of individual span,
The table show Analog data to be at that time Digital controller 5002u
transmitted and its sequence. will send process value fed to it to
PC.
Sr Analog Access Typ Add 2. Same way when process value is
No Paramete Type e lower then 5 % of individual zero
r Digital controllers 5002u will show
1 Process Read Int 40001 ‘under’ on its display but it will send
Value process value fed to it to PC.
3. If Digital controller 5002u process
2 Set-point 1 Read/ Int 40002 value is out of limit for particular I/P
write type then Digital controller 5002u
3 Set-point 2 Read/ Int 40003 will show ‘Open’ on display but it will
write send ‘10000’ to PC
4 Set-point 3 Read/ Int 40004 4. The serial no of Digital controller
write 5002u Indicators must be within 00
5 Set-point 1 Read/ Int 40005 to 99.
Hysteresis write 5. Before starting the communication,
match the Baud rate and Sr. no. of
6 Set-point 2 Read/ Int 40006
Master and Slave devices.
Hysteresis write
6. Analog Parameter RX Zero and RX
7 Set-point 3 Read/ Int 40007 Span are writable only when input
Hysteresis write type 0-2V and Retransmission card is
8 Input Type Read/ Int 40008 selected.
write
9 No. of set Read/ Int 40009
points write 10. TROUBLE SHOOTING
10 Act_zero Read/ Int 40010
write 1 Indicator does not Switch ON.
11 Act_span Read/ Int 40011
write • Check the Mains Cord.
• I/P power may not be
12 Type of Read/ Int 40012
present. Check power supply
Set-point 1 write
voltage is it proper as per
13 Type of Read/ Int 40013 order
Set-point 2 write • Check fuse, if blown off
14 Type of Read/ Int 40014 replace it
Set-point 3 write
15 No. of Slot Read/ Int 40015 2 Calibration of the unit is doubted
configurat- write to have drifted.
ion
16 Decimal Read/ Int 40016 • Check the O/P of sensor is as
Point write per the chart supplied to you
by sensor manufacturer.

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Measure it with instrument •Shielded cables should used

with better then 0.1% for input. Shield should be
accuracy. Standard multi- EARTHED near the unit only.
meter with 3½ digit display • Check any of the sensor is not
may have poor accuracy then getting EARTHED or having
Indicator. weak insulation with respect
• For temperature to earth. If so, remove that
measurements check position sensor and check the cabling.
of the sensor and check for • Check the lead resistance of
the problem related to sensor all the three arms of RTD’s.
first. All the three leads should
• Calibrate the unit as have same lead resistance. If
explained in the manual. no, change the cables.
Select the proper method • Check that Input cables are
according to your Indicator properly tighten
input type. • Take separate earth wires for
separate instruments, avoid
3 In linear type input the unit looping of earth wires.
shows false reading or ‘OVER’ or • Check for AC voltage pick up
‘UNDER’. at the signal at Indicator side
• All low-level input and output
• Check for the polarity of the such as T/C, Rtd, Linear I/P
I/P connections. and control signal wires must
• Check the current I/P coming be kept separate from supply
from the field, it may be and relay output cabling.
below 4 or over 20 mA. 6 Communication Problem
• Check for the proper range between the Unit and Host
programmed in that channel. PC/Operator Terminal

4 In thermocouple type input the • Check the cabling.

reading indicated has got some • Check the serial No. and baud
error. rate settings at PC side and
Indicator side.
• Check for the proper I/p type • Check the RS-485 to RS232
selected. converter for 485
• Ensure that the compensating communication.
cables used are of proper type • Check RS 232 –RS 485
and connected in proper connection at PC and
direction Positive and Indicator side.
negative.
• Check the calibration of the 7 Relay O/P Action problem
unit.
• Check that proper zero-span • Check power to the contactor
range is programmed or not. operated by relay from Indicator.
• If relay burnt out frequently
5 Reading indicated by Indicator is check for the rating of the relay
unstable, wrong or open. or rating of contactor driven by
relay.
• Check the process input and This is an electronics instrument
also check their connections it may have problem not listed
are as per the back-plate above, in case of such fault while
supplied. reporting to factory (Masibus
• Ensure the perfect EARTHING area office or head office),
to the unit & also check that mention exact nature of fault
neutral should not be floating. with sequence of events.

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