DIGITAL CONTROLLER 5002U

Ref No: m55A/om/101

Issue No: 08

masibus

Operators Manual

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

Operators Manual

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DIGITAL CONTROLLER 5002U

Ref No: m55A/om/101
Issue No: 08

masibus

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

Operators Manual

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Ref No: m55A/om/101
Issue No: 08

1.

TECHNICAL DETAILS

This is a versatile microprocessor based

ON/OFF controller with a very high
performance to price ratio. The features
offered in this product are better than
any other controller available in similar
price range.
The instrument is made in 96 x 96 x 180
mm size with standard cutout of 92 x
92 mm. Front is sealed membrane type
to withstand dusty environment.
On
back plate, PCB soldered terminals are
used. The programming and calibration
of the instrument is done by a 4-button
keypad, equipped with two independent
displays for set point and process
variable. Set point display is kept 0.3 to
differentiate it from process variable
display. Status of control/alarm relays
and presently displayed set point are
displayed by 3 mm red LED.
The operation of the
menudriven
with
prompts.

Provision for zero and span setting is

made to restrict range of usage and
programming. This restricts accidental
wrong setting of set-point beyond the
range of interest. Outside this range the
unit will indicate temperature as 'OVER'
for some abnormal condition. This zero
and span setting is used for linear inputs
for setting the range between -1999 to
9999 counts.
Also, the unit has an optional provision
for isolated linearzed retransmission
signal
or
isolated
serial
communication
using
RS-485.
Retransmission signal is useful for
recorder or secondary display.
The
output can be 4-20 mA for the
programmed range or 1 mV/degree (15V) for thermocouple types so that an
ordinary DPM can be connected to this
signal
for
remote
indication
of
temperature.

instrument is
user-friendly

The product is made to accept all the

Ten standard thermocouple inputs,
PT100 RTD, 4 - 20 Ma, 0-5 VDC and 02V 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.
Operators Manual

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2.

SPECIFICATIONS

DISPLAY

4 digit 0.56" Red LEDs for Process

Variable
4 digit 0.3" Red LEDs for Set Point
Individual discrete Red LEDs to
indicate relay status, set point
selection, and serial transmit and
receive indication.

If Input type is fixed [Factory set]

to 0-2V dc then other input type are
not applicable.
[for O 2 measurement]
CONTROL/ALARM OUTPUT

INPUT

Thermo-couple types B,C E, J, G, K,

N, R, S & T (ANSI standard)
RTD - PT100 3-wire
4-20mA & 0-20mA linear
1-5 V dc & 0-5 V dc linear
0-100 mV dc linear
0-2V dc linear
Input field selectable.
Other types on request
Cold
junction
compensation
automatic for thermocouples
Accuracy: +/- 1 Count @ +/- 0.1%
of Span
Input open protection upscale
Input Impedance: >1M (for DC
Volt/mV input)
Input Impedance : <100 (for DC
Current input)

Calibration

-200 to 1000 C
-200 to 1200 C
-200 to 1372 C
-200 to 400 C
450 to 1820 C
0 to 1768
C
0 to 1768
C
-200 to 1300 C
0 to 2320
C
0 to 2320
C
-199.9 to 850.0 C
-1999 to 9999
-1999 to 9999
-1999 to 9999
-1999 to 9999
-1999 to 9999
0 to 2000

[Configurable Input Voltage Scale]

Operators Manual

Ambient, Zero and Span adjusted by

digital calibration through front
panel keys
One shot calibration of both input
and output

CONTROL KEYS AND TERMINALS

Set, Increase, Decrease and Enter

keys for operation, programming
and calibration

GENERAL

RANGE
E
J
K
T
B
R
S
N
G
C
PT100
4-20 mA dc
0-20 mA dc
1-5 V dc
0-5 V dc
0-100 mV dc
+
0-2V dc

Up to three set-points with individual

relay output rated for 2A@230V ac;
selectable for alarm or control. Setpoint 2 and 3 can be absolute or
deviation type.
Individual Hysteresis setting: 0 to 99
Relays: configurable to energize or
de-energize above set-points

Power supply:
110V/230V ac 50Hz
(Internal Jumper selectable),
24V DC (optional) or
24V AC (optional)
Ambient Temperature:
0 to 55 C
Humidity:
20% to 95% RH non-condensing
Power consumption:
Less than 10 VA

PHYSICAL

Case:
M.S. powder coated with ABS
molded bezel
Terminals:
PCB type terminal block can accept
up to 2.5 mm wire
Bezel size:
96 X 96 mm
Depth behind Panel:
200 mm maximum including
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3.

terminals
Panel cutout:
92 X 92 mm

DIMENSIONS &
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
(Optional *)

Communication

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:

Load Impedance: 250 ohms max.

1.

Output Type: 4-20 mA Isolated

.
O/P**.
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.

Operators Manual

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4.

FRONT FASCIA

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

Note:

Here Terminal Nos. are shown

(which are not marked on back
plate),
for
the
purpose
of
explanation only.

Here some terminals may not be

available, if they are not applicable
as per Purchase order.

Operators Manual

5.

CONNECTIONS
DETAIL

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
17 Common
Relay 3 output
18 Normally Open
rated for 230V
ac
19 Normally Close
@ 2A
20 TXD
Serial
Communication
21 RXD
RS485

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6.
6.1

USER GUIDE

INTRODUCTION

DTC 5002U is an on-off controller userfriendly key-pad and display for guiding
the
user
with
programming
and
calibration operation. The manual covers
all
aspects
of
operation
of
the
instrument. Users are requested to go
read the instructions carefully before
altering any configuration.
6.2

POWER SUPPLY

Before
connecting
power
to
the
instrument
ensure
that
you
are
connecting right input voltage to right
terminal. The instrument is having
terminals for both 110V ac and 230V ac
or 24V dc. On application of correct
power supply, the instrument will display
input type set, for five seconds.
Once the input is applied, its value will
be displayed in PV window and presently
selected set-points will be displayed in
the SV display along with appropriate
set-point LED.
6.3

KEY BOARD

There are four keys for operation of the

instrument.
SELECT (SET)
This key is used for programming set
points. Set-points data can be checked
and reprogrammed by this key.
First press select key, it will display setpoint parameter. By pressing INC/DEC
keys value of the set-points and
Hysteresis can be changed as desired.
Bring the set-point at a desired value
and press enter key for storing the value
permanently. On pressing of enter key
the display shows the parameter
prompt. On pressing of set key next
parameter in sequence are selected and
changed by the same procedure.
The parameters in sequence are:

Sp1

Hys1
Sp2
Hys2
Sp3
Hys3

Hysteresis for first set-point

Setpoint2
Hysteresis for second set-point
Setpoint3
Hysteresis for Third set-point

After the last parameter display will go

back to normal run mode. If no key is
pressed for 20 seconds, the display will
fall back to normal run mode.
To exit from any mode to normal run
mode press select key for 3 seconds.

ENTER
This key is used for entering into mode
(CALb Or ConF) and for entering the
value of the selected parameter. After
setting the data to proper value, if enter
key is pressed, the data will be
permanently stored in non-volatile
memory. On pressing of enter key,
display shows the parameter which you
have entered. Now data change is not
possible until Enter key pressed once
again. On pressing of Enter key decimal
point on last digit will glow and allow
changing data.

INC ()

This key will increment the selected

parameter value by one count in all
operating mode. If the key is pressed
continuously than the rate of increment
will be made five times faster. This
facility is called dual speed increment
facility to allow faster data change for
higher values. This key is also used to
move into different mode (calibration
and configuration).

DEC ()
This key is used to select the desired
operating mode and parameter in
various operating modes. On first press
of this key in RUN mode for 3 second, it
will display PASS in PV (Process value)
window.

PASS

Setpoint1

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Now, setting correct value of password

in SV (set value) window and pressing
enter key mode will be displayed.

mode
By pressing INC/DEC Key, user can view
operating modes (CALb Or ConF) in
PV (Process value) window and by
pressing Enter key unit will enter into
that particular operating mode.

Conf
Calb
After Entering into operating mode
(CALb Or ConF), first parameter will be
displayed in SV window and by Pressing
select key subsequent parameter will be
displayed.
Corresponding
parameter
values will be displayed in PV window.
By pressing INC/DEC Key, user can
select desired value and by pressing
ENTER Key, user can store selected
value. After the last parameter is
displayed, pressing of SEL key for 3
second will bring the instrument in Run
mode.
This key will also decrement the selected
parameter value by one count in all
operation modes.
If the key is pressed continuously than
the rate of decrement will be made five
times faster. This facility is called dual
speed decrement facility to allow faster
data change for higher values. This key
is also used to move onto different mode
(calibration and configuration).

7.
There

MODE OF
OPERATION

are five modes of operations.

Run mode
Password mode
Program mode
Configuration mode
Calibration mode

Before looking into various modes of

operations,
it
will
be
better
to
understand some fundamentals for
Operators Manual

various types of set-points and effect of

Hysteresis on relay operation.
7.1

SET-POINTS &
HYSTERESIS EFFECTS
For set-points selection, there are three
different options, which can be selected
for a particular set-point.

On-Above/On-Below Set-point
If user selects on above set-point option,
the relay will be energized when the
process variable is more than set
variable. In case of on below set-point
operation of relay is reverse.
Control/ Alarm Set-point
In the case of control set-point the
Hysteresis effect is different from alarm
type. In case of alarm set-point, the
relay can be acknowledged on pressing
of ENTER key in run mode. So, this
selection should be done carefully
according to application.
Absolute/ Deviation Set-point
Deviation option is applicable only for
second and third set-points. In case of
deviation set-point, it is added to the
first set-point to derive the actual setpoint.
This set-point selection can be done by
changing the configuration. Refer to
section on reconfiguration elsewhere in
this manual.
Now, let us see an example to illustrate
the effect of Hysteresis setting on relay
operation.
For control set-point and
alarm set-point the effect of Hysteresis
is little different so we will consider each
case separately.
Suppose you have selected a set-point
of 200 and Hysteresis of 5. Also the
setting is for control type and on below
set-point. So in this case the Hysteresis
effect is applicable while turning ON the
relay. The relay will turn off exactly at
200 after being turned on. But it will not
turn on once again until temperature
falls below 200 - 5 = 195. This provides
a band of 5 around the set-point. In
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case of on above set-point type, the

operation will be reverse.
Now suppose you have kept same setpoint of 200 and Hysteresis of 5. Setpoint type is alarm and on below setpoint. In this case the Hysteresis effect
will be applicable while turning OFF the
relay. The relay will turn ON when the
process value goes below 200. But it will
not turn OFF until the temperature goes
beyond 200 + 5 = 205. This provides a
band of 5 around the set-point. In case
of on above set-point type, the
operation will be reverse.
Band Set-point
In case of band set point main set point
is taken as a reference and band set
point is distributed both side of main set
point equally.
7.2

RUN MODE

This is normal mode of display. From

other modes of operations, display falls
back to this mode if no key is pressed
for 20 seconds. In this mode PV display
will show value of input signal and SV
display will show the selected set-point
for normal display.
7.3

PASSWORD MODE

In Run mode on first press of DEC key

for 3 second, it shows password mode.
By setting correct password in SV(Set
value) window and pressing enter key
display will show menu mode. but if
password is wrong than it comes back to
the run mode.
7.4

PROGRAM MODE

This mode is used for programming setpoints. In this mode set-points data can
be checked and reprogrammed.
For entering this mode press select key,
It will display first set-point parameter.
By pressing INC/DEC keys value of the
set-points and Hysteresis can be
changed as desired.

Operators Manual

If either of the key is kept pressed

continuously for more than 10 counts
change
in
setting,
it
will
start
incrementing or decrementing the data
at a five time faster rate. Bring the setpoint at a desired value and press enter
key for storing the value permanently.
On pressing of enter key the display
shows the parameter prompt. On
pressing of select key other parameter
in sequence are selected and changed
by the same procedure.
The parameters in sequence are:

Sp1
Hys1
Sp2
Hys2
Sp3
Hys3

Setpoint1
Hysteresis for first set-point
Setpoint2
Hysteresis for second set-point
Setpoint3
Hysteresis for Third set-point

After the last parameter display will go

back to normal run mode. If no key is
pressed for 20 seconds, the display will
fall back to normal run mode.
7.5

CONFIGURATION MODE

This mode is useful for changing the

basic configuration of the unit. No
hardware changes are necessary for
changing input type. It can be changed
by just using front keys.
For entering this mode press DEC key
for 3 seconds, PASS will be displayed,
now enter correct password and press
enter key to enter in menu mode. Now
press INC ( ) and DEC ( ) for
selecting Configuration mode Conf.
Now if Enter key is pressed the unit will
enter in the configuration mode and will
Inpt as first
display
input
configuration mode. These parameters
can
be
changed
by
increment,
decrement and enter keys as described
earlier. User can select parameter to be
programmed by SET key.
The parameters which can be changed
by this mode are described below in
sequence in which they are displayed.

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First we will see the meaning of various

prompts displayed.
Input type

Inpt
zerO
SpaN
NOSP
Tsp1
Tsp2
Tsp3
D SP
dp
OPSE
PASS
init
SLOt
Byps

Zero setting
Span setting
Number of set-point
Type of first set-point
Type of second set-point
Type of third set-point
Default Display set-point
Decimal point position
Open sensor
Password
Initialization
Slot configuration

Bypass selection[used to
bypass 3rd Relay and
RL3 LED Indication in
front]
Serial No

N-tc input -200 to 1300.

G-tc input
0 to 2320.
C-tc input
0 to 2320.
Rtd input 0.1 deg. Resolution
-199.9 to 850.0.

4-20 mA input -1999 to 9999.

0-20 mA input -1999 to 9999.
1-5V input -1999 to 9999.
0-5V input -1999 to 9999.
0-100 mV input -1999 to 9999.
0-2V input 0 to 2000.
For changing of input type, no internal
hardware changes are required.
When an input type is selected its
corresponding zero and span range is
automatically adjusted as per its table.
However if user wants to change zero
and span as required he can move to the
zero or span prompt and can change .

for 0-2V input and Retransmission Option ]

With this facility if the same input is

selected (i.e. ENTER key is pressed on
the same input), its zero and span range
is kept as it is. For setting the range as
per the table one has to change the
input type only. Refer corresponding
range as per the inputs.

7.6

ZERO & SPAN

srNo
baud
rt-Z

Baud Rate
RX zero setting [ Applicable

for 0-2V input and Retransmission Option ]

RX span setting [ Applicable

rt-S

Input Type

Type of input is displayed as code for

input type. The type of inputs available
is E, J, K, T, B, R, S, N, G ,C, RTD, 4-20
mA DC, 0-20 mA DC and 0-5 Volt DC, 15 Volt DC, 0-100 mV DC, 0-2 Volt DC
with display prompt shown below.
Input type can be selected by INC key or
DEC key. Input type and each type of
input are displayed by prompt as
follows.

Inpt

E-tc
J-tc
K-tc
T-tc
B-tc
R-tc
S-tc

input -200 to 1000.

input -200 to 1200
input 200 To 1372.
input -200 to 400
input 450 to 1820.
input

0 to 1768

input

0 to 1768

Operators Manual

These settings are for specifying

minimum and maximum range of
operation. Although full sensor input
range is supported, user can select his
range of operation. The set-point cannot
be set below zero setting and above the
span setting. The reading will display
over when the input is below zero
setting by 5% or above span setting by
5%. This 5% is calculated for the
difference of zero and span settings.
Extreme limits for thermocouple and
RTD types for the setting are sensor
limits.

zerO
spaN
Zero and span setting are used for
selecting range for all inputs.
This
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 setpoints 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
configured any time depending upon
application. Be careful in selecting
proper type as this decides final relay
action.
Also
refer
description
of
Hysteresis effect in section 7.1 described
earlier for various set-point types.

Retransmission o/p

Default Display Set-point

NO output

This option decides the set-point to be

displayed in normal run mode display.
User can select any of the set-point for
display.
Normally first set-point is considered
main set-point and that is displayed as
default.
Decimal Point Position
This decides the decimal point position
for linear inputs (4-20 mA and voltage
inputs). For other input types it is not
having any effect on display. Decimal
point position can be programmed from
0 to 3. Position of 0 means no decimal
point. Any non-zero number puts
decimal point after that digit. For
example if decimal point position is set
to 2 and input reading is 1000, it will be
displayed as 10.00. Make sure to put
correct decimal point for linear inputs.
Password
Password parameter can be set in the
range of 0 to 9999 this mode.
Initialization
This parameter is used for initialization
of all the parameters. By setting default
password for initialization and pressing
enter key it will display yes and by
Operators Manual

rtrC
Serial communication

COMC
none
Serial Number
This parameter is basically used for
Modbus communication, to identify the
unit. Modbus communication is master
and slave communication, in which
master will send query and slave will
give response. If there are multiple
slaves connected, so to synchronies
communication,
slave
has
its
identification no (serial no) and it
responds to only those query, which
have its serial no. Range of serial no is
from 1 to 99.

Srno
0 to 99
This parameter is required while using
the Serial Communication facility. It
represents the serial number or the ID
number of the Unit. It can be configured
between 1 and 99 by using INC/DEC
keys.
Baud Rate

bd
9600 19.2k

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This parameter is used to set the BAUD

RATE for serial communication. Different
baud rates can be selected by using
INC/DEC keys.
In Asynchronous communication, master
and slave has its separate clock source,
for synchronizing, they must have same
baud rate. Baud rate can be set from
9600 and 19.2KB.

Cals
Cala
rtrz

RX ZERO & SPAN

Calibration procedure for ANALOG

INPUT.

These setting are provided only for input

type 0-2V and retransmission card is
seleted. These settings are for specifying
minimum and maximum range of RX
operation. Although full sensor input
range is supported, user can select his
range of RX operation.

Rt-z
Rt-s
This allows selecting any value between
0 to 2000. This range can be changed
any time, to make instrument usable for
any type of 4-20 mA output transmitters
or such other instrument.
CALIBRATION MODE
The
instrument
is
factory
calibrated for the specified range, but
due to long term drift of components,
recalibration may be necessary in some
cases. For calibrating the instrument a
reliable source is required. This source
should be at least ten times accurate
compared
to
the
range
of
the
instrument.
The unit can be calibrated
without opening it and without trimpots.
For entering this mode press select key,
PASS will be displayed, now enter
correct password and press enter key to
enter in menu mode and then
INCR/DECR to choose Calibration mode
and then press Enter key. It will display
first calibration parameter. Now the
subsequent calibration parameter can be
viewed by pressing the select key. The
parameters in sequence are as below.

Calz

- Zero Calibration

Operators Manual

-Span Calibration
-Ambient Calibration.
- Retransmission zero
Calibration [ Applicable for
Retransmission Option ]

-Retransmission span

rtrs

Calibration [ Applicable .
for Retransmission Option]

[A] For T/C type

1. Short the input terminals.
2. Press the SET Key and then press
INC/DEC Key to select CALb
(Calibration mode) and press ENTER
key. Now press SET key twice SV
window will indicate CALA. Now set
the current ambient temperature
with the help of INC or DEC keys
and press ENTER key to calibrate
Ambient.
3. Feed the mV (Amb. subtracted
except for B type) according to the
T/C chart (For TC type) for ZERO
value.
4. Again go to Calibration mode by
Pressing the SET Key and then press
INC/DEC Key to select CALb
(Calibration mode) and press ENTER
key. SV window will indicate CALZ.
Now set the ZERO (lower limit of
range) with the help of INC or
DEC keys and press ENTER key to
calibrate ZERO value.
5. Feed the mV (Amb. subtracted
except for B type) according to the
T/C chart (For TC type) for SPAN
value.
6. Press the SET Key once. More, SV
window will indicate CALS. Now set
the SPAN (higher limit of range) by
INC or DEC keys and press
ENTER key to calibrate SPAN (value
is according to requirement & TC
type).
Now check the linearity for the whole
range.
[B] For RTD type

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Ref No: m55A/om/101
Issue No: 08

1. Set the input resistance at 100.0

ohm, get CALZ Prompt on the
display and set it to 00.0 C by
INC or DEC keys and press
ENTER key to calibrate ZERO.
2. Now set the input resistance at
375.61 ohm. Get CALS Prompt on
the display and set 800.0 by INC
or DEC keys and press ENTER key
to calibrate SPAN.
Now check the linearity for the whole
range
[C] For Linear type
1.

Set the input at 4.000 mA, get

CALZ Prompt on the display and
set it to Actual ZERO by INC or
DEC keys and press ENTER key to
calibrate ZERO.
2.
Now set the input at 20.000 mA.
Get CALS Prompt on the display
and set it to Actual SPAN by INC
or DEC keys and press ENTER key
to calibrate SPAN.

Now check the linearity for the

whole range.

ISOLATED
SIGNAL

RETRANSMISSION

This is an optional feature. This output

can be either 4-20 mA or voltage output
up to 5 volts. This output is proportional
to the zero and span setting for input
type. For example, if you set zero and
span at 0 deg. and 1200 deg. for K type
thermocouple input, it will output 4 mA
for 0 deg. and 20 mA for 1200 Deg.
Calibration procedure for ANALOG
OUTPUT .
1. Enter into calibration mode as
explained
in
the
above
paragraph.
2. Now SV window will display
rtrZ and PV window will
display 4.000 (4 mA). With
help of INC or DEC keys set
this mA value exactly same as at
Ampere-meter reading connected
Operators Manual

at output. Now Press ENTER key

to calibrate O/P for 4 mA.
3. Now on pressing SET key SV
rtrS
window
will
display
(calibrate span) and PV will
display 20.000. and 2. .
(20 mA). With help of INC or
DEC keys set this mA value
exactly same as on Amperemeter reading connected at
output.
Press
ENT
key
to
calibrate O/P for 20 mA.
Note: For input type 0-2V: rt-Z
parameter must be set to 0 and rt-S
parameter must be set to 2000 to
calibrate the unit for analog output.
After calibration user can set rt-Z
and
rt-S
parameter
as
per
requirement.

7.7

Now check the linearity for the

whole range.
SPECIAL NOTE

This controller is storing all data

programmed by user and calibration in
EEPROM. There are lots of software and
hardware
protections
added
for
safeguarding against data corruptions.
There can be a very rare possibility of
data getting disturbed. The controller is
having unique algorithm to store data at
multiple places. So, even if the data in
one
place
gets
disturbed,
it
is
automatically over-ridden by other
correct data values. It is also having
software protections against accidental
writing to EEPROM also.
Even after all this, if the data gets
corrupted by heavy transients on power
line or noise on power line (for which
protections
are
already
given
in
hardware), the unit will display dAtA

Err message on the display and will

stop control action, keeping all relays in
OFF condition as safety. In this event,
programming mode will still continue
working. User can go to program mode
and check the data, which has changed.
Re-program the data if it is changed and
still it shows data error message, select
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Ref No: m55A/om/101
Issue No: 08

all entries of configuration and program

modes and press ENTER key once for all
parameters. This is required because the
data displayed may be correct, but the
same data at other positions might be
disturbed.
Even after this the data error message is
not removed, calibration data would
have got disturbed. Re-calibrate the unit
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.
8.1

When messages are transmitted on

standard Modbus serial networks, each
character or byte is sent in this order
(left to right):
Least
Significant
Bit
(LSB)...Most
Significant Bit (MSB) with RTU character
framing, the bit sequence is:
i.e.,
1 start bit,
2 stop bit and
No parity.

8.2.2 MESSAGE QUERY

MODBUS DETAIL
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
two-pass protocol is available on Digital
controller 5002u and hence when using
the Digital controller 5002u, only twopass protocol is assumed. This speeds
up the total throughput.
8.2

COMMUNICATION PROTOCOL

The communication protocol is a HEX

protocol. The host computer issues the
commands to the Digital controller
5002u that in turn respond to each
command. The entire protocol is based
on the command/answer protocol.
8.2.1 SERIAL TRANSMISSION

Operators Manual

8.2.3 RTU FRAMING

8.2.4 START DELAY AND ADDRESS

Always contains the start of message
with 3.5 null char delay followed by the
address of the Digital controller 5002u to
be addressed.
The address is represented by a HEX
character ranges from 00 to 99.
8.2.5 FUNCTION

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Ref No: m55A/om/101
Issue No: 08

When a message is sent from a master

to a slave device the function code field
tells the slave what kind of action to
perform.
In Digital controller 5002u the functions
implemented are
01
03
06

READ COIL STATUS

(REFERENCE - 0x)
READHOLDING
REGISTERS
(REFERENCE- 4x)
PRESET SINGLE REGISTER
(REFERENCE - 4x)

Here Same Reference Functions are

used for Reading and writing a
parameter, so only one Variable Tag is
required for reading and writing a
parameter.
8.2.6 DATA FIELD
Read
The query message specifies the starting
register and quantity of registers to be
read. Registers are addressed starting at
zero- registers 1 ... 12 are addressed as
0 ... 11.
Write
The query message specifies the register
address and the data to be written in
that register. Registers are addressed
starting at zero- register 1 is addressed
as 0.
8.2.7 CHECKSUM COMPUTATION
The error checking field contains a 16-bit
value implemented as two eight-bit
bytes. The error check value is the result
of a Cyclical Redundancy Check (CRC)
calculation performed on the message
contents.

masibus
CRC to the message. The receiving
device recalculates a CRC during receipt
of the message, and compares the
calculated value to the actual value it
received in the CRC field. If the two
values are not equal, an error is
encountered.
The CRC is started by first pre loading a
16-bit register to all 1's. Then a process
begins of applying successive eight-bit
bytes of the message to the current
contents of the register. Only the eight
bits of data in each character are used
for generating the CRC. Start and stop
bits, and the parity bit, do not apply to
the CRC.
During generation of the CRC, each
eight-bit character is exclusive ORed
with the register contents. Then the
result is shifted in the direction of the
least significant bit (LSB), with a zero
filled into the most significant bit (MSB)
position. The LSB is extracted and
examined. If the LSB was a 1, the
register is then exclusive ORed with a
preset, fixed value. If the LSB was a 0,
no exclusive OR takes place.
This process is repeated until eight shifts
have been performed. After the last
(eighth) shift, the next eight-bit byte is
exclusive ORed with the register's
current value, and the process repeats
for eight more shifts as described above.
The final content of the register, after all
the bytes of the message have been
applied, is the CRC value.
When the CRC is appended to the
message,
the
low-order
byte
is
appended first, followed by the highorder byte.
8.2.9 MESSAGE RESPONSE

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
Operators Manual

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Ref No: m55A/om/101
Issue No: 08

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
exception
application
next action

9.4

occurs, the field contains an

code
that
the
master
can use to determine the
to be taken.

CHECKSUM COMPUTATION

CRC of the message is calculated same

way as explained earlier and appended
to message.

9.
9.1

COMMUNICATION
PROTOCOL
DELAY AND ADDRESS

Always contains the start of message

with 3.5 null char delay followed by the
address of the Digital controller 5002u to
be addressed. The address is
represented by a HEX character ranges
from 00 to 99.
9.2

9.5

The table explains the meaning of error

codes, if Digital controller 5002u
Indicator transmits error message.
COD
E
1

FUNCTION

When the Digital controller 5002u

Indicator responds to the master, it uses
the function code field to indicate either
a normal (error-free) response or that
some kind of error occurred (called an
exception response).

Operators Manual

EXCEPTION RESPONSE

MEANING
Function code Invalid.
It must be 01, 05, 03 or
06.
Illegal data starting address.
The range is specified for
different functions in the
Table below.
Illegal data value. The range
is specified for different
Functions in the table below.
Check sum (CRC) error.
Garbled message.

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Ref No: m55A/om/101
Issue No: 08

The table show Digital data to be

transmitted and its sequence.
Sr
Digital
Type
Typ
Add
No Paramete
of
e
r
Acces
s
1
RELAY 1
Read
Bit
00001
2

RELAY 2

Read

Bit

00002

RELAY 3

Read

Bit

00003

The table show Analog data to be

transmitted and its sequence.

Analog
Paramete
r
Process
Value
Set-point 1

Set-point 2

Set-point 3

Read/
write

Int

40004

Set-point 1
Hysteresis
Set-point 2
Hysteresis
Set-point 3
Hysteresis

Read/
write
Read/
write
Read/
write

Int

40005

Int

40006

Int

40007

Input Type

Int

40008

No. of set
points

Read/
write
Read/
write

Int

40009

10

Act_zero

Read/
write

Int

40010

11

Act_span

Read/
write

Int

40011

12

Type of
Set-point 1

Read/
write

Int

40012

13

Type of
Set-point 2

Read/
write

Int

40013

14

Type of
Set-point 3

Read/
write

Int

40014

15

No. of Slot
configuration
Decimal
Point

Read/
write

Int

40015

Read/
write

Int

40016

Sr
No
1

6
7

16

Operators Manual

Access
Type

Typ
e

Add

Read

Int

40001

Read/
write
Read/
write

Int

40002

Int

40003

17
18

Open
Sensor
RX Zero

19

RX Span

Read/
write
Read/
write
Read/
write

Int

40017

Int

40018

Int

40019

Note:
1. Display on Digital controller 5002u
will show over when process value
is higher then 5 % of individual span,
at that time Digital controller 5002u
will send process value fed to it to
PC.
2. Same way when process value is
lower then 5 % of individual zero
Digital controllers 5002u will show
under on its display but it will send
process value fed to it to PC.
3. If Digital controller 5002u process
value is out of limit for particular I/P
type then Digital controller 5002u
will show Open on display but it will
send 10000 to PC
4. The serial no of Digital controller
5002u Indicators must be within 00
to 99.
5. Before starting the communication,
match the Baud rate and Sr. no. of
Master and Slave devices.
6. Analog Parameter RX Zero and RX
Span are writable only when input
type 0-2V and Retransmission card is
selected.

10.
1

TROUBLE SHOOTING

Indicator does not Switch ON.

Check the Mains Cord.

I/P power may not be
present. Check power supply
voltage is it proper as per
order
Check
fuse, if
blown off
replace it

Calibration of the unit is doubted

to have drifted.

Check the O/P of sensor is as

per the chart supplied to you
by
sensor
manufacturer.
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Ref No: m55A/om/101
Issue No: 08

In thermocouple type input the

reading indicated has got some
error.

Check for the proper I/p type

selected.
Ensure that the compensating
cables used are of proper type
and connected in proper
direction
Positive
and
negative.
Check the calibration of the
unit.
Check that proper zero-span
range is programmed or not.

Check for the polarity of the

I/P connections.
Check the current I/P coming
from the field, it may be
below 4 or over 20 mA.
Check for the proper range
programmed in that channel.

Shielded cables should used

for input. Shield should be
EARTHED near the unit only.
Check any of the sensor is not
getting EARTHED or having
weak insulation with respect
to earth. If so, remove that
sensor and check the cabling.
Check the lead resistance of
all the three arms of RTDs.
All the three leads should
have same lead resistance. If
no, change the cables.
Check that Input cables are
properly tighten
Take separate earth wires for
separate instruments, avoid
looping of earth wires.
Check for AC voltage pick up
at the signal at Indicator side
All low-level input and output
such as T/C, Rtd, Linear I/P
and control signal wires must
be kept separate from supply
and relay output cabling.
Communication
Problem
between the Unit and Host
PC/Operator Terminal

In linear type input the unit

shows false reading or OVER or
UNDER.

Measure it with instrument

with
better
then
0.1%
accuracy. Standard multimeter with 3 digit display
may have poor accuracy then
Indicator.
For
temperature
measurements check position
of the sensor and check for
the problem related to sensor
first.
Calibrate
the
unit
as
explained in the manual.
Select the proper method
according to your Indicator
input type.

Reading indicated by Indicator is

unstable, wrong or open.

Check the process input and

also check their connections
are as per the back-plate
supplied.
Ensure the perfect EARTHING
to the unit & also check that
neutral should not be floating.

Operators Manual

Check the cabling.

Check the serial No. and baud
rate settings at PC side and
Indicator side.
Check the RS-485 to RS232
converter
for
485
communication.
Check RS 232 RS 485
connection
at
PC
and
Indicator side.

Relay O/P Action problem

Check power to the contactor
operated by relay from Indicator.
If relay burnt out frequently
check for the rating of the relay
or rating of contactor driven by
relay.
This is an electronics instrument
it may have problem not listed
above, in case of such fault while
reporting to factory (Masibus
area office or head office),
mention exact nature of fault
with sequence of events.

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Ref No: m55A/om/101
Issue No: 08

Operators Manual

masibus

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