Operator s Manual. masibus

Transcription

1 Operator s Manual BARGRAPH INDICATOR DUAL CHANNEL Masibus Automation & Instrumentation Pvt. Ltd. B/30, GIDC Electronics Estate, Sector-25, Gandhinagar , Gujarat, India. Ph: /76/77/78/79 Fax: /2 support@.com Web: OPERATION MANUAL DUAL CHANNEL 1 of 20

2 CONTENTS 1. TECHNICAL DETAILS 2. SPECIFICATIONS 3. FRONT FASCIA 4. CONNECTIONS DETAIL 5. USER GUIDE 6. MODE OF OPERATION 7. TROUBLE SHOOTING 8. MODBUS DETAIL (OPTIONAL) 9. COMMUNICATION PROTOCOL IN BARGRAPH 10. SPACIAL NOTE APPENDIX A OPERATION MANUAL DUAL CHANNEL 2 of 20

3 1. TECHNICAL DETAILS This 101 segment dual channel Bargraph indicator is versatile micro-controller based instrument designed for all industry standard inputs. For different type of I/P s only user have to select the type and range of input. It indicates the process variable on a 101- segment bar with 1-% resolution and a four digit seven segment display. The instrument is made in a 72 x 144-mm bezel size. By just unscrewing the two screws from backside the whole chassis can be opened out. Front is sealed membrane type to withstand dusty environment. Internally, the instrument is built around an 8-bit microcontroller to control the overall activity. Micro-controller is featured with ISP (In System Programming) facility so, can be directly programmed through Computer with out removing it from its place. For better noise immunity and operation at lower voltage, precision switch mode power supply is used. setting is more useful for linear inputs for setting the range between to 9999 counts. Isolated Retransmission output 4-20 ma and 0-5 VDC. Retransmission o/p is jumper selectable. Serial Communication with RS 485 is also provided for using the bargraph as backend for Supervisory Control or for P.C. connectivity. Standard protocol for communication used is MODBUS-RTU. The instrument is designed in such a fashion in order to avoid the number of hard wire connections. All PCB are self-detachable, means any card can be isolated by other card by just plugging out the connector. Apart from this there is a precaution for the costly bar display in case of failure of CPU hardware. To be more precise, if the CPU fails to refresh the data to Bar display at it's specified rate, there is an additional circuit, which will reset the bar making all segment of bar switched off. The programming, calibration and operation of the instrument is by four simple keys with two independent displays for channel 1 & 2. The product is made to accept all 7 standard thermocouple, PT100 RTD, Linear voltage and current inputs. The type of input can be changed in field also. The calibration of the unit is done without trim-pots. The unit can be calibrated in installed condition itself by front panel keys at any given point. The instrument software is written to provide all possible features with minimum hardware requirements. It is having a powerful watch dog circuit with a close monitoring of the software loop. This ensures the instrument operation in case of power spikes or mains noise. This may not protect the instrument from these but can bring the instrument out of disturbances caused to the micro-controller software due to such spikes. 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 data as OVER towards span side up to 5% more than programmed span and UNDR towards zero side up to 5% less then programmed zero. Outside the full scale the unit will indicate data as OPEN. This zero and span OPERATION MANUAL DUAL CHANNEL 3 of 20

4 2. SPECIFICATIONS PV Input Signals: Number of Inputs: 2 Input Type: 1. Thermocouple types B, E, J, K, R, S & T (ANSI standard) 2. RTD - Pt100 3-wire ma/1-5 V DC linear mA/0-5 V DC linear Note: Other types on request Input field select ability Cold junction compensation automatic for thermocouples Accuracy: ± (0.1% of full scale + 1 Count) Resolution: 14 1/2 bits Sampling Period: 500 ms Burn out detection: Input shows OPEN in display. Burn out Current: 1.2 ua Measuring Current in RTD : 0.166mA Input Resistance: TC / V : >1 MΩ Allowable signal source resistance: 1.TC input: 100Ω or less Effect from allowable signal source.. resistance: 2.4 uv / Ω or less 2. DC input voltage: 1KΩ or less Effect from allowable signal source.... resistance: 0.01 % / 100Ω or less Allowable lead wire resistance: 15Ω / wire or less Effect from allowable lead wire..... resistance: 0.66 C / 10Ω or less Allowable Input Voltage: TC / RTD: ±10V DC DC voltage: ±20V DC Noise Rejection Ratio: Common Mode: > 100 db (50 Hz) Normal Mode: > 50 db (50 Hz) Reference-junction compensation error: ± 2 C (10 to 55 C) Applicable standard: ITS-90 Response time: 1. Input to relay o/p: < 5 Sec. 2. Input to Analog o/p: 1 second or.... less, 63%(10-90%) Range : B 450 to 1820 º C E -200 to 1000 º C J -200 to 1200 º C K -200 to 1372 º C R 0 to 1768 º C S 0 to 1768 º C T -200 to 400 º C PT to º C 4-20 ma DC to 9999 Field. Scalable 0-5 V DC to 9999 Field.. Scalable Calibration : Zero and span adjusted by front panel keyboard only. No trimpots. Operation : Four operating mode, software selectable, selected by pressing front panel keys in pre defined sequence. INC, DEC (for increase & decrease of various parameters and set points) SET & ENT (set parameters and set points) Contact Output: Usage Alarm O/P No. of relay contact outputs 4 Relay contact rating 230 VAC / 2Amp. Relay Contact terminal 3 ( NO, NC, Common) Alarm Types PV High limit, PV low limit Setting Ranges for Process Value Alarms PV Alarms Min = Zero of individual I/P type Max. = Span of individual I/P type Alarm hystersis width 0 to 100 Display Specifications: CH-1 4 digit, 0.3" Red LEDs for Process Variable 101 Segment Red Bar for indicating process variable in percentage. CH-2 4 digit, 0.3" Red LEDs for Process Variable 101 Segment Red Bar for indicating process variable in percentage. Display Update Rate : Continuous Individual Discrete Leds For Set And Relay Status Indication. OPERATION MANUAL DUAL CHANNEL 4 of 20

5 Construction, Installation, and Wiring: Case M.S. powder coated with ABS molded bezel Case color Dark Grey Protection IP54 (Front Fascia) complied (Not verified) Weight Approximately 1.7 Kg or less Bezel size 72mm(W) X 144 mm(h) X 245 mm(d) Depth behind panel 245 mm maximum including terminals Mounting Panel mounting Panel cutout 68.0mm(W) X mm(h) Chassis Fixed Standard Accessories 2 mounting clamp Terminals PCB Termination Block can accept up to 2.5 Sq.mm wire. Power Supply Specifications: Power supply 90V to 270 V AC, 50 Hz OR 24VDC + 10% Power consumption Less than 15 VA Memory backup EEPROM Primary terminal Power supply, relay output Secondary terminal Analog input/output signal terminals Withstanding voltage Between primary terminal and secondary terminal 500V AC for 1min. Between primary terminal and ground terminal 500V AC for 1min Between ground terminal and Secondary terminal 500V AC for 1min. Between two Secondary terminal 500V AC for 1min. Isolation resistance Between power supply terminal and ground terminal, 500V DC 50 MΩ Environmental Conditions: Ambient 0 to 55 deg C Humidity up to 95% RH non-condensing Warm up time > 30 min Storage Temperature 0 to 70 deg C Effect of operating conditions 1. Effect of Ambient temperature For T/C input, ± 0.01% of F.S./ C or less For Voltage input, ± 0.01% of F.S./ C or. less For RTD input, ± 0.02% of F.S./ C or less For analog output, ± 0.02% of F.S./ C or. less 2. Effect on power supply fluctuation (within rated voltage range) For analog input, within ± % of... F.S./ 10V For analog output, ± 0.01% of F.S./ 10V Isolated Retransmission Output: No of Output 2. Output Type 4-20 ma Isolated O/P. Load Impedance 600 ohms maximum. Accuracy % of Full scale. Isolation 500 VDC Output Regulation 0.01% for full load change Resolution 12 bits Isolated Transmitted Power Supply: No of Supply 1. Voltage Rating ma Isolated O/P. Isolation 500 VDC Isolated Serial Communication: Communication standard RS-485 Communication Protocol Modbus RTU. Communication method 2 wire half duplex (RS-485) Data frame N,8,1 Communication rate 9600,19200 bps Address range 001 to 247 Distance of Communication1200 meter (Twisted pair cable as per EIA 485 standard). Maximum Slaves 32 without repeaters. Isolation 500 VDC OPERATION MANUAL DUAL CHANNEL 5 of 20

6 Special function: Square root extraction 4. CONNECTION DETAIL Back panel connections are as shown in diagram given below. 3. FRONT FACIA The instrument front is a transparent Acrylic over which overlay is pasted. Left upper row of four digits represents numerical value of process variable of channel-1 and right upper row of four digits represents numerical value of process variable of channel-2. Bar is calibrated with 1-% resolution and graduated at every 5%, for ease of reading from distance. RL1 RL1 RL2 RL2 SET RL1 RL1 RL2 RL2 SET SEL OPERATION MANUAL DUAL CHANNEL 6 of 20

7 FOR CHANNEL 1: FOR CHANNEL 2: +24V TPS OUTPUT 1-24V TPS OUTPUT 2 +THERMOCOUPLE 4 INPUT -THERMOCOUPLE 5 INPUT + CURRENT INPUT 4 - CURRENT INPUT 5 * PUT 250R,0.1% RESISTOR EXTERNALY + VOLT INPUT 4 - VOLT INPUT 5 COMMON 3 IN+ 4 IN- 5 RE1+ + Re-transmission 6 output RE1- - Re-transmission 7 output D+ RS D- COMMUNICATION 9 RELAY1 COMMON-RELAY1 10 NORMALLY OPEN- RELAY1 11 NORMALLY CLOSE RELAY1 12 RE1+ RE1- RELAY1 RELAY2 +THERMOCOUPLE 20 INPUT -THERMOCOUPLE 21 INPUT + CURRENT INPUT 20 - CURRENT INPUT 21 * PUT 250R,0.1% RESISTOR EXTERNALY + VOLT INPUT 20 - VOLT INPUT 21 COMMON 19 IN+ 20 IN Re-transmission 22 output - Re-transmission 23 output COMMON-RELAY1 24 NORMALLY 25 OPEN-RELAY1 NORMALLY 26 CLOSE -RELAY1 COMMON-RELAY2 27 NORMALLY 28 OPEN-RELAY2 NORMALLY 29 CLOSE -RELAY2 RELAY2 POWER SUPPLY COMMON-RELAY2 13 NORMALLY OPEN- 14 RELAY2 NORMALLY CLOSE- 15 RELAY2 LINE/+24V 16 NEATURAL /-24V 17 EARTH USER GUIDE INTRODUCTION This is a single chip micro-controller based bargraph designed for universal input type. Instrument is operated by four user friendly keys. These keys are used for operation, programming and calibration. On applying power, the instrument will display I/P type for first five seconds. If the I/P is not connected 4 digit seven segment display will indicate OPEN and 1 to 100 LED of 101 segment bar will fully ON with 101 LED OFF for open sensor up where as for open sensor down 1 to 100 LED of 101 segment bar will fully OFF with 101 LED ON (Refer Appendix A). Now, if the I/P is connected with proper polarity, the instrument will display the process variable reading on seven segment display and bar will show process value in terms of percentage input with 1% resolution. In order to understand the operation of the instrument more precisely one whole description for Zero OPERATION MANUAL DUAL CHANNEL 7 of 20

8 value considered as 0 and span value considered as 100 is given below: In case for Linear I/P (or any Type of I/P) at 4mA(minimum value of I/P range), 4-digit seven segment should display "0" and the Bar display should indicate 0%, with 1 to 100 LED of 101 segment bar in OFF condition and 101 LED of it in "ON" condition(refer Appendix A). If the I/P value reaches to 12mA (half of the I/P range), then 4-digit seven segment display should display "50" as process variable and Bar display should indicate 50%, by turning off 101 LED of 101 segment bar and by turning on it's 50 LED's out of 1 to 100(Refer Appendix A). If the I/P reaches 20mA(maximum value of I/P range) in other terms to the span value, seven segment 4-digit display will indicate 100 as a process variable and Bar display will show 100% by turning on all 100 LED's ON with 101 LED OFF (Refer Appendix A). If the I/P ma exceeds 20mA, the process variable window will display "OPEN" message. If the I/P ma goes below 4mA, the process variable window will display "OPEN" message. For I/P TC, if the input temp. exceeds then programmed span, the process variable window will display "OVer" message up to 5% of programmed span and simultaneously the bar will flash at 100%, with 101 LED OFF, at the rate of 0.5sec. For I/P TC, if the input temp. goes below programmed zero, the process variable window will display "under" message up to 5% of programmed zero and 1 to 100 LED of 101 segment bar will OFF with 101 LED ON. This differentiates the I/P condition given to the instrument at Upper and lower limits of I/P. After 5% of programmed zero and programmed span unit will indicate OPEN and 1 to 100 LED of 101 segment bar will fully ON with 101 LED OFF for open sensor up where as for open sensor down 1 to 100 LED of 101 segment bar will fully OFF with 101 LED ON (Refer Appendix A). One additional feature to this instrument is added to protect the costly bar from the circumstances when the CPU fails to refresh the bar, by data at the specified rate according to the software. Under this condition one special watch dog hardware incorporated, will turn off the Bar and prevent it from being damaged due to long time continuous flow of current through the bar. The manual covers all aspects of operation of the instrument. Please read instructions carefully before altering any programming or configuration information. OPERATION POWER SUPPLY Always be sure that you are connecting right input supply voltage to right power terminal of the instrument. The instrument is having 3/2 terminals 230VAC/24VDC for mains Supply. On application of proper power, the instrument will display I/P type for 5 seconds and then come to RUN Mode. Now, if the input signal is connected, unit will display value of input in PV (process value) window. KEY BOARD There are four keys for operation of the instrument. For understanding the operation first let us see the operation of keys. SELECT This key is used to select the desired operating mode and parameter in various operating modes. On first press of this key, it will display Password. pass By pressing INCR/DECR Key user can change the password and using ENTER key user can give the password.if the password matches with the password set in configuration than user can view operating modes (CALb, ConF or ProG) and by pressing Enter key unit will enter into that particular operating mode. Calb Conf Prog After Entering into operating mode (CALb, ConF or ProG) first parameter will be displayed and by Pressing select key subsequent parameter will be displayed. After OPERATION MANUAL DUAL CHANNEL 8 of 20

9 the last parameter displayed, pressing of SEL key will bring the instrument in Run mode. ENTER This key is used for entering into mode (CALb, ConF or ProG) 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 nonvolatile memory. On pressing of enter key, display shows the parameter which you have entered. Now data change is not possible until INCR/DECR key pressed once again. On pressing of Enter key decimal point on last digit will glow and allow to change data. INC ( ) This key will increment the selected parameter value by one count in all operating mode. If the key is pressed continuously for more than 10 counts change, 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 onto different mode (calibration, configuration and program). DEC ( ) This key will decrement the selected parameter value by one count in all operation modes.. If the key is pressed continuously for more than 10 counts change, 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, configuration and program). 6. MODES OF OPERATIONS There are four modes of operations. 6.1 Run mode. 6.2 Program mode. 6.3 Configuration mode. 6.4 Calibration mode. Each are described in detail in individual chapter. 6.1 RUN MODE This is normal mode of display. From other mode of operations, display fall back to this mode if no key is pressed for 20 Seconds. In this mode PV display will show the value of input signal of each channel and bar shows the % process variable corresponding to the input. 6.2 PROGRAM MODE This mode is used for programming setpoints. In this mode setpoints data can be checked and reprogrammed. For entering this mode press Select key and then INCR/DECR to choose Program mode and then press Enter key. It will display first setpoint parameter. By pressing INCR/DECR keys value of the setpoints and hystersis can be changed as desired. 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 set key other parameter in sequence are selected and changed by the same procedure. The parameters in sequence are: Sp1 Hys1 Sp2 Hys2 Sp3 Hys3 Sp4 Hys4 Setpoint1 of CH-1 Hystersis for first setpoint Setpoint2 of CH-1 Hystersis for second setpoint Setpoint1 of CH-2 Hystersis for first setpoint Setpoint2 of CH-2 Hystersis for second setpoint 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. 6.3 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. OPERATION MANUAL DUAL CHANNEL 9 of 20

10 For entering this mode press select key, MODE will be displayed, now press INCR ( ) and DECR ( ) for selecting Configuration mode Conf. Now if Enter key is pressed the unit will enter in the configuration mode and will display input Inpt as first in the PV display of CH-1. Now by pressing the INCR/DECR key display will show the input type (eg. k-tc, E-tC or 4-20 ) of that channel, which can be selected by pressing Enter key. User can select the parameter to be programmed by SEL key. The parameters for both channels that can be changed by this mode are described below in sequence in which they are displayed except serial no and baud rate, which is common for both channel and will be displayed as last two parameter in channel-2 PV display. First we will see the parameter displayed. These parameters are for Channel-1 and will be displayed in Channel-1 PV display Window. Inpt zero SpaN Tsp1 Tsp2 Sqrt dp --- Input type. --- Zero setting. --- Span setting. --- Type of first set-point. --- Type of second set-point. ---Square root enable/disable. --- Decimal point position. These parameters are for Channel-2and will be displayed in Channel-2 PV display Window. Inpt zero SpaN Tsp1 Tsp2 Sqrt dp --- Input type. --- Zero setting. --- Span setting. --- Type of first set-point. --- Type of second set-point. --- Square root enable/disable. --- Decimal point position. These parameters are common for Channel-1 & 2 and will be displayed in Channel-2 PV display Window. srno baud pass --- Serial No. --- Baud Rate --- Pass word 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, SPL, RTD, 4-20 ma DC and 0-5 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 is displayed by prompt as follows. Inpt E-tc J-tc K-tc T-tc B-tc R-tc S-tc Spl E - type thermocouple -200 to 1000 J - type thermocouple -200 to 1200 K - type thermocouple -200 to 1372 T - type thermocouple -200 to 400 B - type thermocouple 450 to 1820 R - type thermocouple 0 to 1768 S - type thermocouple 0 to 1768 Special - type for any new input type 0 to 1768 Rtd RTD PT-100, 0.1 deg. Resolution to ma or 1-5 V input to V input or 0-20 ma to 9990 For changing of input type, no internal hardware changes are required. If input type is 4-20mA then you are required to connect the 250ohm Resistors supplied between the INHI and INLOW terminals of the terminal plate. 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. With this facility if the same input is selected (ie. 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 OPERATION MANUAL DUAL CHANNEL 10 of 20

11 change the input first and then change back to same input as required. Refer corresponding range as per the inputs. ZERO & SPAN These settings are for specifying minimum and maximum range of operation. Zero and Span for both Channels is displayed by Prompt as follows. zero span This allows to select any value between Range of particular Input. This value can be changed any time to make instrument enable to use for any type output transmitter or such other instrument. The setpoint can not be set below the zero setting and above the span setting. The reading will display undr when input is below zero setting by 5% and will display over when input is above span setting buy 5%. This 5% is calculated for the difference of zero and span settings. Outside the full scale the unit will indicate data as OPEN. TYPE OF SET-POINT There is two set point for each Channel and it can be defined as Low-ON or High-ON. Low and High ON means that Relay will operate when PV is higher or lower then Set-Point. The Set-Point parameter for both Channels is displayed by Prompt as follows. tsp1 tsp2 Type of Set Point can be selected by INC key or DEC key and is displayed by prompt, for both Channel as follows. l-on - ON If PV (Process Variable). is lesser then Set-Point. H-ON - ON If PV (Process Variable). is Higher then Set-Point. SQUARE ROOT By making this prompt yes user can use 4-20 ma as square root input type. The 4-20 ma input type will be very much useful in flow measurement application. For example if input type is 4-20 ma with square root yes and zero and span scaling is 0 to 1000 with dp at position one, then at different input process variable will be as under ma input Square root calculated inside Process Variable ( 0%) (25%) (50%) (75%) (100%) This parameter can be displayed by prompt shown below. Sqrt Above example is just for explanation purpose only, user can set any value at zero and span parameter. Basic equation to calculate process variable for 4-20mA square root input type is Square root ( (input - 4mA )/16) * 100 %. DECIMAL POINT This parameter can be displayed by prompt shown below. dp This decides the decimal point position. Decimal point position can be programmed from 0 to 3. Position of zero means no decimal point. Any non zero number puts decimal point after that digit. For example if decimal point position is set to two and reading is 1000, it will be displayed as Make sure to put correct decimal point. 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 slave 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 001 to 247. OPERATION MANUAL DUAL CHANNEL 11 of 20

12 Srno 001 to 247 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 001 and 247 by using INC/DEC keys. BAUD RATE bd k 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. PASS WORD pass Pass word for entering in program mode,configureation mode and calibration mode. Factory set password is 10. 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. You can calibrate instrument after entering in Calibration mode. Here there are 4 groups of calibration. Group 1: E-t/c, Jt/c, Kt/c, Tt/c. Group2 : Bt/c, Rt/c, St/c. Group3 : RTD, Group4 : 0-5V, 4-20mA. The unit can be calibrated with opening it and without trimpots. For entering this mode press Select key and then INCR/DECR to choose Calibration mode and then press Enter key. It will display first set point parameter. Now the calibration parameter is selected by pressing the select key. The parameters in sequence are as below: Calz Cals rtrz - Zero Calibration prompt for CH-1 -Span Calibration prompt for CH-1 - Retransmission zero Calibration prompt for CH-1 rtrs -Retransmission span Calibration prompt for CH-1 Cala -Ambient Calibration. Calz -Zero Calibration prompt for CH-2 Cals rtrz -Span Calibration prompt for CH-2 - Retransmission O/P zero Calibration prompt for CH-2 rtrs -Retransmission O/P span Calibration prompt for CH-2 Calibration procedure for CH-1 is described below and CH-2 calibration procedure is same as CH-1. [1] Calibration procedure for ANALOG INPUT. [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 four times, 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 OPERATION MANUAL DUAL CHANNEL 12 of 20

13 SPAN (value is according to requirement & TC type). Now check the linearity for the whole range. [B] For RTD type 1. Set the input resistance at ohm, get CALZ 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 ohm. Get CALS on the display and set 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 ma, get CALZ on the display and set it to by INC or DEC keys and press ENTER key to calibrate ZERO. 2. Now set the input at ma. Get CALS on the display and set 9990 by INC or DEC keys and press ENTER key to calibrate SPAN. Now check the linearity for the whole range. [2] Calibration procedure. for ANALOG OUTPUT. 1. Enter into calibration mode as explained in the above paragraph. 2. Now PV window will display rtrz and Press INC/DEC Key it will display (4 ma). With help of INC or DEC keys set the ma value exactly same as at Amperemeter reading connected at output. Now Press ENTER key to calibrate O/P for 4 ma. 3. Now on pressing SET key PV window will display rtrs (calibrate span) and by pressing INC/DEC Key window will display and 2.. (20 ma). With help of INC or DEC keys set the ma value exactly same as on Ampere-meter reading connected at output. Press ENT key to calibrate O/P for 20 ma. Now check the linearity for the whole range. (Refer Appendix A) 7. Trouble shooting Bargraph 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 in SMPS. Check the Power ON Indication LED in SMPS. 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. Measure it with instrument with better then 0.1% accuracy. Standard multi-meter with 3½ digit display may have poor accuracy then bargraph. 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 bargraph input type. In linear type input the unit shows false reading or OVER or UNDER. Check for the polarity of the I/P connections. Check that the 250Ω resistor is connected across the I/P terminals, if the I/P type is 4 20 ma. 250Ω resistor is mandatory for linear I/P type 4 to 20mA. 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. In thermocouple type input the reading indicated has got some error. OPERATION MANUAL DUAL CHANNEL 13 of 20

14 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. Reading indicated by Bargraph 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. 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 RTD s. 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 Bargraph 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 Check the cabling. Check the serial No. and baud rate settings at PC side and Bargraph side. Check the RS-485 to RS232 converter for 485 communications. Check RS 232 RS 485 connection at PC and Bargraph side. Relay O/P Action problem Check power to the contactor operated by relay from Bargraph. If relay burnt out frequently check for the rating of the relay or rating of contactor driven by relay. General In Configuration, Program, Verify Configuration, Verify Program and Calibration modes, 20 Sec time out is provided i.e. if no key is pressed for 20 second, it will fall back into Run/Man mode. While programming value, if the INC or DEC key is kept pressed for more than 10 counts, the Speed of change will be increased by 5 times. It is the dual speed concept for changing value at faster rate. On power on Bargraph will first display input type, and then it will come to actual Run mode display. If there is any error in EEPROM data, it will display error message and halt. -Err SUPPLY VOLTAGE Supply voltage should be given through a good isolation transformer. This being a microprocessor based instrument, a massive voltage spike can damage it. A good isolation transformer shields the instrument from such voltage spikes and surges. All supply connections to final control devices such as contactors, solenoids etc. must be taken directly from the supply and not from the supply terminals of the instrument. An effective earth is mandatory for the instrument. In absence of proper earthing instrument body will float at half some part of the supply voltage and this may give shock to user. 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. OPERATION MANUAL DUAL CHANNEL 14 of 20

15 8. MODBUS DETAIL (OPTIONAL) MESSAGE QUERY: INTRODUCTION The bargraph can be connected in RS-485 communication data link either in multi drop or repeat mode. Each bargraph must have unique Serial Number. No two bargraph have the same address. Entire range of addresses (001 to 247) 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 bargraph and hence when using the bargraph, only two-pass protocol is assumed. This speeds up the total throughput. COMMUNICATION PROTOCOL The communication protocol is a Modbus protocol. The host computer issues the commands to the bargraph that in turn respond to each command. The entire protocol is based on the command/answer protocol. How Characters are transmitted serially 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: RTU Framing i.e. 1 start bit, 2 stop bit and No parity. START DELAY and ADDRESS: Always contains the start of message with 3.5 null char delay followed by the address of the bargraph to be addressed. The address is represented by a HEX character ranges from 001 to 247. OPERATION MANUAL DUAL CHANNEL 15 of 20

16 FUNCTION: 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 bargraph the functions implemented are 01 READ COIL STATUS (REFERENCE - 0x). 03 READ HOLDING REGISTERS.. (REFERENCE- 4x). 06 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. DATA FIELD: Read: The query message specifies the starting register and quantity of registers to be read. Registers are addressed starting at zero- registers are addressed as 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. 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 high-order byte. MESSAGE RESPONSE : 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. 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 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 results. 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 OPERATION MANUAL DUAL CHANNEL 16 of 20

17 9. COMMUNICATION PROTOCOL IN BARGRAPH 1.START DELAY AND ADDRESS: When the bargraph Indicator sends its response, it places its own address in this address field of the response to let the master know which bargraph Indicator is responding. 2.FUNCTION: When the bargraph 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). For a normal response, the bargraph Indicator simply echoes the original function code. For an exception response, the bargraph Indicator returns a code that is equivalent to the original function code with its most significant bit set to logic 1. 3.DATA FIELD: If no error occurs, the data field of a response from a bargraph 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. 4.CHECKSUM COMPUTATION: CRC of the message is calculated same way as explained earlier and appended to message. EXCEPTION RESPONCE : The table explains the meaning of error codes, if bargraph Indicator transmits error message. CODE MEANING 01 Function code Invalid. It must be 01,03 or Illegal data starting address. The range is specified for different functions in the table below. 03 Illegal data value. The range is specified for different functions in the table below. 08 Check sum ( CRC ) error. Garbled message. The table show Digital data to be transmitted and its sequence. Sr. No. Digital Parameters Type of Access Parameter Type Absolute Address 1. RELAY -1 Read Bit RELAY 2 Read Bit RELAY 3 Read Bit RELAY 4 Read Bit The table show Analog data to be transmitted and its sequence. OPERATION MANUAL DUAL CHANNEL 17 of 20

18 Sr. No. Analog Parameters Type of Access Parameter Type Absolute Address 1. PROCESS VALUE-1 Read Int PROCESS VALUE-2 Read Int SET POINT-1 Read/write Int SET POINT-2 Read/write Int SET POINT-3 Read/write Int SET POINT-4 Read/write Int SET POINT-1 HYSTERESIS Read/write Int SET POINT-2 HYSTERESIS Read/write Int SET POINT-3 HYSTERESIS Read/write Int SET POINT-4 HYSTERESIS Read/write Int INPUT-1 Read/write Int ACT _ZERO-1 Read/write Int ACT_SPAN-1 Read/write Int TYPE OF SETPOINT-1 Read/write Int TYPE OF SETPOINT-2 Read/write Int SQUARE ROOT-1 Read/write Int DECIMAL POINT-1 Read/write Int OPEN SENSOR-1 Read/write Int INPUT-2 Read/write Int ACT _ZERO-2 Read/write Int ACT_SPAN-2 Read/write Int TYPE OF SETPOINT-3 Read/write Int TYPE OF SETPOINT-4 Read/write Int SQUARE ROOT-2 Read/write Int DECIMAL POINT-2 Read/write Int OPEN SENSOR-2 Read/write Int BAUD RATE Read/write Int SERIAL NO. Read/write Int AMBIENT Read Int PASSWORD Read Int Note : a) Display on BARGRAPH will show over when process value is higher then 5 % of individual span, at that time BARGRAPH will send to PC. b) Same way when process value is lower then 5 % of individual zero BARGRAPH will show under on its display but it will send to PC. c) If BARGRAPH process value is out of limit for particular I/P type then BARGRAPH will show Open on display but it will send to PC d) The serial no of bargraph Indicators must be within 001 to 247. e) Before starting the communication, match the Baud rate and Sr. no. of Master and Slave devices. OPERATION MANUAL DUAL CHANNEL 18 of 20

19 10. SPECIAL NOTE This controller is storing all data programmed at factory. There are lot 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 overridden 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 ' Err' message on the display. If such symptoms are seen the system should be needed to be reprogrammed. APPENDIX A Table for BAR: OPEN SENSOR BAR PV ON DISPLAY UP DOWN UNDER -5% 0% 1% 100% 5% OVER OPEN 1 to 100 OFF OFF OFF ON ON ON FLASH FLASH 101 ON ON ON OFF OFF OFF OFF OFF 1 to 100 OFF OFF OFF ON ON ON FLASH OFF 101 ON ON ON OFF OFF OFF OFF ON Table for Retransmission O/P: Input: RTD Range : -200 deg C to 850 deg C Retransmission o/p: 4 to 20mA. Retransmission o/p will follow as the below indication: Set zero= 0, Set span = 500 Process value on display Open sensor UNDER -25 (5%) 0 0<PV< (5%) OVER OPEN ma O/P Retrasmission UP 3.2 ma 3.2 ma DOWN 3.2 ma 3.2 ma 4 ma 4 ma 4mA<O/P <20mA 4mA<O/P <20mA 20 ma 20 ma 20.8 ma 20.8 ma 20.8 ma 20.8 ma 20.8 ma 3.2m A Note: 1. For above table default I/P type is RTD. 2. For TC I/P above table is also applicable. OPERATION MANUAL DUAL CHANNEL 19 of 20

20 Below Table shown display values only according to PV for Linear Input Type. For Retransmission output please follow above table Table for Retransmission O/P according to below display values. Input: Linear Range: 0 to 500 OPEN (I/P Type of SQRT BELOW TOTAL -25 PV >0, input RANGE) UNDER (5%) 0 PV < mA NO UNDER UNDER mA YES UNDER UNDER UNDER mA NO mA YES (5%) OVER OPEN(I/P OVER TOTAL RANGE) PV >0, PV < OVER OPEN PV >0, PV < OPEN OPEN OPEN PV >0, PV < OVER OPEN PV >0, PV < OPEN OPEN OPEN Table for Relay Logic: CONDITION NORMAL ABNORMAL UP (O/S) DOWN(O/S) HH HL Relay 1 OFF ON ON OFF Relay 2 OFF ON ON OFF Relay 1 OFF ON ON OFF Relay 2 OFF ON OFF ON LL Relay 1 OFF ON OFF ON Relay 2 OFF ON OFF ON Note: 1. This Table is made with assumption of being normal relay status of relay is off and abnormal relay status will be relay on. 2. Hysteresis is assumed to be Zero. OPERATION MANUAL DUAL CHANNEL 20 of 20