Masibus 5040 User manual

User’s Manual
S
SI IN NG GL LE E L LO OO OP P P PI ID D C CO ON NT TR RO OL LL LE ER R
w
wi it th h A AU UT TO O T TU UN NE E
5
50 04 40 0
Masibus Automation & Instrumentation Pvt. Ltd.
B/30, GIDC Electronics Estate,
Sector-25, Gandhinagar-382044, Gujarat, India
[phone]- -82
Email: [e-mail]
Web: www.masibus.com

PID CONTROLLER -5040
REF NO: m53A/om/101
Issue NO: 08
User’s Manual Page 2 of 53
Contents
1. INTRODUCTION ..................................................................................4
Foreword................................................................................................................ 4
Notice..................................................................................................................... 4
Trademarks............................................................................................................ 4
Checking the Contents of the Package.................................................................. 4
Product Ordering Code .......................................................................................... 4
List of Accessories ................................................................................................. 5
Safety Precautions................................................................................................. 5
2. INSTALLATION DETAILS ..................................................................6
2.1 How to Install.................................................................................................... 6
2.2 External Dimensions and Panel Cutout Dimensions ....................................... 7
2.3 How to connect wires ...................................................................................... 8
3. HARDWARE SPECIFICATION DETAILS...........................................9
3.1 Inputs............................................................................................................... 9
3.2 Display & Keys .............................................................................................. 10
3.3 Output............................................................................................................ 10
3.4 Communication Details.................................................................................. 11
3.5 Power Supply................................................................................................ 12
3.6 Physical......................................................................................................... 12
3.7 Environmental ............................................................................................... 12
4. WIRING DIAGRAM ...........................................................................13
4.1 BACK PLATE WIRING DETAIL .................................................................... 13
4.2 TRASMITTED POWER SUPPLY WIRING DIAGRAM.................................. 14
4.3 VALVE POSITION FEEDBACK WIRING...................................................... 14
5. FRONT PANEL DETAILS.................................................................15
5.1 Key Function Description............................................................................... 16
6. MENU LAYOUT ................................................................................18
6.1 RUN TIME INDICATION/FUNCTION............................................................ 18
6.2 Set Point Setting............................................................................................ 18
6.3 LEVEL - 1...................................................................................................... 18
6.4 LEVEL - 2...................................................................................................... 19
6.5 LEVEL - 3...................................................................................................... 22

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Issue NO: 08
User’s Manual Page 3 of 53
6.6 LEVEL - 4...................................................................................................... 24
6.7 LEVEL –5..................................................................................................... 26
6.8 Calibration..................................................................................................... 27
6.9 Factory Reset Parameters............................................................................. 28
7. PARAMETER FLOW CHART ............................................................30
8. ALARMS & DIGITAL OUTPUTS........................................................33
9. DIGITAL INPUTS ..............................................................................36
10. CONTROL FUNCTION DETAILS....................................................37
11. CALIBRATION PROCEDURE..........................................................42
11.1 Ambient temperature adjustment ................................................................ 42
11.2 PV input sensor calibration.......................................................................... 42
11.3 Remote set point calibration........................................................................ 43
11.4 Position Feedback Calibration..................................................................... 43
11.5 Retransmission output calibration (Voltage/current output)......................... 44
11.6 Control output calibration (current output)................................................... 44
12. COMMUNICATION DETAILS..........................................................45
12.1 Function codes use for Modbus .................................................................. 45
12.2 Exception responses for Modbus ................................................................ 45
12.3 Modbus parameters .................................................................................... 45
13. Appendix ........................................................................................49
13.1 Troubleshooting........................................................................................... 49
13.2 PV INPUT STATUS DISPLAY DURING BURNOUT CONDITION.............. 49
13.3 RSP (REMOTE SET POINT) BURNOUT CONDITION............................... 50
13.4 VALVE POSITION FEEDBACK OPEN CONDITION .................................. 50
13.5 RETRAMISSION OUTPUT TABLE FOR OPEN /OVER /UNDER
CONDITION......................................................................................................... 51
13.6 CONTROL OUTPUT TABLE OPEN/OVER/ UNDER CONDITION............. 52
13.7 Digital Input & Retransmission Output Type Selection Settings.................. 53

PID CONTROLLER -5040
REF NO: m53A/om/101
Issue NO: 08
User’s Manual Page 4 of 53
1. INTRODUCTION
Foreword
Thank you for purchasing 5040 series PID controller. This manual describes the basic
functions and operation methods of 5040.Please read through this user’s manual
carefully before using the product.
Notice
The contents of this manual are subject to change without notice as a result of
continues improvements to the instrument’s performance and functions
Every effort has been made to ensure accuracy in the preparation of this manual.
Should any errors or omissions come to your attention, however, please inform
MASIBUS Sales office or sales representative. Under no circumstances may the
contents of this manual, in part or in whole, be transcribed or copied without our
permission.
Trademarks
Our product names or brand names mentioned in this manual are the trademarks or
registered trademarks of Masibus Automation and Instrumentation (P) Ltd. (herein
after referred to as MASIBUS).
Adobe, Acrobat, and Postscript are either registered trademarks or trademarks of
Adobe Systems Incorporated. All other product names mentioned in this user's
manual are trademarks or registered trademarks of their respective companies.
Checking the Contents of the Package
Unpack the box and check the contents before using the product. If the product is
different from which you have ordered, if any parts or accessories are missing, or if the
product appears to be damaged, contact your sales representative.
Product Ordering Code
Ordering Code
Model
Input
Power Supply
Control O/P
Rx O/P
5040
1
E
U1
85-265VAC/
100-300VDC
1
Relay
1
4-20mA
2
J
U2
18-36VDC
2
Pulse
2
0-20mA
3
K
3
Linear
3
1-5V
4
T
4
MOV
4
0-5V
5
B
5
0-10V
6
R
7
S
8
N
9
Pt-100
A
-10 to 20mV
B
0 to 75mV
C
0 to 100mV
D
0.4 to 2V
E
0 to 2V
F
0 to 5V
G
1 to 5V
H
0 to 10 V

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REF NO: m53A/om/101
Issue NO: 08
User’s Manual Page 5 of 53
The Single Loop Controller unit has a nameplate affixed to the one side of the
enclosure.Check the model and suffix codes inscribed on the nameplate to confirm
that the product received is that which was ordered.
List of Accessories
The product is provided with the following accessories according to the model and
suffix codes (see the table below). Check that none of them are missing or damaged.
No
Item name
Part number
Qty
Remarks
1
Mounting Clamps
-
2
Safety Precautions
The product and the instruction manual describe important information to prevent
possible harm to users and damage to the property and to use the product safely.
Understand the following description (signs and symbols), read the text and
observe Descriptions.
DESCRIPTION OF SIGNS

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Issue NO: 08
User’s Manual Page 6 of 53
2. INSTALLATION DETAILS
2.1 How to Install
Mounting method: Panel mounting
To install the controller select a location where:
no one may accidentally touch the terminals
mechanical vibrations are minimal
corrosive gas is minimal
temperature can be maintained at about 25˚C to 35˚C and the fluctuation is
minimal
no direct radiant heat is present
no magnetic disturbances are caused
no wind blows against the terminal board
no water splashed
no flammable materials are around
Turn off the power to the controller before installing it on the panel because there is
a possibility of electric shock

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REF NO: m53A/om/101
Issue NO: 08
User’s Manual Page 7 of 53
2.2 External Dimensions and Panel Cutout Dimensions
Unit: mm

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User’s Manual Page 8 of 53
2.3 How to connect wires
Before carrying out wiring, turn off the power to the controller and check that the
cables to be connected are not alive because there is a possibility of electric shock.
NOTE:
All wiring must confirm to appropriate standards of good practice and local
codes and regulations. Wiring must be suitable for Voltage, Current and
temperature rating of the system.
Provide power from a single-phase instrument power supply. If there is a lot of
noise in the power line, insert an insulating transformer into the primary side of
the line and use a line filter on the secondary side. Do not place the primary
and secondary power cables close to each other.
For thermocouple input, use shielded compensating lead wires for wiring. For
RTD input, use shielded wires that have low conductor resistance and cause no
significant differences in resistance between the three wires. Do not connect
Terminal –23 when thermocouple or Linear input is selected.
Use repeater after each set of 32 instruments connected in RS-485
Communication.
Unused terminals shouldnot be used as jumper points asthey may be internally
connected, which may cause damage to the unit.
CAUTION:
High voltage transients may occur when switching inductive loads such as some
contactors or solenoid valves. Through the internal contacts, these transients may
introduce disturbances which could affect the performance of the instrument.
For this type of load it is highly recommended that a “snubber” is connected across the
normally open contact of the relay switching through load. The snubber recommended
consists of a series connected resistor/capacitor (typically 15nF/100Ohms). A snubber
will also prolong the life of the relay contacts. A snubber should also be connected
across the output of a tric output to prevent false triggering under line transient
conditions.

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REF NO: m53A/om/101
Issue NO: 08
User’s Manual Page 9 of 53
3. HARDWARE SPECIFICATION DETAILS
3.1 Inputs
Analog Input
Input Type
Thermocouple (E, J, K, T, B, R, S, N), RTD (Pt100),
Current, Voltage
Display Range
Table-3.1
Accuracy
TC, RTD: ± 0.1% of F.S ± 1 degC
Current, Voltage: ± 0.1% of F.S ± 1 Count
ADC Resolution
17 bits
Display Resolution
0.1°C / 1 Count
Sampling Rate
4 Samples/Sec
CJC Error
±2.0 °C Max
Sensor Burnout current
0.25uA
RTD excitation current
1mA Max
Allowable wiring resistance for
RTD
Maximum 15 ohms/wire (Conductor
resistance between three wires should be equal)
NMRR
> 40 dB
CMRR
> 120 dB
Temp-co
< 100ppm/°C
Input Impedance
> 1MΩ
Max Voltage
20VDC
Protection
Wire beak detection of any wire
Resolution
0.1%
Table-3.1: Input Display Range
Input Type
Range
Thermocouple
E
-200 to 1000°C
J
-200 to 1200°C
K
-200 to 1370°C
T
-200 to 400°C
B
450 to 1800°C
R
0 to 1750°C
S
0 to 1750°C
N
-200 to 1300°C
RTD
Pt-100
-199.9 to 850.0°C
Voltage
-10 to 20mV
-1999 to 9999
0 to 75mV
0 to 100mV
0 to 5V
1 to 5V
0 to 10 V
0.4 to 2V
0 to 2V
Current
4 to 20mA (Ext. 100Ω)
0 to 20mA (Ext. 100Ω)

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REF NO: m53A/om/101
Issue NO: 08
User’s Manual Page 10 of 53
Remote Input Signal
Input Type
Settable in a range from 0-5 V or 1-5 V DC.
The input type can be selected with the front keypad.
For 0 –20mamp (0-5v) and 4 –20mamp (1-5v)
250ohms (0.1%, low ppm) resistor should be connected
externally.
Input sampling time for remote input is 3 times the PV
input.
Input Range
-1999 to 9999 counts
Resolution
17-bit
Input Resistance
> 1Mohm
Input Accuracy
±0.1% instrument range, ±1 Count
Feedback Resistance Input
Slide resistance value
100 ohms to 1K ohms of overall resistance
(burnout detection for all the three wires provided)
Measuring resolution:
0.1% of overall resistance (After User’s adjustment).
3.2 Display & Keys
Front Panel Details
PV Display
4-digits, 7-segment, Red LEDs, character height of 0.56’’
SV Display
4-digits, 7-segment, Green LEDs, character height of 0.4’’
Bar Display
20 Orange LEDs for %POWER, Valve position indication
Status Indication
Red LEDs for RELAY and Alarm status, Manual mode
status, Remote status.
Green LEDs for Communication,
Red LEDs for Set Point selection 1 and 2, Auto-tune
status, Valve Position Feedback status
Keys
5 keys for configuration, calibration and operation
3.3 Output
Output Types
RELAY OUTPUT(PID and ON/OFF control)
SSR OUTPUT
LINEAR OUTPUT (4-20mAmp)
VALVE POSITION WITH FEEDBACK CONTROL (VPFB)
VALVE POSITION WITHOUT FEEDBACK CONTROL (VPFN)
Digital Input
No of DI
4
Input Type
Non-Voltage Contact or Pulse Input(24VDC,@5mA)
Rating
24VDC@5mA Max
Purpose
Target Set point selection,
Auto/Manual selection,
Remote /Local mode switching,
Run/Stop mode selection
Minimum status detection Holds
Time
About 1 Second