User’s Manual

FLOW INDICATOR TOTALISER

SMIT 1019

Manufactured By:

SAMYAK INSTRUMENTATION PVT. LTD.

F-4 Memnagar complex, Opp. Petrol Pump Memnagar, Ahmedabad, India-380 052
Phone: +91-79-2749 5500/5600 FAX: +91-79-2741 7997
URL: http//www.samyak.co.in Email [email protected]
CONTENTS

1 INTRODUCTION
1.1 TECHNICAL DETAILS

2 SPECIFICATIONS

3 HARDWARE DESCRIPTIONS
3.1 CPU CARD
3.2 KB / DISPLAY CARD AND FRONT PANEL
3.3 ENCLOSURE
3.4 POWER SUPPLY
3.5 RELAY CARD

4 INSTALLATION GUIDE
4.1 CONNECTION DETAILS

5 OPERATING DETAILS
5.1 DISPLAY
5.2 KEYBOARD
5.3 RUN MODE
5.4 EDIT MODE
5.5 PARAMETER DESCRIPTION
-PROGRAMMING MODE
-CONFIGURATION MODE
-CALIBRATION MODE

6 CALIBRATION PROCEDURE

TABELS
Table 1 Specifications

Table 2 Connection Details

Table 3 Keyboard Details

Table 4 Run Mode Parameter Details

Table 5 Program Mode Parameter Details

Table 6 Configuration Mode Parameters

Details

Table 7 Time base Setting details

Table 8 Five Point Linearization

Table 9 Calibration Mode Parameters Details

 1. INTRODUCTION
This is a microcontroller based Indicator - Totaliser unit, with very high performance to
price ratio. It is highly versatile, accurate and different from the conventional indicators.

1.1 TECHNICAL DETAILS:

The instrument is made in 96 x 96 x 110 mm size with DIN standard panel cutout of 92 x
92 mm.

Front is sealed membrane type to withstand dusty environment. On back plate

detachable terminals are provided for easy connection.

The programming, calibration and operation of the instrument are by four simple keys
and with two independent displays groups: one for flow rate and one for batch total. This
unit is driven with user understandable prompts. For protecting programmed data
password protection facility is provided. Integrated total, batch total and roll count are
cleared by special password say 3210.

The product is made to accept current (4-20 mA, 0-20mA), Voltage (1-5Volt, 0-5 Volt)
input, pulse input & Digital input. It is available as a single input version only. The
instrument is providing with the five-point calibration. The unit can be calibrated in
installed condition itself by front panel keys at predefine points.

The set Parameters and integrated total are stored in serial NVRAM. No battery backup
is required.
 2. SPECIFICATIONS
DISPLAY:
 5 Digit 0.56” red LEDs for flow rate of output INPUT SIDE:
channel 1 Input
 Digit 0.40” red LEDs for flow rate of output channel
1 Impedance 250 Ohms
2 2 CMRR >100dB
3 Resolution 20000 Counts
KEYBOARD: 4 NMRR >50dB
 Four keys membrane like.  0.1% of F.S 
5 Accuracy 1Digit.
INPUT: Input & Logic
 Current (4-20 mA, 0-20mA), Voltage (1-5Volt, 0-5 supply provided
Volt), and Frequency 6 Isolation thro' Opt isolator
No of
SCALING: 7 inputs 1
 Linear and square root extraction, 8
Programmable Input type 0-20mA, 4-20mA
0-5 VDC, 1-5VDC
CALIBRATION: 0-10 KHz
 Zero and span adjusted by software calibration OUTPUT SIDE:
through front panel keys. No trim ports. Maximum
1 load 500 Ohms
CONTROL: 2 Resolution 5 uA/Count
 Control is given by Esc, Increase, Digit shift & Index 0.25% of Full
(Enter) keys for operation, programming3 and Accuracy scale
calibration. 4 Stability 5 ppm/C
Response
ACCURACY:  0.1% of F.S  1Digit 5 time 1 sec
Temperature ± 3 ppm of
POWER SUPPLY: 6 coefficients FSR/Deg.
Operating supply: 90-255VAC +/- 10% 50Hz

TRANSMITTER POWER SUPPLY: +24VDC ±5%@ 50mA

GENERAL:
 Operating Temperature Range: 0 – 55 Deg. C
 Humidity: 30 to 95% RH.
 Power consumption: Less than 10 VA.
 Contact Rating: 230VAC, 2 A
 Warm up time: 10 Minutes.
PHYSICAL:
OPTIONAL:
 Case: ABS Plastic
 Flame proof housing  Terminals: 92 mm
 Driving Thirteen Barrier screw type can accept up to 2.5  Bezel size: 96 x
sq.mm wire. 96mm.
 cutout: 92 x (8 + 5) digit multiplexed Display  Depth behind panel:
 Four key keypad interface. 110 mm maximum.
 Watch dog circuit.
 ADS1110 circuit interface for input.
 DAC7571 circuit for current output.
3. HARDWARE DESCRIPTION

The unit consists of a CPU, KB/Display card and Power Supply (SMPS)

3.1 CPU CARD:

The CPU card has necessary hardware Relay card carries a 12-pin, 5.08 mm pitch, and
detachable Male connector. The connectors are accessible from back panel cutout.
Matching female connectors are supplied along with the instrument.

3.2 KB / DISPLAY CARD:

It carries 5-pin & 4 pin, 3.84mm pitch and detachable Male connectors. The connector is
accessible from back panel cutout. Matching female connectors are supplied along with
the instrument. The card is connected with KB/Display card and it is fitted with front &
back plate.

FRONT PANEL:

A KB / Display card has two set of displays:

5-digit display for rate indication of output channel 1.

8-digit display for rate indication of output channel 2.

Four keys are also mounted on this card. The card is connected with CPU card with 20-
pin connector. The card is fitted with the bezel. An overlay is provided on the front side.

3.3 ENCLOSURE:

This is general purpose DIN standard ABS Plastic enclosure suitable for panel mounting.
Panel mounting is to be done using side brackets.

3.4 POWER SUPPLY:

This is a Switch mode power supply. It accepts mains input ranging from 90-255 VAC. It
generates DC supply required for Logic & signal conditioning. It also generates +24VDC
for transmitter.
The SMPS card carries a 3-pin, a 5 pin and a 2 pin, 5.08 mm pitch, detachable Male
connectors. The connectors are accessible from back panel cutout. Matching female
connectors are supplied along with the instrument.

3.5 RELAY CARD:

A Relay Card is connected between CPU card and SMPS card. It consists of 4 OMRON
12V DC Relays mounted with the help of side PCBs.
 4. INSTALLATION GUIDE
Following steps should be followed for proper installation of the instrument.

1. Unpack the instrument from the packing Box carefully Mount the instrument in the
panel cutout of 92mm x 92mm.
2. Fix the instrument with the panel using two side brackets.
3. All the electrical connections to be done at Back panel on screw type terminals.
4. Refer the Appendix for back panel connection.
5. Make sure that no wire is connected loosely to avoid generation of spark and
RFI.
6. Before connecting the mains, check the mains configuration on the back panel.
7. Ensure that the instrument is properly earthed.
8. Check voltage between earth and neutral terminal. It should be less than 2 volts
AC.
9. If this voltage is greater then it results in unstable reading. In such a case use
ISOLATION TRANSFORMER to provide mains to the instrument.

4.1 CONNECTION DETAILS:

 These are the connection details:

No. No.
Detail Detail
1 Line 17 C3
2 Neutral 18 NO3
3 Earth 19 NC3
4 DIN1 20 C4
5 DIN2 21 NO4
6 DIN3 22 NC4
7 DIN4 23 RxTx+
8 COM 24 RxTx-
9 POUT+ 25 OUT+
10 POUT- 26 OUT-
11 C1 27 C
12 NO1 28 I/P +ve
13 NC1 29 I/P -ve
14 C2 30 Pulse I/p (0-10KHz)
15 NO2 31 24V DC (50mA)
16 NC2

5. OPERATING DETAILS

The following paragraphs give detailed description of how to operate the unit. Before
using the instrument, make sure to study and understand this section.
5.1 DISPLAY:
The unit has two windows/groups of display:
Upper:
Five digits 7-segment, 0.56” Red LED display: It displays Flow rate/Process variable of
output channel 1.
Lower:
Eight digits 7-segment 0.40” Red LED display:
In normal mode of operation, flow rate of output channel 2 is displayed. While in EDIT
mode, parameters are displayed in this window.

5.2 KEYBOARD:

Unit has 4 key membrane keypad organized as 4 x 1 matrix. Following Table explain the
Operation of the Keys used for configuration.

Key Function
1. It will allow user to enter in EDIT mode, when instrument is in RUN mode.
SET 2. It will scroll menu and submenu when it is enabled
(Index) 3. It will save edited data.
1. It will enter into the submenu, when main menu is enabled and shows
submenu’s value.
(Decr) 2. It will select the digit to modify, when value is edited.
3. It will start batch, if pressed, when IT & BT are being displayed
1. It will increment value of digit selected or constant selected.
2. It will stop batch, if pressed, when BT/IT are being displayed.
(Incr)
It will escape to previous status, with reference to its current status.
ESC Sequence of status:
(Cancel) IT MENU SUB-MENU Parameter’s Value
Escape sequence
When Esc key is pressed in Menu, the instrument will come in RUN Mode.
The unit will come out of EDIT Mode. If user wants to go in EDIT mode, he will
have to enter the correct password again.

Note:- On pressing ESC key will display DENSITY value in upper display & DENSITY
tag in lower display; it will display flow value after one minute if ESC is not pressed
again.

5.3 RUN MODE:

Whenever mains are switched on to the unit, engineering value proportional to the input
signal will be displayed as Process variable. Decimal point is displayed at selected
position. Last saved batch total/integration total will be displayed on the lower window.
5.4 EDIT MODE:

In this mode user can verify or modify, various parameters. To enter the EDIT mode,
correct password is to be entered.

Password Protection:

Whenever the instrument is powered on and INDEX key is pressed, a “PASSWORD”

MSG will be displayed at lower panel 7-segment display. Press “START KEY” (It is digit
select key for editing the parameters), password value “0000” is displayed.

Enter the correct password value with the help of START (digit select key) and STOP
key (Incr key) and press INDEX KEY (INDEX key is used as ENTER key) If correct
password is entered & INDEX key is pressed, it will show the first mode PROG MOD. If
wrong password is entered, then “Password” MSG will be displayed again at lower
display window.

Note: If user forgot the password then a default Password “1975” should be entered, it will
reset the password to “0000”.

5.5 PARAMETER DESCRIPTION:

There are total three Menu Items:

Following section will describe the different Item of individual submenu.

1. Program Mode
2. Configuration Mode
3. Calibration Mode

Programming mode:
Programming menu provides facility to configure the relay for different function.

Low alarm and high alarm:

Value of Low alarm should be lower than that of high alarm. If user tries to set value of
Low alarm greater than high alarm Value, error message will be displayed. Similarly, if
user set value of High alarm lower than low alarm Value, error message will be
displayed. Alarms value cannot be set greater than Full-scale Value (FS).

Comparison with Zero and full-scale:

Low Alarm value should be greater then Zero value. If user tries to set value of Low
alarm less than Zero Value, error message will be displayed. If (Low Alarm< Zero value),
“error” message appears. High-Alarm value should be less then Full-scale value. . If user
tries to set value of High-alarm greater than Full-scale value, error message will be
displayed. If (High Alarm > full-scale value), “error” message appears.

Set point and pre warn:

Error message will be displayed if, set point value is lower than pre-warn and vice versa.

Alarm ON-OFF :( sub menu no 5 to 8):

Using these settings, user can set alarm/relay availability. If particular relay is set as
‘yes’, that particular alarm indication will be present over the display card and relay
action will come into effect.

Configuration mode:
Details of configuration parameters, which will appear in configuration mode:

Sr. Name Description No Of Lo Limit Hi Limit

No Digit
1 Batch Type Of Mode, For Flow Control - Normal, Counter
Mode
2 Input Type Type Of Input - 0-5v, 1-5v, 0-20ma,
4-20ma,Pulse
3 Type Of Type Of Instrument, Which You Want - Indicator/
Instrument To Use. Totaliser
4 Square Mode Of Linearization - Yes/No
Root
5 Digital To Be Used To Reset Batch Total Yes/No
Input
6 Digital If Yes Than In Programming Mode It - Yes/No
Filter Will Show Filter No.
7 Time Base For Calculation/Display Of Flow Rate - Sec, Min, Hour, Day

8 ZR1 Zero Value 5 00000 30000

9 FS1 Full Scale Value 6 00000 20000
10 No Of 2 00 99
Batches
11 Batch Counter Will Count How Much 2 00 99
Count Batches Has Been Taken
12 Relay Two Type Of Mode - Normal, Failsafe
Mode
13 Cut Off 3 000 100
14 DP Decimal Point - 0,0.1,0.01,0.001
15 SF1 Full Scale For Segment 1 6 00000 30000
16 SL1 % Age Of Full Scale (Segment 1) -
17 SF2 Full Scale For Segment 2 6 00000 30000
 18 FL2 % Age Of Full Scale (Segment 2) -
19 SF3 Full Scale For Segment 3 6 00000 30000
20 FL3 % Age Of Full Scale (Segment 3) -
21 SF4 Full Scale For Segment 4 6 00000 30000
22 FL4 % Age Of Full Scale (Segment 4) -
23 SF5 Full Scale For Segment 5 6 00000 30000
24 FL5 % Age Of Full Scale (Segment 5) -
25 Baud Rate - 9600,19200
26 Serial no 2 00 to 99
26 Pout 4 0001 to 9999
27 Default - Batch
Display Total/Integration
Total
28 Pass 4 0000-9999
29 Conversion 4 00.00-99.99
Factor
30 Clear To Clear Integration /Batch Total And 4 “PAS” & 0000-9999
Total Roll Count
31 Rounding - 1,2,5,10

Batch Mode:

If parameter ‘Batch Mode’ (Batch Mod) is selected to ‘Counter’, then two parameters
“Batch count” (Bat cnt) and “No of Batches” (No_of_bh) will be displayed in
Configuration mode. If ‘Batch Mode’ is selected to ‘Normal’, two parameters will not be
displayed.

Input Type:

Based on requirement, user can select input type. It will be either Voltage or Current or
Pulse.

Square root:

If user selects this mode as ‘yes’, flow rate will calculated using square root algorithm.
Alternatively linear calculation will be done.

Batch counter and no of batches:

These parameters will be displayed only if the ‘Batch mode’ is selected to counter type.

No of batches:

Set the parameter according to the requirement. It decides how much batches are to be taken.

Batch counter:
It will be incremented by 1 whenever a new batch is started by START key in run mode.
When batch counter value becomes equals to ‘no of batches’ value, then it will not start
new batch.
Note: To reset batch counter, Enter in batch count (bat cnt) parameter in configuration
mode. Press “Start” key to see its value. Now if user presses “Stop” key Batch counter
value will be cleared to 0.

Relay-mode:

In ‘Relay-mode’ (relay nod), if set to ‘normal ‘mode then alarm relays and LEDs will
work according to alarm values. I.e. Relays on, LEDs on, Relays off, LEDs off. But if set
to ‘Failsafe’ Mode then alarm relays and LEDs will operate reversibly. I.e. Relays on,
LEDs off, Relays off, LEDs on.

Cut off:

Cut off could be set to 0000 to 0100. Cut off will display the % value.

Cutoff value = Cutoff parameter (in %)*Full-scale-value

If full-scale value is 10000 and cut off is 5%. Then cut off value will be calculated as
(5/100)*10000 = 500. So, if the displayed flow rate (displayed at upper window) is less
then 500, it will not be added in integration.

Decimal Point Selection:

Decimal point selection will be given from the configuration mode.

Select Decimal position
0 No decimal
0.1 One decimal
0.01 Two decimals
0.001 Three decimals

Five point Linearization:

This instrument has feature of five-point linearization. User can define up-to five
different segments of the full-scale input (in percentage) with Full-scale engineering
value for each segment.

We have to program the value of flow rate at different inputs.

Here we are defining five scale factors for the current input 4 mA to 20mA. Let’s have
one example to understand this concept.

Default Display:

This parameter will select the parameter to be displayed in run mode. If Int tot / Bat tot
is selected then in run mode ‘Integration total ‘/ ‘Batch total ‘will be displayed on lower
panel accordingly. If “instrument type” parameter is set as indicator, then this parameter
will not be displayed in Configuration mode and Integration total will be displayed in run
mode.
Password:

‘PASS’ parameter is added in configuration mode. But it will always show ‘0000’.User
has to remember the password. If user needs to change password, then go in ‘pass’
parameter, enter the required password and press Enter key. For e.g. If user enters
‘1234’ in ‘pass’ parameter, then, to enter in EDIT mode, a password ‘1234’is to be
entered.

Calibration mode:
This menu allows user to perform calibration of analog input & output out zero and out

Sr. Setting Description No of Lo Hi limit

No digit limit
1 Cal Zr 1 Zero Cal. Count 4
2 Cal SP1 Span Cal. Count 5
3 Out Zr1 Zero Cal. Count for Output 4 0000 4095
4 Out SP1 Span Cal Count for Output 4 0000 4095
5 Out Zr1 Zero Cal. Count for Output 4 0000 4095
6 Out SP1 Span Cal Count for Output 4 0000 4095
7 Default If user selects ‘yes’, then Out Yes/No
Out zero = 800 and Out span
(4000) is selected.

span. These two parameters are used for the calibration of re-transmission output.
Users have to change the value of out zero and out span for the zero setting (for 4mA)
and span setting (20 mA) respectively for re-transmission out put. If user enters values
greater than 4095 “error” message will appear. It user enters out zero value > out span
value then also “error” message will appear.
INDICATION:

For conversion in engineering value, the input is scaled between Zero and Full scale set
values as per following formula (for linear mode): For any type of input:

Indication (Engineering Value)

[X/ (CALS-CALZ)] + Zero

X = (Input signal - CALZ) * (Full scale - Zero)

CALZ = Value of input applied during zero calibration

CALS = Value of input applied during Span calibration
If input signal is outside the set Zero and Full-scale limit, all the four digits of the Process
variable starts flashing. Only when input signal comes back into the allowed range, display
becomes steady.

Note:
1). When no input is connected to the unit, it will display “open” message in pulse mode or
current mode
2) When input is voltage type, then it will display “0”.
3). When input is out of the range the display will blink.

Accuracy of retransmission O/p - 0.25% of Full scale

6. Calibration Procedure:
Input Calibration:

As explained earlier, One can do calibration thro' the keyboard itself, Zero and Full-
scale values are stored in NVRAM.

1. Switch on the instrument and allow 15 minutes of warm up time before starting
calibration.

2. Take a standard source. Set it’s output at desired Zero value. Apply output of the
source to the input terminals of connector pin according to input select.

3. Go to ‘cal_zr1’ menu. Lower window displays a count. This is raw count proportional
to analog input. Wait till counts are stable, save this count by pressing ‘Index’ key twice.

4. Now apply input equal to Full scale/Span (CALS):

 Set output of the source at desired full-scale value.

 Apply output of the source to the input terminals

 Cal-span’ for Span calibration will be displayed.

  Raw counts of will be displayed.

 Allow the reading to settle and Press ‘Index’ Key twice to save the count.

 This reading will be stored as Span, now the instrument is calibrated.

7. MODBUS protocol
Here we will Two-function code:
Function code:
03h: for reading parameter value.
06h: for writing parameter value.

Command message consist of 4 fields as shown below.

Command message.
Station no (1 byte).
Function code (1 byte)
Data (4 byte)
Crc (2 byte)

Here master will send command to the slave and slave will response to the master
if its unit no. Matches with command message’s station no. Field.
To a relevant message, slave station creates and sends back a response message,
which corresponds to the command message.

If the content of the command message have any abnormality (for example, non
actual function code is designated) other than transmission error, slave does not
execute that command but creates and sends back a response at error detection.

The composition of error message at error detection is shown below.

Error message:
Station no
Function code +80H
Error code
Error check (crc-16)
Error code:
01H: illegal function
02H: illegal data address
03H: illegal data value.
08H: crc error.

Here slave will first check crc, if crc is o.k. it will assume that there is no transmission
error. And if crc is not matched with crc calculated by slave station, slave station will send
back error message with error code 08H. After crc slave will check unit no. If it matches
with its own unit no, it will go ahead with command. Otherwise it will neglect the
command.

Sr. no CMD.NO Parameter Length in Read/Write

(Fun. No). Name bytes
(Words)
1 0001 High alarm 2(1) R/W
2 0002 Low alarm 2(1) R/W
3 0003 Setpoint 2(1) R/W
4 0004 Setpoint+2 2(1) R/W
5 0005 Prewarn 2(1) R/W
6 0006 Prewarn+2 2(1) R/W
7 0007 Conv-Factor 2(1) R/W
(00.00-99.99)
8 0008 Filter no 2(1) R/W
9 0009 Batch mode 2(1) R/W
(Normal=0,
Counter=1)
10 0010 Type of 2(1) R/W (0 -4)
input (for pulse it is 4)
11 0011 Type of Inst 2(1) R/W (indicator =0
, Totalizer =1)
12 0012 Sqrt mode 2(1) R/W
(Yes =0, No=1)
13 0013 Digital input 2(1) R/W (yes –0,no –
1)
14 0014 Digital filter 2(1) R/W (yes –0,no –
1)
15 0015 Time base 2(1) R/W (0-3)
16 0016 ZR 2(1) R/W
17 0017 FS 2(1) R/W
18 0018 No of 2(1) R/W
batches
19 0019 Batch 2(1) Read only
counter
20 0020 Relay mode 2(1) R/W (normal
=0.failsafe =1)
21 0021 Cut-off 2(1) R/W (000.0 to
100.0)
22 0022 Dp 2(1) R/W (0-3)
23 0023 SF1 2(1) R/W (0-20000)
Sr. no Reg. Parameter Length in Read/Write
No. byte
(Word)
24 0024 FL1 2(1) R/W (0-9)
25 0025 SF2 2(1) R/W (0-20000)
26 0026 FL2 2(1) R/W (0-9)
27 0027 SF3 2(1) R/W (0-20000)
28 0028 FL3 2(1) R/W (0-9)
29 0029 SF4 2(1) R/W (0-20000)
30 0030 FL4 2(1) R/W (0-9)
31 0031 SF5 2(1) R/W (0-20000)
32 0032 FL5 2(1) R (9)
33 0033 Baud rate 2(1) R/W (19200-
1,9600 -0)
34 0034 Serial no 2(1) R/W
35 0035 Pout 2(1) R/W (0000-9999)
36 0036 Default 2(1) R/W
display (0-batch total,
1-integration
total)
37 0037 Out zero 2(1) R/W (0000-4095)
38 0038 Out span 2(1) R/W (0000-4095)
39 0039 Default out 2(1) R/W (0 for yes /1
for no)
40 0040 Int total 2(1) Read only
41 0041 Int total+2 2(1) Read only
42 0042 Batch total 2(1) Read only
43 0043 Batch 2(1) Read only
total+2
44 0044 Roll count 2(1) Read only
45 0045 Flow rate 2(1) Read only
46 0046 K FACTOR 2(1) R/W
47 0047 K 2(1) R/W
FACTOR+2
48 1 Set point 1 R, digital
relay
49 2 Prewarn 1 R, digital
relay
50 3 High alarm 1 R, digital
relay
51 4 Low alarm 1 R, digita1
relay
52 5 Stop batch 0000 W, digital
53 5 Start batch FF00 W, digital
Formula for K-FACTOR:

FLOW: - [(Pulse count per second *Time base)/ (K-FACT)]

Where,
Time Base value =

Number Unit Value

1 Second 1
2 Minute 60
3 Hour 3600
4 Day 86400

For example: - if we want to set FLOW value equals to 250.00 and remaining parameter at: -

 For Flow per minute:

Time base = 2 = 60
Pulse count = 10000
Then FLOW = [(10000 * 60)/2400]
FLOW = 250 per minute.

 For Flow per Hour:

Time base = 3 = 3600

Pulse count = 10000
Then FLOW = [(10000 * 3600)/144000]
FLOW = 250 per Hour.

Note: - K-factor works linearly at 60/minute.

For Retransmission Output, “F.S” parameter is provided.