APG DCR-1003 Manuale utente
Operator’s Manual
AUTOMATION
PRODUCTS
GROUP, INC.
Automation Products Group, Inc.
APG...Providing tailored solutions for measurement applications
Tel:1/888/525-7300•Fax:1/435/753-7490 • www.apgsensors.com•E-mail:[email protected]
DCR-1003
and
DCR-1004
Rev. A3, 10/08
Doc. 9002661
DCR-1003 and DCR-1004 Rev. A3, 10/08
2
Automation Products Group, Inc.
APG...Providing tailored solutions for measurement applications
Tel:1/888/525-7300•Fax:1/435/753-7490 • www.apgsensors.com •[email protected]
Table of Contents
Warranty ......................................................................................... 3
Introducing...................................................................................... 4
Understanding Ultrasonics............................................................. 5
Installation ...................................................................................... 7
Installing the DST Sensor ............................................................ 7
Installing the DCR-1003, 1004 .................................................. 10
Wiring............................................................................................ 11
Programming ................................................................................ 13
Operation ................................................................................... 15
Filtering ..................................................................................... 16
Outputs ...................................................................................... 19
Applications ............................................................................... 25
Calibrations ............................................................................... 37
Utilities ...................................................................................... 38
Quick Reference Sheet .................................................................. 39
Troubleshooting ............................................................................ 41
Maintenance ................................................................................. 42
Specifications ................................................................................ 43
Rev. A3, 10/08 DCR-1003 and DCR-1004
3
Automation Products Group, Inc.
APG...Providing tailored solutions for measurement applications
Tel: 1/888/525-7300•Fax:1/435/753-7490• www.apgsensors.com •[email protected]
APG warrants its products to be free from defects of material and workmanship
and will, without charge, replace or repair any equipment found defective upon
inspection at its factory, provided the equipment has been returned,
transportation prepaid, within 24 months from date of shipment from factory.
THE FOREGOING WARRANTYIS IN LIEU OFAND EXCLUDESALLOTHER
WARRANTIES NOTEXPRESSLYSETFORTH HEREIN,WHETHER
EXPRESSED OR IMPLIED BY OPERATION OF LAWOR OTHERWISE
INCLUDING BUTNOT LIMITED TOANYIMPLIEDWARRANTIES OF
MERCHANTABILITYOR FITNESS FORAPARTICULAR PURPOSE.
No representation or warranty, express or implied, made by any sales
representative, distributor, or other agent or representative of APG which is not
specifically set forth herein shall be binding uponAPG. APG shall not be liable
for any incidental or consequential damages, losses or expenses directly or
indirectly arising from the sale, handling, improper application or use of the
goods or from any other cause relating thereto andAPG’s liability hereunder, in
any case, is expressly limited to the repair or replacement (at APG’s option) of
goods.
Warranty is specifically at the factory. Any on site service will be provided at
the sole expense of the Purchaser at standard field service rates.
All associated equipment must be protected by properly rated electronic/
electrical protection devices. APG shall not be liable for any damage due to
improper engineering or installation by the purchaser or third parties. Proper
installation, operation and maintenance of the product becomes the
responsibility of the user upon receipt of the product.
Returns and allowances must be authorized byAPG in advance. APG will
assign a Return Material Authorization (RMA) number which must appear on
all related papers and the outside of the shipping carton. All returns are subject
to the final review by APG. Returns are subject to restocking charges as
determined by APG’s “Credit Return Policy”.
• Warranty and Warranty Restrictions
DCR-1003 and DCR-1004 Rev. A3, 10/08
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Automation Products Group, Inc.
APG...Providing tailored solutions for measurement applications
Tel:1/888/525-7300•Fax:1/435/753-7490 • www.apgsensors.com •[email protected]
•Introducing
The DCR-1003, 1004 controllers with DST series sensors were specifically
designed to provide a rugged and reliable non-contact sensor system that is
easily programmed yet flexible enough to use in a wide range of applications.
The DCR-1003, 1004 controllers have a large display to show readings and
parameters. They also include a mode display to provide easy setup of the
programmable modes. The controller can be configured to monitor level, flow,
volume or differential. The DCR-1003 comes standard with four relay outputs.
The DCR-1004 or analog version, also includes a standard 4-20 mA output with
optional configurations of 0-20 mA or voltage outputs.
The DST series sensors are non-contact ultrasonic which measure the
distance to a surface through air. The standard DCR-1003, 1004 sensor is the
DST-1002. It is a totally sealed PVC sensor with a range of 25 ft. Several other
versions of DST are available to fit almost any application.
Typical applications include:
•Monitoring water levels in a well
•Monitoring open channel flow
•Determining material volume in a tank
• Taking differential measurements
•Obstacle avoidance
•Product dimensioning
Rev. A3, 10/08 DCR-1003 and DCR-1004
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Automation Products Group, Inc.
APG...Providing tailored solutions for measurement applications
Tel: 1/888/525-7300•Fax:1/435/753-7490• www.apgsensors.com •[email protected]
•Understanding Ultrasonics
Ultrasonic sensors measure distance
using a transducer to send out ultrasonic
bursts. Each burst contains a series of 1-
20 pulsed sound waves that emit in the
shape of a cone, reflect off the target, and
are received by the sensor. The time
required for the sound burst to travel to
and from the target is converted into a
distance measurement by the sensor.
Ultrasonic sensing is affected by
several factors including the target
surface, distance, size, and angle. The
following considerations will help ensure
the best possible target conditions.
Surface
The ideal target surface is hard and smooth and perpendicular to the face of
the transducer. This surface will reflect a greater amount of signal than a soft,
sound wave absorbent surface. Atarget with poor sound wave reflection
characteristics will reduce the operating distance of the sensor and decrease its
accuracy.
detection
area
beam spread
low sensitivity
and
pulses
high sensitivity
and
pulses
DCR-1003 and DCR-1004 Rev. A3, 10/08
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Automation Products Group, Inc.
APG...Providing tailored solutions for measurement applications
Tel:1/888/525-7300•Fax:1/435/753-7490 • www.apgsensors.com •[email protected]
Distance
The shorter the distance from the sensor to an object, the stronger the
returning echo will be. Therefore, as the distance increases, the object requires
better reflective characteristics to return a sufficient echo.
Size
A large object will have a greater surface area to reflect the signal than a
small one, therefore, a large target will be detected at a greater distance than a
small target. The surface area recognized as the target is generally the portion
closest to the sensor.
Angle
The inclination of the object's surface facing the ultrasonic sensor affects the
reflectivity of the object. The portion perpendicular to the sensor returns the
echo. If the entire surface is at a great enough angle, the signal will be reflected
away from the sensor and no echo will be detected. Generally a target at an
angle greater than 5 degrees off perpendicular will not be detected.
Rev. A3, 10/08 DCR-1003 and DCR-1004
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Automation Products Group, Inc.
APG...Providing tailored solutions for measurement applications
Tel: 1/888/525-7300•Fax:1/435/753-7490• www.apgsensors.com •[email protected]
•Installation
Installing the DST Sensor
The DST sensor should be installed so that it has a clear sound path to the
intended target. The path should be free from obstructions and as open as
possible. Follow the guidelines mentioned in this manual under “Understanding
Ultrasonics”, found on page 5.
NPT and Flange Mounting
•Mounting in a coupler or half coupler welded to the top of tank. (see
drawings below)
•Coupling should extend through the top of tank.
•Coupler must be aligned perpendicular to the target level.
•Screw sensor in only hand tight.
•To avoid false Echoes, the coupler should be installed where there is a clear
sound path perpendicular to the detection surface and where the sound
path will not intersect vessel fill spouts, rough vessel walls, ladders…etc.
BEST GOOD
*Soft gasket
material is
recommended with
flange mounting.
DCR-1003 and DCR-1004 Rev. A3, 10/08
8
Automation Products Group, Inc.
APG...Providing tailored solutions for measurement applications
Tel:1/888/525-7300•Fax:1/435/753-7490 • www.apgsensors.com •[email protected]
Stand Pipe Mounting
The stand pipe should be as large in diameter and as short in length as
possible. Mount the sensor above the highest anticipated material by at least
the published blanking distance.
The stand pipe should be seamless to provide a smooth path for the sound
waves to propagate into the tank. Because the sound waves will concentrate
along the inside wall of the pipe, any seams from couplers, nipples, and welds
will cause echo returns that will be picked up by the sensor. The sensor
blanking will need to be changed to a distance greater than the length of the
pipe (found on page 15; mode 5).
The end of the stand pipe should extend inside the tank and be cut to a 45°
angle. Make sure that the cut is clean and free from burs. If the standpipe is cut
at 90°, there will develop a standing wave echo at the end of the pipe that will be
seen by the sensor as a target. If a 45° cut is not feasible in your application,
then the cut should be made as close to 45° as possible (often, even a 10° cut
will shrink the standing wave enough to allow the sensor to see past it).
To avoid false Echoes, the stand pipe should be installed where there is a
clear sound path perpendicular to the detection surface and where the sound
path will not intersect vessel fill spouts, rough vessel walls, ladders…etc. Any
angle off perpendicular will degrade the performance of the sensor.
Top of Tank
Stand Pipe
10-45
o
CUT
Rev. A3, 10/08 DCR-1003 and DCR-1004
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Automation Products Group, Inc.
APG...Providing tailored solutions for measurement applications
Tel: 1/888/525-7300•Fax:1/435/753-7490• www.apgsensors.com •[email protected]
Stilling Well Mounting
Provides access to difficult areas and eliminates problems with foam.
•Extend the pipe above the highest anticipated level by at least the
published blanking distance.
•Provide a vent hole at the top of the tube. Keep the hole inside the blanking
distance of the sensor to prevent false echoes.
•Use only in liquid materials that will not leave deposits on the inside of the
pipe (material build-up will result in false echoes).
•Pipe must have smooth walls and should be seamless to provide a smooth
path for the sound waves to propagate into the tank. Because the sound
waves will concentrate along the inside wall of the pipe, any seams from
couplers, nipples, and welds will cause echo returns that will be picked up
by the sensor.
Minimum Blanking Distance
Highest Anticipated
Tank Level
DCR-1003 and DCR-1004 Rev. A3, 10/08
10
Automation Products Group, Inc.
APG...Providing tailored solutions for measurement applications
Tel:1/888/525-7300•Fax:1/435/753-7490 • www.apgsensors.com •[email protected]
Installing the DCR-1003, 1004
The DCR-1003, 1004 should be installed using the 4 mounting feet provided.
The enclosure must be mounted out of direct sunlight and should have good
clearance to the left for opening the hinged cover.
DCR-1003 and DCR-1004 Mounting Dimensions
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