AUTOMATION P R O D U C T S GROUP, INC. Operator’s Manual DCR-1006A Ultrasonic Controller Rev. A1 2/14 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: sales@apgsensors.
DCR-1006A Ultrasonic Controller Rev. A1, 2/14 Table of Contents Warranty......................................................................................... 3 Understanding Ultrasonics........................................................... 4-5 Installation.................................................................................... 6-8 Wiring......................................................................................... 9-11 Powering the DCR-1006A.................................
DCR-1006A Ultrasonic Controller Rev. A1, 2/14 • Warranty and Warranty Restrictions 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.
DCR-1006A Ultrasonic Controller Rev. A1, 2/14 • Understanding Ultrasonics Ultrasonic sensors use a transducer to transmit bursts of ultrasonic sound waves. Each burst contains a series of pulsed sound waves that emit in the shape of a cone, reflect off the target, and are detected by the sensor. The time required for the sound waves to travel to and from the target is converted into a distance measurement by the sensor.
Rev. A1, 2/14 DCR-1006A Ultrasonic Controller Angle The inclination of the object’s surface in relation to the sensor face will affect the strength of the reflected sound waves. Surfaces perpendicular to the sensor will reflect more signal directly back to the sensor. If a surface is more than a few degrees off perpendicular, enough of the signal will be reflected away from the sensor that the target will not be detected.
DCR-1006A Ultrasonic Controller Rev. A1, 2/14 • Installation Proper sensor mounting is critical for successful operation of an ultrasonic sensor. Using the following guidelines can help ensure trouble free installation and operation: • Ensure that the sensor face is perpendicular to the target surface. If the target is more than a few degrees off perpendicular, it may not be detected. Targets at greater distances will require more precise sensor alignment.
DCR-1006A Ultrasonic Controller Rev. A1, 2/14 • Always mount above the highest anticipated target level by at least the published minimum blanking distance. If a target enters into the blanking area, error in the detection will occur. It is always advisable to allow for sufficient headroom to ensure that the target does not enter the blanking area. • Generally it is advisable to mount the sensor away from any vessel fill spouts.
DCR-1006A Ultrasonic Controller Rev. A1, 2/14 Stand Pipe Mounting Stand pipes are used to provide headroom at the top of a tank when the target is expected to come closer to the sensor than the minimum blanking distance. It’s very critical that the stand pipe be installed perpendicular to the target. This is especially important on longer range applications. The pipe must have smooth walls (no joints) and no burs or obstructions. If possible, cut the end of the pipe at a 10°-45° angle (see drawing).
DCR-1006A Ultrasonic Controller Rev. A1, 2/14 • Wiring Powering the DCR-1006A Power to the DCR-1006A can be supplied from either 85-264 VAC or 12-28 VDC. GND Ground AC/N (-) Neutral AC/L (+) Hot Vs OUT OR 24V 85-264 VAC INPUT GND DC Voltage Powered Powering with AC Voltage 12-24 VDC INPUT NOTE: terminals will source 24 VDC when powering via AC voltage. Sensor Wiring The DCR-1006A is compatible with DST and MNU series ultrasonic sensors.
DCR-1006A Ultrasonic Controller Rev. A1, 2/14 4-20mA Output Wiring The 4-20mA output runs on an independent isolated circuit that must be supplied 9-28 VDC in order to operate. The source voltage (Vs) can be supplied from the 24 VDC source on the DCR-1006A, or from an external power source in an isolated circuit as shown below.
DCR-1006A Ultrasonic Controller Rev. A1, 2/14 RST-5002 or RST-6001 Communication Module Wiring The DCR-1006A can be connected to the RST-6001 RS-485-to-USB module for interfacing with the APG Modbus software, or to the RST-5002 internet communications module to provides remote access to the DCR’s readings and settings. The “RS-485 NET A and B terminals are the only connection required for either RST module. RST Module Wiring: connect the RS-485 RST Module B1(+) terminals of the RST module.
DCR-1006A Ultrasonic Controller Rev. A1, 2/14 • Programming The DCR-1006A can be programmed using the on-board push buttons or by using the RS-485 NET interface to communicate with APG’s Modbus software or RST-5002 communications module. Push Button Functions: ENTER Opens the programming menu, selects menu options, accepts parameter settings, and steps left one digit within any numeric settings. NOTE: In order to save changes to a parameter setting, the ENTER button must be used to exit the setting.
DCR-1006A Ultrasonic Controller Rev. A1, 2/14 Upper Level Menu Structure UNITS dIST bACK L LEVEL CUSTOM VOLUNI SCHbOT bASIC SCCbOT IN SEL SRECTC dECIML APP TY SENS N HCSPHE SPHERI L CALC TRIP1V VERTOV TRIP1W HORTOV TRIP1T CURVE TRIP2V TRIP2W SENSIT TRIP2T PULSES TRIP3V bLANK TRIP3W GAIN C OUTPUT AVERAG TRIP3T TRIP4V WINdOW ULTRA TRIP4W OUTRAN TRIP4T SAMP R SET4MA T-COMP SET20M MULTIP CAL4MA OFFSET CAL20M MAXdIS Automation Products Group, Inc. APG...
DCR-1006A Ultrasonic Controller Rev. A1, 2/14 • bASIC (Basic Parameters) UNITS bACK L back light CUSTOM custom units bASIC basic VOLUNI volume units IN SEL input select dECIML decimal place SENS N sensor number inches, feet, meters 0, 1, 2, 3, 4, 5, 6, 7, 8 6-digit alpha-numeric ft3, Mft3, Gallons, m3, Liters, in3, Barrels DST, LR DST, MNU 0, 1, 2, 3 1 to 247 Automation Products Group, Inc. 14 APG...
DCR-1006A Ultrasonic Controller Rev. A1, 2/14 UNITS: Determines the unit of measure for the Calculated Reading when in Application Types 1, 2 or 7 (see below). bACK L (Back Light): Allows the user to adjust the intensity of the display backlight. There are 9 settings from off to 100% intensity. CUSTOM (Custom Units): Allows the user to define a custom alphanumeric label for the Curve Fit and Linear Calculation Application Types.
DCR-1006A Ultrasonic Controller Rev. A1, 2/14 • ULTRA (Ultrasonic Sensor Parameters) SENSIT sensitivity 0 to 100 PULSES pulses 0 to 20 bLANK blanking 0 to Max. GAIN C gain control ULTRA ultrasonic Manual, Auto, *Hard, *Soft, *Auto Soft *Available with MNU sensors only AVERAG averaging 1 to 20 WINdOW window 0 to Max. OUTRAN out of range 0 to 250 SAMP R sample rate 0 to 1000 T-COMP temp. comp. On, Off MULTIP multiplier 0 to 1.999 OFFSET offset 0 to Max. MAXdIS max. distance 0 to Max.
DCR-1006A Ultrasonic Controller Rev. A1, 2/14 SENSIT (Sensitivity): Controls the level of amplification applied the returning target echoes (signals). The sensitivity setting is expressed as a percentage; 0 to 100%. PULSES: Controls the number of sound wave pulses sent in each ultrasonic burst. The greater the number of pulses, the stronger the transmitted signal. Range: 0 to 20 pulses.
DCR-1006A Ultrasonic Controller Rev. A1, 2/14 MAXdIS (Maximum Distance): Sets the distance (beginning at the sensor face) to the point where the sensor will stop looking for target echoes. Targets detected beyond the Maximum Distance will be ignored. WINdOW (Filter Window): Sets the width of the target acceptance window.
DCR-1006A Ultrasonic Controller Rev. A1, 2/14 MULTIP (Multiplier): Sets the conversion Multiplier that will be applied to the sensor readings. The default is 1000 (see note below) and typically does not need to be adjusted. However, since the speed of sound is not constant through all environments, the multiplier parameter allows the user to adjust for variations in atmosphere when maximum accuracy is required.
DCR-1006A Ultrasonic Controller • APP TY Rev. A1, 2/14 Application Types The DCR-1006A has 11 Application Type operating modes to convert the measurement to the target into a calculated reading, such as a tank volume. Refer to the following section for a descriptions and settings. Note: all dimensional values must be entered in the selected Units.
DCR-1006A Ultrasonic Controller Rev.
DCR-1006A Ultrasonic Controller Rev. A1, 2/14 dIST (Distance to Target) Displays the distance to the target in the selected Units. Distance LEVEL (Depth of Level) Displays the depth of level in the selected Units. Parameters: FULL d (Full Distance) EMPTYd (Empty Distance) Level SCHbOT (Standing Cylinder with Hemispherical Bottom) Parameters: FULL d (Full Distance) Diameter Full Distance EMPTYd (Empty Distance) dIAMET (Tank Diameter) *bOTRAd (Bottom Radius) *set to 0 for flat bottom tanks.
DCR-1006A Ultrasonic Controller Rev.
DCR-1006A Ultrasonic Controller Rev. A1, 2/14 HCSPHE (Horizontal Cylinder with Hemispherical Ends) Parameters: FULL d (Full Distance) EMPTYd (Empty Distance) LENGTH (Tank Length) dIAMET (Tank Diameter) Full Distance Empty Distance Diameter End Radius Length *ENd RA (End Radius) *set to 0 for flat ended tanks.
DCR-1006A Ultrasonic Controller Rev. A1, 2/14 VERTOV (Vertical Oval) Parameters: FULL d (Full Distance) EMPTYd (Empty Distance) LENGTH (Tank Length) DEPTH (Tank Depth) WIDTH (Tank Width) Full Distance Empty Distance Depth Width Length HORTOV (Horizontal Oval) Parameters: FULL d (Full Distance) EMPTYd (Empty Distance) LENGTH (Tank Length) DEPTH (Tank Depth) WIDTH (Tank Width) Full Distance Empty Distance Depth Length Width Automation Products Group, Inc. APG...
DCR-1006A Ultrasonic Controller Rev. A1, 2/14 CURVE (Curve Fit) Allows the sensor to mimic a tank strapping chart by using a 3rd degree polynomial equation to produce a “curve fit” approximation. NOTE: The 4 coefficient values must be entered using the APG Modbus software. Refer to the instructions below to enter Curve Fit data. Parameters: FULL d (Full Distance) EMPTYd (Empty Distance) Open the APG Modbus software and select “Strapping Chart” from the “Tools” menu.
Rev. A1, 2/14 DCR-1006A Ultrasonic Controller Once the all data points have been entered, click the “Calculate” button to determine the values required for the “curve fit” calculation. NOTE: before clicking “Calculate” ensure that there is only one empty row following the last line of data (as shown). Use the keyboard “Delete”key to remove any addition empty rows. Click the “Save to Sensor” button to populate the appropriate Holding Resister fields (see below) and close the Strapping Chart window.
DCR-1006A Ultrasonic Controller • OUTPUT Rev. A1, 2/14 (Outputs) The DCR-1006A is equipped with 4 SPDT relays and an isolated 4-20mA output.
DCR-1006A Ultrasonic Controller Rev. A1, 2/14 Relay Settings NOTE: All Trip Value and Trip Window settings must be entered using the units being displayed. For example if the display is setup to read in gallons, then the Trip Value and Trip Window parameters would be set in gallons. TRIP V (Trip Value): Sets the reading (in the units being displayed) for the first actuation point of the relay.
DCR-1006A Ultrasonic Controller Rev. A1, 2/14 Relay Trip Types NEAR: Activates whenever the reading is less than the Trip Value. EXCLSV (Exclusive): Activates whenever the reading is less than the Trip Value or greater than the Trip Value + Trip Window. H NEAR (Hysteresis Near): Activates until the reading exceeds the Trip Value + Trip Window, then deactivates until the reading falls below the Trip Value. FAR: Activates whenever the reading is greater than the Trip Value.
DCR-1006A Ultrasonic Controller Rev.
DCR-1006A Ultrasonic Controller Rev. A1, 2/14 4-20mA Settings NOTE: The 4-20mA Set Points must be entered in the units being displayed. For example if the display is setup to read in gallons, then the 4mA and 20mA Set Points would be set in gallons. SET4MA (4mA Set Point): Sets the reading to be associated with a 4mA output. SET20M (20mA Set Point): Sets the reading to be associated with a 20mA output.
DCR-1006A Ultrasonic Controller Rev. A1, 2/14 APG Modbus Software Communications Step 1: select “Communication” from the “Configure” menu. Step 2: select “DCR” from the Sensor Type menu, then click the “Save Config” button at the bottom of the screen. Automation Products Group, Inc. APG...Providing tailored solutions for measurement applications Tel: 1/888/525-7300 • Fax: 1/435/753-7490 • www.apgsensors.com • sales@apgsensors.
DCR-1006A Ultrasonic Controller Rev. A1, 2/14 Step 3: set the mode of communication by selecting the . Select the appropriate Comm Port when using direct serial communications. OR Check the “USB Communications (RST-6001)” box when using the RST-6001 communications module. Automation Products Group, Inc. 34 APG...Providing tailored solutions for measurement applications Tel: 1/888/525-7300 • Fax: 1/435/753-7490 • www.apgsensors.com • sales@apgsensors.
DCR-1006A Ultrasonic Controller Rev. A1, 2/14 Using the APG Modbus Software Click on the description to open the programming window for that address. Sensor readings are displayed in the Input Registers table. The register values should automatically populate. If not, click “Receive All” to retrieve the register values from the sensor. (continued on next page) Automation Products Group, Inc. APG...
DCR-1006A Ultrasonic Controller Rev. A1, 2/14 To change an individual parameter, click on the value you wish to change, enter the desired value, then click the adjacent “Send” button to implement the change. To send all the register values as currently listed, click “Send All” To retrieve the register values saved in a sensor, click “Receive All” A green window indicates successful communication. A yellow window indicates a communication failure.
DCR-1006A Ultrasonic Controller Rev. A1, 2/14 • Inspection and Maintenance The DCR-1006A requires little maintenance but should be inspection periodically to ensure proper working order. Keep the sensor clean from heavy buildup on the sensing face. Ensure that the wire connections are secure, sealed against the elements and free from corrosion. • Specifications Sensor Operating Ranges: DST or MNU 5000 series: 4 to 72 in. (101 to 1829 mm) DST or MNU 7000 series: 6 to 144 in.
DCR-1006A Ultrasonic Controller Rev. A1, 2/14 MNU or DST-5410 Series 2.0” 3/4” NPT 4.0” 1” NPT MNU or DST-3400 Series 3.06” 2.0” 3/4” NPT 3” NPT 5.52” 4.17” Automation Products Group, Inc. 38 APG...Providing tailored solutions for measurement applications Tel: 1/888/525-7300 • Fax: 1/435/753-7490 • www.apgsensors.com • sales@apgsensors.
DCR-1006A Ultrasonic Controller Rev. A1, 2/14 MNU or DST-5420 or 7420 Series 2.0” 3/4” NPT 3.6” 2” NPT MNU or DST-2420 Series 3.06” 2.0” 3/4” NPT 5.0” 2” NPT 3.1” Automation Products Group, Inc. APG...Providing tailored solutions for measurement applications Tel: 1/888/525-7300 • Fax: 1/435/753-7490 • www.apgsensors.com • sales@apgsensors.
AUTOMATION P R O D U C T S GROUP, INC. APG...Providing tailored solutions for measurement applications Automation Products Group, Inc. Tel: 1/888/525-7300 1/435/753-7300 Fax: 1/435/753-7490 e-mail: sales@apgsensors.com www.apgsensors.com Automation Products Group, Inc. 1025 W. 1700 N.
