AUTOMATION P R O D U C T S G R O U P, I N C. Operator’s Manual DCR-1005 and DCR-1006 Rev. A4, 10/08 Doc. 9002664 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-1005 and DCR-1006 Rev. A4, 10/08 Table of Contents Warranty ......................................................................................... 3 Introducing ...................................................................................... 4 Understanding Ultrasonics ............................................................. 5 Installation ...................................................................................... 7 Wiring .....................................................
Rev. A4, 10/08 DCR-1005 and DCR-1006 • 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-1005 and DCR-1006 Rev. A4, 10/08 • Introducing The DCR-1005 and DCR-1006 controller 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-1005 and DCR-1006 controllers have a 0.5 in. 4 character LCD display to show readings and parameters. The controller can be configured to monitor distance, level or volume.
Rev. A4, 10/08 DCR-1005 and DCR-1006 • Understanding Ultrasonics Ultrasonic sensors measure distance using a transducer to send out ultrasonic bursts. Each burst contains a series of 120 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.
DCR-1005 and DCR-1006 Rev. A4, 10/08 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.
Rev. A4, 10/08 DCR-1005 and DCR-1006 • Installation Installing the DCR The DCR-1005 and DCR-1006 should be installed using the 4 screws through 4 holes in the back of the enclosure. The enclosure must be mounted out of direct sunlight. Installing the DST The DST sensor should be installed so that it has a clear sound path to the intended target. Mount the sensor away from tank walls and inlets. The path should be free from obstructions and as open as possible for the 9° off axis beam pattern.
DCR-1005 and DCR-1006 Rev. A4, 10/08 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.
Rev. A4, 10/08 DCR-1005 and DCR-1006 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).
DCR-1005 and DCR-1006 Rev. A4, 10/08 • Wiring Step 1: Depending on the DST cable version (coax or 2-conductor), connect the DST to the DCR Controller by way of the coaxial ‘F’ connector located on the outside of the DCR box, or use the terminal strip located inside the DCR box. The DST sensors can be mounted up to 2000 feet from the controller. Step 2: To obtain access to the DCR’s terminal strip, remove the DCR’s polycarbonate cover by turning the 4 screws counterclockwise 1/4 turn.
Rev. A4, 10/08 DCR-1005 and DCR-1006 • Programming The DCR-1005 and DCR-1006 has a four-digit LCD readout and four red LED’s labeled TRIPS 1, 2, 3, and 4. These LED’s indicate the status of the relays. Four momentary push-buttons located under the cover, are used to program the DCR. The cover makes reading the displays easy while sealing the electronics and preventing the buttons from being accidentally bumped. The different modes of the DCR can be easily accessed using the mode buttons, M-UP and M-DN.
DCR-1005 and DCR-1006 Rev. A4, 10/08 • Programming Modes 1) 2) 3) 4) 5) 6) Operation Filtering Outputs Applications Calibration Utilities (Modes 1-5) (Modes 6-11) (Modes 12-27) (Modes 28-37) (Modes 38-39) (Modes 40-42) Mode Sequence For best results when programming your DCR, follow the steps below. Following the steps in sequence will eliminate most of the problems encountered when setting up the DCR controller. 1. MODES 1-2 Determine units to be displayed 2.
Rev. A4, 10/08 DCR-1005 and DCR-1006 Operation The operation modes are used to perform basic initialization of the DCR. MODE DESCRIPTION 1 Units PARAMETERS Range = 1 - 3 1 - inches 2 - feet 3 - meters Default = 2 EXPLANATION Selects the units to be displayed. 2 Decimal Point Range = 0000.- 0.000 Default = 00.00 Selects the decimal point position. 3 Operating Mode Range = 1 - 2 1 - distance 2 - volume/level Default = 1 Selects mode of measurement for the application.
DCR-1005 and DCR-1006 Rev. A4, 10/08 Filtering The filtering modes are provided to change how fast the system will respond to changes. The default settings should be appropriate for most level applications, however, the delays and windows can be changed to increase or decrease reaction time and filtering. MODE DESCRIPTION PARAMETERS 7 Sample Rate Units = milliseconds Range = 80 - 9999 Default = 120 EXPLANATION Sets the delay between sensor samples (readings).
Rev. A4, 10/08 DCR-1005 and DCR-1006 Example: Rapid Level Changes If the DCR’s filtering is too slow and the level to be monitored is changing rapidly, the display will seem to jump between readings instead of scrolling smoothly as the level changes. To reduce the filtering and quicken the response, mode 7 or 8 should be changed. MODE 7 VALUE 0.
DCR-1005 and DCR-1006 Rev. A4, 10/08 Outputs The DCR-1005 and DCR-1006 contain 4 SPDT relays which are capable of handling a 10 amp load. These relays have programmable BEGIN and END points as well as TYPE of operation. The LED’s on the DCR indicate the status of the relays. The programming units must be the same as those displayed. i.e. If gallons are displayed the trip location should be set in gallons. MODE DESCRIPTION PARAMETERS EXPLANATION 12 Begin Trip 1 Units = mode 1 Default = 2.5 ft.
Rev. A4, 10/08 DCR-1005 and DCR-1006 Trip Type Explanation ZERO BEGIN END Type 0: Near On Off Off Type 1: Exclusive On Off On Off Off Type 2: Hysteresis Near On On Type 3: Far Off On On Type 4: Inclusive Off On Off On On Type 5: Hysteresis Far Type 6: Off Off Trip Point Disable Type 7: Relay remains closed (trip light on) unless an error is detected in communication, loss of echo, or loss of power.
DCR-1005 and DCR-1006 Rev. A4, 10/08 Example: Relay Settings for Distance to Level A 10 ft. deep lift station requires that a pump turn on when a level is closer than 6 ft to the DST. The pump must stay on until the level drops to 9 ft. from the DST. An alarm relay is to be energized under normal operation and should open for failure in power, communication, invalid readings, high level closer than 5 ft., or loss of echo.
Rev. A4, 10/08 DCR-1005 and DCR-1006 Example: Relay Settings For Product Level rather than Distance to Level A 10 ft. deep lift station requires that a pump turn on when a level reaches 4 ft. and stay on until the level drops to 1 ft. from the bottom of the station. An 6 ft alarm relay is to be energized under 9 ft normal operation and should open for 10 ft failure in power, communication, invalid readings, high level above 5 ft., 4 ft or loss of echo.
DCR-1005 and DCR-1006 Rev. A4, 10/08 Analog The DCR-1006 has an Isolated 4-20 mA circuitry. To set up this feature, enter the two end points. For performing a distance to level measurement, the zero point of distance will be at the transducer and the 4-20 limits will be programmed in the same units as mode 1. For volumetric monitoring, the zero point will be at the empty point of the tank and the end points must be set in the units used in the volume measurement.
Rev. A4, 10/08 DCR-1005 and DCR-1006 Applications The DCR Controller can be configured for two different types of applications. They are: • Distance: Measuring the distance to an object. • Volume: Determining the volume, or level of a product in a tank. DISTANCE Measuring the distance to a target is the most basic application. The DCR Controller will do this without any special settings. Example: Distance Measurement A batch plant operator needs a display to show the level of rock in a hopper 5 m deep.
DCR-1005 and DCR-1006 Rev. A4, 10/08 VOLUME A very popular use for the DCR is to display for the amount of product in a tank. If tank type 0 is selected, the zero point is at the DST, and the display will show the distance to the product. Selecting tank type 1 is the most common setting for DCR this allows the display to show the level of the product in the tank. This setting would be used for any style of tank to indicate level, the zero point is moved to the bottom of the tank.
Rev. A4, 10/08 DCR-1005 and DCR-1006 Conversion Factors It is often desirable to display a volume output in units of measurement other than cubic feet, inches, or meters. In order to do this you need to apply a conversion factor. For tank types 2-5 the conversion factor needs to be entered into modes 29- 30, and the DCR does the rest. For flat bottom tanks (type 1), the conversion factor needs to be multiplied by the area of the bottom of the tank, and the result entered into modes 29-30.
DCR-1005 and DCR-1006 Rev. A4, 10/08 Example: Volumetric Setting for a Horizontal Cylindrical Tank Gallons of diesel fuel need to be displayed in a horizontal cylindrical tank. The dimensions of the tank are 11 ft. span, 10 ft. length and a radius of 5 ft. To convert the volume (cubic feet) to gallons requires a multiplier of 7.4805. If relay and analog outputs were to be used, they must be programmed in gallons.
Rev. A4, 10/08 DCR-1005 and DCR-1006 Example: Volumetric Setting for a Vertical Cylindrical Flat Bottom Tank Liters of DI water need to be displayed in a vertical cylindrical tank. The dimensions of the tank are 96 in. tall and 48 in. in diameter. In order to display the desired indication of liters a multiplier must be calculated. The multiplier is calculated based on the units selected in Mode 1. In this case it is inches (Mode 1 set to 1).
DCR-1005 and DCR-1006 Rev. A4, 10/08 Temperature Compensation As air temperature changes, so does the speed of sound. This change can cause 0.18% drift in distance for every degree C change. Mode 35 allows compensation in the readings for this change. The DST contains an internal thermistor which measures temperature in degrees F. By turning temperature compensation on, the effects of temperature changes are be reduced.
Rev. A4, 10/08 DCR-1005 and DCR-1006 Example: Calibration 1 Point Calibration The Calibration Factor is used to bring the displayed reading in line with the measured distance. To obtain the measured distance, measure from the level to be detected to 0.5 in. behind the DST face. (0.5 in. behind the DST face is the electrical zero of the sensor.) The calibration factor is determined by dividing the actual distance measured, by the displayed distance. Enter this number in the calibration modes 38 and 39.
DCR-1005 and DCR-1006 Rev. A4, 10/08 Utilities Input Select Allows the customer to use either a DST type sensor or other APG sensors with a pulse width output (digital) to drive the display. MODE 40 DESCRIPTION Input Select PARAMETERS Range = 0,1 0 = DST Sensor 1 = Pulse Width Default = 0 EXPLANATION Selects which type of sensor input to accept. Reset When the DCR is powered up, ‘0’ is loaded in mode 41. This saves the userselected modes into the DCR.
Rev. A4, 10/08 DCR-1005 and DCR-1006 Extended Range Modes 43 - 44 allows the DCR to display ranges greater than 50 ft. These modes are enabled only in DST’s with extended range. MODE 43 44 DESCRIPTION Range Selection PARAMETERS Range = 0,1 0 = 1 - 35 ft. Range 1 = 1 - 72 ft. Range Default = 0 EXPLANATION Some DSTs will allow a detection range of up to 72 ft. This parameter enables the DCR to display that distance. Maximum Range Range = 1 - 72 ft. Default = 35 ft.
DCR-1005 and DCR-1006 Rev.
Rev. A4, 10/08 DCR-1005 and DCR-1006 MODE DESCRIPTION PARAMETERS Analog 24 25 26 27 4 mA Distance 20 mA Distance 4 mA Calibration 20 mA Calibration ________________________ ________________________ ________________________ ________________________ Volume 28 29 30 31 32 33 34 Tank Type Mult Above Mult Below Span Tank Length Sphere.
DCR-1005 and DCR-1006 Rev. A4, 10/08 • Maintenance The DCR-1005 /1006 controller and DST sensors do not require maintenance. However, a periodic visual inspection of the system would be in order. The DST should be kept as clean as possible for optimum performance. Dust buildup may be removed from the transducer with a cloth or by low pressure air. The DST housing can be cleaned with soap and water. If the DST is visibly affected by the environment, a different type of transducer may be required.
Rev. A4, 10/08 DCR-1005 and DCR-1006 • DCR Specifications Outputs DCR-1005 4 relays (10 A 110 VAC) DCR-1006 4 relays (10 A 110 VAC) with isolated 4-20 mA. Supply Voltage 24 VDC or 110/220 VAC 24 VDC or 110/220 VAC Total Current Draw 0.1 A 0.1 A Housing Poly-Carbonate Poly-Carbonate Rating NEMA 4X, IP65 NEMA 4X, IP65 Dimensions (in.) 6.25 x 3.125 x 2.25 6.25 x 3.125 x 2.25 Resolution Maximum of 0.1 in. (2.5mm) Maximum of 0.1 in. (2.
DCR-1005 and DCR-1006 Rev. A4, 10/08 • DST Specifications Application DST-1002 Wet corrosive Environments DST-2421 Wet corrosive Environments Operating Range (ft.) 1.5 to 35 1 to 25 Enclosure PVC PC/PET Transducer Type Ceramic Ceramic Transducer Material PVC PVDF Ratings NEMA 6P/IP65 NEMA 4X Approvals Class I, Div. 1 n/a Operating Temp -30 to 60°C -40 to 60ºC Internal Temp Comp. Yes Yes Accuracy 0.25% of range 0.25% of range Dimensions L x D (in.) 7 x 3.5 7 x 2.
Rev. A4, 10/08 DCR-1005 and DCR-1006 • DST Specifications (continued) Application DST-3431 Wet corrosive Environments DST-5111 Wet corrosive Environments Operating Range (ft.) 1.25 to 50 4 to 72 inch Enclosure PC/PET PC/PET Transducer Type Ceramic Ceramic Transducer Material PC/PET PVDF Ratings NEMA 4X NEMA 6P/IP65 Approvals n/a n/a Operating Temp -40 to 60°C -30 to 60ºC Internal Temp Comp. Yes Yes Accuracy 0.25% of range 0.25% of range Dimensions L x D (in.) 7.5 x 3.5 4.
DCR-1005 and DCR-1006 Rev. A4, 10/08 • DST Specifications (continued) Application DST-9421 Dry stable Environments Operating Range (ft.) 0.5 to 35 Enclosure PC/PET Transducer Type Electrostatic Transducer Material Gold-Kapton Ratings NEMA 12 Approvals n/a Operating Temp -40 to 70ºC Internal Temp Comp. Yes Accuracy 0.25% of range Dimensions L x D (in.) 5.5 x 2.
Rev. A4, 10/08 DCR-1005 and DCR-1006 Notes 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-1005 and DCR-1006 Rev. A4, 10/08 Notes Automation Products Group, Inc. APG...Providing tailored solutions for measurement applications 38 Tel: 1/888/525-7300 • Fax: 1/435/753-7490 • www.apgsensors.com • sales@apgsensors.
Rev. A4, 10/08 DCR-1005 and DCR-1006 Notes 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 G R O U P, I N C. 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.
