Princo Model L4660 Series SmartSonic for Free-Flowing Solids

Transcription

1 Instrumentation designed with the user in mind Instruction Manual Princo Model L4660 Series SmartSonic for Free-Flowing Solids Smart Narrow-Beam Ultrasonic Level transmitter Rev. 1, 31 Aug 07 PRINCO INSTRUMENTS INC., 1020 INDUSTRIAL BLVD., SOUTHAMPTON, PA PHONE: or FAX: WEB SITE:

2 CONTENTS 1 INTRODUCTION ORDER CODES TECHNICAL DATA Data of SmartSonic for SOLIDS Accessories Maintenance and Repair INSTALLATION Mechanical Installation Positioning Gravity Filling Pneumatic Filling Mounting Aiming of the SmartSonic Wind Effects Electrical Connections PROGRAMMING Programming of the SmartSonic with the SAP-100 Programming Module The SAP-100 Display and Keys Programming with the SAP-100 Programming Module Indications of the SAP-100 Programming Module and the LEDs Current Output Scaling QUICKSET Full Parameter Access PARAMETERS DESCRIPTIONS AND PROGRAMMING Measurement Configuration Current Output Relay Output Measurement Optimization Volume Measurement Point Linearization Informational Parameters Test Parameters Simulation Mode Software/Hardware Codes Access Lock DIAGNOSTICS AND TROUBLESHOOTING / ERROR CODES SOUND VELOCITIES IN DIFFERENT GASES PARAMETER TABLE SmartSonic for Free-Flowing Solids Instruction Manual Page i Rev 1, 31 Aug 07o

3 1 INTRODUCTION The SmartSonic ultrasonic level transmitters from PRINCO are excellent tools for level measurement of liquids and free-flowing solids. This manual applies to units designed for measuring freeflowing solids with model numbers beginning with L4660-STD- 33J-_ and L4660-STD-31J-_. For other Princo Model L4660 Series units refer to manuals designated for Four-Wire Smartsonic, Two-Wire Smartsonic and Remote Two-Wire Smartsonic. These units are used primarily for liquid level measurement. The units are available with two input power options: 85 to 255Vac and 10.5 to 40Vdc. Application The level measurement technology is based on the noncontacting ultrasonic principle. It is especially well suited to applications where, for any reason, no physical contact may be established with the material being measured. Such reasons may include corrosive attack by the process medium against the measuring device material (acids), possible contamination (sewage) or, particles of the process medium adhering to the measuring device (adhesive materials). Principle of Operation The ultrasonic level measurement technology is based on the principle of measuring the time required for the ultrasound pulses to make a round trip from the sensor to the level to be measured and back again. The sensor emits an ultrasonic pulse train and receives the reflected echoes. This intelligent electronic device processes the received signal by selecting the echo reflected by the surface and calculating the time of flight. Thus, the SmartSonic measures distance only. All other parameters, such as level and volume are calculated by the unit based on this highly accurate distance measurement and on specific application data programmed into the unit by the user. The unit calculates level by subtracting the measured distance from the programmed value of the maximum measuring distance. Advanced Features The SmartSonic contains numerous features that enhance its reliability and accuracy beyond that of previous generations of ultrasonic devices. Simplified and Full Programming Modes Many basic level measurement applications can be set up using an abbreviated programming mode called Quickset. This saves the personnel involved the time required to program in the Full Parameter Access mode. The same SAP-100 plug-in display module may be used for either programming mode. The module is transportable and can be used for any number of SmartSonic units. Metric or US Engineering Units The SmartSonic may be easily set up to display either metric or US engineering units. Mathematical Algorithms for Volume The SmartSonic contains within its memory a wide array of algorithms by which it can calculate volumes based on various tank geometries. 32-point Linearization The unit may be programmed by the user with a 32-point linearization table for applications not included in the unit s set of internal algorithms. Echo tracking and Selection The reliability of the SmartSonic is enhanced by its ability to select the correct echo if more than one echo is present. The nature of ultrasonic measurement technology is such that a device emitting an ultrasonic signal will often receive more than one return signal. The geometries of the holding vessel may diffract the return signal into different signals returning to the sensor at different times. The SmartSonic maintains a measurement window around the signal that it is tracking, disregarding other signals. If there are two signals within the measurement window, it will normally track the stronger of the two signals, but can be programmed to track the first one received. The SmartSonic can also be programmed to ignore up to two fixed objects that lie within its signal path, as well as to ignore signals within a certain proximity of the sensor or within a certain distance from the bottom of the vessel. The unit can also be set up to read accurately through atmospheres other than air. Sound travels at different speeds through different gases. This affects the accuracy of the measurement. The SmartSonic can be programmed for the sound velocity of whatever gas is present. The default setting is the sound velocity in air (343.8 m/sec, 1128 ft/sec.) Informational and Self-diagnostic Functions The SmartSonic automatically displays error codes for certain self-diagnostic functions. The codes may be interpreted according to the Error Code chart in Section 7. The SmartSonic memory also records the following information which may be read out on the SAP-100 display by the user: overall operating hours, time elapsed since last switch-on, actual temperature of the transducer, and the maximum and minimum recorded temperatures of the transducer. The unit will also provide data that is useful for problem diagnosis. These include the number of echoes the unit is presently receiving and the relative amplitudes of these echoes, the amplitude of the echo in the measurement window, the echo time in milliseconds and the signal to noise ratio of the echo. The SmartSonic also has a current output test whereby the unit can be programmed to put out specified currents in the range of 3.9 to 20.5 ma. Basic Measurement Concepts Total Beam Angle A total beam angle of 5 to 7 at 3 db is featured by most of Princo s SmartSonic transducers ensuring a reliable measurement in narrow silos with uneven side walls as well as in process tanks with various protruding objects. Furthermore, because of the narrow beam angle, the emitted ultrasonic signals SmartSonic for Free-Flowing Solids Instruction Manual Page 1 of 27 Pages Rev 1, 31 Aug 07

4 have an outstanding focus. Deep penetration through gases, vapor and foam is ensured. Dead Band Dead Band is a feature common to all ultrasonic level meters. The unit cannot successfully make a level reading of a material that is within a minimum distance from the transducer. It is specified as the Minimum measuring distance in the Technical Data Table. Measurement within this range cannot be interpreted. Minimum measuring distance, Xm (Close-end Blocking) Minimum measuring distance (Xm) is the distance from the transducer (determined by the design of the unit) within which measurement is not possible (dead band). This distance can be extended by programming in order to avoid possible disturbing echoes coming from fixed objects. (Close-end Blocking). Maximum measuring distance (XM) Maximum measuring distance (XM) is the greatest distance (determined by the design of the unit), which can be measured by the unit under ideal conditions. The maximum measuring distance of the actual application (H) must not be greater than XM. The unit may be programmed for a smaller maximum measuring distance in order to ignore the disturbing effects of stirrers or heaters at the bottom of the tank.. X D X D (meters) (meters) (feet) (inches) Diameters corresponding to a 5 beam angle. Notes on Beam Angle: The basic formula for calculating the target area of the ultrasonic beam is D=tanΘ * X where D = the diameter of the target area, X = the distance from the face of the transducer to the zero level point and Θ = the beam angle of the unit (in most cases 5 degrees). The example in the above chart is calculated for a unit with a 5-degree beam angle. A distance of.122 meters has been added to the result to account for a.293m diameter transducer. As a practical matter, when determining the distance a unit should be mounted away from a sidewall or other obstruction, calculate the target diameter (D above) and divide the result by two. Make sure that the outer diameter of the transducer (not the center) is at least this far from the sidewall or obstruction. SmartSonic for Free-Flowing Solids Instruction Manual Page 2 of 27 Pages Rev 1, 31 Aug 07

5 ULTRASONIC LEVEL SOLIDS MEASUREMENT PRINCIPLES Min. meas. distance (Xm) DEFAULT value of P05=Xm Close end blocking (XB) progr. value of P05=XB>Xm Angle of repose Max. measuring distance of the device (X M ) DEFAULT value of P04=X M Max. measuring range of the device application(h) Programmed value of P04=H Programmed measurement range Displayable range Far end blocking DEFAULT value of: P06=0 DIST DIST=distance (measured) LEV=( level calculated H-DIST) VOL= volume (calculated from LEV) 2 ORDER CODES The order codes of the SmartSonic for solids: L S D Type Code Range Code Application Code Power supply Output Code Stand Ex* Transmitter T 197 ft/ 60m 1 Normal J 85 to 255 Vac 4 to 20 ma + relay 1 5 Transmitter + 4 to 20 ma + relay + B 100 ft/ 30m 3 Dust Ex X 85 to 255 Vac 3 7 Local Indicator HART 11.4 to 40 Vdc 4 to 20 ma + relay to 28 Vac 11.4 to 40 Vdc 11.4 to 28 Vac 4 to 20 ma + relay + HART 4 8 *The order code of an EX version should end in Ex. SmartSonic for Free-Flowing Solids Instruction Manual Page 3 of 27 Pages Rev 1, 31 Aug 07

6 3 TECHNICAL DATA Princo SmartSonic for Free-Flowing Solids 3.1 Data of SmartSonic for SOLIDS General data Product name Sensor material Housing material Process temperature Ambient temperature Pressure (Absolute.) SmartSonic L4660-STD/SBD series Closed cell Polyurethane foam sensor face (PUR), Polypropylene sensor housing, Aluminum mounting accessories Epoxy powder coated Aluminum -22ºF to 167ºF (-30 C to +75 C) Mechanical protection Sensor: IP65 (NEMA 5) -22ºF to 140ºF (-30 C to +60 C); with SAP-100 programming module: 13ºF to 140ºF (-25 C to +60 C) 0.7 to 1.1 bar (10.15 to psi) and ± 0.1 bar (1.45 psi) difference between outside and internal silo space Housing: IP67 (NEMA 4X) Power supply / Consumption Version I: 120 to 375 Vdc / 5.5 W 85 to 255 Vac (50/60 Hz) / 6.8 VA Accuracy* Resolution Outputs Electrical protection Version II: 10.5 to 40 Vdc / 4.1 W 10.5 to 28 Vac (50/60 Hz) / 4.6 VA ± (0.2% of the measured distance plus 0.1% of the maximum measuring distance of the device) 0.5 (10 mm) Analog: 4 to 20 ma, max. 600 Ohm, galvanically isolated, overvoltage protection Relay: SPDT, 250 V ac / 3 A, AC1 Display (SAP-100): 6 digits, icons and bargraph, Custom LCD Digital communication: HART Class I Electrical connections 2 x Pg16 and 2 x ½ NPT Wire cross section: 0.5 to 2.5 mm 2 (20 AWG to 13 AWG) * Under optimal circumstances of reflection and stabilized transducer temperature. TYPE SPECIFIC DATA Type STD-33J STD-31J, STD-31X Maximum measuring distance* (m/feet) 30 / / 197 Minimum measuring distance* (m/feet) 0.6 / 2 1 / 3.33 Total beam angle (at -3dB) 5 Measuring frequency 30 khz 15 khz Weight 15 lbs. (7 kg) 22 lbs. (10 kg) * taken from the transducer face SAP-100 Programming Module Field indication 6 digits custom LCD with icons, engineering units and bargraph, programming keys Ambient temperature 13ºF to 140ºF (-25 C to +60 C) Housing material PBT fiber-glass reinforced plastic, flame-retardant (DuPont ) SmartSonic for Free-Flowing Solids Instruction Manual Page 4 of 27 Pages Rev 1, 31 Aug 07

7 Dimensions (in inches / mm) of SmartSonics for solids Ball-joint housing (view from above) L4660-S D-33J- L4660-S D-31J SFA-3D5 Split Flange 3.2 Accessories Instruction Manual 2 x Pg16 cable glands 4 INSTALLATION 4.1 Mechanical Installation Split flange, order code: SFA-3 5 (optional) SAP-100 Display Module (optional) Eview Light software, CD-ROM (HART units only) 3.3 Maintenance and Repair The SmartSonic series does not require maintenance on a regular basis. Repairs during or after the warranty period are carried out exclusively by the manufacturer. The equipment sent back for repairs should be cleaned or neutralized (disinfected) by the user Positioning When selecting optimal location for the transmitter various considerations should be made. If the measured material is granular (material size > 5 mm) and the tank roof is dome shaped or conical, do not install the transmitter in the center of the tank/silo. In general the transmitter can be installed on the radius r= (0.3 to 0.5) R. Avoid having the 5 conical beam angle of the transmitter contact the tank/silo wall. In case the transmitter is mounted close to the wall, it should be tilted (See section Aiming). Protect the transmitter electronics from overheating due to direct sunshine. SmartSonic for Free-Flowing Solids Instruction Manual Page 5 of 27 Pages Rev 1, 31 Aug 07

8 Sunshade Gravity Filling r R Select a location that is as far away from the filling point(s) as possible Pneumatic Filling Select a location where the speed of the in-flowing material is the smallest Mounting Suggested location (view from above) 40 m 3,8 m 50 m 4,7 m (See Illustration for Mounting below) The SmartSonic consists of a sensor that is attached to the aiming arm (a pipe with a ball-joint housing and ball joint) that is attached to the housing of the electronics. It is recommended to mount the transmitter on the roof of the tank/silo using a flange (see drawing). The ball-joint housing has a screw hole diameter of 125 mm for fastening it. For easy installation, we recommend using our special flange with a split insertion, available with four sizes of DN125/150/200/300 (to be ordered separately). Removing the split insertion, the flange is placed around the aiming arm and the ball-joint housing is fastened to the split flange after re-inserting the insert. It is essential to use the washers and the bolts (4 each) delivered with the split flange. The ball-joint is pressed against the housing by a spring allowing adjustment and aiming. The 4 M12 bolts only have to be tightened after completing the adjustment/aiming. Mounting SmartSonic versions L4660-S -33J 1. Check the split flange for matching the boreholes with those of the counter-flange on the silo. 2. Remove the split insertion from the flange and put the flange around the aiming arm between the sensor and the aluminum base. 3. Slide the split insertion back to its place and screw the ball-joint housing to the flange with the 4 bolts in a way that will allow free movement of the aiming arm ball joint. 4. Pass the sensor through the opening cut on the roof and fasten the flange in place. 5. Perform the aiming (See section Aiming below). 6. Fix the position of the aiming arm by tightening the 4 bolts of the ball-joint housing (max. 3.5 Nm). Mounting SmartSonic L4660-S D-31 versions, with silo/tank roof opening of (300 mm) The procedure is the same as above but the flange diameter is 12. Mounting SmartSonic S D -31 version with silo/tank roof opening less than (300 mm) and the silo space is accessible from inside 1. Check the split flange for matching the boreholes with those of the bolt places or counter-flange on the silo. 2. Place the sealing below the flange (if necessary). 3. Push the unit out of the silo (upwards). (See on the next page.) 4. With the ball-joint over the counter-flange, place the special flange around the aiming arm. (See on the next page.) 5. Place the split flange on the counter-flange and lower the balljoint housing onto it. 6. Slide the insertion into its place. (See on the next page.) 7. Screw in the 4 bolts (see on the next page) to such an extent as will allow free aiming. 8. After completing aiming, tighten the 4 bolts (max. 3.5 Nm). If the entire tilting range of the aiming arm is required, the thickness of the roof cannot exceed specifications in the table below. The SmartSonic can also be mounted on existing (manhole) covers, access lids or on a steel structure lowered into a larger (ex.: 0.5 x 0.5 m) opening on the roof. This solution is to be used with roof thicker than 350 to 380 mm. SmartSonic for Free-Flowing Solids Instruction Manual Page 6 of 27 Pages Rev 1, 31 Aug 07

9 Diameter of the opening D (inches / mm) Thickness of the roof V (inches / mm) 6.3 / / / / / / / / / / Wind Effects Intensive air (gas) movements near the ultrasonic cone should be avoided. A strong draft of wind may "blow away" the ultrasound. Devices with lower measuring frequency are recommended where airflow is a factor. 4.2 Electrical Connections See diagrams below. To access the wiring terminals, loosen the screw on the side of the unit and lift the hinged cover. The 4 to 20 ma signal cable, the power supply cable, and the output relay cable must be separated by shielding. The unit may be grounded either by using the grounding screw terminal on the outside of the housing, or when using a three-wire power cable, connecting the ground wire to the internal grounding screw terminal. Illustration for mounting Aiming of the SmartSonic Weak signal reflection from the material surface may occur because of an angle of repose due to the filling and/or emptying process. It may be compensated for by aiming the sensor by means of the aiming arm. Aiming is best carried out during operation, when the tank/silo is almost empty. In most cases, the sensor should be aimed towards the middle of the tank/silo bottom by aiming at the silo outlet. In applications where repose is not present, or with tall and narrow silos (diameter/height 5), aiming is not critical: the sensor should face straight downward. Aiming is also aided by the informational parameters P70 to P75. Using these parameters one can ensure that the unit is focused on the correct echo and maximize the amplitude of that echo by aiming the unit while monitoring the parameters. Aiming should also be tested with full silo, since due to the great angle of repose the echo might be weak despite of the fact that level is near the sensor. In such cases a reasonable compromise of aiming should be achieved that provides acceptable echo in every state of the filling. Thread wires through the ½ NPT or Pg16 conduit openings and fasten to appropriate terminal block connections per drawing below for AC or DC powered unit as applicable. Three-wire installation is also possible for the 24 V DC versions by connecting the terminals 1 and 6. In this case, the galvanic isolation is not provided. The unit may be damaged by electrostatic discharge (ESD), via terminals. Thus, apply the precautions commonly used to avoid electrostatic discharge. SmartSonic for Free-Flowing Solids Instruction Manual Page 7 of 27 Pages Rev 1, 31 Aug 07

10 5 PROGRAMMING The SmartSonic is delivered with the following Factory Default settings: Current output, display and bargraph: LEVEL 4 ma: assigned to the minimum (0%) level 20 ma: assigned to the maximum (100%) level Error indication by the current output: hold last value Damping: 60 sec for liquids, 300 sec for solids Wiring Connections for 85 to 255 Vac Units The SmartSonic is programmed using the SAP-100 programming module (see section 5.1). All features of the device can be set, such as measurement configuration and optimization, relay programming, 32-point linearization and dimensions for 6 tanks with different shapes. Units equipped with HART communication protocol may also be programmed using Eview HART configuration software. Refer to the Princo Programming Instruction Manual for Eview and Eview Light software which is used in conjunction with the Parameters defined in Section 6 of this manual. The SmartSonic is fully operational without the SAP-100. The SAP-100 is only needed for programming and/or displaying measurement and informational values. If the transmitter is left in Programming Mode by mistake, it will automatically return to Measurement Mode after 30 minutes and will operate with the parameters entered during the last completed programming. 5.1 Programming of the SmartSonic with the SAP-100 Programming Module The SAP-100 supports 3 separately accessible programming modes representing 3-layers of programming complexity, depending on user choice. PLUG-IN PROGRAMMER Current Output Scaling QUICKSET Full Parameter Access Wiring Connections for 10.5 to 40Vdc Units Current Output Scaling (5.1.4) Recommended as a simple and fast way to modify the scaling of the current output (relative to current settings for level). QUICKSET (5.1.5) Recommended as a simple and fast way to set up the SmartSonic using 8 basic parameters. This menu driven programming mode supports the following basic settings: SmartSonic for Free-Flowing Solids Instruction Manual Page 8 of 27 Pages Rev 1, 31 Aug 07

11 Engineering units for the display (Metric or US) Maximum measuring distance Assignment of minimum level to 4mA Assignment of maximum level to 20mA Error indication by the current output Damping time Assignment of level for energizing of the relay Princo SmartSonic for Free-Flowing Solids Assignment of level for de-energizing of the relay Full Parameter Access (5.1.6) All features of the SmartSonic can be accessed by parameter addresses: Example: Measurement configuration Outputs Measurement optimization Pre-programmed tank shapes for volume calculation 32-point linearization table The SAP-100 Display and Keys The plug in programming and display module is used for programming and also as a readout display. ENTER UP NEXT DOWN COM ECHO RELAY Symbols used on the LCD: DIST Distance (measuring) mode LEV Level (measuring) mode VOL Volume (measuring) mode PROG - Programming mode (device under programming) RELAY Relay FAIL - Measurement / device error - Level changing direction Bargraph assigned to the current output or echo strength Symbols used on the frame: M Metric system US US calculation system ft 3 / m3 cubic feet / cubic meters ft / m feet / meters in / cm inches / centimeters gal / l gallons / liters ºF - degrees Fahrenheit sec seconds min minutes hour hours day - days SmartSonic for Free-Flowing Solids Instruction Manual Page 9 of 27 Pages Rev 1, 31 Aug 07

12 5.1.2 Programming with the SAP-100 Programming Module Programming will be performed by pressing one or two keys (simultaneously). Single key pressing: E Press ENTER to save parameter address and go to parameter value to return from parameter value to parameter address. Press NEXT to move the blinking of the digit to the left. Press UP to increase value of the blinking digit. Press DOWN to decrease value of the blinking digit. Double key pressing: (Short overview, for details see in 5.1.4, and 5.1.6) Press the two keys simultaneously for desired programming step. Notes: If the parameter value is not accessible i.e. the parameter address keeps blinking after pressing ENTER E : the parameter is either a read-out type, or the secret code prevents the modification (see P99). If the modification of the parameter value is not accepted, i.e. the parameter value keeps blinking after pressing ENTER E : the modified value is either out of the range, or the code entered is not valid for this parameter Enter into or quit programming modes Basic steps while parameter address is blinking Basic steps while parameter value is blinking E Full Parameter Access Current output scaling Quickset E Cancel all modifications ** Return to default* Default Parameter value E Cancel all modifications return to parameter address* Display default value Actual Parameter value * LOAD will be displayed ** CANCEL will be displayed * cancellation immediately active Indications of the SAP-100 Programming Module and the LEDs ENTER UP NEXT DOWN COM ECHO RELAY Field indication Depending on the measuring mode (see P01 in Chapter 6.1), the following values can be displayed (relevant symbol is lit): Distance Level Volume Error code (if FAIL is blinking) To scroll through the displays above press NEXT repeatedly. To display transducer temperature, press UP : ( C/ F) To display current output value, press DOWN : (ma) LED indications: ECHO LED LED is lit as long as the device receives a valid echo signal RELAY LED LED is lit when relay is energized COM LED LED is lit during communication (Remote control) SmartSonic for Free-Flowing Solids Instruction Manual Page 10 of 27 Pages Rev 1, 31 Aug 07

13 5.1.4 Current Output Scaling This programming mode is the simple and fast way to modify the scaling of the current output (relative to current settings for level). For changing all parameters other than those assigned to 4 and 20 ma use either the QUICKSET (5.1.5). or the Full Parameter Access (5.1.6). Current Output Scaling mode is useful for re-scaling, i.e. for modifying, of the minimum and maximum level assigned to the 4 and 20 ma output signals, if other than the factory default. Current Output Scaling uses 2 screens for setting. The instructions for this programming can also be found below the screw cover on the front panel of the SmartSonic. Note: For this programming the SmartSonic has to be in level measurement mode. See chapter 6.1 (P01). Keys Function ENTER E + UP (press for 3 seconds) Enter or exit Current Output Scaling programming mode UP / DOWN Increase/decrease blinking digit or scroll up/down NEXT Move left with the blinking digit UP + DOWN "GET LEVEL" - display actual level value measured by the SmartSonic ENTER E Save actual value on the screen and move to the next screen NEXT + UP Quit Current Output Scaling without saving the modifications NEXT + DOWN Display Factory Default of the relevant screen 4:xxxx Screens 4 represents the output signal x = level value to be assigned 20:xxxx 20 represents the output signal x = level value to be assigned Actions 4 ma xxxx: level value assigned to 4 ma current output Manual: set required value (by UP / DOWN / NEXT keys) and save it (by the key ENTER E ) Automatic: use the GET LEVEL function (UP + DOWN ) to obtain actual measured value with level in tank or a fix target, e.g. wall. ( GET LEVEL functions only if ECHO LED is lit) and save it as above. DEFAULT: 0 m (0%, Empty tank) 20 ma xxxx: Level value assigned to 20 ma current output Manual: set required value (by UP / DOWN / NEXT keys) and save it (by the key ENTER E ) Automatic: use the GET LEVEL function (UP + DOWN ) to obtain actual measured value with level in tank or a fix target, e.g. wall. ( GET LEVEL functions only if ECHO LED is lit) and save it as above. DEFAULT: max. level = max. measuring distance - dead band (100%, Full tank) See chapter 5.1 (P04, P05) QUICKSET Recommended as a simple and fast way to start up SmartSonic. QUICKSET programming mode has 8 screens used to set the 8 basic parameters of the device. It is used for simple level metering applications only. Recommended for liquids only. The instructions for this programming mode are also to be found below the screw cover on the front panel of the SmartSonic. The DEFAULT of the Current output, Display and Bargraph is LEVEL. This can be modified only in the Full Parameter Access mode see 6.1 (P01). SmartSonic for Free-Flowing Solids Instruction Manual Page 11 of 27 Pages Rev 1, 31 Aug 07

14 Keys Function ENTER E + DOWN (press for 3 seconds) Enter or exit QUICKSET programming mode UP / DOWN Increase / decrease blinking digit or scroll up / down NEXT Move left with the blinking digit UP + DOWN "GET LEVEL" - display actual level measured by SmartSonic ENTER E Save value on the screen and move to the next screen NEXT + UP Quit QUICKSET programming mode without saving the modifications NEXT + DOWN Display Factory Default of the relevant screen Screens AP:xxyy H:xxxx 4:xxxx 20:xxxx Er:xxxx dt: xxxx re:xxxx Actions APplication xx= select EU (European) for metric or US for US engineering units (Use UP / DOWN keys) yy= indicating Li for liquids or So for solids level measurement (can not be changed). DEFAULT: US H = xxxx maximum measuring distance Distance between transducer face and tank/silo bottom Manual: set value (Use UP / DOWN / NEXT keys) and save it (by ENTER E ) Automatic: use the GET LEVEL function (UP + DOWN ) to obtain actual measured value with level in tank or a fixed target, i.e. wall. ( GET LEVEL functions only if ECHO LED is lit) and save it as above. DEFAULT: maximum measuring distance [m], see Technical Data Table 4 ma xxxx level value assigned to 4 ma current output Manual: set level value (by UP / DOWN / NEXT keys) and save it (by ENTER E ) Automatic: use the GET LEVEL function (UP + DOWN ) to display the actual measured value with level in tank or a fix target, i.e. wall. ( GET LEVEL functions only if ECHO LED is lit) and save it as above. DEFAULT: 0 m (0%, Empty tank) 20 ma xxxx level value assigned to 20 ma current output Manual: set level value (Use UP / DOWN / NEXT keys) and save it (by ENTER E ) Automatic: use the GET LEVEL function (UP + DOWN ) to obtain actual measured value with level in tank or a fixed target, i.e. wall. ( GET LEVEL functions only if ECHO LED is lit) and save it as above. DEFAULT: max. level = max. measuring distance dead band [m] (100%, Full tank) (See Technical Data Table) Error indication by the current output Select Hold, 3.6 ma or 22 ma (by UP / DOWN key) and save it as above. DEFAULT: hold last value (HOLD) damping time Select required damping time (by UP / DOWN key) and save it as above. DEFAULT: 300 sec relay Energized xxxx: level of the relay energized state If the value exceeds this programmed value the relay will be energized. rd : xxxx relay de-energized xxxx: level of the relay de-energized state If the value sinks below this programmed value the relay will be de-energized. Note: Current output can also be programmed for inverted operation: 4 ma= 100% (Full), 20 ma= 0% (Empty) SmartSonic for Free-Flowing Solids Instruction Manual Page 12 of 27 Pages Rev 1, 31 Aug 07

15 5.1.6 Full Parameter Access To access all features provided by the SmartSonic. Description of all parameters can be found in section 6. Keys ENTER E + NEXT (press for 3 seconds) Function Enter or exit Full Parameter Access programming mode. In this programming mode, the display will indicate: yy is the Parameter Address yy:xxxx xxxx is the Parameter Value Note: Measuring is going on during programming in accordance with the old parameter set. The new parameter set will be valid after returning to the measurement mode from the programming mode. Steps and indications of the Full Parameter Access programming mode pressing Keys while Parameter Address is blinking while Parameter Value is blinking ENTER E Go to the Parameter Value Save the modification of the Parameter Value and return to the Parameter Address NEXT + UP Cancel all modifications of the actual programming phase. Pressing for 3 secs is required while CANCEL will be displayed for warning. NEXT + DOWN Reset entire device to Factory Default. Since this action will reset all parameters, LOAD will appear on the display: - to confirm, press ENTER - to escape, press any other key NEXT Move blinking of the digit to the left UP / DOWN Modify the blinking digit (increase, decrease) or scroll up/down Neglect the modification of the Parameter Value. and return to the Parameter Address without saving the modifications Display default of the Parameter Values (it can be saved by pressing ENTER E ) SmartSonic for Free-Flowing Solids Instruction Manual Page 13 of 27 Pages Rev 1, 31 Aug 07

16 6 PARAMETERS DESCRIPTIONS AND PROGRAMMING 6.1 Measurement Configuration P00: - cba Application/Engineering Units Programming of this parameter will result in loading the factory default with the corresponding engineering units. a Operating (measurement) mode Display indication 0 Liquid level measurement Li 1 Free flowing solids level measurement So Engineering units b (according to c ) Metric US 0 m ft 1 cm inch Attention: mind the sequence! When programming this parameter the right value a will be blinking first. Examples: 110 US, inches, liquid 000 metric, meters, liquid c Calculation system 0 Metric 1 US FACTORY DEFAULT: 101 P01: - ba Measurement Mode, Bargraph Parameter value a will determine the basic measurement value that will be displayed proportional with the current output. Depending on the value of a, process values as listed in the 4th column (Displayed values) can also be displayed by pressing NEXT. To return to the display of the basic value the ENTER E key should be pressed. a Measurement Mode Display symbol Displayed values 0 Distance DIST Distance 1 Level LEV Level, Distance 2 Level in percentage LEV% Level%, Level, Distance 3 Volume VOL Volume, Level, Distance 4 Volume in percentage VOL% Volume%, Volume, Level, Distance Attention: mind the sequence! When programming this parameter the right value a will be blinking first. Parameter value b will determine whether the height of the bargraph will be proportional to the current output or to the echo strength. b Bargraph indication 0 Echo strength 1 Current output FACTORY DEFAULT: 11 P02: - cba Calculation units a Temperature Attention: mind the sequence! 0 C When programming this parameter the right 1 F value a will be blinking first. This table is interpreted according to P00(c), P01(a) & P02(c) and is irrelevant in case of percentage measurement ( P01(a)= 2 or 4 ). b Volume Weight (set also P32) Metric US Metric US 0 m 3 ft 3 - lb (pound) 1 liter gallons tons tons c Time 0 Sec 1 Min 2 Hour 3 Day FACTORY DEFAULT: 101 SmartSonic for Free-Flowing Solids Instruction Manual Page 14 of 27 Pages Rev 1, 31 Aug 07

17 P03: a Values Displayed-Rounding Princo SmartSonic for Free-Flowing Solids It is important to keep in mind that the instrument is measuring distance as basic quantity. Measured distance X min 2m Resolution 1mm 2m 5m 2mm 5m 10m 5mm over 10m 10mm Displayed VOL Displayed value Displayed form x.xxx xx.xx xxxx xxxxx xxxxxx. x.xxxx : e 1 million *10 9 (exponential form) over 1*10 10 (overflow) Err4 Rounding Parameter value a Steps in the displayed value 0 1 no rounding The resolution depending on the distance can be considered as a kind of rounding that will be contained in all further values (of level or volume) calculated. Therefore if programmed for DIST or LEV measurement the setting of P03 is irrelevant. Obviously the decimal position will be shifted with increasing value displayed. (See table at the left). Values over one million will be displayed in exponential format where the value e represents the exponent. Over the value of 1x10 10 Err4 (overflow) will be displayed. A couple of millimeters of fluctuation of the basic DIST value (e.g. due to waves) will be enlarged by the mathematical operations. This enlarged fluctuation in displaying VOL can (if disturbing) be avoided by rounding to be set in P03. Rounding value 2, 5, 10 etc represents the steps by which the calculated value will be changed in its (one or two) last digit(s). Examples: P03=1 steps by 2: 1,000; 1,002; 1,004 P03=5 steps by 50: 1,000; 1,050; 1,100 or 10,00; 10,05(0); 10,10(0); 10,15(0) (the 0 from the steps 50, 100, 150 etc will not be displayed) FACTORY DEFAULT: 0 P04: Maximum measuring distance The maximum distance to be measured is the greatest distance between the surface of the transducer and the level to be measured. This is the only parameter that has to be programmed for each application other than distance. (However, to avoid the disturbing effects of possible multiple echoes, it is recommended to do this for distance measurement applications also.) Values of the maximum measuring distance will be displayed as below. The DEFAULT value of P04 (see table below) can also be displayed by double key pressing NEXT + DOWN. Engineering Unit Display Format m x.xxx or xx.xx cm xxx.x ft xx.xx or xxx.x inch xxx.x The factory programmed DEFAULT values the greatest distances which can be measured by the units - are listed in the table below. For the actual application, the maximum distance to be measured, i.e. the distance between the sensor and the bottom of the tank, should be entered in P04. To obtain the best accuracy, measure this distance in the empty tank with the SmartSonic by using the GET LEVEL function (by double key pressing of UP + DOWN ), provided the bottom is flat. Enter the actual measured value displayed as P04. SmartSonic Maximum measuring distance [m/ft] STD-33J 30 / 100 STD-31J 60 / 197 STD-31X 60 / 197 Keep in mind that LEVEL (as the result of the measurement) = P04 (programmed) DISTANCE (measured by the device) SmartSonic for Free-Flowing Solids Instruction Manual Page 15 of 27 Pages Rev 1, 31 Aug 07

18 The accuracy of level and all further calculated values depend on the accuracy of the maximum measuring distance of the application which is the distance between the sensor face and the tank / silo bottom. FACTORY DEFAULT: Maximum Measuring Distance per above table P05: Minimum measuring distance (Close-end blocking) The SmartSonic will not accept any echo within the blocking distance set here. Automatic Close-end-blocking (Automatic Dead Band control) By using the factory default value, the unit will automatically set the smallest possible close-end-blocking distance, i.e. the dead band. Manual close-end-blocking Manual close-end-blocking would be used, for example, to block out the echo originating from the bottom rim of a stand-off pipe or from any object protruding into the ultrasonic cone near the transmitter. By entering a value higher than the factory default, the minimum measuring range will be extended and fixed to the specified value. To display factory default of the minimum measuring distance press NEXT + DOWN. SmartSonic Minimum measuring distance [m/ft] STD-33J 0.6 / 2 STD-31J 1 / 3.33 STD-31X 1 / 3.33 FACTORY DEFAULT: automatic dead band control per above table P06: Far-end blocking Far end blocking is used to ignore incorrect level/volume readings and output actions below a pre-set level programmed into P06. Level measurement The far-end blocking can be used to avoid disturbing effects of stirrer or heaters at the bottom of the tanks. ma 20 ma 4 ma If the level of the medium sinks below the blocked out range: - Sub 0 will be indicated for the level and volume. - Distance value is not interpretable. - Current output will hold the value corresponding to the far end blocking level. Level Volume "SUB 0" indication below this level P06 Far end blocking If the medium level is above the blocked out range: The calculation of level and volume will be based on the programmed tank dimensions. Therefore, the measured or calculated process values will not be influenced in any way by the far end blocking value. FACTORY DEFAULT: 0 SmartSonic for Free-Flowing Solids Instruction Manual Page 16 of 27 Pages Rev 1, 31 Aug 07

19 6.2 Current Output P10: Value (of distance, level, volume or flow) assigned to 4 ma current output P11: Value (of distance, level, volume or flow) assigned to 20 ma current output Values are interpreted according to P01(a) and P02 (b & c). Level or Volume %: Please note that in case of programming for (LEV or VOL) % measurement, the min and max values have to be entered in the relevant engineering units of LEV (m, ft) or VOL (m 3, ft 3 ). Maximum Value: The largest number that can be entered into these parameters is Certain volume applications may exceed this value. Therefore, it may be necessary to convert the value to a workable unit of measure. For example, it may be necessary to convert gallons to cubic feet, or to convert liters to cubic meters in order to have a value of 9999 or less. This will require also making the equivalent change in P02. Inverse Proportion: Assignment can be made such that the relationship between the change of the (measured or calculated) process values and the change of the current output will be either direct or inverse. E.g., level of 1 m assigned to 4 ma and level of 10 m assigned to 20 ma represents direct proportion and level of 1 m assigned to 20 ma and level of 10 m assigned to 4 ma represents the inverse proportion. FACTORY DEFAULT: P10 0 level (max distance) P11 max level (min distance) H P12: a Error indication by the current output In case of error, the SmartSonic will provide one of the current outputs below. (For errors and their interpretation, see Chapter 7). This parameter may be set to meet the alarm needs of the particular application. a ERROR INDICATION 0 Hold last value ma 2 22 ma FACTORY DEFAULT: Relay Output P13: a Relay function a Relay function Also set: 0 DIFFERENTIAL LEVEL CONTROL (Hysteresis control) Relay is energized if the measured or calculated value exceeds the value set in P14 Relay is de-energized if the measured or calculated value descends under the value set in P15 Level Relay P14 P15 Time Energised: De-energised: P14, P15 There is a need to set (in level min 20mm) hysteresis between P14 and P15 1 Relay is energized in case of Echo Loss - 2 Relay is de-energized in case of Echo Loss - FACTORY DEFAULT: 2 P14: Relay parameter Setpoint value FACTORY DEFAULT: 0 P15: Relay parameter Setpoint value FACTORY DEFAULT: 0 P19: Short HART Address For HART units only. This is the polling address for HART communications. For multi-drop networks, may be set for 1 through 15. For point-to-point operation, set to 0. FACTORY DEFAULT: 0 SmartSonic for Free-Flowing Solids Instruction Manual Page 17 of 27 Pages Rev 1, 31 Aug 07

20 6.4 Measurement Optimization Princo SmartSonic for Free-Flowing Solids P20: a Damping Use this parameter to reduce unwanted fluctuation of the display and output. a Damping time (seconds) FREE FLOWING SOLIDS Granules: >2-3 mm Powders: < 2-3 mm 0 no filter Recommended for testing only 1 3 not recommended not recommended 2 6 not recommended not recommended 3 10 not recommended not recommended 4 30 applicable not recommended 5 60 recommended applicable recommended recommended recommended recommended recommended recommended applicable applicable FACTORY DEFAULT: 300 sec P22: a Dome top tank compensation To reduce disturbing effect of possible multiple echoes. a Compensation Applied 0 OFF In case the SmartSonic is mounted not in the center of the top and the top is flat. 1 ON In case the SmartSonic is mounted in the center of a tank with dome-shaped top FACTORY DEFAULT: 0 P23: a Angle of repose (repose formation) only for free flowing solids applications This parameter provides information for the QUEST+ software for optimizing the echo-search pattern. a Estimated angle of repose 0 No angle of repose (default) 1 Below 15 (α) 2 Over 15 (α) The optimal setting of this parameter can be achieved by monitoring parameter P72. Parameter P72 indicates the echo amplitude in db. The ideal setting of P23 is that at which the parameter value in P72 becomes the best (nearest 0). 1). Set P23 for a= 1, confirm it with [E] and switch to Measurement Mode then return to Programming Mode. 2). Observe the change of echo amplitude in P72 and record an average value. 3). Perform the above with the P23 = 2 setting. 4). Finally set P23 with the value of (a) at which the amplitude value in P72 is nearest to 0. FACTORY DEFAULT: 0 SmartSonic for Free-Flowing Solids Instruction Manual Page 18 of 27 Pages Rev 1, 31 Aug 07

21 P24: a Target tracking speed Princo SmartSonic for Free-Flowing Solids a Tracking speed Remark 0 Standard For most applications 1 Fast For fast changing level 2 Special Only for special applications (measuring range is reduced to 50% of the nominal value). The measuring window is inactive and the SmartSonic will respond practically instantly to any target. Recommended to fast target tracking, but usually not applicable for level metering. FACTORY DEFAULT: 0 P25: a Selection of Echo within the measuring window A so-called measuring window is formed around the echo signal. The position of this measuring window determines the flight time for calculation of the distance of the target. (The picture below can be seen on a test oscilloscope.) Received signal amplitude Echo 1. Echo 2. "t" ultrasound flight time t Some applications involve multiple (target + disturbing) echoes even within the measuring window. Basic echo selection will be done by the Quest + software automatically. This parameter only influences the echo selection within the measuring window. a Echo in the window to be Remark selected 0 With the highest amplitude For most applications (both with liquids and solids) 1 First one For liquids applications with multiple echoes within the Measuring Window 2 Largest one Recommended for certain free flowing solids applications FACTORY DEFAULT: 0 P26: Level elevation rate (filling speed - m/hour or ft/hour depending on P00(c)) Very heavy fuming P27: Level descent rate (emptying speed - m/hour or ft/hour depending on P00(c)) Very heavy fuming These parameters provide additional protection against echo loss in applications involving dust during the filling process (powders, dusting granules.) Reliability of the measurement can be enhanced by correct setting of this parameter. The parameters must not be smaller than the fastest possible filling/emptying rate of the actual technology. For all other applications, use the factory default setting. FACTORY DEFAULT: 500m/h or 1640ft/h for both P26 and P27 SmartSonic for Free-Flowing Solids Instruction Manual Page 19 of 27 Pages Rev 1, 31 Aug 07

22 P a Echo-loss handling a Echo-loss error indication Remark 0 Delayed During echo-loss, display and analog output will hold last value. If the echo-loss prevails for twice the time period set in P20 (damping time), the reading on the display will change to "no Echo" and the outputs will change according to the "Error Indication Mode" preset in P12. 1 None For the time of echo-loss, display and analog output will hold last value. 2 Advance to full During echo-loss in case of filling, the reading on the display and analog output will shift towards the "full" tank/silo state with a level elevation rate (filling speed) preset in P26 3 Immediate In case of echo-loss, the display will immediately change to no Echo and the outputs will change according to the "Error Indication Mode" preset in P12. 4 No echo-loss indication in case of empty tank/silo Echo-loss may occur in completely empty tanks with a spherical bottom due to deflection of the ultrasonic beam, or in case of silos with an open outlet. If the echo is lost when the tank/silo is completely empty, the indication will correspond to empty tank. In all other cases echo-loss indication will function according to the Delayed. FACTORY DEFAULT: 0 P29 Blocking out of object #1 P30 Blocking out of object #2 Up to two fixed objects in the tank/silo that disturb the measurement can be blocked out. Enter the distance of the object from the transducer. Use the Echo Map (P70) to read out the precise distance of disturbing objects. FACTORY DEFAULT: 0 P31: Sound velocity at 20 C (m/sec or ft/sec depending on P00(c) ) Use this parameter if the sound velocity in the gases above the measured surface differs largely from that of in air. Recommended for applications where the gas is more or less homogeneous. If it is not, the accuracy of the measurement can be improved using the 32-point linearization (P48, P49). For sound velocities in various gases see section 8, Sound Velocities. FACTORY DEFAULT: m/s or 1128 ft/s depending on P00(c) P32: Weight If you enter a value (other than 0 ) in this parameter, the weight will be displayed instead of VOL. In order to display weight instead of volume, enter the weight per unit volume of the process material. The units of volume, as defined by P00 and P02, must be either m 3 or ft 3. Thus the number entered must be in either kg/m 3 or lb/ft 3. The volume will be multiplied by the value entered. This parameter will not function when the units are set to read gallons or liters. FACTORY DEFAULT: 0 [kg/m 3 ] or [lb/ft 3 ] depending on P00(c) and P02(b) must be set to 0. SmartSonic for Free-Flowing Solids Instruction Manual Page 20 of 27 Pages Rev 1, 31 Aug 07

23 P33: Manual echo selection by moving the Measuring Window A so-called measuring window is formed around the echo signal. The distance of the target will be calculated from the flight time in accordance with the position of the measuring window. Use this parameter if the SmartSonic unambiguously selects a wrong echo; for example the echo reflected from the surface is much weaker than the interfering one(s) (see figure beside). Enter the distance of the correct echo and the software will move the measuring window and calibrate itself to the echo found there. To determine the distance of the correct echo, either use the Echo Map (to load-in a value from the Echo Map, see parameter P70), or measure the distance with an appropriate device, and enter this value in P If this parameter has been used (P33 is not 0), its value will be continuously updated with the valid echo position. This means, that in case of a power loss, the SmartSonic will restart the signal processing with the measuring window at the last updated position. To switch-off this function, set P33= 0. FACTORY DEFAULT: 0 Received signal amplitude (flight time) Window signal (comp.) (locked on the disturbing echo) Displayed DIST value (of the disturbing echo) 5.2 Window signal (comp.) Setting: P33=4.00 (results in shifting the measuring window to 4m) Window signal (comp.) Measuring Window finds the echo from the surface Displayed DIST The value is correct SmartSonic for Free-Flowing Solids Instruction Manual Page 21 of 27 Pages Rev 1, 31 Aug 07