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1. Trip Type Explanation ZERO BEGIN END Type 0 On Of o Off Near Type 1 lt E gt lt emi s on Exclusive am Off Off Type 2 ian On m ES Hysteresis Near E End Type 3 i gt lt ca 2i Far Type 4 Off a On lt lt Off Inclusive On On peu Off Of Hysteresis Far ee Type 6 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 NOTE The Zero line represents the face of the sensor when operating in Distance mode and the bottom of the tank when indicating volume or level NOTE TRIP END should always be a larger value than TRIP BEGIN Automation Products Group Inc APG APG Providing tailored solutions for measurement applications Tel 1 888 525 7300 Fax 1 435 753 7490 www apgsensors com sales apgsensors com 17 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 To program the DCR 1005 and DCR 1006 for this application the following modes must be set MODE VALU
2. 1 mode 3 Default 2 9 ft Range 0 7 Default 0 See Trip Type Explanation for details 15 Begin Trip 2 16 End Trip 2 17 Trip 2 Type Units mode 1 mode 3 Default 3 ft Units mode 1 mode 3 Default 3 4 ft Range 0 7 Default 0 See Trip Type Explanation for details 18 Begin Trip 3 I9 End Trip 3 20 Trip 3 Type Units mode 1 mode 3 Default 3 50 ft Units mode 1 mode 3 Default 3 90 ft Range 0 7 Default 0 See Trip Type Explanation for details 21 Begin Trip 4 22 End Trip 4 23 Trip 4 Type Units mode 1 mode 3 Default 4 0 ft Units mode 1 mode 3 Default 4 40 ft Range 0 7 Default 0 See Trip Type Explanation for details EXPLANATION Sets the begin point of Trip 1 Sets the end point of Trip 1 Selects the type of function Trip 1 will perform Sets the begin point of Trip 2 Sets the end point of of Trip 2 Selects the type of function Trip 2 will perform Sets the begin point of Trip 3 Sets the end point of Trip 3 Selects the type of function Trip 3 will perform Sets the begin point of Trip 4 Sets the end point of of Trip 4 Selects the type of function Trip 4 will perform Automation Products Group Inc APG Providing tailored solutions for measurement applications 16 Tel 1 888 525 7300 Fax 1 435 753 7490 www apgsensors com sales apgsensors com Rev A4 10 08 DCR 1005 and DCR 1006
3. Keep this in mind when referring to the diagram below Remember that this circuit is Loop Powered Power must be supplied to the 4 20 mA terminal for this feature to operate Current sourcing 4 to 20 ma output Isolated 4 to 20 ma output External Power Source C 4 20 ma output Analog Ground MODE DESCRIPTION PARAMETERS EXPLANATION 24 4maA distance Units mode 1 Sets the minimum value Default 3 00 ft of the analog output slope 23 20 mA distance Units mode 1 Sets the maximum value Default 4 00 ft of the analog output slope 260 4mA calibration Approx 5000 Fine tunes the minimum current sourced on the analog output 27 20 mA calibration Approx 5000 Fine tunes the maximum current sourced on the analog output a 20 mA 7 20 mA 4 mA Zero Point 20 mA 4 mA Max Distance Zero Point 4 mA 20 mA Max Distance Distance Distance Distance Distance HN APG Automation Products Group Inc E Eo APG Providing tailored solutions for measurement applications 20 Tel 1 888 525 7300 Fax 1 435 753 7490 www apgsensors com sales apgsensors com 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 dista
4. Products Group Inc APG Providing tailored solutions for measurement applications 26 Tel 1 888 525 7300 Fax 1 435 753 7490 www apgsensors com sales apgsensors com 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 2 Point Calibration If a more precise calibration is required a two point calibration should be used This is accomplished by using the linear equation of Y AX B where Y Measured distance X DCR Reading A Multiplier B Offset The multiplier A can be determined by taking ultrasonic readings at two known distances and dividing the difference of the known distances D by the difference of the ultrasonic U readings A D D U U where D far known distance U Ultrasonic reading at D D close known distance U Ultrasonic reading at D Enter this multiplier in Modes 38 and 39 The multiplier can then be entered in the above equation to calculate the offset B D A U The offset should be entered using Modes 36 and 37 Automatio
5. S 5 26 694 6946 6 564 6 G3 O nN a eo z o z zz o zzz o z z o z 110 220 VAC 24V 4 20 DST TRIP 1 TRIP 2 TRIP 3 TRIP 4 uy 1e161q DIG Automation Products Group Inc APG Providing tailored solutions for measurement applications 10 Tel 1 888 525 7300 Fax 1 435 753 7490 www apgsensors com sales apgsensors com Rev A4 10 08 DCR 1005 and DCR 1006 e 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 They operate similar to a digital watch To cycle forward through the modes hold down the M UP key To cycle backward through the modes hold down the M DN key To select a mode press the M UP or M DN key until the desired mode number is displayed Pressing either the V UP or V DN will display the selected mode setting on the LCD display To change the selected mode setting hold down the V UP or V DN key until the desired setting is displayed Enter the new value by pressing either of the mode keys The display will then show the DST distance reading Error Indicators There are 4 error indicators which
6. apgsensors com Rev A4 10 08 DCR 1005 and DCR 1006 Notes Automation Products Group Inc APG APG Providing tailored solutions for measurement applications Tel 1 888 525 7300 Fax 1 435 753 7490 www apgsensors com sales apgsensors com 39 PRODUCTS GROUP INC APG Providing tailored solutions for measurement applications APG 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 Logan UT 84321
7. being detected even though they are occasionally in the ultrasonic detection beam MODE 9 10 VALUE 40 0 3 ft Automation Products Group Inc APG APG Providing tailored solutions for measurement applications DESCRIPTION Increase the Out of Range Samples before updating If the sample rate is set to 0 500 seconds and mode 9 set to 40 then the DCR will require at least 40 0 5 or 20 seconds of readings outside of the filter window Mode 10 before the display and outputs will recognize a new target Reduce the filter window for good readings This will help qualify only echoes at the surface level If the level changes rapidly the average level indication may lag behind the actual level If this occurs the actual level may move outside the filter window if the window size is too small Tel 1 888 525 7300 Fax 1 435 753 7490 www apgsensors com sales apgsensors com 15 DCR 1005 and DCR 1006 Outputs Rev A4 10 08 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 12 Begin Trip 1 13 End Trip 1 14 Trip 1 Type PARAMETERS Units 2 mode 1 Default 2 5 ft Units mode
8. gallons multiplier below decimal point 3l 11 00 Set the distance from the DST to the bottom of the tank 32 10 00 Set the length of the tank 34 5 00 Set the tank radius of 5 ft H Automation Products Group Inc APG Providing tailored solutions for measurement applications 24 Tel 1 888 525 7300 Fax 1 435 753 7490 www apgsensors com sales apgsensors com 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 If no multiplier is input the controller will display the distance in inches from the bottom of the tank We will show how to program this application in 2 steps First setting up the controller to display the level of the liquid in the tank second showing how to convert that level indication to display in liters To indicate the level of water in the tank make the following adjustments MODE VALUE DESCRIPTION 1 Sets units to inches 3 2 Selects the operating mode to calculate level volume 28 I Selects the type of tank to be monitored 31 96 0 Sets the distance from the transducer to the bottom of the tank This will display the lev
9. tailored solutions for measurement applications Tel 1 888 525 7300 Fax 1 435 753 7490 www apgsensors com sales apgsensors com 9 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 Remove the display board by removing the four 4 40 screws to expose the terminal strip Step 3 The DCR 1005 and DCR 1006 is shipped from the factory configured for 120 VAC input power INPUT POWER JUMP JUMP 120 VAC 2 3 4 5 240 VAC 3 4 N A Step 4 Wires can be pulled into the DCR 1005 and DCR 1006 through the strain reliefs on the enclosure The screw terminal can be wired using solid or stranded wire between 16 22 AWG Wires should be stripped leaving a 0 4 in bare wire For wiring the 2 conductor DST connect the red wire to DST and the black and shield wire to the DST GND Step 5 Perform an internal check to ensure that all wires are properly connected and secured Step 6 Secure the Display Board and make the power connection The LCD should light DI 2 a 2 2
10. 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 e Stand Pipe Top of Tank lt ES 10 45 CUT APGz Automation Products Group Inc APG Providing tailored solutions for measurement applications 8 Tel 1 888 525 7300 Fax 1 435 753 7490 www apgsensors com sales apgsensors com Rev A4 10 08 DCR 1005 and DCR 1006 Stilling Well Mounting Provides access to difficult areas and eliminates problems with foam e Extend the pipe above the highest anticipated level by at least the published blanking distance e 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 D Minimum Blanking Distance Highest Anticipated Tank Level TIUS Automation Products Group Inc APG APG Providing
11. upon receipt of the product Returns and allowances must be authorized by APG 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 Automation Products Group Inc APG APG Providing tailored solutions for measurement applications Tel 1 888 525 7300 Fax 1 435 753 7490 www apgsensors com sales apgsensors com 3 DCR 1005 and DCR 1006 Rev A4 10 08 e 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 The DCR 1005 comes standard with four relay outputs The DCR 1006 also includes an isolated 4 20 mA output The DST series sensors are non contact ultrasonic sensors which measure the distance to a target through air A list of available sensors can be found under DST Specifications found at the end of this manual starting on page 35 Typical applications include Monitoring water levels in a well Determining material volu
12. 1 Sets the length of the Spherical Ends Default 2 00 ft bottom cone or spherical ends or Cone tank type 3 or 5 34 Tank Radius Units mode 1 Sets the radius of the cylinder Default 5 00 ft not used in tank type 0 or 1 PH Automation Products Group Inc a a ja P P P APG Providing tailored solutions for measurement applications 22 Tel 1 888 525 7300 Fax 1 435 753 7490 www apgsensors com sales apgsensors com 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 This is only necessary for type 1 tanks Common Conversion Factors Common Area Formulas Cubic Feet ft x 7 4805 Gallons for use with type 1 tanks Cubic Feet ft x 28 317 Liters Area of a Circle P x r Cubic Inches in x 0 00433 Gallons Area of a Square or Rectangle LxW Gallons x 3 7854 Liters For each tank type as shown below values for modes 31 34 must be entered If a mode is not indicated in the drawing the value stored in that mode setting will be ignored For example if tank type 4 is selec
13. E DESCRIPTION 5 2 00 Do not set closer than the minimum distance recommended for the DST sensor type being used 12 6 00 Set the pump begin point at 6 ft from the DST 13 9 00 Set the pump end point at 9 ft from the DST 14 2 Use the hysteresis near type of gate to keep the pump on while pumping the level down 15 5 00 Begin the alarm trip point at 5 ft 16 10 00 End the alarm trip point at 10 ft because any reading greater will indicate loss of echo or communication 17 4 Any signal higher than 5 ft or lower than 10 ft will cause the alarm relay to open us Automation Products Group Inc a a ja P P P APG Providing tailored solutions for measurement applications 18 Tel 1 888 525 7300 Fax 1 435 753 7490 www apgsensors com sales apgsensors com 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 alarm relay is to be energized under normal operation and should open for failure in power communication invalid readings high level above 5 ft or loss of echo To program the DCR 1005 and DCR 1006 for this application the following modes must be set MODE VALUE DESCRIPTION Select Volumetric Monitoring for this application so the display will indicate the distance from
14. Operator s Manual DCR 1005 and DCR 1006 Rev A4 10 08 Doc 9002664 APG 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 com DCR 1005 and DCR 1006 Rev A4 10 08 Table of Contents ligera P n 3 TTT O GCA as cases ss ste ope encase ec E E ER E Understanding Ultrasonics esee euvete iei usen PReRUUhI Tint Eb ruPEPL ILE a se RrRevta 5 IY TII A OM E nina E E T i 72 10 PO qoi ir MT mes 1l Error Indicators aos cehncrin seu honaesdinapaaciunocbace bout nadandeapseniantadiuneeastuoses Il POC qe M N r 12 91727111777 T E E E I E O 13 GTS E AANI E ON E E 14 77 16 72 92 COT OVS autres EN ea aos oa Zl eio 26 i I 28 OMERO TOE SNOOT aves 30 ME a EE E E A NEUE 32 DORS PaA ICAI OMS sorrir aeris EE EERS 33 DST Specifications ME 34 APG Automation Products Group Inc APG Providing tailored solutions for measurement applications 2 Tel 1 888 525 7300 Fax 1 435 753 7490 www apgsensors com sales apgsensors com Rev A4 10 08 DCR 1005 and DCR 1006 e 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 equipm
15. Products Group Inc APG APG Providing tailored solutions for measurement applications Tel 1 888 525 7300 Fax 1 435 753 7490 www apgsensors com sales apgsensors com 5 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 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 Environmental Conditions Temperature humidity gases dust and pressure may also affect the sensor s performance APG ultrasonic sensors automatically compensate for many of these conditions However these conditions can degrade the sensor s performance enough it may be necessary to use a longer range sensor than normal conditions would r
16. Range DCR 1005 and DCR 1006 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 DESCRIPTION PARAMETERS 43 Range Range 0 1 Selection 0 1 35 ft Range 1 1 72 ft Range Default 0 44 Maximum Range 1 72 ft Range Default 35 ft AutoSense EXPLANATION Some DSTs will allow a detection range of up to 72 ft This parameter enables the DCR to display that distance This parameter works only with 72 ft DSTs and enables the user to limit the maximum distance Modes 45 disables or enables the AutoSense feature on selected models MODE DESCRIPTION PARAMETERS EXPLANATION 45 AutoSense Range 0 1 Sensors with the extended 0 OFF range software can have ON the AutoSense feature Default 0 disabled or enabled Automation Products Group Inc APGH APG Providing tailored solutions for measurement applications Tel 1 888 525 7300 Fax 1 435 753 7490 www apgsensors com sales apgsensors com 29 DCR 1005 and DCR 1006 Rev A4 10 08 e Quick Reference Sheet MODE DESCRIPTION PARAMETERS Operation 1 Units 2 Decimal Point 3 Operating Mode 4 Sensitivity 5 Blanking 6 Pulses Filtering 7 Sample Rate 8 Samples Averaged 9 Out of Range Sample 10 Out of Range Span 11 Loss of Echo Delay Relay 12 Begin Trip 1 13 End Trip 1 14 Trip 1 Type 15 Begin Trip 2 16 End Trip 2 17 Trip 2 Type 18 Begin Trip 3 19 E
17. dependant on Keep above DST s minimum DST model specification 6 Pulses Range 1 20 Sets the number of pulse waves sent Default 16 in each ultrasonic burst Adjusts the strength of the transmitting signal If using a DST version 2000 sensor Mode 6 will display the sensor s selected pulse setting The pulse setting is not user adjustable Automation Products Group Inc APG APG Providing tailored solutions for measurement applications Tel 1 888 525 7300 Fax 1 435 753 7490 www apgsensors com sales apgsensors com 19 DCR 1005 and DCR 1006 Filtering Rev A4 10 08 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 7 Sample Rate 8 Samples Averaged 9 Out of Range 10 Filter Window 11 Loss of Echo Delay PARAMETERS Units milliseconds Range 80 9999 Default 120 Units Samples Range 50 Default 20 Units samples Range 50 Default 10 Units Mode 1 Range 0 20 ft Default 2 00 ft Units seconds Range 0 9999 Default 5 EXPLANATION Sets the delay between sensor samples readings Sets the number of samples to be averaged in the buffer memory on a first in first out basis Sets the number of out of range samples in success
18. ed to be adjusted for volume applications 1 Distance skip to step 5 2 Volume Level setup Modes 28 34 5 MODES 12 23 Setup relay outputs Remember to program relays in the units of measurement be displayed and to disable relays that are not being used 6 MODES 24 27 Setup analog output 7 MODE35 Set temperature compensation 8 Advanced setup not required in most applications MODES 26 27 36 45 us Automation Products Group Inc E o z APG Providing tailored solutions for measurement applications 12 Tel 1 888 525 7300 Fax 1 435 753 7490 www apgsensors com sales apgsensors com Rev A4 10 08 DCR 1005 and DCR 1006 Operation The operation modes are used to perform basic initialization of the DCR MODE DESCRIPTION PARAMETERS EXPLANATION l Units Range 3 Selects the units to be displayed 1 inches 2 feet 3 meters Default 2 2 Decimal Point Range 0000 0 000 Selects the decimal point Default 00 00 position 3 Operating Mode Range 1 2 Selects mode of measurement for distance the application 2 volume level Default 1 4 Sensitivity Units Sets sensitivity or gain as a Range 0 100 percentage of maximum If using a DST version 2000 sensor Mode 4 will display the selected sensor s sensitivity The sensitivity is not user adjustable in these models 5 Blanking Units 2 mode 1 Sets a dead zone in front of the Range 0 36 ft DST where echoes are ignored Default
19. el of water in the tank in inches To convert the read out so it displays the volume in liters we calculate the volume per unit of measure In this case liter inch The volume of a cylinder is calculated by the following formula Pi R H Volume in cubic inches Pi 3 1415927 R Radius of tank in this example 48 in 2 24 in H Height of the cylinder We are concerned only about volume per inch so H 1 Inserting the radius into this equation 3 1415927 x 24 x 1 1 809 216 cubic inches Cubic inches are converted to liters by multiplying it by 0 01639 So the multiplier is calculated by 0 01639 x 1 809 216 29 6530 liters inch MODE VALUE DESCRIPTION 2 0 Move decimal point all the way to the right 29 20 Multiplier above the decimal point 30 6586 Multiplier Below the decimal point Automation Products Group Inc APGH APG Providing tailored solutions for measurement applications Tel 1 888 525 7300 Fax 1 435 753 7490 www apgsensors com sales apgsensors com 25 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 For the DST temperature sensor
20. ent 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 WARRANTY IS IN LIEU OF AND EXCLUDES ALL OTHER WARRANTIES NOT EXPRESSLY SET FORTH HEREIN WHETHER EXPRESSED OR IMPLIED BY OPERATION OF LAW OR OTHERWISE INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR 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 upon APG 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 and APG 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
21. equire 10 Of 81 7h 2217 2534 285r 3165 H Automation Products Group Inc APG Providing tailored solutions for measurement applications 6 Tel 1 888 525 7300 Fax 1 435 753 7490 www apgsensors com sales apgsensors com 6 ft 1 901 Typical Beam Pattern of a Ceramic Transducer at high sensitivity and power settings 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 Follow the guidelines mentioned in 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 e Coupler must be aligned perpendicular to the target level e 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 BETTER GOOD Soft gaske
22. ion that will be ignored before the new target is accepted Sets the window of acceptance The window is or this distance from the current reading If a sample distance is outside of this window it will be ignored the number of times set in mode 9 Sets the delay in seconds before the output will show a loss of echo condition Allows the controller to maintain the current level indication for temporary loss of echo conditions During a loss of echo condition the controller will maintain the last reading for the time frame indicated in seconds Automation Products Group Inc APG Providing tailored solutions for measurement applications 14 Tel 1 888 525 7300 Fax 1 435 753 7490 www apgsensors com sales apgsensors com 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 J VALUE 0 125 10 DESCRIPTION Sets the sampling interval to a shorter time requirement thus decreasing the interval between samples from the default of 250 ms to 125 ms Decrease the samples averaged so that the DCR can respond faster Example Ignoring Intermittent Obstacles To prevent agitators splashing or other intermittent objects from
23. may appear on the display given the appropriate conditions E1 indicates a short in the DST Power connection or termination E2 indicates that a sensor is not connected or the sensor is not communicating E3 indicates a Loss of Echo condition The sensor is not able to acquire a target within the range of the sensor dashes indicate that the number to be displayed is larger than the display will allow To correct this condition try adjusting the Decimal Position Mode 2 or changing the multiplier Modes 29 and 30 This indication may also result from a negative number to be displayed Automation Products Group Inc APG APG Providing tailored solutions for measurement applications Tel 1 888 525 7300 Fax 1 435 753 7490 www apgsensors com sales apgsensors com 11 DCR 1005 and DCR 1006 Rev A4 10 08 e Programming Modes 1 Operation Modes 1 5 2 Filtering Modes 6 11 3 Outputs Modes 12 27 4 Applications Modes 28 37 5 Calibration Modes 38 39 6 Utilities 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 MODES 4 6 Determine settings to get a reliable distance reading on your target 3 MODES 7 11 Determine appropriate filtering for your application 4 MODE3 Select application type MODE 2 will ne
24. me in a tank Obstacle avoidance Product dimensioning Loop control us Automation Products Group Inc a ga P z APG Providing tailored solutions for measurement applications 4 Tel 1 888 525 7300 Fax 1 435 753 7490 www apgsensors com sales apgsensors com Rev A4 10 08 DCR 1005 and DCR 1006 e 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 low sensitivity shape of a cone reflect off the target and pulses and are received by the sensor The time required for the sound burst to travel to and from the target is converted into a T distance measurement by the sensor area Ultrasonic sensing is affected by l high sensitivity several factors including the target a pulses surface distance size and angle The following considerations will help ensure the best possible target conditions beam spread 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 A target with poor sound wave reflection characteristics will reduce the operating distance of the sensor and decrease its accuracy 1j 00 Er0 s 91 S surface distance size angle BETTER BETTER BETTER CORRECT JD I JD EE Automation
25. n Products Group Inc APG APG Providing tailored solutions for measurement applications Tel 1 888 525 7300 Fax 1 435 753 7490 www apgsensors com sales apgsensors com 2 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 DESCRIPTION PARAMETERS EXPLANATION 40 Input Select Range 0 1 Selects which type of 0 DST Sensor sensor input to accept Pulse Width Default 0 Reset When the DCR is powered up 0 is loaded in mode 41 This saves the user selected modes into the DCR If the mode adjustments get scrambled or if the factory preset values are wanted press the V UP If 1 is entered into this mode all of the parameters will be RESET to their factory defaults MODE DESCRIPTION PARAMETERS EXPLANATION 41 Reset Range 0 1 Entering a here will Default 0 reset the DST to its factory default values Software Version Mode 42 displays the software version for the DCR The value corresponds to the operating version and the approximate date of manufacture MODE DESCRIPTION PARAMETERS EXPLANATION 42 Software Displays the software Version version H Automation Products Group Inc APG Providing tailored solutions for measurement applications 28 Tel 1 888 525 7300 Fax 1 435 753 7490 www apgsensors com sales apgsensors com Rev A4 10 08 Extended
26. nce 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 To program the DCR for this application the following values must be entered in the modes indicated Many of them are the same as the preset values but are shown again for example purposes MODE VALUE DESCRIPTION 1 2 Set units to meters because the output is to be displayed in meters 2 0 Change the display so that it will have a 10 cm resolution 3 Select distance monitoring for application 80 Adjust percent of sensitivity This would not apply for DST sensor operating with Auto Sense 5 0 60 Do not set closer than the minimum distance recommended for the DST sensor type being used 6 9 Set strength of transmit signal Automation Products Group Inc APG APG Providing tailored solutions for measurement applications Tel 1 888 525 7300 Fax 1 435 753 7490 www apgsensors com sales apgsensors com 21 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 fo
27. nd Trip 3 20 Trip 3 Type 21 Begin Trip 4 22 End Trip 4 23 Trip 4 Type APG Automation Products Group Inc APG Providing tailored solutions for measurement applications 30 Tel 1 888 525 7300 Fax 1 435 753 7490 www apgsensors com sales apgsensors com Rev A4 10 08 DCR 1005 and DCR 1006 MODE DESCRIPTION PARAMETERS Analog 24 4 mA Distance 25 20 mA Distance 26 4 mA Calibration 2 20 mA Calibration Volume 28 Tank Type 20 Mult Above 30 Mult Below 3l Span 32 Tank Length 33 Sphere Length 34 Tank Radius Calibration 33 Temp Comp 36 Distance Offset 37 Offset Polarity 38 Calibration Above 39 Calibration Below Utilities 40 Input Select 41 Reset 42 Software Version Extended Range 43 Range Select g Max Range Extended Range 45 AutoSense 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 com 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 t
28. r any style of tank to indicate level the zero point is moved to the bottom of the tank It is also used for volume calculations of flat bottom tanks If tank type 2 5 are selected the zero point is the bottom of the tank and the controller will compute product volume using the units selected in mode 1 These tank types are used only if a volumetric readout is desired MODE DESCRIPTION PARAMETERS EXPLANATION 28 Tank Type Range 0 5 Selects the type of tank to be 0 distance to level monitored Set by V UP or V DN level indication Types 2 5 converts to volume 2 hzontal flat ends using units selected in mode If 3 hzontal sphere ends feet is the unit of measure then 4 spherical tank display will read cubic feet of 5 conical bottom product Default 0 29 Constant Above Range 0 9999 Sets the portion of the multiplier Decimal Point Default 1 above the decimal point Used for Note The relay and analog outputs converting distance to volume or must be programmed in the same converting from one unit to units used here another for example ft to gallons 30 Constant Below Range 0000 9999 Sets the portion of the multiplier Decimal Point Default 0000 below the decimal point 3l Span Units 2 mode 1 Sets distance from the transducer Default 12 00 ft to bottom of the tank 32 Tank Length Units 2 mode 1 Sets the length of a horizontal Default 10 00 ft tank or the length to a conical bottom 33 Length of Units 2 mode
29. ransducer may be required H Automation Products Group Inc APG Providing tailored solutions for measurement applications 32 Tel 1 888 525 7300 Fax 1 435 753 7490 www apgsensors com sales apgsensors com Rev A4 10 08 e DCR Specifications Outputs Supply Voltage Total Current Draw Housing Rating Dimensions in Resolution Display 24 VDC Output Operating Temp Sample Rate Adjustments Connector Sensor Connector DCR 1005 4 relays 10 A 110 VAC 24 VDC or 110 220 VAC 0 1A Poly Carbonate NEMA 4X IP65 6 25 x 3 125 x 225 Maximum of 0 1 in 2 5mm 4 character digital LCD 200 mA current max 30 to 60 C 10 sec to 80 msec Programmable modes Terminal Strip Coaxial F connector or 2 conductor cable Automation Products Group Inc DCR 1005 and DCR 1006 DCR 1006 4 relays 10A 110 VAC with isolated 4 20 mA 24 VDC or 110 220 VAC 0 1A Poly Carbonate NEMA 4X IP65 0 253 X 3 125x 225 Maximum of 0 1 in 2 5mm 4 character digital LCD 200 mA current max 30 to 60 C 10 sec to 80 msec Programmable modes Terminal Strip Coaxial F connector or 2 conductor cable APG Providing tailored solutions for measurement applications Tel 1 888 525 7300 Fax 1 435 753 7490 www apgsensors com sales apgsensors com dd DCR 1005 and DCR 1006 e DST Specifications Application Operating Range ft Enclosure Transducer Type Transducer Material Rating
30. s Approvals Operating Temp Internal Temp Comp Accuracy Dimensions L x D in Beam Pattern Standard Cable DST 1002 Wet corrosive Environments 1 5 to 35 PVC Ceramic PVC NEMA 6P IP65 Class I Div 1 30 to 60 C Yes 0 25 of range 7x3 5 9 off axis Coaxial RG 6 Rev A4 10 08 DST 2421 Wet corrosive Environments 1 to 25 PC PET Ceramic PVDF NEMA 4X n a 40 to 60 C Yes 0 25 of range TX 9 off axis 2 conductor Automation Products Group Inc APG Providing tailored solutions for measurement applications 34 Tel 1 888 525 7300 Fax 1 435 753 7490 www apgsensors com sales apgsensors com Rev A4 10 08 e DST Specifications continued Application Operating Range ft Enclosure Transducer Type Transducer Material Ratings Approvals Operating Temp Internal Temp Comp Accuracy Dimensions L x D in Beam Pattern Standard Cable Automation Products Group Inc DST 3431 Wet corrosive Environments 1 25 to 50 PC PET Ceramic PC PET NEMA AX n a 40 to 60 C Yes 0 25 of range FEST deus 9 off axis 2 conductor DCR 1005 and DCR 1006 DST 5111 Wet corrosive Environments 4 to 72 inch PC PET Ceramic PVDF NEMA 6P IP65 n a 30 to 60 C Yes 0 25 of range 45x3 9 off axis 2 conductor APG Providing tailored solutions for measurement applications Tel 1 888 525 7300 Fax 1 435 753 7490 w
31. t material is recommended with flange mounting me aaia n aa bre na aaa Automation Products Group Inc APG APG Providing tailored solutions for measurement applications Tel 1 888 525 7300 Fax 1 435 753 7490 www apgsensors com sales apgsensors com 7 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 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 13 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
32. ted in Mode 28 only Modes 31 and 34 will be used in calculations Values in Modes 32 and 33 are ignored It is not necessary to set unused Modes to 0 Length of nre or Cone Rodis 5 ili k Tork flat bottom 3 horizontal with spherical ends Tark T r Length of J Spon Radius ai iod Wre 5 conical bottom k Tork Length Y 2 horizontal with spherical tank flat ends Automation Products Group Inc APGH APG Providing tailored solutions for measurement applications Tel 1 888 525 7300 Fax 1 435 753 7490 www apgsensors com sales apgsensors com 23 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 To program the DCR 1006 for this application the following modes must be changed from their preset values MODE VALUE DESCRIPTION l 2 Set units to feet 2 0 Set the decimal to the right to prevent display overflow 3 2 Select Volume Monitoring for application 28 2 Set the tank type to 2 for horizontal tank 29 7 Converting ft to gallons multiplier above decimal point 30 4805 Converting ft to
33. the tank bottom to the level Do not set closer than the minimum distance recommended for Use the hysteresis far type of trip to keep the pump on while Begin the alarm trip point at the bottom because any signal Any signal higher than 5 ft or lower than 0 ft will cause the 3 2 5 2 00 the DST sensor type being used 12 1 00 Set the pump begin point at 1 ft from the bottom 13 4 00 Set the pump end point at 4 ft from the bottom 14 5 pumping the level down 15 0 00 below the zero point will indicate loss of echo or communication 16 5 00 End the alarm trip point at 5 ft for high level alarm 17 4 alarm relay to open 28 l Select a Flat Bottom Tank 31 10 Automation Products Group Inc APG APG Providing tailored solutions for measurement applications Distance from sensor to bottom of tank The Controller subtracts the measured distance from the Tank Span to display level Tel 1 888 525 7300 Fax 1 435 753 7490 www apgsensors com sales apgsensors com 19 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
34. to operate properly it must be shielded from radiant heat Because the temperature sensor is internal to the DST it requires several minutes to react to air temperature changes MODE DESCRIPTION PARAMETERS EXPLANATION 32 Temperature Range 0 2 Selects internal temperature Compensation 0 OFF compensation for changes in the 1 ON speed of sound on off or view 2 Current Temp sensor temperature set by V UP Default OFF or V DN Calibration For most open air applications the factory set calibration should be correct Variations between the distance measured by the DCR DST System and the actual distance are caused by environmental conditions such as temperature humidity or chemical atmospheres These environments can be compensated for by using a calibration factor which alters the reading to match the application conditions MODE DESCRIPTION PARAMETERS EXPLANATION 36 Distance Offset Units mode 1 Sets an offset for the Range 0 000 9999 display when measuring Default 0 distance to a level 37 Offset Polarity Range 0 1 Selects the direction of the 0 2 Subtract offset adds or subtracts 1 Add offset to reading Set by V Default NEG UP or V DN 38 Calibration Above the Decimal Point Range 0 9999 Default 1 Sets the integer portion of the calibration factor 39 Calibration Range 0000 9999 Sets the fractional portion Below the Default 0 of the calibration factor Decimal Point APG Automation
35. ww apgsensors com sales apgsensors com 35 DCR 1005 and DCR 1006 Rev A4 10 08 e DST Specifications continued Application Operating Range ft Enclosure Transducer Type Transducer Material Ratings Approvals Operating Temp Internal Temp Comp Accuracy Dimensions L x D in Beam Pattern Cable DST 9421 Dry stable Environments 0 5 to 35 PC PET Electrostatic Gold Kapton NEMA 12 n a 40 to 70 C Yes 0 25 of range 35x25 9 off axis 2 conductor AutoSense SOFTWARE The AutoSense software is a built in feature available with the DST sensor models listed above It provides automatic sensitivity adjustment and is preferable in tank and level applications Please use the above part numbers when ordering a DST with the AutoSense option Automation Products Group Inc APG Providing tailored solutions for measurement applications 36 Tel 1 888 525 7300 Fax 1 435 753 7490 www apgsensors com sales apgsensors com Rev A4 10 08 DCR 1005 and DCR 1006 Notes Automation Products Group Inc APG APG Providing tailored solutions for measurement applications Tel 1 888 525 7300 Fax 1 435 753 7490 www apgsensors com sales apgsensors com 3 DCR 1005 and DCR 1006 Rev A4 10 08 Notes us Automation Products Group Inc a a ja P P P APG Providing tailored solutions for measurement applications 38 Tel 1 888 525 7300 Fax 1 435 753 7490 www apgsensors com sales

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