APG DCR-1004 User Manual

PRODUCTS

AUTOMATION

Operator’s Manual

GROUP, INC.

DCR-1003

and

DCR-1004

Rev. A3, 10/08

Doc. 9002661

Automation Products Group, Inc.

APG...Providing tailored solutions for measurement applications

Tel: [phone] • Fax: [phone] • www .apgsensors.com • E-mail: [e-mail]

DCR-1003 and DCR-1004 Rev. A3, 10/08

Table of Contents

Warranty ......................................................................................... 3

Introducing...................................................................................... 4

Understanding Ultrasonics............................................................. 5

Installation ...................................................................................... 7

Installing the DST Sensor ............................................................ 7

Installing the DCR-1003, 1004 .................................................. 10

Wiring............................................................................................ 11

Programming................................................................................ 13

Operation ................................................................................... 15

Filtering ..................................................................................... 16

Outputs ...................................................................................... 19

Applications ............................................................................... 25

Calibrations ............................................................................... 37

Utilities ...................................................................................... 38

Quick Reference Sheet .................................................................. 39

Troubleshooting ............................................................................ 41

Maintenance ................................................................................. 42

Specifications ................................................................................ 43

Automation Products Group, Inc.

2

APG...Providing tailored solutions for measurement applications

Tel: [phone] • Fax: [phone] • www.apgsensors.com • [e-mail]

Rev. A3, 10/08 DCR-1003 and DCR-1004

• Warranty and Warranty Restrictions

APG warrants its products to be free from defects of material and workmanship
and will, without charge, replace or repair any equipment found defective upon
inspection at its factory, provided the equipment has been returned,
transportation prepaid, within 24 months from date of shipment from factory .

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 OTHER WISE
INCLUDING BUT NOT LIMITED T O ANY IMPLIED WARRANTIES OF
MERCHANT ABILITY OR FITNESS FOR A P AR TICULAR 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 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...Providing tailored solutions for measurement applications

Tel: [phone] • Fax: [phone] • www .apgsensors.com • [e-mail]

3

DCR-1003 and DCR-1004 Rev. A3, 10/08

• Introducing

The DCR-1003, 1004 controllers with DST series sensors were specifically
designed to provide a rugged and reliable non-contact sensor system that is
easily programmed yet flexible enough to use in a wide range of applications.

The DCR-1003, 1004 controllers have a large display to show readings and
parameters. They also include a mode display to provide easy setup of the
programmable modes. The controller can be configured to monitor level, flow,
volume or differential. The DCR-1003 comes standard with four relay outputs.
The DCR-1004 or analog version, also includes a standard 4-20 mA output with
optional configurations of 0-20 mA or voltage outputs.

The DST series sensors are non-contact ultrasonic which measure the
distance to a surface through air. The standard DCR-1003, 1004 sensor is the
DST-1002. It is a totally sealed PVC sensor with a range of 25 ft. Several other
versions of DST are available to fit almost any application.

Typical applications include:

• Monitoring water levels in a well

• Monitoring open channel flow

• Determining material volume in a tank

• Taking differential measurements

• Obstacle avoidance

• Product dimensioning

Automation Products Group, Inc.

4

APG...Providing tailored solutions for measurement applications

Tel: [phone] • Fax: [phone] • www.apgsensors.com • [e-mail]

Rev. A3, 10/08 DCR-1003 and DCR-1004

detection

area

beam spread

low sensitivity
and
pulses

high sensitivity
and
pulses

• Understanding Ultrasonics

Ultrasonic sensors measure distance
using a transducer to send out ultrasonic
bursts. Each burst contains a series of 1­20 pulsed sound waves that emit in the
shape of a cone, reflect off the target, and
are received by the sensor. The time
required for the sound burst to travel to
and from the target is converted into a
distance measurement by the sensor.

Ultrasonic sensing is affected by
several factors including the target
surface, distance, size, and angle. The
following considerations will help ensure
the best possible target conditions.

Surface

The ideal target surface is hard and smooth and perpendicular to the face of
the transducer. This surface will reflect a greater amount of signal than a soft,
sound wave absorbent surface. A target with poor sound wave reflection
characteristics will reduce the operating distance of the sensor and decrease its
accuracy.

Automation Products Group, Inc.

APG...Providing tailored solutions for measurement applications

Tel: [phone] • Fax: [phone] • www .apgsensors.com • [e-mail]

5

DCR-1003 and DCR-1004 Rev. A3, 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.

Automation Products Group, Inc.

6

APG...Providing tailored solutions for measurement applications

Tel: [phone] • Fax: [phone] • www.apgsensors.com • [e-mail]

Rev. A3, 10/08 DCR-1003 and DCR-1004

• Installation

Installing the DST Sensor

The DST sensor should be installed so that it has a clear sound path to the
intended target. The path should be free from obstructions and as open as
possible. Follow the guidelines mentioned in this manual under “Understanding
Ultrasonics”, found on page 5.

NPT and Flange Mounting

• Mounting in a coupler or half coupler welded to the top of tank. (see
drawings below)

• Coupling should extend through the top of tank.

• Coupler must be aligned perpendicular to the target level.

• Screw sensor in only hand tight.

• To avoid false Echoes, the coupler should be installed where there is a clear
sound path perpendicular to the detection surface and where the sound
path will not intersect vessel fill spouts, rough vessel walls, ladders…etc.

BEST GOOD

*Soft gasket

material is

recommended with

flange mounting.

Automation Products Group, Inc.

APG...Providing tailored solutions for measurement applications

Tel: [phone] • Fax: [phone] • www .apgsensors.com • [e-mail]

7

DCR-1003 and DCR-1004 Rev. A3, 10/08

Top of Tank

Stand Pipe

10-45

o

CUT

Stand Pipe Mounting

The stand pipe should be as large in diameter and as short in length as
possible. Mount the sensor above the highest anticipated material by at least
the published blanking distance.

The stand pipe should be seamless to provide a smooth path for the sound
waves to propagate into the tank. Because the sound waves will concentrate
along the inside wall of the pipe, any seams from couplers, nipples, and welds
will cause echo returns that will be picked up by the sensor. The sensor
blanking will need to be changed to a distance greater than the length of the
pipe (found on page 15; mode 5).

The end of the stand pipe should extend inside the tank and be cut to a 45°
angle. Make sure that the cut is clean and free from burs. If the standpipe is cut
at 90°, there will develop a standing wave echo at the end of the pipe that will be
seen by the sensor as a target. If a 45° cut is not feasible in your application,
then the cut should be made as close to 45° as possible (often, even a 10° cut
will shrink the standing wave enough to allow the sensor to see past it).

To avoid false Echoes, the stand pipe should be installed where there is a
clear sound path perpendicular to the detection surface and where the sound
path will not intersect vessel fill spouts, rough vessel walls, ladders…etc. Any
angle off perpendicular will degrade the performance of the sensor .

Automation Products Group, Inc.

8

APG...Providing tailored solutions for measurement applications

Tel: [phone] • Fax: [phone] • www.apgsensors.com • [e-mail]

Rev. A3, 10/08 DCR-1003 and DCR-1004

Minimum Blanking Distance

Highest Anticipated

Tank Level

Stilling Well Mounting

Provides access to difficult areas and eliminates problems with foam.

• Extend the pipe above the highest anticipated level by at least the
published blanking distance.

• Provide a vent hole at the top of the tube. Keep the hole inside the blanking
distance of the sensor to prevent false echoes.

• Use only in liquid materials that will not leave deposits on the inside of the
pipe (material build-up will result in false echoes).

• Pipe must have smooth walls and should be seamless to provide a smooth
path for the sound waves to propagate into the tank. Because the sound
waves will concentrate along the inside wall of the pipe, any seams from
couplers, nipples, and welds will cause echo returns that will be picked up
by the sensor.

Automation Products Group, Inc.

APG...Providing tailored solutions for measurement applications

Tel: [phone] • Fax: [phone] • www .apgsensors.com • [e-mail]

9

DCR-1003 and DCR-1004 Rev. A3, 10/08

Installing the DCR-1003, 1004

The DCR-1003, 1004 should be installed using the 4 mounting feet provided.
The enclosure must be mounted out of direct sunlight and should have good
clearance to the left for opening the hinged cover.

10

DCR-1003 and DCR-1004 Mounting Dimensions

Automation Products Group, Inc.

APG...Providing tailored solutions for measurement applications

Tel: [phone] • Fax: [phone] • www.apgsensors.com • [e-mail]

Rev. A3, 10/08 DCR-1003 and DCR-1004

• Wiring

Step 1: Connect the DST to the DCR Controller using RG-6 coaxial cable

with ‘F’ series connectors. If more than one DST is to be connected for a
differential application, the two sensors should be connected to the DCR using
an external splitter.

Step 2: To obtain access to the DCR’S terminal strip, open the DCR’s

plexiglass cover and raise the hinged panel by loosening the knurled thumb
screws.

Step 3: The DCR-1003, 1004 is shipped from the factory configured for 100-

120 VAC input power. If 200-230 VAC is to be used, change the jumpers
configuration to 220 VAC as shown in the diagram below.

Automation Products Group, Inc.

APG...Providing tailored solutions for measurement applications

Tel: [phone] • Fax: [phone] • www .apgsensors.com • [e-mail]

11

DCR-1003 and DCR-1004 Rev. A3, 10/08

Step 4: Wires can be pulled into the DCR-1003, 1004 through the strain
reliefs on the enclosure, or the strain reliefs may be removed and 1/2 in.
conduit used in their place.

The spring loaded terminal can be wired using solid or stranded wire
between 16 - 20 AWG . Wires should be stripped, leaving a .4 in. bare wire. The
wires can then be inserted into the terminal by depressing the associated
orange lever with a #5 1/8 in. screwdriver. While the lever is depressed, the
conductor should be pushed into the terminal until it bottoms out. The lever
should then be released, securing the conductor in the terminal.

Follow the legend on the circuit board when wiring the DCR. The DCR­Controller should never be used without the earth ground terminal being
connected.

Step 5: Perform an internal check to ensure that all wires are properly
connected and secured.

Step 6: Close the hinged panel and make the power connection. The LED
display should turn on and the COM light illuminate.

Automation Products Group, Inc.

12

APG...Providing tailored solutions for measurement applications

Tel: [phone] • Fax: [phone] • www.apgsensors.com • [e-mail]

Rev. A3, 10/08 DCR-1003 and DCR-1004

• Programming

The DCR-1003, 1004 has a four-digit LED readout, a two-digit display showing
the modes, and four lights labeled TRIPS 1, 2, 3, and 4. These lights indicate the
status of the relays. The keypad, located under the clear cover, is used to
program the DCR-1003, 1004. The front cover makes reading the displays easy
while preventing the buttons on the keypad from being accidentally bumped.

The different modes of the DCR-1003, 1004 can be easily accessed using the
mode buttons, MODE UP and MODE DN. They operate similar to a digital
watch. To cycle forward through the modes, hold down the MODE UP key. To
cycle backward through the modes, hold down the MODE DN key .

To select a mode, press the MODE UP or MODE DN key until the desired
mode number is displayed. Pressing either the NUM UP, NUM DN, or one of the
numeric keys will display the selected mode setting on the large LED display.

To change the selected mode setting, hold down the NUM UP or NUM DN
key until the desired setting is displayed. If the setting is not a menu item, such
as a multiplier or distance, then it may be keyed using the numeric keypad. To
change non-numeric values
(i.e.., ON, OFF , NEG, POS) or
a menu number, use the
NUM UP and NUM DN
keys.

Enter the new value by
pressing the ENTER key or
either of the mode keys. The
display will then show the
DST distance reading.

To leave a mode without
entering the setting, press
the function key, F1, and the
DCR-1003, 1004 will return to
displaying the DST reading.

Automation Products Group, Inc.

APG...Providing tailored solutions for measurement applications

Tel: [phone] • Fax: [phone] • www .apgsensors.com • [e-mail]

13

DCR-1003 and DCR-1004 Rev. A3, 10/08

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 7-10 Determine appropriate filtering for your application

4. MODE 3 Select application type *(MODE 2 will need to be

adjusted for volume and flow applications)

1. Distance: skip to step 5

2. Volume: setup Modes 29-35

3. Differential: setup Modes 36-37

4. Open Channel Flow: setup Modes 38-43

5. MODES 12-23 Setup relay outputs (disable relays that are not used in

your application)

6. MODES 24-26 Setup analog output

7. MODE 44 Set temperature compensation

8. Advanced setup *(not required in most applications) MODES 27-28,

45-48

14

Automation Products Group, Inc.

APG...Providing tailored solutions for measurement applications

Tel: [phone] • Fax: [phone] • www.apgsensors.com • [e-mail]