APG DCR-1006 User Manual

PRODUCTS

AUTOMATION

Operator’s Manual

GROUP, INC.

DCR-1005

and

DCR-1006

Rev. A4, 10/08

Doc. 9002664

Automation Products Group, Inc.

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DCR-1005 and DCR-1006 Rev. A4, 10/08

Table of Contents

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

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

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

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

Wiring............................................................................................ 10

Programming................................................................................ 11

Error Indicators ............................................................................ 11

Programming Modes .................................................................... 12

Operation ................................................................................... 13

Filtering ..................................................................................... 14

Outputs ...................................................................................... 16

Applications ............................................................................... 21

Calibration................................................................................. 26

Utilities ...................................................................................... 28

Quick Reference Sheet .................................................................. 30

Maintenance ................................................................................. 32

DCR Specifications ....................................................................... 33

DST Specifications ........................................................................ 34

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Rev. A4, 10/08 DCR-1005 and DCR-1006

• Warranty and Warranty Restrictions

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

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”.

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3

DCR-1005 and DCR-1006 Rev. A4, 10/08

• Introducing

The DCR-1005 and DCR-1006 controller with DST series sensors were
specifically designed to provide a rugged and reliable non-contact sensor
system that is easily programmed yet flexible enough to use in a wide range of
applications.

The DCR-1005 and DCR-1006 controllers have a 0.5 in. 4 character LCD
display to show readings and parameters. The controller can be configured to
monitor distance, level or volume. 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.

T ypical applications include:

• Monitoring water levels in a well

• Determining material volume in a tank

• Obstacle avoidance

• Product dimensioning

• Loop control

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Rev. A4, 10/08 DCR-1005 and DCR-1006

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.

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DCR-1005 and DCR-1006 Rev. A4, 10/08

1 ft.

2 ft.

3 ft.

4 ft.

5 ft.

6 ft.

7 ft.

8 ft.

9 ft.

10 ft.

Sensor

Typical Beam Pattern of a Ceramic Transducer
at high sensitivity and power settings.

0.317'

0.634'

0.950' 1.267'

1.584' 1.901' 2.217' 2.534'

2.851'

3.168'

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

T emperature, 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 require.

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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.

• 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.

BETTER GOOD

*Soft gasket

material is

recommended with

flange mounting.

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DCR-1005 and DCR-1006 Rev. A4, 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 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 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 .

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Rev. A4, 10/08 DCR-1005 and DCR-1006

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.

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DCR-1005 and DCR-1006 Rev. A4, 10/08

TRIP 1

TRIP 2

TRIP 3

TRIP 4

DST

4-20

24V

110-220 VAC

24VDC
INPUT

OR

COM

COM

COM

COM

N.C.

N.O.

N.C.

N.O.

N.C.

N.O.

N.C.

N.O.

24V

L2

L1

GND

DIG

GND

GND

Digital In

4-20(+)

4-20(-)

DST(+)

• 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.

S tep 3: The DCR-1005 and DCR-1006 is shipped from the factory configured

for 120 VAC input power. If 24 VDC or 230 VAC is to be used, change the
jumpers on the bottom board. A soldering iron will be required for this operation.
The jumpers are soldered into pads located on the bottom board and labeled J4.
The pads are labeled 1 through 6.

INPUT POWER JUMP JUMP

24 VDC 1-2 5-6
120 VAC 2-3 4-5
240 VAC 3-4 N/A

S tep 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.

10

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Rev. A4, 10/08 DCR-1005 and DCR-1006

• Programming

The DCR-1005 and DCR-1006 has a four-digit LCD readout and four red LED’s
labeled TRIPS 1, 2, 3, and 4. These LED’ s indicate the status of the relays. Four
momentary push-buttons located under the cover, are used to program the DCR.
The cover makes reading the displays easy while sealing the electronics and
preventing the buttons from being accidentally bumped.

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

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DCR-1005 and DCR-1006 Rev. A4, 10/08

• 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 7-1 1 Determine appropriate filtering for your application

4. MODE 3 Select application type (MODE 2 will need 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. MODE 35 Set temperature compensation

8. Advanced setup (not required in most applications) MODES 26-27, 36-45

12

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