APG DCR-1006 User Manual

PRODUCTS

AUTOMATION

Operator’s Manual

GROUP, INC.

DCR-1005

and

DCR-1006

Rev. A4, 10/08

Doc. 9002664

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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.

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• 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

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Operation

The operation modes are used to perform basic initialization of the DCR.

MODE DESCRIPTION PARAMETERS EXPLANA TION

1 Units Range = 1 - 3

1 - inches
2 - feet
3 - meters
Default = 2

Selects the units to be displayed.

2 Decimal Point Range = 0000.- 0.000

Default = 00.00

3 Operating Mode Range = 1 - 2

1 - distance

Selects the decimal point
position.

Selects mode of measurement for

the application.
2 - volume/level
Default = 1

4 Sensitivity Units = %

Range = 0 - 100 %

Sets sensitivity (or gain) as a

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 = mode 1

Range = 0 - 36 ft.
Default = dependant on
DST model

6 Pulses Range = 1-20

Default = 16

Sets a dead zone in front of the

DST where echoes are ignored.

Keep above DST’s minimum

specification.

Sets the number of pulse waves sent

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.

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

Filtering

The filtering modes are provided to change how fast the system will respond
to changes. The default settings should be appropriate for most level
applications, however, the delays and windows can be changed to increase or
decrease reaction time and filtering.

MODE DESCRIPTION PARAMETERS EXPLANATION

7 Sample Rate Units = milliseconds

Range = 80 - 9999
Default = 120

Sets the delay between
sensor samples (readings).

8 Samples Units = Samples

Averaged Range = 1 - 50

Default = 20

9 Out-of-Range Units = samples

Range = 1 - 50
Default = 10

10 Filter Window Units =Mode 1

Range = 0 - 20 ft.
Default = 2.00 ft.

11 Loss of Units = seconds

Echo Delay Range = 0 - 9999

Default = 5

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 succession 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.

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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 VALUE DESCRIPTION

7 0.125 Sets the sampling interval to a shorter time requirement, thus

decreasing the interval between samples from the default of 250
ms to 125 ms.

8 10 Decrease the samples averaged so that the DCR can respond

faster.

Example: Ignoring Intermittent Obstacles

To prevent agitators, splashing, or other intermittent objects from being
detected even though they are occasionally in the ultrasonic detection beam:

MODE VALUE DESCRIPTION

9 40 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.

10 0.3 ft. 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.

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

Outputs

The DCR-1005 and DCR-1006 contain 4 SPDT relays which are capable of
handling a 10 amp load. These relays have programmable BEGIN and END
points as well as TYPE of operation. The LED’s on the DCR indicate the status
of the relays. The programming units must be the same as those displayed. i.e.
If gallons are displayed the trip location should be set in gallons.

MODE DESCRIPTION PARAMETERS EXPLANATION

12 Begin Trip 1 Units = mode 1 Sets the begin point

Default = 2.5 ft. of Trip 1.

13 End Trip 1 Units = mode 1/mode 3 Sets the end point

Default = 2.9 ft. of Trip 1.

14 Trip 1 Type Range = 0 - 7 Selects the type of function

Default = 0 Trip 1 will perform.

See Trip Type Explanation for details.

15 Begin Trip 2 Units = mode 1/mode 3 Sets the begin point

Default = 3 ft. of Trip 2.

16 End Trip 2 Units = mode 1/mode 3 Sets the end point of

Default = 3.4 ft. of Trip 2.

17 Trip 2 Type Range = 0 - 7 Selects the type of function

Default = 0 Trip 2 will perform.

See Trip Type Explanation for details.

18 Begin Trip 3 Units = mode 1/mode 3 Sets the begin point

Default = 3.50 ft. of Trip 3.

19 End Trip 3 Units = mode 1/mode 3 Sets the end point

Default = 3.90 ft. of Trip 3.

20 Trip 3 Type Range = 0 - 7 Selects the type of function

Default = 0 Trip 3 will perform.

See Trip Type Explanation for details.

21 Begin Trip 4 Units = mode 1/mode 3 Sets the begin point

Default = 4.0 ft. of Trip 4.

22 End Trip 4 Units = mode 1/mode 3 Sets the end point of

Default = 4.40 ft. of Trip 4.

23 Trip 4 Type Range = 0 - 7 Selects the type of function

Default = 0 Trip 4 will perform.

See Trip Type Explanation for details.

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Off

On

Off

On

On

On

Off

Off

On

Off

On

Off

Off

On

Off

On

On

On

Off

Off

ZERO BEGIN END

Type 0:
Near

Type 1:
Exclusive

Type 2:

Type 3:
Far

Type 4:
Inclusive

Type 5:
Hysteresis Far

Type 6:

Hysteresis Near

Trip Point Disable

loss of echo, or loss of power.

an error is detected in communication,

Type 7: Relay remains closed (trip light on) unless

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.

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

Trip T ype Explanation

NOTE: TRIP END should always be a larger value than TRIP BEGIN.

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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 VALUE 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.

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

10 ft

4 ft

1 ft

6 ft

9 ft

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 DCR­1006 for this application, the following
modes must be set:

MODE VALUE DESCRIPTION

3 2 Select Volumetric Monitoring for this application so the display

will indicate the distance from the tank bottom to the level.

5 2.00 Do not set closer than the minimum distance recommended for

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 Use the hysteresis far type of trip to keep the pump on while

pumping the level down.
15 0.00 Begin the alarm trip point at the bottom because any signal

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 Any signal higher than 5 ft. or lower than 0 ft. will cause the

alarm relay to open.
28 1 Select a Flat Bottom Tank.
31 10 Distance from sensor to bottom of tank. The Controller subtracts

the measured distance from the T ank Span to display level.

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

External
Power
Source

(-)

(+)

4-20(+)

4-20(-)

Isolated 4 to 20 ma output

24V

DIG

GND

4-20 ma output
Analog Ground

Current sourcing 4 to 20 ma output

Analog Ground

4-20 ma output

4-20(+)

4-20(-)

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. 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.

MODE DESCRIPTION PARAMETERS EXPLANATION

24 4 mA distance Units = mode 1 Sets the minimum value

Default = 3.00 ft. of the analog output slope

25 20 mA distance Units = mode 1 Sets the maximum value

26 4 mA calibration Approx. 5000 Fine tunes the minimum

27 20 mA calibration Approx. 5000 Fine tunes the maximum

20

Default = 4.00 ft. of the analog output slope

current sourced on the
analog output

current sourced on the
analog output

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

Applications

The DCR Controller can be configured for two different types of

applications. They are:

• Distance: Measuring the distance to an object.

• Volume: Determining the volume, or level of a product in a tank.

DISTANCE

Measuring the distance to a target is the most basic application. The DCR

Controller will do this without any special settings.

Example: Distance Measurement

A batch plant operator needs a display to show the level of rock in a hopper

5 m deep.

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 3 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 1 Select distance monitoring for application.

4 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.

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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 for 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

0 - distance to level
1 - level indication
2 - hzontal flat ends
3 - hzontal sphere ends
4 - spherical tank
5 - conical bottom
Default = 0

Selects the type of tank to be
monitored. Set by V-UP or V-DN
Types 2-5 converts to volume
using units selected in mode. If
feet is the unit of measure then
display will read cubic feet of
product.

29 Constant Above Range = 0 - 9999

Decimal Point Default = 1
[Note: The relay and analog outputs
must be programmed in the same
units used here.]

30 Constant Below Range = .0000 - .9999

Decimal Point Default = .0000

31 Span Units = mode 1

Default = 12.00 ft.

32 Tank Length Units = mode 1

Default = 10.00 ft.

33 Length of Units = mode 1

Spherical Ends Default = 2.00 ft.
or Cone

34 Tank Radius Units = mode 1

Default = 5.00 ft.

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Sets the portion of the multiplier
above the decimal point. Used for
converting distance to volume or
converting from one unit to
another for example ft3 to gallons.

Sets the portion of the multiplier
below the decimal point.

Sets distance from the transducer
to bottom of the tank.

Sets the length of a horizontal
tank or the length to a conical
bottom.

Sets the length of the
bottom cone or spherical ends
(tank type 3 or 5)

Sets the radius of the cylinder
(not used in tank type 0 or 1)

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:

Cubic Feet (ft.3) x 7.4805 = Gallons
Cubic Feet (ft.3) x 28.317 = Liters
Cubic Inches (in.3) x 0.00433 = Gallons

Common Area Formulas
(for use with type 1 tanks):

Area of a Circle = P x r

2

Area of a Square or Rectangle =

L x W

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 selected 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.

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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

1 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.3 to gallons, multiplier above decimal point.

30 4805 Converting ft.3 to gallons, multiplier below decimal point.

31 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.

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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 1 Sets units to inches

3 2 Selects the operating mode to calculate level/volume
28 1 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 level 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)(R2)(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 242 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 29 Multiplier above the decimal point
30 6586 Multiplier Below the decimal point

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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 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

35 Temperature Range = 0 - 2

Compensation 0 = OFF

1 = ON
2 = Current Temp.
Default = OFF

EXPLANATION

Selects internal temperature
compensation for changes in the
speed of sound, on, off, or view
sensor temperature set by V-UP
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

Range = 0.000 - 9999
Default = 0

37 Offset Polarity Range = 0,1

0 = Subtract
1 = Add
Default = NEG

38 Calibration Range = 0 - 9999

Above the Default = 1
Decimal Point

Sets an offset for the
display when measuring
distance to a level.

Selects the direction of the
offset. adds or subtracts
offset to reading. Set by V­UP or V-DN.

Sets the integer portion of
the calibration factor.

39 Calibration Range = .0000-.9999

Below the Default = 0
Decimal Point

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Sets the fractional portion
of the calibration factor

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) = (D2-D1)/ (U2-U1) where;

D2 = far known distance U2 = Ultrasonic reading at D
D1 = close known distance U1 = Ultrasonic reading at D

2

1

Enter this multiplier in Modes 38 and 39. The multiplier can then be entered in
the above equation to calculate the offset B = D2 - (A)U2. The offset should be
entered using Modes 36 and 37.

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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.
1 = Pulse Width
Default = 0

Reset

When the DCR is powered up, ‘0’ is loaded in mode 41. This saves the user­selected 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 1 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

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

Extended Range

Modes 43 - 44 allows the DCR to display ranges greater than 50 ft. These

modes are enabled only in DST’ s with extended range.

MODE DESCRIPTION PARAMETERS EXPLANATION

43 Range Range = 0,1 Some DSTs will allow a

Selection 0 = 1 - 35 ft. Range detection range of up to

1 = 1 - 72 ft. Range 72 ft. This parameter
Default = 0 enables the DCR to

display that distance.

44 Maximum Range = 1 - 72 ft. This parameter works

Range Default = 35 ft. only with 72 ft. DSTs and

enables the user to limit
the maximum distance.

AutoSense

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
1 = ON the AutoSense feature
Default = 0 disabled or enabled.

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29

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

• 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 End Trip 3 ________________________
20 Trip 3 Type ________________________
21 Begin Trip 4 ________________________
22 End Trip 4 ________________________
23 Trip 4 Type ________________________

30

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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 ________________________
27 20 mA Calibration ________________________

Volume

28 Tank Type ________________________
29 Mult Above ________________________
30 Mult Below ________________________
31 Span ________________________
32 Tank Length ________________________
33 Sphere. Length ________________________
34 Tank Radius ________________________

Calibration

35 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 ________________________
44 Max. Range ________________________

Extended Range

45 AutoSense ________________________

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

• Maintenance

The DCR-1005 /1006 controller and DST sensors do not require maintenance.

However, a periodic visual inspection of the system would be in order.

The DST should be kept as clean as possible for optimum performance. Dust
buildup may be removed from the transducer with a cloth or by low pressure air.
The DST housing can be cleaned with soap and water.

If the DST is visibly affected by the environment, a different type of
transducer may be required.

32

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

• DCR Specifications

DCR-1005 DCR-1006

Outputs 4 relays (10 A 110 VAC) 4 relays (10 A 110 VAC)

with isolated 4-20 mA.

Supply Voltage 24 VDC or 110/220 VAC 24 VDC or 110/220 VAC

T otal Current 0.1 A 0.1 A
Draw

Housing Poly-Carbonate Poly-Carbonate

Rating NEMA 4X, IP65 NEMA 4X, IP65

Dimensions (in.) 6.25 x 3.125 x 2.25 6.25 x 3.125 x 2.25

Resolution Maximum of 0.1 in. Maximum of 0.1 in.

(2.5mm) (2.5mm)

Display 4 character digital LCD 4 character digital LCD

24 VDC Output 200 mA current max. 200 mA current max.

Operating Temp -30 to 60°C -30 to 60°C

Sample Rate 10 sec to 80 msec. 10 sec to 80 msec.

Adjustments Programmable modes Programmable modes

Connector T erminal S trip T erminal Strip

Sensor Coaxial “F” connector or Coaxial “F” connector or
Connector 2-conductor cable 2-conductor cable

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

• DST Specifications

DST-1002 DST-2421

Application Wet corrosive Wet corrosive

Environments Environments

Operating Range (ft.) 1.5 to 35 1 to 25

Enclosure PVC PC/PET

Transducer Type Ceramic Ceramic
Transducer Material PVC PVDF
Ratings NEMA 6P/IP65 NEMA 4X

Approvals Class I, Div. 1 n/a
Operating Temp -30 to 60°C -40 to 60ºC

Internal T emp Comp. Yes Yes
Accuracy 0.25% of range 0.25% of range

Dimensions L x D (in.) 7 x 3.5 7 x 2.5
Beam Pattern 9° off axis 9° off axis

Standard Cable Coaxial RG-6 2-conductor

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

• DST Specifications (continued)

DST-3431 DST-5111

Application Wet corrosive Wet corrosive

Environments Environments

Operating Range (ft.) 1.25 to 50 4 to 72 inch

Enclosure PC/PET PC/PET

Transducer Type Ceramic Ceramic
Transducer Material PC/PET PVDF

Ratings NEMA 4X NEMA 6P/IP65
Approvals n/a n/a

Operating Temp -40 to 60°C -30 to 60ºC
Internal T emp Comp. Yes Yes

Accuracy 0.25% of range 0.25% of range
Dimensions L x D (in.) 7.5 x 3.5 4.5 x 3

Beam Pattern 9° off axis 9° off axis
Standard Cable 2-conductor 2-conductor

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

• DST Specifications (continued)

DST-9421

Application Dry stable

Environments

Operating Range (ft.) 0.5 to 35

Enclosure PC/PET

Transducer Type Electrostatic
Transducer Material Gold-Kapton
Ratings NEMA 12

Approvals n/a
Operating Temp -40 to 70ºC

Internal T emp Comp. Yes
Accuracy 0.25% of range

Dimensions L x D (in.) 5.5 x 2.5
Beam Pattern 9° off axis

Cable 2-conductor

AutoSense SOFTW ARE ~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.

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

Notes

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

Notes

38

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

Notes

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AUTOMATION

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for measurement applications

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GROUP, INC.

1/435/753-7300

PRODUCTS

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