APG DCR-WEB User Manual

PRODUCTS

AUTOMATION

Operator’s Manual

GROUP, INC.

DCR-WEB

Rev. A3, 10/08

Doc. 9002666

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Automation Products Group, Inc.

DCR-WEB Rev. A3, 10/08

Table of Contents

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

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

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

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

Wiring.............................................................................................. 8

Programming.................................................................................. 9

Programming Modes .................................................................... 10

Operation ................................................................................... 10

Filtering ..................................................................................... 11

Outputs ...................................................................................... 13

Calibration................................................................................. 16

Utilities ...................................................................................... 17

Specifications ................................................................................ 19

Dimensions.................................................................................... 19

Maintenance ................................................................................. 20

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Automation Products Group, Inc.

Rev. A3, 10/08 DCR-WEB

• 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-WEB Rev. A3, 10/08

• Introducing

The DCR-WEB is a non-contact loop control system that is shipped ready to
be put into service. It has been completely tested at the factory and is easily
configured to any application. The sensor is fully programmable to meet the
needs of all different kinds of loop control applications. Operating parameters
are modified using 4 push buttons and a 2 X 8 alphanumeric display . The
controls are accessed by removing the front cover. It is recommended that this
manual be read before attempting to make any changes to the default
parameters.

The unit is available in a clear plastic enclosure. There are two types of
transducers availably . The electrostatic type in a 2 in. x 3.3 in. x 1.6 in.
enclosure. The ceramic type in a 3 in. x 3 in. x 2 in. enclosure. Both types are
attached to the controller with a 6 ft. length of RG6 coaxial cable.

T wo outputs can be wired by the customer are labeled “RLY1” and “RLY2”.
These outputs are 5 A relays suitable for 120 VAC and up to 5 A continuous.
They are fully programmable outputs.

There are two terminal sections on the board. Each can be wired to a switch.

• INV-SW allows the user to invert the 0-10 V output without changing

software settings.

• AP-SW allows the user to switch between two different pre-programmed

settings. For example, two different filter settings and trip distances for
different materials can be stored and selected with a switch.

4

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Automation Products Group, Inc.

Rev. A3, 10/08 DCR-WEB

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 1-20 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

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5

DCR-WEB Rev. A3, 10/08

accuracy.

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.

6

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Rev. A3, 10/08 DCR-WEB

• Installation

Accurate readings require 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 “Understanding Ultrasonics”.

The DCR-WEB should be installed using the 4 screws through 4 holes in the
bottom of the enclosure.

Inputs

• 110 VAC Power

• 4 button Key Pad
Mode Up, Mode Down, Number Up and Number Down Keys.

• 0-10 V Invert
When a switch is closed across the INV-SW terminals, the port on the
processor is pulled low the distance programmed in the 0 V distance
becomes the 10 V distance and the distance programmed in the 10 V
distance becomes the 0 V distance.

• Alternate Program
When a switch is closed across the AP-SW terminals the DCR can be
programmed with a second setup that will be stored for that switch
position.

Outputs

• Isolated 0-10 V output
To connect to a variable speed drive for loop control.

• T wo 5 A Relays
Fully programmable.
Can be jumpered

Normally Open or Normally Closed

(Default = NO) *See drawing on next page

• Display
2 X 8 LCD alphanumeric display that displays the detected distance or the
mode value on the top and the parameter on the bottom.

Automation Products Group, Inc.

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7

DCR-WEB Rev. A3, 10/08

RELAY

RELAY

2-3 = NO

1-2 = NC

Relay Jumper Settings

Default = NO

1 3

3

21

2

• Wiring

Step 1: Mount sensor so that transducer has a clear path to the target.

Step 2: To obtain access to the terminal strip, remove the front cover by

turning out the 4 screws. This will expose the terminal strip and 2 X 8 character
display.

Step 3: Wires can be pulled into the DCR-WEB through the strain reliefs on

the enclosure.

The screw terminal can be wired using solid or stranded wire between 16 - 20

A WG. W ires should be stripped, leaving a 0.4 in. bare wire.

Follow the legend on the circuit board when wiring. The DCR-WEB should

never be used without the earth ground terminal being connected.

Step 4: Perform an internal check to ensure that all wires are properly

connected and secured.

8

APG...Providing tailored solutions for measurement applications

Automation Products Group, Inc.

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