Hycontrol Microflex LR Integral Installation/operation Instruction Manual

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Page 1

Elec. Iss. 04

Hycontrol Limited, Larchwood House, Orchard Street,

Redditch, Worcestershire, UK. B98 7DP

Tel: + 00 44 (0)1527 406800 Fax: +00 44(0)1527 406810

Email: [email protected] Web: www.hycontrol.com

May 2013 Rev 04

Microflex LR – Integral

(Ultrasonic Level Measurement)

Installation & Operation

Instruction Manual

Page 2

INDEX

PAGE

1. GENERAL DESCRIPTION 3

1.1. Microflex LR Integral 4

2. INSTALLATION GUIDE 5

2.1. Installation Position 5

2.2. Installation Dimensions 6

2.3. Installation Wiring 7

2.3.1. MI2 – 2 wire loop powered transmitter 7

2.3.2. MI3 – transmitter with 2 relays and 4-20mA outputs 7

2.3.2.1. MI3 - Terminal Connections for AC supply 7 a. Modulating from User’s External DC Supply (RL to Pos) 7 b. Modulating from User’s External DC Supply (RL to Neg) 8 c. 4 Wire DC – Driving from Internal Isolated Supply (Is) 8

2.3.2.2. MI3 – Terminal Connections for DC Supply 8 a. 4 Wire DC – Driving from Internal Isolated Supply (Is) 8 b. 3 Wire DC – Modulating from Common User Supply (RL to +DC) 8 c. 3 Wire DC – Modulating from Common User Supply (RL to GND) 9

2.4. Hycontrol Link Wiring for Remote diagnostics via GSM 9

3. PROGRAMMING 10

3.1. Entering Data 10

3.2. Access to Main Menu 10

3.3. Entering Basic Data – QUICKSET 11

3.3.1. Flow – Programming 12

3.3.2. Volume 13

3.4. Entering Output Adjustments 13

3.5. Tx Set-up for Gain and Threshold 14

3.6. Diagnostic Display 15

4. GENERAL SPECIFICATION 16

5. PART NUMBER SELECTION 17

6. LABELLING INFORMATION 18

7. MODBUS REGISTER LIST 19 - 22

8. ASSEMBLY OF FLANGE AND CONES 23 APPENDIX A. CROSS TALK PREVENTION 24 - 25 APPENDIX B. APPLICATION TYPES 26 - 27

Microflex LR Integral Transmitter Operating & Installation Manual May 2013 Rev 4 Page 2

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USER MANUAL

GENERAL DESCRIPTION

The Microflex LR – Integral Transmitter is capable of non-contact level measurement over distances of up to 60 metres, depending on the application. The Integral is an intelligent, system approach to measurement of solids and liquids with maximum performance combined with a display and keypad.

The Integral is available with four different transducers for ranges of 10, 20, 40 and 60 metre operation. Each configuration is available as a 2-wire, DC powered 4-20mA loop (MI2) or 2, 3 and 4 wire DC and AC powered (MI3) with a combination of Modbus, 2 relays, 4-20mA and PC comms outputs.

The transmitter must be mounted directly above the surface of the material to be monitored.

Ultrasonic pulses are transmitted to the surface of the material to be monitored and reflected back to the transmitter. The time period between transmission and reception of the pulses is directly proportional to the distance between the transmitter and the material.

Since the speed of sound through air is affected by temperature, a temperature sensor is integrated into the face of the transmitter to improve accuracy.

The Integral transmitter is suitable for measuring the following on solids and liquids:

a) Ullage space or distance to material b) Material level c) Volume measurement d) Material percentage e) Flow of liquids in open channels

MICROFLEX LR LONG RANGE LEVEL TRANSMITTERS

WARNING

Do not open the transmitter terminal cover or remove

any connection whilst the power is ON.

REFER TO ‘ATEX Safety & Operating Instructions Manual’

IF INSTALLING IN A HAZARDOUS AREA

Microflex LR Integral Transmitter Operating & Installation Manual May 2013 Rev 4 Page 3

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1.1 Microflex LR Integral

The Integral Transmitter is an easy-to-use level transmitter available with four (4) different high power, low frequency front ends, capable of reliably tracking the level of solids and liquids under difficult conditions, programmed via a 4 button keypad and an integral menu driven display.

The transmitter is available with a choice of 2 relay switches, 4-20mA or Modbus outputs; up to 32 instruments can be networked together.

If specified, the instruments are available approved for ATEX EEx ia Zone 0 gases & Zone 20 dusts (24Vdc only) or ATEX Dust Protection only, Zone

20. Remote programming of the product is available via

Hycontrol’s Vision System II software and all the

instruments can be connected via the Hycontrol Link to a Service Engineer in the Redditch office to analyse and overcome any problems which may be experienced in the field, without incurring any expensive call-out charges.

Microflex LR Integral Transmitter Operating & Installation Manual May 2013 Rev 4 Page 4

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INSTALLATION GUIDE

The Integral transmitters are designed to be screwed directly into a flange on a tank. For long range and dusty applications, the use of a focaliser on the underside of the flange improves the concentration of the signal and ensures that spurious signals are eliminated.

2.1 Installation Position

Ensure that the mounting surface is not subject to vibration and is not in close proximity to high voltage power cables, contactors or drive controls. The unit should not be mounted in a confined space where temperature might exceed the safe working temperature –20°C to + 60°C*. If the unit is mounted outside it should be protected from direct sunlight or severe weather conditions.

When using a focaliser cone, ensure that it protrudes at least 50mm into the vessel.

The transmitter must be installed to ensure a clear line of sight from the radiating face to the product being monitored. Refer to diagrams on Page 6.

Avoid mounting near fill points, ladders, baffles, agitators etc.

Minimum 50mm (2")

NOZZLE

MOUNT

FLUSH

MOUNT

STAND PIPE

MOUNT

Minimum 50mm (2")

‘B’

TOP LEVEL

For ‘B’ blanking – refer to table on page 6.

30KHz 2"

BSP / NPT

MOUNT

*For ATEX temperature classifications see ATEX Safety & Operating Instructions Manual.

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Transmitter Mounting

SOLID (Granular)

LIQUID

DUAL OUTFEED

POWDER

Aim transmitter at

point of outfeed.

Transmitter should be

as perpendicular to

product as practicable.

Use two transmitters and

wire and program as

shown in Appendix A to

avoid cross-talk.

Mount away from

infeed

2.2 Installation Dimensions

MI2 Two wire loop powered transmitter with display and 4-20mA output.

MI3 2, 3 or 4 wire transmitter with display and can have PC Comms, Modbus and Relay output.

Thread

size

Flange

optional

120LC

Optional

160

3 x M16 Conduit

entries

MI2 Two wire transmitter with display MI3 2, 3 or 4 wire transmitter with display and 2 relays

Range Metres

Optional

Thread

Size

Flange

Optional

177 - 50 - 2”

255

275

3”

4”

410

413

236

3.5”

10”

687

460

236 - 10”

Flange Options: ANSI, DIN or JIS

Dimensions for 10, 20, 40 & 60 metre range

Ensure that the transmitter face always has the minimum Blanking Distance above the highest product level in the tank. See table below.

TRANSMITTER

MINIMUM DISTANCE

Minimum

Nominal

MI__10

0.35m (1.2ft)

0.5m (1.6ft)

MI__20

0.5m (1.6ft)

0.8m (2.6 ft)

MI__40

1.0m (3.3ft)

1.3m (4.2 ft)

MI__60

1.2m (4ft)

1.5m (5 ft)

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2.3 Installation Wiring

2.3.1 Wiring Diagram – MI2 – 2 wire Loop Powered Transmitter

Terminals

Terminal Connection

Use

Shielded cable

User 24V

DC Supply

PLC DCS

IND

RL Max 750Ω

4-20mA

TEST

4-20mA

MI2

Terminal

Connection

2.3.2 Wiring Diagram – MI3 – Transmitter with 2 relays & 4-20mA Outputs

Terminals

RL2 COMMS RL1

See Appendix A for ‘Test’ function.

2.3.2.1 MI3 – Terminal Connections for AC Supply

a) Modulating from User’s External DC Supply (RL to Pos.)

4-20mA

Use

Shielded cable

PLC

DCS

IND

RL Max 750Ω

4-20mA

MI3

Terminal

Connection

AC-IN

User 90 – 260V AC Supply

User 24V

DC Supply

NOTE: RL Max = 750Ω If user DC Supply 24V

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b) Modulating from User’s External DC Supply (RL to Neg.)

Use

Shielded cable

PLC DCS

IND

RL Max 750Ω

4-20mA

MI3

Terminal

Connection

AC-IN

User 90 – 260V AC Supply

User 24V

DC Supply

NOTE: RL Max = 750Ω If user DC Supply 24V

c) 4 Wire DC – Driving from Internal Isolated Supply (Is)

Use

Shielded cable

PLC

DCS

IND

RL Max 400Ω

4-20mA

MI3

Terminal

Connection

AC-IN

User 90 – 260V AC Supply

NOTE: Isolated current output can be made common with external DC Supply Positive or Negative if required (e.g. RL – connected to GND)

2.3.2.2 MI3 – Terminal Connection for DC Supply

a) 4 Wire DC – Driving from Internal Isolated Supply (Is)

Use

Shielded cable

User 24V

DC Supply

PLC DCS

IND

RL Max 400Ω

4-20mA

MI3

Terminal

Connection

GND

+DC

DC-IN

NOTE: Isolated current output can be made common with +DC or GND if required (e.g. RL – connected to GND)

b) 3 Wire DC – Modulating from Common User Supply (RL to +DC)

Use

Shielded cable

User 24V

DC Supply

PLC DCS

IND

RL Max 750Ω

4-20mA

MI3

Terminal

Connection

GND

+DC

DC-IN

NOTE: RL Max = 750Ω If user DC Supply 24V

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c) 3 Wire DC – Modulating from Common User Supply (RL to GND)

Use

Shielded cable

User 24V

DC Supply

PLC DCS

IND

RL Max 750Ω

4-20mA

MI3

Terminal

Connection

GND

+DC

DC-IN

NOTE: RL Max = 750Ω If user DC Supply 24V

2.4 Hycontrol Link GSM Connection

The Hycontrol Link is a separately powered GSM module which enables Hycontrol Service Engineers to interrogate and programme any MI3 transmitter.

The following diagram shows how to wire it to the MI3.

Hycontrol Link Terminal

MI3 Series Transmitter (2 Relays)

To other Microflex LR and Reflex LR units

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PROGRAMMING – Integral via 4 button & display

3.1 Entering Data

All software adjustments are achieved via the four PUSH BUTTONS on the front panel of the Transmitter.

(A)

Press for 3 secs – this interrupts normal operations to allow access to customized options and enables headings and functions to be edited.

IN SET-UP

(B)

Momentary press – saves selected value. Press and hold – scrolls through set-up menus and parameters.

(A) (B)

Increases displayed value. Scrolls up through software set-up options.

(A) (B)

Decreases displayed value. Scrolls down through software set-up options.

(A)

(B)

One press takes the user back one step. Press twice when all selections are finished.

Stores the current set-up in memory and checks the validity of the software selections, then returns the instrument to normal operating condition.

Use these 4 buttons along with the following ‘software tree’ to customize the

instrument for your application.

3.2 To access main menu

Space

5.72m

Unlock

QuickSet

Output Adj

CAL

Factory default code = 0

To enter a different code use

arrow buttons

NOTE: - At switch on display

may appear different but

instrument is pulsing

CAL

To adjust QuickSet

settings see

Quickset menu 3.3

START HERE

1. To enter programming

mode press and hold CAL

button until Unlock appears

Tx Set up

2. Press CAL again to enter program menu

To adjust Output

settings see

Output Adj menu 3.4

To adjust Gain or

Threshold see

Tx Set up menu 3.5

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3.3 Entering Basic Data – QUICKSET

Go to QUICKSET and enter the values for the specific application.

QuickSet

Units

Low Level

High Level

Fail Time

Failsafe

Application

Type

Fill Speed

View

Empty Speed

View

Display Mode

CAL

Use arrows to select from:

Inches Feet Metres Centimetres

Use arrows to adjust Low Level

Enter the distance from the face of the Transducer that corresponds to the low level in the vessel - 4mA output level.

Use arrows to adjust High Level

Enter the distance from the face of the Transducer that corresponds to the high level in the vessel - 20mA output level.

Use arrows to enter the number of pulses to be tried before failure condition is accepted.

Recorded value 60 for MI2 and 200 for MI3 which relates to approximately 2 minutes delay before indicating failure.

Use arrows to select required output value under failure condition from:

20mA

4.0mA Last known > 20mA = 20.2mA < 4.0mA = 3.8 – 3.5 mA

Use arrows to select from List:

See Appendix B for options

Use arrows to select appropriate speed of rate of change of level:

Custom (units/hour) View (displays current speed setting) Fast Medium Slow

Use arrows to select normal display output from:

Space Material % Material Flow (See note on FLOW-Section 3.3.1) Volume

Clear All

CAL

Use arrows to toggle selection:

YES will cancel all past entries and return the instrument to factory defaults. NO will leave everything as previously programmed.

To adjust

Units

To adjust

Low Level

To adjust

High Level

To adjust Fail Time

To adjust

Failsafe

To adjust

Application

To adjust

Fill Speed

To adjust

Empty Speed

To adjust

Display Mode

To toggle

selection

To accept

change

To accept

change

To accept

change

To accept

change

To accept

change

To accept

change

To accept

change

To accept

change

To accept

change

To accept

change

To enter

QuickSet

*Press RUN twice to exit program mode and revert to normal operation

Part of MAIN menu

1. Press CAL to

access Quickset

4. User arrows to adjust value or

select options

3. Press CAL to

access parameter

2. User arrows to select parameter

to adjust

5. Press CAL to accept change

Note: After changing

the Application Type

always set

appropriate Fill and

Empty Speed.

CAL

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3.3.1 Flow

In the QUICKSET menu, Section 3.3 select Flow as the Display Mode to allow open channel flow using q = khn. This enables 4 additional parameters allowing the instrument to be programmed for flow.

Display Mode

XXXXX

Display Mode

Flow

CAL

Space Material Material %

Flow

Volume

Use arrows to select from:

Cube ft Cube mtr M litres K litres Litres

Use arrows to adjust to required exponent.

Use arrows to adjust to maximum Flow rate value in Flow units.

End of Flow Setup.

Returns to start of

Quickset menu

Use arrows to adjust to minimum level of flow to be recorded in level measuring units. (When the head is below this value it is deemed not to be flowing).

1. Use arrows to select Flow for

Display Mode

CAL

Flow Unit

Flow Exp.

Flow Max

Lo Cut Off

CAL

2. Press CAL

to select Flow

3. Additional flow parameters now

available

Part of QUICKSET

To adjust

Flow Unit

To adjust

Flow Exp.

To adjust

Flow Max

To adjust

Lo Cut Off

To accept

change

To accept

change

To accept

change

To accept

change

Example 3/2 Rectangular flume, with a maximum flow of 150 l/s at head 0.3m, with a bottom of flume level of 1.30m. Low cut off of 0.010m.

1. Select the required Flow Unit - Litres

2. For a 3/2 Rectangular flume enter a Flow Exp. (n) of 1.50.

3. Enter the maximum flow value 150 l/s that corresponds to the maximum head of 0.3m in Flow Max (Low level – High level).

4. Enter Lo Cut Off of 0.010m.

5. Ensure that the Low Level value in Quickstart menu is 1.30m from transducer face.

6. Ensure that the High Level Value in Quickstart menu is 1.00m from transducer face.

1.300m

(Low Level)

1.000m

(High Level)

Transducer position

3-4 times max. head.

0.900m –

1.200m

Flow

0.300m

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3.3.2 Volume

Volume can only be programmed via the Hycontrol Vision System II programming software package - please refer to Hycontrol office for further information.

3.4 Set-up – Output Adjustments

CAL

Use arrows to adjust Fill Damping

000 Min. 999 Max.

Use arrows to adjust Empty Damping

Adjusts the speed of response. Low number gives fast response. If damping set to 60 the display will be the average of the last 60 pulses.

CAL

Output Adj

Rly Mode 1 Off

Rly Mode 2 Off

Fill Damp

Empty Damp

4mA Adj

20mA Adj

Analogue

4-20mA

Simulate

Comms Type

CAL

Forces instrument to output 4mA so that remote indicator can be set.

Use arrows to adjust the 4mA value outputted to indicator if required.

Forces instrument to output 20mA so that remote indicator can be set.

Use arrows to adjust the 20mA value outputted to indicator if required.

Use arrows to select analogue output

20-4mA 4-20mA

Use arrows to enter a test value to output as a 4-20mA signal. This is cleared once program mode is exited.

Use arrows to select Comms Type.

Device Net Profibus Hart Modbus

*Press RUN twice to exit program mode and revert to normal operation

Settings applicable to both relays

Use arrows to select Relay Mode

DEN Relay normally de-energised.

Will energise if level above L1. Will de-energise if level below L2.

En Relay normally energised.

Will de-energise if level above L1. Will re-energise if level below L2.

FS Relay will be normally energised

and De-energised if instrument goes to failsafe condition.

OFF Relay not used

No Relays included in MI2 and 2 relays included in MI3

CAL

To adjust

Relay 1

To adjust

Relay 2

To adjust

Fill Damping

To adjust

Empty Damping

To force

output to

4mA value

To force

output to

20mA value

To change

Analogue Output

Selection

To Simulate

4-20mA change

To adjust

Comms Type

Use arrows

to enter

Device ID.

CAL

Use arrows

to enter

Baud Rate

CAL

To accept

change

To accept

change

To accept

change

To accept

change

To accept

change

To accept

change

To accept

change

Part of MAIN menu

1. Press CAL to

access Output Adj

4. User arrows to adjust value or

select options

3. Press CAL to

access parameter

2. User arrows to select parameter

to adjust

5. Press CAL to accept change

CAL

To accept

change

CAL

To accept

change

CAL

Rly L1

CAL

Rly L2

Use arrows

to adjust Relay L1

Use arrows

to adjust Relay L2

CAL

To accept

change

Enter L1 & L2 values

as distance from the

transducer face

DispChar

BkLight

CAL

Use arrows to select display.

12 char 8 char

Use arrows to select backlight.

On Off

CAL

To select

Display Type

To select

backlight

CAL

To accept

change

To accept

change

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3.5 Tx Set-up for Gain and Threshold

It is only necessary to change the Tx Set-up for Gain and Threshold in difficult applications, usually associated with level control of solids products.

3.5.1.

If, after completing the entry of all Quick Start (Section 3.3) and Output Adjustments (Section 3.4), the instrument is monitoring the level correctly then do not adjust the Tx Set-up parameters.

Do go into Diagnostic Display (Section 3.6) and check that the echo size “S” in volts is stable at approximately 1.0 to 2.0 volts.

3.5.2

If the instrument is not reading the correct level or the echo size “S” is unstable then go into Tx Set-up (See 3.2) Gain “GN” and adjust “Gain” as follows:

Tx Setup Gain

Increase gain if no echo detected or is less than 1.0 volts. (See A)

Reduce gain, if echo detected is in front of the true larger echo, but it is greater than the threshold. (See B & C)

CAL

Threshold

CAL

Increase threshold to increase noise immunity (See D)

CAL

CALCAL

If no echo is detected or the echo size “S” in volts is below 1.0 volt, then increase “Gain” until the echo is detected and “S” equals 1.0 volt

minimum.

If the instrument is detecting an echo which is closer to the transducer than the true level, then reduce gain until the correct level is detected. Now check that the echo size “S” is still at least 1.0 volt. If it is below this level contact Hycontrol – it may be that the transducer position is not optimal.

If the echo size “S” is unstable, flicking between two echoes, then

increase gain until the echo stabilizes on an incorrect close echo. Note

the “Gain” and then reduce the value by 30. This will give the best gain “GN” to use to avoid any close in echoes. Check to ensure that echo

size “S” is between 1.0 and 2.0 volts.

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Threshold is rarely adjusted unless there is a problem during filling. On occasions the echo, caused by the fill-stream, may be large enough and constant enough for it to be above the threshold setting. This would show itself as a closer unwanted echo. If this occurs, check the size of

the unwanted echo “S” in diagnostics and adjust the “Threshold” voltage

above the echo size seen during filling.

3.6 Diagnostic Display

If you press the or push buttons when the instrument is in its normal RUN mode, the following diagnostics are available.

Instant echo distance. This is the distance which the instrument records for each pulse of the transducer and should be reasonably stable

Echo size in volts This should be stable around 1.0 to 1.5 volts for a good signal.

Gain used to detect echo.

The amount of gain to recover if the echo is less than threshold detection voltage level

Noise value

Temperature at sensor face

Window starting distance

Window finishing distance

Normal or recover. Normal if echo is above threshold. Recover if there is an echo but it is not reaching the threshold.

Damped distance

E: 4.2

S: 1.11v

G: 37.6

R: 0.0%

N: 1.9%

T: 23.2ºC

W: 2.0m

W: 2.4m

Normal

Tx 1

Space

4.221m

Liquids

Application Type

INITIAL

DISPLAY

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GENERAL SPECIFICATION

Instrument Type : Microflex LR Integral (MI)

Power Supply : 2 wire 4-20mA loop (MI2) or 2,3,4 wired AC/DC (MI3)

Range : Up to 60 metres

Blanking : Variable from 0.3 metres (dependent on instrument type)

Process media : Liquids or Solids

Analogue Output : 4-20mA into 750 Ohm Ext. Supply.

400 Ohm Int. Supply.

Power Supply : 12 - 30V DC

: 90 - 260V AC

Relays : 2 Form C SPDT rated 0.5 amp at 240V AC (MI3)

Resolution : 1mm up to 20 metre range

: 4mm from 20-60 metre range

Accuracy : +/- 0.25% of maximum range Operating temperature : -40ºC to + 80ºC *

Ambient temperature : Electronics -40ºC to + 80ºC * Display : 2 line 8 digit LCD Enclosure : Integral System IP67

Key Pad : Integral 4 button

Mounting : MI__10 2" NPT or BSPT

MI__20 4" Flanged ANSI, DIN or JIS MI__40/60 10" Flanged ANSI, DIN or JIS

Weight : MI_10 1.75Kg (Typical weight)

MI_20 3.5Kg (Typical weight including flange & cone)

MI_40 9.5Kg (Typical weight including flange & cone)

MI_60 13.5Kg (Typical weight including flange & cone)

Cable Entries : M16 Cable Glands

Comms : Modbus (MI3 option)

: Multi-drop capability (up to 32 units)

: Vision System II Software Package

: Hycontrol GSM Link (GSM/CDMA connectable)

*For ATEX models refer to ATEX Safety & Operating Instructions Manual.

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PART NUMBER SELECTION:- MICROFLEX LR INTEGRAL

MODEL Microflex LR Ultrasonic Level Transmitters

MI2 Integral 2 wire transmitter with display and no relays (Select Analog 4-20mA or HART in output section) MI3 Integral 2, 3, & 4 wire transmitter with display and 2 relays

Power Supply

12-30V DC

U Universal power supply 90-260V AC / 24V DC MI3 only

Measuring Range - Transducer Frequency

10 30kHz 10m max 20 20kHz 20m max 40 10kHz 40m max 60 5kHz 60m max

Process Temperature - Transducer Facing Material

S T Standard temperature ~ Wet atmosphere ~ Teflon face, 30 & 20KHz

Transducer Housing Material

Polypropylene

20, 10 & 5KHz

6 Teflon 30KHz

Process Connection

FA ANSI Flange FD DIN Flange FJ

JSI Flange

SB BSP 30KHz only SN NPT 30KHz only XX Not required

Process Connection Size

02 2 inch thread 30KHz only 04 4" Flange only 06 6" Flange only 08 8" Flange only 10 10" Flange only Standard on 10KHz & 5KHz

XX Not required

Flange Material

4 Polypropylene 6 Teflon 7 Carbon Fibre X Not required Z Special

Cone

XX Not required

04 4" 10 10"

Cone Material

4 Polypropylene 6 Teflon 7 Carbon Fibre 8 Polyurethane X Not required Z Special

Approvals

X Without

A ATEX EEx ia* MI2 only not MI3

D ATEX DIP*

H HART MI2 only A 4/20 mA only MI2 or MI3 M Modbus 4/20mA MI3 only S Switch 2 relays MI3 only

I HART isolated MI3 only

W Modbus only MI3 only

MI2 B 10 S 4 SB XX X XX X X A Typical Part Number

*For ATEX models refer to ATEX Safety & Operating Instructions Manual.

MI2 or MI3

Standard Temperature ~ Dry product ~ Polyolefin face, 10 & 5KHz

Standard on 20KHz

MI2 & MI3

Output

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LABELLING INFORMATION.

Standard label fitted to all Microflex LR Integral Transmitters.

HYCONTROL LTD. ENGLAND

Tel:+44(0)1527 406800 www.hycontrol.com



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MODBUS REGISTER LIST

BASIC MODBUS SPAN AND DIAGNOSTIC REGISTERS FOR HYCONTROL MICROFLEX LR SERIES INSTRUMENTS

Hycontrol Microflex LR series units communicate using ‘2 wire’ (plus Ground) RS485 connection, and can be connected in ‘multi-drop’ configurations.

Protocol: Modbus RTU (2 wire) Speed: 19200 Baud Data bits: 8 Parity: None Stop Bits: 1

Hycontrol Microflex LR series units act as ‘slave’ devices on a Modbus network. Units are shipped from the factory with a default Modbus address of 1.

The Modbus address of any unit can be changed individually if units are to be connected in a multi-drop network. Each address number must only be used once on any network (possible addresses are 1…255).

Diagnostic Block (Read Only): *Can be read as Singles or any Block wholly within the limits of this range of addresses*

40124 - LOW LEVEL span set point in mm 40125 - HIGH LEVEL span set point in mm 40126 - DISPLAYED DISTANCE (DISTANCE) in mm 40127 - NOT USED 40128 - NEW DISTANCE (E-DISTANCE) in mm 40129 - CONFIRM DISTANCE (C-DISTANCE) in mm 40130 - ECHO SIZE in Volts/102 40131 - GAIN at Echo detection point in %/7.5 40132 - NOT USED (Gain Limit) 40133 - RECOVER GAIN currently being used in %/7.5 40134 - NOISE in %/7.5 40135 - TEMPERATURE in Degrees K/10 ((DegreesC+273.2)/10) 40136 - NOT USED 40137 - CONFIRM COUNTER current value 40138 - HOLD COUNTER current value 40139 - NOT USED 40140 - WINDOW FORWARD POSITION in mm 40141- WINDOW BACK POSITION in mm

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Identity Information (Read Only): *MUST Read as SINGLES-NOT BLOCKS*:

40002 - SERIAL NUMBER raw number 40003- TYPE NUMBER raw binary values- bits defined as listed here: Bit0- Power Configuration- ‘0’= 234 wire

‘1’= 2 wire Bit1- Range/Resolution- ‘0’=Standard(60m/1mm) ‘1’=Long(175/4mm) Bit5- Mechanical Config- ‘0’=Remote ‘1’=Integral 40004- AMPLIFIER SOFTWARE VERSION raw number/100 40005- AMPLIFIER MODBUS ID raw number 40006- AMPLIFIER MODEL NUMBER- values defined as listed here: 0-Ultrasonic Air 1-Sonar 7-N/A 8-N/A 9-N/A 40402- TRANSDUCER SERIAL NUMBER raw number 40403- TRANSDUCER MODEL NUMBER raw number (tx freq. in kHz) 40404- TRANSDUCER SOFTWARE VERSION raw number/100 40405- TRANSDUCER MODBUS ID raw number

Span Adjustment (Read/Write) *MUST Read/Write SINGLES-NOT BLOCKS*:

40013 - LOW LEVEL span set point in mm 40014 - HIGH LEVEL span set point in mm

RELAY Function Adjustment (Read/Write) *MUST Read/Write SINGLESNOT BLOCKS*:

40052- Relay 1 Mode setting- values defined as listed here: 0-OFF 1-FS (Failsafe) 2-EN (Energise on Level) 3-DEN (De-Energise on Level) 40053- Relay 2 Mode setting- values defined as listed for Relay 1 above 40054- Relay 3 Mode setting- values defined as listed for Relay 1 above 40055- Relay 4 Mode setting- values defined as listed for Relay 1 above 40056- Relay 5 Mode setting- values defined as listed for Relay 1 above 40036- Relay 1 L1 set point in mm 40037- Relay 1 L2 set point in mm 40038- Relay 2 L1 set point in mm 40039- Relay 2 L2 set point in mm 40040- Relay 3 L1 set point in mm 40041- Relay 3 L2 set point in mm 40042- Relay 4 L1 set point in mm 40043- Relay 4 L2 set point in mm 40044- Relay 5 L1 set point in mm 40045- Relay 5 L2 set point in mm

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Extended Params (Read/Write) *MUST Read/Write SINGLES-NOT BLOCKS*:

40060- DISPLAY UNITS parameter setting- values defined as listed here: 0-Frequency (Hz) *Not valid for level instruments* 1-Pressure (kPa) *Not valid for level instruments* 2-Pressure (PSI) *Not valid for level instruments* 3-Millimetres 4-Centimetres 5-Metres 6-Feet 7-Inches 40015- FAILSAFE MODE parameter setting- values defined as listed here:

0- 3.5mA 1- 3.8mA 2- 20.2mA 3- Last Known 4- 4.0mA 5- 20.0mA 40016- FAILSAFE TIME parameter setting- in seconds 40017- APPLICATION TYPE parameter setting- values defined as listed

here: 0-Liquid 1-Solid 2-Slurry 3-Position 40018- FILL RATE parameter setting- in metres per hour/10 40019- EMPTY RATE parameter setting- in metres per hour/10 40020- DISPLAY MODE parameter setting- values defined as listed here: 1-Volume 2-Flow 3-Material % 4-Material 5-Space 6-Differential Output 7-Average Material 40065- FLOW UNITS parameter setting- values defined as listed here: 32-Litres 33-Kilolitres 34-Megalitres 35-Cubic Metres 36-Cubic Feet 40031- FLOW EXPONENT parameter setting- in raw units/100 40032- FLOW MAX parameter setting- in selected flow units per

second/10 40033- LOW CUT OFF parameter setting- in mm 40033- OFFSET parameter setting- in mm (0-5000) 40021- LOCK CODE parameter setting- raw number 40022- FILL DAMPING parameter setting- raw number 40023- EMPTY DAMPING parameter setting- raw number

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40064- ANALOG mode parameter setting- values defined as listed here:

0- 4-20mA (4mA low, 20mA high- standard)

1- 20-4mA (20mA low, 4mA high- inverted) 40448- GAIN parameter setting in %/7.5 40449- GAIN STEP parameter setting in %/7.5 40450- DISTANCE STEP parameter setting in mm 40451- THRESHOLD parameter setting in Volts/100 40452- BLANKING parameter setting in mm 40453- EMPTY DISTANCE parameter setting in mm 40454- TEMPERATURE ADJ parameter setting- raw number 40455- DISTANCE ADJ parameter setting in mm 40456- VELOCITY parameter setting Value/10000 40457- MAP DISTANCE parameter setting in mm 40458- MAP USED parameter setting in mm 40461- MAP MARGIN parameter setting in %/7.5 40434- RECOVER FIRST parameter setting in %/7.5 40435- RECOVER MAX parameter setting in %/7.5 40436- RECOVER INCREMENT parameter setting in %/7.5 40437- WINDOW parameter setting in mm 40438- WINFWD INC parameter setting in mm 40439- WINBACK INC parameter setting in mm 40440- CONFIRM parameter setting- raw number 40441- HOLD parameter setting- raw number 40442- TX VOLTAGE parameter setting in V/413.25 40445- NOISE SWITCH parameter setting in %/7.5 40446- ECHO WIDTH parameter setting in mm 40433- SEARCH FIRST parameter in %/7.5 40034- MOVEMENT parameter setting in mm 40419- SLOPE DIST parameter setting in mm 40420- SLOPE INC parameter setting in %/7.5 40421- DETECTOR parameter setting in V/1240.7 40422- GAIN STEP1 parameter setting in %/7.5 40423- DISTANCE STEP1 parameter setting in mm 40424- GAIN STEP2 parameter setting in %/7.5 40425- DISTANCE STEP2 parameter setting in mm 40426- GAIN MAX parameter setting in %/7.5 40427- PULSE POWER parameter setting- raw number 40428- PULSE RATE parameter setting- raw number 40429- FREQUENCY parameter setting- raw number 40430- FILTER parameter setting- raw number 40431- ADVANCED FILTER parameter setting- raw number 40026- I-WASTE parameter setting in mA/1000 40035- I-CHARGE parameter setting in mA/37.22

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ASSEMBLY OF FLANGE AND CONES.

05, 10 & 20KHz – Transducer Assembly Process

1. Remove red cap (including cardboard).

2. Screw the flange assembly fully down onto the cone (as far down as it will go until the parts are tightly fastened).

3. Screw the transducer tightly down onto the flange and cone assembly.

4. Tighten the locking ring down to the flange to fix the components in place.

COMPLETED ASSEMBLY

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APPENDIX A.

CROSS TALK PREVENTION

Setup

1. Units to be linked must have a common ground connection, or wire between ' ', or 'DC -' terminals (parallel connection of all units).

MICROFLEX LR

AC-IN AC-IN

AC-IN

DC-IN DC-IN DC-IN

NOTE:- ‘ ’ and ‘DC IN-‘ are electrically the same

At each unit, wire a connection between Relay 1 'COM' terminal and the terminal labelled 'TEST'. See below.

Wire a connection between the Relay 1 'NO’ terminal on each unit linked

together (parallel connection of all units). See below.

COM

Test In

RELAY 1 RELAY 1 RELAY 1

MICROFLEX LR

In the software setup of each unit, program ‘RlyMod1’ (Relay Mode 1) parameter

to 'FS' (Failsafe) mode in Output Adjust menu. (You could use a different relay number in the same way if relay 1 is needed for another function).

The units will now be linked so that they cannot crosstalk.

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Theory

The 'TEST' terminal acts as an input when the unit is about to pulse, and will cause the instrument to enter a paused state (not pulse) if you apply a connection to ground. Each unit also drives its own 'TEST' terminal to ground when it is busy pulsing. These two functions combined mean that if two or more units have their 'TEST' terminals connected in parallel, and share a common ground, then at any time when one is pulsing, it will ground the ‘TEST’ terminals of all units it is connected to, and temporarily pause them until it is finished, then release them. The next unit, which is ready to pulse, then does the same thing in turn, and the process repeats.

The connections above also include the normally open contact of a relay

programmed into Failsafe mode in line with the ‘TEST’ terminals. The function of

this is simply to prevent a possible lock up of the whole system if one unit has a problem (such as power failure). Any time that a unit is in the failed state, it will be disconnected by the relay from the other units, so they can continue working together.

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Application

Type

Fill Speed

View

CAL

Use arrows to select from List:

See Appendix B for options

Use arrows to select appropriate speed of rate of change of level:

Custom (units/hour) View Fast Medium Slow

To adjust

Application

To adjust

Fill Speed

To Select

application

To accept

change

CAL

Empty Speed

View

Bin Level Fast Fill 100m/h Empty 100m/h Med Fill 50m/h Empty 50m/h Slow Fill 10m/h Empty 10m/h

Cement Fast Fill 20m/h Empty 20m/h Med Fill 10m/h Empty 10m/h Slow Fill 5m/h Empty 5m/h

Coal Fast Fill 100m/h Empty 100m/h Med Fill 50m/h Empty 50m/h Slow Fill 10m/h Empty 10m/h

Conveyor Fast Fill 6000m/h Empty 6000m/h Med Fill 3000m/h Empty 3000m/h Slow Fill 1000m/h Empty 1000m/h

Crusher Fast Fill 800m/h Empty 800m/h Med Fill 200m/h Empty 200m/h Slow Fill 20m/h Empty 20m/h

Detection Fast Fill 6000m/h Empty 6000m/h Med Fill 3000m/h Empty 3000m/h Slow Fill 1000m/h Empty 1000m/h

Iron Ore Fast Fill 100m/h Empty 100m/h Med Fill 50m/h Empty 50m/h Slow Fill 5m/h Empty 5m/h

Liquids Fast Fill 200m/h Empty 200m/h Med Fill 50m/h Empty 50m/h Slow Fill 5m/h Empty 5m/h

Agitated Liquids Fast Fill 200m/h Empty 200m/h Med Fill 60m/h Empty 60m/h Slow Fill 10m/h Empty 10m/h

Agitated Liquids Fast Fill 200m/h Empty 200m/h Med Fill 50m/h Empty 50m/h Slow Fill 10m/h Empty 10m/h

Appendix B. APPLICATION TYPES

Hycontrol have added additional application types to the software from v5.78 (released December 2012) along with a basic selection of process speed of ‘Fast’, Medium, or ‘Slow’. You can also manually select and adjust the fill & empty speeds (in selected unit per hour e.g. metres per hour) by using the ‘Custom’ option.

The application types are selectable in the ‘QuickSet’ menu, after selecting the application type you will see the menu item ‘Fill Speed View’. Pressing ‘Cal’ will allow you to use the arrows to scroll through the options ‘Custom’, ‘View’, ‘Fast’, ’Medium’ or ‘Slow’. Pressing ‘Cal’ whilst displaying ‘View’ will show the currently selected speed in units per hour.

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Ore Fast Fill 100m/h Empty 100m/h Med Fill 50m/h Empty 50m/h Slow Fill 5m/h Empty 5m/h

Plastics Fast Fill 20m/h Empty 20m/h Med Fill 10m/h Empty 10m/h Slow Fill 5m/h Empty 5m/h

Positioning Fast Fill 4000m/h Empty 4000m/h Med Fill 2000m/h Empty 2000m/h Slow Fill 1000m/h Empty 1000m/h

Powder Fast Fill 30m/h Empty 30m/h Med Fill 15m/h Empty 15m/h Slow Fill 5m/h Empty 5m/h

Reflective Fast Fill 20m/h Empty 20m/h Med Fill 10m/h Empty 10m/h Slow Fill 5m/h Empty 5m/h

ROM Bin Fast Fill 1200m/h Empty 400m/h Med Fill 700m/h Empty 250m/h Slow Fill 300m/h Empty 100m/h

Silo Level Fast Fill 100m/h Empty 100m/h Med Fill 50m/h Empty 50m/h Slow Fill 10m/h Empty 10m/h

Slurry Fast Fill 100m/h Empty 100m/h Med Fill 50m/h Empty 50m/h Slow Fill 20m/h Empty 20m/h

Solids Fast Fill 100m/h Empty 100m/h Med Fill 50m/h Empty 50m/h Slow Fill 10m/h Empty 10m/h

Stockpile Fast Fill 200m/h Empty 200m/h Med Fill 50m/h Empty 50m/h Slow Fill 20m/h Empty 20m/h

Sump Fast Fill 200m/h Empty 200m/h Med Fill 40m/h Empty 40m/h Slow Fill 10m/h Empty 10m/h

Process Sump Fast Fill 1000m/h Empty 1000m/h Med Fill 300m/h Empty 300m/h Slow Fill 20m/h Empty 20m/h

Tank Level Fast Fill 200m/h Empty 200m/h Med Fill 50m/h Empty 50m/h Slow Fill 5m/h Empty 5m/h

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