How it Works
Kenco Engineering
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SmartSonic Transmitter
User Manual
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User Manual
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Kenco Engineering SmartSonic Transmitter User Manual

KENCO ENGINEERING COMPANY
P.O. BOX 470426 TULSA, OK 74147-0426 ● PHONE: (918) 663-4406 FAX: (918) 663-4480
www.kenco-eng.com e-mail: info@kenco-eng.com
SMARTSONIC REMOTE ACOUSTIC WAVE LEVEL / OPEN CHANNEL FLOW TRANSMITTER
INSTALLATION / OPERATION INSTRUCTIONS
TABLE OF CONTENTS
Page 1
GENERAL DESCRIPTION
Process
Media
Air
Acoustic
The SmartSonic Acoustic Wave Transmitter is designed for high accuracy level measurement of a variety of liquids. The SmartSonic Integral can also be used for Open Channel Flow Measurement.
PRINCIPLE OF OPERATION
The SmartSonic Transmitters consist of two main components:
• The Electronics
• The Sensor (Transducer)
The transducer contains a piezoelectric crystal that converts an electrical signal from the electronics, into acoustic (sound) waves. These acoustic waves are directed through the air toward the process media surface. They are then reflected off of this surface and returned to the transducer. The piezoelectric crystal then converts the received waves into an electrical signal which is analyzed by the electronics.
The time difference between the transmitted wave and the received wave is proportional to the distance from the face of the transducer to the process media surface. This distance is used by the electronics to calculate level or open channel flow in the units selected by the operator.
Waves
MODEL DESCRIPTION
P50-L35V-6N8AE - Remote Transmitter KAWT-xx – Remote Cable (xx = Length in Feet) PN5-XGB-1-C – 1” NPT Polypropylene Transducer ACC-I – Remote Cable Connector PN5-XGD-1-C – 1” NPT PVDF (Kynar) Transducer
SPECIFICATIONS
Description Specification
Power Supply 100-230 Vac Maximum Range 39.4 feet Minimum Dead Zone 1.3 feet Maximum Span 38.1 feet Frequency 50 kHz
Output Signal
Ratings
Interface Wave Angle 5º @ 3db Mounting Connection 1” NPT
Range Accuracy ±0.2% of max. range Resolution 0.04” (1 mm) Enclosure Material ABS + UV Transducer Housing Material Polypropylene or PVDF Transducer Material Glass Reinforced Epoxy Cable Length 328ft. (std.); 656ft. (opt.)
Weight
INSTALLATION
Unpack the transmitter carefully. Inspect all units for damage. Report any damage to carrier immediately. Check the contents against the packing slip and purchase order. Kenco’s SmartSonic Acoustic Wave Transmitters are manufactured to the highest quality standards. These instruments use electronic components that can be damaged by static electricity. Make sure that you are properly grounded before starting installation. Insure that all electrical connections are properly made, and that there are no “floating” connections.
Analog 4-20mA Digital RS-422 Discrete (5) SPDT Relays AC 2A @ 220Vac Relay DC 2A @ 30Vdc Display Graphical LCD User Keypad 4 Button
Ambient -40ºF to 140ºF Temperature Process -40ºF to 212ºF
Electronics 2.4 lbs Sensor 1.1 lbs.
Page 2
DIMENSIONS - INCHES
3.15
3.31
9.68
3.26
2.87
2.28
2.75
Transducer
(Sensor)
2.83
0.59
4.88
2.56
0.55
1” NPT
7.87
Mounting Plate
Page 3
MOUNTING GUIDELINES
MOUNTING INSTRUCTIONS
Precautions:
• Ensure that the sensor is mounted in an area that meets the stated temperature, pressure and technical specifications.
The transmitter must be mounted in such a way, as to avoid the process fluid level from entering the Dead Zone.
If the level enters the Dead Zone, an error will occur, and the transmitter will not measure the fluid level
The sensor needs to be mounted as far away as possible from processes that can interfere with the Acoustic Wave. This example shows a fluid filling inlet.
While the narrow wave diameter of the Kenco Acoustic Wave Transmitters allows you to mount the sensor closer to the vessel wall, than other Ultrasonic transmitters, it is recommended to mount the sensor at least 1.64 feet away from the wall.
The sensor must be mounted perpendicular with the process fluid level. Even the slightest mounting off perpendicular will affect the measurement. Anything over 4º will usually result in a loss of echo or at the very least, an inaccurate reading
• Ensure that high voltage (ac) sources or cables are at least 1 yard away from the sensor and its cable.
• Installation and Operation of this transmitter must conform to the National Electric Code and any applicable local
codes.
Direct Mounting of the Sensor to the Tank
1.) Open the top of the tank
2.) Feed the free end of the sensor cable from the inside of the tank, through the 1” NPT coupling attached to the top of the tank (customer supplied).
3.) Keep feeding the cable until the sensor threads are touching the coupling. Screw the sensor threads into the coupling.
Page 4
Mounting the Sensor to a Flange
2
1
JP1
1.) Feed the free end of the sensor cable through the 1” NPT threaded connection on the flange. Feed the cable from the process side of the flange
2.) Keep feeding the cable until the sensor threads are touching the inside of the flange. Screw the sensor threads into the 1” NPT threaded connection on the flange.
3.) Bolt the flange to the top of the tank. Use a soft gasket.
Mounting the Transmitter (Electronics)
1.) Drill (2) holes, 2.75” apart, onto the desired mounting surface. Install (2) screws into these holes.
2.) Attach the mounting plate to the SmartSonic, using the (4) screws provided.
3.) Mount the SmartSonic onto the desired mounting surface, using the slotted holes on the mounting plate and the (2) screws on the desired mounting surface from Step #1.
WIRING
It is recommended that conduit be installed onto the ½” NPT connections (C1 thru C4) on the electronics housing. Seal drain fittings should be used to prevent moisture from entering the transmitter. In high humidity areas, use breather drains to minimize moisture intrusion.
All wiring, conduit, and fittings must conform to local electrical codes for the location selected. If the transmitter is to be used in a Hazardous Area, the applicable sections of the National Electric Code must be followed as well.
GND
Page 5
Sensor cable side
Wiring Connections
In order to connect the wiring, remove the ribbed faceplate on the front of the electronics, using a 7/64” (3mm) Allen wrench. Ensure that the cover is reinstalled, with the gasket in place, after completing the wiring. Refer to the drawing on the previous page for the location of the wiring connections and cable entries.
NOTE: Power must be off when wiring the electronics. Damage and/or injury may occur if power is applied during wiring.
Wiring the Sensor Connections
The sensor uses a custom 5-conductor cable between the sensor and electronics. The cable comes with a cable connector, which can be used to extend the length of the cable. Make sure that you use Helukabel p/n 16028. Use of any other cable may damage the sensor, or interfere with the signal.
If you are only using the standard 16.4 ft. of cable supplied attached to the sensor, or the non-connector end of an extended cable:
1.) Remove the cable connector from the sensor-side of the cable (the male plug). Skip this step if you are using the non-connector end of an extended cable.
2.) Thread the cable through aperture (C1 – see wiring drawing on page 5) located on the right side of the SmartSonic electronics base.
3.) Connect each wire by color, to the appropriate screw terminal on connector JP5. If the cable contains multiple black wires, connect as follows:
JP5 Post Color
1 Green (Black 1) 2 Brown (Black 2) 3 Blue (Shield) 4 White (Black 3) 5 Yellow
If you are using the cable connector, follow these directions:
Nut
1.) Unscrew the nut holding the cable connector together.
Loose cable side
2.) Disassemble the “loose cable side” of the connector.
3.) Disconnect the “dummy cable” wires from the connector, and connect the wires from the extended cable (supplied separately). The blue wire is connected to the cable shield. Make sure that the wires match exactly. If you aren’t sure, disassemble the “Sensor cable side” connector and match up the pins to the wire color. If you have any questions, please contact Kenco. Do not apply power unless the connector is wired correctly.
Page 6
Wiring the Digital and Analog Communication Cables
SmartSonic data can be monitored on a PC or PLC via RS-485 (MODBUS RTU) digital communications, when connected to JP22. You can also monitor a 4-20mA output by connecting to JP32 (the 4mA and 20mA settings are discussed in the CALIBRATION section).
1.) Thread the connection wires through aperture C2.
2.) Connect each wire to the appropriate screw terminal at connection block JP22 (MODBUS) and / or JP32 (4-20mA). JP22 connections are as follows:
JP22 Post Wire
1 B (TxD) 2 A (RxD) 3 Ground
JP32 connections are as follows: Post 1 (+); Post 2 (-).
JP32 Post Wire
1 + 2 -
Wiring the Power Connections
1.) Thread the power wires through aperture C4
2.) If you have 100-230Vac power, connect each wire to the appropriate screw terminal on JP1 as follows:
JP1 Post Wire
1 Neutral 2 Hot
GND Ground
NOTE: If you are using 100-230Vac leave the red and black wires connected to JP2.
3.) If you have a 24Vdc power source, disconnect the red and black wires from JP2, and connect your power wires:
JP2 Post Wire
1 + 2 -
NOTE: Use either JP1 or JP2. Do not connect external power to both.
Wiring the Relays
1.) Thread the power wires through aperture C2 (DC Power) or C4 (AC Power). C3 may not be available when using conduit.
2.) Connect each wire to the appropriate screw terminal (see wiring drawing on page 5).
Page 7
CALIBRATION
This section explains how to set up and calibrate the SmartSonic for accurate measurement monitoring using the basic menu options. SmartSonic is supplied with preprogrammed default settings, making it ready for immediate operation. Measurement readings are displayed on the default screen as soon as the unit is powered on. It is recommended that you replace the default tank height value with the actual tank height, as described later in this section.
Display / Keypad
The LCD display screen functioning in “Normal” mode provides continuously updated measurement readings. This display is also used to view the program menus, options, settings, and data values. These are accessed by using the keypad. The picture below shows the display of the SmartSonic:
The keypad buttons are used to perform various operations, summarized in the following table
Indication modes
Numerical area
Measurement units
Relays Flow
measurements
Application types
Button Uses Include:
or
20 mA/4 mA levels
Tank graphic
Operation modes
Scan distance
Tank height
Sensor offset
mode indicator
Clear scan distance
• Accessing the program menu (when pressed simultaneously with “ESC.”
• Accessing a function within a menu, enabling you to make modifications
• Moving from left to right between displayed digits.
• Saving changes to data.
• Accessing the program menu (when pressed simultaneously with “ENT.”
• Moving from right to left between displayed digits.
• Returns you to the previous function (without saving changes), or back to
the default screen
• Moving to the next/previous function within a menu.
• Scrolling through or back data values in programs.
NOTE: Within some programs, the digits in the display can be individually modified. This is indicated by a flashing digit. In this case the ENT and ESC buttons are used to move between digits. The BACK and NEXT buttons are used to change the value of the flashing digit.
Page 8
Tank Terminology
Process
Media
r
Tank
Span
Dead Zone
Ai
Dead Zone
SmartSonic Remote
● Minimum 1.3 feet
Tank Height
SmartSonic Remote
● Maximum 39.4 feet
Height
Span Range
(4mA to 20mA)
SmartSonic Remote
● Maximum 38.1 feet
Default Screen
As soon as SmartSonic is fully installed and powered on, the LCD displays the default screen. The default screen provides continuously updated measurement readings and displays the current settings for some functions (either the default settings or the settings selected from the main menu). The relay number is displayed for each activated relay. You can toggle between display indication types, such as: level, distance, volume and others, by using the SmartScan Main Menu.
The tank graphic in the default screen gives an approximate visual indication of the current level of the tank contents, while the numerical area gives the exact reading. If the level enters the dead zone, the numerical area displays FF FFF. If the tank is empty, the numerical area displays the tank height. 000000 may be displayed temporarily while SmartSonic is taking a reading. You can refresh the reading by pressing the ENT and BACK buttons simultaneously.
NOTE: By default, the displayed value is in meters, and gives the distance measurement, meaning from the sensor face to the level of the fluid. The measurement indication mode and measurement unit can be changed, as described in Setting
Main Menu Options
Page 9
Accessing the Main Menu
and
This section describes the procedure for accessing the SmartSonic Main Menu. The main screen (see Page #7) is accessed as follows:
Press / Action Display Description
The SmartSonic takes several seconds to
Connect SmartSonic to power supply See Wiring Section
and simultaneously
Flashes for 5
Flashes for 5 seconds, then is displayed
seconds
warm-up. During this time various characters will turn on and off, and the Tank Graphic will cycle
This is the password display
Use to enter the password (716) in place of (000). BACK and NEXT will change the vlue of the digit (0-9). ENT steps to the next digit; ESC steps to the previous digit.
Single Sensor (only available option).
Press ENT.
The main screen (Page #7) is now displayed.
Main Screen Functions
Indication modes
Numerical area
Measurement units
Relays Flow
measurements
Application types
20 mA/4 mA levels
Tank graphic
Operation modes
Scan distance
mode indicator
Tank height
Sensor offset
Clear scan distance
Page 10
SETTING MAIN MENU OPTIONS
The following functions are available in the SmartSonic Main Menu:
Functions Page
Setting the Indication Mode 11
Setting the Measurement Units 12
Setting the Relay Values 12
Setting The 20mA and 4mA Values 17
Setting the Open Channel Flow Measurements 17
Setting the Tank Height 17
Setting the Application Type 18
Setting the Operation Modes 18
Setting the Sensor Offset 19
Setting the Scan Distance Values 20
Clearing the Scan Distance Values 21
NOTES: After you select any option the “Tank Graphic” will cycle a few times. Wait until one of the options starts to blink before proceeding to the next step.
When you change an option, a flashing “Ar. 5” may appear. This is just to remind you that the option you just selected may affect the Relay or 4-20mA Settings, and that you need to review these settings.
Setting the Indication Mode
The first function in the Main Menu is the Indication Mode. This sets the type of measurement. The options are:
• DIST: The displayed reading represents the distance from the sensor face to the process media.
• LEVEL: The displayed reading represents the level of the process media measured from the bottom of the vessel.
• FLOW: The displayed reading represents the flow rate through the configured Flume or Weir.
• DIA: DO NOT USE
Setting an Indication Mode enables you to toggle between other indication types as well, using the BACK and NEXT buttons as described in the table below: For example, if the unit is configured for Level, the BACK and NEXT buttons will toggle between Level and Distance.
Indication Toggle Selections (BACK / NEXT Buttons)
Distance Distance / Level
Level Level / Distance
Flow Flow / Level / Distance / Totalization (High) / Totalization (Low)
Totalization indicates the total accumulative flow. It is expressed in 10 digits. The first 5 digits (High) are shown as H00000, and the second 5 digits (Low) are shown as L00000. This function will be described later in this manual (Additional Features).
Press / Action Display Description
and
Move between the available options. DIA (Diameter) is no longer available.
For Example
Select the desired option. This will show on the display for a few moments, then return to the Main Menu
Go to the next function (Measurement Mode)
Page 11
Setting the Measurement Mode
This function is used to select the units used for the display. The following measurement options are available:
• METER (default), INCH, or FEET: Select one of these options for Level or Distance measurements
• M3/HR or G.P.M.: Select one of these for Flow measurements
After setting the measurement unit, the selected unit flashes on the display whenever you enter numerical values during the setup procedure. The values for functions, such as Relay, will be displayed in the selected measurement unit.
Press / Action Display Description
Move between the available options.
and
For Example
Select the desired option. This will show on the display for a few moments, then return to the Main Menu
Go to the next function (Relay Values)
NOTE: If you select METER any relevant flow measurement will be in metric units (M3/HR). The opposite also applies, so that if you select M3/HR, any relevant distance or level measurements will be in meters. If you select INCH or FEET, the flow measurements will be in G.P.M.. If you select G.P.M., any relevant distance or level measurements will be in inches.
If you select METER when using a FLOW unit configured to show G.P.M., the METER sign will flash rapidly for a few seconds. If you approve the selection by pressing ENT, the flow unit will change to M3/HR.
Setting the Relay Values
The relays in the SmartSonic Remote are SPDT (Single Pole, Double-throw). This means that each relay has (3) connections:
• Normally Closed (NC)
• Common (C)
• Normally Open (NO)
In the SmartSonic, the term CLOSED means that the relay is de-energized. In this state the NC and C terminals are closed (connected), and the NO and C terminals are open (disconnected).
The term OPEN means that the relay is energized. In this state the NC and C terminals are open (disconnected), and the NO and C terminals are closed (connected).
In the event of power loss to the SmartSonic, the relays automatically go to the CLOSED state (NC & C are connected; NO & C are disconnected). Make sure that any auxiliary equipment connected to the SmartSonic relays, will be in a safe condition upon loss of power to the SmartSonic.
You can set the relays to (5) different indication modes:
• Level
• Distance
• Flow
• Volume
• Totalization
Page 12
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