Milltronics HydroRanger Plus Instruction Manual
HydroRangerPlus
33455070
Rev 2.1
Instruction Manual
PL-507
October 1997
T echnology based. Customer driven.
hank you for purchasing Milltronics products. We endeavour to design
T
equipment that is simple to use and reliable in its operation, with the aim
of satisfying our customers' needs.
Milltronics has been designing and manufacturing process equipment since
1954. Our fields of expertise include ultrasonic and capacitance level
measurement, in-line weighing of dry bulk solids and motion sensing.
Milltronics is established world wide through associate offices and
representatives. Our network is continually being refined to provide our
customers with first rate sales information, engineering assistance and after
sales support.
For more details on our products and service, please contact us and we will
provide you with a listing of the offices or representatives nearest you.
TABLE OF CONTENTS
TITLE PAGE #
INTRODUCTION
About this Manual 5
About the HydroRanger Plus 6
Important HydroRanger Plus Features 8
INSTALLATION
Environmental 9
Outline 9
Mounting 11
Programmer 17
ComVerter 17
Interconnection 18
PROGRAMMING
Program Mode Entry 27
Display 28
Keypad 29
Parameter Value Alteration 31
Special Parameters 31
Parameter Reset Features 31
Programming Security 32
OPERATION
Run Mode Entry 33
Display 34
Keypad 35
System Performance Evaluation 36
Performance Test Results 37
Maintaining Operation 38
APPLICATIONS
General Application 39
Wet Well Control (Pump Down) 42
Reservoir Control (Pump Up) 44
Rake Control (Differential Level) 46
Penstock Control 48
General Alarms 50
OCM (Open Channel Monitor) 52
Volume Calculation 54
Pumped Volume Total 56
Failsafe Operation 58
Application Assistance 60
3
TITLE PAGE #
PARAMETERS
Security 61
Quick Start 62
Volume 65
Reading 67
Failsafe 69
Relays 71
mA Output 89
mA Input 94
Data Logging 95
OCM 105
Totalizer 119
Range Calibration 122
Temperature Compensation 124
Rate 126
Measurement Verification 128
Scanning 130
Display 131
Echo Processing 133
Advanced Echo Processing 136
Test 144
Measurement 146
Master Reset 148
TECHNICAL REFERENCE
Transmit Pulse 149
Echo Processing 149
Scope Displays 149
Distance Calculation 150
Sound Velocity 150
Scanning 151
Volume Calculation 152
Flow Calculation 153
Measurement Response 154
Relay Set Up 155
Maintenance 156
TROUBLESHOOTING
Troubleshooting Chart 157
Measurement Difficulties 158
SPECIFICATIONS
HydroRanger Plus 161
Programmer 163
Options 163
PROGRAMMING CHART 165
4
INTRODUCTION
ABOUT THIS MANUAL
INTRODUCTION
This instruction manual provides information specific to the Milltronics
(HYDRO+) level monitor*. Other products (including transducers) associated with
Plus
a HYDRO+ based level monitoring system, are supplied with individual instructions.
All general start up information is included in the white pages. Refer to the grey pages
for additional information or technical assistance, if required.
After reading this INTRODUCTION and completing the physical INSTALLATION, first
time system installers may wish to use the
Guide, PL-439
INTRODUCTION
INSTALLATION
PROGRAMMING
OPERATION
APPLICATIONS
PARAMETERS
TECHNICAL REFERENCE
TROUBLESHOOTING GUIDE
SPECIFICATIONS
PROGRAMMING CHART
INTRODUCTION
HYDRORANGER PLUS Quick Start
for step by step start up instructions.
briefly describes key features.
step by step mounting and wiring procedure.
program mode LCD and keypad functions.
run mode LCD and keypad functions.
10 brief examples of common HYDRO+ uses.
specific programmable feature definitions.
detailed information for complex features.
quick problem solving techniques.
lists physical and operational characteristics.
space to record all programming for future
reference. (Also used as a Parameter index).
HydroRanger
INSTALLATION
"Programming is not complete until the Programming Charts are completed".
*
This manual applies to the wall, rack, and panel mount HYDRO+ versions.
For simplicity, the rack mount version is illustrated only
where necessary to identify version differences.
Throughout this manual (unless stated otherwise) "level" refers to the
PL-507 5
relative position of a monitored liquid surface.
REMEMBER!
ABOUT THE HYDRORANGER PLUS
Reservoir
Screen Rake
The HydroRanger Plus is to be used only in the
manner outlined in the instruction manual.
The HYDRO+ includes the features of the successful Milltronics "HydroRanger 1"
PLUS a variety of new features, incorporating advances in electronic component,
manufacturing, and software technology.
This multi-purpose microprocessor based level monitor contains numerous features
ideally suited for liquid monitoring and pump control applications.
Open Channel
HYDRO +
%
3
5
214
Wet Well
A HYDRO+ level monitor, utilizing a single ultrasonic transducer (ordered separately),
accurately monitors level without contacting the surface monitored.
The HYDRO+ provides the transmit pulse to the transducer. The transducer emits
ultrasonic pulses in a narrow beam, perpendicular from the transducer face. The
HYDRO+ measures the time between pulse emission and reflection (echo) reception,
to calculate the transducer face to monitored surface distance.
The transducer internal temperature sensor is used to automatically compensate
for sound velocity variations due to air temperature changes within the
measurement range.
PL-507 6
The HYDRO+ monitors levels 0.3 to 15 m (1 to 50 ft) from the transducer face, with
Alarm
outstanding accuracy, usually within 0.25% of range. (Ensure the transducer selected
suits the material and measurement range monitored).
TM
This versatility is accomplished by Milltronics patented Sonic Intelligence
, providing
high measurement reliability, regardless of operating conditions.
LCD
The HYDRO+ provides the following
(Liquid Crystal Display) Readings:
» Level, space, distance, volume, or remaining capacity in open or closed vessels.
» Differential level across a channel filter or screen (2 transducers required).
» Average level in a large vessel with an uneven material surface (2 transducers).
» Head, flow, or totalized flow in free flowing open channels.
» Pumped volume from wet wells or into reservoirs.
The HYDRO+ relays and/or mA output may be used as preset (or programmed as
desired) to activate alarms, pump controls, chart recorders, or virtually any process
control equipment.
Chart
Recorder
HYDRO +
INTRODUCTION
Pump
%
3
5
214
PLC
The HYDRO+ infrared interface permits one programmer to be used for any number
of HYDRO+ level monitors. Upon programming completion, the programmer may be
locked away for programming security. All Operator programming is stored in
non-volatile memory, unaffected by power interruption.
While the HYDRO+ is typically used to monitor liquid level, any process which
requires a distance measurement or object presence/lack of presence (within the
system maximum measurement range) is a candidate for HYDRO+ application.
Refer to APPLICATIONS for detailed descriptions of a small sample of process
measurement requirements to which the HYDRO+ may be applied.
PL-507 7
IMPORTANT HYDRORANGER PLUS FEATURES
FIXED FEATURES
ENCLOSURE: Chemical resistant, light weight, dust/liquid tight.
LCD: Large digits and symbols for Readings and continuous
HAND PROGRAMMER: 20 tactile feedback keys, (ordered separately).
DOLPHIN COMPATIBLE: HYDRO+ / RS 232C interface, (ordered separately).
COMMUNICATIONS: Non-invasive infra-red digital data transfer.
SPEED: 16/32 bit microprocessor at 16.7 MHz clock speed.
RELIABILITY: Sonic Intelligence
PROGRAMMABLE FEATURES
Typically, a very small percentage of the HYDRO+ operator programmable features
require alteration from default settings. However, for demanding measurement
requirements any number of features may be adjusted as required.
Following is a list of the features that make the HYDRO+ easy to program, yet
versatile enough to handle complex level measurement requirements.
GENERAL FEATURES
DIRECT ACCESS: Any operator programmable feature may be accessed directly.
SCROLL ACCESS: Scroll forward or backward to key programmable features.
OPERATION: 7 modes of operation to suit specific requirements.
MATERIAL: Preset for optimum performance on all liquid surfaces.
RESPONSE: Slow, medium, or fast response to level changes.
UNITS: Readings in m, cm, mm, ft, in, %, (or any other units desired).
operating condition indication.
TM
Surface Mount Technology (SMT)
Immune to power interruptions. All programming is retained
indefinitely. Operating data is retained for 30 seconds min;
updated promptly upon resumption.
ADDITIONAL FEATURES (use as desired)
VOLUME: 8 pre-programmed tank shape options
2 universal tank shape programming methods
FLOW: Open channel flowrate and total, 5 pre-programmed flumes.
PUMPED TOTAL: Total volume pumped including/excluding inflow/discharge.
DATA LOGS: Time and Date of important operational events.
FAIL-SAFE: Automatic process control equipment activation.
RELAYS: 6 alarm functions, 7 pump functions, 5 control functions,
storm condition and energy saving pump function modifiers.
mA OUTPUT: 7 functions, range selectable and scalable, overrange limits.
mA INPUT: HYDRO+ features based on any level monitor mA output.
PL-507 8
INSTALLATION
Installation shall only be performed by qualified personnel,
and in accordance with local governing regulations.
ENVIRONMENTAL
Choose a mounting location suited to the HYDRO+ enclosure.
The ideal HYDRO+ mounting location is where the:
1. Ambient temperature is always within -20 to 50°C (-5 to 122°F).
2. HYDRO+ display window is at eye level.
3. Cable length requirements are minimal.
4. Mounting surface is free from vibration.
Avoid mounting locations where the HYDRO+ is:
» exposed to direct sunlight, (otherwise, provide a sun shield).
» close to high voltage/current runs, contactors, SCR control drives, or
frequency inverters.
This product is susceptible to electrostatic shock.
Follow proper grounding procedures.
OUTLINE
WALL MOUNT
195 mm
(7.7")
13 mm (0.5")
20 mm (0.8")
168 mm
(6.6")
77 mm
(3.0")
INSTALLATION
102 mm
(4")
180 mm
(7.1")
Suitable location for conduit entrances. Use water
tight conduit hubs to maintain the enclosure rating.
Non metallic enclosure does not provide grounding between conduit
connections. Use grounding type bushings and jumpers.
PL-507 9
mounting holes,
4.5 mm (0.18") Ø,
4 places
RACK MOUNT
The HYDRO+ rack mount version is a standard DIN 3U/14 HP, 4 rail plug-in unit, for a
standard 84 HP deep sub-rack.
PANEL MOUNT
72 mm
(2.9")
144 mm
(5.7")
150 mm
(5.9")
slip on mounting bracket top & bottom
screws to be tightened to no more than
PL-507 10
16 mm
(0.6")
1 inch / lb. torque.
201 mm
(7.9")
MOUNTING
WALL MOUNT
Voltage Selection
display
terminal block
scope
connection
clock module
EPROM
board A
Supply
Voltage
(ac)
All field wiring must have insulation suitable for at least 250 V .
Hazardous voltage present on transducer terminals during operation.
Voltage
Selection
Switches
INSTALLATION
dc terminals shall be supplied from an SELV source
in accordance with IEC 1010-1 Annex H.
Relay contact terminals are for use with equipment having no accessible
live parts and wiring having insulation suitable for at least 250 V.
The maximum allowable working voltage between
adjacent relay contacts shall be 250 V.
PL-507 11
Installation
The HYDRO+ wall mount version enclosure design permits quick electronic package
removal for enclosure drilling and mounting.
1. Remove the HYDRO+ enclosure lid (4 captivated screws).
2. With the enclosure upright, press down enclosure TABS A and B.
3. Push in on TABS C and D to release the electronics package.
4. Drill sufficient holes for cable / conduit entry in the enclosure bottom.
5. Fasten the enclosure to the mounting surface, (4 predrilled screw holes).
6. Attach the conduit / cable hubs to the enclosure. (Do not apply undue force.)
7. Snap the electronics package back into the enclosure.
PL-507 12
RACK MOUNT
Voltage
Selection
Switches
Voltage Selection
1. Set the voltage switches.
Supply
Voltage
(ac)
scope
connections
clock module
EPROM
voltage
selection
switches
INSTALLATION
PL-507 13
Installation
1. Slide the Hydro+ into the sub-rack, aligning the connector with the
rail mounted terminal block.
connector,
2 row form D male 32 way, per DIN41612
terminal block,
2 row form D female 32 way,
per DIN41612
All field wiring must have insulation
suitable for at least 250 V .
Hazardous voltage present on transducer
terminals during operation.
dc terminals shall be supplied
from an SELV sourcein
accordance with IEC 1010-1
Annex H.
84 HP (19") sub-rack
HYDRO+
DIN 3U/14 HP
plug-in unit
blanking panels must
cover any unused slots
2. Push the Hydro+ into the sub-rack until the HYDRO+ front
cover is snug to the front rails.
3. Tighten the 4 captivated screws to secure the HYDRO+ in place.
PL-507 14
PANEL MOUNT
Voltage
Selection
Switches
Supply
Voltage
(ac)
Voltage Selection
1. Set the voltage switches.
scope
connections
clock module
EPROM
voltage
selection
switches
Installation
1. Slide the HYDRO+ through the panel cut-out.
2. Assemble mounting brackets to the HYDRO+ chassis by hooking them into
the top and bottom
mounting bracket
(top & bottom)
cut-out dimension
68 + 0.7 mm x 138 + 1.0 mm
(2.68 + 0.03" x 5.43 + 0.04")
INSTALLATION
DIN 43700
72 x 144
PL-507 15
3. Tighten mounting bracket clamping screw (top & bottom)
terminal block ‘A’
4. Plug terminal blocks ‘A’ and ‘C’ into corresponding connector sockets,
prewired by customer (refer to \ Rack and Panel Mount).
INTERCONNECTION
clamping screw
connector
terminal block ‘C’
All field wiring must have insulation
suitable for at least 250 V .
Hazardous voltage present on transducer
terminals during operation.
dc terminals shall be supplied
from an SELV source in
accordance with IEC 1010-1
Annex H.
Use the tool provided
to open terminals for
insertion of wires.
PL-507 16
PROGRAMMER
Rack or Panel Mount
Rack or Panel Mount
Wall Mount
Programmer
The hand held programmer is aimed at the receiver as depicted, while the
keys are pressed.
INSTALLATION
COMVERTER (optional)
The ComVerter is pressed into the docking area as depicted and held in place
by its pressure tabs.
Refer to Dolphin instruction manual, for interconnection details.
PL-507 17
Wall Mount
ComVerter
INTERCONNECTION
Milltronics transducer,
see Specifications
Milltronics TS-3
temperature sensor
(optional)
Verify all HYDRO+ system components have been installed in accordance with the
associated product instruction manuals.
Connect all cable shields to the HYDRO+ shield connections. To avoid differential
ground potentials, do not connect cable shields to ground (earth) elsewhere. Insulate
(tape) cable shields at all shield junctions to prevent ground loops
SYSTEM DIAGRAM
HydroRanger
Plus
mA output
customer
device
relay output
customer alarm, pump
or control device
mA input
PL-507 18
customer
device
TRANSDUCER
#1 #2
to transducers
Run the transducer cable in grounded metal conduit, separate from other wiring,
(except TS-3 temperature sensor wiring, if applicable).
Typically, one transducer is used. However, if differential or average level monitoring
is required, 2 transducers are used.
Wall Mount
Single Transducer
to transducer
Rack or Panel Mount
Single Transducer
to
transducer
blk
wht
See transducer
instructions for
wiring details.
to
transducer
#1
to
transducer
#2
Dual Transducer
INSTALLATION
Dual Transducer
jumper
blk
blk
wht
Hazardous voltage present on transducer terminals during operation.
PL-507 19
TEMPERATURE SENSOR
All Milltronics Echomax and ST-H transducers have an internal temperature sensor.
For optimum accuracy, use a separate TS-3 temperature sensor if:
» the transducer is exposed to direct sunlight (or other radiant heat source),
» the transducer connected is not an Echomax or ST-H, or
» the transducer face and monitored surface temperature differs.
» faster response to temperature changes are required.
TECHNICAL REFERENCE
(See TECHNICAL REFERENCE Sound Velocity).
Wall Mount Rack or Panel Mount
blk
wht
to optional TS-3
to optional TS-3
See TS-3 instructions for wiring detail.
Use a TS-3 temperature sensor only. Don’t jumper unused TS-3 terminals.
PL-507 20
RELAYS
n. o.
Connect, alarm, pump, and/or control devices, to the HYDRO+ relays, after RUN
mode operation is verified. (See for connection details).
APPLICATIONS
Wall Mount
Rack or Panel Mount
com
relay 5
n. c.
n. o.
com
n. c.
relay 2
INSTALLATION
com
n. c.
n. o.
relay 1
relay 4
com
n. c.
n. o.
com
relay 3
n. c.
n. o.
See for relay ratings.
SPECIFICATIONS
Relays are shown in the alarm on / pump off / power off / de-energized position.
PL-507 21
mA OUTPUT
The HYDRO+ mA output may be used to operate a variety of control/monitoring
devices (1000 Ω max. load), providing 300 Vac continuous isolation.
Wall Mount
mA out
Rack or Panel Mount
mA out
mA output to customer instrumentation, ground shield at one end only.
mA INPUT
If HYDRO+ features are required based upon measurements obtained from another
level monitor, connect the level monitor mA output, to the HYDRO+ mA input
terminals. Most HYDRO+ display, relay and mA output features may be used based
upon the measurements provided by the auxiliary level monitor.
If this feature is used, refer to Transducer (P004) and mA Input
PARAMETERS
Parameters (P250, P251, and P252).
Wall Mount
Rack or Panel Mount
mA input
mA input proportional to level, ground shield at one end only.
PL-507 22
mA input
LEVEL SYSTEM SYNCHRONIZATION
to next
device
When multiple ultrasonic level monitors are installed within a single plant/facility,
ensure the transducer cable(s) of each system are run in separate grounded metal
conduits. Otherwise, synchronize the level monitors.
When level monitors are synchronized, no unit can transmit while another is awaiting
echo reception.
To synchronize the HYDRO+ with a DPL+, XPL+, and/or another HYDRO+...
1. Mount the level monitors together in one cabinet.
2. Use a common power (mains) supply and ground (earth) for all units.
3. Interconnect the SYNC terminals of all level monitors.
Wall Mount
INSTALLATION
Rack or Panel Mount
HYDRO +
# 1
HYDRO +
# 1
HYDRO +
# 2
to next
device
HYDRO +
# 2
To synchronize the HYDRO+ with other Milltronics
ultrasonic level monitors contact Milltronics
or your local distributor.
PL-507 23
POWER
The HYDRO+ uses 100, 115, 200, or 230 Vac or 9 to 30 Vdc power. If ac and dc
power are supplied, the HYDRO+ draws power from the ac supply. In the event of an
ac power interruption, the dc supply is used until ac power is restored.
IMPORTANT!
Before applying ac power (mains), ensure the correct voltage is selected!
Never operate the HYDRO+ with the enclosure lid open,
or with the ground (earth) wire disconnected!
Before applying power to the HYDRO+ for the first time,
ensure any connected alarm/control equipment is disabled
until satisfactory system operation and performance is verified!
AC SUPPLY WIRING
Wall Mount
to ac supply
Set voltage selection switches per Mounting instructions.
Rack or Panel Mount
to ac supply
INSTALLATION
PL-507 24
DC SUPPLY WIRING
Rack or Panel Mount
to dc supply
Wall Mount
to dc supply
Negative dc input (A12) is tied to earth (A14).
INSTALLATION
Customer voltage supply 9 to 30 V dc.
The equipment must be protected by a 15 A fuse or circuit
breaker in the building installation.
A circuit breaker or switch in the building installation, marked
as the disconnect switch, shall be in close proximity to the
equipment and within easy reach of the operator.
PL-507 25
PL-507 26
PROGRAMMING
Those not previously familiar with the HYDRO+, may wish to use the step by step
initial start up procedure illustrated in the HYDRORANGER PLUS QUICK START
GUIDE provided. Then, reference to the remainder of this instruction manual is only
necessary if operation modification is required.
All programmable features are identified by a Parameter Number, which has a preset
Parameter Value. Programming is accomplished by altering the Parameter Value of
specific Parameter Numbers to obtain the RUN mode operation desired.
When applicable, the Point Number to be affected, must be identified before the
Parameter Value is altered.
See APPLICATIONS for common HYDRO+ programming requirements. If more
APPLICATIONS
detailed parameter information is required, see PARAMETERS .
To enable the programmer
interface of the HYDRO+
rack or panel mount version,
press the key on the
front panel.
Program enable is confirmed
by the icon appearing in
the display. To disable
programming, press again.
Program disable is confirmed by
absence of the icon in the
display. Disable all nearby units
to avoid inadvertent programming.
PARAMETERS
PROGRAMMING
PROGRAM MODE ENTRY
Upon power application, RUN mode operation begins. To enter the program mode,
hold the programmer within 0.3 m (1 ft) of the
display window and,
When the program mode is entered, all operating data is retained in memory.
Alarm relay status and mA output values are "held" at "last known" values and
control relays are de-energized (unless affected by a parameter alteration
or is pressed), until the RUN mode is re-entered. The RUN mode is
automatically re-entered if the HYDRO+ is left unattended in the program
mode for an extended period (approximately 5 minutes).
PL-507 27
DISPLAY
In the program mode, the Parameter Number, Parameter Value (and Point Number if
applicable) may be viewed (as well as numerous other programming indicators).
Note that some indicators are specific to certain programming conditions and
therefore,
e.g. The Transducer Point Number is only displayed when Differential or Average
all indicators are not displayed at any given time.
level monitoring is selected, (requiring programming for 2 transducers).
wall mount rack or panel mount
a) Parameter Number (programmable feature accessed).
b) Parameter Value (setting for the Parameter Number displayed).
c) Point Type: transducer relay analog output
temperature index
d) Point Number (of the Point Type accessed).
e) Units (the Parameter Value is displayed in: m, cm, mm, ft, in, or %).
f) Relay Number (programmed for RUN mode operation).
g) Invalid Entry (the Parameter Value is questionable, are you sure?).
h) Auxiliary Function (of the Parameter Number is accessed).
i) Scroll Access Tag (the Parameter Number may be scroll accessed, or ).
j) Program Mode On (is accessed, operation has ceased).
Wall Mount: Program Mode accessed.
Rack or Panel Mount: Programmer interface enabled / Program Mode accessed.
PL-507 28
KEYPAD
These instructions ar e for hand programmer (keypad) use. Use the instructions
provided with the DOLPHIN interface package, if applicable.
Aim the HYDRO+ programmer infra-red transmitter at the HYDRO+ display within 0.3
m (12") of the display window. In the program mode, use the HYDRO+ programmer
keys to perform the following identified functions.
Numeric
Value
Keys
Function
Keys
KEY NUMERIC ENTRIES
input a numeric value into the display field accessed.
to
input a decimal point (moves TVT Pointers left).
input a negative value (moves TVT Pointers right).
FUNCTION
shift access to another display field.
delete the current field value (initiate a parameter reset).
store the field values in memory (complete a parameter reset).
switch to % or Units (access Auxiliary Parameter Function).
increase the current field value.
decrease the current field value.
fire the transducer to take an ultrasonic measurement.
enter the RUN mode.
PROGRAMMING
PL-507 29
98/03/19
PARAMETER VALUE ALTERATION
In the program mode...
1. to underline the Parameter Number display field and...
a) key in the desired Parameter Number, (
b) as required (
(As preset, only Quick Start and altered parameters may be scroll accessed).
2. If the Point Number field is not displayed, proceed to step 3. Otherwise...
a) key in the desired Point Number, (
b) as required, (
To alter all Point Numbers at once, select Point Number 00.
3. With the Parameter Number (and Point Number if applicable) displayed...
key in the desired Parameter Value and,
or
to underline the Point Number display field and...
or
scroll access
scroll access
direct access
).
direct access
).
) or...
) or...
Record Parameter Value alterations on the appropriate
If Parameter Value alteration is not permitted, access the Lock parameter (P000)
and enter the security code, (see Programming Security).
PL-507 30
PROGRAMMING CHA
PROGRAMMING CHARTS
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