MJK Automation Shuttle Ultrasonic Level Transmitter User Manual
MJK Automation A/S
Byageren 7
DK-2850 Nærum
Denmark
Tel.: +45 45 56 06 56
Fax: +45 45 56 06 46
mjk@mjk.com
www.mjk.com
Ultrasonic Level Transmitter
and Sensor
GB Shuttle Manual 100316
User Manual
1
New
All MJK’s newest ultrasonic
sensors covered and described
in this manual
New setup procedure.
See page 14 for choosing correct
sensor type at initial setup.
SW 838023
Ultrasonic Level Transmitter and Sensor
IMPORTANT
The first time power is applied to the mounted Shuttle® level transmitter and ultrasonic
sensor, the level transmitter must be configured for the connected sensor type.
The procedure is located on page 14, "Applying power".
If, at a later time, another or a newer sensor type is connected to the transmitter,
the level transmitter must be re-configured accordingly.
The procedure is located on page 69, "Appendix F New sensor / changing sensor".
June 2007
CE Certificate of Conformity
This product complies with the requirements concerning electromagnetic compatibility (EMC)
stipulated in Council directive no. 89/336/EEC of 3rd May 1989, altered at directive no.
92/31/EEC, on the approximation of the laws of the Member States relating to electromagnetic compatibility.
CE approvals
We declare that the Shuttle
®
transmitter and ultrasonic sensors comply with the values stipu-
lated in EN 50081-1 and EN 50082-1.
Ex approval of ultrasonic sensors
®
Shuttle
ultrasonic sensors are approved for mounting in explosive amospheres.
Types 200630/31/40/41: FM Class 1, Div. 1, Group A-G
GB Shuttle Manual 100316
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Ultrasonic Level Transmitter and Sensor
Table of Contents
Introduction .................................5
About this manual .............................5
Main sections .........................................5
Illustrations .............................................5
Safety instructions .............................6
Repair ....................................................6
Ex equipment .........................................6
Product identification .........................6
Mounting ......................................7
General .............................................7
Explosion hazardous areas ................7
Mechanical mounting ........................7
Level transmitter .....................................7
Ultrasonic sensor ....................................8
Electrical mounting ............................9
Level transmitter .....................................9
Ultrasonic sensor ..................................10
Cutting the cable ..................................10
Display and keyboard ...............11
General ...........................................11
The display symbols ........................12
Displayed during programming .............12
Displayed during normal service ...........12
The keyboard .................................. 13
Basic settings .......................................13
Special settings ....................................13
Get started .................................14
Applying power ...............................14
Sensor type selection ...........................14
- the well is empty… .............................15
- the well is not empty… .......................15
Basic settings ............................16
Units of measurement ..........................17
Sensor to zero point distance ...............18
Level read-out ......................................19
The well is not empty ............................19
mA output ............................................20
Relay outputs .......................................21
Selection of relays 1 and 2 ....................21
Pump control with relays 1 and 2..........22
Level control with relay 1 ......................23
System alarm on relay 1 .......................24
Selection of relay function for relay 2 .....25
Level control with relay 2 ......................26
System alarm on relay 2 .......................27
Start of the learning function ............28
First time activation ...............................28
Activating the learning function ........29
Activation / deactivation ........................29
Settings ......................................30
User settings ................................... 30
User and factory settings ..........30
Factory settings ...............................30
Possible settings .............................31
Fault finding ...............................32
General ...........................................32
Indications on system errors ............32
Normal read-out ...................................32
Too weak or missing echo ....................32
System (sensor) error............................32
Temperature error .................................32
Internal stack error ................................32
EE-PROM error ....................................33
Power failure.........................................33
Fault finding table ............................ 33
GB Shuttle Manual 100316
Ex Instructions ...........................35
3
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Ultrasonic Level Transmitter and Sensor
A Technical specifications ............... 37
Dimensions ..........................................37
Shuttle® Ultrasonic Sensors ..................38
Standard Range Version .......................38
Standard Range Version/FM Approved .39
Extended Range Version ......................40
Chemical Resistant Version ..................41
B Changing supply voltage ............. 42
Conversion from 230 to 115 V AC ........42
Conversion from 115 to 230 V AC ........42
C Sensor mounting considerations .43
General ................................................43
Signal spread .......................................43
Measurements......................................44
Along a wall / other surface ................44
Through a concrete deck ....................44
In a tank / container ............................44
Through pipe for foam protection .......44
D Service menu ..............................45
E Special menus ............................46
Bar graph read-out ...............................47
Active measuring range ........................48
Response time .....................................49
Measuring method (application) ............50
mA output signal during system error ...51
Calibration of the level measurement ....52
Offset level readout ...............................53
Indication of echo quality ......................54
Indication of signal amplification ............55
Indication of time period without echo ..56
Select factory settings ..........................57
Access code ........................................58
Readout of version numbers .................59
Find zero level at next power-up ...........60
Fixed mA signal ....................................61
Investigative measurement intervals ......62
System alarm delay ..............................63
Averaging the level measurement .........64
Max. amplification level .........................65
Min. level for accept of ultrasonic echo .66
Sensitivity of the learning function .........67
Changing the access code ...................68
F New sensor / changing sensor .... 69
Open the choose sensor menu.............69
GB Shuttle Manual 100316
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Introduction
Introduction
Thank you for choosing a Shuttle® Ultrasonic Level Transmitter.
We have done everything possible to make
a level transmitter that can fulfill all your
demands.
®
Shuttle
is suitable for all kinds of level
measurements with ultrasound and can
control and supervise levels in wells and
tanks - including aggressive and polluted
media.
The level meter is both easy to install and
put into service, but read this manual first then you will get the most benefits from the
®
Shuttle
Ultrasonic Level Transmitter right
from the beginning.
You can always contact your representative
or the MJK Service Hotline for advice and
guidance.
Also, take a look at http\\:www.mjk.com.
®
Shuttle
is registered trademark of MJK.
About this manual
Main sections
This manual is divided into the following
three main sections:
1: Introduction
presentation of the Shuttle
manual
2: Mounting
information for performing mechanical
and electrical mounting.
3: Basic settings
a look through the most common set-
tings
®
and this
Illustrations
®
All the Shuttle
display read-outs are illustrated in this manual. Some of the display
segments will flash, and in this manual the
display read-outs with flashing segments are
coloured white and the fixed segments are
coloured black.
Example: Normal display read-out -
none of the segments are flashing.
Example: Missing echo -
the bar on the right hand side is flashing.
Section "Display" gives a more detailed
description of the display symbols shown
during programming and during normal
service. Furthermore, the menu explanations
show all the display indications belonging
to the specific menu during programming of
the Shuttle® Ultrasonic Level Transmitter.
GB Shuttle Manual 100316
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Introduction
Safety instructions
1: Read this manual carefully.
2: Be aware of the environment at the in-
stallation site. Wear necessary protective
equipment and follow all current safety
regulations.
3: Shuttle
4: There is a risk of lethal electrical shock
Repair
1: Repair of Ex approved equipment (ul-
Ex equipment
1: All current local and national standards,
®
can provide a start signal for
dangerous machinery. Always ensure
that connected machinery and other
equipment are effectively being put
out of service (i.e. removal of main
fuses, lock main- and/or security
switches in off position) before commencing setting, fault finding, service
and maintenance work etc.
from terminal 1 to 5 and L-N. Be careful
not to touch these while Shuttle
service.
trasonic transmitter) must only be made
by MJK or by a service representative
approved by MJK.
regulations regarding installation and use
of Ex approved equipment, certifications
and safety instructions for Ex equipment,
that have been used together with the
installation of Shuttle
observed.
®
must be strictly
®
is in
Product identification
Check that the item(s) delivered corresponds to the ordered item(s). The item
number is printed on a label that is sticked
onto the packing. Shown below is the label
for a delivery including a level transmitter
and a ultrasonic sensor:
➀
➁
➀
➂
➁
➂
➀ Item number
➂ Serial number
➁ Item description
An identical marking can be found on the
right hand side of the level transmitter
cabinet:
GB Shuttle Manual 100316
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Mounting
Mounting
General
®
Shuttle
measures the level by sending an
ultrasonic signal against the surface and
measuring the delay time of the received
echo.
Although Shuttle
advanced system for eliminating measuring errors, the ultrasonic sensor must - as
much as possible - be mounted so that the
ultrasonic signal is not disturbed by liquid
being pumped in or by mixers, ladders or
other installations in the tank.
The liquid surface should also be calm and
without waves and possibly without foam
that may muffle the ultrasonic echo too
much.
Since the ultrasonic beam is extremely
narrow (between 3 - 7 ° depending on
the sensor type), Shuttle
measurements in very narrow tanks or wells.
This requires that the ultrasonic sensor is
mounted so it points absolutely vertical
against the surface - or the ultrasonic echo
will simply miss the sensor.
Explosion hazardous areas
The ultrasonic sensor is Ex approved in
accordance with EN 50021:1999 and can
be mounted in Zone 2 without the need of
a zener barrier. Please check local requirements before installing in hazarduous
locations.
The level transmitter (= the electronic
box with display) must not be mounted in
explosive hazardous areas.
®
is equipped with a very
®
can be used for
Mechanical mounting
Level transmitter
®
Shuttle
is in IP65 enclosure and can be
mounted outdoors directly on a wall, a
railing or a banister with mounting plate
200240 and universal bracket 200205.
Shuttle® Ultrasonic Level Transmitter
mounted directly on a wall.
Shuttle® Level Transmitter mounted on the plant
with mounting plate 200240 and universal bracket
200205.
Shuttle® must be mounted
vertically in order to observe the
NEMA4X standard.
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Mounting
Ultrasonic sensor
Two things are extremely important when
mounting the ultrasonic transmitter: (See
also appendix C!)
1: It should be mounted securely.
2: It should be mounted absolutely vertical.
Use a spirit level in TWO directions.
To ensure a reliable and precise level measurement it
is of vital importance that the ultrasonic sensor points
down absolutely vertical against the liquid surface.
The ultrasonic sensor should be mounted
so the ultrasonic signal has no obstructions
between sensor and surface, i.e. no pipes,
cables, grates etc.
The ultrasonic sensor is equipped with a
nut for bracket mounting. Note the recess
on the nut - it must be fitted safely in the
bracket for firm fixing to the bracket:
For the highest accuracy, the ultrasonic
sensor should be mounted as close as
possible to the highest possible level that
can occur + 35 cm (types 200570, 200640
and 200660) or 80 cm (type 200630). See
below:
Min. 35 cm (200570,
200640,200660)
Highest pos-
sible level
Min. 80 cm (200630)
We deliver two types of sensor brackets that can be
used in almost any installation. The bracket shown is a
standard universal mounting bracket (200220).
GB Shuttle Manual 100316
Max. measuring range:
200570: 15 m
200640: 12 m
200630: 25 m
200660: 10 m
Bottom
8
Total distance: Max. + Min.
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Mounting
Electrical mounting
Level transmitter
The Shuttle
the power supply before the ultrasonic
sensor is mounted and connected cor-
When the cover has been removed, the
green plastic film with the menu symbols is
tipped up to gain access to the terminals.
Shuttle
on terminal 10 and 12 or with 230 / 115 V
AC on terminal L and N.
Current regulations for conductor and
fuse dimensions should always be ob-
Always confirm that the Shuttle
rating match the present voltage.
If Shuttle
it will be indicated with a label below the
leftmost terminal block as shown here:
®
must not be connected to
rectly.
®
can be supplied with 10 - 30 V DC
served.
®
voltage
®
is delivered for 115 V AC supply,
Mount the wires according to the terminal
numbers on the reverse side of the green
plastic film:
Terminal: Designation:
1 - 5 Ultrasonic sensor
6 - 7 Relay output 1
(Max. 50 V, 1 A resistive load)
8 - 9 Relay output 2
(Max. 50 V, 1 A resistive load)
10 and 11 4-20 mA output
(Max. 500 Ω load)
10 and 12 10 - 30 V DC supply
L 230 / 115 V AC live
N 230 / 115 V AC neutral
Shuttle® is intended Shuttle® is intended
for 230 V AC. for 115 V AC.
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Mounting
Ultrasonic sensor
The ultrasonic sensor is delivered as standard with 12 metres of cable. The ultrasonic
sensor can be delivered with up to 100 m of
cable on order, or the standard 12 m cable
can be extended to max. 100 m.
The cable is a special low capacity cable,
so extensions should always
be made with the same type of cable.
On of the most common faults on a Shuttle
installation is bad or faulty cable connections or using cables that dose not meet the
required specifications.
It is recommended to use connection
box 200590 if the sensor cable must be
extended.
To ultrasonic
sensor
Max.
To Shuttle
level
transmitter
100 m !
Cutting the cable
The cable is delivered with the wires
stripped as shown with the black wire (no.
5) soldered to the shield:
®
When the cable is cut, only 4 wires will
appear:
®
The ultrasonic sensor cable has 5 wires with
both color code and number:
Number: Color: Designation:
1 Brown Ultrasonic pulse
2 Red
3 Orange Temperature compensation
4 Yellow
5 Black Shield ➀
➀ This wire is connected to the cable shield.
The wires are mounted according to the
terminal markings on the connection box
PCB and on the Shuttle® respectively.
GB Shuttle Manual 100316
When the cable has been cut, the shield
should be mounted in terminal 5 instead
of the black wire !
When the ultrasonic sensor is mounted and
connected correctly, the Shuttle
®
can be
connected to the power supply.
See section 'Get started'.
10
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Display and keyboard
Display and keyboard
General
The keyboard is used only for the initial programming of the Shuttle
behind the front lid. The keys are marked with symbols indicating their function.
The same symbols are used throughout this manual under the explanation of the individual
menus.
LCD-display with
symbols for indica-
tion during program-
ming, servicing and
normal operation.
®
, and is therefore hidden
Keyboard for
programming the
Shuttle
A brief program-
ming instruction.
The lower part can
be tipped up to
show the connec-
tion terminals and
their designations.
Interface used during
®
manufacturing and
for test purposes.
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Display and keyboard
The display symbols
The different display segments indicates the actual level, the state of the output relays etc.
during normal service and indicates limit values, selection of measuring unit and other settings during programming.
The segments shown will be lit during
programming of the Shuttle®.
Displayed during programming
Numerical read-out of limit values.
delays and other numerical settings
and selections. Is also used to show
an initial letter code at start up of the
special settings.
See also pages 46 - 69.
Displayed when selecting the desired measuring unit (see page 17)
and when selecting time delays.
Start / activation of the learning
function. See also pages 28 - 29.
Flashes when setting the time
delays.
See also pages 22 - 24, 26 and 27.
Displayed when programming the
output relays.
See also pages 23 - 24, 26 and 27.
Displayed when setting the start and
stop levels for the output relays.
See also pages 21 - 23 and 25 -26.
Displayed when setting the zero
point and span for the mA output.
See also page 20.
Displayed when setting the distance
between sensor and zero point and
setting of level read-out.
See also pages 18 - 19.
The segments shown will be lit when
®
are in normal service.
Shuttle
Displayed during normal service
Numerical read-out of the actual
level.
Bar graph for indication of the signal
level on the mA-output or for indication of the actual level.
Alarm symbol. The symbol is shown
if a system error should occur on the
®
Shuttle
.
See also pages 24 and 27.
Indication of the status of the output
relays and whether the output relays
are in use. The round dot below
the relay number will appear steady
when the relay is activated and will
appear flashing when the relay is
about to be activated after a preset
time delay.
See also pages 22 - 24, 26 and 27.
This group of symbols indicates the
strength of the received ultrasonic
echo. A good measuring signal is
indicated by three or more sets of
archs.
See also page 32.
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Display and keyboard
The keyboard
From the Shuttle
6 basic settings and 15 special settings.
There is direct access to the menus for basic settings by pressing one the keys A to F.
See appendix E for instructions for access to the special settings.
When a menu has been selected, settings are made with the UP and DOWN keys and
the selection is confirmed with the ENTER key (
read-out. To leave any menu without changing the settings, press the UP and DOWN keys
simultaneously (ESCape, ➂).
®
keyboard the keys marked A - F (➀) gives access to 21 menus divided in
➃) whereafter Shuttle
®
reverts to normal
➀ ➁
➂
➃
Basic settings
A (LEARNING)
Start and activation/deactivation of the
learning function.
B (UNIT)
Selection of measuring unit.
C (ZERO ADJUST)
Setting of sensor distance and zero
point.
D (mA OUTPUT)
Setting of the mA output.
E (RELAY 1)
Setting of the functions for relay
output # 1.
F (RELAY 2)
Setting of the functions for relay
output # 2.
(see pages 14 - 29)
Special settings
Shift + A (bA - bar graph readout)
Shift + B (rA - Active measuring range)
Shift + C (rE - response time for level
changes)
Shift + D (AP - Application setup)
Shift + E (S. Err - System error indication)
Shift + F (LE - Level readout calibration)
Esc + A (nAP - Setting of reference level)
Esc + B (Qu - Indication of signal quality)
Esc + C (Sh - Indication of signal amplifi-
cation)
Esc + D (dE - Period without echo)
Esc + E (Choose sensor)
Esc + F (FA - Factory settings)
AxsC + A (S. Ln - HW/SW/Serial numbers)
AxsC + B (S.St - Find zero level at next
power-up)
AxsC + C (12nA - Constant mA signal out)
AxsC + D (nS - Investigative measurements
interval)
AxsC + E (S. Al - System alarm delay)
(see Appendix E)
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Display and keyboard
Get started
Applying power
When Shuttle
lowing texts (Choose Sensor Press Enter) will appear across
the display:
Press "Enter" once to select the required sensor type.
Sensor type selection
When "No Sensor" (no S) is displayed, press the 'Up' or
'Down' arrow key to leaf through the different sensor types:
2005xx and 2006xx.
When the required sensor type appears on the display (here:
200570), press "Enter" once.
®
is connected to power for the first time, the fol-
The sensor type is now registered by the level transmitter,
and "Press Enter" passes across the display to indicate that
you may continue with setting/measuring a level of 0 meter
(nil, empty tank).
Press "Enter" once to proceed with the initial settings.
Notes:
When a sensor type has been selected, the factory settings will have no influence on this selection.
If you choose "No Sensor" (no S), the Shuttle will
invoke the choose sensor menu at start-up. From this
point the correct sensor type can be selected.
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Display and keyboard
®
At the same moment Shuttle
level that is present in the tank or well.
Furthermore, the mA output is set to 4 mA at the current zero point and 20 mA at a level corresponding to a distance of 35 cm from the ultrasonic sensor.
- the well is empty…
Level read-out = distance
between sensor and bottom
- (minus) the distance between sensor and surface.
- the well is not empty…
registers an echo, the zero point is automatically set to the
35 cm from sensor (types 200570,
200640 and 200660)
80 cm from sensor (type 200630)
0.00 m
4 mA 20 mA
The distance from the sensor to the zero point or the
35 cm from sensor
level read-out must be set
manually - see page 18.
Note: The dead band
varies for the different
sensor types: 35 cm for
types 200570, 200640 and
200660, and 80 cm for type
200630.
See also Appendix A, Technical Specifications begining on
page 37.
Shuttle® will now indicate the current level in the tank or well
(0 m immediately after initial startup) and is now in service
as a regular level meter, i.e. without the use of the relays and
the analog output for control / alarm.
See the next section for basic settings.
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Display and keyboard
Basic settings
The automatic setting of the zero point and the mA output made by Shuttle® during initial
startup may be adequate.
If changes of the zero point read-out and mA output setting should be necessary, and when
®
Shuttle
is to be used as a pump controller or for level monitoring, an additional 5 settings
should be made. These settings are described in detail on the following pages.
Proceed with set-up in the order listed below:
1: Setting units of measurement See page 17.
2: Setting the distance from sensor to zero point and
Setting the level read-out: See pages 18 - 19.
3: Setting the mA output: See page 20.
4: Setting the the relay limits: See page 21.
5: Start of the learning function: See pages 28 - 29.
When the settings are made, Shuttle® is ready to be put into service.
Bar graph
The bar graph can
be set to indicate
either the level
read-out or the mA
output.
Alarm
A flashing bell
indicates, that a
level is exceeded
or that Shuttle
®
is
not certain that the
measured level is
correct.
MJK
will always be at
your disposal.
Display
®
Shuttle
continuosly reads
out the current level with
bright and easy-to-read
figures.
Echo strength
®
Shuttle
indicates
that the ultrasonic
echo is sufficient
for a reliable level
measurement.
Relay outputs
When Shuttle
®
measures a level
that has exceeded
a setpoint limit, the
relays are activated
and their current position are indicated
here. (Relay no. 2 is
activated.)
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Display and keyboard
Units of measurement
If the measuring unit is changed, all other values in menus
and settings will automatically be converted to the new
measuring unit.
In this example the measuring unit is changed from metres
to feet.
The settings will be rounded off automatically.
Select unit with the arrow keys.
The dot indicates the position of the decimal separator.
2,00 m
0,00 m
6,59 ft
0,0 ft
Note: 'mm' or 'in' cannot be selected if it could cause
overrun in the display read-out.
Shuttle® reverts to normal read-out with the new measuring
unit.
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Display and keyboard
Sensor to zero point distance
The level read-out (zero point) can be adjusted as required.
This is almost always required if the well was not empty during initial startup.
Note: The learning function settings will be erased and
In this example, the level read-out is changed to be 1.50 ft
from the bottom of the well / tank.
Set the new zero point with the arrow keys.
the relays will be deactivated if the zero point setting is changed.
2,00 m
0,50 m
0,00 m
If the learning function has been activated, Shuttle® will deactivate the learning function and erase the suspicious levels
that were found last time the learning function was activated.
The learning function must therefore both be started and
reactivated again.
If the relay outputs are configured for pump control, the
relays will be deactivated, but their limit settings will not be
erased. Also, delay settings and other settings will not be
erased.
Shuttle® will now read out - 0,50 m when the well is empty.
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Display and keyboard
Level read-out
The well is not empty
With this function the level read-out can be increased or
decreased on demand. This is almost always required if the
well was not empty during initial startup.
Note: The learning function settings will be erased and
In this example, the actual level is 80 cm, but Shuttle
out 0 m.
Select the desired level read-out with the arrow keys.
Shuttle
the relays will be deactivated if the zero point setting is changed.
®
®
will now read out 0,00 m when the well is empty.
reads
1,20 m
0,00 m
- 0,80 m
2,00 m
0,80 m
0,00 m
If the learning function has been activated, Shuttle® will deactivate the learning function and erase the suspicious levels
that were found last time the learning function was activated.
If the relay outputs are configured for pump control, the
relays will be deactivated, but their limit settings will not be
erased.
Also, delay settings and other settings will not be erased.
Shuttle® will now revert to normal level read-out with a
increased read-out value.
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Display and keyboard
mA output
When Shuttle
®
is connected to the power supply for the first
time, the mA-output is automatically set to provide 4 mA
at zero level and 20 mA at a level corresponding to 35 cm
below the ultrasonic transmitter.
In this example the range of the mA output is changed from
0 - 1,65 m to 0,5 - 1,5 m. Changes made will not affect the
relay settings.
Note: Both values can be set over the whole range thus
making it possible to decrease the mA signal at
rising levels and vice versa.
2,00 m
1,65 m
0,00 m
4 mA 20 mA
2,00 m
1,50 m
0,50 m
0,00 m
4 mA 20 mA
Shuttle® reverts to normal read-out.
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Display and keyboard
Relay outputs
Selection of relays 1 and 2
Three functions are available:
- pump control with alternation of two pumps
- level control
- system alarm
Note: If Pump Control is selected, the start and stop
If Level Control is selected, the start and stop set-
Select the desired function with the arrow keys.
Pump control:
Continue on the facing page.
settings cannot be set any closer than 10 cm.
tings cannot be set any closer than 1 cm.
Note: If pump control is selected, both relays are set in this menu and relay 2 will not be
The relays can control both pumping in and pumping out, but both relays will have
If it is later desired to change the setting, simply change the setting for relay 1 after
If the relays are configured for pump control, they will always be deactivated on
Level control:
See page 23.
System alarm:
See page 24.
available for other functions.
the same function. The function is selected automatically when relay 1 is set according to the start and stop levels. If the start level is set higher than the stop level,
both relays will then be configured for pumping in. On the other hand, if the start
level is set lower than the stop level, both relays will be configured for pumping in.
which the start and stop setting for relay 2 will be switched automatically.
system errors after 30 seconds independent of the selected time delay to prevent
dry run of the pumps.
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