Operation & Installation
Version A2.1
Echo Smart Sensor
Echo Smart Controller
Echo Smart Power Supply Unit
M a n u a l
Table of Contents
Table of Contents ............................................................................................................................ i
Safety Precautions........................................................................................................................... v
1. Product Description ......................................................................................................... 1
1.1. Stand-Alone Instrument Option ............................................................................................... 1
1.2. Field Network Option ................................................................................................................ 1
1.3. Network Integrated to Customer Data Acquisition and Controls ........................................ 1
2. Applications........................................................................................................................ 2
2.1. Wastewater and Water Treatment Clarifiers and Thickeners ............................................. 2
2.2. Industrial Wastewater and Raw Water Treatment ............................................................... 2
2.3. Industrial Process Applications ................................................................................................ 2
3. EchoSmart Sensor (ESS) ................................................................................................ 3
3.1. General Overview ...................................................................................................................... 3
4. EchoSmart Controller – Graphical User Interface (ESC) ....................................... 4
4.1. General Overview ...................................................................................................................... 4
4.1.1. Operator Interface Overview (Figure 4.1)........................................................................................ 4
4.1.2. Keypad ................................................................................................................................................. 5
4.2. Power, Cabling, and General Electrical Connections for the ESC ....................................... 5
4.2.1. Power Requirements .......................................................................................................................... 6
4.2.2. Connections Overview (Figure 4.2 and Table 4.1) ........................................................................... 6
4.3. Utilization of Informational Displays....................................................................................... 9
4.3.1. Echo Profile Display (Figure 4.3) ...................................................................................................... 9
4.3.2. Sensor Register Displays (Figure 4.4 and 4.5) ................................................................................ 10
4.3.3. Tank View Display (Figure 4.6) ....................................................................................................... 11
4.3.4. Historical Trend Display (Figure 4.8) ............................................................................................. 12
4.3.5. Modify Settings Display (Figure 4.9) ............................................................................................... 12
4.3.6. Advanced Settings Display (Figure 4.11) ........................................................................................ 14
4.3.7. Controller Setup Display (Figure 4.12) ........................................................................................... 14
4.3.8. Sensor Selection Drop-down Window (Figure 4.14) ...................................................................... 16
4.4. Initializing and Configuring Controller and Smart Sensor(s) ............................................ 16
4.4.1. Initial Controller Setup Display (Figure 4.15) ............................................................................... 16
4.4.2. First Time Controller & Sensor System Installation (Figure 4.16 and 4.17) ............................... 17
4.4.3. Replacing a Controller with Existing Sensor(s) (Figure 4.15) ..................................................... 18
4.5. Automatic Initialization and Reboot Sensor ......................................................................... 19
5. EchoSmart Power Supply Unit (ESP) ........................................................................ 20
5.1. Power, Cabling, and General Electrical Connections for the ESP ..................................... 20
5.1.1. Power Requirements ........................................................................................................................ 20
5.1.2. Connections Overview (Figure 5.1 and Table 5.1) ......................................................................... 20
6. Installation of Equipment .............................................................................................. 23
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6.1. Installation of EchoSmart Sensor .......................................................................................... 23
6.2. Sensor Location Selection Criteria......................................................................................... 25
6.2.1. Acceptable Process Liquid ............................................................................................................... 25
6.2.2. Responsive Interface Material ......................................................................................................... 25
6.2.3. Stationary Objects in Path of Transmit Pulse ................................................................................ 25
6.2.4. Areas of Excessive Air/Gas Bubbles and Turbulence .................................................................... 25
6.2.5 Typical Circular Clarifier Installation (Figure 6.2) ....................................................................... 26
6.2.6 Typical Rectangular Clarifier Installation ..................................................................................... 27
6.2.7 Installing Sensors in Applications with Surface Skimmers........................................................... 27
6.3. Installation of EchoSmart Controller and EchoSmart Power Supply Unit ....................... 27
7. Tank Configuration, Waveform Analysis, and Tracking ....................................... 30
7.1. Tank Configuration (Figure 7.1) ............................................................................................ 30
7.2. Waveform Analysis (Figure 7.2) ............................................................................................. 30
7.3. Tracking ................................................................................................................................... 31
7.3.1. Gate ................................ ................................................................ ................................ .................... 31
7.3.2. Signal Waveform Symbols ............................................................................................................... 32
8. Communications, Outputs, and Networking ........................................................... 33
8.1. Configuration of Individual Units and Networks ................................................................. 33
8.1.1. Stand-Alone Instrument (Figure 8.1) .............................................................................................. 33
8.1.2. Wired RS-485 Field Network (Figure 8.2) ...................................................................................... 34
8.1.3. Wireless Radio Frequency (RF) Field Network (Figure 8.3) ........................................................ 35
8.1.4. Integrated Field Networks (Figure 8.4) .......................................................................................... 36
8.2. Outputs ..................................................................................................................................... 36
8.2.1. RS-485 Modbus RTU ....................................................................................................................... 37
8.2.2. Analog 4-20 mA Current Loop ........................................................................................................ 37
8.3. Communication Options and Facilities ................................................................................. 37
8.3.1. RS-485 Modbus RTU Communication ........................................................................................... 37
8.3.2. Local RS-232 Serial Communication .............................................................................................. 37
8.3.3. Factory Remote Service ................................................................................................................... 38
9. Instrument Programming Parameters ....................................................................... 40
9.1. Modify Settings Display Parameters ...................................................................................... 40
9.1.1. Units (ft) ................................ ................................ ................................................................ ............. 40
9.1.2. Tank Depth (10.0) ............................................................................................................................. 40
9.1.3. Zero Adjust (0.5) ................................................................ ............................................................... 40
9.1.4. Min Range (3.0)................................................................................................................................. 41
9.1.5. Auto Gain (ON) ................................................................................................................................. 41
9.1.6. Current Gain (30) ............................................................................................................................. 41
9.1.7. AG Set Point (Auto Gain Set Point) (10) ........................................................................................ 41
9.1.8. Update Rate (10) ............................................................................................................................... 41
9.1.9. Interface (First) ................................................................................................................................. 41
9.1.10. Dampening (130) ............................................................................................................................... 42
9.1.11. Settling Zone (ON) ............................................................................................................................ 42
9.1.12. Tank Display (ON) ............................................................................................................................ 42
9.1.13. Trend Display (ON) .......................................................................................................................... 42
9.1.14. Display Contrast (55) ........................................................................................................................ 42
9.2. Advanced Settings Display Parameters ................................................................................. 43
9.2.1. Max Range (11.0) .............................................................................................................................. 43
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9.2.2. Measure (Level) ................................................................................................................................. 43
9.2.3. Wiper Timing (240) .......................................................................................................................... 43
9.2.4. Gain Band (20) .................................................................................................................................. 43
9.2.5. Gain Increment (0.1) ........................................................................................................................ 43
9.2.6. Save GB Midpoint (MP) (OFF) ....................................................................................................... 43
9.2.7. GB Midpoint (Automatically set) ...................................................................................................... 44
9.2.8. Wall Zone (0.5) .................................................................................................................................. 44
9.2.9. Wall Zone AG (40) ............................................................................................................................ 44
9.2.10. Sound Speed (4862 fps) ..................................................................................................................... 44
9.2.11. Sensitivity (20) ................................................................................................................................... 44
9.2.12. LG Min (2.0) ...................................................................................................................................... 45
9.2.13. RG Min (2.0) ..................................................................................................................................... 45
9.2.14. 4mA Set Point (0.0) ........................................................................................................................... 45
9.2.15. 20mA Set Point (10.0) ....................................................................................................................... 45
9.2.16. Echo Loss (OFF) ............................................................................................................................... 45
9.2.17. Echo Delay (60) ................................................................................................................................. 45
9.2.18. Echo Loss Action (Cycle) .................................................................................................................. 45
10. Maintenance and Troubleshooting ............................................................................ 47
10.1. Preventative Maintenance ...................................................................................................... 47
10.1.1. Sensor Cleaning and Maintenance .................................................................................................. 47
10.1.2. Other Routine Maintenance ............................................................................................................ 48
10.2. Troubleshooting ....................................................................................................................... 49
10.2.1. Comm Error Message ...................................................................................................................... 49
10.2.2. Echo Loss Message ........................................................................................................................... 49
10.2.3. Validating Message ........................................................................................................................... 49
10.2.4. Validation Failure Message ............................................................................................................. 49
10.2.5. Wiper Stalled Message ..................................................................................................................... 50
10.2.6. Wiper Motor Failure Message ......................................................................................................... 50
10.2.7. 4-20 mA Measurement Discrepancy ............................................................................................... 50
10.2.8. Sensors Not Detected and No Sensors Found Message ................................................................. 50
10.2.9. Troubleshooting Radio Communications ....................................................................................... 51
10.2.10. Persistent “Acquiring Waveform” Message on Echo Profile Screen ........................................... 51
11. System Options ............................................................................................................... 52
11.1. Self-Cleaning Wiper Sensor with Turbidity Measurement ................................................ 52
11.1.1. Application ........................................................................................................................................ 52
11.1.2. Principle of Operation ...................................................................................................................... 52
11.1.3. Sensor Cleaning ................................................................................................................................ 52
11.1.4. Installation......................................................................................................................................... 52
11.1.5. Connections ....................................................................................................................................... 53
11.1.6. Turbidity Sensor Calibration .......................................................................................................... 53
11.2. Integrated Wireless Radio (RF) Modules .............................................................................. 53
11.2.1. General Overview ............................................................................................................................. 53
11.2.2. Internal Configuration ..................................................................................................................... 53
11.2.3. External Configuration .................................................................................................................... 54
11.2.4. Equipment Orientation for Units with Integrated Wireless Radio Modules............................... 55
11.3. Relays ........................................................................................................................................ 56
11.3.1. General Overview ............................................................................................................................. 56
11.3.2. Operation (Figure 11.3) .................................................................................................................... 56
11.3.3. Cabling and Connections for Relays (Figure 11.4 and Table 11.1) .............................................. 57
12. Warranty ............................................................................................................................ 58
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13. Quick Start Guide ............................................................................................................ 59
13.1. Configuring a Single Sensor ................................................................................................... 59
13.2. Configuring a Sensor Network ............................................................................................... 60
13.3. Special Settings for Filter Applications ................................................................................. 63
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Safety Precautions
About this Manual: PLEASE READ THE ENTIRE MANUAL PRIOR TO
INSTALLING OR USING THIS PRODUCT.
The following safety precautions should be observed in the implementation and use of this
product.
The EchoSmart Controller (ESC), EchoSmart Power Supply Unit (ESP), and EchoSmart
Sensor (ESS) are intended for use by qualified personnel who recognize shock hazards and
are familiar with the safety precautions required to avoid possible injury. Read the operating
information carefully before using the product.
User’s Responsibility for Safety:
Responsible body: this is the individual or group responsible for the use and maintenance of
equipment, and for ensuring that operators are adequately trained. Operators are to use the
product for its intended function. They should not be allowed access to the electrical
connections within the control box, and would normally only operate the external keypad
and monitor the display.
Maintenance personnel perform routine procedures on the product to keep it operating, for
example, checking the line voltage or checking electrical connections, replacing main fuses,
etc. Only service personnel should perform other tasks.
There are no user serviceable parts on the main PCB section of the EchoSmart ESC or ESP.
Service personnel are trained to work on live circuits, and perform safe installations and
repairs of products. Only properly trained service personnel may perform installation and
service procedures.
Wiring and Electrical: Users of this product must be protected from electric shock at all
times. The responsible body must ensure that users are prevented access and/or insulated
from every connection point. Product users must be trained to protect themselves from the
risk of electric shock.
Before operating an instrument, make sure the line cable is connected to a properly grounded
power receptacle. Inspect the connection cables for possible wear, cracks, or breaks before
each use. When fuses are used in a product, replace with same type and rating for continued
protection against fire hazard.
For CE and safety compliance, adequate grounding and shielding is required. All
EchoSmart system cables are to be installed in metal conduit that is properly grounded and
shielded utilizing EMC compliant methods. Each conduit should be individually shielded
and grounded. Where metal enclosures are supplied, each enclosure should be grounded and
shielded to each individual conduit.
External chassis components can not be used as safety earth ground connections.
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Standard fuses, with applicable national safety approvals, may be used if the rating and type
are the same. If you are unsure about the applicability of a replacement component, call
Entech Design for information. Only use the EchoSmart ESC or ESP with the sensor
supplied. Replace Fuse with: 1.25A 5x20mm T-Lag UL approved.
This equipment is suitable for use with 110-240 Volts AC power at 50-60 Hz. No internal
changes are required within this range. Equipment is optionally available and can be ordered
for use with 24VDC power. Caution must be taken to supply main power in the form for
which the equipment is designed.
A protective earth should be provided for all installations.
WARNING
If this equipment is used in a manner not specified by Entech Design, the protection provided
may be impaired. The EchoSmart ESC, ESP, and ESS are regarded as permanently installed
equipment and as such a switch or circuit breaker must be included in the installation. This
should be in close proximity to the equipment, it should be marked as the disconnecting
device, and it should disconnect both current carrying conductors.
WARNING
CHECK THAT THE POWER SUPPLY IS SUITABLE BEFORE SWITCHING POWER
ON.
Proper Installation and Handling: The normal application for the EchoSmart ESC or
ESP requires it to be installed at industrial installations including water and wastewater
treatment plants. While the ESC and ESP enclosures are liquid-resistant (IP65), they are not
designed to be immersed. These items should be mounted in such a way that the enclosure
does not come into contact with the application media under normal operational conditions.
The ESS (sensor) and its cabling are designed to be submerged without hazard to the
equipment or to operators when correctly connected as described in this manual.
To clean the instrument, use a damp cloth or mild, water based cleaner. Clean the exterior
of the instrument only. Do not apply cleaner to the inside of the instrument or allow liquids
to enter or spill on the instrument.
Material Compatibility: The ESC and ESP enclosures are made of flame retardant
Polycarbonate (PC/ABS FR). The ESS enclosure is made of epoxy-filled ABS. Some sensor
models include additional wetted parts. Make sure that the model which you have selected
is chemically compatible with the application media, temperatures, and pressures to which it
will be exposed.
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WARNING WHEN APPLICABLE
This equipment complies with FCC radiation exposure limits set forth for an uncontrolled
environment. This equipment should be installed and operated with minimum distance 20cm
between the radiator and your body. This transmitter must not be co-located or operating in
conjunction with any other antenna or transmitter.
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1. Product Description
EchoSmart is an exciting new development in liquid/solid interface level analyzers.
Instruments employ digital sensors in an architecture that locates microprocessor signal
control, enhancement and interpretation in the ultrasonic sensor rather than in a remote
analyzer. The sensor is a Smart device. When connected to a power source and instrument
programmer (typically EchoSmart Controller or EchoSmart Power Supply Unit), it produces
the Level or Range measurement and an indication of the dispersed solids Level above the
primary interface. Optional sensors are available that additionally provide surface back
scatter turbidity measurements.
This equipment design opens the door for a wide range of flexible installation configuration
options. The Controller is the operator graphical user interface device and power source to a
sensor. It is also a communication hub for analog and digital communication outputs to the
customer data acquisition system. EchoSmart can be implemented as a stand-alone
instrument (Controller + Smart Sensor) or with numerous sensors networked together and
operated by a single Controller as discussed below.
1.1. Stand-Alone Instrument Option
When connected to an EchoSmart Controller, the instrument has all the functionality
of a complete measurement system. The Controller provides power to the sensor and
is the user interface for instrument programming and communication with the sensor.
Customer terminations for digital and analog communications to the customer’s data
acquisition and control system are provided inside the Controller.
A large graphical LCD with control keypad provides a simple and intuitive platform to
implement Sensor Parameters, configure communications, view current and historical
measurements, and perform system diagnostics. HELP PROMPTS are automatically
displayed for each parameter and system function.
1.2. Field Network Option
Up to 16 EchoSmart Sensors can be operated by a single Controller in a wired or
wireless Field Network. In either arrangement, the network is fully integrated and
requires no software integration by the customer.
The Controller handles all programming and monitoring functions for all sensors in the
network. Power Supply Units provide power to associated sensors and are fitted with
integrated two-way transmitter modules when used in an RF network. Terminations for
analog communication (4-20mA signal) are also at the Power Supply Unit.
1.3. Network Integrated to Customer Data Acquisition and Controls
EchoSmart Field Networks can be integrated to the customer’s data acquisition and
control system via two-wire RS-485, Modbus RTU protocol. See Section 8.4 for
additional information.
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2. Applications
EchoSmart is suitable for most municipal and industrial liquid/solid separation processes in
which a reliable measurement of the level of a solids or suspended-solids blanket is desired.
Typical applications include municipal and industrial wastewater and water treatment
clarifiers and gravity thickeners. Sensors with optional turbidity measurement are available
for applications in which a 0-50 NTU turbidity indication at the location of the sensor is
desired. A broad range of industrial process applications are also appropriate. Self-cleaning
sensors and special design sensors to accommodate high temperature and exposure to
chemical environments are available.
2.1. Wastewater and Water Treatment Clarifiers and Thickeners
EchoSmart instruments are most frequently implemented to provide reliable sludge
blanket level measurements in municipal wastewater and water treatment operations.
Instruments are suitable for circular and rectangular basins, uncovered and covered
tanks, and those with both fixed and traveling bridge arrangements. Mounting
arrangements easily accommodate surface skimmers and rakes. Automatic signal
control functions adapt to differences in sludge density that typically occur in primary,
secondary and final clarifiers, and gravity thickeners.
Instruments are also effective in granular media gravity and pressure filters for
conditional backwash control. Measurements include media level and expansion, and
above filter turbidity (backwash turbidity).
2.2. Industrial Wastewater and Raw Water Treatment
EchoSmart is effective in providing sludge level measurements in a wide range of
industrial water treatment applications. Raw water from a surface water source is often
sent to a clarifier for particulate removal prior to introduction to plant processes. Water
spent in plant processes often requires primary, and even secondary treatment prior to
being directed to a municipal plant for further processing or being discharged in the
environment. EchoSmart sludge level measurements can be used to effectively control
clarifier solids blow-down, optimize chemical application, and limit solids discharge
in the effluent stream.
2.3. Industrial Process Applications
Suitable process applications are found in the Power Generation, Mining and Mineral
Processing, Chemical, Pulp and Paper and other process industries. Contact Entech
Design or an authorized representative for further information on the characteristics
and requirements for successful implementation of EchoSmart equipment in these
environments.
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3. EchoSmart Sensor (ESS)
The EchoSmart Sensor is a microprocessor controlled piezoelectric transducer designed
specifically for operation under water (submerged in the process liquid).
3.1. General Overview
The EchoSmart Sensor generates an ultrasonic sound wave that propagates through a
liquid medium and is reflected back from material that is present in the vessel (typically
settled solids, suspended solids, and/or the tank bottom). The sound wave travels at
known velocities providing the ability to convert elapsed time into Range and Level
measurements.
The EchoSmart Sensor does more than just produce a raw signal. It is equipped with
an advanced programmable microprocessor and dynamic memory. Through these
facilities, the sensor provides all signal control, enhancement and interpretation, and
determines the final process measurement. The Smart Sensor communicates with an
EchoSmart Controller via digital communication. The sensor also generates a 4-20 mA
proportional current loop signal. Customer connections are provided at the Controller.
If a Smart Sensor is part of a field network, connections are made at the Controller or
Power Supply Unit that is supplying power to the sensor.
Sensors with a 90◦ surface back-scatter turbidity meter integrated into the ESS are
available. This option can be beneficial and cost effective in applications where a
turbidity measurement at the location of the sensor is desired. It is often used in
secondary clarifiers and similar applications to alert process upset conditions. It is also
employed in water and wastewater treatment media filters as part of an effective
conditional backwash control system.
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4. EchoSmart Controller – Graphical User Interface
Sensor Name & Address
Current Measurement
and Operating Gain
“Help Prompts” Field
Soft Key
Prompts
Soft Keys
Navigation
Keys
Main Display Area
(ESC)
The EchoSmart Controller allows for programming and local monitoring of one to sixteen
EchoSmart Sensors.
4.1. General Overview
The Controller display consists of a graphical backlit LCD (2.6 x 3.45 inch viewing
area) that is divided into five functional sections. Soft Keys and Navigation Keys
located to the right of the screen are used for data entry and other operations. Figure
4.1 points out the functional sections of the screen and the location of the Soft Keys
and Navigation Keys.
Figure 4.1: The LCD Display
4.1.1. Operator Interface Overview (Figure 4.1)
The display has five informative sections:
Smart Sensor Name & Address
The bar at the top of the display shows the name and network address that has been
assigned to the sensor. This is the sensor that is currently being interrogated.
Information on this and all other displays relates to this sensor.
If the Controller is operating a multi-sensor field network, other sensors are
available by pressing the Change Sensor soft key. A listing of network sensors will
appear (See Figure 4.12). Use the Navigation Keys to select the desired sensor and
press Select Sensor.
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Current Measurement and Operating Gain
The current measurement, operating gain (signal amplification), and turbidity value
(when applicable) are conveniently available in the lower left corner of all displays.
Additionally, messages regarding external communication (see Sections 8.3 and
8.5) taking place and error messages (see Section 10.2) associated with the active
sensor are displayed in this section.
Help Prompts Field
The Help Prompts Field across the lower section of each display provides an
explanation of the screen, or the highlighted parameter. Help Prompts reduce the
need for reference to the print operating manual.
Main Display Area
The area has both digital and graphical capabilities. The content changes with the
functionality of the selected display.
Soft Key Prompts
The vertical bar on the right side of the display consists of four boxes. Each box
contains text that describes the function of the Soft Key that is located next to that
box. The text changes when the user selects a different function or navigates to a
different instrument parameter.
4.1.2. Keypad
The Echo Smart Controller has four Soft Keys and four Navigation Keys.
Soft Keys
The function of a Soft Key is described by the Soft Key Prompt located
immediately to the left of the key. Soft Keys are used to change instrument settings,
switch to a different display, or trigger other actions.
When using a soft key to increase or decrease a value, the key can be held down in
order to quickly modify the value.
Navigation Keys
Navigation Keys advance the instrument cursor to the desired location on the
display for operation by Soft Key commands.
4.2. Power, Cabling, and General Electrical Connections for the ESC
This section pertains to the physical layout of the Controller terminal connectors and
how they are connected as a stand-alone system. If you are wishing to network the
Controller with other devices (Ex: ESP, SCADA Systems, etc), see Section 8 for
sample connection diagrams.
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4.2.1. Power Requirements
100-240 VAC, 50/60 Hz – 1.5A
Supply cable: 10-18 AWG, -40 to +140 F
65 W (fused) 1.25A 250V 5x20mm T-lag UL approved fuse
4-20 mA Current Loop: 15 – 24 VDC (provided by ESC)
Optional: 24 VDC (19 – 42 VDC Input)
Caution must be taken to supply main power in the form for which the equipment
is designed.
4.2.2. Connections Overview (Figure 4.2 and Table 4.1)
The ESC circuit board contains four screw-terminal connectors as well as additional
plug-in connectors as shown in Figure 4.2. Use caution in tightening the screw
terminals to prevent damage from over-tightening.
Ensure the power cable (10-18 AWG) is connected to the power connector
properly. A breaker should be installed to fully remove power from the unit in the
event that repairs to the unit are required. Sensors (ESS) should be connected to
the controller by color code as shown in Figure 4.2 below. Table 4.1 contains a
functional description of the screw terminal connectors.
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L G N
J10
J7
Red
Black
White
Brown
Yellow
Blue
Orange
Green
1
8
1
3
Sensor
Connections
Power
(120/240 VAC)
* FOR 24 VDC *
4-20 mA
Connectors
1
4
Level
Turbidity
_
_
RS-485
1
3
_
S
External USB
(Future)
USB
(Future
)
RS-232
Laptop /Cellular
Ethernet
(Future
)
RF Module
Connector
(optional)
J1
Cell Modem
Power
J9
J18
J11
Relays
J4
J17
+ – –
LEDs
Aux
Data
RS-232
Data
Connector
Figure 4.2: Connections for Controller
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Table 4.1: Connections
Power
Connector
(J1)
4-20 Analog
Connectors
(J10)
Sensor
Connections
(J9)
RS-485
Connector
(J7)
Pin #
Description
Pin #
Description
Pin #
Description
Pin #
Description
1
Live
1
Level +
1
15 V
1
Sensor
Comm
2
Ground
2
Level –
2
Ground
2
Sensor
Comm
3
Neutral
3
Turbidity +
3
Sensor
Comm (+)
3
Ground
4
Turbidity –
4
Sensor
Comm (–)
* FOR 24 VDC *
(J1)
5
4-20mA
Level
1 + 6
4-20mA
Level
2 – 7
4-20mA
Turbidity
3
–
8
4-20mA
Turbidity
Notes:
Sensor Connector (J9): Use Pin 3 and Pin 4 to link the Sensor
Communication cable from the Controller to the next Power Supply Unit
in a Wired RS-485 Field Network. Conductors are ganged with those from
the sensor. Connection at the associated Power Supply Unit is at the RS485 Connector (J8).
RS-485 Connector (J7): Use this connector when integrating a Field
Network to the customer data acquisition and control system. This is the
communication link between the Controller and an outside device. It is not
used to interconnect Controllers and Power Supply Units.
4-20mA current loops are internally powered, grounded, and galvanically
isolated.
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4.3. Utilization of Informational Displays
Sensor
Tank Bottom Indicator
Echo Profile (waveform)
The Controller has four informational displays: Echo Profile Display, Sensor Register
Display, Tank View Display, and Historical Trend Display. Selections are made by
pressing the Change Display Soft Key. At power up, the system defaults to the Echo
Profile Display.
There are also three displays that are used to enter instrument settings: Modify Settings
Display, Advanced Settings Display and Controller Setup Display.
4.3.1. Echo Profile Display (Figure 4.3)
The Echo Profile Display shows the echo waveform generated by the selected
sensor. To view the waveform of another sensor, press the Change Sensor soft key,
select the desired sensor from the dropdown list, and press Select Sensor.
Figure 4.3: Echo Profile Display
This display presents the actively updated signal waveform generated by the sensor
and used to determine the Level or Range measurement.
The horizontal x-axis is a distance axis based on the span between the sensor (lower,
left side of the screen) and the bottom of the tank (lower, right side of the screen).
The vertical y-axis corresponds to the strength of signal at locations between the
sensor and the tank bottom. EchoSmart proprietary interpretive algorithms are
applied to the signal waveform to determine the position of an interface – typically
between a supernatant liquid and settled solids or suspended solids.
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4.3.2. Sensor Register Displays (Figure 4.4 and 4.5)
This display consists of a table that shows the name of each sensor and its Current
Measurement and Operating Gain value. If the Controller is communicating with
four or fewer sensors, information is presented as shown in Figure 4.4.
Figure 4.4: Four Sensor Field Network Display
With five or more sensors, information is presented as shown in Figure 4.5.
Figure 4.5: Multiple Sensor Field Network Display
These displays are not available when only one sensor is in use.
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4.3.3. Tank View Display (Figure 4.6)
The Tank View Display shows a scaled cross-sectional view of the tank. The arrow
on the left side of the tank provides a visual indication of the current fill Level.
Dispersed solids that may be indicated in the echo waveform are represented by
pixilated gradients above the primary interface.
Figure 4.6: Tank View Display
The Tank View Display is enabled at the Modify Settings Display. Optional
diagrams are available to correspond with the specific application (Figure 4.7).
Figure 4.7: Tank Options
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4.3.4. Historical Trend Display (Figure 4.8)
The EchoSmart Controller captures and stores the current measurement value every
six minutes. The database is updated on a “first in/first out” basis to maintain a
continuous register of the most recent seven days of data for all sensors. Newest
data is reported on the right side of the screen.
The Historical Trend Display provides a graphical illustration of stored
measurements for the selected sensor. The user may choose to view from one to
seven days of data.
Figure 4.8: Historical Trend Display
The Historical Trend Display is enabled at the Modify Settings Display.
4.3.5. Modify Settings Display (Figure 4.9)
This display is used to enter the primary parameter settings for each sensor and to
enable the Historical Trend Display and the Tank View Display. A Display Contrast
adjustment function is also found here.
Changes are implemented once entered and the user exits the display. No
confirming command is required.
Descriptions of parameter functions are found in Section 9.0.
- Page 12 -
Figure 4.9: Modify Settings Display
A unique Alpha-Numeric name may be assigned to the sensor and its identifier
address can be changed by pressing the Soft Key next to the Modify Name or
Address prompt (See Figure 4.10).
Figure 4.10: Modifying Sensor Name and Address Display
When modifying the sensor name, the Navigation Keys are used to scroll to selected
letters, numbers and symbols to enter the desired sensor name. The Soft Keys assist
with other functions, as indicated by the Soft Key Prompts.
- Page 13 -
4.3.6. Advanced Settings Display (Figure 4.11)
This display is used to enter additional parameter settings for each sensor. It is also
used to establish the Analog Output parameters for the sensor.
The Advanced Settings Display is accessed by Soft Key function from the Modify
Settings Display.
Figure 4.11: Advanced Settings Display
Descriptions of parameter functions are found in Section 9.0.
4.3.7. Controller Setup Display (Figure 4.12)
The purpose of this display is to change the Current Date and Time, and to initiate
either a manual or automatic establishment of the sensor network.
Auto Detect Sensors begins a search for sensors that are directly connected to the
Controller and are part of a Field Network of sensors. This option is used to
initialize a new instrument and to add or remove sensors from an existing network.
Manually Set Database (Figure 4.13) allows the user to specify sensor addresses
and establishes the order in which the addresses will appear in the Sensor Register
Display. Manually setting the database causes the Controller to persist in attempts
to detect listed sensors in cases where Auto Detect has failed to locate all sensors.
After initiating either the Auto Detect Sensors or the Manually Set Database
command, the Help Prompt field (lower right portion of display area) will report
the number of sensors found, followed by the number of sensors validated. The
display will then redirect to the Echo Profile screen and begin polling all the sensors
in the database.
- Page 14 -
The Controller Setup Display is accessed from the Advanced Settings Display by
pressing the Controller Setup soft key.
Figure 4.12: Controller Setup Display
Figure 4.13: Sensor Database Display
- Page 15 -
4.3.8. Sensor Selection Drop-down Window (Figure 4.14)
To change the sensor that the Controller is currently displaying, press the Change
Sensor Soft Key (available at any informational display and the settings displays).
Use the Navigation Keys to move to the desired sensor and press the Select Sensor
key.
Figure 4.14: Sensor Selection Drop-down Window
4.4. Initializing and Configuring Controller and Smart Sensor(s)
IMPORTANT: Disconnect any outside RS-485 device prior to initiating Controller
Setup to avoid communication errors.
4.4.1. Initial Controller Setup Display (Figure 4.15)
The Initial Controller Setup Screen will appear when power is applied to a
Controller with an empty sensor register.
EchoSmart instruments employ Smart Sensor technology and are often
implemented with multiple sensors operating in union with one Controller. To
establish communication, each Smart Sensor must be assigned a unique address
during initialization (see also Section 4.4.2). This address is held in the memory of
both the Controller and the Smart Sensor(s).
IMPORTANT: All Smart Sensors are shipped from the factory with the preassigned address of 01. In multiple sensor Network installations it is imperative that
sensors be added to the Network one at a time as further described in Section 4.4.2
below. The address of each sensor must be changed to a unique number from 2 –
240. The sensor that is directly connected to the Controller must be initialized first.
Power and initialize additional sensors one at a time, carefully noting the location
of the tank and the corresponding sensor name and address.
Enter the Current Date and Time at this screen using the Navigation and Soft Keys.
- Page 16 -
Figure 4.15: Initial Controller Setup
4.4.2. First Time Controller & Sensor System Installation (Figure 4.16 and 4.17)
If this is a new installation, select First Time Controller & Sensor System
Installation and press the Soft Key next to New System Installation (Figure 4.15).
The Controller will automatically locate the Smart Sensor that has been powered
(this will take a few seconds) and will open the Initial Sensor Setup Display (Figure
4.16).
Figure 4.16: Initial Sensor Setup
Follow the Soft Key Prompts and use the Navigation Keys to enter the Sensor Name
and Sensor Address. It is imperative that the Sensor Address be changed from 01
- Page 17 -
to any unrepeated number from 2 – 240 before initializing the next sensor in a
network.
CAUTION: All sensors are supplied from the factory with the Sensor Address set
at 01. A unique address must be assigned to each sensor as it is added to the network
(powered ON). This procedure allows the Controller to establish communication
and provide a unique address for each sensor as it is added to the network. Failure
to follow this procedure will result in multiple sensors having the same address and
will prevent communication.
Press the Soft Key next to Sensor Setup Complete to finalize setup of the sensor.
The Power Next Sensor Screen (Figure 4.17) will appear. Apply power to the
EchoSmart Power Supply Unit connected to the next sensor and repeat the steps
above.
After all sensors have been initialized, Press the Soft Key next to the Network Setup
Complete prompt (Figure 4.17).
Figure 4.17: Power Next Sensor
All EchoSmart Sensors are now operational. See also Section 13.2 in the Quick
Start Guide of this manual.
4.4.3. Replacing a Controller with Existing Sensor(s) (Figure 4.15)
If Smart Sensors have previously been initialized and the Controller is being
replaced, select Replacing Controller with Existing Sensors and press the Soft Key
next to Replace Controller Only. The Controller will automatically detect the
existing sensors and return to full operation after the initialization routine is
completed.
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4.5. Automatic Initialization and Reboot Sensor
EchoSmart performs automatic initialization whenever power is applied to the sensor
or the Reboot Sensor command is selected at the Echo Profile Display. Instrument
settings are not lost as a result of power interruption.
Automatic Initialization establishes operating gain (signal amplification) and
determines current measurement values and signal outputs. It is advisable to reinitialize a sensor that has been out of service or has been operating while not
submerged in the process water. Re-initializing the sensor after a process upset has
stabilized will quickly return the sensor to normal operation.
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5. EchoSmart Power Supply Unit (ESP)
The Echo Smart Power Supply Unit provides power to an EchoSmart Sensor and acts as a
communication hub to facilitate analog, digital and Wireless RF communications from an
EchoSmart Sensor.
EchoSmart Power Supply Units do not have display monitors or data entry keypads. They
are typically used in a Field Network arrangement in which an EchoSmart Controller
provides the user interface function for setup and monitoring of EchoSmart Sensors. See
Section 8: Communications, Outputs, and Networking.
5.1. Power, Cabling, and General Electrical Connections for the ESP
This section pertains to the physical layout of the ESP terminal connectors and how
they are implemented. If you are wishing to network the ESP with other devices (Ex:
ESC, other ESPs, SCADA Systems, etc), see Section 8 for sample connection
diagrams.
5.1.1. Power Requirements
100 to 240 VAC, 50/60 Hz – 1 A
Supply cable: 10-18 AWG, -40 to +140 F
Power 20 W (fused) 0.250A, 250V 5x20mm T-lag UL approved
4-20 mA Current Loop: 15 – 24 VDC (provided by the ESP)
Optional: 24 VDC (18 – 36 VDC Input)
Caution must be taken to supply main power in the form for which the equipment
is designed.
5.1.2. Connections Overview (Figure 5.1 and Table 5.1)
The ESP circuit board contains four screw-terminal connectors as well as additional
plug-in connectors as shown in Figure 5.1. Use caution in tightening the screw
terminals to prevent damage from over-tightening.
Ensure the power cable (10-18 AWG) is connected to the power connector
properly. Sensors (ESS) should be connected to the power supply by color code as
shown in Figure 5.1 below. Table 5.1 contains a functional description of the screw
terminal connectors.
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+ – –
L G N
Red
Black
White
Brown
Yellow
Blue
Orange
Green
1
8
1
3
Power
Connector
(120/240 VAC)
* IF 24 VDC *
Sensor
Connections
4-20 mA
Connectors
1
4
Level
Turbidity
_
_
RS-485
1
3
_
S
RS-232
Laptop/Cellular
RF Module
Connector
(optional)
J2
J8
J6
Cell Modem
Power
J4
J1
J7
J3
Status
RS-485
RS-232
LEDs
Figure 5.1: Connections for Power Supply
- Page 21 -
Table 5.1: Connections
Power
Connector
(J2)
FOR 100-240
VAC
4-20 Analog
Connectors
(J6)
Sensor
Connections
(J4)
RS-485
Connector
(J8)
Pin #
Description
Pin #
Description
Pin #
Description
Pin #
Description
1
Live
1
Level +
1
15 V
1
Sensor
Comm
2
Ground
2
Level –
2
Ground
2
Sensor
Comm
3
Neutral
3
Turbidity +
3
Sensor
Comm (+)
3
Ground
4
Turbidity –
4
Sensor
Comm (–)
* FOR 24 VDC *
(J2)
5
4-20mA
Level
1 + 6
4-20mA
Level
2 – 7
4-20mA
Turbidity
3 – 8
4-20mA
Turbidity
Notes:
RS-485 Connector (J8): Attach the Network Communication cable from
the Controller or Power Supply Unit in a Wired RS-485 Field Network to
this connector. Connection at the Controller is made at Pin 3 and Pin 4 of
the Sensor Connector (J9).
4-20mA current loops are internally powered, grounded, and galvanically
isolated.
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6. Installation of Equipment
6.1. Installation of EchoSmart Sensor
The EchoSmart Sensor must be fully submerged in the supernatant process liquid
during operation. It is not capable of transmitting a signal through gas (air) or solid
materials.
Mount the sensor using a rigid pipe or conduit to minimize excessive side-to-side sway
or other avoidable movement. If a surface skimmer is present, install using a sensor
mounting fixture that rotates the sensor out of the path of the skimmer (EDI Transducer
Multi-flex Assembly, Part No. 9300-13-13).
Orient the sensor such that the path of the transmit pulse is at 90˚ with respect to the
surface of the sludge blanket or other material that is to be measured, as illustrated in
Figure 6.1 (Entech Design Drawing #ESS-210).
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Figure 6.1 EchoSmart Sensor Mounting Arrangements
- Page 24 -
6.2. Sensor Location Selection Criteria
Optimal performance depends on: (1) acceptable process liquid (supernatant) in which
the ultrasonic pulse is to be transmitted, (2) responsive interface material (suspended
solids blanket, other settled solids), (3) freedom from objects encroaching into the path
of the transmit pulse, and (4) avoiding areas of excessive turbulence.
6.2.1. Acceptable Process Liquid
Most relatively uniform and homogeneous liquids found in water and wastewater
treatment applications and many industrial process applications are suitable for
transmitting the ultrasonic pulse. Excessive amounts of suspended solids, gas or air
bubbles or other concentrations of solids in the supernatant may inhibit or obstruct
the signal. The sensor should be positioned to avoid these conditions if possible.
6.2.2. Responsive Interface Material
The EchoSmart Sensor relies on minimal qualifying characteristics of the material
that is it measuring. Relatively dense, well-settled suspended solids form a welldefined interface and are effective in reflecting signal to the sensor. Light density
material (< 0.5% solids) that is not well-settled does not form a well-defined
interface and is less effective in reflecting signal to the sensor. If possible, locate
the sensor in an area that minimizes exposure to these conditions. Attempt to
position the sensor in an area where the material (sludge) is relatively deep in the
tank under normal process operating conditions.
6.2.3. Stationary Objects in Path of Transmit Pulse
Do not locate the sensor near piping, tank structural elements, or other objects that
encroach on the signal trajectory. Continuously moving rakes and skimmers found
in water and wastewater treatment applications typically do not interfere with
measurements.
6.2.4. Areas of Excessive Air/Gas Bubbles and Turbulence
Avoid locating the sensor in areas where there are high concentrations of air/gas
bubbles or suspended solids in the supernatant. When possible, select sensor
locations to avoid these conditions.
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6.2.5 Typical Circular Clarifier Installation (Figure 6.2)
Figure 6.2: Typical 1/3 – 2/3 Location in Circular Clarifier
- Page 26 -
6.2.6 Typical Rectangular Clarifier Installation
Sensors may be located along the length of the clarifier or in the area of the sludge
sump. Care should be taken to consider inlet flow and the design of the sludge
collection system. Contact Entech Design factory service for specific
recommendations regarding sensor location to assure optimal performance.
6.2.7 Installing Sensors in Applications with Surface Skimmers
Surface skimmers are common in many municipal and industrial clarifiers and
thickeners. Skimmer sweep arms typically pass in the area of installed sensors and
special mounting equipment is required. The Entech Design Sensor Multi-flex
Assembly provides a safe, durable and maintenance-free solution in most
installations. The standard Multi-flex Assembly must be installed in accordance
with manufacturer recommendations and cannot be used if the skimmer sweep rises
more than six inches above the operating water line in the application or in cases
where multiple structural members or supports prevent sensors from returning to
the water without striking one of these objects. Special mounting arrangements and
assemblies are available for virtually all applications with surface skimmers.
Contact Entech Design for additional information.
6.3. Installation of EchoSmart Controller and EchoSmart Power Supply Unit
The EchoSmart Controller and EchoSmart Power Supply Unit are designed for outdoor
installation and are typically attached to safety railing or other structure.
Typically, locate the Controller or Power Supply Unit within 20.0 ft. of the sensor, as
illustrated in Figures 6.4 (Entech Design Drawing #ESC-211) and Figure 6.5 (Entech
Design Drawing #2107-52), below. Sensor cables may be extended at water-tight
junction boxes using manufacturer specified cables or by special order of sensors with
continuous cable of longer lengths.
- Page 27 -
Figure 6.4: Controller Installation Drawing
- Page 28 -
Figure 6.5: EchoSmart Power Supply Unit Installation Drawing
- Page 29 -
7. Tank Configuration, Waveform Analysis, and
Level
Range
Tank Depth
Zero
Adjust
Instrument Settings
Measurements
Tracking
EchoSmart applies advanced proprietary echo waveform analysis and filtering routines to
provide reliable and repeatable measurements. For proper operation, instrument settings
must conform to the dimensions of the tank in which the sensor is installed.
7.1. Tank Configuration (Figure 7.1)
Tank Depth and Zero Adjust parameters (See also Sections 9.1.2 and 9.1.3) orient the
instrument to the dimensions of the tank and assure that the echo waveform corresponds
with tank dimensions at the location of the sensor.
Figure 7.1: Tank Configuration
7.2. Waveform Analysis (Figure 7.2)
The EchoSmart Sensor produces a signal waveform that is used to produce LEVEL
and RANGE measurements. The waveform is available to the user as a diagnostic tool
in the Echo Profile Display, as illustrated here.
- Page 30 -
Gates
Candidate
Track
Tank Bottom
Signal
7.3. Tracking
7.3.1. Gate
Figure 7.2: Echo Profile Display
The signal waveform is presented graphically with the horizontal x-axis representing
the Tank Depth and the vertical y-axis as the strength of signal at positions along the
dimensional axis. The Sensor is identified by symbol in the lower left corner of the
graph, and the Tank Bottom is indicated in the lower right corner.
An interface is generally identified as a rising slope (left side) of the curve of a signal.
This reflects a significant increase in the amplitude of signal at a particular location
(distance from the sensor). Stable and repeated signals are given preference over more
transient ones.
The selected signal is identified on the waveform by a dashed vertical line that is called
a Candidate.
Tracking is the term EchoSmart uses to specify the process of producing the primary
measurement and following (tracking) its progress over time. The “Track” is the
position of the Current Measurement on the Waveform graphic and is identified by a
downward pointing arrow at the top of the screen.
EchoSmart employs enhanced algorithms that operate to stabilize measurements
and prevent inadvertent tracking to transient or spurious signals. One of these is
referred to as the Gate mechanism. The Gate is a stable yet dynamic area around
the Current Measurement. Signal that is inside the Gate is given preferential
consideration. Signal outside the Gate must persist in order to be considered valid.
It is seen on the waveform graphic as dotted lines on either side of the Track. See
9.2.11 LG Min and 9.2.12 RG Min for parameters that establish the dimensions of
the Gate.
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7.3.2. Signal Waveform Symbols
The Down Arrow points to the current Track (See Section 7.2). This position
corresponds with the Current Measurement.
The Right Arrow indicates that a signal meeting tracking criteria is located
outside the Gate, to the right. The measurement will only be affected by this signal
if it persists for repeated updates.
The Left Arrow indicates that a signal meeting tracking criteria is located
outside the Gate, to the left. The measurement will only be affected by this signal
if it persists for repeated updates.
! ! The Double Exclamation Mark indicates that the current signal is insufficient
for tracking purposes. The Current Measurement will be held until sufficient signal
returns. An Echo Loss message will accompany the output measurement on the
Controller if it persists longer than the Echo Delay setting. Loss of Echo will be
reported on the 4-20mA circuit if the Loss of Echo parameter has been activated
(See 9.2.16-18).
- Page 32 -
8. Communications, Outputs, and Networking
ESC = Echo Smart
Controller
RS485
or SCADA
1
RS-485 (J7)
1
3
S
EchoSmart may be implemented as a stand-alone instrument, or it may be configured in a
Wired or Wireless RF Field Network arrangement. In a stand-alone environment
Communication refers to analog signal outputs and digital communication with external
devices. (See Section 1.1)
When implemented in a Field Network arrangement, Communication additionally refers to
information exchange and control functions between EchoSmart devices, as well as
communication and output signals that are connected to the customer data and control
systems. (See Section 1.2)
8.1. Configuration of Individual Units and Networks
Multiple configurations are possible for the EchoSmart equipment.
8.1.1. Stand-Alone Instrument (Figure 8.1)
A stand-alone instrument consists of an EchoSmart Controller with a Smart Sensor
connected to the Controller.
ESC
to DCS
Figure 8.1: Controller with Single Sensor
- Page 33 -
8.1.2. Wired RS-485 Field Network (Figure 8.2)
ESP*
* A 120 resistor needs to be inserted between the + and –
terminals of the last power supply in the series.
ESC = Echo Smart Controller
ESP = Echo Smart Power Supply
RS-485 (J8)
RS485
or SCADA
1 2 16
–
ESP
1
8
Sensor
Connections
(J9)
RS-485 (J8)
RS-485 (J7)
1
3
3
2
4
S
S
3
1
1
3
120 *
S
Up to sixteen Smart Sensors can be operated with one EchoSmart Controller via
two-wire RS-485 from a Controller to each Power Supply Unit. No user
programming or other integration is required.
To create the wired network, a shielded two-wire twisted pair (recommended
Belden 9463) should be used between each ESP and to the ESC. Connections for
the RS-485 communication line are made at the 3-pin terminal strip (J8) on each
ESP and at the 8-pin sensor connector (J9) on the ESC as shown in Figure 8.2
below.
ESC
to DCS
Figure 8.2: Single Wired Field Network
- Page 34 -
8.1.3. Wireless Radio Frequency (RF) Field Network (Figure 8.3)
* The ESC can be used as a remote operator interface to
network field sensors without a directly connected sensor.
ESC = Echo Smart Controller
ESP = Echo Smart Power Supply
ESP
ESP
1 2 16
–
RS-485 (J7)
1
3
S
RS485
or SCADA
Field Networks as described and configured in Section 8.2 can be implemented
using optional fully integrated RF Modules without the installation of field
interconnection cabling and conduit. The Controller and each Power Supply Unit
in the Field Network must be equipped with an RF Module. No user programming
or other integration is required.
Figure 8.3 illustrates a single wireless RF Field Network configuration. Multiple
RF Field Networks may be integrated to a SCADA system by connecting
Controllers as shown in the “Customer Integration” section of Figure 8.4.
ESC
to DCS
Figure 8.3: Single RF Field Network
- Page 35 -
8.1.4. Integrated Field Networks (Figure 8.4)
ESP
ESP*
1 2 16
–
ESP
ESP*
RS485
or SCADA
1 2 16
–
Customer
Integration
Field
Networks
* The individual Field Networks should be wired as shown in
Figure 8.2 or utilize radios as in Figure 8.3.
ESC = Echo Smart Controller
ESP = Echo Smart Power Supply
RS-485 (J7)
1
3
S
RS-485 (J7)
1
3
S
EchoSmart Controllers operating Field Networks may be interconnected in an
integrated two-wire RS-485 Network of up to 240 Smart Sensors. Each Controller
can maintain a network of up to sixteen sensors utilizing either wired connections
or the wireless radio modules. The Controllers can then be connected using a twowire twisted pair so that only one cable run has to be made to the control system.
Customer Modbus RTU integration is required.
IMPORTANT: The two-wire cable to the control system should not be connected
to the ESC until all sensors are installed and communicating with the local ESC.
to DCS
ESC
8.2. Outputs
ESC
Figure 8.4: Integrated Wired Field Network
Current measurements from each sensor can be accessed through a Modbus RTU
command request or an analog 4-20 mA current loop in addition to the measurement
displayed on the installed ESC.
- Page 36 -
8.2.1. RS-485 Modbus RTU
EchoSmart sensors respond to Modbus RTU command requests via the local ESC
that is monitoring the sensor(s). See the OEM Smart Sensor Probe (SSP)
Communications Protocol for detailed information on programming and integration
with a control system. When polling for current measurements, Entech
recommends implementing a one minute pause after retrieving data from all
connected sensors to allow the local ESC to interrogate the sensors.
A shielded two-wire twisted pair (recommended Belden 9463) should be used
between the RS-485 3-pin connector (J7) of the ESC and the local control system.
IMPORTANT: This two-wire cable should not be connected to the ESC until all
sensors are installed and communicating with the local ESC.
When communication is occurring through the RS-485 connection, an “RS-485”
message will appear in the lower left portion of most display screens.
8.2.2. Analog 4-20 mA Current Loop
Two 4-20 mA proportional current loop signals are generated by each sensor.
These signals are accessed through the 4-pin 4-20 Loop connector on the ESC (J10)
or ESP (J6) that is supplying power to the sensor. One current loop is assigned to
the Level or Range measurement and the other to either the turbidity measurement
(when applicable) or the secondary interface.
The sensor’s 4 mA Set Point and 20 mA Set Point (see Section 9.2.14 and 9.2.15)
should be scaled to represent the installation environment with consistent scaling
at the control device. Set Points for the primary Level measurement are
automatically assigned to the output for the secondary interface measurement and
no additional assignment is required or available.
The turbidity 4-20 mA current loop output is factory scaled from 0.0 to 50 NTU
and is not user-adjustable.
8.3. Communication Options and Facilities
The following communication options are provided in all instruments.
8.3.1. RS-485 Modbus RTU Communication
Modbus RTU commands can be used to retrieve and adjust any setting from the
sensor in addition to accessing the output measurement as discussed in Section
8.2.1. See the OEM Smart Sensor Probe (SSP) Communications Protocol
document for detailed information.
8.3.2. Local RS-232 Serial Communication
Controllers and Power Supply Units have RS-232 capabilities. The RS-232 facility
enables communication with an optional Data Cell Modem for Factory Remote
Start-up Support and Service (see Section 8.3.3).
- Page 37 -
When communication is occurring through the RS-232 connection, a “Maint Port”
message will appear in the lower left portion of most display screens.
8.3.3. Factory Remote Service
EchoSmart Controllers are designed for optional installation of a cellular service
modem. With the user’s authorization, this facility enables startup and service by
expert factory technicians. Cellular connectivity is included with the service and is
limited to areas where cell service is available.
See Figure 8.5 below for instructions on how to properly install and remove the
modem from an ESC.
- Page 38 -
Do NOT disconnect
cables at the modem
Connect/Disconnect four screws
to install/remove modem
Red wire on
LEFT at J18
Connect/Disconnect
modem cables here
Modem backplate (do NOT
detach from modem)
Figure 8.5: Proper Installation and Removal of Modem
- Page 39 -
9. Instrument Programming Parameters
Controller and Smart Sensor parameter settings are established at the Modify Settings and
Advanced Settings displays. Standard default parameters exist in all instruments until
modified by the user.
Some settings, as noted below (Ex: Tank Depth, Zero Adjust), require site-specific values.
Other parameters may be changed for convenience or preference (Ex: Units, Interface,
Dampening). However, most parameters should be left at the default value unless instructed
by a factory technician.
Default values for each parameter discussed below are indicated by parenthesis ( ).
9.1. Modify Settings Display Parameters
Parameters found at this display are the primary instrument settings and may require
adjustment to meet the requirements of the installation and process environment.
Note: Accurate values for Tank Depth and Zero Adjust must be entered in order
to secure reliable measurements.
9.1.1. Units (ft)
The Units parameter establishes the desired engineering units that the instrument
will use for all calculations and displayed values.
Options for Units are: Feet (ft), Inches (in), Meters (m), and Centimeters (cm)
9.1.2. Tank Depth (10.0)
Tank Depth is the distance from the top of the tank (Typically the surface of the
water) to the bottom of the tank at the location of the sensor. Tank Depth is used in
conjunction with Zero Adjust to establish the correct empty distance and ensure
that the instrument signal corresponds with tank dimensions. (See Figure 7.1)
The range for Tank Depth is: 3.0 to 32.0 ft
Note: Accurate values for Tank Depth and Zero Adjust must be entered in
order to secure reliable measurements.
9.1.3. Zero Adjust (0.5)
Zero Adjust locates the sensor position relative to the top of the tank. Use a positive
value for Zero Adjust when the sensor is located below the top of the tank. (See
Figure 6.1)
The range for Zero Adjust is: -32.0 to 32.0 ft
Note: Accurate values for Tank Depth and Zero Adjust must be entered in
order to secure reliable measurements.
- Page 40 -
9.1.4. Min Range (3.0)
Min Range establishes the dimension of the measurement blanking-zone near the
sensor. It is referenced to the top of the tank.
Min Range must be at least the value of Zero Adjust plus 1 foot.
The range for Min Range is: 1.0 ft to 32.0 ft
9.1.5. Auto Gain (ON)
This parameter determines whether the Auto Gain function is operational. When
activated, Auto Gain continually monitors signal characteristics and adjusts signal
amplification in response to changes in the process environment. It is recommended
that Auto Gain remain ON unless otherwise advised by a factory-trained technician.
The options for Auto Gain are: ON and OFF
9.1.6. Current Gain (30)
With Auto Gain ON, Current Gain is established automatically and is not accessible
as a parameter that can be modified manually. With Auto Gain OFF, this parameter
establishes the constant level of signal amplification at which the instrument will
operate.
The range for Current Gain is: 0 to 100
9.1.7. AG Set Point (Auto Gain Set Point) (10)
The AG Set Point determines the relative signal strength that the Auto Gain routine
will seek. Increase this parameter to cause Auto Gain to seek a generally higher
level of signal amplification. Decrease this parameter to cause Auto Gain to seek a
generally lower level of signal amplification.
The range for AG Set Point is: 5 to 50
9.1.8. Update Rate (10)
Update Rate determines the number of signal data sets used to develop the current
signal waveform and update the current measurement. This setting effectively
establishes the instrument response time, ranging proportionately from
approximately 2 – 10 seconds.
The range for Update Rate is: 1 to 20
9.1.9. Interface (First)
The Interface parameter establishes the primary Level or Range measurement
algorithm.
- Page 41 -
FIRST Interface causes the instrument to respond to a signal that is nearest to the
sensor (typically lighter density material). LAST Interface causes the instrument to
respond to a signal that is furthest from the sensor when multiple interfaces are
present.
FIRST is the typical selection for wastewater and water treatment clarifiers,
thickeners, sedimentation basins and similar processes.
Select LAST algorithm for filter applications to prevent the adverse effect of
suspended solids and air-bubbles in the filter water column during backwash.
The options for Interface are: FIRST or LAST
9.1.10. Dampening (130)
Dampening establishes the number of updates that are averaged to determine the
Current Measurement. This parameter is used to remove the effects of random
fluctuations caused by settling or disturbed material and prevents sudden changes
in the measurement resulting from the action of rakes and skimmers.
The range for Dampening is: 5 to 255
9.1.11. Settling Zone (ON)
When Settling Zone is ON the instrument ignores signal originating to the left of
LG Min. This enables the sensor to disregard suspended solids, air/gas bubbles and
similar sources of disturbance in the supernatant.
The options for Settling Zone are: ON and OFF
9.1.12. Tank Display (ON)
Tank Display allows the user to select a tank diagram for the Tank View Display.
There are five common tank designs from which to choose. (See Section 4.3.3 and
Figure 4.7)
The options for Tank Display are: ON and OFF
9.1.13. Trend Display (ON)
Trend Display allows the user to activate the Historical Trend Display. (See
Section 4.3.4 and Figure 4.8)
The options for Trend Display are: ON and OFF
9.1.14. Display Contrast (55)
Display Contrast allows the user to adjust the LCD Contrast for optimal visibility.
The range for Display Contrast is: 0 to 255
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9.2. Advanced Settings Display Parameters
Additional parameters, including those used to set up Analog Output Signals are found
at this display. Access this display by pressing the Soft Key next to the Advanced
Settings prompt at the Modify Settings Display.
9.2.1. Max Range (11.0)
Max Range establishes an optional measurement blanking-zone near the bottom of
the tank. Its location is referenced from the top of the tank.
When the Tank Depth parameter is changed, Max Range is automatically set to
110% of the Tank Depth value.
The range for Max Range is: 1.0 to 35.2 ft
9.2.2. Measure (Level)
Measure determines whether the calculated measurement is the depth of the
material (LEVEL) or the distance from the top of the tank to the material (RANGE).
The options for Measure are: LEVEL and RANGE
9.2.3. Wiper Timing (240)
Wiper Timing establishes the time (minutes) between wiper cycles. The sensor
wiper will also operate automatically on detection of signal loss regardless of the
selected Wiper Timing setting. This reduces the need to establish a short wiper
timing sequence and prolongs the life of the wiper mechanism.
The range for Wiper Timing is: 0 [OFF] to 240 minutes
9.2.4. Gain Band (20)
Gain Band establishes the amount that Current Gain (with Auto Gain ON) can vary
once the initial gain level (GB Midpoint) has been established. At the default value,
Current Gain can increase or decrease by 20 around the GB Midpoint.
The range for Gain Band is: 5 to 30
9.2.5. Gain Increment (0.1)
Gain Increment determines the rate of change in gain as Auto Gain operates to
change the Current Gain level over time.
The range for Gain Increment is: 0.1 to 5.0
9.2.6. Save GB Midpoint (MP) (OFF)
When turned ON, the Save Gain Band Midpoint option allows the user to manually
set the gain midpoint
The options for Save GB MP are: ON and OFF
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9.2.7. GB Midpoint (Automatically set)
Automatic sensor initialization establishes the initial signal amplification (Gain)
that is appropriate for the process environment. This value is held in the GB
Midpoint register.
With Auto Gain ON, Gain increases and decreases around the Midpoint to maintain
optimal signal amplification. The Gain Band Parameter establishes the maximum
increase or decrease in Gain above and below the Midpoint.
With Save GB Midpoint (MP) set to ON, the midpoint can be manually set by the
user.
The range for GB Midpoint is: 0 to 100
9.2.8. Wall Zone (0.5)
This parameter establishes a zone near the bottom of the tank that permits special
handling of a dominant signal that originates from the tank floor. The instrument
differentiates this signal from other signals in order to correctly calculate
measurements.
The range for Wall Zone is: 0.0 to 32.0
9.2.9. Wall Zone AG (40)
This parameter limits gain amplification when the primary signal is a reflection
from the tank bottom. Since the desire is to track blankets, it prevents overamplification of the signal in applications with light-density material, or when the
tank bottom is the only signal present (tank has no suspended solids blanket or
settled solids).
The range for Wall Zone AG is: 0 to 100
9.2.10. Sound Speed (4862 fps)
Sound Speed is the transmit velocity the instrument uses to calculate Level and
Range Measurements. Changes to Sound Speed may be required to calibrate the
instrument for use if the process liquid is extreme in temperature or pressure, or is
other than water.
The range for Sound Speed is: 1000 to 6000 fps
9.2.11. Sensitivity (20)
Sensitivity determines whether a signal is sufficient for tracking. Lower Sensitivity
to promote tracking a less well-defined signal (gradual slope or low amplitude
signal). Increase Sensitivity to produce the opposite effect.
The range for Sensitivity is: 0 to 100
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9.2.12. LG Min (2.0)
LG Min establishes the margin of the left side of the Gate (See Section 7.3 for a
description of the Gate and its function).
The range for LG Min is: 0.0 to 32.0
9.2.13. RG Min (2.0)
RG Min establishes the margin of the right side of the Gate (See Section 7.3 for a
description of the Gate and its function).
The range for RG Min is: 0.0 to 32.0
9.2.14. 4mA Set Point (0.0)
The 4mA Set Point establishes the instrument measurement value at which the user
expects the sensor to output a current of 4mA. Establish the same Set Point value
in the control device that the instrument is connected to.
The range for 4mA Set Point is: 0 to Tank Depth
9.2.15. 20mA Set Point (10.0)
The 20mA Set Point establishes the instrument measurement value at which the
user expects the sensor to output a current of 20mA. Establish the same Set Point
value in the control device that the instrument is connected to.
The range for 20mA Set Point is: 0 to Tank Depth
9.2.16. Echo Loss (OFF)
Echo Loss provides an alarm function through the 4 – 20mA current loop signal
when this Echo Loss setting is set to ON. The selected Echo Loss Action is executed
after loss of echo persists for the time lapse defined by the Echo Delay setting.
The options for Echo Loss are: ON and OFF
9.2.17. Echo Delay (60)
Echo Delay establishes the amount of time (in minutes) that the sensor must
experience a loss of echo before initiating the Echo Loss Action.
The range for Echo Delay is: 0 to 255 minutes
9.2.18. Echo Loss Action (Cycle)
Echo Loss Action determines the state that the current loop adopts in response to
loss of echo when the Echo Loss alarm function is activated.
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The options for Echo Loss Action are: 4mA, 20mA, and Cycle. When Cycle is
selected, the output continually alternates between 4mA and 20mA until the loss of
echo condition ceases.
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10. Maintenance and Troubleshooting
10.1. Preventative Maintenance
10.1.1. Sensor Cleaning and Maintenance
1. Standard Sensor (Non Self-Cleaning)
Non Self-Cleaning Sensors are typically used in applications in which the
sensor is regularly and periodically rotated out of the water by the action of a
surface skimmer. It is expected that this action will provide sufficient cleaning
of the face of the sensor to prevent signal degradation for an extended period.
However, it is recommended that the sensor face be inspected and cleaned at
regular three (3) month intervals to prevent buildup of material, or as needed to
preserve signal integrity. When the buildup of material becomes too great, it
can adversely affect performance.
If you find that cleaning must take place on a very frequent basis (daily/weekly)
or cleaning is more frequent than desired, self-cleaning sensors with wipers are
available. Please contact Entech Design at (940) 898-1173 for details.
2. Wiper Sensors (Self-Cleaning, including sensors with turbidity option)
The Wiper mechanism and blade are designed to remove air/gas bubbles and
light suspended solids that may collect on the face of the sensor and degrade
signal quality. Supplemental manual cleaning may be required in processes in
which suspended solids attach aggressively to the face of the sensor.
Wiper blade and motor life will vary with process conditions and the user
established frequency of operation (Wiper Timing parameter, Section 9.2.3). It
is generally expected that the wiper blade assembly will require replacement
yearly and the wiper motor will require replacement every two years in typical
water and wastewater treatment applications.
It is recommended that the sensor be inspected frequently during the initial three
(3) to six (6) months of operation to determine whether supplemental cleaning
is needed and that the wiper blade assembly is intact. From these observations,
an ongoing preventive maintenance schedule suitable for the application can be
established.
CAUTION: Unless determined to be insufficient for the process environment,
Wiper Timing (Advanced Settings) should be set to 240 to reduce wiper blade
and motor wear. Lowering this parameter will reduce motor assembly life
proportionately.
Wiper Assembly Replacement:
The EchoSmart Sensor Wiper Blade Assembly (Part No. 9306-54-19) is field
replaceable.
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Remove the wiper by unscrewing in counter-clockwise direction. Secure and
retain the stainless steel spacing washer from the wiper shaft for use with the
replacement wiper.
Screw the new wiper clockwise until the arm makes contact with the seated
spacing washer, plus 1/8th of a turn. DO NOT OVER TIGHTEN. Overtightening may result in the wiper not operating. A Wiper Stall message will
be indicated at the EchoSmart Controller.
3. Sensor Cleaning and Inspection
Remove the sensor from the process using safety procedures, protective
clothing and equipment appropriate for the process environment. Protective
gloves and eyewear should always be used when there is the possibility of
exposure to dangerous or unsanitary materials or conditions.
Carefully remove larger debris, rags and similar material that may have attached
to the sensor. Do not rotate the wiper blade by hand. Algae, slime and
accumulations of suspended solids in the process liquid should be brushed away
using a soft to medium bristle non-metallic brush or soft cloth and mild
detergent. For disinfection, use 8 oz. of regular bleach (sodium hypochlorite
8.25% solution) to one gallon of water.
Before returning the sensor for service, operate the wiper system to observe that
it rotates in the expected manner and that the wiper blade is secure. In normal
operation, the wiper blade with make 1-3 rotations when power is supplied or
when the wiper timing setting is changed.
10.1.2. Other Routine Maintenance
Visually inspect the analyzer monthly during normal clarifier “walk downs” to
determine that there are no obvious signs of damage to the equipment and that
mounting brackets and hardware are secure. Tighten mounting bolts as may be
required.
Observe the sensor to assure that it is fully submerged below the surface of the
water and that there are no rags or similar debris wrapped around it. Clear rags and
debris from the sensor with an extension brush or by flushing with water (see 10.1.1
Sensor Cleaning and Maintenance).
If your clarifier employs a surface skimmer, watch skimmer flights as they pass the
location of the sensor to assure that the flights contact the sensor shield-rod
allowing it to flex freely and rotate the sensor out of the path of the flights. Ensure
that the shield is aligned to prevent the skimmer from making contact with the
sensor.
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10.2. Troubleshooting
The following recommendations address the most often encountered troubleshooting
needs with the EchoSmart equipment. If the described procedure does not resolve the
problem, contact Entech Design for further assistance.
10.2.1. Comm Error Message
A Comm Error message indicates that communication between the Controller and
Sensor(s) has been interrupted for an extended period of time. Verify that the
sensor associated with the alarm is properly powered and that all sensor and
communication cables are connected correctly.
In the case of a Wireless Field Network of Sensors, consider metal structures,
cabinets and mounting fixtures that may intervene in the path of the RF signal.
Contact Entech Design for corrective actions that may be necessary.
10.2.2. Echo Loss Message
An Echo Loss message indicates that the instrument does not have a signal that is
reliable for measurement. This can occur as a result of the sensor not being
submerged in water or as a result of an abnormal process condition (sludge level
too near the sensor, excessive off-gassing, unsettled suspended solids in the
supernatant, or material or bubbles collecting on the face of the sensor). It can also
be the result of incorrect operating parameters installed in the sensor.
Corrective action includes a physical inspection of the sensor(s) and process to
determine whether any of the above referenced conditions exist. If a Wiper Sensor
is in use, confirm that the wiper arm is in place and that the wiper turns when (1)
power is cycled, (2) the sensor Reboot command is called, or (3) the Wiper Timing
setting is changed.
Check instrument parameters. Confirm that the Tank Depth, Zero Adjust, Min
Range and Max Range settings are correct and that Auto Gain is ON. Contact
Entech Design for information regarding other parameter settings that may require
adjustment.
10.2.3. Validating Message
Validating is the “handshake” process that occurs when an EchoSmart Controller
initiates communication with the sensor(s). This takes place when the Controller is
initialized or when a sensor is manually added to the sensor database. This step is
normally completed rapidly and may not be noticed by the user. If the Validating
message continues for an extended period of time, there is a communication
problem that may require corrective action (See Sec. 10.2.4).
10.2.4. Validation Failure Message
If a sensor does not validate as expected, the Controller has been unable to
communicate with the sensor, and the Validation Failure message will be displayed.
Check all sensor and network cabling and connections and re-check main power to
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the Controller and all Power Supply Units. If a wireless sensor network is in use,
investigate possible impediments to network communications.
10.2.5. Wiper Stalled Message
A Wiper Stalled message will appear if the wiper does not operate when expected
or if rotation of the wiper blade is not detected. It may also indicate drag on the
wiper motor as a result of debris being attached to the wiper blade or shaft. Visually
inspect the sensor to determine that the wiper blade and shaft are free of debris.
Verify that the wiper is securely connected to the wiper shaft and that it turns freely
(1-3 revolutions) when power is cycled to the sensor or the Wiper Timing parameter
is changed. Replace the wiper blade, as indicated in Section 9.3.1.
10.2.6. Wiper Motor Failure Message
This message indicates an internal electronic failure of the wiper motor. Contact
Entech Design for repair or replacement options.
Note: Wiper motor failure may cause unreliable measurements.
10.2.7. 4-20 mA Measurement Discrepancy
EchoSmart 4-20 mA devices are active (powered) and isolated current loops. Check
that no other power or isolation is present on the loop, and confirm that no other
electronic devices or electrical elements intervene on the current loop. Check that
appropriate signal cable is in use.
EchoSmart allows the user to span the 4-20 mA signal with reference to Level
(depth of sludge) or Range (distance from water surface to top of sludge). Confirm
that the correct parameter has been entered.
The maximum span is 0.0 to Tank Depth. The 4mA Set Point and 20mA Set Point
must be correctly entered to establish the desired span. Check that corresponding
Set Point values are entered in the customer data acquisition system.
Disconnect loop cables from the EchoSmart equipment and measure the current
output to determine whether it corresponds with the measurement indication from
the instrument.
10.2.8. Sensors Not Detected and No Sensors Found Message
If sensors are not detected or a No Sensors Found message is reported, confirm that
all sensor and communication cables are securely landed at the respective
Controller or Power Supply Unit(s) and that main power is ON.
If a Controller operates more than one sensor, confirm that all sensors have been
added to the Network as directed in 13.2. Configuring a Sensor Network, and that
each has a unique address designation. If multiple sensors have the same address
number, the Controller will not be able to establish communication with those
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sensors. If unique sensor addresses have not been assigned, power OFF the
RS-232
Laptop/Cellular
J7
Status
RS-485
RS-232
LEDs
equipment and follow the steps in 13.2.
If a wired field network is being used, refer to Section Error! Reference source
not found. to verify that all connections are made at the proper terminals.
10.2.9. Troubleshooting Radio Communications
System-wide communications troubleshooting:
Ensure the radio in the Controller is fully seated. If an external antenna is being
utilized, verify the antenna is hand tight and the connecting cable is properly
connected to the radio and the antenna. If the Controller is using an external radio
unit, ensure the cable connections are made as outlined in Section 11.2.3.
Sensor specific communications troubleshooting:
LEDs located near the serial port of each ESP give an
indication of the communication that is occurring in the
network. The Status LED should be on solid and the RS-
485 LED should flash with each transmitted message.
If the Status LED is flashing, cycle power on the ESP.
If the Status LED is on solid and the RS-485 LED is not
flashing, verify that the radio is seated properly and cycle
power to determine if communication can be reestablished.
10.2.10. Persistent “Acquiring Waveform” Message on Echo Profile Screen
If an “acquiring waveform” message appears for an extended period of time on the
Echo Profile screen, a search of the network may be necessary to establish proper
communication with the sensor. Go to Modify Settings Advanced Settings
Controller Setup, select the “Auto Detect Sensors” option and press Auto Detect
Sensors. After a few seconds, the display will redirect to the Echo Profile screen.
This persistent message can also appear if an external device, such as an integrated
control system, is constantly requesting information from the sensor(s).
Temporarily disconnect the external device to see if waveform data can then be
gathered from the sensor. If this resolves the issue, modifications to the external
device’s polling routine are likely needed.
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11. System Options
11.1. Self-Cleaning Wiper Sensor with Turbidity Measurement
This sensor incorporates a scattered light turbidity meter into the EchoSmart Wiper
Sensor to provide continuous Level and Turbidity measurements.
11.1.1. Application
This sensor is recommended for use in applications in which there is need for a
Level and Turbidity measurements at the location of the sensor. It is specifically
recommended for use in water and wastewater treatment clarifiers and thickeners
to continuously monitor sludge level and to provide an indication of turbidity at the
location of the sensor – typically near the effluent weir.
The Level and Turbidity Sensor is also recommended to measure Media Level,
Backwash Expansion and Backwash Turbidity in granular media filters. It may be
used separately or in conjunction with the available in-air Water Level Sensor for
effective conditional control of filter backwashing.
11.1.2. Principle of Operation
Sludge level measurements use the EchoSmart ultrasonic time-in-flight
measurement technique as with all EchoSmart interface level sensors.
Turbidity measurements are provided by a 90º scattered-light turbidity meter
located in the combined sensor housing. Sensors are factory calibrated from 0 – 50
NTU. Power to the sensor is provided by an EchoSmart Controller or Power Supply
Unit to which it is connected. The measurement indication is displayed on the
Controller. Output signals include a 4-20mA proportional signal and RS-485
Modbus RTU digital.
11.1.3. Sensor Cleaning
Sensing surfaces of the sludge level and turbidity sensor are automatically cleaned
by a fully integrated wiper system with a replaceable rubber wiper blade. The wiper
is operated by an internal motor powered by the EchoSmart Controller or Power
Supply Unit.
11.1.4. Installation
The sensor has a ¾ in. NPT female threaded connection to provide simple
attachment to a user supplied mounting pipe. The connection is a direct replacement
for the standard EchoSmart sensor. In general, locate the sensor in accordance with
instructions for ultrasonic sensors as otherwise described in Section 6. Additionally,
the sensor may be located near an effluent weir to optimize the effluent turbidity
measurement without adversely affecting sludge level measurements.
In filter applications, sensors are located immediately below the top of the
backwash trough to secure measurements during active backwashing and while the
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filter is on-line. Contact Entech Design for additional instructions for proper
installation.
11.1.5. Connections
The sensor connection is made in the same manner as an EchoSmart sensor. Refer
to Section 4.2.2, Figure 4.2, and Table 4.1 for further connection details when
operated by an EchoSmart Controller, or Section 5.1.2, Figure 5.1, and Table 5.1
when operated by an EchoSmart Power Supply Unit.
11.1.6. Turbidity Sensor Calibration
The turbidity sensor is factory calibrated using a resin emulsion turbidity
conforming solution.
11.2. Integrated Wireless Radio (RF) Modules
Communication between the Controller and associated Power Supply Units can be
achieved with integrated wireless radio modules to eliminate the need for cabling and
conduit between units.
11.2.1. General Overview
The radios use a proprietary message structure for communication between units
and utilize mesh networking capabilities to achieve redundancy and reliability.
11.2.2. Internal Configuration
In this configuration, the radio module is mounted inside the Controller or Power
Supply enclosure. An external antenna is then affixed to the outside of the
enclosure with a U.FL to RP-SMA cable connecting the antenna to the module.
The module additionally requires a two-wire cable to be connected between the
radio’s 4-pin terminal strip (J2) and the 8-pin terminal strip on the associated
Controller (J9) or Power Supply (J4). The cable should link red to red terminal
locations and black to black (see Figure 11.1).
- Page 53 -
Figure 11.1 Connections for Wireless Radio Module
ESC = Echo Smart Controller
ESP = Echo Smart Power Supply
1
8
Sensor
Connections
(J9/J4)
Radio Connector (J2)
3
2
4
Black
Red
4
1
ESC or
ESP
11.2.3. External Configuration
In this configuration, the radio module is mounted in a separate enclosure that can
be located in an optimal location. An external antenna is affixed to the outside of
the enclosure with a U.FL to RP-SMA cable connecting the antenna to the module.
A four-wire cable is required to connect the radio’s 4-pin terminal strip (J2) and the
8-pin terminal strip on the associated Controller (J9) or Power Supply (J4). The
cable should link red to red terminal locations, black to black, white to white, and
brown to brown (see Figure 11.2).
This configuration is ideal when Controllers or other units are placed in buildings
or other locations that may create less than ideal paths for radio transmissions. The
radio can then be located in a more optimal location.
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ESC = Echo Smart Controller
ESP = Echo Smart Power Supply
1
8
Sensor
Connections
(J9/J4)
Radio Connector (J2)
3
2
4
White
Black
Red
4
1
Brown
ESC or
ESP
Figure 11.2 Connections for Wireless Radio Module
11.2.4. Equipment Orientation for Units with Integrated Wireless Radio Modules
Equipment containing the integrated wireless radio modules should be oriented
such that the antenna mounting location is on the side of the enclosure with the
antenna pointed in the upward direction. See Figure 11.3.
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11.3. Relays
Figure 11.3 Orientation of Units with Wireless Radio Modules
Relays require additional circuit board installation in the EchoSmart Controller. Relays
are not available in the EchoSmart Power Supply Unit.
11.3.1. General Overview
One to four relays may be added as an option to a Controller. Each relay is capable
of monitoring the sludge level or turbidity (with optional sensor) and can be
assigned to separate sensors, or multiple relays can be assigned to one sensor.
11.3.2. Operation (Figure 11.4)
Relay controls are accessed by pressing the Set Up Relays soft key from the
Controller Setup Display (Figure 4.12).
The relay Status must be set to ON in order for the relays to operate. The sensor
associated with each relay is listed below the “Status” setting. Each relay is capable
of monitoring the sludge level or the turbidity value (when installed) by selecting
the desired setting under the “Assign to” option. The “Enable >” parameter
determines the value at which the relay will be energized and change states while
the “Disable <” determines the value at which the relay will de-energize and change
states.
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NC
C
NO
Relay
Connections
J1
NC
C
NO
NC
C
NO
NC
C
NO
Relay 1
Relay 2
Relay 3
Relay 4
1
12
Figure 11.4: Relays Display
11.3.3. Cabling and Connections for Relays (Figure 11.5 and Table 11.1)
This section pertains to the physical layout and terminal connections for the relays.
Figure 11.5: Connections for Relay Board
- Page 57 -
Table 11.1: Connections
Relay Connections
(J1)
Pin #
Relay
Description
1 1 Normally Closed
2
Common
3
Normally Open
4 2 Normally Closed
5
Common
6
Normally Open
7 3 Normally Closed
8
Common
9
Normally Open
10 4 Normally Closed
11
Common
12
Normally Open
12. Warranty
Analytical Technology, Inc., (Manufacturer) warrants to the Customer against defect in parts
of the Manufacturer’s products that prove to be defective in materials or workmanship within
the earlier of 18 months of the date of shipment or 12 months of the date of start-up in
accordance with the terms of its PRODUCT WARRANTY. Analytical Technology, Inc.
makes no other warranty expressed or implied except as stated in the PRODUCT
WARRANTY.
- Page 58 -
13. Quick Start Guide
13.1. Configuring a Single Sensor
Follow these instructions when only one sensor is to be operated by the EchoSmart
Controller.
1. Ensure all sensor connections are correct and that power is properly applied to the
device.
IMPORTANT: Disconnect any outside RS-485 device from the ESC prior to
initiating Controller Setup to avoid communication errors.
2. From the Initial Controller Setup
screen, press New System Installation.
This routine will take approximately 20
seconds to complete.
3. Change the Sensor Address to a unique value other than 1 and enter the correct
parameters associated with the sensor on the Initial Sensor Setup screen – most
importantly the Tank Depth, Zero Adjust, and 4-20mA Set Points (if being used).
See Section 7.1 for help in determining correct values for Tank Depth and Zero
Adjust. Press Sensor Setup Complete.
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4. When a screen appears with instructions
to “Power Next New Sensor for Setup,”
press Network Setup Complete.
5. You will be directed to the Echo Profile
screen. The sensor will go through an
initialization process and then begin to
report the current interface location.
6. If an external RS-485 polling device is to be used, it can now be connected. See
Section 8.2.1 for recommendations and information regarding an RS-485
connection.
13.2. Configuring a Sensor Network
Follow these instructions when an EchoSmart Controller will communicate with more
than one sensor in a Network arrangement.
1. Ensure all sensor connections are correct and that power is properly applied to the
EchoSmart Controller. If a sensor is not directly connected to the Controller,
additionally power the first EchoSmart Power Supply with its sensor. Sensors must
be powered and added to the network one at a time.
IMPORTANT: Disconnect any outside RS-485 device from the ESC prior to
initiating Controller Setup to avoid communication errors.
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2. From the Initial Controller Setup
screen, press New System Installation.
This routine will take approximately 20
seconds to complete.
3. Change the Sensor Address to a unique
value other than 1 and enter the correct
parameters associated with the sensor on
the Initial Sensor Setup screen – most
importantly the Tank Depth, Zero Adjust,
and 4-20mA Set Points (if being used).
See Section 7.1 for help in determining
correct values for Tank Depth and Zero
Adjust. Press Sensor Setup Complete.
4. When a screen appears with instructions
to “Power Next New Sensor for Setup,”
apply power to the next sensor that needs
to be configured.
5. Repeat steps 3 and 4 for all sensors in the network, ensuring that each sensor has a
unique Sensor Address. Once all have been setup, press Network Setup Complete.
6. You will then be directed to the Echo
Profile screen. The sensors will go
through an initialization process and then
begin to report the current interface
location.
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7. To see the sensor name, current measurement, gain value, and turbidity output
(when applicable) of all connected sensors, press Change Display from the Echo
Profile screen.
8. If a sensor is not automatically found
(once powered) during the network
setup process or needs to be added later,
go to Modify Settings Advanced
Settings Controller Setup, highlight
the Auto Detect Sensors option, and
press Auto Detect Sensors.
9. If an external RS-485 polling device is to be used, it can now be connected. See
Section 8.2.1 for recommendations and information regarding an RS-485
connection.
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13.3. Special Settings for Filter Applications
Two dimensions are needed to set up the EchoSmart unit for filter applications: the
distance from the Sensor to the Media (SM), and the Depth of the expandable Media
(DM). Installation recommendations and a guide to help determine correct input
dimensions are found in Figure 13.1 below. SM should be measured after installation
of the sensor. The setup parameters can then be implemented as follows:
Units: Set to Inches (or Centimeters)
A smaller measurement unit provides finer resolution in the output
measurement.
Tank Depth: SM + DM
(The measured distance from the Sensor to the Media (SM) plus the Depth of
the Media (DM)).
Zero Adjust: Set to zero (0.0)
Min Range: Set to 12 inches
Update Rate: Set to 8
Interface: Set to LAST
Dampening: Set to 5
Max Range: SM + 4 inches
(The measured distance from the Sensor to the Media plus 4 inches)
4mA Set Point: 0.0
(This locates the zero Level at the bottom of the expandable media. See Figure
13.1)
20mA Set Point: Tank Depth (SM + DM, Figure 13.1)
Additional notes:
The initial measurement and 4-20 mA output should equal the depth of the
expandable media (DM). If the output does not match the known media depth,
check the SM measurement and adjust the Tank Depth value accordingly.
Depth of Media is NOT a directly measured value. Accuracy of this
measurement and changes over time depend on a correct starting DM provided
by the user.
If the Tank Depth value is changed, Max Range will need to be re-calculated
and set to the new value after the new Tank Depth is entered.
If a narrower 4-20 mA span is desired, caution should be taken not to reduce
the span such that it does not allow for media expansion during backwash or
loss of media over time. The 4-20mA set points for turbidity are factory set to
0-50 NTU. Any data collection devices should be scaled accordingly.
All other parameters should be left at factory defaults unless directed by Entech
Design or one of their representatives.
- Page 63 -
igure 13.1: Installation Recommendations and Field Measurement for Filter Applications
F
- Page 64 -
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