Pulsar blackbox 130 Instruction Manual

blackbox 130 (UL)
INSTRUCTION MANUAL
BLACK BOX LEVEL 130 UL (SECOND EDITION)
June 2017 Part Number M-130-0-002-0U
COPYRIGHT
© Pulsar Process Measurement Limited, 2003 -17. All rights reserved. No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any language in any form without the written permission of Pulsar Process Measurement Limited.
WARRANTY AND LIABILITY
Pulsar Process Measurement Limited guarantee for a period of 2 years from the date of delivery that it will either exchange or repair any part of this product returned to Pulsar Process Measurement Limited if it is found to be defective in material or workmanship, subject to the defect not being due to unfair wear and tear, misuse, modification or alteration, accident, misapplication or negligence.
DISCLAIMER
Pulsar Process Measurement Limited gives nor implies any process guarantee for this product, and shall have no liability in respect of any loss, injury or damage whatsoever arising out of the application or use of any product or circuit described herein.
Every effort has been made to ensure accuracy of this documentation, but Pulsar Process Measurement Limited cannot be held liable for any errors.
Pulsar Process Measurement Limited operates a policy of constant development and improvement and reserves the right to amend technical details as necessary.
The blackbox shown on the cover of this manual is used for illustrative purposes only and may not be representative of the actual blackbox supplied.
TECHNICAL ENQUIRIES
Please contact Pulsar Process Measurement for technical support.
COMMENTS AND SUGGESTIONS
If you have any comments or suggestions about this product, then please contact:
Pulsar Process Measurement Limited
Pulsar Process Measurement Inc.
Cardinal Building Enigma Business Centre Sandy’s Road Malvern Worcestershire WR14 1JJ United Kingdom
PO Box 5177 Niceville
FL 32578 - 5177 USA
Tel: + 44 (0) 1684 891371 Fax: + 44 (0) 1684 575985
Tel: + 1 850 279 4882 Fax: + 1 850 279 4886
Web Site: http://www.pulsar-pm.com e-mail: info@pulsar-pm.com (general
information) e-mail: support@ pulsar-pm.com (product
support)
Web Site: http://www.pulsar-pm.com e-mail: info.usa@pulsar-pm.com (general
information) e-mail: support.usa@ pulsar-pm.com (product
support)
Contents
Chapter 1 Start Here… ......................................................................................................................................... 1
About this Manual ........................................................................................................................................... 1
About the blackbox range ............................................................................................................................... 2
Functional Description .................................................................................................................................... 3
Product Specification....................................................................................................................................... 4
EC Declaration of Conformity ........................................................................................................................ 6
Chapter 2 Installation............................................................................................................................................ 7
Power Supply Requirements ........................................................................................................................... 7
Location ........................................................................................................................................................... 8
Dimensions ...................................................................................................................................................... 9
Standard Enclosure .................................................................................................................................. 9
Large Enclosure (optional) .................................................................................................................... 12
Terminal Connection Details ........................................................................................................................ 14
Power ..................................................................................................................................................... 15
Transducer.............................................................................................................................................. 15
Relay Outputs ........................................................................................................................................ 17
Current Output ....................................................................................................................................... 17
RS232 Serial Interface ........................................................................................................................... 17
Fuse Location ................................................................................................................................................ 17
Preparation for Operation .............................................................................................................................. 18
Maintenance ................................................................................................................................................... 19
Chapter 3 How To Use Your blackbox Level System .................................................................................... 20
PC Handheld Programmer (Standard).......................................................................................................... 20
Communication Port Configuration ..................................................................................................... 21
Handheld Communicator (Optional) ............................................................................................................ 21
On board integral Keypad and Display (Optional) ...................................................................................... 22
Operating the Controls .................................................................................................................................. 23
Display ................................................................................................................................................... 23
Keypad ................................................................................................................................................... 24
Run Mode ...................................................................................................................................................... 26
LED’s ..................................................................................................................................................... 27
Program Mode ............................................................................................................................................... 27
How to Access Program Mode ............................................................................................................. 28
Test Mode ...................................................................................................................................................... 30
LED’s ..................................................................................................................................................... 31
Using the RS232 Serial Interface .................................................................................................................. 31
Parameter Defaults ........................................................................................................................................ 32
Factory Defaults ..................................................................................................................................... 32
Chapter 4 Programming Guide .......................................................................................................................... 34
Level ............................................................................................................................................................... 34
Example 1 Level Measurement ............................................................................................................ 34
Example 2 Alternating Control (pump down) ..................................................................................... 36
Volume (Optional) ........................................................................................................................................ 38
Example 3 Volume Application ........................................................................................................... 38
Chapter 5 Parameter Guide ................................................................................................................................ 40
Menu System Diagrams ................................................................................................................................ 40
Top Level Menu .................................................................................................................................... 40
Application Menu .................................................................................................................................. 40
Relays Menu .......................................................................................................................................... 41
Data Logs Menu .................................................................................................................................... 41
Volume Menu ........................................................................................................................................ 42
Display Menu ........................................................................................................................................ 43
Output Menu .......................................................................................................................................... 43
Compensation Menu ............................................................................................................................. 43
Stability Menu........................................................................................................................................ 44
Echo Processing Menu .......................................................................................................................... 44
System Menu ......................................................................................................................................... 45
Test Menu .............................................................................................................................................. 46
Parameter Listing ........................................................................................................................................... 47
Application Parameters ................................................................................................................................. 47
Operation ................................................................................................................................................ 47
Dimensions ............................................................................................................................................ 48
Remote Alarm........................................................................................................................................ 50
SMS Time .............................................................................................................................................. 51
Relay Parameters ........................................................................................................................................... 53
Relay Type ............................................................................................................................................. 53
Alarms .................................................................................................................................................... 54
Control.................................................................................................................................................... 57
Common Parameters ............................................................................................................................. 59
Data Log Parameters ..................................................................................................................................... 60
Temperature ........................................................................................................................................... 60
Volume (Optional) ........................................................................................................................................ 61
Conversion ............................................................................................................................................. 61
Breakpoints ............................................................................................................................................ 64
Tables ..................................................................................................................................................... 66
Display Parameters ........................................................................................................................................ 66
Options ................................................................................................................................................... 66
Failsafe ................................................................................................................................................... 67
Output Parameters ......................................................................................................................................... 68
Range ..................................................................................................................................................... 68
Operation ................................................................................................................................................ 68
Setpoint .................................................................................................................................................. 69
Limits ..................................................................................................................................................... 69
Trim ........................................................................................................................................................ 70
Failsafe ................................................................................................................................................... 70
Compensation Parameters ............................................................................................................................. 70
Offset ...................................................................................................................................................... 71
Temperature ........................................................................................................................................... 71
Stability Parameters ....................................................................................................................................... 72
Damping................................................................................................................................................. 72
Filters ...................................................................................................................................................... 72
Echo Processing Parameters ......................................................................................................................... 73
Transducer Status................................................................................................................................... 73
System Parameters ........................................................................................................................................ 74
Passcode ................................................................................................................................................. 74
System Information ............................................................................................................................... 74
Date & Time .......................................................................................................................................... 75
Daylight Saving Time ........................................................................................................................... 76
Test Parameters .............................................................................................................................................. 79
Simulation .............................................................................................................................................. 79
Hardware ................................................................................................................................................ 80
Chapter 6 Troubleshooting ................................................................................................................................ 82
Parameter Record .................................................................................................................................................. 83
Page 1
Chapter 1 Start Here…
Congratulations on your purchase of a Pulsar blackbox 130 Level System. This quality system has been developed over many years and represents the latest in high technology ultrasonic level measurement and control.
It has been designed to give you years of trouble free performance, and a few minutes spent reading this operating manual will ensure that your installation is as simple as possible.
About this Manual
It is important that this manual is referred to for correct installation and operation.
There are various parts of the manual that offer additional help or information as shown.
Tips
At various parts of this manual you will find tips to help you.
Additional Information
Additional Information
At various parts of the manual, you will find sections like this that explain specific things in more detail.
References
See Also
References to other parts of the manual
Page 2
About the blackbox range
The Pulsar blackbox is a non-contact Level Control System. It has been designed to provide a new concept in low cost maintenance-free fit and forget level measurement without any compromise on performance.
The blackbox is ideally suited to applications where level monitoring, reporting, control or logging is required, with or without the need for a local display.
The blackbox level system is available in a variety of different versions offering a wide choice of output options.
The blackbox is very easy to use and may be calibrated quickly and simply via a laptop, using the software supplied with the unit, or alternatively by using the optional hand held calibrator, which connects to the unit via the RS232 interface, and provides an on-board LCD display. Certain models are also available with an optional LCD display and integral keypad fitted.
All models of the blackbox range can be used with any of the extensive range of Pulsar dB transducers for distances up to 131ft (40m).
The blackbox range is designed to provide you with highly reliable measurement in a robust and functional package that is easy to use and low in cost.
Page 3
Functional Description
The blackbox ultrasonic Level System sends a transmit pulse to the transducer, which emits an ultrasonic pulse perpendicular to the transducer face, and the returned echo is sent back to the blackbox. The time taken to receive the echo is measured and the distance from the transducer face to the surface being monitored is calculated.
The blackbox utilises the unique DATEM software (Digital Adaptive Tracking of Echo Movement). This is a unique digital mapping technique
developed especially for Pulsar’s range of ultrasonic level and control
systems. It gives the system edge when identifying the “true target level” in
the face of competing echoes from pipes, pumps or other obstructions. The blackbox can measure from 0.41ft (0.125m) to 131 feet (40m) from the
transducer to the surface being monitored, dependent on the application and transducer used.
The blackbox can measure level, space or distance and provide a representative output. When fitted with the optional display and keyboard it can also measure and provide an output representative of volume. There are two user definable relays, with individual setpoints, which can be programmed to activate alarms or control functions, a mA output that can be used for remote indication purposes and a RS232 port, so that the blackbox can be programmed or monitored remotely by a PC or other equipment.
The blackbox can be programmed either by PC, via the RS 232 Serial Interface, using the supplied software (standard) or by hand held calibrator (optional) which is connected to the blackbox via the RS 232 interface.
Those units fitted with the optional on board display can be programmed via the integral keyboard.
All the parameters are stored in non-volatile memory, so are retained in the event of power interruption.
Page 4
Product Specification
Physical
Standard Wall Mount Enclosure Outside dimensions 5.12 x 5.12 x 2.36 inches
(130 x 130 x 60 mm)
Weight Nominal 1.4lbs (0.65 kg) Cable entry detail underside fitted with 3 x M20, nylon cable
glands
Large Wall Mount Enclosure (optional) Outside dimensions 5.12 x 7.09 x 3.35 inches (130 x 180 x 85 mm) Weight Nominal 1.65lbs (0.75 kg) Cable entry detail underside fitted with 5 x M20, nylon cable
glands
Enclosure material/description Polycarbonate base with Polycarbonate lid,
flammability rating UL94-5V
Separation
Transducer cable extensions 3 conductor 20AWG screened Nominal separation 3,280 ft. (1000m). For greater separation
distances please consult Pulsar
Environmental
Mounting Indoor/Outdoor Relative Humidity (IP Rating) IP66 (NEMA 4X enclosure) <35oC (95oF) at 93% relative humidity
Pollution Degree 2
Altitude 2000m maximum Max. & min. temperature (electronics) -4ºF to 120ºF (-20 ºC to +50 ºC) Flammable atmosphere approval Safe area: compatible with approved dB
transducers (see transducer spec' sheet)
Approvals
UL Certificate Number E257330 CE approval See EU Declaration of Conformity
Performance
Accuracy 0.25% of the measured range or
0.24" (6 mm) (whichever is greater)
Resolution 0.1% of the measured range or 0.08" (2 mm)
(whichever is greater)
Max. range Dependant on transducer (maximum 131ft
(40m) dB40)
Min. range Dependent upon transducer (minimum 0.41ft
(0.125m) dB 3)
Rate response fully adjustable
Echo Processing
Description DATEM (Digital Adaptive Tracking of Echo
Movement)
Page 5
Outputs
Analogue output Isolated (floating) or non-isolated output of
4-20 mA or 0-20 mA into 1K (user programmable and adjustable) 0.1% resolution
Serial Port (Digital output) Full Duplex RS232 for programming and
data extraction
Volt free contacts, number and rating 2 form "C" (SPDT) rated at 2A at 115V AC Display (optional) 2 x 12 alpha numeric
Programming
PC programming (standard) via RS232 using supplied software Remote programming (optional) via RS232 using optional hand held
calibrator
On board programming (optional) via integral keypad Programming security via passcode (user selectable and
adjustable)
Programmed data integrity via non-volatile RAM
Supply
Power supply 115 VAC +5% / -10% 50/60 Hz,
dc 10 - 28V 10W maximum power (typically 5W)
Overvoltage Category II Fuses
Mains (F1) 100 mA T at 115 VAC DC (Battery) (F2) 1A Thermal (self resetting after power
removed). Not user replaceable
Transducer (F3, F5) Littelfuse 242 series 100mA Part No.
0242.100. This fuse is not user replaceable and has a 4000A breaking capability to comply with certification of the Exm version of dB series transducers.
Remote Communicator
Power Supply Power supplied via blackbox RS232
interface.
Pulsar Process Measurement Limited operates a policy of constant development and improvement and reserve the right to amend technical details as necessary.
Page 6
EU Declaration of Conformity
Page 7
Chapter 2 Installation
Power Supply Requirements
The blackbox can operate from AC supply or from a DC battery and is designed for use in temperatures between -4oF to +140oF (-20oC to +50oC). The AC is 115V +5%/-10%. The DC is 10-28V. In all cases the blackbox will typically consume 5W of power, with a maximum of 10W. If the blackbox has both an AC and DC supply available then the AC supply source will be automatically sensed and used, should the AC supply be removed for any reason then the DC supply will take over.
The AC and DC wiring should be completed using either 16 – 14AWG (1.5–
2.5mm2) stranded or 16 – 14AWG (1.5–4mm2) solid wire, with all terminals being tightened to 4.5in. lbs. (0.5Nm).
An external supply isolator/circuit breaker (AC or DC) must be fitted and labelled to identify the instrument to which it refers.
Safety Symbols
Detailed below are descriptions and meanings of safety/warning symbols that are used on the blackbox 130 and in this manual.
Direct Current
Alternating Current
Protective Conductor Terminal
Caution (Refer to accompanying Documents)
!
Page 8
Location
All electronic products are susceptible to electrostatic shock, so follow proper grounding procedures during installation.
The blackbox level controller must be mounted in a non-hazardous (safe) Area, and the transducer fitted in the hazardous area.
Note: the blackbox shown in the above diagram is for illustrative purposes only and may not be representative of the actual blackbox supplied.
FM APPROVED TRANSDUCERS
Class I, Div. 1, Group A, B, C & D
Class II, Div. 1, Group E, F & G
Class III
Page 9
When choosing a location to mount the enclosure, bear in mind the following:
Ensure that the blackbox is installed in a “Safe”, non-hazardous,
area.
Easy access to the enclosure is maintained.
The mounting surface is vibration-free.
The ambient temperature is between -4ºF and 120ºF (-20ºC and
50ºC)
There should be no high voltage cables or inverters close by.
Dimensions
Standard Enclosure
The dimensions of the mounting holes are as shown below.
Page 10
The blackbox should be mounted by drilling four holes suitable for size 8 pan or round headed screws. The screw length will be dependent on the wall to which the blackbox is to be mounted to, if it is unclad use 1.5" long screws with suitable wall fixings, if the wall is clad add the cladding thickness to the 1.5" screw length.
Fit all four screws by removing the top cover to access the pre-moulded mounting holes which are located in the corners of the base of the enclosure, under the lid retaining screws.
Important Information
The enclosure lid screws should be tightened to 10in.lbs (1.1Nm).
Care should be taken not to over tighten the screws.
Page 11
The full dimensions of the enclosure are as shown below.
Cable Entry
There are 3 x 20mm (0.79") cable glands, suitable for 6 – 12mm (0.24" –
0.63") cables, fitted to the base of the blackbox enclosure.
Page 12
Large Enclosure (optional)
The dimensions of the mounting holes are as shown below.
Page 13
The full dimensions of the enclosure are as shown below.
Cable Entry
There are 5 x 20mm (0.79") cable glands, suitable for 6 – 12mm (0.24" – 0.63") cables, fitted to the base of the fitted to the base of the blackbox enclosure.
Page 14
Terminal Connection Details
The terminal strip is as detailed below. There is also a wiring diagram attached to the board directly underneath the terminal strip.
Important Information
All terminal connection screws should be tightened to 4.5in.lbs. (0.5Nm).
Care should be taken not to over tighten the screws.
Page 15
Terminal Connections
Power
The blackbox can operate from mains AC and automatically from a DC power source or battery backup, in the event of power failure, or can be operated permanently from DC or batteries.
The AC and DC wiring should be completed using either 16 – 14AWG (1.5–
2.5mm2) stranded or 16 – 14AWG (1.5–4mm2) solid wire. An external supply isolator/circuit breaker (AC or DC) must be fitted and
labelled to identify the instrument to which it refers.
Transducer
The transducer should be installed, and connected, in accordance with the installation instructions contained in the Transducer User Guide.
The entire range of, standard dB transducers are certified for use in hazardous areas and different models, for each, are available for use in EEx m (Zone 1) or EEx ia (Zone 0).
Wire the transducer to the blackbox transducer terminals as detailed below:
Red = Power (Terminal 19) White = Signal (Terminal 20) Black = 0 volts (Terminal 18)
Green (screen) = SCR (Terminal 17)
If splicing, it is recommended using a junction box with standard twisted, shielded pair at 20 AWG.
When using 2 core screened extension cable, the Black and Green wires of the transducer should be connected to the screen of the extension cable and connected to the 0 volts’ terminal (Terminal 18).
Page 16
When installing a transducer in a hazardous area use an approved transducer suitable for the proposed application as detailed below:
FM For EEx m (Zone 1) applications a transducer certified to FM Class I Div 1
Group A, B, C & D, ClassII Div 1 Group E, F & G, Class III is used, and
must be supplied via a 1500A breaking fuse, which is fitted as standard to the blackbox level controller.
Restrictions do not use in the presence of these groups of Chemicals, Aliphatic Hydro Carbons, Ketones or Esters
For EEx ia (I.S.) a transducer certified to FM Class I Div 1 Group A, B, C & D, ClassII Div 1 Group E, F & G is used, which must be connected to the blackbox via an external Zener barrier.
ATEX For EEx m (Zone 1) applications a transducer certified to Sira
02ATEX5104X is used, and must be supplied via a 4000A breaking fuse,
which is fitted as standard to the blackbox level controller. For EEx ia (Zone 0) a transducer certified to Sira 02ATEX2103X is used,
which must be connected to the blackbox via an external Zener barrier. See transducer label for certification details.
Important Information
Please note that if the output of the ultrasonic transducers used with blackbox are capable of emitting sound pressure levels in excess of 85dBA (above a reference sound pressure level of 20µPA), then the blackbox must be located remote from the transducer such that a sound pressure level of 85dBA is not exceeded when standing at the blackbox in the operator’s position.
Page 17
Relay Outputs
The two relays can be programmed to a variety of alarm and control functions. The relay contacts are all rated at 2A at 115V AC. Wiring should be completed by using suitable cable, to meet the specified 115V AC 2A contact rating, up to maximum size of 14AWG. All connections should be such that the short circuit capacity of the circuit to which they are connected, is limited by fuses rated so that they do not exceed the relay rating.
Current Output
This is an isolated mA output of 4 - 20mA or 0 - 20mA, and the load should not exceed 1K.
RS232 Serial Interface
The serial interface is used to programme the blackbox either via a PC (standard) using the software supplied or alternatively using the hand-held calibrator (optional).
Fuse Location
The mains fuse is located, on the bottom board, to the left of the mains terminals, as illustrated below.
Page 18
Important Information
Before applying AC power (mains), make sure the supply is 115 VAC +5% / -10%
Never operate the blackbox with terminal access exposed. An external switch or circuit breaker should be installed near to the
blackbox to allow the supply to be removed during installation and maintenance. In addition, the relay contacts should also have a means of isolating them from the blackbox.
Interconnecting cables must be adequately insulated in accordance with local regulations. Strip back 30 mm of the outer insulation of the cable. Strip 5 mm of insulation from the end of each conductor. Twist all exposed strands of the conductor together. Insert the stripped conductor into the terminal block as far as it will go and tighten the terminal block screw. Ensure that all strands are firmly clamped in the terminal block and that there is no excess bare conductor showing, and no stray strands.
Important Information
If the equipment is installed or used in a manner not specified in this manual, then the protection provided by the equipment may be impaired.
Preparation for Operation
Before switching on, check the following:
The blackbox is mounted correctly and is in a ‘safe’ area. The power supply is correctly installed. The relays are connected correctly.
Page 19
Maintenance
There are no user serviceable parts inside your blackbox, except the mains power fuse. If you experience any problems with the equipment, then please contact Pulsar Process Measurement for advice.
Important Information
Please note that the on-board Lithium battery, mounted to the processor PCB, is not user serviceable.
To clean the equipment, wipe with a damp cloth. Do not use any solvents on the enclosure or transducer.
Important Information
The unique DATEM software comes into operation as soon as power is applied, and is designed to monitor a moving level or target with the transducer in a fixed position.
If, after any period of use, it should become necessary to move the transducer, for any reason, from its original operating position, switch off the blackbox, before proceeding, to prevent any undesirable updates to the DATEM trace. If after moving the transducer the reading is not as expected, please refer to Chapter 6 Troubleshooting.
Page 20
Chapter 3 How To Use Your blackbox Level System
In order to view or change parameter values one of the following methods must be used:
PC Handheld Programmer (Standard)
Your blackbox 130 comes complete with the PC Handheld Programmer software, contained on CD. Insert the CD into the CD drive of the PC intended to be used to carry out the programming of the blackbox and install the software, following the on-screen instructions. Once the software is installed connect the computer via its serial port to the blackbox RS232 serial interface RJ11 connector, located on the terminal connector strip, inside the blackbox
enclosure. Double click the ‘Handheld Programmer’ icon, installed on your
desktop and the PC will automatically connect to the blackbox. Once connected you will briefly see the message illustrated on the display below which, after connecting successfully, will then change to display the current measurement, dependent on mode and measurement unit's chosen. When using the PC Handheld Programmer software, keypad input can be achieved
by using a ‘mouse’ or similar device to place the cursor over the relevant key followed by a ‘left’ click, alternatively numeric detail can be entered directly
from the PC keyboard as can ‘ENTER’ and ‘CANCEL’ (Esc. Key).
Page 21
Communication Port Configuration
If the PC Handheld Programmer fails to connect to the blackbox unit you may need to change the communications port that is being used, to do this
‘right click’ on the PC Handheld Programmer keypad and a ‘pop up’ menu
will appear allowing you to select the appropriate communications port.
Handheld Communicator (Optional)
The optional Handheld communicator can be used to programme any number of blackbox units and works in a similar way to the PC Software. Connect the Handheld Communicator, with the cable supplied, to the RS232 interface via the RJ11 connector located on the terminal connector, inside the blackbox enclosure. Once connected you will briefly see a message, similar to that as seen when using the PC Software which, after connecting successfully, will then change to display the current measurement, dependent on mode and measurement unit's chosen.
Page 22
On board integral Keypad and Display (Optional)
When fitted, the blackbox can be programmed directly via the integral keypad.
Page 23
Operating the Controls
Display
The display in all cases is identical, the only difference being is that both the PC Programming Software (standard) and the Hand-Held Calibrator (optional) need to be connected to the blackbox via the RS232 interface, whereas the on-board keypad and display (optional) are permanently connected to the blackbox provides information on the current mode of operation.
When in the Run Mode it will display the current level reading and its units of measure, along with status messages with regards to the Transducer, Echo reception and Fail Safe Mode. When in the Program mode the display is used to read information on the Menu System, Parameter Number and parameter details and values, which can be entered. During Test Mode, the display is used to monitor the simulated level.
1234.56
mm
1) Main Display, 6-digit numeric display:
Run Mode, current measurement displayed, dependent on mode and measurement unit's chosen, and value of Hot Key function selected. Program Mode, displays parameter number and values entered for parameters. Test Mode, displays simulated level.
2) Auxiliary Display, scrolling twelve-digit alpha numeric display
Run Mode, displays measurement units (P104), status messages on signal and transducer, detail of Hot Key function selected. Program Mode, displays Menu and Sub Menu headings, parameter
3) details and options.
1
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