Remote Automation Solutions Manual: Digital Level Sensor (DLS) for ROC800-Series User Program Manual Manuals & Guides

Form A6142

Part Number D301189X012
July 2010

Digital Level Sensor Program
(for ROC800-Series)
User Manual

Remote Automation Solutions

Digital Level Sensor Program User Manual

Revision Tracking Sheet

July 2010

This manual may be revised periodically to incorporate new or updated information. The revision date of each
page appears at the bottom of the page opposite the page number. A change in revision date to any page also
changes the date of the manual that appears on the front cover. Listed below is the revision date of each page
(if applicable):

Page Revision

All Pages Jul-10
All Pages Jun-05
All Pages Jul-03
Initial release Apr-03

NOTICE

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manual or omissions from this manual. RAS MAKES NO WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING THE IMPLIED
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© 2003-2010 Remote Automation Solutions, division of Emerson Process Management. All rights reserved
.

ii Rev. Jul-10

Digital Level Sensor Program User Manual

Contents

Page

Chapter 1 – Introduction.................................................................................................................. 1-1

1.1 Scope and Organization................................................................................................1-1

1.2 Product Overview .......................................................................................................... 1-1

1.2.1 Wave Smoothing................................................................................................ 1-2

1.2.2 Communications................................................................................................1-5

1.2.3 Module Wiring....................................................................................................1-5

1.3 Program Requirements.................................................................................................. 1-6

1.3.1 License Keys...................................................................................................... 1-6

Chapter 2 – Installation....................................................................................................................2-1

2.1 Installing the License Key.............................................................................................. 2-1

2.1.1 Verifying the License Key Installation................................................................2-2

2.2 Downloading the LevelSensorIF.tar Program................................................................ 2-2

Chapter 3 – Configuration...............................................................................................................3-1

3.1 Communication Ports .................................................................................................... 3-2

3.2 Level Sensor Program Configuration Screen................................................................3-3

3.3 Level Sensors – Configuration and Status Screen........................................................3-5

3.4 Saving the Configuration ............................................................................................. 3-11

Chapter 4 – Reference Materials..................................................................................................... 4-1

4.1 Point Type 63: Digital Level Sensor Program Configuration ......................................... 4-2

4.2 Point Type 64: Tank Gauge Parameters.......................................................................4-6

Rev. Jul-10 Contents iii

Digital Level Sensor Program User Manual

[This page is intentionally left blank.]

iv Rev. Jul-10

Chapter 1 – Introduction

This chapter describes the structure of this manual and presents an
overview of the Digital Level Sensor user program for the ROC800­Series Remote Operations Controller.

1.1 Scope and Organization

This document serves as the user manual for the Digital Level Sensor
user program, which is intended for use in a ROC800-Series Remote
Operations Controller (ROC800). This manual describes how to install
and configure the Digital Level Sensor user program (referred to as the
“DLS program” or “the program” throughout the rest of this manual).
You access and configure this program using ROCLINK
Configuration Software loaded on a personal computer running
Windows
Vista®.

®

2000 (with Service Pack 2), Windows XP, or Windows

Digital Level Sensor Program User Manual

™

800

The sections in this manual provide information in a sequence
appropriate for first-time users. Once you become familiar with the
procedures and the software, the manual becomes a reference tool.

This manual has the following major sections:

 Chapter 1 – Introduction
 Chapter 2 – Installation
 Chapter 3 – Configuration
 Chapter 4 – Reference

This manual assumes that you are familiar with the ROC800 and its
configuration. For more information, refer to the following manuals:

 ROC809 Remote Operations Controller Instruction Manual (Form

A6116).

 ROC827 Remote Operations Controller Instruction Manual (Form

A6175).

 ROCLINK 800 Configuration Software User Manual (Form A6121).

1.2 Product Overview

The DLS program enables the ROC800 to communicate directly with
up to 30 level sensors (reporting on oil or water or both) on the same
EIA-232 (RS-232) or EIA-485 (RS-485) communications port. The
program supports the Advanced Telemetrics digital tank gauges or any
other level sensor using the protocol described in the Advanced
Telemetrics document Tank Gauge Commands – Model ATL-
TGM1000C. The program polls the level sensor for data at a user­configured interval, validates the retrieved data, and updates the
appropriate production totals using that data.

Rev. Jul-10 Introduction 1-1

Digital Level Sensor Program User Manual

The program polls each sensor and requests current tank levels and fluid
temperatures. As each sensor responds, the program compares the
current tank level value against that sensor’s last good level value.

If the sensor reports a difference (representing a drop in the level), the
program multiplies that difference by a conversion factor (“strapping
value”) you define, reflects that change in the accumulated runs, and
calculates and updates the closing stock value. For this program, the
drop in level value represents a load. The program also determines
production values (representing an increase in the level) using the
following calculations:

Closing Stock = (Current Tank Level) X (Conversion Factor)
Production = (Closing stock) + (Accumulated runs) – (Opening stock)

At the contract hour (user-defined in the program), the program:
 Copies the total production values for all tanks to yesterday’s total

production and initializes total production.

 Copies the closing stock values to the opening stock values and

initializes the accumulated runs and production.

This program has been tested to work with the Rosemount™ 3300
series level sensor using Levelmaster (also known as “Siemens” or
“Tank” protocol) communication. For more information see the
Rosemount 3300 Series with HART to Modbus Converter, Manual
Supplement 00809-0300-4811.

1.2.1 Wave Smoothing

The program uses an algorithm to limit the detection of “waves,” or
false changes in fluid level. You use the Level Sensor Data screen (see
Section 3.3) to configure the wave smoothing parameters, which
include:

 Maximum wave limit (distance in inches above or below the last

valid reading).

 Scan periods (the number of times the program reads the level to

validate the wave height).

 Wave timeout (the number of scans to determine if level variations

are due to liquid movement or “sloshing”). This parameter enables
you to validate and count level changes that are smaller than the
maximum wave limit.

To assist in the calculations, the program also tracks the following
values and displays them on the Level Sensor Data screen:

 Current level (the actual measured level).
 Production accumulation (positive changes in level).
 Load accumulation (negative changes in level).
 Change (sensor level minus production or load level).

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Digital Level Sensor Program User Manual

Once each scan period, the program reads the sensors and performs
wave smoothing calculations. You can configure maximum wave limits
(typically 1 inch) and specify the number of scan periods (typically one
per second) until the program considers a wave a valid reading for oil or
water.

When the program first reads the sensor, the program stores that value
as the production or load level. When the next sensor reading occurs,
the program compares the stored production level value to the actual
reading and, depending on the amount of change, performs one of three
actions:

No Change

Positive Change

Negative Change

If the difference between one reading and the
next is less than or equal to the maximum
wave limit value, the program retains the current
value for the specified number of scan periods
until wave timeout value expires. At that time the
level becomes the production or load level and
the program adjusts the accumulators
accordingly.

If the difference between one reading and the
next is positive and greater than the maximum
wave limit value, the program adds the change
to the production accumulator and the new level
becomes the production or load level. The
program continues to add positive changes to the
production accumulator until there are no more
changes outside of the maximum wave limit and
the wave timeout value expires. At that time the
level becomes the production or load level.

If the difference between one reading and the
next is negative and greater than the
maximum wave limit value, the program adds
the change to the load accumulator and
continues adding subsequent values to the load
accumulator as long as the level continues to
drop and the wave timeout value has not expired.

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Digital Level Sensor Program User Manual

Figure 1. Wave Smoothing Flow Chart

1-4 Introduction Rev. Jul-10

1.2.2 Communications

The ROC800 can communicate with the level sensors using the
following methods:

 The EIA-232 (RS232) serial communications port on the CPU for

distances up to 15 meters (50 feet). This port is designated Comm2.

 An optional EIA-232 serial communications module, for distances

up to 15 meters (50 feet), can be installed in module slots 1–3. These
ports are designated Comm3, Comm4, or Comm5, depending on the
module slot location.

 An optional EIA-485 (RS485) serial communications module, for

distances of up to 605 meters (2000 feet), can be installed in module
slots 1–3. These ports are designated Comm3, Comm4, or Comm5,
depending on the module slot location. EIA-485 (RS-485)
communications supports multiple field devices (multi-drop) and
use two conductors (A, B).

1.2.3 Module Wiring

Connect the sensor(s) to the communications port on the module using
between 16 and 24 AWG wiring. Figure 2 shows example wiring
between the module and several sensors.

Digital Level Sensor Program User Manual

Note: Level sensors can be either externally powered or obtain power

through the sensor wiring itself.

120 OHM
TERMINATION RESISTO R
USER SUPPLIED

FIELD

DEVICE

A

B

EXTERNAL

+

-

FIELD

DEVICE

A

FIELD

DEVICE

B

++

--

EXTERNAL

POWERPOWER

A

B

EXTERNAL

POWER

Figure 2. Module Wiring

DO Points

You can specify a DO point controlled by the
program. This discrete output enables you to
power on a level sensor before it is polled and
then power it off after polling. This is typically a
DO status point (102,x,8). To accomplish this, you
need to connect to a DOR module on the ROC800
or supply your own relay.

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Digital Level Sensor Program User Manual

1.3 Program Requirements

The DLS program is compatible with version 3.10 (or greater) of the
ROC800 Series 2 firmware, version 2.16 (or greater) of the ROC800
Series 1 firmware, and with version 1.87 (or greater) of the ROCLINK
800 software. The software requires you to install a hardware based
License Key.

Program specifics include:

Target

File Name

LevelSensorIF.tar 63, 64 35976 3912 86016 1.87 7, 8

Unit/

Version

ROC800

Series 2

3.10

ROC800

Series 1

2.16

User Defined

Point (UDP)

Flash Used

(in bytes)

SRAM Used

(in bytes)

DRAM

Used (in

bytes)

ROCLINK

800

Version

Display

Number

Note: You must connect a PC to the ROC800’s LOI or Ethernet port

before starting the download.

For information on viewing the memory allocation of user programs,
refer to Section 7.7 of the ROCLINK 800 Configuration Software User
Manual (Form A6121).

1.3.1 License Keys

License keys, when matched with valid license codes, grant access to
applications such as DLS program.

The term “license key” refers to the physical piece of hardware that can
contain up to seven different licenses (refer to Figure 3). Each ROC800
can have none, one, or two license keys installed. If you remove a
license key after enabling an application, the firmware disables the task
from running. This prevents unauthorized execution of protected
applications in a ROC800.

J1

U1

DOC0422A

Figure 3. License Key

Note: You must install the Level Sensor I/F license key to use the DLS

program.

1-6 Introduction Rev. Jul-10

Chapter 2 – Installation

This chapter provides instructions for installing the DLS program. Read
Section 1.3 of this manual for program requirements.

2.1 Installing the License Key

If you order the DLS program for a new ROC800, your ROC800 is
delivered with the license key installed. Go to Section 2.2. If you order
the program for an existing ROC800, you must install the license key
yourself.

Digital Level Sensor Program User Manual

Caution

Failure to exercise proper electrostatic discharge precautions, such
as wearing a grounded wrist strap may reset the processor or
damage electronic components, resulting in interrupted operations.

When working on units located in a hazardous area (where
explosive gases may be present), make sure the area is in a non­hazardous state before performing these procedures. Performing
these procedures in a hazardous area could result in personal injury
or property damage.

To install a license key:

1. Remove power from the ROC800.

2. Remove the wire channel cover.

3. Unscrew the screws from the Central Processing Unit (CPU)

faceplate.

4. Remove the CPU faceplate.

5. Place the license key in the appropriate terminal slot (P4 or P6) in

the CPU.

Incorrect

Correct

DOC0423A

Figure 4. License Key Installation

Note: When using a single license key, install it in slot P4.

6. Press the license key into the terminal slot until the key firmly seats

(refer to Figure 4).

7. Replace the CPU faceplate.

8. Replace the screws on the CPU faceplate.

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Digital Level Sensor Program User Manual

9. Replace the wire channel cover.

10. Restore power to the ROC800.

11. Proceed to Section 2.2.1 to verify the license key installation.

2.1.1 Verifying the License Key Installation

After you install the license key, you can verify whether the ROC800
recognizes the key. From the ROCLINK 800 screen, select Utilities >
License Key Administrator. The License Key Administrator screen
displays:

Figure 5. License Key Administrator

Level Sensor I/F appears in the Application Name column. (For further
information on the License Key Administrator screen, refer to the
ROCLINK 800 Configuration Software User Manual, Form A6121.)

After you verify that the license key is correctly installed and
recognized, proceed to Section 2.3.

2.2 Downloading the LevelSensorIF.tar Program

This section provides instructions for installing the LevelSensorIF.tar
program file into the Flash memory on the ROC800.

To download the program using ROCLINK 800 software:

1. Connect the ROC to your computer using the LOI port.

2. Start and logon to ROCLINK 800.

3. Select Utilities > User Program Administrator from the

ROCLINK menu bar. The User Program Administrator screen
displays (see Figure 6):

2-2 Installation Rev. Jul-10