APG DCR-WEB User manual

Operator’s Manual
AUTOMATION
PRODUCTS
GROUP, INC.
Automation Products Group, Inc.
APG...Providing tailored solutions for measurement applications
Tel:[phone]•Fax:[phone] • www.apgsensors.com•E-mail:[email protected]
DCR-WEB
Rev. A3, 10/08
Doc. 9002666

DCR-WEB Rev. A3, 10/08
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APG...Providing tailored solutions for measurement applications
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Table of Contents
Warranty ......................................................................................... 3
Introducing...................................................................................... 4
Understanding Ultrasonics............................................................. 5
Installation ...................................................................................... 7
Wiring.............................................................................................. 8
Programming .................................................................................. 9
Programming Modes .................................................................... 10
Operation ................................................................................... 10
Filtering ..................................................................................... 11
Outputs ...................................................................................... 13
Calibration................................................................................. 16
Utilities ...................................................................................... 17
Specifications ................................................................................ 19
Dimensions.................................................................................... 19
Maintenance ................................................................................. 20

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APG warrants its products to be free from defects of material and workmanship
and will, without charge, replace or repair any equipment found defective upon
inspection at its factory, provided the equipment has been returned,
transportation prepaid, within 24 months from date of shipment from factory.
THE FOREGOING WARRANTYIS IN LIEU OFAND EXCLUDESALLOTHER
WARRANTIES NOTEXPRESSLYSETFORTH HEREIN,WHETHER
EXPRESSED OR IMPLIED BY OPERATION OF LAWOR OTHERWISE
INCLUDING BUTNOT LIMITED TOANYIMPLIEDWARRANTIES OF
MERCHANTABILITYOR FITNESS FORAPARTICULAR PURPOSE.
No representation or warranty, express or implied, made by any sales
representative, distributor, or other agent or representative of APG which is not
specifically set forth herein shall be binding uponAPG. APG shall not be liable
for any incidental or consequential damages, losses or expenses directly or
indirectly arising from the sale, handling, improper application or use of the
goods or from any other cause relating thereto andAPG’s liability hereunder, in
any case, is expressly limited to the repair or replacement (at APG’s option) of
goods.
Warranty is specifically at the factory. Any on site service will be provided at
the sole expense of the Purchaser at standard field service rates.
All associated equipment must be protected by properly rated electronic/
electrical protection devices. APG shall not be liable for any damage due to
improper engineering or installation by the purchaser or third parties. Proper
installation, operation and maintenance of the product becomes the
responsibility of the user upon receipt of the product.
Returns and allowances must be authorized byAPG in advance. APG will
assign a Return Material Authorization (RMA) number which must appear on
all related papers and the outside of the shipping carton. All returns are subject
to the final review by APG. Returns are subject to restocking charges as
determined by APG’s “Credit Return Policy”.
• Warranty and Warranty Restrictions

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•Introducing
The DCR-WEB is a non-contact loop control system that is shipped ready to
be put into service. It has been completely tested at the factory and is easily
configured to any application. The sensor is fully programmable to meet the
needs of all different kinds of loop control applications. Operating parameters
are modified using 4 push buttons and a 2 X 8 alphanumeric display. The
controls are accessed by removing the front cover. It is recommended that this
manual be read before attempting to make any changes to the default
parameters.
The unit is available in a clear plastic enclosure. There are two types of
transducers availably. The electrostatic type in a 2 in. x 3.3 in. x 1.6 in.
enclosure. The ceramic type in a 3 in. x 3 in. x 2 in. enclosure. Both types are
attached to the controller with a 6 ft. length of RG6 coaxial cable.
Two outputs can be wired by the customer are labeled “RLY1” and “RLY2”.
These outputs are 5 Arelays suitable for 120 VAC and up to 5 Acontinuous.
They are fully programmable outputs.
There are two terminal sections on the board. Each can be wired to a switch.
•INV-SW allows the user to invert the 0-10 Voutput without changing
software settings.
•AP-SW allows the user to switch between two different pre-programmed
settings. For example, two different filter settings and trip distances for
different materials can be stored and selected with a switch.

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•Understanding Ultrasonics
Ultrasonic sensors measure distance
using a transducer to send out
ultrasonic bursts. Each burst contains
a series of 1-20 pulsed sound waves
that emit in the shape of a cone,
reflect off the target, and are received
by the sensor. The time required for
the sound burst to travel to and from
the target is converted into a distance
measurement by the sensor.
Ultrasonic sensing is affected by
several factors including the target
surface, distance, size, and angle. The
following considerations will help
ensure the best possible target
conditions.
Surface
The ideal target surface is hard and smooth and perpendicular to the face of
the transducer. This surface will reflect a greater amount of signal than a soft,
sound wave absorbent surface. Atarget with poor sound wave reflection
characteristics will reduce the operating distance of the sensor and decrease its
detection
area
beam spread
low sensitivity
and
pulses
high sensitivity
and
pulses

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accuracy.
Distance
The shorter the distance from the sensor to an object, the stronger the
returning echo will be. Therefore, as the distance increases, the object requires
better reflective characteristics to return a sufficient echo.
Size
A large object will have a greater surface area to reflect the signal than a
small one, therefore, a large target will be detected at a greater distance than a
small target. The surface area recognized as the target is generally the portion
closest to the sensor.
Angle
The inclination of the object's surface facing the ultrasonic sensor affects the
reflectivity of the object. The portion perpendicular to the sensor returns the
echo. If the entire surface is at a great enough angle, the signal will be reflected
away from the sensor and no echo will be detected. Generally a target at an
angle greater than 5 degrees off perpendicular will not be detected.

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•Installation
Accurate readings require a clear sound path to the intended target. The path
should be free from obstructions and as open as possible. Follow the guidelines
mentioned in “Understanding Ultrasonics”.
The DCR-WEB should be installed using the 4 screws through 4 holes in the
bottom of the enclosure.
Inputs
•110 VAC Power
•4 button Key Pad
Mode Up, Mode Down, Number Up and Number Down Keys.
•0-10 V Invert
When a switch is closed across the INV-SW terminals, the port on the
processor is pulled low the distance programmed in the 0 V distance
becomes the 10 V distance and the distance programmed in the 10 V
distance becomes the 0 V distance.
•Alternate Program
When a switch is closed across the AP-SW terminals the DCR can be
programmed with a second setup that will be stored for that switch
position.
Outputs
•Isolated 0-10 V output
To connect to a variable speed drive for loop control.
•Two 5 ARelays
Fully programmable.
Can be jumpered Normally Open or Normally Closed
(Default = NO) *See drawing on next page
•Display
2 X 8 LCD alphanumeric display that displays the detected distance or the
mode value on the top and the parameter on the bottom.

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RELAY
RELAY
2-3 = NO
1-2 = NC
Relay Jumper Settings
Default = NO
1 3
3
21
2
•Wiring
Step 1: Mount sensor so that transducer has a clear path to the target.
Step 2: To obtain access to the terminal strip, remove the front cover by
turning out the 4 screws. This will expose the terminal strip and 2 X 8 character
display.
Step 3: Wires can be pulled into the DCR-WEB through the strain reliefs on
the enclosure.
The screw terminal can be wired using solid or stranded wire between 16 - 20
AWG. Wires should be stripped, leaving a 0.4 in. bare wire.
Follow the legend on the circuit board when wiring. The DCR-WEB should
never be used without the earth ground terminal being connected.
Step 4: Perform an internal check to ensure that all wires are properly
connected and secured.

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•Programming
The DCR-WEB has a two line by eight character alphanumeric display. Four
momentary push-buttons located under the cover, are used to program the
sensor. The cover prevents the buttons from being accidentally bumped.
The different modes can be easily accessed using the mode buttons,
M-UP and M-DN. They operate similar to a digital watch. To cycle forward
through the modes, hold down the M-UP key. To cycle backward through the
modes, hold down the M-DN key.
To select a mode, press the M-UP or M-DN key until the desired mode name
is displayed on the lower line of the display. The upper line will show the current
setting of that mode.
To change the selected mode setting , hold down the N-UP or N-DN key until
the desired setting is displayed. Enter the new value by pressing either of the
mode keys.
Program Switch
It is possible to save two separate setups in the sensor. The programmed
setups are selected using a program switch. The switch (supplied by the
customer) is wired to the terminal strip labeledAP-SW.
When programming the controller the values in the modes that are displayed
are those that are associated with the position of the application switch. To save
parameters in “Program 1” flip the switch to “Program 1” and make the
necessary changes. The changes will be saved in EEprom associated with
Program 1. To save a program in “Program 2” change the switch to the “Program
2” position and the changes will be saved in the EEprom associated with this
position.
Invert Switch
There are two terminals on the terminal strip, labeled inv-sw, if they are
connected to a SPST switch and the switch is closed the end points for the
analog slope will be reversed.

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•Programming Modes
For ease of programming, the DCR-WEB modes are grouped into phases of an
application setup. The phases are:
1) Operation
2) Filtering
3) Outputs
4) Calibration
5) Utilities
This order should be followed for setting up any application.
Operation
The operation modes are used to perform basic initialization of the DCR-WEB.
MODE DESCRIPTION PARAMETERS EXPLANATION
SENSITIV Sensitivity Units = %
Range = 0 - 100 %
Default = 50
BLANKING Blanking Units = Inches
Range = 6 - 99
Default= 6 in.
PULSES Pulses Range = 1-20
Default = 10
• Higher number of pulses allows the sensor to detect smaller objects better.
Adjust responsiveness to outside
stimuli, KEEPAS LOWAS
POSSIBLE,
Sets a dead zone in front of the
transducer where echoes are
ignored.
Sets the number of times the
transducer is pulsed for each
ultrasonic burst. Adjusts the
strength of the transmitting
signal.

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Filtering
The filtering modes are provided to change how fast the system will respond
to changes. The default settings should be appropriate for most level
applications, however, the delays and windows can be changed to increase or
decrease reaction time and filtering.
MODE DESCRIPTION PARAMETERS EXPLANATION
SAMP RATSample Rate Units = milliseconds
Range = 40 - 120
Default = 75
(Higher number = Slower Response Time)
AVERAGE Sample Units = Samples
Averaged Range = 1 - 20
Default = 5
(Higher number = Slower Response Time)
OOR SAMP Out-of-Range Units = samples
Range = 1 - 50
Default = 10
(Higher number = Slower Response Time)
OOR SPAN Filter Window Units = Inches
Range = 0 - 120
Default = 12 in.
TARGE Target Threshold Units = Targets
Range = 0 - 100
Default = 50
Set to 10 to 15% above view target reading
(Noise Level)
VIEW TAR View Number Units = Targets
of Targets
Sets the delay between
sensor samples.
Sets the number of samples to be
averaged in the buffer.
Sets the number of out-of range
samples in succession that will
be ignored before the new target
is accepted.
Sets the window of acceptance.
The window is + or - this
distance from the current
reading. If a sample distance is
outside of this window it will be
ignored the number of times set
in OUTRANGE SAMP.
Sets the maximum number of
targets that can be detected
before the sensor considers the
readings noise.
This mode is used only to view
the number of target detected by
the sensor.

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Example: Ignoring Intermittent Noise
The transceiver in the DCR-WEB is tuned to detect sound waves within a
range. There are certain external sources of noise in that range that can affect
the proper operation of the sensor, high pressure air escaping is the most
common source. In order to have the sensor ignore this noise a filter has been
installed. It allows the operator to set a threshold of the number of target that
can be received. If the number of targets exceed that threshold the sensor will
hold the last reading until the number of targets detected moves below it.
Filtering
MODE VALUE DESCRIPTION
VIEW TAR 20
TARGETS 26
Example: Rapid Level Changes
If the DCR-WEB’s filtering is too slow the distance being monitored is
changing rapidly, the display will seem to jump between readings instead of
scrolling smoothly as the level changes. To make the detected distance follow
the target better the amount of filtering will have to be reduced.
MODE VALUE DESCRIPTION
SAMPLE 50
RATE
AVERAGE 5
OUT-24
RANGE
SAMP
View the number of targets that are detected when the
material that is to be monitored is at the closest acceptable
point to the sensor. If the number of target is higher than
75 it may be advisable to reduce sensitivity.
Set the number of targets slightly higher than the reading
obtained above so that the sensor will not be affected by
external sources of 50khz noise.
Set the sampling interval to a shorter time requirement.
This will provide more reading in a given period of time
to the sensor.
The number of samples averaged can be reduced
providing less of a lag in updating the sensor.
Increasing the filter window for good readings. This will
increase the update time but decrease the filtering of
unwanted echoes.

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Outputs
The DCR-WEB contains 2 relays which are capable of handling a 5Aload.
These relays have programmable BEGIN and END points as well as TYPE of
operation. The relays can also be jumpered NO (default) or NC. *see drawing on
earlier page of this manual.
MODE DESCRIPTION PARAMETERS EXPLANATION
BEGRLY1 Begin Trip 1 Units = inches Sets the begin point
Default = 24 of Trip 1.
• Straight line from inlet of press to reel or straightener exit point.
• Distance from transducer to material that is taut or no loop - condition that could
cause damage.
ENDRLY1 End Trip 1 Units = inches Sets the endpoint
Default = 36 of Trip 1.
TYPE 1 Trip 1 Type Range = 0 - 7 Selects the type of
Default = 0 function Trip 1 will
See Trip Type Explanation for details. perform.
BEGRLY2 Begin Trip 2 Units = inches Sets the begin point
Default = 40 of Trip 2.
ENDRLY2 End Trip 2 Units = inches Sets the end point of
Default = 48 of Trip 2.
TYPE 2 Trip 2 Type Range = 0 - 7 Selects the type of function
Default = 0 Trip 2 will perform.
See Trip Type Explanation for details.

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Trip Type Explanation

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Example: Relay Settings For High and Low Level Indication
With the sensor mounted at 52.5 in. off of the floor looking down. An
indication is needed if the material being monitored is detected closer than 13 in.
or lower than 39 in. from the sensor. Relay number 1 will be used to activate an
alarm.
To program the DCR-WEB for this application, the following modes must be
set:
MODE VALUE
BEGRLY1 13.0
ENDRLY2 39.0
TYPE 1 1
If it is desired that the relays be wired in a fail-safe configuration so that the
relays are closed during normal operation and open if the material is detected
outside of the normal window of operation. This setup also provides for alarm
indication in the event of a loss of power to the sensor.
To program the DCR-WEB for this application the following modes must be
set:
MODE VALUE
BEGRLY1 13.0
ENDRLY2 39.0
TYPE 1 4

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Calibration
Analog
The DCR-WEB has an Isolated 0-10 Voutput. To set up this feature, enter the
two end points. If the level is beyond the bounds of the window created by the
two end points the voltage level will stay at the voltage level of the point it is
nearest to. Refer to the diagram below.
MODE DESCRIPTION PARAMETERS EXPLANATION
0V DIST 0 V Distance Units = inches
Default = 24.0
10V DIST 10 V Distance Units = inches
Default = 48.0
The sensor can be programmed to any maximum voltage desired from 1 to 10.45
VDC. The calibration numbers are used to set the maximum and minimum voltage levels
of the analog slope. In most cases the minimum voltage is desired to be 0 so the value
for 0 V CAL mode is set to 0. However, if it was desired to have the minimum voltage
be 1.0 volts the value of this mode would be set to 4095(1)/10.45=391. The same is true
for the maximum voltage levels. If the maximum voltage is to be 6 VDC then 4095(6.0)/
10.45=2351 would be entered into the 10 V CAL mode.
MODE DESCRIPTION PARAMETERS EXPLANATION
0V CAL 0 V Calibration Units = 0-4095
10V CAL 10 V Calibration Units = 0-4095
2351 = 6 VDC
3919 = 10 VDC
10 VDC
0 VDC 0 VDC
10 VDC
Distance
0 V
Distance
10 V
Distance
0 V Distance
10 V
Max. Distance
Zero Point
Max. Distance
Zero Point
Sets the distance where the 0 V
point of the analog slope will
begin.
Sets the distance for the
maximum voltage of the analog
output slope.
Distance from transducer to the
floor.
Adjusts the minimum voltage on
the analog output.
Adjusts the maximum voltage
on the analog output.

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Utilities
Temperature Compensation
As air temperature changes, so does the speed of sound. This change can
cause 0.18% drift in distance for every °C change. The TEMPCOMP Mode
allows compensation in the readings for this change. The DCR-WEB contains
an internal thermistor which measures temperature in °F. By turning temperature
compensation on, the effects of temperature changes will be reduced.
MODE DESCRIPTION PARAMETERS
TEMPCOMP TemperatureRange = ON-OFF
Compensation Default = OFF
VIEWTEMP Displays Detected Range = -20 to +140
Temperature
Reset
If the mode adjustments get scrambled or if the factory preset values are
wanted, Change this mode to 1 and press M-UP or M-DN and all of the
parameters will be “RESET” to their factory defaults.
MODE DESCRIPTION PARAMETERS EXPLANATION
RESET Reset Range = 0,1
Calibration
Entering a 1 will RESET the
Controller to Factory
Defaults.

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The Calibration parameter is used to adjust the unit for the change in speed of
sound due to environments other than air. For example, units operating in a
heavy fuel or gaseous environment may wish to calibrate the controller output
distance with a measured distance. For most applications, this parameter will
remain at 1.000.
MODE DESCRIPTION PARAMETERS EXPLANATION
Calib Calibration Range = 0.000 - 9.999
Default = 1.000
MaxGain
This parameter is used to limit the maximum amount of amplification available
to the micro-processor. This is factory preset at 7 and should not need
adjustment.
MODE DESCRIPTION PARAMETERS EXPLANATION
Max Gain Max Gain Range = 1 - 8
Default = 7 Used to limit the
maximum amount of gain
desired in an application.
This setting should be left
at 7.
Allows user to calibrate
controller output distance
with a measured distance.
Usually used for mediums
other than air.

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•Specifications
Operating Range.............. 6 in. to 120 in.
Sample Rate..................... 40 to 120 msec
Outputs ............................ Isolated 0 to 10 VDC
2 relays (5 A120 VAC)
Enclosure ......................... Poly-Carbonate
Transducer Type .............. Electrostatic/Ceramic
Ratings............................. NEMA 4
Operating Temperature.... -20 to 140°F
Internal Temperature
Compensation.................. yes
Accuracy.......................... ± 0.25% of range
Resolution........................ 0.1 in.
Beam Pattern ................... 8° Electrostatic / 9° Ceramic
Display............................. 2 line x 8 character alphanumeric LCD
Supply Voltage ................ 110 VAC or 220 VAC
•Dimensions
Controller
Ceramic Transducer
Electrostatic Transducer
7.000"
7.000"
3.50"
2.600"
2.600"
3.000"
3.000" 2"
2"1.5"

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•Maintenance
The DCR-WEB sensor does not require maintenance. However, a periodic
visual inspection of the system would be in order.
The transducer should be kept as clean as possible for optimum performance.
Dust buildup may be removed from the transducer with a cloth or by low
pressure air.