APM 3DLevelScanner Series User manual

M
3DLevelScanner
OPERATING
INSTRUCTIONS
Level / Volume
measurement in solid
applications with
mapping capabilities
Changing the market
from level to volume

Table of contents
1ABOUT THIS DOCUMENT ................................................................................................................. 4
1.1 SYMBOLISM USED............................................................................................................................. 4
1.2 FOR YOUR SAFETY ............................................................................................................................ 4
1.2.1 Authorized personnel .................................................................................................................. 4
1.2.2 Appropriate use .......................................................................................................................... 4
1.2.3 Warning about misuse ................................................................................................................ 4
1.2.4 General safety instructions ......................................................................................................... 4
1.2.5 CE conformity............................................................................................................................. 5
1.2.6 Safety information for Ex areas .................................................................................................. 5
1.2.7 Environmental instructions ......................................................................................................... 5
2PRODUCT DESCRIPTION .................................................................................................................. 6
2.1 DELIVERY CONTENTS ....................................................................................................................... 6
2.2 COMPONENTS ................................................................................................................................... 6
2.3 THEORY OF OPERATION.................................................................................................................... 6
2.4 WIDE APPLICATION RANGE.............................................................................................................. 6
2.5 ADVANTAGES................................................................................................................................... 7
2.6 STORAGE AND TRANSPORT ............................................................................................................... 7
2.6.1 Storage and transport temperature............................................................................................. 7
3MOUNTING ............................................................................................................................................ 8
3.1 INSTALLATION POSITION .................................................................................................................. 8
3.2 MOISTURE ........................................................................................................................................ 8
3.3 MEASURING RANGE ......................................................................................................................... 8
3.4 PRESSURE ......................................................................................................................................... 8
3.5 INSTALLATION LOCATION ................................................................................................................ 9
3.6 MOUNTING DIRECTION................................................................................................................... 10
3.7 SOCKET .......................................................................................................................................... 11
3.8 SENSOR ORIENTATION.................................................................................................................... 12
3.9 INFLOWING MATERIAL ................................................................................................................... 12
4CONNECTIONS ................................................................................................................................... 13
4.1 GENERAL REQUIREMENTS .............................................................................................................. 13
4.2 POWER SUPPLY .............................................................................................................................. 13
4.2.1 Connection Cable...................................................................................................................... 13
4.3 CONNECTION PROCEDURE .............................................................................................................. 13
4.4 WIRING PLANS ............................................................................................................................... 14
5ADJUSTMENT ..................................................................................................................................... 15
5.1 3DLEVELSCANNER M-LCD PANEL .............................................................................................. 15
5.2 ADJUSTING THE SCANNER USING THE SOFTWARE TOOL ................................................................ 17
6OPERATION......................................................................................................................................... 18
6.1 OPERATING MENU.......................................................................................................................... 18
6.2 FUNCTION INDICATION ................................................................................................................... 18
6.3 SWITCHING ON ............................................................................................................................... 19
6.4 BASIC/DEFAULT SCREEN................................................................................................................ 20
6.5 SETUP PROCEDURE ......................................................................................................................... 20
6.5.1 Address setting for several sensors on one input –RS485-Multidrop (Daisy Chain)............. 20
6.5.2 Parameter adjustment............................................................................................................... 20
6.5.3 Medium selection ...................................................................................................................... 21
6.5.4 Process Conditions ................................................................................................................... 21
6.5.5 Performing empty calibration adjustment ................................................................................ 21

About this document Symbolism used
3DLevelScanner Operating Instruction. © 2009 APM all rights reserved 2
6.5.6 Performing Full Calibration adjustment................................................................................... 23
7FALSE ECHO STORAGE................................................................................................................... 24
7.1 RANGE OF MAPPING FUNCTION (052) ............................................................................................. 24
8OPTIONAL SETTINGS....................................................................................................................... 24
8.1 BASIC/DEFAULT DISPLAYED SCREEN .............................................................................................. 25
8.2 LINEARIZATION SCREEN ................................................................................................................. 25
8.3 EXTENDED CALIBRATION SCREEN .................................................................................................. 26
8.4 OUTPUT SCREEN ............................................................................................................................. 26
8.5 DISPLAY SCREEN ............................................................................................................................ 27
8.6 MEASURED PARAMETERS............................................................................................................... 28
8.7 DEVICE INFO .................................................................................................................................. 29
8.8 DEVICE RESET................................................................................................................................ 29
9MAINTENANCE AND FAULT RECTIFICATION......................................................................... 30
9.1 MAINTENANCE ............................................................................................................................... 30
9.2 FAULT RECTIFICATION ................................................................................................................... 30
9.2.1 24 hours support ....................................................................................................................... 30
9.2.2 Checking the 4 …20 mA signal............................................................................................... 30
9.3 REPLACING THE ELECTRONICS ....................................................................................................... 31
9.4 DEVICE REPAIR............................................................................................................................... 31
10 DISMOUNTING............................................................................................................................... 32
10.1 DISMOUNTING PROCEDURE ............................................................................................................ 32
11 DIMENSIONS .................................................................................................................................. 33
12 APPENDIX ....................................................................................................................................... 35
12.1 TECHNICAL DATA ........................................................................................................................... 35
12.2 AMBIENT CONDITIONS .................................................................................................................... 36
12.3 PROCESS CONDITIONS..................................................................................................................... 36
12.4 PROCESS TEMPERATURE ................................................................................................................. 36
12.5 ELECTROMECHANICAL DATA.......................................................................................................... 36

About this document Symbolism used
3DLevelScanner Operating Instruction. © 2009 APM all rights reserved 3
Table of Figures
Figure 1: Measuring range................................................................................................................................. 8
Figure 2: Mounting on arched vessel tops.......................................................................................................... 9
Figure 3: Mounting Direction .......................................................................................................................... 10
Figure 4: Recommended socket mounting ........................................................................................................ 11
Figure 5: Inflowing material ............................................................................................................................ 12
Figure 6: Connection Scheme........................................................................................................................... 14
Figure 7: 3DLevelScanner M front panel LCD ................................................................................................ 15
Figure 8: Software Tool connection ................................................................................................................. 17
Figure 9: Empty and Full Calibration.............................................................................................................. 22
Figure 11: 3DLevelScanner M with horn antenna in threaded version ........................................................... 33
Figure 12: 3DLevelScanner M with horn antenna in flange version................................................................ 33
Figure 13: 3DLevelScanner M housing............................................................................................................ 34
Figure 14: Voltage diagram ............................................................................................................................. 35
Figure 15: Accuracy ......................................................................................................................................... 37

About this document Symbolism used
1About this document
This operation manual provides complete instructions for quick setup and safe
operation of the 3DLevelScanner M. This manual is designed for trained personnel.
Please read it carefully before you proceed.
1.1 Symbolism use
Information, tip, note
A itional information
ndication of helpful Additional information
Caution, warning, risk of anger
ndication of a potentially dangerous situation, which could result in serious
injury to persons and/or damage to the 3DLevelScanner.
Ex applications
ndication of special instructions for Ex applications.
Earth (groun ) terminal
ndication of functional earth to use for grounding the 3DLevelScanner M.
1.2 For your safety
1.2.1 Authorize personnel
All operations described in this manual must be carried out by authorized trained
personnel only. For safety and warranty reasons, any internal work on the devices
must be carried out by manufacturer-authorized personnel only.
1.2.2 Appropriate use
The 3DLevelScanner M is a sensor designed for continuous level / volume measurement.
1.2.3 Warning about misuse
Inappropriate or incorrect use of the device can give rise to application-specific hazards,
e.g., vessel overfill or damage to system components through incorrect mounting or
adjustment.
f the 3DLevelScanner is used in a manner not specified in this manual, the protection
provided by the 3DLevelScanner will be impaired.
1.2.4 General safety instructions
The 3DLevelScanner is a high-tech device requiring strict observance of standard
regulations and guidelines. The user must take note of the safety instructions in this
operating manual, as well as local and national electrical codes should be always

About this document For your safety
3DLevelScanner Operating Instruction. © 2009 APM all rights reserved 5
considered during installation and all common safety regulations and accident
prevention rules.
1.2.5 CE conformity
The 3DLevelScanner conforms to CE's EMC and NSR standards. CE conformity is as
follows:
EMC (2004/108/EC)
- Emission EN 61326: 1997 (class B)
- Susceptibility EC / EN 61326:1997 + A1: 1998 + A2:2001 + A3:2003
NSR (73/23/EWG) EN 61010-1: 2001
1.2.6 Safety information for Ex areas
Please note the Ex-specific safety information for installation and operation in Ex areas.
These safety instructions are part of the operating instructions manual that comes with
Ex-approved devices.
WARN NG – Substitution of components may impair ntrinsic Safety.
WARN NG – To prevent ignition of flammable or combustible atmospheres, read,
understand and adhere to the manufacturer’s live maintenance procedures.
1.2.7 Environmental instructions
Protection of the environment is one of our most important duties. Please help us fulfill
this obligation by observing the environmental instructions in the following chapters of
this manual:
Storage and transport, page 7.
Dismounting, page 32.

Product description Delivery contents
2Product description
2.1 Delivery contents
3DLevelScanner M sensor
Documentation
CD with the 3DLevel Manager software and marketing materials
Ex-specific safety instructions (with Ex versions)
Certificates if applicable
2.2 Components
Special horn antenna
Process fitting (depending on the flange or thread version)
Housing with electronics, optionally available with a plug connector and connection
cable
The components are available in different configurations.
2.3 Theory of Operation
The APM 3DLevelScanner™is the only device presently available that delivers accurate
measurement of bulk solids and powders – regardless of the type of material or
product characteristics, type and size of storage silo, bin or container, and harshness
of the storage environment. t incorporates APM's unique dust-penetrating technology
to achieve an unrivalled degree of process measurement and inventory control.
The 3DLevelScanner employs an array of three antennas to transmit low frequency
pulses and to receive echoes of the pulses from the contents of the silo, bin, or other
container. Using these antennas, the unit measures not only the time/distance of each
echo, but also its direction. The device's Digital Signal Processor samples and analyzes
the received signals to provide accurate measurements of the level, volume, and mass
of the stored contents and generates a 3D representation of the actual allocation of the
product within the container for display on remote computer screens. This unique
device measures practically any kind of material stored in a great variety of containers,
including silos, large open bins, bulk solid storage rooms, stockpiles, and warehouses.
t maps build-up loads and other irregularities that randomly form over time, offering
solutions for this and many other previously inaccessible challenging applications.
2.4 Wi e Application Range
The 3DLevelScanner M measures practically any kind of solid material, stored in
practically unlimited variety of containers, including large open bins, bulk solid storage
rooms and warehouses, mapping loads that randomly form over time inside silos, and
many other challenging applications that were not possible until now. The sensor can
measure ranges of up to 70 m (230 ft) and generate 3D maps of the surface.

Product description Advantages
3DLevelScanner Operating Instruction. © 2009 APM all rights reserved 7
2.5 A vantages
Practice-oriente evice versions - The 3DLevelScanner S is available with both
thread and flange fittings.
Service an maintenance-frien ly - Thanks to the non-contact measuring
principles, the 3DLevelScanner S is particularly easy to service and maintain.
The only volume measurement device for solid applications
Suitable for measuring all solid materials (including ones with low dielectric
constants)
Operates in dusty and moisture environment
Profiles and warns of adhesions of materials to the walls of vessels
The only device that measures volume as well as minimum level and maximum
level
Self cleaning antenna
3D mapping visualization tool to help decide where to fill from (in vessels with
multiple filling points
Most reliable sensor on the market (has 3 transmitters and 3 receivers)
2.6 Storage an transport
The device is protected by special packaging during transport, and is guaranteed to
handle normal loads during transport.
2.6.1 Storage an transport temperature
For storage and transport temperature please see Technical data, Ambient
conditions, page 36.

Mounting Installation position
3Mounting
3.1 Installation position
Install the 3DLevelScanner M where you can easily reach it for mounting and
connecting. You can install the housing in eight different positions. n each position,
the housing can be rotated 45°.
3.2 Moisture
Use the recommended cable (see Connections, page 13) and tighten the cable
connection.
For additional protection against moisture, lead the connection cable downward in front
of the cable entry. Rain and condensation water can thus drain off. This applies mainly
to mounting outdoors, in areas where moisture is expected (e.g., by cleaning processes),
or on cooled or heated vessels.
3.3 Measuring Range
The reference plane of the sensor measuring range is the seal surface of the thread or
the lower side of the flange. All information regarding the measuring range as well as
the internal signal processing relates to the reference plane.
NOTE:
f the container content reaches the antenna, buildup could form on it over time and
cause measurement errors.
Figure 1: Measuring range
3.4 Pressure
The process fitting must be sealed if there is low pressure in the vessel. Before use,
verify that the seal material is resistant to the medium. The maximum permissible
pressure is stated in Technical data, page 35, and on the type label of the sensor.

Mounting Installation Location
3DLevelScanner Operating Instruction. © 2009 APM all rights reserved 9
3.5 Installation Location
When mounting the 3DLevelScanner M, a distance of at least 400 mm from the vessel
wall (500mm from the center of the scanner to the vessel wall) should be maintained.
f the 3DLevelScanner M is installed in the center of the vessel, multiple echoes can
occur.
Note: t’s recommended not to install the 3DLevelScanner M in the center of the silo.
Figure 2: Mounting on arche vessel tops
1. Reference plane
2. Vessel center or symmetry axis
f this distance cannot be maintained, a false echo storage should be carried out. For
more information see False echo storage, page 24. This applies particularly if buildup
of residue on the vessel wall is expected.
Note: t is very important to use “range of mapping” right after installation, in order to
map all false echoes. The results are better when the silo is empty.

Mounting Mounting Direction
3DLevelScanner Operating Instruction. © 2009 APM all rights reserved 10
3.6 Mounting Direction
The 3DLevelScanner must be mounted in the right direction in order to scale and
adjust the position of the unit.
The mounting direction is indicated by a sticker labeled 00 on the instrument (see
image below). The 00 must point to the center of the vessel (including square vessels
and open bins).
Figure 3: Mounting Direction

Mounting Socket
3DLevelScanner Operating Instruction. © 2009 APM all rights reserved 11
3.7 Socket
Socket pieces should be positioned so that the antenna end protrudes at least 10 mm
(0.4 inch) out of the socket.
Important Note: Rails/frames should never interfere with the 700 beam angle
transmitted and received (see figures below).
Figure 4: Recommen e socket mounting

Mounting Sensor Orientation
3DLevelScanner Operating Instruction. © 2009 APM all rights reserved 12
3.8 Sensor Orientation
The sensor will generate optimal performance if it is located halfway between the wall
and the center of the silo.
3.9 Inflowing Material
Do not mount the devices in or above the filling stream. The optimal position is as far
away from the inflowing material.
Figure 5: Inflowing material

Connections General Requirements
4Connections
Note on safety
Always observe the following safety instructions:
Connect only in the complete absence of line voltage
f overvoltages are expected, overvoltage arresters should be installed.
A safety certified power supply which provides double insulation between the
primary and output must be used for powering the unit. The power supply must be
limited power source with output rating 20-32VDC, 1A.
n hazardous areas you should take note of the appropriate regulations,
conformity and type of approval certificates of the sensors and power supply
units.
4.1 General Requirements
The power supply range can differ depending on the device version. See the Technical
data, page 35, for full details.
4.2 Power Supply
A safety certified power supply which provides double insulation between the primary
and output must be used for powering the unit. The power supply must be limited
power source with maximum output current 1A. The power supply voltage range
should be 20 V DC minimum and 32 V DC maximum
4…20 mA/HART 4-wire
Power supply and signal current are carried on two separate connection pairs of
wires.
4.2.1 Connection Cable
•Use a 8…12 mm diameter cable to ensure the seal effect of the cable entry
•Conductor size of minimum 22AWG, shielded twisted pairs
•Suitable for application (indoor or outdoor) and safety certified according to
national rules.
4.3 Connection proce ure
1. Unscrew the back cover
2. Loosen the compression nut of the cable entry.
3. Remove approx. 10 cm (4 inch) of the cable mantle, strip approx. 1 cm (0.4 inch)
insulation from the ends of the individual wires.
4. Insert the cable into the sensor through the cable entry.
5. Push the terminals top with a screwdriver (see following illustration).
6. Insert the wire ends into the open terminals according to the wiring plan.
7. Let go of the terminal top.
8. Check the hold of the wires in the terminals by lightly pulling on them.

Connections Wiring Plans
3DLevelScanner Operating Instruction. © 2009 APM all rights reserved 14
9. Use a 16AWG cable for the ground cable to connect the screen to the internal
ground terminal and the external ground terminal to potential equalization.
10. Tighten the compression nut of the cable entry. The seal ring must completely
encircle the cable.
11. Screw the back cover back on.
4.4 Wiring Plans
Figure 6: Connection Scheme
Left Connector Right (“Display”) Connector
Ports Description Ports Description
PS N
+ -
Feed N power supply
20…32 VDC
PS OUT
+ -
Feed OUT power supply
20…32 VDC
4..20mA
- +
4..20 / HART
communication
connections
RS485
+ -
RS485 / Modbus RTU
communication connections
For more information about the connections, refer to “Different wa s of connecting to
3DLevelScanner” document for additional help in connecting to the 3DLevelScnner
using various interfaces (HART / RS485 / GSM / GPRS / Ethernet / Modbus).

Adjustment 3DlevelScanner M - LCD Panel
5Adjustment
The 3DLevelScanner M can be set up and operated using one of the following:
An adjustment software tool (3DLevel Manager)
GSM / GPRS communication using 3DLink Pro
5.1 3DlevelScanner M - LCD Panel
Figure 7: 3DLevelScanner M front panel LCD
Note: The 3DLevelScanner M can be adjusted but not configured with the LCD panel

Adjustment
3DLevelScanner Operating Instruction. © 2009 APM all rights reserved 16
A justment keys:
-
Navigates downwards in the selection list
Shifts to the right within a function
+
Navigates upwards in the selection list
Edit numeric values within a function
Esc Navigates to the Left within a function group; Press Esc for 3
sec to go back to the default screen
E Navigates to the right within a function group;
Confirmation
+ + E
Simultaneously
ncreases the contrast of the LCD
- + E
Simultaneously
Decreases the contrast of the LCD
+ + -
+ E
Simultaneously
Har ware lock/unlock
After a hardware lock, operation of the device via display or
remote communication is not possible.
The hardware can only be unlocked via the display, and an
unlock parameter must be entered to do so.
The display continues – uninterrupted.
When all three buttons are pressed the message “Hardware
locked” is displayed.
When all three buttons are pressed again, the message
“unlock parameter.” Appears. Enter the unlock parameter
(100) and confirm by pressing E.

Adjusting the Scanner Using the Software Tool
3DLevelScanner Operating Instruction. © 2009 APM all rights reserved 17
5.2 A justing the Scanner Using the Software Tool
The 3DLevelScanner M can be configured and operated via APM’s Software Tool.
Connect the 3DLevelScanner M according to the following diagram:
RS485
RS232 / USB
Figure 8: Software Tool connection
1. For specific instructions on adjusting parameters with APM's software tool,
please see the "APM 3DLevel Manager Software Operating Instructions" manual.
2. The example above is an RS485 connection. There are more possibilities to
connect to the 3DLevelScanner M using a different interface or protocol – for
more help refer to "Different wa s of connecting to 3DLevelScanner" manual.

Operation Operating Menu
3DLevelScanner Operating Instruction. © 2009 APM all rights reserved 18
6Operation
6.1 Operating Menu
The operating menu consists of two levels:
1. Function groups (00, 01, 03, …, 0C, 0D)
The devices functions are organized in function groups. The available function
groups are: basic setup, safet settings, output, displa , s stem parameters,
diagnostics, extended calibration, linearization, temperature.
2. Functions (001, 002, 003, …, 0D8, 0D9)
Each function group consists of one or more functions. The functions perform
actions or set up the device's parameters. Numerical values can be entered and
parameters can be selected and saved. The available functions of the basic
setup function group (00) include: media t pe (002), process cond. (004),
empt calibr. (005), etc.
For example, if you wish to change the media type, do the following:
Select the basic setup (00) function group.
Select the media type (002) function (where the existing media type is
selected).
6.2 Function in ication
A three digit identifier is displayed on the right-hand side of the function on the
display. The first two digits identify the function group. The third digit indicates the
individual function within the function group.

Operation Switching on
3DLevelScanner Operating Instruction. © 2009 APM all rights reserved 19
6.3 Switching on
After 3DLevelScanner M is connected to the power supply, it carries out a self-test for
approx. 30 seconds. After the initialization is complete, the following is displayed,
allowing you to select a language and distance units.
After 30 seconds, the following message
appears:
Vxx.yy.zz Prot.
xx – hw version
yy – sw version
zz – sw version
prot – HART (Protocol name)
After five seconds or after pressing E,
you will be presented with language
selection: (appears on the first time the
device is switched on): Use the +/- to
select the desired language and press
E.
Select the distance units
(this selection appears on the first time
the device is switched on)
Press E to reach the group selection.
This selection enables you to perform
the basic setup.