Aq elteknik D72 User manual

Ultrasound Controller

D72 DP72 D128 G72

Manual

AQ Elteknik AB

2 Ultrasound Controller Manual

AQ Elteknik AB Ultrasound Controller Manual 3

Ultrasound Controller

D72 DP72 D128 G72

AQ Elteknik AB

Manual version 4.70

Software version 4.7x

D72 hardware version RevE

DP72 hardware version RevE

D128 hardware version RevA

G72 hardware version RevA

GSD file version 3.2

The manual version should agree with the software and

hardware version of the Ultrasound Controller.

The version of the Ultrasound Controller is shown briefly

on the display when power is switched on. This manual

is available at www.aqelteknik.com

September 2014

4 Ultrasound Controller Manual

Table of contents

1. Manufacturer information......................................................................................................................................................................................................5

Manufacturer Declaration of Conformity............................................................................................................................................................................5

Limited Warranty ...............................................................................................................................................................................................................5

Warning.............................................................................................................................................................................................................................5

Certificate of Quality and Function....................................................................................................................................................................................5

Manufacturer .....................................................................................................................................................................................................................5

2. Introduction.............................................................................................................................................................................................................................6

Ultrasound Controller ........................................................................................................................................................................................................6

Installing the Ultrasound Controller D72 and G72.............................................................................................................................................................6

Installing the Ultrasound Controller DP72.........................................................................................................................................................................7

Installing the Ultrasound Controller D128..........................................................................................................................................................................7

3. Navigating the menu system.................................................................................................................................................................................................8

Sensor MODE and the start-screen..................................................................................................................................................................................8

4. Air Sensor Mode.....................................................................................................................................................................................................................9

Quick start guide................................................................................................................................................................................................................9

Functional Description.......................................................................................................................................................................................................9

Orientation of the Air Sensor.............................................................................................................................................................................................9

Setting lowest possible sensitivity for bubbles ................................................................................................................................................................10

Connecting the Air Sensor ..............................................................................................................................................................................................11

SETTINGS.......................................................................................................................................................................................................................11

Air Sensor start-screen....................................................................................................................................................................................................12

ADVANCED SETTINGS .................................................................................................................................................................................................13

CALIBRATION.................................................................................................................................................................................................................13

SHOW DATA...................................................................................................................................................................................................................13

Calibration Data...............................................................................................................................................................................................................13

Normal Measurement Data .............................................................................................................................................................................................13

Very Low Sensitivity Data................................................................................................................................................................................................14

AUXILIARY DATA...........................................................................................................................................................................................................14

HELP...............................................................................................................................................................................................................................14

Sound velocity in the Air Sensor .....................................................................................................................................................................................14

Air Sensor TROUBLESHOOTING ..................................................................................................................................................................................14

5. Level Switch Mode ...............................................................................................................................................................................................................16

Connecting the Level Switch...........................................................................................................................................................................................16

Level Switch Type and Technique ..................................................................................................................................................................................16

Echo Technique...............................................................................................................................................................................................................17

WR Technique.................................................................................................................................................................................................................17

Mounting the Level Switch ..............................................................................................................................................................................................18

Level Switch start-screen ................................................................................................................................................................................................18

Container with jacket.......................................................................................................................................................................................................19

Sound velocity and the Level Switch...............................................................................................................................................................................20

Measurement Reliability..................................................................................................................................................................................................20

Level Switch TROUBLESHOOTING...............................................................................................................................................................................20

6. Level Sensor Mode...............................................................................................................................................................................................................22

Connecting the level sensor............................................................................................................................................................................................22

Mounting the Level Sensor..............................................................................................................................................................................................23

Installing the level sensor on a non-horizontal bottom....................................................................................................................................................23

Mounting the velocity sensor...........................................................................................................................................................................................24

Container top...................................................................................................................................................................................................................24

Level Sensor start-screen ...............................................................................................................................................................................................24

Level Sensor TROUBLESHOOTING ..............................................................................................................................................................................26

7. Gel Sensor Mode ..................................................................................................................................................................................................................28

Connecting the Gel Sensor .............................................................................................................................................................................................28

Measuring Gel.................................................................................................................................................................................................................29

Measurement technique..................................................................................................................................................................................................29

Gel Sensor start-screen ..................................................................................................................................................................................................30

Gel Sensor TROUBLESHOOTING .................................................................................................................................................................................32

8. Profibus DP...........................................................................................................................................................................................................................34

Connecting Profibus........................................................................................................................................................................................................34

PROFIBUS Parameters ..................................................................................................................................................................................................34

Profibus Status-symbol ...................................................................................................................................................................................................34

Request Data...................................................................................................................................................................................................................34

Response Data................................................................................................................................................................................................................35

Request Data table..........................................................................................................................................................................................................35

TROUBLESHOOTING ....................................................................................................................................................................................................35

9. Technical specifications Ultrasound Controller................................................................................................................................................................37

10. Parameter settings ...............................................................................................................................................................................................................38

AQ Elteknik AB Ultrasound Controller Manual 5

1. Manufacturer information

AQ Elteknik AB operates a policy of on-going development and reserves the right to make

changes and improvements to any of the products described in this manual without prior notice.

Under no circumstances shall AQ Elteknik be held responsible for any loss or indirect damage

howsoever caused. The content of this document is provided as it is. AQ Elteknik AB reserves the

right to revise this document or withdraw it at any time without prior notice.

Manufacturer Declaration of Conformity

Manufacturer AQ Elteknik AB, Sweden declares, that the product: Ultrasound Controller marked

with CE-label conforms with the following standards: EN 61000-6-2, EN 61000-6-4, EN55011

(Group 1, Class B).

Ultrasound Controller marked with conforms to WEEE directive 2002/96/EC. The Ultrasound

Controller also conforms to RoHS directive 2002/95/EC. When the Ultrasound Controller is to be

discarded, send it back to AQ Elteknik AB for safe disposal.

Limited Warranty

AQ Elteknik AB warrants to the original end user that the Ultrasound Controller is free from any

defects in materials or workmanship for a period of one year from the date of purchase. During the

warranty period, should the Ultrasound Controller have indications of failure due to faulty

workmanship or materials, AQ Elteknik AB will replace it with no charge. This warranty shall not

apply if the Ultrasound Controller is modified, misused or subjected to abnormal working

conditions. Replacement as provided under this warranty is the only remedy of the purchaser. The

purchaser pays freight to AQ Elteknik AB. AQ Elteknik AB shall in no event be held liable for

indirect or consequential damages of any kind or character to the purchaser.

Warning

The Ultrasound Controller is intended to be used with the Air Sensor or the Level Switch, all of

them manufactured by AQ Elteknik AB. AQ Elteknik AB takes no responsibility for any possible

damage that could happen if any other sensor not manufactured by AQ Elteknik AB is connected

to the Ultrasound Controller.

Certificate of Quality and Function

AQ Elteknik AB guaranties that the Ultrasound Controller has passed function and quality tests.

Manufacturer:

AQ Elteknik AB

Alsikegatan 4 Phone: +46 18183430

SE-753 23 Uppsala Fax: +46 18105004

Sweden www.aqelteknik.com [email protected]

6 Ultrasound Controller Manual

1 Terminal

2 Terminal (for Sensors)

3 D-sub

2. Introduction

Ultrasound Controller

Ultrasound Controller uses ultrasound to make measurements. It can detect bubbles in flowing

liquid or it can detect presence of liquid behind a container wall or it can measure continuous

liquid level. The Ultrasound Controller has four different modes of operation:

Air Sensor mode: The Air Sensor monitors the presence of gas or particles in flowing liquid. The

Air Sensor is very reliable and easy to use. Two Air Sensors can be connected to one

Ultrasound Controller.

Level Switch mode: The Level Switch is a small sensor which attached to the outside of the

container can sense the presence of liquid inside the container without making hole in the

container. Four Level Switches can be connected to one Ultrasound Controller.

Level Sensor mode: Continuous liquid level is measured with a Level Switch attached under the

container bottom (no hole in the container). High accuracy is achieved with a second Level

Switch measuring liquid sound velocity. Two levels can be measured with one Ultrasound

Controller.

Gel Sensor mode: The Level Switch attached to the outside of the container can sense the

presence of gel inside the container without making hole in the container. Four single gel-

levels can be measured with one Ultrasound Controller.

Installing the Ultrasound Controller D72 and G72

The Ultrasound Controller D72 should be protected from

dust and water. It is made to be attached to a DIN-rail, to

which it snaps easily and can be removed by pushing up

and bending the top out. Usually it is installed in a cabinet.

The green connector terminals can be removed by pulling

the connector out.

The Ultrasound Controller should be installed in accordance

with national regulations. A person with the required

knowledge should perform the installation.

D72, G72

Terminal

Description

+ supply PLUS 24V

–supply MINUS

Relay common

Relay 1

Relay 2

Relay 3

Relay 4

D-sub 1

Cable screen

D-sub 2

D-sub 3

Reserved

D-sub 4

+ 4-20mA output B

D-sub 5

mA output MINUS

D-sub 6

D-sub 7

D-sub 8

Reserved

D-sub 9

+ 4-20mA output A

AQ Elteknik AB Ultrasound Controller Manual 7

1 Enclosure

2 Gasket

3 Bottom plate

4 Screws

5 Terminals

6 Dummy coverings

7,8 Cable glands (small and big)

9 Pressure compensation element

1 Terminal

2 Terminal (for Sensors)

3 D-sub

Installing the Ultrasound Controller DP72

The Ultrasound Controller DP72 should be protected from dust

and water. It is made to be attached to a DIN-rail, to which it

snaps easily and can be removed by pushing up and bending

the top out. Usually it is installed in a cabinet. The green

connector terminals can be removed by pulling the connector

out.

The Ultrasound Controller should be installed in accordance

with national regulations. A person with the required knowledge

should perform the installation.

Installing the Ultrasound Controller D128

The Ultrasound Controller D128 is protected according to IP65

and can be installed outside a protecting cabinet. The bottom

plate must be removed in order to access the terminals to

connect the cables (8 screws). Remove dummy coverings and

insert cable glands as many as needed. There are 3 small and 4

big cable glands, see page 37. There should be only one cable

in each cable gland to achieve IP65 protection. The pressure

compensation element can be moved but must not be removed.

Make sure the gasket is in place when screwing the bottom

plate.

The Ultrasound Controller should be installed in accordance with

national regulations. A person with the required knowledge

should perform the installation.

DP72

terminal

Description

+ supply PLUS

24V

–supply MINUS

Relay common

Relay 1

Relay 2

Relay 3

Relay 4

D-sub 1

Cable screen

D-sub 2

D-sub 3

Profibus B+

D-sub 4

+ 4-20mA output B

D-sub 5

mA output MINUS

D-sub 6

+5V output

D-sub 7

D-sub 8

Profibus A-

D-sub 9

+ 4-20mA output A

D128

terminal

Description

+ supply PLUS

24V

–supply MINUS

Relay common

Relay 1

Relay 2

Relay 3

Relay 4

mA output MINUS

+ 4-20mA output A

+ 4-20mA output B

8 Ultrasound Controller Manual

3. Navigating the menu system

Switches

Keep MENU button pressed to scroll continuously. Press BACK button while pressing MENU

button to scroll backwards. Menu-text, parameter-names and parameter-values as seen on the

display is in the manual written in blue italic.

Sensor MODE and the start-screen

When power is applied to the Ultrasound Controller it displays the software version on the LCD-

display, followed by the start-screen. Depending on which mode is set; the corresponding start-

screen will be shown. The Ultrasound Controller can be set to either Air Sensor mode, Level

Switch mode, Level Sensor mode or Gel Sensor mode. When the Ultrasound Controller is

powered on for the first time Set sensor MODE is displayed. Then press MENU button to scroll to the

desired mode and press SELECT button. How to change sensor mode once it has been set is

described in ADVANCED SETTINGS.

Air Sensor mode Level Switch mode Level Sensor mode Gel Sensor mode

CALIBRATION CALIBRATION CALIBRATION CALIBRATION

Calibrate LIQUID AS 1 CALIBRATE with AIR (empty) CALIBRATE with AIR (low) 1-4 together

Calibrate AIR AS 1 Level Switch 1 Level Sensor 1 GelSensor 1

Calibrate LIQUID AS 2 Level Switch 2 Level Sensor 2 GelSensor 2

Calibrate AIR AS 2 Level Switch 3 CALIBRATE with LIQUID (high) GelSensor 3

Level Switch 4 Level Sensor 1 GelSensor 4

SHOW DATA LS1-LS4 together Level Sensor 2

Air Sensor 1 CALIBRATE with LIQUID (full) SHOW DATA

Calibration Data same as above SHOW DATA Gel Sensor Measured data

Normal Measurement Data Level Sensor 1 Gelconcentration %

Very Low Sensitivity Data SHOW DATA Level Relativ Signal %

Air Sensor 2 LevelSwitch 1 Sound Velocity Relativ Attenuation dB/m

same as above Echo DATA Calibration Data Signal dB

AUXILIARY DATA WR DATA Level Sensor 2 Liq WR sensor

Auxiliary data same as above Gel Sensor Cal Data

SETTINGS LevelSwitch 2 same as above Cal Liquid dB

SET Air Sensor 1 parameters LevelSwitch 3 same as above SETTINGS Freq

SET TYPE LevelSwitch 4 same as above SET parameters Level Sensor 1 Test Sensor dB

SET DIAMETER Test LevelSwitch SET 100% Level

SET SENSITIVITY SET 0% Level SETTINGS

SET FILTER SETTINGS SET Liquid Sound VELOCITY SET parameters Sensor 1

SET Air Sensor 2 parameters SET parameters LevelSwitch 1 SET Velocity Sensor EchoDISTANCE SET TYPE

same as above SET Type AND Technique SET Velocity Sensor HEIGHT SET ECHO DISTANCE

SET RELAY 1 SET FILTER SET Velocity Sensor Control SET GEL-TYPE

SET RELAY 2 SET ECHO-DISTANCE SET Container Bottom-Thickness SET GEL-THRESHOLD

SET RELAY 3 SET Jacket SET Container Wall-Thickness SET FREQUENCY

SET RELAY 4 SET FREQUENCY SET Container Wall-Thickness SET WR THRESHOLD

SET mA output A SET parameters LevelSwitch 2 SET parameters Level Sensor 2 SET RELAY1,2

SET mA output B SET parameters LevelSwitch 3 same as above SET RELAY3,4

SET parameters LevelSwitch 4 SET mA output A SET mA output A

HELP same as above SET mA output B SET mA output B

CONNECTOR Terminals 1-7 SET RELAY 1 SET RELAY 1

CONNECTOR Terminals 8-17 SET RELAY 2 SET RELAY 2 HELP

Information SET RELAY 3 SET RELAY 3 CONNECTOR Terminals 1-7

Software version SET RELAY 4 SET RELAY 4 CONNECTOR Terminals 8-17

Information

ADVANCED SETTINGS HELP HELP Software version

set sensor MODE CONNECTOR terminals 1-7 CONNECTOR Terminals 1-7

SIMULATE CONNECTOR terminals 8-17 CONNECTOR Terminals 8-17 ADVANCED SETTINGS

RESTORE settings and calibrations Information Information set sensor MODE

PROFIBUS SETTING Software version Software version RESTORE settings and calibrations

BITRATE PROFIBUS SETTING

ADDRESS ADVANCED SETTINGS ADVANCED SETTINGS BITRATE

PARAMETER ACCESS Set sensor MODE set sensor MODE ADDRESS

CONTROL SIMULATE SIMULATE PARAMETER ACCESS

RESTORE settings and calibrations RESTORE settings and calibrations CONTROL

PROFIBUS SETTING PROFIBUS SETTING

BITRATE BITRATE

ADDRESS ADDRESS

PARAMETER ACCESS PARAMETER ACCESS

CONTROL CONTROL

Toggle between

standby and

power-on.

(D128 only)

Go back to previous

menu-level

Cancel a

Selected

operation

Scroll through menu-

text, parameter-names

or parameter-

values

Select a menu

Confirm the

selection of a

parameter-value

AQ Elteknik AB Ultrasound Controller Manual 9

4. Air Sensor Mode

In Air Sensor mode the Air Sensor is used to measure the presence of bubbles in flowing liquid.

One or two Air Sensors model SAC, PAC, FCS or FCP can be connected to one Ultrasound

Controller.

Quick start guide

Install Air Sensors according to instructions in the Air Sensor Manual.

Connect cables, see page 6 or 7 and 10.

Switch on external power supply.

Read about navigating the menu system, page 8.

Display show: SET sensor MODE. Press MENU button to scroll to Press SELECT for Air Sensor

mode. Confirm by pressing SELECT button.

Go to SETTINGS to set parameters, page 11.

Fill Air Sensor 1 (AS1) with liquid. Select Calibrate LIQUID AS1 and Press SELECT button one

second.

Empty Air Sensor 1 (AS1) of liquid. Select Calibrate AIR AS1 and press SELECT button one

second.

Do the calibration in the same way for Air sensor 2 (AS2). The calibration order can be

mixed for sensor and liquid/air.

Do a simple validation: AIR should be indicated when the Air Sensor is empty and LIQUID

when it is filled with liquid.

Go to SHOW DATA for a more thorough validation of the calibrated values, page 13.

Ready.

Functional Description

Bubbles in the liquid flowing through the Air Sensor are monitored by the use of ultrasound. Inside

the Air Sensor two low intensity beams of ultrasound are transmitted across the liquid-path in

directions perpendicular to the liquid flow.

If a bubble moves into one of the ultrasound-beams the ultrasound will be partially deflected and

the intensity of the ultrasound decreases. The controller constantly measures the intensity of the

ultrasound and if the intensity becomes lower than the threshold it detects a bubble. Dense

particles in the liquid can also deflect the ultrasound in a similar way and can therefore be

detected.

The measurements of very low sensitivity and very very low sensitivity uses a different

measurement technique. It measures how ultrasound vibrations in the Air Sensor walls are

dampened by the presence of liquid inside.

The measurement accuracy depend on how well the Air Sensor is calibrated, the flow-rate, the

type of liquid, how the Air Sensor is mounted and weather there is a single bubble or many

bubbles and the Air Sensor size.

Orientation of the Air Sensor

If the Air Sensor is mounted horizontally orientation is important. Liquid flowing through the Air

Sensor tends to pull bubbles towards the center of the tube but when flow rate decrease bubbles

rises to the top. The Air Sensor is more sensitive to bubbles at the top if it is rotated so that the

cable connector (and label) is facing up. If instead low bubble sensitivity is desirable rotate the Air

10 Ultrasound Controller Manual

Sensor so that the cable connector (and label) is facing down. This makes the Air Sensor less

sensitive for bubbles at the top of the tube.

Setting lowest possible sensitivity for bubbles

If mounted horizontally rotate the Air Sensor so that the cable connector is facing down.

The FILTER setting determines the delay (response time) for detecting air. Consider what can be

the longest acceptable delay for detecting air and set FILTER accordingly: delay 0,3s or longer (do

not set it to integrate). Bubbles that quickly come and go will then pass undetected.

Set the SENSITIVITY to low. SENSITIVITY can also be set to very low or very very low, but these

settings uses a different measurement technique where the presence of liquid is detected

regardless of bubbles. This technique is less reliable and is sensitive to temperature changes and

works only on diameters > 16mm. Don’t use it if there is more than +- 5°C temperature variation

during measurement and calibration. Try first set SENSITIVITY to low and FILTER to delay 0,3s or

longer. If there is still unwanted detections of bubbles, then change the setting of SENSITIVITY to

very low or very very low.

Terminal number

SAC,

SAC Ex

PAC

FCP

FCS

FCS Ex

D72 /

DP72

D128

cable color

Air Sensor 1

Brown

White

White &

JumperA

Screen of

Brown cable

& Screen of

Green cable

Screen of

Brown cable

& Screen of

Green cable

Screen of White

cable & Screen

of Yellow cable

Green

Yellow

Yellow &

Screen

Screen &

JumperA

Screen of

White cable

Screen of

White cable

& Screen of

Yellow cable

Screen of

Brown cable &

Screen of

Green cable

Yellow

White

White &

Yellow

Brown & Green

Air Sensor 2

Brown

White

White &

JumperB

Screen of

Brown cable

& Screen of

Green cable

Screen of

Brown cable

& Screen of

Green cable

Screen of White

cable & Screen

of Yellow cable

Green

Yellow

Yellow &

Screen

Screen &

JumperB

Screen of

White cable

Screen of

White cable

& Screen of

Yellow cable

Screen of

Brown cable &

Screen of

Green cable

Yellow

White

White &

Yellow

Brown & Green

AQ Elteknik AB Ultrasound Controller Manual 11

Connecting the Air Sensor

The cable from the Air Sensor should connect directly to the Ultrasound Controller. Maximum

cable length depends on the Air Sensor, see Air Sensor manual. The cable screen must always

be connected (screened cable must always be used). Any unscreened part of the cable should be

no longer than 30mm. (The outer screen which exists only on FCS and FCP should not connect to

the Ultrasound Controller but may be connected to ground via screened cable glands). PAC also

needs a 50mm jumper cable to connect two terminals. To minimize the risk of electric interference

it is important that sources of interference like frequency inverters should use screened cables

between inverter and motor.

In an ex-installation, shielding aluminum plates must be

placed outside each group of zener barriers belonging to

each Ultrasound Controller, order number: Ex-

barriershield, see Air Sensor Ex manual.

SETTINGS

Through the SETTINGS-menu the parameters of the Air Sensor can be set.

Select SET TYPE to set the type of Air Sensor connected. This tells the Ultrasound Controller to

make the correct adjustments for this Air Sensor type.

Select SET DIAMETER to set it to the diameter of the connected Air Sensor or as close as

possible. This tells the Ultrasound Controller to make the correct adjustments for this Air Sensor

diameter.

Select SET SENSITIVITY to set the sensitivity. This determines how sensitive the Air Sensor is for

bubbles.

SENSITIVITY can be set to high, medium, low, very low and very very low.

At high sensitivity, a single bubble of approximately 2mm diameter can be detected.

At medium sensitivity, a single bubble of 3mm diameter can be detected.

At low sensitivity, a single bubble of approximately 10mm diameter can be detected. Low

sensitivity is achieved by requiring both detectors inside the Air Sensor to detect bubbles at the

same time. Many small bubbles together will be detected as if they were a single big bubble. Even

tiny (microscopic almost invisible) bubbles can be detected if there are many of them.

High, medium and low sensitivity are the normal measurements.

At very low and very very low sensitivity a different measuring technique is used. This technique

measures the presence of liquid or no liquid, making the Air Sensor very insensitive for bubbles.

Very low sensitivity does not work well for Air Sensors with diameter < 22mm. Very low sensitivity

measurements have temperature dependence and should not be used if there are temperature

variations of more than ±5ºC.

Select SET FILTER to set the filter-time. It determines how the measurement-data is filtered.

FILTER can be set to either integrate 1ms -3s or delay 300ms -10s.

Integrate means integrating (adding) the duration of each bubble. When the sum becomes higher

than the integrate time, air will be indicated. When liquid is next time indicated, the integration-

process starts over.

Delay means that air will be indicated when air has been continuously detected for a time longer

than the delay time.

Long FILTER delay and low SENSITIVITY is useful if some quantities of bubbles should be

undetected.

12 Ultrasound Controller Manual

1 AIR AirSens

2 --- 1234

Short FILTER integrate and high SENSITIVITY is useful when almost every bubble should be

detected.

Select SET RELAY to set how the relays should act. There are four relays each with one normally

open contact (at power off and when sensor is not connected the relay is open). Each relay can

be set independently. Choose between Closed with air or closed with liquid and choose between

Air Sensor 1 and Air Sensor 2. The duration of air being indicated is minimum 0,5 second even if

the bubble is detected much shorter time (to make sure the indication of air is registered).

Select SET mA output to set the assignment of the mA-outputs. There are two outputs: A and B.

They can be assigned to Air Sensor 1 or Air Sensor 2 and Normal Measurement Data or All Sensitivities

Normal Measurement Data Assigns a combination of the analog Ndata during the time liquid is

indicated and 6mA when air is indicated:

8mA –20mA = Ndata = 0% –150% during the time Liquid is indicated

6mA = when Air is indicated

4mA = error

All Sensitivities Assigns bubble sizes to mA.

16mA = Liquid (no bubble) 14mA = small bubble

12mA = medium bubble 10mA = big bubble

8mA = very big bubble 6mA = very very big bubble

4mA = error.

The bubble indication time is always minimum 0,5 second.

Air Sensor start-screen

When power is applied, the Air Sensor start-screen is

displayed showing something like this:

On the first line to the right is written AirSens meaning this is Air Sensor-mode. The first digit

to the left indicates Air Sensor 1 and Air Sensor 2. Following the digit is diagnostic information

about each Air Sensor:

--- No Air Sensor is connected and Air Sensor TYPE or DIAMETER is set to no Air Sensor

set Settings are missing

cal Waiting for calibration to be done

CalAir Waiting for calibration of Air to be done

CalLiq Waiting for calibration of Liquid to be done

err 1 Error, no Air Sensor is detected

err 2 Error, NAir too high, see troubleshooting

err 3 Error, VLthld too low, see troubleshooting

err 4 Error, NLiq too low, see troubleshooting

AIR Air or bubble is detected

LIQUID Liquid without bubble is detected.

(LIQUID is blinking if measurement data is higher than 200% suggesting a new calibration may be

advisable)

On the second line to the right is written 1234which shows the state of each of the four relays. A

light digit on dark signifies a closed relay.

AQ Elteknik AB Ultrasound Controller Manual 13

ADVANCED SETTINGS

Select Set sensor MODE to set either Air Sensor mode, Level Switch mode, Level Sensor mode or Gel

Sensor mode mode. It determines which sensor can be connected.

Select SIMULATE to simulate detection of air or liquid. Press SELECT button to toggle between

simulation of AIR and LIQ. Press MENU button to change between Air Sensor 1 and 2.

Select RESTORE settings and calibrations to restore all settings and calibrations to factory-settings.

CALIBRATION

Calibration must be done both with air (with empty Air Sensor) and liquid (with full Air Sensor) and

it can be done in any order. To calibrate liquid, make sure there is liquid inside the Air Sensor and

select calibrate LIQUID (and press SELECT button one second). To calibrate air make sure the Air

Sensor is empty and select calibrate AIR (and press SELECT button one second). During

calibration of liquid, Ultrasound Controller adjusts the intensity of the ultrasound to become 100%.

Each Air Sensor should be calibrated after installation. After the calibration it is advisable also to

check the values in SHOW DATA (see below).

A new calibration of liquid may be required if the liquid properties has changed significantly since

the last calibration. For the Air Sensor PAC or FCP a temperature change over 20ºC requires a

new calibration of liquid.

SHOW DATA

There are two measurement techniques, normal measurement and very low sensitivity

measurement. These are then doubled into two perpendicular measurements for increased

reliability and sensitivity.

During normal measurement a beam of ultrasound is transmitted and the echo is amplified. A

bubble scatters the sound causing reduced intensity. This is how a bubble is being detected.

During very low sensitivity measurements the Air Sensor transmits ultrasound and listens to how

quickly vibrations inside the walls of the Air Sensor disappear into the liquid.

Calibration Data

The Calibration Data page shows calibration data from normal measurement. Calibration data is

measured and stored during calibration. The two data on each line correspond to the two

perpendicular measurements.

On the first line is NLiq which is the ultrasound strength measured in dB with liquid in the Air

Sensor. NLiq is usually around 40dB, depending on type of Air Sensor. A high value means strong

sound which is better than a low value. Check that NLiq is higher than 30dB for SAC and FCS,

higher than 18dB for SAC Ex or FCS Ex, higher than 19dB for PAC and FCP.

On the second line is NAir which is the relative sound strength, relative to NLiq, with air in the Air

Sensor. Ideally NAir should be 0% but as sound travels around the walls it will not be 0%. Check

that NAir is less than 15%.

Normal Measurement Data

This page shows the current normal measurement data, Ndata (The two data correspond to the

two perpendicular measurements). It is the relative ultrasound strength (relative to NLiq). With

liquid in the Air Sensor, it should be near 100%, depending on the liquid. All liquids do not conduct

sound equally well. If Ndata with liquid is > 130% or if it is < 80% it is advisable to calibrate the Air

Sensor with liquid again.

14 Ultrasound Controller Manual

With air in the Air Sensor, Ndata should be less than 15%. The threshold at which air bubble is

detected depend on sensitivity setting and type and size of Air Sensor (approximately at high

sensitivity threshold is 44% and at low sensitivity threshold is 27%).

Very Low Sensitivity Data

This page shows data from the very low sensitivity measurement. This measurement technique is

different from the normal measurement technique and is used only for very low and very very low

sensitivity settings. The two data on each line correspond to the two perpendicular measurements.

On the first line is VLdata showing the current measured ultrasound strength.

On the second line is VLthld showing the threshold. VLthld is measured and stored during

calibration. Liquid is detected when VLdata is > VLthld. For reliable operation VLthld should be > 5.

AUXILIARY DATA

This page shows unprocessed data from the Air Sensor. It can be used for troubleshooting when

contacting AQ Elteknik AB.

HELP

Select HELP to show information about how to connect the Ultrasound Controller.

Sound velocity in the Air Sensor

With sensitivity set to low, medium or high and with two liquids having different sound velocities in

the Air Sensor and with these liquids not well mixed, there can be false indication of air. The

sound is refracted due to velocity change, as it travels from one liquid to another. Setting longer

filter times and lower sensitivity can reduce such false indications of air.

Air Sensor TROUBLESHOOTING

Air or Liquid is indicated on the display but the relay does not change = RELAY setting is wrong.

Display shows:

Cal - Calibration should be done.

CalAir - Calibration Air should be done.

CalLiq - Calibration Liquid should be done.

set - Settings of TYPE or DIAMETER is missing

err 1 - No Air Sensor is detected. The reason for this can be wrongly connected Air Sensor, or

faulty Air Sensor.

err 2 - The relative signal with Air is too strong (at low, medium or high sensitivity). err 2 is shown

if NAir is higher than 21-25%.

The reason for high NAir can be:

Calibration of AIR has been done with liquid in the Air Sensor. Or Wrong settings of Air

Sensor Type or Diameter. Or electric interference. Or a faulty Air Sensor. Or calibration of

LIQUID has been done with liquid having lots of bubbles or particles attenuating the sound.

Electric interference will show itself as Ndata being unstable with Air in the Air Sensor. To

minimize the risk of interference it is important that sources of interference like frequency

inverters should use screened cables between inverter and motor. Also any unscreened part

of the cable between the Air Sensor and Ultrasound Controller should be short. If ex-barriers

are used, Ex-barriershields must be used especially if there is more than one Ultrasound

Controller.

err 3 -There is not enough signal difference between air and liquid (at very low or very very low

sensitivity). err 3 is shown if Very Low sensitivity threshold is not high enough for reliable

AQ Elteknik AB Ultrasound Controller Manual 15

measurement (VLthld<6). Air Sensor with diameter less than 22mm may have difficulty

measuring at very low sensitivity. Change SENSITIVITY to low, medium or high instead.

err 4 - The absolute signal with Liquid is too weak (at low, medium or high sensitivity). err 4 is

shown if the calibrated data with Liquid, NLiq is lower than 31dB for SAC and FCS or 19dB

for SAC Ex and FCS Ex or lower than 18dB for PAC or FCP.

The reason for this can be: Calibration of LIQUID has been done with air or liquid having lots

of bubbles or particles attenuating the sound. Or wrong settings of Air Sensor Type or

Diameter. Or Air Sensor is wrongly connected. Or Air Sensor is faulty

16 Ultrasound Controller Manual

5. Level Switch Mode

In Level Switch Mode the Level Switch measures a single level from the side of the container. It

measures the presence or no presence of liquid behind the container (or pipe) wall. The Level

Switch senses through the wall AND no hole is needed. Four Level Switches can be connected to

one Ultrasound Controller.

Quick start guide

Install Level Switches according to instructions in the Level Switch Manual.

Connect cables, see page 6 or 7 and 16.

Switch on external power supply. You may have to press POWER to exit standby on D128.

Read about navigating the menu system, page 8

Display show: SET sensor MODE. Press MENU button to scroll to Press SELECT for

LevelSwitchmode. Confirm by pressing SELECT button.

Go to SETTINGS to set parameters, page 18.

Now calibrate Level Switch 1. Make sure liquid level is below the Level Switch. Select

CALIBRATE with AIR (empty) then select Calibrate AIR Level Switch1 and press SELECT button

one second.

Make sure liquid level is above the Level Switch. Select CALIBRATE with LIQUID (full) then

select Calibrate LIQUID Level Switch1 and press

SELECT button one second.

Do the calibration for all connected Level Switches. The

calibration order air/liquid and Level Switch number

can be mixed.

Go to SHOW DATA to check calibrated values, page13

Ready.

Connecting the Level Switch

The cable from the Level Switch should

connect directly to the Ultrasound Controller.

(Yellow and green cable are not used.) The

cable screen must always be connected to

Ultrasound Controller (screened cable must

always be used). Any unscreened part of the

cable should be no longer than 30mm. To

minimize the risk of electric interference it is

important that sources of interference like

frequency inverters should use screened

cables between inverter and motor.

In an ex-installation, shielding aluminum

plates must be placed outside each group of

zener barriers belonging to each Ultrasound

Controller, order number: Ex-barriershield,

see Level Switch Ex manual.

Level Switch Type and Technique

There are two different measuring techniques

Ultrasound

Controller

Terminal

Level Switch Cable

D72 /DP72

D128

Level Switch 1Brown

Level Switch 1White

Level Switch 2Brown

Level Switch 1Screen &

Level Switch 2Screen

Level Switch 2White

Level Switch 3Brown

Level Switch 3White

Level Switch 4Brown

Level Switch 3Screen &

Level Switch 4Screen

Level Switch 4White

AQ Elteknik AB Ultrasound Controller Manual 17

Echo and WR (Wall Reverberate) and there are three different Level Switches: Level Switch KS,

Level Switch LS and Level Switch RS.

Echo Technique

The echo-technique uses echo from a reflecting surface inside the container (usually the opposite

container wall) to determine if there is liquid or not inside. Level Switch KS or Level Switch LS can

be used but not Level Switch RS.

The echo-technique transmits short sounds and then measures the echo bouncing on the

reflecting surface. When there is an echo, there is liquid inside and with no liquid there is no echo.

The liquid must not attenuate the sound too much. Small bubbles and particles in the liquid can

cause attenuation and unmixed liquids having different sound velocities can cause refraction of

the sound and thereby wrong indication of low level. It is important that the sound-beam from the

sensor is reflected back to the sensor and not diverted in the wrong direction.

It is desirable that the ultrasound passes as easy as possible through the container wall. How well

it passes depend on the wall material and thickness. Steel or glass wall should be in the range

1,2mm - 15 mm and plastic wall <15mm (PP<10mm). Plastic with fiberglass can be troublesome.

Testing on the actual container is recommended. Any welding or other unevenness in the wall

should be avoided as it can refract (bend) the sound-beam in an unwanted direction.

The ultrasound beam behaves similar to a light-beam, the direction of the echo depend on from

what angle it hits the reflecting surface. Obstructing object in the path between sensor and the

reflecting surface should be avoided. The sound beam is approximately 1cm in diameter. A tube

in the center of the container can give an echo but it is weak. In case there are obstructing objects

inside the container, perhaps the Level Switch RS with the WR-technique is a better choice.

On small containers, disturbing background echoes becomes stronger in relation to the echo.

Level Switch LS and KS should therefore not be used on containers smaller than 44mm diameter.

WR Technique

The WR technique measures vibrations in the container wall to determine if there is liquid or not

behind the wall. Level Switch RS should be used (and on plastic walls Level Switch KS can also

be used)

The WR-technique transmits sound and then measures how quickly vibrations in the container

wall disappear. Vibrations in the wall disappear more quickly with liquid inside due to the

dampening effect of the liquid. The WR-technique works with most liquids since the sound does

not have to travel through the liquid. But the WR-technique is dependent on the material and

thickness of the wall. Steel or glass wall 1,2mm - 15 mm or plastic wall < 15mm (PP<10mm)

should be ok. Fiberglass-plastic could be troublesome and testing on the actual container is

recommended. WR technique has quite high temperature dependence, depending on wall

material, and should not be used if temperature differ more than 15ºC from temperature during

calibration.

On plastic walls it is also possible to use Level Switch KS with the WR-technique. Level Switch KS

can also be used with the WR-technique on a container with jacket to sense the presence of liquid

in the inner container (if the gap between the jacket and the container is filled with liquid).

The WR-technique measures very small signal changes and is sensitive to small movements of

the Level Switch. The Level Switch should therefore be glued with silicone. The WR-technique

can also be sensitive to liquid drops remaining on the inside of the wall and sensitive to

temperature changes. The advantage of the WR-technique is it is independent of liquid properties

and there is no need for a reflecting surface.

18 Ultrasound Controller Manual

1 LIQ 3 cal Lev Sw

2 set 4 1234

Mounting the Level Switch

How to mount the Level Switch on the container is described in Level Switch manual.

Level Switch start-screen

When power is applied, the Level Switch start-screen is displayed showing Lev Sw on first line

to the right signifying this is Level Switch start-screen. . On the second line to the right is written

1234 which shows the state of each of the four relays. A dark background signifies a closed

relay.

To the left are four small digits signifying Level Switch 1 2 3 and 4 with three-letter-text following

each digit showing information about each Level Switch:

AIR air is detected

LIQ liquid is detected

cal Waiting for calibration of Air and/or Liquid

set parameters need to be set

-- Level Switch disconnected

err error –see troubleshooting

™™™ Level Switch is not existing

Example: Level Switch 1 detecting liquid, Level Switch 2 connected but not set, Level Switch 3

need to be calibrated, Level Switch 4 not existing, Relay1 closed.

SETTINGS

Through the SETTINGS-menu the parameters of the Level Switch can be set.

Select SET Type AND Technique to set it to either Type: KS or LS, Technique: ECHO or Type: RS,

Technique: WR or Type KS or LS, Technique WR or No Level Switch.

Select SET DISTANCE to reflecting wall to set it between 46mm (minimum) and 600mm (maximum).

This parameter is needed if the “ECHO”technique is chosen and should be set to actual distance

±10%.

Select SET FILTER to set the filter-time between 0,5s 1s 2s or 4s. It determines how fast the Level

Switch detects air or liquid.

Select SET Jacket to set the distance in mm between jacket and container. Set it only if container

has a jacket.

Select SET FREQUENCY to set the measurement frequency. If set to Auto, the best frequency

(1=1,3MHz, 2=1,5MHz, 3=1,7MHz, 4=2,0MHz or 5=2,2MHz) is automatically selected. Changing

the FREQUENCY does not change the calibration.

Select SET RELAY to set how the relays should act. Each relay have one normally open contact

(at power off and when sensor is not connected the relay is open).). There are four relays and

each relay can be controlled independently by any Level Switch. Choose between Closed with air

or closed with liquid. It is also possible to set one relay to be controlled by two Level Switches.

Example (pump filling a container): LS1 is placed high and LS2 is placed low on a container.

The relay is set to: Open LS1 Liq, Closed LS2 Air. When liquid level drops below LS2, the relay closes

(starting the pump to fill the container). When liquid level rises to LS1, the relay opens (stopping

the pump).

Example (pump emptying container): LS1 is placed high and LS2 is placed low on a container.

The relay is set to: Open LS2 Air, Closed LS1 Liq. When liquid level rises to LS1, the relay closes

AQ Elteknik AB Ultrasound Controller Manual 19

(starting the pump to empty the container). When liquid level drops to LS2, the relay opens

(stopping the pump).

Container with jacket

In a container with a jacket the small space between the container and the jacket is filled with

liquid to regulate the temperature of the inner container. This is a special case when a Level

Switch KS can use the Technique set to WR and Jacket set to the distance between the jacket and

container walls. Measurements will then be made on the inner container using the WR technique.

The space between the jacket and container must be filled with liquid.

CALIBRATION

Select CALIBRATION to calibrate the Level Switch. Each Level Switch must be calibrated after

installation. Calibration must be done both for liquid and for air. The order or the time between the

calibration of air and liquid is of no importance.

A new calibration has to be done if the Level Switch is moved and should be done if the

temperature or the liquid properties has changed significantly since the last calibration. To see

how well the Level Switch behaves at different temperatures or with a different liquid the

measurement data can be checked.

SHOW DATA

Select Echo DATA to show Edata: echo measurement data (echo strength) relative to ELiq. During

calibration it is set to be 100% with liquid. Efrq: shows the frequency (1, 2, 3 or 4). On the second

line threshold Ethd: is displayed. If Edata is higher than Ethd then liquid is detected. ELiq shows

calibrated echo strength with liquid (0,7dB units). Maximum is 100 and a value of 40 is a weak

echo. Eliq depends on the sensor and the container. Ethd is best if it is less than 40%. If higher

than 60% the difference between echo strength with liquid and air is too low.

Select WR DATA to show measurement data of the WR-technique. This screen shows first Wdata:

WR measurement data. Wdata is approximately zero when there is air. With Liquid it becomes

approximately twice Wthld. Wfrq: shows the frequency that has been chosen either manually or

automatically (1, 2, 3 or 4). The best frequency depends on the container wall thickness. On the

second line is Wthd: WR threshold which is the value of Wdata at which indication changes

between Air and Liquid. If Wdata is higher than Wthd then liquid is indicated. Wthd is set during

calibration to half the value of Wdata with Liquid. Wss: approximate signal (set at calibration) in

0,3dB units.

Select Auxiliary data to show raw data from the Level Switch. There are two pages A and B (press

MENU button to switch between them).

Select Test Level Switch to show test-data for the Level Switch when it is not attached to a

container. A value is shown for each Level Switch. If the Level Switch is correctly connected a

value between 0 and 70 should be shown. Then by pressing on the inner side of the Level Switch

with a finger this value should increase if the Level Switch is ok. A Level Switch wrongly

connected or unconnected shows a value higher than 100.

20 Ultrasound Controller Manual

ADVANCED SETTINGS

Select Set sensor MODE to set either Air Sensor mode, Level Switch mode, Level Sensor mode or Gel

Sensor mode mode. It determines which sensor can be connected.

Select SIMULATE to simulate detection of air or liquid. Press SELECT button to toggle between

simulation of Air and Liq. Press MODE button to change between Level Switch 1, 2, 3 and 4.

Select RESTORE settings and calibrations to restore all settings and calibrations to factory-settings.

HELP

Select HELP to show information about connecting the Ultrasound Controller.

Sound velocity and the Level Switch

When ECHO Technique is used and there are two liquids with significant different sound velocity in

the container and these liquids are not well mixed, then there can be a false indication of air

because the sound is refracted at the surface between the two liquids. Sound velocity of liquids

lies usually within 900-2000m/s. A sound velocity outside this range may be compensated by

increasing or decreasing DISTANCE to reflecting wall.

Measurement Reliability

Many factors determine the reliability (wall material, wall thickness, liquid properties, temperature

and glue). Therefore it is always advisable to make tests on the actual container under varying

conditions and temperatures.

Level Switch TROUBLESHOOTING

Display shows:

-- -The Level Switch is not connected or there is a short circuit.

cal -Calibration has not been done. It must be calibrated both for Air and Liquid before cal

disappears.

set - Echo technique is chosen but the DISTANCE to reflecting wall is not set.

The relay does not change but the display changes between Air and Liquid. —Wrong setting of

RELAY.

err - Measurement cannot be done. During calibration there was not enough difference between

the signal with air and with liquid: For ECHO technique, echo threshold Ethd must be < 50%

and for WR technique, WR threshold Wthd must be > 5. The reason for err can be:

Calibration was made for Air but there was Liquid in the container or calibration was made

for Liquid but there was Air in the container.

The Level Switch is not attached correctly to the container. There is a tiny air-gap between

the Level Switch and the container.

If ECHO technique is chosen and the DISTANCE to reflecting wall is wrong.

If ECHO technique is chosen and the echo is reflected in a direction so it does not bounce

back to the Level Switch.

If ECHO technique is chosen and the something is obstruckting the sound beam.

The liquid does not let through enough sound. Try using a Level Switch RS instead of a

Level Switch LS.

The container wall does not let through enough sound. Try a different FREQUENCY or set it to

Auto.

Wrong connection or faulty Level Switch. Select Test Level Switch: to test the level switch and

its connection.

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