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
Quick start guide..............................................................................................................................................................................................................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
SETTINGS.......................................................................................................................................................................................................................18
Container with jacket.......................................................................................................................................................................................................19
CALIBRATION.................................................................................................................................................................................................................19
SHOW DATA...................................................................................................................................................................................................................19
ADVANCED SETTINGS .................................................................................................................................................................................................20
HELP...............................................................................................................................................................................................................................20
Sound velocity and the Level Switch...............................................................................................................................................................................20
Measurement Reliability..................................................................................................................................................................................................20
Level Switch TROUBLESHOOTING...............................................................................................................................................................................20
6. Level Sensor Mode...............................................................................................................................................................................................................22
Quick start guide..............................................................................................................................................................................................................22
Functional Description.....................................................................................................................................................................................................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
SETTINGS.......................................................................................................................................................................................................................24
CALIBRATION.................................................................................................................................................................................................................25
SHOW DATA...................................................................................................................................................................................................................25
ADVANCED SETTINGS .................................................................................................................................................................................................25
HELP...............................................................................................................................................................................................................................26
Level Sensor TROUBLESHOOTING ..............................................................................................................................................................................26
7. Gel Sensor Mode ..................................................................................................................................................................................................................28
Quick start guide..............................................................................................................................................................................................................28
Connecting the Gel Sensor .............................................................................................................................................................................................28
Measuring Gel.................................................................................................................................................................................................................29
Measurement technique..................................................................................................................................................................................................29
Mounting the Level Switch ..............................................................................................................................................................................................30
Gel Sensor start-screen ..................................................................................................................................................................................................30
SETTINGS.......................................................................................................................................................................................................................31
CALIBRATION.................................................................................................................................................................................................................31
SHOW DATA...................................................................................................................................................................................................................32
ADVANCED SETTINGS .................................................................................................................................................................................................32
HELP...............................................................................................................................................................................................................................32
Measurement Reliability..................................................................................................................................................................................................32
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: [phone]
SE-753 23 Uppsala Fax: [phone]
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
1
+ supply PLUS 24V
2
–supply MINUS
3
Relay common
4
Relay 1
5
Relay 2
6
Relay 3
7
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
1
+ supply PLUS
24V
2
–supply MINUS
3
Relay common
4
Relay 1
5
Relay 2
6
Relay 3
7
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
1
+ supply PLUS
24V
2
–supply MINUS
3
Relay common
4
Relay 1
5
Relay 2
6
Relay 3
7
Relay 4
8
mA output MINUS
9
+ 4-20mA output A
10
+ 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
or
Cancel a
Selected
operation
Scroll through menu-
text, parameter-names
or parameter-
values
Select a menu
or
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
cable color
cable color
cable color
cable color
8
11
Air Sensor 1
Brown
Brown
Brown
Brown
White
9
12
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
10
13
Green
Green
Green
Green
Yellow
11
14
Yellow &
Screen
Screen &
JumperA
Screen of
White cable
Screen of
White cable
& Screen of
Yellow cable
Screen of
Brown cable &
Screen of
Green cable
12
15
Yellow
White
White &
Yellow
Brown & Green
13
16
Air Sensor 2
Brown
Brown
Brown
Brown
White
14
17
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
15
18
Green
Green
Green
Green
Yellow
16
19
Yellow &
Screen
Screen &
JumperB
Screen of
White cable
Screen of
White cable
& Screen of
Yellow cable
Screen of
Brown cable &
Screen of
Green cable
17
20
Yellow
White
White &
Yellow
Brown & Green