AQ Elteknik D72 User manual

Ultrasound Controller
D72 DP72 D128 G72
Manual
AQ Elteknik AB

2

AQ Elteknik AB Ultrasound Controller Manual 3
Ultrasound Controller
D72 DP72 D128 G72
D72 version RevE
DP72 version RevE
D128 version RevA
G72 version RevA
Manual version 4.52
Software version 4.5x
Gsd file (for DP72) version 3.2
January 2014
AQ Elteknik AB

4
Table of contents
1. Manufacturer information.......................................................................................................................................................................................5
Version................................................................................................................................................................................................................5
Manufacturer Declaration of Conformity.............................................................................................................................................................5
Limited Warranty.................................................................................................................................................................................................5
Warning...............................................................................................................................................................................................................5
Manufacturer Information ...................................................................................................................................................................................5
Certificate of Quality and Function .....................................................................................................................................................................5
2. Introduction..............................................................................................................................................................................................................6
Ultrasound Controller..........................................................................................................................................................................................6
Installing the Ultrasound Controller D72.............................................................................................................................................................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................................................................................................................................................................................10
SETTINGS........................................................................................................................................................................................................11
Air Sensor start-screen.....................................................................................................................................................................................12
ADVANCED SETTINGS...................................................................................................................................................................................13
CALIBRATION..................................................................................................................................................................................................13
SHOW DATA....................................................................................................................................................................................................13
HELP.................................................................................................................................................................................................................14
Sound velocity in the Air Sensor ......................................................................................................................................................................14
Air Sensor TROUBLESHOOTING ...................................................................................................................................................................15
5. Level Switch Mode ................................................................................................................................................................................................16
Quick start guide...............................................................................................................................................................................................16
Connecting the Level Switch............................................................................................................................................................................16
Level Switch Type and Technique ...................................................................................................................................................................17
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................................................................................................................................................................21
6. Level Sensor Mode................................................................................................................................................................................................22
Quick start guide...............................................................................................................................................................................................22
Functional Description......................................................................................................................................................................................22
Connecting the level sensor .............................................................................................................................................................................23
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...................................................................................................................................................................................26
HELP.................................................................................................................................................................................................................26
Level Sensor TROUBLESHOOTING ...............................................................................................................................................................26
7. Gel Sensor Mode...................................................................................................................................................................................................28
Quick start guide...............................................................................................................................................................................................28
Connecting the Gel Sensor ..............................................................................................................................................................................29
Measuring Gel ..................................................................................................................................................................................................29
Measurement technique...................................................................................................................................................................................30
Mounting the Level Switch................................................................................................................................................................................30
Gel Sensor start-screen....................................................................................................................................................................................31
SETTINGS........................................................................................................................................................................................................31
CALIBRATION..................................................................................................................................................................................................32
SHOW DATA....................................................................................................................................................................................................32
ADVANCED SETTINGS...................................................................................................................................................................................33
HELP.................................................................................................................................................................................................................33
Measurement Reliability ...................................................................................................................................................................................33
Gel Sensor TROUBLESHOOTING ..................................................................................................................................................................34
8. Profibus DP............................................................................................................................................................................................................35
Connecting Profibus .........................................................................................................................................................................................35
PROFIBUS Parameters....................................................................................................................................................................................35
Profibus Status-symbol.....................................................................................................................................................................................35
Request Data....................................................................................................................................................................................................35
Response Data.................................................................................................................................................................................................36
Request Data table...........................................................................................................................................................................................36
TROUBLESHOOTING .....................................................................................................................................................................................36
Response Data table........................................................................................................................................................................................37
9. Technical specifications Ultrasound Controller................................................................................................................................................38
10. Parameter settings................................................................................................................................................................................................39

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
contents of this document are provided as it is. AQ Elteknik AB reserves the right to revise this document or withdraw it
at any time without prior notice.
Version
It is important that the manual version agree with the software version and hardware version of Ultrasound Controller.
See page 3. Note that terminal numbers can be different on different versions.
This manual can be downloaded at www.aqelteknik.com
The software version and hardware version of Ultrasound Controller is shown briefly on the display when power is
switched on.
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.
Manufacturer Information
AQ Elteknik AB
Alsikegatan 4 Phone: + 46 18-18 34 30
SE-753 23 Uppsala Fax: + 46 18-10 50 04
Sweden
www.aqelteknik.com [e-mail]
Certificate of Quality and Function
AQ Elteknik AB guaranties that the Ultrasound Controller has passed function tests and quality tests.

6
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 38. 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
3. Navigating the menu system
Switches
Keep MENU button pressed to scroll continuous through parameter values. Press BACK button
while pressing MENU button to scroll backwards.
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 (Gel Sensor mode is not available in RevA-RevD).
The mode determines the type of sensor that can be connected. 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 the menu
or
Scroll through a
list of 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
AirSensormode. 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.
Go to SHOW DATA to check 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
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.

10
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 is the
longest acceptable delay for detecting air that can be accepted and set FILTER accordingly:
delay 0,3s or longer (don’t 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 are using 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 +- 5C temperature
variation during measurement and calibration. Try first SENSITIVITY low and FILTER 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.
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
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

AQ Elteknik AB Ultrasound Controller Manual 11
Ultrasound Controller but may be connected to ground via screened cable glands). PAC also
needs a 50mm jumper cable. 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. It can be set to either integrate 1ms - 3s or delay 300ms - 10s.
Integrate means integrating (adding) the duration of each bubble. When the integrated sum
becomes higher than the FILTER-integrate - time, air will be indicated. When liquid is
next time indicated, the integration-process starts over.
Delay means that air will be indicated only after air has been continuously detected for a time
longer than FILTER-delay.
Long FILTER-delay and low SENSITIVITY is useful if some quantities of bubbles
should be undetected.
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

12
1 AIR AirSens
2 --- 1234
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 mA-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.
20mA = Ndata =150% 16mA = Ndata =100%
8mA = Ndata = 0% 6mA = Air is detected
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.
AIR 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 or Level
Sensor mode. It determines which sensor can be connected. Changing sensor mode does not alter
any settings or calibrations.
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
During normal measurement the Air Sensor transmits beams of ultrasound and listens to the
sound. Bubbles scatter the sound and thereby reduce the sound intensity and in this way the Air
Sensor detects air. Each Air Sensor uses two beams to make two measurements, perpendicular to
each other. During the very low sensitivity measurements the Air Sensor transmits beams of
ultrasound and listens to how fast the vibrations within the walls of the Air Sensor disappears into
the liquid inside the Air Sensor.
Select Calibration Data to show NLiq: normal measurement liquid signal, which is
measured in dB. NLiq is measured and stored during calibration. NLiq over 45dB is normal,
depending on type of Air Sensor. A faulty Air Sensor may show NLiq less than 30dB. If NLiq is
low, err 4 will be shown, see troubleshooting. Also shown is NAir: normal measurement air signal
relative to NLiq, which is measured in %. NAir is measured and stored during calibration.
NAir should be 15% or less. Lower is better.
Select Normal Measurement Data to show Ndata: the current normal measurement
signal relative to NLiq which is measured in %. With liquid in the Air Sensor, Ndata is
expected to be near 100%. If it deviates too much from 100% (>120% or < 80%) it is advisable to
calibrate the Air Sensor with liquid again. With air in the Air Sensor, Ndata should be 15% or
less. The threshold of Ndata at which air bubbles are detected depends on the sensitivity setting
and the type and size of Air Sensor (approximately at high sensitivity 44% and at low sensitivity
27%).
Select Very Low Sensitivity Data to show VLdata: very low sensitivity
measurement data and VLthld: very low sensitivity calibrated and stored threshold. With air,
VLdata becomes close to zero and with liquid, VLdata becomes higher than VLthld.
VLthld depends on the type of Air Sensor. Air Sensors with diameter < 14mm can not use very
low sensitivity. err 3 is displayed if VLthld becomes too low for reliable measurements, see
troubleshooting.

14
Select AUXILIARY DATA to show unprocessed data from the Air Sensor. It can be used for
troubleshooting when contacting AQ Elteknik AB.
HELP
Select HELP to show information about connecting the Ultrasound Controller.
Sound velocity in the Air Sensor
When there are two liquids with significant different sound velocity in the Air Sensor and these
liquids are not well mixed, there can be a false indication of air. It happens because the sound is
refracted when it travels from one liquid to the other. Setting longer filter times may filter out the
false indication of air. Sound velocity of liquids lies in the range 900-2000m/s. If the sound velocity
is outside this range the Air Sensor may not work.

AQ Elteknik AB Ultrasound Controller Manual 15
Air Sensor TROUBLESHOOTING
Air or Liquid is indicated on the display but the relay does not change = RELAY setting is wrong.
Display shows:
cal, CalAir or CalLiq Calibration must 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.
Wrong settings of Air Sensor Type or Diameter.
Electric interference.
A faulty Air Sensor.
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
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 approximately 38dB for SAC and
FCS or 35dB for FCS Ex or lower than 40dB 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.
Wrong settings of Air Sensor Type or Diameter.
Wrong connected Air Sensor.
A faulty Air Sensor

16
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
Go to SHOW DATA to check calibrated values, page13.SELECT for
LevelSwitchmode. Confirm by pressing SELECT button.
Display show: SET sensor MODE.Press MENU button to scroll to Press 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.
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.
Ultrasound
Controller
Terminal
Level Switch Cable
D72 /DP72
D128
8
11
Level Switch 1Brown
9
12
Level Switch 1White
10
13
Level Switch 2Brown
11
14
Level Switch 1Screen &
Level Switch 2Screen
12
15
Level Switch 2White
13
16
Level Switch 3Brown
14
17
Level Switch 3White
15
18
Level Switch 4Brown
16
19
Level Switch 3Screen &
Level Switch 4Screen
17
20
Level Switch 4White

AQ Elteknik AB Ultrasound Controller Manual 17
Level Switch Type and Technique
There are two different measuring techniques 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 weaker than the echo from the opposite
container wall. 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 in some cases also Level Switch KS can 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. The WR-technique
works well 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. Plastic with fiberglass could be troublesome
and testing on the actual container is recommended. WR technique has temperature dependence
and should not be used if temperature when full or empty differ more than 15ºC from temperature
during calibration.
On plastic walls it is also possible to use Level Switch KS with the WR-technique however there
can be temperature dependence. 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 must therefore preferably be glued. The WR-technique can also be
sensitive to liquid drops remaining on the inside of the wall and sensitive to temperature changes.

18
1 LIQ 3 cal Lev Sw
2 set 4 1234
The advantage of the WR-technique is it is independent of liquid properties and that there is no
need for a reflecting surface.
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 LS and Technique ECHO or
Type RS and Technique WR or No Level Switch. All other settings are for special cases
only.
Select SET DISTANCE to reflecting wall to set it between 46mm (minimum) and
600mm (maximum). This parameter is needed only 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=1,1MHz, 2=1,5MHz, 3=2MHz or 4=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

AQ Elteknik AB Ultrasound Controller Manual 19
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 (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 unprocessed data from the Level Switch.
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. If by pressing on the inner side of the Level Switch with
your finger this value increases then the Level Switch is working. A Level Switch wrongly
connected or unconnected shows a value higher than 100.

20
ADVANCED SETTINGS
Select Set sensor MODE to set either Air Sensor mode or Level Switch mode or Level
Sensor mode. It determines which sensor can be connected. Changing sensor mode does not alter
any settings or calibrations.
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 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
Measurement reliability is good but many factors determine the reliability (wall material, wall
thickness, liquid properties, temperature and glue). Therefore it is always advisable to make tests
under varying conditions and temperatures. Best is to test and evaluate both Level Switch RS and
Level Switch KS before deciding.