AQ M-TECH D72 User manual

Ultrasound Controller
Manual
AQ M-Tech AB

2 Ultrasound Controller Manual

AQ M-Tech AB Ultrasound Controller Manual 3
Ultrasound Controller
D72, DP72, D128, G72, GP72, G128, GS72
AQ M-Tech AB
•Manual version 6.32
•Software version 6.3x
•D72 hardware version RevE
•DP72 hardware version RevE
•D128 hardware version RevA
•G72 hardware version RevA
•GP72 hardware version RevA
•GSD file version 6.0
The manual version should conform to the software and
hardware version of the Ultrasound Controller.
The software version of the Ultrasound Controller is
shown briefly on the display when power is switched on.
It can also be found in the HELP-menu. This manual is
available at www.aqgroup.com/en/aqm-tech/aq-m-tech
Dec 2022

4 Ultrasound Controller Manual
Table of contents
1. Manufacturer information.................................................................................................................6
Manufacturer Declaration of Conformity.........................................................................................6
Limited Warranty ............................................................................................................................6
Warning ..........................................................................................................................................6
Certificate of Quality and Function .................................................................................................6
Manufacturer: .................................................................................................................................6
2. Introduction .......................................................................................................................................7
Ultrasound Controller......................................................................................................................7
Installing Ultrasound Controller D72, G72......................................................................................7
Installing Ultrasound Controller DP72, GP72.................................................................................8
Installing Ultrasound Controller D128, G128..................................................................................8
3. Navigating the menu system ...........................................................................................................9
Sensor MODE and the start-screen...............................................................................................9
4. Electric Noise...................................................................................................................................10
Ground Connection and Sensor Cable ........................................................................................10
Noise from Variable Frequency Drives.........................................................................................10
5. Ex-installation with ex-barriers......................................................................................................10
6. Air Sensor Mode..............................................................................................................................11
Quick start guide...........................................................................................................................11
Functional Description..................................................................................................................11
Orientation of the Air Sensor........................................................................................................11
Connecting the Air Sensor............................................................................................................12
Connecting the Air Sensor Ex via Ex-barrier................................................................................12
Setting lowest possible sensitivity for bubbles .............................................................................13
SETTINGS....................................................................................................................................14
Air Sensor start-screen.................................................................................................................15
ADVANCED SETTINGS...............................................................................................................15
CALIBRATION..............................................................................................................................16
SHOW DATA................................................................................................................................16
Calibration Data............................................................................................................................16
Normal Measurement Data ..........................................................................................................16
Very Low Sensitivity Data.............................................................................................................17
AUXILIARY DATA ........................................................................................................................17
HELP ............................................................................................................................................17
Sound velocity in the Air Sensor ..................................................................................................17
Air Sensor CQS............................................................................................................................17
Air Sensor TROUBLESHOOTING ...............................................................................................17
7. Level Switch Mode..........................................................................................................................19
Quick start guide...........................................................................................................................19
Connecting the Level Switch........................................................................................................19
Level Switch Type and Technique ...............................................................................................20
Echo Technique............................................................................................................................20
WR Technique..............................................................................................................................20
Dual Technique ............................................................................................................................21
Mounting the Level Switch............................................................................................................21
Mounting Level Switch MK...........................................................................................................21
Mounting Level Switch KS / KSF / RS / RSF / CF / LS / LSF ......................................................21
Stainless Steel and Glass Containers..........................................................................................22
Level Switch start-screen .............................................................................................................22
SETTINGS....................................................................................................................................23
Container with jacket....................................................................................................................23
CALIBRATION..............................................................................................................................23
SHOW DATA................................................................................................................................24
ADVANCED SETTINGS...............................................................................................................24
HELP ............................................................................................................................................24
Sound velocity and the Level Switch............................................................................................24
Measurement Reliability...............................................................................................................24
Level Switch TROUBLESHOOTING............................................................................................25
Requesting support from AQ M-Tech AB.....................................................................................25

AQ M-Tech AB Ultrasound Controller Manual 5
8. Level Sensor Mode .........................................................................................................................27
Quick start guide...........................................................................................................................27
Functional Description..................................................................................................................27
Connecting the level sensor.........................................................................................................28
Mounting the Sensor for level and the velocity sensor.................................................................28
Mounting the velocity sensor........................................................................................................28
Installing the sensor on a non-horizontal bottom .........................................................................29
Container top................................................................................................................................29
Level Sensor start-screen.............................................................................................................29
SETTINGS....................................................................................................................................29
CALIBRATION..............................................................................................................................30
SHOW DATA................................................................................................................................31
ADVANCED SETTINGS...............................................................................................................31
HELP ............................................................................................................................................31
Level Sensor TROUBLESHOOTING ...........................................................................................31
9. Gel Distance Mode..........................................................................................................................33
Quick start guide...........................................................................................................................33
Functional Description..................................................................................................................33
Connecting the gel distance sensor .............................................................................................34
Gel Distance start-screen.............................................................................................................34
SETTINGS....................................................................................................................................34
CALIBRATION..............................................................................................................................35
SHOW DATA................................................................................................................................35
ADVANCED SETTINGS...............................................................................................................35
HELP ............................................................................................................................................35
Gel Distance TROUBLESHOOTING............................................................................................35
10. Gel Sensor Mode.............................................................................................................................36
Quick start guide...........................................................................................................................36
Connecting the Gel Sensor ..........................................................................................................36
Measuring Gel ..............................................................................................................................37
Measurement technique...............................................................................................................37
Mounting the Level Switch............................................................................................................38
Gel Sensor start-screen................................................................................................................38
SETTINGS....................................................................................................................................39
CALIBRATION..............................................................................................................................40
SHOW DATA................................................................................................................................40
ADVANCED SETTINGS...............................................................................................................41
HELP ............................................................................................................................................41
Measurement Reliability...............................................................................................................41
Gel Sensor TROUBLESHOOTING ..............................................................................................41
11. Profibus DP......................................................................................................................................42
Connecting Profibus .....................................................................................................................42
PROFIBUS Parameters................................................................................................................42
Profibus Status-symbol.................................................................................................................42
Request Data................................................................................................................................42
Response Data.............................................................................................................................43
Request Data table.......................................................................................................................43
TROUBLESHOOTING .................................................................................................................43
12. Technical specifications Ultrasound Controller ..........................................................................46
13. Parameter settings..........................................................................................................................48
Level Sensor mode.......................................................................................................................49
Gel Sensor mode..........................................................................................................................50
PROFIBUS ...................................................................................................................................50
Gel Distance Sensor mode...........................................................................................................50
14. Software Version History ...............................................................................................................51

6 Ultrasound Controller Manual
1. Manufacturer information
AQ M-Tech AB,(previously 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 M-Tech be held responsible for any
loss or indirect damage howsoever caused. The content of this document is provided as it is. AQ
M-Tech AB reserves the right to revise this document or withdraw it at any time without prior
notice.
Manufacturer Declaration of Conformity
Manufacturer AQ M-Tech 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 2012/19/EU. The Ultrasound
Controller also conforms to RoHS directive (EU) 2015/863. When the Ultrasound Controller is to
be discarded, send it back to AQ M-Tech AB for safe disposal.
Limited Warranty
AQ M-Tech 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 M-Tech 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 M-Tech AB. AQ M-Tech 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 M-Tech AB. AQ M-Tech AB takes no responsibility for any possible
damage that could happen if any other sensor not manufactured by AQ M-Tech AB is connected
to the Ultrasound Controller.
It is not allowed to repair or modify sensors or Ultrasound Controller.
Certificate of Quality and Function
AQ M-Tech AB guaranties that the Ultrasound Controller has passed function and quality tests.
Manufacturer:
AQ M-Tech AB
Bolandsgatan 10 Phone: [phone]
SE-753 23 Uppsala
Sweden
www.aqgroup.com/en/aqm-tech/aq-m-tech info.aq[email protected]

AQ M-Tech AB Ultrasound Controller Manual 7
1 Terminal
2 Terminal for sensors
3 D-sub
2. Introduction
Ultrasound Controller
Ultrasound Controller uses ultrasound to make measurements of liquids. 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 Distance Sensor mode: Continuous gel distance is measured with a Gel Distance Sensor.
This mode is only available in GS72.
Gel Sensor mode: Gel Sensor GF90 installed inside or Level Switches attached outside the
container can sense the presence of gel in the container. Four gel sensors can be
connected to one Ultrasound Controller.
The software version of the Ultrasound Controller is shown briefly on the display when power is
switched on. The software version can also be found in the HELP-menu. Software versions may
differ slightly and therefore it is usually better to use a manual version corresponding to the
software version, even though a later manual version can have less errors.
Installing Ultrasound Controller D72, G72
The Ultrasound Controller 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 an electric cabinet. The
connector terminals can be removed by pulling the connector
straight out. Connections for terminal 1-7 and D-sub, see
table. Connections for terminal 8-17 depend on the selected
mode, see table in the corresponding chapter.
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

8 Ultrasound Controller Manual
1 Terminal
2 Terminal (for Sensors)
3 D-sub
Installing Ultrasound Controller DP72, GP72
The Ultrasound Controller DP72 and GP72 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 an electric cabinet.
The green connector terminals can be removed by pulling the
connector out. Connections for terminal 1-7 and D-sub, see
table. Connections for terminal 8-17 depend on the selected
mode, see table in the corresponding chapter.
The Ultrasound Controller should be installed in accordance
with national regulations. A person with the required knowledge
should perform the installation.
Installing Ultrasound Controller D128, G128
The Ultrasound Controller D128 and G128 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. Remove dummy covering and insert cable
glands as needed. There are 3 small and 4 big cable glands.
There should be only one cable in each cable gland to achieve
full IP65 protection. The pressure compensation element can
be moved to different place but must not be removed
completely. Make sure the gasket is in place when screwing
the bottom plate. Connections for terminal 1-10, see table.
Connections for terminal 11-20 depend on the selected mode,
see table in the corresponding chapter.
The Ultrasound Controller should be installed in accordance
with national regulations. A person with the required knowledge
should perform the installation.
DP72
GP72
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,
G128
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
1 Enclosure
2 Gasket
3 Bottom plate
4 Screws (x8)
5 Terminals
6 Dummy coverings
7,8 Cable glands (small and big)
9 Pressure compensation element

AQ M-Tech AB Ultrasound Controller Manual 9
3. Navigating the menu system
Switches
Keep MENU-button pressed to scroll continuously. Press also BACK-button while pressing
MENU-button to scroll backwards. Menu-text, parameter-names and parameter-values as seen on
the display is here 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. Press the MENU-button to scroll to the
desired mode and press the SELECT-button to select it. Sensor mode can be changed again in
ADVANCED SETTINGS. Here is a map of the menu-system:
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 LIQUID >100mm 1-4 together
Calibrate AIR AS 1 Level Switch 1 Cal Sensor 1 & 2 (Lev & Vel) GelSensor 1
Calibrate LIQUID AS 2 Level Switch 2 Cal Sensor 3 & 4 (Lev& Vel) GelSensor 2
Calibrate AIR AS 2 Level Switch 3 CALIBRATE with AIR GelSensor 3
SHOW DATA Level Switch 4 Cal Sensor 2 (Vel) GelSensor 4
Air Sensor 1 LS1-LS4 together Cal Sensor 4 (Vel) SHOW DATA
Calibration Data CALIBRATE with LIQUID (full) SHOW DATA Gel Sensor Measured data
Normal Measurement Data same as above Sensor 1 & 2 Gelconcentration %
Very Low Sensitivity Data SHOW DATA Measured Level Sensor 1 Relativ Signal %
Air Sensor 2 LevelSwitch 1 Calibrated Level Sensor 1 Relativ Attenuation dB/m
same as above Echo DATA Measured Velo Sensor 2 Signal dB
AUXILIARY DATA WR DATA Calibrated Velo Sensor 2 Liq WR sensor
SETTINGS Auxiliary data Sensor 3 & 4 Gel Sensor Cal Data
SET Air Sensor 1 parameters LevelSwitch 2 same as above same as above Cal Liquid dB
SET TYPE LevelSwitch 3 same as above SETTINGS Freq
SET DIAMETER LevelSwitch 4 same as above SET parameters Sensor 1 & 2 Test Sensor dB
SET SENSITIVITY Test LevelSwitch SET Range SETTINGS
SET FILTER SETTINGS SET Offset SET parameters Sensor 1
SET FREQUENCY SET parameters LevelSwitch 1 SET WR threshold SET TYPE
SET Air Sensor 2 parameters SET Type AND Technique SET Liquid SoundVELOCITY SET ECHO DISTANCE
same as above SET FILTER SET Sensor 2 InnerDISTANCE SET GEL-TYPE
SET RELAY 1 SET ECHO-DISTANCE SET Sensor 2 Sensor HEIGHT SET GEL-THRESHOLD
SET RELAY 2 SET Jacket SET Sensor 2 Sensor Control SET FREQUENCY
SET RELAY 3 SET FREQUENCY SET Sensor 1 Bottom THICKNESS SET WR THRESHOLD
SET RELAY 4 SET parameters LevelSwitch 2 SET Sensor 2 Wall THICKNESS SET RELAY1,2
SET mA output A SET parameters LevelSwitch 3 SET Sensor 1 FREQUENCY SET RELAY3,4
SET mA output B SET parameters LevelSwitch 4 SET Sensor 2 FREQUENCY SET mA output A
HELP same as above SET parameters Sensor 3 & 4 SET mA output B
CONNECTOR Terminals 1-7 SET RELAY 1 same as above HELP
CONNECTOR Terminals 8-17 SET RELAY 2 SET RELAY 1 CONNECTOR Terminals 1-7
Information SET RELAY 3 SET RELAY 2 CONNECTOR Terminals 8-17
Software version SET RELAY 4 SET RELAY 3 Information
ADVANCED SETTINGS HELP SET RELAY 4 Software version
set sensor MODE CONNECTOR terminals 1-7 SET mA output A ADVANCED SETTINGS
SIMULATE CONNECTOR terminals 8-17 SET mA output B set sensor MODE
RESTORE settings and calibrations Information HELP RESTORE settings and calibrations
PROFIBUS SETTING Software version CONNECTOR Terminals 1-7 PROFIBUS SETTING
BITRATE ADVANCED SETTINGS CONNECTOR Terminals 8-17 BITRATE
ADDRESS Set sensor MODE Information ADDRESS
PARAMETER ACCESS SIMULATE Software version PARAMETER ACCESS
CONTROL (eabl/disabl profibus) RESTORE settings and calibrations ADVANCED SETTINGS CONTROL (enabl/disabl profibus)
PROFIBUS SETTING set sensor MODE
BITRATE RESTORE settings and calibrations
ADDRESS PROFIBUS SETTING
PARAMETER ACCESS BITRATE
CONTROL (enabl/disabl profibus) ADDRESS
PARAMETER ACCESS
CONTROL (enabl/disabl profibus)
Toggle between
standby and power-
on.
(D128 only)
Go back to previous
menu-level
or
Cancel a
Selected
operation
Scroll through the menu,
scroll through parameter-
names
or scoll through
parameter-
values
Select a menu
or
Select a
parameter-value

10 Ultrasound Controller Manual
4. Electric Noise
Ground Connection and Sensor Cable
All sensor cables must be shielded. The unshielded part of the
sensor cable should be maximum 40mm. The sensor cable may not
be extended.
Best connection to ground is achieved by using grounded cable
glands on the sensor cables. Only if the sensor cable is not grounded
via the cable gland, is it recommended to connect terminal 16 on the
D72, DP72, G72, GP72, GS72 or terminal 19 on D128, G128 to
ground, near the transmitter as shown in the picture.
Electric noise, with frequency around 2 MHz, entering the sensor
cable can cause measurement problems and is better to be minimized by using shielded cables
and by not routing the sensor cables along high voltage cables connected to a variable frequency
drive.
Noise from Variable Frequency Drives
Variable frequency drives produces noise which exist mainly in the cable connecting the variable
frequency drive to the motor. It is good if this cable is shielded and not routed along the sensor
cables. The variable frequency drive also produces ground current noise, caused by noise
travelling capacitively to ground inside the motor. To reduce
such ground current, a common mode filter can be used. The
most simple common mode filter is a ferrite clamp, clamped on
the three wires coming out of the variable frequency drive. An
even more efficient filter is a toroid. It consist of a ferrite toroid
with the three wires, connected to the 3-phase output of the
variable frequency drive, threaded through the toroid as shown
in the picture.
The filter in the picture is very good and is made of two ferrite
toroids. The three wires are wound three times through the
toroid. The ground wire do not go through the toroid.
Ferroxcube toroid TN25/15/10-3F3 is suitable for wires up to
2,5mm2and it is shown in the picture. Alternatively, EPCOS
toroid B64290L616X830 can be used. If the wires do not fit, a
larger toroid can be used. Ferroxcube toroid of material 3F3 or
EPCOS toroid of material N30 or Amidon toroid of material 77
are suitable for filtering frequencies around 2MHz.
5. Ex-installation with ex-barriers
Ex-barriers are not shielded so if ex-barriers are
used, Ex-barrier shields must be inserted on
each side of the group of EX-barriers connected
to each Ultrasound Controller (see picture). The
ex-barrier connects the sensor cable shield to
ground which makes it possible for ground
currents to enter. Because of this, minimizing
ground currents is very important especially
when EX-barriers are used.

AQ M-Tech AB Ultrasound Controller Manual 11
6. Air Sensor Mode
In Air Sensor mode the Air Sensor is used to measure the presence of bubbles in flowing liquid.
To one Ultrasound Controller there can be connected two Air Sensors model SAC, APS, DAP,
DAT, CCS, PAC, FCS or FCP. For Air Sensor model CQS only one can be connected.
Quick start guide
•Install Air Sensors according to instructions in the Air Sensor Manual.
•Connect cables, see page 7 or 8 and 12.
•Switch on external power supply.
•Read about navigating the menu system, page 9.
•If display show: SET sensor MODE. Choose Press SELECT for Air Sensor mode by scrolling with
MENU button and selecting with SELECT button.
•Go to SETTINGS see page 14 and set all parameter that need to be set.
•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 can be done in any
order as long as both air and liquid will be calibrated.
•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, see page 16.
•Ready.
Functional Description
Bubbles in the liquid flowing through the Air Sensor are monitored using ultrasound. Inside the Air
Sensor two low intensity beams of ultrasound are transmitted across the liquid-path. When a
bubble moves through an ultrasound-beam the sound will be partially deflected and the intensity
of the ultrasound beam changes. The controller constantly measures ultrasound intensity and in
this way detects bubbles. Dense particles in the liquid can also deflect ultrasound and therefore
can cause bubble detection. Normally there are two ultrasound beams or four beams for Air
Sensor CQS. Using muliple beams allowes higher sensitivity and more reliable bubble detection.
The measurement when very low sensitivity is selected, uses a different measurement technique.
It measures ultrasound echoes in the air sensor walls being dampened by liquid. The sensitivity
for bubbles is very low. However there is a temperature dependency so it is good if temperature
during calibration and operation do not vary more than +-5ºC in this case.
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 is low, bubbles can
rise to the top. The Air Sensor is slightly more sensitive to bubbles if it is rotated so that the
cable/connector is facing up.

12 Ultrasound Controller Manual
Connecting the Air Sensor
Maximum cable length depends on the Air Sensor, see Air Sensor manual. The Air Sensor cable
can be ordered in different length and should not be extended. The unshielded part of the cable
should be no longer than 40mm.
SAC, PAC, DAP, APS and DAT uses M8 connectors. Screened cable with 4pin M8 connector can
also be used. Then instead of green, black is connected and instead of yellow, blue.
If D72 is mounted inside a metal cabinet it is good to connect D72 to the cabinet (ground) and this
is best done using shielded cable glands for the Air Sensor cables. If shielded cable glands are
not used then terminal 11 or 16 on the D72, DP72 or terminal 14 or 19 on D128 can be connected
to the cabinet instead. Note that Air Sensor PAC needs a short jumper cable. To minimize the risk
of electric interference and noise, see Electric Noise page 10.
Connecting the Air Sensor Ex via Ex-barrier
In hazardous area, intrinsically safe barriers must be used to connect SAC Ex, CCS Ex or FCS Ex
to the Ultrasound Controller. In this table connection is shown for a dual channel zener ex-barrier
Terminal
number
Cable Color
D72
DP72
D128
SAC
PAC
FCP
FCS
CCS
DAP APS
DAT
CQS
8
11
Air Sensor 1
Brown
Brown
Brown
Brown
Brown
Brown
Brown
9
12
White
White &
Jumper A
Shield of Brown
&
Shield of Green
Shield of Brown
&
Shield of Green
White
White
White
10
13
Green
Green
(Black)
Green
Green
Black
Green
(Black)
Green
11
14
Yellow &
Shield
Shield &
Jumper A
Shield of White
(Yellow not
used)
Shield of White
&
Shield of Yellow
Blue &
Shield
Shield
Shield
12
15
Yellow
(Blue)
White
Yellow & (White
not used)
Yellow
(Blue)
Yellow
13
16
Air Sensor 2
Brown
Brown
Brown
Brown
Brown
Brown
Pink
14
17
White
White &
Jumper B
Shield of Brown
&
Shield of Green
Shield of Brown
&
Shield of Green
White
White
Grey
15
18
Green
Green
(Black)
Green
Green
Black
Green
(Black)
Blue
16
19
Yellow &
Shield
Shield &
Jumper B
Shield of White
& (Yellow not
used)
Shield of White
&
Shield of Yellow
Blue &
Shield
Shield
(Shield)
17
20
Yellow
(Blue)
White
Yellow & (White
not used)
Yellow
(Blue)
Red

AQ M-Tech AB Ultrasound Controller Manual 13
(channel A and B). Read Air Sensor Ex Manual about how to select the barrier and how to
connect the Air Sensor Ex to the barrier. To minimize the risk of electric interference and noise,
see Electric Noise page 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. Set FILTER to delay 0,3s
or longer depending on maximum acceptable delay (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 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 are still unwanted detections of bubbles, then change the setting of SENSITIVITY to very low or
very very low.
Terminal
number
Cable Color
D72
DP72
D128
Dual channel
zener Ex-
Barriers
SAC Ex or
CCS Ex
Dual channel
zener Ex-
Barriers
FCS Ex
8
11
Air Sensor 1
Channel A
Brown
Channel A
White
9
12
Ground
White
Ground
Shield of White & Shield of
Yellow
10
13
Channel B
Green (Black)
Channel B
Yellow
11
14
Ground
Yellow (Blue) &
Shield
Ground
Brown & Green and Shield
of Brown & Shield of Green
12
15
13
16
Air Sensor 2
Channel A
Brown
Channel A
White
14
17
Ground
White
Ground
Shield of White & Shield of
Yellow
15
18
Channel B
Green (Black)
Channel B
Yellow
16
19
Ground
Yellow (Blue) &
Shield
Ground
Brown & Green and Shield
of Brown & Shield of Green
17
20

14 Ultrasound Controller 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. Detectable bubble size is
somewhat dependent on Air Sensor inner diameter:
At high sensitivity, a single bubble of approximately 1-60μl can be detected depending on Air
Sensor diameter: SAC10,FCS10: 1μl, SAC22,FCS22: 6μl, SAC35,FCS35: 8μl, SAC46,FCS46:
80ul, DAP6,APS6: 3μl, DAP10,APS10: 20μl, DAP22,APS22: 60μl
At medium sensitivity, a single bubble of approximately 10-150μl can be detected depending on Air
Sensor diameter: SAC10,FCS10: 10μl, SAC22,FCS22: 30μl, SAC35,FCS35: 40μl,
SAC46,FCS46: 170ul, DAP6,APS6: 30μl, DAP10,APS10: 60μl, DAP22,APS22: 150μl
At low sensitivity, a single bubble of approximately 500-1200μl can be detected depending on Air
Sensor diameter: SAC10,FCS10: 500μl, SAC22,FCS22: 900μl, SAC35,FCS35: 1000μl,
SAC46,FCS46: 5000ul, DAP6,APS6: 200μl, DAP10,APS10: 500μl, DAP22,APS22: 1200μl
Sensitivity is also affected by liquid flow rate. At a flow rates above 4m/s sensitivity starts
decreasing. Many small bubbles together may also detect as if they were a big bubble. Even tiny,
microscopic bubbles may cause detection if there are very 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 (WR-technique).
This technique measures the presence of liquid or no liquid, making the Air Sensor very
insensitive for bubbles. It can be used for Air Sensors DAP and APS with diameter ≥6mm and Air
Sensor SAC with diameter ≥22mm. There is temperature dependence and this setting should not
be used if temperature variation between calibration and operation is more than ±5ºC.
Select SET FILTER to set the filter-time. It determines how the detection-data is filtered. FILTER
can be set to either integrate 1ms -3s or delay 300ms -10s.
Integrate means integrating (adding) the duration of each bubble in the measuring zone. When
the sum becomes higher than the integrate time, air will be indicated. Whenever liquid is next time
indicated, the integration-process will start over.
Delay means that air will only be indicated when air has been continuously detected for a time
longer than the delay time.
Long FILTER delay and low SENSITIVITY is useful if some quantity of bubbles are acceptable.
Short FILTER integrate and high SENSITIVITY is useful when almost every bubble must be detected.
Select SET FREQUENCY to set the ultrasound frequecy that is used to detect bubbles. Normally it
should be set to Auto, then the frequency that works best is automatically selected. However for
some liquids it works better to set it manually. (For example acetic acid is better to set to 2,0MHz)
Select SET RELAY to set how the relays should act. There are four relays each with one normally
open contact (at power off and when sensor is not connected the relay is open). Each relay can
be set independently. Choose between Closed with air or closed with liquid and choose between
Air Sensor 1 and Air Sensor 2. The duration of air being indicated is minimum 0,5 second even if
the bubble is detected much shorter time (to make sure the indication of air is registered).

AQ M-Tech AB Ultrasound Controller Manual 15
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 output Normal Measurement Data or All Sensitivities for air sensor 1 or 2.
Normal Measurement Data This is a combination of the analog Ndata (during the time liquid is
indicated) and 6mA whenever air is indicated. Note that Ndata is filtered with very long (1s) time
constant and is too slow to be used for detecting bubbles. The reaction time for the air indication
is 40ms and detection is always minimum 500ms.
8mA –20mA = Ndata = 0% –150% (but only during the time Liquid is indicated)
6mA = when Air is indicated
4mA = error
All Sensitivities This is a combination of all sensitivities so that different bubble sizes can be output
to the mA output. The reaction time is 40ms but the bubble indication time is always minimum
500ms regardless of how long the bubble is being detected.
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 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 Calibration of air is perhaps good to do (after calibration of liquid)
CalLiq Calibration of liquid is perhaps good to do (after calibration of air)
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
SetErr Error, wrong settings, 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.
ADVANCED SETTINGS
Select Set sensor MODE to set either Air Sensor mode, Level Switch mode, Level Sensor mode or Gel
Sensor mode mode. It determines which sensor can be connected.
Select SIMULATE to simulate detection of air or liquid. Press SELECT button to toggle between
simulation of AIR and LIQ. Press MENU button to change between Air Sensor 1 and 2.
Select RESTORE settings and calibrations to restore all settings and calibrations to factory-settings.
Select PROFIBUS SETTINGS see page 42 (for DP72).
1 AIR AirSens
2 --- 1234

16 Ultrasound Controller Manual
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. When very very low sensitivity is used a temperature change of more
than 4ºC requires a new calibration of both air and liquid.
SHOW DATA
There are two measurement techniques, normal measurement and very low sensitivity
measurement. These are then doubled into two perpendicular measurements for increased
reliability and sensitivity.
During normal measurement a beam of ultrasound is transmitted and the echo is amplified. A
bubble scatters the sound causing reduced intensity. This is how a bubble is being detected.
During very low sensitivity measurements the Air Sensor transmits ultrasound and listens to how
quickly vibrations inside the walls of the Air Sensor disappear into the liquid.
Calibration Data
The Calibration Data page shows calibration data from normal measurement. Calibration data is
measured and stored during calibration. The two data on each line correspond to the two
perpendicular measurements.
On the first line is NLiq which is the ultrasound strength measured in dB with liquid in the Air
Sensor. NLiq is usually around 40dB, depending on type of Air Sensor. A high value means strong
sound which is better than a low value. Check that NLiq is higher than 30dB for SAC and FCS,
higher than 18dB for SAC Ex, CCS Ex or FCS Ex, higher than 19dB for PAC and FCP.
On the second line is NAir which is the relative sound strength, relative to NLiq, with air in the Air
Sensor. Ideally NAir should be 0% but as sound travels around the walls it will not be 0%. Check
that NAir is less than 15%.
Normal Measurement Data
This page shows the current normal measurement data, Ndata (The two data correspond to the
two perpendicular measurements). It is the relative ultrasound strength (relative to NLiq). With
liquid in the Air Sensor, it should be near 100%, depending on the liquid. All liquids do not conduct
sound equally well. If Ndata with liquid is > 130% or if it is < 80% it is advisable to calibrate the Air
Sensor with liquid again.
With air in the Air Sensor, Ndata should be less than 15%. The threshold at which air bubble is
detected depend on sensitivity setting and type and size of Air Sensor (approximately at high
sensitivity threshold is 44% and at low sensitivity threshold is 27%).

AQ M-Tech AB Ultrasound Controller Manual 17
Very Low Sensitivity Data
This page shows data from the very low sensitivity measurement. This measurement technique is
different from the normal measurement technique and is used only for very low and very very low
sensitivity settings. The two data on each line correspond to the two perpendicular measurements.
On the first line is VLdata showing the current measured ultrasound strength.
On the second line is VLthld showing the threshold. VLthld is measured and stored during
calibration. Liquid is detected when VLdata is > VLthld. For reliable operation VLthld should be > 5.
AUXILIARY DATA
This page shows unprocessed data from the Air Sensor. It can be used for troubleshooting when
contacting AQ M-Tech AB.
HELP
Select HELP to show information about how to connect the Ultrasound Controller.
Sound velocity in the Air Sensor
With sensitivity set to low, medium or high and with two liquids having different sound velocities in
the Air Sensor and with these liquids not well mixed, there can be false indication of air. The
sound is refracted due to velocity change, as it travels from one liquid to another. Setting longer
filter times and lower sensitivity can reduce such false indications of air.
Air Sensor CQS
Air Sensor CQS has a relatively large diameter and therefore it uses four measurement zones
instead of two. This improves bubble detection. However only one Air Sensor CQS can be
connected to one D72. Settings should be set for air sensor 1 (setttings for air sensor 2 is disabled
when air sensor 1 is set to CQS).
Air Sensor TROUBLESHOOTING
Air or Liquid is indicated on the display but the relay does not change = RELAY setting is wrong.
Display shows:
Cal Calibration should be done.
CalAir Calibration Air should be done.
CalLiq Calibration Liquid should be done.
Set Settings of TYPE or DIAMETER is missing
err 1 No Air Sensor is detected. The reason for this can be wrongly connected Air Sensor, or
faulty Air Sensor.
err 2 The relative signal with Air is too strong (at low, medium or high sensitivity). err 2 is shown if
NAir is higher than 21-25%.
The reason for high NAir can be:
Calibration of AIR has been done with liquid in the Air Sensor. Or Wrong settings of Air
Sensor Type or Diameter. Or electric interference. Or a faulty Air Sensor. Or calibration of
LIQUID has been done with liquid having lots of bubbles or particles attenuating the
sound.

18 Ultrasound Controller Manual
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 shielded cables between inverter and motor. Also any unshielded
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 31dB for SAC and FCS or 19dB
for SAC Ex, CCS Ex and FCS Ex or lower than 18dB for PAC and FCP.
The reason for this can be: Calibration of LIQUID has been done with air or liquid having
lots of bubbles or particles attenuating the sound. Or wrong settings of Air Sensor Type or
Diameter. Or Air Sensor is wrongly connected. Or Air Sensor is faulty
SetErr Air Sensor DAP, DAT and APS can not be used together with another type of Air Sensor
(this is due to an internal configuration common to both air sensors). When TYPE is set to
DAP, DAT or APS on one air sensor, the other air sensor must also be set to DAP, DAT or
APS or No Air Sensor.

AQ M-Tech AB Ultrasound Controller Manual 19
7. 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.
•Attach the included tape, see page 21
•Connect cables, see page 7 or 8 and 19.
•Switch on external power supply. You may have to press POWER to exit standby on D128.
•Read about navigating the menu system, page 9
•If display show: SET sensor MODE. Choose Press SELECT for Air LevelSwitchmode by scrolling
with MENU button and selecting with SELECT button.
•Go to SETTINGS see page 23 and set all parameter that need to be set.
•Now calibrate Level Switch 1. Make sure liquid level is below the Level Switch. Select
CALIBRATE with AIR (empty) then select Calibrate AIR Level Switch1 and press SELECT button
one second.
•Make sure liquid level is above the Level Switch. Select CALIBRATE with LIQUID (full) then
select Calibrate LIQUID Level Switch1 and press SELECT button one second.
•Do the calibration for all connected Level Switches. The calibration order air/liquid and Level
Switch number can be mixed.
•Go to SHOW DATA to check calibrated values, page16
•Ready.
Connecting the Level Switch
The Level Switch cable is better not
be extended. Maximum cable length,
see Level Switch manual. The
unshielded part of the cable should be
no longer than 40mm. Yellow and
green wire are not used except for
Level Switch DL which is a Level
Switch with two sensors.
If D72 is mounted inside a metal
cabinet it is good to connect D72 to
the cabinet (ground) and this is best
done using grounded cable glands for
the Level Switch cables. If grounded
cable glands are not used then
terminal 16 on the D72, DP72 or
terminal 19 on D128 can be
connected to the cabinet instead.
To minimize the risk of electric
interference and noise, especially in
ex-installation, see Electric Noise
page 10.
Ultrasound
Controller
Terminal
Level Switch
Cable
Level Switch DL
(two sensors with a single
cable)
D72
DP72
D128
Cable Color
Cable Color
8
11
Sensor 1Brown
Sensor 1 Brown
9
12
Sensor 1White
Sensor 1 White
10
13
Sensor 2Brown
Sensor 2 Green (or black)
11
14
Sensor 1Shield &
Sensor 2Shield
Shield
12
15
Sensor 2 White
Sensor 2 Yellow (or blue)
13
16
Sensor 3 Brown
Sensor 3 Brown
14
17
Sensor 3 White
Sensor 3 White
15
18
Sensor 4 Brown
Sensor 4 Green (or black)
16
19
Sensor 3 Shield &
Sensor 4 Shield
Shield
17
20
Sensor 4 White
Sensor 4 Yellow (or blue)

20 Ultrasound Controller Manual
Level Switch Type and Technique
There are two different measuring techniques: Echo and WR (Wall Reverberate). The different
Level Switches are optimized for each technique. Level Switch RS works well with the WR-
technique and do not work well with Echo-technique. Level Switch MK has a soft silicone surface
adapting to the container surface and works well with Echo-technique and does not work well with
the WR-technique. Two Level Switch MK also works well with the dual-technique for improved
detection when the container is small. Level Switch KS and LS works well with the Echo-
technique and on plastic containers they also works well with the WR-technique.
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. All types of Level Switch except Level
Switch RS can be used.
The echo-technique transmits short sounds and then measures the echo bouncing on the
opposite reflecting surface. With liquid inside, there is an echo and with no liquid there is no echo.
If the liquid attenuates the sound too much the echo may disappear. 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 the echo disappear resulting in wrong indication of low
level. It is important that the sound-beam from the sensor is reflected, back to the sensor and not
diverted in the wrong direction.
It is desirable that the ultrasound passes as easy as possible through the container wall. How well
it passes depend on the wall material and thickness. Steel or glass wall should be in the range
1,2mm - 15 mm and plastic wall <15mm (PP<10mm). Plastic with fiberglass can be troublesome.
Testing on the actual container is recommended. Any welding or other unevenness in the wall
should be avoided as it can refract (bend) the sound-beam in an unwanted direction.
The ultrasound beam behaves similar to a light-beam, the direction of the echo depend on from
what angle it hits the reflecting surface. Obstructing object in the path between sensor and the
reflecting surface should be avoided. The sound beam is approximately 1cm in diameter. A tube
in the center of the container can give an echo but it is weak. In case there are obstructing objects
inside the container, perhaps the Level Switch RS with the WR-technique is a better choice.
On small containers, disturbing background echoes becomes stronger in relation to the echo.
Level Switch LS and KS should therefore not be used on metal and glass 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. However, on plastic walls Level Switch KS or
LS can also be used.
The WR-technique transmits sound and then measures the remaining vibrations in the container
wall. Vibrations decay more quickly with liquid inside due to the dampening effect of the liquid.
The WR-technique works with most liquids since the sound does not have to travel through the
liquid. But the WR-technique is dependent on the material and thickness of the wall. Steel or glass
wall 1,2mm - 15 mm or plastic wall < 15mm (PP<10mm) should be ok. Fiberglass-plastic would be
troublesome and testing on a container is recommended. WR technique can have quite high
temperature dependence, depending on wall material, and should not be used if temperature
differ more than 15ºC between temperatures during operation and calibration.
When using the WR-technique on plastic walls Level Switch KS can be used instead of Level
Switch RS.