Bin Master SmartBob AO User manual

SmartBob AO
OPERATING INSTRUCTIONS
PLEASE READ CAREFULLY
BinMaster: Division of Garner Industries
7201 N. 98th St., Lincoln, NE 68507
402-434-9102 • email: [e-mail]
www.binmaster.com
925-0406 0613

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SmartBob AO
TABLE OF CONTENTS
Safety Summary ..................................................................................................................... 3
Introduction ............................................................................................................................. 4
Specications.......................................................................................................................... 5
Location and Mounting ........................................................................................................... 6
Connections and Wiring ......................................................................................................... 6
Power............................................................................................................................. 6
Start Input ...................................................................................................................... 7
Override Input................................................................................................................ 7
4-20 mA Output ............................................................................................................. 8
Relay 1 and 2 Outputs................................................................................................... 9
Wiring Diagram............................................................................................................ 10
Air Purge System.................................................................................................................. 11
User Interface ....................................................................................................................... 11
Run/Display Mode....................................................................................................... 12
Setup Menu ................................................................................................................. 12
Calibrating the 4-20 mA Output............................................................................................ 14
Motor Driven Operations ...................................................................................................... 14
Cable Replacement Instructions .......................................................................................... 15
Probe Options....................................................................................................................... 17
Limiting Stainless Steel Cable.............................................................................................. 19
Mounting Options ................................................................................................................. 20
5-1/8" Floor Flange Template ............................................................................................... 21
7" Floor Flange Template ..................................................................................................... 22
SureDrop Cable Release ..................................................................................................... 23

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SmartBob AO
Safety Summary
Review the following safety precautions to avoid injury and prevent damage to the equipment.
The product should be installed, commissioned, and maintained by qualied and authorized
personnel only.
Install according to installation instructions and comply with all National and Local codes.
Use electrical wire that is sized and rated for the maximum voltage and current of
the application.
Properly ground the enclosure to an adequate earth ground.
Observe all terminal and relay contact ratings as called out on the nameplate and in
the installation manual.
Ensure that the enclosure cover is in place and secured tightly during normal operation.
If this product is used in a manner not specied by the manufacturer the safety protection
could be compromised.
Safety Terms and Symbols
WARNING: Warning statements identify conditions or practices that could result
in injury or loss of life. Risk of electrical shock.
CAUTION: Caution statements identify conditions or practices that could result
in damage to this product or other property.
Safety Precaution
Whenever personnel are going to enter a vessel that has a SmartBob mounted on it,
the power to the SmartBob should be turned o󰀨. The SmartBob lowers a 2 pound weight
(probe) of either metal or plastic material at a rate of up to 2 feet per second when it is taking a
measurement. The weighted probe impacting personnel while it is descending could result in
injury. Turning o󰀨 the power to the SmartBob will disable the probe from dropping.

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The SmartBob AO is a remote sensor for on-demand level measurements. It measures the vertical
distance between the sensor and the surface of product in a tank or silo. During a measurement,
the SmartBob AO lowers a weighted probe and measures the distance by counting pulses from an
internal encoder. When the SmartBob AO detects a lack of encoder pulses (detection of product),
it reverses direction and retracts the probe. The drop and retract encoder counts are compared to
determine the distance to product. The distance to product measurement is then used to update a
display and a 4-20 mA current transmitter. The display simply shows the measured drop distance
while the 4-20 mA output provides a scale of the measurement based upon user-entered calibration
points. There are also two user-congurable relays for level alarms, error and/or measurement indi-
cation. Measurements can be initiated by either the on-board interval timer or a dry contact closure
on the Start terminals. Another dry contact input (Override terminals) can be used for inhibiting a
measurement during the tank’s ll cycle.
INTRODUCTION

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SPECIFICATIONS
Power Requirements
115 VAC Model 110 to 120 VAC at 60 Hz
230 VAC Model 225 to 235 VAC at 50/60 Hz
Power Consumption 12 VA continuous, 140 VA intermittent
Operating Temperature -4 to 158°F (-20 to 70°C)
Displayed Accuracy 0.25% plus +/-0.01 ft/m
Displayed Resolution 0.01 ft/m
4-20 mA Current Output
Mode 1 (recommended) Isolated (3,750 Vrms surge), external power required
Mode 2 Non-isolated, SmartBob AO powers the loop
Max Loop Resistance (Mode 1) Depends on external power
Max Loop Resistance (Mode 2) 500 ohms
Accuracy 0.35%
Resolution 16 bits maximum
Relay Outputs 220 VDC/0.24A, 250 VAC/0.25A, 30 VDC/2A
Start Input Dry contact only, 50 ms minimum closure time to trigger
Override Input Dry contact only, normally closed
Enclosure Type 4X, 5, 12
Mounting 3” NPT oor ange
Conduit Entry 3/4” NPT
Weight 25 lb.
Height 14-3/4”
Width 15-3/4”
Depth 7-1/2”
Air Purge Entry 1/4” NPT
Cable 316 stainless steel, 0.063” diameter, nylon coated

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Location and Mounting
The SmartBob AO should be mounted on the top of the storage vessel using a 3-inch NPT
coupling and always in a vertical position. If a 3-inch NPT oor ange is used, it must be on a
at level surface to provide a vertical mount for the unit. For measuring dry solids which involve
an angle of repose, it is recommended that the unit be mounted 1/6th of the vessel diameter in
from the side, see gure below. Two mounting ange templates, for a standard 3-inch NPT oor
ange, are provided towards the end of the manual.
Connections and Wiring
All eld wiring should be installed according to local and/or national codes and have a tem-
perature rating of at least 85 ° C. All wiring and jumper conguration should be made with AC
power removed.
Power
A disconnecting means should be provided to safely remove AC power from the SmartBob
AO. Refer to the gure on the following page for connection of the power wiring. The AC
power connects to the 2-pole terminal block located on the motor mount bracket. The left
terminal should receive the line conductor and the right terminal should receive the neutral
conductor.
A good electrical ground must be connected to the ground screw just to the left of the AC
terminal block. This is required for safety, to bleed o󰀨 any static buildup and to provide surge
protection on the Override and Start inputs. It is recommended that the power cable be run in
metal conduit.

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Start Input
This input is used to initiate a measurement and should only be connected to a normally
open set of dry contacts, such as a relay or a push button switch. Momentarily closing
the contacts connected to these terminals will be detected as a start signal and initiate a
measurement. An unshielded two-conductor cable between 14 and 20 AWG will work
for a connection to this input.
Override Input
This input is used to prohibit measurements from occurring and should only be connected
to a normally closed set of dry contacts. Whenever the contacts connected to this input are
open, all measurement requests will be ignored, whether it’s the by the start input or the
on-board interval timer. If this feature is not needed, then the two terminals labeled OVER-
RIDE should be shorted together. These two terminals are shorted together at the factory.
An unshielded two-conductor cable between 14 and 20 AWG will work for a connection to
this input.

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4-20 mA Output
This output will provide a 4-20 mA output scale based on the user-set calibration points and the last
measurement. It will also provide a 22 mA signal following an error condition or when no measure-
ment has been taken. There are two modes available, which require the user to properly set jumpers
on the printed circuit board and to properly wire to the correct terminals. A 3-pole terminal block is
provided for this output; however, only two of the terminals are used at any one time depending
on the mode of use. An unshielded two-conductor cable between 14 and 20 AWG will work for a
connection to this input.
Mode 1 provides for electrical isolation up to 3,750 Vrms. In this mode, the SmartBob electronics are
isolated from the on-board 4-20 mA transmitter, the eld wiring and the receiver (PLC). This mode
does require that the DC loop power be provided externally or by the receiver (PLC).
To use Mode 1, rst power down the SmartBob and locate the 4-20 OUT terminal. Next, connect
the positive wire of the 4-20 loop wiring to the top terminal and the negative wire to the middle termi-
nal. Do NOT connect anything to the bottom terminal. If the cable being used has a shield, do NOT
connect it to anything at the SmartBob. Finally, locate jumpers J10 and J11 and move the shunts
on both to pins 2 and 3 (upper position). See diagram below.

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Mode 2 does not provide electrical isolation, but does provide the DC power for the loop. Be sure not
to provide external power when using this mode.
To use Mode 2, rst power down the SmartBob and locate the 4-20 OUT terminal block. Next, con-
nect the positive wire of the 4-20 loop wiring to the middle terminal and the negative wire to the bottom
terminal. Do NOT connect anything to the top terminal. If the cable being used has a shield, do NOT
connect it to anything at the SmartBob. Finally, locate jumpers J10 and J11 and move the shunts on
both to pins 1 and 2 (lower position). See diagram below.
Relay 1 and 2
There are two user-congurable, normally-open, relay outputs available for signaling a high-level alarm,
a low-level alarm, an error alarm or a measurement indication. When set for a level alarm, the relay
contacts will be closed when a measurement has exceeded a user-specied level. Once a measure-
ment is taken with results that no longer exceed the user-specied level, the relay contacts will open.
When set for an error alarm, the relay contacts will be closed when a measurement has resulted in an
error. When a measurement successfully occurs without error, the relay contacts will open. When set
for a measurement indication, the relay contacts will be closed during the measurement and then open
when completed. With each relay output there is an LED on the circuit board that will turn on when the
associated relay’s contacts are closed.

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There is a 2-pin terminal block available for connection to each relay output. These relays can switch
low current signals and are not meant to power motors or high-wattage light bulbs. Be sure to read
the voltage and current limitations in the Specication sections. An unshielded two-conductor cable
between 14 and 20 AWG will work for a connection to this input.
Wiring Diagram

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Air Purge System
Located on the lower right side of each SmartBob AO is a 1/4” NPT air tting. This tting can
be used to connect an external source of dry, clean air or noncombustible gas to the remote
housing. By adding pressure to the remote housing that is slightly greater than that in the vessel,
material and dust from the vessel is prevented from entering into the unit. The external pressure
should be one (1) psi greater than the ambient pressure in the storage vessel and should be free
from moisture and other contaminates.
User Interface
The user interface consists of a small 2-line LCD display and four keys labeled UP, DOWN,
MENU and CYCLE. All are located on the top portion of the circuit board inside the electrical side
of the SmartBob AO. Refer to the diagram below and familiarize yourself with the user interface
before continuing to the following sections, which explain how to use it.

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Run/Display Mode
When not in the setup menu, the display will provide measurement progress and last
measurement results.
The top line of the display will show status:
• Idle
• Dropping
• Retracting
• In Override
• Error
The bottom line of the display will show results of last measurement:
• Measurement distance in feet or meters
• No Results
• Stuck Top
• Stuck Bottom
Setup Menu
In order to operate the setup menu, the electrical side of the SmartBob AO must be opened.
After operating the setup menu, be sure to properly close and seal the SmartBob AO.
Press MENU to enter the setup menu. This is only accessible when not performing a
measurement or other motor driven operation. Once in the setup menu, measurements
and other motor operations will not occur.
Use UP/DN keys to change the displayed setting. Hold the key for repeated adjustments
with automatic rate change.
Press MENU to accept the current setting and advance to the next setting. If at the last set-
ting, pressing MENU will return to display/run mode.
If left in setup mode for 8 seconds without a key press, it will automatically return to run/dis-
play mode.
The settings available in the Setup Menu are as follows:
Measurement Interval – This is used to setup automatic re-occurring measurements.
The interval can range from 2 min to 99 hours 59 minutes. It can also be disabled and
is by default.
Measurement Units – This is for setting the units of measure that get displayed.
It can be feet or meters. The default is feet.

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4mA Drop Distance – This is for setting the drop distance associated with a 4 mA output.
It can range from 0.00 to 409.59 feet or 0.00 to 124.84 meters. The default is 60.00 feet.
20mA Drop Distance – This is for setting the drop distance associated with a 20 mA output.
It can range from 0.00 to 409.59 feet or 0.00 to 124.84 meters. The default is 0.00 feet.
Maximum Drop Distance – This is the maximum distance the SmartBob AO will allow the
bob to drop, which can range from 0.34 to 409.59 feet or 0.11 to 124.84 meters. The default
is 60.00 feet.
Output Relay 1 – Normally open relay output that can be set to any of the following:
• Disabled (default)
• High-Level Alarm Drop Distance – Can range from 0.00 to 409.59 feet
or 0.00 to 124.84 meters.
• Low-Level Alarm Drop Distance – Can range from 0.00 to 409.59 feet
or 0.00 to 124.84 meters.
• Error Alarm
• Measurement Indication
Output Relay 2 – Same as Output Relay 1.

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Calibrating the 4-20 mA Output
Considering the tank shown at right, if
you wanted 20 mA to indicate full and
4 mA to indicate empty, then set the
4 mA drop distance to 6.00 feet and
the 20 mA drop distance to 0.50 feet.
Any measurement of 6.0 feet or more
(empty) will drive the output to 4 mA,
any measurement of 0.5 feet or
less (full) will drive the output to
20 mA and any measurement in
between 0.5 and 6.0 feet will be
scaled. For example, a drop distance
of 3.25 feet would produce 12 mA
output (50% full).
It is also possible to reverse the
polarity, so that the full point would
provide 4 mA output and the empty
point would provide 20 mA output.
In this case, simply set the 4 mA drop
distance to 0.50 feet and the 20 mA
drop distance to 6.00 feet. Any mea-
surement of 6.0 feet or more (empty)
will drive the output to 20 mA, any
measurement of 0.5 or less (full) will
drive the output to 4 mA and any
measurement in between 0.5
and 6.0 feet will be scaled.
Motor Driven Operations
Press the CYCLE button to perform a test measurement cycle. The display, the 4-20 mA
output and the relays will not be updated based on the results of a test cycle.
Press and hold the DOWN button to lower the probe. It will stop when the key is released, when
it hits product or when the max drop limit is reached.
Press and hold the UP button to retract the probe. It will stop when the key is released or when
it is fully retracted.
Momentarily short the START terminals to initiate a measurement.

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Before Starting
Disconnect the power source. Remove
the at cover on the back of the remote
housing.
Cable Replacement
1. Remove the cable from the supply
pulley by pressing the “CYCLE”
button on the top of the PC board.
While keeping the cable taut, pull on
the cable as the cable spools o󰀨 the
pulley. When the line is all paid out,
the motor will reverse and try to
rewind the cable. Hold the cable tight
so it cannot rewind. The motor should
now be shut o󰀨. Discard old cable.
2. Attached to the end of the new
cable is a terminal crimp ring. Attach
this crimp ring to the supply pulley
ange as shown in the illustration.
3. To rewind onto the supply pulley
refer to the “Loading the Supply
Pulley”.
4. After loading the supply pulley
skip to “Threading the Cable”.
Kit Replacement
1. Loosen the 1/4" set screw located
on the hub of the supply pulley then
remove the supply pulley assembly.
2. Remove and discard the old
supply pulley and cable.
3. Assemble the new supply
pulley replacement kit.
4. Skip to “Threading the Cable”.
Threading the Cable
Thread the cable over the top of the idler arm
pulley, over the top of the front groove of the
idler pulley, under the timing pulley, then over
the top of the back groove of the idler pulley
as shown in the illustration. Then thread the
cable down through the brushes and threaded
mount assembly. Refer to the “SureDrop Cable
Release System” for attaching the SureDrop
assembly and weighted probe.
NOTE: At this point you should refer to the
attached manual instruction sheet “Limiting
Stainless Steel Cable”. Follow steps 2
through 6.
Cable Replacement Instructions

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SmartBob AO
Loading the Supply Pulley
1. Reconnect the power source.
2. If loading the supply pulley is necessary, pull the cable taut. Load supply pulley by pressing the
UP button located on the circuit board. Pressing this button will start the supply pulley turning in
a clockwise direction, with the cable winding over the top. Keep the cable taut until the pulley is
full. When the supply pulley is full, release the button.
3. Replace the cable wiper brushes and reattach the cover.

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Probe Options
B1 and B2
This stainless steel probe is designed for granular materials from 20 lb. per cubic foot and greater.
This probe is shipped standard with every SmartBob AO. A 416 SS magnetic version is order
code B2.
B3
This probe is a hollow inverted 4-inch cone made of stainless steel and is designed for bulk
products with a density from 5 lb. to 20 lb. per cubic foot. This probe should not be used in liquids.
B4
This probe is a hollow inverted 6-inch cone made of stainless steel and is designed for bulk
products with a density from 1.5 lb. to 20 lb. per cubic foot. This probe may also be used in
liquid applications.

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B5 and B6
This probe is designed for granular material with a density from 20 lbs. per cubic foot and greater.
This probe is a digestible bottle that is lled with 32 oz. of para󰀩n wax. The digestible bottle is
made from an engineering plastic which will not damage the material handling auger in the
unlikely event that the probe should become separated from the unit. Order code B6 is an
empty bottle option of this probe which is to be lled in the eld to a weight of about 32
ounces.
B9
This probe is a 6-inch stainless steel hollow sphere and is designed for use in liquids, slurries,
and for light powder applications.

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Limiting Stainless Steel Cable
It is important to limit the length of cable on the SmartBob
AO, so that the probe is not lowered into an airlock, screw
conveyor, or any other area that the probe might become
trapped in. The SmartBob AO is shipped with 90 feet of cable
unless otherwise specied. Disregard these instructions if the
unit was ordered with the exact amount of cable necessary
for your vessel. This procedure for limiting the cable should
be done before the unit is installed.
1. Remove the cable from the supply pulley by pressing the
CYCLE button on the printed circuit board. Keeping the
cable taut, pull on the cable as the cable spools o󰀨 the
pulley. When the line is all paid out, the motor will reverse
and try to rewind the cable. Hold the cable tight so it
cannot rewind. The motor should now be shut o󰀨.
2. From the throat or pipe extension of the SmartBob AO,
measure the height of your vessel or the maximum
distance you want the probe to travel into your vessel
then add 48” to that length.
3. Cut the stainless steel cable at this distance (vessel
height + 48”).
4. Refer to “SureDrop Cable Release System” assembly
instructions in this manual.
5. Thread the stainless steel cable through the SureDrop,
thimble and probe as shown.
6. Tighten and crimp the noose around the thimble.
Locate and crimp the round crimp as shown.
7. Test crimp by pulling on the cable and probe.
8. Rewind the cable onto the supply pulley or lower the
cable and probe into the vessel. To rewind onto the supply
pulley: Pull the cable taut. Load the supply by pressing
and holding the UP button located on the circuit board.
Pressing this button will start the supply pulley turning in a
clockwise direction, with the cable winding over the top.

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SmartBob AO
SMARTBOB REMOTE MOUNTING TEMPLATE
5 inch oor ange
Mounting Options
Standard Flange Mount High Temperature Mount