Milltronics EnviroRanger ERS500 User manual

33456010
Rev. 1.3
ENVIRORANGER ERS 500
INSTALLATION GUIDE
Instruction Manual PL-601 January 2001
ENVIRORANGER ERS 500

© Siemens Milltronics Process Instruments Inc. 2001
Safety Guidelines
Warning notices must be observed to ensure personal safety as well as that of others, and to
protect the product and the connected equipment. These warning notices are accompanied
by a clarification of the level of caution to be observed.
Qualified Personnel
This device/system may only be set up and operated in conjunction with this manual.
Qualified personnel are only authorized to install and operate this equipment in accordance
with established safety practices and standards.
Warning: This product can only function properly and safely if it is correctly transported,
stored, installed, set up, operated, and maintained.
Note: Always use product in accordance with specifications.
Copyright Siemens Milltronics Process
Instruments Inc. 2000. All Rights Reserved Disclaimer of Liability
This document isavailable inbound version and in
electronic version. We encourage users to
purchase authorized bound manuals, or to view
electronic versions as designed and authored by
Siemens Milltronics Process Instruments Inc.
Siemens Milltronics Process Instruments Inc. will
not be responsible for the contents of partial or
whole reproductions of either bound or electronic
versions.
While we have verified the contents of
this manual for agreement with the
instrumentation described, variations
remain possible. Thus we cannot
guarantee full agreement. The
contents of this manual are regularly
reviewed and corrections are included
in subsequent editions. We welcome
all suggestions for improvement.
Technical data subject to change.
MILLTRONICS®is a registered trademark of Siemens Milltronics Process Instruments Inc.
Contact SMPITechnical Publications at the following address:
Technical Publications
Siemens Milltronics Process Instruments Inc.
1954 Technology Drive, P.O. Box 4225
Peterborough, Ontario, Canada, K9J 7B1
Email: [e-mail]
For the library of SMPI instruction manuals, visit our Web site: www.milltronics.com

PL-601 EnviroRanger Installation Guide Page 3
Table of Contents
Specifications..........................................................................................5
About the EnviroRanger ERS 500…........................................................9
About the Installation Guide….............................................................9
About ymbols…..............................................................................10
About Configuring ER 500 Parameters............................................10
About Power Interruptions….............................................................10
Installation.............................................................................................11
Mounting Considerations ..................................................................11
Mounting..........................................................................................13
Installing the Battery.........................................................................18
Installing Optional Cards...................................................................19
Wiring.................................................................................................... 2
ystem Diagram...............................................................................23
Terminal Board.................................................................................24
Cables..............................................................................................25
Transducers.....................................................................................25
Relays..............................................................................................26
Temperature ensor.........................................................................26
mA Input...........................................................................................27
Level ystem ynchronization...........................................................27
Power...............................................................................................28
Optional Card Wiring.........................................................................29
Digital Communications....................................................................32
Maintenance .......................................................................................... 8
Battery Replacement........................................................................38
oftware Upgrades...........................................................................38
Index...................................................................................................... 9

Page 4 EnviroRanger Installation Guide PL-601

PL-601 EnviroRanger Installation Guide Page 5
Specifications
Specifications
Power
AC version:
• 100-230 Vac ± 15%, 50 / 60 Hz, 36 VA (17W)1
• fuse: F3: 2 AG, low Blow, 0.375A, 250V
DC version:
• 12-30 Vdc, 20W1
• fuse: F3: 2 AG, low Blow, 3A, 250V
Transmitter fuse:
• F1: Belling Lee, L754, 4000A HRC, ceramic type, 100mA, 250V
Temperature Sensor fuse:
• F2: Belling Lee, L754, 4000A HRC, ceramic type, 50mA, 250V
Environmental - Rack or Panel Mount
Location:
• indoor
Altitu e:
• 2000 m max.
Ambient temperature:
• -20 to 50°C (-5 to 122°F)
Relative humi ity:
• 80% for temperatures up to 50°C (122°F)
Installation category:
• II
Pollution egree:
• 2
Environmental - Wall Mount
Location:
• indoor / outdoor
Altitu e:
• 2000 m max.
Ambient temperature:
• -20 to 50°C (-5 to 122°F)
Relative humi ity:
• suitable for outdoors
Installation category:
• II
Pollution egree:
• 4
Range
• 0.3 m (1 ft) to 15 m (50 ft) dependent on transducer
Accuracy
• 0.25% of maximum range or 6 mm (0.24”) whichever is greater
1 Power consumption is listed at maximum. The power consumption is considerably
lower if no load is placed on the EnviroRanger’s 24V rails which are used to power
discrete interlocks on passive devices.

Page 6 EnviroRanger Installation Guide PL-601
Specifications
Resolution
• 0.1% of program range2 or 2 mm (0.08”), whichever is greater
Memory
• 1024 KB static RAM with battery backup
• 1MB flash EPROM
Programming
Primary:
• PC running Dolphin Plus software
Secon ary:
• hand held programmer
Display
• back lit LCD
Temperature Compensation
Range:
• -50 to 150°C (-58 to 302°F)
Source:
• integral transducer sensor
• T -3 temperature sensor
• programmable fixed temperature
Temperature Error
Sensor:
• 0.09% of range
Fixe :
• 0.17% per °C deviation from programmed value
Outputs
Trans ucer rive:
• 315 V peak
Relays3:
• 4 control / 1 alarm relay
• all relays rated 4 A at 250 V ac, non-inductive
Control Relays:
• 4 form “A”, NO relays (number 1-4)
Alarm Relay
Rack or panel mount:
• 1 form “B”, NC relay (number 5)
Wall mount:
• 1 form “C”, NO or NC relay (number 5)
Communication:
• R -232 running Milltronics Dolphin protocol
• R -232 running Modbus RTU and A CII
Optional:
• martLinx® compatible
• R -485
2 Program range is defined as the empty distance from the face of the transducer
(P006) plus any range extension (P801).
3 All relays are certified only for use with equipment that fails in a state at or under the
rated maximums of the relays.

PL-601 EnviroRanger Installation Guide Page 7
Specifications
Inputs
mA (analog) (1):
• 0-20 or 4-20 mA, from alternate device, scaleable
Discrete (8):
• 10-50 V dc switching level
• logical 0 = < 0.5 V dc
• logical 1 = 10 to 50 V dc
• 3 mA max. draw
Frequency (2)4:
• 1-20,000 Hz
Counter (2)4:
• 5 msec minimum pulse width
Enclosure
Rack mount:
• DIN 3U/21HP, 4 rail plug in unit
• suitable for standard 3U/84HP (19”) sub rack
Panel mount:
• suitable for DIN 43700 72 x 144 standard panel cut-out on 110mm
(4.33“) centres
Wall mount:
• 224mm W x 285mm H x 102mm D (8.8” W x 11.2” H x 4.0” D)
• Type 4X / NEMA 4X / IP 65
• Polycarbonate
Weight
Rack or Panel mount:
• 1.5 kg (3.3lbs)
Wall mount:
• 2.5 kg (5.5lbs)
Approvals
• ee product nameplate
Compatible Trans ucers
• Echomax series and TH series
Trans ucers
Base:
• second transducer can only be used for average differential
Option:
• dual point (44 kHz)
4 Discrete inputs 7 and 8 can be configured as frequency inputs, pulse counters, or
simple discrete inputs.

Page 8 EnviroRanger Installation Guide PL-601
Specifications

PL-601 EnviroRanger Installation Guide Page 9
Introduction
About the EnviroRanger ERS 500…
The EnviroRanger is intended for advanced water and wastewater
applications. This device can handle virtually all of your pump control and
level monitoring needs – often replacing expensive PLCs and integrating into
a CADA system for a fraction of the cost of competitive systems.
The EnviroRanger is programmable.
It can be configured for nearly any water or wastewater application, control
up to five pumps, gates, or alarms – and can communicate its status by way
of direct serial connection, modem, or industrial communication network.
The EnviroRanger is flexible.
It can take discrete input from pumps or other devices to modify its
operation, and ca`n also time events to maximize efficiency or minimize cost.
The EnviroRanger is upgra eable.
Its basic features can be further enhanced with any of the following:
Har ware Upgra es
• I/O Analog Cards
• RAM memory
• Discrete inputs
Software Upgra es
• Dual Point
• Data Logging
About the Installation Gui e…
This is the second in the series of four manuals in the ER library.
Manual Uses
User Gui e
(PL-600)
• Learn how to program the unit
• Example applications
• Principles of operation
Installation Gui e
(PL-601)
• Outline diagrams
• Wiring diagrams
• nstallation requirements
Communications Reference
(PL-602)
• MODBUS register mapping
• Modem configuration
Parameter Reference
(PL-603)
• Parameter values
• Parameter uses

Page 10 EnviroRanger Installation Guide PL-601
Introduction
Note:
The ER 500 is to be used only in the manner outlined in this Installation
Guide or protection provided by the equipment may be impaired.
About Symbols…
The following symbols are used in the EnviroRanger manuals:
Symbol Meaning
alternating current
direct current
earth (ground) terminal
protective conductor terminal
caution (refer to instructions)
program button on front of instrument
infra-red communication port on front of instrument
RJ-11 communications port
no co-axial cable connections
About Configuring ERS 500 Parameters
The primary method of configuring the EnviroRanger is using Milltronics
Dolphin Plus software and a serial connection to the device.
Configuring the EnviroRanger using the optional Hand Programmer is
possible but is not recommended for complex installations.
As a rule of thumb, if your application falls into one of the pre-configured
applications outlined in the EnviroRanger User Guide, then use the hand
programmer. If your application is more complex than this, then we suggest
that you use Dolphin Plus. To purchase a copy of Dolphin Plus, contact your
Milltronics representative.
About Power Interruptions…
All operator programming is stored in non-volatile memory, and is unaffected
by power interruptions. Reporting functions use volatile RAM with battery
backup.

PL-601 EnviroRanger Installation Guide Page 11
Installation
Installation
Notes:
• Installation must only be performed by qualified personnel, and in
accordance with local governing regulations.
• This product is susceptible to electrostatic shock. Follow proper
grounding procedures
All field wiring must have insulation suitable for at least 250 V.
Hazardous voltage present on transducer terminals during
operation.
DC terminals shall be supplied from an SELV source in
accordance with IEC 1010-1 Annex H.
• Relay contact terminals are for use with equipment that has no
accessible live parts and wiring that has insulation suitable for at least
250 V. The maximum allowable working voltage between adjacent
relay contacts shall be 250 V.
• The non-metallic enclosure does not provide grounding between
conduit connections. Use grounding type bushings and jumpers.
Mounting Consi erations
The i eal location to mount the EnviroRanger is as follows:
• Ambient temperature is always within -20 to 50°C (-5 to 122°F)
• EnviroRanger display window is at eye level, unless most interaction is
through a CADA system
• Cable length requirements are minimal
• Mounting surface is free from vibration
Avoi locations where the EnviroRanger is:
• Exposed to direct sunlight. (Provide a sun shield to avoid direct sunlight).
• Close to high voltage/current runs, contacts, CR or variable frequency
motor speed controllers
Laptop Access
RS-232 Connections
When mounting the EnviroRanger, it is a good idea to provide a place for a
laptop computer. When linked to the EnviroRanger’s RJ-11 port via an R -
232 connection, the laptop becomes an excellent configuration and
diagnosis tool.

Page 12 EnviroRanger Installation Guide PL-601
Installation
This RJ-11 port is located inside the enclosure of the Wall mount version,
and on the face of the rack and panel units (see below).
In addition, all EnviroRanger units have R -232 connections on the
terminal board so they can be permanently wired to modems for remote
access, or telephone jacks for easy local access. ee Optional Card Wiring
on page 29 for information on how to wire a permanent communications
connection to the EnviroRanger terminal board.
RS-485 Connections
R -485 ports are available on optional I/O cards. ee Optional Card Wiring
on page 29 for wiring of the R 485.
Hand Programmer Access
If a laptop is not used to configure the EnviroRanger then ensure there is
enough room in front of the unit to stand with a hand programmer. The
hand held programmer is aimed at the receiver as shown below.
If values from the hand programmer are not accepted, (display does not
respond), try repositioning it. For the rack and panel mounted versions,
ensure that the program button is pressed and the unit is in program mode.
RJ-11 Port

PL-601 EnviroRanger Installation Guide Page 13
Installation
Mounting
Notes:
• Rack and rails are supplied by the customer.
• Terminal board screws are supplied by the customer.
• Metallic racks must be grounded.
Rack Mount
1. Install rails at positions 5 and 15 as in diagram below.
Note:
Positions are in relation to left end of rack. Adjust measurements
accordingly if the unit is to be installed elsewhere along the rails.
21 HP
3U
18mm
0.71” 176mm
6.91”

Page 14 EnviroRanger Installation Guide PL-601
Installation
2. Test the fit of the EnviroRanger to ensure the rails are aligned correctly by
sliding the EnviroRanger unit in and then out again.
3. Mount the terminal board on the inside rails of the rack, with mounting
screws at positions 6, 10, and 16.
4. lide the EnviroRanger into the rack and press fit it with the rail mounted
terminal board.
5. Tighten the four mounting screws on the faceplate.
6. Wire the unit from the back according to the Rack or Panel Mount wiring
diagrams on page 24 of this manual.
unit connector
terminal board
(Milltronics supplied)
to be mounted on
the inside of the
rear rack rails.
6
10
16
3U/84HP (19”) sub-rack
EnviroRanger rack
mount (DIN 3U/21HP)
blanking panels must
cover all unused slots
I/O card di
g
ital analo
g

PL-601 EnviroRanger Installation Guide Page 15
Installation
Panel Mount
1. Unlatch the retaining clips and remove the terminal board from the unit.
72mm
2.8”
144mm
5.7”
152mm
6.0”
11mm
0.4”
195mm
7.7”
mounting bracket hand tighten
(1 in. lb. torque max)
104mm
4.1”
terminal board extends
beyond panel faceplate
clampin
g
screw
terminal board
(Milltronics supplied)
Ensure wiring is
externally supported
retainin
g
clip for terminal board
faceplate
rear

Page 16 EnviroRanger Installation Guide PL-601
Installation
2. lide the EnviroRanger through the panel cut-out.
3. Assemble mounting brackets to the EnviroRanger chassis by hooking them
into the top and bottom (bottom first).
4. Tighten the mounting bracket clamping screw (top & bottom).
5. Wire terminal board as per the Rack or Panel Mount wiring on page 24.
mountin
g
bracket, hand ti
g
hten to
(1 in. lb. torque max)
panel cut out:
68 +0.7 by 138 +1.0 mm
(2.68 +0.03 by 5.43 +0.04 in.)
on 110mm (4.33”) centres
DIN 4370
0
72 x 14
4
panel material
68+0.7mm
(2.68+0.03”)
41mm minimum
(1.6”)
138+1.0mm
(5.43+0.04”)

PL-601 EnviroRanger Installation Guide Page 17
Installation
6. Press fit the terminal board to the EnviroRanger. To ensure that the pressure
on the rear of the unit is minimized, provide external support for the wires.
Wall Mount
Notes:
• We recommend mounting the unit on ¾” plywood using #6 screws.
• If another mounting surface is used, it MU T be able to support four
times the weight of the unit.
1. Mark and drill holes for the four mounting screws (customer supplied), and
mount the enclosure using a long screwdriver.
If your cable is route through a con uit:
2. Unplug the display ribbon cable from the motherboard.
3. Remove the four mounting screws holding the motherboard to the enclosure.
4. Be careful not to damage the electronics with static electricity. Remove the
motherboard from the enclosure by pulling the board straight out and tilting it
with the right side higher to clear the ferrite assembly.
5. Drill any required cable entry holes.
6. Attach the conduit to the enclosure using approved Conduit Entrance Hubs.
7. Reinstall the motherboard with the mounting screws and attach ribbon cable.
209mm
(8.2”)
172mm
(6.8”)
15mm
(0.6”)
267mm
(10.5”) 285mm
(11.2”)
102mm
(4.0”)
mounting holes
(4 places)
28mm
(1.1”)

Page 18 EnviroRanger Installation Guide PL-601
Installation
If your cable is expose an enters through the supplie cable glan s:
2. Unscrew the glands and attach them loosely to the enclosure.
3. Thread the cables through the glands, ensure the power cable is kept
separated from the signal cables.
4. Wire the cables to the terminal blocks.
5. Tighten the glands to form a good seal.
6. If you require more holes than are supplied in the enclosure, follow the
previous steps under conduit.
Installing the Battery
The battery (Rayovac BR2032) has a life expectancy of ten years, and is
affected by ambient temperature. In the event that the unit loses external
and battery power, a capacitor will power the RAM for about 10 minutes.
The flash memory is updated every hour. Therefore, up to an hour of data
logging can be lost if all of the following conditions happen:
• the external power fails
• the battery is not supplying power
• the time it takes to restore power to the EnviroRanger is greater than the
time the capacitor can supply power.
Notes:
• Do not install the memory backup battery until the EnviroRanger is
installed, as it begins operation immediately.
• The unit is supplied with one battery. Insert the battery into the holder
as shown in the following diagrams before using the EnviroRanger.
Disconnect power before installing or replacing the battery.
Wall Mount
1. Open the enclosure lid.
2. lide the battery into the holder
being careful to align the + and –
terminals (sides) correctly.
3. Close and secure the enclosure
lid.
batter
y

PL-601 EnviroRanger Installation Guide Page 19
Installation
Rack or Panel Mount
1. Remove the plastic side shield.
2. lide the battery into the holder
being careful to align the + and –
terminals (sides) correctly.
3. Replace the plastic side shield.
Installing Optional Car s
The following optional cards can be ordered from Milltronics:
SmartLinx mo ule
Used to enhance the existing EnviroRanger Communications ystem.
Expansion Memory Car
Used in conjunction with the EnviroRanger’s Optional Data Logging Feature.
Analog Input / Output car s:
• mA Output Card
This card has 4 mA Outputs.
• mA Input /Output Card
This card has 2 mA inputs, and 2 mA outputs.
• mA Input card
This card has 4 mA Inputs.
• Discrete Input card
This card has 8 discrete inputs.
• Discrete Input, mA Input / Output Card (Wall Mount unit only)
This card has 8 discrete inputs, 2 mA inputs, and 2 mA outputs.
Warning:
Before installing cards, ensure that power is off.
batter
y

Page 20 EnviroRanger Installation Guide PL-601
Installation
nstalling Optional Cards in Rack or Panel Units
wire the communications cable to the
martLinx terminal block (65 – 73)
mountin
g
posts
female connector
and
(used to install an
optional martLinx
card)
batter
y
male connector
(used to install
expansion memory
card)
male connector
(used to install
optional I/O cards)