Milltronics AiRanger SPL PL-573 User manual

AIRANGER SPL
Instruction Manual PL-573 March 2001
AIRANGER SPL
33455730
Rev. 1.2

© 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 is available in bound 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 SMPI Technical 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: techpub[email protected]om
For the library of SMPI instruction manuals, visit our Web site: www.milltronics.com

PL-573 AiRanger SPL Page 3
Table of Contents
Specifications.............................................................................................................5
Electronics.......................................................................................................5
Programmer ....................................................................................................6
Transducer......................................................................................................6
Options............................................................................................................6
Cable...............................................................................................................7
Introduction ................................................................................................................9
About this Manual............................................................................................9
About the AiRanger SPL...............................................................................10
Important AiRanger SPL Features................................................................13
Installation ................................................................................................................15
AiRanger SPL................................................................................................15
Mounting........................................................................................................16
Interconnection..............................................................................................17
Optional Smartlinx®Module...........................................................................18
System Diagram............................................................................................18
Communication .............................................................................................20
SmartLinx®.....................................................................................................21
Level System Synchronization......................................................................22
Power............................................................................................................22
Programming............................................................................................................25
Display...........................................................................................................25
Keypad..........................................................................................................26
Program Mode Entry.....................................................................................27
Parameter Value Alteration...........................................................................27
Parameter Reset Features............................................................................27
Special Parameters.......................................................................................28
Programming Security...................................................................................28
Quick Start Parameters ...........................................................................................29
Operation ..................................................................................................................31
Display...........................................................................................................31
Keypad..........................................................................................................32
System Performance Evaluation...................................................................33
Performance Test Results.............................................................................34
Application Parameters...........................................................................................35
Volume Parameters (P050 to P055) .............................................................35
Failsafe Parameters (P070 to P072).............................................................39
Relay Parameters (P100 to P104, P110 to P113, P129)..............................41
mA Output Parameters (P200 to P203, P210 to P215, P219)......................48
Enhancement Parameters.......................................................................................51
Data Logging Parameters (P300 and P302).................................................52
Profile Records (P330 to P337).....................................................................53
Installation Records (P340 to P342)..............................................................56
Range Calibration Parameters (P650 to P654).............................................56
Temperature Compensation Parameters (P660 to P664).............................59
Rate Parameters (P700 to P707)..................................................................60
Measurement Verification Parameters (P710 to P713).................................62

Page 4 AiRanger SPL PL-573
Scanning Parameters (P725 to P729) ..........................................................64
Display Parameters (P730 to P733, P740) ...................................................65
Peripheral Communication Support Parameters (P740 to P749).....................67
SmartLinx®Parameters (P750 to P792).......................................................68
Echo Processing Parameters (P800 to P807) ..............................................69
Advanced Echo Processing (P810,P816-P825,P830-P835,P840-P845,P850-
P852).............................................................................................................72
Test Parameters (P900 to P913)...................................................................80
Measurement Parameters (P920 to P923)....................................................83
Master Reset (P999).....................................................................................85
Technical Reference ................................................................................................87
Transmit Pulse ..............................................................................................87
Echo Processing ...........................................................................................87
Distance Calculation......................................................................................88
Sound Velocity ..............................................................................................88
Volume Calculation .......................................................................................89
Measurement Response...............................................................................90
Application Examples....................................................................................91
Communication Support................................................................................98
Maintenance ...........................................................................................................101
Troubleshooting Guide..........................................................................................103
Measurement Difficulties.............................................................................104
Flashing “LOE” Display ...............................................................................104
Fixed Reading.............................................................................................105
Wrong Reading ...........................................................................................106
Programming Charts .............................................................................................109

PL-573 AiRanger SPL Page 5
Specifications
Specifications
Electronics
Power: ac: 100/115/200/230 V ac ±15%, 50/60 Hz, 31 VA
Environmental: location indoor / outdoor
altitude 2000 m max
ambient temperature –20 to 50°C (–5 to 122 °F)
relative humidity suitable for outdoor (Type 4X / NEMA 4X / IP65
enclosure)
installation category II
pollution degree: 4
Scan Points: 1 point per AiRanger SPL max.
frequency independent
Range: Level Measurement: 0.3 m (1 ft) to 60 m (200 ft) max.
Accuracy: 0.25% of range or 6 mm (0.24"), whichever is greater
Resolution: 0.1% of program range*or 2 mm (0.08"), whichever is greater
Memory: EEPROM (non-volatile) no back-up battery required
Programming: via removable programmer or optional Dolphin Plus
Display: Custom Graphics backlit LCD with 51 mm (2 in) x 127 mm (5 in) viewing
area
Temperature Compensation:
–50 to 150 °C (–58 to 302 °F)
integral transducer sensor
TS-3 temperature sensor
programmable fixed temperature
Temperature Error: with compensation: 0.09% of range
fixed temperature: 0.17% / °C deviation from programmed temperature.
Outputs: transducer drive: 150 to 315 V peak (transducer model dependent)
relays: 4 alarm/control relays
1 form "C" SPDT contact per relay,
rated 5 A at 250 V ac, non-inductive
analog: 1 output max.
0.1% resolution
0-20 or 4-20 mA, scalable
750 Ω, isolated, 30V rms
*program range is defined as the empty distance to the face of the transducer
(P006) plus any range extension (P801).

Page 6 AiRanger SPL PL-573
Specifications
Communications: SmartLinx®compatible
(see Options) RS-232 / 485 port
Dolphin compatible
proprietary bipolar current loop for BIC-2 communication
Enclosure: Type 4X / NEMA 4X / IP65
285 mm W x 209 mm H x 92 mm D (11.2" W x 8.2" H x 3.6" D)
polycarbonate
Weight: 2.7 kg (6 lb)
Approvals: See device nameplate.
Programmer
Power: 9 V (ANSI/NEDA 1604, PP3 or equivalent)
Ambient Temperature: –20 to 50°C (–5 to 122°F)
Keypad: 20 keys with tactile feedback
Interface: non-invasive, digital, infra-red
Enclosure: general purpose
67 mm W x 100 mm H x 25 mm D (2.6" W x 4" H x 1" D)
ABS plastic
Weight: 150 g (0.3 lb)
Transducer
Compatible Models: ST Ultrason®, LR, STH and Echomax®series
Refer to the associated instruction manual.
Options
Temperature Sensor: TS-3
Buffered Interface Converter:
BIC-II, SPL bipolar communication current loop to remote RS232 or RS422
port
SmartLinx®Modules
protocol specific modules for interface with popular industrial communication
systems. Refer to associated product documentation.
Dolphin Plus:
Milltronics Windows®-compatible interface and infrared ComVerter link
Refer to associated product documentation.

PL-573 AiRanger SPL Page 7
Specifications
Cable
Transducer: RG-62 A/U (or equivalent), 365m (1,200 ft) max.
See transducer instructions for short extensions
(in grounded metal conduit, separate from other wiring)
mA Output: Belden 8760, shielded / twisted pair, 18 AWG (0.75 mm
2
) or equivalent
maximum separation 1,500 m (5,000 ft)
Synchronisation: Belden 8760, shielded / twisted pair, 18 AWG (0.75 mm
2
) or equivalent
Relays: No shielded cable necessary
Bipolar current loop: Belden 8760, shielded / twisted pair, 18 AWG (0.75 mm
2
) or equivalent
maximum separation 1,500 m (5,000 ft)
Temperature Sensor: Belden 8760 shielded / twisted pair, 18 AWG (0.75 mm
2
) or equivalent
365 m (1200 ft) per TS-3 maximum
RJ11 Link: No shielded cable necessary
maximum length 3 m (10 ft)
RS-232 Link: Belden 8770, 3 conductor/shielded, 18 AWG (0.75mm
2
) or equivalent
maximum separation 15m (50ft)
RS-485 Link: Belden 8770, 3 conductor/shielded, 18 AWG (0.75mm
2
) or equivalent
maximum separation 1200m (4000ft)
Smartlinx
®
module: refer to the associated instruction manual.

Page 8 AiRanger SPL PL-573
Specifications

PL-573 AiRanger SPL Page 9
Introduction
Introduction
About this Manual
This instruction manual provides information specific to the AiRanger SPL (Single
Point Level) monitor.
When references are made to other Milltronics products associated with an AiRanger
SPL based level measurement system, refer to the associated product instruction
manuals, if necessary.
After reading this Introduction and completing the physical Installation, first time
system installers may wish to use the AiRanger SPL Quick Start Guide, PL-431 for
step by step start up instructions.
Specifications lists the environmental, physical, and operational
characteristics associated with the SPL.
Introduction introduces installers and operators to the SPL, with brief
descriptions of key features.
Installation provides a step by step procedure to install and
interconnect a SPL based level measurement system.
Programming defines program mode display and keypad functions,
and general programming information.
Quick Start Parameters details the minimum recommended programming
required to prepare the SPL for RUN mode operation.
Operation defines RUN mode display and keypad functions,
including the RUN mode entry procedure and
performance evaluation recommendations.
Application Parameters details the programmable features which may be used to
alter Run mode display, failsafe, relay, and mA output
operation.
Enhancement Parameters defines the programmable features used to enhance
RUN mode operation. (Typically used as directed by the
Troubleshooting Guide).
Technical Reference provides detailed information for complex features and
details 2 specific application examples.
Troubleshooting Guide provides a quick reference to installation modification
and programming remedies to overcome challenging
operating conditions.
Programming Chart provides a convenient space to record all programming
for future reference.
REMEMBER!
"Programming is not complete until the Programming Chart is completed".

Page 10 AiRanger SPL PL-573
Introduction
About the AiRanger SPL
Note:
The AiRanger SPL is to be used only in the manner outlined in this instruction
manual.
This microprocessor based level monitor is designed specifically for bulk solids and
liquid level measurement applications. A SPL level monitor, utilizing a single
Milltronics ultrasonic transducer (ordered separately), accurately monitors vessel
material level without material contact.
The
SPL transmits electronic pulses to the ultrasonic transducer. The transducer
converts the electronic pulses to ultrasonic pulses which are emitted from the
transducer face in a narrow beam. The SPL measures the time from the pulse
emission, to receiving the reflection (echo) from the material. Using the time
measured, the SPL calculates the distance from the transducer face to the material.
The distance calculation is dependent upon the sound velocity within the vessel.
When a Milltronics ultrasonic/temperature transducer is used, variable air
temperatures are automatically compensated. For superior air temperature
compensation, a Milltronics TS-3 temperature sensor may be used. A simple
calibration feature compensates for
homogeneous (consistent composition)
atmospheres other than air.
The SPL is capable of monitoring wheat in 60 m (200 ft) high silo's, acetone in 45
gallon barrels, or almost anything in between.
This material and measurement range versatility is accomplished by utilizing
Milltronics patented Sonic IntelligenceTM. Sonic Intelligence provides high
measurement reliability, regardless of changing conditions within the vessel
monitored.

PL-573 AiRanger SPL Page 11
Introduction
By utilizing ultrasonic echo ranging principles with Sonic Intelligence and velocity
compensation, the SPL provides outstanding measurement accuracy, usually within
0.25% of range.
The distance calculation may be converted to space, material level, material volume,
or remaining vessel capacity. The Reading chosen (and operating data) is displayed
on the
Liquid Crystal Display (LCD).
The relays and mA output may be used as preset (or programmed as desired) to
activate alarms and/or operate remote monitoring equipment and/or process control
equipment.
As well, the SPL may be connected to a Milltronics BIC-II (Buffered Interface
Converter) to provide RS-232C and/or RS-422 communications for host computers,
Distributed Control Systems, and
special (capable of operating as a host device)
Programmable Logic Controllers.
With the addition of a Milltronics Smartlinx®protocol specific ‘plug-in’ communications
module, the SPL is compatible with popular industrial control system standards.
Programming can be done locally using the portable programmer keypad, or
remotely through optional Dolphin Plus software or SmartLinx®.
or
0/4—20mA
(PLC or DCS)
SmartLinx®
RS-232 or 485
(local)
bipolar
current loop
(remote)
RS-232 or 422
or
plant-wide
control system
network

Page 12 AiRanger SPL PL-573
Introduction
•The programmer transmits the keypad entries via infrared link to the SPL, and can be
removed when not in use.
•Dolphin allows programming either through the portable ComVerter and infrared link
or hardwired via the RS-232/485 communication port.
•SmartLinx®provides protocol specific hardware and software for interface with
popular industrial communication systems.
While the SPL is typically used to monitor material level in open or closed vessels,
any process which requires a distance measurement (within the system range) is a
candidate for SPL application.
Refer to Technical Reference / Application Examples for detailed descriptions of a
small sample of process measurement requirements to which the SPL may be
applied.
Throughout this manual (unless stated otherwise) references to material level also
apply to any material or object surface to be monitored by the SPL.

PL-573 AiRanger SPL Page 13
Introduction
Important AiRanger SPL Features
Fixed Features
Enclosure: Chemical resistant, light weight, dust tight, liquid tight,
easy to work with.
Backlit LCD: Large digits for Reading and programming value
displays.
Illuminated LCD insures readability under all lighting
conditions.
Custom Graphic Symbols for continuous indication of
operating conditions.
Programmer: 20 tactile feedback keys for easy access to programming
and operating functions.
Magnetic mounting and infrared interface permit removal
on programming completion.
Communications: SmartLinx®Compatible
Communications ready when equipped with an
appropriate Milltronics SmartLinx module.
Milltronics Peripherals
The communication port provides connection for RS-
232, RS-485 or Milltronics bipolar current loop. The
current loop provides remote communication via
Milltronics BIC II to the peripheral device. The BIC II
converts the current loop to RS-232 or RS-422
signal
Dolphin Compatible Communications
Dolphin Plus is Milltronics’ Windows95®-compatible
software. It offers local interface through the infrared
ComVerter, or remote connection through the RS-
232 or RS-485 port. The software provides an easy
means for programming, uploading, or downloading
parameters.
Speed: Fast 16/32 bit microprocessor at 16.7 MHz clock speed.
1 vessel (point) per second scanning speed capability.
Reliability: Surface Mount Technology (SMT), also provides for full
features in a compact design. Sonic IntelligenceTM
ensures all measurements are accurate and reliable.
Immune to power interruptions. All programming is
stored indefinitely. Dynamic operating data is retained
for one hour and updated immediately on power
resumption.

Page 14 AiRanger SPL PL-573
Introduction
Programmable Features
Typically, a very small percentage of the programmable features require operator
alteration. However, for demanding measurement requirements any operator
programmable feature may be adjusted as desired.
Following is a list of some of the features that make the SPL easy to program, yet
versatile enough to handle complex level measurement requirements.
General Features
Direct Access: Any operator programmable feature may be accessed
directly.
Scroll Access: Single button "scroll forward", single button "scroll back",
to key features.
Operation: Select "level", "space", "distance", "difference",
"average", or "tripper" operation.
Material: Liquid or Solid; automatically adjusts echo processing
with one entry.
Response: Slow, medium, fast, surge, or immediate response to
material level changes, one entry.
Units: Display Readings in m, cm, mm, ft, in, %, or any other
units desired.
Additional Features (use as desired)
Volume: 8 pre-programmed tank shape options.
2 universal tank shape programming methods
Failsafe: Numerous failsafe options for process control equipment
activation.
Relays: 8 functions including level, rate of change, pump control,
temperature and more.
Fixed or independent on/off setpoints
mA Output: Based on level, space, distance, or volume
4 range selections, 0-20, 4-20, 20-0, or 20-4 mA
Adjustable range and over-range limits

PL-573 AiRanger SPL Page 15
Installation
Installation
Note:
Installation shall only be performed by qualified personnel, and in
accordance with local governing regulations.
The following procedure applies to all SPL level monitor installations. See Application
Examples for additional installation requirements. Also, refer to the instruction
manuals of all other equipment connected to the SPL for additional installation
instructions.
AiRanger SPL
Location
Inspect all potential mounting locations. Choose a location suited to the SPL
polycarbonate enclosure and the following location recommendations.
The ideal SPL mounting location:
•is conformant to the units specifications
•provides clearance to swing open the front cover and perform the required wiring
connections
•provides access for viewing
•is vibration free
Avoid a location that is:
•exposed to continuous direct sunlight. (Otherwise, provide a sun shield.)
•close to high voltage or current runs, contactors, or SCR control drives
Cable/Conduit Entry Requirements
Determine the number of enclosure cable/conduit entries required for:
•Transducer
•TS-3 temperature sensor (if used)
•mA output (if used)
•Relays (if used)
•Synchronization (see Interconnection/Level System Synchronization)
•Power
•Communications: Smartlinx®, RS-485, RS-232, bipolar.
Note:
Transducer cable must be run in a grounded metal conduit, separate from other
wiring, (except TS-3 temperature sensor wiring, if applicable).

Page 16 AiRanger SPL PL-573
Installation
Mounting Inspect all cartons and packaging for possible damage during shipment, before
removing the SPL and associated equipment.
1. Loosen the 6 enclosure lid (captivated) screws and swing the lid open.
2. Remove the 4 Board B mounting screws (outer corners) and remove the circuit board
assembly.
3. Drill sufficient holes in the enclosure bottom to meet enclosure cable/conduit entry
requirements.
4. Attach the enclosure to the selected mounting surface. (4 predrilled screw holes provided.)
5. Attach the conduits/cable hubs to the enclosure. (Do not apply undue force.)
6. Reinstall the circuit board assembly.
Warnings:
•Non metallic enclosure does not provide grounding between
connections. Use grounding type bushings and jumpers.
•This product is susceptable to electrostatic shock. Follow proper
grounding procedures.
Transducer Mounting
Objects near the transducer face cannot be reliably detected. Mount the transducer
above the highest material level (away from the nearest monitored object) by the
following
Nearest Distance .
Nearest Distance Transducer Types
0.45m (1.5ft) XCT-8, XCT-12
0.3m(1 ft) ST-H, ST-25, XRS-5, XKS-6, XPS-10, XPS-15, ST-50
0.6m (2 ft) XPS-30, XPS-40
0.9m (3 ft) ST-100, LR-21, XLT-30, XLS-30
1.2m.(4 ft) LR-13
1.8m (6 ft) XLT-60, XLS-60
285 mm
(11.2”)
209 mm
(8.2”)
267 mm
(10.5”)
106 mm
(4.2”)
Suitable location for conduit entrances.
Use water tight conduit hubs to maintain the enclosure rating. mounting hole, 4.3 mm (0.17”)
diameter, access under lid
(4 places).
172 mm
(6.8”)
lid screw
(6 places)
programmer
lid
(hinged) customer
mounting screws

PL-573 AiRanger SPL Page 17
Installation
Interconnection
Before interconnecting system components to the SPL terminals, verify all
components have been installed in accordance with the associated product
instruction manuals.
Connect all associated equipment cable shields to the SPL shield connections. To
avoid differential ground potentials, do not connect cable shields to ground (earth)
elsewhere. Insulate (tape) cable shields at all shield junctions to prevent ground
loops.
Warnings:
•All field wiring must have insulation suitable for at least 250V.
•Hazardous voltage present on transducer terminals during operation
•Relay contact terminals are for use with equipment having no accessible
live parts and wiring having insulation suitable for at least 250V.
voltage
select
communication
mode LED
display scope
connections
optional
SmartLinx
module EPROM
board A
board B
terminal block

Page 18 AiRanger SPL PL-573
Installation
Optional Smartlinx®Module
The SPL is software/hardware ready to accept an optional Milltronics Smartlinx
communications module that provides an interface to one of several popular
industrial communications systems.
Your SPL may be shipped to you without a SmartLinx®module, for installation at a
later date.
If you are ready to install you SmartLinx®module, or want to change it, follow the
procedure as outlined on page 21.
System Diagram
Note:
Maximum system capability. Not all components or their maximum quantity may be
required.
AiRanger
SPL
fieldbus communication
point to point communication
Milltronics transducer
see Specifications
Milltronics temperature sensor
Milltronics BIC-2,
Dolphin, or customer
device
customer alarm, pump or
control device
industry control system
such as PLC or DCS,
SCADA, etc.
customer device
1
1
1
4
optional
SmartLinx®
mA output
relay output

PL-573 AiRanger SPL Page 19
Installation
Transducer
to transducer
Notes:
•Transducer cable must be run in a grounded
metal conduit separate from other wiring
(except TS-3 temperature sensor wiring, if
applicable).
•Hazardous voltage present on transducer
terminals during operation.
Temperature Sensor
to TS-3
Note:
Use TS-3 temperature sensors only. Don't jumper
the terminals if TS-3's are not used.
Relays
All relays are certified for use
in equipment where the short
circuit capacity of the circuits
in which they are connected is
limited by fuses having ratings
not exceeding the rating of the
relays.
Note:
Relays are shown in de-
energized state.
See Specifications for ratings. to customer’s equipment

Page 20 AiRanger SPL PL-573
Installation
mA Output
0/4-20mA isolated ouput to
750Ωmax
Communication
Notes
•The communication protocol is automatically detected by the SPL and shown
via LED on the motherboard.
•Ground shield at one end only.
Serial
RS-232 RS-485
to customer device,
RS-232 port
15m (50 ft) max
to customer device,
RS-485 port
1200m (4,000 ft) max