Milltronics airanger XPL plus User manual

AiRanger XPL Plus
Technology based. Customer driven.
October 1997
Instruction Manual
PL-532
33455320
Rev 2.2

hank you for purchasing Milltronics products. We endeavour to design
equipment that is simple to use and reliable in its operation, with the aim of
satisfying our customers' needs.
Milltronics has been designing and manufacturing process equipment since 1954.
Our fields of expertise include ultrasonic and capacitance level measurement ,
in-line weighing of dry bulk solids and motion sensing.
Milltronics is established world wide through associate offices and representatives.
Our network is continually being refined to provide our customers with first rate
sales information, engineering assistance and after sales support.
For more details on our products and service, please contact us and we will
provide you with a listing of the offices or representatives nearest you.
T

TABLE OF CONTENTS
TITLE PAGE #
About this Manual 5
About the AIRANGER XPL PLUS 6
Important AIRANGER XPL PLUS Features 8
Fixed Features 8
Programmable Features 8
AIRANGER XPL PLUS 11
Location 11
Cable/Conduit Entry Requirements 11
Mounting 12
Transducer Mounting 12
Optional Cards 13
Communications Module 13
TIB-9 Card 13
Interconnection 14
System Diagram 15
Transducer 16
Temperature Sensor 16
Peripherals 17
Level System Synchronization 17
Power 18
Display 19
Keypad 20
Program Mode Entry 21
Parameter Value Alteration 21
Parameter Reset Features 22
Special Parameters 22
Programming Security 22
Security Parameter 22
Operation 25
Material 25
Measurement Response 25
Transducer 26
Units 26
Empty 26
Span 26
Display 29
Keypad 30
System Performance Evaluation 31
Performance Test Results 32
INTRODUCTION
INSTALLATION
PROGRAMMING
QUICK START PARAMETERS
OPERATION
PL-532 3

Volume 33
Reading 35
Failsafe 37
Relay 39
mA Output 44
Data Logging 50
Profile Records 51
Installation Records 54
Range Calibration 55
Temperature Compensation 57
Rate 59
Measurement Verification 61
Scanning 63
Display 65
SmartLinx Parameters 67
Echo Processing 67
Advanced Echo Processing 70
Test Parameters 78
Measurement Parameters 80
Master Reset 82
Transmit Pulse 83
Echo Processing 83
Distance Calculation 84
Sound Velocity 84
Scanning 84
Volume Calculation 85
Measurement Response 86
Application Examples 86
Example 1 Level (Material Volume) 87
Example 2 Space (Remaining Capacity) 89
Example 3 mA Multi Point Average 91
Example 4 Distance 93
Application Assistance 94
BIC-II Support 95
Maintenance 97
Symptom-Cause-Action Chart 99
Measurement Difficulties 100
Flashing LOE Display 100
Fixed Reading 101
Wrong Reading 102
AiRanger XPL Plus 103
Programmer 104
Transducer 104
Options 104
PROGRAMMING CHART 107
01/25/99
APPLICATION PARAMETERS
ENHANCEMENT PARAMETERS
TECHNICAL REFERENCE
TROUBLESHOOTING GUIDE
SPECIFICATIONS
PL-532 4

INTRODUCTION
ABOUT THIS MANUAL
This instruction manual provides information specific to the AIRANGER XPL PLUS (Ten Point Level) monitor.
When references are made to other Milltronics products associated with an
AIRANGER XPL PLUS (XPL+)
based level measurement system, refer to the associated product instruction manuals, if necessary.
All initial start up information is included in the white pages of this instruction manual. Refer to the grey pages
for additional information or technical assistance, if required.
After reading this and completing the physical , first time system
installers may wish to use the
AIRANGER XPL PLUS Quick Start Guide, for step by step start up instructions.
INTRODUCTION introduces installers and operators to the XPL+, with brief
descriptions of key features.
INSTALLATION provides a step by step procedure to install and interconnect an
XPL+ 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 XPL+ 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 XPL+
display, failsafe, SAM-20 relay, and AO-10 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 4
specific application examples.
TROUBLESHOOTING GUIDE provides a quick reference to installation modification and
programming remedies to overcome challenging operating conditions.
SPECIFICATIONS lists the environmental, physical, and operational characteristics
associated with the XPL+.
PROGRAMMING CHARTS provides a convenient space to record all programming for future
reference. (May also be used as a complete Parameter index).
REMEMBER!
"Programming is not complete until the Programming Charts are completed".
INSTALLATIONINTRODUCTION
INTRODUCTION
PL-532 5

ABOUT THE AIRANGER XPL PLUS
The AirRanger XPL+ is to be used only in the manner outlined in this instruction manual.
The XPL+ is a microprocessor based level monitor designed specifically for bulk solids and liquid level
measurement applications. An XPL+ level monitor, utilizing a single Milltronics ultrasonic transducer,
accurately monitors vessel material level without material contact. By using an additional transducer for
each vessel, the XPL+ can monitor the material level in up to 10 vessels.
The XPL+ transmits electronic pulses to each scanned ultrasonic transducer. The transducer converts the
electronic pulses to ultrasonic pulses which are emitted from the transducer face in a narrow beam. The
XPL+ measures the time from the pulse emission, to receiving the reflection (echo) from the material. Using
the time measured, the XPL+ calculates the distance from the transducer face to the material.
The distance calculation is dependent upon the sound velocity within the vessel. When Milltronics
ultrasonic/temperature transducers are used, variable air temperatures are independently compensated for
each vessel. For superior air temperature compensation, a TIB-9 card may be used with individual Milltronics
TS-3 temperature sensors for each vessel. A simple calibration feature compensates for
homogeneous
(consistent composition) atmospheres other than air.
The XPL+ is capable of monitoring wheat in 60 m (200 ft) high silos, acetone in 45 gallon barrels, or almost
anything in between, in any combination. (Ensure the transducer selected for each vessel suits the material
and measurement range required).
This material and measurement range versatility is accomplished by utilizing Milltronics patented Sonic
Intelligence TM. Sonic Intelligence provides high measurement reliability, regardless of changing conditions
within the vessel monitored.
By utilizing ultrasonic echo ranging principles with Sonic Intelligence and velocity compensation, the XPL+
provides outstanding measurement accuracy, usually within 0.25% of range.
PL-532 6

The distance calculation may be converted to space, material level, material volume, or remaining vessel
capacity Readings. The Reading chosen (and operating data) for each vessel is displayed on the
Liquid
Crystal Display
(LCD).
Up to 3 Milltronics Peripherals may be connected to the XPL+. The AO-10, SAM-20 and/or BIC-II,
respectively provide analog output , relays and RS-232 or RS-422 communication interface, as programmed
by the XPL+.
With the addition of a Milltronics SmartLinx protocol specific ‘plug in ’ communications module, the XPL+ is
compatible with popular industrial control system standards.
Operator programming, via a Milltronics infrared programmer, is stored in non-volatile memory, unaffected by
power interruption. The infrared interface permits one programmer to be used for any number of XPL+ level
monitors. Upon programming completion, the removable programmer may be locked away, thereby securing
all programming.
While the XPL+ 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 XPL+ application.
Refer to Application Examples for detailed descriptionsof a small sample of
process measurement requirements to which the XPL+ 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 XPL+.
XPL+ with SmartLinx
bus
industrial control system
proprietary Milltronics communications loop
TECHNICAL REFERENCE
INTRODUCTION
PL-532 7

IMPORTANT AIRANGER XPL PLUS FEATURES
FIXED FEATURES
ENCLOSURE: Chemical resistant, light weight, dust tight, liquid tight, easy to work with.
LCD: Large digits for Reading and programming value displays.
Graphic Symbols for continuous indication of operating conditions.
PROGRAMMER: 20 tactile feedback keys or Dolphin ( XPL+/RS-232C interface) each with magnetic
mounting and infrared interface ( ordered separately ).
SCANNING: Substantially reduces equipment costs for additional vessels (present or future).
COMMUNICATIONS:
Milltronics Peripherals
Proprietary bipolar communications with AO-10, SAM-20 and BIC-2 peripheral devices,
for respective analog mA output, alarm control relays and RS-232 or RS-422 interface.
and /or
SmartLinx Compatible
Communications ready when equipped with an appropriate Milltronics SmartLinx module.
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.
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 XPL+ 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", or "distance" operation.
MATERIAL: Liquid or Solid; automatically adjusts echo processing with one entry.
RESPONSE: Slow, medium, fast, surge, or turbo response to material level changes, one entry.
UNITS: Display Readings in m, cm, mm, ft, in, %, or any other units desired.
PL-532 8

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: 7 alarm functions including level, rate of change, temperature and more,
(SAM-20 required) Fixed or independent on/off setpoints.
mA OUTPUTS: Based on level, space, distance, or volume,
(AO-10 required) 4 range selections, 0-20, 4-20, 20-0, or 20-4 mA,
Adjustable range and over-range limits.
INTRODUCTION
PL-532 9

PL-532 10

INSTALLATION
Installation shall only be performed by qualified personnel,
and in accordance with local governing regulations.
The following procedure applies to all XPL+ level monitor installations. See
Application Examples for additional installation requirements. Also, refer to the instruction manuals of all other
equipment connected to the XPL+ for additional installation instructions.
AIRANGER XPL PLUS
Installation should only be performed by qualified personnel, and in accordance with all governing regulations.
LOCATION
Inspect all potential mounting locations. Choose a location suited to the XPL+ polycarbonate enclosure and
the following location recommendations.
The ideal XPL+ mounting location is where the:
1. Ambient temperature is always within -20 to 50 °C (-5 to 122 °F).
2. XPL+ front cover has sufficient room to swing open.
3. Operator and electronics are not exposed to the weather.
4. Cable length requirements are minimal.
5. Mounting surface is free from vibration.
Avoid mounting locations where the XPL+ is:
» exposed to 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:
» Transducers
» TS-3 temperature sensors ( if used )
» BIC-II ( if used )
» SAM-20 ( if used )
» AO-10 ( if used )
» Synchronization ( see Interconnection \ Level System Synchronization )
» Power
Transducer cables must be run in a grounded metal conduit, separate
from other wiring, ( except TS-3 temperature sensor wiring, if applicable ).
TECHNICAL REFERENCE
INSTALLATION
PL-532 11

MOUNTING This product is susceptible to electrostatic shock.
Follow proper grounding procedures.
Inspect all cartons and packaging for possible damage during shipment, before removing the XPL+ 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.
Non metallic enclosure does not provide grounding between conduit connections.
Use grounding type bushings and jumpers.
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
0.5 m ( 1.65 ft ) ST-H, ST-25, XCT-8, XPS-10, XCT-12, XPS-15, ST-50
0.66 m ( 2.17 ft ) XPS-30, XPS-40
0.99 m ( 3.25 ft ) ST-100, LR-21, XLT-30, XLS-30
1.32 m ( 4.33 ft ) LR-13, XLT-60, XLS-60
05/25/98
106 mm
(4.2")
267 mm
(10.5")
172 mm
(6.8")
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)
285 mm
(11.2")
209 mm
(8.2")
PL-532 12

OPTIONAL CARDS
COMMUNICATIONS MODULE
The XPL+ 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 XPL+ may be shipped to you without a SmartLinx module, for installation at later date.
If you are ready to install your SmartLinx module, or want to change it, please follow the procedure
as outlined.
TIB-9 CARD
The standard XPL+ supports one Milltronics TS-3 temperature sensor. When equipped with a TIB-9 card, the
XPL+ supports up to 10 TS-3s.
Your XPL+ may be shipped to you without a TIB-9 card, for installation at a later date.
If you are ready to install your TIB-9 card, please follow the procedure as outlined.
INSTALLATION PROCEDURE
With power off and the XPL+ lid opened:
1. Remove the 4 LCD card screws and the card itself.
2. If there is no TIB-9 card being installed, proceed to step 6, otherwise proceed with step 3.
3. Remove the 5 board A screws, and lift off the board (though still attached by ribbon connectors).
4. Mount the TIB-9 card by mating the connectors and secure the card in place using the 3
screws provided.
5. Replace board A and secure in place using the screws removed in step 3.
6. If installing an optional SmartLinx module, mount the card by mating the connectors and
secure the card in place using the two screws provided.
Refer to the SmartLinx module documentation for any required hardware
settings prior to replacing the LCD card or closing the XPL+ lid.
7. Replace the LCD card and secure in place using the screws removed in step 1.
communications module
board A
LCD card
TIB-9 card
INSTALLATION
PL-532 13

INTERCONNECTION
Before interconnecting system components to the XPL+ terminals, verify all components have been installed
in accordance with the associated product instruction manuals.
Connect all associated equipment cable shields to the XPL+ 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.
board B terminal block EPROM SW1
voltage
selection
display scope connections board A
optional
TIB-9
optional
SmartLinx
module
Hazardous voltage present on transducer terminals during operation.
All field wiring must have insulation suitable for at least 250 V.
PL-532 14

SYSTEM DIAGRAM
Maximum system capability. Not all components or their maximum quantity may be required.
AiRanger XPL Plus 10
10
bipolar current
(Milltronics communications)
Milltronics transducer,
see Specifications
Milltronics TS-3,
temperature sensor
Milltronics AO-10,
analog output device
Milltronics SAM-20,
relay output device
Milltronics BIC-2,
buffered interface converter
industry bus industry control system
optional
SmartLinx
INSTALLATION
PL-532 15

TRANSDUCER
Transducer cables must be run in a grounded metal conduit separate from other wiring
( except TS-3 temperature sensor wiring, if applicable ).
TEMPERATURE SENSOR
Use TS-3 temperature sensors only. Don’t jumper the terminals if TS-3’s are not used.
single Temp Sensor TIB-9 card for multiple Temp Sensors (optional)
XPL+
(board B)
to additional Temp Sensors
to Temp Sensor #1
Use Belden 8760 ( or equivalent ) 18 AWG, 2 wire shielded / twisted, 365 m (1200 ft) per TS-3 max.
To Transducers (10 max), RG62 A / U Coax, 365 m (1200 ft) / Transducer max.
TRANSDUCERS
Hazardous voltage present on transducer terminals during operation.
PL-532 16

PERIPHERALS
The XPL+ is compatible with the following Milltronics peripherals ( 3 max ).
SAM-20: 20 relay satellite alarm module ( 2 max )
AO-10: 10 output analog output module ( 1 only )
BIC-II:buffered XPL+ to RS-232C / RS-422 interface ( 1 only )
Connect the peripherals used, in a serial loop as follows:
Use Belden 8760 ( or equivalent ) 18 AWG, 2 wire shielded / twisted, 3000 m ( 10,000 ft ) total loop length.
LEVEL SYSTEM SYNCHRONIZATION
Avoid mounting the XPL+ near another ultrasonic level monitor. Likewise, when more than one monitor is
installed within a single plant / facility, ensure the transducer cables of each system are run in separate
grounded metal conduits. If this system separation is impractical, or despite separation efforts measurement
difficulties are encountered, system synchronization may be required.
To synchronize the XPL+ with an AiRanger DPL Plus or another XPL+...
1. Mount the level monitors together in one cabinet.
2. Ensure the level monitors share a common power ( mains ) supply, and ground ( earth ).
3. Interconnect the SYNC terminals of the level monitors to be synchronized.
To synchronize the XPL+ with other Milltronics ultrasonic level monitors
( not listed ) contact Milltronics or your local distributor.
INSTALLATION
PL-532 17

POWER
Before making the power connection, ensure proper voltage selection.
Never operate the XPL+ with the enclosure lid open,
or with the ground ( earth ) wire disconnected.
Ensure that any connected alarm or control
equipment is disabled until satisfactory system
operation and performance is verified.
The equipment must be protected by a 15 A fuse or
circuit breaker in the building installation.
A circuit breaker or switch in the building installation, marked as the
disconnect switch, shall be in close proximity to the equipment
and within easy reach of the operator.
SW1 switch shown in the
‘OFF’ position. Select
appropriate voltage.
100/115/200/230 V
50 / 60 Hz
select voltage via SW1.
PL-532 18

PROGRAMMING
Operator programmable features are identified by a Point Number and Parameter Number. The Point Number
refers to the Transducer (vessel) Number, Relay Number, mA Output Number, or TS-3 Number
as identified by the Point Type indicators. Parameter Numbers have a preset Parameter Value for each
Point Number.
Programming is accomplished by altering the preset Parameter Values as required to obtain the RUN mode
operation desired. All operator programmable features are defined in the Quick Start Parameters, Application
Parameters, and Enhancement Parameters sections of this instruction manual.
DISPLAY
In the program mode, the Point Type, Point Number, Parameter Number, and Parameter Value (as well as a
variety of other programming information) may be viewed.
Note that many indicators are specific to certain programming conditions and therefore,all indicators are not
displayed at any given time.
Parameter Number the programmable feature the Parameter Value pertains to.
Point Type the Point Number refers to a Transducer, Relay, mA Output, TS-3, or Breakpoint.
SAM-20 Bank Number identifies the SAM-20 the Relay Number displayed pertains to.
Point Number the Transducer, Relay, mA Output or TS-3 # the Parameter Value pertains to.
Parameter Value the current value of the Parameter Number for the Point Number displayed.
Units indicates the Parameter Value is displayed in: m, cm, mm, ft, in, or %.
Invalid Entry indicates the value entered is questionable (are you sure?).
Auxiliary Function indicates Auxiliary Function access (applies to only some Parameter Numbers).
Scroll Access Tag indicates the Parameter Value may be scroll accessed.
Program Mode indicates the program mode is accessed.
Point in Service indicates the Point Numbers which will be scanned in the RUN mode.
Auxiliary Function
Units
Parameter
Value
Point
Number
SAM-20 Bank
Number
Point Type
Scroll Access
Tag
Invalid Entry
Parameter
Number
Program
Mode
Transducer
Relay
Analog Output
TS - 3
Point in Service
Index
PROGRAMMING
PL-532 19

KEYPAD
In the program mode, use the XPL+ programmer keys to perform the identified functions.
shift access to the Point Number, Parameter Number, or Parameter Value display.
input a numeric value into the accessed display.
input a Parameter Value decimal point (moves Profile and TVT Pointers left).
input a negative Parameter Value (moves Profile and TVT Pointers right).
delete the current Parameter Value display (initiate a parameter reset).
store the current Parameter Value in memory (complete a parameter reset).
switch the Parameter Value to % or Units (access Auxiliary Parameter Function).
increase the accessed display value.
decrease the accessed display value.
take an ultrasonic measurement.
enter the RUN mode.
%
Numeric Value Keys
Function Keys
_
%
9
PL-532 20