Milltronics PL-590 User manual

September 1999
Instruction Manual
PL-590
33455900
Rev 1.0
XRS-5 Transducer
ISO 9001
Certificate #002284
Peterborough, Ont., Canada
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GERMANY
SWITZERLAND
Singapore, Brazil
AUSTRALIA
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THE UNITED STATES
www.milltronics.com
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Capacitance
Radar
Belt scales
Motion sensing
Weigh feeders
Acoustic sensing
Flowmeters
Ultrasonic level
Point level
Communications
At Milltronics, 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 electronics
based process measurement
equipment since 1954. Our
fields of expertise include
continuous and point level
measurement, weighing and
feeding systems and motion
sensing. Technologies include
ultrasonic, capacitance and
microwave radar.
Milltronics sells and markets
world wide through
subsidiaries, distributors and
representatives. Through
continuous improvement, we
are striving to provide our
customers with first rate sales
information, engineering
assistance and after sales
support.
For more details on our
products and services, please
contact us and we will provide
you with a listing of the offices
or representatives nearest you.

PL-590 XRS-5 Transducer Page 3
Table of Contents
Specifications
..............................................................................................5
About the Transducer ..................................................................................7
General Guidelines ................................................................................. 8
Installation.....................................................................................................9
Outline and Dimensions ..........................................................................9
Mounting .....................................................................................................11
Recommendations ................................................................................11
Applications................................................................................................13
Open Channel Meter.............................................................................13
Standpipes and Stilling Wells................................................................14
Water / Wastewater...............................................................................15
Transducer Placement ..........................................................................16
Locations...............................................................................................16
Interconnection
..........................................................................................19
Direct Connection.................................................................................. 19
Coaxial Connection ...............................................................................20
2-Wire Extension (for EnviroRanger ERS 500 only) .............................20
Maintenance
...............................................................................................20
Installation Diagram ...................................................................................21

Page 4 XRS-5 Transducer PL-590

PL-590 XRS-5 Transducer Page 5
Specifications
Specifications
Process Application: {liquids and slurries
{Measurement Range {0.3 to 5m (1 to 15 ft) typical
(may depend on application variables)
{Vessel Pressure {vented to atmosphere
Operation:
{Beam Angle {10°
{Frequency {43 KHz
{Temperature Sensor {internal
{Supply Source {transducer shall only be supplied by Milltronics
certified controller
Environmental:
{Location {indoor / outdoor
{Ambient temperatures {-20 to 65 °C (-4 to 149 °F)
{Altitude {2000 m maximum
{Pollution degree {4
Construction:
{Housing {Kynar Flex®1 body and Hypalon2face
{Mounting {1” NPT conduit connection
Cable:
{2 wire shielded / twisted, 0.5 mm2(18 AWG) PVC jacket
Ingress protection:
{IP-68
Weight3:
{1.2 Kg (2.6 lb)
Options:
{factory flanged to suit ANSI , DIN or JIS standard
{split flange (field mount) to suit ANSI, DIN or JIS standard
{submergence shield (flooding applications)
Cabling (maximum run):
{365 m (1200 ft) using RG-62 A/U coaxial cable
{365 m (1200 ft) using 2-wire twisted pair / braided and foil shielded 20
AWG (0.5 mm2), PVC jacket (EnviroRanger ERS 500 only)
Approvals:
{CE4, CSA, FM, CENELEC, ATEX, see device nameplate
1Kynar Flex®is registered trade mark of ELF Atochem.
2Hypalon®is a registered trademark of Du Pont
3approximate weight of transducer with standard cable length
4EMC performance available upon request

Page 6 XRS-5 Transducer PL-590
Specifications

PL-590 XRS-5 Transducer Page 7
About this …
About the Transducer
The Echomax XRS-5 transducer works with Milltronics transceivers and
provides the ultrasonic pulse and echo reception
that these devices require.
The transducer converts electrical pulses
provided by the transceiver to ultrasonic pulses
used for measurement and then converts the
ultrasonic echoes back to an electrical signal.
This signal is interpreted by the Milltronics
tranceiver using the patented Sonic
Intelligence™ algorithms. The ultrasonic pulse
reduces in power by 3dB in a 10° cone from the
transducer face. It is important to keep objects
out of this cone to reduce the chance of false
echos being recorded.
The XRS-5 transducer incorporates an
integral temperature sensor that reports the
ambient temperature to the transceiver. The
connection is transparent in that both the
ultrasonic and temperature components of
the transducer use the same leads. This
ensures that the Milltronics transceiver can
automatically compensate the speed of
sound constant for varying temperatures.
transducer
transducer
face
-3db
boundary
axis of
transmission,
perpendicular
to transducer
face

Page 8 XRS-5 Transducer PL-590
About this …
General Guidelines
The equipment may be used in all hazardous zones with all gases with
temperature classes T1, T2, T3, T4, T5 and T6. The equipment is only
certified for use in ambient temperatures in the range of -20°C to +65°C and
should not be used outside this range.
•Installation shall be carried out in accordance with the applicable code of
practice by suitably trained personnel.
•The apparatus shall only be supplied from a circuit containing a suitably-
rated fuse having a breaking capacity of 4000A. This fuse is included in
Milltronics’ transceivers.
•Repair of this equipment shall be carried out in accordance with the
applicable code of practice.
•The certification of this equipment relies on the following materials used in its
construction:
Enclosure: Kynar Flex 2800-02 (former designation 2820) /
Chlorosulfonated polyethylene / Nitrile / Ethylene propylene
/ Chloroprene
Encapsulant: LA-9823-76
•Manual override can be accomplished by using the disconnect switch
provided in the building installation of the associated controller.

PL-590 XRS-5 Transducer Page 9
Installation
Installation
Outline and Dimensions
Standard Flange (optional)
Submergence Shield Split Flange (optional)
Refer to Milltronics
instruction manual PL-530.
127mm
(5.0”)
89mm
(3.5”)
127mm
(5.0”)
ANSI, DIN or JIS
standards
155mm
(6.1”)
124mm
(4.9”)
ANSI, DIN or JIS
standards
133mm
(5.2”)
nominal

Page 10 XRS-5 Transducer PL-590
Installation

PL-590 XRS-5 Transducer Page 11
Mounting
Mounting
Recommendations
•Mount the transducer so that it is above the maximum material level by more
than the blanking value to ensure that accurate results are achieved. Refer
to the associated transceiver manual for information on setting the blanking
value.
•The transducer must be mounted so that the axis of transmission is
perpendicular to the liquid’s surface.
•Do not over tighten mounting. Hand tightening of the mounting hardware is
sufficient.
•Consider the optional temperature sensor when mounting the transducer.
Suspended Conduit Bracket
Flexible conduit transducer should not be
subjected to wind, vibration or jarring.
Submersible Plywood
Submersible transducer, used in
applications where flooding is possible.
Plywood mounting provides excellent
isolation, but must be rigid enough to
avoid flexing if subjected to loading.
rigid metal
conduit
coupling
transducer
rigid metal
conduit
submergence
shield
flexible conduit
steel channel
coupling
coupling
coupling

Page 12 XRS-5 Transducer PL-590
Mounting
Blind Flange
Face Flange
nipple welded
to bind flange
coupling
factory flanged
transducer
bolt
gasket
customer flanged,
flat face only
nut
coupling

PL-590 XRS-5 Transducer Page 13
Applications
Applications
Notes:
•The transducer is to be used only in the manner outlined in this
instruction manual.
•This transducer requires no maintenance, and is recommended for use
with liquids only.
Open Channel Meter
Refer to OCM manufacturer specification for proper point of head
measurement.
The use of an external temperature sensor provides better temperature
tracking in applications where the temperature can change quickly.
typical flume or weir
refer to Milltronics
transceiver manual for
minimum distance above
maximum head.

Page 14 XRS-5 Transducer PL-590
Applications
Standpipes and Stilling Wells
In many applications, access must be made via a standpipe. In such cases,
Milltronics can provide factory flanged transducers or split flange kit that will
readily mate to the flanged standpipe. Another option is to hang the
transducer from a blind flange.
The standpipe length should be as short and the diameter as large as
possible. As a rule of thumb, the -3 dB cone of the sound beam should not
intersect the standpipe wall in applications opening into a vessel or larger
area. Otherwise, additional blanking will be required to compensate for the
interference zone created by the opening.
no additional blanking required no additional blanking required
no additional blanking required near blanking extension of 150 mm (6”)
past end of standpipe may be required.
no
intersection
flanged
transducer
vessel
no
vessel
blind flange
mounting
transducer
sound beam
intersects
reflection at
interference
zone created
by opening
vessel
standpipe
end cut on a
45° angle
typically
blind flange
mounting
transducer
can read
level inside
or below
standpipe
vent

PL-590 XRS-5 Transducer Page 15
Applications
Water / Wastewater
Differential Level
Pump Control
Sewage Lift

Page 16 XRS-5 Transducer PL-590
Applications
Transducer Placement
The following graphic shows the best placement of the XRS-5 transducer.
Locations
A. Primary location. This is the preferred location and should be used
whenever possible. The centre of the tank generally gives the most reliable
readings because there are fewer obstructions to provide false echos.
B. Alternate location. This location is used if the centre of the tank is already
in use or if the tank roof is too weak to hold the transducer safely.
C. Poor location. This is a poor installation location. The echos are shown
reflecting away from the transducer face.
beam
angle
rise
‘B’ ‘A’ ‘C’
may require target to
obtain empty reading discharge
tank
manufacturer’s
empty level
Empty level for ‘B’
location. Below this
level, echo would
reflect away from
the transducer.
Maintain full fluid
level for full o
r
offset calibration.
Do not allow
material to ente
r
blanking zone.
span:
distance between
Empty and Full
levels in the
measured process
run

PL-590 XRS-5 Transducer Page 17
Applications
Notes
1. Beam should not detect bin bottom.
If this occurs, use range extension parameters (on
transceivers where available) to omit false echoes.
The XRS-5 transducer operates with a beam
angle of 10° and has a rise:run ratio of
approximately 12:1. This means that for every 1m
(3.3’) of tank height, the transducer projects a
circular area over the material surface with a
radius of 83mm (32.7”). In most tanks the
transducer should be centred as much as
possible (without interference from inlet) for
optimum reading range.
2. Sound beam must be perpendicular to
liquid surface.
When mounting the standpipe and flange you must ensure that the
transducer face will be parallel with the liquid’s surface.
3. Echo has missed an improperly levelled transducer.
As 2, ensure that the standpipe and flange are mounted to set the
transducer face level with the measured liquid.
4. Calibrate under normal conditions.
When performing an empty or full calibration, the tank must contain its
normal vapour and be at its normal temperature.
83mm
1m

Page 18 XRS-5 Transducer PL-590
Applications

PL-590 XRS-5 Transducer Page 19
Interconnection
Interconnection
Note:
Installation shall only be performed by qualified personnel and in
accordance with local governing regulations.
Dos and Don’ts
For best results follow these installation rules:
•Do not route cable openly, instead run cable separately in a grounded metal
conduit to protect it from ambient electrical noise.
•Seal all thread connections to prevent the ingress of moisture.
•Do not run cable near high voltage or current runs, contactors or SCR
control drives.
In all of the following examples the terminal blocks on the transceiver are
described in the transceiver manual.
Direct Connection
Connect the transducer directly to the Milltronics transceiver via the 2
conductor shielded cable.
Note:
When connecting to an EnviroRanger ERS 500, the white, black, and
shield wires are all connected separately. Do not tie the white and shield
wires together
bl
k
drain / shield
wht

Page 20 XRS-5 Transducer PL-590
Interconnection
Coaxial Connection
Connect the transducer to the Milltronics transceiver via a junction box and
RG–62 A/U coaxial cable. This setup is effective for combined runs up to
365m (1200’).
Note:
When connecting to an EnviroRanger ERS 500, do NOT use coaxial
cable, see diagram below for proper procedure.
2-Wire Extension (for EnviroRanger ERS 500 only)
Maintenance
The XRS-5 requires no special maintenance.
extend cable using
RG – 62 A/U coax
blk
drain / shield
wht
extend cable using 18 AWG
shielded / twisted pair
junction box