MTS Systems Level Plus Specification sheet

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Level Plus®
DDA Tank Gauge Monitor
Operation Guide and Installation Manual
DDA Tank Gauge Monitor
550421 Revision C

Table of Contents
Section Page
1. Introduction 1
2. General Software Information 2
3. Model Number Information 7
4. Level Plus Tank Monitor Specification 8
5. Monitor Installation and Electrical Terminations 9
6. The Control Panel 16
7. Keypad Control Functions 18
8. Error Message Descriptions 22
9. Pre Start Up Check List 28
10. Start Up 29
11. Programming the Level Plus 30
12. System Parameters 34
13. Gauge and Tank Parameters 43
14. Side Tank Indicator Parameters 51
15. Analog Parameters 52
16. Volumetric Parameters 54
17. System Test Functions 67
18. Ending the Programming Sessions 75
19. Level Plus Host Communication Protocol 76
20. DDA Level Plus Monitor Modbus Implementation 87
Appendices Page
A. Procedure for Calculating Volume Correction Factors (VCF) 89
B. Typical RS232 Printer Connections 90
C. Scan Rate Calculation Procedure 91
D. EPROM Replacement Procedure 95
E. Connecting Level Plus DDA monitor to MTSLPS80 Software System 100
F. Level Plus Monitor Modbus Register Maps 101
NOTICE TO USER:
See section 9 of this manual for important information
about the installation, setup, and use of this product.

I Introduction
The Level Plus® DDA monitor is an industrial quality microprocessor based data acquisition and
display system for use with the Level Plus DDA tank gauges. In its standard form, the monitor
performs the following functions:
• Provides intrinsically safe power and communications to the tank gauges (up to 8)
• Displays the following parameters:
- Product level, volume and mass
- Interface level and volume
- Temperature
- Alarm status
• Provides 8 alarm contact outputs
• Provides 8 isolated 4-20 milliamp analog outputs
• Provides 1 serial asynchronous host communication port (RS485 or RS232)
Figure 1. Level Plus DDA System Architecture
KEYPAD
DISPLAY
Level Plus DDA Monitor
AC
Power
ASYNC
Communication
Port
8 Relay
Outputs 8 Isolated 4-20 Outputs
Up To 8
DDA Tank
Gauges
4Wire BusTo DDATank Gauges
1

2General Software Information
Advanced software techniques and concurrent operations are used to provide minimum scan
times and optimum overall system performance. The SCAN processor runs in background mode
scanning each gauge for level and temperature information. Temperature scans occur once per
five level scans. In addition, the scan processor performs level, temperature, and volume calcula-
tions; alarm processing; and maintenance of the active data arrays. The DISPLAY processor is a
foreground operation that transfers the array data to the LCD display. The DISPLAY processor
runs under keypad control allowing the user to alter the scan sequence and the type of data
being displayed. The COMMUNICATION processor is another background operation that handles
all external host communications to the Level Plus monitor. All three operations run independent-
ly, allowing immediate access to the data array with no additional over-head imposed on the
SCAN processor; thereby, minimizing scan rates and alarm response times. See Figure 2.
Figure 2. Level Plus DDA Monitor Software Structure
In addition to the advanced processing environment offered by the Level Plus system, the soft-
ware also supports a high degree of programmability, allowing the user to configure the system
to satisfy particular needs. The programming software is user friendly and allows the user to alter
many system parameters. Where possible, the software provides error checking on data entered
by the user. The software checks for valid assignments and erroneously entered data values. If the
software receives an illegal assignment or erroneous value, the entered parameter is rejected and
the user is prompted to reenter the correct value. The programmable parameters are described in
the following pages.
Display Update Rate
The display update rate is programmable from 1 to 25 seconds. This parameter affects
only the display update rate and does not affect the data acquisition scan rate. The soft-
ware also supports scan override and scan hold functions.
LCD Contrast Ratio
The Level Plus monitor uses a LED backlit, top-view LCD display module. The software
allows the user to adjust the optimum contrast ratio (viewing angle).
I/O
PROCESSOR
ASYNCHRONOUS
COMMUNICATION
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2

Communications
The Level Plus monitor is available with either EIA 485 or EIA 232 communications hard-
ware for communications with external host equipment. The user can program both baud
rate and communication address parameters.The software also supports a data logger
mode allowing gauge data to be sent to a serial interface printer at scheduled intervals.
Security Password
Programming parameters are protected by a 6-digit security access code. This code may
be reprogrammed or disabled.
Display Units/Resolution
Both MKS and U.S. customary display units are supported. Available level display units
include the following: decimal inches, feet, millimeters, meters or fractional inches.
Available temperature display units include degrees Centigrade or Fahrenheit. These are
global parameters and affect all gauge data.
Level data resolution is also a programmable parameter, but can be different for each
gauge displayed. Level resolutions of 0.1, 0.01 and 0.001 inches can be displayed.
Temperature data resolution is also programmable for each gauge in the system.
Temperature resolutions of 1, 0.2, and 0.02 degrees Fahrenheit can be displayed.
System Clock
The Level Plus monitor maintains system time with on board real time clock (RTC) cir-
cuitry. The RTC uses the power line frequency as a time base offering very high accura-
cy. In the absence of power, the clock automatically switches over to battery power and
a crystal time base. The RTC information (date and time) is printed on all data logger
reports and is also accessible via keypad control.
Gauge Parameters
Programmable gauge parameters include the following items: level data resolution, level
average factor, level offset, temperature function enable/disable, alarm parameters (see
next section) and gauge tag (alphanumeric label). The level data resolution parameter
determines the resolution of the data displayed on the LCD (0.1, 0.01 or 0.001 inches).
The higher the resolution selected, the longer the system scan delays will be. See the
programming section of this manual for additional information about scan delay times.
The level average factor determines how many level readings to average together before
displaying the data. This function can be useful to smooth level changes due to tank agi-
tation or waves. The level offset function is used to calibrate the displayed level data to
the actual measured level in the tank. The level offset value can be directly entered from
the keypad or calculated by the system from data acquired from the DDA Tank gauge.
The temperature enable/disable function allows temperature scans to be enabled or dis-
abled on a gauge by gauge basis. The alarm parameters are described in the next section.
The gauge tag is a seven character programmable label that appears on the LCD display
and printer reports to identify tanks with text labels. The default gauge tag is “TANK#X:”
where X is the actual tank gauge number in the system (i.e. 1-8).
3

Alarm Parameters
The Level Plus monitor provides both software and hardware alarm functions. The soft-
ware alarms are individually programmable and include the following: product low low,
product low, product high, product high high, interface high, interface low, temperature
high, temperature low, mass leak detect, and general gauge failure (gauge inoperative).
Each gauge in the system has independent alarms as described above and can have indi-
vidual limit settings for each alarm function. All of the software alarms can be assigned to
hardware alarms (relay contacts). The Level Plus is available with eight alarm contacts.
Any gauge alarm function can be assigned to any relay output. In addition, the software
supports multiple assignments and cross assignments of relay outputs (each relay output
may represent any combination of software alarm assignments). Programmable dead
band (hysteresis) values are also supported for pump/process control applications. All
alarm information is maintained in the active data array and may be accessed via remote
host communications.
MTS Side Tank Indicator (STI) Support
MTS DDA Side Tank Indicator modules can be connected to the Level Plus monitor sys-
tem to provide display of tank data at remote locations. The devices are multidropped on
the 4-wire MTS DDA network and can be located physically anywhere along the main
cable run. See the Side Tank Indicator Operation and Installation manual for additional
information about this MTS product.
Analog Output Parameters
The Level Plus monitor is provided with eight isolated analog (4-20 milliamp) outputs.
Each output channel can be assigned to any gauge in the system and can be assigned to
track any of the three control parameters (product level, interface level, or temperature).
Volumetric outputs can also be assigned as analog control parameters. Both the 4 mil-
liamp and the 20 milliamp end points are programmable to allow the user to scale the
output values, and inversion of the output channels is also possible. The output channels
can also be programmed to indicate a gauge malfunction alarm by driving the outputs to
either 4 or 20 milliamps.
Volumetric Parameters
The Level Plus Monitor system includes volumetric correction software, which is useful in
many tank gauging applications. The volume software is powerful, fast, and easy to use;
providing the user with gross observed volume (GOV), net standard volume (NSV), and
net mass information. See the section below labeled VOLUMETRIC SUPPORT for addi-
tional information on volume calculations. Programmable volumetric parameters include
the following: temperature correction methods (6A, 6B, 6C, 6C MOD, CUST TAB), display
units (gallons, liters, barrels, pounds, and kilograms), thermal expansion coefficients or
API gravity values, reference temperature (6C MOD only), product density, tank capacities
(optional tank information for ullage calculations), and strapping table information.
Strapping tables can be up to 100 entries per table (8 tables total) and are accessed via
powerful editing software. In addition to basic volume calculations the system incorpo-
rates a static mass stabilization (leak detect) function. The user can program the desired
mass change limits and can assign software and hardware alarms to each tank. Activation
and deactivation of the mass stabilization function is protected through security access
codes.
Volumetric Support
The thermal expansion correction software is based upon standards presented in the
American Petroleum Institute (API) Standard 2540. The Level Plus software strictly
adheres to API guidelines for software implementation, insuring repeatable data accurate
to API tables 6A, 6B, and 6C.
Volume information is calculated real time after the level and temperature data is read
from each gauge and does not affect the overall scan rate of the system. All volume data
is maintained in the active data arrays and is accessible through the host communication
interface. In addition, the software provides error checking on the calculated data and
4

signals the user when volume data is invalid. For example, loss of temperature data or
gauge input data that exceeds allowable limits for API table entries would cause invalid
volume data. Additional information on error messages and the use of the keypad to dis-
play different types of volumetric data can be found in the PROGRAMMING section of
this manual.
Volume Calculations
1. GOVP = TOTVOL - INTVOL (two float system)
GOVP = TOTVOL (one float system)
GOVI = INTVOL (two float system)
GOVT = GOVP + GOVI (two float system)
GOVT = GOVP (one float system)
GOVU = WORKING CAPACITY - GOVT (one or two float system)
The gross observed volume of the product (GOVP) is equal to the total volume of the
tank (TOTVOL) minus the interface volume (INTVOL). The TOTVOL is measured by the
product float (the float closest to the flange of the gauge) and the INTVOL is measured
by the interface float (the float closest to the tip of the gauge). The level information
from the gauge is used along with the tank gauging table or tank equations to calculate
the corresponding gross observed volumes.
2. NSVP = GOVP x VCF
The net standard volume of the product (NSVP) is equal to the gross observed volume of
the product (GOVP) multiplied by the volume correction factor (VCF). The VCF is calcu-
lated from thermal expansion properties of the product (programmed by the user) and
the temperature information from the gauge. See item #4 below.
3. MASS = NSVP x DENSITY
The mass of the product (MASS) is equal to the net standard volume of the product
(NSVP) multiplied by the density of the product (DENSITY) programmed by the user.
4. VOLUME CORRECTION FACTOR
VCF = EXP {- A(T) x (t-T) x [ 1 + (0.8 x A(T) x (t-T)) ]}
Where:
t = any temperature*
T = base temperature (60 degrees F)
A(T) = coefficient of thermal expansion at base temperature T
Where:
EXP is the exponential function (ex).
The coefficient of thermal expansion at the base temperature T is related to the density of
the product at the base temperature T by:
A (T) = [ K0 + K1 x DEN (T) ] / [ DEN (T) x DEN (T) ]
Where:
Density is defined in units of KG/M3
K0 and K1 are constants related to each product.
* API 2540 states that temperature data is rounded to the nearest tenth (0.1) degree.
5

API Table Information
This section includes information on the constants used by the software to calculate the
volume correction factors and valid ranges for the API (density) and temperature data.
* For the transition group, A(T) = [ K1 + K0 / ( DEN (T) x DEN (T)) ]
* * TEC is the thermal expansion coefficient of the product being measured.
NOTE
Volumetric modes 6C MOD and CUST TAB are not
intended for custody transfer applications since they
do not follow API standard 2540 exactly. The soft-
ware for 6C MOD incorporates a moveable tempera-
ture reference and allows for a wider range of TEC
values.
0 to +300.0 deg F 100.0 to 999.0 * 10E-6/deg F
Valid temperature ranges Valid TEC ranges
Special products using TEC (Table 6C MOD)
Valid temperature ranges ValidTEC ranges
0 to +300.0 deg F
0 to +250.0 deg F
0 to +200.0 deg F
270.0 to 510.0 * 10E-6/deg F
510.5 to 530.0 * 10E-6/deg F
530.5 to 930.0 * 10E-6/deg F
Special products using TEC** (Table 6C)
Product type Constants Gravity range (API)
Fuel oil K0 = 103.8720
K1 = 0.2701 0.0 to 37.0
Jet Group K0 = 330.3010
K1 = 0.0 37.1 to 47.9
Transition
Group * K0 = 1489.0670 K1 = -0.0018684 48.0 to 52.0
Gasolines K0 = 192.4571
K1 = 0.2438 52.1 to 85.0
Generalized products (Table 6B)
Valid temperature ranges Valid gravity ranges (API)
0 to +300.0 deg F
0 to +250.0 deg F
0 to +200.0 deg F
0.0 to 40.0 deg API
40.1 to 50.0 deg API
50.1 to 85.0 deg API
Valid temperature ranges Valid gravity ranges (API)
0 to +300.0 deg F
0 to +250.0 deg F
0 to +200.0 deg F
0.0 to 40.0 deg API
40.1 to 50.0 deg API
50.1 to 100.0 deg API
Crude oils (Table 6A)
Constants: K0 = 341.0957
K1 = 0.0
6

3Model Number Information
Model Number: Level Plus DDA Monitor
NOTE
All Level Plus DDA Monitors include:
• 8 alarm contact outputs
• EIA485A or EIA232C communications
• Factory installed safety barriers to permit DDA tank
gauge installation (up to 8) in hazardous areas
(Class I, II, III, Division 1, Groups C, D, E, F and G)
• Option of (8) 4-20 milliamp outputs
83
LEVEL PLUS DDA MONITOR
POWER SUPPLY INPUT
0 = 115 V
1 = 230 V
ENCLOSURE
1= NEMA 1 Indoor Enclosure (w/4-20 mA outputs)
2= NEMA 1 Indoor Enclosure
4= NEMA 4X Indoor/Outdoor Enclosure (w/ 4-20mA outputs)
5= NEMA 4X Indoor/Outdoor Enclosure
7= NEMA 7 Explosion-proof Enclosure (w/4-20 mA outputs)
8= NEMA 7 Explosion-proof Enclosure
COMMUNICATIONS PROTOCOL
0= MTS ASCII Communication Protocol
1= Modbus RTU Communication Protocol
2= Modbus ASCII Communication Protocol
COMMUNICATIONS
2 = EIA232C Communications
4= EIA485A Communications
SAFETY BARRIERS
3= 3 Safety Barriers
7

4Level Plus Tank Monitor Specifications
Parameter Specification
Power Consumption • NEMA 1: 60 Watts maximum @ 120 VAC, 50/60 Hz, fuse protected
• NEMA 4X and 7 (with internal heater): 260 Watts maximum @ 120 VAC, 50/60 Hz, fuse protected
• AC power connection includes 2-stage input filter (line-to-line and line-to-ground) and
transient protection (line-to-line) 1200 watts maximum.
Operating Temperature: • NEMA 1: +35 to 135°F (+2 to +54°C)
• NEMA 4X and 7: -40 to 135°F (-40 to +54°C)
Relay Contacts • 3 Amps @ 30 VDC or 250 VAC maximum, NO contacts, continuous duty
4-20 mA Analog Outputs: • Loop powered, opto-isolated from system ground.
• All outputs are reverse polarity protected.
• All outputs are transient protected (line-to-line) 600 watts maximum.
• Maximum non-linearity + 0.5% F.S. over operating temperature range
• 12 bit maximum resolution.
Communication Port • Industry standard EIA 485 or EIA 232.
8

5Monitor Installation and Electrical Terminations
See the following MTS drawings when installing and terminating Level Plus DDA Monitors:
1. 650562 - External wiring NEMA 1 Level Plus DDA Monitor
2. 650615 - External wiring NEMA 4 Level Plus DDA Monitor
2. 650564 - External wiring NEMA 7 Level Plus DDA Monitor
3. 650567 - Field wiring Level Plus DDA Monitor
4. 650561 - Terminal block identification Level Plus DDA Monitor
5. 650511 - Wiring diagram intrinsically safe DDA Liquid Level
Also reference MTS Level Plus DDA Gauge Manual #550164 for additional information about DDA
Tank Gauge installation requirements.
9

6The Control Panel
The Level Plus control panel is shown in Figure 3.
Figure 3. Level Plus Control Panel
The control panel includes LED’s for power and alarm indication, a LCD screen displaying 4 lines
of 20 characters each, 12 numeric keys, and 4 control keys.
In program mode, the number keys (0 to 9, ±, and •) are used
to enter numeric values for programmable parameters. In mea-
surement mode, the number keys are used to access tank
gauge measurement data and to change the basic display
modes provided by the software.
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the control panel. The Power LED is lit when the monitor is connected to
power and Switch S1 is in the ON (up) position. The red Alarm LED
flashes to indicated an alarm condition.
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16

The LCD screen displays current measurements of level, tem-
perature, and volume. During programming, the screen dis-
plays parameters and prompts the user for information.
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The four control keys are primarily used to enter parameters and move to differ-
ent programming displays:
• Mode: Used to indicate that you wish to change the parameter displayed on
the screen. For scrolling type menus, Mode will scroll forward through the
available selections. The ± key can be used to scroll backwards through the
available selections. In measurement mode, the Mode key is used to access
Program mode.
• Enter: Used to confirm the parameter on the screen or advance to the next
parameter. In measurement mode, the Enter key is used to initiate a printer
report.
• Fnctn: Used to return to a previous parameter.
NOTE: In measurement mode, the Fnctn key is used as a “shift” key providing
dual functions for each numeric key (0 to 9).
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ming mode screens. In measurement mode, the Clear key is used to acknowl-
edge system alarms and to clear the audible alarm beeper.
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