Pulsar blackbox 130 User manual

blackbox 130 (UL)
INSTRUCTION MANUAL

BLACK BOX LEVEL 130 UL (SECOND EDITION)
June 2017
Part Number M-130-0-002-0U
COPYRIGHT
© Pulsar Process Measurement Limited, 2003 -17. All rights reserved. No part of this publication may be
reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any language in any
form without the written permission of Pulsar Process Measurement Limited.
WARRANTY AND LIABILITY
Pulsar Process Measurement Limited guarantee for a period of 2 years from the date of delivery that it will
either exchange or repair any part of this product returned to Pulsar Process Measurement Limited if it is
found to be defective in material or workmanship, subject to the defect not being due to unfair wear and
tear, misuse, modification or alteration, accident, misapplication or negligence.
DISCLAIMER
Pulsar Process Measurement Limited gives nor implies any process guarantee for this product, and shall
have no liability in respect of any loss, injury or damage whatsoever arising out of the application or use of
any product or circuit described herein.
Every effort has been made to ensure accuracy of this documentation, but Pulsar Process Measurement
Limited cannot be held liable for any errors.
Pulsar Process Measurement Limited operates a policy of constant development and improvement and
reserves the right to amend technical details as necessary.
The blackbox shown on the cover of this manual is used for illustrative purposes only and may not be
representative of the actual blackbox supplied.
TECHNICAL ENQUIRIES
Please contact Pulsar Process Measurement for technical support.
COMMENTS AND SUGGESTIONS
If you have any comments or suggestions about this product, then please contact:
Pulsar Process Measurement Limited
Pulsar Process Measurement Inc.
Cardinal Building
Enigma Business Centre
Sandy’s Road
Malvern
Worcestershire
WR14 1JJ
United Kingdom
PO Box 5177
Niceville
FL 32578 - 5177
USA
Tel: + 44 (0) 1684 891371
Fax: + 44 (0) 1684 575985
Tel: + 1 850 279 4882
Fax: + 1 850 279 4886
Web Site: http://www.pulsar-pm.com
e-mail: [e-mail] (general
information)
e-mail: support@ pulsar-pm.com (product
support)
Web Site: http://www.pulsar-pm.com
e-mail: [e-mail] (general
information)
e-mail: support.usa@ pulsar-pm.com (product
support)

Contents
Chapter 1 Start Here….........................................................................................................................................1
About this Manual...........................................................................................................................................1
About theblackbox range...............................................................................................................................2
Functional Description....................................................................................................................................3
Product Specification....................................................................................................................................... 4
EC Declaration of Conformity........................................................................................................................6
Chapter 2 Installation............................................................................................................................................7
Power Supply Requirements...........................................................................................................................7
Location...........................................................................................................................................................8
Dimensions......................................................................................................................................................9
Standard Enclosure..................................................................................................................................9
Large Enclosure (optional)....................................................................................................................12
Terminal Connection Details........................................................................................................................14
Power .....................................................................................................................................................15
Transducer..............................................................................................................................................15
RelayOutputs........................................................................................................................................17
Current Output.......................................................................................................................................17
RS232 Serial Interface...........................................................................................................................17
Fuse Location................................................................................................................................................17
Preparation for Operation..............................................................................................................................18
Maintenance...................................................................................................................................................19
Chapter 3 How To Use Your blackbox Level System....................................................................................20
PC Handheld Programmer (Standard)..........................................................................................................20
Communication Port Configuration.....................................................................................................21
Handheld Communicator (Optional)............................................................................................................21
On board integralKeypad and Display(Optional)......................................................................................22
Operating the Controls..................................................................................................................................23
Display...................................................................................................................................................23
Keypad...................................................................................................................................................24
Run Mode......................................................................................................................................................26
LED’s .....................................................................................................................................................27
Program Mode...............................................................................................................................................27
Howto Access Program Mode.............................................................................................................28
Test Mode......................................................................................................................................................30
LED’s.....................................................................................................................................................31
Using the RS232 Serial Interface..................................................................................................................31
Parameter Defaults........................................................................................................................................32
FactoryDefaults.....................................................................................................................................32
Chapter 4 Programming Guide..........................................................................................................................34
Level...............................................................................................................................................................34
Example 1 Level Measurement............................................................................................................34
Example 2 Alternating Control (pump down).....................................................................................36
Volume (Optional) ........................................................................................................................................38
Example 3 Volume Application...........................................................................................................38
Chapter 5 Parameter Guide................................................................................................................................40
Menu System Diagrams................................................................................................................................40
Top Level Menu....................................................................................................................................40
Application Menu..................................................................................................................................40
Relays Menu..........................................................................................................................................41

Data Logs Menu....................................................................................................................................41
Volume Menu........................................................................................................................................42
DisplayMenu........................................................................................................................................43
OutputMenu..........................................................................................................................................43
Compensation Menu.............................................................................................................................43
StabilityMenu........................................................................................................................................44
Echo Processing Menu..........................................................................................................................44
System Menu.........................................................................................................................................45
Test Menu..............................................................................................................................................46
Parameter Listing...........................................................................................................................................47
Application Parameters.................................................................................................................................47
Operation................................................................................................................................................47
Dimensions............................................................................................................................................48
Remote Alarm........................................................................................................................................50
SMS Time..............................................................................................................................................51
RelayParameters...........................................................................................................................................53
RelayType.............................................................................................................................................53
Alarms....................................................................................................................................................54
Control....................................................................................................................................................57
Common Parameters.............................................................................................................................59
Data Log Parameters.....................................................................................................................................60
Temperature...........................................................................................................................................60
Volume (Optional) ........................................................................................................................................61
Conversion.............................................................................................................................................61
Breakpoints............................................................................................................................................64
Tables.....................................................................................................................................................66
DisplayParameters........................................................................................................................................66
Options...................................................................................................................................................66
Failsafe...................................................................................................................................................67
Output Parameters.........................................................................................................................................68
Range.....................................................................................................................................................68
Operation................................................................................................................................................68
Setpoint..................................................................................................................................................69
Limits.....................................................................................................................................................69
Trim........................................................................................................................................................70
Failsafe...................................................................................................................................................70
Compensation Parameters.............................................................................................................................70
Offset......................................................................................................................................................71
Temperature...........................................................................................................................................71
StabilityParameters.......................................................................................................................................72
Damping.................................................................................................................................................72
Filters......................................................................................................................................................72
Echo Processing Parameters.........................................................................................................................73
Transducer Status...................................................................................................................................73
System Parameters........................................................................................................................................74
Passcode.................................................................................................................................................74
System Information...............................................................................................................................74
Date & Time..........................................................................................................................................75
Daylight Saving Time...........................................................................................................................76
Test Parameters..............................................................................................................................................79
Simulation..............................................................................................................................................79
Hardware................................................................................................................................................80
Chapter 6 Troubleshooting ................................................................................................................................82
Parameter Record..................................................................................................................................................83

Page 1
Chapter 1 Start Here…
Congratulations on your purchase of a Pulsar blackbox 130 Level System.
This quality system has been developed over many years and represents the
latest in high technology ultrasonic level measurement and control.
It has been designed to give you years of trouble free performance, and a few
minutes spent reading this operating manual will ensure that your installation
is as simple as possible.
About this Manual
It is important that this manual is referred to for correct installation and
operation.
There are various parts of the manual that offer additional help or information
as shown.
Tips
At various parts of this
manual you will find tips to
help you.
Additional Information
Additional Information
At various parts of the manual, you will find
sections like this that explain specific things in
more detail.
References
See Also
References to other parts of the manual

Page 2
About the blackbox range
The Pulsar blackbox is a non-contact Level Control System. It has been
designed to provide a new concept in low cost maintenance-free fit and forget
level measurement without any compromise on performance.
The blackbox is ideally suited to applications where level monitoring,
reporting, control or logging is required, with or without the need for a local
display.
The blackbox level system is available in a variety of different versions
offering a wide choice of output options.
The blackbox is very easy to use and may be calibrated quickly and simply
via a laptop, using the software supplied with the unit, or alternatively by
using the optional hand held calibrator, which connects to the unit via the
RS232 interface, and provides an on-board LCD display. Certain models are
also available with an optional LCD display and integral keypad fitted.
All models of the blackbox range can be used with any of the extensive range
of Pulsar dB transducers for distances up to 131ft (40m).
The blackbox range is designed to provide you with highly reliable
measurement in a robust and functional package that is easy to use and low in
cost.

Page 3
Functional Description
The blackbox ultrasonic Level System sends a transmit pulse to the
transducer, which emits an ultrasonic pulse perpendicular to the transducer
face, and the returned echo is sent back to the blackbox. The time taken to
receive the echo is measured and the distance from the transducer face to the
surface being monitored is calculated.
The blackbox utilises the unique DATEM software (Digital Adaptive
Tracking of Echo Movement). This is a unique digital mapping technique
developed especially for Pulsar’s range of ultrasonic level and control
systems. It gives the system edge when identifying the “true target level” in
the face of competing echoes from pipes, pumps or other obstructions.
The blackbox can measure from 0.41ft (0.125m) to 131 feet (40m) from the
transducer to the surface being monitored, dependent on the application and
transducer used.
The blackbox can measure level, space or distance and provide a
representative output. When fitted with the optional display and keyboard
it can also measure and provide an output representative of volume. There are
two user definable relays, with individual setpoints, which can be
programmed to activate alarms or control functions, a mA output that can be
used for remote indication purposes and a RS232 port, so that the blackbox
can be programmed or monitored remotely by a PC or other equipment.
The blackbox can be programmed either by PC, via the RS 232 Serial
Interface, using the supplied software (standard) or by hand held calibrator
(optional) which is connected to the blackbox via the RS 232 interface.
Those units fitted with the optional on board display can be programmed via
the integral keyboard.
All the parameters are stored in non-volatile memory, so are retained in the
event of power interruption.

Page 4
Product Specification
Physical
Standard Wall Mount Enclosure
Outside dimensions 5.12 x 5.12 x 2.36 inches
(130 x 130 x 60 mm)
Weight Nominal 1.4lbs (0.65 kg)
Cable entry detail underside fitted with 3 x M20, nylon cable
glands
Large Wall Mount Enclosure (optional)
Outside dimensions 5.12 x 7.09 x 3.35 inches
(130 x 180 x 85 mm)
Weight Nominal 1.65lbs (0.75 kg)
Cable entry detail underside fitted with 5 x M20, nylon cable
glands
Enclosure material/description Polycarbonate base with Polycarbonate lid,
flammability rating UL94-5V
Separation
Transducer cable extensions 3 conductor 20AWG screened
Nominal separation 3,280 ft. (1000m). For greater separation
distances please consult Pulsar
Environmental
Mounting Indoor/Outdoor
Relative Humidity (IP Rating) IP66 (NEMA 4X enclosure)
<35oC (95oF) at 93% relative humidity
Pollution Degree 2
Altitude 2000m maximum
Max. & min. temperature (electronics) -4ºF to 120ºF (-20 ºC to +50 ºC)
Flammable atmosphere approval Safe area: compatible with approved dB
transducers (see transducer spec' sheet)
Approvals
UL Certificate Number E257330
CE approval See EU Declaration of Conformity
Performance
Accuracy 0.25% of the measured range or
0.24" (6 mm) (whichever is greater)
Resolution 0.1% of the measured range or 0.08" (2 mm)
(whichever is greater)
Max. range Dependant on transducer (maximum 131ft
(40m) dB40)
Min. range Dependent upon transducer (minimum 0.41ft
(0.125m) dB 3)
Rate response fully adjustable
Echo Processing
Description DATEM (Digital Adaptive Tracking of Echo
Movement)

Page 5
Outputs
Analogue output Isolated (floating) or non-isolated output of
4-20 mA or 0-20 mA into 1K

(user
programmable and adjustable) 0.1%
resolution
Serial Port (Digital output) Full Duplex RS232 for programming and
data extraction
Volt free contacts, number and rating 2 form "C" (SPDT) rated at 2A at 115V AC
Display (optional) 2 x 12 alpha numeric
Programming
PC programming (standard) via RS232 using supplied software
Remote programming (optional) via RS232 using optional hand held
calibrator
On board programming (optional) via integral keypad
Programming security via passcode (user selectable and
adjustable)
Programmed data integrity via non-volatile RAM
Supply
Power supply 115 VAC +5% / -10% 50/60 Hz,
dc 10 - 28V
10W maximum power (typically 5W)
Overvoltage Category II
Fuses
Mains (F1) 100 mA T at 115 VAC
DC (Battery) (F2) 1A Thermal (self resetting after power
removed). Not user replaceable
Transducer (F3, F5) Littelfuse 242 series 100mA Part No.
0242.100. This fuse is not user replaceable
and has a 4000A breaking capability to
comply with certification of the Exm version
of dB series transducers.
Remote Communicator
Power Supply Power supplied via blackbox RS232
interface.
Pulsar Process Measurement Limited operates a policy of constant development and
improvement and reserve the right to amend technical details as necessary.

Page 6
EU Declaration of Conformity

Page 7
Chapter 2 Installation
Power Supply Requirements
The blackbox can operate from AC supply or from a DC battery and is
designed for use in temperatures between -4oF to +140oF (-20oC to +50oC).
The AC is 115V +5%/-10%. The DC is 10-28V. In all cases the blackbox
will typically consume 5W of power, with a maximum of 10W. If the
blackbox has both an AC and DC supply available then the AC supply source
will be automatically sensed and used, should the AC supply be removed for
any reason then the DC supply will take over.
The AC and DC wiring should be completed using either 16 –14AWG (1.5–
2.5mm2) stranded or 16 –14AWG (1.5–4mm2) solid wire, with all terminals
being tightened to 4.5in. lbs. (0.5Nm).
An external supply isolator/circuit breaker (AC or DC) must be fitted and
labelled to identify the instrument to which it refers.
Safety Symbols
Detailed below are descriptions and meanings of safety/warning symbols that
are used on the blackbox 130 and in this manual.
Direct Current
Alternating Current
Protective Conductor Terminal
Caution (Refer to accompanying Documents)
!

Page 8
Location
All electronic products are susceptible to electrostatic
shock, so follow proper grounding procedures during
installation.
The blackbox level controller must be mounted in a non-hazardous (safe)
Area, and the transducer fitted in the hazardous area.
Note: the blackbox shown in the
above diagram is for illustrative
purposes only and may not be
representative of the actual blackbox
supplied.
FM APPROVED TRANSDUCERS
Class I, Div. 1, Group A, B, C & D
Class II, Div. 1, Group E, F & G
Class III

Page 9
When choosing a location to mount the enclosure, bear in mind the following:
•Ensure that the blackbox is installed in a “Safe”, non-hazardous,
area.
•Easy access to the enclosure is maintained.
•The mounting surface is vibration-free.
•The ambient temperature is between -4ºF and 120ºF (-20ºC and
50ºC)
•There should be no high voltage cables or inverters close by.
Dimensions
Standard Enclosure
The dimensions of the mounting holes are as shown below.

Page 10
The blackbox should be mounted by drilling four holes suitable for size 8
pan or round headed screws. The screw length will be dependent on the wall
to which the blackbox is to be mounted to, if it is unclad use 1.5" long
screws with suitable wall fixings, if the wall is clad add the cladding
thickness to the 1.5" screw length.
Fit all four screws by removing the top cover to access the pre-moulded
mounting holes which are located in the corners of the base of the enclosure,
under the lid retaining screws.
Important Information
The enclosure lid screws should be tightened to 10in.lbs (1.1Nm).
Care should be taken not to over tighten the screws.

Page 11
The full dimensions of the enclosure are as shown below.
Cable Entry
There are 3 x 20mm (0.79") cable glands, suitable for 6 –12mm (0.24" –
0.63") cables, fitted to the base of the blackbox enclosure.

Page 12
Large Enclosure (optional)
The dimensions of the mounting holes are as shown below.

Page 13
The full dimensions of the enclosure are as shown below.
Cable Entry
There are 5 x 20mm (0.79") cable glands, suitable for 6 –12mm (0.24" –0.63")
cables, fitted to the base of the fitted to the base of the blackbox enclosure.

Page 14
Terminal Connection Details
The terminal strip is as detailed below. There is also a wiring diagram attached
to the board directly underneath the terminal strip.
Important Information
All terminal connection screws should be tightened to 4.5in.lbs.
(0.5Nm).
Care should be taken not to over tighten the screws.