Pulsar blackbox 130 User manual

BlackBox 130
Instruction Manual

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PULSAR MEASUREMENT
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BACKBOX 130 (SEVENTH EDITION REV 1)
March 2021
Part Number M-130-0-007-1P
COPYRIGHT
© Pulsar Measurement, 2003 - 21. 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 Measurement neither 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 Measurement
cannot be held liable for any errors.
Pulsar Measurement 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.
CONTACT
For technical support, please contact:
Europe: [e-mail]
Outside Europe: [e-mail]
If you have any comments or suggestions about this product, please contact:
Europe: [e-mail]
Outside Europe: [e-mail]
Pulsar Measurement website: www.pulsarmeasurement.com
United States
11451 Belcher Road South
Largo,
FL 33773
888-473-9546
Canada
16456 Sixsmith Drive
Long Sault, Ont.
K0C 1P0
855-300-9151
United Kingdom
Cardinal Building, Enigma
Commercial Centre
Sandy’s Road, Malvern
WR14 1JJ
00 44 (0)1684 891371

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CONTENTS
Chapter 1: Start Here… ...........................................................................................................7
About this Manual ...............................................................................................................7
About the BlackBox .............................................................................................................8
Functional Description .......................................................................................................9
Product Specification....................................................................................................... 10
EU Declaration of Conformity ...................................................................................... 12
Chapter 2 Installation........................................................................................................... 13
Unpacking............................................................................................................................13
Power Supply Requirements......................................................................................... 13
Location ................................................................................................................................13
Dimensions ..........................................................................................................................14
Terminal Connection Detail .......................................................................................... 16
Terminal Connection Detail .......................................................................................... 17
ATEX ....................................................................................................................................... 17
FM ........................................................................................................................................... 18
Voltage Selector and Fuse Location .......................................................................... 19
Preparation for Operation ............................................................................................. 20
Maintenance ....................................................................................................................... 20
Chapter 3 How To Use Your BlackBox...........................................................................21
On board integral Keypad .............................................................................................21
PC Handheld Programmer ............................................................................................ 21
Handheld Communicator (Optional).........................................................................22
Operating the Controls...................................................................................................23
Hot Keys................................................................................................................................24
Menu Keys ........................................................................................................................... 25
Numeric Keys......................................................................................................................25
Run Mode.............................................................................................................................26
LED’s....................................................................................................................................... 26
Program Mode................................................................................................................... 26
How to Access Program Mode.................................................................................... 27

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Directly Editing Parameters...........................................................................................28
Test Mode ............................................................................................................................ 29
Using the RS232 Serial Interface................................................................................. 30
Parameter Defaults........................................................................................................... 31
Chapter 4 Programming Guide........................................................................................ 32
Chapter 5 Parameter Guide ...............................................................................................38
Menu System Diagrams ................................................................................................. 38
Application Menu.............................................................................................................. 39
Relays Menu........................................................................................................................40
Data Logs Menu ................................................................................................................ 41
Volume Menu .....................................................................................................................42
Display Menu...................................................................................................................... 43
mA Output Menu.............................................................................................................. 43
Stability Menu .................................................................................................................... 44
Echo Processing Menu....................................................................................................45
System Menu ...................................................................................................................... 46
Test Menu ............................................................................................................................ 47
Application Parameters................................................................................................... 48
Operation ............................................................................................................................. 48
Dimensions ..........................................................................................................................49
Remote Alarm.....................................................................................................................51
SMS Time..............................................................................................................................52
Relay Parameters............................................................................................................... 54
Alarms.................................................................................................................................... 55
Control................................................................................................................................... 58
Common Parameters.......................................................................................................60
Data Logs ............................................................................................................................. 60
Volume ..................................................................................................................................61
Breakpoints.......................................................................................................................... 67

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Tables..................................................................................................................................... 68
Display Parameters........................................................................................................... 69
Options.................................................................................................................................. 69
Failsafe................................................................................................................................... 70
mA Output Parameters................................................................................................... 71
Range.....................................................................................................................................71
Operation ............................................................................................................................. 71
Setpoint................................................................................................................................. 72
Limits......................................................................................................................................72
Trim.........................................................................................................................................73
Failsafe................................................................................................................................... 73
Compensation Parameters............................................................................................ 74
Stability Parameters .........................................................................................................75
Filters......................................................................................................................................75
Echo Processing Parameters.........................................................................................76
System Parameters ........................................................................................................... 77
Passcode............................................................................................................................... 77
System Information.......................................................................................................... 77
Date & Time ........................................................................................................................78
Daylight Saving Time....................................................................................................... 78
Test Parameters ................................................................................................................. 82
Simulation ............................................................................................................................ 82
Hardware .............................................................................................................................. 83
Chapter 5 Troubleshooting................................................................................................85
Chapter 6 Disposal ................................................................................................................86

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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
TIP: Look for this icon throughout your Pulsar Measurement manual
to find helpful information and answers to frequently asked
questions.
Additional Information
Additional Information
At various parts of the manual, you will find sections
like this that explain specific things in more detail.

BLACKBOX 130 INSTRUCTION MANUAL
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About the BlackBox
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 handheld 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 can be used with any of the extensive range of
Pulsar transducers for distances up to 40m (131ft).
The BlackBox is designed to provide you with highly reliable measurement in
a robust and functional package that is easy to use and low in cost.

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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 0.125m (0.41 feet) to 40m (131 feet) 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 handheld 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.

BLACKBOX 130 INSTRUCTION MANUAL
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Product Specification
PHYSICAL
Outside dimensions
143 x 150 x 63.5 mm (5.63 x 5.91 x 2.5”)
Weight
Nominal 0.65 kg (1.4 lbs)
Enclosure material/description
ABS base with Polycarbonate lid, flammability rating
UL94HB
Cable entry detail
Underside fitted with 3 x M20, nylon cable glands
suitable for 6 –12mm cable
Transducer cable extensions
2 –core screened. (2 conductor 20AWG screened)
Nominal separation
1000 m (3,280 ft.). 500m (1,640 ft.) for dBR16 & dBR8,
for greater distances consult Pulsar
ENVIRONMENTAL
IP Rating (Wall)
IP66
Max. & min. temperature
(electronics)
-20 ºC to +50 ºC (-4ºF to 120ºF)
Flammable atmosphere
approval
Safe area: compatible with approved dB transducers (see
transducer spec' sheet)
CE Approval
See EU Declaration of Conformity
PERFORMANCE
Accuracy
0.25% of the measured range or 6 mm (0.24”)
(whichever is greater)
Resolution
0.1% of the measured range or 2 mm (0.08”) (whichever
is greater). ±2mm for dBR16 & dBR8
Max. range
Dependant on transducer (maximum 40m (131ft) dB40)
Min. range
Dependent upon transducer (minimum 0.077m (0.252 ft)
dBR16 & dBR8)
Rate response
Fully adjustable
OUTPUTS
Analogue output
Isolated active output (passive output optional) of 4-20
mA or 0-20 mA into 1K(user programmable and
adjustable) 0.1% resolution
Display
2 x 12 alpha numeric
Serial Port
RS232 for programming and data extraction
Volt free contacts, number,
and rating
5 form "C" (SPDT) rated at 5A at 115V/240V AC
ECHO PROCESSING
Description
DATEM (Digital Adaptive Tracking of Echo Movement)

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PROGRAMMING
On-board programming
By integral keypad
Programming security
Via passcode (user selectable and adjustable)
Programmed data integrity
Via non-volatile RAM
PC Programming
Via RS232 using supplied software
Remote programming
via RS232 using optional hand-held calibrator
SUPPLY
Power Supply
115 VAC +5% / -10% 50/60 Hz,
230 VAC +5% / -10% 50/60 Hz,
DC 10 - 28V
10W maximum power (typically 5W
Fuses
50 mA at 230V AC (fitted as standard)
100 mA at 115V AC (not supplied)
Pulsar Measurement operates a policy of constant development and
improvement and reserve the right to amend technical details, as necessary.

BLACKBOX 130 INSTRUCTION MANUAL
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EU Declaration of Conformity

PULSAR MEASUREMENT
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CHAPTER 2 INSTALLATION
Unpacking
Power Supply Requirements
The BlackBox can operate from AC supply or from a DC battery. The AC is
115V +5%/-10% 50/60Hz or 230V +5%/-10% 50/60Hz, depending on the
position of the selector switch. The DC is 10-28V. In all cases the Blackbox
will typically consume 5W of power, with a maximum of 10W.
Location
All electronic products are susceptible to electrostatic shock, so follow proper
grounding procedures during installation.
The BlackBox must be mounted in a non-hazardous (safe) Area.
Important Notice
All shipping cartons should be opened carefully. When using a box
cutter, do not plunge the blade deeply into the box, as it could potentially
cut or scratch equipment components. Carefully remove equipment from
each carton, checking it against the packing list before discarding any
packing material. If there is any shortage or obvious shipping damage to
the equipment, report it immediately to Pulsar Measurement.

BLACKBOX 130 INSTRUCTION MANUAL
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When choosing a location to mount the enclosure, bear in mind the
following:
•Easy access to the enclosure is maintained.
•The mounting surface is vibration-free.
•The ambient temperature is between -20ºC and 50ºC (-4ºF and
120ºF).
•There should be no high voltage cables or inverters close by.
Dimensions
The dimensions of the mounting holes are as shown below:
The BlackBox should be mounted by drilling four holes suitable for size 8
screws (length and type to suit your application) And fix all four screws by
removing the top cover to access the pre-moulded mounting holes which
are in the base of the enclosure under the lid retaining screws

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The full dimensions of the enclosure are as shown below.
Cable Entry
There are 3 x M20 cable glands, suitable for 6 –12mm cables, fitted to the
base of the BlackBox enclosure.
3 off M20
Glands
130mm (5.12”)
63.5mm (2.5”)
150mm (5.91”)
13mm
(0.51”)
Important Notice
All cable glands should be tightened to the manufacturer’s specifications.
The terminal compartment cover screws should be tightened to 0.5Nm
Care should be taken not to over tighten the screws.

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Terminal Connection Detail
The terminal strip is as detailed below. There is also a wiring diagram
attached to the board directly underneath the terminal strip.

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Terminal Connection Detail
Power
The BlackBox can operate from mains AC and automatically from a DC
power source or battery backup, in the event of power failure, or can be
operated permanently from DC or batteries.
Transducer
The transducer should be installed, and connected, in accordance with the
installation instructions contained in the Transducer User Guide.
The entire range of standard dB transducers are certified for use in
hazardous areas and different models, for each, are available for use in EEx
m (Zone 1) or EEx ia (Zone 0).
Wire the transducer to the BlackBox transducer terminals as detailed below:
Red = Power (Terminal 19)
White = Signal (Terminal 20)
Black = 0 volts (Terminal 18)
Green (screen) = SCR (Terminal 17)
When using 2 core screened extension cable, the Black and Green wires of
the transducer should be connected to the screen of the extension cable and
connected to the 0 volts’ terminal (Terminal 18).
ATEX
For EEx m (Zone 1) applications a transducer certified to Sira
02ATEX5104X is used, and must be supplied via a 4000A breaking fuse,
which is fitted as standard to the BlackBox level controller.
For EEx ia (Zone 0) a transducer certified to Sira 02ATEX2103X is used,
which must be connected to the BlackBox via an external Zener barrier.

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FM
For EEx m (Zone 1) applications a transducer certified to FM Class I Div 1
Group A, B, C & D, ClassII Div 1 Group E, F & G, Class III is used, and must
be supplied via a 1500A breaking fuse, which is fitted as standard to the
blackbox level controller.
Restrictions do not use in the presence of these groups of Chemicals,
Aliphatic Hydrocarbons, Ketones or Esters
For EEx ia (I.S.) a transducer certified to FM Class I Div 1 Group A, B, C &
D, ClassII Div 1 Group E, F & G is used, which must be connected to the
blackbox via an external Zener barrier.
See transducer label for certification details.
Relay Outputs
The two relays can be programmed to a variety of alarm & control functions.
The relay contacts are all rated at 2A at 240V AC. All connections should be
such that the short circuit capacity of the circuit to which they are
connected, is limited by fuses rated so that they do not exceed the relay
rating.
Current Output
This is an isolated active mA output of 4 - 20mA or 0 - 20mA, with an option
of a passive mA output. The load should not exceed 1K

.
RS232 Serial Interface
The serial interface is used to program the BlackBox either via a PC
(standard) using the software supplied or alternatively using the handheld
calibrator (optional).

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Voltage Selector and Fuse Location
The voltage selector switch, and AC mains power fuse is located, on the
bottom board to the left and above of the power input terminals, as
previously illustrated in the Terminal Connections Detail drawing.
Make sure you move the voltage selector switch to the correct
position for your supply.
Important Notice
Before applying AC power (mains), make sure you have correctly selected the
voltage selector switch which is located to the left and above of the mains
supply input terminals, as illustrated in the Terminal Connections Detail drawing.
Please note that all units are supplied set to 230 volts AC for safety reasons, with
a 50mA fuse fitted as standard.
Never operate the BlackBox with the cover removed.
An external switch or circuit breaker should be installed near to the BlackBox to
allow the supply to be removed during installation and maintenance. In addition,
the relay contacts should also have a means of isolating them from the Blackbox.
Interconnecting cables must be adequately insulated in accordance with local
regulations. Strip back 30 mm of the outer insulation of the cable. Strip 5 mm of
insulation from the end of each conductor. Twist all exposed strands of the
conductor together. Insert the stripped conductor into the terminal block as far
as it will go and tighten the terminal block screw. Ensure that all strands are
firmly clamped in the terminal block and that there is no excess bare conductor
showing, and no stray strands.
Important Notice
If the equipment is installed or used in a manner not specified in this manual,
then the protection provided by the equipment may be impaired.

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Preparation for Operation
Before switching on, check the following:
√The BlackBox is mounted correctly and is in a ‘safe’ area.
√The power supply is correctly installed.
√The relays are connected correctly.
√The voltage selector switch is in the correct position.
Maintenance
There are no user serviceable parts inside your Blackbox, except the mains
power fuse. If you experience any problems with the equipment, then please
contact Pulsar Process Measurement for advice.
To clean the equipment, wipe with a damp cloth. Do not use any solvents on
the enclosure or transducer.
Important Notice
The unique DATEM software comes into operation as soon as power is applied,
and is designed to monitor a moving level or target with the transducer in a
fixed position.
If, after any period of use, it should become necessary to move the transducer,
for any reason, from its original operating position, switch off the Blackbox,
before proceeding, to prevent any undesirable updates to the DATEM trace. If
after moving the transducer the reading is not as expected, please refer to
Chapter 6 Troubleshooting.