Pulsar SLUDGE FINDER 2 User manual

SLUDGE FINDER 2
INSTRUCTION MANUAL

SLUDGE FINDER 2(THIRD EDITION)
June 2016
Part Number M-920-0-003-0P
COPYRIGHT
© Pulsar Process Measurement Limited, 2009 - 16. 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.
TECHNICAL ENQUIRIES
Please contact Pulsar Process Measurement Limited 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 Commercial Centre
Sandy’s Road
Malvern
Worcestershire
WR14 1JJ
United Kingdom
PO Box 5177
Niceville
FL 32578-5177
USA
Tel: + 44 (0) 870 6039112
Fax: + 44 (0) 870 6039114
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 theSludge Finder 2..............................................................................................................................2
Applications.....................................................................................................................................................3
Functional Description.................................................................................................................................... 4
Product Specification.......................................................................................................................................5
EC Declaration of Conformity........................................................................................................................7
Chapter 2 Installation............................................................................................................................................9
Power Supply Requirements...........................................................................................................................9
Unpacking........................................................................................................................................................9
Location.........................................................................................................................................................10
Dimensions....................................................................................................................................................11
Wall mount............................................................................................................................................11
Transducer..............................................................................................................................................13
Terminal Connection Details........................................................................................................................14
Wall Mount............................................................................................................................................14
Transducer (Sensor) ......................................................................................................................................17
Locating the Sludge Transducer...........................................................................................................17
Installing the Transducer.......................................................................................................................17
Wall mount unit.............................................................................................................................................18
Locating the Sludge Finder 2 unit.........................................................................................................18
Installing the controller..........................................................................................................................18
Preparation for Operation..............................................................................................................................20
Maintenance...................................................................................................................................................20
Transducer Maintenance...............................................................................................................................20
Transducer Installation Options....................................................................................................................23
Transceiver Mounting...................................................................................................................................28
Cabinet Mounting..........................................................................................................................................29
Pulsar Radio Telemetry System...........................................................................................................................31
Chapter 3 How to Use Your Sludge Finder 2.................................................................................................49
Operatingthe Controls..................................................................................................................................49
Display...................................................................................................................................................49
Run Mode..............................................................................................................................................50
Program Mode.......................................................................................................................................53
How to Access Program Mode.....................................................................................................................53
Screenshots of program mode...............................................................................................................53
Information screen.................................................................................................................................54
Hot Keys................................................................................................................................................55
Menu Keys.............................................................................................................................................56
Numeric Keys........................................................................................................................................57
UsingtheMenu System........................................................................................................................58
Test Mode......................................................................................................................................................60
Usingthe RS232 Serial Interface..................................................................................................................61
Parameter Defaults........................................................................................................................................63
FactoryDefaults.....................................................................................................................................63
Chapter 4 Programming Guide..........................................................................................................................65
Example 1: Primary Settlement Sludge Interface monitoring.....................................................................65
Setting Up Point2 with asan UltrasonicPoint ofMeasurement................................................................67
Example 2: Level Monitoring with High and Low Alarms on Point 2......................................................67
Example 3: Using a Single Viper Transducer to Measure 2 Different Interface Levels............................70
Example 4: Setting the Unit to Alarm on Hi-Floc Levels ...........................................................................71
Chapter 5 Menu System and Parameter Guide ................................................................................................74
Top Level Menu....................................................................................................................................74

Application Menu..................................................................................................................................75
Relays Menu..........................................................................................................................................76
Floc Alarm Menu..................................................................................................................................77
................................................................................................................................................................77
Data Logs Menu....................................................................................................................................78
DisplayMenu........................................................................................................................................79
mA Output Menu..................................................................................................................................80
Compensation Menu.............................................................................................................................81
StabilityMenu........................................................................................................................................82
Echo Processing Menu..........................................................................................................................83
System Menu.........................................................................................................................................84
Device Comm Menu.............................................................................................................................86
Test Menu..............................................................................................................................................87
Chapter 6 Parameter Listing and Descriptions.................................................................................................89
Application Parameters.................................................................................................................................89
Point 1 / Point 2......................................................................................................................................89
Global.....................................................................................................................................................93
RelayParameters...........................................................................................................................................94
Alarms....................................................................................................................................................96
Control....................................................................................................................................................99
Miscellaneous......................................................................................................................................101
Common Parameters...........................................................................................................................102
Floc Alarm parameters................................................................................................................................103
Service Interval Alarm Parameters.............................................................................................................104
Data Log Parameters...................................................................................................................................104
Point 1 / Point 2....................................................................................................................................104
DisplayParameters......................................................................................................................................105
Point 1 / Point 2....................................................................................................................................105
Failsafe.................................................................................................................................................106
mAOutput Parameters................................................................................................................................107
mA Out 1 / mA Out 2..........................................................................................................................107
Setpoints...............................................................................................................................................108
Compensation Parameters...........................................................................................................................110
Offset....................................................................................................................................................110
Temperature.........................................................................................................................................110
StabilityParameters.....................................................................................................................................111
Point 1 / Point 2....................................................................................................................................111
Damping...............................................................................................................................................111
Filters....................................................................................................................................................111
Echo Processing Parameters.......................................................................................................................113
Point 1 / Point 2....................................................................................................................................113
System Parameters......................................................................................................................................114
Passcode...............................................................................................................................................114
Backup.................................................................................................................................................114
System Information.............................................................................................................................115
Date &Time........................................................................................................................................116
LED Colour .........................................................................................................................................116
Watchdog.............................................................................................................................................117
Daylight Saving Time.........................................................................................................................118
Device Comm..............................................................................................................................................121
RS232 Set Up......................................................................................................................................121
Modbus or ProfibusRS485 Setup......................................................................................................121
Test Parameters............................................................................................................................................122
Simulation............................................................................................................................................122
Hardware..............................................................................................................................................123
Chapter 7 Troubleshooting ..............................................................................................................................125
Parameter Record...............................................................................................................................................127

Page 1
Chapter 1 Start Here…
Congratulations on your purchase of a Pulsar Sludge Finder 2. This quality system
has been developed over many years and represents the latest in high technology
ultrasonic sludge monitoring.
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
At various parts of this manual
you may 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 Sludge Finder 2
The single Sludge Finder 2 unit provides dual point level sensing in liquids
and/or air.
Easily installed, conduit entry on unit via 5 x 20mm Knockouts and 1 x 16mm
knockout.
Outstanding stability, accuracy and repeatability.
Sophisticated algorithms for echo extraction utilizing powerful Digital Signal
Processing (DSP) microprocessors.
Superior performance based on current leading edge technology and modern
design procedures.
Two independent transducer channels with the option of combining
submersible and air transducers
Two fully adjustable 4-20 mA outputs
Six fully programmable SPDT status relays
RS232 and RS485 communications ports for multiple unit installations.
Radio communications for remote 4-20mA Indication (optional).
All these features and more plus the ease of programming, make this
instrument the number one choice for interface level measurement in liquids.

Page 3
Applications
The Sludge Finder 2 is designed to monitor the levels of materials in various
processes and to regulate the control loops, start and stop motors, and initiate
events based on measured process conditions.
Some applications for the units are listed below:
 Water & Wastewater Treatment Clarifiers
 Water & Wastewater Gravity & DAF Thickeners
 Raw Water Clarifiers
 Sumps, lagoons, settling ponds
 Industrial Process Thickeners
 Salt Brine Tanks
 Material Inventory Tanks
 Process Thickeners
 Dewatering/Hydro Bins
 Pyrite Holding/Transfer Tanks
 FGD Thickeners
 Surge & Settling Tanks
Oil/Water separators
 SBR Tanks

Page 4
Functional Description
Sludge Finder 2 sends a transmit pulse to the transducer, which then emits a high
frequency ultrasonic sound wave perpendicular to the transducer face, the returned
echo is received by the Sludge Finder 2. The time taken to receive the echo is
measured and the distance from the transducer face to the sludge interface is
calculated.
The relays can be programmed to activate alarms, pump starters, or other control
equipment. There is an isolated 4-20 mA output for each of two transducer
channels that can be connected to a recorder or PLC to monitor the sludge
interface independently from that shown on the display. Finally, there is an RS232
port, so that the Sludge Finder 2 can be operated remotely by a PC or other
equipment to download/upload parameters or view real time echo traces.
Sludge Finder 2 can be programmed either by the built-in keypad, or by PC via
the RS 232 Serial Interface. All parameters are stored in non-volatile memory, so
are retained in the event of power interruption. A second backup copy of all
parameters can also be retained in the Sludge Finder 2 memory, in case an
alternative set of parameters needs to be stored.
Six user definable control relays with individual setpoints and intelligent
performance logging software features ensure maximum control versatility.
The Pulsar Sludge Finder 2 ultrasonic sludge detector has been designed to
provide maintenance-free fit and forget performance.

Page 5
Product Specification
Physical
Wall Mount
Outside dimensions 235 x 184 x 120 mm
Weight Nominal 1 kg
Enclosure material/description Polycarbonate, flame resistant to UL94-5V
Cable entry detail 10 cable entry knock outs, 5 x M20
and 1 x M16 underside,
4 x PG11 at rear
Transducer cable extensions 2 twisted pair 0.5mm2with overall screen
Maximum separation 200 m
Environmental
IP Rating (Wall) IP65
Max. & min. temperature (electronics) -20 ºC to +50 ºC
Flammable atmosphere approval Safe area: compatible with approved dB
transducers (see transducer spec' sheet)
CE Approval See EC Declaration of Conformity
Performance (with Sludge)
Accuracy 0.25% of the measured range or
10 mm (whichever is greater)
Resolution 0.25%of the measured range or 10 mm
(whichever is greater)
Max. range 10m
Min. range 0.3m
Outputs
Analogue output 2 off Isolated (to 150V floating) output of 4-
20 mA or 0-20 mA into 1k

(user
programmable and adjustable) 0.1%
resolution
Digital output Half Duplex RS232
Volt free contacts, number and rating 6 form "C" (SPDT) rated at 5A at 115V AC
Display 192 x 128 pixel illuminated graphical display
Fully programmable display options Integral
keypad with menu navigation keys
Radio Modem (optional) 4 –20mA using wireless exempt
frequencies
Maximum range 500m line of site
Communication bus (optional) RS485 Modbus RTU/ASCII or Profibus
DPV0 or DPV1 (slave device)
Programming
On-board programming By integral keypad
PC programming via RS232
Programming security Via passcode (user selectable and
adjustable)

Page 6
Programmed data integrity Via non-volatile memory
Supply
Power supply universal 100-240V ac 50-60 Hz,
dc 22 - 28V
20W maximum power (typically 11W)
Fuse 2A slow blow
Pulsar Process Measurement Limited operates a policy of constant development and improvement
and reserve the right to amend technical details as necessary.

Page 7
EC Declaration of Conformity

Page 8
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Page 9
Chapter 2 Installation
Power Supply Requirements
Sludge Finder 2 can operate from AC supply or from a DC battery. The AC is
supplied via a universal 100-200VAC transformer. The DC is 22-28V. In all cases
the Sludge Finder 2 will typically consume 11W of power, with a maximum of
20W.
All electronic products are susceptible to electrostatic
shock, so follow proper grounding procedures during
installation.
Unpacking
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 Process Measurement

Page 10
Location
All electronic products are susceptible to electrostatic
shock, so follow proper grounding procedures during
installation.
Sludge Finder 2 must be mounted in a non-hazardous (safe) area at all times.
When fitted with a transducer from the dB range (air transducers), the dB
transducer may be mounted in a hazardous area as shown below. At the time of
publication of this manual, the VT range of transducers do not have hazardous area
approval. There are two types of approval available for dB transducers, EEx m and
EEx ia. The EEx m transducer can be connected directly to the Sludge Finder 2
terminals but the EEx ia transducer must be connected through a suitable zener
barrier as shown below.

Page 11
When choosing a location to mount the enclosure, bear in mind the following:
Ensure that the Sludge Finder 2 is installed in a “Safe”, non-hazardous,
area.
For a clear view of the LCD display it is recommended that it is mounted
at eye level.
The mounting surface is vibration-free.
The ambient temperature is between -20ºC and 50ºC.
There should be no high voltage cables or inverters close by.
Dimensions
Wall mount
The dimensions of the wall fixing holes are as shown below.
Sludge Finder 2 should be mounted by drilling three holes suitable for size 8
screws (length to suit your application) and fixing the top screw in place. Hang
the unit on this and fix the two remaining screws by removing the terminal
access cover to access the pre drilled holes.

Page 12
The full dimensions of the enclosure are as shown below.

Page 13
Cable Entry
There are 6 cable gland knockouts on the base of the Sludge Finder 2 (5 x M20,
1 x M16) and 4 on the rear (4 x PG11). Select which ones you wish to take out,
and remove them by using a circular cutter, such as a tank cutter. Take care not to
damage the circuit board inside whilst undertaking this. Do not use a hammer, as
this may cause damage to the enclosure.
It is recommended that you use suitable cable glands to ensure that the ingress
rating is maintained.
Transducer

Page 14
Terminal Connection Details
Wall Mount
The terminal strip is as detailed below. There is also a wiring diagram inside the
terminal access cover.
Terminal Connections
Power
Sludge Finder 2 can operate from mains AC and automatically from DC or battery
backup in the event of power failure, or can be operated permanently from DC or
batteries.
Wire the transducer to the Sludge Finder 2’s transducer terminals as follows:
Transducer 1
VT transducer
Terminal Connection Details
Unit Type
Orange
Motor
Red
Power
White
Signal
Black
0 volts
Green
Screen
Terminal no.
37
38
39
40
40
dB transducer
Terminal Connection Details
Unit Type
N/C
Red
Power
White
Signal
Black
0 volts
Green
Screen
Terminal no.
37
38
39
40
40