Siemens interranger DPS300 Operating and maintenance manual

Instructional Manual March 2008
DPS300
interranger

© Siemens Milltronics Process Instruments Inc. 2008
Safety Guidelines
Warning notices must be observed to ensure personal safety as well as that of others, and to protect the product and the connected equipment.
These warning notices are accompanied by a clarification of the level of caution to be observed.
Qualified Personnel
This device/system may only be set up and operated in conjunction with this manual. Qualified personnel are only authorized to install and
operate this equipment in accordance with established safety practices and standards.
Warning:This product can only function properly and safely if it is correctly transported, stored, installed, set up, operated, and maintained.
This product is intended for use in industrial areas.
Note: Always use product in accordance with specifications.
Copyright Siemens Milltronics Process
Instruments Inc. 2008. All Rights Reserved
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Inc. will not be responsible for the contents of partial or
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manual for agreement with the instrumentation
described, variations remain possible. Thus we
cannot guarantee full agreement. The contents of
this manual are regularly reviewed and
corrections are included in subsequent editions.
We welcome all suggestions for improvement.
Technical data subject to change.
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Siemens Milltronics Process Instruments Inc.
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Peterborough, Ontario, Canada, K9J 7B1
Email: [email protected]
•For a selection of Siemens Milltronics level measurement manuals, go to:
www. siemens.com/processautomation. Under Process Instrumentation, select
Level Measurement and then go to the manual archive
listed under the product family.
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Continuous Weighing Systems and then go to the manual
archive listed under the product family.

7ML19981BC01 3InterRanger DPS300
TABLE OF CONTENTS
Table of Contents.....................................................................................................3
Specifications...........................................................................................................5
Electronics............................................................................................................5
Programmer .........................................................................................................6
Transducer ...........................................................................................................6
Options.................................................................................................................7
Cable....................................................................................................................8
Introduction..............................................................................................................9
About This Manual................................................................................................9
About The InterRanger DPS300.........................................................................10
Important InterRanger DPS300 Features ...........................................................13
Programmable Features.....................................................................................14
As a System .......................................................................................................15
Application Planning ..............................................................................................16
Circular Clarifiers ................................................................................................16
Rectangular Clarifiers .........................................................................................18
Application Example...............................................................................................22
Installation..............................................................................................................24
Location..............................................................................................................24
Optional Mounting Assembly ..............................................................................25
Optional Skimmer Guard ....................................................................................29
Transducer Mounting..........................................................................................33
Assembly............................................................................................................35
Communication...................................................................................................39
Level System Synchronization............................................................................40
Power .................................................................................................................40
Programming .........................................................................................................42
Display................................................................................................................42
Keypad – Program Mode....................................................................................43
Programming Security ........................................................................................45
Quick Start Parameters .........................................................................................46
Operation................................................................................................................49
Display................................................................................................................49
Keypad – Run Mode...........................................................................................50
System Performance Evaluation.........................................................................51

InterRanger DPS300 47ML19981BC01
Performance Test Results.................................................................................. 52
Application Parameters ........................................................................................ 53
Volume Parameters (P050 to P055) .................................................................. 53
Reading Parameters (P060 to P062) ................................................................. 55
Failsafe Parameters (P070 to P072) .................................................................. 56
Relay Parameters (P100 to P104, P110 to P113, P129).................................... 58
mA Output Parameters (P200 to P203, P210 to P215, P219)............................ 64
Enhancement Parameters .................................................................................... 68
Data Logging Parameters (P300 and P302) ...................................................... 68
Profile Records (P330 to P337) ......................................................................... 69
Installation Records (P340 to P342)................................................................... 72
Range Calibration Parameters (P650 to P654) .................................................. 72
Temperature Compensation Parameters (P660 to P664) .................................. 74
Rate Parameters (P700 to P707)....................................................................... 75
Measurement Verification Parameters (P710 to P713) ...................................... 77
Display Parameters (P730 to P733, P740)......................................................... 78
Peripheral Communication Support Parameters (P740 to P772) ....................... 79
SmartLinx®Parameters (P790 to P792)........................................................... 81
Echo Processing Parameters (P800 to P807).................................................... 81
Advanced Echo Processing (P810 to P853) ...................................................... 83
Test Parameters (P900 to P913)........................................................................ 90
Measurement Parameters (P920 to P923)......................................................... 92
Master Reset (P999).......................................................................................... 93
Technical Reference ............................................................................................. 95
Transmit Pulse................................................................................................... 95
Echo Processing................................................................................................ 96
Distance Calculation .......................................................................................... 97
Sound Velocity................................................................................................... 97
Scanning............................................................................................................ 97
Volume Calculation ............................................................................................ 97
Communication Support..................................................................................... 98
Maintenance ........................................................................................................ 102
Troubleshooting Guide....................................................................................... 103
DEFAULT PARAMETER SETTINGS ................................................................... 106
Programming Charts........................................................................................... 107

7ML19981BC01 5InterRanger DPS300
SPECIFICATIONS
Electronics
Power: !100/115/200/230 V AC ±15%, 50/60 Hz, 31 VA
Environmental: !location !indoor / outdoor
!altitude !2000 m max
!ambient temperature !-20 to 50°C (-5 to 122 °F)
!relative humidity !suitable for outdoor (Type 4X /
NEMA 4X / IP65 enclosure)
!installation category !II
!pollution degree: !4
Scan Points: !2 points per DPS300
Accuracy: !1% of program range* or 2 cm (0.8”), whichever is greater
(ideal conditions)
Resolution: !1% of program range* or 2 cm (0.8”),
whichever is greater (ideal
conditions)
Memory: !EEPROM (non-volatile) no back-up battery required
Programming: !via removable programmer and / or Dolphin Plus interface package
Display: !custom graphics, backlit LCD with 51 x 127 mm (5 x 2”) viewing
area
Temperature : !-50 to 150 °C (-58 to 302 °F)
Compensation !integral transducer sensor
!2 TS-3 temperature sensors, max.
!programmable fixed temperature
Temperature Error: !with compensation: !0.1% of range
!fixed temperature: !0.22% / °C deviation from
programmed temperature.
Outputs: !transducer drive: !150 to 315 V peak
!relays: !4 alarm/control relays
!1 form “C” SPDT contact per relay,
!rated 5 A at 250 V AC, non-inductive
!mA output: !2 outputs max.
!0.1% resolution
!0-20 or 4-20 mA, scalable
!750 Ω, isolated, 30 V rms
* program range is defined as the empty distance to the face of the transducer
(P006) plus any range extension (P801).

InterRanger DPS300 67ML19981BC01
Communications: !SmartLinx ® compatible
(see Options) !RS-232 / 485 port
!Dolphin compatible
!proprietary bipolar current loop for BIC-2 communication
Enclosure: !Type 4 / NEMA 4 / IP65
!285 mm W x 209 mm H x 92 mm D (11.2” W x 8.2” H x 3.6” D)
!polycarbonate
Weight: !2.7 kg (6 lb)
Approvals: !CE *, CSA NRTL/C
*EMC performance available upon request.
Programmer
Power: may be supplied with either:
!3 V Lithium (non-replaceable)
or
!9 V (ANSI/NEDA 1604, PP3 or equivalent)
Ambient Temperature: !-20 to 50°C (-5 to 122°F)
Keypad: !20 keys with tactile feedback
Interface: !non-invasive, digital, infra-red
Enclosure: !general purpose
!67 mm W x 100 mm H x 25 mm D (2.6” W x 4” H x 1” D)
!ABS plastic
Weight: !150 g (0.3 lb)
Transducer
Model: !Echomax®XCT-12
Beam angle: !30°
(in water)
Range: !1 to 30m (3.3 to 99’)
Refer to the associated instruction manual for wiring only (not installation).

7ML19981BC01 7InterRanger DPS300
Options
Skimmer Guard
!for protecting the transducer and allowing it to slide over the
skimmer as it passes.
Mounting Assembly
!for securing and positioning the transducer in the clarifier.
Temperature Sensor:
!model TS-3
Buffered Interface Converter:
!BIC-II, DPS300 bipolar communication current loop to remote
RS232 or RS422 port
SmartLinx® Modules
!protocol specific modules for interface with popular industrial
communication systems. Refer to associated product
documentation.
Dolphin Plus:
!Windows®-compatible interface and infrared ComVerter link
. Refer to associated product documentation.
Cable:
!to suit transducer, temperature sensor, instrumentation and
communication
Skimmer Guard
Model: !Type A for 20cm (8”) skimmers
!Type B for 40cm (16”) skimmers
Temperature: !-40 to 80 °C (-40°C to 176°F)
Construction: !stainless steel hinged conduit with guard, and neoprene
hinge boot
Connection: !transducer: 1” NPT or BSP coupling
!conduit: ¾” NPT or BSP coupling
Articulation: !± 90°off vertical
Weight: !Type A: 1.4 kg (3 lb)
!Type B: 2.1 kg (5 lb)
Mounting Assembly
Application: !railings, typically 50mm dia. pipe or less, 2 rails spaced 432
to 610mm (17 to 24”)apart on centre
Temperature: !-40 to 80°C (-40 to 176°F)
Construction: !epoxy coated aluminum, with stainless steel hardware
Weight: !6.5 kg (15 lbs)

InterRanger DPS300 87ML19981BC01
Cable
Transducer: !RG-62 A/U (or equivalent), 365m (1,200 ft) max.
See transducer instructions for short extensions
(in grounded metal conduit, separate from other wiring)
MA Output: !Belden 8760, shielded / twisted pair, 18 AWG (0.75mm2) or
equivalent
Maximum separation 1,500 m (5,000 ft)
Synchronisation: !Belden 8760, shielded / twisted pair, 18 AWG (0.75mm2) or
equivalent
RJ-11 Port: !No shielded cable necessary
Maximum length 3m
Bipolar Current Loop: !Belden 8760, shielded / twisted pair, 18 AWG (0.75mm2) or
equivalent
Maximum separation 1,500 m (5,000 ft)
RS-232 Link !Belden 8770, shielded / twisted pair, 18 AWG (0.75mm2) or
equivalent
Maximum separation 15 m (50 ft)
RS-485 Link: !Belden 8770, shielded / twisted pair, 18 AWG (0.75mm2) or
equivalent
Maximum separation 1,200 m (4,000 ft)

7ML19981BC01 9InterRanger DPS300
INTRODUCTION
About This Manual
This instruction manual provides information specific to the InterRanger DPS300
(Dual Point Sludge) monitoring system.
Introduction introduces installers and operators to the DPS300,
with brief descriptions of key features.
Installation provides a step by step procedure to install the
DPS300.
Programming defines program mode display and keypad functions,
and general programming information.
Quick Start Parameters details the minimum programming required to get
started.
Operation defines RUN mode display and keypad functions,
including the RUN mode entry procedure and
performance evaluation recommendations.
Application Parameters details the programmable features which may be
used to alter Run mode display, failsafe, relay, and
mA output operation.
Enhancement Parameters defines the programmable features used to enhance
RUN mode operation. (Typically used as directed by
the Troubleshooting Guide).
Technical Reference provides detailed information for complex features
and provides application examples.
Troubleshooting Guide provides a quick reference to installation modification
and programming remedies to overcome challenging
operating conditions.
Specifications lists the environmental, physical, and operational
characteristics associated with the DPS300.
Programming Chart provides a convenient space to record all
programming for future reference.

InterRanger DPS300 10 7ML19981BC01
About The InterRanger DPS300
Note:
•The InterRanger DPS300 is to be used only in the manner outlined in this
instruction manual.
•This product is intended for use in industrial areas. Operation of this equipment
in a residential area may cause interference to several frequency based
communications.
This microprocessor based level monitor is designed specifically for the
measurement of sludge blanket levels in wastewater clarifiers. A DPS300 level
monitor, and Siemens ultrasonic transducer, accurately monitor the sludge blanket
level without contacting the blanket.
The DPS300 transmits electrical pulses to the transducer. The transducer
converts the electrical pulses to ultrasonic pulses, which are emitted from the
transducer face. The DPS300 measures the time from pulse emission to reception
of the echo from the sludge interface. The time measured, is used to calculate the
distance from the transducer face to the sludge blanket.
The distance calculation is dependent upon the sound velocity through the
wastewater in the clarifier, which is in turn dependent upon the temperature of the
wastewater. The transducer, having an integral temperature sensor, and being
immersed into the wastewater, also monitors the temperature of the wastewater.
The transducer transmits the temperature to the DPS300, where velocity
compensation is applied to the level measurement calculation.
Nominally speaking, the DPS300 is capable of detecting down to 4% solids, in up
to 30m of turbid wastewater, and 0.2% solids in 5 m of clear wastewater.
This material and measurement range versatility is accomplished by using
Siemens patented Sonic Intelligence™. Sonic Intelligence provides high
measurement reliability, regardless of changing conditions in the clarifier.

7ML19981BC01 11 InterRanger DPS300
By using ultrasonic echo ranging principles with Sonic Intelligence and velocity
compensation, the DPS300 provides outstanding measurement accuracy, up to
1% of range, depending on process conditions.
The distance calculation may be converted to space, material level, material
volume, or remaining capacity. The Reading chosen (and operating data) for each
clarifier is displayed on the Liquid Crystal Display (LCD).
The relays and mA outputs may be used as preset (or programmed as desired) to
activate alarms and/or operate remote monitoring equipment and/or process
control equipment.
As well, the DPS300 may be connected to a Milltronics BIC-II (Buffered Interface
Converter) to provide RS-232 and/or RS-422 communications for host computers,
Distributed Control Systems, and special (capable of operating as a host device)
Programmable Logic Controllers.
Programming can be done locally using the portable programmer keypad, or
remotely through optional Dolphin software or SmartLinx®.
•The programmer transmits the keypad entries via infrared link to the DPS300, and
can be removed when not in use.
•Dolphin allows programming either through the portable ComVerter and infrared
link or hardwired via the RS-232/485 communication port.
•SmartLinx®provides protocol specific hardware and software for interface with
popular industrial communication systems.

InterRanger DPS300 12 7ML19981BC01
DPS300 Communication Overview
or
0/4—20mA
(PLC or DCS)
SmartLinx®
RS-232 or 485
(local)
Bipola
r
current loop
(remote)
RS-232 or 422 or
Plant-wide
control system
network

7ML19981BC01 13 InterRanger DPS300
Important InterRanger DPS300 Features
Fixed Features
Enclosure: Corrosion resistant, dust and liquid tight.
Backlit LCD: Large digits for Reading and programming value
displays.
Illuminated LCD insures readability under all lighting
conditions.
Custom Graphic Symbols for continuous indication of
operating conditions.
Programmer: 20 keys for easy access to programming and
operating functions.
Magnetic mounting and infrared interface permit
removal on programming completion.
Scanning: Capable of scanning two clarifiers, with the addition of
a second transducer.
Communications: SmartLinx® Compatible
Communications ready when equipped with an
appropriate Siemens SmartLinx module.
Milltronics Peripherals
The communication port provides connection for
RS-232, RS-485 or Milltronics bipolar current
loop. The current loop provides remote
communication via Milltronics BIC II to the
peripheral device. The BIC II converts the current
loop to RS-232 or RS-422 signal
Dolphin Compatible Communications
Dolphin Plus is Windows95®-compatible
software. It offers local interface through the
infrared ComVerter, or remote connection
through the RS-232 or RS-485 port. The software
provides an easy means for programming,
uploading, or downloading parameters.
Reliability: Sonic Intelligence™ ensures all measurements are
accurate and reliable.
Immune to power interruptions. All programming is
stored indefinitely. Dynamic operating data is retained
for one hour and updated immediately on power
resumption.

InterRanger DPS300 14 7ML19981BC01
Programmable Features
Typically, a very small percentage of the programmable features require operator
alteration. However, for demanding measurement requirements any operator
programmable feature may be adjusted as desired.
Following is a list of some of the features that make the DPS300 easy to program,
yet versatile enough to handle complex level measurement requirements.
General Features
Direct Access: Any operator programmable feature may be accessed
directly.
Scroll Access: Single button “scroll forward”, single button “scroll
back”, to key features.
Operation: Select “level”,”space”,or ”distance”.
Material: Select clarifier type; automatically adjusts echo
processing for the type of clarifier.
Units: Display Readings in m, cm, mm, ft, in, %, or any other
units desired.
Additional Features (Use as Desired)
Failsafe: Numerous failsafe options for process control
equipment activation.
Relays: 8 functions including level, rate of change, pump
control, temperature and more.
Fixed or independent on/off setpoints
mA outputs: Based on level, space, or distance.
4 range selections, 0-20, 4-20, 20-0, or 20-4 mA.
Adjustable range and over-range limits.

7ML19981BC01 15 InterRanger DPS300
As a System
As a system, the DPS300 is made up of:
minimum maximum
one DPS300 one DPS300
one XCT-12 transducer two XCT-12 transducers
one Skimmer Guard per transducer
one Mounting Assembly per transducer
one SmartLinx communications module
DPS300 System Integration
•Assemble the transducer to the Siemens Skimmer Guard if provided. Otherwise
install directly to your conduit with a ¾” to 1” NPT or BSP reducer.
Refer to the Skimmer Guard section for dimension and assembly details. Refer to
the XCT-12 manual for connection and wiring details only.
•Assemble the Siemens Mounting Assembly, if provided, to the handrail. And,
mount the transducer (with Skimmer Guard if provided) to the Mounting Assembly.
Otherwise mount the transducer assembly in a secure fashion.
Refer to the Mounting Assembly section for dimensions and assembly details.
•Install the DPS300 and program the unit for your specific application.
Refer to the Application and Parameters sections of this manual.
DPS300
Siemens Mounting Assembly
Mounts the transducer to
handrails along the clarifier
walkway or bridge.
Optional Siemen
s
Skimmer Guar
d
The Skimmer Guard
protects the transducer b
y
allowing it to ride over a
passing skimmer.
custome
r
conduit
Siemens XCT-12
The ultrasonic transducer used with the DPS300. If
the DPS300 is programmed to monitor two clarifiers,
then two transducers are required.
Note:
Operation of the transducer requires that the face be
immersed 3 to 6 cm into the clarifier wastewater.
DPS300
mounting
plate

InterRanger DPS300 16 7ML19981BC01
APPLICATION PLANNING
The DPS300 is designed to detect and measure the sludge blanket in up to two
wastewater clarifiers. The basic requirements of a working DPS system are the
transducers and the associated electronics.
The electronics can be mounted at the clarifier or up to 365 m away from the
transducer. Refer to DPS300 Specifications in this manual.
The transducer is installed such that its face is immersed 3 to 6 cm in the clarifier
wastewater.
Beyond these given requirements, a few practical aspects of the clarifier
application and its operation are of particular concern.
Circular Clarifiers
There are several different types of circular clarifiers, but all operate in the same
basic way and share common design features that will need to be considered
when installing an InterRanger™ DPS300.
Some of these considerations are:
Catwalk, Bridge or Walkway
Most circular tanks have a catwalk that extends into the centre of the tank, usually
with 2" (51 mm) or similar, tubular railings. These railings are the recommended
mounting location for the InterRanger™.
The Siemens Mounting Assembly is available to locate the transducer in this
location.
Inlet
This is where the wastewater flows into the tank. Do not mount the transducer
close to the inlet because the water is aerated and the sludge is disturbed. To
obtain the most accurate readings, the sensor should be located above a relatively
undisturbed portion of the tank where aeration is not present.
Tank sides
The sensor must be mounted at least 1 m (3') from the side of the tank. If the
sensor is mounted closer than this the walls could cause interference and
ultimately lead to inaccurate signals or errors.
Ladders, Beams, Supports, etc.
Be sure that there are no permanent underwater obstructions within 1 m (3') of the
sensor that could disrupt the signal. Obtain drawings and/or consult with plant
personnel to locate any of these structures that may not be visible.

7ML19981BC01 17 InterRanger DPS300
Surface Skimmers
Skimmers are used to remove the scum from the surface of the water in the
clarifier. The scum is skimmed away from the effluent weirs into a trough where it
can be removed easily.
It is important to observe the skimmer action when setting up the InterRanger. If
the best location for the sensor is in the path of the skimmer (often the case) then
the optional Skimmer Guard must be used.
Circular Clarifier
Scrapers
Scrapers keep the oldest sludge on the bottom of the tank from hardening and
help to move the sludge into a hopper for pumping.
In circular tanks, the skimmer and scraper are often connected to the same
rotating mechanism radiating from the centre of the tank. Common configurations
could include one or two skimmers and up to four scrapers. Usually these arms
are 90° or 180° apart.
scum trough
skimmer
direction
skimmer
mounting
location
handrail
bridge

InterRanger DPS300 18 7ML19981BC01
Moving or Travelling Bridges
On some clarifiers the bridge or walkway moves with the skimmer. For clarifiers
with these types of arrangements, care must be taken when choosing a mounting
location. The following items should be considered when choosing a location on
the bridge:
•The transducer should be mounted in front of the bottom scraper mechanism.
The sludge becomes very disturbed after the passing of a bottom scraper and a
clean interface will be difficult to detect. Mount the transducer in front of the
scraper, ideally 180°from the scraper or 90°if two scrapers exist.
•Ensure that the transducer will not come into contact with the scum trough.
It is important to observe the bridge motion through at least one complete cycle to
ensure that the transducer and/or the mounting assembly will not collide with any
structures in the tank.
Rectangular Clarifiers
There are several different types of rectangular clarifiers, but all operate in the
same basic way and share common design features that will need to be
considered when installing an InterRanger™ DPS300.
Some of the considerations are:
Catwalk, Bridge or Walkway
Some rectangular tanks have a bridge that spans across the entire width of the
tank, usually with 2" (51 mm) or similar, tubular railings. These railings are the
recommended mounting location for the InterRanger™ once a suitable spot has
been found.
The Siemens Mounting Assembly is available to secure the transducer in this
location.
bridge
direction
mounting
location
handrail
travelling bridge

7ML19981BC01 19 InterRanger DPS300
Inlet
This is where the wastewater flows into the tank. Do not mount the transducer
close to the inlet because the water is aerated and the sludge is disturbed. To
obtain the most accurate readings, the sensor should be located above a relatively
undisturbed portion of the tank where aeration is not present.
Tank sides
The sensor must be mounted at least 1 m (3') from the side of the tank. If the
sensor is mounted closer than this, the walls could cause interference and
ultimately lead to inaccurate signals or errors.
Ladders, Beams, Supports, etc.
Be sure that there are no underwater obstructions within 1m (3') of the sensor that
could disrupt the signal. Obtain drawings and/or consult with plant personnel to
locate any of these structures that may not be visible.
Surface Skimmers
Skimmers are used to remove the scum from the surface of the water in the
clarifier. They are usually short fences called “flights” that are pulled along the top
of the water with a chain mechanism in rectangular tanks. The scum is skimmed
away from the effluent weirs into a trough where it can be removed easily. It is
important to observe the skimmer action when setting up the InterRanger. If the
best location for the sensor is in the path of the skimmer then the optional
Skimmer Guard must be used.
Rectangular Clarifier
Scrapers
Scrapers keep the oldest sludge on the bottom of the tank from hardening and
help to move the sludge into a hopper for pumping. In rectangular tanks, often the
scrapers are also the skimmers. They run along the bottom on a chain mechanism
for the length of the tank, up the side and then along the top to pull the scum into a
trough.
skimmer direction
mounting location
scum
trough effluent
wei
r
flights
handrail

InterRanger DPS300 20 7ML19981BC01
Moving or Travelling Bridges
For clarifiers with these types of arrangements, care must be taken in choosing a
mounting location. The following items should be considered when choosing a
location on the bridge:
•The transducer should be mounted behind (after) the surface skimmer (if present).
This is to help minimize the amount of potential scum build-up on the transducer.
•The transducer should be mounted in front of the bottom scraper mechanism.
The sludge becomes very disturbed after the passing of a bottom scraper and a
clean interface will be difficult to detect. Mount the transducer in front of the
scraper, not behind.
•The transducer should not be mounted near any siphoning-type outlet.
Some clarifiers utilize a siphoning technique to maintain sludge levels. Do not
locate the transducer near these outlets as the sludge is more disturbed there.
•Ensure the transducer will not come into contact with effluent weirs or scum
troughs at either end of the bridge travel.
It is important to observe the bridge motion through at least one complete cycle to
ensure that the transducer and/or the mounting assembly will not collide with any
structures in the tank.
Location
An average sludge level reading will be displayed for the location at which the
transducer is installed. This location may have to be compromised for practical
reasons, pertaining to the physical installation of the transducer, and physical or
operational characteristics of the clarifier.
We suggest these examples:
Skimmers
Where surface skimmers are in use, the optional Skimmer Guard should be used
to protect the transducer and from passing skimmers.
scum
trough
effluent
weir
mounting
location
bridge movement
handrail
travelling
bridge
skimme
r