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Bindicator SonoTracker Ultrasonic Liquid Level Installation & Operation Manual

Can monitor up to a total of 8 transducers of various frequencies, accommodating multiple vessels of different heights and shapes.
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SonoTracker Ultrasonic
Liquid Level
Installation & Operation Manual

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Summary of Contents for Bindicator SonoTracker Ultrasonic Liquid Level

  • Page 1 SonoTracker Ultrasonic Liquid Level Installation & Operation Manual...

  • Page 3: Table Of Contents

    SonoTracker Ultrasonic Liquid Level Installation & Operation Manual CONTENTS HANDLING AND STORAGE ..................................1 GENERAL SAFETY ......................................2 III. PRODUCT DESCRIPTION ..................................3 IV. MECHANICAL INSTALLATION .................................6 General Installation Guidelines Mounting Transducers Mounting Temperature Probe Drilling Holes In The Enclosure Prepare The Enclosure For Conduit...
  • Page 4 SAFETY SYMBOLS WARNING: IDENTIFIES CONDITIONS OR PROCEDURES, WHICH IF NOT FOLLOWED, COULD RESULT IN SERIOUS INJURY. RISK OF ELECTRICAL SHOCK. CAUTION: IDENTIFIES CONDITIONS OR PROCEDURES, WHICH IF NOT FOLLOWED, COULD RESULT IN SERIOUS DAMAGE OR FAILURE OF THE EQUIPMENT.

  • Page 5: Handling And Storage

    SonoTracker Ultrasonic Liquid Level & Open-Channel Flow Controller Installation & Operation Manual HANDLING AND STORAGE SAVE THESE INSTRUCTIONS INSPECTIONS AND HANDLING Do not dispose of the carton or packing materials. Each package should be inspected upon receipt for damage that may have occurred d ue to mishandling during shipping.

  • Page 6: General Safety

    GENERAL SAFETY AUTHORIZED PERSONNEL All instructions described in the document must be performed by authorized and qualified service personnel only. Before installing the unit, please read these instructions and familiarize yourself with the requirements and functions of the device. The required personal protective equipment must always be worn when servicing this device.

  • Page 7: Product Description

    III. PRODUCT DESCRIPTION The SonoTracker Series Ultrasonic System can monitor up to a total of 8 transducers of various frequencies, accommodating multiple vessels of different heights and shapes. The high scan rates of the SonoTracker Series provide fast information updates on material level. The SonoTracker Series has an integral keyboard and a display that provide easy access for programming and allows the user to input their own vessel identifications.
  • Page 8 CONTROLLER SPECIFICATIONS FUNCTIONAL Operating Power 110/230 VAC (+/- 10%) 50/60 Hz or 24 VDC Power Requirement 20 VA Operating Temperature -5º to 122º F (-20º to 50º C) Measuring Distance 1 to 125 ft (0.3 to 38 m) depending on sensor...
  • Page 9 Figure 1. SonoTracker Series Ultrasonic System Configuration Diagram SON280020 Rev. C...

  • Page 10: Mechanical Installation

    MECHANICAL INSTALLATION GENERAL INSTALLATION GUIDELINES • Aim the transducer perpendicular to the surface of liquids. • Provide sufficient flexible conduit at the transducer location to facilitate transducer aiming movement and removal. • Run transducer cable from the transducer to the junction box, and from the junction box to the controller in dedicated grounded metal conduit or in cable tray.
  • Page 11 This is required to avoid having material within the transducer’s blind space (amount of time required for transducer vibration to decay to a level where ultrasonic measurement is possible). SON280020 Rev. C...

  • Page 12: Mounting Temperature Probe

    MOUNTING TEMPERATURE PROBE Location Guidelines: • Ensure that the temperature probe does not come in contact with the liquid during normal fill and during overfill conditions. The probe may be damaged if it comes in contact with the liquid during these conditions.

  • Page 13: Mounting Controller

    2. Drill the mounting holes. 3. Attach the junction box using hardware that will secure it firmly in place. Note: Mounting hardware for the junction box is not supplied by Bindicator. MOUNTING CONTROLLER When mounting the controller, be sure there is enough clearance to open the front door completely. Removal and insertion of the modular PCBs and wiring of the transducers and the PCBs are done through the front of the unit.
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  • Page 22: Electrical Installation

    ELECTRICAL INSTALLATION WARNING: VERY HIGH VOLTAGE IS PRESENT. REMOVE POWER FROM THE UNIT BEFORE INSTALLING, REMOVING, OR MAKING ADJUSTMENTS GENERAL SAFETY When using electrical equipment, you should always follow basic safety precautions, including the following: • The installation and wiring of this product must comply with all national, federal, state, municipal, and local codes that apply.

  • Page 23: Wiring Junction Box To Controller

    Notes: 1. Seal all conduit fittings against water entry. Install drain holes at conduit’s lowest elevation(s) to allow condensation to drain. 2. Wiring for transducer, from junction box to controller: Use Belden 8760 two-conductor twisted shielded pair cable. Maximum lengths are: •...
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  • Page 25: Synchronization Of Transducers

    Figure 4: Wiring Transducers to Controller The current output transmitter drives a maximum load of 600 ohms. If an external current loop power supply is provided, the transmitter drives a maximum load of 1,000 ohms. Multiple current outputs share a common lowside.
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  • Page 35: Set-Up

    SET-UP SETTING SERIAL ADDRESSES The controller will monitor up to 16 channels, with each channel having its own address. The SW2 switch, located on the Display PCB inside the door of the controller, sets the base address for channel 1. See Figure 2-4: SW2 on the Display PCB.

  • Page 36: Installing Pcbs

    INSTALLING PCBS The SonoTracker Series controller arrives from Bindicator with the specified PCBs installed. However, you can expand your system. There are three positions on the motherboard of the controller that accept PCBs. Note the following restrictions on PCB positions in the controller:...

  • Page 37: Menu Tree

    The controller keyboard is used to access the different menus, scroll through the vessel monitoring display screens, and enter setup and calibration parameters. The function of each key on the keyboard is described in the sections to follow. See Figure 7: Display and Keyboard...
  • Page 38 Main Menu returns the display to the RUN Mode. • The Esc Key also has another function. The SonoTracker Series controller arrives from Bindicator with a factory-set ID number assigned to each channel. If you replaced the number with a customer-defined ID during the Startup Procedure or in the Display Menu, pressing the Esc Key while the display is in the Manual Mode (Auto LED off ) briefly displays the factory-set ID.
  • Page 39 “. ” (PERIOD) KEY Figure 8: Characters Available for When the controller is in the Manual Mode, pressing the “. ” key briefly Customer-Defined ID displays the current controller software revision letter and the date of the release. The “. ” key also functions as a decimal point when entering numbers in the math channel.

  • Page 40: Menu Tree

    Note: The Sensor Key only works if you are at the “end” of a menu; i.e., where the screen allows you to enter a value or select from a list of choices on the display. If you press the Sensor Key, the display changes to: ‘Enter’...

  • Page 41: Menu Tree

    MENU TREE The menu tree of the SonoTracker Series controller is used to enter and view settings, set up, calibrate, and troubleshoot for the system. There are nine submenus listed in the Main Menu: • 10 Display: enter and view display settings •...
  • Page 42 Figure 10b: 30 Relay Set Point Figure 10c: 50 Serial / PLC SON280020 Rev. C...
  • Page 43 Figure 10d: 70 Range Filters Figure 10e: 90 Service Menu SON280020 Rev. C...

  • Page 44: Operating The Sonotracker Series In Level Applications

    OPERATING THE SONOTRACKER SERIES IN LEVEL APPLICATIONS INTRODUCTION The SonoTracker Series is designed to get you up and running quickly once the system is installed. The controller guides you through the Startup Procedure. See . During the Startup Figure 11: Startup Procedure Diagram Procedure, you will be asked to input a number of parameters, including: •...
  • Page 45 4. Press ENTER and the display shows: Transducer Freq * 43 KHz The model number of the transducer indicates the nominal frequency of operation: SC43PT = 43KHz, SC22PT = 22KHz. Refer to the model number of the transducer for the proper frequency selection.
  • Page 46 If Full Point is less than the Minimum Range for the transducer, be aware that the SonoTracker Series will not detect or report material levels near the top of the Span. Full Point is normally 0.0. Figure 12: Span Diagram...
  • Page 47 INTRODUCTION Refer below to the block diagram of the initial part of the Startup Procedure, and for the remainder of Figure 15 the Startup Procedure. The SonoTracker Series is designed to get you up and running quickly once the system is installed.
  • Page 48 Figure 15: Flow Start-Up Procedure * Kennison: The 20” Kennison Nozzle is the only nozzle size currently available. If you select another Kennison nozzle size, the display shows function not available. Figure 16: SonoTracker Series Definitions for Flow Applications (0.3m) Maximum...
  • Page 49 START-UP When performing the Startup Procedure, do not worry if you make an error. The parameters can be corrected after you complete the startup, in the Calibration Menu, , or the entire Startup can be repeated by Figure 17 defaulting the channel in the Service Menu.
  • Page 50 Press the arrow keys to access the options of the Weir Menu. Press Enter for your desired options. Once completed, you will go to Step 9, Select Flow Type. 8. Nozzle—The only option here is Ken. Press ENTER. Scroll through the Kennison Nozzle options with the arrow keys and press Primary Element ENTER.9.
  • Page 51 14. For Auto and Manual calibration, the display shows: Maximum Head Hgt > .0 in Use the keypad or the up/down arrow keys to enter the Maximum Head Height, obtained from the flow chart supplied by the primary element manufacturer. Press ENTER.
  • Page 52 Figure 17: Flow Calibration Menu Prim: Select primary element ReSet: Reset minimum flow, type and size maximum flow and total flow Zero: Calibrate the system Avg: Establish number of reading to average for display Sim: Simulate head to check...
  • Page 53 • Curr Head — The current head; to perform an accurate calibration, measure this just before you input the value. • Zero Dist — The distance from the face of the transducer to the bottom of the channel. Zero Dist shown on the display is a calculated value, the sum of Curr Head and the distance measured by the transducer from the face of the transducer to the liquid surface.
  • Page 54 26 RESET The ReSet Menu allows you to reset calculated flow values: • Minimum flow (MinF) — reset to the current flow rate • Maximum flow (MaxF) — reset to the current flow rate • Total flow (Tot) — reset to 0 The ReSet function is useful if you want to monitor total flow and minimum and maximum flows on a regular basis (for example, you want to track daily total flow and daily minimum and maximum flows).

  • Page 55: Sonotracker Series Menu Descriptions

    SONOTRACKER SERIES MENU DESCRIPTIONS MENU OPTIONS The following options are available from the MENU key in manual mode: Figure 18: Controller Menu • 10 Display: Select desired display formats, input vessel and adjust Access Diagram brightness and contrast. FROM CHAPTER FOUR •...

  • Page 56: Menu Tree

    ID. The SonoTracker Series controller arrives from Bindicator with a factory-set ID number assigned for each channel in the system. Note that after you have input a customer-defined ID, you can still view the original factory-set ID when vessel monitoring in the Manual Mode by pressing the Esc Key.

  • Page 57: Menu Tree

    120% while the graph remains at 100%.The default for the display is bar graph Off (bar graph not displayed when vessel monitoring). The current selection for Enable is indicated by an asterisk. If enabled, the bar graph displays for the channel while channel monitoring in both Manual and Auto Modes.
  • Page 58 21 FULL POINT Refer to . Full Point is the distance from the face of the transducer to the top of the Span. Modifying Full Figure 12 Point allows you to change the point of reference for measurement. If you add 1’ to Full Point you are essentially moving the Span down 1’...
  • Page 59 25 TEMPERATURE This menu sets up the temperature compensation parameters. Temperature has three submenus: Fixed, Monitor, and Scale. FIXED (FIXED TEMPERATURE) • Fixed allows you to enter a fixed temperature, usually to match the temperature inside the vessel where the transducer is operating.

  • Page 60: Menu Tree

    Number of points — allows you to select the number of points to input for the linearization (32 maximum points). Contact Bindicator for technical assistance in calculating linearization parameters. 27 Speed O Sound The Speed O Sound Menu allows you to monitor and adjust the value for the speed of sound, which is used by the SonoTracker Series controller in the calculation of range.
  • Page 61 The deadband value equals the change in the measured parameter before the setpoint relay returns to its normal state. Bindicator recommends the use of a non-zero deadband to prevent relays from oscillating. The value is entered directly or scrolled to with the Arrow Keys.
  • Page 62 OnTm (flow applications only) - if you want the relay to pulse once it is activated, this menu sets up how long the relay pulses. Setting OnTm to 0 turns off the pulsing function.

  • Page 63: Menu Tree

    Up and Down Arrow Keys until the setpoint you want to delete is displayed. Then, press the Enter Key. Caution: Manually activating setpoint relays may cause damage if control equipment is connected. Disconnect any control equipment before proceeding.
  • Page 64 Current output is typically used to retransmit continuous level/flow data to a remote display or PLC/Distributed Control System (DCS). The current output setup functions are accessed in this menu. The functions include adding and deleting outputs, and selecting fail-safe and operating modes. Up to two sets of current outputs can be assigned per channel.
  • Page 65 Note: The value entered for the 4/0 mA operation point does not have to be smaller than the value entered for the 20 mA operation point. Note: See Figure 10c: Transducer Menu, for information on setting the threshold time for echo loss.
  • Page 66 Pressing the ESC Key or Scan/Hold Key terminates the function. Once the test is terminated, the current outputs return to automatic control. Caution: Manually activating current output can cause damage if control equipment is connected. Disconnect control equipment before proceeding.

  • Page 67: Menu Tree

    49 MODE The current transmitter can be set up to output 0-20 mA or 4-20 mA. This menu is used to select one of the two operating modes. The controller default current output mode is 4-20 mA. Figure 23: PLC Menu Tree...

  • Page 68: Menu Tree

    60 TRANSDUCER Figure 24: Transducer Menu Tree 61 FREQUENCY Frequency has three submenus: • Target — under Target, the target frequency of the transducer set up for the current channel is displayed and can be modified. For example, a 56T-25PT Transducer has a ‘nominal’ frequency of 43 KHz, but the actual default frequency is 43.5 KHz.
  • Page 69 TVG affects the sensitivity of the system in detecting return echoes by amplifying the return signal in relation to the time it takes the signal to reach the transducer (which is related to the distance from transducer to measured material).

  • Page 70: Menu Tree

    67 MID GAIN ADJ (CONSULT BINDICATOR BEFORE MODIFYING!) Mid Gain Adj allows the adjustment of the TVG curve in the middle distance ranges. It is generally not used. Mid Gain Adj has two submenus: • Position is the distance (in the selected length units) from the face of the transducer to the beginning of the midrange delay.
  • Page 71 Note: In Manual Mode, Max Range must be greater than Full Point + Span. The system will NOT allow a span value that violates this distance. Change Max Range prior to changing Span. 73 SENTRY DSP™ (CONSULT BINDICATOR BEFORE MODIFYING!) Extraneous noise caused by acoustical or electrical interference can cause changes in the SonoTracker Series display, even though no material is moved.
  • Page 72 Enable to Off. Figure 26: Sentry DSP Function Examples 74 NOISE (CONSULT BINDICATOR BEFORE MODIFYING!) The Noise function reduces the effect of extraneous noises that may confuse the signal processor. This menu sets up the noise routine algorithm. The algorithm is activated when the measured noise level (Monitor) exceeds the noise threshold level (Threshold).
  • Page 73 The default for Std Dev Ratio is 3.0. • Listen Deviation monitors the listen deviation value. The absolute value of each of 16 listen noise values are subtracted from the mean value. The results of each subtraction are added together to calculate Listen deviation.

  • Page 74: Menu Tree

    The SonoTracker Series arrives from the factory without a user-defined access code in place, allowing the user to access any function (other than those requiring the Bindicator Mfg Code or Bindicator Service Code) in the system at will. The User function allows you to set up a code to limit access to changing most system parameters (i.e., display parameters, setpoint parameters, calibration parameters, etc.).

  • Page 75: Menu Tree

    The Service Code, described earlier in this chapter, is entered when prompted by the display and is the same as Bindicator Mfg Code. The Mfg Code is entered when in the Access Menu, as described below:...

  • Page 76: Menu Tree

    92 DEFAULT This function clears all SonoTracker Series setup parameters, resets them to factory default values, and automatically leads you through the Startup Procedure again. Default has two submenus: • Single clears all parameters only for the channel whose menu tree you are in and used when bringing new channels online or reconfigured.

  • Page 77: Menu Tree

    Manual Mode. The Auto LED turns off. 2. Press the Menu Key to display the Main Menu. 3. Press the up/down arrow key until 90 Service Menu appears. Press Enter. 4. Scroll with the up arrow key to 93 Enable. Press Enter.
  • Page 78 Cx=( ‘C’ ‘+’ ‘*’ " 9. Press the F1 Key to select C. Press 1 on the keypad. Press the F2 Key to select +. The display shows: Cx=(C1+ ‘C’ ‘+’ ‘*’ " 10. Press the F1 Key to select C. Press 2 on the keypad. Press the F2 Key to select +. The display shows: Cx = (C1+C2+ ‘C’...
  • Page 79 Channel x will now display the average of the vessels in vessel 1 through 4. Identifies a specific channel in the equation. C must be immediately followed by a channel number (for example, C9 indicates the channel with factory-set ID# 9). See Appendix F for errors. All equations must start with the current channel designation and an equal sign (for example, C9= must be the start of the equation when you are in channel 9).
  • Page 80 Upon completion of the test, the display should say RAM TEST PASSED! If it does not, contact Bindicator. When the test is complete, press the Esc Key to return to the Micro Func Menu.

  • Page 81: Menu Tree

    (i.e., calibration parameters, setpoint parameters, display parameters, etc.). The controller requires you to enter the Bindicator Service Code (9111) to access this function (unless you have already entered it during this Manual Mode session), and requests verification before it resets the NVRAM, to prevent accidental reset of the NVRAM.
  • Page 82 FUNCTION MASTER TO SONOTRACKER SERIES TRANSMITTED RECEIVED BY BY MASTER SONOTRACKER FROM SERIES ASCII SONOTRACKER SERIES Bindicator product identification number >aa#ssr Addssr (A956Er for SonoTracker Series) Request application type: 0=level; 1=flow; 99=math >aaassr Addssr Request engineering units. See notes following. >aa2ssr Adddddddssr Note 1.
  • Page 83 CHECKSUM CALCULATION The one-byte checksum is calculated by adding the Hex values of all ASCII characters between the start of message character ‘>’ or acknowledge character ‘A’ and the checksum character ’ss. ’ Overflows from the addition are ignored.
  • Page 84 ‘#’ COMMAND — BINDICATOR PRODUCT IDENTIFICATION NUMBER This command is sent by the master to request the controller to send its Bindicator product identification code (code is 95 for the controller). For this example, the master requests the code from a SonoTracker Series controller channel at address 01, which returns a code of 95 and a checksum of 6E.

  • Page 85: Vii. Maintenance

    ‘T’ COMMAND — REQUEST TOTALIZER DATA (FLOW APPLICATIONS ONLY) This command is sent by the master to request the controller to send the totalizer data. For this example, the master requests the totalizer data from a controller channel at address 01, which is set up with standard totalizer format of XXXX.X and standard totalizer units of cubic feet.

  • Page 86: Viii. Troubleshooting

    20 to 40 times to see any effect on the display. 4. Turn off the unit, then while holding the period key, turn unit back on. 5. If the display still does not illuminate, contact the Bindicator Service Department.
  • Page 87 Contact the Bindicator Service Department. 8. If you have followed the above steps and the displayed data still does not agree with the known measured level in the vessel, contact the Bindicator ® Service Department. In order to allow us to help you with troubleshooting over the phone, first write down all the parameters you entered during the Startup Procedure and calibration.
  • Page 88 Solution: Echo loss will occur occasionally while filling. Other situations that can cause echo loss include foam on a liquid. If echo loss frequently occurs, you may need to adjust power, Near 6 or TVG to improve the system performance; contact Bindicator. 3. A BOX (P) ON THE DISPLAY Explanation: A box (p) displays while vessel monitoring to indicate that the system senses a temperature greater than 300º...
  • Page 89 6. NVRAM FAILURE Explanation: This error message will only occur at power-up. NVRAM data has been corrupted. Solution: Contact Bindicator® Technical Support at 1-800-426-9010 or 864-574-2763 or default the unit. 7. NOISE ^ Explanation: The amount of noise exceeds noise limit.
  • Page 90 ERROR CODES If you make an error entering an equation in a math channel, the controller will respond in one of two ways: • After you enter the equation and press the Enter Key, the controller will not be able to compile the equation, and will respond with a compile error code.
  • Page 91 2. Equation tries to take a square root of a negative number that is calculated as part of the equation (i.e., square root of (8-12). 3. Equation tries to take a natural log (ln) of a negative number or of 0.
  • Page 92 • View Serial Address for a channel Press the Esc Key while in the Manual Mode. • Display Current SonoTracker Series Software Revision letter and Date of Release Press the “. ” Key briefly while in the Manual Mode.
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  • Page 96 150 Venture Boulevard Spartanburg, SC 29306 2015 All rights reserved. Tel: (800) 778-9242 Fax: (864) 574-8063 All data subject to change without notice. sales@bindicator.com SON280020 Rev. C www.bindicator.com...

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