1. Manuals
  2. Brands
  3. Nivetec Manuals
  4. Control Systems
  5. Echo Smart Series
  6. Operation & installation manual

Nivetec Echo Smart Series Operation & Installation Manual

Sensor, controller, power supply unit
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Operation & Installation
M a n u a l
Version A2.1
Echo Smart Sensor
Echo Smart Controller
Echo Smart Power Supply Unit

Advertisement

Table of Contents
loading

Summary of Contents for Nivetec Echo Smart Series

  • Page 1 Operation & Installation M a n u a l Version A2.1 Echo Smart Sensor Echo Smart Controller Echo Smart Power Supply Unit...

  • Page 3: Table Of Contents

    Table of Contents Table of Contents ..........................i Safety Precautions........................... v Product Description ......................1 1.1. Stand-Alone Instrument Option ....................1 1.2. Field Network Option ........................ 1 1.3. Network Integrated to Customer Data Acquisition and Controls ........1 Applications........................2 2.1.
  • Page 4 6.1. Installation of EchoSmart Sensor ..................23 6.2. Sensor Location Selection Criteria..................25 6.2.1. Acceptable Process Liquid ....................... 25 6.2.2. Responsive Interface Material ......................25 6.2.3. Stationary Objects in Path of Transmit Pulse ................25 6.2.4. Areas of Excessive Air/Gas Bubbles and Turbulence ..............25 6.2.5 Typical Circular Clarifier Installation (Figure 6.2) ...............
  • Page 5 9.2.2. Measure (Level) ..........................43 9.2.3. Wiper Timing (240) .......................... 43 9.2.4. Gain Band (20) ..........................43 9.2.5. Gain Increment (0.1) ........................43 9.2.6. Save GB Midpoint (MP) (OFF) ....................... 43 9.2.7. GB Midpoint (Automatically set) ...................... 44 9.2.8. Wall Zone (0.5) ..........................44 9.2.9.
  • Page 6 13. Quick Start Guide ......................59 13.1. Configuring a Single Sensor ....................59 13.2. Configuring a Sensor Network ....................60 13.3. Special Settings for Filter Applications ................. 63 - Page iv -...

  • Page 7: Safety Precautions

    Safety Precautions About this Manual: PLEASE READ THE ENTIRE MANUAL PRIOR TO INSTALLING OR USING THIS PRODUCT. The following safety precautions should be observed in the implementation and use of this product. The EchoSmart Controller (ESC), EchoSmart Power Supply Unit (ESP), and EchoSmart Sensor (ESS) are intended for use by qualified personnel who recognize shock hazards and are familiar with the safety precautions required to avoid possible injury.
  • Page 8 Standard fuses, with applicable national safety approvals, may be used if the rating and type are the same. If you are unsure about the applicability of a replacement component, call Entech Design for information. Only use the EchoSmart ESC or ESP with the sensor supplied.
  • Page 9 WARNING WHEN APPLICABLE This equipment complies with FCC radiation exposure limits set forth for an uncontrolled environment. This equipment should be installed and operated with minimum distance 20cm between the radiator and your body. This transmitter must not be co-located or operating in conjunction with any other antenna or transmitter.

  • Page 10: Product Description

    1. Product Description EchoSmart is an exciting new development in liquid/solid interface level analyzers. Instruments employ digital sensors in an architecture that locates microprocessor signal control, enhancement and interpretation in the ultrasonic sensor rather than in a remote analyzer. The sensor is a Smart device. When connected to a power source and instrument programmer (typically EchoSmart Controller or EchoSmart Power Supply Unit), it produces the Level or Range measurement and an indication of the dispersed solids Level above the primary interface.

  • Page 11: Applications

    2. Applications EchoSmart is suitable for most municipal and industrial liquid/solid separation processes in which a reliable measurement of the level of a solids or suspended-solids blanket is desired. Typical applications include municipal and industrial wastewater and water treatment clarifiers and gravity thickeners. Sensors with optional turbidity measurement are available for applications in which a 0-50 NTU turbidity indication at the location of the sensor is desired.

  • Page 12: Echosmart Sensor (Ess)

    3. EchoSmart Sensor (ESS) The EchoSmart Sensor is a microprocessor controlled piezoelectric transducer designed specifically for operation under water (submerged in the process liquid). 3.1. General Overview The EchoSmart Sensor generates an ultrasonic sound wave that propagates through a liquid medium and is reflected back from material that is present in the vessel (typically settled solids, suspended solids, and/or the tank bottom).

  • Page 13: Echosmart Controller - Graphical User Interface (Esc)

    4. EchoSmart Controller – Graphical User Interface (ESC) The EchoSmart Controller allows for programming and local monitoring of one to sixteen EchoSmart Sensors. 4.1. General Overview The Controller display consists of a graphical backlit LCD (2.6 x 3.45 inch viewing area) that is divided into five functional sections.

  • Page 14: Keypad

    Current Measurement and Operating Gain The current measurement, operating gain (signal amplification), and turbidity value (when applicable) are conveniently available in the lower left corner of all displays. Additionally, messages regarding external communication (see Sections 8.3 and 8.5) taking place and error messages (see Section 10.2) associated with the active sensor are displayed in this section.

  • Page 15: Power Requirements

    4.2.1. Power Requirements 100-240 VAC, 50/60 Hz – 1.5A Supply cable: 10-18 AWG, -40 to +140 F 65 W (fused) 1.25A 250V 5x20mm T-lag UL approved fuse 4-20 mA Current Loop: 15 – 24 VDC (provided by ESC) Optional: 24 VDC (19 – 42 VDC Input) Caution must be taken to supply main power in the form for which the equipment is designed.
  • Page 16 RF Module Connector (optional) Relays Power Cell Modem Connector Power (120/240 VAC) * FOR 24 VDC * Black White Brown – – Yellow Level Blue RS-232 Orange Data Data Turbidity Green LEDs External USB (Future) Figure 4.2: Connections for Controller - Page 7 -...
  • Page 17 Table 4.1: Connections Power 4-20 Analog Sensor RS-485 Connector Connectors Connections Connector (J1) (J10) (J9) (J7) Pin # Description Pin # Description Pin # Description Pin # Description Sensor Live Level + 15 V Comm Sensor Level – Ground Ground Comm Sensor Neutral...

  • Page 18: Utilization Of Informational Displays

    4.3. Utilization of Informational Displays The Controller has four informational displays: Echo Profile Display, Sensor Register Display, Tank View Display, and Historical Trend Display. Selections are made by pressing the Change Display Soft Key. At power up, the system defaults to the Echo Profile Display.

  • Page 19: Sensor Register Displays (Figure 4.4 And 4.5)

    4.3.2. Sensor Register Displays (Figure 4.4 and 4.5) This display consists of a table that shows the name of each sensor and its Current Measurement and Operating Gain value. If the Controller is communicating with four or fewer sensors, information is presented as shown in Figure 4.4. Figure 4.4: Four Sensor Field Network Display With five or more sensors, information is presented as shown in Figure 4.5.

  • Page 20: Tank View Display (Figure 4.6)

    4.3.3. Tank View Display (Figure 4.6) The Tank View Display shows a scaled cross-sectional view of the tank. The arrow on the left side of the tank provides a visual indication of the current fill Level. Dispersed solids that may be indicated in the echo waveform are represented by pixilated gradients above the primary interface.

  • Page 21: Historical Trend Display (Figure 4.8)

    4.3.4. Historical Trend Display (Figure 4.8) The EchoSmart Controller captures and stores the current measurement value every six minutes. The database is updated on a “first in/first out” basis to maintain a continuous register of the most recent seven days of data for all sensors. Newest data is reported on the right side of the screen.
  • Page 22 Figure 4.9: Modify Settings Display A unique Alpha-Numeric name may be assigned to the sensor and its identifier address can be changed by pressing the Soft Key next to the Modify Name or Address prompt (See Figure 4.10). Figure 4.10: Modifying Sensor Name and Address Display When modifying the sensor name, the Navigation Keys are used to scroll to selected letters, numbers and symbols to enter the desired sensor name.

  • Page 23: Advanced Settings Display (Figure 4.11)

    4.3.6. Advanced Settings Display (Figure 4.11) This display is used to enter additional parameter settings for each sensor. It is also used to establish the Analog Output parameters for the sensor. The Advanced Settings Display is accessed by Soft Key function from the Modify Settings Display.
  • Page 24 The Controller Setup Display is accessed from the Advanced Settings Display by pressing the Controller Setup soft key. Figure 4.12: Controller Setup Display Figure 4.13: Sensor Database Display - Page 15 -...

  • Page 25: Sensor Selection Drop-Down Window (Figure 4.14)

    4.3.8. Sensor Selection Drop-down Window (Figure 4.14) To change the sensor that the Controller is currently displaying, press the Change Sensor Soft Key (available at any informational display and the settings displays). Use the Navigation Keys to move to the desired sensor and press the Select Sensor key.

  • Page 26: First Time Controller & Sensor System Installation (Figure 4.16 And 4.17)

    Figure 4.15: Initial Controller Setup 4.4.2. First Time Controller & Sensor System Installation (Figure 4.16 and 4.17) If this is a new installation, select First Time Controller & Sensor System Installation and press the Soft Key next to New System Installation (Figure 4.15). The Controller will automatically locate the Smart Sensor that has been powered (this will take a few seconds) and will open the Initial Sensor Setup Display (Figure 4.16).

  • Page 27: Replacing A Controller With Existing Sensor(S) (Figure 4.15)

    to any unrepeated number from 2 – 240 before initializing the next sensor in a network. CAUTION: All sensors are supplied from the factory with the Sensor Address set at 01. A unique address must be assigned to each sensor as it is added to the network (powered ON).

  • Page 28: Automatic Initialization And Reboot Sensor

    4.5. Automatic Initialization and Reboot Sensor EchoSmart performs automatic initialization whenever power is applied to the sensor or the Reboot Sensor command is selected at the Echo Profile Display. Instrument settings are not lost as a result of power interruption. Automatic Initialization establishes operating gain (signal amplification) and determines current measurement values and signal outputs.

  • Page 29: Echosmart Power Supply Unit (Esp)

    5. EchoSmart Power Supply Unit (ESP) The Echo Smart Power Supply Unit provides power to an EchoSmart Sensor and acts as a communication hub to facilitate analog, digital and Wireless RF communications from an EchoSmart Sensor. EchoSmart Power Supply Units do not have display monitors or data entry keypads. They are typically used in a Field Network arrangement in which an EchoSmart Controller provides the user interface function for setup and monitoring of EchoSmart Sensors.
  • Page 30 RF Module Connector (optional) Cell Modem Power Power Connector (120/240 VAC) * IF 24 VDC * Black RS-232 White Laptop/Cellular Brown – – Yellow Level Blue Orange Turbidity LEDs Green Figure 5.1: Connections for Power Supply - Page 21 -...
  • Page 31 Table 5.1: Connections Power Connector 4-20 Analog Sensor RS-485 (J2) Connectors Connections Connector FOR 100-240 (J6) (J4) (J8) Pin # Description Pin # Description Pin # Description Pin # Description Sensor Live Level + 15 V Comm Sensor Level – Ground Ground Comm...

  • Page 32: Installation Of Equipment

    6. Installation of Equipment 6.1. Installation of EchoSmart Sensor The EchoSmart Sensor must be fully submerged in the supernatant process liquid during operation. It is not capable of transmitting a signal through gas (air) or solid materials. Mount the sensor using a rigid pipe or conduit to minimize excessive side-to-side sway or other avoidable movement.
  • Page 33 Figure 6.1 EchoSmart Sensor Mounting Arrangements - Page 24 -...

  • Page 34: Sensor Location Selection Criteria

    6.2. Sensor Location Selection Criteria Optimal performance depends on: (1) acceptable process liquid (supernatant) in which the ultrasonic pulse is to be transmitted, (2) responsive interface material (suspended solids blanket, other settled solids), (3) freedom from objects encroaching into the path of the transmit pulse, and (4) avoiding areas of excessive turbulence.

  • Page 35: Typical Circular Clarifier Installation (Figure 6.2)

    6.2.5 Typical Circular Clarifier Installation (Figure 6.2) Figure 6.2: Typical 1/3 – 2/3 Location in Circular Clarifier - Page 26 -...

  • Page 36: Typical Rectangular Clarifier Installation

    6.2.6 Typical Rectangular Clarifier Installation Sensors may be located along the length of the clarifier or in the area of the sludge sump. Care should be taken to consider inlet flow and the design of the sludge collection system. Contact Entech Design factory service for specific recommendations regarding sensor location to assure optimal performance.
  • Page 37 Figure 6.4: Controller Installation Drawing - Page 28 -...
  • Page 38 Figure 6.5: EchoSmart Power Supply Unit Installation Drawing - Page 29 -...

  • Page 39: Tank Configuration, Waveform Analysis, And Tracking

    7. Tank Configuration, Waveform Analysis, Tracking EchoSmart applies advanced proprietary echo waveform analysis and filtering routines to provide reliable and repeatable measurements. For proper operation, instrument settings must conform to the dimensions of the tank in which the sensor is installed. 7.1.

  • Page 40: Tracking

    Track Candidate Gates Signal Tank Bottom Figure 7.2: Echo Profile Display The signal waveform is presented graphically with the horizontal x-axis representing the Tank Depth and the vertical y-axis as the strength of signal at positions along the dimensional axis. The Sensor is identified by symbol in the lower left corner of the graph, and the Tank Bottom is indicated in the lower right corner.

  • Page 41: Signal Waveform Symbols

    7.3.2. Signal Waveform Symbols  The Down Arrow points to the current Track (See Section 7.2). This position corresponds with the Current Measurement.  The Right Arrow indicates that a signal meeting tracking criteria is located outside the Gate, to the right. The measurement will only be affected by this signal if it persists for repeated updates.

  • Page 42: Communications, Outputs, And Networking

    8. Communications, Outputs, and Networking EchoSmart may be implemented as a stand-alone instrument, or it may be configured in a Wired or Wireless RF Field Network arrangement. In a stand-alone environment Communication refers to analog signal outputs and digital communication with external devices.

  • Page 43: Wired Rs-485 Field Network (Figure 8.2)

    8.1.2. Wired RS-485 Field Network (Figure 8.2) Up to sixteen Smart Sensors can be operated with one EchoSmart Controller via two-wire RS-485 from a Controller to each Power Supply Unit. No user programming or other integration is required. To create the wired network, a shielded two-wire twisted pair (recommended Belden 9463) should be used between each ESP and to the ESC.

  • Page 44: Wireless Radio Frequency (Rf) Field Network (Figure 8.3)

    8.1.3. Wireless Radio Frequency (RF) Field Network (Figure 8.3) Field Networks as described and configured in Section 8.2 can be implemented using optional fully integrated RF Modules without the installation of field interconnection cabling and conduit. The Controller and each Power Supply Unit in the Field Network must be equipped with an RF Module.

  • Page 45: Integrated Field Networks (Figure 8.4)

    8.1.4. Integrated Field Networks (Figure 8.4) EchoSmart Controllers operating Field Networks may be interconnected in an integrated two-wire RS-485 Network of up to 240 Smart Sensors. Each Controller can maintain a network of up to sixteen sensors utilizing either wired connections or the wireless radio modules.

  • Page 46: Rs-485 Modbus Rtu

    8.2.1. RS-485 Modbus RTU EchoSmart sensors respond to Modbus RTU command requests via the local ESC that is monitoring the sensor(s). See the OEM Smart Sensor Probe (SSP) Communications Protocol for detailed information on programming and integration with a control system. When polling for current measurements, Entech recommends implementing a one minute pause after retrieving data from all connected sensors to allow the local ESC to interrogate the sensors.

  • Page 47: Factory Remote Service

    When communication is occurring through the RS-232 connection, a “Maint Port” message will appear in the lower left portion of most display screens. 8.3.3. Factory Remote Service EchoSmart Controllers are designed for optional installation of a cellular service modem. With the user’s authorization, this facility enables startup and service by expert factory technicians.
  • Page 48 Connect/Disconnect four screws to install/remove modem Modem backplate (do NOT detach from modem) Do NOT disconnect cables at the modem Red wire on LEFT at J18 Connect/Disconnect modem cables here Figure 8.5: Proper Installation and Removal of Modem - Page 39 -...

  • Page 49: Instrument Programming Parameters

    9. Instrument Programming Parameters Controller and Smart Sensor parameter settings are established at the Modify Settings and Advanced Settings displays. Standard default parameters exist in all instruments until modified by the user. Some settings, as noted below (Ex: Tank Depth, Zero Adjust), require site-specific values. Other parameters may be changed for convenience or preference (Ex: Units, Interface, Dampening).

  • Page 50: Min Range (3.0)

    9.1.4. Min Range (3.0) Min Range establishes the dimension of the measurement blanking-zone near the sensor. It is referenced to the top of the tank. Min Range must be at least the value of Zero Adjust plus 1 foot. The range for Min Range is: 1.0 ft to 32.0 ft 9.1.5.

  • Page 51: Dampening (130)

    FIRST Interface causes the instrument to respond to a signal that is nearest to the sensor (typically lighter density material). LAST Interface causes the instrument to respond to a signal that is furthest from the sensor when multiple interfaces are present.

  • Page 52: Advanced Settings Display Parameters

    9.2. Advanced Settings Display Parameters Additional parameters, including those used to set up Analog Output Signals are found at this display. Access this display by pressing the Soft Key next to the Advanced Settings prompt at the Modify Settings Display. 9.2.1.

  • Page 53: Gb Midpoint (Automatically Set)

    9.2.7. GB Midpoint (Automatically set) Automatic sensor initialization establishes the initial signal amplification (Gain) that is appropriate for the process environment. This value is held in the GB Midpoint register. With Auto Gain ON, Gain increases and decreases around the Midpoint to maintain optimal signal amplification.

  • Page 54: Lg Min (2.0)

    9.2.12. LG Min (2.0) LG Min establishes the margin of the left side of the Gate (See Section 7.3 for a description of the Gate and its function). The range for LG Min is: 0.0 to 32.0 9.2.13. RG Min (2.0) RG Min establishes the margin of the right side of the Gate (See Section 7.3 for a description of the Gate and its function).
  • Page 55 The options for Echo Loss Action are: 4mA, 20mA, and Cycle. When Cycle is selected, the output continually alternates between 4mA and 20mA until the loss of echo condition ceases. - Page 46 -...

  • Page 56: Maintenance And Troubleshooting

    10. Maintenance and Troubleshooting 10.1. Preventative Maintenance 10.1.1. Sensor Cleaning and Maintenance 1. Standard Sensor (Non Self-Cleaning) Non Self-Cleaning Sensors are typically used in applications in which the sensor is regularly and periodically rotated out of the water by the action of a surface skimmer.

  • Page 57: Other Routine Maintenance

    Remove the wiper by unscrewing in counter-clockwise direction. Secure and retain the stainless steel spacing washer from the wiper shaft for use with the replacement wiper. Screw the new wiper clockwise until the arm makes contact with the seated spacing washer, plus 1/8 of a turn.

  • Page 58: Troubleshooting

    10.2. Troubleshooting The following recommendations address the most often encountered troubleshooting needs with the EchoSmart equipment. If the described procedure does not resolve the problem, contact Entech Design for further assistance. 10.2.1. Comm Error Message A Comm Error message indicates that communication between the Controller and Sensor(s) has been interrupted for an extended period of time.

  • Page 59: Wiper Stalled Message

    the Controller and all Power Supply Units. If a wireless sensor network is in use, investigate possible impediments to network communications. 10.2.5. Wiper Stalled Message A Wiper Stalled message will appear if the wiper does not operate when expected or if rotation of the wiper blade is not detected. It may also indicate drag on the wiper motor as a result of debris being attached to the wiper blade or shaft.

  • Page 60: Troubleshooting Radio Communications

    sensors. If unique sensor addresses have not been assigned, power OFF the equipment and follow the steps in 13.2. If a wired field network is being used, refer to Section Error! Reference source not found. to verify that all connections are made at the proper terminals. 10.2.9.

  • Page 61: System Options

    11. System Options 11.1. Self-Cleaning Wiper Sensor with Turbidity Measurement This sensor incorporates a scattered light turbidity meter into the EchoSmart Wiper Sensor to provide continuous Level and Turbidity measurements. 11.1.1. Application This sensor is recommended for use in applications in which there is need for a Level and Turbidity measurements at the location of the sensor.

  • Page 62: Connections

    filter is on-line. Contact Entech Design for additional instructions for proper installation. 11.1.5. Connections The sensor connection is made in the same manner as an EchoSmart sensor. Refer to Section 4.2.2, Figure 4.2, and Table 4.1 for further connection details when operated by an EchoSmart Controller, or Section 5.1.2, Figure 5.1, and Table 5.1 when operated by an EchoSmart Power Supply Unit.

  • Page 63: External Configuration

    Black Radio Connector (J2) ESC or ESC = Echo Smart Controller ESP = Echo Smart Power Supply Figure 11.1 Connections for Wireless Radio Module 11.2.3. External Configuration In this configuration, the radio module is mounted in a separate enclosure that can be located in an optimal location.

  • Page 64: Equipment Orientation For Units With Integrated Wireless Radio Modules

    Black White Brown Radio Connector (J2) ESC or ESC = Echo Smart Controller ESP = Echo Smart Power Supply Figure 11.2 Connections for Wireless Radio Module 11.2.4. Equipment Orientation for Units with Integrated Wireless Radio Modules Equipment containing the integrated wireless radio modules should be oriented such that the antenna mounting location is on the side of the enclosure with the antenna pointed in the upward direction.

  • Page 65: Relays

    Figure 11.3 Orientation of Units with Wireless Radio Modules 11.3. Relays Relays require additional circuit board installation in the EchoSmart Controller. Relays are not available in the EchoSmart Power Supply Unit. 11.3.1. General Overview One to four relays may be added as an option to a Controller. Each relay is capable of monitoring the sludge level or turbidity (with optional sensor) and can be assigned to separate sensors, or multiple relays can be assigned to one sensor.

  • Page 66: Cabling And Connections For Relays (Figure 11.4 And Table 11.1)

    Figure 11.4: Relays Display 11.3.3. Cabling and Connections for Relays (Figure 11.5 and Table 11.1) This section pertains to the physical layout and terminal connections for the relays. Relay 1 Relay 2 Relay 3 Relay 4 Figure 11.5: Connections for Relay Board - Page 57 -...

  • Page 67: Warranty

    Table 11.1: Connections Relay Connections (J1) Pin # Relay Description Normally Closed Common Normally Open Normally Closed Common Normally Open Normally Closed Common Normally Open Normally Closed Common Normally Open 12. Warranty Analytical Technology, Inc., (Manufacturer) warrants to the Customer against defect in parts of the Manufacturer’s products that prove to be defective in materials or workmanship within the earlier of 18 months of the date of shipment or 12 months of the date of start-up in accordance with the terms of its PRODUCT WARRANTY.

  • Page 68: Quick Start Guide

    13. Quick Start Guide 13.1. Configuring a Single Sensor Follow these instructions when only one sensor is to be operated by the EchoSmart Controller. 1. Ensure all sensor connections are correct and that power is properly applied to the device. IMPORTANT: Disconnect any outside RS-485 device from the ESC prior to initiating Controller Setup to avoid communication errors.

  • Page 69: Configuring A Sensor Network

    4. When a screen appears with instructions to “Power Next New Sensor for Setup,” press Network Setup Complete. 5. You will be directed to the Echo Profile screen. The sensor will go through an initialization process and then begin to report the current interface location.
  • Page 70 2. From the Initial Controller Setup screen, press New System Installation. This routine will take approximately 20 seconds to complete. 3. Change the Sensor Address to a unique value other than 1 and enter the correct parameters associated with the sensor on the Initial Sensor Setup screen –...
  • Page 71 7. To see the sensor name, current measurement, gain value, and turbidity output (when applicable) of all connected sensors, press Change Display from the Echo Profile screen. 8. If a sensor is not automatically found (once powered) during the network setup process or needs to be added later, ...

  • Page 72: Special Settings For Filter Applications

    13.3. Special Settings for Filter Applications Two dimensions are needed to set up the EchoSmart unit for filter applications: the distance from the Sensor to the Media (SM), and the Depth of the expandable Media (DM). Installation recommendations and a guide to help determine correct input dimensions are found in Figure 13.1 below.
  • Page 73 Figure 13.1: Installation Recommendations and Field Measurement for Filter Applications - Page 64 -...

Table of Contents