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APG DCR-1003 Operator's Manual

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AUTOMATION
P R O D U C T S
G R O U P,
I N C.
Operator's Manual
DCR-1003
and
DCR-1004
Rev. A3, 10/08
Doc. 9002661
Automation Products Group, Inc.
APG...Providing tailored solutions for measurement applications
Tel: 1/888/525-7300 • Fax: 1/435/753-7490 • www.apgsensors.com • E-mail: sales@apgsensors.com

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Summary of Contents for APG DCR-1003

  • Page 1 P R O D U C T S G R O U P, I N C. Operator’s Manual DCR-1003 DCR-1004 Rev. A3, 10/08 Doc. 9002661 Automation Products Group, Inc. APG...Providing tailored solutions for measurement applications Tel: 1/888/525-7300 • Fax: 1/435/753-7490 • www.apgsensors.com • E-mail: sales@apgsensors.com...

  • Page 2: Table Of Contents

    Warranty ..................3 Introducing ..................4 Understanding Ultrasonics ............. 5 Installation ..................7 Installing the DST Sensor ............7 Installing the DCR-1003, 1004 ..........10 Wiring .................... 11 Programming ................13 Operation ................... 15 Filtering ..................16 Outputs ..................19 Applications ................

  • Page 3: Warranty

    No representation or warranty, express or implied, made by any sales representative, distributor, or other agent or representative of APG which is not specifically set forth herein shall be binding upon APG. APG shall not be liable for any incidental or consequential damages, losses or expenses directly or indirectly arising from the sale, handling, improper application or use of the goods or from any other cause relating thereto and APG’s liability hereunder, in...

  • Page 4: Introducing

    0-20 mA or voltage outputs. The DST series sensors are non-contact ultrasonic which measure the distance to a surface through air. The standard DCR-1003, 1004 sensor is the DST-1002. It is a totally sealed PVC sensor with a range of 25 ft. Several other versions of DST are available to fit almost any application.

  • Page 5: Understanding Ultrasonics

    A target with poor sound wave reflection characteristics will reduce the operating distance of the sensor and decrease its accuracy. Automation Products Group, Inc. APG...Providing tailored solutions for measurement applications Tel: 1/888/525-7300 • Fax: 1/435/753-7490 • www.apgsensors.com • sales@apgsensors.com...
  • Page 6 Generally a target at an angle greater than 5 degrees off perpendicular will not be detected. Automation Products Group, Inc. APG...Providing tailored solutions for measurement applications Tel: 1/888/525-7300 • Fax: 1/435/753-7490 • www.apgsensors.com • sales@apgsensors.com...

  • Page 7: Installation

    BEST GOOD *Soft gasket material is recommended with flange mounting. Automation Products Group, Inc. APG...Providing tailored solutions for measurement applications Tel: 1/888/525-7300 • Fax: 1/435/753-7490 • www.apgsensors.com • sales@apgsensors.com...
  • Page 8 Any angle off perpendicular will degrade the performance of the sensor. Stand Pipe Top of Tank 10-45 Automation Products Group, Inc. APG...Providing tailored solutions for measurement applications Tel: 1/888/525-7300 • Fax: 1/435/753-7490 • www.apgsensors.com • sales@apgsensors.com...
  • Page 9 Minimum Blanking Distance Highest Anticipated Tank Level Automation Products Group, Inc. APG...Providing tailored solutions for measurement applications Tel: 1/888/525-7300 • Fax: 1/435/753-7490 • www.apgsensors.com • sales@apgsensors.com...

  • Page 10: Installing The Dcr-1003, 1004

    Rev. A3, 10/08 Installing the DCR-1003, 1004 The DCR-1003, 1004 should be installed using the 4 mounting feet provided. The enclosure must be mounted out of direct sunlight and should have good clearance to the left for opening the hinged cover.

  • Page 11: Wiring

    Step 3: The DCR-1003, 1004 is shipped from the factory configured for 100- 120 VAC input power. If 200-230 VAC is to be used, change the jumpers configuration to 220 VAC as shown in the diagram below.
  • Page 12 DCR-1003 and DCR-1004 Rev. A3, 10/08 Step 4: Wires can be pulled into the DCR-1003, 1004 through the strain reliefs on the enclosure, or the strain reliefs may be removed and 1/2 in. conduit used in their place. The spring loaded terminal can be wired using solid or stranded wire between 16 - 20 AWG.

  • Page 13: Programming

    DCR-1003, 1004. The front cover makes reading the displays easy while preventing the buttons on the keypad from being accidentally bumped. The different modes of the DCR-1003, 1004 can be easily accessed using the mode buttons, MODE UP and MODE DN. They operate similar to a digital watch.
  • Page 14 6. MODES 24-26 Setup analog output 7. MODE 44 Set temperature compensation 8. Advanced setup *(not required in most applications) MODES 27-28, 45-48 Automation Products Group, Inc. APG...Providing tailored solutions for measurement applications Tel: 1/888/525-7300 • Fax: 1/435/753-7490 • www.apgsensors.com • sales@apgsensors.com...

  • Page 15: Operation

    If using a DST version 2000 sensor, Mode 6 will display the sensor selected pulse setting. The pulse setting is not user adjustable. Automation Products Group, Inc. APG...Providing tailored solutions for measurement applications Tel: 1/888/525-7300 • Fax: 1/435/753-7490 • www.apgsensors.com • sales@apgsensors.com...

  • Page 16: Filtering

    The window is equal Default = 2.00 ft. to + or – the value entered in mode 10 from the current Automation Products Group, Inc. APG...Providing tailored solutions for measurement applications Tel: 1/888/525-7300 • Fax: 1/435/753-7490 • www.apgsensors.com • sales@apgsensors.com...
  • Page 17 Example 1: Rapid Level Changes If the DCR-1003, 1004 filtering is too slow and the level to be monitored is changing rapidly, the display will seem to jump between readings instead of scrolling smoothly as the level changes. To reduce the filtering and quicken the response, modes 7 to 10 should be changed.
  • Page 18 Should be kept to a small value to help qualify only echoes from the target surface. Automation Products Group, Inc. APG...Providing tailored solutions for measurement applications Tel: 1/888/525-7300 • Fax: 1/435/753-7490 • www.apgsensors.com • sales@apgsensors.com...

  • Page 19: Outputs

    DCR-1003 and DCR-1004 Outputs The DCR-1003 comes standard with 4 relay outputs fused at 5 A each. The DCR-1004 is equipped with relays and an analog output. Detailed explanations of the two output types are given in the RELAY and ANALOG sections.
  • Page 20 Trip 4 Trip 4 Type Range = 0 - 7 Selects the type of function Default = 0 Trip 4 will perform Automation Products Group, Inc. APG...Providing tailored solutions for measurement applications Tel: 1/888/525-7300 • Fax: 1/435/753-7490 • www.apgsensors.com • sales@apgsensors.com...
  • Page 21 Rev. A3, 10/08 DCR-1003 and DCR-1004 Trip Type Explanation Automation Products Group, Inc. APG...Providing tailored solutions for measurement applications Tel: 1/888/525-7300 • Fax: 1/435/753-7490 • www.apgsensors.com • sales@apgsensors.com...
  • Page 22 Any signal higher than 5 ft. or lower than 10 ft. will cause the alarm relay to open Automation Products Group, Inc. APG...Providing tailored solutions for measurement applications Tel: 1/888/525-7300 • Fax: 1/435/753-7490 • www.apgsensors.com • sales@apgsensors.com...
  • Page 23 5 ft., or loss of echo. To program the DCR-1003, 1004 for this application, the following modes must be set: MODE VALUE DESCRIPTION...
  • Page 24 Fine tunes the minimum current sourced on the analog output 20 mA Calibration Fine tunes the maximum current sourced on the analog output Automation Products Group, Inc. APG...Providing tailored solutions for measurement applications Tel: 1/888/525-7300 • Fax: 1/435/753-7490 • www.apgsensors.com • sales@apgsensors.com...

  • Page 25: Applications

    A batch plant operator needs a display to show the level of rock in a hopper 5 meters deep. To program the DCR-1003, 1004 for this application, the following values must be entered in the modes indicated. Many of them are the same as the preset values but are shown again for example purposes.
  • Page 26 Rev. A3, 10/08 VOLUME A very popular use for the DCR-1003, 1004 is to do volumetric conversions for the amount of product in a tank. If 0 is selected as the tank type , the zero point is at the DST, and the display will show the distance to the product. If tank type 1 - 5 are selected, the zero point is the bottom of the tank, and the display will show how much product is in the tank.
  • Page 27 Units = mode 1 Sets the radius of the cylinder Default = 5.00 ft. (not used in tank type 0 or 1) Automation Products Group, Inc. APG...Providing tailored solutions for measurement applications Tel: 1/888/525-7300 • Fax: 1/435/753-7490 • www.apgsensors.com • sales@apgsensors.com...
  • Page 28 *Because the units set in mode 1 are set to feet, any tank dimensions entered must also be in feet. This does NOT include output settings, outputs are setup in the units of volume being used. Automation Products Group, Inc. APG...Providing tailored solutions for measurement applications Tel: 1/888/525-7300 • Fax: 1/435/753-7490 • www.apgsensors.com • sales@apgsensors.com...
  • Page 29 *Because the units set in mode 1 are set to feet, any tank dimensions entered must also be in feet. This does NOT include output settings, outputs are setup in the units of volume being used. Automation Products Group, Inc. APG...Providing tailored solutions for measurement applications Tel: 1/888/525-7300 • Fax: 1/435/753-7490 • www.apgsensors.com • sales@apgsensors.com...
  • Page 30 A mechanical rake is to be engaged for cleaning a screen when the upstream level is 2 feet higher than the downstream level. To program the DCR-1003, 1004 for this application, the following modes must be changed from their preset values.
  • Page 31 DCR-1003 and DCR-1004 Differential CONNECT ONLY ONE OF THE DST SENSORS TO THE DCR-1003, 1004 Program the DST that is connected to the DCR-Controller to be sensor # 2. The other DST will be sensor # 1 as set at the...
  • Page 32 Rev. A3, 10/08 OPEN CHANNEL FLOW The DCR-1003, 1004 and DST ultrasonic system can be used to compute the flow of a liquid in an open channel such as rivers, canals, and partially filled conduits. The flow is determined by using the DCR/DST system to measure the liquid level upstream from a weir or flume.
  • Page 33 Sets the portion of the exponent Decimal Point Default = 0 (X) below the decimal point, used to convert distance to flow Automation Products Group, Inc. APG...Providing tailored solutions for measurement applications Tel: 1/888/525-7300 • Fax: 1/435/753-7490 • www.apgsensors.com • sales@apgsensors.com...
  • Page 34 *NOTE: The DCR-1004 does NOT work with contracted-end weirs. To program the DCR-1003, 1004 for this application, the following modes must be set: MODE...
  • Page 35 The associated flow equation for the 1 meter flume is: Flow in LPS = 11.48 * H^1.56 where H is the upstream head measurement as specified for this flume type. To program the DCR-1003, 1004 for this application, the following modes must be set: MODE VALUE...
  • Page 36 Default = OFF speed of sound, on, off, or view sensor temperature set by NUM UP or NUM DN Automation Products Group, Inc. APG...Providing tailored solutions for measurement applications Tel: 1/888/525-7300 • Fax: 1/435/753-7490 • www.apgsensors.com • sales@apgsensors.com...

  • Page 37: Calibrations

    If a more precise calibration is required, a two point calibration should be used. This is accomplished by using the linear equation of Y = AX + B where; Automation Products Group, Inc. APG...Providing tailored solutions for measurement applications Tel: 1/888/525-7300 • Fax: 1/435/753-7490 • www.apgsensors.com • sales@apgsensors.com...

  • Page 38: Utilities

    Mode 50 displays the software version for the DCR. The value corresponds to the operating version and the approximate date of manufacture. MODE DESCRIPTION PARAMETERS EXPLANATION Software Version Displays the software version Automation Products Group, Inc. APG...Providing tailored solutions for measurement applications Tel: 1/888/525-7300 • Fax: 1/435/753-7490 • www.apgsensors.com • sales@apgsensors.com...

  • Page 39: Quick Reference Sheet

    End Trip 4 ________________________ Trip 4 Type ________________________ Analog Analog Output ________________________ 0 or 4 mA Distance ________________________ 20 mA Distance ________________________ Automation Products Group, Inc. APG...Providing tailored solutions for measurement applications Tel: 1/888/525-7300 • Fax: 1/435/753-7490 • www.apgsensors.com • sales@apgsensors.com...
  • Page 40 Temp Comp ________________________ Distance Offset ________________________ Offset Polarity ________________________ Calibration Above ________________________ Calibration Below ________________________ Utilities Reset ________________________ Software Version ________________________ Automation Products Group, Inc. APG...Providing tailored solutions for measurement applications Tel: 1/888/525-7300 • Fax: 1/435/753-7490 • www.apgsensors.com • sales@apgsensors.com...

  • Page 41: Troubleshooting

    DCR-1003 and DCR-1004 • Trouble Shooting The DCR-1003, DCR-1004 and DST sensor are a rugged, reliable level measurement system that is easy to install and setup. But occasionally problems will occur during set up. A list of symptoms and possible corrective actions are provided for troubleshooting.

  • Page 42: Maintenance

    Rev. A3, 10/08 • Maintenance The DCR-1003, 1004 controller and DST sensor do not require maintenance. However, a periodic visual inspection of the system would be in order. The DST should be kept as clean as possible for optimum performance. Dust buildup may be removed from the transducer with a cloth or by low pressure air.

  • Page 43: Specifications

    Terminal Strip Sample Rate 1-12 Hz 1-12 Hz Programmable Settings microprocessor microprocessor controlled modes controlled modes Sensor Connector F connector F connector Automation Products Group, Inc. APG...Providing tailored solutions for measurement applications Tel: 1/888/525-7300 • Fax: 1/435/753-7490 • www.apgsensors.com • sales@apgsensors.com...
  • Page 44 AUTOMATION P R O D U C T S G R O U P, I N C. APG...Providing tailored solutions for measurement applications Automation Products Group, Inc. Tel: 1/888/525-7300 1/435/753-7300 Fax: 1/435/753-7490 e-mail: sales@apgsensors.com www.apgsensors.com Automation Products Group, Inc. 1025 W. 1700 N.

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Dcr-1004

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