Milltronics MiniRanger Plus PL-604 Instruction Manual
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Milltronics MiniRanger Plus PL-604 Instruction Manual

Milltronics MiniRanger Plus PL-604 Instruction Manual

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MINIRANGER PLUS
April 2001
Instruction Manual PL-604
33456040
Rev. 1.2

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Summary of Contents for Milltronics MiniRanger Plus PL-604

  • Page 1 MINIRANGER PLUS April 2001 Instruction Manual PL-604 33456040 Rev. 1.2...
  • Page 2 Contact SMPI Technical Publications at the following address: Technical Publications Siemens Milltronics Process Instruments Inc. 1954 Technology Drive, P.O. Box 4225 Peterborough, Ontario, Canada, K9J 7B1 Email: techpubs@milltronics.com For the library of SMPI instruction manuals, visit our Web site: www.milltronics.com © Siemens Milltronics Process Instruments Inc. 2001...

  • Page 3: Table Of Contents

    Table of Contents General Information ................5 About this Manual .............. 5 About MiniRanger Plus ............6 Specifications ..................7 Installation.................... 11 Dimensions ..............11 Mounting ................13 Interconnection ..............18 Synchronization ............... 19 Communication..............21 Start Up....................25 General ................25 Display and Keypad............
  • Page 4 Page 4 MiniRanger Plus PL-604...

  • Page 5: General Information

    General Information About this Manual It is essential that this manual be referred to for proper installation and operation of your MiniRanger Plus. As MiniRanger Plus requires an ultrasonic transducer to make a working system, refer to the associated transducer manual as well. Installation gives you step by step direction for the installation and interconnection of your MiniRanger Plus.

  • Page 6: About Miniranger Plus

    The MiniRanger Plus emits a series of ultrasonic pulses from the associated transducer. Each pulse is reflected as an echo from the material and sensed by the transducer. The echo is processed by the MiniRanger using Milltronics' proven `Sonic Intelligence' techniques. Filtering is applied to help discriminate between the true echo from the material, and false echoes from acoustical and electrical noise and agitator blades in motion.

  • Page 7: Specifications

    Specifications MiniRanger Plus Power • 9-250 Vac, 40-70 Hz, 38 VA, 12W or 9-250 Vdc, 11W Fuse • F1 2AG, SlowBlow, 2 amp, 250 V • F3 2 AG, SlowBlow, 1 amp, 250 V • F4 Belling Lee, L754, 4000A HRC, ceramic type 100 mA, 250V Environmental •...
  • Page 8 • installation category: II • pollution degree: 4 Display • 38 x 100 mm (1.5 x 4") multi-field backlit liquid display Communications • Dolphin Plus compatible via optional Milltronics ComVerter Enclosure • Type 4X/NEMA 4X/IP65 Weight • 1 kg (2.2 lb.)
  • Page 9 Transducer Compatible models: • ST-25 / 50 Ultrason ® ® , STH and Echomax models XRS-5, XKS-6, XPS- 10, XPS-15, XCT-8 and XCT-12. • Refer to the associated transducer manual. Cable Transducer: • RG-62 A/U (or equivalent), 365 m (1,200 ft) max. •...
  • Page 10 Page 10 MiniRanger Plus PL-604...

  • Page 11: Installation

    Installation Notes: • Installation shall only be performed by qualified personnel and in accordance with local governing regulations. • This product is susceptible to electrostatic shock. Follow proper grounding procedures. Dimensions Wall Mount 270mm (10.6”) 254mm (10”) 138mm (5.4”) 69mm (2.7”) sealed enclosure integral junction box...
  • Page 12 Rack Mount The MiniRanger Plus rack mount version is a standard DIN 3U/14 HP, 4 rail plug-in unit, for a standard 84 HP deep sub-rack. Panel Mount 208mm 72mm (8.2”) (2.9”) 16mm (0.6”) 144mm (5.7”) 150mm (5.9”) slip on mounting bracket top and bottom screws to be tightened to no more than 1 inch / lb.

  • Page 13: Mounting

    Mounting Wall Mount terminal block integral junction box (cover removed) with terminal block Conduit entry location. Recommend drilling the enclosure with a hole saw and the use of suitable cable glands to maintain ingress rating Terminal Block Layout (Wall Mount) Notes: Non metallic enclosure does not provide grounding between connections.
  • Page 14 Rack Mount Slide the MiniRanger Plus into the sub-rack, aligning the connector with the rail mounted terminal block. connector, 2 row form D male 32 way, per DIN 41612 terminal block, 2 row form D female 32 way, per DIN 41612 Push the MiniRanger Plus into the sub-rack until the MiniRanger Plus front cover is snug to the front rails.
  • Page 15 Terminal Block Layout (Rack Mount) RS-232 ground only Warning: All field wiring must have insulation suitable for at least 250V. Hazardous voltage present on transducer terminals during operation. PL-604 MiniRanger Plus Page 15...
  • Page 16 Panel Mount Slide the MiniRanger Plus through the panel cut-out. Assemble mounting brackets to the MiniRanger Plus chassis by hooking them into the top and bottom. mounting bracket (top and bottom) cut-out dimension 68 + 0.7 mm x 138 + 1.0 mm (2.68 + 0.03”...
  • Page 17 Terminal Block Layout (Panel Mount) RS-232 ground only Warning: All field wiring must have insulation suitable for at least 250V. Hazardous voltage present on transducer terminals during operation. PL-604 MiniRanger Plus Page 17...

  • Page 18: Interconnection

    Interconnection System Diagram *Milltronics transducer, MiniRanger Plus see Specifications mA output customer device isolated customer alarm, pump or control device bipolar current * Milltronics BIC-2, buffered interface (Milltronics communications) converter *rack and panel only Transducer Wall Mount Rack and Panel Mount...

  • Page 19: Synchronization

    180 ms of the prior one(s). To synchronize, interconnect the SYNC terminals of all devices and ensure that there is a common electrical ground interconnecting all units. To synchronize MiniRanger Plus with other Milltronics products, consult Milltronics or your distributor. Wall Mount...
  • Page 20 Current Output Wall Mount Rack and Panel Mount to customer instrumentation to customer isolated mA output, 750 Ω max load instrumentation Relay Output Wall Mount Rack and Panel Mount relay 2 n.o. n.o. n.c. relay 1 n.c. relays shown in de-energized state, contacts rated 5 A at 250 V non-inductive Note: All relays are certified for use in equipment where the short circuit capacity of the circuits in which they are connected is limited by fuses having...

  • Page 21: Communication

    Communication Rack and Panel Mount (only) Bipolar and RS-232 communication are both achieved through a common `TX' port terminal C4 and C6, without any hardware or software intervention. IBM PC Computer Connection / RS-232 MiniRanger Plus (Rack and Panel mount (only) *100 Ω...
  • Page 22 BIC-2 Connection / Bipolar Current MiniRanger Plus Rack and Panel mount BIC-2 ♦ ♦ C8 is direct to ground typical of BIC-2 ports 1-6 Note: Ground shield at one end only Power 9-250 V , 40 – 70 Hz, 38 VA, 12W 9-250 V , 11W Note:...
  • Page 23 Dolphin Optional Dolphin Interface Wall Mount ComVerter MiniRanger Plus computer RS-232 link via infrared ComVerter Rack and Panel Mount computer RS-232 link direct Note: Refer to Dolphin instruction manual for interconnection details. PL-604 MiniRanger Plus Page 23...
  • Page 24 Page 24 MiniRanger Plus PL-604...

  • Page 25: Start Up

    Start Up General The MiniRanger Plus has two modes of operation: run and program . When the unit is powered, after installation procedures have been completed, it is programmed to start up in the run mode, to detect the distance from the transducer face to the target in meters.

  • Page 26: Display And Keypad

    Display and Keypad Wall Mount Rack and Panel Mount communication jack keypad keypad Page 26 MiniRanger Plus PL-604...

  • Page 27: Run Mode

    Run Mode Wall Mount Rack and Panel Mount reading units high alarm indicators: = high, = high-high process material level rising or falling bar graph representation of material level, 0 to 100% of span low alarm indicators: = low, = low-low reading questionable, appears during fail-safe operation auxiliary reading relay status...

  • Page 28: Program Mode

    Program Mode Wall Mount Rack and Panel Mount parameter type ( transducer, relay, or mA output ) reading units `change value' accessed breakpoint accessed Keypad alternates program mode between access scroll ‘select parameter’ scroll up run mode down and ‘change value’ functions Page 28 MiniRanger Plus...

  • Page 29: Setting Up

    Setting Up Programming depicts the wall mount LCD. Display for the rack and panel mount units is the same except for the position of readings and icons. To Access Program: run display program starts at Press P001 To Select a Parameter : Press To Change a Parameter Value : select parameter,...
  • Page 30 increase or decrease to the desired value. Press if no response, security not disabled! save and return to Press ‘select parameter’ function, Note: e.g. p001 =4 Must be pressed to Save change! Express: Parameter: to jump back to P001, or Value: to jump to the factory setting.

  • Page 31: Display Messages

    To Return to Run Mode from the program mode e.g. P001 Press exit and return to run mode. Display Messages ‘OPEn’ in transducer circuit. Refer to Troubleshooting. ‘Short’ in transducer circuit or wiring reversed. Refer to Troubleshooting PL-604 MiniRanger Plus Page 31...
  • Page 32 Express Viewing To view the following readings while in run mode, simultaneously press the depicted keys. Echo Confidence (P805) Echo Strength (P806) Noise (P807) Distance (P923) Page 32 MiniRanger Plus PL-604...

  • Page 33: Functional

    Functional Transceiver The MiniRanger Plus transceiver operates under 1 of 5 sets of preset conditions (P003), summarized as follows: parameter measurement echo f-s timer* long value response verification filter (P070) pulses* 0.1 m/min (slow) 1 m/min 10 m/min 102 m/min / 1.7 m/sec 1020 m/min / 17 m/sec (fast) *each measurement consists of one short pulse plus the set number of long pulses.

  • Page 34: Sound Velocity

    If the transducer does not have an integral sensor, temperature compensation is fixed at a programmed value, P661. The difference between the fixed value and the actual temperature surrounding the transducer will cause an error in measurement. Sound Velocity The MiniRanger Plus can be calibrated to compensate for sound velocity error in fixed temperature, homogenous atmospheres.

  • Page 35: Loss Of Echo

    In applications where the zero level is above the bottom of the vessel and it is desired to monitor the zone below the normal zero, range extension (P801) can be used to extend the range into the far end blanking. Range extension is entered as a percent of P006.

  • Page 36: Relays

    Relays General Two onboard relays are provided in the MiniRanger Plus. Each relay can be assigned one of two functions: Alarm or Pump. Relay two can also be used to control a totalizer when the unit is in OCM mode. Functions Alarm Note:...
  • Page 37 pump sequencing: pumps 1 and 2 operate in lead lag fashion alternating roles on successive pump cycles (first pump on, to all pumps off) . Specifically, pump 1 responds to relay 1 setpoints and pump 2 responds to relay 2 setpoints during the first pump cycle.
  • Page 38 Status Programming Upon entering the program mode, the alarm relays hold their prior status, pump relays are held off. Relay programming: - select relay & function (P111) - enter setpoints (P112 & P113) relay 1 function e.g. 0 = off relay 2 function Press e.g.
  • Page 39 relay status, relay 1 status, relay 2 relay operational, e.g. relay 2 alarm / pump on e.g. relay 1 Fail-safe When the fail-safe timer (P070) expires, the relays respond as follows*: Status Fail-Safe Mode (P071) high alarm low alarm pump down pump up high hold...

  • Page 40: Ma Output

    mA Output The MiniRanger Plus can be programmed to provide an mA output (P200) of 0 to 20 or 4 to 20 mA, and for proportional or inverse span. Programming Upon entering the Program mode, the mA output level holds its prior value. The mA output responds in the following manner: * reference value only.

  • Page 41: Run / Program

    Volume Note: Volume calculation is an optional feature. MiniRangers with the volume feature have this icon on the front: If reading is programmed for volume, P050 entry other than 0, then the mA output is proportional to volume. To program the unit for volume, set: •...
  • Page 42 Page 42 MiniRanger Plus PL-604...

  • Page 43: Applications

    Applications This section highlights the most common applications to which the MiniRanger Plus is likely to be applied. Other applications not described here, such as position monitoring of a piston on a wood pulverizer, are basically improvisational and imaginative ways of applying the MiniRanger Plus.

  • Page 44: Simple Level Application

    Simple Level Application One of the most common applications of a Milltronics process material level monitor is simple level measurement, whereby the material level or space between the transducer and reflecting surface is measured and displayed. This may or may not include alarms and mA output.
  • Page 45 Parameter Directions Description P999 master reset P001 enter '1' mode of measurement = level P002 enter '2' material = solids P003 enter `2' measurement response = 1 m/min. the transducer model purchased with this P004 enter `102' system is an XPS-10 P005 enter `1' units = metres...

  • Page 46: Pump Control Application

    Pump Control Application The basic difference between a simple level application and a pump control application is that the relays assigned to pump function (P111) are normally de-energized (off) and energized when required to run the pump. In the program mode, pump relays are held de-energized. Pumps can be programmed to work independently or in lead/lag fashion.
  • Page 47 Parameter Directions Description P999 master reset P001 enter `1' mode of measurement = level P002 enter `1' material = liquids measurement response = 1 m / min Note: P003 enter `2' the associated preset fail-safe timer is 10 minutes. Override this value by setting P070.

  • Page 48: High Level Switch

    High Level Switch The MiniRanger Plus can be programmed as a high level switch. Significant differences between this and other modes of operation are: • the fail-safe function (P070 and P071) is effectively disabled • on loss of echo, the measurement immediately defaults to a low value (P006) •...
  • Page 49 Parameter Directions Description P999 master reset mode of measurement = high level P001 enter `4' switch P002 enter `2' material = solids measurement response = 1 m/min Note: P003 enter `2' this is the next fastest response rate that would satisfy the given maximum filling rate the transducer model purchased P004...

  • Page 50: Applications With Standpipe

    Applications with Standpipe In many liquid applications, access to the vessel must be made via a standpipe. In such cases, Milltronics can provide optional flanged transducers, or split flanges that mate to a flanged standpipe. Another option is to hang the transducer from a blind flange.

  • Page 51: Volume Conversion

    Volume Conversion Volume conversion can be applied to the measurement, to convert level into volume. Note: Volume calculation is an optional feature. MiniRangers with the volume feature have this icon on the front: For this example we'll assume the following: •...
  • Page 52 Parameter Settings Number Description Instructions Enter "1" for level . P001 Operation No entry required (preset for P002 Material liquid) . Measurement Enter "4" for (100 m/min, Failsafe P003 Response Timer = 0.1 minutes). P004 Transducer Enter "101" for XCT-8 . Enter "4"...

  • Page 53: Open Channel Monitoring (Ocm)

    Open Channel Monitoring (OCM) OCM converts a level reading (head) into a flow value using a linear algorithm. When the MiniRanger is used to calculate flow the mA Output is scaled to the maximum flow (P604) rather than the span (P007). Note: OCM calculation is an optional feature.
  • Page 54 Example PMD Programming P006 P801 If you do not have the characterization chart for the PMD then you will have to create the chart yourself by measuring the head and flow at multiple points. It is much easier to use the chart supplied by your PMD manufacturer.

  • Page 55: Parameter Description

    Parameter Description P000 Lock Locks out the programming 'change value' function such that the values of P001 through P999 cannot be changed. This however does not prevent the `select' function from use for viewing values. Programming is locked out if the value of P000 is other than 1954.
  • Page 56 P003 Measurement Response Collectively sets a number of operating parameters that determine the maximum rate of change in target range that the reading, alarm and mA output functions can keep up to. If MiniRanger Plus cannot keep up with the rate of level change, select a faster rate.
  • Page 57 P004 Transducer Identifies transducer model connected (0 is Default after RESET - same as ST-25). entry : 1 = ST-25 2 = ST-50 100 = ST-H 101 = XCT-8 102 = XPS-10 103 = XCT-12 104 = XPS-15 111 = XKS-6 112 = XRS-5 P005 Units Determines the units for programming and measurement.
  • Page 58 In the RUN mode, Readings are displayed in volumetric units, see Max Volume (P051). When percent is selected, the displayed Reading is the calculated volume as a percentage of Max Volume. entry: 0 = disabled (Factory) 1 = flat bottom 2 = conical or pyramidal bottom 3 = parabolic bottom 4 = spheric bottom...
  • Page 59 P051 Max Volume For Readings in volumetric units (rather than percent), enter the vessel volume between Empty (P006) and Span (P007). The units of measurement for this reading are non-dimensional. The volume is calculated from the empty position to the maximum position and is scaled according to the Tank Shape (P050) value.
  • Page 60 Example To reference the displayed level to sea level, enter the distance in Units (P005), between Empty (P006) and sea level. (Enter a negative value if Empty is below sea level.) P006 P007 P062 sea level reservoir Values -999 to 9999 Preset: 0.000 P070 Fail-Safe Timer The amount of time delay, in minutes, before going into fail-safe mode.
  • Page 61 P111 Relay Function Assigns an alarm function to the selected relay. Refer to page 36. entry : 0 = off (default) 1 = alarm on level 2 = control 3 = control with pump sequencing (both relays must be set to 3) 4 = alarm on loss of echo Note: OCM calculation is an optional feature.
  • Page 62 P600 Primary Measuring Device The type of primary measuring device (PMD) used for Open Channel Monitoring (OCM). Note: OCM calculation is an optional feature. MiniRangers with the OCM feature have this icon on the front: This parameter (P600) is not available unless P001 – Operation is set to “1”. Values 0 = off (no OCM calculation) (default) 1 = Universal Linear Flow Calculation (see P610, P611)
  • Page 63 P610 Head Breakpoints The head breakpoints for which flowrate is known. These are the values in the Span for which flowrates are known. See Open Channel Monitoring (OCM) on page 53 for a description of how to specify breakpoints. Values 0.0 to 15.0 meters (or equivalent units as defined by P005) P611 Breakpoint Flowrates The flowrate corresponding to each Head Breakpoint entered.
  • Page 64 P650 Offset Calibration Typically used to calibrate the ultrasonic measurement, and its associated outputs, to a known value. • fill the tank as much as permissible, without going into the near blanking. • monitor P650 until a stable reading is obtained. •...
  • Page 65 2 = formatted commas are inserted between message fields The MiniRanger plus Rack and Panel units provide a proprietary 20 mA bipolar current loop for communication with the Milltronics BIC-2 peripheral device. The MiniRanger Plus uses simplex convention communication protocol.
  • Page 66 Status A 1 character, $0 to $F (convert to binary, e.g. temp, echo, and cable OK, not priority) 0 = reserved 1 = loss of echo (f.s. expired) 1 = transducer cable fault 0 = reserved Status B 1 character, $0 to $F (convert to binary, e.g. scan point is in high alarm) 1 = low low alarm 1 = low alarm 1 = high alarm...
  • Page 67 MT-01 Hold Message start of message message type end of message Field Name Definition Start Of Message STX ($02) Message Type 2 characters, 01 (indicates the MiniRanger was removed from the RUN mode) End Of Message CR ( $0D ) P800 Near Blanking Sets the amount of blanking as measured from the transducer face and extending into the measurement range.
  • Page 68 P805 Echo Confidence A measure of echo reliability. display: ## : ## = short : long where: ## = 0 to 99 ; confidence value P806 Echo Strength The absolute strength of the selected echo, in dB above 1 uV rms. P807 Noise The peak and average ambient noise, in dB above 1 uV rms.
  • Page 69 Tests the memory. Test is initiated by scrolling to the parameter or repeated by pressing. display: PASS = normal FAIL = consult Milltronics P907 Programmer Interface Tests the infrared communication link. Test is initiated by scrolling to the parameter or repeated by pressing.
  • Page 70 P910 Relay Tests the alarm relays. entry: 0 = de-energizes selected relay 1 = energizes selected relay P911 mA Output Value Displays the value from the previous measurement. A test value can be entered and the displayed value is transmitted to the output. Upon returning to the run mode, the parameter assumes the actual mA output level.

  • Page 71: Troubleshooting

    Troubleshooting The following is a list of operating symptoms, their probable causes and the actions needed to resolve them. Symptom Cause Action Loss of echo display reads ‘Short’, connection of a check transducer type no pulsing is felt on the transducer without a and correct P004 if transducer face...
  • Page 72 Symptom Cause Action … continued transducer location for relocate or re-aim aiming: transducer for maximum echo confidence, P805 poor installation moved my material or vibration flanging not level transducer malfunction: check P300, P805, p807 temperature too high physical damage inspect excessive foam on use foam deflector or liquid face...
  • Page 73 Symptom Cause Action Reading erratic echo confidence weak, refer to P805, P807 liquid surface agitated, decrease measurement response P003 enable filter, echo verification relocate transducer* material filling check P807 under electrical noise quiescent conditions, noise should be 15 dB transducer cable must be in grounded metal conduit and cable grounded only at TB-1*...

  • Page 74: Maintenance

    Maintenance The MiniRanger Plus. requires no maintenance, however a program of periodic checks is advised. If the MiniRanger Plus wall unit is mounted in a dusty or oily environment, make sure that the programmer, optional Dolphin ComVerter, and front cover are kept clean; otherwise it may impede the infrared signal transmission.

  • Page 75: Appendices

    Appendices Alphabetical Parameter List algorithm P820 range extension P801 breakpoint flowrates P611 relay P910 confidence threshold P804 relay A setpoint P112 echo confidence P805 relay B setpoint P113 echo marker trigger P825 relay function P111 echo strength P806 remote totalizer multiplier P640 empty P006...
  • Page 76 Programming Chart Parameter Name Value P001 Operation P002 Material P003 Measurement Response P004 Transducer P005 units P006 Empty P007 Span P050 Tank Shape P051 Max Volume P052 Tank Shape ‘A’ P053 Tank Shape ‘L’ P062 Offset Reading P070 Fail-Safe Timer P071 Fail-Safe Material P111[1]...
  • Page 77 *7ml19981cj01*...

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