Milltronics InterRanger IR-200 Instruction Manual Download Page 1

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InterRanger IR-200

Technology based. Customer driven.

January 1998

Instruction Manual

PL-545

33455450

Rev 1.0

Summary of Contents for InterRanger IR-200

Page 1: ...InterRanger IR 200 Technology based Customer driven January 1998 Instruction Manual PL 545 33455450 Rev 1 0 ...

Page 2: ...ude ultrasonic and capacitance level measurement in line weighing of dry bulk solids and motion sensing Milltronics is established world wide through associate offices and representatives Our network is continually being refined to provide our customers with first rate sales information engineering assistance and after sales support For more details on our products and service please contact us an...

Page 3: ...or 14 IRT 100 series Sensor 14 IRP 8D Transceiver 14 Quick Start 15 Configuring the Unit 15 Determining Tank Depth 16 Operation 19 RUN Mode 19 Graphs 19 Program Mode 21 Parameters 23 Program Mode 23 Test Mode 29 Security Lockout for PGM and TEST Modes 30 Drawings are referenced throughout this manual All referenced drawings are located at the end of the manual ALSO CONTAINED IN THIS MANUAL IR 200 ...

Page 4: ...m 0 4 ft 30 5m 100 ft Stability 0 1 per degree C Operating Temperatures Sensor standard 30 C to 80 C 22 F to 176 F Sensor high temperature 30 C to 105 C 22 F to 221 F Monitor standard 10 C to 50 C 14 F to 122 F Monitor with optional heater 30 C to 50 C 22 F to 122 F Humidity Monitor 5 to 100 non condensing Outputs 4 20 mA scalable to any range 900 max load 4 Programmable relays rated to 7A 250Vac ...

Page 5: ...g Rail mount for Monitor Rail mount for Transceiver Stationary Handrail Bracket Kit for Sensor Swing out Adapter Kit for Sensor Heating Heater for Monitor Communications Profiling Software RS232 to RS485 Optically Isolated Converter RS 485 Repeater DB9M to DB25F Converter COMPONENT DESCRIPTIONS The InterRanger is made up of three main components the Monitor the Transceiver and the Sensor The Monit...

Page 6: ...tion The optional heater should be ordered when the Monitor is to be located in a climate that drops below 10 C 14 F The heater has a built in thermostat so that power consumption is kept to a minimum When operating the heater will consume an additional 50 watts of power and is available in 115Vac and 230Vac configurations IRP 8D TRANSCEIVER Description The Transceiver is housed in a polycarbonate...

Page 7: ...ielded cable optional 22 5 m 75 available Temperature Range 30 C to 80 C 22 F to 176 F Drawing 0 8140001Z DU C IRT 100DC SENSOR Description Same as the IRT 100D but is constructed of high temperature epoxy Supplied with either a Kynar or 316 stainless steel 3 4 NPT nipple and 7 5 m 25 of Teflon jacketed cable optional 22 5 m 75 available Temperature Range 30 C to 105 C 22 F to 221 F Drawing 0 8140...

Page 8: ... U bolts are supplied and all holes are pre drilled Drawing 0 8130004Z DU C RAIL MOUNT FOR TRANSCEIVER Description This anodized aluminum plate allows the Transceiver to be mounted on a horizontal or vertical standard 2 hand rail Two U bolts are supplied and all holes are pre drilled Drawing 0 8130008Z DU C Anodized Aluminum Plate 2 Hand Rail Anodized Aluminum Plate 2 Hand Rail ...

Page 9: ...ling needed to connect the Sensor to the bracket are supplied by the customer Drawing 0 8140004Z DD C SWING OUT ADAPTOR KIT FOR SENSOR Description This kit contains a swing out bracket a skimmer guard and six 3 4 U bolts for use with an IRT 100 series Sensor and Stationary Handrail Bracket This kit should be used if the tank has a surface skimmer so that the Sensor deflects out of the way when the...

Page 10: ...hen it is subject to algae or scale build up Cleaning of the Sensor face is required is if build up of material exceeds algae or debris 1 5 cm 1 2 scaling 0 75 cm 1 4 Greater build ups than these will make it difficult for the Sensor to detect the return echo signal and may result in incorrect or null readings The timing of this maintenance is determined by the rate of accumulation and should be e...

Page 11: ...ay and stores the result in memory Once enough information has been gathered over a user determined time frame the Monitor displays a Tank Profile on the LCD display All interfaces detected are displayed and a user specified interface will be tracked by the unit and shown in the numerical display above the keypad DEAD ZONES BLANKING DISTANCES Two dead zones exist where an interface is difficult or...

Page 12: ...InterRanger IR 200 12 PL 545 ...

Page 13: ... mode See Program Mode on page 21 When in an alarm condition the output will drop below 4 mA and cause an underflow alarm to alert any external devices that use this output SET POINT RELAYS Four Form C relays are available for set point control outputs with relay contacts rated for 7A resistive load at 250 Vac Each relay can be programmed to perform as either a high or low alarm and the hysteresis...

Page 14: ...wer than that if conditions dictate but there is no performance advantage The easiest method of installation is to use one of the Milltronics Handrail Brackets in conjunction with a piece of 3 4 stainless steel or galvanized pipe and a 3 4 pipe coupling If the monitored tank has any type of surface skimming mechanism then the Milltronics Swing out Adapter should be utilized See drawings 0 8140003Z...

Page 15: ...w key to select a value of 4 clear water depth in meters or 3 clear water depth in feet 5 Press the next page key twice to advance to the ECHO PROFILE UPDATE RATE screen 6 Press the down arrow key until you select a value of 1 7 5 sec 7 Press the next page key once to advance to the INTERFACE LEVEL AVERAGING CYCLES screen 8 Press the down arrow key until you select a value of 1 9 Press the previou...

Page 16: ...sical Measurement If the bottom is not visible on the graph or no major peaks appear where expected this usually means that the solids are very thick on the bottom or that the tank bottom is sloped In this case carefully measure the distance between the Sensor face and the bottom of the tank to obtain your TANK DEPTH measurement This is the preferred method of measurement because it is the most ac...

Page 17: ...o scroll forward through the other parameters and the up and down arrow keys to set the following values listed These are good starting points for most applications and can be fine tuned later Each of the following parameters is described in more detail in Parameters on page 23 Parameter Example Setting Trend Graph Time Scale 1 Echo Profile Update Rate 4 Interface Level Avg Cycles 10 Trigger Point...

Page 18: ...InterRanger IR 200 18 PL 545 ...

Page 19: ...s and displays the depth of the selected interface Opens or closes the relays depending on their configuration The InterRanger starts in RUN mode This allows the unit to keep functioning if the power fails and then resumes GRAPHS There are two display formats available for viewing while in the RUN mode described below Use the next page and previous page keys to switch between the two graphs shows ...

Page 20: ...s or 4 1 minute The Echo Profile Graph is the default screen that appears when RUN Mode is enabled In the event that the InterRanger cannot detect an interface level Err will appear in the numeric display and the graphical display will continue to show the echo profile with Interface Not Found displayed at the top of the screen TREND GRAPH This display is a virtual strip chart recorder showing the...

Page 21: ... parameter settings are accessed by using the PREV PAGE and NEXT PAGE keys while in the PGM Mode The digital display shows the current setting for each program parameter These values are adjusted by using the up and down arrow keys Hold down the appropriate arrow key to scroll through the available values quickly Parameters may be adjusted in any order except for DISPLAY FORMAT Whenever DISPLAY FO...

Page 22: ...InterRanger IR 200 22 PL 545 ...

Page 23: ...must be made in feet TREND GRAPH TIME SCALE This sets the time span desired for the Trend Graph The clock for the graph may be set in TEST Mode See Test Mode on page 29 Values 1 3 hours 2 6 hours 3 12 hours 4 24 hours ECHO PROFILE UPDATE RATE The IR 200 transmits approximately four times per second Each of these transmit pulses produces an echo profile of the tank If these profiles were analyzed i...

Page 24: ...Track the peak closest to the bottom of the tank regardless of size This setting generally works well in gravity thickeners 4 Track the peak closest to the top of the tank This setting will track the very lightest fluff in the tank 5 This special algorithm can be used in tanks where the heaviest sludge never exceeds 0 5 solids It tracks the beginning of any mound at the bottom of the tank 6 This a...

Page 25: ...ulse generates This noise can be seen at the top of the echo profile Values 0 00 to 30 00 m 0 0 to 100 0 GAIN CONTROL When this value is set to 0 the IR 200 will adjust transmitter power automatically The automatic gain control AGC will adjust the power level so that the biggest peak in the echo profile is about 80 of full scale on the display graph This automatic mode is well suited for tanks whe...

Page 26: ... can increase the size of the smaller peaks thereby improving the reliability of the detection process The value entered should be the approximate width of the main peak entered in tenths of a foot The unit will then ignore the main peak when adjusting transmit power Values 0 to 100 SPEED OF SOUND CORRECTION In typical ambient temperature wastewater tanks this value should be left at its default v...

Page 27: ...ding For example if the specified interface level is needed to span the 4 to 20 mA range between 2 m and 4 m 6 6 to 13 1 then set this value at 2 6 6 and set the next parameter 20 mA LEVEL at 4 13 1 Then for levels of 2 m 6 6 or less the reading will be 4 mA and levels of 4 m 13 1 or higher will read 20 mA An interface level of 3 m 9 85 will produce a reading of 12 mA It is possible to set the 4mA...

Page 28: ...feet depending on the DISPLAY FORMAT parameter Values 0 00 to 30 00 m 0 0 to 100 0 RELAY NUMBER X OFF SETPOINT To allow for hysteresis in the activation of the relays this parameter sets the reading that must be reached in order to turn a relay off after it has been turned on Once the corresponding relay has been turned on see RELAY NUMBER x ON SETPOINT it will not turn off until the specified int...

Page 29: ... of hours for Trend Graph 24 hour clock DISPLAY TEST lights all LED s and LCD segments 4 mA ADJUST fine tuning of 4 mA output 20 mA ADJUST fine tuning of 20 mA output RELAY X TEST independent testing of all relays ALARM RELAY TEST testing of alarm relay PRINT PROFILE prints echo profile on serial printer 3 Press the test key again to run the selected test 4 Press the up and down arrow keys to chan...

Page 30: ...en the front panel of the Monitor and locate the Processor PC card on the backside of the front panel behind the graphic display There are four DIP switches on this card For complete access to the PGM and TEST Modes the switches must be in the following factory setting Switch Status 1 OFF 2 ON 3 ON 4 OFF If these switches are set any other way only the RUN Mode will function ...

Page 31: ...r 37 Incomplete Message Error 37 Hardware Related Errors 37 Data Transmission Errors 37 Model IR 200 Messages 39 Host Originated Messages 39 Request Data Report 39 Request Tank Profile 39 Request Relay Configuration 40 Request Trend Data 40 Request Program Parameter Value 40 Change Program Parameter Value 41 Change Mode 41 Program Parameter Numbers 42 MODEL IR 200 ORIGINATED MESSAGES 43 Data Repor...

Page 32: ...InterRanger IR 200 32 PL 545 ...

Page 33: ...ingle communications line When using the RS 232 interface though only a single instrument may be connected on a communications line unless suitable modems or other communications devices are used DATA FORMAT A serial byte oriented asynchronous protocol is used Each data byte is transmitted in a data frame containing a single start bit eight data bits no parity bits and one stop bit The data bits a...

Page 34: ...InterRanger IR 200 34 PL 545 ...

Page 35: ...he host originated message The instrument address field is one byte long It is transmitted as two ASCII encoded hexadecimal digits OO to FF DATA LENGTH FIELD The data length field specifies how many bytes of data are part of a particular message s data field The data length field is normally one byte long It is transmitted as two ASCII encoded hexadecimal digits O1 to FF However if a message lengt...

Page 36: ...in the transmission of a message It is calculated as the 16 bit sum of all previous byte values the value of a two hexadecimal digit pair excluding the start character The checksum field is two bytes long It is transmitted most significant byte first as four ASCII encoded hexadecimal digits OOOO to FFFF ...

Page 37: ...eding character This time is called the intercharacter timeout If the next character of the message is not received within the intercharacter timeout an incomplete message error is declared Remote instruments ignore any incomplete messages If the host computer receives an incomplete message it may retransmit its request to the remote instrument if desired The intercharacter timeout is 500 millisec...

Page 38: ...InterRanger IR 200 38 PL 545 ...

Page 39: ...rigger priority 1 to 6 Profile averaging time Tank depth Current blanket level The message is formatted as follows Data Length 01 Message Type 01 Additional Data none Expected Reply Data Report Example The string M0201010004 requests a data report from a unit answering to address 02 The final 0004 is the checksum REQUEST TANK PROFILE A request Tank Profile message directs the Model IR 200 to trans...

Page 40: ...lution 3 hours 01 2 minute resolution 6 hours 02 4 minute resolution 12 hours 03 8 minute resolution 24 hours Expected Reply Trend Data Example A message string M070204030010 will request a unit answering to address 07 to transmit the previous 24 hours worth of trend data at a resolution of 8 minutes REQUEST PROGRAM PARAMETER VALUE This message instructs the Model IR 200 to report the current valu...

Page 41: ...sage to IR 200 number 2 would be M0204060100F50102 To transmit a speed of sound correction factor parameter number 0F of 1 180 the host must transmit the hexadecimal equivalent of 1180 or 049C The complete message to IR 200 number 2 would be M0204060F049C00BB To transmit a GAIN CONTROL parameter number 0B value of 75 the value would be encoded as 004B The complete message to analyzer number 1 woul...

Page 42: ... Yes Interface Level Averaging Cycles 05 Yes Trigger Point 06 No Median or Average 07 Yes Sensitivity 08 No Bottom Dead Zone 09 No Top Dead Zone 0A No Gain Control 0B No Maximum Transmit Gain 0C No Bottom Echo in Gain Control 0D No AGC Exclusion 0E No Speed of Sound Correction 0F No Lost Interface Control 10 No Serial Address 11 No Baud Rate 12 No 4 mA Level 13 No 20 mA Level 14 No Relay Number 1 ...

Page 43: ...s 4 7 Error status 03 bits 0 2 Instrument scale bits 3 5 Trigger priority 04 Profile averaging time 05 Tank depth MSB 06 Tank depth LSB 07 Interface level MSB 08 Interface level LSB 09 Transmitter Power AGC level The relay status bits in the message indicate whether a particular setpoint relay is energized or not Bit 0 corresponds to relay 1 bit 1 corresponds to relay 2 and so on The relay status ...

Page 44: ...suring the blanket level The transmitter power level is a value between 0 and 100 decimal which indicates the power being used to generate profiles This information is useful when comparing profiles or troubleshooting TANK PROFILE A Tank Profile message is transmitted by the IR 200 in response to a Request Tank Profile message transmitted by the host computer The tank profile indicates the strengt...

Page 45: ...ach of the Model IR 200 s four setpoint relays is transmitted High low selection Relay on value Relay off value The message is formatted as follows Data Length 13 Message Type 83 Additional Data 02 Instrument scale 03 bits 0 3 High low selection 04 Relay 1 on value MSB 05 Relay 1 on value LSB 06 Relay 1 off value MS 07 Relay 1 off value LSB 08 Relay 2 on value MSB 09 Relay 2 on value LSB 0A Relay ...

Page 46: ... is 12 3 feet it is transmitted as 123 decimal or 007B For instrument scales in meters the tank depth is transmitted in hundredths of meters A tank depth of 2 62 meters would be transmitted as 262 decimal or 0106 The current time is transmitted as an hour 00 to 18 and a minute 00 to 3C The interface level samples are transmitted next as 180 2 byte values beginning with the most current sample For ...

Page 47: ...cknowledge optional enhanced serial port only This message is a response to a host originated message to indicate that the requested change in mode or program parameter has been successfully implemented The message format is as follows Data Length 01 Message Type F0 Additional Data none Example Monitor number 1 would respond R0101F000F2 NEGATIVE ACKNOWLEDGE This message is a response to a host ori...

Page 48: ...InterRanger IR 200 48 PL 545 ...

Page 49: ...Introduction 51 Hardware Requirements 51 General 51 RS 232 communications 52 RS 485 communications 53 Setup 54 IR200LOG EXE Software 55 Installation 55 Operation 57 Main Menu 57 Run Mode 57 Profile Viewer 58 Trend Graph Viewer 58 Program Setup 58 Quit 60 MILLTRONICS SOFTWARE LICENSE 61 ...

Page 50: ...InterRanger IR 200 50 PL 545 ...

Page 51: ...ieved through the unit s RS 232 or RS 485 transceiver and a standard RS 232 port on any IBM compatible computer running DOS 4 01 or higher Up to 40 units can be monitored with this program and the profiles and trend graphs may be saved to disk HARDWARE REQUIREMENTS GENERAL IR200LOG EXE runs in VGA color mode and requires a 80286 or higher processor This program will NOT run on an XT type machine ...

Page 52: ...orts that follow this standard RS 232 communication is only possible between two pieces of equipment and requires three wires for communication Maximum communication distance is approximately 200 m 600 Parts 3 wire communication cable shielding discretional Female DB9 or DB25 RS 232 connector or 3 wire cable ...

Page 53: ...tely 1200 m 4000 There can be no Y branches in this network and the last unit in the chain must have a termination resistor 130 to 150 ohms connected across the X and X at the terminal strip TB4 Parts RS 232 to RS 485 converter Milltronics Part 20150158 Converter power supply Milltronics Part 24900031 Optional Repeater for distances 4000 or for 32 to 40 units Milltronics Part 21500159 Termination ...

Page 54: ...d that each has a unique address See SERIAL ADDRESS parameter A 9600 BAUD rate must be set in the IR200LOG program as well See IR200LOG Software If a slower BAUD rate is desired read the documentation included with the converter on how to achieve this Be sure BAUD rate is changed in all IR 200 units and the IR200LOG program as well The Unit Address in the IR200LOG program corresponds to the SERIAL...

Page 55: ...ry that the executable resides in The only available output from the program is a screen printout This is done by pressing the Print Screen key If printouts are required the graphics com utility should be run before starting the IR200 EXE program A batch file may be created to simplify program execution Use a text editor to create a file e g IR200LOG BAT Enter the following text echo off C IR200LO...

Page 56: ...InterRanger IR 200 56 PL 545 ...

Page 57: ... s normal RUN mode where all units enabled are polled and the results displayed in a graphical format on the computer screen The graph will be scaled according to the unit s DISPLAY FORMAT parameter setting The graph may be saved by typing S A comment consisting of up to 28 characters no punctuation may be entered at this time to identify the profile later and this will become the graph s title Th...

Page 58: ...T Trend to view trend graphs from a previous date This mode allows the operator to view the trend graphs of a particular unit for a specified date The trend graphs are referenced by unit number and date The trend graph is automatically stored in memory it does not have to be saved from the RUN mode PROGRAM SETUP S Setup to change operational parameters of this program All program settings are made...

Page 59: ... connected to the network If the time interval is set to 15 seconds for example and only one unit is being polled the computer s display will update every 15 seconds If three IR 200 units are being polled then the computer s display will be updated every 15 seconds and it will take 45 seconds to cycle through all three units Enter the number of seconds between 8 and 120 5 Trend Graph span The tren...

Page 60: ...ompted Type X to return to Program Setup Enter the unit number between 1 and 40 8 Saving changes Saves all settings in this menu that have been changed or verified and returns to the Main Menu QUIT Q Quit to return to DOS Ends the program and returns to DOS ...

Page 61: ...5 LIMITED WARRANTY Milltronics warrants that the SOFTWARE will perform substantially in accordance with the accompanying written materials for a period of one year from the date of receipt Any implied warranties on the SOFTWARE are limited to one 1 year Some states jurisdictions do not allow limitations on duration of an implied warranty so the above limitation may not apply to you 6 CUSTOMER REME...

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