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Nivetec Echo Smart Series Operation & Installation Manual Download Page 28

- Page 19

 -

 

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.

 

  It  is  advisable  to  re-

initialize  a  sensor  that  has  been  out  of  service  or  has  been  operating  while  not 
submerged  in  the  process  water.  Re-initializing  the  sensor  after  a  process  upset  has 
stabilized will quickly return the sensor to normal operation. 

Summary of Contents for 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 2: ......

Page 3: ...zation of Informational Displays 9 4 3 1 Echo Profile Display Figure 4 3 9 4 3 2 Sensor Register Displays Figure 4 4 and 4 5 10 4 3 3 Tank View Display Figure 4 6 11 4 3 4 Historical Trend Display Figure 4 8 12 4 3 5 Modify Settings Display Figure 4 9 12 4 3 6 Advanced Settings Display Figure 4 11 14 4 3 7 Controller Setup Display Figure 4 12 14 4 3 8 Sensor Selection Drop down Window Figure 4 14 ...

Page 4: ...f Individual Units and Networks 33 8 1 1 Stand Alone Instrument Figure 8 1 33 8 1 2 Wired RS 485 Field Network Figure 8 2 34 8 1 3 Wireless Radio Frequency RF Field Network Figure 8 3 35 8 1 4 Integrated Field Networks Figure 8 4 36 8 2 Outputs 36 8 2 1 RS 485 Modbus RTU 37 8 2 2 Analog 4 20 mA Current Loop 37 8 3 Communication Options and Facilities 37 8 3 1 RS 485 Modbus RTU Communication 37 8 3...

Page 5: ...ion Failure Message 49 10 2 5 Wiper Stalled Message 50 10 2 6 Wiper Motor Failure Message 50 10 2 7 4 20 mA Measurement Discrepancy 50 10 2 8 Sensors Not Detected and No Sensors Found Message 50 10 2 9 Troubleshooting Radio Communications 51 10 2 10 Persistent Acquiring Waveform Message on Echo Profile Screen 51 11 System Options 52 11 1 Self Cleaning Wiper Sensor with Turbidity Measurement 52 11 ...

Page 6: ... Page iv 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 7: ...orm other tasks There are no user serviceable parts on the main PCB section of the EchoSmart ESC or ESP Service personnel are trained to work on live circuits and perform safe installations and repairs of products Only properly trained service personnel may perform installation and service procedures Wiring and Electrical Users of this product must be protected from electric shock at all times The...

Page 8: ... both current carrying conductors WARNING CHECK THAT THE POWER SUPPLY IS SUITABLE BEFORE SWITCHING POWER ON Proper Installation and Handling The normal application for the EchoSmart ESC or ESP requires it to be installed at industrial installations including water and wastewater treatment plants While the ESC and ESP enclosures are liquid resistant IP65 they are not designed to be immersed These i...

Page 9: ...on 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: ...nstrument has all the functionality of a complete measurement system The Controller provides power to the sensor and is the user interface for instrument programming and communication with the sensor Customer terminations for digital and analog communications to the customer s data acquisition and control system are provided inside the Controller A large graphical LCD with control keypad provides ...

Page 11: ... to differences in sludge density that typically occur in primary secondary and final clarifiers and gravity thickeners Instruments are also effective in granular media gravity and pressure filters for conditional backwash control Measurements include media level and expansion and above filter turbidity backwash turbidity 2 2 Industrial Wastewater and Raw Water Treatment EchoSmart is effective in ...

Page 12: ...es the sensor provides all signal control enhancement and interpretation and determines the final process measurement The Smart Sensor communicates with an EchoSmart Controller via digital communication The sensor also generates a 4 20 mA proportional current loop signal Customer connections are provided at the Controller If a Smart Sensor is part of a field network connections are made at the Con...

Page 13: ...The LCD Display 4 1 1 Operator Interface Overview Figure 4 1 The display has five informative sections Smart Sensor Name Address The bar at the top of the display shows the name and network address that has been assigned to the sensor This is the sensor that is currently being interrogated Information on this and all other displays relates to this sensor If the Controller is operating a multi sens...

Page 14: ...xt that describes the function of the Soft Key that is located next to that box The text changes when the user selects a different function or navigates to a different instrument parameter 4 1 2 Keypad The Echo Smart Controller has four Soft Keys and four Navigation Keys Soft Keys The function of a Soft Key is described by the Soft Key Prompt located immediately to the left of the key Soft Keys ar...

Page 15: ... ESC circuit board contains four screw terminal connectors as well as additional plug in connectors as shown in Figure 4 2 Use caution in tightening the screw terminals to prevent damage from over tightening Ensure the power cable 10 18 AWG is connected to the power connector properly A breaker should be installed to fully remove power from the unit in the event that repairs to the unit are requir...

Page 16: ... Green 1 8 1 3 Sensor Connections Power Connector 120 240 VAC FOR 24 VDC 4 20 mA Connectors 1 4 Level Turbidity _ _ RS 485 1 3 _ S External USB Future USB Future RS 232 Laptop Cellular Ethernet Future RF Module Connector optional J1 Cell Modem Power J9 J18 J11 Relays J4 J17 LEDs Aux Data RS 232 Data ...

Page 17: ...sor Connector J9 Use Pin 3 and Pin 4 to link the Sensor Communication cable from the Controller to the next Power Supply Unit in a Wired RS 485 Field Network Conductors are ganged with those from the sensor Connection at the associated Power Supply Unit is at the RS 485 Connector J8 RS 485 Connector J7 Use this connector when integrating a Field Network to the customer data acquisition and control...

Page 18: ...er sensor press the Change Sensor soft key select the desired sensor from the dropdown list and press Select Sensor Figure 4 3 Echo Profile Display This display presents the actively updated signal waveform generated by the sensor and used to determine the Level or Range measurement The horizontal x axis is a distance axis based on the span between the sensor lower left side of the screen and the ...

Page 19: ...perating 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 Figure 4 5 Multiple Sensor Field Network Display These displays are not available when only one sensor is in use ...

Page 20: ...al 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 Figure 4 6 Tank View Display The Tank View Display is enabled at the Modify Settings Display Optional diagrams are available to correspond with the specific application Figure 4 7 Figure 4 7 Tank Options ...

Page 21: ...ed measurements for the selected sensor The user may choose to view from one to seven days of data Figure 4 8 Historical Trend Display The Historical Trend Display is enabled at the Modify Settings Display 4 3 5 Modify Settings Display Figure 4 9 This display is used to enter the primary parameter settings for each sensor and to enable the Historical Trend Display and the Tank View Display A Displ...

Page 22: ...ssing 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 The Soft Keys assist with other functions as indicated by the Soft Key Prompts ...

Page 23: ...irectly connected to the Controller and are part of a Field Network of sensors This option is used to initialize a new instrument and to add or remove sensors from an existing network Manually Set Database Figure 4 13 allows the user to specify sensor addresses and establishes the order in which the addresses will appear in the Sensor Register Display Manually setting the database causes the Contr...

Page 24: ... Page 15 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 25: ... Sensor technology and are often implemented with multiple sensors operating in union with one Controller To establish communication each Smart Sensor must be assigned a unique address during initialization see also Section 4 4 2 This address is held in the memory of both the Controller and the Smart Sensor s IMPORTANT All Smart Sensors are shipped from the factory with the pre assigned address of...

Page 26: ... 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 Figure 4 16 Initial Sensor Setup Follow the Soft Key Prompts and use the Navigation Keys to enter the Sensor Name and Sensor Address It is imperative that the Sensor Address ...

Page 27: ...sensor The Power Next Sensor Screen Figure 4 17 will appear Apply power to the EchoSmart Power Supply Unit connected to the next sensor and repeat the steps above After all sensors have been initialized Press the Soft Key next to the Network Setup Complete prompt Figure 4 17 Figure 4 17 Power Next Sensor All EchoSmart Sensors are now operational See also Section 13 2 in the Quick Start Guide of th...

Page 28: ... are not lost as a result of power interruption Automatic Initialization establishes operating gain signal amplification and determines current measurement values and signal outputs It is advisable to re initialize a sensor that has been out of service or has been operating while not submerged in the process water Re initializing the sensor after a process upset has stabilized will quickly return ...

Page 29: ...the ESP with other devices Ex ESC other ESPs SCADA Systems etc see Section 8 for sample connection diagrams 5 1 1 Power Requirements 100 to 240 VAC 50 60 Hz 1 A Supply cable 10 18 AWG 40 to 140 F Power 20 W fused 0 250A 250V 5x20mm T lag UL approved 4 20 mA Current Loop 15 24 VDC provided by the ESP Optional 24 VDC 18 36 VDC Input Caution must be taken to supply main power in the form for which th...

Page 30: ...e Brown Yellow Blue Orange Green 1 8 1 3 Power Connector 120 240 VAC IF 24 VDC Sensor Connections 4 20 mA Connectors 1 4 Level Turbidity _ _ RS 485 1 3 _ S RS 232 Laptop Cellular RF Module Connector optional J2 J8 J6 Cell Modem Power J4 J1 J7 J3 Status RS 485 RS 232 LEDs ...

Page 31: ...3 Neutral 3 Turbidity 3 Sensor Comm 3 Ground 4 Turbidity 4 Sensor Comm FOR 24 VDC J2 5 4 20mA Level 1 6 4 20mA Level 2 7 4 20mA Turbidity 3 8 4 20mA Turbidity Notes RS 485 Connector J8 Attach the Network Communication cable from the Controller or Power Supply Unit in a Wired RS 485 Field Network to this connector Connection at the Controller is made at Pin 3 and Pin 4 of the Sensor Connector J9 4 ...

Page 32: ...ipe or conduit to minimize excessive side to side sway or other avoidable movement If a surface skimmer is present install using a sensor mounting fixture that rotates the sensor out of the path of the skimmer EDI Transducer Multi flex Assembly Part No 9300 13 13 Orient the sensor such that the path of the transmit pulse is at 90 with respect to the surface of the sludge blanket or other material ...

Page 33: ... Page 24 Figure 6 1 EchoSmart Sensor Mounting Arrangements ...

Page 34: ...cs of the material that is it measuring Relatively dense well settled suspended solids form a well defined interface and are effective in reflecting signal to the sensor Light density material 0 5 solids that is not well settled does not form a well defined interface and is less effective in reflecting signal to the sensor If possible locate the sensor in an area that minimizes exposure to these c...

Page 35: ... Page 26 6 2 5 Typical Circular Clarifier Installation Figure 6 2 Figure 6 2 Typical 1 3 2 3 Location in Circular Clarifier ...

Page 36: ...r recommendations and cannot be used if the skimmer sweep rises more than six inches above the operating water line in the application or in cases where multiple structural members or supports prevent sensors from returning to the water without striking one of these objects Special mounting arrangements and assemblies are available for virtually all applications with surface skimmers Contact Entec...

Page 37: ... Page 28 Figure 6 4 Controller Installation Drawing ...

Page 38: ... Page 29 Figure 6 5 EchoSmart Power Supply Unit Installation Drawing ...

Page 39: ...epth and Zero Adjust parameters See also Sections 9 1 2 and 9 1 3 orient the instrument to the dimensions of the tank and assure that the echo waveform corresponds with tank dimensions at the location of the sensor Figure 7 1 Tank Configuration 7 2 Waveform Analysis Figure 7 2 The EchoSmart Sensor produces a signal waveform that is used to produce LEVEL and RANGE measurements The waveform is avail...

Page 40: ...Candidate 7 3 Tracking Tracking is the term EchoSmart uses to specify the process of producing the primary measurement and following tracking its progress over time The Track is the position of the Current Measurement on the Waveform graphic and is identified by a downward pointing arrow at the top of the screen 7 3 1 Gate EchoSmart employs enhanced algorithms that operate to stabilize measurement...

Page 41: ...at a signal meeting tracking criteria is located outside the Gate to the left The measurement will only be affected by this signal if it persists for repeated updates The Double Exclamation Mark indicates that the current signal is insufficient for tracking purposes The Current Measurement will be held until sufficient signal returns An Echo Loss message will accompany the output measurement on th...

Page 42: ...dditionally refers to information exchange and control functions between EchoSmart devices as well as communication and output signals that are connected to the customer data and control systems See Section 1 2 8 1 Configuration of Individual Units and Networks Multiple configurations are possible for the EchoSmart equipment 8 1 1 Stand Alone Instrument Figure 8 1 A stand alone instrument consists...

Page 43: ...ld be used between each ESP and to the ESC Connections for the RS 485 communication line are made at the 3 pin terminal strip J8 on each ESP and at the 8 pin sensor connector J9 on the ESC as shown in Figure 8 2 below Figure 8 2 Single Wired Field Network ESC ESP A 120 resistor needs to be inserted between the and terminals of the last power supply in the series ESC Echo Smart Controller ESP Echo ...

Page 44: ... an RF Module No user programming or other integration is required Figure 8 3 illustrates a single wireless RF Field Network configuration Multiple RF Field Networks may be integrated to a SCADA system by connecting Controllers as shown in the Customer Integration section of Figure 8 4 Figure 8 3 Single RF Field Network ESC The ESC can be used as a remote operator interface to network field sensor...

Page 45: ...quired IMPORTANT The two wire cable to the control system should not be connected to the ESC until all sensors are installed and communicating with the local ESC Figure 8 4 Integrated Wired Field Network 8 2 Outputs Current measurements from each sensor can be accessed through a Modbus RTU command request or an analog 4 20 mA current loop in addition to the measurement displayed on the installed E...

Page 46: ... supplying power to the sensor One current loop is assigned to the Level or Range measurement and the other to either the turbidity measurement when applicable or the secondary interface The sensor s 4 mA Set Point and 20 mA Set Point see Section 9 2 14 and 9 2 15 should be scaled to represent the installation environment with consistent scaling at the control device Set Points for the primary Lev...

Page 47: ...mart 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 Cellular connectivity is included with the service and is limited to areas where cell service is available See Figure 8 5 below for instructions on how to properly install and remove the modem from an ESC ...

Page 48: ...Installation and Removal of Modem Do NOT disconnect cables at the modem Connect Disconnect four screws to install remove modem Red wire on LEFT at J18 Connect Disconnect modem cables here Modem backplate do NOT detach from modem ...

Page 49: ...re reliable measurements 9 1 1 Units ft The Units parameter establishes the desired engineering units that the instrument will use for all calculations and displayed values Options for Units are Feet ft Inches in Meters m and Centimeters cm 9 1 2 Tank Depth 10 0 Tank Depth is the distance from the top of the tank Typically the surface of the water to the bottom of the tank at the location of the s...

Page 50: ...e modified manually With Auto Gain OFF this parameter establishes the constant level of signal amplification at which the instrument will operate The range for Current Gain is 0 to 100 9 1 7 AG Set Point Auto Gain Set Point 10 The AG Set Point determines the relative signal strength that the Auto Gain routine will seek Increase this parameter to cause Auto Gain to seek a generally higher level of ...

Page 51: ...ing or disturbed material and prevents sudden changes in the measurement resulting from the action of rakes and skimmers The range for Dampening is 5 to 255 9 1 11 Settling Zone ON When Settling Zone is ON the instrument ignores signal originating to the left of LG Min This enables the sensor to disregard suspended solids air gas bubbles and similar sources of disturbance in the supernatant The op...

Page 52: ... Timing 240 Wiper Timing establishes the time minutes between wiper cycles The sensor wiper will also operate automatically on detection of signal loss regardless of the selected Wiper Timing setting This reduces the need to establish a short wiper timing sequence and prolongs the life of the wiper mechanism The range for Wiper Timing is 0 OFF to 240 minutes 9 2 4 Gain Band 20 Gain Band establishe...

Page 53: ...e for Wall Zone is 0 0 to 32 0 9 2 9 Wall Zone AG 40 This parameter limits gain amplification when the primary signal is a reflection from the tank bottom Since the desire is to track blankets it prevents over amplification of the signal in applications with light density material or when the tank bottom is the only signal present tank has no suspended solids blanket or settled solids The range fo...

Page 54: ...e instrument measurement value at which the user expects the sensor to output a current of 20mA Establish the same Set Point value in the control device that the instrument is connected to The range for 20mA Set Point is 0 to Tank Depth 9 2 16 Echo Loss OFF Echo Loss provides an alarm function through the 4 20mA current loop signal when this Echo Loss setting is set to ON The selected Echo Loss Ac...

Page 55: ... Page 46 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 56: ...o remove air gas bubbles and light suspended solids that may collect on the face of the sensor and degrade signal quality Supplemental manual cleaning may be required in processes in which suspended solids attach aggressively to the face of the sensor Wiper blade and motor life will vary with process conditions and the user established frequency of operation Wiper Timing parameter Section 9 2 3 It...

Page 57: ...isinfection use 8 oz of regular bleach sodium hypochlorite 8 25 solution to one gallon of water Before returning the sensor for service operate the wiper system to observe that it rotates in the expected manner and that the wiper blade is secure In normal operation the wiper blade with make 1 3 rotations when power is supplied or when the wiper timing setting is changed 10 1 2 Other Routine Mainte...

Page 58: ...e the result of incorrect operating parameters installed in the sensor Corrective action includes a physical inspection of the sensor s and process to determine whether any of the above referenced conditions exist If a Wiper Sensor is in use confirm that the wiper arm is in place and that the wiper turns when 1 power is cycled 2 the sensor Reboot command is called or 3 the Wiper Timing setting is ...

Page 59: ... loop and confirm that no other electronic devices or electrical elements intervene on the current loop Check that appropriate signal cable is in use EchoSmart allows the user to span the 4 20 mA signal with reference to Level depth of sludge or Range distance from water surface to top of sludge Confirm that the correct parameter has been entered The maximum span is 0 0 to Tank Depth The 4mA Set P...

Page 60: ...each transmitted message If the Status LED is flashing cycle power on the ESP If the Status LED is on solid and the RS 485 LED is not flashing verify that the radio is seated properly and cycle power to determine if communication can be re established 10 2 10 Persistent Acquiring Waveform Message on Echo Profile Screen If an acquiring waveform message appears for an extended period of time on the ...

Page 61: ...ents are provided by a 90º scattered light turbidity meter located in the combined sensor housing Sensors are factory calibrated from 0 50 NTU Power to the sensor is provided by an EchoSmart Controller or Power Supply Unit to which it is connected The measurement indication is displayed on the Controller Output signals include a 4 20mA proportional signal and RS 485 Modbus RTU digital 11 1 3 Senso...

Page 62: ... Units can be achieved with integrated wireless radio modules to eliminate the need for cabling and conduit between units 11 2 1 General Overview The radios use a proprietary message structure for communication between units and utilize mesh networking capabilities to achieve redundancy and reliability 11 2 2 Internal Configuration In this configuration the radio module is mounted inside the Contr...

Page 63: ...adio s 4 pin terminal strip J2 and the 8 pin terminal strip on the associated Controller J9 or Power Supply J4 The cable should link red to red terminal locations black to black white to white and brown to brown see Figure 11 2 This configuration is ideal when Controllers or other units are placed in buildings or other locations that may create less than ideal paths for radio transmissions The rad...

Page 64: ...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 See Figure 11 3 ESC Echo Smart Controller ESP Echo Smart Power Supply 1 8 Sensor Connections J9 J4 Radio Connector J2 3 2 4 White Black Red 4 1 Brown ESC or ESP ...

Page 65: ...can be assigned to one sensor 11 3 2 Operation Figure 11 4 Relay controls are accessed by pressing the Set Up Relays soft key from the Controller Setup Display Figure 4 12 The relay Status must be set to ON in order for the relays to operate The sensor associated with each relay is listed below the Status setting Each relay is capable of monitoring the sludge level or the turbidity value when inst...

Page 66: ...ections for Relays Figure 11 5 and Table 11 1 This section pertains to the physical layout and terminal connections for the relays Figure 11 5 Connections for Relay Board NC C NO Relay Connections J1 NC C NO NC C NO NC C NO Relay 1 Relay 2 Relay 3 Relay 4 1 12 ...

Page 67: ...ly 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 Analytical Technology Inc makes no other warranty expressed ...

Page 68: ...g Controller Setup to avoid communication errors 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 most importantly the Tank Depth Zero Adjust and 4 20mA Set Point...

Page 69: ...egarding an RS 485 connection 13 2 Configuring a Sensor Network Follow these instructions when an EchoSmart Controller will communicate with more than one sensor in a Network arrangement 1 Ensure all sensor connections are correct and that power is properly applied to the EchoSmart Controller If a sensor is not directly connected to the Controller additionally power the first EchoSmart Power Suppl...

Page 70: ... See Section 7 1 for help in determining correct values for Tank Depth and Zero Adjust Press Sensor Setup Complete 4 When a screen appears with instructions to Power Next New Sensor for Setup apply power to the next sensor that needs to be configured 5 Repeat steps 3 and 4 for all sensors in the network ensuring that each sensor has a unique Sensor Address Once all have been setup press Network Se...

Page 71: ...r is not automatically found once powered during the network setup process or needs to be added later go to Modify Settings Advanced Settings Controller Setup highlight the Auto Detect Sensors option and press Auto Detect Sensors 9 If an external RS 485 polling device is to be used it can now be connected See Section 8 2 1 for recommendations and information regarding an RS 485 connection ...

Page 72: ...t Point 0 0 This locates the zero Level at the bottom of the expandable media See Figure 13 1 20mA Set Point Tank Depth SM DM Figure 13 1 Additional notes The initial measurement and 4 20 mA output should equal the depth of the expandable media DM If the output does not match the known media depth check the SM measurement and adjust the Tank Depth value accordingly Depth of Media is NOT a directly...

Page 73: ... Page 64 Figure 13 1 Installation Recommendations and Field Measurement for Filter Applications ...

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