GaugerGSM - Ultrasonic Level Sensor - Manual

User Manual of GaugerGSM and Gauger485 You Can Measure the Solid Benefits… ______________________________________________________________________________ GaugerGSM/485 – User Manual page 2 of 92 May 2013 Rev 4.1 Notices and safety guidelines This manual is delivered subject to the following conditions and restrictions: ? The manual contains proprietary information belonging to Solid Applied Technologies Ltd. The information is published solely for the purpose of assisting authorized users of GaugerGSM/485. ? Some features of GaugerGSM/485 are firmware dependent. These features are described in this user manual but will not apply to all GaugerGSM/485 versions. ? Some features of GaugerGSM are not applicable to Gauger485 and vice-verse. The user should verify whether any specific feature is applicable to his/her model. ? Some features of GaugerGSM/485 are hardware dependent. These features are described in this user manual but will not apply to all GaugerGSM/485 versions. ? No part of this manual may be used for any other purpose, or disclosed to any person or firm, or reproduced by any means, without the prior written permission of Solid Applied Technologies Ltd. ? The text and graphics in this manual are for the purpose of illustration and reference only. ? Information included in this manual is subject to change without notice. Information in the manual may contain inaccuracies. Specifications are based on laboratory test results which are performed under tightly controlled environment. Field performance may vary from laboratory test results. We always welcome suggestions and recommendations from the users of our manuals. ? All company names, brand products and service names that may appear in this manual are trademarks or registered trademarks of their respective holders. ? Solid Applied Technologies shall not be liable for loss or damage caused by the use of this manual or of products described in the manual. Solid Applied Technologies sole warranty is that products sold by the company shall be free of defects in material and in workmanship for a period of 12 months. ? GaugerGSM/485 must be installed, connected and operated in accordance with the instructions of this manual and with the GaugerGSM/485 certifications. Specific local regulations may also apply. ? Installation and use of GaugerGSM/485 models that are rated for use in explosive atmosphere must closely follow the instructions detailed in the proper section for this model type. ? Do not open or disassemble GaugerGSM/485 except as required for electrical connections. ? Any type of modifications and repairs are permissible only upon the manufacturer or re-seller written approval and by pre-qualified personal. Never reuse defective parts. Date Revision Software version Part number May 2013 4.1 GaugerGSM/485 V 2.7 GaugerGSM/485 ______________________________________________________________________________ GaugerGSM/485 – User Manual page 3 of 92 May 2013 Rev 4.1 Table of Contents NOTICES AND SAFETY GUIDELINES......................................................................................................................... 2 TABLE OF CONTENTS .............................................................................................................................................. 3 LIST OF FIGURES ..................................................................................................................................................... 7 I. INTRODUCTION .................................................................................................................................................. 8 I.1. DESCRIPTION ........................................................................................................................................................... 8 I.2. GAUGERGSM/485 PARTS ......................................................................................................................................... 9 I.3. DIMENSIONS ......................................................................................................................................................... 10 I.4. SPECIFICATIONS ...................................................................................................................................................... 11 I.5 HOW TO USE THIS USER MANUAL ................................................................................................................................ 14 I.5.1 Looking for specific tasks… .......................................................................................................................... 14 I.5.2 Proposed study guide .................................................................................................................................. 14 II. PHYSICAL AND ELECTRICAL INSTALLATION GUIDELINES ................................................................................... 15 II.1. GEOMETRICAL CONSIDERATIONS ............................................................................................................................... 15 II.2. TANK FITTING ....................................................................................................................................................... 16 II.3. DEAD ZONE .......................................................................................................................................................... 17 II.4. EXTENSION PIPE .................................................................................................................................................... 17 II.5. TEMPERATURE CONSIDERATIONS AND TEMPERATURE SENSORS - GAUGERGSM ................................................................. 19 II.6. ELECTRICAL CONNECTIONS ....................................................................................................................................... 20 II.7. BATTERY OPERATION AND PTS ................................................................................................................................. 21 II.8. SIM CARD FOR GAUGERGSM .................................................................................................................................. 22 II.9. SPECIAL INSTRUCTION FOR EX-RATED MODELS ............................................................................................................ 23 II.9.1 EX rating and general conditions for use ................................................................................................... 23 II.9.2 EX wiring restrictions.................................................................................................................................. 24 II.9.3 EX electrical powering schemes ................................................................................................................. 25 II.9.4 Special instructions for the use of an EX-rated PTS and battery pack ........................................................ 27 II.9.5 Repair and maintenance for EX-rated Gauger, PTS and battery pack ....................................................... 28 II.10. TEST MODE DURING INSTALLATION ......................................................................................................................... 28 II.11. MUST BE PAMPHLET .......................................................................................................................................... 29 III. KEYPAD AND DISPLAY ..................................................................................................................................... 30 III.1. KEYPAD .............................................................................................................................................................. 30 III.1.1 Navigation keys ......................................................................................................................................... 30 III.1.2 Execution keys ........................................................................................................................................... 30 III.2. NAVIGATION THROUGH MENUS ............................................................................................................................... 31 III.2.1 Sub-Menu style.......................................................................................................................................... 31 III.2.2 Numeric menu style .................................................................................................................................. 31 III.3. MEASUREMENT SCREEN ......................................................................................................................................... 32 III.3.1 Status reports ............................................................................................................................................ 32 III.3.2 Contrast ..................................................................................................................................................... 33 III.3.3 Main menu / setup .................................................................................................................................... 33 ______________________________________________________________________________ GaugerGSM/485 – User Manual page 4 of 92 May 2013 Rev 4.1 III.3.4 Temperature readings ............................................................................................................................... 33 III.3.5 Ultrasonic echo conditions ........................................................................................................................ 33 III.3.6 Product identification details .................................................................................................................... 33 IV. CONFIGURATION WITH THE KEYPAD AND DISPLAY ........................................................................................ 34 IV.1. MENU AND SUB-MENU ORGANIZATION .................................................................................................................... 34 IV.2. QUICK SETUP ...................................................................................................................................................... 35 IV.3. ADVANCED SETTINGS ............................................................................................................................................ 35 V. CONFIGURATION WITH A PC OR OVER-THE-AIR .............................................................................................. 37 V.1. INTRODUCTION ..................................................................................................................................................... 37 V.2. PREPARING A CONFIGURATION TEXT FILE .................................................................................................................... 37 V.2.1 Sample files ................................................................................................................................................ 37 V.2.2 Configuration text file - summary notes .................................................................................................... 39 V.3. DOWNLOAD OPERATION ......................................................................................................................................... 39 V.3.1 Procedure ................................................................................................................................................... 39 V.3.2 Launching and setting up HyperTerminal .................................................................................................. 40 V.3.3 Downloading a configuration file .............................................................................................................. 42 V.4. RESPONSES FROM GAUGERGSM/485 ...................................................................................................................... 43 V.4.1 Good response ........................................................................................................................................... 43 V.4.2 Erroneous responses .................................................................................................................................. 43 V.4.3 Communication Errors ............................................................................................................................... 45 V.5. LIST OF COMMANDS FOR CONFIGURATION FROM A PC.................................................................................................. 46 V.5.1 Conventions ............................................................................................................................................... 46 V.5.2 Command list ............................................................................................................................................. 48 V.6 SOME USEFUL EXAMPLES ......................................................................................................................................... 54 V.6.1 Basic setup ................................................................................................................................................. 54 V.6.2 Advanced setup.......................................................................................................................................... 54 V.6.3 GPRS setup example .................................................................................................................................. 55 V.6.4 OCF – Flow Mapping Table example (American Units) .............................................................................. 55 V.7 CONFIGURATION OVER-THE-AIR (OTA) BY SMS ......................................................................................................... 56 V.8 CONFIGURATION OVER RS485 ................................................................................................................................. 57 VI. FIRMWARE UPGRADE TOOL ........................................................................................................................... 58 VI.1. INTRODUCTION .................................................................................................................................................... 58 VI.2. YOU WILL NEED .................................................................................................................................................... 58 VI.3. INSTALLATION OF FIRMWARE UPGRADE TOOL AND USB DRIVER ................................................................................... 58 VI.4. UPGRADE PROCEDURE ........................................................................................................................................... 58 VI.5. TROUBLESHOOTING THE FIRMWARE UPGRADE PROCESS ............................................................................................... 60 VII. SERIAL DATA MONITORING ........................................................................................................................... 61 VII.1. INTRODUCTION ................................................................................................................................................... 61 VII.2. INSTALLATION AND OPERATION .............................................................................................................................. 61 VII.3. RECORD FORMAT ................................................................................................................................................ 62 VIII. USB DRIVER INSTALLATION ON A PC ............................................................................................................ 63 IX. REFERENCE GUIDE .......................................................................................................................................... 66 ______________________________________________________________________________ GaugerGSM/485 – User Manual page 5 of 92 May 2013 Rev 4.1 APPLICATION DIMENSIONS AND CONSTRAINTS .................................................................................................................... 66 (a) Basic dimensions ............................................................................................................................................ 66 (b) Distance to empty level ................................................................................................................................. 67 (c) Distance to full level ....................................................................................................................................... 67 (d) Far blocking distance ..................................................................................................................................... 67 (e) Near blocking distance................................................................................................................................... 68 APPLICATION TYPE ........................................................................................................................................................ 68 CELLULAR COMMUNICATION (GAUGERGSM) .................................................................................................................... 68 CONTACT ALERT (GAUGERGSM) .................................................................................................................................... 68 DEFAULT VALUES .......................................................................................................................................................... 69 DESTINATION PHONE NUMBER (GAUGERGSM) ................................................................................................................. 70 DISTANCE UNITS AND VALUE TO DISPLAY ........................................................................................................................... 70 EQUIPMENT STATUS REPORT ........................................................................................................................................... 71 FALSE ECHO SCAN BY KEYPAD ......................................................................................................................................... 71 FALSE ECHO SCAN BY PC ................................................................................................................................................ 72 FILLING RATE ............................................................................................................................................................... 72 FULL AND EMPTY ALERTS ................................................................................................................................................ 72 GAS VELOCITY COEFFICIENT ........................................................................................................................................... 72 GAUGERBUS .............................................................................................................................................................. 73 GPRS ARCHITECTURE (GAUGERGSM) ............................................................................................................................. 73 GPRS MESSAGE FORMAT (GAUGERGSM) ........................................................................................................................ 74 GSM DISPLAY STATUS REPORTS (GAUGERGSM) ................................................................................................................ 75 GSM REPORTING INTERVAL (GAUGERGSM) ..................................................................................................................... 77 HART COMMUNICATIONS – APPLICABLE TO GAUGER420 ONLY WITH HART OPTION ............................................................. 77 INTERDEPENDENCIES ..................................................................................................................................................... 78 MAPPING TABLE .......................................................................................................................................................... 78 OPEN CHANNEL FLOW (OPTIONAL FEATURE) ..................................................................................................................... 79 PTS CONFIGURATION FOR BATTERY OPERATION .................................................................................................................. 80 REFILL ALERTS .............................................................................................................................................................. 82 RELAY TRUTH TABLE ..................................................................................................................................................... 82 RESET AND OPERATING HOURS ........................................................................................................................................ 83 SMS FORMAT (GAUGERGSM) ....................................................................................................................................... 83 TEMPERATURE COEFFICIENT OF EXPANSION ...................................................................................................................... 83 TEMPERATURE SENSORS, UNITS AND TEMPERATURE DISPLAY ................................................................................................. 83 TEST MODE DURING INSTALLATION .................................................................................................................................. 84 THEFT ALERTS .............................................................................................................................................................. 84 TRIGGER ALERTS ........................................................................................................................................................... 85 VOLUME MEASUREMENT ............................................................................................................................................... 86 (a) General .......................................................................................................................................................... 86 (b) Box shaped .................................................................................................................................................... 86 (c) Cylindrical tanks ............................................................................................................................................. 86 4-20 COMMUNICATIONS – APPLICABLE TO GAUGER420 ONLY ........................................................................................... 87 (a) 4-20 Setup ...................................................................................................................................................... 87 (b) 4-20 Performance .......................................................................................................................................... 88 (c) 4-20 constraints ............................................................................................................................................. 88 (d) 4-20 default settings ...................................................................................................................................... 89 ______________________________________________________________________________ GaugerGSM/485 – User Manual page 6 of 92 May 2013 Rev 4.1 X. TROUBLESHOOTING ......................................................................................................................................... 91 ______________________________________________________________________________ GaugerGSM/485 – User Manual page 7 of 92 May 2013 Rev 4.1 List of Figures Figure 1 – GaugerGSM/485 parts ................................................................................................................. 9 Figure 2 – GaugerGSM/485 dimensions (75 KHz version) .......................................................................... 10 Figure 3 – Minimum horizontal gap ............................................................................................................ 15 Figure 4 - Silo (left) and liquid (right) examples .......................................................................................... 16 Figure 5 - Threaded flange (left) Thread-free flange (right) ....................................................................... 17 Figure 6 – Possible extension pipe settings ................................................................................................ 18 Figure 7 – Possible extension pipe fittings – 75 KHz example .................................................................... 19 Figure 8 - Electrical ports ............................................................................................................................ 20 Figure 9 - Programmable Timer Switch Connections ................................................................................. 22 Figure 10 - SIM Card .................................................................................................................................... 23 Figure 11 - Electrical feeding scheme within hazardous zone (battery pack) ............................................ 25 Figure 12 - Electrical feeding scheme when crossing zones (battery pack) ............................................... 25 Figure 13 - Electrical feeding scheme for external power supply ............................................................... 27 Figure 14 - Navigation keys ......................................................................................................................... 30 Figure 15 - Execution keys .......................................................................................................................... 30 Figure 16 - Sub menu screens ..................................................................................................................... 31 Figure 17 - Numeric menu .......................................................................................................................... 31 Figure 18 - Measurement screen ................................................................................................................ 32 Figure 19 - Temperature readings .............................................................................................................. 33 Figure 20 - Menu and submenu organization ............................................................................................. 34 Figure 21 - Application dimensions for sensor 75KHz ................................................................................ 66 Figure 22 - GPRS communication architecture ........................................................................................... 73 Figure 23 - OCF weir example ..................................................................................................................... 79 Figure 24 - Low power predefined levels .................................................................................................... 81 Figure 25 - Temperature readings .............................................................................................................. 84 Figure 26 - Trigger definition in percentage ............................................................................................... 85 Figure 27 - Box shaped tank ........................................................................................................................ 86 Figure 28 - Cylindrical horizontal tank ........................................................................................................ 87 Figure 29 - Cylindrical vertical tank ............................................................................................................. 87 Figure 30 - Default 4-20 values for Level .................................................................................................... 89 Figure 31 - Default 4-20 values for Volume ................................................................................................ 89 Figure 32 - Default 4-20 values for Distance ............................................................................................... 90 ______________________________________________________________________________ GaugerGSM/485 – User Manual page 8 of 92 May 2013 Rev 4.1 I. Introduction I.1. Description GaugerGSM/485 is a mono-block ultrasonic level meter with integrated GSM cellular modem (GaugerGSM only) and USB interface. Optional items include display, external temperature sensor, dry contact input and relay. GaugerGSM/485 measures distance. Targets may be liquid or solids. Measurement is continuous and does not require contact with the target. The system can accurately measure steady or agitated target surfaces. The system can also rapidly track filling and emptying of vessels. GaugerGSM/485 (75 KHz) measures distance to liquid targets up to 8 meters and GaugerGSM/485 (50 KHz) up to 9.5 meters. In addition to distance, GaugerGSM/485 also measures temperature of the environment. GaugerGSM/485 makes use of the measured distance to calculate additional variables of importance. These variables include target level, volume and OCF (model dependent). GaugerGSM/485 operates at an ultrasonic frequency of 75KHZ or 50 KHz and is robust in noisy conditions. The sensor is made of PVDF – providing good chemical resistance to corrosive targets. GaugerGSM/485 is fed from 8-33VDC power. The system may be fed by an external battery pack. A low power mode is available for using batteries and requires the use of a Programmable Timer Switch (PTS). GaugerGSM/485 is equipped with a large graphic display and keypad allowing a simple wizard-driven setup of the system. The keypad and display allow configuration of many GaugerGSM/485 configuration parameters. Complete setup of all GaugerGSM/485 parameters can be executed using a USB equipped PC or laptop. This method of configuration supports rapid cloning of many GaugerGSM/485 systems. GaugerGSM transmits measurement information to a predefined destination – whether cellular phone or cellular PC modem. The information is transmitted via SMS or GPRS. Reporting interval is user-programmable. The system also identifies and transmits an alert in boundary events such as full and empty situations. The system can be programmed to identify and alert for rapid changes of level indicating theft and refuel quantities. The system can also transmit On/Off contact state information. Gauger485 sends the measured data over RS485 wires or over a USB interface (to a PC). The protocol is character-based. This user manual is intended for operators of GaugerGSM/485. The manual covers system description, installation, operation and troubleshooting of GaugerGSM/485. ______________________________________________________________________________ GaugerGSM/485 – User Manual page 9 of 92 May 2013 Rev 4.1 I.2. GaugerGSM/485 parts Figure 1 – GaugerGSM/485 parts ______________________________________________________________________________ GaugerGSM/485 – User Manual page 10 of 92 May 2013 Rev 4.1 I.3. Dimensions All figures in mm. Figure 2 – GaugerGSM/485 dimensions (75 KHz version) ______________________________________________________________________________ GaugerGSM/485 – User Manual page 11 of 92 May 2013 Rev 4.1 I.4. Specifications Measuring range (75 KHz version) Maximum range for liquids - 8 meter / 26’ Maximum range for Solids - 5 meter / 16’ Approximate, depending on type of solid Minimum range (dead zone) - 15 cm / 6” Measuring range (50 KHz version) Maximum range for liquids - 9.5 meter / 30’ Maximum range for Solids - 6 meter / 19’ Approximate, depending on type of solid Minimum range (dead zone) - 35 cm / 14” Accuracy – precision – resolution –tracking (75 KHz version) Display Accuracy 15cm, D1 , D2, D3,…,Vin, RSSI, 99” ______________________________________________________________________________ GaugerGSM/485 – User Manual page 75 of 92 May 2013 Rev 4.1 Where: Field Description Format Units N Friendly name <30 characters D Measured distance xx.xxx Meter or feet L Measured Level xx.xxx Meter or feet D1 if S1 = 5 Refill start xx.xxx or xxxxxx.x Distance or Volume D1 if S1 = 6 Refill quantity xx.xxx or xxxxxx.x Distance or Volume V Measured Volume xxxxxx.x Liters or Gallons T1 Internal temperature xx.x Celsius or Fahrenheit T2 External temperature xx.x Celsius or Fahrenheit Vin Voltage In (*) xx.x Volt RSSI Cellular signal strength (*) xx From 2-Low to 32-High S1 Equipment status(**) xx Digits LAT Geodesic Latitude xxxx.xxxxxx Deg*100+minutes N/S Latitude North or South LON Geodesic Longitude xxxx.xxxxxx Deg*100+minutes E/W Longitude East or West TI Time interval for logger xxx Minutes Average temperature(***) xx.x Celsius or Fahrenheit Dx Distance during wakeup x xx.xxx Meter or feet (*) Optional – depends on firmware version and settings (**)See the section Equipment status report for S1 options (***) Average over all wakeups GSM display status reports (GaugerGSM) The following status reports may be displayed on the display: Error indications Proper operation GSM REGISTRATION FAIL GSM NOT ACTIVE (temporary) GSM MODEM NOT READY GSM INITIALIZING GSM TRANSMISSION FAIL GSM REGISTRATION SENT GSM SIM FAIL GSM PERIODIC ACTIVE (*) GSM NOT ACTIVE (fixed) GSM DESTINATION ASSIGNED GSM SMS SENT GSM EVENTS ONLY GSM_MSG_LOGGED # ______________________________________________________________________________ GaugerGSM/485 – User Manual page 76 of 92 May 2013 Rev 4.1 In addition, when GPRS is active, the following messages may be displayed: Error indications Proper operation UNKNOWN GPRS INITIALIZING OPERATION FAILED GPRS MSG SENDING OPERATION TEMPORARILY NOT ALLOWED GPRS PERIODIC ACTIVE (*) OPERATION NOT ALLOWED GPRS RESTARTING NETWORK IS DOWN GSM_MSG_LOGGED # (*) GSM/GPRS PERIODIC ACTIVE may also appear if GaugerGSM cannot transmit a message after one minute of repeated trials. For SMS messages, the following sequence of status reports is as follows: When GaugerGSM is turned ON, it first searches for a proper level target. Once found, GaugerGSM begins to seek for a GSM network. A status report GSM INITIALIZING will be displayed at this time. The search for GSM network may take between 10 seconds and up to a minute. If GaugerGSM fails to locate a GSM network, one of the error indications will be displayed. When such an error is displayed, verify by using a cell-phone that the area is indeed covered by a GSM network and that the SIM card you inserted into GaugerGSM is good. Let GaugerGSM do some retries for 30 seconds and then turn GaugerGSM OFF and then ON again to try again. If GaugerGSM successfully locates a GSM network, the status report GSM PERIODIC ACTIVE will be displayed. When an SMS is transmitted, a sequence of status reports will be displayed: GSM DESTINATION ASSIGNED, GSM SMS SENT and GSM PERIODIC ACTIVE. GSM PERIODIC ACTIVE may also appear if GaugerGSM fails to send a message after repeated trials for over one minute. GSM EVENTS ONLY report is displayed if the user disabled periodic SMS reports. Disabling the periodic SMS report is performed by entering 0 (zero) at the report interval, either manually or by using the PC configuration command SMST. For GPRS messages, the following sequence of status reports is as follows: When GaugerGSM is first turned on, a “GPRS INITIALIZING” report is displayed. If no GSM network is available or if the network is available but GPRS services are not supported, one of the error messages will be displayed. If the GPRS service is available, the report: “GPRS PERIODIC ACTIVE” will be displayed. GPRS PERIODIC ACTIVE may also appear if GaugerGSM does not succeed in sending messages for repeated trials lasting more than a minute. When a GPRS message is transmitted, the status report “GPRS MSG SENDING” is displayed. If the message transmission fails, one of the error messages will be displayed. GSM/GPRS MESSAGE LOGGED # is presented when GaugerGSM operates in log mode and # presents the index number of the logged message. ______________________________________________________________________________ GaugerGSM/485 – User Manual page 77 of 92 May 2013 Rev 4.1 GSM reporting interval (GaugerGSM) You can determine the periodic reporting interval using one of the configuration methods. The interval is defined in seconds. For example, for an SMS report once every hour, modify the interval to 3600. Report interval lower than 180 seconds are not accepted and will revert to 180 seconds. Maximum report interval is 3,999,999 seconds which comes up to about 45 days. A reporting interval of 0 (zero) disables the periodic reports. HART communications – Applicable to Gauger420 ONLY with HART option HART is a standard digital communication protocol carried by the two power lines of Gauger420. When using HART communications make sure that the voltage on Gauger420 port is at least 14VDC. In addition, the loop current should not be lower than 7mA. The protocol can provide information on four different measurands which may be selected at setup. HART may be used as a bus protocol allowing up to 16 devices on the same bus, each identified by a unique address. HART parameters may be set using the PC configuration option. The setup provides for: ? Determining the four measurands (PV, SV, QV and TV) ? Determining the Gauger420 address Some notes related to HART configuration. ? Support for HART depended on firmware version. ? Guidelines related to the configuration of PV, SV, TV and QV using the PC: (1) Value 3 is Temperature as defined in SNS and may not be used by PV. (2) Values 2 and 6 may be selected only if VAL=3 or 6. (4) Each of PV, SV, TV and QV must be unique. ? HART should be configured after configuring all other settings. IF EMP or FUL are modified then HART configuration will be reset to the default values. Default values are defined at the EMP and FUL levels. Gauger420 with HART option supports HART Universal commands: 0,1,2,3,6,7,8,9,11,12,13,14,15,16,17,18,19,20,21,22. Gauger420 with HART option also supports selected Practice commands: 36, 37, 38, 40, 42. Gauger420 is compatible with HART Communicator Model 375 revision 6. The following parameters have been verified: PV (measurement and unit), Current (in mA), LRV (read and set), URV (read and set), Percentage-Current, TAG 8 (read and set), LSL and USL. ______________________________________________________________________________ GaugerGSM/485 – User Manual page 78 of 92 May 2013 Rev 4.1 Interdependencies For Metric units of GaugerGSM/485-75 Applicable to items Interdependencies 1 EMP, FUL,NBD, FBD 0.15 = NBD = FUL = EMP = FBD = 8.000 2 VAL=3,6 One and only one of the following must be configured: CUB, CYLH, CYLV For American units Applicable to items Interdependencies 1 EMP, FUL,NBD, FBD 0.50 = NBD = FUL = EMP =FBD = 26.00 2 VAL=3,6 One and only one of the following must be configured: CUB, CYLH, CYLV Similar interdependencies apply to GaugerGSM in accordance with the specification limits. Mapping Table A mapping table can be defined for mapping between level and flow in Open Channel Flow applications where no hydrologic formula exists. Up to 32 entries may be defined. The Gauger measures level and calculates flow by interpolation between two corresponding table entries. A typical series of commands to enable table based Open Channel Flow is as follows: $TBL 1, 0.1, 234.4 $...........................Define first entry in table (level = 0.1 corresponds to flow 234.4) $TBL 2, 0.25, 434.0 $.........................Define second entry in table $TBL 3, 0.9, 1057 $............................Define third entry in table … $TBL 15, 1.5, 2560.4 $.......................Define entry #15 in table $TBL 16, 1.55, 2600.0 $.....................Define entry #16 in table $STBL$.............................................Show all table entries on the HyperTerminal $OCF 10, 0, 15, 3$.............................Enable Table based Open Channel Flow. Level table entries are in metric units. Flow units are in Liter/sec and use only entries 1-15 (entry 16 is ignored). $VAL 7$...........................................Show flow on display ______________________________________________________________________________ GaugerGSM/485 – User Manual page 79 of 92 May 2013 Rev 4.1 Open Channel Flow (optional feature) Open Channel Flow refers to the flow of water or wastewater in natural channels such as rivers or in artificial channels such as irrigation ditches. Under some conditions, fluid level in the channel (in units of meters or feet) can be mapped to flow (in units of cubic meter per hour, gallons per minute etc..). Typically, flumes or weirs are constructed in the channel to allow calculation of flow from level. Flumes and weirs are structures that introduce a well-designed obstacle to the fluid flow causing a measureable increase in the fluid level nearby the obstacle. This level increase can be measured to obtain flow using hydrological formulas or empirical equations. Several different designs of flumes and weirs are applied world-wide. GaugerGSM implements flow equations for nine different designs: ? Rectangular suppressed sharp crested weir ? Rectangular contracted sharp crested weir ? Trapezoidal (Cipolletti) sharp crested weir ? V-Notch (Triangular) sharp crested weir ? Parshall Flume ? Palmer-Bowlus Flume ? H-Flume ? Khafagi-Venturi Flume ? Leopold-Lagco Flume Figure 23 - OCF weir example For each design GaugerGSM/485 supports a range of sizes which usually represent the obstacle size within the structure (crest length in weirs or flume throats). These sizes can be defined in either cm or inches. ______________________________________________________________________________ GaugerGSM/485 – User Manual page 80 of 92 May 2013 Rev 4.1 The calculated flow may be obtained in one of the flowing units: ? Cubic meter per hour (M3H) ? Cubic feet per second (CFS) ? Gallons per minute (GPM) ? Liter per second (LPS) ? Million Gallons per day (MGD) Additional flume and weirs as well as additional flow units may be added to GaugerGSM upon request. When no flume or weirs are present within the channel, the Manning Formula may be applied: http://en.wikipedia.org/wiki/Manning_formula. With this formula, flow may be calculated if certain characteristics of the channel are known. Specifically, channel cross section shape and size, channel slope along the flow and roughness coefficient. GaugerGSM implements the Manning Formula for channels in the shape of pipes (e.g. semi circular cross section). For hydrologic structures where level can be mapped to flow but no mapping formula exits, a mapping table may be used. The mapping table maps level to flow and defined with the $TBL command. Activation of the table-based OCF is with command $OCF 11. Flow is calculated as a linear interpolation of table entries. Levels beyond the last entry of the table will set the flow to the flow corresponding to the last entry. GaugerGSM is setup for a specific flume, weir or Manning circular pipe by using a USB command. See chapter “Configuration with a PC”. PTS configuration for battery operation The Programmable Timer Switch (PTS) is an external device for enabling low power mode of GaugerGSM. This low power mode is required for battery based operations. The PTS turns GaugerGSM/485 ON to take a measurement and, in some cases, to transmit the measured information. Then the PTS turns GaugerGSM/485 OFF for another sleeping period. GaugerGSM is then turned ON again and so on. With this method, a 20AH/12V battery can typically feed GaugerGSM for 1-3 years before replacement is needed. Two different sleeping intervals may be programmed by the user: long interval and short interval. The sleeping interval in-effect depends on the level being measured. For example, assume that a river overflows at a level of 2.0 meters and calm waters are defined at a level of 1.0 meter. A very long sleeping interval (e.g. 6 hours) can be set for level measurement between 0 meters and 1.0 meters. A shorter interval of 30 minutes can be set for levels between 1.0 meters and 1.8 meters. Finally, above 1.8 meters the PTS may be disabled and GaugerGSM/485 will operate continuously and transmit messages as defined for continuous operation. When operating continuously, the period ______________________________________________________________________________ GaugerGSM/485 – User Manual page 81 of 92 May 2013 Rev 4.1 between messages is defined by the GSM reporting interval parameter (SMST). In some firmware versions, the Gauger may be turned off at this high level and turned on again after period of SMST. This mode is controlled by the command PTS. This three phase concept is further described in the following figure. Vessel Predefined levels Standby modes Full Level Continuous measurement or sleep interval of SMST High Level Short sleep intervals Low Level Empty Level Long sleep intervals Figure 24 - Low power predefined levels When the low-power mode is active (during short or long sleep intervals), message may be transmitted at each wake up. Alternatively, a burst message may be transmitted once in a few sleeping intervals. The burst message will contain a set of data messages taken from each wakeup. This mode of operation allows logging of messages. Up to 20 messages may be logged (SMS) or 200 messages (GPRS). PTS parameters are defined by the command LPST as described in the chapter “Configuration with a PC”. Both sleep intervals must be longer than 10 minutes. The last parameter in the LPST command may be “0” – disabling any messages during the long sleep interval. The parameter may be “1” allowing a message at each turn on. The parameter may also be a number between 2 and 20, allowing logging of several messages prior to transmission. When this parameter is larger than 1, the message format (both SMS and GPRS) changes to accommodate for the data set. See section SMS format and section GPRS message format. As a precaution, the PTS is set to shut down the Gauger by force if the Gauger is not communicating with the PTS. Shut down is inflicted after 2 minutes (SMS) or 4 minutes (GPRS). Do not configure GaugerGSM/485 while the system is connected to a battery through the PTS. A shutdown may be forced by the PTS causing loss of data. ______________________________________________________________________________ GaugerGSM/485 – User Manual page 82 of 92 May 2013 Rev 4.1 When using EX-rated PTS and battery pack the special instructions described in the Installation chapter must be closely followed. Refill alerts When Refill alerts are activated, GaugerGSM/485 identifies a refilling process. GaugerGSM transmits an SMS soon after the refilling is identified and a second SMS soon after the refilling process has ended. The first SMS provides distance information (distance between sensor and fuel surface). The second SMS provides information about the filling quantity. This procedure allows more accurate refilling information when compared with the information that can be extracted from periodic reports. Relay Truth Table Some Gauger models support relay operation. Relay A operation is defined by USB command RLY and Relay B operation is complementary to Relay A. When Relay A is Short, Relay B is Open and vice verse. Electrical connections are described in the Physical and Electrical Installation Guideline Chapter. The RLY command is defined in the list of commands for configuration from a PC section and consists of four configuration parameters: ? Mode (0,1,2) ? Value (numerical value) ? Direction (0,1) ? Hysteresis (numerical value) The following truth table summarizes options. Mode Value Direction Hysteresis Theft Previous New relay state 0 x x x x x Open 1 v 1 h x x IF(reading > v ) then close 1 v 1 h x short IF(reading > v-h) then open 1 v 0 h x x IF(reading > v) then open 1 v 0 h x open IF(reading < v-h) then close 2 x 1 x No x open 2 x 1 x Yes x close 2 x 0 x No x close 2 x 0 x Yes x Open X designates “not important” in this table. ______________________________________________________________________________ GaugerGSM/485 – User Manual page 83 of 92 May 2013 Rev 4.1 Reset and operating hours GaugerGSM/485 may be reset to their factory defaults. This operation may be performed from the keypad or from the PC configuration tool (command RSD). Once executed, the Gauger will return to the state as delivered from the factory. GaugerGSM/485 may also be reset to restart without any change in the pre-configured parameters (command RST). GaugerGSM/485 keeps track of two counters for measuring operating hours. ? Non resettable counter (Odometer principle) ? Resettable counter (Trip-meter principle) The non-resettable counter displays the total hours of operation since the system is out of the factory. This counter aids both manufacturer and user in keeping track of specific GaugerGSM/485 history. The resettable counter displays the total hours of operation since the recent turn-on of the equipment or since the last reset of this counter. This counter aids the user in keeping track of the equipment for maintenance and other operations. The resettable counter may be activated from the built-in display or using the PC command RSC. SMS format (GaugerGSM) See section GPRS Format (for GaugerGSM). The NAME (“N”) is not included in SMS messages. Not all GPRS options are implemented with SMS. Check with the manufacturer. Temperature Coefficient of Expansion Liquids expand when temperature rises. Measured volume will therefore increase when heated. Gauger systems can compensate for this effect by re-calculating volume to a fixed reference temperature. Example: Assume the fixed reference temperature is set to 23°C and measurement takes place at 35°C showing volume of 900 L. Also assume that temperature coefficient of volume expansion for this liquid is 750ppm/°C. The recalculated volume for 23°C will be: 900 / [1 + (35-23)*0.00075] = 892 L. Activating the USB command TCOF enables re-calculation of volume to a reference temperature. Two parameters are defined by the user: reference temperature and temperature coefficient of volume expansion for the liquid. Re-calculation affects volume measurement but not level or distance. Temperature sensors, units and temperature display Gauger systems implement automatic compensation of deviations due to temperature variations in the air temperature of the ultrasonic media. The temperature is sensed by a temperature sensor which is embedded within the acoustic sensor. In installations where temperature varies very rapidly in time and location, it may be preferable to install an external temperature sensor (GaugerGSM) which will follow more closely the varying temperature. ______________________________________________________________________________ GaugerGSM/485 – User Manual page 84 of 92 May 2013 Rev 4.1 For these installations you can select the internal embedded temperature sensor or the external temperature sensor (if one is connected) or average both readings. Physical connection and installation of the external temperature sensor is described in the chapter physical installation guidelines. Temperature units may either be selected as Celsius or Fahrenheit. Temperature may be viewed on the built-in display. Temperature readings on the display present the following table: Sens: Cur High Low Int 29.5 31.0 26 Ext 29.4 32 23.3 Reset Done Figure 25 - Temperature readings The second line displays temperature measured by the internal temperature sensor. The third line displays temperature measured by the external temperature sensor. The column “Cur” displays the current temperature while “High” and “Low” columns display the highest and lowest temperature ever recorded by the temperature sensors since the last reset was performed. Test Mode during installation GaugerGSM functionality can be monitored by cable (USB / RS485)) during installation. See chapter “Serial Data Monitoring” for additional details. In sites where cable monitoring is not practical, the installer must rely on SMS / GPRS messages. These messages include important information such as RSSI (cellular Received Signal Strength Indication). When message interval is set to long duration such as several hours, it may not be practical to wait at the site for this long period of time. In these cases, the installer can use the TEST command to quickly send up to five messages from equipment turn-on. Additional information about TEST command can be found in the chapter “Configuration By PC”. Theft alerts GaugerGSM/485 supports theft detection alerts by examining rate of liquid consumption. Determine the rate which would be considered as inappropriate in units of level per minute (e.g. mm/min) or volume per minute (e.g. liter/min) and modify the deviation number accordingly. Limits are defined in the chapter: “Configuration with PC”. Rates lower than 4mm/min may cause excessive false alerts. Entries lower then 4mm/min will automatically be converted to 4mm/min. It is recommended to experiment with the specific tank and environment with this figure until no false alarms are transmitted. Alert SMS or GPRS will be transmitted within a minute following detection of an inappropriate consumption rate. Alert SMS / GPRS will be sent once a minute as long as the excessive consumption rate is detected. This may aid the user in determining the duration and persistence of the implied theft. Theft alerts co-exist with periodic alerts and with Full and Empty alerts. ______________________________________________________________________________ GaugerGSM/485 – User Manual page 85 of 92 May 2013 Rev 4.1 Trigger alerts GaugerGSM/485 supports up to three level-triggered alerts. Each alert is characterized by two parameters: (a) The percentage of level that will trigger the alert. For example, 25% will trigger an alert when a tank is a quarter full. (b) The direction, when crossing the predefined level, which will initiate an alert. The direction may upwards (tank is being filled) or downwards (tank is being emptied) or both directions. Alternatively, the triggers may be defined for volume (if applicable) instead of level. For example, an alert may be defined when volume is 10% of the maximum volume in the tank. The percentage definitions are shown in the following figure. Figure 26 - Trigger definition in percentage When more than one trigger point is defined, a gap of at least 2 percent points must be kept between any two triggers. GaugerGSM/485 automatically spreads trigger points that are too close to each other. For example, trigger points defined as 30%, 31% and 32% will be spread out as 30%, 32% and 34%. In this case, a warning is sent to the configuring PC. GaugerGSM/485 avoids excess messages in the event of large target ripples in the vicinity of the trigger point by implementing a hysteresis algorithm. In addition, messages of any type may only be transmitted if three minutes have passed since the previous message. If two trigger levels are crossed in less than three minutes, an alert will not be sent from the first trigger level. When the Gauger is just turned on and if trigger alerts are defined, the downward alert will be sent. When operating with the PTS which enforces a Gauger ON/OFF operation, only downwards alerts are sent. Trigger alerts co-exist with periodic alerts and with Full and Empty alerts. ______________________________________________________________________________ GaugerGSM/485 – User Manual page 86 of 92 May 2013 Rev 4.1 Volume measurement (a) General Based on measured Level, tank shape and tank dimensions, GaugerGSM/485 can calculate and report Volume rather than Distance or Level. Configuration of Volume elements can only be executed using the PC configuration method. Currently, three tank shapes are supported: ? Box shaped ? Horizontal cylindrical tanks with curved or non-curved sides ? Vertical cylindrical tank with curved or non-curved bottom-side (b) Box shaped Two horizontal box dimensions should be configured (X, Y), allowing Volume calculation of the liquid contained within the box shaped tank. The third dimension is the level measured by the Gauger (Z). Figure 27 - Box shaped tank (c) Cylindrical tanks Horizontal cylindrical tank with curved sides: For advanced users The box shaped tank may also represent any other tank if Volume (V) and Level (L) are linearly related in that tank. Mathematically stated, if V = k * L where k is a constant. For such a tank, enter X=1 and Y=k. X Y Z ______________________________________________________________________________ GaugerGSM/485 – User Manual page 87 of 92 May 2013 Rev 4.1 Figure 28 - Cylindrical horizontal tank The breadth may be zero for straight ends. Vertical cylindrical tank with concave bottom: Figure 29 - Cylindrical vertical tank See also the section: “Interdependencies” in this chapter. 4-20 communications – Applicable to Gauger420 ONLY (a) 4-20 Setup Gauger420 is powered by two-wires which also carry measurement information. Measurement related information is conveyed by current magnitude which may take any value between 4mA and 20mA. During setup, the user determines: ? The measurement value represented by 4mA ? The measurement value represented by 20mA ? The current value representing an error ______________________________________________________________________________ GaugerGSM/485 – User Manual page 88 of 92 May 2013 Rev 4.1 The current may represent one of the following Measurands: ? Level ? Distance ? Volume In addition, the current may be set at some fixed value thereby not carrying any measurement information. An error state (echo is lost for at least 3 minutes) may be represented by one of the following: ? 3.6mA ? 22mA ? Holding the most recent legal value ? 3.6mA or 22mA, the one nearest to the most recent legal value Pressing any keypad button will cause the current to jump 22mA regardless of the 4-20 error settings. The current will return to represent measurement as soon as the device resumes normal measurement The current read by the user should be interpreted as follows: ......{ .. .. ..4 }..............{ .. .. ..20 .. .. ..4 }*..........................................................................Measurement valuevalue represented by mAvalue represented by mA value represented by mA???.........................................( [ ] 4) /16current mA ? Setup may be performed using the keypad or by PC configuration. Each is described in the appropriate chapter of this user manual. The reader is further advised to review the interdependencies section in the PC configuration chapter. (b) 4-20 Performance When Gauger420 is fed by low current, the performance of the system is modified to accommodate for the available electrical power. In particular, the rate of ultrasonic pulse transmissions is decreased. This decrease means that Gauger420 response to rapidly moving targets is reduced. At low current and low voltage the pulse rate may be four times lower than the maximum rate. (c) 4-20 constraints 4-20 settings must be configured after settings of Full and Empty levels. Once Full and Empty levels are configured, 4-20 settings are modified to their default values. For other constraints related to 4-20 setting please refer to the Interdependencies section. ______________________________________________________________________________ GaugerGSM/485 – User Manual page 89 of 92 May 2013 Rev 4.1 (d) 4-20 default settings Default settings when measuring level Figure 30 - Default 4-20 values for Level Default settings when measuring Volume Figure 31 - Default 4-20 values for Volume ______________________________________________________________________________ GaugerGSM/485 – User Manual page 90 of 92 May 2013 Rev 4.1 Default settings when measuring Distance Figure 32 - Default 4-20 values for Distance ______________________________________________________________________________ GaugerGSM/485 – User Manual page 91 of 92 May 2013 Rev 4.1 X. Troubleshooting Symptom Recommendation Power On faults Gauger does not power on 1. Check the rating of your power supply and verify these ratings are within the specifications of the GaugerGSM. 2. Check the electrical cables between the power supply and the Gauger. In particular, check the connections on the GaugerGSM. Gauger powers on but does not measure 1. Check the rating of your power supply and verify these ratings are within the specifications of the GaugerGSM. 2. Check if a USB connection powers up the GaugerGSM – do not use a USB connection to power up the GaugerGSM. Gauger resets itself 1. For GaugerGSM and for some firmware versions, GaugerGSM will reset itself periodically every two minutes or so if SIM card is not inserted. 2. If level measurement is absolutely fixed for 20 minutes, Gauger will reset itself. Ultrasonic related faults Status line 1 reports constant ECHO SEARCH 1. Check your target is between 15 cm and 8 meters (6 meters for solids). 2. Verify that the sensor is precisely directed towards the target. 3. Check the sensor face and make sure the face is clear of dust or dirt. 4. If you use an extension pipe, recheck all the recommendations stated in the extension pipe section in this manual. Level measurement is incorrect 1. Check that distance measurement is correct. Verify the settings of Full level and of Far Blocking Distance. Level measurement displays Full level continuously 1. Check and clear out physical disturbances above the empty level. 2. If you are using an extension pipe, increase NBD to a distance which is 2-3 cm beyond the edge of the pipe. Cellular related faults Line status 2 displays error messages such as registration fail or GSM SIM fail 1. Verify you have properly inserted a SIM card into GaugerGSM. 2. Carefully walk through the SIM instructions in the installation chapter. 3. Reposition your cellular antenna, the cellular coverage may be weak in your area. Line status 2 displays SMS or GPRS SENT but no SMS or GPRS message is received SMS: 1. Verify the correctness of the destination phone number that you entered into GaugerGSM. Review the rules for entering a phone number as described in this manual. Remember, it is your responsibility to enter a valid phone number. GPRS: 1. Verify the correctness of the IP address and port number that you configured with the aid of a PC. Check that the server is up and running. Line status 2 reports GSM is OK but no SMS / GPRS 1. Check if the reporting interval you entered in the GaugerGSM is correct. Notice that reporting interval is entered in seconds so that half an hour ______________________________________________________________________________ GaugerGSM/485 – User Manual page 92 of 92 May 2013 Rev 4.1 messages are sent would be entered as 1800 and five minutes would be entered as 300. 2. Check if the reporting deviation is set to zero. GaugerGSM powers on but does not send a GPRS message after 1 minute 1. Check if the SIM used supports GPRS 2. Check if GPRS network is online 3. Check if remote server is online 4. Activate the $MLOG 1$ USB command. Verify that the first responded value is no less than 10, if not relocate the Gauger while observing this value. 5. Check Gauger configuration using $STAT 0$ command : a. DATA command should show 1 b. User, password and APN in GPRS command should be configured according to GPRS cellular provider information. c. IP address and port number should match the ones defined on the remote server. d. Gauger name configured via the NAME command should match the one defined on the remote server (required in the Site Monitoring Center (SMC) software. GaugerGSM powers on but does not send a GPRS message after 1 minute even though all GPRS parameters viewed via STAT command are correct and network is OK . reconfigure GPRS command manually , verify no white characters are entered , verify Gauger responds with OK message and the correct parameter value 2. Reconfigure NAME command manually , verify no white characters are entered , verify Gauger responds with OK message and the correct parameter value 3. Verify using $STAT 0$ command , GPRS parameters are correct GaugerGSM powers on but does not send a GPRS message after 1 minute even though all GPRS parameters manually reconfigured are correct 1. Reset the Gauger 2. Activate the USB $MLOG 2$ command 3. Record HT display for at least the time defined in SMST command and send to the manufacturer SolidAT. GaugerGSM sends GPRS messages not accordingly to interval defined in SMST command 1. Reset the Gauger 2. Activate the USB $MLOG 2$ command 3. Activate the $ENDT$ command 4. Record HT display for at least the time defined in SMST command and send to the manufacturer SolidAT.