This quality system has been developed over many years and represents the latest in high technology ultrasonic level measurement and control (258 pages)
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ARRANTY AND IABILITY Pulsar Process Measurement Limited guarantee for a period of 2 years from the date of delivery that it will either exchange or repair any part of this product returned to Pulsar Process Measurement Limited if it is found to be defective in material or workmanship, subject to the defect not being due to unfair wear and tear, misuse, modification or alteration, accident, misapplication or negligence.
Contents Chapter 1 Start Here… ............................1 About this Manual ............................1 About the blackbox range ..........................2 Functional Description ............................ 3 Product Specification............................4 EC Declaration of Conformity ........................6 Chapter 2 Installation............................7 Power Supply Requirements ........................... 7 Location ................................
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Data Logs Menu ............................ 41 Volume Menu ............................42 Display Menu ............................43 Output Menu ............................43 Compensation Menu ..........................43 Stability Menu............................44 Echo Processing Menu .......................... 44 System Menu ............................45 Test Menu .............................. 46 Parameter Listing ............................47 Application Parameters ..........................
Chapter 1 Start Here… Congratulations on your purchase of a Pulsar blackbox 130 Level System. This quality system has been developed over many years and represents the latest in high technology ultrasonic level measurement and control. It has been designed to give you years of trouble free performance, and a few minutes spent reading this operating manual will ensure that your installation is as simple as possible.
About the range The Pulsar blackbox is a non-contact Level Control System. It has been designed to provide a new concept in low cost maintenance-free fit and forget level measurement without any compromise on performance. The blackbox is ideally suited to applications where level monitoring, reporting, control or logging is required, with or without the need for a local display.
The blackbox utilises the unique DATEM software (Digital Adaptive Tracking of Echo Movement). This is a unique digital mapping technique developed especially for Pulsar’s range of ultrasonic level and control systems. It gives the system edge when identifying the “true target level” in the face of competing echoes from pipes, pumps or other obstructions.
Polycarbonate base with Polycarbonate lid, flammability rating UL94-5V Separation Transducer cable extensions 3 conductor 20AWG screened Nominal separation 3,280 ft. (1000m). For greater separation distances please consult Pulsar Environmental Mounting Indoor/Outdoor Relative Humidity (IP Rating) IP66 (NEMA 4X enclosure) <35...
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Exm version of dB series transducers. Remote Communicator Power supplied via blackbox RS232 Power Supply interface. Pulsar Process Measurement Limited operates a policy of constant development and improvement and reserve the right to amend technical details as necessary. Page...
An external supply isolator/circuit breaker (AC or DC) must be fitted and labelled to identify the instrument to which it refers. Safety Symbols Detailed below are descriptions and meanings of safety/warning symbols that are used on the blackbox 130 and in this manual. Direct Current Alternating Current Protective Conductor Terminal...
Location All electronic products are susceptible to electrostatic shock, so follow proper grounding procedures during installation. The blackbox level controller must be mounted in a non-hazardous (safe) Area, and the transducer fitted in the hazardous area. Note: the blackbox shown in the FM APPROVED TRANSDUCERS above diagram is for illustrative Class I, Div.
When choosing a location to mount the enclosure, bear in mind the following: • Ensure that the blackbox is installed in a “Safe”, non-hazardous, area. • Easy access to the enclosure is maintained. • The mounting surface is vibration-free. • The ambient temperature is between -4ºF and 120ºF (-20ºC and 50ºC) •...
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The blackbox should be mounted by drilling four holes suitable for size 8 pan or round headed screws. The screw length will be dependent on the wall to which the blackbox is to be mounted to, if it is unclad use 1.5" long screws with suitable wall fixings, if the wall is clad add the cladding thickness to the 1.5"...
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The full dimensions of the enclosure are as shown below. Cable Entry There are 3 x 20mm (0.79") cable glands, suitable for 6 – 12mm (0.24" – 0.63") cables, fitted to the base of the blackbox enclosure. Page...
Large Enclosure (optional) The dimensions of the mounting holes are as shown below. Page...
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The full dimensions of the enclosure are as shown below. Cable Entry There are 5 x 20mm (0.79") cable glands, suitable for 6 – 12mm (0.24" – 0.63") cables, fitted to the base of the fitted to the base of the blackbox enclosure. Page...
Terminal Connection Details The terminal strip is as detailed below. There is also a wiring diagram attached to the board directly underneath the terminal strip. Important Information All terminal connection screws should be tightened to 4.5in.lbs. (0.5Nm). Care should be taken not to over tighten the screws. Page...
Terminal Connections Power The blackbox can operate from mains AC and automatically from a DC power source or battery backup, in the event of power failure, or can be operated permanently from DC or batteries. The AC and DC wiring should be completed using either 16 – 14AWG (1.5– ) stranded or 16 –...
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When installing a transducer in a hazardous area use an approved transducer suitable for the proposed application as detailed below: For EEx m (Zone 1) applications a transducer certified to FM Class I Div 1 Group A, B, C & D, ClassII Div 1 Group E, F & G, Class III is used, and must be supplied via a 1500A breaking fuse, which is fitted as standard to the blackbox level controller.
Relay Outputs The two relays can be programmed to a variety of alarm and control functions. The relay contacts are all rated at 2A at 115V AC. Wiring should be completed by using suitable cable, to meet the specified 115V AC 2A contact rating, up to maximum size of 14AWG.
Important Information Before applying AC power (mains), make sure the supply is 115 VAC +5% / -10% Never operate the blackbox with terminal access exposed. An external switch or circuit breaker should be installed near to the blackbox to allow the supply to be removed during installation and maintenance.
There are no user serviceable parts inside your blackbox, except the mains power fuse. If you experience any problems with the equipment, then please contact Pulsar Process Measurement for advice. Important Information Please note that the on-board Lithium battery, mounted to the processor PCB, is not user serviceable.
PC Handheld Programmer (Standard) Your blackbox 130 comes complete with the PC Handheld Programmer software, contained on CD. Insert the CD into the CD drive of the PC intended to be used to carry out the programming of the blackbox and install the software, following the on-screen instructions.
Communication Port Configuration If the PC Handheld Programmer fails to connect to the blackbox unit you may need to change the communications port that is being used, to do this ‘right click’ on the PC Handheld Programmer keypad and a ‘pop up’ menu will appear allowing you to select the appropriate communications port.
Operating the Controls Display The display in all cases is identical, the only difference being is that both the PC Programming Software (standard) and the Hand-Held Calibrator (optional) need to be connected to the blackbox via the RS232 interface, whereas the on-board keypad and display (optional) are permanently connected to the blackbox provides information on the current mode of operation.
Run Mode. In program mode, they have different functions, the functions are shown below. Run Mode Program Mode Not used with blackbox Not used with blackbox 130. 130. Displays echo confidence, echo Not used with blackbox strength, H.A.L.L., average 130.
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Menu Keys The menu keys are used to navigate around the built-in menu system and have the following functions: Menu Key Function 1) Arrow keys for moving left and right around the menu system. 2) Used in test mode to simulate the level moving up and down.
There are two main operating modes for your blackbox, Run Mode and Program Mode. There is also a Test Mode, used for checking the set-up. All modes are now described. Run Mode This mode is used once the blackbox has been set up in program mode. It is also the default mode that the unit reverts to when it resumes operation after a power failure.
LED’s There are two LED’s which can be seen through the lid, of the blackbox enclosure, which will indicate the operational status of the unit when in RUN mode, as follows: blackbox without on board display (standard). LED 1 LED 2 Run Mode Green No power to unit...
How to Access Program Mode To enter program mode, you simply enter the passcode, via the keypad on the PC Programming Software (standard), Hand Held Calibrator (optional) or integral keypad (optional), followed by the ENTER key. The default passcode is 1997, so you would press the following: Note There is a time-out period of 15 minutes when in program mode, after which time run mode will be resumed if you do not press any...
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Once you have reached the relevant section, scroll through the parameters, and enter the necessary information. To enter the information, use the numeric keys and press ENTER and you will see the message “Saved!”, if you press CANCEL, then no change will be made, and the message “Unchanged!!” will be displayed.
Test Mode Test mode is used to simulate the application and confirm that all parameters and relay setpoints have been entered as expected. During simulation, there is a choice of whether the relays will physically change state (hard simulation) or not (soft simulation), the LED’s will always change state to indicate that the relay setpoints have been activated, and the output will change in accordance to the chosen mode of operation.
The RS232 serial interface is used to program the blackbox, and communicate between the blackbox and a PC using the optional blackbox PC and other associated Pulsar software packages, to obtain information such as data logging and view echo traces upload, download and save parameter files. In addition, it can also be used to control or obtain information using a standard PC or other computer based equipment.
Parameter Defaults Factory Defaults Factory Defaults When first installing the blackbox, or subsequently moving or using the unit on a new application, before proceeding to program the unit for its intended application it is recommended that you ensure that all parameters are at their default values by completing a Factory Defaults P930, as described in Chapter 5 Parameter Guide.
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Chapter 4 Programming Guide Level Example 1 Level Measurement empty distance (P105), 11.0 feet 100%, span (P106), 10.0 feet (output = 20mA) high alarm on (P213), 8.5 feet high alarm off (P214), 8.0 feet low alarm off (P224),1.5 feet low alarm on (P223),1.0 feet 0% , empty level (output = 4mA) In this example, the blackbox and dB6 is being used to monitor a moving level within a vessel and is required to provide a 4 to 20mA output...
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To program the blackbox for this Example, proceed as follows. Access the Program Mode Key in the passcode 1997 and press ENTER Using the menu system access the parameters, as detailed below, and select the relevant options and ENTER. Top Level Selected Parameter Detail Sub Menu...
Example 2 Alternating Control (pump down) A sump is typically used to temporarily hold water or effluent, and when the level reaches a specific point, the sump is pumped down, with the fluid being transferred to another process. empty distance (P105), 15.0 feet 100%, span (P106), 13.5 feet (output = 20mA) pump 2 on (P 223), 6.0 feet...
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To program the blackbox for this Example, proceed as follows. Access the Program Mode Key in the passcode 1997 and press ENTER Using the menu system access the parameters, as detailed below, and select the relevant options and ENTER. Top Level Selected Parameter Detail Sub Menu...
Volume (Optional) Example 3 Volume Application Only available on blackbox 130D, fitted with optional LCD display and integral keypad. A cylindrical tank with a diameter of 2m and a flat base that is typically used to temporarily hold liquid, and you wish to know the volume of liquid. You also require a high and low alarm.
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To program the blackbox for this Example, proceed as follows. Access the Program Mode Key in the passcode 1997 and press ENTER Using the menu system access the parameters, as detailed below, and select the relevant options and ENTER. Top Level Parameter Detail Selected Value Sub Menu...
Chapter 5 Parameter Guide This chapter describes all of the parameters contained in your blackbox. Menu System Diagrams Shown below is a set of charts to show you how all the various parts can be found using the menu system. Top Level Menu Volume Application...
Relays Menu Relay 1 Relay 2 P210 R1 Type P220 R2 Type P211 R1 Function P221 R2 Function P212 R1 ID P222 R2 ID P213 R1 Set 1 P223 R2 Set 1 P214 R1 Set 2 P224 R2 Set 2 P217 R1 Closures P227 R2 Closures P218 R1 Failsafe...
System Menu Date System Daylight Passcode & Info Saving Time P926 P921 P931 P970 Software Enable Date Revision Code Enable P932 P971 P927 P922 Time Hardware Passcode Difference Revision P933 Date P972 P928 Format Serial Start Time Number P973 P929 Start Day Site Ident.
Test Menu Simulation Hardware P980 P990 Simulate Self Test P981 P991 Increment Hard Test P982 P992 Rate Out Test P993 Relay Test P994 Transducer Test Page...
Parameter Listing This section describes all of the parameters. Any parameter can be reset to its default, by pressing the hot key, while in program mode. Application Parameters Operation P100 Mode of Operation This parameter sets the mode of operation, when in run mode, and can be set to one of the following: Option Description...
Dimensions P104 Measurement Units This parameter sets the units you want to use for programming and display Option Description 1 = metres All units of measure are METRES 2 = cm All units of measure are CENTIMETRES 3 = mm All units of measure are MILLIMETRES All units of measure are...
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P107 Near Blanking Distance This parameter is the distance from the face of the transducer that is not measurable, and is pre-set to the minimum value dependant on the Xducer (P101) selected. It should not be set to less than this figure, but can be increased, typical to ignore close in obstructions.
When a Modem is connected to the blackbox, via the RS232 port, (Consult Pulsar or your local distributor for further details), the following parameters are used to set up the blackbox so that when the level reaches a specific alarm point, as determined by the setting of the relay(s) the unit will dial and connect to a remote telephone number to provide details of the event.
1 = Ring This option initiates a connection to a remote modem/computer which will then allow remote communication with the unit. Please consult Pulsar or your local distributor for further details. 2= SMS This option initiates a predetermined message which is sent to the remote...
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P998 SMS Days This parameter will determine on which days the SMS message is active and is entered as a Boolean value equating to the total of the days that the SMS message is required to be active. Add together any combination up to a maximum of 127 (every day). Examples: 21 = Mon, Wed, Fri., 31 = Mon to Fri.,...
Relay Parameters All relay related parameters are prefixed with a 2**. The second digit of the three-figure parameter number denotes the relay number as follows: 21* parameters for Relay 1 22* parameters for Relay 2 The third digit selects specific parameters for the setting up of the relays, which can be selected individually and results in the following parameter numbers for each relay.
Alarms P210, P220 =1 (Alarm) The second parameter for each relay determines the function of the alarm. P211, P221 - Relay Function This parameter defines what function the alarm will respond to as follows. Option Description Relay will not operate. 0= Off (Default) 1= Level Alarm is based on the level in the vessel, and the...
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The third parameter for each relay determines the alarm ID for the relay you wish to set. P212, 222 - Relay Alarm ID When P211, P221 = 3 (Loss of Echo) or 4 (Loss of Clock) This parameter has no function and will not be displayed. When P211, P221 = 1 (Level) or 2 (Temperature) This parameter defines which alarm type, the relay should respond to, as follows.
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Alarm ID Description Setpoints Relay goes “ON” if 6= In bounds Relay Setpoints, value is inside the zone P213, 223 and between the two P214, 224 can be setpoints. set in any order as the unit ‘knows’ that you are setting an inbounds alarm.
Important Information Setpoints are entered in values according to the function selected. Level - entered in Display Units as referenced to Empty Level. Temperature - entered in ºC. See the appropriate alarm function, table (P211, 221) for further information. Control P210, P220 = 2 (Control) When a relay is being set up as a control relay, the second parameter that will be displayed in the menu determines its function.
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The third parameter determines if the control is fixed or alternating. P212, 222 Relay Control ID P210, 220 = 2 (Control) P211, 221 = 1 (General) Description 1= Fixed All control devices are used to assist each other (run at the same time) and each device has its own setpoints.
Common Parameters P217, P227 - Relay Closures The blackbox will record how many times each relay is operated, this parameter displays the number of times the relay has activated since the relay has been in use. It can be reset with any value. P218, P228 - Relay Fail Safe Your blackbox has a general fail-safe parameter P808.
Data Log Parameters The data log parameters contain the following information. Temperature The following parameters give information on temperature conditions seen by the Temperature source (P852) in ºC. These parameters are read only and cannot be changed, though if P852 is changed they will be reset. P580 Minimum Temperature This parameter displays the minimum temperature recorded.
Volume (Optional) Only available on blackbox 130D, fitted with optional LCD display and integral keypad and provides a variety of volume calculation features, with 11 pre-programmed vessel shapes. See Vessel Shape (P600) for more information. For each vessel, you will need to know the dimensions (P601- 603) in Measurement Units (P104) which are required to calculate the volume (P604) which will be displayed in the selected Volume Units (P605).
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Vessel Shape P600 Value Dimensions P600=4 Cylindrical Cylinder diameter Required and height of Parabola base bottom P600=5 Cylindrical Cylinder Diameter Half-sphere base P600=6 Cylindrical Cylinder diameter Flat sloped base and height of bottom P600=7 Rectangular Width and Breadth Flat sloped base of rectangular section and height of bottom...
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P601-P603 Vessel Dimensions These three parameters are used to enter the dimension required to calculate the volume. The dimensions required are as shown below and are entered Measurements Units (P104). Vessel Shape P601 P602 P603 P600=0 Cylinder Cylindrical Flat base Diameter P600=1 Width of...
P605 Volume Units This parameter determines the units that you wish to display, for volume conversion. It is used in conjunction with P607 (maximum volume), and the units are shown on the display (subject to P810). The choices are: Option Description 0 = No Units Volume will be totalised with no units...
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Universal Linear (P600=11) This volume calculation creates a linear approximation of the level/volume relationship, and works best if the vessel has sharp angles between each section. Level You should enter a level/volume breakpoint for each place where the vessel changes direction, and numerous where the section is slightly curved (mostly linear, but has got a small arc).
Tables P696 Reset Breakpoints This parameter allows the resetting, to the default value, of all previously set breakpoints (P610-673), without having to access them individually. When it is necessary to reset or amend particular breakpoints this can be achieved by directly accessing the desired parameter (P610-673) and changing as required.
Failsafe P808 Fail-safe Mode By default, if a fail-safe condition occurs, then the display and the output are held at their last known values until a valid reading is obtained. If required, then you can change this so that the unit goes to high (100% of span), or low (empty) as follows: Option Description...
Output Parameters Range P830 Out Range This parameter determines the range of the mA output, from the following. Option Description 0= Off mA output disabled. mA output directly proportional to the out mode 1= 0 to 20 mA (P831), so if the reading is 0% the output is 0 mA. If the reading is 100% the output is 20 mA.
Setpoint By default, the mA output will represent the empty (0 or 4mA dependant on (P830) Out Range) and 100% of the operational span (20mA), but you may wish to have the output represent a section of the operational span. For example, the application has an operational span of 20 feet but output is to represent empty (0 or 4mA dependant on (P830) Out Range) to a level of 15 feet (20mA).
Trim P838 Out Low Trim If the remote device you are connected to is not calibrated, and not showing the correct low value (reading), then you can trim it using this parameter. You can either type in the offset directly, or use the arrow keys to move the output up and down until you get the expected result (reading) on the remote device that is connected.
Offset P851 Measurement Offset The value of this parameter is added to the measured distance, in Measurement Units (P104). This Offset will be added to the level, as derived from the transducer, and will affect everything including the reading on any display in use, relay setpoints and the output.
Stability Parameters Damping Damping is used to damp the display, to enable it to keep up with the process but ignore minor surface fluctuations. P870 Fill Damping This parameter determines the maximum rate at which the unit will respond to an increase in level. It should be set slightly higher than the maximum vessel fill rate.
P905 Sensitivity This parameter determines the sensitivity of the unit. Please consult Pulsar for further information and assistance on changing the value of this parameter. Page...
P906 Side Clearance This parameter is used to set the distance by which the DATEM trace will “stand-off” from around unwanted echoes such as obstructions. Please consult Pulsar for further information and assistance on changing the value of this parameter. System Parameters...
P929 Site Identification This parameter allows you to give each unit an individual reference number, for identification purposes. You can set any number between 1 and 99999. P930 Factory Defaults This parameter resets all parameter values to the original Factory Set values that were installed when the unit was tested, before despatch to you.
Daylight Saving Time Important Information In order to ensure the correct operation of Daylight Saving Time P932 Time should be checked, and adjusted if necessary, to ensure that it is set for the current valid time. P970 DST Enable When Enabled (set to 1) the internal clock will be automatically adjusted to compensate for the difference between standard time and Daylight Saving Time.
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P974 Start Week This parameter will determine the week of the month (P975) in which Daylight Saving Time is to start. Option Description 1= Week 1 DST will start on day (P973) in the first week (P974) of the month (P975). 2= Week 2 DST will start on day (P973) in the second week (P974) of the month (P975).
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P977 End Day Use this parameter to enter the day of the week (P974) that Daylight Saving Time is to end. Option Description 2= Monday DST will end on a Monday 3= Tuesday DST will end on a Tuesday 4= Wednesday DST will end on a Wednesday 5= Thursday DST will end on a Thursday...
P979 End Month This parameter is used to select the month, in which Daylight Saving Time will end. Option Description 1= January DST will end during the month of January 2= February DST will end during the month of February 3= March DST will end during the month of March 4= April...
The choices for you to enter are as follows. 1= Manual soft simulation 2= Automatic soft simulation 3= Manual hard simulation 4= Automatic hard simulation To return to program mode, press CANCEL and test mode will end. P981 Increment By default, simulation mode will move by 0.328 feet steps in manual simulation and by 0.328 feet/min in automatic simulation.
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* Keys. You should press each key, to confirm it works, with a counter showing how many more keys you have to press. Be sure to press the CANCEL key last, as this will show if all keys were pressed or not.
Chapter 6 Troubleshooting This section describes many common symptoms, with suggestions as to what to do. Symptom What to Do reading being obtained, Check power supply. Check transducer not firing. wiring to transducer. Incorrect reading being obtained for Measure actual distance from current level.
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