APM Customer Support Technical Training

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APM Automation Solutions Ltd.

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APM Customer Support Technical Training



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Introduction


Company Profile

• Privately held APMAutomation Solutions Ltd.specializes in developingtechnologically innovative,effective and economicalnon-contact 3D levelmeasurement instrumentsfor a range of industrial applications.

• APM's headquarters and state-of-the-artR&D and manufacturing facilities arelocated in Israel.

• Sales and support are provided by a network of resellersand distributors in the US and over 20 countries across Europe.


What is the 3DLevelScanner?

The APM 3DLevelScanner™is the only device presently available that delivers accurate measurement of bulk solids and powders – regardless of the type of material or product characteristics, type and size of storage silo, bin or container, and harshness of the storage environment. It incorporates APM's unique dust-penetrating technology to achieve an unrivalled degree of process measurement and inventory control.

Click on image forVision of 3D Measurement video.



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APM Technology


Mapping and Echo Detection

Traditional sensors with single transducer are only capable of measuring a single point on the contents surface.

APM implements a circular array of three transducers for beam forming both at reception and transmission.


APM TechnologyHow does it work

By collecting all echoes bounced from the surface area, the patented algorithm of the 3DLevelScanner™ is able to detect: The distance to the material (time of flight for

each echo) The location of every returning echo at the

surface area (by calculating the arriving angle of the echo using the time difference between the received echo at each antenna).

The echoes are being converted to mapping points and constructs the 3D image of the surface area using APM 3DLevelManager™ software.


APM TechnologyHow does it work - General Concepts

SNR – The Signal to Noise Ratio that determines the ability of the 3DLevelScanner to measure the contents of the vessel.

Volume – The volume [%] of the material in the vessel.

Mass – The volume multiplied by the product’s bulk density.

R distance –“R distance” is the absolute diagonal distance measured from the flange level at the mounting position of the 3DLevelScanner.

Mapping Points – are the X, Y and Z coordinates of every measured echo, the 0,0,0 coordinate is at the top center of the silo. {(X-X0)² +(Y-Y0) ²+(Z-Z0)^2}^½ = R X0,Y0,Z0 are the coordinates of the

3DLelvelScanner’s location. Full & Empty Calibration – Distance to 100% and

0% from the flange level of the 3DLevelScanner.

Z Distance(17.3)

R Distance(26)


APM Technology How does it work – Cont.

Signal Attenuation due to Dust/Moisture concentration in air

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Self Cleaning Exmple


Accuracy3DLevelScanner MV Vs. Single Point Device

A comparison of the volume (%) accuracy of the 3DLevelScanner MV Vs. Single Point Device

The silo dimensions are: Width=10m, Height=20m. The material is cone sloped with 45 deg. 3DLevelScanner accuracy = 1.55% Laser volume accuracy = 16%

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Measurement Characteristics

Frequency: 2.6- 7 KHz Beam angle: 30-70 degrees Accuracy (vertical): 15 mm (0.6”) Measuring range: 0.5-70 m (1.6’-

230’) Dead zone: 50 cm (20”) from flange Temperature Accuracy: 0.5°C (0.5 °F)


Environment and Certifications

Process temperature: -40° – 85°C (-40 – 185 °F) Process pressure: -0.2 – 3 bar Protection: IP 67 ATEX II 1/2D, 2G (Head-zone 21, Antenna-zone 20) FM CL I,II Div I GP CDEFG CE EMC EN 61326 CE Safety IEC EN 61010-1 FCC 47CFR part 15 subpart B ISO 9001 2000


Interfaces

Power supply: 20-36 VDC Interface: 4…20 mA,

HART

RS485

Modbus

GSM (CSD), GPRS (via RS485)

TCP IP (via GUI)



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Products


Product Line

3DLevelScanner S Similar performance to presently

available top-of-the-line products

3DLevelScanner M Mapping capabilities

3DLevelScanner MV Visualization capabilities

3DLevelScanner MVL 2 scanners in 1 silo integrated (via PC) to work as one unit.

3DLinkPro Accessories

Modems, displays, etc. All models have the same hardware but different embedded software

(remotely upgradeable)


Device types S/M/MV3DLevelScanner S

30 º opening beam angle – covers more area than other traditional level measurement devices

Low frequency – dust penetrating Fast response – suitable for small silos

or fast-changing process silos requiring fast tracking Provide average Distance/Level Provides Average Volume (4..20 mA) Linear mode enabled (for non standard and

segmented silos)


Device types S/M/MV3DLevelScanner M

70º opening beam angle - covers wide surface area Low frequency – dust penetrating Suitable for big silos that require high accuracy and

inventory control Provides minimum/maximum and average distance Provides average volume at 4..20 mA output. 3D Mapping – detects mapping points of the surface

area Visualization disabled.


Device types S/M/MV3DLevelScanner MV

70º opening beam angle - covers wide surface area Low frequency – dust penetrating. Suitable for big silos that require high accuracy and

inventory control Provides minimum/maximum and average distance Provides average volume at 4..20 mA output 3D Mapping – detects mapping points of the surface

area Visualization of 3DMapping is enabled


Device types S/M/MV3DLevelScanner MVL

• The solution for wide silos, open bins and warehouses.

• Multiple 3DLevelScanners cover the entire surface area.

• APM Multi Scanner Controller is (1) synchronizing and (2) merging the measurements from the MVL units.

• 3D Vision software (client) enables users via a network to view real time measurement and combined 3D image of all silos in the plant.

• GPRS based support via 3DLinkPro available.


3DLinkPro Remote Communication

The 3DLinkPro is used for remote assistance and tracking the measurements.

SIM card with SMS (Text) and GPRS enabled is required.

Automatic power reset when losing cellular signal.

Enable upgrading the 3DLevelScanner remotely to the various product types (M/MV).

Enable performing firmware updates remotely.

You may find the connection scheme at the “Connecting 3DLinkPro” file.


Installation Preparations

Positioning Guidelines

Always use the 3DLocator Software to finalize position.

1. Clear vision to material

2. 90° to the ground

3. At least 10 mm (0.4”) gap between the socket’s floor and the antenna's bottom


Internal Structures to avoid


Installation Preparation

Positioning Guidelines (cont.)

6. Orientation:i. The mounting direction is indicated by a tendon on the unit.

ii. The 0º should point to the center of the vessel (including square vessels and open bins).


Neck Extensions

20cm, 30cm, or 50cm1m, 2.5m, or 10m


Head-Body Separation



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Neck Extensions


Mounting Location



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Shipping


Shipping



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Mechanical & Electrical Installation

It’s practically plug and play!


Connection Methods

Interface 4..20 mA Port RS-485 Port

Direct connection(HART/RS485)

Analog signal (Volume %)

Modbus (RTU)

GPRS/GSM

TCP/IP

Multi-Drop

To Learn more about the various connection methods available - click here


Site Preparations & Requirements Wiring Diagram – Multi-Drop

Cables RS485 Communication –

Twisted, Shielded pair ONLY.

Power and 4..20 – 4 wire Shielded Cable

24 VDC Power Supply NOT LOOP POWERED

Wiring Diagram Multi-Drop System – Daisy Chain ONLY

Up to 64 scanners on the same bus.

120 Ohm Resistor – every system must have 2 resistors of 120 Ohm in both ends of the chain


Site Preparations & Requirements Wiring Diagram

– Single unit with a 3DLinkPro and HART


Preparing the 3DLevelScanner

To view steps for preparing the device for mounting 3DLevelScanner2 - click here.

Make sure that the following is ready on site: Mounting location ready (200mm/8” wide). RS485 Twisted Cable (Optional)


Startup

Use the Startup Checklist to verify the installation

The technician should follow the checklist in the COI form.


Recommended Tools

Description

The site application documents, including the Silo drawings.

Large Phillips screwdriver (2x100).

Medium Phillips screwdriver (1x100).

Set of small precision screwdrivers (for the green connectors).

13” wrench.

Allen Key #4 (preferably with a handle).

Large adjustable wrench 18”.

Stanley knife.

Cutter.

Pointed pliers.

Insulating tape.

* Laser measurement device (or other device to ensure correct positioning and distance to the material).

PC/Laptop.

USB HART modem.

Software drivers for the HART modem.

RS485 to USB converter

Software drivers for the RS485 converter

120 Ohm and 250 Ohm resistors (for Communication usage)



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Site Preparation & Scanner Location

Location, location, location!!


Installation Procedure


Pre PO Procedure


Installation Preparation – AAF

AAF – Application Approval Form. Go/No Go – Simplify the approving procedure of

new applications. Provides basic understanding of customer’s

expectations from the 3dlevelscanner. Helps in deciding which product best fit the

application (S/M/MV/MVL). To better understand the application, it is

recommended to request a detailed silo drawing. To view the AAF – click here.


Installation Preparation - IPF

IPF – Installation Preparation Form. To be filled after an order has been made. Main Objective – Maximum information before

shipping & installing the 3DLevelScanner. More information needed:

Detailed drawing of vessel is mandatory at this stage.

Drawing of 3DLevelScaner's Location – to verify that APM’s positioning guidelines are applied

To view the IPF – click here


Installation Preparation

Scanner Locator

Use the Scanner Locator For Optimal Mounting Location

Selection.• Suggest a location according to this IPF


Modem Wizard

Modem Wizard is your tool to check the 3DLinkPro and the connectivity to the internet via GPRS. See manual.



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System Calibration

Do it right the first time


3DLevelManager

The 3DLevelManager software is the configuration tool developed by APM to configure the 3DLevelScanner for every application approved by APM’s customer support.

Also used to view the results by the customer on site.


3DLevelManager Main Screen – Technician Mode


3DLevelManager Connecting to the 3Dlevel Scanner

To get connected to the 3DLevelScanner, go to “Device Manually Connect”

Select the connection Method For direct connection (RS485 or HART), select the

serial COM port that holds the modem/converter. In the polling address list select the polling address of

the 3DLevelScanner. If there is more than one 3DLevelScanner on the same line (Multi drop), choose multiple.

Select “Verbose” in the communication log field Click “Connect”


3DLevelManager Configuring the 3DLevelScanner - Update Firmware

To update the firmware of the 3DLevel Scanner, go to “Device Update Firmware”

Click on the browse button “…” Select latest firmware file (*.ldr) Click “Start Update” Wait until the update is

complete. Do not close the software or

disconnect from the 3DLevelScanner while updating the firmware.

Note: Always make sure, prior to configuring the 3DLevel Scanner, that the latest firmware version is installed in the 3DLevel Scanner. The latest firmware version available on the website.


3DLevelManager Configuring the 3DLevelScanner – Reset to Factory Settings

To Reset to factory settings go to “Device Advanced Configurations”

Click on “Reset to Factory Settings”

Click “Yes” On the first message that appears

Click “OK” On the first message that appears

Close the window and Reconnect to the scanner.

Note: Reset to Factory Settings is Mandatory after firmware update.


3DLevelManager Configuration Wizard – Step 1

To open the configuration wizard go to “Tools Configuration Wizard”

Set Device Tag Name Select Distance Units (m/ft) Select Temperature units

(Celsius/Fahrenheit) Click Next



Select “Custom” Configure silo shape according

to the IPF and silo drawings (See possible shapes below.

Click Next


3DLevelManager Configuration Wizard – Step 3 to 6

Step 3 – Set device mounting position on silo’s top

Step 4 – Set Horizontal Angle

Step 5 – Set filling points Step 6 – Set empting

points Click Next



Select Media type (Transmission Frequency)

Set Process Condition (Usually set to Standard)

Set Empty calibration distance (From Flange)

Set Full Calibration distance (From Flange)

Set Filling/Emptying Rates Set Max. Capacity.



Note: Click on upload all to apply the settings to the 3DLevelScanner. You may also click OK and yes to apply the settings.


3DLevelManager Additional Settings Set Output Dumping Time Set Steepest Material Slope Map False Echoes Upload all – to apply

changes into the 3DLevelScanner


3DLevelManager Advanced Configurations

Mechanics Type: I – 3DLevelScanner I II – 3DLevelScanner II

Activate Extrapolation – used in MV license for mathematically enhanced 3D image. Inactive by default

False Echo Sensitivity – Ratio between the mapped false echo and the true echo.

Top Dead Band : Discard – don’t measure above

Full Calibration line. Don’t Discard – Measure above

Full Calibration line. Restrain Coefficient - Defines

preference of an echoes to between every pair of echoes (along the grades graph) above the steepest material slope.

Window Size – Size of window around the group of chosen echoes.


3DLevelManager Advanced Configurations – Contd’

CFAR sensitivity – Control the CFAR (automatic threshold) sensitivity above the noise (default 10 db).

Good SNR [db]- The threshold of the good SNR. Above this level, the sensor increases its measurement speed.

Minimal SNR [dB] — The lower SNR threshold. Below this level the sensor does not measure and the reading stays stable.

Reset to factory settings – recommended after firmware update.

Note: to apply changes go to “device upload all”


3DLevelManager Advanced Configurations – Contd’

Auto False Echoes Recognition – Ratio between the automatic false echoes and the true echoes.

Note: to apply changes go to “device upload all”


3DLevelManager Grades Analysis

Shows the Echoes Map. X axis – Distance. Y axis – Power level. The example below shows an echo returned

from a distance of 23 feet.


3DLevelManager Log File

In the log file you can view the history of: Distance Volume SNR Temperature

The 3DLevelManager is collecting and storing the information as long as it is connected to a scanner.


3DLevelManager Visual Mapping (MV only)

To view the 3D imaging of the surface area click “viewVisual Mapping” You may switch Zoomed in/out views by clicking on the “Switch Views” menu.


3DLevelManager Viewer Mode

Designed to the use of untrained personal.

All configuration abilities are disabled.

The password to switch back to technician mode: “techAPM”


Reports



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Website

www.apm-solutions.com


Distributors Zone

It is highly recommended to visit APM’s distributors' zone at least twice a month where you will find: Marketing material Latest announcements Latest software and firmware Guides and training materials FAQ’s and more Go to http://www.apm-solutions.com/SiteFiles/1/4/12075.asp



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And remember:practice makes perfect

Thank You!

APM Customer Support Technical Training

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