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DPW400 SeriesUSER GUIDE

GSM VERSION

Covering the operation of the following products:

♦ DPW421 Dual Channel, Single Display.

♦ DPW422 Dual Channel, Dual Display.

♦ DPW424 Dual Channel, Quad Display.

♦ DPA410 G.P.S. Service Module.

♦ DPA420 Local Area Network Service Module.

♦ DPA430 2 Channel 4

♦ DPA910 2 Channel Alarm Relay Card.

♦ DPA940 2 Channel Relay Isolation Card.

♦ DPA950 2 Channel Galvanic Isolation Card.

♦ DPA975 Single Channel 4

ATAONLINE LLC OTTAGE ST. BERKELEY HEIGHTS NJ 07922 USA

HONE: 908-464-2646 FAX: 908-464-3891 WWW.DATAONLINELLC.COM

INSTALLATIONREV 3.023

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CUSTOMER SERVICE & TECHNICAL SUPPORT CENTRE ON: M2M-TICKE(ET) OR 1-866-626-8425

DPW400 Series USER GUIDE

GSM VERSION

Covering the operation of the following products:

DPW421 Dual Channel, Single Display.

DPW422 Dual Channel, Dual Display.

Channel, Quad Display.

DPA410 G.P.S. Service Module.

DPA420 Local Area Network Service Module.

DPA430 2 Channel 4-20mA Expansion Card.

DPA910 2 Channel Alarm Relay Card.

DPA940 2 Channel Relay Isolation Card.

DPA950 2 Channel Galvanic Isolation Card.

DPA975 Single Channel 4-20mA Signal Output Card.

INSTALLATION GUIDE 3.0 NOVEMBER 2009

20mA Signal Output Card.

DATAONLINE LLC 10 COTTAGE ST. BERKELEY HEIGHTS NJ 07922 USA PHONE: 908-464-2646 FAX: 908-464-3891 WEB: WWW.DATAONLINELLC.COM

INSTALLATION GUIDE REV 3.0 23

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CONTACT THE DATAONLINE CUSTOMER SERVICE & TECHNICAL SUPPORT CENTRE ON: 1-866-M2M-TICKE(ET) OR 1-866-626-8425

DPW400 SERIES

PRODUCT RANGE

OVERVIEW



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PRODUCT RANGE OVERVIEW The DPW400 (GSM) series of products provide a four channel wireless telemetry solution utilising the GSM Wide Area Communications network. When fitted with the Motorola g24 Data Module and equipped with a suitable SIM card, it will automatically operate on GSM networks at 850MHz and 1900MHz (within the U.S.A.) or at 900MHz and 1800MHz (outside of the U.S.A.). There are three basic variants of this product, as described below:

DPW421 Dual Channel, Single Display A dual channel device, fitted with just a single 6 digit numeric display, thus allowing two tank parameters to be monitored, but only one of the parameters may be displayed. The operation of this unit is initially limited to single channel operation, but the second channel may be remotely enabled, as and when it is required.

DPW422 Dual Channel, Dual Display A dual channel device, fitted with a pair of 6 digit numeric displays, thus allowing two tank parameters to be monitored and displayed. The operation of this unit is initially configured for dual channel operation. However with the addition of a DPA430 2 channel 4-20mA analogue input expansion card its operation can be upgraded to allow it to monitor up to 4 tank parameters, whilst only 2 tank parameters may actually be displayed. Alternatively, with the addition of a DPA420 Local Area Network service module its operation can again be upgraded to allow it to monitor up to 4 tank parameters, some or all of which may be supplied by a remote DPR400 series unit. Again only two tank parameters may actually be displayed.

DPW424 Dual Channel, Quad Display A dual channel device, fitted with four 6 digit numeric displays, thus allowing two tank parameters to be monitored, and displayed. The operation of this unit is initially configured for dual channel operation. However with the addition of a DPA430 2 channel 4-20mA analogue input expansion card its operation can be upgraded to allow it to monitor and display up to 4 tank parameters. Alternatively, with the addition of a DPA420 Local Area Network service module its operation can again be upgraded to allow it to monitor and display up to 4 tank parameters, some or all of which may be supplied by a remote DPR400 series unit.

All of the above DPW400 series products may be further enhanced to include G.P.S. location determination with the addition of the DPA410 GPS module. See below for further details.



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ASSOCIATED PRODUCTS The DPW400 Series product range is modular and many different product variants with a wide range of capabilities may be built from the three basic products described above. The various expansion cards, modules and power supplies available are described below.

WIRELESS SERVICE EXPANSION MODULES There are two wireless service expansion modules available for use with the DPW400 series product range. These modules plug into the connector marked “XBEE1” located adjacent to the connector marker “PROG” on the inside of the DPW400 series unit lid assembly. See the appropriate chapter within this manual for complete details of the fitment, configuration and use of each of these wireless service expansion modules.

DPA410 – G.P.S. Service Module. This module provides the DPW400 series unit with a G.P.S. location determination facility. This in turn allows the current location of the unit to be displayed and tracked from the “Google Maps” interface on the unit’s web page.

DPA420 – Local Area Network Service Module. This module provides the DPW400 series unit with a Local Area Network capability which allows data to be retrieved from up to four remote DPR400 series units. There are a number of benefits to this arrangement, such as extension of service into areas which have poor GSM network coverage, and the “concentration” of data from multiple tanks onto a single GSM connection, to name but two.

GENERAL SERVICE EXPANSION CARDS There are five general service expansion cards available for use with the DPW400 series product range. These modules plug into one or more of the connectors marked “ALARM”, “EXP1”, “INPUT1”, “INPUT2” and “TEST” on the inside of the DPW400 series unit lid assembly. See the appropriate chapter within this manual for complete details of the fitment, configuration and use of each of these general service expansion cards.

DPA430 – 2 Channel 4-20mA Analogue Expansion Card. This card provides the DPW400 series unit with 2 additional hardwired 4-20mA analogue input channels. In this way the DPW422 or DPW424 versions of the basic unit may be expanded from 2 to 4 hardwired 4-20mA channels. This expansion card makes connections to the “ALARM” and “EXP1” connectors on the DPW400 series unit lid assembly.

DPA910 – 2 Channel Alarm Relay Card. This card provides the DPW400 series unit with a local alarm capability. This feature is useful when a local “alarm” beacon or sounder is required at the tank, to indicate a low or high tank level or pressure for example.



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This expansion card makes a single connection to the “ALARM” connector on the DPW400 series unit lid assembly.

DPA940 – 2 Channel Relay Isolation Card. This card provides the DPW400 series unit with inter-channel electrical isolation on the two 4-20mA analogue inputs. This feature is useful when two 4-20mA signals from an external system are connected to the unit (the external system would provide the loop power under these conditions). Without the Relay Isolation card fitted, the negative side of the two 4-20mA loops would be connected together, and also connected to the DPW400 series unit ground. In many cases this would cause one or both of the 4-20mA signals to be disturbed, leading to incorrect readings. This expansion card makes connections to the “INPUT1”, “INPUT2” and “TEST” connectors on the DPW400 series unit lid assembly.

DPA950 – 2 Channel Galvanic Isolation Card. This card provides the DPW400 series unit with both inter-channel, and ground reference electrical isolation in a similar way to the DPA940 card described above. The advantage of the DPW950 unit is that it provides complete galvanic isolation between channels and the ground reference of the DPW400 series unit. This expansion card makes connections to the “INPUT1”, “INPUT2” and “TEST” connectors on the DPW400 series unit lid assembly.

DPA975 – Single Channel 4-20mA Signal Output Card. This card provides the DPW400 series unit with the capability to output a single 4-20mA signal which is a “spanned” version of the 4-20mA signal on channel 1 of the unit. This feature is useful if a local control system requires a 4-20mA signal which represents 0-30 tonnes of product for example, derived from a sensor which is spanned 0-600”W.C. In this example 0-30tonnes may only represent a small proportion of the sensor span. This expansion card makes a connection to the “ALARM” connector on the DPW400 series unit lid assembly.

POWER SUPPLIES DPA960 – 110V a.c. Power Supply. This unit allows the Solar Panel to be replaced by a 110V a.c. (100V to 125V) mains power source.

DPA961 – 230V a.c. Power Supply. This unit allows the Solar Panel to be replaced by a 230V a.c. (200V to 250V) mains power source.

DPA964-12 – 12V d.c. Power Supply. This unit allows the Solar Panel to be replaced by a 12V d.c. (10V to 15V) power source.

DPA964-24 – 24V d.c. Power Supply.



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This unit allows the Solar Panel to be replaced by a 24V d.c. (20V to 30V) power source.

DPA965 – Wide Input Range a.c. Heated Power Supply. This unit allows the Solar Panel to be replaced by an a.c. (85V to 265V) power source. It also has a thermostatically controlled heater, which maintains a minimum temperature of 5 Degrees C within the DPW400 series unit’s cabinet. This product is designed to be used where the unit is operated in an extremely cold environment, where the operation of the LCD displays, and the “gore-tex” cabinet breather would be compromised by the cold conditions. Operating the unit without this Power Supply at ambient temperatures below –5 Degrees F (–20 Deg C) can lead to very slow LCD display operation, and may lead to condensation (frost) build up within the cabinet.

ALLOWED COMBINATIONS OF EXPANSION CARDS AND MODULES MODULE DPA410 DPA420 DPA430 DPA910 DPA940 DPA950 DPA975

DPA410

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DPA420

�

� � � � � �

DPA430

� �

� � � � �

DPA910

� �

� � � � �

DPA940

� �

� � � � �

DPA950

� �

� � � � �

DPA975

� �

� � � � �



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4-20mA SENSOR INTERFACE The units 4-20mA sensor interface is programmable, allowing it to provide a loop excitation voltage of either 15V or 23V d.c. The default setting being 15V. The parameter which controls the “Loop Voltage” may be programmed either locally (see Programming Guide), or remotely from the Tank Graph Web page (see Web Configuration Guide) and is independently configurable for each active channel. The two additional hardwired 4-20mA sensor interfaces on the DPA430 expansion card have a fixed loop voltage of 18V, and so the programmed setting for loop voltage on channels 3 and 4 is ignored in this scenario. The amount of time that the sensor remains energized before a 4-20mA loop measurement is taken is also programmable between ¼ of a second and 1 minute. The default setting being 2 seconds. The parameter which controls the “Transducer Wake Up Wait” may be programmed either locally (see Programming Guide), or remotely from the Tank Graph Web page (see Web Configuration Guide) and is independently configurable for each active channel. NOTE: It is good practice to use the lowest 4-20mA loop voltage and the shortest sensor power up wait that will work reliably with the sensor you plan to use. The use of excessive loop voltages and long power up waits present a significant drain on the systems power resources.

CONNECTING TO A TWO-WIRE 4-20mA SENSOR Connect the sensor 4-20mA loop positive connection to the "+VE" terminal on the 3 way connector marked "INPUT 1" ("INPUT 2" for the second channel etc). Connect the sensor 4-20mA loop return connection to the "IP1" (or "IP2" for the second channel etc) terminal on the 3 way connector marked "INPUT 1" ("INPUT 2" for the second channel, etc).

CONNECTING TO AN EXTERNAL 4-20mA SIGNAL Connect the 4-20mA signal positive to the "IP1" (or "IP2" for the second channel etc) terminal on the 3 way connector marked "INPUT 1" ("INPUT 2" for the second channel etc). Connect the 4-20mA signal negative to the "GND" terminal on the 2 way connector marked "TEST" (“GND” on “INPUT3” and “INPUT4” for channels 3&4). In this connection mode, the unit adds a 100 Ohm burden into each 4-20mA loop. You must ensure that there is sufficient voltage “headroom” in the equipment powering the loop to cope with an additional voltage drop of 2.0V at 20mA. NOTE: As you can see, in this scenario the negative leg of all of the 4-20mA loops involved are effectively joined together at the “GND” connection. Unless all of the 4-20mA loops are completely isolated from each other, and also from any external ground references this setup will not work correctly !! In order to overcome this potential problem there are two Signal Isolation Cards which effectively isolate all of the channels from one another, and in the case of the galvanic version of the isolation card isolation



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is provided from the system ground too.

FITTING AND CONNECTING A DPA940 RELAY SIGNAL ISOLATION CARD The DPA940 Relay Isolation Card is physically fitted to the 4 mounting holes at the bottom of the lid PCB, adjacent to the 4-20mA loop connectors marked “INPUT1” and “INPUT2”. Clip the four pillars on the DPA940 card into the four holes in the lid PCB, and then connect the flying leads from the DPA940 connector marked “DATA” into the lid PCB connectors marked “TEST”, “INPUT1” and “INPUT2”.

In order to make the DPW400 series unit aware of the fact that a DPA940 Relay Isolation card has been fitted, the “Expansion Card Selection” parameter must be set to “0”, (see Programming Guide for further details). Wiring from the 4-20mA loops may then be terminated at the DPA940 card connectors marked “LOOP1” and “LOOP2”. If a 4-20mA signal directly from an on-site control system is to be connected, then the 4-20mA loops are simply terminated at the “+VE1” and “-VE1” terminals of the “LOOP1” connector or the “+VE2” and “-VE2” terminals of the “LOOP2” connector. The positive leg of the 4-20mA loop should be connected to the appropriate “+VE” terminal and the negative leg to the “-VE” terminal.

Alternatively, if the internal Differential Pressure and/or Pressure sensors are to be used in conjunction with the DPA940 Relay Isolation card, but an external loop power supply is to be employed, then the wiring should be performed as follows. The positive leg of the loop power supply, and the positive wire to the Differential Pressure or Pressure sensor should be connected together in the appropriate “TIE” terminal. The negative leg of the loop power supply should be connected to the appropriate ”-VE” terminal, and the negative wire to the Differential Pressure or Pressure sensor should be connected to the appropriate “+VE” terminal.

FITTING AND CONNECTING A DPA950 GALVANIC SIGNAL ISOLATION CARD The DPA950 Relay Isolation Card is physically fitted to the 4 mounting holes at the bottom of the lid PCB, adjacent to the 4-20mA loop connectors marked “INPUT1” and “INPUT2”.

NOTE: Before the DPA950 Galvanic Isolation Card may be fitted, two resistors must be removed from the DPW400 series lid PCB. These resistors are the two 100ohm precision measurement resistors marked R15 and R18. Failure to remove these components will lead to erroneous readings on the affected channels. Clip the four pillars on the DPA950 card into the four holes in the lid PCB, and then connect the flying leads from the DPA950 connector marked “DATA” into the lid PCB connectors marked “TEST”, “INPUT1” and “INPUT2”.



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In order to make the DPW400 series unit aware of the fact that a DPA950 Relay Isolation card has been fitted, the “Expansion Card Selection” parameter must be set to “0”, (see Programming Guide for further details).

Wiring from the 4-20mA loops may then be terminated at the DPA950 card connectors marked “LOOP1” and “LOOP2”. If a 4-20mA signal directly from an on-site control system is to be connected, then the 4-20mA loops are simply terminated at the “+VE1” and “-VE1” terminals of the “LOOP1” connector or the “+VE2” and “-VE2” terminals of the “LOOP2” connector. The positive leg of the 4-20mA loop should be connected to the appropriate “+VE” terminal and the negative leg to the “-VE” terminal.

Alternatively, if the internal Differential Pressure and/or Pressure sensors are to be used in conjunction with the DPA950 Galvanic Isolation card, but an external loop power supply is to be employed then the wiring should be performed as follows. The positive leg of the loop power supply, and the positive wire to the Differential Pressure or Pressure sensor should be connected together in the appropriate “TIE” terminal. The negative leg of the loop power supply should be connected to the appropriate ”-VE” terminal, and the negative wire to the Differential Pressure or Pressure sensor should be connected to the appropriate “+VE” terminal.

FITTING A DPA430 4-20mA INPUT EXPANSION CARD The DPA430 4-20mA Input Expansion Card provides an additional two channels 4-20mA input capability in addition to the standard 2 channels provided on a DPW400 series unit, taking the total number of 4-20mA Analogue Inputs up to 4.

DPA430 expansion card is physically fitted to the 4 mounting holes at the bottom of the lid PCB, adjacent to the 4-20mA loop connectors marked “INPUT1” and “INPUT2”. Clip the four pillars on the DPA430 card into the four holes in the lid PCB, and then connect the flying lead from the DPA430 connector marked “ALARM” into the lid PCB connector also marked “ALARM”. Also connect the DPA430 connector marked “EXP1” into the lid PCB connector marked “EXP1”.

In order to make the DPW400 series unit aware of the fact that a DPA430 Input Expansion Card has been fitted, the “Expansion Card Selection” parameter must be set to “3”, (see Programming Guide for further details).

DATA LOGGING The period of time between 4-20mA loop readings is programmable between 15 minutes and 24 hours. The default setting being hourly. The parameter which controls the “Logging Period” may be programmed either locally (see Programming Guide), or remotely from the Tank Graph Web page (see Web Configuration Guide) and is independently configurable for each active channel. When a reading falls due, the appropriate 4-20mA loop is energized with the programmable loop voltage of either 15V or 23V. Following the programmable "Transducer Wake Up Wait" time, a loop current measurement is taken.



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As soon as this process is complete, the loop power is turned off again, and the appropriate display will be updated with the new reading. The measurement is also entered into the appropriate channel’s data logging buffer, along with a time stamp relating to the time of the reading. The log buffer consists of a 27 reading deep circular buffer for each of the four channels on the DPW400 series unit. As the 4-20mA loop is never permanently powered, it is often difficult or even impossible to configure a programmable sensor during the short power up delay of a normal reading cycle. A better way of programming or configuring such measuring instruments, is provided when the unit is used in Programming Mode. Each 4-20mA loop may be powered individually for extended periods of time in order to facilitate the configuration of devices such as loop powered programmable Ultrasonic Sensors. See the DPW400 series Programming Guide for further details.

REGULAR DATA TRANSMISSION The period of time between data transmissions is programmable, between 15 minutes and 24 hours. The default setting being every 12 hours. The parameter which controls the “Transmit Period” may be programmed either locally (see Programming Guide), or remotely from the Tank Graph Web page (see Web Configuration Guide) and is independently configurable for each active channel. A further programmable parameter is used to set the “Primary Transmission Hour” for data transmissions. The first data transmission of each day will occur at this hour, followed by subsequent transmission at the programmed interval. The default setting being 3 (i.e. 03:00 each day). The parameter which controls the primary transmission hour may be programmed either locally (see Programming Guide), or remotely from the Tank Graph Web page (see Web Configuration Guide) and is independently configurable for each active channel. In order to make the data transmission regime even more flexible, it is possible to limit the number of data transmissions that occur in each 24 hour period to between 2 and 14 transmissions, or this feature may be disabled completely so that an unlimited number of transmissions are allowed. The default setting is an unlimited data transmission regime. The parameter which controls the “Maximum Transmissions Per Day” may be programmed either locally (see Programming Guide), or remotely from the Tank Graph Web page (see Web Configuration Guide) and is independently configurable for each active channel. Using a combination of these three parameters it is possible to configure a regime which delivers data in a timely fashion, with the minimum number of “wasted” transmissions. For example it is possible to configure the unit to deliver data every 3 hours during a 12 hour working shift, beginning at 06:00 and ending at 18:00 each day. In this way the associated web page will contain data that is no more than 3 hours old during the working day, whilst using just 4 data transmissions in order to keep communications costs to an absolute minimum.



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UNSCHEDULED DATA TRANSMISSIONS There are 8 programmable low or high level alarm thresholds for each of the four channels on the DPW400 series products. Each alarm threshold setting has an associated “direction” setting which determines if the alarm is configured as a “rising” or a “falling” event. Each time that a new 4-20mA loop reading is performed, the signal level is compared with each of these thresholds in turn, and a “Level Alarm” transmission will take place if the level has fallen below, (or optionally risen above) the next applicable threshold. The signal level must then rise to a half a percent above that threshold, (or optionally half a percent below the threshold) for two or more reading periods before that particular threshold is re-armed. This is a measure to prevent the continuous transmission of level alarm messages when the signal level hovers at or around a level alarm threshold. Each channel of the DPW400 series unit has 8 programmable alarm thresholds, and “direction” controls. This arrangement makes it possible to have high level alarms for tank “over pressure” or “over fill”, as well as the more normal “low tank level” and “critical tank level” alarms for example. These “Channel Alarm Level” settings may be programmed either locally (see Programming Guide), or remotely from the Tank Graph Web page (see Web Configuration Guide) and are independently configurable for each active channel.

DATA POLLING The DPW400 series product range normally operates with its Motorola g24 GSM modem powered down in order to reduce the operating current to a level compatible with its ultra low power regime. It is therefore not normally possible to request a tank level update remotely from the tank web page. Such a “poll request” would only be received when the DPW400 series unit next powered the GSM modem in order to perform a regular data transmission, making the poll response “late” and completely redundant. In order to facilitate “Data Polling” where this feature is a requirement, a number of polling modes are available which give additional flexibility at the expense of increased power consumption. These “Pollable Mode Flag” may be programmed either locally (see Programming Guide), or remotely from the Tank Graph Web page (see Web Configuration Guide). The various modes of “Data Polling” are described below:

NO POLLING MODE This poll mode causes the DPW400 Series unit to disable polling completely. A “Pollable Mode Flag” setting of “0” is required to enable this mode of operation (default mode).

SLOW POLL MODE This poll mode causes the DPW400 Series unit to power the Motorola g24 GSM modem for a short period of time following each 4-20mA loop measurement. No data transmission is performed, but any “poll



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request” messages that are pending will be received and a poll response transmission performed in order to update the appropriate tank web page. In this mode a response to a "poll request" will normally be received within one 4-20mA loop reading period. In a typical application this could be 1 hour. This mode of operation is allowed when the unit is Solar or Mains powered, but not when the power source is a non-rechargeable Alkaline or Lithium battery pack. A “Pollable Mode Flag” setting of “1” is required to enable this mode of operation.

FAST POLL MODE This poll mode causes the DPW400 Series unit to power the Motorola g24 GSM modem permanently, as long as the battery voltage remains above the programmable “low battery threshold”. Every 5 minutes a check is made for inbound poll request or configuration updates, and a an appropriate transmission is performed in response. In this mode a response to a "poll request" will normally be received within around 5 minutes depending upon the delays experienced sending data across the GSM network. This mode of operation is allowed when the unit is Solar or Mains powered, but not when the power source is a non-rechargeable Alkaline or Lithium battery pack. NOTE: If a Solar Panel power source is used the installation must be “optimal” otherwise battery life will be reduced considerably. Each time that a periodic or alarm data transmission occurs, the GSM Modem is powered down upon completion of the data transaction. This is a deliberate act, and is used to ensure that the modem cannot “hang” in a way which would block further communication with the unit. The GSM Modem is powered up again within a further 5 minute period. A “Pollable Mode Flag” setting of “2” is required to enable this mode of operation. NOTE: Data Polling can lead to excessive power drain and increased communications costs. Full consideration should be given to the effects of using these features.

SLOW NETWORK POLL MODE This poll mode causes the DPW400 Series unit to power the GSM Modem for a complete hour at a programmable time of the day, in order to receive any pending poll requests or configuration updates. This mode of operation was specifically designed to deal with GSM networks where the delivery of incoming messages is slow and unpredictable, making it difficult to perform configuration updates remotely. The “Slow Network Poll Hour” setting may be programmed either locally (see Programming Guide), or remotely from the Tank Graph Web page (see Web Configuration Guide),such that the unit may be polled for new data, or its configuration updated quickly, and securely at a known time each day.



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As the modem is powered up for a whole hour at a known time, it is also possible to communicate directly with the unit at this time. A “Pollable Mode Flag” setting of “3” is required to enable this mode of operation.

FILL MODE “Fill Mode” is designed to facilitate the more frequent display updates required during a tank filling exercise, such that the operator can judge when the tank is approaching full without the need to refer to any other instrumentation. Additionally, it provides a trouble free mechanism for triggering the transmission of an end of fill data transmission when the fill cycle is complete, in order to facilitate a timely web page update reflecting the recent tank filling event. The duration of the "Fill Cycle", and the requirement for a "Fill Alarm" transmission at the end of the fill cycle may be programmed independently for the four channels either locally (see Programming Guide), or remotely from the Tank Graph Web page (see Web Configuration Guide). NOTE: The Fill Mode duration should be programmed to be no longer than the time taken to fill the tank being monitored. The use of excessive fill mode duration’s present a significant drain on the systems power resources. Pressing and holding the “FILL” button, until “FILL” appears on the display(s) will initiate a fill cycle on all active channels. The display(s) will blink intermittently to indicate that a fill cycle is in progress, and the value(s) will change in accordance with a changing tank level. If only one tank is being actively filled on a unit monitoring two or more separate tanks, then the tank with a static level will discontinue “Fill Mode” automatically after 15 minutes. To remain in “Fill Mode” the tank level must rise by a half of one percent of span in the first 15 minutes. At the end of the “Fill Cycle” if “Fill Alarm” transmissions are enabled, an assessment of the change in level within the tank will be performed. A fill event will be deemed to have occurred if the level has risen by more than two percent of span. If this is the case then a data transmission will be scheduled following the next 4-20mA loop reading on that channel. The display update rate will return to the normal programmed rate at the end of the fill cycle.

LOCAL DISPLAY INDICATION The display(s) fitted to the DPW400 Series unit are used to show the current product level, pressure or some other parameter related to the tank, or system being monitored. The numeric value displayed, is controlled by three programmable parameters which set the “Sensor Zero”, “Sensor Span” and “Number Of Decimal Places” for the displayed data. These parameters may be programmed either locally (see Programming Guide), or remotely from the



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Tank Graph Web page (see Web Configuration Guide) and are independently configurable for each active channel. The zero adjustment is used to compensate for a signal zero offset which could place the zero reading point at a current slightly greater than 4mA. The span control sets the value or tank level displayed when a 20mA signal is presented to the DPW400 Series unit (i.e. the span of the instrument, regardless of the fact that the signal may never actually reach this level). The number of Decimal Places is adjustable between 0 and 5, and simply illuminates the appropriate decimal point. For this reason the span must be multiplied by an appropriate power of 10 in order that the scaling remains correct. Currently the display value calculations will only operate correctly where there is a linear relationship between the measured sensor current and volume or other display parameter. This makes it impossible for the unit to accurately display the level in a horizontal mounted cylindrical tank, but a vertical cylinder will operate correctly.

OPTIONAL DISPLAY BACKLIGHT The display back-light is a high consumer of battery power. For this reason the back-light is disabled if the unit is operating from a Non-Rechargeable (Alkaline or Lithium) battery pack. If a Mains Supply is used then the back-light is enabled as long as the night time battery voltage remains above the low battery threshold. If a Solar Panel is used then the back-light will only work when ambient light levels are subdued, and the night time battery voltage remains above the low battery threshold. There is a further description of the operation of the backlight in the “User Interface” section of this manual.

ALARM RELAY OUTPUT The DPA910 Alarm Relay Card provides the unit with a local alarm signalling capability. This feature is useful when a “local alarm” beacon or sounder is required at the tank, to indicate a low or high tank level or pressure for example. There are two alarm relays on the DPA910 Alarm Relay card, and both have normally open and normally closed contacts. The two alarm relays can be freely allocated to any of the 4 channels of the DPW400 series unit. It is also possible to allocate both alarm relays to a single DPW400 unit channel, operating at different levels for example. Allocation of alarm relays to DPW400 unit channels is performed via the “Alarm Relay Channel Allocation” command (see Programming Guide for further details). Each channel of the DPW400 series unit has a pair of programmable alarm thresholds, and “direction” controls. This arrangement makes it possible to have a high level alarm for tank “over pressure”, as well as the more normal “low tank level” alarm control for example.



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These “Channel Alarm Level” settings may be programmed either locally (see Programming Guide), or remotely from the Tank Graph Web page (see Web Configuration Guide) and are independently configurable for each active channel.

INSTALLING THE ALARM RELAY CARD The DPA910 Alarm Relay Card is physically fitted to the 4 mounting holes at the bottom of the lid PCB, adjacent to the 4-20mA loop connectors marked “INPUT1” and “INPUT2”. Clip the four pillars on the DPA910 card into the four holes in the lid PCB, and then connect the flying lead from the DPA910 connector marked “DATAPORT” into the lid PCB connector marked “ALARM”.

In order to make the DPW400 series unit aware of the fact that a DPA910 Alarm Relay card has been fitted, the “Expansion Card Selection” parameter must be set to “1”, (see Programming Guide for further details).

WIRING TO THE ALARM RELAY CARD Field wiring to the DPA910 Alarm Relay Card is terminated at the 6 way screw terminal block marked “RL1” and “RL2”. The top three terminals adjacent to the “RL1” marking relate to channel 1, and the bottom three terminals adjacent to the “RL2” marking relate to channel 2 of the device. On each channel the three terminals are designated “COM” (common terminal), “N/O” (normally open terminal) and “N/C” (normally closed terminal). If a connection is made to “COM” and “N/C” then the contact will normally be closed, and will open when the alarm condition exits. A connection made to “COM” and “N/O” will normally be open, and will close when the alarm condition exits.

4-20mA SIGNAL OUTPUT This card provides the DPW400 series unit with the capability to output a single 4-20mA signal which is a “spanned” version of the 4-20mA signal present on channel 1 of the unit. This feature is useful if a local control system requires a 4-20mA signal which represents 0-30 tonnes of product for example, derived from a sensor which is spanned 0-600”W.C. In this example 0-30tonnes may only represent a small proportion of the sensor span. The DPA975 card output current is automatically adjusted each time that a new reading is taken on channel 1 of the DPW400 series unit. The output current is re-calculated based upon three pieces of information. The first of these being the value currently shown on the display associated with channel 1 of the DPW400 series unit. The second is the user programmable parameter “Analogue Out 4mA Level (Zero)” which defines the display value associated with an output current of 4mA. The final user programmable parameter “Analogue Out 20mA Level (Span)” defines the display value which is to be associated with an output current of 20mA.



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These parameters may currently only be adjusted locally by making a connection to the unit from a P.C. in Programming Mode (see Programming Guide for further details).

INSTALLING THE 4-20mA SIGNAL OUTPUT CARD The DPA975 4-20mA Signal Output Card is physically fitted to the 4 mounting holes at the bottom of the lid PCB, adjacent to the 4-20mA loop connectors marked “INPUT1” and “INPUT2”. Clip the four pillars on the DPA975 card into the four holes in the lid PCB, and then connect the flying lead from the DPA975 connector marked “ALARM” into the lid PCB connector also marked “ALARM”.

In order to make the DPW400 series unit aware of the fact that a DPA975 4-20mA Signal Output card has been fitted, the “Expansion Card Selection” parameter must be set to “2”, (see Programming Guide for further details).

WIRING TO THE 4-20mA SIGNAL OUTPUT CARD Field wiring to the DPA975 4-20mA Signal Output Card is terminated at the 2 way screw terminal block marked “OUTPUT”. The positive side of the 4-20mA loop output is available at the terminal marked “+VE”, and the negative side is available at the terminal marked “-VE”. When an external system is correctly connected the led marked “LED1” should be constantly illuminated. The 4-20mA loop excitation voltage provided by the DPA975 4-20mA Signal Output Card is 12V, and so the resistance of any device connected to this output must be 500 Ohms or less in order to achieve a full and accurate 4mA to 20mA current swing.

GPS LOCATION DETERMINATION The DPA410 GPS Service Module provides the DPW400 series unit with a G.P.S. location determination facility. This in turn allows the current location of the unit to be displayed and tracked from the “Google Maps” interface on the unit’s web page. The number of GPS “fixes” performed each day, and the timing of these “fixes” is controlled by two programmable parameters. These parameters can currently only be adjusted locally by making a connection to the unit from a P.C. in Programming Mode (see Programming Guide for further details). The period of time between GPS “fixes” is programmable, between 15 minutes and 24 hours. The default setting being every 12 hours. The parameter which controls the period of time between GPS “fixes” is called the “GPS Fix & Transmit Period” (see Programming Guide for further details). A further programmable parameter is used to set the “GPS Fix Hour”. The first GPS “fix” of each day will occur at this hour, followed by subsequent “fixes” at the programmed interval. The default setting being 3 (i.e. 03:00 each day). Following each successful GPS “fix” the new position information will be transmitted back to the tank web



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page, triggering a position update on the “Google Map” interface.

INSTALLING THE GPS SERVICE MODULE The DPA410 GPS Service Module is physically fitted via single mounting hole, and the 8 way connector marked “XBEE1”, adjacent to the programming adapter connector. Align the DPA410 connector with the “XBEE1” connector, making sure that it is not mated 1 pin out of alignment !!!! Push the connector firmly home, and finally click the single mounting pillar into the hole on the lid PCB.

In order to make the DPW400 series unit aware of the fact that a DPA410 GPS Service Module has been fitted, the “Wireless Card Selection” parameter must be set to “2”, (see Programming Guide for further details).

WIRELESS OPERATION WITH DPR400 SERIES UNITS The DPA420 Wireless Network Module provides the DPW400 series unit with a Local Area Network capability which allows data to be retrieved from up to four remote DPR400 series units. In order for data collection from remote DPR400 series unit’s to operate in a controlled manner, an “association” must be formed between the DPW400 series “master” unit and the DPR400 series “remote” unit(s). This “association” can be formed by performing a “TEST” transmission from an unassigned DPR400 series remote unit whilst the DPW400 series master unit is waiting in “SEARCH” mode. In this manner up to four DPR400 series remote units may be individually associated with a single DPW400 series master unit, in combination with normal hard-wired 4-20mA channels if required. The following paragraphs describe in detail the steps required to configure the DPW400 series master and DPR400 series remote units to form a network:

INSTALL THE WIRELESS NETWORK MODULE The DPA420 Wireless Network Module is physically fitted via single mounting hole, and the 8 way connector marked “XBEE1”, adjacent to the programming adapter connector. Align the DPA420 connector with the “XBEE1” connector, making sure that it is not mated 1 pin out of alignment !!!! Push the connector firmly home, and finally click the single mounting pillar into the hole on the lid PCB.

In order to make the DPW400 series unit aware of the fact that a DPA420 Wireless Network Module has been fitted, the “Wireless Card Selection” parameter must be set to “1”, (see Programming Guide for further details).

CONFIGURE THE FREE CHANNELS ON THE DPW400 SERIES MASTER UNIT Before you may associate the DPW400 series remote unit(s) with the DPW400 series master unit, you must configure the appropriate channels on the master as “unused” so that they may later be associated with remote units in “Search Mode”.



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Refer to the User Interface Guide section of this manual for details on how to do this. The section which covers this operation is called “Inputs Mode” and allows the analogue input channels to be viewed and/or reverted to “unused” by the correct use of the two user buttons on the inside of the DPW400 series unit lid marked “CLEAR” and “DEFAULT”.

PREPARE THE DPR400 SERIES UNIT(S) FOR ASSOCIATION Un-associate the DPR400 series remote units from any previous “master” by powering down the DPR400 series unit, and leaving it de-powered until the displays go blank.

At this point the battery may be re-connected, but the “FILL” and “MODE” buttons must be held simultaneously depressed during the power up sequence until “RESET” appears on the display(s). Refer to the DPR400 Series Unit User manual for further details on how to perform this operation.

PERFORM THE ASSOCIATION OF EACH DPR400 SERIES UNIT IN TURN For each channel on each DPW400 series master unit which needs associating with a DPR400 series remote unit you must perform a separate TEST transmission whilst the DPW400 series master is in “Search Mode”. Refer to the User Interface Guide section of this manual for details on how to do this. The section which covers this operation is called “Search Mode”. When a successful association has been performed the ID of the DPR400 series remote unit will be displayed on the DPW400 series master before it exits from “Search Mode” again.

POWER SOURCE CONSIDERATIONS The DPW400 series products can operate with three different power sources. The options are; a non-rechargeable source such as an Alkaline or Lithium Battery Pack, a Solar Charged Lead Acid Battery, or a Mains Charged Lead Acid Battery.

BATTERY CONNECTION DETAILS The Battery Pack must be correctly wired to the four-way connector marked “BATTERY” at the top of the CSI-DP189 PCB according to the battery type. The programmable battery type and low voltage threshold must also be set correctly to ensure that the power control, and charging regimes match that of the battery pack fitted. See the Programming Guide for further details. When a Lead-Acid battery is used, a Solar Panel or Mains Charger must be connected to the connector at the base of the DPW400 Series unit PCB marked “POWER”. The positive connection must be made to the screw terminal marked “+ve” and the negative connection to the one marked “-ve”.

BATTERY CHARGE CONTROL The charge current applied to the lead acid battery is controlled to maximize charging without allowing the battery to be overcharged. If a Mains Power source is fitted, then the battery is charged more gently in order to extend its life, safe in the knowledge that the power source for charging is available for 24 hours each day.



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If a Solar panel is fitted, then the charge control regime is more complex, in order to extract the maximum available energy from the Solar Panel whilst it is available, without damaging the battery. To do this the system looks at day and night time battery voltage, as well as the temperature, and the actual charge current in order to determine a safe charge current.

SYSTEM TIME SYNCHRONIZATION Most functions of the DPW400 series products are time related, and so it will not be a surprise that the system must have some form of internal time base. In order to allow the unit to initially “synchronize” its internal time base, it has the capability to obtain the correct time from the GSM network. In the case of a unit operating on the GSM network this “synchronization” process may also be triggered remotely should it be noticed that the time base has drifted over a number of years. A unit operating on the GSM network will only attempt to re-synchronize its time following a power-up cycle, or when a time update is requested remotely (see Web Configuration Guide). Following a time update the log buffers are cleared of all previously logged data, as the time stamp associated with this data will now be invalid. All periodic tasks are then re-scheduled based upon the new and accurate date and time. It is important to note that the time and date obtained when the re-synchronisation process is performed is “local time”, as seen by the “home” GSM network. That is to say that a unit operating with a U.K. based GSM SIM card, on a U.S. GSM network would have its time base synchronised to U.K. Greenwich Mean Time, and not the time of the local GSM carrier !!

SHIPPING MODE “Shipping Mode” as its name suggests, prepares a unit to be stored or shipped by shutting it down into a low power condition, in which it only consumes an average of 180uA. Furthermore it shuts down all periodic level readings on the 4-20mA loops, and suspends all data transmissions. In practice, a unit should not be allowed to remain in this mode for more than 3 months, without being removed from storage and the battery fully recharged, or replaced in the case of a non-rechargeable battery supply. When a DPW400 series product is placed into “Shipping Mode” the word “ASLEEP” will appear on the display(s) and the unit will appear to be completely inactive. It will not respond to the “FILL” and “MODE” buttons in the normal way. In order to “wake” a unit form “Shipping Mode” the “FILL” button must be pressed and held for 20 seconds or so. Upon “waking” the unit will change the contents of the display(s) as described in the “User Interface Operation” section below.



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PREVENTING MOISTURE INGRESS INTO THE UNIT The DPW400 series products are fitted with a "GoreTex" breather to prevent the build up of moisture within the unit over a period of time. This device acts by allowing moisture to pass through the breather from the inside to the outside as the internal air expands through ambient heating. It will not allow moisture to pass back into the unit as the internal air contracts upon ambient cooling. As such, any accidental moisture ingress is drawn out of the unit over a period of time. To make sure that this process can maintain a "dry" enclosure, the lid must be fitted correctly to ensure that the lid seal is effective. The following steps should be followed to ensure reliable lid sealing: 1) Ensure that all of the internal cabling is routed such that it will not impede the lid from closing fully

without the need to apply excessive pressure. 2) Close the lid down, and ensure that it is fully seated and centrally aligned on the seal. 3) Using a ¼ inch or 6mm Phillips screwdriver, lightly tighten diagonally opposite lid screws. 4) When all 4 lid screws are lightly tightened, proceed to tighten the lid screws, again in diagonally

opposite pairs. Only tighten them "hand tight". Over tightening of the lid screws can cause the lid to be distorted, opening up the seal in the middle of the two long sides. Obviously under tightening will not cause the lid seal to be compressed enough to be effective.



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DPW400 SERIES

PRODUCT RANGE

TECHNICAL

SPECIFICATIONS



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DPW421: Specification Options

Power Source: Solar Panel and 2.5 Ah Sealed Lead Acid Battery

Optional 110V or 240V a.c. or 12V or 24V d.c. supplies.

Supply Voltage: 100V to 125V or 200V to 250V 50-60Hz a.c. 10V to 15V or 20V to 30V d.c

Battery Life: 7 to 10 years typical.

Temperature Range: -20 DegC to +50 Deg C Ambient Temperature.

Enclosure Type: Wall Mount 190mm x 125mm x 178mm.

Enclosure Material: Polycarbonate.

Enclosure Rating: IP67

Clamping Plate: Stainless Steel back-plate 215mm x 315mm x 90mm, including Solar Panel mounting.

Optional Barton compatible mounting bracket.

CE Compliance: EN 50082-2 immunity, EN 55011 emission, EN 61010-1 safety.

LCD Display: One, 6 digit 7 segment LCD displays.

User Buttons: Two, multi-function membrane keys.

Calibration: Pre-calibrated - post calibration available on DataOnline website.

Security: Password protection on all access to DataOnline website.

Analog Input: 2 Analogue Inputs 4-20mA, loop voltage settings of 15V and 24V available.

Memory: 27 data point FIFO buffer per channel.

Remote Reporting: GSM messaging protocol to DataOnline Web Site. Reporting period programmable from once every 15 minutes to once every 24 hours (separately programmable for each channel).

Logging Period: Logging period programmable from once every 15 minutes to once every 24 hours (separately programmable for each channel).

Alarms: Up to 8 set points for low level "early data" trigger alarming. 2 set points for "local" alarming. Tank filling "early data" trigger alarming.

Optional 2 Channel local alarm relay card for low/high level alarming.

Direct Connection: RS232C to P.C. or P.D.A. via DataOnline supplied programming adaptor.

Optional programming adaptor.

Empty Cable Gland: One spare PG11 cable gland included for optional mains supply lead.

Sensor Support: Sensors pre-wired.

Sensor Specifications: D.P. Sensor: Endress + Hauser DT1, 0 to 600" W.G. with 4-20mA interface. Pressure Sensor: AST 4000A, 0 to 50 Bar with 4-20mA interface.

Bare unit with no sensors fitted.

Fittings: All Stainless Steel - O2 cleaned, final pipe fittings 1/4" NPT.

1/4" or 6mm compression fittings.



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DPW422: Specification Options

Power Source: Solar Panel and 2.5 Ah Sealed Lead Acid Battery

Optional 110V or 240V a.c. or 12V or 24V d.c. supplies.

Supply Voltage: 100V to 125V or 200V to 250V 50-60Hz a.c. 10V to 15V or 20V to 30V d.c

Battery Life: 7 to 10 years typical.

Temperature Range: -20 DegC to +50 Deg C Ambient Temperature.

Enclosure Type: Wall Mount 190mm x 125mm x 178mm.

Enclosure Material: Polycarbonate.

Enclosure Rating: IP67

Clamping Plate: Stainless Steel back-plate 215mm x 315mm x 90mm, including Solar Panel mounting.

Optional Barton compatible mounting bracket.

CE Compliance: EN 50082-2 immunity, EN 55011 emission, EN 61010-1 safety.

LCD Display: Two, 6 digit 7 segment LCD displays.

User Buttons: Two, multi-function membrane keys.

Calibration: Pre-calibrated - post calibration available on DataOnline website.

Security: Password protection on all access to DataOnline website.

Analog Input: 2 Analogue Inputs 4-20mA, loop voltage settings of 15V and 24V available.

Optional 2 Channel signal isolation card.

Memory: 27 data point FIFO buffer per channel.

Remote Reporting: GSM messaging protocol to DataOnline Web Site. Reporting period programmable from once every 15 minutes to once every 24 hours (separately programmable for each channel).

Logging Period: Logging period programmable from once every 15 minutes to once every 24 hours (separately programmable for each channel).

Alarms: Up to 8 set points for low level "early data" trigger alarming. 2 set points for "local" alarming. Tank filling "early data" trigger alarming.

Optional 2 Channel local alarm relay card for low/high level alarming.

Direct Connection: RS232C to P.C. or P.D.A. via DataOnline supplied programming adaptor.

Optional programming adaptor.

Empty Cable Gland: One spare PG11 cable gland included for optional mains supply lead.

Sensor Support: Sensors pre-wired.

Sensor Specifications: D.P. Sensor: Endress + Hauser DT1, 0 to 600" W.G. with 4-20mA interface. Pressure Sensor: AST 4000A, 0 to 50 Bar with 4-20mA interface.

Bare unit with no sensors fitted.

Fittings: All Stainless Steel - O2 cleaned, final pipe fittings 1/4" NPT.

1/4" or 6mm compression fittings.



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Please call (908) 464-2646 ext 123

for ordering and price information.

Optional Parts for Wireless Units.

DAP-BAT1034-189 6v re-chargeable battery for solar and 110v unit models FF4, FF5 & FF6.

DAP-TRFMA1012 Battery charger for 6v re-chargeable.

DAP_BP172-189 9v Alkaline battery packs for models FF4, FF5 and FF6.

DAP-BP296-189 7v lithium battery packs for models FF4, FF5 and FF6.

DPK-BAT1035/9139 Satellite battery pack.

DQ-ANT-GSM External antenna for GSM (cellular) unit.

DAP-FST3000 Fuse kit for RT124 wired/phone line unit.

DAP-FST4000 Fuse kit for Satellite unit.

DPA910 2ch Alarm relay board for Models FF4, FF5, FF6 and FF78.

DPA940 2ch isolation relay board for Models FF4, FF5, FF6 wireless units.

DPA444 4ch isolation relay unit for Model FF78 wireless unit.

DPA960 110vac supply for Models FF4, FF5, FF6 and FF78 wireless units.

DPA430 2 Channel 4-20mA Expansion Card

DPA910 2 Channel Alarm Relay Card

DPA940 2 Channel Relay Isolation Card

DPA950 2 Channel Galvanic Isolation Card

DPA975 1 Channel 4-20mA Signal Output Card

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{Doc} A

LD245 + DUAL LC229s + DP262 wiring scheme

1 1Thursday , June 12, 2008

Title

Size Document Number Rev

Date: Sheet of

CSI-DP262

CSI-LD245

CSI-LC229B+

max cable length is 100 f eet without line driv ers

set SW1 f or correct channel 3 display

CSI-LC229B+

set SW1 for correct channel 4 display

2 wire 4-20 mA SENSOR

2 wire 4-20 mA SENSOR

+VE

+VE

-VE

-VE

+VE

+VE

IP3

IP4

GND

GND

DPA430 MODULE

can be up to 100 feet of 9 core cable

PROG

mx6

123456

PORT

mx4

1234

LINE

screw 5

12345

RS232

screw 5

12345

FILL

mx2

12

KEY

0.1"

123

RS232

screw 5

12345

IP3

.

123

IP4

.

123



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{Doc} A

DP262 BASED DATAPORT WITH 4 WIRED INPUT CHANNELS

1 1Thursday , June 12, 2008

Title

Size Document Number Rev

Date: Sheet of

DP262 DATAPORT

FITTED WITH

A DPA430 ANALOG

EXPANSION CARD

CSI-AE280 based

DPA430 module

+VE

+VE

+VE

+VE

TIE

TIE

IP1

IP2

IP3

IP4GND

GND

4-20 mA 2 wireSENSOR

+VE

-VE


+VE

-VE


+VE

-VE


+VE

-VE

CHANNEL 1

CHANNEL 2

CHANNEL 3

CHANNEL 4

ALARM

IP1

.

123

IP2

.

123

IP3

.

123

IP4

.

123



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INSTALLATION INFORMATION SHEET

UNIT DETAILS: Unit ID: Sensor 1 Span:

Unit Type: Power Source: Sensor 2 Span:

Notes:

SITE DETAILS: Customer/Site Name:

Site Address:

Country: ZIP/Postcode: Time Zone:

Site Contact: Phone No:

Site Contact E-Mail Addresses:

Notes:

TANK DETAILS: Tank Name/ID:

Tank Type: Horizontal / Vertical Dished Ends: YES / NO Dish Depth:

Tank Height/Length: Tank Diameter: Manufacturer:

Notes:

PRODUCT DETAILS: Product: Specific Gravity:

Notes:

WEB-SITE SETUP: Preferred Units:

Re-Order Level: Critical Level: High Level:

Level Alarms: YES / NO Alarm Delivery Via: Email / SMS / Both

Email Address: Mobile No:

Auxiliary Channel: YES / NO Function: Preferred Units:

Notes:

LOCAL DISPLAY: Preferred Units:

Second Display: YES / NO Preferred Units:

Notes:

CURRENT READINGS: Level and or Pressure readings taken from existing sensors or gauges.

Current Product Level: Auxiliary Channel Reading:

Date & Time: Notes:

"DEBUG" VALUES: Note the value of the parameters listed here, as viewed in DEBUG mode.

C1: mA C2: mA bd: V bn: V



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dp262 shipping condense

Documents