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ULTRASCAN DSP

INSTRUCTION HANDBOOK
- installation, setup, technical reference -

www.betalasermike.com

Manual Part Number: 92611 Manual Drawing Number: 0921-00822 English Revision F Copyright Apr 2009
UltraScan DSP Instruction Handbook

Contents
Proprietary Statement................................................................................ 3
European Commission Requirements ..................................................... 4
Declaration of Conformity ......................................................................... 5
Safety Information...................................................................................... 6
General Safety Information ..................................................................... 6
Warning Labels ....................................................................................... 6
Intended Use ........................................................................................... 6
Introduction ................................................................................................ 7
Components of a Typical Ultrasonic System ........................................... 7
Application of the UltraScan DSP System ............................................... 8
Ultrasonic Measurement Principle ........................................................... 9
Mechanical Installation ............................................................................ 12
Locating and Positioning the UltraScan DSP ........................................ 12
Dimensional Drawing, Non I/O Version - inches [mm] .......................... 13
Electrical Installation ............................................................................... 14
Safety Considerations ........................................................................... 14
Performance Considerations ................................................................. 14
Typical Configuration Diagram .............................................................. 14
UltraScan DSP Front Panel View (Non I/O Version) ............................. 15
UltraScan DSP Rear Panel View .......................................................... 15
Connecting the UltraScan DSP to the Ultrasonic Gauge ...................... 16
Connecting UltraScan DSP to Host System Using RS232.................... 17
Connecting UltraScan DSP to the Host System .................................... 21
The Profibus Connector Pinout ............................................................. 21
Connecting UltraScan DSP to the Host System .................................... 22
Connecting UltraScan DSP to External Equipment Via Input and Output Signals (User
I/O) ........................................................................................................ 23
Supplying Power to the UltraScan DSP (+VDC) ................................... 25
Downloading Software ............................................................................ 26
Servicing and Returning Your Equipment ............................................. 30
Specifications ........................................................................................... 31
Index .......................................................................................................... 33

Drawing No. 0921-00822/ Part No. 92611 Page 2 of 33 Rev F (Apr 2009)
UltraScan DSP Instruction Handbook
Proprietary Statement

Proprietary Statement
Manufacturer/Distributor

Beta LaserMike, 8001 Technology Blvd., Dayton, OH 45424, USA

About This Manual

This manual contains descriptions, drawings, and specifications for a Beta LaserMike product. Equipment or
products made prior to or subsequent to the publication date of this manual may have parts, features, options,
or configurations that are not covered by this manual. Specifications contained herein are subject to change
by Beta LaserMike without prior notice. Beta LaserMike is not responsible for errors or omissions that may be
contained herein or for incidental or consequential damages in connection with the furnishing or use of this
information. Comments or suggestions for possible improvements to the manual are appreciated.
Please email us at manualfeedback@betalasermike.com.

The information contained in this manual is the property of Beta LaserMike. The information disclosed in this
document is furnished in confidence and upon the condition that individual and corporate intellectual rights,
whether patented or not, will be respected. If this document is supplied on removable media (e.g. CD), an
electronic copy (stored on-site) and one printout is permitted. If this document is supplied in printed form, no
part of this document may be reproduced or scanned without the prior written consent of Beta LaserMike. This
document may not be distributed or circulated to third parties.

Limited Warranty

Beta LaserMike will correct by repair, or at Beta LaserMikes option, by replacement, F.O.B Beta LaserMikes
plant, any defect in workmanship or material in any equipment manufactured by Beta LaserMike which
appears under normal and proper use within twelve months from the date of shipment (eighteen months for
OEMs), provided Beta LaserMike is given reasonable opportunity to inspect the alleged defective equipment
at the place of its use and under conditions of its use.

EXCLUSIONS: This warranty does not cover products which have been modified, altered, or repaired by any
other party than Beta LaserMike or its authorized agents. Furthermore, any product which has been, or is
suspected of being damaged as a result of negligence, misuse, incorrect handling, servicing, or maintenance;
or has been damaged as a result of excessive current/voltage or temperature; or has had its serial number(s),
any other markings, or parts thereof altered, defaced, or removed will also be excluded from this warranty.
Note:
WARRANTY SERVICE AT CUSTOMER SITE: Warranty service performed at the customers facility will be
free of charge for parts and labor; however, the customer will be liable for transportation and living expenses For information
of personnel dispatched to effect such repair. A purchase order or other written confirmation of the about servicing
acceptance of these charges, signed by an authorized individual, will be required prior to commencement of and returning
repairs. Additional charges may be assessed the customer if: 1) The equipment is not made available on a your equipment,
timely basis, 2) The equipment is found to be without fault, and/or 3) It is determined the equipment is not see the section
under warranty, whether by expiration of the warranty or any act which voids the warranty. at the end of this
OTHER THAN AS SET FORTH HEREIN, BETA LASERMIKE MAKES NO WARRANTIES, EXPRESSED OR manual.
IMPLIED, OF MERCHANTABILITY AS TO THE EQUIPMENT MANUFACTURED BY IT, AND THERE ARE
NO EXPRESSED OR IMPLIED WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE
FACE THEREOF. Beta LaserMikes obligation to correct defects in such equipment by repair or replacement
in accordance with the foregoing provisions is in lieu of any other warranties, expressed or implied, and in no
event shall Beta LaserMike be liable for incidental or consequential damages. No service of Beta LaserMikes
equipment is permitted during the warranty period without the specific written consent of Beta LaserMike.

Drawing No. 0921-00822/ Part No. 92611 Page 3 of 33 Rev F (Apr 2009)
UltraScan DSP Instruction Handbook
European Commission Requirements

European Commission Requirements


This equipment is intended for use in a heavy industrial environment. The equipment generates, uses and
can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may
cause harmful interference to other equipment. There is no guarantee that interference will not occur in a
particular installation. If this equipment does cause harmful interference to other equipment the user is
encouraged to try to correct the interference by one or more of the following measures:

- Re-orientate or relocate the equipment.

- Increase the separation between the pieces of equipment.

- Connect the pieces of equipment on separate mains circuits.

- Ensure that the relevant items of equipment are properly and securely earthed to a common earth point
using adequately sized cable or other means of connection.

Where supplied or specified, shielded interconnection cables must be employed with this equipment to ensure
compliance with the pertinent RF limits. Changes or modifications not expressly approved by the company
could void the users authority to operate the equipment.

This product has been rigorously tested to comply with the European EMC (Electromagnetic Compatibility)
Directive. With regard to this, Beta LaserMike recommends that any non-Beta LaserMike peripheral
equipment is CE marked for the Heavy Industrial environment (EN50082-2). Beta LaserMike also
recommends that any cables not supplied by Beta LaserMike, but used for powering Beta LaserMike
equipment, be built using good EMC practices (i.e. cables with braided shield, and connectors with 360
termination of the braid to a metal/metalised shell connector at both ends). If you have any questions
regarding this, contact the Beta LaserMike Service Department.

Drawing No. 0921-00822/ Part No. 92611 Page 4 of 33 Rev F (Apr 2009)
UltraScan DSP Instruction Handbook
Declaration of Conformity

Declaration of Conformity

Drawing No. 0921-00822/ Part No. 92611 Page 5 of 33 Rev F (Apr 2009)
UltraScan DSP Instruction Handbook
Safety Information

Safety Information

General Safety Information


Any electrical connections must be carried out by a suitable
technician for the country of installation.
This equipment must be earthed/grounded.
HIGH VOLTAGES are present inside the UltraScan DSP unit.
DO NOT attempt to service this unit! Contact Beta LaserMike
if there is a reason to service the unit which requires
opening the unit.

Warning Labels
Observe all warning labels on this and all Beta LaserMike equipment.

Intended Use
If the equipment is not used in the manner specified by Beta LaserMike,
the protection provided by the equipment may be impaired.

Drawing No. 0921-00822/ Part No. 92611 Page 6 of 33 Rev F (Apr 2009)
UltraScan DSP Instruction Handbook
Introduction

Introduction
Note: If the

Components of a Typical Ultrasonic System equipment is not


used in the manner
specified by Beta
LaserMike, the
Transducer protection provided
connections RS232, by the equipment
(4, 6, or 8) DeviceNet, may be impaired.
or Profibus
UltraScan Host system
Ultrasonic
DSP module
gauge
RS232

BenchMike
(remote cal)
(optional)

A typical ultrasonic measurement system consists of an ultrasonic gauge,


the UltraScan DSP, a host system, and potentially a BenchMike for
remote calibration of the UltraScan DSP. The ultrasonic gauge is a fixture
that holds ultrasonic transducers for taking dimensional measurements of
extruded products (typically wall thickness and concentricity
measurements). The ultrasonic gauge is placed in a water bath so that
there is a medium to carry the ultrasonic signal. Typically the cooling
trough of an extrusion line is chosen for this location. The ultrasonic
transducers from the ultrasonic gauge are connected to the UltraScan
DSP. The UltraScan DSP receives the signals from the transducers and
analyzes them to compute the measurements required. The UltraScan
DSP then sends the information to a host system, where the user
interface will reside. The host system can be a controller, PC, PLC, or
HMI of some kind.
For more details on the ultrasonic gauge or a host system (controller)
supplied by Beta LaserMike, please see the Instruction Handbook for
those respective products.

Drawing No. 0921-00822/ Part No. 92611 Page 7 of 33 Rev F (Apr 2009)
UltraScan DSP Instruction Handbook
Introduction

Application of the UltraScan DSP System


Ultrasonic technology is used in a very wide variety of applications, but
the UltraScan DSP system from Beta LaserMike is designed specifically
for in-process extrusion applications. This can include a variety of cable,
tube, pipe, and hose extrusion applications.
A mimic extrusion line is shown below to demonstrate one example of an
UltraScan DSP system configuration for an extrusion application.

Drawing No. 0921-00822/ Part No. 92611 Page 8 of 33 Rev F (Apr 2009)
UltraScan DSP Instruction Handbook
Introduction

Ultrasonic Measurement Principle


1) To initiate the ultrasonic signal for taking measurements, the
UltraScan DSP will send an electrical pulse to the ultrasonic
transducer. This electrical drive pulse hits a crystal element inside
the ultrasonic transducer and a sound wave is created. The
ultrasonic transducer transmits this sound wave (by turning electrical
energy into mechanical) toward the product to be measured.

1) Electrical 2) Ultrasonic 3) Transmitted


drive pulse transducer sound waves

UltraScan DSP

Electrical energy Mechanical energy


(in the form of sound)

2) When the sound wave hits the outer wall of the product, it changes
speed and a reflection, or echo occurs. Some of the sound energy is
reflected at the wall, but the remaining energy continues to travel
through the product. When the remaining energy hits the inside wall
of the product, it again changes speed and another reflection, or
echo, occurs. Both of the echoes from the product walls travel back
to the ultrasonic transducer. The transducer then converts these
echoes into an electrical signal that is sent back to the UltraScan
DSP.

3) Electrical 2) Ultrasonic 1) Return echo


waveform transducer sound waves

Echo 1 Echo 2
UltraScan DSP
Echo 1
Echo 2

Electrical signal Mechanical energy


(in the form of sound)

Drawing No. 0921-00822/ Part No. 92611 Page 9 of 33 Rev F (Apr 2009)
UltraScan DSP Instruction Handbook
Introduction

3) The wall thickness of the product is calculated by the UltraScan DSP


based on the time gap between the two echoes (t). The wall
thickness calculation is Wall = (t * s) / 2 where t is the time
between the two echoes received and s is the speed of sound
through the material being measured. The speed of sound through
the material is determined when the UltraScan DSP is calibrated. For
more information on the procedure to calibrate the UltraScan DSP,
see the Instruction Handbook of the controller that is used with the
UltraScan DSP.

Echo 1 Echo 1
Echo 2

UltraScan DSP
Echo 2

t Wall = (t * s) / 2

t = time between echoes


s = speed of sound through the material

NOTE: If more than one layer of the product is being measured, then the
UltraScan DSP will look for more than two echoes. The number of
echoes that the UltraScan DSP will look for is n + 1 where n is the number
of layers being measured.

Drawing No. 0921-00822/ Part No. 92611 Page 10 of 33 Rev F (Apr 2009)
UltraScan DSP Instruction Handbook
Introduction

4) The concentricity of a product is measured by taking multiple points


of measurement around the product (using multiple transducers) and
comparing the maximum wall and the minimum wall measured.
Various calculations can be used for concentricity. Some are linear
differences and some are ratios, but all involve the maximum and
minimum wall of the product.

Drawing No. 0921-00822/ Part No. 92611 Page 11 of 33 Rev F (Apr 2009)
UltraScan DSP Instruction Handbook
Mechanical Installation

Mechanical Installation

Locating and Positioning the UltraScan DSP


The UltraScan DSP should be mounted and secured on a sturdy
horizontal or vertical surface. It contains 4 mounting holes in its bottom
plate for this purpose. Since each UltraScan DSP is connected to an
ultrasonic gauge with approximately 1.5m (5 feet) of cable, the UltraScan
DSP must be mounted within this distance from the gauge head.
Therefore, the gauge should be installed and the cables routed for the
measurement application before positioning the UltraScan DSP.
The case of the UltraScan DSP must be earthed/grounded to a quality
earth/ground source. A grounding stud is provided on the front plate of
each UltraScan DSP, and shall be connected to earth ground. A heavy
grounding wire (minimum 10 gauge) should be used to insure a low
impedance ground connection.
The UltraScan DSP is IP65 rated splash/water proof. However, it is
recommended to place the unit so that it is not continuously subjected to
water runoff/splashing, as cables to/from the unit may be more
susceptible to water ingression.

Drawing No. 0921-00822/ Part No. 92611 Page 12 of 33 Rev F (Apr 2009)
UltraScan DSP Instruction Handbook

Dimensional Drawing, Non I/O Version - inches [mm]

Drawing No. 0921-00822/ Part No. 92611 Page 13 of 33 Rev F (Apr 2009)
UltraScan DSP Instruction Handbook
Electrical Installation

Electrical Installation

Safety Considerations
Any electrical connections should be performed by a person
suitably qualified for the country of installation.
This equipment must be earthed/grounded.
HIGH VOLTAGES are present inside of the UltraScan DSP
unit. DO NOT attempt to service the UltraScan DSP unit.
Contact Beta LaserMike if there is a reason to service the
unit that requires the opening of the unit.

Performance Considerations
All cables interconnecting UltraScan DSP equipment shall be:
braid/foil shielded cables, including shielded metal
backshells
approved by Beta LaserMike
Failure to install shielded cables with the UltraScan DSP system can
cause degradation of system performance and loss of CE
compliance

Typical Configuration Diagram

Drawing No. 0921-00822/ Part No. 92611 Page 14 of 33 Rev F (Apr 2009)
UltraScan DSP Instruction Handbook
Electrical Installation

UltraScan DSP Front Panel View (Non I/O Version)

Profibus socket

ProfiBus Status LED

DeviceNet Status LED

Serial port 1 Serial port 2

DeviceNet &
Earth/ground stud Power socket
Measurement
Status LED

UltraScan DSP Rear Panel View

8
Transducer
(BNC)
connectors

Connector for water


temperature sensor

Drawing No. 0921-00822/ Part No. 92611 Page 15 of 33 Rev F (Apr 2009)
UltraScan DSP Instruction Handbook
Electrical Installation

Connecting the UltraScan DSP to the Ultrasonic Gauge


Each UltraScan DSP unit can transmit and receive signals to/from 4, 6, or
8 ultrasonic transducers. Each ultrasonic gauge is connected to the
UltraScan DSP unit by connecting each coaxial cable connector
associated with each transducer to the corresponding BNC connector on
the UltraScan DSP back panel. It is recommended that the BNC caps
supplied with the UltraScan DSP unit remain on any unused channel to
protect the BNC connector from water, debris, and possible mechanical
damage.
See Rear panel photo above for location and labelling of the BNC
connector layout on the UltraScan DSP back panel.
It is important to connect the transducers sequentially according to
position in the gauge. In following this method, the visual display of the
gauge on the Display Controller and data for product being tested will
correspond. Please see the illustration below as an example. In this
case, XD1 (transducer 1) should be connected to Channel 1 of the
UltraScan DSP. XD2 shall be connected to Channel 2, and so on.
Numbering of the transducers can be either in clockwise or counter-
clockwise direction. The display module can then be set-up to display the
data in the same orientation to correspond to the gauge.
Some gauges (depending on the application) will contain a temperature
sensor that measures cooling trough temperature for use in speed of
sound calculations. If the gauge contains a temperature sensor, connect
the temperature sensor connector from the ultrasonic gauge to the
UltraScan DSP rear panel temperature sensor connector.
For specifics relative to the ultrasonic gauge, please refer to the
Instruction Manual for each respective gauge to be connected to the
UltraScan DSP.

Drawing No. 0921-00822/ Part No. 92611 Page 16 of 33 Rev F (Apr 2009)
UltraScan DSP Instruction Handbook
Electrical Installation

Gauge/Transducer Sequencing

XD1

XD4/ XD2/
XD2 XD4

XD3

Temperature Connector Pinout

Pin No. Circuit name Description Color

1 RTD_SENSE1+ Voltage Sense + connection White

2 RTD_SENSE1- Voltage Sense connection Red

3 RTD_FORCE1- Current Source connection Red

4 RTD_FORCE1+ Current Source + connection White

Connecting UltraScan DSP to Host System Using RS232


The UltraScan DSP has two RS232 (ie serial) ports and supports
simultaneous communications over both.
Port 1 is the primary serial port and supports speeds up to 38400
bps.
Port 2 is a secondary port and supports speeds up to 9600 bps.
The default port configurations are as follows:
Port 1 38400 bps, no parity, 8 data bits, 1 stop bit, no
hardware/software handshaking.
Port 2 9600 bps, no parity, 8 data bits, 1 stop bit, no
hardware/software handshaking

One port is for connection to the host computer system controller, or PC,
and one for connection to a remote calibration gauge, remote display, or
data logging device.

Drawing No. 0921-00822/ Part No. 92611 Page 17 of 33 Rev F (Apr 2009)
UltraScan DSP Instruction Handbook
Electrical Installation

Specifications and options available with both serial ports


Description Port #1 (IOIOI 1) Port #2 (IOIOI 2)

Interface EIA RS-232 (standard) EIA RS-232 (standard)

Transfer Rate 38400 bits per second 9600 bits per second

Connector type DB9 female DB9 female

Pinout RS-232C: IBM AT Standard for DCE RS-232C: IBM AT Standard for
DCE

Word Length 8 bits 8 bits

Parity None None

Stop Bits 1 1

Flow Control CTS, RTS CTS,RTS

Addressability N/A N/A

Max. Cable Length Please see Specification section at back of manual

Connection of the UltraScan DSP unit to a Beta LaserMike Controller


For this connection a shielded Male DB9 to Male DB9 Null Modem cable
shall be used. Port #1 should be used for connection to the host system
or controller due to its higher baud rate. Port #2 should be used for
connection to the remote calibration device (BenchMike) as the lower
baud rate is sufficient.
Null Modem Cable pinouts:

Pin no. Pin no.


(DB9 Male end) (DB9 Male end)

2 3

3 2

4 6

5 5

6 4

7 8

8 7
SHIELD: Copper Braid and Foil (360 degrees), drain tied to metal
backshell/hood; PVC sheathing.
EMI/RFI Metal Hood with male screwlocks.

Drawing No. 0921-00822/ Part No. 92611 Page 18 of 33 Rev F (Apr 2009)
UltraScan DSP Instruction Handbook
Electrical Installation

Connection of UltraScan DSP unit to PC terminal serial ports


For this connection a shielded Male DB9 to Female DB9 straight through
cable shall be used. Either Port #1 or Port #2 can be connected to the
PC terminal ports depending on baud rate desired.

STRAIGHT - THROUGH (COMPUTER) CABLE

Pin no. (DB9 Female) Pin no. (DB9 Male end)

1 1

2 2

3 3

4 4

5 5

6 6

7 7

8 8

9 9
SHIELD: Copper Braid and Foil (360 degrees), drain tied to metal
backshell/hood; PVC sheathing.
EMI/RFI Metal Hood and male screwlocks.

Refer to Electrical installation for Front Panel photo of RS232 Port #1 and
Port #2.

Pin-outs for the RS232 ports

Pin no. Circuit name Description Direction Level

2 TXD Data to External Equipment Analog output 5-12V

3 RXD Data from External Equipment Analog input 5-12V

5 GND Signal Ground - 0V

7 CTS Flow control signal from external Analog input 5-12V


equipment

8 RTS Flow control signal from USDSP Analog output 5-12V


always asserted

Drawing No. 0921-00822/ Part No. 92611 Page 19 of 33 Rev F (Apr 2009)
UltraScan DSP Instruction Handbook
Electrical Installation

RTS
This signal is the standard RS232 Request To Send signal. The signal is
an output from the gauge and is usually high (+12V). The signal will go
low if the gauge cannot accept any more RS232 characters. This will only
occur if the characters are sent at high baud rate continuously over a long
period. The computer sending the characters must stop until this signal
goes high again otherwise some characters will be lost.

CTS
This signal is the standard RS232 Clear To Send signal. The signal is an
input to the gauge and is usually high (+12V). If the signal is pulled low (-
12V) the gauge will not send characters to the computer. This line should
be used if the computer cannot accept data as fast as the gauge can
send it. The characters are not forgotten while this signal is low and will
be transmitted when the signal becomes high again. The signal is pulled
high inside the gauge so if this signal is not required the signal can be left
unconnected. If this pin is left low and characters are still sent to request
data, the RTS line will eventually go low to tell the sending computer that
it can no longer remember all of the characters waiting to be sent. Some
characters must be read by pulling CTS high before RTS will go high to
allow more characters to be accepted by the gauge.

Connecting UltraScanDSP to a computer or terminal


RS232 port pins Connect Computer or Terminal pins
to (see computer manual for details)

RXD TXD

TXD RXD

RTS CTS

It may also be necessary to connect


this to the DSR (Data set ready)
line.

CTS RTS

Drawing No. 0921-00822/ Part No. 92611 Page 20 of 33 Rev F (Apr 2009)
UltraScan DSP Instruction Handbook
Electrical Installation

Connecting UltraScan DSP to the Host System


The UltraScan DSP can be connected to the host system, controller, or
PC via a Profibus connection. The Profibus provides a high speed data
connection (up to 12Mbaud depending on cable length). In this
configuration, the host system, controller, or PC shall have a Profibus DP
card installed and configured for communicating with the UltraScan DSP.
The appropriate cables and interface card can be supplied by Beta
LaserMike as part of the installed system.
The Profibus connection is available on the front panel of the UltraScan
DSP by connecting to the port labelled PROFI. Refer to Electrical
installation - Front panel photo for location and labelling of the connector.
For information about connecting the UltraScan DSP to a device other
than a Beta LaserMike controller, consult the UltraScan DSP Integration
Instruction Handbook (Part Number 92005), under Fieldbus
Communications.

The Profibus Connector Pinout


Pin no. Circuit name Description Direction Level

1 +5V Profi +5V Profi Supply(for fibre Output 5V


applications and termination)

2 A-Line Profi Bus A Line Input/Output 0-5V

3 GND Profi Signal Ground - 0V

4 B-Line Profi Bus B Line Input/Output 0-5V

5 Shield Profi Cable Shield(drain) line Input 0V

Maximum segment/cable length


The cable length and the Baud rate limit the length of any node to node
segment.

Cable Type A (preferred cable type)

Kbaud 9.6 19.2 93.75 187.5 500 1500 12000

Length (m) 1200 1200 1200 1000 400 200 100

Optical fibre can be used for longer segment lengths. Each connection
(installation dependant) shall be terminated at both ends. The UltraScan
DSP supplies +5VDC to the PROFI connector as required to supply the
terminating resistor.

Drawing No. 0921-00822/ Part No. 92611 Page 21 of 33 Rev F (Apr 2009)
UltraScan DSP Instruction Handbook
Electrical Installation

A terminating resistor plug is usually required (depending on installation)


to terminate the Profibus at both ends, including the UltraScan DSP end
of the bus, which can be accomplished by using a Profibus T connection
and a terminating resistance stub. The termination is not supplied internal
to the UltraScan DSP module in order to provide maximum configuration
flexibility.
It is recommended to use Beta LaserMike supplied Profibus cables to
ensure proper Profibus operation and CE compliance.

Connecting UltraScan DSP to the Host System


The UltraScan DSP can be connected to the host system, controller, or
PC via a DeviceNet connection. This provides a high speed data
connection (up to 500KBps depending on cable length). In this
configuration, the host system, controller, or PC shall have a DeviceNet
card installed and configured for communicating with the UltraScan DSP.
The appropriate cables and interface card can be supplied by Beta
LaserMike as part of the installed system.
When utilizing the DeviceNet installation option, the UltraScan DSP unit
will use the DeviceNet power to operate. In this case, an additional
+24VDC external power supply is not required. Power can be supplied to
the UltraScan DSP through the use of a DeviceNet power drop box. It is
important to follow DeviceNet power drop guidelines to ensure that any
other DeviceNet devices and the UltraScan DSP module receive their
acceptable power requirements.
The DeviceNet connection is available on the front panel of the UltraScan
DSP by connecting to the port labelled DNET/+VDC. Refer to Front
panel photo for location and labelling of the connector. For information
about connecting the UltraScan DSP to a device other than a Beta
LaserMike controller, consult the UltraScan DSP Integration Instruction
Handbook (Part Number 92005), under Fieldbus Communications.

DeviceNet Connector Pin-out:

Pin no. Circuit name Description Direction Level

1 Shield Shield connection (drain line for - 0V


DeviceNet Cable)

2 +VDC +Voltage: DeviceNet supplied V+ Input 11-25VDC

3 -VDC -Voltage: DeviceNet supplied V- Input 0V

4 Can Hi Can Hi signal (communication line) Input/Output 0-5V

5 Can Lo Can Lo signal (communication line) Input/Output 0-5V

Drawing No. 0921-00822/ Part No. 92611 Page 22 of 33 Rev F (Apr 2009)
UltraScan DSP Instruction Handbook
Electrical Installation

A terminating resistor plug may be required to terminate the DeviceNet at


the UltraScan DSP end of the DeviceNet bus, depending on installation
and number of nodes connected. This can be accomplished by using a
DeviceNet T connection and a terminating resistance stub at the
UltraScan DSP end of the bus, if required.
It is recommended to use Beta LaserMike supplied DeviceNet cables and
Power Drop box to ensure proper DeviceNet operation and CE
compliance. The DeviceNet cable MUST be a 5 wire cable. The 5th wire
ties the drain of the cable to the coupling nut, which is earth grounded to
the UltraScan DSP enclosure.
Note: After installation and connection of the UltraScan DSP to the
DeviceNet, the DeviceNet voltage shall be verified to ensure
voltage at the UltraScan DSP unit is within specifications. The
power line must be 11VDC minimum at the UltraScan DSP
connector. Refer to Specification - Electrical section for power
consumption of the UltraScan DSP module.

Connecting UltraScan DSP to External Equipment Via


Input and Output Signals (User I/O)
The UltraScan DSP offers a User I/O connection port that can be used to
transfer control, timing, and/or data between the UltraScan DSP and other
external equipment. The User I/O functionality is enabled via the
firmware and software of the UltraScan DSP. This specific software to
enable the I/O functions can be designed for each specific application.
The following table describes the signal type available at each respective
pin of the I/O connector.
All signals are optically isolated from the UltraScan DSP signal ground to
eliminate interference and ground offsets.
Note: Do not connect User I/O unless appropriate BetaLaserMike
personnel have been consulted. Failure to do so could result in
damage to the UltraScan DSP unit.

The following table describes the pin-outs for the User I/O port. These
signals are supplied through sealed DB25 pin socket connector. Signal
notation is relative to the UltraScan DSP.

Drawing No. 0921-00822/ Part No. 92611 Page 23 of 33 Rev F (Apr 2009)
UltraScan DSP Instruction Handbook
Electrical Installation

User I/O Pinout

Pin Circuit Name Description Direction Level


No.

1 CLAMP Clamp for Inductive loads Input 0-35V

2 DIGITAL OUTPUT 1 Open Collector Output Output 0-35V

3 DIGITAL OUTPUT 2 Open Collector Output Output 0-35V

4 DIGITAL OUTPUT 3 Open Collector Output Output 0-35V

5 DIGITAL OUTPUT 4 Open Collector Output Output 0-35V

6 DATA OUT CH1 + RS422 data + Output 0-5V

7 DATA OUT CH1 - RS422 data - Output 0-5V

8 DATA OUT CH2 + RS422 data + Output 0-5V

9 DATA OUT CH2 - RS422 data - Output 0-5V

10 DATA IN CH1 + RS422 data + Input 0-5V

11 DATA IN CH1 - RS422 data - Input 0-5V

12 DATA IN CH2 + RS422 data + Input 0-5V

13 DATA IN CH2 - RS422 data - Input 0-5V

14 DATA IN CH3 + RS422 data + Input 0-5V

15 DATA IN CH3 - RS422 data - Input 0-5V

16 DATA IN CH4 + RS422 data + Input 0-5V

17 DATA IN CH4 - RS422 data - Input 0-5V

18 GROUND1 Ground for signals pins 1-17 - -

19 GROUND1 Ground for signals pins 1-17 - -

20 GROUND2 Ground for signals pins 21-24 - -

21 INPUT1 Digital Input Input 0-26V

22 INPUT2 Digital Input Input 0-26V

23 INPUT3 Digital Input Input 0-26V

24 INPUT4 Digital Input Input 0-26V

25 VCC Power for signals pins 21-24 - -

26 GROUND2 Ground for signals pins 21-24 - -

Drawing No. 0921-00822/ Part No. 92611 Page 24 of 33 Rev F (Apr 2009)
UltraScan DSP Instruction Handbook
Electrical Installation

Supplying Power to the UltraScan DSP (+VDC)


The UltraScan DSP is powered by +24VDC nominal power. Before
switching on the controller or host system, ensure that the UltraScan DSP
unit is powered on first.
For installations requiring DeviceNet operation, see the previous
DeviceNet section for installation instructions.
For installations not requiring DeviceNet operation, an external power
supply (Beta LaserMike can supply) can be used to power the UltraScan
DSP unit. The PSU6024 power supply module requires connection to
either 120VAC or 220VAC 50 or 60Hz, 1.4A maximum. The output power
of this power module is connected to the UltraScan DSP module through
a shielded DeviceNet style cable. The DeviceNet cable MUST be a 5
wire cable. The 5th wire ties the drain of the cable to the coupling nut,
which is earth grounded to the UltraScan DSP enclosure. It is important
to use Beta LaserMike approved shielded cable to ensure CE
compliance.
It is suggested to keep the cable length between the power supply to the
UltraScan DSP relatively short. Longer cable will increase the voltage
dropped through the cable and increase the current required to operate
the unit.

LED Indicator
The LED Indicator on the front panel of the UltraScan DSP shall be lit
whenever the unit is powered. When the UltraScan DSP unit has not yet
initialised or is not yet measuring and locked onto a valid measurement
sample, the LED shall be RED in colour. When the UltraScan DSP unit is
measuring and locked onto a valid measurement sample, then the LED
shall be GREEN in colour.
The LED indicator can be used as a quick check to verify that the
ultrasonic gauge is connected properly to the UltraScan DSP and that the
UltraScan DSP is configured properly for the gauge connected and
sample being measured.

Drawing No. 0921-00822/ Part No. 92611 Page 25 of 33 Rev F (Apr 2009)
UltraScan DSP Instruction Handbook
Downloading Software

Downloading Software
The UltraScan DSP platform incorporates a Fujitsu microcontroller that
handles all the communication interfaces and general processing and a
Texas Instruments digital signal processor (DSP) that collects and
processes the measurement signals. The software for the microcontroller
is stored in the microcontrollers internal flash memory and the software
for the DSP is stored in the external flash memory connected to the DSP.
A loader program is stored in the microcontrollers flash memory, enabling
the gauge software to be downloaded and upgraded at any time; it is also
possible for the loader program to upgrade itself. New microcontroller
software is downloaded using the download application BL90543, version
5 or newer.
The DSP software is capable of updating its external flash memory with a
new version of the DSP software. The DSP does not employ a software
loader program but instead uses a hardware loader to move the first
64KB of program from the external flash to its internal program memory at
start-up. New DSP software is downloaded using the UltraScanDSP DSP
code updater utility.
Important: When upgrading both the microcontroller and DSP software,
it is recommended that the DSP software be upgraded first to
avoid any possible incompatibilities between the old DSP
software and the new microcontroller software.

Equipment
PC running Windows 95/98/ME or NT/2000/XP
UltraScanDSP/DeviceNet 24VDC power supply
RS232 cable, 9 pin to 9 pin
Loader program update utility BL90543.exe Version 5 or newer
o S2 record file for microcontroller Loader 400-0015.S2
o S2 record file for microcontroller Application program
91950.S2
UltraScanDSP DSP software (code) update utility v2.0.5 or newer
o Binary file for DSP program 91949.out
If downloading the microcontroller software for the first time, or if the
microcontroller loader program has been corrupted, it is necessary to
install the new loader program from scratch. This will require the gauge
to be opened to change a jumper setting. Once the loader is installed and

Drawing No. 0921-00822/ Part No. 92611 Page 26 of 33 Rev F (Apr 2009)
UltraScan DSP Instruction Handbook
Downloading Software

operational, further upgrades can be carried out without opening the


gauge.
With either method, the first step is to create a list of the files to be
downloaded. Once the list is set up, it can be used every time.

Creating a new microcontroller file list


Lists can be created to download all files or just one file as required.
1) Run the BL90543.exe application.
2) Select a list form the drop down menu which does not contain
any files e.g. List0 no name
3) Hit the Add File button, search through the directory tree and
select an S2 file.
4) e.g. a Loader file - G:/test/PlusRange/microcontroller
Loader/400-0015.S2.
5) Hit the Open button to add the file to the list.
6) Add the file for the microcontroller application software in the
same way if needed.
7) Hit the List Name button and create a meaningful list name.

Download microcontroller from scratch


1) Unless a File list has been previously created, create a File list,
as described above, containing the following files: microcontroller
loader file and microcontroller application file.
2) With the power off, open the UltraScanDSP and remove the
mode jumper JP1 to select bootload.
3) Connect the RS232 cable between the UltraScanDSP RS232
connector for port 2 and the PC.
4) Run the BL90543.exe application.
5) Set the COM port as appropriate.
6) Select a list from the drop down menu for downloading both files;
ensure the file window displays the correct files.
7) Enable Fujitsu burn-in ROM by clicking the box.
8) Disable Transmit S-Records as binary data by clicking the box.
9) Hit the Connect, Update, Reset, Disconnect button. A message
Bootloader not responding should be displayed.
10) Connect the gauge to 24VDC and switch on the power.
11) The first file on the list should automatically start to download
followed by the remaining file.

Drawing No. 0921-00822/ Part No. 92611 Page 27 of 33 Rev F (Apr 2009)
UltraScan DSP Instruction Handbook
Downloading Software

12) When downloading is complete switch off the power and replace
the mode jumper JP1 to set the gauge for normal operation.

Further microcontroller upgrades


The following can be carried out without removing the gauge lid, as no
internal access is necessary.
1) Unless a File list has been previously created, create a File list,
as described above, containing the following files: microcontroller
loader file and/or microcontroller application file.
2) Remove power from the UltraScanDSP.
3) Connect the RS232 lead between the UltraScanDSP RS232
connector port 1 and the PC.
4) Run the BL90543.exe application.
5) Set the COM port as appropriate.
6) Select a list from the drop down menu for downloading desired
file. Ensure the file window displays the correct filename.
7) Ensure Using Fujitsu burn-in ROM is disabled.
8) Ensure Transmit S-Records as binary data is enabled.
9) Hit the Connect, Update, Reset, Disconnect button. A message
Bootloader not responding should be displayed.
10) Connect the gauge to 24VDC and switch on the power.
11) The file should automatically start to be downloaded.
12) When downloading is complete the gauge should restart and run
automatically.

Upgrading the DSP software


The following can be carried out without removing the gauge lid, as no
internal access is necessary. The DSP software is downloaded via the
Fujitsu microcontroller. If the microcontroller has never been
programmed or if the microcontroller program has become corrupted, the
DSP will not be upgradable without performing the Download
microcontroller from scratch instructions above.
1) Connect the RS232 lead between the UltraScanDSP RS232
connector port 1 and the PC.
2) Connect the gauge to 24VDC and switch on the power.
3) Run the UltraScanDSP DSP code updater utility.
4) Set the COM port as appropriate (mode is normally 38400,n,8,1).
5) Browse to the DSP software file to be downloaded and select it.

Drawing No. 0921-00822/ Part No. 92611 Page 28 of 33 Rev F (Apr 2009)
UltraScan DSP Instruction Handbook
Downloading Software

6) Hit the Start button. The download status should change from
Waiting for download ready , to Downloading data , to
Writing to flash , and finally to Download complete.
7) When downloading is complete, hit the Reset button to begin
running the new DSP software.

Drawing No. 0921-00822/ Part No. 92611 Page 29 of 33 Rev F (Apr 2009)
UltraScan DSP Instruction Handbook
Servicing and Returning Your Equipment

Servicing and Returning Your Equipment


Your instrument was carefully inspected electrically and mechanically
prior to shipment. It should be free of surface mars and scratches, and it
should be in perfect working order upon receipt. If any indication of
damage is found, file a claim with the carrier immediately, prior to using
the instrument. If no damage is apparent, proceed by using this manual to
install and setup this instrument.
Save the shipping carton and packing material for future storing or
shipment of the instrument. If, at some future time, the instrument must be
returned to the factory for service, include a full description of the
instrument failure and the mode of operation the instrument was in at the
time of failure. Also include a contact person to discuss the instrument
failure.
When returning equipment for service, it is important to first obtain a
Return Material Authorization (RMA) number. The RMA number is
needed for proper handling of returned equipment.
To obtain an RMA, go to www.betalasermike.com
Select Service
Select Equipment Return / RMA from the drop-down menu.
Follow the instructions to obtain an RMA.
Ship the instrument in the original carton, or, if the original carton is
unavailable, ship in a carton providing sufficient protection. Send the
instrument to the Asia, Europe, or USA office (addresses listed in the
supplied Contacts/CE Compliance Manual), whichever is closest to you or
to the office indicated by your sales engineer. Place the RMA number on
the outside of the carton, and include a purchase order number and any
other information specific to your instrument. Field warranty service is
available, if the customer pays travel expenses by advance purchase
order. All service operations should be performed by skilled electronics
technicians, who have been trained by Beta LaserMike.

Drawing No. 0921-00822/ Part No. 92611 Page 30 of 33 Rev F (Apr 2009)
UltraScan DSP Instruction Handbook
Specifications

Specifications
General

Expected life 10 years


(Time frame is based on routine maintenance/ calibration and
includes possible replacements of serviceable parts)

Dimensions 106 x 198 x 305 mm


(Height x Width x Depth) 4.182 x 7.785 x 12.024 in. (See Dimensional Drawing)

Weight 3.32kg (7.3 lb.)

Environmental conditions

Altitude Up to 2000m (6560 ft)

Ambient operating temp. 5-40C (41-104F)

Ambient storage temperature -40 - +50C (-40 - +122F)

Max relative humidity 80% for temp. up to 31C or 88F


(decreasing linearly to 50% relative humidity at 40C or 104F)

Installation category Installation Category 2

Pollution degree Pollution Degree 1

(Equipment has been designed for operation with a level of


pollution of its internal micro-environment, which corresponds with
the definition of Pollution Degree 1 in BSEN 61010-1:1993)

IP rating IP65 (as defined in BSEN 60529) / NEMA4

Voltage fluctuations 10 of nominal voltage

Performance

Concentricity measurement 0.1%


accuracy

Repeatability 1 m (0.00004 in)

Wall measurement resolution 1 m (0.00004 in)


(May improve with materials having a slower speed of sound)

Rate of scan 400 to 1200 wall measurements per sec

Electrical

UltraScan DSP Power +24VDC, 1.1A (Input Voltage range = 11-30VDC)


requirements +11VDC, 2.3A
+30VDC, 0.9A

External Power Supply Input 90-132Vac OR 180-264Vac


Voltage/Current Range 47-63Hz, 1.4A maximum
(PSU6024)

Drawing No. 0921-00822/ Part No. 92611 Page 31 of 33 Rev F (Apr 2009)
UltraScan DSP Instruction Handbook
Specifications

External Power Supply Output +24VDC 5%, 2.5A maximum


Voltage/Current range (PSU6024)

Fuse Size and Type 3AG Slo Blo, 3A, 250V

Network connection - RS232

Max. cable length 15m (50ft) for baud rate of 9600bps.

Longer cables may work but this will depend on capacitance and
quality of cable. If problems occur with longer cables, a
RS232/RS422 converter box can be purchased from Beta
LaserMike to overcome this.

Data rate Please refer to Serial port specifications under section


'Connecting UltraScan DSP to host using RS232'.

Network connection DeviceNet (option)

Max. cable length 39m* (128ft) at 500 KBps, 78m* (256ft) at 250 KBps, 156m*
(512ft) at 125 KBps

* accumulative distance of branches

Data rate 125/250/500 kbits/s (depends on cable length)

Max. number of nodes 64

Network connection - Profibus (option)

Cable length 500m (1640ft) at 12MBps with 4 repeaters


For more details, refer to Maximum (longer cables are possible at a slower data rate and with more
segment/cable length under heading repeaters)
Connecting UltraScan DSP to the
Host System Using Profibus.

Data rate Up to 12 MBps (dependent on cable length and repeaters)

Max. number of nodes 32

Drawing No. 0921-00822/ Part No. 92611 Page 32 of 33 Rev F (Apr 2009)
UltraScan DSP Instruction Handbook
Index

Index
Cable Length for Profibus .......................... 30 Introduction .................................................. 7
Cable length for DeviceNet ........................ 30 LED Indicator ............................................. 23
Cable length for for RS232 30 Locating/positioning the UltraScan DSP .... 11
CTS ........................................................... 19 Mechanical Installation............................... 11
DeviceNet Connector Pin-out: ................... 21 Network connections.................................. 30
Dimensions ................................................ 12 Performance .............................................. 29
Downloading Software ............................... 25 Performance Considerations ..................... 13
DSP module overview ................................. 7 Power......................................................... 29
Electrical Installation .................................. 13 Profibus connector pinout .......................... 20
Electrical specification ............................... 29 Rear Panel ................................................. 15
EMC Directive .............................................. 4 RTS...................................................... 18, 19
Environmental conditions ........................... 29 Safety Information ........................................ 6
Front Panel ................................................ 14 Specifications ............................................. 29
Fuse........................................................... 29 Temperature: ............................................. 29
Gauge/Transducer Sequencing ................. 16 Typical Configuration Diagram ................... 13
I/O Pinout ................................................... 22 UltraScan DSP ............................................. 7
Industrial Environment ................................. 4 Ultrasonic Measurement Principle ............... 8
Intended Use ............................................... 6

Drawing No. 0921-00822/ Part No. 92611 Page 33 of 33 Rev F (Apr 2009)

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