DCR-1006A Instructional Video Pt. 2

This two-part video series provides a step-by-step guide to setting up and configuring the APG DCR-1006A controller for sensor control and monitoring. The DCR-1006A is a versatile solution for on-site level monitoring and remote communication through APG’s Tank Cloud.

You’ll learn how to:

  • Wire DST, MNU, and MPX sensors using RS485 communication

  • Connect AC or DC power to the DCR-1006A

  • Configure relay trip points for applications like conveyor control

  • Set up level monitoring in tanks using 4–20 mA analog output

  • Adjust sensor sensitivity, blanking, and application modes for your needs

Whether you’re monitoring moving equipment or managing tank levels, this tutorial walks through practical examples and shows how to tailor the DCR-1006A for your application.

Transcript: (Part 2)

“The DCR-1006A is a versatile display and controller designed for use with APG’s DST, MNU, and MPX sensors. Because of the DCR-1006A’s wide range of functionality, settings may need to be changed to optimize the unit for your specific sensor and application. If you encounter an error code during setup, this video serves as a troubleshooting guide to help identify and remedy the problem. Different error codes designate different failures. In this video, we will cover what the various error codes mean, along with potential causes and solutions.

The DCR-1006A is equipped with a failsafe designed to prevent sensor damage from an electrical short. An E1 error code means a short-circuit has been detected in the DST sensor line, and power to the sensor has been interrupted to prevent damage. The most common cause of this failure is sensor wires inadvertently making contact, which may occur due to wire fraying or excessive insulation being stripped from the wire, allowing contact between bare wires. Use caution when installing wires, ensuring all strands are twisted and properly secured in the connector. Strip wire ends so the insulation covers the wires as close to the connector as possible without being pinched. To prevent damage, always verify that your power supply is compatible and that the wiring of the DCR and all components is correct before applying power. For more details, see DCR-1006A Instructional Video #1 for a guide to powering your unit.

An E2 error is displayed when the DCR-1006A is not communicating with the selected sensor. For DST sensors, communication failure may be caused by damage to components on the positive power line due to exposure to excessive power. This issue may be diagnosed by checking the current draw of the sensor. While low or no current draw does not rule out this type of damage, a high current draw over 100 milliamps indicates damaged components. The most common cause of communication failure is improper setup. First, check the DCR’s communication settings by accessing the Basic Menu and Input Select submenu, verifying that the setting matches the sensor you are trying to communicate with. If the DCR is set up for RS485 communication while you have a DST sensor installed—or vice versa—the devices will not communicate. Always double-check sensor wiring before powering the sensor, as incorrect wiring can prevent communication and potentially damage the sensor. If you are using an RS485 sensor, make sure the sensor address is set to Address 1, since the DCR-1006A can only communicate with a sensor at this address. You can change the Modbus address of the DCR-1006A by accessing the Basic Menu and Sensor Number submenu. If you have verified correct setup but still cannot establish communication, test the sensor directly with your RS485 connection and computer. If the sensor successfully communicates with another device, the DCR-1006A may be damaged. In this case, please contact the factory for technical support.

An E3 error indicates a loss of echo, meaning the sensor is communicating with the DCR-1006A but cannot acquire a target. This failure commonly occurs due to installation or setup issues. To avoid this error, ensure that the sensor is mounted perpendicular to your target; deviations of more than five degrees may prevent detection. Ideal target surfaces are hard and smooth, while materials that absorb sound waves will reduce operating range and accuracy. These factors become increasingly important as the distance between the sensor and target grows. Sensitivity and pulse settings can be adjusted for better target acquisition. For sound-absorbing targets, increase these settings for a stronger ultrasonic pulse. Conversely, if the sensor is mounted in a tank prone to echoing, lower these settings for more precise readings. There should always be a three- to four-foot diameter column of unobstructed air between the sensor and target. Mount the sensor away from fill spouts to avoid false readings from splashing or sloshing. If the tank has a domed top, avoid mounting the sensor at the center of the dome, as this can create echoes that cause target loss. Similarly, avoid placing the sensor too close to tank walls, which may inadvertently be detected as targets.

The distance from the sensor to the closest possible target should always be greater than the blanking distance. In applications where headroom does not allow this, a standpipe can be used to mount the sensor above the tank. The standpipe should be smooth and straight with no joints, burrs, or obstructions. Ideally, its diameter should be half its length, and the end of the pipe should be cut at a 10- to 45-degree angle. In areas that are difficult to access or prone to sloshing liquid or foam buildup, a stilling pipe may be used to provide a better target for the sensor. However, this solution is only suitable for liquid targets that do not leave deposits. A vent hole must be included above the liquid level but inside the blanking distance. Since a stilling pipe greatly reduces the target area, sensitivity and pulse settings will likely need to be reduced to prevent unwanted echoes.

Environmental conditions such as temperature, humidity, vapors, dust, and pressure can affect sensor performance. APG sensors are built to compensate for many of these factors; however, in extreme conditions you may need a sensor rated for longer ranges than would normally be required. Environments with heavy chemical vapors such as solvents or gasoline, heavy dust, or excessive surface foam may not be suitable for ultrasonic sensors. For additional troubleshooting help, please contact APG technical support.”