Icon Process Controls Level Pro UltraPro 500 Series Bedienungsanleitung

Ultrasonic level meters

ULTRAPRO 500 MANUAL

UltraPro® 500

INSTRUCTION MANUAL

Ultrasonic level meters

ULTRAPRO 500 MANUAL

www.iconprocon.com | [email protected] | 905.469.9283

1 . Safety ..........................................................................................................................................................................4

2 . Packing, transportation and storage ......................................................................................................4

3 . Measuring principle ..........................................................................................................................................5

4 . Range of application ........................................................................................................................................5

5 . Features of variants ...........................................................................................................................................5

6 . Dimensional drawings ....................................................................................................................................6

7 . Installation and putting into operation .................................................................................................6

8 . Installation instructions...................................................................................................................................7

9 . Electrical connection ......................................................................................................................................10

10 . Set-up elements ..............................................................................................................................................14

11 . Status signalization .........................................................................................................................................15

12 . Setting up ............................................................................................................................................................16

12 .1 . Setting procedure for level meters UPS-500 ...............................................................................16

13 . Protocol Modbus .............................................................................................................................................20

14 . Order code .........................................................................................................................................................20

15 . Accessories ..........................................................................................................................................................21

16 . Safety, protection, compatibility and explosion proof ...............................................................21

17 . Use, manipulation and maintenance .................................................................................................22

18 . General conditions and warranty .........................................................................................................22

19 . Marking of labels ............................................................................................................................................23

20 . Speciﬁcations ..................................................................................................................................................24

TABLE OF CONTENTS

Ultrasonic level meters

ULTRAPRO 500 MANUAL

www.iconprocon.com | [email protected] | 905.469.9283

USED SYMBOLS

1. SAFETY

2. PACKAGING, TRANSPORT AND STORAGE

In order to provide maximum safety of processes, we have defined the following safety and information instructions.

Each of the instructions is marked with an icon.

Any operations described in this User's Guide may only be performed by trained personnel or by an authorized

person. Warranty and post-warranty repairs shall be performed exclusively on the manufacturer's site.

Improper use, installation or setting of the level meter may lead to crashes in the application (overfilling of the

tank or damage to system components).

The manufacturer is not responsible for improper use , work losses resulting from direct or indirect damage

and expenses incurred during installation or use of the level meter.

Alert, warning, danger

This symbol informs about particularly important instructions for installation and operation of the

equipment or about dangerous situations that may occur during installation and operation. Failure to

comply with the instructions may cause failures, damage or destruction of the equipment, or may cause

injuries to persons.

The UPS-500 or UPS-700 device is packed in a cardboard packaging and the whole shipment is placed in a cardboard

box. The cardboard box is suitably filled to prevent mechanical damage during transport. Remove the device from

the package just prior to its use to prevent possible damage.

Transport to the customer is provided by a forwarding company. Subject to prior arrangement, personal pick-up of

the ordered goods is possible in the company's seat. Upon receipt, please check whether the shipment is complete

and corresponds to the extent of the order, or whether during the transport the packaging and the device has not

been damaged. Do not use a device apparently damaged during transport and contact the manufacturer to resolve

the situation.

If the device is transported further, it shall be wrapped in the original packaging and protected against shocks and

weather.

Store the device in its original packaging in a dry place, sheltered from weather, with humidity up to 85% without the

effects of chemically active substances. The range of storage temperature is -20°C to +60°C.

Level meters (sensors) of variants UPS are fitted with protective caps to prevent damage

to the ultrasonic transducer. Remove the caps before commissioning!

Information

This symbol informs about particularly important characteristics of the equipment.

Ultrasonic level meters

ULTRAPRO 500 MANUAL

www.iconprocon.com | [email protected] | 905.469.9283

The UPS Series ultrasonic level sensors are compact measure-ment devices containing an electro-acoustic

transducer and an electronic module. Using the electro-acoustic transducer, level meters and level sensors transmit

a series of ultrasonic puls-es that spread towards the surface. The transducer then receives the reflected acoustic

wave, which is subsequently processed in the electronic module. The current distance to the surface level is

calculated from the time of spread of individual pulses towards the surface and back and the temperature measured

in the tank. The output is then set on the basis of the surface height. The outputs of the ULM level meter are current

4 -20 mA, voltage 0 - 10 V and industrial line RS-485 with Modbus RTU communication. The output of the ULS sensor

consists of a PNP transistor with an open collector and a two-state current switch 4 mA / 20 mA.

3. MEASURING PRINCIPLE

Thanks to the proximity principle employed, the devices are suitable for continuous or limit measurement of the level

of liquids, waste water, sludge, suspensions, adhesives, resins in various open and closed vessels, sumps, open

channels and drains. Applicability for measuring the surface level of loose materials is limited, the range of

measurement is shorter there. Setting is carried out either using two buttons or a magnetic pen or by remote setting

in case of Modbus RTU output. The device is equipped with optical indication of its state (RUN) and the setting

process (STATE). It is manufactured in designs for normal (N) and explosive atmospheres (Xi).

4. RANGE OF APPLICATION

UPS_–53_–01–_ measurement range 0.1 m to 1 m, all-plastic design, source of PVDF (polyvinylidene fluoride),

mechanical connection with thread G ¾.

UPS_–53_–02–_ measurement range 0.20 m to 2 m, all-plastic design, source of PVDF, mechanical connection with

thread G 1''.

UPS_–53_–06–_ measurement range 0.20 m to 6 m, all-plastic design, source of PVDF, mechanical connection with

thread G 1 ½".

UPS_–53_–10–_ measurement range 0.4 m to 10 m, all-plastic case, source of PVDF, mechanical connection with

thread G 2 ¼“.

UPS_–53_–20–_ measurement range 0.5 m to 20 m, all-plastic case, source of PVDF, mechanical connection with

flange of aluminium alloy.

5. FEATURES OF VARIANTS

Ultrasonic level meters

ULTRAPRO 500 MANUAL

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6 . DIMENSIONAL DRAWINGS

ground

terminal

UPS_–53_–02–_ UPS_–53_–06–_

UPS_–53_–10–_ UPS_–53_–20–_

Al alloy

UPS_–53_–01–_

7 . INSTALLATION AND PUTTING INTO OPERATION

This procedure includes the following three steps.

Installation

Electric connection

Setting

Ultrasonic level meters

ULTRAPRO 500 MANUAL

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with the dead zone, the device will not measure properly.

f) If the maximum level in the tank gets into the dead zone, the device shall be mounted into a higher installation

neck. The tank can be then filled nearly up to the maximum volume. The neck’s inner surface shall be even and

smooth (without edges and welded joints), the inner edge should be rounded in the spot where the ultrasonic wave

leaves the pipe. Choose the largest possible neck diameter, but keep the neck height as low as possible. The

recommended dimensions of

a) The device is installed in a vertical position into the upper lid of the tank or reservoir using a lug, a fastening nut or

a flange in such a way that the axis of the device is perpendicular to the surface level of the measured liquid (Fig. 1).

Tightening of the level meter in the welding flange (or. by the fixing nut) is done by hand *. The device shall be

installed in places with no risk of mechanical damage to the front of the sensor.

b) The minimum dimensional parameters when installing into the lid or

the ceiling of the tank are listed in Fig. 3.

c) When installing in an open channel (sump, drain, etc.),

install the device onto a console as close as possible to the expected

maximum level.

d) The reference plane for the measurement is the lower

edge of the transducer (Fig.2). In compliance with the measuring

principle, no signals reflected in the area directly below the device (dead

zone) can be evaluated.

The dead zone (Fig. 2) determines the minimum distance possible

between the device and the highest level. The minimum distances to the

medium are listed in the chapter "Technical specifications".

e) The device shall be installed so that the surface does not interfere with

the dead zone when the tank is filled to the maximum. If the measured

surface interferes

6 . DIMENSIONAL DRAWINGS

Fig. 1: Correct installation of the sensor,

perpendicular to the liquid surface

Fig. 2: Dead zone of the device Fig. 3: Distance of the device from the tank wall

Fig. 4: Installation of the device in the installation neck

UPS_–53–01 ; 02 ; 10

UPS_–53–06

UPS_–53–20

d > c/12

(min. 200 mm)

d > c/8

(min. 200 mm)

d > c/10

(min. 200 mm)

UPS_–53–01; 02; 06

UPS_–53–10

UPS_–53–20

a < 3 b

b > 100 mm

a < 1.5 b

b > 100 mm

a < 1.5 b

b > 150 mm

reference plane for

the measurement

a – neck height from source edge

b – neck width

m – dead zone

d – distance from tank wall

c – maximum reach of the device

m – dead zone

*) To loosen the level meter can be used suitable torque wrench.

Ultrasonic level meters

ULTRAPRO 500 MANUAL

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Fig. 5: Thick foam on the surface

Fig. 6: Minimum distance from close objects in the tank

Fig. 7: Installation of the device out of reach of filling circulation

g) Foam may be produced on the surface of the measured liquid

during filling, mixing and other processes. The thick foam

significantly absorbs the ultrasound signal and may cause

malfunction of the device (Fig. 5). In those cases it is necessary to

test the device in advance and, if necessary, to contact the

manufacturer.

h) The site for installing the level meter needs to be chosen so that

the emitted acoustic signal is not affected by nearby objects

(reinforcements, supports, brackets, ladders, heating elements,

mixers, etc.). These obstacles may result in false rebounds,

increasing measurement inaccuracy (Fig. 6).

i) Do not install the device in or above the filling point (Fig. 7).

The measurement could be affected by the inflowing medium.

j) Applicability for measuring the surface level of bulk-solid materials is limited, the range of measurement is shorter

there. We recommend to consult the suitability of the device for measuring

UPS_–53–01 ;02 ; 10

UPS_–53–06

UPS_–53–20

x > c/12

(min. 200 mm)

x > c/8

(min. 200 mm)

x– distance from the edge of the longest object

c – maximum reach of the level meter

x > c/10

(min. 200 mm)

Ultrasonic level meters

ULTRAPRO 500 MANUAL

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k) The measuring device shall not be installed in places with direct sunlight and

shall be protected against weather conditions.

l) If installation in places with direct sunlight is inevitable, it is necessary to

mount a shielding cover above the device (Fig. 8).

m) It is advisable to keep cable under the cable gland (sagging down) as shown

in Fig. 9 to prevent penetration of moisture. Rain and condensing water can be

therefore drained away freely.

n) The cable gland as well as the connector shall be tightened sufficiently to

prevent penetration of moisture.

o) The ultrasonic signal can be scattered or attenuated if the surface is

moderately stirred or rippled (due to a mixer, inflow of liquid, etc.). This may

result in reduction of the measurement range or unreliable operation of the

device (Fig. 10).

p) False surface reflections of the ultrasonic signal and unreliable operation of

the device might result from the mixer's rotating blades that ripple the surface

level(Fig. 11).

q) The device should not be installed in places with the risk of false reflections of

the ultrasonic signal from the mixer's blades (Fig. 12).

r) Horn adapter ST–G1 (for UPS-500_–02), ST–G1,5 (for UPS-500_-06) or

ST–G2,25 (for UPS-500_–10) for improved reception of the transmitted signal

can be used in open chanels, sumps, etc.

s) Horn adapter ST increases the directivity of the emitted acoustic waves,

improves the reception of weak echoes (unstable surface level, loose

materials) and reduces the risk of false reflections.

t) The horn adapter is installed on the device via process.

Fig. 8: Shielding cover against

direct sunlight

Fig. 9: Protection against penetration

of moisture

Fig. 10: Moderately

stirred surface

Fig. 11: Strongly

stirred surface

Fig. 12: False reflection

from mixer blades

Fig. 13: Horn adapter installation

Horn adapter ST

Ultrasonic level meters

ULTRAPRO 500 MANUAL

www.iconprocon.com | [email protected] | 905.469.9283

• If the level sensor is mounted to bottlenecks and places with

barriers, or near uneven walls or the filling area, where the

transmission signal could be distorted, we recommend using

a guide tube (acoustic horn). The tube must be made from a

single material with a smooth inner surface (see image 14a,

14b ). The minimum tube diameter must have the dimension

„b“ according to image 4

The UPS level meter or ULS level sensor with a G type cable gland are connected to

processing (display) units by means of a cable with an outer diameter of 6 to 8 mm

(recommended wire cross-section 0.5 to 0.75 mm2), via a detachable ISO connector

with inner screw terminals, which is part of the delivery. The connection diagram and

the inner view of the connector are shown in Fig.15 and 16. Non-detachable connector

IP67 with PVC cable 5 m long can be supplied as an extra option.

1. Unscrew the connector from the device body using a

suitable screwdriver.

2. Remove the inner part of the connector using a flat

screwdriver (insert the screwdriver in the gap marked with an

arrow).

3. Unscrew the cable gland and pull the supply cable inside

the connector.

4. Connect the cable wires to the screw terminals as shown in

Fig. 15 (current output 4-20 mA), Fig. 16 (voltage output 0-10

V), Fig. 17 (S type output) or Fig. 18 (P) type output. Tighten the

terminals firmly.

5. Insert the terminals back in the connector so that the NC

terminal points away from the cable gland. Fasten the cable

gland.

6. Check the sealing on the connector and attach the

connector back to the device body.

9. ELECTRIC CONNECTION

Fig. 14a: Short guide tube installation

ventilation

holes

sleeves for

mounting

Fig. 14b: Total guide tube installation

legend:

BK – black brown

BU – blue not connected

BN –

NC –

0 V

Uout

U+

0 V

Fig.15: Connection diagram of

(variant –I) and inside view

the ULM level

meter of the connector

Fig.16: Connection diagram of the ULM level meter

(variant –U) and inside view of the connector

BN 1( )

BU 2( )

Uout

BN 1( )

BK (3)

BU 2( )

BN 1( )

Valid for: UPS_-53_-_ _-_-_-G-_

Performance “G”

with connector ISO

Connection through ISO connector

Connecting the cable to the device:

Ultrasonic level meters

ULTRAPRO 500 MANUAL

www.iconprocon.com | [email protected] | 905.469.9283

Type UPS-500_–_ _–_–S–G–_

Positive supply pole +U is

connected to the brown wire

or to connector pin 1, negative

pole to the blue wire or to

connector pin 2.

Type UPS-500_–_ _–_–P–G–_

Positive supply pole +U is

connected to the brown wire

or to connector pin 1, negative

pole to the blue wire or to

connector pin 2. Load is

connected to the black wire or

to connector pin 3.

Type UPS-500_–_ _–_–I–C–_

The positive supply pole +U is

connected to connector pin 1 or the

brown wire of the connected cable,

the negative pole is connected to

connector pin 3 or the blue wire of

the connected cable.

Type UPS-500_–_ _–_–U–C–_ The

positive supply pole +U is

connected to connector pin 1 or the

brown wire of the connected cable,

the negative pole is connected to

connector pin 3 or the blue wire of

the connected cable. Output

voltage is connected to connector

pin 4 or the black cable wire.

The ULM level meter or ULS level sensor with a C type cable gland are connected to processing (display)

units by means of a cable with an outer diameter of 4 to 6 mm (recommended wire cross-section 0.5 to

0.75 mm2), via a connector socket with a moulded cable (2 or 5 m long) or via a detachable connector

socket without a cable (see accessories). In this case connect the cable to the inner socket pins under

Fig. 19.

Connection through M12 connector

0 V

Uout

0 V

legend:

BN – brown

BK – black

BU – blue

output (BK)

0V (BU)

+U (BN)

0 V

Uout

Fig. 17: Connection diagram of the ULS sensor with S type output

(two-statecurrent switch 4 mA / 20 mA)

Fig. 18: Connection diagram of the ULS sensor with P

type output (PNP) with an open collector

Fig. 19: Inside view of the connector socket

Fig. 21: Connection diagram of the ULM level meter (variant –U)

and view of the connector

Fig. 20: Connection diagram of the ULM level meter (variant –I)

BN 1( )

BU 2( )

mA +U

BN (1)

BU (2)

BK (3)

UUout

BN 1( )

BU (3)

BK(4)

mA +U

BN 1( )

BU (3)

Performance "C"

with connector M12

Valid for: UPS_-53_-_ _-_-_-C

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