Limaco ULM-3D Series Technisches Datenblatt

ULM-3D RADAR LEVEL TRANSMITTER

FOR BULK MATERIALS

Operating and Installation Manual

300028, Tula, 94 Boldina St.

t/f +7-4872-22-44-09

e-mail: in@limaco.ru

www.limaco.ru

LIMACO

JSC

TABLE OF CONTENTS

1 Document Info

1.1 Purpose……………………………………………………….. 5

1.2 Target group…………………………………………………... 5

1.3 Symbols …………………………………………………….... 5

2 Safety basics

2.1 Personnel requirements………………………………………. 6

2.2 Purpose ………………………………………………………. 6

2.3

Operational safety ……………………………………………. 6

2.4 General safety guidelines……………………………………... 7

2.5 Environmental safety ………………………………………… 7

3 Product description

3.1 ULM-3D scope of supply….…………………………………. 7

3.2 Product design ……………………………………………….. 8

3.3 Product identification ………………………………………… 9

3.4 Operation concept ……………………………………………. 9

3.5

ULM-3D-5 operation specifics………………………….......... 12

3.6 Acceptance, packaging, transportation, and storage rules

…………………………………………………………………

4 Installation

4.1 General recommendations for level transmitter placement

…………………………………………………........................

4.2 Position for installation ………………………………………. 19

4.3 Requirements for the installation on mounting nozzle for

ULM-3D-5 …………………………………………….……...

4.4 Requirements for the installation on mounting nozzle for

ULM-3D-1 …………………………………………….……...

4.5 Measurement beam coverage ………………………………… 21

4.6 Blind spot …………………………………………………….. 21

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4.7 Installation examples for ULM-3D-5………………………… 22

4.8 Installation examples for ULM-3D-1………………………… 23

5 Electrical connection

5.1 General instructions…………………………………………... 25

5.2 Connection cable ……………………………………………... 25

5.3 Shielding and earthing ……………………………………….. 26

5.4 Pin assignment. Connection. …………………………………. 27

5.5 Power supply …………………………………………………. 30

5.6 How to connect the device …………………………………… 31

6 Initial setup and commissioning

6.1 Level transmitter address setup ………………………………. 34

6.2 PC connection via RS-485……………………………………. 35

6.3

Setting key parameters of level transmitter using PC via RS-

485 …………………………………………………………….

7Troubleshooting 39

The structure of volume measurement system ………………..

Brief description of the initial master software setup…………

10 Maintenance ………………………………………………… 48

10.1 Preventive inspection, preventive maintenance ………………

10.2 Preventive inspection with the removal of level transmitter,

preventive maintenance ……………………………..………..

Dismantling

11.1 Dismantling procedure ……………………………………….. 48

11.2 Disposal ………………………………………………………. 49

12 Repair………………………………………………………... 49

13 Appendices

13.1 Technical specifications………………………………………. 50

13.2 Level transmitter connection to the mounting flange and over-

all dimensions of ULM-3D-5 ……………………….………..

13.3 Level transmitter connection to the mounting flange and over-

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all dimensions of ULM-3D-5 ……………………….………..

13.4 Handling of cable gland ……………………………………… 56

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1 DOCUMENT INFO

1.1 Purpose

This operating manual contains information necessary for installation, connection,

commissioning, and configuration, as well as instructions for maintenance and

Troubleshooting. Please read the instructions provided here before the installation

and commissioning of the level transmitter.

1.2 Target group

This operating manual is intended for trained personnel who perform installation,

commissioning, diagnostics, and maintenance of the level transmitter. The person-

nel shall know and follow the instructions provided in this document.

1.3 Symbols

Symbol

Description

Failure to follow the instructions may disable the

device or cause its malfunction.

Failure to follow the instructions may cause damage

to personnel and/or to the device.

The symbol indicates useful information that needs

attention.

ATTENTION

WARNING

NOTE

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2SAFETY BASICS

2.1 Personnel requirements

Personnel who perform installation, commissioning, diagnostics, and maintenance

of the level transmitter shall read this manual and be admitted to work with the de-

vice. When working with equipment, personnel shall use the required personal pro-

tective equipment in accordance with the company's regulations.

2.2 Purpose

ULM-3D level transmitter is designed for continuous non-contact measurement of

the level of any bulk materials and is intended for use in process flow metering sys-

tems and product inventory management. ULM-3D level transmitter can be used to

measure the level and volume in tanks and open storage facilities. A system of mul-

tiple level transmitters can be used for large tanks and storage facilities. The soft-

ware package can display a three-dimensional picture of the measured material on a

remote computer.

The level transmitter marked Ex tb IIIC T85°C Db is intended for use in explosive

dust environments for conductive dust for installation in zones of class 21, 22 as per

GOST IEC 60079-10-2-2011.

Before using level transmitters in an explosion hazardous zone, make sure that the

version indicated on the nameplate corresponds to the one acceptable for use in this

zone.

Climatic category is О1 as per GOST 15150-69.

The level transmitter belongs to D3 group as per GOST R 52931-2008 in terms of

resistance to the influence of temperature and ambient air humidity.

Undue device application can result in occupational accident or device failure and is

a source of potential danger.

2.3 Operational safety

The operational safety of device is ensured only subject to the observation of in-

structions provided herein.

The level transmitter corresponds to safety integrity level 3 (SIL 3) as per GOST R

IEC 61508-1-2012, GOST R IEC 61511-1-2011.

Due to operational safety and warranty reasons, any modifications to the device de-

sign are prohibited. Any actions with the device other than those described in this

manual can only be performed with the official permission of the manufacturer. The

service life of level transmitters is 20 years.

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2.4 General safety guidelines

ULM-3D level transmitter meets all modern requirements and safety standards.

The operating frequency of level transmitter is about 125 GHz. The radiation pow-

er does not exceed 8 MW, which is significantly lower than the maximum permissi-

ble values. The level transmitter is completely safe for humans and animals.

The device may be operated only in good working order to avoid occupational acci-

dents.

ULM-3D level transmitter without an explosion protection label may be used only

in an explosion-proof zone.

2.5 Environmental safety

Compliance with the recommendations provided in sections "Packaging, transporta-

tion, and storage" and "Disposal" contributes to environmental protection.

3. PRODUCT DESCRIPTION

3.1 ULM-3D scope of supply

The scope of supply includes:

- Radar level transmitter

- Documentation and software on electronic media:

- Ulmcfg setup and configuration software;

- Software for setup via Bluetooth for Android mobile operating system;

- Limaco OPC-server software;

- Multi Beam Radar Surface Plotter software;

- Operating and Installation Manual;

- Supplementary documentation (certificates and permits, if necessary, other

technical information).

1 piece of software and documentation on electronic media can be supplied for the

entire order as per the specification.

Optional equipment that can be included in the order specification:

- power supply;

- RS-485 interface converters;

- mounting kit.

The specific type of optional equipment (interface adapters, mounting products)

may have different versions. This is to be agreed when ordering the equipment and

stated in the order specification.

NOTE

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3.2 Product design

Fig. 3.1. Appearance and location of key ULM-3D-5 components

Fig. 3.2. Appearance and location of key ULM-3D-1 components

1 – aerial unit housing;

2 – mounting flange;

3 – cable gland or cable gland plug;

4 – electronic module housing;

5 – electronic module cover;

6 – Bluetooth module plug;

7 – aerial unit shield.

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3.3 Product identification

The device is identified in one of the possible ways:

- as per the data specified on the device nameplate;

- as per the attached product data sheet;

- upon request to the manufacturer with the indication of level transmitter serial

numbers.

A standard level transmitter nameplate contains the following data for device identi-

fication and application:

- manufacturer's logo;

- device type;

- serial number;

- year of manufacture;

- IP rating;

- explosion protection marking;

- name of the certification body and number of the certificate of conformity;

- permissible ambient temperature;

- supply voltage;

- output signals.

An example of a standard nameplate is shown in Fig. 3.3

ОС ООО « ХХ Х »

№ ТС RU C-RU.АМ02.В. ХXXX

Fig. 3.3. Standard nameplate

Level transmitter designation system has the following form:

ULM-3D-Х, where

Х – level transmitter version: 1 – one measuring channel, 5 – measuring channels.

3.4 Operation concept

The level transmitter is installed above the measured surface of material. The device

is mounted in an opening on the tank roof using a flange in a closed tank (Fig. 3.4),

and using a special bracket in open tanks and storage facilities. The device measures

the distance Lifrom the bottom surface of mounting flange to the product surface

for each of the measuring channels. Then the level is calculated using the formula

Ui=H-Li *cos(ai), where H is the installation height, aiis the tilt angle of i-channel.

The base plane of the measuring range of level transmitter is the lower surface of

mounting flange (Fig. 3.1 item 2).

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Fig. 3.4. ULM-3D-5 level transmitter on the tank

Radar level transmitter aerial system emits a radio signal with a frequency of about

125 GHz and receives an echo signal reflected from the product surface. The elec-

tronic unit processes the echo signal by means of a software and hardware complex

and converts it into a corresponding output signal that carries information about the

measured value.

1 – level transmitter;

2 – emitted signal;

3 – reflected signal;

4 – the surface of measured product.

Fig. 3.5. Measurement method

The level transmitter operates as a FMCW (Frequency Modulated Continuous

Wave) radar. This is one of conventional methods of non-contact distance mea-

surement, which minimizes the influence of spurious interference and interference

associated with irregularities (disturbances) of the surface of measured product.

The operation concept is as follows: a low-power microwave generator generates a

probing radio signal with linearly increasing frequency during the measurement pe-

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