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Summary of Contents for Dwyer Instruments ULS Series
- Page 1 L‐ULS Series ULS Small Tank Ultrasonic Transmitter, Switch and Controller Series ULSS, ULSM, ULSL Manual Rev A MN890570 1 of 30 ...
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Page 2: Table Of Contents
INTRODUCTION / TABLE OF CONTENTS Step One Series ULS is an innovative level sensor family that replaces float, conductance and pressure sensors that fail due to contact with dirty, sticking and scaling media in small (< 4’/1.25m) to medium (<18’/5.5m) tall tanks. Applied in skid, machine, tool and process applications, the general purpose sensors are available with single and multi‐function capabilities including measurement, switching and control. Features Simple configuration with ULSX‐CAL software, no more target calibration Adjustable Loop Fail‐Safe Easy to reverse mA output Increased output filtering Table of Contents Specifications: ................................. 3 Dimensions: ................................. 4 Safety Precautions: .............................. 5 Components: ................................. 6 Getting Started: .............................. 7 USB Fob Interface: ............................. 7 ULSX‐CAL: ................................. 8 Configuration: ............................ 9 Tank Levels & Relay Values: ........................ 16 Write to Unit & Wiring Diagram: ...................... 17 Wiring: ............................... 18 Wire Connections: ............................ 18 Switch Inductive Loads: .......................... 19 Installation: ... -
Page 3: Specifications
SPECIFICATIONS Step Two Range: ULSS: 49.2” (1.25m) Contact rating: 60 VA, 1A maximum ULSM: 9.8’ (3.0m) Contact fail‐ Power loss: Hold last, ULSL: 18.0’ (5.5m) safe: Power on: Open, close or hold last Accuracy: ULSS: 0.125” (3mm) Hysteresis: Selectable ULSM: +/‐ 0.2% of range Process temp.: F: 20° to 140° ULSL: +/‐ 0.2% of range C: ‐7° to 60° Resolution: ULSS: 0.019” (0.5mm) Temp. comp.: Automatic ULSM: 0.039” (1mm) Ambient temp.: F: ‐31° to 140° ULSL: 0.079” (2mm) C: ‐35° to 60° Dead band: ULSS: 2” (5 cm) Pressure: MWP = 30 PSI ULSM: 4” (10 cm) Enclosure rating: Type 6P encapsulated, corrosion ULSL: 8” (20 cm) resistance & submersible (IP68) Beam width: ULSS: 2” (5cm) dia. ... -
Page 4: Dimensions
DIMENSIONS Step Three Series ULSL Series ULSM Series ULSS 4 of 30 MN890570 Rev A ... -
Page 5: Safety Precautions
SAFETY PRECAUTIONS Step Four About this Manual: PLEASE READ THE ENTIRE QUICK START PRIOR TO INSTALLING OR USING THIS PRODUCT. This manual includes information on the Series ULS Ultrasonic Level Switch, controller and transmitter from Dwyer Instruments, Inc. Please refer to the part number located on the switch label to verify the exact model configuration, which you have purchased. User’s Responsibility for Safety: Dwyer Instruments, Inc manufactures a broad range of level sensing technologies. While each of these sensors is designed to operate in a wide variety of applications, it is the user’s ... -
Page 6: Components
COMPONENTS Step Five Series ULS is offered in different models. Depending on the model purchased, you may or may not have been shipped all the components shown below. You do however, need a Series ULS, USB Fob and FKM gasket to configure, install and operate Series ULS. P/N Max. Range Dead Band Thread Fob * Outputs ULSS‐10 4.1’ (1.25 m) 2” (5cm) 1” NPT No Fob 1,2 ULSS‐11 4.1’ (1.25 m) 2” (5cm) 1” NPT Fob Included 1,2 ULSS‐20 4.1’ (1.25 m) 2” (5cm) 1” G No Fob 1,2 ULSS‐21 4.1’ (1.25 m) 2” (5cm) 1” G Fob Included 1,2 ULSM‐10 9.8’ (3.0 m) 4” (10cm) 1” NPT No Fob 1,2 ... -
Page 7: Getting Started
GETTING STARTED Step Six Series ULS is configured through ULSX‐CAL, a PC software program. ULSX‐CAL is a free download from Dwyer Instrument, Inc’s website. You must download and install ULSX‐CAL prior to plugging in the USB Fob. Please go to http://www.Dwyer‐Inst.com/software, click on ULSX‐CAL. Please observe the following requirements for the ULSX‐CAL software: ULSX‐CAL System Requirements Windows(R) 2000, Windows(R) XP, Windows Vista (R), Windows(R) 7 32 or 64‐bit operating system 1 USB 2.0 port 10 mB hard drive space 256 mB RAM Internet connection USB Fob Interface: The Series ULS communicates with ULSX‐CAL through a USB interface (p/n: ULS‐ACC‐USB) called a Fob. Before plugging your Fob into your computer’s USB port, be sure that you have installed ULSX‐ CAL on your computer. Connect the red, green, white and black wires from Series ULS into the correct terminals on the Fob. Tighten the screws on the terminals and plug your Fob into the USB port of your computer. Wiring identical for all series – Use only the Red, Black, Green and White wires. The maximum cable distance between the computer and Series ULS is 15’ (4.6 m). This only applies when configuring the Series ULS. Once Series ULS is configured and prior to installation, isolate the white and green wires from active power to prevent a short of the configuration circuit. When using the Fob, do not add VDC power. The Fob, when connected to the computer, will provide the required power to the Series ULS. Windows(R) is a registered trademark of Microsoft Corporation ... -
Page 8: Ulsx-Cal
ULSX‐CAL Step Seven With Series ULS connected to your computer, open the ULSX‐CAL software by clicking on the ULSX‐CAL icon. Follow steps 1‐3 to configure the transmitter. Click “Help” in the lower right hand corner and open the help menu of ULSX‐CAL for additional instructions on ULSX‐CAL. If you need additional assistance using ULSX‐CAL, please contact a Dwyer Instruments, Inc Applications Engineer at (800) 872‐9141. Above Screen Capture is for the Series ULSS. 8 of 30 MN890570 Rev A ... -
Page 9: Configuration
ULSX‐CAL CONFIGURATION Step Seven This section of ULSX‐CAL is where you select the application’s configuration settings. Start from the top and work to the bottom, choosing the selections that are applicable to your configuration. “Not Applicable” will automatically show when a selection doesn’t apply to your configuration settings, and you may move on. All configuration settings must be selected or have “Not Applicable” before you can continue to the next step. Note: Pressing the Clear Screen button will reset the configuration table and allow access to all of the features. Number of Pumps: This feature allows you to select the number of pumps or valves used with Series ULS. This is the setting that activates the control capabilities of up to two relays. Control relays are often referred to as latching relays. o Switch/Alarms Only – The relays will be standard single point relays (High and/or Low alarms). Relays are non‐latching. o 1‐ Pump/Valve – One relay will be configured as a control or latching relay (relay will have a start level and a separate stop level). Use this setting to control one pump or valve for automatic filling or emptying of a tank. - Page 10 ULSX‐CAL CONFIGURATION (continued) Step Seven Pump/Valve Action: This feature allows you to select if the pumps or valves will be used to automatically fill or empty the tank. For 2‐ Pump/Valve mode, both devices must be the same (automatic fill or empty). You cannot set one relay for fill and the other for empty. o Empties Tank – Will set relay(s) to automatically empty a tank. Start level will be above the Stop level for each relay. o Fills Tank – Will set relay(s) to automatically fill a tank. Start level will be below the Stop level for each relay.
- Page 11 ULSX‐CAL CONFIGURATION (continued) Step Seven Pump/Valve Mode: This feature allows you to select the mode for a control or latching relay. Pump/Valve mode is not active for Switch/Alarms Only or 4‐20 mA Transmitter Only. o Simplex – Allows for the relay to be used as an automatic fill or empty. This is the default and only configuration when 1‐ Pump/Valve is selected. o Simplex used to Empty Tank (example) o Lead/Lag – Allows for the two relays to have unique start levels and a common stop level. The first relay will be identified as the ...
- Page 12 ULSX‐CAL CONFIGURATION (continued) Step Seven Relay Fail‐Safe: This feature allows you to select the fail‐safe state for the relays. When the sensor regains signal, the output current will revert back to the current level condition. o Relays Off ‐ The relays will revert to the OFF state. Appears when Switch/Alarms Only is selected. o Relays On ‐ The relays will revert to the ON state. Appears when Switch/Alarms Only is selected. o Hold State ‐ The relay(s) will remain in the same state as the last echo detected. When the sensor regains signal, the relays will revert to the level when the signal was regain.
- Page 13 ULSX‐CAL CONFIGURATION (continued) Step Seven Switch/Alarm Configuration: This feature allows you to select the operation for the switches / alarms (used as a high or low alarm). This setting adjusts the number of available relays based upon the previous settings. o No Alarm – Turns off all of the remaining relays. o High Alarm Options – Set from 1 to 4 High Alarms (1‐High, 2‐ High, 3‐High, 4‐High). o Low Alarm Options – Set from 1 to 4 Low Alarms (1‐Low, 2‐ Low, 3‐Low, 4‐Low).
- Page 14 ULSX‐CAL CONFIGURATION (continued) Step Seven Switch Hysteresis/Dead band: This feature allows you to select a hysteresis or dead band for the remaining high and/or low alarms. o Options for Hysteresis/Dead band – No Hysteresis, ¼”, ½”, 1”, 2”, ½ cm, 1cm, 2 cm, 5 cm or Not Applicable. o High Alarms – Relay activates above set point. Relay will deactivate when level goes below the set point plus the value of the hysteresis. o Low Alarms – Relay activates below set point. Relay will deactivate when level goes above the set point plus the value of the hysteresis.
- Page 15 ULSX‐CAL CONFIGURATION (continued) Step Seven Loop Fail‐Safe: This feature allows you to select the fail‐safe current output if the sensor fails to detect a return signal. When the sensor regains signal, the output current will revert back to the current level condition. o Hold Last Value ‐ The output will remain in the same state as the last echo detected. Example: If the output was 6.7 mA just prior ...
- Page 16 ULSX‐CAL TANK LEVELS / WRITE TO UNIT Step Seven ULSX‐CAL ‐ Tank Levels: This section of ULSX‐CAL is where you enter application measurement values. This applies to all versions of the Series ULS. You must enter the Sensor Height and Fill Height values. For the Series ULSS, ULSM and ULSL, the Sensor Height and Fill Height values determine the operational range for the 4‐20 mA output. Sensor Height: Distance from the bottom of the tank to the bottom of the transducer. Fill Height: Distance from the bottom of the tank to the maximum liquid height. ULSX‐CAL ‐ Relay Values: (Series ULSS, ULSM and ULSL only): This section of ULSX‐CAL is where you enter the operational values for relays. You must enter values within all of the fields shown. The value fields shown are based upon the configuration of the Series ULS. All values must be in the units of operation selected above and are based upon units of liquid. All relay values must be greater than Liquid Empty (0) and less than ...
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Page 17: Write To Unit Wiring Diagram
ULSX‐CAL ‐ WRITE TO UNIT Step Seven After you have entered configurations and tank Write to Unit values, click “Write to Unit” and send the Wiring diagram configuration to your Series ULS. Now use ULSX‐CAL’s file management features to save your configuration by clicking “Save Config File” and print your wiring diagram by clicking “Wiring Diagram.” Save Config File Wiring Diagram ‐ Sample Diagram will change based upon the configuration of the Series ULS, use ULSX‐CAL to view appropriate wiring diagram. ... -
Page 18: Wiring
WIRING Step Eight Wire Connections: Red & Black: Red and Black leads are for connection to a 12‐28 VDC power supply or to a 4‐20 mA loop power source (Series ULSS, ULSM & ULSL only). The red and black wires can be extended up to 1,000 feet using a 22 gauge or larger wire, however do not extend the green and white wires. White & Green: White and Green leads are reserved for use with ULSX‐CAL and should not be connected during usage in the application. These wires should not be connected to ULSX‐CAL while power is supplied from any source other than the ULS‐ACC‐USB Fob. The maximum cable distance between the computer and Series ULS is 15’. Never allow the white or green wires to touch any power supply. Blue, Orange, Yellow, Purple & Brown: Blue, Orange, Yellow & Purple wires are the relay contacts (normally open) from each of the relays respectively. The Brown wire is the common for all the relays. Relay selection is determined by the configuration in ULSX‐CAL. Note: Series ULS uses latching relays. When power is removed to the sensor, the relays will remain in their last state. Ex: If the relay is energized, when power is removed, the relay will remain in an energized state. General notes for electrical connections, usage and safety: Where personal safety or significant property damage can occur due to a spill, the installation must have a redundant backup safety system installed. Wiring should always be completed by a licensed electrician. ... - Page 19 WIRING Step Eight Switching Inductive Loads: The use of suppressors (snubbers) is strongly recommended when switching inductive loads to prevent disrupting the microprocessor’s operation. The suppressors also prolong the life of the relay contacts. Suppression can be obtained with a catch diode for DC circuits and a resistor‐capacitor (RC) for AC circuits. Catch Diode Always use stepper relays between the sensor and external loads. For DC circuits use a catch diode such as 1N4148, shown on left. Refer to the following circuits for RC network assembly and installation: Choose R and C as follows: R: 0.5 to 1 Ohms for each volt across the contacts C: 0.5 to 1 μF for each amp through closed contacts Notes: 1. Use capacitors rated for 250 VAC. 2. RC networks may affect load release time of solenoid loads. Check to confirm proper operation. 3. Install the RC network at the meters relay screw terminals. An RC network may also be installed across the load. Experiment for best results. Voltage Output: Series ULS can be used as a 0 to 5 or 0 to 10 VDC output device. A resistor will need to be added to the circuit to enable a voltage output (refer to the wiring diagram below). ...
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Page 20: Installation
INSTALLATION Step Nine The Series ULS should always be mounted perpendicular to the liquid surface and installed using the provided FKM mounting gasket. Make sure that the fitting and transmitter threads are not damaged or worn. Always hand‐tighten the transmitter within the fitting. Perform an installed leak test under normal process conditions prior to system start up. Note: The preferred mounting fitting for the Series ULSS & ULSM is the ULS‐ACC‐121 (2” thread x 1” thread) reducer bushing. Mounting Guide 1. Do not mount at an angle 2. Liquid should never enter the dead band 3. Side Wall: a. Mount at least 2” from the side wall b. For Series ULSL ‐ mount at least 3” from the side wall 4. Do not mount where obstacles will intrude on sensor’s beam width a. See Specifications, Step Two 5. Do not mount in a vacuum 6. Avoid mounting in the center of a dome top tank. 7. In cone bottom tank, position the sensor over the deepest part of the tank. Do not install at Do not install within angle relative to the 2” of tank sidewall. liquid. (3” for Series ULSL) Do not install with Do not install in objects in the beam. applications with vacuum. Installation in existing fittings: If the existing fitting is larger than the threads of the Series ULS, select a reducer bushing such as the ULS‐ACC‐121 (2” thread x 1” thread) or ULS‐ACC‐131 (3” thread x 2” thread). ... -
Page 21: Fitting Selection
INSTALLATION Step Nine Fitting Selection: Check the part number to determine the required fitting mount size and thread type. Series ULS is commonly installed in tank adapters, flanges, brackets or standpipes. Note: Always include the gasket when installing the Series ULS. 1. Tank Adapter: Select a tank adapter fitting, such as the ULS‐ACC‐410 for the Series ULSS & ULSM or the ULS‐ACC‐420 for the Series ULSL. a. For best results, select a 2” tank adapter and add a reducer bushing such as the ULS‐ACC‐121, thread x thread, reducer bushing. b. Avoid tank adapter (thread x thread) styles and/or pipe stops forward of the installed transducer. c. Always mount the tank adapter so the majority of fitting is outside the tank. i. Never mount the tank adapter upside down or the bulk of the material is inside the tank. -
Page 22: Flange
INSTALLATION Step Nine 3. Flange (Series ULSS & ULSM): If installing on a flange, select a flange with a thread that is above the plane of the flange, such as the ULS‐ACC‐312. a. The Series ULSL works well with flange installations. b. Avoid the use of blind flanges with tapped threads or flanges where the threads are even with the plane of the flange, such as the Banjo 1" Poly ANSI Flange (series AF100). c. Use a flange with a 2” thread and add a 2” to 1” reducer bushing to complete the installation. 2” Flange w/ 1” Flange w/ 2” Flange w/ thread out of plane thread in plane reducer bushing (ULS‐ACC‐312) (ULS‐ACC‐121) Do not use thread in plane 4. Side Mount Bracket: For installations in open tanks and sumps, use the ULS‐ACC‐510 or ULS‐ACC‐520 side mount bracket. a. For the Series ULSS & ULSM, order the ULS‐ACC‐510, which includes a 2” x 1” Reducer Bushing. b. For the Series ULSL, order the ULS‐ACC‐520 side mount bracket. 22 of 30 MN890570 Rev A ... -
Page 23: Stand Pipe
INSTALLATION Step Nine 5. Stand Pipe: A standpipe maybe used to dampen turbulence or when foam is present in the application. a. Pipe can be made of any material. b. Select a minimum 3” ID pipe for the stand pipe. i. A 2” pipe is usable with the Series ULSS & ULSM, but is the minimum. ii. Pipes larger than 3” can also be used. c. Use a coupling and reducer bushing to attach the Series ULS to the pipe. i. Be sure to use a plastic reducing bushing such as ULS‐ACC‐121 (2” T x 1” T) fitting or the ULS‐ACC‐221 (2” S x 1” T) fitting. ii. For the Series ULSL, use a reducer bushing such as ULS‐ACC‐131 (3” T x 2” T) fitting or the ULS‐ACC‐231 (3” S x 2” T) fitting. d. The pipe length should run the measurement span and the bottom of the pipe should remain submerged at all times to prevent foam from entering the pipe. e. -
Page 24: Advanced Feature
ADVANCED FEATURES Step Ten This tool is designed to help solve operational issues. Changing these setting will alter the performance of your unit. Please read through this HELP file to assist you in making adjustments or if you are still unclear about a specific issue, please contact Dwyer Instruments, Inc, Applications Engineering. ... - Page 25 ADVANCED FEATURES Step Ten Increase Output Filtering: Placing a check mark in the box will increase the filtering (averaging) of the analog output. Use this filter if the 4 to 20 mA output requires a smooth output for the application such as open channel flow measurement. Decrease Output Filtering: Placing a check mark in the box will eliminate all filtering (averaging) of the analog output. Enables a pulse by pulse level reading. Use this filter to see changes in level after every sound pulse. Note: Never check increase output filtering and decrease output filtering at the same time. Stabilize Output in Dead band: Placing a check mark in the box will activate a filter to hold the output at Full Level if the level enters the dead band of the Series ULS. This filter requires the level to leave the dead band at a smooth and steady rate. Turn OFF Fast Level Changes: Placing a check mark in the box will turn off the filter enabling fast level changes. Use this filter if your application has very smooth, slow and steady level changes. The filter instructs Series ULS to look only for small incremental changes in level. Turn ON Noisy Mount Start Filter: Placing a check mark in the box will activate a filter that reduces sound interference from the installation mount. Use this filter if the Series ULS will not go to full range in the installation. Invert Relay States: Placing a check mark in any of the four boxes will reverse the state of that relay.
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Page 26: Appendix
APPENDIX Step Eleven Updating ULSX‐CAL Software: ULSX‐CAL software can be updated directly from the software. Simply click on the Updates Tab at the top of the window and press the “Download” button. Make sure that your computer has access to the Internet. If not, an error window will appear. When the Download button is pressed, the software will check the version of software you are using with the most recent version at Dwyer Instruments, Inc. If the versions are similar, a window indicating that the most recent version is installed. If not, then a window will appear asking to download the latest version. Follow the instructions for installing the latest version. 26 of 30 MN890570 Rev A ... -
Page 27: Updating Transmitter Firmware
APPENDIX Step Eleven Updating Transmitter Firmware: ULSX‐CAL software can also be used to update firmware inside the Series ULS transmitter. This feature allows the transmitter to be updated when new features are added. First open ULSX‐CAL with an Series ULS transmitter connected and the latest version of ULSX‐CAL installed to your PC. Click on the “Updates” Tab and then click on “Select Program” to select the firmware update. Select the latest version of the firmware file and click on OK. Confirm that the address is correct and then click on “Update Sensor” to begin the firmware update. This step should take less than 1 minute. You can follow the progress with the status bar to the right of the Update Sensor button. When completed, click on the Configuration tab to configure the transmitter. Remember, when the firmware has been updated, the unit will return to its original factory settings. If there is a communication interruption during the update, the process will stop. It is OK to click on Update Sensor again to start the process over again. Rev 5 MN890570 27 of 30 ... -
Page 28: Troubleshooting
TROUBLESHOOTING Step Twelve Factory Default: Pressing the “Factory Config” button in the Configuration menu will return the screen to the following settings. Out of the box, the Series ULS will output a 4‐20 mA output that is maximized for its operational range. Series ULSS – 4 mA @ 4.1’ (1.25 m) away and 20 mA @ 2” (5 cm) away from sensor. Series ULSM – 4 mA @ 8.2’ (2.5 m) away and 20 mA @ 4” (10 cm) away from sensor. Series ULSL – 4 mA @ 18.0’ (5.5 m) away and 20 mA @ 8” (20 cm) away from sensor. Factory Defaults Table Testing the Transmitter 1. Connect a multimeter in series with the black wire to read the current output. 2. Verify that the current increases (tank filling) and decreases (tank emptying) appropriately in the calibrated span. - Page 29 TROUBLESHOOTING Step Twelve PROBLEM SOLUTION Transmitter indicates a Check the wiring for an open circuit. An open circuit is the most current of 0 mA common issue with a 0 mA signal. Transmitter jumps to a Check the installation of the transmitter. Bad installation current reading between fittings will cause false signals near the top of the tank, which 19 and 20 mA typically translates to a signal between 19 and 20 mA. Also look for interference just below the transmitter. If the transmitter is installed in a metal fitting, switch to a plastic fitting. Transmitter indicates a Immediately check the wiring for a short circuit. The Series ULS current over 23 mA is current limited to 22 mA. Anything above 23 mA indicates a ...
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Page 30: Maintenance & Repair
MAINTENANCE & REPAIR Step Thirteen MAINTENANCE/REPAIR Upon final installation of the Series ULSS, ULSM or ULSL, no routine maintenance is required. The Series ULSS, ULSM or ULSL is not field serviceable and should be returned is repair is needed (field repair should not be attempted and may void warranty). WARRANTY/RETURN Refer to “Terms and Conditions of Sale” in our catalog or on our website. Contact customer service to receive a Return Goods Authorization number before shipping your product back for repair. Be sure to include a brief description of the problem plus any relevant application notes. 30 of 30 MN890570 Rev A ...
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