L‐ULS Rev A MN890570 1 of 30 Series ULS Small Tank Ultrasonic Transmitter, Switch and Controller Series ULSS, ULSM, ULSL Manual Dwyer Instruments Inc. 102 Indiana Hwy. 212 (P.O. Box 373) Michigan City, IN 46360 (46361) USA www.Dwyer‐Inst.com 2 of 30 MN890570 Rev A 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: ....................................................................................................................................................... 20 Mounting Guide: ...................................................................................................................................... 20 Fitting Selection: ...................................................................................................................................... 21 Tank Adapter: ............................................................................................................................... 21 Riser: ............................................................................................................................................ 21 Flange: .......................................................................................................................................... 22 Side Mount Fitting: ...................................................................................................................... 22 Stand Pipe: ................................................................................................................................... 23 Advanced Feature: ............................................................................................................................................... 24 Appendix: ....................................................................................................................................................... 26 Updating ULSX‐CAL Software: .................................................................................................................. 26 Updating Transmitter Firmware: ............................................................................................................. 27 Troubleshooting: .................................................................................................................................................. 28 Factory Defaults: ...................................................................................................................................... 28 Solution Table: ......................................................................................................................................... 29 Maintenance & Repair: ........................................................................................................................................ 30 Rev 5 MN890570 3 of 30 SPECIFICATIONS Step Two Range: ULSS: 49.2” (1.25m) ULSM: 9.8’ (3.0m) ULSL: 18.0’ (5.5m) Accuracy: ULSS: 0.125” (3mm) ULSM: +/‐ 0.2% of range ULSL: +/‐ 0.2% of range Resolution: ULSS: 0.019” (0.5mm) ULSM: 0.039” (1mm) ULSL: 0.079” (2mm) Dead band: ULSS: 2” (5 cm) ULSM: 4” (10 cm) ULSL: 8” (20 cm) Beam width: ULSS: 2” (5cm) dia. ULSM: 2” (5cm) dia. ULSL: 3” (7.6cm) Configuration: ULSX‐CAL ® PC Windows USB 2.0 Memory: Non‐volatile Supply voltage: 12‐28 VDC Consumption: 0.5 W Loop resistance: 400 Ohms max Signal output: 4‐20 mA, two‐wire Signal invert: 4‐20 mA or 20‐4 mA Signal fail‐safe: 4 mA, 20 mA, 21 mA, 22 mA or hold last Contact type: (4) SPST relays Contact rating: 60 VA, 1A maximum Contact fail‐safe: Power loss: Hold last, Power on: Open, close or hold last Hysteresis: Selectable Process temp.: F: 20° to 140° C: ‐7° to 60° Temp. comp.: Automatic Ambient temp.: F: ‐31° to 140° C: ‐35° to 60° Pressure: MWP = 30 PSI Enclosure rating: Type 6P encapsulated, corrosion resistance & submersible (IP68) Encl. material: Polycarbonate Strain relief material: Santoprene Trans. material: PVDF Cable jacket material: Polyurethane Cable type: 9‐conductor, shielded Cable length: 48” (1.2 m) Process mount: ULSS: 1” NPT (1” G) ULSM: 1” NPT (1” G) ULSL: 2” NPT (2” G) Mount gasket: FKM Classification: General purpose Compliance: CE, RoHS 4 of 30 MN890570 Rev A DIMENSIONS Step Three Series ULSL Series ULSM Series ULSS Rev 5 MN890570 5 of 30 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 responsibility to select a sensor model that is appropriate for the application, install it properly, perform tests of the installed system, and maintain all components. The failure to do so could result in property damage or serious injury. Proper Installation and Handling: Only professional staff should install and/or repair this product. Install the transmitter with the included FKM gasket and never over tighten the transmitter within the fitting. Always check for leaks prior to system start‐up. Wiring and Electrical: A supply voltage of 12 to 28 VDC is used to power the Series ULS. Electrical wiring of the transmitter should be performed in accordance with all applicable national, state, and local codes. 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. Material Compatibility: The enclosure is made of Polycarbonate (PC). The transducer is made of Polyvinylidene Fluoride (PVDF). Make sure that the model, which you have selected, is chemically compatible with the application media. Enclosure: While the transmitter housing is liquid‐resistant the Series ULS is not designed to be operational when immersed. It should be mounted in such a way that the enclosure and transducer do not come into contact with the application media under normal operational conditions. Safety Installation should be done by properly trained staff Supply voltage should never exceed a maximum of 28 VDC Make sure the sensor is chemically compatible with your application Design a fail‐safe system that accommodates the possibility of sensor and/or power failure This sensor should not be used in classified hazardous environments Make a Fail‐Safe System: Design a fail‐safe system that accommodates the possibility of transmitter and/or power failure. Dwyer Instruments, Inc recommends the use of redundant backup systems and alarms in addition to the primary system. Flammable, Explosive or Hazardous Applications: Series ULS should not be used within classified hazardous environments. Warning: Always use the FKM gasket when installing the Series ULS, and make sure that all electrical wiring of the switch is in accordance with applicable codes. 6 of 30 MN890570 Rev A 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. FKM Gasket o ULS‐ACC‐SGK – used with ULSS series o ULS‐ACC‐MGK – used with ULSM series o ULS‐ACC‐LGK – used with ULSL series USB Fob o Part# ULS‐ACC‐USB Quick Start Guide *Outputs 1. 4‐20 mA, loop powered output 2. 4 SPST 60 VA relays 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 ULSM‐11 9.8’ (3.0 m) 4” (10cm) 1” NPT Fob Included 1,2 ULSM‐20 9.8’ (3.0 m) 4” (10cm) 1” G No Fob 1,2 ULSM‐21 9.8’ (3.0 m) 4” (10cm) 1” G Fob Included 1,2 ULSL‐10 18.0’ (5.5 m) 8” (20cm) 2” NPT No Fob 1,2 ULSL‐11 18.0’ (5.5 m) 8” (20cm) 2” NPT Fob Included 1,2 ULSL‐20 18.0’ (5.5 m) 8” (20cm) 2” G No Fob 1,2 ULSL‐21 18.0’ (5.5 m) 8” (20cm) 2” G Fob Included 1,2 Rev 5 MN890570 7 of 30 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 Windows Vista (R) is a registered trademark of Microsoft Corporation 8 of 30 MN890570 Rev A 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. Rev 5 MN890570 9 of 30 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. o 2‐Pumps/Valves – Two relays are configured as control or latching relays. Each relay will have a unique start level and a common stop level. Use this setting to control two pumps or valves for automatic filling or emptying of a tank. o 4‐20mA Transmitter Only – This setting will disengage all of the relays. Use this function if you are not using any relays and using only the 4‐20 mA current output. Note: Right click on any menu that you may have questions on to open the help menu. Note: To reset, press the Clear Screen button. Next >