(8) Ultrameter Series
Contents
1. the reliable operation of the Ultrameter The transmitter should be positioned to avoid obvious obstructions in the beam path such as ledges walkways exposed pipes etc The instrument beam angle is 11 degrees if the Ultrasound beam impacts on a vertical smooth wall this will not prevent the instrument from working As a guide the perpendicular path of the beam should be 100mm away from any obstacle per 1000mm of measurement span Eg for a 5 metre range the beam perpendicular should be 500mm away from obstructions Care should also be taken to position the transmitter beam away from unsuitable process surfaces such as heavy banks of foam which may result in signal attenuation or excessive surface turbulence which would cause scattering of the return echo Mounting Ultrameter may be directly cable suspended or mounted via its integral 2 BSP thread either direct to the tank or to an adapter flange If cable suspended the cable must be securely held using a proprietary gland to ensure stability of location and prevent chafing of the cable Cable suspension should only be considered where process conditions would not cause movement of the unit Eg where wind may be present Ultrameter must remain still for it to receive the returning echoes If the unit is to be mounted in a stand off on top of the tank top ideally it should be suspended such that the nose is set slightly into the tank Mounting the unit within the stand of2. IGURATION MODE In addition to setting the Zero and Span calibration the magnetic keys and LED s may be used to set the fault indication mA level and the response rate of the unit This is not normally something a user would undertake as Measurement Kesourees would usually set the unit to the client s requirements before delivery However these changes can be made at any time provided that two magnets are available RESPONSE RATE AVERAGED FAULT INDICATION CURRENT 22Ma To enter configuration mode using two magnets simultaneously touch both the zero and span targets until LED A is seen to turn from green to red Touch the zero target to toggle the response rate LED B will indicate which setting is selected i e LED B OFF Immediate response LED B Flashing Yellow Averaged response To set the FAULT INDICATION CURRENT enter or remain in configuration as described above LED A is Red Touch the span target to enter the fault indication current set mode LED A will now be flashing Green with LED B flashing yellow sequences to indicate which fault current is set To step through the fault current settings touch the zero target until the desired value from the following list is set With LED A flashing green and LED B flashing sequences of Ultrameter Series User Manual 8 UM ULTRAMETER A 99 ONE FLASH 3 8mA Two flashes 4mA Three flashes 22mA SECTION 9 LED FUNCTIONS IN NORMAL MODE DISPLAY OUTPUT CONDITION AC
3. TION LED A flashing red Between 4 20 mA System operating but no return echo Red LED flashes on 3 8 4 or 22 mA Lost Echo Green Flashes Constantly Red Yellow and Random Instrument Fault Refer to supplier Green operating in memory corruption sequence Ultrameter Series User Manual 9 UM ULTRAMETER A 99 SECTION 10 MAINTENANCE Only minimum is required Inspection of physical damage and normal working is recommended at 6 monthly intervals Ensure transmitter face is clean of any build up of grease and debris SECTION 11 APPLICATION BENEFITS Some of the technology related advantages and competitive benefits of Ultrameter include e Non Contact Suitable for highly viscous and or corrosive products Unaffected By S G or product temperature changes air space temp is monitored Easy Retrofit Top mounted so need to empty tank Simple Calibration Requires no monitoring or diagnostic instruments Constant Indication Operational health of the unit is continually shown by the integral LED s Completely Sealed Construction tamper proof and undamaged by immersion Average Response Rate Eliminates unstable output due to process fluctuations Built in Transorbers Transient absorbers offer a high degree or protection from damage caused by lightning strikes on the signal lines Reverse Polarity Protection Incorrect connection will not damage the unit e Reliability Circuit board construction is all surface mount techn
4. ULTRAMETER USER MANUAL CONTENTS SECTION SECTION 1 Instrument Overview SECTION 2 Specification SECTION 3 Initial Inspection SECTION 4 Wiring Connections SECTION 5 Principle of Operation and Fault Conditions SECTION 6 Successful Installation SECTION 7 Calibration and Commissioning SECTION 8 Configuration Mode SECTION 9 LED Functions in Normal Mode SECTION 10 Maintenance SECTION 11 Application Benefits SECTION 12 Target Markets SECTION 13 Outline Dimensions SECTION 1 INSTRUMENT OVERVIEW The Ultrameter is a microprocessor controlled Ultrasonic Transmitter intended for use in the level measurement of Liquids Slurries and Sludges The Ultrameter is a compact single piece instrument utilising a fully sealed IP68 enclosure with L E D indication of instrument operation see section 9 integral temperature compensation and 5 metres of instrument cable Calibration of this instrument is carried out by momentary application of the Magnetic key provided This confirms and locks the calibration points into the non volatile memory The Instrument provides a 4 20mA signal proportional to level and operates from a nominal 24Vdc supply Mounting possibilities are e Own wire suspension e 2 inch BSP male screwed connection e Mounting flange customer to specify ULTRAMETER CONSTRUCTION LED INDII TEFZEL NOSE SECTION gig Note Magnetic Calibration key is supplied as a loose item Ultramete
5. d bases the signal will have no perpendicular reflective surface when empty resulting in signal loss A plate Ultrameter Series User Manual 6 UM ULTRAMETER A 99 positioned directly below the mounting point of the Ultrameter addresses this This plate should have a minimum surface area of 0 2metres square Maximum level Following transmission of an ultrasound pulse the piezo crystal within the Ultrameter needs a period of time to stabilize before it can detect the returning echo This means that if the liquid level is too close to the Ultrameter 1t will not be able to measure it with accuracy and stability To ensure this does not occur Ultrameter should be mounted at least 250mm above the maximum expected liquid level This distance provides sufficient stabilisation time for the unit Heasaremeat Kesoarece will be pleased to make recommendations on particular applications INSTALLATION DO s AND DON T S e DO Aim transmitter perpendicular to the target surface e DO Mount transmitter to avoid internal obstructions ladders ledges chains tank seams etc e DO Mount transmitter to avoid banks of surface foam or excessive turbulence e DO Periodically clean the transmitter face e DO Provide a flat surface at minimum level on tanks which have a sloping base e DO Mount the unit at least 25cm above the highest expected liquid level e DON T Overtighten transmitter on screwed or flanged connections e DON T Damage the t
6. echoes False echoes can be generated as a result of poor installation covered later obstacles in the tank or they may be multiples of the original pulse The Ultrameter will lock onto a valid echo and ignore occasional echoes which would signify significant shifts in process level eg from a tank stirrer blade and only accepts a new position as valid provided it is within the permitted rate of change During normal operation the Ultrameter stops pulsing every second and listens to the ambient noise levels in the tank The acceptance threshold for the returning echo is then continuously updated based upon the noise level Automatic Gain Control controls the energy level of the Ultrasound burst relative to the position of the process level With the target distance at a maximum empty tank the energy level is at a maximum As the level rises the energy is varied as appropriate always ensuring that performance is not compromised until it is at its lowest level with the level at maximum This greatly reduces the generation of multiple echoes HIGH EFFICIENCY DESIGN OF THE SENSOR AND ADVANCED SOFTWARE ALGORITHMS ARE KEY TO THE ULTRAMETER S SUPERIOR PERFORMANCE In normal operation the instrument will pulse approximately every 0 8 seconds Ifa valid return echo has not been received over a time of approx 20 seconds 30 pulses the Ultrameter will assume a fault has occurred and change the output signal to its preset fault indicat
7. f can significantly reduce the unit s ability to see the returning echoes Where it is unavoidable that the Ultrameter is mounted within a stand off it is recommended that it is less than 100mm high Also the pipe section should extend into the tank with its end cut at an angle This should prevent Ultrameter from registering a false return echo 8 8 STAND OFF FLANGE 3 or DN80 minimum When mounting the unit to the tank directly or via An adapter flange particular care should be taken not to overtighten the unit Ultrameter is supplied with an O ring seal which serves two purposes One it seals the connection and two it acts as an acoustic decouplant Overtightening the unit can yq ____ _ _ T pi lead to condition known as ringing This is j where the unit becomes acoustically coupled to the 100mm tank structure and is thus unable to generate an Max ultrasonic pulse this condition is normally indicated by a continuous high current output If Y possible a uPVC flange should be employed in preference to a metal one as this will further reduce the likelihood of ringing Ullage space It is a requirement that the atmosphere above the liquid surface can transmit ultrasound Gases such as Carbon Dioxide and Methane above the liquid will seriously attenuate an Ultrasonic signal to the point that application is not recommended Minimum level On tanks which have a sloping base such as vertical cylinders with cone
8. ion level of 3 8 4 or 22mA programmable The unit does however continue to search and upon requiring a valid echo will change the output to represent the correct level Changes to factory preset levels for the unit s response time and fault output signal require the use of 2 set up magnets to enter the Configuration mode Details of the actual changes possible are given in section 8 It is expected that the user will normally advise their requirement and will not need access to this mode However it is accepted that changes may be required after delivery and additional set up Magnets will be available Configuration changes possible are self explanatory fault condition current may be set to 3 8 4 0 or 22mA The default setting is 22mA Ultrameter Series User Manual 4 UM ULTRAMETER A 99 Response rate has two possibilities the default condition is damped In this case the Ultrameter will evaluate a number of consecutive echoes and ensure that they represent the same level before accepting that the level is valid It will then progressively change the output signal to suit This setting is recommended for most applications The immediate setting should only be considered under ideal operating conditions or where an immediate response is required and a fluctuating output signal can be tolerated Ultrameter Series User Manual 5 UM ULTRAMETER A 99 SECTION 6 SUCCESSFUL INSTALLATION Location Correct location is essential for
9. ology SECTION 12 TARGET MARKETS Applications for the Ultrameter will be found in WASTE AND WATER CHEMICAL FOOD amp BEVERAGE PETROCHEMICAL POWER GENERATION PAPER SECTION 13 OUTLINE DIMENSIONS Ultrameter Series User Manual 10 UM ULTRAMETER A 99
10. r Series User Manual UM ULTRAMETER A 99 SECTION 2 INSTRUMENT TECHNICAL SPECIFICATIONS Instrument Range Operating Temperature Temperature Compensation Max Sensor survival Temperature Operating Pressure Voltage Power Consumption Environment Material Housing Material Sensor Material Cable Weight Ultrasonic Beam Angle Maximum Error Repeatability Response Rate SECTION 3 Ultrameter Series User Manual UM ULTRAMETER A 99 5 metres 10 metres 20 to 70 degrees C Automatic over operating range 100 deg C for 30 minutes 2 Bar G Max 15 30 Volts DC loop powered max 0 48 watts IP68 submersible UV stabilised uPVC TEFZEL Polyurethane Sheath 900gms including 5 metres cable 11 degrees at 3db boundary 0 2 of set Span lt 3 mm Immediate or damped to 6 metres minute maximum INITIAL INSPECTION The Ultrameter is a totally sealed unit the only initial inspection necessary is for external physical damage to instrument housing transmitter face or cable which may have occurred in transit or subsequent storage SECTION 4 WIRING CONNECTIONS The Ultrameter is factory fitted with a 5 metre of 2 core screened signal cable Removal of this cable is not possible Connections follow normal instrument practice the Red conductor should be connected to Supply Positive and the Blue conductor to Supply Negative Connection of the cable screen is not always essential but in elec
11. ransmitter face with sharp implements e DON T Attempt to open Ultrameter instrument is totally sealed e DON T Use Ultrameter on applications with gas blankets without prior reference to Measurement Resources SECTION 7 CALIBRATION AND COMMISSIONING Initial Check ensure that the Ultrameter is connected to a suitable 24vdc power supply and a 4 20mA display unit or meter Ultrameter Series User Manual 7 UM ULTRAMETER A 99 Set up procedure Ultrameter has 2 LED s which are used to indicate operational health of the unit and also to confirm calibration has been effected LED A is Dual colour RED amp GREEN LED B is YELLOW STEP 1 With the Ultrameter aimed at process EMPTY level or at a simulated distance touch calibration point Z with the magnetic key LED A will give 5 short green flashes followed by a single yellow flash from LED B to confirm acceptance of the ZERO 4mA instruction STEP 2 With the Ultrameter aimed at process FULL level or at a simulated distance touch the calibration point S with the magnetic key LED A will give 5 short green flashes followed by a single yellow flash from LED B to confirm acceptance of the SPAN 20mA instruction STEP 3 The Ultrameter is now calibrated and operational LED A should be flashing green and LED B should be unlit indicating healthy operation NOTE The Ultrameter can also be calibrated with 20mA at Empty and 4mA at Full position by reversing steps 1 and 2 SECTION 8 CONF
12. trically noisy environments it should be connected to the system earth to guard against RFI POWER SUPPLY UNIT 15 TO 30 VDC TT A OPTIONAL SCREEN gt CONNECTION KS ED CONDUCTOR SECTION 5 PRINCIPLE OF OPERATION AND FAULT CONDITIONS Ultrameter Series User Manual 3 UM ULTRAMETER A 99 The Ultrameter contains a piezo crystal which when energised by application of a Voltage emits a burst of Ultrasound energy Timing of the applied voltage pulses is under control of the internal microprocessor and the Ultrameter s transducer is carefully designed to channel the Ultrasound energy so it is emitted from the front face only After each burst the Ultrameter listens for a return echo of the pulse where it is reflected from the process surface The elapsed time between transmission of the pulse and receipt of a return echo is measured and the internal microprocessor then calculates the distance to the process level A number of other factors are also considered by the microprocessor to ensure reliability and accuracy of measurement Firstly the speed of sound is dependent upon the temperature of the medium in which it is travelling The Ultrameter has an inbuilt thermistor temperature detector which provides a signal used to compensate for this effect The return echo must be evaluated to ensure it is genuine The Ultrameter has powerful signal analysis algorithms which are used to filter out false or invalid
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