Ametek Drexelbrook USonic Series User manual

A Leader in
Level Measurement
Installation and
Operating Instructions
USonic™ Series
Continuous Ultrasonic Level
Transmitter using US-XX Series
Electronics
Telephone: [phone]
Fax: [phone]
E-mail: drexelbrook.ser[email protected]
Website: www.drexelbrook.com

AMETEK Drexelbrook makes no warranty of any kind with regard to the material contained in this
manual, including, but not limited to, implied warranties or fitness for a particular purpose. Drexelbrook
shall not be liable for errors contained herein or for incidental or consequential damages in connection
with the performance or use of material.
© Copyright AMETEK Drexelbrook

USonic™ Series
Continuous Ultrasonic Level Transmitter
using US-XX Series Electronics
EDO# 3-20-102
US-XX-LM
Issue #11

Table of Contents
Glossary of Terms ........................................................................................................................... vi
Quick Start Menu........................................................................................................................... viii
Section 1: Introduction..................................................................................................................... 1
1.1 Product Description ............................................................................................................. 1
1.2 Models Available.................................................................................................................. 1
1.3 Approvals: (See Section: 6.4 for Details) ............................................................................ 1
1.4 System Specifications:......................................................................................................... 2
1.5 Definition of Terms ............................................................................................................... 2
1.6 Types of Output.................................................................................................................... 3
1.7 Types of Flumes and Weirs ................................................................................................. 4
Section 2: Installation..................................................................................................................... 11
2.1 Unpacking.......................................................................................................................... 11
2.2 Mounting the Transmitter ................................................................................................... 11
2.3 Wiring the Transmitter ........................................................................................................ 13
2.4 Installation Examples......................................................................................................... 14
Section 3: Configuration................................................................................................................ 17
3.1 System Configuration with Display / Keypad ..................................................................... 17
3.2 Configuration Menu............................................................................................................ 18
3.3 Menu Functions ................................................................................................................. 18
3.4 Error Messages ................................................................................................................. 24
3.5 Menu / Display Abbreviations............................................................................................. 24
Section 4: Troubleshooting............................................................................................................ 25
4.1 Troubleshooting Procedures ............................................................................................. 25
4.2 Optimized Field Calibration................................................................................................ 26
4.3 Troubleshooting the Loop Connections.............................................................................. 26
4.4 Diagnostic Messages......................................................................................................... 27
4.5 Telephone Assistance........................................................................................................ 28
4.6 Equipment Return / Warranty ............................................................................................ 28
4.7 Field Service...................................................................................................................... 29
Section 5: Configuration and Calibration With HARTWin™ ....................................................... 31
5.1 General Description ........................................................................................................... 31
5.2 Model Number ................................................................................................................... 31
5.3 System Requirements ....................................................................................................... 31
5.4 Installing The RS232 Modem............................................................................................. 32
5.5 Installing The USB Modem ................................................................................................ 33
5.6 Install the Windows Version HARTWin™ Software on Hard Drive..................................... 34
5.7 Description of Function Keys ............................................................................................. 35
5.8 Configuration ..................................................................................................................... 36
Section 6: System Specifications ................................................................................................. 51
6.1 Transmitter Specifications.................................................................................................. 51
6.2 Transducer Specifications.................................................................................................. 52
6.3 Enclosure Specifications.................................................................................................... 52
6.4 Approvals........................................................................................................................... 52
Section 7: Control Drawings / General Safety Information......................................................... 55
7.1 General Safety Information ................................................................................................ 55
7.2 US-2X FM/FMc Control Drawing ....................................................................................... 57
7.3 US-1X FM/FMc Control Drawing ....................................................................................... 60
7.4 ATEX Control Drawing ....................................................................................................... 63

USonic™ US-XX Series
vi
Distance The measured distance from the sensor face to the target.
Distance Mode Output signal increases as the distance increases (reverse acting
output)
Distance to Zero Flow This is the “No Flow” condition in a ume or weir. It may be to the bottom
of the ume/weir, or depending on the type of ume/weir the “no ow”
condition may be above the bottom of the ume/weir, with standing water
below this point.
Fault Indication Output goes to 3.7 mA or 22 mA (user selectable in conguration menu)
during a fault condition such as Lost Echo or Near Zone. See Error
Messages section
Flow Mode Output increases as level (head height) increases. Output is non-linear
with level and is based on Flume/Weir primary element characterization,
or strapping table
Flow rate The instantaneous ow rate measured in ow mode of operation.
Flume Size A selection of the various throat sizes of specic ume and weir tables
contained in the pre-programmed software.
Flume Type A selection of the specic ume and weir types that have been pre-
programmed in the software.
Gain Adjustment The USonic’s default gain setting is with SmartGain™, abbreviated a
“HD” in the software code. Other gain settings are available for use in
abnormal application requirements. Contact the factory before changing
from “HD” mode.
HD Adjustments SmartGain™ (sometimes seem abbreviated as “HD”) provides an algorithm
that permits the system to ignore most internal obstructions that are
inside of the ultrasonic beam path. Changing an “HD” setting will allow
this same algorithm to be used at different power settings. Consult factory
before changing HD Adjustments.
Head Units In Flow conguration the level measurement (bottom of ume/weir to
surface of level) is referred to a head height. Enter the units in ow rate
that will be used, GPM (Gallons per minute), MGD (Million Gallons per
Day), M3/Hr (Cubic Meters per Hour, Litres per Second, Litres per Minute)
Input Type Allows the selection of Level, Distance, Volume or Flow. Based on user
input type selection, the USonic menu items will only allow data entry in
valid, related menus. I.e.: If Level is selected, menu’s for distance, volume
and ow are locked out.
Level The measured distance from the sensor face to the target minus the tank
height. Or, the distance from the tank bottom to the liquid surface.
Level Mode Output signal increases as the level increases (direct acting output)
Lost Echo A condition that occurs when the ultrasonic transmission does not return
to the sensor. This could be due to foam, irregular surface, dished tank
bottom, etc.
LRV (Lower Range Value) The point at which the output signal is equal to 4
mA (0%). Also see Zero.
Glossary of Terms

vii
Glossery of Terms
Max Flow This is the maximum ow rate that is expected in a specic ume or weir.
This is not necessarily the maximum ow that the ume/weir is capable
of producing.
Maximum Capacity Used in level to volume conversions, the maximum capacity of the vessel
at a known maximum level point.
Near Zone The distance below the sensor where the measurement cannot be made
(12 inches/305 mm)
Range The maximum distance measurable from the sensor face
Range of Percent The percentage of level or distance between the LRV (4 mA, 0%) point and
the URV (20 mA, 100%), always enabled on the display.
Repetition Rate This is the number of milliseconds that elapses between ultrasonic pulse
transmissions. Longer repetition rates may be helpful if there are multiples
reections that are being picked up or if lost echoes are encountered due
to intermittent presence of foam or agitator blades. Consult Factory before
changing this parameter.
Sensor Offset Used to tell the transmitter the amount of distance above or below the tank
height that the sensor is mounted in order to calculate the tank volume.
Span The point in the vessel where the output signal is equal to 20 mA (100%).
Also see URV
Strapping Table Correlates Level information to Volume information. A 21-point table that
can be customized to accommodate an irregular shaped vessel, ume or
weir. Information is entered as a Level “in” point vs. a Volume “out” point
for all 21 possible points.
Tank Height This is the measurement from the Tank Bottom to the face of the
sensor.
Time Delay Time delay allows signal averaging over the specied duration (0-90
seconds). Useful if wave action causes the output signal to be too “jumpy”
for control / indication use.
Totalizer reset The USonic has two totalizers, one that is a permanent record of the
total volume that has been measured and a second totalizer that can be
reset to zero by the user. The Reset Totalize can be reset to zero in the
conguration software to allow the user to take periodic measurements
from a reference point in time.
Totalizer Scale The totalizer keeps record of the total volume that has passed through the
ume/weir. In large umes & weirs multipliers annotate this total volume.
Each “count” on the totalizer can be representative of an exponential
volume of water (X-1, X-10, X-1M, X-100, X-1,000, X-10,000 or X-100,000
can be selected)
URV (Upper Range Value) The point at which the output signal is equal to 20
mA (100%). Also see Span.
Volume The level of the liquid in the vessel converted to volume based on tank
strapping tables,
Zero The point in the vessel where the output signal is equal to 4 mA (0%).
Also see LRV.
Glossary of Terms

USonic™ US-XX Series
viii
Quick Start Menu
1.00 Input Type Select Application Type
1.01 Type Level / Distance / Volume / Flow
2.00 Level Enabled Only When Level Selected
2.01 Units Inches / Feet / Meters / Centimeters / Millimeters
2.02 Tank Height User Dened Numeric Value
2.03 Sensor Offset User Dened Numeric Value
2.04 LRV User Dened Numeric Value
2.05 URV User Dened Numeric Value
3.00 Distance Enabled Only When Distance Selected
3.01 Units Inches / Feet / Meters / Centimeters / Millimeters
3.02 LRV User Dened Numeric Value
3.03 URV User Dened Numeric Value
4.00 Volume Enabled Only When Volume Selected
4.01 Level Units Inches / Feet / Meters / Centimeters / Millimeters
4.02 Tank Height User Dened Numeric Value
4.03 Sensor Offset User Dened Numeric Value
4.04 Vessel Type Vertical / Hor Cyl Flat / Hor Cyl Dished / Hor Cyl Hemi / Sphere
/ Custom
4.05 Load Standard Table Vertical / Hor Cyl Flat / Hor Cyl Dished / Hor Cyl Hemi / Sphere
4.06 Vessel Units Gallons / M3 / Liters / Barrels / Imperial Gallons
4.07 Max Capacity User Dened Numeric Value
4.08 LRV User Dened Numeric Value
4.09 URV User Dened Numeric Value
5.00 Flow Enabled Only When Flow Selected
5.01 Flume Type Parshall / Palmer Bowlus / Trapezoidal Flume / Rect Weir W/
End Contr. / Rect Weir W/o End Contr. / Trapezoidal Weir / V-
Notch Weir / Custom / H-Flume / Leopold Lagco
5.02 Flume Size Code from Table / or / Numeric Value
5.03 Flow Units GPG/ MGD / M3/HR / LPS / LPM
5.04 Max Flow User Dened Numeric Value
Menu Navigation:
1. Hold ENTER Button 5 seconds to access conguration menu.
2. Use UP & DOWN buttons to select menu items
3. Press ENTER button to change selected items
4. Hold ENTER button to go to previous menu or continue to hold to
return to operate mode.
5. Press UP & DOWN buttons simultaneously to force target
acquisition.

ix
Glossery of Terms
Quick Start Menu
5.05 Head Units Inches / Feet / Meters / Centimeters / Millimeters
5.06 Distance to Zero User Dened Numeric Value
5.07 Sensor Offset User Dened Numeric Value (Used Only With Custom Flumes)
5.08 Totalizer Scale X1 / X10 / X100 / X1k / X10k / X100k / X1Mil
5.09 Reset Totalizer? No / Yes
6.00 Strapping Table Enabled When Volume or Flow Selected
6.01 Max Points 0…21
6.02 In Point 1 User Dened Numeric Value
6.03 Out Point 1 User Dened Numeric Value
6.04-6.43 In / Out Points User Dened Numeric Value
7.00 System Settings
7.01 Temperature Units F / C
7.02 Gain Adjustment Hd / Hd High / 100% / 84% / 67% / 50% / 32% / 17% / 8%
7.03 HD Adjustment Numeric Value (Consult Factory)
7.04 Rep Rate 300ms / 700ms / 1100 ms / 1500ms
7.05 Echoes 1-10 Consult Factory
7.06 Damping Time User Dened Numeric Value
7.07 Near Zone Fault High / Low
7.08 Lost Echo Fault High / Low / LST VAL
7.09 Lock Ma Output User Dened Numeric Value
7.10 Trim 4ma User Dened Numeric Value
7.11 Trim 20ma User Dened Numeric Value
7.12 Hart Mode Normal / DCS (X100)
7.13 Polling Address 0…15
7.14 Restore Factory Defaults? No / Yes
7.15 Password Edit Password
7.16 Password Enabled? No / Yes
7.17 Contrast 0…10…50
7.18 Low Offset User Dened Numeric Value, Consult Factory
7.19 High Offset User Dened Numeric Value, Consult Factory
7.20 Pipe Length User Dened Numeric Value
7.21 Pipe Diameter User Dened Numeric Value
8.00 Display
8.01 Toggle? No / Yes
8.02 Level Enable / Disable
8.03 Distance Enable / Disable
8.04 Volume Enable / Disable
8.05 Flow Enable / Disable
8.06 Total Enable / Disable
8.07 Resettable Total Enable / Disable
8.08 mA Output Enable / Disable
8.09 Temperature Enable / Disable
9.00 Calibration
9.01 Point Calibration Enter Distance To Product

USonic™ US-XX Series
x
Quick Start Menu
Rectangular Weir - with or without End Contractions: Enter Crest Length
Trapezoidal Weir: Enter Crest Length
Leopold Lagco Flume: Enter Flume Size
PALMER BOWLUS
CODE SIZE (IN)
1 4
2 6
3 8
4 10
5 12
6 15
7 18
8 21
9 24
10 27
11 30
PARSHALL
CODE THROAT
(IN)
1 1
2 2
3 3
4 6
5 9
6 12
7 18
8 24
9 36
10 48
11 60
12 72
13 96
TRAPEZOIDAL FLUME
CODE SIZE
1 SMALL 60 DEG16
2 LARGE 60 DEG
3 X-LARGE 60 DEG
4 3 FT 60 DEG
5 2 IN 45 DEG WSC
612 IN 45 DEG SRCRC
7 24 SRCRC
H - FLUME
CODE SIZE (IN)
1 6
2 9
3 12
4 18
5 24
6 30
7 36
8 54
V-NOTCH WEIR
CODE SIZE
1 22.5 DEG
2 30 DEG
3 45 DEG
4 60 DEG
5 90 DEG
6 120 DEG
PRIMARY DEVICE CODES

Introduction
1
Section 1: Introduction
1.1 Product Description
The AMETEK Drexelbrook® USonic™ Series instrument is a Two-
Wire (Integral) assembly. Using ultrasonic technology, the USonic™
continuously and accurately measures Level up to a range of 30 feet, or
Open Channel Flow. The measurement output is a 4-20 mA current
signal or HART® digital communications.
The Ultrasonic sensor is made of CPVC for compatibility with a wide
range of process materials.
1.2 Models Available
Technology
Housing
US USonic Continuous Two-Wire Ultrasonic Transmitter
1PBT (Valox), NEMA 4X with display / Keypad * (Not Available with ATEX / CE Approvals)
2Cast Aluminum XP Housing - non indicating with display / Keypad **
Mounting
1 2" NPT with 1/2" NPT Electrical Connections - Approvals: FM, FMc, IECEX
2 2" BSP with M20 Electrical Connections - Approvals: FM, FMc, IECEX
3 2" NPT with 1/2" NPT Electrical Connections- Approvals: ATEX / CE, IECEX
4 2" BSP with M20 Electrical Connections - Approvals: ATEX / CE, IECEX
* Intrinsic Safety Approvals
** Intrinsic Safety Approvals & FM / FMc Approved Explosion Proof
US
USonic™
1.3 Approvals: (See Section: 6.4 for Details)
FM, FMc, ATEX, IECEX
Intrinsically Safe for Class I, Div. 1, Zone 0, Zone 1 hazardous
locations.
Cast Aluminum Housing versions:
FM Explosion Proof for Class I, Div. 1 hazardous locations.

USonic™ US-XX Series
2
1.4 System Specifications:
• Power: 19 to 30 Vdc
• Output: 2-Wire, 4-20 mA, HART
• Sensor: 6.5” CPVC sensor rated: -40°F to +160°F (-40°C to +71°C)
• Sensor Mounting: 2” NPT or 2” BSP, CPVC
• Display Option: 2-Line, 7 digit LCD
• Software: Level, Distance, Volume, Flow rate via user selectable
Flume and Weir characterizations or 21-Point strapping table,
Totalization via 1 resettable and 1 non-resettable totalizer.
1.5 Definition of Terms
Zero: (LRV)
The point at which the output signal is equal to 4 mA (0%)
Span: (URV)
The point at which the output signal is equal to 20 mA (100%)
Range:
The Maximum distance measurable from the transducer face.
Near Zone:
The distance just below the transducer face where the transmitter
cannot make a level measurement (12 inches / 305 mm).
Lost Echo:
A condition that occurs when the ultrasonic energy is not being
returned to the transducer. For example, a loss of echo may occur
when large amounts of foam are present.
Strapping Table:
Displays the value of the input to level and output to volume in
percent in a 21-Point table. This also allows points to be changed
to accommodate irregular shaped vessels and custom ume or weir
characterizations.

Introduction
3
Sensor Offset:
Sensor Offset is used to tell the transmitter the amount of distance
above or below the top of the tank that the transducer face is located
in order to calculate the tank volume. Sensor Offset can be applied in
cases where:
• The transducer protrudes below the top of the tank, or
• The transducer is mounted above the top of the tank, or
• A pipe extension is installed to raise the transducer face 12 inches
above the tank height to compensate for the 12-Inch Near Zone.
See Section 5.8.1.
1.5 Definition of Terms (Continued)
1.6 Types of Output
Level Mode:
Output increases as the internal level of the vessel increases.
Level output is the most common type of output measurement.
Conguration is referenced from the bottom of the vessel.
Distance Mode:
Output increases as the distance increases away from the transducer.
Conguration is referenced from the Transducer Face.
Flow Mode:
Output increases as head height level increases (increasing ow
rate). Output is non-linear with level changes and is based on the
ow characteristic of a selected Flume, Weir, or strapping table for a
custom primary ow device.
Fault Indication:
Output goes to 3.7 or 22 mA (user selectable) during a fault condition
such as Lost Echo or Near Zone violations.

USonic™ US-XX Series
4
1.7 Types of Flumes and Weirs
The USonic™ Supports the Following Flumes and Weirs:
Flume Diameter (D)
D/2
Leopold-Lagco Flumes (Variable Sizes):

Introduction
5
Plan
Measuring Point
Flume
Size
Front
“H” Flumes:
Code Inches Millimeters
16 152
29 229
312 305
418 457
524 610
630 762
736 914
854 1372
1.7 Types of Flumes and Weirs (Continued)

USonic™ US-XX Series
6
Conduit Diameter (D)
D/2
Throat
Palmer Bowlus Flumes:
Code Inches Millimeters
14102
26 152
38203
410 254
512 305
615 381
718 457
821 533
924 610
10 27 686
11 30 762
1.7 Types of Flumes and Weirs (Continued)

Introduction
7
Crest Length
min. 3-4 Hmax
Hmax
Trapezoidal (Cipolletti ) Flume:
Code Size
1Small 60° V
2Large 60° V
3X Large 60° V
43 ft 60° V
52 in 45° WSC
612 in 45°
SRCRC
724 in SRCRC
1.7 Types of Flumes and Weirs (Continued)
Trapezoidal (Cipolletti ) Weir (Variable Sizes):

USonic™ US-XX Series
8
V-Notch Angleº
min. 3-4 Hmax
Hmax
V-Notch Weirs:
Code Size
122.5°
230°
345°
460°
590°
6120°
1.7 Types of Flumes and Weirs (Continued)

Introduction
9
Crest Length
FLOW
min. 3-4 Hmax
H
Rectangular Weirs (Variable Sizes):
1.7 Types of Flumes and Weirs (Continued)
Crest Length
min. 3-4 Hmax
Hmax
Crest Length
min. 3-4 Hmax
Hmax
Crest Length
FLOW
min. 3-4 Hmax
H
Rectangular Weir with End Contractions
Rectangular Weir without End Contractions

USonic™ US-XX Series
10
W
2/3 Z
Z
Parshall Flumes:
Code Inches Millimeters
1125
2251
3376
46 152
59 229
612 305
718 457
824 610
936 914
10 48 1219
11 60 1524
12 72 1829
13 96 2438
1.7 Types of Flumes and Weirs (Continued)