Icon Process Controls Level Pro UltraPro 500 Series User manual

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Ultrasonic level meters
ULTRAPRO 500 MANUAL
UltraPro® 500
INSTRUCTION MANUAL

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Ultrasonic level meters
ULTRAPRO 500 MANUAL
www.iconprocon.com | [email protected] | 905.469.9283
1 . Safety ..........................................................................................................................................................................4
2 . Packing, transportation and storage ......................................................................................................4
3 . Measuring principle ..........................................................................................................................................5
4 . Range of application ........................................................................................................................................5
5 . Features of variants ...........................................................................................................................................5
6 . Dimensional drawings ....................................................................................................................................6
7 . Installation and putting into operation .................................................................................................6
8 . Installation instructions...................................................................................................................................7
9 . Electrical connection ......................................................................................................................................10
10 . Set-up elements ..............................................................................................................................................14
11 . Status signalization .........................................................................................................................................15
12 . Setting up ............................................................................................................................................................16
12 .1 . Setting procedure for level meters UPS-500 ...............................................................................16
13 . Protocol Modbus .............................................................................................................................................20
14 . Order code .........................................................................................................................................................20
15 . Accessories ..........................................................................................................................................................21
16 . Safety, protection, compatibility and explosion proof ...............................................................21
17 . Use, manipulation and maintenance .................................................................................................22
18 . General conditions and warranty .........................................................................................................22
19 . Marking of labels ............................................................................................................................................23
20 . Specifications ..................................................................................................................................................24
TABLE OF CONTENTS

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Ultrasonic level meters
ULTRAPRO 500 MANUAL
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USED SYMBOLS
1. SAFETY
2. PACKAGING, TRANSPORT AND STORAGE
In order to provide maximum safety of processes, we have defined the following safety and information instructions.
Each of the instructions is marked with an icon.
Any operations described in this User's Guide may only be performed by trained personnel or by an authorized
person. Warranty and post-warranty repairs shall be performed exclusively on the manufacturer's site.
Improper use, installation or setting of the level meter may lead to crashes in the application (overfilling of the
tank or damage to system components).
The manufacturer is not responsible for improper use , work losses resulting from direct or indirect damage
and expenses incurred during installation or use of the level meter.
Alert, warning, danger
This symbol informs about particularly important instructions for installation and operation of the
equipment or about dangerous situations that may occur during installation and operation. Failure to
comply with the instructions may cause failures, damage or destruction of the equipment, or may cause
injuries to persons.
The UPS-500 or UPS-700 device is packed in a cardboard packaging and the whole shipment is placed in a cardboard
box. The cardboard box is suitably filled to prevent mechanical damage during transport. Remove the device from
the package just prior to its use to prevent possible damage.
Transport to the customer is provided by a forwarding company. Subject to prior arrangement, personal pick-up of
the ordered goods is possible in the company's seat. Upon receipt, please check whether the shipment is complete
and corresponds to the extent of the order, or whether during the transport the packaging and the device has not
been damaged. Do not use a device apparently damaged during transport and contact the manufacturer to resolve
the situation.
If the device is transported further, it shall be wrapped in the original packaging and protected against shocks and
weather.
Store the device in its original packaging in a dry place, sheltered from weather, with humidity up to 85% without the
effects of chemically active substances. The range of storage temperature is -20°C to +60°C.
Level meters (sensors) of variants UPS are fitted with protective caps to prevent damage
to the ultrasonic transducer. Remove the caps before commissioning!
Information
This symbol informs about particularly important characteristics of the equipment.

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Ultrasonic level meters
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The UPS Series ultrasonic level sensors are compact measure-ment devices containing an electro-acoustic
transducer and an electronic module. Using the electro-acoustic transducer, level meters and level sensors transmit
a series of ultrasonic puls-es that spread towards the surface. The transducer then receives the reflected acoustic
wave, which is subsequently processed in the electronic module. The current distance to the surface level is
calculated from the time of spread of individual pulses towards the surface and back and the temperature measured
in the tank. The output is then set on the basis of the surface height. The outputs of the ULM level meter are current
4 -20 mA, voltage 0 - 10 V and industrial line RS-485 with Modbus RTU communication. The output of the ULS sensor
consists of a PNP transistor with an open collector and a two-state current switch 4 mA / 20 mA.
3. MEASURING PRINCIPLE
Thanks to the proximity principle employed, the devices are suitable for continuous or limit measurement of the level
of liquids, waste water, sludge, suspensions, adhesives, resins in various open and closed vessels, sumps, open
channels and drains. Applicability for measuring the surface level of loose materials is limited, the range of
measurement is shorter there. Setting is carried out either using two buttons or a magnetic pen or by remote setting
in case of Modbus RTU output. The device is equipped with optical indication of its state (RUN) and the setting
process (STATE). It is manufactured in designs for normal (N) and explosive atmospheres (Xi).
4. RANGE OF APPLICATION
UPS_–53_–01–_ measurement range 0.1 m to 1 m, all-plastic design, source of PVDF (polyvinylidene fluoride),
mechanical connection with thread G ¾.
UPS_–53_–02–_ measurement range 0.20 m to 2 m, all-plastic design, source of PVDF, mechanical connection with
thread G 1''.
UPS_–53_–06–_ measurement range 0.20 m to 6 m, all-plastic design, source of PVDF, mechanical connection with
thread G 1 ½".
UPS_–53_–10–_ measurement range 0.4 m to 10 m, all-plastic case, source of PVDF, mechanical connection with
thread G 2 ¼“.
UPS_–53_–20–_ measurement range 0.5 m to 20 m, all-plastic case, source of PVDF, mechanical connection with
flange of aluminium alloy.
5. FEATURES OF VARIANTS

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6 . DIMENSIONAL DRAWINGS
ground
terminal
UPS_–53_–02–_ UPS_–53_–06–_
UPS_–53_–10–_ UPS_–53_–20–_
Al alloy
UPS_–53_–01–_
7 . INSTALLATION AND PUTTING INTO OPERATION
This procedure includes the following three steps.
Installation
Electric connection
Setting

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with the dead zone, the device will not measure properly.
f) If the maximum level in the tank gets into the dead zone, the device shall be mounted into a higher installation
neck. The tank can be then filled nearly up to the maximum volume. The neck’s inner surface shall be even and
smooth (without edges and welded joints), the inner edge should be rounded in the spot where the ultrasonic wave
leaves the pipe. Choose the largest possible neck diameter, but keep the neck height as low as possible. The
recommended dimensions of
a) The device is installed in a vertical position into the upper lid of the tank or reservoir using a lug, a fastening nut or
a flange in such a way that the axis of the device is perpendicular to the surface level of the measured liquid (Fig. 1).
Tightening of the level meter in the welding flange (or. by the fixing nut) is done by hand *. The device shall be
installed in places with no risk of mechanical damage to the front of the sensor.
b) The minimum dimensional parameters when installing into the lid or
the ceiling of the tank are listed in Fig. 3.
c) When installing in an open channel (sump, drain, etc.),
install the device onto a console as close as possible to the expected
maximum level.
d) The reference plane for the measurement is the lower
edge of the transducer (Fig.2). In compliance with the measuring
principle, no signals reflected in the area directly below the device (dead
zone) can be evaluated.
The dead zone (Fig. 2) determines the minimum distance possible
between the device and the highest level. The minimum distances to the
medium are listed in the chapter "Technical specifications".
e) The device shall be installed so that the surface does not interfere with
the dead zone when the tank is filled to the maximum. If the measured
surface interferes
6 . DIMENSIONAL DRAWINGS
Fig. 1: Correct installation of the sensor,
perpendicular to the liquid surface
Fig. 2: Dead zone of the device Fig. 3: Distance of the device from the tank wall
Fig. 4: Installation of the device in the installation neck
UPS_–53–01 ; 02 ; 10
UPS_–53–06
UPS_–53–20
d > c/12
(min. 200 mm)
d > c/8
(min. 200 mm)
d > c/10
(min. 200 mm)
UPS_–53–01; 02; 06
UPS_–53–10
UPS_–53–20
a < 3 b
b > 100 mm
a < 1.5 b
b > 100 mm
a < 1.5 b
b > 150 mm
reference plane for
the measurement
a – neck height from source edge
b – neck width
m – dead zone
d – distance from tank wall
c – maximum reach of the device
m – dead zone
*) To loosen the level meter can be used suitable torque wrench.

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Fig. 5: Thick foam on the surface
Fig. 6: Minimum distance from close objects in the tank
Fig. 7: Installation of the device out of reach of filling circulation
g) Foam may be produced on the surface of the measured liquid
during filling, mixing and other processes. The thick foam
significantly absorbs the ultrasound signal and may cause
malfunction of the device (Fig. 5). In those cases it is necessary to
test the device in advance and, if necessary, to contact the
manufacturer.
h) The site for installing the level meter needs to be chosen so that
the emitted acoustic signal is not affected by nearby objects
(reinforcements, supports, brackets, ladders, heating elements,
mixers, etc.). These obstacles may result in false rebounds,
increasing measurement inaccuracy (Fig. 6).
i) Do not install the device in or above the filling point (Fig. 7).
The measurement could be affected by the inflowing medium.
j) Applicability for measuring the surface level of bulk-solid materials is limited, the range of measurement is shorter
there. We recommend to consult the suitability of the device for measuring
UPS_–53–01 ;02 ; 10
UPS_–53–06
UPS_–53–20
x > c/12
(min. 200 mm)
x > c/8
(min. 200 mm)
x– distance from the edge of the longest object
c – maximum reach of the level meter
x > c/10
(min. 200 mm)

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k) The measuring device shall not be installed in places with direct sunlight and
shall be protected against weather conditions.
l) If installation in places with direct sunlight is inevitable, it is necessary to
mount a shielding cover above the device (Fig. 8).
m) It is advisable to keep cable under the cable gland (sagging down) as shown
in Fig. 9 to prevent penetration of moisture. Rain and condensing water can be
therefore drained away freely.
n) The cable gland as well as the connector shall be tightened sufficiently to
prevent penetration of moisture.
o) The ultrasonic signal can be scattered or attenuated if the surface is
moderately stirred or rippled (due to a mixer, inflow of liquid, etc.). This may
result in reduction of the measurement range or unreliable operation of the
device (Fig. 10).
p) False surface reflections of the ultrasonic signal and unreliable operation of
the device might result from the mixer's rotating blades that ripple the surface
level(Fig. 11).
q) The device should not be installed in places with the risk of false reflections of
the ultrasonic signal from the mixer's blades (Fig. 12).
r) Horn adapter ST–G1 (for UPS-500_–02), ST–G1,5 (for UPS-500_-06) or
ST–G2,25 (for UPS-500_–10) for improved reception of the transmitted signal
can be used in open chanels, sumps, etc.
s) Horn adapter ST increases the directivity of the emitted acoustic waves,
improves the reception of weak echoes (unstable surface level, loose
materials) and reduces the risk of false reflections.
t) The horn adapter is installed on the device via process.
!
Fig. 8: Shielding cover against
direct sunlight
Fig. 9: Protection against penetration
of moisture
Fig. 10: Moderately
stirred surface
!
Fig. 11: Strongly
stirred surface
Fig. 12: False reflection
from mixer blades
Fig. 13: Horn adapter installation
Horn adapter ST

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• If the level sensor is mounted to bottlenecks and places with
barriers, or near uneven walls or the filling area, where the
transmission signal could be distorted, we recommend using
a guide tube (acoustic horn). The tube must be made from a
single material with a smooth inner surface (see image 14a,
14b ). The minimum tube diameter must have the dimension
„b“ according to image 4
The UPS level meter or ULS level sensor with a G type cable gland are connected to
processing (display) units by means of a cable with an outer diameter of 6 to 8 mm
(recommended wire cross-section 0.5 to 0.75 mm2), via a detachable ISO connector
with inner screw terminals, which is part of the delivery. The connection diagram and
the inner view of the connector are shown in Fig.15 and 16. Non-detachable connector
IP67 with PVC cable 5 m long can be supplied as an extra option.
1. Unscrew the connector from the device body using a
suitable screwdriver.
2. Remove the inner part of the connector using a flat
screwdriver (insert the screwdriver in the gap marked with an
arrow).
3. Unscrew the cable gland and pull the supply cable inside
the connector.
4. Connect the cable wires to the screw terminals as shown in
Fig. 15 (current output 4-20 mA), Fig. 16 (voltage output 0-10
V), Fig. 17 (S type output) or Fig. 18 (P) type output. Tighten the
terminals firmly.
5. Insert the terminals back in the connector so that the NC
terminal points away from the cable gland. Fasten the cable
gland.
6. Check the sealing on the connector and attach the
connector back to the device body.
9. ELECTRIC CONNECTION
Fig. 14a: Short guide tube installation
ventilation
holes
sleeves for
mounting
Fig. 14b: Total guide tube installation
legend:
BK – black brown
BU – blue not connected
BN –
NC –
0 V
Uout
U+
0 V
+U
Fig.15: Connection diagram of
(variant –I) and inside view
the ULM level
meter of the connector
Fig.16: Connection diagram of the ULM level meter
(variant –U) and inside view of the connector
BN 1( )
mA
BU 2( )
0V
+U
V
+U
Uout
0V
U
BN 1( )
BK (3)
BU 2( )
BN 1( )
Valid for: UPS_-53_-_ _-_-_-G-_
Performance “G”
with connector ISO
Connection through ISO connector
Connecting the cable to the device:

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Ultrasonic level meters
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Type UPS-500_–_ _–_–S–G–_
Positive supply pole +U is
connected to the brown wire
or to connector pin 1, negative
pole to the blue wire or to
connector pin 2.
Type UPS-500_–_ _–_–P–G–_
Positive supply pole +U is
connected to the brown wire
or to connector pin 1, negative
pole to the blue wire or to
connector pin 2. Load is
connected to the black wire or
to connector pin 3.
Type UPS-500_–_ _–_–I–C–_
The positive supply pole +U is
connected to connector pin 1 or the
brown wire of the connected cable,
the negative pole is connected to
connector pin 3 or the blue wire of
the connected cable.
Type UPS-500_–_ _–_–U–C–_ The
positive supply pole +U is
connected to connector pin 1 or the
brown wire of the connected cable,
the negative pole is connected to
connector pin 3 or the blue wire of
the connected cable. Output
voltage is connected to connector
pin 4 or the black cable wire.
The ULM level meter or ULS level sensor with a C type cable gland are connected to processing (display)
units by means of a cable with an outer diameter of 4 to 6 mm (recommended wire cross-section 0.5 to
0.75 mm2), via a connector socket with a moulded cable (2 or 5 m long) or via a detachable connector
socket without a cable (see accessories). In this case connect the cable to the inner socket pins under
Fig. 19.
Connection through M12 connector
+U
0 V
Uout
+U
0 V
legend:
BN – brown
BK – black
BU – blue
output (BK)
0V (BU)
+U (BN)
1
3
4
0 V
+U
1
3
4
0 V
+U
Uout
Fig. 17: Connection diagram of the ULS sensor with S type output
(two-statecurrent switch 4 mA / 20 mA)
Fig. 18: Connection diagram of the ULS sensor with P
type output (PNP) with an open collector
Fig. 19: Inside view of the connector socket
Fig. 21: Connection diagram of the ULM level meter (variant –U)
and view of the connector
and view of the connector
Fig. 20: Connection diagram of the ULM level meter (variant –I)
BN 1( )
BU 2( )
mA +U
0V
+U
0V
BN (1)
BU (2)
BK (3)
V
+U
0V
UUout
BN 1( )
BU (3)
BK(4)
mA +U
0V
BN 1( )
BU (3)
Performance "C"
with connector M12
Valid for: UPS_-53_-_ _-_-_-C

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Type UPS-500_–_ _–_–S–C–_
The positive supply pole +U is
connected to connector pin 1
or the brown wire of the
connected cable, the negative
pole is connected to connector
pin 3 or the blue wire of the
connected cable.
Type UPS-500_–_ _–_–P–C–_
The positive supply pole +U is
connected to connector pin 1
or the brown wire of the
connected cable, the negative
pole is connected to connector
pin 3 or the blue wire of the
connected cable. Load is
connected to connector pin 4
or the black cable wire.
Valid for: UPS-53_-_ _-_-_-B(H)-_
Type UPS-500_–_ _–_–I–B(H)–_
The positive supply pole +U is
connected to the brown wire of the
connected cable, the negative pole
is connected to the blue wire of the
connected cable.
Type UPS-500_–_ _–_–U–B(H)–_
The positive supply pole +U is
connected to the brown wire of the
connected cable, the negative pole
is connected to the blue wire of the
connected cable. Output voltage is
connected to the black wire of the
cable.
The ULM level meter or ULS sensor with a B or H type cable
gland are connected to processing (display) units by means of
a fixed PVC cable 5 m long. PG 11 (B) or plastic bushings with a
thread for protective hoses (H) can be used as a cable gland.
Connection diagrams are shown in Fig. 24, 25, 26, 27 and 27.
Connection via PG 11 gland or gland for protective hoses
1
3
4
0 V
+U
1
3
4
0 V
+U
Uout
Fig.22: Connection diagram of the ULS sensor with S type
Fig.23: Connection diagram of the ULS sensor with P type
(PNP) with an openoutput collector
output (two-state current switch 4 mA
4/ 20 mA)
mA +U
0V
BN 1( )
BU (3)
+U
0V
BN (1)
BU (3)
BK (4)
Performance “H” with cable
gland for protective hose
Fig. 24: Connection diagram of the ULM level meter (variant –I)
Fig. 25: Connection diagram of the ULMlevel meter with
a voltage output (variant –U)
Performance “B” with
short cable gland

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Type UPS-500_–_ _–_–M–B(H)–_
Level meters are designed for
connection to the PLC input (RS–485).
The positive supply pole +U is
connected to the brown wire of the
connected cable, the negative pole is
connected to the blue wire of the
connected cable. Terminals A and B of
line RS-485 are connected to the yellow
and green communication wires. The
ground terminal of line RS-485 is
connected to cable shielding.
Type UPS-500_–_ _–_–S–B(H)–_
The positive supply pole +U is
connected to the brown wire of the
connected cable, the negative pole is
connected to the blue wire of the
connected cable.
Type UPS-500_–_ _–_–P–B(H)–_
The positive supply pole +U is
connected to the brown wire of the
connected cable, the negative pole is
connected to the blue wire of the
connected cable. Load is connected to
the black wire of the cable.
legend:
BK – black WH – white
BU – blue YE – yellow
BN – brown GN – green
+U
0V
BN (1)
BU (2)
BK (3)
Fig. 26:Connection diagram of thelevel meter
with an RS–485 output(variant –M)
Fig. 27: Connection diagram of the ULS sensor
typewith S output
switch 4 mA /(two-state current 20 mA)
Fig. 28: Connection diagram of the ULS sensor with P
type output (PNP) with an open collector
Wiring operations shall only be carried out without voltage!
Taking into account the potential occurrence of electrostatic discharge on nonconducting parts of the
level meter, it is necessary to ground the flange of level meters UPS–53Xi–20–F and sensors
UPS–53Xi–20–F, located in an explosive atmosphere, using a ground terminal!
The supply source should be preferably designed as a stabilized source of safe voltage 18 V to 36 V DC
(max. 30 V DC for version Xi), which is part of the downstream processing or display system. In case of
strong ambient electromagnetic disturbance, parallel run of the input cable with the power line or its
length exceeding 30 m, we recommend using a shielded cable.
It is also necessary to design and take measures to reduce the effects of static electricity to a safe level
in the wiring.
Installation in explosive atmospheres needs to be carried out in compliance with EN 60079-14 (Electrical
installations for explosive gaseous atmospheres – Part 14: Electrical installations in dangerous areas
other than mining) and possibly also in compliance with other standards relating to the area concerned.

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10. SET-UP ELEMENTS
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Valid for: UPS_-53_-_ _-_-_-_-T
Valid for: UPS_-53_-_ _-_-_-_-M

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Ultrasonic level meters
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Ultrasonic level meters
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