Level Pro ULTRAPRO 1000 User manual

Read carefully the instructions published in this manual before the rst use of the level meter. Keep the manual
at a safe place. The manufacturer reserves the right to implement changes without prior notice.
INSTRUCTION MANUAL
průmyslová elektronika
Ultrasonic level meters ULTRAPRO 1000
Firmware: v.2.0
Reliable Non-Contact Level

Table of conTenTs
1 . Measuring principle .................................................................................................................3
2 . Range of applications ..............................................................................................................3
3 . Variants of sensors ..................................................................................................................3
4 . Dimensional drawings .............................................................................................................4
5 . Installation and putting into operation ..................................................................................4
6. Installation instructions ..........................................................................................................5
7. Electrical connection ...............................................................................................................9
8. Examples of UltraPro 1000 connection ...............................................................................10
8.1 . Wiring diagram of the level meter with current output and PDU unit .................................10
8.2 . WiringdiagramofthelevelmeterwithcurrentoutputandPDUunit ..............................
in versions for explosive areas ..........................................................................................11
8 .3 . WiringdiagramofthelevelmeterwithcurrentoutputandMGUunit ................................13
8 .4 . WiringdiagramofthelevelmeterwithModbus/RS485andMGUunit ...........................13
8 .5 . WiringdiagramofthelevelmeterwithModbus/RS485andPDUunit ............................13
9 . Set-up elements .......................................................................................................................14
10. Status signalization ................................................................................................................14
11 . Operation and setting ............................................................................................................15
10.1 . Basicconguration ..........................................................................................................15
10.2 . Servicesettings ...............................................................................................................18
10 .3 . Additionalfunctions .........................................................................................................20
12. HART®
communication protocol ...........................................................................................22
13. Modbus®
communication protocol ........................................................................................23
14 . Order code ..............................................................................................................................23
15 . Accessories ............................................................................................................................23
16 . Safety, protection, compatibility and explosion proof .......................................................24
17 . Use, manipulation and maintenance ....................................................................................24
18 . Marking of labels ....................................................................................................................25
19 . Menu structure .......................................................................................................................27
20 . Specification .........................................................................................................................28
21 . Packing, shipping and storage .............................................................................................30

UltraPro-1000 © Levelpro, s.r.o.
3
1 .
Measuring principle
UltrasoniclevelmeterUltrapro UPS® 1000 Series is a compact measuring device consisting of
two parts - main level meter(thebodywithmeasuringelectronics)and the displaymodule.Using
the electroacoustic converter, the level meter transmits a sequence of ultrasonic pulses that
spread towards the surface level. The converter recuperates reflected acoustic waves that are
subsequently processed in the electronic module. The Utraflo filters out interfering signals,
compares the cleaned received signal with the false reflection map (e.g. from mixers, ladders,
reinforcementetc.)andselectsasuitablereflection(echo).Basedontheperiodduringwhichthe
individual pulses spread towards the surface level and back and based on the measured
temperatureinthetank,theinstantdistancetothe surface level is calculated. According to the
levelheight,thelevelmeteroutputissetandthemeasuredvalueisshownonthedisplay.
2 .
range of applicaTions
Forcontinuousnon-contactlevelmeasurementofliquids(watersolutions,seweragewater,etc.),
mashandpastematerials(sediments,sticks,resinsetc.)inclosedoropenvessels,sumps,reser-
voirsandopenchannels.Incasethelevelofbulk-solidmaterialsismeasured,themeasurement
rangeisreduced.Thelevelmeterscancontinuouslymeasurelevelsofbulk-solidmaterialswith
a low concentration of dust particles. Consult the manufacturer on recommended use of the level
meterforbulk-solidmaterials.
3 .
VarianTs of sensors
All operations described in this instruction manual have to be carried out only by trained
personnel or an accredited person. Warranty and post warranty service must be exclusively
carried out by the manufacturer.
Improper use, installation or set-up of the level meter can result in crashes in the application
(overlling of the tank or damage of system components).
The manufacturer is not responsible for improper use, losses of work caused by either direct or
indirect damage, and for expenses incurred during installation or use of the level meter.
safeTy
UPS-1000 –02 Measuring range from 0.15m to 2m, plasticPVDFtransmitter,mechanical
connectionwiththread1".
UPS-1000–06 Measuring range from 0.25m to 6m, plasticPVDFtransmitter,
mechanicalconnectionwiththreadG1½".
UPS-1000–10 Measuring range from 0.4m to 10m PVDFtransmitter,
mechanical connection with thread 2¼".
UPS-1000-20 Measuring range from 0.5m to 20m, PVDFtransmitter,mechanical
connectionwithaluminiumalloyange.

4
© Levelpro, s.r.o. UltraPro-1000
4 .
DiMensional Drawings
UPS-1000-02
Pg11 cable gland
Ground terminal
variant UPS -with protective
conductor
UPS-1000–06
UPS-1000-20
UPS-1000–10
This procedure includes the following three steps.
•
insTallaTion
•
elecTric connecTion
•
seTTing
5 .
insTallaTion anD puTTing inTo operaTion

Ultrapro-1000 © Levelpro, s.r.o.
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Fig. 2: Level meter dead zone
m – Dead zone
(blind zone, blocking distance)
6 .
InstallatIon InstructIons
•Install the level meter in the vertical positionintotheupperlidofthetankorreservoirusingaweld-
ingflange,afasteningnutoraflangesothatthe
levelmeteraxisisperpendiculartothesurfacelevel
ofthemeasuredliquid(Fig.1).
• Themin.dimensional parameters to install the level
meterintoalidoraceilingofatankaregiveninFig.3.
•When installing in an open channel(reservoir,drain
etc.),installthelevelmeterontoabracketascloseas
possibletotheexpectedmax.level.
•Inconnectionwiththemeasurementprinciple,nosig-
nals reectedintheareaimmediatelyunderthelevel
metercanbeevaluated.The zone(Fig.2)determines
themin.distancepossiblebetweenthelevelmeter
and the highest surface level. The min. distances to
themediumaregiveninthechapter"Specications".
•It is necessary to install the level meter so that the
bin level cannot interfere with the dead zone when
filled uptothemaximum.Ifthemeasuredlevelinter-
fereswiththedeadzone,thelevelmeterwillnot
work
properly.
Fig. 1: Recommended installation in
the tank
Fig. 3: Installation distance from the tank wall
•Ifthemaximumsurfacelevelinthetankinterfereswiththedeadzone,thelevelmeterhas
tobemountedintoahigherinstallation neck.Inthisway,thetankcanbefi lednearlyupto
themaximumvolume.Theinnernecksurfacehastobeevenandsmooth(withoutedgesand
weldedjoints);theinneredgeshouldberoundedwheretheultrasonicwaveleavesthepipe.The
neckdiametershouldbeaslargeaspossiblebuttheneckheightshouldbeaslowaspossible.
RecommendeddimensionsoftheinputneckaregiveninFig.4.
UPS 1000–02 ; 10 d > 1/12 c
(min. 200 mm)
UPS 1000–06 d > 1/8 c
(min. 200 mm)
UPS 1000–20 d > 1/10 c
(min. 200 mm)
Fig. 4: Possible installation of the installation neck
a – Neck height
b – Neck width
m – Dead zone (blind zone, blocking dist.)
UPS 1000–02 ; 06 a < 3 b
b > 100 mm
UPS 1000–10 a < 1,5 b
b > 100 mm
UPS 1000–20 a < 1,5 b
b > 150 mm
d – Distance from
the tank wall
c – Maximum reach
of the level meter

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© Levelpro, s.r.o. UltraPro 1000
•Iftheemittedacousticsignalofthelevelmeterisaffectedbynearobjects(roughnessonwalls
ofthetank,variouspartitions,mixersetc.),itisnecessarytomapfalsereectionsbyactivating
themode"TEACHING".Incaseofinstalledmixers,itisnecessarytoputthemixerstoposition
underthelevelmeter(directthemixerpaddletotheultrasonicsignalbeam)(Fig.5and6).
•Donotinstallthelevelmeterinorabovethefillingpoint(Fig.7).
Fig. 5: False echo from obstacles in the tank Fig. 6: False echo from the mixer paddle
Fig. 7: Level meter installation outside the inuence of lling
•Incasethelevelofbulksolids beingthe
measurementrangeisreducedDuetoabsorp-
tionofacousticwavesbymedium,the
shorteningofthemeasuringrangecan be
reduced byupto 50% depending on the
medium and the particle size. We therefore
recommend selecting a level meter with greater
range than the maximum range of measuring
the medium. It is also recommended to use a
directionalhorn(seeimage8),whichwill
increase the rangethemeasuringrange,
(concentratesacousticenergy)whilepre-
servingthesamebeamangle,andimproves
thesensitivitywhenreceivingthereflected
echo. We recommend to consult the use with the
manufacturer.
Fig. 8: Level meter installation in silo or hopper
horn
adapter

UltraPro 1000 © Levelpro, s.r.o.
7
!
!
•Scatteringorattenuationofthe
ultrasonic signal can result if the
surfacelevelhasbeenmoderate-
ly stirred or rippled(bya mixer,
comingliquidetc.). Itcanresult
in reduction of the measurement
rangeorunreliablefunctionofthe
levelmeter(Fig.10).
•Rotatingmixer blades can cause
thatthesurfaceisstirred,whichre-
sultsinfalsereectionsoftheultra-
sonic signal from the surface level
andunreliableoperationofthe
levelmeter(Fig.13).(obr.11).For a
rippled or swirling level, you can
use the directional horn to elimi-
nate scattering of the ultrasonic
signal.
•Duringfiling,mixingandotherprocesses,foam can arise
on the surface level of the measured liquid.Thefoam
absorbstheultrasonicsignal which may cause malfunction
of the level meter (Fig.9).Forsuchcases,itisnecessaryto
setup"SENSITIVITY"modeto"high"orto contactthe
manufacturer. Incaseofathinlayeroffoam,itisalso
recommendedtousethe directionalhornforimproving
receiptoftheecho.
Fig. 9: Foam on the surface
Fig. 10: Moderately stirred
surface
Fig. 11: Intensely stirred surface
•If the level sensor is mounted to
bottlenecksandplaceswithba-
rriers,ornearunevenwallsorthe
fi lingarea,wherethetransmissi-
on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
12a,12b).Theminimumtubedia-
metermusthavethedimension"b"
according to image 4 on page 5.
Afterinstalling,youmustperform
theprocedure"LEARNING".We
recommend consulting with the
manufacture on the construction of
theguidetube.
Obr. 12a: Short guide tube
installation
ventilation
holes
sleeves for
mounting
Obr. 12b: Total guide tube
installation

8
© Levelpro, s.r.o. UltraPro 1000
•Thelevelmetermustnotbeinstalledinplaceswithdirectso-
lar radiationandmustbeprotectedagainstweathereffects.
•If the installation in places with direct solar radiation is inevi-
table,itisnecessarytomountashielding coverabovethe
levelmeter (Fig.13).
•Itissuitabletorunthecableunderacablebushing(obliquely
downinslack)accordingtoFig.14topreventpenetration
of humidity.Thentherainandcondensingwatercanfl w
offfreely.
•Thecablebushingandconnectorhavetobesufciently
tightenedtopreventpenetrationofhumidity.
•Tolowertheminimumdistancetothemeasuredmedium,
a reection boardmadefromsolid,evenandsmoothmate-
rialcanbeinstalledtothelevelmeter.Thenthetankcanbe
fi lednearlyuptothemaximumheight.Thesolutionissuit-
ableforopentanksandreservoirs(Fig.15).
H + L = mrtvá zóna
Fig. 13: Solar radiation shielding
cover
Fig. 14: Prevention to avoid
intrusion of humidity Fig. 15: Reection board

Ultrapro-1000 © Levelpro, s.r.o.
9
7 .
elecTrical connecTion
Thelevelmeterisconnectedtoconsequential(evaluating)devicewithasuitablecablewiththe
outerdiameterof6to8mmusingscrewterminalslocatedunderthedisplaymodule.Therecom-
mendedcrosssectionofcoresforthecurrentversion2x0,5÷0,75mm2 and for the version with
Modbuscommunication2x2x0,25mm2 (twistedpair,
shielded).Pluspole(+U)isconnectedtotheterminal
(+),minuspole(0V)totheterminal(-)andtheshielding
(onlyforshieldedcables)totheterminal().Commu-
nicationwiresAandBofthelineRS-485(forversion
"M"-Modbus)areconnectedtotheterminalsAandB.
Procedure to connect the cable to the level meter:
1. Unscrew the nut of the upper transparent lid.
2. Take the upper edge of the display module and
takeitoutcarefullybymildswingingup.
3. If you cannot grasp the module, you can use
a small screwdriver. Insert it as far as the seam and
usefromseveralsidestoslightlyliftthemodule.
4. Release the cable outlet and thread the stripped
supplycablein.
5. Connectthecabletothescrewterminalsaccord-
ingtothediagraminFig.17or18.Firmlytighten
theterminalsandthecableoutlet.
6. If the level meter with Modbus is involved as a
terminalforRS-485,werecommend(toavoidre-
flections ontheline)toconnect120Ωtermination
resistor. This is done by moving a small lever of
theswitchmarked120ΩtotheONposition.Onthe
levelmetersconnectedtothelineRS-485as an
intermediatedevice, the termination resistorsare
notconnected(switchremainsoff).
7. Insert the display module back into the head so
thattheconnectorisproperlyconnected.
8. Slidesiliconesealonthethreadofthelevelmeter
body,thentightenthenutoftheupperlid.Connect
thecabletoconsequentialdevice.
Fig. 16: Wiring diagram of the level meter
with current output UPS 1000 _-_-_- I
metal clip display unit connector
Terminal block
Electrical connection must be done in de-energized state!
With regard to possible occurrence of electrostatic charge on non-conductive parts of the
level meter, all level meters for explosive spaces (UPS–70Xi type) must be grounded. It
will be done using a screw placed on the head of the level meter under the cable outlet.
Fig. 17: Inside view of screw terminals of the
level meter with current output UPS 1000_-_-_-I
+ABIS
GND
ON
120
display unit connector
Terminal block
metal clip
120Ω switch
Fig. 18: Wiring diagram of the level
meter with Modbus UltraPro
1000_-_-_-M
Fig. 19: Inside view of screw terminals of the
level meter with Modbus UPS 1000_-_-_-M