Limaco ULM-3D Series Operating And Installation Manual Download

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ULM-3D RADAR LEVEL TRANSMITTER

FOR BULK MATERIALS

Operating and Installation Manual

300028, Tula, 94 Boldina St.
t/f +7-4872-22-44-09
e-mail: [email protected]
www.limaco.ru

LIMACO

JSC

Summary of Contents for ULM-3D Series

Page 1: ...ULM 3D RADAR LEVEL TRANSMITTER FOR BULK MATERIALS Operating and Installation Manual 300028 Tula 94 Boldina St t f 7 4872 22 44 09 e mail in limaco ru www limaco ru LIMACO JSC ...

Page 2: ... design 8 3 3 Product identification 9 3 4 Operation concept 9 3 5 ULM 3D 5 operation specifics 12 3 6 Acceptance packaging transportation and storage rules 14 4 Installation 4 1 General recommendations for level transmitter placement 15 4 2 Position for installation 19 4 3 Requirements for the installation on mounting nozzle for ULM 3D 5 20 4 4 Requirements for the installation on mounting nozzle...

Page 3: ...itter using PC via RS 485 37 7 Troubleshooting 39 8 The structure of volume measurement system 43 9 Brief description of the initial master software setup 45 10 Maintenance 48 10 1 Preventive inspection preventive maintenance 48 10 2 Preventive inspection with the removal of level transmitter preventive maintenance 48 11 Dismantling 11 1 Dismantling procedure 48 11 2 Disposal 49 12 Repair 49 13 Ap...

Page 4: ...all dimensions of ULM 3D 5 54 13 4 Handling of cable gland 56 4 RE_ULM3DX_18_02_20 ...

Page 5: ...his operating manual is intended for trained personnel who perform installation commissioning diagnostics and maintenance of the level transmitter The person nel shall know and follow the instructions provided in this document 1 3 Symbols Symbol Description Failure to follow the instructions may disable the device or cause its malfunction Failure to follow the instructions may cause damage to pers...

Page 6: ...environments for conductive dust for installation in zones of class 21 22 as per GOST IEC 60079 10 2 2011 Before using level transmitters in an explosion hazardous zone make sure that the version indicated on the nameplate corresponds to the one acceptable for use in this zone Climatic category is О1 as per GOST 15150 69 The level transmitter belongs to D3 group as per GOST R 52931 2008 in terms o...

Page 7: ...DUCT DESCRIPTION 3 1 ULM 3D scope of supply The scope of supply includes Radar level transmitter Documentation and software on electronic media Ulmcfg setup and configuration software Software for setup via Bluetooth for Android mobile operating system Limaco OPC server software Multi Beam Radar Surface Plotter software Operating and Installation Manual Supplementary documentation certificates and...

Page 8: ...s Fig 3 2 Appearance and location of key ULM 3D 1 components 1 aerial unit housing 2 mounting flange 3 cable gland or cable gland plug 4 electronic module housing 5 electronic module cover 6 Bluetooth module plug 7 aerial unit shield 1 2 3 4 5 6 7 2 3 4 5 7 8 RE_ULM3DX_18_02_20 ...

Page 9: ...ОС ООО ХХХ ТС RU C RU АМ02 В Х XXX Fig 3 3 Standard nameplate Level transmitter designation system has the following form ULM 3D Х where Х level transmitter version 1 one measuring channel 5 measuring channels 3 4 Operation concept The level transmitter is installed above the measured surface of material The device is mounted in an opening on the tank roof using a flange in a closed tank Fig 3 4 a...

Page 10: ... 2 emitted signal 3 reflected signal 4 the surface of measured product Fig 3 5 Measurement method The level transmitter operates as a FMCW Frequency Modulated Continuous Wave radar This is one of conventional methods of non contact distance mea surement which minimizes the influence of spurious interference and interference associated with irregularities disturbances of the surface of measured pro...

Page 11: ...a low frequency dif ference frequency signal F is released This signal is then digitized and processed by a signal processor DSP Using a Fourier transform algorithm and original adap tive processing and noise reduction algorithms the DSP performs a spectral analy sis of the signal that results in an accurate difference frequency value By determin ing this frequency we will derive the delay time of...

Page 12: ...system that calculates the distance to the product surface from each channel Each measuring channel has its own serial number the numbering of channels is shown in Fig 3 8 Information from each measuring channel of the level transmitter can be transmitted to the Multi Beam Radar Surface Plotter software which builds a model of the product surface profile and calculates the volume of measured mater...

Page 13: ...oriented strictly along the vertical axis of the level transmitter Other channels are oriented based on the specific application see cl 4 2 for more details Tilt angle relative to the vertical axis of the level transmitter for each measurement channel is specified in the level transmitter data sheet The direction of the measur ing beams of channels is shown in Fig 3 9 13 RE_ULM3DX_18_02_20 ...

Page 14: ... manual the data sheet contains a QC stamp and the stamp of state verification officer in case of verification The level transmitter that has not passed visual inspection is not admitted to opera tion The level transmitter is supplied in a package that protects it during transportation The packaging is made of cardboard which is a recyclable material In some cases PE foam and PE film may be used w...

Page 15: ...ion The requirements of handling marks on the container shall be strictly observed dur ing loading and transportation The level transmitter shall be preserved as per the temporary anti corrosion protec tion option VZ 15 as per GOST 9 014 78 4 INSTALLATION 4 1 General notes on the placement of level transmitter The correct installation of level transmitter determines the stability of readings and t...

Page 16: ... install the device in such a way that the flow of product filling the vessel falls within the range of beam the best location for the device is away from the loading site Fig 4 2 Device installation on the tank Product supply 16 RE_ULM3DX_18_02_20 ...

Page 17: ...mperature at the location of level transmitter installation shall not exceed 50 C If the device is used in a tank when it is impossible to stick to installation require ments for the absence of structures and the flow of incoming product in the measur ing beam observe the following recommendations choose the distance from the vessel wall to the central axis of the level transmitter within 1 2 1 3 ...

Page 18: ...ce from the wall shall be as far as possible If the device is used on tanks made of non conductive material for example plas tic it should be taken into account that structures outside the tank may fall into the measuring beam Therefore choose the installation position with this fact in mind NOTE 18 RE_ULM3DX_18_02_20 ...

Page 19: ...the best choice of installation location provide the following data on the in tended use 1 The name of measured product 2 Product density 3 Tank shape cylindrical bin rectangular bin open dump a dome shaped tank etc 4 The dimensions of tank and its components for example in a cylindrical tank the dimensions of cylindrical and conical parts Provide drawings or sketches with dimensions 5 Presence of...

Page 20: ...l nozzle diameter D shall be 305 mm min The permissible nozzle axis devia tion from the vertical is 1 4 4 Requirements for the installation on mounting nozzle for ULM 3D 1 Fig 4 8 Device installation on the mounting nozzle Internal nozzle diameter D shall be 100 mm min The permissible deviation of nozzle axis from the vertical when measuring the level of liquid products is 1 min 5 mm 140 mm min 30...

Page 21: ...the product surface The width of beam pattern is 2 degrees The coverage of measuring beams is determined independently in two mutually perpendicular planes The value of angular sector for each plane is equal to the sum of beam tilt angles of two channels lying in this plane For each device for each measuring channel the value of beam tilt angle is given in the device data sheet The maximum beam ti...

Page 22: ...Нестабильные измерения Unstable measurements Стабильные измерения с пониженной точностью Stable low accuracy measurements Стабильные измерения с паспортной точностью Stable rated accuracy measurements Рабочая зона Operating area 4 7 Installation examples for ULM 3D 5 Fig 4 10 Installation on the concrete tank roof 22 RE_ULM3DX_18_02_20 ...

Page 23: ...tal lation with a nozzle Options C E show typical installation errors that should be noted Option C the edge of the roof under the nozzle protrudes into the nozzle besides the opening in the roof is less than the minimum permissible one Option D the lower edge of the nozzle is buried relative to the roof so the nozzle length is more than permissible one Option E level transmitter is installed with...

Page 24: ...Fig 4 13 Installation examples 24 RE_ULM3DX_18_02_20 ...

Page 25: ...ble leave the level transmitter in the mounting position with the cable connected but the cable gland not tightened leave unused cable glands unplugged a certified plug shall be installed in their place 5 2 Connection cable To connect analog output 4 20 mA use a standard pair of conductors in a separate shield To connect RS 485 digital interface use a pair of shielded conductors a batch shielded c...

Page 26: ...ing and earthing When using a shielded cable connect the cable shield to the ground potential on one side Use the ground terminal on the output receiver side The device shall be grounded There is an external ground terminal on the device housing that is connected to the tank ground Fig 5 1 Ground terminal Клемма заземления Ground terminal NOTE 26 RE_ULM3DX_18_02_20 ...

Page 27: ...rter 3 RS 485 line shield connection to the ground on the side of converter 4 Control unit e g PLC 5 Terminal for HART modem connection 6 HART digital line shield 7 Analog display unit 8 24V power supply 9 Switch matching load of RS 485 line RA B 120 Ohm 10 microSD slot under development 11 Modbus address switch 12 Backup program switch return to factory settings 27 RE_ULM3DX_18_02_20 ...

Page 28: ... RS 485 line shield connection to the ground on the side of converter 4 Control unit e g PLC 5 Terminal for HART modem connection 6 HART digital line shield 7 Analog display unit 8 24V power supply 9 microSD slot under development 10 Switch for selecting the interface in use 11 Backup program switch return to factory settings 12 Modbus address switch 28 RE_ULM3DX_18_02_20 ...

Page 29: ...13 Switch matching load of RS 485 line RA B 120 Ohm 29 RE_ULM3DX_18_02_20 ...

Page 30: ... program Вкл On Выкл Off Экран Shield Реле 1 Relay switch 1 Реле 2 Relay switch 2 1 Connecting to a PC 2 RS 485 USB converter 3 6 15 Connecting the shields interface lines 4 Control unit e g PLC 5 Terminal for HART modem connection 7 Analog display unit 8 24V power supply 30 RE_ULM3DX_18_02_20 ...

Page 31: ...ent of at least 1A per level transmitter where n is the number of level transmitters connected to the source The power of source shall be at least ИП ИП ИП I U P Fig 5 5 Diagram of level transmitter connection to power source Источник питания Power supply If the power supply line is extended take into account the voltage drop on the supply wires If the external diameter of cable will be more than ...

Page 32: ... the company s safety regulations perform all works with deactivated voltage the supply voltage shall match the technical characteristics of the device before the supply of power connect the external ground terminal of the device Required tools flat screwdriver 3 mm flat screwdriver 6 mm stripper or any suitable wire stripping tool use tips in case of multi conductor wires Getting ready for connec...

Page 33: ...le into the device through the rubber seal of the cable gland The absence or damage to O ring affects the device s dust protection and may cause it to fail 4 Remove the external insulation of the cable In case of shielded cable remove the shield 5 Remove 4 6 mm of the insulation from the wire edge When using multi conductor wires compress the stripped ends into tips 6 Connect the cable as per the ...

Page 34: ...he cable 9 Check the presence and integrity of the cover O ring cl 12 7 item 3 and tighten the device cover 10 Connect the external ground terminal to the tank ground using a 6 mm screwdriver When the connection is over check the quality of works performed as to the follow ing no cable damage no mechanical stress due to cable tension cable glands are installed twisted and sealed properly the cover...

Page 35: ...number from 1 to 255 The address is set in bi nary mode using an 8 bit DIP switch located inside the device opposite Sensor Address inscription on the nameplate The address is obtained as the sum of digits indicated on the nameplate opposite switch category raised to the unit digit power Fig 6 1 Switch position 0 Адрес датчика Sensor address When all the switches are in 0 position Fig 6 1 the leve...

Page 36: ...c controller PLC To connect the level transmitter to RS 485 line terminals A and B are provided on its terminal box Each level transmitter has a unique Modbus address The ad dress is set by an 8 bit DIP switch or determined by the internal device program if 0 address is set A USB RS 485 converter is used to connect the level transmitter to a computer via a digital interface Terminal A of the level...

Page 37: ... kilometers Fig 6 4 Conventional method of RS 485 line laying The diagram of the conventional method of line laying that meets the general re quirements of RS 485 standard designed for high speed data transmission in man made noise is shown in Fig 6 4 If the line is long install 120 Ohm matching resis tors at the ends of the line between A and B wires For this purpose a switch that connects this r...

Page 38: ...contains a control computation to de termine the unreliability of readings Such data will be ignored 6 3 Setting key parameters of level transmitter using PC via RS 485 Minimum PC requirements Pentium II 256 MB RAM 800x600 monitor USB or COM port OS Windows 95 or higher CONFIGURATOR software ULMCFG is used to configure level transmitters The software helps obtain and change key settings of level t...

Page 39: ...extensive opportunities to find and fix measurement problems using a PC and Configurator software In most cases this can help you determine the cause of failures and fix the mea surement problem You can also diagnose the device using the Bluetooth channel Checking and Troubleshooting operations for the level transmitter are summarized in the table below Failure Cause Troubleshooting method No 4 20...

Page 40: ...the horizon incorrect measurement of temperature or tilt angle The corresponding channels in the electronic module of the device are faulty Further operation is possible in the absence of overheating In other cases send the device for re pair lack of stability of read ings agitation on the prod uct surface unstable sur face A reference parameter operation can be continued unstable mode no stable r...

Page 41: ...he tech nical support 4 20 mA sig nal does not correspond to the actual val ue of the mo nitored varia ble The malfunction of level transmitter electronic unit Check the current signal perfor mance by emulation cl 7 2 In case of non conformance send the device for repair 4 20 mA sig nal does not correspond to the actual val ue of the mo nitored varia ble the elec tronic unit is in good work ing or...

Page 42: ... that occupy the COM port turn them off and restart the PC if necessary The list of possible critical failures The list of possible critical failures possible human user errors that lead to emer gency equipment modes and actions that prevent these errors are given in the table below Fault name Possible cause Troubleshooting method Mechanical damage to the housing dents cracks damage to threaded co...

Page 43: ...e levels This software records the above data to the Limaco OPC server Thus Limaco OPC Server and Multi Beam Radar Surface Plotter have to work continuously for the volume measurement system to work properly WCF data exchange interface helps use multiple instances of such software including those that run on remote computers connected to the host via Ethernet network Data can also be transmitted t...

Page 44: ...аленный ПК Remote PC Удаленный Remote Главный ПК Host PC Главный Host 3D Профиль 3D Profile Объем Volume Средний уровень Average level Минимальный уровень Minimum level Максимальный уровень Maximum level Отдельные уровни Separate levels 44 RE_ULM3DX_18_02_20 ...

Page 45: ...ny text editor Check the following lines WCF SERVER MODBUS YES If these lines differ align their contents with the above lines 9 1 5 If you need to transfer data to remote computers connected over the network in the future select the port for remote connection on this computer and make sure that it is open 9 2 Multi Beam Radar Surface Plotter 9 2 1 Before starting the configuration of this softwar...

Page 46: ...ed in the data sheet for a 3D level transmitter Enter an gles as per the measuring channel numbers channel Min Height field displays the automatically calculated minimum level that corresponds to the intersection of the beam with the vessel surface If there is inter ference in the tank that prevents level measurement increase the minimum level for this beam In this case when a level less than the ...

Page 47: ... connection of SCADA system To enable connection to SCADA volume measurement system installed on a remote computer first install Limaco OPC Server software on this computer Configure it as a remote server To do this make changes manually to limacopc cfg file generated during the instal lation Replace MODBUS YES line with MODBUS NO line Next set the direction of WCF exchange towards the server loca...

Page 48: ...anical damage and the tightness of cable gland nut 10 2 Preventive inspection with the removal of level transmitter preventive maintenance Perform work in accordance with cl 10 1 De energize the level transmitter Carefully remove the level transmitter Examine the state of aerial lens If necessary gently wipe the aerial or aerial shield with an alcohol impregnated swab Check the integrity of sealin...

Page 49: ...rn of the equipment to the manufacturer for repair fill out a special form Repair Application posted on the website www limaco ru Procedure for sending the device for repair fill out the Repair Application form clean the device and pack it in a container that ensures its safety during transporta tion send the equipment and Repair Application to the address specified in Contacts section on the webs...

Page 50: ...ass Weight kg max ULM 3D 5 ULM 3D 1 11 3 Overall dimensions mm max ULM 3D 5 ULM 3D 1 330х330х235 205х170х135 Type of installation on the process flange Output signals Analog 4 20 mA Active Alarms 3 ma 21 mA installable Load 300 Ohm max Error in the temperature range 40 60 C 0 25 of the measurement range max Digital RS 485 Modbus RTU Resolution 0 1 mm Wireless Bluetooth Version 4 0 or higher Relay ...

Page 51: ...nstallation location 40 60 С At a temperature on the level transmitter flange above 60 С The installation of radar transparent in sulating gasket is required Atmospheric pressure 84 0 106 7 kPa 630 800 mmHg Relative humidity at the level transmitter installation location 95 35 С or lower temperatures without moisture condensation Mechanical impacts vibration amplitude vibration frequency 0 1 mm ma...

Page 52: ...al data Cable gland Option 1 1 x cable gland M20x1 5 round cable Ø 7 12 mm 1 x plug М20х1 5 Option 2 2 x cable glands M20x1 5 round cable Ø 7 12 mm Screw terminals for electrical connection of wires of 2 5 m AWG 14 max Permits and certificates You can download this documents from the website www limaco ru 52 RE_ULM3DX_18_02_20 ...

Page 53: ...13 2 Level transmitter connection to the mount flange and overall dimensions of ULM 3D 5 53 RE_ULM3DX_18_02_20 ...

Page 54: ...all dimensions of ULM 3D 1 4 отв М6х8 12 4 holes М6х8 12 Mounting dimensions of ULM 3D 1 level transmitter without a mounting flange Винт М6х10 DIN 912 4 шт Screw М6х10 DIN 912 4 pcs Connecting ULM 3D 1 level transmitter to a mounting flange 54 RE_ULM3DX_18_02_20 ...

Page 55: ...Installation of ULM 3D 1 level transmitter on a nozzle 55 RE_ULM3DX_18_02_20 ...

Page 56: ...m 7 12 Wrench size 22 Material Nickel plated brass Procedure for connecting the cable to the level transmitter 1 Screw the cable gland into the level transmitter housing Fig 3 1 3 2 2 Loosen the clamp nut 3 Run a cable of the appropriate diameter through the cable gland 4 Tighten the clamp nut Special conditions for operation and installation Cable entries are only applicable for perma nently laid...

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