KENCO ENGINEERING COMPANY
Sensor Material
Sensor Length
Flange Size
Flange Material
Input Power
Output
P.O. BOX 470426 TULSA, OK 74147-0426 ● PHONE: (918) 663-4406 FAX: (918) 663-4406
www.kenco-eng.com e-mail: info@kenco-eng.com
MODEL KUSG ULTRASONIC SWITCH
INSTALLATION / OPERATION INSTRUCTIONS
GENERAL DESCRIPTION
The KUSG Series Ultrasonic Level Switches are ideal, low cost solutions for many liquid level control applications. They
operate in a wide variety of services.
PRINCIPLE OF OPERATION
Ultrasonic switches use piezoelectric crystals to transform electrical energy into mechanical motion (sound). The
Transmit Crystal sends a pulse of sound through the space between the crystals, to the Receive Crystal. If the space is
filled with air, gas, or vacuum, the Receive Crystal does not detect the sound pulse. However, if the space is filled with
liquid, any liquid, the pulse is detected by the Receive Crystal, and the switch output changes.
MODEL DESCRIPTION
Input Power
Output
Switch Mounting
Sensor Material
Sensor Length
Process Connection
Flange Size
KUSG - - - - - - - -
Flange Material
Description Code Description Code Description Code Description Code
316LSS S Standard (1”) 00 None None
Monel® M Inches (2” – 120”) xxx 1-1/2” 0 Carbon Steel A
Hastelloy B® HB 1 1 316SS S
Hastelloy C® HC 2 2 Hastelloy C® HC
Teflon® T 3 3 CPVC C
Kynar® K Kynar® K
CPVC C Teflon® T
INSTALLATION
Unpack the switch carefully. Inspect all units for damage. Report any damage to carrier immediately. Check the
contents against the packing slip and purchase order.
Kenco’s Ultrasonic Switches are manufactured to the highest quality standards. These switches use electronic
components that can be damaged by static electricity. Make sure that you are properly grounded before starting
installation. Insure that all electrical connections are properly made, and that there are no “floating” connections.
Description Code Description Code
115Vac 1 10A DPDT 1
230Vac 2
24Vdc 3
Process Connection
12Vdc 4 Description Code
Switch Mounting
¾” NPT 1
150# Flange F
Description Code 300# Flange H
Integral 1 Sanitary Flange S
*Remote 2
*Remote 10ft. (std.)
100ft. (max)
Operational Check
¾” NPT
point
Vessel Wall
Before installing the switch a simple operational check should be performed, as follows:
1. Fill a container with water
2. Open the electronics housing cover and connect power (see section on “Wiring”).
3. Set the Fail Safe jumper to the LLFS position (lower two pins).
4. Apply power
5. Place the sensor gap into the water. The relay will energize (the contacts between (NC) and (C) should open).
6. Remove the sensor from the liquid. The relay will de-energize (the contacts between (NC) and (C) should close).
7. Disconnect the wiring.
Mounting
For threaded process connections, screw sensor into the opening using a wrench on the sensor mounting nut flats. Use
thread tape or suitable pipe compound on the threads. If flanged, bolt the sensor to the mating flange with the proper
gasket.
The sensor gap must protrude into the vessel / pipe being measured. The sensor will not function properly if the detection
tip is in a nozzle. See the following drawings for mounting guidelines:
Never tighten by
turning housing
Use wrench here
Gap must face
sideways
Actuation
Gap must
clear nozzle
Wiring
It is recommended that conduit be installed onto the ¾” NPT connection on the electronics housing. A seal drain fitting
should be used to prevent moisture from entering the switch. All wiring, conduit, and electrical fittings must conform to
local electrical codes for the location selected. If the switch is to be used in a Hazardous Area, the applicable codes of the
National Electrical Code must be followed as well.
1. Connect power wiring
2. Connect relay wiring (see diagram)
3. Connect Manual Self-Test terminals to a remote pushbutton (maximum distance 30 feet).
4. Adjust failsafe jumper
The following table shows the relay condition for each switch state:
Jumper
High Level Failsafe
(HLFS)
Low Level Failsafe
(LLFS)
Manual Self-Test
Maximum Wiring
Distance - 30ft.
Molex Conn. &
Coaxial Cable
To Sensor
a. AC – Hot (L2), Neutral (L2), and Ground (G)
b. DC – Positive (L1), Negative (G)
a. HLFS – top (2) pins
b. LLFS – bottom (2) pins
{
Level
Setpoint
Setpoint
+ GL2L1NCCNONCCNO-
Fail Safe
Setting
HLFS De-Energized Closed Open Above
LLFS Energized Open Closed
HLFS Energized Open Closed Below
LLFS De-Energized Closed Open
Condition
Relay
+
12 or 24Vdc
}
-
115Vac or 230Vac
}
Relay Terminals Media
NC to C NO to C
50/60 Hz
Specifications
Description Specification
Input Power
Output 10A DPDT
Temperature Range
Pressure Range
Sensitivity (Signal-to-noise Ratio) 1000:1
Repeatability ±2mm
Response Time 0.5 sec. non-adjustable
TROUBLESHOOTING
Problem Solution
No output change with level change
The output is “chattering”
AC 115Vac or 230Vac; 50/60Hz
DC 12 or 24Vdc
Switch -20°F to 170°F
Sensor (Metal) -40°F to 300°F
Metal Sensors Vacuum to 1000psig
Non-metal Sensors Vacuum to 100psig
Check wiring; verify that the correct input
voltage is applied
Verify that liquid is filling the sensor gap
Check for dense foam or dried product in
the gap. Switch may not function properly
if either condition exists.
Check sensor phono plugs for a good
connection. Unplug and Re-plug each
connection.
Check for excessive aeration in process
fluid. This is particularly important in
viscous fluids.
Check wiring; verify that the correct input
voltage is applied
Check for turbulence. Relocate switch or
isolate from turbulence
Check for excessive aeration in process
fluid. This is particularly important in
viscous fluids.
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