Omega Products LVU-1000 Installation Manual

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Page 1

LVU-

1000

Ultrasonic Level Measurement

System

Operator’s Manual

Page 2

Unpacking instructions

Trr...l.#h OMIYEA

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Page 3

LVU-

1000

Series

System Description

Chapter 1 Chapter 2 Chapter 3

Chapter 4

Chapter 5

Chapter 6 Chapter 7

System Description Principles of Operation Installation

Control Unit Installation Sensor Installation Wiring Diagram Sensor Diagram

System Features and Operating Modes

General Standard Features Optional Features

System Calibration

General ........................................ .

Calibration Procedure Calibration Diagram Specifications Linear Characterization Rrief Description Analog Output Calibration VERIFICATION Procedure

Programming Prompt list System Configuration Document

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Figure 2

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Figure 1

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Figure 3

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Page

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5-4

5-5 5-6

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.7- 1

System Description

The OMEGA Model LVU-1000 series liquid level system is a of-the-art level measurement instrument. Based on the latest ultrasonic technologies, the LVU-1000 series provides an efficient, reliable and cost effective means of level control.

The LVU-1000 series consists of 2 major components: a contacting ultrasonic sensor and a compact, remote electronic control.

The LVU-1000 series is available in a variety of sizes and materials to suit virtually any application. Standard mounting configurations

%”

include a to meet user specifications. Sensor materials of construction include CPVC, 316 SS, Kynar or Teflon.

and 2 ” NPT fittings. Flange mounting is also available

Chapter 8

Dimensional Drawings

Figure 4

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.8- 1

.8-l

Page 4

.::::

System Description

Principles of Operation

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Principles of Operation

operation, the electronics generates an electronic signal which is converted by the sensor (mounted on ultrasonic pulses. These pulses are transmitted through the air towards the liquid surface. As the pulses reach the liquid surface, they are reflected back to the sensor. These received echoes are converted back to an electronic signal, which is then sent to the microprocessor. The microprocessor uses the return signals to calculate the time it takes for the pulses to travel to the liquid surface and back. This “Time of Flight ” is directly proportional to the distance of the liquid surface from the sensor. The microprocessor then compares these calculated values with user programmed system parameters to provide the required control outputs.

1-2

Page 5

P ri nc ip les of Operation

..&

,:p

,:.>

Con tr o l

Senso r

Un it I ns ta ll a ti on

Ins ta ll a ti on

The sensor is mounted on the top of the vessel with the sensor facing downward. A clear path, free of any obstructions, must be provided between the sensor and the liquid surface. Due to the narrow sensor beam pattern, vertical-axis positioning of the sensor is important. The sensor must be installed so as to maintain perpendicularity to the liquid surface.

Open control unit enclosure and remove the printed circuit board.

Replace printed circuit board, and route power and control wiring to the enclosure. Observe all applicable local electrical codes and

wiring procedures. Connect power and control wiring to the control unit as shown in

the wiring diagram (see figure 1).

Be sure that all wiring is carefully dressed to prevent pinching between the housing and the cover.

For sensors provided with an NPT threaded fitting, drill a suitable

hole in the vessel top and tap for the correct NPT thread. In thin walled vessels, or vessels constructed of material not suitable for tapping, weld or braze a bushing to accept the

Screw the sensor into the threaded fitting, being careful not to cross thread the sensor. When possible, the use of a pipe compound or sealing tape is recommended.

tightening!

2-2

For flange mounted sensors, simply bolt the sensor/flange

3 .

assembly to the proper mating flange connection. Route the sensor cable to the electronic control unit and connect

4. per the Wiring diagram (see figure 1).

IF ROUTING THE SENSOR CABLE THROUGH CONDUIT, A DEDICATED CONDUIT SHOULD BE UTILIZED. AVOID ROUTING THE SENSOR CABLE IN CLOSE PROXIMITY TO ANY SOURCE OF ALTERNATING CURRENT OR RFI.

Page 6

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Installation

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Vogramming

Switches

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Enter

Temperature

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Temp.

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Do not attempt to remove a threaded sensor from the vessel with the cable attached to the control unit, otherwise cable may be damaged.

W-0)

3-2

Figure

1 Wiring Diagram

Figure 2 Sensor Diagram

Page 7

System Features and

General

The LVU-1000 series is an extremely versatile instrument. It ’s many standard programmable features and available options can be utilized to perform a wide variety of control functions. In many cases, a single LVU-1000 can accomplish control functions which would otherwise only be possible through the use of multiple instruments or expensive computer based systems.

Standard

Operating

Modes

Features

Automatic temperature compensation compensates for sound velocity errors (due to temperature variations) over the entire

sensor temperature range. Simple 2 button programming. Four programmable Alarm point relays. User selectable Height or Distance operating mode. fully

isolated analog output with programmable output offset.

Three “Lost Echo” condition modes (user selectable).

Internal 4-digit display provides programming prompts, system

heartbeat, and “Lost Echo” feedback. Enhanced noise rejection algorithm ignores spurious signals and

other noise sources such as 60 cycle and RFI.

Optional Features

External (front covered mounted) 4 digit display for local indication.

2.3.Optional “Lost Echo” alarm relay, in place of alarm Customized response times and output damping to meet special

application requirements. Call factory for application assistance.

Page 8

System Features and Operating Modes

General

System Calibration

The LVU-1000 series is calibrated via push-button entry switches

(Enter and Increment) and an provides the necessary programming prompts. All data entered during the calibration procedure is stored in a nonvolatile memory to prevent loss of data in the event of a power failure.

During the calibration procedure, you may wish to refer to the Programming Prompt List and the Calibration Diagram found elsewhere within this manual.

During the Calibration procedure, if no button is pressed for more than 60 seconds, the system will automatically return to the Operating Mode, saving only those parameter

values already entered.

onboard

4-2

Upon completion of the Calibration procedure, the Analog Output may be verified by following the Calibration Verification Procedure (see step 11).

Calibration Procedure

Open control unit enclosures and simultaneously depress and

hold the Enter and Increment buttons. After approximately 3

seconds, the

“COdE”. Enter button once to bypass this prompt (this prompt is for factory use only, and is not user accessible).

onboard

The

2. once and the operotion, or “d” for Distance Mode of operation, depending on the previously programmed mode. Pressing the Increment button now will toggle the display between “H” and “d”. The Height Mode of operation will provide an analog output proportional to the liquid level, while the Distance Mode will provide an inverse

onboard

Release both Enter and Increment and then press the

display will issue the prompt

display will read either “H” for Height Mode of

programming display will issue the prompt

Page 9

/’

System Calibration

output (refer to the Calibration Diagram). With the desired operating mode displayed, press Enter to select that mode.

3. The next prompt to be displayed will be “SLOS” for “select analog offset”. The Analog offset determines if the analog output signal is referenced to zero or some offset a current output, or O-l 0 V dc vs. 2-l 0 V dc for voltage output). Press Enter to display the previously entered selection (either 0 or

1). Pressing Increment now will toggle the display between 0 and II

Entering “1 “0” disables the displayed, press the Enter button to store the selection.

4. The display

At this time the analog output is driven to its proper state and may be verified, see step 11.

The Zero Point is the point at which the level will be closest to the sensor (refer to the Calibration Diagram). The minimum Zero Point is normally 12 ” from the sensor face.

In certain applications, the LVU- provide a closer Zero Point. Consult factory.

Press Enter now, and the display will indicate the previously programmed Zero value, with the “hundreds” digit flashing. Press Increment to increment the flashing digit to its desired value. With the desired value displayed for the “hundreds” place digit, press Enter to store the value. The next digit be flashing. Repeat the above steps for the “Tens”, “Inches” and

will invoke the

Analog Offset. With the desired selection

will

now issue the

value

(O-20 ma vs. 4-20 ma for

Analog Offset, while entering a

“SL-0”

prompt, for “select zero”.

1000

may be configured to

(

the ‘Tens” place) will now

“Tenths of inches” places to obtain the desired Zero point as measured in inches from the sensor face.

Upon entry of the Zero Point, the display will issue the prompt

“SL_?

for “select Span”.

At this time the analog output may be verified, see step 1 1.

The Span is the measurement range in inches as measured from the Zero Point. Press Enter now and the display will indicate the current Span value, with the hundreds place digit flashing. Proceed as in step 4 to enter the desired Span in inches from the Zero Point.

6. After entering the desired Span, the system will issue the prompt “SLdF”

for “select display function”. This parameter will define the

operation of the operational

provided). Press Enter now, and the on board programming

display will indicate a digit of 0 or 1, depending on the previously entered selection. The Display Function Modes are as follows:

digit panel-mounted display (if

Mode 0: Display reads distance of target from sensor

in inches.

Mode 1: Display indicates value of linear range programmable by the user. See the calibration Linear Characterization Display Scaling for details on programming this mode.

Pressing Increment will toggle the programming display through the above Display Function Modes. Press Enter to store the desired Mode.

If you have selected display mode 1 at the “SLdF” prompt, then you have chosen Custom Display Scaling and the unit proceeds to step 6a in the following manner, otherwise the unit proceeds to step 7.

5-2

Page 10

System Calibration

Specifications

Range:

Repeatability: Accuracy: Temperature

Compensation:

Input Power:

Output Signal:

Controls:

Display:

Alarm

Setpoink:

Temperahrre Range:

Sensor Pressure

Rating:

Construction: Cable: E&onics

Enclosures:

Mountings:

1-12 feet

1 to 30 feet

Analog output-x% of

&VU-1000)

&VU-1010)

typical

Automatic over

temperature

115 V oc,

4-20

Programmable zero and span, height and

50/60

ma dc (isolated)

mode Four digit (optional) Four 1 OA SPDT relays. Programmable

increments of (optional)

Sensor -22°F to Electronics -10°F

250 psig psig) 316 S.S.

20”

NEMA-4X (standard) %“:

2”: (Range up

316 SS (Plastic models limited to 150

St&&x

(Range up to 12

Figure 3 Calibration Diagram

Page 11

System Calibration

linear Characterization Brief Description:

The LVU-1000 series allows the user to enter a four digit minimum arbitrary value, a four digit maximum arbitrary value, and a decimal position. The display output is

two

values across the previously programmed Span (Calibration

Procedure

step 5). The display always increases or decreases in a manner that is directly proportional to the analog output, which is based on the selection of Height or Distance mode.

6a.

The unit issues the “SLLO” prompt for “select display value. Pressing Enter causes the display to advance and show the previously programmed Low value.

then linearly scaled between these

LOw”

minimum

The unit checks that the Hlgh value. If this error is detected the unit returns to step 6a

and the user must re-enter valid

6c.

The unit issues the Pressing Enter causes the display to advance and show the previously programmed Decimal Place. The display digit from 0 to 3 indicating the desired precision or the number of decimal digits to be displayed. Pressing Increment will step the display through the above decimal place values. Once the desired decimal place is displayed, press Enter to select that value.

LOw value is not greater than the

“SLdP”

prompt for “Select Decimal Place”.

Ignore the decimal point on the

and it has no meaning in this mode. Proceed as in the Calibration Procedurestep 4 to enter the desired arbitrary low point.

6b.

The unit next issues the “SLHI” prompt for “Select High, maximum display value”. Pressing Enter causes the display to advance and show the previously programmed Hlgh value.

Again, ignore the decimal point on the Proceed as the Calibration Procedure-step 4 to enter the desired arbitrary Hlgh point.

onboard

display-it is fixed

disploy.

Now the unit proceeds with step 7 of this Calibration Procedure.

will

The next prompt issue

7. Press Enter to enable the flashing digits as in step 4 and enter the desired Alarm Point

The

the sensor face, regardless of Operating Mode.

Repeat step 7 for Alarm Points 2, 3, and 4 (prompts

8. and

After

prompt “SLLE” for “Select Lost Echo Mode”. The last Echo mode selection determines the stotus of the analog output should a loss of valid return echo occur. Press the Enter button now and the display will Pressing Increment will toggle the programming display through the Lost Echo Modes listed below. Press Enter to select the desired Lost Echo Mode: The Lost Echo Modes are as follows:

Points are always programmed in inches from

Alarm

SLA4).

Alarm Point 4 is entered, the display will then issue the

indicate

in inches from the sensor face.

the current Lost Echo Mode (either 0,

5-6

Page 12

Programming Prompt list

.::::

..:..

. .. .

.::::

.:::.

.:::

Mode 0: Analog output goes to minimum output. Mode 1: Analog output holds last valid reading.

Mode 2: Analog output goes to maximum output.

10. Upon entry of the desired Lost Echo Mode, the system will return to the operating mode. The programming displays will display the system “heartbeat”, a pulsing

complete.

“0”

character. Calibration is

Analog output calibration verification procedure

11. To verify the digital current meter or voltmeter to the (refer to Wiring Diagram, page 3-3). Access the Calibration

Mode by simultaneously pressing ond holding the Enter and

Increment buttons, until the

two buttons, then repeatedly press and release the Enter button until the Analog output is correct per the selected Operating Mode (Distance or Height Mode, with or without Analog Offset. Also refer to the Calibration Diagram). Continue to repeatedly press

and release Enter,

Verify that the Analog output is correct per the selected Operating Mode. The system will automatically return to the normal operating mode after 60 seconds, displaying heartbeat.

The analog output level can be adjusted through the analog adjust multi-turn potentiometer shown in figure 1. With the analog adjust this potentiometer until your digital multimeter is precisely at 20 requires no

“SL-0”

output at its maximum

adiustment.

output of the LVU- 1000 series, connect a

analog

Analog

Output terminals

“COdE” prompt appears. Release the

(Select Zero) prompt is issued. Verify that the

until

the

“SL_S” (Select Span) prompt appears.

(20

or 10 V dc),

mA or

IeveI

V dc. The analog minimum value

Prompt

SLdH

SLOS

SL_O

SL_S

SLdF

SLLO

SLHI

SLdP

SLAl

SLA2

SLA3

SLA4

Definition

Select Distance or Height

Mode

Select Analog Offset

Select Zero

Select Span

Select Display Function

Select Low or Minimum Value

Select High or Maximum Value

Select Decimal Points

Select Alarm

Select Alarm 2

Select Alarm 3

Select Alarm 4

Description

The Height mode provides an analog output proportional to the liquid level (4-20 ma or dc), and the Distance mode provides an inverse

(20-4 ma or

output Height Mode or “d” for Distance Mode.

Allows for an analog output referenced to Zero or some Offset reference (4-20 ma vs O-20 ma for a current output, or a 2-10 V dc vs O-10 V dc for a voltage output). Select 0 to disable the Offset; select 1 to invoke the Offset.

Programs the system Zero point as measured from the sensor face in inches. The system Zero is the point at which the level is closest to the sensor face.

Programs the system Span as measured in inches from the system Zero point.

Defines the operational mode of the optional 4 digit display. Mode “0” displays target distance from sensor in inches. Mode “1” displays user defined Linear scaled output.

Linear Characterization sub-mode that defines the minimum value that the display should indicate.

Linear Characterization sub-mode that defines the maximum value that the display should indicate.

Linear Characterization sub-mode that defines the decimal digits to be displayed.

Programs Alarm Point 1 as measured in inches from the sensor face.

Programs Alarm Point 2 as measured in inches from the sensor face.

Programs Alarm Point 3 as measured in inches from the sensor face.

Programs Alarm Point 4 as measured in inches from the sensor face.

5-8

Page 13

Programming Prompt List

.:v

System Configuration Document

SLLE

Select Lost Echo Mode

Programs the analog output condition in the event of a loss of a valid return echo for more than 8 seconds. Mode 0 Output goes to minimum. Mode 1 Output holds last reading. Mode 2 Output goes to maximum. In a lost echo condition, the 4 digit display and the

onboard

display will display

“-LE-“.

SITE/LOCATION ID:

JOB:

UNIT SERIAL NUMBER:

PROGRAMMABLE PARAMETERS,

O N

HEIGHT MODE:

DISTANCE MODE:

ANALOGOFFSET:

DISPLAY MODE:

LOST ECHO MODE:

ZERO :

SPAN

ALARM1

ALARM 2

: :

PROGRAMMED BY:

4-20

(

O-20mA

(

inches from sensor face

inches from zero

inches from sensor face

inches

6-2

ALARM3

ALARM4 :

LINEAR CHARACTERIZATION -DISPLAY

VALUE:

HI VALUE:

DECIMAL

PLACE:

inches from sensor face

Page 14

8-l

Dimensional Drawings

FIBERUlllf ENCLOSURE

NW-IX

WARRANTY

OMEGA warrants this unit to be free of defects in materials and workmanship and to satisfactory adds an additional one (1) month grace period to the normal one (1) year product

warranty

receive maximum coverage on each product. If the unit should malfunction, it must be returned to the factory for evaluation. OMEGA’s Customer Service Department will issue an Authorized Return (AR) number immediately upon phone or written request. Upon examination by OMEGA, if the unit is found to be defective it will be repaired or replaced at no charge. However, this WARRANTY is VOID if the unit shows evidence of having been tampered with or shows evidence of being damaged as a result of excessive corrosion; or current, heat, moisture or vibration; improper specification; misapplication; misuse or other operating conditions outside of OMEGA’s control. Components which wear or which are damaged by misuse are not warranted. These include contact points, fuses, and

OMEGA is glad to theless, OMEGA only

service for a period of 13 months from date of purchase. OMEGA Warrantv

to cover

handling and shipping time. This ensures that OMEGA’s customers

offer suggestions on the use of its various products. Never-

warrants that

the

parts manufactured by it will be as

specified and free of defects.

OMEGA MAKES NO OTHER WARRANTIES OR REPRESENTATIONS OF ANY KIND WHATSOEVER, EXPRESSED OR IMPLIED, EXCEPT THAT OF TITLE AND IMPLIED WARRANTIES INCLUDING ANY WARRANTY AND FITNESS FOR A PARTICULAR PURPOSE ARE HEREBY DISCLAIMED.

LIMITATION OF LIABILITY: The remedies of purchaser set forth herein are exclusive and the total liability of OMEGA with respect to this order, whether based on contract, warranty, negligence, indemnification, strict liability or otherwise, shall not exceed the purchase price of the component upon which liability is based. In no event shall OMEGA be liable for consequential, incidental or special damages.

Every precaution for accuracy has been taken in the preparation of this manual; however, OMEGA ENGINEERING, INC. neither assumes responsibility for any omissions or errors that may appear nor assumes liability for any damages that result from the use of the products in accordance with the information contained in the manual.

SPECIAL CONDITION: Should this equipment be used in or with any nuclear installation or activity, purchaser will indemnify OMEGA and hold OMEGA harmless from any liability or damage whatsoever arising out of the use of the equipment in such a manner.

RETURN REQUESTS

Direct all warranty and repair requests/inquiries to the OMEGA ENGINEERING Customer Service Department. BEFORE RETURNING ANY PRODUCT(S) TO OMEGA, PURCHASER MUST OBTAIN AN AUTHORIZED RETURN (AR) NUMBER FROM OMEGA’S CUSTOMER SERVICE DEPARTMENT (IN ORDER TO AVOID PROCESSING DELAYS). The assigned AR number should then be marked on the outside of the return package and on any correspondence.

FOR

WARRANTY

FOR

the following information available

BEFORE contacting OMEGA:

1. P.O. number under which the product was PURCHASED,

2. Model and serial number of the product under warranty, and

3. Repair instructions and/or specific problems relative to the product.

OMEGA’s policy is to make running changes, not model changes, whenever an improvement is possible. This affords our customers the latest in technology and engineering. OMEGA 0 may not be medium or machine-readable form, in whole or in part, without prior written consent of OMEGA ENGINEERING, INC.

a registered trademark of OMEGA ENGINEERING. INC.

RETURNS, please have

copled. photocopied, reproduced, translated, or reduced to any electronic

NON-WARRANTY

CALIBRATION,

repair/calibration charges. Have the following information available BEFORE contacting OMEGA:

1. P.O. number to cover the COST of the repair/calibration,

2. Model and serial number of product, and

3. Repair instructions and/or specific

problems relative to the product.