Alex Electronics Co.

UTS80

UTS80 Series Ultrasonic Transmitters

 Alex Electronics Co.

2 UTS80 Series Ultrasonic Transmitters

Alex Electronics Co.

Contents
1 About this document...............................................................................................................................2
1.1 Function............................................................................................................................................................................2
1.2 Target group.........................................................................................................................................................................2
1.3 Symbols used........................................................................................................................................................................2

2 For your safety.........................................................................................................................................3

2.1 Authorized personnel...........................................................................................................................................................3
2.2 Appropriate use....................................................................................................................................................................3
2.3 Warning about incorrect use................................................................................................................................................3
2.4 General safety instructions..................................................................................................................................................3
2.5 Safety label on the instrument..............................................................................................................................................4
2.6 Environmental instructions..................................................................................................................................................4
2.7 Packaging, transport and storage........................................................................................................................................4
2.8 Accessories and replacement parts......................................................................................................................................4

3 Product description.................................................................................................................................5
3.1 Configuration.......................................................................................................................................................................5
3.2 Principle of operation..........................................................................................................................................................6

4 Mounting. ...............................................................................................................................................8
4.1 General Instructions............................................................................................................................................................8
4.2 Mounting instructions .......................................................................................................................................................10

5 Connecting to power supply.................................................................................................................15

5.1 Preparing the connection...................................................................................................................................................15
5.2 Connection Procedure........................................................................................................................................................18

6 Calibration.............................................................................................................................................19
6.1 Calibration procedures......................................................................................................................................................19

7 Temperature compensation (Optional)...............................................................................................21

7.1 The operation.....................................................................................................................................................................21

8 Maintenance and fault rectification.....................................................................................................22

8.1 Maintenance.......................................................................................................................................................................22
8.2 Rectify faults.......................................................................................................................................................................22
8.3 Exchanging the electronics module....................................................................................................................................23
8.4 Exchanging the transducer ...............................................................................................................................................24

9 Disposal. .............................................................................................................................................25
9.1 Dismounting steps..............................................................................................................................................................25
9.2 Disposal..........................................................................................................................................................................25

10 Supplement............................................................................................................................................26
10.1 Technical Data.................................................................................................................................................................26
10.2 Special data of the transducers........................................................................................................................................26
10.3 Dimensions.......................................................................................................................................................................27
10.4 Industrial property rights.................................................................................................................................................28
10.5 Trademark........................................................................................................................................................................28

UTS80 Series Ultrasonic Transmitters

 Alex Electronics Co.

Safety instructions for Ex areas

Take note of the Ex specific safety instructions for Ex

applications(Group 2). These instructions are attached as
documents to each instrument with Ex approval and are
part of the operating instructions manual.

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1 About this document

1.1 Function
This operating instructions manual provides all the information you
need for mounting, connection and setup, as well as important
instructions for maintenance and fault rectification. Please read
these information before putting the instrument into operation
and keep this manual accessible in the immediate vicinity of the
device.
1.2 Target group
This operating instructions manual is directed to trained specialist
personnel. The contents of this manual should be made available
to these personnel and put into practice by them.
1.3 Symbols used

i Information, tip, note:

This symbol indicates helpful additional information.
Caution:
If this warning is ignored, faults or malfunctions can result.
Warning:
If this warning is ignored, injury to persons and/or serious damage
to the instrument can result.
Danger:
If this warning is ignored, serious injury to persons and/or
destruction of the instrument can result.
Ex applications:
This symbol indicates special instructions for Ex applications.

SIL SIL applications:

This symbol indicates instructions for functional safety which must
be taken into account particularly for safety-relevant applications.

• List:
The dot set in front indicates a list with no implied sequence.
Action:
This arrow indicates a single action.

1 Sequence of actions:
Numbers set in front indicate successive steps in a procedure.

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2 For your safety

2.1 Authorized personnel
All operations described in this operating instructions manual must
be carried out only by trained specialist personnel authorized by
the plant operator.
During work on and with the device the required personal protective
equipment must always be worn.
2.2 Appropriate use
UTS80 is a sensor for continuous level measurement.
You can find detailed information about the area of application in
chapter “Product description”.
Operational reliability is ensured only if the instrument is properly
used according to the specifications in the operating instructions
manual as well as possible supplementary instructions.
For safety and warranty reasons, any invasive work on the device
beyond that described in the operating instructions manual may
be carried out only by personnel authorized by the manufacturer.
Arbitrary conversions or modifications are explicitly forbidden.
2.3 Warning about incorrect use
Inappropriate or incorrect use of the instrument can give rise to
application-specific hazards, e.g. vessel overfill or damage to
system components through incorrect mounting or adjustment.
2.4 General safety instructions
This is a state-of-the-art instrument complying with all prevailing
regulations and guidelines. The instrument must only be operated
in a technically flawless and reliable condition. The operator is
responsible for the trouble-free operation of the instrument.
During the entire duration of use, the user is obliged to determine
the compliance of the necessary occupational safety measures
with the current valid rules and regulations and also take note of
new regulations.
The safety instructions in this operating instructions manual,
the national installation standards as well as the valid safety
regulations and accident prevention rules must be observed by
the user.
For safety and warranty reasons, any invasive work on the device
beyond that described in the operating instructions manual may
be carried out only by personnel authorized by the manufacturer.
Arbitrary conversions or modifications are explicitly forbidden.
The safety approval markings and safety tips on the device must
also be observed.

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2.5 Safety label on the instrument

The safety approval markings and safety tips on the device must
be observed.

2.6 Environmental instructions

Protection of the environment is one of our most important duties.

One of our goals is continuously improving company environmental
protection.

Please help us fulfill this obligation by the environmental

instructions in this manual:

• Chapter “Packaging, transport and storage”

• Chapter “Disposal”

2.7 Packaging, transport and storage

Packaging Your instrument is protected by packaging during transport.
The packaging of standard instruments consists of environment-
friendly, recyclable cardboard. For special versions, PE foam or PE
foil is also used. Dispose of the packaging material via specialized
recycling companies.
Transport Transport must be carried out in due consideration of the notes on
the transport packaging. Nonobservance of these instructions can
cause damage to the device.
Transport inspection The delivery must be checked for completeness and possible
transit ceiled defects must be appropriately dealt with.
Storage Up to the time of installation, the packages must be left closed
and stored according to the orientation and storage markings on
the outside.
Unless otherwise indicated, the packages must be stored only
under the following conditions:
• Not in the open
• Dry and dust free
• Protected against solar radiation
• Avoiding mechanical shock and vibration

2.8 Accessories and replacement parts

Protective Caps The protective cover protects the sensor housing against soiling
and intense heat from solar radiation.
Electronics Module Electronics module “UTS80” is a replacement part for ultrasonic
sensors of UTS80. A different version is available for each model.

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3 Product description
3.1 Configuration
Scope of delivery The scope of delivery encompasses:
• Ultrasonic level sensor
• Documentation
- Quick setup guide for UTS80

- Instructions for optional instrument features

- Ex-specific “Safety instructions” (with Ex versions)

- if necessary, further certificates are included

• Special adjustment tools

- Small screwdriver
Magnetic pen

i Information:
In this operating instructions manual, the optional instrument
features are described. The respective scope of delivery results
from the order specification.
Constituent parts The UTS80 consists of the components:
• Transducer
• Housing with electronics
• Housing cover
The components are available in different versions.

4
2

Fig.1: UTS80 Constituent parts

1. Aluminum housing cover.
2. Aluminum housing with electronics.
3. Ultrasonic transducer.
4. Cable gland.
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Label Contents The Label contains the most important data for identification and
use of the instrument
• Instrument type.
• Serial number device.
• Technical data: For example probe length / measuring range,
signal output, power supply..

Application area UTS80 is an ultrasonic sensor for continuous level measurement

It is suitable for liquids and solids in virtually all industries,
particularly in the water and waste water industry.
3.2 Principle of operation

Functional principle The ultrasonic level metering technology is based on the principle
of measuring the time required for the ultrasound pulses to cover
the distance from the sensor to the level to be measured and
[Link] echoes, bounced back from the surface of the medium,
are measured when theyt reach the sensor surface, after the time
of flight of the ultrasonic impulse. The time of flight of the reflected
signal is measured and processed by the electronics module
giving reliable level monitoring.
The level can be converted to volume by simply entering the tank
dimensions.
Voltage supply The data for power supply are specified in chapter “Technical
data”.

Fig.2: Ultrasonic Concept

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Features • No contact with the product.

• Independent of product properties.

• Not affected by the product change.

• No calibration is needed.

• Accurate measuring system.

• Maintenance-free device.

• Capable of measuring solids and liquids.

• Suitable for open tanks.

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4 Mounting
4.1 General Instructions

Suitability for the process Make sure that all parts of the instrument coming in direct contact
conditions. with the process, especially the sensor element, process seal and
process fitting, are suitable for the existing process conditions,
such as process pressure, process temperature as well as the
chemical properties of the medium.

Installation Angle Sensor should be installed EXACTLY vertical 90 degree to achieve

maximum sensing distance, If the sensor is not installed 90 degree,
vertical sensing distance will decrease dramatically because with
the more traveling distance for the wave, the more deflection you
have in the signal, for example one degree away from vertical and
a traveling distance of 6 meters will reflect the signal 20 cm away
from the sensor, this will increase with more angles away from 90
degree, So keep in mind that with bad installation you decrease
the sensing distance of the sensor.

Review following figures for more illustration.

(a) (b)

Fig.3: Installation Angle

As shown in fig. 2 installation angle:

(a) The correct installation angle
(b) The wrong installation angle

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Reference plane for The reference plane for the measuring range is the lower edge of
measuring range the sensor.
Measuring range The sensor is calibrated to its maximum sensing distance for
liquids upon leaving the factory review the following figure for
illustration:

1 2

Fig.4: Measuring range

11. Empty ([Link] distance)
22. Full
33. Measuring range

Dead zone There is a minimum Distance that can be measured by the sensor,
which is called sensor dead zone.

The dead zone varies from sensor to another according to its

maximum measuring distance, Sensors with higher measuring
range have larger dead zone. (Find the dead zone value in the
Technical Data page)

i Information:

If the product surface reaches the sensor, build up may exist, and
this will cause false signals or sensor malfunction.

Presence of the product inside the dead zone area will result in
faulty readings, so adjust your system to work within given limits.

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Fig.5: Minimum distance to the max. Level

4.2 Mounting instructions

Screwing In Screw UTS80 into the mounting socket with an appropriate

spanner applied to the hexagon of the process fitting.

Warning:

• The housing must not be used to screw the instrument

• Applying tightening force can damage internal parts of the

housing.

• Please be careful of dropping the device on the ultrasonic

sensor part, Doing so will damage the sensor immediately.

• The silver part inside the sensor is its crystal, don’t try to touch
this part and avoid any chance of scratching this part to protect
your device.
Installing Positions When mounting the sensor, Keep a distance from the vessel
wall that is, minimum, 30 cm, the sensor may operate in a less
distance but you will be risking, in case of buildups on the vessel
wall, getting a false echo.

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Fig.6: Mounting on round vessel tops

11. Reference plane
22. Vessel wall.

If this distance cannot be maintained, a false signal storage should

be carried out during setup. This applies particularly if buildup
on the vessel wall is expected. In such cases, we recommend
repeating the false signal storage later, with existing buildup.

Conical base vessels and In case of conical base vessels and spherical vessels it’s
spherical vessels recommended to install the sensor in the center of the vessel to
get the maximum measurable distance.

(a) (b)
Fig.7: Vessel with conical bottom and spherical bottom
(a) Spherical base vessel
(b) Conical vessel

Vessel installations The ultrasonic sensor should be installed at a location where no

other installations cross the ultrasonic beam.

Vessel installations such as: ladders, limit switches, heating

spirals, struts etc. can cause false echoes that interfere with the
signal echo. Make sure when planning your measuring site that
the ultrasonic signals have a “clear view” to the measured product.

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Socket Socket pieces should be dimensioned so that the lower end of the
transducer protrudes at least 10 mm (0.394 in) out of the socket.

d = 10mm

Fig.8: Recommended socket mounting

If the reflective properties of the medium are good, you can

mount UTS80 on sockets which are higher than the length of the
transducer. You will find recommended values for socket heights
in the following illustration. The socket end should be smooth and
burrfree, if possible also rounded.

d
Fig.9: Deviating socket dimensions

d (mm) h (mm)
80 20
100 170
150 270

Inflowing Medium Keep the sensor away from the flow source to avoid getting false
echoes from the flow material instead of the product surface.

Make sure that you detect the product surface, not the inflowing
product. Through the action of filling, stirring and other processes
in the vessel.

Dense foams which considerably damp the emitted signals may

form on the product surface.

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(a) (b)
Fig.10: Inflowing liquid
(a) Good installation
(b) Bad installation

Foam If foams are causing measurement errors, the sensor should be

used in a standpipe.
Air turbulences If there are strong air currents in the vessel, e.g. due to strong
winds in outdoor installations or air turbulence, e.g. by cyclone
extraction, you should mount UTS80 in a standpipe.

Standpipe measurement By using a standpipe (surge or bypass tube), the influence of

vessel installations, foam generation and turbulence is excluded.

Standpipes must extend all the way down to the requested min.
level, as measurement, in this case, is only possible within the
tube.

4 inch

Fig.11: Standpipe in the tank

11. Vent hole: ø 10 … 5 mm (0.394 … 0.197 in)

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- UTS80 can be used with tube diameters of 4 inch.

- Avoid large gaps and thick welding joints when connecting the
tube

- Measurement in a standpipe is not recommended for extremely

adhesive products

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5 Connecting to power supply

5.1 Preparing the connection
Safety instructions Always keep in mind the following safety instructions:
• Please disconnect supply from power lines before beginning
the connection steps for your safety and the safety of the
equipment.
• The electrical connection must only be carried out by trained
personnel authorized by the plant operator.
• If over-voltage surges are expected, over-voltage arresters
should be installed.

11
Prog
2
2
AEC
Alex Electronics Co. 33
UTS80-X
Span
44
Zero

- +

88 77 66 55
Fig.12: Connection card

1. Out of range led

2. Programming switch
3. 20 ma adjustment POT
4. 4 ma adjustment POT
5. Supply +ve terminal
6. Supply –ve terminal
7. Earth terminal
8. Magnetic pen

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Connecting to power supply In case of the two wires system connect the two power lines to the
card as shown in figure taking into consideration the line polarity.

Prog

AEC
Alex Electronics Co.
UTS80-X
Span

Zero

- +

- GND +

0000
Fig.13: Connecting to power supply

The output signal can be read by putting as many reading devices

as needed and take the signal for long distance without problems.

Fig.14: Connecting to PLC

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Prog

AEC
Alex Electronics Co.
UTS80-X
Span

Zero

- +

R1

R2

220 V ac R3

Fig.15: Connecting to the Process indicator with internal power supply

i Note:

- Choose the suitable cable diameter for the cable gland on your
equipment and tighten it around the cable to protect the sensor
from water and humidity.

- In case if high electromagnetic noise is expected at the field

of operation it is recommended to use a shielded cable and
connect the shield to earth terminal

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5.2 Connection Procedure

Proceed as follows:

1. Unscrew the housing cover

2. Loosen the compression nut of the cable entry gland
3. Remove approx. 10 cm (4 in) of the cable mantle (current
output), strip approx. 1 cm (0.4 in) insulation from the ends of
the individual wires
4. Insert the cable into the sensor through the cable entry
5. Lift the opening levers of the terminals with a screwdriver
6. Insert the wire ends into the open terminals
7. Press down the opening levers of the terminals, you will hear
the terminal spring closing
8. Check the hold of the wires in the terminals by gently pulling
them
9. Tighten the compression nut of the cable entry gland. The seal
ring must completely encircle the cable
10. Connect the lead cable for power supply in the same way
according to the wiring plan, in addition connect the ground
conductor to the inner ground terminal.
11. Screw the housing cover back when the electrical connection
is finished
C
AE

Prog

AEC
Alex Electronics Co.
UTS80-X
Span

Zero

- +

Fig.16: Connection steps 5 and 6w

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6 Calibration
6.1 Calibration procedures

Factory Calibration The sensor is calibrated to its maximum sensing distance for
liquids upon leaving the factory

The sensor can be calibrated at any flat object, this makes the
calibration process easier by calibrating the sensor to a wall
instead of installing it in the tank
Calibration Steps If the factory calibration is suitable for you don’t change it. If you
need different calibration setting please follow this steps:
1. Install the sensor probably following the installation Instructions
2. Fill the vessel to the zero level needed
3. Make sure the out of range indicator is off
4. If the out of range indicator is on check the trouble shooting
section
5. Press zero and hold for two seconds by touching the zero
circle with the magnetic pen until the led indicator starts to
flash then release immediately.
6. Span distance will be defined automatically according to the
measuring distance.

i Note:

The zero distance must not exceed the maximum sensing distance
of the sensor

Prog

AEC
Alex Electronics Co.
UTS80-X
Span

Zero

- +

Fig.17: Calibration step 5

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Out of range indicator This led indicates that there is no measured object in the range of
the sensor If it’s dimmed then there is an object inside the range,
if it lights then there is no object inside the range, use the led to
avoid false calibration settings and getting out of the sensor range

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7 Temperature compensation (Optional)

7.1 The operation

The Operation UTS80 has a temperature sensor equipped with the ultrasonic
sensor. The sensor function is to measure the surrounding
temperature and provide this reading to the control card, then
adjust the speed of sound according to the temperature reading.

The speed of sound varies according to temperature, and in case

of no temperature compensation there will be a drift in reading
from day to night.

The base idea of the level sensor depends on a calculated speed

of sound, the level is equal to:

L = T/2 * S

Where S is the sound speed

L is the measured level

T is the traveling time

The variation of the sound speed is according to this formula

Speed = 331 + (0.6 * Temperature)

Warning:

Don’t install the sensor in direct sun light, especially in open tanks
or open channel, because direct sunlight on the sensor will raise
the surrounding temperature higher than ambient temperature
and will give a deviation in temperature readings and accordingly
a deviation in level reading.

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8 Maintenance and fault rectification

8.1 Maintenance

If the instrument is used properly, no special maintenance is

required in normal operation.

8.2 Rectify faults

Reaction when malfunction The operator of the system is responsible for taking suitable
occurs measures to rectify faults.

Causes of Malfunction UTS80 offers maximum reliability. Nevertheless, faults can occur
during operation. These may be caused by one of the following:

• Sensor
• Process
• Voltage supply
• Signal processing
Fault Rectification The first measures to be taken are to check the output signals.
The procedure is described below, the causes can be determined
and the faults rectified this way.

Check the 4 ... 20 mA Signal Connect a multimeter in the suitable measuring range according
to the wiring plan.

The following table describes possible errors in the current signal

and helps to eliminate them:

Error Cause Rectification

Use a shielded
High
4 … 20 mA signal cable and connect
electromagnetic
not stable the shield to earth
noise expected
terminal
Check connection
Electrical according
connection faulty to chapter
“Connection steps”
Check cables for
4 … 20 mA signal Voltage supply missing breaks; repair if
missing necessary
Check, adapt
Operating voltage if necessary
too low or load Exchange the
resistance too high instrument or send
it in
Current Signal is Exchange the
Electronics module
greater than 22 mA instrument or send
in sensor defective
or less than 3.6 mA it in for repair

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In Ex applications (Group2), the regulations for the wiring of

intrinsically safe circuits must be observed.

Error Cause Rectification

There is no object
inside the sensor Install the sensor
range Work in probably
sensor limits
Out of range led is There is no sensor Check sensor
on attached to the card connection
Wrong angle Install the sensor
installation probably
Replace sensor or
Damaged sensor
send for repair

8.3 Exchanging the electronics module

If the electronics module is defective, it can be replaced by the

user.

In Ex applications(Group 2), only instruments and electronics

modules with appropriate Ex approval may be used.

The new electronics module must be loaded with the settings of

the sensor. These are the options:

• At the factory by AEC

• Or on site by the user

In both cases, the sensor serial number is necessary. The serial

numbers are stated on the type label of the instrument, inside the
housing or on the delivery note.

The electronics modules are adapted to the respective sensor

and distinguish also in the signal output or power supply.

To change the electronics modules do the following:

1. Remove the head cover.

2. Disconnect power supply.

3. Disconnect wires connected to the card

4. Slightly move the card up vertically from its place don’t try to
screw

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(a) (b)
Fig.18: Changing the electronic module

8.4 Exchanging the transducer

To change the electronics modules do the following:

1. Remove the card as previous steps.

2. Unscrew the sensor from vessel using hexagonal key.

3. Remove the 6mm Allen key screw in the side of the head.

4. Unscrew the sensor from the head.

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9 Disposal
9.1 Dismounting steps

Warning:

Before dismounting, be aware of dangerous process conditions

such as e.g. pressure in the vessel or pipeline, high temperatures,
corrosive or toxic products etc.

Take note of chapters “Mounting” and “Connecting to power

supply” and carry out the listed steps in reverse order.

9.2 Disposal

The instrument consists of materials which can be recycled by

specialized recycling companies. We use recyclable materials
and have designed the parts to be easily separable.

Pass the instrument directly on to a specialized recycling company

and do not use the municipal collecting points.

Correct disposal avoids negative effects on humans and the

environment and ensures recycling of useful raw materials.

Materials: see chapter “Technical data”

If you have no way to dispose of the old instrument properly,

please contact us concerning return and disposal.

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10 Supplement
10.1 Technical Data

Version UTS80-3 UTS80-6 UTS80-10 UTS80-18 UTS80-22

System 2-Wire 3-Wire

Process Pressure: up to 1BAR
Condition Temperature: Up to 70oC
Housing Material Aluminum

Probe Material PVC

Installation 2” G Thread
Intrinsic safety
Protection Ex ib IIB T6
IP67
Mass 1288gm

Accuracy ± (0.2 % of measured distance +0.05 % of range)

Resolution 1mm 3mm 6mm 8mm 1cm

Beam angle 3° 6°
Max. measuring
3m 6m 10m 18m 22m
range
Min. measuring
0.25m 0.30m 0.40m 0.45 0.5
range

10.2 Special data of the transducers

Version UTS80-3 UTS80-6 UTS80-10 UTS80-18 UTS80-22

Supply 24Vdc

Output Data 4-20 mA

Power
Less than 0.6W
consumption
Protection
Reverse polarity protection
applied

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10.3 Dimensions

UTS80-3 UTS80-6

104mm 104mm

27mm 27mm
3mm 3mm
27mm 27mm
9mm 9mm
22mm 22mm
13mm 13mm
14mm 14mm
31mm 31mm

80mm 80mm

UTS80-10 UTS80-18

104mm 104mm

27mm 27mm
3mm 3mm

27mm 27mm
9mm
9mm
22mm
22mm
13mm
13mm
14mm

31mm 80mm

10mm
80mm 25mm

25mm

UTS80-22

104mm

27mm
3mm

27mm
9mm

22mm
13mm

80mm

10mm

25mm

25mm

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10.4 Industrial property rights

AEC product lines are global protected by industrial property rights. Further information see http://
[Link]

10.5 Trademark

All the brands as well as trade and company names used are property of their lawful proprietor /
originator.

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