LU27 LU 29 Instruction Manual

LU27 LU 29 Instruction Manual
EchoSonic II
Manual
09 JUL 08
Revision A
Flowline Inc.
10500 Humbolt Street
Los Alamitos, CA 90720
Tel: (562) 598-3015
Fax: (562) 431-8507
www.flowline.com
09 JUL 09
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Preface
This manual explains how to use the EchoSonic II, LU27 LU28 and LU29 series level
transmitter.
Warranty, Service & Repair
To register your product with the manufacturer, go to the Flowline website for on-line
registration. The website address is as follows:
www.flowline.com
On-line Warranty Registration can be found under Contact Us in the Navigation Bar along the
side of the home page.
If for some reason your product must be returned for factory service, go to the Flowline website
to receive a Material Return Authorization number (MRA), providing the following information:
1. Full Part Number, Full Serial Number
2. Name and telephone number of someone who can answer technical questions related
to the product and its application.
3. Return Shipping Address
4. Brief Description of the Symptom
5. Brief Description of the Application
On-line Material Return Authorization can be found under Contact Us in the Navigation Bar
along the side of the home page. Click on Return Authorization to begin the MRA request.
Once you have received a MRA number, ship the product prepaid in its original packing to:
Flowline Factory Service
MRA_____
10500 Humbolt Street
Los Alamitos, CA 90720
To avoid delays in processing your repair, write the MRA on the shipping label. Please include
the information about the malfunction with your product. This information enables our service
technicians to process your repair order as quickly as possible.
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Warranty
Flowline warrants to the original purchaser of its products that such products will be free from
defects in material and workmanship under normal use and service for a period which is equal to
the shorter of one year from the date of purchase of such products or two years from the date of
manufacture of such products.
This warranty covers only those components of the products which have non-moving and not
subject to normal wear. Moreover, products which are modified or altered, and electrical cables
which are cut to length during installation are not covered by this warranty.
Flowline’s obligation under this warranty is solely and exclusively limited to the repair or
replacement, at Flowline’s option, of the products (or components thereof) which Flowline’s
examination proves to its satisfaction to be defective. FLOWLINE SHALL HAVE NO
OBLIGATION FOR CONSEQUENTIAL DAMAGES TO PERSONAL OR REAL
PROPERTY, OR FOR INJURY TO ANY PERSON.
This warranty does not apply to products which have been subject to electrical or chemical
damage due to improper use, accident, negligence, abuse or misuse. Abuse shall be assumed
when indicated by electrical damage to relays, reed switches or other components. The warranty
does not apply to products which are damaged during shipment back to Flowline’s factory or
designated service center or are returned without the original casing on the products. Moreover,
this warranty becomes immediately null and void if anyone other than service personnel
authorized by Flowline attempts to repair the defective products.
Products which are thought to be defective must be shipped prepaid and insured to Flowline’s
factory or a designated service center (the identity and address of which will be provided upon
request) within 30 days of the discovery of the defect. Such defective products must be
accompanied by proof of the date of purchase.
Flowline further reserves the right to unilaterally waive this warranty and to dispose of any
product returned to Flowline where:
a.
There is evidence of a potentially hazardous material present with product.
b.
The product has remained unclaimed at Flowline for longer than 30 days after dutifully
requesting disposition of the product.
THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON
THE FACE OF THIS WARRANTY. This warranty and the obligations and liabilities of
Flowline under it are exclusive and instead of, and the original purchaser hereby waives, all other
remedies, warranties, guarantees or liabilities, express or implied. EXCLUDED FROM THIS
WARRANTY IS THE IMPLIED WARRANTY OF FITNESS OF THE PRODUCTS FOR A
PARTICULAR PURPOSE OR USE AND THE IMPLIED WARRANTY OF
MERCHANTABILITY OF THE PRODUCTS.
This warranty may not be extended, altered or varied except by a written instrument signed by a
duly-authorized officer of Flowline, Inc.
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Introduction:
The EchoSonic II is a general-purpose ultrasonic level transmitter that provides a loop powered
4-20 mA output. The 4-20 mA output can be used to provide the proportional level of liquid in
any tank or vessel. The signal can be connected to any device that accepts a loop powered 4-20
mA signal, such as a PLC, SCADA, DCS, display, controller, etc.
New Features
• Simple configuration with WebCal software, no more target calibration.
• Adjustable Loop Fail-Safe, Hold Last, Empty, Full, 21 mA, 22 mA
• Easy to reverse mA output, 4-20 mA to 20-4 mA
• Adjustable start-up condition, Empty, Mid (12 mA), Full, Over range (22 mA)
• Increased output filtering
Table of Contents
Introduction ............................................................................................................................5
New Features ............................................................................................................................5
About this manual ......................................................................................................................6
Specifications ............................................................................................................................8
Dimensions ............................................................................................................................8
Getting Started ...........................................................................................................................9
USB® Fob Interface ....................................................................................................10
WebCal ........................................................................................................................11
Step 1: Configuration .......................................................................................12
Step 2: Tank Levels .........................................................................................14
Step 3: Write to Unit ........................................................................................14
Wiring
..........................................................................................................................15
Wiring Diagram ...........................................................................................................15
Wiring EchoSonic II ....................................................................................................15
Installation
..........................................................................................................................17
Position and Mount ......................................................................................................17
Mounting Guide ...........................................................................................................18
Fitting Selection ...........................................................................................................18
Tank Adapter: ..................................................................................................18
Riser .................................................................................................................19
Flange...............................................................................................................19
Side Mount Fitting ...........................................................................................19
Stand Pipe ........................................................................................................20
Advanced Feature ....................................................................................................................21
Appendix
..........................................................................................................................23
Updating WebCal Software .........................................................................................23
Updating Transmitter Firmware ..................................................................................24
Factory Defaults ...........................................................................................................25
Troubleshooting ...........................................................................................................26
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About this Manual:
PLEASE READ THE ENTIRE QUICK START PRIOR TO INSTALLING OR USING THIS
PRODUCT. This manual includes information on the EchoSonic II series Ultrasonic Level
Switch from FLOWLINE. Please refer to the part number located on the switch label to verify
the exact model configuration, which you have purchased.
User’s Responsibility for Safety: FLOWLINE manufactures a broad range of level sensing
technologies. While each of these sensors is designed to operate in a wide variety of applications,
it is the user’s responsibility to select a sensor model that is appropriate for the application,
install it properly, perform tests of the installed system, and maintain all components. The failure
to do so could result in property damage or serious injury.
Proper Installation and Handling: Only properly trained staff should install and/or repair this
product. Install the transmitter with the included Viton gasket and never over tighten the
transmitter within the fitting. Always check for leaks prior to system start-up.
Wiring and Electrical: A supply voltage of 14 to 28 VDC is used to power the EchoSonic II.
Electrical wiring of the transmitter should be performed in accordance with all applicable
national, state, and local codes.
Material Compatibility: The enclosure is made of Polycarbonate (PC). The transducer is made
of Polyvinylidene Fluoride (PVDF). Make sure that the model, which you have selected, is
chemically compatible with the application media.
Enclosure: While the transmitter housing is liquid-resistant the EchoSonic II is not designed to
be operational when immersed. It should be mounted in such a way that the enclosure and
transducer do not come into contact with the application media under normal operational
conditions.
Safety
• Installation should be done by properly trained staff
• Supply voltage should never exceed a maximum of 28 VDC
• Make sure the sensor is chemically compatible with your application
• Design a fail-safe system that accommodates the possibility of sensor and/or power failure.
• This sensor should not be used in classified hazardous environments
Make a Fail-Safe System: Design a fail-safe system that accommodates the possibility of
transmitter and/or power failure. FLOWLINE recommends the use of redundant backup systems
and alarms in addition to the primary system.
Flammable, Explosive or Hazardous Applications: EchoSonic II should not be used within
classified hazardous environments.
Warning: Always use the Viton gasket when installing the EchoSonic II, and make sure that all
electrical wiring of the switch is in accordance with applicable codes.
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Components: EchoSonic II is offered in three different models. Depending on the model
purchased, you may or may not have been shipped all the components shown below. You do
however, need an EchoSonic II, USB® Fob and Viton® gasket to configure, install and operate
EchoSonic II.
•
•
•
•
EchoSonic II
o LU27-01
– 8.2’ (2.5 m) range,
Type 6P encl., 1” NPT
o LU27-11
– 8.2’ (2.5 m) range,
Type 6P encl., 1” G
o LU28-01
– 24.6’ (7.5 m) range, Type 6P encl., 2” NPT
o LU28-11
– 24.6’ (7.5 m) range, Type 6P encl., 2” G
o LU29-01
– 32.8’ (10 m) range, Type 6P encl., 2” NPT
o LU29-11
– 32.8’ (10 m) range, Type 6P encl., 2” G
Viton Gasket
o Part #200128 for LU27-01 or LU27-11
o Part #220129 for LU28-01, LU28-11, LU29-01 or LU29-11
USB® Fob
o Part #LI99-1001
Quick Start Guide
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Specifications:
Range:
LU27: 4" to 8.2'
(10 cm to 2.5m)
LU28: 8" to 24.6'
(20 cm to 7.5m)
LU29: 8" to 32.8'
(20 cm to 10m)
Accuracy:
± 0.2% @ Max. Range
Resolution:
LU27: 0.039” (1 mm)
LU28/29: 0.079” (2 mm)
Beam width:
LU27: 2” (5 cm) dia.
LU28/29: 3" (7.6 cm) dia.
Dead band:
LU27: 4” (10 cm)
LU28/29: 8” (20 cm)
Memory:
Non-volatile
Supply voltage: 24 VDC
Consumption:
0.5 W
Loop resistance: 500 Ohms @ 24 VDC
Signal output:
4-20 mA, two-wire
Signal invert:
4-20 mA or 20-4 mA
Configuration:
WebCal® PC Windows®
USB 2.0
Fail-safety:
4 mA, 20 mA, 21 mA,
22 mA or hold last
Process temp.:
F: -4° to 140°
C: -20° to 60°
Temp. comp.:
Automatic
Ambient temp.: F: -31° to 140°
C: -35° to 60°
Pressure:
MWP = 30 PSI
Enclosure type: Type 6P encapsulated,
corrosion resistance &
submersible
Encl. material:
Polycarbonate
Trans. material: PVDF
Cable jacket mat.: Polyurethane
Cable type:
4-cond., shielded
Cable length:
10’ (3 m)
Process mount: LU27: 1” NPT (1” G)
LU28/29: 2” NPT (2” G)
Mount. gasket: Viton®
Classification:
General purpose
Compliance:
RoHS
Approvals:
CE, cFMus
Dimensions:
Side View / LU27 Series
Side View / LU28 and LU29 Series
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Getting Started:
EchoSonic II is configured through WebCal, a PC software program. WebCal is a free
download from Flowline’s website. You must download and install WebCal prior to plugging
in the USB® Fob. Please go to http://www.flowline.com/webcal and select download.
WebCal System Requirements
Windows® XP or 2000
10 mB hard drive space
256 mB RAM
1 USB® 2.0 port
Internet connection
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USB® Fob Interface
EchoSonic communicates with WebCal through a USB® interface called a Fob. Before
plugging your Fob into your computer’s USB® port, be sure that you have installed WebCal on
your computer.
Connect the red, green, white and black wires from EchoSonic II into the correct terminals on the
Fob. Tighten the screws on the terminals and plug your Fob into the USB® port of your
computer.
*
Once EchoSonic is configured and prior to installation, isolate the white and green wires
from active power to prevent a short of the configuration circuit
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WebCal
With EchoSonic II connected to your computer, open the WebCal software by clicking on the
WebCal icon. Follow steps 1-3 to configure the transmitter. Click “Help” in the lower right
hand corner and open the help menu of WebCal for additional instructions on WebCal. If you
need additional assistance using WebCal, please contact a Flowline Applications engineer at
(562) 598-3015.
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WebCal Step 1: Configuration
This section of WebCal is where you select the application’s configuration settings. Start from
the top and work to the bottom, choosing the selections that are applicable to your configuration.
“Not Applicable” will automatically show when a selection doesn’t apply to your configuration
settings, and you may move on. All configuration settings must be selected or have “Not
Applicable” before you can continue to step 2.
Loop Fail-Safe
This feature allows you to select the fail-safe current output if the sensor
fails to detect a return signal. When the sensor regains signal, the output
current will revert back to the current level condition.
o Hold Last Value - The output will remain in the same state as
the last echo detected. Example: If the output was 6.7 mA just
prior to the lost signal, the device will continue to output 6.7
mA. When the sensor regains signal, the output will indicate the
level when the signal was regain.
o Empty - The output will revert to the current value for a Empty
condition. The empty state is dependent upon the Output at
Empty setting. When 4 mA at Bottom is selected, the sensor will
output 4 mA when a fail-safe condition occurs. If 20 mA at
Bottom is selected, the sensor will output 20 mA when a fail-safe
condition occurs
o Full - The output will revert to the current value for a Full
condition. The full state is dependent upon the Output at Empty
setting. When 4 mA at Bottom is selected, the sensor will output
20 mA when a fail-safe condition occurs. If 20 mA at Bottom is
selected, the sensor will output 4 mA when a fail-safe condition
occurs
o Overfill (21mA) - The output current will go to 21mA when the
return signal is lost.
o Overfill (22mA) - The output current will go to 22mA when the
return signal is lost.
Right click on any menu that you may have questions on to open the help menu.
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Output at Empty
This feature allows you to select the orientation of the 4 to 20mA
output (4 to 20 mA or 20 to 4 mA). Choose which output setting
best fits the application. Typical installations are set with 4 mA at
Bottom. This will not affect the performance of the sensor other
than the output of the EchoSonic II. WebCal’s factory default is
4mA at bottom and 20mA at top. When connecting your sensor to
a display, you must account for your output settings.
o 4mA at Bottom - The output current will be 4mA when
the sensor measures an empty tank and 20mA when the
sensor measures a full tank.
o 20mA at Bottom - The output current will be 20mA when
the sensor measures an empty tank and 4mA when the
sensor measures a full tank
Startup Condition
This feature allows the operator to select the output current on
initial startup prior to acquiring a true return signal (level
measurement). This only occurs during the initial powering of
EchoSonic II and the transmitter will revert to the correct level
reading when the level is acquired.
o Empty - Selects the start up current established in Output
at Empty. Example: Select 4 mA at Bottom, the output
will remain at 20 mA until the unit acquires a true return
echo. Select 20 mA at Bottom, the output will remain at
20 mA until the unit acquires a true return echo.
o Mid Tank - When selected, the startup current will read 12
mA until the unit acquires a true return echo.
o Full Tank - Uses the opposite current that was selected in
Output at Empty. Example: If you select 4 mA at Bottom
then the start up current would be 20 mA. If you select 20
mA at Bottom then the start up current would be 4 mA.
o Overfill (22mA) - The output at startup would be 22 mA.
This condition will remain until the unit acquires a true
return echo.
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WebCal Step 2: Tank Levels
This section of WebCal is where you enter application measurement values. All values must be
filled in before moving to step 3.
Sensor Height: Distance
from the bottom of the tank
to the bottom of the
transducer.
Fill Height: Distance from
the bottom of the tank to the
maximum liquid height.
WebCal Step 3: Write to Unit
After you have entered configurations and tank values, click “Write to Unit” and send the
configuration to your EchoSonic. Now use WebCal’s file management features to save your
configuration by clicking “Save Config File” and print your wiring diagram by clicking
“Wiring Diagram.”
Write to Unit
Wiring diagram
Save Config File
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Wiring Diagram
Wiring EchoSonic
After you have finished positioning and mounting EchoSonic II, follow WebCal’s wiring
diagram to wire EchoSonic II. Flowline recommends using a qualified licensed electrician to
wire EchoSonic II and your application’s components.
Note: Do not extend the White & Green wires beyond 15’.
Note: Once EchoSonic is configured, isolate the white and green wires from active power to
prevent a short of the configuration circuit.
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Installation
Install the appropriate installation fitting. Make sure that the fitting and transmitter threads are
not damaged or worn. Install the transmitter with the included Viton mounting gasket. Handtighten the transmitter within the fitting. Perform an installed leak test under normal process
conditions prior to system start up.
Warning - Flowline Ultrasonic transmitters have been optimized for use in non-metallic fittings.
For best performance, avoid the use of metallic fittings.
Position and Mount
Positioning and mounting EchoSonic II is critical to the sensor performing correctly. EchoSonic
II should always be mounted perpendicular to the liquid in the tank, clear of any obstructions in
the beam path. Not doing so will result in poor performance. Refer to Flowline’s mounting
guide for further instruction.
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Mounting Guide
1. Do not mount at an angle
2. Liquid should never enter the dead band
3. Mount at least 2” from the side wall
4. Do not mount where obstacles will intrude on 2” beam width
5. Do not mount in a vacuum
6. Never screw directly into tank, always use a non-metallic fitting
7. Always use a tank adapter with the minimal height possible
Do not install at
angle relative to the
liquid.
Do not install within
3” of tank sidewall.
Do not install with
objects in the beam.
Do not install in
applications with
vacuum.
Fitting Selection: Check the part number to determine the required fitting mount size and
thread type. EchoSonic II is commonly installed in tank adapters, flanges, brackets or
standpipes. Note: Always include the gasket when installing the EchoSonic II.
1. Tank Adapter: Select a tank adapter fitting with minimal height so as to ensure that the
installed transducer will not be substantially elevated into the fitting such as the Hayward
2” Tank Adapter (socket by thread). For the LU27 series, add a Reducer Bushing such as
the Spears 2” x 1”, thread x thread, Reducer Bushing (series 839-249, Flowline p/n
LM52-1001). Avoid tank adapter (thread x thread) styles and/or pipe stops forward of
the installed transducer.
2” Tank Adapter
Socket x Thread
Tank Adapter
w/ 2”x1” Reducer Bushing
Tank Adapter
Thread x Thread
Do not use thread x thread
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2. Riser: Installations with tall, narrow risers can impede the acoustic signal. Select a
fitting with the right riser height versus inner diameter geometry.
3. Flange: If installing on a flange, select a flange with a thread that is above the plane of
the flange, such as the Spears 2” One Piece Flange (series 852-020). Avoid the use of
blind flanges with tapped threads or flanges where the threads are even with the plane of
the flange, such as the Banjo 2" Poly ANSI Flange (series AF200).
2” Flange w/
thread out of plane
2” Flange w/
thread in plane
2” Flange w/
Reducer Bushing
Do not use thread in plane
If the installation requires the use of a blind flange, tap a thread 1” larger than the sensors
thread and add a Reducer Bushing such as a Spears thread x thread Reducer Bushing [Use
the 439-338 (3” x 2”) for LU28/LU29 series or 439-249 (2” x 1”) for LU27 series].
4. Side Mount Bracket: The LM50-1001 side mount bracket or equivalent can be used for
open tank top installations against the sidewall. For the LU27 series, order the LM501001-1, which includes a 2”x 1” Reducer Bushing.
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5. Stand Pipe: A standpipe maybe used to dampen turbulence. Flowline recommends
using a standpipe when foam is present in the application. Select a 2” pipe for the LU27
series and a 3” pipe for all other models. The pipe length should run the measurement
span. Cut a 45°notch at the bottom of the pipe and drill a 1/4”pressure equalization hole
high in the dead band.
6. Reducer Bushings: A reducer bushing can be used to decouple the EchoSonic II from
metallic fittings or flanges with threads in the plane or to connect the transmitter to a
larger stand pipe.
Flowline P/N
LM52-1400
Hayward P/N
439-249
LM52-1410
438-249
LM52-2400
439-338
LM52-2410
438-338
Thread x Thread
Reducer Bushing
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Description
2" Thread x 1" Thread,
PVC, Sch 40
2" Socket x 1" Thread,
PVC, Sch 40
3" Thread x 2" Thread,
PVC, Sch 40
3" Socket x 2" Thread,
PVC, Sch 40
Socket x Thread
Reducer Bushing
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Advanced Features
This tool is designed to help solve operational issues. Changing these setting will alter the
performance of your unit. Please read through this HELP file to assist you in making adjustments
or if still unclear about a specific issue, please contact FLOWLINE, Applications Engineering.
NOTE: When the Advanced Button is highlighted with a RED border, this indicates you have
selected an advanced feature…
•
Increase output filtering: Placing a check mark in the box will increase the filtering
(averaging) of the analog output. If you require the 4 to 20 mA output to be smooth for
the application such as Open Channel Flow measurement, you might check this box.
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Appendix
Updating WebCal Software
WebCal software can be updated directly from the software. Simply click on the Updates Tab at
the top of the window and press the WebCal button. Make sure that your computer has access to
the Internet. If not, an error window will appear.
When the WebCal button is pressed, the software will check the version of software you re using
with the most recent version at Flowline. If the versions are similar, a window indicating that the
most recent version is installed. If not, then a window will appears asking to download the latest
version. Follow the instructions for installing the latest version.
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Updating Transmitter Firmware
WebCal software can also be used to update the firmware inside the EchoSonic II transmitter.
This feature allows the transmitter to be updated when new features are added. First open
WebCal with an EchoSonic II transmitter connected and the latest version of WebCal
downloaded to your PC.
Click on the Updates Tab and then click on Browse to select the Firmware update.
Select the latest version of the firmware (*.fep) file and click on Open. To identify the latest
version, look in the part number and the version will be after the letters “ver”.
Confirm that the address is correct and then click on Update Sensor to begin the firmware
update. This step should take less than 1 minute. You can follow the progress with the status
bar to the right of the Update Sensor button. When completed, click on the Configuration tab to
configure the transmitter. Remember, when the Firmware has been updated, the unit will return
to its original factory settings.
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Factory Default
Pressing the Factory Config button in the Configuration menu will return the screen to the
following settings.
Part
Number
LU27-0
LU27-1
LU28-0
LU28-1
LU29-0
LU29-1
Units
Inches
Inches
Inches
Factory Defaults Table
Sensor
Fill
Loop
Height
Height
Fail-Safe
98.4
94.4
Overfill
(22 mA)
295.2
287.2
Overfill
(22 mA)
393.7
385.7
Overfill
(22 mA)
Output
at Empty
4 mA @
Bottom
4 mA @
Bottom
4 mA @
Bottom
Startup
Condition
Empty
Empty
Empty
Testing the Transmitter
1. Connect a multimeter in series with the black wire to read the current output.
2. Verify that the current increases (tank filling) and decreases (tank emptying)
appropriately in the calibrated span.
3. If not, carefully observe and attempt to correlate any installation, level or application
event for more specific troubleshooting direction.
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Troubleshooting
PROBLEM
Transmitter indicates a
current of 0 mA
Transmitter jumps to a
current reading between 19
and 20 mA
Transmitter indicates a
current over 23 mA
Transmitter always jumps
to LOST condition
Output of transmitter is
opposite of the level of
liquid
No Unit Detected in
WebCal
Internet error. The server
name or address could not
be resolved.
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SOLUTION
Check the wiring for an open circuit. An open circuit is
the most common issue with a 0 mA signal
Check the installation of the transmitter. Bad installation
fittings will cause false signals near the top of the tank,
which typically translates to a signal between 19 and 20
mA.
Also look for interference just below the
transmitter. If the transmitter is installed in a metal
fitting, switch to a plastic fitting.
Immediately check the wiring for a short circuit. The
EchoSonic II is current limited to 22 mA. Anything
above 23 mA indicates a short circuit.
Check the dimensional configuration (Height and Fill H)
of the EchoSonic II. Make sure that the Fill H setting
corresponds to the full level of liquid (from the bottom
up) and not the distance from the transmitter to the liquid
(top down).
Check the Output at Empty Setting. Make sure the
setting is correct (4mA at bottom or 20 mA at bottom).
WebCal cannot detect an EchoSonic II connected to the
computer. Check that the Fob is connected to the USB
port. Also check that all four wires (Red, Black, White
and Green) are securely attached to the Fob.
This is a warning indicating the computer configuring
EchoSonic II is not connected to the internet. Click OK
to continue. Flowline recommends being connecting to
the internet for all configurations. Not being connected
to the internet will not prevent the EchoSonic II from
being configured.
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