ECHOSAFE Installation manual
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 on the Navigation Bar along the side of the home page. If for some reason your product must be returned for factory service, contact Flowline Inc. at (562)598-3015 to receive a Material Return Authorization number (MRA), providing the following information: EchoSafe® Explosion-Proof Ultrasonic Level Transmitter Model XP88 / XP89 Owner’s Manual We Do Your Level Best 1. Part Number, 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 Once you have received a Material Return Authorization 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. Version 1.1 © 2007 FLOWLINE Inc. All rights reserved. Manual # MN300600 B RoHS Compliant 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. 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. This warranty covers only those components of the products which are 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 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. 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. 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 MERCHANT ABILITY 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. SPECIFICATIONS Step One Pressure: Enclosure rating: Enclosure mat.: Window mat.: Transducer mat.: Process mount: Conduit entrance: Compliance: Classification: Approvals: 3.89" (9.9 cm) 6.06" (15.4 cm) UP SELECT FAST 6.06" 15.4 cm 2" NPT 4.00" (10.2 cm) Front View 4.44" (11.3 cm) 1/2" NPT EchoSafe™ UP SELECT DOWN FAST 6.06" 15.4 cm 2" NPT PRELIMI OVE Top View 4.00" (10.2 cm) 4.44" (11.3 cm) 1/2" NPT Operating Pressure (psi) Temp. comp.: Electronics temp.: EchoSa 3.89" (9.9 cm) Process Temp.: 6.06" (15.4 cm) Display type: Display units: Memory: Supply voltage: Loop resistance: Signal output: Signal invert: Calibration: Fail-safe: 1/2" NPT 3.89" (9.9 cm) Accuracy: Resolution: Beam width: Dead band: XP88: 8" to 24.6' (20 cm to 7.5 m) XP89: 8" to 32.8' (20 cm to 10 m) ± 0.2% of max. range 0.079" (2 mm) 3" (7.6 cm) dia. XP88: 8" (20 cm) XP99: 8" (20 cm) LCD, 6-digits Inch, cm, ft, m, percent Non-volatile 18-28 VDC (loop) 250Ω max @ 24 VDC 4-20 mA , two-wire 4-20 mA or 20-4 mA Push button (3-button) 4 mA, 20 mA, 21 mA, 22 mA or hold last F: -4° to 140° C: -20° to 60° Automatic F: -40° to 160° C: -40° to 71° 30 psi (2 bar) NEMA 4 Aluminum Glass PVDF 2" NPT Dual, 1/2" NPT RoHS Explosion proof FM: Class 1, Div 1, Groups A, B, C, D Class II/III, Div 1, Groups E, F, G 6.06" (15.4 cm) Range: Side View 4.44" (11.3 cm) 6.06" 15.4 cm 2" NPT 40 30 Temperature/Pressure Derating ™ EchoSafe Unacceptable Range UP SELECT DOWN FAST 20 Acceptable Range 10 00 -40 -20 00 20 40 Temperature ( C) 60 80 PRELIMINARY OVERALL SAFETY Step Two About this Manual: PLEASE READ THE ENTIRE MANUAL PRIOR TO INSTALLING OR USING THIS PRODUCT. This manual includes information on the XP8_-0 Ultrasonic Level Transmitter from FLOWLINE. Please refer to the part number located on the transmitter label to verify the exact model configuration which you have purchased. User’s Responsibility for Safety: FLOWLINE manufac- tures 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 OVERVIEW Step Three A. Application: The explosion proof ultrasonic transmitter provides non-contact level detection up to 32.8’ or 10m. The transmitter is well suited for a wide range of corrosive, waste and slurry type media, and is broadly selected for atmospheric bulk storage, day tank and waste sump applications. B. Part Number: The part and serial numbers are located on the wrench flat. Check the part number on the product label and confirm which of the below model configurations you have purchased: Part Number Range Supply Mount XP89-0 32.8’ (10 m) 18-28 VDC 2” NPT XP88-0 24.6’ (7.5 m) 18-28 VDC 2” NPT so could result in property damage or serious injury. Proper Installation and Handling: Only properly trained staff should install and/or repair this product. Never overtighten the transmitter within the fitting. Always check for leaks prior to system start-up. Opening The Enclosure: EchoSafe is designed to be installed in a hazardous areas and, when installed, do not open the unit while power is applied. Always disconnect the power source from EchoSafe prior to opening, programming, installing, or removing it. Additionally, ensure that electrical wiring, fittings and mechanical connections conform to all applicable electrical codes. Material Compatibility: The XP8_ series enclosure is made of a Aluminum. The transducer is made of Polyvinylidene Fluoride (PVDF). Make sure that the model which you have selected is chemically compatible with the application media and it’s environment. Enclosure: While the transmitter housing is liquid-resistant the XP8_ series 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. 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. Handling Static-Sensitive Circuits/Devices When handling the transmitter, the technician should follow these guidelines to reduce any possible electrostatic charge build-up on the technicians body and the electronic part. 1. Always touch a known good ground source before handling the part. This should be repeated while handling the part and more frequently after sitting down from a standing position, sliding across the seat or walking a distance. 2. Avoid touching electrical terminals of the part unless making connections. PREPARATION MENU ITEMS Step Four Step Five A. Supply Voltage: The transmitter power supply voltage should A. WARM UP: This is the initial power up mode. When this mes- meters have built-in 24 VDC power supplies for use with the trans- sage is displayed, the transmitter is going through its power up routine, and validating the target value. After a short period of time, this message will disappear and be replaced by a numeric value. output of 18 VDC may also be used with the transmitter for calibra- B. FULL: Level has reached the programmed FULL set point. never exceed a maximum of 28 VDC. Flowline controllers and mitter. Alternative controllers and/or power supplies with a minimum tion and/or operation. C. EMPTY: Level has reached the programmed EMPTY set point XP89-0 Reverse Mode D. UNITS: Selectable in inches centimeters, feet, meter or percent. The factory default is Inches. EchoSafe™ EchoSafe™ B. Factory Span: All transmit- E. INCHES: Inch units of measurement. ter models are factory calibrated with F. CM: Centimeters units of measurement. 4 mA at their maximum range (tank 4 mA empty) and 20 mA at their minimum range (tank full). The 4 and 20 mA span set points can be reverse cali- 20 mA G. FEET: Feet units of measurement. H. METERS: 4 mA Meter units of measurement. 20 mA I. PERCNT: 0-100% units of measurement. Percent is the calcu- brated on all models. lated value based on the 4mA and 20mA set points. J. TANK: Menu through which the 4-20 mA span is adjusted. EchoSafe™ C. Maximum Applied Range: The Individual or cumulative effects of agitation or vapor can reduce the overall quality of signal return and shorten the maximum applied range of the transmitter. To determine the maximum applied range of the transmitter in your application, refer to the below de-rating chart. K. HEIGHT: The point in inches, feet, meters, or centimeters from the transducer face where the output will (MinR) be 4 mA (generally the bottom of the tank). Factory is the same as HEIGHT FILLdefault H (MaxR) the unit’s maximum range. Example: XP88 = 295” maximum range which is also the same 4 mA set point under factory default. FULL EMPTY L. Fill H (Fill Height): The point Maximum Applied Range De-rating Chart XP88/89-0 EchoSafe™ Agitation = 1-3 @ 50 kHz Vapor = 3-5 @ 50 kHz 0% 50Khz in inches, feet, meters or centimeters from the bottom of the tank to the high level where the output will be 20 mA (generally the straight wall distance from the bottom of the tank). NOTE: The transmitter dead band is automatically subtracted from the FILL H. Example: XP88 = 8” dead band. Therefore the maximum FILL H is 295” [maximum range] - 8” [dead band] = 287”. EchoSafe™ (MinR) HEIGHT (MaxR) FILL H M. REV mA (Reverse mA): Allows the user to select 20 mA at 50% the bottom and 4 mA at the top of the tank (20-4 mA). Factory default is 4 mA (MaxR) at the bottom and 20 mA (MinR) at the top. N. NORM: Sets EchoSafe so 4 mA is at the bottom of the tank and 20 mA at the top. This is the default settings. 100% 0 1 2 3 4 5 6 7 8 9 Ultrasonic Derating Chart LU12-5__1 LU13-5__1 & LU14-5__1 Agitation = 1 - 5 @100Khz Agitation = 1 - 7 @50Khz Temp = 3 @100Khz Temp = 3 @50Khz 10 O. REV: Sets EchoSafe so 20 mA is at the bottom of the tank and 4 mA at the top. MENU ITEMS Step Six P. SAFE: The FAIL-SAFE current output of the transmitter if the acoustic signal is LOST. Selectable at 4 mA, 20 mA, 21 mA, 22 mA or HOLD. (HOLD is the last 4-20 mA value prior to LOST). Q. HELP: Allow the user to view the current configuration settings in EchoSafe. R. SETUP: Displays the present configuration settings such as UNITS, HEIGHT, FILL H, SAFE, REV. PROGRAMMING Step Seven EchoSafe is designed to be installed in a hazardous areas, and when installed, do not open the unit while power is applied. Always disconnect the power source from EchoSafe prior to opening, programming, installing or removing it. A. Introduction: The transmitter has two modes, RUN and MENU. In the RUN mode, the transmitter is operational and the display will indicate the liquid height in inches, centimeters or percent. T. SEGMENT CHECK: Tests all LED segments for operation. In the MENU mode, the display will indicate the selected mode of calibration. The transmitter arrives from the factory with its settings at 4 mA = maximum range and 20 mA = minimum range (defined by the dead band or minimum measurement distance). The transmitter is programmed with it’s built-in display and three button keyboard. U. RANGE: Displays the current inch, centimeter, feet, meter or B. Entering the Program Mode: Press and hold the S. TEST P: Allows the user to view the test parameters of SEGMENT CHECK, RANGE, ECHO, POWER, VER. Percent measured value. V. ECHO: Displays the present acoustic signal strength. EchoSafe™ W. POWER: Displays the present acoustic power level X. VER (VERSION): Displays the transmitter software version. UP Y. R ALL: Allows the user to reset the transmitter to its original fac- tory default settings Z. ERROR: Indicates that the new value has NOT been saved in memory (after depressing the SELECT/FAST or EXIT key). AA. RUN: When displayed, if the user depresses the SELECT/ FAST key, the transmitter will exit the programming mode and return to the RUN mode for normal operation. BB. UP / DOWN: Increases or decreases the SET 20 and SET 4 display values in the programming mode. NOTE: Simultaneously holding down the SELECT/FAST button while pressing the UP or SELECT DOWN FAST SELECT/FAST button for approximately 5 seconds until the display changes from a numeric value to MENU, indicating that you have entered the MENU mode. Note: When MENU mode is active, the EchoSafe will hold the last current value. The value will not change until the transmitter is returned to RUN Mode. EchoSafe™ DOWN button will increase the speed of the display. UP SELECT FAST DOWN Hold for 5 Seconds After entering the MENU mode, the display will scroll through the top menu, alternately flashing UNITS, TANK, OUTPUT, HELP and RUN. Top Menu PROGRAMMING PROGRAMMING Step Eight Step Nine C. Programming UNITS: To change UNITS from INCHES to E. Programming HEIGHT: To change HEIGHT 4 mA value. CM or PERCENT. SELECT SELECT MENU 0HQX FAST FAST SELECT UP FAST 1. Press the SELECT/FAST button and hold it for 5 seconds until MENU appears. 2. When UNITS appears, press the SELECT/FAST button. The display will rotate between INCHES, CM,, FT, M, PERCENT and DISPLAY. 3. Press the SELECT/FAST button when the UNITS you want (INCHES, CM, FT, M or PERCENT) appear. The display will then display SAVED. You have successfully changed the UNITS function. FAST FAST DOWN 1. Press the SELECT/FAST button and hold it for 5 seconds until MENU appears. 2. When TANK appears, press the SELECT/FAST button. The display will rotate between HEIGHT, FILL H and EXIT. 3. When HEIGHT appears, press the SELECT/FAST button. The display will show a decimal reading in the selected UNITS. 4. Press the UP/DOWN buttons to increase or decrease this value. This value is the distance from the transducer face to the bottom of the tank. NOTE: Simultaneously holding down the SELECT/FAST button while pressing the UP or DOWN button will increase the speed of the display. You have successfully programmed the HEIGHT or 4 mA value. D. Programming Off Tank: If you know the dimensions of your tank, you may input the 4 mA and 20 mA set points manually. To do so, review the following: F. Programming FILL H: To change FILL H 20 mA value. 0HQX SELECT FAST HEIGHT: The point in inches or centimeters from the transducer face where the output will be 4 mA (generally the bottom of the tank). Factory default is the same as the unit’s maximum range. Example XP88 = 295” maximum range which is also the same 4 mA set point under factory default. FILL H: The point in inches or centimeters from the bottom of the tank to the high level where the output will be 20 mA (generally the straight wall distance from the bottom of the tank). NOTE: The transmitter dead band is automatically subtracted from the FILL H. Example: XP88 = 8” dead band. Therefore the maximum FILL H is 295” [maximum range] - 8” [dead band] = 287”. SELECT UP FAST SELECT FAST DOWN 1. Press the SELECT/FAST button and hold it for 5 seconds until MENU appears. 2. When TANK appears, press the SELECT/FAST button. The display will rotate between HEIGHT, FILL H and EXIT. 3. When FILL H appears, press the SELECT/FAST button. The display will show a decimal reading in the selected UNITS. EchoSafe™ EchoSafe™ 4. Press the UP/DOWN buttons to increase or decrease this value. This value is the distance from the bottom of the tank to the full point (typically FULL the straight wall height). (MinR) (MaxR) SELECT 5. When you have reached the desired value, press SELECT/FAST to SAVE. Note: Percent units can only be selected after the transmitters Height (4 mA) and Fill H (20 mA) set points have been programmed. Therefore initial programming should always be done in INCH, CM, FT or M UNITS. HEIGHT SELECT FILL H EMPTY 5. When you have reached the desired value, press SELECT/FAST to SAVE it. You have successfully programmed the FILL H or 20mA value. PROGRAMMING PROGRAMMING Step Ten Step Eleven G. Programming SAFE Mode: To change SAFE mode. H. Programming REV mA (Optional): In factory default, SELECT FAST 0HQX SELECT SELECT FAST FAST the transmitter operates with 4 mA at the maximum range, and 20 mA at the dead band. Using the menu item REV mA, you can change the unit to reverse this to 20 mA at the furthest distance and 4 mA at the closest distance. EchoSafe™ EchoSafe™ EchoSafe™ 4 mA 20 mA 20 mA 4 mA Normal mA Mode (4 mA) set at empty tank and (20 mA) set at full tank. 1. Press the SELECT/FAST button and hold it for 5 seconds until MENU appears. 2. When SAFE appears, press the SELECT/FAST button. 3. The display will now rotate through 22mA, 21mA, 20mA, 4mA and HOLD. When you reach the desired setting, press the SELECT/FAST button to SAVE it.. 4 mA 20 mA Reverse mA Mode (20 mA) set at empty tank and (4 mA) set at full tank. I. Programming REV mA (Mode): SELECT FAST 0HQX You have successfully programmed the SAFE mode. SELECT FAST SELECT FAST (;,7 NOTE: You must set HEIGHT and FILL H prior to reversing the 4 and 20 mA. Regardless of which mode you are in (Norm or Rev), changes to the HEIGHT or FILL H are always with respect to the original settings programmed. NOTE: Any changes to the HEIGHT will effect the FILL H value. The FILL H will stay at the same physical level in the tank. An increase to the HEIGHT value will result in an equal increase to the FILL H value. A decrease to the HEIGHT value will result in an equal decrease to the FILL H value. INSTALLATION PROGRAMMING Step Thirteen Step Twelve . Do not install at angle relative to the liquid fe Sa ho Ec Do not install within 3” of tank side wall EchoSafe A. Wiring: A supply voltage of 18 - 28 VDC is used to power the XP8_ series. The sensor circuit should never exceed a maximum of 28 volts DC. Electrical wiring of the sensor should be performed in accordance with all applicable national, state, and local codes. EchoSafe EchoSafe Do not install with objects in the beam Do not install in applications with vacuum VACUUM (+) 24 VDC (-) Warning Flowline Ultrasonic transmitters have been optimized for use in non-metallic fittings. For best performance, avoid the use of metal fittings. 1 2 Install the appropriate installation fitting. Make sure that the fitting and transmitter threads are not damaged or worn. Hand tighten the transmitter within the fitting. Perform an installed leak test under normal process conditions prior to system start up. Gasket A. Fitting Selection: Check the transmitter part number to determine the required 2” fitting thread type. The transmitter is commonly installed in tank adapters, flanges, brackets or stand pipes. EchoSafe 1. 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. Avoid tank adapter styles with threads and/or pipe stops forward of the installed transducer. Adapter EchoSafe Flange 2. Flange: Tall flanges with narrow risers impede the acoustic signal. Select a fitting with the right riser height versus inner diameter geometry. The transmitter may be elevated up to 12” (30 cm) in a 6” (15 cm) riser, 8” (20 cm) in a 4” (10 cm) riser and 3” (7.6 cm) in a 2” (5 cm) riser. Height Riser EchoSafe Inner Diameter Bracket EchoSafe 3. Bracket: The LM50-1001 bracket or equivalent can be used for open tank top installations against the side wall. Stand Pipe EchoSafe 3" Minimum Diameter Dead Band Highest Liquid Level Operational Range Ventilation Hole Lowest Liquid Level 4. Stand Pipe: A stand pipe may be used to dampen turbulence or separate surface foam. Select a minimum 3” pipe for the stand pipe. 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 in the dead band. (FKR6DIHÙ Opening The Enclosure: EchoSafe is designed to be installed in a hazardous areas and, when installed, do not open the unit while power is applied. Always disconnect the power source from EchoSafe prior to opening, programming, installing, or removing it. Additionally, ensure that electrical wiring, fittings and mechanical connections conform to all applicable electrical codes. TROUBLESHOOTING TROUBLESHOOTING Step Fourteen Step Fifteen A. Viewing Programmed VALUES: C. Factory RESET: SELECT FAST 0HQX SELECT FAST SELECT SELECT FAST FAST 0(18 81,76 SELECT FAST +(,*+7 ),//+ SELECT :$,7 FAST 6$)( (;,7 5(90$ '21( 1. Press the SELECT/FAST button and hold it for 5 seconds until MENU appears. 2. When HELP appears, press the SELECT/FAST button. The display will rotate between SETUP, TEST P and R ALL. 3. When SETUP appears, press the SELECT/FAST button. You will now begin viewing calibration settings (UNITS, HEIGHT, FILL H, SAFE, REV mA) that are programmed in the transmitter. When complete the display will revert back to the HELP menu. 1. Press the SELECT/FAST button and hold it for 5 seconds until MENU appears. 2. When HELP appears, press the SELECT/FAST button. The display will rotate between SETUP, TEST P and R ALL. 3. When R ALL appears, press the SELECT/FAST button. 4. Unit will reset. Note: FACTORY RESET resets the transmitter back to its original factory default settings: (20 mA = Minimum Range, 4mA = Maximum Range and SAFE = 22mA). D. Testing the Transmitter Factory Set Points B. Viewing TEST P: SELECT FAST 0(18 Transmitter 4 mA Setting 20 mA Setting XP88-0 XP89-0 26.4 (7.5m) 32.8 (10m) 8 (20 cm) 12 (30 cm) SELECT FAST SELECT FAST :$,7 5$1*( 9(5 1. Press the SELECT/FAST button and hold it for 5 seconds until PROG appears. 2. When VALUES appears, press the SELECT/FAST button. The display will rotate between SETUP, TEST P and RESET. 3. When DIAG appears, press the SELECT/FAST button. You will now begin viewing diagnostic values (LEVEL, TEMP ECHO, POWER, MOUNT and VER) that may be relevant to the transmitter and it’s performance in your application. When complete the display will revert back to the VALUES menu. 1. Connect a multi-meter in series with the black wire to read the current output. Power Supply 5 6 Power Supply 19 20 mA 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. 4 Black Red 21 mA Black EchoSafe Red EchoSafe 20 mA 4 mA 4. Write down the information in TEST P (SEGMENT, RANGE, ECHO, POWER, VER) and have it ready when you contact your Flowline representative. E. Additional Information: Go to www.flowline.com and click on the nav-bar “Application Info” button for FAQ’s, tech-tips, case studies, white papers, glossary and success stories.
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