Flowline LG10, LG11 Operating Manual
EchoWave®
Guided Wave Liquid Level Transmitter
LG10 & LG11 Series Manual
Flowline, Inc. | 10500 Humbolt Street, Los Alamitos, CA 90720 p 562.598.3015 f 562.431.8507 w flowline.com MN300840 REV A10
Introduction / Table of Contents Step One
EchoWave
®
utilizes TDR (Time Domain Reflectometry) technology. It is best described as low-energy, highfrequency electromagnetic impulses, generated by the sensor’s circuitry that is propagated along the probe as
it is immerged in the liquid to be measured. Impulses hit the surface of the media and part of the impulse
energy is reflected back up the probe to the circuitry. Level Measurement is calculated from the time difference
between the impulses sent and the impulses reflected. The sensor analyzes the level output as a continuous
measurement reading from its analog output. TDR-Sensors are also known as Guided Radars or Guided Wave
Radars (GWR).
NEW FEATURES
Precise continuous level measurement in one device
Complete galvanic insulation of device electronics from its inputs/outputs and the tank potential (no
problems with electrochemical corrosion protection)
Highly robust measurement due to 3-wire design, innovative signal analysis and disturbance signal
suppression
TABLE OF CONTENTS
Introduction: ...................................................................................................................... 2
Specifications: .................................................................................................... 3-4
Dimensions: .......................................................................................................... 5
About this Manual: ................................................................................................ 6
Getting Started (Setup Overview): .................................................................................... 7
Part Numbers: ....................................................................................................... 8
Probe Length: ....................................................................................................... 9
Measurement Range: ......................................................................................... 12
Distance (Height of Liquid) vs. Volume of Liquid: ............................................... 14
Installation (Mounting Considerations): .......................................................................... 15
Installation Tips: ............................................................................................. 17-20
Wiring (Analog Output): .................................................................................................. 21
Common Wiring to Displays, Controllers & PLCs: ......................................... 23-24
Configuration: ................................................................................................................. 25
Step 1 – Install WebCal Software: ...................................................................... 26
USB Fob Interface: .................................................................................. 27
Step 2 – Measure the Tank: ................................................................................ 28
Step 3 - Sensor Configuration: ............................................................................ 29
Step 4 - Dimensional Entry: ................................................................................ 30
Step 5 - Tank Level Configuration: ..................................................................... 31
Step 6 - Write to Unit: .......................................................................................... 32
Empty Signal Scan: ........................................................................................................ 32
Appendix: ........................................................................................................................ 34
Echo Curve: ........................................................................................................ 34
Sensor Configuration: .................................................................................... 35-37
Volumetric Configuration: ............................................................................... 38-40
Tank Level Confirmation: .................................................................................... 41
Write to Unit: ....................................................................................................... 42
Cutting the Probe: .......................................................................................... 43-45
Troubleshooting: ................................................................................................ 47
Warranty: ....................................................................................................................... 48
| 2 MN300840 REV A10
Introduction Step One
ELECTRICAL
Analog output: 4 to 20mA
Total load resistance: < 250Ω
Lower range value: 4.0mA (span 0%)
Upper range value: 20.0mA (span 100%)
Supply voltage: 10 to 30VDC (reverse-polarity protected)
Current consumption: <50mA at 24VDC
Start-up time: <6s
Cable terminals: Terminal block [wires 16 to 26 AWG (solid or stranded)]
MEASUREMENT
Reference condition: (dielectric constant [εr] =80, water surface, tank 01m, DN200 metal flange)
Accuracy: ±3mm
Repeatability: <2mm
Resolution: <2mm
Probe type:
Rod: 4mm
Cable: 4mm, type 7x19
Coaxial: 21.34mm (NPT ½", sch. 40)
Probe length [can be ordered in 5mm (0.2”) increments from the reference point]
Rod: 0.61 to 3.0m (2’ to 9.8’)
Cable: 1.0 to 5.5m (3.3’ to 18’)
Coaxial: 0.61 to 3.0m (2’ to 9.8’)
Probe loading
Rod: Maximum lateral load: 6Nm… (0.2kg at 3 m)
Cable: Maximum tensile load: 5kN
Coaxial: Maximum lateral load: 100Nm… (1.67kg at 6 m)
Top dead band: 100mm (4”)
Bottom dead band: 50mm (2”)
APPLICATION SPECIFICATIONS
Intended Installation:
Rod: Metallic tank or below grade concrete basin
Cable: Metallic tank or below grade concrete basin
Coaxial: Non-metallic, plastic, fiberglass or metallic tank or below grade concrete basin
Dielectric [εr] >1.8
Conductivity: No restrictions
Density: No restrictions
MN300840 REV A10 3 |
Introduction Step One
APPLICATION SPECIFICATIONS (CONTINUED)
Process temperature
Rod: F: -40° to 302° C: -40° to 150°
Cable: F: -40° to 302° C: -40° to 150°
Coaxial: F: -40° to 266° C: -40° to 130°
Ambient temperature
Operation: F: -13° to 176° C: -25° to 80°C
Storage: F: -40° to 185° C: -40° to 85°C
Application pressure: -14.5 to 250 psi -1bar to 17.2bar
Rate of level change: 1”/s
MECHANICAL SPECIFICATIONS
Wetted materials:
Rod: 1.4404 / 316L, PEEK
Cable: 1.4401 / 316, PEEK
Coaxial: 1.4404 / 316L, PEEK
Housing materials
Housing rating: IP66, NEMA 4
Cable entries: Single cable entry ½” NPT
Cord grip: ½” NPT, Ferrite Bead included
Cord grip material: Nylon
Cord grip cable
Minimum size: 0.170” (4.3mm)
Maximum size: 0.450” (11.4mm)
Process mount: ¾”NPT (G)
Certification:
Compliance: CE: EN61326-1: 2013 & EN55011 Class A Group 1
CRN
RoHS
CSAus: UL Std. No 61010-3 (3rd edition) & CAN/CSA-C22.2 No. 61010-1-12
c
Aluminum alloy EN AC-AlSi9Cu3 (DIN EN 1706), epoxy
Housing body and cover:
spray coating (~70μm) other alloys and coatings on
request.
Cover o-ring: Silicone rubber (Elastosil R 750/50)
Screws; cover locking screw: 1.4301 / 304 external earth terminal
Screw: Tin plated stainless steel 1.4301 / 304
| 4 MN300840 REV A10
Introduction Step One
DIMENSIONS
MN300840 REV A10 5 |
Introduction Step One
About this Manual: PLEASE READ THE ENTIRE MANUAL PRIOR TO INSTALLING OR USING THIS
PRODUCT. This manual includes information on the EchoWave
from Flowline
®
. Please refer to the part number located on the switch label to verify the exact model
®
series Guided Wave Radar Level Transmitter
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 professional staff should install and/or repair this product. Never
over tighten the sensor within the fitting. Always check for leaks prior to system start-up.
Wiring and Electrical: A supply voltage of 10 to 30 VDC is required to power the EchoWave®. 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 metal. Make sure that it is chemically compatible with
the application media.
Enclosure: While the sensor housing is liquid-resistant the EchoWave® is not designed to be operational
when fully immersed. It should be mounted to insure the enclosure does not come into contact with the
application media under normal operational conditions. The probe is designed for full liquid contact.
Note: If using the Flowline
®
LM90-1001 (liquid tight fitting) on the ½” conduit, the cable minimum is 0.170”
(4.3mm) and the maximum is 0.450” (11.4mm).
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 technician’s 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.
3. DO NOT open the unit cover until it is time to calibrate.
Make a Fail-Safe System: Design a fail-safe system that accommodates the possibility of switch and/or
power failure. Flowline
®
recommends the use of a redundant backup system and alarm in addition to the
primary system.
Flammable, Explosive or Hazardous Applications: The EchoWave® sensor is not certified for
application in a hazardous location.
| 6 MN300840 REV A10
Getting Started Section Two
SETUP OVERVIEW
Below highlights the initial steps in setting up your sensor for operation.
1. Check Part Number (Section Two)
a. Confirm that the sensor’s part number matches the ordered part number and all components
are provided with the model delivered.
2. Measure Probe & Installation (Section Two)
a. Prior to installation, measure the length of the probe. Confirm that the probe length matches the
actual installation location.
b. If the probe length is too long, refer to Cutting the Probe in Section 8.
c. Understand the location of the sensor’s Measurement Range as well as Minimum Fill-Height
and Maximum Fill-Height settings.
3. Install the sensor (Section Three)
a. Section 3 contains information on the location and mechanical installation of the sensor.
4. Wire the sensor (Section Four)
a. Section 4 contains information on electrical wiring and power requirements for the sensor.
5. Configure Sensor with WebCal™ (Section Five)
a. Section 5 contains information on using the WebCal
®
configuration software.
6. Perform an Empty Scan (Section Six)
a. Section 6 contains information on how to run an empty scan.
b. An empty scan may not be required on a sensor that has a coaxial probe.
MN300840 REV A10 7 |
Getting Started Section Two
Components: EchoWave
®
is offered in 28 different models. Depending on the model purchased, you may or
may not have been shipped the configuration component shown below.
Part
Number
LG10-0003-00-036
LG10-0003-01-036 Yes
LG10-0013-00-036
LG10-0013-01-036 Yes
LG10-0003-00-072
LG10-0003-01-072 Yes
LG10-0013-00-072
LG10-0013-01-072 Yes
LG10-0003-00-118
LG10-0003-01-118 Yes
LG10-0013-00-118
LG10-0013-01-118 Yes
LG10-1003-00-036
LG10-1003-01-036 Yes
LG10-1013-00-036
LG10-1013-01-036 Yes
LG10-1003-00-072
LG10-1003-01-072 Yes
LG10-1013-00-072
LG10-1013-01-072 Yes
LG10-1003-00-118
LG10-1003-01-118 Yes
LG10-1013-00-118
LG10-1013-01-118 Yes
LG11-2003-00
LG11-2003-01 Yes
LG11-2013-00
LG11-2013-01 Yes
Maximum
Range
3’
(0.91m)
6’
(1.83m)
9.8’
(3m)
3’
(0.91m)
6’
(1.83m)
9.8’
(3m)
18.0’
(5.5m)
Probe
Style
Rod
Coaxial
Cable 316 SS
Mat’l of
Const.
316L SS
Thread Fob Components
¾” NPT
¾” G
¾” NPT
¾” G
¾” NPT
¾” G
¾” NPT
¾” G
¾” NPT
¾” G
¾” NPT
¾” G
¾” NPT
¾” G
The above are standard length models. For custom length probes, add a
length dimension to the end of the part number (i.e. LG10-0003-01-060” or
LG11-2003-01-4.5m). Be sure to indicate the units of measurement.
Coaxial style probe
Cable style probe
1
- includes rod, threaded ½” tube and spacers
2
- includes counterweight
No
No
No
No
No
No
No
No
No
No
No
No
No
No
Housing,
feed-through,
rod style probe
Housing,
feed-through,
coaxial style probe
Housing,
feed-through,
cable style probe
1
2
Quick Start
| 8 MN300840 REV A10
Getting Started Section Two
UNDERSTANDING SENSOR HEIGHT
This is a critical setting for EchoWave®. Sensor Height defines the height of the sensor above the bottom of
the tank. The height value must take into account the shape of the tank and any risers, fittings, structures or
extensions associated with the tank or the installation (see examples below). The reference point for definition
of the Sensor Height is always the bottom of the mounting nut.
Simple
Tank
Cone Bottom Raises
Sensor Height
Dome Top Raises
Sensor Height
(SH)
Mounting Fixture
Raises Sensor Height
Sensor Off Center
Changes SH
Simple
Tank
Simple Open
Top Tank
Sensor Extends
into Sump
Lowering SH
Riser Raises
Sensor Height
UNDERSTANDING PROBE LENGTH
The reference point for definition of the probe length [Length] is always the bottom of the threads [bottom of
the feed through (see below)]. Note: This is a different reference location from the Sensor Height. The probe
Length is an important mechanical dimension which is needed to make sure the probe physically fits into the
tank at the anticipated mounting location. Probe length has an influence on the actual measuring range of the
sensor, but it is a different aspect of the sensor.
Rod
Probe
Coaxial
Probe
Cable
Probe
Note: Sensor Height and Probe Length have different reference points for measurement.
MN300840 REV A10 9 |
Getting Started Section Two
UNDERSTANDING INSTALL LOCATION LENGTH
Measure the space below the actual installation location for the sensor. This distance (install length) must be
greater than the probe length. In many tanks, the install length corresponds to the height of the tank. With
dome top, cone bottom and horizontal tanks, include the added height of the curved surface. Be sure to take
into account the height of fittings, risers, tank flats etc. which may be added for installation. All of the above can
raise the bottom of the probe higher in the tank than what was originally expected resulting in a reduced lowest
level of measurement (see Measurement Range).
Tank with Flat Top
& Flat Bottom
Tank with Dome Top
& Flat Bottom
Horizontal
Tank
CONE AND ROUNDED BOTTOM TANKS
The location of an EchoWave® installed along the top of a dome or cone bottom tank may have an effect on
the installation of the sensor. Be sure to measure from the actual point of installation. Round or cone bottom
tanks will reduce the install height available, depending on install location. If this occurs, either the sensor can
be raised using fittings (see Adding a Riser to Avoid Cutting the Probe) or the probe’s length may be reduced
by cutting the probe (see Cutting the Probe in Section 7).
Install Height >
Probe Length
Install Height <
Probe Length
Install Height >
Probe Length
| 10 MN300840 REV A10
Getting Started Section Two
ADDING A RISER TO AVOID CUTTING THE PROBE
In some conditions, a riser may be added to avoid cutting the probe.
Rod and Cable Probes
With the Rod and Cable versions
of the probe, the maximum height
for the riser is 12” (300mm). The
minimum diameter of the riser is 2”
(50mm). The riser must be
metallic in construction using the
least number of fittings
/connections. Note: An Empty
Signal Scan is a requirement so
that the EchoWave
®
can eliminate
the odd geometry created by the
riser.
Least Number of Fittings
Too Many Fittings
Coaxial Probes
With the coaxial probe, there is no
maximum riser height or minimum
riser diameter. This is because the
coaxial shield isolates the physical
changes to the installation from the
sensor’s energy signal. In both
examples, the energy signal
cannot see any changes to the
fitting/connections or from being
installed in an extension that
exceeds the maximum height for
rod and cable probes.
MN300840 REV A10 11 |
Getting Started Section Two
UNDERSTANDING MEASUREMENT RANGE
EchoWave
the presence of unavoidable signal disturbances at both ends of the probe. In these dead band areas the
measurements are non-linear or have reduced accuracy. Therefore, it is not recommended to actually measure
level within these dead band areas. Their length depends on the probe type and the reflectivity
(i.e. dielectric constant) of the liquid to be measured.
®
level transmitters have small dead band areas at both the top and bottom of the probe. It is due to
The Measurement Range of LG10/LG11 series extends between the
top and bottom dead band areas; this is the area in which a sensor will
have the specified measurement performance. It is recommended that
the maximum and minimum levels to be measured in the tank are
actually within the Measurement Range of the sensor. The span
between the lower range value [4mA] and the upper range value [20mA]
of the current output is proportionally equal from 0 to 100% of your
continuous level measurement reading. It is recommended that the span
between these two range values stays within the Measurement Range.
The [Top Dead Band], closest to the threads, is set to 4” (100mm). This
is measured from the top of the threads down to the probe. This is
consistent for all styles of probe. Note: the measurement location for the
Top Dead Band is different to the measurement location for the probe
length.
The [Bottom Dead Band], closest to the end of the probe, is set to 2”
(50mm). This is measured from the end of the probe on rod and coaxial
probes. For cable probes, it is measured from the top of the counterweight. The counter-weight must be included with the dead band as the
sensor’s inactive area.
| 12 MN300840 REV A10
Getting Started Section Two
®
UNDERSTANDING MINIMUM FILL-HEIGHT (PUTTING IT ALL TOGETHER)
EchoWave
from the bottom of the tank to the top of the Bottom Dead Band. As
shipped from the factory, Min. Fill-H is where the 4mA current is located
and is the lowest point on the probe where the sensor can detect a liquid
level. Any point below this position will stop at 4mA. The Min. Fill-H is
influenced by the Sensor Height (SH), Probe Length (P), Height of the
Threads [0.65” (16.5mm)] and Bottom Dead Band.
Min. Fill-H = (SH) – [0.65” (16.5mm)] – (P) + (Bottom Dead Band)
With a cable probe, include the height of the counter-weight.
Switch output to volumetric will allow Min. Fill-H to be set to (0).
If the 4-20 mA output is reversed (20mA at bottom and 4mA at
Note: Because of the bottom dead band, the Minimum Fill-Height can never be at the end of the probe.
Note: The configuration of the sensor (Distance or Volume) will affect the current output at Minimum Fill-
Height. Upon selecting Distance, the current will be set to 4mA at Min Fill-H. However, upon selecting volume,
the current at Min Fill-H will be the calculated based upon 4mA being set at the bottom of the tank [see
Distance (Height of Liquid) vs. Volume of Liquid].
®
has a Minimum Fill-Height (Min. Fill-H), which is measured
top), then the level will max out at 20 mA when the level falls
below the Min. Fill-H.
Understanding Maximum Fill-Height
EchoWave
has a Maximum Fill-Height (Max. Fill-H), which is measured from the
bottom of the tank to the Top Dead Band. As shipped from the factory, Max. Fill-H
defines the 20mA current depicting the highest point on the probe where the
sensor detects liquid level. Any point above this position will stop at 20mA. The
Max. Fill-H is influenced by the Sensor Height (SH), Height of the Threads [0.65”
(16.5mm)] and Top Dead Band.
Max. Fill-H = (SH) – [0.65” (16.5mm)] – (Top Dead Band)
The Max. Fill-H may be decreased to lower the 20mA location, but it cannot
be raised above its original setting.
If the 4-20 mA output is reversed (20mA at bottom and 4mA at top), then
the level will max out at 4 mA when the level rises above the Max. Fill-H.
Note: Because of the top dead band, the Maximum Fill-Height can never be at the bottom of the threads.
MN300840 REV A10 13 |
Getting Started Section Two
DISTANCE (HEIGHT OF LIQUID) VS. VOLUME OF LIQUID
®
With WebCal
of liquid) or volume of a liquid. The location of the empty current will adjust depending on which configuration
method is selected.
Note: The empty (4mA) location is placed at a different location based upon selecting distance (liquid height)
or liquid volume.
, the LG10/LG11 series can be configured to operate as a device that reads the distance (height
Distance (Height of Liquid): When the EchoWave
®
is configured to read the
distance (height of the liquid), the default for the sensor Empty will be at the
bottom of the measurement range (end of the probe minus the bottom dead
band). This is where 4mA will be set. The default for sensor Full will be at the
top of the measurement range (Top Dead Band), where 20mA will be set. The
20mA can be set by the Maximum Fill-Height.
Volume of Liquid: When the LG10 series is configured to read the volume of
liquid, the output will track the volume of the tank as the level increases and
decreases. Like Distance, the Empty and Full settings will default to the low
and high end of the Measurement Range. The location of the 20 mA can be
adjusted with the Maximum Fill-Height settings. However, the shape of the
tank can influence the current output, depending upon the tank being linear or
non-linear (see below).
Linear Tank Example
Note: In the above illustration, 10” of liquid will
always be equal to 100 gallons of liquid (1” = 10
gallons).
Non-Linear Tank Example
Note: In the above illustration, 1” of liquid does not
equal 10 gallons. The 10” at the bottom represents a
rise of 62.8 gallons. As a change between 10” and
20” represents an increase of 109.6 gallons (i.e.
172.4 gallons – 62.8 gallons).
| 14 MN300840 REV A10
Installation Section Three
EchoWave
®
is mounted vertically into the tank via its connection thread. It is then screwed directly into a
standard threaded tank connection, i.e. tank adapter, bushing, weld-in socket, or it can be
screwed into a flange which is connected to a tank nozzle.
Always use metal fittings with the Rod Probe (LG10-0 series) and Cable Probe (LG11-
2 series. The Coaxial Probe (LG10-1 series) can use any type of fitting material.
LG10/LG11 series should not be welded directly into the tank. Neither should flanges be
welded onto the sensor. Welding on the metal parts of EchoWave
®
will cause serious
damage to the transmitter.
®
Do not lift or handle the EchoWave
probe connection. EchoWave
®
should be handled by the hexagon or the lower section of the
by its probe: This will cause excessive stress on the
housing. Do not screw in the sensor by its housing. It should be tightened only via its
hexagon (wrench size 32mm).
The end user has to ensure proper sealing of the sensor connection; based upon process
conditions, i.e. temperature, pressure and resistance against the process liquid’s
atmosphere.
For NPT thread connections, pressure-tight joints require a sealant directly on the threads.
In the case that the LG10/LG11 series is delivered with a detached probe (cable version only), attach the probe
onto the small threaded stud below the hexagon. Make sure to avoid cross threading or misaligning the
threads.
MOUNTING CONSIDERATIONS
The probes should be installed so that they are not directly impacted by liquids flowing out of the filling inlet.
They should neither touch nor sway towards other objects inside the tank or the tank/nozzle walls; e.g. by
agitator or mixer swirls. In
applications with very strong fluid
movements which can also cause
excessive lateral force on the
probe, it is recommended to
anchor the probe. The anchoring
fixtures are end user supplied.
MN300840 REV A10 15 |
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