Flowline UG01, UG03 Operating Manual
EchoPod®
Ultrasonic Level Transmitter
UG01 & UG03 Series Manual
Flowline, Inc. | 10500 Humbolt Street, Los Alamitos, CA 90720 p 562.598.3015 f 562.431.8507 w flowline.com MN310125 Rev A3
Introduction / Table of Contents Step One
An ultrasonic sound wave is pulsed from the base of the transducer. The sound wave reflects against the
process medium below it. The sound wave energy is returned to the transducer. The microprocessor based
electronics measures the time of flight between the sound pulse generation and its receipt. This translates into
the distance or range between the transducer and process media below.
NEW FEATURES
Reflective Ultrasonic Technology
Simple configuration with WebCal
®
software configuration
Increased temperature range
Increased output filtering
TABLE OF CONTENTS
Introduction: .......................................................................................................................................................... 2
Specifications: ........................................................................................................................................... 4
Dimensions: .............................................................................................................................................. 5
About this manual: .................................................................................................................................... 6
Getting Started: ..................................................................................................................................................... 7
Setup Overview: ........................................................................................................................................ 7
Reflective Technology: .............................................................................................................................. 7
Components: ............................................................................................................................................. 8
Basic Configuration: .................................................................................................................................. 9
Basic Relay Settings: ................................................................................................................................ 9
Understanding Sensor Height: ................................................................................................................ 10
Understanding Fill-Height: ................................................................................................................. 11-12
Sensor Output to Local Display: ............................................................................................................. 13
Configuration: .................................................................................................................................................... 14
Configuring EchoPod
®
with WebCal: ...................................................................................................... 14
Step 1 – Install WebCal Software: .......................................................................................................... 15
WebCal System Requirements: .................................................................................................. 15
USB
®
Fob (LI99-2001) Interface: ................................................................................................ 16
Step 2 – Measure the Tank: .................................................................................................................... 17
Step 3 – Sensor Configuration: ............................................................................................................... 18
Step 4 – Dimensional Entry: ................................................................................................................... 19
Step 5 – Tank Level Confirmation: .......................................................................................................... 20
Step 6 – Write to Unit: ............................................................................................................................. 20
Installation: .......................................................................................................................................................... 21
Mounting Guide: ...................................................................................................................................... 21
Fitting Selection: ................................................................................................................................ 22-24
| 2 MN310125 Rev A3
Introduction / Table of Contents Step One
Wiring: ................................................................................................................................................................. 25
Wiring Diagram – Sample: ...................................................................................................................... 25
Wiring EchoPod
Wire Connections: ................................................................................................................................... 26
General Notes for Electrical Connections, Usage and Safety: ............................................................... 26
Common Wiring to Displays, Controllers & PLCs: ............................................................................. 27-28
Switching Inductive Loads: ..................................................................................................................... 29
Voltage Output: ....................................................................................................................................... 29
WebCal
®
Appendix: ............................................................................................................................................ 30
Sensor Configuration: ........................................................................................................................ 30-36
Number of Pumps: ...................................................................................................................... 30
Pump/Valve Action: ..................................................................................................................... 31
Pump/Valve Mode: ...................................................................................................................... 32
Relay Fail-Safe: ........................................................................................................................... 33
Switch/Alarm Configuration: ........................................................................................................ 34
Switch Hysteresis/Dead Band: .................................................................................................... 35
Loop Fail-Safe: ............................................................................................................................ 36
Output at Empty: ......................................................................................................................... 36
Volumetric Configuration: ................................................................................................................... 37-39
Tank Level Confirmation: ........................................................................................................................ 40
Write to Unit” ........................................................................................................................................... 41
Appendix: ............................................................................................................................................................ 42
Factory Settings: ..................................................................................................................................... 42
User Settings: ......................................................................................................................................... 42
Troubleshooting: ..................................................................................................................................... 43
Warranty: ............................................................................................................................................................ 44
®
..................................................................................................................................... 25
MN310125 Rev A3 3 |
Introduction (continued) Step One
SPECIFICATIONS
Electrical:
Supply Voltage: 14-28 Vdc
Signal output: 4 to 20 mA current loop; 22 mA
max.
Signal invert: 4-20mA or 20-4mA
Signal fail-safe: 4mA, 20mA, 21mA, 22mA or
hold last value
Loop resistance: 500 Ohms @ 24 VDC
Contact type: (4) SPST relays, 1A
Contact fail-safe: Power loss: Hold last
Power on: Open, close or hold
last
Hysteresis: Selectable
Mechanical:
Enclosure: Polypropylene (PP-FR GF30)
Transducer: Polyvinylidene Fluoride (PVDF)
Environmental:
Process temperature: F: -40° to 176°
C: -40° to 80°
Temp. compensation: Automatic
Ambient temp.: F: -31° to 140°
C: -35° to 60°
Pressure: 30 psi, derated @ 1.667 psi per
degree C above 25 °C
Enclosure: IP68, NEMA 6P
Functional:
Range: UG01: 1.5m (4.92 feet)
UG03: 3.0m (9.84 feet)
Dead band: UG01: 3.8cm (1.5 inches)
UG03: 10cm (4 inches)
Accuracy: UG01: 0.125” (3mm)
UG03: 0.2% of Range in air at
Cable jacket mat’l: Polyurethane
Cable type: 9-conductor
Cable length: 4’ (121.9 cm)
Process Mount: 2" NPT or 2” G
Gasket Viton A (G thread only)
Resolution: 0.125" (3mm)
Beam width: 2” (5cm)
Configuration: WebCal
Memory: Non-volatile
Classification: General purpose
Compliance: CE, RoHS
20 °C
®
configuration software
| 4 MN310125 Rev A3
Introduction (continued) Step One
DIMENSIONS
Dimensions for UG01 & UG03 Series
Cable Dimensions for UG01 & UG03 Series
MN310125 Rev A3 5 |
Introduction (continued) Step One
About this Manual: PLEASE READ THE ENTIRE MANUAL PRIOR TO INSTALLING OR USING THIS
PRODUCT. This manual includes information on the EchoPod
®
series Ultrasonic Level Transmitter from
FLOWLINE. Please refer to the part number located on the sensor 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 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 14 to 28 VDC is used to power the EchoPod®. 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 Polypropylene (PP-FR GF30). 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 sensor housing is liquid-resistant the EchoPod® 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.
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.
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 redundant backup systems and alarms in addition to the
primary system.
Flammable, Explosive or Hazardous Applications:
EchoPod® should not be used within classified hazardous environments.
Warning: Always use the Viton® gasket when installing the “G” threaded version of EchoPod®.
Warning: Make sure that all electrical wiring of the switch is in accordance with applicable NEC codes.
| 6 MN310125 Rev A3
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. Measurements, Installation & Software (Section Two)
a. Understand the location placement of the sensor relative to Measurement Range including
Sensor Height and Fill-Height settings.
b. Download the WebCal
3. Configure Sensor with WebCal
a. Section 3 contains information on using the WebCal
4. Install the sensor (Section Four)
a. Section 4 contains information about the sensor location placement and its mechanical
installation.
5. Wire the sensor (Section Five)
a. Section 5 contains information about the sensor’s electrical wiring and power requirements.
REFLECTIVE TECHNOLOGY
®
software from www.flowline.com/webcal-software/.
®
(Section Three)
®
configuration software.
Condensation is the most common variable in liquid level applications. Condensation attenuates the acoustic
signal of ultrasonic sensors with horizontal transducers, weakening their signal strength and signal to noise
ratio by up to 50%, and substantially reducing their measurement reliability. At the core of Reflective
Technology™ is a simple fact. Unlike flat horizontal surfaces, significant water droplets cannot adhere to
smooth vertical surfaces. By orienting the transducer vertically, condensation runs off the transducer and does
not affect sensor performance. The unimpeded transmit and receive signals are redirected to and from the
liquid off a 45º reflector, delivering reliable level measurement.
FLAT TRANSDUCER REFLECTIVE TRANSDUCER
Signal Attenuation Reliable Measurement
MN310125 Rev A3 7 |
Getting Started (continued) Section Two
COMPONENTS
EchoPod® is offered in two different models with 4-20 mA output and relay control. Depending on the model
purchased, you may or may not have been shipped all the components shown below. All G threaded process
mounts require a Viton
®
gasket for installation and operation of EchoPod®.
P/N
UG03-0001-40
Max.
Range
Dead
Band
Thread Fob Output Configuration
Not Included
2” NPT
UG03-0001-41 Included
UG03-0011-40
9.8’
(3m)
4”
(10cm)
Not Included
2” G
UG03-0011-41 Included
UG01-0001-40
Not Included
2” NPT
UG01-0001-41 Included
UG01-0011-40
4.9’
(1.5m)
1.5”
(3.81cm)
Not Included
2” G
UG01-0011-41 Included
®
Viton
Gasket (G threaded version only)
o Part #210138
Fob (UG0_-00_1-41 series only)
o Part #LI99-2001
Quick Start Guide
4-20mA
&
4 SPST
Relays
WebCal
®
only
| 8 MN310125 Rev A3
Getting Started (continued) Step Two
BASIC CONFIGURATION
EchoPod® can be configured using the Flowline™ on-line free WebCal® software download coupled to a USB®
port with a USB
EchoPod
®
®
Fob.
can be configured before installation or after installation. The transmitter features non-volatile
memory, so any settings configured before installation will not be lost when the sensor is powered down To
start, the following information is required:
Basic Tank Information
o HEIGHT (Sensor Height) – Distance from
the bottom of the tank to the bottom of the
sensor.
o FILL-H (Fill-Height) – Distance from the
bottom of the tank to the fill-height of the
liquid.
Power:
o Provide input power to the EchoPod
®
Note: The HEIGHT and Fill-Height (FILL-H) settings also determine the 4 to 20 mA current span. The
HEIGHT setting determines the 4mA position and the FILL-H setting determines the 20 mA position.
BASIC RELAY SETTINGS
High Alarms (Hi) – Used to energize a relay
(ON) when the level reaches the Hi setting.
Relay will de-energize (OFF) when level falls
below the original setting.
Tank Fill (ON & OFF) – Used to automatically
fill a tank using only one relay. Relay
energize at ON level and remains energized
until it reaches the OFF level where it deenergizes. Relay remains de-energized until
the level falls below ON level.
Tank Empty (not shown) – is the exact
opposite of Tank Fill. One relay is used to
empty the tank with ON set to a high point in
the tank and OFF set to a low point.
Lo Alarms (Lo) – Used to energize a relay (ON) when the level falls below the Lo setting. Relay will
de-energize (OFF) when level rises above the original setting.
Note: All relay settings are referenced from the Empty or 4mA setting of the tank.
MN310125 Rev A3 9 |
Getting Started (continued) Step Two
UNDERSTANDING SENSOR HEIGHT
This is a critical setting for EchoPod®. Sensor Height (SH) defines the location of the sensor from the bottom
of the tank. The 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.
Sensor Off-center
Simple Vertical Tank Dome Top Raises HEIGHT
Changes HEIGHT
Simple Open Top Tank Sensor Extends into Sump
Simple Horizontal Tank Riser Elevates HEIGHT
Cone Bottom
Elevates HEIGHT
Mounting Fixture
Elevates HEIGHT
| 10 MN310125 Rev A3
Getting Started (continued) Step Two
UNDERSTANDING FILL-HEIGHT
This is another critical setting for EchoPod®. Fill-Height defines the location of the highest point in the tank
where the sensor will read level changes. When the level rises above Fill-Height, the sensor will read full (as
long as the level does not enter the dead band). The reference point for definition of Fill-Height is always from
the bottom location of the Sensor Height. The value must take into account the sensors dead band, any risers,
fittings, structures or extensions associated with the tank or the installation as well as the tanks geometry.
Example #1 – Flat Top Tanks
Tank A is a vertical tank with a flat top. The
highest value for Fill-Height can be calculated by
subtracting the Dead Band from the Sensor Height.
Fill-Height = Sensor Height – Dead Band
Tank B is another vertical tank with a riser that
matches the dead band of the sensor. In this case,
the Fill-Height will be set to the top of the tank.
Note: The ratio of height to diameter of the riser
must be no greater than 2:1. Any higher and the
sensor will target the inside wall of the riser.
Example #2 – Dome Top Tanks
Tank C has a tall enough dome whereas the Dead
Band is above the straight side of the tank. The
Fill-Height can be set to the top of the straight side
(this is advantageous because the top of the
straight side is typically a known volume of liquid).
The sensor is moved to a flat part of Tank D. As a
result, the Dead Band is now below the straight
side of the tank. Fill-Height cannot be set to match
the straight side of the tank. Calculate Fill-Height
as follows:
Fill-Height = Sensor Height – Dead Band
Example #3 – Horizontal Tanks
Tank E is a horizontal tank with a rounded top.
The highest value for Fill-Height can be calculated
by subtracting the Dead Band from the Sensor
Height.
Fill-Height = Sensor Height – Dead Band
Tank F is another horizontal tank with a riser that
matches the dead band of the sensor. In this case,
the Fill-Height will be set to the top of the tank.
Note: The ratio of height to diameter of the riser
must be no greater than 2:1. Any higher and the
sensor will target the inside wall of the riser.
MN310125 Rev A3 11 |
Getting Started (continued) Step Two
Example #4 – Cone Bottom Tank
Tank G and Tank H are both vertical tanks that are
being supported above ground level with tank
stands. The location of the Sensor Height (Tank G
- bottom of tank or Tank H – ground level) will
influence the Fill-Height setting.
Note: Fill-Height must always be referenced to the
lowest location of the Sensor Height.
Since Tank G is off of the ground, the lowest
location may be difficult to identify/measure. This
location is required if the Volumetric Mode in
WebCal
Tank H uses ground level as the main reference
location. This method is easiest to use and ideal
for using the Distance Mode of WebCal
®
is used.
®
.
Cone and Rounded Bottom Tanks
The location of an EchoPod
®
installed along the top of a cone or rounded bottom tank may have an effect on
the installation of the sensor. Be sure to understand the geometry directly underneath the sensor. Cone or
rounded bottom tanks will provide off angled surfaces that can reflect the ultrasonic sound energy away from
the sensor as the liquid level is lowered.
#1 Center of Cone #2 Above an Angled Tank
Bottom (straight side only)
#3 Above an Angled Tank
Bottom (full range)
Tank
Geometry
Does not impede sensor’s
performance. Sensor is able
to track the entire range of
the tank.
Does not impede sensor’s
performance as long as the
level remains within the
straight side of the tank wall.
Does impede sensor’s
performance. The angled
bottom will reflect ultrasonic
energy away from the
sensor.
Distance
Reading
Sensor Height is typically
set to the bottom of the tank.
Sensor will track the full
range of the tank.
Sensor Height is typically
set to the bottom of the
straight side. Sensor will
only tack the straight side of
the tank.
Sensor Height is set to the
bottom of the tank; the
sensor will function as long
as the level is within the
straight side of the tank.
| 12 MN310125 Rev A3
Getting Started (continued) Step Two
SENSOR OUTPUT TO LOCAL DISPLAY/CONTROLLER
EchoPod® outputs a 4-20 mA signal to a local display/controller or to remote devices such as PLCs, SCADA,
DCS or other displays/controllers. The 4-20 mA signal is set relative to the Sensor Height and Fill-Height
settings. These settings create an operational range that can be translated into a level reading in defined units
(i.e. inches, feet, gallons, meters, liters, etc.).
Tank A
In the Tank A example, the Sensor Height sets the 4mA to the bottom of the tank. Fill-Height sets the 20mA to
the top of the straight side of the tank.
In the Tank B example, the 4-20mA sensor range is correlated to actual units of level measurement. The
operational range now will have engineering values of 0 to 10 feet or 0 to 1000 gallons or 0 to 120 inches.
In the Tank C example, the 20mA setting was lowered by 1 foot, so the engineering values for the new shorter
operational ranges are either 0 to 9 feet, 0 to 900 gallons or 0 to 108 inches.
Tank B
Tank C
MN310125 Rev A3 13 |
Configuration Step Three
EchoPod
®
can be configured before installation. The transmitter features non-volatile memory, so any setting
configured before installation will not be lost when the switch is powered down. To configure, follow the steps
below:
1. Install WebCal
a. Go to www.flowline.com/webCal-software/
b. Review how USB
®
software
®
and select language version.
Fob interfaces with EchoPod® and your computer.
2. Measure the Tank
a. Begin by measuring the key tank and fitting dimensions.
b. Include all settings for each relay.
c. Correct tank dimensions will result in accurate sensor measurement.
3. Sensor Configuration
a. Configures Number of Pumps, Pump/Valve Action, Pump/Valve Mode, Relay Fail-Safe,
Switch/Alarm Configuration, Switch Hysteresis/Dead Band, Loop Fail-Safe & Output at Empty for
the sensor.
4. Dimensional Entry
a. Distance Mode (default)
i. Basic information for operation (Sensor Height & Fill-Height).
ii. Relay activation settings.
5. Tank Level Confirmation
a. Confirm the values are accurate for the application.
6. Write to Unit
a. Uploads configuration into the sensor.
b. Access to a customer wiring diagram specific to the relay configuration.
| 14 MN310125 Rev A3
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