Flowline UG06, UG12 Operating Manual
EchoPod®
Ultrasonic Level Transmitter
UG06 & UG12 Series Manual
Flowline, Inc. | 10500 Humbolt Street, Los Alamitos, CA 90720 p 562.598.3015 f 562.431.8507 w flowline.com MN310140 Rev A5
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 push button or WebCal
®
software configuration
Increased temperature range
Increased output filtering
TABLE OF CONTENTS
Introduction: ...................................................................................................................................................... 2
Specifications: ........................................................................................................................................... 4
Dimensions: .............................................................................................................................................. 5
Reflective Technology: .............................................................................................................................. 6
About this manual: .................................................................................................................................... 7
Getting Started: ..................................................................................................................................................... 8
Setup Overview: ........................................................................................................................................ 8
Components: ............................................................................................................................................. 9
WebCal
®
vs. Display Configuration: ........................................................................................................ 10
Understanding Sensor Height (Height): .................................................................................................. 11
Understanding Fill-Height (Fill-H): ...................................................................................................... 12-13
Sensor Output to Local Display: ............................................................................................................. 14
Configuration (with WebCal
Step 1 – Install WebCal
WebCal
®
): ............................................................................................................................ 15
®
Software: ......................................................................................................... 16
®
System Requirements: ................................................................................................ 16
USB Fob Interface: ...................................................................................................................... 17
Step 2 – Measure the Tank: .................................................................................................................... 18
Step 3 – Sensor Configuration: ............................................................................................................... 19
Step 4 – Dimensional Entry: ................................................................................................................... 20
Step 5 – Tank Level Confirmation: .......................................................................................................... 21
Step 6 – Write to Unit: ............................................................................................................................. 21
Configuration
(
with Display): ................................................................................................................................ 22
Step1 – Measure Tank: ........................................................................................................................... 23
Step 2 – Setting the Units of Measurement: ........................................................................................... 24
Step 3 – Setting the Height: .................................................................................................................... 25
Step 4 – Setting the Fill-H: ...................................................................................................................... 26
Step 5 – Setting the Fail-Safe Current Output: ....................................................................................... 27
Installation: .......................................................................................................................................................... 28
Mounting Guide: ...................................................................................................................................... 28
Fitting Selection: ................................................................................................................................ 29-31
| 2 MN310140 Rev A5
Introduction / Table of Contents Step One
Wiring: ................................................................................................................................................................ 32
Wiring Diagram – Sample: ...................................................................................................................... 32
Wiring EchoPod
Wire Connections: ................................................................................................................................... 33
General Notes for Electrical Connections, Usage and Safety: ............................................................... 33
Analog Output: ........................................................................................................................................ 34
Common Wiring to Displays, Controllers & PLCs: ............................................................................. 35-36
Voltage Output: ....................................................................................................................................... 37
WebCal
®
Appendix: ............................................................................................................................................ 38
Sensor Configuration: ........................................................................................................................ 38-39
Volumetric Configuration: ................................................................................................................... 40-42
Tank Level Confirmation: ........................................................................................................................ 43
“Write to Unit” .......................................................................................................................................... 44
Display Appendix: ............................................................................................................................................... 45
Air Gap vs. Liquid Level: ......................................................................................................................... 45
How to reverse the current output (Rev mA): ......................................................................................... 46
How to Setup to Start-up Power: ............................................................................................................ 47
Values Menu: .......................................................................................................................................... 48
SETUP: ....................................................................................................................................... 48
Diagnostic (DIAG) parameters: ................................................................................................... 48
Reset: .......................................................................................................................................... 49
Appendix: ............................................................................................................................................................ 50
Factory Settings: ..................................................................................................................................... 50
User Settings: ......................................................................................................................................... 50
Troubleshooting: ..................................................................................................................................... 51
Warranty: ............................................................................................................................................................ 52
®
: .................................................................................................................................... 32
MN310140 Rev A5 3 |
Introduction (continued) Step One
SPECIFICATIONS
Electrical:
Supply Voltage: 14-28 Vdc
Signal: 4 to 20 mA current loop; 22 mA
max.
Mechanical:
Display Module: Removable via short cable and
plug
LCD: 6 characters, 10 mm (0.394”)
height
Buttons: Three, UP / OK / DN
Pin Connection: Display can be removed such
that the open connection allows
the sensor to be WebCal
®
capable.
Enclosure: Polypropylene head with skirt to
Environmental:
Temperature: -40 to 80 °C (-40 to 176 °F)
Pressure: 30 psi (2 bar)
Enclosure: IP68
Functional:
Range: UG06: 6.0m (19.69 feet)
UG12: 12.0m (39.4 feet)
Dead band: UG06: 20cm (8 inches)
UG12: 45.7cm (18 inches)
Accuracy: 0.2% of Range in air at 20 °C
Resolution: UG06: 2mm (0.079 inches)
UG12: 5mm (0..196 inches)
Beam width: UG06: 7.6cm (3 inches)
UG12: 15.2cm (6 inches)
Menu: Self-scrolling
support transducer w/ conduit
Conduit Connection: Single, 1/2 inch NPT
Transducer: Black, PVDF with Viton A
gasket
Process Mount: UG06: 2" NPT or 2” G
UG12: 3” NPT or 3” G
Gasket Viton A (G thread only)
Electrical Connections:
Power & Return: 2-pin quick connect terminal
block
WebCal Connect.: 2-pin quick connect terminal
block
Display Connect.: 5-pin plug & socket
| 4 MN310140 Rev A5
Introduction (continued) Step One
DIMENSIONS
Dimensions for UG06 Series
Dimensions for UG12 Series
MN310140 Rev A5 5 |
Introduction (continued) Step One
REFLECTIVE TECHNOLOGY
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
| 6 MN310140 Rev A5
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 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 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). 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.
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 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 “G” threaded versions of EchoPod®.
Warning: Make sure that all electrical wiring of the switch is in accordance with applicable codes.
MN310140 Rev A5 7 |
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. Configure Sensor with Push Button (Section Four)
a. Section 4 contains information on using the Push Button Display to configure the sensor.
5. Install the sensor (Section Five)
a. Section 5 contains information about the sensor location placement and its mechanical
installation.
6. Wire the sensor (Section Six)
a. Section 6 contains information about the sensor’s electrical wiring and power requirements.
Note: When configuring EchoPod
accomplish the goal of sensor configuration. Changes to the configuration can be made using the alternative
method. When beginning with one method, it is recommended to complete the configuration before using the
other method to make any adjustments.
®
software from www.flowline.com/webcal-software/.
®
(Section Three)
®
, choose either the WebCal® or Push Button method. Either method will
®
configuration software.
| 8 MN310140 Rev A5
Getting Started (continued) Section Two
COMPONENTS
EchoPod® is offered in different models. 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
®
installation and operation of EchoPod
P/N
Max.
Range
Dead
Band
UG06-0001-00
.
Thread Fob Output Configuration
Not Included
®
gasket for
2” NPT
UG06-0001-01 Included
UG06-0011-00
UG06-0011-01 Included
UG12-0001-00
UG12-0001-01 Included
UG12-0011-00
19.7’
(6m)
39.4’
(12m)
8”
(20cm)
18”
(45.7cm)
2” G
3” NPT
Not Included
Not Included
Not Included
4-20 mA
Display
with
Push Button
or
®
WebCal
3” G
UG12-0011-01 Included
Viton Gasket (G threaded version only)
o Part # 200129 – (UG06-0011-0_ only)
o Part # 210157 – (UG12-0011-0_ only)
Liquid Tight Fitting
o Part # LM90-1001
o Note: If using the Liquid Tight Fitting on
the ½” conduit, the cable minimum is
0.170” (4.3mm) and the maximum is
0.450” (11.4mm).
Quick Start Guide
MN310140 Rev A5 9 |
Getting Started (continued) Step Two
WEBCAL® VS. DISPLAY CONFIGURATION
EchoPod® can be configured using either the free WebCal® software and USB® Fob or with the internal display
module. Either method will accomplish the goal of sensor configuration. Changes to the configuration can be
made using the alternative method. Upon implementing one methodology, it is recommended to complete the
configuration before using the other methodology in making any adjustments.
EchoPod
®
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.
| 10 MN310140 Rev A5
Getting Started (continued) Step Two
UNDERSTANDING SENSOR HEIGHT (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
MN310140 Rev A5 11 |
Getting Started (continued) Step Two
UNDERSTANDING FILL-HEIGHT (FILL-H)
This is another critical setting for EchoPod®. FILL-H (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-H, the sensor will read full
(as long as the level does not enter the dead band). The reference point for definition of FILL-H 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-H can be calculated by subtracting
the Dead Band from the Sensor Height.
FILL-H = 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-H 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-H 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-H cannot be set to match the
straight side of the tank. Calculate FILL-H as
follows:
FILL-H = Sensor Height – Dead Band
Example #3 – Horizontal Tanks
Tank E is a horizontal tank with a rounded top.
The highest value for FILL-H can be calculated by
subtracting the Dead Band from the Sensor
Height.
FILL-H = 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-H 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.
| 12 MN310140 Rev A5
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-H setting.
Note: FILL-H 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.
HEIGHT is set to the bottom
of the tank; the sensor will
function as long as the level
is within the straight side of
Distance
Reading
HEIGHT is typically set to
the bottom of the tank.
Sensor will track the full
range of the tank.
HEIGHT is typically set to
the bottom of the straight
side. Sensor will only tack
the straight side of the tank.
the tank.
MN310140 Rev A5 13 |
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.
Tank B
Tank C
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.
| 14 MN310140 Rev A5
Configuration Using WebCal® 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. Correct tank dimensions will result in accurate sensor measurement.
3. Sensor Configuration
a. Configures Loop Fail-Safe, Output at Empty & Startup Condition for the sensor.
4. Dimensional Entry
a. Distance Mode (default)
i. Basic information for operation (Sensor Height & Fill-Height).
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.
Note: When configuring EchoPod
®
, choose either the WebCal® or Push Button method. Either
method will accomplish the goal of sensor configuration. Changes to the configuration can be
made using the alternative method. When beginning with one method, it is recommended to
complete the configuration before using the other method to make any adjustments.
MN310140 Rev A5 15 |
Configuration Using WebCal
STEP 1 – INSTALL WEBCAL® SOFTWARE
®
(continued) Step Three
EchoPod® 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 (LI99-
2001). Please go to .flowline.com/webcal-software/, and select your language version.
WEBCAL® SYSTEM REQUIREMENTS
Windows® XP, Vista, 7, 8, 10
32 or 64-bit system
1 USB
®
2.0 port
10 mB hard drive space
256 mB RAM
Internet connection
*
For complete information on the WebCal
®
software, please refer to the WebCal® manual located at
www.flowline.com/webcal-software/.
| 16 MN310140 Rev A5
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