Flowline XP89 User Manual

Warranty, Service & Repair

RoHS

Compliant

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:

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.

EchoSafe Explosion-Proof

Ultrasonic Level Transmitter Model XP88 / XP89 Owner’s Manual

WARRANTY

Flowline warrants to the original purchaser of its products that such products will be free from defects in material and workmanship under normal use and service for a period which is equal to the shorter of one year from the date of purchase of such products or two years from the date of manufacture of such products.

This warranty covers only those components of the products which 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’s obligation under this warranty is solely and exclusively limited to the repair or replacement, at Flowline’s option, of the products (or components thereof) which Flowline’s examination proves to its satisfaction to be defective. FLOWLINE SHALL HAVE NO OBLIGATION FOR CONSEQUENTIAL DAMAGES TO PERSONAL OR REAL PROPERTY, OR FOR INJURY TO ANY PERSON.

This warranty does not apply to products which have been subject to electrical or chemical damage due to improper use, accident, negligence, abuse or misuse. Abuse shall be assumed when indicated by electrical damage to relays, reed switches or other components. The warranty does not apply to products which are damaged during shipment back to Flowline’s factory or designated service center or are returned without the original casing on the products. Moreover, this warranty becomes immediately null and void if anyone other than service personnel authorized by Flowline attempts to repair the defective products.

Products which are thought to be defective must be shipped prepaid and insured to Flowline’s factory or a designated service center (the identity and address of which will be provided upon request) within 30 days of the discovery of the defect. Such defective products must be accompanied by proof of the date of purchase.

Flowline further reserves the right to unilaterally waive this warranty and to dispose of any product returned to Flowline where:

a. There is evidence of a potentially hazardous material present

with product.

b. The product has remained unclaimed at Flowline for longer than

30 days after dutifully requesting disposition of the product.

THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE OF THIS WARRANTY. This warranty and the obligations and liabilities of Flowline under it are exclusive and instead of, and the original purchaser hereby waives, all other remedies, warranties, guarantees or liabilities, express or implied. EXCLUDED FROM THIS WARRANTY IS THE IMPLIED WARRANTY OF FITNESS OF THE PRODUCTS FOR A PARTICULAR PURPOSE OR USE AND THE IMPLIED WARRANTY OF 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

-40 -20 00 20 40 60 80

Acceptable

Range

Unacceptable

Range

Temperature/Pressure Derating

Operating Pressure (psi)

Temperature ( C)

4.00"

(10.2 cm)

4.44" (11.3 cm)

4.00"

(10.2 cm)

6.06"

15.4 cm

PRELIMINARY XP HOUSING

OVERALL DIMENSIONS

6.06" (15.4 cm)

3.89" (9.9 cm)

2" NPT

DOWN

SELECT

FAST

EchoSafe

™

1/2" NPT

4.00"

(10.2 cm)

6.06"

15.4 cm

PRELIMINARY XP HOUSING

OVERALL DIMENSIONS

DOWN

SELECT

FAST

EchoSafe

™

Range:

Accuracy: Resolution: Beam width: Dead band:

Display type: Display units: Memory: Supply voltage: Loop resistance: Signal output: Signal invert: Calibration: Fail-safe:

Process Temp.:

Temp. comp.: Electronics temp.:

Pressure: Enclosure rating: Enclosure mat.: Window mat.: Transducer mat.: Process mount: Conduit entrance: Compliance: Classification: Approvals:

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

Step One

Side View

Front View

Top View

SAFETY

Step Two

OVERVIEW

Step Three

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 configura-

tion 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 applica-

tions, it is the user’s responsibility to select a sensor model that is

appropriate for the application, install it properly, perform tests of

the installed system, and maintain all components. The failure to do

so could result in property damage or serious injury.

Proper Installation and Handling: Only properly trained

staff should install and/or repair this product. 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, install-

ing, or removing it. Additionally, ensure that electrical wiring,

fittings and mechanical connections conform to all applicable

electrical codes.

A. Application: The explosion proof ultrasonic transmitter pro-

vides 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

XP88-0 24.6’ (7.5 m) 18-28 VDC 2” NPT

XP89-0 32.8’ (10 m) 18-28 VDC 2” NPT

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 environ-

ment.

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

50Khz

012345678910

50%

100%

EchoSafe

™

EchoSafe

™

HEIGHT

(MaxR)

EMPTY

FULL

FILL H

(MinR)

EchoSafe

™

EMPTY

FULL

EchoSafe

™

EchoSafe

™

4 mA

20 mA

4 mA

Step Four

MENU ITEMS

Step Five

A. Supply Voltage: The transmitter power supply voltage should

never exceed a maximum of 28 VDC. Flowline controllers and

meters have built-in 24 VDC power supplies for use with the trans-

mitter. Alternative controllers and/or power supplies with a minimum

output of 18 VDC may also be used with the transmitter for calibra-

tion and/or operation.

XP89-0

Reverse Mode

B. Factory Span: All transmit-

ter models are factory calibrated with

4 mA at their maximum range (tank

empty) and 20 mA at their minimum

range (tank full). The 4 and 20 mA

span set points can be reverse cali-

brated on all models.

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.

A. WARM UP: This is the initial power up mode. When this mes-

sage is displayed, the transmitter is going through its power up rou-

tine, and validating the target value. After a short period of time, this

message will disappear and be replaced by a numeric value.

B. FULL: Level has reached the programmed FULL set point.

C. EMPTY: Level has reached the programmed EMPTY set point

D. UNITS: Selectable in inches centimeters, feet, meter or percent.

The factory default is Inches.

E. INCHES: Inch units of measurement.

F. CM: Centimeters units of measurement.

G. FEET: Feet units of measurement.

H. METERS: Meter units of measurement.

I. PERCNT: 0-100% units of measurement. Percent is the calcu-

lated value based on the 4mA and 20mA set points.

J. TANK: Menu through which the

4-20 mA span is adjusted.

K. HEIGHT: The point in inches,

feet, meters, 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.

Maximum Applied Range De-rating Chart

XP88/89-0

Agitation = 1-3 @ 50 kHz

Vapor = 3-5 @ 50 kHz

L. Fill H (Fill Height): The point

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”.

M. REV mA (Reverse mA): Allows the user to select 20 mA at

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.

O. REV: Sets EchoSafe so 20 mA is at the bottom of the tank and

4 mA at the top.

MENU ITEMS

DOWN

SELECT

FAST

EchoSafe

™

DOWN

SELECT

FAST

EchoSafe

™

Step Six

PROGRAMMING

Step Seven

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.

S. TEST P: Allows the user to view the test parameters of

SEGMENT CHECK, RANGE, ECHO, POWER, VER.

T. SEGMENT CHECK: Tests all LED segments for operation.

U. RANGE: Displays the current inch, centimeter, feet, meter or

Percent measured value.

V. ECHO: Displays the present acoustic signal strength.

W. POWER: Displays the present acoustic power level

X. VER (VERSION): Displays the transmitter software version.

Y. R ALL: Allows the user to reset the transmitter to its original fac-

tory default settings

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.

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.

B. Entering the Program Mode: Press and hold the

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

DOWN button will increase the speed of the display.

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.

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

SELECT

FAST

SELECT

FAST

EchoSafe

™

EchoSafe

™

HEIGHT

(MaxR)

EMPTY

FULL

FILL H

(MinR)

SELECT

FAST

SELECT

FAST

SELECT

FAST

DOWN

0HQX

SELECT

FAST

SELECT

FAST

SELECT

FAST

DOWN

0HQX

Step Eight

Step Nine

C. Programming UNITS: To change UNITS from INCHES to

CM or PERCENT.

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 dis-

play 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.

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.

E. Programming HEIGHT: To change HEIGHT 4 mA value.

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 dis-

play 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.

5. When you have reached the desired value, press SELECT/FAST

to SAVE.

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:

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”.

F. Programming FILL H: To change FILL H 20 mA value.

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 dis-

play 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.

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 the straight wall height).

5. When you have reached the desired value, press SELECT/FAST

to SAVE it.

You have successfully programmed the FILL H or 20mA value.

EchoSafe

™

4 mA

20 mA

SELECT

FAST

SELECT

FAST

SELECT

FAST

0HQX

(;,7

EchoSafe

™

EchoSafe

™

4 mA

20 mA

4 mA

PROGRAMMING

SELECT

FAST

SELECT

FAST

SELECT

FAST

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Step Ten

PROGRAMMING

Step Eleven

G. Programming SAFE Mode: To change SAFE mode.

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..

You have successfully programmed the SAFE mode.

H. Programming REV mA (Optional): In factory default,

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.

Normal mA Mode

(4 mA) set at empty tank

and (20 mA) set at full tank.

Reverse mA Mode

(20 mA) set at empty tank

and (4 mA) set at full tank.

I. Programming REV mA (Mode):

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.

PROGRAMMING

EchoSafe

VACUUM

EchoSafe

Dead Band

Ventilation Hole

Operational Range

Highest Liquid Level

Lowest Liquid Level

3" Minimum Diameter

EchoSafe

Height

Inner Diameter

EchoSafe

(+)

(-)

24 VDC

(FKR6DIH

Step Twelve

Do not install at

angle relative

to the liquid

Do not install

within 3” of

tank side wall

INSTALLATION

Step Thirteen

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.

Do not install

with objects

in the beam

Do not install

in applications

with vacuum

Warning

Flowline Ultrasonic transmitters have been optimized for use in non-metallic fittings. For best performance, avoid the use of metal fittings.

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.

Adapter

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

Flange

of the installed transducer.

2. Flange: Tall flanges with narrow risers

impede the acoustic signal. Select a fit-

Bracket

Riser

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”

ting with the right riser height versus inner

(7.6 cm) in a 2” (5 cm) riser.

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.

Stand Pipe

3. Bracket: The LM50-1001 bracket or equiva-

lent can be used for open tank top installa-

tions against the side wall.

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.

SELECT

FAST

SELECT

FAST

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FAST

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TROUBLESHOOTING

Transmitter

XP88-0

XP89-0

4 mA Setting

26.4 (7.5m)

32.8 (10m)

20 mA Setting

8 (20 cm)

12 (30 cm)

Factory Set Points

Power

Supply

Power

Supply

0 mA

4 mA

456

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Black

Red

EchoSafe

Black

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FAST

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Step Fourteen

A. Viewing Programmed VALUES:

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 dis-

play 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.

TROUBLESHOOTING

Step Fifteen

C. Factory RESET:

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

B. Viewing TEST P:

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 trans-

mitter 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.

2. Verify that the current increas-

es (tank filling) and decreases

(tank emptying) appropriately

in the calibrated span.

3. If not, carefully observe and

attempt to correlate any instal-

lation, level or application event

for more specific troubleshoot-

ing.

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.

Flowline XP89 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual