APG LPU-2428 User manual

APG
R
Doc #9002999
Rev B1, 04/15
LPU-2428 & RST-4001
User Manual

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Table of Contents
Introduction ................................................................................................................ iii
Warranty and Warranty Restrictions.................................................................... iv
Chapter 1: Specications and Options..................................................................... 1
Dimensions ........................................................................................................................................1
Specications ................................................................................................................................... 2
Chapter 2: Installation and Removal Procedures and Notes..............................3
Tools Needed..................................................................................................................................... 3
Installation Notes ............................................................................................................................ 3
Mounting Instructions ................................................................................................................... 4
Electrical Installation ..................................................................................................................... 4
Software Installation....................................................................................................................... 5
Removal Instructions ..................................................................................................................... 5
Chapter 3: Maintenance .............................................................................................5
General Care...................................................................................................................................... 5
Troubleshooting............................................................................................................................... 6
Calibration ..................................................................................................................................... 6-7
Repair and Returns.......................................................................................................................... 7
Chapter 4: Programming and Parameter Conguration .....................................7
RST-4001 User Interface................................................................................................................. 7
RST-4001 Menu Navigation ...................................................................................................... 8-11
Software User Interface................................................................................................................ 12
Programming the LPU-2428........................................................................................................ 13
Basic Setup Menu (BASICSET) ..............................................................................................14-15
App. Setup Menu (APPLICAT)................................................................................................16-34
4-20 Setup Menu (4-20 SET).................................................................................................. 34-36
Calibration (CALIBRAT).......................................................................................................... 36-37
Advanced (ADVANCED) .......................................................................................................... 37-39
Utilities (UTILITIE)..................................................................................................................39-40
Totalization (TOTALIZE)............................................................................................................... 41
Chapter 5: Hazardous Location Drawing and Certication ..............................42
Intrinsically Safe Wiring Diagram .............................................................................................42
Hazardous Location Wiring Diagram ........................................................................................43
CSA Certicate of Compliance..............................................................................................44-47
IMPORTANT: The LPU-2428 software will only operate in a 32-bit Windows environ-
ment. It WILL NOT operate on a 64-bit Windows machine.

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Introduction
Thank you for purchasing an LPU-2428 ultrasonic sensor and RST-4001 programming module from APG. We
appreciate your business! Please take a few minutes to familiarize yourself with your LPU-2428, RST-4001,
and this manual.
The LPU-2428 loop-powered ultrasonic sensor provides a low-power, non-contact level measurement
solution rated for hazardous locations and suitable for harsh chemical environments. The RST-4001 oers
a two-line by eight-character LCD display and ve-button keypad or USB connection for programming your
sensor.
The default Application setting for the LPU-2428 is Distance, which will work in a wide variety of settings. The
LPU-2428 has several additional Application settings that can be congured to meet your needs.
Reading your label
Every APG instrument comes with a label that includes the instrument’s model number, part number, serial
number, and a wiring pinout table. Please ensure that the part number and pinout table on your label
match your order. The following electrical ratings and approvals are also listed on the label. Please refer to
the Certicate of Compliance at the back of this manual for further details.
IMPORTANT: Your LPU-2428 MUST be installed according to drawing 9002747 as
indicated above to meet Instrinsically Safe approvals. Faulty installation will invalidate all
safety approvals and ratings.
Electrical ratings
Input: 12 to 28 Volts DC; Output: 4-20mA
Class I Division 1; Groups C, D T3
Class I, Zone 0, Group IIB
AEx ia IIB T3 (USA): Ta: -40°C to 60°C; IP65
Ex ia IIB T3 (Canada): Ta: -40°C to 60°C; IP65
Vmax Ui= 28VDC, Imax Ii = 130mA, Pmax Pi= 0.91W, Ci= 0nF, Li = 110μH
Install in accordance with drawing 9002747 (page 42).
Input: 12 to 28 Volts DC; Output: 4-20mA
Class I Division 2; Groups C, D T6
Class I, Zone 2, Group IIB
AEx nA IIB T6: Ta: -40°C to 60°C; IP65
Ex nA IIB T6: Ta: -40°C to +60°C; IP65
Install in accordance with drawing 9002745 (page 43).

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Warranty and Warranty Restrictions
APG warrants its products to be free from defects of material and workmanship and will, without charge,
replace or repair any equipment found defective upon inspection at its factory, provided the equipment has
been returned, transportation prepaid, within 24 months from date of shipment from factory.
THE FOREGOING WARRANTY IS IN LIEU OF AND EXCLUDES ALL OTHER WARRANTIES NOT EXPRESSLY SET
FORTH HEREIN, WHETHER EXPRESSED OR IMPLIED BY OPERATION OF LAW OR OTHERWISE INCLUDING
BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE.
No representation or warranty, express or implied, made by any sales representative, distributor, or other
agent or representative of APG which is not specically set forth herein shall be binding upon APG. APG shall
not be liable for any incidental or consequential damages, losses or expenses directly or indirectly arising
from the sale, handling, improper application or use of the goods or from any other cause relating thereto
and APG’s liability hereunder, in any case, is expressly limited to the repair or replacement (at APG’s option)
of goods.
Warranty is specically at the factory. Any on site service will be provided at the sole expense of the
Purchaser at standard eld service rates.
All associated equipment must be protected by properly rated electronic/electrical protection devices. APG
shall not be liable for any damage due to improper engineering or installation by the Purchaser or third
parties. Proper installation, operation and maintenance of the product becomes the responsibility of the
user upon receipt of the product.
Returns and allowances must be authorized by APG in advance. APG will assign a Return Material
Authorization (RMA) number which must appear on all related papers and the outside of the shipping
carton. All returns are subject to the nal review by APG. Returns are subject to restocking charges as
determined by APG’s “Credit Return Policy”.

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Chapter 1: Specications and Options
• Dimensions
5.06
[128.59 mm]
ø2.79
[70.78mm]
2.65
[67.24mm]
2" NPT
THREADS
ø2.00
[50.80 mm]
7.25
[184.15 mm]
3/4" NPT
THREADS
NON-METALLIC
STRAIN RELIEF

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Performance
Operating Range 1 - 25 ft. (0.3 - 7.6 m) on liquids and hard, at surfaces
1 - 10 ft. (0.3 - 3 m) on bulk solids
Analog Output (Sensor) 4-20 mA
Analog Output (Module) USB
Beam Pattern 9° o axis
Frequency 69 kHz
Response Time 0.6 - 3 seconds (dependent on output range)
Sample Rate 3 seconds @ 4 mA
0.6 seconds @ 20 mA
Accuracy
Accuracy ±0.25% of detected range
Resolution 0.1 inch (2.54 mm)
Environmental
Operating Temperature -40 to 60°C (-40 to 140°F)
Internal Temperature Compensation Yes
Enclosure Protection IP65
NEMA rating (Sensor) 4X
Electrical
Supply Voltage (at sensor) 12-28 VDC
Current Draw 22 mA max
Output Signal 3-30 mA max
Load Resistence 150Ω max @ 12 VDC
600Ω max @ 24 VDC
Cable Connection (Sensor) 2-wire cable included
Cable Connection (Module) 2-terminal Pheonix connector, USB
Masterials of Construction
Transducer Housing PVDF (Kynar®)
Upper Housing (Sensor) PC/PBT
Housing (Module) ABS PA-756
• Specications

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Chapter 2: Installation and Removal Procedures and Notes
Tools are not necessary for installing the LPU itself. If you are using a stand pipe to mount your LPU, you will
probably need tools to install the stand pipe, but not for the LPU.
• Tools Needed
• Installation Notes
• Mount your LPU sensor so that it has a clear, perpendicular sound path to the surface being moni-
tored. Your sensor should be mounted away from tank or vessel walls and inlets. See Figure 2.1.
• The sound path should be free from obstructions and as open as possible for the 9° o axis beam
pattern.
• If you are using a stand pipe, please see our guide to stand pipes on our website:
http://www.apgsensors.com/about-us/blog/how-to-install-a-stand-pipe.
Figure 2.1
NOTE: Do not mount the sensor where the beam will intersect objects such as ll
streams, pipes, ladder rungs, wall seams, or corrugated tank walls.

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• Mounting Instructions
For normal operation, connect the provided cable to your control system:
• Connect the red wire to +24 VDC.
• Connect the black wire to 4-20 mA input. Circuit load resistance + input resistence must be greater
than 150Ω. 249Ω is recommended for optimal signal tranmission.
• Refer to drawing 9002747 (page 42) for Intrinsically Safe installation.
• Refer to drawing 9002745 (page 43) for hazardous location installation.
For programming:
• Connect (+) terminal of RST-4001 to +24 VDC supply of sensor (red wire).
• Connect (-) terminal of RST-4001 to 4-20 mA signal from sensor (black wire).
• Ensure that load resistor is between RST-4001 and control network or PLC, rather than between sensor
and RST-4001. (See Figure 2.2)
• Electrical Installation
Mounting your LPU is easy if you follow a few simple steps:
• Never over-tighten the sensor.
• Always screw in your sensor by hand to avoid cross-threading. Thread failure can be a problem if you
damage threads by over-tightening them or by crossing threads.
IMPORTANT: Do not over tighten! The sensor should be threaded in only hand tight.
Figure 2.2
4.25
COM
Power Supply
(24Vdc)
+-
+24vdc
4 to 20ma Out
I/0
Load Resistor
APG
Ammeter
4-20ma
IS
Barrier
USB Cable
mA
Computer
Terminal Strip
(Provided)

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• Download the software zip le from http://apgsensors.com/support.
• Open the zip le.
• Choose “Install” from the options at the top of the zip le window.
• The installation process will prompt you as needed to complete the installation.
• The software will create and run from a folder in your start menu titled “APG”.
• Software Installation
• Ensure that power to the sensor is o.
• Disconnect the cable from the sensor.
• Remove the sensor and store it in a dry place, at a temperature between -40° F and 180° F.
• If the sensor was installed in a hazardous location, ensure that the cable will not be energized while the
sensor is disconnected.
• Removal Instructions
DANGER: Do not disconnect equipment installed in hazardous locations unless power
has been switched o or area is known to be non-hazardous.
IMPORTANT: The LPU-2428 software will only operate in a 32-bit Windows environ-
ment. It WILL NOT operate on a 64-bit Windows machine.
Your LPU-2428 ultrasonic sensor is very low maintenance and will need little care as long as it was installed
correctly. However, in general, you should:
• Avoid applications for which the sensor was not designed, such as extreme temperatures, contact with
incompatible corrosive chemicals and fumes, or other damaging environments.
• Inspect the threads whenever you remove the sensor from duty or change its location.
Chapter 3: Maintenance
• General Care

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measure
measure
This procedure uses targets at known distances to calibrate the sensor’s accuracy. A wall or other large, at
object is recommended for the long range target.
• Point the sensor at a target at a known distance near the maximum range of the sensor, 25’ for a single
solid object (See Figure 3.1).
• Adjust the Multiplier value until the distance reading on the sensor matches the actual measured dis-
tance to the target (See Figure 4.29).
• Point the sensor at a target near the minimum measurement range, 1’ plus any Blanking distance (See
Figure 3.2).
• Adjust the Oset value until the distance reading on the sensor matches the actual measured distance
to the target (See Figure 4.29).
• Repeat previous two steps until no further adjustment is required.
• Calibration
Figure 3.1 Figure 3.2
Should you have problems with your LPU-2428, here are some troubleshooting steps.
• Check the received signal strength (just to left of the three Help buttons in the lower right corner. See
Figure 4.32). If the signal strength is low, alternately increase Pulses and Sensitivity (Figure 4.30) until
the signal strength improves.
• Ensure Temperature Compensation (Figure 4.30) is turned on.
• Set the Gain Control to AutoSense (Figure 4.30).
• Ensure that Blanking (Figure 4.30) is accurately set to account for any unwanted targets between the
sensor and the closest acceptable target.
• Ensure that the LPU-2428 software is installed in a 32-bit Windows environment. Although the software
will install in a 64-bit environment, it will not operate.
• Trouble Shooting
IMPORTANT: The LPU-2428 software will only operate in a 32-bit Windows environ-
ment. It WILL NOT operate on a 64-bit Windows machine.