FlowLine EchoPod UG01-03 User manual

Flowline, Inc. | 10500 Humbolt Street, Los Alamitos, CA 90720 p 562.598.3015 f 562.431.8507 w flowline.com QS310125 Rev A2
©2018 Flowline, Inc.
All Rights Reserved
Made in USA
UG01 & UG03 Series Quick Start
EchoPod®
Ultrasonic Liquid Level Switch, Controller & Transmitter

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WELCOME TO THE ECHOPOD® UG01 & UG03 SERIES QUICK START
The EchoPod® Quick Start provides basic mounting, setup and use instructions for getting the EchoPod®
up and running quickly. If you have a non-standard installation or setup requirement that is not addressed
here, please refer to the EchoPod® Manual or other support documentation located at flowline.com.
WE DO YOUR LEVEL BEST
Thank you for purchasing EchoPod®. The sensor provides level measurement, switching and/or control for
your tank application. This Quick Start includes everything you’ll need to get the sensor up and running.
COMPONENTS
Depending on the sensor part number/configuration that was shipped, EchoPod® comes with a 4’ (1.2m) cable,
Viton® gasket for installation and the Quick Start. Some models have the USB® Key Fob (LI99-2001) included
with the EchoPod® and other’s do not. Fob’s can be purchased separately. A LI99-2001 Fob is required to
interface to WebCal® and configure the sensor.
EchoPod
®
UG01-0001-40
UG01-0001-41
UG01-0011-40
UG01-0011-41
UG03-0001-40
UG03-0001-41
UG03-0011-40
UG03-0011-41
Viton
®
gasket (2”)
P/N: 210138
G Version Only
USB
®
Key Fob
P/N: LI99-2001

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CONFIGURING ECHOPOD®
EchoPod® is configured through WebCal®, a PC software program. Configuration of your sensor should be
performed prior to mounting, since it requires connection to your PC.
STEP 1: INSTALL WEBCAL® SOFTWARE
Download WebCal® software from www.flowline.com/webcal-software onto a PC with the following minimum
specifications:
Windows® 2000/XP/Vista/7/8/10, 32 or 64-bit system, 10 MB storage space, 256 MB RAM, 1 USB® 2.0 port
You must have an active Internet connection to download WebCal®. Double-click the WebCal® installer to
install software before proceeding to Step 2. Installer program will automatically install any required drivers.
STEP 2: CONNECT THE USB® FOB
NOTE: Do not connect the Fob to your computer until after you’ve installed WebCal® software.
The sensor communicates to WebCal® through the USB® Fob. Prior to plugging the Fob into your computers
USB® port, ensure that all external power is disconnected from EchoPod®. The maximum distance between
the computer and EchoPod® is 15’.
1. Connect the red, green, white, and black
wires from the EchoPod® to the
corresponding colored terminals on the
Fob.
2. Tighten the terminal screws with a slotted
screwdriver.
3. Plug the Fob into your PC’s USB® port.
Wiring identical for all series – Use only the Red,
Black, Green and White wires.
STEP 3 - MEASURE THE TANK
Measuring the tank is one of the most important aspects
in configuring the sensor. When measuring the tank,
take into account the location of the sensor with respect
to fittings, risers, dome tops and bottoms, and identify
where the measurements are taken from the sensor.
The HEIGHT and FILL-H settings determine the 4-
20mA span and are always measured from the bottom
of the tank up.
Relay set points will always be measured from the
bottom of the tank up, regardless of the function of the
relay (Pump, Valve, Alarm or Independent Relay).

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STEP 4 - SENSOR CONFIGURATION
Configures the relays in terms of pump/valve operations and level alarms as well as the setting fail-safe for
relays and signal output.
STEP 5 – DIMENSIONAL ENTRY
Distance Mode (default): Output of sensor is based on the distance (height of liquid) in the tank. Any change
in liquid level will reflect linearly to the current output. The two values (Sensor Height and Fill-Height) below set
the 4-20 mA current span for the sensor. Both values will be set in the units shown under Height Units.
Height Units: Confirm units for use in Sensor Height and Fill-Height settings.
Sensor Height: Sets the location for 4mA. It is based on the distance from the Empty level position
(bottom of tank) to the Measurement location for the sensor (bottom of sensor).
Fill-Height: Sets the location for 20mA. It is based on the distance from the Empty level position
(bottom of tank) to the Full level position (see below).
Relay Units: Confirm units for use in setting the relays.
Relay Settings: Sets the location for each relay activation point. All values are based upon the
distance or volume from Empty level position (bottom of tank). Each setting will have a descriptor for its
function. I.E. Hi-1 for high level alarm #1 or Lo-2 for low level alarm #2. Note: Units for the relays are
independent of the units used for Sensor Height and Fill-Height.

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STEP 6 - TANK LEVEL CONFIRMATION
Verify the Height Units, Sensor Height, Fill-Height, Relay Units & Relay Settings. All values were calculated
and set in the previous Dimensional Entry window. Make any adjustments if required.

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STEP 7 - WRITE TO UNIT
This WebCal®* operation uploads the configuration into the sensor, provides a custom wiring diagram specific
to the signal output and/or relay configuration, and saves the configuration file to your hard drive.
* For complete information on the WebCal® software, please refer to the WebCal® manual located at
flowline.com/webcal-software.
Before configuration can be completed:
 You must click the Write to Unit button to save the settings to the unit.
 Then, click Wiring Diagram for a hard copy of the sensor’s settings.
 Finally, enter the file name under which you wish to save the configuration file and click Save Config
File.
Configuration is now complete.
Disconnect the USB® Fob before continuing to the next step: Mounting the EchoPod®.

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MOUNTING ECHOPOD®
The sensor should always be mounted perpendicular to the liquid surface. Insure that there are no restrictions
or obstacles in the path of the acoustic signal. For further mounting information, please refer to the EchoPod®
manual at www.flowline.com.
Installation in existing 3” fittings:
Use a LM52-2400 3” thread x 2” thread adapter or a LM52-2410 3”
slip x 3” thread adapter.
Basic Tank Installation:
Use a 2” bulkhead fitting, such as the LM52-2890 bulkhead fitting.
Use a larger bulkhead fitting, such as the LM52-3890 with a
reducer bushing such as the LM52-2400.
Use a flange with a 2” thread, such as the LM52-2850.
Weld a plastic 2” half coupling to the tank top.
Mounting in Riser:
Installations with tall, narrow risers can impede the acoustic signal.
2" diameter risers should be no taller than 4". Larger diameter
risers should be no taller than 12". For best results, follow a 2:1
Height to Inner Diameter ratio (example: 8” High to 4” Inner
Diameter).
Installation in open tanks and sumps:
Use Flowline's LM50-1001 side mount bracket.
Note: The Side Mount Bracket (LM50 series) is not designed
for use with stand pipes or as a method to secure stand pipes.
There are too few threads to properly hold the sensor and the
stand pipe.
LM50-1001
LM52-2400
LM52-2890
LM52-2850
Mounting in Riser

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IMPORTANT MOUNTING GUIDELINES
1. Never mount the sensor at an angle.
2. Liquid should never enter the dead band.
3. Mount sensor at least 2” from the side wall.
4. Never mount the sensor in a vacuum.
5. Do not obstruct the sensor’s beam width with objects underneath the sensor.
6. Avoid mounting in the center of a dome top tank.
7. In a cone bottom tank, position the sensor over the deepest part of the tank.
8. Avoid mounting in a riser where the sensor is recessed more than twice the diameter of the riser.
MOUNTING IN STAND-PIPE
A stand-pipe may be used to dampen turbulence, separate surface foam from the point of measurement or
increase performance in heavy vapor. When mounting the sensor in a stand-pipe, the minimum diameter of
the pipe is 2”. Larger diameter pipes can be used. The pipe should be attached with a coupling or tank
adapter and reducer bushing. Avoid the use of multiple pipe fittings when possible. An ideal mount would be
to select a 3” tank adapter (S x T or S x S) and connect the pipe to the inside slip and use a reducer bushing to
attach the sensor (see example below).
The pipe length should run the measurement span and the bottom of the pipe should remain submerged at all
times to prevent foam from entering the pipe. Cut the bottom end of the pipe at 45° and drill a 1/4”pressure
equalization hole high in the sensor’s dead band. Locate the stand-pipe away from pump outlets and/or other
sources of substantial turbulence which might cause the liquid in the pipe to oscillate.
3” x 2”
Reducer Bushing
(TxT)
3” Tank
Adapter
(S x T)
3” PVC Pipe
Stand-Pipe Example
Stand-Pipe Mounting

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WIRING ECHOPOD®
After mounting the sensor, make the necessary electrical connections. A wiring diagram with specific
recommendations for the sensor’s configuration can be printed from the WebCal® program. A typical wiring
diagram is shown on the next page.
UG01 & UG03 Series
Red & Black: Red (Power) and Black (Return) leads are for connection to a 24 VDC power supply or to a 4-
20 mA loop power source. The Red and Black wires can be extended up to 1,000 feet using a 22-gauge or
larger wire; however do not extend the green and white wires beyond 15’.
White & Green: White (TX) and Green (RX) leads are reserved for use with WebCal® communication and
should not be connected during usage in the application. These wires should not be connected to WebCal®
while power is supplied from any source other than the LI99 series Fob. The maximum cable distance
between the computer and EchoPod® is 15’. Note: Never allow the white or green wires to touch any power
supply.
Blue, Orange, Yellow, Purple & Brown: Blue (Rly1), Orange (Rly2), Yellow (Rly3) & Purple (Rly) wires are
the relay contacts (normally open) from each of the relays respectively. The Brown wire (RLY Common) is the
common for all the relays. Relay selection is determined by the configuration in WebCal®.
Note: EchoPod®uses latching relays. When power is removed to the sensor, the relays will remain in their
last state. For example, if the relay is energized when power is removed, the relay will remain in the
energized state.

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WIRING ECHOPOD®
Typical wiring diagram shown.
Diagrams will change based upon your exact sensor series and configuration. Print and use the appropriate
wiring diagram in WebCal®.
GENERAL NOTES FOR ELECTRICAL CONNECTIONS, USAGE AND SAFETY:
 Where personal safety or significant property damage can occur due to a spill, the installation must
have a redundant backup safety system.
 Wiring should always be completed by a licensed electrician.
 Supply voltage should never exceed 28 VDC.
 Do not exceed 28 VDC power on the relays within EchoPod®.
 Always use stepper relays between the sensor and external loads. For DC circuits use a catch diode
such as 1N4148 shown above.
 Protect the sensor from excessive electrical spikes by isolating the power, whenever possible.
 The sensor materials must be chemically compatible with the liquids to be measured.
 Design a fail-safe system for possible sensor and/or power failure.
 Never use the sensor in environments classified as hazardous.
SampleWiringDiagram
Diagram will change based upon
the sensor’s configuration, use
WebCal®toviewappropriatewiring
diagram.