FlowLine EchoSonic II User manual

23 MAR 11 EchoSonic II 1 of 24
Rev B MN300610
EchoSonic II
Manual
LU23-0, LU27-0, LU28-0, LU29-0,
LU23-1, LU27-1, LU28-1, LU29-1 Series
Flowline Inc.
10500 Humbolt Street
Los Alamitos, CA 90720
Tel: [phone]
Fax: [phone]
www.flowline.com

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Preface
This manual explains how to use the EchoSonic II, LU23, LU27, LU28 and LU29 series ultrasonic level
transmitter.
Warranty, Service & Repair
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 in the Navigation Bar along the side of the home
page.
If for some reason your product must be returned for factory service, go to the Flowline website to receive a
Material Return Authorization number (MRA), providing the following information:
1. Full Part Number, Full 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
On-line Material Return Authorization can be found under Contact Us in the Navigation Bar along the side of
the home page. Click on Return Authorization to begin the MRA request. Once you have received a MRA
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.

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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 in accordance with instructions furnished by Flowline
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. 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, which
Flowline's examination determines to its satisfaction to be defective in material or workmanship within the
warranty period. Flowline must be notified pursuant to the instructions below of any claim under this warranty
within thirty (30) days of any claimed lack of conformity of the product. Any product repaired or replaced
under this warranty will be warranted only for the remainder of the original warranty period.
Returns
Products cannot be returned to Flowline without Flowline's prior authorization. To return a product that is
thought to be defective, go to www.flowline.com, and submit a customer return (MRA) request form and follow
the instructions therein. All warranty and non-warranty product returns to Flowline must be shipped prepaid and
insured. Flowline will not be responsible for any products lost or damaged in shipment.
Limitations
This warranty does not apply to products which: 1) are beyond the warranty period or are products for which
the original purchaser does not follow the warranty procedures outlined above; 2) have been subjected to
electrical, mechanical or chemical damage due to improper, accidental or negligent use; 3) have been modified
or altered; 4) anyone other than service personnel authorized by Flowline have attempted to repair; 5) have
been involved in accidents or natural disasters; or 6) are damaged during return shipment to Flowline. Flowline
reserves the right to unilaterally waive this warranty and dispose of any product returned to Flowline where: 1)
there is evidence of a potentially hazardous material present with the product; or 2) the product has remained
unclaimed at Flowline for more than 30 days after Flowline has dutifully requested disposition. This warranty
contains the sole express warranty made by Flowline in connection with its products. ALL IMPLIED
WARRANTIES, INCLUDING WITHOUT LIMITATION, THE WARRANTIES OF MERCHANTABILITY
AND FITNESS FOR A PARTICULAR PURPOSE, ARE EXPRESSLY DISCLAIMED. The remedies of
repair or replacement as stated above are the exclusive remedies for the breach of this warranty. IN NO EVENT
SHALL FLOWLINE BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY
KIND INCLUDING PERSONAL OR REAL PROPERTY OR FOR INJURY TO ANY PERSON. THIS
WARRANTY CONSTITUTES THE FINAL, COMPLETE AND EXCLUSIVE STATEMENT OF
WARRANTY TERMS AND NO PERSON IS AUTHORIZED TO MAKE ANY OTHER WARRANTIES OR
REPRESENTATIONS ON BEHALF OF FLOWLINE. This warranty will be interpreted pursuant to the laws
of the State of California. If any portion of this warranty is held to be invalid or unenforceable for any reason,
such finding will not invalidate any other provision of this warranty.

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Introduction:
The EchoSonic II is a general-purpose ultrasonic level transmitter that provides a loop powered 4-20 mA
output. The 4-20 mA output can be used to provide the proportional level of liquid in any tank or vessel. The
signal can be connected to any device that accepts a loop powered 4-20 mA signal, such as a PLC, SCADA,
DCS, display, controller, etc.
New Features
Simple configuration with WebCal software, no more target calibration.
Adjustable Loop Fail-Safe, Hold Last, Empty, Full, 21 mA, 22 mA
Easy to reverse mA output, 4-20 mA to 20-4 mA
Adjustable start-up condition, Empty, Mid (12 mA), Full, Over range (22 mA)
Increased output filtering
Table of Contents
Introduction.........................................................................................................................4
New Features ......................................................................................................................4
About this manual...............................................................................................................5
Specifications......................................................................................................................7
Dimensions .........................................................................................................................7
Getting Started....................................................................................................................8
USB® Fob Interface ......................................................................................................9
WebCal ..........................................................................................................................9
Step 1: Configuration.......................................................................................10
Step 2: Tank Levels .........................................................................................12
Step 3: Write to Unit........................................................................................12
Wiring ..........................................................................................................................13
Wiring Diagram ...........................................................................................................13
Wiring Connections ....................................................................................................13
Wiring to Displays, Controllers & PLC’s ...................................................................14
Installation.........................................................................................................................16
Position and Mount......................................................................................................16
Mounting Guide...........................................................................................................16
Fitting Selection...........................................................................................................17
Tank Adapter: ..................................................................................................17
Riser.................................................................................................................17
Flange...............................................................................................................18
Side Mount Fitting...........................................................................................18
Stand Pipe ........................................................................................................19
Advanced Feature .............................................................................................................20
Appendix ..........................................................................................................................20
Updating WebCal Software.........................................................................................21
Updating Transmitter Firmware ..................................................................................23
Factory Defaults...........................................................................................................23
Troubleshooting...........................................................................................................24
User Settings................................................................................................................24

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About this Manual:
PLEASE READ THE ENTIRE QUICK START PRIOR TO INSTALLING OR USING THIS PRODUCT.
This manual includes information on the EchoSonic II series Ultrasonic Level Switch 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. Install the transmitter with the included Viton
gasket and never over tighten the transmitter within the fitting. Always check for leaks prior to system start-up.
Wiring and Electrical:
A supply voltage of 12 to 28 VDC is used to power the EchoSonic II. 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 Polycarbonate (PC). 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 transmitter housing is liquid-resistant the EchoSonic II 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.
Safety;
Installation should be done by properly trained staff
Supply voltage should never exceed a maximum of 28 VDC
Make sure the sensor is chemically compatible with your application
Design a fail-safe system that accommodates the possibility of sensor and/or power failure.
This sensor should not be used in classified hazardous environments
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.
Flammable, Explosive or Hazardous Applications:
EchoSonic II should not be used within classified hazardous environments.

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Warning:
Always use the Viton gasket when installing the EchoSonic II, and make sure that all electrical wiring of the
switch is in accordance with applicable codes.
Components:
EchoSonic II is offered in three different models. Depending on the model purchased, you may or may not have
been shipped all the components shown below. You do however, need an EchoSonic II, USB® Fob and
Viton® gasket to configure, install and operate EchoSonic II.
EchoSonic II
oLU27-01 - 9.8’ (3 m) range, Type 6P encl., 1” NPT
oLU27-11 - 9.8’ (3 m) range, Type 6P encl., 1” G
oLU23-01 –18.0’ (5.5 m) range, Type 6P encl., 2” NPT
oLU23-11 –18.0’ (5.5 m) range, Type 6P encl., 2” G
oLU28-01 –26.2’ (8 m) range, Type 6P encl., 2” NPT
oLU28-11 –26.2’ (8 m) range, Type 6P encl., 2” G
oLU29-01 –32.8’ (10 m) range, Type 6P encl., 2” NPT
oLU29-11 –32.8’ (10 m) range, Type 6P encl., 2” G
Viton Gasket
oPart #200128 for LU27 series
oPart #220129 for LU23, LU27 or LU29 series
USB® Fob
oPart #LI99-1001
Quick Start Guide

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Specifications:
Range:
Accuracy: ± 0.2% of range
Resolution: LU27: 0.019” (0.5mm)
LU23: 0.039” (1mm)
LU28: 0.079” (2 mm)
LU28: 0.079” (2 mm)
Dead band: LU27: 4” (10cm)
LU23/28/29: 8” (20cm)
Beam width: LU27: 2” (5cm)
LU23/28/29: 3” (7.6cm)
Configuration: WebCal® PC
Windows® USB 2.0
Memory: Non-volatile
Supply voltage: 24 VDC (loop)
Consumption: 0.5 W
Loop resistance: 500 Ohms @ 24 VDC
Signal output: 4-20 mA, two-wire
Signal invert: 4-20 mA or 20-4 mA
Signal fail-safe: 4 mA, 20 mA, 21 mA,
22 mA or hold last
Process temp.: F: -4° to 140°
C: -20° to 60°
Temp. comp.: Automatic
Ambient temp.: F: -31° to 140°
C: -35° to 60°
Pressure: MWP = 30 PSI
Enclosure type: Type 6P encapsulated,
corrosion resistance &
submersible
Encl. material: Polycarbonate
Trans. material: PVDF
Cable jacket mat.: Polyurethane
Cable type: 4-conductor shielded
Cable length: 10’ (3 m)
Process mount: LU27: 1” NPT (1” G)
LU23/28/29: 2” NPT (2”
G)
Mount. gasket: Viton®
Classification: General purpose
Compliance: CE, RoHS
Approvals: cFMu
Dimensions:
Side View / LU27 Series
Side View / LU23, LU28 and LU29 Series
LU27: 4" to 9.8'
(10 cm to 3 m)
LU23: 8" to 18.0'
(20 cm to 5.5 m)
LU28: 8" to 26.2'
(20 cm to 8 m)
LU29: 8" to 32.8'
(20 cm to 10 m)

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Getting Started:
EchoSonic II 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. Please
go to http://www.flowline.com, click on WebCal Software and select your language version.
WebCal System Requirements
Windows® XP or 2000
10 mB hard drive space
256 mB RAM
1 USB® 2.0 port
Internet connection

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USB® Fob Interface
EchoSonic II communicates with WebCal through a USB® interface called a Fob. Before plugging your
Fob into your computer’s USB® port, be sure that you have installed WebCal on your computer.
Connect the red, green, white and black wires from EchoSonic II into the correct terminals on the Fob.
Tighten the screws on the terminals and plug your Fob into the USB® port of your computer.
* Once EchoSonic II is configured and prior to installation, isolate the white and green wires
from active power to prevent a short of the configuration circuit
WebCal
With EchoSonic II connected to your computer, open the WebCal software by clicking on the WebCal
icon. Follow steps 1-3 to configure the transmitter. Click “Help” in the lower right hand corner and open
the help menu of WebCal for additional instructions on WebCal. If you need additional assistance using
WebCal, please contact a Flowline Applications engineer at [phone]

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WebCal Step 1: Configuration
This section of WebCal is where you select the application’s configuration settings. Start from the top and
work to the bottom, choosing the selections that are applicable to your configuration. “Not Applicable”
will automatically show when a selection doesn’t apply to your configuration settings, and you may move
on. All configuration settings must be selected or have “Not Applicable” before you can continue to step
2. Note: Pressing the Clear Screen button will reset the configuration table and allow access to all of the
features.
Loop Fail-Safe
This feature allows you to select the fail-safe current output if the sensor
fails to detect a return signal (LOST). When the sensor regains signal,
the output current will revert back to the current level condition.
oHold Last Value - The output will remain in the same state as
the last echo detected. Example: If the output was 6.7 mA just
prior to the LOST signal, the device will continue to output 6.7
mA. When the sensor regains signal, the output will indicate the
level when the signal was regain.
oEmpty - The output will revert to the current value of an Empty
tank. The empty state is dependent upon the Output at Empty
setting. When 4 mA at Bottom is selected, the sensor will output
4 mA when a fail-safe condition occurs. If 20 mA at Bottom is
selected, the sensor will output 20 mA when a fail-safe condition
occurs
oFull - The output will revert to the current value of a Full tank.
The full state is dependent upon the Output at Empty setting.
When 4 mA at Bottom is selected, the sensor will output 20 mA
when a fail-safe condition occurs. If 20 mA at Bottom is
selected, the sensor will output 4 mA when a fail-safe condition
occurs
oOverfill (21mA) - The output current will go to 21mA when the
return signal is lost.
oOverfill (22mA) - The output current will go to 22mA when the
return signal is lost.
Note: Right click on any menu that you may have questions on to open the help menu.
Note: To reset, press the Clear Screen button.

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Output at Empty
This feature allows you to select the orientation of the 4 to 20mA output
(4 to 20 mA or 20 to 4 mA). Choose which output setting best fits the
application. Typical installations are set with 4 mA at Bottom. This will
not affect the performance of the sensor other than the output of the
EchoSonic II. WebCal’s factory default is 4mA at bottom and 20mA at
top. When connecting your sensor to a display, you must account for
your output settings.
o4mA at Bottom - The output current will be 4mA when the
sensor measures an empty tank and 20mA when the sensor
measures a full tank.
o20mA at Bottom - The output current will be 20mA when the
sensor measures an empty tank and 4mA when the sensor
measures a full tank
Startup Condition
This feature allows the operator to select the output current on initial
startup prior to acquiring a true return signal (level measurement).
This only occurs during the initial powering of EchoSonic II and the
transmitter will revert to the correct level reading when the level is
acquired.
oEmpty - Selects the start up current established in Output at
Empty. Example: Select 4 mA at Bottom, the output will
remain at 4 mA until the unit acquires a true return echo.
Select 20 mA at Bottom, the output will remain at 20 mA until
the unit acquires a true return echo.
oMid Tank - When selected, the startup current will read 12
mA until the unit acquires a true return echo.
oFull Tank - Uses the opposite current that was selected in
Output at Empty. Example: If you select 4 mA at Bottom then
the start up current would be 20 mA. If you select 20 mA at
Bottom then the start up current would be 4 mA.
oOverfill (22mA) - The output at startup would be 22 mA. This
condition will remain until the unit acquires a true return echo.
Note: Right click on any menu that you may have questions on to open the help menu.
Note: To reset, press the Clear Screen button.

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WebCal Step 2: Tank Levels
This section of WebCal is where you enter application measurement values. All values must be filled in
before moving to step 3.
Sensor Height: Distance from
the bottom of the tank to the
bottom of the transducer.
Fill Height: Distance from the
bottom of the tank to the
maximum liquid height.
WebCal Step 3: Write to Unit
After you have entered configurations and tank values, click “Write to Unit” and send the configuration
to your EchoSonic. Now use WebCal’s file management features to save your configuration by clicking
“Save Config File” and print your wiring diagram by clicking “Wiring Diagram.”
Write to Unit
Wiring diagram
Save Config File

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Wiring Diagram
Wiring EchoSonic II
After you have finished positioning and mounting EchoSonic II, follow WebCal’s wiring diagram to wire
EchoSonic II. Flowline recommends using a qualified licensed electrician to wire EchoSonic II and your
application’s components.
Wire Connections:
Red & Black
Red and Black 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.
White & Green
White and Green leads are reserved for use with WebCal 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.
Note: Once EchoSonic is configured, isolate the white and green wires from active power to
prevent a short of the configuration circuit.
Note: Do not extend the White & Green wires beyond 15’.

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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 installed.
Wiring should always be completed by a licensed electrician.
Supply voltage should never exceed 28 VDC.
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.
Voltage Output
EchoSonic II can be used as a 0 to 5 or 0 to 10 VDC output device. A resistor will need to be added to the
circuit to enable a voltage output (refer to the wiring diagram below).
0-5 VDC output
oAdd a 250 Ohm resistor
oActual output will be 0.8 to 5 VDC
0-10 VDC output
oAdd a 500 Ohm resistor
oActual output will be 2 to 10 VDC
Wiring to Display, Controllers & PLC’s
Below is a quick review of wiring the EchoSonic II to common display, controllers and PLC’s.
DataView LI55 Series
Level Controller
Commander LI90 Series
Multi-Tank Level Controller

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DataLoop LI25 Series
Level Indicator
without the backlight
DataLoopLI25 Series
Level Indicator
with the backlight
Wiring to Display, Controllers & PLC’s (continued)
DataPoint LC52 Series
Level Controller
JWA mode (Factory Setting)
DataPoint LC52 Series
Level Controller
JWB mode
Generic Loop
Powered Display
Generic PLC

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Installation
The EchoSonic II should always be mounted perpendicular to the liquid surface and installed using the
provided Viton mounting gasket. Make sure that the fitting and transmitter threads are not damaged or
worn. Always hand-tighten the transmitter within the fitting. Perform an installed leak test under normal
process conditions prior to system start up. Note: The preferred mounting fitting for the LU27 series is the
LM52-1400 (2” thread x 1” thread) reducer bushing.
Mounting Guide
1. Do not mount at an angle
2. Liquid should never enter the dead band
3. Side Wall:
a. For LU27 Series - mount at least 2” from the side wall
b. For LU23, LU28 & LU29 Series - mount at least 3” from the side wall
4. Do not mount where obstacles will intrude on sensor’s beam width
a. See Specifications on page 8
5. Do not mount in a vacuum
6. Avoid mounting in the center of a dome top tank.
7. In cone bottom tank, position the sensor over the deepest part of the tank.
Do not install at
angle relative to the
liquid.
Do not install within
3” of tank sidewall.
Do not install with
objects in the beam.
Do not install in
applications with
vacuum.

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Installation in existing fittings
If the existing fitting is larger than the threads of the EchoSonic II, select a reducer bushing such as
the LM52-1400 (2” thread x 1” thread) or LM52-2400 (3” thread x 2” thread).
Metal Tanks (LU27 series)
Flowline ultrasonic transmitters have been optimized for use in non-metallic fittings.
1. For best performance, avoid the use of metallic fittings.
a. Use a plastic 2” x 1” reducer bushing, such as the LM52-1400 or a plastic 1” flange,
such as the LM52-1850 for metallic tanks.
2. While installations directly into a 1” metal fitting are not recommended, acceptable results
may be obtained if the 1” fitting is a half coupling in form and the outer diameter of the
coupling is tightly wrapped in vinyl tape to dampen vibrations.
Fitting Selection:
Check the part number to determine the required fitting mount size and thread type. EchoSonic II
is commonly installed in tank adapters, flanges, brackets or standpipes. Note: Always include the
gasket when installing the EchoSonic II.
1. Tank Adapter: Select a tank adapter fitting, such as the LM52-1890 for the LU27 series
or the LM52-2890 for the LU23, LU28 & LU29 series.
a. For best results, select a 2” tank adapter and add a reducer bushing such as the
LM52-1400, thread x thread, reducer bushing.
b. Avoid tank adapter (thread x thread) styles and/or pipe stops forward of the
installed transducer.
2” Tank Adapter
Socket x Thread
Tank Adapter
w/ 2”x1” Reducer Bushing
Tank Adapter
Thread x Thread
Do not use thread x thread
2. Riser: Installations with tall, narrow risers can impede the acoustic signal.
a. LU23, LU28 & LU29 Series: 2” (5 cm) diameter risers should be no taller than 5”
(12.7 cm). Larger diameter risers should be no taller than 12” (30.5 cm).
b. LU27 Series:

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Note: Do not exceed the dimensions listed above
2. Flange (LU27 series):
If installing on a flange, select a flange with a thread that is above the plane of the flange,
such as the LM52-1850.
a. The LU23, LU28 & LU29 series works well with Flange installations.
b. Avoid the use of blind flanges with tapped threads or flanges where the threads are
even with the plane of the flange, such as the Banjo 1" Poly ANSI Flange (series
AF100).
c. Use a flange with a 2” thread and add a 2” to 1” reducer bushing to complete the
installation.
2” Flange w/
thread out of plane
2” Flange w/
thread in plane
2” Flange w/
Reducer Bushing
Do not use thread in plane
3. Side Mount Bracket:
For installations in open tanks and sumps, use the LM50 series side mount bracket.
a. For the LU27 series, order the LM50-1001-1, which includes a 2”x 1” Reducer
Bushing.
b. For the LU23, LU28 & LU29, series, order the LM50-1001 side mount bracket.

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4. Stand Pipe:
A standpipe maybe used to dampen turbulence or when foam is present in the application.
a. Pipe can be made of any material.
b. Select a minimum 3” ID pipe for the stand pipe.
i. A 2” pipe is usable with the LU27 series, but is the minimum.
ii. Pipes larger than 3” can also be used.
c. Use a coupling and reducer bushing to attach the EchoSonic II to the pipe.
i. With the LU27 series, be sure to use a plastic reducing bushing such as
LM52-1400 2” T x 1” T fitting or the LM52-1410 2” S x 1” T fitting.
d. 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.
e. Cut a 45°notch at the bottom of the pipe and drill a 1/4”pressure equalization hole
in the dead band.
f. The pumps should not drive liquid past the open end of the stand pipe which causes
the liquid in the pipe to oscillate.

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Advanced Features
This tool is designed to help solve operational issues. Changing these setting will alter the performance of
your unit. Please read through this HELP file to assist you in making adjustments or if still unclear about a
specific issue, please contact FLOWLINE, Applications Engineering.
NOTE: When the Advanced Button is highlighted with a RED border, this indicates you have
selected an advanced feature…
Increase output filtering: Placing a check mark in the box will increase the filtering
(averaging) of the analog output. If you require the 4 to 20 mA output to be smooth for the
application such as Open Channel Flow measurement, you might check this box.