FlowLine EchoSonic LU23-00 User manual

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| 2 MN300610 Rev C3
Introduction / Table of Contents Step One
The EchoSonic® 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 loop powered 4-20 mA signals, such as a PLC, SCADA, DCS,
display, controller, etc.
NEW FEATURES
 Simple configuration with WebCal® software.
 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)
TABLE OF CONTENTS
Specifications: .................................................................................................................. 3
Dimensions: .................................................................................................................. 3
About this Manual: ........................................................................................................... 4
Components: .................................................................................................................. 5
Getting Started: ................................................................................................................ 6
USB
® Fob Interface: ............................................................................................. 7
Four Steps for Using WebCal®: ........................................................................... 8
Step 1: Sensor Configuration: .................................................................. 8
Step 2: Tank Shape Selection: ................................................................. 9
Step 3: Tank Levels Configuration: .......................................................... 9
Step 4: Write to Unit: .............................................................................. 10
Wiring: ............................................................................................................................ 11
Wiring Diagram: ................................................................................................. 11
Wiring Connections: ........................................................................................... 11
Voltage Output: ................................................................................................... 12
Wiring to Displays, Controller’s & PLC’s: ........................................................... 13
Installation: ................................................................................................................ 15
Mounting Guide: ................................................................................................. 15
Installation in Existing Fittings: ............................................................................ 15
Metal Tanks: ....................................................................................................... 15
Fitting Selection: ................................................................................................ 16
Tank Adapter: .......................................................................................... 16
Riser: ...................................................................................................... 16
Flange: ................................................................................................... 17
Side Mount Fitting: ................................................................................. 17
Stand Pipe: ............................................................................................. 18
Advanced Features: ....................................................................................................... 19
Appendix: ........................................................................................................................ 20
Updating WebCal® Software: ............................................................................ 20
Demo Tab: ......................................................................................................... 20
Factory Defaults: ................................................................................................ 21
User Settings: .................................................................................................... 22
Troubleshooting: ................................................................................................ 23
Warranty: ........................................................................................................................ 24

MN300610 Rev C3 3 |
Specifications / Dimensions Step Two
Range:
Accuracy: ± 0.2% of range
Resolution: LU27: 0.019” (0.5mm)
LU23: 0.039” (1mm)
LU28: 0.079” (2 mm)
LU29: 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: Polyvinylidene Fluoride (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: cFMus
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)

| 4 MN300610 Rev C3
Safety Precautions Step Three
About this Manual: PLEASE READ THE ENTIRE MANUAL PRIOR TO INSTALLING OR USING THIS
PRODUCT. This manual includes information on the EchoSonic® series Ultrasonic Level transmitter from
FLOWLINE. Please refer to the part number located on the sensor 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®. 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® 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® should not be used within classified hazardous environments.
Warning: Always use the Viton gasket when installing the EchoSonic®, and make sure that all electrical
wiring of the switch is in accordance with applicable codes.

MN300610 Rev C3 5 |
Components Step Four
COMPONENTS
EchoSonic® is offered in four 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®, USB® Fob and Viton®
gasket to configure, install and operate EchoSonic®.
P/N Max. Range Dead Band Thread Fob
LU23-00
18.0’ (5.5m) 8” (20cm)
2” NPT No Fob
LU23-01 Fob Included
LU23-10 2” G No Fob
LU23-11 Fob Included
LU27-00
9.8’ (3m) 4” (10cm)
1” NPT No Fob
LU27-01 Fob Included
LU27-10 1” G No Fob
LU27-11 Fob Included
LU28-00
26.2’ (8m) 8” (20cm)
2” NPT No Fob
LU28-01 Fob Included
LU28-10 2” G No Fob
LU28-11 Fob Included
LU29-00
32.8’ (10m) 8” (20cm)
2” NPT No Fob
LU29-01 Fob Included
LU29-10 2” G No Fob
LU29-11 Fob Included
 Viton
® Gasket
o Part #200128 for LU27 series
o Part #200129 for LU23, LU28 or LU29 series
 USB
® Fob
o Part #LI99-2001
 Quick Start Guide

| 6 MN300610 Rev C3
Getting Started Step Five
EchoSonic® 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 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
flowline.com/webcal-software.

MN300610 Rev C3 7 |
Getting Started Step Five
USB® FOB INTERFACE
EchoSonic® 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® into the correct terminals on the Fob. Tighten
the screws on the terminals and plug your Fob into the USB® port of your computer.
Wiring identical for all series - Use only the Red, Black, Green and White wires.
 The maximum cable distance between the computer and EchoSonic® is 15’. This only applies when
configuring the EchoSonic®. Otherwise, upon installing the sensor, the maximum cable length is 1,000 feet
(Red and Black wires only, minimum 22-gauge).
 Once EchoSonic® is configured and prior to installation, isolate the white and green wires from active
power to prevent a short of the configuration circuit
 Note: When using the Fob, do not add VDC power. The Fob, when connected to the computer, will provide
the required power to the EchoSonic®.
* For complete information on the WebCal® software, please refer to the WebCal® manual located at
www.flowline.com/webcal-software.
NOTE: EchoSonic®II ships with the LI99-2001 Fob (white in color). The LI99-1001 Fob (black in color)
can be used with EchoSonic®II (LU23, LU28 & LU29 series) to configure the sensor with
WebCal®.

| 8 MN300610 Rev C3
Getting Started Step Five
With EchoSonic® connected to your computer, open the WebCal® software by clicking on the WebCal® icon.
Follow steps 1-4 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].
*For complete information on the WebCal® software, please refer to the WebCal® manual located at
www.flowline.com/webcal-software.
CONFIGURING ECHOSONIC® WITH WEBCAL®
1. Sensor Configuration
a. Configures the Loop Fail-Safe, Output at Empty and Startup condition for the sensor.
2. Tank Shape Selection
a. Defines the shape of the tank as well as the dimensional information for the tank with respect to
the sensor’s location on the tank.
3. Tank Level Configuration
a. Enter the settings for the relay activation points as well as confirm the operational range.
4. Write to Unit
a. Uploads configuration into the sensor.
b. Access to a customer wiring diagram specific to the relay configuration.
SENSOR CONFIGURATION
v

MN300610 Rev C3 9 |
Getting Started Step Five
TANK SHAPE SELECTION
Defines the shape of the tank as well as the dimensional information for the tank with respect to the sensor’s
location on the tank.
TANK LEVEL CONFIGURATION
The Height Units, Sensor Height, Fill-Height and Capacity were all calculated in the previous Dimensional
Entry window. To adjust these settings, click on Select Tank Shapes.

| 10 MN300610 Rev C3
Getting Started Step Five
WRITE TO UNIT
This WebCal®* operation uploads configuration into the sensor, provides a custom wiring diagram specific to
the signal output, and saves the configuration file to your hard drive.
* For complete information on the WebCal® software, please refer to the WebCal® manual located at
www.flowline.com/webcal-software.

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| 12 MN300610 Rev C3
Wiring Step Six
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.
 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.
VOLTAGE OUTPUT
EchoSonic® 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
o Add a 250 Ohm resistor
o Actual output will be 0.8 to 5 VDC
 0-10 VDC output
o Add a 500 Ohm resistor
o Actual output will be 2 to 10 VDC

MN300610 Rev C3 13 |
Wiring Step Six
WIRING TO DISPLAY, CONTROLLERS & PLC’S
Below is a quick review of wiring the EchoSonic® to common display, controllers and PLC’s.
DataView™ LI55 Series
Level Controller
Commander™ LI90 Series
Multi-Tank Level Controller
DataLoop™ LI23 Series
Level Indicator Without Backlight
DataLoop™ LI23 Series
Level Indicator With Backlight

| 14 MN300610 Rev C3
Wiring Step Six
WIRING TO DISPLAY, CONTROLLERS & PLC’S (CONTINUED)
Below is a quick review of wiring the EchoSonic® to common display, controllers and PLC’s.
DataPoint™ LC52 Series
Level Controller
*JWA mode (Factory Setting)
DataPoint™ LC52 Series
Level Controller
*JWB mode
Generic Loop
Powered Display
Generic PLC
* Refer to the DataPoint™, LC52 Series, Level Controller manual for information on JWA mode and JWB mode
settings in the controller.

MN300610 Rev C3 15 |
Installation Step Seven
The EchoSonic® 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 the sensor at an angle.
2. Liquid should never enter the dead band.
3. Side Wall:
a. Mount the sensor at least 3” from the side wall.
b. LU27 Series - Mount at least 2” from the side
wall.
4. Do not mount where obstacles will intrude on sensor’s
beam width.
a. LU27 Series - Mount at least 2” from the side
wall.
b. LU23, LU28 & LU29 Series - Mount at least 3”
from the side wall.
5. Do not mount the sensor 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.
INSTALLATION IN EXISTING FITTINGS
If the existing fitting is larger than the threads of the
EchoSonic®, select a reducer bushing such as the LM52-
1400 (2” thread x 1” thread) or LM52-2400 (3” thread x 2”
thread).
LM52-1400
LM52-2400
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.
Do not install in the
center of a dome
top tank.
METAL TANKS (LU27 SERIES ONLY)
The LU27 series has 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.

| 16 MN300610 Rev C3
Installation Step Seven
FITTING SELECTION
Check the part number to determine the required fitting mount size and thread type. EchoSonic® is commonly
installed in tank adapters, flanges, brackets or standpipes. Note: Always include the gasket when installing the
EchoSonic®.
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.
c. Always mount the tank adapter so the majority of fitting is outside the tank.
i. Note: Never mount the tank adapter upside down or where the bulk of the material is
inside the tank.
2” Tank Adapter
Socket x Thread
(LM52-2890)
Tank Adapter
w/ 2”x1” Reducer Bushing
LM52-2890 w/LM52-1800)
Tank Adapter
Thread x Thread
Do not use thread x thread
2. Riser: Installations with tall, narrow risers can impede the acoustic signal.
a. Core Out Concrete: Applications where tank with a concrete ceiling that has been cored out
can also be considered as a riser type application. In these applications follow a 2:1 ratio (Core
Height to Inner Diameter) for the diameter of the core.
a. LU23, LU28 & LU29 Series: 2” (5 cm) diameter risers should be no taller than 4” (10 cm).
Larger diameter risers should be no taller than 12” (30.5 cm).
b. LU27 Series:
Riser Specifications
Inner
Diameter
Maximum
Height
2” (5cm)
4” (10cm)
6” (15cm)
4” (10cm)
8” (20cm)
12” (30cm)
Note: Do not exceed the dimensions listed above.
Note: If attempting to raise the
sensor above the top of the tank
to allow for a higher fill capacity,
avoid the use of tall and narrow
risers. The example to the left
exceeds the dimensions listed in
the Riser Specifications chart.
Use a larger tank adapter which
takes into account the Riser
Specifications.

MN300610 Rev C3 17 |
Installation Step Seven
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 for
the LU27 series.
2” Flange w/
thread out of plane
(LM52-1850)
2” Flange w/
thread in plane
2” Flange w/
Reducer Bushing
(w/LM52-1800)
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.
LM52-1001 Shown
LM52-1001-1 Shown
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.

| 18 MN300610 Rev C3
Installation Step Seven
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. Minimum ID for the stand pipe is listed below.
i. A 2” pipe (min. pipe ID) is usable with the LU27
series.
ii. A 3” pipe (min. pipe ID) is usable with the LU23,
LU28 & LU29 series.
iii. Pipes larger than 3” can also be used.
c. Use a coupling and reducer bushing to attach the
EchoSonic® 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.
ii. For 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.
iii. For the LU23, LU28 & LU29 series, use a reducer
bushing such as LM52-2400 (3”T x 2”T) fitting or
the LM52-2410 (3”S x 2”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.
EchoSonic®
LU27
2” x 1”
Reducer Bushing
(TxT)
2” Coupling
(S x T)
Vent Hole (1/4”)
2” PVC Pipe
LU27 attached to a LM52-1400
(2”x1” reducer bushing) to a S x T
2” coupling.
Avoid the use of a tee within the
stand pipe. A tee can create false
signals which will interfere with the
sensor’s performance.

MN300610 Rev C3 19 |
Advanced Features Step Eight
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. Use this filter if the 4 to 20 mA output requires a smooth output for the application such as open channel
flow measurement.
 Decrease Output Filtering: Placing a check mark in the box will eliminate all filtering (averaging) of the
analog output. Enables a pulse by pulse level reading. Use this filter to see changes in level after every
sound pulse.
Note: Never check increase output filtering and decrease output filtering at the same time.
 Stabilize Output in Dead band: Placing a check mark in the box will activate a filter to hold the output at Full
if the level enters the dead band of the EchoSonic®. This filter requires the level to leave the dead band at a
smooth and steady rate.

| 20 MN300610 Rev C3
Appendix Step Nine
UPDATE AND DEMO TABS
WebCal® has two other page tabs which can be used to assist in the configuration of the EchoSonic®. These
page tabs are the Updates and Demo tabs.
 Updates: The Updates tab has two key features. The first is the ability to update the WebCal® software to
its latest version. The second is the ability to update EchoSonic®’s firmware to its latest version.
 Demo: The Demo tab has the ability to test the EchoSonic® sensor against a fixed target.