EchoSwitch® Ultrasonic Level Switch and Transmitter LU74, LU77 & LU78 Series Manual Flowline Inc. 10500 Humbolt Street Los Alamitos, CA 90720 Tel: (562) 598‐3015 Fax: (562) 431‐8507 www.flowline.
INTRODUCTION / TABLE OF CONTENTS Step One The EchoSwitch® is a general‐purpose ultrasonic level switch that provides the end user the ability to control up to three unique devices (pump, valves and/or alarms) through an advanced non‐contact technology. EchoSwitch® features push button configuration that uses real engineering values for setting up the relay operation(s). One relay has SPDT Form “C” contacts useful for controlling a valve and the other two relays are SPST Form “A”.
SPECIFICATIONS/DIMENSIONS Range: Repeatability: Loop Output: Dead band: LCD indication: Configuration: Supply voltage: Contact type: Contact rating: Contact fail‐safety: Temp. comp.: Electronics temp.: Pressure: Enclosure rating: Enclosure vent: Encl. material: Encl. hardware: Trans. material: Process mount: Mount. gasket: Conduit entrance: Classification: Compliance: Approvals: Rev A LU74: 8" to 18.0’ (20 cm to 5.5m) Step Two LU77: 4" to 9.8' (10 cm to 3m) 0.25" (6.
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 EchoSwitch® series ultrasonic level switch and transmitter 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.
SAFETY PRECAUTIONS (cont.) Step Three Make a Fail‐Safe System: Design a fail‐safe system that accommodates the possibility of switch and/or power failure. FLOWLINE recommends the use of redundant backup systems and alarms in addition to the primary system. Adding a redundant high level float switch to the system is a cost effective means to prevent costly tank overflows. The switch has (3) relay channels.
GETTING STARTED Step Four EchoSwitch® can be configured before installation. The switch features non‐volatile memory, so the set points configured before installation will not be lost when the switch is powered down. To start, all you need is the following information: Basic Tank Information o HEIGHT – Distance from the transducer face to the bottom of the tank. o FILL‐H – Maximum fill height of the liquid from the bottom of the tank.
GETTING STARTED (continued) Step Four TOP‐LEVEL MENU Descriptions UNITS – Allows end user to select the units for configuration and operation. o Select between Inches, Centimeters, Feet, Meters or Percent. o Press EXIT to return to the TOP‐LEVEL MENU. TANK – Allows the end user to configure the operational range for the switch as well as the 4‐20 mA output signal. o HEIGHT – Distance from the transducer face to the bottom of the tank.
GETTING STARTED (continued) FILL – used to control a pump that fills a tank. Step Four Typically, Relay ON is the LOW set point and Relay OFF the HIGH set point. Relay will energize at the low set point (ON) and remain on until the level reaches the high set point (OFF) and will remain off until the level returns to the low set point (ON). DELAY – used as a start pump delay when the ON setting is reached. The delay pump (in seconds) will delay the start of the value for this period.
GETTING STARTED (continued) Step Four o ALARM – Alarm operation allows for a single set point (Relay ON and OFF at the same level). Choose between HIGH and LOW operation. Both operations will require a single set point and a setting for the Hysteresis (HYSTER) HIGH – used to control a High Level alarm. Relay will energize (ON) when the level is above the setting and will de‐energize (OFF) when the level falls below the setting plus the added distance from the hysteresis (HYSTER).
CONFIGURATION Step Five This section will take you through the key steps in the setup and configuration of the EchoSwitch®: 1) Select the units for configuration. a. Determine the measurement units that will be used to configure the sensor. 2) Measure the distance from the bottom of the tank (empty level) to the bottom of the sensor. a. Be sure to include the added height of installation fittings. 3) Measure the distance from the bottom of the tank (empty level) to the full level of liquid. a.
CONFIGURATION (cont.) Step Five How to configure the Operational range of EchoSwitch® Before starting, take two measurements. 1) Measure the distance from the bottom of the sensor (transducer face) to the bottom of the tank. This will be the HEIGHT setting. 2) Measure the distance from the bottom of the tank to the Maximum Level of Liquid (Full). This will be the FILL‐H setting. 1. In TOP‐LEVEL MENU mode, select TANK. 2. Select HEIGHT. 3.
CONFIGURATION (cont.) Step Five How to set a HIGH ALARM Before starting, measure the distance from the bottom of the tank to the High Alarm position (ON) in the tank. 1. In TOP‐LEVEL MENU mode, select RELAY1, RELAY2 or RELAY3. 2. Select ALARM. 3. Select HIGH. 4. Using the UP and DOWN buttons, set the HIGH (ON) set point for the relay. 5. To enter the value, press and hold SELECT for 2 seconds and release. SAVED will display. 6. Select HYSTER to set the Hysteresis. a.
CONFIGURATION (cont.) Step Five How to set a LOW ALARM Before starting, measure the distance from the bottom of the tank to the Low Alarm position (ON) in the tank. 1. In TOP‐LEVEL MENU mode, select RELAY1, RELAY2 or RELAY3. 2. Select ALARM. 3. Select LOW. 4. Using the UP and DOWN buttons, set the LOW (ON) set point for the relay. 5. To enter the value, press and hold SELECT for 2 seconds and release. SAVED will display. 6. Select HYSTER to set the Hysteresis. a.
CONFIGURATION (cont.) Step Five How to set a PUMP to FILL Before starting, take two measurements. 1) Measure the distance from the bottom of the tank to the Pump ON position. 2) Measure the distance from the bottom of the tank to the Pump OFF position. Pump ON will be physically lower than the Pump OFF position. 1. 2. 3. 4. 5. 6. In TOP‐LEVEL MENU mode, select RELAY1, RELAY2 or RELAY3. Select PUMP. Select FILL. Select ON. Using the UP and DOWN buttons, set the ON set point for the relay.
CONFIGURATION (cont.) Step Five How to set a PUMP to EMPTY Before starting, take two measurements. 1) Measure the distance from the bottom of the tank to the Pump ON position. 2) Measure the distance from the bottom of the tank to the Pump OFF position. Pump ON will be physically higher than the Pump OFF position. 1. 2. 3. 4. 5. 6. In TOP‐LEVEL MENU mode, select RELAY1, RELAY2 or RELAY3. Select PUMP. Select EMPTY. Select ON. Using the UP and DOWN buttons, set the ON set point for the relay.
CONFIGURATION (cont.) Step Five How to set a VALVE to FILL Before starting, take two measurements. 1) Measure the distance from the bottom of the tank to the Valve ON position. 2) Measure the distance from the bottom of the tank to the Valve OFF position. Valve ON will be physically lower than the Valve OFF position. 1. 2. 3. 4. 5. 6. In TOP‐LEVEL MENU mode, select RELAY1, RELAY2 or RELAY3. Select VALVE. Select FILL. Select ON. Using the UP and DOWN buttons, set the ON set point for the relay.
CONFIGURATION (cont.) Step Five How to set a VALVE to EMPTY Before starting, take two measurements. 1) Measure the distance from the bottom of the tank to the Valve ON position. 2) Measure the distance from the bottom of the tank to the Valve OFF position. Valve ON will be physically higher than the Valve OFF position. 1. 2. 3. 4. 5. 6. In TOP‐LEVEL MENU mode, select RELAY1, RELAY2 or RELAY3. Select VALVE. Select EMPTY. Select ON. Using the UP and DOWN buttons, set the ON set point for the relay.
CONFIGURATION (cont.) Step Five How to set Relay Fail‐Safe / LOST: In the event the sensor does not receive an echo, the Fail‐Safe Output or LOST setting can be set to turn each relay ON, OFF or HOLD (to last state) to achieve the desired fail‐safe condition. During fail‐safe, the display will read LOST. 1. 2. 3. 4. In TOP‐LEVEL MENU mode, select SAFE. Select R1 (Relay 1), R2 (Relay 2) or R2 (Relay 3). Select ON, OFF, or HOLD. Select EXIT to return to TOP‐LEVEL MENU.
CONFIGURATION (cont.) Step Five How to Duplex two relays: Duplex enables EchoSwitch® to use two relays to alternate after each cycle while performing a lead‐lag operation. To begin, configure two relays in the same mode (ex: two relays are set as PUMPs that FILL or two relays set as PUMPs that EMPTY). Be sure to set one relay with an ON Set Point at the Primary Level and the other relay ON Set Point at the Backup Level.
CONFIGURATION (cont.) Step Five How to Alternate two relays: Alternate enables EchoSwitch® to use two relays to alternate after each cycle. The configuration of Alternate is identical to Duplex with the exception of the Backup level is at a setting where the level will never achieve set point. To begin, configure two relays in the same mode (ex: two relays are set as PUMPs that FILL or two relays set as PUMPs that EMPTY).
CONFIGURATION (cont.) Step Five How to Triplex three relays: Triplex enables EchoSwitch® to use three relays to alternate after each cycle while performing a lead lag‐lag operation. To begin, configure all three relays in the same mode (ex: all relays are set as PUMPs that FILL or all relays set as PUMPs that EMPTY). Be sure to set all three relay with different ON Set Point, one for Primary, one for Backup and the other for Backup 2).
CONFIGURATION (cont.) Step Five How to Time Alternate relays: This function is only operational when two or more relays are configured as pumps performing the same function (either filling or emptying). This function is useful when a complete cycle of the pumps cannot be guaranteed such as a continuous inflow to a sump. Thus one pump may run longer than the other pump. To insure equal wear of both pumps, the alternating cycle can be set up on a timer.
ELECTRICAL Step Six Input Power and Relay Connections: The EchoSwitch® is powered from 95 to 250 VAC power. Power is applied to the L1 and L2 terminals. Typically, Hot is applied to L1 and Neutral to L2. The Gnd terminal should be connected to a solid earth ground to help shield the sensor from external EMI/RFI interference. The EchoSwitch® features three 60 VA, 2A max relays. Relay 1 has both the Normally Open and Normally Closed contacts available.
ELECTRICAL (cont.) Step Six Analog Output (4/20 mA): The analog output of the EchoSwitch® is a sinking 4/20 mA control circuit. The typical way to use this feature is to connect a positive supply to the MA+ input and to sense the current flow out of the MA‐ output with a sampling resistor as shown in the following diagram. The cabling should be a shielded twisted pair to minimize EMI interference. Typically 20 to 24 gauge wire is used in this application.
WIRING TO COMMON FLOWLINE DISPLAYS/CONTROLLERS Step Seven Wiring to Common Flowline Displays & Controller: Below is a quick review of wiring to the most common Flowline Displays & Controllers.
INSTALLATION Step Seven The EchoSwitch® 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 LU77 Series is the LM52‐1400 (2” thread x 1” thread) reducer bushing.
INSTALLATION (cont.) Step Seven Fitting Selection: Check the part number to determine the required fitting mount size and thread type. EchoSwitch® is commonly installed in tank adapters, flanges, brackets or standpipes. Note: Always include the gasket when installing the EchoSwitch®. 1. Tank Adapter: Select a tank adapter fitting, such as the LM52‐1890 for the LU74 Series or the LM52‐ 2890 for the LU74 & LU78 Series. a.
INSTALLATION (cont.) Step Seven 3. Flange (LU77 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 LU74 & LU78 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.
INSTALLATION (cont.) Step Seven 5. Stand Pipe: A standpipe maybe used to dampen turbulence or separate surface foam from the point of measurement 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 LU77 series, but this is the minimum size. ii. Pipe sizes larger than 3” can also be used. c. Use a coupling and reducer bushing to attach the EchoSwitch® to the pipe. i.
APPENDIX Step Eight Setup: Setup will display setting for all functions of EchoSwitch®. configuration of the sensor. 1. In TOP‐LEVEL MENU, select HELP. 2. Select SETUP. 3. Setup will list the following settings: a. UNITS, HEIGHT, FILL_H, RELAY1*, RELAY2*, RELAY3*. b. * Each relay will list the following settings: i. Relay Function, On Setting, Off Setting, Safe Setting and Delay 4. Select EXIT to return to TOP‐LEVEL MENU.
APPENDIX (continued) Step Eight Simulation (SIM‐T): This mode enables the end user to simulate changes in level without having the level of liquid move. The display will simulate level of liquid and will turn the relays ON and OFF according to how they were configured. Example: If Relay 1 is set as a High Alarm with an ON setting for 100.0 inches and a Hysteresis of 2.0 inches, then when the display goes above 100.0, Relay 1 will energize and when the level falls below 98.0, Relay 1 will de‐energize.
APPENDIX (continued) Step Eight Troubleshooting PROBLEM TANK does not appear on the main menu Display always jumps to the LOST condition M‐PLEX does not appear on the main menu Display shows FULL Display shows EMPTY Pumps or Valves do not alternate Relay closes, but does not open again Relay chatters on and off repeatedly Relay does not initially switch. 32 of 34 SOLUTION Units function is set for PERCENT on EchoSwitch®: When Units is set for PERCENT, the TANK function is disabled.
APPENDIX (continued) Step Eight User Settings: Fill out the chart below and keep as a record of your configuration.
WARRANTY Step Nine 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 of two years from the date of manufacture of such products.
