1. Introduction
The Flowline DL10-01 EchoPod Ultrasonic Level Transmitter is a general-purpose, non-contact liquid level sensor designed for continuous level measurement. It provides a 4-20 mA signal output and is suitable for various applications involving corrosive, sticky, or dirty liquids. This manual provides essential information for the proper installation, operation, and maintenance of your DL10-01 EchoPod transmitter.
Image showing the Flowline DL10-01 EchoPod Ultrasonic Level Transmitter, a compact device with a 1-inch NPT process mount and integrated cable.
2. Product Overview
The DL10-01 EchoPod offers reliable level measurement through ultrasonic technology. Key features include:
- Continuous Non-Contact Measurement: Measures liquid levels up to 49.2 inches (1.25 meters) without physical contact with the medium.
- 4-20 mA Output: Provides a standard industrial signal for integration with control systems, supporting distances up to 1000 feet (300 meters).
- WebCal Software Configuration: Easy setup and calibration using the free WebCal software and a USB adapter (Fob).
- Optimized Design: Features a narrow 2-inch beam width and a short 2-inch dead band, making it suitable for small tanks.
- Corrosion Resistance: Constructed with a PVDF transducer and a Type 6P polycarbonate enclosure, ensuring durability in corrosive environments.
- Automatic Temperature Compensation: Ensures accurate measurements across varying process temperatures.
The device includes a 48-inch (1.2m) 4-conductor shielded polyurethane cable for connection.
3. Setup and Installation
3.1 Mounting
The DL10-01 EchoPod features a 1-inch NPT process mount. Ensure the mounting location provides a clear, unobstructed path for the ultrasonic beam to the liquid surface. Use the provided Viton gasket to ensure a proper seal during installation.
3.2 Wiring
The transmitter operates on a 24 VDC loop power supply. It is a two-wire device with a 4-20 mA signal output. Connect the 4-conductor shielded cable according to the wiring diagram provided in the full product documentation. Ensure proper polarity and secure connections to prevent signal interference.
3.3 Configuration
Configuration of the DL10-01 is performed using the WebCal PC Windows software and a USB 2.0 adapter (Fob). This Fob is essential for setting parameters such as range, signal invert (4-20 mA or 20-4 mA), and signal fail-safe options (4 mA, 20 mA, 21 mA, 22 mA, or hold last). Connect the Fob to your PC and the transmitter to access the configuration interface.
The device features non-volatile memory, retaining settings even after power loss. Automatic temperature compensation is integrated to maintain measurement accuracy.
4. Operating Instructions
Once properly installed and configured, the DL10-01 EchoPod continuously emits ultrasonic pulses towards the liquid surface. The time it takes for these pulses to return is used to calculate the liquid level. This measurement is then converted into a 4-20 mA current signal, which can be read by a PLC, DCS, or other control system.
- Signal Output: The output signal directly corresponds to the measured liquid level, as configured in WebCal.
- Fail-Safe Mode: In the event of a measurement error or loss of signal, the transmitter will output the pre-configured fail-safe current (e.g., 4 mA, 20 mA, 21 mA, 22 mA, or hold last value).
- Monitoring: Regularly monitor the output signal and compare it with known liquid levels to ensure accurate operation.
5. Maintenance
The Flowline DL10-01 EchoPod is designed for minimal maintenance due to its non-contact measurement principle and robust construction.
- Cleaning: Periodically inspect the transducer face for any buildup of dirt, scale, or other contaminants. Clean gently with a soft cloth and mild detergent if necessary. Avoid abrasive materials that could damage the PVDF transducer.
- Enclosure Integrity: Ensure the Type 6P polycarbonate enclosure remains sealed and free from damage to maintain its submersible and corrosion-resistant properties.
- Cable Inspection: Check the polyurethane cable for any signs of wear, cuts, or damage. Replace if integrity is compromised.
No internal user-serviceable parts are present. Refer all repairs to qualified personnel.
6. Troubleshooting
This section addresses common issues you might encounter with the DL10-01 EchoPod transmitter.
6.1 Noisy or Erratic Signal
- Cause: Environmental interference, obstructions in the beam path, or temporary software/firmware glitch.
- Solution:
- Inspect the tank for any new obstructions or changes in the liquid surface that might interfere with the ultrasonic beam.
- Check for strong air currents or foam on the liquid surface.
- Disconnect and reconnect the power to the sensor to perform a "reboot." This can resolve temporary glitches.
- Verify wiring connections for looseness or corrosion.
- Use the WebCal software to check diagnostic information and re-calibrate if necessary.
6.2 No Output Signal
- Cause: No power, incorrect wiring, or sensor failure.
- Solution:
- Verify that 24 VDC power is supplied to the transmitter.
- Check all wiring connections for correctness and integrity.
- Ensure the Fob is not connected during normal operation, as it is for configuration only.
- If the issue persists, contact technical support.
6.3 Configuration Issues (Fob Related)
- Cause: Missing or faulty USB adapter (Fob), incorrect WebCal software installation, or driver issues.
- Solution:
- Ensure you have the correct Flowline USB adapter (Fob) for configuration.
- Verify that the WebCal software is correctly installed on your PC and that the necessary USB drivers are present.
- Try connecting the Fob to a different USB port or another computer.
7. Specifications
| Parameter | Value |
|---|---|
| Measurement Range | 49.2 inches (1.25 meters) |
| Accuracy | 0.125 inches (3 mm) |
| Resolution | 0.019 inches (0.5 mm) |
| Dead Band | 2 inches (5 cm) |
| Beam Width | 2 inches (5 cm) |
| Configuration | WebCal PC Windows USB 2.0 (requires Fob) |
| Memory | Non-volatile |
| Supply Voltage | 24 VDC (loop) |
| Consumption | 0.5W |
| Loop Resistance | 400Ω maximum |
| 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 Temperature | 20 to 140°F (-7 to 60°C) |
| Ambient Temperature | -31 to 140°F (-35 to 60°C) |
| Temperature Compensation | Automatic |
| Pressure (MWP) | 30 PSI (2 bar) |
| Enclosure Rating | Type 6P, encapsulated, corrosion resistant and submersible |
| Enclosure Material | Polycarbonate |
| Transducer Material | PVDF |
| Cable Type | 4-conductor, shielded |
| Cable Length | 48 inches (1.2 meters) |
| Process Mount | 1 inch NPT |
| Mount Gasket | Viton |
| Classification | General Purpose |
| Compliance | CE, RoHS |
| Approvals | cFMus |
| Product Dimensions | 7.5 x 7 x 2.3 inches |
| Item Weight | 7 ounces |
8. Warranty and Support
For specific warranty information regarding your Flowline DL10-01 EchoPod Ultrasonic Level Transmitter, please refer to the documentation provided at the time of purchase or contact your authorized Flowline distributor or the manufacturer directly. Warranty terms typically cover defects in materials and workmanship for a specified period.
For technical support, troubleshooting assistance beyond this manual, or inquiries about replacement parts, please contact Flowline customer service or your local distributor. Ensure you have your product model number (DL10-01) and any relevant purchase details available when seeking support.
