Echotel® 961/962 - Magnetrol International

ECHOTEL® 961/962
LOOP POWERED
Installation and Operating Manual
Ultrasonic
Single and
Dual Point
Level Switches
Model 961
Model 962
®
UNPACKING
Unpack the instrument carefully. Make sure all components
have been removed from the foam protection. Inspect all
components for damage. Report any concealed damage to
the carrier within 24 hours. Check the contents of the carton/crates against the packing slip and report any discrepancies to Magnetrol. Check the nameplate model number to
be sure it agrees with the packing slip and purchase order.
Check and record the serial number for future reference
when ordering parts.
0038
0344
Nameplate:
- part number
- serial n°
These units are in compliance with:
1. The EMC directive 2004/108/EC. The units have been tested to
EN 61326: 1997 + A1 + A2.
2. Directive 94/9/EC for equipment or protective system intended for use in
potentially explosive atmospheres. EC-type examination certificate number
ISSeP12ATEX033X - intrinsically safe and ISSeP12ATEX042 - flameproof enclosure.
3. The PED Directive 97/23/EC (pressure equipment directive). Safety accessories per category IV
module H1.
SPECIAL CONDITIONS FOR ATEX INTRINSICALLY SAFE USE
Materials marked as Category 1 equipment and used in hazardous areas requiring this category, shall be installed in such a
way that, even in the event of rare incidents, the aluminium enclosure cannot be an ignition source due to impact or friction.
MOUNTING
High alarm
High high alarm
Filling line
Pump control
High alarm
High alarm
Auto fill or
empty pump control
Pump protection
Low alarm
Pump
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Welded flange
Tri-Clamp®
DIN 11851
Varivent®
WIRING
Echotel® 961 electronics
Echotel® 962 electronics
MODEL 961
FAULT
TEST
LOOP
TEST
8
Hi 22
Lo 3.6
16
F
A
U
L
T
External grounding screw,
only for ATEX flameproof
enclosure.
TIME
DELAY
MODEL 962
FAULT
TEST
LOOP
TEST
Hi 22
Lo 3.6
8
TIME
DELAY
12
16
– +
– +
Cable gland
Plugged entry
– +
Ground
Shield to green grounding screw
Shield not connected
Standard shielded
twisted pair cable
(recommended but not needed
when wired as per NAMUR NE 21
for field strengths up to 10 V/m).
HAZARDOUS AREA
SAFE AREA
Standard trip amplifier
card
Important: Connect the unit to the ground for avoiding earth potential drifts.
USER INTERFACE
Echotel® 961
Echotel® 962
MODEL 961
FAULT
TEST
LOOP
TEST
8
Hi 22
Lo 3.6
Testing
fault
signal
Testing
loop
signal
Safe
green
LED
(8 mA)
16
Alarm
yellow
LED
(16 mA)
F
A
U
L
T
TIME
DELAY
Time delay
potentiometer
– +
Separate
fault red LED
MODEL 962
FAULT
TEST
LOOP
TEST
8
Hi 22
Lo 3.6
Testing
fault
signal
Testing
loop
signal
Safe
green
LED
(8 mA)
TIME
DELAY
12
16
Lower
gap
yellow
LED
(12 mA)
Time delay
potentiometer
– +
Upper
gap
red
LED
(16 mA)
3
SET UP AND FUNCTIONS
Set up
High – Low Level Failsafe selection:➀
In «Hi» position, the current will shift to 12/16 mA (report alarm) when the transducer is wet.
In «Lo» position, the current will shift to 12/16 mA (report alarm) when the transducer is dry.
In both positions, the current will stay at 8 mA to report a safe condition.
Fault selection:
Select for which signal the unit should report a malfunction ≥ 22 mA or ≤ 3,6 mA
Time delay setting:
Turning the potentiometer clockwise will increase the time delay from 0,5 s to 45 s. Time delay is typically used where turbulence, boiling or splashing can cause false level alarms.
Indication
Echotel 961
Failsafe➀
mode
Level
«Hi»
High Level
Failsafe
«Lo»
Low Level
Failsafe
Fault LED is ON = Fault indication
Echotel 962
Failsafe
mode
Level
«Hi»
High Level
Failsafe
«Lo»
Low Level
Failsafe
Output
signal
Fault
red LED
8 mA (± 1 mA)
ON
OFF
OFF
16 mA (± 1 mA)
OFF
ON
OFF
8 mA (± 1 mA)
ON
OFF
OFF
16 mA (± 1 mA)
OFF
ON
OFF
Output
signal
8 mA
12 mA
green LED yellow LED
16 mA
red LED
8 mA (± 1 mA)
ON
OFF
OFF
12 mA (± 1 mA)
OFF
ON
OFF
16 mA (± 1 mA)
OFF
OFF
ON
8 mA (± 1 mA)
ON
OFF
OFF
12 mA (± 1 mA)
OFF
ON
OFF
16 mA (± 1 mA)
OFF
OFF
ON
All LED’s OFF = Fault indication
➀ Use the following settings to replace Echotel 915 series with the new Echotel 961 series:
4
8 mA
16 mA
green LED yellow LED
For High Level Failsafe, use «Lo» setting = low current draw (from 16 mA (safe) to 8 mA (alarm))
For Low Level Failsafe, use «Hi» setting = high current draw (from 8 mA (safe) to 16 mA (alarm))
MAINTENANCE
Manual Testing
Loop Test: (8 mA / 12mA / 16mA):
Pressing the “Loop Test” pushbutton, will manually test the loop and connected actuators/indicators. The loop test forces the
output and corresponding LED’s to shift from 8 mA to 12 mA (only 962) to 16 mA back to 8 mA. The time delay setting is not
active during testing.
Fault Test (3.6 mA /22 mA):
Pressing the “Fault Test” pushbutton for min 2 s, will manually test the fault output and connected actuators/indicators. The fault
test simulates a circuit failure and forces the output to either ≤ 3.6 mA or ≥ 22 mA. The time delay setting is not active during
testing.
Troubleshooting
Problem
Action/Indication
No loop signal
No LED’s are ON
No change in output between
wet gap / dry gap
Gap may be plugged by
solids / dense foam
Chattering output
Excessive aeration / Turbulence
Fault LED is ON (961)
All LED’s OFF (962)
Gap is out of reach of liquid
A system fault has been detected
Press «Loop Test» pushbutton
to identify the problem:
*
--- *
: 1 flash (red LED)
** --- ** : 2 flashes (red LED)
*** --- *** : 3 flashes (red LED)
Solution
Check wiring / input power
Check for malfunction (962). See below
Clean the transducer
Check mounting section on page 2 and
relocate the unit or check blocking
valves.
Introduce a time delay
Check input power
Relocate the switch
Check input power
Check wiring between transducer and
electronics or replace transducer.
Replace electronics
The unit senses excessive noise
interference. Check shield connection or
eliminate interference from a walkietalkie, radio or other nearby source
5
REPLACEMENT PARTS
Replacing electronics/transducer
Echotel electronics can be removed in the field under process conditions. Follow below steps to exchange electronics/transducer:
Note: Adjust set up of the replacing electronics following the settings of the old electronics (see configuration section)
1.
2.
3.
4.
5.
6.
Disconnect power before removing the housing cover
Remove power/output wires (a)
(Skip step 3 if hygienic housing.) Click out the protection cap of the electronics (b)
Remove the 2 bracket screws and slide out electronics (c)
Remove the transducer wires (see Wiring section) (d)
Re-assemble following the same procedure in opposite way. Make sure that the tip on the bracket of the electronic block is
seated properly in the corresponding recess in the housing base - (e)
Replacement parts
Partn°:
Digit in partn°:
X 1 2 3
4 5 6 7
8 9 10
1
X = product with a specific customer requirement
Serial n°:
See nameplate, always provide complete partn° and
serial n° when ordering spares.
No.
1
2
3
4
Description
Cast aluminium cover (digit 10 = 0 or 1)
Blind
With window
Cast stainless steel cover (digit 10 = 2 or 3)
Blind
Deep drawn stainless steel cover
(digit 10 = 4 or 5)
Blind
With window
“O”-Ring
digit 10 = 0, 1, 2 or 3
digit 10 = 4 or 5
Electronic module for industrial
housing (digit 10 = 0, 1, 2 or 3)
961 - ATEX Exi/Exd
961 - Weatherproof
962
Electronic module for hygienic
housing (digit 10 = 4 or 5)
961
962
Transducer
Part Number
004-9192-009
036-4410-010
2
b
3
c
a
3
004-9192-011
036-5702-003
036-5702-002
012-2201-237
012-2201-155
3
d
3
e
089-7259-005
089-7259-003
089-7258-003
089-7256-003
089-7257-003
consult factory
4
6
MODEL IDENTIFICATION
A complete measuring system consists of:
1. Echotel® electronics
2. Echotel® transducer
1. Code for Echotel® electronics
BASIC MODEL NUMBER
9 6 1
9 6 2
Echotel® 961 electronics for single setpoint 9M1 transducers
Echotel® 962 electronics for dual setpoint 9M2 transducers
INPUT POWER
5 0 A
24 V DC 2-wire loop powered electronics with current shift output
ACCESSORIES
0
1
Blind housing cover
Housing cover with glass window (not for cast stainless steel housings)
MOUNTING
0
Integral mount electronics
APPROVALS
A
C
ATEX II 1 G Ex ia IIC T5 Ga, intrinsically safe
- except deep drawn SST housing
ATEX II 1/2 G / IEC Ex d IIC T6 Ga/Gb, flameproof enclosure
- except deep drawn SST housing
Weatherproof
- except deep drawn SST housing
Weatherproof
- deep drawn SST housing
1
7
HOUSING / CABLE ENTRY
1
0
3
2
5
4
9 6
5 0 A
0
Cast aluminium housing with M20 x 1,5 cable entry (2 entries – one plugged)
Cast aluminium housing with 3/4" NPT cable entry (2 entries – one plugged)
Cast stainless steel with M20 x 1,5 cable entry (2 entries – one plugged)
Cast stainless steel with 3/4" NPT cable entry (2 entries – one plugged)
Deep drawn 304 stainless steel with M20 x 1,5 cable entry (2 entries – one plugged)
Deep drawn 304 stainless steel with 1/2"NPT cable entry (1 entry)
complete code for Echotel® electronics
X = product with a specific customer requirement
7
MODEL IDENTIFICATION
2. Code for Echotel® transducer
BASIC MODEL NUMBER
9 M 1
9 M 2
Echotel® 961 transducer with single setpoint
Echotel® 962 transducer with dual setpoints
TRANSDUCER MATERIALS (use only metal transducers for hazardous area)
A
B
C
P
R
S
316/316L (1.4401/1.4404) stainless steel
Hastelloy® C (2.4819) – only available with 9M1
Monel® (2.4360) – only available with 9M1
CPVC
Kynar® (PVDF) – only available with 9M1
316/316L (1.4401/1.4404) stainless steel with 0,5 µm Ra (20 Ra) surface finish
PROCESS CONNECTION
Threaded (plastic transducers are only available with 3/4" NPT connection)
1 1
3/4" NPT
2 1
1" NPT
2 2
1" BSP (G 1")
ANSI Flanges for metal transducers
2 3
1"
150 lbs ANSI RF
2 4
1"
300 lbs ANSI RF
2 5
1"
600 lbs ANSI RF
3 3
1 1/2" 150 lbs ANSI RF
3 4
1 1/2" 300 lbs ANSI RF
3 5
1 1/2" 600 lbs ANSI RF
4 3
2"
150 lbs ANSI RF
4 4
2"
300 lbs ANSI RF
4 5
2"
600 lbs ANSI RF
ANSI Flanges for plastic transducers➀
2 3
3 3
4 3
1"
150 lbs ANSI RF➁
1 1/2" 150 lbs ANSI RF➁
2"
150 lbs ANSI RF➁
B
B
C
C
D
D
D
D
B
C
B
C
A
B
D
E
DN 25
DN 25
DN 40
DN 40
DN 50
DN 50
DN 50
DN 50
PN 16/25/40
PN 63/100
PN 16/25/40
PN 63/100
PN 16
PN 25/40
PN 63
PN 100
1 1/2" Tri-clamp®
2" Tri-clamp®
DN 65 Varivent® type N
SENSOR TYPE
A
C
EN 1092-1 Type A
EN 1092-1 Type B2
EN 1092-1 Type A
EN 1092-1 Type B2
EN 1092-1 Type A
EN 1092-1 Type A
EN 1092-1 Type B2
EN 1092-1 Type B2
EN (DIN) Flanges for plastic transducers➀
B A
C A
D A
DN 25 PN 16
DN 40 PN 16
DN 50 PN 16
B S
C S
D S
DN 25 DIN 11851
DN 40 DIN 11851
DN 50 DIN 11851
➀ CPVC flanges for CPVC transducers, Kynar® cladded SST flanges for Kynar® transducers
➁ FF (flat face) flanges for CPVC transducers
Hygienic
3 T
4 T
V V
EN (DIN) Flanges for metal transducers
EN 1092-1 Type A
EN 1092-1 Type A
EN 1092-1 Type A
Standard sensor: min -40 °C / max +165 °C (-40 °F / +325 °F)
Low temperature sensor: min -80 °C / max +120 °C (-110 °F / +250 °F) – only available with 9M1-A
ACTUATION LENGTH – specify per cm (0.39") increment
Total insertion length = actuation length + 6 mm (0.25")
9M1 transducers
0 0 3
0 0 5
3 3 0
Minimum 3 cm (1.2") – for metal transducers with NPT connections only
Minimum 5 cm (2") – for all other connections
Maximum 330 cm (130")
0 1 3
0 1 5
3 3 0
Minimum 13 cm (5.1") – for metal transducers with NPT connections only
Mininimum 15 cm (5.9") – for all other connections
Maximum 330 cm (130")
9M2 transducers "A" length
specify "B" length separately (min 8 cm and max 318 cm between "A" and "B")
9 M
8
complete code for Echotel® transducer
X = product with a specific customer requirement
DIMENSIONS IN mm (inches)
102
(4)
102
(4)
113 (4.43) without window
123 (4.85) with window
113 (4.43) without window
123 (4.85) with window
46 (1.8) Typical
Actuation
length
for BSP
connection
6 (0.25)
60 (2.35) Typical
Actuation length
for NPT connection
Actuation length
6 (0.25)
Ø 22,9 (0.90)
961 - Threaded connection
Ø 22,9 (0.90)
961 - Flanged connection
102
(4)
102
(4)
113 (4.43) without window
123 (4.85) with window
113 (4.43) without window
123 (4.85) with window
Actuation length
“B” for BSP
connection
Actuation
length “A”
for BSP
connection
6 (0.25)
46 (1.8) Typical
60 (2.35) Typical
Actuation length “B”
for NPT connection
Actuation length
“B”
Actuation length “A”
for NPT connection
Ø 22,9 (0.90)
962 - Threaded connection
Actuation length “A”
6 (0.25)
Ø 22,9 (0.90)
962 - Flanged connection
9
DIMENSIONS IN mm (inches)
58
(2.28)
52
(2.05)
60
(2.36)
125
(4.92)
Cable entry
109
(4.28)
43°
43° View
35 (1.38)
29 (1.14)
Actuation Length
Ø 22,9 (0.90)
6 (0.25)
Actuation Length
Ø 22,9 (0.90)
6 (0.25)
Actuation Length
Ø 22,9 (0.90)
6 (0.25)
DIN 11851
Tri-Clamp®
46 (1.81)
Varivent®
PRESSURE / TEMPERATURE RATINGS
160
CPVC Transducer Ratings
30
Process pressure (bar)
Process pressure (bar)
Kynar® Transducer Ratings
25
20
15
10
5
0
-40
0
40
80
120
Process temperature (°C)
120
30
25
20
Range with 3/4" NPT
15
10
Range with 150# flange
5
0
-40
Range with PN16 flange
0
40
80
120
Process temperature (°C)
Metal Transducer Ratings
80
Process pressure (bar)
40
-40
10
160
120
80
0
40
80
120
138 bar➀
165
103 bar
316/316L (1.4401/1.4404)➁
Hastelloy® C (2.4819)
Monel® (2.4360)
82,8 bar
40
-40
0
40
80
120
165
Process temperature (°C)
➀ Only applicable to NPT-connections with actuation length = 3 cm
and BSP/ANSI/EN (DIN)-connections with actuation length = 5 cm
➁ For low temperature sensor: from -80 °C up to +120 °C
SPECIFICATIONS
Electronics specifications
Description
Input Voltage
Power Consumption
Output
Time delay
Indication
Selftest
Housing material
Automatic
Manual
Approvals ➀
SIL (Safety Integrity Level)
Electrical data
Equivalent data
Shock/Vibration
Net weight
Specification
2 wire loop powered, 11 - 35 V DC
< 1 Watt
961: 8 mA (safe), 16 mA (alarm) ± 1 mA
962: 8 mA (safe), 12 mA (lower gap alarm), 16 mA (upper gap alarm) ± 1 mA
961/962: ≤ 3,6 or ≥ 22 mA error signal
0,5 to 45 s adjustable (in addition to transducer response time)
LED’s for process alarm status, malfunction (error of transducer, electronics or electrical noise interference)
Continuously verifies electronics, transducer and noise interference
Via pushbutton for checking alarm output(s) and error output/function.
IP66, cast aluminium, cast stainless steel or deep drawn 304 stainless steel (IP 67)
ATEX II 1 G Ex ia IIC T5 Ga, intrinsically safe (units with metal transducers)
ATEX II 1/2 G Ex d IIC T6 Ga/Gb, flameproof enclosure (units with metal transducers)
IEC Ex d IIC T6 Ga/Gb
Overfill prevention TÜV - WHG § 19 / VLAREM II 5.17.7
Other approvals are available, consult factory for more details
Functional safety to SIL 2 in accordance to IEC 61508 – SFF > 90 %
Full FMEDA report and declaration sheets available at request
Ui = 28,4 V, li = 94 mA, Pi = 0,67 W
Ci = 10,4 nF (961) / Ci = 60 nF (962), Li = 400 µH
ANSI/ISA-S71.03 Class SA1 (shock), ANSI/ISA-S71.03 Class VC2 (vibration)
Aluminium / Deep drawn 304 SST: 1 kg (2.2 lbs) – electronics only
Cast SST: 2,5 kg (5.5 lbs) – electronics only
➀ Only available with cast aluminium or cast stainless steel housings
Performance
Description
Response time
Repeatability
Ambient Temperature
Humidity
Electromagnetic Compatibility
Transducer specifications
Specification
0,5 s typical
± 2 mm (0.078")
-40 °C to +70 °C (-40 °F to +160 °F)
0-99 %, non-condensing
Meets CE requirements (EN 61326: 1997 + A1 + A2) and NAMUR NE 21
Description
Plastic transducers
Mounting
Threaded (NPT/BSP) – Flanged (ANSI - EN (DIN)) – Hygienic
Material
Actuation length
Process temp. (consult temp/
press. graphs)
Max pressure (consult temp/
press. graphs)
CPVC
Kynar® (PVDF)
Metal transducers
316/316L SST (1.4401/1.4404)
Hastelloy® C (2.4819)
Monel® (2.4360)
From 5 cm up to 330 cm (2" up to 130")
From 3 cm up to 330 cm (1.2" up to 130")
13,8 bar @ +40 °C (200 psi @ +100 °F)
for NPT threaded units
82,8 bar (1200 psi) for Monel transducers
Consult temp/press. graphs for other
materials
-40 °C to +120 °C (-40 °F to +250 °F) – PVDF
-40 °C to +80 °C (-40 °F to +180 °F) – CPVC
-40 °C to +165 °C (-40 °F to +325 °F) – standard
-80 °C to +120 °C (-110 °F to +250 °F) – low
temperature version in 316/316L SST
Flanged models are downrated to the design pressure of the selected flange
11
IMPORTANT
SERVICE POLICY
Owners of Magnetrol products may request the return of a control; or, any part of a control for complete rebuilding or
replacement. They will be rebuilt or replaced promptly. Magnetrol International will repair or replace the control, at no cost to
the purchaser, (or owner) other than transportation cost if:
a. Returned within the warranty period; and,
b. The factory inspection finds the cause of the malfunction to be defective material or workmanship.
If the trouble is the result of conditions beyond our control; or, is NOT covered by the warranty, there will be charges for labour
and the parts required to rebuild or replace the equipment.
In some cases, it may be expedient to ship replacement parts; or, in extreme cases a complete new control, to replace the
original equipment before it is returned. If this is desired, notify the factory of both the model and serial numbers of the
control to be replaced. In such cases, credit for the materials returned, will be determined on the basis of the applicability of
our warranty.
No claims for misapplication, labour, direct or consequential damage will be allowed.
RETURNED MATERIAL PROCEDURE
So that we may efficiently process any materials that are returned, it is essential that a “Return Material Authorisation” (RMA)
form will be obtained from the factory. It is mandatory that this form will be attached to each material returned. This form is
available through Magnetrol’s local representative or by contacting the factory. Please supply the following information:
1. Purchaser Name
2. Description of Material
3. Serial Number and Ref Number
4. Desired Action
5. Reason for Return
6. Process details
Any unit that was used in a process must be properly cleaned in accordance with the proper health and safety standards
applicable by the owner, before it is returned to the factory.
A material Safety Data Sheet (MSDS) must be attached at the outside of the transport crate or box.
All shipments returned to the factory must be by prepaid transportation. Magnetrol will not accept collect shipments.
All replacements will be shipped Ex Works.
BULLETIN N°:
EFFECTIVE:
SUPERSEDES:
UNDER RESERVE OF MODIFICATIONS
BE 51-646.8
FEBRUARY 2013
June 2012
www.m a gne t r ol.c om
BENELUX
FRANCE
Heikensstraat 6, 9240 Zele, België -Belgique
Tel. +32 (0)52.45.11.11 • Fax. +32 (0)52.45.09.93 • E-Mail: info@magnetrol.be
DEUTSCHLAND
Alte Ziegelei 2-4, D-51491 Overath
Tel. +49 (0)2204 / 9536-0 • Fax. +49 (0)2204 / 9536-53 • E-Mail: vertrieb@magnetrol.de
INDIA
C-20 Community Centre, Janakpuri, New Delhi - 110 058
Tel. +91 (11) 41661840 • Fax +91 (11) 41661843 • E-Mail: info@magnetrolindia.com
ITALIA
Via Arese 12, I-20159 Milano
Tel. +39 02 607.22.98 • Fax. +39 02 668.66.52 • E-Mail: mit.gen@magnetrol.it
RUSSIA
198095 Saint-Petersburg, Marshala Govorova street, house 35A, office 343
Tel. +7-812.702.70.87 • E-Mail: info@magnetrol.ru
U.A.E.
DAFZA Office 5EA 722 • PO Box 293671 • Dubai
Tel. +971-4-6091735 • Fax +971-4-6091736 • E-Mail: info@magnetrol.ae
UNITED
KINGDOM
Unit 1 Regent Business Centre, Jubilee Road Burgess Hill West Sussex RH 15 9TL
Tel. +44 (0)1444 871313 • Fax +44 (0)1444 871317 • E-Mail: sales@magnetrol.co.uk