ECHOTEL® 961/962 LINE 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 ISSeP12ATEX042 - flameproof enclosure. 3. The PED Directive 97/23/EC (pressure equipment directive). Safety accessories per category IV module H1. 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 ÀÀÀ @@@ @@@@ ÀÀÀÀ @@@ ÀÀÀ @@@@ @@@ÀÀÀÀ ÀÀÀ @@@@ ÀÀÀÀ Threaded 2 @@@@ @@@@ ÀÀÀÀ @ÀÀ@ÀÀÀÀ À@À@ ÀÀÀ @@@ @@@@ ÀÀÀÀ @@@ ÀÀÀ @@@ @ÀÀ@À@À@À@À@ ÀÀÀ @@@ @@@ ÀÀÀ À@À@À@À@À@À@ ÀÀÀ @@@ ÀÀÀ Welded flange Tri-Clamp® DIN 11851 Varivent® WIRING Echotel® 961 electronics Malfunction SPDT relay Echotel® 962 electronics 1 x DPDT (961) 2 x SPDT (962) relay(s) Ground Input power NC C NO NC Hi PC Lo LC NC C NO MALF RELAY Hi I Lo J NC C MALF TEST NO NC C NO WET MALF FAULT LEVEL L1 C NO C NO L1 L2 TIME DELAY LEVEL TEST MODEL 962 102 to 265 V AC L2 L1 TIME DELAY L2 18 to 32 V DC LEVEL TEST MODEL 961 NC UPPER LOWER MALF MALF UPPER TEST FAULT LOWER MALF RELAY + - HAZARDOUS AREA SAFE AREA NC Malfunction relay Process relay(s) C NO NC C NO Process relay(s) NC C NO Important: Connect the unit to the ground for avoiding earth potential drifts. Use the green internal grounding screw USER INTERFACE Echotel® 961 NC C NO MALF RELAY Hi I Lo J Testing malfunction relay NC MALF TEST Fault red LED C Echotel® 962 NO NC C NO WET MALF FAULT LEVEL Alarm status yellow LED NC L2 TIME DELAY LEVEL TEST MODEL 961 Wet yellow LED L1 C NO MALF RELAY Testing DPDT process relay Malfunction green LED Note: in normal operation «Fault» is OFF / «MALF» is ON in malfunction condition: «Fault» is ON / «MALF» is OFF NC C NO NC C NO L1 LOWER UPPER MALF MALF UPPER TEST FAULT LOWER Hi PC Lo LC Fault red LED MODEL 962 Malfunction green LED L2 TIME DELAY LEVEL TEST Lower gap alarm yellow LED Upper gap alarm yellow LED 3 SET UP AND FUNCTIONS Set up High – Low Level Failsafe selection: In «Hi» position, the process relay will de-energize (report alarm) when the transducer is wet. In «Lo» position, the process relay will de-energize (report alarm) when the transducer is dry. Fault selection: The echotel 961 is equipped with a malfunction relay separate from the 5A DPDT process relay. The separate or joined operation of both relays can be selected : I = in case of a malfunction, only the malfunction relay will de-energize. The process relay will only de-energize in case of a process alarm J = in case of a malfunction, both the malfunction relay and the process relay will de-energize The Echotel 962 is equipped with a malfunction relay separate from the two 5A SPDT process relays. In case of a malfunction, both the malfunction relay and the process relays will de-energize. The operation of the two process relays can be selected: LC (level control) = the two relays operate independent and will be de-energized when the corresponding tranducer gap is immerged/dry (following Hi/Lo setting) PC (pump control) = the two relays operate in a latched mode, allowing to perform an automatic fill or drain pump control function in between the 2 transducer gaps. Consult below tables for proper indication and function. 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. 961 - Relay/ LED Indication: When «WET» (wet LED): OFF = transducer gap is dry / ON = transducer gap is immerged When «LEVEL» (level LED): ON = relay is energized / OFF = relay de-energized Echotel 961: Relay/LED indication Mode «Hi» High level failsafe «Lo» Low level failsafe 4 Level Process relay « LEVEL» LED (relay - yellow) « WET» LED (gap - yellow) Energized ON OFF De-energized OFF ON Energized ON ON De-energized OFF OFF Error LED indication Fault (red) Malfunction (green) OFF = Normal operation ON = Normal operation ON = Malfunction See troubleshooting for malfunction identification OFF = Malfunction See troubleshooting for malfunction identification SET UP AND FUNCTIONS Echotel 962 as level control «LC»: Relay/LED indication Relay # 1 = lower gap – Relay # 2 = upper gap Level Mode «Hi» High level failsafe «Lo» Low level failsafe «Hi» High level failsafe «Lo» Low level failsafe «Hi» High level failsafe «Lo» Low level failsafe Process relay Lower LED Upper LED # 1 & 2: Energized ON ON # 1 & 2: De-energized OFF OFF OFF ON ON OFF De-energized OFF OFF Energized ON ON # 1: De-energized # 2: Energized # 1: Energized # 2: De-energized Error LED indication Malfunction Fault (red) (green) OFF = Normal operation ON = Malfunction See troubleshooting for malfunction identification ON = Normal operation OFF = Malfunction See troubleshooting for malfunction identification Echotel 962 pump control «PC»: Relay/LED indication High Level Failsafe (Hi) = auto empty mode Low Level Failsafe (Lo) = auto fill mode Level Mode Process relay Lower LED Upper LED «Hi» High level failsafe Energized ON ON «Hi» High level failsafe De-energized OFF OFF De-energized OFF OFF Energized ON ON De-energized OFF OFF Energized ON ON Energized ON ON De-energized OFF OFF «Lo» Low level failsafe «Lo» Low level failsafe «Hi» High level failsafe «Lo» Low level failsafe «Hi» High level failsafe «Lo» Low level failsafe Error LED indication Malfunction Fault (red) (green) OFF = Normal operation ON = Malfunction ON = Normal operation OFF = Malfunction See See troubleshooting troubleshooting for malfunction for malfunction identification identification 5 MAINTENANCE Manual Testing Level Test: (process relay(s)): Pressing the “Level Test” pushbutton, will manually test the process relays and connected actuators/indicators. The level test forces the relay(s) to change from a de-energized to an energized status and vice versa. The LED’s will be ON/OFF corresponding (see tables in the configuration section). The time delay setting is not active during testing. Malfunction Test (malfunction relay): Pressing the “Malfunction Test” pushbutton for min 2 s, will manually test the malfunction relay and connected actuators/indicators. The malfunction test simulates a circuit failure and forces all relays to de-energize. The «MALF» LED will turn OFF and the «FAULT» LED ON. The time delay setting is not active during testing. Troubleshooting Problem Action/Indication No output 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 Gap is out of reach of liquid A system fault has been detected Press «LEVEL TEST» test pushbutton to identify the problem: * --- * : 1 flash ** --- ** : 2 flashes *** --- *** : 3 flashes 6 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. 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 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 – AC power 961 – DC power 962 – AC power 962 – DC power Electronic module for hygienic housing (digit 10 = 4 or 5) 961 – AC power 961 – DC power 962 – AC power 962 – DC power Transducer Part Number 004-9192-009 036-4410-010 004-9192-011 036-5702-003 036-5702-002 2 b 3 c a 3 3 d 3 e 012-2201-237 012-2201-155 089-7259-001 089-7259-002 089-7258-001 089-7258-002 089-7256-001 089-7256-002 089-7257-001 089-7257-002 consult factory 4 7 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 2 D A 7 D A 18 - 32 V DC line powered electronics with 5 A gold flash relay(s) output 102 - 265 V AC line powered electronics with 5 A gold flash relay(s) output ACCESSORIES 0 1 Blind housing cover Housing cover with glass window (not for cast stainless steel housings) MOUNTING 0 Integral mount electronics APPROVALS C 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 3 7 HOUSING / CABLE ENTRY 1 0 3 2 5 4 9 6 8 D 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 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 transducers 2 3 1" 150 lbs ANSI RF 3 3 1 1/2" 150 lbs ANSI RF 4 3 2" 150 lbs ANSI RF EN (DIN) Flanges for metal transducers 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 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 transducers B A DN 25 PN 16 EN 1092-1 Type A C A DN 40 PN 16 EN 1092-1 Type A D A DN 50 PN 16 EN 1092-1 Type A CPVC flanges for CPVC transducers, Kynar® cladded SST flanges for Kynar® transducers FF (flat face) flanges for CPVC transducers Hygienic 3 T 4 T V V 1 1/2" Tri-clamp® 2" Tri-clamp® DN 65 Varivent® type N SENSOR TYPE A C B S C S D S DN 25 DIN 11851 DN 40 DIN 11851 DN 50 DIN 11851 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 complete code for Echotel® transducer X = product with a specific customer requirement 9 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 Actuation length “B” for NPT connection Actuation length “B” Actuation length “A” for NPT connection Ø 22,9 (0.90) 962 - Threaded connection 10 60 (2.35) Typical Actuation length “A” 6 (0.25) Ø 22,9 (0.90) 962 - Flanged connection DIMENSIONS IN mm (inches) 52 (2.05) 58 (2.28) 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) Actuation Length Ø 22,9 (0.90) 6 (0.25) 6 (0.25) Tri-Clamp® 46 (1.81) Actuation Length Ø 22,9 (0.90) 6 (0.25) DIN 11851 Varivent® 11 SPECIFICATIONS Electronics specifications Description Input Voltage Power Consumption Output Time delay Indication Selftest Housing material Automatic Manual Approvals SIL (Safety Integrity Level) Shock/Vibration Net weight Specification 102 - 265 V AC 50/60 Hz or 18 - 32 V DC < 3 Watt 961: one 5 A DPDT relay, 962: two 5 A SPDT relays 961/962: one 5 A SPDT malfunction relay 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) and wet/dry status of transducer (961 only) 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 1/2 G Ex d IIC T6 Ga/Gb flameproof enclosure (units with metal transducers) IEC Ex d IIC T6 Ga/Gb Overfill prevention TÜV - WHG § 63 / 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. 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 Only available with cast aluminium or cast stainless steel housings. Performance Description Response time Repeatability Ambient Temperature Humidity Electromagnetic Compatibility Transducer specification 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) 12 Metal transducers CPVC Kynar® (PVDF) 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 PRESSURE / TEMPERATURE RATINGS 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) 160 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) 120 Metal Transducer Ratings 80 Process pressure (bar) 40 -40 160 120 80 0 40 80 120 138 bar 165 103 bar 316/316L (1.4401/1.4404) Hastelloy® C (2.4819) Monel® (2.4360) 82,8 bar 40 -40 0 40 80 120 165 Process temperature (°C) Only applicable to NPT-connections with actuation length = 3 cm and BSP/ANSI/EN (DIN)-connections with actuation length = 5 cm For low temperature sensor: from -80 °C up to +120 °C 13 14 15 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. 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