Echotel Model 961/962 Instruction Manual

Model 961/962
Installation and Operating Manual
Ultrasonic
Single and
Dual Point
Level Switches
Model 961
Model 962
Read this Manual Before Installing
This manual provides information on the Echotel®
Models 961 and 962 Ultrasonic Liquid Level Switches.
It is important that all instructions are read carefully and
followed in sequence. Detailed instructions are included
in the Installation section of this manual.
Conventions Used in this Manual
Certain conventions are used in this manual to convey
specific types of information. General technical material,
support data, and safety information are presented in
narrative form. The following styles are used for notes,
cautions, and warnings.
Notes
Notes contain information that augments or clarifies
an operating step. Notes do not normally contain
actions, they follow the procedural steps to which
they refer.
Cautions
Cautions alert the technician to special conditions
that could injure personnel, damage equipment, or
reduce a component’s mechanical integrity. Cautions
are also used to alert the technician to unsafe practices or the need for special protective equipment or
specific materials. In this manual, a caution box indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury.
Warnings
Warnings identify potentially dangerous situations or
serious hazards. In this manual, a warning indicates
an imminently hazardous situation which, if not
avoided, could result in serious injury or death.
Safety Messages
ECHOTEL Models 961 & 962 are designed for use in
Category II, Pollution Degree 2 installations. Follow all
standard industry procedures for servicing electrical and
computer equipment when working with or around high
voltage. Always shut off the power supply before touching any components.
Electrical components are sensitive to electrostatic discharge. To prevent equipment damage, observe safety
procedures when working with electrostatic sensitive
components.
This device complies with Part 15 of the FCC rules.
Operation is subject to the following two conditions:
(1) This device may not cause harmful interference,
and (2) This device must accept any interference
received, including interference that may cause
undesired operation.
WARNING! Explosion hazard. Do not connect or disconnect equipment unless power has been switched off
or the area is known to be non-hazardous.
Low Voltage Directive
For use in Category II installations. If equipment is used
in a manner not specified by manufacturer, protection
provided by equipment may be impaired.
Notice of Trademark, Copyright, and Limitations
Magnetrol®, Magnetrol® logotype and Echotel® are
registered tradenames of Magnetrol International,
Incorporated.®
Copyright © 2014 MAGNETROL INTERNATIONAL,
INCORPORATED. All rights reserved.
Performance specifications are effective with date of issue
and are subject to change without notice. MAGNETROL
reserves the right to make changes to the product
described in this manual at any time without notice.
MAGNETROL makes no warranty with respect to the
accuracy of the information in this manual.
Warranty
All MAGNETROL electronic level and flow products
are warranted free of defects in materials or workmanship for one full year from the date of original factory
shipment.
If returned within the warranty period; and, upon factory
inspection of the control, the cause of the claim is
determined to be covered under the warranty; then,
MAGNETROL will repair or replace the control at no
cost to the purchaser (or owner) other than transportation.
MAGNETROL shall not be liable for misapplication,
labor claims, direct or consequential damage or expense
arising from the installation or use of equipment. There
are no other warranties expressed or implied, except special written warranties covering some MAGNETROL
products.
Quality Assurance
The quality assurance system in place at MAGNETROL
guarantees the highest level of quality throughout the
company. MAGNETROL is committed to providing
full customer satisfaction both in quality products and
quality service.
The MAGNETROL quality assurance
system is registered to ISO 9001
affirming its commitment to known
international quality standards
providing the strongest assurance of
product/service quality available.
51-646 Echotel® Model 961 & 962 Ultrasonic Level Switches
Echotel® Model 961 & 962
Ultrasonic Single and Dual Point
Liquid Level Switches
Table of Contents
1.0 Introduction ...................................................................4
1.1 Principle of Operation ..............................................4
2.0 Installation .....................................................................4
2.1 Unpacking ................................................................4
2.2 ESD Handling Procedure..........................................5
2.3 Mounting..................................................................5
2.4 Wiring ......................................................................6
2.4.1 Model 961 Line-powered Wiring ...................6
2.4.1.1 Model 961 Remote Transducer
Housing Wiring ......................................7
2.4.2 Model 961 Loop-powered Wiring..................8
2.4.2.1 Model 961 Remote Transducer
Housing Wiring ......................................8
2.4.3 Model 962 Line-powered Wiring ...................9
2.4.3.1 Model 962 Remote Transducer
Housing Wiring ....................................10
2.4.4 Model 962 Loop-powered Wiring................11
2.4.4.1 Model 962 Remote Transducer
Housing Wiring ....................................11
2.5 Configuration .........................................................12
2.5.1 Model 961 Line-powered Configuration ......12
2.5.1.1 Time Delay Potentiometer ....................13
2.5.1.2 Level Test Push Button..........................13
2.5.1.3 Malfunction Test Push Button ..............13
2.5.1.4 High/Low DIP Switch ..........................14
2.5.1.5 Independent/Joint DIP Switch..............14
2.5.2 Model 961 Loop-powered Configuration.....15
2.5.2.1 Time Delay Potentiometer ....................15
2.5.2.2 Loop Test Push Button..........................15
2.5.2.3 Fault Test Push Button..........................15
2.5.2.4 High/Low DIP Switch ..........................16
2.5.2.5 22/3.6 DIP Switch ................................16
2.5.3 Model 962 Line-powered Configuration ......17
2.5.3.1 Time Delay Potentiometer ....................17
2.5.3.2 Level Test Push Button..........................17
51-646 Echotel® Model 961 & 962 Ultrasonic Level Switches
2.5.3.3 Malfunction Test Push Button ..............17
2.5.3.4 High/Low DIP Switch ..........................18
2.5.3.5 PC/LC DIP Switch ...............................18
2.5.3.6 LC and Hi/Lo DIP Switch Configuration 18
2.5.3.7 PC and Hi/Lo DIP Switch Configuration 19
2.5.4 Model 962 Loop-powered Configuration.....20
2.5.4.1 Time Delay Potentiometer ....................20
2.5.4.2 Loop Test Push Button..........................20
2.5.4.3 Fault Test Push Button..........................20
2.5.4.4 High/Low DIP Switch ..........................21
2.5.4.5 22/3.6 DIP Switch ................................21
3.0 Reference Information..................................................22
3.1 Electronics Specifications ........................................22
3.1.1 Model 961/962 with Relay Output..............22
3.1.2 Model 961/962 with Current Shift Output .22
3.2 Performance Specifications ......................................22
3.3 Physical Specifications.............................................23
3.4 Transducer Specifications ........................................23
3.4.1 Model 9A1/9M1 Single Point ......................23
3.4.2 Model 9A2/9M2 Dual Point........................23
3.5 Dimensional Specifications .....................................24
3.6 Agency Approvals....................................................26
3.6.1 Agency (FM/CSA) Drawing and
Entity Parameters .........................................27
3.7 Troubleshooting ......................................................28
3.8 Replacement Parts...................................................30
3.9 Model Number .......................................................32
3.9.1 Model 961/962 Electronics ..........................32
3.9.2 Model 961 Single Point Transducer..............33
3.9.3 Model 962 Dual Point Transducer ...............34
3.9.4 Connecting Cable ........................................35
1.0
Introduction
ECHOTEL Model 961 and 962 ultrasonic level switches
utilize pulsed signal technology to detect high, low, or dual
point level in a broad range of liquid media applications.
Model 961 is a single point level switch. Model 962 is a
dual point switch used as a level controller or to control
pumps in an auto-fill or auto-empty mode.
1.1
Ultrasonic
transducer
Transmit
crystal
Receive
crystal
Figure 1
Ultrasonic Signal Transmission
Across Transducer Gap
Principle of Operation
Model 961/962 switches utilize ultrasonic energy to detect
the presence or absence of liquid in a single or dual point
transducer. Ultrasonic contact level technology uses highfrequency sound waves that are easily transmitted across a
transducer gap (see Figure 1) in the presence of a liquid
media, but are attenuated when the gap is dry. Model
961/962 switches use an ultrasonic frequency of 2 MHz to
perform this liquid level measurement in a wide variety of
process media and application conditions.
The transducer uses a pair of piezoelectric crystals that are
encapsulated in epoxy at the tip of the transducer. The
crystals are made of a ceramic material that vibrates at a
given frequency when subjected to an applied voltage. The
transmit crystal converts the applied voltage from the electronics into an ultrasonic signal. When liquid is present in
the gap, the receive crystal senses the ultrasonic signal from
the transmit crystal and converts it back to an electrical
signal. This signal is sent to the electronics to indicate the
presence of liquid in the transducer gap. When there is no
liquid present, the ultrasonic signal is attenuated and is not
detected by the receive crystal.
2.0
Installation
2.1
Unpacking
Unpack the instrument carefully. Inspect all units for
damage. Report any concealed damage to carrier within
24 hours. Check the contents of the packing slip and
purchase order. Check and record the serial number for
future reference when ordering parts.
serial number
4
51-646 Echotel® Model 961 & 962 Ultrasonic Level Switches
2.2
Electrostatic Discharge (ESD) Handling
Procedure
MAGNETROL electronic instruments are manufactured to
the highest quality standards. These instruments use
electronic components that may be damaged by static
electricity present in most work environments.
•
•
•
•
2.3
Dual Point Alarm
Pump
Protection
Low Alarm
Figure 2
Typical Mounting Orientations
Mounting
The Model 961 level switch may be mounted in a variety
of positions as shown in Figures 2 through 5. Model 962
is always mounted vertically.
High Alarm
Fill Line
The following steps are recommended to reduce the risk of
component failure due to electrostatic discharge.
Ship and store circuit boards in anti-static bags. If an antistatic bag is not available, wrap the board in aluminum
foil. Do not place boards on foam packing materials.
Use a grounding wrist strap when installing and removing
circuit boards. A grounded workstation is recommended.
Handle circuit boards only by the edges. Do not touch
components or connector pins.
Make sure that all electrical connections are completely
made and none are partial or floating. Ground all equipment to a good, earth ground.
Proper orientation of the transducer gap will facilitate
maximum performance in difficult applications. When the
Model 961 is mounted horizontally, the transducer gap
must be turned vertically to allow proper drainage of liquid
out of the gap. The wrench flats on the mounting nut are
aligned with the transducer gap; therefore, proper transducer mounting can be achieved by aligning the mounting
nut flats in a vertical orientation. See Figure 4. For flanged
transducers, a vertical gap orientation should be confirmed
prior to installing unit to the mating flange.
When installing a Model 961 switch in a nozzle or pipe,
the transducer gap must extend into the tank at least one
inch beyond the inside tank wall. Refer to Figure 5.
Screw transducer into the opening using a wrench on the
transducer mounting nut flats. If flanged, bolt unit to mating flange with proper gasket. Use thread tape or suitable
pipe compound on the threads. Do not over-tighten.
Use wrench on flats
Process
connection
Bottom View
Bottom View
Figure 3
Vertical Mounting
51-646 Echotel® Model 961 & 962 Ultrasonic Level Switches
Figure 4
Horizontal Mounting
Figure 5
Nozzle Mounting
5
2.4
Wiring
Wiring for Model 961/962 level switches is different for all
four versions. These switches are available as 4-wire, linepowered units with 5-amp relays, or as 2-wire loop-powered units with mA current shift output. Determine which
version you have from the table below and proceed to the
proper wiring section.
Model
Input
Output
Wiring Information
961
Line-powered
5 amp relays
Proceed to section 2.4.1
961
Loop-powered
Current shift
Proceed to section 2.4.2
962
Line-powered
5 amp relays
Proceed to section 2.4.3
962
Loop-powered
Current shift
Proceed to section 2.4.4
2.4.1 Model 961 Line-powered Wiring
Power and relay wiring connections are suitable for
12–24 AWG wire.
Caution: OBSERVE ALL APPLICABLE ELECTRICAL CODES
AND PROPER WIRING PROCEDURES.
Level DPDT
Relay
Malfunction
SPDT Relay
NC
Input
Power
Ground
C
NO
MALF RELAY
Hi I
Lo J
NC
MALF
TEST
C
NO
NC
C
NO
WET
MALF
FAULT LEVEL
MODEL 961
L1
L2
TIME
DELAY
LEVEL
TEST
Figure 6
Model 961 Line-Powered Wiring
1. Make sure the power source is turned off.
2. Unscrew and remove housing cover.
3. Pull power supply and relay wires through the conduit
connection.
4. Refer to Figure 6. Connect power leads to proper terminals.
Model 961 is available for AC power (102 to 265 VAC) or
for DC power (18–32 VDC)
a. AC Power – Connect “hot” wire to terminal marked L1
and the “neutral” wire to the terminal marked L2. The
green head screw should be used for grounding.
b. DC Power – Connect wires to terminals (+) and (-) on
the terminal block. The green head screw should be
used for grounding.
5. Connect desired relay wiring as shown in Figure 6.
6. Prevent moisture seepage into housing by installing an
approved seal drain fitting in the conduit run leading to
the unit.
7. Wiring is complete. Replace housing cover.
Caution: In hazardous areas, do not power the unit until the
conduit is sealed and enclosure cover is screwed
down securely.
NOTE: Housing must be grounded via green head ground screw in
the base of the housing.
6
51-646 Echotel® Model 961 & 962 Ultrasonic Level Switches
2.4.1.1 Model 961 Remote Transducer Housing Wiring
Remote mount Model 961 units have a “1” as the 8th
digit (961-XXXX-1XX) of the model number. The
037-3316-XXX cabling is connected at the factory on the
electronics end, and secured with a cable tie. The other
end of the cabling is connected by the user inside the
remote transducer housing at a terminal block marked as
1 2 3 4 on a blue label. See Figure 7.
NOTE: The 037-3316-XXX cabling is connected at the factory on the
electronics end. TB1 and TB2 connections are shown below
in Figure 7 in the event the cable needs to be reattached.
Model 961 Line-powered Remote Mount Wiring
Transducer Housing
Terminal Position
Wire
Electronics Terminal Block
& Terminal Position
1
Receive Shield
2
Receive Signal
3
Transmit Shield
4
Transmit Signal
TB1
RECV
TB2
XMIT
NOTE: The Signal wires are 30 AWG RG Type 178/U coax with the white jacket stripped
off. The Shield wires are prepared with solid tinned copper 22 AWG bus wire.
Ground
RECV
TB1
TB2
TB2
XMIT
P2
TB1
Shield: 1, 3
030-3591-001
Signal: 2, 4
R29
Electronics Module
Remote Transducer Housing
037-3316-xxx Cabling
Figure 7
Model 961 Line-Powered Remote Transducer Wiring
51-646 Echotel® Model 961 & 962 Ultrasonic Level Switches
7
2.4.2 Model 961 Loop-powered Wiring
For intrinsically safe installations, refer to the Agency
Drawing in Section 3.6.1. Loop wiring connections are
suitable for 12–24 AWG wire.
Caution: OBSERVE ALL APPLICABLE ELECTRICAL CODES
AND PROPER WIRING PROCEDURES.
MODEL 961
FAULT
TEST
LOOP
TEST
8
Hi 22
Lo 3.6
16
F
A
U
L
T
TIME
DELAY
1.
2.
3.
4.
Make sure the power source is turned off.
Unscrew and remove housing cover.
Pull twisted pair wire through the conduit connection.
Refer to Figure 8. Connect wires to terminals (+) and (-)
on the terminal block. Unshielded cable may be used. If
shielded cable is used, attach shield to green head screw.
5. Prevent moisture seepage into housing by installing an
approved seal drain fitting in the conduit run leading to
the unit.
6. Wiring is complete. Replace housing cover.
– +
– +
Ground
Figure 8
Model 961 Loop-Powered Wiring
Caution: In hazardous areas, do not power the unit until the
conduit is sealed and enclosure cover is screwed
down securely.
2.4.2.1 Model 961 Remote Transducer Housing Wiring
Remote mount Model 961 units have a “1” in the 8th
digit (961-XXXX-1XX) of the model number. The
037-3316-XXX cabling is connected at the factory on the
electronics end, and secured with a cable tie. The other
end of the cabling is connected by the user inside the
remote transducer housing at a terminal block marked as
1 2 3 4 on a blue label. See Figure 9.
NOTE: The 037-3316-XXX cabling is connected at the factory on the
electronics end. TB2 and TB3 connections are shown in
Figure 9 in the event the cable needs to be reattached.
Model 961 Loop-powered Remote Mount Wiring
Transducer Housing
Terminal Position
Wire
1
Receive Shield
Electronics Terminal Block
& Terminal Position
RECV
Wire
Receive Signal
TB3
2
Receive Signal
3
Transmit Shield
Receive Shield
XMIT
Transmit Signal
TB2
4
Transmit Signal
Transmit Shield
NOTE: The Signal wires are 30 AWG RG Type 178/U coax with the white jacket stripped off. The Shield wires
are prepared with solid tinned copper 22 AWG bus wire.
8
51-646 Echotel® Model 961 & 962 Ultrasonic Level Switches
RECV
FORCE
FAULT
TB3
FORCE
CHANGE
TB3
XMIT
8ma
16ma
FAULT
DELAY
Ground
TB2
Shield: 1, 3
TB2
Signal: 2, 4
037-3316-xxx Cabling
Electronics Module
Remote Transducer Housing
Figure 9
Model 961 Loop-Powered Remote Transducer Wiring
2.4.3 Model 962 Line-powered Wiring
Lower Gap
SPDT Relay
Malfunction
SPDT Relay
NC
Input
Power
Ground
C
NO
MALF RELAY
Hi PC
Lo LC
NC
Power and relay wiring connections are suitable for 12–
24 AWG wire.
Upper Gap
SPDT Relay
Caution: OBSERVE ALL APPLICABLE ELECTRICAL CODES
AND PROPER WIRING PROCEDURES.
C
NO
NC
C
NO
LOWER
UPPER
MALF
MALF
UPPER
TEST
FAULT
LOWER
MODEL 962
L1
1. Make sure the power source is turned off.
2. Unscrew and remove housing cover.
3. Pull power supply and relay wires through the conduit
connection.
4. Refer to Figure 10. Connect power leads to proper terminals.
Model 962 is available for AC power (102 to 265 VAC) or
for DC power (18–32 VDC)
a. AC Power – Connect “hot” wire to terminal marked L1
and the “neutral” wire to the terminal marked L2. The
green head screw should be used for grounding.
b. DC Power – Connect wires to terminals (+) and (-) on
the terminal block. The green head screw should be
used for grounding.
5. Connect desired relay wiring as shown in Figure 10.
6. Prevent moisture seepage into housing by installing an
approved seal drain fitting in the conduit run leading to
the unit.
7. Wiring is complete. Replace housing cover.
L2
TIME
DELAY
LEVEL
TEST
Figure 10
Model 962 Line-Powered Wiring
Caution: In hazardous areas, do not power the unit until the
conduit is sealed and enclosure cover is screwed
down securely.
51-646 Echotel® Model 961 & 962 Ultrasonic Level Switches
9
2.4.3.1 Model 962 Remote Transducer Housing Wiring
Remote mount Model 962 units have a “1” in the 8th
digit (962-XXXX-1XX) of the model number. The
037-3317-XXX cabling is connected at the factory on the
electronics end, and secured with a cable tie. The other
end of the cabling is connected by the user inside the
remote transducer housing at terminal blocks marked as
1 2 3 4 5 6 7 8 on a blue label. See Figure 11 for proper
terminations.
NOTE: The 037-3317-XXX cabling is connected at the factory on the
electronics end. TB1, TB2, TB3, and TB4 connections are
shown below in Figure 11 in the event the cable needs to be
reattached.
Ground
TB1
TB4
TB3
XMIT1
RCV2
TB2
Signal: 2, 4, 6, 8
TB2
TB3
Shield: 1, 3, 5, 7
XMIT2
TB4
RCV1
P2
TB1
Model 962 Remote Transducer Wiring
037-3317-xxx Cabling
Figure 11
Model 962 Line-Powered Remote Transducer Wiring
Model 962 Line-powered Remote Mount Wiring
Transducer
Gap
Cable
Marker
Wire
Marker
Transducer
Housing TB
Position
Electronics
Housing TB &
Terminal Position
Wire
Upper
High
1
1
Transmit Shield
Upper
High
1
2
Transmit Signal
Upper
High
(none)
3
Receive Shield
Upper
High
(none)
4
Receive Signal
Lower
Low
1
5
Transmit Shield
Lower
Low
1
6
Transmit Signal
Lower
Low
(none)
7
Receive Shield
Lower
Low
(none)
8
Receive Signal
TB4
TB1
TB2
TB3
XMT1
RCV1
XMT2
RCV2
NOTE: The Signal wires are 30 AWG RG Type 178/U coax with the white jacket stripped off. The Shield wires
are prepared with solid tinned copper 22 AWG bus wire.
10
51-646 Echotel® Model 961 & 962 Ultrasonic Level Switches
2.4.4 Model 962 Loop-powered Wiring
For intrinsically safe installations, refer to the Agency
Drawing in Section 3.6.1. Loop wiring connections are
suitable for 12–24 AWG wire.
Caution: OBSERVE ALL APPLICABLE ELECTRICAL CODES
AND PROPER WIRING PROCEDURES.
MODEL 962
1.
2.
3.
4.
Make sure the power source is turned off.
Unscrew and remove housing cover.
Pull twisted pair wire through the conduit connection.
Refer to Figure 12. Connect wires to terminals (+) and (-)
on the terminal block. Unshielded cable may be used. If
shielded cable is used, attach shield to green head screw.
5. Prevent moisture seepage into housing by installing an
approved seal drain fitting in the conduit run leading to
the unit.
6. Wiring is complete. Replace housing cover.
TIME
DELAY
FAULT
TEST
LOOP
TEST
8
Hi 22
Lo 3.6
12
16
– +
Ground
– +
Figure 12
Model 962 Loop Power Wiring
Caution: In hazardous areas, do not power the unit until the
conduit is sealed and enclosure cover is screwed
down securely.
2.4.4.1 Model 962 Remote Transducer Housing Wiring
Remote mount Model 962 units have a “1” in the 8th
digit (962-XXXX-1XX) of the model number. The
037-3317-XXX cabling is connected at the factory on the
electronics end and secured with a cable tie. The other end
of the cabling is connected by the user inside the remote
transducer housing at terminal blocks marked as
1 2 3 4 5 6 7 8 on a blue label. See Figure 13 for proper
terminations.
51-646 Echotel® Model 961 & 962 Ultrasonic Level Switches
11
TB1
Ground
TB1
TB3
XMIT2
TB4
RECV2
Shield: 1, 3, 5, 7
Signal: 2, 4, 6, 8
037-3317-xxx Cabling
XMIT1
TB2
RECV1
TB4
TB3
TB2
Model 962 Remote Transducer Wiring
Figure 13
Model 962 Loop-Powered Remote Transducer Wiring
Model 962 Loop-powered Remote Mount Wiring
Transducer
Gap
Cable
Marker
Wire
Marker
Transducer
Housing TB
Position
Electronics
Housing TB &
Terminal Position
Wire
Upper
High
1
1
Transmit Shield
Upper
High
1
2
Transmit Signal
Upper
High
(none)
3
Receive Shield
Upper
High
(none)
4
Receive Signal
Lower
Low
1
5
Transmit Shield
Lower
Low
1
6
Transmit Signal
Lower
Low
(none)
7
Receive Shield
Lower
Low
(none)
8
Receive Signal
TB2
TB3
TB4
TB1
XMT1
RCV1
XMT2
RCV2
NOTE: The Signal wires are 30 AWG RG Type 178/U coax with the white jacket stripped off. The Shield wires are
prepared with solid tinned copper 22 AWG bus wire.
2.5 Configuration
2.5.1 Model 961 Line-powered Configuration
•
•
•
•
•
12
Model 961 line-powered units have the following
configuration options:
TIME DELAY potentiometer for 0.5 to 45 second
signal averaging
LEVEL TEST push button for testing of the DPDT
process level alarm
MALF TEST push button for testing of the SPDT
malfunction alarm
Hi/Lo DIP switch for fail-safe high or low level selection
I/J DIP switch for independent or joint operation of
the relays
51-646 Echotel® Model 961 & 962 Ultrasonic Level Switches
2.5.1.1 Time Delay Potentiometer
NC
C
NO
MALF RELAY
Hi I
Lo J
NC
C
MALF
TEST
NO
NC
C
NO
L1
WET
MALF
FAULT LEVEL
MODEL 961
The time delay potentiometer is typically used in applications where turbulence or splashing may cause false level
alarms. This is a 25-turn pot with a factory default setting
of 0.5 seconds. If desired, this pot may be turned clockwise
to increase the response time from the standard 0.5 seconds
to a maximum of 45 seconds. Turning the pot counterclockwise decreases the time delay.
L2
TIME
DELAY
The WET LED is not influenced by the time delay pot.
As an example, turning the pot clockwise several turns will
put a time delay into the 961. Immersing the tip of the
transducer in water with the Hi/Lo switch in the Hi position, will produce the following results:
• WET LED will immediately turn on
• After the time delay the LEVEL LED will turn off and the
DPDT process level relay will de-energize
LEVEL
TEST
Level Test
Pushbutton
High/Low
DIP Switch
Malfunction Test
Pushbutton
Time Delay Pot
Independent/Joint
DIP Switch
Turn
to increase delay
Turn
to decrease delay
When removing the tip of the transducer from the water
the WET LED will immediately turn off. After the time
delay the LEVEL LED will turn on and DPDT process
level relay will energize.
Figure 14
Model 961 Line Power Configuration
2.5.1.2 Level Test Push Button
The level test push button is used to manually test the
DPDT process level relay. Pressing this push button reverses
the state of the DPDT relay, from energized to de-energized or vice-versa. This can be used to manually test the
relay, and whatever is connected to this relay. The time
delay pot does not affect the operation of the level test
push button.
Fault and Malfunction LED Indication
Operating
Condition
Red
Fault LED
Green
Malfunction LED
Normal
Off
On
Fault
On
Off
2.5.1.3 Malfunction Test Push Button
The malfunction test push button is used to manually test
the SPDT malfunction relay. Pressing and holding this
push button for 2 seconds will cause the SPDT relay to
de-energize indicating a fault condition. This can be used
to manually test the relay, and whatever is connected to
this relay. The time delay pot does not affect the operation
of the malfunction push button.
NOTE: Under normal operating conditions the green MALF (malfunction) LED is on to indicate that the malfunction relay is energized, and the red FAULT LED is off to indicate that there are
no faults. Should a fault condition occur, the red FAULT LED
turns on and the green MALF LED turns off, indicating that the
malfunction relay is de-energized.
51-646 Echotel® Model 961 & 962 Ultrasonic Level Switches
13
2.5.1.4 High/Low DIP Switch
The Hi/Lo Dip Switch is used to select whether the
Model 961 will be used as a high level fail-safe (HLFS)
switch or a low level fail-safe (LLFS) switch.
In the Hi position the DPDT process level relay will
de-energize (alarm condition) when the gap becomes wet.
In the Lo position the DPDT process level relay will
de-energize (alarm condition) when the gap becomes dry.
The table below provides assistance in configuring the
Hi/Lo DIP switch.
High/Low DIP Switch Configuration (Model 961 Line-powered)
Hi/Lo DIP
Switch
Gap
Condition
Level
Condition
Relay
Contacts
WET LED
LEVEL
LED
Off
On
On
Off
On
On
Off
Off
NC
Hi
(HLFS)
C
Dry
NO
Normal
Energized
NC
Hi
(HLFS)
C
Wet
NO
Alarm
De-energized
NC
Lo
(LLFS)
C
Wet
NO
Normal
Energized
NC
Lo
(LLFS)
C
Dry
NO
Alarm
De-energized
2.5.1.5 Independent/Joint DIP Switch
The I/J DIP switch is used to configure whether the SPDT
malfunction relay acts independently or jointly with the
DPDT process level relay. The factory default is for this
switch to be in the “I” position, where the relays act totally
independent of each other. If this DIP switch is in the “J”
position, both the SPDT malfunction relay and the DPDT
process relay will de-energize when a fault is detected.
14
51-646 Echotel® Model 961 & 962 Ultrasonic Level Switches
2.5.2 Model 961 Loop-powered Configuration
•
•
MODEL 961
FAULT
TEST
LOOP
TEST
8
Hi 22
Lo 3.6
16
F
A
U
L
T
TIME
DELAY
•
– +
•
•
Model 961 loop-powered units have the following configuration options:
TIME DELAY potentiometer for 0.5 to 45 second signal
averaging
LOOP TEST push button for testing the 8/16 mA loop
output
FAULT TEST push button for testing the 3.6 or 22 mA
fault output
Hi/Lo DIP switch for fail-safe high or low level selection
22/3.6 DIP switch to select the fault mA current output
2.5.2.1 Time Delay Potentiometer
High/Low
DIP Switch
Fault Test
Push Button
22/3.6 mA
DIP Switch
The time delay potentiometer is typically used in applications where turbulence or splashing may cause false level
alarms. This is a 25-turn pot with a factory default setting
of 0.5 seconds. If desired, this pot may be turned clockwise
to increase the response time from the standard 0.5 seconds
to a maximum of 45 seconds. Turning the pot counterclockwise decreases the time delay.
Time Delay Pot
Loop Test
Push Button
Turn
to increase delay
Turn
to decrease delay
Figure 15
Model 961 Loop Power Configuration
2.5.2.2 Loop Test Push Button
The loop test push button is used to manually test the loop
current output. Pressing the LOOP TEST push button
reverses the output from 8 mA to 16 mA or from 16 mA
to 8 mA. This can be used to manually test the loop output and whatever is connected to the 961. The time delay
pot does not affect the operation of the loop test push button.
2.5.2.3 Fault Test Push Button
The FAULT TEST push button is used to manually force
the 961 to the mA value that is selected at the 22/3.6 DIP
switch. Pressing this push button for 2 seconds will simulate a circuit test failure. This causes the output to go to
the selected fault current of either 22 or 3.6 mA, and the
red FAULT LED will light. The time delay pot does not
affect the operation of the FAULT TEST push button.
NOTE: Fault current will be greater than 21 mA, or less than 3.6 mA.
51-646 Echotel® Model 961 & 962 Ultrasonic Level Switches
15
2.5.2.4 High/Low DIP Switch
The Hi/Lo DIP switch is used to select whether the 961
will be used as high level fail-safe switch or low level fail-safe
switch. Normal process level operation produces an 8 mA
value, and 16 mA is produced when the unit is in a level
alarm state. The table can be used to assist in configuring
the Hi/Lo DIP switch.
High/Low DIP Switch Configuration (Model 961 Loop-powered)
Hi/Lo DIP
Switch
Gap
Condition
Level
Condition
Dry
Output
Signal
8 mA
LED
16 mA
LED
FAULT
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
Normal
Hi
(HLFS)
Wet
Alarm
Wet
Normal
Lo
(LLFS)
Dry
Alarm
NOTE: The FAULT LED only turns on during a fault condition.
2.5.2.5 22/3.6 DIP Switch
The 22/3.6 DIP switch is used to select whether the 961
will produce a 22 mA or a 3.6 mA output when the unit
detects a fault condition.
NOTE: Fault current will be greater than 21 mA, or less than 3.6 mA.
16
51-646 Echotel® Model 961 & 962 Ultrasonic Level Switches
2.5.3 Model 962 Line-powered Configuration
•
•
NC
C
NO
MALF RELAY
Hi PC
Lo LC
NC
C
NO
NC
C
NO
L1
LOWER
UPPER
MALF
MALF
UPPER
TEST
FAULT
LOWER
MODEL 962
L2
•
TIME
DELAY
LEVEL
TEST
•
•
Level Test
Push Button
Model 962 line-powered units have the following configuration options:
TIME DELAY potentiometer for 0.5 to 45 second signal
averaging
LEVEL TEST push button for testing of the SPDT
process level relays
MALF TEST push button for testing of the SPDT malfunction relay
Hi/Lo DIP switch for fail-safe high or low level selection
PC/LC DIP switch for level control or pump control
operation
High/Low
DIP Switch
Malfunction Test
Push Button
Time Delay Pot
2.5.3.1 Time Delay Potentiometer
The time delay potentiometer is typically used in applications where turbulence or splashing may cause false level
alarms. This is a 25-turn pot with a factory default setting
of 0.5 seconds. If desired, this pot may be turned clockwise to increase the response time from the standard 0.5
seconds to a maximum of 45 seconds. Turning the pot
counterclockwise decreases the time delay.
Pump Control/Level Control
DIP Switch
Turn
to increase delay
Turn
to decrease delay
Figure 16
Model 962 Line Power Configuration
2.5.3.2 Level Test Push Button
The LEVEL TEST push button is used to manually test
both of the SPDT process level relays. Pressing this push
button reverses the state of both SPDT process level relays,
from energized to de-energized or vice-versa. This can be
used to manually test these relays, and whatever is connected to them. The time delay pot does not affect the
operation of the LEVEL TEST push button.
2.5.3.3 Malfunction Test Push Button
The MALF TEST push button is used to manually test
the SPDT malfunction relay. Pressing and holding this
push button for 2 seconds will cause all three relays to
de-energize, indicating a fault condition. This can be used
to manually test the relay, and whatever is connected to
this relay. The time delay pot does not affect the operation
of the malfunction push button.
Fault and Malfunction LED Indication
Operating
Condition
Red
Fault LED
Green
Malfunction LED
Normal
Off
On
Fault
On
Off
NOTE: Under normal operating conditions the red fault LED is off and
the green malfunction LED is on, indicating that the
malfunction relay is energized. Should a fault condition occur,
the red fault LED turns on and the green malfunction LED
turns off, indicating that the malfunction relay is de-energized.
51-646 Echotel® Model 961 & 962 Ultrasonic Level Switches
17
2.5.3.4 High/Low DIP Switch
The Hi/Lo DIP switch is used to select whether the 962
will be used as a high level fail-safe (HLFS) switch or low
level fail-safe (LLFS) switch. The setting of the Hi/Lo DIP
also affects how the PC/LC DIP switch configures the
unit. Read Section 2.5.3.5 below and then proceed to the
appropriate table in Section 2.5.3.6 or 2.5.3.7 for proper
setting of the DIP switches.
2.5.3.5 PC/LC DIP Switch
The PC/LC DIP switch is used to select whether the 962
will operate in a pump control or a level control mode.
Select LC to use the 962 as a level controller where the
relays operate independently of each other. Select PC to
operate the 962 as a pump controller where the relays
latch to enable an auto fill or auto empty mode.
The configuration tables (Section 2.5.3.6 & 2.5.3.7) are
used for proper setting of the Hi/Lo and PC/LC DIP
switches. They also indicate the status of the yellow
LOWER and UPPER LEDs. The green MALF (malfunction) LED and the red FAULT LEDs are not included in
these tables.
2.5.3.6 LC and Hi/Lo DIP Switch Configuration Table
Level Control (DIP switch set to LC)
Level
Condition
Lower Gap
Upper Gap
Hi/Lo DIP
Switch
Relay
LED
Relay
LED
Hi
energized
On
energized
On
Lo
de-energized
Off
de-energized
Off
Hi
de-energized
Off
energized
On
Lo
energized
On
de-energized
Off
Hi
de-energized
Off
de-energized
Off
Lo
energized
On
energized
On
NOTE: During a fault condition all three relays de-energize
18
51-646 Echotel® Model 961 & 962 Ultrasonic Level Switches
2.5.3.7 PC and Hi/Lo DIP Switch Configuration Tables
Pump Control (DIP switch set to PC)
Auto-empty Pump Control Sequence
Level
Condition
Lower Gap
Upper Gap
Hi/Lo DIP
Switch
Relay
LED
Relay
LED
Hi
energized
On
energized
On
Hi
energized
On
energized
On
Hi
de-energized
Off
de-energized
Off
Hi
de-energized
Off
de-energized
Off
Hi
energized
On
energized
On
NOTE: During a fault condition all three relays de-energize
Pump Control (DIP switch set to PC)
Auto-fill Pump Control Sequence
Level
Condition
Lower Gap
Upper Gap
Hi/Lo DIP
Switch
Relay
LED
Relay
LED
Lo
de-energized
Off
de-energized
Off
Lo
de-energized
Off
de-energized
Off
Lo
energized
On
energized
On
Lo
energized
On
energized
On
Lo
de-energized
Off
de-energized
Off
NOTE: During a fault condition all three relays de-energize
51-646 Echotel® Model 961 & 962 Ultrasonic Level Switches
19
2.5.4 Model 962 Loop-powered Configuration
•
MODEL 962
TIME
DELAY
FAULT
TEST
LOOP
TEST
8
Hi 22
Lo 3.6
12
16
•
– +
•
•
•
Model 962 loop-powered units have the following configuration options:
TIME DELAY potentiometer for 0.5 to 45 second signal
averaging
LOOP TEST push button for testing the 8/12/16 mA
loop output
FAULT TEST push button for testing the 3.6 or 22 mA
fault output
Hi/Lo DIP switch for fail-safe high or low level selection
22/3.6 DIP switch to select the fault mA current output
2.5.4.1 Time Delay Potentiometer
High/Low
DIP Switch
Fault Test
Push Button
22/3.6 mA
DIP Switch
Time Delay Pot
Loop Test
Push Button
Turn
to increase delay
Turn
to decrease delay
Figure 17
The time delay potentiometer is typically used in applications where turbulence or splashing may cause false level
alarms. This is a 25-turn pot with a factory default setting
of 0.5 seconds. If desired, this pot may be turned clockwise to increase the response time from the standard 0.5
seconds to a maximum of 45 seconds. Turning the pot
counterclockwise decreases the time delay.
Model 962 Loop Power Configuration
2.5.4.2 Loop Test Push Button
The loop test push button is used to manually test the
loop current output. Pressing the LOOP TEST push button will force the output from 8 mA to 12 mA, 12 mA to
16 mA, or 16 mA to 8 mA. This can be used to manually
test the loop output and whatever is connected to the 962.
The time delay pot does not affect the operation of the
loop test push button.
2.5.4.3 Fault Test Push Button
The FAULT TEST push button is used to manually force
the 962 to the mA value that is selected at the 22/3.6 DIP
switch. Pressing this push button for 2 seconds will simulate a circuit test failure. This causes the output to go to
the selected fault current of either 22 or 3.6 mA, and all 3
LEDs will go dark. The time delay pot does not affect the
operation of the FAULT TEST push button.
NOTE: Fault current will be greater than 21 mA, or less than 3.6 mA.
20
51-646 Echotel® Model 961 & 962 Ultrasonic Level Switches
2.5.4.4 High/Low DIP Switch
The Hi/Lo DIP switch is used to select whether the 962
will be used as high level fail-safe switch or low level failsafe switch. Normal process level operation produces an
8 mA value, and 16 mA is produced when the unit is in a
level alarm state. The table below can be used to assist in
configuring the Hi/Lo DIP switch:
High/Low DIP Switch Configuration (Model 962 Loop-powered)
Hi/Lo DIP
Switch
Hi
(HLFS)
Lo
(LLFS)
Level
Condition
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
NOTE: During a fault condition all three LEDs will turn off
2.5.4.5 22/3.6 DIP Switch
The 22/3.6 DIP switch is used to select whether the 962
will produce a 22 mA or a 3.6 mA output when the unit
detects a fault condition.
NOTE: Fault current will be greater than 21 mA or less than 3.6 mA.
51-646 Echotel® Model 961 & 962 Ultrasonic Level Switches
21
3.0
Reference Information
3.1
Electronics Specifications
3.1.1 Model 961/962 with Relay Output
Supply Voltage
Relay Outputs
961:
962:
DPDT:
SPDT:
Relay Ratings
Fail-safe
SIL (Safety Integrity Level)
Power Consumption
Ambient Temperature
961:
962:
961/962:
102 to 265 VAC, or 18 to 32 VDC
One DPDT level relay and one SPDT malfunction relay
Two SPDT level relays and one SPDT malfunction relay
5 amps @ 120 VAC, 250 VAC, and 30 VDC, 0.15 amp @ 125 VDC
5 amps @ 120 VAC, 250 VAC, and 30 VDC, 0.15 amp @ 125 VDC
Selectable for high or low level
SIL 2 as 1oo1 with 92.0% Safe Failure Fraction (SFF)
SIL 2 as 1oo1 with 91.5% Safe Failure Fraction (SFF)
Less than 3 watts
-40° to +160° F (-40° to +71° C)
3.1.2 Model 961/962 with Current Shift Output
Supply Voltage
Current Shift Output
961:
962:
961/962:
Loop Resistance
Fail-safe
SIL (Safety Integrity Level)
Power Consumption
Ambient Temperature
961:
962:
961/962
12 to 35 VDC
8 mA normal operation, 16 mA level alarm (±1 mA)
8 mA normal operation, 12 mA lower gap alarm, 16 mA upper gap alarm (±1 mA)
3.6 mA or 22 mA selectable fault signal (±1 mA)
104 ohms with 11 VDC input, 1100 ohms with 35 VDC input
Selectable for high or low level
SIL 2 as 1oo1 with 91.4% Safe Failure Fraction (SFF)
SIL 2 as 1oo1 with 91.8% Safe Failure Fraction (SFF)
Less than 1 watt
-40° to +160° F (-40° to +71° C)
3.2 Performance Specifications
Repeatability
Response Time
Time Delay
Self-Test
Automatic:
Manual:
Shock Class
Vibration Class
Humidity
Electromagnetic Compatibility
22
±0.078" (2 mm)
⁄2 second typical
Variable 0.5 – 45 seconds on rising and falling levels
Continuously verifies operation of electronics, transducer,
piezoelectric crystals, and electrical noise
Push button verifies operation of electronics, transducer,
and piezoelectric crystals
ANSI/ISA-S71.03 Class SA1
ANSI/ISA-S71.03 Class VC2
0 – 99%, non-condensing
Meets CE requirements EN 61326
1
51-646 Echotel® Model 961 & 962 Ultrasonic Level Switches
3.3 Physical Specifications
Housing Material
Cast aluminum A356-T6, or cast 316 stainless steel
3
⁄4" NPT, or M20
Cable Entry
Gross Weight
3.4
961/962 Electronics:
2.2 lbs. (1.0 kg)
2" (5 cm) Transducer:
0.6 lbs. (0.3 kg)
Transducer Specifications
3.4.1 Model 9A1/9M1 Single Point
Transducer Material
Material Code (Section 3.9.2)
Maximum Pressure ¡
Operating Temperature Range
Actuation Length
-40° to +325° F (-40° to +163° C)
2000 psi (138 bar)
1" and 2" (3 and 5 cm)
316 Stainless Steel
A¿, S, N, K
A¿, S, N, K
-40° to +325° F (-40° to +163° C)
1500 psi (103 bar)
3" to 130" (6 to 330 cm)
Hastelloy C-276
B
-40° to +325° F (-40° to +163° C)
2000 psi (138 bar)
1" and 2" (3 and 5 cm)
Hastelloy C-276
B
-40° to +325° F (-40° to +163° C)
1500 psi (103 bar)
3" to 130" (6 to 330 cm)
Monel
C
-40° to +325° F (-40° to +163° C)
1200 psi (83 bar)
1" to 130" (3 to 330 cm)
Kynar
R
-40° to +250° F (-40° to +121° C)
see graphs below
2" to 130" (5 to 330 cm)
P
-40° to +180° F (-40° to +82° C)
see graphs below
2" to 130" (5 to 330 cm)
316 Stainless Steel
®
CPVC
3.4.2 Model 9A2/9M2 Dual Point
Maximum Pressure ¡
Transducer Material
Material Code (Section 3.9.3)
Operating Temperature Range
Actuation Length
316 Stainless Steel
A, K
-40° to +325° F (-40° to +163° C)
1500 psi (103 bar)
5" to 130" (13 to 330 cm)
CPVC
P
-40° to +180° F (-40° to +82° C)
see graphs below
5" to 130" (13 to 330 cm)
¿ Model 9A1/9M1 Material Code “A” has a Cryogenic Transducer Option for -110° to +250° F (-80° to +120° C) operating temperature range
¡ Minimum pressure for all transducers is -10 psi (-0.7 bar)
300
30
25
250
25
200
150
100
50
0
-40
20
15
10
0
60 120 180 240
Temperature (°F)
51-646 Echotel® Model 961 & 962 Ultrasonic Level Switches
200
150
100
50
5
0
-40
Pressure (bar)
Range with 150# flange
Range with PN16 flange
30
250
Pressure (psi)
" NPT
CPVC Transducer Ratings
300
Pressure (bar)
Range with
Pressure (psi)
Kynar Transducer Ratings
0
40
80
120
Temperature (°C)
0
-40
20
15
10
5
0
40 80 120 160 200
Temperature (°F)
0
-40
0
40
80
120
Temperature (°C)
23
3.5
Dimensional Specifications
Inches (mm)
5.24
(133)
4.00
(102)
4.00
(102)
4.43 (113)
5.75
(146)
4.43 (113)
2.35 (60) Typical
1.05 (26)
Typical
1.8 (46) Typical
Actuation length
for Tri-Clamp fitting
0.25 (6)
0.25 (6)
0.25 (6)
∅ .875 (22)
∅ .875 (22)
∅ .875 (22)
Model 961
with Hygienic Housing
and Tri-Clamp® 16 AMP Fitting
Model 961
with Cast Aluminum Housing
and NPT Connection
Model 961
with Cast Stainless Steel
Housing and ANSI Flange
4.00
(102)
4.00
(102)
4.43 (113)
4.43 (113)
2.35 (60) Typical
2.35 (60) Typical
Actuation length
for CPVC flange
Actuation length
for Kynar flange
0.25 (6)
24
Actuation length
for ANSI flange
Actuation length
for NPT connection
0.25 (6)
∅ .875 (22)
∅ .875 (22)
Model 961
with Cast Aluminum Housing
and CPVC Flange
Model 961
with Cast Aluminum Housing
and Kynar Flange
51-646 Echotel® Model 961 & 962 Ultrasonic Level Switches
3.5
Dimensional Specifications
Inches (mm)
4.00
(102)
4.00
(102)
3.95
(100)
4.43 (113)
1.8 (46) Typical
2.75
(70)
2 Holes
.38 (10) dia.
Actuation length
for NPT connection
3.00
(76)
2.00
(51)
0.25 (6)
3.50
(89)
∅ .875 (22)
Model 961/962 with Remote Electronics
Remote Transducer
with NPT Connection
4.00
(102)
4.00
(102)
4.43 (113)
4.43 (113)
1.8 (46) Typical
2.35 (60) Typical
Actuation
length B
Actuation
length B
Actuation
length A
0.25 (6)
∅ .875
(22) Dia.
Model 962
with NPT Connection
51-646 Echotel® Model 961 & 962 Ultrasonic Level Switches
Actuation
length A
0.25 (6)
∅ .875
(22) Dia.
Model 962
with ANSI Flange
25
3.6
Agency Approvals
AGENCY
APPROVED MODELS
PROTECTION METHOD
AREA CLASSIFICATION
FM & CSA
96X-X0A0-X10
96X-X0A0-X11
96X-X0A0-X12
96X-X0A0-X13
96X-X0A1-X10
96X-X0A1-X11
96X-XDA0-X30
96X-XDA0-X31
96X-XDA0-X32
96X-XDA0-X33
96X-XDA1-X30
96X-XDA1-X31
with transducers
9AX-XXXX-XXX or
9MX-XXXX-XXX
Explosion Proof
Class I, Div. 1,Groups B, C, & D
Class II, Div. 1, Groups E, F, & G
Class III, Type 4X, IP 66, T6
96X-XXAX-XXX or
with transducers
9AX-XXXX-XXX or
9MX-XXXX-XXX
Non-Incendive
Class I, Div. 2,Groups A, B, C, & D
Class II, Div. 2, Groups E, F, & G
Class III, Type 4X, IP 66, T4
96X-50AX-X1X
with transducers
9AX-XXXX-XXX or
9MX-XXXX-XXX
Intrinsically Safe
Class I, Div. 1,Groups A, B, C, & D
Class II, Div. 1, Groups E, F, & G
Class III, Type 4X, IP 66, T4
96X-XXAX-XC0
96X-XXAX-XC1
96X-XXAX-XC2
96X-XXAX-XC3
with transducers
9XX-AXXX-XXX
9XX-SXXX-XXX
9XX-BXXX-XXX
9XX-CXXX-XXX
9XX-NXXX-XXX
9XX-KXXX-XXX
Flameproof
II 1/2 G, Ex d IIC T6 Ga/Gb (ATEX)
Ex d IIC T6 Ga/Gb (IEC)
96X-50AX-XA0
96X-50AX-XA1
96X-50AX-XA2
96X-50AX-XA3
Intrinsically Safe
All transducers (except
Hygienic Connections 3T,
4T & VV from page 33)
comply with Canadian
Electrical Code requirements of ANSI/ISA
12.27.01-2003 as a single
seal device
ATEX/IEC
II 1 G, Ex ia IIC T5 Ga (ATEX)
with transducers:
9XX-AXXX-XXX
9XX-SXXX-XXX
9XX-BXXX-XXX
9XX-CXXX-XXX
9XX-NXXX-XXX
9XX-KXXX-XXX
INMETRO
Consult Factory for
Approved Models
Explosion Proof
Intrinsically Safe
BR-Ex d IIC T6 Gb IP66W
BR-Ex ia IIC T5 Ga IP66W
CCOE
Consult Factory for
Approved Models
Flameproof
Intrinsically Safe
EEx d IIC T6
Ex ia IIC T5 Ga
These units have been tested to EN 61326 and are
in compliance with the EMC Directive 2004/108/EC.
26
51-646 Echotel® Model 961 & 962 Ultrasonic Level Switches
3.6.1 Agency (FM/CSA) Drawing and Entity Parameters
51-646 Echotel® Model 961 & 962 Ultrasonic Level Switches
27
3.7 Troubleshooting
Caution: In hazardous areas, do not remove the housing cover until
power is disconnected and the atmosphere is determined
to be safe.
The Model 961/962 has a unique diagnostics feature to
assist in troubleshooting should a failure occur. A microprocessor in the electronics continuously monitors all selftest data. Should a fault occur, the microprocessor can
determine whether the malfunction is due to the electronics, transducer, piezoelectric crystals, or the presence of
environmental noise. A push button and Fault LED is
used to assist in troubleshooting the switch:
• One flash of the Fault LED indicates a problem with the
transducer, piezoelectric crystals, or the interconnection
wiring
• Two flashes of the Fault LED indicates a problem with one
of the electronics boards
• Three flashes of the Fault LED indicates presence of excessive levels of environmental noise
If a fault condition is detected by a line-powered 961/962,
the MALF LED will turn off indicating that the MALF
relay has been de-energized, and the FAULT LED will
turn on. If a fault condition is detected by a loop-powered
961, the 8 and 16 mA LED turn off, and the FAULT
LED will turn on. If a fault condition is detected by a
loop-powered 962, all three LEDs will turn off.
The push button indicated below should be pressed and
held while observing the LED:
Electronics Version
Push Button
LED
961 with 5 amp relays
LEVEL TEST
FAULT
961 with current shift
LOOP TEST
FAULT
962 with 5 amp relays
LEVEL TEST
FAULT
962 with current shift
LOOP TEST
16 mA
If the above diagnostic LED flashes once when the push
button is pressed, the most common issue is the interconnection wiring between the electronics and the transducer.
Check all wiring inside the housing to make sure that all
wires are secure in their respective terminal blocks. Make
sure that all the terminal block screws are fully tightened.
If all wires are secure then contact the factory. A replacement transducer may be needed. See Section 3.9, Model
Number, for proper replacement part numbers.
28
51-646 Echotel® Model 961 & 962 Ultrasonic Level Switches
Two flashes of the LED indicates an issue with the electronics module. Contact the factory for a replacement
electronics module. See Section 3.8 for spare electronics
module part numbers.
Environmental noise is the issue if the diagnostic LED
flashes three times. Common sources of environmental
noise are conducted electrical noise from a VFD (variable
frequency drive), radiated electrical interference from a
two-way radio transceiver, or mechanical vibration from
some nearby source. This noise could affect the 961/962
and other electrical instrumentation. Check to see if any
of the above listed sources may be causing the interference
and correct the issue to ensure proper operation of the unit.
It is also possible that application related issues may be
affecting the proper operation of the 961/962 unit. The
table below assists in troubleshooting.
PROBLEM
ACTION
No signal with level change
Check wiring to make sure proper input voltage is supplied.
Make sure liquid is reaching the gap. If installed in a riser or standpipe, make sure a
vent is provided such that liquid can enter the pipe and wet the transducer gap.
Check for dense foam on surface or dried product in the gap.
Unit may not function properly if either condition exists.
No change in output between
wet gap or dry gap
Check to see if transducer gap is plugged with solids.
The switch is chattering
Check for proper input voltage supply.
Check for dense foam in gap.
Check for turbulence. Relocate switch or isolate from turbulence.
Check for excessive aeration.
If installed horizontally, make sure the 961 transducer gap is oriented in a vertical
position as described in Section 2.3. This allows proper drainage from the gap, and
prevents air bubbles from accumulating in the gap.
51-646 Echotel® Model 961 & 962 Ultrasonic Level Switches
29
3.8
Replacement Parts
Model 961/962 Common Parts
Item
Description
Part Number
1
Cast Aluminum Cover without Window
089-6607-005
1
Cast Aluminum Cover with Window
036-4410-010
1
Cast 316 SS Cover without Window
089-6607-006
1
Deep Drawn SS Hygienic Cover without Window
036-5702-003
1
Deep Drawn SS Hygienic Cover with Window
036-5702-002
2
O-Ring with Cast Aluminum or 316 SS Housing
012-2201-237
2
O-Ring with Deep Drawn SS Hygienic Housing
012-2201-155
3
Bezel & Electronics Module Kit
See table below
4
Cast Aluminum Remote Transducer Housing Cover
004-9193-002
4
Cast 316 SS Remote Transducer Housing Cover
004-9193-006
5
Transducer
See Model Number
Model 961 Electronics Modules with Cast Aluminum or 316 SS Housings
Item
Description
Part Number
3
102 to 265 VAC Line-powered Module
089-7259-001
3
18 to 32 VDC Line-powered Module
089-7259-002
3
11 to 35 VDC Loop-powered Module (FM/CSA units w/961-50AX-X1X or 961-50AX-X7X) 089-7259-003
3
11 to 35 VDC Loop-powered Module (ATEX units w/961-50AX-XAX or 961-50AX-XCX)
089-7259-005
Model 961 Electronics Modules with Deep Drawn SS Hygienic Housing
Item
Description
Part Number
3
102 to 265 VAC Line-powered Module
089-7256-001
3
18 to 32 VDC Line-powered Module
089-7256-002
3
11 to 35 VDC Loop-powered Module
089-7256-003
Model 962 Electronics Modules with Cast Aluminum or 316 SS Housings
Item
Description
Part Number
3
102 to 265 VAC Line-powered Module
089-7258-001
3
18 to 32 VDC Line-powered Module
089-7258-002
3
11 to 35 VDC Loop-powered Module
089-7258-003
Model 962 Electronics Modules with Deep Drawn SS Hygienic Housing
Item
30
Description
Part Number
3
102 to 265 VAC Line-powered Module
089-7257-001
3
18 to 32 VDC Line-powered Module
089-7257-002
3
11 to 35 VDC Loop-powered Module
089-7257-003
51-646 Echotel® Model 961 & 962 Ultrasonic Level Switches
1
2
4
3
5
Model 961/962
51-646 Echotel® Model 961 & 962 Ultrasonic Level Switches
Model 961/962
Remote Transducer
31
3.9 Model Number
3.9.1 961/962 Electronics
BASIC MODEL NUMBER
961
962
Single-point electronics
Dual-point electronics
INPUT POWER
2
5
7
18 to 32 VDC line-powered
11 to 35 VDC loop-powered
102 to 265 VAC line-powered
OUTPUT SIGNAL
0
D
mA current shift (available with Input Power code 5)
5 amp gold flash relays (available with Input Power codes 2 or 7)
HOUSING COVER
0
1
Standard housing cover
Glass window cover (available with Electronics Housing codes 0, 1, 4 or 5)
MOUNTING
0
1
Integral
Remote ¿ (requires Connecting Cable from page 35)
AGENCY APPROVAL
1
3
7
A
C
FM/CSA Intrinsically safe, Non-Incendive
& Explosion Proof ¡
(use with current shift Output Signal code 0)
FM/CSA Explosion Proof & Non-Incendive
(use with relay Output Signal code D,
and Housing codes 0, 1, 2 & 3)
FM/CSA Non-incendive (available with Output Signal
codes 0 & D and Housing codes 4 & 5)
ATEX, Intrinsically safe
(available with Output Signal code 0)
ATEX/IEC Flameproof ¿
(available with Output Signal code 0 or D)
ELECTRONICS HOUSING
0
1
2
3
4
5
Cast aluminum with 3⁄4" NPT dual conduit entries
Cast aluminum with M20 dual conduit entries
Cast SS with 3⁄4" NPT dual conduit entries
Cast SS with M20 dual conduit entries
Deep drawn SS with 1⁄2" NPT dual conduit entries
Deep drawn SS with M20 dual conduit entries
¿ Not available with housing codes 4 & 5
¡ Explosion Proof approvals not available with
housing codes 4 & 5
9
32
6
A
51-646 Echotel® Model 961 & 962 Ultrasonic Level Switches
3.9.2 Model 961 Single Point Transducer
TRANSDUCER UNIT OF LENGTH
A
M
English (length in inches)
Metric (length in centimeters)
MATERIALS OF CONSTRUCTION
A
S
B
C
R
P
N
K
316/316L stainless steel
316/316L with 20 Ra hygienic finish (use only with Process Connection codes 3T, 4T, or VV)
Hastelloy C-276
Monel
Kynar ¬ (use only with Process Connection codes 11, 23, 33, 43, BA, CA, DA)
CPVC (use only with Process Connection codes 11, 23, 33, 43, BA, CA, DA)
316/316L stainless steel, NACE construction
316/316L stainless steel, ASME B31.1 &B31.3 construction
PROCESS CONNECTIONS
THREADED CONNECTIONS
11
21
22
⁄4" NPT
1" NPT
1" BSP (G1)
3
HYGIENIC CONNECTIONS
3T
4T
VV
11⁄2" Tri-Clamp® 16 AMP fitting
2" Tri-Clamp® 16 AMP fitting
DN65 – Varivent
ANSI RAISED FACE FLANGES EN/DIN FLANGES
23
24
25
33
34
35
43
44
45
1" 150# ANSI RF flange
1" 300# ANSI RF flange
1" 600# ANSI RF flange
11⁄2" 150# ANSI RF flange
11⁄2" 300# ANSI RF flange
11⁄2" 600# ANSI RF flange
2" 150# ANSI RF flange
2" 300# ANSI RF flange
2" 600# ANSI RF flange
BA
BB
BC
CA
CB
CC
DA
DB
DD
DE
DN
DN
DN
DN
DN
DN
DN
DN
DN
DN
25
25
25
40
40
40
50
50
50
50
PN
PN
PN
PN
PN
PN
PN
PN
PN
PN
16 EN 1092-1 Type A
25/40 EN 1092-1 Type A
63/100 EN 1092-1 Type B2
16 EN 1092-1 Type A
25/40 EN 1092-1 Type A
63/100 EN 1092-1 Type B2
16 EN 1092-1 Type A
25/40 EN 1092-1 Type A
63 EN 1092-1 Type B2
100 EN 1092-1 Type B2
TRANSDUCER OPTIONS
A
C
Standard design
Cryogenic design to -110° F (-80° C) (available with Materials code A)
ACTUATION LENGTH (unit of length specified in second digit)
1" to 130" (120” for Kynar & CPVC) in 1" increments (Example: 4 inches = 004)
1" minimum for NPT process connections
2" minimum for BSP, hygienic, and flanged process connections
2" minimum for all Kynar transducers
3
3
5
5
cm
cm
cm
cm
to 330 cm in 1 cm increments (Example: 6 centimeters = 006)
minimum for NPT process connections
minimum for BSP, hygienic, and flanged process connections
minimum for all Kynar transducers
¬ Kynar flanged transducers have Kynar
faced 316 stainless steel flanges
9
1
51-646 Echotel® Model 961 & 962 Ultrasonic Level Switches
33
3.9.3 Model 962 Dual Point Transducer
TRANSDUCER UNIT OF LENGTH
A
M
English (length in inches)
Metric (length in centimeters)
MATERIALS OF CONSTRUCTION
A
P
K
316/316L stainless steel
CPVC (use only with Process Connection codes 11, 23, 33, 43, BA, CA, DA)
316/316L stainless steel, ASME B31.1 &B31.3 construction
PROCESS CONNECTIONS
THREADED CONNECTIONS
11
21
22
⁄4" NPT
1" NPT
1" BSP (G1)
3
ANSI RAISED FACE FLANGES EN/DIN FLANGES
23
24
25
33
34
35
43
44
45
1" 150# ANSI RF flange
1" 300# ANSI RF flange
1" 600# ANSI RF flange
11⁄2" 150# ANSI RF flange
11⁄2" 300# ANSI RF flange
11⁄2" 600# ANSI RF flange
2" 150# ANSI RF flange
2" 300# ANSI RF flange
2" 600# ANSI RF flange
BA
BB
BC
CA
CB
CC
DA
DB
DD
DE
DN
DN
DN
DN
DN
DN
DN
DN
DN
DN
25
25
25
40
40
40
50
50
50
50
PN
PN
PN
PN
PN
PN
PN
PN
PN
PN
16 EN 1092-1 Type A
25/40 EN 1092-1 Type A
63/100 EN 1092-1 Type B2
16 EN 1092-1 Type A
25/40 EN 1092-1 Type A
63/100 EN 1092-1 Type B2
16 EN 1092-1 Type A
25/40 EN 1092-1 Type A
63 EN 1092-1 Type B2
100 EN 1092-1 Type B2
Important:
Use the “A” dimension as the
actuation length code. The
“B” dimension must also be
specified in quote/order.
Example:
For a 962 with an “A” dimension of 18" and a “B” dimension of 7", specify actuation
length code 018.
Actuation
length B
Actuation
length A
Minimum distance
between actuation points
A and B is 3" (8 cm)
Maximum distance
between actuation points
A and B is 128" (325 cm)
“A” DIMENSION ACTUATION LENGTH (units specified in second digit)
5" to 130" in 1" increments
5" minimum for NPT process connections
6" minimum for BSP, and flanged process connections
Example: 5 inches = 005
13 cm to 330 cm in 1 cm increments
13 cm minimum for NPT process connections
15 cm minimum for BSP, and flanged process connections
Example: 13 centimeters = 013
9
34
2
A
51-646 Echotel® Model 961 & 962 Ultrasonic Level Switches
3.9.4 Connecting Cable
ELECTRONICS MODEL
6
7
Remote cable for Model 961
Remote cable for Model 962
CONNECTING CABLE LENGTH (FEET)
Maximum Length: 150 feet
Example: 12 feet = 012
0
3
7
3
3
Minimum Length: 10 feet
1
51-646 Echotel® Model 961 & 962 Ultrasonic Level Switches
35
ASSURED QUALITY & SERVICE COST LESS
Service Policy
Return Material Procedure
Owners of MAGNETROL controls 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. Controls returned under our service policy must
be returned by Prepaid transportation. MAGNETROL
will repair or replace the control at no cost to the purchaser (or owner) other than transportation if:
So that we may efficiently process any materials that are
returned, it is essential that a “Return Material
Authorization” (RMA) number be obtained from the factory, prior to the material’s return. This is available through
a MAGNETROL local representative or by contacting the
factory. Please supply the following information:
1. Returned within the warranty period; and
2. The factory inspection finds the cause of the claim
to be covered under the warranty.
If the trouble is the result of conditions beyond our control; or, is NOT covered by the warranty, there will be
charges for labor 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, labor, direct or consequential damage will be allowed.
1.
2.
3.
4.
5.
Company Name
Description of Material
Serial Number
Reason for Return
Application
Any unit that was used in a process must be properly
cleaned in accordance with OSHA standards, before it is
returned to the factory.
A Material Safety Data Sheet (MSDS) must accompany
material that was used in any media.
All shipments returned to the factory must be by prepaid
transportation.
All replacements will be shipped F.O.B. factory.
NOTE: See Electrostatic Discharge Handling Procedure
on page 5.
705 Enterprise Street • Aurora, Illinois 60504-8149 • 630-969-4000 • Fax 630-969-9489
[email protected]rol.com • www.magnetrol.com
Copyright © 2014 Magnetrol International, Incorporated. All rights reserved. Printed in the USA.
MAGNETROL, MAGNETROL logotype and ECHOTEL are registered trademarks of MAGNETROL INTERNATIONAL, INCORPORATED.
Kynar® is a registered trademark of Elf Atochem North America, Inc.
Hastelloy® is a registered trademark of HAYNES INTERNATIONAL, INC. (DELAWARE CORPORATION).
Monel® is a registered trademark of the INCO family of companies.
BULLETIN: 51-646.3
EFFECTIVE: December 2014
SUPERCEDES: June 2010