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 2014/32/EU. The units have been tested to EN 61326: 1997 + A1 + A2. 2. Directive 2014/34/EU 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 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 Echotel® 962 electronics External grounding screw, only for ATEX flameproof enclosure. MODEL 961 FAU LT TEST LOOP TEST 8 16 Hi 22 Lo 3.6 F A U L T TIME DELA Y MODEL 962 TIME DELA Y FAU LT TEST LOOP TEST 8 12 16 Hi 22 Lo 3.6 – + – + Cable gland Plugged entry – + G round 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 FAU LT TEST LOOP TEST 8 16 Hi 22 Lo 3.6 Testing fault signal Testing loop signal Safe green LED (8 mA) Alarm yellow LED (16 mA) F A U L T TIME DELA Y Time delay potentiometer MODEL 962 TIME DELA Y FAU LT TEST – + Hi 22 Lo 3.6 Separate fault red LED Testing fault signal LOOP TEST 8 12 Time delay potentiometer 16 – + Testing loop signal Safe green LED (8 mA) Lower gap yellow LED (12 mA) Upper gap red LED (16 mA) 3 SET UP AND FUNCTIONS Set up High – Low Level Failsafe selection:¿ 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 Failsafe¿ 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 ¿ 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 Solution No loop signal No LED’s are ON Check wiring / input power No change in output between wet gap / dry gap Gap may be plugged by solids / dense foam Clean the transducer Chattering output Excessive aeration / Turbulence Introduce a time delay Gap is out of reach of liquid Check for malfunction (962). See below Check mounting section and relocate the unit or check blocking valves. Check input power Relocate the switch Fault LED is ON (961) All LED’s OFF (962) If installed horizontally, make sure the 961 transducer gap is oriented in a vertical position as shown in the mounting section. This allows proper drainage from the gap, and prevents air bubbles from accumulating in the gap. A system fault has been detected Check input power * Check wiring between transducer and electronics or replace transducer. Press «Loop Test» pushbutton to identify the problem: --- * : 1 flash (red LED) ** --- ** : 2 flashes (red LED) *** --- *** : 3 flashes (red LED) 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. EXPEDITE SHIP PLAN (ESP) Several parts are available for quick shipment, within max. 1 week after factory receipt of purchase order, through the Expedite Ship Plan (ESP). Parts covered by ESP service are conveniently grey coded in the selection tables. No. 1 2 3 4 6 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) 961 962 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 3 d 3 e 004-9224-014 032-3934-001 036-5702-002 012-2201-237 012-2201-155 089-7259-005 089-7258-003 089-7256-003 089-7257-003 consult factory 4 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 1 7 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 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 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 N P R S 9 M 316/316L (1.4401/1.4404) stainless steel Hastelloy® C (2.4819) – only available with 9M1 Monel® (2.4360) – only available with 9M1 316/316L (1.4401/1.4404) stainless steel & NACE MR0175/MR0103 CPVC Kynar® (PVDF) – only available with 9M1 316/316L (1.4401/1.4404) stainless steel with 0,5 µm Ra (20 Ra) surface finish SEE NEXT PAGE complete code for Echotel® transducer X = product with a specific customer requirement 7 MODEL IDENTIFICATION 2. Code for Echotel® transducer SEE PREVIOUS PAGE PROCESS CONNECTION Threaded (plastic transducers are only available with 3/4" NPT connection) 1 1 2 1 3/4" NPT 1" NPT 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 5 3 3" 150 lbs ANSI RF 5 4 3" 300 lbs ANSI RF 5 5 3" 600 lbs ANSI RF 6 3 4" 150 lbs ANSI RF 6 4 4" 300 lbs ANSI RF 6 5 4" 600 lbs ANSI RF ANSI Flanges for plastic transducers¿ 2 3 3 3 4 3 1" 150 lbs ANSI RF¡ 1 1/2" 150 lbs ANSI RF¡ 2" 150 lbs ANSI RF¡ 1 2 2 2 3/4" BSP (G 3/4") 1" BSP (G 1") EN (DIN) Flanges for metal transducers B B DN 25 PN 16/25/40 EN 1092-1 Type A B C DN 25 PN 63/100 EN 1092-1 Type B2 C B DN 40 PN 16/25/40 EN 1092-1 Type A C C DN 40 PN 63/100 EN 1092-1 Type B2 D A DN 50 PN 16 EN 1092-1 Type A D B DN 50 PN 25/40 EN 1092-1 Type A D D DN 50 PN 63 EN 1092-1 Type B2 D E DN 50 PN 100 EN 1092-1 Type B2 E A DN 80 PN 16 EN 1092-1 Type A E B DN 80 PN 25/40 EN 1092-1 Type A E D DN 80 PN 63 EN 1092-1 Type B2 E E DN 80 PN 100 EN 1092-1 Type B2 F A DN 100 PN 16 EN 1092-1 Type A F B DN 100 PN 25/40 EN 1092-1 Type A F D DN 100 PN 63 EN 1092-1 Type B2 F E DN 100 PN 100 EN 1092-1 Type B2 EN (DIN) Flanges for plastic transducers¿ 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 ¿ 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 EN 1092-1 Type A EN 1092-1 Type A EN 1092-1 Type A SENSOR TYPE A C 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 3 0 0 0 3 3 5 4 0 Minimum 3 cm (1.2") – for metal transducers with NPT connections only Minimum 5 cm (2") – for all other connections Maximum 304 cm (120") – for Kynar® (PVDF) material Maximum 330 cm (130") – for all other materials 9M2 transducers "A" length specify "B" length separately (see drawing and note shown in the dimensions section) 0 1 3 0 1 5 3 3 0 9 M 8 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") 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 Actuation length “B” for NPT connection Actuation length “B” Actuation length “A” for NPT connection Ø 22,9 (0.90) 962 - Threaded connection Note: 60 (2.35) Typical Actuation length “A” 6 (0.25) Ø 22,9 (0.90) 962 - Flanged connection - Difference between actuation lengths "A" and "B" must be min. 8 cm. - Max. length for dimension "B" is 322 cm. 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) Actuation Length Ø 22,9 (0.90) 6 (0.25) 6 (0.25) Actuation Length Ø 22,9 (0.90) 6 (0.25) DIN 11851 Tri-Clamp® 46 (1.81) Varivent® 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) 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) Process pressure (bar) Metal Transducer Ratings 10 160 138 bar¿ 120 103 bar 80 316/316L (1.4401/1.4404)¡ Hastelloy® C (2.4819) Monel® (2.4360) 82,8 bar 40 -40 Process temperature (°C) 0 40 80 120 165 ¿ 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 SPECIFICATIONS Electronics specifications Description Input Voltage Power Consumption Output Time delay Indication Selftest Housing material Automatic Manual Approvals ¿ 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 § 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 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 ¿ Only available with cast aluminium or cast stainless steel housings Performance Description Response time Repeatability Ambient Temperature Humidity Electromagnetic Compatibility Transducer specifications Description 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 Plastic transducers Metal transducers 316/316L SST (1.4401/1.4404) Hastelloy® C (2.4819) Monel® (2.4360) Material CPVC Kynar® (PVDF) Actuation length From 5 cm up to 304 cm (2" up to 120") – PVDF From 3 cm up to 330 cm (1.2" up to 130") From 5 cm up to 330 cm (2" up to 130") – CPVC Mounting Process temp. (consult temp/ press. graphs) Max pressure (consult temp/ press. graphs) Threaded (NPT/BSP) – Flanged (ANSI - EN (DIN)) – Hygienic -40 °C to +120 °C (-40 °F to +250 °F) – PVDF -40 °C to +80 °C (-40 °F to +180 °F) – CPVC 13,8 bar @ +40 °C (200 psi @ +100 °F) for NPT threaded units -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 82,8 bar (1200 psi) for Monel transducers Consult temp/press. graphs for other materials 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 51-646.10 DECEMBER 2015 September 2014 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: [email protected] DEUTSCHLAND Alte Ziegelei 2-4, D-51491 Overath Tel. +49 (0)2204 / 9536-0 • Fax. +49 (0)2204 / 9536-53 • E-Mail: [email protected] INDIA B-506, Sagar Tech Plaza, Saki Naka Junction, Andheri (E), Mumbai - 400072 Tel. +91 22 2850 7903 • Fax. +91 22 2850 7904 • E-Mail: [email protected] ITALIA Via Arese 12, I-20159 Milano Tel. +39 02 607.22.98 • Fax. +39 02 668.66.52 • E-Mail: [email protected] RUSSIA 198095 Saint-Petersburg, Marshala Govorova street, house 35A, office 427 Tel. +7 812 320 70 87 • E-Mail: [email protected] U.A.E. 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