Echotel ® Models 960/961 Ultrasonic Level Switches for Hygienic Applications D E S C R I P T I O N Echotel® Model 960/961 Ultrasonic Level Switches use pulsed signal technology for superior performance in difficult process conditions, and to provide excellent immunity from sources of electrical noise interference. Extensive self-testing of the electronics and transducer make this advanced switch suitable for a wide variety of hygienic level switch applications. Model 960 Switches use AS-Interface® (AS-i) bus digital communications for high or low single point liquid level measurement. The AS-i bus system provides a digital serial interface with a single unshielded two-wire cable for power and data transfer. Model 961 is offered with either a 5-amp relay or a current shift electronics. The relay output electronics has a DPDT relay for level detection, and a SPDT malfunction relay. The current shift version indicates 8 mA during normal operation, 16 mA as a level alarm condition and a user-selectable 3.6 or 22 mA malfunction indication. The 960/961 switches are designed for the stringent requirements of hygienic applications. These switches are offered with a deep-drawn 304 stainless steel housing that is favorable to CIP and SIP procedures. A 20 Ra surface finish is featured with hygienic Model 960/961 transducers. These transducers are available with 11⁄2" & 2" Tri-Clamp® fittings, and DN65 Varivent® Type N flanges. Model 960/961 (with Varivent® fitting) Model 960/961 (with Tri-Clamp® fitting) A P P L I C A T I O N S • High or low level alarm • CIP buffer tanks • WFI systems • Hygienic pump protection • Beer vats • Leak detection F E A T U R E S • Self-test technology provides unsurpassed reliability and testing of electronics, transducer, piezoelectric crystals, and electromagnetic noise • 20 Ra surface finish with Tri-Clamp and Varivent fittings • Adjustable time delay for turbulent aerated liquids • Tip-sensitive transducer measures level within 1⁄4" of the vessel bottom • Pulsed signal technology provides superior performance in difficult process conditions • Liquid chromatography skids • Overfill protection I N D U S T R I E S • Bio-technology • Chemical • Brewing and spirits • Food and beverage • Pharmaceutical P U L S E D S I G N A L T E C H N O L O G Y Model 960/961 switches use pulsed signal technology to detect the presence or absence of liquid in an ultrasonic transducer gap. The transducer uses a pair of piezoelectric crystals that vibrate 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 and converts it back into an electrical signal. This signal is sent to the electronics to indicate a wet gap condition. When no liquid is present, the ultrasonic signal is attenuated and is not detected by the receive crystal. Ultrasonic transducer Transmit crystal Challenging process conditions like aeration, suspended solids, and high viscosities are overcome by using pulsed signal circuitry in 960/961 switches. Unlike many tuning forks, pulsed signal ultrasonic switches do not need to be configured for different media densities, making these units the most universally applied level switches on the markey today. ADVANCED SELF-TEST Ultrasonic switches are often used as the last means of detecting whether a cer Transdu ls ta process vessel will overflow and cause a s & cry s ic spill of potentially hazardous liquids, or Electron e empty out and possibly cavitate the Nois pumps. In these critical applications it is desirable to have a method of periodically testing the ultrasonic switch to ensure that it is functioning properly. Receive crystal Ultrasonic signal transmission across transducer gap AND DIAGNOSTICS A microprocessor in the 960/961 electronics continuously monitors all self-test 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 pushbutton and Fault LED is used to assist in troubleshooting the switch: 5 One flash of the Fault LED indicates a problem with the transducer or piezoelectric crystals Model 960/961 switches feature an advanced self-test technology that not only tests the electronics, transducer, and piezoelectric crystals, but also tests for the presence of industrial sources of environmental noise. Should the switch detect any problems a malfunction output is generated to alarm the user, and a red LED is lit to indicate an alarm condition. ADJUSTABLE TIME problem with one of the electronics boards 555 Three flashes of the Fault LED indicates excessive levels of environmental noise DELAY Turbulence and splashing can cause some fixed time response switches to produce false level alarms. Model 960/961 switches overcome this difficulty with an adjustable time delay feature. 2 55 Two flashes of the Fault LED indicates a A potentiometer allows a 1⁄2 – 45-second delay to be set to disregard waves or splashes, and reliably detect the true liquid level. A P P L I C A T I O N S Model 960/961 Switches may be used for high or low level alarm, empty pipe detection and pump protection in Spray Ball Fill Line High Alarm a wide variety of hygienic applications. Available with a 304 stainless steel electronics housing and a 20 Ra surface finish transducer, typical applications include: • CIP/SIP day tank point level • Water for Injection (WFI) storage • Liquid chromatography skids Pump Protection • Brewery fill lines • Condensate receiver tanks Low Alarm A G E N C Y A P P R O V A L S AGENCY APPROVED MODELS PROTECTION METHOD FM & CSA 960-58AX-030 960-58AX-031 961-50AX-010 961-50AX-011 961-XDAX-030 or 961-XDAX-031 with transducers: 9X1-XXXX-XXX Explosion Proof 960-58AX-074 960-58AX-075 961-XXAX-01X 961-XXAX-03X or 961-XXAX-07X with transducers: 9X1-XXXX-XXX Non-Incendive 961-50AX-01X with transducers: 9X1-XXXX-XXX Intrinsically Safe 960-58AX-0C0 960-58AX-0C1 961-XXAX-0C0 961-XXAX-0C1 with all metallic transducers* Flameproof Ex II 1/2 G, EEx d IIC T6 961-50AX-0A0 961-50AX-0A1 with all metallic transducers* Intrinsically Safe Ex II 1 G, EEx ia IIC T5 ATEX AS-i AREA CLASSIFICATION Class I, Div. 1, Groups B, C, & D Class II, Div. 1, Groups E, F, & G Class III, Type 4X, IP 66, T6 Class I, Div. 2, Groups A, B, C, & D Class II, Div. 2, Groups F & G Class III, Type 4X, IP 66, T4 IP67 for 304 Stainless Steel Housing Class I, Div. 1, Groups A, B, C, & D Class II, Div. 1, Groups E, F, & G Class III, Type 4X, IP 66, T4 These units have been tested to AS-Interface Specification EN50295 and IEC 62026-2, and have met the demands of the AS-Interface Test Requirements. AS-Interface certificate #76401 *Consult factory for model numbers These units have been tested to EN 61326 and are in compliance with the EMC Directive 89/336/EEC. 3 E L E C T R O N I C S M O D E L 9 6 0 Supply Voltage AS-i Version AS-i Slave Type AS-i Slave Profile AS-i Data Bits W I T H S P E C I F I C A T I O N S A S - I n t e r f a c e Connectable Load 21 to 31 VDC V 3.0 A/B (Maximum of 62 nodes) S-0.A.E D2 = 1 with a wet gap D2 = 0 with a dry gap D3 = 1 during malfunction D3 = 0 in normal state EN50295 and IEC 62026-2 Power Consumption Less than 1 watt Gap Condition: Malfunction Status: Ambient Temperature Storage Temperature M O D E L 9 6 1 Supply Voltage Relay Outputs Relay Ratings Electronics: Electronics: W I T H R E L A Y DPDT: SPDT: Fail-safe Power Consumption Ambient Temperature M O D E L 9 6 1 W I T H T R A N S D U C E R 4 18 to 32 VDC, or 102 to 265 VAC, 50/60 Hz One DPDT level relay and one SPDT malfunction relay 5 amps @ 120 VAC, 250 VAC, and 30 VDC, 0.4 amp @ 110 VDC 5 amps @ 120 VAC, 250 VAC, and 30 VDC, 0.15 amp @ 125 VDC Selectable for high or low level Less than 3 watts -40° to +160° F (-40° to +70° C) S H I F T O U T P U T 11 to 35 VDC 8 mA normal operation, 16 mA level 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 Less than 1 watt -40° to +160° F (-40° to +70° C) Loop Resistance Fail-safe Power Consumption Ambient Temperature Operating Frequency Surface Finish O U T P U T C U R R E N T Supply Voltage Current Shift Output Operating Temperature Maximum Pressure -13° to +160° F (-25° to +70° C) -40° to +160° F (-40° to +70° C) S P E C I F I C A T I O N S 1" and 2": 3" to 130": -40° to +325° F (-40° to +163° C) 2000 psi (138 bar) 1500 psi (103 bar) 2 MHz 20 Ra (when ordered with 4th digit code S) P E R F O R M A N C E Repeatability Response Time Time Delay Self-Test Automatic: Manual: Shock Class Vibration Class Humidity Electromagnetic Compatibility P H Y S I C A L S P E C I F I C A T I O N S ±0.078" (± 2 mm) 1 ⁄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 S P E C I F I C A T I O N S Housing Material Cable Entry Cast Aluminum: 304 Stainless Steel: Cast aluminum A356-T6, or deep drawn 304 stainless steel Dual 3⁄4" NPT, or M20 Dual 1⁄2" NPT, or M20 D I M E N S I O N A L I N C H E S S P E C I F I C A T I O N S ( m m ) 5.24 (133) 4.00 (102) 4.43 (113) 5.24 (133) 5.75 (146) 5.75 (146) 1.80 (46) Typical 1.05 (26) Typical 2.70 (69) Typical Actuation length with NPT connection Actuation length with Tri-Clamp fitting Actuation length with Varivent fitting 0.25 (6) ∅ .875 (22) ∅ .875 (22) 0.25 (6) Model 960/961 with NPT Connection 0.25 (6) ∅ .875 (22) Model 960/961 with Tri-Clamp® fitting Model 960/961 with DN65 Varivent® Flange 5 M O D E L 9 6 0 / 9 6 1 N U M B E R E L E C T R O N I C S Models available for quick shipment, usually within one week after factory receipt of a complete purchase order, through the Expedite Ship Plan (ESP) BASIC MODEL NUMBER 960 961 Actuator-Sensor-Interface (AS-i) electronics Relay or current shift electronics INPUT POWER 2 5 7 24 VDC line-powered (Model 961 only) 24 VDC loop-powered (Model 960 & 961) 102 to 265 VAC line-powered (Model 961 only) OUTPUT SIGNAL 0 8 D mA current shift for Model 961 (available with Input Power code 5) Actuator-Sensor-Interface (AS-i) for Model 960 (available with Input Power code 5) 5 amp gold flash relays for Model 961 (available with Input Power codes 2 or 7) COVER 0 1 Standard cover Glass window cover MOUNTING 0 Integral 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 Output Signal code 8 & D, and Housing codes 0, 1) FM/CSA Non-incendive (available with Output Signal codes 0, 8 & D and Housing codes 4 & 5) ATEX II 1G EEx ia IIC T5, Intrinsically safe (available with Output Signal code 0 and Housing codes 0 &1) ATEX II 1/2G EEx d IIC T6, Flameproof (available with Output Signal codes 0, 8 & D, and Housing codes 0 & 1)) * Explosion Proof approvals not available with housing codes 4 & 5 HOUSING & CONDUIT CONNECTION 0 1 4 5 9 6 6 A 0 Cast aluminum with 3⁄4" NPT dual conduit entries Cast aluminum with M20 dual conduit entries Deep drawn 304 stainless steel w/ 1⁄2" NPT dual conduit entries Deep drawn 304 stainless steel w/M20 dual conduit entries M O D E L 9 6 0 / 9 6 1 N U M B E R S I N G L E P O I N T T R A N S D U C E R Models available for quick shipment, usually within one week after factory receipt of a complete purchase order, through the Expedite Ship Plan (ESP) TRANSDUCER UNIT OF LENGTH A M English (length in inches) Metric (length in centimeters) MATERIALS OF CONSTRUCTION A S 316/316L stainless steel 316/316L with 20 Ra hygienic finish (use only with Process Connection codes 3T, 4T, or VV) PROCESS CONNECTIONS 11 3T 4T VV 3 ⁄4" NPT 11⁄2" Tri-Clamp® 16 AMP fitting 2" Tri-Clamp® 16 AMP fitting DN65 – Varivent® Type N flange ACTUATION LENGTH (unit of length specified in second digit) 1" to 130" in 1" increments 1" minimum for NPT process connections 2" minimum for 3T, 4T & VV process connections Example: 4 inches = 004 Available English ESP lengths: 1", 2", 4", 6", 8", 12" 3 cm to 330 cm in 1 cm increments 3 cm minimum for NPT process connections 5 cm minimum for 3T, 4T & VV process connections Example: 6 centimeters = 006 Available metric ESP lengths: 3, 5, 10, 30 cm 9 1 A 7 Q U A L I T Y 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 and service quality available. Several ECHOTEL Model 961 units are available for quick shipment, usually within one week after factory receipt of a complete purchase order, through the Expedite Ship Plan (ESP). ESP service may not apply to orders of ten units or more. Contact your local representative for lead times on larger volume orders, as well as other products and options. E S P Expedite Ship Plan To take advantage of ESP, simply match the color coded model number codes (standard dimensions apply). W A R R A N T Y All MAGNETROL electronic level and flow controls 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. For additional information, see Instruction Manuals 51-632 & 51-646. 5300 Belmont Road • Downers Grove, Illinois 60515-4499 • 630-969-4000 • Fax 630-969-9489 • www.magnetrol.com 145 Jardin Drive, Units 1 & 2 • Concord, Ontario Canada L4K 1X7 • 905-738-9600 • Fax 905-738-1306 Heikensstraat 6 • B 9240 Zele, Belgium • 052 45.11.11 • Fax 052 45.09.93 Regent Business Ctr., Jubilee Rd. • Burgess Hill, Sussex RH15 9TL U.K. • 01444-871313 • Fax 01444-871317 Copyright © 2011 Magnetrol International, Incorporated. All rights reserved. Printed in the USA. Performance specifications are effective with date of issue and are subject to change without notice. Magnetrol, Magnetrol logotype and Echotel are registered trademarks of Magnetrol International, Incorporated. AS-Interface® is a registered trademark of the AS-International Association 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 Tri-Clamp® is a registered trademark of Ladish Co. Varivent® is a registered trademark of Tuchenhagen GmbH LTD BULLETIN: 51-160.2 EFFECTIVE: August 2011 SUPERSEDES: October 2009