® Echotel® Models 915 & 916 Two-Wire, Intrinsically Safe Ultrasonic Level Switch Instruction Manual and Parts List UNPACKING Unpack the instrument carefully. Make sure all components have been removed from the packing material. Inspect all components for damage. Report any damage to the carrier within 24 hours. Check the contents of 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. MODEL IDENTIFICATION Each Model 915/916 ultrasonic level switch has a nameplate on which the model number of the unit is shown. Refer to the model number below, to determine which options the unit contains. Model 915 Model 916 DESCRIPTION Echotel Models 915/916 ultrasonic, loop-powered level switches utilize state-of-the-art ultrasonic technology to detect a broad range of viscous to light liquids. The 915 features a continuous wave, 1 MHz transducer crystal, in a variety of transducer materials. The 916 features a stainless steel tip-sensitive transducer and a 3 MHz transducer crystal. Both the 915 and 916 consist of a transducer and a solid-state amplifier mounted in a NEMA 7/9 housing. Models 915/916 are intrinsically safe when connected through an approved intrinsically safe barrier. PRINCIPLE OF OPERATION A high frequency, ultrasonic signal is transmitted across the transducer gap when it is filled with liquid. This signal is detected by the circuit which establishes a loop current draw of 16 mA. When the transducer is dry, the ultrasonic signal is attenuated by the air and the circuit switches the loop current to 8 mA. When the transducer becomes dry, a unique continuous selftest feature tests the transducer to ensure that it will respond when the liquid reaches the transducer. This test is performed approximately 10 times every second, however, the loop current will remain at 8 mA during the tests as long as the circuit and transducer are operating properly. If a malfunction is detected, the loop current will be switched to either 5 mA or 19 mA (field selectable) to indicate that a problem exists with the transducer or related circuitry. CAUTION: This unit contains CMOS electronics which may be damaged by static electricity. Do not touch any semiconductor devices unless you are properly grounded. Electronics Part Number 91 –G22A–0D0 FREQUENCY 5 = 1 MHz (Use with Model 681 Transducers) 6 = 3 MHz (Use with Model 671 Transducers) Transducer Part Number 6 1–1 1– FREQUENCY 7 = 3 MHz (For Model 916 Electronics) 8 = 1 MHz (For Model 915 Electronics) TRANSDUCER MATERIAL 22 = 316 Stainless Steel (Model 915 or 916) CC = CPVC (915 only) FF = Teflon* (915 only) HB = Hastelloy B (915 only) HC = Hastelloy C (915 only) KK = Kynar (915 only) MM = Monel (915 only) * Actuation length maximum is 48 inches. ACTUATION LENGTH 1 - 130 inches (Nominal distance from bottom of threads to top of gap in inches). Example: 12 inches = Code 012 PRELIMINARY OPERATIONAL CHECK After unpacking and before installation, perform the following operational check on the unit in a non-hazardous area. 1. Fill a suitable container with liquid. 2. In a non-hazardous environment, power the unit with proper voltage. See Wiring on Page 3. The unit should draw 8 mA ± 1 mA and the green LED should be on. 3. Place transducer in the liquid. The unit should draw 16 mA ± 1 mA and the red LED should be on. 4. Remove transducer from the liquid. The loop current should return to 8 mA ± 1 mA, with the green LED on if the unit is operating properly. In case of malfunction, consult Page 3 — Troubleshooting. ,, , ,, , ,, , ,,,, ,, ,, INSTALLATION MOUNTING POSITION AND LOCATION MOUNTING POSITION AND LOCATION cont. Models 915/916 level switches should be located to allow easy access for service. Units should not be exposed to ambient temperatures above 160° F (71° C) or below -40° F (-40° C). Special precaution should be taken to prevent exposure to corrosive atmosphere, excessive vibration, shock or physical damage. NOTE: Models 915/916 level switches are designed for use in various liquids. For applications with aeration, solids or corrosive conditions, contact factory for information. GENERAL UNIT MOUNTING REQUIREMENTS When installed in a nozzle or pipe, the transducer gap must extend into the tank at least one inch beyond the inside tank wall. See Figure 3. Gap must extend 1" (25) beyond tank wall Models 915/916 level switches are shipped assembled to the transducer. Units may be mounted in any position or orientation. See Figures 1 and 2. Conduit connection Horizontal Nozzle Mounting Figure 3 All wiring, conduit and electrical fittings must conform to local electrical codes for the location selected. Never tighten by turning housing Use wrench here 3/4" NPT thread Vertical Mounting Figure 1 Gap must be turned vertical to allow medium to fall through INSTALLATION Install so that wrench flats are vertical Screw transducer into the opening using pipe compound or thread tape. If flanged, bolt unit to mating flange with proper gasket. CAUTION: Never tighten unit on the tank connection by turning the housing. Use a wrench on the transducer mounting nut flats. Use thread tape or suitable pipe compound on the threads. Do not overtighten. Tank wall Horizontal Mounting Figure 2 ELECTROSTATIC DISCHARGE (ESD) HANDLING PROCEDURE Magnetrol’s electronic instruments are manufactured to the highest quality standards. These instruments utilize electronic components which may be damaged by static electricity present in most work environments. The following steps are recommended to reduce the risk of component failure due to electrostatic discharge: 1. Ship and store circuit boards in anti-static bags. If an anti-static bag is not available, wrap board in aluminum foil. Do not place boards on foam packing materials. 2 2. Use a grounding wrist strap when installing and removing circuit boards. A grounded workstation is also recommended. 3. Handle printed circuit boards only by the edges. Do not touch components or connector pins. 4. Ensure that all electrical connections are completely made and none are partial or floating. Ground all equipment to a good, earth ground. WIRING AND CONFIGURATION WIRING CONFIGURATION All power and control connections are made at the terminal strip within the electronics enclosure. Use of 16-24 AWG twisted shielded pair wire is recommended. NOTE: Observe all local electrical codes and proper wiring procedures. 1. Make sure the power is turned off. 2. Unscrew and remove housing cover. 3. Pull twisted shielded pair wire through conduit connection. NOTE: Transducer phono plugs are factory installed in phono jacks J1 and J2. These connections are not interchangeable, therefore, if they should become disconnected, reinsert the cable marked 1 into jack J1 and the remaining cable into jack J2. 4. Connect wiring to proper terminals of TB1 as shown in Figure 4. 5. Dress wiring to guard against interference or contact with cover or circuit board components. 6. Prevent moisture seepage into housing by installing an approved seal-drain fitting in the conduit run leading to the unit. 7. Installation is complete. Replace housing cover. 1. 2. Select High/Low failsafe setting by placing jumper in desired position. For low level failsafe, position jumper between the middle pin and the pin above the LL mark on P1. In this position the unit will produce 5 mA during a malfunction condition. For high level failsafe, position jumper between the middle pin and the pin above the HL mark on P1. In this position the unit will produce 19 mA during a malfunction condition. See Figure 4 and the Troubleshooting table below. There is an S1 switch located at the center of the board. This two-position switch has a direct (DIR) and a reverse (REV) indication. In the direct position, a dry gap will produce 8 mA and a wet gap produces 16 mA. In the reverse position a dry gap will produce 16 mA and a wet gap produces 8 mA. Normally the switch is kept in the direct (DIR) position. Transducer (J2) Failsafe Jumper LL Transducer (J1) HH DRY WET DIRECT S1 Switch REVERSE COM V+ Wiring and Configuration Figure 4 OPERATIONAL TEST Bring liquid level to a point above transducer gap. When liquid fills transducer gap, the red LED on the PC board should light and the loop current should read 16 mA ± 1 mA. When liquid falls below gap, the green LED on the PC board should light and the loop current should read 8 mA ± 1 mA. In case of malfunction, consult the Troubleshooting section below. TROUBLESHOOTING CAUTION: In hazardous areas, do not remove housing until power is disconnected and atmosphere is determined to be safe. NO CHANGE IN LOOP CURRENT BETWEEN FULL GAP/EMPTY GAP A. B. Check transducer for plugged gap. Check for dense foam or liquid in gap. NO SIGNAL WITH LEVEL CHANGE A. Check power and control circuit wiring. (10 Vdc min. at TB1) B. Make sure liquid is filling the transducer gap. C. Check for dense foam on surface or dried product in gap. Unit will not function if either condition exists. MODE Low level Failsafe * High level Failsafe * SENSOR WET Output = 16 mA Wet (red) LED is on Dry (green) LED is off Output = 16 mA Wet (red) LED is on Dry (green) LED is off OUTPUT CURRENT AT 0 mA A. Check power wiring connections and power source. SENSOR DRY Output = 8 mA Wed (red) LED is off Dry (green) LED is on Output = 8 mA Wet (red) LED is off Dry (green) LED is on MALFUNCTION Output = 5 mA Wed (red) LED is off Dry (green) LED is off Output = 19 mA Wet (red) LED is on Dry (green) LED is on * For High/Low level Failsafe Jumper selection, refer to Figure 4 on Page 3. 3 INTRINSIC SAFETY INTRINSIC SAFETY The Agency Approvals table on page 5 shows the Model 915/916 units that have been CSA approved for intrinsic safety when connected through a certified zener safety barrier rated 28V or less and 300 W or more. Page 5 shows the Model 915/916 units that have been FM entity approved for use in an intrinsically safe circuit per the instructions on drawing 99-5042 Rev F. Below is a copy of this drawing including the description of the intrinsically safe barrier to be used with this unit. Refer to Agency Approvals on Page 5 for complete information. REPLACEMENT PARTS No. Description Part Number 1 915 PC Board 916 PC Board 030-2168-001* 030-2168-002* 2 Base 004-9104-001 3 Cover 004-9105-001 4 O-Ring 012-2101-345 5 Transducer 3 1 4 Select from Model Identification on Page 1. 2 * Recommended spare parts for either the Model 915 or 916 switch. 5 4 SPECIFICATIONS ELECTRICAL SPECIFICATIONS Description DIMENSIONAL SPECIFICATIONS Specification Input Voltage 10-35 vDC (24 vDC nominal) Power Consumption 1 Watt Maximum Loop Resistance 700 ½ at 24 Vdc Ambient Temperature (Electronics) -40° F to +160° F (-40° C to +71° C) Process Temp. (Transducer) 22, HB, HC, MM, CC: -40 to +250° F (-40 to +121° C) FF: 0° to +250° F (-18° to +121° C) KK: +32 to 250° F (0 to +121° C) 22, HB, HC, MM: Process Pressure 800/1500 psig (55/103 Bar) (Operating/Non-operating) FF, CC, KK: 100 psig (7 Bar) Signal Technology Continuous wave Transducer Frequency 1 MHz (Model 915) 3 MHz (Model 916) Response Time 0.1 second typical Repeatability ± 0.078" (2 mm) Output Dry Sensor Wet Sensor Malfunction, High Malfunction, Low CSA 3.00 (76) Rotation clearance 2.75 (70) 6.25 (159) 3⁄ 4'' NPT conduit connection Optional mounting flange Actuation Length (A) 1.00 (25) min. 3⁄ 4'' NPT tank connection 1.62 (41) .875 (22) Dia. Model 915 4.63 (118) Dia. 3.00 (76) Rotation clearance 2.75 (70) 8 mA ± 1 mA 16 mA ± 1 mA 19 mA ± 1 mA 5 mA ± 1 mA 6.25 (159) 3⁄ 4'' NPT Conduit connection Optional mounting flange AGENCY APPROVALS FM 4.63 (118) Dia. NEMA 4X/7/9 polymer powder coated Housing Agency Inches (mm) Model No. Approval 916-G22A-0D0 w/ 671-1221-XXX and IS: I, II, III/1/ABCDEFG - 99-5042/F; 915-G22A-0D0 w/ Entity; XP: I, II, III/1/CDEFG; NEMA 4X 681-1XX1-XXX1➀ 916-G22A-0D0 w/ IS:Class I, Div. 1, Groups A, B, C, & D 671-1221-XXX and Class II, Div. 1, Groups E, F, & G 915-G22A-0D0 w/ Class III, Enclosure Type 4X 681-1XX1-XXX 916-G22A-0D0 w/ XP:Class I, Div. 1, Groups C & D 671-1221-XXX and Class II, Div. 1, Groups E, F, & G 915-G22A-0D0 w/ Class III, Enclosure Type 4X 681-1XX1-XXX ➁ 916-G22A-0D0 w/ 671-1221-XXX and CENELEC EEx ia IIC T4 915-G22A-0D0 w/ 681-1XX1-XXX ➁ Actuation Length (A) 1.00 (25) min. 3⁄ 4'' NPT Tank connection .25 (6) .875 (22) Dia. Model 916 NOTES: 1. Allow 4.00 (102) overhead clearance for cover removal. 2. When units are mounted in a flange, the actuation lengths are reduced by the following amounts: 150 lb. flange – .14 (4) 300 lb. flange – .26 (7) 600 lb. flange – .57 (14) ➀ Excluding Teflon® transducer model 681-1FF1-XXX. ➁ Excluding transducer models 681-1FF1-XXX (Teflon), 681-1KK1-XXX (Kynar®), and 681-1CC1-XXX (CPVC) These units have been tested to EN 50081-2 and EN 50082-2 and are in compliance with the EMC Directive 89/336/EEC. 5 IMPORTANT PRODUCT WARRANTY QUALITY ASSURANCE All Magnetrol/STI 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. Repair parts are warranted free of defects in materials and workmanship for one year from the date of shipment. Materials, specifications, and contents are subject to change without prior written notice. The quality assurance system in place at Magnetrol/STI guarantees the highest level of quality throughout the company. Magnetrol/STI is committed to providing full customer satisfaction both in quality products and quality service. 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/STI will repair or replace the control at no cost to the purchaser (or owner) other than transportation. Magnetrol’s 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. Magnetrol/STI 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/STI products. ASSURED QUALITY & SERVICE COST LESS SERVICE POLICY RETURN MATERIAL PROCEDURE Owners of Magnetrol/STI 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/STI 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 Magnetrol/STI's local representative or by contacting the factory. Please supply the following information: 1. 2. 3. 4. 5. 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. 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 2. 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. 5300 Belmont Road • Downers Grove, Illinois 60515-4499 • 630-969-4028 • Fax 630-969-9489 5300 Belmont Road • Downers Grove, Illinois 60515-4499 • 630-969-4000 • Fax 630-969-9489 • www.magnetrol.com 6291 Dorman Road • Mississauga, Ontario L4V-1H2 • 905-678-2720 • Fax 905-678-7407 Heikenstraat 6 • B 9240 Zele, Belgium • 052 45.11.11 • Telex 25944 • Fax 052 45.09.93 Regent Business Ctr., Jubilee Rd. • Burgess Hill, Sussex RH15 9TL U.K. • 01444-871313 • Fax 01444-871317 ©1999 Magnetrol International, Incorporated. All rights reserved. Printed in the USA. Magnetrol and Magnetrol logotype are registered trademarks of Magnetrol International. Performance specifications are effective with date of issue and are subject to change without notice. The brand and product names contained within this document are trademarks or registered trademarks of their respective holders. BULLETIN: 51-606.4 EFFECTIVE: August 1999 SUPERCEDES: August 1998