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] • 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