Echotel ® Model 960 AS-Interface® Ultrasonic Level Switches D E S C R I P T I O N Echotel® Model 960 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 critical level applications. Model 960 Switches use Actuator-Sensor-Interface (AS-i) bus digital communications for high or low single-point liquid level measurement. AS-i is a versatile, low-cost ASME BPE cabling solution that is a digital replacement for traditional hard wiring of field devices. The AS-i bus system provides a digital serial interface with a single unshielded two-wire Model 960 (Industrial Design) Model 960 (Hygienic Design) cable for power and data transfer. The industrial version of the Model 960 has a cast aluminum electronics housing and a wide variety of threaded A P P L I C A T I O N S or flanged versions of the ultrasonic transducer. The • High level alarm hygienic version is offered in a deep drawn 304 stainless • Overfill protection steel housing and transducers with a 20 Ra surface finish. • Low level alarm • Pump protection F E A T U R E S • Seal pot level • Leak detection • Advanced self-test technology provides unsurpassed reliability and testing of electronics, transducer, piezoelectric crystals, and electromagnetic noise • Adjustable time delay for turbulent aerated liquids • Compressor skids I N D U S T R I E S • Tip-sensitive transducer measures level within 1⁄4" of the vessel bottom • Power • Pulsed signal technology provides superior performance in difficult process conditions • Petrochemical • AS-i output reduces cabling costs and simplifies installation • Food and beverage • Chemical • Brewing and spirits • Pharmaceutical T E C H N O L O G Y B A S I C O P E R A T I O N Model 960 switches utilize ultrasonic energy to detect the presence or absence of liquid in a single point transducer. Ultrasonic contact level technology uses high-frequency sound waves that are easily transmitted across a transducer gap in the presence of a liquid media, but are attenuated when the gap is dry. Model 960 switches use an ultrasonic frequency of 2 MHz to perform this liquid level measurement in a wide variety of process media and application conditions. Ultrasonic transducer 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. PULSED SIGNAL TIME Ultrasonic signal transmission across transducer gap This technology also provides excellent immunity from electromagnetic noise interference. Pulsed signal technology makes the 960 units more reliable than older continuous wave ultrasonic 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 market today. DELAY Turbulence and splashing can cause some fixed time response switches to produce false level alarms. Model 960 switches overcome this difficulty with an adjustable time delay feature. 2 Receive crystal TECHNOLOGY Challenging process conditions such as aeration, suspended solids, and high viscosities are easily handled with the pulsed signal technology utilized in the 960 switches. Pulsed signal circuitry drives the transmit piezoelectric crystal to produce powerful pulses of high-frequency ultrasonic energy. These ultrasonic pulses are readily transmitted through liquids, but are attenuated when the transducer gap is dry. ADJUSTABLE Transmit crystal A potentiometer allows a 1⁄2 to 45-second delay to be set to disregard waves or splashes, and reliably detect the true liquid level. ADVANCED SELF-TEST Ultrasonic switches are often used as the last means of detecting whether a process vessel will overflow and cause a spill of potentially hazardous liquids, or empty out and possibly cavitate the pumps. In these critical applications it is desirable to have a method of periodically testing the ultrasonic switch. Model 960 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 fault LED is lit to indicate an alarm condition. A G E N C Y Self-test is performed automatically and continuously several times per second to verify proper operation of the ultrasonic switch. In addition, a push button is provided to initiate a manual self-test mode. Pressing this test button stops all transmit pulses, which simulates an electronics failure. Taking diagnostics one step further is the unique noise self-test mode feature that is standard in all 960 switches. This tests for electromagnetic and acoustical noise that can influence many instrumentation technologies. If high levels of environmental noise are detected, the electronics reports a fault condition to alert the user of potential instrumentation reliability concerns. A P P R O V A L S AGENCY APPROVED MODELS PROTECTION METHOD AREA CLASSIFICATION FM 960-58AX-030 or 960-58AX-031 with transducers 9X1-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 960-58AX-07X or 960-58AX-03X with transducers 9X1-XXXX-XXX Non-Incendive 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 960-58AX-030 or 960-58AX-031 with transducers 9X1-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 960-58AX-07X or 960-58AX-03X with transducers 9X1-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 IP67 for 304 Stainless Steel Housing ATEX 960-58AX-0C0 or 960-58AX-0C1 with all metallic transducers* Flame Proof AS-i 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 CSA *Consult factory for model numbers II 1/2 G, EEx d IIC T6 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 W I T H Supply Voltage AS-i Version AS-i Slave Type AS-i Slave Profile AS-i Data Bits 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: E N V I R O N M E N T A L Ambient Temperature Storage Temperature Process Temperature Humidity Electronics: Electronics: Transducer: T R A N S D U C E R M O D E L Transducer Material S P E C I F I C A T I O N S 9 A 1 -13° to +160° F (-25° to +71° C) -40° to +160° F (-40° to +71° C) -40° to +325° F (-40° to +163° C) 0-99%, Non-condensing S P E C I F I C A T I O N S S I N G L E P O I N T Material Code Operating Temperature Range (page 7) Maximum Pressure Actuation Length 316 Stainless Steel A*, S, N, K -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 -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 graph below 2" to 130" (5 to 330 cm) CPVC P -40° to +180° F (-40° to +82° C) 2" to 130" (5 to 330 cm) * see graph below Material Code “A” has a Cryogenic Trandsucer Option for -110° to +250° F (-80° to +120° C) operating temperature range 300 30 25 250 25 200 150 100 50 0 -40 4 20 15 10 0 60 120 180 240 Temperature (°F) 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) P E R F O R M A N C E Repeatability Response Time Time Delay Self-Test Automatic: Manual: Shock Class Vibration Class Electromagnetic Compatibility P H Y S I C A L ±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 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 S P E C I F I C A T I O N S ( m m ) 3.12 (79) 2.12 (54) 4.00 (102) 4.00 (102) 2.30 (58) 4.43 (113) 4.43 (113) 2.70 (69) Typical 2.35 (60) Typical 1.80 (46) Typical Actuation length for Varivent fitting 0.25 (6) 0.25 (6) Actuation length for ANSI flange Actuation length for NPT connection 0.25 (6) ∅ .875 (22) ∅ .875 (22) ∅ .875 (22) Hygienic Housing with DN65 Varivent® Flange Cast Aluminum Housing with NPT Connection Cast Aluminum Housing with ANSI Flange 5 M O D E L 9 6 0 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 Integral mount ultrasonic level switch INPUT POWER 5 24 VDC loop-powered OUTPUT SIGNAL 8 Actuator-Sensor-Interface (AS-Interface) SELF-TEST A Automatic & manual via push button OPTIONS 0 1 None Glass window in housing cover MOUNTING 0 Integral AGENCY APPROVAL 3 7 C FM/CSA Explosion proof & Non-incendive (Available with 10th digit = 0 or 1) FM/CSA Non-incendive & General Purpose (Available with 10th digit = 4 or 5) ATEX II 1/2 G EEx d II C T6 Flame Proof (Available with 10th digit = 0 or 1) HOUSING & CONDUIT CONNECTION 0 1 4 5 9 6 6 0 5 8 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 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 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 * Flanged transducers have Kynar faced 316 stainless steel flanges PROCESS CONNECTIONS THREADED CONNECTIONS 11 21 22 3 ⁄4" NPT 1" NPT 1" BSP (G1) ANSI RAISED FACE 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 HYGIENIC CONNECTIONS 3T 4T VV 1"/11⁄2" Tri-Clamp® 16 AMP fitting 2" Tri-Clamp® 16 AMP fitting DN65 – Varivent® EN/DIN FLANGES 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" 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 Available English ESP lengths: 1", 2", 4", 6", 8", 12" 3 cm to 330 cm in 1 cm increments (Example: 6 centimeters = 006) 3 cm minimum for NPT process connections 5 cm minimum for BSP, hygienic, and flanged process connections 5 cm minimum for all Kynar transducers Available metric ESP lengths: 3, 5, 10, 30 cm 9 1 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 Magnetrol’s 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. quality service. E S P Expedite Ship Plan Several Echotel Model 960 units are available for quick shipment, usually within one week after factory receipt of a 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. 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 Manual 51-632. 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 © 2010 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. 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: 51-132.1 EFFECTIVE: May 2010 SUPERSEDES: February 2007