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| actuator- sensor-interface (as-interface ? ) ultrasonic level switch model 960 model 960 (with stainless steel housing) model 960 (with cast aluminum housing) installation and operating manual
51-632 echotel model 960 ultrasonic level switches read this manual before installing this manual provides information on the echotel ? model 960 ultrasonic liquid level switch. it is impor- tant 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 components mechanical integrity. cautions are also used to alert the technician to unsafe practices or the need for special protective equipment or specific mate- rials. in this manual, a caution box indicates a poten- tially 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 model 960 is 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 dis- charge. 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 dis- connect 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 ? 2009 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 war- ranted 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 writ- ten warranties covering some magnetrol products. quality assurance the quality assurance system in place at magnetrol guar- antees the highest level of quality throughout the compa- ny. magnetrol is committed to providing full customer satisfaction both in quality products and quality service. magnetrols 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. 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 2.5 configuration .........................................................7 2.5.1 model 960 as-i bus address .......................7 2.5.2 model 960 unit configuration....................7 2.5.2.1 time delay potentiometer ......................7 2.5.2.2 level test pushbutton .............................8 2.5.2.3 malfunction test pushbutton..................8 2.5.3 led status indications................................8 3.0 reference information....................................................9 3.1 electronics specifications ........................................9 3.2 environmental specifications..................................9 3.3 transducer specifications........................................9 3.4 performance specifications....................................10 3.5 physical specifications ..........................................10 3.6 dimensional specifications ...................................10 3.7 agency approvals .................................................11 3.8 troubleshooting....................................................11 3.9 replacement parts ................................................13 3.10 model number.....................................................14 3.10.1 electronics .................................................14 3.10.2 transducer .................................................15 echotel model 960 ultrasonic single point liquid level switch atpbvu hv8>cy; 9>wy; dbs s;ca2b>=9v nyey; qf9cv8yb 4 figure 1 1.0 introduction echotel model 960 ultrasonic level switches utilize pulsed signal technology to detect high or low point level in a broad range of liquid media applications. 1.1 principle of operation model 960 switches utilize ultrasonic energy to detect the presence or absence of liquid in single point level applications. ultrasonic contact level technology uses high-frequency 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 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. 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 elec- tronics 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. tq '(? ;2s)q vrmwts d.73q? h7+q? &wp n?3 (t7;'. gquq? lv'3.qt ultrasonic transducer transmit crystal receive crystal ultrasonic signal transmission across transducer gap figure 2 typical mounting orientations 5 2.2 electrostatic discharge (esd) handling procedure magnetrols 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. 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 anti- static 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 equip- ment to a good, earth ground. 2.3 mounting the model 960 level switch may be mounted in a variety of positions as shown in figures 2 through 5. proper orientation of the transducer gap will facilitate maximum performance in difficult applications. when the model 960 is mounted horizontally, the transducer gap must be turned vertical 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 trans- ducer mounting can be achieved by aligning the mounting nut flats in a vertical orientation. see figure 4. when installing a model 960 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 mat- ing flange with proper gasket. use thread tape or suitable pipe compound on the threads. do not over-tighten. vrmwts d.73q? h7+q? &wp n?3 (t7;'. gquq? lv'3.qt pump protection f ill line high al arm low ala rm figure 3 vertical mounting use wrench on flats yctuation point process connection bottom view bottom view figure 4 horizontal mounting figure 5 nozzle mounting 6 51-632 echotel model 960 ultrasonic level switches 2.4 wiring model 960 units can be supplied with or without a m12x1 as-i bus quick disconnect male connector installed in one of the cable entries. if the m12x1 connector has been ordered, then complete the wiring by threading on the female m12x1 quick disconnect connector. if the m12x1 connector was not ordered then refer to the figure below for wiring instructions. &n;s+w fah?gj? ydd y55d?&yad? ?d?&-g?&yd &fb?h y8b 5gf5?g k?g?8: 5gf&?big?hh 1. make sure the power source is turned off. 2. unscrew and remove housing cover. 3. pull as-i cabling through the conduit connection. 4. refer to figure 6. connect wires to terminals (+) and (-) on the terminal block. 5. prevent moisture seepage into housing by installing an approval seal drain fitting in the conduit run leading to the unit. 6. wiring is complete. replace housing cover. &n;s+w in hazardous areas, do not power the unit until the conduit is sealed and enclosure cover is screwed down securely. 7m)d ( 7m)d ) adbnky 2 fhxye 52, rdkdgb 7 51-632 echotel model 960 ultrasonic level switches 2.5 configuration 2.5.1 model 960 as-i bus address 1clmx bwk mxmfzrcauft etm fzebzcr 6matcr /azmrobfm f 6tug det luruzbx fcyyeaufbzucat ocr surs cr xcg xuleul xmfmx ualufbzucah 6tu ut b fmrtbzuxmh xcg fctz fbdxuar tcxezuca zsbz ut b luruzbx rmexbfmymaz ocr zrbluzucabx ebrbxxmx guruarh 7sm 6tu det titzmy ercfulmt b luruzbx tmrubx uazmrobfm guzs b tuarxm eatsumxlml zgctgurm fbdxm zc fcaamfz ee zc cd txbfmt fwd txbfmt ua zsm mhzmalml bllrmttuar yclmg ca cam amzgcrwh /a crlmr ocr lbzb mhfsbarm zc cfferh mbfs txbfm fcaamfzml zc zsm 6tu amzgcrw yetz dm ercrrbyyml guzs b eaulem bllrmtth aeydmrml dmzgmma d bal cdh /a mhzmalml bllrmttuar yclmh zsm cr # fsbaamx tmxmfz yetz dm erct rrbyyml bt gmxxh 1clmx bwk eauzt brm obfzcri fcaourerml bt eabtturaml txbfmt guzs zsm bllrmtt lmobexzml zc kh 7sm bllrmtt yetz dm fsbarml di zsm mal etmr fub ercrrbyyuar bz zsm 40& cr guzs temfubx sbalsmxl bllrmttuar lmfufmth 2.5.2 model 960 unit configuration 1clmx bwk eauzt sbfm zsm ocxxcguar fcaourerbzuca cezucatg e 7/1) ()0 a eczmazucymzmr ocr khp zc qpttmfcal turabx bfmrbruarh e 0)9)0 7)67 eets dezzca ocr zmtzuar co zsm ercfmtt xmfmx turabxh e 1 0+ 7)67 eets dezzca ocr zmtzuar co zsm ybxoeafzuca turabxh 2.5.2.1 time delay potentiometer v9- b1r- h-q,i 3 b-sb1 r-b-: 1< bi31f,qqi e<-h 1s ,33q1f,o b1 s< g9-:- be:eeq-sf- : <3q,<91sn r,i f,e<- k,q<- q-f-q ,q,:r 10 51-632 echotel model 960 ultrasonic level switches 3.4 performance specifications repeatability + - 0.078" ( + - 2 mm) response time 1 M 2 second typical time delay variable 0.5 C 45 seconds on rising and falling levels self-test automatic: continuously verifies operation of electronics, transducer, piezoelectric crystals, and electrical noise manual: push button verifies operation of electronics, transducer, and piezoelectric crystals shock class ansi/isa-s71.03 class sa1 vibration class ansi/isa-s71.03 class vc2 electromagnetic compatibility meets ce requirements en 61326 3.5 physical specifications housing material cast aluminum a356-t6, or deep drawn 304 stainless steel cable entry cast aluminum: dual 3 M 4 " npt, or m20 304 stainless steel: dual 1 M 2 " npt, or m20 model 960 with dn65 varivent flange model 960 with npt connection model 960 with ansi flange 1.80 (46) typical 2.70 (69) typical 4.00 ( 102) 4.00 ( 102) ? .875 (22) ? .875 (22) ? .875 (22) actuation length for v arivent fitting 4.43 (113) 4.43 (113) 0.25 (6) 0.25 (6) 0.25 (6) a ctuation length for npt connection actuation length for ansi flange 2.35 (60) typical 3.12 (79) 2.12 (54) 2.30 (58) 3.6 dimensional specifications inches (mm) 3.7 agency approvals agency approved models protection method area classification fm 960-58ax-030 or explosion proof class i, div. 1, groups b, c & d 960-58ax-031 class ii, div. 1, groups e, f & g with transducers class iii, type 4x, ip 66, t6 9x1-xxxa-xxx 960-58ax-07x or non-incendive class i, div. 2, groups a, b, c & d 960-58ax-03x class ii, div. 2, groups f & g with transducers class iii, type 4x, ip 66, t4 9x1-xxxa-xxx ip67 for 304 stainless steel housing csa 960-58ax-030 or explosion proof class i, div. 1, groups b, c, & d 960-58ax-031 class ii, div. 1, groups e, f & g with transducers class iii, type 4x, ip 66, t6 9x1-xxxa-xxx 960-58ax-030 or non-incendive class i, div. 2, groups a, b, c & d 960-58ax-031 class ii, div. 2, groups e, f & g with transducers class iii, type 4x, ip 66, t4 9x1-xxxa-xxx ip67 for 304 stainless steel housing atex 960-58ax-0c0 or flame proof ex ii 1/2 g, eex d iic t6 960-58ax-0c1 with all metallic transducers* 960-58ax-0ex non-sparking ex ii 3 g, eex n ii t6 with all metallic transducers* 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 * consult factory for model numbers these units have been tested to en 61326 and are in compliance with the emc directive 89/336/eec. 11 51-632 echotel model 960 ultrasonic level switches 3.8 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 960 has a unique diagnostics feature to assist in troubleshooting should a failure occur. a microprocessor in the electronics continuously monitors all self-test data. should a fault occur, the microprocessor can determine whether the malfunction is due to the electronics, transducer, piezoelectric crystals, or the presence of environmental noise. the level test pushbutton and diagnostic led are used to assist in troubleshooting the switch: when a fault occurs, as indicated by the diagnostic led being on continuously, press the level test pushbutton and observe the diagnostic led. pending february 2007 12 51-632 echotel model 960 ultrasonic level switches 3.8 troubleshooting (cont.) ? one flash of the diagnostic led indicates a problem with either the transducer, piezoelectric crystals, or the interconnection wiring. ? two flashes of the diagnostic led indicates a prob- lem with the electronics boards. ? three flashes of the diagnostic led indicates exces- sive levels of environmental noise. if the diagnostic led flashes once when the level test 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 fac- tory. a replacement transducer may be needed. see the model number section on pages 14 and 15 for proper replacement part numbers. two flashes of the led indicates an issue with the electronics module. contact the factory for a replacement electronics mod- ule. see section 3.9 for spare electronics boards 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 walkie-talkie or radio, or mechanical vibration from some nearby source. this noise could affect the 960 and other electrical instrumentation. check to see if any of the above listed sources may be causing the interference and correct the issue to insure proper operation of the unit. it is also possible that application related issues may be affecting the proper operation of the 960 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 filling 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. check for dense foam in gap. the switch is chattering check for proper input voltage supply. check for turbulence or excessive aeration. relocate or isolate switch. 2 1 4 6 7 5 3 cast aluminum housing 3.9 replacement parts item description part number 1 housing cover without window 004-9193-002 1 housing cover with window 036-4410-005 2 o-ring 012-2201-237 4 board mounting bracket 005-6690-003 6 fm/csa housing base with 3 M 4 " npt 004-9212-002 6 fm/csa housing base with m20 004-9212-005 6 atex housing base with 3 M 4 " npt 004-9212-003 6 atex housing base with m20 004-9212-004 item description part number 1 housing cover without window 036-5702-003 1 housing cover with window 036-5702-002 2 o-ring 012-2201-155 4 board mounting bracket 005-6691-002 6 housing base 036-5701-004 deep drawn 304 stainless steel housing item description part number 3 bezel overlay sticker 005-9734-001 5 electronics board 030-3588-001 7 transducer see model number common parts 13 51-632 echotel model 960 ultrasonic level switches 960 integral mount ultrasonic level switch 3.10 model number 3.10.1 960 electronics basic model number 0 none 1 window in enclosure cover options agency approval 0 cast aluminum with 3 M 4 " npt dual conduit entries 1 cast aluminum with m20 dual conduit entries 4 deep drawn 304 ss w/ 1 M 2 " npt dual conduit entries 5 deep drawn 304 ss w/m20 dual conduit entries housing & conduit connection 960 58a 0 3 fm/csa explosion proof & non-incendive (available with 10th digit = 0 or 1) 7 fm/csa non-incendive & general purpose (available with 10th digit = 4 or 5) c atex ii 1/2 g eex d ii c t6 flame proof (available with 10th digit = 0 or 1) e atex eex n ii t6, non-sparking (available with 10th digit = 4 or 5) 5 24 vdc loop powered input power 8 actuator sensor interface (as-i) output signal a automatic & manual via push button self-test 0 integral mounting 14 51-632 echotel model 960 ultrasonic level switches 3.10.2 model 960 transducer 91 a a english (length in inches) m metric (length in centimeters) transducer unit of length a 316/316l stainless steel s 316/316l with 20 ra sanitary finish (use only with process connection codes 3t, 4t, or vv) b hastelloy c-276 c monel r kynar (use only with process connection codes 11, 23, 33, 43, ba, ca, da) p cpvc (use only with process connection codes 11, 23, 33, 43, ba, ca, da) n 316/316l stainless steel, nace construction k 316/316l stainless steel, asme b31.1 &b31.3 construction materials of construction 1" to 130" in 1" increments 1" minimum for npt process connections 2" minimum for bsp, sanitary, and flanged process connections example: 4 inches = 004 3 cm to 330 cm in 1 cm increments 3 cm minimum for npt process connections 5 cm minimum for bsp, sanitary, and flanged process connections example: 6 centimeters = 006 actuation length (unit of length specified in second digit) process connections 11 3 M 4 " npt 21 1" npt 22 1" bsp (g1) threaded connections 23 1" 150# ansi rf flange 24 1" 300# ansi rf flange 25 1" 600# ansi rf flange 33 1 1 M 2 " 150# ansi rf flange 34 1 1 M 2 " 300# ansi rf flange 35 1 1 M 2 " 600# ansi rf flange 43 2" 150# ansi rf flange 44 2" 300# ansi rf flange 45 2" 600# ansi rf flange ansi raised face flanges 3t 1"/1 1 M 2 " tri-clamp ? 16 amp fitting 4t 2" tri-clamp ? 16 amp fitting vv dn65 C varivent sanitary connections ba dn 25 pn 16 en 1092-1 type a bb dn 25 pn 25/40 en 1092-1 type a bc dn 25 pn 63/100 en 1092-1 type b2 ca dn 40 pn 16 en 1092-1 type a cb dn 40 pn 25/40 en 1092-1 type a cc dn 40 pn 63/100 en 1092-1 type b2 da dn 50 pn 16 en 1092-1 type a db dn 50 pn 25/40 en 1092-1 type a dd dn 50 pn 63 en 1092-1 type b2 de dn 50 pn 100 en 1092-1 type b2 en/din flanges 15 51-632 echotel model 960 ultrasonic level switches bulletin: 51-632.0 effective: march 2007 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 ? 2009 magnetrol international, incorporated. all rights reserved. printed in the usa. service policy 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: 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 con- trol; 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 consequen- tial damage will be allowed. return material procedure 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 fac- tory, prior to the material's return. this is available through magnetrols local representative or by contacting the factory. please supply the following information: 1. company name 2. description of material 3. serial number 4. reason for return 5. 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. assured quality & service cost less as-interface? is a registered trademark of 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 varivent? is a registered trademark of tuchenhagen gmbh ltd tri-clamp? is a registered trademark of ladish co. |
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