Magnetrol Echotel 962 Instruction Manual

Ultra onic

Level Switche





Applicati n

Echotel®Model 961/962 ultrasonic level switches utilize

pulsed signal technology to detect high, low, or dual-

point level in a broad range of liquid media applications.

The advanced self-test technology provides reliability

and continuous testing of electronics, transducer, piezo-

electric crystals, and electromagnetic noise.

Benefits

The Echotel Model 961/962 ultrasonic level switches

provide the following benefits:

• Single- or dual-point liquid level measurement

• Adjustable time-delay for turbulent aerated liquids

• Reliable liquid level measurement independent of

changes in media density, conductivity, or temperature

• Two-wire mA current shift and relay output options

• Relay output or mA current shift with separate

malfunction indication

• Integral or remote mount electronics

• Pulsed signal technology

• Extensive FM, CSA, ATEX and IEC explosion proof

and intrinsically safe approvals

• Suitable for Safety Integrity Level (SIL) 2 loops



This manual complements and is intended to be used with

the Magnetrol Echotel®Model 961/962 Ultra onic Single and

Dual Point Level Switche In tallation and Operating Manual

(Bulletin 51-646).





51-650 Mo el 961/962 Echotel SIL Safety Manual

Table f C ntents

1.0 Int oduction ...................................................................3

1.1 Product Description..................................................3

1.2 Theory of Operation.................................................3

1.2.1 Transducer Design..........................................3

1.2.2 Transducer Materials ......................................4

1.3 Determining Safety Integrity Level (SIL) ..................4

2.0 Applicable Models ..........................................................4

3.0 Mean Time To Repai (MTTR).....................................4

4.0 Supplementa y Documentation......................................5

5.0 Inst uctions ....................................................................5

5.1 Systematic Limitations ..............................................5

5.1.1 Application Locations.....................................5

5.1.2 Operating Temperature ..................................5

5.1.3 Operating Pressure .........................................5

5.2 Skill Level of Personnel .............................................6

5.3 Necessary Tools .........................................................6

5.4 Installation ................................................................6

5.4.1 Hygienic-specific Installation..........................7

5.4.2 Pump-specific Installation ..............................7

5.5 Configuration ...........................................................7

5.5.1 Time-delay Potentiometer ..............................7

5.5.2 High/Low DIP Switch ...................................7

5.5.3 Malfunction Test Push Button........................8

5.5.4 High/Low DIP Switch ...................................8

5.5.5 Independent/Joint DIP Switch.......................8

5.5.6 Loop Test Push Button...................................8

5.5.7 Fault Test Push Button ...................................8

5.5.8 22/3.6 DIP Switch .........................................8

5.6 Site Acceptance Testing .............................................9

5.7 Maintenance ..............................................................9

5.7.1 Diagnostics.....................................................9

5.7.2 Troubleshooting .............................................9

6.0 Recu ent Function Tests .............................................10

6.1 Proof Testing...........................................................10

6.1.1 Introduction.................................................10

6.1.2 Interval.........................................................10

6.1.3 Recording Results.........................................10

6.1.4 Suggested Proof Test.....................................10

6.1.5 Proof Test Coverage......................................18

7.0 Appendices ...................................................................19

7.1 SIL Summary..........................................................19

7.2. FMEDA Report ......................................................20

7.2.1 FMEDA Report: Management Summary.....21

7.3 Lifetime of Critical Components ............................23

Echotel®Model 961/962 Ult asonic Level Switches

51-650 Mo el 961/962 Echotel SIL Safety Manual

1.0 Intr ducti n

1.1 Pr duct Descripti n

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.

Both Model 961 and 962 switches are suitable for use in

Safety Integrity Level (SIL) 2 loops.

1.2 The ry f Operati n

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 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 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 crys-

tals are made of a ceramic material that vibrates at a given

frequency when subjected to an applied voltage. The trans-

mit 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.

 

Magnetrol’s advanced transducer design performs in difficult

process conditions. Model 961 has a tip-sensitive transducer

with an arched gap increasing its performance in aerated or

foamy liquids. Model 962 has a tip-sensitive lower gap and

flow-through upper gap permitting separations of 125 inches

(318 cm).

Ultrasonic

transducer

Transmit

crystal

Receive

crystal







451-650 Mo el 961/962 Echotel SIL Safety Manual

 

A broad selection of transducer materials is available for the

Model 961/962. Metallic transducers include 316 SS,

Hastelloy®C, and Monel®. The 316 SS transducer has a

NACE construction option for sour gas service, and can

also be built per ASME B31.1 and B31.3 piping codes.

Thermoplastic transducers include Kynar®and CPVC.

These corrosion resistant plastic transducers feature a stiff-

ening tube that runs the length of the transducer for extra

rigidity. Kynar-faced 316 SS flange options are offered with

the Kynar transducers.

1.3 Determining Safety Integrity Level (SIL)

The FMEDA report provides the failure rates and informa-

tion for the PFDavg and Architecture Constraint.

The architecture constraint was determined using the 2H

approach according to 7.4.4.3 of IEC 61508-2, 2010 edi-

tion. The Model 961/962 meets the hardware architecture

constraints for up to SIL 2 at HFT=0 (or SIL 3 at HFT=1)

when the failure rates listed in the FMEDA report are used.

2.0 Applicable M dels

This manual is applicable to the following models of the

Echotel ultrasonic level switches with current shift output:

• Model 961 Single-Point Level Switches

• Model 962 Dual-Point Level Switches

3.0 Mean Time T Repair (MTTR)

SIL determinations are based on a number of factors including

the Mean Time To Repair (MTTR). The analysis for the

Echotel Model 961/962 ultrasonic level switch is based on

a MTTR that is dependent on the end-user practices.

















4≥10-5 to <10-4

3≥10-4 to <10-3

2≥10-3 to <10-2

1≥10-2 to <10-1

51-650 Mo el 961/962 Echotel SIL Safety Manual

4.0 Supplementary D cumentati n

Refer to the following documents as supplements to this

Echotel Model 961/962 SIL Safety Manual:

•Echotel Model 961/962 Ultra onic Level Switche In tallation

and Operating Manual (Bulletin 51-646)

• Failure Modes, Effects and Diagnostics Analysis (FMEDA)

exida Report No.: MAG 17/10-006 R001

Version V2, Revision R0, August 17, 2018

NOTE: The Failure Mo es, Effects, an Diagnostic Analysis (FMEDA)

report can be foun in the Downloa s tab of the Echotel

961/962 site page on magnetrol.com.

5.0 Instructi ns

5.1 Systematic Limitati ns

The following application and environmental limitations

must be observed to avoid systematic failures.

 

The Model 961/962 ultrasonic level switch should be located

for easy access for service, configuration, and monitoring.

There should be sufficient headroom to allow installation

and removal of the unit. Special precautions should be

made to prevent exposure to corrosive atmosphere, excessive

vibration, shock, or physical damage.

 

The ambient temperature range for the 961/962 electronics is

-40 to +160 F (-40 to + 70 C). The operating temperature

for the transducer is dependent on transducer material.

 

Maximum operating pressures are dependent on the trans-

ducer material. Refer to Section 3.4 in the Echotel Model

961/962 Ultra onic Level Switche In tallation and Operating

Manual (Bulletin 51-646).





316 Stainless Steel,

Hastelloy C, an Monel -40 to +325 °F (-40 to +163 °C)

Kynar -40 to +250 °F (-40 to +121 °C)

CPVC -40 to +180 °F (-40 to +82 °C)

651-650 Mo el 961/962 Echotel SIL Safety Manual

5.2 Skill Level f Pers nnel

Personnel following the procedures of this safety manual

should have technical expertise equal to or greater than that

of a qualified instrument technician.

5.3 Necessary T ls

No special equipment or tools are required to install Echotel

Model 961/962 ultrasonic level switch. The following items

are recommended:

• Wrenches, flange gaskets, and flange bolting appropriate for

process connection(s)

• Screwdrivers and assorted tools for making conduit and

electrical connections

• Digital multimeter or DVM for troubleshooting

5.4 Installati n

The Model 961 single point switch may be used for high or

low level alarm, overfill protection, or seal pot level and

pump protection. Model 961 can be mounted vertically or

horizontally in vessels, bridles, or pipes.

The Model 962 dual point switch may be used to measure

high/low, high/high, or low/low levels. It can be used as a

level controller or to control pumps in an auto-fill or auto-

empty mode. Model 962 must be top mounted.

Refer Figures 2–5 to the Echotel Model 961/962 Ultra onic

Switche In tallation and Operating Manual (Bulletin

51.646) for the proper installation instructions.

Bottom View





Bottom View





Use wrench on flats

Process

connection





Pump

Protection

Fill Line Dual Point Alarm

High Alarm

Low Alarm





51-650 Mo el 961/962 Echotel SIL Safety Manual



The hygienic version of the Model 961 is available with a

deep-drawn 304 stainless steel housing. A variety of hygienic

process connections are offered for use in food and beverage,

pharmaceutical, and biotechnology applications. These

hygienic transducers have 3-A (Authorization #596), EHEDG

certification (per TNO Report # V4772/01) and a 20 Ra

finish providing a uniform and ultra-smooth surface that

inhibits microbial growth. Electron beam welding technology

is utilized to facilitate a crevice-free surface inside the trans-

ducer tip. This allows these transducers to be used in a wide

variety of hygienic applications where CIP (clean-in-place) is

used to remove any contamination from the transducer surface.

 

A DIP switch on the Model 962 allows it to be configured

to control level, or to function as a pump controller. In the

pump control mode the unit can perform auto-fill or auto-

empty of tanks, sumps, or wet wells. The tip sensitive lower

gap allows liquid levels to be pumped down to within 1⁄4"

from the bottom of the vessel. The rigidity of the flow

through upper gap allows the Model 962 to be used even

when sumps experience severe turbulence from vessel fill lines.

5.5 C nfigurati n

Refer to Section 2.5 in the Echotel Model 961/962

Ultra onic Level Switche In tallation and Operating Manual

(Bulletin 51-646) for complete configuration instructions.

 

The time-delay potentiometer is used in applications where

turbulence or splashing may cause false level alarm. The

response time can be adjusted from factory-set standard of

0.5 seconds to a maximum of 10 seconds. The time-delay

potentiometer is an option for both Model 961 and Model 962.

The safety function must be designed so that it will operate

correctly with the 961/962 set to maximum delay.

 

The level test push button is used to manually test the

DPDT process level relay and whatever is connected to the

relay. Pressing this push button reverses the state of the

DPDT relay from engaged to de-engaged, or vise-versa.

The level test push button is an option for both Model 961

and Model 962 in line-powered configuration only.

851-650 Mo el 961/962 Echotel SIL Safety Manual

 

The malfunction test push button is used to manually test

the SPDT malfunction relay and whatever is connected to

the relay. Pressing and holding this push button for 2 seconds

causes the SPDT relay to de-engage, indicating a fault

condition. The malfunction test push button is an option

for both the Model 961 and Model 962 in line-powered

configuration only.

 

The Hi/Lo DIP switch is used to select whether the switch

is used as a high-level fail-safe or a low-level fail-safe switch.

See Section 2.5 of the Echotel Model 961/962 Ultra onic

Level Switche In tallation and Operating Manual (Bulletin

51-646) for high/low DIP switch configuration tables.

 

The I/J DIP switch is used to configure the SPDT malfunc-

tion relay to act independently or jointly with the DPDT

process-level relay. In the factory-set I position, the SPDT

and DPDT relays act independent of each other. In the

J position, both the SPDT and DPDT relays will de-engage

when a fault is detected. The I/J DIP switch is an option for

the Model 961 in line-powered configuration only.

 

The loop test push button is used to manually test the loop

current output. For Model 961, pressing the loop test push

button reverses the output from 8 mA to 16 mA or from

16 mA to 8 mA. For Model 962, pressing the loop test push

button changes the output from 8 mA to 12 mA, 12 mA to

16 mA, or 16 mA to 8 mA.

 

The fault test push button is used to manually change the

mA values to that selected at the 22/3.6 DIP switch.

Pressing this push button for two seconds simulates a circuit

test failure. The output goes to the selected fault current of

either 22 or 3.6 mA, and all three LEDs go dark. The fault

test push button is an option on both Model 961 and

Model 962.

 

The 22/3.6 switch is used to produce a 22 mA or 3.6 mA

output when the unit detects a fault. The 22/3.6 switch is

on both the Model 961 and Model 962.

51-650 Mo el 961/962 Echotel SIL Safety Manual

5.6 Site Acceptance Testing

Complete a site acceptance test to ensure proper operation

after installation and configuration. Results of site accept-

ance testing must be recorded for future reference.

5.7 Maintenance

 

Wor t-ca e internal fault detection time i 10 econd .

 

Report all failures to the MAGNETROL Technical Support

Department.

Refer to the Echotel Model 961/962 Ultra onic Level Switche

In tallation and Operating Manual (Bulletin 51-646) for

troubleshooting device errors.

• As there are no moving parts in this device, the only main-

tenance required is the SIL Proof Test.

• Firmware can only be upgraded by factory personnel.





  

1 flash

In icates a problem with either the

trans ucer, piezoelectric crystals, or

the interconnection wiring.

Check wiring insi e 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

tightene . If all wires are secure then contact the factory. Replace trans ucer if

nee e . Refer to Section 3.8 of the Installation and Operating Manual for proper

replacement part numbers.

2 flashes In icates a problem with one of the

electronics boar s.

Contact the factory for a replacement electronics mo ule. Refer Section 3.8 of the

Installation and Operating Manual for spare electronics mo ules part numbers.

3 flashes In icates excessive levels of

environmental noise.

Check if any source may be causing the interference, such as VFD (variable

frequency rive), ra iate electrical interference (two-way ra io transceiver) or

mechanical vibration from nearby source.





  

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

10 51-650 Mo el 961/962 Echotel SIL Safety Manual

6.0 Recurrent Functi n Tests

6.1 Pr f Testing

 

Following are the procedures utilized to detect Dangerous

Undetected (DU) failures.

 

To maintain the appropriate Safety Integrity Level of a

Safety Instrumented System, it is imperative that the entire

system be tested at regular time intervals (shown as TI in the

appropriate standards). The necessary time interval is deter-

mined by what is required to achieve the appropriate SIL

level for PFDavg.

NOTE: It is the responsibility of the owner/operator to select the type

of inspection an the time perio for these tests.

 

Results of the Proof Test should be recorded for future

reference.

 

Suggested proof tests are provided for the relay and loop

versions of the 961/962.

51-650 Mo el 961/962 Echotel SIL Safety Manual -– Loop Version

  

Refer to the Mo el 961 installation an operation manual an the SIL Safety Manual

(note the chart in section 2.5.2.4 of the I & O Manual).

 Bypass the PLC or take other action to avoi a false trip.



Inspect the Unit in etail outsi e an insi e for physical amage or evi ence of environmental or

process leaks

a.) Inspect the exterior of the Unit housing. If there is any evi ence of physical amage that may

impact the integrity of the housing an the environmental protection, the unit shoul be repaire

or replace .

b.) Inspect the interior of the Unit. Any evi ence of moisture, from process or environment, is an

in ication of housing amage, an the unit shoul be repaire or replace .



Observe an recor the settings of the HI/LOW an 22/3.6 DIP switches, the LED in icators, Loop

Current an Sensor GAP con ition (WET or DRY).

If the FAULT LED is lighte , iagnose the fault an repair or replace the unit.

Confirm proper operation of the unit: WET/DRY GAP con ition; 8mA LED or 16mA LED is lighte ;

Loop current = 8mA ±1mA or 16mA ±1 mA.

a.) Press LOOP TEST push button an confirm change; 8mA >> 16mA or 16mA >> 8mA.

Release the button an unit returns to proper operation.

b.) Change HI/LOW DIP switch position. Confirm both LED & Loop Current change state;

8mA >> 16mA or 16mA >> 8mA. Observe the time elay from change of DIP switch until

LED an Loop current change. Delay is set by Time Delay Pot, so elay may be as long as

15 secon s. Change HI/LOW DIP switch back to original setting an confirm proper operation,

after the elay.

c.) Press FAULT TEST push button an confirm: FAULT LED lights; Loop current ≥22mA or ≤3.6mA

base on 22/3.6 switch. Release button.

.) Change the 22/3.6 DIP switch position. Press FAULT TEST push button an confirm: FAULT

LED lights; Loop current ≥22mA or ≤3.6mA as expecte . Release push button. Return 22/3.6

switch to original setting

e.) A just the Time Delay Pot to maximum elay, fully clock-wise up to 20 turns. Change HI/LOW

DIP switch position an observe the time elay from change of DIP switch until LED an Loop

current change. Confirm elay ≥10 secon s. Change HI/LOW DIP switch back to original set-

ting an confirm ≥10 secon s elay. A just the Time Delay Pot to minimum elay, fully counter-

clock-wise ~20 turns. Change HI/LOW DIP switch position an observe the time elay. Confirm

elay ≤1 secon s. Change HI/LOW DIP switch back to original setting an confirm minimum

elay.



When possible moving the process level will provi e a more complete proof test.

Confirm proper operation of the unit: WET/DRY GAP con ition; 8mA LED or 16mA LED is lighte ;

Loop current = 8mA ±1mA or 16mA ±1 mA.

a.) Move the process level an confirm the GAP con ition has change . Confirm proper operation

of the unit: WET/DRY GAP con ition; 8mA LED or 16mA LED is lighte ;

Loop current = 8mA ±1mA or 16mA ±1 mA.

b.) Move the process level an confirm the GAP con ition has returne to orginal state. Confirm

proper operation of the unit: WET/DRY GAP con ition; 8mA LED or 16mA LED is lighte ;

Loop current = 8mA ±1mA or 16mA ±1 mA.

c.) If unit fails the tests of steps 4a or 4b procee to step 5.

.) A just the Time Delay Pot to the original setting. Use HI/LOW DIP switch (as escribe in

step 2e) to confirm that elay is returne to original setting.

e.) Procee to step 6.

continued on next page

12 51-650 Mo el 961/962 Echotel SIL Safety Manual -– Loop Version

  



If the unit un er test fails to respon to process level changes remove the unit from the process an

bench test.

a.) Remove the unit from the process. Inspect the ultrasoun trans ucer for evi ence of amage or

coating buil up. Fouling on the trans ucer surface may interfere with normal operation. If heavy

fouling is evi ent, it is suggeste to service the trans ucer more frequently.

b.) Clean the ultrasonic trans ucer, especially in the area of the sensor GAP.

c.) Perform a bench test per the steps of section 4. When possible it is best to use the actual

process material, because materal properties affect the ultrasonic performance. Confirm proper

unit operation: WET/DRY GAP con ition; 8mA LED or 16mA LED is lighte ; Loop current = 8mA

±1mA or 16mA ±1mA

.) If unit passes the tests of steps 5c, return to the process installation an repeat the tests of

step 4.

e.) If the unit fails re-test in the process, it must be replace .

Proof test is complete. Restore loop to full operation.

51-650 Mo el 961/962 Echotel SIL Safety Manual -– Loop Version

  

Refer to the Mo el 961 installation an operation manual an the SIL Safety Manual

(note the charts in section 2.5.1 of the I & O Manual).

 Bypass the PLC or take other action to avoi a false trip.



Inspect the Unit in etail outsi e an insi e for physical amage or evi ence of environmental or

process leaks.

a.) Inspect the exterior of the Unit housing. If there is any evi ence of physical amage that may

impact the integrity of the housing an the environmental protection, the unit shoul be repaire

or replace .

b.) Inspect the interior of the Unit. Any evi ence of moisture, from process or environment, is an

in ication of housing amage, an the unit shoul be repaire or replace .



Observe an recor the settings of the HI/LOW an INDEPENDENT/JOINT (I/J) DIP switches, the LED

in icators, Relay contact con itions an Sensor GAP con ition (WET or DRY).

If the FAULT LED is lighte or the MALF LED is OFF, iagnose the fault an repair or replace the unit.

Confirm proper operation of the unit: WET/DRY GAP con ition an WET LED; LEVEL LED an relay

operation.

a.) Press LEVEL TEST push button an confirm Relay Contacts an LEVEL LED change state.

Release the button an unit returns to proper operation base on the GAP con ition an switch

settings.

b.) Change HI/LOW DIP switch position. Confirm LED & Relay change state. Observe the time

elay from change of DIP switch until LED an Relay contacts change. Delay is set by Time

Delay Pot, so elay may be as long as 10 secon s. Change HI/LOW DIP switch back to

original setting an confirm proper operation, after the elay.

c.) Press MALF TEST push button an confirm: FAULT LED lights, MALF an WET LEDs goes OFF

an MALF Relay contacts go to the e-energize state. Release button. Confirm unit returns to

normal operation

.) A just the Time Delay Pot to maximum elay, fully clock-wise up to 20 turns. Change HI/LOW

DIP switch position an observe the time elay from change of DIP switch until LED an Relays

change. Confirm elay ≥10 secon s. Change HI/LOW DIP switch back to original setting an

confirm ≥10 secon s elay. A just the Time Delay Pot to minimum elay, fully counter-clock-

wise ~20 turns. Change HI/LOW DIP switch position an observe the time elay. Confirm elay

≤ 1 secon s. Change HI/LOW DIP switch back to original setting an confirm minimum elay.



When possible moving the process level will provi e a more complete proof test.

Confirm proper operation of the unit: WET/DRY GAP con ition, WET LED an relay operation.

a.) Move the process level an confirm the GAP con ition has change . Confirm proper operation

of the unit: WET/DRY GAP con ition an correspon ing LED an Relay contacts state.

b.) Return process level to original state. Confirm proper operation of the unit: WET/DRY GAP

con ition an correspon ing LED an Relay contacts state.

c.) If unit fails the tests of steps 4a or 4b procee to step 5.

.) A just the Time Delay Pot to the original setting. Use HI/LOW DIP switch (as escribe in step

3b) to confirm that elay is returne to original setting.

e.) Procee to step 6.

continued on next page

14 51-650 Mo el 961/962 Echotel SIL Safety Manual -– Loop Version

  



If the unit un er test fails to respon to process level changes remove the unit from the process an

bench test.

a.) Remove the unit from the process. Inspect the ultrasoun trans ucer for evi ence of amage or

coating buil up. Fouling on the trans ucer surface may interfere with normal operation. If heavy

fouling is evi ent, it is suggeste to service the trans ucer more frequently.

b.) Clean the ultrasonic trans ucer, especially in the area of the sensor GAP.

c.) Perform a bench test per the steps of section 4. When possible it is best to use the actual

process material, because materal properties affect the ultrasonic performance. Confirm proper

unit operation: WET/DRY GAP con ition; LEDs an Relay contacts state.

.) If unit passes the tests of steps 5c, return to the process installation an repeat the tests of

step 4.

e.) If the unit fails re-test in the process, it must be replace .

Proof test is complete. Restore loop to full operation.

51-650 Mo el 961/962 Echotel SIL Safety Manual -– Loop Version

  

Refer to the Mo el 962 installation an operation manual an the SIL Safety Manual

(note the chart in section 2.5.4.4 of the I & O Manual).8p5.158

Bypass the PLC or take other action to avoi a false trip.



Inspect the Unit in etail outsi e an insi e for physical amage or evi ence of environmental or

process leaks.

a.) Inspect the exterior of the Unit housing. If there is any evi ence of physical amage that may

impact the integrity of the housing an the environmental protection, the unit shoul be repaire

or replace .

b.) Inspect the interior of the Unit. Any evi ence of moisture, from process or environment, is an

in ication of housing amage, an the unit shoul be repaire or replace .



Observe an recor the settings of the HI/LOW an 22/3.6 DIP switches, the LED in icators, Loop

Current an Sensor GAP con itions (WET or DRY).

If the FAULT con ition is in icate by loop current an LED in icators all OFF, iagnose the fault an

repair or replace the unit.

Confirm proper operation of the unit: WET/DRY GAP con itions; 8mA LED, 12mA or 16mA LED is

lighte ; Loop current = 8mA ±1mA, 12mA ±1mA or 16mA ±1 mA.

a.) Press LOOP TEST push button an confirm change; 8mA >> 12mA, 12mA >> 16mA or

16mA >> 8mA. Release the button an unit returns to proper operation.

b.) Change HI/LOW DIP switch position. Confirm both LED & Loop Current change state;

8mA >> 16mA or 16mA >> 8mA. Note that 12mA will stay at 12mA with the switch change.

Observe the time elay from change of DIP switch until LED an Loop current change. Delay is

set by Time Delay Pot, so elay may be as long as 12 secon s. Press LOOP TEST push button

an confirm change; 8mA >> 12mA, 12mA >> 16mA or 16mA >> 8mA.

Release the button an unit returns to proper operation. Change HI/LOW DIP switch back to

original setting an confirm proper operation, after the elay.

c.) Press FAULT TEST push button an confirm: all LEDs go OFF; Loop current ≥22mA or ≤3.6mA

base on 22/3.6 switch. Release button.

.) Change the 22/3.6 DIP switch position. Press FAULT TEST push button an confirm: all LEDs

go OFF; Loop current ≥22mA or ≤3.6mA as expecte . Release push button. Return 22/3.6

switch to original setting.

e.) A just the Time Delay Pot to maximum elay, fully clock-wise up to 20 turns. Change HI/LOW

DIP switch position an observe the time elay from change of DIP switch until LED an Loop

current change. Confirm elay ≥10 secon s. Change HI/LOW DIP switch back to original set-

ting an confirm ≥10 secon s elay. A just the Time Delay Pot to minimum elay, fully counter-

clock-wise ~20 turns. Change HI/LOW DIP switch position an observe the time elay. Confirm

elay ≤1 secon s. Change HI/LOW DIP switch back to original setting an confirm minimum

elay.

continued on next page

16 51-650 Mo el 961/962 Echotel SIL Safety Manual -– Loop Version

  



Move the process level to achieve three possible states: 1. both GAPs DRY, 2. one GAP DRY & one

GAP WET, 3. Both GAPs WET. This test confirms operation with all GAP states.

Confirm proper operation of the unit: WET/DRY GAP con itions; 8mA LED, 12mA or 16mA LED is

lighte ; Loop current = 8mA ±1mA, 12mA ±1mA or 16mA ±1mA.

a.) Move the process level to achieve state 1. Both GAPS DRY. Confirm proper operation of the

unit: WET/DRY GAP con itions; 8mA LED or 16mA LED is lighte ; Loop current = 8mA ±1mA

or 16mA ±1 mA.

b.) Move the process level to achieve state 2. one GAP DRY an one GAP WET. Confirm proper

operation of the unit: WET/DRY GAP con itions; 12mA LED is lighte ; Loop current = 12mA

±1mA.

c.) Move the process level to achieve state 3. Both GAPS WET. Confirm proper operation of the

unit: WET/DRY GAP con itions; 8mA LED or 16mA LED is lighte ; Loop current = 8mA ±1mA

or 16mA ±1 mA.

.) If unit fails the tests of steps 4a 4b or 4c procee to step 5.

e.) A just the Time Delay Pot to the original setting. Use HI/LOW DIP switch (as escribe in

step 2e) to confirm that elay is returne to original setting.

f.) Procee to step 6.



If the unit un er test fails to respon to process level changes remove the unit from the process an

bench test.

a.) If the unit un er test fails to respon to process level changes remove the unit from the process

an bench test.

b.) Clean the ultrasonic trans ucer, especially in the area of the sensor GAPs.

c.) Perform a bench test per the steps of section 4. When possible it is best to use the actual

process material, because materal properties affect the ultrasonic performance. Confirm proper

unit operation: WET/DRY GAP con itions; 8mA LED, 12mA LED or 16mA LED is lighte ;

Loop current = 8mA ±1mA, 12ma ±1mA or 16mA ±1mA.

.) If unit passes the tests of steps 5c, return to the process installation an repeat the tests of

step 4.

e.) If the unit fails re-test in the process, it must be replace .

Proof test is complete. Restore loop to full operation.

51-650 Mo el 961/962 Echotel SIL Safety Manual -– Loop Version

  

Refer to the Mo el 962 installation an operation manual an the SIL Safety Manual

(note the charts in section 2.5.3 of the I & O Manual).

Bypass the PLC or take other action to avoi a false trip.



Inspect the Unit in etail outsi e an insi e for physical amage or evi ence of environmental or

process leaks.

a.) Inspect the exterior of the Unit housing. If there is any evi ence of physical amage that may

impact the integrity of the housing an the environmental protection, the unit shoul be

repaire or replace .

b.) Inspect the interior of the Unit. Any evi ence of moisture, from process or environment, is an

in ication of housing amage, an the unit shoul be repaire or replace .



Observe an recor the settings of the HI/LOW an PUMP CONTROL/LEVEL CONTROL (PC/LC) DIP

switches, the LED in icators, Relay contact con itions an Sensor GAP con ition (WET or DRY).

If the FAULT LED is lighte or the MALF LED is OFF, iagnose the fault an repair or replace the unit.

Confirm proper operation of the unit: WET/DRY GAP con ition for each GAP; UPPER LED an relay

operation; an LOWER LED an relay operation.

a.) Press LEVEL TEST push button an confirm both UPPER an LOWER Relay Contacts change

state, an LEDs also change. Release the button an unit returns to proper operation base on

the GAP con ition an switch settings.

b.) Change HI/LOW DIP switch position. Confirm LEDs & Relays change state. Observe the time

elay from change of DIP switch until LEDs an Relay contacts change. Delay is set by Time

Delay Pot, so elay may be as long as 10 secon s. Change HI/LOW DIP switch back to origi-

nal setting an confirm proper operation, after the elay.

c.) Press MALF TEST push button an confirm: FAULT LED lights, All other LEDs goes OFF, an

all Relay contacts go to the e-energize state. Release button. Confirm unit returns to normal

operation.

.) A just the Time Delay Pot to maximum elay, fully clock-wise up to 20 turns. Change HI/LOW

DIP switch position an observe the time elay from change of DIP switch until LED an

Relays change. Confirm elay ≥10 secon s. Change HI/LOW DIP switch back to original set-

ting an confirm ≥10 secon s elay. A just the Time Delay Pot to minimum elay, fully counter-

clock-wise ~20 turns. Change HI/LOW DIP switch position an observe the time elay.

Confirm elay 1 secon s. Change HI/LOW DIP switch back to original setting an confirm

minimum elay.



When possible moving the process level will provi e a more complete proof test.

Confirm proper operation of the unit: WET/DRY GAP con ition for each GAP; UPPER LED an relay

operation; an LOWER LED an relay operation.

a.) Move the process level an confirm the GAP con ition has change . Confirm proper operation

of the unit: WET/DRY GAP con ition an correspon ing LED an Relay contacts state.

Continue to move process level in or er to test three possible states; 1. Both GAPS DRY

2. One GAP WET 3. BOTH GAPS WET.

b.) Change the PUMP CONTROL / LEVEL CONTROL (PC/LC) DIP switch position. Repeat the test

of step 4a to test all three possible GAP states an confirm expecte operation. Return the

PC/LC DIP to the original position.

c.) If unit fails the tests of steps 4a or 4b procee to step 5.

.) A just the Time Delay Pot to the original setting. Use HI/LOW DIP switch (as escribe in step

2e) to confirm that elay is returne to original setting.

e.) Procee to step 6.

continued on next page

18 51-650 Mo el 961/962 Echotel SIL Safety Manual -– Loop Version

  