Magnetrol ECHOTEL 960 User manual

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Installation and Operating Manual
ECHOTEL®960
AS-INTERFACE®

2
UNPACKING
Unpack the instrument carefully. Make sure all components
have been removed from the foam protection. Inspect all
components for damage. Report any concealed damage to
the carrier within 24 hours. Check the contents of the car-
ton/crates against the packing slip and report any discrep-
ancies to Magnetrol. Check the nameplate model number
(Model number/approvals as per inserted separate sheet) to
besure it agrees with the packing slip and purchase order.
Check and record the serial number for future reference
when ordering parts.
MOUNTING
Tri-Clamp®16 AMP connectionVarivent®connectionThreaded G1A connection Welded flange ANSI/DIN connection
These units are in compliance with:
1.The EMC directive 89/336/EEC. The units have been tested to
EN 61326.
2.Directive 94/9/EC (ATEX 95A) for equipment or protective system intended
for use in potentially explosive atmospheres. EC-type examination certifi-
cate ISSeP06ATEX008 - explosion proof.
3.The PED Directive 97/23/EC (pressure equipment directive). Safety accessories per category IV
module H1.
Nameplate:
-part number
-serial n°
High alarm
High alarm
High alarm
Low alarm
Filling line
Pump protection
Pump
Low alarm
Max pressure: metal transducer: 138 bar (2000 PSIG)
plastic transducer: 19 bar (275 PSIG)
Ambient temperature: -25°C (-13°F) to +70°C (+160°F)
Max temp: metal transducer: +165 °C (+325 °F)
plastic transducer: +120 °C(+250 °F)
Min temp: -80 °C(-110 °F)

3
WIRING
USER INTERFACE
TIME DELAY
ASI + ASI –
FAULT
MODEL 960
POWER
WET
DIAGNOSTIC
LEVEL TEST
MALF. TEST
Standard unshielded
2-wire cable
Up to 31 units (slaves) / 62 units (in the
extended addressing mode) on one net-
work
M12 x 1 AS-i bus quick
disconnect male connector
or cable gland
Adjustable time delay: 1 to 45 s. Time delay is typically used where turbulence,
boiling or splashing can cause false level alarms
AS-i wiring terminals
Plugged entry
HAZARDOUS AREA SAFE AREA
Echotel®960 electronics
Important: In extended addressing mode, the Aor B channel select must be programmed as well. Model 960
units are factory configured as unassigned slaves with the address defaulted to 0. The address must be
changed by the end user via programming at the PLC or with special handheld addressing devices.
TIME
DELAY
ASI +
ASI –
FAULT
MODEL 960
POWER
WET
DIAGNOSTIC
LEVEL
TEST
MALF.
TEST
Red fault LED: ON = AS-i communication fault,
FLASHES when an instrument failure is detected
(red Diagnostic LED is ON)
Green power LED: ON = power is on
Yellow wet LED: ON = sensor gap is immersed
Pushbutton for testing alarm output signal: D2 = 1 means immersed gap
D2 = 0 means dry gap
Pressing pushbutton causes D2 to change state
Pushbutton for testing malfunction output. Pressing pushbutton (min 8-10 s)
causes a malfunction:«FAULT»LED flashes and «DIAGNOSTIC» LED is ON
Red diagnostic LED: ON = unit malfunction
FLASHES when activating troubleshooting
(see troubleshooting section)

4
MAINTENANCE
Manual Testing
Level Test:
Pressing the “Level Test” pushbutton, will manually test the AS-i output. The level test forces the D2 output and corresponding
LED’s from “1” (wet gap) to “0” (dry gap) data bits or vice versa. The time delay setting is not active during testing.
Fault Test
Pressing the “Fault Test” pushbutton for min 2 s, will manually test the fault output. The fault test simulates a circuit failure and
forces the D3 output to “1” data bits. The time delay setting is not active during testing.
Troubleshooting
Problem Action/Indication Solution
Nopower NoLED’s are ON Check wiring / input power
Check for malfunction. See below
No change in output between
wet gap / dry gap Gap may be plugged by solids / dense foam Clean the transducer
Gap is out of reach of liquid Check mounting section on page 2 and
relocate the unit or check blocking
valves.
Chattering output Excessive aeration / Turbulence Introduce a time delay
Check input power
Relocate the switch
Fault LED FLASHES
Diagnostic LED is OFF A system fault has been detected Check input power
Press «Level Test»pushbutton
to identify the problem:
* --- * : 1 flash (red LED) Check wiring between transducer and
electronics or replace transducer.
** --- ** : 2 flashes (red LED) Replace electronics
*** --- *** : 3 flashes (red LED) The unit senses excessive noise
interference. Check shield connection or
eliminate interference from a walktie-
talkie, radio, mechanical vibration from a
nearby source

5
REPLACEMENT PARTS
Replacing electronics/transducer
Replacement parts
Echotel electronics can be removed in the field under process conditions. Follow below steps to exchange electronics/trans-
ducer:
Note: Adjust set up of the replacing electronics following the settings of the old electronics (see configuration section)
1. Disconnect power before removing the housing cover
2. Remove power/output wires (a)
3. Remove the 2 bracket screws and slide out electronics (b)
4. Remove the transducer wires (c)
5. Re-assemble following the same procedure in opposite way. Make sure that the tip on the bracket of the electronic block is
seated properly in the corresponding recess in the housing base - (d)
No. Description Part Number
1Cast aluminium cover
Blind
With window
Deep drawn stainless steel cover
Blind
With window
004-9192-009
036-4410-010
036-5702-003
036-5702-002
2 “O”-Ring 012-2201-237
3Electronic module 089-7255-001
4 Transducer See model
identification
2
1
3
4
3
3
a
d
c
b

6
MODEL IDENTIFICATION
Acomplete measuring system consists of:
1.Echotel 960 electronics
2. Echotel 9M1 transducer
3. M12 x 1, AS-i quick disconnect male connector part n° for 960 electronics: 037-7916-001
1. Code for Echotel 960 electronics
9 8 A
5
6 0 0 complete Code for Echotel 960 electronics
0Integral mount electronics
BASIC MODEL NUMBER
9 6 0 Echotel 960 electronics with AS-i bus communication
INPUT POWER
MOUNTING
0 Blind housing cover
1 Housing cover with glass window (for aluminium housings only)
ACCESSORIES
3 ATEX II 1 G EEx ia IIC T5, intrinsically safe (except deep drawn SST housing)
1Non flammable area
C ATEX II 1/2 G EEx d IIC T6, explosion proof
APPROVALS
Units with aluminium housing
1 Cast aluminium housing with M20 x 1,5 cable entry (2 entries – one plugged)
0 Cast aluminium housing with 3/4" NPT cable entry (2 entries – one plugged)
5 Deep drawn steel with M20 cable entry (2 entries – one plugged)
4 Deep drawn steel with 1/2"NPT cable entry (2 entries – one plugged)
HOUSING / CABLE ENTRY
5 8 A 2-wire loop powered with current shift output
7 Non flammable area for all outputs
EATEX II 3 G EEx n II T6, non sparking for AS-i bus
Units with stainless steel housing

7
MODEL IDENTIFICATION
2. Code for Echotel 961 transducer
9 M 1 complete code for Echotel 961 transducer
A316/316 L (1.4401/1.4404) stainless steel➀
B Hastelloy C (2.4819)
C Monel (2.4360)
PCPVC
R Kynar (PVDF)
S316/316L (1.4401/1.4404) with 0,5 µm(Ra 20) hygienic finish
PROCESS CONNECTION
Threaded (Plastic transducers are only available with 3/4" NPT connection)
1 1 threaded 3/4" NPT connection
2 1 threaded 1" NPT connection
2 P threaded G1A connection, compatible with hygienic weld flange
ANSI RF Flanges
2 3 1" 150 lbs Raised face
2 4 1" 300 lbs Raised face
2 5 1" 600 lbs Raised face
3 3 1 1/2" 150 lbs Raised face
3 4 1 1/2" 300 lbs Raised face
3 5 11/2" 600 lbs Raised face
4 3 2" 150 lbs Raised face
4 4 2" 300 lbs Raised face
4 5 2" 600 lbs Raised face
EN/DIN Flanges
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
C A 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
D E DN 50 PN 100 EN 1092-1 Type B2
BASIC MODEL NUMBER
9 M 1 Echotel 961 transducer with single setpoint
TRANSDUCER MATERIALS (use only metal transducers for hazardous area)
CPVC flanges for CPVC transducers.
Kynar cladded SST flanges for Kynar transducers
Use only 150 lbs / PN 16 order codes for plastic transducers
Hygienic (use only in combination with hygienic transducer material code “S”)
3 T 1" / 11/2"Tri-Clamp®16 AMP fitting
4 T 2" Tri-Clamp®16 AMP fitting
VVDN 65 Varivent®flange
A Standard sensor: min -40 °C / max +165 °C (-40 °F / +325 °F)
C Low temperature sensor: min -80 °C / max +105 °C (-110 °F / +220 °F) – only for 961 with 316/316L sensor
SENSOR TYPE
ACTUATION LENGTH – specify in cm (per 0.39") increments
Total insertion length = actuation length + 6 mm (0.25")
0 0 3 Min 30 mm (1.2")
0 0 4 Min 40 mm (1.5") - for 1" BSP (G1) / flanged and hygienic units
3 3 0 Max 3300 mm (130")
➀Low temperature sensor (min -80 °C) is only available in 316/316L SST for 961 units

8
DIMENSIONS IN mm (inches)
102
(4)
6(0.25)
46 (1.8) Typical
Ø22 (.875)
Actuation length
for NPT connection
Actuation
length
for BSP (G1)
connection
113 (4.43) without window
123 (4.85) with window
102
(4)
6(0.25)
26 (1.05) Typical
Ø22 (.875)
Actuation length
for Tri-Clamp fitting
113 (4.43) without window
123 (4.85) with window
102
(4)
6(0.25)
60 (2.35) Typical
Ø22 (.875)
Actuation length
113 (4.43) without window
123 (4.85) with window
102
(4)
6(0.25)
27 (1.08)
Ø22 (.875)
Actuation length
113 (4.43) without window
123 (4.85) with window
Threaded connection Flanged connection
Tri-Clamp®16 AMP fitting Varivent flange
79
(3.12)
58
(2.30)
146
(5.75)
54
(2.12)
Threaded connection Threaded G1A connection
6(0.25)
Ø22 (.875)
Actuation length
for NPT connection
Actuation
length
for BSP (G1)
connection
Actuation
length
for G1A
connection
79
(3.12)
31
(1.23)
58
(2.30)
125
(4.94)
54
(2.12)
6(0.25)
Ø22 (.875)

9
SPECIFICATIONS
Description Specification
Input Voltage 21-31 V DC (2-wire)
Power Consumption <1Watt
Signal Output D2 = “1” with a wet gap / “0” with a dry gap
D3 = “1” during malfunction / “0” during normal operation
Indication LED’s for process alarm status, malfunction (error of transducer, electronics or elec-
trical noise interference) and wet/dry status of transducer
Selftest Automatic Continuously verifies electronics, transducer and noise interference
Manual Via pushbutton for checking alarm output and error output/function.
Housing material IP66, cast aluminium or deep drawn 304 stainless steel
Approvals ➀
ATEX, II 3G, EEx n II T6, non sparking
ATEX, II 1/2 G, EEx d IICT6, explosion proof
(units with metal transducers)
EHEDG certification (per TNO report # V4772/01)
AS-i: tested to EN 50295 and IEC 62026-2 (AS-i test certificate #76401)
FM/CSA, non incendive and explosion proof
Overfill prevention TÜV - WHG § 19 / VLAREM II 5.17.7
Shock/Vibration ANSI/ISA-S71.03 Class SA1 (shock), ANSI/ISA-S71.03 Class VC2 (vibration)
Net Weight 1.5 kg (3 lbs) with 50 mm (2") transducer
AS-i bus
specifications
AS-i version V3.0
Slave type A/B (maximum of 62 nodes)
Slave profile S-0.A.E.
Connectable load EN 50295 and IEC 62026-2
Description Plastic transducers Metal transducers
Transducer materials CPVC
Kynar®(PVDF)
316/316L SST (1.4401/1.4404)
Hastelloy®C(2.4819)
Monel®(2.4360)
Mounting Threaded (NPT) – Flanged (ANSI - EN/DIN)
Actuation length From 50 mm up to 3300 mm (2" up to 130") From 30 mm up to 3300 mm (1" up to 130")
Max process temp. (consult temp/
press. graphs)
-40 °C up to 120 °C (-40 °F up to 250 °F) – PVDF
-40 °Cup to 80 °C(-40 °F up to 180 °F) – CPVC
-40 °Cup to 165 °C(-40 °Fup to 325 °F)
-80 °C up to +105 °C (-110 °F up to +220 °F) –
316/316L SST
Max pressure (consult temp/
press. graphs)
14 bar @ +40 °C(200 psi @ +100 °F)
for NPT threaded units
138 bar (2000 psi): ≤5cm transducers – except Monel
103 bar (1500 psi): > 5 cm transducers – except Monel
83 bar (1200 psi) for Monel transducers
Flanged models are downrated to the design pressure of the selected flange
Max viscosity 10.000 cP
Description Specification
Response time 0,5 s typical
Repeatability ±2mm (0.078")
Ambient Temperature -25 °Cup to +70 °C (-13 °F to +160 °F)
Humidity 0-99 %, non condensing
Electromagnetic Compatibility Meets CE requirements (EN 61326)
Physical/Functional specifications
Performance specifications
Transducers specifications
➀Only available with cast aluminium or cast stainless steel housings.

10
PRESSURE / TEMPERATURE RATINGS
0-40 40 80 120 165
40
80
120
160
316/316L (1.4404) ➀
Hastelloy c (2.4819)
Monel C
Range with 3/4" NPT
Range with 150# flange
Range with PN16 flange
≤5cm transducer 138 bar
103 bar
83bar
>5cm transducer
Process temperature (°C)
Process temperature (°C)
Process pressure (bar)
Process pressure (bar)
30
25
20
15
10
5
-40 0 40 80 120
0
Kynar Transducer Ratings
Process temperature (°C)
Process pressure (bar)
30
25
20
15
10
5
-40 0 40 80 120
0
CPVC Transducer Ratings
Metal Transducer Ratings
➀For low temperature sensor: from -80 °C up to +105 °C

11

IMPORTANT
SERVICE POLICY
Owners of Magnetrol products 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. Magnetrol International will repair or replace the control, at no cost to
the purchaser, (or owner)
other than transportation cost if:
a.Returned within the warranty period; and,
b. The factory inspection finds the cause of the malfunction to be defective material or workmanship.
If the trouble is the result of conditions beyond our control; or, is NOT covered by the warranty, there will be charges for labour
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, labour, direct or consequential damage will be allowed.
RETURNED MATERIAL PROCEDURE
So that we may efficiently process any materials that are returned, it is essential that a “Return Material Authorisation” (RMA)
form will be obtained from the factory. It is mandatory that this form will be attached to each material returned. This form is
available through Magnetrol’slocal representative or by contacting the factory.Please supply the following information:
1. Purchaser Name
2. Description of Material
3. Serial Number and Ref Number
4. Desired Action
5. Reason for Return
6. Process details
Any unit that was used in a process must be properly cleaned in accordance with the proper health and safety standards
applicable by the owner, before it is returned to the factory.
A material Safety Data Sheet (MSDS) must be attached at the outside of the transport crate or box.
All shipments returned to the factory must be by prepaid transportation. Magnetrol
will not accept collect shipments.
All replacements will be shipped FOB factory.
®
www.magnetrol.com
BENELUX Heikensstraat 6, 9240 Zele, België
Tel. [phone] • Fax. [phone] • E-Mail: [email protected]
DEUTSCHLAND Alte Ziegelei 2-4, D-51491 Overath
Tel. 02204 / 9536-0 • Fax. 02204 / 9536-53 • E-Mail: [email protected]
FRANCE 40 - 42, rue Gabriel Péri, 95130 Le Plessis Bouchard
Tél. [phone] • Fax. [phone] • E-Mail: [email protected]
ITALIA Via Arese 12, I-20159 Milano
Tel. [phone] (R.A.) • Fax. [phone] • E-Mail: [email protected]
UNITED Unit 1 Regent Business Centre, Jubilee Road Burgess Hill West Sussex RH 15 9TL
KINGDOM Tel. [phone] • Fax [phone] • E-Mail: [email protected]
INDIA C-20 Community Centre, Janakpuri, New Delhi - 110 0058
Tel. [phone] • Fax [phone] • E-Mail: [email protected]
BULLETIN N°: BE 51-632.0
EFFECTIVE: JULY 2007
SUPERSEDES: New
UNDER RESERVE OF MODIFICATIONS