Magnetrol ECHOTEL 960 User manual

®
Actuator-
Sensor-Interface
(AS-Interface®)
Ultrasonic
Level Switch
Installation and Operating Manual
ECHOTEL®
MODEL 960
odel 960
Aluminium housing
odel 960
Stainless steel housing

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 to
be sure it agrees with the packing slip and purchase order.
Check and record the serial number for future reference
when ordering parts.
OUNTING
These units are in compliance with:
1.The MC directive 2004/108/ C. The units have been tested to
N 61326: 1997 + A1 + A2.
2.Directive 94/9/ C for equipment or protective system intended for use in
potentially explosive atmospheres. C-type examination certificate
ISSeP06AT X008 - flameproof enclosure.
3.The P D Directive 97/23/ C (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
0038
0344
Varivent®
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Tri-Clamp®DIN 11851Threaded Welded flange

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
12 x 1 AS-i bus quick
disconnect male connector
or cable gland
Adjustable time delay: 0,5 to 45 s. Time delay is typically used where turbu-
lence, boiling or splashing can cause false level alarms
AS-i wiring terminals
Plugged entry
HAZARDOUS AREA SAFE AREA
chotel®960 electronics
Important: In extended addressing mode, the A or B channel select must be programmed as well. odel 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 L D: ON = AS-i communication fault,
FLASH S when an instrument failure is detected
(red Diagnostic L D is ON)
Green power L D: ON = power is on
Yellow wet L D: ON = sensor gap is immersed
Pushbutton for testing alarm output signal: data bit D2 = 1 means immersed gap
data bit D2 = 0 means dry gap
Pressing pushbutton causes data bit D2 to change state
Pushbutton for testing malfunction output. Pressing pushbutton (min 8-10 s)
causes a malfunction:«FAULT»L D flashes and «DIAGNOSTIC» L D is ON
Red diagnostic L D: ON = unit malfunction
FLASH S when activating troubleshooting
(see troubleshooting section)

4
AINTENANCE
anual Testing
Level Test:
Pressing the “Level Test” pushbutton, will manually test the AS-i output. The level test forces the data bit D2 output and corre-
sponding L Dʼs 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 data bit D3 output to “1” data bits. The time delay setting is not active during testing.
Troubleshooting
Problem Action/Indication Solution
No power No L Dʼs 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 xcessive aeration / Turbulence Introduce a time delay
Check input power
Relocate the switch
Fault L D FLASH S
Diagnostic L D is OFF
A system fault has been detected Check input power
Press «Level Test» pushbutton
to identify the problem:
* --- * : 1 flash (red L D) Check wiring between transducer and
electronics or replace transducer.
** --- ** : 2 flashes (red L D) Replace electronics
*** --- *** : 3 flashes (red L D) The unit senses excessive noise
interference. Check shield connection or
eliminate interference from a walkie-
talkie, radio or other nearby source

5
REPLACE ENT PARTS
Replacing electronics/transducer
Replacement parts
chotel electronics can be removed in the field under process conditions. Follow below steps to exchange electron-
ics/transducer:
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)
2
1
3
4
3
3
a
d
c
b
1X 74 2 3 8 9 105 6
Digit in partn°:
Partn°: Serial n°:
X = product with a specific customer requirement
See nameplate, always provide complete partn° and
serial n° when ordering spares.
(1) Housing cover
Digit 7 Digit 10 Replacement part
00 or 1 004-9193-003
4 or 5 036-5702-003
10 or 1 036-4410-003
4 or 5 036-5702-002
(2) "O"-ring
Digit 10 Replacement part
0 or 1 012-2201-237
4 or 5 012-2201-155
(3) Electronic module
Digit 10 Replacement part
0 or 1 089-7255-002
4 or 5 089-7255-001
Replacement part
(4) Transducer consult factory

6
ODEL IDENTIFICATION
A complete measuring system consists of:
1. chotel®electronics
2. chotel®transducer
3. Option: AS-i quick disconnect male connector M12 x 1: order code: 037-7916-001
1. Code for Echotel®electronics
9 8 A
5
6 0 0 complete code for Echotel®electronics
0 Integral mount electronics
MOUNTING
0 Blind housing cover
1 Housing cover with glass window
ACC SSORI S
C AT X II 1/2 G x d IIC T6, flameproof enclosure - except deep drawn SST housing
3 Weatherproof - except deep drawn SST housing
7 Weatherproof - deep drawn SST housing
APPROVALS
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 304 stainless steel with M20 x 1,5 cable entry (2 entries – one plugged)
4 Deep drawn 304 stainless steel with 1/2"NPT cable entry (2 entries – one plugged)
HOUSING / CABL NTRY
X = product with a specific customer requirement
960- 5 8 A 24 V DC 2-wire loop powered electronics with AS-i bus communication

7
ODEL IDENTIFICATION
2. Code for Echotel®transducer
9A M 1 complete code for Echotel®transducer
A 316/316L (1.4401/1.4404) stainless steel
B Hastelloy®C (2.4819)
C Monel®(2.4360)
P CPVC
R Kynar®(PVDF)
S 316/316L (1.4401/1.4404) stainless steel with 0,5 µm Ra (20 Ra) surface finish
ACTUATION L NGTH – specify per cm (0.39") increment
Total insertion length = actuation length + 6 mm (0.25")
003 Minimum 3 cm (1.2") – for metal transducers with NPT connections only
005 Minimum 5 cm (2") – for all other connections
330 Maximum 330 cm (130")
BASIC MOD L NUMB R
9M1 chotel®transducer with single setpoint
TRANSDUC R MAT RIALS (use only metal transducers for hazardous area)
A Standard sensor: min -40 °C / max +165 °C (-40 °F / +325 °F)
S NSOR TYP
X = product with a specific customer requirement
PROC SS CONN CTION
11 3/4" NPT
21 1" NPT
22 1" BSP (G 1")
Threaded (plastic transducers are only available with 3/4" NPT connection)
23 1" 150 lbs ANSI RF
24 1" 300 lbs ANSI RF
25 1" 600 lbs ANSI RF
33 1 1/2" 150 lbs ANSI RF
34 1 1/2" 300 lbs ANSI RF
35 1 1/2" 600 lbs ANSI RF
43 2" 150 lbs ANSI RF
44 2" 300 lbs ANSI RF
45 2" 600 lbs ANSI RF
ANSI Flanges for metal transducers
23 1" 150 lbs ANSI RF➁
33 1 1/2" 150 lbs ANSI RF➁
43 2" 150 lbs ANSI RF➁
ANSI Flanges for plastic transducers➀
BA DN 25 PN 16 N 1092-1 Type A
CA DN 40 PN 16 N 1092-1 Type A
DA DN 50 PN 16 N 1092-1 Type A
EN (DIN) Flanges for plastic transducers➀
3T 1 1/2" Tri-clamp®
4T 2" Tri-clamp®
VV DN 65 Varivent®type N
Hygienic
BS DN 25 DIN 11851
CS DN 40 DIN 11851
DS DN 50 DIN 11851
BB DN 25 PN 16/25/40 N 1092-1 Type A
BC DN 25 PN 63/100 N 1092-1 Type B2
CB DN 40 PN 16/25/40 N 1092-1 Type A
CC DN 40 PN 63/100 N 1092-1 Type B2
DA DN 50 PN 16 N 1092-1 Type A
DB DN 50 PN 25/40 N 1092-1 Type A
DD DN 50 PN 63 N 1092-1 Type B2
D DN 50 PN 100 N 1092-1 Type B2
EN (DIN) Flanges for metal transducers
➀CPVC flanges for CPVC transducers, Kynar®cladded SST flanges for Kynar®transducers
➁FF (flat face) flanges for CPVC transducers

8
DI ENSIONS IN mm (inches)
102
(4)
6 (0.25)
46 (1.8) Typical
Ø 22,9 (0.90)
Actuation length
for NPT connection
Actuation
length
for BSP
connection
100 (3.95) without window
113 (4.43) with window
102
(4)
6 (0.25)
60 (2.35) Typical
Ø 22,9 (0.90)
Actuation length
100 (3.95) without window
113 (4.43) with window
Threaded connection Flanged connection
109
(4.28)
43° View
Cable entry
60
(2.36)
125
(4.92)
29 (1.14)
Ø 22,9 (0.90) Actuation Length
43°
52
(2.05)
58
(2.28)
Tri-Clamp®
35 (1.38)
Ø 22,9 (0.90) Actuation Length
DIN 11851
46 (1.81)
Ø 22,9 (0.90)
6 (0.25)
6 (0.25)
6 (0.25)
Actuation Length
Varivent®

9
SPECIFICATIONS
Description Specification
Input Voltage 21 - 31 V DC (2-wire)
Power Consumption < 1 Watt
Output Data bit D2 = “1” with a wet gap / “0” with a dry gap
Data bit D3 = “1” during malfunction / “0” during normal operation
Time delay 0,5 to 45 s adjustable (in addition to transducer response time)
Indication L Dʼs for malfunction (error of transducer, electronics or electrical 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 (IP 67)
Approvals ➀AT X II 1/2 G x d IIC T6, flameproof enclosure (units with metal transducers)
Other approvals are available, consult factory for more details
Shock/Vibration ANSI/ISA-S71.03 Class SA1 (shock), ANSI/ISA-S71.03 Class VC2 (vibration)
Net weight 1 kg (2.2 lbs) - electronics only
AS-i bus
specifications
AS-i version V3.0 (AS-i test certificate #76401)
Slave type A/B (maximum of 62 nodes)
Slave profile S-0.A. .
Connectable load N 50295 and I C 62026-2
Description Specification
Response time 0,5 s typical
Repeatability ± 2 mm (0.078")
Ambient Temperature -25 °C to +70 °C (-13 °F to +160 °F)
Humidity 0-99 %, non-condensing
lectromagnetic Compatibility Meets C requirements ( N 61326: 1997 + A1 + A2)
Electronics specifications
Performance
Transducer specifications
➀Only available with cast aluminium housings.
Description Plastic transducers etal transducers
Material CPVC
Kynar®(PVDF)
316/316L SST (1.4401/1.4404)
Hastelloy®C (2.4819)
Monel®(2.4360)
Mounting Threaded (NPT/BSP) – Flanged (ANSI - N (DIN)) – Hygienic
Actuation length From 5 cm up to 330 cm (2" up to 130") From 3 cm up to 330 cm (1.2" up to 130")
Process temp. (consult temp/
press. graphs)
-40 °C to +120 °C (-40 °F to +250 °F) – PVDF
-40 °C to +80 °C (-40 °F to +180 °F) – CPVC
-40 °C to +165 °C (-40 °F to +325 °F)
Max pressure (consult temp/
press. graphs)
13,8 bar @ +40 °C (200 psi @ +100 °F)
for NPT threaded units
82,8 bar (1200 psi) for Monel transducers
Consult temp/press. graphs for other
materials
Flanged models are downrated to the design pressure of the selected flange

10
PRESSURE / TE PERATURE RATINGS
0-40 40 80 120 165
40
80
120
160
316/316L (1.4401/1.4404)
Hastelloy®C (2.4819)
onel®(2.4360)
Range with 3/4" NPT
Range with 150# flange
Range with PN16 flange
138 bar➀
103 bar
82,8 bar
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
etal Transducer Ratings
➀Only applicable to NPT-connections with actuation length = 3 cm
and BSP/ANSI/ N (DIN)-connections with actuation length = 5 cm

11

I PORTANT
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 ATERIAL 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 Magnetrolʼs local 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 x Works.
www.magnetrol.com
BENELUX Heikensstraat 6, 9240 Zele, België -Belgique
FRANCE Tel. [phone] • Fax. [phone] • E-Mail: [email protected]
DEUTSCHLAND Alte Ziegelei 2-4, D-51491 Overath
Tel. [phone] / 9536-0 • Fax. [phone] / 9536-53 • E-Mail: [email protected]
INDIA C-20 Community Centre, Janakpuri, New Delhi - 110 058
Tel. [phone] • Fax [phone] • E-Mail: [email protected]
ITALIA Via Arese 12, I-20159 Milano
Tel. [phone] • Fax. [phone] • E-Mail: [email protected]
U.A.E. DAFZA Office 5EA 722 • PO Box 293671 • Dubai
Tel. [phone] • 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]
BULL TIN N°: B 51-632.3
FF CTIV : MAY 2012
SUP RS D S: January 2011
UND R R S RV OF MODIFICATIONS