Magnetrol Echotel 961 Instructions for use

Ultrasonic
Le el Switches
SIL Safety Manual for
Echotel®Model 961/962
Application
Echote ®Mode 961/962 u trasonic eve switches uti ize
pu sed signa techno ogy to detect high, ow, or dua -
point eve in a broad range of iquid media app ica-
tions. The advanced se f-test techno ogy provides re ia-
bi ity and continuous testing of e ectronics, transducer,
piezoe ectric crysta s, and e ectromagnetic noise.
Benefits
The Echote Mode 961/962 u trasonic eve switches
provide the fo owing benefits:
• Sing e or dua point iquid eve measurement
• Adjustab e time-de ay for turbu ent aerated iquids
• Re iab e iquid eve measurement independent of
changes in media density, conductivity, or temperature
• Re ay output or mA current shift with separate
ma function indication
• Integra or remote mount e ectronics
• Pu sed signa techno ogy
• Extensive FM, CSA, and ATEX exp osion proof and
intrinsica y safe approva s
• Suitab e for Safety Integrity Leve (SIL) 2 oops
Functional Safety Manual
This manua comp ements and is intended to be used with
the Magnetro Echotel®Model 961/962 Ultrasonic Single and
Dual Point Le el Switches Installation and Operating Manual
(Bu etin 51-646, dated October 2008 or ater).
Model 961
Model 962

51-650 Echotel SIL Safety Manual
Table of Contents
SIL Saf ty Manual for Mod l 961/962....................................1
Echot l Mod l 961/962 Ultrasonic L v l Switch s...........1
Application.......................................................................1
B n fits............................................................................ 1
1.0 Introduction................................................................... 3
1.1 Product D scription.................................................. 3
1.2 Th ory of Op ration.................................................3
1.2.1 Transduc r D sign..........................................4
1.2.2 Transduc r Mat rials...................................... 4
1.3 D t rmining Saf ty Int grity L v l (SIL).................. 4
2.0 Applicable Models..........................................................5
3.0 Mean Time To Repair (MTTR).....................................5
4.0 Supplementary Documentation......................................5
5.0 Instructions.................................................................... 6
5.1 Syst matic Limitations.............................................. 6
5.1.1 Application Locations.....................................6
5.1.2 Op rating T mp ratur .................................. 6
5.1.3 Op rating Pr ssur ......................................... 6
5.1.4 Environm ntal................................................6
5.2 Skill L v l of P rsonn l............................................. 6
5.3 N c ssary Tools......................................................... 7
5.4 Storag ...................................................................... 7
5.5 Installation................................................................ 7
5.5.1 Hygi nic-Sp cific Installation......................... 8
5.5.2 Pump-Sp cific Installation..............................8
5.6 Configuration........................................................... 8
5.6.1 Tim -d lay Pot ntiom t r.............................. 8
5.6.2 L v l T st Push Button...................................8
5.6.3 Malfunction T st Push Button........................9
5.6.4 High/Low DIP Switch................................... 9
5.6.5 Ind p nd nt/Joint DIP Switch.......................9
5.6.6 Loop T st Push Button...................................9
5.6.7 Fault T st Push Button................................. 10
5.6.8 22/3.6 DIP Switch....................................... 10
5.6.9 PC/LC DIP Switch...................................... 10
5.7 Sit Acc ptanc T sting........................................... 10
5.8 Maint nanc ............................................................ 10
5.8.1 Diagnostics...................................................11
5.8.2 Troubl shooting........................................... 11
6.0 Appendices................................................................... 12
6.1 SIL D claration of Conformity............................... 12
6.2 FMEDA R port Manag m nt Summary................ 13
6.2.1 Mod l 961 Loop-Pow r d L v l Switch....... 13
6.2.2 Mod l 961 AC/DC Ultrasonic
L v l Switch with R lay Output...................13
6.2.3 Mod l 962 Loop-Pow r d Ultrasonic
L v l Switch s.............................................. 14
6.2.4 Mod l 962 AC/DC Ultrasonic
L v l Switch with R lay Output...................14
6.3 R port - Lif tim of Critical Compon nts.............. 15
Echotel Model 961/962 Ultrasonic Level Switches

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51-650 Echotel SIL Safety Manual
1.0 Introduction
1.1 Product Description
Echot l Mod l 961 and 962 ultrasonic l v l switch s
utiliz puls d signal t chnology to d t ct high, low, or dual
point l v l in a broad rang of liquid m dia applications.
Mod l 961 is a singl -point l v l switch. Mod l 962 is a
dual-point switch us d as a l v l controll r or to control
pumps in an auto-fill or auto- mpty mod .
Both Mod l 961 and 962 switch s ar suitabl for us in
Saf ty Int grity L v l (SIL) 2 loops.
1.2 Theory of Operation
Mod l 961/962 switch s utiliz ultrasonic n rgy to d t ct
th pr s nc or abs nc of liquid in a singl or dual point
transduc r. Ultrasonic contact l v l t chnology us s high-
fr qu ncy sound wav s that ar asily transmitt d across a
transduc r gap (s Figur 1) in th pr s nc of a liquid
m dia, but ar att nuat d wh n th gap is dry.
Mod l 961/962 switch s us an ultrasonic fr qu ncy of
2 MHz to p rform this liquid l v l m asur m nt in a wid
vari ty of proc ss m dia and application conditions.
Th transduc r us s a pair of pi zo l ctric crystals that ar
ncapsulat d in poxy at th tip of th transduc r. Th crys-
tals ar mad of a c ramic mat rial that vibrat s at a giv n
fr qu ncy wh n subj ct d to an appli d voltag . Th trans-
mit crystal conv rts th appli d voltag from th l ctronics
into an ultrasonic signal. Wh n liquid is pr s nt in th gap,
th r c iv crystal s ns s th ultrasonic signal from th
transmit crystal and conv rts it back to an l ctrical signal.
This signal is s nt to th l ctronics to indicat th pr s nc
of liquid in th transduc r gap. Wh n th r is no liquid
pr s nt, th ultrasonic signal is att nuat d and is not d t ct d
by th r c iv crystal.
Ultrasonic
transducer
Transmit
crystal
Receive
crystal
Figure 1
Ultrasonic Signal Transmission
Across Transducer Gap

451-650 Echotel SIL Safety Manual
1.2.1 Transducer Design
Magn trol’s advanc d transduc r d sign p rforms in difficult
proc ss conditions. Mod l 961 has a tip-s nsitiv transduc r
with an arch d gap incr asing its p rformanc in a rat d or
foamy liquids. Mod l 962 has a tip-s nsitiv low r gap and
flow-through upp r gap p rmitting s parations of 125 inch s
(318 cm).
1.2.2 Transducer Materials
A broad s l ction of transduc r mat rials is availabl for th
Mod l 961/962. M tallic transduc rs includ 316 SS,
Hast lloy®C, and Mon l®. Th 316 SS transduc r has a
NACE construction option for sour gas s rvic , and can
also b built p r ASME B31.1 and B31.3 piping cod s.
Th rmoplastic transduc rs includ Kynar®and CPVC.
Th s corrosion r sistant plastic transduc rs f atur a stiff-
ning tub that runs th l ngth of th transduc r for xtra
rigidity. Kynar-fac d 316 SS flang options ar off r d with
th Kynar transduc rs.
1.3 Determining Safety Integrity Level (SIL)
Tabl s 1 and 2 d fin th crit ria for th achi vabl SIL
against th targ t mod of op ration in D mand Mod
Op ration.
Tabl 1 shows th r lationship b tw n th SIL and th
Probability of Failur on D mand Av rag (PFDavg).
Tabl 2 can b us d to d t rmin th achi vabl SIL as a
function of th Hardwar Fault Tol ranc (HFT) and th
Saf Failur Fraction (SFF) for th compl t saf ty syst m
(Typ B–compl x compon nts as p r IEC 61508 Part 2) of
which th l v l transmitt r is on compon nt.
Table 2
Minimum Hardware Fault Tolerance
SFF
Hardware Fault
Tolerance (HFT)
012
None: <60% Not
Allowed SIL 1 SIL 2
Low: 60% to <90% SIL 1 SIL 2 SIL 3
Medium: 90% to <99% SIL 2 SIL 3
High: ≥99% SIL 3
Table 1
SIL vs. PFDavg
Safety
Integrity Level
(SIL)
Target Average
Probability of Failure
on Demand (PFDavg)
≥10-5 to <10-
3≥10- to <10-3
2≥10-3 to <10-2
1≥10-2 to <10-1

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51-650 Echotel SIL Safety Manual
2.0 Applicable Models
This manual is applicabl to th following mod ls of th
Echot l ultrasonic l v l switch s with r lay output or
curr nt shift output:
• Mod l 961 Singl -Point L v l Switch s
• Mod l 962 Dual-Point L v l Switch s
3.0 Mean Time To Repair (MTTR)
SIL d t rminations ar bas d on a numb r of factors including
th M an Tim To R pair (MTTR). Th analysis for th
Echot l Mod l 961/962 ultrasonic l v l switch is bas d on
a MTTR of 24 hours.
4.0 Supplementary Documentation
R f r to th following docum nts as suppl m nts to this
Echot l Mod l 961/962 SIL Saf ty Manual:
• Echot l Mod l 961/962 Ultrasonic Singl and Dual Point
L v l Switch s Installation and Op rating Manual
• Magn trol Mod l 961 AC/DC Ultrasonic L v l Switch with
R lay Output, Failur Mod s, Eff cts, and Diagnostic Analysis
• Magn trol Mod l 961 Loop-Pow r d Ultrasonic L v l
Switch, Failur Mod s, Eff cts, and Diagnostic Analysis
• Magn trol Mod l 962 AC/DC Ultrasonic L v l Switch with
R lay Output, Failur Mod s, Eff cts, and Diagnostic Analysis
• Magn trol Mod l 962 Loop-Pow r d Ultrasonic L v l
Switch, Failur Mod s, Eff cts, and Diagnostic Analysis
NOTE: The Failure Modes, Effects, and Diagnostic Analysis (FMEDA)
reports can be found in the Downloads tab of the Echotel
961/962 site page on magnetrol.com.

651-650 Echotel SIL Safety Manual
5.0 Instructions
5.1 Systematic Limitations
Th following application and nvironm ntal limitations
must b obs rv d to avoid syst matic failur s.
5.1.1 Application Locations
Th Mod l 961/962 ultrasonic l v l switch should b locat d
for asy acc ss for s rvic , configuration, and monitoring.
Th r should b suffici nt h adroom to allow installation
and r moval of th unit. Sp cial pr cautions should b
mad to pr v nt xposur to corrosiv atmosph r , xc ssiv
vibration, shock, or physical damag .
5.1.2 Operating Temperature
Th ambi nt t mp ratur rang for th 961/962 l ctronics is
-40 to +160 °F (-40 to + 70 °C). Th op rating t mp ratur
for th transduc r is d p nd nt on transduc r mat rial (s
Tabl 3).
5.1.3 Operating Pressure
Maximum op rating pr ssur s ar d p nd nt on th trans-
duc r mat rial. R f r to S ction 3.4 in th Echotel Model
961/962 Ultrasonic Le el Switches Installation and Operating
Manual (Bull tin 51-646).
5.1.4 Environmental
S S ction 3.4 of th Echot l Mod l 961/962 Ultrasonic
Singl and Dual Point L v l Switch s Installation and
Op rating Manual (Bull tin 51-646) for nvironm ntal
limitations.
5.2 Skill Level of Personnel
P rsonn l following th proc dur s of this saf ty manual
should hav t chnical xp rtis qual to or gr at r than that
of a qualifi d instrum nt t chnician.
Table 3
9A1/9M1 Transducer Operating Temperatures
316 Stainless Steel,
Hastelloy C, and Monel - 0° to +325° F (- 0 to +163 °C)
Kynar - 0° to +250° F (- 0 to +121 °C)
CPVC - 0° to +180° F (- 0 to +82 °C)

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51-650 Echotel SIL Safety Manual
5.3 Necessary Tools
No sp cial quipm nt or tools ar r quir d to install Echot l
Mod l 961/962 ultrasonic l v l switch. Th following it ms
ar r comm nd d:
• Wr nch s, flang gask ts, and flang bolting appropriat for
proc ss conn ction(s)
• Scr wdriv rs and assort d tools for making conduit and
l ctrical conn ctions
• Digital multim t r or DVM for troubl shooting
5.4 Storage
Mod l 961/962 should b stor d in its original shipping
box and not b subj ct d to t mp ratur s outsid th stor-
ag t mp ratur rang -40 to +160 °F (-40 to +70 °C), as
shown in S ction 3.1 of th Echotel Model 961/962
Ultrasonic Le el Switches Installation and Operating Manual
(Bull tin 51.646).
5.5 Installation
Th Mod l 961 singl point switch may b us d for high or
low l v l alarm, ov rfill prot ction, or s al pot l v l and
pump prot ction. Mod l 961 can b mount d v rtically or
horizontally in v ss ls, bridl s, or pip s.
Th Mod l 962 dual point switch may b us d to m asur
high/low, high/high, or low/low l v ls. It can b us d as a
l v l controll r or to control pumps in an auto-fill or auto-
mpty mod . Mod l 962 must b top mount d.
R f r Figur s 2–5 to th Echotel Model 961/962 Ultrasonic
Single and Dual Point Le el Switches Installation and
Operating Manual (Bull tin 51.646) for th prop r installa-
tion instructions.
Pump
Protection
Fill Line Dual Point Alarm
High Alarm
Low Alarm
Figure 2
Typical Mounting Orientations
Use wrench on flats
Process
connection
Figure 3
Vertical Mounting
Bottom View
Figure 4
Horizontal Mounting
Bottom View
Figure 5
Nozzle Mounting

851-650 Echotel SIL Safety Manual
5.5.1 Hygienic-Specific Installation
Th hygi nic v rsion of th Mod l 961 is availabl with a
d p-drawn 304 stainl ss st l housing. A vari ty of hygi nic
proc ss conn ctions ar off r d for us in food and b v rag ,
pharmac utical, and biot chnology applications. Th s
hygi nic transduc rs hav 3-A (Authorization #596), EHEDG
c rtification (p r TNO R port # V4772/01) and a 20 Ra
finish providing a uniform and ultra-smooth surfac that
inhibits microbial growth. El ctron b am w lding t chnology
is utiliz d to facilitat a cr vic -fr surfac insid th trans-
duc r tip. This allows th s transduc rs to b us d in a wid
vari ty of hygi nic applications wh r CIP (cl an-in-plac ) is
us d to r mov any contamination from th transduc r surfac .
5.5.2 Pump-Specific Installation
A DIP switch on th Mod l 962 allows it to b configur d
to control l v l, or to function as a pump controll r. In th
pump control mod th unit can p rform auto-fill or auto-
mpty of tanks, sumps, or w t w lls. Th tip s nsitiv low r
gap allows liquid l v ls to b pump d down to within 1⁄4"
from th bottom of th v ss l. Th rigidity of th flow
through upp r gap allows th Mod l 962 to b us d v n
wh n sumps xp ri nc s v r turbul nc from v ss l fill lin s.
5.6 Configuration
R f r to S ction 2.5 in th Echotel Model 961/962
Ultrasonic Single and Dual Point Le el Switches Installation
and Operating Manual (Bull tin 51.646) for compl t
configuration instructions.
5.6.1 Time-Delay Potentiometer
Th tim -d lay pot ntiom t r is us d in applications wh r
turbul nc or splashing may caus fals l v l alarm. Th
r spons tim can b adjust d from factory-s t standard of
0.5 s conds to a maximum of 45 s conds. Th tim -d lay
pot ntiom t r is an option for both Mod l 961 and Mod l 962
in ith r lin -pow r d or loop-pow r configuration.
5.6.2 Level Test Push Button
Th l v l t st push button is us d to manually t st th
DPDT proc ss l v l r lay and what v r is conn ct d to th
r lay. Pr ssing this push button r v rs s th stat of th
DPDT r lay from ngag d to d - ngag d, or vis -v rsa.
Th l v l t st push button is an option for both Mod l 961
and Mod l 962 in lin -pow r d configuration only.

51-650 Echotel SIL Safety Manual
5.6.3 Malfunction Test Push Button
Th malfunction t st push button is us d to manually t st
th SPDT malfunction r lay and what v r is conn ct d to
th r lay. Pr ssing and holding this push button for 2 s conds
caus s th SPDT r lay to d - ngag , indicating a fault
condition. Th malfunction t st push button is an option
for both th Mod l 961 and Mod l 962 in lin -pow r d
configuration only.
5.6.4 High/Low DIP Switch
Th Hi/Lo DIP switch is us d to s l ct wh th r th switch
is us d as a high-l v l fail-saf or a low-l v l fail-saf switch.
S S ction 2.5 of th Echotel Model 961/962 Ultrasonic
Single and Dual Point Le el Switches Installation and
Operating Manual (Bull tin 51.646) for high/low DIP
switch configuration tabl s.
5.6.5 Independent/Joint DIP Switch
Th I/J DIP switch is us d to configur th SPDT malfunc-
tion r lay to act ind p nd ntly or jointly with th DPDT
proc ss-l v l r lay. In th factory-s t I position, th SPDT
and DPDT r lays act ind p nd nt of ach oth r. In th
J position, both th SPDT and DPDT r lays will d - ngag
wh n a fault is d t ct d. Th I/J DIP switch is an option for
th Mod l 961 in lin -pow r d configuration only.
5.6.6 Loop Test Push Button
Th loop t st push button is us d to manually t st th loop
curr nt output. For Mod l 961, pr ssing th loop t st push
button r v rs s th output from 8 mA to 16 mA or from
16 mA to 8 mA. For Mod l 962, pr ssing th loop t st push
button chang s th output from 8 mA to 12 mA, 12 mA to
16 mA, or 16 mA to 8 mA.

10 51-650 Echotel SIL Safety Manual
5.6.7 Fault Test Push Button
Th fault t st push button is us d to manually chang th
mA valu s to that s l ct d at th 22/3.6 DIP switch.
Pr ssing this push button for two s conds simulat s a circuit
t st failur . Th output go s to th s l ct d fault curr nt of
ith r 22 or 3.6 mA, and all thr LEDs go dark. Th fault
t st push button is an option on both Mod l 961 and
Mod l 962 in loop-pow r d configuration only.
5.6.8 22/3.6 DIP Switch
Th 22/3.6 switch is us d to produc a 22 mA or 3.6 mA
output wh n th unit d t cts a fault. Th 22/3.6 switch is
on both th Mod l 961 and Mod l 962 in loop-pow r d
configuration only.
5.6.9 PC/LC DIP Switch
Th PC/LC DIP switch is us d to s l ct pump control (PC)
or l v l control (LC) mod . In PC mod , th switch func-
tions as a pump controll r wh r th r lays latch to nabl
an auto fill or auto mpty op ration. In LC mod , th
switch functions as a l v l controll r wh r th r lays op r-
at ind p nd ntly of ach oth r. S S ction 2.5 of th
Echotel Model 961/962 Ultrasonic Single and Dual Point
Le el Switches Installation and Operating Manual (Bull tin
51.646) for prop r s tting of th PC/LC DIP switch s.
5.7 Site Acceptance Testing
Compl t a sit acc ptanc t st to nsur prop r op ration
aft r installation and configuration. R sults of sit acc pt-
anc t sting should b r cord d for futur r f r nc .
5.8 Maintenance
• R port all failur s to Magn trol.
• Firmwar can only b upgrad d by factory p rsonn l.