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.

5.8.1 Diagnostics
Mod l 961/962 has a uniqu diagnostics f atur to assist in
troubl shooting should a failur occur. A microproc ssor in
th l ctronics continuously monitors all s lf-t st data.
Should a fault occur, th microproc ssor can d t rmin
wh th r th malfunction is du to th l ctronics, transduc r,
pi zo l ctric crystals, or th pr s nc of nvironm ntal nois .
Tabl 4 shows th push buttons and LEDs us d for ach
v rsion of th 961/962 for diagnostic troubl shooting:
5.8.2 Troubleshooting
Mod l 961/962 has a diagnostic push button and Fault LED
us d to assist in troubl shooting th switch (s Tabl 5).
R f r to S ction 3.7 of th Echotel Ultrasonic Single and
Dual Point Le el Switches Installation and Operating Manual
(Bull tin 51.646) for troubl shooting d vic rrors.
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51-650 Echotel SIL Safety Manual
Table 4
Diagnostic Push Buttons and LED Indications
Electronics Version Push Button LED
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 5 amp relays LOOP TEST 16 mA
Table 5
Troubleshooting Faults and Corrective Actions
Flashes Fault Action
1 flash
Indicates a problem with either the
transducer, piezoelectric crystals,
or the interconnection wiring.
Check 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 factory. Replace
transducer if needed. Refer to
Section 3.8 of the Installation and
Operating Manual for proper
replacement part numbers.
2 flashes Indicates a problem with one of
the electronics boards.
Contact the factory for a replace-
ment electronics module. Refer
Section 3.8 of the Installation and
Operating Manual for spare elec-
tronics modules part numbers.
3 flashes Indicates excessive levels of
environmental noise.
Check if any source may be caus-
ing the interference, such as VFD
(variable frequency drive), radiated
electrical interference (two-way
radio transceiver) or mechanical
vibration from nearby source.

12 51-650 Echotel SIL Safety Manual
6.0 Appendices
6.1 SIL Declaration of Conformity
Functional saf ty according to IEC 61508.
Magn trol Int rnational, Incorporat d, 705 Ent rpris Str t,
Aurora, Illinois 60504 d clar s as th manufactur r, that th
l v l switch s:
Echotel® Model 961/962 Ultrasonic Single and
Dual Point Level Switches
ar suitabl for us in saf ty instrum nt d syst ms according
to IEC 61508, if th saf ty instructions and following
param t rs ar obs rv d:
FIT = Failur in Tim (1¥10-9 failur s p r hour)
Product Model 961
Loop-Powered
Model 961 AC/DC
Line-Powered
Model 962
Loop-Powered
Model 961 AC/DC
Line-Powered
SIL 2 2 2 2
Proof Test Interval 1 Year 1 Year 1 Year 1 Year
SFF 91. % 92.0% 91.8% 91.5%
PFDavg ➀1.61E-0 1.77E-0 1.87E-0 2.31E-0
λsd 0 FIT 0 FIT 0 FIT 0 FIT
λsu 96 FIT 106 FIT 110 FIT 130 FIT
λdd 288 FIT 351 FIT 362 FIT 27 FIT
λdu 36 FIT 0 FIT 2 FIT 52 FIT
Magnetrol International, Incorporated
705 Enterprise Street
Aurora, Illinois 6050
Name Name
Title Title
Date Date
➀As determined in compliance with ANSI/ISA-8 .01 clause 9.2.3 for 1oo1 system.

6.2 FMEDA Report Management Summary
6.2.1 Model 961 Loop-powered Level Switch
Th Mod l 961 ultrasonic l v l switch is a compl x d vic
classifi d as Typ B according to IEC61508, having a hardwar
fault tol ranc of 0. This 24 VDC loop-pow r d unit contains
s lf diagnostics programm d to output ith r 3.6 mA or
22 mA during a failur stat . Additionally, any output that
xc ds th nominal valu s of 8 mA and 16 mA by a
tol ranc of ±1.6 mA must b d t ct d as a fault by th
logic solv r. Th FMEDA analysis assur s th diagnostic
signal is b ing transmitt d to a logic solv r programm d to
d t ct ov r-scal and und r-scal curr nts.
Th Mod l 961 failur rat s ar shown on Tabl 6.
Th s failur rat s can b us d in a probabilistic mod l of a
Saf ty Instrum nt d Function (SIF) to d t rmin suitability
in part of Saf ty Instrum nt d Syst m (SIS) usag in a
particular Saf ty Int grity L v l (SIL). A mor compl t
listing of failur rat s is provid d in S ction C.4 of th
FMEDA for th 961 Loop-Pow r d Switch.
6.2.2 Model 961 AD/DC Ultrasonic Level Switch
with Relay Output
Th Mod l 961 ultrasonic l v l switch is a compl x d vic
and is classifi d as Typ B according to IEC 61508 having a
hardwar fault tol ranc of 0. Th Mod l 961 ultrasonic
l v l switch is an 18–32 VDC or 102–265 VAC pow r
d vic that provid s r lay outputs. Mod l 961 has only on
output failur stat (fail-saf ), with th r lay d - n rgiz d.
Mod l 961 failur rat s ar shown in Tabl 7.
A mor compl t listing of failur rat s is provid d in
S ction C.4 of th FMEDA for th 961 Lin -Pow r d Switch.
13
51-650 Echotel SIL Safety Manual
Failure Category λsd λsu λdd λdu SFF
Model 961 0 FIT 96 FIT 288 FIT 36 FIT 91. %
Table 6
Model 961 IEC 61508 Format Failure Rates
Failure Category λsd λsu λdd λdu SFF
Model 961 0 FIT 106 FIT 351 FIT 0 FIT 92.0%
Table 7
Model 961 IEC 61508 Format Failure Rates

6.2.3 Model 962 Loop-powered
Ultrasonic Level Switches
Th Mod l 962 ultrasonic l v l switch is a compl x d vic
classifi d as Typ B according to IEC61508, having a hardwar
fault tol ranc of 0. This 24 VDC loop-pow r d unit
contains s lf diagnostics programm d to output ith r 3.6 mA
or 22 mA during a failur stat . Additionally, any output
that xc ds th nominal valu s of 8 mA and 16 mA by a
tol ranc of ±1.6 mA must b d t ct d as a fault by th
logic solv r. Th FMEDA analysis assum s th diagnostic
signal is b ing transmitt d to a logic solv r programm d to
d t ct ov r-scal and und r-scal curr nts.
Mod l 962 failur rat s ar shown in Tabl 8.
A mor compl t listing of failur rat s is provid d in Tabl 1,
of th FMEDA for th 962 Loop-pow r d Switch.
6.2.4 Model 962 AC/DC Ultrasonic Level Switch
with Relay Output
Th Mod l 962 ultrasonic l v l switch is a compl x d vic
classifi d as Typ B according to IEC61508, having a hardwar
fault tol ranc of 0. Th Mod l 962 ultrasonic l v l switch
is an 18–32 VDC or 102–265 VAC pow r d vic that pro-
vid s r lay outputs. Th Mod l 962 has only on output
failur stat (fail-saf ) with th r lay d - n rgiz d.
Th Mod l 962 failur rat s ar shown in Tabl 9.
A compl t listing of failur rat s is provid d in Tabl 1 of
th FMEDA for th 962 Lin -Pow r d Switch.
14 51-650 Echotel SIL Safety Manual
Failure Category λsd λsu λdd λdu SFF
Model 961 0 FIT 110 FIT 362 FIT 2 FIT 91.8%
Table 8
Model 962 IEC 61508 Format Failure Rates
Failure Category λsd λsu λdd λdu SFF
Model 961 0 FIT 130 FIT 27 FIT 52 FIT 91.5%
Table 9
Model 962 IEC 61508 Format Failure Rates

6.3 Report - Lifetime of Critical Components
According to S ction 7.4 of IEC 61508-2, a us ful lif tim ,
bas d on xp ri nc , should b assum d.
Although a constant failur rat is assum d by th proba-
bilistic stimation m thod, this only appli s provid d that
th us ful lif tim of compon nts is not xc d d. B yond
th ir us ful lif tim , th r sult of th probabilistic calcula-
tion m thod is th r for m aningl ss, as th probability of
failur significantly incr as s with tim . Th us ful lif tim
is highly d p nd nt on th subsyst m its lf and its op rating
conditions.
This assumption of a constant failur rat is bas d on th
bathtub curv . Th r for it is obvious that th PFDavg
calculation is only valid for compon nts that hav this
constant domain and that th validity of th calculation is
limit d to th us ful lif tim of ach compon nt.
As th r ar no l ctrolytic capacitors us d, th r ar no
l ctrical compon nts that limit th us ful lif tim of
th syst m.
Bas d on g n ral fi ld failur data, a us ful lif p riod of
approximat ly 50 y ars is xp ct d for th Echot l Mod l
961/962 Ultrasonic L v l Switch s.
Wh n plant xp ri nc indicat s a short r us ful lif tim
than indicat d, th numb r bas d on plant xp ri nc
should b us d.
15
51-650 Echotel SIL Safety Manual



Service Policy
Own rs of Magn trol controls may r qu st th r turn of
a control or any part of a control for compl t r building
or r plac m nt. Th y will b r built or r plac d promptly.
Controls r turn d und r our s rvic policy must b
r turn d by pr paid transportation. Magn trol will r pair
or r plac th control at no cost to th purchas r (or
own r) oth r than transportation if:
1. R turn d within th warranty p riod; and
2. Th factory insp ction finds th caus of th claim to
b cov r d und r th warranty.
If th troubl is th r sult of conditions b yond our
control; or, is NOT cov r d by th warranty, th r will b
charg s for labor and th parts r quir d to r build or
r plac th quipm nt.
In som cas s it may b xp di nt to ship r plac m nt
parts; or, in xtr m cas s a compl t n w control, to
r plac th original quipm nt b for it is r turn d. If this
is d sir d, notify th factory of both th mod l and s rial
numb rs of th control to b r plac d. In such cas s, cr dit
for th mat rials r turn d will b d t rmin d on th basis
of th applicability of our warranty.
No claims for misapplication, labor, dir ct or cons qu ntial
damag will b allow d.
Return Material Procedure
So that w may ffici ntly proc ss any mat rials that
ar r turn d, it is ss ntial that a “R turn Mat rial
Authorization” (RMA) numb r b obtain d from th
factory prior to th mat rial’s r turn. This is availabl
through Magn trol’s local r pr s ntativ or by contacting
th factory. Pl as supply th following information:
1. Company Nam
2. D scription of Mat rial
3. S rial Numb r
4. R ason for R turn
5. Application
Any unit that was us d in a proc ss must b prop rly
cl an d in accordanc with OSHA standards, b for it is
r turn d to th factory.
A Mat rial Saf ty Data Sh t (MSDS) must accompany
mat rial that was us d in any m dia.
All shipm nts r turn d to th factory must b by pr paid
transportation.
All r plac m nts will b shipp d F.O.B. factory.

• ANSI/ISA-84.00.01-2004 Part 3 (IEC 61511-3Mod)
“Functional Saf ty: Saf ty Instrum nt d Syst ms for th
Proc ss Industry S ctor–Part 3 Guidanc for th
D t rmination of th R quir d Saf ty Int grity L v ls–
Informativ ”
• ANSI/ISA-TR84.00.04 Part 1 (IEC 61511 Mod)
“Guid lin on th Impl m ntation of ANSI/ISA-
84.00.01-2004”
Disclaimer
Th SIL valu s in this docum nt ar bas d on an FMEDA analysis using xida’s SILVER Tool. Magn trol acc pts
no liability whatso v r for th us of th s numb rs of for th corr ctn ss of th standards on which th g n ral
calculation m thods ar bas d.
References
• ANSI/ISA-84.00.01-2004 Part 1 (IEC 61511-1Mod)
“Functional Saf ty: Saf ty Instrum nt d Syst ms for
th Proc ss Industry S ctor–Part 1 Hardwar and
Softwar R quir m nts”
• ANSI/ISA-84.00.01-2004 Part 2 (IEC 61511-2Mod)
“Functional Saf ty: Saf ty Instrum nt d Syst ms for
th Proc ss Industry S ctor–Part 2 Guid lin s for th
Application of ANSI/ISA84.00.01-2004 Part 1 (IEC
61511-1 Mod)–Informativ ”
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