910-A1A0-006 MAGNETROL | Alldatasheet
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Installation and OperatingMan ual Echotel ® Mode l910
Read thisMan ualBefore Installing T hism anualprovidesinformationon the EchotelMod el 910 U ltrasonicLiquidLevelSwitches.Itisimportantthat allinstructionsare read carefullyand follow ed in sequence. De tailed instructions are included in the Installation sectionofthisma nual. ConventionsUsed in thisMan ual Certain conventions areused in thisman ualto convey specifictypesofinformation.Generaltechnicalmaterial, supportdata,and safety information are presented in narrative form.The following stylesareused for notes, cautions,and warnings. NOTES Notescontain inform ation thataugm ents or clarifies an operatingstep. Notes do not normally contain actions. Th ey follow the proceduralstepsto wh ich they refer. C autions Cautionsalertthetechniciantospecialconditionsthat couldinjurepersonnel,damage equipment,orreduce a comp onent’sme chanicalintegrity.C autionsarealso used toalertthe techniciantounsafepracticesor the needforspecialprotective equipmentorspecificmate - rials.In thism anual,a cautionbox indicates a poten - tially hazardous situation wh ich,ifnot avoided,may resultin minorormoderateinjury. WAR NING S W arningsidentify potentially dangerous situationsor serioushazards.In thism anual,a warning indicatesan imminently hazardoussituationwh ich,ifnotavoided, couldresultin seriousinjuryordeath. SafetyMessages The EchotelM odel910 isdesignedforuseinCategoryII, Pollution Degree 2 installations. Follow allstandard industryproceduresforservicingelectricaland compu ter equipmentwhen workingwith or around highvoltage. Alw aysshut offthe power supplybefore touchingany com ponents.Although highvoltageisnotpresentinthis system ,itma y be presentinothersystem s. Electrical comp onents are sensitive to electrostatic discharge. To prevent equipmen t damage, observe safety procedures when working w ith electrostatic sensitive com ponents. This devicecomp liesw ithPart15 of the FC C rules. Op eration is subject to the following two conditions: (1) Th isdevice m ay not cause harmful interference, and (2) This device must accept any interference received,including interferencethatma y cause unde - sired operation. WA RN IN G! Explosion hazard.Do not connect or disconnectequipmentunlesspowerhasbeenswitched off orthe area isknow n to be non-hazardous. Low Voltage Directive ForuseinCategoryIIinstallations.Ifequipmentisused in a m anner not specifiedby m anufacturer,protection provided by equipmentmay be impaired. NoticeofT radem ark,Copyright,and Limitations Magn etrol& M agnetrollogotypeand Echotelare regis - tered tradem arksofM agnetrolInternational. C opyright© 2011 M agnetrolInternational,Incorporated. All rightsreserved. Performa nce specificationsare effective w ith dateofissue and are subject to change w ithout notice. Magne trol reserves the right to mak e changes to the product described in thism anualat any time w ithout notice. Magn etrolm akesno w arranty w ithrespecttothe accura - cyofthe inform ationinthism anual. Wa rranty Al l Mag netrol M odel 910 Level Switches are warranted freeofdefectsinm aterialsorwo rkmanshipfor two full years from the date of original factory shipment. If returned within the w arranty period; and,upon factoryinspection ofthe control,thecause ofthe claim is determined to be covered under the warranty; then, Ma gnetrol will repair or replace the control at no cost to the purchaser (or owner) other than transportation. Magn etrol shallnot be liablefor m isapplication,labor claims,directorconsequentialdam ageorexpensearising from the installation or use of equipmen t. Th ere are no other w arrantiesexpressed or implied, except special w ritten w arranties covering some Magn etrolproducts. Qu alityAssurance Th e qualityassurance system inplace atM agnetrolguar - anteesthe highestlevelofqualitythroughoutthe compa - ny. Magn etrol is com mitted to providing fullcustomer satisfaction both in quality productsand quality service. The Ma gnetrolqualityassurancesystem isregistered to ISO 9001 affirming its com mitme nt to know n international qualitystandardsprovidingthe strongest assurance of product/service quality available.
Ultrasonic signal transmission across transducer gap Figure 1
1.0 Introduction
EchotelM odel910 LevelSw itchesutilize ultrasonic contacttechnologyform easuring levelin clean liquid applications.
1.1 PrincipleofOperation
The M odel910 LevelSw itch usesultrasonic energyto detectthe presence orabsenceofliquid ina transducergap. The basic principlebehind ultrasonic contacttechnologyis thathigh-frequency sound w avesare easilytransmitted acrossa transducergap inthe presenceofa liquidm edium, butare severelyattenuated w hen the gap isdry.T he Mo del 910 usesan ultrasonic frequency of3 MHz to perform thisliquidlevelmeasuremen tin a w ide varietyof processme diaand application conditions. The transducerusesa pairofpiezoelectric crystalsthatare encapsulated inepoxy atthe tip ofthe 316 stainlesssteel transducer.The crystalsare m adeofa ceramic material, thatvibratesata given frequency w hen subjectedtoan applied voltage.The transmitcrystalconvertsan electrical signalfrom theM odel910 electronicsinto an ultrasonic signal.Whe n liquid ispresentin the gap,the receive crystalisableto sensethe ultrasonic signalfrom the transmitcrystaland convertitback to an electricalsignal. Thissignalissenttothe electronicsto indicatethepres - enceofliquid inthetransducergap.Whe n thereisno liquid present,theultrasonic signalisattenuated,and is notdetected by thereceivecrystal.
2.0 Installation
2.1 Unpa cking
Unp ackthe instrumentcarefully.Inspectallunitsfor dam age.R eportany concealeddam agetocarrierwithin 24 hours.Check thecontentsofthepacking slip and purchase order.Check and recordthe serialnumber for futurereference when ordering parts.
2.2 ElectrostaticDischarge (ESD)
Magne trolelectronicinstrumentsarem anufactured tothe highestqualitystandards.T hese instrum entsuseelectronic comp onentsthatm aybe damaged by static electricity presentin mo stw ork environm ents. The follow ingstepsarerecomme nded to reduce theriskof comp onentfailuredue toelectrostatic discharge.
- Ship and store circuitboardsin anti-static bags.Ifan anti- staticbag isnotavailable,wrap the board inaluminum foil.D o notplaceboardson foam packing materials.
- Use a grounding wriststrap w hen installing and remo ving circuitboards.A grounded w orkstation isrecommend ed.
- Handlecircuitboardsonlyby the edges.D o nottouch comp onentsorconnectorpins.
- Make sure thatallelectricalconnections are comp letely mad e and none arepartialorfloating.Ground allequip - me nttoa good,earthground.
2.3 Preliminary O perationalChec k
Afterunpackingand beforeinstallation,perform the following operationalcheck on the unitina non- hazardousarea: 1. Ap plyproperoperating voltageto term inalsL1 and L2/N. Powersupplyground shouldbe connected to the green ground screw inhousing base. 2. Filla suitablecontainerw ithliquid. 3. Placetransducergap intheliquid.The relayoutputshould actuate. 4. Rem ovetransducerfrom the liquid.T he relayoutput shouldde-actuate.In case ofm alfunction,consult Section 3.1, T roubleshooting on page8. C aution: This unitcontains C MOS electronics which m ay becom e dama ged by static electricity.Do nottouch any sem icon - ductordevices unless you areproperlygrounded. 51-604EchotelModel910
" NPT thread Never tighten by turning housing Use wrench here Conduit connection 3 4 Figure 3 VerticalM ounting
2.4 Mounting
Mo del910 levelswitchesareshipped asintegralunitsw ith theelectronicsassembledto thetransducer.They may be mo unted ina variety ofpositions asshow n in Figures2 through 5. Properorientation ofthetransducergap w illprovide max imum performan cein difficultapplications.W hen theswitch ismo unted horizontally,thetransducergap mu stbe turned verticaltoallow properdrainageofthe liquid m edia.See Figures2 and 4. Screw transducerintothe opening using pipe compou nd orthread tape.Ifflanged,boltunitto mating flangew ith propergasket. Cau tion: Never tightenuniton thetankconnectionby turning the housing.Use a w rench on the transducer mo unting nut flats.U se thread tape or suitable pipecomp ound on the threads.D o notovertighten. Whe n installed ina nozzleorpipe,the transducergap mu stextend into thetank atleastone inch beyond the inside tank wall.RefertoFigure5. Install so that wrench flats are vertical Tank wall Gap must be turned vertical to allow medium to fall through Gap must extend 1" (25 mm) beyond end of nozzle Figure 4 Ho rizontalM ounting Figure 5 No zzle M ounting High alarm High alarmGap must be turned vertical Top View of□ Horizontal Mounting Low alarm Low alarm Filling line Pump protection Pump Figure 2 TypicalM ountingOrientations
2.5 Wiring
2.5.1 Powe r
Powerconnectionsaremad e atthe tw o-position terminal block labeled TB 1 withintheelectronics enclosure. Use of14–22 AWG wire isrecomme nded. NOTE: O bserve allapplicable electrical codes and proper wiring procedures. 1. Make sure thepoweristurned off. 2. Unscrew and rem ovethe housing cover. 3. Preventm oisture seepageinto housing by installing an approved seal-drain fitting intheconduitrun leadingto theunit. 4. Ro utewiresintohousing. 5. Con nectground wire to green ground screw located in thebase ofthehousing.D O NOT proceed untilground connection ismad e. 6. Aftergroundingiscom plete,connectthe pow erleadsto properterm inalsasfollows: VA C U nits VD C Un its L1,L2/N +,– C aution: In hazardous areas, do not powe r the unituntilthe conduit is sealed and the enclosure cover is screwed down securely. 7. D ressw iring to ensure no interference orcontactwith coverorcircuitboard comp onents. 51-604EchotelModel910
2.5.2 R elay
M odel910 switcheshavea numbe rofpossiblerelay wiring options.The tablebelow liststherelaycontact positionsforallpossiblecombinationsofpow erfailure, condition ofthetransducergap,and fail-safejumper position.T he usermu stdecide w hich com binations constitutefail-safe and alarm conditions,and thenselect theappropriaterelaywiring and fail-safe position. 1. R un relayoutputwiring to the terminalblockslabeled TB 2 and TB 3. Ensure thattheload tobe con trolledis withinthe relay’srated capacityasshown inSection 3.3.2, Electrical on page 10. 2. Selecthigh orlow fail-safe using the P1 jump er. 3. R eplacehousing cover.Installation iscomp lete. Ca ution: Nevertighten unit to the tank connection by turningthe housing.U se a w rench on the transducer mo untingnut flats.U se thread tape or suitable pipe com pound on threads.D o notovertighten. P1 Fail-safe Line Transducer RelayTerminals Jumper Position Power Gap CM toNC CM toNO On Dry Closed Open Low level Wet Open Closed Failure Dry Closed Open Wet Closed Open On Dry Open Closed Highlevel Wet Closed Open Failure Dry Closed Open Wet Closed Open Relay Output Wiring P1 Fail-safe Jumper LL HL
3.0 Reference Information
3.1 Troubleshooting
C aution: Inhazardousareas,do notremove housing coveruntilpowe risdisconnectedand atmosphereisdeter - mined to be safe. 3 .1.1 No signalwithlevelchange a. Verifypow erand controlcircuitwiring. b. Make sureliquid isfilling the transducergap. c. Ch eck fordensefoam on surfaceordriedproductin the gap.Un itwillnotfunctionproperlyif eithercondition exists. d. Ch eck transducerphone plugsforproperinsertioninJ1 and J2. e. Ifcontrolcircuitdoesnotactuate,consultfactory. 3 .1.2 Ca libration Mode l910 switchesdo notrequirefieldcalibration.T he setpointisnotadjustable. 3 .1.3 Sw itch chatter a. Ch eck voltageto make sureitiswithintolerancesshown in Section 3.3.2. b. Ch eck forturbulence.Relocate controlorisolatefrom turbulence. c. Ch eck forexcessiveaeration. d. Con sultfactory. 3 .1.4 Con troloutput w illnotde-actuate a. Ch eck transducerforplugged gap. b. Ch eck fordensefoam orliquidin gap. c. Ifcontrolcircuitdoesnotde-actuate,consultfactory.
3.2 Agency Approvals
FM 910-XXXX-XXX ExplosionProof Class I,Div.1; Groups B,C &D Class II ,Div.1; Groups E, F ,&G Class III ,NEMA Type 4X,T6 910-XXXX-XXX Non-Incendive Class I,Div.2; Groups A,B,C, &D Class II ,Div.2; Groups F &G Class III ,NEMA Type 4X,T5 C SA 910-XXXX-XXX ExplosionProof Class I,Div.1; Groups C &D Class II ,Div.1; Group E, F ,&G Class III ,Type 4X,T6 910-XXXX-XXX Non-Incendive Class I,Div.2; Groups A,B,C, &D Class II ,Div.2; Groups E, F ,&G Class III ,Type 4X,T5 ATEX 910-5XXX-XXX II 1/2G EEx d II C T6/EEx e II T6 910-PXXX-XXX AGE NC Y APPRO VED MODEL PROTECTION ME THO D AREA C LASSIFICATION 51-604EchotelModel910 These units have been tested to EN 50081-2□ and EN 50082-2 and are in compliance with□ the EMC Directive 89/336/EEC. Note: ConsultfactoryforBrazilianINMETRO BR-Ex d IIC T6 IP66 approval.
3.3 .1 Physical
3.3 Specifications
inches (mm) .875 (22) Dia. Actuation length ➀➁ 2.75 (70)
3.00 Rotation
(76) clearance 4.63 (117) Dia. Optional mounting flange 3.50 (88) 6.25 (158) 4.48 (113) 3/4" NPT tank connection 3/4" NPT .25 (6)Actuation point Actuation point .875 (22) Dia. Actuation length ➀➁ 2.75 (70) 4.63 (117) Dia. 3.44 (87) Rotation clearance 4.48 (113) .25 (6) Optional mounting flange 6.25 (158) 3/4" NPT plugged 3/4" NPT 3/4" NPT tank connection 3.50 (88) 316 stainless steelhousing (Single 3 ⁄4"NP T conduit) Aluminum sand casthousing (Dual3 ⁄4"NP T conduits) Actuation point .875 (22) Dia. Actuation length ➁ 2.75 (70) 4.63 (117) Dia. 3.44 (87) Rotation clearance 4.48 (113) .25 (6) 6.25 (158) 3/4" NPT plugged 3/4" NPT 1" BSP process connection Aluminum sand casthousing (Dual3 ⁄4"NPT conduitw/ 1"BSP process connection) 1" (Code 001)minimum withNPT threadedprocessconnections. 2" (Code 002)minimum withhygienicorANSIflangedprocessconnections. 25 (Code 003)mm minimum withNPT threadedprocessconnections. 50 (Code 005)mm minimum with1" BSP ,and hygienicorANSIflangedprocessconnections. 2.75 (70) 4.63 (117) Dia. 4.48 (113) 3.44 (87) Rotation clearance .25 (6) Actuation point .875 (22) Dia. .25 (6) 3/4" NPT (plugged) Actuation length ➀➁ 3/4" NPT Aluminum sand casthousing (Dual3 ⁄4"NP T conduitwithhygienicflange)
3.3 .2 Electrical Pow erSupply: 120 VAC (+10%/-15%),50/60Hz
24 VDC (±10%)
Pow erConsu mption: 2.5VA nominal RelayO utput: G oldflash D PDT relay:10 amps @ 120VAC, 240 VAC, 24 VD C Herme tically sealed D PDT relay:5 amps @ 120 VAC, 24 VD C ,and 3 am ps @ 240 VAC Repeatability: 0.078 " (2 mm) Fail-safeConf iguration: Fieldselectablehigh orlow Ca libration: None required AmbientTem perature: Electronics:-40°to+158° F (-40° to+70° C ) Process Temp erature: Transducer:-40° to+250°F (-40°to+121° C) Operating/Non-OperatingPressure: 8 00/1500 psig (55/103 bar) Shock ANSI/ISA-S71.03 Class SA1 Vibration ANSI/ISA-S71.03 Class VC2 Gold flashDPDT relayisratedat8 amps when used withhousingcodes 5 orP
3.4 Replacement Parts
No. Description PartNumber 120VAC w/10amp relay Z30-2043-003
240 VAC w/10amp relay Z30-2043-004
1 PC Board 24 VDC w/10amp relay Z30-2043-002
120VAC w/5amp HS relay Z30-2043-011
240 VAC w/3amp HS relay Z30-2043-012
24 VDC w/5amp HS relay Z30-2043-010
Aluminum w/FMand CSA 004-9182-002
2 Housing Aluminum w/all3 approvals 004-9182-008
Base 316 SS w/FMand CSA 004-9140-001
316 SS w/CENELEC 004-9140-001
Aluminum w/FMand CSA 004-9105-001
3 Housing Aluminum w/all3 approvals 004-9105-005
Cover 316 SS w/FMand CSA 004-9142-001
316 SS w/CENELEC 004-9142-001
4 O-Ring 012-2101-345
5 Transducer Consultfactory
WARN ING! Exp losion hazard — Substitutionof com - ponents m ay im pair suitability for C lass 1, Division 2 rating. WARN ING! Explosion hazard — D o not disconnect equipm entunless pow erhas been switched off,or the area is known to be non- hazardous. 51-604EchotelModel910
3.5 Mod elNumbers
3.5.1 M odel910
A Aluminum sand castw ith3⁄4" NPT dualconduit,FM orC SA approvals Y 316 stainless steelw ith3⁄4" NPT single conduit,FM orC SA approvals P Aluminum sand castw ith3⁄4" NPT dualconduit,FM,C SA and ATEX approvals 5 316 stainless steelw ith3⁄4" NPT single conduit,ATEX approval H O US ING
1 En glish (actuationlength ininches)
M Metric (actuation lengthin centime ters) TR ANSD UCER UN ITO F LEN GTH A 3⁄4" NPT 2 1" NPT 9 1" BSP 31 1⁄2" hygienicflange (Comp atiblew ithTri-Clam p ® fittings) 4 2" hygienicflange (Com patible withTri-C lam p ® fittings) 1 1" 150 lb.ANSIraised face flange C1 1⁄2" 150 lb.ANSIraised face flange D 2" 150 lb.ANSIraised face flange E 1" 300 lb.ANSIraised face flange F1 1⁄2" 300 lb.ANSIraised face flange G 2" 300 lb.ANSIraised face flange PR OC ES S CO NN ECTION 0 120 VAC with10 am p DPDT gold flash relay 1 240 VAC with10 am p DPDT goldflashrelay 2 24 VD C w ith10 am p D PD T goldflash relay H 120 VAC with5 am p D PDT hermeticallysealed relay J 240 VAC with3 amp D PDT hermeticallysealed relay K 24 VD C w ith5 am p DPDT hermeticallysealedrelay INPUT PO WER ACTUATIO N LENGTH 1" to96" in 1" increm ents(withTransducerUnitofLeng th code 1)Exa m ple:4 inches = 004 3 cm to244 cm in1 cm increm ents(withTransducerU nit ofLen gthcode M)Ex am ples:6 centimeters= 006 1" (code001)minimum withNPT processconnections,2" (code002)minimum withhygienicorANSIflangedprocessconnections. 2.5cm (code003)minimum withNPT processconnections,5 cm (code005)minimum with1" BSP ,orhygienicorANSIflanged processconnections. Consultfactoryforlongerlengths.
BULLETIN: 51-604.16 EFFECTIVE: February2011 SU PERSEDE S: July 2010 5300 Belmont Road • Downers Grove, Illinois 60515-4499 • 630-969-4000 • Fax 630-969-9489 • www.magnetrol.c om
145 Jardin Drive, Units 1 & 2 • Concord, Ontario Canada L4K 1X7 • 905-738-9600 • Fax 905-738- 1306
Heikensstraat 6 • B 9240 Zele, Belgium • 052 45.11.11 • Fax 052 45.09.93 Regent Business Ctr., Jubilee Rd. • Burgess Hill, Sussex RH15 9TL U.K. • 01444-871313 • Fax 01444-871317 Copyright © 2011 Magnetrol International, Incorporated. All rights reserved. Printed in the USA. Service Policy Ow nersofMag netrolm ayrequestthe returnofa control oranypartofacontrolforcompleterebuildingorreplace - ment.T hey w illbe rebuiltorreplaced promptly.Con trols returned under our service policymust be returnedby Prepaid transportation.Magn etrolwillrepairor replace the controlatno costto the purchaser (or owner) other than transportationif: 1. Returned withinthewarranty period; and 2. T he factoryinspection findsthe cause ofthe claim to be covered underthe w arranty. Ifthe troubleisthe resultofconditionsbeyond ourcon - trol;or,isNOT coveredby the warranty,therew illbe charges for labor and the partsrequiredto rebuildor replace theequipment. In some casesitm ay be expedient to ship replacement parts; or,in extreme casesa com pletenew control,to replace the originalequipment before itisreturned.If this is desired,notify the factoryofboth themodel and serial numbe rs of the controlto be replaced. In such cases,creditforthem aterialsreturned willbe determined on the basisoftheapplicabilityofourw arranty. No claims formisapplication,labor,directorconsequen - tialdama gewillbe allow ed. Re turn M aterialProcedure So thatw e may efficientlyprocess any m aterialsthatare returned, it is essential that a “Return Material Auth orization” (RM A ) numbe r be obtained from the factory,prior to the material’s return. T hisis available througha Magn etrollocalrepresentativeorby contacting the factory.Pleasesupplythe follow inginformation: 1. Co m pany Nam e 2. D escription ofM aterial 3. SerialNum ber 4. R eason forR eturn 5. A pplication An y unitthat w as used in a processmus t be properly cleaned in accordancew ith O SHA standards,beforeitis returned to the factory. A MaterialSafety D ata Sheet (M SD S) mus t accompany materialthatw asused inany m edia. All shipmentsreturned tothe factorym ustbe by prepaid transportation. All replaceme ntsw illbe shippedF .O.B.factory. N OTE: SeeElectrostaticD ischargeH andling Procedure on page4. ASSUR ED Q U ALITY & SER VICE COST LESS Tri-Clamp® isa registeredtradema rkofLadish Co.