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Installation and OperatingMan ual Ultrasonic Single and Dua lPoint LevelSw itches

51-646 Echotel ® Model 961 & 962 UltrasonicLevelSwitches Read thisMan ualBefore Installing Thism anualprovidesinformationon the Echotel ® Models961 and 962 UltrasonicLiquidL evelSwitches. Itisimportantthatallinstructionsareread carefullyand followed in sequence.Detailedinstructionsareincluded inthe Installationsectionofthism anual. ConventionsUsed in thisMan ual Cer tainconventionsareusedinthism anualtoconvey specifictypesofinformation.Gen eraltechnicalmaterial, supportdata,and safetyinformationarepresentedin narrativeform.Th e followingstylesareusedfornotes, cautions,and warnings. Notes Notescontain information thataugm entsorclarifies an operatingstep.N otesdo notnormallycontain actions,they follow the proceduralstepsto w hich theyrefer. C autions Cau tionsalertthetechnicianto specialconditions thatcouldinjurepersonnel,dam age equipment,or reducea com ponent’sm echanicalintegrity.C autions are alsoused toalertthe technicianto unsafeprac - ticesortheneed forspecialprotective equipmentor specific materials.Inthism anual,a cautionbox indi - catesa potentiallyhazardoussituationwhich,ifnot avoided,may resultinm inororm oderateinjury. W arnings W arningsidentify potentially dangeroussituationsor serioushazards.Inthism anual,a warning indicates an immi nently hazardoussituation w hich,ifnot avoided,couldresultinseriousinjuryordeath. SafetyMessages ECH OTEL M odels961 & 962 are designed foruse in Category II, Pollution De gree2 installations.Followall standardindustryproceduresforservicing electricaland com puterequipmentwhen wo rking withoraroundhigh voltage.Alwaysshutoffthe powersupplybeforetouch - ing anycompo nents. Electricalcompo nentsaresensitivetoelectrostaticdis - charge.T o preventequipmentdam age,observesafety procedureswh en workingwithelectrostaticsensitive com ponents. Thisdevicecomp lieswithPart15 ofthe FCC rules. Op erationissubjecttothefollowing two conditions: (1) Thisdevicem ay notcause harmfulinterference, and (2)Thisdevice m ustacceptany interference received,including interferencethatma y cause undesired operation. WA RN ING ! Explosion hazard.D o notconnectordis - connectequipmentunlesspower hasbeensw itchedoff orthe area isknow n to be non-hazardous. Low Voltage Directive ForuseinCat egoryIIinstallations.Ifequipmentisused in a m anner not specifiedby m anufacturer,protection provided by equipmentmay be impaired. NoticeofT radem ark, Copyright,and Limitations Ma gnetrol ® ,M agnetrol ® logotype and Echotel ® are registered tradenam esofM agnetrolInternational, Incorporated. ® Co pyright© 2011 MAG NETROL INTERNATI ON AL , INCOR PO R AT ED .Allrightsreserved. Perform ance specificationsareeffective w ithdateofissue and are subjecttochangewithoutnotice.M AGN ETR OL reservesthe rightto m akechangesto the product described inthism anualatany time w ithoutnotice. MA GN ET ROL m akesno w arranty with respectto the accuracy ofthe information inthism anual. Wa rranty AllM AG NE TR O L electronicleveland flow products arewarranted freeofdefectsinmaterialsorw orkman - shipforone fullyearfrom the date oforiginalfactory shipment. Ifreturned within the warranty period; and,upon factory inspection ofthe control,the cause ofthe claim is determinedto be covered underthe warranty; then, MA GN ET ROL w illrepairorreplacethe controlatno costto the purchaser(orowner)otherthan transportation. MA GN ET ROL shallnotbe liableform isapplication, laborclaims,directorconsequentialdamage orexpense arisingfrom the installation oruseofequipment.T here areno otherwarrantiesexpressedorimplied,exceptspe - cialw ritten w arrantiescoveringsom e M AGN ET ROL products. Qu alityAssurance The qualityassurance system in place atM AG NETROL guaranteesthe highestlevelofqualitythroughoutthe compan y.M AGNE T RO L iscom mitted to providing fullcustome rsatisfaction bothinqualityproductsand qualityservice. The M AGN ETR OL qualityassurance system isregistered to ISO 9001 affirmingitscom m itme nttoknow n internationalquality standards providing the strongestassurance of product/service qualityavailable.

51-646 Echotel ® Model 961 & 962 UltrasonicLevelSwitches Table ofContents

2.4.1.1 Mod el961 R em oteT ransducer

2.4.2.1 Mod el961 R em oteT ransducer

2.4.3.1 Mod el962 R em oteT ransducer

2.4.4.1 Mod el962 R em oteT ransducer

2.5.3.6 L C andHi/Lo DIP SwitchConfiguration 18

2.5.3.7 PC andHi/Lo DIP SwitchConfiguration 19

3.1.2 Model 961/ 962 w ith Cu rrentShiftOutput .22

3.6.1 Agency (FM /CSA ) D rawing and

Echotel ® Mo del961 & 962 Ultrasonic Singleand D ualPoint LiquidLevelSwitches

4 51-646 Echotel ® Model 961 & 962 UltrasonicLevelSwitches

1.0 Introduction

ECHO TEL Mo del961 and 962 ultrasoniclevelswitches utilizepulsed signaltechnologyto detecthigh,low,ordual pointlevelin a broad rangeofliquidm edia applications. Mo del961 isa singlepointlevelswitch.M odel962 isa dualpointswitchused asa levelcontrollerorto control pum psin an auto-fillorauto-emp ty mod e.

1.1 PrincipleofO peration

Mo del961/ 962 switchesutilizeultrasonic energytodetect thepresenceorabsence ofliquid in a singleordualpoint transducer.U ltrasonic contactleveltechnology useshigh- frequencysound w avesthatareeasilytransmitted acrossa transducergap(see Figure1) in thepresence ofa liquid me dia,butare attenuated w hen the gapisdry.Mod el 961/ 962 switchesuse an ultrasonic frequency of2 MHz to perform thisliquid levelme asurementin a w ide varietyof processm edia and application conditions. The transducerusesa pairofpiezoelectriccrystalsthatare encapsulated in epoxy atthe tipofthe transducer.T he crystalsare m adeofa ceramic m aterialthatvibratesata givenfrequency when subjected to an applied voltage.T he transm itcrystalconvertsthe applied voltagefrom theelec - tronicsinto an ultrasonic signal.Whe n liquid ispresentin thegap,thereceivecrystalsensesthe ultrasonicsignalfrom thetransmitcrystaland convertsitback toan electrical signal.T hissignalissentto theelectronicsto indicatethe presenceofliquid inthe transducergap.Whe n there isno liquid present,theultrasonic signalisattenuated and isnot detected by thereceivecrystal.

2.0 Installation

2.1 Unpacking

Unpack theinstrume ntcarefully.Inspectallunitsfor dam age.Reportany concealeddamage to carrierw ithin 24 hours.Che ck thecontentsofthe packing slip and purchase order.Che ck and recordthe serialnumbe rfor future referencew hen ordering parts. serialnumber Ultrasonic transducer Transmit crystal Receive crystal Figure1 UltrasonicSignalTransm ission A cross TransducerGap

551-646 Echotel ® Model 961 & 962 UltrasonicLevelSwitches Figure 2 TypicalM ountingOrientations

2.2 ElectrostaticDischarge (ESD) Handling

MAGN ET ROL electronic instrum entsarema nufactured to thehighestqualitystandards.T hese instrum entsuse electroniccomp onentsthatm aybe damaged by static electricity presentin m ostwo rkenvironme nts. The follow ing stepsarerecomm ended to reducetheriskof com ponentfailure due to electrostatic discharge.

• Shipand store circuitboardsinanti-static bags.Ifan anti- staticbagisnotavailable,w rap theboardin aluminum foil.D o notplaceboardson foam packing m aterials.
• U se a grounding w riststrap w hen installing and remo ving circuitboards.A grounded w orkstation isrecommend ed.
• Han dlecircuitboardsonlyby the edges.D o nottouch com ponentsorconnectorpins.
• M akesure thatallelectricalconnectionsarecompletely mad e and none are partialorfloating.Ground allequip - me nttoa good,earth ground.

2.3 M ounting

The Mo del961 levelswitch m aybe m ounted ina variety ofpositionsasshow n in Figures2 through 5.Mod el962 is alwaysm ounted vertically. Properorientation ofthe transducergapw illfacilitate maximu m performance indifficultapplications.Whe n the Mo del961 ism ounted horizontally,the transducergap must be turned vertically toallow properdrainage ofliquid outofthegap.The w rench flatson them ounting nutare aligned with thetransducergap; therefore,propertrans - ducerm ounting canbe achievedby aligning themou nting nutflatsina verticalorientation.SeeFigure4 . When installinga M odel961 switch ina nozzleorpipe, thetransducergapm ustextend intothe tank atleastone inchbeyond theinside tank wall.Referto Figure 5. Screw transducerinto the opening using a w renchon the transducerm ounting nutflats.Ifflanged,boltunittomat - ingflangewithpropergasket.Use threadtape orsuitable pipecom pound on the threads.D o notover-tighten. Pump Protection Fill Line Dual Point Alarm High Alarm Low Alarm Figure3 VerticalM ounting Use wrench on flats Process connection Bottom View Bottom View Figure4 Ho rizontalM ounting Figure5 No zzleMoun ting

6 51-646 Echotel ® Model 961 & 962 UltrasonicLevelSwitches

2.4 Wiring

Wiring forM odel961/962 levelswitchesisdifferentforall fourversions.T hese switchesareavailableas4-wi re,line- pow ered unitsw ith5 -amp relays,oras2-w ire loop-pow - ered unitsw ithmA currentshiftoutput.De termine w hich version you havefrom the tablebelow and proceed tothe properwiringsection.

2.4.1 Mod el961 Line-powe red W iring

Powerand relaywiring connectionsaresuitablefor 12–24 AW G wire. C aution: OB SER VE A LL A PPLICAB LE ELEC TR ICAL COD ES AN D PR O PER W IRING PR O CEDURES. 1. Make sure thepowersource isturned off. 2. Unscrew and rem ovehousing cover. 3. Pullpowersupplyand relayw iresthrough the conduit connection. 4. Referto Figure 6 .Con nectpower leadstoproperterminals. Mo del961 isavailableforAC power(102to 265 VAC) or forD C power(18–32VD C) a. AC Power– Co nnect“hot” w ireto terminalmarked L1 and the“neutral” wireto the term inalmarked L 2.The green head screw shouldbe used forgrounding. b. D C Power– Co nnectw iresto terminals(+) and (-) on theterminalblock.T he green headscrew shouldbe used forgrounding. 5. Con nectdesired relaywiring asshown inFigure 6. 6. Preventm oisture seepageinto housing by installing an approved sealdrainfitting in the conduitrun leadingto theunit. 7. Wiringiscom plete.R eplacehousing cover. C aution: In hazardous areas, do not powe r the unituntilthe conduit is sealed and enclosure cover is screwed down securely. NOT E: H ousing m ust be grounded viagreen head ground screw in the base ofthehousing. TIME DELAY LEVEL TEST MALF TEST MALF RELAY FAULT WET LEVEL MALF MODEL 961 NC C NO NC C NO NC C NO L2 L1 Malfunction SPDT Relay Input Power Ground Level DPDT Relay Hi I Lo J M odel Input Ou tput Wiring Inform ation 961 Line-powered 5 am p relays Proc ee d to sec tion 2.4.1 961 Loo p-pow ered Cu rrentshift Proc ee d to sec tion 2.4.2 962 Line-powered 5 am p relays Proc ee d to sec tion 2.4.3 962 Loo p-pow ered Cu rrentshift Proc ee d to sec tion 2.4.4 Figure 6 Mo del96 1 Line-Powe red Wiring

751-646 Echotel ® Model 961 & 962 UltrasonicLevelSwitches

2.4.1.1 Mod el961 R emote TransducerHou sing Wiring

Remo tem ountMo del961 unitshavea “1”asthe8th digit(961-X X X X - 1X X) ofthem odelnum ber.Th e 037 -3316- XXX cabling isconnectedatthe factory on the electronicsend,and secured w ith a cabletie.T he other end ofthecabling isconnected by the userinside the remo tetransducerhousing ata term inalblock marked as 1 2 3 4 on a bluelabel.See Figure 7. NO TE: The 037 -3316 -XXX cabling is connectedatthefactory on the electronics end.TB1 and TB 2 connections areshown below inFigure7 in the eventthecableneeds tobe reattached. NOTE: The Signalwiresare30 AWG RG Type 178/U coax withthewhitejacketstripped off.The Shieldwiresarepreparedwithsolidtinnedcopper 22 AWG bus wire. Ground 037-3316-xxx Cabling Shield: 1, 3 Signal: 2, 4 030-3591-001 R29 TB1 TB1 TB2 TB2 RECV XMIT Figure 7 M odel96 1 Line-Powered Remote TransducerWiring Remote TransducerHousing ElectronicsModule TransducerHousing TerminalPosition W ire ElectronicsTerminalBlock & TerminalPosition

1 ReceiveShield

2 ReceiveSignal RECV

3 Transm itShield

4 Transm itSignal XM IT

Mode l961 Line-powe red Rem oteMou ntWiring

8 51-646 Echotel ® Model 961 & 962 UltrasonicLevelSwitches

2.4.2 Mo del961 Loop-powe red Wiring

Forintrinsicallysafeinstallations,referto theAgency D rawing in Section 3.6.1.L oop wiring connectionsare suitablefor12–24 AW G w ire. Cau tion: O BS ERV E A LL A PPLICABLE ELECTRICAL COD ES A ND PRO PER WIR ING PR OC EDURES. 1. Make surethe pow ersource isturned off. 2. Un screw and rem ovehousing cover. 3. Pulltwisted pairw ire through the conduitconnection. 4. R efertoFigure 8.Co nnectw iresto terminals(+) and (-) on the terminalblock.U nshielded cablem aybe used.If shielded cableisused,attach shieldtogreenheadscrew. 5. Preventm oistureseepageinto housing by installing an approvedsealdrainfitting in the conduitrun leading to theunit. 6. Wi ring iscom plete.Replace housing cover. Cau tion: In hazardous areas, do not power the unituntil the conduit is sealed and enclosure cover is screwed dow n securely.

2.4.2.1 M odel961 R emote TransducerHou sing W iring

R em otem ountM odel961 unitshavea “1”in the 8th digit(961-X XX X - 1X X ) ofthe mo delnumber.T he 037 -3316-X XX cablingisconnected atthe factory on the electronicsend,and securedw itha cabletie.T he other end ofthe cabling isconnected by the userinside the rem otetransducerhousing ata term inalblock m arked as 1 2 3 4 on a blue label.See Figure 9. NO TE: The 037 -3316-XXX cabling is connected atthefactoryon the electronics end.TB 2 and TB 3 connections are shown in Figure9 in theeventthecable needs tobe reattached. TIME DELAY FAULT TEST MODEL 961 Hi 22 Lo 3.6 LOOP TEST 8 16 F A U L T Ground Figure8 Mod el961 Loop-Powe redWiring TransducerHousing TerminalPosition W ire

2 ReceiveSignal

3 TransmitShield

4 TransmitSignal

& TerminalPosition Wire TB 3 RE CV Receive Signal Receive Shield TB 2 XMIT Transm itSignal Transm itShield Mode l961 Loop-pow ered R em oteMount Wiring NOTE: The Signalwiresare30 AWG RG Type 178/U coax withthewhitejacketstrippedoff.The Shieldwires arepreparedwithsolidtinnedcopper 22 AWG bus wire.

951-646 Echotel ® Model 961 & 962 UltrasonicLevelSwitches

2.4.3 Mod el962 Line-powe red W iring

Powerand relaywiring connectionsaresuitablefor 12–24 AW G wire. Cau tion: OB SER VE AL L A PPLICABLE ELECTRICA L CODES AN D PR OP ER W IR ING PR O CEDURES. 1. Make sure thepowersource isturned off. 2. Unscrew and rem ovehousing cover. 3. Pullpowersupplyand relayw iresthrough the conduit connection. 4. Referto Figure 10.Con nectpowerleadstoproperterminals. Mo del962 isavailableforAC power(102to 265 VAC) or forD C power(18–32VD C) a. AC Power– Con nect“hot” w ireto terminalmarked L1 and the“neutral” wireto the term inalmarked L 2.The green head screw shouldbe used forgrounding. b. D C Power– Co nnectw iresto terminals(+) and (-) on theterminalblock.T he green headscrew shouldbe used forgrounding. 5. Con nectdesired relaywiring asshown inFigure 10. 6. Preventm oisture seepageinto housing by installingan approved sealdrainfitting in the conduitrun leading to theunit. 7. Wiringiscom plete.R eplacehousing cover. Cau tion: In hazardous areas, do not power the unit until the conduit is sealed and enclosure cover is screwed dow n securely. TIME DELAY LEVEL TEST MALF TEST MALF RELAY FAULT MALF LOWER UPPER MODEL 962 NC C NONC C NO NC C NO L2 L1 Malfunction SPDT Relay Input PowerGround Lower Gap SPDT Relay Upper Gap SPDT Relay Hi PC Lo LC LOWER UPPER Figure10 Mod el962 Line-Powered Wiring Ground Shield: 1, 3 Signal: 2, 4 TB3 DELAY FAULT 16ma 8ma FORCE CHANGE FORCE FAULT TB2 XMIT TB2 TB3 RECV 037-3316-xxx Cabling Figure 9 Mo del961 Loop-Powered Remo teTransducerWiring Remote TransducerHousing ElectronicsModule

10 51-646 Echotel ® Model 961 & 962 UltrasonicLevelSwitches

2.4.3.1 Mod el962 R emote TransducerHou sing W iring

Rem ote mo untMo del962 unitshavea “1”in the 8th digit(962-X X X X- 1X X) ofthe mo delnumbe r.T he 037 -3317-XX X cabling isconnected atthe factory on the electronicsend,and secured w ith a cabletie.The other end ofthecablingisconnected by theuserinside the rem ote transducerhousing atterminalblocksm arked as 12345678 on a blue label.SeeFigure11 forproper terminations. NOT E: The 037 -3317 -XXX cabling is connected atthefactoryon the electronics end.TB 1,TB 2,TB 3,and TB4 connections are shown below in Figure11 inthe eventthecableneeds to be reattached. TB1 TB1 TB4 TB4 RCV1 XMIT1 TB3 TB3 TB2 TB2 RCV2 XMIT2 037-3317-xxx Cabling Ground Shield: 1, 3, 5, 7 Signal: 2, 4, 6, 8 Model 962 Remote TransducerWiring Figure11 Mo del962 Line-Pow eredRemo teTransducerWiring Transducer Gap Ca ble Ma rker W ire M arker Transducer Ho using TB Position W ire Electronics Housing TB & TerminalPosition Upper H igh 1 1 TransmitShield TB 4 Upper H igh 1 2 TransmitSignal XM T1 Upper H igh (none) 3 ReceiveShield TB 1 Upper H igh (none) 4 ReceiveSignal RCV1 Lo w er Lo w 1 5 TransmitShield TB 2 Lo w er Lo w 1 6 TransmitSignal XM T2 Lo w er Lo w (none) 7 ReceiveShield TB 3 Lo w er Lo w (none) 8 ReceiveSignal RCV2 Mode l962 Line-powered Remote Mount Wiring NOTE: The Signalwiresare30 AWG RG Type 178/U coax withthewhitejacketstrippedoff.The Shieldwires arepreparedwithsolidtinnedcopper 22 AWG bus wire.

11 51-646 Echotel ® Model 961 & 962 UltrasonicLevelSwitches TIME DELAY FAULT TEST MODEL 962 Hi 22 Lo 3.6 LOOP TEST 8 12 16 Ground Figure 12 Mo del96 2 Loop Power Wiring

2.4.4 Mo del962 Loop-powe red W iring

Forintrinsicallysafe installations,referto the Agency D rawingin Section 3.6.1.Lo op w iring connectionsare suitablefor12–24 AW G w ire. C aution: O BSER VE A LL A PPLICAB LE ELEC TR ICAL COD ES A ND PR O PER W IRING PR O CEDURES. 1. M akesure thepowersourceisturned off. 2. U nscrew and rem ovehousing cover. 3. Pulltwisted pairwirethrough the conduitconnection. 4. R eferto Figure 12.Con nectw iresto terminals(+) and (-) on theterminalblock.U nshielded cablemay be used.If shielded cableisused,attach shieldto green head screw. 5. Preventmo isture seepageinto housing by installingan approved sealdrain fitting in the conduitrun leadingto theunit. 6. W iring iscomp lete.Replace housing cover. C aution: In hazardous areas, do not powe r the unit until the conduit is sealed and enclosure cover is screwed dow n securely.

2.4.4.1 M odel962 R emote TransducerH ousing Wiring

Remo tem ountMo del962 unitshavea “1”in the8th digit(962-X X X X - 1XX ) ofthe mod elnumber.The 037 -3317-XX X cabling isconnected atthe factoryon the electronicsend and secured w ith a cabletie.T he otherend ofthecabling isconnected by the userinside theremote transducerhousing atterminalblocksm arked as 12345678 on a bluelabel.SeeFigure 13 forproper terminations.

12 51-646 Echotel ® Model 961 & 962 UltrasonicLevelSwitches TB1 TB1 TB4 TB4 TB3 TB3 TB2 TB2 RECV1 XMIT1 RECV2 XMIT2 037-3317-xxx Cabling Ground Shield: 1, 3, 5, 7 Signal: 2, 4, 6, 8 Model 962 Remote TransducerWiring Figure 1 3 M odel96 2 Loop-Pow eredRemo teTransducerWiring Transducer Gap Ca ble Ma rker W ire M arker Transducer Ho using TB Position W ire Electronics Housing TB & TerminalPosition Uppe r H igh 1 1 TransmitShield TB 2 Uppe r H igh 1 2 TransmitSignal XM T1 Uppe r H igh (none) 3 ReceiveShield TB 3 Uppe r H igh (none) 4 ReceiveSignal RCV1 Lo w er Lo w 1 5 TransmitShield TB 4 Lo w er Lo w 1 6 TransmitSignal XM T2 Lo w er Lo w (none) 7 ReceiveShield TB 1 Lo w er Lo w (none) 8 ReceiveSignal RCV2 Mode l962 Loop-powered R emote Mount Wiring

2.5 Configuration

2.5.1 Mod el961 Line-powe red C onfiguration

Mo del961 line-powered unitshavethe follow ing configuration options:

• TIM E D ELA Y potentiometerfor0.5to45 second signalaveraging
• LE V EL T EST pushbutton fortesting ofthe DP DT processlevelalarm
• MA LF TEST push button fortesting ofthe SPDT malfunction alarm
• Hi/Lo D IPswitchforfail-safe high orlow levelselection
• I/JD IPswitchforindependentorjointoperation of therelays NOTE: The Signalwiresare30 AWG RG Type 178/U coax withthewhitejacketstrippedoff.The Shieldwiresare preparedwithsolidtinnedcopper 22 AWG bus wire.

13 51-646 Echotel ® Model 961 & 962 UltrasonicLevelSwitches TIME DELAY LEVEL TEST MALF TEST MALF RELAY FAULT WET LEVEL MALF MODEL 961 NC C NONC C NO NC C NO L2 L1 High/Low DIP Switch Independent/Joint DIP Switch Level Test Pushbutton Malfunction Test Pushbutton Hi I Lo J Time Delay Pot to decrease delay to increase delay Turn Turn Figure 1 4 Mo del96 1 Line Powe rCon figuration

2.5.1.1 Time D elay Potentiometer

The time delaypotentiome teristypicallyused inapplica - tionsw here turbulence orsplashing may cause falselevel alarms.Thisisa 25-turn potw itha factorydefaultsetting of0.5 seconds.Ifdesired,thispotm aybe turned clockwise toincreasethe responsetim e from the standard0.5 seconds toa m aximu m of45 seconds.T urning the potcounter - clockwisedecreasesthetime delay. The WET LED isnotinfluenced by the time delaypot. As an examp le,turning the potclockw iseseveralturnsw ill puta time delayinto the 961.Imm ersing the tipofthe transducerin w aterw ith the H i/Lo switch in theH iposi - tion,willproduce thefollow ing results:

• WET LED willimmed iatelyturn on
• Afterthetime delaythe L EVEL LED willturn offand the DPD T processlevelrelayw illde-energize Whe n rem oving the tip ofthe transducerfrom thew ater theWET LED willimme diatelyturn off.Afterthetime delaytheL EV EL LED willturn on and D PD T process levelrelaywillenergize.

2.5.1.2 LevelTestPush B utton

The leveltestpush button isusedto man uallytestthe DPDT processlevelrelay.Pressingthispush button reverses thestateofthe DP DT relay,from energized tode-ener - gized orvice-versa.T hiscan be usedto man uallytestthe relay,and whateverisconnected tothisrelay.T he time delaypotdoesnotaffecttheoperation ofthe leveltest pushbutton.

2.5.1.3 M alfunction TestPush Bu tton

The m alfunction testpushbutton isused tomanu allytest theSPDT malfunction relay.Pressing and holdingthis pushbutton for2 secondsw illcausethe SPD T relayto de-energize indicating a faultcondition.Thiscanbe used tom anuallytesttherelay,and whateverisconnectedto thisrelay.The time delaypotdoesnotaffecttheoperation ofthem alfunction pushbutton. N OTE: Un dernorm aloperating conditions thegreen MALF (malfunc - tion)LED is on to indicatethatthe malfunction relay is ener - gized,and theredFAU LT LED is offtoindicatethatthereare no faults.Sho uld a faultcondition occur,thered FAU LT LED turns on and thegreen MALF LED turnsoff,indicating thatthe ma lfunction relay is de-energized. Operating Cond ition R ed FaultLE D Green M alfunction LE D Normal Off On Fault On Off Faultand M alfunction LE D Indication

14 51-646 Echotel ® Model 961 & 962 UltrasonicLevelSwitches

2.5.1.4 H igh/Low DIP Switch

The Hi/Lo Di p Switch isused to selectwhetherthe Mo del 961 w illbe used asa high levelfail-safe (H LFS ) switch ora low levelfail-safe(LL FS) switch. IntheHi position theD PD T processlevelrelayw ill de-energize (alarmcondition) w hen the gapbecome swet. IntheLo position theD PD T processlevelrelayw ill de-energize (alarmcondition) w hen the gapbecome sdry. The tablebelow providesassistance inconfiguring the Hi/Lo D IPswitch. Hi/Lo DIP Switch Gap Cond ition Level Condition Relay Con tacts W E T LE D LE VE L LE D Hi (HLFS ) D ry NC C NO Off On Hi (HLFS ) Wet NC C NO On Off Lo (LLFS ) Wet NC C NO On On Lo (LLFS ) D ry NC C NO Off Off High/Low DIP Switch Con figuration (Model9 61 Line-pow ered) Norm al Alarm Norm al Alarm Energized De -energized Energized De -energized

2.5.1.5 Independent/JointD IP Switch

Th e I/JD IP switch isusedtoconfigurewh etherthe SPDT malfunction relayactsindependentlyorjointlyw iththe DPD T processlevelrelay.T he factorydefaultisforthis switch tobe in the “I”position,w here therelaysacttotally independentofeach other.IfthisDIP switch isin the“J” position,both the SPD T m alfunction relay and the DPD T processrelaywillde-energize w hen a faultisdetected.

15 51-646 Echotel ® Model 961 & 962 UltrasonicLevelSwitches TIME DELAY FAULT TEST MODEL 961 Hi 22 Lo 3.6 LOOP TEST 8 16 F A U L T High/Low DIP Switch 22/3.6 mA DIP Switch Fault Test Push Button Loop Test Push Button Time Delay Pot to decrease delay to increase delay Turn Turn Figure15 Mod el961 Loop Power Configuration

2.5.2 Mod el961 Loop-powered C onfiguration

Mo del961 loop-pow ered unitshavethe followingconfig - uration options:

• TIM E D ELA Y potentiometerfor0.5to45 second signal averaging
• LOO P TES T push button fortesting the 8/16 mA loop output
• FAULT T EST pushbutton fortesting the 3.6or22 mA faultoutput
• Hi/Lo D IPswitchforfail-safe high orlow levelselection
• 22/3.6DIP switch to selectthe faultm A currentoutput

2.5.2.1 Time D elay Potentiometer

The time delaypotentiome teristypicallyused inapplica - tionsw here turbulence orsplashing may cause falselevel alarms.Thisisa 25-turn potw itha factorydefaultsetting of0.5 seconds.Ifdesired,thispotm aybe turned clockwise toincreasethe responsetim e from the standard0.5 seconds toa m aximu m of45 seconds.T urning the potcounter - clockwisedecreasesthetime delay.

2.5.2.2 Loop TestPush B utton

Th e loop testpushbutton isusedto m anuallytestthe loop currentoutput.Pressing theLO OP T EST pushbutton reversesthe outputfrom 8 mA to16 mA orfrom 16 mA to8 m A.Thiscanbe used tom anuallytestthe loopout - putand whateverisconnected to the961.T he timedelay potdoesnotaffectthe operation ofthe loop testpush button.

2.5.2.3 FaultTestPush B utton

The FAULT TEST push button isusedto ma nuallyforce the961 to them A valuethatisselected atthe 22/3.6DIP switch.Pressing thispush button for2 secondsw illsimu - latea circuittestfailure.T hiscausesthe outputtogo to theselected faultcurrentofeither22 or3.6mA ,and the red FAULT L ED w illlight.The tim e delaypotdoesnot affecttheoperation ofthe FAULT TES T push button. N OTE: Faultcurrentw illbe greaterthan 21 mA, orless than3.6mA.

16 51-646 Echotel ® Model 961 & 962 UltrasonicLevelSwitches

2.5.2.4 H igh/Low DIP Switch

The Hi/Lo DIP sw itch isused to selectwhetherthe 961 willbe usedashighlevelfail-safeswitchorlowlevelfail-safe switch.No rmalprocessleveloperation producesan 8 mA value,and 16 m A isproduced w hen the unitisina level alarmstate.The tablecan be used to assistinconfiguring theHi/Lo DIP switch. 2.5.2.5 22/3.6D IPSw itch The 22/3.6DIP switch isused toselectw hetherthe961 willproduce a 22 m A ora 3.6 m A outputwhen theunit detectsa faultcondition. NO TE: Faultcurrentw illbe greaterthan21 mA, orlessthan 3.6mA. Hi/Lo DIP Switch Gap C ondition Level C ondition Output Signal 8 mA LE D 16 mA LE D FAULT LE D H i (HLFS ) D ry 8 m A (±1m A) On Off Off Wet 16 m A (±1m A) Off On Off Lo (LLFS ) Wet 8 m A (±1m A) On Off Off D ry 16 m A (±1m A) Off On Off High/Low D IPSwitchC onfiguration (Model96 1 Lo op-powered) NOTE: The FAULT LED onlyturnson duringa faultcondition. Norm al Alarm Norm al Alarm

17 51-646 Echotel ® Model 961 & 962 UltrasonicLevelSwitches

2.5.3 Mo del962 Line-powe red C onfiguration

Mo del962 line-pow ered unitshavethe follow ing configu - ration options:

• TIM E D ELA Y potentiometerfor0.5to45 second signal averaging
• LE V EL T EST pushbutton fortesting ofthe SPDT processlevelrelays
• MA LF TEST push button fortesting ofthe SPDT mal - function relay
• Hi/Lo D IPswitchforfail-safe high orlow levelselection
• PC/ LC D IPswitch forlevelcontrolorpum p control operation

2.5.3.1 Time D elayPotentiometer

The time delaypotentiome teristypicallyused inapplica - tionsw here turbulence orsplashing may cause falselevel alarms.Thisisa 25-turn potw itha factorydefaultsetting of0.5seconds.Ifdesired,thispotm aybe turned clock - wise toincrease the response time from the standard0.5 secondstoa m aximum of45 seconds.T urningthepot counterclockw ise decreasesthe time delay.

2.5.3.2 LevelTestPush Bu tton

The LE V EL TEST push button isusedto m anuallytest both ofthe SPD T processlevelrelays.Pressing thispush button reversesthestate ofbothSPD T processlevelrelays, from energized to de-energized orvice-versa.Thiscanbe used tom anuallytestthese relays,and w hateveriscon - nected tothem .T he time delaypotdoesnotaffectthe operation oftheL EVEL T EST pushbutton.

2.5.3.3 Malfunction TestPush B utton

The M ALF TES T pushbutton isused to m anuallytest theSPDT malfunction relay.Pressing and holdingthis pushbutton for2 secondsw illcauseallthreerelaysto de-energize,indicating a faultcondition.Thiscanbe used tom anuallytesttherelay,and whateverisconnectedto thisrelay.The time delaypotdoesnotaffecttheoperation ofthem alfunction pushbutton. NOT E: U ndernorm aloperating conditions the red faultLED isoffand the green malfunction LED is on, indicating that the m alfunction relay is energized.Shou lda faultcondition occur, the red fault LED turnson and the green ma lfunction LED turnsoff,indicating thatthe m alfunction relay isde-energized. TIME DELAY LEVEL TEST MALF TEST MALF RELAY FAULT MALF LOWER UPPER MODEL 962 NC C NO NC C NO NC C NO L2 L1 Hi PC Lo LC LOWER UPPER High/Low DIP Switch Pump Control/Level Control DIP Switch Level Test Push Button Malfunction Test Push Button Time Delay Pot to decrease delay to increase delay Turn Turn Figure 16 Mod el962 LinePower Configuration Operating Cond ition R ed FaultLE D Green M alfunction LE D Normal Off On Fault On Off Faultand M alfunction LE D Indication

18 51-646 Echotel ® Model 961 & 962 UltrasonicLevelSwitches

2.5.3.4 High/Low DIP Sw itch

The Hi/Lo DIP sw itch isused to selectwhetherthe 962 willbe used asa high levelfail-safe(HL FS) switch orlow levelfail-safe(LL FS) switch.T he setting oftheH i/Lo DIP alsoaffectshow the PC/ LC D IPsw itch configuresthe unit.Read Section 2.5.3.5below and then proceed tothe settingoftheD IPswitches.

2.5.3.5 PC/LC D IPSw itch

The PC/ LC D IPswitchisusedto selectw hetherthe962 willoperateina pum p controlora levelcontrolmod e. SelectLC touse the962 asa levelcontrollerw herethe relaysoperateindependentlyofeach other.SelectPC to operatethe962 asa pum p controllerw herethe relayslatch toenablean auto fillorauto em ptym ode. used forpropersetting oftheH i/Lo and PC/LC DIP switches.They alsoindicate the statusofthe yellow LOW ER and UP PER LED s.The green MA LF (malfunc - tion) LED and thered FAULT L ED sarenotincluded in thesetables.

2.5.3.6 LC and Hi/Lo D IP Sw itchC onfiguration Table

Hi energized On energized On Lo de-energized Off de-energized Off Hi de-energized Off energized On Lo energized On de-energized Off Hi de-energized Off de-energized Off Lo energized On energized On LevelCon trol (DIPsw itchsettoLC) NOTE: During a faultconditionallthreerelaysde-energize

19 51-646 Echotel ® Model 961 & 962 UltrasonicLevelSwitches

2.5.3.7 PC and H i/Lo DIP Sw itchCon figuration Tables

Hi energized On energized On Hi energized On energized On Hi de-energized Off de-energized Off Hi de-energized Off de-energized Off Hi energized On energized On Pum p C ontrol (DIPsw itch settoPC) Auto-em ptyPum p C ontrolSequ ence NOTE: During a faultconditionallthreerelaysde-energize Level Condition Hi/Lo DIP Sw itch Low erGap Upper Gap Relay LE D Relay LE D Lo de-energized Off de-energized Off Lo de-energized Off de-energized Off Lo energized On energized On Lo energized On energized On Lo de-energized Off de-energized Off Pum p C ontrol (DIPsw itch settoPC) Auto-fillPum p C ontrolSequ ence NOTE: During a faultconditionallthreerelaysde-energize

20 51-646 Echotel ® Model 961 & 962 UltrasonicLevelSwitches

2.5.4 Mod el962 Loop-powe red C onfiguration

Mo del962 loop-pow ered unitshavethe following config - uration options:

• TIM E D ELA Y potentiometerfor0.5to45 second signal averaging
• LOO P TES T push button fortesting the 8/12/16 mA loop output
• FAULT T EST pushbutton fortesting the 3.6or22 mA faultoutput
• Hi/Lo D IPswitchforfail-safe high orlow levelselection
• 22/3.6DIP switch toselectthe faultm A currentoutput

2.5.4.1 Time D elayPotentiometer

The time delaypotentiome teristypicallyused inapplica - tionsw here turbulenceorsplashing may cause falselevel alarms.Thisisa 25-turn potw itha factorydefaultsetting of0.5seconds.Ifdesired,thispotm aybe turned clock - wise toincrease the response time from the standard 0.5 secondstoa m aximum of45 seconds.T urning thepot counterclockw ise decreasesthe time delay.

2.5.4.2 Loop TestPush B utton

The loop testpush button isused to man uallytestthe loop currentoutput.Pressing theLO OP T EST pushbut - ton w illforcetheoutputfrom 8 mA to12 mA ,12 mA to 16 m A, or16 m A to 8 m A.Thiscan be used to manually testtheloop outputand w hateverisconnected tothe962. The time delaypotdoesnotaffectthe operation ofthe loop testpush button.

2.5.4.3 FaultTestPush B utton

The FAULT TEST push button isusedto man uallyforce the962 to them A valuethatisselected atthe 22/3.6DIP switch.Pressing thispush button for2 secondswillsimu - latea circuittestfailure.T hiscausesthe outputtogo to theselected faultcurrentofeither22 or3.6mA ,and all3 LEDs w illgo dark.The time delaypotdoesnotaffectthe operation oftheFAULT T EST pushbutton. NOT E: Faultcurrentw illbe greaterthan 21 mA, orless than 3.6m A. TIME DELAY FAULT TEST MODEL 962 Hi 22 Lo 3.6 LOOP TEST 8 12 16 High/Low DIP Switch 22/3.6 mA DIP Switch Fault Test Push Button Loop Test Push Button Time Delay Pot to decrease delay to increase delay Turn Turn Figure17 M odel962 Loop Power Configuration

21 51-646 Echotel ® Model 961 & 962 UltrasonicLevelSwitches

2.5.4.4 H igh/Low DIP Switch

The Hi/Lo DIP sw itch isused to selectwhetherthe962 willbe used ashighlevelfail-safe sw itch orlow levelfail- safe switch.No rmalprocessleveloperation producesan 8 m A value,and 16 mA isproduced w hen the unitisin a levelalarm state.T he tablebelow canbe used toassistin configuringtheHi/Lo D IPswitch: 2.5.4.5 22/3.6D IPSwitch The 22/3.6DIP switch isused toselectw hetherthe962 willproduce a 22 mA ora 3.6mA outputw hen theunit detectsa faultcondition. N OTE: Faultcurrentw illbe greaterthan 21 mA orlessthan 3.6m A. Hi/LoDIP Switch Level Cond ition Output Signal 8 mA Green LE D 12 mA YellowLE D 16 mA Red LED Hi (HLFS) 8 m A (±1m A) On Off Off 12 m A (±1m A) Off On Off 16 m A (±1m A) Off Off On Lo (LLFS ) 8 m A (±1m A) On Off Off 12 m A (±1m A) Off On Off 16 m A (±1m A) Off Off On High/Low D IPSw itchC onfiguration (Model962 Loo p-powered) NOTE: During a faultconditionallthreeLEDs willturnoff

22 51-646 Echotel ® Model 961 & 962 UltrasonicLevelSwitches

3.0 Reference Information

3.1 ElectronicsSpecifications

3.1.1 M odel96 1/962 w ith R elay Output

SupplyVoltage 102 to265 VAC, or18 to32 VD C RelayOutputs 961 : One DPD T levelrelay and one SPDT m alfunctionrelay 962 : Two SPDT levelrelays and one SPD T ma lfunctionrelay RelayRatings DPD T: 5 amps @ 120 VAC, 250 VAC, and 30 VDC, 0.15amp @ 125 VDC SPDT : 5 am ps @ 120 VAC ,250 VAC, and 30 VDC, 0.15amp @ 125 VDC Fail-safe Selectableforhigh orlow level Pow erConsum ption 961 /96 2: Less than 3 wa tts Am bientTem perature -40° to+16 0°F (-40°to+71° C)

3.1.2 M odel96 1/962 w ith C urrentShiftOutput

Sup plyVoltage 11 to35 VD C CurrentShiftOutput Norma lOperation: 8 mA LevelAlarm Con dition: 16 mA Malfunction: 3.6m A or22 mA selectable Lo op Resistance 104 ohms with11 VDC input,1100 ohms with35 VD C input Fail-safe Selectableforhigh orlow level Pow erConsum ption 961/962 Less than 1 wa tt Am bientTem perature -40° to+16 0°F (-40°to+71° C)

3.2 Performan ce Specifications

Repeatability ±0.078" (2mm ) Response Time 1⁄2 second typical Time Delay Variable 0.5– 45 seconds on risingand fallinglevels Self-Test Automatic: Co ntinuouslyverifiesoperation ofelectronics,transducer, piezoelectriccrystals,and electricalnoise Ma nual: Push buttonverifiesoperation ofelectronics,transducer, and piezoelectriccrystals Sho ck Class ANSI/ISA-S71.03ClassSA1 Vibration Class ANSI/ISA-S71.03ClassVC2 Humid ity 0 – 99%, non-condensing ElectromagneticCo mp atibility Me etsCE requiremen tsEN 6132 6

3.3 PhysicalSpecifications

Ho usingMa terial Cast aluminum A356-T6, orcast316 stainlesssteel Cable Entry 3⁄4" N PT,orM20 Gross Weight 961/9 62 Electronics: 2.2lbs.(1.0kg) 2" (5cm )Transducer: 0.6lbs.(0.3kg)

23 51-646 Echotel ® Model 961 & 962 UltrasonicLevelSwitches

3.4 Transducer Specifications

3.4.1 M odel9A1/9M1 Single Point

TransducerMaterial MaterialCode (Section3.9.2) OperatingTemperatureRange Maximum Pressure ActuationLength

316 StainlessSteel AŒ,S,N, K -40°to+325° F (-40°to+163° C) 2000psi(138bar) 1" and 2" (3and 5 cm)

316 StainlessSteel AŒ,S,N, K -40°to+325° F (-40°to+163° C) 1500 psi(103bar) 3" to130" (6 to330 cm)

HastelloyC-276 B -40°to+325° F (-40°to+163° C) 2000psi(138bar) 1" and 2" (3and 5 cm) HastelloyC-276 B -40°to+325° F (-40°to+163° C) 1500 psi(103bar) 3" to130" (6 to330 cm) Monel C -40°to+325° F (-40°to+163° C) 1200psi(83bar) 1" to130" (3to330 cm) Kynar ® R -40°to+250°F (-40°to+121° C) see graphsbelow 2" to130" (5to330 cm) CPVC P -40°to+180°F (-40°to+82° C) see graphsbelow 2" to130" (5to330 cm) TransducerMaterial MaterialCode (Section3.9.3) OperatingTemperatureRange Maximum Pressure ActuationLength

316 StainlessSteel A,K -40°to+325° F (-40°to+163° C) 1500 psi(103bar) 5" to130" (13to330 cm)

CPVC P -40°to+180°F (-40°to+82° C) see graphsbelow 5" to130" (13to330 cm)

3.4.2 M odel9A2/9M2 Du alPoint

-40 0 60 120 180 240 Pressure (psi) Temperature (°F) -40 0 40 80 120 Pressure (bar) Temperature (°C) Range with PN16 flange Range with 150# flange Range with "NPT 300 250 200 150 100 -40 0 40 80 120 160 200 Pressure (psi) Temperature (°F) -40 0 40 80 120 Pressure (bar) Temperature (°C) Kynar Transducer Ratings CPVC Transducer Ratings Œ Model 9A1/9M1 MaterialCode “A”has a CryogenicTransducerOptionfor-110°to+250°F (-80°to+120°C)operatingtemperaturerange  Minimum pressureforalltransducersis-10psi(-0.7bar)

24 51-646 Echotel ® Model 961 & 962 UltrasonicLevelSwitches Mo del96 1 withHygienicHousing and Tri-Clamp ® 16 AM P Fitting M odel961 withCast Alum inum Housing and NP T Conn ection M odel961 withCast StainlessSteel Housing and A NSI Flange 1.8 (46) Typical 1.05 (26) Typical 4.00 (102) 4.00 (102) Actuation length for Tri-Clamp fitting 4.43 (113) 4.43 (113) Actuation length for NPT connection Actuation length for ANSI flange 2.35 (60) Typical 5.24 (133) 5.75 (146) Mo del961 with C astA luminum Housing and CPV C Flange M odel961 withCast A luminum Housing and Kynar Flange 4.00 (102) 4.00 (102) ∅ .875 (22) 4.43 (113) 0.25 (6) Actuation length for Kynar flange 2.35 (60) Typical ∅ .875 (22) 4.43 (113) 0.25 (6) Actuation length for CPVC flange 2.35 (60) Typical

3.5 Dimen sionalSpecifications

Inches(mm)

25 51-646 Echotel ® Model 961 & 962 UltrasonicLevelSwitches Actuation length A Actuation length B ∅ .875 (22) Dia. 4.00 (102) 4.43 (113) 1.8 (46) Typical 0.25 (6) 3.50 (89) 2.75 (70) 2.00 (51) 3.00 (76)

2 Holes

.38 (10) dia. 4.00 (102) 4.00 (102) 3.95 (100) 4.43 (113) ∅ .875 (22) 0.25 (6) Actuation length for NPT connection 1.8 (46) Typical Mo del96 1/96 2 with Remote E lectronics Remote Transducer withNP T Co nnection Mo del962 withNPT Con nection Actuation length A Actuation length B ∅ .875 (22) Dia. 4.00 (102) 4.43 (113) 2.35 (60) Typical 0.25 (6) Mod el962 withA NSI Flange

3.5 Dim ensionalSpecifications

Inches(mm)

26 51-646 Echotel ® Model 961 & 962 UltrasonicLevelSwitches

3.6 Agency Approvals

A G EN CY APP RO VED MODELS PROTECTION METHOD ARE A CLASSIFICATION FM & CS A 96X -X0A0-X10 ExplosionProof ClassI,D iv.1,Groups B ,C,& D 96X -X0A0-X11 ClassII,Div.1,Groups E,F ,& G 96X -X0A0-X12 ClassIII,Type 4X,IP66 ,T6 96X -X0A0-X13 96X -X0A1-X10 9 6X -X0A1-X11 96X -XDA 0-X30 96X -XDA 0-X31 96X -XDA 0-X32 96X -XDA 0-X33 96X -XDA 1-X30 96X -XDA 1-X31 w ithtransducers 9A X-XXX X-XXX or 9M X-XXX X-XXX 96X -XXAX-XXX or Non-Incendive ClassI,Div.2,Groups A,B, C,& D w ithtransducers ClassII,Div.2,Groups E,F ,& G 9A X-XXX X-XXX or ClassIII,Type 4X,IP66 ,T4 9M X-XXX X-XXX 96X -50AX-X1X IntrinsicallySafe ClassI,Div.1,Groups A,B, C,& D w ithtransducers ClassII,Div.1,Groups E,F ,& G 9A X-XXX X-XXX or ClassIII,Type 4X,IP66 ,T4 9M X-XXX X-XXX ATE X 96X -XXAX-XC0 Flame Proof Ex II1/2 G, EEx d IIC T6 96X -XXAX-XC1 96X -XXAX-XC2 96X -XXAX-XC3 w ithtransducers 9XX -AXXX-XXX 9XX -SXXX-XXX 9XX -BXXX-XXX 9XX -CXXX-XXX 9XX -NXXX-XXX 9XX -K XXX-XXX 96X -50AX-XA0 IntrinsicallySafe Ex II1 G, EEx ia IIC T5 96X -50AX-XA1 96X -50AX-XA2 96X -50AX-XA3 w ithtransducers: 9XX -AXXX-XXX 9XX -SXXX-XXX 9XX -BXXX-XXX 9XX -CXXX-XXX 9XX -NXXX-XXX 9XX -K XXX-XXX INME TR O ConsultFactoryfor ExplosionProof BR -Ex d IICT6 IP66 W Approved Mod els IntrinsicallySafe BR-Ex ia IICT5 IP66 W These units have been tested to EN 61326 and are in compliance with the EMC Directive 2004/108/EC. Alltransducers(except HygienicConnections 3T, 4T & VV from page 33) comply with Canadian ElectricalCode require - ments of ANSI/ISA 12.27.01 -2003 as a single sealdevice

2751-646 Echotel® Model 961 & 962 Ultrasonic Level Switches

3.6.1 Agency (FM/CSA) Drawing and Entity Parameters

28 51-646 Echotel ® Model 961 & 962 UltrasonicLevelSwitches

3.7 Troubleshooting

C aution: Inhazardous areas,do notremove thehousingcoveruntil powe ris disconnectedand theatmosphereisdetermined tobe safe. The M odel961/ 962 hasa unique diagnosticsfeature to assistintroubleshootingshoulda failureoccur.A micro - processorintheelectronicscontinuouslym onitorsallself- testdata.Shoulda faultoccur,the microprocessorcan determine whetherthe malfunction isdue tothe electron - ics,transducer,piezoelectriccrystals,orthe presenceof environme ntalnoise.A push button and FaultLED is used toassistintroubleshooting the switch:

• On e flashofthe FaultL ED indicatesa problem w ith the transducer,piezoelectric crystals,orthe interconnection wiring
• T w o flashesoftheFaultL ED indicatesa problem withone oftheelectronicsboards
• Threeflashesofthe FaultLED indicatespresence ofexces - sivelevelsofenvironme ntalnoise Ifa faultcondition isdetected by a line-pow ered961/962, theM ALF LED willturn offindicating thattheMA LF relayhasbeen de-energized,and the FAULT LED will turn on.Ifa faultcondition isdetected by a loop-pow ered 961, the8 and 16 m A LED turn off,and the FAULT LED willturn on.Ifa faultcondition isdetected by a loop-powered 962, allthree LED sw illturn off. The push button indicated below shouldbe pressed and heldw hileobserving the LED : IftheabovediagnosticL ED flashesoncew hen thepush button ispressed,the mostcom m on issue istheintercon - nection wiring between the electronicsand the transducer. Che ck allw iring inside thehousing to make surethatall wiresaresecurein theirrespectiveterminalblocks.Make sure thatalltheterminalblock screwsarefullytightened. Ifallw iresare secure thencontactthe factory.A replace - me nttransducerm aybe needed.See Section 3.9,Mod el Num ber,forproperreplacem entpartnumbe rs. E lectronicsVersion Push B utton LE D 961 with5 am p relays LEVEL TES T FAULT 961 withcurrentshift LOOP TES T FAULT 962 with5 am p relays LEVEL TES T FAULT 962 withcurrentshift LOOP TES T 16 m A

29 51-646 Echotel ® Model 961 & 962 UltrasonicLevelSwitches T w o flashesoftheL ED indicatesan issuew iththeelec - tronicsm odule.Con tactthe factoryfora replacement electronicsmo dule.See Section 3.8forspareelectronics mo dulepartnum bers. Environm entalnoiseisthe issue ifthe diagnostic L ED flashesthree tim es.Co mmo n sourcesofenvironmental noise areconducted electricalnoise from a V FD (variable frequency drive),radiated electricalinterferencefrom a two-way radio transceiver,ormechanicalvibration from som e nearby source.T hisnoise couldaffectthe 961/962 and otherelectricalinstrum entation.Che ck to see ifany oftheabovelisted sourcesmay be causing the interference and correctthe issue toensureproperoperation ofthe unit. Itisalso possiblethatapplication related issuesmay be affectingtheproperoperation ofthe 961/962 unit.The tablebelow assistsin troubleshooting. PR OB LE M A CTION No signalw ith levelchange C heck w iringtom ake sureproperinputvoltageissupplied. M ake sure liquidisreachingthe gap.Ifinstalledina riserorstandpipe,make surea ventis providedsuch thatliquidcan enterthe pipeand wet thetransducergap. C heck fordense foam on surfaceordriedproductinthegap. U nitmay notfunctionproperlyifeitherconditionexists. No change inoutputbetween wet gap ordrygap C heck tosee iftransducergap isplugged withsolids. C heck fordense foam ingap. The switch ischattering C heck forproperinputvoltagesupply. C heck forturbulence.Relocateswitchorisolatefrom turbulence. C heck forexcessiveaeration.

30 51-646 Echotel ® Model 961 & 962 UltrasonicLevelSwitches M odel961/ 962 Com mon Parts

3.8 Replacement Parts

Item D escription PartNu mbe r

1 Ca stAluminum Cove rwithoutWindow 089-66 07-005

1 C astAluminum Cove rwithWindow 036-4410-010

1 Ca st316 SS Cover w ithoutWindow 089-66 07-006

1 D eep D rawn SS Hygienic C overw ithoutWindow 036-5702-003

1 D eep D rawn SS Hygienic C overw ithW indow 036-5702-002

2 O-Ringwith C astAluminum or316 SS Ho using 012-2201-237

2 O-Ringwith Deep Dr aw n SS H ygienicHo using 012-2201-155

3 B ezel& ElectronicsMo dule Ki t See table below

4 Ca stAluminum Rem oteTransducerH ousingCove r 004-9193-002

4 Ca st316 SS Remote TransducerH ousing Co ver 004-9193-006

5 Transducer See Mod elN umb er

M odel961 E lectronicsM odules with Cast Aluminum or316 SS Housings Item D escription PartNu mbe r 3 102 to 265 VAC Line-powe red Mod ule 089-7259-001 3 18 to 32 VDC Line-powe redMod ule 089-7259-002 3 11 to 35 VDC Loop-pow eredMo dule 089-7259-003 M odel961 E lectronicsM odules with Deep Drawn SS HygienicHo using Item D escription PartNu mbe r 3 102 to265 VAC Line-powe redMod ule 089-7256-001 3 18 to 32 VDC Line-powe redMod ule 089-7256-002 3 11 to 35 VDC Loop-pow eredMo dule 089-7256-003 M odel962 E lectronicsM odules with Cast Aluminum or316 SS Housings Item D escription PartNu mbe r 3 102 to265 VAC Line-powe redMod ule 089-7258-001 3 18 to 32 VDC Line-powe redMod ule 089-7258-002 3 11 to 35 VDC Loop-pow eredMo dule 089-7258-003 M odel962 E lectronicsM odules with Deep Drawn SS HygienicHo using Item D escription PartNu mbe r 3 102 to265 VAC Line-powe redMod ule 089-7257-001 3 18 to 32 VDC Line-powe redMod ule 089-7257-002 3 11 to 35 VDC Loop-pow eredMo dule 089-7257-003

3151-646 Echotel® Model 961 & 962 Ultrasonic Level Switches 2 4 Model 961/962 Model 961/962 Remote Transducer

32 51-646 Echotel ® Model 961 & 962 UltrasonicLevelSwitches

3.9 Mo delNum ber

3.9.1 961/ 962 E lectronics Œ Not availablewithhousingcodes 4 & 5  ExplosionProofapprovalsnotavailablewith housingcodes 4 & 5

961 Single-pointelectronics

962 D ual-pointelectronics

2 18 to32 VDC line-powered 5 11 to35 VDC loop-powered 7 102 to26 5 VAC line-powered INPU T PO WER 0 m A currentshift(availablewithInputPower code 5) D 5 am p goldflashrelays(availablewithInputPower codes 2 or7) OU TPU T SIGNAL

0 Integral

1 Rem oteΠ(requires ConnectingCable from page 35)

1 FM/ CSA Intrinsicallysafe,No n-Incendive

& ExplosionProo f  (usewithcurrentshift OutputSignalcode 0 ) FM/C SA Explosion Proof& Non-Incendive (use w ithrelayOu tputSignalcode D , and Housing codes 0,1,2 & 3)

7 FM/ CSA Non-incendive(availablewithOutputSignal

codes 0 & D and Housing codes 4 & 5) A ATEX II1G EEx iaIIC T5,Intrinsicallysafe (availablewithOutputSignalcode 0) C ATEX II1/2GEEx d IIC T6, Explosionproof (availablewithOutputSignalcode 0 orD) AGEN CY A PPR O VA L

0 Cast aluminum with3⁄4" NP T dualconduitentries

1 Cast aluminum withM 20 dualconduitentries

2 Cast SS with3⁄4" NP T dualconduitentries

3 Cast SS withM 20 dualconduitentries

4 D eep drawn SS with1⁄2" NP T dualconduitentries

5 D eep drawn SS withM2 0 dualconduitentries

0 Standardhousingcover

1 Glasswindow cover(availablewithElectronicsHou singcodes 0,1,4 or5)

33 51-646 Echotel ® Model 961 & 962 UltrasonicLevelSwitches

3.9.2 M odel961 SinglePointTransducer

A English(lengthininches) M Metric(lengthincentimeters) TRA N SDUCE R UN ITOF LEN GTH A 316 /316L stainlesssteel S 316 /316L with20 Ra hygienicfinish(useonlywithProcessConnection codes 3T,4T,orVV) B H astelloyC-276 C M onel R K ynarŽ (useonlywithProcessConnectioncodes 11,23,33,43,B A,CA,D A) P C PVC (use onlywithProcess Connectioncodes 11,23,33,43,BA ,CA ,D A) N 316/316 L stainlesssteel,NACE construction K 316/316 L stainlesssteel,ASME B31.1&B31.3construction MATER IAL S O FCON STR UC TION PR O CESS CO NNECTI O NS 11 3⁄4" NP T 21 1" NP T 22 1" B SP (G1) THR EAD ED CO NN ECTI ON S 23 1" 150# ANSI RF flange 24 1" 300#ANSI RF flange 25 1" 600# ANSI RF flange 33 11⁄2" 150# ANS IRF flange 34 11⁄2" 300#ANS IRF flange 35 11⁄2" 600# ANS IRF flange 43 2" 150# ANSI RF flange 44 2" 300#ANSI RF flange 45 2" 600# ANSI RF flange AN SIR AISED FAC E FLA N GES 3T 11⁄2" Tri-Clamp ® 16 AMP fitting 4T 2" Tri-Clam p ® 16 AM P fitting VV D N65 – Varivent HY GIENIC C O N NECTI O NS B A D N 25 PN 16 EN 1092-1 Type A BB D N 25 PN 25/40EN 1092-1 Type A BC D N 25 PN 63/100 EN 1092-1 Type B2 C A D N 40 PN 16 EN 1092-1 Type A C B D N 40 PN 25/40EN 1092-1 Type A C C D N 40 PN 63/100 EN 1092-1 Type B2 D A D N 50 PN 16 EN 1092-1 Type A D B D N 50 PN 25/40EN 1092-1 Type A D D D N 50 PN 63 EN 1092-1 Type B2 D E D N 50 PN 100 EN 1092-1 Type B2 EN/D IN FLA NGES Ž Kynar flangedtransducershave Kynar faced316 stainlesssteelflanges 1" to 130" in1" increments(Example:4 inches=004) 1" m inimum forNPT processconnections 2" m inimum forB SP ,hygienic,and flanged processconnections 2" m inimum forallKynar transducers 3 cm to330 cm in1 cm increments(Example:6 centimeters=006) 3 cm minimum forNPT processconnections 5 cm minimum forBSP ,hygienic,and flangedprocessconnections 5 cm minimum forallKynar transducers ACTU ATION LENGTH (unitoflengthspecified insecond digit) A Standard design C Cryogenicdesignto-110°F (-80°C)(availablewithMaterialscode A) TRA NS DU CER O PTIO NS

34 51-646 Echotel ® Model 961 & 962 UltrasonicLevelSwitches

3.9.3 M odel96 2 D ualPointTransducer

A English(lengthininches) M Metric(lengthincentimeters) TRA N SDUCER UNIT OF LEN GTH A 316 /316L stainlesssteel P C PVC (use onlywithProcessConnectioncodes 11,23,33,43,BA ,CA ,D A) K 316/316 L stainlesssteel,ASME B31.1&B31.3construction MATE RIAL S O FC ONS TRU CTION 11 3⁄4" NP T 21 1" NP T 22 1" B SP (G1) TH REA DED CO NN ECTI O NS PR O CESS CO NNECTI O NS Actuation length A Minimum distance between actuation points A and B is 3" (8 cm) Maximum distance between actuation points A and B is 128" (325 cm) Actuation length B Important: Use the “A” dimensionas the actuation lengthcode.The “B ” dimensionm ustalsobe specifiedinquote/order. Example: For a 96 2 withan “A”dimen - sionof18" and a “B” dimen - sionof7" ,specifyactuation lengthcode 018. 5" to 130" in1" increments 5" m inimum forNPT processconnections 6" m inimum forB SP ,and flangedprocessconnections Exam ple:5 inches =005 13 cm to330 cm in1 cm increments 13 cm minimum forNPT processconnections 15 cm minimum forBSP ,and flangedprocess connections Exam ple:13 centimeters=013 “A” D IMENS ION A CTUATI O N LENGTH (unitsspecifiedinsecond digit) 23 1" 150# ANSI RF flange 24 1" 300# ANSI RF flange 25 1" 600# ANSI RF flange 33 11⁄2" 150# ANS IRF flange 34 11⁄2" 300#ANS IRF flange 35 11⁄2" 600# ANS IRF flange 43 2" 150# ANSI RF flange 44 2" 300# ANSI RF flange 45 2" 600# ANSI RF flange A NS IRA ISED FACE FLA NGES B A D N 25 PN 16 EN 1092-1 Type A BB D N 25 PN 25/40EN 1092-1 Type A BC D N 25 PN 63/100 EN 1092-1 Type B2 C A D N 40 PN 16 EN 1092-1 Type A C B D N 40 PN 25/40EN 1092-1 Type A C C D N 40 PN 63/100 EN 1092-1 Type B2 D A D N 50 PN 16 EN 1092-1 Type A D B D N 50 PN 25/40EN 1092-1 Type A D D D N 50 PN 63 EN 1092-1 Type B2 D E D N 50 PN 100 EN 1092-1 Type B2 EN /DIN FLAN GES

35 51-646 Echotel ® Model 961 & 962 UltrasonicLevelSwitches

3.9.4 Co nnectingCa ble

M aximum Leng th: 150 feet M inimum Length: 10 feet Exam ple:12 feet=012 CON NECTI NG CA BL E LENGTH (FEET) 037 331

6 Rem otecableforM odel961

7 Rem otecableforM odel962

BULLETIN: 51-646.2 EFFECTIVE: June 2010 SUPERCEDES: January 2009 5300 Belmont Road • Downers Grove, Illinois 60515-4499 • 630-969-4000 • Fax 630-969-9489 • www.magnetrol.com

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 Owners of MAGNETROL controls 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. Controls returned under our service policy must be returned by Prepaid transportation. MAGNETROL will repair or replace the control at no cost to the purchas- er (or owner) other than transportation if: 1. Returned within the warranty period; and 2. The factory inspection finds the cause of the claim to be covered under the warranty. If the trouble is the result of conditions beyond our con- trol; or, is NOT covered by the warranty, there will be charges for labor 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, labor, direct or consequen- tial damage will be allowed. Return Material Procedure So that we may efficiently process any materials that are returned, it is essential that a “Return Material Authorization” (RMA) number be obtained from the fac- tory, prior to the material’s return. This is available through a MAGNETROL local representative or by contacting the factory. Please supply the following information: 1. Company Name 2. Description of Material 3. Serial Number 4. Reason for Return 5. Application Any unit that was used in a process must be properly cleaned in accordance with OSHA standards, before it is returned to the factory. A Material Safety Data Sheet (MSDS) must accompany material that was used in any media. All shipments returned to the factory must be by prepaid transportation. All replacements will be shipped F .O.B. factory. NOTE: See Electrostatic Discharge Handling Procedure on page 5. ASSURED QUALITY & SERVICE COST LESS MAGNETROL, MAGNETROL logotype and ECHOTEL are registered trademarks of MAGNETROL INTERNATIONAL, INCORPORATED. Kynar® is a registered trademark of Elf Atochem North America, Inc. Hastelloy® is a registered trademark of HAYNES INTERNATIONAL, INC. (DELAWARE CORPORATION). Monel® is a registered trademark of the INCO family of companies.