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MAGNETROLNON-CONTACT ULTRASOUND
The Total Spectrum of Solutions
Magnetrol products employ a number of
technologies to meet the challenges of
level and flow measurement. Echotel
non-contact transmitters and controllers
utilize high frequency sound waves for
accurate and reliable measurement of
liquid level, volume, and open channel flow.
3
Magnetrol International
—a world leader in level and
flow measurement technology—
designs, manufactures, markets and
services level and flow instrumenta-
tion worldwide.
Magnetrol’s product groups are
based upon these technologies:
• Buoyancy
• Contact Ultrasound
• Non-Contact Ultrasound
• Guided Wave Radar
• RF Capacitance
• Thermal Dispersion
• Vibration
• Visual Indication
The industries we serve include:
• Petroleum Production
• Petroleum Refining
• Power Generation
• Petrochemical
• Chemical
• Water & Wastewater
• Pulp & Paper
• Food & Beverage
• Pharmaceutical
An Introduction to Ultrasonic Level Sensing
• Measuring with Ultrasound
• Assuring Signal Integrity
• Technology Advantages and Limitations
• Echotel Products at a Glance
Echotel Non-Contact Ultrasonic Products
• Model 300/301
• Model 335
• Model 338
• Model 344/345
• Model 350/351
• Model 3P1
4
5
6
7
8
9
10
11
4
5
4
Non-contact ultrasonic level technology is a
proven method for accurate liquid level meas-
urement. Process control instruments utilizing
this technology sense and measure liquid level, volume,
or open channel flow without making physical contact
with the liquid itself. This offers distinct advantages
over many contact technologies in applications where
corrosive media, suspended solids, changing media
characteristics, or coating media are present.
MMeeaassuurriinngg wwiitthh UUllttrraassoouunnddTwo components make
up a typical non-contact
ultrasonic measurement
device: the transmitter, or
electronics; and the trans-
ducer, or sensor. A piezo-
electric crystal within the
transducer converts electrical
signals generated by the
transmitter into a series of
ultrasonic pulses. Under
ideal conditions, these pulses
are transmitted through free
air at the speed of sound
until they come into contact
with the liquid surface
where they are reflected
back to the transducer. The
transmitter’s electronics then
measures the pulse’s round-
trip time and digitally
processes the information to
indicate liquid level. A trans-
mitter programmed with a
vessel’s geometry can calcu-
late the liquid volume of a
vessel. A transmitter pro-
grammed to convert the
level reading into units of volume per time can meas-
ure the liquid flow rate in an open channel.
AAssssuurriinngg SSiiggnnaall IInntteeggrriittyyIn the real world of process management an ultra-
sonic signal launched into free air is vulnerable to
distortion from many sources, and unless safeguards
are taken by mechanical means or advanced
signal processing, non-contact measurement
can be greatly compromised.
The most obvious form of inter-
ference are the physical structures
inside a vessel—pipes, ladders, struts,
agitator blades, or irregular tank geometry. All of these
can fall within the path of the ultrasonic beam to com-
promise the signal.
The greater the distance from the transducer, the
wider the beam spreads,
thereby increasing the like-
lihood that a “false target”
will enter the beam’s path.
(At 2 feet from the trans-
ducer, a typical ultrasonic
beam may be less than 6
inches in diameter; but at
35 feet from the transducer
the conical shaped beam
will expand to a diameter
of 7 feet.)
Magnetrol’s 335, 338,
344 and 345 transmitters
have a False Target
Buffering feature which fil-
ters out obstructions that
may lie within the path of
the beam. By entering the
locations of the obstruc-
tions into the transmitter’s
false target memory, the
user can program out the
erroneous targets.
As an additional
measure to assure instru-
ment integrity, Magnetrol
transmitters feature a self-
diagnostics capability which continuously checks all
relays, outputs and the overall function of the trans-
ducer and electronics.
Ambient temperature can also have a significant
effect on the accuracy of a non-contact ultrasonic
transmitter. As temperature decreases, air becomes
Non-Contact Ultrasonic Level Measurement
The Transmitter housesthe electronics for signalprocessing and controloutputs. Depending onthe model, transmitterscan be mounted eitherintegrally or remotely.
The Transducer islocated inside the ves-sel. It transmits andreceives the ultrasonicsignals.
Product ApplicationsEchotel non-contactultrasonic productshave been engineeredto meet the processrequirements of majorindustries, includingOil and Gas, Chemicals,Food and Beverage,Power Generation, Pulpand Paper, Water andWastewater, Biotechand Pharmaceutical.
Ultrasound 101:
The Basics
5
more dense, resulting in slower sound velocity. Since
measurement is directly dependent on sound speed, it is
necessary to compensate for temperature changes. All
Magnetrol’s EchoMaster® transducers include a temperature
compensation circuit which continuously monitors the
temperature at the sensor and compensates for variations
over the full temperature range of the transducer.
Ultrasonic non-contact devices are typically rated for
a maximum range in ideal conditions. But process condi-
tions can impact the maximum range of measurement.
These conditions include surface agitation, vapors and
steam, foam and air movement. A derating multiplier can
be computed to yield a new maximum range for optimum
performance. A lower frequency transducer, such as the
38 kHz model, provides increased power with a longer
wavelength to increase measurement range and improve
performance where steam, vapors or turbulence may be
present.
TTeecchhnnoollooggyy AAddvvaannttaaggeess aanndd LLiimmiittaattiioonnss
The advantages of non-contact sensing are:
• No contact with corrosive, contaminating liquids.
• Accurate to within 0.25% of measured span.
• Continuous and multiple-point sensing available.
• No moving parts for reduced maintenance.
• Not affected by changes in liquid properties such as
specific gravity, dielectric shifts, pH, etc.
• General purpose, intrinsically-safe and explosion-
proof instruments are available.
Conditions limiting ultrasound’s effectiveness include:
• Surface foam that absorbs the ultrasonic signal.
• Vapors and steam that alter sound speed.
• Operating Pressures exceeding 50 psig (3.45 bar).
• Temperatures exceeding +200° F (+93° C).
Non-Contact Ultrasonic Products at a Glance
ZE
RO
MOVING PAR
TS
•100
%ELECTRON
IC•
300/301 335 338 344/345 350/351 350/351 3P1
FUNCTION 4-Wire Transmitter 4-Wire Transmitter 2-Wire Transmitter 4-Wire Transmitter Transmitter Controller Transmitter/Controller
RELAYS 0, 2, 4 SPDT 1 SPDT 0 4 SPDT 0 2 SPDT 8 SPDT
OUTPUT 4-20 mA, RS-485 4-20 mA 4-20 mA 4-20 mA, RS-232 4-20 mA 2 SPDT 4-20 mA dual mode
RANGE 30 ft. (9.1 m) 26 ft. (8 m) 20 ft. (6 m) 35 ft. (10.7 m) 25 ft. (7.6 m) 33 ft. (10 m)
TRANSDUCER 38 kHz, 12° 50 kHz, 7° 80 kHz, 5° 38 or 50 kHz, 12° 50 kHz, 12° 38 kHz, 12°
INTERFACE Keypad with LCD Plug-in Module Plug-in Module Keypad with LCD Keypad with LED Keypad with LCD
TEMPERATURE COMPENSATION
CONTINUOUS SELF-DIAGNOSTICS
CONFIGURATION PROTECTION
FALSE TARGET BUFFERING
TOTALIZER OPTION
DATA LOGGER OPTION
NON-CONTACT ULTRASOUND
6
300/301For Liquid Level,Volume or OpenChannel Flow
Available as an integral or remote mounted unit, this versatile and powerful ultrasonic transmitter is easy to install and quick to calibrate.
Advanced Electronics Isolated 4-20 mA output with an active/passive mode forloop power or device power. RS-485 with Modbus protocolallows bi-directional communication with DCS or PLC. Two
or four 10 amp SPDT gold flash relays for a wide variety ofalarm and control schemes.
Explosion-Proof Transmitter and Transducer The Model 300/301 has Explosion-Proof FM and CSAagency approvals for both the transducer and the trans-mitter: Class I, Division 1, Groups B, C, and D.
Fast, Password-Protected CalibrationUnique QuickCal™ calibration feature allows complete system calibration in 90 seconds. A password protection feature also prevents unwanted tampering with the configuration data.
Model 300/301 Transmitter Specifications
Power Supply 120 VAC ±10%, 50-60 Hz
240 VAC ±10%, 50-60 Hz
24 VDC ±20%
Power Consumption 12 watts maximum
Analog Output Signal
Active Mode 4-20 mA (isolated); maximum of
1,000 Ω loop resistance
Passive Mode 4-20 mA (isolated); loop resist-
ance dependent on power supply
(32 volt max) 1,000 Ω @ 24 volts
Digital Output RS-485 with Modbus
Relays 10 amp SPDT resistive (0, 2 or 4)
Fail-safe User selectable for analog and
relay outputs
Ambient Temperature
Electronics -40° to +160° F (-40° to +71° C)
Display Two-line, 32 character LCD
Keypad 16-button (inside housing)
Response Time 2 seconds, typical
Accuracy ±0.25% of calibrated span
• Viscous Fluids
• Acids, Caustics
• Water & Wastewater
• Chemicals
• Pulp & Paper
• Power Generation
Applications
Model 300/301A 16-button keypad andtwo-line, 16-characterLCD display is insidethe explosion-proofhousing
Transducer Specifications
Frequency 38 kHz
Beam Angle Conical 12°
Max Range/Span 30 feet (9.1 m) / 28.5 feet (8.7 m)
Dead Zone 18 inches (460 mm) minimum
Process Temp -40° to +163° F (-40° to +73° C)
Process Pressure Atmospheric to 50 psig (3.45 bar)
Cable Length 500 feet maximum
NON-CONTACT ULTRASOUND
7
335 For Liquid Level,Volume or Open Channel Flow
Echotel 335 Transmitter Specifications
Power Supply 85 to 255 VAC (Input code A)
10.5 to 40 VDC (Input code D)
Output Signal 4-20 mA (isolated); 600 Ω load
Fault Detection Configurable 3 amp SPDT relay,
LED, and 3.6 or 22 mA
Relay One, 3-amp SPDT
Fail-safe Software selectable
Ambient Temperature -22° to +140° F (-30° to +60° C)
Display Removable six-digit LCD module
with dual function bar graph
Keypad 4-button menu-driven data entry
LED Status Indication Echo strength, power, relay LED’s
Compensation Auto temperature compensation
over transducer operating range
Accuracy ±0.2% of measured distance,
plus 0.05% of the range
Enclosure Dual compartment cast aluminum
Protection NEMA 6 (IP 67)
• Sump, Well, & Tank Level
• Open Channel Flow
• Water & Wastewater Treatment
• Chemical Storage Tanks
• Food & Beverage Containers
• Pulp & Paper Vessels
Applications
View of LCDmodule throughhousing coverwindow
Enlarged viewof LCD modulein working unit
LCD moduleremoved
With flexible software, advanced signal processingand a powerful transducer, the Model 335 offersoutstanding measurement performance and value.
Hinged, Dual CompartmentsThe LCD module compartment houses theuser interface and the lower compartmenthouses the wiring terminals. A screwrelease allows the LCD compartmentto swing completely clear of thewiring module.
Plug-In Display Module The module offers easy set-up and config-uration of all process parameters via fourpush buttons. The custom graphics LCDdisplays six-characters and a bar graph ofsignal strength or tank level. The module can
be removed to configure other 335 units.
335 ElectronicsAdvanced digital signal processing providesoptimum performance in a variety of processconditions.
Transducer Specifications
Frequency 50 kHz
Beam Angle Conical 7°
Max Range 26 feet (8 m)
Dead Zone 14 inches (350 mm)
Process Temp -22° to +195° F (-30° to +90° C)
Process Pressure Atmospheric to 44 psig (3 bar)
Material Polypropylene
Protection NEMA 6P (IP68)
NON-CONTACT ULTRASOUND
8
338 For Liquid Level,Volume or OpenChannel Flow
Model 338 Transmitter Specifications
Power Supply 12 to 36 VDC
Output Signal 4-20 mA (isolated); 600 Ω load
Fault Detection LED, and 3.6 or 22 mA
Fail-safe Software selectable
Ambient Temperature -22° to +140° F (-30° to 60° C)
Display Removable six-digit LCD module
with dual function bar graph
Keypad 4-button menu-driven data entry
LED Status Indication Echo strength, power
Compensation Auto temperature compensation
over transducer operating range
Accuracy ±0.2% of measured distance,
plus 0.05% of the range
Enclosure Plastic (PBT)
Protection NEMA 6 (IP 67)
Model 338A powerfultwo-wire,loop-poweredtransmitter
Transducer Specifications
Frequency 80 kHz
Beam Angle Conical 5°
Max Range 20 feet (6 m)
Dead Zone 10 inches (250 mm)
Process Temp -22° to +195° F (-30° to +90° C)
Process Pressure Atmospheric to 44 psig (3 bar)
Material Polypropylene
Protection NEMA 6P (IP 68)
• Sump, Well, Tank Level
• Highly Viscous Media
• Paint, Ink & Solvents
• Food & Beverage Vessels
• Batch & Day Tanks
Applications
Outstanding measurement performance and valuein a two-wire, integral transmitter featuring flexiblesoftware and advanced signal processing.
2-Wire, Loop-Powered, Full-Featured Transmitter The Model 338 has features normally found only in line-powered unitssuch as volume configuration, dual-totalizers, open channel flow meas-urement, and the ability to perform in difficult level applications thatextend to 20 feet (6 meters). These features make theModel 338 a very versatile, two-wire instrument.
Plug-In Display Module The module offers easy set-up and configuration ofall process parameters via four push buttons. Thecustom graphics LCD displays six-characters and abar graph of signal strength or tank level. The modulecan be removed to configure other 338 units.
High Performance Transducer Technology:The 338’s advanced transducer technology produces an extremelynarrow 5° beam angle with just a 10" (25 cm) blind space. Thisprovides better performance, especially in applications where tankobstructions or nozzles are present that may cause problems forother ultrasonic transmitters.
Available 1st quarter, 2003
NON-CONTACT ULTRASOUND
9
344/345 For Liquid Level,Volume or OpenChannel Flow
A remote mounted, full-featured ultrasonic transmitter withextensive agency approvals. Many transducer configurationsand transmitter options are available for greater versatility.
Convenient Front Panel InterfaceFront panel keypad makes programming convenient;once wired, there’s no need to open the enclosure.A large, 16-character alphanumeric display shows allparameters and a password code prevents unautho-rized tampering with configuration data.
Choice of EchoMaster™ TransducersThe Model 344 employs the powerful 38 kHz Kynar transducerused primarily for level and volume applications. The Model 345uses the 50 kHz transducer, available either in Kynar or 316stainless steel. Transducers feature temperature compensation.
Full-Featured ElectronicsAutomatic, continuous self-test checks transducersignal, temperature sensor, all outputs and systemfunctionality for proper operation. False targetbuffering feature eliminates signal interference forup to nine fixed tank obstructions.
Model 344/345 Transmitter Specifications
Power Supply 120 VAC ±10%, 50-60 Hz
240 VAC ±10%, 50-60 Hz
24 VDC ±20%
Power Consumption 12 watts (without heater)
Output Signal 4-20 mA isolated (1,000 Ω load),
RS-232 (data logger downloading)
Relays Four, 10-amp resistive, SPDT
Fail-safe User selectable for analog and
relay outputs
Display 16-character alphanumeric
Keypad 16-button integral to front panel
Response Time 2 seconds, typical
Accuracy ±0.25% of configured span
Ambient Temperature
with Heater & Thermostat -40° to +160° F (-40° to +70° C)
w/o Heater & Thermostat -4° to +160° F (-20° to +70° C)
Agency Approvals Class I, Division 2, Non-incendive
and NEMA 4X from FM and CSA
• Sump & Wastewater
• Slurries, Viscous Fluids
• Pulp & Paper
• Power Generation
• Petrochem
Applications
Transducer Specifications
Frequency 38 kHz 50 kHz
Max Range 35 feet (10.7 m) 25 feet (7.6 m)
Max Span 33.5 feet (10.2 m) 24 feet (7.3 m)
Process Temp -40° to +163° F -40° to +200° F
(-40° to +73° C) (-40° to +93° C)
Process Pressure Atmospheric to 50 psig (3.45 bar)
Beam Angle Conical 12°
Cable Length 500 feet maximum
Transducer
Temperature
Outputs
System
Microprocessor-Based Transmitter...Provides continuous level measurement. User selection of
operating parameters include range, span, fail-safe, and units ofmeasurement. 4-20 mA isolated current loop for external control
devices. User selectable fail-safe: 4 mA, 20 mA, or last value.
As a Microprocessor-Based Controller...Provides high/low level alarm, pump control, or lead/lagalternation. User selection of operating parameters includerange, span, set points, time delay, units of measurement,alarm/pump control and selectable alarm fail-safe. Unit fea-tures fully adjustable set points and a 1 to 120-second time delay.
Other Transmitter and Controller Features: • Four-digit LED display with readout of distance, level or signal strength• FM and CSA hazardous location approvals for transmitter and transducer• An adjustable span of 2 inches to 24 feet (51 mm to 7.3 meters)• Integral or remote mounting capability
NON-CONTACT ULTRASOUND
10
350/351 Liquid LevelController orTransmitter
Available as a dual-point level controller or continuouslevel transmitter, the 350 (integral) and 351 (remote)excel in sump control applications.
Model 350/351 Transmitter Specifications
Power Supply 120 VAC ±10%, 50-60 Hz
240 VAC ±10%, 50-60 Hz
Power Consumption 5 watts maximum
Output Controller 2 SPDT 10 amp relays,
120/240 VAC, adjustable differential
Transmitter 4-20 mA (isolated), maximum of
1,000 Ω loop resistance
Fail-safe Controller User selectable, on or off
Transmitter User selectable, 4 or 20 mA or last
Time Delay Controller 1–120 seconds, adjustable
Response Time 1 second minimum
Repeatability ±0.125" (±3 mm)
Accuracy ±0.25% of full scale
Ambient Temperature -40° to +160° F (-40° to +71° C)
Display 4-digit, LED
Agency Approvals FM and CSA hazardous approvals
with cast aluminum housing
• Pump Control
• Sumps & Wet Wells
• Water & Wastewater
• Food & Beverage Processing
Applications
Transducer Specifications
Frequency 50 kHz
Beam Angle Conical 12°
Max Range/Span 25 feet (7.6 m); 24 feet (7.3 m)
Dead Zone 12 to 18 inches (305 to 457 mm)
(temperature dependent)
Ambient Temp -20° to +160° F (-29° to +71° C)
Process Pressure Atmospheric to 50 psig (3.45 bar)
Cable Length 100 feet (30 m) maximum
Dual-PointController
Four-WireTransmitter
NON-CONTACT ULTRASOUND
11
3P1 Magnetrol’sleading Pump Controllerfor sumps and wet wells
A full-featured transmitter with extensive pump controlcapability. The 3P1 is specifically designed to monitorpump efficiency and improve performance in sumps.
The Ultimate Pump Control Transmitter • Up to six pumps can be included in a lead/lag
alternation group to reduce pump wear.• Select between sequential or equalized time
alternation of the pumps in the lead/lag group.• Pump data logger logs run times, cycle counts and
pump efficiency of each pump. • When programmed for volume, the system will
calculate and totalize the volumetric flow through the sump or well.• Pump maintenance alarm notifies the operator when a pump falls
below a user-defined percent efficiency.
Convenient User InterfaceA front panel keypad makes programming convenient; once wired,there’s no need to open the enclosure. A large, 16-character alphanu-meric display shows all parameters, and a password code preventsunauthorized tampering of calibration data. Menu-driven programmingprovides for ease of configuration.
• Pump Control
• Sumps & Wet Wells
• Water & Wastewater
• Food & Beverage
• Pulp & Paper
• Power Generation
Applications
Model 3P1Features a 16-buttonfront panel keypad anda two-line, 16-characterLCD display
Transducer Specifications
Frequency 38 kHz
Beam Angle Conical 12°
Max Range 33 feet (10 m) / 31.5 feet (9.6 m)
Dead Zone 18 inches (460 mm) minimum
Process Temp -40° to +163° F (-40° to +73° C)
Process Pressure Atmospheric to 50 psig (3.45 bar)
Cable Length 500 feet maximum
Model 3P1 Transmitter Specifications
Power Supply 120 VAC ±10%-15%, 50-60 Hz
240 VAC ±10%-15%, 50-60 Hz
24 VAC ±20%
Power Consumption 12 watts (without heater)
Analog Output Signal
Active Mode 4-20 mA (isolated); maximum of
1,000 Ω loop resistance
Passive Mode 4-20 mA (isolated); loop resistance
dependent on power supply
Fail-safe Software selectable for 3.5 mA,
22 mA, hold, or last value
Digital Output RS-232 or RS-485 with Modbus
Relays Eight, 10-amp SPDT with gold
flash contacts
Ambient Temperature
with Heater -40° to +160° F (-40° to +70° C)
without Heater -4° to +160° F (-20° to +70° C)
Display Two-line, 32 total character LCD
Keypad 16-button integral to front panel
CORPORATE HEADQUARTERS5300 Belmont Road • Downers Grove, Illinois 60515-4499 USA
Phone: 630-969-4000 • Fax: 630-969-9489www.magnetrol.com • [email protected]
EUROPEAN HEADQUARTERSHeikensstraat 6 • 9240 Zele, Belgium
Phone: 052 45.11.11 • Fax: 052 45.09.93
BRAZIL: Av. Luis Stamatis • 620-Jacana • Sao Paulo CEP 02260-001
CANADA: 145 Jardin Drive, Units 1 & 2 • Concord, Ontario L4K 1X7
CHINA: Room #8008 • Overseas Chinese Mansion • 129 Yan An Road (W) • Shanghai 200040
DEUTSCHLAND: Schloßstraße 76 • D-51429 Bergisch-Gladbach 1 (Bensberg)
DUBAI: Suite 1F1 Hamarain Centre • Abu Baker Al Siddique Road • P. O. Box-10984 • Dubai, United Arab Emirates
FRANCE: Le Vinci 6 – Parc d’Activities • de mitry Compans • 1 rue Becquerel • 77290 Mitry Mory
INDIA: E-22, Anand Niketan • New Delhi 110 021
ITALIA: Via Arese, 12 • 20159 Milano
SINGAPORE: 23 Woodlands Industrial Park E1 #04-01 • Singapore 757741
UNITED KINGDOM: Regent Business Centre • Jubilee Road • Burgess Hill, West Sussex RH15 9TL
Copyright © 2003 Magnetrol International. All rights reserved. Printed in the USA.
Bulletin: 51-180.0 • Effective: March 2003