ECHOTEL NON-CONTACT ULTRASOUND - Powerflo · An Introduction to Ultrasonic Level Sensing ... 344 and 345 transmitters ... NON-CONTACT ULTRASOUND 8 338 For Liquid Level, Volume or

E C H O T E L ® N O N - C O N TA C T U LT R A S O U N D

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

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5

6

7

8

9

10

11

4

5

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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

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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


• Chemicals

• Pulp & Paper


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


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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.


Frequency 50 kHz


Max Range 26 feet (8 m)

Dead Zone 14 inches (350 mm)


Process Pressure Atmospheric to 44 psig (3 bar)

Material Polypropylene

Protection NEMA 6P (IP68)


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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


Frequency 80 kHz


Max Range 20 feet (6 m)

Dead Zone 10 inches (250 mm)


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


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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.



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


• Petrochem

Applications


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)




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


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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.



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


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


• Food & Beverage Processing

Applications


Frequency 50 kHz


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)


Cable Length 100 feet (30 m) maximum

Dual-PointController

Four-WireTransmitter


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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


• Food & Beverage

• Pulp & Paper


Applications

Model 3P1Features a 16-buttonfront panel keypad anda two-line, 16-characterLCD display


Frequency 38 kHz


Max Range 33 feet (10 m) / 31.5 feet (9.6 m)

Dead Zone 18 inches (460 mm) minimum




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


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

Documents

ECHOTEL NON-CONTACT ULTRASOUND - Powerflo · An Introduction to Ultrasonic Level Sensing ... 344 and 345 transmitters ... NON-CONTACT ULTRASOUND 8 338 For Liquid Level, Volume or