KOTRON® SMART RF MODEL 805 TRANSMITTER Installation and Operating Manual R.F. Capacitance Level Measurement ® UNPACKING Unpack the instrument carefully. Make sure all components have been removed from the foam protection. Inspect all components for damage. Report any concealed damage to the carrier within 24 hours. Check the contents of the carton/crates against the packing slip and report any discrepancies to Magnetrol. Check the nameplate model number (Model number/approvals as per inserted separate sheet) to be sure it agrees with the packing slip and purchase order. Check and record the serial number for future reference when ordering parts. Nameplate: - partnumber - amplifier - serial n° - tag n° These units have been tested to EN 50081-2 and EN 50082-2 and are in compliance with the EMC Directive 89/336/EEC and Directive 94/9/EC for Equipment or protective system for use in potentially explosive atmospheres. MOUNTING KOTRON R.F probes (For installation details see bulletin BE50 - 125) min. 1" - 150 lbs DN 25 PN 16 3/4" 1" G1(1"BSP) d1 Guarded probe inactive sheath d1 = d2 d2 Wrong Probe with inactive sheath Stillwell probe Bent probe Flexible probe 2 cable entries (one plugged): M20 x 1.5, 3/4" NPT or PG 13.5 For replacing electronics only: The electronic insert can easily be removed by loosening the 3 mounting screws and unplugging the module. The probe wire is fixed to the PCB by means of a spade plug. (a) (b) Handtighten or use Size: 33 mm (1 1/8") or adjustable wrench Disconnect white probe wire always at the probe - never at the electronics (see above). WARNING: Never mount or dismantle a threaded probe by the upper mounting nut for the amplifier (a), ALWAYS use the lower probe mounting nut (b). 2 WIRING CAUTION: power must be switched OFF before wiring the unit. TB1 Positive supply to (+) terminal/HART® connection Negative supply to (-) terminal/HART® connection min. 11 V DC required IS Current loop test points P1 + – IS + LOOP CURRENT – P2 ® www.magnetrol.com Ground wire to green grounding screw or to external grounding screw Standard shielded twisted pair cable 100 % 0% Customer supplied local current meter Ex Ex Ex Non Ex Non Ex Non Ex Galvanic Barrier: max: 28,6 V DC @ 140 mA ANALOG I/O or DIGITAL I/O (only for units with HART) CAUTION: ALWAYS check for proper grounding, Improper grounding will cause malfunction of the unit. CALIBRATION NOTE: When connected to an approved barrier, the intrinsically safe electronics of the Kotron 805 allow to remove both covers with power switched on – even if the area is known to be hazardous 2 line – 8 characters LCD Default display cycles every 5 s through “LEVEL”/“% OUTPUT”/“LOOP” Returns to default display if after 5 minutes no keystrokes are sensed Enter Down Up Pushbuttons IMPORTANT: When the amplifier is not connected to a probe, the screen will show "NO LEVEL SIGNAL". Ignore this message for bench configuration. 3 CALIBRATION - TRANSMITTER WITH LCD SCREENMENU: STEP BY STEP PROCEDURE Display Comment Units! cm Press : The last character on the first line of the display changes to "!". This sign confirms that the values/choices of the second line can be modified via the and push buttons. Units! cm Press : * Scroll through the choices or increase/decrease the values on the second line of the display by and pushbuttons. pushbutton. * Accept values/choices as selected by Units cm Press : Scroll through the menu. TERMINOLOGY Units cm or Inch 20 mA Level (100%-point) Hi Cal min. 2 % of probe length Lo Cal 4 mA Level (0%-point) cm or inches Select the units of measurement in which the unit will be calibrated and will show values. 20 mA Level = cm or inches or 100 % level point, is measured from the end of the probe. Keep this reference point also for the introduction of all future values. Hi Cal = cm or inches High Calibration point is the highest level from which the calibration is performed. Hi Cal is measured from the end of the probe. Lo Cal = cm or inches Low Calibration point is the lowest level from which the calibration is performed. Lo Cal is measured from the end of the probe. 4 mA Level = cm or inches or 0 % level point, is measured from the bottom of the probe. The 4 mA level is by preferrence located on the probe. The unit will not measure below the end of the probe. NOTE: The above example shows the end of the probe as reference point. Also the bottom or top of the tank can be used as reference point. Whichever point is used, it must always be used for all further values. Display Action Comment Ent Pass 0 "0" means that no password is introduced Factory default setting Ent Pass! 1 Press and last character changes into "!" Enter a value between 1 up to 255 as your personal password with and Changing password New Pass 4096 Display shows an encrypted value, enter your password or call Magnetrol for assistance to recoop your password if necessary Data is protected by a valid Password New Pass 0000 Protect data by new password Data is not protected 4 CALIBRATION - TRANSMITTER WITH LCD SCREENMENU: STEP BY STEP PROCEDURE Diagnostics Configuration Run mode Screen Action Comment 1 *Level* *%Output* *Loop* Transmitter Display Transmitter default display. Level, % Output, and Loop values cycle every 5 seconds. 2 Level xx.x cm Transmitter Display Transmitter displays Level measurement in cm or in. 3 %Output xx.x% Transmitter Display Transmitter displays % Output measurement derived from the 4-20 mA span. 4 Loop xx.xx mA Transmitter Display Transmitter displays Loop measurement (mA). 5 Units xxx Select units for level measurement readout. cm or inches. 6 Lo Cal xxx.x lu Enter level value of the low calibration point Set level at low calibration point and adapt with Up and Down the displayed value 7 Lo Cap Xxxx pF Transmitter Display Transmitter displays capacitance at low calibration point in pF 8 Hi Cal xxx.x lu Enter level value of the high calibration point Set level at high calibration point and adapt with Up and Down the displayed value 9 Hi Cap Xxxx pF Transmitter Display Transmitter displays capacitance at high calibration point in pF 10 Set 4mA xxx.x Enter the level value for the 4 mA point. 4 mA level cannot be set at a lower level than the end of the probe 11 Set 20mA xxx.x Enter the level value for the 20 mA point. 20 mA level cannot be set at a higher level than the top of the probe 12 Damping xx sec Enter the damping factor. A Damping factor (1-45 seconds) may be added to smooth a noisy display and/or output due to turbulence. 13 Fault Choice Enter the default value. Select 3.6 mA, 22 mA or HOLD (last value). 3.6 mA is not valid if unit includes HART. 14 Poll Adr xx Enter HART ID number. Select a HART poll address (0-15). Enter 0 for a single transmitter installation. 15 Trim 4 xxxx Fine tune the 4 mA point. Attach a mA meter to the output. If the output does not equal 4.0 mA, adjust the value on the display to equal 4.00 mA. 16 Trim 20 xxxx Fine tune the 20 mA point. Attach a mA meter to the output. If the output does not equal 20.0 mA, adjust the value on the display to equal 20.00 mA. 17 Loop Tst xx.x mA Enter a mA Output value. Set mA Output to any given value to perform loop test. 18 Prb Rdg Xxxx pF None, do not adjust. Transmitter displays capacitance at present level 19 Osc Tst Xxx tk None, do not adjust. Transmitter displays internal timing count with fixed capacitance (factory diagnostic) 20 Opn Prb xxxx tk None, do not adjust. Transmitter displays internal timing count with probe disconnected (factory diagnostic) 21 # Ticks xxxx None, do not adjust. Transmitter displays internal timing count at present level (factory diagnostic) 22 Reint xxx Reinitialize all values. Reinitialize - choose YES to reset all configuration values back to factory defaults. 23 Vern.nAa None, do not adjust. Transmitter displays version number of firmware 24 New Pass xxx Enter new password. Use arrows to select desired value. Values between 1 and 255 = min. required calibration 5 CALIBRATION USING HART® IMPORTANT: Check whether your HART® communicator is equiped with the 805 Device Descriptors (DD’s). Older purchased devices may require an update – consult your local HART Service Centre or Magnetrol for further assistance. CONNECTIONS - + Connection of your Hart communicator: • at power terminals (+) and (-) in wiring compartment • at first junction box between unit and control room. IMPORTANT: The digital HART® communication is superimposed on the 4-20 mA loop and requires a min. load resistance of 250 Ω and a max load resistance of 450 Ω. Junction HART MENU 250 Ω < RL < 450 Ω - + Control Room Display Power Supply Current Meter 1 Device Setup 2 Level 3 % Output 4 Loop I/O Start up the device 1 Enter DEVICE SET UP Press one of the following alphanumeric keys (if no key is sensed after 5 s, the unit will automatically jump to RUN mode and alternatively show Level/% Output and Loop signal 1 for entering CALIBRATION (see page 5 for additional information) 2 for entering BASIC SETUP – general HART 3 for ADVANCED SET UP CONFIGURATION (see page 5 for additional information) 4 for entering DIAGNOSTICS (see page 5 for additional information) 5 for entering REVIEW to review all settings. 1 Calibration 2 Basic Setup 3 Advanced Setup/ Configuration 4 Diagnostics 5 Review 6 1 Units 2 Empty Calibration 3 Full Calibration 4 4 mA Set Point 5 20 mA Set Point 6 Damping 7 Fault State 8 Date/Time/Initials 1 Tag 2 Descriptor 3 Date 4 Message 5 Final Asmbly Num 6 Poll Address 7 New Password 1 Adjust Trim 4 mA 2 Adjust Trim 20 mA 3 4 mA Trim Value 4 20 mA Trim Value 5 Enter Password 6 Set Magnetrol S/N 7 Set Dev ID Number 1 Loop Test 2 Error Codes 3 Probe Reading 4 Cap at empty Cal 5 Cap at full Cal 1 Model 2 Manufacturer 3 Dev Id, S/N 4 Tag 5 Descriptor 6 Date 7 Message 8 Units 9 Cap at empty Cal 10 Cap at full Cal 11 4 mA Set Point 1 3.6 mA 2 4 mA 3 20 mA 4 22 mA 5 Other 12 20 mA Set Point 13 Damping 14 Fault State 15 Date/Time/Initials 16 Final Asmbly Num 17 Universal Rev 18 Fld Dev Rev 19 Software Rev 20 Poll Address 21 Num Req Preams 22 Firmware Version MAINTENANCE TROUBLESHOOTING SYSTEM PROBLEMS – LCD version Symptom Problem Solution LEVEL, % OUTPUT and LOOP values are all inaccurate. Basic configuration data is questionable. Check values and recalibrate if necessary (either or both points). LEVEL readings are repeatable but consistently high or low from actual by a fixed amount. Configuration data does not accurately match tank height. Recalibrate if necessary. LEVEL, % OUTPUT and LOOP values fluctuate. Turbulence. Increase the Damping factor until the readings stabilize. LOOP value jittery, usually in tenths or hundredths digit. Factory settings corrupted. Check # of Ticks. If the number is also jittery, consult the Factory. HART device only: handheld will only read Universal Commands. Most current Device Descriptors (DDs) are not installed in handheld. Contact local HART service center for the latest DDs. HART device only; reads Product information (e.g., Mfgs. ID, Device #, Serial #, etc.) but will not read any process variables. Early HART software does not account for Mfgs. ID #’s greater than 63. Magnetrol’s ID is 86. Contact manufacturer of your HART master software for upgrade. This is a shortcoming of early HART master software. ERROR MESSAGES – LCD version Symptom Problem Solution OSC FAIL (HART error code = 0x40) malfunctioning analog board and/or 32 pin connector (electronic module) between electronics and probe. Check connection between electronics and probe or replace electronic module. CORRUPT PARAMTRS (HART error code = 0x10) Configuration parameters may have been lost. Check all configuration parameters and recalibrate if required. 805 FAULT (Open) Probe disconnected. Check white probe wire (see page 2) and electronic module. 805 FAULT (Shorted) Probe shorted. Check white probe wire (see page 2) and probe insulation. LEVEL (Uncal) Unit is not calibrated. Enter both Low and High calibration points. ABV RNG (Above range) Measured capacitance is higher than 12,000 pF. Consult factory. SFWR ERROR (Software error) Software error. Consult factory. 7 REPLACEMENT PARTS Item Description Part number 1 Electronic module English display and HART® French display and HART® German display and HART® Spanish display and HART® HART® only English display only French display only German display only Spanish display only 031-2809-001 031-2809-031 031-2809-041 031-2809-021 031-2809-002 031-2809-003 031-2809-033 031-2809-043 031-2809-023 Terminal board General Purpose (GP) Intrinsically Safe (IS) O-Ring (neoprene) Housing cover blind - Aluminium Housing cover blind - 316 SST Housing cover with glass Housing cover with glass - 316 SST 30-9106-003 30-9106-003 12-2201-237 04-9193-003 Consult factory 36-4410-001 Consult factory 4 3 5 2 3 1 2 3 4 5 APPROVALS Agency Description Agency Description ATEX II 1G EEx ia IIC T4 (ambient -40° C to +40° C) II 1G EEx ia IIC T6 (ambient -40° C to +80° C) CSA (*) FM (*) Intrinsically safe Class I, Div.1; Grps. A, B, C, D Class II, Div.1; Grps. E, F, G Class III,NEMA 4X Intrinsically safe Class I, Div.1; Grps. A, B, C, D Class II, Div.1; Grp. G Class III,Type 4X Non-Incendive Class I, Div.2; Grps. A,B,C,D Class II, Div.2; Grps. F,G Class III,NEMA 4X (*) Consult factory for proper part n° and entity parameters. 8 Non-Incendive Class I, Div.2; Grps A, B, C, D Class II, Div.2; Grps E, F, G Class III, Type 4X (*) Consult factory for proper part n° (*) and entity parameters. MAINTENANCE TROUBLESHOOTING FLOWCHART (LCD version) Start Unit Equipped with Display? No HART Communications OK? Yes Yes Active HART No Display has Text? No Check Voltage at Terminal Board No Voltage? 3 See page 12 Yes Check Power Supply and Wiring Yes Reverse Wiring Yes Call Factory Yes Check Loop Current at terminal Board Some problems could be temporarily solved by power cycling the unit. Please call factory if this problem persists. No Negative Voltage? Yes No Voltage Above 36 Volts? No Faint Display? Yes Voltage < 11V IS or 14.5V XP? No No Loop Current Above 23 mA? Failure to Operate with Correct Loop Inputs Good Display Yes Remove Electronic Module Loop Current Above 1 mA? Yes No No 2 1 Yes Loop Resistance Wrong? No See page 11 Replace Electronic Module Replace Terminal Board No Correct Loop Resistance Reseat Boards. Check Power Supply and Wiring Display Working? Yes Retest 9 MAINTENANCE TROUBLESHOOTING FLOWCHART (LCD version) 1 Failure to Operate with Correct Loop Inputs Display Working? Reseat Boards Yes Retest No No Check Loop Current at Terminal Board Loop Current Above 23 mA? Yes Remove Electronic Module Loop Current Above 1 mA? Yes No Replace Electronic Module Replace Terminal Board 2 Good Display Display Working? No Yes Key Board Responds? No Replace Electronic Module Yes HART Working? Retest Unit Yes Unit has HART? No Yes No Check Loop Current at Wiring Board Loop Current 22 - 4.0 mA? Yes 4 See page 11 10 Adjust 4 and 20 mA No Correct Address Yes Address Correct? Unit with Display Communicates No Replace Electronic Module MAINTENANCE TROUBLESHOOTING FLOWCHART (LCD version) 4 Unit with Display Communicates Call Factory Yes Yes No "Software Error?" Corrupt Display Text? Yes No Replace Electronic Module "Above Range?" No No "Shorted Probe?" Yes "Corrupt Parameters?" No No No Error Displayed? "Uncal?" No "Open Probe?" Yes "OSC Fail?" Yes Yes Yes Check Analog Parameters Check Calibration Parameters No Check Probe and Connectors Analog Loop Correct? No Check Offset and 4-20 mA Set Points Trim 4-20mA Retest No Same Error Message? Yes 3 Active HART Replace Electronic Module Yes No Display Reading Correctly? Yes Call Factory 11 TRANSMITTER SPECIFICATIONS FUNCTIONAL/PHYSICAL Description Specification Power (at terminals) General Purpose: 11 to 36 V DC ATEX Intrinsically Safe: 11 to 28.6 V DC Signal Output 4-20 mA or 4-20 mA with HART® 3.8 to 20.5 mA useable (meets NAMUR NE 43) Span minimum 5 pF - maximum 10.000 pF Zero and Range 0 mm to 45 m (0' to 150') Resolution Analog: 0.01 mA Digital display: 0,1 cm (0.1") Loop Resistance ATEX Intrinsically Safe/General Purpose: 650 Ω @ 24 V DC Damping Adjustable 1-45 s Diagnostic Alarm Adjustable 3.6 mA, 22 mA, HOLD (3.6 mA is not valid if unit includes HART®) Digital Communication (HART®) compatible with software version 5.x User Interface 3-button keypad and/or HART communicator Display 2-line x 8-character LCD Approvals ATEX II 1 G EEx ia IIC T4/T6 or FM/CSA intrinsically safe / non incendive Electrical Data Ui = 28,6 V, li = 140 mA, Pi = 1 W Equivalent Data Ci = 2,2 nF; Li = 0,037 mH Menu Language English/Spanish/French or German Housing Material Aluminium A356T6 (< 0.25% copper) or 316 SST (1.4401)/IP 65 Net and Gross Weight 2.70 kg net; 3.20 kg gross Overall Dimensions H 214 mm (8.43") x W 111 mm (4.38") x D 188 mm (7.40") PROCESS CONDITIONS Description Specification Maximum Process Temperature 540 °C @ 35 bar (1000 °F @ 500 PSIG) - depending probe selection Maximum Process Pressure 345 bar @ 40 °C (5000 PSIG @ 100 °F) - depending probe selection Ambient temperature electronics -40 °C to +80 °C (-40 °F to +175 °F) – blind transmitter -20 °C to +70 °C (-5 °F to +160 °F) – with LCD display and keypad Storage temperature -40 °C to +80 °C (-40 °F to +175 °F) Humidity 0-99 %, non-condensing Electromagnetic Compatibility Meets CE requirements (EN-50081-2, EN 50082-2) / NAMUR NE 21 (EMV) PERFORMANCE Description Specification Reference conditions 20 °C (70 °F) Accuracy +/- 0.5% of span or 2.5 mm whichever is greater Resolution 0.1 pF Repeatability +/- 0.1% of span Linearity +/- 0.25% of span Response time less than 1 s (adjustable via damping) Ambient temperature effect approximately +0.03% per °C Warm up time less than 5 s 1200 20 mA 1000 23 mA 800 Ω 650 Ω 600 620 Ω 400 200 24 V DC 0 11 0 10 20 30 OUTPUT TABLE 12 40 V DC DIMENSIONS in mm (inches) 83 (3.28) 105 (4.12) 45° View 214 (8.43) 200 (7.88) 126 (4.94) 98 (3.85) 111 (4.38) Kotron 805 Housing front View 45° 2 cable entries Mounting Flange 220 (8.66) 220 (8.66) Optional Mounting Flange Probe Insertion Length 3/4" NPT 1" NPT 1G (1" BSP) Insertion Length Optional Mounting Flange 3/4" NPT Optional Anchor Assembly 5 (0.1875) 6 (0.2500) 124 (4.87) 75 (2.95) 127 (5.00) 13 (0.50) - bare probe 16 (0.625) - insulated probe Kotron 805 Housing side view Rigid probe Optional Weight 34 (1.32) Flexible probe CONNECTIONS Insertion length Insertion length Insertion length Insertion length Sanitary 3A Threaded NPT Threaded 1" BSP Welded flange ANSI / DIN 13 IDENTIFICATION A complete measuring system consists of a: 1. Smart R.F. KOTRON® 805 amplifier. 2. KOTRON® Probe; a full range of rigid and flexible probes for conductive and non-conductive media is available (see bulletin BE 50-125). Rigid probes: from 150 mm (6") to 6000 mm (20') insertion length Flexible probes: from 1 m (3,28') to 45 m (150') insertion length 3. OPTION: HART communicator Magnetrol P/N : 089 - 5213 - 012 (Euro Plug) 089 -5213 - 013 (UK Plug) 1. Code for SMART R.F. KOTRON® 805 amplifier BASIC MODEL NUMBER 8 0 5 Smart R.F. KOTRON® 805 amplifier SIGNAL OUTPUT 0 1 4 - 20 mA analog output 4 - 20 mA analog output with HART® communication MENU LANGUAGE 0 1 2 3 4 None, for use with blind transmitter (requires HART® communication) English for use with transmitter with LCD display and keypad Spanish for use with transmitter with LCD display and keypad French for use with transmitter with LCD display and keypad German for use with transmitter with LCD display and keypad TRANSMITTER TYPE 0 A Blind transmitter (requires HART® communication) Transmitter with 2 line x 8 character LCD display and keypad APPROVALS 1 A General Purpose (FM/CSA intrinsically safe) Intrinsically safe, ATEX II 1G EEx ia II C T6 HOUSING 1 2 Cast aluminium, dual compartiment housing – IP 65 Stainless steel, dual compartiment housing – IP 65 CABLE ENTRY 0 3/4" NPT (2 entries - one plugged) 1 M20 x 1.5 (2 entries - one plugged) 2 PG 13.5 (2 entries - one plugged) 8 0 5 14 5 complete code for SMART R.F. KOTRON® 805 amplifier 15 IMPORTANT SERVICE POLICY Owners of Magnetrol products 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. Magnetrol International will repair or replace the control, at no cost to the purchaser, (or owner) other than transportation cost if: a. Returned within the warranty period; and, b. The factory inspection finds the cause of the malfunction to be defective material or workmanship. If the trouble is the result of conditions beyond our control; or, is NOT covered by the warranty, there will be charges for labour 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, labour, direct or consequential damage will be allowed. RETURNED MATERIAL PROCEDURE So that we may efficiently process any materials that are returned, it is essential that a “Return Material Authorisation” (RMA) form will be obtained from the factory. It is mandatory that this form will be attached to each material returned. This form is available through Magnetrol’s local representative or by contacting the factory. Please supply the following information: 1. 2. 3. 4. 5. 6. Purchaser Name Description of Material Serial Number and Ref Number Desired Action Reason for Return Process details All shipments returned to the factory must be by prepaid transportation. Magnetrol will not accept collect shipments. All replacements will be shipped FOB factory. BULLETIN N°: EFFECTIVE: SUPERSEDES: UNDER RESERVE OF MODIFICATIONS www.magnetrol.com ® BE 50-660.1 APRIL 2002 March 2000 BENELUX Heikensstraat 6, 9240 Zele, België Tel. +32 (0)52.45.11.11 • Fax. +32 (0)52.45.09.93 • E-Mail: [email protected] DEUTSCHLAND Schloßstraße 76, D-51429 Bergisch Gladbach-Bensberg Tel. 02204 / 9536-0 • Fax. 02204 / 9536-53 • E-Mail: [email protected] FRANCE Le Vinci 6 - Parc d’activités de Mitry Compans, 1, rue Becquerel, 77290 Mitry Mory Tél. 01.60.93.99.50 • Fax. 01.60.93.99.51 • E-Mail: [email protected] ITALIA Via Arese 12, I-20159 Milano Tel. (02) 607.22.98 (R.A.) • Fax. (02) 668.66.52 • E-Mail: [email protected] UNITED KINGDOM Unit 1 Regent Business Centre, Jubilee Road Burgess Hill West Sussex RH 15 9TL Tel. (01444) 871313 • Fax (01444) 871317 • E-Mail: [email protected] INDIA B4/115 Safdurjung Enclave, New Delhi 110 029 Tel. 91 (11) 6186211 • Fax 91 (11) 6186418 • E-Mail: [email protected]