KOTRON®
MODEL 805 SMART RF
LEVEL TRANSMITTER
Installation and Operating Manual
RF
Capacitance
Level
Measurement
7xxx
6xxx
5xxx
4xxx
3xxx
2xxx
1xxx
Read this Manual Before Installing
This manual provides information on the Kotron Model
805 Smart RF Transmitter. It is important that all
instructions are read carefully and followed in sequence.
The QuickStart Installation instructions are a brief guide
to the sequence of steps for experienced technicians to
follow when installing the equipment. Detailed instructions are included in the Complete Installation section of
this manual.
Conventions Used in this Manual
Certain conventions are used in this manual to convey
specific types of information. General technical material,
support data, and safety information are presented in
narrative form. The following styles are used for notes,
cautions, and warnings.
Notes
Notes contain information that augments or clarifies
an operating step. Notes do not normally contain
actions. They follow the procedural steps to which
they refer.
Cautions
Cautions alert the technician to special conditions that
could injure personnel, damage equipment, or reduce
a component’s mechanical integrity. Cautions are also
used to alert the technician to unsafe practices or the
need for special protective equipment or specific materials. In this manual, a caution box indicates a potentially hazardous situation which, if not avoided, may
result in minor or moderate injury.
Warnings
Warnings identify potentially dangerous situations or
serious hazards. In this manual, a warning indicates an
imminently hazardous situation which, if not avoided,
could result in serious injury or death.
Safety Messages
The Kotron Model 805 system may be properly installed
in Category II, Pollution Degree 2 installations. Follow all
standard industry procedures for servicing electrical and
computer equipment when working with or around high
voltage. Always shut off the power supply before touching
any components. Although high voltage is not present in
this system, it may be present in other systems.
Electrical components are sensitive to electrostatic discharge. To prevent equipment damage, observe safety
procedures when working with electrostatic sensitive
components.
Low Voltage Directive
For use in Category II installations. If equipment is used
in a manner not specified by manufacturer, protection
provided by equipment may be impaired.
WARNING! Explosion hazard. Do not connect or disconnect equipment unless power has been switched off or
the area is known to be non-hazardous.
Notice of Trademark, Copyright, and Limitations
Kotron is a registered trademark of Magnetrol
International, Incorporated. Kotron Model 805 Smart RF
Transmitter is a tradename of Magnetrol International,
Incorporated.
Copyright © 2004 Magnetrol International,
Incorporated. All rights reserved.
Magnetrol reserves the right to make changes to the
product described in this manual at any time without
notice. Magnetrol makes no warranty with respect to the
accuracy of the information in this manual.
Warranty
All Magnetrol/STI electronic level and flow controls
are warranted free of defects in materials or workmanship
for one full year from the date of original factory shipment.
If returned within the warranty period; and, upon factory
inspection of the control, the cause of the claim is determined to be covered under the warranty; then,
Magnetrol/STI will repair or replace the control at no cost
to the purchaser (or owner) other than transportation.
Magnetrol/STI shall not be liable for misapplication,
labor claims, direct or consequential damage or expense
arising from the installation or use of equipment.
There are no other warranties expressed or implied,
except special written warranties covering some
Magnetrol/STI products.
Quality Assurance
The quality assurance system in place at Magnetrol/STI
guarantees the highest level of quality throughout the
company. Magnetrol/STI is committed to providing full
customer satisfaction both in quality products and
quality service.
Magnetrol’s quality assurance system
is registered to ISO 9001 affirming its
commitment to known international
quality standards providing the
strongest assurance of product/service
quality available.
Kotron Model 805 Smart RF
Level Transmitter
Table of Contents
1.0 QuickStart Installation
1.1 Getting Started .......................................................1
1.1.1 Equipment and Tools...................................1
1.1.2 Configuration Information ..........................1
1.2 QuickStart Mounting .............................................2
1.2.1 Probe ...........................................................2
1.2.2 Transmitter ..................................................2
1.3 QuickStart Wiring ..................................................3
1.4 QuickStart Configuration and Calibration
(LCD version) ........................................................3
2.0 Complete Installation
2.1 Unpacking ..............................................................5
2.2 Electrostatic Discharge (ESD) Handling Procedure...5
2.3 Before You Begin ....................................................6
2.3.1 Site Preparation............................................6
2.3.2 Equipment and Tools...................................6
2.3.3 Operational Considerations .........................6
2.4 Mounting ...............................................................7
2.4.1 Installing a Rigid Probe................................8
2.4.2 Installing a Flexible Probe ............................8
2.4.3 Installing the Transmitter .............................9
2.5 Wiring ..................................................................10
2.5.1 General Purpose or Non-incendive
(CI I, Div 2) ..............................................10
2.5.2 Intrinsically Safe .........................................10
2.6 Configuring & Calibrating the Transmitter
(LCD Version)......................................................11
2.6.1 Operating Parameters .................................11
2.6.2 LCD Transmitter Display and Keypad .......12
2.6.3 Password Protection (Default = 0) .............12
2.6.4 LCD Menu: Step-By-Step Procedure .........12
2.7 Configuration Using HART®..............................14
2.7.1 Connections...............................................14
2.7.2 HART Display Menu ................................14
2.7.3 HART Device Description (DD)...............14
2.7.4 HART Menu .............................................15
3.0 Reference Information
3.1 Description...........................................................16
3.2 Theory of Operation ............................................16
3.3 Troubleshooting....................................................17
3.3.1 Troubleshooting System Problems (LCD)..18
3.3.2 Error Messages (LCD) ...............................18
3.3.3 Troubleshooting Flowchart (LCD).............19
3.4 Agency Approvals .................................................22
3.4.1 Agency Specifications – Intrinsically
Safe Installation..........................................23
3.5 Parts......................................................................24
3.5.1 Replacement Parts......................................24
3.5.2 Recommended Spare Parts .........................24
3.6 Specifications ........................................................25
3.6.1 Functional..................................................25
3.6.2 Performance ...............................................26
3.6.3 Physical......................................................27
3.7 Model Numbers ...................................................28
3.7.1 Transmitter .................................................28
Glossary..............................................................................29
Index...................................................................................31
Configuration and Calibration Data Sheet........................32
1.0
QuickStart Installation
The QuickStart Installation procedures provide the key
steps for mounting, wiring, and configuring the Kotron
Model 805 Level Transmitter. These procedures are intended for experienced installers of electronic level measurement instruments. See Complete Installation, Section 2.0,
for detailed installation instructions.
1.1
Getting Started
Before beginning the QuickStart Installation procedures,
have the correct equipment, tools, and information
available.
1.1.1 Equipment and Tools
• 11⁄8" open-end wrench or adjustable wrench to fit the probe
process connection size and type.
• 11⁄4" open-end wrench or adjustable wrench to fit adaptor
on transmitter housing.
• Flat-blade screwdriver
• Digital multimeter or digital volt/ammeter
• 24 VDC power supply, 23 mA
1.1.2 Configuration Information
Some key information is needed to configure the Model
805 transmitter. Complete the following operating
parameters table before beginning configuration.
1
Display
Question
Answer
Units
What units of measurement will be
used? (inches or centimeters)
_____________
Set
4.0 mA
What is the 0% reference point for the
4.0 mA value?
_____________
Set
20.0 mA
What is the 100% reference point for
the 20.0 mA value?
_____________
50-660 Kotron Model 805 Smart RF Level Transmitter
1.2
QuickStart Mounting
NOTE: Confirm the configuration style and process connection size
and type of the Kotron Model 805 transmitter. Ensure it matches the requirements of the installation before continuing with
the QuickStart installation.
x
x Confirm the model and serial numbers.
1.2.1 Probe
y Carefully place the probe into the vessel. Align the probe
|
process connection with the threaded or flanged mounting
on the vessel.
z Tighten the probe using the flats of the probe process connection or flange bolts.
}
x
1.2.2 Transmitter
{ Loosen screw on top of the probe and attach white wire to
z
probe, making sure that spade lug is at a 90° upward
angle. Tighten probe screw securely. (See figure below)
y
| Place the transmitter on the probe.
} Tighten the connection by using the flats on the adaptor.
{
90° Bend
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2
1.3
QuickStart Wiring
WARNING! Explosion hazard. Do not connect or disconnect equipment unless power has been switched off or the area is
known to be safe.
NOTE: Make sure the electrical wiring to the Kotron Model 805 transmitter is complete and in compliance with all regulations
and codes.
1. Remove the cover of the wiring compartment of the
transmitter.
Black (-)
2. Attach a conduit fitting and mount the conduit plug in
the spare opening. Pull the power supply wire (twisted,
shielded pair of at least 22 AWG) through the conduit
fitting.
Red (+)
(+)
(-)
3. Connect shield to an earth ground at power supply and
leave floating at the transmitter.
4. Connect an earth ground to the nearest green ground
screw. (Not shown in illustration.)
5. Connect the positive supply wire to the (+) terminal and
the negative supply wire to the (-) terminal.
6. Replace the cover and tighten.
1.4
QuickStart Configuration and Calibration
(LCD version)
NOTE: The Kotron Model 805 transmitter can be equipped with either
a 2-line by 8-character LCD.
1. Power-up the transmitter.
The display changes every 5 seconds to show one of the
three measured values: Level, %Output, and Loop current.
Á
Á
2. Remove the cover of the electronic compartment.
3. Use the Up ( ) or Down ( ) Arrow keys to move from
one step of the configuration program to the next step.
Á
Enter
4. Press the Enter Arrow ( ) key. The last character in the
first line of the display changes to an exclamation point
(!). For example: Units!
xxx
3
5. Use the Up ( ) or Down ( ) keys to increase or decrease
the value in the display or to scroll through the choices.
Á
Up
Á
Down
50-660 Kotron Model 805 Smart RF Level Transmitter
Á
6. Press the Enter Arrow ( ) key to accept a value and
move to the next step of the configuration program.
7. The default password is 0. (No password is required.)
The following parameter entries are the minimum
required for initial setup and calibration. The default
password is 0.
Units
lu
y
Lo Cal
xxx.x lu
Scroll down to the Lo Cal display. Press the Enter
Arrow (
) key. Enter the current level (in or cm) of
media on the probe by using the Up and Down
Arrow (
) keys. Holding either key down causes
the values to change first by 1’s and then by 10’s.
Single depression of either key causes the values to
change by 0.1’s. Once the desired value is displayed, press the Enter Arrow (
) key.
z
Hi Cal
xxx.x lu
Move the media in the tank to a higher level. The
greater the amount at level change, the more accurate the level measurement. Scroll down to the Hi Cal
display. Press the Enter Arrow ( ) key. Enter the
new current media level in the same manner as
above. Press the Enter Arrow ( ) key.
In or Cm
Á
Á
3 Hi Cal
Á
20mA Level
(100%-point)
Á
5
Á
1
Scroll down to the Units display. Press the Enter
Arrow (
) key. Select the Units of measurement
for the level readout (cm or inches). Press the
Enter Arrow (
) key.
x
2 Lo Cal
Á
4
4mA Level
(0%-point)
Á
Á
NOTE: If calibrating the 805 for interface measurement,
enter the level of the interface rather than the
upper level.
{
Set 4mA
xxx.x
Scroll down to the Set 4 mA display. Press the
Enter Arrow (
) key. Enter the minimum level
value for the desired 4 mA point. Press the
Enter Arrow (
) key.
|
Set 20mA
xxx.x
Scroll down to the Set 20 mA display. Press the
Enter Arrow (
) key. Enter the maximum level
value for the desired 20 mA point. Press the
Enter Arrow (
) key.
Á
Á
Á
Á
The transmitter is now calibrated for this probe in this
medium in this tank (or vessel) and it provides a 4–20 mA
output over the desired range. Damping factor and Fault
output will automatically default to factory set values of
1 second and 22 mA. Changing these values and those for
other parameters are covered in detail in the next section,
Complete Installation.
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4
2.0
Complete Installation
This section provides detailed procedures for properly
installing, configuring, and, as needed, troubleshooting the
Kotron Model 805 Level Transmitter.
2.1
Unpacking
Unpack the instrument carefully. Make sure all components have been removed from the packing material.
Check all the contents against the packing slip and report
any discrepancies to the factory. Before proceeding with
the installation, do the following:
• Inspect all components for damage. Report any damage to
the carrier within 24 hours.
• Make sure the nameplate model number agrees with the
packing slip and purchase order.
• Record the model and serial numbers for future reference
when ordering parts.
2.2
Electrostatic Discharge (ESD)
Handling Procedure
Magnetrol’s electronic instruments are manufactured to the
highest quality standards. These instruments use electronic
components that may be damaged by static electricity present in most work environments.
The following steps are recommended to reduce the risk of
component failure due to electrostatic discharge.
• Ship and store circuit boards in anti-static bags. If an antistatic bag is not available, wrap the board in aluminum
foil. Do not place boards on foam packing materials.
• Use a grounding wrist strap when installing and removing
circuit boards. A grounded workstation is recommended.
• Handle circuit boards only by the edges. Do not touch
components or connector pins.
• Make sure that all electrical connections are completely
made and none are partial or floating. Ground all
equipment to a good, earth ground.
5
50-660 Kotron Model 805 Smart RF Level Transmitter
2.3 Before You Begin
2.3.1 Site Preparation
Each Kotron Model 805 transmitter is built to match the
specific physical specifications of the required installation.
Make sure the probe connection is correct for the threaded
or flanged mounting on the vessel or tank where the transmitter will be placed. See Mounting, Section 2.4.
Make sure that the wiring between the power supply and
Model 805 transmitter is complete and correct for the type
of installation. See Specifications, Section 3.6.
When installing the Model 805 transmitter in a general
purpose or hazardous area, all local, state, and federal
regulations and guidelines must be observed. See Wiring,
Section 2.5.
2.3.2 Equipment and Tools
No special equipment or tools are required to install
the Model 805 transmitter. The following items are
recommended:
• 11⁄8" Open-end wrench or adjustable wrench to fit the
probe process connection size and type
• Flat-blade screwdriver
• Digital multimeter or digital volt/ammeter
• 24 VDC power supply, 23 mA
2.3.3 Operational Considerations
The Model 805 transmitter should be located for easy
access for service, configuration, and monitoring. There
should be sufficient headroom to allow the probe to be
inserted into the tank. Special precautions should be made
to prevent exposure to corrosive atmosphere, excessive
vibration, shock, or physical damage.
The transmitter electronics should not be exposed to
ambient temperatures above +175° F (+80° C) or below
-40° F (-40° C). The proper operating temperature range
for the display is -10° to +160° F (-20° to +70° C).
The temperature limits for the probe depend on the
style and part number of the specific probe used. See
Brochure 50-125, Kotron RF Sensing Probes.
50-660 Kotron Model 805 Smart RF Level Transmitter
6
2.4
Mounting
The Model 805 transmitter can be mounted to a tank
using a variety of process connections. Generally, either a
threaded or flanged connection is used. For information
about the sizes and types of connections available, see
Brochure 50-125, Kotron RF Sensing Probes.
Make sure all mounting connections are properly in place
on the tank before installing the probe. Make sure the
Kotron probe is correct for the intended installation.
It is common practice to use the metal tank wall as the reference electrode. In such cases, it is required that the probe
housing makes a good electrical connection to the tank
wall. If there is any doubt about this connection or to the
use of PTFE thread tape gaskets, paint, rust, or any other
reason, a separate strap should be installed between the
probe housing and the tank.
Caution: This unit contains CMOS electronics which may be damaged by static electricity. Do not touch any semi-conductor devices unless you are properly grounded.
Metal Walled Tanks
On water-based liquids, there should be no problem with
sensitivity or linearity. With non-conductive, low dielectric
media, sensitivity can be enhanced by locating the probe
close to and parallel with the tank wall. If this is not practical, a concentric ground tube surrounding the probe
(sometimes called a stilling well), may be the solution.
NOTE: These comments are also true for glass-lined metal
walled tanks.
Tanks/Silos with Non-Conductive Materials of
Construction
With plastic, concrete, wood, or any other non-conductive
walled vessels, the reference electrode mentioned above
needs clarification. Most commonly, this electrode will be
in the form of a concentric ground tube (i.e. stilling well).
In questionable circumstances, consult the factory. In all
cases, a good electrical connection must be made between
the ground surface and the probe housing.
7
50-660 Kotron Model 805 Smart RF Level Transmitter
Transmitter/Probe Assembly
Transmitters with probes up to and including 12 inches
(305 mm) in length are shipped pre-assembled. All other
transmitters are shipped unassembled to avoid damage
during transit. These transmitters must be assembled prior
to mounting. Choose your particular configuration from
the following sections and follow the instructions carefully.
2.4.1 Installing a Rigid Probe
Before installing, ensure the:
x
y
z
{
• Probe has adequate headroom for installation and has
unobstructed entry to the bottom of the vessel.
• Process temperature, pressure, dielectric, and viscosity are
within the probe specifications for the installation. See
Specifications, Section 3.6.
To install a probe:
x Make sure the process connection is at least 3⁄4" NPT or a
flanged mounting.
y Carefully place the probe into the vessel. Align the gasket
on flanged installations.
z Align the probe process connection with the threaded or
flanged mounting on the vessel.
{ Tighten the threaded probe process connection using
only the flats on the probe.
Caution: Packing glands used on all Magnetrol rigid probe assemblies have been sealed at the factory under controlled
conditions. Care must be exercised when installing probe
assemblies to avoid breaking the pressure tight gland
seal, which destroys the seal.
2.4.2 Installing a Flexible Probe
Caution: Flexible probes are shipped with the cable clamp and the
packing gland nut hand tightened. The end of a flexible
probe MUST be kept taut by attaching the anchor end at
the bottom of the vessel or by using a Magnetrol supplied
probe weight.
Caution: Do not discard the Mylar housing insulator.
Caution: The probe cable must not be in contact with any metallic
surface in its final installation position.
50-660 Kotron Model 805 Smart RF Level Transmitter
8
To install a probe:
➄➈ Clamp
➄➈ Teflon
Retaining
Bushing
Probe Connection
Screw
➃➉ Mylar Housing
Insulator (slips
over clamp)
➄➉ Socket Head
Clamp Screws (2)
➅➆ Upper Probe
Mounting Gland
➂ Lower Probe
Mounting Gland
Flexible
Probe
Probe
Termination
➀ Optional Weight
Probe Locking
Set Screw
➀ Optional
Mounting
Bracket
(Used w/
Insulated
Probes)
➁ Tank Bracket
Connection
x Attach the weight or anchor assembly to the end of
the probe. Insert the probe through the vessel’s
mounting connection, and feed the cable into the
vessel. Do not allow the probe to scrape against the
connection threads.
y Secure the anchor assembly (if used), to the bottom of
the vessel.
z Apply thread sealant to the mounting nut. Screw the
mounting nut into the mounting connection until tight.
{ Remove the Mylar housing insulator located over the
clamp. DO NOT DISCARD.
| Loosen both socket head screws from the clamp. Pull
the clamp and Teflon retaining bushing off of the probe.
} While holding on to the probe cable, loosen the upper
packing gland nut. DO NOT ALLOW THE PROBE
CABLE TO FALL INTO THE VESSEL.
~ Pull the excess cable up through the packing gland nut
until the cable is taut. Tighten the packing gland nut.
Cut the cable 1.35" (34 mm) above the packing gland
nut and strip off 1.25" (32 mm) of insulation.
Slide the Teflon retaining bushing onto the cable and
seat it into the packing gland nut. Slide the clamp
onto the cable and seat it against the Teflon retaining
bushing.
y
Tighten both socket head screws, on the clamp, to
y
approximately 35 in/lbs of torque. Slip the Mylar
insulator over the clamp.
2.4.3 Installing the Transmitter
x Loosen screw on top of the probe and attach white wire to
probe, making sure that spade lug is at a 90° upward
angle. Tighten probe screw securely.
y Slide white wire through the adaptor while placing the
transmitter on the probe. Tighten the connection by using
the flats on the adaptor.
x
90° Bend
9
50-660 Kotron Model 805 Smart RF Level Transmitter
2.5
Black (-)
Red (+)
Wiring
Caution: The Kotron Model 805 transmitter operates at voltages of
11–36 VDC (GP) and 11–28.6 VDC (IS). Higher voltages
will damage the transmitter.
All wiring between the power supply and the Model 805
transmitter should be made using 18–22 AWG shielded
twisted pair instrument cable. Within the transmitter
enclosure, connections are made to the terminal strip and
the ground connections. The directions for wiring the
Model 805 transmitter depend on the application:
(+)
(-)
• General Purpose or Non-incendive (Cl I, Div. 2)
• Intrinsically Safe
WARNING! Explosion hazard. Do not disconnect equipment
unless power has been switched off or the area is
known to be safe.
2.5.1 General Purpose or Non-incendive (Cl I, Div. 2)
A general purpose installation does not have flammable
media present. Areas rated non-incendive (Cl I, Div. 2)
have flammable media present only under abnormal
conditions. No special electrical connections are required.
If flammable media is contained in the vessel, the transmitter must be installed per Cl I, Div. 1 standards of
area classification.
1.
2.
3.
4.
5.
6.
To install General Purpose or Non-incendive wiring:
Remove the cover to the wiring compartment of the transmitter. Install the conduit plug in the unused opening.
Install a conduit fitting and pull the supply wires.
Connect shield to an earth ground at power supply and
leave floating at the transmitter.
Connect an earth ground wire to the nearest green ground
screw. (Not shown in illustration.)
Connect the positive supply wire to the (+) terminal and
the negative supply wire to the (-) terminal.
Replace the cover to the wiring compartment of the
transmitter.
2.5.2 Intrinsically Safe
An intrinsically safe (IS) installation potentially has flammable media present. An approved IS barrier must be
installed in the nonhazardous (safe) area. See Agency
Drawing – Intrinsically Safe Installation, Section 3.4.4.
50-660 Kotron Model 805 Smart RF Level Transmitter
10
1.
2.
3.
4.
5.
6.
7.
2.6
To install Intrinsically Safe wiring:
Make sure the IS barrier is properly installed in the safe
area (refer to local plant or facility procedures). Complete
the wiring from the barrier to the Model 805 transmitter.
See Agency Specifications – Intrinsically Safe Installations,
Section 3.4.1.
Remove the cover to the wiring compartment of the transmitter. Install the conduit plug in the unused opening.
Install a conduit fitting and pull the supply wires.
Connect shield to an earth ground at power supply and
leave floating at the transmitter.
Connect an earth ground wire to the nearest green ground
screw. (Not shown in illustration.)
Connect the positive supply wire to the (+) terminal and
the negative supply wire to the (-) terminal.
Replace the cover to the wiring compartment of the
transmitter.
Configuring and Calibrating the
Transmitter (LCD version)
Before configuring the Model 805 transmitter, collect the
operating parameters information. Then, power-up the
transmitter. Information on configuring the transmitter
using a HART communicator is given in Configuration
Using HART, Section 2.7.
2.6.1 Operating Parameters
Some key information is needed to calibrate the Model
805 transmitter. Complete the configuration information
table. See Configuration Information, Section 1.1.2.
2.6.2 LCD Transmitter Display and Keypad
Á
The Model 805 LCD transmitter has a liquid-crystal display (LCD) capable of showing two lines of 8 characters
each. Transmitter measurements and configuration menu
screens are shown on the LCD.
The transmitter default display is the measurement screen.
It cycles every 5 seconds to display LEVEL, %OUTPUT,
and LOOP information. The transmitter defaults to this
display after 5 minutes if no keystrokes are sensed.
The keypad has three arrows used to scroll through the
displays and to calibrate the transmitter – the Up ( ) or
Down ( ) Arrow keys and the Enter ( ) key.
Either the Lo Cal or Hi Cal point levels can be entered
first. It is not necessary to do the Lo Cal first. In addition,
the 4 mA and 20 mA setpoints can be entered for either
DIRECT action or REVERSE action as desired.
Á
Á
11
50-660 Kotron Model 805 Smart RF Level Transmitter
Arrows
Function in
Display Mode
Á
Enter
Á
Up and Down Moves forward and backward
in the configuration program
from one display to another.
Function in
Configuration Mode
Increases or decreases the
value displayed or moves to
another choice.
NOTE: Hold arrow key for
rapid scrolling.
Enters the configuration mode Accepts a value and moves
(noted by an exclamation point to the next step of the
as the last character in the top configuration program.
display line).
Á
2.6.3 Password Protection (Default = 0)
The Model 805 transmitter includes optional password
protection to restrict access to certain portions of the
menu structure that affect the operation of the system.
The password can be changed to any numerical value up
to 255. The password is required whenever configuration
values are changed.
The default password installed in the transmitter at the
factory is 0. The last step in the configuration menu provides the option to enter a new password. With 0 as the
password, the transmitter is no longer password protected
and any value in the menu can be altered without entering
a confirming password.
NOTE: If the password is not known, the menu item New Password
displays an encrypted value representing the present password. Call the factory with this encrypted value to determine
the present password.
2.6.4 LCD Menu: Step-By-Step Procedure
The following table provides a complete explanation of the
software menus displayed by the Model 805 transmitter.
Use this table as a step-by-step guide to configure the
transmitter.
The first column presents the menus shown on the transmitter display. The displays are in the order they would
appear if the arrow keys were used to scroll through the
menu. The numbers are not shown on the display. They
are provided as a reference.
The second column provides the actions to take when configuring the transmitter. Additional information or an
explanation of an action is given in the third column.
50-660 Kotron Model 805 Smart RF Level Transmitter
12
DIAGNOSTICS
CALIBRATION/CONFIGURATION
RUN MODE
Display
13
Action
Comment
1
*Level*
*%Output*
*Loop*
Transmitter Display
Transmitter default display. Level, % Output, and Loop
values cycle every 5 seconds (two seconds each value).
2
Level
xx.x lu
Transmitter Display
Level measurement in cm or in.
3
%Output
xx.x%
Transmitter Display
Level as percentage of loop current (20 mA) span.
4
Loop
xx.xx mA
Transmitter Display
Loop current output.
5
Units
lu
Select units for level
measurement display.
lu = cm or in.
6
Lo Cal
xxx.x lu
Enter level value for the
lower calibration point.
Use Up and Down keys to set reading to present level of
medium in vessel. See Section 1.4.
7
Lo Cap
xxxx pF
Transmitter Display
Measured capacitance at low calibration point.
8
Hi Cal
xxx.x lu
Enter level value for the
higher calibration point.
Move the level in the tank. Use Up and Down keys to set
reading to present level of medium in vessel. See Section 1.4.
9
Hi Cap
xxxx pF
Transmitter Display
Measured capacitance at high calibration point.
10
Set 4mA
xxx.x lu
Enter the level value for the
4 mA point.
Use Up and Down keys to set reading to level corresponding
to 4 mA loop current.
11
Set 20mA
xxx.x lu
Enter the level value for the
20 mA point.
Use Up and Down keys to set reading to level corresponding
to 20 mA loop current.
12
Damping
xx sec
Enter damping factor.
Choose the damping factor (1–45 sec) for smoothing the
level/output/loop displays.
13
Fault
Choice
Enter the desired loop current
in presence of a fault.
Select 22 mA, 3.6 mA or Hold. (3.6 mA is not valid if unit
includes both digital display and HART)
14
Poll Adr
xx
Enter HART poll address.
Select a HART poll address (0–15). Enter 0 for a single
transmitter installation.
15
Trim 4
xxx
Trim loop current to 4.00 mA.
With a meter in the loop, use Up and Down keys to adjust
current to 4.00 mA.
16
Trim 20
xxxx
Trim loop current to 20.00 mA.
With a meter in the loop, use Up and Down keys to adjust
current to 20.00 mA.
17
Loop Tst
xx.x mA
Enter test value of loop current
Use Up and Down keys to set loop current to a desired value
(3.5–22.0 mA) for testing.
18
Prb Rdg
xxxx pF
Transmitter Display
Measured capacitance at present level of medium in vessel.
19
Osc Tst
xxxx tk
Transmitter Display
Internal timing count with known capacitance in circuit
(factory diagnostic).
20
Opn Prb
xxxx tk
Transmitter Display
Internal timing count with probe disconnected (factory
diagnostic).
21
# Ticks
xxxxx tk
Transmitter Display
Internal timing count at present level of medium in vessel
(factory diagnostic).
22
Reinit
xx
Select Yes to reinitialize
all values
Resets all configuration parameters to factory default
values.
23
Ver n.nAa
Transmitter Display
Shows version number of firmware.
24
New Pass
xxx
Enter new password
Use Up and Down keys to select desired value (0–255).
50-660 Kotron Model 805 Smart RF Level Transmitter
2.7
Configuring and Calibrating the
Transmitter Using HART
A HART (Highway Addressable Remote Transducer)
remote unit, such as a HART 275 handheld communicator, can be used to provide a communication link to the
Model 805 transmitter. When connected to the control
loop, the same system measurement readings shown on
the transmitter are shown on the communicator. In
addition, the communicator can be used to configure
the transmitter.
-
The HART communicator may need to be updated to
include the Model 805 software (Device Descriptors).
Contact your local HART Service Center for additional
information.
+
2.7.1 Connections
A HART communicator can be operated from a remote
location by connecting to a remote junction or by connecting directly to the terminal block in the electronics
housing of the Model 805 transmitter.
Junction
R L > 250
-
+
Control
Room
Display
HART uses the Bell 202 frequency shift key technique of
high-frequency digital signals. It operates on the 4–20 mA
loop and requires 250 W of minimum load resistance.
A typical connection between a communicator and the
Model 805 transmitter is illustrated.
2.7.2 HART Display Menu
Power
Supply
Current
Meter
A typical HART communicator display is an 8-line by
21-character LCD. When connected, the top line of each
online menu displays the model (Model 805) and its tag
number or address. Usually the bottom line of each menu
is reserved for software-defined function keys (F1–F4). For
detailed operating information, refer to the instruction
manual provided with the HART communicator.
The Model 805 transmitter online menu tree is shown in
the following illustration. Open the menu by pressing the
alphanumeric key 1, Device Setup, to display the secondlevel menu.
2.7.3 HART Device Description (DD)
Device Version 1 (Dev v1), Device Description 2
(DD v2) was registered with HART Communication
Foundation in May, 1999 and is available on the
CD-ROM 1999–2 issued in July, 1999.
50-660 Kotron Model 805 Smart RF Level Transmitter
14
2.7.4 HART Menu
1
2
3
4
Device Setup
Level
% Level Output
Loop
1 Calibration
1
2
3
4
5
6
7
8
Units
Empty Calibration
Full Calibration
4 mA Set Point
20 mA Set Point
Damping
Fault State
Date/Time/Initials
2 Basic Setup
1
2
3
4
5
6
7
Tag
Descriptor
Date
Message
Final Asmbly Num
Poll Address
New Password
1
2
3
4
5
6
7
Adjust 4 mA Trim
Adjust 20mA Trim
4mA Trim Value
20mA Trim Value
Enter Password
Set Magnetrol S/N
Set Dev ID Number
1
2
3
4
5
Loop Test
Error Codes
Probe Reading
Cap at Empty Cal
Cap at Full Cal
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Model
Manufacturer
Dev id
Tag
Descriptor
Date
Message
Units
Cap at Empty Cal
Cap at Full Cal
4 mA Set Point
20 mA Set Point
Damping
Fault State
Date/Time/Initials
FinalAsmbly Num
Universal Rev
Fld Dev Rev
Software Rev
Poll Address
Num Req Preams
Firmware Version
3 Advanced Setup/
Configuration
4 Diagnostics
5 Review
15
1
2
3
4
5
3.6 mA
4 mA
20 mA
22 mA
Other
50-660 Kotron Model 805 Smart RF Level Transmitter
3.0
This section presents an overview of the operation of the
Kotron Model 805 transmitter, information on troubleshooting common problems, listings of agency
approvals, lists of replacement and recommended spare
parts, and detailed physical, functional, and performance
specifications.
+
–
Power Supply
24 Vdc
+
–
Reference Information
Test
Current Meter
Current Meter
3.1
Description
Model 805 is a two wire, 24 VDC, level transmitter based
on the concept of RF Capacitance.
The Model 805 electronics are housed in an ergonomic
housing comprised of two tandem compartments angled at
45 degrees for ease of wiring and calibration. These two
compartments connect via an explosion-proof and watertight feed-through.
3.2
Theory of Operation
RF capacitance electronic level measurement utilizes the
same fundamentals as any electronic capacitor (Figure A).
A capacitor is formed when an AC signal is applied across
two conductive plates separated by an insulating medium,
or dielectric. The value of a capacitor is determined by the:
AC
1. Area of the conductive plates (A);
2. Distance between the plates (D), and;
3. Dielectric of the insulating medium between the
plates (E). Refer to Figure A.
Conductive
Plate
Insulating
Medium
Conductive
Plate
Capacitance = EA/D
(The AC frequency is fixed as part of the design.)
Figure A
50-660 Kotron Model 805 Smart RF Level Transmitter
16
Capacitance is measured in Farads. The value we utilize in
industrial measurement is an extremely small unit called a
pico Farad (pF). A pico Farad is one trillionth of a Farad
(10-12).
Bare
metal
probe
Capacitance value increases as the dielectric increases,
the plate size increases, or the distance between the
plates decreases.
Air
Metal
tank wall
(ground
reference)
In industrial applications (Figure B), the probe is one plate
of the capacitor, the tank wall is the other plate (ground
reference). The insulating material that separates them is
the dielectric. A tank that is empty is actually filled with
air that has a dielectric of 1, the baseline of the dielectric
scale. All materials have a dielectric higher than air, e.g.
oil = 2.5, alcohol = 18, tap water = 80, etc. As a tank is
filled with media, the air (dielectric = 1) is being displaced
by the media having a higher dielectric; consequently, the
amount of capacitance being generated between the probe
and the tank wall increases.
Non-conductive
(insulating)
medium
Figure B
3.3
Troubleshooting
The Model 805 transmitter is designed and built for
trouble-free operation over a wide range of operating conditions. Common transmitter problems are discussed in
terms of their symptoms and recommended corrective
actions. In addition, information on how to handle material build-up on the probe is provided in this section.
WARNING! Explosion hazard. Do not connect or disconnect
equipment unless power has been switched off or the
area is known to be safe.
17
50-660 Kotron Model 805 Smart RF Level Transmitter
3.3.1 Troubleshooting System Problems
Symptom
Problem
Solution
OUTPUT signal always
at 4 mA.
HART Poll address
is not 0.
Change HART Poll Address to 0.
See Secion 2.6.4, Step 14.
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.
Symptom
Problem
Solution
805 FAULT
(Open)
Open probe.
Check probe wiring and electronics
module connector.
805 FAULT
(Shorted)
Shorted probe.
Check probe wiring and integrity of
insulated probe in conductive liquid.
OSC FAIL
(HART error code = 0x40)
Malfunctioning analog board and/or
32 pin connector.
Check connection between boards and
replace electronic module if necessary.
ABV RNG
Above range.
Measured capacitance > 12,000 pF.
Contact factory.
CORRUPT PARAMTRS
(HART error code = 0x10)
Configuration parameters may
have been lost.
Check all Configuration parameters and.
recalibrate if necessary.
SFWR ERROR
Software error.
Bad internal state, unexpected condition.
Contact factory.
LEVEL
(Uncal)
Unit is not calibrated.
Make sure that both Lo Cal and Hi Cal
points have been entered.
3.3.2
Error Messages
50-660 Kotron Model 805 Smart RF Level Transmitter
18
3.3.3 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
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
16V 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
Replace Electronic
Module
Replace Terminal
Board
No
Correct Loop
Resistance
19
Reseat Boards.
Check Power
Supply and Wiring
Display
Working?
Yes
Retest
50-660 Kotron Model 805 Smart RF Level Transmitter
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?
No
Correct Address
Yes
4
50-660 Kotron Model 805 Smart RF Level Transmitter
Adjust 4 and 20 mA
Yes
Address
Correct?
Unit with Display
Communicates
No
Replace Electronic
Module
20
4
Unit with Display
Communicates
Call Factory
Yes
Yes
No
"Software Error?"
Corrupt Display
Text?
Yes
No
Replace Electronic
Module
"Above Range?"
"Uncal?"
No
No
No
"Shorted Probe?"
No
No
Error
Displayed?
Yes
"Corrupt
Parameters?"
No
"Open Probe?"
Yes
"OSC Fail?"
Yes
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
21
Call Factory
50-660 Kotron Model 805 Smart RF Level Transmitter
3.4
Agency Approvals
AGENCY
FM
CSA
ATEX
MODEL APPROVED
APPROVAL CATEGORY
APPROVAL CLASSES
805-5XXX-11X
Intrinsically Safe
805-5XXX-11X
Non-Incendive
805-5XXX-110
Intrinsically Safe
805-5XXX-110
Suitable for:
805-5XXX-A1X
Intrinsically Safe
Class I, Div. 1; Groups A, B, C, & D
Class II, Div. 1; Groups E, F, & G
Class III
T4 Ta = +71° C
Entity
NEMA 4X IP66
Class I, Div. 2; Groups A, B, C, & D
Class II, Div. 2; Groups F & G
Class III
T4 Ta = +71° C
NEMA 4X IP66
Class I, Div. 1; Groups A, B, C, & D
Class II, Div. 1; Group E, F, & G (insulated probes)
(Group G only with bare probe)
Class III
T4 Ta = +71° C
Entity
Type 4X
Class I, Div. 2; Groups A, B, C, & D
Class II, Div. 2; Groups E, F, & G (insulated probes)
(Group G only with bare probe)
Class III
T4 Ta = +71° C
Type 4X
II 1G EEx ia IIC T6*
(-40° to +40° C ambient temp.)
II 1G EEx ia IIC T4*
(-40° to +80° C ambient temp.)
*Special conditions for safe use:
Because the enclosure of the transmitter is made of aluminum alloy, the
transmitter must be installed so, that even in the event of rare incidents,
an ignition source due to impact or friction between the enclosure an
iron/steel is excluded.
These units have been tested to EN 50081-2
and EN 50082-2 and are in compliance with
the EMC Directive 89/336/EEC.
Probes with an insulating layer, used in potentially explosive atmosphere
with gas, vapor or mist of gas group IIC, may only be used for the
measurment of the level of a conductive fluid.
50-660 Kotron Model 805 Smart RF Level Transmitter
22
3.4.1 Agency Specifications – Intrinsically Safe Installation
23
50-660 Kotron Model 805 Smart RF Level Transmitter
3.5
Parts
{
z
|
y
z
x
3.5.1 Replacement Parts
Item
1
2
3
4
5
50-660 Kotron Model 805 Smart RF Level Transmitter
Description
Electronic module includes:
Display (English) and HART
Display only
Terminal board includes:
O-ring (neoprene)
Housing cover without glass
Housing cover with glass
Part Number
Z31-2809-001
Z31-2809-003
Z30-9106-003
012-2201-237
004-9193-003
036-4410-001
24
3.6
Specifications
3.6.1 Functional
System Design
Measurement Principle
RF Capacitance
Input
Measured Variable
Level, determined by change in capacitance values
Zero and Range
0" to 1800" (0 cm to 4572 cm)
Span
5 pF min., 10,000 pF max.
Output
Type
Analog
4 to 20 mA with optional HART digital signal
Range
Analog
3.8 to 20.5 mA useable
Digital
0 to 1800" (0 to 4472 cm)
Analog
0.01 mA
Resolution
Digital
0.1"
Loop Resistance (maximum)
GP/IS-620 Ω @ 24 VDC
Alarm
Adjustable 3.6 mA, (no Display or no HART) 22 mA, HOLD
Damping
Adjustable 1–45 seconds
LCD User Interface
Keypad
3-button menu-driven data entry and system security
Indication
2-line x 8-character display
Digital Communication
HART Version 5.x compatible
Power (Measured at instrument terminals)
General Purpose
11 to 36 VDC
Intrinsically Safe
11 to 28.6 VDC
Housing
Material
Aluminum A356T6 (< 0.2% copper)
⁄4" NPT, M20, PG13.5, PG16
Cable Entry
3
1200
20 mA
1000
800
Ω
600
620
400
200
24 VDC
0
25
11
50-660 Kotron Model 805 Smart RF Level Transmitter
3.6
Specifications
3.6.1 Functional (continued)
Process Conditions
Maximum process temperature
+1000° F @ 500 psig (+538° C @ 35 bar)
Maximum process pressure
5000 psig from -500° to +100° F (345 bar from -296° to +38° C)
Minimum process pressure
-85° F (-65° C)
Environment
Operating temperature
-40 to +175° F (-40 to +80° C)
Display function operating temperature
-5 to +160° F (-20 to +70° C)
Storage temperature
-40 to +175° F (-40 to +80° C)
Humidity
Electromagnetic compatibility
0–99%, non-condensing
Meets CE Requirements (EN 50081-2, EN 50082-2)
Installation
Orientation
Vertical, top-mounted
Depends on probe selection.
See bulletin 50-125 for specifications of available probes.
3.6.2 Performance
Reference conditions
+20° C (+68° F)
Accuracy
±0.5% of span or 0.1" (whichever is greater)
Resolution
0.1 pF
Repeatability
±0.1% of span
Linearity
±0.25% of span
Hysteresis
±0.1% of span
Response time
Warm up time
Temperature effect
50-660 Kotron Model 805 Smart RF Level Transmitter
< 1 s (adjustable via damping)
<5s
Approximately +0.03%/° C
26
3.6
Specifications
3.6.3 Physical
45° View
8.43
(214)
4.94
(126)
3.28
(83)
3.28
(83)
4.12
(105)
4.12
(105)
4.38
(111)
7.88
(200)
7.88
(200)
3.85
(98)
3.85
(98)
45°
Elect.
Conn.
Qty. 2
Optional
Mounting
Flange
Process
Conn.
2.50
(64)
45°
Elect.
Conn.
Qty. 2
2.30
(58)
2.30 (59)
Optional
Mounting
Flange
Probe
Insertion
Length
4.87
(124)
27
2.50
(64)
2.75
(75)
5.55
(141)
50-660 Kotron Model 805 Smart RF Level Transmitter
3.7
Model Numbers
3.7.1 Transmitter
BASIC MODEL NUMBER:
805
Kotron Smart RF Level Transmitter
POWER:
5
24 VDC, Two Wire, Loop Powered
SIGNAL OUTPUT:
0
4–20 mA only, without HART
(must be ordered with Accessory Code A
1
4–20 mA with HART (HART communicator
Magnetrol P/N 089-5213-XXX sold separately)
MENU LANGUAGE:
1
2
3
4
English (Use with Accessory Code A)
Spanish (Use with Accessory Code A)
French (Use with Accessory Code A)
German (Use with Accessory Code A)
ACCESSORIES:
A
Digital display and keypad
MOUNTING/CLASSIFICATION:
Integral, General Purpose, Non-incendive & Intrinsically
1
Safe (FM & CSA)
A
Integral, Intrinsically Safe (CENELEC)
HOUSING
1
Aluminum, Dual Compartment, 45°
2
316 Stainless Steel, Dual Compartment, 45°
CONDUIT CONNECTION:
3
0
⁄4" NPT
1
M20
2
PG 13.5
3
PG 16
8
0
5
5
50-660 Kotron Model 805 Smart RF Level Transmitter
Complete details on the available probes can be
found in Bulletin 50-125, Kotron RF Sensing Probes
28
Glossary
Accuracy The maximum positive and negative % deviation over the total span.
ANSI
American National Standards Institute.
CE Conformité Européene Standards and performance
criteria for the new European Union.
CSA Canadian Standards Association Canadian,
third party agency that qualifies the safety of electrical
equipment.
Damping The mathematical averaging of a meter and/or
output signal to stabilize the effects of a noisy process due
to surface turbulence.
Ground An electrical connection to the Earth’s potential
that is used as a reference for the system and electrical
safety.
Grounded A state where no electrical potential exists
between the ground (green) connection on the transmitter
and the Earth or system ground.
HART Highway Addressable Remote Transducer. Protocol
that uses the Bell 202 frequency shift keying (FSK)
method to superimpose low level frequencies (1200/2000
Hz) on top of the standard 4–20 mA loop to provide
digital communication.
HART ID
See Poll Address.
Default Values The main position of the menu structure
that displays the primary measurement values of LEVEL,
% OUTPUT, and LOOP. The transmitter returns to this
position after 5 minutes of inactivity.
Hazardous Area An area where flammable gases or
vapors are or may be present in the air in quantities sufficient to produce explosive or ignitable mixtures.
Dielectric Constant (ε) The electrical permitivity of a
material. The units are farad/meter.
IEC International Electrotechnical Commission
Organization that sets international standards for electrical
devices.
DVM/DMM
Digital Volt Meter/Digital Multimeter.
EMI Electromagnetic Interference Electrical noise caused
by electromagnetic fields that may affect electrical circuits,
particularly low-power electronic devices.
EN European Normal Committee guidelines in EC
countries that take precedence over local, country guidelines.
Ergonomic A mechanism that considers human capability in its design or function.
Fault A defect or failure in a circuit. The current (mA)
value unit defaults to 3.6, 22, or Hold when a diagnostic
condition occurs.
Feedthrough A small, connecting cavity between the
main housing compartments, carrying the cable that supplies the operating energy to the measurement circuitry
and returns the output value proportional to level. This
cavity is potted to maintain the environmental isolation
between the two compartments.
FM Factory Mutual American, third party agency that
qualifies the safety of electrical equipment.
Four Wire An electronic instrument design that uses one
set of wires to supply power (120/240 VAC, 24 VDC)
and another set to carry the process measurement signal
(4–20 mA). Also called Line Powered.
FSK
29
Frequency Shift Keying.
Increased Safety Designs and procedures that minimize
sparks, arcs, and excessive temperatures in hazardous areas.
Defined by the IEC as Zone 1 environments (Ex e).
Interface: Electrical
electronic circuits.
A boundary between two related,
Interface: Process A boundary between two or more
immiscible liquids.
Intrinsic Safety A design or installation approach that
limits the amount of energy that enters a hazardous area to
eliminate the potential of creating an ignition source.
Level The present reading of the height of material in a
vessel.
Linearity The worst case error calculated as a deviation
from a perfect straight line drawn between two calibration
points.
Line Powered
See Four Wire.
Loop The present reading of the 4–20 mA current
output.
Loop Powered
See Two Wire.
Low Voltage Directive A European Community requirement for electrical safety and related issues of devices using
50–1000 VDC or 75–1500 VAC.
Measured Value The typical level measurement values
used to track the level of a process: Level, % Output,
and Loop.
Kotron Model 805 Smart RF Level Transmitter
Glossary (continued)
Media The liquid material being measured by the level
transmitter.
Multidrop The ability to install, wire, or communicate
with multiple devices over one cable. Each device is given
a unique address and ID.
Nonhazardous Area An area where no volatile mixtures
of vapors/gas and oxygen will be found at any time. Also
called General Purpose Area.
Non-incendive Equipment and wiring which in its normal operating condition is incapable of igniting a specific
hazardous atmosphere or hazardous dust layer.
Offset The distance from the bottom of the tank to the
bottom of the probe.
Password A numerical value between 0 and 65,000 that
protects stored configuration data from unauthorized
manipulation.
Percent (%) Output The present reading as a fraction of
the 16 mA scale (4–20mA).
Poll Address (HART ID) A number between 1 and 15
which sets an address or location of a device in a multidrop loop.
Probe A waveguide that propagates an electromagnetic
pulse from the top of the tank into the process fluid.
Probe Length Exact measurement from the bottom of
the process thread connection to the very bottom of the
probe.
Range
A value related to probe length (factory setting).
Relative Dielectric (εr) A unitless number that indicates
the permitivity of a material.
Repeatability The maximum error between two or more
output readings of the same point.
RFI Radio Frequency Interference Electrical noise that can
have an adverse affect on electrical circuits, particularly
low-power devices.
Span The difference between the upper and lower limits
of the range.
Specific Gravity (SG) The ratio of the density of a
material to the density of water at the same conditions.
Tst Loop Test Loop Built-in system capability to
test/calibrate a loop (or separate loop device) by driving
the transmitter output to a particular value.
Trim 4/Trim 20 Built-in system capability to fine tune
the 4 mA and 20 mA points so the transmitter output
corresponds exactly to user’s meter, DCS input, etc.
Two Wire An electrical instrument design that uses
one set of wires to provide both the supply power and
process measurement signal. The process measurement is
achieved by varying the current of the loop. Also called
Loop Powered.
Units The engineering units used to measure level in the
system. The choices are in (inches) and cm (centimeters).
Probe Type Particular RF configuration or design. Each
probe type is designed to accomplish specific objectives in
an application.
QuickStart The essential information needed for the
Model 805 transmitter and probe to be installed, wired,
and calibrated.
50-660 Kotron Model 805 Smart RF Level Transmitter
30
Index
Agency Approvals: 22
ATEX: 22
Intrinsically Safe installation: 10–11
Keypad: 3,11
Complete Installation: 5
Configuration:
Information: 1
Menu: 15
Password: 12
Operating Parameters: 12, 13
QuickStart: 3
Set 4 mA: 1, 4, 11
Set 20 mA: 1, 4, 11
Shop Set-Up: 10
Transmitter: 11
Units: 1, 4
Using HART: 14
CSA (Canadian Standards
Association): 22
LCD (liquid-crystal display): 3, 13
Electrostatic Discharge (ESD): 5
Equipment and Tools: 1, 6
Menu: 13
Damping: 13
Fault: 13
Level, % Output, Loop: 3, 11,
13, 15, 18
Loop Tst: 13
New Pass: 12
Poll Adr: 15
Set 20 mA: 4, 11, 13
Set 4 mA: 4, 11, 13
Trim 20: 13
Trim 4: 15
Units: 4, 11, 13
Model number:
Probe: 28
Mounting, flexible probe: 8
Mounting, rigid probe: 8
Transmitter: 2, 9
Fault: See Troubleshooting, 17
FM (Factory Mutual): 22
Non-incendive installation: See
Wiring
General Purpose installation: 10
Operating parameters: 11
Operation, theory of: 16
Operational Considerations: 6
Operating Limits: 6
Default password: 4, 12
Display menu: See Menu, 13
HART Communicator: 14–15
Configuring the transmitter: 14
Connections: 14
Display: 14
Menu: 15
Troubleshooting: 18
Installation
Before You Begin: 1, 6
Configuration: 11
Configuration Using HART: 14
Complete Installation: 5
Electrostatic Discharge: 5
Mounting: 7–8
Probe: 8–9
Transmitter: 11
Unpacking: 5
Wiring: 10–11
31
Parts
Replacement: 24
Spare: 24
Password: 4, 12
Probe:
Inspecting: 5
Installing: 8–9
Model Number: 28
Process Connection: 2, 8
Specifications: 25–27
Unpacking: 5
QuickStart Installation: 1–4
Configuration: 1,3
Mounting, probe: 2
Mounting, transmitter: 2
Wiring: 3
Reference Information: 16
Site Preparation: 6
Specifications: 25–27
Functional: 25–26
Performance: 26
Physical: 27
Temperature-Pressure Rating: 26
Transmitter
Configuring: 3–4, 11
Installing: 9
Keypad: 3,11
Model Number: 28
Operating Parameters: 11
Troubleshooting: 17–21
Unpacking: 5
Troubleshooting: 17–21
Error Messages: 18
Flowcharts: 19–21
System Problems: 19
Unpacking: 5
Wiring: 10
General purpose,
non-incendive: 10
Installation: 10–11
Intrinsically Safe: 10–11
Warning: 3, 10
50-660 Kotron Model 805 Smart RF Level Transmitter
Kotron Model 805 Smart RF Transmitter
Configuration and Calibration Data Sheet
Copy blank page and store calibration data for future reference.
Item
Value
Value
Value
Vessel Name
Vessel #
Media
Tag #
Probe P/N
Electronics P/N
Electronics S/N
Units
Lo Cal
Lo Cap
Hi Cal
Hi Cap
4mA point
20mA point
Damping
Fault Choice
HART Poll Address
Trim 4
Trim 20
Loop Test
Probe Reading
OSC Test
Open Probe
# Ticks
Reinit
Version Firmware
New Password
Name
Date
Time
50-660 Kotron Model 805 Smart RF Level Transmitter
32
ASSURED QUALITY & SERVICE COST LESS
Service Policy
Return Material Procedure
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 purchaser (or
owner) other than transportation if:
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 factory, prior to the material's return. This is available
through Magnetrol’s local representative or by contacting
the factory. Please supply the following information:
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 control; 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 consequential damage will be allowed.
1.
2.
3.
4.
5.
Company Name
Description of Material
Serial Number
Reason for Return
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.
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
5300 Belmont Road • Downers Grove, Illinois 60515-4499 • 630-969-4028 • Fax 630-969-9489 • www.sticontrols.com
Copyright © 2006 Magnetrol International, Incorporated. All rights reserved. Printed in the USA.
Magnetrol and Magnetrol logotype are registered trademarks of Magnetrol International.
STI and STI logotype are registered trademarks of Magnetrol International.
Performance specifications are effective with date of issue and are subject to change without notice.
BULLETIN: 50-660.2
EFFECTIVE: May 2006
SUPERSEDES: March 2004