Kotron® 805 Installation and Operating Manual R.F. Capacitance Level Transmitter ® 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 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 are in conformity with the provisions of: 1. The EMC Directive: 2014/32/EU. 0038 The units have been tested to 0344 EN 61326: 1997 + A1 + A2. 2. Directive 2014/34/EU for Equipment or protective system for use in potentially explosive atmospheres. EC-type examination certificate number KEMA98ATEX4467X. 3. The PED directive 97/23/EC (pressure equipment directive). Safety accessories per category IV module H1. SPECIAL CONDITIONS FOR ATEX INTRINSICALLY SAFE USE 1. Because the enclosure of the transmitter is made of aluminium 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 and iron/steel is excluded. 2. Probes with an insulating layer, used in a potentially explosive atmosphere with gas, vapour or mist of gas group IIC, may only be used for the measurement of the level of a conductive fluid. MOUNTING KOTRON R.F probes (For installation details see bulletin BE50 - 125) d1 inactive sheath Bent probe Wrong d1 = d2 d2 Probe with inactive sheath Stillwell probe Flexible probe 2 cable entries (one plugged): M20 x 1.5 or 3/4" NPT (a) (b) 2 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. 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). 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 Current loop test points P1 + LOOP CURRENT – P2 – IS IS + www.magnetrol.com ® Ground wire to green grounding screw or to external grounding screw Standard shielded twisted pair cable 100 % 0% Ex Non Ex Ex Non Ex Ex Galvanic Barrier: max: 28,6 V DC @ 140 mA Customer supplied local current meter Non Ex 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 Enter 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 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 Units! cm Comment Press : Units! cm Press : 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. * 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 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 Ent Pass 0 Ent Pass! 1 New Pass 4096 New Pass 0000 4 Action Comment "0" means that no password is introduced Factory default setting Press and last character changes into "!" Enter a value between 1 up to 255 as your personal password with and Changing password 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 Protect data by new password Data is not protected CALIBRATION - TRANSMITTER WITH LCD SCREENMENU: STEP BY STEP PROCEDURE Screen Run mode 1 2 3 4 5 6 7 8 Configuration 9 10 11 12 13 14 15 16 17 18 19 Diagnostics 20 21 22 23 24 *Level* *%Output* *Loop* Level xx.x cm %Output xx.x% Loop xx.xx mA Units xxx Action Transmitter Display Transmitter Display Transmitter Display Transmitter Display Select units for level measurement readout. Comment Transmitter default display. Level, % Output, and Loop values cycle every 5 seconds. Transmitter displays Level measurement in cm or in. Transmitter displays % Output measurement derived from the 4-20 mA span. Transmitter displays Loop measurement (mA). cm or inches. = min. required calibration Lo Cal xxx.x lu Enter level value of the low calibration point Transmitter Display Transmitter displays capacitance at low calibration point in pF Hi Cal xxx.x lu Enter level value of the high calibration point Transmitter Display Set level at high calibration point and adapt with Up and Down the displayed value Transmitter displays capacitance at high calibration point in pF 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 Lo Cap Xxxx pF Hi Cap Xxxx pF Set 20mA xxx.x Damping xx sec Fault Choice Poll Adr xx Trim 4 xxxx Trim 20 xxxx Enter the level value for the 20 mA point. Enter the damping factor. Enter the default value. Enter HART ID number. Fine tune the 4 mA point. Fine tune the 20 mA point. Set level at low calibration point and adapt with Up and Down the displayed value 20 mA level cannot be set at a higher level than the top of the probe A Damping factor (1-45 seconds) may be added to smooth a noisy display and/or output due to turbulence. Select 3.6 mA, 22 mA or HOLD (last value). 3.6 mA is not valid if unit includes HART. Select a HART poll address (0-15). Enter 0 for a single transmitter installation. 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. 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. Enter a mA Output value. Set mA Output to any given value to perform loop test. Prb Rdg Xxxx pF None, do not adjust. Transmitter displays capacitance at present level None, do not adjust. Opn Prb xxxx tk None, do not adjust. Transmitter displays internal timing count with fixed capacitance (factory diagnostic) Loop Tst xx.x mA Osc Tst Xxx tk # Ticks xxxx Reint xxx Vern.nAa New Pass xxx None, do not adjust. Reinitialize all values. None, do not adjust. Enter new password. Transmitter displays internal timing count with probe disconnected (factory diagnostic) Transmitter displays internal timing count at present level (factory diagnostic) Reinitialize - choose YES to reset all configuration values back to factory defaults. Transmitter displays version number of firmware Use arrows to select desired value. Values between 1 and 255 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. + Junction 250 Ω < RL < 450 Ω + Control Room Display Power Supply Current Meter 1 Device Setup 2 Level 3 % Output 4 Loop 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. HART MENU 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 1 Tag 2 Descriptor 3 Date 4 Message 1 Adjust Trim 4 mA 2 Adjust Trim 20 mA 3 4 mA Trim Value 4 20 mA Trim Value 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 5 20 mA Set Point 6 Damping 7 Fault State 8 Date/Time/Initials 5 Final Asmbly Num 6 Poll Address 7 New Password 5 Enter Password 6 Set Magnetrol S/N 7 Set Dev ID Number 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, % OUTPUT and LOOP values fluctuate. Turbulence. Increase the Damping factor until the readings stabilize. HART device only: handheld will only read Universal Commands. Most current Device Descriptors (DDs) are not installed in handheld. LEVEL readings are repeatable but consistently high or low from actual by a fixed amount. Configuration data does not accurately match tank height. LOOP value jittery, usually in tenths or hundredths digit. Factory settings corrupted. 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. ERROR MESSAGES – LCD version Symptom OSC FAIL (HART error code = 0x40) CORRUPT PARAMTRS (HART error code = 0x10) 805 FAULT (Open) 805 FAULT (Shorted) LEVEL (Uncal) ABV RNG (Above range) SFWR ERROR (Software error) Problem Recalibrate if necessary. Check # of Ticks. If the number is also jittery, consult the Factory. Contact local HART service center for the latest DDs. Contact manufacturer of your HART master software for upgrade. This is a shortcoming of early HART master software. Solution malfunctioning analog board and/or 32 pin connector (electronic module) between electronics and probe. Check connection between electronics and probe or replace electronic module. Probe disconnected. Check white probe wire (see page 2) and electronic module. Configuration parameters may have been lost. Check all configuration parameters and recalibrate if required. Probe shorted. Check white probe wire (see page 2) and probe insulation. Unit is not calibrated. Measured capacitance is higher than 12,000 pF. Software error. Enter both Low and High calibration points. Consult factory. Consult factory. 7 REPLACEMENT PARTS Partn°: Digit in partn°: 8 0 5 X 1 2 3 5 4 5 6 7 8 9 10 Serial n°: See nameplate, always provide complete partn° and serial n° when ordering spares. X = product with a specific customer requirement EXPEDITE SHIP PLAN (ESP) Several parts are available for quick shipment, within max. 1 week after factory receipt of purchase order, through the Expedite Ship Plan (ESP). Parts covered by ESP service are conveniently grey coded in the selection tables. Digit 5 6 4 2 0 5 3 1 1 (1) Electronic module Digit 6 Replacement part 1 031-2809-003 2 031-2809-023 3 031-2809-033 4 031-2809-043 0 031-2809-002 1 031-2809-001 2 031-2809-021 3 031-2809-031 4 031-2809-041 (2) Wiring PC board (3) "O"-ring (4) "O"-ring Digit 7 0 A Digit 9 1 2 8 Replacement part Z30-9106-003 012-2201-237 012-2201-237 (5) Housing cover Digit 9 Replacement part 1 004-9225-002 2 004-9225-003 1 036-4413-005 2 036-4413-002 (6) Housing cover Replacement part 004-9225-002 004-9225-003 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 No No Loop Current Above 23 mA? Failure to Operate with Correct Loop Inputs Good Display 2 Voltage < 11V IS or 14.5V XP? 1 Yes Remove Electronic Module Loop Current Above 1 mA? No Yes See page 11 Loop Resistance Wrong? No Correct Loop Resistance Reseat Boards. Check Power Supply and Wiring Yes No No Display Working? Replace Electronic Module Yes Replace Terminal Board Retest 9 MAINTENANCE TROUBLESHOOTING FLOWCHART (LCD version) 1 Failure to Operate with Correct Loop Inputs No Display Working? Reseat Boards Yes Retest 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 2 Good Display Replace Terminal Board Display Working? No Yes Key Board Responds? No Replace Electronic Module Yes HART Working? Retest Unit Yes Unit has HART? No Yes Check Loop Current at Wiring Board Loop Current 22 - 4.0 mA? Yes 4 See page 11 No Adjust 4 and 20 mA No Correct Address Yes Address Correct? Unit with Display Communicates 10 No Replace Electronic Module MAINTENANCE TROUBLESHOOTING FLOWCHART (LCD version) 4 Unit with Display Communicates Yes Corrupt Display Text? Yes Replace Electronic Module No Error Displayed? Yes "Open Probe?" No "Above Range?" "Shorted Probe?" No No Call Factory Yes "Software Error?" No No No No "Uncal?" "Corrupt Parameters?" Yes "OSC Fail?" Yes Yes Yes Check Analog Parameters No Check Calibration Parameters Check Probe and Connectors Analog Loop Correct? No 3 Check Offset and 4-20 mA Set Points Trim 4-20mA Retest No Same Error Message? Yes 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 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®) 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 (ambient temperature: -40 °C up to +80 °C) ATEX II 1 G EEx ia IIC T6 (ambient temperature: -40 °C up to +40 °C) Electrical Data Ui = 28,6 V, li = 140 mA, Pi = 1 W Housing Material Aluminium A356T6 (< 0.25% copper) or 316 SST (1.4401) / IP 66 Equivalent Data Ci = 2,2 nF; Li = 0,037 mH Menu Language English/Spanish/French or German 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 Storage temperature -40 °C to +80 °C (-40 °F to +175 °F) Ambient temperature electronics -40 °C to +80 °C (-40 °F to +175 °F) Display not readable below -20 °C (-5 °F) Humidity 0-99 %, non-condensing Electromagnetic Compatibility Meets CE requirements (EN 61326: 1997 + A1 + A2) and NAMUR NE 21 PERFORMANCE Description Specification Reference conditions 20 °C (70 °F) Repeatability +/- 0.1% of span Accuracy +/- 0.5% of span or 2.5 mm whichever is greater Resolution 0.1 pF 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 800 Ω 23 mA 650 Ω 600 620 Ω 400 200 0 12 0 10 11 20 24 V DC 30 OUTPUT TABLE 40 V DC DIMENSIONS in mm (inches) 83 (3.28) 105 (4.12) 45° View 200 (7.88) 126 (4.94) 98 (3.85) 214 (8.43) 111 (4.38) Kotron 805 Housing front View 45° 2 cable entries Mounting Flange 220 (8.66) Probe Insertion Length Insertion Length Optional Mounting Flange 3/4" NPT 1" NPT 1G (1" BSP) 220 (8.66) Rigid probe 3/4" NPT Optional Anchor Assembly 5 (0.1875) 6 (0.2500) 124 (4.87) 13 (0.50) - bare probe 16 (0.625) - insulated probe Kotron 805 Housing side view Optional Mounting Flange 127 (5.00) 75 (2.95) 34 (1.32) Flexible probe Optional Weight CONNECTIONS Insertion length Tri-Clamp® Insertion length Threaded NPT Insertion length Threaded BSP Insertion length Welded flange ANSI / EN (DIN) 13 IDENTIFICATION A complete measuring system consists of: 1. Kotron 805 transmitter head/electronics. 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. 1. Code for KOTRON® 805 transmitter head/electronics BASIC MODEL NUMBER 8 0 5 KOTRON® 805 transmitter POWER 5 24 V DC, two wire loop powered 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 ACCESSORIES 0 A Blind transmitter (no display/keypad) - requires HART® communication Digital display and keypad APPROVAL 1 A Weatherproof Intrinsically safe, ATEX II 1G EEx ia II C T6 HOUSING 1 2 Cast aluminium, dual compartiment housing – IP 66 Stainless steel, dual compartiment housing – IP 66 CABLE ENTRY 0 1 8 0 5 5 3/4" NPT (2 entries - one plugged) M20 x 1.5 (2 entries - one plugged) complete code for KOTRON® 805 transmitter head/electronics X = product with a specific customer requirement 14 Notes 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. Purchaser Name 2. Description of Material 3. Serial Number and Ref Number 4. Desired Action 5. Reason for Return 6. Process details Any unit that was used in a process must be properly cleaned in accordance with the proper health and safety standards applicable by the owner, before it is returned to the factory. A material Safety Data Sheet (MSDS) must be attached at the outside of the transport crate or box. All shipments returned to the factory must be by prepaid transportation. Magnetrol will not accept collect shipments. All replacements will be shipped Ex Works. BULLETIN N°: EFFECTIVE: SUPERSEDES: UNDER RESERVE OF MODIFICATIONS BE 50-660.2 JANUARY 2016 April 2002 www.m a gne t r ol.c om BENELUX FRANCE Heikensstraat 6, 9240 Zele, België -Belgique Tel. +32 (0)52.45.11.11 • Fax. +32 (0)52.45.09.93 • E-Mail: [email protected] DEUTSCHLAND Alte Ziegelei 2-4, D-51491 Overath Tel. +49 (0)2204 / 9536-0 • Fax. +49 (0)2204 / 9536-53 • E-Mail: [email protected] INDIA B-506, Sagar Tech Plaza, Saki Naka Junction, Andheri (E), Mumbai - 400072 Tel. +91 22 2850 7903 • Fax. +91 22 2850 7904 • E-Mail: [email protected] ITALIA Via Arese 12, I-20159 Milano Tel. +39 02 607.22.98 • Fax. +39 02 668.66.52 • E-Mail: [email protected] RUSSIA 198095 Saint-Petersburg, Marshala Govorova street, house 35A, office 427 Tel. +7 812 320 70 87 • E-Mail: [email protected] U.A.E. DAFZA Office 5EA 722 • PO Box 293671 • Dubai Tel. +971-4-6091735 • Fax +971-4-6091736 • E-Mail: [email protected] UNITED KINGDOM Unit 1 Regent Business Centre, Jubilee Road Burgess Hill West Sussex RH 15 9TL Tel. +44 (0)1444 871313 • Fax +44 (0)1444 871317 • E-Mail: [email protected]