KOTRON® SERIES 82 CE Installation and Operating Manual RF Level Transmitter Read this Manual Before Installing This manual provides information on the Kotron Series 82 CE RF Level Transmitter. It is important that all instructions are read carefully and followed in sequence. Detailed instructions are included in the 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. NOTE: 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. WARNING! Explosion hazard. Do not connect or disconnect equipment unless power has been switched off or the area is known to be non-hazardous. Safety Messages The Kotron Series 82 CE RF Level Transmitter 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. Notice of Trademark, Copyright, and Limitations Kotron is a registered trademark of Magnetrol International, Incorporated. Kotron Series 82 CE RF Level Transmitter is a tradename of Magnetrol International, Incorporated. Manual 50-613.11 Copyright © 2006 Magnetrol International, Incorporated. 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. 50-613 Kotron Series 82 CE RF Level Transmitter Kotron Series 82 CE RF Level Transmitter Table of Contents 1.0 Complete Installation 1.1 Unpacking ...........................................................1 1.2 Electrostatic Discharge (ESD) Handling Procedure...1 1.3 Installation Location..............................................2 1.4 Mounting ..............................................................2 1.4.1 Metal Walled Tanks ....................................2 1.4.2 Non-Metallic and Glass-Lined Tank Construction ..............................................3 1.4.3 Transmitter Probe Assembly .......................3 1.5 Probe Installation ..................................................3 1.5.1 Rigid Probe.................................................3 1.5.1.1 Integral Electronics................................3 1.5.1.2 Remote Electronics................................3 1.5.2 Flexible Probe .............................................4 1.5.2.1 Integral Electronics................................5 1.5.2.2 Remote Electronics................................5 1.6 Wiring ..................................................................6 1.6.1 Two-Wire Transmitter without Meter.........6 1.6.2 Two-Wire Transmitter with Meter ..............6 1.6.3 Four-Wire Transmitter without Meter ........7 1.6.4 Four-Wire Transmitter with Meter .............8 1.7 Calibration ............................................................9 1.7.1 Calibration Procedure A .............................9 1.7.2 Calibration Procedure B ...........................10 50-613 Kotron Series 82 CE RF Level Transmitter 2.0 Reference Information ...............................................11 2.1 Description .........................................................11 2.2 Theory of Operation ...........................................11 2.3 Troubleshooting...................................................11 2.3.1 Installation................................................11 2.3.2 Calibration ................................................12 2.3.3 Operation..................................................13 2.4 Agency Approvals ................................................15 2.4.1 Agency Specifications – Intrinsically Safe Installation ................................................16 2.5 Parts ....................................................................17 2.5.1 Replacement Parts ....................................17 2.5.1.1 Transmitter..........................................17 2.5.1.2 Meter ..................................................17 2.5.1.3 Remote Probe Housing .......................17 2.5.1.4 Remote Transmitter Housing ..............17 2.6 Specifications.......................................................18 2.6.1 Electrical...................................................18 2.6.2 Physical.....................................................19 3.0 Model Numbers .........................................................20 1.0 Complete Installation This section provides detailed procedures for properly installing, configuring, and, as needed, troubleshooting the Kotron Series 82 CE RF Level Transmitter. 1.1 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. 1.2 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. 1 50-613 Kotron Series 82 CE RF Level Transmitter 1.3 Installation Location Kotron RF Transmitters should be located for easy access for service, calibration and monitoring. Units should not be exposed to ambient temperatures below -40° F (-40° C) or above +160° F (+70° C). Special precaution should be made to prevent exposure to corrosive atmosphere, excessive vibration, shock or physical damage. 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. 1.4 Mounting The Series 82 CE transmitter can be mounted to a tank using a variety of process connections. 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 semiconductor devices unless you are properly grounded. Caution: When a probe is used in an abrasive medium, inspect the probe periodically for visible surface wear. If damage to the probe insulation is found, replace the probe. 1.4.1 Metal Walled Tanks On water-based liquids, there should be no problem with sensitivity. 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 ground reference probe may be the solution. 50-613 Kotron Series 82 CE RF Level Transmitter 2 1.4.2 Non-Metallic and Glass-Lined Tank Construction With plastic, concrete, wood, or any other non-conductive walled vessels, a ground reference is required. 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. Probe Connection Screw Packing Gland Nut (When installing, use wrench on this nut only) 1.4.3 Transmitter/Probe Assembly Transmitters with probes up to and including 12 inches (300 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. Figure 1 1.5 Transmitter Housing 1.5.1 Rigid Probe Probe Terminal 1. Thread the probe into the mounting connection on the vessel. Tighten securely, making sure that the wrench is applied ONLY to the mounting nut. Refer to Figure 1. Conduit connection P.C. Board Probe Installation Packing Gland Nut 2. Screw the transmitter housing onto the probe until hand tight. The housing can be wrench-tightened to align the conduit connection with the conduit. Refer to Figure 2. Rigid Probe 1.5.1.1 Integral Electronics 1. Remove the housing cover. Locate the white wire which is fastened to the (+) probe terminal. Refer to Figure 3. Connect the free end of this wire to the probe connection screw. Refer to Figure 1. Figure 2 Integral Mount Models with Rigid Probe 2. Proceed to Wiring, Section 1.6. White wire attached to (+) probe terminal 1.5.1.2 Remote Electronics L M H O E I W D G H SPAN + – PROBE 30-9012-001 COARSE ZERO W 101 HIGH MED LOW 322C FINE TP – COARSE TP + POWER FINE 1. Connect the positive lead of the interconnection cable (supplied by Magnetrol), to the screw terminal at the top of the probe. Connect the negative lead to the green ground screw at the base of the housing. Cut the shield; do not connect it at probe end. Refer to Figure 4 on page 4. 2. Install the transmitter housing using the bracket (supplied by Magnetrol). Make sure to provide adequate clearance to remove the housing cover. Refer to Figure 3. 2. Proceed to Wiring, Section 1.7. Figure 3 3 50-613 Kotron Series 82 CE RF Level Transmitter 2. Install the transmitter housing using the bracket (supplied by Magnetrol). Make sure to provide adequate clearance to remove the housing cover. Refer to Figure 3 on page 3. 3. Remove the transmitter housing cover. Connect the positive lead of the interconnection cable to the (+) probe terminal. Connect the negative lead and shield to the (–) probe terminal. Refer to Figure 3 on page 3. Transmitter Housing Probe Connection Screw Probe Terminal Probe Housing 1.5.2 Flexible Probe Shielded Twisted Pair Shielded Conduit Twisted connection Pair Mounting Bracket Caution: Flexible probes are shipped with the cable clamp and the packing gland nut hand tightened to permit length adjustment in the field. The cable clamp and packing gland nut must be tightened before use. 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. Conduit Supplied By User Packing Gland Nut Rigid or Flexible Probe 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. Figure 4 Side View Remote Mount Models w/Rigid or Flexible Probe 1. 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. PROBE WIRE SCREW MYLAR INSULATOR 4. Proceed to Wiring, Section 1.6. CLAMP SET SCREW CLAMP RETAINING BUSHING 2. Secure the anchor assembly (if used) to the bottom of the vessel. 3. Apply thread sealant to the mounting nut. Screw the mounting nut into the mounting connection until tight. 4. Remove the Mylar housing insulator located over the clamp. DO NOT DISCARD. Refer to Figure 4. UPPER MOUNTING NUT HALF 5. Loosen both socket head screws from the clamp. Pull the clamp and Teflon retaining bushing off of the probe. SEAL FLARE LOWER MOUNTING NUT HALF 6. While holding on to the probe cable, loosen the upper packing gland nut. DO NOT ALLOW THE PROBE CABLE TO FALL INTO THE VESSEL. 7. Pull the excess cable up through the packing gland nut until the cable is taut. Tighten the packing gland nut. 8. Cut the cable 1.35 inches (34mm) above the packing gland nut and strip off 1.25 inches (32mm) of insulation. PROBE CABLE 3/8 16 UNC 2B 9. 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. ECTFE Flexible Probe 50-613 Kotron Series 82 CE RF Level Transmitter 4 10. Tighten both socket head screws on the clamp to approximately 35 in./lbs of torque. Slip the Mylar insulator over the clamp. 11. Screw the transmitter onto the probe until hand tight. The housing can be wrench-tightened to align the conduit connection with the conduit. Refer to Figure 2 on page 3. 1.5.2.1 Integral Electronics 1. Remove the housing cover. Locate the white wire which is fastened to the (+) probe terminal. Connect the free end of this wire to the probe connection screw. 2. Proceed to Wiring, Section 1.6. 1.5.2.2 Remote Electronics 1. Remove the probe housing cover. Connect the positive lead of the interconnection cable (supplied by Magnetrol), to the screw terminal at the top of the probe. Connect the negative lead to the green ground screw at the base of the housing. Cut the shield; do not connect it at probe end. Refer to Figure 4 on page 4. 2. Install the transmitter housing using the bracket (supplied by Magnetrol). Make sure to provide adequate clearance to remove the housing cover. Refer to Figure 4 on page 4. 3. Remove the transmitter housing cover. Connect the positive lead of the interconnection cable to the (+) probe terminal. Connect the negative lead and shield to the (–) probe terminal. Refer to Figure 3 on page 3. 4. Proceed to Wiring, Section 1.6. 5 50-613 Kotron Series 82 CE RF Level Transmitter 1.6 Wiring The wiring directions are different depending upon the configuration of your particular transmitter. Choose the appropriate configuration from the following sections and follow the directions carefully. 1.6.1 Two-Wire Transmitter without Meter WARNING: These units are designed to operate with voltages between 14 VDC and 40 VDC only. Application of 120 VAC will destroy the transmitter. Caution: All power must be turned off until all of the wiring connections have been made. + Auxiliary Current Meter Power + Source 14-40 VDC – – 1. TP2 TP1 + + – –+ 4-20 mA Meter Shielded Twisted Pair Cable 2. – Green Ground Screw Figure 5 3. 4. 5. All wiring between the power supply and the transmitter should be done with 16 AWG to 22 AWG shielded twisted pair. The connection is made at the terminal strip within the transmitter enclosure. Remove the transmitter housing cover. Pull the power supply wires through the conduit connection. Connect the positive supply wire to the (+) terminal and the negative supply wire to the (–) terminal. Connect the shield to the green ground screw at the base of the housing. Make the shield wire as short as possible. Refer to Figure 3 on page 3, and Figure 5. Replace the transmitter housing cover until calibration. Connect the positive supply wire to the positive terminal on the power source. Connect the negative supply wire to the negative terminal on the power source. Connect the shield to the power source’s ground terminal and apply power. The yellow LED on the potted module should be on. Proceed to Calibration, Section 1.7. 1.6.2 Two-Wire Transmitter with Meter WARNING: These units are designed to operate with voltages between 14 VDC and 40 VDC only. Application of 120 VAC will destroy the transmitter. Caution: All power must be turned off until all of the wiring connections have been made. All wiring between the power supply and the transmitter should be done with 16 AWG to 22 AWG shielded twisted pair. The connection is made at the terminal strip within the transmitter enclosure. 1. Remove the meter housing cover. 2. Remove the two screws holding the meter bracket to the housing. Pull the meter gently out of the housing, being careful not to disturb the wiring. Lay it on one side. 50-613 Kotron Series 82 CE RF Level Transmitter 6 Transmitter Housing Meter – Power Supply Terminals – – + + Probe Terminal + Conduit Connection – – + Shielded Twisted Pair Power Supply & Signal Terminals + Factory Supplied Wiring Figure 6 3. Pull the power supply wires through the conduit connection. 4. Connect the positive supply wire to the (+) terminal and the negative supply wire to the (–) terminal. Connect the shield to the green ground screw at the base of the housing. Make the shield wire as short as possible. Refer to Figure 6. 5. Replace the meter in its housing and install the meter bracket screws. Be sure that the meter wires are tucked away before replacing the meter housing cover. 6. Connect the positive supply wire to the positive terminal on the power source. Connect the negative supply wire to the negative terminal on the power source. Connect the shield to the power source’s ground terminal. 7. Apply power; the yellow LED on the potted module should be on. 8. Proceed to Calibration, Section 1.7. 1.6.3 Four-Wire Transmitter without Meter Caution: All power must be turned off until all of the wiring connections have been made. Transmitter Housing GND 1. AC 24v +- 2. M+ M- AC 3. Figure 7 4. 5. 7 All wiring between the power supply and the transmitter should be done with 14 AWG to 18 AWG wire. The connection is made at the terminal strip, on the vertical board, within the transmitter enclosure. Remove the transmitter housing cover. Pull the power supply and signal wires through the conduit connection. Connect the hot and neutral wires to the terminals marked AC. Connect the ground wire to the terminal marked GND. Refer to Figure 7. Connect the positive signal wire to the (M+) terminal and the negative signal wire to the (M-) terminal. Connect the shield to the GND terminal. Replace the transmitter housing cover until calibration. Proceed to Calibration, Section 1.7. 50-613 Kotron Series 82 CE RF Level Transmitter 1.6.4 Four-Wire Transmitter with Meter Caution: All power must be turned off until all of the wiring connections have been made. All wiring between the power supply and the transmitter should be done with 14 AWG to 18 AWG wire. The connection is made at the terminal strip, on the vertical board, within the transmitter enclosure. 1. Remove the meter housing cover. 2. Remove the two screws holding the meter bracket to the housing. Pull the meter gently out of the housing, being careful not to disturb the wiring. Lay it on one side. 3. Pull the power supply wires through the conduit connection. 4. Connect the hot and neutral wires to the outer terminals on the terminal strip. Connect the ground wire to the green ground screw at the base of the housing. Refer to Figure 8. 5. Replace the meter in its housing and install the meter bracket screws. Be sure that the meter wires are tucked away before replacing the meter housing cover. 6. Replace the transmitter housing cover until calibration. 7. Proceed to Calibration, Section 1.7. Meter Transmitter Housing AC (H) AC Power AC (N) Power Supply & Signal Terminals Figure 8 50-613 Kotron Series 82 CE RF Level Transmitter 8 1.7 Calibration There are two calibration methods that can be used, depending on your particular situation. Calibration Procedure A will require mov-ing the level from the 0% point (4 mA) to the 100% point (20 mA). Calibration Procedure B allows you to start at a level greater than 0% and stop at a level less than 100%. To attain the best accuracy and linearity use Calibration Procedure A. The following is a list of abbreviations and definitions used in the procedures. L0 The level of the media in the vessel which corresponds to the 0% (4 mA) point L3 100% L2 less than 100% L1 A media level higher than L0 L2 A media level higher than L0 and L1 but less than L3 Calibration Procedure B A L1 greater than 0% Refer to Figure 9. L0 0% The output current can be measured either by inserting a milliammeter into the loop, or by measuring across TP1 (+) and TP2 (–). The intensity of the LED between the test points is a relative indicator of current flow. (The LED will not light with a meter across the test points.) F 2 LOW NOTE: Prior to starting any calibration procedure, turn all potentiometers Zero Coarse, Zero Fine, and Span Fine, 20 turns clockwise. Place the Span Coarse DIP switches in the open position. The Zero Coarse DIP switch should have only the “low” position closed. OPEN 3 MED 1 Figure 9 HIGH closed dip switch Figure 10 9 L3 The level of the media in the vessel which corresponds to the 100% (20 mA) point open dip switch 1.7.1 Calibration Procedure A 1. Move the media level in the vessel to the 0% (4 mA) point. 2. Turn potentiometer Zero Coarse counterclockwise until the loop output is between 4.00 mA and 4.50 mA. 3. If the loop current can not be decreased to at least 4.50 mA, turn the Zero Coarse potentiometer fully clockwise, close DIP switch positions “MED” and “HIGH” sequentially (ONLY ONE SWITCH POSITION SHOULD BE CLOSED AT A TIME—THE OTHER TWO POSITIONS MUST REMAIN OPEN). Repeat Step 2. See Figure 10. 4. Turn potentiometer Zero Fine counterclockwise until the loop output reads exactly 4.00 mA. 5. Move the media level in the vessel to the 100% (20 mA) point. 6. Turn the Span Fine potentiometer counterclockwise until the loop current is exactly 20.00 mA. 50-613 Kotron Series 82 CE RF Level Transmitter 7. If 20 mA cannot be reached, individually close Span Coarse DIP switches (in sequence), #1, #2, and #3, until the loop current is close to (and not less than), 20 mA. (ONLY ONE SWITCH POSITION SHOULD BE CLOSED AT A TIME—THE OTHER TWO POSITIONS MUST REMAIN OPEN). 8. Turn the Span Fine potentiometer counterclockwise until the loop current is exactly 20.00 mA. If 20 mA cannot be reached, repeat Step 6. Calibration is now complete. 1.7.2 Calibration Procedure B 1. Move the media level in the vessel to the lowest level you can set. 2. To determine the correct output level at this point, use the following formula: - L0) L1mA = ( (L1 (L3 - L0) x 16) + 4 3. Turn the Zero Coarse potentiometer counterclockwise until the loop output is between L1mA and L1mA + 0.5 mA. 4. If the loop current output cannot be decreased to at least L1mA + 0.5 mA, turn the Zero Coarse potentiometer fully clockwise, close Zero Coarse DIP switch positions #2 and #3 sequentially (ONLY ONE SWITCH POSITION SHOULD BE CLOSED AT A TIME—THE OTHER TWO POSITIONS MUST REMAIN OPEN). Repeat Step 3. See Figure 10. 5. Turn potentiometer Zero Fine counterclockwise until the loop output reads exactly L1mA. 6. Move the media level in the vessel to the highest level you can set. 7. To determine the correct output level at this point, use the following formula: - L0) L2mA = ( (L2 (L3 - L0) x 16) + 4 8. Turn the Span Fine potentiometer counterclockwise until the loop current reaches the desired value calculated (L2mA) in Step 7. 9. If the desired value cannot be obtained, individually close the Span Coarse DIP switches #1, #2, and #3, until the loop current is as close to (and not less than), L2mA. (ONLY ONE SWITCH POSITION SHOULD BE CLOSED AT A TIME—THE OTHER TWO POSITIONS MUST REMAIN OPEN). 10. Turn the Span Fine potentiometer counterclockwise until the loop current is exactly L2mA. Calibration is now complete. 50-613 Kotron Series 82 CE RF Level Transmitter 10 2.0 Reference Information This section presents an overview of the operation of the Kotron Series 82 CE RF Level Transmitter, information on troubleshooting common problems, intrinsic safety information, physical, functional and performance specifications, listings of agency approvals, and a list of recommended parts. 2.1 Description Kotron Series 82 CE Level Transmitters are designed to measure liquids, slurries, dry-bulk, or liquid-liquid interfaces. The transmitter may be mounted integrally with the probe or can be remote mounted up to 40 feet (12 meters) away. This unit is available as a four-wire transmitter with either 120 VAC or 240 VAC input power, or as a two-wire transmitter with a supply voltage between 14 VDC and 40 VDC. Available options include an analog meter and reverse acting output (20–4 mA). This transmitter can be used with any Kotron R.F. Capacitance probe. 2.2 Theory of Operation The Kotron Series 82 CE Level Transmitter monitors the level by determining the capacitance of the media. The probe and a ground (usually the metal tank wall), form a capacitor. As the level rises and falls in the tank, the amount of capacitance developed between the probe and the ground changes. This change of capacitance is converted to a proportional 4–20 mA signal. 2.3 Troubleshooting The output current can be measured either by inserting a milliammeter into the loop, or by measuring across TP1 (+) and TP2 (–). The intensity of the LED between the test points is a relative indicator of current flow. Caution: When a probe is used in an abrasive medium, inspect the probe at least annually for visible surface wear. In case any wear is found, replace the probe or consult the factory. 2.3.1 Installation LED does not light after wiring is completed and power turned on. a. Wires reversed at supply or transmitter. b. Wires broken or not connected. 11 50-613 Kotron Series 82 CE RF Level Transmitter c. Excessive loop resistance. Refer to Chart 1 on page 15 for maximum resistance. d. Power supply not turned on. e. Insufficient source voltage. 14 volts minimum is required at transmitter terminals. f. Test points jumpered together with current meter. Remove meter. g. LED is actually on but very dim. Turn span and zero potentiometers fully clockwise; if LED is now on, proceed with calibration. h. Potted module defect. Consult factory for help. 2.3.2 Calibration 1. Test meter connected to calibration points, but LED still on. a. Wrong test meter mode. Use low resistance current meter. b. Test meter resistance is too high. Obtain meter with less than 10 ohms resistance. c. Test meter not properly connected to calibration points. d. Defective test meter or leads; meter fuse blown. 2. Cannot read loop current at calibration points and LED is off. a. Meter set at too high of a range. Maximum loop current is 38 mA (0.038 amps). b. Calibration points jumpered together. Remove jumper. c. No power, or sufficient power at transmitter terminals. — Refer to Steps “a” through “h” under Installation section beginning on page 11. 3. Zero point cannot be set to 4.00 mA at low level. a. Wires reversed at supply or transmitter. b. Span controls incorrectly set — Turn span potentiometers fully clockwise before calibrating zero. c. Excessive probe capacitance — Decrease length of probe covered at zero level; — Remove stilling well; — Increase diameter or stilling well; — Locate probe farther from walls; — Use probe with lower dielectric insulation; — Replace bare probe with insulated probe; — Consult factory. 50-613 Kotron Series 82 CE RF Level Transmitter 12 4. Span point cannot be increased to 20 mA at high level. a. Span controls incorrectly set — Turn span controls clockwise b. Insufficient probe capacitance — Increase span length or probe; — Increase probe diameter; — Locate probe closer to wall(s); — Use probe with higher dielectric insulation; — Install stilling well; — Use smaller diameter stilling well; — Consult factory. c. Excessive loop resistance — Refer to Chart 1 for maximum allowable loop resistance. 5. Span current cannot be reduced to 20 mA at high level. a. Span controls set too high — Turn span controls counterclockwise b. Excessive probe capacitance — Maximum span range is: 110 pF – switches open 485 pF – switch 1 closed 1950 pF – switch 2 closed 4000 pF – switch 3 closed — Decrease span length of probe; — Remove stilling well; — Increase diameter of stilling; — Locate probe farther from walls; — Use probe with lower dielectric insulation; or — Replace bare probe with an insulated one; — Consult factory. c. Low probe resistance to ground — Probe resistance must be more than 10 megohms. — Consult factory. 2.3.3 Operation 1. Loop current oscillates or hunts. a. Waves or disturbances in medium — Use stilling well; — Use external cage or standpipe for transmitter; — Correct instability of medium. b. Probe moving within vessel — Improve probe anchoring 13 50-613 Kotron Series 82 CE RF Level Transmitter 2. Loop current randomly unstable. a. Disturbances in medium — Correct instability of medium b. Power supply unstable — Repair or replace power supply c. Electrical interference (RFI) — Consult factory. 3. Loop current exceeds 20 mA. a. Incorrect calibration — Recalibrate unit b. Material level above 100% — No corrective action needed on transmitter c. Extreme material build-up on probe — Possible misapplication; consult factory. d. Shorted or resistive probe — Replace probe. e. Supply voltage out of limits at transmitter terminals — Allowable voltage between 14 and 40 VDC. Refer to Chart 1 on page 15. f. Excessive temperatures at transmitter electronics — Use remote electronics g. Excessive loop resistance. Refer to Chart 1 on page 15. — Reduce loop resistance; — Increase supply voltage; consult factory. 4. Loop current less than 4 mA. a. Incorrect calibration — Recalibrate unit b. Material level below 0% — No corrective action needed on transmitter c. Shorted or resistive probe — Replace probe. d. Supply voltage out of limits at transmitter terminals — Adjust power supply; or — Reduce loop resistance e. Excessive temperatures at transmitter electronics — Use remote electronics f. Excessive loop resistance. — Reduce loop resistance 50-613 Kotron Series 82 CE RF Level Transmitter 14 Loop Resistance vs. Power Supply Voltage 1300 MAXIMUM LOOP RESISTANCE (Ohms) (Including Barrier Resistance) 1200 1100 1000 900 800 700 600 500 500 ohms at 24 V 400 300 200 100 0 12 14 16 18 20 22 24 26 28 30 32 34 36 38 Power Supply Voltage (Volts) Chart 1 5. Non-linear output a. Incorrect calibration — Recalibrate unit b. Excessive loop resistance. 1300 ohms — Reduce loop resistance @ 40 V c. Damaged jacket on insulated probe — Replace probe d. Extreme material build-up on probe — Possible misapplication; consult factory. e. Interfering surfaces too close to probe — Mount probe in better location; — Use stilling well; — Use non-metallic brackets and/or standoffs to position flexible or extremely long rigid probes a uniform distance from the tank wall. 40 f. Curved or non-parallel surfaces near probe — Mount probe in better location; — Use stilling well. 2.4 Agency Approvals AGENCY APPROVED MODEL PROTECTION METHOD FM 082-8303-400 082-8303-410 082-8304-400 082-8304-410 Intrinsically Safe Non-Incendive Suitable for: CSA 082-8303-400 082-8303-410 Intrinsically Safe Suitable for: 082-8303-400 082-8303-410 ATEX 082-84XX-4XX Explosion Proof Intrinsically Safe Not I.S. (CSA) for Groups E & F when used with a bare probe. Approval is valid only with the use of insulated probes. Non-hazardous process fluids only AREA CLASSIFICATION Class I, Div 1, Groups A, B, C & D; Class II, Div 1, Groups E, F & G; Class III, NEMA 4X Class I, Div 2, Groups A, B, C & D Class II, Div 2, Groups F & G; Class III Class I, Div 1, Groups A, B, C & D; Class II, Div 1, Groups E, F & G; Class III, TYPE 4X Class I, Div 2, Groups A, B, C & D; Class II, Div 2, Groups F & G; Class III Class I, Div 1, Groups C & D; Class II, Div 1, Groups E, F & G Class III, TYPE 4X II 1 G EEx ia IIC T6* These units have been tested to EN 50081-2 and EN 50082-2 and are in compliance with the EMC Directive 89/336/EEC. *Special conditions for safe use: When the amterial is equipped with an aluminum enclosure, all precautions shall be taken in order to avoid all impacts or frictions which can induce the ignition of the potentially explosive atmosphere. The probes in their insulated finitions, don’t answer to the requirements of clause 4.4 of the standar EN 50284. The user shall, therefore, taken all necessary precautions during the use of these probes in a category 1 (Zone 0) zone. Furthermore, these probes shall be only used in conductive liquids (conductivity ≥ 10 u8/cm). For the remote mount, the cable between the probe and the amplifier shall not exceed 6 m and shall withstand a voltage test of 500 VAC at least. 15 50-613 Kotron Series 82 CE RF Level Transmitter 2.4.1 Agency Specifications – Intrinsically Safe Installation 50-613 Kotron Series 82 CE RF Level Transmitter 16 2.5 Parts 2.5.1 Replacement Parts 2.5.1.1 Transmitter Item Description Part Number Potted Module Base 004-9104-001 Cover 004-9105-001 O-Ring 012-2101-345 Probe Same as Original Part Number Probe Wire 009-7176-001 Shielded Twisted Pair 4-20 mAdc 20-4 mAdc Up to 20 ft. (6.1M) 20 to 40 ft. (6.1 to 12 M) Z30-9012-001 Z30-9012-002 009-7176-001 009-8222-001 Flexible Probe Anchor Assembly 032-8814-001 Flexible Probe Weight 004-4355-001 Four-Wire Power Supply Assembly consisting of: Transformer, Power Supply Board and Bracket 120 VAC 240 VAC Z30-9111-001 Z30-9111-002 2.5.1.2 Meter Item Description Part Number Meter Assembly 037-3145-001 11 Base 004-9112-001 12 Cover Assembly 036-3908-001 13 O-Ring 012-2501-247 14 1" x ⁄4" Bushing 004-1739-001 15 1.5" Long, ⁄4" NPT Pipe Nipple 011-1105-014 3 3 2.5.1.3 Remote Probe Housing Item Description Part Number 16 Base 004-9104-001 17 Cover 004-9105-001 18 O-Ring 012-2101-345 2.5.1.4 Remote Transmitter Housing Item 19 17 Description Part Number Mounting Bracket 036-3805-001 50-613 Kotron Series 82 CE RF Level Transmitter 2.6 Specifications 2.6.1 Electrical Supply Voltage 24 VDC, (14-40 VDC) 120/240 VAC, 50-60 Hz, (+10/-15%) 38 mA maximum Current Line Variation Ambient Temperature Less than ± .10%/volt, for voltages between 14-40 VDC -40° to +160° F (-40 to +70° C) Zero Range Span Range Output Linearity 1000 pF (max.), 0pF (min.) 4000 pF (max.), 50pF (min.) 50-500 pF ± 1% of span 501-1500 pF ± 2% of span 1501-4000 pF ± 1% of span Less than 0.1 second ± 0.25% Response Time Repeatability Temperature Coefficient of Output -40° to +160° F (-40° to +70° C) 4000 pF span: Less than 0.035%/° F (0.063%/° C) 1000 pF span: Less than 0.025%/° F (0.045%/° C) 50 pF span: Less than 0.075%/° F (0.135%/° C) Consult factory for higher temperatures on remote mounted transmitter Potted Module 1 6 Probe Wire 3 Cover Cover Assembly 12 13 O-Ring 10 Meter Assembly O-Ring Bushing 14 4 11 Base 20 40 60 80 100 0 7 Shielded Twisted Base 2 Mounting 19 Bracket 15 Pipe Nipple Probe 5 Two-Wire Transmitter Meter Transformer Bracket Cover Four-Wire 17 Power Supply Board O-Ring 16 Base 1 Four-Wire Transmitter 50-613 Kotron Series 82 CE RF Level Transmitter Remote Probe Housing 18 2.6.2 Physical 4.63 (118) Dia. 3.00 12.65 (321) 4.63 (118) Dia. 3.00 (76) (76) 2.75 (70) 3/4" NPT Optional mounting flange 1" NPT Optional mounting flange 3.5" (90) 3.5" (90) 3/4" NPT 3/4" NPT I.L. I.L. .50 (13) .625 (16) .50 (13) .625 (16) Integral Mount with Rigid Probe (24 VDC Two-Wire) 4.63 (118) Dia. 3.00 Integral Mount with Rigid Probe and Meter (24 VDC Two-Wire) (76) 4.54 (115) 3/4" NPT Optional mounting flange 4.63 (118) Dia. 3.00 (76) 6.68 (170) 4.63 (118) Dia. 2 Holes .38 Dia. (10) 2.75 (70) 4.76 (121) 4.38 (110) 2.37 (60) Optional mounting flange 3.5" (90) 3/4" NPT Probe 2 diameter .1875 (5) .2500 (6) 2 Optional anchor assembly P/N 032-8814-001 I.L. 3.00 (76) 2.00 (51) 3.75 (95) 3.50 (89) 3/4" NPT 3.00 (76) 3/4" NPT I.L. Side View Bracket Front View 2.95 (75) 4.87 (124) 5.50 (141) .50 (13) .625 (16) .75 (19) Optional weight P/N 032-8814-001 1.25 (32) Remote Mount with Rigid Probe (24 VDC Two-Wire) Integral Mount with Flexible Probe (120 VAC or 240 VAC Four-Wire) 4.63 (118) Dia. 14.08 (358) 4.63 (118) Dia. 3.00 (76) 2 Holes .38 Dia. (10) 3.00 2.75 (70) 4.76 (121) (76) Optional mounting flange 2.37 (60) 3.75 (95) 10.33 (262) Side View 3/4" NPT 3.50 (89) 1" NPT 3.5" (90) 3.00 (76) 2.00 (51) 3/4" NPT I.L. Bracket Front View .50 (13) .625 (16) Remote Mount with Rigid Probe and Meter (24 VDC Two-Wire) 19 50-613 Kotron Series 82 CE RF Level Transmitter 3.0 Model Numbers BASIC 082 82 CE transmitter HOUSING 8 FM/CSA/ATEX EEx ia, aluminum 3⁄4" NPT dual conduit FUNCTION/INPUT POWER 0 Four-wire, 120 VAC 1 Four-wire, 240 VAC 3 Two-wire, 24 VDC Nominal (14 to 40 VDC), FM, CSA 4 Two-wire, 24 VDC Nominal (14 to 40 VDC), ATEX Intrinsically Safe METER 0 None 1 Analog meter (Not CSA, FM, or ATEX approved) OUTPUT SIGNAL 3 4 Standard 4-20 mA Reversed 20-4 mA (Not CSA approved) MOUNTING CONFIGURATION 00 04 10 14 Integral, NEMA 4X/7/9 aluminum housing Integral, NEMA 4X/7/9 316 stainless steel housing Remote, NEMA 4X/7/9 aluminum housing Remote, NEMA 4X/7/9 316 stainless steel housing PROBE ASSEMBLIES A full range of rigid and flexible probes, for conductive and non-conductive process media, is available. For further information on probe assemblies, please refer to bulletin 50-125. Not available with mounting codes 04 and 14. Consult factory on reversed output model. Not available with function/input power codes 0 and 1. Remote units supplied with separate probe and transmitter housing, 20 feet (6 meters) of cable and transmitter housing bracket. Remote units up to 40 feet (12 meters) with special cable, order cable part number 009-8222-001. Not available with Meter option code 1. 0 8 2 50-613 Kotron Series 82 CE RF Level Transmitter 4 20 ASSURED QUALITY & SERVICE COST LESS Service Policy Return Material Procedure Owners of Magnetrol/STI 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/STI 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. 2. 3. 4. 5. 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. 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 1. 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 Heikenstraat 6 • B 9240 Zele, Belgium • 052 45.11.11 • Telex 25944 • 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 STI Controls, L.P. All rights reserved. Printed in the USA. 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: 50-613.11 EFFECTIVE: May 2006 SUPERSEDES: May 2003