MAGNETROL 082-8113-404

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