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KOT RON ® SERIES 82 C E Installation and OperatingMan ual

50-613Kotron Series82 CE RF LevelTransmitter ReadthisMan ualBefore Installing Thism anualprovidesinformationon the Ko tron Series 82CE R F LevelT ransmitter.Itisimportantthatall instructionsare readcarefullyand followed insequence. Detailedinstructionsareincluded inthe Installation sectionofthism anual. ConventionsUsed in thisMan ual Certainconventionsareusedinthism anualtoconvey specifictypesofinformation.Gen eraltechnicalmaterial, supportdata,and safetyinformationarepresentedin narrativeform. Th e followingstylesareusedfornotes, cautions, and warnings. NOTE: Notescontain information thataugm entsorclarifies an operatingstep. N otesdo notnormallycontain actions. T hey follow the proceduralstepstowhich theyrefer. C autions Cautionsalertthetechnicianto specialconditions thatcouldinjurepersonnel, dam age equipment,or reducea com ponent’sm echanicalintegrity. C autions are alsoused toalertthe technicianto unsafeprac - ticesortheneed forspecialprotective equipmentor specific materials.Inthism anual,a cautionbox indi - catesa potentiallyhazardoussituationwhich,ifnot avoided, may resultinm inororm oderateinjury. W arnings W arningsidentify potentially dangeroussituationsor serioushazards.Inthism anual, a warning indicates an immi nently hazardoussituation w hich, ifnot avoided, couldresultinseriousinjuryordeath. WARN ING ! Explosion hazard. Do notconnectordis - connectequipmentunlesspower hasbeenswitchedoff orthe areaisknown tobe non-hazardous. SafetyMessages The K otron Series82C E RF LevelT ransmittersystem may be properlyinstalledinC ategoryII,Pollution Degree2 installations.F ollowallstandard industryproce - duresforservicing electricaland computerequipment when w orking withoraround highvoltage.Alwaysshut offthe powersupplybeforetouchinganycom ponents. Although highvoltageisnotpresentinthissystem, it may be presentin othersystems. Electricalcompo nentsaresensitivetoelectrostaticdis - charge. T o preventequipmentdam age, observesafety procedureswh en workingwithelectrostaticsensitive com ponents. Low Voltage Directive Fo ruseinCategoryIIinstallations.Ifequipmentisused in a m anner not specifiedby m anufacturer, protection provided by equipmentmay be impaired. NoticeofT radem ark,Copyright,and Limitations Kotronisa registeredtradema rkofM agnetrol International,Incorporated. Ko tron Series82CE RF LevelT ransmitter isa tradenam e ofM agnetrol International, Incorporated. Man ual50-613.11 Copyright© 2006 Magn etrol International,Incorporated. Magn etrolreservesthe rightto m akechangesto the productdescribedinthism anualatany time w ithout notice. Magn etrolm akesno w arranty w ithrespectto the accuracy ofthe informationinthism anual. Wa rranty AllM agnetrol/ST Ielectronicleveland flow controlsare warranted freeofdefectsinm aterialsorwo rkmanship forone fullyearfrom the date oforiginalfactory shipment. Ifreturned withinthe w arranty period;and, upon factoryinspection ofthe control,the causeoftheclaim isdetermined to be covered underthe w arranty;then, Magn etrol/STI w illrepairorreplacethe controlat no costto the purchaser(orowner)otherthan transportation. Magn etrol/STI shallnotbe liableform isapplication, laborclaims, directorconsequentialdamage orexpense arisingfrom the installation oruseofequipment. Th ere are no otherw arrantiesexpressed orimplied, exceptspecialw ritten w arrantiescovering some Magn etrol/STI products. Qu alityAssurance Th e qualityassurance system inplace atM agnetrol /STI guaranteesthe highestlevelofquality throughoutthe compan y.Magn etrol /STI iscom m itted to providingfull custom ersatisfaction both inquality productsand qualityservice. Magn etrol’squality assurancesystem isregisteredto ISO 9001 affirming its comm itmentto know n international qualitystandardsproviding the strongestassurance ofproduct/service qualityavailable.

50-613Kotron Series82 CE RF LevelTransmitter TableofContents

1.0 C om pleteInstallation

1.2 E lectrostaticD ischarge(ESD) Han dlingProcedure ... 1

1.4.2 Non-Metallic and Gl ass-Lined Tank

2.4.1 A gencySpecifications– Intrinsically Safe

50-613Kotron Series82 CE RF LevelTransmitter 1 1 .0 Com pleteInstallation Thissection providesdetailedproceduresforproperly installing, configuring, and, asneeded, troubleshooting the Ko tron Series82CE RF LevelT ransmitter.

1.1 Unpa cking

Un pack the instrumen tcarefully. Ma ke sureallcom ponents havebeen rem oved from the packing material.Ch eck allthecontentsagainstthe packing slip and reportany discrepanciestothe factory. Be fore proceeding w iththeinstallation, do the following:

  • Inspectallcom ponentsfordam age.Reportany damage tothecarrierw ithin24 hours.
  • Make sure thenameplate mod elnumber agreeswiththe packing slipand purchase order.
  • Record them odeland serialnumbersforfuture reference when ordering parts.

1.2 ElectrostaticDischarge (ESD)

Magne trol’selectronicinstrumentsarem anufactured tothe highestqualitystandards. T hese instrumentsuseelectronic comp onentsthatm aybe damaged by static electricitypre - sentinm ostwo rkenvironme nts. The follow ingstepsarerecomme nded to reduce theriskof comp onentfailuredue toelectrostatic discharge.

  • Ship and store circuitboardsin anti-static bags.Ifan anti- staticbagisnotavailable,wrap the board inaluminum foil.D o notplaceboardson foam packing materials.
  • Use a grounding wriststrap w hen installing and remo ving circuitboards.A grounded w orkstation isrecommend ed.
  • Hand lecircuitboardsonlyby the edges. D o nottouch comp onentsorconnectorpins.
  • Make sure thatallelectricalconnectionsare comp letely mad e and none arepartialorfloating. Gr ound all equipme nttoa good, earthground.

50-613Kotron Series82 CE RF LevelTransmitter 2

1.3 InstallationLocation

Ko tron RF T ransm ittersshouldbe located foreasyaccess forservice, calibration and m onitoring. U nitsshouldnot be exposedtoam bienttem peraturesbelow -40°F (-40°C ) orabove+160° F (+70° C). Specialprecaution shouldbe mad e topreventexposure tocorrosiveatmosphere, exces - sivevibration, shock orphysicaldamage. Cau tion: This unit contains CM OS electronics which m ay be dam aged by static electricity. Do not touch any semi-conductor devices unless you are properly grounded.

1.4 Mounting

The Series82CE transmittercan be m ounted toa tank using a varietyofprocessconnections. Make sure allm ounting connectionsareproperlyinplace on thetank before installing the probe. M akesure the Ko tron probe iscorrectforthe intended installation. Itiscom m on practice to use the m etaltank w allasthe referenceelectrode. Insuch cases,itisrequired thatthe probe housing m akesa good electricalconnectiontothe tankwall.Ifthereisany doubtaboutthisconnectionor totheuse ofPT FE thread tape gaskets, paint, rust,orany otherreason, a separate strap shouldbe installed between theprobe housing and thetank. Cau tion: This unit contains CM OS electronics which may be dam aged by staticelectricity. Do not touch any semi- conductordevices unless you areproperlygrounded. Cau tion: W hen a probe is used in an abrasiveme dium,inspectthe probe periodically for visible surface wea r.Ifdam age to theprobe insulation is found,replace theprobe.

1.4.1 MetalWalled Tanks

On water-based liquids, there shouldbe no problem w ith sensitivity. W ithnon-conductive,low dielectric me dia, sensitivitycanbe enhanced by locating the probe closeto and parallelwith thetank w all.Ifthisisnotpractical,a ground referenceprobe may be the solution.

50-613Kotron Series82 CE RF LevelTransmitter 3

1.4.2 No n-Metallic and Glass-Lined Tank C onstruction

Wi thplastic,concrete, w ood, orany othernon-conductive walled vessels,a ground reference isrequired. Mo stcom - m only,thiselectrode willbe in theform ofa concentric ground tube (i.e. stillingwell).In questionablecircum - stances, consultthefactory.In allcases,a good electrical connection mu stbe mad e between the ground surfaceand theprobe housing.

1.4.3 Transmitter/Probe Assem bly

T ransm itterswith probesup to and including 12 inches (300m m )inlength areshipped pre-assembled. Allother transmittersare shipped unassembled toavoiddamage during transit.Thesetransmittersmustbe assembled prior tom ounting. Cho ose yourparticularconfigurationfrom thefollowing sectionsand followtheinstructionscarefully.

1.5 Probe Installation

1.5.1 RigidProbe

  1. Thread theprobe intothe mou nting connection on the vessel.Tighten securely, making surethatthe wrench is applied ONL Y to them ounting nut.Referto Figure 1. 2. Screw thetransmitterhousing ontothe probe untilhand tight.The housing canbe w rench-tightened to alignthe conduitconnection w ith theconduit. RefertoF igure2.

1.5.1.1 IntegralElectronics

  1. R em ovethehousing cover.Locate the white wirew hich isfastened to the (+) probe terminal.Referto Figure 3. Co nnectthefree end ofthisw ireto the probe connection screw. R efertoF igure 1. 2. Proceed toW iring,Section 1.6 .

1.5.1.2 R emote Electronics

  1. Co nnectthepositivelead ofthe interconnection cable (supplied by Magn etrol),to the screw term inalatthetop ofthe probe. Co nnectthe negativelead tothe green ground screw atthebase ofthe housing. C utthe shield; do notconnectitatprobe end. R eferto F igure4 on page4. 2. Installthetransm itterhousing using the bracket(supplied by Magn etrol).Make sureto provide adequate clearanceto rem ovethehousing cover.RefertoF igure3. 2. Proceed toW iring,Section 1.7 . Probe Terminal Transmitter Housing P.C. Board Packing Gland Nut Rigid Probe Conduit connection Figure2 IntegralMou ntModels withRigidProbe Packing Gland Nut (When installing, use wrench on this nut only) Probe Connection Screw Figure 1 W hitewireattached to (+)probe terminal COARSE L O W M E D H I G H FINE + – TP – TP + COARSE POWER HIGH ZERO PROBE 30-9012-001 MED FINE LOW SPAN W 101 322C Figure 3

50-613Kotron Series82 CE RF LevelTransmitter 4 2. Installthetransm itterhousing using the bracket(supplied by Magn etrol).Make sureto provide adequate clearance toremo vethehousing cover. R eferto Figure 3 on page3. 3. R em ovethetransmitterhousing cover. Con necttheposi - tiveleadoftheinterconnection cableto the (+) probe terminal.Co nnectthe negativelead and shieldtothe(–) probe terminal.R eferto Figure3 on page3. 4. Proceed toW iring,Section 1.6 .

1.5.2 FlexibleProbe

Ca ution: Flexibleprobes areshipped withthecableclamp and the packing gland nuthand tightened topermitlengthadjust - me ntin thefield.The cable clam p and packinggland nut must be tightened beforeuse.The end ofa flexible probe MU ST be kept taut by attaching the anchor end at the bottom of the vesselor by using a Ma gnetrolsupplied probe w eight. Ca ution: Do notdiscard theMylarhousinginsulator. Ca ution: The probe cable m ustnotbe incontactwithany m etallic surface in itsfinalinstallation position. 1. A ttachthew eightoranchorassemblyto the end ofthe probe. Inserttheprobe through the vessel’smou ntingcon - nection and feed the cableintothe vessel.Do notallow theprobe toscrape againsttheconnection threads. 2. Secure theanchorassembly(ifused)to the bottomof thevessel. 3. A pplythread sealantto them ounting nut.Screw the m ountingnutintothe mou nting connection untiltight. 4. R em ovetheM ylarhousing insulatorlocated overthe clamp. D O NOT DISCA RD . Referto Figure4. 5. Loosen both sockethead screwsfrom the clamp. Pullthe clamp and T eflon retaining bushing offofthe probe. 6. Whi leholding on to theprobe cable,loosen the upper packingglandnut.D O NO T A LLOW T HE PRO BE CAB LE TO FAL L INTO T HE VES SEL . 7. Pullthe excesscableup through thepacking glandnut untilthecableistaut. Tighten the packing gland nut. 8. Cu tthecable1.35 inches(34m m )abovethepacking glandnutand stripoff1.25 inches(32mm )ofinsulation. 9. Slide theT eflon retaining bushing onto the cableand seat itintothepacking gland nut. Slide theclamp ontothe cableand seatitagainstthe T eflon retaining bushing. Probe Terminal Transmitter Housing Probe Housing Shielded Twisted Pair Probe Connection Screw Packing Gland Nut Conduit Supplied By User Rigid or Flexible Probe Conduit connection Shielded Twisted Pair Mounting Bracket Figure4 Side View Rem oteMo untM odels w/ Rigid orFlexibleProbe ECTF E FlexibleProbe MYLAR INSULATOR PROBE WIRE SCREW CLAMP SET SCREW SEAL FLARE 3/8 16 UNC 2B PROBE CABLE CLAMP RETAINING BUSHING UPPER MOUNTING NUT HALF LOWER MOUNTING NUT HALF

50-613Kotron Series82 CE RF LevelTransmitter 5 10. Tighten bothsocketheadscrewson the clamp to approxi - m ately35 in./lbsoftorque. Slip the Mylar insulatorover theclamp. 11. Screw thetransmitterontothe probe untilhand tight. The housing can be w rench-tightened to aligntheconduit connection with theconduit. R eferto Figure 2 on page3.

1.5.2.1 IntegralElectronics

  1. R em ovethehousing cover.Locate the white wirew hich is fastened tothe (+) probeterminal.Co nnectthe free end ofthiswireto theprobe connection screw. 2. Proceed toW iring,Section 1.6 .

1.5.2.2 R emote Electronics

  1. R em ovetheprobe housing cover. Co nnectthe positive lead oftheinterconnection cable(supplied by M agnetrol), tothe screw terminalatthe top oftheprobe. Con nectthe negativeleadto thegreenground screw atthe baseofthe housing. Cu ttheshield;do notconnectitatprobe end. R efertoF igure 4 on page4. 2. Installthetransm itterhousing using the bracket(supplied by Magn etrol).Make sureto provide adequate clearance toremo vethehousing cover. R eferto Figure 4 on page4. 3. R em ovethetransmitterhousing cover. Con nectthe positiveleadoftheinterconnection cableto the (+) probe terminal.Co nnectthenegativelead and shieldtothe (–)probe terminal.RefertoF igure3 on page3. 4. Proceed toW iring,Section 1.6 .

50-613Kotron Series82 CE RF LevelTransmitter 6

1.6 Wiring

The wiring directionsare differentdepending upon the configuration ofyourparticulartransmitter.C hoosethe appropriate configuration from the following sectionsand followthedirectionscarefully.

1.6.1 Two-W ire TransmitterwithoutMe ter

WA RNING : These units are designed to operate with voltages between 14 VD C and 40 VDC only.Application of 120 VAC w illdestroythetransm itter. Cau tion: A llpow erm ustbe turned offuntilallofthewiring connec - tions have been m ade. Allw iring between thepowersupplyand the transmitter should be done with 16 A WG to 22 A WG shielded twisted pair. The connectionism adeatthe terminalstrip w ithin thetransmitterenclosure. 1. Rem ovethe transmitterhousing cover. Pullthe power supplywiresthrough the conduitconnection. 2. Con nectthepositivesupplyw ireto the (+) terminaland thenegativesupplyw ireto the (–)terminal.Connectthe shieldto thegreen ground screw atthe baseofthehous - ing.Make theshieldw ireasshortaspossible. R eferto Figure 3 on page3, and Figure5. 3. Replace thetransmitterhousing coveruntilcalibration. 4. Con nectthepositivesupplyw ireto the positiveterminal on thepowersource. Con nectthe negativesupplywireto thenegativeterminalon the pow ersource. Co nnectthe shieldto thepowersource’sground terminaland apply power. Th e yellow LED on the potted module shouldbeon. 5. Proceed toCa libration,Section 1.7 .

1.6.2 Two-W ire TransmitterwithMe ter

WA RNING : These units are designed to operate with voltages between 14 VD C and 40 VDC only.Application of 120 VAC w illdestroythetransm itter. Cau tion: A llpow erm ustbe turned offuntilallofthewiring connec - tions have been m ade. Allw iring between thepowersupplyand the transmitter should be done with 16 A WG to 22 A WG shielded twisted pair. The connectionism adeatthe terminalstrip w ithin thetransmitterenclosure. 1. Rem ovethe m eterhousing cover. 2. Rem ovethe two screws holding the meterbrackettothe housing. Pulltheme tergentlyoutofthe housing,being carefulnotto disturb the w iring. Layiton one side. Power Source 14-40 VDC Shielded Twisted Pair Cable 4-20 mA Meter Auxiliary Current Meter – + Green Ground Screw – – TP1 TP2 Figure5

50-613Kotron Series82 CE RF LevelTransmitter 7 3. Pullthe powersupplyw iresthrough the conduit connection. 4. Co nnectthepositivesupplyw ireto the(+) terminaland thenegativesupplyw ireto the(–)terminal.Co nnect theshieldtothe green ground screw atthe baseofthe housing. Make the shieldw ire asshortaspossible. R efer toF igure 6. 5. R eplacethem eterin itshousing and installthe meter bracketscrews.Be surethatthe meterwiresaretucked away before replacingthe m eterhousing cover. 6. Co nnectthepositivesupplyw ireto thepositiveterminal on the powersource. Con nectthenegativesupplywire to thenegativeterminalon the pow ersource. Con nectthe shieldtothepowersource’sground terminal. 7. A pplypower;theyellow LED on thepotted m odule shouldbe on. 8. Proceed toC alibration, Section 1.7 .

1.6.3 Four-WireTransm itterwithoutM eter

Cau tion: Allpowe r m ust be turned offuntilallof the wiring con - nections have been m ade. Allwiringbetween thepowersupplyand the transmitter shouldbe done with 14 AWG to 18AW G w ire.The con - nection ismad e attheterminalstrip, on the vertical board, w ithin the transmitterenclosure. 1. R em ovethetransmitterhousing cover. Pullthe powersupplyand signalw iresthrough theconduit connection. 2. Co nnectthehotand neutralw iresto the terminals m arked AC. Con necttheground w ireto theterm inal m arked GND. R eferto Figure7. 3. Co nnectthepositivesignalwireto the (M+) terminaland thenegativesignalwireto the (M-) terminal.Co nnectthe shieldtotheGND terminal. 4. R eplacethetransm itterhousing coveruntilcalibration. 5. Proceed toC alibration, Section 1.7 . Figure6 Transmitter Housing Meter Conduit Connection Probe Terminal Factory Supplied Wiring Power Supply & Signal Terminals Shielded Twisted Pair Power Supply Terminals + + ++ Transmitter Housing +-24v M+ M- GND AC AC Figure7

50-613Kotron Series82 CE RF LevelTransmitter 8

1.6.4 Four-WireTransmitterwith Me ter

Cau tion: A llpow erm ustbe turned offuntilallofthewiring connec - tions have been m ade. Allw iring between thepowersupplyand the transmitter shouldbe done w ith 14 AW G to 18AWG wire.T he con - nection ism ade atthe terminalstrip, on the verticalboard, withinthetransmitterenclosure. 1. Rem ovethe m eterhousing cover. 2. Rem ovethe two screws holding the meterbrackettothe housing. Pulltheme tergentlyoutofthe housing,being carefulnotto disturb the w iring. Layiton one side. 3. Pullthepowersupplywiresthrough the conduit connection. 4. Con nectthehotand neutralw iresto theouterterminals on theterminalstrip.Con nectthe ground wiretothe green ground screw atthe baseofthe housing. R eferto Figure 8. 5. Replace them eterin itshousing and installthe meter bracketscrews. B e surethatthe me terw iresare tucked away beforereplacing the meterhousing cover. 6. Replace thetransmitterhousing coveruntilcalibration. 7. Proceed toCa libration,Section 1.7 . Figure8 Transmitter Housing Meter AC Power AC (N) AC (H) Power Supply & Signal Terminals

50-613Kotron Series82 CE RF LevelTransmitter 9

1.7 Calibration

Thereare two calibration methodsthatcan be used, depending on yourparticularsituation. Calibration Procedure A willrequire mov -ing the levelfrom the 0% point(4 m A) tothe100% point(20mA ).Calibration Procedure B allowsyou to startata levelgreaterthan0% and stop ata levellessthan 100% . T oattainthebest accuracy and linearityuse Calibration Procedure A. The following isa listofabbreviationsand definitionsused in theprocedures. L0 The levelofthe media in the vesselw hich corresponds to the 0% (4mA )point L1 A media levelhigherthan L0 L2 A media levelhigherthan L0 and L1 but less thanL3 L3 The levelofthe media in the vesselw hich corresponds to the 100% (20mA )point RefertoF igure9. The outputcurrentcanbe m easuredeitherby inserting a m illiamm eterintotheloop, orby me asuring across TP1 (+) and TP2 (–).T he intensity ofthe LED between thetestpointsisa relativeindicatorofcurrentflow. (The LED willnotlightw itha m eteracrossthe testpoints.) NOT E: Prior to starting any calibrationprocedure,turn all poten - tiom eters Zero C oarse,Zero Fine,and Spa n Fine,20 turns clockw ise.Place the Sp an C oarse DIP switches inthe open position.The Zero C oarse DIP switch should have onlythe “low ” position closed.

1.7.1 Ca librationProcedure A

  1. Mov e the m edialevelinthe vesseltothe 0% (4 mA) point. 2. T urnpotentiome terZero Co arse counterclockw iseuntil theloop outputisbetw een 4.00 m A and 4.50 mA . 3. Ifthe loopcurrentcannotbedecreased to atleast 4.50 mA, turntheZeroCo arse potentiometerfullyclockwise, close DIP switch positions“MED ” and “HIGH” sequentially (ONL Y O NE SWITCH PO SITION SHO UL D B E CLOSED AT A TIM E—T HE OT HER T W O PO SITIO NS MUS T REM AIN O PEN). RepeatStep 2. SeeF igure10. 4. T urnpotentiome terZero F ine counterclockwiseuntilthe loop outputreadsexactly4.00 m A. 5. Mo vethem edia levelinthevesselto the 100% (20mA) point. 6. T urntheSpan Fine potentiome tercounterclockw iseuntil theloop currentisexactly20.00 m A . Calibration Procedure F 100% less than 100% greater than 0% B A Figure9 Figure10 OPEN HIGH MED LOW 1 2 3 closed dip switch ope n dip switch

50-613Kotron Series82 CE RF LevelTransmitter 10 7. If20 mA cannotbe reached, individuallycloseSpan Co arse DIP sw itches(in sequence),#1,#2,and #3,until theloop currentiscloseto (and notlessthan),20 mA . (O NLY O NE SWIT CH POS ITION SHO ULD BE CLO SED AT A TIM E—T HE O THER TW O PO SITIONS M UST REMA IN O PEN). 8. T urn the Span F inepotentiom etercounterclockwiseuntil theloop currentisexactly20.00 mA . If20 mA cannotbe reached, repeatStep 6. Calibration isnow comp lete.

1.7.2 C alibration Procedure B

  1. M ovethe me dialevelin the vesselto thelow estlevelyou canset. 2. T o determine thecorrectoutputlevelatthispoint,usethe following formula: 3. T urn the ZeroCo arse potentiome tercounterclockwise untiltheloop outputisbetween L1mA and L1m A + 0.5 m A. 4. Ifthe loop currentoutputcannotbe decreased toatleast L1m A + 0.5 m A, turntheZ ero Coarsepotentiometer fullyclockwise, close Z ero CoarseD IP switch positions#2 and #3sequentially(ONL Y O NE SW ITCH POS ITIO N SHO ULD B E CLO SED A T A T IM E—THE OT HER T W O POS ITIO NS M US T REM AIN OP EN). R epeat Step 3. See F igure 10. 5. T urn potentiom eterZ ero F ine counterclockwiseuntilthe loop outputreadsexactlyL1mA . 6. M ovethe me dialevelin the vesselto thehighestlevelyou canset. 7. T o determine thecorrectoutputlevelatthispoint,usethe following formula: 8. T urn the Span F inepotentiom etercounterclockwiseuntil theloop currentreachesthe desired value calculated (L2mA) inStep 7. 9. Ifthe desired valuecannotbe obtained, individuallyclose theSpan CoarseD IP switches#1,#2,and #3, untilthe loop currentisasclose to(and notlessthan),L2mA . (O NLY O NE SWIT CH POS ITION SHO ULD BE CLO SED AT A TIM E—T HE O THER TW O PO SI - TIO NS MUS T REMA IN OPEN). 10. T urn the Span F inepotentiometercounterclockwiseuntil theloop currentisexactlyL2mA . Calibration isnow comp lete.

50-613Kotron Series82 CE RF LevelTransmitter 11

2.0 Reference Information

Thissection presentsan overview ofthe operation ofthe Ko tron Series82CE RF LevelT ransmitter,information on troubleshooting com mon problems, intrinsic safety information, physical,functionaland performan ce specifications,listingsofagency approvals, and a list ofrecom m ended parts.

2.1 Description

Ko tron Series82CE LevelT ransmittersaredesigned to me asure liquids, slurries, dry-bulk,orliquid-liquidinter - faces. T he transmittermay be m ounted integrallywiththe probe orcan be remo temo unted up to 40 feet(12 me ters) away.Thisunitisavailableasa four-wiretransm itterwith either120 VA C or240 VA C inputpower, orasa two-wire transmitterw itha supplyvoltagebetween 14 VDC and 40 VD C. Availableoptionsinclude an analog me terand reverse acting output(20–4m A). Thistransmittercanbe used with any Ko tron R.F . Capacitance probe.

2.2 Theory ofO peration

The Ko tron Series82CE LevelT ransmittermo nitorsthe levelby determining the capacitance ofthe med ia. T he probe and a ground (usuallythem etaltank w all),form a capacitor. A sthelevelrisesand fallsin the tank, the amo untofcapacitancedeveloped between the probe and theground changes.T hischangeofcapacitanceis converted toa proportional4–20 m A signal.

2.3 Troubleshooting

The outputcurrentcanbe m easuredeitherby inserting a m illiamm eterintothe loop,orby measuring across TP1 (+) and TP2 (–).T he intensity ofthe LED between thetestpointsisa relativeindicatorofcurrentflow. C aution: Whe n a probe is used inan abrasivemedium, inspectthe probe atleastannually forvisiblesurface wea r.Incase any we aris found,replace theprobe orconsultthefactory.

2.3.1 Installation

LED doesnotlightafterw iring iscomp leted and power turned on. a. Wiresreversed atsupplyortransmitter. b. Wiresbroken ornotconnected.

50-613Kotron Series82 CE RF LevelTransmitter 12 c. Excessiveloop resistance. R eferto Chart1 on page15 form aximu m resistance. d. Powersupplynotturned on. e. Insufficientsource voltage.14 voltsm inimu m is required attransmitterterminals. f. T estpointsjump ered togetherw ithcurrentmeter. Rem ovem eter. g. LED isactuallyon butverydim. T urn span and zero potentiom etersfullyclockw ise;ifLED isnow on, proceed with calibration. h. Potted m oduledefect.Con sultfactoryforhelp.

2.3.2 Ca libration

  1. T estme terconnectedto calibration points, butLED stillon. a. Wro ng testm etermod e. Use low resistancecurrent me ter. b. T estm eterresistance istoo high.Obt ain meterwith lessthan10 ohm sresistance. c. T estm eternotproperly connected tocalibrationpoints. d. Defectivetestm eterorleads;m eterfuseblown. 2. Cannotread loop currentatcalibration pointsand LED isoff. a. Me tersetattoo high ofa range. M axim um loop currentis38m A (0.038amp s). b. Calibration pointsjump ered together. Remove jump er. c. No power, orsufficientpowerattransmitterterminals. — RefertoSteps“a”through “h” under Installation section beginning on page11. 3. Zeropointcannotbe setto4.00 mA atlow level. a. Wiresreversed atsupplyortransmitter. b. Span controlsincorrectlyset — T urn span potentiome tersfullyclockw isebefore calibrating zero. c. Excessiveprobe capacitance — Decrease lengthofprobe coveredatzerolevel; — Rem ovestilling well; — Increase diameterorstilling w ell; — Locateprobe fartherfrom w alls; — Use probe w ith lowerdielectric insulation; — Replace bareprobe with insulated probe; — Con sultfactory.

50-613Kotron Series82 CE RF LevelTransmitter 13 4. Span pointcannotbe increased to 20 m A athigh level. a. Span controlsincorrectlyset — T urn span controlsclockw ise b. Insufficientprobe capacitance — Increase span length orprobe; — Increase probe diam eter; — Locateprobe closertow all(s); — Use probe w ith higherdielectric insulation; — Installstilling well; — Use smallerdiameterstilling w ell; — Con sultfactory. c. Excessiveloop resistance — RefertoChart1 formaximum allowableloop resistance. 5. Span currentcannotbe reduced to 20 m A athigh level. a. Span controlssettoo high — T urn span controlscounterclockwise b. Excessiveprobe capacitance — Maximu m span rangeis: 110 pF – switchesopen 485pF – switch 1 closed 1950 pF – switch 2 closed 4000 pF – switch 3 closed — Decrease span length ofprobe; — Rem ovestillingwell; — Increase diameterofstilling; — Locateprobe fartherfrom w alls; — Use probe w ith lowerdielectric insulation;or — Replace bareprobe with an insulated one; — Con sultfactory. c. Low probe resistance to ground — Probe resistancem ustbe more than10 m egohms. — Con sultfactory.

2.3.3 O peration

  1. Loop currentoscillatesorhunts. a. Wavesordisturbancesin me dium — Use stilling w ell; — Use externalcageorstandpipe for transmitter; — Correctinstability ofm edium . b. Probe m ovingwithinvessel — Improveprobe anchoring

50-613Kotron Series82 CE RF LevelTransmitter 14 2. Loop currentrandomly unstable. a. D isturbancesinm edium — Correctinstability ofm edium b. Powersupplyunstable — Repairorreplace pow ersupply c. E lectricalinterference (RFI) — Con sultfactory. 3. Loop currentexceeds20 mA . a. Incorrectcalibration — Recalibrateunit b. Materiallevelabove100% — No correctiveaction needed on transmitter c. Extreme m aterialbuild-upon probe — Possiblemisapplication;consultfactory. d. Shorted orresistiveprobe — Replace probe. e. Supplyvoltageoutoflimitsattransm itterterminals — Allowablevoltagebetween 14 and 40 VDC. RefertoCh art1 on page15. f. Excessivetem peraturesattransmitterelectronics — Use rem oteelectronics g. Excessiveloop resistance. R eferto Chart1 on page15. — Reduce loop resistance; — Increase supplyvoltage;consultfactory. 4. Loop currentlessthan4 mA . a. Incorrectcalibration — Recalibrateunit b. Materiallevelbelow 0% — No correctiveaction needed on transmitter c. Shorted orresistiveprobe — Replace probe. d. Supplyvoltageoutoflimitsattransm itterterminals — Ad justpowersupply;or — Reduce loop resistance e. Excessivetem peraturesattransmitterelectronics — Use rem oteelectronics f. Excessiveloop resistance. — Reduce loop resistance

50-613 Kotron Series 82 CE RF Level Transmitter15

2.4 Agency Approvals

AGENCY APPROVED MODEL PROTECTION METHOD AREA CLASSIFICATION FM 082-8303-400 Intrinsically Safe Class I, Div 1, Groups A, B, C & D; 082-8303-410 Class II, Div 1, Groups E, F & G; 082-8304-400 Class III, NEMA 4X 082-8304-410 Non-Incendive Class I, Div 2, Groups A, B, C & D Suitable for: Class II, Div 2, Groups F & G; Class III CSA 082-8303-400 Intrinsically SafeŒ Class I, Div 1, Groups A, B, C & D; 082-8303-410 Class II, Div 1, Groups E, F & G; Class III, TYPE 4X Suitable for: Class I, Div 2, Groups A, B, C & D; Class II, Div 2, Groups F & G; Class III 082-8303-400 Explosion Proof Class I, Div 1, Groups C & D; 082-8303-410 Class II, Div 1, Groups E, F & G Class III, TYPE 4X ATEX 082-84XX-4XX Intrinsically Safe II 1 G EEx iaIIC T6* 5. Non-linear output a. Incorrect calibration — Recalibrate unit b. Excessive loop resistance. — Reduce loop resistance 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. f. Curved or non-parallel surfaces near probe — Mount probe in better location; — Use stilling well. Loop Resistance vs. Power Supply Voltage 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 100 200 300 400 500 600 700 800 900 1000 MAXIMUM LOOP RESISTANCE (Ohms) (Including Barrier Resistance) 500 ohms at 24 V 1300 ohms @ 40 V Power Supply Voltage (Volts) 1100 1200 1300 Chart 1 Œ Not I.S. (CSA) for Groups E & F when used with a bare probe.  Approval is valid only with the use of insulated probes. Ž Non-hazardous process fluids only *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 cat- egory 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. These units have been tested to EN 50081-2□ and EN 50082-2 and are in compliance with□ the EMC Directive 89/336/EEC.

50-613Kotron Series82 CE RF LevelTransmitter 16 2.4 .1 Ag ency Specifications – Intrinsically SafeInstallation

50-613Kotron Series82 CE RF LevelTransmitter 17

2.5 Parts

2.5.1 Re placement Parts

2.5.1.1 Transmitter

Item Description PartNum ber Œ Potted Mod ule 4-20 m A dc Z30-9012-001 20-4 m A dc Z30-9012-002  Base 004-9104-001 Ž Co ver 004-9105-001  O-Ring 012-2101-345 Sam e as  Probe Original PartNu m ber ‘ Probe Wire 009-7176-001 ’ Shielded Up to20 ft.(6.1M) 009-7176-001 Tw isted Pair 20 to40 ft.(6.1to12 M) 009-8222-001 “ FlexibleProbe A nchor Assemb ly 032-8814-001 ” FlexibleProbe W eight 004-4355-001 Four-WirePower SupplyA ssemb lyconsistingof: 120 VAC Z30-9111-001 Transform er,Po we rSupplyBoard and B racket 240 VAC Z30-9111-002

2.5.1.2 Meter

Item Description PartNum ber • MeterA ssem bly 037-3145-001 Base 004-9112-001 Co verAssem bly 036-3908-001 O-Ring 012-2501-247 1"x 3⁄4"B ushing 004-1739-001 1.5"Long, 3⁄4"N PT Pipe Nipple 011-1105-014

2.5.1.3 Rem oteProbe H ousing

Item Description PartNum ber Base 004-9104-001 Co ver 004-9105-001 O-Ring 012-2101-345

2.5.1.4 R em ote TransmitterHo using

Item Description PartNum ber Mou nting Bracket 036-3805-001

50-613Kotron Series82 CE RF LevelTransmitter 18

2.6 Specifications

2.6.1 Electrical

Œ Consult factoryforhighertemperatureson remote mounted transmitter SupplyVoltage 24 VDC, (14-40VD C) C urrent 38 mA maximum Line Variation Less than ± .10%/volt,forvoltages between 14-40VDC Ambie ntTem perature -40° to+160° F(-40 to+70°C )Œ ZeroR ange 1000 pF (max.),0pF(min.) Span R ange 4000 pF (max.),50pF(min.) Ou tputLinearity 50-500 pF ± 1% ofspan 501-1500 pF± 2% ofspan 1501-4000 pF± 1% ofspan Respo nse Time Less than 0.1second Repe atability ± 0.25% Tem perature Co efficientofO utput 4000 pF span: Less than 0.035%/° F(0.063%/° C) -40°to +16 0°F(-40°to+70°C ) 1000 pF span: Less than 0.025%/° F(0.045%/° C) 50 pF span: Less than 0.075%/° F(0.135%/°C) Base Meter Shielded Twisted Mounting Bracket Two-Wire Transmitter 19 5 4 14 Probe Probe Wire Cover Pipe Nipple Base Meter Assembly Cover Assembly O-Ring O-Ring Potted Module Bushing 20 40 60 80 100 O-Ring Base Cover Remote Probe Housing Four-Wire Transmitter Bracket Transformer Four-Wire Power Supply Board

50-613Kotron Series82 CE RF LevelTransmitter 19 2 .6.2 Physical 3/4" NPT 3/4" NPT 1" NPT Optional mounting flange 4.63 (118) Dia. 4.63 (118) Dia. 14.08 (358) 10.33 (262) 3.00 (76)3.00 (76) 3.75 (95) 3.00 (76) 4.76 (121) 2.75 (70) .50 (13) .625 (16) I.L. 3.5" (90)

2 Holes

.38 Dia. (10) 2.00 (51) 3.50 (89) Bracket Front View Side View 2.37 (60) NPT 3/4" NPT Optional mounting flange 4.63 (118) Dia. 12.65 (321) (76) (90) 3.00 .50 (13) .625 (16) I.L. 3.5" 3/4" NPT 3/4" NPT Optional mounting flange 4.63 (118) Dia. (76)3.00 3.5" (90) 2.75 (70) .50 (13) .625 (16) I.L. 3/4" NPT .1875 (5) .2500 (6) 3/4" NPT Optional mounting flange Optionalanchor assembly P/N 032-8814-001 4.63 (118) Dia. (76)3.00 4.54 (115) 4.38 (110) 1.25 (32) Optionalweight P/N 032-8814-001 .75 (19)5.50 (141) I.L. Probe diameter 3/4" NPT 3/4" NPT Optional mounting flange 4.63 (118) Dia. 4.63 (118) Dia.6.68 (170) 3.00 (76) 3.00 (76) 3.75 (95) 3.00 (76) 4.76 (121) 2.75 (70) .50 (13) .625 (16) I.L. 3.5" (90) .38 Dia. (10) 2.00 (51) 3.50 (89) Bracket Front View Side View 2.37 (60) IntegralM ountwithRigidProbe (24 VDC Two-W ire) IntegralM ountwithRigidProbe and M eter (24 VDC Two -W ire) IntegralM ountwithFlexibleProbe (120 VAC or 240 VAC Four-Wire) R emote M ount withRigidProbe (24 VDC Two -W ire) R em oteM ountwithRigidProbe and Meter (24 VDC Tw o-W ire)

50-613Kotron Series82 CE RF LevelTransmitter 20

0 N one

1 A nalogmeter(NotCSA, FM,or ATEX approved)

00 Integral,NEM A 4X/7/9aluminum housing

04 Integral,NEM A 4X/7/9316 stainlesssteelhousingŽ ‘

10 R em ote,NEM A 4X/7/9 aluminum housing 

14 R em ote,NEM A 4X/7/9 316 stainlesssteelhousingŽ   ‘

3 Standard 4-20 mA

4 R eversed20-4m A  (NotCSA approved)

0 Four-wire,120 VA C Œ

1 Four-wire,240 VA C Œ

3 Tw o-wire,24 VDC No m inal(14to40 VDC), FM,CSA

4 Tw o-wire,24 VDC No m inal(14to40 VDC), ATE X IntrinsicallySafe

8 FM/CSA /ATEX EEx ia,alum inum 3⁄4"NP T dualconduit

M OU NTING CO N FIGU R ATIO N PRO BE AS SEM BL IES A fullrange ofrigid and flexibleprobes,forconductive and non-conductive process m edia,is available.For furtherinformationon probe assem blies,please referto bulletin 50-125. M ETER O UTP UT SIGNA L Œ Not availablewithmounting codes 04 and 14.  Consult factoryon reversedoutputmodel. Ž Not availablewithfunction/inputpower codes 0 and 1.  Remote unitssuppliedwithseparateprobe and transmitterhousing,20 feet(6 meters)ofcable and transmitterhousingbracket.  Remote unitsup to40 feet(12meters)withspecial cable,ordercablepartnumber 009-8222-001. ‘ Not availablewithMeter optioncode 1.

3.0 M odelNu mb ers

BULLETIN: 50-613.11 EFFECTIVE: May 2006 SUPERSEDES: May 2003 Service Policy Owners of Magnetrol/STI controlsmay request the return ofacontrol or any part of a control for complete rebuild- ing or replacement. They will be rebuilt or r eplaced promptly. Controls returned under our service policy must be r eturned by Pre paid transpor tation. Magnetrol/STI will repair or replace the control at no cost to the purchaser (or owner) other thantransportation if: 1. Returned within thewarranty period; and 2. The factory inspection finds thecause ofthe claim to be coveredunder thewarranty. If the trouble is the result of conditions beyond our con- trol; or, is NOT covered by thewarranty, the re 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 casesaco mplete new control, to replace theoriginal 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 thematerials returned will bedetermined onthe basis of theapplicability ofour warranty. No claims for misapplication, labor, direct orconsequen- tial damage will beallowed. Return Material Procedure So that we may efficiently process any materials that are returned, it is es sential thata“R eturn M aterial Authorization”(RMA) number be obtained fromthe fac- tory, prior to the material's return. This is av ailable through Magnetrol’slocal representative or bycontacting the factory. Please supply the following information: 1. Company Name 2. Description of Material 3. Serial Number 4. Reason for Return 5. Application Any unit that was used inaprocess must be properly cleaned inaccordance with OSHA standards, before it is returned tothe factory. A Material Safety Data Sheet (MSDS) must accompany material thatwas used in anymedia. All shipments returned to thefactory must be by prepaid transportation. All replacements will be shipped F .O.B. factory. NOTE: See Elect rostatic Discharge Handling Procedure on page 1. ASSURED QUALITY & SERVICE COST LESS 5300 Belmont Road • Downers Gro ve, Illi nois 60515-4499 • 630-969 -4028 • Fax 630- 969-9489 • w ww.stico ntrols.com Copyright © 200 6 STI Contr ols, L.P. All rights reserv ed. Printed in the USA. STI and STI logotype are register ed trademarks of Magnetrol Inter national. Performance specifications are effective with date of issue and are subject to change withou t notice. 5300 Belmont Road • Downers Grove, Illinois 6 0515-4499 • 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 25 944 • Fax 052 45.09.93 Regent Busi ness Ctr., Jubil ee Rd. • Burgess Hill , Sussex RH15 9TL U.K . • 01444-871313 • Fax 01444-871317