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Installation and OperatingMan ual RF Ca pacitance Level Measu rement Kotron ® Mod el810 RF PointLevelSensor
50-607 Kotron Model 810 RF PointLevelSensor Read thisMan ualBefore Installing Thisma nualprovidesinformationon the KotronMo del 810 R F Point LevelSensor.It isimportant that all instructions areread carefullyand followed insequence. Detailedinstructions are includedin the Installation sectionofthism anual. Co nventionsUsed in thisMan ual Certain conventions areusedin thisman ualto convey specifictypesofinformation.Generaltechnicalmaterial, supportdata, and safetyinformation are presented in narrative form.The following stylesareusedfor notes, cautions, and warnings. Notes Notescontain informationthataugm ents or clarifies an operatingstep. Notes do not normally contain actions. Th ey follow the proceduralstepsto wh ich theyrefer. C autions Cautionsalertthetechniciantospecialconditionsthat couldinjurepersonnel, damage equipment,orreduce a comp onent’sme chanicalintegrity.C autionsarealso used toalertthe techniciantounsafepracticesor the needforspecialprotectiveequipmentorspecificmate - rials.In thism anual, a cautionbox indicatesa poten - tially hazardous situation wh ich, ifnot avoided,may resultin minorormoderateinjury. Warnings W arningsidentify potentially dangerous situationsor serioushazards.In thism anual,a warning indicatesan imminently hazardoussituationwh ich, ifnotavoided, couldresultin seriousinjuryordeath. SafetyMessages The K otronM odel810 system may be properlyinstalled inCategoryII, PollutionD egree 2 installations.Followall standard industryproceduresforservicingelectricaland com puterequipmen twh en workingwithoraround high voltage.A lwaysshutoffthe powersupplybeforetouching any com ponents.A lthough highvoltage isnotpresentin thissystem, itma y be presentinothersystems. Electrical compo nentsaresensitiveto electrostaticdis - charge. T o prevent equipment damage, observesafety procedures when working with electrostatic sensitive com ponents. WA RNING! E xplosion hazard.Do not connect or disconnectequipme ntunlesspowerhasbeenswitchedoff orthe areaisknown tobe non-hazardous. Low Voltage Directive Fo ruseinInstallationCategoryII,Pollution De gree 2.If equipment isused in a man ner not specified by the man ufacturer, protection provided by the equipment may be impaired. NoticeofT radem ark,Co pyrightand Lim itations Magn etrol& M agnetrollogotype,ST Iand ST Ilogotype, and Kotron are registered trademarks of Magne trol International,Incorporated. Cop yright© 2008 Ma gnetrolInternational. Allrightsreserved. Performa nce specificationsare effective w ith dateofissue and are subjectto changew ithoutnotice.M agnetrol/STI reserves the right to mak e changes to the product described in thism anualat any time w ithout notice. Magn etrol/STI m akesno w arranty w ith respectto the accuracy ofthe information inthism anual. Wa rranty AllMagn etrol/STI electronicleveland flow controlsare warranted freeofdefectsinm aterialsorwo rkmanshipfor one full year from the date of originalfactory shipment. If returned w ithin the w arranty period; and, upon factoryinspection ofthe control,the causeofthe claimis determined to be covered under the warranty; then, Magn etrol/STI w illrepairor replace the control at no cost to the purchaser (or ow ner) other than transportation. Magn etrol/STI shallnot be liablefor misapplication, laborclaims, direct or consequentialdam ageor expense arising from the installation or use of equipmen t. Th ere are no other w arrantiesexpressed or implied, except special w ritten w arranties covering some Magn etrol/STI products. Qu alityAssurance The quality assurance system in place atMag netrol/STI guaranteesthe highestlevelofquality throughoutthe com pany.Ma gnetrol/STI iscom m ittedtoproviding full custom ersatisfaction both in qualityproducts and qualityservice. Mag netrol’squality assurancesystem isregistered to ISO 9001affirmingits commitmen tto know n international quality standards providing the strongestassurance ofproduct/service qualityavailable.
50-607 Kotron Model 810 RF PointLevelSensor TableofContents
1.0 Introduction
1.2 E lectrostaticDischarge (ESD )Han dlingProcedure ... 1
2.0 Installation
50-607 Kotron Model 810 RF PointLevelSensor 1 The Ko tron Mo del810 RF PointLevelSensorcan be utilized in liquid orbulkm aterialapplications.T here are no m ovingpartsin contactw ith the med ium. T heseunits areintegralsystems w ith thesensing probe mou nted with theelectronics.G uarded probesareutilized tom inimize effectofbuildup on theprobe.
1.1 PrincipleofOperation
As them edium coversthe probe, the amo untofcapaci - tance developed betweentheprobe and ground changes. Thischangeincapacitance isconverted into a relayaction. As them edium drainsfrom the sensing probe, the relay position reverses. Thissection providesdetailedproceduresforproperly installing pointlevelsensors. Ca ution: This unit contains C MO S electronics which may be dam aged by staticelectricity. Do not touch any sem i- conductordevices unless you areproperlygrounded .
2.1 Unpa cking
Unp ackthe instrum entcarefully.Inspectallcomp onents fordam age.Reportany concealeddamage to carrier within24 hours.Check the contentsofthepackingslip againstpurchase order.Check and recordthe mod el numbe ragainstserialnum berforfuturereference when orderingparts. M odelNu m ber: SerialN um ber:
50-607 Kotron Model 810 RF PointLevelSensor 2
2.2 ElectrostaticDischarge (ESD)
Magne trol’selectronic instrumentsarem anufactured tothe highestqualitystandards.T hese instrum entsuseelectronic comp onentsthatm aybe damaged by static electricitypre - sentinm ostwo rkenvironme nts. The follow ingstepsarerecomme nded to reducetheriskof comp onentfailuredue toelectrostatic discharge.
- Ship and store circuitboardsin anti-static bags.Ifan anti- staticbagisnotavailable,wrap the board inaluminum foil.D o notplaceboardson foam packing ma terials.
- Use a grounding wriststrap w hen installing and removing circuitboards.A grounded w orkstation isrecomme nded.
- Hand lecircuitboardsonlyby the edges.D o nottouch comp onentsorconnectorpins.
- Make sure thatallelectricalconnectionsare completely mad e and none arepartialorfloating.Gr ound all equipme nttoa good, earthground.
2.3 Installation
- 3.1 Installation Location Ko tron pointsensorsshouldbe located in areasallowing easy accessforservice, calibration and mo nitoring.U nits shouldnotbe exposed to am bienttemp eraturesabove +160° F (+71° C) orbelow -40°F (-40°C).Specialpre - caution shouldbe taken to preventexposuretocorrosive atmosphere, excessivevibration, shock orphysicaldamage. Sensing probesshouldbe located close tothe tankwallfor greatestsensitivity innon-conductivemed ia.Probesshould be isolated from severe mo tion in thetank, becausesurface turbulence m aycausesignaldeviation. NO TE: Do not attempt to disassem ble probe from housing until the w ires have been disconnected and the electronic m odule has been rem oved. Co nsultSec tion 3.1, Troublesho oting on page 8.
50-607 Kotron Model 810 RF PointLevelSensor 3 2. 3.2 Probe Length Ifthegeome tryofyourapplication requiresa probe short - erthan12" (305mm ) ofactivelength,referto Figure 1 below to determine them inimum dielectric constantin which itcanbe used.
2.4 Mounting
Whe n installing, applywrench to mou nting gland only. Gu ard elem entshouldbe located freeofnozzle. Ca ution: When a probe is used in an abrasivemedium,inspectthe probe atleastannually forvisible surface wea r.Incase any wea risfound,replace the probe orconsultthefactory. 2. 4.1 Ho rizontalMo unting Unitw illsignalatprobe level.Referto F igures2 and 3. Ca ution: Do NOT horizontallymo unttheunitina nozzledeeperthan 3" (75 m m ).Refer to Figures 2 and 3.The med ium m ay build up in thenozzle and cause false actuation. 2. 4.2 VerticalMo unting As m edium riseson the probe, the unitw illsignalata pointdetermined by thecalibration ofthe unitand the dielectricconstantofthe m edium .In conductivemed ia, theactuation pointwillbe atthe tip ofthe probe overa wide rangeofadjustment.Referto Figure4. INS TALLATION INSTRUCTI ON S 1. Threadam plifierassembly into mo unting bushing on tank using suitablepipe com pound orthread tape.A ssembly may also be attached toa flangeand bolted to the vessel using a suitablegasket. 2. Tighten securely, beingcertain thatthe w rench isapplied O NL Y to them ountinggland.R eferto Figures2 through 4. 1 2 3 4 5 6 7 8 9 10 11 1 2 13 14 15 16 17 18 19 20 Probe Lengthvs. DielectricConstant Figure 1 M inimum dielectricconstantofmaterial Mounting Gland Nozzle Mounting Gland Figure 2 Horizontal Mo unting Figure 3 Ho rizontal Mounting in Nozzle /// /// Mounting Gland Figure 4 Mounting Gland Mounting Gland Nozzle Mounting Gland
2.5 Wiring
recom me nded for pow er and control circuits. NO TE: There are special w iring requireme nts for intrinsic safety. conductor devices unless you are properly grounded.
- Make sure the power source is turned off.
- Unscrew and rem ove housing cover.
- Pull power supply and control wires through conduit
- Con nect green ground w ire to green ground screw located
NO TE: If separate I.S. ground is required in this application, then I.S. the barrier at this tim e. Refer to NEC and agency guidelines.
- After grounding is com plete, connect A C power leads
NO TE: For DC supply voltage connect DC + to HO T and DC – to COM.
- Con nect control circuit leads to relay term inals. R efer to
Figure 6. Make sure the load to be controlled is within the
- Prevent moisture seepage into housing by installing an
- Select operating mode. (Refer to OPER ATING MODE
is sealed and the enclosure cover is screwe d dow n securely.
- Installation is comp lete. Replace housing cover.
50-607 Kotron Model 810 RF Point Level Sensor 5 O PERATIN G M ODE SELECTIO N The chart below is provided to aid in the proper choice of relay wiring and calibration. Please note: 1. Equipm ent controlled by the relay is assumed to be pow - ered from one source, while the Mod el 810 itself is assume d to be powered from a different source. 2. There are fail-safe switches on the switch w hich may be set in either a High or Low position. Refer to Figure 7. 3. “Fail” m eans a loss of power to the 810 unit. 4. HL (High Level) means a material level in the tank which is equal to or above the set point. 5. LL (Low Level) means a material level in the tank which is equal to or below the set point. 6a. Whe n relay coil is de-energized (fail-safe) the circuit between com mo n (COM) and the norm ally open (NO ) terminal is open and a connection is made betw een comm on (CO M ) and the normally closed (NC) terminals. The LED is off. 6b. Whe n the relay coil is energized the NO contact is closed and the NC contact is open. The LED is on. R efer to the Relay Wiring Chart below. Kotron Material Fail-safe Relay Power Level Position Coil CM to NC CM to NO High HL De-energized Closed Open On LL Energized Open Closed Low HL Energized Open Closed LL De-energized Closed Open High HL De-energized Closed Open Fail LL De-energized Closed Open Low HL De-energized Closed Open LL De-energized Close d Open Relay Terminal RE LAY WIRING CHART Figure 7 Time delay control (R9) Relay LED Level control (R4) Fail-safe switches Time delay switches between 1 and 2
50-607 Kotron Model 810 RF Point Level Sensor 6
2.6 Calibration
Cau tion: In hazardous areas, do not rem ove housing cover until pow er is disconnected and atmosphere os determined to be safe. H azardous environments mu st be declared safe by the local safety authority. 2. 6.1 Ca libration Procedure 1. T urn on power to the instrumen t. 2. Rem ove housing cover. 3. Set point location: a. Con ductive media: The set point is located at the tip of the probe. Calibration is not required for m ost conduc - tive liquids. If the unit does not switch on alarm test, then proceed to Step 4. b. Non -conductive me dia: The set point is located on the probe at a point determined by the set point adjust - me nt. Minimum probe coverage is 4 inches (100 mm). Calibration is required. Proceed to Step 4. 4. The LED shows the status of the relay coil: LED on = relay energized LED off = relay de-energized 5. Initial Settings a. T urn the LEV EL control (R4) clockw ise a full twenty turns or until a ratcheting sound is heard. b. Set the DIP sw itch w ith positions 1 and 2 O N. c. T urn the TIM ER control (R9) fully counterclockwise. d. Note that if DIP switch positions 3 and 4 are both O N the LED will remain on. Set D IP switches based on the following information: 2. 6.2 Ca libration Co nditions Com plete calibration by utilizing the follow ing conditions that best suits your application: 1. Fail-safe Low— a. Set DIP switch position 3 ON and position 4 O FF . b. T urn the LEV EL control counterclockw ise until the LED turns on. c. T urn the LEV EL control clockwise until the LED turns off. d. If media is on probe, slow ly turn the LE VEL control counterclockw ise until the LED com es on.
50-607 Kotron Model 810 RF Point Level Sensor 7 2. Fail-safe High— a. Set DIP switch position 3 OFF and position 4 O N. b. T urn the LEV EL control counterclockw ise until the LED turns off. c. T urn the LEV EL control clockwise until the LED turns on. d. If media is on probe, slow ly turn the LE VEL control counterclockw ise until the LED turns off. 3. Time Delay If Time Delay is required (i.e., surface w aves causing relay chatter), two choices must be made: a. Delay Function: — De lay on FILL (rising Level) switch 1 O FF , 2 O N — De lay on EM PTY (falling Level) switch 1 O N,
2 O FF
b. Delay Duration: — 0 to approximately 45 seconds (Tim er R9) — CW rotation increases duration (approximately 270° stop to stop)
50-607 Kotron Model 810 RF Point Level Sensor 8
3.0 Reference Information
3.1 Troubleshooting
3.1. 1 No Signal with Level Change 1. Check power and control circuit wiring. 2. Check fail-safe switch position. 3. Check calibration. 4. Check for proper ground reference particularly in non- me tal tanks. If removal of electronic mo dule is necessary: 1. Loosen mounting screws. Refer to Figure 5. 2. Slowly raise electronic module exposing probe wiring. 3. Disconnect probe and guard leads. Remo ve electronic mo dule. 3.1. 2 Switch Cha tter 1. Check for turbulence. If turbulence is present, increase time delay. 2. Check for low voltage. 3. Check for proper ground reference. 4. Check for proper DIP switch position. NO TE: If these suggestions prove unsuccessful, consult factory.
50-607 Kotron Model 810 RF Point Level Sensor 9 AGE N CY APP RO VED MODEL PROTE CTION METHOD ARE A CLASSIFICATION FM A ll mod els Explosion Proof Explosion proof with intrinsically safe probe circuit C lass I, Div. 1, Groups C & D Class II , Div. 1, Groups E, F , & G General purpose NEMA 4X CSA A ll mod els Explosion Proof Explosion proof with intrinsically safe probe circuit Class I, Div. 1, Groups C & D Class II , Div. 1, Groups E, F , & G General purpose TYPE 4X These units have been tested to EN 50081-2□ and EN 50082-2 and are in compliance with□ the EMC Directive 89/336/EEC.
3.2 Agency Approvals
50-607 Kotron Model 810 RF Point Level Sensor 10
3.3 Specifications
3.3.1 Electrical
Supply voltage 120 VAC, 50–60 Hz (+10%, -15%)
24 VDC (±10%)
12 VDC (±10%)
Pow er consumption 120 or 240 VAC Less than 5 volt-amps 12 or 24 VDC 1 watt maxim um Zero range 0 pF minimum to 500 pF maximum Fixed differential 0.5 pF O utput relays (reversible DPDT) AC 5 am p @ 250 VAC resistive DC 5 amp @ 30 VDC , 0.5 amp @ 125 VDC resistive Response time 100 milliseconds Repeatability Better than 1.0% A mbient temperature Electronics -40° to +160° F (-40° to +70° C) O perating process pressure/temperature 3500 psig @ +100° F (240 bar @ +40° C) 1750 psig @ +200° F (120 bar @ +95° C) Temp erature coefficient of set point -40° to +160° F (-40° to +70° C) ± .01% per degree F of setpoint (± .018% per degree C of setpoint)
3.3.2 Dimen sional
6" (152) Guard length 12" (305) or 30" (762) Active length 18" (457) or 36" (914) 2.75 (70) 3/4" NPT 3/4" NPT Conduit connection 4.63 (118) Dia. 4.11 (104) Rotation clearance 3.44 (87) 3/4" NPT plugged
50-607 Kotron Model 810 RF Point Level Sensor 11 Refer to Section 2.2, Electrostatic Discharge (ESD) Handling Procedure on page 2.
3.4 Replacement Parts
N o. De scription Part Numbe r Co mplete Electronic Assemb ly
120 VAC Z30-9 101-001
240 VAC Z30-9 101-002
24 VDC Z30-9 101-004
12 VDC Z30-9 101-003
Co ver Aluminum 04-9105-001
316 SS 04-9142-00
O-ring 12-2101-345 Base Aluminum 3⁄4" NPT conduit connection 04-918 2-002
316 SS, single hub 04-9140-001
Probe 18" (457 mm) 8AD-AA1A- 018 Probe 36" (914 mm) 8AD-AA1A- 036
50-607 Kotron Model 810 RF Point Level Sensor 12
3.5 M odel Num bers
8 10 K otron RF Capac itance Level Switch 810 00 5 0 HOUSING INPUT POW ER BASIC MO DEL PRO BE 0 120 VAC 1 240 VAC 2 24 VDC 3 12 VDC 1 18" (455 m m ) guarded probe 2 36" (915 m m ) guarded probe D NEM A 4X/7/9 Groups C & D, aluminum, 3⁄4" NPT conduit Y NEM A 4X/7/9 Groups C & D, 316 SS , 3⁄4" NPT conduit
BULLETIN: 50-607.5 EFFECTIVE: October 2004 SU PERSEDE S: M ay 2002 5300 Belmont Road • Downers Grove, Illinois 60515-4499 • 630-969-4000 • Fax 630-969-9489 • www.magnet rol.com
145 Jardin Drive, Units 1 & 2 • Conco rd, Ontario Canada L4K 1X7 • 905-738-9600 • Fax 905-738-1306
Heikensstraat 6 • B 9240 Zele, Belgium • 052 45.11.11 • Fax 052 45.09.93 Regent Business Ct r., 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.sticont rols.com Copyright © 2008 Magnetrol Inte rnational, Incorporated. All rights reserved. Printed in the USA. Service Policy Ow ners of Magnetrol/STI controls may request the return of a control or any part of a control for complete rebuild - ing or replacement. They w ill be rebuilt or replaced promptly. Controls returned under our service policy mu st be retu rned by P repaid t ransportation. Magn etrol/STI will repair or replace the control at no cost to the purchaser (or owner) other than transportation if: 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 con - trol; or, is NO T 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 num bers of the control to be replaced. In such cases, credit for the materials returned will be determ ined on the basis of the applicability of our warranty. No claims for misapplication, labor, direct or consequen - tial damage will be allowed. Return M aterial Procedure So that we may efficiently process any materials that are returned, it is essential that a “Return Ma terial Au thorization” (R M A) numb er be obtained from the fac - tory, prior to the m aterial's return. Th is is available through Ma gnetrol’s local representative or by contacting the factory. Please supply the following information: 1. Com pany Name 2. Description of Material 3. Serial Num ber 4. Reason for Return 5. Application An y unit that was used in a process mu st be properly cleaned in accordance with OS H A standards, before it is returned to the factory. A Ma terial Safety D ata Sheet (MS DS ) must accompany material that was used in any media. All shipments returned to the factory must be by prepaid transportation. All replaceme nts will be shipped F .O.B . factory. NOT E: See Electrostatic Discharge Han dling Procedure on page 2. ASSUR ED QU ALITY & SER VICE COST LESS