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Installation and OperatingMan ual Kotron ® Mod el80/81 RF Point Level Swi tches
Read thisMan ualBefore Installing This ma nual providesinformation on Kotron Model 8 0/8 1 R F Point LevelSwitches.Itisimportantthatall instructions areread carefullyand followedinsequence. De tailed instructions are included in the Installation sectionofthismanual. Co nventionsUsed in thisMan ual Cer tain 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 Cau tionsalertthetechniciantospecialconditionsthat couldinjurepersonnel, damage equipment,orreduce a comp onent’sme chanicalintegrity.C autionsarealso used toalertthe techniciantounsafepracticesor the need for specialprotective equipment or specific m aterials.In thism anual,a cautionbox indicatesa potentiallyhazardous situationwh ich, ifnotavoided, m ayresultinm inorormo derateinjury. Warnings W arningsidentify potentially dangerous situationsor serioushazards.In thism anual,a warning indicatesan imminently hazardoussituationwh ich, ifnotavoided, couldresultin seriousinjuryordeath. SafetyMessages Follow allstandardindustryproceduresforservicingelec - tricalequipmen t when working w ithor around high voltage.Alwaysshutoffthe power supplybeforetouch - inganycompo nents. Low Voltage Directive For useinCa tegoryIIinstallations.Ifequipmentisused in a m anner not specifiedby m anufacturer,protection provided by equipment may be impaired. WA R N ING ! Explosion hazard. Do not connect or disconnectequipmentunlesspowerhasbeenswitched off orthe area isknown to be non-hazardous. NoticeofT radem ark, Co pyright,and Limitations Magnetrol& M agnetrollogotype,ST Iand ST Ilogotype, and Kotron are registered trademarks of Magnetrol International,Incorporated. Cop yright© 2007 Ma gnetrolInternational. Allrightsreserved. Performa nce specificationsare effective w ith dateofissue and are subjectto changew ithoutnotice.M agnetrol/STI reserves the right to m ake changes to the product described in thism anualatany time w ithout notice.Magnetrol/ST Im akesno w arrantyw ithrespectto the accuracy ofthe informationinthism anual. Wa rranty All Magnetrol/STI electronic level and flow controls arewarranted freeofdefectsinm aterialsorw orkm anship foronefullyearfrom thedateoforiginalfactoryshipm ent. Ifreturned w ithin the warranty period;and, upon factory inspection ofthe control,the causeofthe claimis deter - m ined to be covered under the w arranty; then, Magnetrol/ST Iw illrepairorreplace the controlatno cost tothe purchaser(orowner)otherthan transportation. Magnetrol/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 Magnetrol/STI products. Qu alityAssurance The quality assurance system in place atMagnetrol /ST I guaranteesthe highestlevelofquality throughoutthe com pany.Ma gnetrol /STI iscom m ittedtoproviding full custom ersatisfaction both in qualityproducts and qualityservice. Magnetrol’squality assurance system isregistered to ISO 9001affirming its com mi tm ent to know n inter- nationalquality standardsproviding the strongestassurance ofproduct/ service quality available.
1.0 Introduction
2.2.2 Tanks/Silosw/N on-Con ductive Materials
2.3.1 Narrow DifferentialSingle Point
2.6 ElectrostaticDischarge(ESD )
2.8.5.1Wide D ifferentialVerticalProbe
3.0 Reference Information
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1.1 PrincipleofOperation
The am ountofcapacitance developed in any vesselis determined by the size (surface area)ofthe probe, thedis - tance from theprobe toitsground, and the dielectric of them edium beingmeasured.Con sidering thattheprobe’s mo unting position isfixed, and thatthe dielectric value of them edium isconstant, then the am ountofcapacitance developed in any vesselbecomes dependentupon the probe’stotalsurface area. Aprobe’sdiameter,togetherwith itslength,determine its surface area.Adjusting the combination ofprobe diameter, length,and proximityto ground, the necessary capacitance required by the electronic circuitrycangenerate. Asm ediarisesand fallsin the tank, the am ountofcapaci - tance developed betw eenthesensing probe and theground alsorisesand falls.T hischangeincapacitanceissensedby theelectronics. The capacitance-controlledoscillatorcircuit, mou nted on theprobe, changesthe capacitance signaltoa variable frequency.T hisstabilized signalcan then be senttothe main electronicslocated up to 5000feet(1500meters) away via standard shielded, twisted paircable.This eliminatesthe150feet(45me ters) m aximu m distance limitation, usingcostlycoaxialortriaxialcableutilized by otherm anufacturers.
1.2 Description
Kotron RF PointLevelSwitchescan be utilized inlevel controlapplicationswitheitherliquidordry bulkm aterials. They canalsobe used to senseand controlviscous,sticky, highlyconductivematerials.T he electronic am plifiermay be eitherm ounted directlyon the sensing probe orlocated rem ote from theprobe.Inremote applications,thesensing probe isfurnished w ith a housing.
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2.0 Installation
Cau tion: P lease read the entireinstallation sectioncarefully priorto starting installation.
2.1 Unpa cking
Unp ackthe instrumentcarefully.Make sureallcompo - nentshavebeen removed from the packing m aterial. Inspectallcom ponentsfordam age.Reportanyconcealed dam agetothe carrierw ithin 24 hours.Chec k thecontents againstthepackingslip and reportanydiscrepanciestothe factory.Che ck the nam eplatem odelnum bertobe sureit agreesw ith the packing slipand purchaseorder.Check and record theserialnum berforfuturereferencew hen orderingparts.
2.2 InstallationLocation
Kotron RF PointLevelSwitchesshouldbe located foreasy accessforservice, calibration and m onitoring.Switches shouldnotbe exposed to am bienttemp eraturesbelow -40°F (-40°C) orabove+160° F (+71° C). Specialpre - caution shouldbe made to preventexposure tocorrosive atmosphere, excessivevibration, shock orphysicaldamage. Itiscom m on practice to use the m etaltank w allasthe referenceelectrode.Insuch cases,itisrequired thatthe probe housing m akesa good electricalconnectiontothe tankwall.Ifthereisanydoubtaboutthisconnectiondue totheuse ofP T FE thread tape, gaskets, paint,rust,orany otherreason, a separate strap shouldbe installed between theprobe housing and thetank. Cau tion: This unitcontains CMOS electronics which m ay be dam aged by staticelectricity. Do not touch any semi- conductordevices unless you areproperlygrounded.
2.2.1 Me talWalled Tanks
On water-based liquids, there shouldbe no problem w ith sensitivityorlinearity.W ithnon-conductive,low dielectric me dia,sensitivity canbe enhanced by locating theprobe closeto and parallelw ith the tank w all.Ifthisisnotprac - tical,a concentricground tube surrounding the probe, som etimescalleda stilling w ell,may be a solution.
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2.2.2 Tanks/Silos w/N on-Conductive
With plastic, concrete, wo od, oranyothernon-conductive walled vessels, the reference electrode me ntioned above needsclarification.M ostcommo nly, thiselectrode w illbe inthe form ofa concentric ground tube (i.e.stilling well). Inquestionablecircumstances,consultthefactory.In all cases, a good electricalconnection m ustbe made between theground surfaceand the probe housing. NOTE: These com m ents also apply for glass-lined metal wa lled tanks. C aution: Whe n an insulated probe isused ina hazardousand/or abrasive medium, the probe shouldbe inspectedannually forany nicks,cutsorabrasionsw hich m ay ruintheintegrity ofthe insulation.Intheeventthatwe arisfound,replace the probe or consult the factory forfurther instructions. This procedureiscriticalin vesselscontaininghazardous me dia.
2.3 HorizontalM ounting
2.3.1 N arrow DifferentialSingle PointUnitsO nly
Ho rizontallym ounted probesprovide a high degreeof sensitivityforuse withnon-conductiveliquidsasonly approximately0.625"oflevelchangeisrequired tocom - pletelycover(oruncover) the probe. Ho rizontallym ounted probe rodsshouldbe installed so thattherod isparallelto and atthe levelatw hich control pointisdesired.R eferto Figure 1. Avoidanyinstallation m ethod in w hich them aterialmay becom e trapped inthemo unting nozzle,thuspreventing probe from signalingwhen levelrecedes.RefertoFigure 2. NOTE: Ifnozzle m ounting is unavoidable, probe must be installed w ithan inactivem etalsheath having a length at least1 inch (25 m m) greater than length of nozzle.Sheath isrequired to renderlengthofprobe within nozzleinsensitivetocapacitance change.RefertoFigure3. O n applications involving viscous liquids or ma terials which tend tocling orbuildup,horizontalmo untingprobes should be installed ata slightdow nw ardangle toallow m aterialtodrain from probe rod.Withthis typeinstallation,packinggland face of probe assem bly should extend intothe tank (or vessel). RefertoFigure4. Figure1 R ecom m ended HorizontalMo unting Probe Sheath 1" (25 mm) minimum Figure 2 R ecom m ended M ountingwith No zzle Probe Sheath Figure 3 No tR ecom mend ed Figure4 AlternateHorizontalM ounting forViscous Materials
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2.4 VerticalM ounting
Verticallymo unted probesprovide thecapabilitytoadjust thecontrolpointup ordown a section ofproberod by me ansofcalibrationadjustmentswithinthe unit’sam plifier. The verticalm ounting ofa probe rod isthe preferred me thod forapplication involving coating conductivetype liquidsorconductivesolids. Verticallymo unted probesshouldbe installedsothatthe end oftheprobe rod isatleast2 inches(51mm) below thedesired levelcontrolpointw ith conductivematerialsor 4 inches(102m m ) below w ith non-conductivematerials. RefertoF igure5.
2.5 Mounting Procedure
Kotron RF PointLevelSwitchesw ith probesup toand including 12 inches(305mm ) in length areshipped pre- assembled.Un itsw ith probesover12 inches(305mm) in lengthare shipped unassembled to avoid damage during transit.They m ustbe assembled beforem ounting.F ollow them ountingprocedureforyourparticularcase. NOTE: Be forebeginning m ounting procedures,make surethepowe r sourcetothe unitis turned off.
2.5.1 IntegralMo untwith Rigid Probe
- Threadprobe into mou nting bushing on tank. 2. Tighten securely, being certain thatthe w rench isapplied O NL Y to thelowerprobe nut. 3. Screw the am plifierhousing onto the probe. 5. Rem ovehousing cover. 6. Locatethe white wirew hich isfastened to the (+) Probe T erminal.Co nnectthe freeend ofthisw ireto theProbe Con nection Screw. 7. Proceed toSection 2.7, Wiring on page8. Figure5 R ecom me nded VerticalM ounting Packing Gland Nut (When installing, use wrench on this nut only) Probe Connection Screw Figure 6 R igid Probe Assemb ly
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2.5.2 IntegralMount with FlexibleProbe
C aution: Flexible probes areshipped withthe cable clamp and the probe nut hand tightened. The end of a flexible probe MUST be secured to the bottom of the tank by either attachm entto a bracketor to a heavy weightin order to keep theprobe taut. 1. U nscrew probe from probe housing.Rem oveM ylar ® hous - inginsulatorlocated overthe clamp.R eferto F igure 7. C aution: Do notdiscardMylarhousinginsulator. 2. Attachw eight(ifused)to probe end. 3. Insertprobe end through tank m ounting bushing and feed cableintothetank.Do notallow probe insulation tobe dam aged by scraping againstthe bushing threads. C aution: Probe cable mu stnotbe incontactwithanythingm etallic initsfinalinstallation position. 4. Secure lowerend ofprobe (oroptionalweight) totank bracketifone isused.R eferto Figure 7. 5. Applythread sealanttomo unting nut. 6. Screw m ounting nutinto tank bushing untiltight. C aution: Applyw rench tolow erprobe nutonly. NOTE: D o notallow the probe tofallinthetank whilefollowing steps 7 through 11. 7. Loosen bothsocketclamp screws. 8. Pu llclamp and T eflon ® retaining bushing offprobe. 9. W hileholdingprobe cable,loosenupperprobe nut. 10. Pu llexcesscableup through probe nutsuntilcable istaut. 11. Tighten the probe nuts. 12. Cu toffcable1.35inches(34mm) abovetop ofupper probe nutand strip off1.25inches(32mm ) ofinsulation. 13. SlideT eflon retaining bushing onto cableand seatitinto theupperprobe nut. 14. Slide clamp ontocableand seatitin the T eflonretaining bushing. 15. Tighten both sockethead clamp screws to approximately 35 in./lbs.torque. 16. Slip M ylarhousing insulatoroverclamp. 17. Screw housing onto probeand tighten.Make sureconduit connection isproperlyaligned forw ire entry. C aution: Ch eck probe terminalconnectioncarefullyto be certain lug willnotshorttopacking gland orinterferew ithassem - bly ofam plifierhousing toprobe. 18. Proceed toSection 2.7, Wiring on page8. Probe Connection Screw Socket Head Clamp Screws (2) Upper Probe Mounting Gland Lower Probe Mounting Gland Mylar Housing Insulator (slips over clamp)Teflon Retaining Bushing Clamp Optional Weight Tank Bracket Connection Optional Mounting Bracket (Used w/ Insulated Probes) Probe Locking Set Screw Flexible Probe Probe Termination Figure7 Flexible Probe Assem bly
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2.5.3 R em ote Mo untwithRigid Probe
2.5.3.1 Main Amplifier
R em oteam plifierassembliesare normallyshipped from thefactoryassem bled into an “L” mou nting bracket. R efertoF igure 8 whilefollow ing instructions. 1. R em oveamp lifierfrom mo unting bracket. 2. Installbracketina location w hich w illisolate unitfrom tem peraturesbelow -40°F (-40°C) and over+160° F (+71° C) orvibration/me chanicaldam age.Un itcanbe m ounted up to5000feet(1500m eters)from probe assem bly.Location shouldalsooffereasyaccessforw iring, calibration and m aintenance. 3. R e-installam plifierontom ounting bracket. 4. Screw housingon m ounting bracketuntilhand tight. Ho using can be w rench tightened to align conduit connection with conduit.
2.5.3.2 Preamplifier
- Thread probe intom ounting bushing on tank. 2. Tighten securelybeing certainthatthew rench isapplied O NLY tothelowerprobe nut.Referto F igure 8. 3. Screw thepream plifierhousing onto the probe.Referto F igure8. 4. Screw housingon probe untilhand tight.H ousingcanbe wrench-tightened to align conduitconnection withcon - duit.P roceed to Section 2.7, Wiring on page8.
2.5.4 R em ote Mo untwithFlexible Probe
2.5.4.1 Main Amplifier
R em oteam plifierassembliesare normallyshipped from thefactoryassem bled into an “L” mou nting bracket. R efertoF igure 8 whilefollow ing instructions. 1. R em oveamp lifierfrom mo unting bracket. 2. Installbracketina location w hich w illisolate unitfrom tem peraturesbelow -40°F (-40°C) and over+160° F (+71° C) orvibration/me chanicaldam age.Un itcanbe m ounted up to5000feet(1500m eters)from probe assem bly.Location shouldalsooffereasyaccessforw iring, calibration and m aintenance. 3. R e-installam plifierontom ounting bracket. 4. Screw housingon m ounting bracketuntilhand tight. Ho using can be w rench-tightened to alignconduit connection with conduit. Amplifier Housing Probe Terminal Power Wire Conduit Supplied By User Conduit Supplied By User Shielded Twisted Pair Mounting Bracket Probe Housing Packing Gland Nut Probe Connection Screw Rigid or Flexible Probe Figure 8 Side View Rem oteM ountMo dels with R igidorFlexibleProbe
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2.5.4.2 Preamplifier
Cau tion: Flexible probes areshipped withthecableclamp and the probe nut hand tightened. The end of a flexible probe MUST be secured to the bottom of the tank by either attachmenttoa bracketortoa heavy we ightinorderto keep theprobe taut. 1. Un screw probe from probe housing.Rem oveMy larhous - ing insulatorlocated overthe clamp.Referto Figure 7 on page5. Cau tion: Do notdiscardMylarhousing insulator. 2. Attachweight(ifused) toprobe end. 3. Insertprobe end through tank mo unting bushing and feed cableinto thetank.Do notallowprobe insulation to be damaged by scrapingagainstthe bushing threads. Cau tion: Probe cable m ustnotbe incontactwithanythingme tal - licinitsfinalinstallation position. 4. Secure lowerend ofprobe (oroptionalw eight) to tank bracketifone isused. 5. Applythread sealantto mou nting nut. 6. Screw mo unting nutintotank bushing untiltight. Cau tion: Apply w rench tolow erprobe nutonly. NOTE: D o notallow theprobe tofallinthetank whilefollowing steps 7 through 11. 7. Loosen both socketclampscrews. 8. Pu llclamp and T eflon retaining bushing offprobe. 9. Whi leholding probe cable,loosen upperprobe nut. 10. Pu llexcesscableup through probe nutsuntilcableistaut. 11. Tighten theprobe nuts. 12. Cu toffcable1.35inches(34m m) abovetop ofupper probe nutand stripoff1.25inches(32mm) ofinsulation. 13. SlideT eflon retaining bushing ontocableand seatitinto theupperprobe nut. 14. Slide clamp onto cableand seatitin the T eflonretaining bushing. 15. Tighten bothsocketheadclamp screwsto approximately 35 in./lbs.torque. 16. SlipMy larhousing insulatoroverclamp. 17. Screw housingontoprobe and tighten.M akesureconduit connection isproperlyaligned forwireentry. 18. Locate thewhitewirew hich isfastened to the (+) Probe T erm inalon thecircuitboard.Con nectthe freeend of thiswire tothe Probe Co nnection Screw.R eferto F igure7 on page5.
50-605 Kotron RF PointModel80/81LevelSwitches 8 Cau tion: Ch eck probe term inalconnectioncarefullyto be certain lug w illnotshorttopacking gland orinterferewithassem - bly ofam plifierhousing toprobe. 19. Proceed toSection 2.7, Wiring .
2.6 ElectrostaticDischarge (ESD)
Magnetrol’selectronic instrumentsarem anufactured to thehighestquality standards.T heseinstrumentsutilize electroniccom ponentsw hich may be dam aged by static electricity presentin mo stw ork environmen ts.T he following stepsare recomm ended to reduce the riskof comp onentfailuredue toelectrostatic discharge: 1. Ship and store circuitboardsin anti-static bags.Ifan anti-staticbagisnotavailable,wrap boardin aluminum foil.D o notplaceboardson foam packing ma terials. 2. Use a grounding wriststrap w hen installing and rem oving circuitboards.Agrounded wo rkstationis alsorecomm ended. 3. Hand leprinted circuitboardsonlyby the edges.Do not touch com ponentsorconnectorpins. 4. Ensure thatallelectricalconnectionsare comp letelymad e and none arepartialorfloating.Gr ound allequipment to a good, earthground.
2.7 Wiring
2.7.1 IntegralMo untMo dels
Lightgauge(16 AW G or18 AW G) stranded wire should be used forconnection ofpowerand controlcircuits.
2.7.1.1 Relay Wiring
See Section 2.7.3,RelayW iring Ch art on page10for differentrelaywiring options.
2.7.1.2 P ow erWiring
- Make sure powersource isturned off. 2. Pu llpowersupplyw iresthrough conduitconnection. 3. Con nectAC powerto AC(+), AC(–) and GND terminals. Con nectDC powertoD C(+) and GND terminals.R efer toSection 3.4,T erm inalConnections on page21. 4. Dressthe wirestogetherneatlyand securelyw ithcableties. Be certainthatadequateclearanceexistsforreplaceme ntof housing cover.
9 50-605 Kotron RF PointModel80/81LevelSwitches Cau tion: Ob serve allapplicable electricalcodes and properwiring procedures. 5. R eplacehousing cover. 6. Powerup unitand proceed w ith calibration ofinstrume nt asdescribed ininstructionsfollow ing. NOTE: B e certain to routeallpow erand controlwires through con - duitoutletonly and run probe wireup through centerhole in amp lifier housing base. Sup ply voltage and signal wires shouldnot be run in thesame conduit.
2.7.2 R em ote Moun tMo dels
R em otetype unitsare furnishedw itha preamplifierhous - ing having a circuitboardw ithpreamplifier-to-am plifier terminals.Preamplifierconnection terminalsare located attheupperleftside ofthe preamp lifiercircuitboard. R efertoF igure 9. Locate thewhitewirew hich isfastened to the (+) Probe T erm inalon thecircuitboard.Con nectthe freeend of thiswire tothe Probe Co nnection Screw.R eferto F igure6 on page4.
2.7.2.1 Probe P ream plifierWiring
- Stripapproximately.75 inch ofouterjacketinsulation from eachend oftheconductor. 2. Attheprobe pream plifierend, twistthe black w ireand shieldtogethertoform a singleconductor.Cr imp on sol - derlessconnectorssecurelytobothred and black leads. 3. Co nnectthered leadto the positive(+) terminalon the probe pream plifierboard.R eferto F igure9. 4. Co nnecttheblack w ireand shieldto thenegative(–) terminalon the probe pream plifierboard. 5. Atthem ain am plifierlocation, twisttheblack wire and shieldtogethertoform a singleconductor. 6. Crim p on solderlessconnectorssecurelyto both the red and blackleads. 7. Co nnectred lead topositive(+) terminalon the am plifier.RefertoSection 3.4, T erminalC onnections on page21. 8. Co nnectblackwire and shieldto the negative(–) terminalon the am plifier. ++ -- ++ -- ++ -- TB1 POWER LO HI PROBE Connect whitewireto probe connectionscrew. Probe range jumper (JU1) Probe preamplifierto positiveand negative terminalson amplifier. (+) (—) Figure9 Probe pream plifiercircuitboard
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2.7.2.2 Relay Wiring
R efertoSection 2.7.3,RelayW iring Ch art fordifferent relayw iring options.R eferto Section 3.4, T erminal C onnections on page21 forterminallocations.
2.7.2.3 Po we rWiring
- Make surepowersource isturned off. 2. Pu llpowersupplywiresthrough conduitconnection. R efertoF igure 8 on page6. 3. Co nnectAC powerto AC(+), AC(–) and GND terminals. Co nnectDC powerto D C(+) and GND terminals. R efertoSection 3.4, T erminalConnections on page21. 4. D ressthewirestogetherneatlyand securelywithcable ties.B e certain thatadequate clearance existsfor replaceme ntofhousing cover. Ca ution: Ob serve allapplicable electricalcodes and properwiring procedures. 5. R eplacehousing cover. 6. Powerup unitand proceed w ith calibration ofinstrument asdescribed ininstructionsfollow ing. NOTE: B e certainto routeallpow erand controlwiresthrough con - duitoutletonly and run probe w ireup through centerhole in am plifier housing base. Supply voltage and signal wires shouldnot be run in thesam e conduit.
2.7.3 R elay Wiring C hart
HL De-energized Closed Open LL Energized Open Closed Low HL Energized Open Closed LL De-energized Closed Open OFF (Fail) High HL De-energized Closed Open LL De-energized Closed Open Low HL De-energized Closed Open LL De-energized Closed Open
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2.7.4 W iring N otes and De finitions
- Equipm entcontrolled by theKotron relaysisassume d to be powered from one source, whilethe Kotron unititselfis assume d tobe powered from a differentsource. 2. Thereisa fail-safe switch on the Kotron unit,w hichmay be setineithera HL orLL position. 3. “Fail”me ansa lossofpowerto the Kotron unit. 4. HL (high level)me ansa materiallevelin the tank, which isequaltoorabove: a. The setting ofa narrow differentialpoint. b. T he highersetting ofa w ide differentialpoint. 5. LL (lowlevel)m eansa materiallevelinthe tank, w hichis equalto orbelow: a. The setting ofa narrow differentialpoint. b. T he lowersettingofa w ide differentialpoint. 6. W hen the relaycoilisde-energized (fail-safe),a connection ism adebetween comm on (COM ) and the normally closed (NC) and thereisno connection betw een common (COM ) and thenormallyopen (NO ) terminals. 7. W hen the relaycoilisenergized, a connection ismade between theterm inalsCO M and NO , and thereisno connection between CM and NC.
2.8 Calibration
C aution: Whe n instrume ntcalibrationistobe done ina hazardous location, extra steps and precautions must be taken. Pow er m ust be turned off before housing cover is removed from unitam plifier. Allpre-installation checkson the instrumentshouldbe done in a non-hazardousareainorderto minimize the amo untofwo rkrequired on theunitafterinstallation. Instrum entcan be checked on thebench, preferablywith theprocessm aterial,by temp orarilyconnecting powerand performing thestepsoutlined in the calibration adjust - me ntinstructions.
2.8.1 LevelR ange Selection
The preamp lifiercircuitboardhasa rangejum per(JU1), see F igure 9 on page9.Fo rremote units, thisboardis located intheprobe enclosure.
50-605 KotronRF PointModel 80/81 LevelSwitches 12 The position ofthe jum per isdependentupon thefluid being m easured.Locatethisjum per in the "LO" position ifthefluidisnon-conductive (dielectric lessthan 10); for conductivefluids, position thisjum per in the"HI" position. For narrow differentialunits, alwaysplace thejumpe r in the"LO " position.
2.8.2 Fail-safe M ode Se lection
The fail-safe mo de isselected for the particular level detection applicationto provide for relaycontactclosure upon any lossofelectricalpow er. T oselectthe appropriate relaystate, locate thesmalltoggle switch on upperrightportion ofcircuitboardand switch toHL for high levelmo de or LL for low levelmod e.R efer toSection 3.4,T erm inal Co nnections on page 21.
2.8.2.1 H igh LevelMo de
In thism ode, an electricalpow erfailure willde-energize therelaycausing thecontactsto assum e a positionasif productlevelwere ator abovethe setpoint.
2.8.2.2 Low LevelM ode
In thism ode, an electricalpow erfailure willde-energize therelaycausing thecontactsto assum e a positionasif productlevelwere ator below the setpoint.
2.8.3 C alibration Ad justme nts
Ad justm entsshouldbe perform ed w ith unitunderactual operating tem perature and pressure conditions.Zero and span adjustm entsarelocated atupper lefton amplifier cir- cuitboard.A levelrange selectjump erisalso provided.It islocated on the preamp lifierboardofsinglepointintegral unitsand allrem oteunits.Be sure thatthe proper range hasbeen selected.R eferto Section 2.8.1,L evelRang e Selection on previouspage.
2.8.4 Ze ro A djustme nt
1.With theprobe installedin the vesseland the process materialator below the desiredsetpoint,turn ZER O adjustme nt potentiometeron the lefthand side ofthe printed circuitassemblyclockwise(CW) a m inimum of twenty fullturnsor untila clicking sound isdetected. N OTE: Be sureFail-safeMo de Selectionhas been setcorrectly.Re fer toFail-safeMo de Selection above and Relay Wiring C harton page 10.
13 50-605 Kotron RF PointModel80/81LevelSwitches 2. Setthefail-safe mo de forthe alarmrelays: a. Inlow levelfail-safemo de, the alarmrelayw illbe de-energized when the m ateriallevelisB ELO W the alarmsetpoint. b. In high levelfail-safe mo de, the alarmrelayw illbe de-energized when them ateriallevelisABO VE the alarm setpoint. 3. Energize theinstrument.T he calibrate LED sw illbe on regardlessofthesettingsofthe fail-safe switchesortime delaysetting.R elayssetin the low levelfail-safe (LLFS ) mo de willbe energized and therew illbe continuity between thecom m on (CM ) and normallyopen (NO ) relayterminations.Thiscan be checked w ith an ohmmete r orothersuitablecontinuity checking device.Relayssetin thehighlevelfail-safe(HL FS ) m ode w illbe de-energized and there willbe continuity betw eenthecom mon (CM) and normallyclosed (NC) relayterminations. 4. Ifthevesselisnotfilled tothe desiredsetpoint,increase levelofmaterialto therequired setpoint. 5. T urnthezero adjustmen tcounterclockwise(CCW ) until LED indicatorgoesoff(the relayw illchangestate), then turnthecontrolslowlyin the CW direction untiltheLED indicatoragain com eson.R epeatthison–offprocedure severaltimesand leavethe LED indicatoron.T he narrow differentialalarmpointisnow calibrated.
2.8.5 Zeroand Span Adjustment
2.8.5.1 Wide Differential— VerticalProbe MountO nly
- With theprobe installedin the vesseland the process materialatthedesired low level,turnboth the zero and span adjustmenton thelefthand side ofthe printed circuitboard clockwise a m inimum oftwenty fullturnsor untila clicking sound isdetected.Iftheprocessmaterialis notatthispoint, themateriallevelm ustbe changed until thispointisreached. 2. Setthefail-safe mo de forthe relay:(Be sure Fail-safe Mo de Selection hasbeen setcorrectly). a. Inlow levelfail-safe(LLFS ) mod e, relayisde-energized on risingleveland rem ainsde-energized untilupper span pointisreached. b. In high levelfail-safe (HL FS) m ode, relayis de-energized on falling leveland remainsde-energized untillowerzero pointisreached. 3. Energize theinstrument.T he calibrate LED willbe on regardlessoftheposition ofthefail-safe switch.
50-605 Kotron RF PointModel80/81LevelSwitches 14 4. T urnthezero adjustmen tcounterclockwiseuntiltheLED indicatorgoesoff(the relayw illchangestate), then turn thecontrolslowlyin the clockw isedirection untiltheindi - catoragaincome son.Repeatthison-offoperation several timesand leave theLE D indicator O FF .T hiscompletes thezerocalibration ofthew ide differentialpoint. Priortoincreasing the levelofm aterialin the tanktothe span point,turnthe span controltwenty fullturnsCC W . THE LED CA LIB RATION IND ICAT O R WIL L REMA IN O FF . 6. Raise thelevelofthe materialin the vesselto thedesired highlevelsetpoint. 7. Slowlyrotate the span adjustmen tin a CW directionuntil theLED calibration indicatorturnsON. The relayw ill changestate and thew ide differentialspan isnow calibrated.Do notchangesetting afterLED isO N. NOTE: A second span adjustmentcheck can be made by mo vingthe span adjustmenttwo (2)turnsCC W, then remo vingtheprobe (P)wire m om entarily to break the contact.With the probe reconnected,slow ly turn the span adjustmentscrew inCW direction untiltheLED calibration indicatoragain com es O N.
2.8.6 Time Delay Adjustment
2.8.6.1 Narrow D ifferentialO nly
Narrow differentialamp lifiersareequipped w ithan adjustable(0to3 sec) time delay.W ith the time delay calibration fullyCCW , the delayisatm inimu m and in thefullyCW position, itisatmaximum. On standard units, the delayiseffectiveon rising level,i.e.,asthe materiallevelgoesabovethe setpoint, a time delayw ill occurbetw een theLED indicatorcoming ON and the relayoperating and w illeliminate contactchatterin agitated fluids.
15 50-605 Kotron RF PointModel80/81LevelSwitches
3.1 Troubleshooting
3.1.1 Probe
C aution: Whe n an insulated probe isused ina hazardousand/or abrasivem edium ,the probe shouldbe inspected annual - lyfor any nicks,cuts or abrasions which ma y ruin the integrityoftheinsulation.Inthe eventthatwe aris found, replace the probe orconsultthefactory forfurtherinstruc - tions. This procedure is critical in vessels containing hazardous m edia. T ocheck form alfunctioning sensing probe: 1. Rem ovethe white probe lead form the sensing probe and isolate itfrom ground. 2. Con nectan ohm me terbetween the sensing probe terminal and ground.(stainlesssteelprobe nutorhousing base). 3. Measure theresistancebetw eentheprobe and the stainless steelprobe nut,orprobeelectronic housing w ith an ohm m eter.(Selectthe highestresistancescaleavailable). Iftheresistancem easuresinfinity,the probe isoperating correctly.Iftheresistance me asureslessthaninfinity,there may be a problem with the probe.Callthe factoryfor additionalassistance. 4. Inspecta m alfunctioning probe fora cutin the insulating sheathorloosenessin the sealatthe probe mou nting nut. Ifneitherisapparent,check forheavy conductivebuildup between probe and mou nting nut. NOTE: Wh en perform ing checks 3 and 4 inconductive m edia,take resistance reading w hen m edium isatma ximum level. 5. Ifprobe testiswo rking properly, check forinsufficient ground, loose orbroken w iring, including white probe wire.Also check continuity betw een probe m ountingnut and m etaltank — thereshouldbe continuity (zero resist - ance).Ifthereisresistance, check forexcessiveT eflontape used on probe threads.
3.1.2 Electronics
Refertothefollowing procedureto testthe pre-amp lifier P .C.boards,theam plifierand the shieldedtw isted cable between theprobe and the amp lifier. NOTE: RefertoFigure14 on page 21 forlocation ofpotentiom eter.
50-605 Kotron RF PointModel80/81LevelSwitches 16 Cau tion: This procedure changes any previous calibration of the am plifier.Iftheunitchecks outas operational,itwillhave tobe recalibrated beforebeing used inthe process.
3.1.2.1 Narrow differentialpointunits
- T urnoffthepowerto theunit. 2. Rem ovethe leadwirefrom theprobe. 3. T urnthesetpointpotentiom etersfullycounterclockwise. 4. T urnalltim e delaypotentiometersfullycounterclockwise. 5. Mo vetheprobe levelrangejum perto the HI position. RefertoF igure9 on page9. a. Whe n the probe rangejumper(switch) isin theHI position, a low levelissimulated.W hen itisintheLO position, a highlevelissimulated. b. On rem otem ounted units, thisjum perislocatedinside theprobe housing on the probe preamplifierboard. 6. T urnon powertothe unit. 7. The red LEDs willbe off.Adjustthe narrow differential pointpotentiom eter(s)counterclockwiseuntiltheLED(s) turnon.T hen slowlyadjusteach potentiometerclockwise untiltheLED turnsoff. 8. The probe rangejump er(switch) can now be switched between theHI and LO positionsand the LEDs w illgo on and off.The relaysw illalsogo on and offaccordingly. Ifyourunitoperatesasdescribed above, the probe pream - plifierboard, theprobe preamplifiercableand amp lifier arefunctioningcorrectly. IfyourunitdoesNO T operate asdescribed above,itis malfunctioning.Perform the following checks: 1. TakeDC voltagereading acrossprobe preamplifier terminals– shouldbe approximately12 VD C. 2. TakeAC voltagereading acrossprobe pream plifier terminals– shouldbe .1to .2VAC. 3. Con sultfactory– havetestdataavailablefordiscussion. NOTE: These values can also be taken at probe pream plifier wiringterm inals on remoteinstallations.
17 50-605 Kotron RF PointModel80/81LevelSwitches
3.1.2.2 Wide differentialpointunits
- T urnoffthepowerto theunit. 2. Rem ovethe leadw ire from the probe. 3. T urnthezeroand span potentiometersfullyclockwise. NOTE: O n w ide differentialunits,the zero potentiometer islocated above thespan potentiom eter. 4. Mo vetheprobe levelrangejum perto the HI position board.RefertoFigure9 on page 9. a. Whe n the probe rangejumper(switch) isin the HI position, a low levelissimulated.W hen itisin theLO position, a highlevelissimulated. b. On rem otem ounted units, thisjum perislocatedinside theprobe housing on the probe preamplifierboard. RefertoF igure9 on page9. 6. T urnon powertotheunit. 7. The red LED w illbe on.T urn the zeropotentiometer fullycounterclockwise.RefertoF igure10on page19. 8. Mo vetheprobe rangejum per(switch)to the low level position.R eferto F igure12 on page20.T he LED will turnoff.Ifnot, turnthespan potentiome terslowlycoun - terclockwise untiltheLED turnsoff.R eferto Figure10 on page19. 9. The LED shouldnow turn on and offwith m oveme ntof thejum per(switch). 10. The probe rangejum per(switch) can now be sw itched between theHI and LO positionsand the LEDs w illgo on and off.The relaysw illalsogo on and offaccordingly. Ifyourunitoperatesasdescribed above, the probe pream - plifierboard, theprobe preamplifiercableand amp lifier arefunctioningcorrectly. IfyourunitdoesNO T operate asdescribed above, itis malfunctioning.Perform the following checks: 1. TakeDC voltagereading acrossprobe preamplifier terminals– shouldbe approximately12 VD C. 2. TakeAC voltagereading acrossprobe pream plifier terminals– shouldbe .1to .2VAC. 3. Con sultfactory– havetestdataavailablefordiscussion. NOTE: These values can also be taken at probe pream plifier w iring term inals on remo teinstallations.
50-605 Kotron RF PointModel80/81LevelSwitches 18 FM 80-80XXX-3XX ExplosionProof ClassI,Div.1;Groups C & D 81-80XXX-3XX ClassII ,Div.1;Groups E,F & G (Note:Thisapprovalavailablewithrigid insulated probesonly AllModels Non-Hazardous TYPE 4X CSA 80-80XXX-3XX ExplosionProof ClassI,Groups C & D 81-80XXX-3XX ClassII ,GroupsE,F ,& G;Type 4X (Thisapprovalexcludes use withbareprobes) AllModels Non-Hazardous TYPE 4X AGE NC Y M ODE L APPR OVED APPR O VAL CATEGO RY APPR O VAL C LASSE S
3.2 Agency Approvals
3.3 Specifications
3.3.1 E lectrical
Desc ription Specification Supply voltage 240 VAC (+10%/-15%),50–60 Hz
24 VD C (±10%)
P ower consum ption 7 wattsmaximu m Zerorange 0 pF m inimum 3000 pF m aximum High range 4 pF m inimum D ifferentialrange 1500 pF m aximum (wide differentialonly) Low range 2 pF m inimum 500 pF m aximum Fixed minimum differential 0.5pF minimum (narrow differentialonly) Ou tputrelays D P DT AC 10 amp @ 120/240 VAC resistive DC 10 amp @ 24 VD C resistive Num berofrelays One Time delay (narrow 0–3 seconds differentialonly) Response time 100 milliseconds Am bienttemperature -40° to+160° F atelectronics (-40° to+71° C) Op erating pressure/ De pendentupon probe selection. temp erature Referto probebulletin50-125. Temp eraturecoefficientofoutput -40°to+16 0°F +0.02pF perdegreeF (-40° to +71° C ) (+0.036pF perdegreeC)
19 50-605 Kotron RF PointModel80/81LevelSwitches
3.3.2 Dimen sionalSpecifications – IntegralMo unts
Inches (mm ) 2.95 (75) .1875 (5) .2500 (6) NEMA 4X/7/9 9.89 (251) Rotation Clearance Optional Mounting Flange NEMA 4X/7/9 9.91 (251)
2 Holes
.38 (10) Dia. 3.00 (76)2.00 (51) 2.37 (60) 3.50 (89) 3.75 (95) 1/2" NPT (opt.) 3/4" NPT (std.) Transducer/Amplifier Cable Connection G G plugged G plugged G
1 Rotation
B A A B Figure 10 IntegralM ountwithFlexibleProbe (shown withaluminum sand casthousing) Rotation Clearance .38 (10) Dia. 1/2" NPT or 3/4" NPT 3.00 (76)2.00 (51) 2.37 (60) 3.50 (89) 3.75 (95) F B A E Optional Mounting Flange .50 (13) .625 (16) C B A D Rotation Clearance G 1 1 I.L. 3 G Figure 11 IntegralM ountwithStandardRigidProbe (shown withcarbon steelhousing)
50-605 Kotron RF PointModel80/81LevelSwitches 20 Figure 12 Re mo te M ountwithFlexible Probe (shown with aluminum sand casthousing) .50 (13) .625 (16) Optional Mounting Flange 2.75 (70) 3/4" NPT 3.23 (82) 3.00 (76) 4.63 (118) Dia. I.L. Figure 13 R emote M ount withStandard RigidProbe (Shown withcarbon steel or Lexan housing) Optional Mounting Flange 2.75 (70) 4.67 (119) 3.00 (76) 4.63 (118) Dia. 2.95 (75) 3/4" NPT Optional Anchor Assembly 4.87 (124) 1.32 (34) 5.00 (127) .75 (19) Optional Weight .1875 (5) .2500 (6) NOTES: Allow8"(203mm) overheadclearanceforcoverremoval. Standardprocessconnectionis3⁄4"NPT.Consultprobe brochure(50-125)forflangeand otherprobe connections. Probe/amplifierconnectingcableshouldbe shieldedtwistedpair22 gauge strandedconductors. OutlineDimensions Housing A B StandardRigidProbe FlexibleProbe ConduitConnection C D E F C D E F G NEMA 4X Carbon steel 3.25 (82) 4.69 (119) 9.04 (230) 2.29 (58) 11.67 (296) 4.04 (103) 10.48 (266) 3.73 (95) 11.67 (296) 4.04 (103) 3⁄4"NPT singleconduit NEMA 4X/7/9 Sand castaluminum 3.44 (87) 5.81 (148) 11.26 (286) 2.40 (61) 13.81 (351) 4.15 (105) 12.70 (323) 4.67 (119) 13.81 (3.51) 4.15 (105) 3⁄4"NPT dualconduit
3.3.3 Dimen sionalSpecifications – Remote Mo unts
Inches (mm )
21 50-605 Kotron RF PointModel80/81LevelSwitches
3.4 TerminalConnections
(if furnished) LED Indicator Zero Adjustment Span Adjustment (if furnished) OperatingRelay Amplifier Assembly LED Indicator CM2 Fail-safe Mode Selection Switch 120/240 VAC input 50/60 HZ
24 VDC
control relay. Each terminal screw is identified on the terminal strip NO2 NC2 NC1 NO1 CM1 AC AC GND DC+ GND Twisted Pair Terminals SerialNumber Tag Transformer (A.C. Units only) either or Figure 14 SinglePointAmplifier
50-605 Kotron RF PointModel80/81LevelSwitches 22 Amplifier P.C. Board Preamplifier P.C. Board O-Ring Twisted Shielded Pair Conductor Remote Mount□ Probe Housing Remote Electronics□ Mounting Bracket Housing Cover □Housing Base Figure 15
3.5 Replacement Parts
N o. De scription
120 VAC 240 VAC 24 VDC
Integralor Re mote Integralor Re mote Integralor Remot e
1 Amp lifier
Single pointnarrow differential Z30-2124-001 Z30-2124-002 Z30-2127-001 Single pointwide differential Z30-2123-001 Z30-2123-002 Z30-2128-001
2 Preamp lifier P C board,singlepoint 30-2082-001
4 Ho using cover
NEMA 4X carbon steel 89-6510-003 NEMA 4X/7/9 aluminum 89-6554-001
5 O-ring
NEMA 4X forcarbon steelcover 12-1318-001 NEMA 4X/7/9 foraluminum cover 12-2101-345
6 Ho using base
NEMA 4X carbon steel, 3⁄4"NPT singleconduit 04-9160-002 NEMA 4X/7/9 aluminum, 3⁄4"NPT dualconduit 04-9182-002
7 Rem ote mo untprobe housing 89-6585-001
8 Rem ote electronics
1⁄2"NP T mou nting bracket 3⁄4"NP T 36-3805-001 36-3805-003
9 Twisted shielded pairconductor 09-7146-001 (Specifylengthinfeet)
NOTE: You must recalibrateafterchangingthepreamplifierboard. IMPORTANT: When orderingparts,pleasespecifytheserialnumber oftheexistingcontroland thedescriptionand partnumber ofthereplacementpart.
23 50-605 Kotron RF PointModel80/81LevelSwitches
3.6 Mod elNumber s
0 Integral
1 Remote
52 NEMA 4X carbon steel,3⁄4"NP T singleconduit
80 NEMA 4X/7/9aluminum,3⁄4"NP T dualconduit,singlepointm odels
12 Singlepoint,alarmcontrol
22 Singlepoint,pum p control
50-605 Kotron RF PointModel80/81LevelSwitches 24 NO TES
B ULLETIN: 50-605.13 EFFECTIV E : M ay 2004 SU PERSEDE S: November 2000 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 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.sticont rols.com Copyright © 2007 Magnetrol Inte rnational, Incorporated. All rights reserved. Printed in the USA. ASSUR ED Q U ALITY & SERVICE COST LESS ServicePolicy Ow nersofMagnetrol/STI controlsm ay requestthe return ofa controloranypartofa controlforcom pleterebuilding or replacement.T hey willbe rebuiltor replacedpromptly. Cont rolsreturned underourservicepolicym ustbereturned by prepaid transportation.Magnetrol/STI willrepairor replacethe controlat no costto the purchaser(orown er) otherthan transportation if: 1. R eturned withinthe warrantyperiod;and 2. T he factoryinspectionfindsthe causeofthe claimto be covered underthe warranty. Ifthetroubleistheresultofconditionsbeyondourcontrol; or,isNO T covered by the warranty,therewillbe charges forlabor and the partsrequiredto rebuildor replace the equipment. In some cases itmay be expedientto shipreplacement parts; or, in extreme casesa com pletenew control, to replacetheoriginalequipmentbeforeitisreturned.Ifthis isdesired, notify thefactoryofboth the m odeland serial numbersofthecontroltobe replaced.Insuch cases,credit forthema terialsreturnedwillbedeterminedon thebasisof theapplicabilityofourwarranty. No claims form isapplication,labor,directorconsequential damage w illbe allowed. Return M aterialProcedure So thatwe m ay efficientlyprocess any m aterialsthatare returned, it is essential that a “Return Ma terial Authorization” (RM A) num ber be obtained from the factory,prior to the m aterial'sreturn. T hisisavailable through Ma gnetrol’s or STI’s local representative or by contacting thefactory.Pleasesupplythefollowinginfor - mation: 1. Co mp any Nam e 2. D escription ofM aterial 3. SerialNum ber 4. R eason forR eturn 5. Application Any unitthat w as used in a processmust be properly cleaned in accordance w ith O SHA standards,beforeitis returned to the factory. A MaterialSafety Data Sheet (MSD S) must accompany materialthatw asused inanym edia. Allshipmentsreturned to the factorymust be by prepaid transportation. Allreplacementsw illbe shippedF .O.B. factory. N OTE: See ElectrostaticD ischargeHan dling Procedure on page8. Magnetrol,Magnetrollogotypeand Kotron areregisteredtrademarksofMagnetrolInternational. STIand STIlogotype areregisteredtrademarksofMagnetrolInternational. C SA logotypeisa registered trademarkofCanadian StandardsAssociation Mylar® isa registered tradema rkofDuP ont Teflon® isa registeredtradem arkofDuP ont.