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Kotron® Model 810 RF Point Level Sensor Installation and Operating Manual RF Capacitance Level Measurement Read this Manual Before Installing This manual provides information on the Kotron Model 810 RF Point Level Sensor. It is important that all instructions are read carefully and followed in sequence. Detailed instructions are included in the Installation section of this manual. Conventions Used in this Manual Certain conventions are used in this manual to convey specific types of information. General technical material, support data, and safety information are presented in narrative form. The following styles are used for notes, cautions, and warnings. Notes Notes contain information that augments or clarifies an operating step. Notes do not normally contain actions. They follow the procedural steps to which they refer. Cautions Cautions alert the technician to special conditions that could injure personnel, damage equipment, or reduce a component’s mechanical integrity. Cautions are also used to alert the technician to unsafe practices or the need for special protective equipment or specific materials. In this manual, a caution box indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. Warnings Warnings identify potentially dangerous situations or serious hazards. In this manual, a warning indicates an imminently hazardous situation which, if not avoided, could result in serious injury or death. Safety Messages The Kotron Model 810 system may be properly installed in Category II, Pollution Degree 2 installations. Follow all standard industry procedures for servicing electrical and computer equipment when working with or around high voltage. Always shut off the power supply before touching any components. Although high voltage is not present in this system, it may be present in other systems. Electrical components are sensitive to electrostatic discharge. To prevent equipment damage, observe safety procedures when working with electrostatic sensitive components. WARNING! Explosion hazard. Do not connect or disconnect equipment unless power has been switched off or the area is known to be non-hazardous. Low Voltage Directive For use in Installation Category II, Pollution Degree 2. If equipment is used in a manner not specified by the manufacturer, protection provided by the equipment may be impaired. Notice of Trademark, Copyright and Limitations Magnetrol & Magnetrol logotype, STI and STI logotype, and Kotron are registered trademarks of Magnetrol International, Incorporated. Copyright © 2008 Magnetrol International. All rights reserved. Performance specifications are effective with date of issue and are subject to change without notice. Magnetrol/STI reserves the right to make changes to the product described in this manual at any time without notice. Magnetrol/STI makes no warranty with respect to the accuracy of the information in this manual. Warranty All Magnetrol/STI electronic level and flow controls are warranted free of defects in materials or workmanship for one full year from the date of original factory shipment. If returned within the warranty period; and, upon factory inspection of the control, the cause of the claim is determined to be covered under the warranty; then, Magnetrol/STI will repair or replace the control at no cost to the purchaser (or owner) other than transportation. Magnetrol/STI shall not be liable for misapplication, labor claims, direct or consequential damage or expense arising from the installation or use of equipment. There are no other warranties expressed or implied, except special written warranties covering some Magnetrol/STI products. Quality Assurance The quality assurance system in place at Magnetrol/STI guarantees the highest level of quality throughout the company. Magnetrol/STI is committed to providing full customer satisfaction both in quality products and quality service. Magnetrol’s quality assurance system is registered to ISO 9001 affirming its commitment to known international quality standards providing the strongest assurance of product/service quality available. 50-607 Kotron Model 810 RF Point Level Sensor Kotron Model 810 RF Point Level Sensor Table of Contents 1.0 Introduction 1.1 Principle of Operation...........................................1 1.2 Electrostatic Discharge (ESD) Handling Procedure...1 2.0 Installation 2.1 Unpacking ...........................................................1 2.2 Electrostatic Discharge Handling Procedure ..........2 2.3 Installation ...........................................................2 2.3.1 Installation Location....................................2 2.3.2 Probe Length...............................................3 2.4 Mounting ...........................................................3 2.4.1 Horizontal Mounting ..................................3 2.4.2 Vertical Mounting .......................................3 2.5 Wiring...................................................................4 2.6 Calibration ...........................................................6 2.6.1 Calibration Procedure.................................6 2.6.2 Calibration Conditions...............................6 3.0 Reference Information .................................................8 3.1 Troubleshooting.....................................................8 3.1.1 No Signal with Level Change .....................8 3.1.2 Switch Chatter............................................8 3.2 Agency Approvals ..................................................9 3.3 Specifications.......................................................10 3.3.1 Electrical...................................................10 3.3.2 Dimensional .............................................10 3.4 Replacement Parts ...............................................11 3.5 Model Numbers ..................................................12 50-607 Kotron Model 810 RF Point Level Sensor 1.0 Introduction The Kotron Model 810 RF Point Level Sensor can be utilized in liquid or bulk material applications. There are no moving parts in contact with the medium. These units are integral systems with the sensing probe mounted with the electronics. Guarded probes are utilized to minimize effect of build up on the probe. 1.1 Principle of Operation As the medium covers the probe, the amount of capacitance developed between the probe and ground changes. This change in capacitance is converted into a relay action. As the medium drains from the sensing probe, the relay position reverses. 2.0 Installation This section provides detailed procedures for properly installing point level sensors. Caution: This unit contains CMOS electronics which may be damaged by static electricity. Do not touch any semiconductor devices unless you are properly grounded. 2.1 Unpacking Unpack the instrument carefully. Inspect all components for damage. Report any concealed damage to carrier within 24 hours. Check the contents of the packing slip against purchase order. Check and record the model number against serial number for future reference when ordering parts. Model Number: Serial Number: 1 50-607 Kotron Model 810 RF Point Level Sensor 2.2 Electrostatic Discharge (ESD) Handling Procedure Magnetrol’s electronic instruments are manufactured to the highest quality standards. These instruments use electronic components that may be damaged by static electricity present in most work environments. The following steps are recommended to reduce the risk of component failure due to electrostatic discharge. • Ship and store circuit boards in anti-static bags. If an antistatic bag is not available, wrap the board in aluminum foil. Do not place boards on foam packing materials. • Use a grounding wrist strap when installing and removing circuit boards. A grounded workstation is recommended. • Handle circuit boards only by the edges. Do not touch components or connector pins. • Make sure that all electrical connections are completely made and none are partial or floating. Ground all equipment to a good, earth ground. 2.3 Installation 2.3.1 Installation Location Kotron point sensors should be located in areas allowing easy access for service, calibration and monitoring. Units should not be exposed to ambient temperatures above +160° F (+71° C) or below -40° F (-40° C). Special precaution should be taken to prevent exposure to corrosive atmosphere, excessive vibration, shock or physical damage. Sensing probes should be located close to the tank wall for greatest sensitivity in non-conductive media. Probes should be isolated from severe motion in the tank, because surface turbulence may cause signal deviation. NOTE: Do not attempt to disassemble probe from housing until the wires have been disconnected and the electronic module has been removed. Consult Section 3.1, Troubleshooting on page 8. 50-607 Kotron Model 810 RF Point Level Sensor 2 2.3.2 Probe Length If the geometry of your application requires a probe shorter than 12" (305 mm) of active length, refer to Figure 1 below to determine the minimum dielectric constant in which it can be used. Probe Length vs. Dielectric Constant 12 11 10 9 8 7 6 5 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Figure 1 Minimum dielectric constant of material Mounting Mounting Gland Gland 2.4 Mounting When installing, apply wrench to mounting gland only. Guard element should be located free of nozzle. Figure 2 Horizontal Mounting Mounting Mounting Gland Gland Nozzle Nozzle Caution: When a probe is used in an abrasive medium, inspect the probe at least annually for visible surface wear. In case any wear is found, replace the probe or consult the factory. 2.4.1 Horizontal Mounting Unit will signal at probe level. Refer to Figures 2 and 3. Caution: Do NOT horizontally mount the unit in a nozzle deeper than 3" (75 mm). Refer to Figures 2 and 3. The medium may build up in the nozzle and cause false actuation. 2.4.2 Vertical Mounting Figure 3 Horizontal Mounting in Nozzle Mounting Gland Mounting Gland As medium rises on the probe, the unit will signal at a point determined by the calibration of the unit and the dielectric constant of the medium. In conductive media, the actuation point will be at the tip of the probe over a wide range of adjustment. Refer to Figure 4. INSTALLATION INSTRUCTIONS 1. Thread amplifier assembly into mounting bushing on tank using suitable pipe compound or thread tape. Assembly may also be attached to a flange and bolted to the vessel using a suitable gasket. 2. Tighten securely, being certain that the wrench is applied ONLY to the mounting gland. Refer to Figures 2 through 4. Figure 4 3 50-607 Kotron Model 810 RF Point Level Sensor 2.5 Wiring All power and control connections are made at the terminal strip within the amplifier enclosure, EXCEPT GROUNDING. Power grounding must be made at green ground screw on the housing base. 16AWG wire is recommended for power and control circuits. Mounting Screws NOTE: There are special wiring requirements for intrinsic safety. Observe all local electrical codes and proper wiring procedures. Caution: This unit contains CMOS electronics which may be damaged by static electricity. Do not touch any semiconductor devices unless you are properly grounded. PROCEDURE: 1. Make sure the power source is turned off. 2. Unscrew and remove housing cover. 3. Pull power supply and control wires through conduit ground connection. 4. Connect green ground wire to green ground screw located in the base of the housing. NOTE: If separate I.S. ground is required in this application, then I.S. ground (conventionally, blue #12 wire) should be connected to Green Ground the barrier at this time. Refer to NEC and agency guidelines. Screw Figure 5 I.S. Ground 5. After grounding is complete, connect AC power leads to the HOT and COM terminals as marked. Refer to Figure 6. NOTE: For DC supply voltage connect DC+ to HOT and DC– to COM. 6. Connect control circuit leads to relay terminals. Refer to Figure 6. Make sure the load to be controlled is within the relay's rated capacity. 7. Prevent moisture seepage into housing by installing an approved seal-drain fitting in the conduit run leading to the unit. 8. Select operating mode. (Refer to OPERATING MODE SELECTION on page 5 for detailed information.) Make sure that the fail-safe switches are in the correct position for your selection. Refer to Figure 7 and the RELAY WIRING CHART on page 5. Caution: In hazardous areas, do NOT power the unit until the conduit is sealed and the enclosure cover is screwed down securely. Figure 6 9. Installation is complete. Replace housing cover. 50-607 Kotron Model 810 RF Point Level Sensor 4 OPERATING MODE SELECTION Relay LED The chart below is provided to aid in the proper choice of relay wiring and calibration. Please note: 1. Equipment controlled by the relay is assumed to be powered from one source, while the Model 810 itself is assumed to be powered from a different source. 2. There are fail-safe switches on the switch which may be set in either a High or Low position. Refer to Figure 7. 3. “Fail” means 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. When relay coil is de-energized (fail-safe) the circuit between common (COM) and the normally open (NO) terminal is open and a connection is made between common (COM) and the normally closed (NC) terminals. The LED is off. 6b. When the relay coil is energized the NO contact is closed and the NC contact is open. The LED is on. Refer to the Relay Wiring Chart below. RELAY WIRING CHART Kotron Material Fail-safe Power Level Position High HL LL HL LL HL LL HL LL Relay Coil De-energized Energized Energized De-energized De-energized De-energized De-energized De-energized Relay Terminal CM to NC CM to NO Closed Open Open Closed Open Closed Closed Open Closed Open Closed Open Closed Open Closed Open Level control (R4) Fail-safe switches Time delay switches between 1 and 2 On Low High Fail Time delay control (R9) Low Figure 7 5 50-607 Kotron Model 810 RF Point Level Sensor 2.6 Calibration Caution: In hazardous areas, do not remove housing cover until power is disconnected and atmosphere os determined to be safe. Hazardous environments must be declared safe by the local safety authority. 2.6.1 Calibration Procedure 1. Turn on power to the instrument. 2. Remove housing cover. 3. Set point location: a. Conductive media: The set point is located at the tip of the probe. Calibration is not required for most conductive liquids. If the unit does not switch on alarm test, then proceed to Step 4. b. Non-conductive media: The set point is located on the probe at a point determined by the set point adjustment. 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. Turn the LEVEL control (R4) clockwise a full twenty turns or until a ratcheting sound is heard. b. Set the DIP switch with positions 1 and 2 ON. c. Turn the TIMER control (R9) fully counterclockwise. d. Note that if DIP switch positions 3 and 4 are both ON the LED will remain on. Set DIP switches based on the following information: 2.6.2 Calibration Conditions Complete calibration by utilizing the following conditions that best suits your application: 1. Fail-safe Low— a. Set DIP switch position 3 ON and position 4 OFF. b. Turn the LEVEL control counterclockwise until the LED turns on. c. Turn the LEVEL control clockwise until the LED turns off. d. If media is on probe, slowly turn the LEVEL control counterclockwise until the LED comes on. 50-607 Kotron Model 810 RF Point Level Sensor 6 2. Fail-safe High— a. Set DIP switch position 3 OFF and position 4 ON. b. Turn the LEVEL control counterclockwise until the LED turns off. c. Turn the LEVEL control clockwise until the LED turns on. d. If media is on probe, slowly turn the LEVEL control counterclockwise until the LED turns off. 3. Time Delay If Time Delay is required (i.e., surface waves causing relay chatter), two choices must be made: a. Delay Function: — Delay on FILL (rising Level) switch 1 OFF, 2 ON — Delay on EMPTY (falling Level) switch 1 ON, 2 OFF b. Delay Duration: — 0 to approximately 45 seconds (Timer R9) — CW rotation increases duration (approximately 270° stop to stop) 7 50-607 Kotron Model 810 RF Point Level Sensor 3.0 3.1 Reference Information Troubleshooting 3.1.1 No Signal with Level Change 1. 2. 3. 4. Check power and control circuit wiring. Check fail-safe switch position. Check calibration. Check for proper ground reference particularly in nonmetal tanks. If removal of electronic module is necessary: 1. Loosen mounting screws. Refer to Figure 5. 2. Slowly raise electronic module exposing probe wiring. 3. Disconnect probe and guard leads. Remove electronic module. 3.1.2 Switch Chatter 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. NOTE: If these suggestions prove unsuccessful, consult factory. 50-607 Kotron Model 810 RF Point Level Sensor 8 3.2 Agency Approvals APPROVED MODEL PROTECTION METHOD AREA CLASSIFICATION AGENCY FM All models 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 NEMA 4X 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. CSA All models Explosion Proof 9 50-607 Kotron Model 810 RF Point Level Sensor 3.3 Specifications 3.3.1 Electrical Supply voltage 120 VAC, 50–60 Hz (+10%, -15%) 240 VAC, 50–60 Hz (+10%, -15%) 24 VDC (±10%) 12 VDC (±10%) Power consumption Zero range Fixed differential Output relays (reversible DPDT) Response time Repeatability Ambient temperature Operating process pressure/temperature Temperature coefficient of set point -40° to +160° F (-40° to +70° C) ± .01% per degree F of setpoint (± .018% per degree C of setpoint) 120 or 240 VAC Less than 5 volt-amps 12 or 24 VDC 1 watt maximum 0 pF minimum to 500 pF maximum 0.5 pF AC 5 amp @ 250 VAC resistive DC 5 amp @ 30 VDC, 0.5 amp @ 125 VDC resistive 100 milliseconds Better than 1.0% Electronics -40° to +160° F (-40° to +70° C) 3500 psig @ +100° F (240 bar @ +40° C) 1750 psig @ +200° F (120 bar @ +95° C) 3.3.2 Dimensional Rotation clearance 3.44 (87) 4.63 (118) Dia. 3/4" NPT plugged 3/4" NPT 2.75 (70) 3/4" NPT Conduit connection 4.11 (104) 6" (152) Guard length 18" (457) or 36" (914) 12" (305) or 30" (762) Active length 50-607 Kotron Model 810 RF Point Level Sensor 10 3.4 Replacement Parts 1 2 3 4 5 No. Œ Description Complete Electronic Assembly Œ 120 VAC 240 VAC 24 VDC 12 VDC Aluminum 316 SS Aluminum 3⁄4" NPT conduit connection 316 SS, single hub Part Number Z30-9101-001 Z30-9101-002 Z30-9101-004 Z30-9101-003 04-9105-001 04-9142-00 12-2101-345 04-9182-002 04-9140-001 8AD-AA1A-018 8AD-AA1A-036  Ž   Cover O-ring Base Probe 18" (457 mm) Probe 36" (914 mm) Œ Refer to Section 2.2, Electrostatic Discharge (ESD) Handling Procedure on page 2. 11 50-607 Kotron Model 810 RF Point Level Sensor 3.5 Model Numbers BASIC MODEL 810 Kotron RF Capacitance Level Switch INPUT POWER 0 1 2 3 120 VAC 240 VAC 24 VDC 12 VDC HOUSING D Y NEMA 4X/7/9 Groups C & D, aluminum, 3⁄4" NPT conduit NEMA 4X/7/9 Groups C & D, 316 SS, 3⁄4" NPT conduit PROBE 1 2 18" (455 mm) guarded probe 36" (915 mm) guarded probe 8 1 0 0 0 5 0 50-607 Kotron Model 810 RF Point Level Sensor 12 ASSURED QUALITY & SERVICE COST LESS Service Policy Owners of Magnetrol/STI controls may request the return of a control or any part of a control for complete rebuilding or replacement. They will be rebuilt or replaced promptly. Controls returned under our service policy must be returned by Prepaid transportation. Magnetrol/STI will repair or replace the control at no cost to the purchaser (or owner) other than transportation if: 1. Returned within the warranty period; and 2. The factory inspection finds the cause of the claim to be covered under the warranty. If the trouble is the result of conditions beyond our control; or, is NOT covered by the warranty, there will be charges for labor and the parts required to rebuild or replace the equipment. In some cases it may be expedient to ship replacement parts; or, in extreme cases a complete new control, to replace the original equipment before it is returned. If this is desired, notify the factory of both the model and serial numbers of the control to be replaced. In such cases, credit for the materials returned will be determined on the basis of the applicability of our warranty. No claims for misapplication, labor, direct or consequential damage will be allowed. Return Material Procedure So that we may efficiently process any materials that are returned, it is essential that a “Return Material Authorization” (RMA) number be obtained from the factory, prior to the material's return. This is available through Magnetrol’s local representative or by contacting the factory. Please supply the following information: 1. 2. 3. 4. 5. Company Name Description of Material Serial Number Reason for Return Application Any unit that was used in a process must be properly cleaned in accordance with OSHA standards, before it is returned to the factory. A Material Safety Data Sheet (MSDS) must accompany material that was used in any media. All shipments returned to the factory must be by prepaid transportation. All replacements will be shipped F.O.B. factory. NOTE: See Electrostatic Discharge Handling Procedure on page 2. 5300 Belmont Road • Downers Grove, Illinois 60515-4499 • 630-969-4000 • Fax 630-969-9489 • www.magnetrol.com 145 Jardin Drive, Units 1 & 2 • Concord, Ontario Canada L4K 1X7 • 905-738-9600 • Fax 905-738-1306 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.sticontrols.com Copyright © 2008 Magnetrol International, Incorporated. All rights reserved. Printed in the USA. BULLETIN: 50-607.5 EFFECTIVE: October 2004 SUPERSEDES: May 2002