KAM Simple Precision LRW User Manual

KAM® LRW™

LOW RANGE WATERCUT

TEL [phone]

FAX [phone]

Email [e-mail]

KAM CONTROLS, INC.

3939 Ann Arbor Drive

Houston, Texas 77063 USA

www.KAM.com

User Manual

LRWMANUAL 0918

An ISO 9001 certified company

TABLE OF CONTENTS

SECTION TITLE PAGE

1 Introduction 2

•Available Models and Mounting Options 2

•Theory of Operation 3

2 Specifications 4

•Specifications 4

3. Installation 5

•Installation Flow Requirements 5

•Prior to Installation 5

•Flow through assembly 5

•Insertable/retractable installation 6

•Removing Fast Loop Models 8

•Wiring 9

4 LRW Operation 15

•RealTerm configuration 15

•Data capture 19

•Calibrating the LRW 21

•Calibration with lab results 23

•Output process values 24

•Density input reconfiguration 24

5 Maintenance 27

•Cleaning/Inspection 27

6 Troubleshooting 28

APPENDIX A: Modbus Registers 32

CAUTION:

When installing the LRW® sensor in a pipeline containing petroleum products,
petrochemicals, waste waters with the presence of pressure & temperature, and high-pressure
steam refer to the Pipeline Operators’ "Health, Safety and Environmental Policy Procedures" to
ensure safe installation.

KAM CONTROLS, INC. reserves the right to make changes to this document without notice.

LRWMANUAL 0918

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KAM CONTROLS, INC.

INTRODUCTION

AVAILABLE MODELS and MOUNTING OPTIONS

LRW™ flow-through
spool for 1", 2", and 3"
pipelines with included
static mixer and
manual draw-off valve

LRW™ fixed insertion for pipelines 3" and up
2", 3" or 4" flanged process connection

LRW Low Range Watercut

www.KAM.com

[phone]
[e-mail]

Made in the USA

LRW™ insertable/retractable for pipelines 3" and up
2", 3" or 4" flanged seal housing or 2" MNPT process connection

LRWMANUAL 0918

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KAM CONTROLS, INC.

INTRODUCTION continued

THEORY OF OPERATION

The KAM LRW™ Low Range Watercut / BS&W meter uses a patented microwave resonance technology, responding

to the differing electrical properties of water and oil to determine water content for ranges 0-3%, 0-5% and 0-10%.

The technology is highly repeatable and offers industry-leading accuracy (±0.03% for a 0-3% range). Additionally,

proprietary AnyDensity™ technology allows the instrument to compensate for any change in density across the

entire API gravity range. Compensation is based on a density input from a mass flow meter or densitometer and

all compensation is automatic. This is paramount in situations where a single truck or rail unloading site could see

swings in API gravity from the 20s to the 60s.

The unit can be calibrated and verified in line.

The LRW's high-quality components are made and assembled entirely in the USA, providing reliable and consistent

performance for long-term use.

TABLE 1-1 MEASUREMENT CAPABILITIES: CALIBRATED RANGE AND ACCURACIES

Range (water in oil) 0-3% 0–5% 0-10%
Accuracy (at listed range) ±0.03% ±0.05% ±0.05% (from 0-5% water); ±0.1% from 5-10% water

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KAM CONTROLS, INC.

SPECIFICATIONS

Media: Crude oil and refined products

Wetted parts: 316 SS, hastelloy, & PEEK (Other materials available)

Fluid temp: To 300º F (149º C)

Electronics temp: -40º F to 158º F (-40º C to +70º C)

Power requirements: 24 VDC

Power consumption: 12 watts

Available ranges: 0-3%, 0-5%, 0-10% water in oil

Accuracy: 1% of range (0-10% models have an accuracy of 0,05% for water from 0-5% and an

accuracy of 0,1% for water from 5-10%)

Repeatability: +/- 0.01%

Resolution: +/- 0.01%

Minimum water detection: 300 ppm (0-3% models)

Outputs/serial ports: 4–20 mA

Alarm relay

RS232 ASCII (calibration and diagnostics only)

RS485 Modbus

Input: 4-20 mA for density

Density Correction: AnyDensity™ compensates for changes in fluid density across entire API gravity range

(requires density input)

Ingress protection: NEMA IV; IP66

Temperature Correction: Automatic

Pressure ratings: ANSI 150, 300, 600, 900

Flow conditions: Well mixed in accordance with API MPMS Chapter 8.2 mixing requirements, vertical

installation strongly recommended

Enclosure hazardous

approvals: Explosion-proof for Class I, Division 1, Groups B, C and D

Dust-ignition-proof for Class II/III, Division 1, Groups E, F and G,

hazardous (classified) locations, indoors and outdoors (Type 4X/IP66)

ATEX: II 2 G D, Ex d IIC, Ex tD A21, IP68, Ta = -40°C to +85°C

IEC EX: Ex d IIC, Ex A21 tD, IP68, Ta = -40°C to +85°C

LRWMANUAL 0918

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KAM CONTROLS, INC.

INSTALLATION

INSTALLATION FLOW REQUIREMENTS

KAM HIGHLY RECOMMENDS VERTICAL INSTALLATIONS WHEREVER POSSIBLE FOR OPTIMAL MIXING.

PLEASE NOTE: In all KAM LRW Installations, the user should ensure that the KAM LRW is installed in a turbulent
flow with the Reynolds Number above 2000. Additionally, all KAM LRW's should be installed in accordance with API
MPMS Chapter 8, Section 2, Table 1, and in accordance with KAM mixing recommendations.

PRIOR TO INSTALLATION

Remove all the protective packaging materials, and ensure that the LRW® sensor was not damaged
during transit.

It is always recommended that the LRW NOT be installed in direct sunlight, and in high-ambient-temperature
installations that it be installed with recommended sunshade.

In cold weather, if LRW is exposed to an open environment, KAM CONTROLS recommends operators insulate
the LRW, and if the pipeline is heated that the heating trace be extended to include the LRW.

If the pipeline is not going to flow for extended amount of time and the pipe is not heated then LRW should be
taken out to avoid damage to the sensor probe by freezing water.

LRW FLOW THROUGH ASSEMBLY

Flow through (spool) units will be shipped partionally assembled. LRW unit can be wired prior to insertion into the
spool for convenience, but this is not required.

For 2" units:

1.

Grease around the O-ring below the small
flange.

Insert LRW body into the spool and ensure

2.

unit is fully seated. NOTE: LCD screen face
should be alined with direction of pipe flow.

3.

Using a 5/8" Allen wrench, install (8) hex
screws around the circumference of the
flange until tight.

4.

Screw pitot probe into valve until tight.

FIG. 3-1 LRW FLOW THROUGH 2" AND 3" MODELS

Hex nutsO-ring

Pitot
probe

For 3" and 4" flow through units:

Screw LRW body into spool using 1 3/4"

1.

wrench flat. KAM Controls recommends
using liquid pipe sealant rather than teflon
tape.

2.

Screw pitot probe into valvue until tight.

LRWMANUAL 0918

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KAM CONTROLS, INC.

INSTALLATION continued

INSERTABLE/RETRACTABLE INSTALLATION

The KAM® LRW sensor should be installed
according to FIG. 3-2. A full-opening ball valve is
used to isolate the LRW sensor from the pipeline
during installation or removal. The seal housing of
the LRW sensor allows the probe to be inserted
and removed from the pipe under pressure and flow
conditions. It is the user’s responsibility to
ensure that the LRW sensor be placed at the most
representative point within the flow profile (see
location recommendations above). The LRW
sensor should be inserted so that the window of
the probe is located in the center of the diameter of
the pipeline.

FIG. 3-2 KAM® LRW INSTALLED ON A MAIN PIPE

Locking Collar

Seal Housing

Full-opening

Ball Valve

Note: If line pressure exceeds 100 psi, use a KAM
IT Insertion Tool when installing/removing
the KAM® LRW sensor.

Prior to mounting verify that the tip of the sensor

1.

is all the way inside the seal housing.
FIGS. 3-3, 3-4.

If sensor is not fully enclosed inside the seal

2.

housing, pull the shaft back until the probe is
all the way in the seal housing and tighten
the Socket Cap Screws on the locking collar.
This will prevent the LRW shaft from sliding
and the probe from getting damaged during
mounting.

®

Socket cap screws

FIG. 3-3

FIG. 3-4

LRWMANUAL 0918

Loosen to retract
probe into seal housing

6

KAM CONTROLS, INC.

INSTALLATION continued

3.

Measure the distance (D1) from the outside diameter of main pipe to the end of the
connection where the LRW sensor is going to be installed. FIG. 3-5.

FIG. 3-5

D1

D1

4.

Calculate the minimum insertion distance for the LRW.

FIG. 3-6

Minimum insertion distance (MID) =
D1 +
Pipe Wall Thickness (WT) +
Gasket Thickness +
3"

Example for D1=16", WT =1/4",
Gasket Thickness=1/8"

MID

MID = 16 + 1/4 + 1/8 + 3
MID = 19 3/8"

5.

Measure the calculated MID from the top of the Locking Collar and place a mark with a permanent marker or
tape on the Shaft. FIG. 3-6.

6.

Bolt or screw the LRW sensor to the valve or designated installation location.
(KAM CONTROLS recommends using thread sealant and not Teflon tape for the threaded LRW).

Open full opening valve.

7.

8.

Loosen Socket Cap Screws on the locking collar.

9.

Push LRW sensor in until the mark is at the top edge of the locking collar. Ensure that LRW flow indicator is
aligned with pipeline flow direction. FIG. 3-7.

FIG. 3-7

Mark

LRWMANUAL 0918

Socket
cap screws

7

Hex Nuts

KAM CONTROLS, INC.

INSTALLATION continued

Re-tighten the Socket Cap Screws.

10.

Tighten the hex nuts holding down the Locking Collar one half turn. (FIG. 3-7) These should never be

11.

over-tightened. Their major function is to apply light pressure on the chevron packing to ensure a seal between
the seal housing body and the insertion shaft.

REMOVING THE LRW SENSOR

To remove the LRW sensor, first shut off power to the instrument. Loosen the Socket Cap Screws on the Lock Down
Collar. Slide the LRW sensor upward until the probe rests inside the seal housing. There is a mechanical stop when
the unit is fully retracted. Retighten the Socket Cap Screws. Next, close the Full-opening Ball Valve tightly. Drain oil
from valve if possible. The LRW sensor may now be unbolted from the system.

Note: If line pressure exceeds 100 psi, use a KAM® IT Insertion Tool when installing/removing the KAM® LRW sensor.

Removal should be conducted in accordance with all regional and Class requirements.

REMOVING THE LRW® SENSOR FROM FLOW THROUGH SPOOLS WITH FIXED INSERTION

To remove the LRW® sensor, first shut off power to the
instrument. Discontinue flow in loop from the main line and
drain fluid from loop. The probe can removed from the hous­ing by removing the 5/8" hex screws on collar (2" models) or
unscrewed from spool body (3" and 4" models). FIG. 3-8. The
probe can then be lifted from the cell for testing/inspection/
calibration purposes.

Removal should be conducted in accordance with all regional
and Class requirements.

FIG. 3-8

2" LRW flow through model

Hex screws

3" and 4" LRW flow through models

LRWMANUAL 0918

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KAM CONTROLS, INC.

INSTALLATION continued

WIRING

CAUTION: Do not connect power to 4-20 mA output. This will damage the board and void product warranty.

FIG. 3-9 WIRING DIAGRAM

Density input

(4-20 mA)

DENSITY IN4-20+

Digital relay output
open drain (max 50 W)

DOUT1

GND

GND

Chassis connection

Power input (12-24 V)

CHS

POWER-

POWER+

4-20 mA current loop output

LRWMANUAL 0918

4-20- GND

GND

GND

232-TXD

232-RXD

RS232
serial connections

9

485-

485+

GND

LCD connector

MODBUS/RS485 serial connections
optional ground

KAM CONTROLS, INC.

INSTALLATION continued

All wiring and maintenance on the KAM LRW must be done in accordance with regional and classification
requirements. It is the user's responsibility to understand these requirements.

It is also recommended that the LRW be wired with flexible wiring/conduit with additional slack/length in the
wire to accommodate insertion, removal, and testing.

To avoid repeatedly opening electronics enclosure during diagnostics, it is recommended operators permanently
wire an RS232 connection to the instrument with corresponding 9-pin connection at junction box for PC
connection.

Operators should take all possible precautions to avoid any moisture from entering the electronics enclosure.
The enclosure should not be left open in inclement weather or for long periods of time, especially during
operation, as condensation will accumulate. All conduits should be sealed and secured in accordance with re­gional and classification requirements, and unused 3/4" NPT openings should be sealed with provided plug. Do
not power wash the unit.

If necessary, disconnect LCD connector in order to access wiring terminals. The LRW supplies power for the
loop. Make sure the device that receives data from the LRW does not have a power source of its own switched
on. Also, the LOOP+ and LOOP- are isolated inputs from the chassis/earth. Do not connect either to a common
ground. Use an isolator if necessary.

INPUTS/OUTPUTS/SERIAL

POWER (–) GND
POWER (+) 24-30 VDC

DENSITY IN From mass flow or densitometer.
GND

4-20 mA (–) Current output, source powered. Set to requisite percent water at factory.
4-20 mA (+)

DIG OUT (–) Alarm or relay (digital contact closure / max 50 W)
DIG OUT (+)

RS232 Console port – communication interface for calibration, connection to PLC
RS485 Modbus interface

LRWMANUAL 0918

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KAM CONTROLS, INC.

INSTALLATION continued

WRONG
WIRING

THE 4-20 mA (-) and
power supply (-) can
not be the same or
connected togeather.

WRONG
WIRING

LRW PROVIDES POWER FOR THE 4-20mA
loop adding external power can damage
4-20mA output

TYPICAL
WIRING

TYPICAL POWER AND LOOP WIRING CONFIGURATIONS

FIG. 3-10

LRW

POWER (+)

POWER (-)

4-20 (+)

4-20 (-)

LRW

POWER (+)

POWER (-)

4-20 (+)

4-20 (-)

POWER SUPPLY

(+)

(-)

(+)

(-)

POWER SUPPLY

(+)

24VDC

ISOLATED
RECEIVER
INPUT

CORRECT

WRONG:

The 4-30 mA (-) and power supply (-)

(-)

24VDC

cannot be the same or connected
together.

(+)

(-)

RECEIVER
INPUT

LRW

POWER (+)

POWER (-)

4-20 (+)

4-20 (-)

LRWMANUAL 0918

POWER SUPPLY

(+)

(-)

(-)

(+)

11

WRONG:

LRW provides power for the 4-20 mA

24VDC

loop. Adding external power can damage
the 4-20 mA outpout.

RECEIVER
INPUT

KAM CONTROLS, INC.

WITH ISOLATOR

INSTALLATION continued

TYPICAL POWER AND LOOP WIRING CONFIGURATIONS

FIG. 3-11 Power and loop with isolator

LRW

POWER SUPPLY

(+)

POWER (+)

POWER (-)

4-20 (+)

4-20 (-)

(-)

(+)

(-)

(-)

RECEIVER

(+)

INPUT

4-20 mA ISOLATOR

OUTPUT

INPUT

24VDC

LRWMANUAL 0918

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KAM CONTROLS, INC.

INSTALLATION continued

DENSITY WIRING

Density meter provides power for the 4-20mA output

DENSITY INPUT WIRING

FIG. 3-12 Density meter provides power for 4-20 mA output

LRW

DESITY METER

(+)

DENSITY IN (+)

GND

POWER SUPPLY

(-)

4-20mA Signal Splitter

LRW

(+)

(-)

POWER
IN

OUTPUT

DENSITY IN (+)

GND

2ND
RECEIVER

(+)

(-)

(+)

(-)

OUTPUT 1

OUTPUT 2

4-20mA
Input

(+)

(-)

DESITY METER

OUTPUT

LRWMANUAL 0918

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KAM CONTROLS, INC.

INSTALLATION continued

DENSITY WIRING

Where density meter 4-20mA output requires external power.

DENSITY INPUT WIRING

FIG. 3-13 Density meter 4-20 mA output requires external power

POWER SUPPLY

LRW

DENSITY IN (+)

GND

POWER SUPPLY

4-20mA Signal Splitter

POWER

(+)

LRW

DENSITY IN (+)

GND

(-)

(-)

(-)

IN

(+)

OUTPUT 1

(+)

OUTPUT 2

(+)

(-)

DESITY METER

OUTPUT

4-20mA
Input

POWER SUPPLY

(+)

(-)

DESITY METER

OUTPUT

2ND
RECEIVER

LRWMANUAL 0918

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KAM CONTROLS, INC.

KAM LRW OPERATION

CONFIGURATION

RealTerm software is used for testing and calibration of the LRW. RealTerm is available as a free download.

To download RealTerm, go to http://sourceforge.net/projects/RealTerm/ and click on download button.

Follow on screen instructions to install RealTerm.

1.

If you haven't already done so, connect the RS232 cable to the LRW board as shown on page 9, FIG. 3-9 of
this manual.

Connect the other end of RS232 cable to the serial port of your computer. An RS232 cable for connecting

2.

your PC to the LRW has been supplied with the LRW as well as a USB adaptor in case your computer does
not have an RS232 serial port.

3.

Open RealTerm software. A window will open as shown in FIG. 4-1.

4.

The window will automatically default to the "Display" tab. Click on the up arrow beneath the "Cols" window
until the number reaches 120. Do not attempt to type the number in as this will result in an error message. If
you receive the error message you must close RealTerm and reopen.

FIG. 4-1

Display

tab

LRWMANUAL 0918

15

Click until value reaches "120"

KAM CONTROLS, INC.

KAM LRW OPERATION continued

5.6.Click on the "Port" tab (FIG. 4-2) and then configure setting to match below.

Baud: 115200
Parity: None
Data Bits: 8
Stop Bits: 1
Hardware Flow Control: 1
Port: Select port number assigned to your serial port or USB port connected to converter

Click on the "Change" button to save these settings.

FIG. 4-2

Port tab

Port
number

Change to
save

LRWMANUAL 0918

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KAM CONTROLS, INC.

KAM LRW OPERATION continued

If not already turned on, turn on power to LRW™. The initial greeting message will appear if the unit

7.

is newly powered up. FIG. 4-3

FIG. 4-3

Click on the "Send" tab and select first four boxes under "EOL" (FIG. 4-4)

8.

FIG. 4-4

Send tab

EOL: Click first four boxes

LRWMANUAL 0918

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KAM CONTROLS, INC.

KAM LRW OPERATION continued

9.

LRW output will start automatically in CSV (comma separated values) format. FIG. 4-5

Data can be exported using the capture function. See next page (19) for instructions.

FIG. 4-5

Column 3: maximum voltage (V)

Column 2: minimum voltage (V)

Column 1: percent water

LRWMANUAL 0918

Column 8: density in volts

Column 7: fluid temperature at probe (˚C)

Column 6: electronics temperature (˚C)

Column 5: frequency offset (Hz)

Column 4: minimum frequency (Hz)

18

Column 11: density correction

frequency (Hz)

Column 10: density in g/cm3

Column 9: density in API gravity

KAM CONTROLS, INC.

KAM LRW OPERATION continued

DATA CAPTURE IN REALTERM

Click on the "Capture" tab. FIG 4-6

1.

2.

Uncheck the "Direct Capture" option

3.

Click on the button marked with the ellipses: "..."

4.

A new window will open. If a folder is not already selected, choose a folder and click open. Name the data file
and save to selected folder. FIG 4-7. Click on "Open".

5.

Press the "Start: Overwrite" button. The screen will clear and start continuously capturing all data. Fig. 4-6.

FIG. 4-6

Capture
tab

Start: Overwrite
(overwrites existing
data)

Start: Append
(resumes data
capture)

FIG. 4-7

Direct captureEllipses button

(pauses data capture)

Click here

LRWMANUAL 0918

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KAM CONTROLS, INC.

KAM LRW OPERATION continued

DATA CAPTURE IN REALTERM CONTINUED

6.

While capturing data, the "Capture" window turns red. FIG 4-8

7.

Press Stop Capture to stop data capturing. The saved file can be opened either in MS Excel or in Notepad.

FIG. 4-8

LRWMANUAL 0918

Stop Capture

20

KAM CONTROLS, INC.

KAM LRW OPERATION continued

ON-LINE CALIBRATION AND VERIFICATION OF THE KAM® LRW

®

PLEASE NOTE: The following calibration steps are to be conducted during initial installation with existing process
conditions; during routine verification procedures; or when LRW readings indicate a slight drift off acceptable
accuracies in continuous operation. You will need an RS232 cable (supplied) or an RS232/USB adapter (supplied), a
PC equipped with RealTerm software, and a means for manually collecting and measuring samples.

Connect PC to the LRW sensor via supplied RS232 serial port or RS232/USB adapter. Launch RealTerm and

1.

follow steps indicated on pages 15-18 to configure RealTerm.

2.

Manually draw (3) samples of fluid according to API MPMS Chapter 8.1, waiting at least 15 minutes between
samples.

3.

Each time a sample is drawn, note or take a screen shot of the current % water LRW reading in the RealTerm
window.

4.

Determine water percentage in sample using a KAM Karl Fischer Moisture Analyzer (recommended), or
available method.

Average the water content from the three samples.

5.

6.

Average the water content from the three LRW screen shots (first data column).

7.

Check the current reading of the LRW in RealTerm.

8.

Subtract or add the value of the difference between sample averages and LRW averages.

9.

Type "lcal" (lower case L) in either command port under the "Send" tab and click on "Send ASCII."

FIG. 4-9

% water

Calibration
mode message

Command port

Send ASCII

button

LRWMANUAL 0918

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KAM CONTROLS, INC.

KAM LRW OPERATION continued

ON-LINE CALIBRATION OF THE KAM® LRW™ continued

Type the calculated percent of water (i.e. 1.58 for 1.58%) and click on the Send ASCII button. FIG. 4-10.

10.

Calibration results will be displayed in the RealTerm menu. FIG. 4-11

FIG. 4-10

FIG. 4-11

Calibration
results

CALIBRATION EXAMPLE

Manual samples water content:

1. 2.51%

2. 2.75%

3. 2.62%

Average = 2.63%

Difference of averages:

2.74% - 2.63% = 0.11%

According to the averages, the LRW is reading 0.11% high.

LRW screen shots water content:

1. 2.60%

2. 2.91%

3. 2.70%

Average = 2.74%

Current reading: 3.0%

To adjust the LRW, the reading needs to be lowered by 0.11%.

3.0% – 0.11% = 2.89%.

This is the new value to be entered into the LRW.

LRWMANUAL 0918

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KAM CONTROLS, INC.

KAM LRW OPERATION continued

CALIBRATION WITH LABORATORY RESULTS

In cases where on-site reference measurement (Karl Fischer or centrifuge) is not available, the LRW™ can be verified
after obtaining results of manual sample analysis at a laboratory.

Connect PC to the LRW™ sensor via supplied RS232 serial port or RS232/USB adapter and launch RealTerm. If

1.

not already done, follow steps indicated on pages 15-18 to configure RealTerm.

Manually draw (3) samples of fluid according to API MPMS Chapter 8.1, waiting at least 15 minutes between

2.

sample draws.

3.

Each time a sample is drawn, note or take a screen shot of the current LRW™ reading in the RealTerm window.

4.

Send the samples to the lab for water content determination.

Once results have been received from the lab, average the water content from the three samples. This value is

5.

the "Lab observed % water."

6.

Average the water content from the three LRW screen shots. This value is the "LRW observed % water."
NOTE: The "LRW observed % water" should be more than 0 and less than the maximum water % on the
calibration table.

Type "=pcal,<LRW observed % water>, <Lab observed % water>" in the command port under the "Send" tab

7.

and click on "Send ASCII." In other words, if the LRW observed water was 1.5% and the Lab observed % water
was 1.75%, you would input "=pcal,1.5,1.75" FIG. 4-12

Calibration results will be displayed. FIG. 4-13

8.

FIG. 4-12

FIG. 4-13

LRWMANUAL 0918

23

KAM CONTROLS, INC.

KAM LRW OPERATION continued

OUTPUT PROCESS VALUES

Values for the 4-20mA loop (water %) and density range can be viewed by following the prompts below.

Connect PC to the LRW sensor via supplied RS232 serial port or RS232/USB adapter.

1.

Launch RealTerm. Type "?ppv" in the command port under the "Send" tab and click on "Send ASCII." The

2.

configured values for process parameters will be displayed. FIG. 4-14

FIG. 4-14

DENSITY INPUT VERIFICATION AND RE-CONFIGURATION

Density input values are configured at the factory according to information provided by the customer. These values
must match output values from the mass flow meter/densitometer for accurate operation of the LRW.

KAM Controls recommends contacting the factory before changing these settings.

Verify the low and high end of the density loop by typing “?ppv” and clicking on "Send ASCII." The parameters will

1.

show the current values for 4mA and 20mA with their respective units (API or g/cm3). FIG. 4-15

FIG. 4-15

LRWMANUAL 0918

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KAM CONTROLS, INC.

KAM LRW OPERATION continued

DENSITY INPUT VERIFICATION AND RE-CONFIGURATION continued

If the density is disabled (FIG 4-16), enable it by typing the command “=don” and clicking on "Send ASCII." FIG.

2.

4-17. The density input should only ever be disabled in situations where process density remains constant. Den­sity can be disabled by typing "=doff" and clicking on "Send ASCII."

FIG. 4-16

FIG. 4-17

Units for the density input range can either be API gravity or g/cm3. Current input units are indicated under Process
Parameter Values. Fig. 4-16. If the input units on the LRW do not match the output units of the densitometer or PLC,
both units and values must be changed to match the output from the densitometer/PLC.

To change the density input range to specific gravity units:

Enter "=den" and click on "Send ASCII."

1.

2.

To change the values, enter "=den4,<4mA Density value>" and "=den20,<20mA Density value>" and then click
"send ASCII." For instance, if the desired low end of the range was 0.8 g/cm3 and the desired high end of the
range was 0.95 g/cm3, you would enter "=den4,0.85" and "=den20,0.95". FIG. 4-18. Values can be entered in
either command port, but you must click the "send ASCII" button associated with each port.

FIG. 4-18

LRWMANUAL 0918

25

KAM CONTROLS, INC.

KAM LRW OPERATION continued

DENSITY INPUT VERIFICATION AND RE-CONFIGURATION continued

To change the density input range to API Gravity units,

Enter "=api" and click on "Send ASCII."

1.

To change the values, enter "=api4,<4mA Density value (API)>" and "=api20,<20mA Density value (API)>" and

2.

click on "Send ASCII". For instance, if the desired low end of the range was API 20 and the desired high end of the
range was API 70, you would , you would enter "=api4,20" and "=api20, 70". FIG. 4-19.

NOTE: For manual calibration instructions please contact KAM Controls.

FIG. 4-19

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KAM CONTROLS, INC.

MAINTENANCE

CLEANING AND INSPECTION

If probe is removed from the line for inspection, NEVER use sharp or metallic objects such as a knife or screw driver
to clean the antennas. Do NOT power wash the unit.

Instead, to remove any oil residue for visual inspection use a clean cloth with oil solvent or part washer.
Preferred solvents include, any petroleum solvent such as mineral spirits, xylene, toluene, gasoline, or diesel. Do not
use WD40 or other chemicals.

If you have a question regarding cleaning solvents, please contact KAM CONTROLS directly at [phone], or
email: [e-mail]

During inspection, ensure that there are no foreign objects stuck in the probe or attached to the antennas.

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KAM CONTROLS, INC.

TROUBLESHOOTING

LRW™ Low Range Watercut

[phone]
[e-mail]

Made in the USA

www.KAM.com

If the LCD display is off despite the LRW being powered on, please follow these instructions:

Turn off the field power supply to the LRW.

1.

Use a 5/64 Allen wrench to remove the set screw on the display cover.

2.

3.

Turning it counterclockwise by hand, remove the display cover.

4.

Remove the four (4) screws on the LCD display plate with a Phillips screwdriver (FIG 6-1).

Unplug the LCD connector from the terminal board (FIG 6-2) and set LCD display plate aside.

5.

6.

Remove the four (4) screws on the Terminal PCB with a Phillips screwdriver. FIG 6-2

Carefully pull the Terminal Board away from the Processor board by firmly holding it on the edges and pulling

7.

straight up. Pulling the unit sideways or at an angle may damage the 26-pin connection.

Check for any fuses or surge protection devices visibly damaged on the bottom side of the Terminal PCB.

8.

9.

If the board passes a visual check, reinstall the Terminal PCB on the LRW by carefully aligning the 26-pin
header with its corresponding mating connector on the Processor board. Push directly down and then install
four (4) screws.

Connect the POWER+ and POWER- pins to the field power supply between 12-30V DC (+24V DC power is

10.

preferred) if not already done

11.

Turn on power to LRW.

FIG 6-2 TERMINAL BOARDFIG 6-1 LCD DISPLAY PLATE

DENSITY IN4-20+

4-20- GND

GND

GND

232-TXD

232-RXD

GND

485+

485-

DOUT1

GND

GND

CHS

POWER-

POWER+

TP3
GND

LED1

KAM LRW

www.KAM.com

[e-mail]

LED2

Screws

Phone: [phone]

MADE IN USA

TP1

LRWMANUAL 0918

LCD Connector

28

KAM CONTROLS, INC.

TROUBLESHOOTING CONTINUED

POWER CONNECTIONS

If you have not already checked the Terminal board for physical defects, please do so according to the instructions on
page 28 of this manual.

The LRW TERMINAL PCB has LEDs to indicate the status of the input power and on board voltages of the LRW. The
sections below provide instructions to verify if the LRW is powered up with the right voltages.

Please note:

LED1 Indicates voltage presence at the input voltage terminals.
LED 2 Indicates voltage presence at the 5V supply.
Lit LEDs do not necessarily indicate proper voltage.

CHECKING THE INPUT POWER

Use a voltmeter to check the POWER + and POWER - terminals and ensure that the voltage across them is

1.

between 12-30 V DC (24 V DC is recommended).

If voltage is not within this range, check the field power supply and bring it within the limits above. Check again.

2.

If it is still not within limits, contact KAM Controls for further assistance.

If the voltage across the input power terminals is within the specified limits, connect the red wire of a voltmeter

3.

on the side of LED1 and the black to TP3/GND. FIG. 6-3. It should show the input voltage (12-30 V). This means
the LRW input power is working properly, proceed to next section ("Checking 5V DC supply").

If it does not show this voltage, either the fuse is blown or the lightning protection has been activated. The
instrument electronics need to be checked for additional damage. Please contact KAM Controls at

[phone] or email [e-mail] for further assistance.

FIG 6-3

DENSITY IN4-20+

4-20- GND

GND

GND

232-TXD

232-RXD

GND

485+

485-

DOUT1

GND

GND

CHS

POWER-

POWER+

LED1

TP3
GND

www.KAM.com

[e-mail]

Phone: [phone]

MADE IN USA

KAM LRW

TP1

LED2

LED1: Touch red wire to this side
of LED

TP1
LED2

TP3/GND (black wire)

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KAM CONTROLS, INC.

TROUBLESHOOTING CONTINUED

CHECKING 5V DC SUPPLY

Once the LRW input power has been verified as per instructions above, proceed to check the 5V DC supply:

Check LED2. If lit, power is flowing to the 5V circuit.

1.

2.

Proceed to verify the level of this 5V supply by connecting the red wire of the multimeter to TP1 and black wire
to TP3 (GND) Terminal. FIG. 6-3.

The DC voltage should read between 4.95V and 5.05V. This means the power supplies are operational, there

3.

could be a fault in the other systems of the instrument. Contact KAM Technical Support for further assistance.

4.

If the voltage is not within limits, the 5V power supply is nonfunctional. Return to the factory for repair.

5.

If LED2 does not light up, the 5V DC supply may be damaged. Please contact KAM Technical Support at +1 713
784 0000 or [e-mail] for further assistance.

LOOP TROUBLESHOOTING

If you have not already done so, follow the steps on page 28 of this manual to remove LCD cover and faceplate.

If the Loop water reading does not match the water % reading on the LRW local display, please follow
these instructions:

The LRW supplies power for the loop. Make sure the device that receives data from the LRW does not have a

1.

power source of its own switched on. Also, the LOOP+ and LOOP- are isolated inputs from the chassis/earth. Do
not connect either to a common ground. Use an isolator if necessary.

2.

Check the voltage across the LOOP+ and LOOP- terminals on the Terminal Board. It should read between 10V
and 12V. If not, contact KAM Controls for further assistance.

3.

If the voltage across the Loop terminals is within the specified limits, make sure the loop is working properly by
switching the multimeter to ammeter mode and checking the current running through it without a load. The
current must correspond with the readings on the LCD display:

If it does, the 4-20mA wire from the LRW to the PLC may be damaged.
If it doesn't, contact KAM Technical Support for further assistance.

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KAM CONTROLS, INC.

TROUBLESHOOTING CONTINUED

RS232 TROUBLESHOOTING

If experiencing either blank or a non-alphanumeric output on the LRW PC software or on the RS232 terminal (e.g.
RealTerm), please follow these instructions:

Make sure the communication settings are set as described on page 16 of this manual. Ensure the communica-

1.

tion port is opened in the terminal software.

Follow steps 1 through 4 on the previous section ("Loop Troubleshooting") to access the terminal board of the

2.

LRW.

Check the RS232 wires connected to the LRW terminals for damage and ensure they are installed as per the wir-

3.

ing diagram on page 9 of this manual. Replace wires if necessary.

Use a multimeter to measure voltage as described below. Please note the red wire on the multimeter should be

4.

connected to RS232 terminals and the black wire to GND.

RS232 RXD (LRW data input line) to GND terminal should be between -5V and -12V.
RS232 TXD (LRW output line) to GND terminal should be should be between -5V and -12V.

If the voltages are not within this range, the RS232 circuit may be damaged. Contact KAM Technical Support for fur­ther instructions.

If either the RS232 RXD or the RS232 TXD terminal voltages read 0V with respect to the GND terminal and the wire
connections are good, try reversing the RS232 RXD and RS232 TXD wires and check the output on the LRW PC soft­ware (If using RealTerm, follow configuration procedure on pages 15 to 18).

If the issue continues, please contact KAM Technical Support for further assistance.

RS485 TROUBLESHOOTING

If not able to read MODBUS registers, please follow the instructions below.

NOTE: The RS585+ and RS485- lines in two wire mode are differential, so their voltage needs to me measured with
respect to each other to conform to the RS485 standards. The bias is provided by the master device.

1.

RS485 is intended for MODBUS output. Check the activity LEDs on any RS485 converter connected to the RS485
terminals on the LRW.

If lit, verify the MODBUS registers and call KAM Technical Support for further assistance.

If not lit, follow steps 1 through 4 on the "Loop Troubleshooting" section on tthe previous page to access the
terminal board on the LRW. Proceed to use a voltmeter and connect the red wire on RS485+ and the black wire on
the RS485- terminal. Measure and take note of the voltages. Call KAM Technical Support for further assistance.

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KAM CONTROLS, INC.

APPENDIX A: MODBUS INTERFACE REGISTERS

LOW ALARM

BOOLEAN 1

HIGH ALARM

BOOLEAN 2

TEMPERATURE LOW ALARM

BOOLEAN 4

BOARD TEMPERATURE

32 BIT FLOAT 42002

API GRAVITY

32 BIT FLOAT 42003

MAXIMUM FREQUENCY

32 BIT FLOAT 42005

MINIMUM FREQUENCY

32 BIT FLOAT 42006

MAXIMUM VOLT

32 BIT FLOAT 42008

CURRENT OUTPUT

32 BIT FLOAT 42009

Register Data Type of Data Register number

TEMPERATURE HIGH ALARM BOOLEAN 3

WATER CONTENT IN % 32 BIT FLOAT 42000

RTD_TEMPERATURE 32 BIT FLOAT 42001

DENSITY 32 BIT FLOAT 42004

MINIMUM VOLT 32 BIT FLOAT 42007

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