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OPERATING MANUAL
CASTELLO & CASTELLO SETUP
Castello & Castello Setup Operating Manual 01-2015 Page 1/26
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Content
1 Castello Overview .....................................................................................................................................3
2 Castello Hardware .....................................................................................................................................4
2.1 "On" Button ..............................................................................................................................................4
2.2 Commands and Functions ("On" Button) ................................................................................................4
2.3 Display .....................................................................................................................................................5
2.4 Castello Housing Dimensions and Interface ...........................................................................................6
2.5 How to Open the Castello Housing .........................................................................................................7
2.6 How to Affix the Castello .........................................................................................................................7
2.7 Connect / Replace Battery.......................................................................................................................7
3 Connection Terminal for Transmitters ....................................................................................................8
3.1 Pin Table..................................................................................................................................................8
3.2 Transmitter Supply...................................................................................................................................9
3.3 Connecting Series 23Q and 26Q Transmitters .......................................................................................9
3.4 Connecting Series 3x Transmitters with the RS485 Interface...............................................................10
3.5 Connect Standard Transmitters with Voltage Output (0.5 ... 4.5 Volts) ................................................11
4 Step by Step Installation ........................................................................................................................12
5 Description of "Castello Setup" Software ............................................................................................15
5.1 Overview................................................................................................................................................15
5.2 Main Castello Settings ...........................................................................................................................17
5.3 Tank Property ........................................................................................................................................19
5.4 Tank Calculation ....................................................................................................................................21
5.5 Read Out Current Values (Online) ........................................................................................................22
6 Configuring the Switch Outputs ............................................................................................................24
6.1 Switch Outputs with Switch Time Delay ................................................................................................24
7 Castello Parts and Accessories.............................................................................................................25
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1 Castello Overview
Castello provides a user-friendly way of showing the pressure measurement at the bottom of a tank as the
remaining quantity of liquid. At the push of a button, the microcontroller performs calculations based on
information about the tank's shape and dimensions so that the remaining tank content (liters, gallons etc.) is
shown on the easy-to-read 5-digit LED display.
The unit is configured using a PC and user-friendly software, so the level (which determines the pressure)
can be converted into the relevant quantity in the tank (in liters, gallons etc.). The tank shape is selected first,
and then the tank dimensions and the liquid's specific density are entered. The program contains the most
common tank shapes, but also allows users to generate any tank shape by entering its parameters in a
specification table.
The Castello system makes exclusive use of absolute pressure transmitters, so capillary vented cables are
eliminated, thus making the Castello very rugged and suitable for reliable applications in humid and wet
environments.
An air pressure sensor (range: 0.8 bar to 1.2 bar absolute [abs]) is integrated in the Castello housing. The
transmitters to measure hydrostatic pressure at the bottom of the tank are calibrated from 0.8 to 1.8 bar abs
for tanks up to 5 m in height, and from 0.8 to 2.3 bar abs for tanks up to 10 m in height. The pressure difference, calculated by the microcontroller, is the relative hydrostatic pressure.
The content of a pressurized tank is determined from the difference between the measurements taken by
two absolute pressure transmitters located at the top and bottom of the tank.
The system achieves overall accuracy of 2 mbar thanks to a computerized calibration and compensation
procedure for the pressure transmitters Series 23Q and 26Q. The coefficients for this calculation are stored
in EEPROMs in the transmitters. These are retrieved by the microprocessor when each measurement is
taken, and are used in the equations to calculate the pressure values. Because these coefficients are stored
in the transmitter, the Castello housing and the hydrostatic transmitter can be exchanged at will with no need
for additional configuration or data entry.
It is also possible to connect a standard 3-wire transmitter with voltage output (0…5V), or a high-precision
digital transmitter (series 3X) that can be configured to an accuracy of 0.02% FS over a range of 0 to 50°C;
this transmitter is read by Castello via the RS485 interface.
The power supply to the system (8 to 28 VDC) can be provided externally, or internally with a 9 V battery.
Castello’s display is powered for a configurable duration by pressing the button on the front of the Castello.
The Castello has two switch outputs with configurable functionality and threshold values. An external power
supply must be provided if the switch outputs are to be used.
Installation
The housing has two holes to mount the unit. The transmitters are easily installed by removing Castello’s
cover plate, leading the cable through the PG screw connections, and then connecting the transmitter wires
to the appropriate screw terminals. The Castello is programmed via the connector on the side, which equally
serves as external power supply and switch output connections. Once the cover plate is installed and the
cable lead through connections are properly tightened, the extremely robust housing is watertight to IP65.
PC Configuration Software
The software to configure Castello can be downloaded from our website or ordered on CD (handling charge
payable). Castello can be connected to the PC via KELLER converter cables K-107 (RS232) or K-104B
(USB) with adapter. The software contains the calculations (pressure/content curves) for several tank
shapes. The dimensions of the tank, the density of the liquid and the measuring unit of the display are set in
the software for the selected tank shape.
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conds
2 Castello Hardware
2.1 "On" Button
Press and release the button to switch the display on for a few seconds.
Press and hold the button down while the display is on to show a
command or function on Castello’s display.
If Castello is configured to use switch outputs, the display will be
continuous and will not turn off.
2.2 Commands and Functions ("On" Button)
The "Standard Version"
Standard Version
Press and hold the button down for ~5 seconds; the Castello display shows
"Id 00".
Increase the counter up to 22 (Password = 22) by clicking on the button.
When the display shows 22, press and hold the button down for ~5 se
until the display shows the first command, "Z Set".
"Z Set" - If you want to set the tank content display to zero, press and hold
the button down for ~5 seconds until the display shows "donE."
*Note: A "Z rES" command should be performed before executing the "Z
SEt" command.
To go to the next command, click on the button.
"Z rES" - If you want to reset the tank content display to the factory setting,
press and hold the button down for ~5 seconds until the display shows
"donE."
To go to the next command, click on the button.
"End" – press the button for ~5 seconds to exit command mode and return
Castello to tank content display mode.
To go back to the first command, click on the button.
The "Ullage version"
Ullage version
In this sample, the tank size is 10,000 liters.
If the button is not pressed, the display shows the tank content.
With the button pressed, the display shows the "Ullage" (used tank content).
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2.3 Display
Software Version
On startup (when power is applied / when the battery is connected), the Castello displays its software version for 2 seconds.
Content
"18435" The digits show the content of the tank.
Void
"Void" Means the lowest level has been reached (no liquid over the transmitter); the tank is empty.
Full
"FULL" The tank is totally full.
E-Tr1
"Error Transmitter 1" Transmitter 1 has returned an incorrect value; check the connection.
E-Tr2
"Error Transmitter 2" Transmitter 2 has returned an incorrect value; check the connection.
OFL
"Display Overflow" The value is larger than 99,999 and exceeds the display capability.
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2.4 Castello Housing Dimensions and Interface
Transmitter Connection
A maximum of two transmitters can be connected to Castello via a cable gland (PG connector).
Air Pressure Sensor
The built-in air pressure sensor can be used to compensate air pressure changes when an absolute pressure sensor is used to measure the content of a vented tank.
Display of Switch Outputs (LED)
The LEDs show the current state of the switch outputs (if they are activated).
External Supply
The device can be supplied from an external power source. If the switch outputs are used (activated), the
instrument must be supplied with an external DC voltage of 8 … 28 volts.
Switch (Relay) Outputs
The relay outputs can handle up to 28VDC / 0.4A. The built-in relays have insulated inputs and outputs.
RS485 Interface
The RS485 interface allows the user to configure and communicate with the Castello (i.e. read current values).
Up to 128 instruments can be addressed via the KELLER BUS protocol.
Please consult our website for a description of the BUS protocol to create custom software, as well as the
PC software for graphic display of the current measurement values.
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2.5 How to Open the Castello Housing
To open the housing, remove the four screws.
2.6 How to Affix the Castello
The two holes indicated by the red arrows below can be used to affix the Castello to the desired area.
2.7 Connect / Replace Battery
Open the Castello housing and connect the 9V battery (type: 6LR61 / 604LC) to the corresponding battery
contact. Then push battery into the battery holder.
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7 8 9 10 11 12
1 2 3 4 5 6
18 19 20 21 22
3 Connection Terminal for Transmitters
3.1 Pin Table
1. GND
2. Transmitter supply, 5 volts
3. I2C DATA
4. I2C CLK
5. Temperature voltage input (TOB2) (Input 0…5V)
6. Pressure voltage input (P2) (Input 0…5V)
7. GND
8. Transmitter supply, 5 volts
9. I2C DATA
10. I2C CLK
11. Temperature voltage input (TOB1) (Input 0…5V)
12. Pressure voltage input (P1) (Input 0…5V)
13. RS485-A
14. RS485-B
15. Transmitter supply 18 volts
16. GND
17. CASE
18. Relay 1 +
19. Relay 1 -
20. Relay 2 +
21. Relay 2 -
22. n.c. (not connected)
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3.2 Transmitter Supply
The Castello contains two different internal voltage supplies for transmitter supply. The voltage sources are 5
volts and 15…20 volts (use the corresponding clamp). The supply is turned on while the Castello reads the
signal from the connected transmitters.
3.3 Connecting Series 23Q and 26Q Transmitters
Transmitter 2
Connect the transmitter to clamps 1..6
1 green (GND)
2 brown (Transmitter supply, 5 volts)
3 yellow (I2C DATA)
4 white (I2C CLK)
5 gray (TOB2 voltage)
6 pink (Pressure voltage)
Transmitter 1
To connect a second transmitter, use clamps 7..12
7 green (GND)
8 brown (Transmitter supply, 5 volts)
9 yellow (I2C DATA)
10 white (I2C CLK)
11 gray (TOB1 voltage)
12 pink (Pressure voltage)
1 2 3 4 5 6
7 8 9 10 11 12
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3.4 Connecting Series 3x Transmitters with the RS485 Interface
The RS485 interface enables communication with Keller digital instruments (transmitters, data loggers etc.).
Connect RS485 A (Pin 1) and RS485 B (Pin 2) to the Castello.
A maximum of two Series 3x transmitters can be connected to the Castello by selecting "Series 30" in
"Types of transmitter settings" (Castello Setup). If two S30 transmitters are to be used, each transmitter's
address must be configured with a unique address (use Prog30 Software to configure the bus address): Set
transmitter 1 to bus address 1, and set transmitter 2 to bus address 2.
If only one S30 transmitter is connected, it is not necessary to set the bus address.
We recommend using Series 30 transmitters from Keller with the low power and low voltage option to reduce
battery consumption (in this case, connect the transmitters to the 5 V power supply).
Connect Series 3x Low Power / Low Voltage transmitters
The picture below shows the connection for a Series 3X transmitter with the low power / low voltage option.
These transmitters can be supplied with a voltage range of 4V … 12V. The transmitter supply should be
connected to the 5V clamp.
Transmitter 1
13 blue (RS485-A)
14 yellow (RS485-B)
13 14 15 16 17
7 8 9 10 11 12
7 white (GND)
8 black (Transmitter supply, 5 volts)
Transmitter 2
13 blue (RS485-A)
14 yellow (RS485-B)
7 white (GND)
8 black (Transmitter supply, 5 volts)
Connect Standard Series 3x Transmitter
The standard Series 3X transmitters have a supply in the range from 8V to 28 V. In this case, you should
connect the transmitter supply to clamp 15 (transmitter supply: 18 volts).
Connect the transmitter to clamps 7 & 8 & 13 & 14.
If only one transmitter is connected to the relevant clamps, the
BUS address does not have to be set.
The second transmitter is connected using the same clamps as
transmitter 1 (connect them in parallel).
Both transmitters must have been configured with BUS addresses 1 and 2.
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3.5 Connect Standard Transmitters with Voltage Output (0.5 ... 4.5 Volts)
Transmitter 1
Connect the transmitter to clamps 12 & 15 & 16.
16 (white) GND
15 (black) Transmitter supply 18 volts
13 14 15 16 17
12 (red) Pressure voltage input (P1)
Transmitter 2
16 (white) GND
15 (black) Transmitter supply 18 volts
6 (red) Pressure voltage input (P2)
1 2 3 4 5 6
7 8 9 10 11 12
Connect a second transmitter to the same clamps as transmitter 1 for supply and ground (connect them in parallel). The
voltage output of the transmitter is connected to P2, clamp 6.
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4 Step by Step Installation
This section shows how to install and configure the Castello. This is a standard configuration which is suitable for most applications:
Castello with one level sensor (Series 26Q) connected @ 5 volts supply.
Absolute – absolute measurement (tank height = Series 26Q – air pressure sensor).
Cubic tank, dimensions 1m x 1m x 10m, tank content = 10,000 liters
1
Open the Castello housing
.
Remove the four screws on the front panel.
2
Connect the battery
.
Connect the battery and push it into the battery holder.
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7 8 9 10 11 12
3
Feed in the level transmitter cable
Feed the transmitter cable through the sleeve and tighten the cable
gland.
4
Connect the level transmitter
5
Close the Castello housing
.
Connect the cable ends to the terminal strip (transmitter 1).
Example with PA-23Q level transmitter :
Connect the level transmitter as follows:
7 green: GND
8 brown: Transmitter supply, 5 volts
9 yellow: I2C DATA
10 white: I2C CLK
11 gray: Temperature voltage input (TOB1) (Input 0…5V)
12 pink: GND
.
Close the housing and install the four screws.
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6
Connect the Castello to the PC
.
Connect the Castello to the PC using converter cable
K104-B (USB) or K107 (RS232). Cable option 5 must be used
between the Castello and the converter cable.
7
.
Start the Castello Setup Software
Start the Castello Setup Software and configure the Castello. The
settings for a tank containing 10,000 liters are listed below.
1. Select Comport
2. Press "Read Configuration"
3. Enter settings as in the example screenshot below
4. Press "Write Configuration"
5. Castello is now configured, and will display the tank content
for 10 seconds when the button is pressed.
Configuration for 10,000 Liter Tank and Castello Configuration with Level Transmitter 26Q
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5 Description of "Castello Setup" Software
5.1 Overview
3
2
6
4
7
5
10
9
8
7
11
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Number Description Explanation / Function
1 Language Selector Select the preferred language
2 Unit Selector Select the length unit (meters or feet) for the Setup
3 Serial Communication Port Select the appropriate COM port number
4 Read Configuration Button Read the current configuration from the connected device
5 Write Configuration Button Write the current configuration to the connected device
6 Device Information Display the device information for the connected device
7 Exit Program Exit the application
8 Open Basic configuration Open a Basic Configuration for the Castello (Sample)
9 File Open an existing (previously saved) configuration file
10 Save Configuration Save all settings to a configuration file to be named
11 Info Retrieve the software version of the Castello Setup
program
Program
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15
5.2 Main Castello Settings
13
1
12
14
17
18
2
3
15
4
5
6
16
7
8
9
10
11
9
1
9
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Number Description Explanation / Function
1
2
3
4
5
6
7
8
9
Unit Selector Unit in which the tank content is displayed (software and Castello
display)
Decimal Point Selector Number of decimal places (0-4) to be displayed
Display Time Tank content display time (how long the Castello display shows the tank
content when the button is pushed). Range is 1 to 254 seconds. For
continuous display, set the value to 255.
Rounding Set the rounding for the display. The display will increment the value by
the steps that you configure.
Full The Castello display will show "FULL" if value "Pmax-x,xxx" bar is
reached, to inform you that the tank is totally full.
Void The Castello display will show "VOID" if value "Pmin+x,xxx" bar is
reached, to inform you that the tank is empty.
Density of Tank Content Density of the liquid in the tank to be measured. The tank content will be
calculated using this density.
Gravity The tank content will be calculated using this gravity.
Standard gravity is 9.81.
Types of Transmitter Transmitter(s) connected to the Castello.
Transmitter 1 (P1) is the level transmitter in the tank, Transmitter 2 (P2)
is the transmitter to measure the air pressure in the tank.
The level is calculated by P1-P2.
10
11
12
13
14
15
16
17
18
Measured Values A display of all measured values, when the "Read out measured values"
button is selected. All current values are listed.
Read Out Current Values (Online) Go to the "Read out current values (Online)" window for a graphic
display of all values.
Device Information Display the device information for the connected device after a Read
Configuration is selected
Read Configuration Read the current configuration from the connected device
Write Configuration Write the current configuration to the connected device
Tank Type Choose the tank type. When a tank type is selected, its properties will
be displayed.
Tank Table / Tank Property This window displays the tank type with its properties, or the tank table
with its values, which are written to Castello’s memory to calculate the
tank content.
Zero Volume Set current display to zero.
Reset Zero Set the zero to its factory setting.
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5.3 Tank Property
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Supported tank types / properties
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5.4 Tank Calculation
For all the different tank types, properties, and settings, "Castello Setup" calculates a table and writes it to
Castello's EEPROM.
The microcontroller then measures the current pressure (level) and searches the table for this value.
The microcontroller interpolates a polynomial over 3 measuring points, calculates the tank content and
shows it on the display.
Tank settings are also stored in the Castello.
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7
2
3
4
5
6
1
5.5 Read Out Current Values (Online)
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Number Description Explanation / Function
1
2
3
Enabled Measuring Channels Activates the desired channels to be measured and
displayed.
P1 → Level transmitter [pressure / bar]
(P2) Second pressure transmitter (air
pressure) [pressure / bar] (e.g. for AA
measurement as barometric sensor)
TOB1 → Temp. sensor of level transmitter P1
[temperature /°C]
(temperature over bridge pressure
transmitter 1)
TOB2 → Temp. transmitter of pressure
transmitter P2 [temperature /°C]
P1-P2 → Pressure difference between
pressure P1 and pressure P2 --> Level
Actual Volume
→ Tank content calculated with current
tank property settings. This is the value
displayed by Castello.
Start and Stop "Online Mode" To start or stop Online Mode. The green (ok) or red
(error) indicator shows the communication status
Clear Clear all charts and the table showing the values
4
5
6
7
Table Table containing time and values
Channel selector for chart Enables or disables the channels that are displayed
in the chart
Chart Chart displays values as function of time
Chart (current tank content) Chart contains values for current tank content
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6 Configuring the Switch Outputs
To configure the switch outputs, the separate "Pressure Switch Console" software must be used.
If switch outputs are enabled, an external supply should be used to power the Castello, since the display is
then in continuous mode and the battery will consequently discharge rapidly.
Disabling the switches (setting them to Off) will return Castello to standard mode (i.e. power down the display after the configured delay).
6.1 Switch Outputs with Switch Time Delay
If a switch delay is set, the corresponding Castello LED switch indicator starts flashing when the switch
setpoint is reached and the time delay countdown starts. When the switch time delay is reached, the LED
stops flashing and shows the corresponding switch state.
LED on = switch closed
LED off = switch open
LED flashing = switch delay is counting, and switch state is set after the delay
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7 Castello Parts and Accessories
DESCRIPTION
Castello
Counter Plug to Binder 723 8 Pole
Level Transmitter Series 23Q
(0.8 … 1.8 bar abs) 5 mWC / 10 m cable
(0.8 … 2.3 bar abs) 10 mWC / 15 m cable
Other ranges and cable lengths are also available
Level Transmitter Series 26Q
(0.8 … 1.8 bar abs) 5 mWC / 10 m cable
(0.8 … 2.3 bar abs) 10 mWC / 15 m cable
Other ranges and cable lengths are also available
PRODUCT NO.
310065.0002
508405.0006
222399.0015
222399.0028
222605.0038
222605.0046
Picture
Level Transmitter Series 36XW
Only: digital output (RS485) / low power
PAA-36XW
(0.8 bar … 1.8 bar) 5 mWC / 5 m cable
(0.8 bar … 1.8 bar) 10 mWC / 10 m cable
Battery, 9 V
Type: 6LR61 / 604LC
233610.0761
233610.0762
557005.0019
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DESCRIPTION
PRODUCT NO.
Picture
K-114B Interface Converter
For communication between the PC and
Castello.
Connection to USB port
(USB – RS 485 converter)
Cable Option 5
Cable adapter 5-pin binder plug Series 723
(m) to 8-pin binder cable socket Series 423 (f)
Used for K-114B
KELLER Software CD
CD includes:
Configuration software: Castello Setup with
operating manual.
Free download at:
www.keller-druck.com
(see "Products"–>"Miscellaneous/Software")
309010.0075
309010.0041
750505.0001
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