KEP LEVELtrol II Operating Manual
LEVELtrol-II Installation & Operating Instructions
LEVELtrol-II
Flow Computer
Version 01.xx
99594 03/14/11
KESSLER-ELLIS PRODUCTS
10 Industrial Way East
Eatontown, NJ 07724
800-631-2165 732-935-1320
Fax 732-935-9344
74
Proprietary Notice
The information contained in this publication is derived in part from proprietary and patent data. This information has been
prepared for the expressed purpose of assisting operating and maintenance personnel in the efficient use of the instrument
described herein. Publication of this information does not convey any rights to use or reproduce it or to use for any purpose
other than in connection with the installation, operation and maintenance of the equipment described herein.
Copyright 1995
Printed in USA. All Rights Reserved.
!
WARNING!
This instrument contains electronic components that are susceptible to damage by static electricity. Proper handling*
procedures must be observed during the removal, installation, or handling of internal circuit boards or devices.
*Handling Procedure
1. Power to unit must be removed.
2. Personnel must be grounded, via wrist strap or other safe, suitable means, before any printed circuit board or other
internal device is installed, removed or adjusted.
3. Printed circuit boards must be transported in a conductive bag or other conductive container. Boards must not be
removed from protective enclosure until the immediate time of installation. Removed boards must be placed immediately
in protective container for transport, storage, or return to factory.
Comments
This instrument is not unique in its content of ESD (electrostatic discharge) sensitive components. Most modern electronic
designs contain components that utilize metal oxide technology (NMOS, CMOS, etc.). Experience has proven that even
small amounts of static electricity can damage or destroy these devices. Damaged components, even though they appear
to function properly, may exhibit early failure.
SAFETY INSTRUCTIONS
!
The following instructions must be observed.
• This instrument was designed and is checked in accordance with regulations in force EN 60950 (“Safety of
information technology equipment, including electrical business equipment”).
A hazardous situation may occur if this instrument is not used for its intended purpose or is used incorrectly.
Please note operating instructions provided in this manual.
• The instrument must be installed, operated and maintained by personnel who have been properly trained.
Personnel must read and understand this manual prior to installation and operation of the instrument.
• This instrument is internally fused. Replace the internal fuse with the following specified type and rating only:
Input Power Recommended Fuse
1 15 VAC 160 mA slow blow fuse
230 VAC 80 mA slow blow fuse
12-24 VDC 800 mA slow blow fuse
Disconnect power supply before replacing fuse!
• The manufacturer assumes no liability for damage caused by incorrect use of the instrument or for modifications
or changes made to the instrument.
Symbols Used On Unit
Number Symbol Publication Description
1 IEC 417, No. 5031 Direct current
2 IEC 417, No. 5172 Equipment protected throughout by DOUBLE
INSULATION or REINFORCED INSULATION
(equivalent to Class II of IEC 536–see annex H)
3
!
ISO 3864, No. B.3.1 Caution (refer to accompanying documents)
Technical Improvements
• The manufacturer reserves the right to modify technical data without prior notice.
CONTENTS
1. Description...................................................................................................................1
1.1 Unit Description:..............................................................................................1
1.2 Unit Features: ................................................................................................. 1
1.3 Specifications:.................................................................................................2
2. Installation....................................................................................................................6
2.1 General Mounting Hints: .................................................................................6
2.2 Mounting Diagrams:........................................................................................6
3. Applications .................................................................................................................7
3.1 Tank Level/Volume ......................................................................................... 7
3.2 Corrected Tank Volume .................................................................................. 8
3.3 Total Mass in Tank..........................................................................................9
3.4 Batching Volume, Corrected Volume or Mass from Tank Level ................... 10
4 WIRING ...................................................................................................................... 11
4.1 Typical Batcher Wiring: ................................................................................. 11
4.2 Typical Level/Total Wiring:............................................................................11
4.3 Wiring In Hazardous Areas: ..........................................................................12
5. UNIT OPERATION .................................................................................................... 13
5.1 Front Panel Operation Concept for Run Mode ............................................. 13
5.2 General Operation ........................................................................................ 14
5.3 Level/Total Operation....................................................................................14
5.3.1 Password Protection for Level/Total mode ................................................ 14
5.3.2 Relay Operation in Level/Total mode.........................................................14
5.3.3 Pulse Output in Level/Total mode..............................................................14
5.3.4 Analog Output in Level/Total mode............................................................15
5.3.5 RS-232 Serial Port Operation in Level/Total mode.................................... 15
5.3.6 RS-485 Serial Port Operation in Level/Total mode.................................... 15
5.4 Batcher Operation.........................................................................................16
5.4.1 Batcher Configuration. ............................................................................... 16
5.4.2 Password Protection for Batcher Mode ..................................................... 17
5.4.3 Relay Operation in Batcher mode..............................................................17
5.4.4 Pulse Output in Batcher mode ................................................................... 17
5.4.5 Analog Output in Batcher mode.................................................................18
5.4.6 RS-232 Serial Port Operation in Batcher mode ........................................ 18
5.4.7 RS-485 Serial Port Operation in Batcher mode ......................................... 18
i
CONTENTS
6. PROGRAMMING.......................................................................................................19
6.1 Front Panel Operation Concept for Program Mode ...................................... 19
6.2 EZ Setup ....................................................................................................... 20
6.2.1 TOP LEVEL SETUP MENU...................................................................... 20
6.2.2 EZ Setup Submenu Groups.......................................................................20
6.3 Setup Menus................................................................................................. 22
6.3.1 Top Level Setup Menu............................................................................... 22
6.3.2 Submenu Groups......................................................................................22
6.4 Setup Sub-Menus ......................................................................................... 23
6.4.1 DO EZ SETUP? .........................................................................................23
6.4.2 SET INSTRUMENT TYPE ......................................................................... 23
6.4.3 SETUP INDICATORS (Vol) ...................................................................... 24
6.4.4 SETUP INDICATORS (Mass)....................................................................24
6.4.5 SETUP INDICATORS (Level)....................................................................25
6.4.6 SETUP INDICATORS (Temperature)........................................................25
6.4.7 SETUP TANK STYLE (Strapping Table) ................................................... 26
6.4.8 SETUP TANK STYLE (Vertical Cylindrical or Horizontal Cylindrical) ........ 27
6.4.9 SETUP TANK STYLE (Sphere) ................................................................. 27
6.4.10 SETUP PROCESS INPUTS (Level) ........................................................ 28
6.4.11 SETUP PROCESS INPUTS (Compensation Input).................................29
6.4.12 SET FLUID PROPERTIES ...................................................................... 30
6.4.13 SETUP OUTPUTS (Analog Output) ........................................................ 30
6.4.14 SETUP OUTPUTS (Pulse Output)...........................................................31
6.4.15 SETUP RELAYS (Relay 1) ...................................................................... 31
6.4.16 SETUP RELAYS (Relay 2) ...................................................................... 32
6.4.17 SETUP RELAYS (Relay 3 & 4)................................................................ 33
6.4.18 SETUP CONTROL INPUTS (LEVEL/TOTAL) ......................................... 34
6.4.19 SETUP CONTROL INPUTS (BATCH)..................................................... 34
6.4.20 SETUP REALTIME CLOCK (Time) .........................................................34
6.4.21 SETUP REALTIME CLOCK (Date)..........................................................35
6.4.22 SETUP SERIAL OUTPUT ....................................................................... 35
6.4.23 SET PRINT OUTPUT (Configure) ........................................................... 36
6.4.24 SET PRINT OUTPUT (Select_list)...........................................................36
6.4.25 SETUP PASSWORDS (Operator) ........................................................... 37
6.4.26 SETUP PASSWORDS (Supervisor) ........................................................37
6.4.27 SETUP NETWORK CARD ...................................................................... 37
ii
CONTENTS
7. Principle Of Operation ............................................................................................... 38
7.1 General Operation ........................................................................................ 38
7.2 Determining the liquid quantity for various Tank Geometries ...................... 38
7.3 Determining Liquid Level .............................................................................. 38
7.4Corrections for density in hydrostatic pressure
based level measurements............................................................................38
7.5 Computation of Corrected Volume in Tank and Mass in Tank ..................... 39
7.6 Calculating the Expansion Factor For a Fluid ............................................... 41
8. Test, Service and Maintenance ................................................................................. 42
8.1 Test Menus ................................................................................................... 42
8.1.1 TOP LEVEL TEST MENUS ...................................................................... 42
8.2 Test Sub-Menus............................................................................................43
8.2.1 Audit Trail Submenu Group ....................................................................... 43
8.2.2 Error History Submenu Group ................................................................... 43
8.2.3 Print System Setup Submenu Group.........................................................43
8.2.4 Keypad test Submenu Group.....................................................................44
8.2.5 Display test Submenu Group ..................................................................... 44
8.2.6 - 8.2.16 Calibration Submenu Group ......................................................... 45
8.2.17 Analog In Test Submenu Group .............................................................. 49
8.2.18 Analog out test Submenu Group..............................................................50
8.2.19 Pulse out test Submenu Group................................................................ 50
8.2.20 Relay test Submenu Group.....................................................................50
8.2.21 Control input test Submenu Group .......................................................... 50
8.2.22 Battery Voltage test Submenu Group ...................................................... 51
8.2.23 Data logger utility Submenu Group.......................................................... 51
8.3 Internal Fuse Replacement...........................................................................52
8.4 Installing New Software ................................................................................ 52
9. RS-232 Serial Port..................................................................................................... 53
9.1 RS-232 Port Description: .............................................................................. 53
9.2 Instrument Setup by PC’s over Serial Port ................................................... 53
9.3 Operation of Serial Communication Port with Printers..................................53
9.4 LEVELtrol-II RS-232 Port Pinout...................................................................53
iii
CONTENTS
10. RS-485 Serial Port (optional) ................................................................................... 54
10.1 RS-485 Port Description:............................................................................. 54
10.2 General........................................................................................................ 54
10.3 Operation of Serial Communication Port with PC ....................................... 54
10.4 LEVELtrol-II RS-485 Port Pinout ................................................................. 54
11. Instrument Setup Software (optional) ....................................................................... 55
11.1 System Requirements: ................................................................................ 55
11.2 Cable and Wiring Requirements: ................................................................. 55
11.3 Installation for Windows™ 3.1 or 3.11 ......................................................... 55
11.4 Using the Setup Software ............................................................................ 56
11.5 File Tab ........................................................................................................ 56
11.6 Setup Tab .................................................................................................... 56
11.7 View Tab ...................................................................................................... 57
11.8 Misc. Tab ..................................................................................................... 57
12. Glossary Of Terms ................................................................................................... 58
13. Diagnosis and Troubleshooting ................................................................................ 62
13.1 Response of LEVELtrol-II on Error or Alarm: .............................................. 62
13.2 Diagnosis Flow Chart and Troubleshooting................................................. 63
13.3 Error & Warning Messages: ........................................................................ 64
13.3.1 Sensor/Process Alarms ............................................................................ 64
13.3 Error & Warning Messages: (Continued) .................................................... 65
13.3.2 Self Test Alarms ........................................................................................ 65
Appendix A ..................................................................................................................... 66
Common Fluid Properties Table .......................................................................... 66
Appendix B
Setup Menus ....................................................................................................... 67
..................................................................................................................... 67
iv
LEVELtrol-II Installation & Operating Instructions
Unit Description
1. Description
1.1 Unit Description:
The LEVELtrol-II satisfies the requirements for a variety of level instrument
needs. Multiple equations and instrument functions for a variety of tank
shapes are available in a single unit with many advanced features.
The alphanumeric display shows measured and calculated parameters
in easy to understand format. Single key direct access to measurements
and display scrolling is supported.
The versatility of the LEVELtrol-II permits a wide measure of versatility
within the instrument package. The various hardware inputs and outputs
can be “soft” assigned to meet a variety of common application needs.
The user “soft selects” the usage of each input/output while configuring
the instrument. Consider the following illustrative examples.
The isolated analog output can be chosen to follow tank levels, volume ,
corrected volume, mass, temperature, or density by means of a menu
selection. Most hardware features are assignable by this method.
Unit Features
The user can assign the standard RS-232 Serial Port for data logging,
transaction printing, or for connection to a modem for remote reading.
An RS-485 Modbus RTU communication card provides multidrop
capabilities.
1.2 Unit Features:
The LEVELtrol-II offers the following features:
• Multiple Tank Shapes
• Level and Tank Volume Indicator
• Batching by Level
• Level Control, Tank Volume, Corrected Volume and
Mass Calculations
• Multiple Instrument Functions
• Menu Selectable Hardware & Software Features
• Two Line LCD or VFD Display
• Isolated Outputs Standard
• RS-232 Port Standard
• DIN Enclosure with Two Piece Connectors
• Windows™ Setup Software (Future)
• Foreign Language Options (Future)
• RS-485 Modbus RTU Option (Future)
1
LEVELtrol-II Installation & Operating Instructions
1.3 Specifications:
Specifications:
Environmental
Indoor Use
Altitude up to 2000m
Operating Temperature: 0°C to +50°C
(-20°C to 55°C optional)
Storage Temperature: -40°C to +85 C
Maximum Relative Humidity : 80% for temperatures
up to 31°C decreasing linearly to 50% RH at
40°C
Mains supply voltage fluctuations not to exceed ±10%
of the nominal voltage
Transient overvoltage according to INSTALLATION
CATEGORY II (see UL 3101-1 Annex J)
POLLUTION DEGREE 2 in accordance with
IEC 664 (see 3.7.3)
Materials: UL, CSA, VDE approved
Approvals: CE Approved Light Industrial,
UL File #: E192404
CSA Pending
Display
Type: 2 lines of 20 characters
Types: Backlit LCD or VFD ordering options
Character Size: 0.3" nominal
User selectable label descriptors and units of
measure
Keypad
Keypad Type: Membrane Keypad
Keypad Rating: Sealed to Nema 4
Number of keys: 16
Enclosure
Size: See Dimensions
Depth behind panel: 6.5" including mating connector
Type: DIN
Materials: Plastic, UL94V-0, Flame retardant
Bezel: Textured per matt finish
Equipment Labels: Model, safety, and user wiring
Power Input
The factory equipped power option is internally fused.
An internal line to line filter capacitor and MOV's are
provided for added transient suppression.
Order Option 1: 110VAC: 85 to 127 Vrms, 50/60 Hz
Order Option 2: 220VAC: 170 to 276 Vrms, 50/60 Hz
Order Option 3: 12VDC: 10.5 to 16 VDC
Order Option 4: 24VDC: 16 to 24 VDC
Level Input:
Analog Input:
Ranges
Voltage: 0-10 VDC, 0-5 VDC, 1-5 VDC
Current: 4-20 mA, 0-20 mA
Basic Measurement Resolution: 16 bit
Update Level: 5 updates/sec minimum
Automatic Fault detection: Signal over/under-range,
Current Loop Broken
Calibration: Self Calibration and Auto-zero
Continuously
Extended calibration: Learns Zero and Full Scale
of each range using special test mode.
Fault Protection:
Fast Transient: 500 V Protection
(Capacitive Clamp)
Reverse Polarity: No ill effects
Over-Voltage Limit: 50 VDC Over voltage
protection
Over-Current Protection: Internally current
limited Protected to 24 VDC.
Compensation Input
The compensation input is menu selectable for
temperature, density or not used.
Operation: Ratiometric
Accuracy: 0.01% FS
Thermal Drift: Less than 100 ppm/C
Basic Measurement Resolution: 16 bit
Update Level: 1 update/sec minimum
Automatic Fault detection:
Signal Over-range/under-range
Current Loop Broken
RTD short
RTD open
Fault mode to user defined default settings
Transient Protection: 500 V (Capacitive Clamp)
Reverse Polarity: No ill effects
Over-Voltage Limit (Voltage Input): 50 VDC
Available Input Ranges
Voltage: 0-10 VDC, 0-5 VDC, 1-5 VDC
Current: 4-20 mA, 0-20 mA
Resistance: 100 Ohms DIN RTD
100 Ohm DIN RTD (DIN 42-760, BS 1904):
Three Wire Lead Compensation
Internal RTD linearization learns ice point
resistance
1 mA Excitation current with reverse polarity
protection
Temperature Resolution: 0.01 C
Control Inputs
Switch Inputs are menu selectable for Start, Stop,
Reset, Lock, Alarm Acknowledge, Print or Not
Used.
Control Input Specifications
Input Scan Rate: 10 scans per second
Logic 1: 4 - 30 VDC
Logic 0: 0 - 0.8 VDC
Transient Suppression: 500 V fast transient
(Capacitive Clamp)
Input Impedance: 100 KΩ
Control Activation: Positive Edge or Pos. Level
based on product definition
Excitation Voltage
24 VDC @ 100 mA (current limited)
Note: Not available on DC powered units
Relay Outputs
The relay outputs are menu assignable to
(Individually for each relay) Level, Total,
Temperature, Density, Low Alarm, Hi Alarm,
Prewarn Alarm, Preset Alarm or General purpose
warning (security).
Number of relays: 4
Note: RS-232 Multidrop not available with
4 relay version.
Contact Style: Form C contacts
Contact Ratings: 250 VAC @ 5 amps
30 VDC @ 5 amps
Fast Transient Threshold: 1000 V
2
LEVELtrol-II Installation & Operating Instructions
Analog Output
The analog output is menu assignable to
correspond to the Uncompensated Volume Level,
Corrected Volume Level, Mass, Temperature,
Density.
Type: Isolated Current Sourcing
Isolated I/P/C: 500 V
Available Ranges: 4-20 mA
Resolution: 12 bit
Accuracy: 0.05% FS at 20 Degrees C
Update Level: 1 update/sec minimum
Temperature Drift: Less than 200 ppm/C
Maximum Load: 1000 ohms (at nominal line
voltage)
Compliance Effect: Less than .05% Span
60 Hz rejection: 40 dB minimum
EMI: No effect at 3 V/M
Calibration: Operator assisted Learn Mode
Averaging:User entry of DSP Averaging constant
to cause an smooth control action.
Isolated Pulse output
The isolated pulse output produces pulses based
on the changing Uncompensated Volume Total,
Compensated Volume Total or Mass Total.
Usage: Quantity entering or leaving tank
Isolation I/O/P: 500 V
Pulse Output Form: Open Collector
Maximum On Current: 25 mA
Maximum Off Voltage: 30 VDC
Saturation Voltage: 1.0 VDC
Maximum Off Current: 0.1 mA
Pulse Duration: 18 msec or 100 msec
Pulse output buffer: 8 bit
Fault Protection
Reverse polarity: Shunt Diode
Transient Protection: 500 VDC
(Capacitive Clamp)
RS-232 Communication
Uses: Printing, Setup, Modem, Datalogging
Baud Rates: 300, 600, 1200, 2400, 4800, 9600,
19200
Parity: None, Odd, Even
Device ID: 0 to 99
Protocol: Proprietary, Contact factory for more
information
Chassis Connector Style: DB 9 Female connector
RS-485 Communication (optional)
Uses: Network Communications
Baud Rates: 300, 600, 1200, 2400, 4800, 9600,
19200
Parity: None, Odd, Even
Device ID: 0 to 255
Protocol: ModBus RTU
Chassis Connector Style: DB 9 Female connector
Operating Mode
The LEVELtrol-II can be thought of as making a
series of measurements of level, temperature/density
sensors and then performing calculations to arrive
at a result(s) which is then updated periodically on
the display. The analog output, the pulse output,
and the alarm relays are also updated. The cycle
then repeats itself.
Step 1:Update the measurements of input signals
Raw Input Measurements are made at each input
using equations based on input signal type selected.
The system notes the “out of range” input signal as
an alarm condition.
Step 2:Compute the Flowing Fluid Parameters
The temperature and density equations are
computed as needed based on the instrument
equations and input usage selected by the user.
Step 3 : Compute the Tank Level
The value is computed based on the level sensor
input type selected and by installation details on the
tank.
Step 4: Compute the Uncorrected Tank Volume
Compute the uncorrected tank volume from
the tank level measurement and known geometry
of the tank.
Step 5: Compute the Corrected Tank Volume at
Reference Conditions or Mass in tank.
Step 6: Check Alarms
The alarm functions have been assigned to one of
the above during the setup of the instrument. A
comparison is now made by comparing the current
value against the specified hi and low limits.
Step 7: Compute the Analog Output
This designated process value is now used to
compute the analog output.
Step 8: Total Preset Comparisons
The total associated with a preset function is then
compared against the corresponding preset value
and any required control actions taken.
Step 9: Pulse Output Service-
The pulse output is next updated by scaling the
total increment which has just been determined by
the pulse output scaler and summing it to any
residual pulse output amount.
Step 10: Update Display and Printer Output-
The instrument finally runs a task to update the
various table entries associated with the front panel
display and serial outputs.
3
LEVELtrol-II Installation & Operating Instructions
Setup Mode
The setup mode is password protected by means of
a numeric lock out code established by the user. In
addition, a secret, manufacturers numeric unlock
entry sequence is available.
The system also provides a minimum implementation
of an “audit trail” which tracks significant setup
changes to the unit. This feature is increasingly being
found of benefit to users or simply required by
Weights and Measurement Officials in systems used
in commerce, trade, or “custody transfer” applications.
A Worksheet is provided to assist the user in setting
up the instrument. In addition, a software program is
available (optional) which runs on a PC using a RS232 Serial for connection to the instrument. Illustrative
examples may be down loaded in this manner.
The setup mode has numerous subgrouping of
parameters needed for the instrument functions.
There is a well conceived hierarchy to the setup
parameter list. Selections made at the beginning of
the setup hide unnecessary items further down in
the lists.
In the setup mode, the instrument activates the
correct setup variables based on the instrument
configuration, the equations, and the hardware
selections made for the compensation transmitter
type, the level transmitter type, and any enhancement
options selected. All required setup parameters are
enabled. All setup parameters not required are
suppressed.
A help line prompt is provided for each entry. In
addition a help message is available which may be
accessed by depressing the “HELP” key.
Also note that in the setup mode are parameter
selections which have preassigned industry standard
values. The unit will assume these values unless
they are modified by the user.
Maintenance Mode:
The Maintenance Mode of the LEVELtrol-II is the
Test and Calibration Mode for the device. This
mode provides a number of specialized utilities
required for factory calibration, instrument checkout
on start-up, and periodic calibration documentation.
A Supervisor or Manufacturers password is
required to gain access to this specialized mode
of operation. Start-up, quality, calibration, and
maintenance personnel will find this mode of
operation very useful. It is also useful for factory
testing.
Many of these tests may be used during start-up
of a new system. Inputs signals may be read, and
output signals may be exercised to verify the
electrical interconnects before the entire system
is put on line.
The following action items may be performed in
the Maintenance Mode:
Print Calibration/Maintenance Report
Examine Audit Trail
Examine Error History
Perform Keypad Checkout
Perform Display Checkout
Perform Pulse Output Checkout
Perform Control Input Checkout
Perform Relay Output Checkout
Perform Analog Input Checkout
Perform Analog Output Checkout
Calibrate Analog Inputs using the Learn Feature
Calibrate Analog Output using the Learn Feature
Battery Voltage Test
Print Datalogger Contents
Note that a calibration of the analog input/output
will advance the audit trail counters since it effects
the accuracy of the system.
Most of the process input variables have available a
“default” or emergency value which must be entered.
These are the values that the unit assumes when a
malfunction is determined to have occurred on the
corresponding input.
It is possible to enter in a nominal constant value for
temperature or density, or analog level inputs by
placing the desired nominal value into both the lo
and hi values. This is also a convenience when
performing bench top tests without simulators.
4
LEVELtrol-II Installation & Operating Instructions
RS-232 Serial Port
The LEVELtrol-II has a general purpose RS-232
Port which may be used for any one of the
following purposes:
Transaction Printing
Data Logging
Remote Metering by Modem (optional)
Computer Communication Link
Configuration by Computer
Print System Setup
Print Calibration/Malfunction History
Instrument Setup by PC’s over Serial Port
A Diskette program is optionally available with
the instrument that enables the user to rapidly
configure the LEVELtrol-II using an Personnel
Computer. Included on the diskette are common
instrument applications which may be used as a
starting point for your application. This permits
the user to have an excellent starting point and
helps speed the user through the instrument
setup.
Operation of Serial Communication Port with
Printers
LEVELtrol-II’s RS-232 channel supports a number
of operating modes. One of these modes is
intended to support operation with a printer in
applications requiring transaction printing, data
logging and/or printing of calibration and
maintenance reports.
In data logging, the user defines the items to be
included in each data log as a print list. The user
can also select when or how often he wishes a
data log to be made. This is done during the setup
of the instrument as either a time of day or as a
time interval between logging.
The system setup and maintenance report lists all
the instrument setup parameters and usage for the
current instrument configuration. In addition, the
Audit trail information is presented along with a
status report listing any observed malfunctions
which have not been corrected.
The user initiates the printing of this report at a
designated point in the menu by pressing the print
key on the front panel.
Operation of Serial Port with Modems (optional)
The LEVELtrol-II RS-232 channel supports a
number of operating modes. One of these modes
is intended to support operation with a modem in
remote metering applications.
For transaction printing, the user defines the items
to be included in the printed document. The user
can also select what initiates the transaction print
generated as part of the setup of the instrument.
The transaction document may be initiated via a
front panel key depression, a remote contact
closure, or upon completion of a batch.
5
2. Installation
LEVELtrol-II Installation & Operating Instructions
2. Installation
WARNING: In control applications, independent safety inter-
locks (liquid level switches) should be used to
!
prevent hazards which could result from a malfunctioning LEVELtrol II.
General Mounting
Hints
Mounting Procedure
2.1 General Mounting Hints:
The LEVELtrol-II Flow Computer should be located in an area with a clean, dry
atmosphere which is relatively free of shock and vibration. The unit is installed in
a 5.43" (138mm) wide by 2.68" (68mm) high panel cutout. (see Mounting
Dimensions) To mount the instrument, proceed as follows:
a. Prepare the panel opening.
b. Slide the unit through the panel cutout until the it touches the panel.
c. Install the screws (provided) in the mounting bracket and slip the bracket over
the rear of the case until it snaps in place.
d. Tighten the screws firmly to attach the bezel to the panel. 3 in. lb. of torque
must be applied and the bezel must be parallel to the panel.
Termination Connectors:
Minimum Wire Gauge: 22 AWG
Maximum Wire Gauge: 14 AWG
Voltage/current limits are limited by unit specifications.
Permanently Connected Equipment:
UL 3101-1, Section 6.12.2.1 specifies that:
• A switch or circuit breaker shall be included in the building installation;
• It shall be in close proximity to the equipment and within easy reach
of the OPERATOR;
• It shall be marked as the disconnecting device for the equipment.
Ensure that the switch or circuit breaker chosen is suitable for the power
requirements of the unit.
2.2 Mounting Diagrams: Standard Mounting Bezel Kit Mounting
LEVELtrol-II
Mounting Bracket
0.5
Dimensions
3.43
(87)
RATE
TOTAL
START
1
GRAND6SCROLL7PRE 28DENS
STOP
Mounting Bracket
5.67 (144)
GPM
147.43
GAL
267395.749
PRINT
TEMP4PRE 13RATE2TOTAL
5
TIME
0
9
–
6.18
Dotted Line Shows Optional Bezel Kit
CLEAR•MENU
HELP
2.83
(72)
ENTER
0.28 (7.2)
0.4 (10)
6.15
(156)
(13)
LEVELtrol-II
Bezel Adaptor
Gasket
5.43
(138)
Panel
Cutout
2.68
(68)
Dimensions are in inches (mm)
6
3. Applications
LEVELtrol-II Installation & Operating Instructions
Tank Level/Volume
3.1 Tank Level/Volume
Measurements:
A level or hydrostatic pressure transmitter measures the liquid level in a
tank. A temperature sensor can also be installed to correct for liquid
thermal expansion or density effects.
Output Results:
• Display Results
Level, Available Tank Volume, Gross Tank Volume
• Analog Output
Level or Tank Volume
• Pulse Output
Changes in Tank Volume
• Relay Outputs
Level or Tank Volume Alarms
Applications:
The LEVELtrol-II can monitor actual liquid level and tank volume of a
liquid. Alarms are provided via relays and datalogging is available via
analog (4-20mA) and serial outputs.
Tank Level/ Volume
Illustration
TOTAL
START
1
GRAND6SCROLL7PRE 28DENS
STOP
LEVEL
TEMP
PRE 1
3
2
PRINT
0
5
TIME
CLEAR•MENU
HELP
–
ENTER
4
9
Tank
Discharge
∆P
DP Transmitter
7
LEVELtrol-II Installation & Operating Instructions
Corrected
Tank Volume
3.2 Corrected Tank Volume
Measurements:
An ultrasonic level sensor measures the liquid level in a horizontal tank.
A temperature sensor is installed to correct for liquid thermal expansion.
Calculations:
• Corrected Tank Volume is calculated using the level and temperature
inputs as well as the liquid's thermal expansion coefficient stored in the
LEVELtrol-II. Use the "SET FLUID PROPERTIES" submenu to define
reference temperature and density values for standard conditions.
Output Results:
• Display Results
Level, Available Corrected Volume, Gross Corrected Volume,
Temperature
• Analog Output
Tank Volume or Temperature or Density
• Pulse Output
Change in Tank Volume
• Relay Outputs
Level or Tank Volume Alarms
Corrected
Liquid Volume
Illustration
Applications:
Monitoring corrected volume of a liquid stored in a horizontal tank. Alarms
are provided via relays and datalogging is available via analog (4-20mA)
and serial outputs.
TEMP
PRE 1
LEVEL
TOTAL
START
STOP
2
1
GRAND6SCROLL7PRE 28DENS
3
PRINT
0
5
TIME
CLEAR•MENU
HELP
–
ENTER
4
9
Ultrasonic
Level Sensor
T
Temperature
Transmitter
8
LEVELtrol-II Installation & Operating Instructions
Total Mass in Tank
3.3 Total Mass in Tank
Measurements:
Actual level is measured by the level sensor (ultrasonic sensor or DP
transmitter). Temperature is measured by the temperature transmitter. A
density transmitter can alternately be used for direct density
measurements.
Calculations:
• The density is calculated using the reference density and the thermal
expansion coefficient of the liquid (see "SET FLUID PROPERTIES"
submenu).
• Total Mass in tank is computed for tank geometry.
Output Results:
• Display Results
Level, Total Available Mass in Tank, Total Gross Mass in Tank,
Temperature, Density
• Analog Output
Level, Total, Temperature or Density
• Pulse Output
Change in Tank Mass
• Relay Outputs
Level, Total or Temperature Alarms
Liquid Mass
Illustration
Applications:
Monitoring level and mass total of any liquid in a tank. Alarms are
provided via relays and datalogging is available via analog (4-20mA) and
serial outputs.
TEMP
PRE 1
LEVEL
TOTAL
START
STOP
2
1
GRAND6SCROLL7PRE 28DENS
3
PRINT
0
5
TIME
CLEAR•MENU
HELP
–
ENTER
4
9
Ultrasonic
Level Sensor
T
Temperature
Transmitter
9
LEVELtrol-II Installation & Operating Instructions
Batching Volume,
Corrected Volume or
Mass from Tank Level
3.4 Batching Volume, Corrected Volume or Mass from Tank Level
Measurements:
A Level transmitter measures the liquid level in a tank. A temperature
sensor can also be installed to correct for liquid thermal expansion (see
3.2 Corrected Volume).
Calculations:
• Fluid Density (if required)
• Actual Level in tank is computed from level signal, installation parameters
and fluid properties.
• Tank Volume, Corrected Volume, Mass
• Compare quantity delivered to quantity requested.
Output Results:
• Display Results
Level, Batch Total, Tank Total, Temperature, Density
• Analog Output
Level, Total, Temperature or Density
• Pulse Output
Amount delivered since start of batch (other uses available)
• Relay Outputs
Batch Total, Level, or Temperature Alarms
Batching Illustration
Applications:
Batching and monitoring level and total quantity in tank of any liquid.
Batching is accomplished via relays and datalogging is available via
analog (4-20mA) and serial outputs.
PRINT
TEMP
PRE 1
LEVEL
TOTAL
START
STOP
2
1
GRAND6SCROLL7PRE 28DENS
4
3
9
0
5
TIME
CLEAR•MENU
HELP
–
ENTER
10
Temperature
Transmitter
T
∆P
DP
Transmitter
Solenoid Valve
4 WIRING
LEVELtrol-II Installation & Operating Instructions
Batcher
Wiring
4.1 Typical Batcher Wiring:
(+) V
Signal
123456
MOV
recommended
Level
Sensor
Remote Counter
115 VAC
115 VAC
SOLENOID VAL VE
1
DC OUTPUT
2
Iin +
3
4
COMMON
5
---------
6
RTD EXCIT +
7
RTD SENS
RTD SENS -
StartStop
8
9
CNTR IN 1
10
CNTR IN 2
11
CNTR IN 3
12
COMMON
13 PULSE OUTPUT +
14
PULSE OUTPUT 15
ANALOG OUTPUT +
16
ANALOG OUTPUT 17 NC
18 COM
19
20
21
22
NO
NC
COM
NO
RLY1
RLY2
Vin +
+
Iin +
25 NC
26
27
28
29
30
LEVEL
IN
COMP
IN
SEE USER
MANUAL
4-20 mA
COM RLY3
NO
NC
COM RLY4
NO
Level / Total
Wiring
115 VAC
4.2 Typical Level/Total Wiring:
(+) V
Level
Sensor
100 Ohm
DIN RTD
STRIP CHART
RECORDER
+
-
Signal
123456
Remote Counter
Alarm Relay 1
Alarm Relay 2
23
AC LINE
AC LINE24
1
DC OUTPUT
2
Iin +
3
4
COMMON
5
---------
6
RTD EXCIT +
7
RTD SENS
RTD SENS -
8
9
CNTR IN 1
10
CNTR IN 2
11
CNTR IN 3
12
COMMON
13 PULSE OUTPUT +
14
PULSE OUTPUT 15
ANALOG OUTPUT +
16
ANALOG OUTPUT 17 NC
{
{
18 COM
19
20
21
22
NO
NC
COM
NO
RLY1
RLY2
DC +
DC -
+
25 NC
26
27
28
29
30
POWER IN
LEVEL
IN
Vin +
COMP
IN
Iin +
SEE USER
MANUAL
4-20 mA
COM RLY3
NO
NC
COM RLY4
NO
115 VAC
11
23
AC LINE
AC LINE24
DC +
DC -
POWER IN
LEVELtrol-II Installation & Operating Instructions
4.3 Wiring In Hazardous Areas:
Examples using MLT787S+ Barrier (MTL4755ac for RTD)
Level Input
Temperature or
Density Input
(4-20mA Transmitter)
Flow Input
Hazardous Area Safe Area
4-20mA
Transmitter
Q/∆P
4-20
+
–
3 4
28V
Diode
2 1
Temperature/Density Input (4-20mA Transmitter)
Hazardous Area Safe Area
1
24V Out
2
3
4-20mA In
4
Common
24V Out
1
Temperature Input
(RTD)
4-20mA
Temp. or Dens.
Transmitter
T/D
4-20
–
+
4 3
Temperature Input (RTD)
Hazardous Area Safe Area
3-Wire RTD
1 2 3 4 5 6
28V
Diode
1 2
7 8 9 10 11 12 13 14 15 16 17
4
Common
8
4-20mA In
Common
4
5
RTD Excite (+)
6
RTD Sense (+)
7
RTD Sense (–)
8
12
LEVELtrol-II Installation & Operating Instructions
5. UNIT OPERATION
5.1 Front Panel Operation Concept for Run Mode
The LEVELtrol-II is fully programmable through the front panel. Please
review the following usage summary before attempting to use the instrument.
TEMP
PRE 1
LEVEL
TOTAL
START
1
GRAND6SCROLL7PRE 28DENS
STOP
3
2
PRINT
0
5
TIME
CLEAR•MENU
HELP
–
ENTER
4
9
How To Use
On-Line Help
How To Use
Function Keys
How To Enter
Presets
How To Create a
Scroll List
How To Use
The Print Key
How To Use
Special Batching
Keys
HELP
On-line help is provided to assist the operator in using this product. The help is
available during RUN and SETUP modes simply by pressing the HELP key. The
HELP key is used to enter decimals when entering numeric values.
FUNCTION KEYS
In the RUN mode, several keys have a special, direct access feature, to display
an item of interest (i.e. LEVEL, TOTAL, PRE 1, etc.). Press the key to view your
choice. Press the SCROLL key to return to scrolling display.
PRESET KEYS
In the RUN mode, PRE 1 & PRE 2 keys are used to view and/or change the preset
setpoints. To view the Presets, simply press the desired Preset key once. Rapidly
press the Preset keys three times, then press the Clear key for direct editing of the
preset setpoints. The access for changing the presets can be locked.
SCROLL
Rapidly press the Scroll key twice to setup a display list.
Press the CLEAR key to remove old scroll list.
Press the function key for the item you wish to add
Use the ∆ ∇ keys to assign the line.
PRINT
The PRINT key is used to print on demand. When the PRINT key is pressed, a
user defined list of data (TOTAL, LEVEL, PRE 1, etc.) is sent to the RS-232 port.
A timed message of "PRINTING" will be displayed to acknowledge the print
request.
SPECIAL BATCHING KEYS
The START and STOP keys are used only when batching to start and stop
batches. The CLEAR key will clear the batch total. All other keys work the same in
both Level/Total mode and Batch mode. The Start and Stop keys operation are set
by the control input settings. The Start options are: START or RESET/START.
The Stop options are: STOP or STOP/RESET.
How To Use
The Menu Key
How To
Acknowledge Alarms
MENU KEY
The MENU key is used to enter the Setup and Test modes. Press the MENU key
to enter the Setup and Test modes. (See section 6 for Setup mode, section 8 for
Test mode). The MENU key is used as "escape" in Setup and Test Programming.
Pressing the MENU key wile programming in the Sub-Menu groups will backup the
display to that Sub-Menu group heading. Pressing the MENU key while viewing
the Sub-Menu groups will backup the display to the Top Level Menu.
ACKNOWLEDGING ALARMS
Most alarm messages are self-clearing. Press the ENTER key to acknowledge
and clear alarms.
NOTE: Some keys and functions are password protected. Enter the password to
gain access. The passwords are factory set as follows:
Operator = 0
Supervisor = 2000
13
LEVELtrol-II Installation & Operating Instructions
General
Operation
Level/Total
Operation
Password Protection
(Level/Total mode)
5.2 General Operation
The unit can display: Level, Available Total, Gross Total, Temperature,
Density, Presets and Time of Day. The Temperature and/or Density can
be displayed even if you are using the Volumetric Flow Equation (a
Temperature or Density sensor must be installed). The unit can perform
Volume, Mass or Corrected Volume equations using a temperature or
density sensor (these equations can be computed without Temp/Dens
sensors by using user defined default values). The unit can be
programmed to perform Level or Batching functions (see section 6.3,
SELECT INSTRUMENT Submenu).
5.3 Level/Total Operation
The Level/Total mode is used primarily to monitor and control level and
tank volume. The relays can be used to trigger level, tank volume,
temperature or density alarms. Analog, pulse and communication outputs
are also provided.
5.3.1 Password Protection for Level/Total mode
After an Operator and/or Supervisor Password is entered in the setup
mode (see section 6.3, SETUP PASSWORD submenu), the unit will be
locked. The unit will prompt the user for the password when trying to
perform the following functions:
Enter Menu
Edit Preset 1 (PRE 1 Key) (if operator access is set to "none")
Edit Preset 2 (PRE 2 Key) (if operator access is set to "none")
Relay Operation
(Level/Total mode)
The Supervisor password should be reserved for supervisors. The
Supervisor password will allow access to restricted areas of the Setup
and Test menus.
A control input can also be configured as a jumper hardware lockout.
5.3.2 Relay Operation in Level/Total mode
Four relays are available for control and/or alarm output functions. The
relays can be assigned to trip according to level, total, temperature or
density readings. The relays can be programmed for low or high alarms.
Preset 1 (RLY1) and Preset 2 (RLY2) are easily accessible by pressing
the PRE 1 or PRE 2 key on the front panel. Preset 3 and Preset 4 are
accessible only through the setup menu.
NOTE: Choose relay operations that will fail safe for your process. Also
use suitable safety interlocks (level switches) to prevent overfilling
containers.
Pulse Output
(Level/Total mode)
5.3.3 Pulse Output in Level/Total mode
The isolated pulse output (open collector) is menu is assigned to follow
changes in the Volume Total, Corrected Volume Total or Mass Total.
The pulse output duration can be set for 10mS (100Hz max) or 100mS
(10Hz max). A pulse output scale factor (pulse value) can be set to scale
the pulse output. The pulse output is ideal for connecting to remote
totalizers or other devices such as a PLC. See section 1.3 for electrical
specifications. Pulse outputs can be used to indicate approximate delivery
totals received or delivered.
14
LEVELtrol-II Installation & Operating Instructions
Analog Output
(Level/Total mode)
RS-232 Serial Port
(Level/Total mode)
5.3.4 Analog Output in Level/Total mode
The analog output is menu assignable to correspond to the Level,
Volume, Corrected Volume, Mass, Temperature, Density. The analog
output is ideal for "trend" tracking using strip chart recorders or other
devices.
5.3.5 RS-232 Serial Port Operation in Level/Total mode
The RS-232 serial port can be used for programming (using the optional
Setup Disk) or for communicating to printers and computers in the
Operating Mode (Run Mode).
PC Communications:
The Setup Disk also allows the user to query the unit for operating
status such as Level, Tank Total, Temperature, Density, Presets, etc.
Operation of RS-232 Serial Port with Printers:
Transaction Printing
For transaction printing, the user defines the items to be included in
the printed document (see SET PRINT OUTPUT, Select_list). The
transaction document can be initiated by pressing the PRINT key or by
a remote contact closure.
Data Logging to Printer
In data logging, the user defines the items to be included in each data
log (see SET PRINTER OUTPUT, Select_list). The user can also
select when (time of day) or how often (print interval) the data log is to
be made (see section 6.3.19 SET PRINT OUTPUT, Configure).
System Setup and Maintenance Report
The system setup and maintenance report lists all of the instrument
setup parameters and usages for the current instrument configuration.
The audit trail information and a status report is also printed. This
report is initiated in the Test menu (see PRINT SYSTEM SETUP).
5.3.6 RS-485 Serial Port Operation in Level/Total mode
The RS-485 serial port can be used for accessing level, total quantity,
temperature, density and alarm status information. The port can also
be used for changing presets and acknowledging alarms.
15
LEVELtrol-II Installation & Operating Instructions
Batcher
Operation
Batcher Configuration
5.4 Batcher Operation
The Batcher mode is used primarily to dispense batches of fluid based
on changes in tank volume as indicated by tank level. The main difference
between the Batch mode and Level/Total mode is the relay operation.
The Batch mode allows the operator to "START" the batch transfer via
the front panel or remote input. Once started, the relays (RLY1 & RLY2)
will energize and send power to a flow control device (i.e. solenoid valve
or pump). The level sensor will send a signal to the unit and total
comparisons will begin. When the Prewarn value (PRE 2) is reached,
Relay 2 will drop out (this is ideal for flow slow down). When the Batch
amount (PRE 1) is reached, Relay 1 will drop out and the Batch is
complete.
Several messages will be displayed during normal batch operation (i.e.
Batch Fill, Batch Stopped).
5.4.1 Batcher Configuration.
When the unit is programmed for the batch mode, several batch
operation choices are available. These choices include: Up or Down
Counting, Batch Into or Out of the Tank, Batch Overrun Correction
feature, Start or Reset/Start, and Stop or Stop/Reset.
BATCH OVERRUN
The batch overrun is used for batch applications that have slow
responding valves and a consistent batching flowrate. When the Batch
Overrun is set, the unit will compensate for batch overruns by
computing an averaged overrun value from the last four batches. This
average is used to internally adjust the batch setpoint to minimize
overrun.
START, RESET/START and STOP, STOP/RESET
When configuring the control inputs, Control Input1 can be set for START
or RESET/START. When set for START, the unit will start batching
when a signal is applied to Control Input1 or the front panel Start key is
pressed. A separate Reset signal must be used to clear the previous
batch total. When set for RESET/START, the unit will automatically
reset then start when a signal is applied to Control Input1 or the front
panel Start key is pressed (provided that the previous batch was
completed). If a previous batch was stopped during a batch cycle, the
unit will Restart from where it was stopped.
Control Input 2 can be set for STOP or STOP/RESET. When set for
STOP, the unit will stop batching when a signal is applied to Control Input
2 or the front panel Stop key is pressed. A separate Reset signal must
be used to clear the batch total. When set for STOP/RESET, a running
batch will stop when a signal is applied to Control Input 2 or the front
panel Stop key is pressed. If the unit is Stopped or after a completed
batch, the unit will reset when a signal is applied to Control Input 2 or the
front panel Stop key is pressed.
NOTE: Applying a voltage level to Control Input 2 will inhibit or override
all Start inputs in either mode.
16
LEVELtrol-II Installation & Operating Instructions
Password Protection
(Batch mode)
Relay Operation
(Batch mode)
5.4.2 Password Protection for Batcher Mode
After an Operator and/or Supervisor Password is entered in the setup
mode (see section 6.3, SETUP PASSWORD submenu), the unit will be
locked. The unit will prompt the user for the password when trying to
enter the menu. The unit will also prompt the user to enter the password if
this access has been limited.
The Supervisor password should be reserved for supervisors. The
Supervisor password will allow access to restricted areas of the Setup
and Test menus.
The passwords are factory set as follows:
Operator = 0
Supervisor = 2000
A control input can also be configured as a jumper hardware lockout.
5.4.3 Relay Operation in Batcher mode
Four relays are available for batch control and/or alarm outputs. Preset 1
(RLY1) is reserved for batch amount, Preset 2 (RLY2) is usually reserved
for prewarn. (see section 5.4 Batcher Operation for Relay 1 & Relay 2
functions)
Preset 1 (RLY1) and Preset 2 (RLY2) are easily accessible by pressing
the PRE 1 or PRE 2 key on the front panel. Preset 3 and Preset 4 are
accessible only through the setup menu.
Relays 3 and 4 can be assigned to trip according to level, temperature,
density, overrun or alarm. When level, temperature or density is selected
the relays can be programmed as low or high alarms.
Overrun can be used to detect minor leakage around valves in some
applications.
Pulse Output
(Batch mode)
NOTE: Choose relay operations that will fail safe for your process. Also
use suitable safety interlocks (level switches) to prevent overfilling
containers.
5.4.4 Pulse Output in Batcher mode
The isolated pulse output (open collector) is assigned to produce pulses
on changing Volume, Corrected Volume or Mass as indicated by the
pulse output usage and the compensation equation selected. The pulse
output duration can be set for 10mS (100Hz max) or 100mS (10Hz max).
A pulse output scale factor (pulse value) can be set to scale the pulse
output. The pulse output is ideal for connecting to remote totalizers or
other devices such as a PLC. It may be used to keep track of deliveries,
the amount sent to/from a tank or for a combination of these. See section
1.3 for electrical specifications.
17
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