STI Magnetrol Kotron 811 Installation And Operating Manual
Installation and Operating Manual
RF
Capacitance
Level
Measurement
Kotron
®
Model 811
RF Point Level Sensor
50-608 Kotron Model 811 RF Point Level Sensor
Read this Manual Before Installing
This manual provides information on the Kotron
Model 811 RF Point Level Sensor. It is important that all
instructions are read carefully and followed in sequence.
Detailed instructions are included in the Installation
section of this manual.
Conventions Used in this Manual
Certain conventions are used in this manual to convey
specific types of information. General technical material,
support data, and safety information are presented in
narrative form. The following styles are used for notes,
cautions, and warnings.
Notes
Notes contain information that augments or clarifies
an operating step. Notes do not normally contain
actions. They follow the procedural steps to which
they refer.
Cautions
Cautions alert the technician to special conditions that
could injure personnel, damage equipment, or reduce
a component’s mechanical integrity. Cautions are also
used to alert the technician to unsafe practices or the
need for special protective equipment or specific materials. In this manual, a caution box indicates a potentially hazardous situation which, if not avoided, may
result in minor or moderate injury.
Warnings
Warnings identify potentially dangerous situations or
serious hazards. In this manual, a warning indicates an
imminently hazardous situation which, if not avoided,
could result in serious injury or death.
WARNING! Explosion hazard. Do not connect or dis-
connect equipment unless power has been switched off or
the area is known to be non-hazardous.
Safety Messages
The Kotron Model 811 system may be properly installed
in Category II, Pollution Degree 2 installations. Follow all
standard industry procedures for servicing electrical and
computer equipment when working with or around high
voltage. Always shut off the power supply before touching
any components. Although high voltage is not present in
this system, it may be present in other systems.
Electrical components are sensitive to electrostatic discharge. To prevent equipment damage, observe safety
procedures when working with electrostatic sensitive
components.
Low Voltage Directive
For use in Category II installations. If equipment is used
in a manner not specified by manufacturer, protection
provided by equipment may be impaired.
Notice of Trademark, Copyright, and Limitations
Kotron is a registered trademark of Magnetrol
International, Incorporated. Kotron Model 811 RF Point
Level Sensor is a tradename of Magnetrol International,
Incorporated.
Copyright © 2006 Magnetrol International, Incorporated.
Magnetrol reserves the right to make changes to the product described in this manual at any time without notice.
Magnetrol makes no warranty with respect to the accuracy
of the information in this manual.
Warranty
All Magnetrol/STI electronic level and flow controls are
warranted free of defects in materials or workmanship for
one full year from the date of original factory
shipment.
If returned within the warranty period; and, upon
factory inspection of the control, the cause of the claim is
determined to be covered under the warranty; then,
Magnetrol/STI will repair or replace the control at
no cost to the purchaser (or owner) other than
transportation.
Magnetrol/STI shall not be liable for misapplication, labor
claims, direct or consequential damage or expense arising
from the installation or use of equipment. There are no
other warranties expressed or implied, except special written warranties covering some Magnetrol/STI products.
Quality Assurance
The quality assurance system in place at Magnetrol/STI
guarantees the highest level of quality throughout the
company. Magnetrol/STI is committed to providing full
customer satisfaction both in quality products and
quality service.
Magnetrol’s quality assurance system
is registered to ISO 9001 affirming
its commitment to known international quality standards providing
the strongest assurance of product/
service quality available.
Table of Contents
1.0 Complete Installation
1.1 Unpacking ..............................................................1
1.2 Electrostatic Discharge (ESD) Handling Procedure ....1
1.3 Before You Begin ....................................................2
1.3.1 Site Preparation ...............................................2
1.3.2 Equipment and Tools ......................................2
1.3.3 Operational Considerations.............................2
1.4 Mounting ..................................................................3
1.4.1 Horizontal Mounting ......................................4
1.4.2 Vertical Mounting ...........................................4
1.5 Probe Installation.......................................................5
1.5.1 Installing a Guarded Probe ..............................5
1.5.2 Installing a Standard Probe ..............................5
1.5.3 Installing a Flexible Probe................................5
1.6 Installing a Remote Mount Unit...............................6
1.6.1 Remote Mount with Guarded Probe ...............6
1.6.1.1 Electronic Housing ....................................6
1.6.1.2 Probe Housing Connections......................7
1.6.2 Remote Mount with Rigid and
Flexible Probes.................................................7
1.6.2.1 Electronic Housing ....................................7
1.6.2.2 Probe Housing Connections......................7
1.7 Wiring .......................................................................8
1.7.1 Probe Wiring...................................................8
1.7.2 Electrical Wiring..............................................9
1.7.3 Operating Mode Selection...............................9
1.7.4 Relay Wiring Chart ......................................10
1.8 Calibration — Narrow Differential.........................10
1.8.1 Set Point Adjustment Alarm ..........................10
1.8.2 Low Level Alarm Fail-safe Low – with no
media on the probe .......................................11
1.8.3 Low Level Alarm Fail-safe Low – with
media on the probe .......................................12
1.8.4 High Level Alarm Fail-safe High – with
no media on the probe ..................................12
1.8.5 High Level Alarm Fail-safe High – with
media on the probe .......................................12
1.8.6 Time Delay....................................................12
1.9 Calibration — Wide Differential ............................13
1.9.1 Set Point Adjustment Control .......................13
1.9.2 Time Delay....................................................15
2.0 Reference Information ................................................16
2.1 Description..............................................................16
2.2 Theory of Operation...............................................16
2.3 Troubleshooting.......................................................16
2.3.1 No Signal with Level Change........................16
2.3.2 Probe..............................................................16
2.3.3 Switch Chatter ...............................................17
2.4 Agency Approvals ....................................................18
2.4.1 Agency Specifications – Intrinsically Safe
Installation ....................................................19
2.4.2 Agency Specifications – Explosion Proof
Installation ....................................................19
2.5 Parts.........................................................................20
2.5.1 Replacement Parts .........................................20
2.6 Specifications ...........................................................21
2.6.1 Functional .....................................................21
2.6.2 Physical .........................................................22
3.0 Model Numbers.........................................................23
NOTES.............................................................................24
Kotron Model 811
RF Point Level Sensor
50-608 Kotron Model 811 RF Point Level Sensor
1
1.0 Complete Installation
This section provides detailed procedures for properly
installing, configuring, and, as needed, troubleshooting the
Kotron Model 811 RF Point Level Sensor.
1.1 Unpacking
Unpack the instrument carefully. Make sure all components have been removed from the packing material.
Check all the contents against the packing slip and report
any discrepancies to the factory. Before proceeding with
the installation, do the following:
• Inspect all components for damage. Report any damage
to the carrier within 24 hours.
• Make sure the nameplate model number agrees with the
packing slip and purchase order.
• Record the model and serial numbers for future
reference when ordering parts.
Model Number _________________________________
Serial Number __________________________________
1.2 Electrostatic Discharge (ESD)
Handling Procedure
Magnetrol’s electronic instruments are manufactured to the
highest quality standards. These instruments use electronic
components that may be damaged by static electricity present in most work environments.
The following steps are recommended to reduce the risk of
component failure due to electrostatic discharge.
• Ship and store circuit boards in anti-static bags. If an antistatic bag is not available, wrap the board in aluminum
foil. Do not place boards on foam packing materials.
• Use a grounding wrist strap when installing and removing
circuit boards. A grounded workstation is recommended.
• Handle circuit boards only by the edges. Do not touch
components or connector pins.
• Make sure that all electrical connections are completely
made and none are partial or floating. Ground all
equipment to a good, earth ground.
50-608 Kotron Model 811 RF Point Level Sensor
2
1.3 Before You Begin
1.3.1 Site Preparation
Each Kotron Model 811 sensor is built to match the
specific physical specifications of the required installation.
Make sure the probe connection is correct for the threaded
or flanged mounting on the vessel or tank where the transmitter will be placed. See Mounting, Section 1.4.
Make sure that the wiring between the power supply
and the Model 811 sensor is complete and correct for
the type of installation. See Specifications, Section 2.6.
When installing the Model 811 sensor in a general
purpose or hazardous area, all local, state, and federal
regulations and guidelines must be observed. See Wiring,
Section 1.7.
1.3.2 Equipment and Tools
No special equipment or tools are required to install
the Model 811 sensor. The following items are
recommended:
•1
1
⁄8" Open-end wrench or adjustable wrench to fit
the probe process connection size and type
• Flat-blade screwdriver
1.3.3 Operational Considerations
The Model 811 sensor should be located to allow for easy
access for service, configuration, and monitoring. There
should be sufficient headroom to allow the probe to be
inserted into the tank. Special precautions should be made
to prevent exposure to corrosive atmosphere, excessive
vibration, shock, or physical damage.
Units should not be exposed to ambient temperatures
above +160° F (+71° C) or below -40° F (-40° C). Probes
should be isolated from severe motion in the tank, because
surface turbulence may cause signal deviation.
NOTE: The unit is designed for maximum safety intrinsically safe
probe circuit). Jumper (J4) must be intact under normal operating conditions. The jumper must not be removed by anyone
unless there is a specific need for intrinsically safe grounding
separate from the standard earth ground. Consult factory
before considering special grounding which would require
removal of the jumper. Violation of this requirement will void
warranty and release Magnetrol of any responsibility.
50-608 Kotron Model 811 RF Point Level Sensor
3
1.4 Mounting
The Model 811 sensor can be mounted to a tank using a
variety of process connections.
Make sure all mounting connections are properly in place
on the tank before installing the probe. Make sure the
Kotron probe is correct for the intended installation.
It is common practice to use the metal tank wall as the
reference electrode. In such cases, it is required that the
probe housing makes a good electrical connection to the
tank wall. If there is any doubt about this connection or to
the use of PTFE thread tape gaskets, paint, rust, or any
other reason, a separate strap should be installed between
the probe housing and the tank.
Caution: This unit contains CMOS electronics which may be
damaged by static electricity. Do not touch any semiconductor devices unless you are properly grounded.
Caution: When a probe is used in an abrasive medium, inspect the
probe periodically for visible surface wear. If damage to
the probe insulation is found, replace the probe.
Metal Walled Tanks
On water-based liquids, there should be no problem with
sensitivity. With non-conductive, low dielectric media,
sensitivity can be enhanced by locating the probe close to
and parallel with the tank wall. If this is not practical, a
ground reference probe may be the solution.
Non-Metallic and Glass-Lined Tank Construction
With plastic, concrete, wood, or any other non-conductive
walled vessels, a ground reference is required. Most commonly, this electrode will be in the form of a concentric
ground tube (e.g., stilling well). In questionable circumstances, consult the factory. In all cases, a good electrical
connection must be made between the ground surface and
the probe housing.
Switch/Probe Assembly
Switches with probes up to and including 12 inches
(300 mm) in length are shipped pre-assembled. All other
switches are shipped unassembled to avoid damage during
transit. These units must be assembled prior to mounting.
Choose your particular configuration from the following
sections and follow the instructions carefully.
50-608 Kotron Model 811 RF Point Level Sensor
4
1.4.1 Horizontal Mounting
Alarm (narrow differential) applications only
Horizontally mounted probes provide a high degree of sensitivity for use with non-conductive liquids as only approximately 0.5 inches (12 mm) of level change is required to
completely cover (or uncover) the probe.
Horizontally mounted probes should be installed so that
the probe is parallel to and at the level at which the control point is desired. Refer to Figure 1.
Avoid any installation method in which the material may
become trapped in the mounting nozzle, thus preventing
the probe from signaling when the level recedes. Refer to
Figures 2 and 3.
NOTE: If nozzle mounting is unavoidable, the probe must be installed
with an inactive metal sheath having a length of at least 1 inch
(25 mm) greater than length of the nozzle. A sheath is required
to render the length of the probe within nozzle insensitive to
capacitance change. Refer to Figure 2.
Guarded Probe
Unit will signal at probe level. Refer to Figures 4 and 5.
NOTE: The guard element must be located outside of the nozzle.
Do not horizontally mount the unit in a nozzle deeper than
3 inches (75 mm). Refer to Figure 5. The medium may buildup
in the nozzle and cause false activation.
Alternate Horizontal Mounting
On applications involving viscous liquids or materials
which tend to cling or buildup, horizontally mounted
probes should be installed at a slight downward angle to
allow material to drain from probe rod. With this type
of installation, the packing gland face of probe assembly
should extend into the tank (or vessel). Refer to Figure 6.
1.4.2 Vertical Mounting
Vertically mounted probes provide the capability to adjust
the control point up or down a section of probe rod by
means of calibration adjustments within the unit.
Vertically mounted probes should be installed so that the
end of the probe rod is at least 2 inches (5 mm) below the
lowest desired level control point with conductive materials or 4 inches (100 mm) below the lowest desired level
control point with non-conductive materials. Refer to
Figure 7 on page 5.
Figure 1
Recommended Horizontal Mounting
Figure 2
Recommended Mounting with Nozzle
Figure 3
Not Recommended
Figure 4
Recommended Horizontal Mounting
Guarded Probe
Figure 5
Recommended Horizontal Mounting
Guarded Probe
Figure 6
Alternate Horizontal Mounting
50-608 Kotron Model 811 RF Point Level Sensor
5
1.5 Probe Installation
1.5.1 Installing a Guarded Probe
1. Thread electronics/probe assembly (pre-assembled) into
mounting bushing on tank.
2. Tighten securely (ensure that the wrench is applied
only to the mounting gland). Refer to Figure 8.
3. Proceed to Wiring, Section 1.7, on page 8.
1.5.2 Installing a Standard Probe
Before installing, ensure the:
• Probe has adequate headroom for installation and has
unobstructed entry in the vessel.
• Process temperature, pressure, dielectric, and viscosity are
within the probe specifications for the installation. See
Specifications, Section 2.6, on page 21.
1. Thread probe into mounting bushing on tank.
2. Tighten securely, being certain that the wrench is applied
ONLY to the mounting gland. Refer to Figure 9.
3. Screw the amplifier housing onto the probe. Refer to
Figure 9.
4. Screw housing on the probe until hand tight. Housing
can be wrench tightened to align conduit connection
with conduit.
1.5.3 Installing a Flexible Probe
Caution: Insulated flexible probes are shipped with the cable clamp
and the packing gland nut hand tightened to permit length
adjustment in the field. The cable clamp and packing
gland nut must be tightened before use.The end of a flexible probe MUST be kept taut by attaching the anchor
end at the bottom of the vessel or by using a Magnetrol
supplied probe weight.
Caution: Do not discard the Mylar housing insulator.
Caution: The probe cable must not be in contact with any metallic
surface in its final installation position.
1. Attach the weight or anchor assembly to the end of the
probe. Insert the probe through the vessel’s mounting connection, and feed the cable into the vessel. Do not allow
the probe to scrape against the connection threads.
2. Secure the anchor assembly (if used), to the bottom of
the vessel.
Figure 7
Vertical Mounting
Figure 8
Integral Mount with Guarded Probe
Figure 9
Integral Mount with
Standard Rigid Probe
Mounting
Gland
Probe
(White)
Guard
(Red)
Probe
(White)
1 2 3 4
OPEN
1 2 3 4
OPEN
Lower Probe
Mounting Gland
50-608 Kotron Model 811 RF Point Level Sensor
6
Clamp
Figure 10
Integral Mount with Flexible Probe
3. Apply thread sealant to the mounting nut. Screw the
mounting nut into the mounting connection until tight.
4. Remove the Mylar housing insulator located over the
clamp. DO NOT DISCARD.
5. Loosen both socket head screws from the clamp. Pull the
clamp and Teflon retaining bushing off of the probe.
6. While holding on to the probe cable, loosen the upper
packing gland nut. DO NOT ALLOW THE PROBE
CABLE TO FALL INTO THE VESSEL.
7. Pull the excess cable up through the packing gland nut
until the cable is taut. Tighten the packing gland nut.
8. Cut the cable 1.35" (34 mm) above the packing gland nut
and strip off 1.25" (32 mm) of insulation.
9. Slide the Teflon retaining bushing onto the cable and seat
it into the packing gland nut. Slide the clamp onto the
cable and seat it against the Teflon retaining bushing.
10. Tighten both socket head screws, on the clamp, to approximately 35 in/lbs of torque. Slip the Mylar insulator over
the clamp.
Caution: Check probe terminal connection carefully to be certain
lug will not short to packing gland or interfere with assembly of amplifier housing to probe.
1.6 Installing a Remote Mount Unit
NOTE: All remote mount units use triaxial cable that is shipped in a
length specified at the time of order. This cable must always
make all 3 connections at the main amplifier. At the probe
head, the cable will always make at least 2 connections.
(PROBE and GROUND). The final connection (GUARD) is only
used with the guarded probe. Cut the guard wire back to the
cable and dress with tape when NOT in use.
1.6.1 Remote Mount with Guarded Probe
1.6.1.1 Electronic Housing
Remote electronic housings are normally shipped from the
factory assembled with a mounting bracket. To install the
electronic housing, proceed as follows. Refer to Figure 11.
1. Install bracket in a location which will isolate unit from
temperatures below -40°F (-40° C) and over +160° F
(+71° C) or vibration/mechanical damage. Unit can be
mounted up to 150 feet (45 m) from probe assembly.
Location should also offer easy access for wiring,
calibration and maintenance.
ECTFE Flexible Probe
Teflon
Retaining
Bushing
Flexible
Termination
Optional Weight
Tank Bracket
Connection
Probe
Probe
1 2 3 4
OPEN
Probe
(White)
Probe Connection Screw
Mylar Housing Insulator
(slips over clamp)
Socket Head
Clamp Screws (2)
Upper Probe
Mounting Gland
Lower Probe
Mounting Gland
Probe Locking
Set Screw
Optional
Mounting
Bracket
(Used w/
Insulated
Probes)
PROBE
MYLAR
INSULATOR
UPPER
MOUNTING
NUT HALF
LOWER
MOUNTING
NUT HALF
PROBE
CABLE
3/8 16 UNC 2B
WIRE SCREW
CLAMP
SET SCREW
CLAMP RETAINING
BUSHING
SEAL
FLARE
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