ABB K-TEK AccuTrak AT500 User manual

AT500-0200-1b (10-2010) DCN0528

AT500-0200-1b (10-2010) DCN0528 2
TABLE OF CONTENTS
1. STORAGE INFORMATION ............................................................................................................................... 3
1.1 AT600 ............................................................................................................................................ 3
1.2 AT500 ............................................................................................................................................ 3
2. INSTALLATION AND STARTUP....................................................................................................................... 3
2.1 Wiring............................................................................................................................................. 3
2.2 Establishing 4mA & 20mA Setpoints ............................................................................................. 4
2.2.1 Setting the 4mA / 0% point ............................................................................................ 4
2.2.2 Setting the 20mA / 100% point ...................................................................................... 4
2.3 Reversing Action............................................................................................................................ 4
2.4 High/Low Alarm Setting ................................................................................................................. 4
2.4.1 Setting ALARM to 3.6 mA (Low Alarm) ......................................................................... 5
2.4.2 Setting ALARM to 21 mA (High Alarm) ......................................................................... 5
2.5 4 mA / 20 mA DAC Trim ................................................................................................................ 5
2.5.1 Setting 4.0 mA DAC Trim .............................................................................................. 5
2.5.2 Setting 20.0 mA DAC Trim ............................................................................................ 5
3. TROUBLESHOOTING INFORMATION ............................................................................................................ 7
3.1 Proper Powerup ............................................................................................................................. 7
3.2 Output Stability............................................................................................................................... 7
3.3 Conversion from AT500 to AT600 or AT600 to AT500 ................................................................. 7
4. APPENDIX A ................................................................................................................................................. 8
4.1 Installation Drawings...................................................................................................................... 8
5. APPENDIX B ............................................................................................................................................... 10
5.1 FMEDA Certificate ....................................................................................................................... 10
6. APPENDIX C ............................................................................................................................................... 11
6.1 Warranty Statement..................................................................................................................... 11
6.2 RMA Form.................................................................................................................................... 12
6.3 EU Declaration of Conformity ...................................................................................................... 13

AT500-0200-1b (10-2010) DCN0528 3
1. STORAGE INFORMATION
If required, storage prior to installation should be indoors at ambient temperature, not to exceed the following:
Temperature range: -40 to 150 degrees F.
Humidity: 0 to 100% R.H. non-condensing.
1.1 AT600
AT600 transmitters are typically mounted to KM26 Magnetic Level Gauges. These operate off the magnet assembly
in the float of the level gauge.
1.2 AT500
AT500 transmitters are directly inserted into the vessel. They operate off of the magnet assembly within the float
riding on the sensor tube.
2. INSTALLATION AND STARTUP
WARNING: When fitted with a compression fitting, the sensor tube is shipped with a set of TEFLON
ferrules, and a set of STAINLESS STEEL ferrules in a separate bag. The TEFLON ferrules are only in-
tended for low-pressure applications; for higher operating pressures and/or permanent installation, replace
the TEFLON ferrules by the STAINLESS STEEL ferrules.
2.1 Wiring
Install conduit to 1/2" NPT pipe nipple seal, and run 18 Gauge twisted shielded pair to housing. Use appropriate
conduit seal fitting to eliminate possible moisture infiltration.
Apply loop power to transmitter as follows:

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2.2 Establishing 4mA & 20mA Setpoints
The unit is a digital transmitter with no routine calibration required.
If re-calibration is required, calibration can be changed using the built in switchpoints as follows:
2.2.1 Setting the 4mA / 0% point
 Establish a tank level of 0%
 Enter the calibration mode by placing Magnet at position X for 2 seconds.
 Slide magnet from position X to position Z to set the ZERO (4.00mA) setpoint; this step is verified by
checking that the output is now at 4.00 mA
2.2.2 Setting the 20mA / 100% point
 Establish a tank level of 100%
 Enter the calibration mode by placing Magnet at position X for 2 seconds.
 Slide magnet to position S to set the SPAN (20.00mA) setpoint; this step is verified by checking that
the output is now at 20.00 mA
Note: These steps can be repeated as many times as needed.
2.3 Reversing Action
If required, transmitter output can be reversed by following these steps (Note: this reverses the 4‑20 mA
output):
 Bring the level to 50% ( + or - 10% ).
-Enter the calibration mode by placing Magnet at position X for 2 seconds.
-Slide magnet from position X to position Z to temporarily set the ZERO (4.00mA) setpoint;
this step is verified by checking that the output is now at 4.00 mA
 Bring the level to the new 20mA point.
-Enter the calibration mode by placing Magnet at position X for 2 seconds.
-Slide magnet from position X to position S to set the SPAN (20.00mA) setpoint; this step is
verified by checking that the output is now at 20.00 mA
 Bring the level to the new 4ma point.
-Enter the calibration mode by placing Magnet at position X for 2 seconds.
-Slide magnet from position X to position Z to set the ZERO (4.00mA) setpoint; this step is
verified by checking that the output is now at 4.00 mA.
2.4 High/Low Alarm Setting
The Unit enters an alarm state when no float is detected. The desired alarm state can be set as fol-
lows:
S
Z
X

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2.4.1 Setting ALARM to 3.6mA (Low Alarm)
 Enter the ALARM SETUP MODE by applying power to the unit while Magnet is at position X.
 Slide magnet to position Z to set the unit to 3.6 mA / Low Alarm; this step is verified by checking that
the output is now at 3.6 mA
2.4.2 Setting ALARM to 21mA (High Alarm) default
 Enter the ALARM SETUP MODE by applying power to the unit while Magnet is at position X.
 Slide magnet to position S to set the unit to 21.0 mA / High Alarm; this step is verified by checking
that the output is now at 3.6 mA
Note: Once in ALARM SETUP MODE, you can toggle the High & Low alarm settings as many times as
needed. After 5 seconds of no switch activity, the unit will time out and resume normal operation using
the new alarm setting.
2.5 4 mA / 20 mA DAC Trim
If required, the unit’s 4 ma and 20 ma outputs can be trimmed as follows:
2.5.1 Setting 4.0 mA DAC Trim
 Enter the 4 mA DAC TRIM MODE by applying power to the unit while Magnet is at position Z.
 Magnet at position Z will decrease the output at - 0.01 mA intervals
 Moving the magnet to position S will increase the output at + 0.01 mA intervals
 Continue to Increase/Decrease the output until the output is at 4.00 mA
 The unit will time out after 5 seconds of no switch activity and resume normal operation using the
new 4.0 mA trimmed value.
2.5.2 Setting 20.0 mA DAC Trim
 Enter the 20 mA DAC TRIM MODE by applying power to the unit while Magnet is at position S.
 Magnet at position S will increase the output at + 0.01 mA intervals
 Moving the magnet to position Z will decrease the output at - 0.01 mA intervals
 Continue to Increase/Decrease the output until the output is at 20.00 mA
 The unit will time out after 5 seconds of no switch activity and resume normal operation using the new 20.0 mA trimmed
value.
S
Z
X

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SWITCH OPERATIONS Summary of operations using the three switch points: SW S, SW X SW Z
Note: Unit will return to normal operation after 5 seconds of no switch activity.
S
Z
X
SW S - ENTER 20 mA DAC TRIM MODE
SW S - INCREMENT DAC +.01 mA
SW Z - DECREMENT DAC -.01 mA
POWER UP
SW Z - ENTER 4.0 mA DAC TRIM MODE
SW S - INCREMENT DAC +.01 mA
SW Z - DECREMENT DAC -.01 mA
POWER UP
SW X - ENTER ALARM MODE SETUP
SW S - SET 21 mA ALARM
SW Z - SET 3.6 mA ALARM
POWER UP
SW X 2 sec - ENTER CALIBRATION MODE
SW S - SET 20 mA / 100% POINT
SW Z - SET 4 mA / 0% POINT
NORMAL
OPERATION
Magnetic switchpoints are located on lines S X & Z at points 90 degrees from the conduit connection indicated by: on FIGURE 1
FIGURE 1

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3. TROUBLESHOOTING INFORMATION
3.1 Proper Power-Up
Use a mA meter to measure the output current (see section 2.2 for mA monitor connections). When power is applied, the output
should go to 4.00 mA for at least 1 second, and then to either the measured level or an alarm condition output. If this does not
happen, the transmitter may not be receiving enough power, or the main electronic is defective. Excessive current above 21 mA
is also an indication of improper power-up or defective electronics.
 Valid Current Loop Outputs:
-21.0 mA If HI ALARM was selected, a loss of signal, no float detected, problem with the configuration, or a malfunction,
will cause the output to be set to the alarm condition of 21.0 mA.
- 20.6 mA OVERRANGE: When the level increases above the 20 mA point, the output will continue up to 20.6 mA and
then latch at that value, until the level comes back down again.
- 3.8 mA - 20.6 mA Normal output range
- 3.8 mA UNDERRANGE: When the level increases below the 4 mA point, the output will continue down to 3.8 mA and
then latch at that value, until the level comes back up again.
-3.6 mA If LOW ALARM was selected, a loss of signal, no float detected, problem with the configuration, or a malfunc-
tion, will cause the output to be set to the alarm condition of 3.6 mA.
3.2 Output Stability
If the current output occasionally jumps up or down but not to an alarm condition:
This can be an indication of noise or grounding problem. Field wiring should be run with an individually shielded cable. Insure
that the transmitter housing is effectively connected to earth ground.
There may be a location on the tube that has retained some magnetization, and needs to be cleared. This can happen if a mag-
net or float was used to manually calibrate the sensor and if it was pulled away at 90 degrees from the tube. To avoid this, al-
ways slide the magnet parallel to the tube and remove it by going past either end of the tube. To clear any remaining magnetiza-
tion, slide a magnet or float against and parallel to the tube, from one end to the other.
3.3 Conversion from AT500 to AT600 or AT600 to AT500
It is possible to convert a bottom connected AT600 to an AT500 by adding a float and other parts. It is also possible to convert an
AT500 to a bottom connected AT600 by adding mounting clips. Please consult the factory.
It is not possible to convert a top connected AT600 to an AT500 or vice versa. If you wish to make this change, the transmitters
will have to be replaced.

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4. APPENDIX A
4.1 Installation Drawings

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4.1 Installation Drawings (continued):

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5. APPENDIX B
5.1