King-Gage LevelPRO 5252-21 Series User manual

®
KING-GAGE
KING ENGINEERING CORPORATION
Effective: March. 1998 (replaces January, 1998) EX-1803
LevelPRO
™
Multiple Tank Level Processor
Installation and Operations
Manual
Models:
• 5252-21-xx
• 5252-31-xx
789
456
1 2 3
0.
Menu
Select
Edit
Enter
Reset
GALS
1.019
9982
TANK 1

Page 2
The information contained in this manual was accurate
at the time of release. Specifications are subject to
change without notice.
Warranty - All King Engineering products are
guaranteed to be free from defects in material and
workmanship for one year from the date of purchase.
Any product or part found to be defective under normal
use within one year of purchase will be repaired or
replaced at no charge if returned to the company at
Ann Arbor, Michigan within ten days of discovery of
the defect. No other warranties, whether expressed,
implied or statutory, including the warranties of fitness
for a particular purpose or merchantability, are given by
this agreement. The exclusive remedy for nonconformity
of these goods shall be repair and/or replacement of
the nonconforming goods or parts.
LevelPRO - Multiple Tank Level Processor EX-1803
Seller will not be liable for consequential damages
resulting from breach of this agreement. The term
“consequential damages” shall include but shall not
be limited to damage to all machines, equipment and
goods other than the goods sold hereby, interruption
of production, loss of profits, delays of any kind,
administrative expense and overhead.
©1997 King Engineering Corporation. All rights reserved.
®KING-GAGE and the KE emblem are registered trademarks and
LevelPRO is a trademark of King Engineering Corporation,
Ann Arbor, Michigan, U.S.A.
Specifications subject to change without notice.
Revisions:
(A) January, 1997 – Original Release
(B) July, 1997 – Revised with LED status and
communications sample response
(C) January, 1998 - 734 Area Code update
(D) March, 1998 - LevelPRO response (pg 12)

Page 3
LevelPRO - Multiple Tank Level Processor EX-1803
Table of Contents
Tank Level Status Display ....................................................................................................................page 4
Specifications — Model 5252-21-xx ...................................................................................................page 5
Specifications — Model 5252-31-xx ...................................................................................................page 6
Installation Requirements ....................................................................................................................page 8
Installing Updated Datapack (SRAM)................................................................................................... page 9
Using the Operator Interface Keypad ..................................................................................................page 10
Troubleshooting Checklist ...................................................................................................................page 12
Network Communications (RS-485) ....................................................................................................page 13
Addendum; Communications Specifications and Protocol ................................................................... page 14

Page 4
KING-GAGE LevelPRO™Multiple Tank
Level Processor
LevelPRO Processors provide continuous measurement of
liquid inventory in storage or processing tanks. They
calculate level on the basis of hydrostatic pressure
created by liquid depth in the tank. This pressure is the
result of both depth and density (specific gravity).
Specific gravity can be entered into the LevelPRO system
through the user keypad.
The LevelPRO Tank Processor expresses output directly in
engineering units. The processor references a capacity
profile to correlate transmitter output to actual tank
geometry. The processor then formats the resulting value
directly as the total weight or volume of liquid in the
tank. As an operator interface, the keypad provides
access to function selection and data entry. Unlike digital
panel meters, there are no user conversion factors
involved or scaling points to enter. All application details
have been factory programmed into SRAM.
LevelPRO - Multiple Tank Level Processor EX-1803
Input Requirements
LevelPRO Tank Level Processor accepts standard propor-
tional 4-20 mA output from the liquid level transmitter.
The sensor used to detect hydrostatic pressure (created
by liquid depth) can be either electronic or pneumatic.
With the latter, an electronic pressure transmitter is used
to convert the sensor’s pneumatic signal into a 4-20 mA
output. This can be done with a KING-GAGE®D/P
Module or D/P Transmitter.
Pneumatic
Sensor
D/P
Module
4-20 mA
Signal
4-20 mA
Signal
Electronic
4-20 mA Sensor
KING-GAGE
KINGENGINEERING CORPORATION
7 8 9
4 5 6
1 2 3
0 .
Menu
Select
Edit
Enter
Reset
GALS
1.109
KING-GAGE
KINGENGINEERING CORPORATION
7 8 9
4 5 6
1 2 3
0 .
Menu
Select
Edit
Enter
Reset
9982
TANK12
GALS
1.109
9982
TANK12
LevelPRO
LevelPRO
Detail - 4-20 mA Input
Detail - Pneumatic Sensor
Tank Level Status Display
A two line alphanumeric LCD readout provides tank level
indication including the unit of measurement (gals, lbs,
ltrs, kgs). The second status line identifies the tank by
name up to 10 characters/spaces in length. Level can be
represented by up to an 8-digit value to allow direct
weight indication for even extremely large tanks (see
detail below).
Detail - Tank Level Status Display
Tank
Name
9982
TANK 1
GALS
1.019
F
Amount
(0-99999999)
Density
(Sp. Gravity)
Units
(LBS, GALS, %, etc.)
Status
F = Full
R= Reserve (or empty)
C= Calibration Mode

Page 5
4.9375 in.
125 mm
9.5 in
241 mm
8.75 in
222 mm
7.3125 in
186 mm
1/2 in.
NPT-F
4.00 in
102 mm
.3125 in. DIA
8 mm (4 pls)
®
KING-GAGE
KING ENGINEERING CORPORATION
9982
TANK 1
GALS
1.019
789
456
123
0 .
Menu
Select
Edit
Enter
Reset
Specifications - 5252-21-xx
Power Requirements
115 Vac, 50/60 Hz., 0.5 Amp, source
grounded. Power consumption 40 watts
max.
Signal input
4-20 mAdc
Input Channels
Eight (8) two wire channel inputs
Memory
SRAM, 8k x 8, 100 ns
Input Impedance
120 Ohm nominal resistance (2.4 Vdc
drop @ 20 mAdc)
Power Output
24 Vdc excitation available at +Signal
terminal, 0.5 Amp max.
Readout
Alphanumeric 0.3173 in. (8 mm)
16-character x 2-line LCD;
numeric 8-digit (0-9999999 maximum).
Resolution
0.024% FS (0.004 mA)
Accuracy
0.048% FS (0.024% FS typical)
Keypad
Membrane numeric keypad, five (5)
function keys, positive tactile response
Temperature Range
30F to 120F / -1C to 49C (operating
environment)
Communications
RS-485; two-wire, multi- drop
RS-422; point to point, two-wire,
half-duplex communication
Housing
Model 5252-21-xx - Fiberglass-
reinforced polyester (FRP) enclosure; U.L.
listed (U.L. 508) types 3, 3R, 3S, 4, 4X and
12. Hinged cover with dual latching
screws.
Bottom View - Model 5252-21-xx
Front View - Model 5252-21-xx
LevelPRO - Multiple Tank Level Processor EX-1803

Page 6
LevelPRO - Multiple Tank Level Processor EX-1803
78 9
4 5 6
1 2 3
0 .
Menu
Select
Edit
Enter
Reset
®
®
KING-GAGE
KING ENGINEERING CORPORATION
6 in.
152 mm
10-3/4 in.
273 mm
8-15/16 in.
227 mm
5/16 in.
Dia., typ.
11-1/2 in.
292 mm
9982
TANK 1
GALS
1.019
1-3/4 in.
44 mm
1-3/4 in.
44 mm
4-3/8 in.
111 mm
1/2 in.
NPT
Front View - Model 5252-31-xx
Bottom View - Model 5252-31-xx
Specifications - 5252-31-xx
Power Requirements
115 Vac, 50/60 Hz., 0.5 Amp, source
grounded. Power consumption 40 watts
max.
Signal input
4-20 mAdc
Input Channels
Eight (8) two wire channel inputs
Memory
SRAM, 8k x 8, 100 ns
Input Impedance
120 Ohm nominal resistance (2.4 Vdc
drop @ 20 mAdc)
Power Output
24 Vdc excitation available at +Signal
terminal, 0.5 Amp max.
Readout
Alphanumeric 0.3173 in. (8 mm)
16-character x 2-line LCD;
numeric 8-digit (0-9999999 maximum).
Resolution
0.024% FS (0.004 mA)
Accuracy
0.048% FS (0.024% FS typical)
Keypad
Membrane numeric keypad, five (5)
function keys, positive tactile response
Temperature Range
30F to 120F / -1C to 49C (operating
environment)
Communications
RS-485; two-wire, multi- drop
RS-422; point to point, two-wire,
half-duplex communication
Housing
Model 5252-31-xx - 14 gauge stainless
steel enclosure; U.L. listed (U.L. 50) types
4, 4X, 12 and 13. Hinged cover with dual
latching screws and clamps.

Page 7
CAUTION 120 VAC
SPARE FUSE
123456789
TMP
+-
CH 8
TMP
+-
CH 1
TMP
+-
CH 7
TMP
+-
CH 6
TMP
+-
CH 5
TMP
+-
CH 4
TMP
+-
CH 3
TMP
+-
CH 2
2
5
2
1
3
4
Tank
Select
Board
(upper)
Processor
Board
(middle)
Power
Supply Bd.
(lower)
D000015
<-- PIN ONE
LevelPRO - Multiple Tank Level Processor EX-1803
Internal User Details:
1. Datapack (SRAM)
2. 1/2 Amp Fuse - 120/250
Volt Fast-Blo Order No.
7469-21-0 (5-pack)
3. Terminal, Power/
Communication
4. Terminal, Signal Input
5. Status LEDs
Signal Input
Terminal
123
1 – +
2 – -
3 – TMP
4-20 mA
Signal
Power
Communications
Terminal
123456789
1 – N/C
2 – N/C
3 – A
4 – B
5 – Shield
6 – N/C
7 – HOT
8 – NEU
9 – GND
RS485
/422
115 Vac
Status LED
Indicators
Power
(Green)
Transmit
(Amber)
Receive
(Red)

Page 8
LevelPRO - Multiple Tank Level Processor EX-1803
Installation Requirements
Mounting -
The LevelPRO Processor may be mounted at the tank, or
up to several thousand feet away. It is important to find
a mounting location that affords some degree of
protection for the unit. Do not locate where sub-freezing
temperatures may be encountered.
Enclosure should be mounted in an upright position to a
wall or other structural member. Cabling access ports are
1/2" NPT and intended for conduit or water-tight cable
connectors. Keep unused connections sealed to maintain
enclosure integrity. When locating enclosure, maintain
adequate clearance for access to bottom connections.
Signal Input and Electrical Connections
We recommend completing the transmitter input signal
(4-20 mA) connections prior to AC power, when practi-
cal. Use approved 3-conductor, source grounded power
cable for 115 Vac connections.
Transmitter Signal Loop
Typical transmitter provides a 4-20 mA output over a
dc-powered two wire current loop circuit. This normally
requires at least a 24 Vdc power source to provide
excitation voltage to the transmitter. The power require-
ments should be calculated to accommodate the total
resistive load residing on the circuit (e.g., cabling imped-
ance, input impedance of receivers, etc.). Refer to the
specific load capacity specifications for the sensor or
transmitter being used.
Recommended Signal Cabling
Shielded twisted pair (two conductor) cable should be
used for routing the output signal from the transmitter
to the LevelPRO Tank Level Processor. Avoid cable
placement along multi-phase power lines or equipment
that generates strong EMI/RFI fields.
(Two Conductor) Shielded Cable
Recommended: 20 AWG shielded cable (Belden 9320
or equivalent)
123456789
1 – N/C
2 – N/C
3 – A
4 – B
5 – Shield
6 – N/C
7 – HOT
8 – NEU
9 – GND
RS485
/422
115 Vac
123
1 – +
2 – -
3 – TMP
4-20 mA
Signal
Signal Input Terminal
Power/ Communications
Terminal
TMP
+
-
123
Transmitter
+-
4-20 mA
+24V
Detail - Onboard 24 Vdc Output

Page 9
Application Programming (Datapack)
The LevelPRO Tank Processor expresses output directly
in engineering units. The processor references a capacity
profile to correlate transmitter output to actual tank
geometry. The processor then displays the resulting
value directly as the total weight or volume of liquid in
the tank. All application details are factory programmed
into SRAM.
Referred to as the Application Datapack, this SRAM
memory contains a default liquid density value, readout
units factor and tank name. In addition to battery
backup, critical data such as the capacity profile are not
user-addressable to prevent any possible corruption of
the original factory programming.
Editing Specific Gravity Value: This avoids the need
to re-range the level transmitter when the tank is used
for more than one liquid product density. The operator
interface keypad permits direct editing of the current
specific gravity corresponding to the tank contents
(see page 11). Another method uses the external
communications link and ASCII command protocol
(see Addendum), to change specific gravity value
from a remote terminal or PLC.
Installing Updated Datapack (SRAM)
Non-addressable application parameters (i.e., tank
name, network polling address, tank capacity profile)
require updated datapack programmed at the factory.
Use caution when accessing the
datapack — internal
circuitry and electrical
connections should
not be exposed to
moisture. Turn off
power to unit prior to
handling internal
components.
Turn off power or
open the enclosure
and disconnect the
plug-in terminal
connector. Datapack
(SRAM) is readily
accessible at the lower
left hand corner of the
lower circuit card.
Detail - Datapack location
A. To remove datapack, lift up on locking lever (see
illustration) on zero insertion force (ZIF) socket.
Remove datapack.
B. To install datapack, insert datapack carefully into
socket. Push locking lever down and forward to lock
datapack within socket.
D000015
<-- PIN ONE
Pin 1
Important! Datapack (SRAM) must be oriented so that
PIN 1 lines up with socket. The <-- symbol on label
designates PIN 1 side. Refer to illustration above.
LevelPRO - Multiple Tank Level Processor EX-1803
Pin 1
(Zif Socket)
Pin 1
Datapack
(SRAM)
Locking
Lever
D000015
<-- PIN ONE

Page 10
LevelPRO - Multiple Tank Level Processor EX-1803
LevelPRO Keypad Operator Interface
Data entry (specific gravity values) or alternate readout
unit selections can be performed through the keypad at
the LevelPRO Multiple Tank processor.
78 9
4 5 6
1 2 3
0 .
Menu
Select
Edit
Enter
Reset
®
®
KING-GAGE
KING ENGINEERING CORPORATION
9982
TANK 1
GALS
1.019
Detail - LevelPRO™Keypad
Menu Display Modes
41420 GALS
TANK ST1 1.000
MENU
SP.GRAVITY
TANK ST1 1.000
MENU
UNITS GALS
TANK ST1
MENU
CALIBRATION
OFF
MENU
41420 GALS
TANK ST1 1.000
Scanning Tank Channels
To view each tank sequentially by its channel assignment
(1-8) merely press SELECT. Repeat to view the next
channel and so on through all the active channels.
19990 GALS
TANK ST1 1.000
SELECT
855 GALS
TANK ST2 1.032
SELECT
11120 GALS
TANK ST3 1.012
SELECT
100 GALS
TANK ST4 1.028
SELECT
35870 GALS
TANK ST5 1.008
Direct Access Tank Selection
For direct or random access, enter the channel number
(1-8) on the keypad. While viewing a selected tank level,
press 5to go directly to the tank level display corre-
sponding to channel #5. Next, press 8to view tank level
display corresponding to channel #8.
19990 GALS
TANK ST1 1.000
5
35870 GALS
TANK ST5 1.008
8
61565 GALS
TANK 8 1.023
3
11120 GALS
TANK ST3 1.012

Page 11
LevelPRO - Multiple Tank Level Processor EX-1803
Specific Gravity Editing
Specific gravity can be entered directly through the user
keypad. Press MENU to access the “SP.GRAVITY” value
and then EDIT. Now merely enter the 4-digit number
directly (the decimal point is a fixed place holder). Press
ENTER to accept the new value and return to the tank
level display.
Selecting Display Units
To change the readout units, use the keypad at the Main
Processor. Press the MENU key. “SP.GRAVITY” appears
on the display. Press the MENU key again for the
“UNITS” display. Then use the SELECT key to sequence
through the readout units selections. When the desired
readout unit is displayed, press the ENTER key to accept
the selection.
41420 GALS
TANK ST1 1.000
MENU
SP. GRAVITY
TANK ST1 1.000
MENU
UNITS GALS
TANK ST1
SELECT
UNITS %
TANK ST1
SELECT
UNITS LBS
TANK ST1
ENTER
345029 LBS
TANK ST1 1.000
41420 GALS
TANK ST1 1.000
MENU
SP.GRAVITY
TANK ST1 1.000
EDIT
SP.GRAVITY
1 TANK ST1 1.000
0 1.000
3 1.030
3 1.033
ENTER 40097 GALS
TANK ST1 1.033
Entering Calibration Mode
The “calibration” mode sets the LevelPRO processor to
read directly in A/D counts (0-4096) corresponding to
the milliamp signal input value (4-20 mA). This may be
used during troubleshooting.
41420 GALS
TANK ST1 1.000
MENU
SP. GRAVITY
TANK ST1 1.000
MENU
UNITS GALS
TANK ST1
MENU
CALIBRATION
OFF
SELECT
CALIBRATION
ON
ENTER
1029 C GALS
TANK ST1 1.000

Page 12
LevelPRO - Multiple Tank Level Processor EX-1803
Troubleshooting Checklist
Certain problems experienced during initial system
installation and start-up may result from incomplete
connections. Optimum performance will occur when
power and cabling recommendations are followed.
No Display
Unit does not appear to be functioning and nothing
appears on the LCD panel.
•Press “Reset” button on keypad.
•Make certain that Tank Processor is connected to
115 Vac power source.
•Check internal fuse(s) on internal board set of
Tank Processor and replace if necessary.
Low Reading
Level value being displayed is inaccurately low, or does
not rise when level increases.
•Press “Reset” button on keypad.
• Check sensor/transmitter output (if necessary, check
zero and span settings).
• Signal connections are reversed at the tank processor
input terminals or were reversed at the transmitter
terminals.
•Resistive load on signal loop exceeds capacity of
transmitter at the supplied 24 Vdc excitation from
the Tank Processor.
•If Datapack (SRAM) is missing or has been removed,
unit will default to “calibration” mode. Unit will only
display A/D counts (0-4096) and the "C" status
indicator will appear in the top line.
High Reading
Level value being displayed is inaccurately high.
•Check sensor/transmitter output (if necessary,
check zero and span settings).
•Check that tank vent is open. (Rapid fill rate may
sometimes exceed venting capacity creating internal
pressure in the tank.)
•Specific gravity of liquid in tank may be greater
than that programmed into tank processor Datapack
(PROM). Check that the specific gravity value (lower
right hand corner) being displayed for that tank is
correct. Use keypad to enter corrected value if
necessary.
Communications Troubleshooting
Using LED Status Indicators
GREEN On = Power is On
GREEN Off = Power is Off
The green LED is illuminated when power is supplied
to the unit. If the green LED is not lit, check that the
external power supply is connected to unit. (Internal
fuse may also be blown.)
AMBER On (Blinking) = Data Transmit
AMBER Off = Not Transmitting
The amber LED is illuminated during each data pulse
transmission. During normal operation, the LED will
be blinking on/off in combination with the red (receive)
LED. If the receive (red) LED is functioning but there is
no indication from the amber LED, unit may have an
internal component failure.
RED On (Blinking) = Data Received
RED Off = No Data Received
RED Always On = RS-485 A + B Line Reversed
The red LED is illuminated in response to each data
pulse received. During normal operation, the LED will be
blinking on/off in combination with the amber (transmit)
LED. If there is no indication from the red LED, there
may be a problem with the data format from the host.
If the red LED is continuously illuminated, this indicates
a crossed connection between the A + B sides of the
RS-485 two wire interface (try reversing the A + B
connections at the LevelPRO).
POWER (GREEN)
TRANSMIT (AMBER)
RECEIVE (RED)

Page 13
LevelPRO - Multiple Tank Level Processor EX-1803
Communications Interface -
Network Systems
Network Communications (RS-485)
LevelPRO tank processors can provide direct ASCII
communications via a two wire multi-drop network
interface. Recommended communications cable is
Belden 9501 (24 AWG twisted pair stranded conductors,
copper drain wire, overall shielding).
Connections are provided on the plug in terminal for A,
B and SH (shield). Refer to the RS-485 diagram for
proper cabling connections. Up to 32 individual
LevelPRO devices can be installed on a multi-drop
network.
Preliminary Network Communications
Troubleshooting
These are only a few possible causes of communications
problems. Also, consult available reference materials for
the host or receiver (i.e., PLC or PC) that is being used to
communicate with the LevelPRO devices.
No Communications
Loss of communications to all devices in the network.
•Check connections at RS-485 terminals at each
device. If one processor has been disconnected from
the network, make certain that cabling has continuity.
• Check that power is being supplied to the LevelPRO
processors. There will be no communications if
individual devices suffer loss of power.
No Communications Response (Individual)
Failure of queried polling address device to respond with
communications
•Check that power is supplied to the LevelPRO
processor. Additionally, check internal power supply
fuse, replace if necessary.
•Check communications connections at RS-485
terminals. If cable conductors have been reversed,
unit will not be able to communicate. Make certain
that A, B, SHD (shield) continuity has been
maintained.
•Possible incorrect polling address. 3-digit ASCII
address value must correspond to polling address
programmed in datapack (SRAM) of LevelPRO.
ABGND ABGND ABGND
LevelPRO LevelPRO Host
Detail - RS-485 diagram
123456789
Shield (Drain Wire)
B (Black Wire)
A (Red Wire)

Page 14
LevelPRO - Multiple Tank Level Processor EX-1803
King Bus ASCII Communications
Communications Technical Specifications:
•Two wire half-duplex with isolated ground
•Automatic signal level shifting for point-to-point
(RS-422) and multi-drop (RS-485).
•ASCII character transmission formatted as (0) start
bit, (8) data bits and (1) stop bit.
• Standard baud rate up to 19.2 kbps.
Host Polling Protocol
The host device must query LevelPRO processors to
receive level data and/or to change specific gravity
values. The query should be configured using the
following ASCII code formats.
Request Level Data:
#NNN*
#= Beginning character, first character sent ($23 Hex)
NNN = 3 character ASCII polling address, 001-256
*= Terminating character, last character sent ($2A
Hex)
Change Specific Gravity:
#NNN_S.SSS*
#= Beginning character, first character sent ($23 Hex)
NNN = 3 character ASCII polling address, 001-256
_= Space character ($20 Hex)
S.SSS = 5 character specific gravity includes decimal
($2E Hex) character
*= Terminating character, last character sent ($2A
Hex)
LevelPRO Response Format
Communications output from individual processor in
response to query by host.
31 Character Response:
NNN_S.SSS_XLLLLLLLL_UUUU_CCCC<CR><LF>
NNN = 3 character ASCII polling address, 001-256
_= Space character ($20 Hex)
S.SSS = 5 character specific gravity includes decimal
($2E Hex) character
_= Space character ($20 Hex)
X= Status code; B (blank), F (full), R (reserve/empty),
C (calibration mode)
LLLLLLLL = 8 character level value, leading zeros
required if applicable
_= Space character ($20 Hex)
UUUU = 4 character units abbreviation/code in the
form, GALS
_= Space character ($20 Hex)
CCCC = Check sum in ASCII representation of a
2-byte number in the form, 0FE5
<CR> = Carriage return ($0D Hex)
<LF> = Line feed ($0A Hex)
Sample Response:
001_1.032_B00023900_GALS_04DC<CR><LF>
Checksum does not include the last space character
($20), carriage return ($0D), line feed ($0A) or the
checksum value itself.
The actual hex data transmission:
$30 $30 $31 $20 $31 $2E $30 $33 $32 $20 $42 $30
$30 $30 $32 $33 $39 $30 $30 $20 $47 $41 $4C $53
$20 $30 $35 $34 $33 $0D $0A
(Underlined values are not added to the preceding bytes
to create the checksum.)
The King Bus ASCII protocol is used by LevelPRO
processors having the KINGCODE.HEX
microcontroller code. These units are designated by
serial numbers beginning with the letter D.
For LevelPRO processors that employ MODBUS
compatible communications, refer to EX-1803-2
protocol manual. Units designated by serial num-
bers beginning with the letter M have the
KINGMBUS microcontroller code.