Kobold PAD User manual

Operating Instructions
for
Smart Pressure Transmitter
Model: PAD

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1. Contents
1. Contents........................................................................................................2
2. Introduction ...................................................................................................4
2.1 Using This Manual ...............................................................................4
2.2 Overview of Transmitter.......................................................................5
2.3 Software Compatibility .........................................................................5
2.4 Transmitter Components .....................................................................6
3. Handling Cautions.......................................................................................10
3.1 Unpacking..........................................................................................11
3.2 Models and Specifications Check ......................................................11
3.3 Storage ..............................................................................................11
3.4 Selecting the Installation Locations....................................................12
3.5 Performing Sensor Zero Trim after Installation ..................................12
3.6 Pressure Connections........................................................................13
3.7 Waterproofing of Cable Conduit Connections....................................13
3.8 Restrictions on Use of Radio Transceivers ........................................13
3.9 Insulation Resistance Test and Dielectric Strength Test....................14
3.10 Installation of Explosion Protected Type Transmitters .......................15
3.11 EMC Conformity Standards ...............................................................16
4. Transmitter Functions .................................................................................16
4.1 Overview............................................................................................16
4.2 Safety Message .................................................................................16
4.3 Warning .............................................................................................17
4.4 Fail Mode Alarm.................................................................................17
4.5 EEProm-Write Enable / Disable Mode Switch ...................................19
4.6 Configuration of Alarm and Security Jumper Procedures ..................20
4.7 Configuration Using Zero and Span Push Buttons ............................20
4.8 Additional Functions (valid for PAD-F only) .......................................31
4.9 Wiring Connections for External HHT/ Ammeter................................38
5. Installation...................................................................................................39
5.1 Overview............................................................................................39
5.2 Safety Message .................................................................................39
5.3 Warning .............................................................................................40
5.4 Commissioning on the bench with Hand-Held Terminal ....................41
5.5 General Considerations .....................................................................42
5.6 Electrical Considerations ...................................................................42
5.7 Wiring.................................................................................................43
5.8 Mechanical Considerations................................................................49
5.9 Environmental Considerations ...........................................................51
6. On-line Operation........................................................................................52
6.1 Overview............................................................................................52
6.2 Safety Message .................................................................................52
6.3 Configuration Data Review ................................................................52
6.4 Check Output.....................................................................................53
6.5 Basic Setup........................................................................................53
6.6 Detailed Setup ...................................................................................54
6.7 Tag Information set up.......................................................................54
6.8 Diagnostics and Services...................................................................55

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6.9 Calibration ......................................................................................... 55
6.10 Advance Set Up:................................................................................ 56
7. Maintenance ............................................................................................... 57
7.1 Overview............................................................................................ 57
7.2 Safety Message................................................................................. 57
7.3 Hardware Diagnostics........................................................................ 58
7.4 Hardware Maintenance...................................................................... 59
8. Appendix I ................................................................................................... 63
9. Declaration of Conformance ....................................................................... 65
10. ATEX Certificate ......................................................................................... 66
Manufactured and sold by:
Kobold Messring GmbH
Nordring 22-24
D-65719 Hofheim
Tel.: [phone]
Fax: [phone]
E-Mail: [email protected]
Internet: www.kobold.com

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2. Introduction
The PAD Smart Pressure Transmitter is correctly calibrated at the factory before
shipment. To ensure correct and efficient use of the instrument, please read this
manual thoroughly and fully understand how to operate the instrument before
operating it
(1) The contents of this manual are subject to change without prior notice.
(2) All rights reserved. No part of this manual may be reproduced in any form
without Kobold Messring’s written permission.
(3) If any question arises or errors are found, or if any information is missing from
this manual, please inform the nearest sales office.
(4) The specifications covered by this manual are limited to those for the
standard type under the specified model number break-down and do not
cover custom-made instrument.
(5) Please note that changes in the specifications, construction, or component
parts of the instrument may not immediately be reflected in this manual at the
time of change, provided that postponement of revisions will not cause
difficulty to the user from a functional of performance standpoint.
2.1 Using This Manual
The Chapters in this operating manual provide information on installing,
operating, and maintaining devices from KOBOLD Model PAD Smart Pressure
Transmitter. Chapters within this manual are organised as follows.
Chapter 3 Handling
Chapter 3 provides instructions on software functions, configuration parameters,
and online variables.
Chapter 4 Transmitter Functions
Chapter 4 contains instructions for configuring and commissioning Model PAD
Smart Pressure Transmitters.
Chapter 5 Installation
Chapter 5 contains mechanical, environment and electrical installation
instructions for Model PAD Smart Pressure Transmitters.

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Chapter 6 On-line Operation
Chapter 6 describes the configuration process and how to use basic and
advanced Model PAD Smart Pressure Transmitter software functions during
configuration.
Included in these sections are details on using:-.
(1) Sensor or Output Trim
(2) Changing range configuration, Output Type, Damping, measurement units
etc.
(3) Change of general data such as Tag No. Date, Message etc.
Chapter 7 Maintenance
Chapter 7 contains hardware diagnostics, troubleshooting and maintenance
tasks.
Appendix I : List of Error Codes available on LCD display
2.2 Overview of Transmitter
Kobold Smart Pressure Transmitter are microprocessor based “smart” pressure
transmitters. It uses a piezoelectric/ capacitance pickup optimised & accurately
characterised with a patented temperature compensation algorithm for high
precision & long term stable gauge and absolute pressure measurements over a
wide range of operating conditions. PAD is a two wire loop power transmitter and
has a standard 4/20mA output scaled for desired output pressure range. In
addition it also offers digital HART® (digital signal superimposed over the
analogue output) communication that allows transmitting additional digital
parameters/diagnostic information for advanced control systems like DCS, PLC.
This transmitter can be configured remotely via HART® communication through a
HHT (HART® Hand-Held Terminal using DDL or DOF technology) or any HART®
enabled PC configurator. This allows critical variables to be changed, configured
and tested remotely by users. Note: For HART® Communication a minimum
250~500 Ohm loop resistance is mandatory between power supply and
transmitter.
2.3 Software Compatibility
KOBOLD Smart Pressure Transmitters are shipped from the factory with the
most up to date firmware. However as product developments and new features
are released a firmware update becomes necessary to incorporate these new
changes. As such transmitters with older firmware may restrict certain functions
when communicating with an external HHT(Model 275/375HART®
Communicator). There may also be some differences on supported functions on
the local push button menu based on the installed firmware revision of the
transmitter. This manual is based on firmware Revision 6.3. Function deviations
as to firmware Revision are same as in table below:

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FUNCTION
Function Supports
ZERO / SPAN Button PC/UMPC HART
275/375
Version 6.3 or above
ZERO/SPAN !!!
ZERO TRIM !!!
ZERO Adj !!!
Units set !!!
Range set !!!
Damping set !!!
LCD Decimal set !!"
LCD Mode !!"
!: Supported.
": Supported but update required
2.4 Transmitter Components
The various components of PAD Series Smart Pressure Transmitter are shown
below:
Figure 2-1. Model PAD Transmitter Exposed View (Housing)

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Figure 2-2. TRANSMITTER COMPONENTS (HOUSING)

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Figure 2-3. Model PAD Exploded View (Sensor Module-D,G)
Figure 2-4. TRANSMITTER COMPONENTS (SENSOR MODULE -D, G)

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Figure 2-5. Model PAD Exploded View (Sensor Module-H)
Figure 2-6. TRANSMITTER COMPONENTS (SENSOR MODULE -H)

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3. Handling Cautions
This chapter consists of cautions for transmitter handling and storage, selection of
installation locations, insulation structure, etc.
[Quick Reference Manual]
Step Job Job Details Instrument
1 Unpacking -Unpack transmitter packing
2
Model and
Specifications
Check
-Make sure whether the delivered transmitter is same
as options attached on its nameplate Nameplate
3 Storage
-Places not exposed to water, non-vibration and non-
impact area
-Ambient temperature 25 deg C and relative humidity
65 % RH
4 Calibration Bench
-Configuration of Range, Zero/Span, Unit, Tag,
Damping Time, Transfer Function, DA Trim and other
parameters
- HHT
- Pressure Source
- Galvanometer
5 Installation
Locations
-Where ambient temperature is not fluctuated
-Where no corrosion happens by chemical materials,
etc.
-Where vibration and impact is not severe
-Where maintenance is very easy
(Engineering)
6 Mechanical
Considerations
-Where transmitter can be handled easily
-Be cautious of the pressure leaks (Engineering)
7 Electrical
Considerations
-Connect 24 VDC
(Recommended Power Supply is 11.9 VDC – 45 VDC)
-For HART communication, total resistance on
transmitter terminal loop should be 250 – 550 Ohm.
(Engineering)
8 Mounting and
Installation
-For mounting transmitter, an appropriate bracket
should be used.
-Transmitter should be firmly to its bracket.
(Mounting and
Installation)
9 Calibration on
Spot
-Sensor Zero Trim is highly recommended during first
installation and start-up. During a Zero trim the zero
baseline of transmitter is established.
-Before initiating zero trim make sure that PV value of
transmitter is zero and current output is at 4 mA
HHT or
Zero/Span button
10 Pressure
-Do not apply the differential and/or full line pressure
suddently.
-Close equalizing valve of 3/5 valve manifold, then,
open stop valve on high and low side slowly and
simultaneously.
(Applying
pressure)
11 Operation - Make sure that transmitter operates within specs. Visual or HHT

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3.1 Unpacking
When moving the transmitter to the installation site, transfer it in its original
packaging. Only unpack the transmitter on site of installation to avoid damage
during transit.
3.2 Models and Specifications Check
The model name and specifications are indicated on the top name plate fixed to
the transmitters. Please check your specification and model supplied for your
installation.
3.3 Storage
The following precautions must be observed when storing the instrument,
especially for a long period.
(1) Select a storage area that meets the following conditions:
(a) It is not directly exposed to rain, water, snow or sun light.
(b) It is exposed to minimum vibration and shock.
(c) If possible, it is advisable to store at normal temperature and humidity
(approx. 25 °C, 65 % RH).
However, it can also be stored under ambient temperature and relative humidity
within the following published ranges.
•Ambient Temperature: -40 ~ 80 °C (with LCD module) *
* General use only. For explosion proof versions follow product certification
requirements.
•Relative Humidity: 5 % ~ 98 % RH (at 40 °C)
(2) When storing the transmitter, repack with original (or similar) packaging that
was shipped from the factory.
(3) If storing a transmitter that has already been used, thoroughly clean all wetted
parts including diaphragm seals (if installed), process connections/manifolds
in contact with process fluid. In addition, make sure before storing the
transmitter that remote seal (if supplied) assemblies are securely mounted.

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3.4 Selecting the Installation Locations
The transmitter is designed to withstand severe environmental conditions.
However, to ensure stable and accurate operation for many years, the following
precautions must be observed when selecting an installation location.
(1) Ambient Temperature
Avoid locations subject to wide temperature variations or a significant
temperature gradient. If the location is exposed to radiant heat from plant
equipment, provide adequate insulation or ventilation.
(2) Ambient Atmosphere
Avoid installing the transmitter in a corrosive atmosphere. If the transmitter
must be installed in a corrosive atmosphere, there must be adequate
ventilation as well as measures to prevent intrusion or stagnation of rainwater
in conduits. Moreover, there should be appropriate ventilation preventing
corrosion by rain gathered on conduit.
(3) Shock and Vibration
Select an installation site suffering minimum shock and vibration (although
the transmitter is designed to be relatively resistant to shock and vibration)
(4) Accessibility
Select location that provides easy access for maintenance & calibration.
(5) Installation of Explosion Protected Transmitters.
Explosion – protected transmitters can be installed in hazardous areas
according to gas types for which they are certified.
3.5 Performing Sensor Zero Trim after Installation
(1) Sensor Zero Trim should be done after transmitter is installed because zero
point can shift due to mounting status of the sensor pick up.
(2) For Sensor Zero Trim, make input pressure of transmitter zero prior to
initiating zero trim calibration. Any Sensor Trim done in field must be carried
out after installation is finalized and with transmitter position fixed. Also if
applying external pressure ensure the display is sufficiently stabilized (after
approximately 10 to 15 seconds) before initiating any Trim function.
(3) There are two recommendations for making input pressure “zero”. One is to
apply a “zero” pressure source (mandatory for absolute pressure models).
The second option is to open equalizing valve of manifolds and venting to
atmospheric pressure (allowed only for Gauge type models).
(4) Sensor Zero Trim can be performed using an external HHC (Hand held
calibrator), PC or PDA configurator, and/ or using Zero/Span local push
buttons provided on the transmitter.
(5) When using local push buttons please refer to Chapter 4.7 of this manuals for
detailed instructions. If using an external HHT or HART® PC configurator
please refer to the user manuals supplied by the third party supplier.

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3.6 Pressure Connections
The following precautions must be observed in order to safely operate the
transmitter under pressure.
(1) Never apply a pressure higher than the maximum working pressure specified
on the nameplate.
(2) Use adequate seals for leak tight process connections and use only quality
and standardized parts.
(3) Regularly inspect for signs of leakage and apply corrective actions when
necessary.
3.7 Waterproofing of Cable Conduit Connections
Apply a non-hardening sealant (silicone or tape, etc.) to the threads to waterproof
the transmitter cable conduit connections.
3.8 Restrictions on Use of Radio Transceivers
#Warning
•Although the transmitter has been designed to resist high frequency
electrical noise, if a radio transceiver is used near the transmitter or its
external wiring, the transmitter may be affected by high frequency noise
pickup. To test for such effects, bring the transceiver in use slowly from a
distance of several meters from the transmitter, and observe the
measurement loop for noise effects. Thereafter, always use the transceiver
outside the area affected by noise.
#Warning
•Instrument installed in the process is under pressure. Never loosen or
tighten the flange bolts as it may cause dangerous spouting of process fluid.
•If the accumulated process fluid may be toxic or otherwise harmful, take
appropriate care to avoid contact with the body or inhalation of vapours
even after dismounting the instrument from process line for maintenance.

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3.9 Insulation Resistance Test and Dielectric Strength Test
Since the transmitter has undergone insulation resistance and dielectric strength
tests at the factory before shipment, normally these tests are not required.
However, if required, observe the following precautions in the test procedures.
(1) Do not perform such tests more frequently than is absolutely necessary. Even
test voltages that do not cause visible damage to the insulation may degrade
the insulation and reduce safety margins.
(2) Never apply a voltage exceeding 500 VDC (100 VDC with an internal lightening
protector) for the insulation resistance test, nor a voltage exceeding 500 VAC
(100 VAC with an internal lighting protector) for the dielectric strength test.
(3) Before conducting these tests, disconnect all signal lines from the transmitter
terminals. Perform the tests in the following procedure.
(4) Insulation Resistance test
(a) Short-circuit the + and - SUPPLY terminals in the terminal box.
(b) Turn OFF the insulation tester. Then connect the insulation tester plus (+)
lead wire to the shorted SUPPLY terminals and the minus (-) lead wire to
the grounding terminal.
(c) Turn ON the insulation tester power and measure the insulation
resistance. The voltage should be applied as short as possible to verify
that insulation resistance is at least 20 M$.
(d) After completing the test and being very careful not to touch exposed
conductors disconnect the insulation tester and connect a 100K$resister
between the grounding terminal and the short-circuiting SUPPLY
terminals. Leave this resistor connected at least three second to
discharge any static potential. Do not touch the terminal while it is
discharging.
(5) Dielectric Strength Test
(a) Short-circuit the + and - SUPPLY terminals in the terminal box.
(b) Turn OFF the dielectric strength tester. Then connect the tester between
th shorted SUPPLY terminal and the grounding terminal. Be sure to
connect the grounding lead of the dielectric strength tester to the ground
terminal.
(c) Set the current limit on the dielectric strength tester to 10mA, then turn
ON the power and gradually increase the tester voltage from '0' to the
specified voltage.
(d) When the specified voltage is reached, hold it for one minute.
(e) After completing this test, slowly decrease the voltage to avoid any
voltage surges.

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3.10 Installation of Explosion Protected Type Transmitters
3.10.1 ATEX Certification
ATEX Certification number : KEMA 10ATEX0141 X
CE 0158 II 2 G
Note 1. Model PAD for potentially explosive atmosphere
•Ex d IIC T6 or T5
•Operating Temperature : -20℃%Tamb ≤+60°C
•T6 for process %85 °C;
•T5 for process %100 °C;
Note 2. Electrical Data
•Supply Voltage : 11.9…42 VDC
•Output Signal : 4 to 20 mA + HART
Note 3. Electrical Connection: see ordering table
Note 4. PAD ATEX Certification is according to the below standards
EN 60079-0 : 2006
EN 60079-1 : 2004
Note 5. Installation
•All wiring shall comply with local installation requirement.
•The cable glands and blanking elements shall be of a certified flameproof type,
suitable for the condition of use and correctly installed. Also those devices
should be endured at the 130°C.
•Housing Ground must be followed to “local electrical codes”. The most efficient
ground procedure is to connect directly to the earth as least impedance.
•How to Housing Ground:
•* Internal Ground Connection: Internal ground connection screw is located in
terminal in housing, the screw can be identified as ground sign.
•* External Ground Assembly: This is located in the right side of housing and
identified as ground sign. (For grounding use a cable lug)
•When use tubing, Stopping boxes must be connected with the wall of housing
directly.
•Tubing is installed a minimum of 5 threads.
•Sensor is to be threaded a minimum of 7 threads and prevented from turning
by tightening the housing rotation set screw.
•Do not disassemble flameproof Joints but in an unavoidable case to
disassemble it or need the specification of flameproof Joints, contact the
manufacturer before doing.

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Note 6. Operation
•WARNING-DO NOT OPEN WHEN AN EXPLOSIVE ATMOSPHERE MAY BE
PRESENT
•Take care not to generate mechanical spark when access to the instrument
and peripheral devices in hazardous location.
Note 7. Maintenance and Repair
•The instrument modification or parts replacement by other than authorized
representative of KOBOLD Messring GmbH is prohibited and will void
KEMA/ATEX Explosion-proof / Flame-proof.
3.11 EMC Conformity Standards
EMI (Emission): EN55011
EMS (Immunity): EN50082-2
Kobold Messring GmbH recommends customer to apply the Metal Conduit Wiring
or to use the twisted pair Shield Cable for signal wiring to conform the
requirement of EMC Regulation, when customer installs Kobold Series
Transmitters to the plant.
4. Transmitter Functions
4.1 Overview
This Chapter contains information on operating Model PAD. Tasks that should be
performed on the bench prior to installation are explained in this chapter.
4.2 Safety Message
Procedures and instructions in this chapter may require special precautions to
ensure the safety of the personal performing the operations. Information that
raises potential safety issues is indicated by warning symbol (#). Refer to the
following safety messages before performing an operation preceded by this
symbol.

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4.3 Warning
#Warning
Electrical can result in death serious injury:
!Avoid contact with the leads and terminals. High voltage that may be present
on leads can cause electrical shock.
#Warning
Electrical can result in death serious injury:
!Only qualified & trained personnel should be allowed to operate these
transmitters.
4.4 Fail Mode Alarm
Kobold Smart Pressure Transmitter automatically and continuously performs self-
diagnostic routines. If the self-diagnostic routines detect a failure, the transmitter
drives its output outside of the normal saturation values. The transmitter will drive
its output low (down) or high (up) based on the position of the failure mode alarm
jumper . See Table 4.1 for Output values.
[Table 4-1 Standard Alarm and Saturation Value]
Level 4~20 mA Saturation 4~20 mA Alarm
Low/Down 3.9 mA %3.75 mA
High/Up 20.8 mA &21.75 mA
Fail Mode Selection (Fail High/UP or Low/DOWN) can be configured using the
appropriate jumper switch provided on the LCD Module or DIP switches included
on the Main CPU Module. For units provided with a LCD module one can select
desired fail safe mode directly from the jumper switch included in the front display
and this setting overrides the DIP settings on the back-end Main CPU module,
provided the DIP switch “2” on CPU module is DOWN. If DIP switch “2” on CPU
module is UP, this setting overrides the jumper setting on LCD module. Default
setting from the factory is “Fail Down” (DIP Switch “2” on CPU Module is DOWN).
However in case of blind units please select your required DIP switch settings
from the DIP switch labelled (2) marked on the Main CPU board. Recommended
jumper & DIP settings are listed in the table below for ready reference.
Select Fail
Mode
Both LCD Module and CPU
Module
Only CPU
Module
CPU Module LCD Module CPU Module
Fail Down Down D D
Fail Up Down U U
Up U or D

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< Fail Mode Selection DIP Switch of CPU Module >
1. WR_EN (EEPROM Write Enable)
DOWN : ENABLE CONFIGURATION CHANGES
UP : DISABLE/ LOCK CONFIGURATION CHANGES
2. Fail Mode(Alarm)
DOWN : LOW
UP : HIGH
Note: DIP Switch (1) shown on Left in Fig 4-1 is for Write Enable/
Disable selection. DIP switch (2) shown on right in Fig 4-1 is for
Fail Mode.
(Figure 4-1. Fail Mode and EEPROM-Write Selection DIP Switch)
< Fail Mode Selection Jumper Switch of LCD Module >
U O O O U O O O D O O O D
(FAIL MODE DOWN,
place jumper to right)
FAIL MODE SELECT
(FAIL MODE UP,
place jumper to left)
Figure 4-2 Fail Mode Selection Jumper Switch of LCD Module
UP
DOWN

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4.5 EEProm-Write Enable / Disable Mode Switch
PAD includes an EEPROM (Electrically Erasable Programmable Read Only
Memory) that allows saving and restoring various configuration data within the
transmitter on power failure. To lock configuration and protect changes to stored
configuration data, one can use a HHC and or external HART® enabled PC
device to enable a software lock feature under Status menu. Optionally for
security lock on hardware side there is a Write-Protect Mode DIP Switch (1) on
the Main CPU Module placed right next to the Fail Safe Mode switch (2). If you
push DIP switch to UP you can lock out users from making any changes to
configuration data through push buttons and/ or remote HHC already saved in the
EEPROM. Alternatively when you push DIP Switch (1) to DOWN you can allow
changes made to configuration data in EEPROM. Default state from factory
(including with NO Jumpers) installed is EN (enable configuration changes).
Figure 4-3. CPU Module Fail Mode, EEPROM-Write Selection Jumper Switch
Note: DIP Switch (1) shown on Left in Fig 4-1 is for Write Enable/
Disable selection.
DIP switch (2) shown on right in Fig 4-1 is for Fail Mode.
4.5.1 Security
To quickly summarize there are three options available to implement
configuration security
lock out within the PAD. These include:
(1) DIP settings on CPU Board
(2) Software enable/ disable on Write function using HHT or HART® PC.
(3) Physically removing Zero and Span Magnetic Buttons from Transmitter
thereby restricting local access to push button menus. This option will still
allow changes via a remote HHT or HART®enabled configurator.
CPU Module Jumper Switch
1) EEPROM Write Selection
2) Fail Mode Selection

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4.5.2 Zero and Span Magnetic Push Buttons
To access push buttons please remove top name plate to expose the magnetic
style push buttons labelled zero/ span. To disable please unscrew and remove
these push buttons.
4.6 Configuration of Alarm and Security Jumper Procedures
To change Jumper/ DIP switch position in field:
(1) If transmitter is already wired and installed, cut off power.
(2) Open the housing front side covers.
Warning: In hazardous areas DO NOT open the covers of
Transmitter when power is energized as this can create a potential
dangerous situation. Always kill power and de-energize the
transmitter prior to opening front OR back covers in a hazardous
location.
(3) Adjust required jumper/ DIP position as detailed in section 4.4 & 4.5 above.
(4) Close the housing covers. You must fully engage all cover threads to ensure
compliance to explosion proof requirements
4.7 Configuration Using Zero and Span Push Buttons
There are ZERO and SPAN Buttons to be seen when the nameplate is opened
(Figure 4-4). You may reconfigure the function settings of ZERO, SPAN, ZERO
TRIM, ZERO ADJ, Units, Range, Damping, LCD and Decimal place, using ZERO
/ SPAN buttons.
[Figure 4-4 Transmitter Zero/Span configuration Buttons]
Zero/Span
Button