Magnetrol STI Kotron 810 User manual
Installation and Operating Manual
RF
Capacitance
Level
Measurement
Kotron®Model 810
RF oint Level Sensor
50-607 Kotron Model 810 RF Point Level Sensor
Read this Manual Before Installing
This manual provi es information on the Kotron Mo el
810 RF Point Level Sensor. It is important that all
instructions are rea carefully an followe in sequence.
Detaile instructions are inclu e in the Installation
section of this manual.
Conventions Used in this Manual
Certain conventions are use in this manual to convey
specific types of information. General technical material,
support ata, an safety information are presente in
narrative form. The following styles are use for notes,
cautions, an warnings.
Notes
Notes contain information that augments or clarifies
an operating step. Notes o not normally contain
actions. They follow the proce ural steps to which
they refer.
Cautions
Cautions alert the technician to special con itions that
coul injure personnel, amage equipment, or re uce
a component’s mechanical integrity. Cautions are also
use to alert the technician to unsafe practices or the
nee for special protective equipment or specific mate-
rials. In this manual, a caution box in icates a poten-
tially hazar ous situation which, if not avoi e , may
result in minor or mo erate injury.
Warnings
Warnings i entify potentially angerous situations or
serious hazar s. In this manual, a warning in icates an
imminently hazar ous situation which, if not avoi e ,
coul result in serious injury or eath.
Safety Messages
The Kotron Mo el 810 system may be properly installe
in Category II, Pollution Degree 2 installations. Follow all
stan ar in ustry proce ures for servicing electrical an
computer equipment when working with or aroun 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 is-
charge. To prevent equipment amage, observe safety
proce ures when working with electrostatic sensitive
components.
WARNING! Explosion hazar . Do not connect or
isconnect equipment unless power has been switche off
or the area is known to be non-hazar ous.
Low Voltage Directive
For use in Installation Category II, Pollution Degree 2. If
equipment is use in a manner not specifie by the
manufacturer, protection provi e by the equipment
may be impaire .
Notice of Trademar , Copyright and Limitations
Magnetrol & Magnetrol logotype, STI an STI logotype,
an Kotron are registere tra emarks of Magnetrol
International, Incorporate .
Copyright © 2008 Magnetrol International.
All rights reserve .
Performance specifications are effective with ate of issue
an are subject to change without notice. Magnetrol/STI
reserves the right to make changes to the pro uct
escribe in this manual at any time without notice.
Magnetrol/STI makes no warranty with respect to the
accuracy of the information in this manual.
Warranty
All Magnetrol/STI electronic level an flow controls are
warrante free of efects in materials or workmanship for
one full year from the ate of original factory
shipment.
If returne within the warranty perio ; an , upon
factory inspection of the control, the cause of the claim is
etermine to be covere un er 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, irect or consequential amage or expense
arising from the installation or use of equipment.
There are no other warranties expresse or implie ,
except special written warranties covering some
Magnetrol/STI pro ucts.
Quality Assurance
The quality assurance system in place at Magnetrol/STI
guarantees the highest level of quality throughout the
company. Magnetrol/STI is committe to provi ing full
customer satisfaction both in quality pro ucts an
quality service.
Magnetrol’s quality assurance system
is registere to ISO 9001 affirming its
commitment to known international
quality stan ar s provi ing the
strongest assurance of pro uct/service
quality available.
50-607 Kotron Model 810 RF Point Level Sensor
Ta le of Contents
1.0 Introduction
1.1 Principle of Operation...........................................1
1.2 Electrostatic Discharge (ESD) Han ling Proce ure...1
2.0 Installation
2.1 Unpacking ...........................................................1
2.2 Electrostatic Discharge Han ling Proce ure..........2
2.3 Installation ...........................................................2
2.3.1 Installation Location....................................2
2.3.2 Probe Length...............................................3
2.4 Mounting ...........................................................3
2.4.1 Horizontal Mounting ..................................3
2.4.2 Vertical Mounting .......................................3
2.5 Wiring...................................................................4
2.6 Calibration ...........................................................6
2.6.1 Calibration Proce ure.................................6
2.6.2 Calibration Con itions...............................6
3.0 Reference Information .................................................8
3.1 Troubleshooting.....................................................8
3.1.1 No Signal with Level Change .....................8
3.1.2 Switch Chatter............................................8
3.2 Agency Approvals ..................................................9
3.3 Specifications.......................................................10
3.3.1 Electrical...................................................10
3.3.2 Dimensional .............................................10
3.4 Replacement Parts ...............................................11
3.5 Mo el Numbers ..................................................12
Kotron Model 810
RF Point Level Sensor
50-607 Kotron Model 810 RF Point Level Sensor
1
1.0 Introduction
The Kotron Mo el 810 RF Point Level Sensor can be
utilize in liqui or bulk material applications. There are
no moving parts in contact with the me ium. These units
are integral systems with the sensing probe mounte with
the electronics. Guar e probes are utilize to minimize
effect of buil up on the probe.
1.1 Principle of Operation
As the me ium covers the probe, the amount of capaci-
tance evelope between the probe an groun changes.
This change in capacitance is converte into a relay action.
As the me ium rains from the sensing probe, the relay
position reverses.
2.0 Installation
This section provi es etaile proce ures for properly
installing point level sensors.
Caution: This unit contains CMOS electronics which may be
damaged by static electricity. Do not touch any semi-
conductor devices unless you are properly grounded.
2.1 Unpacking
Unpack the instrument carefully. Inspect all components
for amage. Report any conceale amage to carrier
within 24 hours. Check the contents of the packing slip
against purchase or er. Check an recor the mo el
number against serial number for future reference when
or ering parts.
Model Number:
Serial Number:
50-607 Kotron Model 810 RF Point Level Sensor 2
2.2 Electrostatic Discharge (ESD)
Handling Procedure
Magnetrol’s electronic instruments are manufacture to the
highest quality stan ar s. These instruments use electronic
components that may be amage by static electricity pre-
sent in most work environments.
The following steps are recommen e to re uce the risk of
component failure ue to electrostatic ischarge.
• Ship an store circuit boar s in anti-static bags. If an anti-
static bag is not available, wrap the boar in aluminum
foil. Do not place boar s on foam packing materials.
• Use a groun ing wrist strap when installing an removing
circuit boar s. A groun e workstation is recommen e .
• Han le circuit boar s only by the e ges. Do not touch
components or connector pins.
• Make sure that all electrical connections are completely
ma e an none are partial or floating. Groun all
equipment to a goo , earth groun .
2.3 Installation
2.3.1 Installation Location
Kotron point sensors shoul be locate in areas allowing
easy access for service, calibration an monitoring. Units
shoul not be expose to ambient temperatures above
+160° F (+71° C) or below -40° F (-40° C). Special pre-
caution shoul be taken to prevent exposure to corrosive
atmosphere, excessive vibration, shock or physical amage.
Sensing probes shoul be locate close to the tank wall for
greatest sensitivity in non-con uctive me ia. Probes shoul
be isolate from severe motion in the tank, because surface
turbulence may cause signal eviation.
NOTE: Do not attempt to disassemble probe from housing
until the wires have been disconnected and the
electronic module has been removed. Consult Section 3.1,
Troubleshooting on page 8.
50-607 Kotron Model 810 RF Point Level Sensor
3
2.3.2 robe Length
If the geometry of your application requires a probe short-
er than 12" (305 mm) of active length, refer to Figure 1
below to etermine the minimum ielectric constant in
which it can be use .
2.4 Mounting
When installing, apply wrench to mounting glan only.
Guar element shoul be locate free of nozzle.
Caution: When a probe is used in an abrasive medium, inspect the
probe at least annually for visible surface wear. In case any
wear is found, replace the probe or consult the factory.
2.4.1 Horizontal Mounting
Unit will signal at probe level. Refer to Figures 2 an 3.
Caution: Do NOT horizontally mount the unit in a nozzle deeper than
3" (75 mm). Refer to Figures 2 and 3. The medium may
build up in the nozzle and cause false actuation.
2.4.2 Vertical Mounting
As me ium rises on the probe, the unit will signal at a
point etermine by the calibration of the unit an the
ielectric constant of the me ium. In con uctive me ia,
the actuation point will be at the tip of the probe over a
wi e range of a justment. Refer to Figure 4.
INSTALLATION INSTRUCTIONS
1. Threa amplifier assembly into mounting bushing on tank
using suitable pipe compoun or threa tape. Assembly
may also be attache to a flange an bolte to the vessel
using a suitable gasket.
2. Tighten securely, being certain that the wrench is applie
ONLY to the mounting glan . Refer to Figures 2
through 4.
1234567891011 121314151617181920
4
5
6
7
8
9
10
11
12
robe Length vs. Dielectric Constant
Figure 1
Minimum dielectric constant of material
Mounting Gland
Nozzle
Mounting Gland
Figure 2
Horizontal Mounting
Figure 3
Horizontal Mounting in Nozzle
Mounting Gland
Figure 4
Mounting
Gland
Mounting
Gland
Nozzle
Mounting
Gland
50-607 Kotron Model 810 RF Point Level Sensor 4
Figure 5
Mounting Screws
Green Ground
Screw
I.S. Ground
Figure 6
2.5 Wiring
All power an control connections are ma e at the
terminal strip within the amplifier enclosure, EXCEPT
GROUNDING. Power groun ing must be ma e at green
groun screw on the housing base. 16AWG wire is
recommen e for power an control circuits.
NOTE: There are special wiring requirements for intrinsic safety.
Observe all local electrical codes and proper wiring
procedures.
Caution: This unit contains CMOS electronics which may be
damaged by static electricity. Do not touch any semi-
conductor devices unless you are properly grounded.
PROCEDURE:
1. Make sure the power source is turne off.
2. Unscrew an remove housing cover.
3. Pull power supply an control wires through con uit
groun connection.
4. Connect green groun wire to green groun screw locate
in the base of the housing.
NOTE: If separate I.S. ground is required in this application, then I.S.
ground (conventionally, blue #12 wire) should be connected to
the barrier at this time. Refer to NEC and agency guidelines.
5. After groun ing is complete, connect AC power lea s
to the HOT an COM terminals as marke . Refer to
Figure 6.
NOTE: For DC supply voltage connect DC+ to OT and DC– to COM.
6. Connect control circuit lea s to relay terminals. Refer to
Figure 6. Make sure the loa to be controlle is within the
relay's rate capacity.
7. Prevent moisture seepage into housing by installing an
approve seal- rain fitting in the con uit run lea ing to
the unit.
8. Select operating mo e. (Refer to OPERATING MODE
SELECTION on page 5 for etaile information.) Make
sure that the fail-safe switches are in the correct position
for your selection. Refer to Figure 7 an the RELAY
WIRING CHART on page 5.
Caution: In hazardous areas, do NOT power the unit until the conduit
is sealed and the enclosure cover is screwed down securely.
9. Installation is complete. Replace housing cover.
50-607 Kotron Model 810 RF Point Level Sensor
5
OPERATING MODE SELECTION
The chart below is provi e to ai in the proper choice of
relay wiring an calibration. Please note:
1. Equipment controlle by the relay is assume to be pow-
ere from one source, while the Mo el 810 itself is
assume to be powere from a ifferent source.
2. There are fail-safe switches on the switch which may be set
in either a High or Low position. Refer to Figure 7.
3. “Fail” means a loss of power to the 810 unit.
4. HL (High Level) means a material level in the tank which
is equal to or above the set point.
5. LL (Low Level) means a material level in the tank which is
equal to or below the set point.
6a. When relay coil is e-energize (fail-safe) the circuit
between common (COM) an the normally open (NO)
terminal is open an a connection is ma e between
common (COM) an the normally close (NC) terminals.
The LED is off.
6b. When the relay coil is energize the NO contact is close
an the NC contact is open. The LED is on. Refer to the
Relay Wiring Chart below.
Kotron Material Fail-safe Relay
ower Level osition Coil CM to NC CM to NO
igh L De-energized Closed Open
On LL Energized Open Closed
Low L Energized Open Closed
LL De-energized Closed Open
igh L De-energized Closed Open
Fail LL De-energized Closed Open
Low L De-energized Closed Open
LL De-energized Closed Open
Relay Terminal
RELAY WIRING CHART
Figure 7
Time delay
control (R9)
Relay LED
Level control
(R4)
Fail-safe switches
Time delay
switches between
1 and 2
50-607 Kotron Model 810 RF Point Level Sensor 6
2.6 Cali ration
Caution: In hazardous areas, do not remove housing cover until
power is disconnected and atmosphere os determined to
be safe. azardous environments must be declared safe by
the local safety authority.
2.6.1 Calibration rocedure
1. Turn on power to the instrument.
2. Remove housing cover.
3. Set point location:
a. Con uctive me ia: The set point is locate at the tip of
the probe. Calibration is not require for most con uc-
tive liqui s. If the unit oes not switch on alarm test,
then procee to Step 4.
b. Non-con uctive me ia: The set point is locate on the
probe at a point etermine by the set point a just-
ment. Minimum probe coverage is 4 inches (100 mm).
Calibration is require . Procee to Step 4.
4. The LED shows the status of the relay coil:
LED on = relay energize
LED off = relay e-energize
5. Initial Settings
a. Turn the LEVEL control (R4) clockwise a full twenty
turns or until a ratcheting soun is hear .
b. Set the DIP switch with positions 1 an 2 ON.
c. Turn the TIMER control (R9) fully counterclockwise.
. Note that if DIP switch positions 3 an 4 are both ON
the LED will remain on. Set DIP switches base on the
following information:
2.6.2 Calibration Conditions
Complete calibration by utilizing the following con itions
that best suits your application:
1. Fail-safe L w—
a. Set DIP switch position 3 ON an position 4 OFF.
b. Turn the LEVEL control counterclockwise until the
LED turns on.
c. Turn the LEVEL control clockwise until the LED
turns off.
. If me ia is on probe, slowly turn the LEVEL control
counterclockwise until the LED comes on.
50-607 Kotron Model 810 RF Point Level Sensor
7
2. Fail-safe High—
a. Set DIP switch position 3 OFF an position 4 ON.
b. Turn the LEVEL control counterclockwise until the
LED turns off.
c. Turn the LEVEL control clockwise until the LED
turns on.
. If me ia is on probe, slowly turn the LEVEL control
counterclockwise until the LED turns off.
3. Time Delay
If Time Delay is require (i.e., surface waves causing relay
chatter), two choices must be ma e:
a. Delay Function:
— Delay on FILL (rising Level) switch 1 OFF, 2 ON
— Delay on EMPTY (falling Level) switch 1 ON,
2 OFF
b. Delay Duration:
— 0 to approximately 45 secon s (Timer R9)
— CW rotation increases uration (approximately 270°
stop to stop)
50-607 Kotron Model 810 RF Point Level Sensor 8
3.0 Reference Information
3.1 Trou leshooting
3.1.1 No Signal with Level Change
1. Check power an control circuit wiring.
2. Check fail-safe switch position.
3. Check calibration.
4. Check for proper groun reference particularly in non-
metal tanks.
If rem val f electr nic m dule is necessary:
1. Loosen mounting screws. Refer to Figure 5.
2. Slowly raise electronic mo ule exposing probe wiring.
3. Disconnect probe an guar lea s. Remove electronic
mo ule.
3.1.2 Switch Chatter
1. Check for turbulence. If turbulence is present, increase
time elay.
2. Check for low voltage.
3. Check for proper groun reference.
4. Check for proper DIP switch position.
NOTE: If these suggestions prove unsuccessful, consult factory.
50-607 Kotron Model 810 RF Point Level Sensor
9
AGENCY A ROVED MODEL ROTECTION METHOD AREA CLASSIFICATION
FM All models Explosion Proof Explosion proof with intrinsically safe probe circuit
Class I, Div. 1, Groups C & D
Class II, Div. 1, Groups E, F, & G
General purpose NEMA 4X
CSA All models Explosion Proof Explosion proof with intrinsically safe probe circuit
Class I, Div. 1, Groups C & D
Class II, Div. 1, Groups E, F, & G
General purpose TYPE 4X
These units have been tested to EN 50081-2
and EN 50082-2 and are in compliance with
the EMC Directive 89/336/EEC.
3.2 Agency Approvals
50-607 Kotron Model 810 RF Point Level Sensor 10
3.3 Specifications
3.3.1 Electrical
Supply voltage 120 VAC, 50–60 z (+10%, -15%)
240 VAC, 50–60 z (+10%, -15%)
24 VDC (±10%)
12 VDC (±10%)
Power consumption 120 or 240 VAC Less than 5 volt-amps
12 or 24 VDC 1 watt maximum
Zero range 0 pF minimum to 500 pF maximum
Fixed differential 0.5 pF
Output relays (reversible DPDT) AC 5 amp @ 250 VAC resistive
DC 5 amp @ 30 VDC, 0.5 amp @ 125 VDC resistive
Response time 100 milliseconds
Repeatability Better than 1.0%
Ambient temperature Electronics -40° to +160° F (-40° to +70° C)
Operating process pressure/temperature 3500 psig @ +100° F (240 bar @ +40° C)
1750 psig @ +200° F (120 bar @ +95° C)
Temperature coefficient of set point
-40° to +160° F (-40° to +70° C) ± .01% per degree F of setpoint
(± .018% per degree C of setpoint)
3.3.2 Dimensional
6" (152)
Guard length
12" (305)
or
30" (762)
Active length
18" (457)
or
36" (914)
2.75
(70)
3/4" NPT
3/4" NPT
Conduit
connection
4.63
(118) Dia.
4.11
(104)
Rotation clearance 3.44 (87)
3/4" NPT
plugged
50-607 Kotron Model 810 RF Point Level Sensor
11
4
1
2
3
5
Refer to Section 2.2, Electrostatic Discharge (ESD) Handling Procedure on page 2.
3.4 Replacement Parts
No. Description art Number
Complete Electronic Assembly
120 VAC Z30-9101-001
240 VAC Z30-9101-002
24 VDC Z30-9101-004
12 VDC Z30-9101-003
Cover Aluminum 04-9105-001
316 SS 04-9142-00
O-ring 12-2101-345
Base Aluminum 3⁄4" NPT conduit connection 04-9182-002
316 SS, single hub 04-9140-001
Probe 18" (457 mm) 8AD-AA1A-018
Probe 36" (914 mm) 8AD-AA1A-036
50-607 Kotron Model 810 RF Point Level Sensor 12
3.5 Model Num ers
810 Kotron RF Capacitance Level Switch
810 005 0
HOUSING
INPUT POWER
BASIC MODEL
PROBE
0 120 VAC
1 240 VAC
2 24 VDC
3 12 VDC
1 18" (455 mm) guarded probe
2 36" (915 mm) guarded probe
D NEMA 4X/7/9 Groups C & D, aluminum, 3⁄4" NPT conduit
Y NEMA 4X/7/9 Groups C & D, 316 SS, 3⁄4" NPT conduit
BULLETIN: 50-607.5
EFFECTIVE: October 2004
SU ERSEDES: May 2002
5300 Belmont Road • Downers Grove, Illinois 60515-4499 • 630-969-4000 • Fax 630-969-9489 • www.magnetrol.com
145 Jardin Drive, Units 1 & 2 • Concord, Ontario Canada L4K 1X7 • 905-738-9600 • Fax 905-738-1306
Heikensstraat 6 • B 9240 Zele, Belgium • 052 45.11.11 • Fax 052 45.09.93
Regent Business Ct r., Jubilee Rd. • Burgess Hill, Sussex RH15 9TL U.K. • 01444-871313 • Fax 01444-871317
5300 Belmont Road • Downers Grove, Illinois 60515-4499 • 630-969-4028 • Fax 630-969-9489 • www.sticontrols.com
Copyright © 2008 Magnetrol International, Incorporated. All rights reserved. Printed in the USA.
Service Policy
Owners of Magnetrol/STI controls may request the return
of a control or any part of a control for complete rebuil -
ing or replacement. They will be rebuilt or replace
promptly. Controls returne un er our service policy
must be returne by Prepai transportation.
Magnetrol/STI will repair or replace the control at no cost
to the purchaser (or owner) other than transportation if:
1. Returne within the warranty perio ; an
2. The factory inspection fin s the cause of the claim to
be covere un er the warranty.
If the trouble is the result of con itions beyon our con-
trol; or, is NOT covere by the warranty, there will be
charges for labor an the parts require to rebuil or
replace the equipment.
In some cases it may be expe ient to ship replacement
parts; or, in extreme cases a complete new control, to
replace the original equipment before it is returne . If this
is esire , notify the factory of both the mo el an serial
numbers of the control to be replace . In such cases, cre it
for the materials returne will be etermine on the basis
of the applicability of our warranty.
No claims for misapplication, labor, irect or consequen-
tial amage will be allowe .
Return Material Procedure
So that we may efficiently process any materials that are
returne , it is essential that a “Return Material
Authorization” (RMA) number be obtaine from the fac-
tory, prior to the material's return. This is available
through Magnetrol’s local representative or by contacting
the factory. Please supply the following information:
1. Company Name
2. Description of Material
3. Serial Number
4. Reason for Return
5. Application
Any unit that was use in a process must be properly
cleane in accor ance with OSHA stan ar s, before it is
returne to the factory.
A Material Safety Data Sheet (MSDS) must accompany
material that was use in any me ia.
All shipments returne to the factory must be by prepai
transportation.
All replacements will be shippe F.O.B. factory.
NOTE: See Electrostatic Discharge Han ling Proce ure
on page 2.
ASSURED QUALITY & SERVICE COST LESS
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