Magnetrol STI Kotron User manual

RF
Level
Sensor
Kotron®Tip Sensitive
RF Level Sensor
Instruction Manual and Parts List

50-606 Kotron Tip Sensitive RF Level Sensor
Read this Manual Before Installing
This manual provides information on the Kotron
Tip-Sensitive RF 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.
Safety Messages
Follow all standard industry procedures for servicing elec-
trical equipment when working with or around high
voltage. Always shut off the power supply before touch-
ing any components.
Low Voltage Directive
For use in Category II Installations. If equipment is used
in a manner not specified by the manufacturer, protection
provided by equipment may be impaired.
Notice of Copyright, and Limitations
Copyright © 2004 Magnetrol International,
Incorporated. All rights reserved.
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 spe-
cial 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.

50-606 Kotron Tip Sensitive RF Level Sensor
Table of Contents
1.0 Installation
1.1 Unpacking ...........................................................1
1.2 Electrostatic Discharge (ESD) Handling Procedure...1
1.3 Preliminary Operational Check .............................1
1.4 Installation Location..............................................2
1.5 Probe Length.........................................................3
1.6 Mounting ..............................................................3
1.6.1 Horizontal Mounting .................................3
1.6.2 Vertical Mounting.......................................4
1.7 Installation Instructions.........................................4
1.8 Wiring ..................................................................4
1.8.1 Operating Mode Selection..........................5
1.9 Calibration ............................................................6
2.0 Reference Information .................................................8
2.1 Description ...........................................................8
2.2 Operating Principle ...............................................8
2.3 Troubleshooting.....................................................8
2.3.1 General Check............................................8
2.3.2 Switch Chatter............................................9
2.3.3 Relay Will Not Reset ..................................9
2.4 Agency Approvals ................................................10
2.5 Parts ....................................................................10
2.5.1 Replacement Parts ....................................10
2.6 Specifications.......................................................11
2.6.1 Electrical...................................................11
2.6.2 Dimensional Data.....................................12
3.0 Model Identification ..................................................12
Kotron Tip Sensitive
RF Level Sensor

50-606 Kotron Tip Sensitive RF Level Sensor
1
1.0 Installation
Kotron Tip Sensitive Level Controls can be utilized in
liquid or bulk material applications. There are no moving
parts in contact with the medium. These units are integral
systems with the sensing probe mounted with the electronics.
1.1 Unpacking
Unpack the instrument carefully. Make sure all compo-
nents have been removed from the packing material.
Inspect all components for damage. Report any concealed
damage to the carrier within 24 hours. Check the contents
against the packing slip and report any discrepancies to the
factory. Check the nameplate model number to be sure it
agrees with the packing slip and purchase order. Check
and record the serial number for future reference when
ordering parts.
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 anti-static 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 printed 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.

50-606 Kotron Tip Sensitive RF Level Sensor 2
1.3 Preliminary Operational Check
After unpacking and before installation, perform
the following operational check on the unit in a
non-hazardous area.
1. Fill a suitable grounded container with water.
2. In a non-hazardous area, power the unit with proper
voltage.
3. Dip the probe in the water. The relay should activate.
4. Withdraw the probe from the water. The relay should
deactivate.
1.4 Installation Location
Kotron RF Point Level Switches should be located for easy
access for service, calibration and monitoring. Switches
should not be exposed to ambient temperatures below
-40° F (-40° C) or above +160° F (+70° C). Special pre-
caution should be made to prevent exposure to corrosive
atmosphere, excessive vibration, shock or physical damage.
Sensing probes should be located close to the tank wall for
greatest sensitivity. Probes should be isolated from severe
motion in the tank, because surface turbulence may cause
signal deviation.
Caution: This unit contains CMOS electronics which may be dam-
aged by static electricity. Do not touch any semi-conduc-
tor devices unless you are properly grounded.

50-606 Kotron Tip Sensitive RF Level Sensor
3
1.5 Probe Length
If the geometry of your application requires a probe shorter
than 14" (356 mm), refer to the Probe Length vs.
Dielectric Constant chart below.
A minimum probe length of 4" (102 mm) is permissible
in a conductive liquid (dielectric of 24 or greater). The full
length should be maintained in a non-conductive liquid or
bulk material.
1.6 Mounting
Tip Sensitive Point Sensors are shipped assembled to the
probe. They may be installed in horizontally or vertically.
1.6.1 Horizontal Mounting
Unit will signal at probe level. Refer to Figures 1 and 2.
Caution: Do NOT horizontally mount the unit in a nozzle. Refer to
Figure 2. The medium may build up in the nozzle and
cause false actuation.
4 5 6 7 8 9 10 11 12 13 14
27
26
25
24
26
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
MINIMUM REQUIRED DIELECTRIC CONSTANT (EPSILON) OF MATERIAL
TOTAL PROBE LENGTH (Inches)
Figure 1
Incorrect horizontal mounting
Figure 2
Correct horizontal mounting

50-606 Kotron Tip Sensitive RF Level Sensor 4
1.6.2 Vertical Mounting
As medium rises on the probe, unit will signal at a point
determined by the calibration of the unit and the dielectric
constant of the medium. In conductive media, the actua-
tion point will be at the tip of the probe over a wide range
of zero calibrations. Refer to Figure 3.
1.7 Installation Instructions
1. Thread amplifier assembly into mounting bushing
on tank using suitable pipe compound or thread
tape. Assembly may also be bolted to a flange with
a suitable gasket.
2. Tighten securely, being certain that the wrench is applied
ONLY to the mounting nut. Refer to Figure 3.
1.8 Wiring
All power and control connections are made at the termi-
nal strip within the amplifier enclosure. 16 AWG wire is
recommended for power and control circuit.
Caution: Observe all local electrical codes and proper wiring
procedures.
1. Make sure the power source is turned off.
2. Unscrew and remove housing cover.
3. Pull power supply and control wires through
conduit connection.
4. Connect power leads to applicable AC or DC terminals as
marked. Refer to Figure 4.
5. Connect control circuit leads to relay terminals. Refer to
Figure 4. Make sure the load to be controlled is within the
relay’s rated capacity.
6. Dress wiring to guard against interference or contact with
cover or circuit board components.
7. Prevent moisture seepage into the housing by installing an
approved seal-drain fitting in the conduit run leading to
the unit.
8. Select operating mode. Refer to Section 1.8.1, Operating
Mode Selection on page 5 for detailed information. Make
sure that the operating mode jumper wire is in the correct
position for your selection. Refer to Figure 4.
Mounting nut
apply wrench here
Tank mounting
bushing
Actuation point in
conductive media
Figure 3
Vertical mounting
Operating
Mode
Jumper
Wire
Terminal Strip
AC Power
Supply
Connections
Control
Connections
DC Power
Supply
Connections
Zero
Adjustment
GND AC AC RELAY +24v LL CM HLGND
Figure 4
Terminal connections

50-606 Kotron Tip Sensitive RF Level Sensor
5
NOTE: This unit is factory supplied with the jumper wire connecting
LL and CM.
Caution: In hazardous areas, do not power the unit until the conduit
is sealed and enclosure cover is screwed down securely.
9. Installation is complete. Replace housing cover.
1.8.1 Operating Mode Selection
Low Level (LL) means tank material below the
set point
High Level (HL) means tanks material above the
set point
Loss of power: The relay contact will open in all
mode selections. Relay contact will
remain open until power is restored.
It will then assume a condition in
accordance with the selection table
below.
Caution: Connect terminal LL or HL, only to terminal CM. Any other
connection may damage the unit.
Line Material Operating Mode Jumper Wire
Power Level CM to LL CM to HL
On Below Set Point Contacts Closed Contacts Open
Above Set Point Contacts Open Contacts Closed
Fail Below Set Point Contacts Open Contacts Open
Above Set Point Contacts Open Contacts Open

50-606 Kotron Tip Sensitive RF Level Sensor 6
1.9 Calibration
Caution: For Hazardous Locations – Extra precautions must be
taken during instrument calibration. Before housing cover
is removed, power MUST be turned off.
1. Turn on power to the instrument.
2. Remove housing cover.
3. Set point locations:
Conductive media — The set point is located at the tip of
the probe. Calibration is not required for most conductive
liquids. If the unit does not switch on alarm test, then
proceed to Step 4.
Non-conductive media — The set point is located at the
probe at a point determined by the dielectric constant of
the medium. Refer to Figure 1 on page 2. Calibration is
required. Proceed to Step 4.
NOTE: An ohmmeter or other indicating device connected across the
relay terminals will indicate switch change with level change,
simplifying the calibration procedure.
4. Alarm adjustments:
High level alarm (refer to Section 1.8.1, Operating Mode
Selection for proper jumper wire connection).
a. With no material on probe, turn zero adjustment con-
trol fully counterclockwise 20 turns. Refer to Figure 4
on page 4.
b. Slowly turn clockwise until relay contact changes.
c. The unit is now calibrated. The relay contact will
change state when the material rises on the probe.
NOTE: The calibration adjustment is more critical in low dielectric
media than in high dielectric media. Care must be taken to
turn the zero adjustment control just enough to deactivate the
alarm. If it is adjusted even 1⁄4 turn beyond the set point, the
zero adjustment band will be out of the operational change.
Low level alarm (refer to Section 1.8.1, Operating Mode
Selection for proper jumper wire connection).
a. With material covering the probe, turn zero adjustment
control fully clockwise 20 turns. Refer to Figure 4 on
page 4.
b. Slowly turn counterclockwise until relay contact
changes.
c. The unit is now calibrated. The relay contact will
change state when the material falls below the probe.

50-606 Kotron Tip Sensitive RF Level Sensor
7
5. Replace housing cover.
6. Bring material to alarm condition and check for relay con-
tact change.
2.0 Reference Information
This section presents an overview of the operation of the
Kotron Tip Sensitive RF Level Sensor, information on
troubleshooting common problems, listings of agency
approvals, a list of replacement parts and electrical and
dimensional data.
2.1 Description
Kotron Tip Sensitive Level controls can be utilized in liquid
or bulk material applications. There are no moving parts in
contact with the medium. These units are integral systems
with the sensing probe mounted with the electronics.
2.2 Operating Principle
As the medium covers the sensing probe, the amount of
capacitance between the probe and tank wall increases.
This capacitance is measured by the electronics. When the
capacitance is the same as the setpoint, the relay changes
state. As the medium drains from the sensing probe, the
relay reverses.
2.3 Troubleshooting
Caution: In hazardous areas do not remove housing until power is
disconnected and atmosphere is determined to be safe.
2.3.1 General Check
1. Check power and control circuit wiring.
2. Check calibration.
3. Check jumper wire position.
4. Check length of probe against chart in Figure 1 on page 3.
5. Check ground system. Unit must be grounded to calibrate
properly. If mounted in non-metallic tank, run grounding
strap from mounting nut to earth ground.
NOTE: If remedies above are unsuccessful, consult factory.

50-606 Kotron Tip Sensitive RF Level Sensor 8
2.3.2 Switch Chatter
1. Check for low voltage.
2. Check ground system.
3. Check for turbulence. Relocate probe or isolate from
turbulence.
2.3.3 Relay Will Not Reset
Check probe for buildup or fouling. Clean and
recalibrate.

50-606 Kotron Tip Sensitive RF Level Sensor
9
FM 80-8032-3X2 Explosion Proof Class I, Groups A, B, C & D
Class II, Groups E, F & G
Class III, NEMA 4X
CSA 80-8032-3X2 Explosion Proof Class I, Groups C & D
Class II, Groups E, F & G
Class III, Type 4X
AGENCY MODEL APPROVED APPROVAL CATEGORY APPROVAL CLASSES
2.4 Agency Approvals
2.5 Parts
2.5.1 Replacement Parts
No. Description Part Number
1PC Board Z30-2034-001
2Base 004-9182-002
3Cover 004-9105-001
4O-Ring 012-2101-345
5Transformer 120 VAC 009-6223-001
240 VAC 009-6224-001
6Probe 041-1105-002
;;;;;
;;;;;
;;;;;
;;;;;
;;;;;
;;;;;
;;;;;
531
4
2
6
Figure 6

50-606 Kotron Tip Sensitive RF Level Sensor 10
Supply Voltage 120 VAC, 50–60 Hz
240 VAC, 50–60 Hz
24 VDC
Power Consumption 120 or 240 VAC, less than 5 volt-amps
24 VDC, 1 watt maximum
Zero Range 0 pF minimum to 350 pF maximum
Fixed Minimum Differential 0.5 pF minimum
Output relays AC (1) Reversible SPST, 5 amp @ 120/250 VAC resistive
DC (1) Reversible SPST, 5 amp @ 30 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 3000 psig @ +100° F (205 bar @ +40° C)
Horizontal Mount 450 psig @ +250° F (31 bar @ +121° C)
Vertical Mount 450 psig @ +200° F (31 bar @ +93° C)
Temperature Coefficient
of Set Point -40° to +160° F (-40° to +70° C) ±0.05 pF per degree F
(±.0.09 pF per degree C)
2.6 Specifications
2.6.1 Electrical

3.0 Model Identification
50-606 Kotron Tip Sensitive RF Level Sensor
11
Model Number Voltage
80-8032-302 120 VAC
80-8032-312 240 VAC
80-8032-322 24 VDC
2.6 Specifications
2.6.2 Dimensional Data
inches (mm)
3/4" NPT
3/4" NPT

3.50 (89)
Min. length
4.00 (102)
14.00 (356)
(std. length)
.375 (10)
Rotation clearance
4.63
(117) Dia.
3.44 (87)
3/4" NPT
plugged
2.75
(70)
Figure 5

50-606 Kotron Tip Sensitive RF Level Sensor 12
NOTES

BULLETIN: 50-606.11
EFFECTIVE: June 2004
SUPERSEDES: April 2003
5300 Belmont Road • Downers Grove, Illinois 60515-4499 • 630-969-4028 • Fax [phone] • www.sticontrols.com
Copyright © 2004 STI Controls, L.P. All rights reserved. Printed in the USA.
STI and STI logotype are registered trademarks of Magnetrol International.
Performance specifications are effective with date of issue and are subject to change without notice.
The brand and product names contained within this document are trademarks or registered trademarks of their respective holders.
5300 Belmont Road • Downers Grove, Illinois 60515-4499 • 630-969-4000 • Fax [phone] • www.magnetrol.com
145 Jardin Drive, Units 1 & 2 • Concord, Ontario Canada L4K 1X7 • 905-738-9600 • Fax [phone]
Heikenstraat 6 • B 9240 Zele, Belgium • 052 45.11.11 • Telex 25944 • Fax [phone]
Regent Business Ctr., Jubilee Rd. • Burgess Hill, Sussex RH15 9TL U.K. • 01444-871313 • Fax [phone]
Service Policy
Owners of Magnetrol/STI controls may request the
return of a control or any part of a control for complete
rebuilding or replacement. They will be rebuilt or replaced
promptly. Controls returned under our service policy
must be returned by prepaid transportation.
Magnetrol/STI will repair or replace the control at no cost
to the purchaser (or owner) other than transportation if:
1. Returned within the warranty period; and
2. The factory inspection finds the cause of the claim to
be covered under the warranty.
If the trouble is the result of conditions beyond our con-
trol; or, is NOT covered by the warranty, there will be
charges for labor and the parts required to rebuild or
replace the equipment.
In some cases it may be expedient to ship replacement
parts; or, in extreme cases a complete new control, to
replace the original equipment before it is returned. If this
is desired, notify the factory of both the model and serial
numbers of the control to be replaced. In such cases, credit
for the materials returned will be determined on the basis
of the applicability of our warranty.
No claims for misapplication, labor, direct or consequen-
tial damage will be allowed.
Return Material Procedure
So that we may efficiently process any materials that are
returned, it is essential that a “Return Material
Authorization” (RMA) number be obtained 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 used in a process must be properly
cleaned in accordance with OSHA standards, before it is
returned to the factory.
A Material Safety Data Sheet (MSDS) must accompany
material that was used in any media.
All shipments returned to the factory must be by prepaid
transportation.
All replacements will be shipped F.O.B. factory.
NOTE: See Electrostatic Discharge Handling Procedure
on page 1.
ASSURED QUALITY & SERVICE COST LESS