Magnetrol Smart EZ Modulevel User manual

Refer to bulletin 48-615 for Analog EZ Modulevel
®
Displacer
Operated
Level/Interface
Measurement
Smart EZ Modulevel®
Installation and Operating Manual
7xxx
6xxx
5xxx
4xxx
3xxx
2xxx
1xxx
I VE GOT
ABILITY
S
A
F
E
T
Y
I
N
T
E
G
R
I
T
Y
L
E
V
E
L

2
UNPACKING
TOP MOUNTED UNITS
After unpacking, inspect all components to see that no
damage has occurred during shipment. Care should be
taken not to bend the displacer stem or enclosing tube
during unpacking or installation.
CHAMBERED UNITS
Astrap and wire assembly retains and protects the
displacer within the chamber during shipment. This
assembly must be removed through bottom chamber
connection before startup. Inspect instrument as described
for top mounting units.
MOUNTING
max 1° tolerance
Use stilling well in case
of turbulent medium
Shut-off valves are
recommended
Always unlock for repositioning or removal
of head assembly and always relock,
after final positioning
calibration vent
is recommended
-40°C (-40°F) to +70°C (160°F)
Liquid
level Size 1/8"
max 360 °
Caution:
If re-shipping to another location, displacer must again
be secured using same strap and wire assembly.
Nameplate
These units are in conformity with the
provisions of:
1. The EMC Directive: 89/336/EEC.
The units have been tested to EN
61000-6-4/2001 and EN 61000-6-
2/2001.
2. Directive 94/9/EC for Equipment or protective system for
use in potentially explosive atmospheres. EC-type
examination certificate number ISSeP00ATEX003X
(intrinsic safe units) or ISSeP01ATEX018 (EEx d units).
3. The PED directive 97/23/EC (pressure equipment
directive). Safety accessories per category IV module
H1.
0038
0344

3
WIRING
INTEGRAL UNITS
AMAXIMUM LOAD RESISTANCE OF 450 ΩMAY
BEINSERTED INTO SUPPLY LINE FOR
CURRENT MONITORING.
IMPORTANT FOR HART®USERS
INSTRUMENT AND ELECTRICAL JUNCTION
FITTING COVERS MUST BE KEPT TIGHT AT ALL
TIMES DURING OPERATION.
IMPORTANT
NOTE: For units with meter, pull meter
out before wiring terminals can be
reached.
ENTER
UP
DOWN
ERROR
SPAN
ZERO
(–)
P2

(+)
P1

®
– TB1 +

E S MODULEVEL ®
5300 BELMONT ROAD,
DOWNERS GROVE, IL 60515,
USA.

HEIKENSSTRAAT 6,
B 9240 ZELE,
BELGIUM.

www.magnetrol.com

REFER TO MODULEVEL MANUAL,
BULLETIN 48-615, FOR
INSTALLATION AND OPERATION
INSTRUCTIONS.
TP1
TP2
J1
05-9123-001
ASSEMBLY PART NO.
TB2
D1
P1
P2
C6 L5
C5
C3
TB1
+
–
+
–
–+
AW3175
L3
D2
JP1
L6
L4
L2
C1
C4
+
–
DC+
Signal/Power Supply
min 12 V DC – ATEX Exd/Exi
max 36 V DC – ATEX Exd
max 28,4 V DC – ATEX Exi
DC- }
%
REMOTE UNITS
NO WIRING CONNECTIONS ARE
REQUIRED INSIDE THE TRANSMITTER
ELECTRONIC ENCLOSURE.
POWER TERMINALS AND LOCAL METER
(IF APPLICABLE) ARE LOCATED IN THE
JUNCTION BOX
The wiring of the EZ Modulevel transmitter assembly, to the
LVDT assembly, is pre-wired from factory by 6 conductor
cables. When transmitter housing is remote mounted by
means of a cable, use the following cables:
The 6 discrete conductors are tagged 1 through 6, and
should be secured to their respective terminals on both
terminal blocks.
Blk
Blu
Red
Yel
Brn
Grn
1
23
56 4
1
2
3
5
6
4
Red
Yellow
Brown
Green
Bleu
Black
LVDT housing
Transmitter housing
Junction box
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
ENTER
UP
DOWN
ERROR
SPAN
ZERO
(–)
P2

(+)
P1

®
– TB1 +

E S MODULEVEL ®
5300 BELMONT ROAD,
DOWNERS GROVE, IL 60515,
USA.

HEIKENSSTRAAT 6,
B 9240 ZELE,
BELGIUM.

www.magnetrol.com

REFER TO MODULEVEL MANUAL,
BULLETIN 48-615, FOR
INSTALLATION AND OPERATION
INSTRUCTIONS.
TP1
TP2
J1
05-9123-001
ASSEMBLY PART NO.
TB2
D1
P1
P2
C6 L5
C5
C3
TB1
+
–
+
–
–+
AW3175
L3
D2
JP1
L6
L4
L2
C1
C4
+
–

4
CALIBRATION – LEVEL
CALIBRATION USING PUSHBUTTONS TESTING on BENCH CALIBRATOR
NOTE: Default Error signal setting
from factory = 22 mA.
Direct action 4 to 20 mA at rising level:
1. Calibrate 4 mA/0 % level
Push = start calibration – loop will go to 22 mA.
Push = lock 4 mA value – red ZERO LED must be
ON.
Push = red ZERO LED turns OFF,after ± 5 s LED
flashes 1x to confirm the new 4 mA setting.
Note: DO NOT move level/push any buttons
before the LED has flashed. Restart the
procedure if any of these occurred.
2. Calibrate 20 mA/100 % level:
Establish liquid level at desired 20 mA level
Push = start calibration
Push = lock 20 mA value – red SPAN LED must
beON
Push = red SPAN LED turns OFF,after ± 5 s LED
flashes 1x to confirm the new 20 mA setting.
Note: DO NOT move level/push any buttons
before the LED has flashed. Restart the
procedure if any of these occurred.
3. In case 100 % level cannot be established:
Establish liquid level at highest possible level
Push = start calibration
Push = lock 20 mA value – red SPAN LED will turn
ON
Toggle /=untill loop signal corresponds with %
of actual level. Each two toggles
correspond with 0.1 mA
eg. 80 % level should match:
(20 mA – 4 mA) x 80 %+4mA = 16.8 mA
Push = red SPAN LED turns OFF,after ± 5 s LED
flashes 1x to confirm the new 20 mA setting.
Note: DO NOT move level/push any buttons
before the LED has flashed. Restart the
procedure if any of these occurred.
The EZ Modulevel bench calibrator is designed to test the
electronics of the unit. The bench calibrator can also be
used for calibration purpose but the calibration requires fine
tuning versus actual levels in the field.
Slide the electronic head over the open topped enclosing
tube, making sure that the white plastic washer is in
place.
1. Calibrate 4 mA/0 % level:
Slide the adjustment rod completely down into the
enclosing tube
Push = start calibration – loop will go to 22 mA.
Push =lock 4 mA value – red ZERO LED must be
ON
Push =red ZERO LED turns OFF,after ± 5 s LED
flashes 1x to confirm the new 4 mA setting.
Note: DO NOT move the adjustment rod/push
any buttons before the LED has flashed.
Restart the procedure if any of these occurred.
2. Calibrate 20 mA/100 % level:
Align the scale of the adjustment rod with the SG of
your medium
Push = start calibration
Push = lock 20 mA value – red SPAN LED will turn
ON
Push = red SPAN LED turns OFF,after ± 5 s LED
flashes 1x to confirm the new 20 mA setting.
Note: DO NOT move the adjustment rod/push
any buttons before the LED has flashed.
Restart the procedure if any of these occurred.
Ordering code: 031-6107-007
...
ENT
ENT
Adjustment rod
Red LED
100 % level,
20 mA output
Zero level, 4 mA output,
bottom of displacer
Desired
level range
(direct acting)
ZERO led
Span led
Error led
Pushbuttons LVDT
White plastic washer
must be installed
For non-Exi units:
Grip ring located
here on
process level
sensors
PC board
"O" rings
Stand
LVDT core
Base & junction
box
BENCH CALIBRATION DOES NOT COMPENSATE FOR ELAVATED TEMPERATURES -
SEE HAND HELD CALIBRATION PROCEDURE
Specific gravity needs to be set in function of selected unit (see partnumber) to establish 100 % level output:
E8x-J/M/A/D/Qxxx-Exx = align adjustment rod with real specific gravity
E8x-K/B/N/E/Rxxx-Exx = align adjustment rod with real specificgravity
multiplied by 2 (density = 0.3 - align with 0.6)
E8x-L/C/P/F/Txxx-Exx = align adjustment rod with real specific gravity
divided by 2 (density = 1.30 - align with 0.65)
IMPORTANT
NOTE: Reverse action: Maintain the same procedure as above described but calibrate 4 mA as 100 % level
(adjustement rod aligned with specific gravity) and 20 mA as 0 % level (adjustement rod entirely in LVDT core)

5
CALIBRATION – LEVEL
CALIBRATION USING HART®
NOTE: Manual calibration should not be attempted while
HART®communication is active.
CHECK WHETHER YOUR HART®COMMUNICATOR IS
EQUIPED WITH THE EZ MODULEVEL DEVICE
DESCRIPTION (DD’S). OLDER PURCHASED DEVICES
MAY REQUIRE AN UPDATE – CONSULT YOUR LOCAL
HART SERVICE CENTRE OR MAGNETROL FOR
FURTHER ASSISTANCE.
IMPORTANT
THE DIGITAL HART®COMMUNICATION IS SUPER-
IMPOSED ON THE 4-20 mA LOOP AND REQUIRES A MIN.
LOAD RESISTANCE OF 250 ΩAND A MAX LOAD
RESISTANCE OF 450 Ω.
IMPORTANT
CONNECTIONS
Connection of your Hart communicator
•At TB1 terminals (+) and (-) at amplifier board
•At first junction box between unit and control room.
+
-
ENTER
UP
DOWN
ERROR
SPAN
ZERO
(–)
P2
(+)
P1

®
–TB1 +

ES MODULEVEL ®
5300 BELMONT ROAD,
DOWNERS GROVE, IL 60515,
USA.

HEIKENSSTRAAT 6,
B9240 ZELE,
BELGIUM.

www.magnetrol.com

REFER TO MODULEVEL MANUAL,
BULLETIN 48-615, FOR
INSTALLATION AND OPERATION
INSTRUCTIONS.
TP1
TP2
J1
05-9123-001
ASSEMBLY PART NO.
Junction
Power
Supply
Current
Meter
Control
Room
Display
250 Ω< RL<450 Ω

6
I/O Start Up the unit
1Enter Device Setup: press one of the following numeric keys to proceed
e1Enter Password
e2Enter Calibration
e1Set Points
e14mA: apply new 4 mA input:
e1Set as 4 mA value: current level will be new 4 mA level
e2Read new value: introduce a value that will match 4 mA
e3Leave as found: keep old 4 mA value
e220 mA
e1Set as 20 mA value: current level will be new 20 mA level
e2Read new value: introduce a value that will match 20 mA
e3Leave as found: keep old 20 mA value
e320 mA by %: enter % of span versus actual level
e4End
e2Damping
e3Fault state (select via and pushbuttons)
3.6 mA
22 mA
e4Date/Time/Initials: details about the last change of data
e5Loop Test
e14mA: unit blocks at 4 mA
e220 mA: unit blocks at 20 mA
e3Other: enter a value between 3.6 and 22 mA
e4End
e3Enter Basic Setup
e1TAG: enter the tag N° of the unit
e2Descriptor: 16 characters – customer description for transmitter
e3Message: 32 characters – for customer message
e4Final Asmbly num: final assembly N° of the unit
e5Poll addr: only to be used when multiple units are connected in the same loop – leave value “0”
when used as a single transmitter
e4Enter Advanced Setup
e1Set dry Point: only needed when the Specific Gravity setting will be changed. Dry point is set when
the displacer free hanging not in contact with the medium
e2LVDT %: read out %
e3Spec Grav: set Specific Gravity value
e4Error codes: consult factory when another value than “0000” is displayed
e5New Password: enter new password “Factory default value 0” will disable the Password function
e6Trim 4 mA Point: coarse match for 4 mA loop current
e7Trim 20 mA Point: coarse match for 20 mA loop current
e84mA trim point: fine match for 4 mA loop current
e920 mA trim point: fine match for 20 mA loop current
e➨set Serial Number: Serial N° is factory set and cannot be changed in the field
e5Enter Review: Review all parameters set
Model Spec Grav
Manufacturer Date
Magnetrol S/N Final asmbly Num
Dev id Universal Rev
Tag Fld Dev Rev
Descriptor Software Rev
Message Poll Adress
Damping Num Req Preams
Fault state
2Level: view level in %
3Current: view level in mA
4Date
CALIBRATION – HART®MENU
ACTION SCREEN/COMMENT

7
For more details about the use of PACTware®and FDT, refer to instruction manual 59-601
PACTware –Configuration and Troubleshooting
WHAT IS FDT, PACTware®AND DTM
HART Interface Adapter
(RS232 or USB)
Power
Transmitter
HART connections
24 V DC
PC with
HART Serial
Interface
•FDT (Field Device Tool) is a new interface code that
describes the standardization between frame programs
(e.g., PACTware)and DTMs (Device Type Manager).
• PACTware®(Process Automation Configuration Tool)
isaframe program. It is a device-independent software
program that communicates with all approved DTMs.
• DTM (Device Type Manager) is not a stand-alone
program but a device-specific software driver designed
tooperate within a frame program such as PACTware. It
includes all special information needed to communicate
with a specific device (e.g., Pulsar RX5). There are two
basic categories of DTMs—Communication (HART,
Fieldbus®,Profibus®,etc.) and Field Device (e.g. Pulsar
RX5 Radar transmitter).
MOST COMMONLY USED SCREENS
• Online parameterization: allows the user to configure the
unit online.
• Offline parameterization: allows the user to configure the
unit offline.
•Tank view: displays a common operating window
graphically showing % output of level.
•Echo curve: shows the actual waveform. The echocurve
isan extremely useful tool for advanced configuration
and troubleshooting.
• Process trend: all key data (Level, % Output, Loop) can
be trended and saved, scales can be adapted.
• Device/diagnosis: the diagnosis: the diagnosis screen
allows examination of all faults, warnings and
international messages.
TROUBLESHOOTING
This program offers a wealth of information critical to
effective troubleshooting. If a problem should arise and
factory assistance is necessary for analysis, be prepared to
save and email the following files:
•ONLINE PARAMETERS: the complete list of
configuration data.
•PROCESS TREND information that includes the time of
upset/error condition.
•Diagnostics: list of possible error messages.
See page 9.
•ERROR MONITOR (VIEW/ERROR MONITOR)
including upset/error condition.
MINIMUM SYSTEM REQUIREMENTS
Following are general requirements for proper operation of
this program:
Pentium®II 500 MHz processor.
128 MB RAM.
120 MB free hard disk space.
Windows®XP/2000 (Service Pack 1) / NT 4.0 (Service
Pack 6).
Graphic Resolution 1024x768 (16-bit color).
Internet Explorer 5.0.
RS232 serial interface.
RS232-HART or USB-HART serial interface for point-to-
point connection or RS232-RS485 converter for connection
to Hart Multiplexer.
HART communication DTM.
Transmitter with current HART revision.
CONNECTIONS
The following diagram shows a typical hardware
configuration. Observe all safety codes when attaching to
instrument loops in hazardous areas or when measuring
flammable media. Computers are not intrinsically safe
devices.

8
CALIBRATION – INTERFACE: all interface transmitters are pre-calibrated from factory
INTERFACE ANY MEDIA - USING THE REAL MEDIA FOR CALIBRATION
DISPLACER MUST REMAIN ALWAYS IMMERGED IN THE UPPER LIQUID
IMPORTANT
air/gases
upper liquid
interface set 4 mA
lower liquid
Calibrate 4 mA/0 % level
Bring interface at lowest level
Push = start calibration – loop will go to 22 mA.
Push = lock 4 mA value – red ZERO LED must be
ON
Push = red ZERO LED turns OFF,after ± 5 s LED
flashes 1x to confirm the new 4 mA setting.
Note: DO NOT move level/push any buttons
before the LED has flashed. Restart the
procedure if any of these occurred.
air/gases
upper liquid
interface set 20 mA
lower liquid
Calibrate 20 mA/100 % level:
Bring interface at highest level
Push = start calibration
Push = lock 20 mA value – red SPAN LED must
be ON
Push = red SPAN LED turns OFF,after ± 5 s LED
flashes 1x to confirm the new 20 mA setting.
Note: DO NOT move level/push any buttons
before the LED has flashed. Restart the
procedure if any of these occurred.
INTERFACE WATER (S.G. 1)/OTHER LIQUID - USING WATER FOR CALIBRATION
air/gases
set 4 mA
water
Calibrate 4 mA/0 % level
Immerge displacer for 80 % in water
Push = start calibration – loop will go to 22 mA.
Push =lock 4 mA value – red ZERO LED must be
ON
Push = red ZERO LED turns OFF,after ± 5 s LED
flashes 1x to confirm the new 4 mA setting.
Note: DO NOT move level/push any buttons
before the LED has flashed. Restart the
procedure if any of these occurred.
air/gases
set 20 mA
water
Calibrate 20 mA/100 % level:
Immerge displacer for 100 % in water
Push = start calibration
Push = lock 20 mA value – red SPAN LED must
be ON
Push =red SPAN LED turns OFF,after ±5 s LED
flashes 1x to confirm the new 20 mA setting.
Note: DO NOT move level/push any buttons
before the LED has flashed. Restart the
procedure if any of these occurred.
=S.G. 0.8
S.G. 1.0 =S.G. 0.8
S.G. 1.0
NOTE: Below procedure is based upon an interface water/liquid (S.G. 0.8). When the density of the upper liquid is
different e.g. 0.78, immerge the displacer for 78 % in the example)

9
NOTE: Below procedure is based upon an interface liquid (S.G. 1.2)/liquid (S.G. 0.8). When the density of the upper
liquid is different e.g. 0.78, immerge the displacer for 78 % in the water – see example)
INTERFACE ANY MEDIA - USING WATER FOR CALIBRATION
ERROR MESSAGES - HART®
air/gases
set 4 mA
water
Calibrate 4 mA/0 % level
Immerge displacer for 80 % in water
Push = start calibration – loop will go to 22 mA.
Push = lock 4 mA value – red ZERO LED must be
ON
Push = red ZERO LED turns OFF,after ± 5 s LED
flashes 1x to confirm the new 4 mA setting.
Note: DO NOT move level/push any buttons
before the LED has flashed. Restart the
procedure if any of these occurred.
air/gases
set 18.5 mA
water
Calibrate 20 mA/100 % level:
Immerge displacer for 100 % in water
Push = start calibration
Push = lock 20 mA value – red SPAN LED must
be ON
Toggle /=untill loop signal corresponds with, in
our example, 12 mA
=S.G. 0.8
S.G. 1.2
=S.G. 0.8
S.G. 1.2
CALIBRATION – INTERFACE: all interface transmitters are pre-calibrated from factory
MAINTENANCE
Message Description/Problem Solution
0010 EEPROM fault Replace PC board, partn° 030-2163-003 – see replacement
procedure at page 10 or consult factory.
0020 LVDT Analog/Digital input values out of
range
Replace PC board, partn° 030-2163-003 – see replacement
procedure at page 10 or consult factory.
0040 LVDT wire broken
Replace LVDT, check Replacement Parts list for the proper spare
and follow the replacement procedure at page 10 or consult
factory
0080 Core dropped out of range Consult factory for assistance.
Push = red SPAN LED turns OFF,after ± 5 s LED
flashes 1x to confirm the new 20 mA setting.
Note: DO NOT move level/push any buttons
before the LED has flashed. Restart the
procedure if any of these occurred.
Calculation: = % Span
100 x (1 - Upper S.G.)
Lower S.G. - Upper S.G.
[(20 mA - 4 mA) x 50 %] + 4 mA = 12mA
=50 %
100 x (1 - 0,8)
1.2 - 0,8

10
MAINTENANCE
TROUBLESHOOTING
Symptom Problem Solution
➀In case of fault indication Red ERROR LED will only be ON when unit is set for 22 mA fault indication. When unit is set
for 3.6 mA, Red ERROR LED will NOT go ON.
No loop current Power supply not turned on. Turn on power.
Insufficient source voltage. Aminimum of 12 V DC is required at
terminal TB1 (see wiring on page 3).
Wires broken/improperly connect. Check wiring.
Defective PC board. Replace PC board (see procedure on
page 10).
Zero point cannot be set
to 4.00 mA at low level.
Incorrect supply Check power supply.
Zero incorrectly set. Recalibrate 0 % level.
Displacer hanging-up. Verify proper and level installation.
Span point cannot be increased
to 20.00 mA at high level.
Incorrect supply. Check power supply.
Span incorrectly set. Recalibrate unit.
Displacer hanging-up. Verify proper and level installation.
Excessive loop resistance. Increase power supply voltage,
or decrease loop resistance (max
545 Ω@24 V DC, 450 Ωfor HART®).
Span point cannot be decreased
to 20.00 mA at high level.
Span incorrectly set. Recalibrate unit.
Displacer hanging-up. Verify proper and level installation.
Loop current oscillates or hunts. Waves or disturbances in medium. Adjust damping via Hart®.
Loop current randomly unstable. Waves or disturbances in medium. Adjust damping via Hart®.
Power supply unstable. Repair or replace power supply.
Electrical interference (RFI). Consult factory for assistance.
Loop current 22 mA or 3.6 mA
fault indication ➀.
Stem is broken, LVDT core is missing,
LVDT wire is broken or unplugged
or a circuitry failure occured.
Verify the unit.
Loop current between 3.8 mA
and 4 mA or 20 mA and 20.5 mA.
Level is out of calibrated span but still
is within safety band before fault
indication.
No action is required.
Non-linear output. Incorrect calibration. Recalibrate unit.
Displacer hanging-up. Verify proper and level installation.

11
➅
➅Unplug LVDT
➆
➆Remove LVDT
CAUTION: BENDING THE ENCLOSING TUBE
WILL PERMANENTLY DAMAGE THE UNIT.
MAINTENANCE
REMOVAL OF TRANSMITTER HEAD
REPLACING TRANSMITTER BOARD CHEKING THE LVDT WINDING RESISTANCE
REPLACING LINEAR VARIABLE DIFFERENTIAL
TRANSFORMER (LVDT)
NOTE: Re-install transmitter head on process level sensor.
Be sure housing base is fully seated downward. White
plastic washer is in place and LVDT assembly is fully
seated downward. Replace grip ring.
NOTE: Re-install by reversing the above procedure.
NOTE: Replace LVDT if the secondary winding is out of
range
ENTER
UP
DOWN
ERROR
SPAN
ZERO
(–)
P2
(+)
P1
®
– TB1 +
E S MODULEVEL ®
5300 BELMONT ROAD,
DOWNERS GROVE, IL 60515,
USA.
HEIKENSSTRAAT 6,
B 9240 ZELE,
BELGIUM.
www.magnetrol.com
REFER TO MODULEVEL MANUAL,
BULLETIN 48-615, FOR
INSTALLATION AND OPERATION
INSTRUCTIONS.
TP1
TP2
J1
05-9123-001
ASSEMBLY PART NO.
TB2
D1
P1
P2
C6L5
C5
C3
TB1
+
–
+
–
–+
AW3175
L3
D2
JP1
L6
L4
L2
C1
C4
➂
➂Unlock for repositioning or removal of
head assembly and always relock,
after final positioning
➃
➃Lift
transmitter
head over
enclosing
tube
➁
➁Remove grip ring
➀
➀Disconnect
Power
Size 1/8"
➇
➇Remove 4 screws
➈
➈Remove transmitter
PC board from housing
➀
➀Remove power
➂
➂Remove grip ring
➄
➄Lift LVDT
& PC board
ENTER
UP
DOWN
ERROR
SPAN
ZERO
(–)
P2
(+)
P1
®
–TB1 +
E S MODULEVEL ®
5300 BELMONT ROAD,
DOWNERS GROVE, IL 60515,
USA.
HEIKENSSTRAAT 6,
B 9240 ZELE,
BELGIUM.
www.magnetrol.com
REFER TO MODULEVEL MANUAL,
BULLETIN 48-615, FOR
INSTALLATION AND OPERATION
INSTRUCTIONS.
TP1
TP2
J1
05-9123-001
ASSEMBLY PART NO.
➆
➆Clip plastic tie-wraps
➁
➁Remove wires:
black (-) and red (+)
1. Using a multimeter, check primary winding. Pins 2
and 6 should have approximately 78 to 117 ohms.
2. Secondary winding (pins 1 and 5 or 4 and 8) should
have approximately 72 to 109 ohms. If not in this range,
replace the LVDT.
1234
55
66
77
88
➃
➃Remove bracket screws
➅
➅Unplug LVDT
➀
➀Remove power
➂
➂Remove grip ring
➄
➄Lift LVDT
& PC board
ENTER
UP
DOWN
ERROR
SPAN
ZERO
(–)
P2
(+)
P1
®
– TB1 +
ES MODULEVEL ®
5300 BELMONT ROAD,
DOWNERS GROVE, IL 60515,
USA.
HEIKENSSTRAAT 6,
B 9240 ZELE,
BELGIUM.
www.magnetrol.com
REFER TO MODULEVEL MANUAL,
BULLETIN 48-615, FOR
INSTALLATION AND OPERATION
INSTRUCTIONS.
TP1
TP2
J1
05-9123-001
ASSEMBLY PART NO.
➁
➁Remove wires:
black (-) and red (+)
➃
➃Remove bracket screws

12
Specify replacement parts from table below by reference to transmitter identification letters. Example: E85-KQ3A- ESD
NOTE: WHEN ORDERING PARTS SPECIFY COMPLETE PART AND
SERIAL NUMBERS OF THE INSTRUMENT.
REPLACEMENT PARTS
Item Description
6
Low pressure enclosing tube – max 600 lbs / PN 100
032-6401-007 – Exi
032-6401-010 – Exd
High pressure enclosing tube – 900 lbs / 1500 lbs / 2500 lbs
032-6401-010 – Exi/Exd
Item Description
7Housing cover consult factory
8Junction consult factory
9 E-tube gasket 012-1204-001
11 Stem assembly consult factory
Item Description
12
Low pressure range spring – max 600 lbs / PN 100
0.23-0.54 Up to
+230 °C
(+450 °F)
089-5340-002
From +230 °C
(+450 °F)
to +315 °C
(+600 °F)
089-5340-003
0.55-1.09 089-5340-005 089-5340-006
1.10-2.20 089-5340-008 089-5340-009
High pressure range spring – 900 lbs / 1500 lbs / 2500 lbs
0.23-0.54 Up to
+230 °C
(+450 °F)
089-5340-010
From +230 °C
(+450 °F)
to +315 °C
(+600 °F)
089-5340-010
0.55-1.09
1.10-2.20
13 Cotter pins 010-5203-001 (standard stainless steel cotter pins) – (qty: 2)
Item Description
14
Displacer kits. Consult factory for other S.G. ranges
Length
Low pressure
150-300-600 lbs
High pressure
900 - 1500 - 2500 lbs
mm inches 0.23-0.54 & 0.55-1.09 1.10-2.2 0.55-1.09
356 14 089-6125-001 089-6126-001 089-6125-010
813 32 089-6125-002 089-6126-002 089-6125-011
1219 48 089-6125-003 089-6126-003 089-6125-012
1524 60 089-6125-004 089-6126-004 089-6125-013
1829 72 089-6125-005 089-6126-005 Consult factory
2134 84 089-6125-006 089-6126-006 Consult factory
2438 96 089-6125-007 089-6126-007 Consult factory
2743 108 089-6125-008 089-6126-008 Consult factory
3048 120 089-6125-009 089-6126-009 Consult factory
Item 1
Transmitter PC board
Item 2
LVDT assembly
Item 3
Meter assembly
Item 4
Housing 'O'-rings
Item 5
Junction box / PC board
ESD
030-2163-003
030-2135-001 N/A
089-6562-001
Z30-2194-001
ESA 030-2135-001 N/A
ESH 030-2135-002 N/A
ESE 030-2135-002 N/A
ESI 030-2135-001 037-3308-001
ESG 030-2135-001 037-3308-001
ESK 030-2135-002 037-3308-001
ESF 030-2135-002 037-3308-001
ESJ 030-2135-001 037-3310-001
ES9 030-2135-001 037-3310-001
ES8 030-2135-002 037-3310-001
ES7 030-2135-002 037-3310-001
RSQ 030-2154-002 N/A
089-6562-001
quantity = 2
RSW 030-2154-002 N/A
RST 030-2154-002 037-3308-001
RSX 030-2154-002 037-3308-001
RSZ 030-2154-002 037-3310-001
RS4 030-2154-002 037-3310-001
10 Chamber gasket / ring joint
Flange type Chamber gasket
Chamber ring joint
Body material
Carbon steel 316 / 316L SST
3" 150 lbs RF 012-1301-017 – –
3" 300 lbs RF 012-1301-018 – –
3" 600 lbs RF 012-1204-021 – –
3" 900 lbs RJ –> 012-1904-002 012-1906-002
3" 1500 lbs RJ –> 012-1904-003 012-1906-003
4" 2500 lbs RJ –> 012-1904-011 012-1906-011

13
14
10
13
2
7
8
1
4
3
6
9
12
11
5
REPLACEMENT PARTS
Transmitter P.C. board assembly
Housing cover
Stem assembly
LVDT assembly
Meter
assembly
Housing
"O"-rings
Junction box / PC board
Junction box cover
Enclosing tube
Range spring in
protector (incl.
spring assembly
screws and lock
washer)
Cotter pins
Displacer kit (displacer
and cotter pins)
Chamber gasket /
ring joint
“E” tube gasket

14
SPECIFICATIONS
PHYSICAL/ELECTRONICAL SPECIFICATIONS
PERFORMANCE
Description Specifications
Power (at terminals) ATEX intrinsically safe: 12 to 28,4 V DC (@ 94 mA)
ATEX explosion proof / Non Ex: 12 to 36 V DC
Signal output
4– 20 mA (direct / reverse action)
3,8 to 20,5 mA usable (meets NAMUR
NE 43) with Hart®and AMS®supported
Span 356 mm up to 3048 mm (14" up to 120") (other ranges at request)
Loop resistance 600 Ohm at 24 V DC
Max 545 Ohm when used in combination with 22 mA error signal
Damping 0 to 60 s
Diagnostic alarm 3,6 mA or 22 mA
User interface Zero/span and error LED’s
3-button keypad and/or HART®/ AMS®PACTware®
Display None (blind), or with local analog or
digital meter
Housing material
IP 66, polyester coated cast iron - 1 x 1" NPT cable entry
IP 66, stainless steel - 1 x M20 x 1,5 cable entry
IP 66, polyester coated cast aluminium - 2 x M20 x 1,5 cable entries (one plugged off)
Wetted materials Spring Inconel (other materials at request)
Displacer 316/316L SST (1.4401/1.4404) or 304 SST (1.4301)
Cage materials Carbon steel or 316/316L SST (1.4401/1.4404) (other materials at request)
Approvals
ATEX II 1G EEx ia II C T6, intrinsically safe
ATEX II 1/2G EEx d II C T6, explosion proof
FM/CSA/SAA, explosion proof
GOST-K/GGTN-K – ROSTECH/FSTS: Russian Authorisation Standards
LRS, Lloyds Register of Shipment (marine applications)
Other approvals are available, consult factory
SIL (Safety Integrity Level) Functional safety to SIL 1 / SIL 2 in accordance to IEC 61508 - SFF 66,5 %.
– full FMEDA reports and declaration sheets available at request.
Electrical data Ui = 28,4 V; Ii = 94 mA; Pi = 0,68 W
Equivalent data Ci = 5 nF; Li = 800 µH
Net and gross weight
14 kg (31 lbs) (cast iron housing with meter) - integral unit
6,3 kg (13,80 lbs) (cast aluminium housing with meter) - integral unit
15 kg (33 lbs) (stainless steel housing with meter) - integral unit
Description Specifications
Linearity ±0,25 % of full span for level measurement
Accuracy 0,5 %
Resolution 0,05 % of range ± 1 digit
Repeatability ± 0,20 % of full span
Response time Less than 1s (electronics)
Sampling rate 15 times / s (digital meter: 1.33 / s)
Ambient temperature -40 °C to +70 °C (-40 °F to +160 °F)
Process temperature
-30 °C to +315 °C (+260 °C for steam) @ +40 °C ambient temp
(-20 °F to +500 °F (+600 °F for steam) @ +100 °F ambient temp)
Max. temp. needs to be derated in case of higher ambient temperature.
For lower process temperature – use Stainless steel constructions.
Process pressure Max 355 bar (5150 psi)
Flanged models are downrated to the design pressure of the selected flange.
Max. ambient temp. effect < 0,056 % / °C (< 0,031 % / °F)
Density range Min 0,23 S.G. – Max 2,20 S.G.
Humidity 0-99 %, non condensing
Electromagnetic compatibility Meets CE requirements (EN 61000-6-4, EN 61000-6-2)

15
OPERATING TEMPERATURES
The following charts lists combinations of process and ambient temperatures that should not be exceeded, with standard
instruments
Ambient temp. °C
Process temperature °C
350
300
250
200
150
100
50
30 35 40 45 50 55 60 65 70 75
0
Non-steam applications
Ambient temp. °C
Digit 4 = J/K/L
Process temperature °C
350
300
250
200
150
100
50
30 35 40 45 50 55 60 65 70 75
0
Steam applications
Digit 4 = A/B/C
Digit 4 = D/E/F
Digit 4 = Q/R/T
Digit 4 = M/N/P

16
DIMENSIONS IN mm (inches)
TEMPERATURE EXTENSIONS
Top Mounted
E81/E82 - J/K/L
A
273
(10.75)
cast iron: 1 x 1" NPT
stainless steel:
1 x M20 x 1,5
367 (14.45)
133 (5.24)
133 (5.24)
Level
Range
Side/bottom cage
E83/E84 - J/K/L
A
B
273
(10.75)
273
(10.75)
367 (14.45)
Level
Range
133 (5.24) 133 (5.24)
Level
Range
Side/side cage
E85/E86 - J/K/L
A
B
1" NPT-F drain
(plug not supplied)
1" NPT-F drain
(plug not supplied)
Side/side cage
E85/E86 - J/K/L
A
B
273
(10.75)
Level
Range
Side/bottom cage
E83/E84 - J/K/L
A
B
C
367 (14.45)
273
(10.75)
Level
Range
367 (14.45) 367 (14.45)
cast aluminium: 2 x M20 x 1,5
(one entry plugged off)
Models E8x-D/E/FModels E8x-A/B/C Models E8x-M/N/P
672
(26.45)
469
(18.45)
570
(22.45) 570
(22.45)
Models E8x-Q/R/T
485 (19.1)

17
DIMENSIONS IN mm (inches)
Dimension A for all models
Cage rating SG range 4 th digit Dimension A
150 / 300 / 600 lbs
PN 16 .. PN 100
0.23 - 0.54 J/A/M/D/Q 236 (9.29)
0.55 - 1.09 K/B/N/E/R 186 (7.32)
1.10 - 2.20 L/C/P/F/T 186 (7.32)
900 / 1500 lbs 0.55 - 1.09 K/B/N/E/R 236 (9.29)
2500 lbs 315 (12.40)
Dimensions B and C for external cage models (E83/E84/E85/E86)
Flanged process connections
Flange size Flange rating Connection type Dimensions
B C
1 1/2"
150 / 300 / 600 lbs Slip on - ANSI RF 180 (7.09) 268 (10.55)
600 lbs Weldneck - ANSI RJ 180 (7.09) 268 (10.55)
900 / 1500 lbs Weldneck - ANSI RJ 193 (7.60) 283 (11.14)
2500 lbs Weldneck - ANSI RJ 235 (9.25) 313 (12.32)
2"
150 / 300 / 600 lbs Slip on - ANSI RF 185 (7.28) 273 (10.75)
600 lbs Weldneck - ANSI RJ 185 (7.28) 273 (10.75)
900 / 1500 lbs Weldneck - ANSI RJ 214 (8.43) 303 (11.93)
2500 lbs Weldneck - ANSI RJ 250 (9.84) 328 (12.91)
DN 40 PN 16 .. PN 100 EN/DIN 180 (7.09) 268 (10.55)
DN 50 PN 16 .. PN 100 EN/DIN 185 (7.28) 273 (10.75)
Threaded / Socket weld process connections
Size Cage rating Connection type Dimensions
B C
1 1/2"
150 / 300 / 600 lbs NPT/SW 81 (3.19)
_
900 / 1500 lbs NPT 81 (3.19)
900 lbs SW 81 (3.19)
1500 lbs SW 89 (3.50)
2500 lbs NPT/SW 102 (4.02)
2"
150 / 300 / 600 lbs NPT/SW 84 (3.31)
900 / 1500 lbs NPT 84 (3.31)
900 lbs SW 84 (3.31)
1500 lbs SW 99 (3.90)
2500 lbs NPT/SW 112 (4.41)

18
MODEL IDENTIFICATION – UP TO 600 lbs
LEVEL RANGE
SPECIFIC GRAVITY AND PROCESS TEMPERATURE (consult factory for interface applications)
TRANSMITTER – ELECTRONICS
Standard codes apply for cast iron housing - use "X" description for stainless steel or cast
aluminium housing
E 8 complete code for EZ Modulevel transmitter – up to 600 lbs
356 813 1219 1524 1829 2134 2438 2743 3048 mm
14 32 48 60 72 84 96 108 120 inches
ABCDEFGH I code
BASIC MODEL NUMBER
E 8 1 top mounted EZ Modulevel - Carbon steel construction
E 8 2 top mounted EZ Modulevel - Stainless steel construction
E 8 3 EZ Modulevel with side/bottom cage - Carbon steel construction
E 8 4 EZ Modulevel with side/bottom cage - Stainless steel construction
E 8 5 EZ Modulevel with side/side cage - Carbon steel construction
E8 6 EZ Modulevel with side/side cage - Stainless steel construction
INTEGRAL MOUNT ELECTRONICS REMOTE ELECTRONICS 24 V DC amplifier head
Max +290 °C
➂
(J, K or L)
Max +230 °C
➃
(A, B, C, M, N or P) Max +315 °C
➁
(Q, R or T)
Process Temperature
(codes as per digit 4)
Blind with meter Blind with meter Blind with meter
Analog Digital Analog Digital Analog Digital
ESD ESI ESJ ESH ESK ES8 RSQ RST RSZ 4 - 20 mA with HART®, intrinsically safe
ESA ESG ES9 ESE ESF ES7 RSW RSX RS4 4 - 20 mA with HART®, explosion proof
Local meter Output
& Safety approvals
b. For external cage models
E81/E82 - ANSI HEAD Flange rating E81/E82 - DIN / EN 1092-1 HEAD Flange rating
150 lbs
RF
300 lbs
RF
600 lbs Size Type B1
PN 16
Type B1
PN 25/40
Type B2
PN 63
Type B2
PN 100 Size
RF RJ
G3 G4 G5 G6 3" EA EB ED EE DN 80
H3 H4 H5 H6 4" FA FB FD FE DN 100
K3 K4 K5 K6 6" GA GB GD GE DN 150
E83 ... E86 - ANSI Flange/Cage rating E83 ... E86 - DIN / EN 1092-1 Flange rating
150 lbs
RF
300 lbs
RF
600 lbs Size Type B1
PN 16
Type B1
PN 25/40
Type B2
PN 63
Type B2
PN 100 Size
RF RJ
P3 P4 P5 P6 11/2" flanged
CA CB CD CE DN 40
flanged
Q3 Q4 Q5 Q6 2" flanged
R3 R4 R5 11/2" NPT-F
S3 S4 S5 2" NPT-F
DA DB DD DE DN 50
flanged
T3 T4 T5 11/2" S.W.
U3 U4 U5 2" S.W.
PROCESS CONNECTION
a.
For top mounted connection type
integral integral integral integral remote
mounting
+150 °C +200 °C +230 °C +290 °C ➀+315 °C ➁
max. temp.
J A M D Q 0.23 - 0.54 specific gravity
KB N E R 0.55 - 1.09 specific gravity
LC P F T 1.10 - 2.20 specific gravity
➀Not for applications with steam.
➁Max +260 °C for steam applications
➂Max +150 °C for steam applications
➃Only for applications with steam

19
MODEL IDENTIFICATION – FROM 900 lbs TO 2500 lbs
PROCESS CONNECTION (for DIN flanges consult factory)
a.
For top mounted connection type (E81, E82) - head flange rating
LEVEL RANGE (consult factory for longer level range)
356 813 1219 1524 mm
14 32 48 60 inches
AB C D code
E 8 complete code for EZ Modulevel transmitter – from 900 lbs to 2500 lbs
BASIC MODEL NUMBER
E 8 1 top mounted EZ Modulevel - Carbon steel construction
E 8 2 top mounted EZ Modulevel - Stainless steel construction
E 8 3 EZ Modulevel with side/bottom cage - Carbon steel construction
E8 4 EZ Modulevel with side/bottom cage - Stainless steel construction
E 8 5 EZ Modulevel with side/side cage - Carbon steel construction
E8 6 EZ Modulevel with side/side cage - Stainless steel construction
SPECIFIC GRAVITY AND PROCESS TEMPERATURE (consult factory for interface applications)
TRANSMITTER – ELECTRONICS
Standard codes apply for cast iron housing - use "X" description for stainless steel or cast
aluminium housing
INTEGRAL MOUNT ELECTRONICS REMOTE ELECTRONICS 24 V DC amplifier head
Max +290 °C
➂
(J, K or L)
Max +230 °C
➃
(A, B, C, M, N or P) Max +315 °C
➁
(Q, R or T)
Process Temperature
(codes as per digit 4)
Blind with meter Blind with meter Blind with meter
Analog Digital Analog Digital Analog Digital
ESD ESI ESJ ESH ESK ES8 RSQ RST RSZ 4 - 20 mA with HART®, intrinsically safe
ESA ESG ES9 ESE ESF ES7 RSW RSX RS4 4 - 20 mA with HART®, explosion proof
Local meter Output
& Safety approvals
900 lbs RJ 1500 lbs RJ 2500 lbs RJ
Type size
G7 – – 3" size
H7 H8 H9 4" size
K7 K8 K9 6" size
b. For external cage models (E83, ... E86) - ANSI rating
900 lbs RJ 1500 lbs RJ 2500 lbs RJ
Flange rating connection
P7 P8 P9 1 1/2" ANSI Flanges
Q7 Q8 Q9 2" ANSI Flanges
900 lbs 1500 lbs 2500 lbs
Cage rating connection
R7 R8 R9 1 1/2" NPT-F
S7 S8 S9 2" NPT-F
T7 T8 T9 1 1/2" Socket Weld
U7 U8 U9 2" Socket Weld
integral integral integral integral remote
mounting
+150 °C +200 °C +230 °C +290 °C ➀+315 °C ➁
max. temp.
K B N E R 0.55 - 1.09 specific gravity
➀Not for applications with steam.
➁Max +260 °C for steam applications
➂Max +150 °C for steam applications
➃Only for applications with steam

IMPORTANT
SERVICE POLICY
RETURNED MATERIAL PROCEDURE
Owners of Magnetrol products 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. Magnetrol International will repair or replace the control, at no cost to
the purchaser, (or owner)
other than transportation cost if:
a. Returned within the warranty period; and,
b. The factory inspection finds the cause of the malfunction to be defective material or workmanship.
If the trouble is the result of conditions beyond our control; or, is NOT covered by the warranty, there will be charges for labour
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, labour, direct or consequential damage will be allowed.
So that we may efficiently process any materials that are returned, it is essential that a “Return Material Authorisation” (RMA)
form will be obtained from the factory. It is mandatory that this form will be attached to each material returned. This form is
available through Magnetrol’s local representative or by contacting the factory. Please supply the following information:
1. Purchaser Name
2. Description of Material
3. Serial Number
4. Desired Action
5. Reason for Return
6. Process details
All shipments returned to the factory must be by prepaid transportation. Magnetrol will
not accept collect shipments.
All replacements will be shipped FOB factory.
®
www.magnetrol.com
BENELUX Heikensstraat 6, 9240 Zele, België
Tel. [phone] • Fax. [phone] • E-Mail: [e-mail]
DEUTSCHLAND Alte Ziegelei 2-4, D-51491 Overath
Tel. 02204 / 9536-0 • Fax. 02204 / 9536-53 • E-Mail: [email protected]
FRANCE 40 - 42, rue Gabriel Péri, 95130 Le Plessis Bouchard
Tél. [phone] • Fax. [phone] • E-Mail: [email protected]
ITALIA Via Arese 12, I-20159 Milano
Tel. [phone] (R.A.) • Fax. [phone] • E-Mail: [email protected]
UNITED Unit 1 Regent Business Centre, Jubilee Road Burgess Hill West Sussex RH 15 9TL
KINGDOM Tel. [phone] • Fax [phone] • E-Mail: [email protected]
INDIA E-22, Anand Niketan, New Delhi - 110 021
Tel. [phone] • Fax [phone] • E-Mail: [email protected]
BULLETIN N°:BE 48-616.6
EFFECTIVE: APRIL 2007
SUPERSEDES: September 2004
UNDER RESERVE OF MODIFICATIONS