Magnetrol STI Kotron 80 User manual

Installation and Operating Manual
Kotron®
Model 80/81
RF Point
Level
Switches

Read this Manual Before Installing
This manual provi es information on Kotron Mo el
80/81 RF Point Level Switches. 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
materials. In this manual, a caution box in icates a
potentially 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
Follow all stan ar in ustry proce ures for servicing elec-
trical equipment when working with or aroun 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 use
in a manner not specifie by manufacturer, protection
provi e by equipment may be impaire .
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.
Notice of Trademar , Copyright, and Limitations
Magnetrol & Magnetrol logotype, STI an STI logotype,
an Kotron are registere tra emarks of Magnetrol
International, Incorporate .
Copyright © 2007 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 eter-
mine 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 inter-
national quality stan ar s provi ing
the strongest assurance of pro uct/
service quality available.

Table of Contents
1.0 Introduction
1.1 Principle of Operation...........................................1
1.2 Description............................................................1
2.0 Installation ...................................................................2
2.1 Unpacking.............................................................2
2.2 Installation Location..............................................2
2.2.1 Metal Walle Tanks ....................................2
2.2.2 Tanks/Silos w/Non-Con uctive Materials
of Construction ..........................................3
2.3 Horizontal Mounting ............................................3
2.3.1 Narrow Differential Single Point
Units Only..................................................3
2.4 Vertical Mounting .................................................4
2.5 Mounting Proce ure..............................................4
2.5.1 Integral Mount with Rigi Probe................4
2.5.2 Integral Mount with Flexible Probe ............5
2.5.3 Remote Mount with Rigi Probe ...............6
2.5.3.1 Main Amplifier .....................................6
2.5.3.2 Preamplifier ..........................................6
2.5.4 Remote Mount with Flexible Probe............6
2.5.4.1 Main Amplifier .....................................6
2.5.4.2 Preamplifier ..........................................7
2.6 Electrostatic Discharge (ESD)
Han ling Proce ure ..............................................8
2.7 Wiring...................................................................8
2.7.1 Integral Mount Mo els...............................8
2.7.1.1 Relay Wiring.........................................8
2.7.1.2 Power Wiring........................................8
2.7.2 Remote Mount Mo els...............................9
2.7.2.1 Probe Preamplifier Wiring ....................9
2.7.2.2 Relay Wiring.......................................10
2.7.2.3 Power Wiring......................................10
2.7.3 Relay Wiring Chart ..................................10
2.7.4 Wiring Notes an Definitions ..................11
2.8 Calibration ..........................................................11
2.8.1 Level Range Selection ...............................11
2.8.2 Fail-safe Mo e Selection ...........................12
2.8.2.1 High Level Mo e................................12
2.8.2.2 Low Level Mo e .................................12
2.8.3 Calibration A justments...........................12
2.8.4 Zero A justment.......................................12
2.8.5 Zero an Span A justment.......................13
2.8.5.1 Wi e Differential Vertical Probe
Mount only.........................................13
2.8.6 Time Delay A justment............................14
2.8.6.1 Narrow Differential only.....................14
3.0 Reference Information
3.1 Troubleshooting...................................................15
3.1.1 Probe ........................................................15
3.1.2 Electronics ................................................15
3.1.2.1 Narrow ifferential point units ...........16
3.1.2.2 Wi e ifferential point units...............16
3.2 Agency Approvals ................................................18
3.3 Specifications.......................................................18
3.3.1 Electrical...................................................18
3.3.2 Dimensional – Integral Mounts................19
3.3.3 Dimensional – Remote Mounts................20
3.4 Terminal Connections .........................................21
3.5 Replacement Parts ...............................................22
3.6 Mo el Numbers ..................................................23
NOTES .............................................................................24
Kotron Model 80/81
RF Point Level Switches

150-605 Kotron RF Point Model 80/81 Level Switches
1.0 Introduction
1.1 Principle of Operation
The amount of capacitance evelope in any vessel is
etermine by the size (surface area) of the probe, the is-
tance from the probe to its groun , an the ielectric of
the me ium being measure . Consi ering that the probe’s
mounting position is fixe , an that the ielectric value of
the me ium is constant, then the amount of capacitance
evelope in any vessel becomes epen ent upon the
probe’s total surface area.
A probe’s iameter, together with its length, etermine its
surface area. A justing the combination of probe iameter,
length, an proximity to groun , the necessary capacitance
require by the electronic circuitry can generate.
As me ia rises an falls in the tank, the amount of capaci-
tance evelope between the sensing probe an the groun
also rises an falls. This change in capacitance is sense by
the electronics.
The capacitance-controlle oscillator circuit, mounte
on the probe, changes the capacitance signal to a variable
frequency. This stabilize signal can then be sent to the
main electronics locate up to 5000 feet (1500 meters)
away via stan ar shiel e , twiste pair cable. This
eliminates the 150 feet (45 meters) maximum istance
limitation, using costly coaxial or triaxial cable utilize
by other manufacturers.
1.2 Description
Kotron RF Point Level Switchescan be utilize in level
control applications with either liqui or ry bulk materials.
They can also be use to sense an control viscous, sticky,
highly con uctive materials. The electronic amplifier may
be either mounte irectly on the sensing probe or locate
remote from the probe. In remote applications, the sensing
probe is furnishe with a housing.

50-605 Kotron RF Point Model 80/81 Level Switches 2
2.0 Installation
Caution: Please read the entire installation section carefully prior to
starting installation.
2.1 Unpacking
Unpack the instrument carefully. Make sure all compo-
nents have been remove from the packing material.
Inspect all components for amage. Report any conceale
amage to the carrier within 24 hours. Check the contents
against the packing slip an report any iscrepancies to the
factory. Check the nameplate mo el number to be sure it
agrees with the packing slip an purchase or er. Check
an recor the serial number for future reference when
or ering parts.
2.2 Installation Location
Kotron RF Point Level Switches shoul be locate for easy
access for service, calibration an monitoring. Switches
shoul not be expose to ambient temperatures below
-40° F (-40° C) or above +160° F (+71° C). Special pre-
caution shoul be ma e to prevent exposure to corrosive
atmosphere, excessive vibration, shock or physical amage.
It is common practice to use the metal tank wall as the
reference electro e. In such cases, it is require that the
probe housing makes a goo electrical connection to the
tank wall. If there is any oubt about this connection ue
to the use of PTFE threa tape, gaskets, paint, rust, or any
other reason, a separate strap shoul be installe between
the probe housing an the tank.
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.
2.2.1 Metal Walled Tanks
On water-base liqui s, there shoul be no problem with
sensitivity or linearity. With non-con uctive, low ielectric
me ia, sensitivity can be enhance by locating the probe
close to an parallel with the tank wall. If this is not prac-
tical, a concentric groun tube surroun ing the probe,
sometimes calle a stilling well, may be a solution.

350-605 Kotron RF Point Model 80/81 Level Switches
2.2.2 Tanks/Silos w/ on-Conductive
Materials of Construction
With plastic, concrete, woo , or any other non-con uctive
walle vessels, the reference electro e mentione above
nee s clarification. Most commonly, this electro e will be
in the form of a concentric groun tube (i.e. stilling well).
In questionable circumstances, consult the factory. In all
cases, a goo electrical connection must be ma e between
the groun surface an the probe housing.
NOTE: These comments also apply for glass-lined metal walled
tanks.
Caution: When an insulated probe is used in a hazardous and/or
abrasive medium, the probe should be inspected annually
for any nicks, cuts or abrasions which may ruin the integrity
of the insulation. In the event that wear is found, replace
the probe or consult the factory for further instructions.
This procedure is critical in vessels containing hazardous
media.
2.3 Horizontal Mounting
2.3.1 arrow Differential Single Point Units Only
Horizontally mounte probes provi e a high egree of
sensitivity for use with non-con uctive liqui s as only
approximately 0.625" of level change is require to com-
pletely cover (or uncover) the probe.
Horizontally mounte probe ro s shoul be installe so
that the ro is parallel to an at the level at which control
point is esire . Refer to Figure 1.
Avoi any installation metho in which the material may
become trappe in the mounting nozzle, thus preventing
probe from signaling when level rece es. Refer to Figure 2.
NOTE: If nozzle mounting is unavoidable, probe must be installed
with an inactive metal sheath having a length at least 1 inch
(25 mm) greater than length of nozzle. Sheath is required to
render length of probe within nozzle insensitive to capacitance
change. Refer to Figure 3.
On applications involving viscous liquids or materials which
tend to cling or buildup, horizontal mounting probes should be
installed at a slight downward angle to allow material to drain
from probe rod. With this type installation, packing gland face
of probe assembly should extend into the tank (or vessel).
Refer to Figure 4.
Figure 1
Recommended Horizontal Mounting
Probe Sheath
1" (25 mm) minimum
Figure 2
Recommended Mounting with ozzle
Probe Sheath
Figure 3
ot Recommended
Figure 4
Alternate Horizontal Mounting
for Viscous Materials

50-605 Kotron RF Point Model 80/81 Level Switches 4
2.4 Vertical Mounting
Vertically mounte probes provi e the capability to a just
the control point up or own a section of probe ro by
means of calibration a justments within the unit’s amplifier.
The vertical mounting of a probe ro is the preferre
metho for application involving coating con uctive type
liqui s or con uctive soli s.
Vertically mounte probes shoul be installe so that the
en of the probe ro is at least 2 inches (51 mm) below
the esire level control point with con uctive materials or
4 inches (102 mm) below with non-con uctive materials.
Refer to Figure 5.
2.5 Mounting Procedure
Kotron RF Point Level Switches with probes up to an
inclu ing 12 inches (305 mm) in length are shippe pre-
assemble . Units with probes over 12 inches (305 mm) in
length are shippe unassemble to avoi amage uring
transit. They must be assemble before mounting. Follow
the mounting proce ure for your particular case.
NOTE: Before beginning mounting procedures, make sure the power
source to the unit is turned off.
2.5.1 Integral Mount with Rigid Probe
1. Threa probe into mounting bushing on tank.
2. Tighten securely, being certain that the wrench is applie
ONLY to the lower probe nut.
3. Screw the amplifier housing onto the probe.
5. Remove housing cover.
6. Locate the white wire which is fastene to the (+) Probe
Terminal. Connect the free en of this wire to the Probe
Connection Screw.
7. Procee to Section 2.7, Wiring on page 8.
Figure 5
Recommended Vertical Mounting
Packing Gland Nut
(When installing, use
wrench on this nut only)
ProbeConnection Screw
Figure 6
Rigid Probe Assembly

550-605 Kotron RF Point Model 80/81 Level Switches
2.5.2 Integral Mount with Flexible Probe
Caution: Flexible probes are shipped with the cable clamp and the
probe nut hand tightened. The end of a flexible probe
MUST be secured to the bottom of the tank by either
attachment to a bracket or to a heavy weight in order to
keep the probe taut.
1. Unscrew probe from probe housing. Remove Mylar®hous-
ing insulator locate over the clamp. Refer to Figure 7.
Caution: Do not discard Mylar housing insulator.
2. Attach weight (if use ) to probe en .
3. Insert probe en through tank mounting bushing an fee
cable into the tank. Do not allow probe insulation to be
amage by scraping against the bushing threa s.
Caution: Probe cable must not be in contact with anything metallic
in its final installation position.
4. Secure lower en of probe (or optional weight) to tank
bracket if one is use . Refer to Figure 7.
5. Apply threa sealant to mounting nut.
6. Screw mounting nut into tank bushing until tight.
Caution: Apply wrench to lower probe nut only.
NOTE: Do not allow the probe to fall in the tank while following steps
7 through 11.
7. Loosen both socket clamp screws.
8. Pull clamp an Teflon®retaining bushing off probe.
9. While hol ing probe cable, loosen upper probe nut.
10. Pull excess cable up through probe nuts until cable is taut.
11. Tighten the probe nuts.
12. Cut off cable 1.35 inches (34 mm) above top of upper
probe nut an strip off 1.25 inches (32 mm) of insulation.
13. Sli e Teflon retaining bushing onto cable an seat it into
the upper probe nut.
14. Sli e clamp onto cable an seat it in the Teflon retaining
bushing.
15. Tighten both socket hea clamp screws to approximately
35 in./lbs. torque.
16. Slip Mylar housing insulator over clamp.
17. Screw housing onto probe an tighten. Make sure con uit
connection is properly aligne for wire entry.
Caution: Check probe terminal connection carefully to be certain
lug will not short to packing gland or interfere with assem-
bly of amplifier housing to probe.
18. Procee to Section 2.7, Wiring on page 8.
Probe Connection
Screw
Socket Head
Clamp Screws (2)
Upper Probe
Mounting Gland
Lower Probe
Mounting Gland
MylarHousing
Insulator (slips
over clamp)
Teflon
Retaining
Bushing
Clamp
Optional Weight
TankBracket
Connection
Optional
Mounting
Bracket
(Usedw/
Insulated
Probes)
Probe Locking
Set Screw
Flexible
Probe
Probe
Termination
Figure 7
Flexible Probe Assembly

50-605 Kotron RF Point Model 80/81 Level Switches 6
2.5.3 Remote Mount with Rigid Probe
2.5.3.1 Main Amplifier
Remote amplifier assemblies are normally shippe from
the factory assemble into an “L” mounting bracket.
Refer to Figure 8 while following instructions.
1. Remove amplifier from mounting bracket.
2. Install bracket in a location which will isolate unit from
temperatures below -40° F (-40° C) an over +160° F
(+71° C) or vibration/mechanical amage. Unit can be
mounte up to 5000 feet (1500 meters) from probe
assembly. Location shoul also offer easy access for wiring,
calibration an maintenance.
3. Re-install amplifier onto mounting bracket.
4. Screw housing on mounting bracket until han tight.
Housing can be wrench tightene to align con uit
connection with con uit.
2.5.3.2 Preamplifier
1. Threa probe into mounting bushing on tank.
2. Tighten securely being certain that the wrench is applie
ONLY to the lower probe nut. Refer to Figure 8.
3. Screw the preamplifier housing onto the probe. Refer to
Figure 8.
4. Screw housing on probe until han tight. Housing can be
wrench-tightene to align con uit connection with con-
uit. Procee to Section 2.7, Wiring on page 8.
2.5.4 Remote Mount with Flexible Probe
2.5.4.1 Main Amplifier
Remote amplifier assemblies are normally shippe from
the factory assemble into an “L” mounting bracket.
Refer to Figure 8 while following instructions.
1. Remove amplifier from mounting bracket.
2. Install bracket in a location which will isolate unit from
temperatures below -40° F (-40° C) an over +160° F
(+71° C) or vibration/mechanical amage. Unit can be
mounte up to 5000 feet (1500 meters) from probe
assembly. Location shoul also offer easy access for wiring,
calibration an maintenance.
3. Re-install amplifier onto mounting bracket.
4. Screw housing on mounting bracket until han tight.
Housing can be wrench-tightene to align con uit
connection with con uit.
Amplifier
Housing
Probe
Terminal
Power
Wire
Conduit Supplied
By User
Conduit Supplied
By User
Shielded
Twisted
Pair
Mounting
Bracket
Probe
Housing
Packing
Gland
Nut
Probe
Connection
Screw
Rigidor
Flexible
Probe
Figure 8
Side View Remote Mount Models
with Rigid or Flexible Probe

750-605 Kotron RF Point Model 80/81 Level Switches
2.5.4.2 Preamplifier
Caution: Flexible probes are shipped with the cable clamp and the
probe nut hand tightened. The end of a flexible probe
MUST be secured to the bottom of the tank by either
attachment to a bracket or to a heavy weight in order to
keep the probe taut.
1. Unscrew probe from probe housing. Remove Mylar hous-
ing insulator locate over the clamp. Refer to Figure 7 on
page 5.
Caution: Do not discard Mylar housing insulator.
2. Attach weight (if use ) to probe en .
3. Insert probe en through tank mounting bushing an
fee cable into the tank. Do not allow probe insulation to
be amage by scraping against the bushing threa s.
Caution: Probe cable must not be in contact with anything metal-
lic in its final installation position.
4. Secure lower en of probe (or optional weight) to tank
bracket if one is use .
5. Apply threa sealant to mounting nut.
6. Screw mounting nut into tank bushing until tight.
Caution: Apply wrench to lower probe nut only.
NOTE: Do not allow the probe to fall in the tank while following steps
7 through 11.
7. Loosen both socket clamp screws.
8. Pull clamp an Teflon retaining bushing off probe.
9. While hol ing probe cable, loosen upper probe nut.
10. Pull excess cable up through probe nuts until cable is taut.
11. Tighten the probe nuts.
12. Cut off cable 1.35 inches (34 mm) above top of upper
probe nut an strip off 1.25 inches (32 mm) of insulation.
13. Sli e Teflon retaining bushing onto cable an seat it into
the upper probe nut.
14. Sli e clamp onto cable an seat it in the Teflon retaining
bushing.
15. Tighten both socket hea clamp screws to approximately
35 in./lbs. torque.
16. Slip Mylar housing insulator over clamp.
17. Screw housing onto probe an tighten. Make sure con uit
connection is properly aligne for wire entry.
18. Locate the white wire which is fastene to the (+) Probe
Terminal on the circuit boar . Connect the free en of
this wire to the Probe Connection Screw. Refer to
Figure 7 on page 5.

50-605 Kotron RF Point Model 80/81 Level Switches 8
Caution: Check probe terminal connection carefully to be certain
lug will not short to packing gland or interfere with assem-
bly of amplifier housing to probe.
19. Procee to Section 2.7, Wiring.
2.6 Electrostatic Discharge (ESD)
Handling Procedure
Magnetrol’s electronic instruments are manufacture to
the highest quality stan ar s. These instruments utilize
electronic components which may be amage by static
electricity present in most work environments. The
following steps are recommen e to re uce the risk of
component failure ue to electrostatic ischarge:
1. Ship an store circuit boar s in anti-static bags. If an
anti-static bag is not available, wrap boar in aluminum
foil. Do not place boar s on foam packing materials.
2. Use a groun ing wrist strap when installing an
removing circuit boar s. A groun e workstation is
also recommen e .
3. Han le printe circuit boar s only by the e ges. Do not
touch components or connector pins.
4. Ensure that all electrical connections are completely ma e
an none are partial or floating. Groun all equipment to
a goo , earth groun .
2.7 iring
2.7.1 Integral Mount Models
Light gauge (16 AWG or 18 AWG) stran e wire shoul
be use for connection of power an control circuits.
2.7.1.1 Relay Wiring
See Section 2.7.3, Relay Wiring Chart on page 10 for
ifferent relay wiring options.
2.7.1.2 Power Wiring
1. Make sure power source is turne off.
2. Pull power supply wires through con uit connection.
3. Connect AC power to AC(+), AC(–) an GND terminals.
Connect DC power to DC(+) an GND terminals. Refer
to Section 3.4, Terminal Connections on page 21.
4. Dress the wires together neatly an securely with cable ties.
Be certain that a equate clearance exists for replacement of
housing cover.

950-605 Kotron RF Point Model 80/81 Level Switches
Caution: Observe all applicable electrical codes and proper wiring
procedures.
5. Replace housing cover.
6. Power up unit an procee with calibration of instrument
as escribe in instructions following.
NOTE: Be certain to route all power and control wires through con-
duit outlet only and run probe wire up through center hole in
amplifier housing base. Supply voltage and signal wires
should not be run in the same conduit.
2.7.2 Remote Mount Models
Remote type units are furnishe with a preamplifier hous-
ing having a circuit boar with preamplifier-to-amplifier
terminals. Preamplifier connection terminals are locate
at the upper left si e of the preamplifier circuit boar .
Refer to Figure 9.
Locate the white wire which is fastene to the (+) Probe
Terminal on the circuit boar . Connect the free en of
this wire to the Probe Connection Screw. Refer to
Figure 6 on page 4.
2.7.2.1 Probe Preamplifier Wiring
1. Strip approximately .75 inch of outer jacket insulation
from each en of the con uctor.
2. At the probe preamplifier en , twist the black wire an
shiel together to form a single con uctor. Crimp on sol-
erless connectors securely to both re an black lea s.
3. Connect the re lea to the positive (+) terminal on the
probe preamplifier boar . Refer to Figure 9.
4. Connect the black wire an shiel to the negative (–)
terminal on the probe preamplifier boar .
5. At the main amplifier location, twist the black wire an
shiel together to form a single con uctor.
6. Crimp on sol erless connectors securely to both the
re an black lea s.
7. Connect re lea to positive (+) terminal on the
amplifier. Refer to Section 3.4, Terminal Connections on
page 21.
8. Connect black wire an shiel to the negative (–)
terminal on the amplifier.
++--
++--
++--
TB1
POWER LOHI
PROBE
Connect white wire to
probe connection screw.
Probe range
jumper (JU1)
Probe preamplifier to
positive and negative
terminals on amplifier.
(+) (—)
Figure 9
Probe preamplifier circuit board

50-605 Kotron RF Point Model 80/81 Level Switches 10
2.7.2.2 Relay Wiring
Refer to Section 2.7.3, Relay Wiring Chart for ifferent
relay wiring options. Refer to Section 3.4, Terminal
Connections on page 21 for terminal locations.
2.7.2.3 Power Wiring
1. Make sure power source is turne off.
2. Pull power supply wires through con uit connection.
Refer to Figure 8 on page 6.
3. Connect AC power to AC(+), AC(–) an GND terminals.
Connect DC power to DC(+) an GND terminals.
Refer to Section 3.4, Terminal Connections on page 21.
4. Dress the wires together neatly an securely with cable
ties. Be certain that a equate clearance exists for
replacement of housing cover.
Caution: Observe all applicable electrical codes and proper wiring
procedures.
5. Replace housing cover.
6. Power up unit an procee with calibration of instrument
as escribe in instructions following.
NOTE: Be certain to route all power and control wires through con-
duit outlet only and run probe wire up through center hole in
amplifier housing base. Supply voltage and signal wires
should not be run in the same conduit.
2.7.3 Relay Wiring Chart
Kotron
Power
Material
Level
Fail-safe
Position Relay Coil Relay Terminal
COM to C COM to O
On
igh
L De-energized Closed Open
LL Energized Open Closed
Low
L Energized Open Closed
LL De-energized Closed Open
OFF
(Fail)
igh
L De-energized Closed Open
LL De-energized Closed Open
Low L De-energized Closed Open
LL De-energized Closed Open

11 50-605 Kotron RF Point Model 80/81 Level Switches
2.7.4 Wiring otes and Definitions
1. Equipment controlle by the Kotron relays is assume to
be powere from one source, while the Kotron unit itself is
assume to be powere from a ifferent source.
2. There is a fail-safe switch on the Kotron unit, which may
be set in either a HL or LL position.
3. “Fail” means a loss of power to the Kotron unit.
4. HL (high level) means a material level in the tank, which
is equal to or above:
a. The setting of a narrow ifferential point.
b. The higher setting of a wi e ifferential point.
5. LL (low level) means a material level in the tank, which is
equal to or below:
a. The setting of a narrow ifferential point.
b. The lower setting of a wi e ifferential point.
6. When the relay coil is e-energize (fail-safe), a connection
is ma e between common (COM) an the normally
close (NC) an there is no connection between common
(COM) an the normally open (NO) terminals.
7. When the relay coil is energize , a connection is ma e
between the terminals COM an NO, an there is no
connection between CM an NC.
2.8 Calibration
Caution: When instrument calibration is to be done in a hazardous
location, extra steps and precautions must be taken.
Power must be turned off before housing cover is
removed from unit amplifier.
All pre-installation checks on the instrument shoul be
one in a non-hazar ous area in or er to minimize the
amount of work require on the unit after installation.
Instrument can be checke on the bench, preferably with
the process material, by temporarily connecting power an
performing the steps outline in the calibration a just-
ment instructions.
2.8.1 Level Range Selection
The preamplifier circuit boar has a range jumper (JU1),
see Figure 9 on page 9. For remote units, this boar is
locate in the probe enclosure.

50-605 Kotron RF Point Model 80/81 Level Switc es 12
The positio of the jumper is depe de t upo the fluid
bei g measured. Locate this jumper i the "LO" positio
if the fluid is o -co ductive (dielectric less tha 10);
for co ductive fluids, positio this jumper i the "HI"
positio .
For arrow differe tial u its, always place the jumper i
the "LO" positio .
2.8.2 Fail-safe Mode Selection
The fail-safe mode is selected for the particular level
detectio applicatio to provide for relay co tact closure
upo a y loss of electrical power.
To select the appropriate relay state, locate the small toggle
switch o upper right portio of circuit board a d switch
to HL for high level mode or LL for low level mode. Refer
to Sectio 3.4, Terminal Connections o page 21.
2.8.2.1 Hig Level Mode
I this mode, a electrical power failure will de-e ergize
the relay causi g the co tacts to assume a positio as if
product level were at or above the set poi t.
2.8.2.2 Low Level Mode
I this mode, a electrical power failure will de-e ergize
the relay causi g the co tacts to assume a positio as if
product level were at or below the set poi t.
2.8.3 Calibration Adjustments
Adjustme ts should be performed with u it u der actual
operati g temperature a d pressure co ditio s. Zero a d
spa adjustme ts are located at upper left o amplifier cir-
cuit board. A level ra ge select jumper is also provided. It
is located o the preamplifier board of si gle poi t i tegral
u its a d all remote u its. Be sure that the proper ra ge
has bee selected. Refer to Sectio 2.8.1, Level Range
Selection o previous page.
2.8.4 Zero Adjustment
1. With the probe i stalled i the vessel a d the process
material at or below the desired set poi t, tur ZERO
adjustme t pote tiometer o the left ha d side of the
pri ted circuit assembly clockwise (CW) a mi imum of
twe ty full tur s or u til a clicki g sou d is detected.
NOTE: Be sure Fail-safe Mode Selection as been set correctly. Refer
to Fail-safe Mode Selection above and Relay Wiring Chart on
page 10.

13 50-605 Kotron RF Point Model 80/81 Level Switches
2. Set the fail-safe mo e for the alarm relays:
a. In low level fail-safe mo e, the alarm relay will be
e-energize when the material level is BELOW the
alarm set point.
b. In high level fail-safe mo e, the alarm relay will be
e-energize when the material level is ABOVE the
alarm set point.
3. Energize the instrument. The calibrate LEDs will be on
regar less of the settings of the fail-safe switches or time
elay setting. Relays set in the low level fail-safe (LLFS)
mo e will be energize an there will be continuity
between the common (CM) an normally open (NO)
relay terminations. This can be checke with an ohmmeter
or other suitable continuity checking evice. Relays set in
the high level fail-safe (HLFS) mo e will be e-energize
an there will be continuity between the common (CM)
an normally close (NC) relay terminations.
4. If the vessel is not fille to the esire set point, increase
level of material to the require set point.
5. Turn the zero a justment counterclockwise (CCW) until
LED in icator goes off (the relay will change state), then
turn the control slowly in the CW irection until the LED
in icator again comes on. Repeat this on–off proce ure
several times an leave the LED in icator on. The narrow
ifferential alarm point is now calibrate .
2.8.5 Zero and Span Adjustment
2.8.5.1 Wide Differential — Vertical Probe Mount Only
1. With the probe installe in the vessel an the process
material at the esire low level, turn both the zero an
span a justment on the left han si e of the printe
circuit boar clockwise a minimum of twenty full turns or
until a clicking soun is etecte . If the process material is
not at this point, the material level must be change until
this point is reache .
2. Set the fail-safe mo e for the relay: (Be sure Fail-safe
Mo e Selection has been set correctly).
a. In low level fail-safe (LLFS) mo e, relay is e-energize
on rising level an remains e-energize until upper
span point is reache .
b. In high level fail-safe (HLFS) mo e, relay is
e-energize on falling level an remains e-energize
until lower zero point is reache .
3. Energize the instrument. The calibrate LED will be on
regar less of the position of the fail-safe switch.

50-605 Kotron RF Point Model 80/81 Level Switches 14
4. Turn the zero a justment counterclockwise until the LED
in icator goes off (the relay will change state), then turn
the control slowly in the clockwise irection until the in i-
cator again comes on. Repeat this on-off operation several
times an leave the LED indicator OFF. This completes
the zero calibration of the wi e ifferential point.
Prior to increasing the level of material in the tank to the
span point, turn the span control twenty full turns CCW.
THE LED CALIBRATION INDICATOR WILL
REMAIN OFF.
6. Raise the level of the material in the vessel to the esire
high level set point.
7. Slowly rotate the span a justment in a CW irection until
the LED calibration in icator turns ON. The relay will
change state an the wi e ifferential span is now
calibrate . Do not change setting after LED is ON.
NOTE: A second span adjustment check can be made by moving the
span adjustment two (2) turns CCW, then removing the probe
(P) wire momentarily to break the contact. With the probe
reconnected, slowly turn the span adjustment screw in CW
direction until the LED calibration indicator again comes ON.
2.8.6 Time Delay Adjustment
2.8.6.1 Narrow Differential Only
Narrow ifferential amplifiers are equippe with an
a justable (0 to 3 sec) time elay. With the time elay
calibration fully CCW, the elay is at minimum an in
the fully CW position, it is at maximum. On stan ar
units, the elay is effective on rising level, i.e., as the
material level goes above the set point, a time elay will
occur between the LED in icator coming ON an the
relay operating an will eliminate contact chatter in
agitate flui s.

15 50-605 Kotron RF Point Model 80/81 Level Switches
3.0 Reference Information
3.1 Troubleshooting
3.1.1 Probe
Caution: When an insulated probe is used in a hazardous and/or
abrasive medium, the probe should be inspected annual-
ly for any nicks, cuts or abrasions which may ruin the
integrity of the insulation. In the event that wear is found,
replace the probe or consult the factory for further instruc-
tions. This procedure is critical in vessels containing
hazardous media.
To check for malfunctioning sensing probe:
1. Remove the white probe lea form the sensing probe an
isolate it from groun .
2. Connect an ohmmeter between the sensing probe terminal
an groun . (stainless steel probe nut or housing base).
3. Measure the resistance between the probe an the stainless
steel probe nut, or probe electronic housing with an
ohmmeter. (Select the highest resistance scale available).
If the resistance measures infinity, the probe is operating
correctly. If the resistance measures less than infinity, there
may be a problem with the probe. Call the factory for
a itional assistance.
4. Inspect a malfunctioning probe for a cut in the insulating
sheath or looseness in the seal at the probe mounting nut.
If neither is apparent, check for heavy con uctive buil up
between probe an mounting nut.
NOTE: When performing checks 3 and 4 in conductive media, take
resistance reading when medium is at maximum level.
5. If probe test is working properly, check for insufficient
groun , loose or broken wiring, inclu ing white probe
wire. Also check continuity between probe mounting nut
an metal tank — there shoul be continuity (zero resist-
ance). If there is resistance, check for excessive Teflon tape
use on probe threa s.
3.1.2 Electronics
Refer to the following proce ure to test the pre-amplifier
P.C. boar s, the amplifier an the shiel e twiste cable
between the probe an the amplifier.
NOTE: Refer to Figure 14 on page 21 for location of potentiometer.

50-605 Kotron RF Point Model 80/81 Level Switches 16
Caution: This procedure changes any previous calibration of the
amplifier. If the unit checks out as operational, it will have
to be recalibrated before being used in the process.
3.1.2.1 Narrow differential point units
1. Turn off the power to the unit.
2. Remove the lea wire from the probe.
3. Turn the setpoint potentiometers fully counterclockwise.
4. Turn all time elay potentiometers fully counterclockwise.
5. Move the probe level range jumper to the HI position.
Refer to Figure 9 on page 9.
a. When the probe range jumper (switch) is in the HI
position, a low level is simulate . When it is in the LO
position, a high level is simulate .
b. On remote mounte units, this jumper is locate insi e
the probe housing on the probe preamplifier boar .
6. Turn on power to the unit.
7. The re LEDs will be off. A just the narrow ifferential
point potentiometer(s) counterclockwise until the LED(s)
turn on. Then slowly a just each potentiometer clockwise
until the LED turns off.
8. The probe range jumper (switch) can now be switche
between the HI an LO positions an the LEDs will go
on an off. The relays will also go on an off accor ingly.
If your unit operates as escribe above, the probe pream-
plifier boar , the probe preamplifier cable an amplifier
are functioning correctly.
If your unit oes NOT operate as escribe above, it is
malfunctioning. Perform the following checks:
1. Take DC voltage rea ing across probe preamplifier
terminals – shoul be approximately 12 VDC.
2. Take AC voltage rea ing across probe preamplifier
terminals – shoul be .1 to .2 VAC.
3. Consult factory – have test ata available for iscussion.
NOTE: These values can also be taken at probe preamplifier
wiring terminals on remote installations.

17 50-605 Kotron RF Point Model 80/81 Level Switches
3.1.2.2 Wide differential point units
1. Turn off the power to the unit.
2. Remove the lea wire from the probe.
3. Turn the zero an span potentiometers fully clockwise.
NOTE: On wide differential units, the zero potentiometer is located
above the span potentiometer.
4. Move the probe level range jumper to the HI position
board. Refer to Figure 9 on page 9.
a. When the probe range jumper (switch) is in the HI
position, a low level is simulate . When it is in the LO
position, a high level is simulate .
b. On remote mounte units, this jumper is locate insi e
the probe housing on the probe preamplifier boar .
Refer to Figure 9 on page 9.
6. Turn on power to the unit.
7. The re LED will be on. Turn the zero potentiometer
fully counterclockwise. Refer to Figure 10 on page 19.
8. Move the probe range jumper (switch) to the low level
position. Refer to Figure 12 on page 20. The LED will
turn off. If not, turn the span potentiometer slowly coun-
terclockwise until the LED turns off. Refer to Figure 10
on page 19.
9. The LED shoul now turn on an off with movement of
the jumper (switch).
10. The probe range jumper (switch) can now be switche
between the HI an LO positions an the LEDs will go
on an off. The relays will also go on an off accor ingly.
If your unit operates as escribe above, the probe pream-
plifier boar , the probe preamplifier cable an amplifier
are functioning correctly.
If your unit oes NOT operate as escribe above, it is
malfunctioning. Perform the following checks:
1. Take DC voltage rea ing across probe preamplifier
terminals – shoul be approximately 12 VDC.
2. Take AC voltage rea ing across probe preamplifier
terminals – shoul be .1 to .2 VAC.
3. Consult factory – have test ata available for iscussion.
NOTE: These values can also be taken at probe preamplifier
wiring terminals on remote installations.