Monitor Technologies MK-2 RF Guide

Remote Calibration Module For
Model MK-2 RF Capacitance Level Sensor
Remote Calibration Module
BULLETIN
434B
INSTALLATION & OPERATION
®
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Remote Calibration Module ever requires service either in or out of war-
ranty, please contact us and obtain an RMA number prior to shipping the
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The Remote Cal Module is designed to be used in conjunction
with a the MK-2 RF Capacitance Level Sensor. The module has
the capability to setup, test and display the various sensor func-
tions from a remote location. This is especially beneficial in
applications where the sensor's accessibility is limited or restrict-
ed, in cases where visual indication of the sensor's conditions
are critical, or in hazardous location applications where it is
unsafe to remove the sensor's cover with power applied. The
ergonomic panel mounted package can be installed to a facility's
control panel where all the functions required to operate the MK-
2 Level Sensor can be performed with a push of a button. One
Remote Cal Module is required for each MK-2 being controlled.
MECHANICAL INSTALLATION
2
ELECTRICAL INSTALLATION
Figure 1 Figure 2
DIMENSIONS ARE SHOWN IN INCHES WITH MILLIMETER EQUIVALENT IN BRACKETS
The Remote Cal Module is packaged as a panel-mount device
with a watertight faceplate. The exposed electronics must be
given proper environmental, mechanical and electrostatic dis-
charge (ESD) protection during handling and installation. Final
installation of the module can be done in a variety of user sup-
plied control panels.
Location
The module can be placed up to 1000 feet from the sensor.
Select a location with moderate lighting so the indicators will
brightly illuminate. The environmental conditions should be in
accordance the specifications listed on page 4. Standard dust-
tight or water-tight cabinets are acceptable depending on the
application. Furthermore, it is recommended to locate the mod-
ule away from electrical equipment which has the capability to
generate electrical surges (i.e. motors, relays, pumps etc.).
Mounting
The module is designed to fit in a standard 1/16 DIN cutout.
Punch or cut hole in desired cabinet as depicted in Figure 1.
Handle the module by the metallic faceplate to eliminate possibil-
ity of electrostatic discharge (ESD) to the circuit. Remove the
retainer bars from the Remote Cal Module by removing the four
corner nuts and lockwashers. Do not remove the gasket from the
backside of the faceplate. Slip module through front side of hole
with the four studs protruding through the cutout. From backside
of hole, reattach retainer bars and tighten nuts and lockwashers
evenly until gasket is roughly 50% compressed (final gasket
thickness approximately 1/16").
DIMENSIONS ARE SHOWN IN INCHES WITH MILLIMETER EQUIVALENT IN BRACKETS

Figure 3
3
CALIBRATION
The Remote Cal Module connects directly to the MK-2 sensor via
a four conductor shielded cable. See Figure 2. Recommended
cable type is Belden 9534 or equivalent. Remove power from the
MK-2 which will connect to the Remote Cal Module. The cable
may be routed through the same conduit as other MK-2 control
wires. Located on the Remote Cal Module is a four-position con-
nector which can be deplugged to simplify wire insertion.
Interconnect the "+D", "-D", "+S" and "-S" on the module to the
respective terminals in the sensor. Note that the sensor's termi-
nal block is not depluggable but its labeling is identical to that of
the Remote Cal Module. Complete the installation by connecting
the shield's drain wire to earth ground at the sensor end only.
The operation of the primary functions on the Remote Cal
Module (i.e. calibration, sensitivity, test and associated indica-
tors) is identical to the operation of those found on the MK-2 RF
Capacitance Sensor. Activation of the module's functions affect
the sensor the same as if the push-button was pressed on the
sensor itself. Status indicators on the module will emulate those
on the sensor. See Figure 3.
Calibration
The calibration of the unit is executed with the push-button des-
ignated "CAL". The purpose of the calibration is to null out or
ignore any initial capacitance due to vessel configuration or
extreme material build up on the probe and shield. When prop-
erly calibrate, the green "CAL" indicator will be illuminated. To
initiate the calibration of the unit, first ensure that the probe is not
submerged in product. Then press and release the "CAL" but-
ton. The "CAL" indicator will flash for a short period. If proper
calibration occurs, the flashing will be followed by a continuous-
ly lit "CAL" indicator. The procedure can be done at anytime after
installation providing the material level has not reached the probe
in order to null out extreme conductive build-up or changes in the
configuration of the probe or vessel.
Sensitivity
The sensitivity of the unit relates the amount of capacitance (in
excess of the calibration value) required to place the sensor into
the detect mode (product sensed). There are four sensitivity set-
tings, "1" being the most sensitive, and "4" being the least sensi-
tive. Therefore, materials with lower dielectric constants will
require the unit to be set to a lower numbered sensitivity setting
for maximum sensing capacity. Materials with higher dielectric
constants can be set to a higher numbered sensitivity setting, so
to provide an additional amount of build-up immunity. See Figure
4 for recommended settings. The sensitivity selection of the sen-
sor is incremented by pressing and releasing the "SEN" push-
button. The existing sensitivity setting of the MK-2 sensor is
shown by the sensitivity indicators. If the unit does not sense
product when the probe is covered with material, choose a lower
numbered sensitivity setting. Conversely, if the sensor tends to
false sense (sensing when the probe is not covered with prod-
uct), increment to a higher numbered sensitivity setting.
Figure 4
SENSITIVITY SETTING OF THE MK-2
SENSITIVITY
SETTING
1
2
3
4
DETECTION
CAPACITANCE
0.5pf
2.6pf
8.3pf
18.0pf
MATERIAL
DIELECTRIC
1.5 - 2.0
2.0 - 4.0
4.0 - 7.0
> 7.0
TYPICAL
APPLICATIONS
PLASTICS, SOAP
, CEMENT
SAND, RUBBER, OILS, COAL
GRAINS, FERTILIZERS, FEED
WASTEWATER, SLURRIES, ANY
WATER BASED SOLUTIONS
Test Function
When initiated, the test function checks the MK-2 sensor's oper-
ation by effectively placing a capacitance value on the probe in
accordance with the sensitivity setting selected. Having the
capability to perform this function from the remote location is par-
ticularly important when the MK-2 is a high level sensor which is
infrequently covered with material. Performance verification pro-
vides additional assurance that the sensor remains ready to
sense product when present. To activate, first ensure that the
unit is calibrated properly indicated by an illuminated "CAL" indi-
cator, and that the probe is not submerged in product. Next,
press and hold the "TST" push-button. Proper operation of the
MK-2 is indicated by illumination of the "DET" indicator. If the
"TST" push-button is continuously pressed longer than the time
delay setting (adjustable on sensor only) the "OPR" indicator will
be activated as well. (Note: The relay contacts at the sensor will
change states whenever the "OPR" indicator status changes. Be
sure the application can tolerate a temporary change in the out-
put prior to activating the test function.) Improper operation is
indicated by the failure of the "DET" indicator to illuminate.
Lockout
In some applications, it may be desirable to restrict access to the
calibration and sensitivity functions after initial MK-2 setup. A
lockout feature is provided on the module PCB which will disable
the Remote Cal Module's "CAL" and "SEN" push-buttons. Select
the desired mode by positioning the slide switch in at either "ON"
(lockout activated) or "OFF" (lockout deactivated) as designated
on the PCB. When lockout is activated, the "LOCKOUT" indica-
tor will illuminate. Note that the test function "TST" push-button
will remain active at all times so verification of operation can still
be made as desired.
Communication Error
In the even of a communication error between the Remote Cal
Module and MK-2 sensor, a visual "error message" will be dis-
played on the Remote Cal Modules sensitivity LEDs. For one
second, the four LEDs will sequentially flash on and off indicating
a communications error. If this occurs repeatedly, see "trou-
bleshooting" section of this bulletin.

WARRANTY
SPECIFICATIONS
434B.2.0404.0M
Monitor Technologies LLC warrants each Remote Calibration
Module it manufactures to be free from defects in material and
workmanship under normal use and service within two (2) years
from the date of purchase. The purchaser must give notice of
any defect to Monitor within the warranty period, return the prod-
uct intact and prepay transportation charges. The obligation of
Monitor Technologies LLC under this warranty is limited to repair
or replacement at its factory. This warranty shall not apply to any
product which is repaired or altered outside of the Monitor
Technologies LLC factory, or which has been subject to misuse,
negligence, accident, incorrect wiring by others or improper
installation. Monitor Technologies LLC reserves the right to
change the design and/or specifications without prior notice.
Operating Temperature: -4˚ to 150˚ F (-20˚ to 65˚ C)
Communications Link: RS-485
Protocol: Proprietary
Power: Supplied from MK-2 Sensor
(24VDC @ 0.1A)
Interconnection Cable: Four conductor, shielded, 24 AWG
(Belden 9534 or equiv)
Interconnection Distance: 1000 ft max (305 m)
Mechanical (cutout): 1/16" DIN 0.94 X 3.77 in
(24 X 96 mm)
Insertion Depth: 3.5 in (89 mm)
Faceplate: Flush mount, water-tight/dust-tight
with gasket, non-hazardous locations
Functions: Calibration, sensitivity and test push-
buttons
Lockout: Internal slide switch-activate or
deactivate lockout
Indicators: "DET" yellow LED illuminates when
material sensed
"OPR" red LED illuminates to indicate
output switching after selected time
delay period
"CAL" green LED illuminates to
indicate that the unit is properly
calibrated
"SEN" bank of four red LEDs indicat-
es the sensitivity setting of the unit
"LOCKOUT" red LED illuminates
when function is activated
Approvals: CE Mark
MECHANICALS
BULLETIN
434B
Monitor Technologies LLC
44W320 Keslinger Rd. tP.O. Box 8048 tElburn, IL 60119-8048 t630-365-9403 t800-766-6486 tFax: 630-365-5646 twww.monitortech.com
DIMENSIONS ARE SHOWN IN INCHES WITH MILLIMETER EQUIVALENT IN BRACKETS
PROBLEM: No LEDs illuminate on the Remote Cal Module.
CAUSE/SOLUTION:
1) Verify polarity of power supply connections "+S" and
"-S".
2) Insure that power is properly supplied to the MK-2
sensor which the Remote Cal Module is connected.
3) Press and release "RESET" switch located on the
Remote Cal Module board. This reboots the internal
software. Wait approximately 3 seconds for software to
reset.
PROBLEM: The sensitivity LEDs repeatedly flash the
communication error message.
CAUSE/SOLUTION:
1) Verify polarity of communication connections "+D" and
"-D".
2) Insure that the "CAL" or "SEN" on the related MK-2
sensor is not being activated while "CAL", "SEN" or
"TST" is activated at the Remote Cal Module.
3) Press and release "RESET" switch located on the
Remote Cal Module board. This reboots the internal
software. Wait approximately 3 seconds for software to
reset.
4) Insure interconnection cable has shield grounded at the
MK-2 sensor.
5) Press and release "RESET" switch located on the
associated MK-2 sensor.
6) Locate and eliminate possible noise sources between
sensor and module. Reroute cable if necessary.
PROBLEM: "CAL" and "SEN" functions do not operate at
the Remote Cal Module.
CAUSE/SOLUTION:
1) Insure the "LOCKOUT" selector switch located on the
Remote Cal Module is in the "off" position.
TROUBLESHOOTING