MTS Systems LevelLimit Level Plus User manual

LevelLimit®
Operation Manual
Level Plus®
Magnetostrictive Liquid Level Transmitters
with Temposonics®Technology

Table of contents
1. Contact information ........................................................................................................................................... 3
2. Terms and definitions ......................................................................................................................................... 4
3. Introduction..................................................................................................................................................... 6
3.1 Purpose and use of this manual ................................................................................................................................................................ 6
3.2 Used symbols and warnings ..................................................................................................................................................................... 6
4. Safety instructions............................................................................................................................................. 6
4.1 Intended use.............................................................................................................................................................................................. 6
4.2 Foreseeable misuse................................................................................................................................................................................... 7
4.3 Installation, commissioning and operation................................................................................................................................................ 7
5. Product overview .............................................................................................................................................. 8
5.1 Components.............................................................................................................................................................................................. 8
5.2 Accuracy.................................................................................................................................................................................................. 10
5.3 Warranty.................................................................................................................................................................................................. 10
5.4 Storage.................................................................................................................................................................................................... 10
5.5 Model number identification.................................................................................................................................................................... 11
5.6 Technical data.......................................................................................................................................................................................... 12
5.7 Technical drawing.................................................................................................................................................................................... 13
6. Installation and mounting ...................................................................................................................................15
6.1 Training ................................................................................................................................................................................................... 15
6.2 Stilling wells and guide poles .................................................................................................................................................................. 15
6.3 Tools........................................................................................................................................................................................................ 15
6.4 Installation steps ..................................................................................................................................................................................... 15
6.5 Mounting................................................................................................................................................................................................. 16
7. Electrical connections........................................................................................................................................17
7.1 Basic information .................................................................................................................................................................................... 17
7.2 Safety recommendations......................................................................................................................................................................... 17
7.3 Industrial topologies................................................................................................................................................................................ 17
7.4 Cable recommendations.......................................................................................................................................................................... 18
7.5 Electrical conduit..................................................................................................................................................................................... 18
7.6 Grounding ............................................................................................................................................................................................... 19
7.7 Safety barriers......................................................................................................................................................................................... 19
8. Commissioning................................................................................................................................................20
8.1 Training ................................................................................................................................................................................................... 20
8.2 Tools........................................................................................................................................................................................................ 20
8.3 Setup software ........................................................................................................................................................................................ 20
8.4 Commissioning steps.............................................................................................................................................................................. 20
9. Maintenance...................................................................................................................................................20
9.1 Training ................................................................................................................................................................................................... 20
9.2 Tools........................................................................................................................................................................................................ 20
9.3 Inspection................................................................................................................................................................................................ 21
9.4 Preventative maintenance........................................................................................................................................................................ 21
10. Repair.........................................................................................................................................................22
10.1 RMA policy............................................................................................................................................................................................ 22
10.2 Training ................................................................................................................................................................................................. 22
10.3 Tools...................................................................................................................................................................................................... 22
10.4 Troubleshooting..................................................................................................................................................................................... 22
10.5 Setup software ...................................................................................................................................................................................... 23
11. Spare Parts...................................................................................................................................................23
12. Interface ......................................................................................................................................................23
12.1 Modbus output...................................................................................................................................................................................... 23
13. Agency information .........................................................................................................................................24
13.1 Approvals overview ............................................................................................................................................................................... 24
13.2 Certificates ............................................................................................................................................................................................ 25
13.3 FM (NEC)............................................................................................................................................................................................... 25
13.4 FMC (CEC)............................................................................................................................................................................................. 30
13.5 ATEX and IECEx..................................................................................................................................................................................... 36

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Operation Manual
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1. Contact information
United States
General
Tel: [phone]
Fax: [phone]
E-mail: [email protected]
http://www.mtssensors.com
Mailing and shipping address
MTS Systems Corporation
Sensors Division
3001 Sheldon Drive
Cary, North Carolina, 27513, USA
Customer service
Tel: [phone]
Fax: [phone]
E-mail: [email protected]
Technical support and applications
24 Hour Emergency Technical Support
Tel: [phone]
E-mail: [email protected]
Germany
General
Tel: [phone]
Fax: [phone]
E-mail: [email protected]
http://www.mtssensors.com
Mailing and shipping address
MTS Sensor Technologie GmbH & Co. KG
Auf dem Schüffel 9
58513 Lüdenscheid, Germany
Technical support and applications
Tel: [phone]
E-mail: [email protected]
http://www.mtssensors.com

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Operation Manual
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2. Terms and definitions
6A Heavy Oils
‘Generalized Crude Oils’, Correction of Volume to 60 °F against API
Gravity.
6B Light Oils
‘Generalized Products’, Correction of Volume to 60 °F against API
Gravity.
6C Chemical
‘Volume Correction Factors (VCF)’ for individual and special
applications, volume correction to 60 °F against thermal expansion
coefficients.
6C Mod
An adjustable temperature reference for defining VCF.
A
API gravity
The measure of how heavy or light a petroleum liquid is compared to
water. Allowable values are 0 to 100 degrees API for (6A) and 0 to 85
degrees API for (6B).
D
DDA (Direct Digital Access)
The proprietary digital protocol developed by MTS for use in
intrinsically safe areas.
Density
Mass divided by the volume of an object at a specific temperature. The
density value should be entered as lb / cu. ft..
Digital I/O
Represents a binary input and output signal that is either in a high or
low state. The LevelLimit generates an output signal that is HI when
the switch float is sitting at rest on the stop collar and LO when switch
float is no longer at rest.
E
Explosion proof
Type of protection based on enclosure in which the parts which can
ignite an explosive gas atmosphere are placed within, and which
can withstand the pressure developed during an internal explosion
of an explosive mixture, and which prevents the transmission of the
explosion to the explosive gas atmosphere surrounding the enclosure.
F
Flameproof
Type of protection based on enclosure in which the parts which can
ignite an explosive gas atmosphere are placed within and which can
withstand the pressure developed during an internal explosion of
an explosive mixture, and which prevents the transmission of the
explosion to the explosive gas atmosphere surrounding the enclosure.
G
GOVI (Gross Observed Volume of the Interface)
The total volume of the tank occupied by the interface liquid. The
GOVI is only given when measuring two liquids and is calculated by
subtracting the volume of the product from the total volume of liquid
in the tank (GOVT – GOVP).
GOVP (Gross Observed Volume of the Product)
The total volume of the tank occupied by the product liquid. When
measuring only one liquid, it is also the total volume of liquid
in the tank (GOVT). When measuring two liquids it is the total
volume of liquid in the tank minus the volume of the interface liquid
(GOVT–GOVI).
GOVT (Total Gross Observed Volume)
The total volume of liquid in the tank. When measuring only one liquid
it is equal to the volume of the product (GOVP). When measuring two
liquids it is equal to the volume of the product and interface liquids
(GOVP + GOVI).
GOVU (Gross Observed Volume Ullage)
The difference in volume between the working capacity of a tank and
the total volume in the tank (Working Capacity – GOVT).
H
HART®
A Bidirectional communication protocol that provides data access
between intelligent field instruments and host systems.
I
Interface
Noun; The measurement of the level of one liquid when that liquid is
below another liquid.
Interface
Adj.; The Software Graphical User Interface (GUI) that allows the user
to access software protocols (HART®, DDA, MODBUS).
Intrinsic safety
‘Intrinsically safe’ - Type of protection based on the restriction of
electrical energy within apparatus of interconnecting wiring exposed to
potentially explosive atmosphere to a level below that which can cause
ignition by either sparking or heating effects.

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Operation Manual
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M
Mass
The property of a body that causes it to have weight in a gravitational
field, calculated by density at the reference temperature multiplied by
the volume correction factor (Density × VCF).
MODBUS
A serial communications protocol published by Modicon in 1979 for
use with its programmable logic controllers (PLCs). It has become a
de facto standard communications protocol in industry, and is now the
most commonly available means of connecting industrial electronic
devices.
N
NEMA Type 4X
A product Enclosure intended for indoor or outdoor use primarily to
provide a degree of protection against corrosion, windblown dust and
rain, splashing water, and hose-directed water; and to be undamaged
by the formation of ice on the enclosure. They are not intended to
provide protection against conditions such as internal condensation or
internal icing.
NPT
U.S. standard defining tapered pipe threads used to join pipes and
fittings.
NSVP (Net Standard Volume of the Product)
The temperature corrected volume for the product liquid in the tank,
requires the transmitter to be ordered with temperature measurement
capabilities. The NSVP is calculated by multiplying the volume of the
product liquid by a volume correction factor based on temperature
(GOVP × VCF).
R
Reference Temperature
The temperature at which the density measurement is given, the
allowable values are 32 °F to 150 °F (0 °C to 66 °C).
S
Specific Gravity
The density ratio of a liquid to the density of water at the same
conditions.
Sphere Radius
The internal radius of the sphere that contains the liquid, the value is
used to calculate the volume along with the Sphere Offset.
Sphere Offset
An offset value that accounts for additional volume in a sphere from
non-uniform sphere geometry, the value is used to calculate the
volume along with the Sphere Radius.
Strap Table
A table of measurement correlating the height of a vessel to the
volume that is contained at that height. The transmitter can contain up
to 100 points.
T
TEC
‘Thermal Expansion Coefficient’ - a value correlating the change in
temperature for an object with the change in its volume. Allowable
values are 270.0 to 930.0. TEC units are in 10 E-6/Deg F.
Temperature Correction Method
One of five product correction methods used to correct the product
volume in the tank due to changes in temperature from 60 °F including
(6A, 6B, 6C, 6C Mod, and Custom Table.
V
Volume Calculation Mode
One of two methods use to calculate volume measurements from level
measurements, including Sphere and Strap Table.
VCF (Volume Correction Factor)
A table of measurements correlating temperature points with
correction factors for the liquids expansion/contraction. The
transmitter can contain up to 50 points.
W
Working Capacity
The maximum volume of liquid that the user desires for their vessel to
hold, typically 80 % of the vessels maximum volume before overfill.

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Operation Manual
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3. Introduction
3.1 Purpose and use of this manual
Important:
Before starting the operation of the equipment read this
documentation thoroughly and follow the safety information.
The content of this technical documentation and of its various annexes
is intended to provide information on mounting, installation and
commissioning by qualified service personnel according to IEC 60079-14
and local regulations or MTS trained service technicians.
3.2 Used symbols and warnings
Warnings are intended for your personal safety and for avoidance
of damage to the described product or connected devices. In this
documentation, safety information and warnings to avoid dangers that
might affect the life and health of personnel or cause material damage
are highlighted by the preceding pictogram, which is defined below.
Symbol Meaning
NOTICE
This symbol is used to point to situations
that may lead to material damage and/or
personal injury.
4. Safety instructions
4.1 Intended use
The liquid level transmitter is intended to be used to measure the level
of liquid(s) contained by a structure as well as the temperature of
the liquid. The product may only be used for the applications defined
under item 1 to item 4 and only in conjunction with third-party devices
and components recommended or approved by MTS Sensors. As a
prerequisite of proper and safe operation, the product requires correct
transport, storage, mounting and commissioning and must be opera-
ted with utmost care.
1. Application does not exceed product’s performance specification in
chapter 5.6.
2. Product may only be installed in hazardous areas as specified by
approval certifications in chapter 13 following special conditions of
use outlined in chapter 13 or in safe areas.
3. The liquid(s) being measured are compatible with the selected
wetted parts of the product.
4. MTS floats should be used for proper functionality and safety
approval.

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Operation Manual
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Forseeable misuse Consequence
Wrong sensor connection Possible damage to electronics
See chapter 7 for Electrical
Connections
Improper Installation Physical damage to packaging
See chapter 6 for Installation
Installation in unapproved
Hazardous Area
Potential Spark
See chapter 13 for Agency
Information
Process Temperature out of range Signal Degradation, Possible
Damage to Sensor
See chapter 5.6 for Specications
Power Supply out of range No Communication, Possible
Damage to Sensor
See chapter 5.6 for Specications
Process Pressure out of range Possible Damage to Sensor,
See chapter 5.6 for Specications
Improper Chemical Compatibility Possible Damage to Sensor,
Customer Must Select Wetted
Material that is compatible with
liquid(s) in tank
Modifying Sensor Warranty Void, Hazardous
Approval Void Customer should
contact factory for custom unit
Improper Grounding Possible Damage to Sensor, Full
Protection Compromised,
See chapter 7.6 for Grounding
Improper Installation of HI Level
Switch
HI Level Switch is not able to
move freely from the intended
location and does not properly
signal overll situations. Potential
is for a tank overll.
Table 1: Foreseeable misuse
4.3 Installation, commissioning and operation
1. Wear proper personal protection equipment such as hard hat,
safety shoes, flame resistant clothing, safety glasses, gloves, and
hearing protection.
2. Follow the specifications given in the technical documentation.
3. Two (2) individuals are recommended to conduct proper
installation, commissioning, and repair of the level transmitter.
4. Ensure the equipment used in a hazardous environment is
selected and installed in compliance with regulations governing
the geographical installation and facility. Only install equipment
that complies with the types of protection relevant to the
applicable classes, division, zones, category, gas group, and
temperature code.
5. Protect the sensor against mechanical damage during installation
and operation.
6. Do not use damaged products and secure them against
unintentional use. Mark damaged products as being defective.
7. Connect the sensor very carefully and pay attention to the polarity
of connections. MTS recommends to not make connections while
power is live.
8. Before turning on power, ensure that nobody’s safety is
jeopardized by starting level transmitter and/or process.
9. Regularly follow preventative maintenance to prevent safety risks
10. Make sure that no wire strands are loose or sticking out of
the terminal block connection which could short and cause a
problem.
11. Make sure that no wire strands, including shield, are in contact
with the electronic module enclosure.
4.2 Foreseeable misuse

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Operation Manual
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Fig. 1: Dual cavity housing
5. Product overview
The Level Plus®LevelLimit®Liquid-Level transmitter is a continuous
multi-functional magnetostrictive transmitter that product level,
interface level, temperature, and volume to the user via Modbus.
Magnetostrictive technology is one of the most accurate and
repeatable level technologies available to date.
The LevelLimit®also includes a HI level switch that is used for overfill
protection via a Digital I/O signal. When the HI level float is raised
approximately 25 mm (1 in.) from its base position the Digital I/O
opens and the controller can detect that a HI level has been detected in
order to enter into a shut down procedure.
MTS is the inventor and purveyor of magnetostrictive technology and
has been serving the level industry for over 35 years.
Industries
• Petroleum
• Liquid Petroleum Gas
• Pharmaceutical
• Food & Beverage
• Chemical
• Mining
Applications
• Tank Farms
• Terminals
• Bullet Tanks
• Separator Tanks
• Battery Tanks
• Storage Tanks
Features
• 5-in-1 Measurement
• Product Level
• Interface Level
• Temperature
• Volume
• Integral HI Level Digital I/O
• No scheduled maintenance or recalibration
• Field Repairable
• Level Inherent Accuracy +/-1mm
• 200 Point Strap Table
• API Temperature Corrected Volumes
• Explosion proof
• Intrinsically Safe
1
1
2
2
3
3
4
4
A A
B B
C C
D D
REV ECO # DESCRIPTION
TITLE
SIZE DWG NO. REV
PRODUCT LINE
SCALE:
BY DATE
SHEET OF
UNLESS OTHERWISE SPECIFIED
TOLERANCES
0 PLACES
MM
1 PLACE
MM ANGLES
  
0.5 0.1
- THREAD DEPTHS ARE TO MIN. FULL THDS
- DRILL DEPTHS ARE TO FULL DIA.
- REMOVE BURRS AND SHARP EDGES
- DO NOT SCALE PRINT
- MACHINED SURFACE FINISH 3.2uM [125 uIn]
PROPRIETARY DATA
THE INFORMATION AND DESIGN(S) DISCLOSED
HEREIN ARE THE PROPERTY OF MTS SYSTEMS
CORPORATION AND MAY NOT BE USED,
REPRODUCED OR DISCLOSED IN ANY FORM
EXCEPT AS GRANTED IN WRITING BY MTS
SYSTEMS CORPORATION. THIS RESTRICTION
EXCLUDES INFORMATION THAT IS IN THE
PUBLIC DOMAIN OR WAS LEGITIMATELY IN THE
PRIOR POSSESSION OF THE RECIPIENT.
mMTS SYSTEMS CORPORATION
SENSORS DIVISION
3001 SHELDON DRIVE, CARY, NC 27513
METRIC
FIRST
ANGLE CLL drawing
1 1
DRAWN BY:
114 mm
(4.5 in.)
127 mm
(5 in.)
124 mm
(4.9 in.)
132 mm
(5.2 in.)
87 mm
(3.4 in.)
109 mm
(4.3 in.)
75 mm
(3 in.)
206 mm
(8.1 in.)
127 mm
(5 in.)
117 mm
(4.6 in.)
145 mm
(5.7 in.)
5.1 Components
The Level Plus®LevelLimit®liquid level transmitter consists of four
main components; a housing, outer pipe, float, and electronics.
Varying the components of the transmitter allows the transmitter to be
customized to almost any application.
Housings
Level Plus®LevelLimit®transmitters are available with a dual-cavity
housings as shown below:

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Operation Manual
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Fig. 2: Outer pipe configuration
Outer pipe configurations
The outer pipe is constructed of a variety of configurations. The
LevelLimit®is available in a flexible hose or a rigid pipe.
Fig. 3: Outer pipe configuration

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Operation Manual
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Floats
LevelLimit®transmitters offer numerous floats for different
applications such as stainless steel and Hastelloy®for both product
level and interface level. To be able to accurately detect the interface
level there needs to be a difference of at least 0.05 in specific gravities
between the product and interface liquids. For detailed information
about floats, refer to the ‘Accessories Catalog’, (MTS Part # 551103).
For assistance with selecting a specific float for your application,
please contact Technical Support with the following information:
• Specific gravity of liquid(s) being measured
• Process temperature
• Process opening size
• Vessel pressure
LevelLimit®transmitters should be used with a float having an offset
weight and made of stainless steel or Hastelloy®C. This allows the
float to stay in contact with the pipe to prevent the buildup of an
electrostatic charge. For detailed information about floats, refer to the
‘Accessories Catalog’, (MTS Part #551103).
Internal electronics
All transmitters come with two electronic components of a sensing
element and a board set. Flexible sensing elements are standard for
the flexible hose option and rigid sensing elements are standard for
the rigid pipe option . The board set consists of up to three electronic
boards and a display.
The LevelLimit®includes a secondary sensing element that is used
for detecting a high tank level. The HI level switch includes a separate
electronic board and sensing element.
A temperature sensing function is optional with the LevelLimit®
transmitter. The temperature sensing device is a Digital Thermometer
mounted inside the transmitter’s outer pipe assembly. The LevelLimit®
can be ordered with 1, 5, 12, or 16 temperature points.
Display
All LP-Series liquid level transmitters are shipped with a stylus (MTS
Part # 404108) to be used for manipulating the display. The stylus is
designed to allow for programming of the unit without removing the
housing. When using the stylus make sure to align the stylus with
the shape outline around the buttons in the same orientation. Failure
to correctly align the stylus can cause the display to not function
properly. Password for entering the menu is 27513. For additional
details consult the protocol specific Modbus Interface Manual (MTS
Part #551700).
Accessories
MTS also offers a series of displays, housings, converters, and other
accessories, please refer to the ‘Accessories Catalog’,
(MTS Part#551103).
5.2 Accuracy
For magnetostrictive transmitters inherent accuracy is measured
in terms of non-linearity. Non-linearity is a measurement of any
imperfections in the waveguide that are reflected in the linearity of
the transmitter’s output. MTS tolerances reflect a maximum non-
linearity of ±1mm. MTS is able to achieve such strict tolerances by
manufacturing all of its own waveguide from a proprietary alloy and
testing 100% of all transmitters before shipping.
5.3 Warranty
Important:
Contact Technical Support or Customer Service for assistance if
you suspect that the transmitter is not working correctly. Technical
support can assist you with troubleshooting, part replacement, and
Returned Material Authorization (RMA) information if required.
All Level Plus®transmitters come with a two year limited warranty
from the factory shipment date. An additional extended warranty can
be purchased. A Return Materials Authorization (RMA) number is
required and must accompany any transmitter returns. 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 also accompany the transmitter that was
used in any process.
5.4 Storage
If storage is required prior to installation, store indoors in a dry
environment at ambient temperature range not to exceed −40…+71°C
(−40…+160°F).
Fig. 4: Stylus (MTS Part # 404108)
Fig. 5: Display

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Operation Manual
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5.5 Model number identification
fNotied body
CCEC (FMC)
EATEX
FNEC (FM)
IIEC
XNone
gProtection method
FExplosion proof / Flameproof - PENDING
IIntrinsically safe
XNo approval
hGas group
AGroup A (not available with “C = CEC (FMC)” notied body and
“F = Flameproof/Explosion“ proof protection method)
BGroup B
CGroup C
DGroup D
3IIC (Instrinsically Safe only)
4IIB + H2 (Explosion Proof / Flameproof only)
XNone
iUnit of measure
MMillimeters (Metric)
UInches (US customary)
kSpecial
SStandard product
j Length (no decimal spaces)
X X X X X Flexible sensor pipe: 1575…22000 mm
(code as 01575 to 22000)
X X X X X Flexible sensor pipe: 62…866 in.
(code as 06200 to 86600)
X X X X X Rigid sensor pipe: 305…7620 mm
(code as 00305 to 76200)
X X X X X Rigid sensor pipe: 12…300 in.
(code as 01200 to 30000)
aSensor model
LP L LevelLimit Level Transmitter
bSensor pipe
B5/8" OD Rigid Pipe
MFlexible, 7/8"OD tube w/bottom xing eye
NFlexible, 7/8"OD tube w/bottom xing weight
PFlexible, 7/8"OD tube w/bottom xing magnet
SFlexible, 7/8"OD tube w/o bottom xing hardware
cProcess connection size
G4 in. NPT adjustable
XNone
dNumber of DT‘s (Digital Thermometers)
0None
1One DT
55 DTs
KTwelve DTs
MSixteen DTs
eDT‘s placement
FEvenly spaced per API
CCustom
XNone
*/ Contact factory for other materials
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
L P L
a b c d e f g h i j k l
l HI Level Switch Position
X X X X X Flexible sensor pipe: 1575…22000 mm
(code as 01575 to 22000)
X X X X X Flexible sensor pipe: 62…866 in.
(code as 06200 to 86600)
X X X X X Rigid sensor pipe: 305…7620 mm
(code as 00305 to 76200)
X X X X X Rigid sensor pipe: 12…300 in.
(code as 01200 to 30000)
NOTICE
Accessories such as floats, cables, and remote displays have to be
ordered separately. All accessories are shown in the Accessories
Catalog (551103).

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Operation Manual
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5.6 Technical data
Level Output
Measured Variable Product level and interface level
Output Signal /Protocol Modbus RTU
Order Length Flexible hose: 1575...22000 mm (62...866 in.)
Rigid pipe: 305...7620 mm (12...300 in.)
Inherent Accuracy ±1 mm (0.039 in.)
Repeatability 0.001% F.S. or 0.381 mm (0.015 in.) whichever is greater (any direction)
Temperature Output
Measured Variable Average and multipoint temperatures
Temperature Accuracy
±0.2 °C (0.4 °F) range −40…−20 °C (−40…−4 °F),
±0.1 °C (0.2 °F) range −20…+70 °C (−4…+158 °F),
±0.15 °C (0.3 °F) range +70…+100 °C (+158…+212 °F),
±0.5 °C (0.9 °F) range +100…+105 °C (+ 212 …221 °F)
Digital I/O
Input Voltage Up to 30 VDC
Resistance 500 Ohm
Current Switch Capability 50 mA @ 28 VDC
Compatibility ABB RMC 100, Emerson ROC 827, Xetawave I/O, and others
Cable Cat5 or equivalent type cable is required (15pF/ft. or 49pF/m) for a max run of 4000 ft. (1200 m)
Electronics
Input Voltage 10.5…28 VDC
Fail Safe High, Full scale
Reverse Polarity Protection Series diode
EMC EN 61326-1, EN 61326-2-3, EN 61326-3-2, EN 61000-6-2, EN 61000-6-3, EN 61000-4-2,
EN 61000-4-3, EN 61000-4-4, EN 61000-4-5, EN 61000-4-6, EN 61000-4-8, EN 61000-4-11
Environmental
Enclosure Rating NEMA Type 4X, IP65
Humidity 0…100% relative humidity, non-condensing
Operating Temperatures
Electronics: −40…+71 °C (−40…+160 ºF)
Sensing element: −40…+125 °C (−40…+257 °F) (contact factory for specific temperature ranges)
Temperature element: −40…+105 °C (−40…+221 °F)
Vessel Pressure Flexible Hose: 30 bar (435 psi)
Rigid Pipe: 69 bar (1000 psi)
Materials Wetted parts: 316L stainless steel (contact factory for alternative materials)
Non-wetted parts: 316L stainless steel, Epoxy coated aluminum
Field Installation
Housing Dimensions Dual cavity: 117 mm (4.6 in.) W × by 127 mm (5 in.) D × 206 mm (8.1 in.) H
Mounting
Flexible hose or Rigid pipe 4 in. adjustable MNPT
Wiring
Connections Terminal block
Electrical connections
Dual cavity ¾ in. FNPT conduit opening, M20 for ATEX/IECEx version
Display
Measured variables Product level, interface level and temperature

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Operation Manual
I13 I
5.7 Technical drawing
TRANSMITTER INACTIVE ZONE REFERENCE
Order Length Inactive Zone
<7.6 m (25 ft.) 76 mm (3 in.)
7.6 m to 12.2 m (25 to 40 ft.) 97 mm (3.8 in.)
12.3 m to 22 m (40 to 72 ft.) 120 mm (4.7 in.)
Controlling design dimensions are in millimeters and measurements in ( ) are in inches
305 mm (12 in.)
1 in. MNPT with 4 in MNPT adapter
4 in. FNPT Tank Opening
Riser
HI Level float
Interface float
Stop collar
Flexible
hose
Measuring range
Order length
1,575 mm (62 in.) to
22,000 mm (866 in.)
Inactive zone
please see table
51 mm
(3 in.) typ.
Total
inactive
zone
Bottom-fixing
Weight
Bottom-fixing
Hook
Bottom-fixing
Magnet
2 in.
(typ.)
127 mm
(5 in.)
76 mm
(3 in.)
3/4 in. FNPT
192 mm
(7.6 in.)
Protection
Method: F
152 mm (6.0 in.)
Protection
Method: I or X
Flex stop collar
Product float
117 mm
(4.6 in.)
Manual Switch Test

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Operation Manual
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TRANSMITTER INACTIVE ZONE REFERENCE
Order Length Inactive Zone
<7.6 m (25 ft.) 76 mm (3 in.)
Controlling design dimensions are in millimeters and measurements in ( ) are in inches
127 mm (5.0 in.)
3/4 in MNPT with 4 in MNPT adapter
4 in. FNPT Tank Opening
Riser
HI Level float
Interface float
Rigid
pipe
Measuring range
Order length
305 mm (12 in.) to
7620 mm (300 in.)
Inactive zone
please see table
3/4 in. FNPT
192 mm
(7.6 in.)
Protection
Method: F
152 mm (6.0 in.)
Protection
Method: I or X
117 mm
(4.6 in.)
Stop collar
Product float
Manual Switch Test
Stop collar

Level Plus® LevelLimit®
Operation Manual
I15 I
6. Installation and mounting
6.1 Training
Warning:
When the pipe/hose of the LP-Series level transmitter is installed or
removed from the tank the release of flammable vapors will occur.
Take all necessary precaution when installing or removing the level
transmitter due to the release of flammable vapors.
Installation should only be conducted by qualified service personnel
according to IEC 60079-14 and local regulations or MTS trained
service technicians. MTS offers web based and in person training
for installation, commissioning, maintenance, and repair. MTS also
offers factory direct services for these same functions. Contact MTS to
discuss training or factory direct services before starting.
6.2 Stilling wells and guide poles
Level Plus®transmitters can be mounted in slotted or unslotted stilling
wells but a slotted stilling well is always preferred. Using a unslotted
stilling well will negatively affect performance of any level device as
the level in the stilling well can differ from the level in the tank. The
Level Plus®transmitter can also be installed to one side of the stilling
well to also allow for sampling and manual gauging from the same
opening as the automatic tank gauging. Contact technical support for
details.
Level Plus®transmitters do not require a stilling well for installation.
Our transmitters are installed in numerous tanks without stilling wells
with no loss in performance due to our patented flexible waveguide
and hose. A stilling well is highly recommended for agitated, turbulent,
and/or fast filling tanks.
6.3 Tools
6.3.1 Flexible Hose Tools
• 9/16"Socket and ratchet
• Channel Lock pliers
• 3/16"Hex Key (Allen wrench)
• 1" Open End wrench
6.3.2 Rigid Pipe Tools
• Channel Lock pliers
• 9/64” Hex Key (Allen wrench)
• ¾” Open End wrench
• Common head screwdriver, slotted screwdriver
6.4 Installation steps
Caution:
When assembling and installing the LevelLimit®transmitter, be
careful not to allow the flexible hose to kink or be coiled in less
than 381 mm (15 in.) diameter. It is recommended that assembly
and mounting of this transmitter should not be done alone. To
ensure proper and safe assembly of the LevelLimit®transmitter, a
minimum of two (2) individuals are recommended. Gloves are also
recommended. PPE may be required for work areas such as safety
shoes, safety glasses, hard hat, and fire resistant clothing.
1. Consult chapter 4.3 before starting.
2. Perform steps 1-10 in chapter 8.4.1
3. Remove stop collar, nut, washer, spacer, and flex stop collar from
flexible hose. Alternatively, remove stop collars and e-ring from
rigid pipe. Do not remove the adjustable fitting from the hose or
pipe.
4. Slide 4” NPT adapter, HI level float, and cable assembly onto level
transmitter. onto flexible hose or rigid pipe and move the adapter
to the top. To prevent damage to the level transmitter keep the
assembly toward the end of the level transmitter.
5. Slide the product float onto the flexible hose or rigid pipe. Slide
the interface float (optional) onto the flexible hose or rigid pipe.
Install stop collar 76 mm (3 in.) from the tip of the rigid section
of the flexible hose or the rigid pipe. Do not drop float(s) or allow
them to free fall along the flexible hose or rigid pipe as damage
may result.
NOTICE
The bottom stop collar can be removed or adjusted based on the
float selected for the application. Please consult the factory for more
information.
6. For the flexible hose mount the hook section of the pipe (this
is the bottom rigid section of the pipe) using the supplied nut,
spacer and washer, tighten securely as shown in Fig. 6, Fig. 7 and
Fig. 8. For the magnet, remove washer before installing in tank.
7. Slide float(s) and 4” NPT adapter assembly back down to the stop
collar to prevent them from free falling during installation into
the tank. Insert the flexible hose or rigid pipe and floats through
the tank opening and lower the transmitter/float assembly into
the tank until it rests on the bottom. If you are using a bottom-
fixing hook, fasten the hook to the appropriate customer-supplied
mating hardware at the tank bottom.
8. Connect the 3/4” NPT (rigid) or the 1” NPT (flex) to the 4” NPT
adapter assembly. Tighten the adjustable NPT fitting to the 4”
NPT adapter.
9. Pull the level transmitter up far enough to add the flex stop collar
or second rigid stop collar over the marking on the pipe. The top
of the stop collar should align with the top of the marking.
10. Lower level transmitter down inside of tank. Tighten the 4”
adapter to the tank.
11. Loosen the Cord Grip on the 4” adapter and make sure the cable
and float move up and down with ease. Tighten cord grip.

Level Plus® LevelLimit®
Operation Manual
I16 I
Warning:
When the pipe/hose of the LP-Series level transmitter is installed or
removed from the tank the release of flammable vapors will occur.
Take all necessary precaution when installing or removing the level
transmitter due to the release of flammable vapors.
Fig. 6: Bottom fixing weight
12. Pull the transmitter upward to straighten the flexible hose until
the resistance of the weight, magnet, or hook is felt without
raising the weight or magnet off the floor of the tank. Tighten
the adjustable fitting to hold the transmitter in place. For the
rigid pipe, pull the transmitter upward until the pipe is straight
and the tip of the pipe touches the bottom of the tank. Tighten
the adjustable fitting. Once the fitting is tightened it is no longer
adjustable and cannot be moved.
13. Terminate the field wire cables noting proper wire orientation.
Wiring diagram is shown in Section 13.
Consult Section 5.7 Technical Drawing to reference what the finished
installation should look like.
6.5 Mounting
The method of mounting the transmitter is dependent on the vessel
or tank in which it is being used, and what type of transmitter is being
mounted. For LevelLimit there is only the standard 4“ NPT mount that
allows for the functionality of the HI level switch manual test.
Threaded flange mounting
The LevelLimit®transmitter can be mounted directly to the tank or
flange via a NPT threaded fitting, assuming there is a proper threaded
connection available as shown in section 5.7. If the float will not fit
through the flange opening when the flange is removed, there must
be some alternative means to mount the float on the transmitter from
inside the vessel; this may require an access port nearby the entry
point of the transmitter.
Hook
2.8" (71 mm) tall
Welded end-plug
Flexible hose
Float stop
collar
Hook mates with
customer supplied
hardware mounted
in the tank bottom
Weight
Ø 3" (Ø 76 mm)
× 2" (51 mm) tall
Washer
Welded end-plug
Flexible hose
Float stop
collar
Spacer
Remove washer
before installing
in tank
Hexagon
nut
Fig. 7: Bottom fixing magnet
Fig. 8: Bottom fixing hook
Weight
Ø 5" (Ø 127 mm)
× 2" (51 mm) tall
Washer
Welded end-plug
Flexible hose
Float stop
collar
Spacer
Hexagon
nut

Level Plus® LevelLimit®
Operation Manual
I17 I
7.3 Industrial topologies
There are four topologies described and illustrated below. However,
the daisy chain topology is not recommended by MTS.
The topologies are shown for the Modbus communication of the level
transmitter. MTS recommends running independent cable runs for
each HI Level Switch in the network.
Point-to-point
The point-to-point topology consists of having only one device on the
loop as shown in Fig. 91. This topology is not usually used with a bus
network since it does not take advantage of placing multiple devices
on a loop.
Bus with spurs
The bus with spurs topology has a main trunk cable that has each
PLC
Fig. 9: Point-to-point topology
Fig. 10: Bus with spurs topology
device connected via its own spur at a junction box as shown in Fig.
102. The bus with spurs and tree topologies can also be used together
to form a hybrid topology.
Tree alignment
The tree topology is very similar to the bus with spurs topology with
PLC
7. Electrical connections
7.1 Basic information
A typical intrinsically safe connection for the Level Plus®LevelLimit®
transmitter includes protective safety barriers, a power supply and a
reading or monitoring device. Refer to Agency information in chapter
13.
A typical Explosionproof/flame proof connection for the Level Plus®
LevelLimit®transmitter includes a power supply and a reading or
monitoring device. All cabling is in approved conduit with sealoffs
as specified by local electrical code. Refer to agency information in
chapter 13.
7.2 Safety recommendations
Be sure to:
1. Always follow applicable local and national electrical codes and
observe polarity when making electrical connections.
2. Never make electrical connections to the LevelLimit®transmitter
with power turned on.
3. Make sure that no wire strands are loose or sticking out of
the terminal block connection which could short and cause a
problem.
4. Make sure that no wire strands, including shield, are in contact
with the electronic module enclosure.
5. The electronics module enclosure is grounded through internal
circuitry and is electrically isolated from the explosionproof
housing.

Level Plus® LevelLimit®
Operation Manual
I18 I
Fig. 11: Tree topology
Fig. 12: Daisy-chain topology
the main difference of having a common junction box for all of the
transmitters as shown in Fig. 113. Bus with spurs and tree topologies
can also be used together to form a hybrid topology.
Daisy chain
The daisy-chain topology utilizes a single cable that is connected to
all of the transmitters with the cable being interconnected at each field
device. When using this topology make sure that the wiring practice
allows for one transmitter to be disconnected without disconnecting
the entire loop as shown in Fig. 124. MTS does not suggest using the
daisy-chain topology.
PLC
PLC
Fig. 13: Electrical conduit installation
Table 2: Cable specification and parameters
Table 3: Cable specifications Digital I/O
7.4 Cable recommendations
Refer to ‘Table 2’ below for general requirements of cable types for the
Level Plus®LevelLimit®analog transmitter.
Cable specifications Modbus communication
7.5 Electrical conduit
Parameter Specifitcation
Minimum cable size Ø 0.51…1.6 mm (24…14 AWG)
Cable type
Single pair shielded or multiple pair with
overall shield; minimum 0.25 mm (0.010 in.)
insulation thickness
Capacitance Less than 98 pF/m (30 pF/ft)
Cable Type Cat5 or equivalent type cable
Capacitance Less than 15 pF/ft. (49 pF/m)
NOTICE
1. Tighten housing cover (both front and back covers if dual cavity)
to full stop against the O-ring.
2. Do not over-tighten compression fittings.
3. Use side conduit entry only.
4. In high humidity areas, use a breather drain type conduit sealing
fitting to minimize moisture intrusion.
5. For Division Installations, an approved conduit seal is required
within 457 mm (18 in.) of the enclosure.
6. For Zone Installations, an approved conduit seal is required within
50 mm (2 in.) of the enclosure.
Conduit sealing fitting
NPT or BSPP Fitting
Do not over-tighten
compression fitting!
Interface float
(ordered
separately)
Product float
(ordered
separately)
View shown with
cover removed
Plugged entry
Do not use
(see notes)
3/4 NPT or M20 conduit access
Use NPT conduit fitting only!
Conduit
(flexible or rigid)
Conduit from
control room
Level Plus®
Do not remove cover with circuit energized in
hazardous locations!
Follow safe work procedures.
Cable specifications Digital I/O

Level Plus® LevelLimit®
Operation Manual
I19 I
7.6 Grounding
7.6.1 Safety grounding
Warning:
Grounding the transmitter through a threaded conduit connection
does not meet the requirements as a grounding of the sensor for
safety.
There are two methods to provide an earth ground connection to
the earth ground of the electronics. Either method must result in a
resistance of less than 1 Ω.
• Run an earth ground through the conduit and connect directly to the
earth ground lug inside the housing.
• Run an earth ground directly to the ground lug on the outside of the
housing.
7.6.2 Shield grounding
Warning:
The shield ground does not meet the requirements as grounding of
the sensor for safety.
Immunity performance of the sensor from external sources of
surge, burst, RF, radiated emissions and other noise is dependent
on a proper ground for the shield of the communications cable.
The communications cable shield should be of a braided type and
connected to the internal ground lug of the sensor housing.
Runs in a continuous metallic conduit
When installed inside a dedicated continuous metallic conduit,
the conduit provides a level of shielding protection from external
interference and a level of ground to the sensor housing. In this case
a foil type shielded cable with a drain wire connected to the internal
ground lug may be sufficient. Sharing of the metallic conduit with
other cables will result in loss of effective shielding performance of
the communication cable and possible degradation in performance
of the sensor. In this case a braided type shielded cable connected to
the sensor internal ground lug would be recommended. In all cases
paralleling the communications cable with any noise generating cable
inside of a conduit or with noise generating cables in close proximity
to the conduit may degrade the performance of the sensor.
Runs without a conduit
In some rare applications, or where safety may not be required, a
metallic conduit may not exist. The communications cable shield
should be of a braided type and connected to the internal ground
lug of the sensor housing. Alternatively a safety approved EMC
Cable Gland can be used for grounding the shield. Contact MTS for
information before using one of these cable glands.
NEC
Undesirable currents (ground loops) is a violation of the NEC and is a
safety hazard.
7.7 Safety barriers
Refer to Table 4 for entity parameters and Table 5 for example safety
barriers
Entity parameters
Digital supply
(1 per LT)
Ui = 28 VDC
Ii = 100 mA
Ci = 0.0 µF
Li = O mH
Pi = 700 mW
Digital communication
(2 per LT)
Ui = 8.6 VDC
Ii = 10 mA
Ci = 0.0 µF
Li = 0.0 mH
Pi = 21.5 mW
Digital I/O
(1 per LT)
Ui = 28 VDC
Ii = 50 mA
Ci = 0.083 µF
Li = 8.5 mH
Pi = 350 mW
R = 666 Ohm
Table 4: Safety barrier entity parameter references
Table 5: Safety barrier entity parameter references
Supplier Stahl Stahl Stahl
Type 9001/01-280-
100-101
9001/01-086-
010-101
9001/01-280-
050-101
Maximum
voltage 28 VDC 8.6 VDC 28 VDC
Maximum
current
(each channel)
100 mA 10 mA 50 mA
Maximum
power
(each channel)
700 mW 21.5 mW 350 mW
Number of
channels 111
Interface Modbus Modbus Digital I/O

Level Plus® LevelLimit®
Operation Manual
I20 I
8. Commissioning
8.1 Training
Commissioning should only be conducted by qualified service
personnel according to IEC 60079-14 or MTS trained service
technicians and local regulations. MTS offers web based and in person
training for installation, commissioning, maintenance, and repair. MTS
also offers factory direct services for these same functions. Contact
MTS to discuss training or factory direct services before starting.
8.2 Tools
8.2.1 Tools for Flexible Hose
• 9/16"Socket and ratchet
• Channel Lock pliers
• 3/16"Hex Key (Allen wrench)
• 1"Open End wrench
• RS485 to USB Converter (MTS Part # 380114)[Modbus and DDA]
• Windows Based PC
• Linear Regulated Power Supply
• MTS Setup Software
•
8.2.2 Tools for Rigid Pipe
• Channel Lock pliers
• 9/64” Hex Key (Allen wrench)
• ¾” Open End wrench
• RS485 to USB Converter (MTS Part # 380114)[Modbus and DDA]
• Windows Based PC
• Linear Regulated Power Supply
• MTS Setup Software
8.3 Setup software
MTS offers Setup Software that is shipped with the level transmitter
and is also available for download from www.mtssensors.com. The
Setup Software is to be used for installation, commissioning, and
troubleshooting. For further details on how to use the setup software
consult the Modbus Interface Manual (MTS Part# 551700).
NOTICE
For Additional details consult the protocol specific Modbus Interface
Manual (MTS Part #551700).
8.4 Commissioning steps
8.4.1 Modbus
1. Consult chapter 4.3 before starting.
2. Remove level transmitter from shipping container.
3. Remove bottom fixing nut, washer, spacer, and stop collars.
4. Insert flexible hose or rigid pipe into float(s) making sure float(s)
are in the active range. Install product float first.
5. Connect power, RS485 to USB converter, and PC.
6. Open MTS Setup Software.
7. Establish Communication.
8. Set Address, Enter Strap Table, Setup Volume Correction Method.
Default address 247.
9. Disconnect Power and Communication. Remove floats. Prepare
level transmitter for transport to the top of the tank.
10. Complete Installation in chapter 6.4.
11. Have qualified technician perform hand measurement. Enter hand
measurement into MTS Setup Software and calibrate.
12. Store all settings as backup file according to site name and tank
number.
8.4.2 Digital I/O
1. Connect Power
2. Place float on level transmitter with float bottom at the top of the
mark on the pipe.
3. Verify Digital I/O is HI.
4. Remove float and verify Digital I/O is LO.
5. Disconnect power.
6. Complete installation in chapter 6.4
9. Maintenance
9.1 Training
Maintenance should only be conducted by qualified service personnel
according to IEC 60079-14 and local regulations or MTS trained
service technicians. MTS offers web based and in person training
for installation, commissioning, maintenance, and repair. MTS also
offers factory direct services for these same functions. Contact MTS to
discuss training or factory direct services before starting.