NOSHOK KING-GAGE ES2 5501 User manual

ESR Serial No. Versions
and Slimline Versions
KING-GAGE, A NOSHOK Company I 1010 West Bagley Road, Berea, Ohio 44017 I Ph: 855-367-2494 I www.king-gage.com
ES2 Electronic
Liquid Level Transmitter
Effective: October 2016 EX-1845
Installation and Operations Manual
Models 5501 • 5502 • 5503

Page 2
ES2 Electronic Liquid Level Transmitter EX-1845
KING-GAGE, A NOSHOK Company
The information contained in this manual was accurate at
the time of release. Specifications are subject to change
without notice.
Warranty - All King Engineering products are guaranteed
to be free from defects in material and workmanship for
one year from the date of purchase. Any product or part
found to be defective under normal use within one year of
purchase will be repaired or replaced at no charge if returned
to the company at Ann Arbor, Michigan within ten days
of discovery of the defect. No other warranties, whether
expressed, implied, or statutory, including the warranties
of fitness for a particular purpose or merchantability, are
given by this agreement.
The exclusive remedy for nonconformity of these goods
shall be repair and/or replacement of the nonconforming
goods or parts.
Seller will not be liable for consequential damages resulting
from breach of this agreement. The term “consequential
damages” shall include but shall not be limited to damage
to all machines, equipment and goods other than the goods
sold hereby, interruption of production, loss of profits,
delays of any kind, administrative expense and overhead.
Revisions:
(A) March, 2008 – Original Release (applicable to ESR- serial no. versions)
(B) August, 2008 – Illustrations based on encapsulated board (ESR-serial no. versions)
(C) May, 2009 – molded cable w/ M12 plug connector
(D) August, 2009 – revised span adjustment ranges
(E) November, 2009 – ES2 Slimline version added
(F) August, 2011 – revised remote junction notes
(G) October, 2016 - model no.s (-3V) added for versions with FKM seal

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ES2 Electronic Liquid Level Transmitter EX-1845
Table of Contents
Specifications ............................................................................................................................ 4
Model No. Designations ............................................................................................................ 5
Mounting Dimensions ........................................................................................................... 6–7
Typical Application .................................................................................................................... 7
Power Requirement .................................................................................................................. 8
Connectors and Signal Cable ............................................................................................... 9-10
Test Point Terminals ................................................................................................................. 10
ES2 Calibration .................................................................................................................. 12-13
Calibration Equipment Setup .................................................................................................. 13
Calculating Milliamp Output ................................................................................................... 14
Service Parts and Replacement ................................................................................................ 15

Page 4
ES2 Electronic Liquid Level Transmitter EX-1845
KING-GAGE ES2
Level Transmitter
Two-wire transmitter provides a direct 4-20 mAdc analog electronic output
signal. The ES2 transmitter is designed specifically for hydrostatic pressure
measurement for liquid level gauging.
Specifications
Pressure Ranges
0-5, 0-10, 0-15, 0-30, 0-50 psig
(Gage pressure measured relative to ambient atmospheric pressure.)
Accuracy
Less than ± 0.20% FS
Includes linearity, hysteresis, non-repeatability errors.
Pressure Media
Gas or Liquids compatible with 316 stainless steel (diaphragm);
silicone rubber (O-ring). All other wetted parts 316L.
Electrical
Input (excitation): 14-40 Vdc
Output (mAdc): 4-20 milliamperes
Span Adjustment Range
Transmitter adjustment turndown is 3:1 for the 0–15, 0–30, 0–50 psig nominal ranges.
Nominal Minimum Range of Adjustment
0–5 psig 0–3 psig 0–83 in. thru 0–138 in. water / 0–2.1 m thru 0–3.5 m water
0–10 psig 0–3 psig 0–83 in. thru 0–277 in. water /0–2.1 m thru 0–7.0 m water
0–15 psig 0–3 psig 0–83 in. thru 0–415 in. water /0–2.1 m thru 0–10.5 m water
0–30 psig 0–10 psig 0–277 in. thru 0–830 in. water /0–7.0 m thru 0–21.0 m water
0–50 psig 0–15 psig 0–415 in. thru 0–1384 in. water /0–10.5 m thru 0–35.1 m water
Operating Limit (Maximum Pressure)
Pressure above 300% nominal range (overrange) will result in damage to the transmitter
(200% may cause a shift in calibration).
Non-Repeatability (Worst Case)
Less than 0.02% FS
Operating Temperature Range
0°F to 175°F/ -17°C to 79°C

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ES2 Electronic Liquid Level Transmitter EX-1845
Model No. Designations
Range Designation
The last two digits of the model number actually refer to the transmitter
range. As an example, MODEL 5502-3-10 is a 0-10 psig range transmitter.
550 2 - 3 - 05 Range
05 = 0-5 psig / 0-0.3 bar
10 = 0-10 psig / 0-0.69 bar
15 = 0-15 psig / 0-1.03 bar
30 = 0-30 psig / 0-2.06 bar
50 = 0-50 psig / 0-3.44 bar
Mounting Application
1= short mount
(single wall, non-insulated tank)
2= standard mount
(insulated wall up to 4.5 in. / 114 mm;
or adapter for non-King "short" shell)
3= long mount
(insulated wall up to 6.75 in. / 171 mm;
or adapter for non-King "standard" shell)
Process Seal Options
3= Silicone O-ring seals, cable w/
integral molded M12 connector
3V = Viton O-ring seals, cable w/
integral molded M12 connector
Slimline Versions
ESR Serial No. Versions

Page 6
ES2 Electronic Liquid Level Transmitter EX-1845
Mounting Dimensions
Mounting dimensions are shown for both the newer
"slimline" design and existing ES2 transmitter housings.
From an application standpoint, there are three (3) models
designations that specify overall mounting length. Allow
adequate clearance for installation and removal of the
transmitter. Clearance dimensions will vary depending
upon type of cable or connector used.
Model 5502 ES2 Slimline Transmitter - Standard Mount
Model 5501 ES2 Slimline Transmitter - Short Mount
Model 5503 ES2 Slimline Transmitter - Long Mount
6.33 in.
161 mm
1.96 in.
50 mm
2.25 in.
57 mm
10.7 in.
272 mm
6.62 in.
168 mm
1.96 in.
50 mm
12.96 in.
329 mm
8.87 in.
225 mm
1.96 in.
50 mm
End view dimensions with M12 Molded Cable
Assembly installed
4.5 in.
114 mm
Overall
1.96 in.
50 mm

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ES2 Electronic Liquid Level Transmitter EX-1845
ES2 Liquid Level Transmitter Application
(typical system with tank level indicator)
Tank Shell
(Receiver)
Sensing
Diaphragm
Clamp
Nut
Molded Cable
Connector
End Cap
KING-GAGE Tank
Level Indicator
®
9982
TANK 1 GALS
1.019
9982
TANK 1
GALS
1.019
789
456
123
0.
Menu
Select
Edit
Enter
Reset
6 in
152 mm
6.35 in
161 mm 2” Flange (150 lb ANSI)
Diameter Flange Size (ANSI)
4.25" / 108mm 1" pipe flange (150 lb)
5.0" / 127mm 1.5" pipe flange (150 lb)
6.0" / 152mm 2" pipe flange (150 lb)
Flange Mounting Configuration
The ES2 level transmitter is available with a flange
mount adapter for installation to a tank pipe outlet. The
dimensional illustration (above) depicts the 2" flange but
is also offered in a 1" flange, 1-1/2" flange, 2" flange or
3" flange.

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ES2 Electronic Liquid Level Transmitter EX-1845
Power Requirement (14– 40 Vdc)
The ES2 transmitter requires a source of DC power for op-
eration. Minimum excitation voltage must be no less than
14 Vdc. Any receiver installed on the signal loop (meters,
data loggers, controllers, etc.) must be taken into account
when determining the required power supply voltage to be
used. The internal resistance of each device added together
represents the total “load” residing on the signal loop circuit.
Load Capacity = (Supply Voltage - 14)
(OHMS) .02
Load Capacity at Supplied Voltage
KING-GAGE tank processors and LevelBAR provide 24 Vdc
excitation to power the signal loop circuit. (If the application
requirement exceeds 500-ohms, an external power supply
of appropriate voltage will be required.)
ES2 Signal Connection
20 Vdc 24 Vdc 28 Vdc 32 Vdc
300 ohms 500 ohms 700 ohms 900 ohms
The external connector of the ES2 transmitter affords an
impermeable barrier against moisture infiltration of the
transmitter housing. This connector receptacle has a metric
M12 screw collar and is intended for plug type molded
cable assemblies designed for 4-pole signal termination.
Our ES2 transmitter package also includes a molded M12
cable (32ft / 10 m) to simplify installation and ensure a
sealed connection at the unit—this molded cable meets
IP68 standards for ingress protection.
NOTE: Avoid installing sensitive measuring equipment, or
wire carrying low level signals, near sources of electrical and
magnetic noise, such as breakers, transformers, motors,
SCR drives, welders, fluorescent lamp controllers, or relays.
Use twisted pair wiring to reduce magnetic noise pickup.
Never run signal-carrying wires in the same conduit that
carries power lines, relay contact leads, or other high-level
voltages or currents.
The signal output is transmitted through 4-20 mA current
loops that are low impedance electric circuits. Long cabling
runs can increase the susceptibility for higher levels of noise
to be transferred to the current loop circuit. Also, inter-
mittent EMI or RFI with a changing frequency or intensity
may induce interference on the transmitted output signal.
Brown: + SIGNAL (+ V power)
White: - SIGNAL (- or common)
Blue: SHIELD (ground)
Black (Not Used)
32 ft.
10 m
4.5 in.
114 mm
Overall
1.96 in.
50 mm
Supplied Cable
M12 Connector

Page 9
ES2 Electronic Liquid Level Transmitter EX-1845
Optional Field Wiring Connector
Refer to the diagram to access the field wiring terminals of
the connector assembly. The connector body incorporates
four (4) terminals – however, only two (2) terminals are used
for the 4-20 mA signal loop with an additional connection
for shield/ground. There may be numbers molded into the
connector body specifying the PIN designations.
Signal Cable
Please follow the installation instructions carefully to ensure
that the connector assembly is adequately sealed to prevent
corrosion of the field wiring terminals. This is especially
critical when stripping back the cable sheath. We strongly
recommend that cable be 20-22 AWG.
1. Strip back 1" (2.5 cm) of the outer cable sheath.
2. Strip back 1/4" (0.5 cm) of the insulation on each
of the two conductors.
NOTE: Cat 5e cable is composed of four pairs 24 AWG
stranded conductors and not suggested for use when
wiring the transmitter.
1 in
2,5 cm
.25 in
0,5 cm
Connector Body Compression Sleeve End Cap
Seal
Grommet
L
Transmitter Signal Cable
Use twisted pair cable (20-22 AWG) for the signal loop
between transmitter and receiver.
3. The connector body employs screw clamping ter-
minals that require a small blade screwdriver. (Note
that screws have been removed from the two unused
terminals.)
4. Connect the positive + signal to PIN 1 (brown).
5. Connect common or negative – signal to PIN 2 (white).
6. Connect shield or ground (if applicable) to PIN 3
(blue).
Assemble and Seal Connector
7. Make certain that the field wiring cable passes through
the seal grommet and end cap.
8. Hand-tighten the compression sleeve until snug.
9. Hand-tighten the end cap until snug. Use a wrench
to tighten an additional 1/2 turn.
10. Plug completed connector assembly into the external
receptacle on ES2 housing (it is keyed for proper ori-
entation). Hand-tighten the stainless steel connector
nut onto the receptacle.
Recommended Signal Cable
Unshielded twisted pair cable (UTP), 20-22 AWG
Example: Belden 9407
Field Wiring Connector Assembly & Connector Body Detail
Part No. 5378-2-1
Pin 2 - White
(-PWR)
Pin 3
- Blue
(GND
Shield optional) Pin 1
- Gold
(+PWR)
Key

Page 10
ES2 Electronic Liquid Level Transmitter EX-1845
Test Point Terminals (TP2, TP3) – Test meter terminals are
provided within the transmitter housing on the lower portion
of the printed circuit board (see diagram) for measuring
the output signal without disturbing the signal loop. Do
not connect any device or meter whose internal resistance
exceeds 20 ohms across these test points. Also refer to “In-
Process Zero/Span Adjustment” in the following section.
Test Meter Posts are visible just below zero and span
potentiometers (see illustration).
– signal (TP2; below span pot)
+ signal (TP3; below zero pot)
Test Meter Post (− Signal)
Test Meter Post (+ Signal)

Page 11
ES2 Electronic Liquid Level Transmitter EX-1845
Zero
Span
-
+
Coarse Span
Rotary Switch
ES2 Calibration – Zero/Span Adjustment
This procedure is intended to recalibrate the existing zero
and span output settings. It is generally recommended
that the zero output be checked at least every 12 months.
Generally speaking, slight adjustment of the zero potenti-
ometer is all that is needed to maintain transmitter accuracy.
However, since zero is an offset adjustment, shifting this
setting upward or downward will have some correspond-
ing effect on span.
Adjusting Zero Setting
Check zero by measuring the output using the test meter
posts on the transmitter board.
1-1. Adjust zero potentiometer
as necessary to increase
output (clockwise) or de-
crease output (counter-
clockwise) until the signal
displays as 4.00 or 4.01 mA
on the test meter.
Adjusting Span Setting
This requires applying pressure to the face of the ES2 sensing
diaphragm equivalent to the maximum depth (hydrostatic)
pressure. Measure the output using the meter terminal
posts on the transmitter board.
1-2. Adjust span potentiometer as necessary to increase
output (clockwise) or decrease output (counterclock-
wise) until the signal displays as 20.00 or 20.01 mA
on the test meter.
1-3. Next step is to re-check the zero output and slightly
adjust if necessary.
In-Process Zero/Span Adjustment
It is possible to make adjustments to the zero setting while
the ES2 transmitter is installed at the tank. The meter terminal
posts permit in-process monitoring without disturbing the
loop wiring. Confirm that the tank is empty (or liquid level
is below sensor). Measure the transmitter output using a
milliammeter and adjust zero potentiometer as required.
Using Multimeter: Set multimeter for DC current, using
mA or .001 amp scale. The internal resistance of the meter
must be 20 ohms or less since higher resistance values will
create incorrect readings. Connect the leads to the meter
posts on the internal circuit board.
Adjusting span settings of an installed transmitter is not a
very precise method for calibration (since the hydrostatic
pressure may not be accurately determined). For this reason,
in-process span adjustment is not recommended.
Zero Adjust &
Span Adjust
Potentiometers
Maximum
25 turns
adjustment

Page 12
ES2 Electronic Liquid Level Transmitter EX-1845
ES2 Range Adjustment Rotary
Switch Settings
The ES2 transmitter span can be turned down from the
nominal range indicated by the model number. (Refer to
"Span Adjustment Range" under Specifications on page
2.) This is how the transmitter's pressure range can be
reduced for a specific application.
Coarse Range Setting
An initial coarse range setting is provided by the rotary
switch. Use the previously outlined Zero/Span Calibration
to achieve the final trim setting for precise 4.00-20.00 mA
output over the intended pressure range.
The Span Ranging rotary switch on the transmitter circuit
board affects the span (range) of the transmitter and can
be used in addition to the fine span adjustment of the
potentiometer.
The rotary switch provides 16 increments of coarse adjust-
ment. Prior to changing the switch setting, check the current
output of the transmitter at the desired upper pressure
value. Also note the existing switch setting.
2-1. Apply the desired maximum pressure to the sensing
diaphragm of the ES2 transmitter (requires a pres-
sure test shell available from King Engineering).
2-2. Record the existing setting position of the rotary
switch.
2-3. Adjust the potentiometer to maximum output by
turning clockwise until it “clicks”.
2-4. To increase the milliamp output, use a higher switch
setting; to reduce the milliamp output, use a lower
setting. (The goal is to achieve a output signal value
just slightly above 20 milliamps and then use the
potentiometer to trim the setting.)
2-5. Follow the Zero/Span Calibration procedure to check
both the zero and span output.
5
A
6
E
D
C
B
0
1
F
3
4
2
9
8
7
F = Highest
Decrease Increase
Detail - Rotary
Span Switch
0 = Lowest
5
A
6
E
D
C
B
0
1
F
3
4
2
9
8
7
WHEN NOT TO CHANGE SPAN
If a KING-GAGE indicator is part of the system, you
should not have to change the range (span) of the
transmitter.
When the ES2 transmitter is used with a KING-GAGE
digital tank level indicator, the "Application Datapack"
(iButton memory module) is generally programmed with
the nominal range setting. The indicator programming
will correlate the output signal to tank capacity regard-
less of whether the maximum tank level generates less
than 20.00 mA output from the transmitter.

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ES2 Electronic Liquid Level Transmitter EX-1845
Calibration Equipment Setup
To ensure specified accuracy during field calibration,
the equipment and setup used must conform to the
minimum requirements noted in this section.
Milliameter (multimeter): 3-1/2 digit minimum,
0.05% accuracy (internal resistance 20 Ohms or less)
Power Supply: 24 Volts DC (regulated); permissible
range is 14-40 Vdc
Pressure Indicator: 0.05% accuracy (corresponding
to transmitter nominal range)
0-5 psig + 0.0025 PSI (or 0.07 in. of water)
0-10 psig + 0.0050 PSI (or + 0.14 in. of water)
0-15 psig + 0.0075 PSI (or + 0.21 in. of water)
0-30 psig + 0.0150 PSI (or + 0.42 in. of water)
0-50 psig + 0.0250 PSI (or + 0.69 in. of water)
Pressure Regulator: High precision fine thread adjust-
ment for stable air/gas pressure application
CAUTION: Some pressure regulators will allow a slight
pressure output even when completely adjusted to the
shut position. It is preferable to vent the transmitter to
atmosphere by disconnecting the pressure input to ensure
accurate zero setting of transmitter.
Test Shell Fixture
This pressure fixture is available in the following con-
figurations based on the mounting length of the ES2
transmitter. Threaded 1/8 NPT connections permit air/
gas pressure to be applied to the face of the transmitter
when seated within the test shell.
Part No. Applicable Transmitter Model
5668-1 short mount ES2 Model 5501-x-xx
5668-2 std mount ES2 Model 5502-x-xx
5668-3 long mount ES2 Model 5503-x-xx
DC
Power
Supply
Pressure
Indicator
Pressure
Regulator
ES2 Transmitter
installed in Test Fixture
Shell, p/n 5668-x
Meter Post (-)
Meter Post (+)
Black (-) Red (+)
Multimeter
2000mA
200mA
20mA
2000µA
DC
mA
1000V DC
750V AC
200V DC
200V AC
20V
2000mA
2000KΩ
200KΩ
20KΩ
2000Ω
VΩ
COM
mA
20.00
Compressed
Air
0 160

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ES2 Electronic Liquid Level Transmitter EX-1845
Calculating Milliamp Output
When Output will be Less Than 20 mA .. .
■ Maximum Pressure Below 3.00 PSI
When the nominal 5 PSI transmitter is used on an applica-
tion whose maximum pressure is less than 3.00 PSI, the
full calculated range output will be less than 20 mA. To
determine the actual milliamp output of the transmitter
when the maximum applied pressure is below the lower
span limit, use the following formula:
(16 × Calculated PSI)
+4 =mA Output
3.0
The KING-GAGE ES2 transmitter is factory-calibrated to
nominal range only. Unless span is adjusted for a specific
calculated pressure range, the milliamp output of the sen-
sor at full tank level will generally be less than 20.00 mA.
Actual output can be calculated based on total tank depth
and specific gravity of the liquid product:
(B- A) × C= Tank Pressure
27.6807
where . . .
A= Reserve (inches of depth from low point of tank to
sensor)
B = Full Tank (inches of depth from low point of tank to
full)
C = Specific Gravity of Tank Contents
MODEL/RANGE
5701-1-15PSIG
Sensor
Assembly
B
A
Tank
Milk
1.032 sp. gr.
Now, using the calculated tank pressure from above, the
actual milliamp value at full can be determined:
(16 × Tank Pressure) + 4 = mA Output
NOMINAL psig RANGE
(NOTE: If the span setting is turned down from the
nominal range, refer to the calculation for determining
milliamp output.)
Example - mA Output Calculation for Tank Gauging
Application
The following example shows how the milliamp output of
the sensor at full tank can be calculated. The “Reserve”
represents the distance from the lowest point on the bot-
tom of the tank to the installed sensor. “Full” is the level of
contents at which the tank is filled to capacity. The liquid
contents of the tank is milk @ 1.032 sp.gr. The sensor
installed is a nominal 15 psig range model.
C= 1.032 (specific gravity)
B= 400 in. (full level)
A= 28 in. (reserve)
(400 - 28) × 1.032 = 13.87 psig
27.6807
(16 × 13.87) + 4 = 18.79 mA
15 psig

Page 15
ES2 Electronic Liquid Level Transmitter EX-1845
Service Parts & Replacement
O-ring seals: The outer O-ring at the head of the sensing element forms the critical seal
at the wetted process connection (generally within the tank mounting shell). This seal
should be replaced if there are any signs of physical damage such as a cut to the O-ring.
Signal wiring connectors: The transmitter provides an M12 threaded outlet on the exterior
of the housing that accepts an M12 (metric thread) connector.
ES2 Slimline Transmitter
O-Ring
Part No. 1747-40 (Viton)
End Cap Seal O-Ring
Part No. 6495-125
Part No. 6554-40 (Silicone)
Field Wiring Connector
Part No. 5378-2-1
Molded Cable & Connector Assy.
Part No. 8027-10 (32 ft/10m)
Part No. 8027-25 (82 ft/25m)

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ES2 Electronic Liquid Level Transmitter EX-1845