TC FLUID CONTROL KMS-2 User manual

Revision D 20/09/2018
Installation and
O
p
eratin
g
Instructions
KMS-2 Exia Magnetostrictive Level Transmitter

KMS-2/Exia Transmitter
Installation and Operating Manual
ATEX
Contents
Symbols Used....................................................................................................... 1
Safety information ................................................................................................. 1
Introduction ........................................................................................................... 2
Outputs ................................................................................................................. 2
Installation General ............................................................................................... 4
Magnetic Level Gauge Applications...................................................................... 4
Immersion or in tank installation............................................................................ 4
Electrical Connections........................................................................................... 7
Cable Selection..................................................................................................... 7
Adjustment and Configuration:.............................................................................. 8
Configuration switches .......................................................................................... 9
Transmitter Front Panel Settings Flowchart ........................................................ 10
Certification ......................................................................................................... 11
Fault analysis Sheet............................................................................................ 12
Maintenance........................................................................................................ 12
Technical Data .................................................................................................... 13

KMS-2/Exia Transmitter
Installation and Operating Manual
ATEX
Rev D 20/09/2018 KMS-2/Exia IOM Page 1 of 13
Symbols Used
The following symbols are used in these operating instructions:
Warning: If ignored injury or damage to property can occur.
Danger: If ignored serious injury or damage to property can occur.
Caution: Failing to comply with these instructions can lead to malfunction
of or damage to the Level Transmitter.
Ex Applications
Instructions which must be complied with when the unit is used in
potentially explosive environments and to meet the requirements of the
EU type examination certificate.
Information
Facts and information concerning proper operation of the
KMS-2 Level Transmitters
Instructions for electrical installation
Information on proper electrical installation.
Safety information
Read these instructions before installation and putting into operation.
Installation commissioning and maintenance should only be carried out by suitably
qualified personnel in conjunction with these instructions.
Comply with the relevant safety regulations when using the equipment.
The transmitter must not be modified as this will invalidate the warranty and or the product certification.
Measures must be taken to prevent risks to persons and property in the event of a defect.
Do not operate the Level Transmitters in the immediate vicinity of strong electromagnetic fields (minimum
distance: 1 m) as this may give rise to incorrect readings.
Comply with the maximum current and voltage ratings as stated in the technical data section.
For intrinsically safe applications installation of this unit must be in compliance with the applicable
National requirements i.e. EN60079-14.

KMS-2/Exia Transmitter
Installation and Operating Manual
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Page 2 of 13
KMS-2/Exia IOM Rev C 14/06/2018
Introduction
A 4-20mA loop powered transmitter for measuring the level of liquid in a vessel either directly (immersion
application) with an annular float, or indirectly by mounting on a magnetic level gauge. The Exia
intrinsically safe version can be used in all hazardous area zones when connected through an approved
isolation barrier.
The transmitter consists of a stainless steel tube, containing the Magnetostrictive measuring element, and an
stainless housing containing the electronic circuit boards.
The unit operates by sending an electrical pulse down the sensing element; the resulting magnetic field
reacts with the field from the magnetic float to produce a return signal. The time taken for the return signal
to be detected enables a level measurement to be made since the precise velocity of the return signal along
the sensing element is known.
Outputs
LCD Indicator: When fitted the display provides local indication dependent on the display mode as shown
in table 1
Mode Function Display Mode*¹
% Range mA PV (mm)
NORMAL Measuring
0.00/100.00 4.00-20.00
Actual distance in mm
from reference point
Fixed Output Zero 0.00 4.00 Distance to Zero point
Span 100.00 20.00 Distance to Span point
CALIBRATION
Start CAL 12.00 CAL
Zero set CAL 12.00 CAL
Span set CAL 12.00 CAL
Fault signalling
current setting
Downscale Set AL.
LO
*
2
3.58*
2
AL.
LO
*
2
Upscale Set AL.h
I
*
2
22.00*
2
AL.h
I
*
2
Alarm
Low Level *
3
ERR.L*
3
3.8*
3
ERR.L*
3
Downscale*
4
AL.LO 3.58 AL.LO
Upscale*
4
AL.HI 22.00 AL.HI
Table 1
LCD indication
*¹ The standard display mode is % range, alternate modes available on request
*² Analogue output remains at last measurement value during setting (Rev 5 Onwards)
*
3
When enabled by front panel switch, else will remain at 4mA until float no longer sensed.
*
4
Alarm action, set as required (Default upscale).

KMS-2/Exia Transmitter
Installation and Operating Manual
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Analogue Output: The process variable and error status are transmitted over the current loop with values as
shown in table 2.
LED’s: Provide local indication during calibration when the optional LCD is not fitted.
Mode Function Outputs
ANALOGUE Zero LED Span LED
NORMAL Measuring
4-20mA Off Off
Fixed Output Zero 4mA On Off
Span 20mA Off On
Fault Signalling
Current Setting
Downscale
4-20mA Flash Off
Upscale
Off Flash
CALIBRATION
Start 12mA Flash Flash
Zero set
12mA On Off
Span set
12mA Off On
Alarm
Low level
3.8mA Off Off
Downscale
3.58mA Off Off
Upscale
22mA Off Off
Table 2
Instrument output status indication
The Low Level alarm must be enabled as shown in the configuration section. When set
the output signal will change to 3.8mA if the float drops more than 13mm below Zero
point.

KMS-2/Exia Transmitter
Installation and Operating Manual
ATEX
Page 4 of 13
KMS-2/Exia IOM Rev C 14/06/2018
Installation General
Magnetic Level Gauge Applications
The unit should be fitted to the level gauge with reference to Fig1 using the mounting clips and insulation
(if required) supplied. The unit should be positioned such that the XXXX marks around the circumference
align with the upper and lower vessel connection points.
Ensure that the sensing tube is not distorted or strained during installation
The fixing clips should be spaced evenly along the length of the tube with a maximum centre distance
1000mm
If it is required to remove the transmitter for maintenance work ensure that any
insulation is correctly fitted during reassembly to ensure operating temperatures are
maintained within the range specified on the EU type approval certificate.
Immersion or in tank installation
The transmitter should be fitted to the tank with reference to Fig.2. The distance between the tank
connection and electronic housing will vary dependent on temperature and for a weld on connection be
factory set.
Caution
When using an adjustable sealing gland ensure that the maximum ambient temperature
for the electronic housing is not exceeded. (See technical data section).
Dependent on the length of the sensor tube an anchor point may be required at the bottom of the tank.
Where the transmitter is supplied with an adjustable gland care must be taken to
ensure that the electronic housing temperature is maintained within that specified on
the EU type examination certificate. Please consult the sales office

KMS-2/Exia Transmitter
Installation and Operating Manual
ATEX
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TRANSMITTER
Fig 1
Typical Installation When Fitted to Magnetic Level Gauge
DISPLAY
TOP MOUNT OPTION
BOTTOM MOUNT OPTION
SCREW
CLAMP
GAUGE
CHAMBER
INSULATION
IF REQUIRED
TRANSMITTER
CLIP

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Installation and Operating Manual
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KMS-2/Exia IOM Rev C 14/06/2018
Fig 2
Immersion Application
Ensure that the PFA/PTFE washer is correctly fitted to prevent the risk of sparking if the
float was to hit the stop.
Ensure that the electronic assembly is maintained within the certified ambient temperature
range consult sales office to determine correct offset.

KMS-2/Exia Transmitter
Installation and Operating Manual
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Electrical Connections
Unscrew the lid to gain access to the rear terminal enclosure; the terminal block can then be removed to
facilitate connections.
Select the correct cable entry point dependent on the orientation of the sensor. The connection cable should
be bought in through an M20 gland suitable to maintain the required IP rating, and then connected to the +
and – terminals.
To prevent the risk of moisture ingress ensures that the connection cable is led downward in front of the
cable gland
Cable Selection
The connection cable should be a twisted pair type suitable for the expected ambient conditions.
When a screened cable is used, the screen should be connected to the internal earth connection provided.
Hazardous area Installation
The installation of this unit must be in compliance with the applicable national
requirements
i.e. EN60079-14.
Intrinsically Safe Circuits
The connection cable shall be identified to prevent confusion with non-intrinsically safe circuits where a
colour code is used it should be light blue.
The total inductance and capacitance of the cable shall not exceed the values stated on the intrinsically safe
control device for the required gas group.
The connection cable should be bought in through the M20 cable entry via a suitable gland as necessary to
maintain the required IP rating (minimum IP54).
When refitting the lid ensure that the sealing gasket is correctly fitted into the lid recess.
Fig 3 Cable entry via M20 Gland Fig 4 Connection Details
28V dc
MAX
K&TC
PCB620
REV D
+
E
+

KMS-2/Exia Transmitter
Installation and Operating Manual
ATEX
Page 8 of 13
KMS-2/Exia IOM Rev C 14/06/2018
Adjustment and Configuration: (See also Flowchart Page 10)
The unit is normally set at the factory to the required specification:
• Range adjustment and output inversion (To customer requirements)
• Low Level Alarm Select (off)
• Fault Current Output (22mA)
Fig 5
Internal layout of case showing
Local Display and calibration switches
Range Adjustment
The measuring range of the unit is set at the factory.
If the default range is unsuitable or adjustment is required the following procedure should be followed. With
reference to Fig. 5
1. Set the float to the minimum level
2. Press the ‘Span’ and ‘Zero’ buttons until both LED,s flash alternatively (output 12mA)
3. Release buttons
4. Press the ‘Zero’ button until the ‘Zero’ LED stays on
5. Wait until the ‘Zero’ LED extinguishes. (output 4mA)
6. Set the float to the maximum level.
7. Press the ‘Span’ and ‘Zero’ buttons until both LED,s flash alternatively (output 12mA)
8. Release buttons
9. Press the ‘Span’ button until the ‘Span’ LED stays on
10. Wait until the ‘Span’ LED extinguishes. (output 20mA)
If the optional LCD is fitted the display will read ‘CAL’ during the setting process.
The measuring range can be set within the factory limits with a maximum turndown of 50%,
If an error is detected during the ranging process the unit will default to the previously saved
values the relevant LED will flash if ranging failed.
Inverse output
The output is normally set so that the 20mA point is at the Head shell end. If it is required to mount the head
shell at the bottom the output can be inverted by following procedure.
1. Move the float to approximately 50% of range
2. Set the ‘Zero’ level as 2-5 above
3. Move the float to the required maximum level
4. Set the ‘Span level as 7-9 above,
5. Move the float to the required minimum level zero level.
6. Set the ‘Zero level as 2-5 above.
The unit will then automatically invert the output.

KMS-2/Exia Transmitter
Installation and Operating Manual
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Caution
The float failure and write protect switches should be set to the ‘OFF’ position before
adjustment to the ranging are made, and reinstated as necessary afterwards.
It is important that the float is kept stationary for approximately 10 seconds before and
after operation of the calibration buttons to ensure that the output signal has stabilised to
the correct value.
Fault signalling Current (Rev 5 Onwards)
When the magnetic field from the float is not detected the default output level is set Upscale (22mA).
To change to Downscale (3.5mA)
1. Press and release the span & zero buttons
2. Setting is indicated on LCD display and or respective LED
3. To change, press and release respective button
a) Zero button (Downscale 3.5mA)*
b) Span button (Upscale 22mA)*
4. Relevant LED will flash to signify save to memory
5. When complete display will revert to normal measurement mode.
*If change not required wait 20 Seconds unit will return to “Measurement Mode”
Low level alarm
The Low Level alarm output signal will change the output to 3.8mA if the float drops more than 13mm
below zero point. When off the output will remain at 4mA below the zero point until the return signal is lost
i.e. the sensor is no longer sensing the magnetic field then output will change to either 3.5mA (Downscale
or 22mA (Upscale).
1) Write Protect
On: Range setting inhibited
Off
2) Alarm Function
On: Low Level (3.8mA)
Off: No Alarm Output Remains at 4mA
Fig. 6
Configuration switches
Caution
Turn power off before changing alarm switch settings to prevent unexpected changes in
loop current. Ensure that the write protect is set to ‘ON’ after changes to range
adjustments.
Fixed Output
To allow for loop calibration the transmitter output can be fixed to either 4 or 20mA. The zero or span
button should be depressed until the respective LED lights, the output will then remain static. To reset to
normal operation either depress the opposite button or cycle the power.

KMS-2/Exia Transmitter
Installation and Operating Manual
ATEX
Page 10 of 13
KMS-2/Exia IOM Rev C 14/06/2018
Transmitter Front Panel Settings Flowchart
*
1
Transmitter must be detecting float before settings can be changed
*
2
Analogue fault signalling setting Rev5 onwards (Displayed during startup Init.5)
*
1

KMS-2/Exia Transmitter
Installation and Operating Manual
ATEX
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Certification
Certificate No’s. Baseefa 06 ATEX 0159 X, IECEx BAS 06.0038 X
Explosion protection Type: Ex ia
Gas Group: IIC
ATEX Approval Type: II 1G Exia IIC T2 … T6 Ga or II 1G Exia IIB T2 … T6 Ga
Notified Body No. CE 1180
Input Parameters Conn1 Terminal + w.r.t -
Ui = 28V, Ii = 93mA, Pi = 0.65W, Ci = 0, Li = 30uH.
Temperature Class
The relationship between the temperature class and maximum process temperature for the ambient
temperature range is as shown in the following table.
Temperature Class Process Temperature Ambient Temperature Range
T2
≤ 250°C
-50°C
≤ Ta ≤ 60°C
T3
≤ 195°C
T4
≤ 130°C
T5
≤ 95°C
T6
≤ 80°C -50°C
≤ Ta ≤ 40°C
Table 2
Relationship between Temperature class,
process temperature, and ambient temperature
In accordance to EN60079-11:2012 clause 6.3.13 this apparatus is capable of withstanding a 500V
isolation test.
EMC
In accordance to EU council directive 2014/30/EU
Emissions EN 61326:2004 (Class B)
STANDARD DESCRIPTION PORT RESULT
EN 61326 Radiated Emissions Enclosure Pass
EN 61326 Conducted Emissions Not applicable Not Tested
Immunity tests to EN 61326: 2004 A1, A2, A3
STANDARD DESCRIPTION PORT RESULT
61000-4-2 Electrostatic Discharge Enclosure Pass
61000-4-3 RF Electromagnetic Field Enclosure Pass
61000-4-4 EFT/ Burst DC Port Pass
61000-4-5 Surge DC Port Pass
61000-4-6 Conducted RF DC Port Pass
61000-4-8 Magnetic Field Enclosure Not Tested
61000-4-11 Voltage Dip/ interruptions Not applicable Not Tested

KMS-2/Exia Transmitter
Installation and Operating Manual
ATEX
Page 12 of 13
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Fault analysis Sheet
Problem Possible Fault Action
Zero current eg. 0mA
Supply Voltage to low < 8V Check voltage and adjust
accordingly
Supply Connections reversed Swap supply cables
Cables/Connecting circuit faulty Rectify as required
Faulty Unit Consult Factory.
Current Greater than 22mA Supply voltage to high > 28V Adjust voltage to less than 28V
Output at
3.8mA (Low level)
Float damaged (sunk) Fit new float
Chamber empty Open check valves
Continual reading of either
3.58mA Downscale
22mA Upscale
Float magnetic field not being
sensed
Check gap distance between
chamber and transmitter
Float Under magnetised Check with spare float if
available
Output static at a particular level
Float stuck or damaged Check against visual display if
fitted. Check float condition
Residual magnetic interference Run magnet along full length of
probe, Consult Factory.
External magnetic interference Check for external magnetic
devices in vicinity.
4-20mA not proportional to
liquid level
“XXXX” marks not in line with
vessel connections
Realign transmitter marks
correctly
S.G range of float incorrect for
media type
Check S.G etched on float
against media S.G
Table 3
Fault Analysis
Maintenance
The unit contains no user serviceable parts; therefore no routine maintenance is required.
Dependent on model or application:
For coated options:
• Where the case of the device may be subjected to impact or friction, periodic examination is
required to ensure that the integrity of the stove enamelled finish is maintained.
For Immersion Applications
• The sensor tube must be kept clean to prevent the float “sticking”.

KMS-2/Exia Transmitter
Installation and Operating Manual
ATEX
Rev D 20/09/2018 KMS-2/Exia IOM Page 13 of 13
Technical Data
Materials
Measuring probe: - 316L Stainless steel
Housing: - 316L Stainless steel
Cable entry
Thread Size: - M20x1.5mm
Connection conductor size: - 0.5mm² - 2.5mm²
Supply voltage (Nominal 24VDC)
Minimum 12V
Maximum 28V
Current Output
Measured Current range: - 4-20mA ± 0.1%
Fault Current: -
Upscale* 22mA
Downscale 3.5mA
Low level (When enabled) 3.8mA
* Default Factory setting
Fixed Output (For loop calibration) 4 or 20mA ± 0.1%
Operating Temperatures
(See certification section for details when used in a potentially explosive atmosphere)
Ambient range: - -50°C / + 60°C (-30°C / +60°C When LCD Fitted)
Process range: - -50°C/ +250°C
Fig 7
Ambient verses process temperature for standard transmitter
Where ambient conditions are outside this range additional insulation or shielding will be required please
consult sales office.

WIKA Instruments Ltd
TC Fluid Control Level Division
Unit 4, The Interchange
Wested Lane,
Swanley,
Kent BR8 8TE
Tel: [phone]
Website: www.tc-fluidcontrol.com