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rf capacitance level measurement 7xxx 6xxx 5xxx 4xxx 3xxx 2xxx 1xxx k otron m odel 805 s mart rf l evel t ransmitter installation and operating manual
read this manual before installing this manual provides information on the kotron model 805 smart rf transmitter. it is important that all instructions are read carefully and followed in sequence. the quickstart installation instructions are a brief guide to the sequence of steps for experienced technicians to follow when installing the equipment. detailed instruc- tions are included in the complete installation section of this manual. conventions used in this manual certain conventions are used in this manual to convey specific types of information. general technical material, support data, and safety information are presented in narrative form. the following styles are used for notes, cautions, and warnings. notes notes contain information that augments or clarifies an operating step. notes do not normally contain actions. they follow the procedural steps to which they refer. cautions cautions alert the technician to special conditions that could injure personnel, damage equipment, or reduce a components mechanical integrity. cautions are also used to alert the technician to unsafe practices or the need for special protective equipment or specific mate- rials. in this manual, a caution box indicates a poten- tially hazardous situation which, if not avoided, may result in minor or moderate injury. warnings warnings identify potentially dangerous situations or serious hazards. in this manual, a warning indicates an imminently hazardous situation which, if not avoided, could result in serious injury or death. safety messages the kotron model 805 system may be properly installed in category ii, pollution degree 2 installations. follow all standard industry procedures for servicing electrical and computer equipment when working with or around high voltage. always shut off the power supply before touching any components. although high voltage is not present in this system, it may be present in other systems. electrical components are sensitive to electrostatic dis- charge. to prevent equipment damage, observe safety procedures when working with electrostatic sensitive components. low voltage directive for use in category ii installations. if equipment is used in a manner not specified by manufacturer, protection provided by equipment may be impaired. warning! explosion hazard. do not connect or dis- connect equipment unless power has been switched off or the area is known to be non-hazardous. notice of trademark, copyright, and limitations kotron is a registered trademark of magnetrol international, incorporated. kotron model 805 smart rf transmitter is a tradename of magnetrol international, incorporated. copyright ?2004 magnetrol international, incorporated. all rights reserved. magnetrol reserves the right to make changes to the product described in this manual at any time without notice. magnetrol makes no warranty with respect to the accuracy of the information in this manual. warranty all magnetrol/sti electronic level and flow controls are warranted free of defects in materials or workmanship for one full year from the date of original factory shipment. if returned within the warranty period; and, upon factory inspection of the control, the cause of the claim is deter- mined to be covered under the warranty; then, magnetrol/sti will repair or replace the control at no cost to the purchaser (or owner) other than transportation. magnetrol/sti shall not be liable for misapplication, labor claims, direct or consequential damage or expense arising from the installation or use of equipment. there are no other warranties expressed or implied, except special written warranties covering some magnetrol/sti products. quality assurance the quality assurance system in place at magnetrol/sti guarantees the highest level of quality throughout the company. magnetrol/sti is committed to providing full customer satisfaction both in quality products and quality service. magnetrols quality assurance system is registered to iso 9001 affirming its commitment to known international quality standards providing the strongest assurance of product/service quality available.
table of contents 1.0 quickstart installation 1.1 getting started .......................................................1 1.1.1 equipment and tools...................................1 1.1.2 configuration information ..........................1 1.2 quickstart mounting .............................................2 1.2.1 probe ...........................................................2 1.2.2 transmitter ..................................................2 1.3 quickstart wiring ..................................................3 1.4 quickstart configuration and calibration (lcd version) ........................................................3 2.0 complete installation 2.1 unpacking ..............................................................5 2.2 electrostatic discharge (esd) handling procedure...5 2.3 before you begin ....................................................6 2.3.1 site preparation............................................6 2.3.2 equipment and tools...................................6 2.3.3 operational considerations .........................6 2.4 mounting ...............................................................7 2.4.1 installing a rigid probe................................8 2.4.2 installing a flexible probe ............................8 2.4.3 installing the transmitter .............................9 2.5 wiring ..................................................................10 2.5.1 general purpose or non-incendive (ci i, div 2) ..............................................10 2.5.2 intrinsically safe .........................................10 2.6 configuring & calibrating the transmitter (lcd version)......................................................11 2.6.1 operating parameters .................................11 2.6.2 lcd transmitter display and keypad .......12 2.6.3 password protection (default = 0) .............12 2.6.4 lcd menu: step-by-step procedure .........12 2.7 configuration using hart..............................14 2.7.1 connections...............................................14 2.7.2 hart display menu ................................14 2.7.3 hart device description (dd)...............14 2.7.4 hart menu .............................................15 3.0 reference information 3.1 description...........................................................16 3.2 theory of operation ............................................16 3.3 troubleshooting....................................................17 3.3.1 troubleshooting system problems (lcd)..18 3.3.2 error messages (lcd) ...............................18 3.3.3 troubleshooting flowchart (lcd).............19 3.4 agency approvals .................................................22 3.4.1 agency specifications ?intrinsically safe installation..........................................23 3.5 parts......................................................................24 3.5.1 replacement parts......................................24 3.5.2 recommended spare parts .........................24 3.6 specifications ........................................................25 3.6.1 functional..................................................25 3.6.2 performance ...............................................26 3.6.3 physical......................................................27 3.7 model numbers ...................................................28 3.7.1 transmitter .................................................28 glossary ..............................................................................29 index ...................................................................................31 configuration and calibration data sheet........................ 32 kotron model 805 smart rf level transmitter
50-660 kotron model 805 smart rf level transmitter 1 1.0 quickstart installation the quickstart installation procedures provide the key steps for mounting, wiring, and configuring the kotron model 805 level transmitter. these procedures are intend- ed for experienced installers of electronic level measure- ment instruments. see complete installation, section 2.0, for detailed installation instructions. 1.1 getting started before beginning the quickstart installation procedures, have the correct equipment, tools, and information available. 1.1.1 equipment and tools ? 1 8 " open-end wrench or adjustable wrench to fit the probe process connection size and type. ? 1 4 " open-end wrench or adjustable wrench to fit adaptor on transmitter housing. flat-blade screwdriver digital multimeter or digital volt/ammeter 24 vdc power supply, 23 ma 1.1.2 configuration information some key information is needed to configure the model 805 transmitter. complete the following operating parameters table before beginning configuration. display question answer units what units of measurement will be used? (inches or centimeters) _____________ set what is the 0% reference point for the 4.0 ma 4.0 ma value? _____________ set what is the 100% reference point for 20.0 ma the 20.0 ma value? _____________ kotron model 805 smart rf level transmitter
50-660 kotron model 805 smart rf level transmitter 2 1.2 quickstart mounting note: confirm the configuration style and process connection size and type of the kotron model 805 transmitter. ensure it match- es the requirements of the installation before continuing with the quickstart installation. confirm the model and serial numbers. 1.2.1 probe carefully place the probe into the vessel. align the probe process connection with the threaded or flanged mounting on the vessel. tighten the probe using the flats of the probe process con- nection or flange bolts. 1.2.2 transmitter loosen screw on top of the probe and attach white wire to probe, making sure that spade lug is at a 90 upward angle. tighten probe screw securely. (see figure below) place the transmitter on the probe. tighten the connection by using the flats on the adaptor. 90 bend
50-660 kotron model 805 smart rf level transmitter 3 1.3 quickstart wiring warning! explosion hazard. do not connect or disconnect equip- ment unless power has been switched off or the area is known to be safe. note: make sure the electrical wiring to the kotron model 805 trans- mitter is complete and in compliance with all regulations and codes. 1. remove the cover of the wiring compartment of the transmitter. 2. attach a conduit fitting and mount the conduit plug in the spare opening. pull the power supply wire (twisted, shielded pair of at least 22 awg) through the conduit fitting. 3. connect shield to an earth ground at power supply and leave floating at the transmitter. 4. connect an earth ground to the nearest green ground screw. (not shown in illustration.) 5. connect the positive supply wire to the (+) terminal and the negative supply wire to the (-) terminal. 6. replace the cover and tighten. 1.4 quickstart configuration and calibration (lcd version) note: the kotron model 805 transmitter can be equipped with either a 2-line by 8-character lcd. 1. power-up the transmitter. the display changes every 5 seconds to show one of the three measured values: level, %output, and loop current. 2. remove the cover of the electronic compartment. 3. use the up ( ) or down ( ) arrow keys to move from one step of the configuration program to the next step. red (+) black (-) (+) (-) enter down up 4. press the enter arrow ( ) key. the last character in the first line of the display changes to an exclamation point (!). for example: 5. use the up ( ) or down ( ) keys to increase or decrease the value in the display or to scroll through the choices. units! xxx
50-660 kotron model 805 smart rf level transmitter 4 units lu set 4ma xxx.x set 20ma xxx.x scroll down to the units display. press the enter arrow ( ) key. select the units of measurement for the level readout (cm or inches). press the enter arrow ( ) key. scroll down to the lo cal display. press the enter arrow ( ) key. enter the current level (in or cm) of media on the probe by using the up and down arrow ( ) keys. holding either key down causes the values to change first by 1s and then by 10s. single depression of either key causes the values to change by 0.1s. once the desired value is dis- played, press the enter arrow ( ) key. move the media in the tank to a higher level. the greater the amount at level change, the more accu- rate the level measurement. scroll down to the hi cal display. press the enter arrow ( ) key. enter the new current media level in the same manner as above. press the enter arrow ( ) key. note: if calibrating the 805 for interface measurement, enter the level of the interface rather than the upper level. scroll down to the set 4 ma display. press the enter arrow ( ) key. enter the minimum level value for the desired 4 ma point. press the enter arrow ( ) key. scroll down to the set 20 ma display. press the enter arrow ( ) key. enter the maximum level value for the desired 20 ma point. press the enter arrow ( ) key. hi cal 20ma level (100%-point) 4ma level (0%-point) in or cm 1 5 4 3 lo cal 2 6. press the enter arrow ( ) key to accept a value and move to the next step of the configuration program. 7. the default password is 0. (no password is required.) lo cal xxx.x lu hi cal xxx.x lu the transmitter is now calibrated for this probe in this medium in this tank (or vessel) and it provides a 4?0 ma output over the desired range. damping factor and fault output will automatically default to factory set values of 1 second and 22 ma. changing these values and those for other parameters are covered in detail in the next section, complete installation . the following parameter entries are the minimum required for initial setup and calibration. the default password is 0.
50-660 kotron model 805 smart rf level transmitter 5 2.0 complete installation this section provides detailed procedures for properly installing, configuring, and, as needed, troubleshooting the kotron model 805 level transmitter. 2.1 unpacking unpack the instrument carefully. make sure all compo- nents have been removed from the packing material. check all the contents against the packing slip and report any discrepancies to the factory. before proceeding with the installation, do the following: inspect all components for damage. report any damage to the carrier within 24 hours. make sure the nameplate model number agrees with the packing slip and purchase order. record the model and serial numbers for future reference when ordering parts. 2.2 electrostatic discharge (esd) handling procedure magnetrols electronic instruments are manufactured to the highest quality standards. these instruments use electronic components that may be damaged by static electricity pre- sent in most work environments. the following steps are recommended to reduce the risk of component failure due to electrostatic discharge. ship and store circuit boards in anti-static bags. if an anti- static bag is not available, wrap the board in aluminum foil. do not place boards on foam packing materials. use a grounding wrist strap when installing and removing circuit boards. a grounded workstation is recommended. handle circuit boards only by the edges. do not touch components or connector pins. make sure that all electrical connections are completely made and none are partial or floating. ground all equipment to a good, earth ground.
50-660 kotron model 805 smart rf level transmitter 6 2.3 before you begin 2.3.1 site preparation each kotron model 805 transmitter is built to match the specific physical specifications of the required installation. make sure the probe connection is correct for the threaded or flanged mounting on the vessel or tank where the trans- mitter will be placed. see mounting, section 2.4. make sure that the wiring between the power supply and model 805 transmitter is complete and correct for the type of installation. see specifications, section 3.6 . when installing the model 805 transmitter in a general purpose or hazardous area, all local, state, and federal regulations and guidelines must be observed. see wiring, section 2.5 . 2.3.2 equipment and tools no special equipment or tools are required to install the model 805 transmitter. the following items are recommended: ? 1 8 " open-end wrench or adjustable wrench to fit the probe process connection size and type flat-blade screwdriver digital multimeter or digital volt/ammeter 24 vdc power supply, 23 ma 2.3.3 operational considerations the model 805 transmitter should be located for easy access for service, configuration, and monitoring. there should be sufficient headroom to allow the probe to be inserted into the tank. special precautions should be made to prevent exposure to corrosive atmosphere, excessive vibration, shock, or physical damage. the transmitter electronics should not be exposed to ambient temperatures above +175 f (+80 c) or below -40 f (-40 c). the proper operating temperature range for the display is -10 to +160 f (-20 to +70 c). the temperature limits for the probe depend on the style and part number of the specific probe used. see brochure 50-125, kotron rf sensing probes .
50-660 kotron model 805 smart rf level transmitter 7 2.4 mounting the model 805 transmitter can be mounted to a tank using a variety of process connections. generally, either a threaded or flanged connection is used. for information about the sizes and types of connections available, see brochure 50-125, kotron rf sensing probes . make sure all mounting connections are properly in place on the tank before installing the probe. make sure the kotron probe is correct for the intended installation. it is common practice to use the metal tank wall as the ref- erence electrode. in such cases, it is required that the probe housing makes a good electrical connection to the tank wall. if there is any doubt about this connection or to the use of ptfe thread tape gaskets, paint, rust, or any other reason, a separate strap should be installed between the probe housing and the tank. caution: this unit contains cmos electronics which may be dam- aged by static electricity. do not touch any semi-conduc- tor devices unless you are properly grounded. metal walled tanks on water-based liquids, there should be no problem with sensitivity or linearity. with non-conductive, low dielectric media, sensitivity can be enhanced by locating the probe close to and parallel with the tank wall. if this is not prac- tical, a concentric ground tube surrounding the probe (sometimes called a stilling well), may be the solution. note: these comments are also true for glass-lined metal walled tanks. tanks/silos with non-conductive materials of construction with plastic, concrete, wood, or any other non-conductive walled vessels, the reference electrode mentioned above needs clarification. most commonly, this electrode will be in the form of a concentric ground tube (i.e. stilling well). in questionable circumstances, consult the factory. in all cases, a good electrical connection must be made between the ground surface and the probe housing.
50-660 kotron model 805 smart rf level transmitter 8 transmitter/probe assembly transmitters with probes up to and including 12 inches (305 mm) in length are shipped pre-assembled. all other transmitters are shipped unassembled to avoid damage during transit. these transmitters must be assembled prior to mounting. choose your particular configuration from the following sections and follow the instructions carefully. 2.4.1 installing a rigid probe before installing, ensure the: probe has adequate headroom for installation and has unobstructed entry to the bottom of the vessel. process temperature, pressure, dielectric, and viscosity are within the probe specifications for the installation. see specifications, section 3.6 . to install a probe: make sure the process connection is at least 3 4 " npt or a flanged mounting. carefully place the probe into the vessel. align the gasket on flanged installations. align the probe process connection with the threaded or flanged mounting on the vessel. tighten the threaded probe process connection using only the flats on the probe. caution: packing glands used on all magnetrol rigid probe assem- blies have been sealed at the factory under controlled conditions. care must be exercised when installing probe assemblies to avoid breaking the pressure tight gland seal, which destroys the seal. 2.4.2 installing a flexible probe caution: flexible probes are shipped with the cable clamp and the packing gland nut hand tightened. the end of a flexible probe must be kept taut by attaching the anchor end at the bottom of the vessel or by using a magnetrol supplied probe weight. caution: do not discard the mylar housing insulator. caution: the probe cable must not be in contact with any metallic surface in its final installation position.
90 bend 50-660 kotron model 805 smart rf level transmitter 9 probe connection screw ?? socket head clamp screws (2) ?? upper probe mounting gland ? lower probe mounting gland ?? mylar housing insulator (slips over clamp) ?? teflon retaining bushing ?? clamp ? optional weight ? tank bracket connection ? optional mounting bracket (used w/ insulated probes) probe locking set screw flexible probe probe termination to install a probe: attach the weight or anchor assembly to the end of the probe. insert the probe through the vessels mounting connection, and feed the cable into the vessel. do not allow the probe to scrape against the connection threads. secure the anchor assembly (if used), to the bottom of the vessel. apply thread sealant to the mounting nut. screw the mounting nut into the mounting connection until tight. remove the mylar housing insulator located over the clamp. do not discard. loosen both socket head screws from the clamp. pull the clamp and teflon retaining bushing off of the probe. while holding on to the probe cable, loosen the upper packing gland nut. do not allow the probe cable to fall into the vessel. pull the excess cable up through the packing gland nut until the cable is taut. tighten the packing gland nut.
cut the cable 1.35" (34 mm) above the packing gland nut and strip off 1.25" (32 mm) of insulation. slide the teflon retaining bushing onto the cable and seat it into the packing gland nut. slide the clamp onto the cable and seat it against the teflon retaining bushing. tighten both socket head screws, on the clamp, to approximately 35 in/lbs of torque. slip the mylar insulator over the clamp. 2.4.3 installing the transmitter loosen screw on top of the probe and attach white wire to probe, making sure that spade lug is at a 90 upward angle. tighten probe screw securely. slide white wire through the adaptor while placing the transmitter on the probe. tighten the connection by using the flats on the adaptor.
50-660 kotron model 805 smart rf level transmitter 10 2.5 wiring caution: the kotron model 805 transmitter operates at voltages of 11?6 vdc (gp) and 11?8.6 vdc (is). higher voltages will damage the transmitter. all wiring between the power supply and the model 805 transmitter should be made using 18?2 awg shielded twisted pair instrument cable. within the transmitter enclosure, connections are made to the terminal strip and the ground connections. the directions for wiring the model 805 transmitter depend on the application: general purpose or non-incendive (cl i, div. 2) intrinsically safe warning! explosion hazard. do not disconnect equipment unless power has been switched off or the area is known to be safe. 2.5.1 general purpose or non-incendive (cl i, div. 2) a general purpose installation does not have flammable media present. areas rated non-incendive (cl i, div. 2) have flammable media present only under abnormal conditions. no special electrical connections are required. if flammable media is contained in the vessel, the trans- mitter must be installed per cl i, div. 1 standards of area classification. to install general purpose or non-incendive wiring: 1. remove the cover to the wiring compartment of the trans- mitter. install the conduit plug in the unused opening. 2. install a conduit fitting and pull the supply wires. 3. connect shield to an earth ground at power supply and leave floating at the transmitter. 4. connect an earth ground wire to the nearest green ground screw. (not shown in illustration.) 5. connect the positive supply wire to the (+) terminal and the negative supply wire to the (-) terminal. 6. replace the cover to the wiring compartment of the transmitter. 2.5.2 intrinsically safe an intrinsically safe (is) installation potentially has flam- mable media present. an approved is barrier must be installed in the nonhazardous (safe) area. see agency drawing ?intrinsically safe installation, section 3.4.4 . red (+) black (-) (+) (-)
50-660 kotron model 805 smart rf level transmitter 11 to install intrinsically safe wiring: 1. make sure the is barrier is properly installed in the safe area (refer to local plant or facility procedures). complete the wiring from the barrier to the model 805 transmitter. see agency specifications ?intrinsically safe installations, section 3.4.1 . 2. remove the cover to the wiring compartment of the trans- mitter. install the conduit plug in the unused opening. 3. install a conduit fitting and pull the supply wires. 4. connect shield to an earth ground at power supply and leave floating at the transmitter. 5. connect an earth ground wire to the nearest green ground screw. (not shown in illustration.) 6. connect the positive supply wire to the (+) terminal and the negative supply wire to the (-) terminal. 7. replace the cover to the wiring compartment of the transmitter. 2.6 configuring and calibrating the transmitter (lcd version) before configuring the model 805 transmitter, collect the operating parameters information. then, power-up the transmitter. information on configuring the transmitter using a hart communicator is given in configuration using hart, section 2.7 . 2.6.1 operating parameters some key information is needed to calibrate the model 805 transmitter. complete the configuration information table. see configuration information, section 1.1.2 . 2.6.2 lcd transmitter display and keypad the model 805 lcd transmitter has a liquid-crystal dis- play (lcd) capable of showing two lines of 8 characters each. transmitter measurements and configuration menu screens are shown on the lcd. the transmitter default display is the measurement screen. it cycles every 5 seconds to display level, %output, and loop information. the transmitter defaults to this display after 5 minutes if no keystrokes are sensed. the keypad has three arrows used to scroll through the displays and to calibrate the transmitter ?the up ( ) or down ( ) arrow keys and the enter ( ) key. either the lo cal or hi cal point levels can be entered first. it is not necessary to do the lo cal first. in addition, the 4 ma and 20 ma setpoints can be entered for either direct action or reverse action as desired.
50-660 kotron model 805 smart rf level transmitter 12 arrows function in function in display mode configuration mode up and down moves forward and backward increases or decreases the in the configuration program value displayed or moves to from one display to another. another choice. note: hold arrow key for rapid scrolling. enter enters the configuration mode accepts a value and moves (noted by an exclamation point to the next step of the as the last character in the top configuration program. display line). 2.6.3 password protection (default = 0) the model 805 transmitter includes optional password protection to restrict access to certain portions of the menu structure that affect the operation of the system. the password can be changed to any numerical value up to 255. the password is required whenever configuration values are changed. the default password installed in the transmitter at the factory is 0. the last step in the configuration menu pro- vides the option to enter a new password. with 0 as the password, the transmitter is no longer password protected and any value in the menu can be altered without entering a confirming password. note: if the password is not known, the menu item new password displays an encrypted value representing the present pass- word. call the factory with this encrypted value to determine the present password. 2.6.4 lcd menu: step-by-step procedure the following table provides a complete explanation of the software menus displayed by the model 805 transmitter. use this table as a step-by-step guide to configure the transmitter. the first column presents the menus shown on the trans- mitter display. the displays are in the order they would appear if the arrow keys were used to scroll through the menu. the numbers are not shown on the display. they are provided as a reference. the second column provides the actions to take when con- figuring the transmitter. additional information or an explanation of an action is given in the third column.
50-660 kotron model 805 smart rf level transmitter 13 display action comment 1 2 3 4 5 6 7 8 9 10 11 12 13 *level* *%output* *loop* transmitter display transmitter default display. level, % output, and loop values cycle every 5 seconds (two seconds each value). transmitter display level measurement in cm or in. transmitter display level as percentage of loop current (20 ma) span. transmitter display loop current output. select units for level lu = cm or in. measurement display. enter level value for the use up and down keys to set reading to present level of lower calibration point. medium in vessel. see section 1.4 . transmitter display measured capacitance at low calibration point. enter level value for the move the level in the tank. use up and down keys to set higher calibration point. reading to present level of medium in vessel. see section 1.4 . transmitter display measured capacitance at high calibration point. enter the level value for the use up and down keys to set reading to level corresponding 4 ma point. to 4 ma loop current. enter the level value for the use up and down keys to set reading to level corresponding 20 ma point. to 20 ma loop current. enter damping factor. choose the damping factor (1?5 sec) for smoothing the level/output/loop displays. enter the desired loop current select 22 ma, 3.6 ma or hold. (3.6 ma is not valid if unit in presence of a fault. includes both digital display and hart) enter hart poll address. select a hart poll address (0?5). enter 0 for a single transmitter installation. trim loop current to 4.00 ma. with a meter in the loop, use up and down keys to adjust current to 4.00 ma. trim loop current to 20.00 ma. with a meter in the loop, use up and down keys to adjust current to 20.00 ma. enter test value of loop current use up and down keys to set loop current to a desired value (3.5?2.0 ma) for testing. transmitter display measured capacitance at present level of medium in vessel. transmitter display internal timing count with known capacitance in circuit (factory diagnostic). transmitter display internal timing count with probe disconnected (factory diagnostic). transmitter display internal timing count at present level of medium in vessel (factory diagnostic). select yes to reinitialize resets all configuration parameters to factory default all values values. transmitter display shows version number of firmware. enter new password use up and down keys to select desired value (0?55). level xx.x lu %output xx.x% loop xx.xx ma units lu lo cal xxx.x lu lo cap xxxx pf hi cal xxx.x lu hi cap xxxx pf set 4ma xxx.x lu set 20ma xxx.x lu damping xx sec fault choice poll adr xx trim 4 xxx trim 20 xxxx 14 15 16 17 18 loop tst xx.x ma prb rdg xxxx pf 19 20 osc tst xxxx tk opn prb xxxx tk 21 22 # ticks xxxxx tk reinit xx 23 24 ver n.naa new pass xxx run mode calibration/configuration diagnostics
50-660 kotron model 805 smart rf level transmitter 14 2.7 configuring and calibrating the transmitter using hart a hart (highway addressable remote transducer) remote unit, such as a hart 275 handheld communica- tor, can be used to provide a communication link to the model 805 transmitter. when connected to the control loop, the same system measurement readings shown on the transmitter are shown on the communicator. in addition, the communicator can be used to configure the transmitter. the hart communicator may need to be updated to include the model 805 software (device descriptors). contact your local hart service center for additional information. 2.7.1 connections a hart communicator can be operated from a remote location by connecting to a remote junction or by con- necting directly to the terminal block in the electronics housing of the model 805 transmitter. hart uses the bell 202 frequency shift key technique of high-frequency digital signals. it operates on the 4?0 ma loop and requires 250 w of minimum load resistance. a typical connection between a communicator and the model 805 transmitter is illustrated. 2.7.2 hart display menu a typical hart communicator display is an 8-line by 21-character lcd. when connected, the top line of each online menu displays the model (model 805) and its tag number or address. usually the bottom line of each menu is reserved for software-defined function keys (f1?4). for detailed operating information, refer to the instruction manual provided with the hart communicator. the model 805 transmitter online menu tree is shown in the following illustration. open the menu by pressing the alphanumeric key 1, device setup, to display the second- level menu. 2.7.3 hart device description (dd) device version 1 (dev v1), device description 2 (dd v2) was registered with hart communication foundation in may, 1999 and is available on the cd-rom 1999? issued in july, 1999. + + - - junction r l > 250 control room display power supply current meter
50-660 kotron model 805 smart rf level transmitter 15 1 calibration 2 basic setup 3 advanced setup/ configuration 4 diagnostics 5 review 1 units 2 empty calibration 3 full calibration 4 4 ma set point 5 20 ma set point 6 damping 7 fault state 8 date/time/initials 1 device setup 2 level 3 % level output 4 loop 1 tag 2 descriptor 3 date 4 message 5 final asmbly num 6 poll address 7 new password 1 loop test 2 error codes 3 probe reading 4 cap at empty cal 5 cap at full cal 1 3.6 ma 2 4 ma 3 20 ma 4 22 ma 5 other 1 model 2 manufacturer 3 dev id 4 tag 5 descriptor 6 date 7 message 8 units 9 cap at empty cal 10 cap at full cal 11 4 ma set point 12 20 ma set point 13 damping 14 fault state 15 date/time/initials 16 finalasmbly num 17 universal rev 18 fld dev rev 19 software rev 20 poll address 21 num req preams 22 firmware version 1 adjust 4 ma trim 2 adjust 20ma trim 3 4ma trim value 4 20ma trim value 5 enter password 6 set magnetrol s/n 7 set dev id number 2.7.4 hart menu
50-660 kotron model 805 smart rf level transmitter 16 3.0 reference information this section presents an overview of the operation of the kotron model 805 transmitter, information on trou- bleshooting common problems, listings of agency approvals, lists of replacement and recommended spare parts, and detailed physical, functional, and performance specifications. 3.1 description model 805 is a two wire, 24 vdc, level transmitter based on the concept of rf capacitance. the model 805 electronics are housed in an ergonomic housing comprised of two tandem compartments angled at 45 degrees for ease of wiring and calibration. these two compartments connect via an explosion-proof and water- tight feed-through. 3.2 theory of operation rf capacitance electronic level measurement utilizes the same fundamentals as any electronic capacitor (figure a). a capacitor is formed when an ac signal is applied across two conductive plates separated by an insulating medium, or dielectric. the value of a capacitor is determined by the: 1. area of the conductive plates (a); 2. distance between the plates (d), and; 3. dielectric of the insulating medium between the plates (e). refer to figure a. capacitance = ea/d (the ac frequency is fixed as part of the design.) current meter + te s t current meter power supply 24 vdc + conductive plate conductive plate insulating medium ac figure a
50-660 kotron model 805 smart rf level transmitter 17 capacitance is measured in farads. the value we utilize in industrial measurement is an extremely small unit called a pico farad (pf). a pico farad is one trillionth of a farad (10 -12 ). capacitance value increases as the dielectric increases, the plate size increases, or the distance between the plates decreases. in industrial applications (figure b), the probe is one plate of the capacitor, the tank wall is the other plate (ground reference). the insulating material that separates them is the dielectric. a tank that is empty is actually filled with air that has a dielectric of 1, the baseline of the dielectric scale. all materials have a dielectric higher than air, e.g. oil = 2.5, alcohol = 18, tap water = 80, etc. as a tank is filled with media, the air (dielectric = 1) is being displaced by the media having a higher dielectric; consequently, the amount of capacitance being generated between the probe and the tank wall increases. 3.3 troubleshooting the model 805 transmitter is designed and built for trouble-free operation over a wide range of operating con- ditions. common transmitter problems are discussed in terms of their symptoms and recommended corrective actions. in addition, information on how to handle mater- ial build-up on the probe is provided in this section. warning! explosion hazard. do not connect or disconnect equipment unless power has been switched off or the area is known to be safe. bare metal probe metal tank wall (ground reference) air non-conductive (insulating) medium figure b
50-660 kotron model 805 smart rf level transmitter 18 output signal always hart poll address change hart poll address to 0. at 4 ma. is not 0. see secion 2.6.4, step 14. level, % output and loop values basic configuration data is check values and recalibrate if are all inaccurate. questionable. necessary (either or both points). level readings are repeatable but configuration data does not recalibrate if necessary. consistently high or low from actual accurately match tank height. by a fixed amount. level, % output and loop turbulence. increase the damping factor until the values fluctuate. readings stabilize. loop value jittery, usually in tenths factory settings corrupted. check # of ticks. if the number is or hundredths digit. also jittery, consult the factory. hart device only: handheld will only most current device descriptors contact local hart service center for the read universal commands. (dds) are not installed in handheld latest dds. hart device only; reads product early hart software does not contact manufacturer of your hart information (e.g., mfgs. id, device #, account for mfgs. id #s greater master software for upgrade. this is a serial #, etc.) but will not read any than 63. magnetrols id is 86. shortcoming of early hart master process variables. software. symptom problem solution 3.3.1 troubleshooting system problems 805 fault open probe. check probe wiring and electronics (open) module connector. 805 fault shorted probe. check probe wiring and integrity of (shorted) insulated probe in conductive liquid. osc fail malfunctioning analog board and/or check connection between boards and (hart error code = 0x40) 32 pin connector. replace electronic module if necessary. abv rng above range. measured capacitance > 12,000 pf. contact factory. corrupt paramtrs configuration parameters may check all configuration parameters and. (hart error code = 0x10) have been lost. recalibrate if necessary. sfwr error software error. bad internal state, unexpected condition. contact factory. level unit is not calibrated. make sure that both lo cal and hi cal (uncal) points have been entered. 3.3.2 error messages symptom problem solution
3.3.3 troubleshooting flowchart (lcd version) unit equipped with display? check voltage at terminal board no voltage? check power supply and wiring negative voltage? reverse wiring call factory check loop current at terminal board loop current above 23 ma? remove electronic module loop current above 1 ma? replace terminal board replace electronic module yes yes yes yes yes yes yes no no no no no no display has text? no reseat boards. check power supply and wiring loop resistance wrong? correct loop resistance start good display no active hart yes failure to operate with correct loop inputs no faint display? yes yes no some problems could be temporarily solved by power cycling the unit. please call factory if this problem persists. display working? no yes no retest yes hart communications ok? voltage above 36 volts? voltage < 11v is or 16v xp? 2 1 3 50-660 kotron model 805 smart rf level transmitter 19
50-660 kotron model 805 smart rf level transmitter 20 check loop current at terminal board loop current above 23 ma? remove electronic module loop current above 1 ma? replace terminal board replace electronic module yes yes no no failure to operate with correct loop inputs display working? yes no retest unit good display key board responds? replace electronic module no check loop current at wiring board loop current 22 - 4.0 ma? adjust 4 and 20 ma unit has hart? hart working? yes yes no yes no address correct? correct address replace electronic module no yes unit with display communicates no yes reseat boards display working? retest no yes 1 2 4
unit with display communicates error displayed? "open probe?" "shorted probe?" "osc fail?" yes check probe and connectors check analog parameters check calibration parameters call factory no yes yes yes yes corrupt display text? replace electronic module no yes replace electronic module same error message? retest no yes "uncal?" active hart analog loop correct? trim 4?0ma check offset and 4?0 ma set points no yes no call factory display reading correctly? 4 yes 3 no "corrupt parameters?" yes no no no "above range?" no no "software error?" no yes yes 50-660 kotron model 805 smart rf level transmitter 21
50-660 kotron model 805 smart rf level transmitter 22 fm 805-5xxx-11x intrinsically safe class i , div. 1; groups a, b, c, & d class ii , div. 1; groups e, f, & g class iii t4 ta = +71 c entity nema 4x ip66 805-5xxx-11x non-incendive class i , div. 2; groups a, b, c, & d class ii , div. 2; groups f & g class iii t4 ta = +71 c nema 4x ip66 csa 805-5xxx-110 intrinsically safe class i , div. 1; groups a, b, c, & d class ii , div. 1; group e, f, & g (insulated probes) (group g only with bare probe) class iii t4 ta = +71 c entity type 4x 805-5xxx-110 suitable for: class i , div. 2; groups a, b, c, & d class ii , div. 2; groups e, f, & g (insulated probes) (group g only with bare probe) class iii t4 ta = +71 c type 4x atex 805-5xxx-a1x intrinsically safe ii 1g eex ia ii c t6* (-40 to +40 c ambient temp.) ii 1g eex ia ii c t4* (-40 to +80 c ambient temp.) agency model approved approval category approval classes 3.4 agency approvals these units have been tested to en 50081-2 and en 50082-2 and are in compliance with the emc directive 89/336/eec. *special conditions for safe use: because the enclosure of the transmitter is made of aluminum alloy, the transmitter must be installed so, that even in the event of rare incidents, an ignition source due to impact or friction between the enclosure an iron/steel is excluded. probes with an insulating layer, used in potentially explosive atmosphere with gas, vapor or mist of gas group iic, may only be used for the measurment of the level of a conductive fluid.
3.4.1 agency specifications ?intrinsically safe installation 50-660 kotron model 805 smart rf level transmitter 23
50-660 kotron model 805 smart rf level transmitter 24 item description part number 1 electronic module includes: display (english) and hart z31-2809-001 display only z31-2809-003 2 terminal board includes: z30-9106-003 3 o-ring (neoprene) 012-2201-237 4 housing cover without glass 004-9193-003 5 housing cover with glass 036-4410-001 3.5.1 replacement parts 3.5 parts
1200 1000 800 600 400 200 0 20 ma 24 vdc 620 11 50-660 kotron model 805 smart rf level transmitter 25 3.6 specifications 3.6.1 functional system design measurement principle rf capacitance input measured variable level, determined by change in capacitance values zero and range 0" to 1800" (0 cm to 4572 cm) span 5 pf min., 10,000 pf max. output type analog 4 to 20 ma with optional hart digital signal range analog 3.8 to 20.5 ma useable digital 0 to 1800" (0 to 4472 cm) resolution analog 0.01 ma digital 0.1" loop resistance (maximum) gp/is-620 @ 24 vdc alarm adjustable 3.6 ma, (no display or no hart) 22 ma, hold damping adjustable 1?5 seconds lcd user interface keypad 3-button menu-driven data entry and system security indication 2-line x 8-character display digital communication hart version 5.x compatible power (measured at instrument terminals) general purpose 11 to 36 vdc intrinsically safe 11 to 28.6 vdc housing material aluminum a356t6 (< 0.2% copper) cable entry 3 4 " npt, m20, pg13.5, pg16
50-660 kotron model 805 smart rf level transmitter 26 3.6 specifications 3.6.1 functional (continued) process conditions maximum process temperature +1000 f @ 500 psig (+538 c @ 35 bar) maximum process pressure 5000 psig from -500 to +100 f (345 bar from -296 to +38 c) minimum process pressure -85 f (-65 c) environment operating temperature -40 to +175 f (-40 to +80 c) display function operating temperature -5 to +160 f (-20 to +70 c) storage temperature -40 to +175 f (-40 to +80 c) humidity 0?9%, non-condensing electromagnetic compatibility meets ce requirements (en 50081-2, en 50082-2) installation orientation vertical, top-mounted depends on probe selection. see bulletin 50-125 for specifications of available probes. 3.6.2 performance reference conditions +20 c (+68 f) accuracy ?.5% of span or 0.1" (whichever is greater) resolution 0.1 pf repeatability ?.1% of span linearity ?.25% of span hysteresis ?.1% of span response time < 1 s (adjustable via damping) warm up time < 5 s temperature effect approximately +0.03%/ c
7.88 (200) 4.12 (105) 3.28 (83) 2.50 (64) 2.30 (58) 4.87 (124) 2.75 (75) 5.55 (141) 3.85 (98) elect. conn. qty. 2 45 optional mounting flange 7.88 (200) 4.12 (105) 3.28 (83) 2.50 (64) 3.85 (98) elect. conn. qty. 2 probe insertion length optional mounting flange process conn. 45 2.30 (59) 4.38 (111) 8.43 (214) 4.94 (126) 45 view 50-660 kotron model 805 smart rf level transmitter 27 3.6 specifications 3.6.3 physical
50-660 kotron model 805 smart rf level transmitter 28 3.7 model numbers 3.7.1 transmitter 0 3 4 " npt 1m20 2 pg 13.5 3pg 16 1 integral, general purpose, non-incendive & intrinsically safe (fm & csa) a integral, intrinsically safe (cenelec) a digital display and keypad 1 english (use with accessory code a) 2 spanish (use with accessory code a) 3 french (use with accessory code a) 4 german (use with accessory code a) menu language: 0 4?0 ma only, without hart (must be ordered with accessory code a 1 4?0 ma with hart (hart communicator magnetrol p/n 089-5213-xxx sold separately) signal output: 805 5 805 kotron smart rf level transmitter 5 24 vdc, two wire, loop powered basic model number: power: accessories: mounting/classification: conduit connection: 1 aluminum, dual compartment, 45 2 316 stainless steel, dual compartment, 45 housing complete details on the available probes can be found in bulletin 50-125, kotron rf sensing probes
accuracy the maximum positive and negative % devia- tion over the total span. ansi american national standards institute. ce conformit? europ?ene standards and performance criteria for the new european union. csa canadian standards association canadian, third party agency that qualifies the safety of electrical equipment. damping the mathematical averaging of a meter and/or output signal to stabilize the effects of a noisy process due to surface turbulence. default values the main position of the menu structure that displays the primary measurement values of level, % output, and loop. the transmitter returns to this position after 5 minutes of inactivity. dielectric constant ( ) the electrical permitivity of a material. the units are farad/meter. dvm/dmm digital volt meter/digital multimeter. emi electromagnetic interference electrical noise caused by electromagnetic fields that may affect electrical circuits, particularly low-power electronic devices. en european normal committee guidelines in ec countries that take precedence over local, country guide- lines. ergonomic a mechanism that considers human capabil- ity in its design or function. fault a defect or failure in a circuit. the current (ma) value unit defaults to 3.6, 22, or hold when a diagnostic condition occurs. feedthrough a small, connecting cavity between the main housing compartments, carrying the cable that sup- plies the operating energy to the measurement circuitry and returns the output value proportional to level. this cavity is potted to maintain the environmental isolation between the two compartments. fm factory mutual american, third party agency that qualifies the safety of electrical equipment. four wire an electronic instrument design that uses one set of wires to supply power (120/240 vac, 24 vdc) and another set to carry the process measurement signal (4?0 ma). also called line powered. fsk frequency shift keying. ground an electrical connection to the earths potential that is used as a reference for the system and electrical safety. grounded a state where no electrical potential exists between the ground (green) connection on the transmitter and the earth or system ground. hart highway addressable remote transducer. protocol that uses the bell 202 frequency shift keying (fsk) method to superimpose low level frequencies (1200/2000 hz) on top of the standard 4?0 ma loop to provide digital communication. hart id see poll address. hazardous area an area where flammable gases or vapors are or may be present in the air in quantities suffi- cient to produce explosive or ignitable mixtures. iec international electrotechnical commission organization that sets international standards for electrical devices. increased safety designs and procedures that minimize sparks, arcs, and excessive temperatures in hazardous areas. defined by the iec as zone 1 environments (ex e). interface: electrical a boundary between two related, electronic circuits. interface: process a boundary between two or more immiscible liquids. intrinsic safety a design or installation approach that limits the amount of energy that enters a hazardous area to eliminate the potential of creating an ignition source. level the present reading of the height of material in a vessel. linearity the worst case error calculated as a deviation from a perfect straight line drawn between two calibration points. line powered see four wire. loop the present reading of the 4?0 ma current output. loop powered see two wire. low voltage directive a european community require- ment for electrical safety and related issues of devices using 50?000 vdc or 75?500 vac. measured value the typical level measurement values used to track the level of a process: level, % output, and loop. glossary 29 kotron model 805 smart rf level transmitter
50-660 kotron model 805 smart rf level transmitter 30 glossary (continued) media the liquid material being measured by the level transmitter. multidrop the ability to install, wire, or communicate with multiple devices over one cable. each device is given a unique address and id. nonhazardous area an area where no volatile mixtures of vapors/gas and oxygen will be found at any time. also called general purpose area. non-incendive equipment and wiring which in its nor- mal operating condition is incapable of igniting a specific hazardous atmosphere or hazardous dust layer. offset the distance from the bottom of the tank to the bottom of the probe. password a numerical value between 0 and 65,000 that protects stored configuration data from unauthorized manipulation. percent (%) output the present reading as a fraction of the 16 ma scale (4?0ma). poll address (hart id) a number between 1 and 15 which sets an address or location of a device in a multi- drop loop. probe a waveguide that propagates an electromagnetic pulse from the top of the tank into the process fluid. probe length exact measurement from the bottom of the process thread connection to the very bottom of the probe. probe type particular rf configuration or design. each probe type is designed to accomplish specific objectives in an application. quickstart the essential information needed for the model 805 transmitter and probe to be installed, wired, and calibrated. range a value related to probe length (factory setting). relative dielectric ( r ) a unitless number that indicates the permitivity of a material. repeatability the maximum error between two or more output readings of the same point. rfi radio frequency interference electrical noise that can have an adverse affect on electrical circuits, particularly low-power devices. span the difference between the upper and lower limits of the range. specific gravity (sg) the ratio of the density of a material to the density of water at the same conditions. tst loop test loop built-in system capability to test/calibrate a loop (or separate loop device) by driving the transmitter output to a particular value. trim 4/trim 20 built-in system capability to fine tune the 4 ma and 20 ma points so the transmitter output corresponds exactly to users meter, dcs input, etc. tw o w i r e an electrical instrument design that uses one set of wires to provide both the supply power and process measurement signal. the process measurement is achieved by varying the current of the loop. also called loop powered. units the engineering units used to measure level in the system. the choices are in (inches) and cm (centimeters).
index agency approvals: 22 atex: 22 complete installation: 5 configuration: information: 1 menu: 15 password: 12 operating parameters: 12, 13 quickstart: 3 set 4 ma: 1, 4, 11 set 20 ma: 1, 4, 11 shop set-up: 10 transmitter: 11 units: 1, 4 using hart: 14 csa (canadian standards association): 22 default password: 4, 12 display menu: see menu, 13 electrostatic discharge (esd): 5 equipment and tools: 1, 6 fault: see troubleshooting, 17 fm (factory mutual): 22 general purpose installation: 10 hart communicator: 14?5 configuring the transmitter: 14 connections: 14 display: 14 menu: 15 troubleshooting: 18 installation before you begin: 1, 6 configuration: 11 configuration using hart: 14 complete installation: 5 electrostatic discharge: 5 mounting: 7? probe: 8? transmitter: 11 unpacking: 5 wiring: 10?1 intrinsically safe installation: 10?1 keypad: 3,11 lcd (liquid-crystal display): 3, 13 menu: 13 damping: 13 fault: 13 level, % output, loop: 3, 11, 13, 15, 18 loop tst: 13 new pass: 12 poll adr: 15 set 20 ma: 4, 11, 13 set 4 ma: 4, 11, 13 trim 20: 13 trim 4: 15 units: 4, 11, 13 model number: probe: 28 mounting, flexible probe: 8 mounting, rigid probe: 8 transmitter: 2, 9 non-incendive installation: see wiring operating parameters: 11 operation, theory of: 16 operational considerations: 6 operating limits: 6 parts replacement: 24 spare: 24 password: 4, 12 probe: inspecting: 5 installing: 8? model number: 28 process connection: 2, 8 specifications: 25?7 unpacking: 5 quickstart installation: 1? configuration: 1,3 mounting, probe: 2 mounting, transmitter: 2 wiring: 3 reference information: 16 site preparation: 6 specifications: 25?7 functional: 25?6 performance: 26 physical: 27 temperature-pressure rating: 26 transmitter configuring: 3?, 11 installing: 9 keypad: 3,11 model number: 28 operating parameters: 11 troubleshooting: 17?1 unpacking: 5 troubleshooting: 17?1 error messages: 18 flowcharts: 19?1 system problems: 19 unpacking: 5 wiring: 10 general purpose, non-incendive: 10 installation: 10?1 intrinsically safe: 10?1 warning: 3, 10 50-660 kotron model 805 smart rf level transmitter 31
50-660 kotron model 805 smart rf level transmitter 32 kotron model 805 smart rf transmitter configuration and calibration data sheet copy blank page and store calibration data for future reference. item value value value vessel name vessel # media tag # probe p/n electronics p/n electronics s/n units lo cal lo cap hi cal hi cap 4ma point 20ma point damping fault choice hart poll address trim 4 trim 20 loop test probe reading osc test open probe # ticks reinit version firmware new password name date time
bulletin: 50-660.2 effective: may 2006 supersedes: march 2004 5300 belmont road ?downers grove, illinois 60515-4499 ?630-969-4000 ?fax 630-969-9489 ?www.magnetrol.com 145 jardin drive, units 1 & 2 ?concord, ontario canada l4k 1x7 ?905-738-9600 ?fax 905-738-1306 heikensstraat 6 ?b 9240 zele, belgium ?052 45.11.11 ?fax 052 45.09.93 regent business ctr., jubilee rd. ?burgess hill, sussex rh15 9tl u.k. ?01444-871313 ?fax 01444-871317 5300 belmont road ?downers grove, illinois 60515-4499 ?630-969-4028 ?fax 630-969-9489 ?www.sticontrols.com copyright ?2006 magnetrol international, incorporated. all rights reserved. printed in the usa. magnetrol and magnetrol logotype are registered trademarks of magnetrol international. sti and sti logotype are registered trademarks of magnetrol international. performance specifications are effective with date of issue and are subject to change without notice. service policy owners of magnetrol controls may request the return of a control or any part of a control for complete rebuilding or replacement. they will be rebuilt or replaced promptly. controls returned under our service policy must be returned by prepaid transportation. magnetrol will repair or replace the control at no cost to the purchaser (or owner) other than transportation if: 1. returned within the warranty period; and 2. the factory inspection finds the cause of the claim to be covered under the warranty. if the trouble is the result of conditions beyond our con- trol; or, is not covered by the warranty, there will be charges for labor and the parts required to rebuild or replace the equipment. in some cases it may be expedient to ship replacement parts; or, in extreme cases a complete new control, to replace the original equipment before it is returned. if this is desired, notify the factory of both the model and serial numbers of the control to be replaced. in such cases, credit for the materials returned will be determined on the basis of the applicability of our warranty. no claims for misapplication, labor, direct or consequen- tial damage will be allowed. return material procedure so that we may efficiently process any materials that are returned, it is essential that a ?eturn material authorization (rma) number be obtained from the fac- tory, prior to the material's return. this is available through magnetrols local representative or by contacting the factory. please supply the following information: 1. company name 2. description of material 3. serial number 4. reason for return 5. application 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 accompany material that was used in any media. all shipments returned to the factory must be by prepaid transportation. all replacements will be shipped f.o.b. factory. note: see electrostatic discharge handling procedure on page 5. assured quality & service cost less

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