Kotron
®
Model 80/81
Installation and Operating Manual
RF Point
Level
Switches
Read this Manual Before Installing
This manual provides information on Kotron Model
80/81 RF Point Level Switches. It is important that all
instructions are read carefully and followed in sequence.
Detailed instructions are included in the 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 component’s mechanical integrity. Cautions are also
used to alert the technician to unsafe practices or the
need for special protective equipment or specific
materials. In this manual, a caution box indicates a
potentially 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
Follow all standard industry procedures for servicing elec-
trical equipment when working with or around high
voltage. Always shut off the power supply before touch-
ing any 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
disconnect equipment unless power has been switched off
or the area is known to be non-hazardous.
Notice of Trademark, Copyright, and Limitations
Magnetrol & Magnetrol logotype, STI and STI logotype,
and Kotron are registered trademarks of Magnetrol
International, Incorporated.
Copyright © 2007 Magnetrol International.
All rights reserved.
Performance specifications are effective with date of issue
and are subject to change without notice. Magnetrol/STI
reserves the right to make changes to the
product described in this manual at any time without
notice. Magnetrol/STI 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.
Magnetrol’s quality assurance system
is registered to ISO 9001 affirming
its commitment to known inter-
national quality standards providing
the strongest assurance of product/
service quality available.
Kotron Model 80/81
RF Point Level Switches
Table of Contents
1.0 Introduction
1.1 Principle of Operation...........................................1
1.2 Description............................................................1
2.0 Installation
...................................................................2
2.1 Unpacking.............................................................2
2.2 Installation Location..............................................2
2.2.1 Metal Walled Tanks ....................................2
2.2.2 Tanks/Silos w/Non-Conductive Materials
of Construction ..........................................3
2.3 Horizontal Mounting ............................................3
2.3.1 Narrow Differential Single Point
Units Only..................................................3
2.4 Vertical Mounting .................................................4
2.5 Mounting Procedure..............................................4
2.5.1 Integral Mount with Rigid Probe................4
2.5.2 Integral Mount with Flexible Probe ............5
2.5.3 Remote Mount with Rigid Probe ...............6
2.5.3.1 Main Amplifier .....................................6
2.5.3.2 Preamplifier ..........................................6
2.5.4 Remote Mount with Flexible Probe ............6
2.5.4.1 Main Amplifier .....................................6
2.5.4.2 Preamplifier ..........................................7
2.6 Electrostatic Discharge (ESD)
Handling Procedure ..............................................8
2.7 Wiring...................................................................8
2.7.1 Integral Mount Models...............................8
2.7.1.1 Relay Wiring.........................................8
2.7.1.2 Power Wiring........................................8
2.7.2 Remote Mount Models...............................9
2.7.2.1 Probe Preamplifier Wiring ....................9
2.7.2.2 Relay Wiring.......................................10
2.7.2.3 Power Wiring......................................10
2.7.3 Relay Wiring Chart ..................................10
2.7.4 Wiring Notes and Definitions ..................11
2.8 Calibration ..........................................................11
2.8.1 Level Range Selection ...............................11
2.8.2 Fail-safe Mode Selection ...........................12
2.8.2.1 High Level Mode................................12
2.8.2.2 Low Level Mode .................................12
2.8.3 Calibration Adjustments ...........................12
2.8.4 Zero Adjustment.......................................12
2.8.5 Zero and Span Adjustment .......................13
2.8.5.1 Wide Differential Vertical Probe
Mount only.........................................13
2.8.6 Time Delay Adjustment............................14
2.8.6.1 Narrow Differential only.....................14
3.0 Reference Information
3.1 Troubleshooting...................................................15
3.1.1 Probe ........................................................15
3.1.2 Electronics ................................................15
3.1.2.1 Narrow differential point units ...........16
3.1.2.2 Wide differential point units...............16
3.2 Agency Approvals ................................................18
3.3 Specifications.......................................................18
3.3.1 Electrical...................................................18
3.3.2 Dimensional – Integral Mounts................19
3.3.3 Dimensional – Remote Mounts................20
3.4 Terminal Connections .........................................21
3.5 Replacement Parts ...............................................22
3.6 Model Numbers ..................................................23
NOTES
.............................................................................24
1.0
1.1
Introduction
Principle of Operation
The amount of capacitance developed in any vessel is
determined by the size (surface area) of the probe, the dis-
tance from the probe to its ground, and the dielectric of
the medium being measured. Considering that the probe’s
mounting position is fixed, and that the dielectric value of
the medium is constant, then the amount of capacitance
developed in any vessel becomes dependent upon the
probe’s total surface area.
A probe’s diameter, together with its length, determine its
surface area. Adjusting the combination of probe diameter,
length, and proximity to ground, the necessary capacitance
required by the electronic circuitry can generate.
As media rises and falls in the tank, the amount of capaci-
tance developed between the sensing probe and the ground
also rises and falls. This change in capacitance is sensed by
the electronics.
The capacitance-controlled oscillator circuit, mounted
on the probe, changes the capacitance signal to a variable
frequency. This stabilized signal can then be sent to the
main electronics located up to 5000 feet (1500 meters)
away via standard shielded, twisted pair cable. This
eliminates the 150 feet (45 meters) maximum distance
limitation, using costly coaxial or triaxial cable utilized
by other manufacturers.
1.2
Description
Kotron RF Point Level Switchescan be utilized in level
control applications with either liquid or dry bulk materials.
They can also be used to sense and control viscous, sticky,
highly conductive materials. The electronic amplifier may
be either mounted directly on the sensing probe or located
remote from the probe. In remote applications, the sensing
probe is furnished with a housing.
1
50-605 Kotron RF Point Model 80/81 Level Switches
2.0
Installation
Caution:
Please read the entire installation section carefully prior to
starting installation.
2.1
Unpacking
Unpack the instrument carefully. Make sure all compo-
nents have been removed from the packing material.
Inspect all components for damage. Report any concealed
damage to the carrier within 24 hours. Check the contents
against the packing slip and report any discrepancies to the
factory. Check the nameplate model number to be sure it
agrees with the packing slip and purchase order. Check
and record the serial number for future reference when
ordering parts.
2.2
Installation Location
Kotron RF Point Level Switches should be located for easy
access for service, calibration and monitoring. Switches
should not be exposed to ambient temperatures below
-40° F (-40° C) or above +160° F (+71° C). Special pre-
caution should be made to prevent exposure to corrosive
atmosphere, excessive vibration, shock or physical damage.
It is common practice to use the metal tank wall as the
reference 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 due
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
damaged by static electricity. Do not touch any semi-
conductor devices unless you are properly grounded.
2.2.1 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 a solution.
50-605 Kotron RF Point Model 80/81 Level Switches
2
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