Kotron
II
Series 801
RF Capacitance
Transmitter For
Level/Flow/Volume
Instruction Manual and Parts List
TABLE OF CONTENTS
General Information ............................................................1
Installation .......................................................................2–4
Wiring ..............................................................................5–6
Unit Configuration .........................................................7–23
Troubleshooting ..........................................................24–25
Electrical Specifications ....................................................25
Agency Approvals .............................................................26
Intrinsically Safe Installations ............................................26
Dimensional Specifications ...............................................27
Replacement Parts............................................................27
MODEL IDENTIFICATION
Each Series 801 capacitance transmitter has a nameplate on
which the model number of the unit is shown. The model
number is coded to identify the options of that specific unit.
TM
801 –
KOTRON II
SERIES 801 TRANSMITTER
NUMBER OF PROBES/OUTPUT
2
= 1 probe, One 4–20mA (isolated),
RS-232
4
= 2 probes, One 4–20mA (isolated),
RS-232
INPUT POWER
0
= 120 VAC
1
= 240 VAC
2
= 24 VDC
3
= 120 VAC with heater and thermostat
4
= 240 VAC with heater and thermostat
3
–
4
DIGITAL, 16 CHARACTER, LCD DISPLAY
REMOTE MOUNTING CONFIGURATION
1
= NEMA 4X
4
= NEMA 4X with I.S. probe circuit
HOUSING
A
=NEMA 4X Noryl (electronics)
w/stainless steel remote probe housing
N
=NEMA 4X Noryl (electronics)
w/aluminum sand cast remote probe housing
(4) 10 AMP SPDT RELAYS
OPTIONS
0
= None
1
= Mechanical Totalizer
2
= 31 Day Data Logger (Smart Watch)
3
= Mechanical Totalizer and 31 Day Data Logger
PRINCIPLE OF OPERATION
The amount of capacitance developed in any application is
determined by the size (surface area) of the probe, the dis-
tance from the probe to its ground reference, and the dielec-
tric constant of the medium being measured.
Considering that the probe's mounting position is fixed, and
the dielectric value of the medium is constant, the amount of
capacitance developed in any vessel becomes dependent
upon the probe's diameter and length.
As a medium rises and falls in the tank, the amount of capac-
itance developed between the sensing probe and the ground
reference also rises and falls. The Pulsatel circuit, mounted
on the probe, changes the capacitance signal to a digital sig-
nal which can then be sent to the main electronics located up
to 2500 feet (760 M) away.
DESCRIPTION
The Kotron
II
Series 801 Transmitter is a new generation RF
Capacitance transmitter that offers the user unparalleled
power. The Series 801 can interface with two separate
vessels, essentially making it a mini-multiplexer, while soft-
ware mathematics allows for the
Sum
or
Difference
of the
two signals.
INSTALLATION
CAUTION: Please read the entire installation section carefully prior to starting installation.
UNPACKING
Unpack the instrument carefully, making sure all components
are removed from the packing material. Inspect the compo-
nents for damage, and report any concealed damage to the
carrier within 24 hours. Check the contents of the
carton/crate against the packing slip and report any discrep-
ancies to the factory. Check the nameplate model number,
making sure it agrees with the packing slip and purchase
order. Check and record the serial number for future refer-
ence when ordering parts.
INSTALLATION LOCATION
Kotron
II
Series 801 transmitters should be located with easy
access for service, calibration and monitoring. The electron-
ics should not be exposed to ambient temperatures as
follows: below -20° F (-29° C) without heater option; -40° F
(-40° C) with heater option; or above +160° F (+71° C).
Special precaution should be made to prevent exposure
to corrosive atmosphere, excessive vibration, shock, or
physical damage.
CAUTION:
This unit contains CMOS electronics which
may be damaged by static electricity. Do not touch
any semi-conductor device unless you are properly
grounded.
INSTALLATION LOCATION cont.
Tanks/Silos with Non-Conductive Materials
of Construction
With plastic, concrete, wood, or any other non-conductive
walled vessel, 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.
NOTE:
These comments also apply to glass-lined metal
walled tanks.
Vertical Mounting
Vertically mounted probes should be installed so that the end
of the probe rod is at least 2.00 inches (51 mm) below the
lowest desired level control point with conductive materials,
or 4.00 inches (102 mm) below the lowest desired level
control point with non-conductive materials. Refer to
Figure 1.
It is common practice to use the metal tank wall as the
ground reference. 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 the use of PTFE
thread tape, gaskets, paint, or rust impede this connection, a
separate metal strap should be installed between the probe
housing and the tank.
In non-conductive media, sensing probes should be located
close to the tank wall for greatest sensitivity. Probes should
be isolated from severe motion in the tank, because surface
turbulence may cause signal deviation.
CAUTION:
When an insulated probe is used in a haz-
ardous and/or abrasive medium, the probe should be
inspected annually for nicks, cuts or abrasions which
may degrade the integrity of the insulation. In the
event that wear is found, replace the probe or consult
the factory for further instructions. This procedure is
critical in vessels containing hazardous media unless
an I.S. probe circuit is used.
Minimum insertion depth:
Conductive material
2.00" (51 mm)
Nonconductive material
4.00" (102 mm)
Insertion
length
(IL)
Figure 1
Transmitter Mounting Location
The transmitter enclosure should be securely fastened to an
appropriate supporting structure in a location that permits
easy access for maintenance. Avoid locations that are
exposed to direct sunlight, flooding, high levels of radiated
electromagnetic interference, and excessive vibration or
shock.
Metal Walled Tanks
On water based liquids, a problem should not be encoun-
tered 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
practical, a concentric ground tube surrounding the probe,
(stilling well), may be a solution.
2
INSTALLATION cont.
MOUNTING PROCEDURE
Transmitter Mounting Procedure
There are two predrilled holes in the enclosure for connect-
ing 3/4" NEMA 4X conduit; one for power and one for the
remote probe wiring. Two additional holes may be drilled in
the base as shown in Figure 2.
MOUNTING PROCEDURE cont.
Standard Rigid Probe
1. Thread probe into mounting bushing on tank.
2. Tighten securely being certain that the wrench is ap-
plied
ONLY
to the lower probe nut. Refer to Figure 4
3. Screw the preamplifier housing onto the probe. Refer to
Figure 4.
4. Screw housing on probe until hand tight. Housing can be
wrench tightened to align conduit connection with
conduit.
5. Locate the white wire assembly on the printed circuit
board. Connect the free end of this wire to the probe
connection screw. Refer to Figure 4.
1.88 1.62
(47) (41)
1.50
(38)
.875
(22) dia.
Bottom view
with existing holes
Side view with
customer drilled holes
CAUTION:
Check probe terminal connection carefully
to be certain lug will not short to packing gland or
interfere with assembly of remote housing to probe.
6. Proceed to Wiring Procedure on Page 5.
Figure 2
Transmitter Mounting Holes
1. Open the door of the unit.
2. Drill holes in the enclosure as required for additional
wiring. Be careful not to damage the printed circuit
boards. Be sure that the PC boards are not damaged or
contaminated when removing filings and/or debris from
the housing.
3. Provide watertight seals for all wiring entrances into
the enclosure.
4. Mount the enclosure to a wall or flat surface using the
appropriate screws or bolts. The mounting tabs on the
back of the enclosure can be rotated to the sides, or top
and bottom to facilitate mounting. Refer to Figure 3.
Side View
Preamplifier
Apply Wrench
Here
White
Probe Wire
+ (Red)
(Black)
Shield–To Be
Connected to Internal
Green Ground Screw
Top View
Preamplifier
Figure 3
Transmitter Mounting Tabs
5. Install conduit for power and control wiring. Be sure all
connections to the enclosure maintain a NEMA 4X rating
6. Close the transmitter door until it is time to wire the
transmitter. Proceed to the Probe Mounting Procedure.
Figure 4
Standard Rigid Probe Mounting
3
INSTALLATION cont.
MOUNTING PROCEDURE cont.
Flexible Probe
CAUTION:
Flexible probes are shipped with the cable
clamp and the probe nut hand tightened. The end of
a flexible probe
MUST
be secured to the bottom of the
tank by either attachment to a bracket or to a heavy
weight in order to keep the probe taut. Follow the
mounting instructions listed below.
1. Remove mylar housing insulator located over the clamp.
2. Attach weight (if used) to probe end.
CAUTION:
insulator.
Do not discard the mylar housing
MOUNTING PROCEDURE cont.
Flexible Probe cont.
CAUTION:
Check probe terminal connection careful-
ly to be certain lug will not short to packing gland or
interfere with assembly of remote housing to probe.
17. Screw housing onto probe and tighten. Make sure con-
duit connection is properly aligned for wire entry. Refer to
Figure 5.
18. Locate the white wire on the upper printed circuit board.
Connect the free end of this wire to the probe connection
screw. Refer to Figure 5.
19. Proceed to Wiring Procedure on Page 5.
3. Insert probe end through tank mounting bushing and
feed cable into the tank. Do not allow probe insulation to
be damaged by scraping against the bushing threads.
4. Secure lower end of probe (or optional weight) to tank
bracket if one is used.
CAUTION:
Probe cable must not be in contact with
anything metallic in its final installation position.
5. Apply thread sealant to mounting nut.
6. Screw mounting nut into tank bushing until tight.
NOTE:
Do not allow the probe to fall in the tank while
following steps 7 through 18.
CAUTION:
Apply wrench to lower probe nut only.
Side View
Preamplifier
Apply Wrench
Here
7. Loosen both socket clamp screws.
8. Pull clamp and teflon retaining bushing off probe.
9. While holding probe cable, loosen upper probe nut.
10. Pull excess cable up through probe nuts until cable is taut.
11. Tighten the probe nuts.
12. Cut off cable 1.35 inches (34 mm) above top of upper
probe nut and strip off 1.25 inches (32 mm) of insulation.
13. Slide teflon retaining bushing onto cable and seat it into
the upper probe nut.
14. Slide clamp onto cable and seat it in the teflon retaining
bushing.
15. Tighten both socket head clamp screws to approximately
35 in./lbs. torque.
16. Slip mylar housing insulator over clamp.
NOTE:
Do not allow the probe to fall in the tank while
following steps 7 through 18.
White
Probe Wire
+ (Red)
(Black)
Shield–To Be
Connected to Internal
Green Ground Screw
Top View
Preamplifier
Figure 5
Flexible Probe Mounting
4
ELECTROSTATIC DISCHARGE (ESD) HANDLING PROCEDURE
Magnetrol’s electronic instruments are manufactured to the
highest quality standards. These instruments utilize electron-
ic components which may be damaged by static electricity
present in most work environments. The following steps are
recommended to reduce the risk of component failure due to
electrostatic discharge:
1. Ship and store circuit boards in anti-static bags. If an anti-
static bag is not available, wrap board in aluminum foil. Do
not place boards on foam packing materials.
2. Use a grounding wrist strap when installing and remov-
ing circuit boards. A grounded workstation is also
recommended.
3. Handle printed circuit boards only by the edges. Do not
touch components or connector pins.
4. Ensure that all electrical connections are completely made
and none are partial or floating. Ground all equipment to a
good, earth ground.
WIRING
(+)
PROBE #1 (TB 1)
(_)
(+)
(_) PROBE #2 (TB 2)
TO
HO
P
NEW
OR
GF
ITIN
WA
NO
COM (Relay #4)
NC
NO
Optional
Totalizer (TOT) (+)
(_)
Optional
Heater (HEAT)
L1 L2/N GND
(+) (–)
Power
(+) (–)
Loop
NC COM NO
(Relay #1)
NC COM NO
(Relay #2)
RS-232
COM (Relay #3)
NC
Figure 6
Mother/Daughter Board Assembly
5
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