Model A38: Capacitance Level Transmitter
Model A38: Capacitance Level Transmitter
Model A38
CAPACITANCE LEVEL TRANSMITTER
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A38 Capacitance Transmitter
TABLE OF CONTENTS
2.0 INSTALLATION 4
2.1 General 4
2.2 Recommendations 5
2.2.1 Integral Units 5
2.2.2 Remote Units 5
2.2.3 Interface Applications 6
2.3 Coaxial Cable Details 7
2.4 Typical Wiring Diagram 7
2.5 Location of Adjustments & Controls 8
4.0 CALIBRATION 12
4.1 Capacitance Range Selection 12
4.2 Remote Option Cable Length 13
4.3 Standard Calibration 14
4.4 Alternate Tank Fill Calibration 14
4.5 Alarm Mode Setup 15
4.6 4 mA / 20 mA DAC TRIM 16
5.0 TROUBLESHOOTING 17
6.0 APPENDICIES 18
6.1 Appendix A: Capacitance Change pF / inch Bare Probes 18
6.2 Appendix B: Capacitance Change pF / inch Insulated Probes 19
6.3 Appendix C: A38 Series Electrical Interconnection Diagram, Part 1 20
6.4 Appendix C: A38 Series Electrical Interconnection Diagram, Part 2 21
6.5 Appendix D: Warranty Statement 22
6.6 Appendix E: RMA Form 23
6.7 Appendix F: EU Declaration of Conformity 24
We, the K-TEK Family, sincerely hope you receive many years of reliable use from this transmitter and welcome
your feedback to consistently improve our products.
The K-TEK Model A38 is a 2-wire microprocessor based level transmitter. It is used to measure the amount of
material in a tank, bin or other container. It can be used with a wide range of liquids.
The standard version of the transmitter consists of an electronic module housed in an explosion-proof enclosure
with an attached sensing probe. The standard probe is a solid 3/8 inch diameter stainless steel rod inside a Tef-
lon sheath. Power and signal are both provided via a standard 4 to 20 mA DC current loop.
An optional version of the transmitter allows the sensing probe to be remotely mounted at some distance from
the electronic module housing.
In most applications, the installation and calibration of the Model A38 is easily accomplished by a competent
technician. Mounting the sensor unit requires three basic steps:
The rugged construction techniques used in building the probes allow them to withstand the rigors of industrial
environments. All of this is accomplished while maintaining the ultimate in simple probes offering the widest pos-
sible range of applications.
There are no operating controls associated with the Model A38 unit and no specific operator actions are required
in connection with the use of this device. However, the unit provides information to the operator that should be
very helpful in making other operating decisions. In most cases, a visual display will keep the operator informed
of how much material is in the measured vessel. Optional set point modules may be used to sound audible or
visible alarms or to control various types of machinery associated with the measured vessel. The Model A38
may also provide information to a computer or programmable controller. The operator should be fully aware of
how the Model A38 fits into the whole system and be prepared to take whatever action is necessitated as sys-
tem conditions change.
2. Installation
2.1 General
After unpacking the unit, inspect it for any evidence of shipping damage. Any claims for damage due to shipping
must be filed with the carrier who handled the package(s).
• Select a mounting location for the transmitter unit and the sensor probe. Your unit may be the integral
mounting option or the remote mounting option. The integral mounting unit consists of a single enclosure
that includes the electronic module and the sensor probe. The remote mounting unit consists of two enclo-
sures, one containing the electronic module and the other containing the sensor probe. See Section 3.1 and
Section 3.2 for some recommended mounting arrangements for integral units. See Section 3.3 for a typical
mounting arrangement for remote units.
• Be sure that there is sufficient clearance around the mounting position to allow for the turning radius of the
transmitter or remote sensor enclosure as the unit is screwed into place. Also, in the case of rigid probes,
allow sufficient room above the vessel entry to be able to insert the probe into the opening of the vessel.
• The thread size of the vessel coupling should be 3/4" NPT for most probes. Certain special applications may
utilize couplings of different sizes.
• The information included in the label should be visible. If necessary to make it readable, clean the label us-
ing a cloth soaked with either water or isopropyl alcohol.
CAUTION: When making the opening in the vessel, observe all safety requirements of the area in which the
work is being done. Be especially careful when working with pressure vessels.
CAUTION: If any of the above statements apply to your application, do not install the transmitter until you con-
tact your local representative or the K-TEK factory for instructions.
2.2 RECOMMENDATIONS
Refer to Section 2.4 for a general schematic layout of a typical loop wiring arrangement. Due to the extremely
wide range of control and/or alarm applications in which the unit may be used, it is not possible to show all con-
ceivable wiring diagrams. Consult your representative or K-TEK factory if assistance is desired.
CAUTION: Be sure that all wiring and conduit conforms to the requirements of the National Electrical Code and
any enforcing authorities or agencies having jurisdiction over the installation. Be sure that any special conditions,
such as areas having explosion hazards, are given full consideration.
• IMPORTANT: Reference Appendix C: A38 Series Electrical Interconnection Diagram for proper installation
of I.S. units.
• After installing and wiring, it is necessary to calibrate the unit to the particular vessel and material that will be
measured. This is accomplished by first emptying the vessel and setting the zero point, then filling the vessel
and setting the full point.
• The A38 has a unique capability of being able to perform a useable calibration on a vessel that is partially
filled at the time of installation. See Establishing custom ZERO/SPAN SENSOR CALIBRATION PRESETS
in Section 4.4 for details of this procedure.
• To obtain the most accurate results, the final calibration should include setting zero with the vessel empty
and full scale with the vessel full. Read all of the following step-by-step instructions before beginning. Refer
to Section 4.5 for the locations of adjustments and controls. These instructions describe the calibration pro-
cedures for the Model A38 transmitter.
• For calibration of optional accessory equipment, consult the appropriate manual(s) for such equipment.
• Both liquid and dry products have dielectric values. The A38 transmitter is designed to monitor continuous
levels of liquid and dry products with a stable dielectric constant greater than 1.7.
When applying level controls to interface detection between a hydrocarbon and water we will refer to the
term normal interface where the higher dielectric product, water (conductive) is on the bottom of the
liquid measurement and the lower dielectric product hydrocarbon (non-conductive) is on the top of the
liquid measurement.
IMPORTANT SETUP INFORMATION: In an oil/water example, as the interface rises on the electrode, a
greater percentage of it is submerged in the higher dielectric constant liquid. This causes an increase in
the capacitance generated and a corresponding increase in the output signal.
For purposes of this document, we will only discuss the “Normal Interface” measurement. By following
the calibration procedures outlined in Section 4 of this manual, calibration can be done on the higher
dielectric product only.
The A38 may not be used to measure total level only when an interface is present. For example, in an
oil-water interface, the A38 may be used to measure the interface of oil and water but not the oil only.
+ +
- -
mA
+ -
+
-
Span
Pushbutton
Zero
Pushbutton
• Pushing both SPAN and ZERO at the same time is equivalent to placing the magnet at position X.
9
A38 Capacitance Transmitter
Remote Dual
Compartment
Electronics
Housing
11
A38 Capacitance Transmitter
4.0 CALIBRATION
Calibration of the A38 Transmitter can be easily accomplished by applying the proper procedure. The most
common procedure involves calibrating the device in place with a known pre-existing tank level. This method is
referred to in this document as Partially Filled Vessel Calibration (Step 4.3).
An alternative method of calibration is available when it is practical to change the level of the vessel as needed
to complete calibration. This method is known as an Alternate Tank Fill. This method of calibration can be used
by employing steps 4.4, then 4.3
Although the Partially Filled Vessel Calibration is the more practical procedure, the Alternate Tank Fill Calibration
Method should be employed when the most accurate measurement is desired.
Push Button Calibration: When using the internal pushbuttons to calibrate the A38 the procedure is the same
as outlined below with the exception that pushbuttons replace the use of the magnet. Refer to Section 4.5 for
button location. Substitute the following:
X Position Press the Zero and Span buttons at the same time
Z Position Press the Zero button only
S Position Press the Span button only
For the calculation, choose the closest curve in your chart for your
application (reference Appendices). Use the curve corresponding to 96
inches if the diameter of the tank is bigger than 96 inches. These curves
represent the probe concentrically located within each diameter.
1. Find the place where a line drawn vertically from the value of the
dielectric constant of the material intersects the curve corresponding to
the diameter of the tank.
2. The value of the “Y” axis of that intersection point corresponds to the
capacitance gain (pf per inch of probe).
3. Multiply the capacitance gain by the length of the probe to obtain the
Capacitance Span.
Figure 4-2
Using the chart for the probe R (Appendix B) find the point where a vertically drawn line at dielectric constant
equal 80 intersects the curve corresponding to 96 inches diameter of the tank. The value of the coordinate axis
Y of that point is the capacitance change, and in this example is equal 6.7 pf/inch.
The recommended range of sensitivity is 76-300 pf (Figure 4-3). Locate the jumper JP1 on the electronics board
(Figure 4-1) and move the black connector to the appropriate jumper position 300 pf (Figure 4-2).
If you are using the remote option it will be necessary to know the maximum length possible. This is determined
by the JP1 Setting. Refer to Figure 4-3 for maximum cable lengths for each capacitance range and correspond-
ing jumper setting.
In the example from Section 4.1 the derived capacitance 301 – 1200 1200 100ft / 30.5m
span of 241.2 pf and a JP1 setting of 300 allows for a remote
1201 – 4800 4800 200ft / 61.0m
cable length up to 50 feet.
The A38 is a digital transmitter and must be calibrated in the measured tank before its first use. No routine
recalibration is required can be changed using the built in switch points. Use the following procedure if the level
in the vessel can be raised and lowered to the required 4 and 20 milliamp points. If the level in the vessel can-
not be raised and lowered to the 4 and 20 milliamp points, proceed to Section 4.4.
The A38 transmitter makes use of presets for the Zero and Span Calibration points. From the factory, these pre-
sets will be set to the values of the DAC Trim (4mA for Zero and 20mA for Span.) In order to calibrate the A38
the level of the vessel must be raised or lowered to establish two points for calibration. Using the Standard Cali-
bration in Section 4.3, the level in the vessel will need to be raised or lowered to the levels for 4 and 20 mA. If
this is not possible, the values for the Zero and Span presets can be changed to coincide with two alternate
points along the required calibration range that the level can be raised and lowered to. Once this procedure is
complete, the A38 can be calibrated following the procedure in Section 4.3. Use the following procedures to
change the presets for Zero and Span.
The two presets must be at least 10% of the measuring range apart from each other.
The Zero Calibration preset can be set in a range from 3.90 mA to 18.50 mA (0-90% of the tank level).
The Span Calibration preset can be set in a range from 5.50 mA to 20.10 mA (10 – 100%) of the tank level).
• Setting the Zero Calibration Preset:
1. Enter the preset calibration mode by placing magnet at position X for more than 8, but less than 15
seconds.
2. Move magnet from position X to position Z to set the Zero Calibration Preset to the desired value.
3. Placing magnet at position S will increase the output at + 0.01 mA intervals
4. Placing magnet at position Z will decrease the output at - 0.01 mA intervals
5. This function incorporates a system in which the first 20 steps occur at 0.01mA/step, then shift to
0.05mA/step for the next 10 steps, then to 0.25mA/step. Interrupting or changing the direction of this
function causes the speed to revert to slow
6. Remove the magnet. The unit will time out after 10 seconds of no switch activity and return to op-
eration.
Note: In order to complete the partially filled vessel calibration, complete the procedures in Section 4.3.
Example: When performing the Partially Filled Vessel Calibration the presets need to be set to indicate the levels
used for calibration:
This procedure is optional and allows you to select either the Low Alarm (3.6mA) or the High Alarm (21mA),
which is going to be output when a shorted probe is detected. It is set by default to 21.0mA. If further changes
are required, use the following procedure:
The DAC TRIM points are the settings used to tune the output circuit to 4 and 20 mA. They have been set at the
factory prior to shipment and should require no further attention. Should there be a question about these set-
tings, the unit’s 4 ma and 20 ma outputs can be trimmed going through the step 4.4.
1. Apply power to the unit for more than 8 seconds while magnet is at position X.
2. A digital multimeter connected to the Loop will indicate 4 mA for a few seconds and just before the
timeout it will indicate 20.00 mA for 2 seconds confirming that the sensor calibration presets have be
adjusted to 4.00 mA and 20.00 mA.
5.0 TROUBLESHOOTING
The output indicates one of the alarm − Short either in the probe or − Check the connection between the
conditions (3.6 or 21 mA). between the banana connector probe and the board. Replace the
and the housing. probe.
− Conductive bridge between the − Clean up to remove bridge between
probe and the vessel wall. probe & vessel wall
− Cut in probe insulation. − Check probe insulation for tears, cuts
− Improper pf range selection or worn spots and if damaged re-
place with new probe.
− Change range jumper JP1 to
applicable range per guidelines in
Section 5.0
Unstable output − Bad ground connection. − Correct ground connection,.
− Radio frequency interference. − Make sure housing covers are closed
− Agitation or waves in liquid and completely screwed into housing
− Stop agitation or wave action and
check output to see if stable if output
is stable, install stilling well for probe
Erratic or incorrect readings − Ungrounded conductive liquid in − Process may need to be grounded a
a dual probe or concentric shield may
fiberglass vessel be required.
Output reading 3.6 mA − Wiring short from shield to − Check and correct wiring
ground in probe head. − Connect probe to transmitter
− Probe not connected to transmit-
ter
Transmitter reading 5% or greater in − Conductive buildup on probe − Inspect and clean probe
error − Transmitter malfunction − Replace transmitter electronics
Concentric Shield probe installed and − Probe touching wall of concentric − Center probe in concentric shield
readings are incorrect shield, material in concentric (may require probe centering
shield may be bridged or partially adapter).
plugged. − Recalibrate transmitter.
− Calibration is incorrect. − Clean out probe and reinstall.
− Vent holes may be plugged − Clean holes and make sure there are
no obstructions
For advanced troubleshooting contact the K-TEK Factory:
6.0 APPENDICES
6.1 Appendix A: Capacitance Change pF / inch Bare Probes
These curves are meant as an application aid; actual values may differ slightly. Always give yourself a 10% margin to ensure
satisfactory performance.
These curves represent the probe concentrically located within each diameter. If a probe is near one wall of a large
tank, do the following: multiply the distance from the tank wall by 2 ( to develop a diameter), choose the closest
curve in your chart for your application, then multiply the resultant pf value x78%. This will account for the probe
not totally surrounded by the ground reference.
(inches) (inches)
8
15
4 4
12 6 12
10
24 24
4 48
48
96
5 96
2
0 0
0 5 10 15 20 0 5 10 15 20
Diameter (inches)
Capacitance change pf/inch
(inches)
20 8 4
Stillwell
6 12
15
12
24
24
10 4
48
48
5 96 2 96
0 0
0 5 10 15 20
0 5 10 15 20
Dielectric constant
Dielectric constant
These curves are meant as an application aid; actual values may differ slightly. Allow a 10% margin to ensure satisfactory perform-
ance.
These curves represent the probe concentrically located within each diameter. If a probe is near one wall of a large tank,
do the following: multiply the distance from the tank wall by 2 ( to develop a diameter), choose the closest curve in your
chart for your application, then multiply the resultant pf value x78%. This will account for the probe not totally surrounded
by the ground reference.
10 (inches) 10
4 Stillw ell
8 8
12 12
6 24 6 24
48 48
4 4
96 96
2 2
0 0
0 20 40 60 80 100 0 20 40 60 80 100
Dielectric constant Dielectric constant
8 (inches) 8 (inches)
7 7 4
6 4
6 12
5 12 5 24
4 24
4 48
3 48
3 96
96
2 2
1 1
0 0
0 20 40 60 80 100 0 20 40 60 80 100
Dielectric constant Dielectric constant
8
Capacitance change pf/inch
(inches) (inches)
7 7
6 4 6 Stillwell
5 12 5 12
24 24
4 4
48 48
3 3 96
96
2 2
1 1
0 0
0 20 40 60 80 100 0 20 40 60 80 100
Dielectric constant Dielectric constant
A38-0200-1 Rev B (10-2005) 19
A38 Capacitance Transmitter
6.3 Appendix C: A38 Series Electrical Interconnection Diagram, Part 1
K-TEK will repair or replace, at K-TEK’s election, defective items which are returned to K-TEK by the original purchaser
within the period specified above from the shipment date of the item and which is found, upon examination by K-TEK, to its
satisfaction, to contain defects in materials or workmanship which arose only under normal use and service and which were
not the result of either alterations, misuse, abuse, improper or inadequate adjustments, applications or servicing of the
product. K-TEK’s warranty does not include onsite repair or services. Field service rates can be supplied on request.
If a product is believed to be defective, the original purchaser shall notify K-TEK and request a Returned Material
Authorization before returning the material to K-TEK, with transportation prepaid by the purchaser. (Request door to door
delivery via New Orleans International Airport located in Louisiana, USA.) The product, with repaired or replaced parts, shall
be returned to the purchaser at any point in the world with transportation prepaid by K-TEK for best-way transportation only.
K-TEK is not responsible for expedited shipping charges. If the product is shipped to K-TEK freight collect, then it will be
returned to the customer freight collect.
If inspection by K-TEK does not disclose any defects in material or workmanship, K-TEK’s normal charges for repair and
shipment shall apply (minimum 250.00 USD).
The materials of construction for all K-TEK products are clearly specified and it is the responsibility of the purchaser to
determine the compatibility of the materials for the application.
THE FOREGOING WARRANTY IS K-TEK'S SOLE WARRANTY AND ALL OTHER WARRANTIES EXPRESSED, IMPLIED,
OR STATUTORY, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OF FITNESS FOR A PARTICULAR
PURPOSE, ARE EXCLUDED AND NEGATED TO THE MAXIMUM EXTENT PERMITTED BY LAW. NO PERSON OR
REPRESENTATIVE IS AUTHORIZED TO EXTEND ANY OTHER WARRANTY OR CREATE FOR K-TEK ANY OTHER
LIABILITY IN CONNECTION WITH THE SALE OF K-TEK’S PRODUCTS. THE REMEDIES SET FORTH IN THIS
WARRANTY ARE EXCLUSIVE OF ALL OTHER REMEDIES AGAINST K-TEK. K-TEK SHALL NOT BE LIABLE FOR ANY
CONSEQUENTIAL, INCIDENTAL, OR SPECIAL DAMAGES OF ANY KIND. K-TEK’S SOLE OBLIGATION SHALL BE TO
REPAIR OR REPLACE PARTS (FOUND TO BE DEFECTIVE IN MATERIALS OR WORKMANSHIP) WHICH ARE
RETURNED BY THE PURCHASER TO K-TEK.