Kenco KT Series Manuale utente

Modbus Interface Manual

“KT” Series Magnetostrictive

Liquid Level Transmitters

Kenco Engineering Company

10001 East 54th Street

Tulsa, Oklahoma 74146

Phone: 918-663-4406

Fax: 918-663-4480

Website: www.kenco-eng.com

Email: [email protected]

79863

(Rev. #)

[5-2-19]

Modbus Interface Manual

Table of contents

.................................................................3

2. .................................................................................5

......................................................................5

4. ..................................................................5

4.1 Before You Begin ...................................................................5

4.2 Quick Start-Up Procedure ..................................................... 5

5. ..............................................................................5

5.1 Operation Modes................................................................... 5

5.1.1 Run Mode ...................................................................... 5

5.1.2 Program Mode............................................................... 5

5.2 Display Diagram.................................................................... 6

5.3 Menu Structure......................................................................6

6. Alarms.........................................................................................6

7. Error Codes (Faults)....................................................................7

8. ........................................................................7

8.1 Dashboard ............................................................................ 8

8.1.1 Installing Dashboard...................................................... 8

8.1.2 Home Screen ................................................................. 8

8.1.3  ................................................................. 9

8.1.4 Signal Settings.............................................................. 9

8.1.5 Level Settings ............................................................... 9

8.1.6 Temperature Settings.................................................. 10

8.1.7 Volume Settings.......................................................... 11

8.1.8 Flash Settings ............................................................. 11

8.1.9 Save Settings .............................................................. 12

8.2 Programming the Display ................................................... 12

8.3 Modbus Function Codes ..................................................... 13

8.4 Modbus Register Maps....................................................... 15

8.5 How Units are Used ............................................................ 19

8.6 Modbus Register Map Notes .............................................. 19

8.7 Formulas Used in Volume Calculation................................. 21

Modbus Interface Manual





‘Generalized Crude Oils’, Correction of Volume to 60 °F against API

Gravity.



‘Generalized Products’, Correction of Volume to

60 °F against API Gravity.



‘Volume Correction Factors (VCF)’ for individual and special applica-

-

cients.







The measure of how heavy or light a petroleum liquid is compared to

water. Allowable values are 0 to 100 degrees API for (6A) and 0 to 85

degrees API for (6B).

DDA

‘Direct Digital Access’ – The digital protocol for use in intrinsically safe

areas.





density value should be entered as lb / cu. ft..



Type of protection based on enclosure in which the parts which can

ignite an explosive gas atmosphere are placed within, and which can

withstand the pressure developed during an internal explosion of an ex-

plosive mixture, and which prevents the transmission of the explosion

to the explosive gas atmosphere surrounding the enclosure.



Type of protection based on enclosure in which the parts which can

ignite an explosive gas atmosphere are placed within and which can

withstand the pressure developed during an internal explosion of an ex-

plosive mixture, and which prevents the transmission of the explosion

to the explosive gas atmosphere surrounding the enclosure.



An all digital, serial, two-way communications system that serves as

the base-level network in a plant or factory automation environment.







‘Gross Observed Volume of the Interface’ – The total volume of the tank

occupied by the interface liquid. The GOVI is only given when mea-

suring two liquids and is calculated by subtracting the volume of the

product from the total volume of liquid in the tank (GOVT – GOVP).



‘Gross Observed Volume of the Product’ – The total volume of the tank

occupied by the product liquid. When measuring only one liquid, it is

also the total volume of liquid in the tank (GOVT). When measuring two

liquids it is the total volume of liquid in the tank minus the volume of

the interface liquid (GOVT – GOVI).



‘Total Gross Observed Volume’ – The total volume of liquid in the tank.

When measuring only one liquid it is equal to the volume of the product

(GOVP). When measuring two liquids it is equal to the volume of the

product and interface liquids (GOVP + GOVI).



‘Gross Observed Volume Ullage’ – the difference in volume between the

working capacity of a tank and the total volume in the tank (Working

Capacity – GOVT).

HART®

A Bidirectional communication protocol that provides data access



Interface

Noun; The measurement of the level of one liquid when that liquid is

below another liquid.

Interface

Adj.; The Software Graphical User Interface (GUI) that allows the user

to access software protocols (HART, DDA, MODBUS).



‘Intrinsically safe’ - Type of protection based on the restriction of

electrical energy within apparatus of interconnecting wiring exposed to

potentially explosive atmosphere to a level below that which can cause

ignition by either sparking or heating effects.

Modbus Interface Manual





The property of a body that causes it to have weight in a gravitational



the volume correction factor (Density * VCF).



A serial communications protocol published by Modicon in 1979 for use

with its programmable logic controllers (PLCs). It has become a de fac-

to standard communications protocol in industry, and is now the most

commonly available means of connecting industrial electronic devices.





A product Enclosure intended for indoor or outdoor use primarily to

provide a degree of protection against corrosion, windblown dust and

rain, splashing water, and hose-directed water; and to be undamaged by

the formation of ice on the enclosure. They are not intended to provide

protection against conditions such as internal condensation or internal

icing.



U.S. standard





‘Net Standard Volume of the Product’ – The temperature corrected

volume for the product liquid in the tank, requires the transmitter to

be ordered with temperature measurement capabilities. The NSVP is

calculated by multiplying the volume of the product liquid by a volume

correction factor based on temperature (GOVP * VCF).



The temperature at which the density measurement is given, the allow-

able values are 32 °F to 150 °F (0 °C to 66 °C).



The density ratio of a liquid to the density of water at the same condi-

tions.



The internal radius of the sphere that contains the liquid, the value is

used to calculate the volume along with the Sphere Offset.



An offset value that accounts for additional volume in a sphere from

non-uniform sphere geometry, the value is used to calculate the volume

along with the Sphere Radius.



A table of measurement correlating the height of a vessel to the volume

that is contained at that height. The transmitter can contain up to 100

points.

TEC

-

perature for an object with the change in its volume. Allowable values

are 270.0 to 930.0. TEC units are in 10 E-6/Deg F.



product correction methods used to correct the product

volume in the tank due to changes in temperature from 60 °F including

(6A, 6B, 6C, 6C Mod, and Custom Table.





One of two methods use to calculate volume measurements from level

measurements, including Sphere and Strap Table.



‘Volume Correction Factor’ – A table of measurements correlating

temperature points with correction factors for the liquids expansion/

contraction. The transmitter can contain up to 50 points.



The maximum volume of liquid that the user desires for their vessel to



Modbus Interface Manual





The content of this technical documentation and of its various

annexes is intended to provide information on mounting, installation



IEC 60079-14 and/or factory trained service technicians and local

regulations.



Warnings are intended for your personal safety and for avoidance

of damage to the described product or connected devices. In this

documentation, safety information and warnings to avoid dangers that

might affect the life and health of personnel or cause material damage





3.1 Intended use

The purpose of this document is to provide detailed information on

the protocol interface. All safety related information is in the product



connecting to the level transmitter.







You must use a RS-485 converter with “Send Data Control” and the

Set-up Software to ensure proper operation.

Example:

RS-485 to USB



1. Connect +24 Vdc to terminals.

2. Connect data lines to terminals.

3. Connect the PC (or other device) to data lines.

(If you are using a PC, use a RS-485 to USB converter. See

Note above for more information.)

4. Turn on power to the transmitter.

5. Start the Dashboard. Select Com Port and Address. Factory

default address is ‘247 ’ for Modbus.

Before starting the operation of the equipment read this documentation

thoroughly and follow the safety information.

Symbol 

NOTICE This symbol is used to point to situations

that may lead to material damage and/or personal

injury.

6. Change the address to one that is suitable for the installation

network.

7. 

temperature.

8. Turn off power to the transmitter.

9. Remove data lines.

10. Install the transmitter into the vessel (see Operation Manual).

11. Reconnect power and data lines.

12. Calibrate current tank level using setup software (optional).

13. Verify communications with the host system.



All liquid level transmitters are shipped with a Stylus (Kenco Part #

79857) to be used for manipulating the display. For single and dual

cavity housings, the Stylus is designed to allow for programming of the

unit without removing the housing. When using the Stylus make sure

to align the Stylus with the shape outline around the buttons in the same

orientation. Failure to correctly align the Stylus can cause the display to

not function properly.



Do not use any device other than the Stylus to operate the display.



Improper use of the Stylus can cause the display to not function

properly.



The level transmitter runs in one of the following modes of operation.

You can use these modes to calibrate and set up various operating

parameters.



Run mode is the primary mode of operation. This mode will perform

measurements, display data, and respond to Modbus commands.



Program mode is the primary mode for commissioning and trouble-

shooting the level transmitter. The full menu and available functions are

shown in section 5.3 Menu Structure. To enter program mode use the

Stylus and press the Enter Key as shown in section 5.2 Display Diagram.

Program Mode is protected by a password to keep unwarranted chan-

ges from occurring. The factory default password is 27513. When in

program mode, remote communications are not functional. An automa-

tic timeout feature is provided so that the transmitter does not remain

inadvertently in program mode. The timeout is set for 1 minute before

prompted for additional time. Total timeout is 2 minutes.



Modbus: 4800 BAUD 8, N, 1 8 Data bits, No Parity, 1 Stop bit

Modbus Interface Manual



Whenever program mode is exited from the display the unit will reset

itself to insure all changes have been accepted. The reset will take

approximately 5 seconds before the level transmitter is able to respond

to commands.



In program mode, the transmitter will not respond to incoming

Modbus commands. A busy error will be sent to the controller to

notify the unit is in program mode. This function will prevent a user at

a remote terminal from programming the unit while a user is accessing

program mode from the display.



 – Used to move cursor on screen up and to increment num-

ber.

 – Used to move cursor on screen down and to decrease

number.

– Used to move cursor on screen to the right, cursor will

cycle back.

 – Used to Enter Program Mode, select Highlighted Item, and



 – Hidden key in the middle of the display that is used to exit

menu at any time.

 – The process variable that is selected to display.

The display will automatically scroll between selected variables.

 – The numerical value for the MEASURED VARIABLE

shown on the display.

 – Unit of measurement for the MEASURED VARIABLE shown on

the display.

 – Average temperature for the product in the tank. Only

shown if the level transmitter was purchased with temperature.

 – Four squares with letters. Top left square will always

be present indicating a D for DDA mode or a M for Modbus mode. Top

right square, A, will only show when there is an alarm. Toggle the

UP Arrow key to view alarms. Bottom right square, F, will only show

when there is a fault. Toggle the DOWN Arrow key to view error codes.

Bottom left square, P, will only show when the unit is being programmed

remotely.



• Data From Device

Display

Units

`Length Units

`Temp Units

`Volume Units

Address

Signal Strength

`Prod Trig Lvl

`Int Trig Lvl

`Roof Trig Lvl

• Calibrate

Product Level

`Current Level

`Offset

Interface Level

`Current Level

`Offset

Roof Level

`Current Level

`Offset

• Factory

Settings

`Gradient

`Serial Number

`HW Revision

`SW Revision

`SARA Blanking

`Magnet Blanking

`Gain

`Min Trig Level

Temp Setup



Auto Threshold

Baud Rate

Volume

Reset to Factory

6. Alarms

The Modbus output is equipped with several alarms that will be shown

on the display. Use the stylus to tap the Up arrow to view alarms. The

Modbus output is set to fail high, greater than the order length, if there

is an issue and the level value output cannot be trusted.

Fig. 1: Modbus Display

Modbus Interface Manual

Fault

Code

 

101 Missing

Magnet





• Verify Float(s) are not in inactive zone.

• Verify Auto Threshold is enabled.

• Cycle power to sensor. If proper operation

is not restored, Contact Factory.

102 Internal

Fault 1

Cycle power to sensor. If proper operation

is not restored, Contact Factory.

103 Internal

Fault 2

Cycle power to sensor. If proper operation

is not restored, Contact Factory.

104 Internal

Fault 3

Cycle power to sensor. If proper operation

is not restored, Contact Factory.

105 Lobe Fault 1 • Verify Auto Threshold is enabled

• Cycle power to sensor.

• If proper operation is not restored, Contact

Factory.

106 Lobe Fault 2 • Verify Auto Threshold is enabled.

• Cycle power to sensor.

• If proper operation is not restored,

Contact Factory.

107 Delta Fault Contact Factory to discuss application.

108 Internal

Fault 4

Cycle power to sensor. If proper operation

is not restored, Contact Factory.

109 Peak Fault • Verify Auto Threshold is enabled.

• Cycle power to sensor.

• If proper operation is not restored,

Contact Factory.

110 Hardware

Fault 1

Cycle power to sensor. If proper operation

is not restored, Contact Factory.

111 Power Fault • Cycle power to sensor.

• Verify Power Supply rating.

• Verify wiring.

• If proper operation is not restored,

Contact Factory.

112 Hardware

Fault 2

Cycle power to sensor. If proper operation

is not restored, Contact Factory.

113 Hardware

Fault 3

Cycle power to sensor. If proper operation

is not restored, Contact Factory.

114 Hardware

Fault 4

Cycle power to sensor. If proper operation

is not restored, Contact Factory.

115 Timing

Fault 1

Cycle power to sensor. If proper operation

is not restored, Contact Factory.

116 Timing

Fault 2

Cycle power to sensor. If proper operation

is not restored, Contact Factory.

117 Timing

Fault 3

Cycle power to sensor. If proper operation

is not restored, Contact Factory.

118 DAC Fault 1 Cycle power to sensor. If proper operation

is not restored, Contact Factory.

119 DAC Fault 2 Cycle power to sensor. If proper operation

is not restored, Contact Factory.

7. Error Codes (Faults)





Termination and biasing of RS-485 data lines are as follows:



Each transmitter uses a Fail-Safe, Slew-Rate-Limited RS-

485/RS-422 Transceivers. No additional biasing, resistors should

be present on the connecting devices (PLC, DCS, PC, Converter).



Each transmitter uses a Fail-Safe, Slew-Rate-Limited RS-485/

RS-422 Transceivers. No additional termination resistors are

necessary in connecting devices (PLC, DCS, PC, Converter).

Fault

Code

 

120 DAC Fault 3 Cycle power to sensor. If proper operation

is not restored, Contact Factory.

121 DAC Fault 4 Cycle power to sensor. If proper operation

is not restored, Contact Factory.

122 SPI Fault 1 Cycle power to sensor. If proper operation

is not restored, Contact Factory.

123 SPI Fault 2 Cycle power to sensor. If proper operation

is not restored, Contact Factory.

124 Setpoint

Fault

The analog setpoints are too close. Mini-

mum distance is 150 mm (6 in.) for analog

and 290 mm (11.5 in.) for SIL. Adjust

programmed setpoints as needed. (Analog

only) If proper operation is not restored,

Contact Factory.

125 Loop 1 Out

of Range

Verify that magnets are positioned within

expected measuring range. Adjust program-

med setpoints as needed. (Analog only) If

proper operation is not restored, Contact

Factory.

126 Loop 2 Out

of Range

Verify that magnets are positioned within

expected measuring range. Adjust program-

med setpoints as needed. (Analog only) If

proper operation is not restored, Contact

Factory.

127 EEPROM

Fault 1

Cycle power to sensor. If proper operation

is not restored, Contact Factory.

128 EEPROM

Fault 2

Cycle power to sensor. If proper operation

is not restored, Contact Factory.

129 Flash Failure Cycle power to sensor. If proper operation

is not restored, Contact Factory.

130 Internal

Error

Cycle power to sensor. If proper operation

is not restored, Contact Factory.

Modbus Interface Manual



The Modbus implementation for the digital transmitter conforms to

the ‘Modicon Modbus Protocol Reference Guide, PIMBUS-300 Rev. G’

available from Modicon, Inc. The information provided below assumes

familiarity with the Modbus protocol as outlined in this reference guide.

All information provided applies to Modbus RTU protocol only.



Adjustments to the calibration and setup parameters of the Modbus

interface can be performed using the Dashboard. The dashboard can be

run from any Windows 7 or newer OS using a RS485 to USB converter.

Perform the following steps to install the Dashboard and establish

communication:

1. Install setup software from the USB stick that came with the level

transmitter or go to factory website to download the latest

version.

2. Connect level transmitter to RS485 to USB converter, connect

24 Vdc power to the level transmitter, and connect the RS485 to

USB converter to the PC. Example setup shown below.

Fig. 2: Example setup

3. Open Dashboard and select Modbus protocol from drop down

menu.

4. Select COM Port. Software will show active COM ports. Make sure

converter is connected before starting Dashboard or COM port

will not show.

5. The default address for the level transmitters from the factory is

247. Select address 247. If you do not know the address you can

use the Search function at the bottom of the address range or the

display menu.

Fig. 3: Initial screen

8.1.2 Home screen

Fig. 4: Home screen

The Dashboard Home Screen will look different based on whether or

not temperature has been ordered and volume measurement has been

enabled. If the level transmitter includes temperature measurement

and volume measurement is enabled then the Home Screen will look as

shown. If the level transmitter does not include temperature measurement

then the Home Screen will not show the middle panel for temperature. If

the level transmitter does not have volume measurement enabled then the

Home Screen will not show the bottom panel. The Home Screen can be

accessed by pressing the three white bars on the top left.

The level panel on top shows the level measurement for the Product





level and the graph is a time lapse of the graphical representation of the

numbers. The red line is the approximate maximum level based off of the

order length of the level transmitter. The numbers on the right of the level

panel are the Trigger Level for the Product Float on top and the Interface

Float on bottom. These are a representation of how strong of a return

signal the level transmitter is experiencing.

The temperature panel will only show if temperature measurement

was ordered and turned on. The left side shows the numerical value of

the average temperature of all temperature sensors below the product

level. The bar graph in the middle of the panel shows each individual

temperature measurement point. Temperature 1 is always the lowest

temperature closest to the bottom of the pipe or hose.

The volume panel is on the bottom. On the left side is the numerical

value for GOVP, GOVI, GOVT, GOVU, NSVP, and mass including units.

The bar graph in the middle is a graphical representation of the volume

measurement.

Across the bottom of the Home Screen is the visual indication of the fault

codes from section 8. Green indicates no fault and red indicates fault.



On the far right are the lights for the soft alarms that can be set in the

Dashboard. Green indicates the alarm is not tripped and red indicates that

the alarm has been tripped.

Modbus Interface Manual



Fig. 5: Configuration





Factory Set:

 Default setting is ON and should not be turned off.

This feature allows the unit to automatically adjust the threshold for

optimal performance.

Default setting of ON for all applications.

Default setting of ON if ordering 2 Loops. Default





the level transmitter will go into Fault.

 Serial Number assigned by factory at the time of

manufacture. The serial number is used for tracking and replacement

parts. Do not change.

 Default setting of OFF if ordered without temperature.

Default setting of ON if ordered with temperature. Turning tempera-

ture ON when the level transmitter was not ordered with temperature

will not cause temperature to work and will force the level transmitter

into Fault.

Default setting of ON. Display can be turned off by

changing to OFF and cycling power.



Allows the end user to change the direction in

which the level transmitter counts. The default setting is OFF and the

level transmitter will reference the tip of the pipe/hose and count up

from the tip. The ON setting will reference the head of the level trans-

mitter and count up as it moves towards the tip.



Default address is 247. The default address should not be used in a

network.

 Allows the end user to select the desired baud rate. Default

setting is 4800.



options are level or volume. Default setting is level.

Allows the end user to turn ON and OFF the volume

calculation.



Fig.6: Signal settings

Factory Set:

 Is the speed at which the magnetostrictive signals travel

along the sensing element. Typical range is from 8.9 to 9.2. Do not

change unless replacing the sensing element. Changing this number

will directly affect accuracy.

Is the strength of the interrogation pulse. Factory uses

the same electronics for all lengths and adjusts the signal based on the

order length. Do not change unless instructed to do so by the factory.



Fig. 7: Signal settings

Modbus Interface Manual



Factory Set:

 a calibration method that directly

changes the offset of the level measurement. The offset is the zero

reference point used in determining the level output. Do not use

without Factory guidance.

 the full length of the level transmitter including order

length, inactive zones, and mounting length. Do not change the Enter

Level Offset method without Factory guidance. The offset will change

after using the Enter Current Tank Level for the Product. The Product

Offset and Interface Offset are independent of one another.

 the full length of the level transmitter including order

length, inactive zones, and mounting length. Do not change the Enter

Level Offset method without Factory guidance. The offset will change

after using the Enter Current Tank Level for the Interface. The Product

Offset and Interface Offset are independent of one another.



 the unit of measurement used for engineering units.

Default is inches if ordered in inches and mm if ordered in mm.

Options include inches, feet, millimeters, centimeters, and meters.

 a calibration method that

calibrates the level transmitter based off of one point of measurement.

Select Enter Current Tank Level from the Method drop down box. Go

to Product Level and enter value of current product level based off of

a manual measurement while the tank level is not changing. Go to

Interface Level and enter value of current interface level based off of

a manual measurement while the tank is not changing. Click Update

box in lower left corner when it appears. Level transmitter is now

calibrated.

 Soft alarm that can be disabled or enabled by



value in the box then the alarm will become active.

 Soft alarm that can be disabled or enabled by



the value in the box then the alarm will become active.

 Soft alarm that can be disabled or enabled by



value in the box then the alarm will become active.

 Soft alarm that can be disabled or enabled by



the value in the box then the alarm will become active.



Fig. 8: Temperature settings

Factory Set:



transmitter is looking for. The number should match the number of

temperature sensors in the model number.

This is the number of temperature readings

that are averaged together for the temperature output. The higher the

number the more temperature readings that are averaged. The higher

the number the smoother the output but also the slower the update to

changes in the process temperature.

The location of the temperature sensor in reference to the

end of the pipe.

Calibration factor for the temperature sensor. The defaults

setting is 1.0. Do not change unless a new sensing element with

temperature is ordered.

Calibration factor for the temperature sensor. The default

setting is 0.0. Do not change unless a new sensing element with

temperature is ordered.



Change the units of measure for the temperature

settings. Options are Fahrenheit or Celsius.

Soft alarm that can be disabled or enabled



value in the box then the alarm will become active.

Soft alarm that can be disabled or enabled by



value in the box then the alarm will become active.

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