Operating instruction manual OI/KCAP300-EN Rev. E 06.

2012

KCAP300
RF Capacitance Level Switch

KCAP300 with KSHIELDTM

sensing probes and electronics

K-TEK Level products

Introduction
This operating instruction manual provides the following
information:
− Specifications—see page 6
− Installation instructions—see page 7
− Operating and setup—see page 9
− Troubleshooting—see page 16
 TABLE OF CONTENTS

1. INTRODUCTION 5
1.1 Description 5
1.2 Basic Theory of Operation 5
1.3 Features 5
1.4 Options 5

2. SPECIFICATIONS 6
2.1 Environmental 6
2.2 Electrical 6
2.3 Dimensional 6

3. INSTALLATION 7
3.1 General 7
3.2 Recommendation 8
3.3 Caution 8

4. OPERATION and SETUP 9

4.1 Detailed Theory of Operation 9
4.2 Accessing Setup Adjustments 12
4.3 Default Settings / Reset 12
4.4 Setpoint Calibration (One Touch Calibration) 13
4.5 Fail Safe / Relay Operation 13
4.6 Sensitivity / Hysteresis 14
4.7 Time Delay 15

5. TROUBLESHOOTING 16
5.1 “Out-of-Calibration” Indication 16
5.2 Symptoms and Remedies 17
5.3 Warranty 19
5.4 Company Information 19

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1. INTRODUCTION

1.1 Description

The KCAP300 is a RF Capacitance switch designed for single point level detection in both solids and liquids. Its
KSHIELD technology, coupled with the three element probe design, provides reliable response in cases were
buildup may occur. The LED indicators of the KCAP300’s modular electronics allow for simple calibration, and status
detection. Its rugged construction allows it to withstand the rigors of just about any industrial environment.

1.2 Basic Theory of Operation

Every material has a relative permittivity or dielectric constant. A basic capacitance switch uses this dielectric con-
stant to complete a capacitance circuit between a sensor and a reference. The presence of a material creates a shift
in the received capacitance causing the switch to activate. While these basic capacitance style switches are useful,
the presence of buildup on the probe can cause the unit to fail.

The KSHIELD technology of the KCAP300, along with the three-element probe design void out the effects of
buildup. By utilizing a second capacitance circuit the buildup can be compensated for in the reference capacitance
and point level detection can be maintained.

1.3 Features

• Liquids and Bulk Solids

• KSHIELD™ Sensing Probes and Single Setpoint Electronics that Provide Immunity to Buildup
• Integral and Remote Electronics
• Easy Set Up Via External Magnet or Pushbuttons
• Housing with Glass Viewing Cover
• Wide Variety of Sensing Probes to (450ºF / 800 psig)
• Single Point Detection
• Single Touch Calibration with Out-of-Cal Light
• Element Sensitivity Down to 0.5 pF

1.4 Options

• 316L SS Enclosure
• External “Alarm” Indicating Lamp
• Tip Extended Extensions to 60 in / 1524 mm
• Pipe Extensions to 240 in / 6096 mm
• Industry Standard Bulk Solids Mounting Plate
• Process Connections: 3/4”NPT, 1 1/4”NPT, and Custom Flanges

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2. SPECIFICATIONS

2.1 Environmental
Housing type Explosion Proof, Powder Coated Cast Aluminum Standard
Temperature Electronics: -40 to 170º F / -40 to 77ºC
Dielectric 1.4 or greater
Remote Mounting Max. length of 200 ft. from sensing probe to the remote electronics
2.2 Electrical
Input Power 95 - 130 VAC, 50-60 Hz, 2 Watts; 180 - 260 VAC, 50 - 60 Hz;
24 VDC +/- 5%;
Relay Contact Rating 1x DPDT Resistive: 10 Amp, 250 VAC; 10 Amp, 30 VDC
Inductive: 1/5 HP 125, 250 VAC
Static Protection Peak Surge Current: 800 amps
Clamp Voltage: 745 volts
Cable Entry 2x 3/4” NPT

2.3 Dimensional

in (mm)

3/4” NPT
Conduit Opening
(Both Sides) 4.81 (122.24 )

8.26 (209.78)

3/4” MNPT Mounting

2.40 (60.96)
0.75 (19.05)

5.90 (149.86)
9.18 (233.26)
0.625
(15.875)
20.25 (514.35)

0.50 (12.7)
Probe / Type Specified
by Customer using
KCAP-0202-1
Table 1A

0.37 (9.40)

Figure 1

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3. INSTALLATION
3.1 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 switch and the sensor probe. Your unit may be the integral mounting op-
tion 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 enclosures, one con-
taining the electronic module and the other containing the sensor probe.

• Be sure that there is sufficient clearance around the mounting position to allow for the turning radius of the
switch or remote sensor enclosure as the unit is screwed into place. 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 on 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.

The Model KCAP300 unit may not work properly if:

• The material dielectric constant is less than 1.7.

• There is a conductive bridge between probe and vessel wall,
• The unit does not have a good ground connection.
• Probe insulation is damaged.
• Probe is located near a material fill line.
• Probe is mounted improperly.

The Model KCAP300 unit may be damaged if:

• Temperature in the Model KCAP300 housing exceeds appropriate limits.

• The process temperature exceeds probe’s operating limits.
• The electronics module is subjected to excessive vibration or shock.
• Vessel pressure exceeds process operating pressure rating of probe.

CAUTION: If any of the above statements apply to your application, do not install the switch until you contact your
local representative or the ABB factory for further instructions.

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3.2 Recommendations

Integral units
• Install the switch into the vessel coupling and connect conduit between the switch and the supply source as
required.
• Be sure the conduit is suitable for the environment in which the units are to be used.
Remote units
• Install the remote sensor probe into the vessel coupling. Select a suitable location for the instrument housing
that allows convenient access for calibration.
• Connect conduit between the remote sensor housing and the instrument housing.
• Connect the RG62 type coaxial cable assembly supplied with the unit from the remote probe to the instrument
input.
• Connect conduit between the switch and the supply source as required. Be sure the conduit is suitable for the
environment in which the units are to be used.
Electrical Connection Diagram

LED 1 LED 2

S1 S2
( Programming (Programming
Push Button) Push Button)

120 / 240 VAC 50 / 60 Hz

or 24 VDC

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 conceivable wiring diagrams. Consult your representative or ABB factory if further assistance is needed.

3.3 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.
• After installing and wiring, it is necessary to calibrate the unit to the particular vessel and material that will be
measured, using the standard calibration procedure.
• The KCAP300 has a Reset capability to restore the factory default values, which can be done by placing the
magnet on the “X” position for 30 seconds. The current level of the tank is chosen as the new set point. See
RESET in Section 4.3 for details of this procedure.
• Both liquid and dry products have dielectric values. The KCAP300 RF Switch is designed to monitor levels of
liquid and dry products with a stable dielectric constant greater than 1.4.

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4. OPERATION and SETUP

4.1 Detailed Theory of Operation

The KCAP300 works on the same principal as any other capacitance type switch. The switching operation takes
place when a sensed capacitance varies in comparison to a reference capacitance set by the user. In simple capaci-
tance switches, a buildup of material between the sensor and the ground reference can cause the switch to malfunc-
tion either not switching or resetting as it should.

To compensate for potential buildup on the sensor, the KCAP300 is equipped with KSHIELD™ software and a three
element probe assembly. The center element of the three element probe acts as a shield for the sensor, both me-
chanically and electronically. Establishing a second capacitance circuit between the shield and the ground reference
allows the switch to vary its reference capacitance and compensate for the buildup on the probe. In essence, the
KCAP300 is not comparing the sensed capacitance to a set reference capacitance but comparing the sensed
capacitance to a floating baseline capacitance.

Figure 4.1.1

Reference
Capacitance

Sensed
Capacitance

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During normal operation, several factors will be taken into account which will affect the action of the relays within the
KCAP300. (For this explanation, we will have the Fail Safe set to Low.) When the KCAP300 is calibrated the soft-
ware establishes a baseline capacitance for the set-point. If the sensed capacitance were to rise or fall across this
baseline the set-point would be reached. If the relays were to act at this point, the switch would operate erratically.
(Figure 4.1.2)

Figure 4.1.2
Capacitance

Setpoint

Time

Relays
Energized De-energized

For this reason, a Sensitivity or Hysteresis adjustment has been incorporated in the software. Sensitivity adds a ca-
pacitance factor to the baseline. In order for the relays to energize, the sensed capacitance must not only surpass
the baseline it must surpass the added capacitance. The set-point plus the sensitivity becomes the switch point.
For the relays to de-energize, the sensed capacitance must decrease to less than 1/3 of the sensitivity plus the
baseline. (Figure 4.1.3)

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 Figure 4.1.3
Switch Point Reset Point
Capacitance

Sensitivity

Setpoint

Time

Relays
Energized De-energized

Along with the Sensitivity a Time Delay adjustment has been incorporated. The Time Delay will allow the relays to
wait a specified time after the switch point has been reached before energizing. This added Time Delay will affect
the relay operation on both energize and de-energize cycles. (Figure4.1.4)

Figure 4.1.4

Switch Point Reset Point

Capacitance

Sensitivity
Setpoint

Time

Relays
Time Delay
Energized De-energized

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4.2 Accessing Setup Adjustments

Calibration and Setup of the KCAP300 may be achieved using a magnet posi-
tioned on the housing or by means of the pushbuttons on the module. In the fol-
lowing operations, pushbuttons will correspond to magnet positions as follows:

X position = S1 and S2 buttons simultaneously

S1 position = S1 button only
S2 position = S2 button only

During normal operation, LED1 will light either red or green

based on the settings of the switch.

4.3 Default Settings / Reset

Each KCAP300 will be supplied with the following default settings:

Time Delay = Instant

Sensitivity/Hysteresis = Medium
Fail Safe Mode = Low Level
Set Point = Current Level

To restore the default settings, place the magnet on the X position for 30 seconds. The following sequence of lights
will be observed (Table 1):

TABLE 1
OPERATION LED 1 LED 2
NORMAL GREEN or RED OFF
X = 30 SECONDS OFF OFF
GREEN GREEN
RED RED
RED GREEN
GREEN GREEN
RED RED
RED GREEN
GREEN GREEN
REMOVE OFF OFF

When both LED’s turn off, remove the magnet and the KCAP300 will be restored to normal operation with the default
settings.

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4.4 Setpoint Calibration (One Touch Calibration)

A typical application will require the switch to activate when the measured product reaches the probe. To set the ac-
tion of the switch for this application, mount and wire the switch in its permanent location. Without product touching
the probe, place the calibration magnet on the “X” position for more than 1 but less than 6 seconds. Move the mag-
net to the “S1” position for 2 seconds. The following sequence of lights will be observed during this operation:

TABLE 2
OPERATION LED 1 LED 2
NORMAL GREEN or RED OFF
1 SECOND < X < 6 SECONDS OFF OFF
S1 GREEN OFF
GREEN or RED OFF

This procedure will establish the reference capacitance of the installation and create the setpoint of the switch.
When the measured product touches the probe, the switch will activate. If this does not occur, the Sensitivity may
need to be increased (Section 4.6.) In applications where the dielectric of the material being detected is greater than
10, the setpoint location can only be established in this manner.

The setpoint of the switch can be established with product touching the probe. In this case, the action of the relays
will take place when the product level increases the sensed capacitance of the switch, typically a rising level. ABB
does not recommend creating a setpoint for the KCAP300 in this manner.

4.5 Fail Safe / Relay Operation

The default setting for the Fail Safe or Relay Operation of the KCAP300 will be Low. This means the relays will be
de-energized when the level is below the switch and energize when the switch point is reached. Likewise, setting
the Fail Safe to High will cause to the relays to be energized when the level is below the setpoint and de-energize
when the switch point is reached. To select the Fail Safe for the relays, place the magnet in the S1 position for 10
seconds. The following sequence of lights will be observed:

TABLE 3
OPERATION LED 1 LED 2
NORMAL GREEN or RED OFF
S1 = 10 SECONDS OFF OFF
REMOVE “GREEN/RED” OFF
“_“ - indicates a blinking LED

Removing the magnet when LED1 is green will set the Fail Safe to Low. Removing the magnet when LED1 is red
will set the Fail Safe to High.

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4.6 SENSITIVITY / HYSTERESIS

The Sensitivity / Hysteresis of the KCAP300 will be set at a default of high, a value of 1.5pf. This means a change of
1.5pf from the set point will be required to activate the switch. This setting will allow switching in most applications.
In applications of higher dielectric materials, it may be necessary to decrease the sensitivity to prevent false indica-
tions. In applications with lower dielectrics, it may be necessary to increase the sensitivity.

To access the Sensitivity Setup Mode, place the magnet on S2 for more than 1 second but less than 6 seconds.
The following sequence of LED’s will be observed:

TABLE 4
OPERATION LED 1 LED 2
NORMAL GREEN or RED OFF
1 SECOND < S2 < 6 SECONDS OFF OFF
RED “GREEN”
OFF OFF
S2 per Table 7 OFF “GREEN”
“_” - indicates a blinking LED

While LED1 is lit red, LED2 will blink the current Sensitivity setting per Table 5.

TABLE 5
LED 2 BLINKS 1 2 3 4
pF 0.5 1.5 6 32
SENSITIVITY VERY HIGH HIGH MED LOW

After LED1 turns “off”, LED2 will blink in correspondence to the different Sensitivity settings per Table 5. Once the
number of blinks required is reached, place the magnet on the S2 position. The sensitivity will be set, and the
KCAP300 will return to normal operation. If a new sensitivity is not selected, the KCAP300 will return to its current
operating mode without affecting a change. The default sensitivity setting is (HIGH), 1.5pF which is the Number 2
setting.

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4.7 Time Delay

The KCAP300 with its default settings will activate the relays instantaneously when the switch point has been
reached. In certain applications it may be necessary to delay the action of the relays in the switch. If this is desired,
a Time Delay for the relays can be set. To enter the Time Delay Setup Mode, place the magnet on S1 for more than
1 second but less than 6 seconds then. The following sequence of LED’s will be observed:

TABLE 6
OPERATION LED 1 LED 2
NORMAL GREEN or RED OFF
1 SECOND < S1 < 6 SECONDS OFF OFF
“GREEN” RED
OFF OFF
S1 per Table 5 “GREEN” OFF
“_“ - indicates a blinking LED

While LED2 is lit red, LED1 will blink the current Time Delay setting per Table 7.

TABLE 7
LED 1 BLINKS 1 2 3
SECONDS 0 5 15

After LED2 turns “off”, LED1 will blink in correspondence to the different Time Delay settings per Table 7. When the
desired Time Delay is reached, place the magnet on the S1 position. The Time Delay will be set and the KCAP300
will return to normal operation. If a time delay is not selected, the KCAP300 will return to its current operating mode
without changing the current Time Delay setting.

During normal operation of the switch if a Time Delay is selected other than 0 seconds, LED1 will change color when
the switch point has been reached. The relays will respond after the elapsed Time Delay on both energize and de-
energize actions.

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5. TROUBLESHOOTING

5.1 “Out-of-Calibration” Indication

An “Out-of-Calibration” Indication does not mean the KCAP300 will not operate.

The KCAP300 uses its 3 element probe design and the KSHIELD™ software to operate in the presence of buildup.
When the switch is installed it will be clean and free from buildup. When the switch is calibrated the reference ca-
pacitance and the setpoint capacitance are stored in the memory of the device. As deposits settle on the probe cre-
ating a buildup, the reference capacitance from the shield element will cause the reference to shift accordingly. De-
spite the shift in reference the sensed capacitance may still be affected.

To identify the presence of excessive buildup, an “Out-of-Calibration” Indication has been added to the software.
For an “Out-of-Calibration” to occur one of two scenarios must take place.

1. The level of sensed capacitance is rising close to the switch point but does not surpass it. The sensed
level remains close to the switch point for 25 minutes.

2. The level of sensed capacitance is falling towards the reset point but does not surpass it. The sensed
level remains close to the reset point for 25 minutes.

An “Out-of-Calibration” Indication will occur when the probe is covered with buildup but the measured product is
actually below the switch. To resolve the situation, recalibrate the switch using the procedure in Section 4.4 or
remove the switch, clean off the excessive buildup, and reinstall the switch.

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5.2 Symptoms and Remedies

Any failure of the KCAP300 can be defined as a negative reaction to an action. Each failure will have certain symp-
toms, which can direct the user to a possible cause and eventual remedy.

SYMPTOMS POSSIBLE CAUSE REMEDY

KCAP300 does not detect Bad ground connection. Ensure correct grounding of
material. the device.
Sensitivity set too low. Refer to Section 4.6 to
increase sensitivity.
Damaged electronics. Replace electronics module
and recalibrate.
Unstable relay action. Bad ground connection. Ensure correct grounding of
the device.

Sensitivity set too high for Refer to Section 4.6 to

high dielectric. decrease sensitivity.
Radio frequency interfer- Ensure housing cover is
ence. completely screwed into
housing.
Ensure proper grounding of
the device.
Agitation or waves in liquid. Refer to Section 4.7 to
increase Time Delay.

Modify or change mounting to

eliminate effects of fluid
motion.
Lack of available power to Ensure proper input voltage
switch. and wattage. (Section 2.2).
Damaged electronics. Replace electronics module
and recalibrate.
LED2 is blinking Red. “Out of Calibration” Recalibrate the setpoint.
indication. (Section 5.1) Section 4.4
Ensure correct grounding of
the device.
Check for excessive buildup
on the probe.

Check the level in the vessel

to ensure calibration is
necessary.
Damaged electronics. Replace electronics module
and recalibrate.

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5.3 Warranty Statement
5 YEAR WARRANTY FOR:
KM26 Magnetic Liquid Level Gauges, Buoyancy Level Switches (LS20, MS50, MS10 & MS8), Magnetic Level Switches (MS30, MS21, MS40,
MS41, PS35 & PS45), EC External Chambers and ST95 Seal Pots.

3 YEAR WARRANTY FOR:

KCAP300 & KCAP 400 capacitance switches.

2 YEAR WARRANTY FOR:

AT100 and AT200 series transmitters; VF20 and VF30 vibrating fork switches; RLT100 and RLT200 reed switch level transmitters; TX, TS, TQ,
IX and IM thermal dispersion switches; MT2000 radar level transmitters; KP paddle switches; A02, A75 & A77 RF capacitance level switches and
A38 RF capacitance level transmitters.

1 YEAR WARRANTY FOR:

KM50 gauging device; AT500 and AT600 series transmitters; LaserM and SureShot series laser transmitters; LPM 100 and 200 series digital
indicators; DPM100 digital indicators; APM100 analog indicators; KVIEW series digital indicators and controllers; SF50 and SF60 vibrating fork
switches, KB Electro-Mechanical Continuous Measuring Devices, KSONIK ultrasonic level switches, transmitters & transducers.

SPECIAL WARRANTY CONSIDERATIONS:

ABB will honor OEM warranties for items not manufactured by ABB (i.e. Palm Pilots).

ABB will repair or replace, at ABB’s election, defective items which are returned to ABB by the original purchaser within the period specified above
from the shipment date of the item and which is found, upon examination by ABB, 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. ABB’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 ABB and request a Returned Material Authorization before returning the
material to ABB, 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 ABB for best-way transportation only. ABB is not responsible for expedited shipping charges. If the product is shipped to ABB freight
collect, then it will be returned to the customer freight collect.

If inspection by ABB does not disclose any defects in material or workmanship, ABB’s normal charges for repair and shipment shall apply
(minimum 100.00 USD).

The materials of construction for all ABB 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 ABB'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 ABB ANY OTHER LIABILITY IN CONNECTION WITH THE SALE OF ABB’S PRODUCTS. THE
REMEDIES SET FORTH IN THIS WARRANTY ARE EXCLUSIVE OF ALL OTHER REMEDIES AGAINST ABB. ABB SHALL NOT BE LIABLE
FOR ANY CONSEQUENTIAL, INCIDENTAL, OR SPECIAL DAMAGES OF ANY KIND. ABB’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
ABB.

5.4 Company Information

For advanced troubleshooting information or repairs, contact the ABB Factory:

Service Department
17100 Manchac Park Lane - Suite B
Baton Rouge, LA 70817 USA
Phone: +1 225 408 0800
Service: +1 225 408 0898
Service e-mail: service@us.abb.com

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Contact us

07.2017
ABB Inc. Note
We reserve the right to make technical changes or
Industrial Automation modify the contents of this document without prior
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OI/KCAP300-EN Rev. E
notice. With regard to purchase orders, the agreed
Warminster, PA 18974 USA particulars shall prevail. ABB does not accept any
responsibility whatsoever for potential errors or
Tel: +1 215 674 6000
possible lack of information in this document.
Fax: +1 215 674 7183
We reserve all rights in this document and in the
ABB Inc. subject matter and illustrations contained therein.
Any reproduction, disclosure to third parties or
17100 Manchac Park Lane - Suite B
utilization of its contents - in whole or in parts – is
Baton Rouge, LA 70817 USA forbidden without prior written consent of ABB.
Phone: +1 225 408 0800
Service: +1 225 408 0898 Copyright© 2017 ABB
All rights reserved
Fax: +1 225 408 0897
Service e-mail: service@us.abb.com

ABB Engineering (Shanghai) Ltd.

No. 4528, KangXin Hwy.
Pudong New District
Shanghai, 201319, P.R. China
Phone: +86 10 64231407
Service: +86 21 61056421
Fax: +86 10 64371913
E-mail: norman-suijun.xia@cn.abb.com
Service e-mail: rola.li@cn.abb.com

www.abb.com/level

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