NIVELCO PiloTREK 2-wire Montageanleitung

PiloTREK 2-wire

Non-contact radar level transmitter

Non-contact radar level transmitterNon-contact radar level transmitter

Non-contact radar level transmitter

INSTALLATION

and

PROGRAMMING MANUAL

Manufacturer:

NIVELCO Control Co.

H-1043 Budapest, Dugonics u. 11.

Tel.: (36-1)-369-7575 Fax: (36-1)-369-8585

E-mail:sales@nivelco.com http://www.nivelco.com

2 Installation andprogramming manual PiloTREK 2-wire

TABLE OF CONTENS

1 Introduction………………………………………………………………………………………………………………………..2

1.1 Measurement principle……………………………………………………………………………………………………… 3

1.2 Product liability and warranty………………………………………………………………………………………………. 3

2 Handling and storage…………………………………………………………………………………………………………….3

3 Items included with supply……………………………………………………………………………………..……………….3

4 Order codes……………………………………………………………………………………..…………………………………3

5 Installation………………………………………………………………………………………………………………………… 4

5.1 Field assembly………………………………………………………………………………………………………………. 4

5.2 Mechanical installation……………………………………………………………………………………………………… 5

6 Electrical connection…………………………………………………………………………………………………………….7

7 Setting the parameters…………………………………………………………………………………………………………..8

8 Maintenance, error handling…………………………………………………………………………………………………..17

9 Safety information……………………………………………………………………………………………………………….18

10 Technical data……………………………………………………………………………………………………………………19

11 PiloTREK 2-WIRE signal converter and flange system marking codes……………………………………………….20

12 Conversion of Order Code to Converter- and Flange Code…………………………………………………………… 23

13 Parameter check list…………………………………………………………………………………………………………… 24

Installation and programming manual PiloTREK 2-wire 3

1. INTRODUCTION

1.1 MEASUREMENT PRINCIPLE

FMCW: Frequency Modulated Continuous Wave

The FMCW-radar uses a high frequency signal ~ 10 GHz.

The frequency of the signal is increased linearly by 1 GHz

during the measurement cycle (frequency sweep) The signal is

emitted via an antenna and reflected by the measuring surface

and received time-delayed. The received signal is frequency

shifted. The difference of frequencys ∆f is calculated from the

mixed time signal of the actual transmit frequency and the

received frequency. The difference is directly proportional to the

distance i.e. a large frequency difference correspond to a large

distance and vice versa.

The frequency difference is transformed via a Fourier transformation (FFT) into a frequency spectrum and then the distance

is calculated from the spectrum.The level results from the difference between tank height and distance.

1.2 PRODUCT LIABILITY AND WARRANTY:

The PiloTREK 2-WIRE level gauge is designed solely for measuring the level, distance, volume and reflection of liquids,

pastes, slurries, particulate materials and solids.

The PiloTREK 2-WIRE level gauge does not form part of an overfill protection system as defined in the WHG (German

water pollution regulation).

Local codes and regulations apply to its use in hazardous areas.

Responsibility as to suitability and intended use of these level gauges rests solely with the user.

Improper installation and operation of our level gauges may lead to loss of warranty.

In addition, the "General conditions of sale", form the basis of the purchasing contract.

If you need to return the level gauge to the manufacturer or supplier, please refer to the information given in Section

“Maintenance, error handling”

2. HANDLING AND STORAGE

SAFETY ADVICE

Depending on the version, the device will weigh between approx. 5 kg and 30 kg. To carry, use both hands to

lift the device carefully by the converter housing. If necessary, use lifting gear.

When handling the PiloTREK 2-WIRE, avoid hard blows, jolts, impact, etc.

When storing the "Wave-Stick" version, make sure that the device is not placed on its side on the PTFE antenna, as this may

cause the rod to bend.

3. ITEMS INCLUDED WITH SUPPLY

The scope of supply includes, in the version as ordered:

Signal converter bolted to wave-guide window and antenna;

optionally: antenna extension, sunshade (with fastening material in each case)

Shielding material with tightening strap for instruments with flange (not for the US market)

Installation and programming manual

Certification and approval documents, unless reproduced in the device documentation

Installation material (stud bolts, flange gasket and cabling) not supplied, to be provided by customer!

∆f

Time signal

Spectrum

4 Installation andprogramming manual PiloTREK 2-wire

4. ORDER CODES

5. INSTALLATION

Most of the PiloTREK 2-WIRE versions are supplied in fully assembled condition. In this case, you may skip this chapter.

However, if a device should be delivered in parts, or parts are subsequently replaced, the following should be noted.

5.1 FIELD ASSEMBLY

For any necessary field assembly of the

PiloTREK 2-WIRE, all parts are included with the

supply (stud bolts, washers, etc.).

Bolt the wave-guide window (flange mount) or

distance piece, if supplied loose, to the PiloTREK 2-

WIRE. Torque for the sets of 4 Allen screws M

(key size 5 mm): max. 8 Nm ∼0.8 kpm (5.8 ft lbf).

Note: Ensure the upper Teflon plug is kept absolutely

dry and clean! Moisture and dirt will impair

functionability of the PiloTREK 2-WIRE!

Bolt antenna extension to the antenna; torque for

the 3 stud bolts A: max. 8 Nm ∼0,8 kpm (5.8 ft lbf).

Do not detach bolts H !

distance piece (for

high-temperature version

up to 250°C (482 °F)

upper Teflon plug

O-ring

lower Teflon plug

O-ring

BM70 A

connecting flange

antenna extension

antenna

signal converter

Installation and programming manual PiloTREK 2-wire 5

Flange system versions:

Flange

Stick plating

Stick

Gasket Gasket

Horn

antenna

Separation

(Metaglass)

Wave-Stick Wave-Stick

(PP or PTFE)

Flange system 96

with horn antenna

LP flange system

max. 2 bar

distance piece

(optional)

High temperature

plate Horn

antenna

Flange

(for Hastelloy,Ti, Ta)

PTFE w/o plate with horn antenna

PiloTREK

converter

5.2 MECHANICAL INSTALLATION

Hazardous-duty systems:

•The PiloTREK 2-WIRE Ex is certified in conformity with European Standard for use in Zone 0, 1 and 2

hazardous locations (dependent on version).

•Attention is drawn to the data and information given on the nameplate of the converter, the nameplate

of the flange and the specifications in the approval certificates.

Safety:

•Check material compatibility of antenna, extension, flange, gaskets, and PP or PTFE

(used in all versions) with the product! See also section 8 "Type code"!

Mounting on the tanknozzle

a) Devices with horn antenna:

The antenna should project out of the nozzle. If necessary, use an antenna extension. Exception: in case of a symmetrical

tank fitting.

Tank nozzle Tank nozzle Antenna

extension

Tank nozzle

„L”

Horn antenna

max. 2 bar

„V”

Horn antenna

„W”

Wave-Stick

antenna

with plate

PTFE

„W”

Wave-Stick

antenna

w/o plate

PP or PTFE

max. 2 bar

6 Installation andprogramming manual PiloTREK 2-wire

b) Wave-Stick

Note the requirements imposed on nozzle diameter and nozzle length:

min. 50 mm

min. 200 mm

Tank nozzle

e.g. DN50

dia. 40...55 mm

Version for

still wells

c) Purging device

Remove screw plug ¼" R and screw in screwed tube joint, e.g.

Ermeto ¼" R.

Consult “Ex“ specifications relating to the purging circuit

(provided by customer)!

Installationon the tank

Do not forget the gasket when positioning the

PiloTREK 2-WIRE on the tank nozzle flange. Align PiloTREK 2-

WIRE and gasket, slightly tighten nuts on stud bolts (by hand).

Press shielding strip C* in the gap between tank and

PiloTREK 2-WIRE flanges and secure with strap retainer S*

(both items included with supply).

Strap retainer S* must fit closely and overlap both flanges.

only required for European radio approvals

Tighten down stud bolt nuts firmly. The tightening torque is

dependent upon the strength properties of the stud bolts and

the pressure rating of the tank

C* = shielding strip B = PiloTREK 2-WIRE flange

S* = strap retainer F = tank flange

short (60 mm)

antenna

for still wells only

Installation and programming manual PiloTREK 2-wire 7

Positioning on the tank

>1/7×H, but max. 1/3×D H

Recommended distance Do not position in Do not position

from the tank wall tank centerline! above internals!

(multiple reflections!) (interference reflections!)

A Stilling Well or Wave-Guide may be mounted in any position on the tank!

When using the PTFE Wave-Stick in hazardous areas of Zone 0, any electrostatic charging of the stick, e.g.

by flow of product, must be avoided!

6. ELECTRICAL CONNECTION

To open the signal converter, please use a screwdriver and release the four visible screws on top of the blue housing.

Terminal assignment of PiloTREK 2-WIRE

The polarity of the 4-20 mA connection is arbitrary.

Equipotential bonding

When used in hazardous areas, the PiloTREK 2-WIRE Ex can be incorporated in the PA equipotential bonding system,

e.g. by using the separate U-clamp terminal at the “neck“ of the PiloTREK 2-WIRE Ex.

Rated temperature of connecting cables: see Section 8.

Supply voltage atthe terminals (1,2)

The 4-20 mA supply must be able to provide the following voltage U at the terminals of the PiloTREK 2-WIRE – dependent

on the current I. Please consider also the line resistance and possible loads on the secondary side of the supply unit.

PE 4-20 mA

current

loop

8 Installation and programming manual PiloTREK 2-wire

4mA 12mA8mA 16mA 20mA

3.6mA 22mA I

13V

14V

15V

16V

17V

The allowed upper limit R for load + line resistance is depending on the specification of the power supply unit:

U at 20mA (power supply unit) 14 V 15 V 16 V 17 V 18 V

Max. resistance R 50 Ω100 Ω150 Ω200 Ω250 Ω

7. SETTING THE PARAMETERS

Setting parameters via program PC-CAT

With the program PC-CAT, version 3.01 or higher, you can configurate PiloTREK 2-WIRE instruments in a very comfortable

way from a PC. Connect the non-intrinsically safe side of the isolation amplifier over a load between 120 Ωand 350 Ωto the

HART®adapter and connect it with a serial port of the PC.

The used isolation amplifier must be HART®compatible.

Adapter

≥120 Ω

RS232

isolation

amplifier

Installation and programming manual PiloTREK 2-wire 9

Localdisplay (optional)

(1) Numeric display, measured values

(2) Alphanumeric display, function/unit

(3) 6 Markers to display measurement status

(4) 4 keys for configuration and error interrogation

Function of keys (only together with local display)

Operator control can be carried out with the aid of local display unit after opening the housing. However, a particularly

convenient form of parameter setting is offered by the PC program PC-CAT (special accessories, see above).

→

→→

→

(cursorkey) - selects the configuration menu,

- branches the menu to the next lower level,

- shifts the cursor* to the next column on the right.

↑

↑↑

↑

resp.

↓

↓↓

↓

(select key) - branches the menu to the next digit on the same level,

- changes the content (digit, text character) at the cursor* position.

↵

↵↵

↵

(ENTER key) - branches the menu to the next higher level,

- stores newly entered parameters,

- executes displayed functions,

- selects special functions (e.g. error memory, see Section 5).

* The cursor position is signalled by flashing of the character at the appropriate place.

Meaning of status markers (only for version with local display)

The 6 markers ▼below the local display only show information about the status of measurement and are no error displays!

▼1: No current measured value: The device is searching for a new value. If the search for a plausible level fails for a

certain time, "SIGNAL DOWN" appears as error display.

▼2: Signal too strong: Mean of reflected microwaves is very high. Gain is automatically stepped down.

▼3: Poor spectrum: Brief showing of this marker has no significance. If permanently on, this may result in uncertain

(incorrect) measured values or the error message "NO M.VALUE".

▼4: No measured value as yet: Evaluable measured values not available after the device has been started up.

Measured value automatically set to the level of the tank bottom. This marker disappears when the first valid

measured value is obtained.

▼5: Tank bottom: In tanks with dished bottom, for example, the measuring signal can "disappear" if measurements are

carried out near the bottom. The measured value is then automatically set to the level of the tank bottom.

▼6: Measurement frozen: Device is in the block distance detection (see below).

nivelco

PiloTREK

Level m

9.500

_ _ _ _ _ _

10 Installation andprogramming manual PiloTREK 2-wire

Simply scaling the currentoutput

1) Drain the tank completely to the 0% marking (= 4 mA) 1).

2) Press the lower keys (↵and ↓) down, until the asterisks on the

display „TANKHEIGHT********“ are replaced by the actual measured

distance value 2).

3) Then release and press ↵. In the lower line: „SURE NO?“ is

displayed.

4) If this value is not plausible or the tank is not empty, abort

by ↵. Or accept the value by pressing ↑(“SURE YES?”) and then

↵.

5) Now the tank height is set.

6) In the next step you can also enter this value as 4 mA scaling (0%).

Press ↵. In the lower line now: „SURE NO?“ is displayed again.

7) If this value shall not be stored, abort by ↵. Or accept this 4mA

scaling by pressing ↑(“SURE YES?”) and then ↵.

8) Fill the tank to the 100% mark. Use the same procedure for the

100% point = 20 mA only now by pressing the top keys →and ↑1) 2).

9) First the measured distance can be taken as block distance.

After this you can enter or adjust the 20 mA point (100%)

according to the actual level.

1) This example was written for the case: current output = level (default).

For distance measurement the points 0% (short distance = high level) and 100% (large distance = low level)

are exchanged

2) If no reliable measurement is possible „NO ACCESS“ is displayed. Abort by pressing ↵

TANKHEIGHT

1234 mm

↵

TANKHEIGHT

1234 mm

SURE YES? 1.

100%

BLOCKDIST.

567 mm

↵

TANKHEIGHT

1234 mm

SURE NO?

SCALE 4mA

0 mm

SURE NO?

SCALE 4MA

0 mm

SURE YES? 1.

SCALE 4mA

0 mm

↵

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