© KROHNE 03/2004 7.02267.22.00 GR Handbook BM 102 MICROFLEX T D R Level gauge 2-WIRE Variable area flowmeters Vortex flowmeters Flow controllers Electromagnetic flowmeters Ultrasonic flowmeters Mass flowmeters Level measuring instruments Communications technology Engineering systems & solutions Switches, counters, displays and recorders Heat metering Pressure and temperature Subject to change without notice.
Table of contents Device description and range of applications ……………………………………………………….. 4 Principal gauge components ……………………..………………………………………………….…. 4 Items included with supply …………………………………………………..…………………….……. 6 Documentation supplied …………………………………………………..……………………….……. 6 Product liability and warranty ………………………….………………………………………….……. 6 1 1.1 1.2 1.3 1.3.1 1.3.2 1.3.3 1.3.4 1.3.5 Mechanical installation........................................................................................................
5 5.1 5.1.1 5.1.2 5.2 5.2.1 5.2.2 5.2.3 5.3 Technical data .....................................................................................................................63 Technical data ......................................................................................................................63 Accuracy ...............................................................................................................................65 Start-up characteristics ................................
Device description and range of applications The BM 102 MICROFLEX level gauge uses the Time Domain Reflectometry (TDR) measuring principle and two-wire technology for level measurement. It is designed solely for measuring the distance, level, volume and ullage of liquids, pastes, slurries and powder products. It can continue to measure the level or distance and total volume in applications with two products.
Standard nameplate *eg. VF030415B0112110110100000. The “type code” gives the options chosen for this unit and is defined in the BM 102 Data Sheet. This document is available from your local KROHNE Sales office or on the “Download Centre” on KROHNE’s website http://www.krohne.com/.
Items included with supply: The scope of supply encompasses: • Signal converter with probe in the version ordered. The version is stated on the nameplate. • PCSTAR 2 computer software for data display and gauge configuration. Documentation supplied: Installation & Operating instructions: Installation, connection, start-up and safety advice in condensed form, but sufficient for most applications. This is supplied as a printed document with the device delivered.
1 Mechanical installation 1.1 Handling and storage To carry: the device will weigh between 3 kg or 7 lb and 12 kg or 25 lb. Carry using both hands to lift the device carefully by the converter housing. If necessary, use lifting gear. No attempt should be made to lift the instrument by its probe. Caution: The probe is a critical gauge component. Do not damage– Handle with care!!! Avoiding blows When handling the BM 102, avoid hard blows, jolts, impacts, etc.
Avoid cable kinks and fraying Do not coil the cable less than 400 mm or 16 “ in diameter. Cable kinks or fraying will cause measurement errors. Storage temperature Store within the given storage temperature limits. 1.2 Installation restrictions Hazardous-duty systems (Ex, FM,…) • Refer to the BM 102 MICROFLEX KEMA 00 ATEX 1101X Supplementary Installation and Operating Instructions for further information on installing gauges approved for use in hazardous locations.
1.3.2 Installation instructions: nozzle Threaded process connections Nozzle height Recommendation Do not fit a nozzle longer than its diameter , especially for single probes and powder applications The simplest and most economic way is to mount the BM 102 directly on the tank with a GAS or NPT threaded connection. h ≤ Ød , where h = nozzle height and d = nozzle diameter Contact KROHNE if this relationship cannot be respected.
Installation of two devices If two devices are to be used on the same tank, these should be mounted at a distance of at least 2 m or 6 ¾ ft away from each other. If not, interferences from the electromagnetic (EM) fields generated by both instruments may cause measurement errors. Not applicable to coaxial probes - the outer shell of the probe contains the EM field: no minimum distance required. Process connection For the gauge to make accurate measurements: • The tank process connection must be level.
Stilling wells Tanks with floating roofs for petro-chemical applications: use a stilling well. 1 Stilling well 2 Tank 3 Floating roof 4 Product (petroleum applications) 5 Well fixed to tank base (no roof deformation) 6 Sediment 1.3.3 Installation instructions: Gauge - all applications BM102 gauges are designed to be mounted on a suitable process connection on a tank or sump. Install the gauge using two people to avoid damaging the probe. Support the housing and the probe.
Probes: entanglement, straightness and tank bottom clearance Rigid section length of single and twin cable probes Cable diameter Rigid section length Single cable Ø4mm or 0.15” 40mm or 1½” Ø8mm or 0.15” 200mm or 8” Twin cable Ø4mm or 0.15” 40mm or 1½” • • Cable probes must be straight once inserted into the tank. They must also be far from other objects (e.g. mixers) to avoid entanglement.
1 Agitator 2 Support beam perpendicular to the pulse direction 3 Abrupt changes in tank cross section 4 Heating tubes 5 Alternative solution: reference chamber -electromagnetic field is contained within chamber 6 Gauge electromagnetic field: Any intruding metallic object will be detected in this zone if perpendicular to the emitted pulse direction. = Do not fit the gauge near to these objects.
Avoid direct solar radiation Fit a sunshade on the gauge for open-air installations: this is either supplied on demand by KROHNE or provided by the customer. The ambient temperature limits of the gauge are given below. 1.3.
Fastening the probe to the tank bottom Flexible probes can be fastened with a chuck (ring), turnbuckle or similar fastening device to the tank bottom: Chuck (ring) Turnbuckle for Ø8 mm cable probes Turnbuckle for Ø4 mm cable probes Shortening cable probes If required, the cable probe can be shortened, but this applies only when used in liquids. Procedure Step Action 1 Detach socket set screw M6x10 (ISO 4026) with a 3mm Allen (hexagon) key (ISO 2936).
1.3.5 Specific installation instructions: gauge - solid applications False readings: 1 Do not let probe touch the side of the nozzle Conical silo nozzles, false readings and traction on the cable probes Caution 2 High traction forces : We recommend that the probe should not be anchored to avoid excessive traction loads on the cable. 3 Bending and traction: Position the connection on the roof at ½ radius of the tank and with minimum nozzle height.
Electro static discharge (E.S.D.) BM 102 non-Ex and Ex gauge electronics are shielded up to 4kV against E.S.D.. Note: E.S.D. cannot be solved by BM102 E.S.D. protection. It is the customer’s responsibility to avoid E.S.D. by grounding the tank, product and probe installation. 1 Danger of injury 2 The probe may receive an electrostatic discharge during operation; earth the probe by pushing it against tank wall with a suitably isolated tool just before touching it to avoid receiving a shock.
2 Electrical connections 2.1 Electrical installation instructions 2.1.1 Wiring general notes Connection to power is effected at the plug connector in the signal converter. Two wiring compartments are available: DIN connector or M16 terminal box. Observe applicable rules and regulations for cable connection: VDE 165 or equivalent national regulations. Always disconnect from power supply before opening wiring compartment. This is not mandatory for Exi applications.
2.1.3 Wiring connections: M16 terminal box Power terminals: Cable entry: Shielding: Wire cross-section: max. 1.5 mm² (AWG 16) 1 x M16 x 1.5, cable diameter: 3.5 … 8 mm (0.14 … 0.31”), IP 65 for USA: ½” NPT conduit connection Do not connect shielding to the terminal compartment. Hazardous-duty systems When used in hazardous areas, only one intrinsically safe power supply may be connected to terminals 1 and 2. Ground terminal E is not connected.
2.2 Power Supply 2.2.1 Non-hazardous-duty version Power supply Rated voltage Max. voltage (Uinput): Min. voltage (Uinput): 24 V DC 35 V DC ’Ex’ = 28 V DC dependent on load impedance, see graph below A supply voltage above 35 V DC can cause irreparable damage to the signal converter. Also, power supply voltages above the specified max. values and below the specified min. values can lead to faulty measurements or to a device reset. Load impedance Rloop Loop resistance, Rloop Min. Rloop Max.
Example for calculating the power supply: The voltage drop is tested at 22 mA. U power min. 22 = 22 mA x load impedance + Uinput min. 22 U power min. 22 = 22 mA x 250 ohms + 10 V = 5.5 V + 10 V = 15.5 V In order to cover the whole current range, the voltage drop must also be tested at 4 mA. By analogy, the following applies: U power min. 4 = 4 mA x load impedance + Uinput min. 4 U power min.
2.3 Electrical output 2.3.1 Network options The output is available in 2 versions: 1. 2. Current output HART®, Current output Ex-ia HART® passive, HART® protocol intrinsically safe; passive, HART® protocol All versions with HART® protocol can be operated with the PC-STAR 2 program. ® 2.3.2 HART communication protocol In accordance with the Rosemount Standard, HART® communication can be used with a BM 102. It is used as a point-to-point connection between the BM 102 as slave and the HART® master.
3 User interface 3.1 Power-on and start-up The BM 102 is pre-configured in accordance to customer order specifications and measurements can be made immediately. A start-up time of less than 23 seconds should be allowed for once connected and the power is switched on. If the probe length has been shortened since delivery, please refer to section 3.3.1: Summary of User Functions, user function 1.1.6: Probe length to modify configured probe length. 3.
Installing and connecting PCSTAR 2 to the gauge 1. Connect the HART® adapter (not included in supply) through a load impedance of 350 ohms maximum (for hazardous-duty purposes, fix to the non-intrinsically safe side of the repeater power supply unit) and plug it into a serial interface on your PC. The repeater power supply unit must have HART® capability. 2. Installing the program: Access the files on the floppy disk supplied with the instrument and execute the file "setup.
4. Define device interface: type F4 or left-click on “F4-Serial” at the bottom of the screen - to define the interface to which the device is to be connected. Serial Port BM102 Address Device Identifier Initial baud rate RTS state 5. The serial port allows the user to select a free serial port (COM 1 to 4) on the computer. Type the “Address” that you have given a gauge (a value between 0 and 15) and press ENTER or OK. This will select the required device.
6. • • • • • • • After the connection has been established, the following screen is shown. This will show the current status of the tank. No further configuration should be necessary. The following functions are available on the screen and will be discussed further in section 8.
3.3.2 Summary of User Functions in PCSTAR 2 (F2 – Configuration) The table below provides an overview of all parameters that can be set in the configuration menu using F2 in PCSTAR2. Reset default values are in bold type in the “Input Range” column. Function 1.0.0 Operation 1.1.0 Basic parameters 1.1.1 Tank height Input Range Description Enter 0 … 60 m or 0 … 197 ft. As per order 1.1.2 Dead zone Enter a value Fct.1.5.1(Detection delay) … probe length. • Twin probe with probe length<1m or 3.3 ft 0.
Function 1.1.6 Probe length 28 Input Range Enter 0.1 m or 3.9” … probe length (max.: 24000 mm or 78¾ ft.) As per order BM 102 Description This value must be equal to the exact length of the probe. This value should be modified when the probe has been replaced or shortened (cable probes). The output unit is set via Fct. 1.2.4 Length Unit. An automatic search for the probe tip can be carried out when the tank is empty to update the parameter using the function F11 in the “Dynamic Configuration” menu.
Function 1.2.0 Display Input Range 1.2.4 Length unit Select m, cm, mm, inch, ft or optional unit* mm 1.2.5 Volume unit Select m³, l, US Gal, ft³, bbl, m³/h, ft³/h, kg, metric tonnes or tons US m³ 1.2.6 New unit (length) 1.2.6.1 Unit name 1.2.6.2 Unit fact. 4 ASCII characters Unit Min.: > 0.0 Max.: 100 000 1.0 Description To display readings in the form and units required Unit for display of level and distance. *When “optional unit” selected, you get to the menu item Fct. 1.2.
Function 1.3.0 Current output I Input Range 1.3.1 Current 1 item Select Off, Level, Distance, Volume* or Ullage volume* Level Select 4-20mA or 420mA + 22 mA on error. 4-20mA 1.3.2 Current 1 range 1.3.3 Scale I1 min. 1.3.4 Scale I1 max. 1.3.5 Error delay Enter a value from 0 mm** to a value lower than that entered for Fct. 1.3.4 Scale I max. As per order Enter value higher than the value selected under Fct. 1.3.3. “Scale I min.
Function 1.4.0 User data 1.4.3 Checksum Input Range Description Read only 1.4.4 Device number** (Tag number) 00000 01 1.4.5 Serial number Read only 1.4.6 French command number Read only 1.4.7 German command number Read only This value is used for identification of the device software version. The checksum is tested when starting. This helps to detect any problems with the microcontroller. This parameter assigns an identification number to the device. A text consisting of max.
Function 1.5.0 Application 1.5.1 Detection delay Input Range Enter a value 0 mm / 0 in. to Fct. 1.1.2 Dead zone As per order 1.6.0 Serial I/O (serial input/output) 1.6.2 Address 1.7.0 Volume table 1.7.2. Input table 32 Addresses from 0 to 15 0 Select point 01 to 20, enter level and then volume values respectively.
3.3.3 Quick Configuration: configuration examples The minimum functions (fct.) to be configured for a simple measurement are listed below: Functions PCSTAR 2 1.1.1 1.1.2 1.3.1 … 4 1.7.0 ® HART 2.1.1.1 2.1.1.4 2.1.3.1 … 4 2.1.7.0 Definition Tank Height Dead zone Current Output Volume table* *For volume measurements Example procedures for each set of functions are given on the following pages.
® Tank height: configuration of user menu PCSTAR 2 function 1.1.1 (HART Fct. 2.1.1.1) This function is usually either defined as true tank height or as factory configured probe length, L1 (see diagram on preceding page) if the former is not supplied by the customer in the order. Why change the tank height? • • ® setting the distance in PCSTAR 2 Fct 1.1.1 (HART Fct. 2.1.1.1) to L1 avoids having a nonmeasurable zone underneath the probe where the measurement on the display freezes.
® Dead zone: configuration of user menu PCSTAR 2 function 1.1.2 (HART Fct. 2.1.1.4) The top dead zone is the minimum measuring distance between the gauge flange facing (the reference point) and the product. The various probes for the BM 102 have differing top dead zones and these are given in section 5.2.3: Probe measurement limits. Why is configuration of the dead zone important? The gauge will not display measurements taken here – the reading is blocked on reaching this zone.
How to set an analogue current output scale User menu functions 1.3.1 to 1.3.4 This set of functions allows users to set up a scale. The minimum (4mA) and maximum (20mA) values of an analogue current output should ideally lie within the device’s active measuring zone, as the device will freeze when the signal is lost. Refer to the measurement limits table for each probe type in the introduction. Refer also to the start of section 3.3.3 for the advantages of changing tank height.
How to configure the gauge to give volume readings ® User menu PCSTAR 2 function 1.7.2 (HART submenu 2.1.7) • • • • To be able to measure the volume, a conversion table (strapping table) will need to be created using the PCSTAR 2 program or the HART® communicator. The strapping table assigns defined volumes to the various levels. In the case of non-symmetrical tanks, e.g. tanks with dished bottom, the accuracy of volumetric measurement will depend on the number of entered “level/volume pairs”.
Supplementary procedure for setting the 4 … 20 mA current to output volume readings (using PCSTAR 2) Step 1 2 3 4 5 6 Action Go to user function 1.3.1 ”Current 1 item” to select measurement function. Go to user function 1.3.2 ”Current 1 range” to set fault status Go to user function 1.3.3 “Scale I1 min” to enter volume value for the minimum output (4 mA) Go to user function 1.3.
Wiring, standard (non-Ex) Caution Refer to the HHC manual for wiring instructions when in an explosive atmosphere. Displaying readings Use the UP and DOWN arrows to move to the correct line and then select with the RIGHT Arrow. 1 HART Communicator 1 Offline 2 → Online 3 Frequency Device 4 Utility F1 3 F2 F3 Main menu 2 BM102:00000 01 Online 1 → 2
® Configuration: summary of user functions via HART Communicator HC 275 Reset default values are in bold type in the “Input Range” column. Refer to the HART® HC275 Communicator operating instructions for further operating details. Function (Fct.) 1.0 PROCESS VAR. 1.1.0 MEASUREMENTS 1.1.1 LEVEL 1.1.2 DISTANCE 1.1.3 VOLUME 1.1.4 ULLAGE VOLUME 1.2.0 1.2.1 INPUTS/OUTPUTS FUNCTION I 1.2.2 1.2.3 I % 40 Input Range Description Level value. Distance value. Volume value if a strapping table is programmed.
Function (Fct.) 2.0 CONFIG./TEST 2.1.0 OPERATION 2.1.1.0 BASIS PARAMETER 2.1.1.1 TANK HEIGHT Input Range Description Enter 0 up to 60000 mm or 2362” As per order 2.1.1.2 PROBE LENGTH Enter 0 mm up to < 24000 mm or 1063” As per order Tank height. The tank height is defined as the distance between the bottom of the tank and the lower flange surface. This value has to be equal to the exact length of the probe. The only situation for changing this value is if the probe length has been changed. 2.1.1.
Function (Fct.) 2.1.2.1.3.0 DEFINE NEW UNIT 2.1.2.1.3.1 UNIT NAME Input Range Description 4 ASCII characters “unit” 2.1.2.1.3.2 UNIT FACTOR Enter 0.0 to 100000 1.0 Optional unit name. User has to enter the unit name before using it in the menu “LENGTH UNIT”. Optional unit factor. User has to enter the Unit Factor before using it in the menu “LENGTH UNIT”. With a factor 1.0, the unit is equivalent to one millimeter. With a factor 1000.0, the unit is equivalent to one meter. 2.1.2.2.0 VOLUME 2.1.2.2.
Function (Fct.) 2.1.4.0 USER DATA 2.1.4.1 TAG 2.1.4.2 SERIAL NUMBER Input Range Description 00000 01 Tag number of device. Read only menu. Each device has its own serial number. Read only menu. This number is factory set. Refer to this number in case of warranty or service claims. Read only menu. This number is factory set. Refer to this number in case of warranty or service claims. Read only menu. Release number of the device (Software and Hardware version). Read only menu.
Function (Fct.) 2.1.5.0 APPLICATION 2.1.5.1.0 THRESHOLD 2.1.5.1.1 LEV. PULSE AMP. Input Range Description Read only value. 2.1.5.1.2 LEV. PULSE GAIN Read only value. 2.1.5.1. THRESHOLD Enter a value from 50mV to 25000mV 500 mV G3 at 1 m 2.1.5.2 DISTANCE INPUT Enter a value from Fct. 2.1.1.4: Dead zone to fct. 2.1.1.2: Probe length Dynamic value. Amplitude of level pulse in millivolts. Dynamic value. Amplification of level pulse (gain 0, 1, 2, or 3). Threshold of the level pulse (in millivolts).
Function (Fct.) 2.2.0 TESTS 2.2.1 TEST OUTPUT 2.3.0 SERVICE 3.0 3.1 ACCESS RIGHTS MAINTENANCE PSW 3.2 SPECIALIST PSW 4.0 WATCH STATUS 5.0 5.1 HART VARIABLES MANUFACTURER Input Range Description Select 4 mA, 20 mA, Other This function allows the current output to be tested. The output can be set to one of the listed values. With a reference ammeter, the calibration of the current output can be verified. Restricted access factory configuration menu. These parameters may be accessed via Fct. 3.
3.3.5 Characters available for alpha-numerical data functions in PC STAR 2 and on the ® HART console This concerns the following functions: PCSTAR 2 fct. 12.6.1: Unit name, fct. 1.4.4: Device number, fct. 1.4.8: Option ® HART console (HHC) fct. 5.7 Message, fct. 5.8 Descriptor, fct. 5.11 Tag @ A B C D E F G 46 H I J K L M N O P Q R S T U V W X Y Z [ \ ] ^ _ Space ! “ # $ % & ‘ BM 102 ( ) * + ‘ .
3.3.6 Local user display (instruments equipped with DIN connectors only) The BM 102 local indicator is available as an option. This fits onto the BM 102’s standard DIN connector. Data can be read from an LED display. The gauge configuration menu cannot be accessed with this option. For non-Ex applications only. Please refer to the DA 06 Supplementary instruction manual for further information.
3.4 BM 102 MICROFLEX T.D.R. meter characteristics This subsection explains: • the four principle configurations for setting up a measurement scale and what the user should be aware of in each case; • what happens when the tank is full or empty; • what is the level threshold and how to modify it and • what happens when level is measured when more than one product in the tank; The measurement scale: five possible configurations for analogue current output – with “Level” selected in PCSTAR 2 function 1.3.
3.4.1 Gauge operating logic when the reflection is lost The product reflection pulse is usually lost when the level is in the top dead zone or near the bottom of the tank. The diagram below shows the action taken by the gauge depending on where ® the last reflection was lost. Use PCSTAR2 F8-Marker display function or HART HHC Fct. 4.0 Watch Status to follow the measurement status of the gauge.
3.4.2 Gain and voltage amplitude As explained in the measuring principle in section 6, the level of a product is converted from a return signal (the product reflection) received by the gauge: this signal has taken a certain amount of time to return to the gauge and it has a certain strength / size measured in milli-volts (dependant on the dielectric constant of the product).
Level measurement: Level pulse amplitude and threshold After connection to a power supply, the BM102 will: 1. Measure reflection pulses in terms of voltage amplitude by cycling through a set of gains. 2. Identify the highest amplitude as being the product level. This screenshot of the PCSTAR 2 F7-Oscilloscope function while measuring a typical one product application identifies: 1 Emitted pulse 2 Flange reflection (except coaxial probe) 3 Non-product reflection (e.g.
The following factors apply to the set gain: Gain Amplification factor 0 1.05 1 2.10 2 4.37 3 8.93 Level threshold The level threshold suppresses interference signals so that only the reflections from the product surface (level signal) are shown. The factory setting of the level threshold is suitable for standard applications. The threshold will need to be adjusted in the case of very low dielectric constants, multiple interference reflections or unfavourable installation conditions.
Setting the level threshold If the level threshold is set too high, i.e. it is greater than the amplitude of the level reflection, the device will not find any level even with maximum amplification. If the level threshold is set too low, i.e. it is below the amplitude of some of the interference signals, the device will identify and indicate one of these interference signals as a level reflection only if the tank is empty.
Automatic adjustment: To maintain a sufficiently strong reflection signal, the gain is adjusted automatically. When the amplitude of the level reflection decreases, the gain will increase to compensate for the loss in signal amplitude. Gain and level threshold thus maintain the same proportion. At gain 3, the level signal (1) is located between a distance of 2 and 4 metres or 6.5 and 13 ft. (2) is the level threshold.
Procedure (example where the level measured is too low compared to true level) • read off displayed peak amplitude using the oscilloscope function – F7 • modify level threshold value Step Action 1 2 Execute PCSTAR 2. Press F2 to connect to gauge. Press F11 to open F11-Dynamic configuration window. The top of the window gives the distance, peak amplitude in volts and gain. 3 4 5 6 7 The configured level threshold is listed under peak amplitude in mV.
3.4.3 Level measurement when more than one phase or layer in the tank Level can be measured with more than one phase in the tank. This requires setting a parameter in the factory menu (Fct. 1.1.
4 Service / Maintenance Maintenance is normally not required in standard applications. However, heavy deposits on the probe can cause measurement deviations or faulty operation. The measuring system is comprised of: • a signal converter, • a probe, • seals and • a process connection. 4.1 Replacement of the signal converter BM 102 servicing by the customer is limited by warranty to the removal and replacement of the housing containing the potted signal converter.
1 2 3 4 Signal converter housing O-ring, grease well before fitting Lock washer Housing (socket head cap) screw x 4 (M5 x 12), non-pressure-bearing Procedure to replace the signal converter (refer to diagram above) Step Action 1 Disconnect all wires (see sections 2.1.2 or 2.1.3) 2 Unscrew the 4 socket head cap screws M5x12 (ISO 4762), item 4, using a 4 mm Allen/hexagon key) and remove the signal converter. 3 The gasket between signal converter and flange must be well greased.
4.2 Fault clearing Event Error messages “Tank full” status marker on*, reading frozen at max. or min. value “Tank empty” status marker on*, reading frozen at max. or min. value “Tank full” and “Level lost” status marker on*, reading frozen at max. or min. value “Level lost” status marker on*, reading is frozen “Reference not found” status marker on* “Level lost” and “Reference not found” status markers on*, reading frozen Fault Action No fault.
Event “Flange not found” status marker on* “Delay out of limits” status marker on*, reading is frozen. “Negative voltage error” status marker on* “VC01 voltage error ” status marker on* “VC02 voltage error” status marker on* “Reprogramming FPGA” status marker on* Fault The signal converter has been incorrectly configured to measure with a cable or rod probe when it is equipped with a coaxial probe. This may also due to installation on a long nozzle which has the effect of attenuating the flange pulse.
Event General operation Instrument is not accurate with a product that has a high dielectric. A constant offset is observed when taking measurements. Fault Action Tank height is not correct. Check current output and tank height parameters. If the signal converter has been replaced, verify that factory calibration parameters are still the same. Ask KROHNE** for the factory calibration sheet (if not supplied) and the password for access to the factory menu.
Event Fault Electrical Connections and Communication Output Current Output value < 4 mA. No power supply. Connection of the device is incorrect. The calibration of the current output is incorrect. Reads 22 mA. An error has occurred. The device is in its start-up phase. The value at the current output does not correspond to the value at the display (PC STAR 2 or HART® communicator). The current output settings are incorrect. Data communication via the digital interface is not working.
5 Technical data 5.1 Technical data Application Range of applications Function and system design Measuring principle Equipment architecture Input Measured variable Measurement range Blocking Distance (dead zone) Output Analogue Digital Digital, Ex ia Signal on alarm Continuous level measurement of liquids, pastes, slurries and powders Time domain reflectometry See section 5.
Repeatability Hysteresis Resolution Transient recovery time ± 2 mm or 0.08 “ none ± 1 mm or 0.04 “ The transient recovery time to 1% deviation from the final value amounts to approx. 4.6 times the programmed time constant. However, the transient recovery time may differ if changes in level are very rapid. Start-up time ≤ 23 seconds Long term drift The long term drift is within the specified error of measurement. Allow for the thermal expansion coefficient in the case of liquids (organic liquids: ~0.
Construction materials Housing Probe Gasket Spacers (on twin probes) Aluminium with epoxy coating Refer to section 5.2.1: BM 102 mechanical options Viton, optionally Kalrez 6375 Refer to section 5.2.1: BM 102 mechanical options Weight Housing Single rod Ø 8 mm Single cable Ø 4 mm Twin cable Ø 4 mm Single cable Ø 8 mm Coaxial 2 kg or 4.4 lb 0.41 kg/m or 0.28 lb/ft 0.12 kg/m or 0.08 lb/ft 0.24 kg/m or 0.16 lb/ft 0.41 kg/m or 0.28 lb/ft 1.3 kg/m or 0.
Special calibration Error of measurement (mm) Distance from flange (m) 5.1.2 Start-up characteristics The current output stays at 22 mA for 15 seconds once switched on. The analogue output subsequently indicates a value between 4 and 20 mA until the level has been found. After a maximum of 23 seconds, the current output indicates the measured level and follows it.
BM 102 SS 316 / 316L Probe material Liquid SS 316 / 316L Hastelloy C22 SS 316 FEP coated DN50 PN 25/40 2” ANSI 150 lbs 1” G / 1” NPT 2.1 Ø600 mm or Ø24 “ ≤ 24 m or 79 ft. * gauge with flange connection ** higher on request SS 316L Hastelloy C276 DN50 PN 25/40 2” ANSI 150 lbs 2” G / 2” NPT*** 1.8 Ø200 mm or Ø8 “ ≤ 24 m or 79 ft. Minimum process DN50 PN 25/40 connection 2” ANSI 150 lbs 1” G / 1” NPT 1.
BM 102 ** on request None Counterweight (dimensions in mm) Gauge illiustration PTFE (if length > 1.5 m or 5 ft). Spacer material Ø45 x 60 (316L) Turnbuckle (316L) FEP moulded onto the cable. Coaxial Øext. 28 mm Twin cable Ø4 mm or 1.1” (Type 3) or 0.15” (Type 4) Probe (Type code) Ø25 x 100 (316L) Ø25 x 100 (HC22) Ø25 x 100 (HC276) Chuck (316L) Turnbuckle (316L) No spacer. Single cable Ø4 mm or 0.15” (Type 2) Liquid / Liquid Gas applications None No spacer. Single rod Ø8 mm or 0.
5.2.2 Definition of terms Distance Level: Probe Length: Tank Height: Ullage (volume): Volume: Distance from the face of flange to the level (1 product) or the surface of the top product (2 products). Height from the bottom of the of the tank to the surface of the top product (Tank height – distance). Ordered length of probe, L1, from face of flange to end of probe (including short circuit and counterweight). Distance from the face of the flange to the bottom of the tank. Unfilled volume.
5.2.3 Probe measurement limits A1, the top dead zone, The minimum distance from the flange to the top limit of the measuring range. The measurement displayed on the gauge will freeze below this distance and status markers will indicate that the reflection has been lost. A2, the bottom dead zone, A length at the end of the probe where measurement is not possible.
5.3 Gauge dimensions This diagram illustrates standard gauge configurations and overall dimensions. Housing Standard, M16 terminal box* Standard, DIN connector** with threaded connection High temperature version With inactive length*** Probe 3: Coaxial Ø 28 (1.1) 4: Twin cable Ø 4 (0.15) 2: Single cable Ø 4 (0.15) 1: Single rod Ø 8 (0.3) 6: Single cable Ø 8 (0.
6 Measuring principle 6.1 General principle The BM102 MICROFLEX has been developed from a tried and tested technology called “Time Domain Reflectrometry” (T.D.R.). Other modern applications include checking for and locating damage along telecommunication cable lines. The BM 102 sends low-power electromagnetic pulses of one nanosecond width along a rod or cable conductor. This pulse travels at a known speed: the speed of light.
Level measurement as signal amplitude over time since signal was emitted 1 Flange reflection 2 Level measurement 6.1.1 Level measurement of one product The pulse is emitted by the instrument and guided along the probe. It reflects off the first product surface it meets and returns to the instrument. The distance from the gauge flange to the product is proportional to the time taken: Distance = c0 . time taken 2 , where c0 is the speed of light in air.
7 Certificates and Approvals Approval and project code ATEX* KEMA 00 ATEX 1101 X Approved classes and groups II 1 G or II 1/2 D T 100 °C EEx ia IIC T6 … T3 or EEx ia IIB T6 … T3 Factory Mutual Research* Project ID 3009543 Intrinsically Safe apparatus for use in Class I, II and III, Division 1, Groups A, B, C, D, E, F and G and Class I Zone 0 Group IIC hazardous (classified) locations in accordance with Entity requirements and Control drawing F0820860412.
8 PCSTAR 2 software user’s guide This section is a complete guide to the functions available in PC STAR 2 V2.01, a software program developed in-house to optimise remote configuration and data display on a PC (Personal Computer) work station. It is supplied as standard with the instrument. 8.1 Software installation Refer to section 3.3.1. 8.2 PCSTAR 2 software history Date of introduction Month/Year 04/2000 07/2000 01/2001 10/2002 06/2003 8.
To enter the functions displayed in the diagram above, move the cursor to the bar concerned and left-click to open or use the keyboard function key (F1 – F10) indicated. The functions and subfunctions available are discussed in sections 8.4.1 to 8.4.7 below. 8.4.1 F1 Help PCSTAR 2 Off- and On-line Help file for a summary of PCSTAR 2 functions. 8.4.2 F2-Connection: on-line functions F2-Connection opens a real-time connection between PCSTAR 2 and the gauge. This establishes a connection with the gauge(s).
This shows the real-time tank status. This screen is divided into three parts. In default layout for a single output, this will show a bar with Current output and level graduations on the left hand side, a representation of the tank with its contents in the middle (the top dead zone will be indicated as a grey dotted line) and a bar with distance and level graduations on the right.
F1 – Help Menu: On-line help file. F2 – Configuration Menu: For creating and modifying gauge settings while PCSTAR 2 is connected to the gauge. The configuration may also be created, modified or saved without sending the new settings to the gauge in this window. The User configuration menu will be listed as shown in Section 3.3.1 of this manual. The values displayed will be either default or customer-order specified values. Follow the instructions in this section to configure the gauge.
F3 – Exit Quit to main title window. F4 – Record Menu The software will temporarily record the last two hours of operation without using the record menu. This information will be displayed on the “Trend” and “Markers” windows. However, if the user wishes to make a permanent record of measurement data then it is necessary to set and confirm a measurement record period in this menu. It is also recommended to activate the “Oscilloscope” option in order to have information on pulse reflection times.
F6 – Trend Menu Displays a real-time graph of level against time since the gauge started recording. Functions:F1 – Help: F3 – Exit: F4 – Zoom -: F5 – Zoom +: F10 – Screen copy 80 On-line help file Exit to real-time measurement main window Reduces the time scale Increases the time scale To select a directory and save the current screen as a bitmap file.
F7 – Oscilloscope function Using the F7 – Oscilloscope function (Oscillo.), all reflections occurring at the probe can be displayed. This is a help for optimum setting of the dead zone, the non-measurable zone, and the threshold under Function F11. It provides details on the position and strength (amplitude) of every signal between the initial pulse and the tip of the probe. Refer to section 3.4.
F8 – Markers Menu Displays a real-time evolving graph of error markers which are either displayed as active (value 1) or inactive (value 0). Refer to section 4.2 “Fault clearing” for corrective procedures when the markers shown above are active.
F10 – Screen copy Menu To save a bitmap image of the active window. F11 – Dynamic configuration Use F11-Dyn. Config. to get into the “Dynamic Configuration” menu. Here, you can: • read the distance to the product surface, the amplitude and the amplification factor, • change the level threshold • specify the distance to the product surface, • initiate automatic search of the probe tip, • test the current output. Fct.
To set the level theshold, we recommend the following filling height: • Minimum height: 300 mm or 12 ” above the probe tip or the upper weight, • Maximum height: distance to flange at least 500 mm or 20 “ Fct. Input distance This function is used to search for the level signal at a pre-configured distance. The current output is set to the appropriate value directly after the distance has been input.
2. Functions: F1 – Help F2 – Start F3 – Exit When OK is pressed, the DAT file details are displayed. On-line help file. Start reading the file data. Goes to record reading main window – see below. Exit to main title window.
Item 1 2 3 4A & B 5 6 7 8 9 10 11 12 13 14 15 Item Description Current output 1/ level in mA/mm Tank diagram showing current position of level Dead zone limit (configured) (A) Distance/ level of top product in mm & (B) Ullage volume/ volume in liters* (*configurable display).
8.4.6 F9 Colors Change colours used on PCSTAR display board. 16 are available. F1 – Help F2 – Exit and save F3 – Exit F4 – Default colors On-line PCSTAR Help Saves new settings for the screen elements concerned Exit to main title window without saving modified elements. Reset to original colour scheme Modifiable color parameters Screen elements Chosen component Select display Selected by scrolling through a drop-down menu or by clicking window from the on the element concerned.
8.5 Fault Clearing PCSTAR 2 Event PCSTAR 2 is unable to connect to the gauge Fault The RTS Shutdown parameter is unable to assign a value to the PC operating system (XP for PCSTAR 2 versions prior to 2.01) When at default value 0, PCSTAR 2 tests the O.S. to identify which one is installed. An RTS Shutdown timing value is assigned depending on the results. However, this test may not recognize Windows XP, so PCSTAR will not work.
Appendix A: BM 102 Level Gauge Configuration Record Please enter the data that has been set in the signal converter. BM 102 Parameters Checklist Firmware-Vers.: Device: Comm. No.: Location: Contact person: Telephone: Remarks: Menu item changed, date: …./…../……….. Fct. User configuration parameters 1.1.1 Tank height 1.1.2 Dead zone 1.1.3 Time constant 1.1.6 Probe length 1.2.4 Length unit 1.2.5 Volume unit 1.2.6.1 (new) unit name 1.2.6.2 (new) unit factor 1.3.1 Current output 1, item 1.3.
Appendix B: BM 102 – CE Declaration of Conformity 90 BM 102
Appendix C: Returning a device for testing or repair to KROHNE Your instrument has been carefully manufactured and tested. If installed and operated in accordance with these operating instructions, it will rarely present any problems. Should you nevertheless need to return an instrument for inspection or repair, please pay strict attention to the following points.
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