- BinMaster
Contents
1. 112 DISTANCE Distance value _ o 1 1 3 VOLUME Volume value if a strapping table is programmed 1 1 4 HEADSPACE VOLUME Headspace Volume value if a strapping table is programmed 120 INPUTSOUTPUTS o GNE Gd Primary Variable 122 1 PCumentouputvaue mA 123 jPementgeofPVrae 20 coNHGmEST 210 OPERATION 2140 BASSPARAMETER 2 1 1 1 TANK HEIGHT Enter probe length to Tank height 60000 mm or 2362 The tank height is defined as the distance between the bottom of the tank and the lower flange surface 2 1 1 2 PROBE LENGTH Enter 0 mm to tank This value has to be equal to the exact height but 24000 length of the probe The only situation mm or 1063 for changing this value is if the probe length has been changed 2 1 1 3 TIME CONSTANT Enter to 100 seconds The time constant allows filtering of pos sible signal fluctuations when the product surface is turbulent 2 1 1 4 DEAD ZONE Enter a value Measurements near the flange may not FCT 1 5 1 Detection be precise or reliable Measurement delay probe length may not be precise in an area less than Warning See Minimal this recommended value depending on Critical Parameter measuring distance the probe type Technical data of the probes 2115 SENSORINO Read only Menu Upper sensor limi2. e e e i as z O T T a E 1 BI DIST measured distance 5 2 5 programmed mal s z E range E E 5 B o the Ts S LEV level H DIST E i if ais VOLs volume calculated fmm DE T LEV lp 5 F E F lower dead zone measurement is nd possible 1 0 INTRODUCTION Application The GWR 1000 2 wire level gauge uses the Time Domain Reflectometry TDR measuring principle and two wire technology for level measurement It is designed for measuring the dis tance level and volume of liquids pastes slurries and powder products The device is applicable in tanks silos rigid pipes reaction vessels and level reference vessels The device is HART capable it can be programmed using a HART Handheld Communicator HHC a Multicont universal process controller and PCSTAR2 software supplied as standard with the gauge Operating principle The GWR 1000 2 wire guided microwave level transmitter uses the TDR Time Domain Reflectom etry principle The instrument sends low power nanosecundum wide pulses along an electrically conductive rod cable or coaxial probe with a known propagation speed the speed of light As the pulse reaches the surface of the medium or phase of two liquids altered dielectric constant r a part of it is reflected back to the electronic module The efficiency of the reflected signal depends on the dielectric constant r difference of the mediums or layers From the
3. e e 0 c z o HART VARIABLES 0 51 MANUFACTURER Read only menu BINMASTER 5 2 MODEL Read only menu 5 9 FLD DEV REV Field device revision Read only menu 5 4 SOFTWARE REV Software revision Read only menu 5 5 HARDWARE REV Hardware revision Read only menu 5 6 DEVICE ID Read only menu The device ID is also the serial number of the device 5 MESSAGE 32 bytes of ASCII characters 5 8 DESCRIPTOR 16 bytes of ASCII characters 5 9 DATE Month Day Year xx xx xx 5 10 NUM RESP PREAM Number of preamble in the response frame of the device 5 11 TAG Tag name of the GWR 1000 2 wire 5 12 POLLADDRESS Address of the device Function Fct Input Range BINMASTER 925 0311 Rev B 0113 5 2 1 CHARACTERS AVAILABLE FOR ALPHA NUMERICAL DATA FUNCTIONS IN PCSTAR2 AND ON THE HART CONSOLE PCSTAR2 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 5 3 GWR 1000 2 WIRE 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 analog current output with Level selected in
4. The threshold level must be adjusted so that it masks the disturbances It also gives enough margin for detection of the level pulse Very large pulses along the measurement signal same amplitude as the initial pulse can be caused by a probe which is touching the nozzle or the tank side see section 1 3 5 Ensure that no contact is possible Contact BinMaster for the corrective procedure or refer to the Service Manual Check that Factory Menu function 1 1 3 Application Type is set to 2 liquids 1 level Check also that there is a layer of more than 100 mm of top product above the bottom product 0113 gt u 2 5 Q I O e e e i as z O BINMASTER Event Faut JAcion Electrical Connections and Communication Output Current Output value 4 mA No power supply Check the power supply Connection of the device Check the connection between the is incorrect device and the power supply The calibration of the Execute the calibration if you have current output is incorrect authorized access or contact BinMaster Technical Service Center Reads 22 mA An error has occurred This happens in case the range 4 20 mA lerror 22 mA is selected Check the sta tus of the device by selecting the marker window F8 or enter the status 4 0 menu of the HART communicator The device is in its startup Wait 50 seconds phase If the current value dro
5. Level signal Flange Level signal Fla Rod or cable probe with gain 1 Rod or cable probe with gain 2 Emitted pulse Emitted pulse Levelsignal Level signal Coaxial probe with gain 1 Coaxial probe with gain 2 The signal from coaxial probes does not include the flange reflection due to the mechanical setup which does not produce any change in impedance at the flange The amplitude of reflection from the product surface increases as the level rises and decreases as the level falls 925 0311 Rev B 0113 BINMASTER 5 3 4 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 2000 and 4000 mm or 6 5 and 13 feet 2 is the level threshold This is shown on the left The amplification factor is 3 The level has dropped increasing the distance between level and flange 1 is located over 4000 mm or 13 feet 2 threshold 3 interference signals The interference signals are now below the level threshold 2 whose lower limit is 50 mV In the diagram to the left the amplification factor is 3 In both cases the automatically adjusted gain of the threshold indicates all signals located above one h
6. PCSTAR 2 function 1 3 1 Current 1 Item 20mA 20mA Tank height Fct 1 1 1 Probe length Fct 1 1 6 Detection delay Fct 1 5 1 Non measurable zone Minimum distance between non measurable zone and dead zone Fct 1 1 2 Fct 1 5 1 Upper dead zone Fct 1 1 2 Measuring range Reference point at tank bottom Fct 1 3 1 Level DS IOT 925 0311 Rev B gt u 2 5 Q I O e e 0 c z 0119 BINMASTER The configurations described below are illustrated in the above diagram 1 The current output range is smaller than the max possible measuring range 2 The current output range is equal to the measuring range Scale min 4 mA Fct 1 3 3 tank height probe length H Scale max 20 mA Fct 1 3 4 tank height dead zone 3 The current output range is greater than the measuring range Scale min 4 mA Fct 1 3 3 0 0 Scale max 20 mA Fct 1 3 4 tank height dead zone 4 The current output range is greater than the measuring range Scale min 4 mA Fct 1 3 3 tank height probe length H Scale max 20 mA Fct 1 3 4 tank height 5 The current output range is greater than the measuring range Scale min 4 mA Fct 1 3 3 0 0 Scale max 20 mA Fct 1 3 4 tank height gt u 2 5 Q I O e e e i as z O NOTE The reference point f
7. r and on the probe type The device sets the gain automatically Amplification factor The following factors apply to the set gain 10 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 r multiple interference reflections or unfavorable installation conditions gt u 2 5 Q I O e e e i as z O The illustrations below show interference signals when the oscilloscope function is used These reflections can be due to various causes e g tank internals or multiple reflections within the measuring range Even though the interference signals are very weak the threshold should nevertheless be set to a value above these signals 1 Initial pulse 2 Flange reflection 3 Level signal 4 Interference signal i 1 Initial pulse 2 Flange reflection 5 3 Level signal 4 Interference signal 5 Threshold UN ee a qe qun ee ee ae ee ure noel rn In the diagram above it can be seen that the level of the threshold is not constant 400 mV at 1000 mm or 3 3 ft and only 250 mV at 10000 mm or 33 ft No attenuation is required at a probe length lt 3000 mm or 10 ft The form
8. 01 Tag number of device 2 1 4 2 SERIAL NUMBER Read only menu Each device has its own serial number 2 1 4 3 2 1 4 5 925 0311 Rev B FRENCH COMMISSION Read only menu NUMBER This number is factory set Refer to this number in case of warranty or service claims GERMAN COMMISSION Read only menu NUMBER This number is factory set Refer to this number in case of warranty or service claims RELEASE NUMBER Read only menu Release number of the device Software and Hardware version PROBE TYPE Rod Twin Rod Read only menu Cable Cable Probe type attached counterweight to the flange Cable without counterweight Twin Cable Twin Cable counterweight Coax Special 1 Special 2 Special 3 CHECKSUM Read only menu Similar to the release number This parameter allows to identify the software version of device gt u 2 5 Q I O e e 0 as z O 0113 BINMASTER Function Fct Input Range 2450 APPLICATION C CCSC CS 24510 THRESHOLD CCC 2 1 5 1 1 LEV PULSE AMP Read only value Dynamic value Amplitude of level pulse in millivolts 2 1 5 1 2 LEV PULSE Read only value Dynamic value GAIN Amplification of level pulse gain 0 1 2 or 3 2 1 5 1 THRESHOLD Enter a value from Threshold of the level pulse in millivolts 50mV to 25000mvV The threshold evolves in terms of gain am 500 mV G3 plification factor changing by the e
9. 15 LL ml zz 4 2 2 SPECIFIC INSTALLATION INSTRUCTIONS GAUGE SOLID APPLICATIONS FALSE READINGS 1 Do not let the probe touch the side of the nozzle BINMASTER 925 0311 Rev B 0113 Conical silo nozzles false readings and traction on the cable probes h 2 High traction forces 3 We recommend that the probe should not be B anchored to avoid excessive traction loads on 1 2R min i BH the cable 3 Bending and traction e T Position the connection on the roof at 5 radius of the tank and with minimum nozzle height This wil eal avoid damage due to bending and traction during i emptying Traction load is dependent upon the height and shape of the tank product particle size amp density and the rate at which the tank is emptied The table below gives the load up to which cable probes will hold Probe type Material Probe Length 6 m Probe Length 12 m Probe Length 24 m Product buildup can occur under the nozzle This may weaken the pulse Avoid cavities that permit the build up of deposits Tank roofs should support loads of at least 3 T for gauge installations using 08 mm or 0 3 single cable probes 4 3 WIRING 1 Detach the cover of the unit 2 Guide the cable into the housing through the cable gland 3 Remove a 4 mm length of isolation from the wires and cut away the free part of the shielding 4 Connect the wire
10. 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 No fault The level has reached and possibly risen above the top configured measurement limit and is either display ing the maximum when measuring level or minimum when measuring distance output No fault The level has entered the gauge s bottom dead zone and can no longer detect a return signal Either the maximum when measuring distance or minimum when measuring level output is displayed No fault The level has entered the gauges top dead zone and can no lon ger detect a return signal The instrument has lost the level signal has searched but not yet found the return pulse This may occur if the pulse has dropped below the threshold Para site signals from the flange or obstruc tions in the tank may render the gauge unable to identify the correct signal None Measurements should be normal once the level is in the configured measurement range None Measurements should be normal once the level is in the configured measurement range Empty the tank below the top mea surement range limit and check the measurement Ensure that tank is emptied below maximum level and check the mea surement If the signal
11. local LCD display you must order SAP 300 GWR 1000 High temperature 2 Wire Guided Microwave Level Transmitter 18 35 VDC 4 to 20 mA output 730 5151 H with HART process temperature from 22 F to 392 F 30 C to 200 C Aluminum housing with powder coated finish 1 1 2 stainless steel process connection for use with the single flexible 8 mm 316 stainless steel cable General purpose IP65 for local LCD display you must order SAP 300 GWR 1000 L 2 Wire Guided Microwave Level Transmitter 18 35 VDC 4 to 20 mA output with HART process 730 5152 temperature from 22 F to 195 F 30 C to 90 C Aluminum housing with powder coated finish 1 stainless steel process connection for use with the single flexible 4 mm 316 stainless steel cable General purpose IP65 for local LCD display you must order SAP 300 GWR 1000 High temperature 2 Wire Guided Microwave Level Transmitter 18 35 VDC 4 to 20 mA output 730 5153 LHT with HART process temperature from 22 F to 392 F 30 C to 200 C Aluminum housing with powder coated finish 1 stainless steel process connection for use with the single flexible 4 mm 316 stainless steel cable General purpose IP65 for local LCD display you must order SAP 300 ORDER CODE MICROWAVE PROBE TYPE DESCRIPTION CP8 length Single flexible 8 mm 316 stainless steel cable with counter weight Maximum length 78 ft Used on microwave remote transmitters with 1 1 2 NPT fittings for measu
12. of them act like a HART master only one programming mode has priority and this is manual programming During manual programming the instrument sends the BUSY response to the external HART master device HART response code 32 Device is busy BINMASTER 925 0311 Rev B 0113 5 1 3 MANUAL PROGRAMMING PCSTAR 2 param ID BASIC SETUP TANK HEIGHT DEAD ZONE FOLOSE END BLOCKING DAMPING TIME PROBE LENGTH CURRENT MODE Do FAILURE CURRENT CURRENT MIN po CURRENT MAX ERROR DELAY gt u 2 5 Q I O e e e i as z O APPLICATION po APPLICATION TYPE Changing parameters can be done by selecting a sub menu and pressing button in two ways Text based list Navigation is the same as in menu lists Accept changes with button cancel changes and exit with button Numerical field Serves for editing a numeric value Editing is helped by a cursor inverted character Change the value of the selected digit with buttons there is no under and overflow between the characters Selecting a digit can be done using the button Accept changes with button After accepting the parameter change the GWR 1000 checks the parameter and downloads it If parameter is incorrect the CHECK WRITE FAILED message appears BINMASTER 925 0311 Rev B 0113 5 2 PROGRAMMING WITH HART HANDHELD HHC COMMUNICATOR Display and configuration can also b
13. plain surface of air water phase the reflected signal s strength will be approximately 8096 of the emitted signal The reflected pulse is detected as an electrical voltage signal and processed by the electronics Level distance is directly proportional to the flight time of the pulse The measured level data is converted into 4 20 mA current and HART signals and is displayed on the LCD display From the level data further derived measuring values can be calculated such as volume and mass The TDR technol ogy is unaffected by the other properties of the medium as well as that of the space above it 925 0311 Rev B 0113 BINMASTER 2 ORDER CODE 1 Transmitter amp 1 1 2 Process Connection 2 Flexible Probe Assembly amp Counterweight Example Our standard Guided Wave Radar Transmitter with a 40 single flexible 8 mm 316 stainless steel cable counterweight 1 1 2 SS fitting and SAP 300 local plug in LCD display unit would be a 730 5150 CP6 40 SAP300 gt u 2 5 Q I O e e e i as z O MODEL MICROWAVE REMOTE TRANSMITTER DESCRIPTION GWR 1000 2 Wire Guided Microwave Level Transmitter 18 35 VDC 4 to 20 mA output with HART process 730 5150 temperature from 22 F to 195 F 30 C to 90 C Aluminum housing with powder coated finish 1 1 2 stainless steel process connection for use with the single flexible 8 mm 316 stainless steel cable General purpose IP65 for
14. 00 mm when measuring a top product with a dielectric constant of r 22 4 The mode 2 liquids 1 level permits level to be measured even when more than 2 liquids are present in the tank The first return signal is identified as being level and the second is ignored This mode may be used with all probe types Example application 1 Level measurement of oil 1 liquid in the tank gt u 2 5 Q I O e e e i as z O With Factory Menu Fct 1 1 3 Application Type set to 1 liquid 1 level the GWR 1000 2 wire will search for the ume ns return signal with the highest amplitude ee i e higher than the threshold It will measure the oil level signal V i 7L 1 Level measurement signal 2 Threshold Example application 2 Level measurement when there are 2 liquids oil water in the tank using a correctly configured gauge E With Factory Menu Fct 1 1 3 Application Type set to 2 liquids 1 level the GWR 1000 2 wire will search for the first return signal higher than the control threshold It will correctly measure the oil level i e level time ns distance 1 Threshold 2 Level signal 3 Oil water interface signal For further information please contact BinMaster Technical Service at support binmaster com 925 0311 Rev B 0113 BINMASTER 5 4 TROUBLESHOOTING ven Faut Action Error messages
15. 2 5 Q I O e e e i as z O If GWR 1000 is not equipped with a sunshade and ambi ent temperature exceeds the operating temperature of SAP 300 do not leave the SAP 300 in the instrument 5 1 2 GWR 1000 S BEHAVIOR IN MANUAL PROGRAMMING MODE After power up GWR 1000 shows the measured value on the SAP display REMOTE MODE If the instrument senses external HART communication it changes its display mode and shows a REMOTE MODE message in the bottom of the display In this mode the measured values are refreshed according to the queries of the external HART master If the HART master does not refresh the display will show the last measured values In the absence of SAP 300 the COM LED indicates the HART communication If HART communication stops the COM LED turns off after 120 sec Entering the menu can be done by pressing the button Scrolling the menu can be done by pressing and buttons Enter into selected menu point with button Exit to the previous menu with button The buttons work only in presence of SAP 300 module When leaving the GWR 1000 in programming menu after 30 minutes the instrument automatically returns to measuring mode If SAP 300 is removed the instrument instantly returns to measuring mode Because manual programming with SAP 300 and remote programming with external HART master Multicont or PCSTAR2 software cannot be performed at the same time as both
16. A passive output error 22 mA Accuracy Liquids 5mm For probe length L 210m 0 05 of the range Under ideal reflection and stabilized temperature conditions Solids 20mm For probe length L 2 10m 0 2 of the range Electrical connection 2 x M20x1 5 metal cable glands Cable diameter 7 13 mm Ex or M20x1 5 plastic cable glands Cable diameter 6 12 mm wire cross section 0 5 1 5 mm2 shielded cable is advised 2 x NPT 77 for cable gland Electrical protection Class Mass housing 1 5 kg gt u 2 5 Q I O e e 0 c z Output data 925 0311 Rev B 0113 BINMASTER TECHNICAL DATA OF THE PROBES Flexible 0 32 8 mm or 0 15 4 mm 316 stainless steel mono cable Connection 1 1 2 NPT with 032 8 mm cable 1 NPT with 0 15 4 mm cable gt u 2 5 Q I O e e e i as z O p E e 5 5 2 10 Dia 3 25 4 mm z e SY N GWR 1000 GWR 1000L R 8 mm cable used in liquids 4 mm cable used in liquids A and heavier bulk solid materials and heavier bulk solid materials N lt 925 0311 Rev B 0113 Q Nameplate Ambient temperature 30 C 60 C Proc temperature 30 C 90 C pmax 16bar 925 0311 Rev B 402 434 9102 BIAMASTER Lincoln NE USA pM suppy p Output L Amb temp Proc te
17. ART Handheld Controller HHC with Marker status window F8 or list displayed 925 0311 Rev B 0113 gt u 2 5 Q I O e e 0 c z BINMASTER Evem Fai Acion Generaloperaton oO oo Instrument is not ac curate with a prod uct that has a high dielectric constant A constant offset is observed when taking measurements The GWR 1000 2 wire indicates an incorrect level value Instrument is not ac curate when there are two or more phases in the tank 925 0311 Rev B Tank height is not correct The GWR 1000 2 wire measures a non valid reflection The instrument may be incorrectly con figured for this type of application i e it is measuring the interface instead of the level Check current output and tank height parameters If the signal converter has been replaced verify that factory calibration parameters are still the same Ask BinMaster for the factory calibration sheet if not supplied and the password for access to the factory menu Check the tank for obstructions and verify that the probe is clean In the case the indicated level is close to the nozzle increase the detection delay and the dead zone with the same ratio or increase the thresh old level if the full measurement range is essential In any case use the PCSTAR 2 oscilloscope function to visualize and to analyze the application
18. GWR 1000 Two Wire Guided Microwave Level Transmitters BinMaster Division of Garner Industries 7201 N 98th St Lincoln NE 68507 402 434 9102 email info binmaster com www binmaster com OPERATING INSTRUCTIONS PLEASE READ CAREFULLY 925 0311 Rev B 0113 TABLE OF CONTENTS gt u 2 5 Q I O e e e i as z O TIN gu COC TON erases 3 PH CODE mc eae eee ee ee ee ee ee ee eee 4 Rye e miri c 5 ACC SONC S ER T m 8 3 2 Maintenance and repali cccccccessssscceecsssssseeeeeeeeesseeeeeeceeecssssaeeeeeeesesesseeeeeeesessssaaeeees 8 4 0 MECHANICAL INSTALLATION eu ua ae ih xus Eres 8 4 1 Handling and St OLA Tm 8 AZ MOUNN ON Ne WAN Rm 10 4 2 1 Installation instructions general notes ssseeeeennnnnne 10 4 2 2 Specific installation instructions gauge solid applications 12 n E 13 4 3 1 BUS HART COMM MUN uu rat nol 16 4 4 Power On and Start UP ccccssccsecssssceecssececesseeeesssseeeesseeeeesseeeeeesseesesssseseessseseesseneeess 16 4 5 Available user oe ee st mes ee eee 16 uec cm ee 16 5 Programming with SAP 300 display cece ccccesececsssseeessseeeesseeeessseeeeess
19. The maximum number of points is 20 Each subsequent value must be greater than the previous one The length and vol 0 ume units can be changed later without af i e no volume fecting the settings in the table Calculations table are done automatically in the instrument 24 7 3 DELETE TABLE This function deletes the strapping table gt u 2 5 Q I O e e e i as z O BINMASTER 925 0311 Rev B 0113 Function Fat TET 220 TESTS 2 2 1 TEST OUTPUT Select 4 mA This function allows the current output to be tested 12mA 20 mA The output can be set to one of the listed values Other With a reference ammeter the calibration of the current output can be verified 2 3 0 SERVICE Restricted access factory configuration menu These parameters may be accessed via Fct 3 2 Specialist PSW password 3 0 ACCESS RIGHTS 0 3 1 MAINTENANCE PSW Yes or No Disables the access lock on the configuration Enter 9 character menu code if Yes The password must contain exactly 9 characters E R or U are used only The password is displayed in a scrambled format It allows BinMaster to decode the password in case it was forgotten 3 2 SPECIALIST PSW See BinMaster Service center or GWR 1000 2 wire Service Manual for code 4 0 WATCH STATUS EE This function displays the status of the device gt u 2 5 Q I O
20. alf of the amplitude of the level signal In the event of operational or installation faults you can frequently identify the cause of the fault by means of this function and normally eliminate it yourself Should the fault persist please send a copy of the screen screen shots with F10 to BinMaster Technical Service at support binmaster com Note that the threshold drops every 2000 mm or 6 5 feet Solid application notes Most dry solid applications except powder or flakes with high dielectric constants r such as coal powder are measured with a Gain of 3 If it is difficult to measure level at a certain point with the gauge using a Gain from 0 to 2 then an internal tank structure exposed girder etc is most likely to be within the electromagnetic pulse field area the gauge will detect the largest signal and assume this is the product level 925 0311 Rev B 0113 gt u 2 5 Q I O e e 0 c z BINMASTER 5 3 5 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 3 Application Type to the follow ing measurement mode 2 liquids 1 level for measuring level with two or more phases 1 liquid 1 level for measuring one phase or liquid Characteristics The level of the top product can be detected if it has a minimum layer of approximately 1
21. ationship cannot be respected Caution Do not use nozzles that penetrate into the tank This will disturb the emitted pulse 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 5 ft away from each other If not interferences from the electromagnetic EM fields generated by both instruments may cause measurement errors Coaxial probes The outer shell of the probe contains the EM field No minimum distance required BINMASTER 925 0311 Rev B 0113 Install far from entry Process connection and entry pipe pipe Caution Do not put the nozzle close to the entry pipe Pouring the product directly onto the probe will give false readings Install a deflector plate if impossible to distance gauge from entry pipe Stilling wells Tanks with floating roofs for petrochemical applications Use a stilling well gt u 2 5 Q I O e e e i as z O 1 Stilling well 2 Tank 3 Floating roof 4 Product petroleum applications 5 Well fixed to tank base no roof deformation 6 Sediment Probes Entanglement straightness and tank bottom clearance Cable probes must be straight once inserted into the tank They must also be far from other objects e g mixers to avoid entanglement In order to maintain the gauge s operating characteristics it is recommended to avoid
22. bending 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 minimum Storage temperature 60 C 40 C 925 0311 Rev B gt O 5 Q I O Q e e e i as z O 0113 BINMASTER 4 2 MOUNTING ON THE TANK 4 2 1 INSTALLATION INSTRUCTIONS GENERAL NOTES Prior the installation some consideration is to be made regarding tank fittings and tank shape nozzle position in relation to the tank walls and other objects inside the tanks Warning This free area will depend on the probe type selected refer to later on in this section type of tank roof i e floating concrete integral etc and base i e conical etc Whenever working on an instal lation remember to Disconnect the power supply before starting work However the gauge may be installed when the tank contains product Threaded process connections Nozzle height The simplest and most economic way is Do not fit a nozzle longer than its diameter to mount the GWR 1000 2 wire directly on especially for single probes and powder applications the tank with the 1 172 BSP or 1 172 NPT threaded connection gt u 2 5 Q I O e e e i as z O Od where ozzle height and ozzle diameter It Il IA h h n d n Contact BinMaster if this rel
23. e carried out with a HART communicator Communicator layout 1 Two pin jack for loop connectors 2 LCD 3 Function keys F1 F4 4 Action keys On off UP n a Arrow LEFT DOWN RIGHT Arrow Arrow Arrow E 8 f _ e m HART Commcrnecatr Other functions LEFT Arrow Previous menu key RIGHT Arrow Select key C 1t 3 1 Wiring standard non Ex rd 250 1 NBED A HAR I compatible device 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 Process Var 2 Online lt Config Test gt 3 Frequency Device lt Access Rights gt 4 Utility lt Watch status gt lt HART Variables gt SAVE Online menu Process Var lt a Measurements Y 1 Measurements 1 Lvl 878 00 mm 2 Input Outputs 2 Dist 121 00 mm SAVE HOME HELP SAVE HOME Measurement amp input amp output functions menu Measurement display function 925 0311 Rev B 0113 gt u 2 5 Q I O e e 0 c z BINMASTER Configuration Summary of user functions via HART Communicator HC 275 Version 1 00 Reset default values are in bold type in the Input Range column Refer to the HART HC275 Communicator operating instructions for further operating details 10 PROCESS VAR a 11 0 MEASUREMENTS J gt o 1444 LEVEL
24. er 5 1 Programming with PCSTAR 2 software PC needed SAP 300 display unit Can be ordered See chapter 5 2 Programming with SAP 300 display unit HART HHC Sold separately Automatic device detection on powering Handheld Communicator See chapter 5 3 Programming with HART HHC Communicator 5 PROGRAMMING GWR 1000 can be programmed in three basic ways e Programming with PCSTAR 2 software e Programming with SAP 300 display unit Programming with HART Handheld HHC Communicator For operating instruction see the User manual of the HHC BINMASTER 925 0311 Rev B 0113 Programming with SAP 300 display unit The main parameters of the GWR 1000 can be set using the SAP 300 display unit The default display shows the primary measured value which the output current is calculated from Besides the numerical display there is a bargraph on the right showing the value of the current output Programming is helped by a text based menu Navigation in the menu can be done with Ef buttons 5 1 1 SAP 300 DISPLAY UNIT Display 64x128 Dot matrix LCD glyphs units and bargraph Ambient temperature 20 C 60 C Housing material PBT fiberglass plastic DuPont SAP 300 is a plug in LCD display and programming module Warning The display of the SAP 300 is based on LCD technology do not expose the SAP 300 to continuous direct sunlight to avoid display damage gt u
25. eturn signal will be given a low gain i e Gain 0 or a small amplification However if the signal is very weak then a Gain of 3 i e high signal amplification is given gt u 2 5 Q I O e e e i as z O Example of signal amplification A normally not less than 0 4 t 0 5 V Microprocessor Peak Threshold t Lnusable signal drove Increase gain Level pulse fX cane Gein 1 for strongest signals mom s m om um T P Find d Unusable signal Rire pl Eis Increase gain T Fas Em i oe GOIG IG2 G3 Threshold FO 1 t2 where Gain f 4A and A level signal amplitude Gain 1 Signal within zone satisfies Operating constraints further amplificalian using Gain 3 tor weakesl signals unnecessary Level measurement Level pulse amplitude and threshold After connection to a power supply the GWR 1000 2 wire 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 925 0311 Rev B 0113 BINMASTER The level signal can be optimized by way of two factors Amplification factor The amplitude of the signals is proportional to the dielectric constant r of the product At low amplitudes the signal should be amplified The amplification factor is dependent on the dielectric constant
26. ion ground the probe by pushing it against tank wall with a suitably isolated tool just before touching it to avoid receiving a shock 2 Ground the entry pipe and product Non hazardous duty version Power supply Nominal voltage 24V DC E Maximum voltage Uinput 35V DC Qr Minimum voltage Uinput dependent on load impedance see graph below N Load impedance RA Loop resistance Rloop RHART Rcable Rammeter Ohm A Minimum load impedance RA 0 Ohm T Maximum load impedance RA 750 Ohm RHART resistance for HART communication 250 Ohm recommended a 925 0311 Rev B 0113 Q voltage minimum supply voltage Veuooy for a loop drop over resistance Roop of 250 Q measured at 250 Tsa X the terminals of the supply resistance iz al 4 mA aL voltage drop over 250 S 2 4 86 8 12 4 16 18 20 22 loop current mA gt O 5 Q I O Q e e e i as z O Line A minimum voltage at the GWR 1000 2 wire terminals Line B minimum supply voltage for voltage drop caused by a 250 Ohm loop resistance Example for calculating the power supply The voltage drop is tested at 22 mA U power minimum 22 22 mA x load impedance U input minimum 22 U power minimum 22 22 mA x 250 Ohm 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 powe
27. is not detect ed then modify the control threshold manually as shown in sections 5 4 2 using the oscilloscope F7 and dynamic configuration F 11 windows in PCSTAR 2 Reference not found Occurs when there is a problem with the Please contact BinMaster status marker on time base on the HF board Level lost and Reference not found status markers on reading frozen Flange not found status marker on Delay out of limits sta tus marker on reading is frozen Negative voltage error VCO1 voltage error VCO2 voltage error Reprogramming FPGA The probe has received an electrostatic discharge The signal converter has been incorrect ly configured to measure with a cable or rod probe when it is equipped with a coaxial probe This may also be due to installation on a long nozzle which has the effect of attenuating the flange pulse The emitted pulse has not been detect ed The gauge will not work until it has been found The gauge will search for the level again and resume readings If the reading remains frozen then the signal converter may have been damaged by ESD and may need replacing Please contact BinMaster Contact BinMaster for the corrective procedure The signal converter may need replacing Please contact BinMaster Occurs when there is a problem with the Please contact BinMaster time base on the HF board Gauge connected to PCSTAR2 software or H
28. is zone but makes a search along the entire length of the probe once every minute The reading will remain frozen during this time The short circuit reflection will become larger than product reflection at this time 925 0311 Rev B 0113 BINMASTER 5 3 2 GAIN AND VOLTAGE AMPLITUDE As explained in the measuring principle in the introduction 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 millivolts dependent on the dielectric constant r of the product All pulse signals returning to the gauge electronics block including flange obstruction and the product surface reflections are converted to voltage amplitudes The gauge s microprocessor looks for part of the largest signal that is over a set voltage amplitude called the threshold and identifies this as the product being measured For this signal to be usable by the gauge the microprocessor will amplify the signal by increasing the gain Once the signal is within a set working range the gauge follows this signal The gauge registers any changes in time for this part of the signal to return to the converter and translate this into a displayed level or volume Gain is a function of voltage amplitude This defines the default threshold value when the gauge is searching for the product level A strong r
29. lectronic at 1000 mm converter 2 1 5 2 DISTANCE INPUT Enter a value from This function forces the GWR 1000 2 wire to Fct 2 1 1 4 Dead search for the product surface in a zone other zone to fct 2 1 1 2 than the actual measuring zone If there is no Probe length level signal you can enter an estimated value 2 1 5 3 DETECTION Enter a value This function forces the instrument not to DELAY Omm or Oin to Fct analyze reflections in a zone directly below the 2 1 1 4 Dead zone flange The entered value of the detection delay must be smaller than the dead zone value 2 1 5 4 SEARCH PROBE Measured in the Automatically measures the probe length units configured in The tank must be empty and the tank height fct 2 1 2 1 1 must be configured to a value greater than estimated probe length for this to be done correctly 2 1 5 5 RESET GWR 1000 Restarts the GWR 1000 2 wire 2 wire 2 1 6 0 SERIAL 2 1 6 1 ADDRESS Enter 0 to 15 Sets the address of the device when this latter is connected on a HART Multidrop networks The current output drifts to 4 mA 0 4 20 mA output current active 1 15 in multidrop mode 2 1 7 0 STRAP TABLE 2 1 7 1 VOLUME UNIT Select m3 US Unit for conversion values volume table Gal Ft3 bbl M3 h The selected unit is used to define the Ft3 h kg Metric strapping table values Tons US Tons 2 1 7 2 INPUT TABLE 0 to 20 points This function defines the strapping table
30. mp C MADE IN HUNGARY A 0113 gt u 2 5 Q I O e e e i as z O BINMASTER 3 1 ACCESSORIES e Installation and programming manual e 2 pcs M20x1 5 cable gland e SAP 300 display module option 3 2 MAINTENANCE AND REPAIR GWR 1000 does not require maintenance on a regular basis In some very rare instances however the probe may need cleaning to remove deposited material This must be carried out gently without damaging the probe Repairs during or after the warranty period are carried out exclusively at BinMaster The equipment sent back for repairs should be cleaned or neutralized disinfected by the user 4 MECHANICAL INSTALLATION gt u 2 5 Q I O e e e i as z O 4 1 HANDLING AND STORAGE The device will weigh between approximately 3 kg or 7 Ib and 12 kg or 25 Ib 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 ATni VAT g y l t BINMASTER 925 0311 Rev B 0113 Avoiding blows avoid hard blows jolts impacts etc Caution fragile electronics m mmm m m AT m Avoid bending single rod and coaxial probes Support the probe to avoid
31. of the threshold is dependent on attenuation and is automatically adjusted by the device over the measured length 925 0311 Rev B 0113 BINMASTER 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 Precise setting of the level threshold is especially important when the dielectric constant r is low To set the level amplitude of the reflection must be known A level of 500 mm or 20 is ideal The level threshold should be halfway between the invalid interference signals and the level reflection signal The reflection from the probe tip which is clearly identifiable at a low r value does not need to lie below the level threshold Take a look at all the reflections over the entire probe length and then change the level threshold and or the amplification factor in the Dynamic configuration F11 menu gt u 2 5 Q I O e e e i as z O 5 3 3 TYPICAL SIGNAL TRENDS The following diagrams show characteristic signals that have been recorded with the oscilloscope function Emitted pulse Emitted pulse
32. or distance measurements is the bottom of the flange face 9 3 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 PCSTAR 2 F8 Marker display function to follow the measurement status of the gauge Zone 1 Dead and detection delay zones Marker Tank full and Level lost is displayed when the product enters the dead zone and no reflection is found This will also occur once the level reflection is within the detection delay zone The gauge assumes the tank is full and displays the maximum level value The gauge searches for a reflection along the entire length of the probe Zone 2 Full zone and dead zone Marker Tank full is displayed in this zone If the gauge loses the signal in this zone it reacts as in zone 1 the tank is assumed to be full The gauge searches for a reflection along the length of the probe Zone 3 Central measurement zone The gauge searches along the length of the probe for the largest pulse reflection If the pulse is lost the reading freezes at the last value Marker Level lost will be displayed Zone 4 Empty zone If the reflection is lost here then the gauge assumes the tank is empty and marker tank empty is displayed The gauge searches for a reflection in th
33. po Number of decimal places Defines the displayed FORMAT nential format auto volume value format Option of the HART communicator H275 Function Fet Input Range 2 1 3 0 ANALOG OUTPUT 2 1 3 1 FUNCTION I Select Level Distance Vol Current output function measured value to ume Headspace Volume be displayed Volume functions will appear if Level a volume table exists in menu 2 1 7 0 gt u 2 5 Q I O e e e i as z O RANGE Select 4 20 mA or Current output range 4 20 mA 4 20 mA 22 mA if error 1st choice When the GWR 1000 2 wire is in error mode the current output is frozen except 4 20 mA if the second choice is selected and then the current output Is fixed at 22 mA Select No delay 10 s 20 5 30 s This menu is available in case the range 1 min 2 min 5 min 15 min menu is set to 4 20 mA with error 22 mA This parameter sets the delay before the current output goes to 22 mA after the error mode occurred SCALE Enter 0 to Scale max Input the lower range value corresponding min 4 mA As per order to 4 mA depending of the parameter 2 1 3 1 chosen SCALE I Enter Scale min to tank Input the upper range value correspond max 20 mA height ing to 20 mA depending of the parameter As per order 2 1 3 1 chosen No delay BINMASTER 925 0311 Rev B 0113 Function Fct Input Range 24 40 USER DATA ee eee 2 1 4 1 TAG 00000
34. ps to a value between 4 and 20 mA and goes immediately back to 22 mA contact your BinMaster Technical Service Center The value at the current output The current output settings Check the current loop and the connec does not correspond to the are incorrect tions Configure the output as described value at the display in Sect 3 3 3 user sub menu 1 3 of PC STAR 2 or HART9 the GWR 1000 2 wire Handbook communicator also try adjusting the threshold using F11 Dynamic Configuration function PCSTAR 2 or menu 2 1 5 1 0 HHC Data communication via the The communication Check computer setting digital interface is not working parameters of the computer address device number The GWR 1000 2 wire is in are set incorrectly its start up phase wait Bad connection to the Check connection 50 seconds and try again interface Current output value is 4 If problem persists then contact mA BinMaster Technical Service Current output value is 22 gt u 2 5 Q I O e e e i as z O 925 0311 Rev B 0113 BINMASTER 5 5 APPENDIX 1 SET UP PARAMETERS OF GWR 1000 H 400 IN CONTROLLER Remote program 90 Basic setup Length unit 120 Basic setup Length unit m Output setup Tank height cm Application Dead zone mm Service Close end blocking Current mode 93 Damping time Level Probe length Distance IB Volume Ou
35. r minimum 4 4 mA x load impedance U input minimum 4 U power minimum 4 4 mA x 250 Ohm 18V 1V 18V 19V At a load impedance of 250 Ohm a power supply voltage of 19 V is sufficient to energize the current device range of 4 to 20 mA BINMASTER 925 0311 Rev B 0113 4 3 1 BUS HART COMMUNICATION GWR 1000 has two output options Current out and HART Passive HART protocol Intrinsically safe passive HART protocol In accordance with the Rosemount Standard HART communication can be used with a GWR 1000 2 wire It is used as a point to point connection between the GWR 1000 2 wire as slave and the HART master gt u 2 5 Q I O e e e i as z O PCSTAR2 or HART spcific software and operating devices HART HHC HART Master 4 4 POWER ON AND START UP The GWR 1000 2 wire is pre configured in accordance to customer order specifications and measurements can be made immediately A start up time of less than 60 seconds should be allowed once the unit is 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 4 5 AVAILABLE USER INTERFACES Programming of GWR 1000 can be done using the following instruments accessories PCSTAR 2 software Accessory shipped with the instrument See chapt
36. rement of liquids and heavy weight bulk solids CP4 length Single flexible 4 mm 316 stainless steel cable with counter weight Maximum length 78 ft Used on microwave remoter transmitters with 1 NPT fittings for measurement of liquids and light weight bulk solids ORDER CODE LOCAL DISPLAY UNIT DESCRIPTION SAP 300 Local plug in LCD display unit With the help of the SAP 300 plug in display a simplified programming can be accomplished which covers most applications The basic parameters of measurement and output can be set using the text based menu system of the SAP 300 The large LCD dot matrix display displays the measured values in numerical and bar graph form BINMASTER 925 0311 Rev B 0113 3 TECHNICAL DATA GENERAL DATA Input data Measured values Between the reference point of the unit and reflection plane material surface distance level and volume Measuring range iden on probe type and the properties of the measured medium see technical data Probes table Probe types and technical data Coaxial twin cable mono cable twin rod and mono rod probes see technical data Probes table Aluminium cast with epoxy coating Medium temperature Flange temperature 30 C 90 C Medium pressure 0 1 1 6 MPa 1 16 bar maximum allowed pressure at 20 C for 1 4571 stainless steel flange 4 Mpa 40 bar 30 C 60 C with display 20 C 60 C Output signals Analogue 4 20 mA 3 9 20 5 m
37. s of the current loop to terminals 2 and 3 any polarity 9 Pull back the cable till a 10 mm cable length remains in the housing behind the cable gland Tighten the cable gland using two spanners Check the connec tion of wires and the tightness at the cable gland 6 Array the wires in the housing and screw the cover on the housing The 500V AC insulation test should not be performed on the instrument because of the overvoltage protection of the electronics 925 0311 Rev B 0113 gt u 2 5 Q I O e e 0 c z BINMASTER Connection to the EP network grounding EP Screw type terminal EP on the housing max Cable cross section 4 mm The housing of the GWR 1000 must be grounded Grounding resistance R 1 Ohm The shielding of the signal cable should be grounded at the control room Avoid coupling of electromagnetic noises place the signal cable away from power current cables Electrostatic discharge E S D GWR 1000 2 wire electronics are shielded up to 4 kV against E S D NPT1 2 M20x1 5 Note E S D cannot be solved by GWR 1000 2 wire E S D protection It is the customer s responsibility to avoid E S D by grounding the tank product and probe installation gt u 2 5 Q I O e e e i as z O DANGER OF INJURY 1 The probe may receive an electrostatic discharge during operat
38. seeesessees 17 Ee ius MEe ze AU M 17 5 1 2 GWR 1000 s behavior in manual programming 17 5 1 3 Manual programming asctscieducnsuntskscctuhbudtsandachd etie iososnd usui mte DM etu rtta biduo pnto ud URL 18 5 2 Programming with HART handheld HHC Communicator 19 5 2 1 Characters available for alpha numerical data functions in PCSTAR2 and on the HART CONSOIe ccccccssccssecesseccssseeseeesseesesseeesseeeaeeens 25 5 3 GWR 1000 2 wire T D R meter characteristics sseeeesesseeesssee 25 5 3 1 Gauge operating logic when the reflection is lost sseeesssssee 26 5 3 2 Gain and voltage amplitude 2 9 9 9 TYPICAL Signal eNd Seisi ee eee 29 29 adus MEN cesa raa 30 5 3 5 Level measurement when more than one phase or layer in the tank 31 OA MOUDISSMOONING ERNEUT 32 5 5 Appendix 1 Set up parameters of GWR 1000 H 400 series in Multicont controller 35 BINMASTER 925 0311 Rev B 0113 INTRODUCTION GUIDED MICROWAVE LEVEL MEASUREMENT factory set value of the Min measuring distance dead zone X Than the pre programmed Y upper dead rone sel hyfer gt u 2 5 Q I O
39. t 2 1 1 5 2 Sensorlowerlimt O Read only Menu Lower sensor limit Read only Menu Sensor minimum span 2120 DISPLAY 925 0311 Rev B 0113 gt u 2 5 Q I O e e e i as z O BINMASTER Function Fct Input Range 2121 LENGTH 2 1 2 1 1 LENGTH Select m cm mm Length unit of displayed value level distance UNIT inch Ft optional unit The optional unit allows the user to define a new unit name and factor see menu 2 1 2 1 3 DISPLAY 0 1 2 3 4 5 expo Number of decimal places FORMAT nential format auto Defines the displayed length values format option of the HART communicator H275 2 1 2 1 3 0 DEFINE NEW UNIT 2 1 2 1 3 1 UNIT 4 ASCII characters Optional unit name User has to enter the unit name NAME UNIT before using it in the menu LENGTH UNIT 2 1 2 1 3 2 UNIT Enter 0 0 to Optional unit factor User has to enter the Unit Factor FACTOR 100000 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 24220 VOLUME o 2 1 2 2 1 VOLUME Select m3 US Gal Unit for conversion values UNIT Ft3 bbl M3 h Ft3 h kg volume table Metric Tons US Tons The selected unit is only used to display the conversion value from the strapping table 2 1 2 2 2 DISPLAY 0 1 2 3 4 5 ex
40. touching the tank bottom with the counterweights for cable probes or probe end other types Avoid mounting near objects discontinuities inside the tank that influence the probe s EM electromagnetic field Install the gauge far from protruding objects such as heating tubes sudden changes in tank cross section tank wall reinforcements and beams weld lines and dip stick pipes etc 925 0311 Rev B 0113 BINMASTER 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 4 Shortening cable probes If required the cable probe can be short T AVAS ened but this applies only when used in 2 liquids E N Procedure NN 1 Detach socket set screw M6x10 ISO 4026 with 5 mm Allen hexagon key ISO 2936 15 28 gt O 5 Q I O e e e i as z O i 2 Pull cable out of counterweight and SS SYN shorten to required length using cable NN cutters to prevent the cable wires and NA B N strands from splaying out SS RS A LL NA 3 Insert cable back into counterweight SS N SS x N and tighten down screws NA SS 4 Change configuration parameters to SS new probe length the reference point is WS the top edge of the weight user menu LR TS N SS function 1 1 6 M12
41. tput setup 92 Ullage volume Current mode Current min Failure current 94 Current max Error delay 9 Hold Failure current L None 8 22 mA Error current 10sec in 20sec 30sec 1 min 2 min 5 min 115 mn gt O 5 Q I O Q e e e i as z O ana Treshold 98 Application Ampl p00 3454 mV Treshold Dist 125 m Pulse ampl 820mV Gain 3 Service 89 Service code Applicationtype 94 type 1 Liq 1 Level Psion T 2Liq 1 Level Parameters in the Service Menu are read only parameters Changing of these parameters requires the service code of the instrument htk4014a0600p 01 doc August 2012 BinMaster reserves the right to change technical data without notice 925 0311 Rev B 0113 BINMASTER
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