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1. KROHNE 03 2004 7 02229 33 00 Subject to change without notice Installation and Operating Instructions BM 102 MICROFLEX TDR Level gauge Variable area flowmeters Vortex flowmeters Flow controllers Electromagnetic flowmeters Ultrasonic flowmeters Mass flowmeters Level measuring instruments Communications technology Engineering systems amp solutions Switches counters displays and recorders Heat metering Pressure and temperature Table of contents wesch x x sch gh w w w w w whin Q OO N Mechanical installation J J U U u u uu uu 5 ele line and Ee le EE 5 Installati n restrictions u u LU L Naa Gusan asas ENEE ENEE EEEEN doc 7 Mounting on the tank a 7 Installation Instructions General notes 7 Installation instructions noze v 2 c cecccseceeseceeeasdeneesandedeedecdecendec deenadaddadesdeedetuedeedaasadaedens 7 Installation instructions Gauge all applications a 9 Specific installation instructions gauge liquid appltcatons 12 Specific installation instructions gauge Solid applcatons a 13 Electrical connections I U u u uu uuu u 16 Electrical installation instructions L a 16 Wiring general notes 16 Wiring connections DIN CGonnechor L a 16 Wiring connections M1
2. 2 gt Online 3 Frequency Device 4 Utility F1 F2 F3 F4 Main menu 3 BM102 00000 01 lt Process Var gt Kal 1 lt Measurements gt 2 lt Input Outputs gt SAVE HOME F1 F2 F3 F4 o N A Measurement amp input and output functions menu ERDHNE 2 BM 102 Two pin jack for loop connectors LCD Function keys F1 F4 Action keys On off UP n a Arrow LEFT DOWN RIGHT Arrow Arrow Arrow Other functions LEFT Arrow Previous menu key RIGHT Arrow Select key BM102 00000 01 Online Kal 1 gt lt Process Var gt 2 lt Config Test gt 3 lt Access Rights gt 4 lt Watch status gt 5 lt HART Variables gt SAVE F1 F2 F3 F4 Online menu BM102 00000 01 v lt Measurements gt i 1 lt Lvl gt 878 00 mm 2 lt Dist gt 121 00 mm HELP SAVE HOME F1 F2 F3 F4 Measurement display function 21 3 3 3 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 This is available on request from KROHNE Technical data DA 06 Plug in Display non Ex DA 06 Plug in display supplied separately m
3. Probe Maximum Load Single cable 8 mm or 0 3 3 5 T or 7700 Ib Traction on cable according to product approximate value in metric tons Probe Length m ft Probe used Material 10 33 20 65 5 24 79 Single cable 8mm or Cement 1 0 Tor 2200lb 2 0 T or 4410 Ib 2 4 T or 5290 Ib 0 3 Flyash 0 5 Tor 1100lb 1 0 T or 2200 Ib 1 2 T or 2650 Ib 14 BM 102 KROHN 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 BM 102 E S D protection It is the customer s responsibility to avoid E S D by grounding the tank product and probe installation Danger of injury 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 Earth the entry pipe and product Product deposits on the nozzle and probe Product build up can occur under the nozzle this may weaken the pulse Avoid cavities that permit the build up of deposits Tank roof deformation Tank roofs should support loads of at least 3 5 tonnes or 7700lb for gauge installations using 8mm or 0 3 type 6 single cable probes KROHNE BM 102 15 2 Electrical connections 2 1 Electrical installation instructions 2 1 1 Wiring general notes Connection to power is effected at the pl
4. and the product surface level liquid interface amp volume Variable according to probe type see Equipment architecture section 4 2 1 Minimum tank height 0 15 m or 0 5 ft Variable according to probe type see probe measurement limits section 4 2 2 4 20 mA passive output Load Passive outputs 750 Q maximum Error signal 22 mA Resolution t3 pA HART passive output HART passive intrinsically safe output Status markers via PC STAR 2 or HART controller HHC Reference operating conditions Ambient temperature Ambient air pressure Relative air humidity Reference target Free space diameter Distance to obstruction Accuracy Level measurement not for coaxial probe 26 20 C 5 C or 68 F 9 F 1013 mbar abs 20 mbar or 14 69 psig 0 29 psi 60 15 coaxial probe single probe 0 8 m or 31 5 in metal plate twin probe metal block short circuit gt 300 mm or gt 11 81 gt 1mor gt 3 3 ft water surface Liquids when probe length L lt 15 m or 50 ft 15 mm or 0 6 outside the dead zone Optional 5 mm or 0 2 Liquids when probe length L gt 15 m or 50 ft 15 mm or 0 6 0 1 of the measured distance Optional 0 05 of the measured distance Solids powders 20 mm or 0 8 with 4 20 mA current output 0 01 of the measured distance BM 102 EROHNE Repeatability Hysteresis Resolution Transient recovery time Start up time
5. o Measuring range Display Accuracy Adjustable parameters Min max value memory Housing Protection Temperature range ambient Electronic system Storage Electrical connection Input signal Max voltage drop across unit Switching output1 CE conformity 22 DA 06 Plug in display mounted on a BM 102 1999 to 9999 digits min and max values user defined 4 digit 7 6 mm or 0 3 high red LED display display housing can be turned through 330 0 1 1 digit Scaling decimal point attenuation switching point delay Displays the minimum and maximum values recorded during operation Plastic PA 6 6 polycarbonate 47mm X 47mm x 68 mm or 1 9 x 1 9 x 2 7 h x w x d housing can be turned by 300 IP 65 EN 60529 or NEMA4 0 C 60 C or 32 F 140 F 30 C 80 C or 22 F 176 F Adapter for plug as per DIN 43650 4 20 mA 2 wire Approximately 6 V DC open collector PNP max 125 mA on and off delay 0 to 100 seconds temperature influence 0 1 10 K EN 50081 1 and EN 50082 2 BM 102 EROHNE 3 4 Fault clearing Event Fault Action Error messages Tank full status marker on reading frozen at max or min value No fault The level has reached and possibly risen above the top configured measurement limit and is either displaying the maximum when measuring level or minimum when measuring distance output
6. Long term drift 2 mm or 0 08 none 1 mm or 0 04 The transient recovery time to 1 deviation from the final value amounts to approximately 4 6 times the programmed time constant However the transient recovery time may differ if changes in level are very rapid lt 23 seconds This is within the specified error of measurement Allow for thermal expansion coefficient in the case of liquids Organic liquids 0 15 K Influence of ambient temperature current output measured value atmosphere digital Environment Ambient temperature Storage temperature Protection Shock resistance Vibration endurance limit Power supply Standard Hazardous duty Ex FM Range Process Process temperature product Process temperature flange Process pressure standard HART typically 70 ppm K 25 ppm approx max deviation over total measurement range 1 ppm K above the liquid product No influence on measured value due to regular self calibration 30 C 60 C or 20 F 140 F 40 C 80 C or 40 F 176 F IP 65 NEMA A AN The device withstands the impact test in conformity with EN 61010 Section 8 2 with 0 5 J energy IEC 68 2 6 and prEN 50178 10 57Hz 0 075 mm 57 150 Hz 1 G 24V DC lt 28 V DC 18 35 V DC 30 C 200 C or 22 F 392 F 30 C 90 C or 22 F 194 F option 200 C or 390 F 1 16 bar abs or 14 5
7. NPT threaded connection diameter especially for single probes and powder applications ed h lt d whereh nozzle height and d nozzle diameter Contact KROHNE if this relationship cannot be respected EROHNE BM 102 7 Nozzles extending into tank Caution Do not use nozzles that extend into the tank This will disturb the electromagnetic emitted pulse and the measurement Installation of two devices If two devices are to be used on the same tank these should be mounted a distance of at least 2 m or 6 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 gt 2mor6 ft Process connection For the gauge to make accurate measurements e The tank process connection must be level e Ensure a good fit with the gauge process connection e The tank roof should not deform under the weight of the gauge 8 BM 102 KROHANE Process connection and entry pipe Caution Do not put the nozzle close to the entry pipe Pouring the product directly onto the probe will give false readings Install deflector plate if impossible to distance gauge from entry pipe Install far from the entry pipe or fit deflector plate product in Stilling wells Tanks with float
8. None Measurements should be normal once the level is in the configured measurement range Tank empty status marker on reading frozen at max or min value 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 None Measurements should be normal once the level is in the configured measurement range Tank full and Level lost status marker on reading frozen at max or min value The level has entered the gauge s top dead zone and can no longer detect a return signal Empty the tank below the top measurement range limit and check the measurement Level lost status marker on reading is frozen 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 Parasite signals from the flange or obstructions in the tank may render the gauge unable to identify the correct signal Empty tank below maximum level or fill tank above the minimum level and check the measurement If the signal is not detected then modify the control threshold manually as shown in sections 3 5 2 and 8 4 2 of the BM 102 Handbook using the oscilloscope F7 and dynamic configuration F11 windows in PCSTAR 2 Reference not found status marker on Occurs
9. X Do not fit the gauge near to these objects Recommended minimum distance of probe from objects inside the tank Probe Type Minimum free space Single types 1 2 and 6 300 mm or 12 Twin type 4 100 mm or 4 Coaxial type 3 0 mm or 0 Electromagnetic field shape around probe by type not to scale Single types 1 2 and 6 Twin type 4 Coaxial type 3 600 mm or B24 Y b H mm or Be 628 mm d EE Zo or 1 1 50 mm or 2 gt n A on E a i We pe SA z No beam angle for any probe type EROHNE BM 102 11 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 180mm or 7 167mm or 6 6 60 C or 140 F l i 30 C or 22 F 185 5mm or 7 3 1 3 4 Specific installation instructions gauge liquid applications Probe bending in agitated products recommended solutions 1 Agitator 2 Turnbuckle for anchoring probe to tank bottom 3 Bypass chamber 3 4 Counterweight centred on request 4 Mounting on a reference vessel or still well is ideal To ensure that the probe does not come into contact with the tank wall the end of the probe should be fixed to the bottom of the chamber or centred 12 BM 102 KROHN Fastening the probe to the tank bottom T
10. in the BM 102 Handbook F2 Device configuration a summary of the parameters are given on the next page F7 Oscilloscope function have all reflections occurring at the probe displayed F11 Dynamic on line device configuration F4 View and record all information during operation F6 Trend observe the level trend since start of the program F8 Marker the status of the device And F10 make printouts screen shots Special note 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 3 4 Fault clearing for corrective procedures when the markers shown above are active This document is available from your local KROHNE Sales office or on the Download Centre on KROHNE s website http www krohne com 20 BM 102 KRUDHNE 3 3 2 HART Communicator Display and configuration can also be carried out via a HART communicator Operator control via this unit is described in detail in the operating instructions supplied with the HHC Basic operating instructions for taking measurements Communicator layout Sa BM102 00000 01 Online Self test in progress 2 l 3 oou HART Commun cator 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
11. is designed solely for measuring the distance level volume and ullage of liquids pastes slurries and powders It can continue to measure the level or distance of the top product and total volume in applications with two or more products The level measurement data can be displayed and the gauge configured using either a HART Handheld Communicator console HHC or a PC work station equipped with PCSTAR 2 software which is supplied as standard with the gauge Principal gauge components BM 102 housing and probes non Ex and Ex versions with high with raising temperature converter option option d di GB 15 12 13 T H dl 10 e A 2 1 Nameplate see next page for details 2 Cable entry output and power supply to wiring compartment 3 Equi potential bonding system connection for Ex applications 4 Flange process connection onto tank or other suitable mounting 5 Single cable probe 6 Counterweight with threaded hole in base for anchoring 7 Twin cable probe 8 Spacer 9 Chuck for single cable probes 10 Turnbuckle for twin or single cable probes 11 Threaded process connection e g G1 NPT1 12 Coaxial probe 13 Extension tube for high temperature applications 14 Single rod probe 15 Raising converter coaxial tube under the process connection i e an inactive length of the probe for installations with long nozzles or concrete roofs for si
12. when there is a problem with the time base on the HF board Please contact your local KROHNE Service Centre Level lost and Reference not found status markers on reading frozen The probe has received an electrostatic discharge 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 your local KROHNE Service Centre Gauge connected to PC STAR 2 software or HART Handheld Controller HHC with Marker status window F8 or Watch status Menu 4 0 list displayed respectively A list of contact details for every KROHNE service centre is supplied on the last page of these instructions KROHAE BM 102 23 Event Fault Action Flange not found status marker on 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 Contact KROHNE for the corrective procedure 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 The emitted pulse has not
13. 1 kg m or 0 28 Ib ft 0 12 kg m or 0 08 Ib ft 0 24 kg m or 0 16 lb ft 0 41 kg m or 0 28 Ib ft 1 3 kg m or 0 87 lb ft The level gauge satisfies the protection requirements of Electromagnetic compatibility Directive 89 336 EEC in conjunction with EN 61326 1 A1 amp A2 and EN 61000 6 2 standards It also respects the NAMUR NE 21 98 standard Protection against EMC emissions is only guaranteed when the device is used in metal tanks except when the device is equipped with coaxial probes Low voltage electrical equipment Directive 73 23 EEC modified by Directive 93 68 EEC art 13 in conjunction with the EN 61010 1 standard ATEX Directive 94 9 EC in conjunction with EN 50014 EN 50020 and EN 50284 standards Refer to the BM 102 MICROFLEX KEMA 00 ATEX 1101X Supplementary Installation and Operating Instructions for further information EP 111 G orl 1 2D T 100 C EEx ia IIC T6 T3 or EEx ia IIB T6 T3 FM Class I Div 1 Gr A B C D and Class Il Ill Gr E F G FM Class Zone 0 AEx ia IIC T4 resp AEx ia IIC T6 Class Div A B C and D Class II Div E F and G Class III Ambient temperature 30 C 60 C or 20 F 140 F max product pressure 4000 kPa 580 psi only approved if requested in customer order 28 BM 102 EROHNE JSONDOI UO pyy 1 PMOd ysenbe uo Jeuf uono uuo2 buey UA o6neb peyeoo qd 91E SS zzo oll seH 92Z9 oll lseH q79LE 9LE S
14. 2 Installation restrictions Hazardous duty systems Ex FM e Refer to the BM 102 MICROFLEX KEMA 00 ATEX 1101X Supplementary Installation and Operating Instructions supplementary instructions for further information on installing gauges approved for use in hazardous locations This document is available from your local KROHNE Sales office or on the Download Centre on KROHNE s website http www krohne com e Check that the flange gasket and probe materials are compatible with the product Read the information given on the converter nameplate the flange markings and specifications in the approval certificates 13 Mounting on the tank 1 3 1 Installation Instructions General notes The fitter should give some thought to tank fittings and tank shape e 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 e Type of tank roof i e floating concrete integral etc and base i e conical etc Whenever working on an installation remember to e Disconnect the power supply before starting work e Drain the tank completely before installing the device not applicable to cable probes 1 3 2 Installation instructions nozzle Threaded process connections Nozzle height The simplest and most economic way is to Recommendation mount the BM 102 directly on the tank with a Do not fit a nozzle longer than its GAS or
15. 232 psig max 40 bar or 580 psig at 20 C or 45 F Dielectric constant er of product measured probe type limits Coaxial type 3 Twin probe type 4 Single probes types 1 2 amp 6 Human interface Communication standard gr gt 1 4 gr gt 1 8 gr gt 2 1 Operator control and data display via PC using PCSTAR 2 software or HART handheld communicator Point to point 1 gauge connected to a PC or HHC Multi drop Up to 5 gauges connected to a PC or HHC see BM 102 MICROFLEX KEMA OOATEX1101X Supplementary Installation and Operating Instructions for Ex values temperature classes higher or lower temperatures on request non Ex Subject to the process temperature and the mechanical properties of the process connection KROHNE BM 102 27 Construction materials Housing Probe Gasket Spacers on twin probes Weight Housing Single rod 8mm or OO 2 Single cable 4mm or G0 15 Twin cable 4mm or 0 15 Single cable 8mm or OO 2 Coaxial 28mm or 1 1 Standards Electromagnetic compatibility directives followed for EU countries Other EU directives Approvals ATEX KEMA 00 ATEX 1101 X Factory Mutual Research Project ID 3009543 CSA Project 1183965 Edition 1 KEMA 2007223 00 Aluminium with epoxy coating Refer to section 4 2 1 BM 102 mechanical options Viton optionally Kalrez 6375 Refer to section 4 2 1 BM 102 mechanical options 2 kg or 4 4 Ib 0 4
16. 6 terminal box 17 Power S pply uu a cates weve tua enue cco cage ev eclec once ne vumenicn dou cesubaene ch esecqeuchsteexseanatice 17 Non hazardous duty version nn sns 17 Flazardous d ty Version 25 2 caus L UI ssceeneautvess as Couneccpcees vacsevacatsewnstosseeacdeeneeartaaes 18 User interface TE 19 Power on and Startup sicecistccctis cet u uuu miays aa aAa PECE KENE KEE bens veces 19 Available User interfaCe ccc cccccceseeecesceceecocdecesdacendaudecesdecdeecndacdeeeudacdenssdeedessedeedausaderdenne 19 Operator control and depnlay ee eeeeeeeeeeeeeeeeneeeceeaeeeseeeeeeesaaeeeeeeeaeeeeneeeeseaeeeeeeeaeees 19 PCSTAR 2 Version 2 01 for Windows basic installation amp operating instructions 19 HART Communtcator n nn nn ua 21 Local user display instruments equipped with DIN connectors only 22 Fault CIOANING TEE 23 Technical data ccccccsccceeseeeeeseeeeeeeeeeseeeeeeeeseneceeeseseeeseseneeeseseneeeeeseaeseseseeesaaseeseseseenseeneaes 26 Technical EC 26 BM 102 equipment architechure lll l u u uuu insiti iiri iiia 29 BM 102 mechanical options by probe type a 29 Probe measurement mie 31 Gauge GIMENSIONS u uuu un apu ee gg REENEN EES 32 BM 102 EROHNE 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
17. E Bottom measurement limit of probe Standard counterweight None 45x60 25x100 None 12x100 O 2x4 or O1 x2 1x4 045x245 1 xX9 Size of threaded hole in base of counterweight for anchoring None M8 M8 None M8 Dimensions in mm inches with a cable fitting M16X1 5 3 5 8 with a cable fitting PG11 8 10 DIN43650 A the inactive length i e a non active extension at the top of the probe may be supplied with the following standard lengths 100 mm or 4 200 mm or 8 300 mm or 12 400 mm or 16 500 mm or 20 and 1 m or 40 for single cable and single rod probe versions only where L gt 10m or gt 33ft where L lt 10m or lt 33ft L ordered probe length 32 BM 102 KROHN 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 Due to statutory regulations on environmental protection and safeguarding the health and safety of our personnel KROHNE may only handle test and repair returned devices that have been in contact with products without risk to personnel and environment This means that KROHNE can only service your instrument if it is accompanied by the following certi
18. S TILE SS T9LE 9LESS T9LE OLE SS TOILE SS Ieu euu qoid LAN ALD AL LAN ab 9D ab LdN bh Dub xxLdN II LdN bh Dub sql OSL ISNV Z sql OSL ISNV Z sql OSL ISNV Z sql OSL ISNV Z sql OSL ISNV Z uono uuoo Ov SZ Nd OSNA Ov SZ Nd OSNA Ov SZ Nd OSNA Ov SZ Nd OSNA Ov SZ Nd 0SNd ss 2o1d unnuuu IN 43 Jue SUOD 911 99 91p L L L sl FL uunuuullW s ninunuoosip V JO Pa 10 vZ 10 8 10 OO Jo iosuomnonidsqo ww 009 ww 009 ww 009 WW OO WU 0 ou og 14 62 1O W pg 5 xx H OLIOWE 5 62 1O W pz 5 62 10 W pz 5 4 oz dO w95 xeuu suey 19497 jJu6i wu lunoo pue 1Ino4i2 poys UA yy6ue eu Buoje p si dsi lu JuBi wu lunoo YMN JuBi9wu nunoo UI si oSeds uA saldE qnl Ano loid YIM lqe2 aide Bu s pos DUDU BuiS lqe25 ajqixey alfue LESS lqix l oA 4oJONpUOD J uul Bu s uondii5s dq BM 102 equipment architecture 9 d L 0 1O ww g ajqeo 6u s L ad 0 10 ww g pol Bu s t 9dA1 G 4 0 10 WW p ajqeo um z adAL GL 0 40 WW p ajqeo 6u s adAL Lg ww gz Ivo IEIEO po d L qoid 4 2 1 BM 102 mechanical options by probe type 4 2 suoneolldde seg pinbi1 pinb 1 29 BM 102 ERDHNE JSONDOI UO pyx y ys nb i uo 1 yfly JapMOod m H f H uoneusnilii Bneo nal TIOUN nal TO LE Oponquin L J9L epronquin L WEE WO
19. been detected The gauge will not work until it has been found Occurs when there is a problem with the time base on the HF board The signal converter may need replacing Please contact your local KROHNE Service Centre Please contact your local KROHNE Service Centre General operation The BM 102 indicates an incorrect level value The BM 102 measures a non valid reflection Check the tank for obstructions and verify that the probe is clean When the indicated level is close to the nozzle increase the detection delay and the dead zone with the same ratio or increase the threshold level if the full measurement range is essential In any case use the PCSTAR 2 oscilloscope function F7 to visualise and to analyse the application The threshold level must be adjusted so that it masks the disturbances Very large pulses along the measurement signal same amplitude as the emitted pulse can be caused by a probe touching the nozzle or tank side section 1 3 5 Instrument is not accurate when there are two or more phases in the tank The instrument may be incorrectly configured for this type of application i e it is measuring the interface instead of the level Contact KROHNE 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 to
20. d with the level meter ordered it is available in the Download Centre on KROHNE s website http www krohne com Supplementary Installation and Operating Instructions BM 102 KEMA 00 ATEX 1101X Supplementary instructions covering devices to be installed and used in hazardous areas This document is only supplied with specially approved instruments This document is available from your local KROHNE Sales office or on the Download Centre on KROHNE s website http Awww krohne com 4 BM 102 KROHN Product liability and warranty The BM 102 TDR level gauge is designed for measuring the distance level and volume of liquids pastes slurries powders and cereal products It may equally measure level distance and total volume in applications with two or more products Special codes and regulations apply to its use in hazardous areas please refer to the BM 102 MICROFLEX KEMA 00 ATEX 1101X Supplementary Installation and Operating Instructions for further information This document is available from your local KROHNE Sales office or on the Download Centre on KROHNE s website http www krohne com 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 forming the basis of the purchasing contract are appli cable If you need to return measurin
21. ependent on Uinput min 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 KROHN BM 102 17 Load impedance Rioop Loop resistance Rioop user Reable Rammeter Min Rioop 0 ohms Max Rioop 750 ohms Ruart resistance for HART communication 250 ohms recommended 20 I 19 voltage B minimum Supply Voltage Van for a loop drop over R g resistance R Of 250 measured at 18J nen o RER ___ the terminals of the supply 17T resistance ass i i T at 4 mA gt 16 g 15 D j voltage drop minimum input voltage Vinput over 250 Q resistance at measured at BM 102 terminals 20 mA zech lt ve DC u GA 0 2 4 6 8 10 12 44 16 18 20 22 loop current mA Line A minimum voltage at the BM 102 terminals Line B voltage drop caused by a 250 ohm loop resistance Example for calculating the required 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 5V 10V 15 5V In order to cover the whole current range the voltage drop must also be tested at 4 mA U power min 4 4 MA x load impedance Uinput mi
22. f the BM 102 Handbook also try adjusting the threshold using F11 Dynamic Configuration function PCSTAR 2 or menu 2 1 5 1 0 Threshold HHO Data communication via the digital interface is not working The BM 102 is in its start up phase wait 50 seconds and try again The communication parameters of the computer are set incorrectly Check computer setting address device number Bad connection to the interface Check connection Current output value is lt 4 mA Contact your KROHNE Service Centre Current output value is 22 mA If problem persists then contact your KROHNE Service Centre This document is available from your local KROHNE Sales office or on the Download Centre on KROHNE s website http www krohne com KROHNE service centre contact details are supplied on the last page of these instructions KROHAE BM 102 25 4 Technical data 4 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 Performance characteristics Continuous level measurement of liquids solids and powders Time domain reflectometry using a direct mode of measurement See section 4 2 Distance between the reference point gauge flange facing
23. ficate confirming that the instrument is safe to handle If the instrument has been operated with toxic caustic flammable or water endangering products you are kindly requested e to check and ensure if necessary by rinsing or neutralizing that all cavities are free from such dangerous substances e to enclose a certificate with the level gauge conforming that it is safe to handle and stating the product used We cannot service your instrument unless accompanied by such a certificate Specimen certificate Company Address Department Name Tel No Fax No The enclosed level gauge Type KROHNE Order No or Serial No has been operated with the following process liquid Because this liquid is water hazardous toxic caustic flammable we have checked that all cavities in the instrument are free from such substances flushed out and neutralized all cavities in the device We confirm that there is no risk to humans or environment through any residual liquid contained in the instrument Date Signature Company stamp KROHN BM 102 33
24. g instruments to KROHNE please note the information given on the last page of these Instructions KROHNE regrets that they cannot repair or check your device unless it is accompanied by the completed form sheet The level gauge does not form part of an overfill protection system as defined for example in WHG German water resources act nor is it concerned by the Pressure Equipment Directive PED 97 23 EC 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 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 7 KEE REEERE z Z7777777 7 ERDHNE BM 102 5 Avoiding blows When handling the BM 102 avoid hard blows jolts impacts etc Caution Fragile electronics bz lt Avoid bending single rod and coaxial probes Support the probe to avoid bending East l t t Support probe here 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 400 mm or 16 minimum Storage temperature Store within the given storage temperature limits 80 C or 176 F 40 C or 40 F 6 BM 102 KROHN 1
25. gt 1 JSuN 191 yonyD CI9LE SHZ X Sr 9ZZOH OOL x SZ ww HEE WO lt 17 aam ZZOH 004 X Geo G9LE eponquin L ul suoiug uiip 19L 00L X ZL uoN 19LE 00L X Geo 19L 09 x sr uoN luBl wmu l unoS lqeo eu U Suouugs lt yaoeds oN aoeds oN ygoeds ON oluo papjnow d34 u jB5u 4 F4id jeueyew veds 9 d L 0 40 WW g jqe 6uis L d 1 0 40 WW g pol Buis z d 1 G 4 0 40 WW PO OO 6uis t d L SL 0 40 WW p 9 qQE2 UML d 1 L L 40 ww gz 1X9 IEIEO apoo d l aqold suoneo ldde seg pinbi1 pinb q KRUDHRE BM 102 30 4 2 2 Probe measurement limits Flange facing d A Meter will freeze if 8 tank filled above this EE 5 level GE S i ER bi CL mD ll S A Ue ee S Meter will indicate probe length if tank Y emptied below this Y _ level Displayed level and distance values displayed will depend on how and at what level the minimum and maximum gauge outputs have been configured Probe measurement limits Probe type Top dead zone Bottom dead Top dead zone Bottom dead A1 zone A2 A1 zone A2 er 80 er 80 er 2 4 er 2 4 Single rod type 1 300mm or 12 20mm or 0 8 400mm or 15 100mm or 4 Single cable 04mm 300mm or 12 20mm or 0 8 400mm or 15 100
26. he flexible probe can be fastened with a chuck ring or a fastening device to the tank bottom Z 5 EI S 8 ee GE il aj ZS ST o J T g a a 8 2 O E O15 5 oc 8 ei El o bo 2 i 03 ET 03 el 5 o 2 a gt a EEN VK 3 3 z Ost 5 g GI CO l gt Ke E S NEE 2 SIE S D Kal j D ff Ds Soyer 1 D E i Chuck ring Turnbuckle for 8 mm cable Turnbuckle for 4 mm cable probes probes 1 3 5 Specific installation instructions gauge solid applications False readings 1 Do not let probe touch the side of the nozzle KRDHNE BM 102 13 Conical silo nozzles False readings and traction on the cable probes Caution 1 High traction forces We recommend that the probe should not be anchored to avoid excessive traction loads on the cable 2 Bending and traction Position the connection on the roof at 1 radius of the tank and with minimum nozzle height This will avoid damage due to bending and traction during emptying Traction forces during emptying cycles for powder applications 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 at which cable probes will support Cable maximum design load traction
27. ing 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 at tat Za aaa Fa 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 KROHAE BM 102 Installation of level meters with single or twin cable probes 2 1 Caution Do not over bend E probe 1 5 2 Inserting the probe hold more than one x metre above the I opening to avoid S F cable bending Probes entanglement straightness and tank bottom clearance Rigid section B see table Rigid section length of single and twin cable probes Cable diameter Rigid section length Single cable 4mm 0 15 40mm or 1 4mm 0 15 200mm or 8 Twin cable 4mm 0 15 40mm or 1 e Cable probes must be straight once inserted into the tank They must also be far from other objects e g mixers to avoid entanglement e In order to maintain the gauge s operating characteristics it is recommended to avoid touching the tank bottom with the counterweights for cable probes or probe end other types Objects discontinuities inside the tank that influence the probe s EM electromagne
28. le setup exe and follow the instructions on the screen 3 Running the program once the program is installed execute the program 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 The serial port allows the user to select a free serial port COM 1 to 4 on the computer BM102 Address 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 If you are ina point to point network leave the box at its default value 1 Device Identifier Device Identifier refers to the Device number given in User Function No 1 4 4 Initial baud rate Transmission rate of data Has a default value of 1200 bd Trials should be run to find the optimum operating conditions RTS state The RTS state depends on the type of RS232 converter used For RS232 lt gt HART i e VIATOR from MACTEK use inversed RTS state On line connection with the gauge Press F2 or left click on F2 Connection to set up the connection with the device the configuration parameters are automatically loaded into the gauge 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 are discussed further
29. mm or 4 or 0 15 type 2 Coaxial type 3 Omm or 0 10mm or 0 4 Omm or 0 100mm or 4 Twin cable 4mm 150mm or 6 20mm or 0 8 300mm or 12 100mm or 4 or 0 15 type 4 Single cable 8mm 300mm or 12 20mm or 0 8 400mm or 15 100mm or 4 or 3 type 6 The dielectric constant er of water is 80 The dielectric constant er of oil is 2 4 Note The default factory setting for A1 is 400 mm or 15 except for the coaxial probe 0 mm or 0 Please consult KROHNE if you wish to reduce the size of the programmed top dead zone A1 If the device is mounted on a tank fitting e g a nozzle include the height of the tank fitting in the programmed dead zone ERDHNE BM 102 31 43 Gauge dimensions The drawing below illustrates standard gauge configurations and overall dimensions 70 2 75 70 2 75 i m Ve 5 HT H41 t G1 zl Ee Log z c Standard Standard DIN 7 High With M16 terminal box with connector with temperature inactive flange threaded version length Li COnnection U GE E Probe EE EES 3 Coaxial 4 Twin cable 2 Single cable 1 Single rod 6 Single cable 28 1 1 4 0 15 4 0 15 8 0 3 8 0 3 F730 1 2 30 1 2 30 1 2 l i I l i I 4 l
30. n 4 U power min 4 4MAx 250 ohms 18V 1V 18V 19V At a load impedance of 250 ohms a power supply voltage of 19 V is sufficient to energize the device current range of 4 to 20 mA 2 2 2 Hazardous duty version The certified device may only be used with other Ex certified equipment Refer to the BM 102 MICROFLEX KEMA 00 ATEX 1101X Supplementary Installation and Operating Instructions supplementary instructions for further information on installing gauges approved for use in hazardous locations This document is available from your local KROHNE Sales office or on the Download Centre on KROHNE s website http www krohne com 18 BM 102 KROHN 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 warm up time of less than 23 seconds should be allowed for once connected and the power is switched on 3 2 Available user interfaces Measurements may be taken using either e PC STAR 2 software Included as standard with the instrument The basic installation amp operating instructions are presented in section 3 3 1 requires PC workstation e HART Handheld Communicator HHC Sold separately Automatic recognition of the instrument when connected A list of HHC accessible parameters is given in the BM 102 Handbook e DA 06 local indicator Sold as an option for devices equipped with DIN connectors For displayi
31. ng readings only Refer to section 3 3 3 for technical data 333 Operator control and display You can configure the device by way of the PC STAR 2 software or the HHC Refer to the BM 102 Handbook section 3 3 for more details This document is available from your local KROHNE Sales office or in the Download Centre on KROHNE s website http www krohne com 3 3 1 PCSTAR 2 Version 2 01 for Windows basic installation amp operating instructions Software description PC STAR 2 is a Windows program that permits clear and concise display of data and configuration of the BM 102 from a remote location The program is available in English German or French PC STAR 2 system requirements PC with at least 486 processor 75 MHz recommended Pentium 120 MHz or higher Microsoft Windows 9x Me 2000 NT and XP Min 16 MB main memory RAM Min 3 MB available hard disk storage 3 Floppy disk drive Mouse or other pointing device Serial RS232 port KROHN BM 102 19 Installing and connecting the PCSTAR 2 software 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 fi
32. ngle rod and single cable probe versions only ERDHNE BM 102 3 Peron C C J MICROFLEX BM102 Type code Jeun Ht Date of manufacture Cuk J Order number Se Lu Tag Gauge ID number Se Ht Serial number L Power supply details Housing protection class e g IP65 Mechanical constant calibration factor Ambient temperature range Maximum allowable working temperature at the flange Standard nameplate eg VF030415B0112110110100000 The type code is defined in the BM 102 Data Sheet This document is available from your local KROHNE Sales office or in the Download Centre on KROHNE s website http www krohne com Items included with supply The scope of supply encompasses in the version as ordered e Signal converter with probe in the version ordered The version is stated on the nameplate e PCSTAR 2 computer software for data display and gauge configuration Documentation supplied Installation amp Operating instructions this manual 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 Handbook Detailed user manual and reference book including how to configure meter parameters available in the user menu and how to perform basic maintenance This is not shippe
33. onnected to the housing of the signal converter or to the device flange To avoid ground current loops the cable shielding may not be connected at both ends Hazardous duty systems Ex When used in hazardous areas only one intrinsically safe power supply may be connected to terminals 1 and 2 Ground terminal E and terminal 3 are not connected 16 BM 102 KROHN 2 1 3 Wiring connections M16 terminal box Power terminals Wire cross section max 1 5 mm AWG 16 Cable entry 1x M16 x 1 5 cable diameter 3 5 8 mm or 0 14 0 31 IP65 or NEMA4 For USA 1 2 NPT conduit connection Shielding 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 to be connected Caution Ground terminal E is not connected to the signal converter housing or to the device flange To avoid ground current loops the cable shielding may not be connected at both ends 1 Detach the 4 screws T and remove cover from terminal compartment 2 Connect the cable ends fitted with ferrules to the power terminal U not polarity sensitive 3 Shut the terminal compartment 2 2 Power Supply 2 2 1 Non hazardous duty version Power supply Rated voltage 24 V DC Max voltage 35 V DC Uinput max Ex 28 V DC Min voltage d
34. p product above the bottom product Gauge connected to PC STAR 2 software or HART Handheld Controller HHC with Marker status window F8 or Watch status list Menu 4 0 displayed respectively KROHNE service centre contact details are supplied on the last page of these instructions 24 BM 102 KROHAE Event Fault Action Electrical Connections and Communication Output Current Output value No power supply Check the power supply lt 4 mA Connection of the device is Check the connection between the incorrect device and the power supply The calibration of the current Execute the calibration if you have output is incorrect authorized access or contact KROHNE Service Centre Reads 22 mA An error has occurred This happens in case the range 4 20 mA error 22 mA is selected Check the status of the device by selecting the marker window F8 or enter the Watch status 4 0 menu of the HART communicator The device is in its start up phase Wait 50 seconds If the current value drops to a value between 4 and 20 mA and goes immediately back to 22 mA contact your KROHNE Service Centre 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 Check the current loop and the connections Configure output as described in Sect 3 3 3 user sub menu 1 3 o
35. tic field Install the gauge far from protruding objects such as e Heating tubes e Sudden changes in tank cross section e Tank wall reinforcements and beams e Weld lines and dip stick pipes etc TDR gauges generate electromagnetic EM fields when a measurement pulse is emitted This field is affected by any nearby discontinuities and these will weaken and potentially block the emitted pulse A minimum distance is recommended depending on the probe type to be installed See the table on the next page for recommended free space dimensions Alternatively the fitter may use a reference chamber or stilling well However the chamber walls must be smooth i e no visible weld lines straight and vertical to maintain the pulse strength and gauge accuracy 10 BM 102 KROHN For clean applications only Coaxial type 3 probes may be used close to or touching objects or walls as the EM field generated by the probe is contained within the probe s outer sheath refer also to the EM field sizes free area given in the figures on the next page d 1 Agitator Tu 2 Support beam perpendicular to the y pulse direction l CG 3 Abrupt changes in tank cross section Ze CS A Heating tubes E 5 Alternative solution reference chamber ae electromagnetic field is contained lee within chamber 6 Gauge electromagnetic field Any intruding metallic object will be detected in this zone if perpendicular to the emitted pulse direction
36. ug 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 Hazardous duty systems Only certified intrinsically safe equipment may be connected to the BM 102 in hazardous areas Please refer to the BM 102 MICROFLEX KEMA 00ATEX1101 X Supplementary Installation and Operating Instructions for further information This document is available from your local KROHNE Sales office or on the Download Centre on KROHNE s website http www krohne com 2 1 2 Wiring connections DIN connector Terminals 3 poles and 1 x ground Wire cross section max 1 5 mm AWG 16 Cable entry 1 x PG11 cable diameter 8 10 mm or 0 31 0 39 IP 65 or NEMA4 Shielding do not connect to the DIN connector Signal cable no shielding required 1 Detach screw P and remove plug from signal converter 2 Separate part N from part R by inserting the flat tip of a screwdriver into gap F 3 Connect current loop to terminals 1 and 2 any polarity Use ferrules to protect cable ends Terminals 3 and E are not connected 4 Fit parts N and R together again 5 Fit gasket re insert connector plug R on the signal converter and replace screw P i Caution Grounding terminal E is not c

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