BERTHOLD TECHNOLOGIES LB 567 User manual

Concentration / Moisture Measuring Systems
MicroPolar 2 (++)
LB 567
User’s uide
Hardware Manual
41988BA2
Rev. Nr.: 04, 07/2017

MicroPolar 2 (++) LB 567
The units supplied should not be repaired by anyone other than Berthold Tech-
nologies Service engineers or technicians by Berthold Technologies.
In case of operation trouble, please address to our central service department
(address see below).
The complete user’s guide consists of the hard are manual and the soft-
are manual.
The hardware manual comprises:
 mechanical components
 installation
 electrical installation
 technical data
 electrical and mechanical dra ings
The software manual comprises:
 operation of the evaluation unit
 parameter description
 basic setup
 calibration
 error messages
The present manual is the hardware description.
Subject to change ithout prior notice.
BERTHOLD TECHNOLOGIES GmbH & Co. KG
Calmbacher Str. 22 ⋅ D-75323 Bad Wildbad
S itchboard: Service:
Phone [phone] Phone [phone]
Fax [phone] Fax [phone]
[e-mail] [e-mail]
.Berthold.com

Table of ontents
MicroPolar 2 (++) LB 567 5
Table of Contents
Page
hapter 1. Safety Summary 7
1.1 Symbols and Warnings 7
1.2 General Information 8
1.3 General Safety Instructions 9
hapter 2. General Information 11
2.1 Use and Function 11
2.2 Frequency License 12
2.3 Intended Use 13
2.4 Explanation of Terms 14
hapter 3. System Description 15
3.1 Principle of Measurement 15
3.2 Calculation of Measured Values 16
3.3 Temperature Compensation 17
3.4 Load Compensation 18
3.4.1 Area Weight Compensation 19
3.4.2 Layer Thickness Compensation 19
3.4.3 Weight/Throughput Compensation 20
3.4.4 Layer Thickness and Weight Compensation 21
3.5 Throughput Calculation and Output 22
3.6 Synchronization of the Current Input Signals 22
3.7 Mechanical Components 23
3.7.1 Evaluation Units 24
3.7.2 Flo Cell 27
3.7.3 Horn and Spiral Antennas 28
3.7.4 Measuring Chute 30
3.7.5 High-frequency Cable 31
3.8 Assembly on a Pipeline 33
3.9 Conveyor Measurement Configuration 34
3.10 Chute Measurement Configuration 35
hapter 4. Getting Started 37
4.1 Transport 37
4.2 Commissioning the Flo Cell 38
4.2.1 Installing the Flo Cell 38
4.2.2 Installing the Evaluation Unit 40
4.2.3 Connecting the HF Cable 41
4.3 Commissioning the Conveyor Belt 43
4.3.1 Components 43
4.3.2 Measuring Geometry and Conditions 43
4.3.3 Installing the Horn Antennas 47
4.3.4 Installing the Spiral Antennas 51
4.3.5 Synchronization 52
4.3.6 Installing the Evaluation Unit 53
4.3.7 Connecting the HF Cable 53
4.4 Commissioning the Chute 54
4.4.1 Components 54
4.4.2 Measuring Geometry and Conditions 54
4.4.3 Installation 55

Table of ontents
6 MicroPolar 2 (++) LB 567
4.4.4 Installing the Evaluation Unit 56
4.4.5 Connecting the HF Cable 56
4.5 Connecting the Evaluation Unit 56
4.5.1 Pin Configuration of the Connector Strip 57
4.5.2 Digital Outputs, Relay 59
hapter 5. Service instructions 61
5.1 General Information 61
5.2 Wear Parts 61
5.3 Instrument Cleaning 61
5.4 Battery 62
5.5 Fuse Replacement 62
hapter 6. Technical Data 63
6.1 Technical Data Evaluation Unit 63
6.2 Technical Data Sensors 66
6.3 Technical Data Horn and Spiral Antennas 67
6.4 Technical Data Measuring Chute 68
6.5 Technical Data HF Cable 69
6.6 Format of Serial Data Output RS232 and RS485 70
hapter 7. ertificates 71
7.1 EC Declaration of Conformity 71
7.2 Frequency License 72
hapter 8. Technical Drawings 73
8.1 Dimensions Dra ings Evaluation Unit Wall Housing 73
8.2 Electrical Wiring Diagram 74
8.3 Dimensional Dra ings Flo Cells 75
8.3.1 Type LB 3543-11 MP, nominal idth 50 mm, options 75
8.3.2 Type LB 3543-11 MP, nominal idth 50 mm,
ith ASA flange adapter 76
8.3.3 Type LB 3543-11 MP, nominal idth 50 mm, adapter 77
8.3.4 Type LB 3547-11 MP, nominal idth 65 mm, options 78
8.3.5 Type LB 3547-11 MP, nominal idth 65 mm,
ith ASA flange adapter 79
8.3.6 Type LB 3545-11 MP, nominal idth 80 mm 80
8.3.7 Type LB 3545-11 MP, nominal idth 80 mm,
ith ASA flange adapter 81
8.3.8 Type LB 3544-11 MP, nominal idth 100 mm, options 82
8.3.9 Type LB 3544-21 MP, nominal idth 100 mm
(DN100/PN16) 83
8.3.10 Type LB 3544-21 MP, nominal idth 100 mm
(DN100/PN16), ith ASA flange adapter 84
8.3.11 Type LB 3548-11 MP, nominal idth 150 mm 85
8.3.12 Type LB 3548-11 MP, nominal idth 150 mm,
ith ASA flange adapter 86
8.4 Dimensional Dra ings Horn and Spiral Antennae 87
8.4.1 Horn Antenna and Horn Antenna Holder 87
8.4.2 Spiral antenna 89
8.5 Installation Proposal at the Conveyor Belt 90
8.6 Installation Proposal at the Measuring Chute 91

hapter 1. Safety Summary
MicroPolar 2 (++) LB 567 7
Chapter 1. Safety Summary
1.1 Symbols and Warnings
In this user manual, the term Berthold Technologies stands for
the company Berthold Technologies GmbH & Co.KG.
To rule out bodily injury and property damage, please keep in
mind the arning and safety instructions provided in this user
manual. They are identified by the follo ing sings: DANGER,
WARNING, CAUTION or NOTICE.
Indicates imminent danger. If it cannot be avoided,
death or most severe personal injuries may be the
consequence.
Indicates a possibly dangerous situation. The consequences
may be death or most severe personal injuries.
Indicates a possibly harmful situation The consequences
may be minor or medium personal injuries.
Indicates a situation that may cause material damage if the
instructions are not follo ed.
IMPORTANT
Paragraphs ith this symbol provide important information on
the product and ho to handle it.
TIP
Contains user tips and other useful information.

hapter 1. Safety Summary
8 MicroPolar 2 (++) LB 567
Other symbols used in this documentation:
Warning: No intervention, do not alter anything
Requirement: Disconnect po er
Requirement: Wear safety boots
1.2 General Information
The most important safety measures a summarized in this user
manual. They supplement the corresponding regulations hich
must be studied by the personnel in charge.
Please pay attention to:
 the national safety and accident prevention regulations
 the national assembly and installation directions
 the generally recognized engineering rules
 the information on transport, assembly, operation, service,
maintenance
 the safety instructions and information in these operating in-
structions
 the enclosed technical dra ings and iring diagrams
 the characteristic values, limit values and the information on
operating and ambient conditions on the type labels and in the
data sheets
 the signs on the devices
 the country-specific licensing schemes

hapter 1. Safety Summary
MicroPolar 2 (++) LB 567 9
1.3 General Safety Instructions
IMPORTANT
The equipment housings have IP 65 protection and are suitable
for outdoor applications. The units are factory tested and are
delivered in a condition that permits safe and reliable operation.
For outdoor applications, the measuring systems must be pro-
tected from direct sunlight and rain, for example by a suitable
shelter.
IMPORTANT
Never change the installation and the parameter settings ith-
out a full kno ledge of these operating instructions, as ell as
a full kno ledge of the behavior of the connected controller and
the possible impact on the operating process to be controlled.
The systems may only be used in perfect technical condition
and only for the intended use!
Only let persons ork ith the systems ho are mandated to
do this and are suitably qualified and adequately trained! In-
stallations and modifications on the systems hich may affect
the operational safety are not permitted!
IMPORTANT
All system components require non-corrosive ambient condi-
tions during transport, storage and operation.
IMPORTANT
If liquid gets inside the instrument, cut off the po er supply.
The equipment must be inspected and cleaned by an authorized
service center.
Ambient
conditions

hapter 1. Safety Summary
10 MicroPolar 2 (++) LB 567
Electrical hazards
Disconnect po er to ensure that contact ith live part is
avoided during installation and hen servicing.
Disconnect the po er supply before opening the instrument.
Work on open and live instruments is prohibited.
Caution! Potential hazards, material damage!
Device type:
LB 567-02 MicroPolar 2 (ID no. 41988-02) and
LB 567-12 MicroPolar 2 ++ (ID no. 54563-02)
When connecting the 24 V DC po er supply, the + and – poles
must be connected correctly. There is no reverse polarity pro-
tection!
Spare fuses must match the rating specified by the device man-
ufacturer. Short-circuiting or manipulation is not permitted.
IMPORTANT
The LB 567 and all additional equipment must be connected to
mains via grounded connection.
IMPORTANT
The concentration meter LB 567 may be installed, serviced and
repaired only by qualified specialists.
Qualified persons Qualified specialists are persons ho through professional train-
ing have acquired sufficient skills in the respective field and ho
are familiar ith the relevant national industrial safety regula-
tions, accident prevention directions, guidelines and accepted en-
gineering standards. They must be able to safely assess the re-
sults of their ork and they must be familiar ith the contents of
these user manual.

hapter 2. General Information
MicroPolar 2 (++) LB 567 11
Chapter 2. General Information
2.1 Use and Function
The MicroPolar 2 LB 567 has been designed as a concentration
measuring system and may be used only for this purpose. If the
devices are used in a manner that are not described in this user
manual, the protection of the devices is compromised and the
arranty ill be lost.
Berthold Technologies is liable and guarantees only that the de-
vices comply ith its published specifications. The LB 567 may
only be installed in an undamaged, dry and clean condition. Al-
terations and modifications to the system components are not
permitted.
The LB 567 is not qualified as a "safety-related measurement".
The standards and guidelines the LB 567 complies ith are item-
ized in these device instructions in chapter 2.2 Frequency License
and chapter 7.1 EC Declaration of Conformity.
The protection type of the LB 567 to IEC 60529 is max. IP 65.
The follo ing use is inappropriate and has to be prevented:
 The use under conditions other than the terms and conditions
stated by the manufacturer in their technical documentation,
data sheets, operating and installation manuals and other
specifications.
 The use after repair by persons not authorized by Berthold
Technologies.
 The use in a damaged or corroded state.
 Operation ith open or inadequately closed cover.
 Operating ith insufficiently tightened adapters and cable
glands.
 Operation ithout the manufacturer’s recommended safety
precautions.
 Manipulating or bypassing existing safety facilities.
Authorized persons are those ho, by la , are permitted to per-
form the respective activity, or ho have been approved by
Berthold Technologies for certain activities.
onformity to
standards
Protection type
Warning
against misuse
Authorized persons

hapter 2. General Information
12 MicroPolar 2 (++) LB 567
2.2 Frequency License
The MicroPolar 2 complies ith Part 15 of the FCC Rules
1
. These
meters are compliant in terms of interference immunity and in-
terference emission and are approved for operation. The certifi-
cate can be found in chapter 7.2 Frequency License.
IMPORTANT
The FCC approval applies to the standard evaluation unit LB 567 in
combination ith flo cells of the type LB 354X-XX, horn and spiral
antenna.
The LB 567++ is not FCC approved.
IMPORTANT
The LB 567 has been manufactured in compliance ith the
safety requirements for micro ave devices. It ill be the user’s
responsibility to adhere to any special legal provisions regard-
ing the use of micro aves.
IMPORTANT
Any change in the frequency or other ise tampering ith the
micro ave device ill lead to a loss of the frequency license
and may result in criminal consequences.
The micro ave modules do not include any replaceable com-
ponents and must not be opened.
1
FCC ... Federal Communications Commission
F
license certificate

hapter 2. General Information
MicroPolar 2 (++) LB 567 13
2.3 Intended Use
The LB 567 can be used to determine the ater or moisture con-
tent and the concentration of virtually any material. The follo ing
sensors and evaluation versions are available:
1. The flo cell is a tubular probe, ith the micro ave transmit-
ter and receiver being firmly elded onto the outside of the
tube. The tube is lined ith Teflon to ensure smooth alls. The
flo cell is either installed directly into the existing pipeline
system or into a bypass.
2. The horn and spiral antennas are al ays used in pairs. Both
antennas are installed diametrically opposite on the conveyor
belt or in a chute. The transmitting antenna is installed so close
to the bottom side of the conveyor belt or to the measuring
chute that the emitted electromagnetic radiation passes al-
most completely through the product.
The evaluation unit is available in t o versions: The standard
model MicroPolar 2 and the high dynamic version MicroPolar
2 ++. The Micro Polar 2 ++ requires a micro ave signal attenu-
ation of at least 50 dB. The MicroPolar 2 must be used for lo er
micro ave attenuation.
During operation, the concentration meters MicroPolar 2 and
MicroPolar 2 ++ emit electromagnetic radiation in the frequency
range bet een 2.4 GHz and 2.5 GHz (range limitations depending
on local regulations in your country). Micro aves are not danger-
ous to human beings and the environment (po er radiation
< 1 mW). The micro aves are emitted directed from the micro-
ave indo ; the product is not altered by the micro aves.
To ensure proper function of the measuring system, please pay
attention to the follo ing:
TIP
 The material to be measured may be electrically conductive
only to a limited degree.
 The product must not contain any gas bubbles or gas bub-
bles have to be compressed ith adequate pressure hen
carrying out measurements in pipelines.
 The ion concentration, for example, salt content must be
nearly constant.

hapter 2. General Information
14 MicroPolar 2 (++) LB 567
2.4 Explanation of Terms
Attenuation Weakening of micro ave signals, micro aves measuring effect.
EVU Evaluation Unit
Factory setting In the factory setting all parameters have been set to default
values. In most cases this considerably facilitates the calibra-
tion of the instrument. Despite factory setting, calibration al-
ways has to be performed.
Flo cell Tubular probe for simple integration into the existing pipeline
system.
HF cable High frequency cable
Micro aves Designation for electromagnetic aves in a specific frequency
range.
Phase Phase or phase shift, micro ave measuring effect.
Quad cable Combination of four HF cables of equal length in a corrugated
tube.
Softkeys Soft are associated keys.
TC Temperature compensation

hapter 3. System Description
MicroPolar 2 (++) LB 567 15
Chapter 3. System Description
3.1 Principle of Measurement
As the micro aves pass through the product, their propagation
velocity is slo ed do n (= phase shift) and their intensity is at-
tenuated (= attenuation). Figure 3-1 illustrates the principle of
measurement: Compared to a reference signal, the propagation
velocity of micro aves passing through the product is slo ed
do n (phase shift) and their intensity (attenuation) is reduced.
Phase shift
Messgut
Phase comparison
--> Phase
mplitude comp.
--> ttenuation
Reference path
Reference signal
Measurement signal
Measured value:
Concentration %DS
HF sources
Receiver
Transmitter
The prerequisite is that the product being measured sho s die-
lectric properties. Generally, ater is a very distinct dielectric
fluid. The ater or dry mass concentration can therefore be de-
termined by measuring the phase shift and/or attenuation.
The concentration to be detected in the product is therefore in
good approximation linearly dependent on the phase shift and
the attenuation. For this reason, e can measure the concentra-
tion or the dry matter content of the product using a linear cali-
bration (see chapter 3.2 Calculation of Measured Values).
Fi ure 3-1:
Schematic dia ram:
Chan e in
microwave by
product

hapter 3. System Description
16 MicroPolar 2 (++) LB 567
3.2 alculation of Measured Values
The micro ave parameters phase and attenuation are calibrated
according to an automatic plausibility analysis.
During calibration, the phase and/or attenuation of a concentra-
tion value (or density value) are assigned through sampling. The
calibration is done automatically and the sampling process is sup-
ported by the evaluation unit.
Which of the parameters (phase, attenuation or both) ill be used
for the calibration depends on the size and interference of the
measuring effect. For example, the attenuation is significantly
more sensitive to electrolytic conductivity (salt content).
In many cases, the pure phase measurement is recommended
and the measured value is calculated as follo s:
Measured value = A ∙ Phase + Eq. 3-1
here:
Measured value Concentration / Moisture / Dry matter
A, C Coefficients of the respective calibration function
The LB 567 allo s you to calibrate, display and output t o con-
centrations: Con1 and Con2. You have to enter the calibration
coefficients separately for concentration 1 and 2. For more infor-
mation please refer to the Soft are Manual.
Limitations
 Weakly bound ater can be detected depending on the
strength of the binding. Thus, the measuring effect may be
dependent on the grain size distribution and the chemical
properties of the product being measured, provided this
changes the binding of ater to the solid matter.
 Walls made of plastic, rubber or insulation materials ith fairly
lo dielectricity hardly affect the measurement and are cali-
brated at a constant level.
 Ice and crystal ater cannot be measured because the ater
molecules cannot rotate freely (ice and crystal ater are dry).
Conductive materials such as graphite or coke cannot be trans-
mitted by micro aves. Metal alls can also not be transmitted by
micro aves. Metal-reinforced conveyor belts may be transmitted
only under certain conditions (see chapters 4.3.3 Installin the
Horn Antenna).

hapter 3. System Description
MicroPolar 2 (++) LB 567 17
ompensation In addition to the ater content, the product temperature,
product density and a varying material load (varying micro ave
irradiation path) may have an influence on the phase and atten-
uation. This influence has to be compensated for during calibra-
tion.
3.3 Temperature ompensation
Temperature compensation (TC) is required for fluctuating prod-
uct temperature. It is generally advisable to provide a tempera-
ture compensation, i.e. a temperature signal (0/4...20 mA or
PT100) to be connected to the evaluation unit and, optionally, to
enable the compensation in the evaluation unit. The evaluation
unit is designed so that the required TC’s can be calculated auto-
matically. The variation in temperature here TC becomes abso-
lutely essential is dependent on the product and on the ater
content. In the first approximation, ± 2° C should be set as fluc-
tuation limit.
For example, if the product temperature is measured via the
PT100 input, then Eq. 3-1 is expanded as follo s:
Measured value = A · Phase + D · T
meas
+ Eq. 3-2
here:
Measured value Concentration / Moisture / Dry matter
A, D, C Coefficients of the calibration function
T
meas
Product temperature
Ho to ork ith the temperature compensation is described in
detail in the Soft are Manual.

hapter 3. System Description
18 MicroPolar 2 (++) LB 567
3.4 Load ompensation
The micro ave irradiates the product to be measured and detects
all changes in the product. Example conveyor belt, see Figure
3-2:
Fi ure 3-2:
Material profile on
the conveyor belt
flat surface
Horn antenna
Microwave beam
> 350 mm
The micro aves irradiate the entire material cross-section in the
radiation field. If the material layer thickness or the bulk density
changes ( ith constant moisture), then the micro ave signals
ill be affected. The goal of the load compensation is to compen-
sate for this influence. This is done by considering the t o pa-
rameters layer thickness and bulk density hich correspond to
the eight per unit area:
Load = weight per unit area [g/cm
2
] = δ ∙ h Eq. 3-3
here:
δ bulk density [g/cm
3
]
h material layer thickness [cm]
With load compensation, equation 3-1 is expanded as follo s:
Measured value = A · Phase + G · Load + Eq. 3-4
here:
Measured value Concentration / Moisture / Dry matter
A, G, C Coefficients of the calibration function
A eight per unit area compensation need not be performed
hen the layer thickness and bulk density are constant in a fixed
measuring geometry. This is the case, for example, if conveyor
belts are al ays loaded ith the same level, or if the filling level
in pipes or chutes is al ays the same, and the material has a
constant density.

hapter 3. System Description
MicroPolar 2 (++) LB 567 19
3.4.1 Area Weight ompensation
The influence of a fluctuating material layer thickness and bulk
density disappears through compensation of the eight per unit
area. The compensation is calculated as follo s:
Load = weight per unit area [g/cm
2
] Eq. 3-5
The area eight signal supplies a 0(4)...20 mA signal.
IMPORTANT
Current input 1 must be used for this compensation.
3.4.2 Layer Thickness ompensation
If only the layer thickness of the product to be measured
changes, one has to compensate as follo s:
Load = Loading level [cm] Eq. 3-6
The layer thickness ill deliver a 0(4)…20 mA signal hich is pro-
portional to the distance from the product surface to a sensor
installed above it.
IMPORTANT
Current input 1 must be used for this compensation.

hapter 3. System Description
20 MicroPolar 2 (++) LB 567
3.4.3 Weight/Throughput ompensation
If the material cross-section is rectangular (see Figure 3-3), the
eight per area [g/cm²] is proportional to the eight per length
[kg/m]. Thus, the load compensation becomes linear; it is calcu-
lated as follo s:
Load = Weight [kg] Eq. 3-7
The 0(4)...20 mA signal is supplied by an existing eighing sys-
tem.
If the eighing system supplies a throughput signal (T/h), either
the conveyor belt speed must be constant, or the belt speed must
be fed as into the evaluation unit 0(4)…20 mA signal via the sec-
ond current input. The compensation is then calculated according
to:
Load=
Throughput [T/h]
Belt speed [m/s]
Eq. 3-8
IMPORTANT
The throughput signal must be fed in via current input 1 and the
speed signal via current input 2.
Fi ure 3-3:
Rectan ular
material cross-section
with wei hin system