BERTHOLD TECHNOLOGIES Uni-Probe LB 490 User manual

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User’s Manual
ID no. 38477BA2B
Rev. no.: 05 25.5.09
Embedded Soft. Rev. 100
Device Description 03 HART
Device Description 01 PA
Device Description 02 FF
Process Control detect and identify
Level Measurement
Uni-Probe LB 490
With All Supplements

1
2
3
4
5
6
7
Volume 1: Safety Manuals
Volume 2: Uni-Probe Installation
Volume 3: HART®Communicator User Interface
Volume 4: PACTware™User Interface FDT/DTM
Volume 5: SIMATIC PDM User Interface HART®
Volume 6: SIMATIC PDM User Interface Profibus PA
Volume 7: FOUNDATION™Fieldbus User Interface

38477BA2B
425.5.09
Volume 1-7
General Information
Dear customers Thank you very much for purchasing the level gauging system
Uni-Probe LB 490 made by BERTHOLD TECHNOLOGIES GmbH &
Co. KG.
The scope of supply also includes this User’s Manual. Be sure to
have this User’s Manual always to hand.
To avoid physical injury and property damage, please observe the
warnings and safety instructions provided in this User’s Manual.
They are identified as follows: DANGER, WARNING, CAUTION or
NOTICE. In Volume 1, "Safety Manuals", you find a summary of all
safety hazards and information how to deal with them.
Please read the User’s Manual prior to installation to get acquainted
with the product.
If you do encounter problems despite careful study of the User’s
Manual, please do not hesitate to contact us.
Your Uni-Probe LB 490 team

Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG 5
Volume 1-7 Contents
Volume 1 Safety Manuals
1About this User’s Manual .................................................. 1 – 19
1.1 Identification and Warning Messages........................1 – 19
1.2 Further Symbols........................................................ 1 – 20
1.3 General Instructions..................................................1 – 21
2Use and Function .............................................................. 1 – 23
3Qualification of Personnel .................................................1 – 25
3.1 Specialized Persons................................................... 1 – 25
3.2 Qualified Persons ......................................................1 – 26
3.3 Authorized Persons................................................... 1 – 26
4Transport and Assembly .................................................... 1 – 27
5Electrical installation.......................................................... 1 – 29
6Radiation Protection.......................................................... 1 – 31
6.1 General Information and Guidelines ......................... 1 – 31
6.2 General Radiation Protection Instructions.................. 1 – 33
6.3 Mounting the Shielding ............................................ 1 – 34
6.4 Safety Measures ....................................................... 1 – 37
6.5 Protection against Theft............................................1 – 37
6.6 Accidents, Loss, Damage, Fire, Theft .........................1 – 38
6.7 Shielding and Source ................................................1 – 40
6.8 Leak Test .................................................................. 1 – 42
7Source Replacement ......................................................... 1 – 45
7.1 Point Source Replacement ........................................ 1 – 45
7.2 Rod Source Replacement ..........................................1 – 48
7.3 Point Source Replacement on Rotary Cylinder
Shielding1 – 52
7.4 Radiation Exposure during Source Replacement ........1 – 55
8Source Disposal.................................................................1 – 57
9Functional Safety .............................................................. 1 – 61
9.1 Scope of Application ................................................ 1 – 61
9.2 Use and Function......................................................1 – 63
9.3 Safety Function......................................................... 1 – 64
9.4 Safety Requirement .................................................. 1 – 64
9.5 Project Planning........................................................1 – 65
Table of Contents

38477BA2B
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Contents Volume 1-7
9.6 Getting Started......................................................... 1 – 67
9.7 Behavior during Operation and during Malfunctions. 1 – 69
9.8 Recurrent Performance Test ...................................... 1 – 70
9.9 Safety-Technical Data................................................ 1 – 71
9.10 Certificate Functional Safety ..................................... 1 – 73
10 Safety Instructions for the Types of Protection
ATEX / FM / CSA ............................................................... 1 – 83
10.1 Overview Ex-Versions................................................ 1 – 85
10.2 Type of Protection ATEX............................................ 1 – 87
10.3 Type of Protection FM/CSA ....................................... 1 – 88
10.4 Type of Protection CSA ............................................. 1 – 88
11 Certificates ....................................................................... 1 – 89
11.1 ATEX Certificate ....................................................... 1 – 89
11.2 FM Certificate......................................................... 1 – 108
11.3 CSA Certificate....................................................... 1 – 110
11.4 EG Declaration of Conformity................................. 1 – 112
11.5 Material Safety Data Sheet for Lubricant OKS 217 .. 1 – 113

Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG 7
Volume 1-7 Contents
Volume 2 Uni-Probe Installation
1System Description..........................................................2 – 119
1.1 Measuring System ..................................................2 – 119
1.2 Uni-Probe Hardware ............................................... 2 – 123
1.3 Measuring Principle ................................................ 2 – 125
1.4 Measuring Arrangements ....................................... 2 – 126
1.5 Technical Data ........................................................ 2 – 130
1.6 Detector Codes ......................................................2 – 133
1.7 Uni-Probe LB 490 Nomenclature .............................2 – 134
1.8 LB 490 Super-Sens Nomenclature ...........................2 – 135
1.9 LB 490 Tower-Sens Nomenclature ...........................2 – 136
2Installation ......................................................................2 – 139
2.1 Transport to the Installation Site..............................2 – 141
2.2 Source-Detector Arrangements...............................2 – 143
2.3 Detector Protection................................................. 2 – 145
2.4 Detector Installation ...............................................2 – 147
2.5 Mounting the Shielding ..........................................2 – 160
3Electrical Installation........................................................ 2 – 183
3.1 Conduits ................................................................2 – 184
3.2 Terminals ................................................................ 2 – 187
3.3 Switch Setting ........................................................2 – 189
3.4 Connecting the Uni-Probe .....................................2 – 192
3.5 Uni-Probe with Ex i Current Output ........................2 – 195
3.6 Uni-Probe with Signal Output Profibus PA /
FOUNDATION™Fieldbus (not intrinsically safe)........2 – 206
3.7 Uni-Probe with Intrinsically Safe Signal Output
Profibus PA / FOUNDATION™Fieldbus.....................2 – 209
4Repair, Maintenance and Service ..................................... 2 – 213
4.1 General Safety Precautions ..................................... 2 – 213
4.2 Visual Inspection of the Uni-Probe .......................... 2 – 216
4.3 Checking the Connection Box ................................2 – 217
4.4 Trouble Shooting ....................................................2 – 218
4.5 Replacing the Complete Uni-Probe ........................ 2 – 220
4.6 Replacing the Electronics Module............................2 – 222
4.7 Replacing the Crystal-Multiplier Assembly
(for Point Detector) ................................................. 2 – 225
4.8 Replacing the Multiplier (for Rod Detector) .............2 – 227

38477BA2B
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Contents Volume 1-7
4.9 Replacing the Plastic Scintillator .............................. 2 – 229
4.10 Replacing the Digital Board..................................... 2 – 231
4.11 Replacing the Power Supply Unit ............................2 – 234
4.12 Replacing Fuses ...................................................... 2 – 236
4.13 Updating the Embedded Software in the Uni-Probe 2 – 237
4.14 Check Detector ...................................................... 2 – 242
4.15 Customer Service.................................................... 2 – 245
4.16 Returning Repairs ................................................... 2 – 246
5Screw Fittings and Accessories ........................................ 2 – 247
5.1 ATEX Cable Screw Fittings ...................................... 2 – 247
5.2 ATEX-Adapter (Ex d IIC) for Screwed Cable Glands . 2 – 249
5.3 Dummy Plug........................................................... 2 – 249
6Technical Drawings ......................................................... 2 – 251
6.1 Point Detector ........................................................ 2 – 251
6.2 Rod Detector .......................................................... 2 – 254
6.3 Super-Sens ............................................................. 2 – 264
6.4 Tower-Sens ............................................................. 2 – 268
6.5 Point Source Shielding LB 744X .............................. 2 – 273
6.6 Point Source Shielding for Rod Detectors ................ 2 – 281
6.7 Rod Source Shielding.............................................. 2 – 282
6.8 Pneumatic for Rod and Point Source Shieldings ...... 2 – 284
6.9 Pneumatic, Design and Electrical Data for Limit
Switch .................................................................... 2 – 285
6.10 Shielding for Rod Source on Dip Tube ..................... 2 – 286
6.11 Flange Adapter for Rod Source Shieldings............... 2 – 287
7Cooling Water Curves..................................................... 2 – 289
7.1 Point Detectors....................................................... 2 – 289
7.2 Rod Detector .......................................................... 2 – 289
7.3 Super-Sens ............................................................. 2 – 291
7.4 Tower-Sens ............................................................. 2 – 291

Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG 9
Volume 1-7 Contents
Volume 3 HART®Communicator User Interface
1General Information on the HART®Communicator.........3 – 297
1.1 Connection, Power On and Power Off of the
HART®Communicator ...........................................3 – 297
1.2 Working with the HART®Communicator ............... 3 – 298
2Menu Structure............................................................... 3 – 299
2.1 Information on the Menu Structure ........................3 – 299
2.2 Menu Overview ......................................................3 – 300
2.3 Start Menu .............................................................3 – 302
2.4 LIVE DISPLAY ...................................................... 3 – 303
2.5 PROBE RAW DATA............................................... 3 – 304
2.6 VIEW PARAMETER ............................................... 3 – 305
2.7 PROCESS VARIABLES .......................................... 3 – 305
2.8 SHOW CAL. CURVE .............................................. 3 – 306
2.9 STATUS CONTROL ................................................ 3 – 307
2.10 SHOW ERROR LOG .............................................. 3 – 308
2.11 REVIEW ................................................................ 3 – 309
2.12 ACCESS TO SETUP ............................................... 3 – 311
2.13 ENTER PASSWORD............................................... 3 – 312
2.14 SETUP ...................................................................3 – 313
2.15 CONFIGURATION..................................................3 – 313
2.16 GENERAL DATA ....................................................3 – 314
2.17 SYSTEM PARAMETER ...........................................3 – 315
2.18 MEASURE PARAMETER......................................... 3 – 316
2.19 DAMPING DATA ................................................... 3 – 317
2.20 RAD. INTERFERENCE ...........................................3 – 319
2.21 PULSE RATE LIMITS............................................3 – 320
2.22 CALIBRATION I/O .............................................. 3 – 321
2.23 CALIBRATION ....................................................... 3 – 321
2.24 SAVE & LOAD CURVE.......................................... 3 – 322
2.25 1-2 POINT CURVE...............................................3 – 323
2.26 MULTI POINT CURVE .......................................... 3 – 324
2.27 CAL. POINT .......................................................... 3 – 325
2.28 INPUT / OUTPUT................................................. 3 – 325
2.29 CURRENT / OUTPUT............................................ 3 – 326
2.30 DIGITAL OUT CONFIG ........................................3 – 327
2.31 SERVICE................................................................ 3 – 328
2.32 TEST CALCULATION .............................................3 – 329
2.33 I/O TEST ............................................................. 3 – 329
2.34 STATUS DIG. INPUT............................................ 3 – 330

38477BA2B
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Contents Volume 1-7
2.35 DIG. OUTPUT TEST ............................................. 3 – 330
2.36 CURRENT OUTPUT ............................................... 3 – 331
2.37 PROBE SETTINGS................................................. 3 – 332
2.38 HV SETTINGS ...................................................... 3 – 334
2.39 PLATEAU ............................................................... 3 – 335
2.40 HART INTERFACE ............................................... 3 – 336
3Getting Started via the HART®Communicator................ 3 – 337
3.1 Steps for Getting Started ........................................ 3 – 337
3.2 Setup Protocol........................................................ 3 – 338
4Calibration...................................................................... 3 – 341
4.1 Preparing Calibration.............................................. 3 – 341
4.2 Operation Modes for Calibration ............................ 3 – 348
4.3 Two-Point Calibration ............................................. 3 – 350
4.4 One-Point Calibration ............................................. 3 – 357
4.5 Multi-Point Calibration ........................................... 3 – 360
5Functional Processes ....................................................... 3 – 367
5.1 Plateau Measurement............................................. 3 – 367
5.2 Changing the Uni-Probe Password.......................... 3 – 369
5.3 Set Multi-Detector Mode ........................................ 3 – 371
6Explanations ................................................................... 3 – 373
6.1 Background............................................................ 3 – 373
6.2 Conditions for Empty Calibration............................ 3 – 375
6.3 Linear and Exponential ........................................... 3 – 377
6.4 Multi-Point Calibration ........................................... 3 – 380
6.5 Radiation Interference Detection............................. 3 – 383
6.6 Reading-in Pulse Rates............................................ 3 – 386
6.7 Software Versions................................................... 3 – 388
7Error Handling ................................................................ 3 – 393
7.1 Device Response to Errors.......................................3 – 393
7.2 Error Handling Modes............................................. 3 – 394
7.3 Corrective Action.................................................... 3 – 395
7.4 Reset ...................................................................... 3 – 397
7.5 Operation Modes during Measurement .................. 3 – 397
7.6 Error Reset.............................................................. 3 – 398
7.7 Fault Current .......................................................... 3 – 399
8Setup Protocol ................................................................ 3 – 401
8.1 Parameter List......................................................... 3 – 401
8.2 Calibration Values................................................... 3 – 402

Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG 11
Volume 1-7 Contents
Volume 4 PACTware™User Interface FDT/DTM
1PC Connection to the Uni-Probe .....................................4 – 407
2Installing and Working with DTM ....................................4 – 409
2.1 Requirements ......................................................... 4 – 409
2.2 FDT Container ........................................................ 4 – 409
2.3 DTM Communication Software............................... 4 – 411

38477BA2B
12 25.5.09
Contents Volume 1-7
Volume 5 SIMATIC PDM User Interface HART®
1Hardware Configuration ................................................. 5 – 421
2General Information on SIMATIC PDM ............................ 5 – 423
2.1 Hardware Requirements ......................................... 5 – 424
2.2 Fifo Buffer .............................................................. 5 – 424
3Getting Started with SIMATIC PDM................................. 5 – 427
3.1 How to Get Started ................................................ 5 – 427
3.2 Installing SIMATIC PDM .......................................... 5 – 427
3.3 Installing the Uni-Probe LB 490 Device Description.. 5 – 432
3.4 Project Setup .......................................................... 5 – 434
3.5 Start SIMATIC PDM................................................. 5 – 438
4Menu Overview .............................................................. 5 – 439
4.1 FILE Menu ............................................................ 5 – 440
4.2 DEVICE Menu ....................................................... 5 – 448
4.3 VIEW Menu........................................................... 5 – 480
4.4 OPTIONS Menu .................................................... 5 – 485
4.5 HELP Menu ........................................................... 5 – 489
5Calibration with SIMATIC PDM........................................ 5 – 491
5.1 Preparing Calibration.............................................. 5 – 491
5.2 Operation Modes for Calibration ............................ 5 – 496
5.3 Two-Point Calibration ............................................. 5 – 498
5.4 One-Point Calibration ............................................. 5 – 504
5.5 Multi-Point Calibration ........................................... 5 – 506
6Functional Processes ....................................................... 5 – 513
6.1 Plateau Measurement............................................. 5 – 513
6.2 Changing the Uni-Probe Password.......................... 5 – 516
6.3 Set Multi-Detector Mode ........................................ 5 – 519
7Working with SIMATIC PDM ........................................... 5 – 521
7.1 Start SIMATIC PDM................................................. 5 – 521
7.2 The SIMATIC PDM Main Window ........................... 5 – 522
7.3 Device Icons in SIMATIC PDM ................................. 5 – 525
8Explanations ................................................................... 5 – 527
8.1 Background............................................................ 5 – 527
8.2 Conditions for Empty Calibration............................ 5 – 529

Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG 13
Volume 1-7 Contents
8.3 Linear and Exponential ...........................................5 – 531
8.4 Multi-Point Calibration ...........................................5 – 534
8.5 Radiation Interference Detection............................. 5 – 537
8.6 Reading-in Pulse Rates............................................ 5 – 540
9Error Handling ................................................................ 5 – 543
9.1 Device Response to Errors .......................................5 – 543
9.2 Error Handling Modes............................................. 5 – 544
9.3 Corrective Action.................................................... 5 – 545
9.4 Reset ...................................................................... 5 – 546
9.5 Operation Modes during Measurement ..................5 – 547
9.6 Error Reset..............................................................5 – 547
9.7 Fault Current .......................................................... 5 – 548

38477BA2B
14 25.5.09
Contents Volume 1-7
Volume 6 SIMATIC PDM User Interface Profibus PA
1Process Operation ........................................................... 6 – 555
1.1 Important Information on the Profibus PA
Operation............................................................... 6 – 555
1.2 Alternative Operation via HART®............................ 6 – 555
1.3 System Overview .................................................... 6 – 556
2Installation / Program Start.............................................. 6 – 559
2.1 Installing the Device Description (DD)...................... 6 – 559
2.2 Starting SIMATIC PDM............................................ 6 – 560
3Device-specific Menus..................................................... 6 – 561
3.1 DEVICE Tab ........................................................... 6 – 562
3.2 VIEW Menu .......................................................... 6 – 592
4Calibration with SIMATIC PDM........................................ 6 – 601
4.1 Preparing Calibration.............................................. 6 – 601
4.2 Operation Modes for Calibration ............................ 6 – 606
4.3 Two-Point Calibration ............................................. 6 – 608
4.4 One-Point Calibration ............................................. 6 – 615
4.5 Multi-Point Calibration ........................................... 6 – 618
5Functional Processes ....................................................... 6 – 625
5.1 Plateau Measurement............................................. 6 – 625
5.2 Set Multi-Detector Mode ........................................ 6 – 630
6Explanations ................................................................... 6 – 633
6.1 Background............................................................ 6 – 633
6.2 Conditions for Empty Calibration............................ 6 – 635
6.3 Linear and Exponential ........................................... 6 – 637
6.4 Multi-Point Calibration ........................................... 6 – 640
6.5 Radiation Interference Detection............................. 6 – 643
6.6 Reading-in Pulse Rates............................................ 6 – 646
7Error Handling ................................................................ 6 – 649
7.1 Device Response to Errors....................................... 6 – 649
7.2 Error Handling Modes............................................. 6 – 650
7.3 Corrective Action.................................................... 6 – 651
7.4 Reset ...................................................................... 6 – 653
7.5 Operation Modes during Measurement .................. 6 – 653

Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG 15
Volume 1-7 Contents
Volume 7 FOUNDATION™Fieldbus User Interface
1Process Operation ........................................................... 7 – 659
1.1 Important Information on the Operation................. 7 – 659
1.2 System Overview .................................................... 7 – 660
2Installation / Program Start .............................................. 7 – 663
2.1 Installing the Device Description..............................7 – 663
2.2 Addressing the Uni-Probe LB 490 Level System .......7 – 663
3Parameter Overview........................................................7 – 665
3.1 Parameters for the Function Block Resource............7 – 665
3.2 Parameters for the Function Block Transducer .........7 – 666
3.3 Parameters for the Function Blocks Analog Input ....7 – 671
4Calibration with FOUNDATION™Fieldbus........................7 – 673
4.1 Preparing Calibration .............................................. 7 – 673
4.2 Operation Modes for Calibration ............................7 – 676
4.3 Two-Point Calibration ............................................. 7 – 678
4.4 One-Point Calibration ............................................. 7 – 682
4.5 Multi-Point Calibration ...........................................7 – 684
5Functional Processes .......................................................7 – 689
5.1 Plateau Measurement ............................................. 7 – 689
5.2 Multi-Detector Mode.............................................. 7 – 691
5.3 Test Calculation (Test Signal Output) .......................7 – 693
5.4 Damping ................................................................7 – 694
5.5 Radiation Interference Detection............................. 7 – 696
5.6 Input Configuration................................................7 – 696
5.7 Relay Configuration................................................ 7 – 697
5.8 Defining the Upper/Lower Pulse Rate Limit.............. 7 – 698
5.9 Protecting Parameters against Modification ............7 – 699
5.10 Reading Out the Error Log ......................................7 – 699
6Explanations ................................................................... 7 – 701
6.1 Background............................................................7 – 701
6.2 Conditions for Empty Calibration............................7 – 703
6.3 Linear and Exponential ...........................................7 – 705
6.4 Multi-Point Calibration ...........................................7 – 708
6.5 Radiation Interference Detection............................. 7 – 711
6.6 Reading-in Pulse Rates............................................ 7 – 714

38477BA2B
16 25.5.09
Contents Volume 1-7
7Error Handling ................................................................ 7 – 715
7.1 Device Response in Case of Error ............................7 – 715
7.2 Error Handling Modes............................................. 7 – 716
7.3 Operation Modes during Measurement .................. 7 – 716
7.4 Corrective Action.................................................... 7 – 717
7.5 Reset ...................................................................... 7 – 719

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Volume 1 Safety Manuals

38477BA2B
1 – 18 25.5.09
Volume 1

Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG 1 – 19
Volume 1 1 About this User’s Manual
1
1About this User’s Manual
1.1 Identification and Warning Messages
The symbols and typefaces used in this User’s Manual have the fol-
lowing meaning:
The term BERTHOLD TECHNOLOGIES in this User’s Manual stands
for the company BERTHOLD TECHNOLOGIES GmbH & Co. KG.
Please observe the warnings and safety instructions given in this
User’s Manual to rule out physical injury and property damage.
They are identified by the following symbols: DANGER, WARNING,
CAUTION or NOTICE.
Indicates an imminently dangerous condition. Failure to fol-
low the instructions will lead to death or serious injury.
Indicates a potentially dangerous condition. Failure to follow the
instructions may lead to death or serious injury.
Indicates a potentially dangerous condition. Failure to follow the
instructions may lead to slight injury or a medium-degree injury.
Indicates a situation which may cause property damage if the
instructions are not followed.
IMPORTANT
Paragraphs with this symbol provide important information on the
product or how to work with the product.
Tip
Includes application tips and other useful information.
prompts you to carry out an action.
1, 2, 3, … identifies items in a graphic.
• identifies enumerations.
italic typeface highlights important information.
SMALL CAPS indicate commands or menu items.

38477BA2B
1 – 20 25.5.09
1 About this User’s Manual Volume 1
1.2 Further Symbols
Warning sign: Never step under hovering loads
Warning sign: Nuclear radiation
Warning sign: Explosion protection
Warning sign: Risk of crushing
Instruction: Disconnect from mains supply
Instruction: Wear hard hat
Instruction: Wear safety shoes