Berthold Duo Xpert LB 478 MPLM User manual

Evaluation unit
LB 478 MPLM
Operating Manual
56925-8BA2
Rev. No.: 00, 07/2019
Embedded software version as of vers. 1.6.0 (CPU) and 1.6.0 (MU)

BERTHOLD TECHNOLOGIES GmbH & Co. KG
Calmbacher Str. 22
75323 Bad Wildbad, Germany
www.berthold.com
Telephone [phone]
Fax [phone]
[e-mail]

LB 478 MPLM Table of Contents
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Table of Contents
1About this Operating Manual............................................................................ 7
1.1 Applicable Documents ................................................................................................. 7
1.2 Some Prior Remarks...................................................................................................... 7
1.3 Storage Place ................................................................................................................ 7
1.4 Target Group ................................................................................................................ 7
1.5 Validity of the Operating Manual............................................................................... 8
1.6 Structure of the Operating Manual ............................................................................ 8
1.7 Copyright ...................................................................................................................... 8
1.8 Representation ............................................................................................................. 8
1.9 Warning notes .............................................................................................................. 9
Symbols Used in the Operating Manual ..................................................................... 9
Symbols Used on the Device ...................................................................................... 10
1.10 Conformity .................................................................................................................. 11
2Safety ................................................................................................................ 13
2.1 Dangers and safety measures .................................................................................... 13
2.2 Proper Use................................................................................................................... 13
2.3 Qualification of the Personnel .................................................................................. 14
2.4 Operator's Obligations............................................................................................... 15
3System Description ........................................................................................... 17
3.1 Overview ..................................................................................................................... 17
3.2 Measuring Principle.................................................................................................... 18
3.3 System Components ................................................................................................... 18
Front/rear view EVU ................................................................................................... 19
Type plate ................................................................................................................... 22
Software...................................................................................................................... 22
3.4 Storage ........................................................................................................................ 22
4Installation........................................................................................................ 23
4.1 General Instructions ................................................................................................... 23
4.2 Unpacking/Scope of Delivery..................................................................................... 23
4.3 Installation in the 19" subrack .................................................................................. 24
Installation with clamp blocks ................................................................................... 25
5Electric Installation........................................................................................... 27
5.1 General Instructions ................................................................................................... 27
Circuit Breaker ............................................................................................................ 28
Cables and Lines ......................................................................................................... 28
Cable Glands and Blanking Elements........................................................................ 29
Protective earth and equipotential bonding ........................................................... 29
EIA-485 (RS-485) Network.......................................................................................... 29
5.2 Wiring diagram........................................................................................................... 30
5.3 Electrical connection in the 19″subrack ................................................................... 31
5.4 Switching current output........................................................................................... 33
6Operation of the Software............................................................................... 35
6.1 System start................................................................................................................. 35
6.2 EVU standard display ................................................................................................. 36
6.3 Navigation................................................................................................................... 37
Diagram display.......................................................................................................... 37
6.4 Status messages .......................................................................................................... 37
6.5 Event Reports.............................................................................................................. 38
6.6 Input field ................................................................................................................... 39
7Main Menu Device Setup ................................................................................. 41

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7.1 Menu Identification.................................................................................................... 42
Location....................................................................................................................... 43
Device Information..................................................................................................... 44
7.2 Menu Access................................................................................................................ 46
7.3 Menu Setup................................................................................................................. 48
System (Date / Time, Interfaces, Units, Network, Reset, Repair Det. Software) .... 48
Sensors (only master EVU) ......................................................................................... 60
Interphase Densities (only master EVU).................................................................... 62
Densities Overview (only master EVU) ...................................................................... 62
Outputs ....................................................................................................................... 63
7.4 Menu Backup/Restore ................................................................................................ 71
Backup......................................................................................................................... 71
Restore ........................................................................................................................ 73
8Main Menu Diagnostics .................................................................................... 75
8.1 Transmitter Temperature........................................................................................... 75
8.2 Transmitter Events...................................................................................................... 76
Trasnmitter Event Log................................................................................................ 76
Transm. Event Overview ............................................................................................ 78
8.3 Change Log................................................................................................................. 79
8.4 Data Log (only master EVU)....................................................................................... 80
8.5 Export service data (only master EVU) ...................................................................... 82
9Troubleshooting ............................................................................................... 83
9.1 Error Search................................................................................................................. 83
9.2 Error Codes of the Evaluation Unit ........................................................................... 84
System ......................................................................................................................... 84
Application.................................................................................................................. 86
Detector ...................................................................................................................... 86
RS 458 Interface .......................................................................................................... 87
Process Connection..................................................................................................... 87
10 Maintenance and Repair .................................................................................. 89
10.1 Replacing of Fuses ...................................................................................................... 90
10.2 Cleaning ...................................................................................................................... 92
10.3 Data backup................................................................................................................ 93
11 Decommissioning.............................................................................................. 95
11.1 Decommissioning 19" subrack................................................................................... 95
11.2 Disposal of Measurement System.............................................................................. 96
12 Appendix........................................................................................................... 97
12.1 Commissioning Guide ................................................................................................ 97
Underlying data.......................................................................................................... 98
Implementation on site............................................................................................ 100
12.2 Setup Protocol LB 478 .............................................................................................. 103
12.3 Setup Protocol LB480 MPLM.................................................................................... 105

LB 478 MPLM 1 About this Operating Manual
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1About this Operating Manual
1.1 Applicable Documents
This manual contains the following document:
•Technical Information Id. No. 56925TIM (see appendix)
1.2 Some Prior Remarks
The product is handed over to you by the manufacturer BERTHOLD TECHNOLOGIES
GmbH & Co. KG (designated as Berthold in the following) in a complete and func-
tionally reliable condition.
This operating manual illustrates how to:
•set up/install the product
•make electrical connections
•perform measurements
•apply software settings
•carry out maintenance on the product
•fix errors
•disassemble the product
•dispose of the product.
Read these instructions thoroughly and completely before working with the prod-
uct. We have tried to compile all information for safe and proper operation for
you.
However, should questions arise which are not answered in this operating manual,
please refer to Berthold.
1.3 Storage Place
This operating manual as well as all product-related documentation relevant to the
respective application must be accessible at all times near the device.
1.4 Target Group
This operating manual is directed at qualified specialist personnel who are familiar
with handling electrical and electronic assemblies as well as with communication
and measuring techniques.
Specialist personnel refers to those who can assess the work assigned to them and
recognise possible dangers through their specialist training, knowledge and expe-
rience as well as knowledge of the relevant regulations.

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1.5 Validity of the Operating Manual
The operating manual is valid from the delivery of the Berthold product to the user
until its disposal. Version and release date of this operating manual can be found
in the bottom of each page. Modification services are not performed by the man-
ufacturer Berthold.
The manufacturer reserves the right to make changes to this operating manual at
any time without stating reasons.
NOTICE
The current revision of this operating manual replaces all previous versions.
1.6 Structure of the Operating Manual
This operating manual has been divided into chapters. The series of chapters should
help you to familiarise yourself quickly and properly with the operation of the
product.
1.7 Copyright
This operating manual contains copyright-protected information. None of the
chapters may be copied or reproduced in any other form without prior authorisa-
tion from the manufacturer.
1.8 Representation
Identifier
Meaning
Example
Quotation mark
Field in the soft-
wareuser interface
"Calibrate"
Vertical line
Path specification Settings | Selection
Pointed brackets
Keys and buttons
<Update>
Round brackets
Image reference
Connect the plug (fig. 1, item
1)
In the software description, the term "clicking" is used if a process is to be acti-
vated. This also refers to the pressing of a button or an area on the touch display
if a mouse is not used for control.

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1.9 Warning notes
Warning notes are designed as follows:
Signal Word
Source and consequence
Explanation, if required
uPrevention
In case of emergency
•Warning symbols: (warning triangle) draws attention to the hazard.
•Signal word: Indicates the severity of danger.
•Source: Specifies the type or source of danger.
•Consequence: Describes the consequences of non-compliance.
•Prevention: Specifies how the hazard can be avoided.
•In case of emergency: Specifies which actions are required in the event of
the occurrence of risk.
Symbols Used in the Operating Manual
In this manual, warning instructions before instructions for action refer to risks of
injury or damage to property. The hazard-prevention measures described must be
observed.
jDANGER
Indicates an
imminent
, major hazard, which will certainly result in serious inju-
ries or even death if the hazard is not avoided.
j
WARNING
Indicates a
potential
hazard, which can result in serious injuries or even death
if the hazard is not avoided.
j
CAUTION
Refers to a
potentially dangerous
situation, which can result in medium or
minor physical injuries or damages to property, if it is not avoided.
NOTICE
If this information is not observed, deterioration in the operation and/or prop-
erty damage may occur.
IMPORTANT
Sections marked with this symbol point out important information on the prod-
uct or on handling the product.
Tip
Provides tips on application and other useful information.

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Symbols Used on the Device
Read the operating manual
Please observe the instructions in this operating manual.
Electrostatic discharge
Please note the handling instructions. Electrostatically endangered compo-
nents. Please observe the instructions in this operating manual.
Protective earth connection
At this position, connect the protective earth conductor (PE).
Equipotential bonding connection
At this position, connect the equipotential bonding conductor.
Direct voltage
The device is operated with direct voltage and may only be connected with a
direct voltage source.
Alternating voltage
The device is operated with alternating voltage and may only be connected
with an alternating voltage source.
No domestic waste
The electric product must not be disposed of in domestic waste.

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1.10 Conformity
The company Berthold hereby declares in its sole responsibility that the design of
this product, which is brought to the market by Berthold, complies with relevant
EU directives stated in the original declaration of conformity.
This statement shall become void in the case of changes not authorised by Berthold
or improper use.
For the original declaration of conformity, please refer to Declaration of Conform-
ity in the document “Technical Information”.

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LB 478 MPLM 2 Safety
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2Safety
2.1 Dangers and safety measures
•Read these instructions thoroughly and completely before working with the
product.
•Store the instructions where they are accessible for all users at all times.
2.2 Proper Use
The evaluation unit DuoXpert LB 478 MPLM (EVU) measures the level together with
compatible detectors and an appropriate radiation source and may only be used
for this purpose.
The following constitutes proper use:
•Adhering strictly to the instructions and operation sequences and not un-
dertaking any different, unauthorised practices which could endanger your
safety and the operational reliability of the EVU!
•Observing the given safety instructions!
•Carrying out the prescribed maintenance measures or having them carried
out for you!
•Only use accessories and spare parts from Berthold.

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Improper use to be prevented:
•Failing to observe the specified safety instructions and instructions for the
operation, maintenance and disposal in the operating manual.
•Any non-compliance with the present operating manual for the supplied
products.
•Applying conditions and requirements which do not conform to those
stated in the technical documents, data sheets, operation manuals and as-
sembly instructions and other specific guidelines of the manufacturer.
•Use of the product if parts of it are damaged or corroded. This also applies
for seals and used cables.
•Restructuring or changing the system components.
•The product is not suitable for use in potentially explosive areas and may
therefore not be operated in such areas. The product is not explosion-proof.
•Operation ...
oin a state where live parts are accessible.
oin a wall housing with inadequately sealed glands and / or insufficiently
tightened or damaged cable glands.
•Operation without the safety precautions provided by the manufacturer.
•Manipulation or avoidance of existing safety equipment.
Berthold shall only accept liability for / guarantee the correspondence of the device
to its publicised specifications.
If the product is used in a way which is not described in the present operating
manual, the device's protection is compromised and the warranty claim becomes
invalid.
NOTICE
The device is not approved according to IEC 61508 “Functional safety of safety-
related electric/electronic/programmable electronic systems”.
2.3 Qualification of the Personnel
NOTICE
A minimum requirement for all work on or with the product would be employ-
ees with general knowledge who are instructed by an expert or authorised
person.
At different parts in this operating manual, reference is made to groups of people
with certain qualifications who can be entrusted with different tasks during instal-
lation, operation and maintenance.
These three groups of people are:
•Employees with General Knowledge
•Experts
•Authorised Persons.

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Employees with General Knowledge
NOTICE
Employees with general knowledge must always be guided by an expert at the
very least. When dealing with radioactive substances, a radiation safety officer
must also be consulted.
Employees with general knowledge are e.g. technicians or welders, who can un-
dertake different tasks during the transportation, assembly and installation of the
product under the guidance of an authorised person. This can also refer to con-
struction site personnel. The persons in question must have experience in handling
the product.
Experts
Experts are persons who have sufficient knowledge in the required area due to
their specialist training and who are familiar with the relevant national health and
safety regulations, accident prevention regulations, guidelines and recognised
technical rules.
Expert personnel must be capable of safely assessing the results of their work and
they must be familiar with the content of this operating manual.
Authorised Persons
Authorised persons are those who are either designated for the corresponding task
due to legal regulations or those who have been authorised by Berthold for par-
ticular tasks. When dealing with radioactive materials, a radiation safety officer
must also be consulted.
2.4 Operator's Obligations
The operator of the product must regularly train his personnel in the following
topics:
•Observation and use of the operating manual and the legal provisions.
•Intended operation of the product.
•Observation of the plant security instructions and the operating instructions
of the operator.
•Regular monitoring/maintenance of the product.

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LB 478 MPLM 3 System Description
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3System Description
3.1 Overview
Multiphase Level Measurement (MPLM) systems can be used to determine the in-
terface position between liquid phases or the height of different product layers.
Berthold’s EmulsionSENS is used to determine multiphase layers and consists of de-
tectors and evaluation units.
A complete measuring system consists of the following components, which are,
according to customer's order, individually assembled:
•Evaluation unit DuoXpert LB 478 MPLM (master and extension module)
•EmulsionSENS Control Cabinet
•Source
•Shields
•Point detector / rod detector(s) LB 480
These instructions concern the operation of the evaluation unit DuoXpert
LB 478 MPLM (Fig. 1, item 7 and item 8). The operation of other system compo-
nents is part of the independent instructions of the respective system components.
Depending on the measuring task and the composition of the measuring product
and containers, different arrangements and system components are required.
1
2
3
4
5
6
7
Dip pipe
Radiation beam
LB 480 Detectors
Power supply 24 V DC
Communication line (RS485)
Electronic cabinet
Evaluation unit LB 478 Master
8
9
10
11
12
13
14
Evaluation unit LB 478 extension module
Blind panels (for further extension mod-
ules)
Communication line (4-20mA) to DCS
Water
Emulsion
Grids
Oil
Fig.
1 Example measurement arrangement

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3.2 Measuring Principle
The Multiphase Level Measurement system EmulsionSENS consists of radiometric
density devices LB 480 at different elevations through the measurement span (see
Figure 1) and evaluation units LB 478 MPLM. Such an arrangement allows accurate
measurement of the density at each of these positions and provides a density pro-
file of the fluids as they separate inside the vessel.
The density measurement is based on the through-beam method and uses the
physical laws of absorption of radiation by matter. The resulting measurement ef-
fect is the ratio I/I0 between the unattenuated radiation I0 and the radiation I
weakened by the measured medium.
The density values of the individual detectors LB 480 are sent to the evaluation unit
LB 478 via RS485. By means of an algorithm implemented in the evaluation unit LB
478, interface levels can be calculated from the measured density values. This al-
lows the operator to see where the top of a layer is located as well as the bottom
of a layer.
Tip
Further information on the functional principle of the detectors can be found
in the operating manual of the detector.
3.3 System Components
1
2
3
Master-EVU / extension module with wide range supply (100-240 V AC, 50/60 Hz)
Alternatively with 24 V supply (18-32 V DC)
19" subrack
Clamp block for electrical connections
Fig.
2 System components

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Front/rear view EVU
Front view EVU
The following control elements are found on the front of the EVU:
•LEDs for status display of individual operating states
•3.5'' Touch display
•USB port.
1
2
3
4
5
6
7
3.5'' Touch display
RUN LED
WARNING LED
ERROR LED
USB port
Mounting screws
Screws front plate
Fig.
3 Front view of the EVU
Operation Display / Touch Screen
The EVU is operated via the touch screen. Alternatively, the device can be con-
nected to a mouse at the USB port. The device can also be operated by remote
control (see chap. 7.3.1).
NOTICE
Damage to the touch screen
Pointed or sharp objects can damage the plastic surface of the touchscreen.
uOperate the touch screen only with your fingers or with a touch pen or con-
nect a mouse. The mouse pointer automatically becomes visible when a
mouse is inserted into the USB port.

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Status displays of the master EVU
The LEDs (Fig. 3, items 2-4) below the touch display show the current operating
status of the master EVU.
Display LED
Description
RUN
This LED lights up green if the device is in operation
and fault-free. The current measurement is carried out.
RUN (flashing)
The RUN LED flashes green while the measurement is
(held) in the STOP state by user actions (e.g. stop func-
tion, simulation mode, plateau recording).
WARNING
WARNING
This LED lights up yellow when a system
event of the type "Outside of specification", "Mainte-
nance required" or "Function check" is present.
All system events are described in chapter 9.2.
ERROR
ERROR
This LED lights up red if a system event of the type "Fail-
ure" is present. The current measurement is retained.
Check the Device Setup.
All system events are described in chapter 9.2.
RUN / WARNING / ERROR flashing
All three LEDS flash during the system test which is per-
formed as part of the start up process.