Berthold DuoXpert LB 476 Level+ User manual

DuoXpert
LB 476 Level+
56925-6BA2 Rev.00 03/2023
Operating Manual
Embedded software version of EVU as of version 1.6.1 (CU and MU)
Embedded software version of Current Output/HART and 7-Wire/RS485-
Repeater as of version 1.0.0

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

LB 476 Level+ Table of Contents
56925-6BA2 Rev.00, 03/2023
Table of Contents
1About this Operating Manual...........................................................................1
1.1 Applicable Documents ................................................................................................. 1
1.2 Some Prior Remarks ..................................................................................................... 1
1.3 Storage Place ................................................................................................................ 1
1.4 Target Group ................................................................................................................ 1
1.5 Validity of the Operating Manual............................................................................... 2
1.6 Structure of the Operating Manual ............................................................................ 2
1.7 Copyright ...................................................................................................................... 2
1.8 Representation ............................................................................................................. 2
1.9 Warning Notes.............................................................................................................. 3
1.9.1 Symbols Used in the Operating Manual ..................................................................... 3
1.9.2 Symbols Used on the Device........................................................................................ 4
1.10 Conformity.................................................................................................................... 5
2Safety ................................................................................................................7
2.1 Dangers and Safety Measures ..................................................................................... 7
2.2 Proper Use..................................................................................................................... 7
2.3 Qualification of the Personnel .................................................................................... 8
2.4 Operator's Obligations................................................................................................. 9
3System Description.......................................................................................... 11
3.1 Overview ..................................................................................................................... 11
3.1.1 Measurement Arrangement LB 4700 Detectors....................................................... 12
3.1.2 Measurement Arrangement LB 480 Detectors......................................................... 13
3.2 Measuring Principle.................................................................................................... 14
3.3 System Components ................................................................................................... 15
3.3.1 Software...................................................................................................................... 15
3.3.2 Master EVU ................................................................................................................. 16
3.3.3 Slave Module .............................................................................................................. 18
3.3.4 View 7-Wire/RS485-Repeater Module....................................................................... 18
3.3.5 Current Output/HART Module .................................................................................. 19
3.4 Type Plate.................................................................................................................... 20
3.5 Storage ........................................................................................................................ 20
4Installation ......................................................................................................21
4.1 General Instructions ................................................................................................... 21
4.2 Unpacking/Scope of Delivery..................................................................................... 21
4.3 Mounting of the Wall Housing ................................................................................. 22
4.4 Installation in the Wall Housing with Terminal Blocks............................................ 23
4.5 Installation in the 19" Subrack with Terminal Blocks.............................................. 24
5Electric Installation .........................................................................................27
5.1 General Instructions ................................................................................................... 27
5.1.1 Circuit Breaker ............................................................................................................ 28
5.1.2 Cables and Lines ......................................................................................................... 28
5.1.3 Cable Glands and Blanking Elements........................................................................ 29
5.1.4 Protective Earth and Equipotential Bonding ........................................................... 30
5.1.5 EIA485 (RS485) Network ............................................................................................ 30
5.2 Electric Connection in the Wall Housing with Terminal Blocks .............................. 31
5.3 Electrical Connection in the 19″Subrack with Terminal Blocks .............................. 33
5.3.1 Master/Slave Plug ....................................................................................................... 35
5.4 Switching Current Output ......................................................................................... 36
6Operation of the Software ............................................................................. 37
6.1 System Start ................................................................................................................ 37
6.2 EVU Display ................................................................................................................. 38
6.3 Navigation................................................................................................................... 39
6.4 Status Messages.......................................................................................................... 39
6.5 Event Reports.............................................................................................................. 40
6.6 Input Field................................................................................................................... 41

Table of Contents LB 476 Level+
56925-6BA2 Rev.00, 03/2023
7Main Menu Device Setup ................................................................................43
7.1 Menu Identification ................................................................................................... 44
7.1.1 Location....................................................................................................................... 45
7.1.2 Device Information..................................................................................................... 46
7.1.3 Perform Software Update.......................................................................................... 47
7.2 Access .......................................................................................................................... 49
7.3 Menu Setup................................................................................................................. 51
7.3.1 System (Date / Time, Interfaces, Units, Network, Reset, Repair Det. Software) .... 51
7.3.2 Sensors......................................................................................................................... 63
7.3.3 Calibration .................................................................................................................. 81
7.3.4 Measurement.............................................................................................................. 99
7.3.5 Signal Condition ....................................................................................................... 100
7.3.6 Inputs......................................................................................................................... 106
7.3.7 Outputs ..................................................................................................................... 108
7.3.8 Alarms ....................................................................................................................... 119
7.3.9 Simulation................................................................................................................. 126
7.4 Menu Backup/Restore .............................................................................................. 128
7.4.1 Backup....................................................................................................................... 128
7.4.2 Restore ...................................................................................................................... 130
8Main Menu Diagnostics................................................................................. 131
8.1 Transmitter Temperature......................................................................................... 131
8.2 Events ........................................................................................................................ 132
8.2.1 Transmitter Event Log.............................................................................................. 132
8.2.2 Transm. Event Overview .......................................................................................... 134
8.3 Change Log............................................................................................................... 135
8.4 Data Log.................................................................................................................... 136
8.5 Network Data Log .................................................................................................... 138
8.6 Export Service Data .................................................................................................. 139
9Troubleshooting............................................................................................ 141
9.1 Error Search............................................................................................................... 141
9.2 Error Codes of the Evaluation Unit ......................................................................... 143
9.2.1 System ....................................................................................................................... 144
9.2.2 Application................................................................................................................ 146
9.2.3 Detector .................................................................................................................... 147
9.2.4 Current Output/HART Module ................................................................................ 148
9.2.5 Process Connection................................................................................................... 149
10 Maintenance and Repair............................................................................... 150
10.1 Replacing of Fuses .................................................................................................... 151
10.2 Cleaning .................................................................................................................... 154
10.3 Data Backup.............................................................................................................. 155
11 Decommissioning .......................................................................................... 156
11.1 Decommissioning Wall Housing.............................................................................. 156
11.2 Decommissioning 19" Subrack ................................................................................ 158
11.3 Disposal of Measurement System............................................................................ 159
12 Appendix....................................................................................................... 160
12.1 Setup Protocol .......................................................................................................... 160

LB 476 Level+ 1 About this Operating Manual
56925-6BA2 Rev.00, 03/2023
1
1About this Operating Manual
1.1 Applicable Documents
This manual contains the following documents:
•Technical Information, 56925TI1LP (see appendix)
•Informations sur la sécurité, 56925BA59 (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
•Install the extension module (optional)
•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.

1 About this Operating Manual
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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. The current revision of this operating manual
replaces all previous revisions.
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 touchscreen if
a mouse is not used for control.

LB 476 Level+ 1 About this Operating Manual
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1.9 Warning Notes
Warning notes are designed as follows:
Signal Word
Source and consequence
Explanation, if required
Prevention
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.
1.9.1 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.

1 About this Operating Manual
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1.9.2 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.

LB 476 Level+ 1 About this Operating Manual
56925-6BA2 Rev.00, 03/2023
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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” (see appendix).

1 About this Operating Manual
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LB 476 Level+ 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 DuoXpert LB 476 Level+ evaluation unit (EVU) is used together with compati-
ble detectors and appropriate sources to measure the level, and is especially
suitable for processes where product buildup may occur, which the system can com-
pensate for to ensure reliable level measurement.
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.

2 Safety
LB 476 Level+
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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 evaluation unit 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.

LB 476 Level+ 2 Safety
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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, who can undertake dif-
ferent tasks during the transportation, assembly and installation of the product
under the guidance of an authorised person. This can also refer to construction 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.

2 Safety
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LB 476 Level+ 3 System Description
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3System Description
3.1 Overview
The measuring device LB 476 Level+ is an industrial measuring system for the con-
tactless and continuous determination of product level in a container whereby the
measurement is optimized by a product buildup compensation (PBC).
A complete measuring system consists of the following components:
•Evaluation unit DuoXpert LB 476 Level+
•Rod detector(s) TowerSENS LB 4700 or LB 480
•Two point detectors LB 4700 or LB 480
•Source(s)
•Shield(s)
These instructions concern the installation of the modules (Fig. 1, item 8, item 11
and item 12, Fig. 2, item 10, item 11 and item 12) and the operation of the evalu-
ation unit DuoXpert LB 476 (Fig. 1, item 11). The operation of other system
components is part of the independent instructions of the respective system com-
ponents. The modules are standard equipment in switch rooms with 19" subracks
or switchboards.
Depending on the measuring task and the composition of the measuring product
and containers, different arrangements and system components are require. Note
the project-specific drawings and documentations.
IMPORTANT
When using RS485 detectors (e.g. LB 480), only the count rate is transmitted to
the LB 476 EVU and is calculated internally to a level value. A calibration of the
current output of the detector itself must be carried out directly at the con-
nected detector.

3 System Description
LB 476 Level+
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3.1.1 Measurement Arrangement LB 4700 Detectors
1
2
3
4
5
6
7
Point source shield
Mounting base
Radiation beam
Product
Product buildups
Rod detector TowerSENS LB 4700
Measurement line to slave module
8
9
10
11
12
13
Slave module
Point detector LB 4700
Measurement line to LB 476
LB 476
Current Output/HART module
5 analog outputs to DCS
Fig. 1 Example measurement arrangement with LB 4700 detectors

LB 476 Level+ 3 System Description
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3.1.2 Measurement Arrangement LB 480 Detectors
1
2
3
4
5
6
7
Point source shield
Mounting base
Radiation beam
Product
Product buildups
Rod detector TowerSENS LB 480
RS485 measurement line
8
9
10
11
12
13
Point detector LB 480
Measurement line 4 … 20mA to DCS (op-
tion)
7-Wire/RS485-Repeater module
LB 476
Current Output/HART module
5 analog outputs to DCS
Fig. 2 Example measurement arrangement with LB 480 detectors
The LB 480 detectors have their own evaluation electronics (see operating manual
SENSseries LB 480 54733-10BA2L and 54733-30BA2D) For the LB 476 Level+ meas-
urement arrangement, only the count rate is transmitted to the LB 476 evaluation
unit.

3 System Description
LB 476 Level+
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56925-6BA2 Rev.00, 03/2023
3.2 Measuring Principle
Gamma radiation is used to penetrate a medium in a container. The attenuation
of the radiation is analysed to measure the level in the container. The evaluation
unit DuoXpert LB 476 Level+ (master EVU) is used for the evaluation, transmission
and visualisation of measured values which it receives from the connected detec-
tors.
With the help of algorithms and calculations that are established in the LB 476
evaluation unit, product buildups and gas pressure fluctuations in the container
can be compensated for.
Tip
Further information on the functional principle of the detectors can be found
in the operating manual of the respective detector type.