Berthold MicroPolar LB 566 User manual

Concentration Meters
MicroPolar (++)
LB 566
User’s Guide
Hardware Manual
41986BA2
Rev. Nr.: 06-E, 09/2017

MicroPolar (++) LB 566
The units supplied should not be repaired by anyone other than Berthold
Technologies 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 hardware manual and the
software manual.
The hardware manual comprises:
mechanical components
installation
electrical installation
technical data
electrical and mechanical drawings
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 without prior notice.
BERTHOLD TECHNOLOGIES GmbH & Co. KG
Calmbacher Str. 22 D-75323 Bad Wildbad
Switchboard: Service:
Phone [phone] Phone [phone]
Fax [phone] Fax [phone]
[e-mail] [email protected]
www.Berthold.com

Table of Contents
MicroPolar (++) LB 566 5
Table of Contents
Page
Safety Summary 7Chapter 1.
1.1 Symbols and Warnings 7
1.2 General Information 8
1.3 General Safety Instructions 9
General Information 11Chapter 2.
2.1 Use and Function 11
2.2 Frequency License 12
2.3 Intended Use 14
2.4 Explanation of Terms 15
System Description 17Chapter 3.
3.1 Principle of Measurement 17
3.2 Calculation of Measured Values 18
3.3 Temperature Compensation 19
3.4 Throughput Calculation and Output 20
3.5 Mechanical Components 21
3.5.1 Evaluation Units 23
3.5.2 FlowCell 25
3.5.4 Container Probe 27
3.5.5 High-frequency Cable 30
3.6 Assembly on a Pipeline 32
3.7 Assembly on a Container 33
Getting Started 35Chapter 4.
4.1 Transport 35
4.2 Commissioning the FlowCell 36
4.2.1 Installing the FlowCell 36
4.2.2 Installing the Evaluation Unit 38
4.2.3 Connecting the HF Cable 39
4.3 Commissioning the Container Probe 41
4.3.1 Installing the Container Probe 41
4.3.2 Setting Up the Evaluation Unit 43
4.3.3 Connecting the HF Cable 43
4.5 Connecting the Evaluation Unit 45
4.5.1 Pin Configuration of the Connector Strip 46
4.5.2 Digital Outputs, Relay 48
Service instructions 51Chapter 5.
5.1 General Information 51
5.2 Wear Parts 52
5.3 Instrument Cleaning 53
5.4 Battery 53
5.5 Fuse Replacement 54

Table of Contents
6MicroPolar (++) LB 566
Technical Data 55Chapter 6.
6.1 Technical Data Evaluation Unit 55
6.2 Technical Data Sensors 58
6.3 Technical Data HF Cable 61
6.4 Format of Serial Data Output RS232 and RS485 62
Certificates 63Chapter 7.
7.1 EC Declaration of Conformity 63
7.2 Frequency License 65
Technical Drawings 73Chapter 8.
8.1 Dimensions Drawings Evaluation Unit Wall Housing 73
8.2 Electrical Wiring Diagram 75
8.3 Dimensional Drawings FlowCell 76
8.3.1 Type LB 5660-102-00X FlowCell DN 50 VFL. FOA 76
8.3.2 Type LB 5660-112-00X FlowCell DN 50 G-BS/M 77
8.4 Dimensional Drawings Container Probes 78
8.4.1 Type LB 5650-01 78
8.4.2 Type LB 5650-02 79
8.4.3 Type LB 5650-03 80
8.4.4 Type LB 5650-04 81
8.4.5 Type LB 5650-05 82
8.4.6 Type LB 5650-09 83
8.4.7 Installation Situation in Pipelines 84
8.5 Dimensional Drawings Container Flush Probes 85
8.5.1 Type LB 5651-01 85
8.5.2 Type LB 5651-02 86
8.5.3 Type LB 5651-03 87
8.5.6 Installation Situation in Pipelines 88

Chapter 1. Safety Summary
MicroPolar (++) LB 566 7
Safety SummaryChapter 1.
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 warning and safety instructions provided in this user
manual. They are identified by the following 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 followed.
IMPORTANT
Paragraphs with this symbol provide important information on
the product and how to handle it.
TIP
Contains user tips and other useful information.

Chapter 1. Safety Summary
8MicroPolar (++) LB 566
Other symbols used in this documentation:
Warning: No intervention, do not alter anything
Requirement: Disconnect power
Requirement: Wear safety boots
1.2 General Information
The most important safety measures a summarized in this user
manual. They supplement the corresponding regulations which
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 drawings and wiring 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

Chapter 1. Safety Summary
MicroPolar (++) LB 566 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
protected from direct sunlight and rain, for example by a
suitable shelter.
IMPORTANT
Never change the installation and the parameter settings
without a full knowledge of these operating instructions, as
well as a full knowledge 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 work with the systems who are mandated to
do this and are suitably qualified and adequately trained!
Installations and modifications on the systems which may
affect the operational safety are not permitted!
IMPORTANT
All system components require non-corrosive ambient
conditions during transport, storage and operation.
IMPORTANT
If liquid gets inside the instrument, cut off the power supply.
The equipment must be inspected and cleaned by an author-
ized service center.
Ambient
conditions

Chapter 1. Safety Summary
10 MicroPolar (++) LB 566
Electrical hazards
Disconnect power to ensure that contact with live part is
avoided during installation and when servicing.
Disconnect the power supply before opening the instrument.
Work on open and live instruments is prohibited.
Caution! Potential hazards, material damage!
Device type:
LB 566-12 MicroPolar ++ (ID no. 51833-02)
When connecting the 24 V DC power supply, the + and –
poles must be connected correctly. There is no reverse
polarity protection!
Spare fuses must match the rating specified by the device
manufacturer. Short-circuiting or manipulation is not permit-
ted.
IMPORTANT
The LB 566 and all additional equipment must be connected to
mains via grounded connection.
IMPORTANT
The concentration meter LB 566 may be installed, serviced
and repaired only by qualified specialists.
Qualified persons Qualified specialists are persons who through professional
training have acquired sufficient skills in the respective field and
who are familiar with the relevant national industrial safety reg-
ulations, accident prevention directions, guidelines and accepted
engineering standards. They must be able to safely assess the
results of their work and they must be familiar with the contents
of these user manual.

Chapter 2. General Information
MicroPolar (++) LB 566 11
General InformationChapter 2.
2.1 Use and Function
The MicroPolar LB 566 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
warranty will be lost.
Berthold Technologies is liable and guarantees only that the de-
vices comply with its published specifications. The LB 566 may
only be installed in an undamaged, dry and clean condition. Al-
terations and modifications to the system components are not
permitted.
The LB 566 is not qualified as a "safety-related measurement".
The standards and guidelines the LB 566 complies with are
itemized in these device instructions in chapter 2.2 Frequency
License and chapter 7.1 EC Declaration of Conformity.
The protection type of the LB 566 to IEC 60529 is max. IP 65.
The following use is inappropriate and has to be prevented:
The use under conditions other than the terms and condi-
tions stated by the manufacturer in their technical documen-
tation, 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 with open or inadequately closed cover.
Operating with insufficiently tightened adapters and cable
glands.
Operation without the manufacturer’s recommended safety
precautions.
Manipulating or bypassing existing safety facilities.
Authorized persons are those who, by law, are permitted to per-
form the respective activity, or who have been approved by
Berthold Technologies for certain activities.
Conformity to
standards
Protection type
Warning
against misuse
Authorized persons

Chapter 2. General Information
12 MicroPolar (++) LB 566
2.2 Frequency License
This device complies with Part 15 of the FCC Rules and with In-
dustry Canada licence-exempt RSS standard(s).
Operation is subject to the following two conditions:
(1) this device may not cause harmful interference, and
(2) this device must accept any interference received,
including interference that may cause undesired
operation.
Le présent appareil est conforme aux CNR d'Industrie Canada
applicables aux appareils radio exempts de licence.
L'exploitation est autorisée aux deux conditions suivantes:
(1) l'appareil ne doit pas produire de brouillage, et
(2) l'appareil doit accepter tout brouillage radioélectrique
subi, même si le brouillage est susceptible d'en
compromettre le fonctionnement.
This equipment has been tested and found to comply with the
limits for a Class B digital device, pursuant to part 15 of the FCC
Rules. These limits are designed to provide reasonable protec-
tion against harmful interference in a residential installation.
This equipment generates, uses and can radiate radio frequency
energy and, if not installed and used in accordance with the in-
structions, may cause harmful interference to radio communica-
tions. However, there is no guarantee that interference will not
occur in a particular installation. If this equipment does cause
harmful interference to radio or television reception, which can
be determined by turning the equipment off and on, the user is
encouraged to try to correct the interference by one or more of
the following measures:
-Reorient or relocate the receiving antenna.
-Increase the separation between the equipment and re-
ceiver.
License labels

Chapter 2. General Information
MicroPolar (++) LB 566 13
-Connect the equipment into an outlet on a circuit differ-
ent from that to which the receiver is connected.
-Consult the dealer or an experienced radio/TV technician
for help.
Changes or modifications made to this equipment not expressly
approved by BERTHOLD TECHNOLOGIES may void the FCC au-
thorization to operate this equipment.
The MicroPolar and MicroPolar ++ comply with the R&TTE Di-
rective 1999/5/EC and thus meet all the requirements for this
type of high-frequency devices. As a mark of conformity in ac-
cordance with the CE mark, the devices bear the no. 0682 of
the certification body. The certificate can be found in chapter
7.3 Frequency License.
IMPORTANT
The frequency approvals and conformities are only applicable
in combination with the container probes and the FlowCell.
To comply with ETSI (European Telecommunications Stand-
ards Institute), the LB 566 ++ in combination with horn and
spiral antennae may only be operated with a 10dB attenuator
pad in the sending path (MTX).
IMPORTANT
The LB 566 has been manufactured in compliance with the
safety requirements for microwave devices. It will be the
user’s responsibility to adhere to any special legal provisions
regarding the use of microwaves.
IMPORTANT
Any change in the frequency or otherwise tampering with the
microwave device will lead to a loss of the frequency license
and may result in criminal consequences.
The microwave modules do not include any replaceable
components and must not be opened.

Chapter 2. General Information
14 MicroPolar (++) LB 566
2.3 Intended Use
The LB 566 can be used to determine the water or moisture
content and the concentration of virtually any material. The fol-
lowing sensors and evaluation versions are available:
1. The container probes have been designed for installation in-
to containers and pipelines with a nominal width of 200
mm. The probe is mounted so that both measuring rods
(transmitter and receiver) are immersed into the product
being measured.
2. The FlowCell is a tubular probe, with the microwave trans-
mitter and receiver being firmly welded onto the outside of
the tube. The tube is lined with Teflon to ensure smooth
walls. The FlowCell is either installed directly into the exist-
ing pipeline system or into a bypass.
The evaluation unit is available in two versions: The standard
model MicroPolar and the high dynamic version MicroPolar ++.
The Micro Polar ++ requires a microwave signal attenuation of
at least 40 dB. The MicroPolar must be used for lower micro-
wave attenuation.
During operation, the concentration meters MicroPolar and Mi-
croPolar ++ emit electromagnetic radiation in the frequency
range between 2.4 GHz and 2.5 GHz (range limitations depend-
ing on local regulations in your country). Microwaves are not
dangerous to human beings and the environment (power radia-
tion < 10 mW). The microwaves are emitted directed from the
microwave window; the product is not altered by the micro-
waves.
To ensure proper function of the measuring system, please pay
attention to the following:
TIP
The material to be measured may be electrically conduc-
tive only to a limited degree.
The product must not contain any gas bubbles or gas
bubbles have to be compressed with adequate pressure
when carrying out measurements in pipelines.
The ion concentration, for example, salt content must be
nearly constant.

Chapter 2. General Information
MicroPolar (++) LB 566 15
2.4 Explanation of Terms
Attenuation Weakening of microwave signals, microwaves 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
always has to be performed.
FlowCell Tubular probe for simple integration into the existing pipeline
system.
Flush probe Container probe with flushing device.
HF cable High frequency cable
Microwaves Designation for electromagnetic waves in a specific frequency
range.
Phase Phase or phase shift, microwave measuring effect.
Quad cable Combination of four HF cables of equal length in a corrugated
tube.
Softkeys Software associated keys.
TC Temperature compensation

Chapter 3. System Description
MicroPolar (++) LB 566 17
System DescriptionChapter 3.
3.1 Principle of Measurement
As the microwaves pass through the product, their propagation
velocity is slowed down (= 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 microwaves passing through the product is slowed
down (phase shift) and their intensity (attenuation) is reduced.
Phase shift
Messgut
Phase comparison
--> Phase
Amplitude comp.
-->Attenuation
Reference path
Reference signal
Measurement signal
Measured value:
Concentration %DS
HF sources
Receiver
Transmitter
The prerequisite is that the product being measured shows die-
lectric properties. Generally, water is a very distinct dielectric
fluid. The water 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, we can measure the concen-
tration or the dry matter content of the product using a linear
calibration (see chapter 3.2 Calculation of Measured Values).
Figure 3-1:
Schematic diagram:
Change in
microwave by
product

Chapter 3. System Description
18 MicroPolar (++) LB 566
3.2 Calculation of Measured Values
The microwave parameters phase and attenuation are calibrat-
ed 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 supported by the evaluation unit.
Which of the parameters (phase, attenuation or both) will be
used for the calibration depends on the size and interference of
the measuring effect. For example, the attenuation is signifi-
cantly more sensitive to electrolytic conductivity (salt content).
In many cases, the pure phase measurement is recommended
and the measured value is calculated as follows:
Measured value = A ∙ Phase + C Eq. 3-1
where:
Measured value Concentration / Moisture / Dry matter
A, C Coefficients of the respective calibration
function
The LB 566 allows you to calibrate, display and output two con-
centrations: Con1 and Con2. You have to enter the calibration
coefficients separately for concentration 1 and 2. For more in-
formation please refer to the Software Manual.
Limitations
Weakly bound water 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 water to the solid matter.
Walls made of plastic, rubber or insulation materials with
fairly low dielectricity hardly affect the measurement and are
calibrated at a constant level.
Ice and crystal water cannot be measured because the water
molecules cannot rotate freely (ice and crystal water are
dry).

Chapter 3. System Description
MicroPolar (++) LB 566 19
Conductive materials such as graphite or coke cannot be trans-
mitted by microwaves. Metal walls can also not be transmitted
by microwaves.
Compensation In addition to the water content, the product temperature,
product density and a varying material load (varying microwave
irradiation path) may have an influence on the phase and at-
tenuation. This influence has to be compensated for during cali-
bration.
3.3 Temperature Compensation
Temperature compensation (TC) is required for fluctuating
product temperature. It is generally advisable to provide a tem-
perature compensation, i.e. a temperature signal (0/4...20 mA
or PT100) to be connected to the evaluation unit and, optional-
ly, to enable the compensation in the evaluation unit. The eval-
uation unit is designed so that the required TC’s can be calcu-
lated automatically. The variation in temperature where TC be-
comes absolutely essential is dependent on the product and on
the water content. In the first approximation, 2° C should be
set as fluctuation limit.
For example, if the product temperature is measured via the
PT100 input, then Eq. 3-1 is expanded as follows:
Measured value = A · Phase + D · Tmeas + C Eq. 3-2
where:
Measured value Concentration / Moisture / Dry matter
A, D, C Coefficients of the calibration function
Tmeas Product temperature
How to work with the temperature compensation is described in
detail in the Software Manual.

Chapter 3. System Description
20 MicroPolar (++) LB 566
3.4 Throughput Calculation and Output
For pipeline applications, the LB 566 allows you to calculate the
throughput (mass flow) and to output the result via a current
output.
The calculation is based on the microwave measured value; if
this value correlates with the product density, one can calculate
the throughput, if some additional information is available. The
additional information needed is: internal pipe diameter/cross
section and the product speed. The product speed has to be fed
via current input.
For details, please see the Software Manual, chapter 4.2.12
Mass Flow.