Burkert 8138 User manual

Operating Instructions
LEVEL TRANSMITTER
8138
4 ... 20 mA/HART

Contents
1About this document
1.1Function.................................. 4
1.2Target group .............................. 4
1.3Symbolism used............................ 4
2For your safety
2.1Authorised personnel ........................ 5
2.2Appropriate use ............................ 5
2.3Warning about misuse ....................... 5
2.4General safety instructions .................... 5
2.5Safety approval markings and safety tips .......... 6
2.6CE conformity ............................. 6
2.7Compatibility according to NAMUR NE 53 ......... 6
2.8SIL conformity ............................. 7
2.9FCC/IC conformity (only for USA/Canada)......... 7
2.10 Safety instructions for Ex areas ................. 7
3Product description
3.1Configuration .............................. 8
3.2Principle of operation ........................ 9
3.3Operation................................. 9
3.4Packaging,transport and storage ............... 9
4Mounting
4.1General instructions ......................... 11
4.2Mounting instructions ........................ 12
5Connecting to power supply
5.1Preparing the connection ..................... 19
5.2Connection procedure........................ 20
5.3Wiring plan,single chamber housing ............. 21
5.4Switch on phase............................ 22
6Set up with the indicating and adjustment module
6.1Short description ........................... 23
6.2Insert indicating and adjustment module........... 23
6.3Adjustment system .......................... 25
6.4Setup procedure............................ 26
6.5Menu schematic............................ 33
6.6Saving the parameter adjustment data............ 35
7Setup with PACTware and other adjustment programs
7.1Connecting the PC .......................... 36
7.2Parameter adjustment with PACTware ............ 36
7.3Parameter adjustment with AMS™and PDM ....... 37
7.4Saving the parameter adjustment data............ 37
2LEVEL TRANSMITTER 8138 •4... 20 mA/HART
Contents
32066-EN-081121

8Maintenance and fault rectification
8.1Maintenance .............................. 38
8.2Remove interferences........................ 38
9Dismounting
9.1Dismounting steps .......................... 40
9.2Disposal ................................. 40
10 Supplement
10.1Technical data ............................. 41
10.2Dimensions ............................... 47
Supplementary documentation
Information:
Supplementary documents appropriate to the ordered version come
with the delivery.You can find them listed in chapter "Product
description".
LEVEL TRANSMITTER 8138 •4... 20 mA/HART 3
Contents
32066-EN-081121

1About this document
1.1Function
This operating instructions manual provides all the information you
need for mounting,connection and setup as well as important
instructions for maintenance and fault rectification.Please read this
information before putting the instrument into operation and keep this
manual accessible in the immediate vicinity of the device.
1.2Target group
This operating instructions manual is directed to trained qualified
personnel.The contents of this manual should be made available to
these personnel and put into practice by them.
1.3Symbolism used
Information,tip,note
This symbol indicates helpful additional information.
Caution:If this warning is ignored,faults or malfunctions can
result.
Warning:If this warning is ignored,injury to persons and/or serious
damage to the instrument can result.
Danger:If this warning is ignored,serious injury to persons and/or
destruction of the instrument can result.
Ex applications
This symbol indicates special instructions for Ex applications.
lList
The dot set in front indicates a list with no implied sequence.
àAction
This arrow indicates a single action.
1Sequence
Numbers set in front indicate successive steps in a procedure.
4LEVEL TRANSMITTER 8138 •4... 20 mA/HART
1About this document
32066-EN-081121

2For your safety
2.1Authorised personnel
All operations described in this operating instructions manual must be
carried out only by trained specialist personnel authorised by the plant
operator.
During work on and with the device the required personal protective
equipment must always be worn.
2.2Appropriate use
LEVEL TRANSMITTER 8138 is a sensor for continuous level
measurement.
You can find detailed information on the application range in chapter
"Product description".
Operational reliability is ensured only if the instrument is properly used
according to the specifications in the operating instructions manual as
well as possible supplementary instructions.
For safety and warranty reasons,any invasive work on the device
beyond that described in the operating instructions manual may be
carried out only by personnel authorised by the manufacturer.Arbitrary
conversions or modifications are explicitly forbidden.
2.3Warning about misuse
Inappropriate or incorrect use of the instrument can give rise to
application-specific hazards,e.g.vessel overfill or damage to system
components through incorrect mounting or adjustment.
2.4General safety instructions
This is a high-tech instrument requiring the strict observance of
standard regulations and guidelines.The user must take note of the
safety instructions in this operating instructions manual,the country-
specific installation standards as well as all prevailing safety
regulations and accident prevention rules.
Depending on the model,the emitting frequencies of all radar sensors
are either in the Cor Kband range.The low transmitting power lies far
below the internationally permitted limit values.When the instrument is
used correctly,it presents no danger to human health.It may be
operated without restriction outside of closed metallic vessels.
The instrument must only be operated in a technically flawless and
reliable condition.The operator is responsible for trouble-free
operation of the instrument.
LEVEL TRANSMITTER 8138 •4... 20 mA/HART 5
2For your safety
32066-EN-081121

During the entire duration of use,the user is obliged to determine the
compliance of the required occupational safety measures with the
current valid rules and regulations and also take note of new
regulations.
2.5Safety approval markings and safety tips
The safety approval markings and safety tips on the device must be
observed.
2.6CE conformity
The protection goals of the EMC Directive 2004/108/EC (EMC), the R
&TTE directive 1999/5/EC and the Low Voltage Directive 2006/95/EC
(LVD)are fulfilled.1)
Conformity has been judged according to the following standards:
EMC:EN 61326-1:2006
(electrical instruments for control technology and laboratory use -EMC
requirements)
lEmission:Class B
lSusceptibility:Industrial areas
R&TTE
I-ETS 300-440 Expert opinion No.0043052-02/SEE,Notified Body No.
0499
LVD:EN 61010-1:2001
(safety regulations for electrical measurement,control and laboratory
instruments -part 1:General requirements)
2.7Compatibility according to NAMUR NE 53
With regard to compatibility,the NAMUR recommendation NE 53 is
fulfilled.This applies also to the corresponding indicating and
adjustment components.
The parameter adjustment of the basic sensor functions is independ-
ent of the software version.The range of available functions depends
on the respective software version of the individual components.
The software version of LEVEL TRANSMITTER 8138 can be
determined as follows:
lon the type label of the electronics
lvia the indicating and adjustment module
1)R&TTE-Richtlinie 1999/5/EC:Not with version with increased sensitivity.
6LEVEL TRANSMITTER 8138 •4... 20 mA/HART
2For your safety
32066-EN-081121

2.8SIL conformity
LEVEL TRANSMITTER 8138 fulfills the requirements for functional
safety according to IEC 61508/IEC 61511.You can find further
information in the Safety Manual "LEVEL TRANSMITTER 813X-
4…20 mA/HART".
2.9FCC/IC conformity (only for USA/Canada)
LEVEL TRANSMITTER 8138 with all antenna versions is FCC/IC
approved.
Modifications not expressly approved by Bürkert will lead to expiry of
the operating licence according to FCC/IC.
LEVEL TRANSMITTER 8138 is in conformity with part 15 of the FCC
directives and fulfills the RSS-210 regulations.Note the corresponding
regulations for operation:
lThe instrument must not cause any interfering emissions
lThe device must be insensitive to immissions,including those that
may cause undesired operating conditions.
The instrument is designed for operation with an antenna according to
chapter "Dimensions"of this operating instructions manual,with a
max.amplification of 33 dB.The instrument must not be operated with
antennas not listed therein or those having an amplification of more
than 33 dB.The required antenna impedance is 50 Ω.
2.10 Safety instructions for Ex areas
Please note the Ex-specific safety information for installation and
operation in Ex areas.These safety instructions are part of the
operating instructions manual and come with the Ex-approved
instruments.
LEVEL TRANSMITTER 8138 •4... 20 mA/HART 7
2For your safety
32066-EN-081121

3Product description
3.1Configuration
The scope of delivery encompasses:
lLEVEL TRANSMITTER 8138 radar sensor
lDocumentation
-this operating instructions manual
-Safety Manual "Functional safety according to IEC 61508
(SIL)"
-Operating instructions manual "Indicating and adjustment
module"(optional)
-Ex-specific"Safety instructions"(with Ex-versions)
-if necessary,further certificates
LEVEL TRANSMITTER 8138 consists of the following components:
lProcess fitting with flange
lHousing with electronics
lHousing cover,optionally available with indicating and adjustment
module
The components are available in different versions.
3
1
2
Fig.1:LEVEL TRANSMITTER 8138 -flange version with plastic housing
1Housing cover with integrated indicating and adjustment module (optional)
2Housing with electronics
3Process fitting with encapsulated antenna system
The type label contains the most important data for identification and
use of the instrument:
lArticle number
lSerial number
lTechnical data
lArticle numbers documentation
Scope of delivery
Components
Type label
8LEVEL TRANSMITTER 8138 •4... 20 mA/HART
3Product description
32066-EN-081121

3.2Principle of operation
LEVEL TRANSMITTER 8138 is a radar sensor in K-band technology
(emitting frequency approx.26 GHz)for continuous level measure-
ment.It is particularly suitable for small vessels that contain aggressive
liquids under easy process conditions.
The antenna of the radar sensor emits short radar pulses with a
duration of approx.1ns.These pulses are reflected by the product
and received by the antenna as echoes.The running time of the radar
pulses from emission to reception is proportional to the distance and
hence to the level.The determined level is converted into an
appropriate output signal and outputted as measured value.
Two-wire electronics 4…20 mA/HART for power supply and
measured value transmission over the same cable.
The supply voltage range can differ depending on the instrument
version.
The data for power supply are specified in chapter "Technical data".
The backlight of the indicating and adjustment module is powered by
the sensor.Prerequisite is a certain level of supply voltage.
The data for power supply are specified in chapter "Technical data".
3.3Operation
LEVEL TRANSMITTER 8138 can be adjusted with different adjust-
ment media:
lwith indicating and adjustment module
lwith the suitable Bürkert DTM in conjunction with an adjustment
software according to the FDT/DTM standard,e.g.PACTware and
PC
lwith manufacturer-specific adjustment programs AMS™or PDM
lWith a HART handheld
The entered parameters are generally saved in LEVEL TRANS-
MITTER 8138,optionally also in the indicating/adjustment module.
3.4Packaging,transport and storage
Your instrument was protected by packaging during transport.Its
capacity to handle normal loads during transport is assured by a test
according to DIN EN 24180.
The packaging of standard instruments consists of environment-
friendly,recyclable cardboard.For special versions,PE foam or PE foil
is also used.Dispose of the packaging material via specialised
recycling companies.
Application area
Functional principle
Power supply
Packaging
LEVEL TRANSMITTER 8138 •4... 20 mA/HART 9
3Product description
32066-EN-081121

Transport must be carried out under consideration of the notes on the
transport packaging.Nonobservance of these instructions can cause
damage to the device.
The delivery must be checked for completeness and possible transit
damage immediately at receipt.Ascertained transit damage or
concealed defects must be appropriately dealt with.
Up to the time of installation,the packages must be left closed and
stored according to the orientation and storage markings on the
outside.
Unless otherwise indicated,the packages must be stored only under
the following conditions:
lNot in the open
lDry and dust free
lNot exposed to corrosive media
lProtected against solar radiation
lAvoiding mechanical shock and vibration
lStorage and transport temperature see chapter "Supplement -
Technical data -Ambient conditions"
lRelative humidity 20 …85 %
Transport
Transport inspection
Storage
Storage and transport
temperature
10 LEVEL TRANSMITTER 8138 •4... 20 mA/HART
3Product description
32066-EN-081121

4Mounting
4.1General instructions
Select an installation position you can easily reach for mounting and
connecting as well as later retrofitting of an indicating and adjustment
module.The housing can be rotated by 330°without the use of any
tools.You can also install the indicating and adjustment module in four
different positions (each displaced by 90°).
Use the recommended cables (see chapter "Connecting to power
supply")and tighten the cable gland.
You can give your instrument additional protection against moisture
penetration by leading the connection cable downward in front of the
cable entry.Rain and condensation water can thus drain off.This
applies mainly to outdoor mounting as well as installation in areas
where high humidity is expected (e.g.through cleaning processes)or
on cooled or heated vessels.
Fig.2:Measures against moisture penetration
The reference plane for the measuring range of the sensors is the
lower edge of the flange.
Information:
If the medium reaches the antenna,buildup can form on it and cause
faulty measurements later on.
Mounting position
Moisture
Measuring range
LEVEL TRANSMITTER 8138 •4... 20 mA/HART 11
4Mounting
32066-EN-081121

1 32
100%
0%
Fig.3:Measuring range (operating range)and max.measuring distance
1full
2empty (max.measuring distance)
3Measuring range
Make sure that all parts of the instrument in contact with the measured
product,especially the sensor element,process seal and process
fitting,are suitable for the existing process conditions such as process
pressure,process temperature as well as the chemical properties of
the medium.
You can find the specifications in chapter "Technical data"in the or on
the type label.
4.2Mounting instructions
When mounting the sensor,keep a distance of at least 200 mm
(7.874 in)to the vessel wall.If the sensor is installed in the center of
dished or round vessel tops,multiple echoes can arise.These can,
however,be suppressed by an appropriate adjustment (see chapter
"Setup").
If you cannot keep this distance you should carry out a false echo
storage before setup.This applies mainly if buildup on the vessel wall
is expected.In this case,we recommend repeating a false echo
storage later with existing buildup.
Suitability for process
conditions
Mounting position
12 LEVEL TRANSMITTER 8138 •4... 20 mA/HART
4Mounting
32066-EN-081121

12
> 200 mm
Fig.4:Mounting on round vessel tops
1Reference plane
2Vessel center or symmetry axis
In vessels with conical bottom it can be advantageous to mount the
sensor in the center of the vessel,as measurement is then possible
down to the lowest point of the vessel bottom.
Fig.5:Vessel with conical bottom
The flange screws of LEVEL TRANSMITTER 8138 must be always
screwed with the torque stated in the technical data so that the PTFE
washer of the encapsulated antenna system seals.
Mounting of instruments
with PTFE plated flanges
LEVEL TRANSMITTER 8138 •4... 20 mA/HART 13
4Mounting
32066-EN-081121

You balance the material-dependent bias voltage loss with PTFE as
follows:
1Number of flange screws according to the number of flange holes
2Also use disc springs to fasten the flange screws
3Tighten the screws steadily with the torque specified in the
technical data
Do not mount the instruments in or above the filling stream.Make sure
that you detect the product surface,not the inflowing product.
Fig.6:Inflowing liquid
Flush mounting
The best way to mount the sensor,also with respect to cleanability,is
flush on a block flange (flange without socket piece)or with hygienic
fittings,e.g.Neumo Biocontrol.
Mounting on socket
If the reflective properties of the medium are good,you can mount
LEVEL TRANSMITTER 8138 on a socket piece.You will find
recommended values for socket heights in the following illustration.
The socket end should be smooth and burr-free,if possible also
rounded.Then carry out a false echo storage.
Inflowing medium
Socket
14 LEVEL TRANSMITTER 8138 •4... 20 mA/HART
4Mounting
32066-EN-081121

d
hmax.
d
50 mm/2"
80 mm/3"
100 mm/4"
150 mm/6"
100 mm
150 mm
250 mm
400 mm
hmax.
Fig.7:Deviating socket dimensions
Information:
The flange screws of LEVEL TRANSMITTER 8138 must always be
tightened with a torque of approx.60 Nm(44 lbf ft)so that the PTFE
washer of the encapsulated antenna system seals reliably.
Align the sensor in liquids as vertical as possible to the product surface
to achieve optimum measurement.
Fig.8:Alignment in liquids
The mounting location of the radar sensor should be a place where no
other equipment or fixtures cross the path of the microwave signals.
Vessel installations such as,for example,ladders,limit switches,
heating spirals,struts,etc.can cause false echoes that get super-
imposed on the useful echo.Make sure when planning your measuring
site that the radar sensor has a "clear view"to the measured product.
In case of existing vessel installations,a false echo storage should be
carried out during setup.
If large vessel installations such as struts or supports cause false
echoes,these can be attenuated through supplementary measures.
Small,inclined sheet metal baffles above the installations scatter the
radar signals and prevent direct interfering reflections.
Sensor orientation
Vessel installations
LEVEL TRANSMITTER 8138 •4... 20 mA/HART 15
4Mounting
32066-EN-081121

Fig.9:Cover smooth profiles with deflectors
If there are agitators in the vessel,a false echo storage should be
carried out with the agitators in motion.This ensures that the interfering
reflections from the agitators are saved with the blades in different
positions.
Fig.10:Agitators
Through the action of filling,stirring and other processes in the vessel,
dense foams which considerably damp the emitted signals may form
on the product surface.
If foams are causing measurement errors,the biggest possible radar
antenna should be used.
LEVEL TRANSMITTER 8185-8186 with guided microwaves are not
influenced by foam generation and are particularly suitable for such
applications.
By using a standpipe,the influence of vessel installations and
turbulence can be excluded.Under these prerequisites,the meas-
urement of products with low dielectric values (from DK value 1.6)is
possible.
Agitators
Foam generation
Measurement in the
standpipe (surge or by-
pass tube)
16 LEVEL TRANSMITTER 8138 •4... 20 mA/HART
4Mounting
32066-EN-081121

Surge or bypass tubes must extend all the way down to the requested
min.level,as measurement is only possible within the tube.
max.
min.
2
1
Fig.11:Pipe antenna systems in a tank
1Marking of the polarisation direction
2Vent hole,max.diameter 5mm (0.2in)
If possible,the antenna diameter of the sensor should correspond to
the inner diameter of the tube.With LEVEL TRANSMITTER 8138 this
is approx.50 mm (1.969 in). The sensor can be used with tube
diameters between 50 …80 mm (1.969 …3.15 in).
Make sure you provide the necessary upper vent hole in the surge
pipe,which must be displaced by 90°to the polarisation marking on
the sensor (see illustration:"Pipe antenna system in a tank").
As an alternative to the surge pipe in the vessel,a pipe system can be
mounted outside of the vessel as a bypass tube.For setup,select the
function "Bypass tube".
Align the sensor in such a way that the polarisation marking on the
process fitting is displaced by 90°to the tube holes or the tube
connection openings (see illustration:"LEVEL TRANSMITTER 8138 in
a bypass tube").
LEVEL TRANSMITTER 8138 •4... 20 mA/HART 17
4Mounting
32066-EN-081121

100%
0%
1
> 300 mm
Fig.12:LEVEL TRANSMITTER 8138 in a bypass tube
1Marking of the polarisation direction
When the sensor is mounted on a bypass tube,the distance from
LEVEL TRANSMITTER 8138 to the upper tube connection should be
approx.300 mm (11.81 in)or more.In case of extremely rough tube
inner walls,you should use an inserted tube (tube in tube)or a radar
sensor with tube antenna.
18 LEVEL TRANSMITTER 8138 •4... 20 mA/HART
4Mounting
32066-EN-081121

5Connecting to power supply
5.1Preparing the connection
Always keep in mind the following safety instructions:
lConnect only in the complete absence of line voltage
lIf overvoltage surges are expected,overvoltage arresters should
be installed
In hazardous areas you should take note of the appropriate
regulations,conformity and type approval certificates of the sensors
and power supply units.
Power supply and current signal are carried on the same two-wire
cable.The voltage supply range can differ depending on the
instrument version.
The data for power supply are specified in chapter "Technical data".
Provide a reliable separation between the supply circuit and the mains
circuits according to DIN VDE 0106 part 101.
Bear in mind the following factors regarding supply voltage:
lOutput voltage of the power supply unit can be lower under
nominal load (with a sensor current of 20.5mAor 22 mAin case of
fault message)
lInfluence of additional instruments in the circuit (see load values in
chapter "Technical data")
The instrument is connected with standard two-wire cable without
screen.If electromagnetic interference is expected which is above the
test values of EN 61326 for industrial areas,screened cable should be
used.
Use cable with round cross-section.Acable outer diameter of 5…9mm
(0.2…0.35 in)ensures the seal effect of the cable gland.If you are
using cable with a different diameter or cross-section,exchange the
seal or use a suitable cable gland.
If screened cable is necessary,connect the cable screen on both ends
to ground potential.In the sensor,the screen must be connected
directly to the internal ground terminal.The ground terminal on the
outside of the housing must be connected to the potential equalisation
(low impedance).
If potential equalisation currents are expected,the connection on the
processing side must be made via a ceramic capacitor (e.g.1nF,
1500 V). The low frequency potential equalisation currents are thus
suppressed,but the protective effect against high frequency interfer-
ence signals remains.
Note safety instructions
Take note of
safety instruc-
tions for Ex ap-
plications
Select power supply
Selecting connection
cable
Cable screening and
grounding
LEVEL TRANSMITTER 8138 •4... 20 mA/HART 19
5Connecting to power supply
32066-EN-081121

Take note of the corresponding installation regulations for Ex
applications.In particular,make sure that no potential equalisation
currents flow over the cable screen.In case of grounding on both sides
this can be achieved by the use of a capacitor or a separate potential
equalisation.
5.2Connection procedure
Proceed as follows:
1Unscrew the housing cover
2If an indicating and adjustment module is installed,remove it by
turning it slightly to the left.
3Loosen compression nut of the cable entry
4Remove approx.10 cm (4in)of the cable mantle,strip approx.
1cm (0.4in)insulation from the ends of the individual wires
5Insert the cable through the cable gland into the sensor
6Lift the opening levers of the terminals with a screwdriver (see
following illustration)
7Insert the wire ends into the open terminals according to the wiring
plan
8Press down the opening levers of the terminals,you will hear the
terminal spring closing
9Check the hold of the wires in the terminals by lightly pulling on
them
10 Connect the screen to the internal ground terminal,connect the
outer ground terminal with potential equalisation
11 Tighten the compression nut of the cable entry.The seal ring must
completely encircle the cable
12 Screw the housing cover on
Select connec-
tion cable for Ex
applications
20 LEVEL TRANSMITTER 8138 •4... 20 mA/HART
5Connecting to power supply
32066-EN-081121