K-TEK MT5000 Owner's manual

MT5000-0200-1 Rev f (10-2010) DCN0528

MT5000-0200-1 Rev f (10-2010) DCN0528 2
TABLE OF CONTENTS
1.0 Introduction................................................................................................................................ 3
2.0 Overview.................................................................................................................................... 4
2.1 Storage and Handling Information ..................................................................................... 4
2.2 Ambient Temperature ........................................................................................................ 4
2.3 Description and Principle of Operation .............................................................................. 4
3.0 Installation.................................................................................................................................. 6
3.1 Mechanical Installation ....................................................................................................... 6
3.2 Shortening of the Probe ..................................................................................................... 7
3.3 Electrical Installation .......................................................................................................... 7
4.0 Commissioning .......................................................................................................................... 8
4.1 Display Operation............................................................................................................... 8
4.1.1. Jumper Settings .................................................................................................... 9
4.1.2. Push Buttons ......................................................................................................... 9
4.2 MT5000 Menu Flow Chart.................................................................................................. 10
4.3 Basic Setup ........................................................................................................................ 11
4.3.1. Units ....................................................................................................................... 11
4.3.2. Probe Type............................................................................................................. 11
4.3.3. Probe Length.......................................................................................................... 12
4.3.4. Mounting Type ....................................................................................................... 13
4.3.5. Nozzle Length ........................................................................................................ 14
4.3.6. Offset...................................................................................................................... 14
4.3.7. Dielectric................................................................................................................. 16
4.3.8. Measure Mode ....................................................................................................... 16
4.3.9. Language ............................................................................................................... 17
4.4 Quick Calibration ................................................................................................................ 18
4.5 mA Output Setup................................................................................................................ 18
4.5.1. Output..................................................................................................................... 19
4.5.2. LRV 4mA ................................................................................................................ 19
4.5.3. URV 20mA ............................................................................................................. 19
4.5.4. Dampening ............................................................................................................. 20
4.5.5. Alarm Delay............................................................................................................ 20
4.5.6. DAC Trim (4mA and 20mA) ................................................................................... 21
4.5.7. LOOP Test ............................................................................................................. 21
4.5.8. HART Address ....................................................................................................... 22
4.5.9. LRS (HART version only)...................................................................................... 22
4.6 Extended Setup.................................................................................................................. 23
4.6.1. Waveform Display .................................................................................................. 23
4.6.2. Functions................................................................................................................ 25
4.6.3. Temperature........................................................................................................... 26
4.6.4. Linearization Menu................................................................................................. 27
4.6.5. SOR (HART version only)...................................................................................... 31
5.0 Troubleshooting......................................................................................................................... 32
5.1 Valid Current Loop Outputs................................................................................................ 32
5.2 Symptoms and Solutions ................................................................................................... 32
5.3 Electronics Module Replacement ...................................................................................... 33
6.0 Installation Drawings for Intrinsic Safety & Standard Wiring..................................................... 34
7.0 Installation Drawings for Explosion Proof.................................................................................. 36
8.0 CE Certificate of Conformity...................................................................................................... 37
9.0 Customer Support ..................................................................................................................... 38
9.1 K-TEK RMA Form .............................................................................................................. 39
10.0 Warranty .................................................................................................................................. 40

MT5000-0200-1 Rev f (10-2010) DCN0528 3
Thank you for using the K-TEK MT5000 Guided Wave Radar Liquid Level Transmitter. The MT5000 series is a
second generation of products which have been designed for simplicity of setup while offering extensive
configuration capabilities. You are invited and urged to review this instruction manual in its entirety prior to use of
the transmitter. This will eliminate most installation problems due to improper configuration.
We, the K-TEK Family, sincerely hope you receive many years of reliable use from the MT5000 transmitter and
welcome your feedback to consistently improve our all of our products. It is our desire to provide you, the user, with
the most reliable, customer friendly device to suit your application needs.
When it comes to measuring the level of liquids, guided wave radar technology now offers more level-detection
capabilities than ever before. For an ever-widening range of previously hard-to-measure products such as molten
sulfur, liquid ammonia and petrochemicals, guided wave radar transmitters provide accurate level measurements
even under harsh chemical environments, wide variations in operating temperatures and pressures, and low
dielectric constants. Great strides have also been taken in making these units easier to configure to a variety of proc-
ess applications coupled with the simplicity of integrating these devices with most digital communication protocols.
These improvements come as a welcome relief to process engineers that seek solutions to measuring the contents
of tanks, silos, hoppers, bins, mixing basins, and vessels in an expanded range of level applications across several
different industries.
Because a guided wave radar transmitter has no moving parts, it has established itself as a level measurement
technology that has distanced itself from traditional mechanical means, which don't hold up as well in dirty service.
Guided wave radar achieves its non-mechanical level detection capability by measuring the time of flight of the
transmitted signal.
Known more accurately as Time Domain Reflectometry (TDR), the process involves:
1. Sending microwave energy down into a vessel guided by an antenna.
2. When the pulse of radar energy reaches the product (indicated by a change in impedance), part of the
pulse is reflected back toward the transmitter.
3. A receiver measures the exact duration of time between the transmitted and reflected signal—the "time
of flight."
4. The device analyzes this time and ultimately displays the level of the product as a distance in inches,
feet, meters, or other engineering units.
The MT5000 transmitter was developed with ease of operation in mind. We made use of a graphic display to pro-
vide a more user friendly aspect to the transmitter configuration. The graphic display allowed us to incorporate multi-
ple language options in the setup menu such as English, Spanish and Chinese. In the incorporation of the graphic
display, the electronics were converted to a digital format. This provided a greater signal recognition capability
and an ability to include an ―onboard oscilloscope‖ as an aid in troubleshooting tough applications.
The emphasis on simplicity extended itself beyond the use of multiple languages. The Basic Setup menu has been
designed with a series of multiple choice questions which, when answered correctly, will configure the transmitter to
the installation. The mA Output Setup menu has been expanded to include Loop Test and HART®Address
capabilities.
Coupled with the development of the MT5000 series was the development of the KCOM™ software. KCOM™ is a
diagnostic tool which allows the MT5000 to be remotely configured using a computer and HART® interface modem.
Beyond the Basic Setup parameters, the software will allow the user to view the return signal of the MT5000 on the
computer screen. As a trouble shooting tool, a screen shot of the waveform may be taken and sent to the factory for
analysis. The KCOM™ software is free and may be downloaded from our website at www.ktekcorp.com.
For more information on the MT5000 series including liquid/liquid interface and bulk solids measurement visit our
website at www.ktekcorp.com.
1.0 INTRODUCTION

MT5000-0200-1 Rev f (10-2010) DCN0528 4
2.0 OVERVIEW
2.1 Storage and Handling Information
If possible, storage prior to installation should be indoors at ambient temperature, not to exceed the following:
Temperature range: -40 to 150 degrees F.
Humidity: 0 to 100% R.H. non-condensing.
To avoid probe damage:
Do not transport or support the weight of the MT5000 by means of the probe.
Installation of rigid probes and flange mounted transmitters may require the use of lifting equipment.
Avoid sharp bending of cable probes which can result in poor instrument operation.
The lids on the MT5000 housing are sealed with o-rings. To avoid damage to the electronics, both lids should be
closed tightly before and after installation.
The MT5000 electronics temperature may not exceed 170°F / 77°C. For higher ambient temperatures due to radiant
process heat, a high temperature extension option is required. The coupler process temperature shall not exceed
the temperature stated in the datasheet specifications for the given coupler.
2.2 Ambient Temperature
The MT5000 is a 4-20mA loop powered Smart Level Transmitter, which is microprocessor based and is available
with HART® communication. It uses very low power microwave energy to determine the level of the product being
measured. In order to obtain optimum performance, it is important to understand the basic principle of operation. The
electronics housing is typically fitted with a special adapter ―Coupler‖ serving as a process connection and seal, and
holding a solid rod or a cable. The rod or cable ―Probe‖ hangs into the vessel and acts as a wave-guide, i.e. the
microwave energy stays concentrated around the probe and along its length, instead of being dispersed in a cone,
as it would be if there was no probe.
2.3 Description & Principle of Operation
PROBE COUPLER
HOUSING

MT5000-0200-1 Rev f (10-2010) DCN0528 5
A measurement cycle consists of the following:
1. A very short ―pulse‖ of microwave energy is applied at the cou-
pler, to the Probe.
2. The pulse travels along the length of the probe and when it en-
counters a discontinuity that is a dielectric constant change,
such as the product surface, some of the energy is reflected
and travels back towards the coupler.
3. When the reflected energy reaches the coupler, it is sensed by
the electronics. By measuring the time elapsed between the
initial pulse and the reflected one, the electronics can calcu-
late the product level.
4. Since the microwave energy travels at the speed of light, one
complete measurement cycle is made up of several thousands
of Pulses. The electronics uses Time Domain Reflectometry
(TDR), a sampling technique to reconstruct a waveform dupli-
cating the actual real time signal, but at a much lower speed, so
that it can be processed by the microprocessor. This process
can be compared to using the stroboscope effect as when ob-
serving a piece of machinery turning at high speed with a
strobe light.
5. The measurement cycles are made 2 times per second and
processed by special filtering techniques, before generating a
current output proportional to the level of the product.
1
23
5
4
A simplified signal trace as seen on the graphic display (Figure 1) can be divided into three identifiable sections:
Coupler Reflection, Signal Reflection and End of Probe Reflection.
The measurement principle using TDR is based on the fact that a dielectric constant discontinuity or geometric
change will yield a positive pulse having certain amplitude above the baseline. The greater the dielectric constant
difference, the greater the positive amplitude of the return signal. This means that a signal will show up on the base-
line if there is a substantial change from a nozzle diameter to an open tank, for example, as signal plot at the proc-
ess connection. This fact will be taken into account in the configuration of the MT5000 (Consult Basic Setup
(Section 4.3) on Commissioning).
Figure 1
Coupler Reflection
Signal Reflection
Blanking Threshold
End of Probe Reflection
Note: Operation is subject to the following two conditions:
1. This device may not cause harmful interference.
2. This device must accept any interference received, including interference that may cause undesired operation.

MT5000-0200-1 Rev f (10-2010) DCN0528 6
3.0 INSTALLATION
3.1 Mechanical Installation
Guidelines and Warnings for MT5000 installation:
Do not tamper or remove coupler from transmitter housing as this will damage the coupler.
All Installations
1. Do not mount the MT5000 in the product fill stream.
2. To obtain the best return signal from the product level mount the MT5000 coupler directly into the top of the ves-
sel.
3. Do not mount MT5000 single probes using bushings. (Figure 2)
4. Ideally, probes should be mounted in the center of the vessel to provide the maximum measuring range.
5. Avoid internal obstructions such as tubing, ladders or agitators.
6. An MT5000 installed in a nozzle whose height is greater than its width will have an increased non-linear zone at
the top of the probe.
7. Cable probes with weights should be allowed to hang under the tension of the weight within the vessel. Shorten-
ing of the probe may be required.
8. To avoid excessive movement of the MT5000 probe in an agitated process, or where installation close to the
vessel wall is required, secure the bottom end of the probe to the vessel. Probes installed from top of the vessel
may require the use of a stilling well.
9. Probes installed in side vessel connections require additional probe support within the nozzle connection.
10. Threaded connections should be installed with thread sealant approved for use by the consumer. Flanged con-
nections should be made using materials (bolts, studs, nuts, and gaskets) and procedures (torque specifications)
approved by the consumer.
Assembly Instructions for Loose Shipments:
At times, the rigid probe (i.e. P01 or P02) or flexible cable (i.e. P11 or P12) will be shipped as a loose (separate) as-
sembly. In this case, an identification tag will be attached to the probe/cable to identify the serial number/transmitter
it is associated with.
1. Locate the top end of the probe/cable that has a threaded FNPT connection.
2. Locate the bottom end of the transmitter coupler that has a threaded MNPT connection.
3. Apply LOCTITE 222MS to the MNPT connection.
4. Fasten the probe/cable hand tight to the MNPT connection and allow this to cure for 15 minutes.
5. Ready for installation.
Plastic Tanks, Fiberglass Tanks, and Open Air Installations
1. Single probe units require the use of a metal mounting flange or plate to launch the microwave energy down
length of the probe. A minimum 6 inch (150mm) OD, 3/8 inch (10mm) thick plate should be used.
2. A MT5000 installed in a non-metallic vessel or open air envi-
ronment will be subject to interference from other electromag-
netic devices such as radios. Stilling wells may be required to
eliminate this interference.
Concrete Tanks
1. Tanks constructed of concrete require probe mounting be:
1 ft. / 0.3 m from wall with up to 20 ft. / 6.1 meter measur-
ing length
2 ft. / 0.61 m from wall over 20 ft. / 6.1 meter measuring
length
2. Single probe units require the use of a metal mounting flange
or plate to launch the microwave energy down length of the
NOT
RECOMMENDED
Figure 2
CORRECT

MT5000-0200-1 Rev f (10-2010) DCN0528 7
The MT5000 single rod and cable probe can be cut to length prior to installation. If shortening of the probe is neces-
sary, cut the rod or cable to the desired length using a hacksaw.
Shortening of coaxial probes in the field is not recommended.
The centering disc or weight at the end of the probe must be reattached for proper operation.
The Probe Length parameter in the Basic Setup menu will need to be adjusted for the new probe length.
3.2 Shortening of Probe
Electrical connection to the MT5000 should approach the transmitter head from below the conduit opening to provide
a drain for moisture. Install conduit to ½‖ NPT port and run 18 gauge twisted, shielded pair to housing. Refer to Sec-
tion 4 wiring diagram ELE1015 for typical loop wiring diagram and to ELE1014 for instructions applicable to intrinsic
safety installation.
Apply loop power to the transmitter as follows:
Terminal Block + 14 VDC minimum to 36 VDC Maximum
Terminal Block - To control System Input
Ground Screw GROUND
Note: The ―+Meter‖ and ―-Meter‖ terminals are available to hook up a mA meter to monitor loop current, without
breaking the loop.
3.3. Electrical Installation
The housing cover can only be removed when the unit is installed in a non-hazardous area, when in-
stalled with intrinsic safety barrier, or when power is removed from the transmitter.
Ground
Screw

MT5000-0200-1 Rev f (10-2010) DCN0528 8
When power is applied to an MT5000 series transmitter, the display will light up with a title screen which shows the
model type and the software revision. (Figure 4) This initial power up cycle will last for 3 seconds and the current
output of the transmitter will hold at 4.00 mA.
After the initial power up cycle, the display will change to show the Measured Level and the Current Output. The
output will also shift to the current corresponding to the level. (Figure 5)
By pushing the UP or Down button, the main display can be scrolled to display the level in terms of a percentage of
calibrated range (Figure 6) or in terms of a linearized / strapped measurement. (Figure 7).
4.0 COMMISSIONING
4.1 Display Operation
The MT5000 transmitter has been designed with a simple easy to follow setup menu. To make this unit operational,
at a minimum, the items in the BASIC SETUP menu must to be entered. If further setup is required, a Quick Calibra-
tion may be used or additional menu items will need to be entered.
Figure 4
Figure 5
Figure 6 Figure 7

MT5000-0200-1 Rev f (10-2010) DCN0528 9
The jumper switches are located on the face of the electronics module and can be set up as follows (Figure 8).
ALARM (Left Jumper)
Placing the jumper to the lower position causes the output to go to 21.00 mA when there is a loss of signal or trans-
mitter malfunction.
Placing the jumper to the upper position causes the output to go to 3.62 mA when there is a loss of signal or trans-
mitter malfunction.
The alarm output works in conjunction with the ALARM DELAY setting available in the mA OUTPUT menu. The out-
put will go to alarm state only if there is a loss of signal that lasts at least the duration of the alarm delay. The alarm
delay default value is two seconds. For instance the output will hold the last measured value if there is a loss of sig-
nal lasting less than two seconds and will go into the alarm condition if the loss signal exceeds two seconds.
WRITE PROTECT (Right Jumper)
When the jumper is in the lower position the transmitter configuration cannot be changed manually or via HART®
communication. (Figure 8).
Placing the jumper in the upper position will allow the configuration parameters to be changed manually or via
HART® communication. (Figure 8).
Figure 8
Fault Jumper:
UP = Fail Low = 3.6 mA
DOWN =Fail High = 21.00 mA
Pushbuttons:
UP
DOWN
SELECT
LVL XX.XX in
XX.XX mA
Write Protect Jumper:
UP = OFF
DOWN = ON
4.1.1. JUMPER SETTINGS
4.1.2. PUSHBUTTONS
Three pushbuttons are located on the lower portion of the module faceplate (Figure 8). These buttons will be used
to navigate through the setup and configuration menu of the MT5000. Some operations will require the pushbuttons
to be used together or held for a period of time to affect a change.

MT5000-0200-1 Rev f (10-2010) DCN0528 10
Pressing the SELECT button at each END MENU
will return to the MAIN DISPLAY.
LVL: XXXX.XX”
XX.XX mA
BASIC SETUP
LVL: XX.XX in XX.XX mA
UNITS
inches
LVL: XX.XX in XX.XX mA
PROBE TYPE
Single Rod / Cable
LVL: XX.XX in XX.XX mA
PROBE LENGTH
XX.XX in
LVL: XXXX.XX “ XX.XX mA
MOUNTING TYPE
Plate
LVL: XX.XX in XX.XX mA
NOZZLE LENGTH
XX.XX in
LVL: XX.XX in XX.XX mA
OFFSET
XX.XX in
LVL: XX.XX in XX.XX mA
DIELECTRIC
XX.XX
LVL: XX.XX in XX.XX mA
MEASURE MODE
Media Level
LVL: XX.XX in XX.XX mA
LANGUAGE
English
LVL: XX.XX in XX.XX mA
END MENU
LVL: XX.XX in XX.XX mA
mA OUTPUT SETUP
LVL: XX.XX in XX.XX mA
OUTPUT
Level
LVL: XX.XX in XX.XX mA
END MENU
LVL: XX.XX in XX.XX mA
EXTENDED SETUP
LVL: XX.XX in XX.XX mA
WAVEFORM AT
COUPLER
LVL: XX.XX in XX.XX mA
WAVEFORM AT
LVL
LVL: XX.XX in XX.XX mA
WAVEFORM AT
XXXX in
LVL: XX.XX in XX.XX mA
WAVEFORM AT
END OF PROBE
LVL: XX.XX in XX.XX mA
TEMPERATURE
XXX.X F/C
LVL: XX.XX in XX.XX mA
LINEARIZATION
MENU
LVL: XX.XX in XX.XX mA
END MENU
LVL: XX.XX in XX.XX mA
LRV 4mA
XX.XX in
LVL: XX.XX in XX.XX mA
URV 20mA
XX.XX in
LVL: XX.XX in XX.XX mA
DAMPING
X.X sec
LVL: XX.XX in XX.XX mA
ALARM DELAY
XX sec
LVL: XX.XX in XX.XX mA
4mA DAC TRIM
LVL: XX.XX in XX.XX mA
20mA DAC TRIM
LVL: XX.XX in XX.XX mA
LOOP TEST
LVL: XX.XX in XX.XX mA
S S S
S
S
S
S
S
UP or DOWN
button
S
SELECT
button
NAVIGATION
Section 4.6.4
S
4.2 MT5000 Menu Flow Chart
LVL XXX.X%
XX.XX mA
LNI XX.XX gal
HART ADDRESS
XX
LVL: XX.XX in XX.XX mA
LRS
3.85 mA
LVL: XX.XX in XX.XX mA
LRM*
LVL: XX.XX in XX.XX mA
SOR
LVL: XX.XX in XX.XX mA
* Used only if SOR is set to ALARM.