K-TEK MT5100 User manual

MT5100-0200-1 Rev b (2-2013) DCN0365
MT5100
Guided Wave Radar Level and Interface Transmitter
MT5100
Guided Wave Radar Level and Interface Transmitter
Installation & Operation Manual
For the latest version of this manual, visit ktekcorp.com.

MT5100-0200-1 Rev b (2-2013) DCN0365 2
MT5100
Guided Wave Radar Level and Interface Transmitter
TABLE OF CONTENTS
1. Introduction ............................................................................................................................................................4
2. Overview ................................................................................................................................................................5
2.1 Storage and Handling Information.................................................................................................................5
2.2 Ambient Temperature....................................................................................................................................5
2.3 Description and Principle of Operation..........................................................................................................6
2.4 Total Level and Interface Level Measurement ..............................................................................................7
3. Installation ..............................................................................................................................................................8
3.1 Special Requirements ...................................................................................................................................8
3.2 Mechanical Installation ..................................................................................................................................9
3.2.1 Shortening of the Probe .....................................................................................................................9
3.2.2 Plastic Tanks, Fiberglass Tanks, and Open Air Installations .............................................................9
3.2.3 Single Probes in Stilling Wells............................................................................................................10
3.2.4 Single Probes in External Chambers .................................................................................................12
3.2.5 Dual Rod/Cable Probes......................................................................................................................13
3.2.6 Coaxial Probes ...................................................................................................................................13
3.2.7 Unmeasurable Zones .........................................................................................................................14
3.3 Shortening of Probes.....................................................................................................................................15
3.4 Electrical Installation......................................................................................................................................15
4. Commissioning.......................................................................................................................................................16
4.1 Display Operation..........................................................................................................................................16
4.1.1 Jumper Settings .................................................................................................................................17
4.1.2 Push Buttons ......................................................................................................................................17
4.2 MT5100 Menu Flow Chart.............................................................................................................................18
4.3 Basic Setup ...................................................................................................................................................19
4.3.1 Units ...................................................................................................................................................19
4.3.2 Probe Type.........................................................................................................................................19
4.3.3 Probe Length......................................................................................................................................20
4.3.4 Offsets ................................................................................................................................................21
4.3.5 Upper Dielectric..................................................................................................................................22
4.3.6 Actual Interface ..................................................................................................................................22
4.3.7 Lower Dielectric (Optional) .................................................................................................................22
4.3.8 Language............................................................................................................................................23
4.4 Quick Calibration ...........................................................................................................................................23
4.5 mA Output Setup ...........................................................................................................................................24
4.5.1 Output.................................................................................................................................................24
4.5.2 LRV 4mA ............................................................................................................................................24
4.5.3 URV 20mA..........................................................................................................................................25
4.5.4 Dampening .........................................................................................................................................25
4.5.5 Alarm Delay........................................................................................................................................26
4.5.6 DAC Trim............................................................................................................................................26
4.5.7 LOOP Test..........................................................................................................................................26
4.5.8 HART Address ...................................................................................................................................27
4.6 Extended Setup.............................................................................................................................................27
4.6.1 Waveform Display ..............................................................................................................................28
4.6.2 Functions ............................................................................................................................................30
4.6.3 Temperature.......................................................................................................................................31
4.6.4 Flooded Chamber...............................................................................................................................31
4.6.5 Flooded Total .....................................................................................................................................31
4.6.6 Linearization Menu .............................................................................................................................32
4.6.6.1 Linearization for Measurement.............................................................................................33
4.6.6.2 Linearization for Volume ......................................................................................................34
4.6.6.3 Linearization for Flow ...........................................................................................................35
4.6.6.4 User Functions .....................................................................................................................36
4.7 Secondary Output - RI100 Option .................................................................................................................36

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MT5100
Guided Wave Radar Level and Interface Transmitter
5. Troubleshooting..................................................................................................................................................... 37
5.1 Valid Current Loop Outputs........................................................................................................................... 37
5.2 Symptoms and Solutions............................................................................................................................... 38
5.3 Electronics Module Replacement .................................................................................................................. 38
6. Installation Drawings for Intrinsic Safety & Standard Wiring ................................................................................. 39
7. Loop Powered TX Hookup / RI Dual Compartment Housing................................................................................ 42
8. CE Certificate of Compliance ................................................................................................................................ 43
9. Customer Support ................................................................................................................................................. 44
9.1 RMA Form...................................................................................................................................................... 45
10. Warranty Statement .............................................................................................................................................. 46

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MT5100
Guided Wave Radar Level and Interface Transmitter
Thank you for using the K-TEK MT5100 Guided Wave Radar Liquid Level and Interface 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 MT5100 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
process 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 MT5100 transmitter was developed with ease of operation in mind. We made use of a graphic display to
provide a more user friendly aspect to the transmitter configuration. The graphic display allowed us to incorporate
multiple 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 MT5100 series was the development of the KCOM™ software. KCOM™ is a
diagnostic tool which allows the MT5100 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 MT5100 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 MT5100 series including liquid/liquid interface and bulk solids measurement visit our
website at www.ktekcorp.com.
1. Introduction

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MT5100
Guided Wave Radar Level and Interface Transmitter
2. 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 MT5100 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 MT5100 housing are sealed with o-rings. To avoid damage to the electronics, both lids should be closed
tightly before and after installation.
2.2 Ambient Temperature
The MT5100 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.

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MT5100
Guided Wave Radar Level and Interface Transmitter
The MT5100 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 or interface of the
products being measured. In order to obtain optimum performance, it is important to understand the basic principle
of operation. The electronics housing is fitted with a special adapter “Coupler” serving as a process connection and
seal, which holds a solid rod or a cable. The rod or cable “Probe” hangs into the vessel and acts as a wave-guide,
i.e. the probe guides the microwave energy to the product surface, instead of being dispersed in a cone, as it would
be if there was no probe.
A measurement cycle consists of the following:
1. A very short “pulse” of microwave energy is applied at the
coupler, to the Probe.
2. The pulse travels along the length of the probe and when it
encounters a discontinuity that is a dielectric constant change, at
the level surface, some of the energy is reflected and travels
back towards the coupler.
3. When the reflected energy from the level 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 calculate the level.
4. The energy not reflected by the level passes through the upper
fluid and is reflected at the interface level.
5. When the reflected energy from the interface level reaches the
coupler, it is sensed by the electronics. The electronics then
calculate the level of the interface using the known dielectric
constant and level of the upper fluid.
6. 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 for both
levels duplicating 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 observing a piece of machinery turning at high speed with
a strobe light.
7. The measurement cycles are made 2 times per second and are
processed by special filtering techniques, before generating a
current output proportional to the level or interface of the
products.
2.3 Description & Principle of Operation
PROBE COUPLER
HOUSING
1
2
4
7
6
3
5

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MT5100
Guided Wave Radar Level and Interface Transmitter
A simplified signal trace as seen on the graphic display (Figure 2.1) can be divided into three identifiable sections:
- Coupler Reflection.
- Level Reflection
- Interface 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
baseline if there is a substantial change from a nozzle diameter to an open tank, for example, as signal plot at the
process connection. This fact will be taken into account in the configuration of the MT5100 (Consult Basic Setup
(Section 4.3 on Commissioning).
Figure 2.1
Coupler Reflection
Level Reflection
Blanking Level Threshold
Interface
Reflection
Interface
Threshold
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.
2.4 Total Level and Interface Measurement
1. If the application utilizes the “non-flooded chamber” menu selection, both the total level and the interface level
can be obtained from a single process connection when the MT5100 is utilized with a RI100 Repeat Indicator.
2. The MT5100 provides a 4-20 mA output representing the interface level while the RI100 provides a 4-20 mA
signal representing the overall level.
3. While this type of application works best with the MT5100 mounted directly on the vessel, an external chamber
with a minimum of three process connections can also be utilized as long as ONLY one interface level (liquid-
liquid or liquid-vapor) occurs between any two (adjacent) process connections.
4. See drawing ELE1004 in this manual’s appendix for the RI100 wiring diagram.
5. See the RI100 Data Sheet and consult K-TEK for additional information.

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MT5100
Guided Wave Radar Level and Interface Transmitter
In order to properly detect the level of interface between two liquids using the MT5100, the following rules must be
adhered to:
1. One of the following probe and mounting configurations must be used:
a. Single rigid rod or flexible cable mounted in a stilling well, external chamber, or existing
displacer.*
 Minimum inside pipe diameter - 1.939 in. (2 in. sch. 80)
 Maximum inside pipe diameter - 4.26 in. (4 in sch. 10)
 For other pipe diameters, consult factory.
 Maximum probe length:
 Single rod - 20 ft.
 Flexible cable - 30 ft
b. Dual rigid rod or flexible cable
Maximum probe length
 Dual rigid rod - 20 ft
 Dual flexible cable - 65 ft
c. Coaxial probe mounted into tank, external chamber, or displacer
 Maximum probe length - 22 ft
 Both fluids must be clean
* This is the preferred mounting configuration to reduce the chance of fouling.
2. Emulsion layers will affect the detection of an interface level. An emulsion layer may negate an interface level
indication completely. The MT5100 will read an interface level in the presence of a 2 inch emulsion. The MT5100
is equipped with a weak interface signal detector (patent pending). This visual indication will let the user know
when an emulsion layer may be present.
3. The minimum upper fluid thickness must be 4 inches when emulsion is present, and 0 inches with a clean
interface.
4. The upper fluid dielectric constant must be greater than 1. 6 and less than 5.
5. The interface level indication is a calculated value based partially upon the dielectric of the upper fluid. The
upper fluid dielectric must remain constant for consistency / accuracy in the interface level indication.
6. The lower fluid dielectric constant must not be less than 15.
7. If the application is a flooded condition (sensor completely submerged in process), it must remain completely
flooded.
8. In a non-flooded condition, the upper fluid must not be allowed to enter the upper unmeasureable zone. The
upper unmeasureable zone is typically located within the mounting nozzle of the vessel.
If the required interface application does not fall within the above mentioned parameters, please consult the factory
for an alternate technology, such as a Magnetostrictive, Magnetic Level Gauge or RF Capacitance.
Stilling Well & Tri-Band
Preferred Configuration External Chamber Preferred Configuration
Flooded or Non-Flooded
Dual Rigid Rod Coaxial
3. Installation
3.1 Special Requirements

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MT5100
Guided Wave Radar Level and Interface Transmitter
3.2 Mechanical Installation
1. Do not mount the MT5100 in the product fill stream.
2. To obtain the best return signal from the product level mount the MT5100 coupler directly into the top of the ves-
sel.
3. Do not mount MT5100 single probes using bushings. (Figure 3.1)
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 MT5100 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 MT5100 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
connections should be made using materials (bolts, studs, nuts, and gaskets) and procedures (torque specifica-
tions) approved by the consumer.
INCORRECT
Figure 3.1
CORRECT
3.2.1 All Installations
3.2.2 Plastic Tanks, Fiberglass Tanks, and Open Air Installations
Dual Probe transmitters should not be used to measure interface levels in non-metallic vessels or open air installa-
tions. Single probes in stilling wells or coaxial probes should be used to prevent interruptions in transmitter opera-
tion.

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MT5100
Guided Wave Radar Level and Interface Transmitter
An MT5100 with a single probe directly inserted in the vessel can be used to measure interface level if a metal still-
ing well is also utilized. This stilling well may already exist, as part of the tank structure, or may be purchased with
the MT5100.
1. The inside diameter of the chamber must not be less than 1.939 inches, the equivalent of 2” schedule 80
pipe (Consult factory for smaller sizes).
2. The inside diameter of the chamber must not be greater than 4.26 inches, the equivalent of 4” schedule 10
pipe (Consult factory for larger sizes).
3. If a rigid type probe is used, a centering disc is required to center the probe in the chamber and provide an
end of probe target.
4. If a flexible type probe is used, a centering weight is required to straighten the cable, center the cable, and
act as an end of probe target.
5. The upper fluid must not be allowed to enter the unmeasureable zone. This can be accomplished by
keeping the dimension between the top edge of the highest stilling well hole and the face of the coupler
greater than the unmeasureable zone (Section 3.2.7).
The hole pattern of the stilling well will be critical in determining the accuracy and reliability of the interface
measurement. One of the following hole patterns must be present for an existing stilling well to be used with the
MT5100 interface option.
For some applications a simple pattern of three holes in the stilling well will be suitable. The top hole will allow the
vapor to enter the stilling well. The center and bottom holes will allow the fluids to enter and equalize, if they are
placed properly. This will work if the upper fluid level continuously covers the center hole. If the upper fluid level
were to rise or fall from the center hole, the upper fluid would be cut off from the probe and inaccurate measurement
would result.
OIL
WATER
3.2.3 Single Probes in Stilling Wells