KROHNE BW25 User manual

Displacer Level Transmitter for heavy-duty level or
interface applications
BW 25
BW 25BW 25
BW 25 Handbook
HandbookHandbook
Handbook
© KROHNE 06/2015 - 4000432305 - MA BW25 R08 en

All rights reserved. It is prohibited to reproduce this documentation, or any part thereof, without
the prior written authorisation of KROHNE Messtechnik GmbH.
Subject to change without notice.
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Copyright 2015 by
KROHNE Messtechnik GmbH - Ludwig-Krohne-Str. 5 - 47058 Duisburg (Germany)
: IMPRINT :::::::::::::::::::::::::::::::::::::::

CONTENTS
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BW25
1 Safety instructions 5
1.1 Intended use ..................................................................................................................... 5
1.2 Certification ...................................................................................................................... 5
1.3 Safety instructions from the manufacturer ..................................................................... 6
1.3.1 Copyright and data protection ................................................................................................ 6
1.3.2 Disclaimer ............................................................................................................................... 6
1.3.3 Product liability and warranty ................................................................................................ 7
1.3.4 Information concerning the documentation........................................................................... 7
1.3.5 Warnings and symbols used................................................................................................... 8
1.4 Safety instructions for the operator................................................................................. 8
2 Device description 9
2.1 Scope of delivery............................................................................................................... 9
2.2 Device version................................................................................................................. 10
2.2.1 Indicator versions ................................................................................................................. 11
2.3 Nameplate ...................................................................................................................... 13
3 Installation 14
3.1 General notes on installation ......................................................................................... 14
3.2 Storage ........................................................................................................................... 14
3.3 Installation conditions ....................................................................................................14
3.4 Installation...................................................................................................................... 15
4 Electrical connections 16
4.1 Safety instructions.......................................................................................................... 16
4.2 Electrical connection indicator M9................................................................................. 17
4.2.1 Limit switch........................................................................................................................... 17
4.2.2 Electrical signal output ESK2A............................................................................................. 20
4.3 Electrical connection indicator M40............................................................................... 22
4.3.1 Indicator M40 – limit switches.............................................................................................. 22
4.3.2 Current output ESK4/ESK4A ................................................................................................25
4.4 Grounding ....................................................................................................................... 28
4.5 Protection category ........................................................................................................29
5 Start-up 30
5.1 Start-up........................................................................................................................... 30
6 Operation 31
6.1 ESK4/4A – Loop Check Mode ......................................................................................... 31
6.2 Operating elements indicator M40................................................................................. 32

CONTENTS
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6.3 Basic principles of operation.......................................................................................... 33
6.3.1 Functional description of the buttons................................................................................... 33
6.3.2 Navigation within the menu structure.................................................................................. 33
6.3.3 Changing the settings in the menu....................................................................................... 34
6.3.4 Measures in the event of faulty indications.......................................................................... 34
6.4 Overview of the most important functions and indicators............................................. 35
6.5 Error messages.............................................................................................................. 36
7 Service 38
7.1 Maintenance ................................................................................................................... 38
7.2 Replacement and retrofitting......................................................................................... 38
7.2.1 Indicator M9 .......................................................................................................................... 38
7.2.2 Indicator M40 ........................................................................................................................ 40
7.3 Spare parts availability...................................................................................................42
7.4 Availability of services .................................................................................................... 42
7.5 Returning the device to the manufacturer..................................................................... 42
7.5.1 General information.............................................................................................................. 42
7.5.2 Form (for copying) to accompany a returned device............................................................ 43
7.6 Disposal .......................................................................................................................... 43
8 Technical data 44
8.1 Operating principle......................................................................................................... 44
8.2 Technical data................................................................................................................. 45
8.3 Dimensions ..................................................................................................................... 49
9 Appendix 52
9.1 Order code ...................................................................................................................... 52

SAFETY INSTRUCTIONS 1
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1.1 Intended use
The level meter is suitable for measuring liquids and separation layers in liquids.
The devices are especially well suited for the measurement of:
•Liquids
•Water
•Chemicals with low corrosiveness
1.2 Certification
The device fulfils the statutory requirements of the following EC directives:
•Pressure Equipment Directive 97/23/EC Article 3.3
•EC directive 94/9 EC - ATEX directive
•EMC Directive 89/336/EC
as well as
•EN 61010
•EMC specification acc. to EN 61326/A1
•NAMUR recommendations NE 21 and NE 43
CAUTION!
Responsibility for the use of the measuring devices with regard to suitability, intended use and
corrosion resistance of the used materials against the measured fluid lies solely with the
operator.
INFORMATION!
The manufacturer is not liable for any damage resulting from improper use or use for other than
the intended purpose.
DANGER!
For devices used in hazardous areas, additional safety notes apply; please refer to the Ex
documentation.
WARNING!
Responsibility for the use of the measurement devices with regard to suitability, intended use
and corrosion resistance of the used materials against the measured fluid lies solely with the
operator. The manufacturer is not liable for any damage resulting from improper use or use for
other than the intended purpose. Do not use any abrasive or highly viscous media.
CE marking

1 SAFETY INSTRUCTIONS
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1.3 Safety instructions from the manufacturer
1.3.1 Copyright and data protection
The contents of this document have been created with great care. Nevertheless, we provide no
guarantee that the contents are correct, complete or up-to-date.
The contents and works in this document are subject to copyright. Contributions from third
parties are identified as such. Reproduction, processing, dissemination and any type of use
beyond what is permitted under copyright requires written authorisation from the respective
author and/or the manufacturer.
The manufacturer tries always to observe the copyrights of others, and to draw on works created
in-house or works in the public domain.
The collection of personal data (such as names, street addresses or e-mail addresses) in the
manufacturer's documents is always on a voluntary basis whenever possible. Whenever
feasible, it is always possible to make use of the offerings and services without providing any
personal data.
We draw your attention to the fact that data transmission over the Internet (e.g. when
communicating by e-mail) may involve gaps in security. It is not possible to protect such data
completely against access by third parties.
We hereby expressly prohibit the use of the contact data published as part of our duty to publish
an imprint for the purpose of sending us any advertising or informational materials that we have
not expressly requested.
1.3.2 Disclaimer
The manufacturer will not be liable for any damage of any kind by using its product, including,
but not limited to direct, indirect or incidental and consequential damages.
This disclaimer does not apply in case the manufacturer has acted on purpose or with gross
negligence. In the event any applicable law does not allow such limitations on implied warranties
or the exclusion of limitation of certain damages, you may, if such law applies to you, not be
subject to some or all of the above disclaimer, exclusions or limitations.
Any product purchased from the manufacturer is warranted in accordance with the relevant
product documentation and our Terms and Conditions of Sale.
The manufacturer reserves the right to alter the content of its documents, including this
disclaimer in any way, at any time, for any reason, without prior notification, and will not be liable
in any way for possible consequences of such changes.

SAFETY INSTRUCTIONS 1
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1.3.3 Product liability and warranty
The operator shall bear responsibility for the suitability of the device for the specific purpose.
The manufacturer accepts no liability for the consequences of misuse by the operator. Improper
installation or operation of the devices (systems) will cause the warranty to be void. The
respective "Standard Terms and Conditions" which form the basis for the sales contract shall
also apply.
1.3.4 Information concerning the documentation
To prevent any injury to the user or damage to the device it is essential that you read the
information in this document and observe applicable national standards, safety requirements
and accident prevention regulations.
If this document is not in your native language and if you have any problems understanding the
text, we advise you to contact your local office for assistance. The manufacturer can not accept
responsibility for any damage or injury caused by misunderstanding of the information in this
document.
This document is provided to help you establish operating conditions, which will permit safe and
efficient use of this device. Special considerations and precautions are also described in the
document, which appear in the form of icons as shown below.

1 SAFETY INSTRUCTIONS
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1.3.5 Warnings and symbols used
Safety warnings are indicated by the following symbols.
• HANDLING
HANDLINGHANDLING
HANDLING
This symbol designates all instructions for actions to be carried out by the operator in the
specified sequence.
iRESULT
RESULTRESULT
RESULT
This symbol refers to all important consequences of the previous actions.
1.4 Safety instructions for the operator
DANGER!
This warning refers to the immediate danger when working with electricity.
DANGER!
This warning refers to the immediate danger of burns caused by heat or hot surfaces.
DANGER!
This warning refers to the immediate danger when using this device in a hazardous atmosphere.
DANGER!
These warnings must be observed without fail. Even partial disregard of this warning can lead to
serious health problems and even death. There is also the risk of seriously damaging the device
or parts of the operator's plant.
WARNING!
Disregarding this safety warning, even if only in part, poses the risk of serious health problems.
There is also the risk of damaging the device or parts of the operator's plant.
CAUTION!
Disregarding these instructions can result in damage to the device or to parts of the operator's
plant.
INFORMATION!
These instructions contain important information for the handling of the device.
LEGAL NOTICE!
This note contains information on statutory directives and standards.
WARNING!
In general, devices from the manufacturer may only be installed, commissioned, operated and
maintained by properly trained and authorized personnel.
This document is provided to help you establish operating conditions, which will permit safe and
efficient use of this device.

DEVICE DESCRIPTION 2
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2.1 Scope of delivery
INFORMATION!
Inspect the packaging carefully for damages or signs of rough handling. Report damage to the
carrier and to the local office of the manufacturer.
INFORMATION!
Do a check of the packing list to make sure that you have all the elements given in the order.
INFORMATION!
Look at the device nameplate to ensure that the device is delivered according to your order.
Check for the correct supply voltage printed on the nameplate.
Figure 2-1: Scope of delivery
1 Measuring device (with options as specified in the customer order)
2 For indicator M40 –key
3 Handbook
4 Certificates and calibration report (as specified in the customer order)

2 DEVICE DESCRIPTION
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2.2 Device version
1BW25/M9
•Local indicator without auxiliary power
•Max. 2 limit switches
•2-wire current output 4…20 mA, HART®communication
•Intrinsically safe (Ex i)
2BW25/M40
•Local indicator without auxiliary power
•Max. 2 limit switches
•2-wire current output 4…20 mA, HART®communication
•PROFIBUS PA or FOUNDATION™fieldbus
•LCD display and digital outputs
•Intrinsically safe (Ex i) or explosion-proof enclosure (Ex d)
Figure 2-2: Device versions
1 BW25 with indicator M9
2 BW25 with indicator M40

DEVICE DESCRIPTION 2
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2.2.1 Indicator versions
The M40 indicator can be fitted with various modules.
Both versions can be combined with one another.
Basic version
Figure 2-3: Basic version
1 Pointer module
2 Bolts for ESK4 attachment
3 Baseplate
4 Module profile
5 Pressure piece for ESK4 attachment
6 Housing cover lock
7 External Earth terminal
K1 / K2 and ESK4/4A versions
Figure 2-4: K1 / K2 and ESK4/4A versions
1 Indicator with K2 contact module
2 Indicator with ESK4/4A current output 4...20 mA

2 DEVICE DESCRIPTION
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ESK4-FF / ESK4-PA fieldbus version
Figure 2-5: ESK4-FF / ESK4-PA fieldbus version
1 Basic module with electronic magnet sensors
2 Connection bus module
3 Hardware settings

DEVICE DESCRIPTION 2
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2.3 Nameplate
Additional markings on the indicator
•SO –sales order / item
•PA –order
•Vx –product configurator code
•AC –article code
INFORMATION!
Look at the device nameplate to ensure that the device is delivered according to your order.
Check for the correct supply voltage printed on the nameplate.
Figure 2-6: Nameplates on the indicator
1 Device type
2 Manufacturer
3 Notified ATEX body
4 Sizing data: temperature & pressure rating
5 PED data
6 Ex data
7 Electrical connection data
8 Note manual
9 KROHNE website

3 INSTALLATION
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3.1 General notes on installation
3.2 Storage
•Store the device in a dry and dust-free location.
•Avoid lasting direct exposure to the sun.
•Store the device in its original packing.
•The permissible storage temperature for standard devices is -40...+80°C / -40...+176°F.
3.3 Installation conditions
INFORMATION!
Inspect the packaging carefully for damages or signs of rough handling. Report damage to the
carrier and to the local office of the manufacturer.
INFORMATION!
Do a check of the packing list to make sure that you have all the elements given in the order.
INFORMATION!
Look at the device nameplate to ensure that the device is delivered according to your order.
Check for the correct supply voltage printed on the nameplate.
CAUTION!
When installing the device, the following points must be observed:
• Before installation, compare the serial number of the display (nameplate) with the serial
number on the displacement rod, the flange and the magnet.
• In the case of level displays with a bypass chamber, the BW25 serial number on the bypass
chamber should be compared with the serial number on the display.
• Avoid combining parts with differing serial numbers.
• Ensure the material compatibility of the parts in contact with the product.
• Screws, bolts and gaskets are to be provided by the customer and must be selected in
accordance with the pressure rating of the mounting flange or the operating pressure.
• Align the gaskets. Tighten the nuts with the tightening torques of the appropriate pressure
rating.
• Do not lay signal cables directly next to cables for the power supply.

INSTALLATION 3
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3.4 Installation
The sealing surface of the tank flange must be horizontal to ensure the perfect function of the
level measurement unit.
• Insert the spring suspension pin in the flange system and secure it with a retaining ring 1.
• Install the retaining ring 1properly and check for a correct seat all round.
• Place the seal on the tank flange.
• Suspend the displacer body on the spring suspension pin.
• Tighten the locking elements of the quick-action lock 2(standard) or, with the variant, 3and
4and check for a tight fit.
• Insert the displacer element and the spring suspension pin into the tank through the tank
flange or into the preinstalled bypass chamber.
• Tighten the flange connection.
Figure 3-1: Installation
1 Lock ring
2 Quick-action lock
3 Retaining screw
4 Cover stop

4 ELECTRICAL CONNECTIONS
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4.1 Safety instructions
DANGER!
All work on the electrical connections may only be carried out with the power disconnected. Take
note of the voltage data on the nameplate!
DANGER!
Observe the national regulations for electrical installations!
DANGER!
For devices used in hazardous areas, additional safety notes apply; please refer to the Ex
documentation.
WARNING!
Observe without fail the local occupational health and safety regulations. Any work done on the
electrical components of the measuring device may only be carried out by properly trained
specialists.
INFORMATION!
Look at the device nameplate to ensure that the device is delivered according to your order.
Check for the correct supply voltage printed on the nameplate.

ELECTRICAL CONNECTIONS 4
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4.2 Electrical connection indicator M9
4.2.1 Limit switch
Indicator M9 can be equipped with a maximum of two electronic limit switches. The limit switch
functions with a slot sensor which is operated inductively through the semicircular metal vane
belonging to the measuring pointer. The switching points are set through the contact pointers.
The position of the contact pointer is indicated on the scale.
The connecting terminals have a pluggable design and can be removed in order to connect the
lines. The built-in contact types are shown on the nameplate of the indicator.
Electrical connection of the limit switches
Limit switch module
Figure 4-1: Limit switch module
1 Min. contact
2 Max. contact
3 Locking screw
4 Maximum pointer
5 Terminal block
Contact MIN MAX
Terminal no. 123456
Connection 2-wire NAMUR - + - +
Connection 3-wire + - + -
Connection Reed SPST + - + -

4 ELECTRICAL CONNECTIONS
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Setting is carried out directly via contact pointers 1and 2:
• Slide the scale away
• Loosen the locking screw 3slightly
• Slide the scale back to the latching point
• Set contact pointers 1and 2to the desired switching point
After setting has been carried out: Fix the contact pointers with the locking screw 3.
Limit switch connection terminals
Figure 4-2: Limit switch connection terminals
1 2-wire limit switch NAMUR
2 3-wire limit switch
3 Limit switch Reed SPST
4 Terminal connection min contact
5 Terminal connection max contact
6 3-wire load
7 NAMUR isolated switching amplifier
8 3-wire power supply
Limit setting
Figure 4-3: Limit setting
1 Contact pointer MAX
2 Contact pointer MIN
3 Locking screw

ELECTRICAL CONNECTIONS 4
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If the measuring pointer vane goes into the slot an alarm is triggered. If the pointer vane lies
outside the slot sensor, a wire break also causes the alarm to be triggered.
The 3-wire limit switch does not have any wire break detection
Current consumption in the position shown:
Switch contact definition
Figure 4-4: Switch contact definition
1 MIN contact
2 MAX contact
3 Pointer vane with switching vane
Definition MinMin –MaxMax
Figure 4-5: Definition MinMin –MaxMax
1 MIN 2 contact or MAX 1 contact
2 MIN 1 contact or MAX 2 contact
Contact Type current
MIN 1 NAMUR ≤1mA
MIN 2 NAMUR ≤1mA
MAX 1 NAMUR ≥3mA
MAX 2 NAMUR ≥3mA

4 ELECTRICAL CONNECTIONS
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4.2.2 Electrical signal output ESK2A
The connecting terminals of the ESK2A have a pluggable design and can be removed in order to
connect the cables.
The circuitry for connection to other devices such as digital evaluator units or process control
equipment must be designed with special care. In some circumstances, internal connections in
these devices (e.g. GND with PE, ground loops) may lead to impermissible voltage potentials,
which can compromise the function of the device itself or a connected device. In such cases a
protected extra-low voltage (PELV) is recommended.
HART®communication
When HART®communication is carried out with the ESK2A, this will not in any way impair
analogue measured-data transmission (4...20 mA). Exception: multidrop operation. In multidrop
operation a maximum of 15 devices with HART®function can be operated in parallel, whereby
their analogue outputs are switched inactive. (I approx. 4 mA per device).
Figure 4-6: Electrical schematic for ESK2A current transmitter
1 ESK2A current transmitter
2 Power supply 12...30 VDC
3 Measuring signal 4...20 mA
4 External load, HART®communication
Figure 4-7: Electrical schematic for ESK2A with a protected extra-low voltage (PELV) circuit
1 Terminal connection
2 Converter supply isolator with electrical isolation
3 Power supply (see supply isolator information)
4 Measuring signal 4...20 mA
5 External load, HART®communication