KROHNE POWERFLEX 2200 C User manual

Guided Radar (TDR) Level Transmitter for the nuclear
industry
POWERFLEX 2200 C/F/S/D
POWERFLEX 2200 C/F/S/DPOWERFLEX 2200 C/F/S/D
POWERFLEX 2200 C/F/S/D Handbook
HandbookHandbook
Handbook
© KROHNE 10/2016 - 4005314002 - MA POWERFLEX 2200 R02 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 2016 by
KROHNE Messtechnik GmbH - Ludwig-Krohne-Str. 5 - 47058 Duisburg (Germany)
: IMPRINT :::::::::::::::::::::::::::::::::::::::

CONTENTS
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1 Safety instructions 7
1.1 Software history ............................................................................................................... 7
1.2 Intended use ..................................................................................................................... 7
1.3 Certification ...................................................................................................................... 7
1.4 Electromagnetic compatibility ......................................................................................... 8
1.5 Safety instructions from the manufacturer ..................................................................... 9
1.5.1 Copyright and data protection ................................................................................................ 9
1.5.2 Disclaimer ............................................................................................................................... 9
1.5.3 Product liability and warranty .............................................................................................. 10
1.5.4 Information concerning the documentation......................................................................... 10
1.5.5 Warnings and symbols used................................................................................................. 11
1.6 Safety instructions for the operator............................................................................... 11
2 Device description 12
2.1 Scope of delivery............................................................................................................. 12
2.2 Device description .......................................................................................................... 16
2.3 Visual Check ................................................................................................................... 18
2.4 Nameplates .................................................................................................................... 19
2.4.1 Nameplate............................................................................................................................. 19
3 Installation 21
3.1 General notes on installation ......................................................................................... 21
3.2 Storage ........................................................................................................................... 21
3.3 Transport ........................................................................................................................ 22
3.4 Pre-installation requirements ....................................................................................... 22
3.5 How to prepare the tank before you install the device.................................................. 23
3.5.1 Pressure and temperature ranges....................................................................................... 23
3.5.2 General information for nozzles........................................................................................... 24
3.5.3 Installation requirements for concrete roofs....................................................................... 27
3.6 Installation recommendations for liquids...................................................................... 27
3.6.1 General requirements .......................................................................................................... 27
3.6.2 How to attach probes to the bottom of the tank................................................................... 28
3.6.3 Installation in standpipes (stilling wells and bypass chambers) ......................................... 31
3.7 How to install the device on the tank: general notes .................................................... 32
3.7.1 How to install a device with a flange connection ................................................................. 32
3.7.2 How to install a device with a threaded connection............................................................. 33
3.7.3 How to install a cable probe in the tank............................................................................... 34
3.7.4 Recommendations for pits and tanks made of non-conductive materials.......................... 35
3.7.5 How to turn or remove the signal converter ........................................................................ 36
3.7.6 How to attach the weather protection to the device............................................................. 37
3.7.7 How to open the weather protection .................................................................................... 40
3.8 How to install the device on the tank: remote version .................................................. 41
3.8.1 Wall support for the remote version .................................................................................... 41
3.8.2 How to prepare the sensor extension for installation.......................................................... 41

CONTENTS
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4 Electrical connections 46
4.1 Safety instructions.......................................................................................................... 46
4.2 Electrical installation: 2-wire, loop-powered ................................................................ 46
4.2.1 Compact version ................................................................................................................... 46
4.2.2 Remote version ..................................................................................................................... 48
4.3 Remote device data ........................................................................................................ 49
4.3.1 Requirements for signal cables supplied by the customer ................................................. 49
4.3.2 How to prepare a signal cable supplied by the customer.................................................... 50
4.3.3 How to connect the signal cable to the device ..................................................................... 51
4.4 Electrical connection for current output ....................................................................... 55
4.5 Protection category ........................................................................................................55
4.6 Networks ........................................................................................................................ 56
4.6.1 General information.............................................................................................................. 56
4.6.2 Point-to-point networks ....................................................................................................... 56
4.6.3 Multi-drop networks ............................................................................................................. 57
5 Start-up 58
5.1 How to start the device................................................................................................... 58
5.1.1 Start-up checklist ................................................................................................................. 58
5.1.2 How to start the device ......................................................................................................... 58
5.2 Operating concept ..........................................................................................................58
5.3 Digital display screen .....................................................................................................59
5.3.1 Local display screen layout .................................................................................................. 59
5.3.2 Functions of keypad buttons................................................................................................. 60
5.4 Remote communication with PACTware™ .................................................................... 61
5.5 Remote communication with the AMS™ Device Manager............................................. 62
6 Operation 63
6.1 User modes .................................................................................................................... 63
6.2 Normal mode.................................................................................................................. 63
6.3 Configuration mode........................................................................................................ 64
6.3.1 General notes........................................................................................................................ 64
6.3.2 How to get access to the commissioning menu................................................................... 65
6.3.3 Menu overview ...................................................................................................................... 66
6.3.4 Keypad functions................................................................................................................... 67
6.3.5 Function description ............................................................................................................. 70
6.4 Further information on device configuration................................................................. 77
6.4.1 Commissioning ..................................................................................................................... 77
6.4.2 Probe length calculation....................................................................................................... 79
6.4.3 Snapshot................................................................................................................................ 80
6.4.4 Test........................................................................................................................................ 82
6.4.5 Protection of the device settings .......................................................................................... 83
6.4.6 HART® network configuration ............................................................................................. 84
6.4.7 Distance measurement ........................................................................................................ 85
6.4.8 Level measurement .............................................................................................................. 85
6.4.9 How to configure the device to measure volume or mass................................................... 86
6.4.10 Thresholds and parasitic signals........................................................................................88
6.4.11 How to decrease the length of probes................................................................................ 90

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6.5 Status and error messages............................................................................................ 92
6.5.1 Device status (markers)........................................................................................................ 92
6.5.2 Error handling....................................................................................................................... 94
7 Service 100
7.1 Periodic maintenance................................................................................................... 100
7.2 Keep the device clean................................................................................................... 100
7.3 How to replace device components ............................................................................. 100
7.3.1 Service warranty ................................................................................................................. 100
7.4 Availability of services .................................................................................................. 101
7.5 Returning the device to the manufacturer................................................................... 101
7.5.1 General information............................................................................................................ 101
7.5.2 Form (for copying) to accompany a returned device.......................................................... 102
7.6 Disposal ........................................................................................................................ 103
8 Technical data 104
8.1 Measuring principle...................................................................................................... 104
8.2 Technical data............................................................................................................... 104
8.3 Minimum power supply voltage ................................................................................... 109
8.4 Measurement limits ..................................................................................................... 110
8.5 Dimensions and weights .............................................................................................. 116
9 Description of HART interface 125
9.1 General description ...................................................................................................... 125
9.2 Software description .................................................................................................... 125
9.3 Connection variants...................................................................................................... 126
9.3.1 Point-to-Point connection – analogue / digital mode ........................................................ 126
9.3.2 Multi-Drop connection (2-wire connection) ....................................................................... 126
9.4 HART® device variables............................................................................................... 126
9.5 Field Communicator 375/475 (FC 375/475) ................................................................. 127
9.5.1 Installation .......................................................................................................................... 127
9.5.2 Operation............................................................................................................................. 127
9.6 Asset Management Solutions (AMS®) ......................................................................... 128
9.6.1 Installation .......................................................................................................................... 128
9.6.2 Operation............................................................................................................................. 128
9.6.3 Parameter for the basic configuration ............................................................................... 128
9.7 Field Device Tool / Device Type Manager (FDT / DTM) ................................................ 128
9.7.1 Installation .......................................................................................................................... 128
9.7.2 Operation............................................................................................................................. 128
9.8 Process Device Manager (PDM)................................................................................... 129
9.8.1 Installation .......................................................................................................................... 129
9.8.2 Operation............................................................................................................................. 129
9.9 HART®menu tree for Basic-DD .................................................................................. 130
9.9.1 Overview Basic-DD menu tree (positions in menu tree).................................................... 130
9.9.2 Basic-DD menu tree (details for settings).......................................................................... 130

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9.10 HART®menu tree for AMS......................................................................................... 132
9.10.1 Overview AMS menu tree (positions in menu tree) .......................................................... 132
9.10.2 AMS menu tree (details for settings)................................................................................ 132
9.11 HART® menu tree for PDM........................................................................................ 134
9.11.1 Overview PDM menu tree (positions in menu tree).......................................................... 134
9.11.2 PDM menu tree (details for settings) ............................................................................... 135
10 Appendix 137
10.1 Glossary ...................................................................................................................... 137

SAFETY INSTRUCTIONS 1
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1.1 Software history
"Firmware revision" agrees with NAMUR NE 53. It is a series of numbers used to record the
revision status of embedded software (firmware) in electronic equipment assemblies. It gives
data on the type of changes made and the effect that changes have on compatibility.
Data about software revisions is shown in menu 1.1.0 IDENT.. For more data, refer to
Function
description
on page 70. If it is not possible to refer to the device menu, record the serial number
of the device (given on the device nameplate) and speak to the supplier.
1.2 Intended use
This TDR level transmitter measures distance, level, mass and volume of liquids.
It is for use in the nuclear industry and can be installed in spent fuel pools.
1.3 Certification
In accordance with the commitment to customer service and safety, the device
described in this document meets the following safety requirements:
•Electromagnetic Compatibility (EMC) Directive 2014/30/EU in conjunction with EN 61326-1
(2013).
All devices are based on the CE marking and meet the requirements of NAMUR Guideline NE 21,
NE 43, NE 53 and NE 107.
Release date Printed circuit assembly Firmware
revision
Hardware
revision
Changes and
compatibility
Documentation
2016-05-30 Converter 1.08.04 4000342401 —MA POWERFLEX
2200 R01 + R02
Sensor 1.22.03 4000357001
HMI (LCD display option) 1.10.05 4000487601
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.

1 SAFETY INSTRUCTIONS
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1.4 Electromagnetic compatibility
The device design agrees with the Electromagnetic Compatibility (EMC) Directive and the related
European Standard when installed in metallic tanks.
The device design agrees with tests done according to performance criteria "A" of International
Standards IEC 61000 (Parts 4-2, 4-4, 4-5, 4-6, 4-8, 4-9, 4-10, 4-12, and 4-16), and CISPR 11.
You can install the device on open-air tanks and tanks that are not made of metal. Refer also to
the note that follows.
CAUTION!
If you install a device with a rod or cable probe in a non-metallic tank or open-air pit, a strong
electromagnetic field near to the device can have an unwanted effect on the accuracy. Use a
device with a coaxial probe for this type of installation.
INFORMATION!
Device operation agrees with residential-class (class B) and industrial-class (class A) emissions.
The device fulfils immunity requirements when it is installed in industrial areas.
The device agrees with these conditions if:
• the device has a single or double probe (rod or cable probe) and is used in a closed tank made
of metal or
• the device has a coaxial probe.

SAFETY INSTRUCTIONS 1
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1.5 Safety instructions from the manufacturer
1.5.1 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.
1.5.2 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.

1 SAFETY INSTRUCTIONS
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1.5.3 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.
1.5.4 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.

SAFETY INSTRUCTIONS 1
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1.5.5 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.
1.6 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.

2 DEVICE DESCRIPTION
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2.1 Scope of delivery
INFORMATION!
Do a check of the packing list to make sure that you have all the elements given in the order.
POWERFLEX 2200 C –Compact version
Figure 2-1: Scope of delivery (POWERFLEX 2200 C –Compact version)
1 Device (compact version: signal converter and probe)
2 Quick Start
3 DVD-ROM. This contains the handbook, the quick start, the technical data sheet and related software.
4 Strap wrench

DEVICE DESCRIPTION 2
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POWERFLEX 2200 S –Compact version with sensor extension
Figure 2-2: Scope of delivery (POWERFLEX 2200 S –Compact version with sensor extension)
1 Signal converter
2 Sensor extension: Coaxial cable and support with one attached length of flexible stainless steel jacket
3 Sensor extension: Wall bracket and lock nut
4 Sensor extension: One length of flexible stainless steel jacket
5 Process connection and probe
6 Quick Start
7 DVD-ROM. This contains the handbook, the quick start, the technical data sheet and related software.
8 Strap wrench

2 DEVICE DESCRIPTION
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POWERFLEX 2200 F –Remote version
Figure 2-3: Scope of delivery (POWERFLEX 2200 F –Remote version)
1 Signal converter
2 Quick Start
3 DVD-ROM. This contains the handbook, the quick start, the technical data sheet and related software.
4 Strap wrench
5 RS-485 cable. A signal cable connects the signal converter to the probe housing. This signal cable is supplied on re-
quest. For more data about the signal cable, refer to
Remote device data on page 49.
6 Probe housing, process connection and probe

DEVICE DESCRIPTION 2
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POWERFLEX 2200 D –Remote version with sensor extension
Figure 2-4: Scope of delivery (POWERFLEX 2200 D –Remote version with sensor extension)
1 Signal converter
2 Quick Start
3 DVD-ROM. This contains the handbook, the quick start, the technical data sheet and related software.
4 Strap wrench
5 RS-485 cable. A signal cable connects the signal converter to the probe housing. This signal cable is supplied on re-
quest. For more data about the signal cable, refer to
Remote device data on page 49.
6 Sensor extension: One length of flexible stainless steel jacket
7 Process connection and probe
8 Sensor extension: Coaxial cable and support with one attached length of flexible stainless steel jacket
9 Probe housing
10 Sensor extension: Wall bracket and lock nut

2 DEVICE DESCRIPTION
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2.2 Device description
The TDR level transmitter is designed to measure the distance, level and volume of liquids.
TDR level transmitters use a probe to guide a signal to the surface of the measured product. The
device has a large choice of probes. Thus, it can measure most products in difficult conditions.
For more data, refer to
Technical data on page 104.
The signal converter of the device has 4 versions: Compact (C), Compact with sensor extension
(S), Remote (F) and Remote with sensor extension (D). The converter can also be ordered with
horizontal or vertical housing options for easy access to the device terminals and the optional
display.
Compact version
Compact versionCompact version
Compact version
The signal converter is attached directly to the process connection and the antenna (vertical
housing option shown).
Remote (Field) version
Remote (Field) versionRemote (Field) version
Remote (Field) version
The signal converter is installed away from the process connection and the antenna (for
example: at the bottom of a tank). The RS-485 signal cable between the signal converter and the
antenna has a maximum length of 300 m / 984 ft.
Figure 2-5: Compact version
Figure 2-6: Remote (Field) version with an RS485 signal cable

DEVICE DESCRIPTION 2
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Sensor extension (with flexible stainless steel jackets)
Sensor extension (with flexible stainless steel jackets)Sensor extension (with flexible stainless steel jackets)
Sensor extension (with flexible stainless steel jackets)
A sensor extension option is available for the compact or remote version of the device. This
option is recommended if the ambient conditions around the process connection are not in the
approved limits. A coaxial cable (maximum length 100 m / 328 ft) is connected between the wall
bracket for the probe housing and the process connection. The coaxial cable has a flexible
stainless steel jacket that has a maximum length of 100 m / 328 ft. This stainless steel jacket can
be in one or more pieces to prevent damage to the coaxial cable.
INFORMATION!
The length of the coaxial cable and the stainless steel jacket depends on the data given in the
customer order.
Figure 2-7: Sensor extension option

2 DEVICE DESCRIPTION
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2.3 Visual Check
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.
Figure 2-8: Visual check
1 Device nameplate (for more data, refer to
Nameplate on page 19)
2 Process connection data (size and pressure rating, material reference and heat number)
3 Gasket material data –refer to the illustration that follows
Figure 2-9: Symbol for the supplied gasket material (on the side of the process connection)
1 EPDM

DEVICE DESCRIPTION 2
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2.4 Nameplates
2.4.1 Nameplate
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 2-10: Compact version (C), compact version with sensor extension (S), remote version (F) and remote version
with sensor extension (D): Nameplate attached to the housing
1 Cable entry size
2 Hardware revision / Software revision (according to NAMUR NE 53)
3 Output signal (analog, digital etc.), input voltage and maximum current
4 Degree of ingress protection (according to EN 60529 / IEC 60529)
5 Customer tag number
6 Date of manufacture
7 Serial number
8 Type code (defined in order)
9 Model name and number. The last letter "X" is either:
C = compact version,
S = compact version with sensor extension,
F = remote (field) version or
D = remote version with (double) sensor extension.
10 Company name and address

2 DEVICE DESCRIPTION
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Figure 2-11: Remote version or remote version with sensor extension: Nameplate attached to the probe assembly
1 Company web address
2 Country of manufacture
3 Degree of ingress protection (according to EN 60529 / IEC 60529)
4 Date of manufacture
5 Serial number
6 Type code (defined in order)
7 Model name and number. X = "F" remote (field) version or "D" remote version with (double) sensor extension.
8 Company logo, name and postal address
!