NIVELCO EchoTREK S-300 Owner's manual

sbd31jen21p05  1 / 50

2 / 50  sbd31jen21p05
CERTIFICATES: Reference document number
BKI ATEX,Certificate No.: BKI16ATEX0020X/1 sbd31j0m060bp_05

sbd31jen21p05  3 / 50

4 / 50  sbd31jen21p05
CONTENTS
1.INTRODUCTION....................................................................................6
2.TECHNICAL DATA................................................................................7
2.1.GENERAL DATA ........................................................................................... 7
2.2.SPECIAL DATA............................................................................................. 7
2.3.EX INFORMATION ......................................................................................... 8
2.3.1.ATEX CERTIFICATE No.: BKI16ATEX0020X/1 ................. 8
2.4.ACCESSORIES ............................................................................................. 8
2.5.ORDER CODES ............................................................................................ 9
2.6.DIMENSIONS.............................................................................................. 10
3.INSTALLATION.................................................................................. 11
4.WIRING............................................................................................... 14
5.COMMISSIONING, ADJUSTING, PROGRAMMING ......................... 15
5.1.COMMISSIONING........................................................................................ 15
5.1.1.The SAP–100 programming and display module ..................... 16
5.1.2.Usage and the indications of the SAP–100 programming and
display module in measurement mode ..................................... 17
5.2.SPECIAL CONDITIONS OF EX USE............................................................... 18
5.3.PROGRAMMING..........................................................................................18
5.3.1.Basic steps of the programming ................................................20
5.3.2.Current output scaling................................................................21
5.3.3.QUICKSET.................................................................................22
5.3.4.Full Parameter Access...............................................................24
5.4.PARAMETERS –DESCRIPTIONS AND PROGRAMMING ..................................25
5.4.1.Measurement Configuration ......................................................25
5.4.2.Analog Output ............................................................................31
5.4.3.Relay Output ..............................................................................32
5.4.4.Measurement Optimization........................................................33
5.4.5.Volume measurement................................................................39
5.4.6.Linearization...............................................................................40
5.4.7.Informational parameters (read only) ........................................41
5.4.8.Test parameters.........................................................................43
5.4.9.Simulation ..................................................................................44
5.4.10.Secret Code ...............................................................................45
5.4.11.Error Codes................................................................................46
6.MAINTENANCE, REPAIR...................................................................47
7.STORAGE CONDITIONS ...................................................................47
8.APPENDIX...........................................................................................48
8.1.PARAMETERS TABLE .................................................................................48

sbd31jen21p05  5 / 50

6 / 50  sbd31jen21p05
Thank you for choosing a NIVELCO instrument!
1. INTRODUCTION
The EchoTREK SBD/STD–300 series compact ultrasonic transmitters from NIVELCO are designed to measure the level of most free-flowing solids powders
and granules. Level measurement technology based on the non-contact ultrasonic principle is especially suited for applications where, for any reason, no
physical contact can be established with the surface of the measured material, and moving parts are to be avoided to eliminate mechanical wear.
A total beam angle of 5° at –3 dB is a feature of all NIVELCO’s ultrasonic sensors designed for the level measurement of free-flowing solids. This uniquely
narrow beam angle ensures reliable measurement in narrow silos with uneven sidewalls or sometimes even in the presence of dusting. Furthermore, due to
the narrow beam angle – the emitted ultrasonic signals have an outstanding focus – a sufficient signal penetration through dust is ensured.
OPERATING PRINCIPLE
Ultrasonic level metering technology measures the time required for the
ultrasound pulses to travel from the sensor to the measured level and back.
The sensor emits a series of ultrasonic pulses and receives the reflected
echoes. The device processes the received signal by selecting the echo
reflected by the surface and calculates the distance between the sensor and
the surface from the time of flight which constitutes the basis of all output
signals of the EchoTREK.
Diameters corresponding to the
5° beam angle.
Minimum measuring distance (Xm): (also known as the “dead band”) is a feature common to all ultrasonic level meters. It is a short distance in front of the
sensor within which the ultrasonic device cannot measure. The unmeasurable range (close-end blocking) must be increased by programming to avoid any
measurement error caused by incorrect mounting or placement of the level transmitter.
Maximum measuring distance (XM): The longest distance under ideal conditions within which the device can measure. No measurement is possible beyond
this distance.

sbd31jen21p05  7 / 50
2. TECHNICAL DATA
2.1. GENERAL DATA
Type SD-3J- SD-3J-Ex
Transducer material Closed cell PVC foam sensor face
PP and Aluminum transducer housing and fitting
Total beam angle 5°
Housing material Powde
r
-coated aluminum
Process temperature −30…+75 °C (−22…+167 °F)
A
mbient temperature
–
30…+60 °C (−22…+140 °F), with SAP−100 display −25…+60 °C (−13…+140 °F)
Process pressure (absolute) 0.7 … 1.1 ba
r
(10…16 psi) Pabsolute and ± 0.1 ba
r
(±1.45 psig) difference between ambient and tank pressure
Mounting 4 × M12 screws on a Ø125 arc
Supply Voltage /
consumption
Version I: 120…255 V DC / 5,5 W 85…255 V AC (50/60 Hz) / 6,8 V
A
Version II: 11,4…40 V DC / 4,1 W, 11,4…28 V
A
C (50/60 Hz) / 4,6 V
A
Accuracy* (0.2 % of the measured distance + 0.1% of the measurement range)
Resolution 10 mm (0.4″)
Output
Analog 4…20 mA, Rtmax = 600 Ω, protection against surge transients
If no echo: continuous 3.6 mA or 22 m
A
or holding value (selectable)
Relay SPDT, 250V AC/ 3A, AC1
Display SAP−100 programming and display module
Digital communication HART®standard on current output or RS485 MODBUS protocol
Damping time 3…1000 s (selectable) Default value: 300 s
Electrical connection
2× M20×1.5 plastic cable glands for Ø6…Ø12 mm (Ø0.24…Ø0.48″) cable,
3× terminal blocks for max. 1.5 mm² (AWG16) wire cross section,
2× inte
r
nally threaded ½" NPT connection for protective pipes.
Electrical protection Class I., protective earth (PE) conductor: 4 mm2(
A
WG11)
Ingress protection IP65
* Under optimal reflection circumstances and constant sensor temperature.
2.2. SPECIAL DATA
Type STD–34J–, SBD–34J–
STD–34J
–
Ex, SBD–34J
–
Ex
STD–33J–, SBD–33J–
STD–33J
–
Ex, SBD–33J
–
Ex
STD–31J–SBD–31J–
STD–31J
–
Ex SBD–31J
–
Ex
Maximum measuring distance (XM) 15 m (50 ft) 30 m (100 ft) 60 m (200
f
t)
Minimum measuring distance (Xm) 0.6 m (2 ft) 0.6 m (2 ft) 1 m (3.3 ft)
Ultrasound frequency 40 kHz 30 kHz 15 kHz
Weight ~7 kg (~15.5 lbs) ~10 kg (~22 lbs)

8 / 50  sbd31jen21p05
Type SAP–100 programming and display module
Display 6-digit LCD display for measurement value, engineering unit and bargraph
A
mbient temperature −25…+60 °C (−13…+140 °F)
Housing material Fiberglass-reinforced plastic (PBT)
2.3. EX INFORMATION
2.3.1. ATEX CERTIFICATE No.: BKI16ATEX0020X/1
Type SD–3J–5 Ex,SD–3J–6 Ex, SD–3J–7 Ex
SD–3J–8 Ex, SD–3J–E Ex, SD–3J–F Ex
Ex marking (ATEX) II 1/2 D Ex ma ta/tb IIIC T85°C…T130 °C Da/Db
Transducer material Closed cell PVC foam sensor face, aluminum transducer housing and fitting
Max. surface temperature on the sensor head +130 °C (+266 °F)
Max. surface temperature on the electronics housing +130 °C (+266 °F)
Supply Voltage /
consumption
Version I: 85… 255 V AC (50/60 Hz) / 6,8 VA
Version II: 11,4…40 V DC / 4,1 W, 11,4…28 V AC (50/60 Hz) / 4,6 VA
Electrical connection
2× M20×1.5 cable glands with Ex ta IIIC protection for Ø7…Ø12 mm (Ø0.28…Ø0.48″) cable,
3× terminal blocks for max. 2.5 mm² (AWG14) wire cross section,
2× internally threaded ½" NPT connection for protective pipes.
2.4. ACCESSORIES
Installation and Programming Manual,
Warranty Card,
EU Declaration of Conformity
2× M20x1.5 cable glands (in case of Ex units certified cable glands with Ex ta IIIC protection type are included)
1× tripolar terminal blocks
2× bipolar terminal blocks
ACCESSORIES (SOLD SEPARATELY)
Split flange (Order code: SFA–35)
SAP−100 programming and display module

sbd31jen21p05  9 / 50
2.5. ORDER CODES
EchoTREK S D – 3 J – *
Type Code
Measuring range /
Frequency Code Supply Voltage / Output Code
Transmitter T 1…60 m (15 kHz) 1 Version I 85…255 V AC
Transmitter + display B 0.6…30 m (30 kHz) 3 4…20 mA + Relay 1
0.6…15 m (40 kHz) 4 4…20 mA + HART®+ Relay 3
4…20 mA + Relay / Ex ma ta/tb D 5
4…20 mA + HART®+ Relay / Ex ma ta/tb D 7
* Order codes of Ex versions end in ’Ex
’
RS485 (MODBUS protocol) + Relay A
RS485 (MODBUS protocol) + Relay / Ex ma ta/tb D E
Version II 11,4…40 V DC and 11,4…28 V AC
4…20 mA + Relay 2
4…20 mA + HART®+ Relay 4
4…20 mA + Relay / Ex ma ta/tb D 6
4…20 mA + HART® + Relay / Ex ma ta/tb D 8
RS485 (MODBUS protocol) + Relay B
RS485 (MODBUS protocol) + Relay / Ex ma ta/tb D F

10 / 50  sbd31jen21p05
2.6. DIMENSIONS
Ball joint housing
(viewed from above) SD–33J-SD–34J–SD–31J–SD–31J–Ex

sbd31jen21p05  11 / 50
3. INSTALLATION
PLACEMENT
Various considerations must be taken to find the ideal position for the EchoTREK level
transmitter.
The transmitter should not be installed in the center of the tank/silo when the tank roof is dome-
shaped or conical. The ideal position for the EchoTREK is on the r = (0.3 … 0.5) R (in the case
of a cylindrical tank). Avoid the transmitter's 5° conical beam angle intersecting the tank/silo
wall. In this case, the transmitter is mounted too close to the wall; therefore, it must be tilted
(See "Aiming").
To avoid overheating, the instrument must be protected against direct sunlight.
GRAVITATIONAL FILLING
The device must be
mounted as far from the
filling stream as possible.
PNEUMATIC FILLING
Select a location where the speed of the
in-flowing material is the lowest.
Ex-type units must not be installed in
the dust path of the pneumatic filling!
MOUNTING (SEE ILLUSTRATION OF MOUNTING OPTIONS ON THE NEXT PAGE)
The EchoTREK consists of a sensor attached to the aiming arm (a pipe with a ball joint housing incorporating a ball joint) attached to the housing of the
electronics. It is recommended to mount the transmitter on the roof of the tank/silo using a flange (See drawing). The Ball joint housing has a screw-hole
diameter of 125 mm (5″) for fixing it. For easy installation, it is recommended to use NIVELCO's special flange with a split insertion, available with four sizes of
DN125/150/200/300 (to be ordered separately). Removing the split insert, the flange is must be put around the aiming arm, and the ball joint housing is to be
fixed to the split flange. It is essential to use the washers and the bolts (4 × each) delivered with the split flange. The ball joint will be pressed to the housing by
a spring allowing adjustment/aiming. After completing the adjustment/aiming, the 4 × of M12 bolts have only to be tightened. The maximum torque for
tightening the bolts is 3.5 Nm.

12 / 50  sbd31jen21p05
Mounting EchoTREK versions SD–33–and SD–34–:
1. Check that the split flange matches the holes of the counter-flange on the silo.
2. Remove the split insert from the flange and put the flange around the aiming arm between the sensor and the aluminum base.
Slide the split insert back to its place and screw the ball joint housing to the flange with the four M12 bolts to such an extent that the aiming arm can
move freely through and tilt by the ball joint for the aiming process.
3. Place the seal below the flange (if necessary).
4. Pass the sensor through the opening on the roof and fasten the flange to its place.
5. Fasten the EchoTREK (with the split flange) to the counter-flange or to the roof of the silo/tank. Perform the aiming process (see “Aiming” below).
6. To fix the position of the aiming arm, tighten the four M12 bolts of the ball joint housing (max. 3.5 Nm).
Mounting EchoTREK SD–31–versions, with silo/tank roof opening of Ø300…Ø340 mm (Ø11.8…Ø13.4″).
The procedure is the same as above, but the required flange diameter is DN300.
Mounting EchoTREK SD–31–version with silo/tank roof opening less than Ø300 mm (Ø11.8″) and the silo space is accessible from inside:
1. Check the split flange's holes with that of the bolt places or counter-flange on the silo
2. Place the seal below the flange (if necessary)
3. Push the unit out of the silo (upwards) (See on the next page)
4. When the aluminum base with the ball joint is above the counter-flange the special flange has to be placed around the aiming arm (see on the
next page)
5. Put the split flange on the counter-flange and lower the ball joint housing on it
6. Slide the insert to its place (See on the next page)
7. Screw in the four of M12 bolts (See on the next page) so they allow free aiming
8. Fasten the EchoTREK (with the split flange) to the counter-flange or to the roof of the silo/tank.
9. After completing aiming, tighten the four 12M bolts (max. 3.5 Nm).
If the entire tilting range of the aiming arm is required, the thickness of the roof cannot exceed the specified value on the drawing next page. The EchoTREK can
also be mounted on existing (manhole) covers, access lids or for instance on a steel structure lowered into a larger (for example: 0.5 x 0.5 m [19.7 x 19.7″])
opening on the roof. This solution is to be used when the roof thickness is greater than 350…380 mm (13.8…15″).
Neither the apparatus nor any part of it is suitable as a fire resistant barrier for the Zone 20 area.
The housing cover of Ex-type units can only be removed after the hex socket set screw providing protection against unauthorized (tool-free) opening
of the cover is screwed in. The instrument can be operated in hazardous environment only if the cover is properly locked by the protective screw.

sbd31jen21p05  13 / 50
Figure 1. Mounting
DIAMETER OF THE
OPENING
D
MAX.ROOF
THICKNESS
V
160 mm (6.3″) 110 mm (4.3″)
190 mm (7.5″) 10 mm (5.9″)
230 mm (9″) 200 mm (7.9″)
300 mm (11.8″) 280 mm (11″)
340 mm (13.4″) 300 mm (11.8″)

14 / 50  sbd31jen21p05
4. WIRING
To access the electric connection point, unscrew the bolt on the side of the
electronics housing. Use cable with a wire cross section of 0.5…2.5 mm2
(AWG20…AWG14).
Electric connections can be made using one or two cables. Wires in different
groups (A, B, C; shown below) cannot to be led in the same cable.
Figure 2. Wiring diagram
Space for the wiring, for better overview without the upper part.
Group A Group B Group C
Low voltage power supply 4…20 mA.
RS485
(shielded twisted pair)
SELV voltage power supply
Low voltage for the relay SELV voltage power or logic
signal for the relay
The unit must be put in place and the cables must be arranged so that the
connecting cables outside the unit are fixed and tension-free.
Devices must be grounded properly at the internal or external grounding
screw terminals, depending on the cables.
DC-powered (Version II) devices can be 3-wire connected. In this case,
terminals 1 and 6 must be interconnected, but there will be no galvanic
isolation.
After making the electrical connections, check for correct sealing and close
the housing!

sbd31jen21p05  15 / 50
5. COMMISSIONING, ADJUSTING, PROGRAMMING
5.1. COMMISSIONING
After switching on the correctly wired unit, the transducer begins to click
audibly. In about 20…50 s, the ECHO LED goes on, and a signal between
4…20 mA appears on the current output. The factory default settings are
suitable for checking the unit's operation or solving most simple level metering
tasks. The programming must be modified for the required measurement task
to use the advanced features of the EchoTREK. Read the following chapters
of this user's and programming manual carefully to get familiar with the
programmable features of the level transmitter and solve challenging level
measurement tasks.
FACTORY DEFAULT PARAMETERS
All the transducers get the same factory default parameters that can be reset
later if needed. Some of the most important parameters default values of the
EchoTREK SD–3 series can be found below:
Measurement mode: level measurement (LEV). The plug-in SAP–
100 display shows the level value.
Zero level is assigned to the maximum measuring distance (XM).
The output current and the bar graph of the SAP–100 module are
assigned to the measured level value.
4 mA and 0% are assigned to zero level (maximum measuring
distance).
20 mA and 100% are assigned to the maximum level (minimum
measuring distance).
Current output in case of error: holding the last measurement
value.
Damping time: 300 s.
Relay is de-energized in the case of "NO Echo."
All the other measurement values are set to fit the values suitable for
standard tasks. The functions used only in exceptional cases are switched off
by default.
AIMING OF THE ECHOTREK FOR SOLIDS
It is recommended to tilt the sensor by the aiming arm of the transmitter to
reduce weak signal reflection from the material surface caused by an angle of
repose building due to the filling and emptying process. The optimal tilting
position can be adjusted during operation and recommended to be checked at
multiple levels during the filling/emptying process. In most cases, the sensor
should be aimed towards the middle of the tank/silo bottom by aiming at the silo
outlet. In applications where repose is absent or tall and narrow silos
(diameter/height ≥5), aiming is not critical: the sensor must face straight
downwards. Aiming must also be tested with full silo since due to the great angle
of repose, the echo might be weak despite the level being near the sensor. In
such cases, a reasonable compromise of aiming must be achieved that provides
a good echo in every state of the filling. Aiming is also aided by the informational
parameters P70 – P75. The aiming procedure is recommended to perform
together with the complete parameter access programming.

16 / 50  sbd31jen21p05
5.1.1. The SAP–100 programming and display module
The plug-in programming and display module can be removed or plugged in during the operation of the EchoTREK level transmitter. The module has 4 push
buttons and a special multifunction LCD display.
The measured values are displayed in the central line of the display. The units are displayed in the bottom or top lines, or indicated by the arrow pointing at the
units on the display's frame.
SYMBOLS USED ON THE LCD
DIST – distance (measuring) mode
LEV – level (measuring) mode
VOL – volume (measuring) mode
%– measured value in percentage
mA – output current
°C – transducer temperature (in Celsius)
PROG – programming mode (device under programming)
RELAY – relay
– level changing direction
FAIL – measurement / device error
SYMBOLS USED ON THE FRAME
Valid if pointed by the arrow
M– metric (European) engineering system
m3m cm l (liter)
US – imperial (US) engineering system
ft3ft in gal (gallon)
t– tonne (1000 kg) or Ton (2000 lbs) (calculated mass)
°F – transducer temperature (in Fahrenheit)
sec – second
hour – hour
min day – not used

sbd31jen21p05  17 / 50
5.1.2. Usage and the indications of the SAP–100 programming and display module in measurement mode
The device is in Measurement Mode, when PROG is not shown on the display. In this case, the display shows the measurement value, which can be changed
following the steps below.
Depending on the selected measuring mode (see P01 in Chapter
5.2.1 for further details) the following primary and other values can be
displayed:
DISTANCE (DIST)
LEVEL (LEV)
LEVEL in percentage (LEV %)
VOLUME or MASS (VOL)
VOLUME or MASS in percentage (VOL %)
The unit of the displayed measurement value is indicated directly or by
the arrow pointing the units on the frame of the display.
When the “FAIL” message is blinking on the display, the error
codes can be displayed after the measured values (see
chapter 5.4.11.).
After powering up the units the measuring mode will be the same as it was
at the last powering off.
LED INDICATIONS

COM-LED
LED is on during communication (Remote programming).

ECHO-LED
LED is on as long as the device receives a valid echo signal.

RELAY-LED
LED is on when relay is energized.

18 / 50  sbd31jen21p05
5.2. SPECIAL CONDITIONS OF EX USE
•Do not place the device in a pneumatic dust stream!
•The device or any part of it must not be used toseal the Zone 20 area in a flameproof manner.
•All earthing screws of the device must be earthed to avoid static charge inorder to fulfill the safety class I.
•The diameter of the cable and the cable entry must match.
•Only Ex ta certified glands may be used to connect the device.
•The current output must be connected via galvanic isolator.
The window of equipment types EchoTREK SBD–3– Ex is susceptible to electrostatic charges; thus, its cleaning is allowed only withuse of wet cloth.
5.3. PROGRAMMING
The factory default settings can be changed by the user. Programming can be performed with an SAP–100 plug-in programming module, which functions as a field
display as well. The EchoTREK SBtypes come with an SAP–100 programming module. After removing the windowed housing cover, the programming buttons
can be accessed. The SAP–100 module can program any EchoTREK level transmitter for solids. The EchoTREK can operate without the SAP–100 module and it
can be removed during operation. Remote programming via HART®communication protocol or RS485 interface is the same as described except for the
measurement simulation.
The instrument may be damaged by electrostatic
discharge (ESD) via its terminal (SAP–100 and TEST);
thus, apply the precautions commonly used to avoid
electrostatic discharge, e.g., by touching an adequately
grounded point before removing the cover of the
enclosure. A possible electrostatic discharge can
cause damage to the instrument.
Measuring will continue during programming using the old parameter set.
The new settings will be in force after returning to Measurement mode from Programming mode.
If the transmitter is left in programming mode by mistake, it will automatically return to measurement mode after 30 minutes and operate with the last saved
parameters. In the case of HART®capable units or versions with an RS-485 interface, the automatic return from remote programming mode to measurement
mode is done after 1 minute.

sbd31jen21p05  19 / 50
PROGRAMMING MODES OFFERED BY THE SAP–100 PROGRAMMING AND DISPLAY MODULE
CURRENT OUTPUT SCALING (5.3.2.)
Assign the level values to the current output (4 and 20 mA). All other parameters remain unchanged.
QUICKSET (5.3.3.)
Recommended as a simple and fast way to set up the EchoTREK by 8 basic parameters. This menu-driven programming mode supports the following basic
settings:
Engineering unit for the display (metric or US)
Maximum measuring distance (H)
Level assigned to 4 mA
Level assigned to 20 mA
Error indication by current output
Damping time
Assigning level to energizing a relay
Assigning level to release a relay
FULL PARAMETER ACCESS PROGRAMMING (5.3.4.)
All the programmable features of the EchoTREK can be accessed by parameter addresses:
Measurement configuration
Outputs
Measurement optimization
13 pre-programmed tank shapes for volume calculation
32-point linearization table
test parameters
secret code
In the full-access programming mode, the parameters are numbered, and they can be identified in the user manual. The unit continues measuring with the last
saved settings while programming. When the currently measured values are used (for example, GET LEVEL) the values are calculated according to the last
saved parameter set. The new parameter set becomes in force only after returning to measurement mode.

20 / 50  sbd31jen21p05
5.3.1. Basic steps of programming
The unit can be programmed directly with the four push buttons of the SAP–100 module. The followings are an overview of handling the programming module.
Detailed programming instructions are covered in chapters 5.3.2, 5.3.3, 5.3.4, and 5.4.
SINGLE-PRESSING THE BUTTONS
The functions of the keys become active after the button is released.
to save parameter address and go to parameter value; to return from parameter value to parameter address
to move the cursor to the left
to increase the value of the digit under the cursor (press the key continuously to increase the value of the digit faster)
to decrease the value of the digit under the cursor (press the key continuously to decrease the value of the digit faster)
PRESSING TWO BUTTONS AT THE SAME TIME
Press the two keys simultaneously to access programming steps (0 ... 3 s). The double key combination is marked with ”+” in the following.
ENTER INTO OR QUIT FROM PROGRAMMING MODES KEY COMBINATIONS FOR CHANGING PARAMETER VALUES
GET LEVEL function can be used only in level and in distance
measurement modes: reading
the actual measured value
Notes:
If the blinking cursor cannot be moved to the parameter value from the parameter address after pressing the button,
the parameter is either read-only, or
modifying the parameter is restricted by a secret code (see P99).
If the parameter value keeps blinking the modification cannot be accepted because
the modified value is either out of range, or
the entered code is not valid for this parameter