NIVELCO EchoTREK ST-400 Series Assembly instructions

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Manufacturer
H-1043 Budapest, Dugonics u. 11.
Phone: [phone] Fax: [phone]
E-mail: [e-mail] www.nivelco.com
NIVELCO Process Control Co.
EchoTREK
ST/SB-400 series four-wire
compact ultrasonic level transmitters
Installation and Programming Manual
2 edition
nd

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BASIC CONCEPTS AND ELEMENTS OF THE ULTRASONIC MEASUREMENT
Programmed
measurement
range of the
application
P06
Far end blocking
DIST= distance (measured)
Close end blocking (programmed value
LEV= level calculated; H - DIST)
VOL= volume (calculated from DIST LEV)
Max measuring distance of the application (H)
Max measuring distance of the device DEFAULT value of P04
XM
Max measurement range of the device
Min measuring distance (dead band) DEFAULT value of P05
programmed value of P04
Xm

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CONTENTS
1. INTRODUCTION....................................................................................5
2. ORDER CODES.....................................................................................6
3. TECHNICAL DATA................................................................................7
3.1 ACCESSORIES ..................................................................................11
3.2 MAINTENANCE AND REPAIR ...............................................................11
3.2.1 Software upgrade..................................................................11
4. INSTALLATION ...................................................................................12
4.1 LIQUID LEVEL MEASUREMENT............................................................12
4.2 OPEN CHANNEL FLOW MEASUREMENT...............................................14
4.3 INSTALLATION AND ELECTRICAL CONNECTION .....................................14
5. PROGRAMMING .................................................................................15
5.1 PROGRAMMING WITHOUT DISPLAY MODULE........................................17
5.2 PROGRAMMING WITH THE SAP-200 DISPLAY MODULE ........................20
5.2.1 SAP-200 Display Module.......................................................21
5.2.2 Steps of the SAP-200 Display Module ..................................21
5.2.3 Indications of the SAP-200 and LED Status.......................... 22
5.2.4 QUICKSET ............................................................................23
5.2.5 Full Parameter Access ..........................................................25
6. PARAMETERS – DESCRIPTIONS AND PROGRAMMING...............27
6.1 MEASUREMENT CONFIGURATION .......................................................27
6.2 CURRENT OUTPUT ...........................................................................33
6.3 RELAY OUTPUT................................................................................34
6.4 MEASUREMENT OPTIMISATION...........................................................35
6.5 DATA LOGGER..................................................................................39
6.5.1 READING DATA OUT FROM THE LOGGER .....................................42
6.6 VOLUME MEASUREMENT ...................................................................43
6.7 VOLUME FLOW MEASURING ..............................................................44
6.8 32-POINT LINEARISATION..................................................................50
6.9 INFORMATIONAL PARAMETERS (READ OUT PARAMETERS)...................51
6.10 ADDITIONAL PARAMETERS OF THE FLOW METERING..........................53
6.11 SUPPLEMENTARY PARAMETER OF THE LOGGER .................................53
6.12 TEST PARAMETERS ........................................................................54
6.13 SIMULATION ...................................................................................55
6.14 ACCESS LOCK................................................................................55
7. ERROR CODES ..................................................................................56
8. PARAMETER TABLE .........................................................................57
9. SOUND VELOCITIES IN DIFFERENT GASES ..................................59

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Thank you for choosing a NIVELCO instrument.
We are sure that you will be satisfied throughout its use.
1. INTRODUCTION
A Total beam angle of 5°-7°at –3 dB as is featured by most of Nivelco’s
SenSonic transducers ensuring a reliable measurement in narrow silos with
uneven side walls as well as in process tanks with various protruding objects.
Furthermore, as a result of the narrow beam angle - the emitted ultrasonic
signals have an outstanding focusing - deep penetration through gases,
vapour and foam is ensured.
rr
D
XD
1 m 0,21 m
2 m 0,3 m
5 m 0,56 m
10 m 1 m
15m 1,45 m
X
Diameters
corresponding to
5° beam angle.
Application
The EchoTREK compact ultrasonic level transmitters from NIVELCO are an
excellent tool for the level measurement of liquids.
Level measurement technology based on the non-contacting ultrasonic
principle is especially suited for applications where, for any reason, no
physical contact can be established to the surface of the material to be
measured.
Such reasons may include corrosive attack by the process medium against
the measuring device material (acids), possible contamination (sewage) or
particles of the process medium adhering to the measuring device
(adhesive materials).
Principle of Operation
The ultrasonic level metering technology is based on the principle of
measuring the time required for the ultrasound pulses to make a round trip
from the sensor to the level to be measured and back. The sensor emits an
ultrasonic pulse train and receives the echoes reflected. The intelligent
electronic device processes the received signal by selecting the echo
reflected by the surface and calculates from the time of flight the distance
between the sensor and the surface which constitutes the basis of all output
signals of the EchoTREK
Dead Band is a feature common to all ultrasonic level meters.
It is specified as “Minimum measuring distance” in the Technical Data Table.
Measurement within this range can not be interpreted.
Minimum measuring distance (Xm) is determined by the design of the unit within which the measurement is not possible (Dead Zone). This distance can be
extended by programming in order to avoid disturbing effects of possible disturbing echoes coming from fixed objects. (Close-end Blocking).
Maximum measuring distance (XM) is the greatest distance (determined by the design of the unit) which can be measured by the unit under ideal conditions.
The maximum measuring distance of the actual application (H) must not be greater than XM.

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2. ORDER CODES
Note: not all combinations are possible
EchoTREK S - 4 -
TYPE CODE TRANSDUCER /
HOUSING CODE MEASURING RANGE * CODE MOUNTING CODE OUTPUT CODE
Transmitter T PP/Aluminium A 25 m 2 BSP thread 0 4…20 mA + R1+R2 / 230V AC 1
PVDF/Aluminium B 12; 15 m 4 NPT thread N 4…20 mA + R1+R2 / 24V AC / DC 2
Transmitter with
local indicator B PTFE/Aluminium T 7; 10 m 6 DN 80 PN 16 / PP 2 4…20 mA + R1+R2 + HART / 230V AC 3
SS316Ti/Aluminium S 6; 8 m 7 DN 100 PN 16 / PP 3 4…20 mA + R1+R2 + HART / 24V AC / DC 4
PP/Plastic P 5; 6 m 8 DN 125 PN 16 / PP 4 4…20 mA + R1+R2 + HART + Logger / 230 VAC G
PVDF/ Plastic V 3; 4 m 9 DN 150 PN 16 / PP 5 4…20 mA + R1+R2 + HART + Logger / 24 VAC/ DC H
PTFE/ Plastic F DN 200 PN 16 / PP 6 4…20 mA + R1+R2 + Logger / 230 VAC K
SS316Ti/ Plastic M 200 mm bracket K 4…20 mA + R1 +R2 + Logger / 24 VAC/ DC L
500 mm bracket L
700 mm bracket M
* Measuring range depends on the material of the transducer

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3. TECHNICAL DATA
GENERAL DATA
Transducer materials Polypropylene (PP) Kynar (PVDF) Teflon (PTFE) Stainless Steel (DIN 1.4571, AISI SS316Ti)
Housing material Plastic: Glass fibre plastic PBT (DuPont®) Aluminium: Powder paint coated
Process temperature PP,PVDF and PTFE transducers: –30 °C ... +90 °C
Stainless Steel transducer : -30°… +100°C (120°C for max. 2 hours)
Ambient temperature Plastic housing: –25°C ... +70°C Aluminium housing –30 °C ... +70 °C with display –25°C ... +70°C
Pressure** (Absolute) 0.5 ... 3 bar (0.05 ... 0.3 MPa) Stainless steel versions 0.9 ... 1.1 bar (0.09 ... 0.11 MPa)
Seals PP transducer: EPDM
All other transducer versions: FPM (Viton)
Ingress protection Sensor: IP68
Housing: IP67 (NEMA 6)
Power supply
230V AC tip: 85 – 255 VAC / 2VA,
24 VAC/DC típ: 24 V ± 15% AC/DC / 100 mA
galvanic isolation; protection against surge transients
Accuracy * ±(0.2% of the measured distance plus 0.05% of the range)
Resolution Depending on the measured distance < 2 m: 1 mm, 2...5 m: 2 mm, 5...10 m: 5 mm, > 10 m: 10 mm
Analogue: 4 … 20 mA (3.9 … 20.5 mA) , Rmax = (Ut- 12V) / 0.02 isolated protection against surge transients
SPDT relay, 250 V AC / 3A AC1
SPDT relay 30 V DC, 1A DC
Display: 6 digits, icons and bargraph, (on SAP-200 display module on the ST version only)
Outputs
Serial communication: HART interface (terminal resistor 250 Ohm)
Electrical connection M20x1.5 Plastic, Cable ∅6 … 12 mm
2 x ½” NPT for cable gland; Wire cross section: 0.5 ... 1.5 mm2
Electrical protection
SELV:
Protection Class III
Mains:
Protection Class I (Aluminium housing)
Protection Class II (Plastic housing)
* Under optimal circumstances of reflection and stabilised transducer temperature.
** For pressures below 1 bar representative of Nivelco should be consulted.

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SPECIAL DATA OF THE FOUR-WIRE EchoTREK WITH PP AND PVDF TRANSDUCERS
TYPE ST-49-
SB-49-
ST-48-
SB-48-
ST-47-
SB-47-
ST-46-
SB-46-
ST-44-
SB-44-
ST-42-
SB-42-
Transducer material PP or PVDF PP or PVDF PP or PVDF PP or PVDF PP or PVDF PP or PVDF
Maximum measuring
distance * [m / ft] 4 6 8 10
15 25
Min. measuring distance*
(Dead band) [m / ft] 0.2 0.25 0.35 0.35 0.45 0.6
Total beam angle (-3 dB) 6° 5° 7° 5° 5° 7°
Measurement frequency 80 kHz 80 kHz 50 kHz 60 kHz 40 kHz 20 kHz
Process connection 1 ½” thread 2” thread 2” thread DN 80 Flange DN 125 Flange DN 150 Flange
* (from the transducer face)
SPECIAL DATA OF THE FOUR-WIRE EchoTREK PTFE AND STAINLESS STEEL TRANSDUCERS
TYPE ST-49-
SB-49-
ST-48-
SB-48-
ST-47-
SB-47-
ST-46-
SB-46-
ST-44-
SB-44-
ST-42-
SB-42-
Transducer material PTFE PTFE PTFE SS316 Ti SS316 Ti SS316 Ti
Maximum measuring
distance * [m/ft] 3 5 6 7 12 15
Min. measuring distance*
(Dead band) [m/ft] 0.25 0.25 0.35 0.4 0.55 0.65
Total beam angle (-3 dB) 6° 5° 7° 5° 5° 7°
Measurement frequency 80 kHz 80 kHz 50 kHz 60 kHz 40 kHz 40 kHz
Process connection 1 ½” thread 2” thread 2” thread DN 80 Flange DN 125 Flange DN 150 Flange
* (from transducer face)
SAP-200 DISPLAY MODULE
Field indication 6 digits Custom LCD, icons and bargraph
Ambient temperature -25°C … +70°C
Housing material PBT fibre-glass reinforced plastic, (DuPont®)

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Dimensions of the four-wire EchoTREK
EchoTREK S-49-/ PP, PVDF, PTFE EchoTREK S-48-/ PP, PVDF, PTFE EchoTREK S-47-/ PP, PVDF, PTFE
2xM20x1,5
2xNPT1/2”
BSP, 15mm
NPT, 22mm
BSP vagy NPT 1½”
Ø42
61 1±~148
60±1
54
BSP or NPT 2"
BSP, 15mm
NPT, 22 mm
2x N PT 1/2"
2xM20x1.5
~148
2xM20x1,5
2xNPT1/2”
BSP, 15mm
NPT, 22mm
BSP vagy NPT 2”
Ø54
80 1±~148
EchoTREK S-46-/ PP, PVDF EchoTREK S-44-/ PP, PVDF EchoTREK S-42-/ PP, PVDF
2xM20x1,5
2xNPT1/2”
Ø74
29,5 1±
18
~143
DIN DN80 PN16
ANSI 3” 150 psi
JIS 10K 80A
122
48±1
DIN DN125 PN16
ANSI 5" 150 psi
JIS 10K 125A
19
2x NPT1/2"
2xM20x1.5
~144
~89
61±1
148
ANSI 6" 150 psi
DIN DN150 PN16
JIS 10K 150A
19
2x NPT1/2"
2xM20x1.5
~144
~89
* Min required flange size

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EchoTREK SS-46-/ SS316 Ti EchoTREK SS-44-/ SS316 Ti
2xM20x1,5
2xNPT1/2”
DIN DN80 PN10
ANSI 3” 150 psi
20
~187
Ø133
Ø200
2xM20x1,5
2xNPT11/2”
Ø250
Ø170
Ø185
25
~192
DIN DN125 PN10
ANSI 5” 150 psi
EchoTREK SS-42-/ SS316 Ti
2xM20x1,5
25 ~198
2xNPT1/2”
DIN DN1510 PN10
ANSI 6” 150 psi
Ø285
Ø185
Ø210

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3.1 ACCESSORIES
−Certificate of Warranty — 2 x M20x1.5 cable gland
−Installation and Programming Manual — SAP-200 Display Module (option)
−Declaration of Conformity — CD-ROM (EViewLight, DataScope softwares) (option)
3.2 MAINTENANCE AND REPAIR
The EchoTREK B/ST series do not require maintenance on a regular basis. In some very rare instances, however, the transducer may need a cleaning from
deposited material. This must be carried out gently, without scratching or pressing the surface of the transducer.
Repairs during or after the warranty period are carried out exclusively at the Manufacturers. The equipment sent back for repairs should be cleaned or
neutralised (disinfected) by the User.
3.2.1 SOFTWARE UPGRADE
Based on the observations & needs of our customers NIVELCO constantly improves and revises the operating software of the device. The software can be
upgraded with the help of the IrDA communication port of the SAP-200 or an ELink (USB) communication adapter plugged into the SAP-200 slot. For more
information about software updates please contact Nivelco.

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4. INSTALLATION
4.1 LIQUID LEVEL MEASUREMENT
POSITION
The optimal position of the EchoTREK is on the radius
r = (0.3 … 0.5) R of the (cylindrical) tank / silo.
(Take also sonic cone on page 1 into consideration.)
SENSOR ALIGNMENT
The sensor face has to be parallel to
the surface of the liquid within ±2-3°.
TEMPERATURE
Make sure that the transmitter will
be protected against overheating by
direct sunshine.
Sunshade

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STAND-OFF PIPE
The structure of the stand off pipe should be rigid; the inner rim where the ultrasonic
beam leaves the pipe should be rounded.
Dmin
LS - 49 S - 48 S - 47 
150 50 60 60
200 50 60 75
250 65 65 90
300 80 75 105
350 95 85 120
OBSTACLES
Make sure that no in-flow path or objects
(e.g. cooling pipes, ladders, bracing
members, thermometers, etc.) or no tank
wall of the ragged surface protrude into
the sensing cone of the ultrasonic beam.
One fix object in the tank / silo that
disturb the measurement can be blocked
out by the appropriate programming of
the EchoTREK
L
Ø D
r
Dmin
LS - 46 S - 44 
90 80 *
200 80 *
350 85 *
500 90 *
FOAM
Foaming of the liquid surface may render ultrasonic level metering
impossible. If possible, a location should be found, where foaming is
the least (device should be located as far as possible from liquid inflow)
or a stilling pipe or well should be used.
r
Ø D
L
* For values contact your distributor
WIND
Intensive air (gas) movements in the vicinity of the ultrasonic cone is to
be avoided. A strong draft of wind may "blow away"the ultrasound.
Devices with lower measuring frequency (40, 20 kHz) are
recommended.
The sensor of the S - 42 has to be in the tank.
Dmin
LS S – 46 S S – 44 S S – 42 
320 80 – –
440 – 125 –
800 – 150
FUMES / VAPOURS
For closed tanks containing chemicals or other liquids, which creats
fume/gases above the liquid surface especially for outdoor tanks
exposed to the sun, a strong reduction of the nominal measuring range
of the ultrasonic device is to be considered during device selection.
Devices with lower measuring frequency (40, 20 kHz) are
recommended in these cases units.
L
Ø D
r

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4.2 OPEN CHANNEL FLOW MEASUREMENT
•For ultimate accuracy, install the sensor as close as possible above the expected maximum water level (see minimum measuring range).
•Install the device in a place defined by the characteristics of the metering channel along the longitudinal axis of the flume or weir. In case of Parshall
flumes supplied by NIVELCO the location of the sensor is marked.
•In some cases foam may develop on the surface. Make sure that the surface, opposite to the sensor remain free of foam for proper sound reflection.
•From the point of view of measurement accuracy the length of the channel sections preceding and following the measuring flume and their method of
joining to the measuring channel section are of critical importance.
•Despite of the most careful installation, the accuracy of flow metering will be lower than that of specified for the distance measurement. It will be
determined by the features of the flume or weir applied.
4.3 INSTALLATION AND ELECTRICAL CONNECTION
Installation of the (BSP or NPT) threaded models
•Screw the unit in to its place. Use open wrench for
tightening; max torque is 20Nm
•After tightening the enclosure can be rotated to the proper
position. (Safety bolt prevents rotation more than 350°)
•The unit may be damaged by electrostatic discharge (EDS)
via its terminal, thus apply the precautions commonly used
to avoid electrostatic discharge e.g. by touching a properly
grounded point before removing the cover of the enclosure.
•Ensure that the power supply is turned off at the source.
•With removal of the cover of the housing and taking out the display module (if any), the
screw terminals can be accessed. Suggested cable core cross section:
0.5 ... 1.5 mm2. Arrange grounding by the inner or outer grounding screw first.
•Switch on the unit and make necessary programming.
•After programming ensure proper sealing and closing of the cover.
2
1

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Transmitter
1
1
2
2
3
4
5
6
7
8
9
10
11
12
230 V AC Power Supply
PLC
HART
HART modem e.g. SAT-304
USB PC
4...20 mA
Rs
24 V DC R 1
in
R 2
in
COM
COM
NC
C2
C1
NO Relay 1
Relay 2
Power Supply Unit
e.g.
PPK-331
Indicator
e.g.
PDF-401-2
S -4
Rs+ Rin1 + Rin2 > 250 has to be, in case of using HART modem
Display Module
Connector
GND
1/2"NPT 1/2"NPT
M20x1,5
M20x1,5
Relay1
4 ... 20 mA
Current Output
(HART)*
789
COM NO
NC
Power supply
12
u
Relay2
10 11 12
COM
45
+ I -
WARNING!
* For proper working the free current output has to be closed with a max. 600 
impedance!
5. PROGRAMMING
The EchoTrek can be programmed by the following two ways:
•Programming without Display Module see 5.1.
Assignment of the levels to the 4 and 20 mA current output, error indication by the analogue signal and damping can be set.
•With the SAP-200 Display Module, see 5.2.
All features of the unit can be set, such as measurement configuration and optimisation, 32-point linearisation, dimensions
for 11 tanks with different shape and for 21 different open channels (flume, weir, etc).

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Devices with the type number EchoTREK SG... are already equipped with the SAP-200.
The EchoTREK is fully operational without the SAP-200. The SAP-200 is only needed for programming and/or displaying measurement values.
The unit will measure during programming in accordance with the previous parameters. The new, modified parameters will only be effective after
returning to the Measurement Mode
If the transmitter is left in Programming Mode by mistake, it will automatically return to Measurement Mode after 30 minutes and will operate with the parameters
entered during the last completed programming.
The EchoTREK will be delivered with the following Factory Default:
⇒Current output, display and bargraph: LEVEL
⇒Current output and bargraph proportional to the level
⇒4 mA: assigned to the minimum level 0%
⇒20 mA: assigned to the maximum level 100%
⇒Error indication by the current output: hold last value
⇒Damping: 60 sec

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5.1 PROGRAMMING WITHOUT DISPLAY MODULE
Programming is only possible if the EchoTREK is in Level Measuring
Mode and receives valid echo i.e. “VALID” LED is lit!
The following can be programmed without display module
•Assignment of the 4 mA to a required e.g. min. level / max. distance
•Assignment of the 20 mA to a required e.g. max. level / min. distance
•Error indication by the current output (Hold, 3.6 mA or 22 mA)
•Damping (10, 30 or 60 sec)
•Reset to the factory default
Note: Current output can also be assigned in inverted mode:
4 mA = 100% (Full), 20 mA = 0% (Empty)
RELAY
Procedure of programming: press button in the relevant sequence and check the state of the LED-s. Symbols for the states of the LED-s:
= LED is off, = LED is blinking, = LED is on, = LEDs are blinking alternatively = Dont care
Minimum level, (0%, empty tank) assignment to 4 mA
Action Led state following the action
1) Check for a valid ECHO = Valid ECHO, transmitter programmable
2) Press NEXT button steadily = EchoTREK in programming mode
3) Press UP button steadily = 4 mA assigned to the distance (see picture)
4) Release buttons = Programming completed
B
B
Use level in tank or a fix target e.g. the wall

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Maximum level (100%, full tank) assignment to 20 mA
Action Led state following the action
1) Check for a valid ECHO = Valid ECHO, transmitter programmable
2) Press NEXT button steadily = EchoTREK in programming mode
3) Press DOWN button steadily = 20 mA as signed to the distance
(see picture)
4) Release buttons = Programming completed
B
B
Use level in tank or a fix target e.g. the wall
“Error state” indication by the analogue signal (Check for a valid echo as above)
As a result of this setting the value of the analogue output will be 3.8 mA; 22 mA or according last value (hold) until the error is ceased.
Action Led state following the action
1) Press button steadily = EchoTREK in programming mode
2) Press any of the DOWN ,
ENTER
E
,
NEXT
buttons steadily
– hold last value
= – 3.6 mA
– 22 mA
3) Release buttons = Programming completed

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Damping time setting (Check for a valid echo as above)
Action Led state following the action
1) Press ENTER
E
button steadily = EchoTREK in programming mode
2) Press any of the NEXT ,
UP ,
DOWN
buttons steadily
– 10 sec
= – 30 sec
– 60 sec
3) Release buttons = Programming completed
RESET: Returning to the default (Check for a valid echo as above)
Action Led state following the action
1) Press NEXT button steadily = EchoTREK in programming mode
2) Press ENTER
E
button steadily = Default loaded
Indication of mistakes (by LEDs) made during programming
Action Led state following the action Possible correction
Attempted programming = blinking twice = no Echo Find a valid Echo
Attempted programming = blinking three times = no access possible With SAP-200 only See 5.2 (P99)
Attempted programming = blinking four times = EchoTREK not in
Level Measurement Mode With SAP-200 only See 5.2 (P01)

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5.2 PROGRAMMING WITH THE SAP-200 DISPLAY MODULE
The EchoTREK should be adjusted to the process by programming the parameters. The SAP-200 Display Module can be used to display the parameters during
programming and measurement values during measurement.
The SAP-200 supports two separately accessible programming modes representing 2-layers of programming complexity, depending on user choice.
PLUG-IN DISPLAY MODULE
QUICKSET
FULL
PARAMETER
ACCESS
QUICKSET (5.2.4)
Recommended as a simple and fast way to set up the EchoTREK by 6 basic parameters
for the following basic settings, marked by abbreviations easy to remember
•Engineering unit for the display (Metric or US)
•Maximum measuring distance (H)
•Assignment of min level to 4 mA
•Assignment of max level to 20 mA
•Error indication by the current output
•Damping time
Full Parameter Access (5.2.5)
All features of the EchoTREK such as:
•Measurement configuration
•Outputs
•Measurement optimisation
•11 pre-programmed tank shapes for volume calculation
•21 pre-programmed formula for flow metering
•32-point linearisation