NIVELCO MicroTREK Assembly instructions

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Manufacturer:
H-1043 Budapest, Dugonics u. 11.
Tel.: [phone] Fax: [phone]
E-mail: @nivelco.com www.nivelco.com
NIVELCO Process Control Co.
sales
MicroTREK
HT HH HB/HP; Ex// //HB/HPHT HH
two-wire guided microwave level transmitters

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GUIDED MICROWAVE LEVEL MEASUREMENT
the factory set maximum measuring
distance of the instrument (Xm)
max. measuring range of the instrument
max. programmed value of the
measuring distance of the appli cation
factory set value of the
min. measuring
distance (dead zone) Xm
programmed
measuring range
of the appli cations
LEV= (H - DIST)
VOL= ( DIST LEV)
level
volume calculated from
lo wer dead zone
(m easurement is not possible )
DIST= measured distance
upper dead zone set higher
than the pre-programmed

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CONTENTS
1. INTRODUCTION ............................................................................................. 5
2. ORDER CODE ................................................................................................6
3. TECHNICAL DATA......................................................................................... 7
3.1 Accessories .................................................................................................... 14
3.2 Safety regulations for the Ex approved units................................................. 14
3.3 Maintenance and repair ................................................................................. 14
4. MECHANICAL INSTALLATION................................................................... 15
4.1 Handling and storage..................................................................................... 15
4.2 Mounting on the tank......................................................................................17
4.2.1 Installation instructions: general notes...................................................17
4.2.2 Specific installation instructions: gauge - solid applications.................. 23
4.3 Wiring ............................................................................................................. 25
4.3.1 BUS ( HART®) communication .............................................................. 29
4.4 Power-on and start-up....................................................................................30
4.5 Available user interfaces................................................................................30
5. PROGRAMMING .......................................................................................... 31
5.1 Programming with PCSTAR 2 software......................................................... 31
5.1.1 PCSTAR 2: installation and execution................................................... 31
5.1.2 Summary of User Functions in PCSTAR 2 (F2 – Configuration) .......... 35
5.1.3 Quick Configuration: configuration examples........................................ 40
5.2 Programming with SAP-300 display unit....................................................... 47
5.2.1 SAP-300 display unit..............................................................................47
5.2.2 MicroTREK’s behaviour in manual programming mode........................ 48
5.2.3 Manual programming............................................................................. 49
5.3 Programming with HART® handheld (HHC) Communicator ..........................50
5.3.1 Characters available for alpha-numerical data functions in PCSTAR2 and
on the HART®console ....................................................................................59
5.4 MicroTREK 2-wire T.D.R. meter characteristics ............................................60
5.4.1 Gauge operating logic when the reflection is lost.................................. 62
5.4.2 Gain and voltage amplitude ...................................................................63
5.4.3 Typical signal trends .............................................................................. 67
5.4.4 Automatic adjustment ............................................................................ 68
5.4.5 Level measurement when more than one phase or layer in the tank....70
5.5 Troubleshooting..............................................................................................72
5.6 Appendix 1 – Set-up parameters of MicroTREK H-400 series in Multicont
controller............................................................................................................... 75

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Thank you for choosing a NIVELCO instrument.
We are sure that you will be satisfied throughout its use!
1. INTRODUCTION
Application
The MicroTREK 2-wire level gauge uses the Time Domain Reflectometry (TDR) measuring principle and two-wire technology for level measurement.
It is designed for measuring the distance, level, volume of liquids, pastes, slurries and powder products.
The device is applicable in tank, silo, rigid pipe, reaction vessel and level reference vessel.
The device is HART capable, it can be programmed using a HART Handheld Communicator (HHC), a Multicont universal process controller and EView2 software
supplied as standard with the gauge.
Operating principle
The MicroTREK 2-wire guided microwave level transmitter uses the TDR (Time Domain Reflectometry) principle. The instrument sends low power nanosecundum
wide pulses along an electrically conductive rod, cable or coaxial probe with a known propagation speed (the speed of light). As the pulse reaches the surface of the
medium or phase of two liquids (altered dielectric constant εr), a part of it is reflected back to the electronic module. The efficiency of the reflected signal depends on
the dielectric constant εrdifference of the mediums or layers. (From the plain surface of air-water phase the reflected signal's strength will be approx. 80% of the
emitted signal). The reflected pulse is detected as an electrical voltage signal and processed by the electronics. Level distance is directly proportional to the flight time
of the pulse. The measured level data is converted into 4-20 mA current and HART signals and is displayed on the LCD display. From the level data further derived
measuring values can be calculated such as volume and mass. The TDR technology is unaffected by the other properties of the medium as well as that of the space
above it.

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2. ORDER CODE
MicroTREK H - - * 2-wire guided microwave level transmitter
TYPE CODE PROBE /PROC.CONN. CODE HOUSING CODE
INSERTION
LENGTH CODE
INSERTION
LENGTH CODE OUTPUT /EXCODE
Transmitter T Caoaxial / 1” BSP A Aluminium 4 4 – 20 mA + HART / Normal 4
Coaxial / 1” NPT B Plastic 5
Coaxial, Rod,
Twin rod
Coaxial, Rod,
Twin rod 4 – 20 mA + HART / Ex tD 5High temp.
transmitter H Coaxial / 11/2” BSP C 0m 0 0m 0 4 – 20 mA + HART / Ex iaD 6
Coaxial / 11/2” NPT H
Stainless
steel 6 1m 1 0.1m 1 4 – 20 mA + HART / Ex ia 8Transmitter +
display B Rod / 1” BSP R 2m 2 0.2m 2
Rod / 1” NPT P 3m 30.3m 3
Rod / 11/2” BSP S Coaxial, Rod (∅14mm) 0.4m 4
High temp.
transmitter +
display
P
Rod / 11/2” NPT Z 4m 4 0.5m 5
Twin rod / 11/2” BSP D 5m 5 0.6m 6
Twin rod / 11/2” NPT E 6m 6 0.7m 7
* The order code of an Ex version
should end in ’Ex’
4mm cable / 1” BSP K 0.8m 8
4mm cable / 1” NPT L 0.9m 9
4mm cable / 11/2” BSP V
4mm cable / 11/2” NPT W Cable version Cable version
8mm cable / 11/2” BSP N 0m 0 0m 0
8mm cable / 11/2” NPT J 10m 1 1m 1
4mm twin cable / 11/2” BSP T 20m 2 2m 2
4mm twin cable / 11/2” NPT U 3m 3
4mm FEP coated cable 1”BSP F 4m 4
4mm FEP coated cable 1”NPT G 5m 5
4mm FEP coat. cable / DN 40 Tricl. X 6m 6
4mm FEP coat. cable / DN 40 Milch Y 7m 7
PFA fully coated rod / DN 50 Q 8m 8
4mm FEP fully coat. cable / DN 50 M 9m 9
PP fully coated rod / DN 50 I
PFA fully coated rod / 1 ½” Triclamp O

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3. TECHNICAL DATA
GENERAL DATA
TYPE PLASTIC HOUSING
H-5-4
ALUMINIUM HOUSING
H-4-4,5,6,8
STAINLESS STEEL HOUSING
H-6-4,5,6,8
Measured values Between the reference point of the unit and reflection plane (material surface), distance, level and volume
Input data
Measuring range Depends on probe type and the properties of the measured medium (see: Technical data of the probes table)
Probe types and technical data Coaxial, twin cable, mono cable, twin rod and mono rod probes (see: Technical data of the probes table)
Housing Plastic PBT Paint coated aluminium Stainless steel
Medium temperature –30 °C ... +200 °C (see Technical data – MEDIUM TEMPERATURE table)
Medium pressure –0.1 … 4 MPa (-1…40 bar) (see Technical data – MEDIUM PRESSURE diagram)
Ambient temperature –30 °C …+60 °C, with display: –20 °C … +60 °C
Sealing FPM (Viton®), optional for high temp version: FFKM Perfluoroelastomer (Kalrez®6375), EPDM
Ingress protection IP67 (NEMA 4 – 4X)
Power supply 18 … 35 V DC, nominal 24 V DC, Ex version: 18 … 28 V DC, protection against surge transients
Analogue: 4–20 mA, (3.9 … 20.5 mA) passive output, error signal: 22 mA
BUS: serial line, HART®interface, terminal resistor max. 750 Ohm
Output signals
Display: SAP-300 plug-in LCD matrix
For liquids: ±5mm; For probe length L ≥10m: ±0.05% of the range
Accuracy* For solids: ±20mm; For probe length L ≥ 10m: ±0.2% of the range
Output
data
Resolution ±3 μA
Electrical connection 2x M20x1,5 metal cable glands for ø 7 … 13 mm cable, or 2x M20x1,5 plastic cable glands for ø 6 … 12 mm cable
wire cross section: 0.5 … 1.5 mm2(shielded cable is recommended) + internal thread for 2x ½” NPT cable protective pipe
Electrical protection Class III.
Mass (housing) 1.5 kg 2.4 kg 4.1 kg
* Under ideal reflection and stabilised temperature conditions.

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SPECIAL DATA FOR EX CERTIFIED MODELS
TYPE ALUMINIUM AND STAINLESS STEEL HOUSING
H--5,6,8
Ex marking (ATEX) II 1 G Ex ia IIC T6…T3 Ga, II 1 G Ex ia IIB T6…T3 Ga
II 1 D Ex ia IIIC T85°C…T180°C Da, II 1/2 D Ex ta/tb IIICT85°C… T180°C Da/Db
Ex marking (IEC) Ex ia llC T6...T3 Ga ; Ex ia llB T6...T3 Ga ; Ex ia lllC T85°C…T180°C Da ; -30 °C ≤ Tamb ≤ +60 °C
Intrinsically safe data (Ex ia IIB and Ex ia IIIC) Ci ≤ 10 nF, Li ≤ 10 μH, Ui ≤ 30 V, Ii ≤ 140 mA, Pi ≤ 1 W
Intrinsically safe data (Ex ia IIC) Ci ≤ 10 nF, Li ≤ 10 μH, Ui ≤ 30 V, Ii ≤ 100 mA, Pi ≤ 0.75 W
Medium temperature –30 °C ... +200 °C (see Technical data – MEDIUM TEMPERATURE table)
Medium pressure –0.1 … 4 MPa (-1…40 bar) (see Technical data – MEDIUM PRESSURE diagram)
TEMPERATURE DATA
EXPLOSIVE GAS ATMOSPHERE EXPLOSIVE DUST ATMOSPHERE
ALUMINIUM AND STAINLESS STEEL HOUSING
H--8
ALUMINIUM AND STAINLESS STEEL HOUSING
H--5,6
HIGH TEMPERATURE
HH--8
HP--8
HIGH TEMPERATURE
HH--6
HP--6
Ex ia IIB, Ex ia IIC Ex ia IIIC/ Ex ta/tb IIIC
Maximum permissible medium
temperature at the antenna +80°C +90°C +100°C +180°C +80°C +90°C +100°C +180°C
Maximum permissible surface
temperature at the process connection +75°C +90°C +100°C +175°C +75°C +90°C +100°C +175°C
Temperature class T6 T5 T4 T3 T85°C T100°C T110°C T180°C

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TECHNICAL DATA OF THE PROBES
TYPE
HK--
HL--
HV--
HW--
HR--
HP--
HS--
HZ--
HN--
HJ--
HT--
HU--
HD--
HE--
HA--
HB--
HC--
HH--
Denomination 4mm cable Rod Rod 8 mm cable 4mm twin cable Twin rod Coaxial
Max. measuring distance 24 m 3 m 6 m 24 m 24 m 3 m 6 m
Min. measuring distance
εr = 80 / εr = 2.4 0.3 m / 0.4 m 0.3 m / 0.4 m 0.3 m / 0.4 m 0.3 m / 0.4 m 0.15 m / 0.3 m 0.15 m / 0.3 m 0 m
Min. distance to objects ∅600 mm ∅600 mm ∅600 mm ∅600 mm ∅200 mm ∅200 mm ∅0 mm
Min. medium εr 2.1 2.1 2.1 2.1 1.8 1.8 1.4
1” BSP 1” BSP
1” NPT 1” BSP 11/2” BSP 11/2” BSP 11/2” BSP 11/2” BSP 1” NPT
11/2” BSP 11/2” BSP
Process connection
11/2” NPT 1” NPT 11/2” NPT 11/2” NPT 11/2” NPT 11/2” NPT 11/2” NPT
Probe material 1.4401 1.4571 1.4571 1.4401 1.4401 1.4571 1.4571
Nominal diameter of probe 4 mm 8 mm 14 mm 8 mm 4 mm 8 mm 28 mm
Mass 0.12 kg/m 0.4 kg/m 1.2 kg/m 0.4 kg/m 0.24 kg/m 0.8 kg/m 1.3 kg/m
Separator material – – – – PFA, welded on
the cable
PTFE-GF25
if length > 1.5m
PTFE,
If length > 1.5m
Weight dimensions ∅25 x 100 mm – –
∅40 x 260 mm ∅40 x 80 mm – –
Weight material 1.4571 – – 1.4571 1.4571 – –

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TECHNICAL DATA OF THE COATED PROBES
TYPE HF--
HG--HTX--HTY--HTM--HTQ--HTI--
Denomination 4mm FEP coated
cable
4mm FEP coated
cable
4mm FEP coated
cable
4mm fully FEP
coated cable Fully PFA coated rod Fully PP coated rod
Max. measuring distance 24 m 24 m 24 m 24 m 3 m 3 m
Min. measuring distance
εr = 80 / εr = 2.4 0.3 m / 0.4 m 0.3 m / 0.4 m 0.3 m / 0.4 m 0.3 m / 0.4 m 0.3 m / 0.4 m 0.3 m / 0.4 m
Min. distance to objects ∅600 mm ∅600 mm ∅600 mm ∅600 mm ∅600 mm ∅600 mm
Min. medium εr2.1 2.1 2.1 2.1 2.1 2.1
1” BSP
Process connection 1” NPT DN 40 Triclamp DN 40 Milch DN 50 DN 50 DN 50
Probe material 1.4401 / FEP 1.4401 / FEP 1.4401 / FEP 1.4401 / FEP 1.4571 / PFA 1.4571 / PP
Nominal diameter of the probe 6 mm 6 mm 6 mm 6 mm 12 mm 16 mm
Mass 0.16 kg/m 0.16 kg/m 0.16 kg/m 0.16 kg/m 0.5 kg/m 0.6 kg/m
Fillet and weight coating material – – – PFA PFA PP
Weight dimensions ∅25 x 100 mm ∅25 x 100 mm ∅25 x 100 mm ∅30 x 183 mm – –
Weight material 1.4571 1.4571 1.4571 1.4571 – –
Max. medium temp. +150 °C +150 °C +150 °C +150 °C +150 °C +60 °C
MEDIUM TEMPERATURE TABLE MEDIUM PRESSURE DIAGRAM
TYPE FLANGE TEMPERATURE
Transmitter –30 °C … +90 °C
High temp. HH_ or HP_ transmitter –30 °C … +200 °C
Lower or higher temperature for non-Ex version on special request
200°C
140°C
80°C
20°C
-30°C
-1 bar 16 bar 24 bar 32 bar 40 bar

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DIMENSIONS
HTK--
HTL--
HTV--
HTW--
HTR--
HTP--
HTS--
HTZ--
HTN--
HTJ--
HTT--
HTU--
HTD--
HTE--
HTA--
HTB--
HTC--
HTH--

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HTF--
HTG--HTX--HTY--HTM--HTQ--HTI--

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1 Housing
2 Cable gland
3 High temp. connection
4 Mono cable probe
5 Weight
6 Twin cable probe
7 Twin cable separator
8 Twin rod separator
9 Twin rod probe
10 Mono rod probe
11 Grounding screw
12 Process connection
13 Coaxial probe

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3.1 ACCESSORIES
• Warranty Card •EView2 software CD
• Installation and Programming Manual •2 pcs M20x1.5 cable gland
• Declaration of Conformity •SAP-300 display module (option)
3.2 SAFETY REGULATIONS FOR THE EX APPROVED UNITS
The level transmitter must be operated in intrinsically safe circuit only.
The metal enclosure of the unit must be connected to the EP circuit.
3.3 MAINTENANCE AND REPAIR
MicroTREK does not require maintenance on a regular basis. In some very rare instances, however, the probe may need a cleaning from deposited material.
This must be carried out gently, without damaging the probe.
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.

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4. MECHANICAL INSTALLATION
4.1 HANDLING AND STORAGE
The device will weigh between approximately 3 kg or 7 lb and 12 kg or 25 lb.
Carry using both hands to lift the device carefully by the converter housing. If necessary, use lifting gear.
No attempt should be made to lift the instrument by its probe.
Caution: The probe is a critical gauge component. Do not damage - Handle with care!
Avoiding blows - avoid hard blows, jolts, impacts, etc.
Caution: fragile electronics

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Avoid bending (single rod and coaxial probes) - Support the probe to
avoid bending.
Avoid cable kinks and fraying
Do not coil the cable less than 400 mm or 16 “ in diameter. Cable
kinks or fraying will cause measurement errors.
400mm
minimum
Storage temperature
+80°C
-40°C

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4.2 MOUNTING ON THE TANK
4.2.1 INSTALLATION INSTRUCTIONS:GENERAL NOTES
Prior the installation some consideration is to be made regarding tank fittings and tank shape. Nozzle position in relation to the tank walls and other objects inside the
tanks
(Warning: this free area will depend on the probe type selected: refer to later on in this section) type of tank roof, i.e. floating, concrete, integral, etc; and base, i.e.
conical, etc. Whenever working on an installation, remember to: Disconnect the power supply before starting work. However, the gauge may be installed when the
tank contains product.
Threaded process connections
The simplest and most economic way is to mount the MicroTREK 2-wire
directly on the tank with the 1” (1½”) BSP or 1” (1½”) NPT threaded
connection.
Nozzle height
Do not fit a nozzle longer than its diameter, especially for single
probes and powder applications
h ≤ Ød , where
h = nozzle height and
d = nozzle diameter
Contact NIVELCO if this relationship cannot be respected.

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Nozzles penetrating into tank
Caution: Do not use nozzles that penetrate into the tank.
This will disturb the emitted pulse.
Installation of two devices
If two devices are to be used on the same tank, these should be
mounted at a distance of at least 2 m or 6.5 ft away from each other.
If not, interferences from the electromagnetic (EM) fields generated
by both instruments may cause measurement errors.
Coaxial probes: the outer shell of the probe contains the EM field: no
minimum distance required.

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Process connection and entry pipe
Caution: Do not put the nozzle close to the entry pipe.
Pouring the product directly onto the probe will give false readings.
Install deflector plate if impossible to distance gauge from entry pipe.
Install far from
entry pipe
or use a
deflector
plate
medium
Stilling wells
Tanks with floating roofs for petrochemical applications: Use a stilling well.
1 Stilling well
2 Tank
3 Floating roof
4 Product (petroleum applications)
5 Well fixed to tank base (no roof deformation)
6 Sediment

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Probes: entanglement, straightness and tank bottom clearance
Cable probes must be straight once inserted into the tank.
They must also be far from other objects (e.g. mixers) to avoid entanglement.
In order to maintain the gauge’s operating characteristics, it is recommended to
avoid touching the tank bottom with the counterweights (for cable probes) or probe
end (other types).
Avoid mounting near objects (discontinuities) inside the tank that influence the
probe’s EM (electromagnetic) field
Install the gauge far from protruding objects such as: heating tubes, sudden
changes in tank cross-section, tank wall reinforcements and beams, weld lines
and dip-stick pipes, etc...