NIVELCO PiloTREK 2-wire Assembly instructions

PiloTREK 2-wire
Non-contact radar level transmitter
Non-contact radar level transmitterNon-contact radar level transmitter
Non-contact radar level transmitter
INSTALLATION
and
PROGRAMMING MANUAL
Manufacturer:
NIVELCO Control Co.
H-1043 Budapest, Dugonics u. 11.
Tel.: [phone] Fax: [phone]
E-mail:[e-mail] http://www.nivelco.com

2 Installation andprogramming manual PiloTREK 2-wire
TABLE OF CONTENS
1 Introduction………………………………………………………………………………………………………………………..2
1.1 Measurement principle……………………………………………………………………………………………………… 3
1.2 Product liability and warranty………………………………………………………………………………………………. 3
2 Handling and storage…………………………………………………………………………………………………………….3
3 Items included with supply……………………………………………………………………………………..……………….3
4 Order codes……………………………………………………………………………………..…………………………………3
5 Installation………………………………………………………………………………………………………………………… 4
5.1 Field assembly………………………………………………………………………………………………………………. 4
5.2 Mechanical installation……………………………………………………………………………………………………… 5
6 Electrical connection…………………………………………………………………………………………………………….7
7 Setting the parameters…………………………………………………………………………………………………………..8
8 Maintenance, error handling…………………………………………………………………………………………………..17
9 Safety information……………………………………………………………………………………………………………….18
10 Technical data……………………………………………………………………………………………………………………19
11 PiloTREK 2-WIRE signal converter and flange system marking codes……………………………………………….20
12 Conversion of Order Code to Converter- and Flange Code…………………………………………………………… 23
13 Parameter check list…………………………………………………………………………………………………………… 24

Installation and programming manual PiloTREK 2-wire 3
1. INTRODUCTION
1.1 MEASUREMENT PRINCIPLE
FMCW: Frequency Modulated Continuous Wave
The FMCW-radar uses a high frequency signal ~ 10 GHz.
The frequency of the signal is increased linearly by 1 GHz
during the measurement cycle (frequency sweep) The signal is
emitted via an antenna and reflected by the measuring surface
and received time-delayed. The received signal is frequency
shifted. The difference of frequencys ∆f is calculated from the
mixed time signal of the actual transmit frequency and the
received frequency. The difference is directly proportional to the
distance i.e. a large frequency difference correspond to a large
distance and vice versa.
The frequency difference is transformed via a Fourier transformation (FFT) into a frequency spectrum and then the distance
is calculated from the spectrum.The level results from the difference between tank height and distance.
1.2 PRODUCT LIABILITY AND WARRANTY:
The PiloTREK 2-WIRE level gauge is designed solely for measuring the level, distance, volume and reflection of liquids,
pastes, slurries, particulate materials and solids.
The PiloTREK 2-WIRE level gauge does not form part of an overfill protection system as defined in the WHG (German
water pollution regulation).
Local codes and regulations apply to its use in hazardous areas.
Responsibility as to suitability and intended use of these level gauges rests solely with the user.
Improper installation and operation of our level gauges may lead to loss of warranty.
In addition, the "General conditions of sale", form the basis of the purchasing contract.
If you need to return the level gauge to the manufacturer or supplier, please refer to the information given in Section
“Maintenance, error handling”
2. HANDLING AND STORAGE
SAFETY ADVICE
Depending on the version, the device will weigh between approx. 5 kg and 30 kg. To carry, use both hands to
lift the device carefully by the converter housing. If necessary, use lifting gear.
When handling the PiloTREK 2-WIRE, avoid hard blows, jolts, impact, etc.
When storing the "Wave-Stick" version, make sure that the device is not placed on its side on the PTFE antenna, as this may
cause the rod to bend.
3. ITEMS INCLUDED WITH SUPPLY
The scope of supply includes, in the version as ordered:
Signal converter bolted to wave-guide window and antenna;
optionally: antenna extension, sunshade (with fastening material in each case)
Shielding material with tightening strap for instruments with flange (not for the US market)
Installation and programming manual
Certification and approval documents, unless reproduced in the device documentation
Installation material (stud bolts, flange gasket and cabling) not supplied, to be provided by customer!
∆f
Time signal
t
Spectrum
f

4 Installation andprogramming manual PiloTREK 2-wire
4. ORDER CODES
5. INSTALLATION
Most of the PiloTREK 2-WIRE versions are supplied in fully assembled condition. In this case, you may skip this chapter.
However, if a device should be delivered in parts, or parts are subsequently replaced, the following should be noted.
5.1 FIELD ASSEMBLY
For any necessary field assembly of the
PiloTREK 2-WIRE, all parts are included with the
supply (stud bolts, washers, etc.).
Bolt the wave-guide window (flange mount) or
distance piece, if supplied loose, to the PiloTREK 2-
WIRE. Torque for the sets of 4 Allen screws M
(key size 5 mm): max. 8 Nm ∼0.8 kpm (5.8 ft lbf).
Note: Ensure the upper Teflon plug is kept absolutely
dry and clean! Moisture and dirt will impair
functionability of the PiloTREK 2-WIRE!
Bolt antenna extension to the antenna; torque for
the 3 stud bolts A: max. 8 Nm ∼0,8 kpm (5.8 ft lbf).
Do not detach bolts H !
distance piece (for
high-temperature version
up to 250°C (482 °F)
upper Teflon plug
O-ring
lower Teflon plug
O-ring
BM70 A
connecting flange
antenna extension
antenna
M
HM
A
signal converter

Installation and programming manual PiloTREK 2-wire 5
Flange system versions:
Flange
Stick plating
Stick
Gasket Gasket
Horn
antenna
Separation
(Metaglass)
Wave-Stick Wave-Stick
(PP or PTFE)
Flange system 96
with horn antenna
LP flange system
max. 2 bar
max. 2 bar
distance piece
(optional)
High temperature
plate Horn
antenna
Flange
(for Hastelloy,Ti, Ta)
PTFE w/o plate with horn antenna
PiloTREK
converter
5.2 MECHANICAL INSTALLATION
Hazardous-duty systems:
•The PiloTREK 2-WIRE Ex is certified in conformity with European Standard for use in Zone 0, 1 and 2
hazardous locations (dependent on version).
•Attention is drawn to the data and information given on the nameplate of the converter, the nameplate
of the flange and the specifications in the approval certificates.
Safety:
•Check material compatibility of antenna, extension, flange, gaskets, and PP or PTFE
(used in all versions) with the product! See also section 8 "Type code"!
Mounting on the tanknozzle
a) Devices with horn antenna:
The antenna should project out of the nozzle. If necessary, use an antenna extension. Exception: in case of a symmetrical
tank fitting.
Tank nozzle Tank nozzle Antenna
extension
Tank nozzle
„L”
Horn antenna
max. 2 bar
„V”
Horn antenna
„W”
Wave-Stick
antenna
with plate
PTFE
„W”
Wave-Stick
antenna
w/o plate
PP or PTFE
max. 2 bar

6 Installation andprogramming manual PiloTREK 2-wire
b) Wave-Stick
Note the requirements imposed on nozzle diameter and nozzle length:
min. 50 mm
min. 200 mm
Tank nozzle
e.g. DN50
dia. 40...55 mm
Version for
still wells
c) Purging device
Remove screw plug ¼" R and screw in screwed tube joint, e.g.
Ermeto ¼" R.
Consult “Ex“ specifications relating to the purging circuit
(provided by customer)!
Installationon the tank
Do not forget the gasket when positioning the
PiloTREK 2-WIRE on the tank nozzle flange. Align PiloTREK 2-
WIRE and gasket, slightly tighten nuts on stud bolts (by hand).
Press shielding strip C* in the gap between tank and
PiloTREK 2-WIRE flanges and secure with strap retainer S*
(both items included with supply).
Strap retainer S* must fit closely and overlap both flanges.
only required for European radio approvals
Tighten down stud bolt nuts firmly. The tightening torque is
dependent upon the strength properties of the stud bolts and
the pressure rating of the tank
C* = shielding strip B = PiloTREK 2-WIRE flange
S* = strap retainer F = tank flange
SW
short (60 mm)
antenna
for still wells only

Installation and programming manual PiloTREK 2-wire 7
Positioning on the tank
D
>1/7×H, but max. 1/3×D H
Recommended distance Do not position in Do not position
from the tank wall tank centerline! above internals!
(multiple reflections!) (interference reflections!)
A Stilling Well or Wave-Guide may be mounted in any position on the tank!
When using the PTFE Wave-Stick in hazardous areas of Zone 0, any electrostatic charging of the stick, e.g.
by flow of product, must be avoided!
6. ELECTRICAL CONNECTION
To open the signal converter, please use a screwdriver and release the four visible screws on top of the blue housing.
Terminal assignment of PiloTREK 2-WIRE
The polarity of the 4-20 mA connection is arbitrary.
Equipotential bonding
When used in hazardous areas, the PiloTREK 2-WIRE Ex can be incorporated in the PA equipotential bonding system,
e.g. by using the separate U-clamp terminal at the “neck“ of the PiloTREK 2-WIRE Ex.
Rated temperature of connecting cables: see Section 8.
Supply voltage atthe terminals (1,2)
The 4-20 mA supply must be able to provide the following voltage U at the terminals of the PiloTREK 2-WIRE – dependent
on the current I. Please consider also the line resistance and possible loads on the secondary side of the supply unit.
1
2
PE 4-20 mA
current
loop

8 Installation and programming manual PiloTREK 2-wire
4mA 12mA8mA 16mA 20mA
3.6mA 22mA I
U
13V
14V
15V
16V
17V
The allowed upper limit R for load + line resistance is depending on the specification of the power supply unit:
U at 20mA (power supply unit) 14 V 15 V 16 V 17 V 18 V
Max. resistance R 50 Ω100 Ω150 Ω200 Ω250 Ω
7. SETTING THE PARAMETERS
Setting parameters via program PC-CAT
With the program PC-CAT, version 3.01 or higher, you can configurate PiloTREK 2-WIRE instruments in a very comfortable
way from a PC. Connect the non-intrinsically safe side of the isolation amplifier over a load between 120 Ωand 350 Ωto the
HART®adapter and connect it with a serial port of the PC.
The used isolation amplifier must be HART®compatible.
Adapter
≥120 Ω
RS232
isolation
amplifier

Installation and programming manual PiloTREK 2-wire 9
Localdisplay (optional)
(1) Numeric display, measured values
(2) Alphanumeric display, function/unit
(3) 6 Markers to display measurement status
(4) 4 keys for configuration and error interrogation
Function of keys (only together with local display)
Operator control can be carried out with the aid of local display unit after opening the housing. However, a particularly
convenient form of parameter setting is offered by the PC program PC-CAT (special accessories, see above).
→
→→
→
(cursorkey) - selects the configuration menu,
- branches the menu to the next lower level,
- shifts the cursor* to the next column on the right.
↑
↑↑
↑
resp.
↓
↓↓
↓
(select key) - branches the menu to the next digit on the same level,
- changes the content (digit, text character) at the cursor* position.
↵
↵↵
↵
(ENTER key) - branches the menu to the next higher level,
- stores newly entered parameters,
- executes displayed functions,
- selects special functions (e.g. error memory, see Section 5).
* The cursor position is signalled by flashing of the character at the appropriate place.
Meaning of status markers (only for version with local display)
The 6 markers ▼below the local display only show information about the status of measurement and are no error displays!
▼1: No current measured value: The device is searching for a new value. If the search for a plausible level fails for a
certain time, "SIGNAL DOWN" appears as error display.
▼2: Signal too strong: Mean of reflected microwaves is very high. Gain is automatically stepped down.
▼3: Poor spectrum: Brief showing of this marker has no significance. If permanently on, this may result in uncertain
(incorrect) measured values or the error message "NO M.VALUE".
▼4: No measured value as yet: Evaluable measured values not available after the device has been started up.
Measured value automatically set to the level of the tank bottom. This marker disappears when the first valid
measured value is obtained.
▼5: Tank bottom: In tanks with dished bottom, for example, the measuring signal can "disappear" if measurements are
carried out near the bottom. The measured value is then automatically set to the level of the tank bottom.
▼6: Measurement frozen: Device is in the block distance detection (see below).
nivelco
PiloTREK
Level m
9.500
_ _ _ _ _ _
12
3
44
44

10 Installation andprogramming manual PiloTREK 2-wire
Simply scaling the currentoutput
1) Drain the tank completely to the 0% marking (= 4 mA) 1).
2) Press the lower keys (↵and ↓) down, until the asterisks on the
display „TANKHEIGHT********“ are replaced by the actual measured
distance value 2).
3) Then release and press ↵. In the lower line: „SURE NO?“ is
displayed.
4) If this value is not plausible or the tank is not empty, abort
by ↵. Or accept the value by pressing ↑(“SURE YES?”) and then
↵.
5) Now the tank height is set.
6) In the next step you can also enter this value as 4 mA scaling (0%).
Press ↵. In the lower line now: „SURE NO?“ is displayed again.
7) If this value shall not be stored, abort by ↵. Or accept this 4mA
scaling by pressing ↑(“SURE YES?”) and then ↵.
8) Fill the tank to the 100% mark. Use the same procedure for the
100% point = 20 mA only now by pressing the top keys →and ↑1) 2).
9) First the measured distance can be taken as block distance.
After this you can enter or adjust the 20 mA point (100%)
according to the actual level.
1) This example was written for the case: current output = level (default).
For distance measurement the points 0% (short distance = high level) and 100% (large distance = low level)
are exchanged
2) If no reliable measurement is possible „NO ACCESS“ is displayed. Abort by pressing ↵
0%
TANKHEIGHT
1234 mm
↵
TANKHEIGHT
1234 mm
SURE YES? 1.
2.
100%
BLOCKDIST.
567 mm
↵
TANKHEIGHT
1234 mm
SURE NO?
SCALE 4mA
0 mm
SURE NO?
SCALE 4MA
0 mm
SURE YES? 1.
2.
SCALE 4mA
0 mm
↵

Installation and programming manual PiloTREK 2-wire 11
Description of functions
The table on the following 3 pages provides an overview of all parameters that can be set in the configuration menu.
This is followed by more precise explanations of some functions and a typical configuration.
Configuration menu (version 7.10)
FUNCTION (FCT.) INPUT RANGE DESCRIPTION
1.0 OPERATION
1.1 DISPLAY
1.1.1 FCT.DISP identical with 3.2.1
1.1.2 UNIT.LENGTH identical with 3.2.2
1.1.3 UNIT.CONV. identical with 3.2.3
2.0 TEST
2.1 HARDWARE
2.1.1 MASTER Master hardware test.
2.1.2 DISPLAY Display hardware test.
2.1.3 STATUS Status information for Service
2.2 CUR.OUTP.I
2.2.1 VALUE I Value display Display of actual value of the current output.
2.2.2 TEST I Select 3.6 mA/4 mA/6 mA/...
... 20 mA/22 mA
Output of selected value to the current output.
With safety query.
2.4 FIRMWARE
2.4.1 MASTER Display Display of master firmware version.
3.0 INSTALL.
3.1 BASIS.PARAM
3.1.1 TANKHEIGHT Select unit m/cm/mm/inch/Ft
Enter 0.50 ... 20.00 [m]
Enter tank height (see explanatory notes).
The unit entered here is also used for all other
length entries.
3.1.2 BLOCKDIST Enter 0.10 [m] ... tank height Enter block distance = non-measurable range
below bottom edge of flange (see explanatory
notes).
3.1.3 ANTENNA Select STANDARD
WAVE-STICK
Select antenna type. WAVE-STICK for all Wave-
Stick versions, except type "SW" for stillwells.
All other = STANDARD.
3.1.4 ANT.EXTENS. Enter 0.00 [m] ... tank height Enter length of antenna extension
(not for Wave-Stick: set to= 0)
3.1.5 DIST.PIECE Enter 0 ... 2000 [mm] Enter length of distance piece above flange
(high temp. version = 120 mm).
3.1.6 STILLWELL Select NO / YES
If “YES“:
enter 25 ... 200 [mm]
Selection: without or with still well.
With still well: enter inside diameter in [mm]
(compensates different wave speeds in still
wells)
3.1.7 REF.OFFSET Enter -10.00...0...+10.00 [m] Reference offset is added to measured distance
values.
3.1.8 TB.OFFSET Enter -100.00...0...+100.00 [m] Tank bottom offset is added to measured level
values.

12 Installation andprogramming manual PiloTREK 2-wire
3.2 DISPLAY
3.2.1 FCT.DISP Select LEVEL
DISTANCE
CONVERSION
Select function of display (value to be
displayed). See also explanatory notes.
3.2.2 UNIT.LENGTH Select m/cm/mm/inch/Ft/
PERCENT/BARGRAPH
Select unit for length value to be displayed (only
for level and distance).
3.2.3 UNIT.CONV. Select m3/l(Liter)/US Gal/ GB Gal/
Ft3/bbl/PERCENT/
BARGRAPH/USER UNIT
Select unit for conversion value to be displayed
(“volume table“).
(see explanatory notes)
3.2.4 USER UNIT Text entry 10 characters Enter user-defined unit for the conversion table.
3.2.5 ERROR MSG. Select NO/YES Select whether error messages to be shown in
display.
3.3 SIGNAL OUT
3.3.1 FUNCTION I Select OFF/LEVEL/DISTANCE/
CONVERSION/SW.OUTP.
Select function of the current output.
3.3.2 RANGE I Select 3.8-20.5mA/E3.6
3.8-20.5mA/E22
4-20mA
4-20mA/E3.6
4-20mA/E22
Select range/error status for the current output
(hold last value or 3.6 mA/22mA in error status)
3.3.3 SCALE 4mA Enter -200.00 ... +200.00 [m]
0.00 ... 99999.99 [m3]
Enter lower measuring range value for the
current output (4 mA).
(see explanatory notes)
3.3.4 SCALE 20mA Enter -200.00 ... +200.00 [m]
0.00 ... 99999.99 [m3]
Enter full-scale range value for the current
output (20 mA).
(see explanatory notes)
3.3.5 BAUDRATE Select 200 Bd Baud rate for HART®communication (do not
change!).
3.3.6 ADDRESS Enter 0... 255 Enter device address.
(for HART®multidrop)
3.3.7 PROTOCOL Select HART/KROHNE-PC Select communications protocol
3.4 USER DATA
3.4.1 LANGUAGE Select GB-USA/D/F/I/E/P/S Select language for the optional display.
3.4.2 ENTRY CODE 1 Select NO/YES Switch the access lockout on/off.
If YES, for every access a 9-digit entry code on
the 4 keys is necessary.
3.4.3 CODE 1 Enter code (RRREEEUUU) Enter the entry code for access lockout.
3.4.4 LOCATION Enter text (8 characters) Enter a device identifier.

Installation and programming manual PiloTREK 2-wire 13
3.5 APPLICAT.
3.5.1 AUTO TANKH. Special function Automatic determination of tank height
(see explanatory notes).
3.5.2 EMPTY.SPEC. Select OFF/ON/RECORD Recording the profile of the empty tank (empty-
tank spectrum)
(see explanatory notes).
3.5.3 TIMECONST. Value 1...10...100 [s] Enter time constant for measured-value filtering
3.5.4 TRACING.VEL. Value 0.01...0.50...10.00 [m/Min] Enter the maximum rate of change in level that
can occur in operation.
3.5.5 MULT.REFL. Select NO/YES Switch the multi-reflection identifier on/off.
3.5.6 BD-DETECT. Select NO/YES Switch the block distance (overfill) identifier
on/off
(see explanatory notes).
3.5.7 FUNCT. FTB Select OFF/PARTIAL Select function of tank bottom tracing system
(see explanatory notes).
3.5.8 EPSILON R Enter 1.1000 ... 8.0000 Enter relative permittivity of product
(only for Fct. 3.5.7)
3.5.9 TANKTYPE Select STORAGE T./PROC TANK Select tank type.
STORAGE T. = smooth product surface
PROC TANK = slightly disturbed product surface
The default settings are marked in the table bold.
Explanatory notes
Tank height
The tank height (Fct. 3.1.1) for the PiloTREK 2-WIRE is defined as the distance between the top edge of the tank connecting
flange and the bottom reference point. The bottom reference point is that “point“ in the tank on which the microwaves of the
PiloTREK 2-WIRE hit and from which they are reflected. This may be the tank bottom (symmetrical tank with flat bottom) or
the non-horizontal part of the bottom (e.g. tank with dished bottom) or an additionally fitted plate. The PiloTREK 2-WIRE
cannot measure below this point (“sump“ in the tank).
Note: When the tank is completely empty and the tank bottom provides good reflections (flat, not dished bottom!), the tank
height can also be automatically determined with the aid of Function Fct. 3.5.1 AUTO TANKH. Before confirming, check
carefully that the proposed tank height is plausible!
Block distance
The “block distance“ function (Fct. 3.1.2) defines a zone below the top reference point in which measurements are not meant
to take place. The value should be at least 10 - 20 cm greater than the length of antenna+antenna extension, or at least 20
cm in the case of the Wave-Stick.
Signals within the block distance are suppressed; a rise in the tank filling above this limit (response threshold) will lead to a
measuring result corresponding to a distance = block distance, when Fct. 3.5.6 BD-DETECT. is switched on.
Scaling of the current output
The scaling of the current output (Fct. 3.3.3: level 1 = 4 mA ; Fct. 3.3.4: level 2 = 20 mA) should if possible lie within the
measuring range (between bottom reference point and response threshold).
By pressing the two upper keys (→and ↑) or the two lower keys (↵and ↓) at the same time, the 0% setting (= 4 mA) or
100% setting (= 20 mA) can be programmed according to the actual level (see page 9).

14 Installation andprogramming manual PiloTREK 2-wire
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+Sump
non
measurable
zone
tank height
(Fct. 3.1.1)
Fct. 3.1.4
upper reference point
(top edge of tank connecting flange)
block distance (Fct. 3.1.2)
response
current output
20
mA max
(Fct. 3.3.4)
4min
(Fct. 3.3.3)
lower reference point
(tank bottom / datum point)
Fct. 3.1.5
threshold
measuring
mA
[e.g.: 5.30 m]
[e.g.: 0]
[e.g.: 0]
[e.g.: 0.6 m]
[e.g.: 0.4 m]
[e.g.: 4.0 m]
range
Empty-tank spectrum
To enable the PiloTREK 2-WIRE to identify and blank out interference signals, e.g. caused by fixed and moving tank
internals, the tank profile (empty-tank spectrum) needs to be recorded once only prior to (initial) start-up.
For recording, the tank should be completely empty and all moving parts (e.g. agitators) switched on. If major interference
through internals is not expected, recording of the empty-tank spectrum can also be dispensed with, since the factory has
already carried out and stored a partial empty spectrum of the flange system.
Empty-tank spectrum recording via display
After selecting menu item Fct. 3.5.2, press key →
→→
→. The display then shows whether the empty spectrum is currently ON or
OFF. Then press the ↵
↵↵
↵key if no change is to be made, or use the ↑
↑↑
↑key to choose between the following options:
ON: the empty-tank spectrum is (again) switched on and taken into account for measurements.
OFF: the empty-tank spectrum is not taken into account for measurements, but remains stored in the
PiloTREK 2-WIRE and can be switched on again at a later date.
RECORD: the existing empty-tank spectrum is to be deleted and a new one recorded.
After selecting "RECORD": if other parameters had previously been changed, the query "ACCEPT YES" is first made as to
whether they are to be stored. In this case, confirm by pressing ↵
↵↵
↵. To record, use the ↑
↑↑
↑key to select one of the following
options:
MAX. VALUES: (only maximum values are taken into account when the empty-tank spectrum is recorded; useful e.g.
with “difficult“ agitators).
AVERAGE: (values are averaged; this setting can be used for most applications).
After selecting with the ↑
↑↑
↑key, press the ↵key to select TOTAL or the ↑
↑↑
↑key to select PARTIAL.
When TOTAL is selected, the empty-tank spectrum is recorded over the entire range (tank height).
If the tank has not been fully drained, the empty-tank spectrum can also be recorded up to a certain distance, in which
case the menu item PARTIAL should be selected. When this has been selected, a query takes place by way of the ↵
key concerning the distance value up to which the empty-tank spectrum is to be recorded. The tank area below the

Installation and programming manual PiloTREK 2-wire 15
current filling level is then excluded from the empty-tank recording. It is recommended to maintain a safety distance of
20 to 30 cm from the actual product distance.
Subsequently press key ↵to start recording the empty-tank spectrum. The display starts with “200“ and counts down to “0“.
The sign WAIT... is shown in the display. READY appears after approx. 1-3 minutes. Then press key ↵five times to store
the recorded empty-tank spectrum, which is taken into account for measurements.
Empty-tank spectrum recording via PC-CAT
Connect the PiloTREK 2-WIRE and press in the display mode of PC-CAT the key combination Ctrl-L. The type of empty-tank
spectrum can be selected by one of the following keys:
1: Max.Values 4: Max. Partial A: Break
2: Average 5: Avg. Partial
Tank bottom tracing mode (FTB)
The PiloTREK 2-WIRE includes an additional function for measuring reliably low levels in tanks with flat bottom and poorly
reflecting products (low dielectric constant). This tank bottom tracing system (abbreviated FTB) is activated in the vicinity of
the tank bottom (max. 20% level). Given higher levels, the normal measuring method is used (reflection from the product
surface).
If the measurement jumps to the correct level only after filling above a certain level (approx. 0.3-1.0 m), you can activate the
FTB function Fct. 3.5.7 „PARTIAL“. The relative permittivity εrof the tank product must be set in Fct. 3.5.8. If it is not known,
enter the figure of 2.0. Since the exact position of the tank bottom must be known for this process, it is advisable when using
the FTB to determine the tank height automatically with an empty tank, using Fct. 3.5.1.
Conversion table/Volume table
A table consisting of a maximum of 50 points can be stored in the PiloTREK 2-WIRE for non-linear or linear conversion of the
level, e.g. into a volumetric value. This table, however, can only be programmed with the PC-CAT program (Fct. 3.7.2).

16 Installation andprogramming manual PiloTREK 2-wire
Sequence for setting parameters (example) (for version with local display)
The following description refers to a storage tank with the parameter examples taken from the illustration in this Section.
If the device no longer contains the default parameters, the keystroke combination for entering the numerical values may
differ.
ACTIVITY KEYS TO BE
ACTUATE
D
CONTENT OF PILOTREK 2-WIRE
DISPLAY
Entry into configuration menu →
→→
→Fct. 1.0
OPERATION
Setting the parameter: tank height ↑
↑↑
↑
↑ ↑↑
↑
→ →→
→
→ →→
→Fct. 3.1.1
TANKHEIGHT
Display of default value →
→→
→10.000 m
Input of tank height "5.30 m" →↓
→↓→↓
→↓
→ →→
→
5x↑ ↑↑
↑
→ →→
→
3x
↑
↑↑
↑
05.300 m
Confirm tank height and move to block distance ↵
↵↵
↵
↑ ↑↑
↑
Fct. 3.1.2
BLOCKDIST
Display default value →
→→
→0.5000 m
Enter block distance "0.60 m" →
→→
→
↑ ↑↑
↑0.6000 m
Confirm block distance and move to current output configuration ↵
↵↵
↵
↵ ↵↵
↵ ↑
↑↑
↑
↑ ↑↑
↑Fct. 3.3
SIGNAL OUT
Move to lower range value →
→→
→
↑ ↑↑
↑
↑ ↑↑
↑Fct. 3.3.3
SCALE 4 mA
Display default value →
→→
→+ 00.000 m
Enter lower range value (0.4 m = 4 mA) 3x
→ →→
→
4x↑ ↑↑
↑
+ 00.400 m
Confirm lower range value and move to full-scale range value ↵
↵↵
↵ ↑
↑↑
↑Fct. 3.3.4
SCALE 20mA
Display of default value →
→→
→010.00 m
Enter full-scale value (4.0 m = 20 mA) 2x→
→→
→
↓ ↓↓
↓
→ →→
→
4x↑ ↑↑
↑004.00 m
Confirm full-scale value and move to empty tank spectrum ↵
↵↵
↵
↵ ↵↵
↵
↑ ↑↑
↑
↑ ↑↑
↑
→ →→
→
↑ ↑↑
↑Fct. 3.5.2
EMPTY.SPEC.
Select: re-record empty spectrum →
→→
→ ↑
↑↑
↑
↑ ↑↑
↑RECORD
Store changed parameters ↵
↵↵
↵ACCEPT. YES
Confirm and select: averaging ↵
↵↵
↵ ↑
↑↑
↑
AVERAGE
Confirm and start recording; then wait for approx. 1-3 minutes! ↵
↵↵
↵
↵ ↵↵
↵READY
Confirm and move to tank type ↵
↵↵
↵
7x↑ ↑↑
↑Fct. 3.5.9
TANK TYPE
Display of default value →
→→
→PROC TANK
Select tank type "storage tank" ↑
↑↑
↑
↑ ↑↑
↑STORAGE T.
Return to measurement function with confirmation of changed
parameters 5x↵
↵↵
↵PARAM.CHECK,
then START,
then meas.val. display

Installation and programming manual PiloTREK 2-wire 17
8. MAINTENANCE, ERROR HANDLING
Replacement of the signal converter
Before commencing, note the parameters of the PiloTREK 2-WIRE and switch off the power supply!
1. Disconnect all cables from the terminals in the terminal compartment.
2. Remove the 4 Allen screws M (Allen key size 5 mm) and lift off the signal converter. The flange unit (incl. Wave-guide
window) will remain tight even with pressurized tanks.
Caution
On pressurized tanks, do not on any account remove the 4 screws H connecting the waveguide window to
the PiloTREK 2-WIRE flange! DANGER!
3. Fit the new PiloTREK 2-WIRE converter.
4. Reconnect all cables in the terminal compartment, as
described in Section 3.
5. Check against the enclosed report on settings whether the
factory-set parameters are correct for your application.
If not, reset.
6. Record the empty spectrum,
see Section 4. distance piece
(for hightemperature
version up to 250°C (482°F)
O-ring
BM70
connecting flange
signal converter
M
H
Returning a PiloTREK 2-WIRE
The party returning a device is obligated to check and ensure that all cavities in the device are free from dangerous
substances (toxic, caustic, flammable, water-endangering), and that a certificate is enclosed with the device confirming that it
is safe to handle.
Error display during measurement (only for versions with local display)
When function 3.2.5 "ERROR. MSG." is set to YES, any error occurring during measurement is indicated in the display and
alternates with the measured value for as long as the error is present.
In addition, all errors are stored. Press the keystroke combination ↵↑→→to get into the error list. You can page through
the list with key →, and acknowledge the errors at the end - if required - by "QUIT YES". Press key ↵twice to return to the
measuring mode.
Fatal errors (FATAL ERROR), that are detected when the device is started up, render operation of the PiloTREK 2-WIRE
impossible.

18 Installation andprogramming manual PiloTREK 2-wire
9. SAFETY INFORMATION
Hazardous-duty systems
Types ofprotection in the PiloTREK 2-WIRE terminal compartment:
Intrinsically safe "ia"
Consult the relevant wiring and installation regulations, e.g. VDE 0165, before mounting, dismantling or making
electrical connections in a hazardous area
Temperature rating of connecting cables:
The temperature rating of connecting cables is dependent on the maximum temperature of the flange:
VERSION MAX. FLANGE TEMPERATURE CABLE TEMPERATURE RATING
Without high temperature ≤100°C (212°F) 70°C (158°F)
distance piece > 100°C (212°F) 80°C (176°F)
With high temperature ≤200°C (212°F) 70°C (158°F)
distance piece > 200°C (212°F) 80°C (176°F)
Temperature limits atthe flange:
Version Minimal flange temperature Maximum flange temperature
(4)(7)
positions
of the
marking code
Sealing
material
Standard version Special version
with marking
„2.4610“ at the
Metaglas ring
Without
high temperature
distance piece
With
high temperature
distance piece
V4 Kalrez™ 2035 - 20°C (-4°F) ––– + 130°C (266°F) + 210°C (410°F)
V2 Kalrez™ 4079 - 20°C (-4°F) ––– + 130°C (266°F) + 250°C (482°F)
V7 Kalrez™ 6230 - 20°C (-4°F) ––– + 130°C (266°F) + 250°C (482°F)
V6 Kalrez™ 6375 - 20°C (-4°F) ––– + 130°C (266°F) + 250°C (482°F)
V1 Viton™ - 20°C (-4°F) ––– + 130°C (266°F) + 200°C (392°F)
V3 FEP-coated Viton™ - 15°C (5°F) ––– + 130°C (266°F) + 200°C (392°F)
V8 FEP-coated Silicone - 30°C (-22°F) - 60°C (-76°F) + 130°C (266°F) + 200°C (392°F)
W1 PTFE - 20°C (-4°F) ––– + 130°C (266°F) + 150°C (302°F)
W2 Kalrez™ 6375 - 20°C (-4°F) ––– + 130°C (266°F) + 150°C (302°F)
W3 Viton™ - 20°C (-4°F) ––– + 100°C (212°F) + 100°C (212°F)
L Kalrez™ 6375 - 20°C (-4°F) ––– + 130°C (266°F) –––

Installation and programming manual PiloTREK 2-wire 19
10. TECHNICAL DATA
Tank height (measuring range) 0.5 to 20 m / 1.6 to 65.6 ft
Measuring accuracy (distance) from 1m/3ft: + 1cm/0.4” ; from 5m/16ft: + 0.2%
Measured-value resolution 1 mm / 0.04”
Rate of change in level (tracking speed) max. 10 m/min / 32.8 ft/min
Connecting flanges
Horn antenna / Wave-Guide DIN 2501 DN 50 to DN 200 / PN 6 to PN 64 and higher;
Form C to DIN 2526 or others
ANSI B16.5 2” to 8", Class 150 lb or 300 lb, RF
Wave-Stick DN 50...150 or ANSI 2”...6”, dairy DIN 11851
DN 50/65/80 Tri-Clamp 2/3/4”,
SMS 51/63/76 mm, G 1½"
Max. allowable operating pressure -1 bar (vacuum) to 64 bar / 928 psig higher on request, depending on version
and flange pressure rating.
L flange system
with horn antenna, Wave-Guide or
Wave-Stick without flange plate -1 bar (vacuum) to +2 bar /29 psig
V flange system
with horn antenna or Wave-Guide:
Flange rated pressure
Connection:
nominal diameter PN 16 PN 25 PN 40 PN 64
DN Inches bar psig Bar psig bar psig bar psig
80 3 16 232 - - 40 580 64 928
100 4 16 232 - - 38 551 55 797
150 6 16 232 - - 34 493 47 681
200 8 16 232 25 362 32 464 45 652
Wave-Stick: max. 16 bar / 232 psig, temperature-dependent according to the diagram:
-20 +150+100
-1
+1
+16 46 - 0.3·T[°C] bar
temperature T
pressure
+232
[psig] [bar]
+14
-14
+212 +302°F
745 - 2.42·T[°F] psig

20 Installation andprogramming manual PiloTREK 2-wire
Operating temperature at flange L flange system: -20°C (-4°F) to +130°C (302°F)
(see also Chapter 10) V flange system:
Basic version: -20°C (-4°F) to +130°C (266°F)
Special version: min. -60°C (-76°F)
High temperature version, FFKM (Kalrez 4079): max. +250°C (482°F)
FFKM (Kalrez 6375): max. +250°C (482°F)
FFKM (Kalrez 2035): max. +210°C (410°F)
FPM (Viton) or FEP-coated: max. +200°C (392°F)
PTFE Wave-Stick: -20°C (-4°F) to +150°C (302°F), pressure dependent
PP Wave-Stick: -20°C (-4°F)to +100°C (212°F)
Product temperature Unrestricted, provided ambient temperature and flange temperature
are within the specified limits.
Ambient temperature Signal converter (Tamb): -20°C (-4°F) to +55°C (131°F)
Microwaves
Measuring principle FMCW Radar
Frequency range X-Band 8.5 - 9.9 GHz
Antenna radiation angle Horn diameter D=140 mm: ± 8°
Horn diameter D=200 mm: ± 6°
Wave-Stick: ± 9°
Ex-i current output HART®(passive)
Current 4 - 20 mA; without or with error message 3.6 mA or 22 mA
or 3.8-20.5 mA according to NAMUR NE43
Firmware version 7.12 and higher
Accuracy and linearity 0.15 %; TC=100 ppm/K
Clamp voltage > 17V (I = 4 mA); > 13V (I = 20 mA)
Digital communication HART®
Ambient conditions
Environment class Locations exposed direct to open-air climate,
D1 Severity in conformity with EN 60654-1
Protection category (converter) IP66 / IP67 (equivalent to NEMA 4 and 4X)
Electrical connection
Cable entries: 1 x M20×1.5
(delivered with 1 pc of cable gland M20x1,5 or
QUICKON®2-pole cutter clamp)
Terminals: Cable cross-section 0.5-1.5 mm² (AWG 20-16)
U-clamp terminals (for PA and FE) cable cross-section max. 4 mm² (AWG 12)