NIVELCO PiloTREK W-200 Owner's manual

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TABLE OF CONTENTS
1.INTRODUCTION........................................................................................... 5
2.ORDER CODES............................................................................................ 6
3.TECHNICAL DATA....................................................................................... 7
3.1.General Data ...............................................................................................................7
3.2.Type-dependent data ..................................................................................................7
3.3.Dimensions..................................................................................................................8
3.4.Accessories .................................................................................................................9
3.5.Conditions of safe operation .......................................................................................9
3.6.Repair, maintenance, and storage conditions ............................................................9
3.7.Firmware update .......................................................................................................10
4.INSTALLATION .......................................................................................... 10
4.1.Level measurement...................................................................................................10
4.2.Flow measurement....................................................................................................12
4.3.Wiring ........................................................................................................................12
4.4.User interfaces ..........................................................................................................13
4.5.BUS (HART®) communication...................................................................................13
4.6.Commissioning and setting up..................................................................................14
5.PROGRAMMING ........................................................................................ 15
5.1.Programming via EView2..........................................................................................15
5.2.Configuring the measurement...................................................................................16
5.3.Current loop output....................................................................................................22
5.4.Relay output (optional)..............................................................................................24
5.5.Digital communication...............................................................................................26
5.6.Measurement optimization ........................................................................................26
5.7.Volume measurement...............................................................................................30
5.8.Open-channel flow measurement .............................................................................32
5.9.Output Conversion Table (OCT) programming........................................................ 38
5.10.Service diagnostic parameters (read only)............................................................. 40
5.11.Flow measurement control parameters (read only) ............................................... 40
5.12.Output control parameters (read only) ................................................................... 40
5.13.Hardware / Software versions (read only).............................................................. 40
6.TROUBLESHOOTING................................................................................ 41
6.1.Status and error indication in HART communication ............................................... 41
7.EView2 INSTRUCTIONS............................................................................ 43
7.1.Device Status Window.............................................................................................. 43
7.2.Echo Diagram oscilloscope function ........................................................................ 43
7.3.Threshold settings .................................................................................................... 43
7.4.Threshold mask ........................................................................................................ 44
7.5.The output conversion table (OCT) – (EView2 OC-Table) ...................................... 45
7.6.Programming example 1 – configuring level measurement (using EView2) ........... 47
7.7.Programming example 2 – configuring the current loop output (using EView2)...... 48
8.PARAMETER LIST..................................................................................... 49

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Thank you for choosing a NIVELCO instrument!
1. INTRODUCTION
Application
The new PiloTREK W–200 non-contact radar level transmitters use the most advanced industrial measurement technology, the 80 GHz FMCW radar. The most
fundamental advantage of 80 GHz radars compared to lower frequencies (5…12 GHz and 25 GHz) is the smaller antenna size, better focusability, and narrow
beam angle.
It uses the latest technology for measuring liquids, masses, emulsions, and other chemicals widely used in, for example, the water industry, food industry, energy
industry, pharmaceutical industry, and chemical industry, which provides measurement results with millimeter accuracy.
It can also measure materials prone to vapor formation and liquids with a gas blanket. Since the propagation of millimeter waves does not require a medium, it
can also be used in a vacuum.
The device is HART®compatible and can be operated with EView2, PACTware, and MultiCONT universal process controller.
Operating Principle
The PiloTREK W–200 level transmitter is a frequency modulated continuous wave (FMCW) radar operating at 80 GHz (W-band).
Depending on the measured medium, part of the energy of the frequency-modulated wave emitted by the antenna of the level transmitter is reflected from the
measured surface.
The electronics module calculates the distance of the reflecting surface from the frequency shift proportional to the flight time of the reflected signal with high
accuracy and converts it into a signal proportional to distance, level, or volume. The propagation speed of the millimeter-wave signal in air, gases, and vacuum is
virtually the same regardless of temperature and pressure, so these factors do not significantly affect the accuracy of the measurement.
The signal strength of the reflected millimeter waves depends largely on the measured medium's dielectric constant (εr). Therefore, the maximum measuring
distance achieved may decrease accordingly. Choosing an antenna with a larger diameter, thus higher gain, is recommended for measuring mediums with a low
dielectric constant.

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2. ORDER CODES (NOT ALL COMBINATIONS ARE AVAILABLE)
V
PiloTREK
W
P
–
2
–
Antenna / housing material
Code
Measurement range
Code
Process connection – lower / upper
Code
Output
Code
PP / PP
A
10 m
1
1″BSP / 1″BSP (1)
2
4…20 mA / HART®
4
PVDF / PVDF
B
20 m
2
1″NPT / 1″BSP (1)
3
4…20 mA + HART®+ relay
H
30 m
3
1½″BSP / 1″BSP (2)
4
1½″NPT / 1″BSP (2)
5
(1)
Only for 10 m (33 ft) measuring range
(2) Only for 10 m or 20 m (33 ft or 66 ft) measuring range

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3. TECHNICAL DATA
3.1. General Data
3.2. Type-dependent data
1" / 10 m (33 ft) measuring range
WP

–212–

/ WP

–213–

1½" / 10 m (33 ft) measuring range
WP

–214–

/ WP

–215–

1½" / 20 m (66 ft) measuring range
WP

–224–

/ WP

–225–

Sensor material
PP, PVDF
Dead zone
(1)
0 m (0 ft)
Maximum measuring range
(2)
10 m (33 ft)
20 m (66 ft)
Accuracy
(3)
±5 mm (±0.2")
±2 mm (±0.08")
Beam angle (–3 dB)
12°
7°
Antenna insertion length (4)
56 mm (2.2")
70 mm (2.75")
Lower process connection
1″ BSP / NPT
1½″ BSP / NPT
Upper process connection
1″ BSP
(1) Measured from the tip of the antenna. (2) May be limited in the case of low dielectric constant or non-perpendicular or non-planar media.
(3) In the case of an ideal reflecting surface. (4) Measured from the sealing plane of the process connection.
Measured and calculated values
Distance; calculated values: level, volume, mass, flow
Signal frequency
77…81 GHz (W-band)
Process /ambient temperature
–40…+80 °C (–40…+176 °F)
Measuring frequency
~ 1 s
Resolution
1 mm (.039")
Process pressure
–1…3 bar (–14.5…43.5 psi)
Supply voltage
12…36 V DC
Output
Analog
4…20 mA; (3.9…20.5 mA); RLmax =(US– 12 V) / 0.02A
Digital
HART
®
interface, loop resistance ≥250 Ω
Relay (optional)
SPDT 30 V / 1 A DC; 48 V / 0.5 A AC
Service interface
SAT−504−3 compatible; galvanically isolated; 3.3 V LVDS; max. 100 mA
Seal
EPDM
Electrical protection
Class I overvoltage protection; (Class III [SELV])
Ingress protection
IP68
Electrical connection
4× 0.5 mm2shielded Ø6 mm cable × 5 m (up to 30 m);
(4× AWG22 shielded Ø0.24" cable × 16.4 ft [up to 98.5 ft]);
For relay option: 7× 0.5 mm
2
(AWG22) shielded cable

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Linearity error
Legend:
WP

–212–

/ WP

–213–

/ WP

–214–

/ WP

–215–

WP

–224–

/ WP

–225–

A. Plane of the device’s process connection
B. The minimum measuring distance (Xm), below which the radar cannot
measure, due to the insertion length of the antenna
C. Maximum measuring distance (XM)
3.3. Dimensions
1" integrated version with plastic housing
WP

–212–

/ WP

–213–

1½" integrated version with plastic housing
WP

–21

–

/ WP

–22

–


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3.4. Accessories
–Warranty card
–User and programming manual
–EU Declaration of Conformity
–2× flat nuts for the upper 1″ BSP thread
–1× O-ring
3.5. Conditions of safe operation
Compliance with technological process conditions
Make sure that all parts of the equipment that come into contact with the measured medium (sensor, seal, and fittings) meet the requirements of the process, such
as the pressure and temperature generated during the process, as well as the chemical effects of the medium and the technologies used.
3.6. Repair, maintenance, and storage conditions
The PiloTREK W–200 does not require regular maintenance. However, there may be cases where the sensor head needs to be cleaned of material deposits.
Clean the device carefully, without scratching or pressing the radiating surface.
All repairs, whether covered by warranty or not, must be carried out by NIVELCO.
The device returned for repair must be cleaned by the user, all chemical deposits must be removed, and the device must be disinfected before sending it back! In
addition, the return package must include a properly filled Returned Equipment Handling Form (B0407/C, download it from our website), in which the sender
declares that the device is free of all contamination and substances hazardous to health.
If the device is not used, store it within the ambient temperature specified in the technical data, with a maximum humidity of 98%.
The cable extending from the device must be fixed and relieved of any tension!
Use a junction box corresponding to the electrical classification of the environment to connect the wires!
The device may only be powered from a Category 2 (SELV/PELV) power supply unit!

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3.7. Firmware update
NIVELCO continuously maintains and improves the device's firmware, considering user feedback. If necessary, the firmware of the device can be updated using
the built-in program update communication port.
Contact the manufacturer about NiFlash Light that is required for the update!
4. INSTALLATION
4.1. Level measurement
LOCATION
The optimal location of the
PiloTREK (cylindrical
container) is on the radius r = (0.3…0.5). In any case,
it is advisable to consider the radiation cone angle.
The surface of the liquid must be perpendicular to the
axis of the device.
Never place the device near the inlet. Improper
placement may cause malfunctions.
OBSTACLES
Objects (cooling pipe, ladder, stiffening structural
element, thermometer, etc.) intruding into the beam
must be avoided.
Up to 4 interfering echoes can be blocked by
programming in the PiloTREK W–200
threshold settings!
DEVICE ANGLE
The radiating surface of the sensor must be parallel
to the measured surface within a deviation of
±2...3°.

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GAS / VAPOR
In a closed (especially outdoor, exposed to sunlight) container,
vapors/gases above the liquid can reduce the penetrating ability of
the millimeter-wave signal.
EMPTY CONTAINER
Especially in the case of tanks with a convex or conical bottom,
or in the case of tanks with equipment (e.g., heating element,
mixing paddle) at the bottom of the tank, the device may
indicate an incorrect level when completely emptied.
The reason for this is that the tank bottom or the objects
located at the bottom of the tank scatter and reflect the emitted
millimeter waves to a certain extent, and the scattered
radiation of a lower signal level in the tank can interfere with
itself.
These interfering objects and a convex or conical tank bottom
must be covered by at least 100 mm (3.9″) of the liquid for a
reliable measurement.
TEMPERATURE
The sensor must be protected
from direct sunlight to avoid
the temperatures higher than
permitted.
FOAM
Foam on the measured surface may defeat the millimeter-wave
level measurement. Therefore, if possible, the sensor must be
installed in a place under which foam formation is the least.

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4.2. Flow measurement
–The device can measure flow in open channels with the flumes described in Chapter 5.8.
–The sensor must be placed as close to the surface as the maximum measured level and the dead zone of the sensor allow.
–The sensor must be placed in the longitudinal axis of the flume, at a location determined by the characteristics of the flume. This point is marked on the
Parshall flumes sold by NIVELCO.
–Foam may form on top of the flowing liquid, which may compromise the measurement. Therefore, the liquid’s surface opposite the sensor face must be
exposed for a suitable echo.
–The sensor must be fixed so that its position cannot change.
–The proper construction of the section before and after the measuring channel is extremely important for an accurate measurement.
–The measurement accuracy based on volume flow change depends on the size and shape of the flume (channel, valve) used and the surface of the
flowing liquid (rippling, foaming). Therefore, flow measurement accuracy inevitably falls short of level measurement accuracy.
–The sensor must be protected from direct sunlight with a shielding roof to avoid temperatures higher than permitted.
4.3. Wiring
……
–Check that the terminals of the already installed terminal box are not energized.
–
Connect the wires of the device according to the diagram. Pay attention to the
polarity: (+) brown, (–) white. (For cabling, it is recommended to use 2× 0.5 mm2
(2× 20AWG) twisted-pair shielded cable or 5× 0.5 mm2(5× 20AWG) for the optional
relay).
–When connecting the shielding, make sure that there is no ground loop.
–After the device is powered on, the necessary programming can be carried out.
Color coding of terminals
pink – C1 relay output white – ICurrent loop, supply voltage, and HART terminal 1
(polarity-independent)
gray – CC relay output brown – ICurrent loop, supply voltage, and HART terminal 2
(polarity-independent)
blue – C2 relay output black – GND Technical ground and shielding point
Extending the cable:
It is recommended to use a terminal box to extend the cable.
The shielding must be connected to the shielding of the extension
cable and grounded at the processing device.
The green and
yellow wires are the connection points of the
"Service interface" (see next chapter). They are not required for
using the device. They are covered with a shrink tube at the cable
end by default.

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4.4. User interfaces
The device can be set (programmed) using the following tools
MultiCONT universal process controller
Available for purchase.
HART®USB modem SAT–504–0, –1, –2
Available for purchase. See “5.1. Programming with EView2”
HART®USB modem SAT–504–3, –4
Available for purchase. See “5.1. Programming with EView2” The firmware of the device can be updated with
NiFlash via the service interface. See "3.7. Updating the firmware”
EView2 software
Download it free of charge here: https://nivelco.com/download#!/software/56
4.5. BUS (HART®) communication
The output of the device can be used as:
–Current loop output and HART®
–Multidrop, HART®protocol
The EView2 program and the MultiCONT universal process controller support the both modes. In accordance with the Rosemount Standard, HART®
communication can be used between the PiloTREK as a “slave” and the HART®“master” as a point-to-point connection.
Communication can be implemented in two modes:
If the device is set to current transmission (4…20 mA, “0” HART®short
address) only one device can be used in the HART®communication loop.
In the case of a multidrop operation (4 mA), several devices (maximum 15)
can be connected in a HART®communication loop. The short address of
the device must be other than 0.

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4.6. Commissioning and setting up
When the device is connected correctly, the radar starts up with a current consumption of 3.5 mA after switching on the power supply. After 3...5 s, the ECHO and
the COM LED light up together. After another 5...10 s, the transmitted current corresponding to the operating mode appears on the current output. In this case,
the device measures with factory settings. The factory default settings are suitable for checking functionality and using the device for simple measurement tasks,
but the device's full potential can only be used with the correct programming tailored to the requirements of the measured process. Therefore, to get to know the
operational characteristics thoroughly and solve complex measuring tasks, it is necessary to study the chapters about programming.
LED states:
•ECHO-LED
–ON, if the device receives a suitable echo.
–BLINKS when the device is searching for an echo.
•COM-LED
–FLASHES UP ONCE if there has been a HART message exchange,
– ON, if the device is in remote programming mode.
– BLINKS for 4 seconds after the device is switched on: service communication
connection can be established during this time. If it continues to blink, it indicates a
firmware error.
•RELAY LED (optional)
–ON, when CC-C2 is conducting.
–OFF, when CC-C1 is conducting.
All parameters of the device have a factory default value, which can be restored later if necessary.
The factory settings of the PiloTREK W−200 level measuring device are as follows
–Measurement mode: level (LEV).
–Zero level is assigned to the maximum measuring distance.
–The current loop output is directly proportional to the level.
–4 mA and 0% are assigned to zero level.
–20 mA and 100% are assigned to the maximum level (minimum measuring distance).
–The current loop output holds the last value in case of an error.
–Level-following time constant: 10 s.

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Status signals involving two LEDs:
ECHO LED
COM LED
Number of blinks
Status
Source -bit- (See 6.1.)
Blinking alternatingly
continuous
Low loop voltage
Bit15, Bit14, Bit11 present at the same time
Flashing at the same time,
then pause, and repeat
2
OCT integrity error
Bit3 or Bit4 or Bit5
3
Not in use
-
4
Relay error
Bit13
5
Not in use
-
6
NV memory error (EEPROM)
Bit1
continuous
•HRP detection failure
•SIM detection failure
Bit12
5. PROGRAMMING
The HART interface of the PiloTREK W−200 lets the user to access and program all device parameters. The parameter set can be accessed in two ways:
–Using a HART modem connected to the sensing resistor in the current loop and the EView2 (see Chapter 7. EView2 instructions) program running on
the computer.
–Using NIVELCO’s MultiCONT multi-channel process controller.
These methods differ in many aspects. This programming guide only discusses the method involving EView2.
For detailed information, refer to the descriptions of the particular access methods or the user manuals.
Some rarely used parameters cannot be set directly from the graphical interface. Instead, they can be changed referring to the parameter number at the
following path.
EView2 parameter: “Device Settings” →“Advanced Mode” →“Parameters”
5.1. Programming via EView2
If necessary, install the “EView2 HART configuration software” (henceforth referred to as EView2) according to Chapter 3 in the program's user manual.
The software can be downloaded from nivelco.com.
Electrical connections: connect the transmitter to the PC using a HART USB modem (accessory supplied separately). Wiring is detailed in Chapter 5.
Further description and setup examples for using EView2 can be found in Chapter 7.

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5.2. Configuring the measurement
P00: d c b a Unit system, default unit FACTORY DEFAULT: 0000
If parameter P00 is changed, the device reverts the entire parameter set to the factory default values according to the new unit system.
Therefore, all parameters must be set again!
a
Mode
0
Normal
EView2 parameter:“Device Settings” →“Application” →“Operating mode”
b
Unit
(per “c”)
Metric (EU)
Imperial (US)
0
m
ft
1
cm
inch
2
mm
inch
EView2 parameter:“Device Settings” →“Application” →“Engineering units”
c
Unit system
0
Metric (EU)
1
Imperial (US)
EView2 parameter:“Device Settings” →“Application” →“Calculation system”
d
Temperature unit
0
°C
1
°F
EView2 parameter:“Device Settings” →“Measurement configuration” →“Temperature”

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P01: - - b a Output source FACTORY DEFAULT: 1011
P01ba defines the source of the primary output value (HART – PV), which also defines the value transmitted on the analog current output.
The device automatically selects the measurement mode according to the selected output source. The device measures the level's distance.
The other quantities are calculated based on the specified tank parameters and material characteristics.
ba
Output data / measuring mode
Parameter
10
Distance
–
11
Level
P04
12
Volume
P04, P40…45
13
Weight
P04, P32, P40…45
14
Flow
P04, P40…45, P46
15
Empty volume
P04, P40…45, P47
16
Level%
P04
17
Volume%
P04, P40…45
EView2 parameter:“Device Settings” →“Measurement configuration” →“Measurement mode”
Distance measurement (DIST) /
Level measurement (LEV)
DIST: Currently measured distance
A: Shortest measurable distance (P05)
H: Longest measurable distance (also the
distance to the zero level) (P04)

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Volume measurement (VOL)
DIST: Currently measured distance
A: Shortest measurable distance
H: Zero-level distance
B: The volume associated with the highest
measurable level
C: Total volume of the container
P02: d c b a Output units FACTORY DEFAULT: 2021
The device calculates the volume, weight, and volume flow over a unit of time using a level-dependent (non-linear) function using P40 or an output correction table
(OCT). This parameter also determines the unit of measure for the “Output” column of the OCT table. The TOT value in flow measurement mode Totalized (total)
amount flowed. The distance, level, and temperature units can be selected in parameter P00.
a
Weight unit
Metric
US
0
kg
lb
1
ton
US ton
2
US ton
metric ton
EView2 parameter:”Device Settings” →“Measurement configuration” →“Mass units”
b
Volume
Metric
US
0
liter
gallon
1
hL(1)
ft3
2
m3
barrel
3
million liter(1)
million gallon(1)
EView2 parameter:“Device Settings” →“Measurement configuration” →“Volume units”

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c
Time
0
second
1
min
2
hour
3
day
EView2 parameter:“Device Settings” →“Measurement configuration” →“Time units”
d
TOT
Metric
US
0
liter
gallon
(1) Its use is not recommended for flow measurement! (In HART transmission,
it can only be interpreted together with reading an application-specific code.)
Except for MGD.
1
hL
ft3
2
m3
barrel
3
million liter(1)
million gallon(1)
EView2 parameter:“Device Settings” →“Measurement configuration” →“TOT units”
P03: Maximum detection distance FACTORY DEFAULT: See Xmax in the table.
The maximum detection distance measured from the process connection. The device only evaluates level signals within the specified distance. The maximum
detection distance is specific to the type. See the Xmax column of the type-dependent measurement distance table below. A smaller value can be set. The minimum
value is parameter P05 + 30 centimeters. It is not necessary to set this parameter. The device automatically selects the detection distance based on the zero-level
distance specified in P04, within the limits of P03.
Type-specific measuring distance
Minimum X
min
Maximum Xmax
WP–212–/ WP–213–
0.056 m (2.2")
10 m (32.8 ft)
WP–214–/ WP–215–
0.070 m (2.76")
10 m (32.8 ft)
WP–224–/ WP–225–
0.070 m (2.76")
20 m (65.6 ft)
*Measured from the process connection
EView2 parameter:“Device Settings” →“Measurement configuration” →“Sensing distance”

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P04: Zero-level distance (container height – H) FACTORY DEFAULT: See Xmax in the table.
This parameter must be set in all cases, except for distance measurement!
The zero-level distance (P04) is the distance between the sealing plane of the process connection and the designated zero level of the level measurement (e.g.,
the bottom of the tank). The device calculates the level value from the P04 value by subtracting the measured level distance. The device automatically sets the
measuring distance within the maximum detection distance (P03). The distance given here is denoted by 'H' in the figures and formulas. The maximum distance
that can be measured (Xmax) is in the measuring distance table above, depending on the selected type. The set zero-level distance can be greater than the
maximum measuring distance but not more than 60 m (200 ft).
Given that the level measured by the device is the calculated difference between the P04 set for the given application and the distance (DIST) measured by
the device, it is important to specify the zero-level distance (H) accurately.
EView2 parameter:“Device Settings” →“Measurement configuration” →“Zero-level dist.”
P05: Close-end blocking (dead-zone) FACTORY DEFAULT: See Xmin the table
The dead-zone (starting from the process connection of the transmitter) is the range within which the device cannot measure due to its physical limitations (antenna
insertion length). This is the minimum measuring distance of the device, and it is type-dependent. See the Xmin column of the type-dependent measuring distance
table above.
Close-end blocking is the user-defined extension of the dead zone, within which the device does not consider any echoes. This, e.g., enables the exclusion of
objects interfering with the measurement close to the sensor. Close-end blocking cannot be less than Xmin.
EView2 parameter:“Device Settings” →“Measurement configuration” →“Minimum(P05)”
P06: Far-end blocking FACTORY DEFAULT: 0.0
In parameter P06, we can specify a level value below which the output will no longer follow any further level decrease. Far-end blocking is used when objects at
the bottom of the tank (mixer, heating coil, hopper, etc.) cause measurement uncertainty in this range, e.g., because interfering echoes cannot be safely
distinguished from the echoes of the measured surface. If an echo falls within the far-end blocking range (LEV < P06), the device sends a special signal and keeps
the level value defined here on the output (see figure). The "Echo in far-end blocking range" flag (see Chapter 6.1) indicates that the echo is in the far-end blocking
zone. Regardless of this, the "VALID" flag is active, but the "HOLD" flag remains inactive.
Far-end blocking can be deactivated with P06 = 0. Min. value: 0 / max. value: P04 – P05 – 5 cm (2")