Tek-Trol TEK-BAR 3120C User manual

Technology SolutionsTAR 3120C
EK-BInstruction ManualSanitaryGauge Pressure Transmitters
Document Number: IM-3120Cwww.tek-trol.com

www.tek-trol.com
NOTICE
Read this manual before working with the product. For personal and system safety, and for optimum product performance, make sure you thoroughly understand the contents before installing, using, or maintaining this product.
For technical assistance, contact
Customer Support
796 Tek-Drive
Crystal Lake, IL 60014
USA
Tel: +1 847 857 6076
© COPYRIGHT Tek-Trol LLC 2021
No part of this publication may be copied or distributed, transmitted, transcribed, stored in a
retrieval system, or translated into any human or computer language, in any form or by any means,
electronic, mechanical, manual, or otherwise, or disclosed to third parties without the express
written permission. The information contained in this manual is subject to change without notice.

Table of Contents
1
Safety Instructions ..............................................................................................................
3
1.1
Intended Use .........................................................................................................................
3
1.3
Safety Instructions from the Manufacturer .............................................................................
3
Disclaimer .....................................................................................................................................
3
Product Liability and Warranty .....................................................................................................
3
Information Concerning the Documentation ...............................................................................
3
Safety Precautions ........................................................................................................................
4
1.4
Packaging, Transportation, and Storage ..................................................................................
4
......................................................................................................................................
4
Transportation ..............................................................................................................................
5
Storage..........................................................................................................................................
5
1.5
Nameplate .............................................................................................................................
6
2
Product Description ............................................................................................................
7
2.1
Introduction ..........................................................................................................................
7
2.2
Measurement Principle ..........................................................................................................
7
2.3
Specifications .........................................................................................................................
8
2.4
Dimensional Drawings ...........................................................................................................
9
2.5
Model Chart.........................................................................................................................
10
3 Installation .........................................................................................................................
11
3.1
Selecting the Installation Location ........................................................................................
11
3.2
Installation Procedure ..........................................................................................................
11
Install Pressure Transmitter .......................................................................................................
11
3.2.1.1. Clamp Connection .............................................................................................................
12
Housing Rotation ........................................................................................................................
12
Terminal Side of Transmitter ......................................................................................................
12
LCD Display .................................................................................................................................
12
Conduit Installation ....................................................................................................................
13
3.3
Mounting Requirements ......................................................................................................
13
Liquid Flow Measurement ..........................................................................................................
13
Gas Flow Measurement ..............................................................................................................
13
Steam Flow Measurement .........................................................................................................
13
3.4
Field Adjustment .................................................................................................................
13
Zero Point Adjustment ...............................................................................................................
14
Full Span Adjustment..................................................................................................................
14
3.5
Product Usage .....................................................................................................................
14
Pipeline pressure measurement-pressure transmitter ..............................................................
14
...........................................
14
Steam flow measurement ..........................................................................................................
15
Liquid flow measurement ...........................................................................................................
15
Air flow measurement ................................................................................................................
15
Open container level measurement-single flange level transmitter .........................................
15
Sealed container level measurement-single flange level transmitter .......................................
15

4
Electrical Connections .......................................................................................................
16
4.1
Grounding of Measuring Device ...........................................................................................
16
4.2
Power Supply Specifications and Connection ........................................................................
17
4.3
Cable Protection System ......................................................................................................
18
Standard Protection System .......................................................................................................
18
4.3.2 Connection to the HART Handheld Communicator ...................................................................
18
5
Operation .........................................................................................................................
19
5.1
Local Operation and Display .................................................................................................
19
5.2
Operation in safe and hazardous area ..................................................................................
19
5.3
Configuration .......................................................................................................................
19
Key Operation .............................................................................................................................
20
Factory Reset ..............................................................................................................................
20
Detailed Operating Instructions .................................................................................................
21
5.4
Handheld Communicator .....................................................................................................
23
6 Maintenance ....................................................................................................................
24
6.1
Hardware Maintenance .......................................................................................................
24
Test Terminal ..............................................................................................................................
24
Disassembling the Electronics Housing ......................................................................................
24
External Cleaning ........................................................................................................................
24
Depot Repair ...............................................................................................................................
25
Discard Disposal ..........................................................................................................................
25
7 Troubleshooting ...............................................................................................................
26
7.1
Symptoms and Corrective Measures .....................................................................................
26

1Safety Instructions
1.1 Intended Use
Tek-bar 3120C is a Sanitary Gauge Pressure Transmitter used for pressure, flow, level and
density measurement of steam and liquids.
The manufacturer is not liable for damage caused by improper or non-designated use.
1.2 Safety Instructions from the Manufacturer
Disclaimer
The manufacturer will not be held accountable for any damage that happens by using its
product, including, but not limited to direct, indirect, or incidental and consequential
damages.
Any product purchased from the manufacturer is warranted in accordance with the relevant
product documentation and our Terms and Conditions of Sale.
The manufacturer has the right to modify the content of this document, including the
disclaimer, at any time for any reason without prior notice, and will not be answerable in
any way for the possible consequence of such changes.
Product Liability and Warranty
The operator shall bear authority for the suitability of the device for the specific application.
The manufacturer accepts no liability for the consequences of misuse by the operator.
Wrong installation or operation of the devices (systems) will cause the warranty to be void.
The respective Terms and Conditions of Sale, which forms the basis for the sales contract
shall also apply.
Information Concerning the Documentation
To prevent any injury to the operator and damage to the device it is essential to read the
information in this document and read the applicable national standard, and safety
instruction. These operating instructions contain all the information that is required in
various stages, like product identification, incoming acceptance and storage, to mounting,
connection, operation and commissioning through to troubleshooting, maintenance and
disposal.

Safety Precautions
You must read these instructions carefully prior to installing and commissioning the device.
These instructions are an important part of the product and must be kept for future
reference. Only by observing these instructions, optimum protection of both personnel and
the environment, as well as safe and fault-free operation of the device can be ensured.
For additional information that are not discussed in this manual, contact the manufacturer.
Warnings and Symbols Used
The following safety symbol marks are used in this operation manual and on the instrument.
WARNING
Indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION
Indicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate injury. It may also be used to alert against unsafe practices.
NOTE
Indicates that operating the hardware or software in this manner may damage it or
lead to system failure.
1.4 Packaging, Transportation, and Storage
This section contains information regarding packaging, transportation, and storage.
Packaging
The original package consists of
1. Tek-Bar 3120C Sanitary Gauge Pressure Transmitter
2. Accessories (optional)
3. Documentation

NOTE
Unpack and check the contents for damages or signs of rough handling. Report
damage to the manufacturer immediately. Check the contents against the packing
list provided.
Transportation
Avoid impact shocks to the device and prevent it from getting wet during transportation.
Verify local safety regulations, directives, and company procedures with respect to
hoisting, rigging, and transportation of heavy equipment.
Transport the product to the installation site using the original manufacturer’s packing
whenever possible.
Storage
If this product is to be stored for a long period of time before installation, take the
following precautions:
Store your product in the manufacturer’s original packing used for shipping.
Storage location should conform to the following requirements:
oFree from rain and water
oFree from vibration and impact shock
oAt room temperature with minimal temperature and humidity variation
Before storing a used flowmeter remove any fluid from the flowmeter line
completely. Properties of the instrument can change when stored outdoors.

1.5 Nameplate
The nameplate lists the order number and other important information, such as design
details and technical data.
NOTE
Check the device nameplate to ensure that the device is delivered according to
your order. Check for the correct supply voltage printed on the nameplate.

2Product Description
This section covers the reference and specification data, as well as ordering information.
2.1 Introduction
Tek-Bar 3120C Sanitary Gauge Pressure Transmitter utilizes world’s leading mono crystal
silicon pressure sensor technology and outstanding encapsulation technology. It can handle
the most rigorous industrial applications and it can cope up with extreme chemical,
mechanical and electrical working conditions. Highly accurate and reliable measurement of
level, density and pressure of liquid, gases or steam is possible with Tek-Bar 3120C. The
performance accuracy is up to 0.05% of URL. This high-performance pressure transmitter
meticulously designed by Tek-Trol supports HART communication protocol and IP66
waterproof protection. It is well equipped with several features that facilitate easy
installation, start-up and minimum maintenance.
2.2 Measurement Principle
Tek-Bar 3120C Sanitary Gauge Pressure Transmitter works on mono silicon technology. The
mono silicon pressure sensor is located on the top of the metal body and away from the
process fluid forming mechanical and thermal isolation.
Pressure applied on the diaphragm creates stress on the pair of piezoelectric crystals causing
a change in the voltage resistance. The change in resistance is directly proportional to applied
pressure and is transferred to the transmitter body through lead wires. The transmitter carries
out the further process of signal conditioning.
Built on semiconductor technology, the resistance change due to piezoelectric effect is
notably higher than that exhibited in standard strain gauges. Therefore, the sensitivity of
mono crystal pressure sensors is higher than most of other pressure sensor types.

2.3 Specifications
All fluids compatible with gases, steam and liquids
Gauge Pressure
5.8 psig - 300 psig
±0.2% of F.S.
±0.2% URL/5 years
-40°F to 185°F (-40°C to 85°C), integrated LCD display: -4°F to 158°F (-20°C to 70°C)
≥20 M Ω at 100 VDC
Apply to any position. Max value lower than 1.6 w.c. (400 Pa) can be corrected by
zero clearing function
5-100% RH at 104 °F
Approx. 3.43 lbs or 1.55 Kg (Without process connections and mounting brackets)
NEMA 4X (IP66)
5.8 psi
8 in.WC
-14.5 psi
5.8 psi
145 psig
36 psi
2 psi
-14.5 psi
36 psi
580 psig
145 psi
7.25 psi
-14.5 psi
145 psi
870 psig
300 psi
15 psi
-14.5 psi
300 psi
1500 psig
The unit of the measuring range above can be converted. Provide other measuring range according to
requirements. Adjust requirements: lower range value (LRV) and upper low value (ULV) can be adjusted within
the scope of the upper and lower range limit, minimum measuring ranges ≤ | URV - LRV | ≤ maximum measuring
ranges
* Over voltage value: depending on the pressure value of the weakest part
Vibration Resistance
According to IEC60068-2-6,
10g RMS (25-2000Hz)
Impact Resistance
According to IEC60068-2-6,
500g/1ms
Output Signal
Signal Type Output
4 mA to 20 mA with HART (Optional
Modbus RS485)
Linearity Two wire

Total damping time constant
Equal to the sum of damping time of
amplifier and sensor capsule
Damping time of amplifier
0 -100 s adjustable
Diaphragm capsule (isolated diaphragm and silicon oil filling)
≤ 0.2 s
damping time
Start-up after power off
≤ 6 s
Normal services after data recovery
≤ 31 s
Standard/flame proof
10-55 VDC
HART protocol
16-55 VDC, communication load resistance 250 Ω
Load resistance
0-2119 Ω for working condition, 250- 600 Ω for HART protocol
Transmission distance
<3281 ft
Power consumption
≤500 mW at 24 VDC, 20 mA
2.4 Dimensional Drawings
Dimension with Display

2.5 Model Chart
Example
Tek-Bar 3120C-G 3 WP 1 SS 1 # Tek-Bar 3120C-G-3-WP-1-SS-1
Series Tek-Bar 3120C-G Sanitary Gauge Pressure Transmitter
10 to 5.8 psig
20-36 psig
Range Options 30-145 psig
4
0-300 psig
Approval Rating
WP
General Purpose NEMA 4X/IP66
CSA
CSA Class 1 Div 1 Explosion-Proof
Process Connections 12" Tri-Clamp
2
1½" Tri-Clamp
Diaphragm Material
SS
316L Stainless Steel
Electrical Connection
1
½" NPT Female
MOD Modbus RS 485 Communication
CC
Custom Calibration with 5 point Calibration Certificate
Options
FC
Factory Configuration, No Certificate
BA
Stainless Steel Bracket with SST Bolts (Flat and Angle)
TAG
Stainless Steel Hang Tag

3Installation
This section covers instructions on installation and commissioning. Installation of the device
must be carried out by trained, qualified specialists authorized to perform such works.
CAUTION
When removing the instrument from hazardous processes, avoid direct
contact with the fluid and the meter
All installation must comply with local installation requirements and
local electrical code
3.1 Selecting the Installation Location
Prior to product installation, check the model, specifications and installation location for the
transmitter. The transmitter is designed to withstand severe environmental conditions.
However, follow the enlisted precautions while selecting the installation site to ensure stable
and accurate operation for years.
Ambient Atmosphere
Avoid corrosive atmosphere while installing the transmitter. If it must be installed in a
corrosive atmosphere, then provide adequate ventilation and take the necessary
measures to prevent intrusion or stagnation of rain water in conduits.
Shock and Vibration
Although the transmitter is designed to withstand shock and vibrations, it is
recommended to select an installation site with minimum shock and vibration to avoid
device damage and improve measurement accuracy.
3.2 Installation Procedure
This section includes the information regarding installation of the transmitter for safe and
precise functioning. It provides the procedure and instruction for mounting, transmitter
functions, and installation for specific applications.
Install Pressure Transmitter
Direct installation or mounting bracket installation may be used depending on the
application and installation site requirement. Various mounting scenarios are illustrated in
sections below.

3.2.1.1 Clamp Connection
Choose gaskets that meet specified standards to avoid excessive clamp locking and
squeezing gasket. Excessive locking of clamp may damage the sensing diaphragm and cause
measuring error.
NOTE
Engage process connection with a minimum of 7 thread connections and tighten
the housing rotation set screw to prevent it from rotating
Housing Rotation
To ensure the visibility of LCD display
Loosen the housing screw
Rotate housing to the desired angle up to 360o
Re-tighten the housing screw
Terminal Side of Transmitter
Mount the transmitter in such a way that the terminal side is easily accessible to the
operator.
LCD Display
Display module is used in field adjustment for parameter settings and site configuration
before starting the measurement process. The local 5-digit LCD displays important
parameters, which can be directly monitored at the measuring point. It enables the
operator to configure the device using the function matrix. Display can be rotated 355°.

Conduit Installation
Improper sealing of connections may damage the transmitter due to excess moisture
accumulation. Mount the transmitter with electrical housing positioned downward so that the
excess of moisture is condensed and drained out from the casing. Secondly, install wiring with a
drip loop and ensure the bottom of the drip loop is mounted lower than the conduit connections
or the transmitter housing to avoid moisture accumulation in the housing.
NOTE
Conduit thread must be engaged with a minimum of 5 thread connections
3.3 Mounting Requirements
Impulse piping configuration and transmitter position depends on specific measurement
conditions. Follow the procedure below while installing transmitter for liquid, gases or steam
processes.
Liquid Flow Measurement
Place the taps to the side of the line/pipe to prevent residue deposits on the
transmitter process isolators
Mount the transmitter beside or below the taps so gases can vent into the process line
Mount drain/vent the valve upward to allow gases to vent
Gas Flow Measurement
Place the taps in the top or side of the line
Mount the transmitter beside or above the taps so liquid will drain into the process line
Steam Flow Measurement
Place taps to the side of the line
Mount the transmitter below the taps to ensure that the impulse piping stays filled
with condensate
In steam service above 250°F (121°C), fill impulse lines with water to prevent the direct
steam contact with the transmitter and to ensure accurate measurement at start-up
NOTE
For steam or other higher temperature processes, ensure that the temperature at the
process connection does not exceed the transmitter’s process temperature limits.
3.4 Field Adjustment
Perform field adjustments only after installing the transmitter at its final work location
otherwise the set parameters may drift due to jerks while transporting or handling.

Zero Point Adjustment
For sensor zero trim, ensure that the vessel is empty and there is no input medium pressure
on the diaphragm. The vessel should be applied a normal atmospheric pressure. If applying
external pressure to the transmitter make sure that the display is sufficiently stabilized (after
approximately 10 to 15 seconds), before initiating any trim function.
There are 3 ways of making input pressure “Zero”.
➢Apply a “Zero” pressure source (mandatory for absolute pressure models)
➢Apply equal pressure on both HP and LP ports (DP models only)
➢Open equalizing valve of manifolds installed and venting to atmospheric pressure
(applicable for Gauge & DP type models only)
Sensor zero trim can be performed using an external HHC (Handheld calibrator), PC or
PDA configurator, and/or using Zero/Span local push buttons provided on the
transmitter.
Using local push buttons set PV=0, refer to section 5.2.1 of this manual for detailed
instructions. If using an external HHT or HART® PC configurator, refer to the user manual
supplied by the third-party supplier.
Full Span Adjustment
For full span adjustment, ensure that the vessel is filled with process medium to
the maximum level.
Maintain static pressure value within the minimum and maximum pressure range
Using local push buttons set output for lower and upper limit of the full scale i.e.
4mA and 20mA, refer to section 5.2 of this manual for detailed key operations.
The device is now ready for the real-time process measurement.
3.5 Product Usage
Pipeline pressure measurement-pressure transmitter
For high temperature steam measurements, pre-inject more than half-tube cooling water
in the condenser. Once the steam pipes are stable, gradually open the shut-off valve to
start measurement.
Pipeline pressure measurement-differential pressure transmitter
For high temperature steam measurement in a pipeline by differential pressure transmitter,
pre-inject cooling water into the guided pipe. Once the steam pipes are stable, slowly open
the shut-off valve and start measuring.
Differential pressure transmitters are commonly used for micro pressure measurement of
hydrostatic pressures such as filter and equipment leakage tests for improving accuracy.

Steam flow measurement
For steam flow measurement, up-tilt the guiding pressure tube by 45°. Ensure that
transmitter installation location is at lower level than that of the process pipeline. Pre-inject
cooling liquid into the guiding pressure tube. Slowly open the shut-off valve to start
measurement. Periodically open the drain vent to clear the residual steam from guided
pipeline to improve the measurement accuracy.
Liquid flow measurement
For liquid flow measurement, tilt down the guiding pressure tube by 45°. Ensure that
transmitter installation location is at lower level than that of the process pipeline. Pre-
inject cooling liquid into the guiding pressure tube. Slowly open the shut-off valve to
start measurement. Periodically open the drain vent to clear the residual liquid, which
will improve the measurement accuracy.
Air flow measurement
For liquid flow measurement, up-tilt the guiding pressure tube by 45°. Ensure that
transmitter installation location is at lower level than that of the process pipeline. Pre-
inject cooling liquid into the guiding pressure tube. Slowly open the shut-off valve to
start measurement. Periodically open the drain vent to clear the residual gas from the
guiding pressure tube, which will improve the measurement accuracy.
Open container level measurement-single flange level transmitter
Verify the process medium compatibility in case of open container level measurement. For
accurate measurement, install the transmitter at a location where liquid level and
temperature fluctuations are minimal.
Sealed container level measurement-single flange level transmitter
Use a single flange diaphragm system for sealed container level measurement. Increase
the isolation tank and multiple shut-off valves. Periodically open the drain/vent valve to
clear off the residual gas and liquid in the guiding pressure tube for higher accuracy.

4Electrical Connections
This section covers the all electrical connection requirement. Electrical connection of the device
must be carried out by trained, qualified specialists authorized to perform such work by the
installation site.
WARNING
Connect all electrical cables when the power is switched off. If the device does
not have switch-off elements, then, overcurrent protection devices, lightning
protection and/or energy isolating devices must be provided by the customer.
The device must be grounded to a spot in accordance with regulations
to protect personnel against electric shocks.
NOTE
When using the measuring device in hazardous areas, installation must
comply with the corresponding national standards and regulations and
the Safety Instructions or Installation or Control Drawings.
4.1 Grounding of Measuring Device
Ensure proper grounding at control cabinet and pressure transmitter.
Ground terminals are provided on the either sides (inside and outside) of the terminal box.
Either one of these terminals may be used for grounding the transmitter.
Use shielded twisted pair cable to avoid ground loops.
Use internal ground terminals for direct grounding.

4.2 Power Supply Specifications and Connection
Use independent linear direct current power supply for pressure transmitter. Large resistive
load results in high pressure drop. Therefore, it is recommended to consider the resistance
across the signal cable, display meter and other equipment to ensure sufficient voltage is
provided to the pressure transmitter for its normal operation.
Standard current signal output: 10.5 to 55 VDC,
Current signal output with HART: 16.5 to 55VDC,
Remove the housing cover on terminal compartment side. Do not remove the cover
in explosive atmospheres when the circuit is live.
Label
Two Wires
Three Wires
Four Wires
+
Power +
Power +
Power +
-
Power -
Power -
Power -
A
Signal +
Signal +
B
Signal -
Power supply connections:
Connect power supply ‘+’ terminal to transmitter ‘+’ terminal.
Connect signal ‘+’ terminal to transmitter ‘-’ terminal.
Connect signal ‘-’ terminal to power supply ‘-’ terminal.
Do not connect power signal wiring to the test terminals as it could damage the test diode.

Power Supply Connections
4.3 Cable Protection System
Apply following cable protection measures to protect the connecting cables from
various factors that affect negatively on the cable lifetime.
Standard Protection System
To avoid liquid flowing along with the cable into the terminal box, configure a U-shaped
ring between pull box and pressure transmitter as shown in the figure below.
Ensure that the level of U-shaped bottom is maintained below the pressure transmitter.
Use sufficiently long cable considering the maintenance and repair factors.
Connection to the HART Handheld Communicator
A loop resistance for HART Communicator is between 250Ω and 550Ω.
Transmitter operates on 16.5 to 55 VDC.
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