Tek-Trol TEK-FLEX 4100A User manual

Technology Solutions
TEK-FLEX 4100A
Explosion Proof Guided Wave
Radar Level Transmitter
Instruction Manual
Document Number: IM-4100A
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© COPYRIGHT Tek-Trol LLC 2019
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: [phone]
www.tek-trol.com
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.

1 Safety instructions 7
1.1 Software history ............................................................................................................... 7
1.2 Intended use ..................................................................................................................... 7
1.3 Certification ...................................................................................................................... 8
1.4 Electromagnetic compatibility ......................................................................................... 8
1.5 Safety instructions from the manufacturer ..................................................................... 9
1.5.1 Copyright and data protection ................................................................................................ 9
1.5.2 Disclaimer ............................................................................................................................... 9
1.5.3 Product liability and warranty .............................................................................................. 10
1.5.4 Information concerning the documentation......................................................................... 10
1.5.5 Warnings and symbols used................................................................................................. 11
1.6 Safety instructions for the operator............................................................................... 11
2 Device description 12
2.1 Scope of delivery............................................................................................................. 12
2.2 Device description .......................................................................................................... 14
2.3 Visual Check ................................................................................................................... 15
2.4 Nameplates .................................................................................................................... 16
2.4.1 Non-Ex nameplate ................................................................................................................ 16
3 Installation 17
3.1 General notes on installation ......................................................................................... 17
3.2 Storage ........................................................................................................................... 17
3.3 Transport ........................................................................................................................ 18
3.4 Pre-installation requirements ....................................................................................... 19
3.5 How to prepare the tank before you install the device.................................................. 19
3.5.1 Pressure and temperature ranges....................................................................................... 19
3.5.2 General information for nozzles........................................................................................... 21
3.5.3 Installation requirements for concrete roofs....................................................................... 23
3.6 Installation recommendations for liquids...................................................................... 24
3.6.1 General requirements .......................................................................................................... 24
3.6.2 How to attach probes to the bottom of the tank................................................................... 25
3.6.3 Standpipes............................................................................................................................. 28
3.6.4 Typical applications............................................................................................................... 32
3.7 Installation recommendations for solids....................................................................... 34
3.7.1 Nozzles on conical silos........................................................................................................ 34
3.7.2 Traction loads on the probe.................................................................................................. 35
3.8 How to install the device on the tank ............................................................................. 36
3.8.1 How to assemble the single rod probe (single-piece probe)............................................... 36
3.8.2 How to assemble the single rod probe (segmented probe)................................................. 40
3.8.3 How to assemble the segmented coaxial probe .................................................................. 43
3.8.4 How to install a device with a flange connection ................................................................. 46
3.8.5 How to install a device with a threaded connection............................................................. 47
3.8.6 How to install a cable probe in the tank............................................................................... 48
3.8.7 Recommendations for pits and tanks made of non-conductive materials.......................... 49
3.8.8 How to assemble the remote version................................................................................... 50
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CONTENTS

3.8.9 How to turn or remove the signal converter ........................................................................ 53
3.8.10 How to attach the weather protection to the device........................................................... 54
3.8.11 How to open the weather protection .................................................................................. 55
4 Electrical connections 56
4.1 Safety instructions.......................................................................................................... 56
4.2 Electrical installation: outputs 1 and 2 .......................................................................... 56
4.3 Electrical connection for current output ....................................................................... 57
4.3.1 Non-Ex devices ..................................................................................................................... 57
4.3.2 Devices for hazardous locations........................................................................................... 57
4.4 Protection category ........................................................................................................58
4.5 Networks ........................................................................................................................ 59
4.5.1 General information.............................................................................................................. 59
4.5.2 Point-to-point networks ....................................................................................................... 59
4.5.3 Multi-drop networks ............................................................................................................. 60
5 Start-up 61
5.1 Start-up checklist........................................................................................................... 61
5.2 Operating concept ..........................................................................................................61
5.3 Digital display screen .....................................................................................................62
5.3.1 Local display screen layout .................................................................................................. 62
5.3.2 Keypad buttons ..................................................................................................................... 62
5.3.3 Help screens ......................................................................................................................... 62
5.3.4 How to start the device ......................................................................................................... 63
5.4 Remote communication with PACTware™ .................................................................... 63
5.5 Remote communication with the AMS™ Device Manager............................................. 64
6 Operation 65
6.1 User modes .................................................................................................................... 65
6.2 Operator mode................................................................................................................ 65
6.3 Supervisor mode ............................................................................................................68
6.3.1 General notes........................................................................................................................ 68
6.3.2 How to get access to the supervisor mode .......................................................................... 68
6.3.3 Keypad functions................................................................................................................... 69
6.3.4 Menu overview ...................................................................................................................... 72
6.3.5 Function description ............................................................................................................. 73
6.4 Further information on device configuration................................................................. 86
6.4.1 Protection of the device settings .......................................................................................... 86
6.4.2 Network configuration .......................................................................................................... 86
6.4.3 Linearisation ......................................................................................................................... 87
6.4.4 Distance measurement ........................................................................................................ 87
6.4.5 Level measurement .............................................................................................................. 88
6.4.6 How to configure the device to measure volume or mass................................................... 89
6.4.7 How to make the device follow the correct level or interface signal .................................. 90
6.4.8 Thresholds and parasitic signals.......................................................................................... 92
6.4.9 How to use the snapshot function to filter parasitic signals ............................................... 96
6.4.10 How to measure products with a low dielectric constant (e
r
)........................................... 97
6.4.11 How to decrease the length of probes................................................................................ 98
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6.5 Service mode .................................................................................................................. 99
6.6 Errors............................................................................................................................ 100
6.6.1 General information............................................................................................................ 100
6.6.2 Error handling..................................................................................................................... 102
7 Service 106
7.1 Periodic maintenance................................................................................................... 106
7.2 Keep the device clean................................................................................................... 106
7.3 How to replace device components ............................................................................. 107
7.3.1 Service warranty ................................................................................................................. 107
7.3.2 Replacement of the display cover....................................................................................... 108
7.3.3 Replacement of the complete electronic module .............................................................. 110
7.3.4 Replacement of the terminal module................................................................................. 112
7.3.5 Replacement of the BM 100 signal converter .................................................................... 114
7.3.6 Replacement of the BM 102 signal converter .................................................................... 120
7.4 Spare parts availability................................................................................................. 1 11
7.5 Availability of services .................................................................................................. 1 11
7.6 Returning the device to the manufacturer................................................................... 1 11
7.6.1 General information............................................................................................................ 1 11
7.6.2 Form (for copying) to accompany a returned device.......................................................... 1 12
7.7 Disposal ........................................................................................................................ 1 13
8 Technical data 1 14
8.1 Measuring principle...................................................................................................... 1 14
8.2 Technical data............................................................................................................... 1 17
8.3 Pressure/temperature table for probe selection ........................................................ 1 22
8.4 Guidelines for maximum operating pressure (CRN certification) .............................. 1 23
8.5 Dimensions and weights .............................................................................................. 126
9 Description of HART interface 158
9.1 General description ...................................................................................................... 1 33
9.2 Software history ........................................................................................................... 1 33
9.3 Connection variants...................................................................................................... 1 34
9.3.1 Point-to-Point connection - analogue / digital mode......................................................... 1 34
9.3.2 Multi-Drop connection (2-wire connection) ....................................................................... 1 34
9.4 HART® device variables............................................................................................... 1 36
9.5 Field Communicator 375/475 (FC 375/475) ................................................................. 1 36
9.5.1 Installation .......................................................................................................................... 1 36
9.5.2 Operation............................................................................................................................. 136
9.6 Asset Management Solutions (AMS) ............................................................................ 137
9.6.1 Installation .......................................................................................................................... 137
9.6.2 Operation............................................................................................................................. 137
9.6.3 Parameter for the basic configuration ............................................................................... 137
9.7 Field Device Tool / Device Type Manager (FDT / DTM) ................................................ 137
9.7.1 Installation .......................................................................................................................... 137
9.7.2 Operation............................................................................................................................. 1 37
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®
9.8 HART menu tree for Basic-DD .................................................................................. 1 38
9.8.1 Overview Basic-DD menu tree (positions in menu tree).................................................... 1 38
9.8.2 Basic-DD menu tree (details for settings).......................................................................... 1 38
®
9.9 HART menu tree for AMS 140..........................................................................................
9.9.1 Overview AMS menu tree (positions in menu tree) ............................................................ 1 40
9.9.2 AMS menu tree (details for settings).................................................................................. 1 41
10 Appendix
144
10.1 Order code ...............................................................................................................
10.2 List of spare parts ......................................................................................................
147
10.3 List of accessories......................................................................................................
149
10.4 Glossary .................................................................................................................
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151
144

1.1 Software history
Data about software revisions is shown in the Supervisor menu. Go to Test > Information >
Test > Information >Test > Information >
Test > Information >
Device ID
Device IDDevice ID
Device ID. For more data, refer to
Function description on page 73. If it is not possible to refer to
the device menu, record the serial number of the device (given on the device nameplate) and
speak to the supplier.
1.2 Intended use
This TDR level transmitter measures distance, level, mass and volume of liquids, pastes,
slurries, granulates and powders. It can also measure level and interface of liquids at the same
time.
It can be installed on tanks, silos and open pits.
Release date
(back end)
[YYYY-MM-DD]
Back end Front end DTM revision Hardware NE 53 level
2005-10-18 1.0.2.73 1.0.0.22 1.0.0.24 2139590100 n/a
2006-02-27 1.02.75 1.0.0.22 1.0.0.24 2139590100 3
2006-05-29 1.02.75 1.0.0.25 1.0.0.24 2139590100 3
2006-09-01 1.02.77 1.0.0.26 1.0.0.32 2139590100 3
2007-11-21 1.02.79 1.0.0.27 1.0.0.33 2139590100 3
2008-06-22 1.02.80 1.0.0.27 1.0.0.34 2139590100 3
2010-03-01 2.02.82
1.02.82 1
1.0.0.28 1.0.0.35 4000659401
21
3
2010-05-01 2.02.83
1.02.83 1
1.0.0.28 1.0.0.37 3 4000659401
43
n/a
2012-03-05 2.02.84
1.02.84 1
1.0.0.28 1.0.0.37 3 4000659401
53
3
1This back end firmware revision is only used for device upgrades
2It is possible to upgrade the hardware (revision 2139590100) with back end firmware revision 1.02.82
3If your computer uses the Windows XP operating system, install DTM revision V 1.0.0.35. If your computer uses the Windows 7 operating
system, install DTM revision V 1.0.0.37.
4It is possible to upgrade the hardware (revision 2139590100) with back end firmware revision 1.02.83
5It is possible to upgrade the hardware (revision 2139590100) with back end firmware revision 1.02.84
CAUTION!
Responsibility for the use of the measuring devices with regard to suitability, intended use and
corrosion resistance of the used materials against the measured fluid lies solely with the
operator.
INFORMATION!
The manufacturer is not liable for any damage resulting from improper use or use for other than
the intended purpose.
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1. SAFETY INSTRUCTION

1.3 Certification
In accordance with the commitment to customer service and safety, the device
described in this document meets the following safety requirements:
•Electromagnetic Compatibility (EMC) Directive 2004/108/EC in conjunction with EN 61326-1
(2013).
All devices are based on the CE marking and meet the requirements of NAMUR Guideline NE 21
and NE 43.
1.4 Electromagnetic compatibility
The device design agrees with European Standard EN 61326-1 (2013) when installed in metallic
tanks.
You can install the device on open-air tanks and tanks that are not made of metal. Refer also to
the note that follows.
DANGER!
For devices used in hazardous areas, additional safety notes apply; please refer to the Ex
documentation.
CAUTION!
If you install a device with a rod or cable probe in a non-metallic tank or open-air pit, a strong
electromagnetic field near to the device can have an unwanted effect on the accuracy. Use a
device with a coaxial probe for this type of installation.
INFORMATION!
Device operation agrees with residential-class (class B) and industrial-class (class A) emissions.
The device fulfils immunity requirements when it is installed in industrial areas.
The device agrees with these conditions if:
• the device has a single or double probe (rod or cable probe) and is used in a closed tank made
of metal or
• the device has a coaxial probe.
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1.5 Safety instructions from the manufacturer
1.5.1 Copyright and data protection
The contents of this document have been created with great care. Nevertheless, we provide no
guarantee that the contents are correct, complete or up-to-date.
The contents and works in this document are subject to copyright. Contributions from third
parties are identified as such. Reproduction, processing, dissemination and any type of use
beyond what is permitted under copyright requires written authorisation from the respective
author and/or the manufacturer.
The manufacturer tries always to observe the copyrights of others, and to draw on works created
in-house or works in the public domain.
The collection of personal data (such as names, street addresses or e-mail addresses) in the
manufacturer's documents is always on a voluntary basis whenever possible. Whenever
feasible, it is always possible to make use of the offerings and services without providing any
personal data.
We draw your attention to the fact that data transmission over the Internet (e.g. when
communicating by e-mail) may involve gaps in security. It is not possible to protect such data
completely against access by third parties.
We hereby expressly prohibit the use of the contact data published as part of our duty to publish
an imprint for the purpose of sending us any advertising or informational materials that we have
not expressly requested.
1.5.2 Disclaimer
The manufacturer will not be liable for any damage of any kind by using its product, including,
but not limited to direct, indirect or incidental and consequential damages.
This disclaimer does not apply in case the manufacturer has acted on purpose or with gross
negligence. In the event any applicable law does not allow such limitations on implied warranties
or the exclusion of limitation of certain damages, you may, if such law applies to you, not be
subject to some or all of the above disclaimer, exclusions or limitations.
Any product purchased from the manufacturer is warranted in accordance with the relevant
product documentation and our Terms and Conditions of Sale.
The manufacturer reserves the right to alter the content of its documents, including this
disclaimer in any way, at any time, for any reason, without prior notification, and will not be liable
in any way for possible consequences of such changes.
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1.5.3 Product liability and warranty
The operator shall bear responsibility for the suitability of the device for the specific purpose.
The manufacturer accepts no liability for the consequences of misuse by the operator. Improper
installation or operation of the devices (systems) will cause the warranty to be void. The
respective "Standard Terms and Conditions" which form the basis for the sales contract shall
also apply.
1.5.4 Information concerning the documentation
To prevent any injury to the user or damage to the device it is essential that you read the
information in this document and observe applicable national standards, safety requirements
and accident prevention regulations.
If this document is not in your native language and if you have any problems understanding the
text, we advise you to contact your local office for assistance. The manufacturer can not accept
responsibility for any damage or injury caused by misunderstanding of the information in this
document.
This document is provided to help you establish operating conditions, which will permit safe and
efficient use of this device. Special considerations and precautions are also described in the
document, which appear in the form of icons as shown below.
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1.5.5 Warnings and symbols used
Safety warnings are indicated by the following symbols.
•HANDLING
HANDLINGHANDLING
HANDLING
This symbol designates all instructions for actions to be carried out by the operator in the
specified sequence.
i
RESULT
RESULTRESULT
RESULT
This symbol refers to all important consequences of the previous actions.
1.6 Safety instructions for the operator
DANGER!
This warning refers to the immediate danger when working with electricity.
DANGER!
This warning refers to the immediate danger of burns caused by heat or hot surfaces.
DANGER!
This warning refers to the immediate danger when using this device in a hazardous atmosphere.
DANGER!
These warnings must be observed without fail. Even partial disregard of this warning can lead to
serious health problems and even death. There is also the risk of seriously damaging the device
or parts of the operator's plant.
WARNING!
Disregarding this safety warning, even if only in part, poses the risk of serious health problems.
There is also the risk of damaging the device or parts of the operator's plant.
CAUTION!
Disregarding these instructions can result in damage to the device or to parts of the operator's
plant.
INFORMATION!
These instructions contain important information for the handling of the device.
LEGAL NOTICE!
This note contains information on statutory directives and standards.
WARNING!
In general, devices from the manufacturer may only be installed, commissioned, operated and
maintained by properly trained and authorized personnel.
This document is provided to help you establish operating conditions, which will permit safe and
efficient use of this device.
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2. DEVICE DESCRIPTION
2.1 Scope of delivery
INFORMATION!
Do a check of the packing list to make sure that you have all the elements given in the order.
Figure 2-1: Scope of delivery for compact version
1 Signal converter and probe –compact version.
2 Probe segments. For the assembly procedure of the single rod probe, refer to How to assemble the single rod probe
(single-piece probe) on page 36. If a single rod or coaxial probe is attached and you ordered the "segmented probe"
option, only part of the probe is attached to the device. For the assembly procedure of the segmented single rod probe,
refer to
How to assemble the single rod probe (segmented probe) on page 40. For the assembly procedure of the seg-
mented coaxial probe, refer to
How to assemble the segmented coaxial probe on page 43.
The assembly instructions and small parts are in a bag attached to the signal converter.
3 Quick Start
4 CD-ROM. This contains the Handbook, the Quick Start, the Technical Datasheet and related software.
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Figure 2-2: Scope of delivery for the remote version
1 Signal converter and probe
2 Probe segments. For the assembly procedure of the single rod probe, refer to How to assemble the single rod probe
(single-piece probe) on page 36. If a single rod or coaxial probe is attached and you ordered the "segmented probe"
option, only part of the probe is attached to the device. For the assembly procedure of the segmented single rod, refer
to How to assemble the single rod probe (segmented probe) on page 40. For the assembly procedure of the segmented
coaxial probe, refer to
How to assemble the segmented coaxial probe on page 43.
The assembly instructions and small parts are in a bag attached to the signal converter.
3 Quick Start
4 CD-ROM. This contains the Handbook, the Quick Start, the Technical Datasheet and related software.
5 Flexible conduit. For the assembly procedure, refer to How to assemble the remote version on page 50.
6 Wall bracket (also for installation on pipes)
INFORMATION!
No special tools, no training required!
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2.2 Device description
The TDR level transmitter is designed to measure the distance, level, interface, mass and
volume of liquids, pastes, slurries, granulates and powders.
TDR level transmitters use a probe to guide a signal to the surface of the measured product. The
device has a large choice of probes. Thus, it can measure most products in difficult conditions.
For more data, refer to
Technical data on page 127.
The device has a set-up wizard, fully-potted electronic sub-assemblies and online help
functions. You usually will not need this document to install, set up and operate the device.
You can order these accessories:
•Stainless steel weather protection.
•RS232 / HART®converter (VIATOR).
•USB / HART®converter (VIATOR).
•ESD protection (30 kV).
•Metaglas®dual process sealing system for dangerous products.
INFORMATION!
For more data on accessories, refer to List of accessories on page 182 .
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2.3 Visual Check
If the device is supplied with an FKM/FPM gasket, there is no symbol on the side of the process
connection.
INFORMATION!
Inspect the packaging carefully for damages or signs of rough handling. Report damage to the
carrier and to the local office of the manufacturer.
Figure 2-3: Visual check
1 Device nameplate (for more data, refer to Non-Ex nameplate on page 16)
2 Process connection data (size and pressure rating, material reference and heat number)
3 Gasket material data - refer to the illustration that follows
Figure 2-4: Symbols for the supplied gasket material (on the side of the process connection)
1 EPDM
2 Kalrez
®
6375
WARNING!
• If the display screen glass is broken, do not touch.
• If the device has to measure the level of dangerous products (ammonia etc.), we recommend
that the device has the Metaglas
®
option.
• If the device has to measure the level of products where there is a risk of electrostatic
discharge, we recommend that the device has the ESD (electrostatic discharge) protection
option.
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2.4 Nameplates
2.4.1 Non-Ex nameplate
INFORMATION!
Look at the device nameplate to ensure that the device is delivered according to your order.
Check for the correct supply voltage printed on the nameplate.
Figure 2-5: Non-Ex nameplate
1 Indicator arrow to cable entry / cable entry size. Notified body for radio approval.
2 Hardware revision / Software revision
3 Nominal voltage for operation. For further information, refer to Non-Ex devices on page 57.
4 Degree of ingress protection (according to EN 60529 / IEC 60529)
5 Customer tag number
6 Date of manufacture
7 Order number
8 Type code (defined in order)
9 Model name and number
10 Company name and address
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3. INSTALLATION
3.1 General notes on installation
3.2 Storage
•Store the device in a dry and dust-free location.
•Store the device in its original packing.
INFORMATION!
Inspect the packaging carefully for damages or signs of rough handling. Report damage to the
carrier and to the local office of the manufacturer.
INFORMATION!
Do a check of the packing list to make sure that you have all the elements given in the order.
INFORMATION!
Look at the device nameplate to ensure that the device is delivered according to your order.
Check for the correct supply voltage printed on the nameplate.
WARNING!
Do not keep the device in a vertical position. This will damage the probe and the device will not
measure correctly.
Figure 3-1: Storage conditions
1 Do not bend rod and coaxial probes –support here
2 Storage temperature range: -50…+85°C/-60…+185°F (min. -40°C/-40°F for devices with the integrated LCD display
option)
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3.3 Transport
Figure 3-2: How to hold the device
Figure 3-3: How to hold the device
1 Remove the converter before you lift the device with a hoist.
2 Wind cable probes greater than 400 mm / 16¨in diameter.
3 Do not hold the probe when you lift the device.
4 Do not wind the flexible conduit less than 330 mm / 13¨in diameter.
WARNING!
If you do not lift the device carefully, you can cause damage to the probe.
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3.4 Pre-installation requirements
•Make sure that there is sufficient space on all sides.
•Protect the signal converter from direct sunlight. If necessary, install the weather protection
accessory.
•Do not subject the signal converter to heavy vibrations. The devices are tested for vibration
and agree with EN 50178 and IEC 60068-2-6.
3.5 How to prepare the tank before you install the device
3.5.1 Pressure and temperature ranges
INFORMATION!
Obey the precautions that follow to make sure that the device is correctly installed.
CAUTION!
To avoid measuring errors and device malfunction, obey these precautions.
Figure 3-4: Pressure and temperature ranges
1 Process connection temperature
The process connection temperature must stay in the temperature range of the gasket material unless the device is
a High-Temperature version. Refer to the table "Temperature ranges for gaskets" that follows and to "Technical data"
on page 130.
Ex devices: see supplementary operating instructions
2 Ambient temperature for operation of the display
-20...+60°C / -5...+140°F
If the ambient temperature is not between these limits, the display screen switches off automatically
3 Ambient temperature
Non-Ex devices: -40...+80°C / -40...+176°F
Ex devices: see supplementary operating instructions
4 Process pressure
Refer to the table "Process pressure limits" that follows and "Pressure/temperature table for probe selection" on
page 136.
WARNING!
The process connection temperature range must agree with the temperature limits of the
gasket material. The operating pressure range is subject to the process connection used and the
flange temperature.
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Temperature ranges for gaskets
Process pressure limits
Gasket material Process connection temperature
Standard version High-Pressure version High-Temperature and
High-Temperature /
High-Pressure
versions
[°C] [°F] [°C] [°F] [°C] [°F]
FKM/FPM -40…+200 -40…+392 -40…+150 -40…+302 -40…+300 -40…+572
Kalrez
®
6375 -20…+200 -4…+392 -20…+150 -4…+302 -20…+300 -4…+572
INFORMATION!
Ø4 mm / 0.16
Ø4 mm / 0.16Ø4 mm / 0.16
Ø4 mm / 0.16 ¨ single cable probe with FEP coating option only:
single cable probe with FEP coating option only:single cable probe with FEP coating option only:
single cable probe with FEP coating option only: The process connection
temperature range is -20...+150 ° C / -4...+302 ° F
INFORMATION!
Single rod probes with protective sheath option only:
Single rod probes with protective sheath option only:Single rod probes with protective sheath option only:
Single rod probes with protective sheath option only: The process connection temperature range
depends on the protective sheath material selected.
PP: -40...+90
° C/-40 … +194 ° F; PVDF: -40...+150 ° C/-40 … +302 ° F; PVC: -15...+80 ° C/+5 … +176 ° F
Device version Maximum process pressure
[barg] [psig]
Ø8 mm / 0.32¨single cable 40 1 580 1
All other probe types and device versions 100 1 1450 1
1Refer also to "Pressure / temperature table for probe selection" in the "Technical data" section
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