Certificates and Approvals ............................................................................................. 61
PC STAR software installation and operation instructions ......................................... 62
Handbook BM 100 A 3
General advice on safety
The device will normally weigh between approx. 11 kg / 25 lb and 35kg / 77 lb. Carry the
device using two people, lifting it by the flange holes and supporting the probe. Lifting
gear may also be used but no attempt should be made to lift the device by the probe.
Range of application
The BM 100 A TDR Level gauge measures the level and volume of liquids and liquid gases. It can
also measure the level and volume of pastes, powders, slurries and granular products.
The BM 100 A also permits continuous and simultaneous measurement of liquid level and interface
of two liquids.
For the storage of volatile products, such as water and carbon disulphide
also be equipped with a probe (type G) to measure the interface with a top mounted probe: this
avoids the resultant safety issues of installing a gauge under the tank.
tanks, the BM 100 A can
Items supplied
• signal converter connected to a cable, coaxial or rod signal guidance probe, as per order.
Optional: remote extension with wall support, sunshade (with fastening material in each case)
• bar magnet for operator control / parameter assignment (only for version with local display)
• wrench for the covers
Documentation supplied
The following documentation will be included with the instrument:
• installation and operating instructions (this manual), and handbook.
• approval documents, unless reproduced in the installation and operating instructions.
4 Handbook BM 100 A
Principal gauge components
Non-Ex version Ex Version
1 Cable entry (output)
2 Cable entry (power supply)
3 Local user interface (display screen, buttons and magnetically-actuated hall sensors)
4 Nameplate (see diagram on the following page)
5 Flange
6 Single cable probe
7 Counterweight
8 Twin cable probe
9 Spacer
10 Short-circuit
11 Equipotential bonding system connection (Ex)
12 Isolating chamber – separates electronics housing from hazardous products
13 Pressure release plug (1 bar or 14.5 psi limit) and vent
14 Coaxial probe
Handbook BM 100 A 5
Standard nameplate
Product liability and warranty
The BM 100 A TDR level gauge is designed solely for measuring the distance, level, interface and
volume of liquids, pastes, slurries, solids and particulate materials.
The BM 100 A TDR level gauge does not form part of an overfill protection system as defined in
WHG nor is it concerned by the Pressure Equipment Directive (PED) 97/23/EC.
Special codes and regulations apply to its use in hazardous areas.
Responsibility as to suitability and intended use of these level gauges rests solely with the user.
Improper installation and operation of our level gauges may lead to loss of warranty.
In addition, the "General conditions of sale", found on the back of the invoice and forming the basis
of the purchasing contract, are applicable.
If you need to return the level gauge to the manufacturer or supplier, please refer to the information
given in appendix A.
6 Handbook BM 100 A
1 Mechanical installation
1.1 Handling and storage
1.1.1 Avoiding blows
Avoid hard blows, impacts and jolts when handling the BM100A.
Caution :
The probe is a critical gauge component.
Do not damage– Handle with care!!!
Caution : fragile electronics
1.1.2 Avoiding bending
Rod/ Coaxial probes: support the probe to avoid bending.
Support probe here
1.1.3 Avoiding cable kinks or fraying
Do not coil the cable less than 400 mm / 16’’ in diameter. Cable kinks or fraying will cause
measurement errors.
Handbook BM 100 A 7
1.2 Installation restrictions
Hazardous-duty systems (Ex, FM…)
• refer to the supplementary instructions for gauges approved for use in hazardous locations
before installation.
• check that the flange, gasket and probe materials are compatible with the product. Read the
information given on the converter nameplate, the flange markings and specifications in the
approval certificates.
1.3 Mounting on a tank
1.3.1 Installation instructions: General notes
The fitter should give some thought to tank fittings and tank shape:
• nozzle position in relation to the tank walls and other objects inside the tanks
(Warning : this free area will depend on the probe type selected: refer to later on in this section)
• type of tank roof , i.e. floating, concrete, integral, etc; and base, i.e. conical,etc.
1.3.2 Installation instructions: Nozzle
Nozzle height
Recommendation (especially for single probes and powder applications):
Do not fit a nozzle longer than its diameter.
h ≤ Ød
Contact KROHNE if this relationship cannot be respected.
, where h = nozzle height and d = nozzle diameter.
8 Handbook BM 100 A
Nozzles extending into tank
Caution:
Do not use nozzles that extend into the tank. This will block the emitted pulse.
Process connection
For the gauge to make accurate measurements:
• the tank process connection must be level.
• ensure a good fit with the gauge process connection
• the tank roof should not deform under the weight of the gauge
Objects (discontinuities) inside the tank that influence the probe EM (electromagnetic) field
Install the process connection far from protruding objects such as:
• heating tubes
• sudden changes in tank cross-section
• tank wall reinforcements and beams,
• weld lines and dip-stick pipes, etc...
Refer to the figure at the top of the following page.
TDR gauges generate electromagnetic fields when a measurement pulse is emitted. This field is
affected by any nearby discontinuities and these will weaken and potentially block the emitted pulse.
A minimum distance is recommended depending on the probe type to be installed. See the table on
the next page for recommended free space dimensions.
Alternatively, the fitter may use a reference chamber or stilling well. However, the chamber walls
must be smooth (i.e. no visible weld lines), straight and vertical to maintain the pulse strength and
gauge accuracy.
For clean applications only :
Coaxial (type D) probes may be used close to or touching objects or walls as the EM field generated
by the probe is contained within the probe’s outer sheath (refer also to the EM field sizes given in
the figures on the next page).
Handbook BM 100 A 9
1 Agitator
2 Support beam perpendicular to the pulse
direction
3 Abrupt changes in tank cross section
4 Heating tubes
5 Alternative solution: reference chamber -
electromagnetic field is contained within
chamber.
6 Gauge electromagnetic field :
Any intruding metallic object will be
detected in this zone if perpendicular to
the emitted pulse direction.
= Do not fit the process connection near to these objects.
Probe Type Recommended minimum distance of probe from
objects inside the tank in millimetres (inches)
Single (types F, H and K) 300 (12)
Twin (types A, B, G and L) 100 (4)
Coaxial (type D) 0 (0)
Electromagnetic field shape around probe, by type (not to scale)
Single (types F, H and K) Twin (types A, B, G and L) Coaxial (type D)
No beam angle for any probe type.
10 Handbook BM 100 A
Process connection and entry pipe
Caution:
Do not put the nozzle close to the entry pipe. Pouring the product directly onto the
probe will give false readings. Install deflector plate if impossible to distance gauge
from entry pipe.
Stilling wells
Tanks with floating roofs for petro-chemical applications: Use a stilling well.
1
Stilling well
2
Tank
3 Floating roof
4 Product (petroleum applications)
5 Well fixed to tank base (no roof
deformation)
6 Sediment
Handbook BM 100 A 11
1.3.3 Installation instructions: Gauge - all applications
BM100 A gauges are designed to be mounted on a suitable process connection on a tank or sump.
Install the gauge using two people to avoid damaging the probe. Support the housing and the probe.
Installation of single and twin cable probe level meters
Caution :
1
Do not over-bend
probe!
Inserting the probe:
2
hold more than one
metre above the
opening to avoid cable
bending.
Outdoor sites
Fit a sunshade on the gauge for open-air installations: this is supplied on demand. The ambient
temperature limits of the gauge are given below.
12 Handbook BM 100 A
Cable probes: entanglement and straightness
The cable must be straight once inserted into the tank. The cable counterweight should not touch
the bottom of the tank. The cable must be far from other objects (e.g. mixers) to avoid entanglement.
Rigid length of single and twin cable probes
Cable diameter Rigid length
Single cable
Ø4mm or 0.15” 145mm or 5¾”
Ø8mm or 0.3” 200mm or 8”
Twin cable
Ø4mm or 0.15” 145mm or 5¾”
Ø6mm or 0.24” 145mm or 5¾”
Handbook BM 100 A 13
1.3.4 Specific installation instructions: gauge - liquid applications
Probe bending in agitated products: recommended solutions
Probe (Type) Supports and fastenings Stilling well installation*
Twin rod (A)
Twin cable (L) Fit an anchor with an M10 x 1 (Ø4mm/0.16”
Weld a 45mm / 1.8” internal diameter tube on
the bottom of the vessel then insert the
probe.
cable) thread (i.e. spring ring or hook) to the
counterweight*** CAUTION: 6 Nm / 4.4 lbf.ft
maximum torque. This cable may also be
ordered with a turnbuckle.
Possible. On-site calibration may
be required to maintain accuracy.
Repeatability is unaffected.
Possible. On-site calibration may
be required to maintain accuracy.
Repeatability is unaffected.
Centring the probe is
recommended. Contact KROHNE
for more information.
Single rod (F) Weld a 12mm / 0.5” internal diameter tube on
the bottom of the vessel, insert the rod****.
Possible. 50 mm / 2” minimum
diameter chamber. Contact
KROHNE for assistance.
Single cable (H) Fit an anchor with M10x1 (Ø4mm cable)
thread underneath the counterweight : spring
ring or hook. CAUTION: 4 Nm / 2.9 lbf.ft
Possible. 50 mm / 2” diameter
minimum. Contact KROHNE for
assistance**.
maximum torque. This cable may also be
ordered with either a chuck or turnbuckle.
Coaxial (D) Weld a 30-32mm / 1.2” internal diameter tube
on the bottom of the vessel, insert the tube. A
Unnecessary: probe unaffected
by nearby objects.
probe may be fixed with braces.
* Reference (bypass) chamber or stilling well.
Spacers supplied by KROHNE.
**
*** Threaded hole provided in base of counterweight.
**** Contact KROHNE. A factory menu function may need to be changed.
1 Turnbuckle
2 Chuck for type H Ø4mm
single cable probe
3 Counterweight with threaded base
4 Avoid play between tube and probe
5 Hole in welded tube for drainage
Anchoring twin rod and coaxial probes
14 Handbook BM 100 A
1.3.5 Specific installation instructions: gauge - solid applications
False readings:
1
Do not let probe touch the side of the nozzle
Conical silo nozzles, False readings and traction on the cable probes
Caution
High traction forces :
2
We recommend that the probe should not be
anchored to avoid excessive traction loads on
the cable.
Bending and traction:
3
Position the connection on the roof at ½
radius of the tank and with minimum nozzle
height. This will avoid damage due to
bending and traction during emptying.
Traction forces during emptying cycles for powder applications
Traction load is dependent upon the height and shape of the tank, product particle size & density,
and the rate at which the tank is emptied. The table below gives the load at which cable probes will
break.
Cable maximum design loads, traction
Probe Maximum Load
Type K : Single cable Ø8 mm / Ø 0.3” 3.5 T / 7700 lb
Type B : Twin cable Ø6 mm / Ø 0.2” 3.6 T / 7900 lb (1.8 T / 3950 lb per cable)
Handbook BM 100 A 15
Traction on cable according to product (approximate value in metric tons)
Material Probe used
Probe Length / m (ft)
10 (32.8) 20 (65.6) 30 (98.4)
Cement Single cable Ø8 / Ø0.3’’ 1.0 T / 2200 lb 2.0 T / 4410 lb 3.0 T / 6620 lb
Flyash Single cable Ø8 / Ø0.3’’ 0.5 T / 1100 lb 1.0 T / 2200 lb 1.5 T / 3300 lb
Wheat Single cable Ø8 / Ø0.3’’ 0.3 T / 660 lb 0.6 T / 1320 lb 1.2 T / 2650 lb
PE granules Twin cable Ø6 / Ø0.2’’ 0.2 T / 440lb 0.6 T / 1320 lb 1.0 T / 2200lb
Electro static discharge (E.S.D.)
BM100 Standard and Ex gauge electronics are normally shielded up to 16KV against E.S.D.*.
*For non-Ex powder applications, BM100A probes are protected up to 32 kV.
Note:
E.S.D. cannot be solved by BM100A E.S.D. protection. It is the customer’s responsibility
to avoid E.S.D. by grounding the tank, product and probe installation.
1
Danger of injury
The probe may become electro
statically-charged during
operation; earth the probe by
pushing it against tank wall with a
suitably isolated tool just before
touching it to avoid receiving a
shock.
2 Earth the entry pipe and product.
Product deposits on the nozzle and probe
Product build-up can occur under the nozzle: this may weaken the pulse. Avoid cavities that permit
the build-up of deposits.
Tank roof deformation
Tank roofs should support loads of at least 3.5 tonnes / 7700lb for gauge installations using type K
single cable probes and 3.6 tonnes / 7900 lb for gauge installations using type B twin cable probes
without deformation.
16 Handbook BM 100 A
2 Electrical Connections
2.1 Insulation rating
The gauge transmitter electrical insulation conforms to IEC 1010-1. Please note the information
below concerning each rating category.
Category
Power supply overvoltage category
Output circuit overvoltage category II Fuses are unnecessary.
Insulation
Protection class 1
Galvanic isolation of terminals
The gauge conforms to the following standard and E.U. Directive:
Standard/Directive Description
EN (IEC) 61010-1 Safety requirements for electrical equipment for measurement, control and
73/23/EEC Council Directive of 19 February 1973 on the harmonisation of the laws of
The BM 100 A gauge outputs are galvanically isolated from the power supply and ground in
accordance with the regulations given above. An external barrier is unnecessary.
Rating Comments
The gauge does not have an integrated switch or circuit-
III
contamination level 2 The contamination level refers to the protection of internal
laboratory use (low tension)
Member States relating to electrical equipment designed for use within
certain voltage limits (low voltage) modified by Directive 93/68/EEC (art.13).
breakers. These elements must be installed in
conformance to local regulations and EU Low Voltage
Guidelines and to properly isolate the equipment when
necessary. Note that this is not obligatory for instruments
with 24 V power supply boards.
4 to 6.3 A time lag fuses are recommended for external
installation.
Fuses must be installed on every electrical conductor for
the system to conform to current regulations.
Note that the active phase conductor, L, is protected by an
internal fuse: the neutral conductor, N, is not.
elements of the signal converter.
Rated IP 67 (equivalent to NEMA 6-6P) against ingress of
water and other foreign bodies.
Note that the gauge can operate in contamination level 4
conditions if installed correctly.
Handbook BM 100 A 17
2.2 Electrical installation instructions
2.2.1 Wiring general notes
Read these instructions carefully!
Wiring must comply with any existing local regulations. Use appropriate wiring methods, conduits
and fittings to maintain a NEMA 6-6P / IP 67 rating.
1. Always disconnect the mains power supply before opening the housing,
2. unscrew the terminal compartment using the special wrench provided,
3. use the top cable entry port for the power supply (see “Principal gauge components”),
4. use a metal cable gland for input power leads to minimise RFI (radio frequency interference) /
5. use a reinforced cable for the outputs,
6. do not cross or loop wires in the signal converter wiring box,
7. do not kink cables close to the glands. Cover with a metallic sheath at this point if necessary,
8. make U-bends in the cable to provide water with run-off points,
9. earthing the device shall be done according to the local applicable installation standards (EN
10. and make sure that the cover thread in the housing is well greased and the O-ring is in good
EMI (electromagnetic interference) effects,
60079.14 in Europe),
condition before replacing the cover.
Shutting off the power supply : non-hazardous zones
Remember to disconnect the power supply before opening the housing.
Shutting off the power supply : hazardous zones
Wait before opening the housing cover. Refer to Supplementary Installation
and Operating Instructions for the BM100 A/Ai KEMA 01 ATEX 1078X
Gauge for the time required.
18 Handbook BM 100 A
2.2.2 Wiring connections
Open the signal converter housing rear cover, using the plastic wrench supplied. The terminal
connections are labelled. The standard connections are shown below.
Before starting to wire:
• check that the power supply corresponds to the power board installed.
• check which output option you have selected: this will be indicated on the underside of the rear
housing cover and on the gauge nameplate.
Terminal layout : non – Ex version
X = Terminal not used (X) = Terminal not used except for RS485 outputs
Ensuring a good contact and protection of wire strands
Local regulations concerning electrical wiring must be followed and obeyed. If no details are
given, we recommend :
• crimped metal sheaths over the wire strands
• power supply cables should be rated for at least 500 V, with a cable diameter of 0.5 to 1.5
mm / 0.02” to 0.06” (non-Ex applications only).
• the output current cable diameter should be from 0.5 to 0.75 mm / 0.02” to 0.03”
PE Ground Terminal notes
The internal earth connection shall be used according local applicable installation standards, in
Europe the Low voltage Standard prescribes the connection of the yellow/green cable in case of
230VAC.
Handbook BM 100 A 19
Terminal layout : Ex version
(X) = Terminal not used except for RS485 outputs
Wiring the gauge for use in hazardous areas (Ex & FM)
Use the correct wires and spade tags for terminal connections as specified in the Supplementary
Installation and Operating Instructions for the BM100 A/Ai KEMA 01 ATEX 1078X Gauge.
PE Ground Terminal notes
The internal earth connection shall be used according local applicable installation standards, in
Europe the Low voltage Standard prescribes the connection of the yellow/green cable in case of
230VAC.
Options, power supply
The type of power supply to be used will be indicated on the gauge nameplate.
1. 100 – 240V AC -15%/+10% ; Power output : 9VA
2. 24 V AC/DC -15%/+10% ; Power output : 9VA
20 Handbook BM 100 A
Options, output
The output wires should be wired to the gauge terminals according to the type of output selected
when the order was placed. The type of output supplied will be indicated on the gauge nameplate
and a sticker on the inside of the housing rear cover. The principle output options are shown below:
• 1 passive output: passive = external power source used for measurement output
• 1 active output: active = internal power source used for measurement output
• 2 passive outputs
Handbook BM 100 A 21
• 1 RS 485 output
with / without optional passive analogue current output for direct readings**
• 1 PROFIBUS PA output *
with / without optional passive analogue current output for direct readings**
* BM 100 A device management: a GSD file providing a device communication features list is
delivered with PROFIBUS PA-output devices.
** must be specified in customer order.
22 Handbook BM 100 A
3 User Interface
The BM100A may be configured and operated using a user interface set into the signal converter
housing or a remote link. Remote links using PC STAR, KROHNE’s in-house developed software
and Fieldbus remote links are given at the end of section 3.4.3.
3.1 Power On and self-test mode
The BM100A automatically self-tests once connected to a
power source. The screen readout shown on the left will be
displayed. This test takes from 20 seconds to 1½ minutes to
complete.
The local display will then switch over to the operation mode
display shown on the following page.
Firmware release currently programmed into the EPROM
(Electrically Programmable Read Only Memory)
3.2 Local user interface
The BM100A Local user interface is simple to use. It has three push-buttons, three magneticallykeyed sensors for configuring the gauge without removing the front cover in hazardous zones and a
three-line LCD (Liquid Crystal Display) screen at the front of the signal converter housing.
ENTER Hall Sensor:
The display screen will go blank below
–20°C / -4°F but data can still be
displayed if the instrument is
connected to a computer with PC
STAR or other remote link.
Handbook BM 100 A 23
1
Keyed using a bar magnet. As item 6.
First Display Line:
2
Operating mode- measurement value
Configuration mode- function number
Second Display Line:
3
Operating mode- item measured and units
Configuration mode- function definition
UP Hall Sensor:
4
Keyed using a bar magnet. As item 5.
Press the UP push-button:
5
• To increase the value of a selected digit
• For password definition : code U or
Press the ENTER push-button:
6
• To go back a step in the menu
• To validate data entered
• For password definition : code E or
Press the RIGHT push-button:
7
• To enter configuration mode
8
Keyed using a bar magnet. As item 7.
9
See the next page for details.
10
• To move cursor right in configuration mode
• For password definition : code R or
RIGHT Hall Sensor:
Status Markers:
Key register symbol:
↑
→
Enter pressed
Up pressed
Right pressed
↑
↵
→
3.3 Status Markers
This line of numbers identifies six types of errors by means of a triangular indictor over the number
concerned.
Status marker
number
▼1 No initial pulse detected See section 4.3: Fault clearing.
▼2 No level reflection detected See section 4.3: Fault clearing.
▼3 Level measurement frozen Output and indication frozen; search initiated to
▼4 No interface reflection found See section 4.3: Fault clearing.
▼5 Interface measurement
▼6 Output communication failure Contact your local KROHNE Service Department.
If the parameter 1.2.6 Error Display is configured to “YES” as explained in section 3.4.5,
the complete display screen will flash when an error occurs.
Error / Status message Result and action
redetect level : if no reflection is registered :
Status marker 2 is activated.
Output and indication frozen; search initiated to
frozen
redetect interface. If no reflection is found, Status
marker 4 is activated.
3.4 Parameter Settings
3.4.1 General Information
Your BM100 A has now been installed on the tank and the necessary electrical connections have
been made. Once the power has been switched on, it may be necessary to configure the gauge to:
• display the readings using the correct units and reference point (level / distance ),
• change the measurement range,
• give the instrument an address so that it may be integrated into a network,
• display volume readings by programming and using a volume calibration table (strap table).
We recommend that any changes to settings be noted on the configuration record supplied in
appendix B, or recorded using PC-STAR, to enable KROHNE service personnel to provide a rapid
response to any enquiries.
3.4.2 Configuration Procedure
The BM100 A starts up in operating mode displaying either information according to customer
specifications or factory default values.
The configuration mode (user menu) can be accessed and parameters modified by following the
operator control concept summary below. Configuration procedure is described in more detail in
section 3.4.3.
Instruments may equally be configured individually using a remote display available in PC-STAR
software for remote connections. Please refer to the PC-STAR on-line Help file for more details.
A restricted-access factory menu is available for advanced configuration. Refer to the BM100 A
Service Manual for further information.
24 Handbook BM 100 A
Handbook BM 100 A 25
3.4.3 Quick Configuration: configuration examples
The minimum functions (fct.) to be configured for a simple measurement are listed below:
• 1.1.1
• 1.2.1-6
• 1.4.2-3
• 1.3.1-4
• 1.7.1-2
Tank Height
Display Functions
Entry Code 1 / Code 1
Current Output 1 (& 2)
Volume calibration*
*For volume measurements
Example procedures for each set of functions are given on the following pages. Each procedure is
given in a series of steps in table form and begins from the Operating Mode.
Useful definitions for quick configuration
Typical gauge used for quick configuration examples
Probe type: twin Ø4mm/0.16” cable probe, type L
Tank height (Fct. 1.1.1): 10000.00mm/33ft
Hold distance (Fct. 1.1.2) 0.25m/10ft (see “probe measurement limits” in section 6.2.3 for
the Ø4mm twin cable probe, type L)
Probe length, L
(Fct. 1.1.7): 9.00m/29.5ft (Do not modify unless advised to)
1
26 Handbook BM 100 A
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