All rights reserved. It is prohibited to reproduce this documentation, or any part thereof, without
the prior written authorisation of KROHNE Messtechnik GmbH.
8.1 Order code for BM 500 ................................................................................................... 24
8.2 Order code for process connections.............................................................................. 25
9 Notes26
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BM 500
1.1 Intended use
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.
SAFETY INSTRUCTIONS 1
The potentiometric level meter BM 500
liquids and pasty and sticky products.
The device is particularly suitable for measuring low levels in the range of 50...1000 mm /
2...39.4". Thanks to the principle involved, this potentiometric measuring system is independent
of sticky deposits and varying product properties. All it needs is a minimum conductivity of
50 µS/cm.
1.2 Certifications
CE marking
The device fulfils the statutory requirements of the following EC directives:
• EMC specification acc. to EN 61326-1 (2006)
The manufacturer certifies successful testing of the product by applying the CE marking.
BM 500 is designed solely for measuring continuously the level of
BM 500BM 500
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1 SAFETY INSTRUCTIONS
1.3 Safety instructions from the manufacturer
1.3.1 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.
BM 500
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.
1.3.2 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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BM 500
1.3.3 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 and 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.
1.3.4 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 underneath icons.
SAFETY INSTRUCTIONS 1
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1 SAFETY INSTRUCTIONS
1.3.5 Warnings and symbols used
Safety warnings are indicated by the following symbols.
DANGER!
This information 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.
BM 500
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.
• HANDLING
HANDLING
HANDLINGHANDLING
This symbol designates all instructions for actions to be carried out by the operator in the
specified sequence.
iRESULT
RESULT
RESULTRESULT
This symbol refers to all important consequences of the previous actions.
1.4 Safety instructions for the operator
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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BM 500
2.1 Scope of delivery
INFORMATION!
Inspect the cartons 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.
The following items are supplied with the device:
• Measuring device
• Hygienic adapter (optional)
• Product documentation
DEVICE DESCRIPTION 2
2.2 Device description
The BM 500 level meter utilises the potentiometric measuring principle and can be used in all
medias that have a minimum conductivity of 50 μS/cm.
From the low resistive measuring rod a high frequent current is fed through the media to the
tank wall. The voltage between the tip of the rod and the tank wall is measured. This output
voltage is proportional to the level in the tank.
The measurement is unaffected by temperature and adhesive media.
The device is ideal for measurements in small vessels with tough, pasty or strong adhesive
media, such as ketchup, honey, and toothpaste. The integrated electronics provide a 4...20 mA
output.
The device has automatic recognition of top/buttom mounting position. Even angled installation
is possible.
In non-conductive tanks, e.g. plastic, a reference rod must be installed (order a standard
LS 7200 without electronics).
The BM 500 is available as compact and remote version. The remote version is recommended for
applications where the ambient temperature at the measuring point exceeds +60°C / +140°F.
Due to the high process temperature limit, the device is well suitable for CIP and SIP processes.
The hygienic installation is guaranteed by using one of the hygienic weld-in sleeves. For further
information refer to the specific data sheet "Hyg. accessories".
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2 DEVICE DESCRIPTION
2.3 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.
BM 500
Figure 2-1: Example of a nameplate
1 Device type
2 Operating pressure and temperature limits
3 Electrical data
4 Serial number
5 Manufacturing date
6 Maximum torque value
7 Approval and disposal icons
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BM 500
3.1 Installation requirements
• Be sure that the measuring rod has the correct depth of immersion when placing your order.
The sensor cannot
• Use only the recommended sleeves or adapters. If other systems are used, no guarantee can
be given for proper functioning or leak-tightness.
• The connection thread must have electrical contact with the metal vessel. If this is not
possible, use a separate grounding cable to meet this condition.
• Do not use Teflon or paper gaskets.
• The tightening torque for the sleeve should be 20...30 Nm.
• If the vessel is electrically non-conductive (e.g. plastic tank), the frame potential can be
established via an additional ground electrode, which is electrically connected to the
connection thread. E.g. a standard LS 7200 without electronics. Consult your local contact for
ordering assistance.
• Make absolutely sure that the measuring rod cannot come into contact with the wall of the
vessel. Also take into consideration the possibility of rod deflection caused by moving
product.
• For distances of less than 100 mm / 3.9" (e.g. when installed in vertical pipe runs) the sensor
rod should be located parallel to the wall, otherwise conditions of non-linearity can occur.
For large distances non-parallelity of the rods can be allowed.
• The level meter measures linearly over the full rod length.
Lower dead zone:
Lower dead zone: approx. 8 mm / 0.3" of the lower end of the measuring rod
Lower dead zone:Lower dead zone:
Upper dead zone:
Upper dead zone: approx. 44 mm / 1.73" of the upper end of the measuring rod (at the lower
Upper dead zone:Upper dead zone:
end of the conical part of the rod)
cannot be shortened subsequently!
cannotcannot
INSTALLATION 3
Figure 3-1: Upper and lower dead zone at measuring rod
1 Upper dead zone: approx. 44 mm / 1.73"
2 Active measuring range
3 Lower dead zone: approx. 8 mm / 0.3" immerged in the liquid
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3 INSTALLATION
INFORMATION!
Please be aware of the active measuring zone of the rod (refer to the following drawing).
BM 500
Figure 3-2: Measuring zone and output settings
1 21.6 mA
2 21.6...20 mA
3 Set point 100% = 20 mA
4 20...4 mA
5 Set point 0% = 4 mA
6 4...2.4 mA
7 2.4 mA
INFORMATION!
The BM 500 tracks level outside its normal 4...20 mA measuring range; up to 21.6 mA and down
to 2.4 mA.
•
Above 21.6 mA, the unit will freeze output at 21.6 mA.
•
Below 2.4 mA level, the unit will freeze output to 2.4 mA.
3.2 Process connection
The hygienic 1" process sleeve is easy to weld into tanks or pipes. This kind of assembly allows
installation in conformity with standards of hygiene such as FDA. The G1 connections can be
mounted in any counter thread acc. to ISO 228.
Various hygienic adapter sleeves are available for fitting to other process connections. For more
information refer to chapter "Appendix" or data sheet "Hyg. accessories".
The level meter can be installed either from top or bottom.
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BM 500
3.3 Mounting of 3A marked products
The 3A mark is valid only when the product is mounted in a 3A marked counterpart and installed
acc. to the installation manual. Use also a 3A marked O-ring or gasket if relevant.
The 3A marked products conform to the 3A sanitary standards criteria. Materials and surfaces
fulfill the FDA demands.
EPDM O-rings supplied with 3A marked products are conform to sanitary standards class II (8%
milk fat).
1 Use only 3A approved counterparts.
2 The inspection hole should be visible and drained. Face it downwards so that possible leaking
can be observed.
3 Mount the device in a self-drained position.
4 Level the inner surface of the pipe with the counterpart.
5 Weld from the inside of the tank, if possible. Welds shall be free from cracks, crevices and
grooves. Weldings should be grinded to R
6 The level meter can be installed on the side of the tank with a bent measuring probe.
7 The level meter can be installed from the bottom of the tank.
=0.8µm.
a
INSTALLATION 3
Figure 3-3: Mounting of 3A products in pipe installations (A) or tank installations (B)
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4 ELECTRICAL CONNECTIONS
4.1 Safety instructions
DANGER!
All work on the electrical connections may only be carried out with the power disconnected. Take
note of the voltage data on the nameplate!
DANGER!
Observe the national regulations for electrical installations!
DANGER!
For devices used in hazardous areas, additional safety notes apply; please refer to the Ex
documentation.
WARNING!
Observe without fail the local occupational health and safety regulations. Any work done on the
electrical components of the measuring device may only be carried out by properly trained
specialists.
BM 500
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.
4.2 Electrical connection diagrams
Terminals 1 (+) and 2 (-) are used for supplying a DC voltage of 18...36 V. Terminal 2 is connected
to the housing via a protective diode.
The maximum power consumption is 200 mA. This value should be taken into account in
connection with the recommended use of a fuse.
An active, galvanically isolated 4...20 mA current output is provided at terminals 3 and 4. Please
consider the applicable wiring regulations.
+-+-
14
Figure 4-1: Electrical connection and LED indication for setpoints for M16 cable gland
1 18...36 VDC
2 4...20 mA
3 LED is flashing at correct measurement
4 Push button > 3 seconds to set point for 100%, 20 mA
5 Push button > 3 seconds to set point for 0%, 4 mA
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BM 500
ELECTRICAL CONNECTIONS 4
Figure 4-2: Electrical connection of M12 plug
1 18...36 VDC (+)
2 4...20 mA (-)
3 18...36 VDC (-)
4 4...20 mA (+)
• Pin 1: brown
• Pin 2: white
• Pin 3: blue
• Pin 4: black
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5 OPERATION
5.1 Start-up
Before connecting to power, please check that the system has been correctly installed.
This includes:
• The device must be mechanically safe and mounted in compliance with the regulations.
• Check that the measuring rod is not in contact with the vessel wall.
• Check the leak-tightness at the leakage inspection hole of the sleeve or adaptor.
• Make sure that the M12 plug is properly connected or the M16 cable gland properly tightened.
• The power connections must have been made in compliance with the regulations.
• Check that the electrical operating data of the power supply are correct.
5.2 4 and 20 mA setting
• The green LED indicates that supply voltage (> 18 V) is present (operation indicator).
• The 2 red LEDs show different flashing rates (LED monitor), according to the control of the
current output.
• The level meter can be installed at the top or the bottom of the tank.
• The level meter is factory calibrated for installation from the top. This corresponds to 4 mA at
the lower rod end and 20 mA at the upper end (lower part of the conical section of the
measuring rod; see drawing on page 11). When installed from the bottom, the current will
drop down step by step until the tank is empty or the current hits 2.4 mA.
• 4 and 20 mA setting:
4 and 20 mA setting:
4 and 20 mA setting:4 and 20 mA setting:
This procedure is only required when a smaller measuring range is needed than the
maximum measuring range calibrated from factory or in case of a big difference in
conductivity with tap water exits. When two liquids are present - choose the liquid with the
lowest conductivity for the lowest level setting.
1. Bring level to 0% level - then press for > 3 seconds the 4 mA setpoint key. The 4 mA red
LED is "ON" which confirms the setting.
2. Raise level to 100% level - then press for > 3 seconds the 20 mA setpoint key. The 20 mA
red LED is "ON" which confirms the setting.
• In bottom mounting position:
In bottom mounting position: The level meter will show a negative value, when the level
In bottom mounting position:In bottom mounting position:
representing the 20 mA level, accidently was set at a lower level than the 4 mA level.
• Resetting to factory calibration:
Resetting to factory calibration:
Resetting to factory calibration:Resetting to factory calibration:
Press simultanously for > 3 seconds both setpoint keys, both red LEDs will continously flash
to indicate that the level meter is reset. Repeat above calibration procedure for setting the 0%
and 100% values.
• The "dry" signalling threshold is set simultaneously with the low level calibration. When the
conductivity measured here is undershot, the sensor signals the "dry" condition with a
current output value of 2.4 mA. Given different products with widely differing conductivity, the
4 mA adjustment should be carried out using the least conductive liquid.
BM 500
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BM 500
5.3 Fault diagnosis and corrective action
INFORMATION!
•
In the event of a fault or malfunction, please go through the various possible faults listed in
the table.
•
Please do not attempt to take the device apart.
•
There are no parts requiring maintenance.
FaultCauseAction / elimination
LED status display not "on"Supply voltage < 18 VMeasure voltage at pin 1, 2.
Supply voltage has false polarity
Note: The level meter is polarity
protected. No damage to the
electronics will occur when the
wiring was accidently reversed.
Current output < 4 mASensor "dry"OK
Conductivity too low4mA adjustment
No connection to metalCheck connection to frame /
Measured value incorrectAdjustment faultyAdjust 4 and 20 mA settings or
Poor connection to frameCheck connection to frame /
OPERATION 5
Reverse terminals 1, 2.
thread
factory reset
thread
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6 SERVICE
6.1 Availability of services
The manufacturer offers a range of services to support the customer after expiration of the
warranty. These include repair, maintenance, technical support and training.
INFORMATION!
For more precise information, please contact your local sales office.
6.2 Spare parts
This device contains no replaceable parts. In case of malfunction the device must be returned to
the manufacturer. Refer also to chapter "Returning the device to the manufacturer".
DesignationType
Housing coverKMD.006.090.000
Cable gland M16KVV.M16.010.008
Connector insert M12KVV.100.004.000
Connector part 4-pinKVK.046.210.018
BM 500
6.3 Returning the device to the manufacturer
6.3.1 General information
This device has been carefully manufactured and tested. If installed and operated in accordance
with these operating instructions, it will rarely present any problems.
CAUTION!
Should you nevertheless need to return a device for inspection or repair, please pay strict
attention to the following points:
•
Due to statutory regulations on environmental protection and safeguarding the health and
safety of our personnel, manufacturer may only handle, test and repair returned devices that
have been in contact with products without risk to personnel and environment.
•
This means that the manufacturer can only service this device if it is accompanied by the
following certificate (see next section) confirming that the device is safe to handle.
CAUTION!
If the device has been operated with toxic, caustic, flammable or water-endangering products,
you are kindly requested:
•
to check and ensure, if necessary by rinsing or neutralising, that all cavities are free from
such dangerous substances,
•
to enclose a certificate with the device confirming that is safe to handle and stating the
product used.
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BM 500
6.3.2 Form (for copying) to accompany a returned device
Company:Address:
Department:Name:
Tel. no.:Fax no.:
Manufacturer's order no. or serial no.:
The device has been operated with the following medium:
SERVICE 6
This medium is:water-hazardous
toxic
caustic
flammable
We checked that all cavities in the device are free from such
substances.
We have flushed out and neutralized all cavities in the
device.
We hereby confirm that there is no risk to persons or the environment through any residual media
contained in the device when it is returned.
Date:Signature:
Stamp:
6.4 Disposal
CAUTION!
Disposal must be carried out in accordance with legislation applicable in your country.
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7 TECHNICAL DATA
7.1 Measuring principle
Figure 7-1: Measuring principle
1 U
to amplifier
out
2 U
gen
3 Medium
4 Tube
5 Tank
BM 500
The liquid is stored in a tank, connected to ground. The immersed measuring rod is a low
resistance rod where the ends are powered by an AC generator operating in the lower kiloherz
frequency range.
Between the rod and the tank wall is an endless amount of high level resistances. Since they
connect to the same potential (the tank wall) they can be shown as two equivalent resistances,
R1 and R2 connected to an imaginary center point. A high resistance input amplifier is connected
between the generator and the tank wall.
Since the generator is supplying a high range current it will create a significant voltage drop
across the low resistance rod. The resistances R1 and R2 form a voltage divider in range of the
immersed part of the rod. Output from this divider will indicate half the level of the liquid. The
amplifier then calculate the actual level of liquid from 0 to 100%.
The formula is:
= 1/2 x media level (%) x U
U
out
Media level (%) = U
out/Ugen
gen
x 2
The level measurement is insensitive to adhesion.
CAUTION!
It is very essential that the media conductivity is homogenious. Otherwise R1 will not be equal to
R2 and the output voltage will be influenced.
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BM 500
TECHNICAL DATA 7
7.2 Technical data
INFORMATION!
•
The following data is provided for general applications. If you require data that is more
relevant to your specific application, please contact us or your local sales office.
•
Additional information (certificates, special tools, software,...) and complete product
documentation can be downloaded free of charge from the website (Download Center).
Measuring system
Measuring principlePotentiometric, low resistive
Application rangeLevel detection of all media with the minimum conductivity of 50 µS/cm in
Design
OptionsRemote version for applications with ambient temperature above +60°C/
AccessoriesComprehensive range of adapters and process connections for hygienic
tanks.
+140°F
installation. Please refer to the chapter "Order information".
Measuring accuracy
Accuracy± 0.5% of full measuring length
Repeatability± 0.1%
Operating conditions
Temperature
Temperature
TemperatureTemperature
Ambient temperature (compact)-20…+60°C / -4…+140°F
Ambient temperature (remote)-20…+100°C / -4…+212°F
Process temperature-20…+140°C / -4…+284°F
Medium conductivity≥ 50 µS/cm
Min. measuring range50 mm / 2", configurable by push-buttons
Pressure
Pressure
PressurePressure
Ambient pressureAtmospheric
Process pressure≤ 16 bar / 232 psi
Other conditions
Other conditions
Other conditionsOther conditions
Ingress protection
(acc. to EN 60529)
IP67 equivalent to NEMA 4X
Installation conditions
InstallationInstallation from top or bottom (automatic position detection)
Probe length200…3000 mm / 0.6…10 ft
Cable length1000…5000 mm / 3.3…16.4 ft (only for remote version)
Dimensions and weightsFor detailed information refer to chapter "Dimensions and weights".
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7 TECHNICAL DATA
BM 500
Materials
ProbeStainless steel 1.4404 / AISI 316 L
HousingStainless steel 1.4301 / AISI 304
Process connectionStainless steel 1.4404 / AISI 316 L
Sensor insulationPEEK, FDA conform
Electrical connectionM16 cable glands: Plastic
M12 plug: Nickel-plated brass
Process connections
StandardHygienic G1
OtherFor other hygienic process connections, e.g. Tri-clamp, 11851, Varivent see
chapter "Order information".
Electrical connections
Power supply 18…36 VDC; max. 200 mA
Resolution, input15 bit
Output4...20 mA; max. load 500 Ohm
Status signal, "dry"2.4 mA
Status signal, "full"21.6 mA
Response timeT66 < 10 ms
Cable entryM16 cable glands, M12 plug
Approvals and certifications
CEThis device fulfils the statutory requirements of the EC directives.
Other standards and approvals
Other standards and approvals
Other standards and approvalsOther standards and approvals