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MT5000
Operation Manual
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K-TEK MT5000 Operation Manual

MT5000-0200-1 Rev f (10-2010) DCN0528
TABLE OF CONTENTS
1.0 Introduction ................................................................................................................................ 3
2.0 Overview .................................................................................................................................... 4
2.1 Storage and Handling Information ..................................................................................... 4
2.2 Ambient Temperature ........................................................................................................ 4
2.3 Description and Principle of Operation .............................................................................. 4
3.0 Installation .................................................................................................................................. 6
3.1 Mechanical Installation ....................................................................................................... 6
3.2 Shortening of the Probe ..................................................................................................... 7
3.3 Electrical Installation .......................................................................................................... 7
4.0 Commissioning .......................................................................................................................... 8
4.1 Display Operation ............................................................................................................... 8
4.1.1. Jumper Settings .................................................................................................... 9
4.1.2. Push Buttons ......................................................................................................... 9
4.2 MT5000 Menu Flow Chart .................................................................................................. 10
5.0 Troubleshooting ......................................................................................................................... 32
6.0 Installation Drawings for Intrinsic Safety & Standard Wiring ..................................................... 34
7.0 Installation Drawings for Explosion Proof.................................................................................. 36
8.0 CE Certificate of Conformity ...................................................................................................... 37
9.0 Customer Support ..................................................................................................................... 38
9.1 K-TEK RMA Form .............................................................................................................. 39
10.0 Warranty .................................................................................................................................. 40
MT5000-0200-1 Rev f (10-2010) DCN0528 2
1.0 INTRODUCTION
Thank you for using the K-TEK MT5000 Guided Wave Radar Liquid Level Transmitter. The MT5000 series is a second generation of products which have been designed for simplicity of setup while offering extensive configuration capabilities. You are invited and urged to review this instruction manual in its entirety prior to use of the transmitter. This will eliminate most installation problems due to improper configuration.
We, the K-TEK Family, sincerely hope you receive many years of reliable use from the MT5000 transmitter and welcome your feedback to consistently improve our all of our products. It is our desire to provide you, the user, with the most reliable, customer friendly device to suit your application needs.
When it comes to measuring the level of liquids, guided wave radar technology now offers more level-detection capabilities than ever before. For an ever-widening range of previously hard-to-measure products such as molten sulfur, liquid ammonia and petrochemicals, guided wave radar transmitters provide accurate level measurements even under harsh chemical environments, wide variations in operating temperatures and pressures, and low dielectric constants. Great strides have also been taken in making these units easier to configure to a variety of proc­ess applications coupled with the simplicity of integrating these devices with most digital communication protocols. These improvements come as a welcome relief to process engineers that seek solutions to measuring the contents of tanks, silos, hoppers, bins, mixing basins, and vessels in an expanded range of level applications across several different industries.
Because a guided wave radar transmitter has no moving parts, it has established itself as a level measurement technology that has distanced itself from traditional mechanical means, which don't hold up as well in dirty service. Guided wave radar achieves its non-mechanical level detection capability by measuring the time of flight of the transmitted signal.
Known more accurately as Time Domain Reflectometry (TDR), the process involves:
1. Sending microwave energy down into a vessel guided by an antenna.
2. When the pulse of radar energy reaches the product (indicated by a change in impedance), part of the pulse is reflected back toward the transmitter.
3. A receiver measures the exact duration of time between the transmitted and reflected signal—the "time of flight."
4. The device analyzes this time and ultimately displays the level of the product as a distance in inches, feet, meters, or other engineering units.
The MT5000 transmitter was developed with ease of operation in mind. We made use of a graphic display to pro­vide a more user friendly aspect to the transmitter configuration. The graphic display allowed us to incorporate multi­ple language options in the setup menu such as English, Spanish and Chinese. In the incorporation of the graphic display, the electronics were converted to a digital format. This provided a greater signal recognition capability and an ability to include an ―onboard oscilloscope‖ as an aid in troubleshooting tough applications.
The emphasis on simplicity extended itself beyond the use of multiple languages. The Basic Setup menu has been designed with a series of multiple choice questions which, when answered correctly, will configure the transmitter to the installation. The mA Output Setup menu has been expanded to include Loop Test and HART® Address capabilities.
Coupled with the development of the MT5000 series was the development of the KCOM™ software. KCOM™ is a
diagnostic tool which allows the MT5000 to be remotely configured using a computer and HART® interface modem. Beyond the Basic Setup parameters, the software will allow the user to view the return signal of the MT5000 on the computer screen. As a trouble shooting tool, a screen shot of the waveform may be taken and sent to the factory for
analysis. The KCOM™ software is free and may be downloaded from our website at www.ktekcorp.com.
For more information on the MT5000 series including liquid/liquid interface and bulk solids measurement visit our website at www.ktekcorp.com.
MT5000-0200-1 Rev f (10-2010) DCN0528 3
2.0 OVERVIEW
2.1 Storage and Handling Information
If possible, storage prior to installation should be indoors at ambient temperature, not to exceed the following: Temperature range: -40 to 150 degrees F. Humidity: 0 to 100% R.H. non-condensing.
To avoid probe damage: Do not transport or support the weight of the MT5000 by means of the probe. Installation of rigid probes and flange mounted transmitters may require the use of lifting equipment. Avoid sharp bending of cable probes which can result in poor instrument operation.
The lids on the MT5000 housing are sealed with o-rings. To avoid damage to the electronics, both lids should be closed tightly before and after installation.
2.2 Ambient Temperature
The MT5000 electronics temperature may not exceed 170°F / 77°C. For higher ambient temperatures due to radiant process heat, a high temperature extension option is required. The coupler process temperature shall not exceed the temperature stated in the datasheet specifications for the given coupler.
2.3 Description & Principle of Operation
The MT5000 is a 4-20mA loop powered Smart Level Transmitter, which is microprocessor based and is available with HART® communication. It uses very low power microwave energy to determine the level of the product being measured. In order to obtain optimum performance, it is important to understand the basic principle of operation. The
electronics housing is typically fitted with a special adapter ―Coupler‖ serving as a process connection and seal, and holding a solid rod or a cable. The rod or cable ―Probe‖ hangs into the vessel and acts as a wave-guide, i.e. the
microwave energy stays concentrated around the probe and along its length, instead of being dispersed in a cone, as it would be if there was no probe.
PROBE
COUPLER
HOUSING
MT5000-0200-1 Rev f (10-2010) DCN0528 4
A measurement cycle consists of the following:
1. A very short ―pulse‖ of microwave energy is applied at the cou- pler, to the Probe.
2. The pulse travels along the length of the probe and when it en­counters a discontinuity that is a dielectric constant change, such as the product surface, some of the energy is reflected and travels back towards the coupler.
3. When the reflected energy reaches the coupler, it is sensed by the electronics. By measuring the time elapsed between the initial pulse and the reflected one, the electronics can calcu­late the product level.
4. Since the microwave energy travels at the speed of light, one complete measurement cycle is made up of several thousands of Pulses. The electronics uses Time Domain Reflectometry (TDR), a sampling technique to reconstruct a waveform dupli­cating the actual real time signal, but at a much lower speed, so that it can be processed by the microprocessor. This process can be compared to using the stroboscope effect as when ob­serving a piece of machinery turning at high speed with a strobe light.
5. The measurement cycles are made 2 times per second and processed by special filtering techniques, before generating a current output proportional to the level of the product.
5
1
4
2 3
A simplified signal trace as seen on the graphic display (Figure 1) can be divided into three identifiable sections: Coupler Reflection, Signal Reflection and End of Probe Reflection.
The measurement principle using TDR is based on the fact that a dielectric constant discontinuity or geometric change will yield a positive pulse having certain amplitude above the baseline. The greater the dielectric constant difference, the greater the positive amplitude of the return signal. This means that a signal will show up on the base­line if there is a substantial change from a nozzle diameter to an open tank, for example, as signal plot at the proc­ess connection. This fact will be taken into account in the configuration of the MT5000 (Consult Basic Setup (Section 4.3) on Commissioning).
Signal Reflection
Threshold
Blanking
Coupler Reflection
End of Probe Reflection
Figure 1
Note: Operation is subject to the following two conditions:
1. This device may not cause harmful interference.
2. This device must accept any interference received, including interference that may cause undesired operation.
MT5000-0200-1 Rev f (10-2010) DCN0528 5
3.0 INSTALLATION
3.1 Mechanical Installation
Guidelines and Warnings for MT5000 installation:
Do not tamper or remove coupler from transmitter housing as this will damage the coupler.
All Installations
1. Do not mount the MT5000 in the product fill stream.
2. To obtain the best return signal from the product level mount the MT5000 coupler directly into the top of the ves­sel.
3. Do not mount MT5000 single probes using bushings. (Figure 2)
4. Ideally, probes should be mounted in the center of the vessel to provide the maximum measuring range.
5. Avoid internal obstructions such as tubing, ladders or agitators.
6. An MT5000 installed in a nozzle whose height is greater than its width will have an increased non-linear zone at the top of the probe.
7. Cable probes with weights should be allowed to hang under the tension of the weight within the vessel. Shorten­ing of the probe may be required.
8. To avoid excessive movement of the MT5000 probe in an agitated process, or where installation close to the vessel wall is required, secure the bottom end of the probe to the vessel. Probes installed from top of the vessel may require the use of a stilling well.
9. Probes installed in side vessel connections require additional probe support within the nozzle connection.
10. Threaded connections should be installed with thread sealant approved for use by the consumer. Flanged con­nections should be made using materials (bolts, studs, nuts, and gaskets) and procedures (torque specifications) approved by the consumer.
Assembly Instructions for Loose Shipments:
At times, the rigid probe (i.e. P01 or P02) or flexible cable (i.e. P11 or P12) will be shipped as a loose (separate) as­sembly. In this case, an identification tag will be attached to the probe/cable to identify the serial number/transmitter it is associated with.
1. Locate the top end of the probe/cable that has a threaded FNPT connection.
2. Locate the bottom end of the transmitter coupler that has a threaded MNPT connection.
3. Apply LOCTITE 222MS to the MNPT connection.
4. Fasten the probe/cable hand tight to the MNPT connection and allow this to cure for 15 minutes.
5. Ready for installation.
Plastic Tanks, Fiberglass Tanks, and Open Air Installations
1. Single probe units require the use of a metal mounting flange or plate to launch the microwave energy down length of the probe. A minimum 6 inch (150mm) OD, 3/8 inch (10mm) thick plate should be used.
2. A MT5000 installed in a non-metallic vessel or open air envi­ronment will be subject to interference from other electromag­netic devices such as radios. Stilling wells may be required to eliminate this interference.
Concrete Tanks
1. Tanks constructed of concrete require probe mounting be:
1 ft. / 0.3 m from wall with up to 20 ft. / 6.1 meter measur­ing length 2 ft. / 0.61 m from wall over 20 ft. / 6.1 meter measuring length
2. Single probe units require the use of a metal mounting flange or plate to launch the microwave energy down length of the
CORRECT
Figure 2
NOT
RECOMMENDED
MT5000-0200-1 Rev f (10-2010) DCN0528 6
3.2 Shortening of Probe
The MT5000 single rod and cable probe can be cut to length prior to installation. If shortening of the probe is neces­sary, cut the rod or cable to the desired length using a hacksaw.
Shortening of coaxial probes in the field is not recommended.
The centering disc or weight at the end of the probe must be reattached for proper operation. The Probe Length parameter in the Basic Setup menu will need to be adjusted for the new probe length.
3.3. Electrical Installation
Electrical connection to the MT5000 should approach the transmitter head from below the conduit opening to provide
a drain for moisture. Install conduit to ½‖ NPT port and run 18 gauge twisted, shielded pair to housing. Refer to Sec-
tion 4 wiring diagram ELE1015 for typical loop wiring diagram and to ELE1014 for instructions applicable to intrinsic safety installation.
Apply loop power to the transmitter as follows:
Terminal Block + 14 VDC minimum to 36 VDC Maximum Terminal Block - To control System Input Ground Screw GROUND
Note: The ―+Meter‖ and ―-Meter‖ terminals are available to hook up a mA meter to monitor loop current, without breaking the loop.
The housing cover can only be removed when the unit is installed in a non-hazardous area, when in­stalled with intrinsic safety barrier, or when power is removed from the transmitter.
Ground Screw
MT5000-0200-1 Rev f (10-2010) DCN0528 7
4.0 COMMISSIONING
The MT5000 transmitter has been designed with a simple easy to follow setup menu. To make this unit operational, at a minimum, the items in the BASIC SETUP menu must to be entered. If further setup is required, a Quick Calibra­tion may be used or additional menu items will need to be entered.
4.1 Display Operation
When power is applied to an MT5000 series transmitter, the display will light up with a title screen which shows the model type and the software revision. (Figure 4) This initial power up cycle will last for 3 seconds and the current output of the transmitter will hold at 4.00 mA.
Figure 4
After the initial power up cycle, the display will change to show the Measured Level and the Current Output. The output will also shift to the current corresponding to the level. (Figure 5)
Figure 5
By pushing the UP or Down button, the main display can be scrolled to display the level in terms of a percentage of calibrated range (Figure 6) or in terms of a linearized / strapped measurement. (Figure 7).
Figure 6 Figure 7
MT5000-0200-1 Rev f (10-2010) DCN0528 8
4.1.1. JUMPER SETTINGS
The jumper switches are located on the face of the electronics module and can be set up as follows (Figure 8).
ALARM (Left Jumper)
Placing the jumper to the lower position causes the output to go to 21.00 mA when there is a loss of signal or trans­mitter malfunction.
Placing the jumper to the upper position causes the output to go to 3.62 mA when there is a loss of signal or trans­mitter malfunction.
The alarm output works in conjunction with the ALARM DELAY setting available in the mA OUTPUT menu. The out­put will go to alarm state only if there is a loss of signal that lasts at least the duration of the alarm delay. The alarm delay default value is two seconds. For instance the output will hold the last measured value if there is a loss of sig­nal lasting less than two seconds and will go into the alarm condition if the loss signal exceeds two seconds.
WRITE PROTECT (Right Jumper)
When the jumper is in the lower position the transmitter configuration cannot be changed manually or via HART® communication. (Figure 8).
Placing the jumper in the upper position will allow the configuration parameters to be changed manually or via HART® communication. (Figure 8).
4.1.2. PUSHBUTTONS
Three pushbuttons are located on the lower portion of the module faceplate (Figure 8). These buttons will be used to navigate through the setup and configuration menu of the MT5000. Some operations will require the pushbuttons to be used together or held for a period of time to affect a change.
Write Protect Jumper:
UP = OFF
DOWN = ON
Fault Jumper:
UP = Fail Low = 3.6 mA
DOWN =Fail High = 21.00 mA
Figure 8
LVL XX.XX in XX.XX mA
Pushbuttons:
UP
DOWN
SELECT
MT5000-0200-1 Rev f (10-2010) DCN0528 9
4.2 MT5000 Menu Flow Chart
LVL: XXXX.XX” XX.XX mA
S
BASIC SETUP
LVL: XX.XX in XX.XX mA
S S S
UNITS inches
LVL: XX.XX in XX.XX mA
PROBE TYPE Single Rod / Cable
LVL: XX.XX in XX.XX mA
PROBE LENGTH XX.XX in
LVL: XXXX.XX “ XX.XX mA
MOUNTING TYPE Plate
LVL: XX.XX in XX.XX mA
NOZZLE LENGTH XX.XX in
LVL: XX.XX in XX.XX mA
OFFSET XX.XX in
LVL: XX.XX in XX.XX mA
DIELECTRIC XX.XX
LVL: XX.XX in XX.XX mA
MEASURE MODE Media Level
LVL: XX.XX in XX.XX mA
LANGUAGE English
LVL: XX.XX in XX.XX mA
LVL XXX.X% XX.XX mA
mA OUTPUT SETUP
LVL: XX.XX in XX.XX mA
OUTPUT Level
LVL: XX.XX in XX.XX mA
LRV 4mA XX.XX in
LVL: XX.XX in XX.XX mA
URV 20mA XX.XX in
LVL: XX.XX in XX.XX mA
DAMPING X.X sec
LVL: XX.XX in XX.XX mA
ALARM DELAY XX sec
LVL: XX.XX in XX.XX mA
4mA DAC TRIM
LVL: XX.XX in XX.XX mA
20mA DAC TRIM
LVL: XX.XX in XX.XX mA
LOOP TEST
LVL: XX.XX in XX.XX mA
HART ADDRESS XX
LVL: XX.XX in XX.XX mA
LRS
3.85 mA
LVL: XX.XX in XX.XX mA
LNI XX.XX gal
EXTENDED SETUP
LVL: XX.XX in XX.XX mA
WAVEFORM AT COUPLER
LVL: XX.XX in XX.XX mA
WAVEFORM AT LVL
LVL: XX.XX in XX.XX mA
WAVEFORM AT XXXX in
LVL: XX.XX in XX.XX mA
WAVEFORM AT END OF PROBE
LVL: XX.XX in XX.XX mA
TEMPERATURE XXX.X F/C
LVL: XX.XX in XX.XX mA
LINEARIZATION MENU
LVL: XX.XX in XX.XX mA
SOR
LVL: XX.XX in XX.XX mA
LRM*
LVL: XX.XX in XX.XX mA
END MENU
LVL: XX.XX in XX.XX mA
NAVIGATION
SELECT
S
button
S
S
S
S
Section 4.6.4
S
* Used only if SOR is set to ALARM.
UP or DOWN button
END MENU
LVL: XX.XX in XX.XX mA
END MENU
LVL: XX.XX in XX.XX mA
MT5000-0200-1 Rev f (10-2010) DCN0528 10
Pressing the SELECT button at each END MENU will return to the MAIN DISPLAY.
4.3 BASIC SETUP
BASIC SETUP is a menu of items that are used to adapt the internal settings of the MT5000 to a particular application. Certain fields are required entry items and will be needed for proper operation of the device. Other entry items are not used for the setup of the transmitter and are listed as optional. At a minimum, the items in the BASIC SETUP menu will need to be entered for the MT5000 to operate. BASIC SETUP menu items include the PROBE TYPE, PROBE LENGTH and MOUNTING TYPE.
From the main display, press the SELECT button to access the items in the BASIC SETUP menu.
4.3.1. UNITS
This function will allow the user to select the UNIT of measure for the process variable of the unit and provide a basis for all of the setup functions. Selectable engineering UNITS include: inches, feet, meters, millimeters and centimeters.
To select the required unit of measure:
1. Press the SELECT button.
2. Scroll UP or DOWN to the desired measurement unit.
3. Press the SELECT button to set the new UNIT.
4. Scroll UP to END MENU.
5. Pressing the SELECT button now will return you to the main screen.
4.3.2. PROBE TYPE
This function will help adjust the transmitter setting for the installed configuration. Certain aspects of the transmitter setup will be adjusted to the probe type entered in this location. Selectable probe types include: Single Rod/Cable, Dual Rod/Cable or Coaxial. Select only the type of probe included with the MT5000 transmitter. Failure to set the actual probe type could result in measurement errors.
To set the PROBE TYPE:
1. Press and hold the SELECT button for two seconds.
2. Scroll UP or DOWN to the PROBE TYPE as it corresponds to Figure 9 on the following
page.
3. Press the SELECT button to set the new PROBE TYPE.
4. Scroll UP to END MENU.
5. Pressing the SELECT button now will return you to the main screen.
BASIC SETUP
LVL: XX.XX in XX.XX mA
UNITS
inches
LVL: XX.XX in XX.XX mA
PROBE TYPE
Single Rod / Cable
LVL: XX.XX in XX.XX mA
MT5000-0200-1 Rev f (10-2010) DCN0528 11
Figure 9
Single Rod/Cable Dual Rod/Cable Coaxial
4.3.3. PROBE LENGTH
Also described as insertion length, PROBE LENGTH is defined as the measured distance from the first thread of the coupler (or the face of the flange) to the end of the probe. This value must be entered in units that correspond to the UNITS of the process variable.
To set the PROBE LENGTH:
1. Press and hold the SELECT button for 2 seconds.
2. Scroll UP or DOWN to set each digit.
3. Press the SELECT button to set the digit and move to the next digit in sequence.
4. After the last digit is set, press the SELECT button to set the new PROBE LENGTH.
5. Scroll UP or DOWN to END MENU.
6. Pressing the SELECT button now will return you to the main screen.
Figure 10
Probe Length
PROBE LENGTH
XX.XX in
LVL: XX.XX in XX.XX mA
MT5000-0200-1 Rev f (10-2010) DCN0528 12
4.3.4. MOUNTING TYPE
Different mounting configurations will affect each probe type in different ways. A coupler mounted on a nozzle whose length is greater than its width will have a reduced signal ca­pacity that must be accounted for by the MT5000. In order to help maximize the range abil­ity of the MT5000, the MOUNTING TYPE corresponding to the installation must be entered. The MOUNTING TYPE should fall into one of the categories listed below. (Figure 11)
To set the MOUNTING TYPE:
1. Review the installation and determine which class of mounting configuration the unit
will be installed in.
2. Press and hold the SELECT button for 2 seconds.
3. Scroll UP or DOWN to the required MOUNTING TYPE.
4. Press the SELECT button to set the new MOUNTING TYPE.
5. Scroll DOWN to END MENU.
6. Pressing the SELECT button now will return you to the main screen
Figure 11
MOUNTING TYPE
Plate
LVL: XX.XX in XX.XX mA
Plate
Coupling / Plate Nozzle/Flange H>S
H
Nozzle/Flange H<S Stilling Well Ext. Chamber
H
S
S
MT5000-0200-1 Rev f (10-2010) DCN0528 13
4.3.5. NOZZLE LENGTH
In this selection you will enter the length of the mounting nozzle from the face of the cou­pler to the top of the tank. Transmitters with a Mounting Type of Plate will have a Nozzle Length of 0. This entry will tell the transmitter to ignore any reading within the nozzle area. (Figure 12)
To enter the NOZZLE LENGTH:
1. Press and hold the SELECT button for 2 seconds.
2. Scroll UP or DOWN to set each digit.
3. Press the SELECT button to set the digit and move to the next digit in sequence.
4. After the last digit is set, press the SELECT button to set the new NOZZLE LENGTH.
5. Scroll UP or DOWN to END MENU.
6. Pressing the SELECT button now will return you to the main screen.
Figure 12
NOZZLE LENGTH
XX.XX in
LVL: XX.XX in XX.XX mA
Nozzle Length
4.3.6. OFFSET
Offset is a value in engineering UNITS which may be entered to compensate for an un­measureable area below a probe or to align the measurement of the MT5000 with another device. The value entered in the Offset will be Added to or subtracted from the LVL indica­tion on the main display. (Figure 13)
To enter the LVL OFFSET:
1. Press the SELECT button.
2. Scroll UP or DOWN to set each digit.
3. Press the SELECT button to set the digit and move to the next digit in sequence.
4. After the last digit is set, press the SELECT button to set the new LVL OFFSET.
5. Scroll DOWN to END MENU.
6. Pressing the SELECT button now will return you to the main screen.
OFFSET
XX.XX in
LVL: XX.XX in XX.XX mA
MT5000-0200-1 Rev f (10-2010) DCN0528 14
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