Pepperl+Fuchs Pulscon LTC57 User Manual
ISO9001
3
PROCESS AUTOMATION
MANUAL
Pulscon LTC57
PROFIBUS PA
Guided Level Radar
Level measurement in bulk solids
Pulscon LTC57 PROFIBUS PA
With regard to the supply of products, the current issue of the following document is applicable:
The General Terms of Delivery for Products and Services of the Electrical Industry,
published by the Central Association of the Electrical Industry (Zentralverband Elektrotechnik und
Elektroindustrie (ZVEI) e.V.) in its most recent version as well as the supplementary clause:
"Expanded reservation of proprietorship"
Pulscon LTC57 PROFIBUS PA
Content
1 Important document information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1 Document function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3 Supplementary documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2 Basic safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1 Requirements for the personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2 Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.3 Workplace safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.4 Operational safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.5 Product safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3 Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.1 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.2 Registered trademarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4 Incoming acceptance and product identification . . . . . . . . . . . . . . . . . . . 16
4.1 Incoming acceptance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.2 Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5 Storage, Transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.1 Storage conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.2 Transport product to the measuring point . . . . . . . . . . . . . . . . . . . . . . 19
6 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.1 Mounting requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.2 Mounting the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.3 Post-installation check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7 Electrical connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.1 Connection conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.2 Connecting the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7.3 Post-connection check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
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Content
8 Operating options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8.2 Structure and function of the operating menu . . . . . . . . . . . . . . . . . . 51
8.3 Display and operating module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
9 Integration into a PROFIBUS network. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
9.1 Overview of the device database files (GSD) . . . . . . . . . . . . . . . . . . . 65
9.2 Set device address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
10 Commissioning (via operating menu) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
10.1 Installation and function check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
10.2 Setting the operating language. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
10.3 Configuration of a level measurement . . . . . . . . . . . . . . . . . . . . . . . . 68
10.4 Recording the reference curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
10.5 Configuration of the on-site display . . . . . . . . . . . . . . . . . . . . . . . . . . 70
10.6 Configuration management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
10.7 Protection of the settings against unauthorized changes. . . . . . . . . 71
11 Diagnostics and troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
11.1 General trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
11.2 Diagnostic information on local display . . . . . . . . . . . . . . . . . . . . . . . 74
11.3 Diagnostic event in the operating tool . . . . . . . . . . . . . . . . . . . . . . . . . 77
11.4 Diagnostic list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
11.5 List of diagnostic events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
11.6 Event logbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
11.7 Firmware history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
12 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
12.1 Exterior cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
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Content
13 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
13.1 General information on repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
13.2 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
13.3 Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
13.4 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
14 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
14.1 Device-specific accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
14.2 Communication-specific accessories . . . . . . . . . . . . . . . . . . . . . . . . . 90
14.3 Service-specific accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
14.4 System components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
15 Operating menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
15.1 Overview of the operating menu (display module). . . . . . . . . . . . . . . 91
15.2 Overview of the operating menu (operating tool) . . . . . . . . . . . . . . . 96
15.3 Setup menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
15.4 Diagnostics menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
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Important document information
1 Important document information
1.1 Document function
These Operating Instructions contain all the information that is required in various phases of
the life cycle of the device: from product identification, incoming acceptance and storage, to
mounting, connection, operation and commissioning through to troubleshooting, maintenance
and disposal.
1.2 Symbols
1.2.1 Symbols used
This document contains information that you must read for your own personal safety and to
avoid property damage. Depending on the risk level, the warning messages are displayed in
descending order as follows:
Safety-relevant symbols
Danger!
This symbol indicates an imminent danger.
Non-observance will result in personal injury or death.
Warning!
This symbol indicates a possible fault or danger.
Non-observance may cause personal injury or serious property damage.
Caution!
This symbol indicates a possible fault.
Non-observance could interrupt the device and any connected systems and plants, or result in
their complete failure.
Informative symbols
Note!
This symbol brings important information to your attention.
Action
This symbol indicates a paragraph with instructions.
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)
*
Important document information
1.2.2 Electrical symbols
Symbol Meaning
Table 1.1
Direct current
A terminal to which DC voltage is applied or through which direct
current flows.
Alternating current
A terminal to which alternating voltage is applied or through which
alternating current flows.
Direct current and alternating current
• A terminal to which alternating voltage or DC voltage is applied.
• A terminal through which alternating current or direct current
flows.
Ground connection
A grounded terminal which, as far as the operator is concerned, is
grounded via a grounding system.
Protective ground connection
A terminal which must be connected to ground prior to establishing
any other connections.
Equipotential connection
A connection that has to be connected to the plant grounding
system: This may be a potential equalization line or a star grounding
system depending on national or company codes of practice.
1.2.3 Tool symbols
Symbol Meaning
Table 1.2
Torx screwdriver
Flat blade screwdriver
Cross-head screwdriver
Allen key
Hexagon wrench
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Important document information
1.2.4 Symbols for certain types of information
Symbol Meaning
Allowed
Indicates procedures, processes or actions that are allowed.
Preferred
Indicates procedures, processes or actions that are preferred.
Forbidden
Indicates procedures, processes or actions that are forbidden.
,…,1. 2. 3.
Table 1.3
1.2.5 Symbols in graphics
Symbol Meaning
Series of steps
Result of a sequence of actions
1, 2, 3 ... Item numbers
,…,1. 2. 3.
A, B, C, ... Views
A-A, B-B, C-C, ... Sections
-
.
Table 1.4
Series of steps
Hazardous area
Indicates a hazardous area.
Safe area (non-hazardous area)
Indicates a non-hazardous location.
1.2.6 Symbols at the device
Symbol Meaning
Safety instructions
Observe the safety instructions contained in the associated
Operating Instructions.
Temperature resistance of the connection cables
Specifies the minimum value of the temperature resistance of the
connection cables.
Table 1.5
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Important document information
1.3 Supplementary documentation
Document Purpose and content of the document
Technical Information
TI01004O (LTC57)
Brief Operating Instructions
KA01073O (LTC57,
PROFIBUS PA)
Description of Device
Parameters
GP01001O (LTC5X,
PROFIBUS PA)
Table 1.6
Note!
For an overview of the scope of the associated Technical Documentation, refer to
www.pepperl-fuchs.com.
1.3.1 Safety documentation
Depending on the approval, the following Safety instructions (SI) are supplied with the device.
They are an integral part of the Operating instructions.
Planning aid for your device
The document contains all the technical data on the device
and provides an overview of the accessories and other
products that can be ordered for the device.
Guide that takes you quickly to the 1st measured value
The Brief Operating Instructions contain all the essential
information from incoming acceptance to initial
commissioning.
Reference for your parameters
The document provides a detailed explanation of each
individual parameter in the operating menu. The description
is aimed at those who work with the device over the entire life
cycle and perform specific configurations.
Safety instructions (SI)
Feature
"Approval"
E1 ATEX II 1G Ex ia IIC T6-
EX ATEX II 1/2G Ex ia IIC T6-
S3 ATEX II 1D Ex ta IIIC
S4 ATEX II 1/2D Ex ta IIIC
E3 ATEX II 3G Ex nA IIC T6-
E4 ATEX II 3G Ex ic IIC T6-T1 GcSI00498O SI01130O SI01131O SI00518O –
SX ATEX II 1/2G Ex ia IIC T6-
EG ATEX II 1/2G Ex d [ia] IIC
Approval Feature "Electrical output"
Option IHa Option IDb Option IEc Option PAd Option AH
T1 Ga
T1 Ga/Gb
T
xx°C Da
500
Txx°C Da/Db
T1 Gc
T1 Ga/Gb
ATEX II 1/2D Ex ia IIIC
Txx°C Da/Db
T6-T1 Ga/Gb
ATEX II 1/2D Ex ta IIIC
Txx°C Da/Db
SI00496O SI01125O SI01126O SI00516O –
SI00496O SI01125O SI01126O SI00516O –
SI00501O SI00501O SI00501O SI00521O SI00501O
SI00501O SI00501O SI00501O SI00521O SI00501O
SI00498O SI01130O SI01131O SI00518O SI01132O
SI00502O SI00502O SI00502O SI00522O –
SI00503O SI00503O SI00503O SI00523O SI01136O
Option DH
e
f
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Important document information
Feature
"Approval"
Approval Feature "Electrical output"
Option IHa Option IDb Option IEc Option PAd Option AH
Option DH
CD CSA C/US DIP Cl.II,III
SI00529O SI00529O SI00529O SI00570O SI00529O
Div.1 Gr.E-G
C1 CSA C/US IS Cl.I,II,III
SI00530O SI00530O SI00530O SI00571O SI00530O
Div.1 Gr.A-G, NI Cl.1
Div.2, Ex ia
C2 CSA C/US XP Cl.I,II,III
SI00529O SI00529O SI00529O SI00570O SI00529O
Div.1 Gr.A-G, NI Cl.1
Div.2, Ex d
FI FM IS Cl.I,II,III Div.1 Gr.A-
SI00531O SI00531O SI00531O SI00573O SI00531O
G, AEx ia, NI Cl.1 Div.2
FN FM XP Cl.I,II,III Div.1
SI00532O SI00532O SI00532O SI00572O SI00532O
Gr.A-G, AEx d, NI Cl.1
Div.2
FE FM DIP Cl.II,III Div.1 Gr.E-GSI00532O SI00532O SI00532O SI00572O SI00532O
IA IECEx Ex ia IIC T6-T1 Ga SI00496O SI01125O SI01126O SI00516O –
IB IECEx Ex ia IIC T6-T1
SI00496O SI01125O SI01126O SI00516O –
Ga/Gb
IE IECEx Ex ta IIIC T
Da
IF IECEx Ex ta IIIC Txx°C
500
xx°C
SI00501O SI00501O SI00501O SI00521O SI00501O
SI00501O SI00501O SI00501O SI00521O SI00501O
Da/Db
IG IECEx Ex nA IIC T6-T1 Gc SI00498O SI01130O SI01131O SI00518O SI01132O
IH IECEx Ex ic IIC T6-T1 Gc SI00498O SI01130O SI01131O SI00518O –
Table 1.7
e
f
a
Option IH: 2-wire, 4 ... 20 mA, HART
b
Option ID: 2-wire, 4 ... 20 mA, HART, switching output
c
Option IE: 2-wire, 4 ... 20 mA, HART, 4 ... 20 mA
d
Option PA: 2-wire, PROFIBUS PA, switching output
e
Option AH: 4-wire, 90 ... 253 V AC, 4 ... 20 mA, HART
f
Option DH: 4-wire, 10.4 ... 48 V DC, 4 ... 20 mA, HART
Note!
For certified devices the relevant Safety instructions (SI) are indicated on the nameplate.
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Basic safety instructions
2 Basic safety instructions
2.1 Requirements for the personnel
The personnel for installation, commissioning, diagnostics and maintenance must fulfill the
following requirements:
• Trained, qualified specialists must have a relevant qualification for this specific function
and task
• Are authorized by the plant owner/operator
• Are familiar with federal/national regulations
• Before beginning work, the specialist staff must have read and understood the instructions
in the Operating Instructions and supplementary documentation as well as in the
certificates (depending on the application)
• Following instructions and basic conditions
The operating personnel must fulfill the following requirements:
• Being instructed and authorized according to the requirements of the task by the facility's
owner-operator
• Following the instructions in these Operating Instructions
2.2 Designated use
Application and measured materials
The measuring device described in these Operating Instructions is intended only for level
measurement of bulk solids. Depending on the version ordered the device can also measure
potentially explosive, flammable, poisonous and oxidizing materials.
Observing the limit values specified in the "Technical data" and listed in the Operating
Instructions and supplementary documentation, the measuring device may be used for the
following measurements only:
• Measured process variable: Level
• Calculated process variables: Volume or mass in arbitrarily shaped vessels (calculated
from the level by the linearization functionality)
To ensure that the measuring device remains in proper condition for the operation time:
• Use the measuring device only for measured materials against which the process-wetted
materials are adequately resistant.
• Observe the limit values in "Technical data".
Incorrect use
The manufacturer is not liable for damage caused by improper or non-designated use.
Verification for borderline cases:
• For special measured materials and cleaning agents, Pepperl+Fuchs is glad to provide
assistance in verifying the corrosion resistance of wetted materials, but does not accept
any warranty or liability.
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Basic safety instructions
Residual risk
The electronics housing and its built-in components such as display module, main electronics
module and I/O electronics module may heat to 80 °C (176 °F) during operation through heat
transfer from the process as well as power dissipation within the electronics. During operation
the sensor may assume a temperature near the temperature of the measured material.
Danger of burns due to heated surfaces!
• For high process temperatures: Install protection against contact in order to prevent burns.
2.3 Workplace safety
For work on and with the device:
• Wear the required personal protective equipment according to federal/national regulations.
2.4 Operational safety
Risk of injury.
• Operate the device in proper technical condition and fail-safe condition only.
• The operator is responsible for interference-free operation of the device.
Conversions to the device
Unauthorized modifications to the device are not permitted and can lead to unforeseeable
dangers.
• If, despite this, modifications are required, consult with the manufacturer.
Repair
To ensure continued operational safety and reliability,
• Carry out repairs on the device only if they are expressly permitted.
• Observe federal/national regulations pertaining to repair of an electrical device.
• Use original spare parts and accessories from the manufacturer only.
Hazardous area
To eliminate a danger for persons or for the facility when the device is used in the hazardous
area (e. g. explosion protection, pressure vessel safety):
• Based on the nameplate, check whether the ordered device is permitted for the intended
use in the hazardous area.
• Observe the specifications in the separate supplementary documentation that is an
integral part of these Instructions.
2.5 Product safety
This measuring device is designed in accordance with good engineering practice to meet
state-of-the-art safety requirements, has been tested, and left the factory in a condition in
which they are safe to operate.
12
It meets general safety standards and legal requirements. It also complies with the
EC directives listed in the device-specific EC Declaration of Conformity. Pepperl+Fuchs
confirms this by affixing the CE mark to the device.
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1
2
5
3
4
Product description
3 Product description
3.1 Design
3.1.1 Device
Figure 3.1 Design
1 Electronics housing
2 Process connection (here as an example: flange)
3 Rope probe
4 End-of-probe weight
5 Rod probe
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E
s
c
–
+
E
1
2
3
4
5
6
9
7
8
Product description
3.1.2 Electronics housing
Figure 3.2 Design of the electronics housing
1 Electronics compartment cover
2 Display module
3 Main electronics module
4 Cable glands (1 or 2, depending on instrument version)
5 Nameplate
6 I/O electronics module
7 Terminals (pluggable spring terminals)
8 Connection compartment cover
9 Grounding terminal
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Product description
3.2 Registered trademarks
®
HART
• Registered trademark of the HART Communication Foundation, Austin, USA
PROFIBUS
• Registered trademark of the PROFIBUS User Organization, Karlsruhe, Germany
KALREZ
• Registered trademark of DuPont Performance Elastomers L.L.C., Wilmington, USA
TEFLON
• Registered trademark of E.I. DuPont de Nemours & Co., Wilmington, USA
TRI CLAMP
• Registered trademark of Alfa Laval Inc., Kenosha, USA
®
®
, VITON
®
®
®
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DELIVERY NOTE
1 = 2
DELIVERYNOTE
Madein Germany
Incoming acceptance and product identification
4 Incoming acceptance and product identification
4.1 Incoming acceptance
Is the order code on the delivery note
(1) identical to the order code on the
product sticker (2)?
Are the goods undamaged?
Table 4.1
Do the nameplate data match the
ordering information on the delivery
note?
Is the DVD (operating tool) present?
If required (see nameplate): Are the
Safety Instructions (SI) present?
Note!
If one of the conditions does not comply, contact your Pepperl+Fuchs distributor.
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20
21
22
24
25
23
26
1
2
3
4
5
6
7
8
9
10
19
18
17
16
15
14
Ext. ord. cd.:
Order code:
Ser. no.:
LN =
Lref =
Mat.:
Date:
FW:
Dev.Rev.:
DeviceID:
Ta :
if modification
see sep. label
X =
MWP:
12
11
47 (1.85)
92 (3.62)
mm (in)
13
Incoming acceptance and product identification
4.2 Product identification
The following options are available for identification of the measuring device:
• Nameplate specifications
• Order code with breakdown of the device features on the delivery note
• Scan the 2-D matrix code (QR code) on the nameplate: all the information for the
measuring device is displayed.
Nameplate
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Figure 4.1 Nameplate
1 Device name
2 Address of manufacturer
3 Order code
4 Serial number (Ser. no.)
5 Extended order code (Ext. ord. cd.)
6 Process pressure
7 Gas phase compensation: reference distance
8 Certificate symbol
9 Certificate and approval relevant data
10 Degree of protection: e. g. IP, NEMA
11 Document number of the Safety Instructions: e. g. SI, ZD, ZE
12 2-D matrix code (QR code)
13 Modification mark
14 Manufacturing date: year-month
15 Permitted temperature range for cable
16 Device revision (Dev.Rev.)
17 Additional information about the device version (certificates, approvals, communication):
e. g. SIL, PROFIBUS
18 Firmware version (FW)
19 CE mark, C-Tick
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Pulscon LTC57 PROFIBUS PA
Incoming acceptance and product identification
20 Device ID
21 Material in contact with process
22 Permitted ambient temperature (T
23 Size of the thread of the cable glands
24 Length of probe
25 Signal outputs
26 Operating voltage
Note!
Only 33 digits of the extended order code can be indicated on the nameplate. If the extended
order code exceeds 33 digits, the rest will not be shown. However, the complete extended
order code can be viewed in the operating menu of the device in the
Extended order code 1 to 3 parameter.
amb
)
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Storage, Transport
5Storage, Transport
5.1 Storage conditions
• Permitted storage temperature: -40 ... +80 °C(-40...+176°F)
• Use the original packaging.
5.2 Transport product to the measuring point
Warning!
Risk of injury!
Housing or probe may be damaged or break away.
• Transport the measuring device to the measuring point in its original packaging or at the
process connection.
• Do not fasten lifting devices (hoisting slings, lifting eyes etc.) at the housing or the probe
but at the process connection. Take into account the mass center of the device in order to
avoid unintended tilting.
• Comply with the safety instructions, transport conditions for devices over 18 kg (39.6 lbs).
Figure 5.1
Figure 5.2
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Pulscon LTC57 PROFIBUS PA
132
A
C
4
B
Mounting
6Mounting
6.1 Mounting requirements
6.1.1 Suitable mounting position
Figure 6.1 Mounting requirements
Mounting distances
• Distance (A) between wall and rod or rope probe:
• for smooth metallic walls: > 50 mm (2 in)
• for plastic walls: > 300 mm (12 in) to metallic parts outside the vessel
• for concrete walls: > 500 mm (20 in), otherwise the available measuring range may be
reduced.
• Distance (B) between rod or rope probe and internal fittings in the vessel: > 300 mm (12 in)
• Distance (C) from end of probe to bottom of the vessel:
• Rope probe: > 150 mm (6 in)
•Rod probe: >10mm(0.4in)
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Mounting
Additional conditions
• When mounting in the open, a weather protection cover (1) may be installed to protect the
device against extreme weather conditions.
• In metallic vessels: Preferably do not mount the probe in the center of the vessel (2), as this
would lead to increased interference echoes.
If a central mounting position can not be avoided, it is crucial to perform an interference
echo suppression (mapping) after the commissioning of the device.
• Do not mount the probe in the filling curtain (3).
• Avoid buckling the rope probe during installation or operation (e. g. through product
movement against silo wall) by selecting a suitable mounting location.
• Check the probe regularly for defects.
Note!
With suspended rope probes (probe end not fixed at the bottom) the distance between the
probe rope and internal fittings in the tank must not fall below 300 mm (12 in) during the entire
process. A sporadic contact between the probe weight and the cone of the vessel, however,
does not influence the measurement as long as the dielectric constant of the medium is at least
DC = 1.8.
Note!
When mounting the electronics housing into a recess (e. g. in a concrete ceiling), observe a
minimum distance of 100 mm (4 in) between the cover of the terminal compartment/electronics
compartment and the wall. Otherwise the connection compartment/electronics compartment is
not accessible after installation.
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A
B
6 Nm
(4.42 lbf ft)
6 Nm
(4.42 lbf ft)
6 Nm
(4.42 lbf ft)
C
C
6 Nm
(4.42 lbf ft)
r = 100 (4)
min
r = 100 (4)
min
Mounting
6.1.2 Applications with restricted mounting space
Mounting with remote sensor
The device version with a remote sensor is suited for applications with restricted mounting
space. In this case the electronics housing is mounted at a separate position from which it is
easier accessible.
Figure 6.2
A Angled plug at the probe
B Angled plug at the electronics housing
C Length of the remote cable as ordered
• Product structure, feature "Probe design": option B "Sensor remote, 3 m/9 ft cable"
• The remote cable is supplied with these device versions, minimum bending radius:
100 mm (4 in)
• A mounting bracket for the electronics housing is supplied with these device versions.
Mounting options:
• Wall mounting
• Pipe mounting; diameter: 42 to 60 mm (1-1/4 to 2 in)
• The connection cable has got one straight and one angled plug (90°). Depending on the
local conditions the angled plug can be connected at the probe or at the electronics
housing.
Note!
Probe, electronics and connection cable are adjusted to match each other. They are marked
by a common serial number. Only components with the same serial number shall be
connected to each other.
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Mounting
6.1.3 Notes on the mechanical load of the probe
Tensile load limit of rope probes
Feature "Probe" Probe Tensile load limit [kN] Max. rupture load [kN]
Option 2, 3 Rope 4 mm (1/6 in) 316 12 20
Option M, Q Rope 6 mm (1/4 in) 316 30 42
Option N, S Rope 6 mm (1/4 in)
Option R, T Rope 8 mm (1/3 in)
Table 6.1
a
The ceiling of the silo must be designed to withstand this load.
PA > Steel
PA > Steel
Tensile load
Bulk solids exert tensile forces on rope probes whose height increases with:
• the length of the probe, i. e. max. cover
• the bulk density of the product,
• the silo diameter and
• the diameter of the probe rope
12 20
30 42
a
Since the tensile forces are also heavily dependent on the viscosity of the product, a higher
safety factor is necessary for highly viscous products and if there is a risk of cornice buildup. In
critical cases it is better to use a 6 mm rope instead of a 4 mm one.
The same forces also act on the silo cover. On a fixed rope, the tensile forces are definitely
greater, but this can not be calculated. Observe the tensile strength of the probes.
Options for reducing the tensile forces:
• Shorten the probe.
• If the maximum tensile load is exceeded, check whether it would be possible to use a noncontact ultrasonic or level-radar device.
The following diagrams show typical loads for frequently occurring bulk solids as reference
values. The calculation is performed for the following conditions:
• Calculation according to DIN 1055, Part 6 for the cylindrical part of the silo.
• Suspended probe (probe end not fixed at the bottom)
• Free-flowing bulk solid, i. e. mass flow. A calculation for core flow is not possible. In the
event of collapsing cornices, considerably higher loads can occur.
• The specification for tensile forces contains the safety factor 2 (in addition to the safety
factors already taken into account by DIN 1055), which compensates for the normal
fluctuation range in pourable bulk solids.
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0 5 10 15 20 25 30 35
0
10
20
30
40
50
60
F
[kN]
6mm
L[m]
F [kN]
4mm
0
4
8
12
16
20
24
28
32
36
40
A
B
C
D
F
[kN]
6mm
L[m]
F[kN]
4mm
0 5 10 15 20 25 30 35
A
B
C
0
2
4
6
8
10
12
14
16
18
0
2
4
6
8
10
12
D
Mounting
Figure 6.3 Silica sand in silo with smooth metallic walls; tensile load as a function of level L for
rope diameters 6mm (0.24in) and 4mm (0.16in)
A Silo diameter 12 m (40 ft)
B Silo diameter 9 m (30 ft)
C Silo diameter 6 m (20 ft)
D Silo diameter 3 m (10 ft)
24
Figure 6.4 Polyethylene pellets in silo with smooth metallic walls; tensile load as a function of
A Silo diameter 12 m (40 ft)
B Silo diameter 9 m (30 ft)
C Silo diameter 6 m (20 ft)
D Silo diameter 3 m (10 ft)
level L for rope diameters 6 mm (0.24 in) and 4 mm (0.16 in)
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F
[kN]
6mm
L[m]
F[kN]
4mm
A
B
C
D
0 5 10 15 20 25 30 35
0
4
8
12
16
20
24
28
32
36
0
4
8
12
16
20
24
F
[kN]
6mm
L[m]
F [kN]
4mm
A
B
C
D
0 5 10 15 20 25 30 35
0
10
20
30
40
50
60
0
4
8
12
16
20
24
28
32
36
40
Mounting
Figure 6.5 Wheat in silo with smooth metallic walls; tensile load as a function of level L for rope
diameters 6mm (0.24in) and 4mm (0.16in)
A Silo diameter 12 m (40 ft)
B Silo diameter 9 m (30 ft)
C Silo diameter 6 m (20 ft)
D Silo diameter 3 m (10 ft)
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Figure 6.6 Cement in silo with smooth metallic walls; tensile load as a function of level L for rope
A Tank diameter 12 m (40 ft)
B Tank diameter 9 m (30 ft)
C Tank diameter 6 m (20 ft)
D Tank diameter 3 m (10 ft)
diameters 6mm (0.24in) and 4mm (0.16in)
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Mounting
Bending strength of rod probes
Feature "Probe" Probe Bending strength [Nm]
Option L, P Rod 16 mm (0.63 in) 316L 30
Table 6.2
6.1.4 Notes on the process connection
Probes are mounted to the process connection with threaded connections or flanges. If during
this installation there is the danger that the probe end moves so much that it touches the tank
floor or cone at times, the probe must, if necessary, be shortened and fixed down.
Threaded connection
Figure 6.7 Mounting with threaded connection; flush with the container ceiling
Seal
The thread as well as the type of seal comply to DIN 3852 part 1, screwed plug form A.
They can be sealed with the following types of sealing rings:
• Thread G3/4: according to DIN 7603 with the dimensions 27 x 32 mm
• Thread G1-1/2: According to DIN 7603 with the dimensions 48 x 55 mm
Please use a sealing ring according to this standard in the form A, C or D and of a material that
is resistant to the application.
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≤150 (6)
H
mm (in)
ø ≤150 (6)
Mounting
Nozzle mounting
Figure 6.8
Length H of the rigid part of the rope probe
Probe H
Rope Ø4 mm (0.16 in) 120mm(4.7in)
Rope Ø6 mm (0.24 in) 135mm(5.3in)
Table 6.3
• Permissible nozzle diameter: 150 mm (6 in).
For larger diameters the near range measuring capability may be reduced.
For nozzles DN300: see next section.
1
• Permissible nozzle height
: 150 mm (6 in).
For a larger height the near range measuring capability may be reduced.
Larger nozzle heights may be possible in special cases: see next section.
Note!
With thermally insulated vessels the nozzle should also be insulated in order to prevent
condensate formation.
Rod extension/centering
For devices with rope probes a rod extension/centering is available on request. It has to be
used if otherwise the probe rope comes into contact with the lower edge of the nozzle.
Note!
Centering disks with small diameters (DN40 and DN50) may only be used if there is no
significant build-up in the nozzle above the disk. The nozzle must not become clogged by the
product.
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Larger nozzle heights on request.
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Pulscon LTC57 PROFIBUS PA
1
2
3
4
Mounting
Installation in nozzles DN300
If installation in 300 mm/12 in nozzles is unavoidable, installation must be carried out in
accordance with the following sketch.
Figure 6.9
1 Lower edge of the nozzle
2 Approx. flush with the lower edge of the nozzle (±50 mm/2 in)
3 Plate
4 Pipe diameter 150 to 180 mm (6 to 7 in)
Nozzle diameter Plate diameter
300 mm (12 in) 280 mm (11 in)
400 mm (16 in) 350 mm (14 in)
Table 6.4
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1
A
C
B
2
Mounting
6.1.5 Securing the probe
Securing rope probes
Figure 6.10
A Sag of the rope: 1 cm per 1 m of the probe length (0.12 in per 1 ft of the probe length)
B Reliably grounded end of probe
C Reliably isolated end of probe
1 Mounting and contact with a bolt
2 Mounting kit isolated
• The end of the probe needs to be secured under the following conditions:
• if otherwise the probe sporadically comes into contact with the wall of the vessel, the
outlet cone, internal fittings or other parts of the installation.
• if otherwise the probe sporadically gets close to a concrete wall (minimum distance
0.5 m/20 in).
• The end of probe can be secured at its internal thread
• rope 4 mm (1/6 in), 316: M14
• rope 6 mm (1/4 in), 316: M20
• rope 6 mm (1/4 in), PA > steel: M14
• rope 8 mm (1/3 in), PA > steel: M20
• Preferably use the 6 mm (1/4 in) rope probe due to the higher tensile strength when fixing a
rope probe.
• The fixing must be either reliably grounded or reliably insulated. If it is not possible to
mount the probe weight with a reliably insulated connection, it can be secured using an
isolated eyelet, which is available as an accessory.
• In the case of a grounded fixing the search for a positive end-of-probe signal must be
activated. Otherwise an automatic probe length correction is impossible.
Navigation: Expert Sensor EOP evaluation EOP search mode
Setting: Positive EOP option
• In order to prevent an extremely high tensile load (e. g. due to thermal expansion) and the
risk of rope crack, the rope has to be slack. Make the rope longer than the required
measuring range such that there is a sag in the middle of the rope that is 1 cm/(1 m rope
length) [0.12 in/(1 ft rope length)].
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1
2
3
4
5
6
∅ a
∅ b
≈50 (1.97)
∅ < 25 (1.0)
≈3 (0.12)
≈50 (1.97)
mm (in)
Mounting
Securing rod probes
• For Ex-approvals: For probe lengths 3 m (10 ft) a support is required.
• In general, rod probes must be supported if there is a horizontal flow (e. g. from an agitator)
or in the case of strong vibrations.
• Rod probes may only be supported at the end of the probe.
30
Figure 6.11
1 Probe rod, uncoated
2 Sleeve bored tight to ensure electrical contact between the rod and sleeve!
3 Short metal pipe, e. g. welded in place
4 Probe rod, coated
5 Plastic sleeve, e. g. PTFE, PEEK or PPS
6 Short metal pipe, e. g. welded in place
Warning!
Poor grounding of the end of probe may cause measuring errors.
• Apply a narrow sleeve which has good electrical contact to the probe.
Warning!
Welding may damage the main electronics module.
• Before welding: Ground the probe and dismount electronics.
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