Tek-Trol 3120B-G4-WP-1-HC-1, 3120B-G3-WP-1-HC-1, 3120B-G1-WP-1-HC-1, 3120B-G6-WP-1-HC-1, 3120B-G2-WP-1-HC-1 User manual

Technology Solutions

EK-B

T

AR 3120B

Smart Gauge Pressure Transmitters

Instruction Manual

Document Number: IM-3120B

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Table of Contents

Table of Contents ................................................................................................................................. 1

1 Safety Instructions ......................................................................................................... 3

1.1 Intended Use .....................................................................................................................3

1.2 Certification .......................................................................................................................3

1.3 Safety Instructions from the Manufacturer .........................................................................3

Disclaimer ................................................................................................................................ 3

Product Liability and Warranty ............................................................................................... 3

Information Concerning the Documentation .......................................................................... 3

Safety Precautions ................................................................................................................... 4

1.4 Packaging, Transportation, and Storage ..............................................................................5

................................................................................................................................. 5

Transportation......................................................................................................................... 5

Storage .................................................................................................................................... 6

1.5 Nameplate .........................................................................................................................6

2 Product Description ....................................................................................................... 7

2.1 Introduction ......................................................................................................................7

2.2 Measurement Principle ......................................................................................................7

2.3 Specifications .....................................................................................................................8

General Specifications ............................................................................................................. 8

Damping Time ......................................................................................................................... 8

Environmental Conditions ....................................................................................................... 8

Power Supply ........................................................................................................................... 9

Measuring Range Limit for Tek-Bar 3110B.............................................................................. 9

2.4 Dimensional Drawings .......................................................................................................9

2.5 Model Chart..................................................................................................................... 10

3 Installation................................................................................................................... 11

3.1 Selecting the Installation Location .................................................................................... 11

3.2 Installation Procedure ...................................................................................................... 11

Install Pressure Transmitter .................................................................................................. 11

Process Connections ............................................................................................................. 12

Housing Rotation ................................................................................................................... 13

Terminal Side of Transmitter ................................................................................................ 13

LCD Display ............................................................................................................................ 13

Conduit Installation ............................................................................................................... 14

3.3 Mounting Requirements .................................................................................................. 14

Liquid Flow Measurement .................................................................................................... 14

Gas Flow Measurement ........................................................................................................ 15

Steam Flow Measurement .................................................................................................... 15

3.4 Field Adjustment ............................................................................................................. 16

Zero Point Adjustment .......................................................................................................... 16

Full Span Adjustment ............................................................................................................ 16

3.5 Product Usage ................................................................................................................. 16

Pipeline pressure measurement-pressure transmitter ......................................................... 16

Pipeline pressure measurement-differential pressure transmitter ...................................... 16

Steam flow measurement ..................................................................................................... 17

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Liquid flow measurement ..................................................................................................... 17

Air flow measurement........................................................................................................... 17

Open container level measurement-single flange level transmitter .................................... 17

Sealed container level measurement-single flange level transmitter .................................. 17

4 Electrical Connections .................................................................................................. 18

4.1 Grounding of Measuring Device ....................................................................................... 18

4.2 Power Supply Specifications and Connection .................................................................... 18

4.3 Cable Protection System .................................................................................................. 20

Standard Protection System .................................................................................................. 20

Explosion-proof Tube Protection System .............................................................................. 20

Connection to the HART Handheld Communicator .............................................................. 21

5 Operation .................................................................................................................... 22

5.1 Local Operation and Display ............................................................................................. 22

5.2 Operation in safe and hazardous area .............................................................................. 22

5.3 Configuration ................................................................................................................... 22

Key Operation ....................................................................................................................... 23

Factory Reset ......................................................................................................................... 23

Detailed Operating Instructions ............................................................................................ 23

5.4 Handheld Communicator ................................................................................................. 27

6 Maintenance ................................................................................................................ 28

6.1 Hardware Maintenance ................................................................................................... 28

Test Terminal ......................................................................................................................... 28

Disassembling the Electronics Housing ................................................................................. 29

External Cleaning ................................................................................................................... 29

Depot Repair ......................................................................................................................... 29

Discard Disposal .................................................................................................................... 29

7 Troubleshooting ........................................................................................................... 30

7.1 Symptoms and Corrective Measures ................................................................................. 30

7.2 Tek-Bar 3120B Smart Gauge Pressure Transmitter LCD Display error codes ........................ 32

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1 Safety Instructions

1.1 Intended Use

Tek-Bar 3120B is a Smart Gauge Pressure Transmitter used for pressure, flow, level and
density measurement of steam and liquids.
The manufacturer is not liable for damage caused by improper or non-designated use.

1.2 Certification

Tek-Bar 3120B has FM approval (Class I Div. I)

1.3 Safety Instructions from the Manufacturer

Disclaimer

The manufacturer will not be held accountable for any damage that happens by using its
product, including, but not limited to direct, indirect, or incidental and consequential
damages.
Any product purchased from the manufacturer is warranted in accordance with the
relevant product documentation and our Terms and Conditions of Sale.
The manufacturer has the right to modify the content of this document, including the
disclaimer, at any time for any reason without prior notice, and will not be answerable in
any way for the possible consequence of such changes.

Product Liability and Warranty

The operator shall bear authority for the suitability of the device for the specific
application. The manufacturer accepts no liability for the consequences of misuse by the
operator. Wrong installation or operation of the devices (systems) will cause the warranty
to be void. The respective Terms and Conditions of Sale, which forms the basis for the
sales contract shall also apply.

Information Concerning the Documentation

To prevent any injury to the operator and damage to the device it is essential to read the
information in this document and read the applicable national standard, and safety
instruction. These operating instructions contain all the information that is required in
various stages, like product identification, incoming acceptance and storage, to mounting,
connection, operation and commissioning through to troubleshooting, maintenance and
disposal.

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WARNING

Indicates a potentially hazardous situation which, if not avoided, could result in death
or serious injury.

CAUTION

Indicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate injury. It may also be used to alert against unsafe practices.

NOTE

Indicates that operating the hardware or software in this manner may damage it or
lead to system failure.

Safety Precautions

You must read these instructions carefully prior to installing and commissioning the
device. These instructions are an important part of the product and must be kept for
future reference. Only by observing these instructions, optimum protection of both
personnel and the environment, as well as safe and fault-free operation of the device can
be ensured.

For additional information that are not discussed in this manual, contact the
manufacturer.

Warnings and Symbols Used

The following safety symbol marks are used in this operation manual and on the

instrument.

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NOTE

Unpack and check the contents for damages or signs of rough handling. Report
damage to the manufacturer immediately. Check the contents against the packing
list provided.

1.4 Packaging, Transportation, and Storage

This section contains information regarding packaging, transportation, and storage.

Packaging

The original package consists of

1. Tek-Bar 3120B Smart Gauge Pressure Transmitter

2. Accessories (optional)

3. Documentation

Transportation

• Avoid impact shocks to the device and prevent it from getting wet during

• Verify local safety regulations, directives, and company procedures with respect to

• Transport the product to the installation site using the original manufacturer’s packing

transportation.

hoisting, rigging, and transportation of heavy equipment.

whenever possible.

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NOTE

Check the device nameplate to ensure that the device is delivered according to
your order. Check for the correct supply voltage printed on the nameplate.

Storage

If this product is to be stored for a long period of time before installation, take the

following precautions:

• Store your product in the manufacturer’s original packing used for shipping.

• Storage location should conform to the following requirements:

o Free from rain and water
o Free from vibration and impact shock
o At room temperature with minimal temperature and humidity variation

• Before storing a used flowmeter remove any fluid from the flowmeter line

completely. Properties of the instrument can change when stored outdoors.

1.5 Nameplate

The nameplate lists the order number and other important information, such as design
details and technical data.

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2 Product Description

This section covers the reference and specification data, as well as ordering information.

2.1 Introduction

Tek-Bar 3120B single crystal silicon pressure transmitter utilizes world’s leading mono
crystal silicon pressure sensor technology and outstanding encapsulation technology. It can
handle the most rigorous industrial applications and it can cope up with extreme chemical,
mechanical and electrical working conditions. Highly accurate and reliable measurement
of level, density and pressure of liquid, gases or steam is possible with Tek-Bar 3120B. The
performance accuracy is up to 0.075% of URL. This high-performance pressure transmitter
meticulously designed by Tek-Trol supports HART communication protocol and IP66
waterproof protection. It is well equipped with several features that facilitate easy
installation, start-up and minimum maintenance.

2.2 Measurement Principle

The Tek-Bar 3120B works on the principle of mono silicon technology. The pressure sensor

of the transmitter is located on the top of the metal body, away from the service fluid. This

enables mechanical and thermal isolation of the sensor from the fluid in service.

When pressure is applied on the diaphragm and the silicon piezoelectric sensor, they

become stressed and undergo a change in voltage resistance. This change in resistance is

directly proportional to the applied pressure, which is transferred to the transmitter body

using lead wires.

Built on semiconductor technology, the resistance change (piezoelectric effect) is notably
higher than exhibited in standard strain gauges. Therefore, the sensitivity of mono­crystalline sensors is higher than the sensitivity of most other types.

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Parameter

Description

Pressure Type

Gauge Pressure

Accuracy

±0.075% F.S.

Diaphragm Materials

Hastelloy C

Ranges

5.8 psig to 5800 psig

Stability

±0.2 % URL/5 year

Process Connection

±0.075% F.S.

Wetted material

316LLS

Working Humidity

5 to 100%

Output Signal

Two wire 4to 20mA with Hart®

Mounting Position Effect

Apply to any position. Max value lower than 1.6 w.c.

(400 Pa) can be corrected by zero clearing function

Insulation Resistance

≥20 M Ω at 100 VDC

Process Connection

¼" NPT Female

Approvals

General purpose NEMA 4X or IP66

Weight
(excluding Option Items)

3.43 lb (1.55kg)
Testing Standard

IEC60770

Parameter

Description

Damping time

0-100s adjustable

Response time

≤0.2 s

Start-up after power off

≤6 s

Parameter

Description

Working temperature

-40 °F to 185 °F (-40 °C to 85 °C),

Storage temperature

-40 °F to 230 °F (-40 °C to 110 °C)

Media temperature

Silicon oil filling: -40 °F to 248 °F (-40 °C to 120 °C)

Working humidity

5-100% RH at 104 °F

Protection class

IP66

2.3 Specifications

General Specifications

Damping Time

Environmental Conditions

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Parameter

Description

Power supply

10.5-55 VDC (Hart: 16.5-55 VDC)

Load resistance

0-2119 Ω for working condition, 250- 600 Ω for HART protocol

Transmission
distance

<3281ft
Power consumption

≤500 mW at 24 VDC, 20.8 mA

Nominal

Value

Smallest

Calibrated Span

Lower Range Limit

(LRL)

Upper Range Limit

(URL)

Overload

Limit

5.8 psi

8 in.WC

-14.5

5.8 psi

145 psig

36 psi

2 psi

-14.5

36 psi

580 psig

145 psi

7.25 psi

-14.5

145 psi

870 psig

435 psi

22.25 psi

-14.5

435 psi

2175 psig

1450 psi

72.5 psi

-14.5

1450 psi

2900 psig

5800 psi

725 psi

-14.5

5800 psi

11600 psig

Power Supply

Measuring Range Limit for Tek-Bar 3110B

2.4 Dimensional Drawings

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Example

Tek-Bar 3120B-G

3

WP

1

HC

1

BA

Tek-Bar 3120B-G-3-WP-1-HC-1-BA

Series

Tek-Bar 3120B-G

Smart Gauge Pressure Transmitter

1

0 to 5.8 psig (40:1 Turndown, Adj. Range: -14.5 to +5.8 psig)

2

0 to 36 psig (40:1 Turndown, Adj. Range: -14.5 to +36 psig)

3

0 to 145 psig (40:1 Turndown, Adj. Range: -14.5 to +145 psig)

Range Options

4

0 to 435 psig (40:1 Turndown, Adj. Range: -14.5 to +435 psig)

5

0 to 1450 psig (40:1 Turndown, Adj. Range: -14.5 to +1450 psig)

6

0 to 5800 psig ( 8:1 Turndown, Adj. Range: -14.5 to 5800 psig)

Approval Rating

WP

AT

General Purpose NEMA 4X/IP66 ATEX

Process Connections

1

X

½" NPT Male

Diaphragm Seal

Diaphragm Material

HC

Hastelloy C

Electrical Connections

1

½" NPT Female

Options

CC

FC

BA

TAG

Custom Calibration with 5 point Calibration Certificate Factory

Configuration, No Certificate

Stainless Steel Bracket (Angle type) with SST Bolts

Custom Etching of the Name Plate (Must specify on P.O.)

2.5 Model Chart

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CAUTION

• When removing the instrument from hazardous processes, avoid direct contact

with the fluid and the meter

• All installation must comply with local installation requirements and local

electrical code

3
3 Installation

This section covers instructions on installation and commissioning. Installation of the device
must be carried out by trained, qualified specialists authorized to perform such works.

3.1 Selecting the Installation Location

Prior to product installation, check the model, specifications and installation location for
the transmitter. The transmitter is designed to withstand severe environmental conditions.
However, follow the enlisted precautions while selecting the installation site to ensure
stable and accurate operation for years.

• Ambient Temperature

Avoid locations subjected to significant temperature gradient or wide temperature
variations. If transmitter is exposed to radiant heat from plant’s equipment, then
providing adequate thermal isolation and/or ventilation is desirable.

• Ambient Atmosphere

Avoid corrosive atmosphere while installing the transmitter. If it must be installed in a
corrosive atmosphere, then provide adequate ventilation and take the necessary
measures to prevent intrusion or stagnation of rain water in conduits.

• Shock and Vibration

Although the transmitter is designed to withstand shock and vibrations, it is
recommended to select an installation site with minimum shock and vibration to avoid
device damage and improve measurement accuracy.

3.2 Installation Procedure

This section includes the information regarding installation of the transmitter for safe and
precise functioning. It provides the procedure and instruction for mounting, transmitter
functions, and installation for specific applications.

Install Pressure Transmitter

Direct installation or mounting bracket installation may be used depending on the
application and installation site requirement. Various mounting scenarios are illustrated
in sections below.

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Process Connections

3.2.2.1 Straight Thread Connection

Picture 1: Ensure that the seal of head face gasket is effective by keeping the length of
the pressure transmitter thread longer than the depth of the thread.
Picture 2: Ensure that the seal of root gasket is effective by maintaining the length of
the pressure transmitter thread shorter than the depth of the thread.

3.2.2.2 Taper Thread Connection

Use tapered thread connections to make better seals. Sealing with Teflon tape or sealant glue results in strong and leak resistant connections.

3.2.2.3 Flange Connection

Picture 1 Picture 2

Choose gasket according to the properties of the process medium and the
temperature range. Pay attention to the bolt balance lock

3.2.2.4 Clamp Connection

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NOTE

Engage process connection with a minimum of 7 thread connections and tighten the
housing rotation set screw to prevent it from rotating

Choose gaskets that meet specified standards to avoid excessive clamp locking and
squeezing gasket. Excessive locking of clamp may damage the sensing diaphragm and
cause measuring error.

Housing Rotation

To ensure the visibility of LCD display

• Loosen the housing screw

• Rotate housing to the desired angle up to 360

• Re-tighten the housing screw

Terminal Side of Transmitter

Mount the transmitter in such a way that the terminal side is easily accessible to the
operator.

LCD Display

Display module is used in field adjustment for parameter settings and site configuration
before starting the measurement process. The local 5-digit LCD displays important
parameters, which can be directly monitored at the measuring point. It enables the
operator to configure the device using the function matrix.

o

The alignment of the display device can be adjusted vertically or horizontally as per the
requirement of installation location. Unscrew the screws on either sides of the LCD screen
to rotate it 90° clockwise or counter clockwise. The figure below illustrates the vertical
and horizontal arrangement of the display device.

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NOTE

Conduit thread must be engaged with a minimum of 5 thread connections

Conduit Installation

Improper sealing of connections may damage the transmitter due to excess moisture
accumulation. Mount the transmitter with electrical housing positioned downward so
that the excess of moisture is condensed and drained out from the casing. Secondly,
install wiring with a drip loop and ensure the bottom of the drip loop is mounted lower
than the conduit connections or the transmitter housing to avoid moisture accumulation
in the housing.

3.3 Mounting Requirements

Impulse piping configuration and transmitter position depends on specific measurement
conditions. Follow the procedure below while installing transmitter for liquid, gases or
steam processes.

Liquid Flow Measurement

• Place the taps to the side of the line/pipe to prevent residue deposits on the

transmitter process isolators

• Mount the transmitter beside or below the taps so gases can vent into the process

line

• Mount drain/vent the valve upward to allow gases to vent

Flow

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NOTE

For steam or other higher temperature processes, ensure that the temperature at the
process connection does not exceed the transmitter’s process temperature limits.

Flow

Flow

Gas Flow Measurement

• Place the taps in the top or side of the line

• Mount the transmitter beside or above the taps so liquid will drain into the process

line

Steam Flow Measurement

• Place taps to the side of the line

• Mount the transmitter below the taps to ensure that the impulse piping stays filled

with condensate

• In steam service above 250°F (121°C), fill impulse lines with water to prevent the

direct steam contact with the transmitter and to ensure accurate measurement at
start-up

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3.4 Field Adjustment

Perform field adjustments only after installing the transmitter at its final work location
otherwise the set parameters may drift due to jerks while transporting or handling.

Zero Point Adjustment

• For sensor zero trim, ensure that the vessel is empty and there is no input medium

pressure on the diaphragm. The vessel should be applied a normal atmospheric
pressure. If applying external pressure to the transmitter make sure that the display
is sufficiently stabilized (after approximately 10 to 15 seconds), before initiating any
trim function.

• There are 3 ways of making input pressure “Zero”.

➢ Apply a “Zero” pressure source (mandatory for absolute pressure models)
➢ Apply equal pressure on both HP and LP ports (DP models only)
➢ Open equalizing valve of manifolds installed and venting to atmospheric

pressure (applicable for Gauge & DP type models only)

• Sensor zero trim can be performed using an external HHC (Handheld calibrator), PC

or PDA configurator, and/or using Zero/Span local push buttons provided on the
transmitter.

• Using local push buttons set PV=0, refer to section 5.2.1 of this manual for detailed

instructions. If using an external HHT or HART® PC configurator, refer to the user
manual supplied by the third-party supplier.

Full Span Adjustment

• For full span adjustment, ensure that the vessel is filled with process medium to the

maximum level.

• Maintain static pressure value within the minimum and maximum pressure range

• Using local push buttons set output for lower and upper limit of the full scale i.e.

4mA and 20mA, refer to section 5.2 of this manual for detailed key operations.

The device is now ready for the real-time process measurement.

3.5 Product Usage

Pipeline pressure measurement-pressure transmitter

For high temperature steam measurements, pre-inject more than half-tube cooling
water in the condenser. Once the steam pipes are stable, gradually open the shut-off
valve to start measurement.

Pipeline pressure measurement-differential pressure transmitter

For high temperature steam measurement in a pipeline by differential pressure
transmitter, pre-inject cooling water into the guided pipe. Once the steam pipes are
stable, slowly open the shut-off valve and start measuring.

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Differential pressure transmitters are commonly used for micro pressure measurement
of hydrostatic pressures such as filter and equipment leakage tests for improving
accuracy.

Steam flow measurement

For steam flow measurement, up-tilt the guiding pressure tube by 45°. Ensure that
transmitter installation location is at lower level than that of the process pipeline. Pre­inject cooling liquid into the guiding pressure tube. Slowly open the shut-off valve to start
measurement. Periodically open the drain vent to clear the residual steam from guided
pipeline to improve the measurement accuracy.

Liquid flow measurement

For liquid flow measurement, tilt down the guiding pressure tube by 45°. Ensure that
transmitter installation location is at lower level than that of the process pipeline. Pre­inject cooling liquid into the guiding pressure tube. Slowly open the shut-off valve to
start measurement. Periodically open the drain vent to clear the residual liquid, which
will improve the measurement accuracy.

Air flow measurement

For liquid flow measurement, up-tilt the guiding pressure tube by 45°. Ensure that
transmitter installation location is at lower level than that of the process pipeline. Pre­inject cooling liquid into the guiding pressure tube. Slowly open the shut-off valve to start
measurement. Periodically open the drain vent to clear the residual gas from the guiding
pressure tube, which will improve the measurement accuracy.

Open container level measurement-single flange level transmitter

Verify the process medium compatibility in case of open container level measurement.
For accurate measurement, install the transmitter at a location where liquid level and
temperature fluctuations are minimal.

Sealed container level measurement-single flange level transmitter

Use a single flange diaphragm system for sealed container level measurement. Increase
the isolation tank and multiple shut-off valves. Periodically open the drain/vent valve to
clear off the residual gas and liquid in the guiding pressure tube for higher accuracy.

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WARNING

• Connect all electrical cables when the power is switched off. If the device does

not have switch-off elements, then, overcurrent protection devices, lightning
protection and/or energy isolating devices must be provided by the customer.

• The device must be grounded to a spot in accordance with regulations to

protect personnel against electric shocks.

NOTE

• When using the measuring device in hazardous areas, installation must

comply with the corresponding national standards and regulations and the
Safety Instructions or Installation or Control Drawings.

4 Electrical Connections

This section covers the all electrical connection requirement. Electrical connection of the
device must be carried out by trained, qualified specialists authorized to perform such work
by the installation site.

4.1 Grounding of Measuring Device

• Ensure proper grounding at control cabinet and pressure transmitter.

• Ground terminals are provided on the either sides (inside and outside) of the terminal

box. Either one of these terminals may be used for grounding the transmitter.

• Use shielded twisted pair cable to avoid ground loops.

• Use internal ground terminals for direct grounding.

4.2 Power Supply Specifications and Connection

Use independent linear direct current power supply for pressure transmitter. Large resistive
load results in high pressure drop. Therefore, it is recommended to consider the resistance
across the signal cable, display meter and other equipment to ensure sufficient voltage is
provided to the pressure transmitter for its normal operation.

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Label

Two Wires

Three Wires

Four Wires

+

Power +

Power +

Power +

-

Power -

Power -

Power -

A Signal +

Signal +

B

Signal -

Standard current signal output: 12-30VDC,
Current signal output with HART: 16.5-55VDC,
Current signal output with intrinsic safety: 12-30VDC,
Modbus-RTU/RS485 signal output: 5VDC/9-30VDC, 0.5-4.5VDC
Voltage signal output: 5 VDC/6-15VDC.

Remove the housing cover on terminal compartment side. Do not remove the cover in
explosive atmospheres when the circuit is live.

Power supply connections:

• Connect power supply ‘+’ terminal to transmitter ‘+’ terminal.

• Connect signal ‘+’ terminal to transmitter ‘-’ terminal.

• Connect signal ‘-’ terminal to power supply ‘-’ terminal.

• Do not connect power signal wiring to the test terminals as it could damage the test

diode.

Power Supply Connections

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4.3 Cable Protection System

Apply following cable protection measures to protect the connecting cables from various
factors that affect negatively on the cable lifetime.

Standard Protection System

• To avoid liquid flowing along with the cable into the terminal box, configure a

U-shaped ring between pull box and pressure transmitter as shown in the
figure below.

• Ensure that the level of U-shaped bottom is maintained below the pressure

transmitter.

• Use sufficiently long cable considering the maintenance and repair factors.

Explosion-proof Tube Protection System

• If the transmitter is situated in dangerous area, use a high quality metallic explosion-

proof tube as a casing for the cable connecting the transmitter to the terminal box.

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Connection to the HART Handheld Communicator

A loop resistance for HART Communicator is between 250Ω and 550Ω. Transmitter
operates on 11.9 –45 VDC. Figure below illustrates the connection details for HHT
communicator.

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NOTE

Calibrate the instrument according the instructions given in this section, otherwise
it could lead to measurement error.

5 Operation

This section covers operation techniques and guidelines along with the configuration and
calibration.

5.1 Local Operation and Display

Tek-Bar 3120B is available with the optional LCD display. The local display enables user to
read important parameters directly at the measuring point and configure the device using
the function matrix. The display indicates output and diagnostic messages. It features a
two-line display with 5-digit. The first line displays measured value and the second line
displays the engineering units. If LCD display is not available, then use HART for
communication (Refer section 5.4).

5.2 Operation in safe and hazardous area

The internal and external buttons are provided for operation in safe and hazardous areas
respectively.

• While operating in safe area, open the front cover and use internal buttons.

• While operating in hazardous area, slide the nameplate located at the upper side of

the transmitter and use the external buttons.

External buttons for operation in hazardous area

5.3 Configuration

This section provides detailed information of initial setup required for transmitter
functioning.
The device consists of 3 operation key: S, Z and M which are used to set parameters and
perform various operations. The primary function of each key is mentioned as below.
Z: Enter the setting options
S: Modify the parameter value
M: Confirm the set value and enter the next menu
The same keys are used in combination to perform several advanced functions.

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Key Operation

Consider the factory setting for pressure measurement is set as follows:
Pressure range: -10 to 100 kPa; Output current display unit: mA
For performing zero-point adjustment and full span pressure adjustment follow the
instructions and display screenshots given in the flow diagram below.

Factory Reset

Achieving the original factory settings at any point of time after the installation of the
transmitter is possible by either of the following methods.

Detailed Operating Instructions

Refer the following flow diagrams to configure various parameters. Use parameter table to know the possible range of values and units.

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Parameter

Values

Display mode

%

Percentage

pV

Process variable

mA

Current

Units

Use the keys Z() and S()
to change the units

kPa

MPa

bar

psi

mmHg

mmH2O

mH2O

inH2O

ftH2O

inHg

mHg

TORR

mbar

g/cm2

Kg/cm2

Pa

ATM

mm

M

Lower and Upper
range

-19999-99999
Damping time

0 ~ 100 s

Output signal type
√

Square root

LINER

Linear

Fault alarm signal

NO

None

H

20.8 mA

L

3.8 mA

Output current

No (none)

3.8000 mA

4.0000 mA

8.0000 mA

12.000 mA

16.000 mA

20.000 mA

20.800 mA

Density

0.0001-99999

Centre distance

0.0001-99999

Coefficient

0.0001-99999

Parameter Table

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Cutting value

0-99.999

Pressure type
GAUGE

Gauge, differential

ABSOLUTE

Absolute pressure

5.4 Handheld Communicator

If custom display is not available, then configure transmitter parameter using
communicator. Decimal point position, Upper range value, Lower range value, Engineering
units are configured. See the below flow chart.

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WARNING

Explosion can result into a serious injury or death.

• Do not remove the transmitter cover in explosive environments when the

circuit is live.

• After disconnecting power wait for a minute to allow the circuit and enclosure

to cool down before opening.

• Avoid direct contact with the leads and terminals. High voltage on leads can

cause electrical shock.

• Ensure that the transmitter casings are sealed when the assembly is in

operating condition.

• Only trained and qualified personnel may undertake start-up and maintenance

activities.

6 Maintenance

This section covers maintenance techniques and guidelines.

6.1 Hardware Maintenance

Perform maintenance task at regular intervals. Set the maintenance schedule in advance
and maintain a logbook to note maintenance activity details. Maintenance schedule
depends on the system, installation conditions, working medium and rigorousness of the
operation. Consider the system downtime when maintenance cycle is running. Ensure that
it does not affect the system performance.

Maintenance majorly involves sensor cleaning and verifying connections.

Test Terminal

Test Terminal is marked as TEST on the terminal
block. Connect TEST and negative terminal to the
test terminal. Ensure that the voltage across the
receptacles is kept below the diode threshold
voltage so that no current passes through the
diode. Make sure that the resistance of the test
connection does not exceed 10 ohms while
connecting an indicating meter or while taking the
test readings. Note that a resistance of 30 ohms can
cause an error of approximately 10% of actual
value.

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Disassembling the Electronics Housing

The transmitter assembly comes in dual-compartment housing; one contains the
electronic module, and the other contains all wiring terminals and the communication
receptacles. The separate compartment of wiring terminals ensures hassle free handling
while running a routine maintenance cycle.

External Cleaning

• Use washing agent that will not damage the instruments.

• Protect the pressure sensing diaphragm from mechanical damage caused by sharp

objects or external pressure.

• Mechanical cleaning of the diaphragm is strictly prohibited.

• Do not point the nozzles to the diaphragm when cleaning by pressure washer.

Depot Repair

Execute following steps before sending the device for depot repair:

• Disconnect the transmitter carefully. Preserve all accessories and cables for

reassembling.

• Remove the harmful residues such as inflammable, poisonous, cancer genic and

radioactive substances.

• Repack the device in original packaging material provided at the time of delivery

and send for repair.

Discard Disposal

It is recommended to pass the instrument to specialized recycling companies rather than
local recycling points.

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Symptom

Potential Source

Corrective Action

No communication
between the
Transmitter and
HART communicator

Loop Wiring

Check for a minimum of 250 ohms
resistance between the power
supply and HHT.

Check for an adequate voltage to the
transmitter. The transmitter always
requires 11.9 to 45 VDC.

Check for intermittent shorts, open
circuits, and multiple grounds

High Output

Sensor Input Failure

Connect

HHT

and enter the
Transmitter test mode to isolate a
sensor failure.

Loop Wiring

Check for dirty or defective
terminals, interconnecting pins, or
receptacles.

7 Troubleshooting

This section provides troubleshooting techniques for most common operating problems.

When device malfunction is suspected despite the absence of any diagnostic messages on
the HHT, inspect following points.

• If measurement signal appears irregular, check whether the process pressure is

within the working range, or the abnormality lies in the measuring system,
installation environment or pressure transmitter. Once diagnosed take
corresponding measures.

• If no signal output or unchanged output signal on corresponding process pressure

changes is observed, then check the power supply polarity, open or short circuit.
Check the parameters like voltage, power and load resistance meet the normal
working requirements. Also, ensure there is no leakage or pressure-impulse line
blockage and shut-off valve is closed.

• If the output signal is large or outside the normal range, check whether the supply

voltage, power consumption, and load resistance meet the normal working
requirements of pressure transmitters. Verify measuring range settings and adjust
the device calibration. Also, ensure there is no leakage, pressure-impulse line
blockage or rapid temperature fluctuations in the installation and shut-off valve is
closed.

7.1 Symptoms and Corrective Measures

Refer to the table below to verify whether the transmitter hardware and process
connections are in good working condition:

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Power Supply

Check the output voltage of the
power supply at the transmitter
terminals. It should be 11.9 to 45
VDC in spite of loop scale

Electronics Module

Connect HHT and enter the
Transmitter test mode to isolate
module failure. Check the sensor
limits to ensure calibration
adjustments are within the sensor
range.

Erratic Output

Loop Wiring

Check the output voltage of the
power supply at the transmitter
terminals. It should be 11.9 to 45
VDC.

Check for intermittent shorts, open
circuits, and multiple grounds.

Check for proper polarity at the
signal terminals.

In case measuring electric current
while digital communication, output
appear around +-0.013mA

Electronics Module

Connect HHT and enter the
transmitter test mode to isolate an
electronics mode failure.

Low Output or No
Output

Sensor Element

Connect HHT and enter the
Transmitter test mode to isolate the
sensor failure.

Check the PV to see if it is out of
range.

Loop Wiring

Check for adequate voltage to the
transmitter. The transmitter always
requires 11.9 to 45 VDC.

Check for intermittent shorts, open
circuits, and multiple grounds.

Check polarity of signal terminal

Check the loop impedance.

Electronics Module

Connect HHT and check the sensor
limits to ensure calibration
adjustments are within the sensor
range.

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Message

Description

ADJ-U

Out of Zero setting value when Zero Adj function using button (upper side)

ADJ-L

Out of Zero setting value when Zero Adj function using button (lower side)

ZERO

Initial message in using the Zero button

SPAN

Initial message in using the Span button

BT-ERR

Button Input Sequence Error

P-LOCK

Button Input Error when Protect Locked

ZT-ERR

Setting Limit (10%) Error when in Zero Trim

-TR-

Zero Trim Complete

ZR-ERR

Setting Limit Error when executing the Zero button function

-TR-

Zero Trim Complete

ZR-ERR

Setting Limit Error when executing the Zero button function

SP-ERR

Setting Limit Error when executing the Span button function

-ZR-

Zero button function Complete

-SP-

Span button function Complete

-ZA-

Zero Adjustment done

-DONE-

Setting Done using button

RNGOVR

Setting Limit error when executing other setting function

LCD_OV

Over figure values for LCD

SCD-ER

Sensor Code Error

F-RST

Flash Setting Data Rese

F-LOCK

While Flash Setting Data Reset, Protect Locked

F-FAIL

Flash Setting Data Reset Failure

-FR-

Flash Reset Done

A-RST

Analog EEPROM Initializing Start

A-STOR

Analog EEPROM Whole Write

A-FAIL

Analog EEPROM Whole Write Failure

7.2 Tek-Bar 3120B Smart Gauge Pressure Transmitter LCD Display error codes

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