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BINMASTER GWR-2000 Operating Instructions Manual

Four-wire 4 - 20 ma/hart rod and cable probe
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Operating Instructions
TDR sensor for continuous level measurement
of bulk solids
GWR-2000
Four-wire 4 - 20 mA/HART
Rod and cable probe
Document ID: 925-0335 Rev B
GWR-2000 Four-wire 4-20 mA/HART

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Summary of Contents for BINMASTER GWR-2000

  • Page 1 Operating Instructions TDR sensor for continuous level measurement of bulk solids GWR-2000 Four-wire 4 - 20 mA/HART Rod and cable probe Document ID: 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...

  • Page 2: Table Of Contents

    Adjustment system ................... 24 Parameter adjustment - Quick setup ..............25 Parameter adjustment - Extended adjustment ..........26 Saving the parameter adjustment data ............. 40 Setup with PACTware ....................42 Connect the PC ....................42 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...
  • Page 3 Safety instructions for Ex areas Take note of the Ex specific safety instructions for Ex applications. These instructions are attached as documents to each instrument with Ex approval and are part of the operating instructions manual. 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...

  • Page 4: About This Document

    This arrow indicates a single action. Sequence of actions Numbers set in front indicate successive steps in a procedure. Battery disposal This symbol indicates special information about the disposal of batteries and accumula- tors. 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...

  • Page 5: For Your Safety

    Depending on the instrument version, the emitting frequencies are in the C, K or W band range. The low emitting frequencies are far below the internationally approved limit values. When used correctly, the device poses no danger to health. 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...

  • Page 6: Ce Conformity

    The environment management system is certified according to DIN EN ISO 14001. Please help us fulfil this obligation by observing the environmental instructions in this manual: ● Chapter "Packaging, transport and storage" ● Chapter "Disposal" 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...

  • Page 7: Product Description

    ● Product code (HTML) ● Delivery date (HTML) ● Order-specific instrument features (HTML) ● Operating instructions and quick setup guide at the time of shipment (PDF) ● Order-specific sensor data for an electronics exchange (XML) 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...

  • Page 8: Principle Of Operation

    3.2 Principle of operation The GWR-2000 is a level sensor with cable or rod probe for continuous level measurement, suitable for applications in bulk solids. High frequency microwave pulses are guided along a steel cable or a rod. Upon reaching the product surface, the microwave pulses are reflected.

  • Page 9: Packaging, Transport And Storage

    The display and adjustment module can be optionally replaced by a display and adjustment module with heating function. You can use this display and adjustment module in an ambient temperature range of -40…+70 °C. 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...
  • Page 10 You can find further information in the operating instructions manual "Rod and cable compo- nents". If you mount the GWR-2000 in a bypass tube or standpipe, you have to avoid contact to the by- pass tube by using a spacer at the probe end.

  • Page 11: Mounting

    These are mainly: ● Active measuring component ● Process fitting ● Process seal Process conditions are particularly: ● Process pressure ● Process temperature ● Chemical properties of the medium ● Abrasion and mechanical influences 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...

  • Page 12: Mounting Instructions

    4.2 Mounting instructions Mount the GWR-2000 in such a way that the distance to vessel installations or to the vessel wall is at least 300 mm (12 in). In non-metallic vessels, the distance to the vessel wall should be at least 500 mm (19.7 in).
  • Page 13 Metal sheet Concrete vessel When installed in thick concrete ceilings, GWR-2000 should be mounted front flush to the lower edge. In concrete silos, the distance to the wall should be at least 500 mm (20 in). Fig. 4: Installation in concrete silo If possible, avoid sockets.
  • Page 14 Do not mount the instruments in or above the filling stream. Make sure that you detect the prod- uct surface, not the inflowing product. 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...
  • Page 15 If there is a danger of the rod probe touching the vessel wall, then the probe must be fastened at the bottom end. Keep in mind that below the fastening, a measurement is not possible. 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...
  • Page 16 To compensate for the resulting changes in signal runtime, let the instrument determine the probe length automatically. You can find further information in the supplementary instructions of the rod and cable compo- nents. 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...

  • Page 17: Connecting To Power Supply

    In the case of instrument housings with metric thread, the cable glands are screwed in at the factory. They are sealed with plastic plugs as transport protection. You have to remove these plugs before electrical connection. 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...

  • Page 18: Connection

    3. Loosen compression nut of the cable gland and remove blind plug 4. Remove approx. 10 cm (4 in) of the cable mantle (signal output), strip approx. 1 cm (0.4 in) insulation from the ends of the individual wires 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...
  • Page 19 The terminal blocks are pluggable and can be removed from the housing insert. To do this, lift the terminal block with a small screwdriv- er and pull it out. When inserting the terminal block again, you should hear it snap in. 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...

  • Page 20: Wiring Plan, Double Chamber Housing

    Terminal Function Polarity Voltage supply Voltage supply 4 ... 20 mA output (active) 4 ... 20 mA output (passive) Mass - output Function ground when installing ac- cording to CSA (Canadian Standards Association) 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...

  • Page 21: Supplementary Electronics

    Second current output (II) - Voltage supply and signal output (without HART) Ground terminal for connection of the cable screen The radio module PLICSMOBILE is an external GSM/GPRS radio unit for transmission of mea- sured values and for remote parameter adjustment. 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...

  • Page 22: Switch-On Phase

    As soon as a plausible measured value is found, the corresponding current is outputted to the signal cable. The value corresponds to the actual level as well as the settings already carried out, e.g. factory setting. 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...

  • Page 23: Set Up The Sensor With The Display And Adjustment Module

    Fig. 15: Installing the display and adjustment module in the double chamber housing Note: If you intend to retrofit the instrument with a display and adjustment module for continuous mea- sured value indication, a higher lid with an inspection glass is required. 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...

  • Page 24: Adjustment System

    If the key is pressed longer than 1 s, the value or position changes continuously. When the [OK] and [ESC] keys are pressed simultaneously for more than 5 s, the display re- turns to the main menu. The menu language is then switched over to "English". 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...

  • Page 25: Parameter Adjustment - Quick Setup

    Approx. 60 minutes after the last pressing of a key, an automatic reset to measured value indi- cation is triggered. Any values not confirmed with [OK] will not be saved. After switching on, the GWR-2000 carries out a short self-test where the device software is checked.

  • Page 26: Parameter Adjustment - Extended Adjustment

    Here you can assign a suitable measurement loop name. Push the "OK" key to start the editing. With the "+" key you change the sign and with the "->" key you jump to the next position. 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...
  • Page 27 You have the option of choosing the demonstration mode. This mode is only suitable for test and demonstration purposes. In this mode, the sensor ignores the parameters of the application and reacts immediately to any change. 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...
  • Page 28 In the "Min. adjustment Level" menu item, you can enter the min. adjustment for the level. Adjust the requested percentage value with [+] and store with [OK]. Enter the suitable distance value in m for the empty vessel (e.g. distance from the flange to the 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...
  • Page 29 For the socket correction you have to enter the height of the socket above the upper edge of the vessel. If the socket is lower than the upper edge of the vessel, this value can also be negative. 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...
  • Page 30 The default setting is output characteristics 4 … 20 mA, failure mode < 3.6 mA. In the "Current output Min./Max." menu item, you determine the reaction of the current output during operation. 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...
  • Page 31 The "Delete" menu item is used to completely delete an already created false signal suppres- sion. This is useful if the saved false signal suppression no longer matches the metrological conditions in the vessel. 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...
  • Page 32 In the "Indication value 1" menu item, you define the indication of the measured value on the display. You can display two different measured values. In this menu item, you define measured value 1. The default setting for the displayed value 1 is "Filling height Level". 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...
  • Page 33 The higher the value, the more reliable the measurement. Values > 90 % indicate reliable measurement. In another window you can reset the peak value. 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...
  • Page 34 During simulation, the simulated value is outputted as 4 … 20 mA current value and digital HART signal. Push the [ESC] key to deactivate the simulation. Information: The simulation is terminated automatically 60 minutes after the activation of the simulation. 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...
  • Page 35 Basic settings: Resetting of the parameter settings, incl. special parameters, to the default values of the respective instrument. Any stored false signal suppression or user programmable linearisation curve, as well as the measured value memory, is deleted. 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...
  • Page 36 Scaling level - 0 % corresponds to Accept scaling of the level measurement Scaling variable - Interface Volume Scaling unit - Interface Litres Scaling format - Interface Without decimal positions Scaling interface - 100 % corresponds to 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...
  • Page 37 3 min. Recording in time interval Device memory - Measured value memory - 15 % Recording with measured value difference Device memory - Measured value memory - Not active Start with measured value 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...
  • Page 38 Since scaling is very extensive, scaling of the level value was divided into two menu items. In the "Level 1" menu item you define the scaling variable and the scaling unit for the level value on the display, e.g. volume in l. 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...
  • Page 39 4 … 20 mA signal in Multidrop mode. In the mode "Fixed current (4 mA)" a fixed 4 mA signal is output independently of the actual level. The default setting is "Analogue current output" and the address 00. 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...

  • Page 40: Saving The Parameter Adjustment Data

    ● All data of the menu "Setup" and "Display" ● In the menu "Additional settings" the items "Sensor-specific units, temperature unit and lin- earization" ● The values of the user programmable linearization curve 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...
  • Page 41 If it is necessary to exchange a sensor, the display and adjustment module is inserted into the replacement instrument and the data are likewise written into the sensor via the menu item "Copy sensor data". 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...

  • Page 42: Setup With Pactware

    Fig. 19: Connecting the PC via HART to the signal cable GWR-2000 HART resistance 250 Ω (optional depending on evaluation) Connection cable with 2 mm pins and terminals Processing system/PLC/Voltage supply Interface adapter, for example BinDisc 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...

  • Page 43: Parameter Adjustment

    In the standard version, all functions for complete setup are already in- cluded. An assistant for simple project configuration simplifies the adjustment considerably. Sav- ing/printing the project as well as import/export functions are also part of the standard version. 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...

  • Page 44: Set Up With The Quick Setup

    To use it, select the function "Quick setup" in the start screen. Quick setup With quick setup you can carry out the parameter adjustment of GWR-2000 for your application in just a few simple steps. The assistant-driven adjustment includes the basic settings for sim- ple, reliable setup and commissioning.

  • Page 45: Set Up With Other Systems

    Internet and new EDDs are automatically taken over into the device catalogue of this soft- ware after they are released by the manufacturer. They can then be transferred to a Field Com- municator. 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...

  • Page 46: Diagnostics And Servicing

    Changes in the measurement conditions during operation or buildup on the sensor can thus be recognized. The echo curve of the setup is stored via: ● PC with PACTware/DTM ● Control system with EDD ● Display and adjustment module 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...

  • Page 47: Status Messages

    This status message is inactive by default. It can be activated by the user via PACTware/DTM or EDD. Maintenance: Due to external influences, the instrument function is limited. The measurement is affected, but the measured value is still valid. Plan in maintenance for the instrument because 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...
  • Page 48 - Error in the calibra- - Exchanging the electronics Bit 8 of Byte 0 … 5 tion carried out in the Send instrument for repair Error in the factory Error in the calibration EEPROM 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...
  • Page 49 Bit 9 of Byte 14 …24 range not available - 100 % adjustment: Increase Overfilling value - Check mounting socket - Remove possible interfering signals in the close range - Use coaxial probe 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...
  • Page 50 Bit 5 of Byte 14 … 24 tect an echo during tion and/or parameter adjust- no measured operation ment value avail- - Process component or - Clean or exchange process- able probe contaminated or component or probe defective 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...

  • Page 51: Rectify Faults

    ● Constant level ● Filling ● Emptying The images in column "Error pattern" show the real level as a broken line and the level dis- played by the sensor as a continuous line. 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...
  • Page 52 4. Measured value - Turbulence on the product - Check parameters, change if remains momentarily surface, quick filling necessary, e.g. in dosing ves- unchanged during sel, reactor filling and then jumps to the correct level 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...

  • Page 53: Exchanging The Electronics Module

    The new electronics module must be loaded with the default settings of the sensor. These are the options: ● In the factory ● Or on site by the user 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...

  • Page 54: Exchange Or Shorten Cable/Rod

    4. Screw the new rod and the new cable manually to the thread on the process fitting. 5. Exert counterforce with the second fork spanner and tighten the measuring rod or cable on the flat surfaces with a torque of 20 Nm (15 lbf ft). 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...
  • Page 55 6. Cable: shift the cable into the gravity weight (according to the drawing) Plastic coated cable: remove coating according drawing to 70 mm (2.76 in). 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...
  • Page 56 - Carrying out max. adjustment"). Fig. 31: Shortening the cable probe Gravity weight - cable ø 4 mm Gravity weight - cable ø 6 mm Threaded pins Thread M12 for eye-bolt Threaded pins 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...

  • Page 57: Removal

    Pass the instrument directly on to a specialized recycling company and do not use the municipal collecting points. These may be used only for privately used products according to the WEEE directive. 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...

  • Page 58: Supplement

    Second Line of Defense (optional) - Supporting material 316L - Glass potting Borosilicate glass GPC 540 - Contacts Alloy C22 - Helium leak rate < 10 mbar l/s Only with Ex d version 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...
  • Page 59 30 KN (6744 lbf) The tensile force of solids are subject of a normal fluctuation range. For this reason, the deter- mined diagram value of the following diagrams must be multiplied with safety factor 2. 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...
  • Page 60 Tensile force in kN (the determined value must be multiplied with safety factor 2) Cable length in m Vessel diameter 12 m (39.37 ft) Vessel diameter 9 m (29.53 ft) Vessel diameter 6 m (19.69 ft) Vessel diameter 3 m (9.843 ft) 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...
  • Page 61 Tensile force in kN (the determined value must be multiplied with safety factor 2) Cable length in m Vessel diameter 12 m (39.37 ft) Vessel diameter 9 m (29.53 ft) Vessel diameter 6 m (19.69 ft) Vessel diameter 3 m (9.843 ft) 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...
  • Page 62 - Relative humidity 45 … 75 % - Air pressure +860 … +1060 mbar/+86 … +106 kPa (+12.5 … +15.4 psig) The output values can be assigned individually The indication values can be assigned individually 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...
  • Page 63 - Medium Bulk solids - cereals, flour, cement (dielectric con- stant ~2.0) - Installation Probe end does not touch the vessel bottom Sensor parameter adjustment No gating out of false signals carried out 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...
  • Page 64 Lower dead band (see following diagrams - grey section) Typical deviation See following diagrams Fig. 37: Deviation GWR-2000 in rod version Dead band - no measurement possible in this area Probe length Depending on the installation conditions, deviations can occur which can be rectified by adapting...
  • Page 65 11 Supplement Fig. 38: Deviation GWR-2000 in cable version in water Dead band - no measurement possible in this area Probe length Repeatability ≤ ±1 mm Variables influencing measurement accuracy Specifications for the digital measured value Temperature drift - Digital output ±3 mm/10 K relating to the max.
  • Page 66 Time span after a sudden measuring distance change by max. 0.5 m in liquid applications, max 2 m with bulk solids applications, until the output signal has taken for the first time 90 % of the final value (IEC 61298-2). 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...
  • Page 67 Fig. 40: Ambient temperature - process temperature, version with temperature adapter Ambient temperature Process temperature (depending on the seal material) Aluminium housing Plastic housing Stainless steel housing, precision casting Stainless steel housing, electropolished 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...
  • Page 68 Via the current output - Digital Via the digital output signal - depending on the electron- ics version Range -40 … +85 °C (-40 … +185 °F) Resolution < 0.1 K Accuracy ±3 K 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...

  • Page 69: Dimensions

    Plastic housing Fig. 41: Housing versions with protection rating IP 66/IP 67 - with integrated display and adjustment module the hous- ing is 9 mm/0.35 in higher Single chamber version Double chamber version 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...
  • Page 70 GWR-2000, cable version ø 4 mm (0.157 in)/ø 6 mm (0.236 in) - PA coated Fig. 42: GWR-2000, cable ø 4 mm (0.157 in)/ø 6 mm (0.236 in) threaded version with gravity weight (all gravity weights with thread M12 for eye-bolt) Sensor length, see chapter "Technical data"...
  • Page 71 GWR-2000, cable version ø 6 mm (0.236 in)/ø 11 mm (0.433 in) - PA coated Fig. 43: GWR-2000, cable ø 6 mm (0.236 in)/ø 11 mm (0.433 in) threaded version with gravity weight (all gravity weights with thread M12 for eye-bolt) Sensor length, see chapter "Technical data"...
  • Page 72 11 Supplement GWR-2000, rod version ø 16 mm (0.63 in) Fig. 44: GWR-2000, rod ø 16 mm (0.63 in), threaded version Sensor length, see chapter "Technical data" Joint - rod 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...

  • Page 73: Index

    Reset 39 Factory calibration date 44 False signal suppression 34 Scaling measured value 43 Fault rectification 54 Sensor characteristics 44 Functional principle 8 Sensor status 36 Simulation 38 Grounding 18 Special parameters 44 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...
  • Page 74 INDEX Type label 7 Type of medium 31 Units 30 925-0335 Rev B GWR-2000 Four-wire 4-20 mA/HART...
  • Page 75 Subject to change without prior notice BinMaster Phone: 402-434-9102 7201 N 98th St Fax: 402-434-9133 Lincoln, NE 68507 E-mail: info@binmaster.com www.binmaster.com 925-0335 Rev B...

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