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The units supplied should not be repaired by anyone other than Berthold Tech- nologies Service engineers or technicians by Berthold Technologies. In case of operation trouble, please address to our central service department (address see below). The complete user’s guide consists of the hardware manual and the soft- ware manual.
Table of Contents Table of Contents Page Safety Summary Symbols and Warnings General Information General Safety Instructions General Information Use and Function Frequency License Intended Use Explanation of Terms System Description Principle of Measurement Calculation of Measured Values Temperature Compensation Throughput Calculation and Output Mechanical Components 3.5.1 Evaluation Units...
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Table of Contents Technical Data Technical Data Evaluation Unit Technical Data Sensors Technical Data HF Cable Format of Serial Data Output RS232 and RS485 Certificates EC Declaration of Conformity Frequency License Technical Drawings Dimensions Drawings Evaluation Unit Wall Housing Electrical Wiring Diagram Dimensional Drawings FlowCell 8.3.1 Type LB 5660-102-00X FlowCell DN 50 Flange, FDA 8.3.2 Type LB 5660-202-00X FlowCell DN 65 Flange, FDA...
Chapter 1. Safety Summary Safety Summary Symbols and Warnings In this user manual, the term Berthold Technologies stands for the company Berthold Technologies GmbH & Co.KG. To rule out bodily injury and property damage, please keep in mind the warning and safety instructions provided in this user manual.
Chapter 1. Safety Summary Other symbols used in this documentation: Warning: No intervention, do not alter anything Requirement: Disconnect power Requirement: Wear safety boots General Information The most important safety measures a summarized in this user manual. They supplement the corresponding regulations which must be studied by the personnel in charge.
Chapter 1. Safety Summary General Safety Instructions IMPORTANT The equipment housings have IP 65 protection and are suitable for outdoor applications. The units are factory tested and are delivered in a condition that permits safe and reliable operation. For outdoor applications, the measuring systems must be pro- tected from direct sunlight and rain, for example by a suitable shelter.
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Chapter 1. Safety Summary Electrical hazards Disconnect power to ensure that contact with live part is avoided during installation and when servicing. Disconnect the power supply before opening the instrument. Work on open and live instruments is prohibited. Caution! Potential hazards, material damage! Device type: LB 566-12 MicroPolar ++ (ID no.
General Information Use and Function The MicroPolar LB 566 has been designed as a concentration measuring system and may be used only for this purpose. If the devices are used in a manner that are not described in this user manual, the protection of the devices is compromised and the warranty will be lost.
Chapter 2. General Information Frequency License This device complies with Part 15 of the FCC Rules and with In- dustry Canada licence-exempt RSS standard(s). Operation is subject to the following two conditions: this device may not cause harmful interference, and this device must accept any interference received, including interference that may cause undesired operation.
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Consult the dealer or an experienced radio/TV technician for help. Changes or modifications made to this equipment not expressly approved by BERTHOLD TECHNOLOGIES may void the FCC au- thorization to operate this equipment. The MicroPolar and MicroPolar ++ comply with the R&TTE Di- rective 1999/5/EC and thus meet all the requirements for this type of high-frequency devices.
Chapter 2. General Information Intended Use The LB 566 can be used to determine the water or moisture con- tent and the concentration of virtually any material. The following sensors and evaluation versions are available: The container probes have been designed for installation into containers and pipelines with a nominal width of ≥...
Chapter 2. General Information Explanation of Terms Attenuation Weakening of microwave signals, microwaves measuring effect. Evaluation Unit Factory setting In the factory setting all parameters have been set to default values. In most cases this considerably facilitates the calibra- tion of the instrument. Despite factory setting, calibration al- ways has to be performed.
Chapter 3. System Description System Description Principle of Measurement As the microwaves pass through the product, their propagation velocity is slowed down (= phase shift) and their intensity is at- tenuated (= attenuation). Figure 3-1 illustrates the principle of measurement: Compared to a reference signal, the propagation velocity of microwaves passing through the product is slowed down (phase shift) and their intensity (attenuation) is reduced.
Chapter 3. System Description Calculation of Measured Values The microwave parameters phase and attenuation are calibrated according to an automatic plausibility analysis. During calibration, the phase and/or attenuation of a concentra- tion value (or density value) are assigned through sampling. The calibration is done automatically and the sampling process is sup- ported by the evaluation unit.
Chapter 3. System Description Conductive materials such as graphite or coke cannot be trans- mitted by microwaves. Metal walls can also not be transmitted by microwaves. Compensation In addition to the water content, the product temperature, product density and a varying material load (varying microwave irradiation path) may have an influence on the phase and atten- uation.
Chapter 3. System Description Throughput Calculation and Output For pipeline applications, the LB 566 allows you to calculate the throughput (mass flow) and to output the result via a current output. The calculation is based on the microwave measured value; if this value correlates with the product density, one can calculate the throughput, if some additional information is available.
(short HF-cable). The evaluation unit is available in two versions: the standard model MicroPolar LB 566 and the high dynamics version MicroPolar ++ LB 566 (see Figure 3-4 and Figure 3-5).
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Chapter 3. System Description The probes/antenna pairs are available in different versions, as pipeline and container probe with or without flushing device (see Figure 3-6 to Figure 3-7). Figure 3-6: From left: Container probe LB 5650 and LB 5651 with flushing device Figure 3-7: FlowCell LB 5660-102-00x...
Chapter 3. System Description 3.5.1 Evaluation Units The evaluation units comprise the evaluation computer and the microwave unit. The microwaves are generated, received and an- alyzed in the microwave unit. Signal processing and communica- tion take place in the evaluation computer. For simple operation, the measuring system includes a display, 4 softkeys and an al- phanumeric keypad.
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Chapter 3. System Description Cable feed-through M 20 and M 16 Rs232 9 pole SubD-connector M-Rx M-Tx R-Tx R-Rx Figure 3-9: Evaluation unit – High-frequency connections bottom view Interpretation of LEDs Five LEDs on the instrument front panel indicate the current de- vice status.
Chapter 3. System Description Terminal block The electrical connections of the LB 566 are located on a con- nector strip in the wall cabinet. The terminal block can be ac- cessed from the front by opening the cover of the housing. There, you also find the power cut-off switch and the fuses.
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Chapter 3. System Description The FlowCell consists of a sturdy stainless steel body. The micro- wave transmitter and receiver are firmly welded to the outside of the pipe. The entire product pipe is PTFE-coated and thus meets the special requirements for use in food for use in food. There are no objects that extend into the pipe (e.g.
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Chapter 3. System Description Sampling valve Combination Conductivity measuring device with Sampling valve Combination Inline PT100 with Sampling valve MicroPolar (++) LB 566...
Chapter 3. System Description 3.5.3 Container Probe The container probe is available in a version with and without flushing device (see Figure 3-12). The technical data are listed in chapter 6.2 Technical Data Sensors. Figure 3-12: Container probe versions A: High-frequency connections B: Process connection, flanges of different sizes Container probe type LB 5650 and type LB 5651 The container probe has been specially designed for concentra-...
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Chapter 3. System Description For the case depicted in Figure 3-13, the flow direction of the product being measured must be perpendicular to the drawing plane. This ensures a representative product between the meas- uring rods, provided the product is mixed thoroughly. Figure 3-13: Container probe LB 5650 PT100...
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Chapter 3. System Description Container probe type LB 5651 with flushing device The flushing probe LB 5661 has been designed for processes in which depositions, for example, due to incrustations are likely to occur on the probe. The flushing probe has two flushing channels which keep the measuring rods free from incrustations;...
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Chapter 3. System Description The flushing slit width is the same for both probe rods and is depicted in Figure 3-16. Flushing pipe Plastic rods Figure 3-16: Rod head with flushing pipe MicroPolar (++) LB 566...
Chapter 3. System Description 3.5.4 High-frequency Cable High-frequency cables (HF cable) are used to transmit microwave signals. HF cables change their conductivity (for microwaves) with tem- perature and would therefore produce measurement errors with varying ambient temperature. This error is compensated for by enabling the automatic cable compensation.
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Chapter 3. System Description Version 2: It consists of a single HF-cable whose ends are ter- minated by an HF-connector (N-type). Available lengths: 2, 2.5, 3, 3.5 and 4 m (see Figure 3-19). 19 mm wrench ø 10 mm Lengths 0.5 to 4 m Figure 3-19: HF cable For further technical data see chapter 6.5 Technical Data HF-...
Chapter 3. System Description Assembly on a Pipeline The evaluation unit is installed close to the FlowCell to keep the HF cable between evaluation unit and probe as short as possible. The shorter the cable connection, the better the stability of the measurement.
Chapter 3. System Description Assembly on a Container The evaluation unit is installed in the immediate vicinity of the container probe to keep the HF-cable between evaluation unit and probe fairly short. The shorter the cable connection, the bet- ter the stability of the measurement. The standard length is 2 m and the maximum length of the HF cable is 10 m.
Chapter 4. Getting Started Getting Started Transport Warning: Possible material damage! System parts may get damaged during transportation! Transport all components in their original packaging. Protect parts against shocks. In particular, the measuring rods of the container probes must be protected against mechanical shock! After unpacking, make sure all parts listed on the packing list have been delivered and show no sign of damage;...
Chapter 4. Getting Started Commissioning the FlowCell 4.2.1 Installing the FlowCell Danger of injury from leaking operating medium. The FlowCell must be mounted correctly. In particular, the correct tightening torque for the flange screws must be observed. Requirements for the hygienic installation of the FlowCell: ...
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Chapter 4. Getting Started No gas inclusions should be present in the product. If gas bubbles cannot be ruled out, a pressure of at least 4 bar is required in the pipeline to minimize the influence of gas bub- bles.
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Chapter 4. Getting Started Abb. 4-1: Installation in a vertical riser Abb. 4-2: Horizontal installation: The drainability of the pipeline must be respected. To en- sure this, the FlowCell must not be rotated. MicroPolar (++) LB 566...
Chapter 4. Getting Started 4.2.2 Installing the Evaluation Unit Note the following points when installing the evaluation unit: Position the evaluation unit depending on the length of the HF cable in the vicinity of the microwave probe. The evaluation unit has to be protected against vibrations. In some cases, it is advisable to set up the evaluation unit on a stand separated from the pipeline system.
2 x HF cables (as signal cable) 1 x HF cable (as reference cable) The decision for a certain cable version is taken by Berthold Tech- nologies in the planning stage. It is subject to the application and the desired distance between evaluation unit and FlowCell.
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Chapter 4. Getting Started Abb. 4-4: FlowCell connection, version 1 Abb. 4-5: FlowCell connection, version 2 Hand tighten all screwed connections of the HF cable (2 Nm = 0.2 kg/m)! Before tightening, carefully screw on the cable by hand. Caution! Threaded joint jams easily. Check occasionally if the screwed connection is still properly tightened.
Chapter 4. Getting Started Commissioning the Container Probe 4.3.1 Installing the Container Probe Danger of injury from leaking operating medium. The Container probe must be mounted correctly. In particular, the correct tightening torque for the flange screws must be observed. For installation of the probes, please keep in mind: ...
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Chapter 4. Getting Started Depending on the process, the probe flange may stick to the Dismounting in the process flange. In such case, during the dismounting process, event of a stuck remove the two eyebolts first. Then insert two longer screws flange (M8) into their bore holes up to the process flange.
Chapter 4. Getting Started The flush duration has to take into account possible inertias of the system, e.g. valve openings. The flush supply pipes must be well insulated to prevent that the flush solution is initially colder. Amounts of water With a 5 bar flushing pressure, the amount of water per flushing connector is approximately 0.8 liters per second.
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Chapter 4. Getting Started Figure 4-6: Connecting the container probe to the evaluation unit Hand tighten all screwed connections of the HF cable (2 Nm = 0.2 kg/m)! Before tightening, carefully screw on the cable by hand. Caution! Threaded joint jams easily. Check occasionally if the screwed connection is still properly tightened.
Chapter 4. Getting Started Connecting the Evaluation Unit Electrical hazards: Disconnect power to rule out any contact with live parts during installation and servicing. Turn off power before opening the instrument. NEVER work on open and live instruments. Caution! Potential hazards, material damage! Device type: LB 566-12 MicroPolar ++ (ID no.
Chapter 4. Getting Started 4.5.1 Pin Configuration of the Connector Strip The connector strip of the evaluation unit includes the following terminals: Figure 4-7: LB 566 wiring diagram Power supply: Terminals 3 (L1, +), 2 (N, -) and 1 (PE, For MicroPolar, depending on device type, see name plate on the housing outer wall.
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Chapter 4. Getting Started PT100 (terminals 23+ and 11-) Connection for temperature measurement. When commissioning the container probe, connect the 4-core cable of the PT100 to the connector strip of the evaluation (see fig. 4-8). Connect the other end of the cable with the corre- sponding plug on the container probe (see fig.
Chapter 4. Getting Started Digital input 3: DI3 (terminals 26+ and 14-) Only for potential-free contacts! Configuration options: No function Start sampling, open: no action, closed: unique measurement starts Product selection Relay 1: (Terminals 4, 5 and 6) and Relay 2: (Terminals 16, 17 and 18) Changeover contacts (SPDT), insulated, configuration option: ...
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Chapter 4. Getting Started Relay no. Error, alarm, no product, Normal measurement stopped, Below load, currentless condition The relays with changeover contacts can either be operated as make contact, terminals 4 & 5 (open at error, alarm ...) or as break contact, terminals 5 &...
Defective modules of the evaluation unit cannot usually be re- paired but must be replaced. The microwave module is firmly bolted to a screening hood and must not be opened. For device disposal, please contact the Berthold Service and ap- ply for a recycling passport. MicroPolar (++) LB 566...
Chapter 5. Service instructions Wear Parts The evaluation unit does not include any parts that are subject to wear or components that require special maintenance. The plastic caps of the measuring rods of the container probes and the PEEK Microwave windows of the FlowCell may be subject to abrasion over the course of time.
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Chapter 5. Service instructions Replacing the Microwave windows of the FlowCell Open the fixing clamp (see fig. 5-2, item 1). Remove the antenna (see fig. 5-2, item 2), the microwave window (see fig. 5-2, item 3) and the sealing O- rings. Attach the new microwave window, the new sealing O-rings and the antenna to the FlowCell with the fixing clamp accord- ing to fig.
Chapter 5. Service instructions Figure 5-4: Assembly Microwave with PEEK window It is recommended to always change the complete set of sealing O-rings. HNBR o-ring must be used instead of EPDM o-ring once a fat/grease content of 8 % is exceeded. Microwave windows set for FlowCell ID no.
Chapter 5. Service instructions Battery If the measuring system LB 566 is a long time without power supply (power failure or disconnected from the mains supply), the system clock is powered by the lithium battery on the moth- erboard. If the battery voltage is no longer sufficient, the error message CODE 14 "Battery voltage"...
Chapter 5. Service instructions Fuse Replacement The mains fuses of the LB 566 are located in the wall housing. Replace the fuses only if the instrument is disconnected from mains. Use only fuses with the correct rating, see chapter 6.1 Spare fuses must match the rating specified by the device man- ufacturer.
Chapter 6. Technical Data Technical Data General specifications Method Microwave transmission measurement Operating fre- 2.4 - 2.5 GHz (ISM band), depending on quency local regulations Transmission MicroPolar: < 0.1 mW (< - 10 dB) power MicroPolar ++: < 10 mW (< 10 dBm) All coaxial line power Application Concentration / moisture measurement in...
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Chapter 6. Technical Data Power supply For Micro Polar, depending on device type: 1.) 100 ... 240 V AC, 45 ... 65 Hz 2.) 24 V DC: 18...36 V; 24 V AC: -20%, +5%, 40 ... 440 Hz For MicroPolar++, depending on device type: 1.) 100 ...240 V AC, 45...65 Hz 2.) 24 V DC: 18...36 V, no reverse polarity protection...
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Chapter 6. Technical Data Digital input 3 x digital inputs (DI1..3), for floating con- nectors (do not connect to a power supply). Configuration options: DI1: none, measurement start/stop DI2: none, measurement hold, product selec- tion DI3: none, sampling, product selection Function description: 1.
Chapter 6. Technical Data Technical Data Sensors FlowCell Application Microwave FlowCell with various nominal diame- ters and flanges for concentration measurement on pipelines Material Inline housing made of stainless steel 1.4404 pol- ished (AISI 316L) Mikrowave windows made of PEEK Product touching sealing made of EPDM Three versions: Process coupling...
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Chapter 6. Technical Data Overview ASA flange adapter Designation ID no. ASA flange adapter set for Flow Cell 50 62324 ASA flange adapter set for Flow Cell 65 62319 ASA flange adapter set for Flow Cell 80 62328 ASA flange adapter set for Flow Cell 100 62331 ASA flange adapter set for Flow Cell 150 62335...
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Chapter 6. Technical Data Overview sensors Designation Id.-Nr. Conductivity sensor hygienic, Clamp-flange 66693 Inductive conductivity measuring device for liquid media in hygienic applications Measurement range: 0-999 mS/cm Process connection: Clamp-flange Process pressure: Max. 16 bar Power supply: 18-36 V DC, max. 190 mA Output: 4-20 mA Temperature sensor EHEDG, Clamp-flange 66694...
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Chapter 6. Technical Data Container Probes Application Container probes with and without flushing device for concentration measurement in process con- tainers and pipelines with nominal width ≥ 200 Material Plastic caps, stainless steel PT100 connection cable: Silicon / Teflon Process coupling Flange according to DIN EN 1092 type 05 DN65 / PN6, DN 80, 100, 150 / PN16;...
Chapter 6. Technical Data Technical Data HF Cable HF cable Quad Material Corrugated tube: Polyamide (PA6) Cable sheath: Polyethylene (PE) Protection type IP 66 In operation: -30 ... +70 °C Temperature When installing: -20 ... +70 °C Cable length [m] ID no.
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Chapter 6. Technical Data Cable length [m] ID no. 11476 11477 11478 11479 11480 MicroPolar (++) LB 566...
Chapter 6. Technical Data Format of Serial Data Output RS232 and RS485 Headline Date·Time→State→Status→Synchronizer→Product→Att→Phi→R2→Tint→IN1→IN2→PT100→ C→Cm→C2→C2m→MF1→MF2 Following lines 01.01.2005·00:00:00→0000→0→0→1→0.43→5.30→0.07→0.0→0.0→0.0→0.0→ 75.36→75.00→0.00→0.00→0.000→0.000¶ Column no. Description Format Date and time DD.MM.YY·HH:MM:SS State 4 digits, HEX Status: Information about the quality of the last : Measurement OK measurement <...
Chapter 8. Technical Drawings Electrical Wiring Diagram Line in for MicroPolar: 1. / 2. depending on con- figuration AC 100-240V, 45-65 Hz DC 24 V (18-36 V) or AC 24 V -20/+5%, 40-440 Hz ------------------------------------------- Line in for MicroPolar ++: 1.
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