Key Technical Specifications

• Product Model: LB444
• Manufacturer: BERTHOLD
• Product Type: Density / Level Controller
• Measurement Principle: Gamma Ray Attenuation
• Pipe Size Compatibility: 25 mm to 1000 mm
• Measurement Type: Non-Contact (External Clamp-on)
• Compensation: Self-attenuation compensation
• Target Media: Acids, Alkalis, Salts, Suspensions
• Application Industries: Chemical, Petrochemical, Mining, Cement
• Mounting Style: Panel Mount / DIN Rail

 

Product Introduction

If you are trying to measure the density of highly corrosive acids or abrasive slurries, putting a probe directly into the pipe is just asking for a massive leak. The BERTHOLD LB444 was built to solve this exact nightmare. It is a nuclear gauge controller that sits safely outside the pipe, using gamma ray attenuation to calculate density or level with zero process contact.Maintenance teams actually prefer this unit because it has virtually no moving parts and requires almost zero mechanical maintenance. The self-attenuation compensation feature is a lifesaver in harsh environments where ambient temperature swings or pipe wall scaling would normally ruin your readings. Just be aware: this is a sealed radioactive source system. Treat it with respect, follow your site’s radiation safety protocols strictly, and it will give you decades of reliable data.

Quality SOP & Tech Pitfalls

Before we ship any BERTHOLD controller, it gets put through the wringer. We start with a strict visual inspection to ensure the housing is intact and there is zero corrosion on the terminals. We then hook it up to a live test rack to verify the signal processing logic and check the self-compensation algorithms. Finally, we log the firmware version and pack it in heavy-duty anti-static and impact-resistant materials.Here is a critical warning for the field: Do not confuse the LB444 controller with the actual detector or source assembly. I have seen procurement teams buy the LB444 thinking it included the gamma source, only to find out on installation day that they still needed the LB565 or LB566 detector. Also, always verify the exact part number suffix. A mismatched suffix means the calibration constants won’t match your specific isotope and pipe geometry, and your density readings will be completely wrong.

 

Installation & Configuration Guide

1. Pre-Installation: ⚠️ STOP. Verify you have the correct Radiation Safety Officer (RSO) approval and permits for handling nuclear gauges. Photograph the existing controller’s DIP switches, jumper settings, and wiring terminal block.
2. Removal: Lock out the 24V DC control power. Label every wire before disconnecting. Carefully release the DIN clips and pull the old LB444 straight off the rail.
3. Installation: Copy the DIP switch and jumper settings exactly as photographed. This step dictates the isotope type, pipe diameter, and measurement range. Slide the new LB444 onto the DIN rail until it clicks securely.
4. Power-On & Testing: Re-energize the 24V DC supply. Watch the LED indicators to confirm the controller boots up and establishes communication with the detector. Verify the density reading on the display or DCS matches the expected process value.

Compatible Replacement Models

• ✅ Drop-in Replacement: LB444 with identical suffix (e.g., LB444-K40). Exact hardware and calibration match. No reconfiguration required.
• ⚠️ Software Compatible: LB440 or LB5530. Same BERTHOLD ecosystem, but you will need to re-enter the pipe geometry, isotope strength, and recalibrate the 4-20mA output scaling. Expect 1-2 hours of commissioning time.
• ❌ Hardware Mod Required: Non-nuclear density meters (e.g., Coriolis). Requires cutting the pipe, welding flanges, and completely changing the process. Only do this if you are actively trying to eliminate the radioactive source.

 

Frequently Asked Questions (FAQ)

• Does this LB444 come with the radioactive source?
  No. The LB444 is strictly the electronic controller. The source and detector are separate components. Always check your BOM before ordering.
• Can I swap this out without shutting down the process?
  Yes, because it is non-contact, you can replace the electronics without opening the pipe. However, you must still follow site lockout/tagout procedures for the electrical power.
• My density readings are drifting. Is the board failing?
  Probably not. Drift usually means the pipe is scaling up on the inside, or the detector alignment has shifted. Check the physical clamping first before condemning the LB444.
• Is this safe to use in a hazardous area?
  The LB444 controller itself is typically housed in an IP65/IP67 enclosure, but you must verify the specific ATEX/IECEx certification for your exact zone. Check the nameplate.
• How long does the calibration last?
  The electronic calibration is permanent, but the physical setup can drift if the pipe vibrates heavily or the clamps loosen. I recommend doing a physical verification check during your annual turnaround.
• Will this work for a gas pipeline?
  Gamma attenuation struggles with low-density gases. The LB444 is primarily designed for liquids, slurries, and solids. If you are measuring gas, you likely need a different technology.