R05-510A-330

® Model RX5 RX5 software v2.1a Installation and Operating Manual Pulse Burst Radar Level Transmitter Read this Manual Before Installing This manual provides information on the Pulsar® Radar transmitter. It is important that all instructions are read carefully and followed in sequence. The QuickStart Installation instructions are a brief guide to the sequence of steps for experienced technicians to follow when installing the equipment. Detailed instructions are included in the Complete Installation section of this manual. Conventions Used in this Manual Certain conventions are used in this manual to convey specific types of information. General technical material, support data, and safety information are presented in narrative form. The following styles are used for notes, cautions, and warnings. NOTES This device complies with Part 15 of the FCC rules. Operation is subject to the following two conditions: (1) This device may not cause harmful interference, and (2) This device must accept any interference received, including interference that may cause undesired operation. FCC ID: LPN R95 Any unauthorized changes or modifications not expressly approved by the party responsible for compliance could void user’s authority to operate this equipment. WARNING! Explosion hazard. Do not connect or disconnect designs rated Explosion-proof or Non-incendive unless power has been switched off and/or the area is known to be non-hazardous Notes contain information that augments or clarifies an operating step. Notes do not normally contain actions. They follow the procedural steps to which they refer. Cautions Notice of Copyright and Limitations Magnetrol® & Magnetrol® logotype and Pulsar® are registered trademarks of Magnetrol® International, Incorporated. Copyright © 2011 Magnetrol® International, Incorporated. All rights reserved. Performance specifications are effective with date of issue and are subject to change without notice. MAGNETROL reserves the right to make changes to the product described in this manual at any time without notice. MAGNETROL makes no warranty with respect to the accuracy of the information in this manual. Warranty All MAGNETROL electronic level and flow controls are warranted free of defects in materials or workmanship for one full year from the date of original factory shipment. If returned within the warranty period; and, upon factory inspection of the control, the cause of the claim is determined to be covered under the warranty; then, MAGNETROL will repair or replace the control at no cost to the purchaser (or owner) other than transportation. MAGNETROL shall not be liable for misapplication, labor claims, direct or consequential damage or expense arising from the installation or use of equipment. There are no other warranties expressed or implied, except special written warranties covering some MAGNETROL products. Quality Assurance The quality assurance system in place at MAGNETROL guarantees the highest level of quality throughout the company. MAGNETROL is committed to providing full customer satisfaction both in quality products and quality service. The MAGNETROL quality assurance system is registered to ISO 9001 affirming its commitment to known international quality standards providing the strongest assurance of product/service quality available. 58-601 Pulsar® Radar Transmitter Cautions alert the technician to special conditions that could injure personnel, damage equipment, or reduce a component’s mechanical integrity. Cautions are also used to alert the technician to unsafe practices or the need for special protective equipment or specific materials. In this manual, a caution box indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. WARNINGS Warnings identify potentially dangerous situations or serious hazards. In this manual, a warning indicates an imminently hazardous situation which, if not avoided, could result in serious injury or death. Safety Messages The Through-Air Radar system is designed for use in Category II, Pollution Degree 2 installations. Follow all standard industry procedures for servicing electrical and computer equipment when working with or around high voltage. Always shut off the power supply before touching any components. Although high voltage is not present in this system, it may be present in other systems. Electrical components are sensitive to electrostatic discharge. To prevent equipment damage, observe safety procedures when working with electrostatic sensitive components. Low Voltage Directive For use in Installations Category II, Pollution Degree 2. If equipment is used in a manner not specified by the manufacturer, protection provided by equipment may be impaired. Pulsar® Pulse Burst Radar Level Transmitter Table of Contents 1.0 QuickStart Installation 1.1 Getting Started..........................................................4 1.1.1 Equipment and Tools .....................................4 1.1.2 Configuration Information.............................5 1.2 QuickStart Mounting................................................6 1.2.1 Antenna .........................................................6 1.2.2 Transmitter.....................................................6 1.3 QuickStart Wiring ....................................................6 1.4 QuickStart Configuration .........................................7 2.0 Complete Installation 2.1 Unpacking ................................................................9 2.2 Electronic Discharge (ESD) Handling Procedure......9 2.3 Before You Begin.....................................................10 2.3.1 Site Preparation ............................................10 2.3.2 Equipment and Tools ...................................10 2.3.3 Operational Considerations..........................10 2.3.3.1 Maximum Distance...............................11 2.3.3.2 Minimum Distance...............................11 2.3.3.3 Problematic Applications; GWR Alternative ..................................11 2.4 Mounting................................................................12 2.4.1 Installing the Antenna ..................................12 2.4.1.1 Location................................................12 2.4.1.2 Beam Angle...........................................12 2.4.1.3 Obstructions .........................................13 2.4.1.4 Nozzles..................................................13 2.4.1.5 Standpipes and Stillwells .......................14 2.4.2 Installing the Transmitter .............................14 2.4.2.1 Orientation ...........................................14 2.4.2.2 Initial Installation..................................15 2.4.2.3 Poor Signal Quality...............................15 2.5 Wiring ....................................................................16 2.5.1 General Purpose or Non-Incendive ..............16 2.5.2 Intrinsically Safe ...........................................16 2.5.3 Explosion Proof............................................17 2.6 Configuring the Transmitter....................................18 2.6.1 Operating Parameters ...................................18 2.6.2 Setting Up for Shop Configuration ..............18 2.6.3 Transmitter Display and Keypad ..................18 2.6.4 Password Protection (Default = 0)................19 2.6.5 Menu: Step-By-Step Procedure.....................20 58-601 Pulsar® Radar Transmitter 2.6.5.1 Radar Transmitter Menu Table..............21 2.7 Configuration Using HART® ..................................25 2.7.1 Connections .................................................25 2.7.2 Display Menu...............................................25 2.7.3 HART Revision Table ..................................25 2.7.3.1 Model RX5 ...........................................25 2.7.4 HART Menu................................................26 3.0 Reference Information 3.1 Description .............................................................27 3.2 Theory of Operation...............................................27 3.2.1 Pulse Burst Radar .........................................27 3.2.2 Equivalent Time Sampling ...........................28 3.3 Troubleshooting ......................................................29 3.3.1 System Problems ..........................................29 3.3.2 Error Messages .............................................30 3.4 Agency Approvals....................................................32 3.4.1 Agency Drawing and Entity Parameters .......33 3.5 Parts ........................................................................34 3.5.1 Replacement Parts ........................................34 3.5.2 Recommended Spare Parts ...........................34 3.6 Specifications ..........................................................35 3.6.1 Functional – Transmitter ..............................35 3.6.2 Performance .................................................36 3.6.3 O-ring (seal) Selection Chart........................36 3.6.4 Functional – Dielectric Rod/Horn ...............37 3.6.5 Antenna Pressure-Temperature Ratings ........37 3.6.6 Physical ........................................................38 3.7 Model Numbers......................................................39 3.7.1 PULSAR Radar Transmitter .........................39 3.7.2 Radar Antennas – Dielectric Rod .................40 3.7.3 Radar Antennas – Horn ...............................41 Glossary .........................................................................42 Model RX5 Configuration Data Sheet ..........................45 1.0 QuickStart Installation The QuickStart Installation procedures provide the key steps for mounting, wiring, and configuring the PULSAR radar level transmitter. These procedures are intended for experienced installers of electronic level measurement instruments. See Complete Installation, Section 2.0, for detailed installation instructions. 1.1 Getting Started Before beginning the QuickStart Installation procedures, have the right equipment, tools, and information available. 1.1.1 Equipment and Tools • • • • • • • No special tools are needed. The following items are recommended: Threaded antenna and transmitter . . . . . . 2" (50 mm) Transmitter/antenna connection. . . . . . . . 13⁄4" (44 mm) Transmitter adjustment . . . . . . . . . . . . . . 11⁄8" (28 mm), 3 ⁄32" (2.5 mm) Hex Torque wrench . . . . . . . . . . . . . . . . . . . . . highly desirable Flat-blade screwdriver Digital multimeter or volt/ammeter . . . . . Optional 24 VDC (23 mA) power supply. . . . . . . . Optional 4 58-601 Pulsar® Radar Transmitter 1.1.2 Configuration Information Some key information is needed to configure the PULSAR radar transmitter. Complete the following operating parameters table before beginning configuration. NOTE: The transmitter will already be configured if this information was provided with the order. Display Units Antenna Type Antenna Extension Question What units of measurement will be used? What type of antenna is being used? Select first 7 digits of Model number. (See nameplate on side of antenna) What is maximum nozzle length that the antenna can be used? Select last 3 digits of Model number. (See nameplate on side of antenna) Is the antenna mounting NPT, BSP, or flanged? Answer _____________ _____________ _____________ _____________ Antenna Mount Sensor Offset What is the distance from the top (100%) of the tank and the Sensor Reference point (bottom of NPT thread, top of BSP thread, or face of flange?) _____________ Is the Tank Top Flat, Horizontal Cylinder, Dome, Irregular or other (non-metallic)? What is the tank height? NOTE: Sensor Offset + Tank Height = Distance from process connection to tank bottom _____________ _____________ Tank Top Tank Height Blocking What is the distance from Sensor Reference point to Maximum Level? Maximum level should never be less than 2" (50 mm) from bottom of antenna. _____________ Is there a region at the very bottom of the vessel that cannot be measured due to heating coils, angle tank bottom, etc.? _____________ What is the dielectric of the process medium? _____________ _____________ _____________ _____________ _____________ _____________ Level Offset Dielectric Turbulence Is turbulence a consideration? Rate of Change Foam Set 4.0 mA Set 20.0 mA What is the maximum rate the level will rise or fall? Will there be foam on the surface? What is the 0% reference point for the 4.0 mA value? What is the 100% reference point for the 20.0 mA value? 58-601 Pulsar® Radar Transmitter 5 Œ 1.2 QuickStart Mounting NOTE: Confirm the configuration style and process connection (size and type) of the PULSAR radar transmitter. Make sure it matches the requirements of the installation before continuing with the QuickStart installation. Œ Confirm the model and serial numbers on the nameplates of PULSAR electronics and antenna are identical.   Œ 1.2.1 Antenna  Ž  Carefully place the antenna into the vessel. Mount in a location equal to 1⁄2 the radius of tank top. Do not mount in center of vessel nor closer than 18" (45 cm) of tank wall. Ž Secure the antenna to the vessel.  Leave the protective plastic cap in place until ready to install the transmitter. NOTE: Do not use sealing compound or TFE tape on antenna connection to transmitter. This connection is sealed by a Viton® O-ring. 1.2.2 Transmitter Index Mark 1 dot: GP/IS 2 dots: XP Set Screw Universal Connector 1. Remove the protective plastic cap from the top of the antenna and store for future use. Make sure the bottom of the Universal connector (TFE)  and inside of the antenna are clean and dry. Clean with isopropyl alcohol and cotton swabs if necessary. 2. Place the transmitter on the antenna. 3. Ensure the housing/launcher set screw is loose and the housing can be turned. Align the antenna index mark so it is at an angle of 45° to a line from the radar unit to the nearest tank wall. Do not optimize the Quality (signal strength) at one level in the vessel. 4. Rotate the transmitter so that it is in the most convenient position for wiring, configuring, and viewing. 5. While keeping the housing and launcher aligned, tighten both the housing/launcher set screw and large Universal connector Hex nut. Tighten the universal connector to 30 ft./lbs of force. A torque wrench is highly desirable. DO NOT LEAVE HAND TIGHT. • Do not place insulating material around any part of the Radar transmitter including the antenna flange. 1.3 QuickStart Wiring WARNING! Explosion hazard. Do not remove covers unless power has been switched off or the area is known to be nonhazardous. NOTE: Make sure the electrical wiring to the PULSAR radar transmitter is complete and in compliance with all regulations and codes. 6 58-601 Pulsar® Radar Transmitter Black (-) Red (+) (+) (-) 1. Remove the cover of the wiring compartment. 2. Attach a conduit fitting and mount the conduit plug in the spare opening. Pull the power supply wire through the conduit fitting. 3. Connect shield to an earth ground at power supply and leave floating at the transmitter. 4. Connect the positive supply wire to the (+) terminal and the negative supply wire to the (-) terminal. For Explosion Proof Installations, see Wiring, Section 2.5.3. 5. Replace the cover and tighten. 1.4 QuickStart Configuration The Radar transmitter comes factory-calibrated and can be configured in minutes for specific applications. Bench configuration provides a convenient and efficient way to set up the transmitter before going to the tank site to complete the installation (disregard Fault messages due to unattached antenna). The minimum configuration instructions follow. Use the information from the operating parameters table before beginning configuration. See Configuration Information, Section 1.1.2. Power-up the transmitter. Upon initial start-up, NO FALSE TARGET REJECTION error message will be displayed. Once in the vessel the FALSE TARGET routine must be run for proper operation. During normal operation the display changes every 5 seconds to show one of the four measured values: Level, Quality, %Output, and Loop. Remove the cover of the electronic compartment. Use the Up or Down Arrow ( ) keys to move from one step of the configuration program to the next step. Press the Enter Arrow ( ) key. If a PASSWORD is active, enter it here. The default=0 (no password necessary). The last character in the first line of the display Units! xxx changes to an exclamation point (!). Use the Up or Down Arrow ( ) keys to increase or decrease the value in the display or to scroll through the choices. Press the Enter Arrow ( ) key to accept a value and move to the next step of the configuration program. Á Á Á Á Á Á 1. Enter Down Up 2. 3. 4. 5. 6. 58-601 Pulsar® Radar Transmitter 7 The following configuration entries are the minimum required for configuration. The default password is 0. Blocking Distance 8 6 2 3 4 17 Sensor Offset 5 1 14 15 13 11 12 Tank Height 7 Level 9 Offset 10 16 1 Units (select) Select the Units of measurement for the level readout (cm, inches, meters, feet). Select the Antenna Type to be used as printed on the transmitter nameplate; first 7 digits of model number. Select the Antenna Extension to be used as printed on the antenna nameplate; last 3 digits of model number. Select the type of Antenna Mounting to be used. Enter the Sensor Offset value; the distance from the top (100%) point of the vessel to the Sensor Reference point (bottom of an NPT thread, top of a BSP thread, face of a flange). Select the type of Tank Top; choices are Flat, Horizontal cylinder, Dome, Irregular, or Other (nonmetallic). Enter the exact Tank Height; inaccurate values will create inaccurate level readings. Enter the Blocking Distance; the distance close to the antenna where measurement is unreliable due to antenna ringing. Minimum value = antenna length + 2" (50 mm) 9 LevlOfst xxx.x 2 Antna Typ (select) Enter the Level Offset; the distance at the bottom of the vessel where measurement may be unreliable due to heating coils, irregular bottom, etc. Select the proper Dielectric range for the process medium. Select the value of Turbulence that corresponds to the application. Select the Rate of Change value that corresponds to the maximum rate the level will rise or fall. Select the Foam value that corresponds to the application. Examine the list of reflections detected by the transmitter to ensure the actual level reflection is present. It may be necessary to rotate the launcher for optimum performance. Run the Target Rejection routine by choosing the correct LEVEL thereby cancelling all false reflections in the vessel; ideally with tank empty. Enter the minimum level value (0%) for the 4 mA point. Enter the maximum level (100%) for the 20 mA point. 10 Dielectrc (select) Turbulnc (select) RateChg (select) 3 Antna Ext (select) 11 4 Antna Mnt (select) SnsrOfst xxxx 12 5 13 Foam (select) Targets 14 6 Tank Top (select) 15 TargRej (status) 7 Tank Ht xxxx 8 BlockDis xxxx 16 Set 4mA xx.x Set 20mA xx.x 17 Note: Clear all diagnostic messages upon completion of configuration. See screens 41 and 42 on page 24. 58-601 Pulsar® Radar Transmitter 8 2.0 Complete Installation This section provides detailed procedures for properly installing, configuring, and, as needed, troubleshooting the PULSAR Radar Level Transmitter. 2.1 Unpacking Unpack the instrument carefully. Make sure all components have been removed from the packing material. Check all the contents against the packing slip and report any discrepancies to the factory. Before proceeding with the installation, do the following: • Inspect all components for damage. Report any damage to the carrier within 24 hours. • Make sure the nameplate model number on the antenna and transmitter agree with the packing slip and purchase order. • Record the model and serial numbers for future reference when ordering parts. 2.2 Electrostatic Discharge (ESD) Handling Procedure MAGNETROL electronic instruments are manufactured to the highest quality standards. These instruments use electronic components that may be damaged by static electricity present in most work environments. The following steps are recommended to reduce the risk of component failure due to electrostatic discharge. Ship and store circuit boards in anti-static bags. If an antistatic bag is not available, wrap the board in aluminum foil. Do not place boards on foam packing materials. Use a grounding wrist strap when installing and removing circuit boards. A grounded workstation is recommended. Handle circuit boards only by the edges. Do not touch components or connector pins. Make sure that all electrical connections are completely made and none are partial or floating. Ground all equipment to a good, earth ground. • • • • 58-601 Pulsar® Radar Transmitter 9 2.3 Before You Begin 2.3.1 Site Preparation Each PULSAR Radar transmitter is built to match the specific physical specifications of the required installation. Make sure the antenna connection is correct for the threaded or flanged mounting on the vessel or tank where the transmitter will be placed. See Mounting, Section 2.4. Make sure that the wiring between the power supply and Radar transmitter are complete and correct for the type of installation. When installing the Radar transmitter in a general purpose or hazardous area, all local, state, and federal regulations and guidelines must be observed. See Wiring, Section 2.5. 2.3.2 Equipment and Tools • • • • • • • No special tools are needed. The following items are recommended: Threaded antenna and transmitter . . . . . . 2" (50 mm) Transmitter/antenna connection. . . . . . . . 13⁄4" (44 mm) Transmitter adjustment . . . . . . . . . . . . . . 11⁄8" (28 mm), 3 ⁄32" (2.5 mm) Hex Torque wrench . . . . . . . . . . . . . . . . . . . . . highly desirable Flat-blade screwdriver Digital multimeter or volt/ammeter . . . . . Optional 24 VDC (23 mA) power supply. . . . . . . . Optional 2.3.3 Operational Considerations Radar applications are characterized by three basic conditions; Dielectric, Distance (measuring range) and Disturbances (turbulence, foam, false targets, multiple reflections and rate of change). The PULSAR Radar transmitter is offered with three antenna configurations—Dielectric Rod, 4" (DN100) Horn and 6" (DN150) Horn. Ideally, the 6" (DN150) Horn antenna should be used to ensure the best possible performance in all operational conditions. 10 58-601 Pulsar® Radar Transmitter 2.3.3.1 The chart below shows the maximum measuring range Sensor Reference Point Sensor Reference Point (Distance) of each antenna based on fundamental conditions of Dielectric, Distance and Turbulence. Maximum distance is calculated as Tank Height + Sensor Offset (see page 20). It is measured from the Sensor Reference Point (bottom of NPT thread, top of BSP thread or face of a flange). MAXIMUM DISTANCE Dielectric feet (meters) Dielectric Rod (11⁄2") 35 (10.7) 28 (8.5) 21 (6.4) 15 (4.6) 50 (15.2) 40 (12.2 30 (9.1) 20 (6.1) 65 (20) 52 (15.8) 39 (11.9) 25 (7.6) 4" Horn 40 (12.2 33 (10.1) 26 (7.9) 17 (5.2) 55 (16.8) 44 (13.4) 33 (10.1) 22 (6.7) 65 (20) 52 (15.8 39 (11.9) 27 (8.2) 6" Horn 45 (13.7) 37 (11.3) 29 (8.8) 20 (6.1) 60 (18.3) 48 (14.6) 35 (10.7) 25 (7.6) 65 (20) 53 (16.2) 41 (12.5) 30 (9.1) Turbulence None 1.7-3.0 Light, < 0.5" Moderate, < 1.0" Heavy, > 1.0" None 3.0-10.0 Light, < 0.5" Moderate, < 1.0" Heavy, > 1.0" None 10.0-100 Light, < 0.5" Moderate, < 1.0" Heavy, > 1.0" NPT Process Connection BSP Process Connection Sensor Reference Point ANSI or DIN Welded Flange Dielectric rod minimum dielectric = 2.0 2.3.3.2 Minimum Distance If the liquid level is allowed onto the antenna, noise and media build-up drastically decrease reliable measurement. Liquid should not be allowed closer than 2 inches (50 mm) from the bottom of the antenna. 2.3.3.3 Problematic Applications; GWR Alternative 2" (50 mm) • • • • • • • Some application concerns can be problematic for Radar. For these, Guided Wave Radar is recommended: Extremely low dielectric media (εr 18" (45 cm) 1/2 Radius The PULSAR Radar transmitter can be mounted to a vessel using a variety of process connections. Generally, either a threaded or flanged connection is used. 2.4.1 Installing the Antenna • • • • • • • Before installing, make sure: Model and Serial numbers on the nameplates of the PULSAR antenna and transmitter are identical. Process temperature, pressure, dielectric, turbulence and distance are within the antenna specifications for the installation. Rod of a Dielectric Rod antenna is protected from bending or breaking; there is no metal sub-structure. Insulating material is not placed around any part of the Radar transmitter including the antenna flange. Protective cap is kept on the antenna if the transmitter is to be installed at a later time. Antenna is being mounted in the optimal location. See following sections: Location, Beam Angle, Obstructions and Nozzles for specific information. If the liquid level is allowed onto the antenna, noise and media buildup drastically decrease reliable measurement. Liquid should not be allowed closer than 2 inches (50 mm) from the bottom of the antenna. 2.4.1.1 Location ∝ W D ∝ W Beam Spread, W @-3dB; ft (m) Antenna Beam Angle (∝) Distance, D 10 (3) 20 (6) 30 (9) 40 (12) 50 (15) 60 (18) 65 (20) 4.5 (1.37) 8.9 (2.71) 13.3 (4.05) 17.8 (5.43) 22.2 (6.77) 26.6 (8.11) 28.9 (8.81) 4.5 (1.37) 8.9 (2.71) 13.3 (4.05) 3.0 (0.91) 6.0 (1.83) 9.0 (2.74) Dielectric Rod 25° 4" Horn 25° 6" Horn 17° Ideally, the Radar transmitter should be mounted providing an unobstructed signal path to the liquid surface where it should illuminate (with microwave energy) the largest, possible surface area. See Section 2.4.1.2, Beam Angle. Unavoidable obstacles will produce reflections that must be minimized during field configuration. See Section 2.6.5.1, Target Rejection. Mount in a location equal to 1⁄2 the radius of tank top. Do not mount in center of vessel nor closer than 18" (45 cm) of tank wall. 2.4.1.2 Beam Angle 17.8 (5.43) 12.0 (3.66) 22.2 (6.77) 15.0 (4.57) 26.6 (8.11) 18.0 (5.49) 28.9 (8.81) 19.5 (5.95) The various antenna designs exhibit different beam patterns. Ideally, the beam pattern should illuminate the maximum liquid surface with a minimum striking other objects in the vessel including the tank wall. Use these drawings to determine the optimum installation location. 12 58-601 Pulsar® Radar Transmitter 2.4.1.3 Obstructions Almost any object that falls within the beam pattern will cause reflections that may be misinterpreted as a false liquid level. Although PULSAR has a powerful False Target Rejection routine, all possible precautions should be taken to minimize false target reflections with proper installation and orientation. 2.4.1.4 Nozzles Improper installation in a nozzle creates “ringing” that will adversely affect measurement. The antenna should always be mounted so the active section of the antenna is a minimum of 0.5" (12mm) outside the nozzle. Antenna extensions are offered to allow the PULSAR transmitter to work reliably in nozzles with “L” dimensions of 1" (25 mm), 4" (100mm), 8" (200mm) or 12" (300mm). Standard antennas (no extension) are shown below for reference. See Section 3.6.5 for dimensional drawings of all antenna designs including nozzle extensions. Dielectric Rod Antenna 2" (50 mm) Minimum Diameter Horn Antenna Coupling " L " Dimension 2" (50 mm) 8" (200 mm) 0.50" (13 mm) Minimum 2" (50 mm) 0.68 (17) Thread Engagement 2.8 (55) C ∅ A D DIELECTRIC RODS Model # B 8th Digit 0 1 2 3 Antenna Extension (maximum “L” dimension) 1" (25 mm) 4" (100 mm ) 8" (200 mm) 12" (300 mm) All Dim A 2.2 (56) All Dim B 11.1 (282) BSP Dim C 3.0 (76) 5.9 (150) 9.9 (251) Antenna Extension O.D. Dimension D TFE Rod PP Rod All-Plastic Rod ∅ 1.625 (41) ∅ 1.50 (38) ∅ 1.625 (41) 5.1 (130) 14.0 (356) 9.1 (231) 18.0 (457) 13.1 (333) 22.0 (559) 13.9 (353) HORNS 3 (76) Model # 8th Digit 0 Antenna Extension (maximum “L” dimension) 1" (25 mm) 4" (100 mm ) 8" (200 mm) 12" (300 mm) 3" Horn Dim H 2.7 (51) 4" Horn Dim H 6" Horn Dim H H 1 2 4.6 (117) N/A 8.4 (213) 12.4 (315) 2.95" (75 mm) 3.75" (95 mm) 8.3 (211) 12.4 (315) 5.75" (146 mm) ∅ Aperture 3 Aperture 58-601 Pulsar® Radar Transmitter 13 2.4.1.5 Standpipes and Stillwells • • • • Set Screw Universal Connector Index Mark 1 dot: GP/IS 2 dots: XP • • • • • Index Mark • PULSAR can be mounted in a standpipe or stillwell but certain considerations should be given: Metal stillwells only: Sizes 3–8 inches (80–200 mm). Diameter must be consistent throughout length; no reducers. Use only horn antennas sized to pipe ID; 3–6" (80–150mm); 8" pipe can use a 6" horn. Stillwell length must cover complete range of measurement (i.e., liquid must be in stillwell). Welds should be smooth. Vents: holes 0. 2.4.2 Installing the Transmitter PULSAR Mounted in Stillwell (Bridle) • Remove the protective plastic cap from the top of antenna. • Carefully place the transmitter on the antenna. • Rotate the transmitter to face the most convenient direction for wiring, configuration and viewing. Do not tighten the universal connector (large hex nut) nor the set screw on the housing base. The transmitter launcher must be oriented properly for optimal performance. • Do not place insulating material around any part of the radar transmitter including the antenna flange. 2.4.2.1 Orientation inde rk x ma 45° The PULSAR transmitter utilizes a linearly polarized, microwave beam that can be rotated to improve its performance. Proper orientation can minimize unwanted target reflections, decrease sidewall reflections (multipath) and maximize direct reflections from the liquid surface. The index mark located on the side of the launcher is oriented in the same direction as the polarization. The index mark is also present for reference(1 dot: GP/IS or 2 dots: XP). The launcher is considered to be at 0° when the index mark is closest to the tank wall. Polarization Pattern 14 58-601 Pulsar® Radar Transmitter 2.4.2.2 Initial Installation 90° 45° 1/2 Radius Ideally, the transmitter should be mounted half the radius from the tank wall. Align the index mark so it is at an angle of 45 degrees to a line from the radar unit to the nearest tank wall. For horizontal cylindrical vessels, align the launcher (index mark) so it is facing along the long axis of the vessel. Do not optimize the Quality (signal strength) at one level in the vessel. Once properly oriented, tighten set screws and Universal connector (30 ft-lbs of force). A transmitter mounted within 18" (45 cm) of a tank wall may demand orientation adjustments to limit multipath and optimize performance. See Section 2.4.2.3 Signal Loss. NOTE: ALWAYS RUN THE TARGET REJECTION ROUTINE AFTER MAKING CHANGES TO MENU CHOICES (Antenna Type, Antenna Mount, Sensor Offset, Tank Height, Blocking Distance, Dielectric, Turbulence, Rate Change, Foam) or when launcher is repositioned. Top View Mounted 1⁄2 radius (fa In Lau de n c ci x m he ng r 45 ark °) 2.4.2.3 Poor Signal Quality Poor signal quality has many potential causes. Following are two initial areas for investigation. Launcher Orientation: Initial launcher orientation is always 45 degrees (see Sections 2.4.1 & 2.4.2). In tall vessels and when antenna is mounted close to the tank wall, improvement in signal quality may be attained by rotating the launcher to 90 degrees. Signal Loss: If the Level signal is lost repeatedly at a specific point in the vessel, it is usually a symptom that multipath (side-wall reflections) are causing cancellation by returning to the transmitter exactly 180° out of phase with the Level signal. Utilize the following procedure: Go to transmitter screen #4 which shows both Level and signal Quality. Bring the Level up (or down) to the exact point where the signal is repeatedly lost. Monitor the Quality value as this point is being approached. The Quality value will degrade to a low point before it begins to increase. At the point of poorest Quality, loosen both the Universal connector and the set screw. Slowly rotate the launcher clockwise approximately 10–20° (the transmitter can be rotated independently). Allow the unit to stabilize for approximately 1 minute. Repeat this process until the signal Quality value is optimized. Without disturbing the position of the launcher, position the transmitter head back to its most convenient location. Tighten both the Universal connector (30 ft-lbs of force) and Launcher set screw. 15 Set Screw Universal Connector • • • • • 58-601 Pulsar® Radar Transmitter NOTE: ALWAYS RUN THE TARGET REJECTION ROUTINE AFTER MAKING CHANGES TO MENU CHOICES (Antenna Type, Antenna Mount, Sensor Offset, Tank Height, Blocking Distance, Dielectric, Turbulence, Rate Change, Foam) or when launcher is repositioned. 2.5 Wiring The PULSAR Radar transmitter operates at voltages of 16–36 VDC (GP), 16-28.6 VDC (IS) and 16–36 VDC (XP). Higher voltage will damage the transmitter. Caution Wiring between the power supply and the Radar transmitter should be made using 18–22 AWG shielded twisted pair instrument cable. Within the transmitter enclosure, connections are made to the terminal strip and the ground connections. The directions for wiring the Radar transmitter depend on the application: • General Purpose or Non-incendive (Cl I, Div. 2) • Intrinsically Safe • Explosion Proof NOTE: For ATEX/IEC installation guidelines refer to bulletin BE 58-601. WARNING! Explosion hazard. Do not remove covers unless power has been switched off or the area is known to be nonhazardous. 2.5.1 General Purpose or Non-incendive (Cl I, Div. 2) Black (-) Red (+) (+) (-) A general purpose installation does not have flammable media present. Areas rated non-incendive (Cl I, Div. 2) have flammable media present only under abnormal conditions. No special electrical connections are required. If flammable media is contained in the vessel, the transmitter must be installed per Cl I, Div. 1 standards of area classification. To install General Purpose or Non-incendive wiring: 1. Remove the cover to the wiring compartment of the transmitter. Install the conduit plug in the unused opening. 2. Install a conduit fitting and pull the supply wires. 3. Connect shield to an earth ground at power supply and leave floating at the transmitter. 4. Connect an earth ground wire to the nearest green ground screw per local electrical code (not shown in illustration). 5. Connect the positive supply wire to the (+) terminal and the negative supply wire to the (-) terminal. 6. Replace cover to the wiring compartment of transmitter. 2.5.2 Intrinsically Safe An intrinsically safe (IS) installation potentially has flammable media present. An approved IS barrier must be installed in the non-hazardous (safe) area. 16 58-601 Pulsar® Radar Transmitter To install Intrinsically Safe wiring: 1. Make sure the IS barrier is properly installed in the safe area (refer to local plant or facility procedures). Complete the wiring from the barrier to the Radar transmitter. 2. Remove the cover to the wiring compartment of the transmitter. Install the conduit plug in the unused opening. 3. Install a conduit fitting and pull the supply wires. 4. Connect shield to an earth ground at power supply and leave floating at the transmitter. 5. Connect an earth ground wire to the nearest green ground screw (not shown in illustration). 6. Connect the positive supply wire to the (+) terminal and the negative supply wire to the (-) terminal. 7. Replace the cover to the wiring compartment of the transmitter. 2.5.3 Explosion Proof Black (-) Red (+) (+) (-) Explosion Proof (XP) is a method of designing equipment for installation in hazardous areas. A hazardous location is an area in which flammable gases or vapors are, or may be, present in the air in quantities sufficient to produce explosive or ignitable mixtures. The wiring for the transmitter must be contained in Explosion Proof conduit extending into the safe area. Due to the specialized design of the Radar transmitter, no Explosion Proof conduit fitting (EY seal) is required within 18" of the transmitter. An Explosion Proof conduit fitting (EY seal) is required between the hazardous and safe areas. To install Explosion Proof wiring: 1. Install Explosion Proof conduit from the safe area to the conduit connection of the Radar transmitter (refer to local plant or facility procedures). 2. Remove the cover to the wiring compartment of the transmitter. 3. Connect shield to an earth ground at the power supply and leave floating at the transmitter. 4. Connect an earth ground wire to the nearest green ground screw per local electrical code (not shown in illustration). 5. Connect the positive supply wire to the (+) terminal and the negative supply wire to the (-) terminal. 6. Replace the cover to the wiring compartment of the transmitter. 58-601 Pulsar® Radar Transmitter 17 2.6 Configuring the Transmitter The Radar transmitter comes factory-calibrated and can be configured in minutes for specific applications. Before configuring the transmitter, collect the operating parameters information. Then, power-up the transmitter on the bench and follow through the step-by-step procedures for the menu-driven transmitter display. Information on configuring the transmitter using a HART communicator is given in Configuration Using HART (Section 2.7). 2.6.1 Operating Parameters (–) negative (+) positive Some key information is needed to configure the Radar transmitter. If necessary, complete the configuration information table in Section 1.1.2. + Power Supply 24 VDC Test Current Meter 2.6.2 Setting Up for Shop Configuration – – + The Radar transmitter can be configured at a test bench by connecting a 24 VDC power supply directly to the transmitter terminals. The connections are illustrated in the accompanying diagrams. An optional digital multimeter is shown if current measurements are desired. NOTE: Current measurements taken at these test points is an approximate value. Accurate current readings should be taken with the digital multimeter in series with the loop. Explosion Proof Model 1. When using a HART communicator for configuration, a minimum 250 Ω line load resistance is required. See the HART communicator manual for more information. 2. The transmitter can be configured without the antenna, but disregard error messages due to the unattached antenna. Radar transmitter may indicate a LEVEL value >0 when disconnected from antenna. 2.6.3 Transmitter Display and Keypad The Radar transmitter has a liquid-crystal display (LCD) capable of showing two lines of 8 characters each. Transmitter measurements and configuration menu screens are shown on the LCD. The transmitter default display is the measurement screen. It cycles every 5 seconds to display LEVEL, %OUTPUT, QUALITY, and LOOP information. The transmitter defaults to this display after 5 minutes if no keystrokes are sensed with the exception of LEVEL, DISTANCE, %OUTPUT, QUALITY, and LOOP screens. The display will not return to the default screen if left in one of these screens. Enter Down Up 18 58-601 Pulsar® Radar Transmitter The keypad has three arrows used to scroll through the displays and to calibrate the transmitter – the Up and Down Arrow ( ) keys and the Enter ( ) key. Arrows Function in Display Mode Function in Configuration Mode Increases or decreases the value displayed or moves to another choice. Note: Hold arrow key for rapid scrolling. Up and Down Moves forward and backward in the configuration program from one display to another. Á Enter Enters the configuration mode Accepts a value and moves (noted by an exclamation point to the next step of the as the last character in the top configuration program. display line). 2.6.4 Password Protection (Default = 0) The Radar transmitter is password protected to restrict access to certain portions of the menu structure that affect the operation of the system. When the proper password is entered, an exclamation point (!) appears as the last character of the first line of the display. The password can be changed to any numerical value up to 255. The password is required whenever configuration values are changed. The default password installed in the transmitter at the factory is 0 (password disabled). The last step in the configuration menu provides the option to enter a new password. If 0 is entered as a password, the transmitter is no longer password protected and any value in the menu can be altered (except diagnostic values) without entering a confirming password. NOTE: If the password is not known, the menu item New Password displays an encrypted value representing the present password. Call the factory with this encrypted value to determine the actual password. 58-601 Pulsar® Radar Transmitter Á Á Á Á Á 19 2.6.5 Menu: Step-By-Step Procedure Sensor Reference Point Sensor Reference Point The following table provides a complete explanation of the software menus displayed by the Radar transmitter. Use this table as a step-by-step guide to configure the transmitter. The first column presents the menus shown on the transmitter display. The displays are in the order they would appear if the arrow keys were used to scroll through the menu. The numbers are not shown on the display. They are provided as a reference. The second column provides the actions to take when configuring the transmitter. Additional information or an explanation of an action is given in the third column. NPT Process Connection BSP Process Connection The following drawings are provided as reference for the configuration procedure. Use of the included PACTware™ PC program is highly recommended and invaluable for troubleshooting and advanced calibration. A HART RS232 or USB modem (purchased separately) is required. See MAGNETROL PACTware™ bulletin 59-101. Sensor Reference Point ANSI or DIN Flange (Welded) Sensor Reference Point Sensor Offset (+) Blocking Distance Safety Zone 20 mA Distance Sensor Offset + Tank Height = Distance from process connection to tank bottom Media Level Tank Height Lowest Measurable Value 4 mA Level Offset 20 58-601 Pulsar® Radar Transmitter 2.6.5.1 Radar Transmitter Menu Table Note: Press UP arrow 3 times to reach screen where menu language can be chosen. Display *Level* *Quality* *%Output* *Loop* Level xxx.x units Action Comment Transmitter default display. Level, Signal Quality, %Output, and Loop values cycle every 5 seconds. All screens (except 2–6) default to this screen after 5 minutes of no keystrokes or if a Fault or Warning message is displayed. Transmitter displays Level measurement in chosen unit of measure. Transmitter displays Distance measurement in chosen unit of measure. Measurement includes Sensor Offset value. Transmitter reports Distance regardless of Blocking Distance and Level Offset settings. Transmitter display showing Level and Quality of signal reflection. Good values are 20–90 Transmitter displays %Output measurement derived from 20 mA span. Transmitter displays Loop value (mA). Select cm (xxxx), inches (xxx.x), meters (xx.xx) or feet (xx.xx). Allowable decimal position is controlled; four characters is maximum reading. Decimal position is controlled by Units and Tank Height. Select first 7 digits of the Model Number (first 4 are significant). Information is located on the nameplate mounted on the side of transmitter housing. 1 Transmitter Display 2 Transmitter Display 3 Distance xxx.x units Transmitter Display 4 Qual xx xxx.x units %Output xx.x% Loop xx.xx mA Transmitter Display Transmitter Display Transmitter Display 5 6 7 Units (select) Select units of measure 8 AntnaTyp (select) Select the Antenna Type used. 9 AntnaExt (select) Select last 3 digits of the Model Number corresponding to the Antenna Extension. This relates to the maximum nozzle Select the Antenna Extension used. length where it can be used: 0** ≤ 1" (25 mm), -1** ≤ 4" (100 mm), -2** ≤ 8" (200 mm), -3** ≤ 12" (300 mm) Select the type of Antenna Mounting Enter the Sensor Offset value. Select the shape/type of tank top Enter the Tank Height Select NPT, BSP, or Flange Sensor Offset is the distance (+ or -) from the Sensor reference point (bottom of NPT thread or flange face, top of BSP thread) to the top of the tank. Select the metallic tank top structure: Flat, Horizontal Cylinder, Dome, Irregular, or Other (non-metallic). Tank Height is measurement from the bottom to the top of tank. Blocking Distance defines an area near the antenna where reflections can not be measured effectively due to antenna ringing. It is measured from the Sensor Reference point. Minimum value is set by choice of Antenna Type and is calculated as antenna length + 2" (50 mm); larger values are encouraged. Output will be held at value corresponding to Blocking Distance. Do not allow liquid on to the antenna. Level Offset defines an area at the bottom of the vessel where reflections can not be measured effectively due to angled bottoms, heating coils, reflections from flat metal tank bottom in low dielectric applications, etc. It is the distance from the bottom of the tank to the lowest valid level reading. Level reading will never be lower than Level Offset value. 10 AntnaMnt (select) SnsrOfst xx.x units Tank Top (select) Tank Ht xxx.x units 11 12 13 14 Block Dis xxx.x units Enter the Blocking Distance 15 LevlOfst xxx.x units Enter the Level Offset 58-601 Pulsar® Radar Transmitter 21 Display Action Comment Select the Dielectric range of the medium. Choices are: 1.7–3.0; 3.0–10.0; 10.0–100.0 (typical values: Hydrocarbons 1.9–3, Glycol 32, Water-based 80. See Technical Handbook 41-600 for complete listing) None, Light, Medium, Heavy. Increase choice if Quality value is consistently 150) None, Light, Medium, Heavy Increase choice if Quality value is consistently 20, it is probably correct. Check the Tank Height and Sensor Offset values to ensure accurate LEVEL reading. Liquid level can be viewed by LEVEL or DISTANCE; access under MODE sub-menu. Choose ESCAPE to exit • Do not proceed with this procedure until confirming LEVEL and QUALITY values in TARGETS screen. • FALSE TARGET REJECTION should be run with vessel at or near empty when all targets are exposed; re-run this routine with liquid at a lower level if initial calibration is done with significant liquid in vessel. • “Level Too High” message indicates liquid is too close to the antenna to run this routine (typically within 30" (750 mm) of end of antenna. • The false target profile will be disabled and this routine should be re-run if the following parameters are modified: ANTENNA TYPE, ANTENNA MOUNT, SENSOR OFFSET, TANK HEIGHT, BLOCKING DISTANCE, DIELECTRIC, TURBULENCE, RATE CHANGE, FOAM or when launcher is repositioned. The NO FALSE TARGET REJECTION message will be displayed if this algorithm is not enabled. The Target Rejection routine detects, stores and cancels false targets to ensure detection of the proper level signal. 1 Choose if Tank is Empty or Partial (some liquid present) 2a If Empty is chosen, press Enter, then select YES to run false target rejection routine for entire tank. 2b If Partial is chosen, various Level targets will be offered; choose the Target reflection that represents the actual Level; all other targets will be cancelled. 3 If correct Level is not offered, ensure Tank dimensional information is correct; information must be entered correctly to ensure reflections offered show correct Level values. 4 If Level cannot be found, manually enter correct value. Choose Entr Lvl, then enter the correct level value. 16 Dielctrc (select) Select the Dielectric range value 17 Turbulnc (select) Select amount of Turbulence of the liquid Select Rate of Change of the liquid 18 RateChng (select) 19 Foam (select) Select amount of Foam Press Enter to view all Targets Target #1–9 Level or Distance Quality (signal amplitude) 90 too strong 20 Targets Measurement value (Level or Distance) Select YES to store false target profile for Empty or Partially full tank. (Maximum of 9 False Targets) 21 Targ Rej (status) Unit will show Enabled after running the routine. False Target Rejection can be suspended for troubleshooting purposes by choosing Disable. 22 Set 4mA xxx.x units Enter the value for the 4 mA point During normal operation, mA value will never read into the area defined by the Level Offset value. Refer to #15. 58-601 Pulsar® Radar Transmitter 22 Display 23 24 25 26 27 Set 20mA xxx.x units Damping xx SysFault (select) LOEFault (select) LOEDelay (xxx sec) Action Comment During normal operation, mA value will never read into the Enter the value for the 20 mA point area defined by the Blocking Distance value. Refer to #14. Enter the Damping factor Select the system Fault value Select the Loss of Echo Fault value Enter value for Loss of Echo Delay A damping factor (0–45) may be added to smooth a noisy display and/or output due to turbulence. Select 3.6 mA, 22 mA or HOLD (last value). See Section 3.3.2 for Fault information. Select 3.6 mA, 22 mA or HOLD (last value). Select a value 0–255; 30 is default Safety Zone is a user-defined area just below the Blocking Distance. See drawing on page 20. Enable Fault if necessary to ensure safe, reliable high-level readings in critical applications. Choices are None, 3.6 mA, 22 mA, Latch 3.6 or Latch 22. If Latch 3.6 or Latch 22 is chosen, the loop current will remain in alarm until it is manually cleared with the SZ Alarm Reset below (#30) Enter a distance value that develops a safety zone just below the Blocking Distance. Here the unit will report a Safety Zone Fault (#28) if the level rises into this area. Clear a latched Safety Zone alarm. Enter a HART Poll Address (0–15). Enter 0 for a single transmitter installation; enter 1–15 for multi-drop network (loop will latch at 4 mA). Attach a mA meter to the output. If the output does not equal 4.00 mA, adjust the value on the display until meter reads 4.00 mA. Attach a mA meter to the output. If the output does not equal 20.00 mA, adjust the value on the display until meter reads 20.00 mA. Trim Lvl is an offset value (± 10" or 244mm) to be used to force the transmitter to output the exact Level. This should only be used after all parameters have been entered correctly, Tank Height and Sensor Offset have been confirmed accurate and it has been confirmed that the transmitter is tracking the correct level target. For mounting in a standpipe/stillwell. Enter a value for inside diameter of the pipe. Range of values is 0", 3" to 20" (0, 40 to 500 mm). Value MUST be left as 0 if no standpipe/stillwell is present. Enter a mA Output of any given value to perform loop test. Use arrows to select desired value between 0 and 255; 0=No Password. During normal operation, an encrypted password is shown. Status information is updated continuously showing only the most recent diagnostic events. See Diagnostic screen in Factory Menu for a cumulative review. Select the Language that will be displayed on the transmitter screen. Choices are English (default), Spanish, German and French. Processor firmware Rev level Revision information Coprocessor firmware Rev level 28 SZ Fault (select) Select the Safety Zone Fault 29 SZHeight (xx.x units) SZ Alarm Reset Poll Adr (xx) Enter a Safety Zone Height 30 Reset Safety Zone Latch 31 Enter HART Poll Address number 32 Trim 4 Fine tune the 4 mA point 33 Trim 20 Fine tune the 20 mA point 34 Trim Lvl xxx.x units Fine Tune the Level value 35 PIPE ID xx.x units Loop Tst xx.xx mA New Pass xxx Enter Pipe ID 36 Enter a mA Output value 37 Enter new Password 38 Status Review Status information 39 Language Select Language 40 ModelRX5 Verxx.xx 58-601 Pulsar® Radar Transmitter 23 Display 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 Notes: Disp Fact Diagnost TrgRjLvl Launcher Fact Cal Peaks Algorithm Range TVG Type TVG Max Fid Pos Fid Gain Sys Gain Conversion Factor Cef dm/s Scale Offset Distance Correction Echo Amp #Run Average Adaptive Filter #Adap Average Scatter High Rate High Scatter Rate Peak Detect Reference Peak Detect Threshold Minimum Threshold ROC/min Max Rate Max dD SZ Hysteresis ES Delay DataLog Action Review Factory parameters Review Diagnostic messages Review Target Rejection Level None, do not adjust None, do not adjust None, do not adjust None, do not adjust None, do not adjust None, do not adjust None, do not adjust None, do not adjust None, do not adjust None, do not adjust None, do not adjust None, do not adjust None, do not adjust None, do not adjust None, do not adjust None, do not adjust None, do not adjust None, do not adjust None, do not adjust None, do not adjust None, do not adjust None, do not adjust None, do not adjust None, do not adjust None, do not adjust None, do not adjust None, do not adjust None, do not adjust None, do not adjust None, do not adjust Comment Select YES to reveal Factory parameters; NO to hide A cumulative review of all diagnostic messages Press ENTER twice to clear Shows level where the last Target Rejection routine was run Diagnostic, factory setting Diagnostic, factory setting Diagnostic, factory setting Diagnostic, factory setting Diagnostic, factory setting Diagnostic, factory setting Diagnostic, factory setting Diagnostic, factory setting Diagnostic, factory setting Diagnostic, factory setting Diagnostic, factory setting Diagnostic, factory setting Diagnostic, factory setting Diagnostic, factory setting Diagnostic, factory setting Diagnostic, factory setting Diagnostic, factory setting Diagnostic, factory setting Diagnostic, factory setting Diagnostic, factory setting Diagnostic, factory setting Diagnostic, factory setting Diagnostic, factory setting Diagnostic, factory setting Diagnostic, factory setting Diagnostic, factory setting Diagnostic, factory setting Diagnostic, factory setting Diagnostic, factory setting Diagnostic, factory setting Clear all Diagnostic messages upon completion of configuration. See Screen 42 above. It is encouraged that all setup information be recorded for future use. Table on page 45 is offered for this information. 24 58-601 Pulsar® Radar Transmitter 2.7 Configuration Using HART® A HART® (Highway Addressable Remote Transducer) remote unit, such as a HART communicator, can be used to provide a communication link to the PULSAR transmitter. When connected to the control loop, the same system measurement readings shown on the transmitter are shown on the communicator. In addition, the communicator can be used to configure the transmitter. To confirm HART hand-held communications, attach unit per Section 2.7.1. If communicator reads GENERIC on first two lines, the HART hand-held does not contain the current DDs (device description) for the PULSAR Radar transmitter. Contact your local HART Service Center and specify a MAGNETROL PULSAR Model RX5 device descriptor. Junction R L > 250 Ω - + See HART Revision Table, Section 2.7.3. 2.7.1 Connections Control Room Display Power Supply A HART communicator can be operated from a remote location by connecting it to a remote junction or by connecting it directly to the terminal block in the electronics housing of the PULSAR transmitter. HART uses the Bell 202 frequency shift key technique of high-frequency digital signals. It operates on the 4–20 mA loop and requires 250 Ω load resistance. A typical connection between a communicator and the PULSAR transmitter is illustrated. 2.7.2 Display Menu Current Meter A typical communicator display is an 8-line by 21-character LCD. When connected, the top line of each menu displays the model (Model RX5) and its tag number or address. Usually the bottom line of each menu is reserved for software-defined function keys (F1–F4). For detailed operating information, refer to the instruction manual provided with the HART communicator. The PULSAR transmitter online menu trees are shown in the following illustration. Open the menu by pressing the alphanumeric key 1, Device Setup, to display the secondlevel menu. 2.7.3 HART Revision Table 2.7.3.1 Model RX5 HART Version Dev V2 DD V1 Dev V4 DD V1 58-601 Pulsar® Radar Transmitter HCF Release Date July 2003 July 2004 Compatible with RX5 Software Version 1.1a–1.2e Version 2.0a and later 25 2.7.4 HART Menu 1 2 3 4 5 6 Device Setup Level Quality % Output Loop Distance 1 Calibration 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 Units Antenna Type Antenna Extension Antenna Mount Sensor Offset Tank Top Tank Height Blocking Distance Level Offset Dielectric Turbulence Rate of Change Foam Targets Target Rejection 4 mA Set Point 20 mA Set Point Damping System Fault State LOE Fault State LOE Delay SZ Fault State SZ Height SZ Alarm Reset Trim Level Pipe ID Date/Time/Initials 2 Basic Setup 1 2 3 4 5 6 Tag Descriptor Date Message Poll addr Final Asmbly Num 3 Advanced Setup 1 2 3 4 5 6 Trim Loop Current Enter Password Factory Settings Magnetrol S/N New User Password Device ID 4 Diagnostics 1 2 3 4 5 6 7 8 9 Loop Test Echo Amplitude Peaks Status Diagnostic Info Targ Rej Level Scatter Rate ROC per minute 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Launcher Algorithm Range TVG Type TVG Max Fiducial Position Fiducial Gain System Gain Conversion Factor CF #Run Average Ceff Scale Offset Distance Corr #Run Average 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Adaptive Filter #Adaptive Average Scatter High Limit Rate High Limit Peak Detect Ref Peak Detect Thresh Min Threshold Max Rate Max Delta Distance SZ Hysteresis ES Delay DataLog FactPar1 FactPar2 5 Review 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Model Manufacturer Magnetrol, S/N Firmware Version Coprocessor Version Tag Descriptor Date Message Final Asmbly Num Device ID Poll Address Units Antenna Type Antenna Extension Antenna Mount Sensor Offset Tank Top Tank Height Blocking Distance Level Offset Dielectric Turbulence 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 Rate of Change Foam Target Rej Status Target Rej Type Targ Rej Level 4 mA Set Point 20 mA Set Point Damping System Fault State LOE Fault State LOE Delay SZ Fault State SZ Height Trim Level Pipe ID Date/Time/Initials Launcher Algorithm TVG Type TVG Max Fiducial Position Fiducial Gain System Gain 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 Conversion Factor CF #Run Average Ceff Scale Offset #Run Average Adaptive Filter #Adaptive Average Scatter High Limit Rate High Limit Peak Detect Ref Peak Detect Thresh Min Threshhold Max Rate Max Delta Distance SZ Hysteresis ES Delay DataLog 4 mA Trim Value 20 mA Trim Value Universal Rev Fld Dev Rev Software Rev Num Req Preams 26 58-601 Pulsar® Radar Transmitter 3.0 Reference Information This section presents an overview of the operation of the PULSAR Radar Level Transmitter, information on troubleshooting, common problems, listings of agency approvals, lists of replacement and recommended spare parts, and detailed physical, functional and performance specifications. 3.1 Description PULSAR is a two-wire, 24 VDC, level transmitter based on the concept of pulse burst radar. The electronics are housed in an ergonomic housing comprised of two tandem compartments angled at a 45 degree angle for ease of wiring and calibration. These two compartments connect via an explosion-proof and watertight feed-through. 3.2 Theory of Operation Pulse 3.2.1 Pulse Burst Radar Pulse Burst PULSAR is a top-mounted, downward-looking pulse burst radar operating at 5.8 GHz (Europe) or 6.3 GHz (North America). Unlike true pulse devices that transmit a single, sharp (fast rise-time) waveform of wide-band energy, PULSAR emits short bursts of 5.8 or 6.3 GHz energy and measures the transit time of the signal reflected off the liquid surface. Distance is calculated utilizing the equation Distance = C × Transit time/2, then developing the Level value by factoring in Tank Height and Sensor Offset information. The exact reference point for distance and level calculations is the Sensor Reference Point—bottom of an NPT thread, top of a BSP thread or face of a flange. 1 ns 500 ns NPT Process Connection BSP Process Connection ANSI or DIN Welded Flange Distance = c × (time ÷ 2) Sensor Reference Point 58-601 Pulsar® Radar Transmitter 27 The exact level measurement is extracted from false target reflections and other background noise via the use of sophisticated signal processing. The new PULSAR circuitry is extremely energy efficient so no duty cycling is necessary to accomplish effective measurement. For this reason, PULSAR can track high rates of change that were heretofore impossible with existing loop-powered radar transmitters. Sensor Reference Point Sensor Offset (+) Blocking Distance Safety Zone 20 Distance Sensor Offset + Tank Height = Distance from process connection to tank bottom Media Level Tank Height Lowest Measurable Value 4 mA Level Offset 3.2.2 Equivalent Time Sampling ETS, or Equivalent Time Sampling, is used to measure the high speed, low power EM (electromagnetic) energy. ETS is a critical key in the application of Radar to vessel level measurement technology. The high speed electromagnetic energy (1000 ft/µs) is difficult to measure over short distances and at the resolution required in the process industry. ETS captures the EM signals in real time (nanoseconds) and reconstructs them in equivalent time (milliseconds), which is much easier to measure with today’s technology. ETS is accomplished by scanning the tank to collect thousands of samples. The round-trip event on a 65 foot (20m) tank takes only 133 nanoseconds in real time. After it is reconstructed in equivalent time it measures 200 milliseconds. 28 58-601 Pulsar® Radar Transmitter 3.3 Troubleshooting The PULSAR transmitter is designed and engineered for trouble-free operation over a wide range of operating conditions. Common transmitter problems are discussed in terms of their symptoms and recommended corrective actions. WARNING! Explosion hazard. Do not remove covers unless power has been switched off or the area is known to be nonhazardous. Use of the included PACTware™ PC program is highly recommended and invaluable for troubleshooting and advanced calibration. A HART RS232 or USB modem (purchased separately) is required. See MAGNETROL PACTware™ bulletin 59-101. 3.3.1 Troubleshooting System Problems Symptom Problem Solution Level reading drops out at a Multipath is cancelling good Orient launcher to reduce multipath; turn launcher 20–30 degrees at a time until repeatable position in the level signal multipath at this point disappears. Refer to Section 2.4.2.3 vessel Level reading locked onto a value that is not correct Level Measurement engine finding 1. Is high dielectric (ε>20) foam present a reflection it believes is 2. Run False Target Rejection routine with Level below this point (or with Empty level signal tank) to eliminate false echoes 1. Check validity of all configuration data 2. Check DISTANCE value of device against manually measured distance LEVEL, % Output and LOOP Basic configuration data values are all inaccurate questionable LEVEL readings are repeat- Configuration data does not 1. Ensure proper values for Tank Height and Sensor Offset able but consistently high (or accurately match tank 2. Check vessel for present liquid level. Trim Level can be used to ensure low) from actual by a fixed dimensions exact measurement amount 3. Reconfigure LOOP values if necessary LEVEL reading on Display is HART Poll Address set a correct but LOOP is stuck at value of 1-15 4 mA LEVEL reading on Display stuck at value related to Blocking Distance Device believes antenna is flooded (level very near or on antenna) Set HART Poll Address to 0 Check actual level. If antenna is not flooded, power down, then power up transmitter with the level well below the antenna. 58-601 Pulsar® Radar Transmitter 29 3.3.2 Error Messages The PULSAR Radar transmitter utilizes a 3-section hierarchy for reporting diagnostic conditions: FAULTS, WARNINGS, and INFORMATION. This information can be reviewed at the STATUS screen in the user menu. This screen captures only current conditions. Historical information can be viewed at the DIAGNOSTIC screen in the Factory menu. FAULT: The highest level in the hierarchy of diagnostics annunciating a defect or failure in circuitry or software that precludes reliable measurement. The current (mA) value unit defaults to 3.6, 22, or HOLD and a message is displayed on the rotating screen. Further error information can be obtained by viewing the Status or Diagnostic (Factory Menu) screens. WARNING (MESSAGE): The second level in the hierarchy of Diagnostics annunciating conditions that are not fatal but may affect measurement. A message will occur on the main (rotating) screen when a Warning is detected but will not affect output current. Further error information can be obtained by viewing the Status or Diagnostic screens. INFORMATION (MESSAGE): The lowest level in the hierarchy of diagnostic conditions providing operational factors that are not critical to measurement. Further error information can be obtained by viewing the Status or Diagnostic (Factory Menu) screens. EFFECTS OF EACH DIAGNOSTIC MESSAGE mA Loop Fault Warning Information 3.6/22/HOLD No Effect No Effect Display Message Yes Yes No Diagnostic (history) Yes Yes Yes 30 58-601 Pulsar® Radar Transmitter ERROR MESSAGES Symptom Echo Lost Problem Target peak cannot be found • • Solution Increase Turbulence setting Decrease Dielectric setting • Increase ROC setting • Increase LOE delay • Confirm valid False Target Rejection; re-run if necessary • Possible multipath if lost repeatedly at same point in tank (See Section 2.4.2.3) Ensure transmitter/antenna Universal connector is tight; Consult Factory if this problem persists Normal operation; modify SZ Alarm parameter screens if not operating to expectations Modifying one parameter clears this condition; check validity of all parameters Consult Factory Consult Factory Consult Factory Consult Factory Re-run False Target Rejection routine or manually enable Lower liquid and re-run False Target Rejection routine Re-run False Target Rejection routine; Consult Factory if problem persists Ensure transmitter/antenna connection is tight; Consult Factory Transmitter requires re-calibration of Factory parameters; the instrument will continue to operate with reduced performance; Consult Factory No Fiducial Can not find valid fiducial signal Faults Safety ZoneAlrm Level within Safety Zone and SZ Alarm parameters enabled Configuration parameters have been corrupted and reset to the factory defaults Software algorithms corrupted EEPROM Write failure EEPROM Read failure Microprocessor failure False Target Rejection has not been run or manually disabled Indicates liquid is too close to antenna to run this routine Invalid False Target Rejection data Fiducial signal quality questionable Invalid Calibration Data Default Paramtrs Sfwr Err Inv Arg EE Write failure EE Read failure CPU failure NoTrgRej Level Too High Warnings CorptTgR FidUnclr Factory Cal Reqd Co-processor Communications IPC bus Internal communication error IPC chks IPC leng (available only in Status or Diagnostic screens) IPC ack Signal DC Noise Signal Too High Signal Too Low Quality IncTrgRj ScattTgt UncerTgt Excessive noise on A/D channel Internal communication error Internal communication error Internal communication error Consult Factory Consult Factory Consult Factory Consult Factory Consult Factory Information Level signal amplitude excessive Choose higher Dielectric range, reduce Turbulence or Foam settings; Consult Factory if problem persists Level signal amplitude insufficient Choose lower Dielectric range, increase Turbulence or Foam settings; Consult Factory if problem persists Incomplete Target Rejection Re-run False Target Routine with level lower in vessel False target only partially captured Return signals scattered due to turbulence Target is missing but not determined to be lost Tank dimensions exceed maximum range of the transmitter Device is holding last valid value while confirming the target position; will continue based upon setting in LOE Delay screen; Consult Factory if problem persists Reduce Tank Height and/or Sensor Offset values TankInv 58-601 Pulsar® Radar Transmitter 31 3.4 Agency Approvals AGENCY MODEL PROTECTION METHOD AREA CLASSIFICATION FM RX5-5X0A-1X0 Intrinsically Safe RX5-5X0A-3X0 Explosion Proof Non-Incendive Œ Intrinsically Safe  RX5-5X0A-XX0 CSA RX5-5X0A-1X0 RX5-5X0A-3X0 Explosion Proof  Non-Incendive Œ Intrinsically Safe Ž Explosion Proof  RX5-5X0A-XX0 ATEX R05-5X0A-AX0 R05-5X0A-CX0 Class I, Div. 1; Groups A, B, C, & D Class II, Div. 1; Groups E, F, & G Class III, NEMA 4X, T4 @80°C Entity Class I, Div. 1; Groups B, C & D Class II, Div. 1; Groups E, F, & G Class III, NEMA 4X, T5 @80°C Class I, Div. 2; Groups A, B, C, & D Class II, Div. 2; Groups F & G Class III, NEMA 4X Class I, Div. 1; Groups A, B, C, & D Class II, Div. 1; Groups E, F & G Class III, Type 4X, T4 @80°C Entity Class I, Div. 1; Groups B, C & D Class II, Div. 1; Groups E, F, & G Class III, Type 4X, T5 @80°C Class I, Div. 2; Groups A, B, C, & D Class II, Div. 2; Groups E, F, & G Class III, Type 4X, T4 @80°C ATEX II 1G EEx ia IIC T4 @70°C IEC Ex ia IIC T4@70°C ATEX II 1/2G EEx d IIC T6 @70°C Œ Measured media inside vessel must be non-flammable only.  The antenna complies with Canadian Electrical Code requirements of ANSI/ISA 12.27.01-2003 as a single seal device. Special conditions for safe use: Ž Ex ia When an insulated probe is used in a potentially explosive atmosphere caused by gas, damp or a non-conducting liquid, precautions must be taken to avoid ignition due to hazardous electrostatic charges.  Ex d When the transmitter enclosure that is made of aluminum alloy is installed in a potentially explosive atmosphere, requiring the use of apparatus of equipment category 1G, it shall be installed so that in the event of rare incidents, an ignition source due to impact or friction between the enclosure and iron/steel is excluded. The transmitter’s antenna shall be installed so that electrostatic discharges are prevented. These units have been tested to EN 61326: 1997+A1+A2 and are in compliance with the EMC Directive 2004/108/EC. ATEX/IEC Entity Parameters Vi li Pi Ci Li 28.4VDC 120mA 0.84w 430µH 2.2nF SIL PULSAR SIL Model RX5 1 as 1oo1 B 73.7% 9.72E-04 FITS Fail Dangerous Undetected Fail Dangerous Detected Safe 222 308 314 Annual 1.94E-03 2.70E-03 2.75E-03 COMMUNICATIONS APPROVALS Region US Canada Europe Agency FCC IC RTTE Frequency 6.3 GHz 6.3 GHz 5.8 GHz Instrument Type SFF PFDavg 32 58-601 Pulsar® Radar Transmitter 3.4.1 Agency (FM/CSA) Drawing and Entity Parameters 58-601 Pulsar® Radar Transmitter 33 3.5 Parts 3.5.1 Replacement Parts Item Œ  Ž   Description Electronic Module Terminal Board 6.3 GHz 5.8 GHz General Purpose Intrinsically Safe Explosion Proof Part Number Z31-2827-001 Z31-2827-003 Z30-9143-001 w/HART w/HART O-ring: Viton Housing cover without glass Housing cover with glass GP/IS XP Ex d 012-2201-237 004-9193-002 Z36-4410-001 036-4410-005 036-4410-003 3.5.2 Recommended Spare Parts Description Electronic Module 6.3 GHz 5.8 GHz Part Number Z31-2827-001 Z31-2827-003 w/HART w/HART  Ž   Œ 34 58-601 Pulsar® Radar Transmitter 3.6 Specifications 3.6.1 Functional – Transmitter System Design Measurement Principle Input Measured Variable Span Output Type Range Resolution Loop Resistance Diagnostic Alarm Damping User Interface Keypad Digital Communication Œ Power (Measured at instrument terminals) General Purpose Intrinsically Safe Explosion Proof Housing Material Cable Entry Ingress Protection Net/Gross Weight Overall Dimensions Aluminum 316 Stainless steel Cast aluminum A356T6 (