Milltronics 160, IQ RADAR 160 Instruction Manual
IQ RADAR 160
Instruction Manual PL-550
January 2001
33455500
Rev. 3.1
Safety Guideline s
Warning notices must be obser v ed to ensure personal safety as w ell as that of others, and to
protect the product and the connected equipment. These warning notices are accompanied
by a clarification of the level of caution to be observed .
Qualified Personnel
This device/system may only be set up and operated in conjunction with this manual.
Qualified personn el ar e only authorized to install and operate this equipment in accordance
with established safety practices and standards.
Warning: This product can only function properly and safely if it is correctly transported,
stored, installed, set up , operated, and maintained.
Note: Always use p r od uct in accordance with specifications.
Copyright Siemens Milltronics Process
Disclaimer of Liability
Instruments Inc. 2000. All Rights Reserved
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electronic versions as designed and authored by
Siemens Milltronics Process Instruments Inc.
Siemens Milltronics Process Instruments Inc. will
not be responsible for t he contents of partial or
whole reproductions of eit her bound or electronic
versions.
MILLTRONICS®is a registered trademark of Siemens Milltronics Process Instrume nt s Inc.
Contact SMPI Technical Publications at the following address:
Technical Publicat ions
Siemens Milltronics Process Instruments Inc.
1954 Technology Drive, P.O. Box 4225
Peterborough, Ontari o, Canada, K9J 7B1
Email: techpubs@millt ronics.com
While we have verified the contents of
this manual for agreement w it h t h e
instrumentation described, variations
remain possible. Thus we cannot
guarantee full agreement. The
contents of this manual are regularly
reviewed and corrections are included
in subsequent editions. We w elcome
all suggestions for improvement.
Technical data subject to change.
For the library of SMPI instr uction manuals, visit our Web site: www.milltronics.com
© Siemens Milltronics Process Instruments Inc. 2001
Table of Contents
General Information .........................................................................................5
About this Manual......................................................................................5
About IQ Radar 160/160 Ex......................................................................6
Specifications ................................................................................................... 7
IQ Radar 160/160 Ex................................................................................7
Installation.......................................................................................................11
Location ...................................................................................................11
Dimensions: Standard Unit with Rod Antenna.......................................12
Dimensions: Ex Unit with Rod Antenna.................................................13
Dimensions: Threaded Rod....................................................................14
Dimensions: Horn....................................................................................15
Dimensions: W aveguide Extension........................................................16
Dimensions: Sanitary Horn.....................................................................17
Dimensions: Sanitary Rod ......................................................................18
Dimensions: W aveguide.........................................................................19
Dimensions: Flanges ..............................................................................20
Mounting..................................................................................................21
Rod Asse m bly.........................................................................................23
Mounting: Rod Assembl y........................................................................24
Mounting: M anhole Covers.....................................................................25
Mounting: Horn Antennas.......................................................................25
Mounting: W aveguide Antenna..............................................................26
Mounting: Still pipe or Side pipe.............................................................27
Mounting: Horn with Waveguide Extensions.........................................28
Mounting: Sanitary Mounting..................................................................28
Mounting: Location/Beam Angle............................................................29
Interconnection ........................................................................................30
Start Up ............................................................................................................33
Overview..................................................................................................33
Display.....................................................................................................35
Aiming the Hand Programmer ................................................................35
Local Operation.......................................................................................36
Operation ........................................................................................................41
Overview..................................................................................................41
Transceiver..............................................................................................41
Los s of Echo............................................................................................42
Blanking...................................................................................................42
Analog Ou tput..........................................................................................43
Run / Pro gram .........................................................................................45
Application Example: Asphalt in Storage Tank......................................46
Application Exam p le: Horizo ntal Tan k with V olume..............................4 7
PL-550 IQ Radar 160/160 Ex Page 3
Application Example: Juice Batch Tank with Sanitary Horn Antenna ..48
Application Example: Sliding Waveguide on Anaerobic Digesters.......49
Application Example: Stand Pipe .........................................................50
Parameter Descriptions..............................................................................53
Troubleshooting ......................................................................................... 63
Maintenance ...............................................................................................64
Appendix I....................................................................................................65
Alphabetical Parameter List .................................................................65
Appendix II...................................................................................................67
Appendix III..................................................................................................69
Temperature Derating ..........................................................................69
Rod Antenna ANSI Hole Pattern, 150# ................................................70
Rod Antenna DN Hole Pattern, PN16 ..................................................70
Rod Antenna Threaded Connection.....................................................71
Rod Antenna Sanitary Connection....................................................... 71
Horn Antenna or Wave Guide Still Pipe – ANSI Hole Pattern, 150#....72
Horn Antenna or Wave Guide Still Pipe DN Hole Pattern, PN16 .........72
Horn Antenna Sanitary Connection......................................................73
Appendix IV .................................................................................................75
BZT Approval – English........................................................................75
BZT Approval – German Original Text................................................. 76
Index.............................................................................................................77
Page 4 IQ Radar 160/160 Ex PL-550
General Information
About this Manual
Refer to this manual for proper installation and operation of your IQ Radar
160/160 Ex.
General Information
Installation
Start-up
Operation
Applications
Parameters
Troubleshooting
gives you step-by-step direction for the installation and
interconnection of your IQ Radar 160/160 Ex.
instructs you in how to operate the keypad, program the
unit and read the display.
describes the operation of the IQ Radar 160/160 Ex.
looks at the IQ Radar 160/160 Ex from a practical point of
view, using a typical application example.
lists the parameters available to you, with a description of
their function and use. You are urged to read this section
to familiarize yourself with the parameters available to you
and get your IQ Radar 160/160 Ex working to its fullest.
tabulates symptoms, causes and actions to common
installation and application problems that you might
encounter. Hopefully you will never have to read this
section, but know it’s there to help you.
Appendices
An alphabetical cross-reference of the parameters and
their numbers, a record sheet for jotting down parameter
values, a Temperature Derating Chart, as well as a list of
approvals and certificates.
PL-550 IQ Radar 160/160 Ex Page 5
About IQ Radar 160/160 Ex
The IQ Radar 160/160 Ex is to be used only in the manner outlined in this
manual.
IQ Radar 160/160 Ex is a versatile process material level monitoring
instrument. Material level measurement is achieved using advanced pulse
General Information
radar techniques. The unit consists of an electronic component coupled to the
antenna and process connection.
IQ Radar 160/160 Ex Features:
{
ANSI, DIN flange or sanitary tri-clamp mounting
{
corrosion-resistant construction, epoxy coated aluminium enclosure with
stainless steel flange and Teflon
{
local display
{
infrared keypad
{
Dolphin-compatible
IQ Radar 160/160 Ex Applications:
1
®
antenna and process seal.
{
liquids, slurries
process temperatures up to 200°C
{
vacuum and pressurized vessels
{
IQ Radar 160/160 Ex Approvals and Certificates
safety and radio
{
hazardous area
{
Note:
See Specifications on page 7 for an approvals listing and Appendix IV on
page 75 for approvals documentation.
1
Teflon is a registered trademark of Du Pont
Page 6 IQ Radar 160/160 Ex PL-550
Specifications
Every attempt has been made to ensure the accuracy of these specifications,
however Milltronics reserves the right to change them at any time. Contact
your Milltronics representative for the most recent specifications.
IQ Radar 160/160 Ex
Power:
AC version:
{
DC version:
{
Fuse:
AC version:
{
DC version:
{
Interface:
analog output:
{
Dolphin/RS-485 link:
{
programmer link:
{
display (local):
{
Performance:
frequency:
{
accuracy at 20° C:
{
temperature drift:
{
measuring range:
{
repeatability:
{
fail-safe:
{
100/115/200/230 ±15% V ac2, 50/60 Hz, 15 VA
{
18 – 36 V dc, 15W
{
FU1, 2AG type, slow blow, .25 Amp, 250V
{
F1, 2AG type, slow blow, 0.375A, 250V
{
optically-isolated 0/4-20 mA into 750 Ω max, 0.02
{
mA resolution
refer to Dolphin Plus product specification
{
infrared receiver (refer to Programmer
{
specification on page 9)
backlit, alphanumeric and multi-graphic liquid
{
crystal for readout and entry
5.8 GHz (U.S.A. 6.3 GHz)
{
better than ±0.3% of range from 1 to 15 m
{
<±0.5% of range from –40 to 60° C (-40 to 392°F)
{
0.4 to 15 m
{
± 10 mm
{
mA programmable high, low or hold upon LOE
{
condition
Specifications
Mechanical:
Process Connections: Refer to Appendix III for pressure / temperature
flat faced flanges:
{
threaded connection:{316 stainless steel, 1-1/2” or 2”, NPT, BSP,G
{
sanitary connection:
{
2
Factory set – see device nameplate
PL-550 IQ Radar 160/160 Ex Page 7
limitations.
316 stainless steel, 2”, 3”, 4”, 50mm, 80mm,
{
100mm. Bolt hole pattern to ANSI & DIN types.
316 stainless steel, 2”, 3”, or 4” tri-clamp
{
Antennas:
dielectric rod:
{
Teflon®3 (PTFE)
{
Ultra high molecular weight Polyethylene
{
(UHMW-PE
Length 41cm (16.3”) including integral gasket
{
4
)
horn:
{
waveguide:
{
Sanitary Antennas (FDA approved materials):
dielectric rod:
{
Specifications
horn:
{
Enclosure (electronic):
construction:
{
conduit:
{
ingress protection:
{
316 stainless steel
{
nominal diameters 100mm (4”), 150mm (6”),
{
200mm (8”)
emitter cone PTFE or UHMW-PE
{
waveguide extensions optional
{
316 stainless steel
{
emitter cone PTFE or UHMW-PE
{
one piece UHMW-PE4, optional PTFE
{
2”, 3”, 4” tri-clamp connection
{
304 stainless steel (316 special order)
{
horn with integral 4” tri-clamp connection
{
PTFE emitter
{
aluminium, epoxy coated
{
2 x 1/2" NPT or PG 16 entry
{
Type 6 / NEMA 6, IP-67
{
4
4
Weight:
6.5 kg (14.3 lb) with 2"/150 psi flange
{
weight will vary with flange size and rating
Environmental:
location:
{
altitude:
{
ambient temperature:{-40 to 60° C (-40 to 140° F)
{
relative humidity:
{
indoor/outdoor
{
2000 m max
{
suitable for outdoor
{
5
(Type 6/NEMA 6/IP 67 enclosure)
installation category:
{
pollution degree:
{
3
Teflon is a registered trademark of Du Pont
4
Not available for CENELEC EEx approval
5
See Temperature Derating on page 69 and Approvals on page 9.
II for ac version; I for dc version
{
4
{
Page 8 IQ Radar 160/160 Ex PL-550
Process:
material dielectric:
{
εr > 1.8
{
(For εr < 3, you should use a wave guide antenna or
still pipe. See Mounting: Waveguide Antenna on page
26 or Mounting: Still pipe or Side pipe on page 27.)
temperature:
{
pressure (vessel):
{
UHMW-PE -40 to 80°C (-40 to 176°F)
{
PTFE -40 to 200°C (-40 to 392°F)
{
dependant on process connection type and
{
temperature. Refer to Appendix III on page 69 for
charts.
Approvals (refer to device nameplate):
safety:
{
radio:
{
hazardous areas:
{
IQ Radar 160:
{
(standard) and G, Class III.
IQ Radar 160Ex6:
{
CSA
{
BAPT, Industry Canada, FCC
{
CSA Class I/II, Div.2, Group A, B, C, D, F
{
CE, CSA
{
Cenelec/Sira7, EEx de IIB+H2 T6 (Note: antenna
{
NRTL/C
, CE, FM
NRTL/C
may be used in Zone 0 environments).
FM (USA) Class I, Div 1, Group A, B, C, D. Class
{
II/III, Div. 1, Group E, F, G (Class I, Zone 1 IIC
T6)
CSA Class I/II, Div. 1, Group B, C, D, E, F, G.
{
CE, CSA
{
NRTL/C
5
Specifications
FM (non-hazardous)
FM (non-hazardous)
Canadian Registration Number (CRN) for pressure fittings8:
{
Ontario, British Columbia, Alberta: OF6494.512
others pending
3A Sanitary
{
Contact Milltronics for complete and up to date list of approvals.
Programmer (remote keypad):
enclosure:
{
ambient temperature:{-20 to 50° C (-5 to 122° F)
{
interface:
{
power:
{
weight:
{
6
Cenelec: -20 to 40°C (-4 to 104°F), CSA and FM: -20 to 60°C (-4 to 140°F) ambient
7
Approved for PTFE material only
8
All process connections except for the sliding waveguide
general purpose
{
67 mm w x 100 mm h x 25 mm d
(2.6" w x 4" h x 1" d)
proprietary infrared pulse signal
{
9V battery (ANSI/NEDA 1604, PP3 or equivalent)
{
150g (0.3 lb)
{
PL-550 IQ Radar 160/160 Ex Page 9
Specifications
Page 10 IQ Radar 160/160 Ex PL-550
Installation
Location
Notes:
• Installation shall only be performed by qualified personnel and in
accordance with local governing regulations.
• This product is susceptible to electrostatic shock. Follow proper
grounding procedures.
• Do not mount in direct sunlight without the use of a sun shield.
Warning:
For vessels with conical or parabolic tops, it is not advisable to
mount the unit at the centre. Otherwise, the concavity of the top can
focus echoes into the centre, giving false readings.
Conical
Parabolic
Installation
Flat
PL-550 IQ Radar 160/160 Ex Page 11
Dimensions: Standard Unit with Rod Antenna
(
)
(
)
(
)
*
Installation
50 mm
2.0"
41 mm(1.6")
183 mm
(7.2")
100 mm
(4.0")
211 mm
8.3"
245 mm
(9.6")
412 mm
(16.3")
136 mm
5.4"
75 mm
(3.0")
enclosure/
electronics
antenna
(resonator)
flange
antenna
(rod)
*
* Flange thickness 25 mm (1") nominal.
** Standard length, 50 and 100 mm (2” and 4") extensions available.
For information on temperature and pressure ratings, see Appendix III on
page 69.
Page 12 IQ Radar 160/160 Ex PL-550
Dimensions: Ex Unit with Rod Antenna
(
)
(
)
(
)
(
)
*
64 mm
2.5"
41 mm (1.6")
183 mm
100 mm (4.0")
(7.2")
239 mm
9.4"
earth
connection
245 mm
(9.6")
412 mm
(16.3")
136 mm
5.4"
75 mm
(3.0")
enclosure/
electronics
antenna
(resonator)
flange
Installation
antenna
rod
*
* Flange thickness 25 mm (1") nominal.
** Standard length, 50 and 100 mm (2” and 4") extensions available.
For information on temperature and pressure ratings, see Appendix III on
page 69.
PL-550 IQ Radar 160/160 Ex Page 13
Dimensions: Threaded Rod
(4”)
optional
extension
Note:
Ingress of water or process fluids into the connecting
threads can cause reflections at the connection,
appearing as false echoes.
Teflon paste
(supplied)
100 mm
50 mm
(2”)
Installation
standard antenna
Apply Teflon paste to threads and tighten slowly.
Ensure that the rod sections mate securely with no
gaps. Do not apply too much Teflon paste or parts
will not mate securely.
Do not use wrenches or pliers. Hand tight only.
Sealant must have
εr < 3
. We recommend a sealant
such as Teflon paste or silicone compound.
Page 14 IQ Radar 160/160 Ex PL-550
Dimensions: Horn
∅ 80 mm
(3”)
horn 131 mm
100 mm
(4”)
150 mm
(6”)
200 mm
(8”)
(5.16”)
enclosure /
electronics
flange
225.8 mm
325.1 mm
(12.8”)
Nominal
Horn
Size
100 mm
(4”)
150 mm
(6”)
200 mm
(8”)
Horn
O.D.
95.3
mm
(3.75”)
146.0
mm
(5.75”)
199.4
mm
(7.85”)
Horn
Height
131.0
mm
(5.16”)
225.8
mm
(8.89”)
325.1
mm
(12.8”)
Beam
Angle
28
degrees
20
degrees
12
degrees
Note:
Signal amplitude increases with horn
diameter, so use the largest size
practical.
Installation
PL-550 IQ Radar 160/160 Ex Page 15
Dimensions: Waveguide Extension
optional sliding flange
(see flange table)
Note:
Always clamp the instrument in the
same position for operation.
(see P006 on page 53).
1000 mm
(40.8”)
Installation
131 mm
(5.16”)
225 mm
(8.89”)
325 mm
(12.8”)
Note:
1. Maximum pressure 0.5 bar at 60 deg. C (140 deg. F) for sliding flange
option.
Page 16 IQ Radar 160/160 Ex PL-550
Dimensions: Sanitary Horn
Materials: standard optional
horn SS 304 SS 316
ferrule SS 304 SS 316
clamp SS 304 SS 316
gasket PTFE
50 mm (2”) clamp
(supplied)
232 mm
(9.13”)
horn
Installation
100 mm (4”) clamp (optional)
gasket (optional)
ferrule (optional)
PL-550 IQ Radar 160/160 Ex Page 17
Dimensions: Sanitary Rod
50 mm (2”), 80 mm (3”) or 100 mm (4”)
with integral gasket
ferrule (optional)
clamp (optional)
406 mm (16”)
Installation
nominal
Materials: SS304 standard
SS316 optional.
Page 18 IQ Radar 160/160 Ex PL-550
Dimensions: Waveguide
41.4 mm
(1.69”)
variable
waveguide
76.2 mm
(3.0”)
min: 100 mm (4.08”)
max: 6000 mm (244.90”)
Note: you can connect multiple waveguides together (maximum 2).
Installation
PL-550 IQ Radar 160/160 Ex Page 19
Dimensions: Flanges
45°
bolt hole
Installation
horn / waveguide
mounting holes
(threaded)
enclosure mounting
holes (threaded)
bolt hole
O.D.
bolt hole
circle
bolt hole
circle
process side
20 mm (0.8”), nominal
Pipe Size Flange
Size
2” ANSI 150# 6.0” 4.75” .7” 4
3” ANSI 150# 7.5” 6.0” .75” 4
4” ANSI 150# 9.0” 7.50” .75” 8
6” ANSI 150# 11.0” 9.50” .88” 8
8” ANSI 150# 13.5” 11.75” .88” 8
50 mm DN PN 16 165 mm 125 mm 18 mm 4
80 mm DN PN 16 200 mm 160 mm 18 mm 8
100 mm DN PN 16 220 mm 180 mm 18 mm 8
150 mm DN PN 16 285 mm 240 mm 22 mm 8
200 mm DN PN 16 340 mm 295 mm 22 mm 12
Page 20 IQ Radar 160/160 Ex PL-550
Flange
O.D.
Bolt Hole
Circle Ø
Bolt
Hole Ø
Number
of Bolts
Mounting
1/2" NPT or PG
16 conduit entry
wiring access
cover
tank
minimum diameter
2" / DIN 50
standpipe/vessel jun cture
customer flange
integral process seal
*
see below
customer flanged
standpipe to suit
straight/taper transition
Notes:
• The straight/taper transition of the rod should extend past the
standpipe/vessel opening. Add extensions as required.
• Refer to the Rod Extension Requirements table.
• The unit in
is improperly mounted. The Integral process seal MUST
rest on customer flange as in .
Installation
PL-550 IQ Radar 160/160 Ex Page 21
Threaded Rod Antenna
You can use 1.5” or 2” threaded process connections. There are three thread
types: NPT, BSP and G.
316 S.S.
PTFE or UHMW-PE
Wetted Parts:
Metal: 316SS
Polymeric: PTFE or UHMW-PE
Internal O-ring: Viton
Installation
Page 22 IQ Radar 160/160 Ex PL-550
Rod Assembly
(4”)
optional
extension
Teflon paste
(supplied)
100 mm
50 mm
(2”)
Note:
Ingress of water or process fluids into the connecting
threads can cause reflections at the connection,
appearing as false echoes.
Apply Teflon paste to threads and tighten slowly. Ensure
that the rod sections mate securely with no gaps. Do not
apply too much Teflon paste or parts will not mate
securely.
Do not use wrenches or pliers. Hand tight only.
Sealant must have
as Teflon paste or silicone compound.
Rod Extension Requirements
standpipe i.d.
<100 (4) 100 to 150 (4 to 6) 150 to 200 (6 to 8)
50 mm (2”)n/r
80 mm (3”) n/r 50 mm 100 mm
100 mm (4”) n/r 50 mm 100 mm
150 mm (6”) n/r 50 mm 100 mm
>150 mm (6”) n/r n/r n/r
n/r extension not required
Consult Milltronics for assistance with standpipe sizes not listed.
*
application not recommended for 50 mm (2”) i.d. standpipes greater than 100 mm (4”)
**
long
standpipe height mm (inches)
εr < 3
. We recommend a sealant such
*
** **
Installation
PL-550 IQ Radar 160/160 Ex Page 23
Mounting: Rod Assembly
Ideally, the stand pipe should be as short as possible. If
your application requires a stand pipe that exceeds our
recommended maximum lengths, consider using a
waveguide and horn combination. If you create a new
stand pipe for the radar unit, ensure the weld seams are
on the outside of the stand pipe, not the inside.
Ensure that there are no seams or lips on the inside of
the stand pipe or you may get erratic readings.
If the mounting illustrated above is not suitable due to the minimum blanking
requirements, consider the following option:
enclosure
minimum diameter 100mm (4”)
A
Installation
Stand pipes that are 8” or larger in diameter provide excellent signal
conditions. These conditions allow for stand pipe lengths of up to 24” using
the standard rod without any extensions.
45
weld on outside
°
Maximum length 610 mm (24”)
No antenna extensions required
Page 24 IQ Radar 160/160 Ex PL-550
Mounting: Manhole Covers
A manhole cover is typically a stand pipe that is 24” in diameter or greater and
that have a cover.
To provide the optimum signal conditions, locate the antenna off-centre with
respect to the cover, typically 100 mm (4”) from the side of the manhole.
100 mm (4”)
Mounting: Horn Antennas
Usually, horns are mounted on short stand pipes.
Installation
The end of the horn should
protrude a minimum of 10 mm
(0.5”) to avoid interference with
the stand pipe.
PL-550 IQ Radar 160/160 Ex Page 25
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