It is essential that this manual be referred to for proper installation and operation
of your IQ Radar 160.
GENERALLINFO. _
Installation
Start-up
Operation
Applications
Parameters
Troubleshooting
Appendices
gives you step-by-step direction for the installation and
interconnection of your IQ Radar 160.
instructs you in how to operate the keypad, program the unit
and read the display.
describes the operation of the IQ Radar 160, detailing the
interoperation of the salient features.
looks at the IQ Radar 160 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 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.
what manual would be complete without one! Ours is an
alphabetical cross-reference of the parameters and their
numbers, and a record sheet for jotting down parameter
values. Handy indeed!
PL-5505
Page 6
ABOUT IQ RADAR 160
The IQ Radar 160 is to be used only in the manner outlined in this manual.
IQ Radar 160 is a versatile process material level monitoring instrument. Material
level measurement is achieved using advanced pulse radar techniques. The unit
consists of an electronic component coupled to the antenna.
GENERAL INFO.
IQ Radar 160 Features:
✓ANSI, DIN flange or sanitary tri-clamp mounting
✓corrosion-resistant construction, aluminum enclosure with stainless steel and
Teflon® wetted parts
✓local display
✓infrared keypad and Dolphin-compatible
IQ Radar 160 Applications:
✓liquids, slurries
✓process temperatures up to 200°C
✓vacuum and pressurized vessels
IQ Radar 160 Approvals and Certificates
✓safety and radio
® Teflon is a registered trademark of Du Pont.
PL-5506
Page 7
_
SPECIFICATIONS
IQ RADAR 160
Power:100/115/200/230 ±15% V ac*, 50/60 Hz, 15 VA
*factory set – see device nameplate
Interface:
analog output:optically-isolated 0/4-20 mA into 750 Ω max,
0.02 mA resolution
Dolphin/RS-485 link: refer to Dolphin product specification
programmer link:infrared receiver (refer to P ro g rammer
specification below)
display (local):backlight , alphanumeric and multi -graphic liquid
crystal for readout and entry
SPECIFICATIONS _
Performance:
frequency:5.8 GHz
accuracy:> ±0.3% of range (1 to 10 m)
range:10 m
repeatability:30 µW average
fail-safe:mA programmable high, low or hold
Mechanical:
enclosure (electronic):
resonator:plated aluminum
flange:316 stainless steel, 150 psi ANSI, DIN PN16,
antenna:
construction:aluminum , epoxy coated
conduit:2 x 1/2" NPT or PG 16 entry
ingress protection: Type 6 / NEMA 6 / IP-67
3" sanitary tri-clamp
type:dielectric rod
construction:Teflon
®
weight:6.5 kg (14.3 lb) with 2"/150 psi ANSI flange,
PL-5507
weight will vary with flange size and rating
Page 8
Environmental:
location:indoor/outdoor
altitude:2000 m max
ambient temperature:-20 to 60° C (-4 to 140° F)
relative humidity:suitable for outdoor
installation category:II
pollution degree:4
Process:
material dielectric:εr > 4
temperature:-40 to 200°C (-40 to 392°F)
pressure (vessel):-100 kPa to 1000 kPa
SPECIFICATIONS _
Programmer (remote keypad):
enclosure:general purpose
ambient temperature:-20 to 50° C (-5 to 122° F)
interface:proprietary infrared pulse signal
power:9V battery (ANSI/NEDA 1604, PP3 or equivalent
weight:150 g (0.3 lb)
(Type 6/NEMA 6/IP 67 enclosure)
(-1 to 10 bar or -10 to 150 psi)
67 mm w x 100 mm h x 25 mm d
(2.6" w x 4" h x 1" d)
Approvals (refer to device nameplate ) :
safety:CSA
radio:BAPT, Transport Canada
NRTL/C
, CE
PL-5508
Page 9
_
INSTALLATION
LOCATION
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.
INSTALLATION _
PL-5509
Page 10
DIMENSIONS
(
)
(3.0")
(2.0")
(8.3")
(
)
(
)
(
)
211 mm
50mm
136 mm
5.4"
75 mm
enclosure/
electronics
41 mm
1.6"
245 mm
9.6"
183 mm
7.2"
antenna
(resonator)
flange or
tri-clamp
antenna
(rod)
INSTALLATION _
412 mm ◊
(16.3")
* Flange thickness varies with size and rating. 25mm (1") nominal.
Check appropriate standard.
◊ Standard length, 50 and 100 mm (2” and 4") extensions available.
PL-55010
Page 11
MOUNTING
FLANGED
1/2" NPT
or PG 16
conduit entry
wiring
access
cover
tank
minimum
diameter
2" / DIN 50
_
supplied ANSI, DIN flange or sanitary tri-clamp
customer flanged standpipe to suit
standpipe/vessel juncture
rod transition
For 2" or 3" / DIN 50 or DIN 80, the straight/taper transition of the rod should
extend past the standpipe/vessel opening. Add extensions as required.
For larger diameter standpipes, refer to Extension Requirements.
INSTALLATION _
PL-55011
Page 12
PL-55012
INSTALLATION _
MOUNTING (continued)
EXTENSION REQUIREMENTS
Page 13
_
MOUNTING (continued)
ROD ASSEMBLY
standard
rod
INSTALLATION _
50 mm
100 mm
extensions
PL-55013
Page 14
INTERCONNECTION
TERMINAL BLOCK LAYOUT
All field wiring must have insulation suitable for at least 250 V.
INSTALLATION _
– mA wiring, 14 – 20 AWG, copper wire, shielded
– RS-485, 14 – 20 AWG, copper wire, shielded
– Line, 12 – 14 AWG, copper wire
– Recommended torque on clamping screws, 0.5 – 0.6 Nm
PL-55014
Page 15
WIRING
_
4-20 mA ,
to instrumentation
RS-485,
to host device
V supply,
see nameplate
Ground shields at one end only.
The equipment must be protected by a 15 A fuse or
circuit breaker in the building installation.
A circuit breaker or switch in the building installation, marked as the
disconnect switch, shall be in close proximity to the equipment and
within easy reach of the operator.
INSTALLATION _
PL-55015
Page 16
INSTALLATION _
PL-55016
Page 17
_
START UP
OVERVIEW
The IQ Radar 160 has two modes of operation:
is powered, after installation procedures have been completed, it is programmed
to start up in the
target in meters.
The unit can be placed into the
program parameters in order to better suit the application or user’s preferences.
Programming can be carried out locally via the hand programmer or remotely via
the optional Dolphin/RS-485 interface.
run
mode, to detect the distance from the antenna flange to the
typical display
program
mode at any time; to alter a number of
run
and
program
. When the unit
PL-55017
START UP _
RS-485
hand programmer
Page 18
The first step in programming is to ensure that all parameters are at their factory
setting. The quickest way is to perform a master reset, P999.
For a Quick Start, P001 to P007 are the key parameters requiring entry.
They set:- mode of measurement
- process material
- antenna configuration
- measurement response
- units
- empty distance
- span
There are a number of other program parameters that can be changed
subsequently or during another programming session. Refer to Parameter
Description for a list of the parameters available.
When programming has been completed, the IQ Radar 160 can be put into
by pressing or exiting Dolphin.
run
START UP
PL-55018
Page 19
_
DISPLAY AND KEYPAD
PL-55019
START UP _
Page 20
LOCAL OPERATION
RUN DISPLAY
➀reading
➁units
➂reading questionable, appears during fail-safe operation
➃auxiliary reading
➄ = normal operation = fail-safe operation
START UP
➅bar graph representation of material level, 0 to 100% of span
PL-55020
Page 21
_
LOCAL OPERATION (continued)
RUN KEYPAD
In the
run
mode, the following programmer keys perform the identified functions.
Auxiliary
Reading Keys
Function
Keys
KeyAuxiliary readings
5
mA
7
8
PX X X
“mA Output Value”
“Rate of Change” (in Units/minute)
“Fail-safe Time Left” (in percent)
“Material Level”
“Distance”
initiate and complete program mode access
%
toggle between Units and %
START UP _
PL-55021
Page 22
LOCAL OPERATION (continued)
PROGRAM DISPLAY
➀parameter type (measurement or mA output)
➁parameter value
➂units
➃parameter number
START UP
PL-55022
Page 23
_
LOCAL OPERATION (continued)
PROGRAM KEYPAD
Function
Keys
Numeric
Keys
Key
0
P
PX X X
C
to
9
values
decimal point
negative value
START UP _
clear value
enter the displayed value
parameter scroll-up
parameter scroll-down
end program session and enable
PL-55023
run
mode
Page 24
LOCAL OPERATION (continued)
Legend
Press the associated ProgrammerDisplay shown on
key on programmer: key:IQ Radar 160:
LOCAL PROGRAMMING
To Access Program
run
mode
Initial program
starts at P000
To Access a Parameter
scroll
direct
START UP
Scroll up
or down
e.g. P000 accessed
0
0
5
mA
index parameter field
PL-55024
e.g. P005 accessed
Page 25
_
LOCAL OPERATION (continued)
Local Programming (continued)
To Change a Parameter Value:
Security must be disabled!
change
Select parameter
e.g. P001 = 3
clear
C
e.g. P001 = 1
START UP _
e.g. field entry = 2
e.g. P001 = 1
PL-55025
Page 26
LOCAL OPERATION (continued)
Local Programming (continued)
reset
e.g. P001 = 1
To Access Run:
START UP
C
Reset to factory value
P001 = 3
from
program
exit and return to
run
PL-55026
Page 27
_
OPERATION
OVERVIEW
IQ Radar 160 is a process material level measuring device using advanced pulse
radar technology. The device emits a series of radar pulses and analyses the
reflection to calculate the material level.
The device consists of an enclosed electronic component, mounted to a flanged
antenna component. The electronic component generates a 5.8 GHz radar signal
which is directed to the antenna, a Teflon® dielectric rod coupled to the core of the
device’s mounting flange.
The radar signal is emitted axially from the antenna and propagates along this
axis in a defined conical beam decreasing in strength at a rate inversely
proportional to the square of the distance.
Radar reflection is based on the dielectric constant and planar property of the
materials encountered and thus radar is very suitable for still (non-agitated) liquids
and slurries. Radar is immune to temperature and atmospheric conditions and
variations in the vessel. In an ideal application, echoes from stratified vapours are
either non-existent, or minimal compared to major echoes from the process
material. Where atmospheric conditions are such that dielectric constants and
stratifications are of significance, their echoes can compete with the desired
reflection from the process material, making the application troublesome.
The series of echoes from the pulses transmitted are sensed by the antenna
during the receive period of the electronics. The echoes are stored as a profile of
the activity in the vessel. The profile is analysed and the distance of the material
surface to the radar antenna is determined. This distance is used as a basis for
display of material level and mA output.
_
OPERATION _
PL-55027
Page 28
TRANSCEIVER
The IQ Radar 160 transceiver operates under 1 of 5 sets of preset conditions
(P003), summarized as follows:
parameter
value
measurement
response
echo
verification
filterfail-safe
timer
10.1 m/min slowonon10 0
21 m/min •onon10
310 m/min •onon1
4100 m/min •offon0. 1
51000 m/min fastoffoff0
When the echoes are received, the relevant echo extraction technique (P820) is
applied to determine the true material echo.
The measurement response limits the maximum rate at which the display and
analog output respond to changes in measurement. It is of concern especially
where liquid surfaces are in agitation or falls into the radar path during filling.
OPERATION
PL-55028
Page 29
_
BLANKING
Near blanking (P800) is used to ignore the zone in front of the antenna where
false echoes (e.g. ladder rung) appear as an echo during the receive cycle. This is
usually indicated by an incorrect high level reading and can be overcome by
increasing the near blanking from its factory set value.
Far end blanking is a feature that ignores the zone below the zero or empty level
where false echoes can appear at levels that interfere with the processing of the
true echo.
end of
transmit
false echo false echo
true echo (level)
Typical receiver signal
0
P800
near blanking
empty distance to antenna
P006
level
far end blanking
range extension
(P801) as % P006
range
Typical receiver signal
In applications where the zero level is above the bottom of the vessel and it is
desired to monitor the zone below the normal zero, range extension (P801) can
be used to extend the range into the far end blanking. Range extension is
entered as a percentage of P006. As range extension reduces the protection
afforded by the far end blanking, it should be used judiciously. Avoid excessive
range extension as this can reduce the measurement’s reliability and accuracy.
Range extension is factory set for 20% of P006. If it is found that false echoes are
appearing ahead of the blanking zone, P006 should be reduced accordingly.
PL-55029
_
OPERATION _
Page 30
LOSS OF ECHO
A loss of echo occurs when the IQ Radar 160 deems that the calculated
measurement is unreliable, i.e. the confidence (P805) is less than the threshold
(P804). This can be due to such circumstances as high level of electrical noise or
poor grounding. Refer to Troubleshooting. If the condition persists for a time
beyond the limit as set by the fail-safe timer (P070), the confidence icon changes
from full to partial and the reading and mA output are immediately forced to the
fail-safe default (P071).
Upon receiving a reliable echo, the loss of echo condition is aborted (icon returns
to full) and the reading and mA output return to the present level immediately.
OPERATION
PL-55030
Page 31
_
ANALOG OUTPUT
The IQ Radar 160 can be programmed to provide an analog output (P200) of 0 to
20 or 4 to 20 mA, and for proportional or inverse span.
Programming
Upon entering the Program mode, the analog output level holds its prior value.
Run
The analog output responds in the following manner:
Level
(P001=1)
Space
(P001=2)
0/4 – 20 mA
(P200 = 1 or 2)
20 – 0/4 mA
(P200 = 3 or 4)
Distance
(P001=3)
*reference value only. mA level limited by near blanking.
0 and 100% are percentage of full scale reading (m, cm, mm, ft, in)
PL-55031
_
OPERATION _
Page 32
Fail-safe
When the fail-safe timer (P070) expires, the mA output responds as follows:
Fail-safe Mode (071)Status
0/4 - 2020 - 0/4
high220/2
low0/222
holdholdhold
RUN / PROGRAM
When the IQ Radar 160 changes from
run
to
program
, the transceiver stops
operating and the unit no longer responds to the process. The last measurement
is stored and the associated reading and mA output are held.
As a courtesy, the unit reverts to the parameter last addressed during the previous
program session.
Upon return to
run
, the transceiver resumes operation. The reading and mA
output default to the last measurement taken. The reading and associated
outputs migrate to the current process level at a rate controlled by the
measurement response (P003).
OPERATION
PL-55032
Page 33
_
APPLICATION EXAMPLE
The minimum distance from the antenna face to the target
is limited by the near blanking, P800.
The application is to obtain a level measurement and corresponding 4-20 mA
output proportional to material levels in a chemical tank. The antenna flange is
5 m from the tank bottom. The empty level is 0 m (bottom) and the full level
(span) is 4.5 m from the bottom. The maximum rate of filling or emptying is about
1 m/min. In the event of a loss of echo, the IQ Radar 160 is to go into fail-safe low
after 2 minutes.
Empty
(P006)
Span
(P007)
reset:
P999master reset
program:
P001enter ‘1’mode of measurement = level
P002enter ‘1’material = liquid
P003enter ‘2’measurement response = 1m/min.
P004enter ‘240’antenna = dielectric rod, standard length
P005enter ‘1’units = metres
P006enter ‘5’empty distance = 5 m
P007enter ‘4.5’span = 4.5 m
P070enter ‘2’fail-safe timer = 2 min.
P071enter ‘2’fail-safe = low
run:
press run to start normal operation
_
OPERATION _
PL-55033
Page 34
OPERATION
PL-55034
Page 35
_
PARAMETER DESCRIPTION
P000lock
Locks out the ability to change parameter values P001 through P999.
The program mode is still active, but restricted to viewing only. The lock
is enabled if P000 value is other than 1954.
entry: 1954 = unlocked
1954 = locked
P001 operation
Determines the mode of measurement.
entry: 1 =level; material level referenced to empty
distance (P006)
2 = space; space to material level referenced
from zero span
PARAMETER DESCRIPTION _
3 = distance; distance to target referenced
from the flange face
LevelSpaceDistance
(P001 = 1)(P001 = 2)(P001 = 3)
PL-55035
Page 36
P002 material
Optimizes measurement reliability for target type.
entry: 1 = liquids, fluids or flat surfaces
P003measurement response
Collectively sets a number of operating parameters that determine the
maximum rate of change in target range that the reading and mA
output can keep up to.
PARAMETER DESCRIPTION
If IQ Radar 160 cannot keep up with the rate of level change, select a
faster rate. If the reading bounces around an average value, select a
slower rate. In general, reliability is traded for speed. Noisy applications
or those with agitators tend to be more manageable at slower response
rates, as these make use of filtering, echo verification and longer failsafe delay.
Select P003 for a measurement response just faster than the
greater of the maximum filling or emptying rate.
echo verification:discriminates between agitator blades in motion or
spurious noise, and the target surface (true echo).
filter:discriminates between false echoes from constant
aco ustical or electrical noise and the target surface.
fail-safe timer:establishes the period from the time a loss of echo
starts until the fail-safe default (P071) is effected.
The P003 preset timer value can be overridden by
P070.
entry:
measurement responseecho
verification
filterf-s timer
(P070)
1 = 0.1 m/minslowonon100
2 = 1 m/min •onon10
3 = 10 m/min •onon1
4 = 102 m/min •offon0 .1
5 = 1020 m/min fastoffoff0
PL-55036
Page 37
_
P004 antenna
Identifies antenna configuration.
entry:240 = dielectric rod
P005units
Determines the units for programming and measurement.
entry:1 = metres
P006empty
Distance from flange face to empty
level or maximum target range.
P007span
Distance from empty (P006) to
full/100% level or minimum target
range.
PARAMETER DESCRIPTION _
241 = rod + 50 mm extension
242 = rod + 100 mm extension
243 = rod + 150 mm extension (50 + 100mm)
The amount of time delay, in minutes, before going into fail-saf e mode.
P071fail-safe material level
Selects the default measurement in the event that the fail-safe timer
expires.
entry:1 = high; maximum span value
2 = low; minimum span value
3 = hold; hold current value
P200mA range
Enables the mA output function by selecting the range and
relationship to span.
Refer to Functional / mA output.
entry:1 = 0 to 20 mA
2 = 4 to 20 mA
3 = 20 to 0 mA
4 = 20 to 4 mA
PL-55037
Page 38
P341run time
View the accumulated number of days the IQ Radar 160 has been
operating.
P652offset correction
An offset value can be applied to the reading as a correction
to the measurement.
values:-999 to 9999
PARAMETER DESCRIPTION
P800near blanking
Sets the amount of blanking as measured from the flange face and
extending into the measurement range. Refer to Operation /
Blanking.
enter value in units of P005.
P801range extension
Sets the amount of range extension as measured from the empty
distance (P006) and extending into the far end blanking. Refer to
Operation / Blanking.
enter as a % of P006, the distance below empty not blanked.
P804confidence threshold
The minimum echo confidence in dB that the echo must meet in order
to prevent a loss of echo condition and the expiration of the fail-safe
timer (P070).
enter value in the range of 0 to 99.
P805echo confidence
A measure of echo reliability.
P806echo strength
The absolute strength of the selected echo, in dB above 1 µV rms.
PL-55038
Page 39
_
P820algorithm
Selects the algorithm to be applied to the echo profile in order to extract
the true echo.
entry:1 = best of first and largest
2 = first echo
3 = largest echo
P830TVT type
Selects the TVT profile applied to the echo profile.
entry:1 = standard
2 = flat
P900software revision
Displays the EPROM software revision level.
P901memory
Tests the memory. Test is initiated by scrolling to the parameter or
repeated by
PARAMETER DESCRIPTION _
display: PASS = normal
FAIL = consult Milltronics
P911mA output value
Displays the value from the previous measurement. A test value can be
entered and the displayed value is transmitted to the output. Upon
returning to the run mode, the parameter assumes the actual mA output
level.
P920reading measurement
Displays the reading measurement that the unit is programmed for in
run mode (P001, operation).
P921material measurement
Displays the reading measurement as though the unit were
programmed to read level (P001 = 1).
P922space measurement
Displays the reading measurement as though the unit were
programmed to read space (P001 = 2).
PL-55039
Page 40
P923distance measurement
Displays the reading measurement as though the unit were
programmed to read distance (P001 = 3)
P999master reset
Resets parameters to their factory setting
PARAMETER DESCRIPTION
C
initiate reset
reset complete
PL-55040
Page 41
_
TROUBLESHOOTING
The following is a list of operating symptoms, their probable causes and the
actions needed to resolve them.
SYMPTOMCAUSEACTION
display reads level or target is out of
range
application too steamy,
under these conditions
range can be adversely
affected.
material build-up on
antenna
location or aiming:
-poor installation
-moved by material
or vibration
-flanging not level
-standpipe not vertical
antenna malfunction:
-temperature too high
-physical damage
-excessive foam or skin
check specifications
check parameters
re-locate IQ Radar 160
increase fail-safe timer,
P070
clean
re-locate IQ Radar 160
relocate or re-aim
IQ Radar 160 for
maximum echo
confidence, P805
inspect
use foam deflector or
stilling well or relocate
TROUBLESHOOTING _
Reading does not
change, but the level
does
*refer to associated manual
PL-55041
IQ Radar 160 processing
wrong echo, i.e. vessel
wall, or structural member
re-locate IQ Radar 160
check standpipe for
internal burrs or welds
increase blanking, P800
raise short measurement
confidence threshold,
P804
… continued
Page 42
SYMPTOMCAUSEACTION
Measurement is
consistently off by a
constant amount
Screen blankpower errorcheck nameplate rating
Reading erraticecho confidence weak,
TROUBLESHOOTING
Reading ‘EEEE’reading too largere-program
measurement offsetcorrect using P652
against voltage supply
check power wiring or
source
refer to P805
liquid surface agitated,
material filling
decrease measurement
response P003
enable filter, echo
verification
re-locate IQ Radar 160
ie. empty distance P006
or span P007
Reading response slowP003 settingincrease response if
possible
Reads correctly but
occasionally reads high
detecting close range
echo
increase blanking
when vessel is not full
High level reading lower
than material level
material is within near
blanking zone
decrease blanking P800
PL-55042
Page 43
_
MAINTENANCE
The IQ Radar 160 requires no maintenance or cleaning; however, a program of
periodic checks is advised.