33455500 Rev 1.
T hank you for purchasing Milltronics products. We endeavour to design equipment that is simple to use and reliable in its operation, with the aim of satisfying our customers' needs. Milltronics has been designing and manufacturing process equipment since 1954. Our fields of expertise include ultrasonic and capacitance level measurement, in-line weighing of dry bulk solids and motion sensing. Milltronics is established world wide through associate offices and representatives.
_ TABLE OF CONTENTS GENERAL INFORMATION About This Manual .................................................................................................5 About IQ Radar 160...............................................................................................6 SPECIFICATIONS IQ Radar 160 ...........................................................................................................7 INSTALLATION Location ................................................................................
PL-550 4
_ GENERAL INFORMATION It is essential that this manual be referred to for proper installation and operation of your IQ Radar 160. Installation gives you step-by-step direction for the installation and interconnection of your IQ Radar 160. Start-up instructs you in how to operate the keypad, program the unit and read the display. Operation describes the operation of the IQ Radar 160, detailing the interoperation of the salient features.
GENERAL INFO. 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.
_ SPECIFICATIONS IQ RADAR 160 100/115/200/230 ±15% V ac*, 50/60 Hz, 15 VA *factory set – see device nameplate Power: Interface: analog output: display (local): Performance: frequency: accuracy: range: repeatability: fail-safe: Mechanical: enclosure (electronic): construction: conduit: ingress protection: resonator: flange: antenna: type: construction: weight: PL-550 5.8 GHz > ±0.
Environmental: location: altitude: ambient temperature: relative humidity: SPECIFICATIONS _ installation category: pollution degree: Process: material dielectric: temperature: pressure (vessel): Programmer (remote keypad): enclosure: ambient temperature: interface: power: weight: indoor/outdoor 2000 m max -20 to 60° C (-4 to 140° F) suitable for outdoor (Type 6/NEMA 6/IP 67 enclosure) II 4 εr > 4 -40 to 200°C (-40 to 392°F) -100 kPa to 1000 kPa (-1 to 10 bar or -10 to 150 psi) general purpose 67 mm w
_ 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.
DIMENSIONS 50 m m (2.0") 136 mm (5.4") 75 mm (3.0") 211 mm (8.3") enclosure/ electronics 41 mm (1.6") 245 mm (9.6") 183 mm (7.2") antenna (resonator) INSTALLATION _ flange or tri-clamp antenna (rod) 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.
_ MOUNTING FLANGED 1/2" NPT or PG 16 conduit entry wiring access cover supplied ANSI, DIN flange or sanitary tri-clamp customer flanged standpipe to suit tank minimum diameter 2" / DIN 50 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 _ MOUNTING (continued) EXTENSION REQUIREMENTS PL-550 12
_ MOUNTING (continued) ROD ASSEMBLY INSTALLATION _ 50 mm 100 mm extensions standard rod PL-550 13
INTERCONNECTION INSTALLATION _ TERMINAL BLOCK LAYOUT All field wiring must have insulation suitable for at least 250 V. – 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.
_ WIRING 4-20 mA, to instrumentation RS-485, to host device V supply, see nameplate 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. PL-550 15 INSTALLATION _ Ground shields at one end only.
PL-550 16 INSTALLATION _
_ START UP OVERVIEW The IQ Radar 160 has two modes of operation: run and program. When the unit is powered, after installation procedures have been completed, it is programmed to start up in the run mode, to detect the distance from the antenna flange to the target in meters. typical display The unit can be placed into the program mode at any time; to alter a number of program parameters in order to better suit the application or user’s preferences.
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.
_ DISPLAY AND KEYPAD START UP _ PL-550 19
LOCAL OPERATION START UP RUN DISPLAY ➀ reading ➁ units ➂ reading questionable, appears during fail-safe operation ➃ auxiliary reading ➄ ➅ = normal operation = fail-safe operation bar graph representation of material level, 0 to 100% of span PL-550 20
_ LOCAL OPERATION (continued) RUN KEYPAD In the run mode, the following programmer keys perform the identified functions.
LOCAL OPERATION (continued) PROGRAM DISPLAY parameter type (measurement or mA output) parameter value units parameter number START UP ➀ ➁ ➂ ➃ PL-550 22
_ LOCAL OPERATION (continued) PROGRAM KEYPAD Numeric Keys Function Keys Key 0 to 9 values P decimal point PX X X negative value clear value enter the displayed value parameter scroll-up parameter scroll-down end program session and enable run mode PL-550 23 START UP _ C
LOCAL OPERATION (continued) Legend Press the associated key on programmer: Programmer key: Display shown on IQ Radar 160: LOCAL PROGRAMMING To Access Program run mode Initial program starts at P000 To Access a Parameter scroll Scroll up or down START UP direct e.g. P000 accessed 0 0 5 index parameter field mA e.g.
_ LOCAL OPERATION (continued) Local Programming (continued) To Change a Parameter Value: Security must be disabled! change Select parameter e.g. P001 = 3 e.g. P001 = 1 clear C PL-550 e.g. P001 = 1 25 START UP _ e.g.
LOCAL OPERATION (continued) Local Programming (continued) reset e.g.
_ 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.
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 filter fail-safe timer 1 0.1 m/min slow on on 100 2 1 m/min • on on 10 3 10 m/min • on on 1 4 100 m/min • off on 0.1 5 1000 m/min fast off off 0 When the echoes are received, the relevant echo extraction technique (P820) is applied to determine the true material echo.
_ 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.
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.
_ 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: 0/4 – 20 mA (P200 = 1 or 2) 20 – 0/4 mA (P200 = 3 or 4) Level (P001=1) Space (P001=2) _ Distance (P001=3) PL-550 31 OPERATION _ *reference value only. mA level limited by near blanking.
Fail-safe When the fail-safe timer (P070) expires, the mA output responds as follows: Fail-safe Mode (071) Status 0/4 - 20 20 - 0/4 high 22 0/2 low 0/2 22 hold hold hold 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.
_ 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.
PL-550 34 OPERATION
_ P000 lock 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: P001 1954 = unlocked 1954 = locked opera tion Determines the mode of measurement.
PARAMETER DESCRIPTION P002 material Optimizes measurement reliability for target type. entry: 1 = liquids, fluids or flat surfaces P003 measurement 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. 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.
_ P004 antenna entry: P005 240 241 242 243 = = = = dielectric rod rod + 50 mm extension rod + 100 mm extension rod + 150 mm extension (50 + 100mm) units Determines the units for programming and measurement. entry: P006 1 2 3 4 5 = metres = centimetres = millimetres = feet = inches empty Distance from flange face to empty level or maximum target range. P007 span Distance from empty (P006) to full/100% level or minimum target range.
PARAMETER DESCRIPTION P341 run time View the accumulated number of days the IQ Radar 160 has been operating. P652 offset correction An offset value can be applied to the reading as a correction to the measurement. values: P800 -999 to 9999 near 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.
_ P820 algorithm entry: P830 1 = best of first and largest 2 = first echo 3 = largest echo TVT type Selects the TVT profile applied to the echo profile. entry: P900 1 = standard 2 = flat software revision Displays the EPROM software revision level. P901 memory Tests the memory. Test is initiated by scrolling to the parameter or repeated by display: P911 PASS = normal FAIL = consult Milltronics mA output value Displays the value from the previous measurement.
PARAMETER DESCRIPTION P923 distance measurement Displays the reading measurement as though the unit were programmed to read distance (P001 = 3) P999 master reset Resets parameters to their factory setting C initiate reset reset complete PL-550 40
_ TROUBLESHOOTING The following is a list of operating symptoms, their probable causes and the actions needed to resolve them. SYMPTOM CAUSE ACTION display reads level or target is out of range check specifications application too steamy, under these conditions range can be adversely affected.
SYMPTOM CAUSE ACTION Measurement is consistently off by a constant amount measurement offset correct using P652 Screen blank power error check nameplate rating against voltage supply TROUBLESHOOTING check power wiring or source Reading erratic echo confidence weak, liquid surface agitated, material filling refer to P805 decrease measurement response P003 enable filter, echo verification re-locate IQ Radar 160 Reading ‘EEEE’ reading too large re-program ie.
_ MAINTENANCE The IQ Radar 160 requires no maintenance or cleaning; however, a program of periodic checks is advised.
PL-550 44 MAINTENANCE
_ APPENDICES ALPHABETICAL PARAMETER LIST algorithm ..................................................................................................P820 antenna ..................................................................................................P004 confidence threshold ............................................................................P804 echo confidence ....................................................................................P805 echo strength..........................
PROGRAMMING CHART APPENDICES PARAMETER # NAME P001 Operation P002 Material P003 Measurement Response P004 Antenna P005 Units P006 Empty P007 Span P070 Fail-Safe Timer P071 Fail-Safe Material Level P200 mA Range P652 Offset Correction P800 Near Blanking P801 Range Extension P804 Confidence Threshold P820 Algorithm P830 TVT Type P841 Long-Shot Number PL-550 VALUE 46
