Model R82 Pulse Burst Radar Level Transmitter D E S C R I P T I O N The Model R82 is an economical, loop-powered radar transmitter bringing radar to everyday applications. Daily applications that have been considered for Ultrasonic can now use radar technology with its superior performance. The electronics are housed in a compact, single compartment cast aluminum or Lexan® housing. The R82 measures effectively even when atmospheres above the liquid are saturated with vapor. Pulse Burst technology and advanced signal processing manage common disturbances such as false echoes caused by obstructions, multi-path reflections from tank sidewalls or turbulence caused by agitators, aggressive chemicals, or aerators. T E C H N O L O G Y Model R82 Pulse Burst Radar emits short bursts of 26 GHz energy. High-speed timing circuitry measures the time of the signal reflected off the liquid surface. Sophisticated signal processing filters out false reflections and other background noises. The exact level is then calculated, by factoring tank height and sensor offset information. The Model R82 circuitry is extremely energy efficient so no duty cycling is needed like with likewise radars. This allows tracking of high rates of level change up to 180"/min (4.5m/min). A P P L I C A T I O N S MEDIA: Liquids and slurries; hydrocarbons to water based media (dielectric 1.7–100) VESSELS: Most effective in storage vessels up to rated temperature and pressure. Pits and sumps, metallic and non-metallic tanks, others including plastic, glass-lined and concrete. F E A T U R E S • 26 GHz frequency • 24 VDC, loop-power supply voltage • Configure with 2-line × 16-character display, 4-pushbutton keypad and PACTware™ PC Program (see bulletin 59-101) • Range (from threads) of 15" to 40 feet (0.4 to 12.2 m) • Volume/Flow: 20-point strapping table • Ambient: -40° to +175° F (-40° to +80° C) • Process Temperature: Pressure: Dielectric: -40° to +200° F (-40° to +93° C) Vacuum to 200 psig (13.8 bar) 1.7-100 • Performs to ±0.2" (5 mm) or 0.05% of tank height • Lexan® EXL or Cast Aluminum housings • Antenna horn encapsulated with Polypropylene, Tefzel® (optional) • Antenna extensions of 2" (50 mm) and 8" (200 mm) CONDITIONS: Virtually all level measurement and control applications including process conditions exhibiting varying specific gravity and dielectric, visible vapors, high fill/empty rates and some turbulence. • 2" NPT or BSP connections (Sch. 40 maximum) MARKETS: All process markets including replacement of loop-powered, ultrasonic transmitters • Safety Integrity Level (SIL) value of 1 (SFF 89.1%) • Adjustable beam pattern without removing transmitter from vessel • Antenna output of <.01 mW (avg), <2 mW (max) A P P L I C A T I O N S P U L S E B U R S T STORAGE HOLDING R A D A R AND INTERMEDIATE TANKS STANDPIPES AND CHAMBERS (2" ONLY) CONDITIONS – Calm Surfaces MIXING AND BLENDING VESSELS ENCLOSED CONDITIONS – Moderate Turbulence and Changing Dielectric CONDITIONS – Turbulence and Changing Dielectric E N C L O S E D F L U M E S A N D W E I R S CONDITIONS – Turbulence and Changing Dielectric 2 SUMPS T E C H N O L O G Y P U L S E B U R S T R A D A R The R82 transmitter is a top-mounted, downward-looking pulse burst radar operating at 26 GHz America. Unlike true pulse devices (Eclipse Guided Wave Radar) which transmit a single, sharp (fast rise-time) waveform of wide-band energy (Figure 1), the R82 emits short bursts of 26 GHz energy (Figure 2) and measures the transit time of the signal reflected off the liquid surface. Distance is calculated utilizing the equation Distance equals the Speed of light multiplied by the transit time divided by two (Distance = C × Transit Time/2), then developing the level value by factoring in tank height and sensor offset information (Figure 3). Pulse The exact reference point for distance and level calculations is the sensor reference point (bottom of an NPT thread, top Figure 1 of a BSP thread, or face of a flange). E Q U I V A L E N T T I M E Pulse Burst 1 ns 500 ns Figure 2 ETS is accomplished by scanning the vessel to collect thousands of samples. The round-trip event on a 40-foot (12.2 meter) tank takes only 82 nanoseconds in real time. After it is reconstructed in equivalent time it measures 135 milliseconds. C O N S I D E R A T I O N S Radar applications are characterized by three basic conditions: Sensor Reference Point Sensor Offset (+) • Dielectric Highest Measureable Value • Distance (measuring range) • Disturbances (turbulence, foam, false targets, multiple reflections and rate of change) Distance = c × (time ÷ 2) S A M P L I N G 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 EM energy (~1 ft/nS) 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. O P E R A T I O N A L The exact level measurement is extracted from false target reflections and other background noise via the use of sophisticated signal processing. The R82 circuitry is extremely energy efficient so no duty cycling is necessary to accomplish effective measurement. For this reason it can track high rates of change (180 inches [450 cm] per minute) that have been impossible with existing loop-powered radar transmitters. Blocking Distance Safe Zone Distance Sensor Offset + Tank Height = Distance from process connection to tank bottom Tank Height Media Level The R82 Radar transmitter is offered with two basic antenna configurations: • Polypropylene-encapsulated horn • Tefzel®-encapsulated horn. 20 mA 4 mA Lowest Measurable Value Level Offset Figure 3 3 O P E R A T I O N A L C O N S I D E R A T I O N S Maximum measuring range (distance) is calculated as Tank Height + Sensor Offset. Refer to Figure 3 on page 3. It is measured from the sensor reference point (bottom of NPT thread, top of BSP thread, or face of flange). The Maximum Distance chart shows the maximum measuring range of each antenna based on dielectric and turbulence. MAXIMUM DISTANCE Dielectric ( c o n t . ) feet (meters) Turbulence R82 26 (8.0) None 1.7-3.0 3.0-10.0 10.0-100 Light, < 0.5" 21 (6.4) Moderate, < 1.0" 14 (4.3) Heavy, > 1.0" 7 (2.1) None 33 (10.1) Light, < 0.5" 26 (7.9) Moderate, < 1.0" 19 (5.8) Heavy, > 1.0" 12 (3.7) None 40 (12) Light, < 0.5" 32 (9.8) Moderate, < 1.0" 24 (7.3) Heavy, > 1.0" 17 (5.2) M O U N T I N G The R82 Radar transmitter can be mounted to a vessel using a variety of process connections. Generally either a threaded or flanged connection is used. L O C A T I O N Ideally the radar transmitter should be mounted 1⁄2 radius from center providing an unobstructed signal path to the liquid surface where it should illuminate (with microwave energy) the largest possible surface area. Do not install in center of tank top or within 10 inches (25 cm) of tank wall. Tank walls may produce reflections that must be minimized during field configuration (Orientation). Refer to Figure 4. B E A M A N G L E Figure 6 shows the beam angle for the R82 antennas. Ideally the beam pattern should illuminate the maximum liquid surface with a minimum of striking other objects in the vessel including the tank wall. Use these drawings to determine the optimum installation location. O B S T R U C T I O N S Almost any object that falls within the beam pattern will cause reflections that may be misinterpreted as a false liquid level. Although the R82 has a powerful Echo Rejection routine, all possible precautions should be taken to minimize false target reflections with proper installation and orientation. Refer to Figures 5 & 6. > 10" 1/2 (25 cm) Radius Distance Feet W Figure 4 4 Figure 5 Beam Spread Feet Meters 10 Meters 3 2.5 0.74 20 6 4.9 1.47 30 9 7.4 2.21 40 12 9.8 2.95 ∝14° Figure 6 M O U N T I N G N O Z Z L E S Improper installation in a nozzle creates “ringing” which will adversely affect measurement. Ideally, the antenna should be mounted so the end of the antenna is a minimum of 0.5" (12 mm) below the nozzle (be sure to include any nozzle dimension inside the vessel). Two Antenna extension lengths (2" or 8") are offered to allow the R82 transmitter to work reliably in a variety of nozzles. 2-inch (50 mm) Antenna 15" (380 mm) Minimum (measured from bottom of threads or flange face) 13" (330 mm) The Minimum Blocking Distance of 15" (380 mm) is always measured from the bottom of the threads or face of a flange. The related distance (as measured from the end of the antenna) varies depending on the antenna extension chosen. Refer to Figure 7. When necessary, the narrow beam width of the 26 GHz, R82 does allow mounting so that the antenna is recessed inside the nozzle. Optimally, the recessed dimension should never exceed 2× the nozzle diameter (Sch. 40 maximum). Refer to Figure 8. 8-inch (200 mm) Antenna 15" (380 mm) Minimum (measured from bottom of threads or flange face) 7" (178 mm) Figure 7 Minimum Blocking Distance Maximum Recess (m) is 2 × Nozzle Diameter (d) (Sch. 40 maximum) example: 2" diameter nozzle example: 4" diameter nozzle 8-inch (200 mm) Antenna 2-inch (50 mm) Antenna 8" (200 mm) 8" (200 mm) 2" (50 mm) d m 4" (100 mm) 15" (380 mm) d 4" (100 mm) 15" (380 mm) 8" (200 mm) m d 3" (75 mm) 9" (225 mm) Maximum Liquid Level Maximum Liquid Level Maximum Liquid Level Figure 8 Maximizing Useable Capacity 5 O R I E N T A T I O N The R82 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 Polarization pattern is parallel to the transmitter Display when the mechanism is at the #11 position. Refer to Figure 9. Each Index number represents 10 degrees of rotation. In a typical vertical tank, the Launcher should be adjusted so the polarization pattern is parallel to a line tangent to the nearest tank wall. Refer to Figure 10. Tangent Line Figure 10 Launcher Orientation For horizontal cylindrical vessels aim beam down the long axis of the vessel. Launcher Adjustment in #11 Position (Default) Ground Figure 9 Internal Launcher Adjustment S T A N D P I P E S , S T I L L W E L L S A N D B R I D L E S The R82 can be mounted in a standpipe or stillwell but certain considerations should be given: • Metal stillwells only: 2" (50 mm), Sched 40 maximum. • Diameter must be consistent throughout length; no reducers. • Stillwell length must cover complete range of measurement (i.e., liquid must be in stillwell). • Welds should be smooth. • Vents: holes <0.125" diameter, slots <0.125" width. • If an isolation valve is used, it must be a full port ball valve with an I.D. equal to the pipe diameter. • Bridles/Bypass Installations: The launcher adjustment (#9 position, default) should be rotated 90° from process connections. • Configuration must include an entry for PIPE I.D. 6 Figure 11 Use in Standpipe/Stillwell P R O B L E M A T I C G U I D E D W A V E A P P L I C A T I O N S R A D A R A L T E R N A T I V E Some applications can be problematic for Pulse Burst Radar. The following are examples of when Guided Wave Radar is recommended. • Extremely low dielectric media (εr<2.0). • Very weak reflections from the liquid surface—particularly during turbulence can cause poor performance. • Tanks heavily cluttered with false targets (mixers, pumps, ladders, pipes, etc.). • Foam can either absorb or reflect the microwave energy depending upon the depth, dielectric, density and wall thickness of the bubbles. Due to typical variations in the amount (depth) of foam, it is impossible to quantify performance. It may be possible to receive most, some or none of the transmitted energy. • During times of very low liquid levels of low dielectric media, the metal tank bottom may be detected (deteriorating performance). • Extremely high liquid level (Overflow) conditions when liquid is very near the antenna can cause erroneous readings and measurement failure. Refer to Eclipse Guided Wave Radar bulletin 57-101. A G E N C Y AGENCY United States Canada ATEX A P P R O V A L S MODEL PROTECTION METHOD AREA CLASSIFICATION R82-52XA-0XX Intrinsically Safe R82-51XA-0XX Non-Incendive R82-52XA-0XX Intrinsically Safe R82-51XA-0XX Non-Incendive Class I, Div. 1; Groups A, B, C, T4 @80°C; Type 4X, IP66/67 Entity Class I, Div. 2; Groups A, B, C, Type 4X, IP66/67 Class I, Div. 1; Groups A, B, C, T4 @80°C; Type 4X, IP66/67 Entity Class I, Div. 2; Groups A, B, C, T4 @80°C; Type 4X, IP66/67 II 1G Ex ia IIC T4 @70°C Ambient Temp: -40° to +70° C Intrinsically Safe R82-5BXA-0XX EN60079-0: 2006 EN60079-11: 2007 EN60079-26: 2007 standards applied Type 4X rating applies to aluminum housing only; &D &D &D &D These units have been tested to ETSI EN 302 372-1 and ETSI EN 301 489-1 and are in compliance with the RTTE Directive 1999/5/EC. In addition these units were tested to EN 61326 and are in compliance with the EMC Directive 2004/106/EC. IP67 rating applies to Lexan housing only. For Division 2 the measured media inside the vessel must be non-flammable only. The transmitter must be connected to an inherently limited Class 2 power source (as defined in the NEC Table 11), or as a low energy Class 2 power source (as defined in the CEC Section 16). Special conditions for safe use (ATEX Ex i) Materials marked as Category 1 equipment and mounted in hazardous areas requiring this Category shall be installed in such a way that, even in the event of rare incidents, the aluminum enclosure cannot be an ignition source due to impact or friction. The transmitter shall be installed so that electrostatic discharges on plastic parts are prevented. ATEX Entity Parameters Vi/Ui 28.4 VDC 28 VDC li 94 mA 120 mA Pi 0.67 w 0.84 w Ci 5.5 nF 370 µH Li SIL Model R82 COMMUNICATIONS APPROVALS SIL 1 as 1oo1 Instrument Type B Region Agency SFF 89.1% US FCC PFDavg 3.34E-04 Canada IC Europe RTTE FITS Annual Fail Dangerous Undetected 68 5.96E-04 Fail Dangerous Detected 388 3.40E-03 Safe 169 1.48E-03 Frequency 26 GHz 7 S P E C I F I C A T I O N S T R A N S M I T T E R : F U N C T I O N A L System Design Pulse burst radar @ 26 GHz Measurement Principle Input Measured Variable Level, determined by the time-of-flight of a radar pulse from Span 15" to 40 feet (380 mm to 12.2 m) measured from threads transmitter to product surface and back Output Type Analog: Range Analog: Digital: Resolution Analog: Digital: 4 to 20 mA with optional HART digital signal 3.8 to 20.5 mA useable (Namur NE43) 0 to 999" (0 to 9999 cm) 0.01 mA 0.1" Loop Resistance GP/IS - 400 Ω @ 24 VDC/20 mA, 350 Ω @ 24 VDC/22 mA Diagnostic Alarm Adjustable 3.6 mA, 22 mA, HOLD Damping Adjustable 0-45 Output at Antenna < .01 mW (avg), < 2 mW (max) User Interface Keypad 4-button menu-driven data entry and system security 2-line × 16-character display Indication Digital Communication HART Version 5 compatible Power (Measured at instrument terminals) General Purpose/Intrinsically Safe 16 to 36 VDC Housing Material Lexan® base and cover Cable Entry ¾" NPT, M20 Cast Aluminum A356T6 (<0.2% copper) Ingress Protection Lexan Housing: Aluminum Housing: Net/Gross Weight NEMA 6P (IP67/68) NEMA 4X/6P (IP67/68) Short Lexan: 23 oz. Long Lexan: 32 oz. Short Aluminum: 49 oz. Long Aluminum: 58 oz. Overall Dimensions Lexan: Refer to drawings on page 11 Aluminum: Refer to drawings on page 11 RTTE: European approval, FCC & IC: North American approval 1200 Installation for NEMA 6P/IP 68: 36 V 1000 Ω 1000 the transmitter can be installed to allow for temporary submergence to 6.5 ft. (2 m) for 24 hours. 800 Ω General Purpose 28.6 V 630 Ω 600 Intrinsically Safe @ 20 mA 400 (350 @ 22 mA) 350 200 0 0 8 10 16 20 24 VDC 30 40 S P E C I F I C A T I O N S T R A N S M I T T E R : F U N C T I O N A L ( C O N T . ) Antenna Polypropylene, Tefzel® (optional) Encapsulated Horn -40° to +200° F @atmos (-40° to +93° C) Vacuum to 200 psig @ +70° F (-1 to 13.8 bar) Wetted Surfaces Polypropylene or Tefzel (optional) Environment Operating Temperature -40° to +175° F (-40° to +80° C) -5° to +160° F (-20° to +70° C) Storage Temperature -50° to +175° F (-46° to +80° C) Humidity 0-99%, non-condensing Electromagnetic Meets CE Requirements: EN 50081-2, EN 50082-2 Surge Protection Meets CE Requirements: EN 61326 (1000 volts) Shock Class ANSI/ISA-S71.03 Class SA1 Vibration Class ANSI/ISA-S71.03 Class VC2 LCD T R A N S M I T T E R : P E R F O R M A N C E Reference Conditions Reflection from ideal reflector at +70° F (+20° C) Linearity ±0.2 inch (5 mm) or 0.05% of tank height (whichever is greater) Measured Error ±0.2 inch (5 mm) or 0.05% of tank height (whichever is greater) (Performance will degrade slightly within 60" (1.5 m) of antenna) Resolution 0.1 inch (2.5 mm) Repeatability < 0.1 inch (2.5 mm) or 0.025% of tank height Response Time < 1 second Warm-up Time 30 seconds Ambient Temp. Effect ±.02% of span per degree C, tank heights > 100" (2.54 m) Process Dielectric Effect < 0.3 inch within selected range Maximum Rate of Change 180 inches (450 cm)/minute Minimum Dielectric: 1.7 A N T E N N A : Encapsulated Horn Antenna F U N C T I O N A L Polypropylene Tefzel® Process Connection 2" NPT/BSP hygienic flanges Maximum Process Temperature -40° to +200° F @ atmos (-40° to +93° C @ atmos) Vacuum to 200 psig @ +70° F (-1 to 13.8 bar @ +20° C) Maximum Process Pressure Minimum Dielectric (application dependent) 1.7 Pressure psig (bar) A N T E N N A : R A T I N G S P R E S S U R E / T E M P E R A T U R E 300 (21) 200 (14) 100 (7) 0 -50 (-46) 0 (-18) 50 (10) 100 (38) 150 (66) 200 (93) 250 (121) 300 (149) Temperature ° F (° C) Maximum Pressure ratings for CRN are derated to 130 psig (-1 to +9 bar) @ +70° F (+20° C) 9 M O D E L N U M B E R Models available for quick shipment, usually within one week after factory receipt of a complete purchase order, through the Expedite Ship Plan (ESP). BASIC MODEL NUMBER R RADAR Level Transmitter OPERATING FREQUENCY 8 26 GHz TRANSMITTER MODEL 2 Economical POWER/SIGNAL 5 24 VDC, Two-Wire; 4-20 mA with HART AGENCY CLASSIFICATION 1 2 A B Integral, Integral, Integral, Integral, General Purpose/Non-Incendive (cFMus) Intrinsically Safe (cFMus) General Purpose (ATEX) Intrinsically Safe (ATEX II 1G Ex ia IIC T4 @70°C) HOUSING/CONDUIT CONNECTION 0 1 6 7 Cast Aluminum, Single Compartment; 3⁄4" NPT Cast Aluminum, Single Compartment; M20 Lexan® Plastic, Single Compartment, 3⁄4" NPT Lexan Plastic, Single Compartment, M20 ACCESSORIES A Digital Display and Keypad ANTENNA TYPE 1 2 3 4 Polypropylene, 2" (50 mm) Extension Polypropylene, 8" (200 mm) Extension Tefzel®, 2" (50 mm) Extension Tefzel, 8" (200 mm) Extension PROCESS CONNECTION 1 2 J K M 2" NPT (Sch. 40 maximum) 2" BSP (G2) (Sch. 40 maximum) 21⁄2" Tri-Clamp® (50 Ra surface finish) 3" Tri-Clamp® (50 Ra surface finish) 68 mm Varivent® Type N (50 Ra surface finish) NOTE: Options J, K and M are available with ANTENNA TYPES 3 and 4 only (Tefzel, 2" (50mm) and Tefzel, 8" (200mm)) R 10 8 2 5 A 0 T H R E A D - O N F O R U S E CARBON 2" 3" 4" 6" 3" 4" 3" 4" W I T H F L A N G E 2 " STEEL 150# 300# 600# N U M B E R S C O N N E C T I O N S 304 SS 2" 3" 4" 6" 316 SS / 316L SS 2" 3" 150# 4" 6" 3" 300# 4" 3" 600# 4" 004-6820-013 004-6820-001 004-6820-007 004-6820-016 004-6820-002 004-6820-008 004-6820-003 004-6820-009 D I M E N S I O N A L I N C H E S N P T P A R T 004-6820-019 004-6820-020 004-6820-021 004-6820-022 004-6820-023 004-6820-024 004-6820-025 004-6820-026 004-6820-005 004-6820-011 004-6820-006 004-6820-012 FIBERGLASS 2" 3" 4" KYNAR 2" 3" 4" PVC 2" 3" 4" 004-6823-018 004-6823-019 004-6823-020 004-6823-028 004-6823-029 004-6823-030 004-6823-008 004-6823-009 004-6823-010 S P E C I F I C A T I O N S ( M M ) Ø 4.00 (102) Ø 3.78 (96) 4.50 (114) 4.00 (102) 3.25 (83) Aluminum Housing Top View 3.31 (84) Lexan® Housing Top View 4.90 (125) 2.98 (76) 4.06 (103) 2.27 (58) 3.25 (83) 5.82 (148) 2.98 (76) 8.98 (228) 2.98 (76) 8.98 (228) Aluminum Housing Side View 5.04 (128) 8.98 (228) Tefzel Antennas with Tri-Clamp and Varivent connections Lexan® Housing Side View 11 Q U A L I T Y 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. Several R82 Through-Air Radar Level Transmitters are available for quick shipment, usually within one week after factory receipt of a purchase order, through the Expedite Ship Plan (ESP). To take advantage of ESP, simply match the color coded model number codes (standard dimensions apply). E S P Expedite Ship Plan Models covered by ESP service are color coded in the selection data charts. ESP service may not apply to orders of ten units or more. Contact your local representative for lead times on larger volume orders, as well as other products and options. W A R R A N T Y 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. For additional information, see Instruction Manual 58-610. 5300 Belmont Road • Downers Grove, Illinois 60515-4499 • 630-969-4000 • Fax 630-969-9489 • www.magnetrol.com 145 Jardin Drive, Units 1 & 2 • Concord, Ontario Canada L4K 1X7 • 905-738-9600 • Fax 905-738-1306 Heikensstraat 6 • B 9240 Zele, Belgium • 052 45.11.11 • Fax 052 45.09.93 Regent Business Ctr., Jubilee Rd. • Burgess Hill, Sussex RH15 9TL U.K. • 01444-871313 • Fax 01444-871317 Copyright © 2010 Magnetrol International, Incorporated. All rights reserved. Printed in the USA. Performance specifications are effective with date of issue and are subject to change without notice. Magnetrol & Magnetrol logotype and Eclipse are registered trademarks of Magnetrol International HART is a registered trademark of the HART Communication Foundation PACTware is trademark of PACTware Consortium CSA logotype is a registered trademark of Canadian Standards Association Tri-Clamp is a registered trademark of Ladish Co. Tefzel is a registered trademark of Du Pont de Nemours and Company Lexan is a registered trademark of General Electric Varivent is a registered trademark of Tuchenhagen GmbH LTD BULLETIN: 58-110.4 EFFECTIVE: November 2010 SUPERSEDES: July 2010