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NCR-80 Four-wire 4-20 mA/HART

925-0332 Rev B

4 Mounting

Fig. 6: Combi compression flange

Combi compression flange

The adapter flange is available in different flange sizes. It is permanently connected with the

radar sensor and sealed.

Fig. 7: Adapter flange

1 Connection screw
2

Adapter flange

3 Process seal

You can find drawings of these mounting options in chapter “

Dimensions

”.

4.3 Mounting preparations, mounting strap

The mounting strap is supplied unassembled (optionally) and must be screwed to the sensor

before setup with three hexagon socket screws M5 x 10 and spring washers. Max. torque, see

chapter “

Technical data

”. Required tools: Allen wrench size 4.

There are two different variants of screwing the strap to the sensor, see following illustration:

Summary of Contents for NCR-80

Page 1: ...NCR 80 Four wire 4 20 mA HART Operating Instructions Radar sensor for continuous level measurement of bulk solids NCR 80 Four wire 4 20 mA HART Document ID 925 0332 Rev B...

Page 2: ...scription 9 3 1 Configuration 9 3 2 Principle of operation 10 3 3 Packaging transport and storage 11 3 4 Accessories and replacement parts 11 4 Mounting 13 4 1 General instructions 13 4 2 Mounting ver...

Page 3: ...5 53 9 Diagnosis asset management and service 54 9 1 Maintenance 54 9 2 Measured value and event memory 54 9 3 Asset Management function 55 9 4 Rectify faults 58 9 5 Exchanging the electronics module...

Page 4: ...sonnel and put into practice by them 1 3 Symbols used Information tip note This symbol indicates helpful additional information Caution If this warning is ignored faults or malfunctions can result War...

Page 5: ...lations and guidelines The instrument must only be operated in a technically flawless and reliable condition The operator is responsible for the trouble free operation of the instrument During the ent...

Page 6: ...utside of closed vessels the following conditions must be fulfilled The installation must be carried out by trained qualified personnel The instrument must be stationary mounted and the antenna direct...

Page 7: ...ice However level probing devices found to interfere with primary licensing operations will be required to be removed at the user s expense This device shall be installed and maintained to ensure a ve...

Page 8: ...t is why we have intro duced an environment management system with the goal of continuously improving company environmental protection The environment management system is certified according to DIN E...

Page 9: ...e 8 Material wetted parts 9 Hardware and software version 10 Order number 11 Serial number of the instrument 12 Data matrix code for smartphone app 13 Symbol of the device protection class 14 ID numbe...

Page 10: ...with poorly reflecting bulk solids such as fly ash plastic granules or wood chips as well as internal installations that cause strong false echoes This is made possible by its functional principle a d...

Page 11: ...ot in the open Dry and dust free Not exposed to corrosive media Protected against solar radiation Avoiding mechanical shock and vibration Storage and transport temperature see chapter Supplement Techn...

Page 12: ...ev B 3 Production description 12 The supplementary electronics is a replacement part for sensors with 4 20 mA HART four wire You can find further information in the operating instructions Supplementar...

Page 13: ...nces You can find detailed information on the process conditions in chapter Technical data as well as on the type label Metric threads In the case of instrument housings with metric thread the cable g...

Page 14: ...n the sensor to the surface of the bulk solid material The following versions are available Length 300 mm Length 170 mm The instrument is normally mounted vertically with a bracket on the ceiling This...

Page 15: ...IS 80 Adapter flange from DN 100 ASME 4 or JIS 100 The combi compression flange is suitable for different flange standards and can be used for simple applications It comes unassembled and not sealed a...

Page 16: ...w 2 Adapter flange 3 Process seal You can find drawings of these mounting options in chapter Dimensions 4 3 Mounting preparations mounting strap The mounting strap is supplied unassembled optionally a...

Page 17: ...gle of inclination in two steps 0 and 90 4 4 Mounting instructions Radar sensors for level measurement emit electromagnetic waves The polarization is the direc tion of the electrical component of thes...

Page 18: ...ng medium as the radar signal could be disrupted Silo with filling from top The optimal mounting position is opposite the filling aperture To avoid heavy soiling the dis tance to any filter or dust ex...

Page 19: ...rounded This reduces false echoes from the vessel mounting socket Fig 13 Recommended socket mounting If the medium has good reflective properties you can also mount the NCR 80 on longer sock ets Appro...

Page 20: ...mm 150 mm 500 mm Socket diameter d Socket length h 3 7 87 in 4 11 8 in 6 19 7 in In order to measure as much of the vessel volume as possible the sensor should be aligned so that the radar signal reac...

Page 21: ...sition and orientation With the help of an optional swiveling holder the sensor can be easily aligned to the vessel centre The necessary angle of inclination depends on the vessel dimensions It can be...

Page 22: ...e distance a between vessel centre and installation position Distance d m 2 4 6 8 10 2 0 1 0 1 0 2 0 3 0 4 4 0 1 0 3 0 4 0 6 0 7 6 0 2 0 4 0 6 0 8 1 1 8 0 3 0 6 0 8 1 1 1 4 10 0 3 0 7 1 1 1 4 1 8 15 0...

Page 23: ...on The max angle of inclination of the swivelling holder is approx 10 3 Re tighten the terminal screws max torque see chapter Technical data The mounting location of the radar sensor should be a place...

Page 24: ...that for these applications the sensors are designed for relatively slow level changes If the sensor is used on a movable boom the max measuring rate must be observed see chapter Technical data Fig 1...

Page 25: ...ity If the radar sensor is mounted very close to a heavily structured vessel wall substantial interfering reflections can be generated Thus the sensor should be mounted at the largest possible distanc...

Page 26: ...cularly in case of strong condensation air rinsing is recommended Metal jacketed lens antenna The NCR 80 with metal jacketed lens antenna is equipped with a rinsing air connection as a standard featur...

Page 27: ...0 mA HART 925 0332 Rev B 4 Mounting 27 Fig 25 Rinsing air connection with adapter flange You can find details on the rinsing air connection in chapter Technical data Fig 24 Rinsing air connection with...

Page 28: ...he instrument version The data for power supply are specified in chapter Technical data Voltage supple via low voltage In this case the instrument is designed in protection class II Generally connect...

Page 29: ...t significant potential differences exist This can lead to unacceptably high currents in the ca ble screen if it is grounded at both ends Information The metallic parts of the instrument process fitti...

Page 30: ...ly pulling on them 7 Connect the screen to the internal ground terminal connect the outer ground terminal to po tential equalisation in case of power supply via low voltage 8 Connect the lead cable fo...

Page 31: ...on to the terminal compartment 2 For display and adjustment module or interface adapter Information The connection of an external display and adjustment unit is not possible with the Ex d ia ver sion...

Page 32: ...ting the instrument to power supply or after a voltage recurrence the instrument carries out a self check for approx 30 s Internal check of the electronics Indication of the instrument type hardware a...

Page 33: ...ceed as follows 1 Unscrew the housing lid 2 Place the display and adjustment module on the electronics in the desired position and turn it to the right until it snaps in 3 Screw housing lid with inspe...

Page 34: ...e parameter ESC key Interrupt input Jump to next higher menu The instrument is operated via the four keys of the display and adjustment module The individ ual menu items are shown on the LC display Yo...

Page 35: ...nics are displayed During the initial setup of an instrument shipped Ex works use the OK key to get to the menu National language This menu item is used to select the national language for further par...

Page 36: ...Setup the individual submenu items should be selected one after the other and provided with the correct parameters to ensure optimum adjustment of the measure ment The procedure is described in the f...

Page 37: ...range up to 120 m This menu item lets you limit the active measuring range in which the instrument searches for level echoes Information The min adjustment must be carried out independently of this T...

Page 38: ...Very high measured value jumps are accepted Heap Sensor mounting on movable conveyor belts Detection of the heap profile Height detection during filling Process measurement conditions Measured value j...

Page 39: ...carried out To perform the adjustment enter the distance with full and empty vessel see the following ex ample Fig 32 Parameter adjustment example min max adjustment 1 Min level max measuring distanc...

Page 40: ...istance value 4 For the full vessel enter the distance value in m matching the percentage value 5 Save settings with OK and move with ESC and to Min adjustment Setup Min Adjustment Proceed as follows...

Page 41: ...Max you determine the reaction of the current output during operation The default setting is min current 3 8 mA and max current 20 5 mA In the menu item Lock unlock adjustment you safeguard the sensor...

Page 42: ...The display and adjustment module has a backlight for the display In this menu item you can switch the lighting on or off You can find the required operating voltage in chapter Technical data In deli...

Page 43: ...he input card of the control system Select the requested simulation variable and set the requested value Caution During simulation the simulated value is outputted as 4 20 mA current value and as digi...

Page 44: ...o the default values see below table Proceed as follows 1 Select with under Additional adjustments the menu item Reset and confirm with OK 2 Confirm with OK and select the requested reset function wit...

Page 45: ...e Setup Measurement loop name Sensor Units Distance in m Temperature in C Application Medium Crushed stones gravel Application Silo Vessel bottom Flat Vessel height Measuring range 120 m Min adjustmen...

Page 46: ...y and adjustment module and remain there even in case of power failure From there they can be written into one or more sensors or kept as backup for a possible electronics exchange Note Before the dat...

Page 47: ...g signals in this section are detected by the sensor and stored after confirming with OK Note Check the distance to the product surface because if an incorrect too large value is entered the existing...

Page 48: ...you specify the HART mode and enter the address for multidrop mode In the mode Fixed current output up to 63 sensors can be operated on one two wire cable Multidrop operation An address between 0 and...

Page 49: ...purposes If the instrument is equipped with a display and adjustment module the data in the sensor can be saved in the display and adjustment module The procedure is described in the menu Addi tional...

Page 50: ...onnection of the PC directly to the sensor via the interface adapter 1 USB cable to the PC 2 Interface adapter BinDisc 3 Sensor Fig 34 Connecting the PC via HART to the signal cable 1 NCR 80 2 Voltage...

Page 51: ...PACTware and a suitable instrument driver DTM according to FDT standard are required The latest PACTware version as well as all available DTMs are compiled in a DTM Collection The DTMs can also be in...

Page 52: ...g printing the project as well as import export functions are also part of the standard version In the full version there is also an extended print function for complete project documentation as well...

Page 53: ...escriptions for the instrument are available as EDD for parameter adjustment with the Field Communicator 375 or 475 For the integration of the EDD in the Field Communicator 375 or 475 the software Eas...

Page 54: ...When the instrument is shipped the measured value memory is active and stores distance measurement certainty and electronics temperature every 3 minutes The requested values and recording conditions...

Page 55: ...the status messages 1 Failure red 2 Out of specification yellow 3 Function check orange 4 Maintenance blue Failure Due to a malfunction in the instrument a failure message is outputted This status me...

Page 56: ...Error in the lineariza tion table Index markers are not continuously rising for example illogical value pairs Check linearization table Delete table Create new Bit 2 of Byte 0 5 F036 No operable softw...

Page 57: ...nstrument not sufficient Check or correct instal lation and or parameter adjustment Use an instrument with bigger measuring range Bit 10 of Byte 0 5 F265 Measurement function disturbed Sensor no longe...

Page 58: ...stallation and process conditions Change polarisation di rection Use instrument with higher sensitivity Clean the antenna Bit 3 of Byte 14 24 M504 Error on an device inter face Hardware defect Check c...

Page 59: ...if necessary correct ac cording to chapter Wiring plan Voltage supply miss ing Check cables for breaks repair if necessary Operating voltage too low or load resis tance too high Check adapt if necessa...

Page 60: ...dium dished bot tom high dielectric constant and adapt if necessary The level echo cannot be distinguished from the false signal at a false signal posi tion jumps to multiple echo Remove reduce false...

Page 61: ...must be downloaded from the Internet see oper ating instructions manual Electronics module Measurement error during emptying Fault description Error pattern Cause Rectification 6 Measured value remain...

Page 62: ...er specific settings must be entered again Hence you have to carry out a new setup after the electronics exchange If you have stored the data of the parameter adjustment during the first setup of the...

Page 63: ...ies We use recyclable materials and have designed the parts to be easily separable Correct disposal avoids negative effects on humans and the environment and ensures recycling of useful raw materials...

Page 64: ...dapter flange PP GF30 black Seal adapter flange FKM COG VI500 EPDM COG AP310 Antenna cone PBT GF 30 Focusing lense PP Material wetted parts rinsing air connection Rinsing air connection PP GFK Seal FK...

Page 65: ...Nm 7 376 lbf ft Aluminum Stainless steel housing 50 Nm 36 88 lbf ft Input variable Measured variable The measured quantity is the distance between the end of the sensor antenna and the product surface...

Page 66: ...See following diagrams Fig 47 Deviation under reference conditions 1 Reference plane 2 Recommended min distance 3 Measuring range end Repeatability 1 mm Deviation with bulk solids The values depend to...

Page 67: ...the process conditions please also note the specifications on the type label The lowest value always applies Process temperature Antenna lens Seal Process temperature measured on the process fitting...

Page 68: ...rature 1 Aluminium housing 2 Plastic housing 3 Stainless steel housing precision casting 4 Stainless steel housing electropolished Fig 50 Ambient temperature Process temperature metal jacketed lens an...

Page 69: ...With adapter flange 2 g at 5 200 Hz according to EN 60068 2 6 vi bration with resonance with mounting strap 1 g at 5 200 Hz according to EN 60068 2 6 vi bration with resonance Shock resistance 100 g...

Page 70: ...al FKM SHS FPM 70C3 GLT EPDM COG AP310 For connection G Opening pressure 0 5 bar 7 25 psig Nominal pressure stage PN 250 Electromechanical data version IP 66 IP 67 and IP 66 IP 68 0 2 bar Options of t...

Page 71: ...ay with backlight Measured value indication Number of digits 5 Size of digits W x H 7 x 13 mm Adjustment elements 4 keys Protection rating unassembled IP 20 mounted in the housing without lid IP 40 Ma...

Page 72: ...search as well as in the download area 11 2 Radio astronomy stations Certain restrictions on the use of NCR 80 outside closed vessels result from the radio license You can find these restrictions in...

Page 73: ...Dimensions of housing with integrated display and adjustment module the housing is 9 mm 0 35 inches higher 1 Plastic housing 2 Aluminium Stainless steel housing NCR 80 plastic horn antenna with compre...

Page 74: ...925 0332 Rev B 74 11 Supplement NCR 80 plastic horn antenna with compression flange and rinsing connection Fig 53 Radar sensor with compression flange and rinsing connection 1 Compression flange 2 Ref...

Page 75: ...NCR 80 Four wire 4 20 mA HART 925 0332 Rev B 11 Supplement 75 NCR 80 plastic horn antenna with adapter flange Fig 54 Radar sensor with adapter flange...

Page 76: ...20 mA HART 925 0332 Rev B 76 11 Supplement NCR 80 plastic horn antenna with adapter flange und rinsing connection Fig 55 NCR 80 adapter flange and air flushing ring 1 Air flushing ring 2 Reflux valve...

Page 77: ...NCR 80 Four wire 4 20 mA HART 925 0332 Rev B 11 Supplement 77 NCR 80 plastic horn antenna with mounting strap Fig 56 NCR 80 plastic antenna and mounting strap in 170 or 300 mm length...

Page 78: ...s acc to drawing flange dimensions acc To DIN ASME JIS 1 Version up to 130 C 266 F 2 Version up to 200 C 392 F NCR 80 metal jacketed lens antenna with rinsing connection Fig 58 NCR 80 metal jacketed l...

Page 79: ...0 mA HART 925 0332 Rev B 11 Supplement 79 NCR 80 metal jacketed lens antenna with swivelling holder Fig 59 NCR 80 metal jacketed lens antenna and swivelling holder 1 Version up to 130 C 266 F 2 Versio...

Page 80: ...80 metal jacketed lens antenna with swivelling holder and rinsing connection Fig 60 NCR 80 metal jacketed lens antenna with swivelling holder and rinsing connection 1 Version up to 130 C 266 F 2 Versi...

Page 81: ...2 E Echo curve Memory 56 Setup 44 Electronics compartment 31 Error codes 57 Event memory 54 F False signal suppression 46 Fault rectification 58 Functional principle 11 H HART Address 48 L Linearizati...

Page 82: ...itions of the sensors and processing systems correspond to the infor mation available at the time of printing Subject to change without prior notice BinMaster 7201 N 98th St Lincoln NE 68507 USA Phone...

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