Sultan Sonar Manual Rev 1.0 A Higher Level of Performance Manual Centurion Guided Radar CGR Series For more information, please visit > www.hawkmeasure.com
Table of Contents Contents Overview 3 Principle of Operation 3 Function 3 Primary Areas of Application 3 Wiring & Dimensions 4 Wiring Compartment 4 Flexible Probe 4 Housing 4 Rigid Probe 4 Probe C35 (Interface) 4 Safety Instructions 5 CGR2 Series Wiring in Hazardous Locations 5 Installation Guide 6 Placement Requirements 6 Connection Requirements - Metallic Vessels 7 Nozzle Mounting 7 Forces On The Probe 9 Powering The Unit For The First Time 10 Setup Procedure 11 1. Setup Parameters 11 2. Advanced Parameters 12 3. Sensitivity Calibration 13 Troubleshooting - via Controller Keypad 14 False Echo Elimination 14 Unit is reading deeper than actual level 16 Unit is measuring deeper than the length of the cable 16 Part Numbering 17 17 Flange Table 18 Specifications 19 Mounting 8 Minimum Clearance 8 2
Overview Principle of Operation Single Probe Microwave pulses are transmitted along a cable or probe to the product being measured. At the point where the wave meets the product surface it is reflected by the product. The unit automatically calculates the distance to the pulse reflection using time of flight & time expansion. The intensity of the reflection depends on the dielectric constant of the product. The instrument measures the time between emission and reception of the signal which is proportional to the distance. Dual Probe The unique patented HAWK Dual probe solution uses specially developed signal mapping techniques. The combination of HAWK s hardware and software give an accurate and consistent output for interfaces level measurement. Function Primary Areas of Application The HAWK range of Guided Radar products are ideal for the measurement of liquids, sludge, powders and granules to a range of 18m for level and interface. This technology is not affected by pressure, temperature, viscosity, vacuum, foam, dust, changes in dielectric constant or coating of the probe. Chemicals Petrochemicals Cement Building Aggregates Energy Food & Beverages Oil & Gas Pharmaceutical Pulp & Paper Wastewater Features Multiple Interface Measurement IECEx Ex d [ia] ia IIC T6 Gb Ga Up to 18m range (316L cable) Simple setup Auto-Calibration to any dielectric Adjustable Sensitivity Precise & continuous accuracy 2 wire loop 4-20mA, 2x 4-20mA, HART, Foundation Fieldbus, Profibus PA Protection class IP66 Measures extremely low dielectric (1.6) Programmable fail safe mode 3
Wiring & Dimensions Wiring Terminal Compartment Housing 110 152 + - EMC GND 9 8 7 6 3 5 4 0 1 GND + - EMC 2 109 GND 87 Ex CABLE GLAND L1 = T.B.D. Flexible Probe Rigid Probe Probe C35 (Interface) (2.5") 63.0 40.0(1.5 ) 1 1/2" BSP or NPT mounting thread A B Cable Length (mm) F C D 4/8/16mm L= Determine by Application E G 4
Safety Instructions Safety Instructions For installation requirements for Hazardous Locations please refer to appropriate Safety Instruction document located at: http://www.hawkmeasure.com/productdetail.asp?id=57 CGR2 Series Wiring in Hazardous Locations + - 4-20mA current loop U = 14-28VDC 9 8 7 See terminal compartment wiring Zone 1 EMC/Protective Ground Zone 1 or Zone 0 NOTE: (Ref Safety Instructions Sect 10a) Application of supply voltages above 28VDC will cause damage to the equipment. Voltages less than the U m will not invalidate the type of protection. 5
Installation Guide Placement Requirements Do NOT mount near infeed Do NOT mount over or adjacent to any obstacles 6
Installation Guide Connection Requirements - Metallic Vessels The unit requires a metallic flange or sheet connected to the unit thread. Avoid mounting adjacent to internal structures Probes should not contact metallic container walls or floors. Nozzle Metal flange Metal flange Interior Vessel Ceiling Min 100mm Multiple segmented connection If using thread multiple connection pieces for thread standard and size integration a metallic plate or flange of minimum recommended size should be at the lowest possible point of the mounting. Nozzle Mounting Avoid Narrow Nozzles Do NOT mount in long narrow nozzles Minimum measurable distance can be affected by narrow nozzles. Conduct Digitisation and/or increase Blanking to a safe minimum distance for example: double nozzle height + 25% safe distance High Level 7
Mounting Minimum Clearance Typically high dielectric materials (such as liquids) provide a good return signal. Low dielectric materials (such as plastics and powders) require higher levels of sensitivity to measure. Failure to adhere to mounting requirements can create a false signal reflection which will exhibit as high level lockups either from the distance of the interference of a multiple of the distance of the interference. Take into account the possibility of cable sway encroaching on the minimum clearance requirements. A B Clearances 8mm Cable 4mm Cable A. Minimum Nozzle Clearance 100mm (4 ) 100mm (4 ) A: Recommended Nozzle Clearance 300mm (12 ) 300mm (12 ) B. Minimum Wall Clearance 100mm (4 ) 100mm (4 ) B. Recommended Wall Clearance 500mm (20 ) 300mm (12 ) 8
Forces On The Probe Forces on the probe Tensile forces are heavily dependent on the viscosity and abrasive characteristics of the product in the vessel. Ensure tensile loading is appropriate for the selected cable (8mm or 4mm) as well as the silo cover and mounting structure. In critical cases it is better to select the larger flexible cable (8mm). Probe Type A04 (4mm flexible cable @ 20ºC) A08 (8mm flexible cable @ 20ºC) Tensile Force 5kN 19kN Lateral forces can exist due to movement and gradual flow of the product in the vessel, particularly with powder and granular materials. These forces can cause stress and strain on the probe, as well as the process fitting and mounting hardware. Ensure that lateral forces are minimised by following the installation guidelines and Placement Requirements. Probe Type B08 (8mm rigid probe @ 20ºC) C35 (Coaxial Probe 1 @ 20ºC) Lateral Force 2kN 4kN 9
Powering The Unit For The First Time A. Confirm mounting is within recommended specifications. B. Check the selected unit matches the required application specifications. For Hazardous Locations see appropriate safety instructions available at http://www.hawkmeasure.com C. Check the wiring is correct and all connections are secure. D. Apply power to the unit. When power is applied the unit will start its normal load sequence. The following messages will cycle on the display. Product Type Serial number Unit ID TDR Warming up The unit may take up to 30 seconds to warm up, and then it will perform a scan to locate the level. 10
Setup Procedure 1. Setup Parameters In this operational state you can use the buttons to navigate through and view unit diagnostics and other measurements. Setting Setup Application Parameters The Setup menu contains the basic parameters required to get the unit up and running. It is one of the three main menu options in the internal software. Main Menu Setup Advanced Autoset Setup Parameter Description Options Display Mode Select default Display mode Volume Level %Level Space Display Unit Adjust displayed measurement unit Centimeters Metres Feet Inches Low Level Set Low Level (4mA) distance Adjustable Hi Level Set High Level (20mA) distance Adjustable See Measured Span Reference Damping Set countdown for failsafe (seconds) Adjustable Fail Mode Set Analogue failsafe output 3.50mA 20.20mA LastKnown 4mA 20.00mA Measured Span Reference A A B C Blanking (non-measurable zone) Measurable Span (blanking to top of weight/end of cable) Weight (non measurable zone) B C 11
Setup Procedure 2. Advanced Parameters Setting Advanced Parameters The Advanced menu parameters are for adjusting primary Sensitivity, echo controls/filters, communications and output settings. Parameter Description Options Comms Adjust communication protocol settings. Device ID Baud Rate Digitize Sensitivity Blanking Cal Mount Perform auto-digitization of Sensitivity based on mounting and Dielectric of material touching the probe (see Setup Procedure A) Manual adjustment of Sensitivity. This value will also be automatically adjusted by other calibration routines. Sensitivity is the primary adjustment for the units ability to detect media Blanking is a non-measurable zone. This can be increased to Blank out high level false echoes caused by mounting Performs a digital mapping routine of a user selected span. Used when there is signal interference at high level or mounting. Use Digit Bias to adjust bias (cal sensitivity) of mapping range Execute Disable Cancel 0-100 Adjustable Cal Start Cal End Analogue Adjust and tune 4-20mA settings 4-20 20-4 4mA tuning 20mA tuning Park 4mA Park 8mA Park 12mA Factry Reset Restore unit to factory defaults Yes No Device Info Display device information Lock Code Adjust the peak Sensitivity cap. This value will be automatically adjusted by other calibration routines Disable Enable 12
Setup Procedure 3. Sensitivity Calibration Procedure A: Running Digitize while material is touching the probe Procedure B: Using dielectric pre-sets Procedure C: Manual Sensitivity Adjustment Procedure A: Running Digitize while material is touching the probe This procedure uses automatic procedure for sensitivity adjustment & mapping to calibrate the system based on the dielectric of the material touching the probe element and the mounting conditions. This is the recommended calibration procedure for fastest and most accurate unit setup. Digitize is located in the Advanced menu. Procedure B: Manual Sensitivity Adjustment This procedure is an advanced method for calibrating the sensitivity of the system. This involves manually adjusting the sensitivity until the unit is measuring the length of the sensing element or to the depth of material touching the sensing element. The Sensitivity parameter is located in Adv Setup You can press CAL to fire test pulses. After each pulse the unit will return the signal strength and distance (depth) of the echo. You should aim for a signal strength of 2-2.5V. This may not be achievable with low dielectric materials. 13
Troubleshooting - via Controller Keypad False Echo Elimination Before conducting these steps it is recommended to perform Setup Procedure: Sensitivity Adjustment Procedure A and ensure mounting requirements are met. Some of the procedures below are performed automatically by the routine. 1a. Sourcing false echo distance (high level lock) While the unit is operating and locked onto a false echo you can scroll through diagnostics using the arrow keys on the keypad. The top line of the display will change but the bottom line will continue to indicate the standard display mode measurement (such as Space or Material%) E: 0.4 110.7% Depth Material% Press the UP arrow until the E: diagnostic is displayed. This indicates the depth of the false reading. 1b. Identify signal size of false echo S: 0.74V 110.7% Press the UP arrow again until the S: diagnostic is displayed on the top line. This indicates the signal size of the echo the unit is measuring (this will be between 0.4V and 2.5V). 2. Eliminating false echo There are three primary methods of echo elimination. 2-1. Cal Mount: If you cannot perform Sensitivity Adjustment Procedure A you can manually perform part of this procedure via Cal Mount in Adv Setup. You will be prompted to enter the Cal Start and Cal End distance. You should enter a distance safely closer and deeper than the false echo. You should not enter a value longer than the probe. If the material in the vessel is touching the probe ensure the Cal Mount does not pass this depth. The parameter CalSnstvty in Adv Setup can be used to increase or decrease the uniform sensitivity of the Cal Mount span. After the Cal Mount is complete press RUN several times to return to unit operation. The unit will then begin to scan deeper down the length of the cable to find the next valid echo. 14
Troubleshooting - via Controller Keypad 2-2. Reduce Sensitivity: Enter the Adv Setup menu and scroll until you see Sensitivity parameter. Press CAL to edit. Use the DOWN arrow to reduce this value. Pressing CAL will fire a test pulse and return the diagnostic data of the Signal size and E: distance. Fire several test pulses for a good sample size. Reduce this value until the unit is no longer displaying the false echo while firing test pulses. Press RUN to save and RUN again to return the unit to operating mode. The unit will then begin to scan deeper down the length of the cable to find the next valid echo.. 100% Fig 1 Sensitivity Range 50% 90% 0% False Echoes Correct Level Distance In Fig 1 you can see at 90% Sensitivity both false echoes and the correct level are considered valid targets by the unit. At 50% Sensitivity the only echo the unit will see is the correct level 3. Blanking & Span adjustment If the previous steps are unable to solve a high level lock up there will be a significant signal interference. Visually examine within the vessel for any objects near or touching the sensing element. Extend Blanking beyond the depth of the false echo and adjust High level so it is not within the blanked distance. Perform a 15 second power cycle, the unit will re-scan for the closest signal which beyond the Blanking distance. Attempt to perform Setup Procedure A, B or C if the unit does not locate the correct distance with the false echoes blanked out. 15
Troubleshooting - via Controller Keypad Unit is reading deeper than actual level This may occur in low dielectric applications where the cable weight returns a stronger echo than the measured material. If you have used any other parameters such as Cal Mount perform a Probe Reset. Increase Sensitivity: Enter the Adv Setup menu and scroll until you see Sensitivity parameter. Press CAL to edit. Use the UP arrow to increase this value. Pressing CAL will fire a test pulse and return the diagnostic data of the Signal size and E: distance. Fire several test pulses for a good sample size. Increase this value until the unit is returning a strong (2-2.5V) Signal size from the false echo. Press RUN to save and RUN again to return the unit to operating mode. Perform a 15 second power cycle - when the unit re-starts it will begin a new scan over the entire probe to find the closest echo which passes the Threshold value. Unit is measuring deeper than the length of the cable Press CAL and enter Unlock Code 196 and press CAL. Scroll through the main menus to locate FactoryTDR menu. Press CAL to enter this menu. Scroll down to locate the EmptDist parameter. This should be the length of the cable by factory default. If not, reduce this value to the correct length with a small additional margin (+250mm/12 ). DO NOT ADJUST ANY OTHER PARAMETERS IN THIS MENU. Perform a 15 second power cycle - when the unit re-starts it will begin a new scan over the entire probe to find the closest echo which passes the Threshold value. 16
Part Numbering Model CGR2 CGR4 2 wire 4 wire Communication X 4-20mA analog H 4-20mA with HART A Profibus PA F Foundation Fieldbus Y 2x 4-20mA with HART on channel 1 Housing 1 Aluminium 2 316L Gland Entry 1 1/2 NPT Cable gland entry 2 3/4 NPT Cable gland entry Probe Type A04 4mm flexible cable A08 8mm flexible cable B04 4mm rigid probe B08 8mm rigid probe B16 16mm rigid probe 3 M20 x 1.5 Cable gland entry 4 M25 x 1.5 Cable gland entry C35 Coaxial model 1 D01 Coaxial model 2 E01 Coaxial model 3 Probe variant / materials S 316L H HC-276 T PTFE coated 316L rod Mounting TN07 3/4 NPT Thread (316L) TB07 3/4 BSP Thread (316L) TN10 1 NPT Thread (316L) FLXX 1 Flange Mount TB10 TN15 TB15 1 BSP Thread (316L) 1.5 NPT Thread (316L) 1.5 BSP Thread (316L) Process O-ring seal S Standard seal V Viton E EPDM K B Kalrez NBR Process Temperature for probe 1 80C 4 250C 2 150C 7 450C Process Pressure 1 5 bar 3 20 bar 2 10 bar 4 40 bar 5 100 bar 9 450 bar CGR2 X 2 2 B08 S TN15 S 1 1 1D 1000 1 See flange selection table. Flange is selected as separate line item Approval Standard XX Not Required 1D IECEx Ex d [ia] ia IIC T6 Gb Ga Probe Length Probe length in cm (max 1800) 17
Part Numbering Flange Table FLA-FA2-SS FLA-FD2-SS FLA-FA3-SS FLA-FD3-SS FLA-FA4-SS FLA-FD4-SS FLA-EA2-SS FLA-ED2-SS FLA-EA3-SS FLA-ED3-SS FLA-EA4-SS FLA-ED4-SS FLA-HA2-SS FLA-HA3-SS FLA-HA4-SS FLA-C2-SS FLA-C3-SS 2 ASME/ANSI 150lb Flange (316L) DN50 pn16 Flange (316L) 3 ASME/ANSI 150lb Flange (316L) DN80 pn16 Flange (316L) 4 ASME/ANSI 150lb Flange (316L) DN100 pn16 Flange (316L) 2 ASME/ANSI 300lb Flange (316L) DN50 pn40 Flange (316L) 3 ASME/ANSI 300lb Flange (316L) DN80 pn40 Flange (316L) 4 ASME/ANSI 300lb Flange (316L) DN100 pn40 Flange (316L) 2 ASME/ANSI 600lb Flange (316L) 3 ASME/ANSI 600lb Flange (316L) 4 ASME/ANSI 600lb Flange (316L) 2 clamp (hygenic) 3 clamp (hygenic) 18
Specifications Operating Voltage 14 28VDC (residual ripple no greater than 100mV) HART 24V @ 250 Ohms Power Consumption <0.6W @ 24VDC Analog Output 14V @ 0 Ohm 19V @ 250 Ohms 24V @ 500 Ohms Load (Ohms) 700 500 250 14 19 24 28 Supply Voltage (VDC) Communications* 4-20mA, 2x 4-20mA, GosHawk, HART, Foundation Fieldbus, Profibus PA. Maximum Range 18m Dielectric Range 1.6 Resolution Distance: 0.65mm Analog: 0.5uA Display: 1.0mm Accuracy +/- 3mm Sum of non linearity, non repeatability, hysteresis Analog +/- 0.02% Repeatability +/- 2mm *Specifications model dependent. Consult part number listing. 19
Specifications Memory Non-Volatile (No backup battery required) >10 years data retention Measurement Range of Electronics Min. 150mm Max. 18m Operating Temperature (Electronics) -20ºC to +80ºC (-28 to +176ºF) Process Pressure* -1 to 450 BAR Process Temperature* -30ºC to +450ºC (-35ºF to +842ºF) Display 4 line graphic display (128 x 64) Approvals* IECEx Ex d [ia] ia IIC T6 Gb Ga Process Pressure (Bar) 40 20 Standard Unit 0-1 -20 0 80 100 Process Temperature (Deg C) Probe Physical Load Max tensile load on 8mm cable: 4 tonnes at 23ºC 3 tonnes at 80ºC Max lateral force on C35 probe: 4 kn *Specifications model dependent. Consult part number listing All company or product names are registered trademarks or trademarks of their respective owners. Hawk Measurement Systems Hawk Measurement (Head Office) 96 Glenn Street 15-17 Maurice Court Lawrence, MA 01843, USA Nunawading VIC 3131, AUSTRALIA Phone: +1 888 HAWKLEVEL (1-888-429-5538) Phone: +61 3 9873 4750 Phone: +1 978 304 3000 Fax: +61 3 9873 4538 Fax: +1 978 304 1462 info@hawk.com.au info@hawkmeasure.com Additional product warranty and application guarantees upon request. Technical data subject to change without notice. DOC-CGR-MAN 1214 20