BINMASTER CNCR-210 Operating Instructions Manual

1 Operating Instructions Radar sensor for continuous level measurement CNCR-210 Two-wire 4-20 mA Document ID: 925-0395 Rev B

2 Contents 1 About this document ............................................................................................................. 3 2 For your safety ....................................................................................................................... 3 2.1 Authorized personnel ....................................................................................................... 3 2.2 Appropriate use. ............................................................................................................... 3 2.3 Warning about incorrect use ............................................................................................ 4 3 Product description ............................................................................................................... 4 � 3.1���Configuration. ................................................................................................................... 4 3.2 Principle of operation ....................................................................................................... 5 3.3 Adjustment ....................................................................................................................... 5 4 Mounting ................................................................................................................................. 6 4.1 General instructions ......................................................................................................... 6 4.2 Mounting versions ............................................................................................................ 6 5 Connecting to power supply ................................................................................................. 9 5.1 Preparing the connection ................................................................................................. 9 5.2 Connecting ..................................................................................................................... 10 5.3 Wiring plan ..................................................................................................................... 11 6 Setup with smartphone/tablet (Bluetooth) ........................................................................ 11 6.1 Preparations ................................................................................................................... 11 6.2 Connecting ..................................................................................................................... 12 6.3 Parameter adjustment .................................................................................................... 13 7 Menu overview ..................................................................................................................... 14 8 Diagnostics and servicing .................................................................................................. 15 8.1 Maintenance .................................................................................................................. 15 8.2 Status messages ........................................................................................................... 15 9 Removal ................................................................................................................................ 17 10 Certificates and approvals .................................................................................................. 17 10.1 Radio licenses. ............................................................................................................. 17 11 Supplement .......................................................................................................................... 17 11.1 Technical data .............................................................................................................. 17 11.2 Dimensions. .................................................................................................................. 19

3 Information, note, tip: This symbol indicates helpful additional information and tips. Note: This symbol indicates notes to prevent failures, malfunctions, damage to devices or facility. Caution: Non-observance may result in personal injury. Warning: Non-observance may result in serious or fatal personal injury. Danger: Non-observance of the information marked with this symbol results in serious or fatal personal injury. Ex applications This symbol indicates special instructions for Ex applications. List The dot set in front indicates a list with no implied sequence. Sequence of actions Numbers set in front indicate successive steps in a procedure. Battery disposal This symbol indicates special information about the disposal of batteries and accumulators. 1 About this document 2 For your safety 2.1 Authorized personnel All�operations�described�in�this�documentation�must�be�carried�out�only�by�trained,�qualified� personnel authorized by the plant operator. Required personal protective equipment must always be worn when working on or with the device. 2.2 Appropriate use CNCR-210 is a sensor for continuous level measurement. Operational reliability is ensured only if the�instrument�is�properly�used�according�to�the�specifications�in�the�operating�instructions.

4 Safety instructions for Ex areas Take�note�of�the�Ex�specific�safety�instructions�for�Ex�applications.�These�instructions� are attached as documents to each instrument with Ex approval and are part of the operating instructions. 2.3 Warning about incorrect use Inappropriate�or�incorrect�use�of�this�product�can�result�in�application-specific�hazards,�e.g.�vessel� overfill�by�incorrect�mounting�or�adjustment.�Damage�to�property�and�persons�or�environmental contamination can result. 3 Product Description 3.1 Configuration Fig. 1: Components of CNCR-210 1 Radar antenna 2� Process�fitting 3 Process seal 4 Electronics housing 5 Ventilation/pressure compensation

5 3.3 Adjustment Devices with integrated Bluetooth module can be adjusted wirelessly via software adjustment tools: • Smartphone/tablet (iOS or Android operating system) • PC/notebook with Bluetooth USB adapter (Windows operating system) Fig. 2: Wireless connection to standard operating devices with integrated Bluetooth LE 1 Sensor 2 Smartphone/Tablet 3 PC/Notebook 3.2 Principle of operation CNCR-210 is a radar sensor for continuous level measurement. It is suitable for liquids and sol- ids in practically all industries. The instrument emits a continuous, frequency-modulated radar signal from its antenna. The emit- ted�signal�is�reflected�by�the�material�and�received�by�the�antenna�as�an�echo�with�a�modified� frequency. The frequency change is proportional to the distance to the material.

6 4.2 Mounting The radar emits pulses of electromagmetic waves which are polarized. By adjusting the rotation of the instrument the polarization can be changed to reduce false echoes. The narrow portion of the radar signal is in the middle of the conduit entry on the instrument. This should be pointed towards the center of the vessel or any obstacle that may cause any unwanted reflections�to�minimize�false�echos,�for�example,�the�sidewall�or�vessel�structure. 4 Mounting 4.1 General instructions The instrument is suitable for standard and extended ambient conditions according to DIN/EN/IEC/ ANSI/ISA/UL/CSA 61010-1. It can be used indoors as well as outdoors. Protect your instrument against moisture ingress through the following measures: • Use a suitable connection cable �����•��Tighten�the�cable�gland�or�plug�connector�firmly • Face the cable connection or conduit entry downward, never upward This applies mainly to outdoor installations, in areas where high humidity is expected (e.g. through cleaning processes) or on cooled or heated vessels. Fig. 3: Polarization position Cable / conduit entry Note: When�the�housing�is�rotated,�the�direction�of�polarization�changes�and�hence�the�influence�of�the�false� echo on the measured value. Please keep this in mind when mounting or making changes later.

7 In vessels with cone bottoms, the sensor can be mounted in the center of the vessel to mea- sure material down to the outlet. When mounting the sensor, distance it at least 200 mm (7.874 in) from the vessel wall. If the sensor is installed in the center of dished or round vessel tops, multiple echoes can arise. However, these can be suppressed by a false signal suppression (see chapter “Setup”). If you cannot maintain this distance, you should carry out a false signal suppression during initial setup. This applies particularly if buildup on the vessel wall is expected. If this is the case, we recommend repeating the false signal suppression later with the additional buildup. Fig. 5: Mounting the radar sensor with conical bottom Fig. 4: Mounting the radar sensor on round vessel tops

8 Do�not�mount�the�instrument�in�or�above�the�fill�stream.�Make�sure�that�it�is�pointed�towards�the material�surface,�not�the�fill�stream. For socket or stand pipe mount, the pipe should be as short as possible and its bottom end rounded�to�reduce�false�reflections�from�the�end�of�the�pipe.� When using a threaded coupling, the antenna end should protrude at least 5 mm (0.2 in) out of the coupling. Fig. 6: Reference plane 1 Reference plane Fig.�7:�Mounting�the�radar�sensor�with�inflowing�material The lower side of the radar antenna is the reference plane for the min./max. adjustment, see following diagram:

9 Socket diameter d Socket length h 40 mm 1½” ≤�150�mm ≤�5.9�in 50 mm 2” ≤�200�mm ≤�7.9�in 80 mm 3” ≤�300�mm ≤�11.8�in 100 mm 4” ≤�400�mm ≤�15.8�in 150 mm 6” ≤�600�mm ≤�23.6�in If�the�reflective�properties�of�the�material�are�good,�you�can�mount�the�CNCR-210�on�sockets� or stand pipes longer than the antenna. The pipe end should be smooth, burr-free and the end rounded. Note: When mounting on longer sockets, we recommend carrying out a false signal suppression after install (see chapter “Parameter adjustment”). Recommended values for socket or stand pipe lengths and heights are in the following table. The values come from typical applications. Fig. 8: Mounting the radar sensor with stand pipes 5 Connecting to power supply 5.1 Preparing the connection •��Electrical�connection�should�be�completed�by�trained,�qualified�personnel�authorized�by� the plant operator. • If overvoltage surges are expected, overvoltage arresters should be installed.

10 Warning: Only connect or disconnect in de-energized state. Note: Power the instrument via an energy-limited circuit (power max. 100 W) according to IEC 61010-1, e.g. • Class 2 power supply unit (acc. to UL1310) • SELV power supply unit (safety extra-low voltage) with suitable internal or external limitation of the output current Use�round�cable�to�ensure�effective�sealing�of�the�cable�gland�to�the�appropriate�IP�rating�and� check�the�cable�diameter�versus�the�cable�gland�before�wiring�for�proper�fit. The instrument is connected with standard two-wire cable. If electromagnetic interference is expected which is above the test values of EN 61326-1 for industrial areas, shielded cable should be used. Note: If the temperatures are too high, the cable insulation can be damaged. 5.2 Connecting Fig. 9: Connection

11 5.3 Wiring plan Connect the instrument as described in the following wiring plan. Fig. 10: Connection compartment CNCR-210 1 Voltage supply +24 VDC, signal output 6 Setup with smartphone/tablet (Bluetooth) 6.1 Preparations Make sure that your smartphone/tablet meets the following system requirements: • Operating system: iOS 8 or newer • Operating system: Android 5.1 or newer • Bluetooth 4.0 LE or newer Download�the�Wireless�Device�Configurator�app�from�the�“Apple�App�Store”�or�“Google�Play� Store” to your smartphone or tablet. To enable the Bluetooth software enter the BinMaster company ID code BMYQXZ.

12 6.2 Connecting Start the adjustment app and select the function “Setup”. The smartphone/tablet searches automatically for Bluetooth-capable instruments in the area. The message “Connecting …” is displayed. The devices found are listed and the search is automatically continued. Select the requested instrument in the device list. When�establishing�the�connection�for�the�first�time,�the�operating�tool�and�the�sensor�must� authenticate�each�other.�After�the�first�correct�authentication,�each�subsequent�connection�is� made without a new authentication query. For�authentication,�enter�the�6-digit�Bluetooth�access�code�in�the�next�menu�window.�You�can�find� the code on the outside of the device housing and on the setup information sheet in the device packaging. Note: If an incorrect code is entered, the code can only be entered again after a delay time and the delay gets longer after each incorrect entry. The message “Waiting for authentication” is displayed on the smartphone/tablet. After connection, the sensor adjustment menu is displayed on the smartphone/tablet. If the Bluetooth connection is interrupted, e.g. due to a too large distance between the two devices, this is displayed on the smartphone/tablet. The message disappears when the connection is restored. Parameter adjustment of the device is only possible if the parameter protection is deactivated, which is default. Parameter protection can be activated later if desired. Fig. 11: Enter Bluetooth access code

13 6.3 Parameter adjustment The sensor adjustment menu is divided into two areas, which are arranged next to each other or one below the other, depending on the smartphone/tablet. • Navigation section • Menu item display The selected menu item can be recognized by the color change. Enter�the�requested�parameters�and�confirm�via�the�keyboard�or�the�editing�field.�The�settings�are� then active in the sensor. Close the app to terminate connection. Note If�the�CNCR�fails�to�connect�to�the�Wireless�Device�Configuration�App�(WDCA)�via�Bluetooth,� close the (WDCA), power cycle the CNCR and attempt to reconnect. If further action is required, power cycle the Bluetooth on your device, and repeat the steps above. Fig. 12: Example of an app view - Setup sensor adjustment

14 Menu item Selection Default settings False signal suppression False signal suppression 0 m Sounded distance to the material 0 m Reset Delivery status, basic settings - Menu item Selection Default settings Measurement loop name Alphanumeric characters Sensor Medium Liquid Bulk solid Liquid Application liquid Storage tank, agitator tank, dosing tank, pumping station/pump�shaft,�rain�overflow�basin,�tank/�collection� basin, plastic tank (measurement through tank top), mobile plastic tank (IBC), level measurement in waters, flow�measurement�flume/over-�flow,�demonstration Storage tank Application bulk solid Silo (slim and high), bunker (large volume), stockpile (point measurement/ profile�detection),�crusher,�demonstration Silo (slender and high) Units Distance unit of the device Temperature unit of the instrument Distance in ft. Temperature in °F Adjustment Max. adjustment (distance A) - 20mA (100%) Min. adjustment (distance B) - 4mA (0%) Distance from sensor Max. adjustment 0.0 m Min. adjustment 8.0 m Menu item Selection Default settings Damping Integration time 0 s Current output Output characteristics 4 to 20 mA = 0% to 100% Current range Min. current 4 mA and max. current 20.5 mA Reaction when malfunctions occur Failure mode < 3.6 mA Linearization Linearization type Linear Scaling Scaling size Scaling unit Scaling format 0% correspond to 0 l 100% correspond to 100 l Display Menu language Displayed value Backlight English Distance On Access protection Bluetooth access code - Parameter Protection Deactivated Menu item Selection Default settings Status Sensor status Measured value status Status output Status additional measured values - Echo curve Indication of echo curve - 7 Menu overview

15 Code Text message Cause Rectification F013 No measured value available No measured value in the boot up phase or during operation Check or correct installation and/ or parameter settings Clean the antenna system F017 Adjustment span too small Adjustment not within specification Change adjustment according to the limit�values�(difference�between�min.� and�max.�≥�10�mm) F025 Error in the linearization table Linearization values are not continuously rising, for example illogical value pairs Check linearization table Delete table/Create new F036 No operable software Checksum error if software update failed or aborted Repeat software update Send instrument in for repair F040 Error in the electronics Limit value exceeded in signal processing Hardware error Restart instrument Send instrument in for repair F080 General software error General software error Restart instrument 8 Diagnostics and servicing 8.1 Maintenance If the device is used properly, no special maintenance is required in normal operation. In�some�applications,�buildup�on�the�antenna�system�can�influence�the�measurement.� Depending on the sensor and application, be careful to avoid heavy soiling of the antenna system. If necessary, clean the antenna system periodically. 8.2 Status messages The status messages are divided into the following categories: • Failure • Function check •��Out�of�specification • Maintenance required Failure

16 Code Text message Cause Rectification S600 Impermissible electronics temperature Temperature of the electronics out of specified�range Check ambient temperature Insulate electronics S601 Overfilling Danger�of�vessel�overfilling Make�sure�that�there�is�no�further�filling Check level in the vessel S603 Impermissible operating voltage Terminal voltage too low Check terminal voltage, increase operating voltage Code Text message Cause Rectification C700 Simulation active A simulation is active Finish simulation Wait for the automatic end after 60 mins. Code Text message Cause Rectification F105 Determine measured value The instrument is still in the boot up phase, the measured value could not yet be determined Wait for the end of the boot up phase Duration up to 3 minutes depending on the measurement environment and parameter settings F260 Error in the calibration Checksum error in the calibration values Error in the EEPROM Send instrument for repair F261 Error in the instrument settings Error during setup False signal suppression faulty Error when carrying out a reset Repeat setup Reset instrument F265 Measurement function disturbed Program sequence of the measuring function disturbed Device restarts automatically Code Text message Cause Rectification M500 Error in the delivery status M501 Error in the delivery status M504 Error at a device interface Hardware defect Check connections Replace the electronics Send instrument in for repair Failure Function check Out of specification Maintenance

17 9 Removal The device is made of recyclable materials that can be disposed of by specialty recycling companies. Observe the applicable local regulations for proper disposal. 10 Certificates and approvals 10.1 Radio licenses Radar The device has been tested and approved in accordance with the current edition of the applicable country-specific�norms�or�standards. Bluetooth The Bluetooth radio module in the device has been tested and approved according to the current edition of�the�applicable�country-specific�norms�or�standards. 11 Supplement 11.1 Technical data Note for approved instruments The technical data in the respective safety instructions which are included are valid for approved instruments�(e.g.�with�Ex�approval).�These�data�can�differ�from�the�data�listed�herein,�for�example� regarding the process conditions or the voltage supply. Code Text message Cause Rectification M505 No echo available Sensor does not detect an echo during operation Antenna dirty or defective Clean the antenna Use a more suitable antenna/sensor Remove possible false echoes Optimize sensor position and orientation M507 Error in the instrument settings Error during setup Error when carrying out a reset False signal suppression faulty Reset instrument and repeat setup M508 Data error in program memory Bluetooth controller M509 Software update M510 No communication with the sensor

18 Fig. 13: Data of the input variable 1 Reference plane 2 Measured variable, max. measuring range Materials and weights Materials, wetted parts –�Antenna,�process�fitting� PVDF – Process seal FKM Materials, non-wetted parts – Housing Plastic PBT (Polyester) – Housing seals O-rings (silicone) – Cable gland PA – Sealing, cable gland NBR – Blind plug, cable gland PA – Weight 0.7 kg (1.543 lbs) Torques Max. torque mounting boss 7 Nm (5.163 lbf ft) Max. torque for NPT cable glands and conduit tubes 10 Nm (7.376 lbf ft) Input variable Measured variable The measurement range is the distance between the antenna face of the sensor and the material surface. The antenna face is also the reference plane for the measurement. Max. measuring range4) 8 m (26.25 ft) Recommended measuring range5) up to 5 m (16.4 ft)

19 Output Output signal 4 to 20 mA Range of the output signal 3.8 to 20.5 mA (default setting) Signal�resolution�� 0.3�μA Resolution, digital 1 mm (0.039 in) Fault�signal,�current�output�(adjustable)�� ≤�3.6�mA,�>=21�mA,�last�valid�measured�value Max. output current 22 mA Load See load resistance under Power supply Starting�current�� ≤�3.6�mA;�≤�10�mA�for�5�ms�after�switching�on Damping (63 % of the input variable), adjustable 0 to 999 s Ambient conditions Ambient temperature -40 to +60 °C (-40 to +140 °F) Storage and transport temperature -40 to +80 °C (-40 to +176 °F) Process conditions For�the�process�conditions,�please�also�note�the�specifications�on�the�printed�label.�The�lowest�value (amount) always applies. Process temperature -40 to +60 °C (-40 to +140 °F) Process pressure -1 to 3 bar (-100 to 200 kPa/-14.5 to 43.51 psig) Voltage supply Operating voltage UB – at 4 mA 12 to 35 V DC – at 20 mA 9 to 35 V DC Reverse voltage protection Integrated Electrical protective measures Altitude above sea level 5000 m (16404 ft) Protection class III Pollution degree 4

20 11.2 Dimensions CNCR-210 Fig. 14: Dimensions CNCR-210 1 Thread G1½ 2 Thread 1½ NPT 3 Thread R1½

21 All statements concerning scope of delivery, application, practical use and operating conditions of the sensors and processing systems correspond to the information available at the time of printing. Subject to change without prior notice. BinMaster Phone: 402-434-9102 7201 N 98th St. Fax: 402-434-9133 Lincoln NE 68507 E-mail: [email protected] USA www.binmaster.com