Ametek DR5200 User manual

Radar (FMCW) Level Transmitter for liquids in storage
and process applications
DR5200
DR5200DR5200
DR5200 Quick Start
Quick StartQuick Start
Quick Start
© AMETEK Drexelbrook - DR5200QS-LM, EDO#6-13-112 - Issue #3

CONTENTS
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DR5200
1 Safety instructions 3
2 Installation 4
2.1 Intended use ..................................................................................................................... 4
2.2 Scope of delivery............................................................................................................... 4
2.3 Visual check...................................................................................................................... 5
2.4 Storage ............................................................................................................................. 6
2.5 How to assemble the PTFE Wave Horn antenna ............................................................. 7
2.6 Transport .......................................................................................................................... 8
2.7 Pre-installation requirements ......................................................................................... 8
2.8 Installation........................................................................................................................ 9
2.8.1 Pressure and temperature ranges......................................................................................... 9
2.8.2 Recommended mounting position........................................................................................ 15
2.8.3 Mounting restrictions............................................................................................................ 17
2.8.4 Standpipes (stilling wells and bypass chambers) ................................................................ 22
2.8.5 Wall support for the remote version .................................................................................... 23
2.8.6 How to attach an antenna extension (Metallic Horn or Wave Guide antennas)................... 23
2.8.7 How to turn or remove the signal converter ........................................................................ 27
2.8.8 How to attach the weather protection to the device............................................................. 28
2.8.9 How to open the weather protection .................................................................................... 31
3 Electrical connections 32
3.1 Electrical installation: 2-wire, loop-powered ................................................................ 32
3.1.1 Compact version ................................................................................................................... 32
3.1.2 Remote version ..................................................................................................................... 34
3.2 Non-Ex devices............................................................................................................... 35
3.3 Devices for hazardous locations .................................................................................... 35
3.4 Minimum power supply voltage ..................................................................................... 36
3.5 Protection category ........................................................................................................37
3.6 Networks ........................................................................................................................ 38
3.6.1 General information.............................................................................................................. 38
3.6.2 Point-to-point connection..................................................................................................... 38
3.6.3 Multi-drop networks ............................................................................................................. 39
3.6.4 Fieldbus networks................................................................................................................. 40
4 Operation 41
4.1 General notes ................................................................................................................. 41
4.2 Digital display screen .....................................................................................................41
4.2.1 Local display screen layout .................................................................................................. 41
4.2.2 Functions of keypad buttons................................................................................................. 41
4.3 Quick Setup (Parameters) .............................................................................................. 42
4.4 Empty spectrum recording ............................................................................................ 44
5 Notes 47

1 SAFETY INSTRUCTIONS
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Warnings and symbols used
HANDLING
• This symbol designates all instructions for actions to be carried out by the operator in the
specified sequence.
iRESULT
RESULTRESULT
RESULT
This symbol refers to all important consequences of the previous actions.
Safety instructions for the operator
DANGER!
This information refers to the immediate danger when working with electricity.
DANGER!
These warnings must be observed without fail. Even partial disregard of this warning can lead to
serious health problems and even death. There is also the risk of seriously damaging the device
or parts of the operator's plant.
WARNING!
Disregarding this safety warning, even if only in part, poses the risk of serious health problems.
There is also the risk of damaging the device or parts of the operator's plant.
CAUTION!
Disregarding these instructions can result in damage to the device or to parts of the operator's
plant.
INFORMATION!
These instructions contain important information for the handling of the device.
CAUTION!
Installation, assembly, start-up and maintenance may only be performed by appropriately
trained personnel. The regional occupational health and safety directives must always be
observed.
LEGAL NOTICE!
The responsibility as to the suitability and intended use of this device rests solely with the user.
The supplier assumes no responsibility in the event of improper use by the customer. Improper
installation and operation may lead to loss of warranty. In addition, the "Terms and Conditions of
Sale" apply which form the basis of the purchase contract.
INFORMATION!
• Further information can be found in the handbook and on the data sheet. These documents
can be downloaded from the website.
• If you need to return the device to the manufacturer or supplier, please fill out the device
return form and send it with the device. Unfortunately, the manufacturer cannot repair or
inspect the device without the completed form. The form can be found in the handbook.

INSTALLATION 2
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2.1 Intended use
This radar level transmitter measures distance, level, mass, volume, flow rate (in open
channels) and reflectivity of liquids, pastes and slurries. It does not touch the measured product.
2.2 Scope of delivery
CAUTION!
Responsibility for the use of the measuring devices with regard to suitability, intended use and
corrosion resistance of the used materials against the measured fluid lies solely with the
operator.
INFORMATION!
The manufacturer is not liable for any damage resulting from improper use or use for other than
the intended purpose.
INFORMATION!
Do a check of the packing list to make sure that you have all the elements given in the order.
Figure 2-1: Scope of delivery
1 Signal converter and antenna (compact version)
2 Quick Start
3 Strap wrench
INFORMATION!
METALLIC HORN AND WAVE GUIDE ANTENNAS
If the device has an antenna extension option, this part is attached to the device if the antenna
extension length, L
ext
≤300 mm / 11.8 ¨ . If L
ext
> 300 mm / 11.8 ¨ , then the antenna extension is
not attached to the device. Obey the assembly procedure on page 23
.

2 INSTALLATION
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2.3 Visual check
If the device is supplied with an FKM/FPM gasket, there is no symbol on the side of the process
connection.
INFORMATION!
Inspect the packaging carefully for damages or signs of rough handling. Report damage to the
carrier and to the local office of the manufacturer.
Figure 2-2: Visual check
1 Device nameplate (for more data, refer to the handbook)
2 Process connection data (size and pressure rating, material reference and heat number)
3 Gasket material data –refer to the illustration that follows
Figure 2-3: Symbols for the supplied gasket material (on the side of the process connection)
1 EPDM
2 Kalrez®6375
3 PFA
INFORMATION!
Look at the device nameplate to ensure that the device is delivered according to your order.
Check for the correct supply voltage printed on the nameplate.

INSTALLATION 2
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2.4 Storage
•Store the device in a dry and dust-free location.
•Keep the converter out of the sunlight.
•Store the device in its original packing.
WARNING!
Do not keep the device in a vertical position. This will damage the antenna and the device will not
measure correctly.
Figure 2-4: Storage conditions
1 When you put the device into storage, do not keep it in a vertical position.
2 Put the device on its side. We recommend that you use the packaging in which it was delivered.
3 Storage temperature range: -50…+85°C/-58…+185°F (min. -40°C/-40°F for devices with the integrated LCD display
option)

2 INSTALLATION
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2.5 How to assemble the PTFE Wave Horn antenna
• Remove the plastic cover from the process connection.
• Remove the 4 wingnuts and screws that attach cardboard packaging.
• Remove the top and the bottom of the cardboard packaging from the PTFE Wave Horn
antenna.
• Attach the Wave Horn antenna to the process connection. Put the end of the antenna that has
a thread in the fitting on the process connection.
Figure 2-5: Equipment needed to assemble the device
1 Signal converter and process connection (compact version) or antenna housing and process connection (remote ver-
sion)
2 PTFE Wave Horn antenna in cardboard packaging. The cardboard packaging is attached with 4 screws and wingnuts.
Part 1: Remove the protective cover from the process connection
Figure 2-6: Part 1: Remove the protective cover from the process connection
Part2: Remove the cardboard packaging from the PTFE Wave Horn antenna
Figure 2-7: Part2: Remove the cardboard packaging from the PTFE Wave Horn antenna
Part3A: Attach the PTFE Wave Horn antenna to the process connection
Figure 2-8: Part3A: Attach the PTFE Wave Horn antenna to the process connection
CAUTION!
Do not use tools to attach the antenna to the process connection.

INSTALLATION 2
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• Turn the PTFE Wave Horn antenna. Tighten with your fingers.
• Make sure that the thread is engaged fully.
iEnd of the procedure.
2.6 Transport
2.7 Pre-installation requirements
•Make sure that there is sufficient space on all sides.
•Protect the signal converter from direct sunlight. If necessary, install the weather protection
accessory.
•Do not subject the signal converter to heavy vibrations.
Part3B: Attach the PTFE Wave Horn antenna to the process connection
Figure 2-9: Part3B: Attach the PTFE Wave Horn antenna to the process connection
CAUTION!
Do not use tools to attach the antenna to the process connection.
WARNING!
• Depending on the version, the device will weight approx. 5...30 kg / 11...66 lb. To carry, use
both hands to lift the device carefully by the converter housing. If necessary, lift the device
with a hoist.
• When handling the device, avoid hard blows, jolts, impact, etc. to prevent damage.
INFORMATION!
Obey the precautions that follow to make sure that the device is correctly installed.

2 INSTALLATION
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2.8 Installation
2.8.1 Pressure and temperature ranges
DANGER!
If the ambient temperature is more than +70
° C / +158 ° F, there is a risk of injury if you touch the
device. Use a protective cover or metallic grid to prevent injury.
Figure 2-10: Pressure and temperature ranges
1 Temperature at the process connection
Non-Ex devices: The temperature range depends on the type of antenna, process connection and the seal material.
Refer to the table that follows.
Devices with Hazardous Location approvals: see supplementary instructions
2 Ambient temperature for operation of the display
-20...+60°C / -4...+140°F
If the ambient temperature is not between these limits, the display screen switches off automatically. The device con-
tinues to operate.
3 Ambient temperature
Non-Ex devices: refer to the ambient temperature / flange temperature graphs in this section
Devices with Hazardous Location approvals: see supplementary instructions
4 Process pressure
Depends on the type of antenna and process connection. Refer to the table that follows.
WARNING!
The process connection temperature range must agree with the temperature limits of the
gasket material.

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For more data on pressure ratings, refer to the "Technical Data" chapter in the handbook.
Antenna type Process
connection
Seal Process connection
temperature
Process pressure
[°C] [°F] [barg] [psig]
PP Wave Horn G1½...2;
1½...2 NPT
—-20...+100 -4...+212 -1...16 -14.5...232
PTFE Wave Horn Flange with
PTFE plate
—-50...+150 -58...+302 -1...40 -14.5...580
Metallic Horn
Wave Guide
Flange Metaglas®
with
FKM/FPM
-40...+200
1
-40...+392
1
-1...40
2
-14.5...580
2
Metaglas®
with
Kalrez®
6375
-20...+250
1
-4...+482
1
-1...40
2
-14.5...580
2
Metaglas®
with PFA
-60...+130
1
-76...+266
1
-1...40
2
-14.5...580
2
Metaglas®
with EPDM
-50...+130
1
-58...+266
1
-1...40
2
-14.5...580
2
1Higher temperature on request
2Higher pressure on request

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PP Wave Horn: compact and remote versions
Ambient temperature / flange temperature, flange and threaded connection, in °C
Figure 2-11: Ambient temperature / flange temperature, flange and threaded connection, in °C
Ambient temperature / flange temperature, flange and threaded connection, in °F
Figure 2-12: Ambient temperature / flange temperature, flange and threaded connection, in °F
1 Maximum ambient temperature, °C
2 Maximum flange temperature, °C
3 Maximum ambient temperature, °F
4 Maximum flange temperature, °F
5 Compact and remote versions of the device with the PP Wave Horn antenna
6 Remote version of the device with the PP Wave Horn antenna

INSTALLATION 2
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PTFE Wave Horn: compact and remote versions
Ambient temperature / flange temperature, flange and threaded connection, in °C
Figure 2-13: Ambient temperature / flange temperature, flange and threaded connection, in °C
Ambient temperature / flange temperature, flange and threaded connection, in °F
Figure 2-14: Ambient temperature / flange temperature, flange and threaded connection, in °F
1 Maximum ambient temperature, °C
2 Maximum flange temperature, °C
3 Maximum ambient temperature, °F
4 Maximum flange temperature, °F
5 Compact and remote versions of the device with the PTFE Wave Horn antenna
6 Compact version of the device with the PTFE Wave Horn antenna
INFORMATION!
When the process temperature is -50
° C/-58 ° F, there is a de-rating for the ambient
temperature. The minimum ambient temperature is -36
° C / -32.8 ° F.

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Metallic Horn and Wave Guide: compact and remote versions
Ambient temperature / flange temperature, flange and threaded connection, in °C
Figure 2-15: Ambient temperature / flange temperature, flange and threaded connection, in °C
Ambient temperature / flange temperature, flange and threaded connection, in °F
Figure 2-16: Ambient temperature / flange temperature, flange and threaded connection, in °F
1 Maximum ambient temperature, °C
2 Maximum flange temperature, °C
3 Maximum ambient temperature, °F
4 Maximum flange temperature, °F
5 Compact and remote versions of the device with the Metallic Horn or Wave Guide antenna
6 Compact version of the device with the Metallic Horn or Wave Guide antenna
INFORMATION!
When the process temperature is -50
° C/-58 ° F and the device has an EPDM gasket, there is a
de-rating for the ambient temperature. The minimum ambient temperature is -35
° C/-31 ° F.

INSTALLATION 2
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Metallic Horn and Wave Guide: compact and remote versions with the high-
temperature (HT) extension
Ambient temperature / flange temperature, flange and threaded connection, in °C
Figure 2-17: Ambient temperature / flange temperature, flange and threaded connection, in °C
Ambient temperature / flange temperature, flange and threaded connection, in °F
Figure 2-18: Ambient temperature / flange temperature, flange and threaded connection, in °F
1 Maximum ambient temperature, °C
2 Maximum flange temperature, °C
3 Maximum ambient temperature, °F
4 Maximum flange temperature, °F
5 Compact and remote versions of the device with the Metallic Horn or Wave Guide antenna, the HT extension and EPDM
and PFA gaskets
6 Compact and remote versions of the device with the Metallic Horn or Wave Guide antenna, the HT extension and a PFA
gasket
INFORMATION!
When the process temperature is -50
° C/-58 ° F and the device has an EPDM gasket, there is a
de-rating for the ambient temperature. The minimum ambient temperature is -39
° C / -38.2 ° F.
When the process temperature is -60
° C/-76 ° F and the device has a PFA gasket, there is a de-
rating for the ambient temperature. The minimum ambient temperature is -37
° C / -34.6 ° F.

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2.8.2 Recommended mounting position
CAUTION!
Follow these recommendations to make sure that the device measures correctly. They have an
effect on the performance of the device.
Figure 2-19: Recommended mounting position for liquids, pastes and slurries
1 Sockets for the PP Wave Horn antenna
2 Nozzles for the PTFE Wave Horn antenna
3 Nozzles for DN150 or DN200 Metallic Horn antennas
4 Nozzles for Wave Guide antennas
5 Tank diameter
6 Minimum distance of the nozzle or socket from the tank wall (depends on the antenna type and size - refer to items
1, 2, 3and 4in this list):
PP/PTFE Wave Horn (1and 2): 1/7 × tank height
Metallic Horn (3): 1/10 × tank height
Wave Guide (4): There is no minimum distance from the Wave Guide antenna to metallic walls and other metal objects
Maximum distance of nozzle from the tank wall (depends on the antenna type and size - refer to items 1, 2and 3in
this list):
PP/PTFE Wave Horn (1and 2): 1/3 × tank diameter
Metallic Horn (3): 1/3 × tank diameter
Wave Guide (4): There is no maximum distance from the Wave Guide antenna to metallic walls and other metal objects
7 Tank height
INFORMATION!
If there is a nozzle on the tank before installation, the nozzle must be a minimum of 200 mm /
7.9
¨ from the tank wall. The tank wall must be flat and there must not be obstacles adjacent to
the nozzle or on the tank wall.

INSTALLATION 2
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Point the device in the correct direction
Figure 2-20: Point the device in the correct direction to get the best performance
Point the tag hole on the housing in the direction of the nearest tank wall.
1 Tag hole
2 Nearest tank wall
Figure 2-21: A maximum of 4 FMCW radar level meters can be operated in a tank
Figure 2-22: Tanks with dish-shaped or conical bottoms
Dish-shaped or conical bottoms have an effect on the measuring range. The device cannot measure to the bottom of the
tank.
1 Axis of radar beam
2 Minimum level reading

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2.8.3 Mounting restrictions
We recommend that you prepare the installation when the tank is empty.
CAUTION!
Follow these recommendations to make sure that the device measures correctly. They have an
effect on the performance of the device.
Mounting restrictions: General data
Figure 2-23: Mounting restrictions: General data
1 Do not tilt the device more than 2°
2 We recommend that you do an empty spectrum recording if there are obstacles in the radar beam (refer to Operation
OperationOperation
Operation).
If necessary, install a bypass chamber or stilling well or use an S-bend antenna extension or an L-bend antenna ex-
tension (the device must be installed on the side of the tank) to move the device away from obstacles.
3 2.5 mm / 0.1¨max. for high-dielectric constant liquids
4 Beam radius (DN80 (3¨) Metallic Horn antenna): increments of 290 mm/m or 3.4¨/ft (16°)
Beam radius (DN100 (4¨) Metallic Horn antenna): increments of 210 mm/m or 2.6¨/ft (12°)
Beam radius (DN150 (6¨) Metallic Horn antenna): increments of 140 mm/m or 1.7¨/ft (8°)
Beam radius (DN200 (8¨) Metallic Horn antenna): increments of 100 mm/m or 1.3¨/ft (6°)
Beam radius (PP Wave Horn and PTFE Wave Horn antenna): increments of 176 mm/m or 2.1¨/ft (10°)

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Obstacles in the tank
Figure 2-24: Obstacles in the tank
Do not put the device directly above obstacles (agitator, support beams, heating tubes etc.). Parasitic signals from obsta-
cles will cause the device to measure incorrectly.
1 Solution 1: Put the device on another process connection away from obstacles
2 Solution 2: Use the same process connection, but also use an S-bend extension
3 Solution 3: Attach the device to the side of the tank and use an L-bend (right angle) extension
CAUTION!
Do not put the device near to the product inlet. If the product that enters the tank touches the
antenna, the device will measure incorrectly. If the product fills the tank directly below the
antenna, the device will also measure incorrectly.
Figure 2-25: Product inlets
1 The device is in the correct position.
2 The device is too near to the product inlet.

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The antenna must project out of the nozzle. If necessary, use an antenna extension. But if the
tank roof is flat and the tank fitting is symmetrical, it is not necessary for the antenna to project
out of the nozzle. Thus, the device can have a larger measuring range.
Devices with Metallic Horn antenna
Figure 2-26: Devices with Metallic Horn antenna
1 If the roof is not flat, the antenna must project out of the nozzle
2 Short tank nozzle
3 Long tank nozzle (device with an antenna extension)
4 If the roof is flat and the tank fitting is symmetrical, it is not necessary for the antenna to project out of the nozzle.
Thus, the device can have a larger measuring range.
Devices with PTFE or PP Wave Horn antenna
Figure 2-27: Devices with PTFE or PP Wave Horn antenna
Recommended height of tank process connection, a = 44...200 mm / 1.7...7.87¨
1 Device with a PTFE Wave Horn antenna and a flange connection. There are antenna extension options available
(100 mm / 4¨, 200 mm / 8¨and 300 mm / 12¨) for long nozzles.
2 Device with a PP Wave Horn antenna and a thread connection
CAUTION!
Do not install devices with Wave Horn antennas on plastic nozzles that have a diameter of
50 mm / 2
¨ .

INSTALLATION 2
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Do an Empty Spectrum recording (refer to Operation
OperationOperation
Operation) to remove parasitic signals with a filter.
Equipment needed:
•Device
•Flange gasket (not supplied)
•Wrench (not supplied)
• Make sure the flange on the nozzle is level.
• Make sure that you use the applicable gasket for the flange dimensions and the process.
• Align the gasket correctly on the flange facing of the nozzle.
• Lower the antenna carefully into the tank.
• Make sure that you point the device in the correct direction. Refer to "Point the device in the
correct direction" in this section.
• Tighten the flange bolts.
iRefer to local rules and regulations for the correct torque to apply to the bolts.
CAUTION!
If there are parasitic signals, the device will not measure correctly. Parasitic signals are caused
by:
• Objects in the tank.
• Sharp corners that are perpendicular to the path of the radar beam.
• Sudden changes in tank diameter in the path of the radar beam.
Requirements for flange connections
Figure 2-28: Flange connection