Bin Master NCR-80 User manual

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

NCR-80 Four-wire 4-20 mA/HART
925-0332 Rev B
2
Contents
Contents
1 About this document ...................................................................................................4
1.1 Function ..............................................................................................................4
1.2 Target group ........................................................................................................4
1.3 Symbols used......................................................................................................4
2 For your safety .............................................................................................................5
2.1 Authorized personnel .........................................................................................5
2.2 Appropriate use...................................................................................................5
2.3 Warning about incorrect use ...............................................................................5
2.4 General safety instructions..................................................................................5
2.5 CE conformity......................................................................................................6
2.6 NAMUR recommendations .................................................................................6
2.7 Radio license for Europe.....................................................................................6
2.8 Radio license for USA .........................................................................................6
2.9 Radio license for Canada....................................................................................7
2.10 Environmental instructions ..................................................................................8
3 Product description .....................................................................................................9
3.1 Conguration.......................................................................................................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 versions, plastic horn antenna.............................................................14
4.3 Mounting preparations, mounting strap...............................................................16
4.4 Mounting instructions ..........................................................................................17
5 Connecting to power supply .......................................................................................28
5.1 Preparing the connection ....................................................................................28
5.3 Wiring plan, double chamber housing.................................................................31
5.5 Switch-on phase .......................................................................................................32
6 Set up the sensor with the display and adjustment module ...................................33
6.1 Insert display and adjustment module.................................................................33
6.2 Adjustment system..............................................................................................34
6.3 Measured value indication – Selection national language ..................................35
6.4 Parameter adjustment - Quick setup...................................................................35

NCR-80 Four-wire 4-20 mA/HART
925-0332 Rev B
Contents
3
6.5 Parameter adjustment - Extended adjustment....................................................36
6.6 Saving the parameter adjustment data ...............................................................49
7 Setting up sensor and Modbus interface with PACTware ........................................50
7.1 Connect the PC...................................................................................................50
7.2 Parameter adjustment.........................................................................................51
7.4 Saving the parameter adjustment data ...............................................................52
8 Set up with other systems ..........................................................................................53
8.1 DD adjustment programs ....................................................................................53
8.2 Field Communicator 375, 475 .............................................................................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 ....................................................................61
10 Removal ........................................................................................................................63
10.1 Removal steps ...................................................................................................63
10.2 Disposal ..............................................................................................................63
11 Supplement ..................................................................................................................64
11.1 Technical data .....................................................................................................64
11.2 Radio astronomy stations....................................................................................72
11.8 Dimensions .........................................................................................................72
INDEX ............................................................................................................................81
Safety instructions for Ex areas
Take note of the Ex specic safety instructions for Ex applications.
These instructions are attached as documents to each instrument
with Ex approval and are part of the operating instructions manual.

NCR-80 Four-wire 4-20 mA/HART
925-0332 Rev B
1 About this document
4
1 About this document
1.1 Function
This operating instructions manual provides all the information you need for mounting, connec-
tion and setup as well as important instructions for maintenance and fault rectication. Please
read this information before putting the instrument into operation and keep this manual accessi-
ble in the immediate vicinity of the device.
1.2 Target group
This operating instructions manual is directed to trained specialist personnel. The contents of
this manual should be made available to these personnel 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.
Warning: If this warning is ignored, injury to persons and/or serious damage to the in-
strument can result.
Danger: If this warning is ignored, serious injury to persons and/or destruction of the
instrument can result.
Ex applications
This symbol indicates special instructions for Ex applications.
List
The dot set in front indicates a list with no implied sequence.
Action
This arrow indicates a single action.
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 accumula-
tors.
●
1

NCR-80 Four-wire 4-20 mA/HART
925-0332 Rev B
2 For your safety
5
2 For your safety
2.1 Authorized personnel
All operations described in this operating instructions manual must be carried out only by trained
specialist personnel authorized by the plant operator.
During work on and with the device the required personal protective equipment must always be
worn.
2.2 Appropriate use
Operational reliability is ensured only if the instrument is properly used according to the speci-
cations in the operating instructions manual as well as possible supplementary instructions.
2.3 Warning about incorrect use
Inappropriate or incorrect use of the instrument can give rise to application-specic hazards,
e.g. vessel overll or damage to system components through incorrect mounting or adjustment.
Also the protective characteristics of the instrument can be inuenced.
2.4 General safety instructions
This is a state-of-the-art instrument complying with all prevailing regulations and guidelines. The
instrument must only be operated in a technically awless and reliable condition. The operator is
responsible for the trouble-free operation of the instrument.
During the entire duration of use, the user is obliged to determine the compliance of the nec-
essary occupational safety measures with the current valid rules and regulations and also take
note of new regulations.
The safety instructions in this operating instructions manual, the national installation standards
as well as the valid safety regulations and accident prevention rules must be observed by the
user.
For safety and warranty reasons, any invasive work on the device beyond that described in the
operating instructions manual may be carried out only by personnel authorised by the manufac-
turer. Arbitrary conversions or modications are explicitly forbidden.
The safety approval markings and safety tips on the device must also be observed.
Depending on the instrument version, the emitting frequencies are in the C, K or W band range.
The low emitting frequencies are far below the internationally approved limit values. When used
correctly, the device poses no danger to health.

NCR-80 Four-wire 4-20 mA/HART
925-0332 Rev B
2 For your safety
6
2.5 CE conformity
The device fulls the legal requirements of the applicable EC guidelines. By a󰀩xing the CE
marking, we conrm successful testing of the product.
2.6 NAMUR recommendations
NAMUR is the automation technology user association in the process industry in Germany. The
published NAMUR recommendations are accepted as the standard in eld instrumentation.
The device fulls the requirements of the following NAMUR recommendations:
●NE 21 – Electromagnetic compatibility of equipment
●NE 53 – Compatibility of eld devices and display/adjustment components
●NE 107 – Self-monitoring and diagnosis of eld devices
For further information see www.namur.de.
2.7 Radio license for Europe
The instrument meets the LPR (Level Probing Radar) radio standard EN 302729-1/2.
It is approved for unrestricted use inside and outside of closed vessels in countries of the EU
and EFTA that have implemented this standard.
For operation outside of closed vessels, the following conditions must be fullled:
●The installation must be carried out by trained qualied personnel
●The instrument must be stationary mounted and the antenna directed vertically downward
●The mounting location must be at least 4 km away from radio astronomy stations, unless
special permission was granted by the responsible national approval authority
●When installed within 4 to 40 km of a radio astronomy station, the instrument must not be
mounted higher than 15 m above the ground
You can nd a list of the respective radio astronomy stations in chapter “Supplement”.
2.8 Radio license for USA
This approval is only valid for USA. Hence the following text is only available in the English lan-
guage.
This device complies with Part 15 of the FCC Rules. Operation is subject to the following two
conditions:
●This device may not cause interference, and
●This device must accept any interference, including interference that may cause undesired
operation of the device
This device is approved for unrestricted use only inside closed, stationary vessels made of
metal or concrete.
For operation outside of closed vessels, the following conditions must be fullled:

NCR-80 Four-wire 4-20 mA/HART
925-0332 Rev B
2 For your safety
7
●This device shall be installed and maintained to ensure a vertically downward orientation of
the transmit antenna’s main beam. Furthermore, the use of any mechanism that does not al-
low the main beam of the transmitter to be mounted vertically downward is prohibited.
●This device shall be installed only at xed locations. The LPR device shall not operate while
being moved or while inside a moving container.
●Hand-held applications are prohibited.
●Marketing to residential consumers is prohibited.
Changes or modications not expressly approved by the manufacturer could void the user’s au-
thority to operate this equipment.
2.9 Radio license for Canada
This approval is only valid for Canada. Hence the following texts are only available in the En-
glish/French language.
This device complies with Industry Canada license-exempt RSS standard(s). Operation is sub-
ject to the following conditions:
●This device may not cause interference, and
●This device must accept any interference, including interference that may cause undesired
operation of the device
●Installation of LPR device shall be done by trained installers, in strict compliance with the
manufacturer’s instructions
●The use of this device is on a “no-interference, no-protection” basis. That is, the user shall
accept operations of high-powered radar in the same frequency band which may interfere
with or damage this device. 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 vertically downward orientation of
the transmit antenna´s main beam
●This device shall be installed only at xed locations. The LPR device shall not operate while
beeing moved or while inside a moving container
Le présent appareil est conforme aux CNR d’Industrie Canada applicables aux appareils radio
exempts de licence. L’exploitation est autorisée aux deux conditions suivantes:
●L’appareil ne doit pas produire de brouillage , et
●L’utilisateur de l’appareil doit accepter tout brouillage radioélectrique subi, même si le brouil-
lage est susceptible d’en compromettre le fonctionnement
●L’installation de l’appareil LPR doit être faite par des installateurs expérimentés dans le re-
spect des instructions du fabricant
●Cet appareil s’utilise en “non-interférence, non-protection”. Ceci veut dire que l’utilisateur ac-
cepte le fonctionnement de radars de
haute puissance agissant dans la même bande de fréquence et pouvant interférer avec cet
appareil ou l’endommager. Toutefois, les appareils de test de niveau qui interfèrent avec les
opérations primaires de prise de licence devront être retirés aux frais de l’utilisateur.
●Cet appareil doit être installé et entretenu de manière à assurer une orientation verticale
vers le bas du faisceau principal de l’antenne de transmission • Cet appareil ne doit être in-
stallé qu’à des emplacements xes. L’appareil LPR ne doit pas fonctionner pendant qu’il se
déplace ou se trouve dans un conteneur en mouvement

NCR-80 Four-wire 4-20 mA/HART
925-0332 Rev B
2 For your safety
8
2.10 Environmental instructions
Protection of the environment is one of our most important duties. That is why we have intro-
duced an environment management system with the goal of continuously improving company
environmental protection. The environment management system is certied according to DIN
EN ISO 14001.
Please help us full this obligation by observing the environmental instructions in this manual:
●Chapter “Packaging, transport and storage”
●Chapter “Disposal”

NCR-80 Four-wire 4-20 mA/HART
925-0332 Rev B
3 Production description
9
3 Product description
3.1 Conguration
The type label contains the most important data for identication and use of the instrument:
Fig. 1: Layout of the type label
1 Instrument type
2 Product code
3 Approvals
4 Voltage supply and signal output, electronics
5 Protection rating
6 Measuring range
7 Process and ambient temperature, process pressure
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 numbers, instrument documentation
15 Reminder to observe the instrument documentation
The type label contains the serial number of the instrument. With it you can nd the following
instrument data on our homepage:
●Product code (HTML)
●Delivery date (HTML)
●Order-specic instrument features (HTML)
●Operating instructions and quick setup guide at the time of shipment (PDF)
●Order-specic sensor data for an electronics exchange (XML)

NCR-80 Four-wire 4-20 mA/HART
925-0332 Rev B
3 Production description
10
This operating instructions manual applies to the following instrument versions:
●Hardware version from 1.0.0
●Software version from 1.1.0
The scope of delivery encompasses:
●Radar sensor
●Hexagon socket wrench (for instruments with swivel holder)
●Documentation
- Quick setup guide
- Instructions for optional instrument features
- Ex-specic “Safety instructions” (with Ex versions)
- If necessary, further certicates
●DVD “Software”, included therein
- PACTware/DTM Collection
- Driver software
Information:
In this operating instructions manual, the optional instrument features are described. The re-
spective scope of delivery results from the order specication.
3.2 Principle of operation
The NCR-80 is a radar sensor for continuous level measurement of bulk solids even under the
most di󰀩cult process conditions and in very large measuring ranges.
It is ideal for use in high, slender silos with poorly reecting bulk solids such as y-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 distance measurement through frequency shifting
with an especially small beam angle.
The instrument is available with di󰀨erent antenna systems and accessories for virtually all appli-
cations and processes:
●Plastic horn antenna or metal-jacketed lens antenna
●Optional or integrated rinsing air connection
●Swivelling holder with seal against the process
The instrument emits a continuous radar signal through its antenna. This signal is frequency
modulated in the form of a sawtooth wave. The emitted signal is reected by the medium and
received by the antenna as an echo.
The frequency of the received signal always deviates from the actual emitting frequency. The
frequency di󰀨erence is proportional to the distance and thus to the lling height. This di󰀨erence
is calculated via special algorithms in the sensor electronics. The determined lling height is
then converted into a corresponding output signal and outputted as the measured value.

NCR-80 Four-wire 4-20 mA/HART
925-0332 Rev B
3 Production description
11
3.3 Packaging, transport and storage
Your instrument was protected by packaging during transport. Its capacity to handle normal
loads during transport is assured by a test based on ISO 4180.
The packaging of standard instruments consists of environment friendly, recyclable cardboard.
For special versions, PE foam or PE foil is also used. Dispose of the packaging material via
specialised recycling companies.
Transport must be carried out in due consideration of the notes on the transport packaging. Non-
observance of these instructions can cause damage to the device.
The delivery must be checked for completeness and possible transit damage immediately at re-
ceipt. Ascertained transit damage or concealed defects must be appropriately dealt with.
Up to the time of installation, the packages must be left closed and stored according to the ori-
entation and storage markings on the outside.
Unless otherwise indicated, the packages must be stored only under the following conditions:
●Not 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 - Technical data - Ambient con-
ditions”
●Relative humidity 20 … 85 %
3.4 Accessories and replacement parts
The display and adjustment module BinDisc is used for measured value indication, adjustment
and diagnosis. It can be inserted into the sensor and removed at any time.
You can nd further information in the operating instructions “Display and adjustment module
BinDisc”.
The protective cover protects the sensor housing against soiling and intense heat from solar
radiation.
Screwed anges are available in di󰀨erent versions according to the following standards: DIN
2501, EN 1092-1, BS 10, ASME B 16.5, JIS B 2210-1984, GOST 12821-80.
For mounting the instrument with plastic horn antenna to a socket, two ange versions are avail-
able: the combi compression ange and the adapter ange
You can nd additional information in chapter “Mounting” of this operating instruction.
A mounting strap is available for mounting the instrument with plastic horn antenna to the wall or
ceiling.
You can nd additional information in chapter “Mounting” of this operating instruction.

NCR-80 Four-wire 4-20 mA/HART
925-0332 Rev B
3 Production description
12
The supplementary electronics is a replacement part for sensors with 4-20 mA/HART - four-
wire.
You can nd further information in the operating instructions “Supplementary electronics for 4-20
mA/HART - four-wire”

NCR-80 Four-wire 4-20 mA/HART
925-0332 Rev B
4 Mounting
13
4 Mounting
4.1 General instructions
Protect your instrument against moisture ingress through the following measures:
●Use the recommended cable (see chapter “Connecting to power supply”)
●Tighten the cable gland
●Loop the connection cable downward in front of the cable gland
This applies particularly to:
●Outdoor mounting
●Installations in areas where high humidity is expected (e.g. through cleaning processes)
●Installations on cooled or heated vessels
Make sure that all parts of the instrument exposed to the process are suitable for the existing
process conditions.
These are mainly:
●Active measuring component
●Process tting
●Process seal
Process conditions are particularly:
●Process pressure
●Process temperature
●Chemical properties of the medium
●Abrasion and mechanical inuences
You can nd 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 glands are screwed in at the
factory. They are sealed with plastic plugs as transport protection.
You have to remove these plugs before electrical connection.
NPT thread
In the case of instrument housings with self-sealing NPT threads, it is not possible to have the
cable entries screwed in at the factory. The free openings for the cable glands are therefore
covered with red dust protection caps as transport protection. The dust protection caps do not
provide su󰀩cient protection against moisture.
Prior to setup you have to replace these protective caps with approved cable glands or close the
openings with suitable blind plugs.
The mounting position and orientation of the sensor must take into account the limitations in
chapter “For your safety”, “Radio approval for USA” “Radio approval for Canada” of this operat-
ing instructions.

NCR-80 Four-wire 4-20 mA/HART
925-0332 Rev B
4 Mounting
14
4.2 Mounting versions, plastic horn antenna
The optional mounting strap allows simple mounting of the instrument on a wall, ceiling or boom.
Especially in the case of open vessels, this is a simple and e󰀨ective way to align 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 allows swivelling the sensor up to 180° for optimal orientation and rotating for optimal con-
nection.
Fig. 2: Ceiling mounting via the mounting strap with length 300 mm
Fig. 3: Rotating with ceil mounting
As an alternative the strap mounting is carried out horizontally or obliquely.

NCR-80 Four-wire 4-20 mA/HART
925-0332 Rev B
4 Mounting
15
Fig. 5: Wall mounting with inclined wall via the mounting strap with length 300 mm
Two versions are available for mounting the instrument on a socket:
●Combi compression ange tting to DN 80 (ASME 3” and JIS 80)
●Adapter ange from DN 100 (ASME 4” or JIS 100)
The combi compression ange is suitable for di󰀨erent ange standards and can be used for
simple applications. It comes unassembled and not sealed against the radar sensor and can
thus only be used unpressurized. It can be retrotted on instruments with single chamber hous-
ing, retrotting to a double chamber housing is not possible.
Fig. 4: Wall mounting horizontally via the mounting strap with length 170 mm

NCR-80 Four-wire 4-20 mA/HART
925-0332 Rev B
4 Mounting
16
Fig. 6: Combi compression ange
1 Combi compression ange
The adapter ange is available in di󰀨erent ange sizes. It is permanently connected with the
radar sensor and sealed.
Fig. 7: Adapter ange
1 Connection screw
2 Adapter ange
3 Process seal
You can nd 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 di󰀨erent variants of screwing the strap to the sensor, see following illustration:

NCR-80 Four-wire 4-20 mA/HART
925-0332 Rev B
4 Mounting
17
Fig. 8: Mounting strap for screwing to the sensor
1 For angle of inclination in steps
2 For angle of inclination, innitely variable
Depending on the selected variant, the sensor can be rotated in the strap:
●Single chamber housing
- Angle of inclination in three steps 0°, 90° and 180°
- Angle of inclination 180°, innitely variable
●Double chamber housing
- Angle of inclination 90°, innitely variable
- Angle 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 these waves.
The polarization direction is marked by a nose on the housing, see following drawing:
Fig. 9: Position of the polarization
1 Nose for marking the direction of polarization
Information:
When the housing is rotated, the direction of polarization changes and hence the inuence
of the false echo on the measured value. Please keep this in mind when mounting or making
changes later.
Mount the sensor at least 200 mm (7.874 in) away from the vessel wall.

NCR-80 Four-wire 4-20 mA/HART
925-0332 Rev B
4 Mounting
18
Fig. 10: Mounting the radar sensor on the vessel top
If you cannot maintain this distance, you should carry out a false signal suppression during
setup. This applies particularly if buildup on the vessel wall is expected. In such cases, we rec-
ommend repeating the false signal suppression at a later date with existing buildup.
The instrument should not be mounted too close to the inowing medium, as the radar signal
could be disrupted.
Silo with lling from top
The optimal mounting position is opposite the lling aperture. To avoid heavy soiling, the dis-
tance to any lter or dust exhauster should be as large as possible.
Fig. 11: Mounting of the radar sensor with inowing medium
Silo with lateral lling
In bulk solids silos with lateral pneumatic lling the instrument should not be mounted above the
lling stream, as the radar signal will be disrupted. The optimal mounting position is to the side
of the lling aperture. To avoid heavy soiling, the distance to any lter or dust exhauster should
be as large as possible.

NCR-80 Four-wire 4-20 mA/HART
925-0332 Rev B
4 Mounting
19
Fig. 12: Mounting of the radar sensor with inowing medium
Information:
The mounting socket should be as short as possible and its end rounded. This reduces false
echoes from the vessel mounting socket.
Fig. 13: Recommended socket mounting
If the medium has good reective properties, you can also mount the NCR-80 on longer sock-
ets. Approximate socket heights are shown in the following illustration.
Information:
When mounting on longer sockets, we recommend carrying out a false signal suppression (see
chapter “Parameter adjustment”).

NCR-80 Four-wire 4-20 mA/HART
925-0332 Rev B
4 Mounting
20
The below charts specify the max. pipe socket length h depending on the diameter d.
Socket diameter d Socket length h
80 mm ≤ 200 mm
100 mm ≤ 300 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 reaches the lowest level in the vessel. In a cylindrical silo with conical
outlet, the sensor is mounted anywhere from one third to one half of the vessel radius from the
outside wall (see following drawing).