Honeywell SMARTLINE RM77 Wiring diagram

10 GHz Radar (FMCW) Level Meter
for distance, level, volume, flow, mass and reflection measurement of liquids
Safety manual
Safety manualSafety manual
Safety manual
SMARTLINE
SMARTLINESMARTLINE
SMARTLINE®RM77
RM77RM77
RM77 Supplementary instructions
Supplementary instructionsSupplementary instructions
Supplementary instructions

CONTENTS
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1 Introduction 5
1.1 Scope of the document..................................................................................................... 5
1.2 Revision history ................................................................................................................ 5
1.3 Device description ............................................................................................................ 6
1.4 Related documentation .................................................................................................... 6
1.5 Terms and definitions....................................................................................................... 7
2 System description 9
2.1 Peripheral equipment ...................................................................................................... 9
2.2 Software for use with the device...................................................................................... 9
3 Installation 11
4 Electrical connection 13
5 Start-up 15
5.1 General notes ................................................................................................................. 15
5.2 Device parameters ......................................................................................................... 15
6 Specification of safety function 17
6.1 Preliminary requirements.............................................................................................. 17
6.2 Safety function definition................................................................................................ 17
6.2.1 General notes........................................................................................................................ 17
6.2.2 Limits of application.............................................................................................................. 17
6.2.3 Safety function characteristics ............................................................................................. 18
7 Operation 19
7.1 Conditions of use ............................................................................................................ 19
7.2 Failure state ................................................................................................................... 19
7.3 Operation mode .............................................................................................................. 20
7.4 Error conditions.............................................................................................................. 21
7.5 User parameters ............................................................................................................22
7.5.1 Limits for supervisor menu functions related to antenna configuration ............................ 22
7.5.2 Limits for supervisor menu functions related to device configuration ............................... 23
8 Service 27
8.1 Periodic maintenance..................................................................................................... 27
8.2 Keep the device clean..................................................................................................... 27
8.3 Availability of services .................................................................................................... 27
8.4 Proof tests ...................................................................................................................... 27

CONTENTS
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8.5 Calibration procedure .................................................................................................... 30
8.5.1 General notes........................................................................................................................ 30
8.5.2 Current output check............................................................................................................ 31
8.5.3 Measuring range check (in process conditions) .................................................................. 32
8.6 Troubleshooting.............................................................................................................. 33
8.7 Returning the device to the manufacturer..................................................................... 33
8.7.1 General information.............................................................................................................. 33
8.7.2 Form (for copying) to accompany a returned device............................................................ 34
9 Technical data 35
9.1 General notes ................................................................................................................. 35
9.2 Assumptions ................................................................................................................... 35
9.3 Characteristics for the device safety function ............................................................... 36
9.4 SIL-specific technical data ............................................................................................. 36
9.5 Support for SIL-approved devices.................................................................................. 38
10 Appendix 39
10.1 Start-up report ............................................................................................................. 39
10.2 Proof test report form (for copying) ............................................................................. 40

CONTENTS
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INTRODUCTION 1
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1.1 Scope of the document
This document supplies functional safety data about the device. This data agrees with the
IEC 61508 standard.
1.2 Revision history
WARNING!
The data in this supplement only contains the data applicable to the SIL approval. The technical
data for the standard version in the handbook (document [N1]) shall be valid in its current
version, provided that it is not rendered invalid or replaced by this supplement.
INFORMATION!
Installation, commissioning and maintenance may only be carried out by approved personnel.
Edition Date Description
1April 28, 2015 First issue.

1 INTRODUCTION
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1.3 Device description
This device is a 2-wire level transmitter that uses FMCW (Frequency Modulated Continuous
Wave) / Radar technology. Radar is a non-contact technology. It measures the distance, level,
mass, volume, flow rate and reflection of liquids, pastes and slurries. It is particularly suitable
for the level measurement of corrosive and viscous products.
Measurements are given through a 4...20 mA current output and can be displayed via a DTM
(device type manager) for remote communication or an integrated display screen with wizard-
driven set-up and online help functions. Only the 4...20 mA current output is used as the safety
function.
When the device detects a measurement error, it supplies an output current less than 3.6 mA.
Although the device can be set to a high error value (≥21 mA), some hardware failures can cause
the device to give a low error value (≤3.6 mA). For more data, refer to
Limits for supervisor
menu functions related to device configuration
on page 23 (2.4.2 RANGE I).
Refer also to "Device description" in the handbook (document [N1]).
1.4 Related documentation
INFORMATION!
The manufacturer designed and developed the device for safety integrity level (SIL) 2.
Data for the SIL approval is not taken from field experience (i.e. it is not
“ proven in use ” ) because
this method can give unrealistic data if assumptions are too optimistic.
[N1] SmartLine®RM77 Handbook
[N2] IEC 61508-1 to 7:2010 Functional safety of electrical / electronic / programmable
electronic safety-related systems
[N3] NAMUR Recommendation NE 043 Standardization of the Signal Level for the Failure
Information of Digital Transmitters
[N4] NAMUR Recommendation NE 053 Software of Field Devices and Signal Processing
Devices with Digital Electronics
[N5] SmartLine®RM77 Supplementary Instructions for ATEX applications

INTRODUCTION 1
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1.5 Terms and definitions
DC
D
Diagnostic Coverage of dangerous failures
Firmware Software embedded in the device.
FIT Failure In Time (1×10
-9
failures per hour)
FMCW Frequency-Modulated Continuous-Wave. The measuring principle. For more
data, refer to “Technical Data”in the handbook (document [N1]).
FMEDA Failure Modes, Effects and Diagnostics Analysis
HFT Hardware Fault Tolerance
High demand or
continuous mode Where the frequency of demands for operation made on a safety-related system is greater than one time per year
I/O Input / output
λ
DD
Rate for dangerous detected failure
λ
DU
Rate for dangerous undetected failure
λ
SD
Rate for safe detected failure
λ
SU
Rate for safe undetected failure
Low demand mode Where the frequency of demands for operation made on a safety-related system
is no greater than one time per year
MTBF Mean Time Between Failures
MTTF Mean Time To Failure
MTTR Mean Time To Recovery
PFD
AVG
Average Probability of Failure on Demand
PFH Probability of a dangerous Failure per Hour
Process safety time The time interval between a potentially dangerous failure and an error value
from the current output.
SFF Safe Failure Fraction
SIL Safety Integrity Level
SIS Safety Instrumented System
TBF Tank bottom following. A device measurement mode. For more data, refer to
“Technical Data”in the handbook (document [N1]).
Type A system "Non-complex" system (all failure modes are well defined). For more data, refer
to subsection 7.4.3.1.2 of IEC 61508-2.
Type B system "Complex" system (all failure modes are not well defined). For more data, refer
to subsection 7.4.3.1.2 of IEC 61508-2.
T[Proof] Proof Test Interval
T[Repair] Time to Repair
T[Test] Internal Diagnostics Test Interval
1oo1 1 out of 1 channel architecture (single architecture performs the safety function)
1oo1D 1 out of 1 channel architecture with diagnostics

1 INTRODUCTION
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SYSTEM DESCRIPTION 2
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2.1 Peripheral equipment
You can use the device with the equipment that follows:
•A logic solver that can read 4...20 mA current input and low error alarm signals
•A PC or workstation (this is used only to change parameters)
•A HART
®
Handheld Controller (this is used only to change parameters)
For more data, refer to "Start-up" in the handbook (document [N1]).
2.2 Software for use with the device
You can change device parameters with the software that follows:
•PACTware™
•AMS™Device Manager
For more data, refer to "Start-up" in the handbook (document [N1]).

2 SYSTEM DESCRIPTION
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INSTALLATION 3
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Calibrate the device to make sure that the safety function operates correctly if:
•the device was delivered without an antenna, or
•the device is delivered with an antenna extension, antenna types for stilling wells (DN80,
DN100, DN150 and DN200 Metallic Horn antennas) or the Wave-Guide antenna
This maintenance task must be done and recorded by approved personnel. For more data, refer
to
Calibration procedure on page 30.
For more data, refer to "Installation" in the handbook (document [N1]).
WARNING!
If the device is to agree with the requirements for functional safety given in IEC 61508, you must
obey the installation instructions given in the handbook (document [N1]). The device must be
installed by approved personnel.
If the device is delivered with an antenna extension, antennas for stilling wells (DN80, DN100,
DN150 and DN200 Metallic Horn antennas) or the Wave Guide antenna, refer to the "Installation"
and "Operation" chapters in the handbook. Make sure that the values for menu items 2.3.5
STILLWELL D., 2.3.6 STILLWELL H. and 2.3.7 ANTENNA.EXT are correct.

3 INSTALLATION
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ELECTRICAL CONNECTION 4
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For more data, refer to “Electrical connection”in the handbook (document [N1]).
DANGER!
If the device is for use in potentially explosive atmospheres, you must obey the electrical
connection instructions given in the supplementary instructions for ATEX applications
(document [N5]). We recommend that you use a galvanically-isolated power supply.
WARNING!
If the device is to agree with the requirements for functional safety given in IEC 61508, you must
obey the electrical connection instructions given in the handbook (document [N1]). The device
must be installed by approved personnel.

4 ELECTRICAL CONNECTION
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START-UP 5
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5.1 General notes
Do a check of the device and tank before you energize the device:
•Are all the wetted components (antenna, flange and gaskets) resistant to the product in the
tank?
•Does the information on the signal converter nameplate agree with the operating data? Does
the order code on the nameplate show the SIL option (RM77xxx1xxxxxx or RM77xxx5xxxxxx)?
•Are the process temperature and pressure in the limits for operation of the device?
•Did you correctly install the device on the tank?
•Do the electrical connections agree with the national electrical codes?
Complete the start-up report on page 39.
The manufacturer offers a range of services to support the customer. These services include
repair, maintenance, technical support and training.
5.2 Device parameters
For more data about device configuration, refer to the "Start-up" and "Operation" chapters in the
handbook (document [N1]). Also refer to
User parameters on page 22.
DANGER!
Make sure that the device and the installation agree with the requirements of the Ex certificate
of compliance. For more data, refer to the supplementary instructions for Ex approvals.
DANGER!
Before you energize the device, make sure that the polarity and the supply voltage are correct.
WARNING!
If the device was delivered without an antenna, then do a device calibration to make sure that the
safety function operates correctly. For more data about the procedure, refer to Calibration
procedure on page 30
.
WARNING!
The device agrees with the data given in the customer order. If you change the configuration of
the device after its delivery, the manufacturer does not accept responsibility for the incorrect
configuration of the SIL-approved version of the device. Use device parameters that are
applicable to the application, because conditions at the plant can have an effect on the functional
safety of the measuring system.

5 START-UP
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SPECIFICATION OF SAFETY FUNCTION 6
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6.1 Preliminary requirements
6.2 Safety function definition
6.2.1 General notes
The device contains a safety function that agrees with the international standard IEC 61508
(document [N2]). This safety function operates if there is a large difference between the level
measurement and the level shown as a current output.
If the device finds that there is a difference of more than 2.5%of the 4...20 mA range between the
level measurement and the level shown as a current output, then the current output changes to
an error signal in less than 30 seconds. The safety integrity level of this safety function is SIL2.
6.2.2 Limits of application
This version of the device has the restrictions that follow:
•Distance is measured in Direct mode
Direct modeDirect mode
Direct mode (only one product in the tank is permitted).
•Only the compact version (the signal converter is attached directly to the antenna) can be
used.
•It is a 2-wire loop-powered device.
•HART®communication is not permitted when you use the safety function.
•The process safety time must be more than 33 minutes. This minimum time agrees with
International Standard IEC 61508 Part 2 (document [N2]), section 7.4.4.1.4.
•Use DN80 and DN100 Metallic Horn antenna only in stilling wells as specified in the handbook
(document [N1]).
For more data, refer to
SIL-specific technical data on page 36.
WARNING!
The data in this supplement only contains the data applicable to the SIL approval. The technical
data for the standard version in the handbook (document [N1]) shall be valid in its current
version, provided that it is not rendered invalid or replaced by this supplement.
INFORMATION!
If menu item 2.4.5 ERROR DELAY = 0 s, then the current output changes to an error signal in less
than 30 seconds. If menu item 2.4.5 ERROR DELAY is more than 0 seconds, then the current
output changes to an error signal in 30 seconds + 2.4.5 ERROR DELAY.
After the device finds an error, it will try to measure the level of the product again. If the device
can measure the level, the error signal will change to the measurement signal. If the device
continues to have the same problem, the output current will change to the error signal. If, after
30 seconds, the output current is not 3.6 mA then the error is recorded as a "dangerous
undetected failure" in the FMEDA analysis. If, after 30 seconds, the output current is 3.6 mA then
the error is recorded as a "dangerous detected failure" in the FMEDA analysis.

6 SPECIFICATION OF SAFETY FUNCTION
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6.2.3 Safety function characteristics
The safety function uses only a 4...20 mA analog output signal to measure the level and give the
device status. The analog output signal has an accuracy of ±2.5% of the 4...20 mA range.
For more data about the top dead zone, refer to the"Operation" and "Technical Data" chapters in
the handbook (document [N1]).
If the device finds a fault:
If a logic solver is used, it must use low error alarm signals (current input ≤3.6 mA) to set itself
to a fail-safe condition.
WARNING!
The device must have the applicable options and settings for the application. The ambient and
process conditions must agree with the technical data given in the handbook (document [N1])
and this document (safety manual). You must obey the installation instructions given in the
handbook (document [N1]).
CAUTION!
We recommend that the 4 and 20 mA limits of the measuring range are not in the top dead zone
(100 mm / 3.9
¨ below the antenna).
The shape of the tank bottom can have a large effect on the accuracy when the tank is almost
empty. We recommend that device is not used to measure the liquid when it is less than 300 mm
from the bottom of the tank.
Function input
Function inputFunction input
Function input None
Function output
Function outputFunction output
Function output 4…20 mA
Error signal
Error signalError signal
Error signal ≤3.6 mA

OPERATION 7
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7.1 Conditions of use
The configuration is protected with a password. For more data on password protection and
device configuration, refer to the “Operation”chapter in the handbook (document [N1]).
7.2 Failure state
For any type of safe or dangerous detected failure, the device sets the current output to less than
3.6 mA. Although this value can also be set to a high error value (≥21 mA), some hardware
failures will always cause the device to give a low error value (≤3.6 mA). Thus, the output signal
for the fail-safe condition is less than 3.6 mA. For more data, refer to
Limits for supervisor menu
functions related to device configuration
on page 23 (2.4.2 RANGE I).
WARNING!
Only approved personnel can change device settings. Keep a report of changes to the device
settings. These reports must include the date, the menu item (e.g. 2.3.1 TANK HEIGHT), the old
parameter and the new parameter.

7 OPERATION
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7.3 Operation mode
In operational conditions, the device continuously measures the distance between the tank
connecting flange face / thread stop and the surface of the product.
The operation mode of the device is shown in the flow chart that follows:
1 Initial state (start the device / new measurement)
2 Make sure that sufficient energy is available
3 Is there sufficient energy?
3a No. There is not sufficient energy.
3b Yes. There is sufficient energy.
4 The device does an auto-diagnostic check at
intervals of 24 hours
5 Is there an error condition?
5a Yes. There is an error condition.
5b No. There is not an error condition.
6 Distance measurement
7 Is a correct measurement available?
7a No. A correct measurement is not available.
7b Yes. A correct measurement is available.
8 Error mode state
9 Current output (distance value or a derived
measurement value)
10 Is the current output setting correct?
10a No. The current output setting is incorrect.
10b Yes. The current output setting is correct.