Keiki MRG-10 User manual

Document No.: KF05-001G
MRG-10
User’s Guide
User’s GuideUser’s Guide
User’s Guide

( i )
Safety Cautions
The caution message shown in the User’s Guide is defined as follows:
!
!!
!
CAUTION
Indicates that incorrect usage may result in death or
serious injury to the operator
!
!!
!
CAUTION
Indicates that incorrect usage may result in injury to the
operator or damage to the equipment
.
Warning
Caution
Warning label
Warning label
WARNING
!
Don't open
lower nut if
tank is
pressurised
or contains
hazardaous
product.

( ii )
Introduction
This User’s Guide includes detailed explanations of MRG-10 safety cautions,
installation, configuration, and troubleshooting Users should carefully read this manual
before operation to ensure an adequate understanding of the equipment
Proper use of the User’s Guide
The following points must be observed:
(1) Carefully read the User’s Guide
The contents of the User’s Guide are very important Carefully read the entire
manual
(2) Store the User’s Guide in safe location
The User’s Guide is very important for the operation of the equipment Store the
manual in a safe and accessible location The storage location and person
responsible for maintaining the Guide should be considered carefully
(3) Ensure that the User’s Guide is supplied to the operator of the equipment
The representative or dealer of this equipment must supply this User’s Guide to
the user who will actually operate the equipment
(4) The User’s Guide should be replaced if it is lost
If the User’s Guide is lost, contact the representative listed on the back cover A
new manual may be purchased
Restrictions and cautions necessary to maintain the equipment
The following items must be observed to ensure that the equipment is maintained
properly Refer to the pages corresponding to each topic for details The
corresponding pages are shown in ( ) brackets
(1) Do not drop unit or subject unit to impact
(2) Use the unit in appropriate temperature environments
(Refer: p 6-2 Operating condition)
(3) Use the unit under appropriate process temperature and pressure
(Refer: p 6-2 Operating condition)
(4) Always use an appropriate power supply
(Refer: p 6-1 Power Supply voltage)
(5) Do not loosen union nut when tank is pressured
(Refer: p 2-5 Mounting the cone antenna)

( iii )
Contents
About this manual
1 Product Description 1-1
1 1 Features 1-1
1 2 Measuring principle 1-1
1 3 MRG-10 measuring system 1-2
2 Mechanical Installation 2-1
2 1 Requirements 2-1
2 2 Dimensions 2-4
2 3 Tools 2-5
2 4 Mounting Cone Antenna 2-6
2 5 Mounting Rod Antenna 2-8
2 6 Installation Hints 2-10
3 Electrical Installation 3-1
3 1 Connection of MRG-10 3-1
3 2 Cables 3-2
3 3 Load 3-2
3 4 Power Supply 3-2
3 5 Grounding 3-2
3 6 Arrester replacement 3-3
4 Configuration method 4-1
4 1 Display Panel & Key SW 4-1
5 Configuration 5-1
5 1 Basic Settings 5-1
5 2 Negative level point measurement 5-3
5 3 Avoiding Disturbance Echoes 5-3
5 4 Volume calculation 5-7
5 5 Analog value compensation 5-8
5 6 Measuring value compensation 5-8
5 7 Bottom recognition 5-9
5 8 Other 5-9
5 9 Pipe antenna setting 5-9
5 10 Key Parameter List 5-11
6 Technical Information 6-1
7 Troubleshooting 7-1
Appendix
Control Drawing for ATEX
Safety Manual

( iv )
About this manual
This User’s Guide provides information about mechanical and electrical
installation of the MRG-10 It also describes how to configure the unit
The main purpose of the book is to serve as a guide to installing and operating
the MRG-10 It is not intended to cover service tasks such as changing circuit
boards or internal software
Chapter 1 reviews some basic concepts of radar based level gauging
Chapter 2 describes how to assemble a gauge and how to mount it onto a tank
Chapter 3 describes electrical installation
Chapter 4 describes configuration method by key SW
Chapter 5 describes how to configure for tank conditions
Chapter 6 provides technical information
Chapter 7 lists some typical problems that might occur and suggestions on how
to solve them

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10 Product Description
Product DescriptionProduct Description
Product Description
1-1
1 1 Product Description
The MRG-10 is a loop-powered radar level gauge, which can be installed easily in a variety of
applications. The MRG-10 employs a non-contact radar level gauging principle based on pulsed
microwave signals and is suitable for level measurement in applications such as li uids, pastes and
slurries.
MRG-10 uses 5.8GHz low power pulsed microwave. It provides good measurement stability,
because propagation of microwaves is not affected by temperature, pressure or gas conditions in
tank.
1.1 Features
MRG-10
MRG-10 needs only a two-wire cable for power supply and output signal.
Communication
MRG-10 incorporates HART
®
protocol function which superimposes a digital output signal on the
4-20mA current output signal. Settings can be made by a HART
®
communicator or PC-based setup
software.
Volume calculation function
Volume calculation function is based level measurement of the remaining li uid in the tank and the
formula takes into consideration three tank configurations - spherical, vertical cylinder and horizontal
cylinder. There is also an applicable user-defined 20-step table.
1.2 Measuring principle
The MRG-10 level gauge utilizes the time-of-flight
measurement principle involving short microwave pulses.
Installed at the top of tanks, it emits short microwave pulses
toward li uids or pastes in the tank. Reflected microwave signals
from the surface are received by the antenna, and processed by
electronics. The time from transmission to reception is
determined by the microprocessor and converted as distance
from the transmitter to the li uid surface (ullage) with output of
the calculated level from the measured ullage (Level = Tank
Height – Ullage).
Ullage
Level
Li uid Surface
Bottom
Tank
Height

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1.3 MRG-10 measuring system
MRG-10 can be configured with its onboard 4 key switches, a handheld terminal or remotely from a
personal computer via a modem.
The MRG-10 is connected to a PLC or power supply unit.
Example Connection from power supply unit to MRG-10 mounted in non-hazardous area
HART
modem
MRG-10
Voltage
source
Load
>250Ω
4...20mA
2

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2 Mechanical Installation
2.1 Requirements
2.1.1 Cone antenna
Mounting position
Do not mount the transmitter at the center of the tank or close to the tank wall as this may reduce the
measuring range or accuracy and make the transmitter more sensitive to echo disturbances. We
recommend that the transmitter be mounted so that the antenna tip is located at least 0. m from the tank
wall.
Socket requirements
The antenna tip should extend past the nozzle (10 mm or
more).
If the antenna tip is located inside the nozzle, echo
disturbances may be generated which will negatively affect
measurement performance.
Free space requirements
The transmitter should be mounted so that no obstacles are
present in the radar beam.
Obstacles in the radar beam may reduce the measuring
range.
Half Power Beam Width.
Diameter of radiated area (m).
Antenna
Tip
Half-power
beam width
10mm
or more
00mm
or more
Antenna Type Half Power Beam Width
(Degrees)
4” cone 34
” cone 22
8” cone 17
Rod 30
Distance
5m
10m
15m
20m
Antenna Type
Distance[m]
4”cone
”cone
8”cone
Rod
5m 2.9 1.9 1.5 2.7
10m 5.8 3.8 3.0 5.4
15m 8.8 5.7 4.4 8.0
20m 11.7 7. 5.9 10.7

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2.1.2 Rod antenna
Mounting position
Do not mount the transmitter at the
center of the tank or too close to the tank
wall as this may reduce the measuring
range or accuracy and make the
transmitter more sensitive to echo
disturbances. We recommend that the
transmitter be mounted so that the
antenna tip is located at least 0. m from
the tank wall.
Socket requirements
There are 2 inactive zone lengths
(100mm and 250mm). Noise
reflections from the nozzle are avoided in
these zones. Nozzle height must be
less than the antenna extension.
Free space requirements
The transmitter should be mounted so that no obstacles are present in the radar beam. Obstacles in the
radar beam may reduce the measuring range.
2.1.3 Key factors for measurement
1. The strength of the microwave reflection from the liquid surface is proportional to the dielectric constant
Er (Epsilon) of the target fluid. The higher the fluid’s dielectric constant, the wider the measurable range.
2. A larger antenna enables more stable measurement and a wider measuring range.
3. Compared to calm fluid surfaces, measuring ranges of turbulent surfaces are reduced due to poorer
reflection.
4. Deposit buildup on the antenna, foaming on liquid surfaces, powder granules in air suspension and
other interior tank conditions may affect measuring range and performance.
5. Obstructions in the microwave radiating area or target fluid surface areas less than the radiating area
will reduce microwave reflection and decrease and narrow the measurable range.
Inactive Zone
NPT 1 1/2
Height of nozzle
10mm or more

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Maximum measuring distance
Maximum measurement distance is determined by antenna type, dielectric constant of the product and
product surface conditions. Please refer to the table below. These values are rough estimates, and are
strongly influenced by the measuring conditions.
Calm surface
4"Cone 6"Cone 8"Cone
0
10
20
0
10
20
0
10
20
0
10
20
a b c a b c a b c
(m) Rod
a b c
Tur ulent surface
4"Cone 6"Cone 8"Cone
0
10
20
0
10
20
0
10
20
0
10
20
a b c a b c a b c
(m) Rod
a b c
a) Dielectric constant 1.9 - 4.0 Oil, gasoline and other hydrocarbons,
petrochemicals
) Dielectric constant 4.0 - 10 Alcohol, concentrated acids, and organic
solvents
c) Dielectric constant >10 Water-based liquids, dilute acids and acetone

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2-4
514
* 250
176
226
148
NPT 1 1/2
176
226
148
NPT 1 1/2
364
*100
148
φ38
Rod Short
Rod Long* : Extended Part
148
238
17
10
22
34
φ215 φ2 5
φ188
φ140
φ92
φ154
φ52
4" Cone Antenna
6" Cone Antenna
8" Cone Antenna
2.2 Dimensions
Weights
MRG-10(except antenna) 2.5 kg
4” Cone antenna 0.8 kg
” Cone antenna 1.2 kg
8” Cone antenna 1.8 kg
MRG-10 with rod antenna short 3.4 kg
MRG-10 with rod antenna long 3.7 kg
*: Part extension

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Flange
The MRG-10 gauge is mounted with a flange of the following specifications :
Cone antenna Rod antenna
Maximum thickness : 29mm (ANSI Class-150 8” ).
2.3 Tools
The following tools are needed for installation of MRG-10:
• Hexagon socket screw keys(-4)
• Adjustable wrench (for locking nut)
• Pipe wrench (for neck of cone antenna)
• Screwdriver (-) width 3mm
NPT 1 ½
Threaded

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2.4 Mounting the cone antenna
Warning
Do not damage the PTFE seal and O-ring during mounting. Damaged seals may cause gas leakage
when the MRG-10 is installed on pressurized tanks.
1. Check and confirm the parts described below which are required for installation of the cone antenna.
2. Mount the flange on top of the cone plate.
Secure the flange with the locking nut.
Make sure that the nut is fitted tightly to the flange.
Warning
Make sure that the bottom side of the flange is flat and all
parts are clean and dry as problems related to this may
result in gas leakage when the MRG-10 is installed on
pressurized tanks.
Transmitter
Locking
Nut
Cone
Antenna
O-ring
Seal
Union Nut
Set Screw(M4)
Flange
Nuts & Bolts
Gasket
65
φ59
Locking
Nut
Flange
Cone
Antenna
Note!
No gasket on
top of this plate.
Cone Plate

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Transmitter
Union Nut
Set Screw
O-ring
Sleeve
Antenna
Adapter
Warning
Make sure that the O-ring inside of the sleeve is clean as
improper sealing may lead to gas leakage problems
when the MRG-10 is installed on pressurized tanks.
3. Carefully insert the antenna adapter of the transmitter into the sleeve.
Secure the antenna adapter with the union nut.
Make sure that the antenna adapter fits inside
of the cone antenna.
Secure the union nut with the set screw.
4. Place the gasket on the tank nozzle.
Carefully fit the flange and the cone antenna
on the tank nozzle.
Tighten the assembly with the screws and nuts.
Warning
Do not loosen the union nut when the tank is pressurized.
Gasket
Tank
Nozzle

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2.5 Mounting rod antenna
Warning
Do not damage antenna. Damaged antenna may cause gas leakage if the MRG-10 is installed on a
pressurized tank.
NPT 1 1/2
Flange
（NPT 1 1/2
）
Gasket
Nuts & Bolts

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2-9
Fix rod antenna to flange
Place the gasket on the tank nozzle.
Carefully fit the flange and the cone antenna on the tank nozzle.
Tighten the assembly with the screws and nuts.
NPT 1 1/2
Flange
NPT 1 1/2
Nuts & Bolts
Gasket
Tank nozzle

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2.6 Installation Hints
Obstacles in the radar beam may generate signal reflections (false echoes) which may be larger than the
reflected signals from the surface of the liquid. The MRG-10 may erroneously interpret such false echoes
as reflections from the liquid surface. To reduce the influence of false echoes, attenuate such signals
using the following methods.
1. Thin pipe or ladder
Microwave reflections from elongated metal objects
such as thin pipes or ladders rungs are largest when
the axis of such objects are in parallel with the
electric field. The orientation of the electric field
generated by the MRG-10 is as shown in the right
figure.
Mount the MRG-10 so that the electric field is not in
parallel with the axis of the obstacle which reduces
the affect of the false echo emitted by it.
Ladder rungs Ladder rungs
Pipe
Pipe
E
EE
E
A-plane
A-plane
Top view
Pipe
Pipe
E
EE
E
A-plane
A-plane
Top view
Correct Wrong
Ladder
E
EE
E
A-plane
A-plane
Top view
E
EE
E
A-plane
A-plane
Top view
Correct Wrong
Ladder Ladder
Ladder
Cone AntennaFront Cover
E
EE
E

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2. Shoulders and Struts
Install a reflector (flat metal plate) above
the obstacle as shown in the figure.
Warning
Measuring range may be reduced if there are obstacles
in the radar beam.
3. Center of the Tank
When the MRG is installed at the center of the tank, measurement may be adversely affected or
become unstable because of microwave side-lobes (non-main beams). Thus center-of-tank
installations should be avoided.
4. Narrow Channel
In case of channel applications, install the MRG so the axis of the electric field is at right angle to the
channel wall to avoid influences from edge reflections off channel walls and the liquid surface.
Correct Wrong
Shoulder
Correct Wrong
Shoulder
Reflector

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5. Tank Installation
For round tank applications, install the MRG so the axis of the electric field is oriented 45 degrees to
the tank wall to avoid influences from edge reflections off channel walls and the liquid surface.
For flat wall tank applications, install the MRG so the axis of the electric field is perpendicular to the
tank wall.
Round wall tank Flat wall tank
. Open area Installation
This is an example of an open area installation.
In these types of applications, install the MRG so the axis of the microwave beam is perpendicular to the
liquid surface.
Fixing bracket
Beam area

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3 Electrical Installation
3.1 Connection of MRG-10
!
!!
!
Caution
Handle the front cover with care as the glass panel and gasket are removable.
he glass panel and gasket are fixed in place when the cover is screwed onto the
case and tightened.
he gasket provides sealing between the housing and front cover and as such the
front cover should be securely and firmly screwed onto the case.
1. Unscrew and remove the front cover.
2. Pass the cable through the entry and connect it to the terminal block.
3. Connect the shield to the ground terminal.
4. Replace the front cover and firmly screw it onto the case.
Ground
Terminal
Terminal block
+
+
-
-
Ground
Terminal
Keys
LCD
+
+
-
-
HAR
modem Power
Supply
Unit
erminal block
250Ω
-
+
MRG-10
Housing
R