KROHNE OPTIWAVE 5200 C/F User manual

OPTIWAVE 5200 C/F Handbook
Non-contact Radar (FMCW) Level Meter
for distance, level and volume measurement of liquids, pastes and slurries
© KROHNE 03/2012 - 4001904901 - HB OPTIWAVE 5200 R01 en

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::
: IMPRINT :::::::::::::::::::::::::::::::::::::
All rights reserved. It is prohibited to reproduce this documentation, or any part thereof, without the prior written authorisation of
KROHNE Messtechnik GmbH.
Subject to change without notice.
Copyright 2012 by
KROHNE Messtechnik GmbH - Ludwig-Krohne-Str. 5 - 47058 Duisburg (Germany)

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OPTIWAVE 5200 C/F CONTENTS
1 Safety instructions 6
1.1 Software history ............................................................................................................... 6
1.2 Intended use ..................................................................................................................... 6
1.3 Certification ...................................................................................................................... 6
1.4 Radio approvals................................................................................................................ 7
1.4.1 European Union (EU)............................................................................................................... 7
1.4.2 U.S.A. and Canada................................................................................................................... 8
1.5 Safety instructions from the manufacturer ..................................................................... 8
1.5.1 Copyright and data protection ................................................................................................ 8
1.5.2 Disclaimer ............................................................................................................................... 9
1.5.3 Product liability and warranty .............................................................................................. 10
1.5.4 Information concerning the documentation......................................................................... 10
1.5.5 Warnings and symbols used ................................................................................................. 11
1.6 Safety instructions for the operator ............................................................................... 11
2 Device description 12
2.1 Scope of delivery............................................................................................................. 12
2.2 Device description .......................................................................................................... 13
2.3 Nameplates .................................................................................................................... 15
2.3.1 Nameplate (examples) .......................................................................................................... 15
3 Installation 16
3.1 Notes on installation ...................................................................................................... 16
3.2 Storage ........................................................................................................................... 16
3.3 Transport........................................................................................................................ 17
3.4 Pre-installation requirements ....................................................................................... 17
3.5 Installation ...................................................................................................................... 18
3.5.1 Pressure and temperature ranges ....................................................................................... 18
3.5.2 Mounting position (theoretical data for nozzle position)...................................................... 20
3.5.3 Mounting restrictions............................................................................................................ 23
3.5.4 Standpipes (stilling wells and bypass chambers) ................................................................ 27
3.5.5 How to turn or remove the signal converter ........................................................................ 31
3.5.6 How to open the weather protection .................................................................................... 32
4 Electrical connections 33
4.1 Safety instructions.......................................................................................................... 33
4.2 Electrical installation: compact version ........................................................................ 33
4.2.1 Non-Ex devices ..................................................................................................................... 35
4.2.2 Devices for hazardous locations ........................................................................................... 35
4.2.3 PROFIBUS PA ........................................................................................................................ 35
4.2.4 FOUNDATION Fieldbus......................................................................................................... 35

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CONTENTS
OPTIWAVE 5200 C/F
4.3 Remote device version ................................................................................................... 36
4.3.1 General notes ........................................................................................................................ 36
4.3.2 Electrical installation: remote version ................................................................................. 36
4.3.3 Requirements for communication cables supplied by the customer.................................. 36
4.3.4 How to prepare a communication cable supplied by the customer .................................... 38
4.3.5 How to connect the communication cable to the device ...................................................... 39
4.4 Protection category ........................................................................................................ 43
4.5 Networks ........................................................................................................................ 44
4.5.1 General information .............................................................................................................. 44
4.5.2 Point-to-point connection ..................................................................................................... 44
4.5.3 Multi-drop networks ............................................................................................................. 45
4.5.4 Fieldbus networks................................................................................................................. 46
5 Start-up 48
5.1 How to start the device ................................................................................................... 48
5.1.1 Start-up checklist ................................................................................................................. 48
5.1.2 How to start the device ......................................................................................................... 48
5.2 Operating concept .......................................................................................................... 48
5.3 Digital display screen ..................................................................................................... 49
5.3.1 Local display screen layout .................................................................................................. 49
5.3.2 Keypad buttons ..................................................................................................................... 50
5.4 Remote communicationwith PACTware™ .................................................................... 50
5.5 Remote communication with the AMS™ Device Manager............................................. 51
6 Operation 52
6.1 User modes .................................................................................................................... 52
6.2 Normal mode.................................................................................................................. 52
6.3 Configuration mode ........................................................................................................ 53
6.3.1 General notes ........................................................................................................................ 53
6.3.2 How to get access to the commissioning menu ................................................................... 54
6.3.3 Keypad functions................................................................................................................... 55
6.3.4 Menu overview ...................................................................................................................... 58
6.3.5 Function description ............................................................................................................. 58
6.4 Further information on device configuration ................................................................. 65
6.4.1 Protection of the device settings .......................................................................................... 65
6.4.2 Network configuration .......................................................................................................... 66
6.4.3 Distance measurement ........................................................................................................ 67
6.4.4 Level measurement .............................................................................................................. 68
6.4.5 How to configure the device to measure volume or mass................................................... 68
6.4.6 How to make a filter to remove radar signal interference .................................................. 69
6.5 Status and error messages ............................................................................................ 71
6.5.1 Device status (markers)........................................................................................................ 71
6.5.2 Device status (NE 107 symbols)............................................................................................ 72
6.5.3 Error handling ....................................................................................................................... 73
7 Service 76
7.1 Periodic maintenance..................................................................................................... 76
7.2 Service warranty............................................................................................................. 76

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7.3 Spare parts availability ................................................................................................... 76
7.4 Availabilityof services.................................................................................................... 76
7.5 Returning the device to the manufacturer..................................................................... 77
7.5.1 General information .............................................................................................................. 77
7.5.2 Form (for copying) to accompany a returned device............................................................ 78
7.6 Disposal .......................................................................................................................... 78
8 Technical data 79
8.1 Measuring principle........................................................................................................ 79
8.2 Technical data................................................................................................................. 81
8.3 Minimum power supply voltage ..................................................................................... 86
8.4 Pressure ratings............................................................................................................. 87
8.5 Antenna selection ........................................................................................................... 89
8.6 Dimensions and Weight.................................................................................................. 90
9 Description of HART interface 99
9.1 General description ........................................................................................................ 99
9.2 Software history ............................................................................................................. 99
9.3 Connection variants...................................................................................................... 100
9.3.1 Point-to-Point connection - analogue / digital mode......................................................... 100
9.3.2 Multi-Drop connection (2-wire connection) ....................................................................... 100
9.4 HART® device variables ............................................................................................... 101
9.5 Field Communicator375 (FC 375)................................................................................ 101
9.5.1 Installation .......................................................................................................................... 101
9.5.2 Operation ............................................................................................................................. 102
9.6 Asset Management Solutions (AMS) ............................................................................ 102
9.6.1 Installation .......................................................................................................................... 102
9.6.2 Operation ............................................................................................................................. 102
9.6.3 Parameter for the basic configuration ............................................................................... 102
9.7 Field Device Tool / Device Type Manager (FDT / DTM) ................................................ 102
9.7.1 Installation .......................................................................................................................... 103
9.7.2 Operation ............................................................................................................................. 103
9.8 HART® menu tree for Basic-DD .................................................................................. 103
9.8.1 Overview Basic-DD menu tree (positions in menu tree) .................................................... 103
9.8.2 Basic-DD menu tree (details for settings).......................................................................... 104
9.9 HART® menu tree for AMS .......................................................................................... 104
9.9.1 Overview AMS menu tree (positions in menu tree) ............................................................ 105
9.9.2 AMS menu tree (details for settings).................................................................................. 105
10 Appendix 107
10.1 Order code .................................................................................................................. 107
10.2 Glossary ...................................................................................................................... 112
11 Notes 115

1 SAFETY INSTRUCTIONS
OPTIWAVE 5200 C/F
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1.1 Software history
Introduction
Signal converter
Mth./year
Hardware
Firmware
Test version for field tests
03/2012
OPTIWAVE 5200
x.xx
Series version
03/2012
OPTIWAVE 5200
x.xx
1.2 Intended use
CAUTION!
Responsibility forthe use of the measuring devices with regard to suitability, intended use and
corrosion resistance ofthe 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.
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.
1.3 Certification
DANGER!
For devices used in hazardous areas, additional safety notes apply; please refer to theEx
documentation.
In accordance with the commitment to customer service and safety, the device described in this document
meets the following safety requirements:
• Electromagnetic Compatibility (EMC) Directive 2004/108/EC in conjunction with EN 61326-1 (2006).
• Radio Equipment and Telecommunications Terminal Equipment (R & TTE) Directive
1999/05/EC in conjunction with ETSI EN 302 372 (2006). For more data, refer to European
Union (EU) on page 7.
• Low-Voltage Directive 2006/95/EC in conjunction with EN 61010-1 (2001).
All devices are based on the CE marking and meet the requirements of NAMUR Guideline NE 21, NE 43, NE 53 and NE 107

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OPTIWAVE 5200 C/F SAFETY INSTRUCTIONS 1
1.4 Radio approvals
1.4.1 European Union (EU)
LEGAL NOTICE!
This level transmitter is intended for installation in closed tanks. It meets the requirements of
theR & TTE (Radio Equipment and Telecommunications Terminal Equipment) Directive
1999/05/EC for use in the member countries of the EU.
An industry agreement includes approval for use of the frequency band (8.6...10.4 GHz) in
industrial environments.
According to article 6.4of the R&TTE Directive, the product is marked bytheCE sign + notified
body number (0682) + Class II identifier (= alert sign).
Refer to EN 302372 for installation conditions.
Figure 1-1: Radio approval information on the nameplate
1 CE sign
2 Notified bodynumber (0682 = CETECOM)
3 Class II identifier
According to ETSI EN 302 372 (2006-04), the radiated power outside a metallic tank is less than
-30 dBm.
Refer also to the radio approval certificate on the internet site. The radio approval report is given on the CD-ROM supplied with the
device.

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1 SAFETY INSTRUCTIONS
OPTIWAVE 5200 C/F
1.4.2 U.S.A. and Canada
LEGAL NOTICE!
This device complies with Part 15 ofthe FCC Rules and with RSS-210 of Industry Canada.
Operation is subject to the following two conditions:
1. This device may not cause harmful interference, and
2. This device must accept any interference received, including interference which may cause un- desired operation.
Changes or modifications made to this equipment not expressly approved by themanufacturer may void the FCC and IC authorizations
to operate this equipment.
This legal information is shownon a label on the rear side of the device.
The radio approval report is given on the CD-ROM supplied with the device. You can also download it from the internet site.
1.5 Safety instructions from the manufacturer
1.5.1 Copyright and data protection
The contents of this document have been created with great care. Nevertheless, we provide no guarantee that the contents are
correct, complete or up-to-date.
The contents and works in this document are subject to copyright. Contributions from third parties are identified as such.
Reproduction, processing, dissemination and any type of use beyond what is permitted under copyright requires written
authorisation from the respective author and/or the manufacturer.
The manufacturertries always to observe the copyrights of others, and to draw on works created in-house or works in the public domain.
The collection of personal data (such as names, street addresses or e-mail addresses) in the manufacturer's documents is always
on a voluntary basis whenever possible. Whenever feasible, it is always possible to make use of the offerings and services without
providing any personal data.
We draw your attention to the fact that data transmission over the Internet (e.g. when communicating by e-mail) may involve gaps
in security. It is not possible to protect such data completely against access by third parties.
We hereby expressly prohibit the use of the contact data published as part of our duty to publish an imprint for the purpose of sending
us any advertising or informational materials that we have not expressly requested.

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OPTIWAVE 5200 C/F SAFETY INSTRUCTIONS 1
1.5.2 Disclaimer
The manufacturer will not be liable for any damage of any kind by using its product, including, but not limited to direct, indirect or
incidental and consequential damages.
This disclaimer does not apply in case the manufacturer has acted on purpose or with gross negligence. In the event any applicable law
does not allow such limitations on impliedwarranties or the exclusion of limitation of certain damages, you may, if such law applies to
you, not be subject to some or all of the above disclaimer, exclusions or limitations.
Any product purchased from the manufacturer is warranted in accordance with the relevant product documentation and our
Terms and Conditions of Sale.
The manufacturer reserves the right to alter the content of its documents, including this disclaimer in any way, at any time, for any
reason, without prior notification, and will not be liable in any way for possible consequences of such changes.

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1 SAFETY INSTRUCTIONS
OPTIWAVE 5200 C/F
1.5.5 Warnings and symbols used
Safety warnings are indicated by the following symbols.
DANGER!
This information refers to the immediate danger when working with electricity.
DANGER!
This warning refers to the immediate danger of burns caused by heat orhotsurfaces.
DANGER!
This warning refers to the immediate danger when using this device in a hazardous atmosphere.
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 thedevice
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 ofthe operator's plant.
CAUTION!
Disregarding these instructions can result in damage to the device orto parts oftheoperator's
plant.
INFORMATION!
These instructions contain important information forthe handling ofthedevice.
LEGAL NOTICE!
This note contains information on statutory directives and standards.
•HANDLING
This symbol designates all instructions for actions to be carried out by the operator in the specified sequence.
i RESULT
This symbol refers to all important consequences of the previous actions.
1.6 Safety instructions for the operator
WARNING!
In general, devices from the manufacturer may only be installed, commissioned, operated and
maintained by properly trained and authorized personnel.
This document is provided to help you establish operating conditions, which will permit safe and
efficient use of this device.

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OPTIWAVE 5200 C/F DEVICE DESCRIPTION 2
2.2 Device description
The FMCW radar level transmitter is designed to measure the distance, level, mass, volume and reflectivity of liquids, pastes and
slurries. Radar level transmitters use an antenna to guide a signal to the surface of the measured product. Radar is a non-contact
technology. It is particularly suitable for the level measurement of corrosive products.
The signal converter of the device has 2 versions: Compact version
The signal converter is attached directly to the process connection and antenna.
Figure 2-2:Compact version
Remote version
The signal converter is installed away from the process connection and antenna (for example: at the bottom of a tank). The
communication cable between the signal converter and the antenna has a maximum length of 100 m / 328 ft.
Figure 2-3: Remote version

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2 DEVICE DESCRIPTION
OPTIWAVE 5200 C/F
The converter can be ordered with horizontal or vertical housing options for easy access to the device terminals and the optional
display.
Figure 2-4: Antenna options
1 PP Wave Horn antenna
2 PTFE Wave Horn antenna
3 Metallic Horn antenna (available sizes: DN80, DN100, DN150 and DN200)
4 Wave Guide antenna (Length options: 1...6 m / 3.28...19.68 ft, in increments of 0.5 m / 1.64 ft)
Antenna extensions are available for PTFE Wave Horn and Metallic Horn antenna options for difficult installation conditions.
A distance piece option is available for high-temperature applications (if the process connection temperature is more than +150°C /
+302°F).
Figure 2-5: Distance piece option
For more data, refer to Technical data on page 79. The device has a set-up wizard. You usually will not need this document to install,
set up and operate the device.

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OPTIWAVE 5200 C/F INSTALLATION 3
3.5 Installation
3.5.1 Pressure and temperature ranges
Figure 3-2:Pressure and temperature ranges
1 Flange temperature
Non-Exdevices:Depends on the type of antenna, process connectionand the seal material. Refer to the table that fol- lows.
Ex devices: see supplementaryoperating 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: -40...+80°C / -40...+176°F
Ex devices: see supplementaryoperating instructions
4 Process pressure
Depends on the type of antenna and process connection. Refer to the table that follows.
Antenna type
Process
connection
Seal
Process connection
temperature
Process pressure
[°C]
[°F]
[barg]
[psig]
PP Wave Horn
G 1½;
1½ NPT
-
-20...+100
-4...+212
-1...16
1
-14.5...232
1
PTFE Wave Horn
Flange with
PTFE plate
-
-50...+150
-58...+302
-1...34
1
-14.5...493
1
Metallic Horn
Wave Guide
Flange
Metaglas® with
FKM/FPM
-40...+200
-40...+392
-1...40
1
-14.5...580
1
Metaglas® with
Kalrez® 6375
-20...+250
-4...+482
-1...40
1
-14.5...580
1
Metaglas® with
PFA
-60...+150
-76...+302
-1...40
1
-14.5...580
1
Metaglas® with
EPDM
-50...+130
-58...+266
-1...40
1
-14.5...580
1
1 Higher pressures on request

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3 INSTALLATION
OPTIWAVE 5200 C/F
Figure 3-3: Ambient temperature / flange temperature,flange and threaded connection, in °C
Figure 3-4: 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, °C
5 PP Wave Horn antenna
6 PTFE Wave Horn and Wave Guide antennas. Metallic Horn antenna (standard temperature version).
7 Metallic Horn antenna (high-temperature version)
For pressure rating data, refer to Pressure ratings on page 87.

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OPTIWAVE 5200 C/F INSTALLATION 3
3.5.2 Mounting position (theoretical data for nozzle position)
CAUTION!
Follow these recommendations to make sure that the device measures correctly.
Figure 3-5: Recommendedmounting position for liquids, pastes and slurries
1 Sockets for the PP Wave Horn antenna
2 Nozzles for the PTFE Wave Horn antenna
3 Nozzles or sockets for DN150 or DN200 Metallic Horn antennas
4 Nozzles or sockets 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 and 3 in this list):
1 1/7 × tank height
2 1/10 × tank height
3 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, 2 and 3 in this list):
1 1/3 × tank diameter
2 1/3 × tank height
3 There is no maximum distance from the Wave Guide antenna to metallic walls and other metal objects.
7 Tank height
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.

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3 INSTALLATION
OPTIWAVE 5200 C/F
Figure 3-6: Product inlets
1 The device is in the correct position.
2 The device is too near to the product inlet.
Point the device in the correct direction
Figure 3-7: 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 3-8: A maximum of 4 FMCW radar level meters can be operated in a tank

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OPTIWAVE 5200 C/F INSTALLATION 3
Figure 3-9: Tanks with tapered (conical etc.) bottoms
Tapered (conical etc.) bottoms have an effect on the measuring range. The device cannot measure to the bottom of the tank.
1 Radar beam
2 Minimum level reading

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3 INSTALLATION
OPTIWAVE 5200 C/F
3.5.3 Mounting restrictions
CAUTION!
Follow these recommendations to make sure that the device measures correctly.
We recommend that you prepare the installation when the tank is empty.
Mounting restrictions: General data
Figure 3-10: Mounting restrictions: General data
1 Do not tilt the device more than 2°
2 If there are too many obstacles in the radar beam, do an empty spectrum scan (refer to Operation) to remove parasitic signals with a filter. If necessary, install a
bypass chamber or stilling well or use an S-shaped extension or a 90° bend extension (the device must be installed on the side of the tank) to move the device away
from obstacles.
3 5 mm / 0.2¨ max. for high-dielectric constant liquids
4 Radius of radar footprint (Wave Guide antenna or DN80 and DN100Metallic Horn antenna):no beam angle. The device transmits the radar signal along a tube of constant
diameter.
Radius of radar footprint (DN150 Metallic Horn antenna): increments of 140 mm/m or 1.7¨/ft (8°) Radius of radar footprint (DN200
Metallic Horn antenna): increments of 100 mm/m or 1.3¨/ft (6°)
Radius of radar footprint (PP Wave Horn and PTFE Wave Horn antenna): increments of 176 mm/m or 2.1¨/ft (10°)

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OPTIWAVE 5200 C/F INSTALLATION 3
Obstacles in the tank
Figure 3-11: 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-shaped extension
3 Solution 3: Attach the device to the side of the tank and use a 90° bend extension
Devices with Metallic Horn antenna
Figure 3-12: 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 (symmetrical tank fitting), it is not necessary for the antenna to project out of the nozzle
The antenna must project out of the nozzle. If necessary, use an antenna extension. If the tank fitting is symmetrical, it is not
necessary for the antenna to project out of the nozzle.

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3 INSTALLATION
OPTIWAVE 5200 C/F
Devices with plastic Wave Horn antenna (PTFE, PP)
Figure 3-13: Devices with plastic Wave Horn antenna
a ≤44 mm / 1.7¨; b ≤40 mm / 1.6¨
1 Device with a PTFE Wave Horn antenna and a flange connection
2 Device with a PP Wave Horn antenna and a thread connection
Risk of mutliple reflections
Figure 3-14: Risk of mutliple reflections
1 Do not install on the centerline of a manhole cover
2 If possible, do not install a nozzle on the tank centerline
CAUTION!
If there are parasitic signals, the device will not measure correctly.
Parasitic signals are caused by:
• Objects in thetank.
• Sharp corners that are perpendicular to the path of thebeam.
• Sudden changes in tank diameter in the path of the beam.