KROHNE OPTIWAVE 6300 C User manual

Non-contact Radar (FMCW) Level Meter
for distance, level and volume measurement of solids
OPTIWAVE 6300 C Handbook
© KROHNE 04/2009 - 4000547001 - HB OPTIWAVE 6300 R01 en

All rights reserved. It is prohibited to reproduce this documentation, or any part thereof, without
the prior written authorisation of KROHNE Messtechnik GmbH & Co. KG.
Subject to change without notice.
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Copyright 2009 by
KROHNE Messtechnik GmbH & Co. KG - Ludwig-Krohne-Straße 5 - 47058 Duisburg
:IMPRINT ::::::::::::::::::::::::::::::::::

CONTENTS
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1 Safety instructions 6
1.1 Intended use ..................................................................................................................... 6
1.2 Certification ...................................................................................................................... 6
1.3 Electromagnetic compatibility ......................................................................................... 6
1.4 Radio approvals ................................................................................................................ 7
1.4.1 European Union (EU)............................................................................................................... 7
1.4.2 U.S.A........................................................................................................................................ 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 ................................................................................................ 9
1.5.4 Information concerning the documentation........................................................................... 9
1.5.5 Warnings and symbols used................................................................................................. 10
1.6 Safety instructions for the operator............................................................................... 10
2 Device description 11
2.1 Scope of delivery............................................................................................................. 11
2.2 Device description .......................................................................................................... 13
2.3 Visual Check ................................................................................................................... 14
2.4 Nameplates .................................................................................................................... 15
2.4.1 Non-Ex nameplate ................................................................................................................ 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 How to prepare the silo before you install the device ................................................... 18
3.5.1 Pressure and temperature ranges....................................................................................... 18
3.5.2 Theoretical data for nozzle position .....................................................................................19
3.6 Installation recommendations for solids....................................................................... 21
3.7 How to install the device on the silo .............................................................................. 22
3.7.1 How to install a device with a flange connection ................................................................. 22
3.7.2 How to install a device with a threaded connection............................................................. 24
3.7.3 How to attach antenna extensions....................................................................................... 26
3.7.4 How to turn or remove the signal converter ........................................................................ 27
3.7.5 How to attach the weather protection to the device............................................................. 28
3.7.6 How to open the weather protection .................................................................................... 29
4 Electrical connections 30
4.1 Safety instructions.......................................................................................................... 30
4.2 Electrical installation: outputs 1 and 2 .......................................................................... 30
4.2.1 Non-Ex................................................................................................................................... 31
4.2.2 Ex i ......................................................................................................................................... 31
4.2.3 Ex d........................................................................................................................................ 31
4.3 Protection category ........................................................................................................32

CONTENTS
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4.4 Networks ........................................................................................................................ 33
4.4.1 General information.............................................................................................................. 33
4.4.2 Point-to-point connection..................................................................................................... 33
4.4.3 Multi-drop networks ............................................................................................................. 34
5 Start-up 35
5.1 Start-up checklist........................................................................................................... 35
5.2 Operating concept ..........................................................................................................35
5.3 Digital display screen .....................................................................................................36
5.3.1 Local display screen layout .................................................................................................. 36
5.3.2 Push-button functions .......................................................................................................... 36
5.3.3 Help screens ......................................................................................................................... 36
5.3.4 How to start the device ......................................................................................................... 37
5.4 Remote communication with PACTware™ .................................................................... 37
5.5 Remote communication with the AMS™ Device Manager............................................. 38
6 Operation 39
6.1 User modes .................................................................................................................... 39
6.2 Operator mode................................................................................................................ 39
6.3 Supervisor mode ............................................................................................................41
6.3.1 General notes........................................................................................................................ 41
6.3.2 How to get access to the supervisor mode .......................................................................... 41
6.3.3 Menu overview ...................................................................................................................... 42
6.3.4 Push-button functions .......................................................................................................... 43
6.3.5 Function description ............................................................................................................. 46
6.4 Further information on device configuration................................................................. 57
6.4.1 Quick Links............................................................................................................................ 57
6.4.2 Protection of the device settings .......................................................................................... 58
6.4.3 Network configuration .......................................................................................................... 59
6.4.4 Linearisation ......................................................................................................................... 60
6.4.5 Distance measurement ........................................................................................................ 60
6.4.6 Level measurement .............................................................................................................. 61
6.4.7 How to configure the device to measure volume or mass................................................... 63
6.4.8 How to use the empty spectrum function to filter parasite signals.................................... 64
6.4.9 How to measure correctly in silos with curved or conical bottoms..................................... 65
6.5 Service mode .................................................................................................................. 66
6.6 Errors.............................................................................................................................. 67
6.6.1 General information.............................................................................................................. 67
6.6.2 Error handling....................................................................................................................... 70
7 Service 73
7.1 Periodic maintenance..................................................................................................... 73
7.2 How to clean the top surface of the device .................................................................... 73
7.3 How to clean horn antennas under process conditions ................................................ 74
7.4 How to replace device components ............................................................................... 75
7.4.1 Service warranty ................................................................................................................... 75
7.4.2 Replacement of the display cover.........................................................................................76
7.4.3 Replacement of the back end and microwave unit .............................................................. 78

CONTENTS
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7.4.4 Replacement of the terminal module................................................................................... 80
7.5 Spare parts availability...................................................................................................82
7.5.1 List of spare parts................................................................................................................. 82
7.5.2 List of accessories ................................................................................................................ 84
7.6 Availability of services .................................................................................................... 86
7.7 Returning the device to the manufacturer..................................................................... 86
7.7.1 General information.............................................................................................................. 86
7.7.2 Form (for copying) to accompany a returned device............................................................ 87
7.8 Disposal .......................................................................................................................... 87
8 Technical data 88
8.1 Measuring principle........................................................................................................88
8.2 Technical data................................................................................................................. 89
8.3 Antenna selection........................................................................................................... 93
8.4 Dimensions and weights ................................................................................................ 94
9 Appendix 100
9.1 Order form.................................................................................................................... 100
9.1.1 Device data .......................................................................................................................... 100
9.1.2 Rating data .......................................................................................................................... 100
9.1.3 Contact data ........................................................................................................................ 100
9.2 Glossary ........................................................................................................................ 101

1SAFETY INSTRUCTIONS
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1.1 Intended use
This radar level transmitter measures distance, level, mass, volume and reflectivity of
granulates and powders.
It can be installed on silos and bunkers.
1.2 Certification
In accordance with the commitment to customer service and safety, the device
described in this document meets the following safety requirements:
•EMC Directive 2004 / 108 / EC and 93 / 68 / EEC in conjunction with EN 61326-1 (2006).
•Low-Voltage Directives 2006 / 95 / EC and 93 / 68 / EEC in conjunction with
EN 61010-1 (2001).
All devices are based on the CE marking and meet the requirements of NAMUR Guideline
NE 21 / 04.
1.3 Electromagnetic compatibility
The device design agrees with European Standard EN 61326-1.
You can install the device on open-air tanks and tanks that are not made of metal. But refer to
Radio approvals on page 7. This agrees with Immunity and Emissions requirements for industrial
environments.
DANGER!
For devices used in hazardous areas, additional safety notes apply; please refer to the Ex
documentation.
INFORMATION!
Device operation agrees with residential-class (class B) immunity and emissions requirements if
the antenna is used in a closed silo made of metal.

SAFETY INSTRUCTIONS 1
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1.4 Radio approvals
1.4.1 European Union (EU)
According to EN 300 440 (2001-09), the radiated power outside a metallic silo 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.
LEGAL NOTICE!
This level transmitter is intended for installation in closed metallic tanks. It
meets the requirements of the R & TTE (Radio Equipment and Telecommunications Terminal
Equipment)
Directive 1999/05/EC for use in the member countries of the EU.
The device operates using a frequency band (24 GHz - 26 GHz) that is not harmonized within the
EU.
According to article 6.4 of the R&TTE Directive, the product is marked by the CE sign + notified
body number (0682) + Class II identifier (= alert sign).
Figure 1-1: Radio approval information on the nameplate
1 CE sign
2 Notified body number (0682 = CETECOM)
3 Class II identifier

1SAFETY INSTRUCTIONS
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1.4.2 U.S.A.
This legal information is shown on 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 German 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 manufacturer tries 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.
LEGAL NOTICE!
This device complies with Part 15 of the FCC Rules. 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.

SAFETY INSTRUCTIONS 1
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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, incidental, punitive 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 implied warranties
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.
1.5.3 Product liability and warranty
The operator shall bear responsibility for the suitability of the device for the specific purpose.
The manufacturer accepts no liability for the consequences of misuse by the operator. Improper
installation and operation of the devices (systems) will cause the warranty to be void. The
respective "Standard Terms and Conditions" which form the basis for the sales contract shall
also apply.
1.5.4 Information concerning the documentation
To prevent any injury to the user or damage to the device it is essential that you read the
information in this document and observe applicable national standards, safety requirements
and accident prevention regulations.
If this document is not in your native language and if you have any problems understanding the
text, we advise you to contact your local office for assistance. The manufacturer can not accept
responsibility for any damage or injury caused by misunderstanding of the information in this
document.
This document is provided to help you establish operating conditions, which will permit safe and
efficient use of this device. Special considerations and precautions are also described in the
document, which appear in the form of underneath icons.

1SAFETY INSTRUCTIONS
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1.5.5 Warnings and symbols used
Safety warnings are indicated by the following symbols.
• HANDLING
This symbol designates all instructions for actions to be carried out by the operator in the
specified sequence.
iRESULT
This symbol refers to all important consequences of the previous actions.
1.6 Safety instructions for the operator
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 or hot surfaces.
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 the device
or parts of the operator's plant.
WARNING!
Disregarding this safety warning, even if only in part, poses the risk of serious health problems.
There is also the risk of damaging the device or parts of the operator's plant.
CAUTION!
Disregarding these instructions can result in damage to the device or to parts of the operator's
plant.
INFORMATION!
These instructions contain important information for the handling of the device.
LEGAL NOTICE!
This note contains information on statutory directives and standards.
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.

DEVICE DESCRIPTION 2
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2.1 Scope of delivery
INFORMATION!
Inspect the cartons carefully for damage or signs of rough handling. Report damage to the
carrier and to the local office of the manufacturer.
INFORMATION!
Check the packing list to check if you received completely all that you ordered.
INFORMATION!
Look at the device nameplate to ensure that the device is delivered according to your order.
Check for the correct supply voltage printed on the nameplate.
Scope of delivery - horn antenna
Figure 2-1: Scope of delivery - horn antenna
1 Signal converter and antenna in compact version
2 Antenna extensions (option)
3 Quick Start
4 CD-ROM (including Handbook, Quick Start, Technical Datasheet and related software)

2DEVICE DESCRIPTION
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Scope of delivery - Drop antenna
Figure 2-2: Scope of delivery - Drop antenna
1 Signal converter and antenna in compact version
2 Antenna extensions (option) and o-ring for each antenna extension
3 Quick Start
4 CD-ROM (including Handbook, Quick Start, Technical Datasheet, and related software)
INFORMATION!
No special tools or training required!

DEVICE DESCRIPTION 2
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2.2 Device description
This device is a 24 GHz FMCW-radar level transmitter. It is a non-contact technology and is 2-
wire loop-powered. It is designed to measure the distance, level, mass, volume and reflectivity
of granulates and powders.
Radar level transmitters use an antenna to guide a signal to the surface of the measured
product. The device has many antennas available. Thus, it can measure most products even in
difficult conditions. Also refer to
Technical data on page 88.
The device has a setup wizard, fully-potted electronic circuit boards and online help functions. It
has a 4...20 mA+HART output (a second output is optional) and an optional local display. You
usually will not need this Handbook to install, setup and operate the device.
If it is ordered with the applicable options, it can be certified for use in hazardous areas.
These accessories are available:
•stainless steel weather protection.
•RS232/HART®converter (VIATOR).
•USB/HART®converter.
•2°PP slanted flange
INFORMATION!
For more data on accessories, refer to List of accessories on page 84
.

2DEVICE DESCRIPTION
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2.3 Visual Check
WARNING!
If the display screen glass is broken, do not touch.
INFORMATION!
Inspect the cartons carefully for damage or signs of rough handling. Report damage to the
carrier and to the local office of the manufacturer.
Figure 2-3: Visual check
1 Device nameplate (for more data, refer to
Non-Ex nameplate on page 15)
2 Process connection data (size and pressure rating, material reference and heat number)
1
INFORMATION!
Look at the device nameplate to ensure that the device is delivered according to your order.
Check for the correct supply voltage printed on the nameplate.
INFORMATION!
Compare the material reference on the side of the process connection with the order.

DEVICE DESCRIPTION 2
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2.4 Nameplates
2.4.1 Non-Ex nameplate
INFORMATION!
Look at the device nameplate to ensure that the device is delivered according to your order.
Check for the correct supply voltage printed on the nameplate.
Figure 2-4: Non-Ex nameplate
1 Indicator arrow to cable entry / cable entry size. Notified body for radio approval.
2 Degree of ingress protection (according to EN 60529 / IEC 529)
3 Customer tag number
4 Date of manufacture
5 Order number
6 Type code (defined in order)
7 Model name and number
8 Company name and address
9 Nominal voltage for operation. For further information, refer to
Non-Ex on page 31.

3INSTALLATION
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3.1 Notes on installation
3.2 Storage
•Store the device in a dry and dust-free location.
•Keep the converter out of the sunlight.
•Store the device in its original packing.
INFORMATION!
Inspect the cartons carefully for damage or signs of rough handling. Report damage to the
carrier and to the local office of the manufacturer.
INFORMATION!
Check the packing list to check if you received completely all that you ordered.
INFORMATION!
Look at the device nameplate to ensure that the device is delivered according to your order.
Check for the correct supply voltage printed on the nameplate.
WARNING!
Do not keep the device in a vertical position. This will damage the antenna and the device will not
measure correctly.
Figure 3-1: Storage conditions
1 When you put the device into storage, do not keep it in a vertical position
2 Put the device on its side. We recommend that you use the packaging in which it was delivered.
3 Storage temperature range: -40...+85°C / -40...+185°F

INSTALLATION 3
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3.3 Transport
3.4 Pre-installation requirements
•Make sure that there is adequate space on all sides.
•Protect the signal converter from direct sunlight and install the weather protection accessory
if necessary.
•Do not subject the signal converter to heavy vibrations. The devices are tested for vibration
and agree with EN 50178 and IEC 60068-2-6.
To make sure that you install the device quickly, easily and safely, prepare the installation as
given in the instructions that follow.
Figure 3-2: How to lift the device
1 Remove the converter before you lift the device with a hoist.
WARNING!
Lift the device carefully to prevent damage to the antenna.
INFORMATION!
The following precautions must be taken to make sure it is correctly installed.

3INSTALLATION
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3.5 How to prepare the silo before you install the device
3.5.1 Pressure and temperature ranges
CAUTION!
To avoid measuring errors and device malfunction, obey these precautions.
Figure 3-3: Pressure and temperature ranges
1 Flange temperature
FKM/FPM gasket: -40...200°C / -40...390°F; Kalrez®6375 gasket: -20...200°C / -4...390°F;
EPDM gasket: -40...+150°C / -40...+300°F
Ex devices: see supplementary operating 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
3 Ambient temperature
Non-Ex devices: -40...80°C / -40...175°F
Ex devices: see supplementary operating instructions
4 Process pressure
PP Drop antenna option: -1...16 bar / -14.5...232 psig
All other antenna options: -1...40 bar / -14.5...580 psig
WARNING!
Maximum process connection temperature:
PTFE Drop antenna option: +150
° C / +300 ° F
PP Drop antenna option: +100
° C / 210 ° F

INSTALLATION 3
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3.5.2 Theoretical data for nozzle position
CAUTION!
Follow these recommendations to make sure that the device measures correctly.
Figure 3-4: Recommended nozzle position for solids
1 Position of the process fitting from the silo wall, r/2 (for DN80 or DN100 Horn antennas, and DN80 or DN150 Drop
antennas)
2 Radius of the silo, r
3 The minimum measured level for a device without a 2°slanted PP flange option
4 The minimum measured level for a device with a 2°slanted PP flange option
INFORMATION!
If possible, do not install a nozzle on the silo centerline.
INFORMATION!
If it is necessary to measure to the bottom of the silo, a 2
° slanted flange option is available for
all antennas. For more data, refer to Installation recommendations for solids on page 21
.
CAUTION!
Do not put the device near to the product inlet. If the product that enters the silo touches the
antenna, the device will measure incorrectly. If the product fills the silo directly below the
antenna, the device will also measure incorrectly.

3INSTALLATION
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More than 1 FMCW radar level meter can be operated in a silo.
Figure 3-5: Product inlets
1 The device is in the correct position.
2 The device is too near to the product inlet.
Figure 3-6: More than 1 FMCW radar level meter can be operated in a silo