KROHNE OPTIWAVE 7300 C User manual

Handbook OPTIWAVE 7300 C
OPTIWAVE 7300 C 2
Content
0. Introduction.........................................................................................................................................................................................4
0.1 General .................................................................................................................................................................................................................. 4
0.1.1 Description of the device........................................................................................................................................................................................ 4
0.1.2 Legal matters ......................................................................................................................................................................................................... 4
0.2 Safety..................................................................................................................................................................................................................... 5
0.2.1 Use in hazardous areas......................................................................................................................................................................................... 5
0.2.2 Documentation symbols......................................................................................................................................................................................... 5
0.3 Visual inspection.................................................................................................................................................................................................... 5
0.3.1 Instrument Integrity................................................................................................................................................................................................ 5
0.3.2 Material compatibility ............................................................................................................................................................................................. 6
0.4 Standards and approvals....................................................................................................................................................................................... 6
0.4.1 Standards............................................................................................................................................................................................................... 6
0.4.2 Approvals............................................................................................................................................................................................................... 6
0.5 Versions and nameplates ...................................................................................................................................................................................... 7
0.5.1 Non-Ex and Ex versions ........................................................................................................................................................................................ 7
0.5.2 Non-Ex namplate................................................................................................................................................................................................... 7
0.5.3 Ex nameplates....................................................................................................................................................................................................... 7
0.6 Items supplied........................................................................................................................................................................................................ 8
1. Mechanical installation......................................................................................................................................................................8
1.1 Storage and handling............................................................................................................................................................................................. 8
1.2 Location.................................................................................................................................................................................................................. 9
1.2.1 All applications....................................................................................................................................................................................................... 9
1.2.2 Liquid applications ............................................................................................................................................................................................... 14
1.2.3 Solid Applications................................................................................................................................................................................................. 15
1.3 Typical installations.............................................................................................................................................................................................. 15
1.3.1 General notes....................................................................................................................................................................................................... 15
1.3.2 Metallic tanks....................................................................................................................................................................................................... 18
1.3.3 Non-metallic tanks and free air applications........................................................................................................................................................ 19
1.3.4 Stilling wells.......................................................................................................................................................................................................... 20
1.3.5 Bypass chambers ................................................................................................................................................................................................ 22
1.3.6 Conical tanks........................................................................................................................................................................................................ 23
1.3.7 Horizontal cylindrical tanks.................................................................................................................................................................................. 23
1.4 Other important information................................................................................................................................................................................. 24
1.4.1 Process conditions............................................................................................................................................................................................... 24
2. Electrical connection........................................................................................................................................................................25
2.1 Wiring................................................................................................................................................................................................................... 25
2.1.1 General notes....................................................................................................................................................................................................... 25
2.1.2 Wiring Procedure................................................................................................................................................................................................. 26
2.2 Power supply........................................................................................................................................................................................................ 28
2.2.1 General notes....................................................................................................................................................................................................... 28
2.2.2 Non-Ex versions................................................................................................................................................................................................... 28
2.2.3 Ex versions........................................................................................................................................................................................................... 28
2.3 Connection, I/Os.................................................................................................................................................................................................. 28
3. Commissioning.................................................................................................................................................................................31
3.1 Power-on and start-up ......................................................................................................................................................................................... 31
4. Operation...........................................................................................................................................................................................31
4.1 Operating concept................................................................................................................................................................................................ 31
4.1.1 Available user interfaces...................................................................................................................................................................................... 31
4.1.2 Display screen...................................................................................................................................................................................................... 32
4.1.3 Normal mode........................................................................................................................................................................................................ 33
4.1.4 Normal mode hot keys......................................................................................................................................................................................... 35
4.1.5 Program mode ..................................................................................................................................................................................................... 36
4.1.6 Program mode hot keys....................................................................................................................................................................................... 39
4.2 Setup.................................................................................................................................................................................................................... 39
4.2.1 PACTware™........................................................................................................................................................................................................ 39
4.2.2 Device display...................................................................................................................................................................................................... 39
4.2.3 Summary of menu items (device display Wizard)................................................................................................................................................ 49
4.2.4 Advanced setup: further notes............................................................................................................................................................................. 54
4.3 Error messages and troubleshooting (device display Wizard)............................................................................................................................. 61
5. Functional checks............................................................................................................................................................................66

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6. Service and maintenance.................................................................................................................................................................67
6.1 General notes....................................................................................................................................................................................................... 67
6.2 Signal converter replacement..............................................................................................................................................................................67
6.3 Modifying antenna extension length .................................................................................................................................................................... 68
7. Technical data...................................................................................................................................................................................70
7.1 Technical data...................................................................................................................................................................................................... 70
7.1.1 Technical data extract.......................................................................................................................................................................................... 70
7.1.2 Blocking distance................................................................................................................................................................................................. 72
7.1.3 Hazardous areas.................................................................................................................................................................................................. 72
7.2 Dimensions and weights...................................................................................................................................................................................... 73
8. Measuring principle..........................................................................................................................................................................74
8.1 General principle.................................................................................................................................................................................................. 74
8.2 Measuring modes ................................................................................................................................................................................................ 75
9. Approvals..........................................................................................................................................................................................77
10. Glossary of terms.............................................................................................................................................................................78
11. Device return form............................................................................................................................................................................79

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0. Introduction
0.1 General
0.1.1 Description of
the device
The OPTIWAVE 7300 C gauge is designed solely for measuring the distance, level, volume and reflectivity of
liquids, pastes, slurries, and solids.
OPTIWAVE can form part of an overfill protection system as defined in WHG if ordered with the appropriate
options.
OPTIWAVE 7300 C is a level meter based upon FMCW radar. It is used for measuring:
•level
•volume
•distance to surface
•reflectivity
of liquids, pastes and slurries.
OPTIWAVE 7300 C is a new-generation level meter with a wizard-driven setup, fully-potted electronic
subassemblies, an online help functions.
It is provided with a pictorial quick setup. You will not normally need this Handbook to install, set up and
operate the device.
All menu items have an on-screen help function that is activated 15 seconds after the last input.
In the unlikely event of a failure, error icons appear on-screen. Clicking on the error icon in the PACTware
device tool manager software or by looking in the error record menu item in program mode using the device
screen wizard displays an error description, which normally is sufficient to rectify the problem. Only in severe
cases will you need to consult the error records.
0.1.2 Legal matters
Authorised personnel
Installation, assembly, commissioning and servicing must only be undertaken by KROHNE-trained personnel.
Maintenance which is considered relevant to safety in the sense of explosion protection must only be carried
out by the manufacturer, his agents or under the supervision of experts.
Liability
Responsibility as to suitability and intended use of these devices rests solely with the user. Improper
installation and operation may lead to loss of warranty. In addition, KROHNE Group's Standard General
Conditions of Sale and Delivery, found on the back of the invoice and forming the basis of the purchasing
contract, are applicable.
Special codes and regulations apply to its use in hazardous areas.
General limitation on liability
Unless otherwise expressly set forth in the Standard Terms and Conditions of Sale and Delivery, the Seller is
only liable for damages, whatever their legal basis is, in case they are based on wilful action or gross
negligence.
This limitation on liability does not apply in the event the Buyer raises claims relating to personal injury or
damages to property according to the product liability law based on a defect of the delivered goods.
Any advice given by the Seller, in particular regarding the application of the delivered goods, shall only commit
the Seller if given or confirmed in writing.
Returning the device
If you need to return the level gauge to the manufacturer or supplier, please read to the instructions and
complete the form given in the appendix.
Warranty
Please consult KROHNE’s General Terms and Conditions for information on guarantee and liability.

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0.2 Safety
•Follow all instructions carefully to make sure that you install the device correctly
•Observe special conditions for installations requiring approved equipment
•Check that that the information on the device nameplate conforms to the on-site data
•Wire according to local rules and regulations
•Remove the device from the installation before servicing, except for replacement of the housing as
described in section 6.2.
0.2.1 Use in hazardous areas
This device is suitable for monitoring level in hazardous areas, when fitted with the appropriate options.
Special regulations are applicable to the use in hazardous areas. Please refer to the special manuals supplied
on a CDROM with the device.
Please read carefully. In certain cases, these instructions will replace the standard installation and operating
instructions.
0.2.2 Documentation symbols
A set of symbols is used to give warnings or information relevant to particular applications.
These are defined below:
Caution
Information that, if not followed, may lead to actions resulting in incorrect functioning of the device.
Warning
Information that, if not followed, may lead to actions resulting in measurement error, personal injury and/or
damage to the device.
Information and instructions for Ex applications
Information that must be used to observe the safety requirements for installation, operation and maintenance
in hazardous areas. If instructions are not followed, this may result in personal injury, damage to the device
and/or incorrect functioning of the device.
0.3 Visual inspection
0.3.1 Instrument Integrity
The level meter withstands corrosive environments.
Visually inspect the equipment before installation to check that it has not been damaged in transit.

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0.3.2 Material compatibility
Check that the flange, gasket and antenna materials are compatible with the product in the tank.
Use the information from the following sources:
•converter nameplate
•flange
•approval certificates
0.4 Standards and approvals
0.4.1 Standards
All versions of the device conform to European Union electromagnetic compatibility (89/336/CEE) and low
voltage equipment (73/23/ CE) Directives and Standards that allow use of the CE mark.
These and other relevant standards are listed in Standards.
0.4.2 Approvals Versions equipped with the necessary options are suitable for use in hazardous areas meeting either
European or American-Canadian approval requirements.
These are:
ATEX (European) -approval
Joint FM and CSA (American-Canadian) -approval
For further information, please refer to:
•special manuals (supplied on a CD-ROM with the device)
•approvals

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0.5 Versions and nameplates
0.5.1 Non-Ex and Ex versions
1 Cover with display (option)
2 Wiring compartment cover
3 Socket head set locking screw for either rotating or removing
the housing
4 Threaded process connection (NPT, G)
5 Cover without display (standard)
6 Flange
7 Horn antenna DN 40
8 Equipotential bonding system connection (Ex)
9 Cable entry (M20, NPT½ or G½ adaptor supplied without
cable gland)
10 Horn antenna DN 50
11 Nameplate
12 Horn antenna DN 80 (standard length)
13 Primary DN 80 antenna extension (optional)
14 Horn antenna DN 80 (specific to primary antenna extension)
15 Supplementary antenna extension module (length 105 mm
or 4.1"; max. 10 modules)
0.5.2 Non-Ex namplate
1 Company name and address
2 Model name and number
3 Type code (defined in order)
4 Order number
5 Factory bar code
6 Manufacturing date
7 Customer tag number
8 Degree of ingress protection provided by the enclosure
(according to EN 60529 / IEC 529)
9 Indicator arrow to cable entry and cable entry size
10 CE mark - device conforms to European Union directives
(code given)
11 WHG code (optional) for German overfill protection standard
12 Company website
13 Read manual symbol
0.5.3 Ex nameplates Please refer to the special manuals on the CD-ROM supplied with your device.

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0.6 Items supplied
•signal converter with process connection connected to horn antenna, material and size as per order.
•optional: sunshade (fastening material supplied)
•quick-start guide
•Ex instructions (for Ex version only)
•calibration certificates with print-out of factory settings (where applicable)
•a CD-ROM containing this handbook, special manuals for supplementary Ex data, data sheets,
certificates, device return form for repairs and servicing, PACTware software for remote configuration
and data display, links to KROHNE internet for further information such as telephone, fax and Email
numbers of all KROHNE companies and representatives worldwide.
Items not supplied
•Nuts, bolts, gaskets and seals for fitting to existing nozzles, etc.
•cabling and non-standard connections / cable glands
•Service manual since - apart from exchanging entire subassemblies - this device can only be factory
serviced.
1. Mechanical installation
1.1 Storage and handling
Handling
Mount OPTIWAVE 7300 C radar level meters on suitable process connections on a tank or sump.
The device weighs between 8 kg/18 lb and 10 kg/22 lb.
•Lift the meter by the flange using two people to avoid damaging the base of antenna.
•Support the housing and antenna while installing the device.

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Avoid hard blows, impacts and jolts!
Storage
Store device on its side. Do not stock upright!
Risk of measurement error and damaging antenna!
Storage temperature
1.2 Location
1.2.1 All applications
General notes
This section covers positioning the process connection and installing the device.
Mount the OPTIWAVE 7300 C gauge on a suitable process connection on a tank or sump.
Check the following:
•nozzle position in relation to the tank walls, product entry points and other objects inside the tanks.
Note: this free space around the probe will depend on the antenna used - refer to later on in this section
•installation according to radio approval requirements (section 1.3.1)
•installation adapted to the application
For further information on applications, refer to section 1.2.2: Location; liquid applications and section 1.2.3:
Location; solid applications. Also refer to section 1.3: Typical installations.

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Hazardous areas
Refer to the special manuals supplied on a CD-ROM with the device.
Process connections
Distance of fitting from tank wall
Do not install fitting on tank centreline. This causes multiple reflections and measurement errors when the
device is in operation.
The ideal distance from the tank wall depends on antenna size. See below,
where H is tank height (including process connection) and D is tank internal diameter

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Other specifications for fittings
For the gauge to make accurate measurements and have a good signal reflected back from the product
surface:
•ensure a good fit with the gauge process connection
•the radar must point directly down onto the product. Angle offset tolerance ±2° from vertical
•the tank roof must support the weight of the meter
Process connection and entry pipes
Do not put the process connection close to the entry pipe!
Pouring the product directly onto the antenna or directly below will cause measurement errors!

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Threaded process connections
The simplest and most economic way is to mount the level meter directly onto the tank with a GAS or NPT-
threaded connection.
Use a 50 mm or 2" open-end wrench or similar to screw the device onto the tank process fitting.
Nozzles
To measure the level, the horn antenna must project out of the nozzle by at least 10 mm or 0.4".
If the nozzle is too long, use antenna extensions. Please note, however, that these are only available for the
DN 80 horn antenna.
Installation relative to other tank components
Factors that influence RADAR waves
Install the process connection far from the tank wall and protruding objects such as heating tubes, sudden
changes in tank cross section, tank wall reinforcements and beams, weld lines, dip-stick pipes and build up
of product.
These objects create false reflections that superimpose on the level measurement reflection.

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Avoid too many objects in the tank!
Risk of measurement error!
1 RADAR beam
2 Tank support beam
3 Agitator
4 Heating tubes
5 Ladder
To avoid interference with the radar beam, make sure that all tank components are located outside the
beam. The beam radius at a distance of one meter is given below. If components are within the beam, we
recommend that you use a reference chamber or stilling well.
See section 1.3.4: Stilling wells and section 1.3.5: Bypass chambers.

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Other ways of avoiding false reflections
False refelctions are caused by obstructions. Obstructions with sharp corners will create big interference
signals which can potentially lead to measurement errors while objects with curved surfaces diffuse the
RADAR signals but create less interference.
If sharp corners or flat surfaces cannot be avoided, use deflector plates (an angled surface over the zone
concerned) to diffuse the RADAR signal and, by so doing, create less interference.
Sharp corners cause multiple reflections!
Risk of measurement errors!
Installing two devices on the tank
Install any number of OPTIWAVE 7300 C radar level meters next to each other on the same tank.
However, as mentioned before, do not mount on tank centreline or outside the limits specified in Distance of
fitting from tank wall above.
1.2.2 Liquid applications
General notes
Follow these instructions and those given in section 1.2.1: location, all applications.
Turbulent products
Install a stilling well or bypass chamber when the product surface is turbulent or a vortex is present.
For further information, refer to section 1.3.4: Typical installations; stilling wells and section 1.3.5: Typical
installations; bypass chambers.
Products and foam
Install a stilling well or bypass chamber when foam is present; especially if it is highly conductive.
For further information, refer to section 1.3.4: Typical installations; stilling wells and section 1.3.5: Typical
installations; bypass chambers.

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Petroleum products
These products may be stocked in vessels with moving roofs. Install a stilling well according to local
standards, rules and regulations relative to the application and site.
Refer to section 1.3.4: Typical installations; stilling wells.
1.2.3 Solid Applications
Location of process connections on conical silos
Position the connection on the roof at approximatively ½ x tank radius (R) for reliable measurement of
product level.
1.3 Typical installations
1.3.1 General notes Electromagnetic compatibility
The OPTIWAVE 7300 C conforms to European EMC standard EN 61326-1 A1+A2.
The device conforms to EU Immunity and Emissions requirements for residential environments when
configured to operate in the open air and in plastic tanks and industrial environments when configured for
metal tanks (with appropriate shielding as per radio approval requirements).
Radio approvals - manufacturer's declarations
European Union (EU)
The level measuring instrument OPTIWAVE 7300 C 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.
OPTIWAVE 7300 C 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).
According to EN 300 440 (2001-09), the radiated power outside a metallic tank is less than -30 dBm.
United States of America (USA)
OPTIWAVE 7300 C complies with USA FCC Part
15 Rules (FCC ID JH5-OPTIWAVE7300C) only
when installed in totally enclosed metal tanks.
The device has this information fixed below the
nameplate

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Installations with difficult measurement conditions
Agitators, other mixing equipment, filling and emptying cycles can cause foam, vortices and turbulent
product surfaces.
Mounting a device in a bypass chamber or stilling well are ideal solutions for these condtions.
For further information, refer to section 1.3.3: Typical installations; stilling wells and section 1.3.4: Typical
installations; bypass chambers.
Ambient temperature
The ambient temperature limits of the device are given below.
Outdoor installations
Fit a sunshade on the level meter for outdoor installations: this is supplied on demand.
Procedure - fitting a sunshade
1. The sunshade is delivered separately; attached to a metal tube (A) to prevent deformation of the
mounting bracket.
2. Unscrew two M6 socket head cap screws (B) with a 5 mm hexagonal key (C).

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3. Remove the bracket (D) along with two screws (B) and washers (E) from the sunshade (F).
4. Lower the sunshade onto the device. Orientate it so that the "keyhole" (G) is at the front of the device.
5. Remount the screws and washers.
6. Remount bracket and tighten the screws slightly.

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7. Raise the sunshade as high as possible up the housing support pillar by bracing it with one hand. Screw
the two bolts tightly so that the sunshade does not slip down the pillar.
Procedure - opening the sunshade
1. Insert a large screwdriver into the "keyhole" on the sunshade and turn it anti-clockwise.
2. The hinge of the sunshade is at the front: pull the back of the sunshade over the device to gain access to
the display screen and keypad.
1.3.2 Metallic tanks Installation has to satisfy radio approval requirements to prevent radio frequency interference (RFI/EMI).
Fit accessories (shown in red, yellow and blue below)
A Washer under every nut and bolt
B Metal shielding strip, available on customer demand
C Strip retainer (metal collar), also available on customer
demand
D Device flange
E Tank flange

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Shielding strip installation procedure
1. Place the gasket on the tank flange
2. Mount the device on the tank flange
3. Align the gasket and the device with the tank flange
4. Fasten the flanges together; making sure that there is a washer (A) under every nut and bolt. The washer
must completely cover the flange hole to block RFI. Tighten up the bolts sightly.
5. Press the shielding strip (B) into the gap between the tank and device flanges. Check that the strip goes
completely round the flange.
6. Cover the shielding strip (B) and space between the two flanges with the strip retainer (C). Tighten
securely.
7. Tighten up the flange bolts. The torque applied depends on local rules and regulations about the bolts's
mechanical properties and the process conditions.
Shield all process connections to the tank as described in the procedure above.
Refer to section 1.3.1: Typical installations; general notes for more information on the radio approvals.
1.3.3 Non-metallic tanks and free air applications
If the device antenna is not totally enclosed, in other words the device is mounted on an open air container
or is on a tank made from non-metallic materials such as plastic or fibre glass, the following rules regarding
frequency bands apply
Sites in the EU
Use ISM bandwidth only.

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Sites in the USA
Do not use OPTIWAVE 7300 C on open-air installations or non-metallic tanks.
Refer to section 1.3.1: Typical installations; general notes and Approvals for further installation information.
1.3.4 Stilling wells Applications
A stilling well is recommended for these applications:
•where instructions for normal tank installation, such as the distance from tank wall or tank internals,
cannot be followed
•tanks with floating roofs for petro-chemical applications
•products with foam
•tanks with turbulent processes
•low dielectric products
Product with foam and turbulent surface