Magnetrol CONTOUR 3DS-S User manual

Installation and Operating Manual
Volume measurement of bulk
solids and powders in any size
or shape of storage vessel

CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved 3
Contents
1ABOUT THIS DOCUMENT........................................................................................ 5
1.1 SYMBOLS IN USE ........................................................................................................ 5
1.2 FOR YOUR SAFETY ...................................................................................................... 5
1.3 STORAGE AND TRANSPORT........................................................................................... 6
2CONTOURᵀᴹ OVERVIEW ......................................................................................... 7
2.1 THEORY OF OPERATION .............................................................................................. 7
2.2 WIDE APPLICATION RANGE ......................................................................................... 7
2.3 ADVANTAGES............................................................................................................ 7
2.4 MODELS .................................................................................................................. 8
3PHYSICAL INSTALLATION ........................................................................................ 9
3.1 LOCATION AND POSITIONING GUIDELINES ....................................................................... 9
3.2 SCANNER ORIENTATION ............................................................................................ 11
3.3 SITE PREPARATIONS ................................................................................................. 12
3.4 ASSEMBLY AND MOUNTING....................................................................................... 13
3.5 WIRING ................................................................................................................. 16
4FIRST-TIME ACTIVATION ...................................................................................... 20
4.1 LOCAL USER INTERFACE ............................................................................................ 20
4.2 SWITCHING ON THE SCANNER..................................................................................... 21
4.3 FIRST-TIME ACTIVATION STEPS SUMMARY.................................................................... 22
4.4 INITIAL SETUP PROCEDURE......................................................................................... 22
5DIFFERENT CONNECTION METHODS .................................................................... 23
5.1 4-20 MACONNECTION ............................................................................................ 23
5.2 HART®COMMUNICATION........................................................................................ 23
5.3 RS485 COMMUNICATION......................................................................................... 25
5.4 COMMUNICATION USING THE CONTOUR CONNECT ..................................................... 25
5.5 TCP/IP COMMUNICATION ........................................................................................ 25

4 CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved
APPENDIX A: ONBOARD CONFIGURATION .................................................................. 26
OUTPUT SETTINGS.............................................................................................................. 26
DISPLAY SETTINGS .............................................................................................................. 28
DEVICE INFO...................................................................................................................... 29
DEVICE RESET .................................................................................................................... 30
APPENDIX B: ACCESSORIES.......................................................................................... 31
INSTALLATION FLANGES ....................................................................................................... 31
NECK EXTENSIONS .............................................................................................................. 33
HEAD-BODY SEPARATION..................................................................................................... 34
CABLE GLANDS .................................................................................................................. 35
APPENDIX C: MAINTENANCE ....................................................................................... 36
APPENDIX D: RECOMMENDED TOOLS ......................................................................... 37
APPENDIX E: SPECIFICATIONS...................................................................................... 38
TECHNICAL DATA ................................................................................................................ 38
DIMENSIONS ..................................................................................................................... 41
APPENDIX F: STANDARDS & APPROVALS .................................................................... 43

About this Document ● Symbols in use
CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved 5
1About this Document
This operation manual provides detailed product related information, installation, setup and
operation instructions for CONTOUR models 3DS-S, 3DS-M and 3DS-V. The manual is
designed for trained personnel. Please read it entirely and carefully before unpacking and
installation of the products.
1.1 Symbols in use
The following symbols indicate different sections of additional information as
follows:
IMPORTANT: An indication for additional information, tips, hints or an indication
of helpful additional knowledge.
WARNING: Indication of a potentially dangerous situation, which could result in
serious injury to persons and/or damage to the CONTOUR.
EX APPLICATION: An indication of special instructions relevant to installations
in hazardous locations.
1.2 For your safety
Authorized personnel
All operations described in this manual must be carried out by authorized, trained
personnel only. For safety and warranty reasons, any internal work on the scanners must
be carried out by manufacturer-authorized personnel only.
Warning about misuse
Inappropriate or incorrect use of the scanner may result in hazards and application-specific
malfunctioning such as vessels overfill or damage to system components through incorrect
mounting or adjustments.
If the CONTOUR is used in a manner not specified in this manual, the protection provided
by the CONTOUR will be impaired.

About this Document ● Storage and transport
6 CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved
General safety instructions
The CONTOUR is a high-tech device requiring strict observance of standard regulations
and guidelines. The user must strictly follow the safety instructions in this operating
manual. Local and national electrical codes and all common safety regulations and
accident prevention rules should be considered during installation as well.
CE conformity
The CONTOUR conforms to CE's EMC and NSR standards. CE conformity is as follows:
EMC
EN 61326-1: 2006
CISPR 11: 2003 Class A
IEC 61000-4-2: 2001 Air Discharge, 8kV
IEC 61000-4-3: 2002 80-1000MHz, 1V/m; 1.4-2GHz, 1V.m;
2.0-2.7GHz, 1V/m
IEC 61000-4-4: 2004 Power Lines: 1kV; Signal Lines: 0.5kV
IEC 61000-4-6: 2004 0.15-80MHz 1VRMS, 80% A.M. by
1kHz Power & Signal Lines
NSR
(73/23/EWG)
EN 61010-1: 2001
FCC conformity (EMC)
FCC Part 15, Sub-part B, Class A.
Safety information for Ex Areas
EX-AREAS: Please note the Ex-specific safety information for installation and
operation in Ex areas. These safety instructions are part of the operating
instructions manual that comes with Ex-approved scanners.
WARNING: Substitution of components may impair Intrinsic Safety.
WARNING: For preventing ignition of flammable or combustible atmospheres,
read, understand and adhere to the manufacturer’s live maintenance procedures.
1.3 Storage and transport
The scanner is protected by special packaging during transport, and is guaranteed to
handle normal loads during transport.

CONTOURᵀᴹ Overview ● Theory of Operation
CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved 7
2CONTOURᵀᴹ Overview
2.1 Theory of Operation
The MAGNETROL®CONTOUR™is the only device available which delivers accurate
measurement of bulk solids and powders –regardless of material type, product
characteristics, storage silo type, size, bin or container, and harshness of the storage
environment. The CONTOUR incorporates MAGNETROL's unique dust-penetrating
technology to achieve an unrivalled degree of process measurement and inventory control.
The CONTOUR includes an array of three antennas that generate low frequency acoustic
signals and receive echo signals from the contents of the silo, bin, or other container type.
Using these antennas, the unit measures not only the time/distance of each echoed signal
but also its direction.
The built-in Digital Signal Processor digitally samples and analyses the echoed signals
and produces accurate measurements of the level, volume, and mass of the stored
contents, and generates a 3D representation of the position and form of the material within
the container for displaying on remote computer screens.
2.2 Wide Application Range
The CONTOUR measures practically any kind of solid material, stored in a variety of
containers,including large open bins, bulk solid storage rooms, stockpiles and
warehouses, mapping loads that randomly form over time inside silos, and many other
challenging applications that were not possible until now.The sensor can measure ranges
of up to 70m (230ft) and generate 3D mapping of the material surface.
2.3 Advantages
Service and maintenance-friendly - Non-contact measuring principles, the
CONTOUR is highly easy to service and maintain
The only available device for solid volume measurement applications
The only available device that measures minimum and maximum levels
Suitable for measuring all solid materials (including ones with low dielectric constants)
Operates in dusty and moisture environments
Profiles of adhesions of materials to vessel walls
Self-cleaning antenna

CONTOURᵀᴹ Overview ● Models
8 CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved
3-Dimensional mapping visualization tool for filling-point choosing assistance (in
vessels with multiple filling points
The most reliable sensor available - includes 3 transmitters and 3 receivers
2.4 Models
The CONTOUR line of products is consisted of three models: 3DS-S, 3DS-M and 3DS-V.
Model 3DS-S
The 3DS-S model determines the average level of the stored contents and average
distance from the scanner to the surface of the material. Based on a 30°beam angle, The
S model is ideal for small and narrow vessels of up to 4m (13ft) in diameter.
Model 3DS-M
The 3DS-M model yields highly accurate readings of level and volume. It is appropriate for
large vessels of up to 15m (50ft) in diameter and at least twice as high (30m / 100ft), open
bins and stockpiles. It is based on a 70°beam angle. The M model also presents the
minimum and maximum Level/Distance measurements along with the calculated average.
Model 3DS-V
The 3DS-V model is identical to the 3DS-M model, with the additional capability of
generating a 3-dimensional representation of the stored contents on a remote computer.
This feature is highly useful for mapping build-up loads that form randomly over time and
other irregularities.
All three models are available in various modes, such as ATEX approved, FM approved,
and non-ATEX (for more information, see Approvals on page 40) and also available with
neck extension (see Appendix B: Accessories: Neck on page 33) and compatible with the
Head-Body separation kit.
The CONTOUR is available in two temperature ranges:
The CONTOUR 3DS-xxxx-Axx-xx-xxx is compatible in applications where the maximal
temperature in the surroundings inside the vessel is up to 85° C (185° F).
The CONTOUR 3DS-xxxx-Hxx-xx-xxx is compatible in applications where the maximal
temperature in the surroundings inside the vessel is up to 180° C (356° F).
All references in this manual to the CONTOUR can be referred to as CONTOUR or simply
the scanner, if nothing else is mentioned it applies to any of the scanner models.

Physical Installation ● Location and positioning guidelines
CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved 9
3Physical Installation
This chapter describes the necessary steps for proper installation of the CONTOUR
beginning with important pre-installation considerations such as environmental conditions,
correct positioning and orientation, through the mounting and configuration process.
3.1 Location and positioning guidelines
When choosing the proper location for the CONTOUR, the installer should consider every
aspect of the vessel and contained materials, including the silo or vessel dimensions, type
of material and angle of repose, locations of filling and emptying points, maximum level of
material, internal construction and moving part and any other consideration which may
possibly affect the scanner performance. MAGNETROL strongly recommends installing
the CONTOUR according to the CONTOUR Locator PC software for properly choosing
installation location and positioning. In case of no satisfying software solution, please
contact CONTOUR Customer Support for assistance with the positioning.
Moisture and water condensation
Use the recommended cable gland and tighten the cable connection.For
additional protection against moisture, lead the connection cable downward in
front of the cable entry. Rain and condensation water can thus drain off. This
applies mainly to mounting in areas where moisture is expected (e.g., by cleaning
processes), or on cooled or heated vessels.
Measuring range
The measuring range is set in the scanner and defined by silo dimensions and the full and
empty calibration levels. These levels set the 100% and 0% values relatively.
The scanner measurements are calibrated to the top of the
body. If the scanner is lowered, or mounted with neck
extension or head-body separation, it is important to adjust
all measurements to the top of the body.
NOTE: If the material level reaches the antenna,
build up could form inside the horn over time and
cause measurement errors or damage to the
membranes.
NOTE: the CONTOUR has a 500mm (20”) of dead
zone (or blanking zone).

Physical Installation ● Location and positioning guidelines
10 CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved
Pressure
The process fitting must be sealed in the case of a low pressured vessel. Before usage,
verify that the sealing material is resistant to the stored medium. The maximum allowed
pressure (stated in page 38: Appendix E: Specifications) is indicated on the type label of
the sensor.
Installation location
Choosing the proper installation location for the CONTOUR is an important part of the
installation process. A wrong location may result in erroneous measurements or loss of
performance.
The usage of the CONTOUR Locator Software is recommended for finding the optimal
location, which is based on various parameters.
The following factors must be taken into consideration while choosing the installation
position: vessel dimensions, filling and emptying point locations, internal structure or
support and other restrictions related to vicinity to noisy devices (such as electrical motor)
and any other element which may affect the proper operation of the scanner.
IMPORTANT: When mounting the CONTOUR, do not install the scanner near the
vessel wall. The installation must consider the vessel dimensions. Installing the
scanner near the side wall will result in bad performance and will not be
supported by CONTOUR.
Installing the CONTOUR at the center of the vessel is not recommended, since the perfect
symmetry from all sides toward the scanner may affect the echoes distinction.
The scanner cannot be mounted at a distance lower than 500mm (20") from the wall.
When choosing the installation location, consider the filling and emptying points.
Use the CONTOUR Locator PC software for choosing a proper location.