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.

Physical Installation ● Scanner Orientation
CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved 11
3.2 Scanner Orientation
Mounting direction
Mounting of the CONTOUR at a specific direction is
important. The ridge on the horn body, and the notch on the
top of the thread (representing antenna no.1) should be
directed toward the center of the vessel.
Mounting direction. 00indication toward vessel center
Standpipe mounting
When mounting the scanner using a standpipe it should
be assembled and positioned at a height that leaves at
least 10mm (0.4”) out of the standpipe, for the antenna
end protrudes, as shown in the figure to the right.
IMPORTANT: Any obstruction as well
as rails, frames or support beams should
never interfere with the acoustic beam
transmitted and received, as shown in
the figure to the right.
This comment applies to all CONTOUR models
including S model.
Wrong Correct
The 00label location

Physical Installation ● Site Preparations
12 CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved
Inflowing material
Do not mount the scanners in or above the filling stream, not too
far from the stream, and not in the direction of the filling stream in
case it is diagonal, to avoid damage to the scanner from the
flowing material. The scanner should be located with a clear line of
sight to the top of the material at high levels, not to be affected by
the filling stream or the noise it creates.
Fitting
The fitting area should be prepared to maintain the
horns/antennas vertically positioned to the ground,
as shown at right.
Wrong Correct
3.3 Site Preparations
IMPORTANT: The site preparations described in this section must be complete
and verified prior to installation. For optimal installation, ensure that the
CONTOUR can be positioned and fitted according to the guidelines described in
the beginning of this chapter.
For a list of items recommended to prepare before installing the CONTOUR, refer
to page 37: Appendix D: Recommended Tools.
Before installing, make sure the following preparations have been completed.
Power
Connecting the CONTOUR chassis to the facility grounding is important for protection.
A 24VDC (1.5 Watt) power supply must be prepared and ready to use near the
scanner mounting location.
The CONTOUR is a 4-Wire device. The voltage supply and data output (4-20 mA) are
carried along two separated two-wire connection cables.

Physical Installation ● Assembly and Mounting
CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved 13
Communications
Route communication cables in proper conduits and use a proper cable type.
The cable used for RS-485 should be of twisted-pair type, shielded, with 120 Ohm
impedance and approved for RS-485 communications.
The cable used for 4-20 mA should be rated for analog signals, twisted-pair, low
resistance and shielded.
3.4 Assembly and Mounting
Package Contents
The supplied package includes:
CONTOUR sensor
Documentation
CD with the CONTOUR Configurator software and marketing materials
Cable glands accessory kit
Ex-specific safety instructions (with Ex versions)
Certificates if applicable
Included components
The CONTOUR includes the following components:
CONTOUR Body CONTOUR Head
CONTOUR Body: Includes three antennas, transducers and temperature sensor. The
flange is mounted on the body and tightened to it.
CONTOUR Head: Includes the electronic board with LCD display and all wiring
connections. The Head is mounted on the body.

Physical Installation ● Assembly and Mounting
14 CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved
Flange preparation
Prior to the installation of the CONTOUR, an installation flange should be
prepared. The flange must have a 52mm (2.05”) hole for the scanner body
thread insertion.
CONTOUR provides two types of standard flanges. Please refer to page 31:
Appendix B: Accessories for flange specifications.
Installing the Flange
Verify existence of
the O-Ring on the
neck tube remains
in place as shown:
Use an adjustable 18"
wrench to untighten
and remove the nut
from the neck tube.
Place flange over the neck tube,
insert until placed as shown:
Replace the nut and tighten it over
the neck tube to the flange, using
an adjustable 18" wrench.
Make sure the
scanner is well
tightened to the
flange, for
vibrations
prevention and proper sealing.
When mounting the scanner body
and flange to the silo standpipe
make sure the scanner is facing the
center of the silo as described in
Scanner Orientation on page 11.
Installing the Scanner Head
Unpack the scanner head.
Untighten the four screws of the housing rear panel
using a 4mm hex key, and remove the rear panel. The
screws are of captive type and will not fall off.
1
2
3
4
1

Physical Installation ● Assembly and Mounting
CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved 15
Remove the cable clamp located at the
bottom inside the scanner as shown.
Gently insert the antenna cable through the scanner head. Make sure not to
damage the (white) cable connector. This connector connects the transmission
signal from the electronic board to the transducers. Damage to the connector or to
the wires will result with malfunctioning operation of the scanner.
Insert the scanner head onto
the neck tube.
IMPORTANT: When
inserting the scanner head
onto the neck tube, make
sure to push the head all
the way down until it fully
contacts the top of the neck tube.
NOTE: It is recommended to lubricate the O-Ring on the neck tube prior to
installing the scanner head. This makes it easier to insert and properly locate
the scanner head over the tube neck.
NOTE: The CONTOUR head may be installed in six different positions.
Tighten the front screw using a 4mm hex key and a 13mm
wrench.
Replace the cable clamp back to
position, between the antenna cable and
the electronic board.
2
3
4
5
6

Physical Installation ● Wiring
16 CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved
Carefully connect the antenna cable
connector back to the electronic board as
shown.
This connector allows the transmission
signal from the electronic board to the
transducers. Damaged connector or wires
will result with malfunctioning operation of
the scanner.
Leave the scanner open at this stage in order to complete the wiring.
3.5 Wiring
The CONTOUR can be connected in different modes and configurations for different
external systems such as PLC or DCS and communications on RS485, ModBus, and
HART and also to RS485 bus converting adapters to communication gateways such as
CONTOUR Connect for GMS or GPRS data relay and TCP/IP gateway. For in-depth
details and explanations on wiring and communication, refer to page 23: Different
Connection Methods.
Use 8-13mm (20-24 AWG) diameter cables to ensure proper and effective sealing of
the cable gland entry opening.
Select a cable suitable for application (indoor or outdoor) and safety certified
according to national regulations.
Communications
NOTE: If electromagnetic interference is expected, usage of a screened and
twisted wired cable is recommended for the signal lines, which should be
connected to the ground reference.
CAUTION: Always observe the following safety instructions:
Connections must be made only in the complete absence of line voltage.
If over-voltage is expected, overvoltage arresters should be installed.
Use only a safety-certified power supply with dual insulation between the primary
and output for powering the unit. The power supply output rating must be limited
to 20-32VDC, 1A for a single CONTOUR device, and not to be connected to a DC
distribution network.
In hazardous areas you should take note of the appropriate regulations,
conformity and type of approval certificates of the sensors and power supply
units. Refer to the printed safety manual provided with the ATEX/FM approved
CONTOUR.
7
8

Physical Installation ● Wiring
CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved 17
Power Supply
For power supply specifications, refer to page 39: Appendix E: Specifications for full
details.
4-20 mA/HART 4-wire: The power supply and signal current inputs must be carried over
two separated pairs.
Connection Procedure
Untighten the four screws of the scanner
housing rear panel
and remove the
rear panel. The
screws are of
captive type and
will not fall off.
Loosen the compression
nut of the cable gland
entry.
Insert the cable into the scanner through the cable
gland and entry opening.
Remove approximately 10cm
(4 inches) of the cable mantle
and strip approximately 1cm
(0.4 inches) the edge of each
conductor.
Open the terminal block screws located inside the
scanner housing using a thin flat (A3/32") screwdriver.
Insert the wire edges into the terminals according to the
wiring plan detailed next, and fasten the terminal
screws. Gently pull the wires to ensure they are
securely connected.
2
3
4
5
1

Physical Installation ● Wiring
18 CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved
Terminal block wiring plan.
The tables below describe the
connections.
Refer to the following Local Connection
and Multi-Drop Connection drawings for
details.
Left Connector
Right Connector
Ports
Description
Ports
Description
PS IN
+-
Feed in power supply
20 –32 VDC
RS-485
+ -
RS-485 / Modbus RTU
Communications
terminals
4-20 mA
-+
4–20 mA / HART
Communications terminals
Connect the external ground terminal with
potential equalization to the external
ground terminal of the scanner, located
as shown.
An internal cable grounding connection is also
possible using the inner connection as shown.
Tighten the compression nut over the cable gland entry opening. Verify that the
sealing ring completely wraps the cable.
IMPORTANT: Gland compression nut tightening provides good sealing.
It is necessary for the scanner to maintain IP67 requirements, and for
extended scanner lifetime.
6
7
8

Physical Installation ● Wiring
CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved 19
Attach the rear panel back to position at the rear of the
scanner housing and tighten the four screws to secure it in
place, using a 4mm hex key.
The CONTOUR is ready for configuration.
IMPORTANT: Use direct connection between the scanners and the plant
(PLC/SCADA).
IMPORTANT: For a remote connection, use the CONTOUR Connect remote
connection module or a local PC/Laptop computer as detailed in the following
drawing.
CAUTION: Do not connect power supply to the 4-20 mA or to the RS485 ports.
The CONTOUR is not a loop powered device but a 4W device.
WARNING: The 4-20 mA / HART lines should NOT be connected using
multidrop.
9

First-Time Activation ● Local User Interface
20 CONTOUR Operating Instructions © 2013 Magnetrol International all rights reserved
4First-Time Activation
4.1 Local User Interface
Configuration and adjustment of the CONTOUR must be done using the CONTOUR
Configurator software, with the optional addition of GSM/GPRS communications using
CONTOUR Connect. For detailed configuration procedure, refer to CONTOUR
Configurator Software Manual and the CONTOUR Connect Manual.
The CONTOUR User Interface
The user interface includes a 4-lines LCD display and
the four keys located on the front side of the device,
marked ESC, +, - and E.
Key functions are as follows:
Navigates back within a function menu.
Continuous 3 second press exits to the
default screen.
Navigates upwards in the navigation list.
Navigates right within a function.
Navigates downwards in the navigation list.
Navigates left within a function.
Navigates to the right when within a function group.
Stores a value once configured.
The following, simultaneous key-press combinations perform special functions as follows:
Increases / decreases the LCD display intensity.
Press and hold the button, then use the or buttons to increase or
decrease the intensity of the display.