Magnetrol PULSAR RADAR R86 Instructions for use

Model R8
2 GHz Pulse Burst Radar
Level Transmitter
SIL Saf ty Manual for
Pulsar Mod l R86
Software v1.x
This manual complements and is intended to be used with
the Pulsar®Model R8 Installation and Operating manual
(Bulletin 58- 03).
Be efits
The PULSAR Model R86 (HART®) Pulse Burst level
transmitter can be applied in most indoor and outdoor
process or storage vessels. The PULSAR Model R86 can
be used in liquids or slurries to meet the safety system
requirements of IEC 61508/IEC 61511-1.
Be efits
The Magnetrol®Model R86 (HART) transmitter pro-
vides the following benefits to your operation
• Protection up to SIL2 as independently assessed
(hardware assessment) by exida as per IEC 61508/
IEC 61511-1. Safe Failure Fraction
•93.2% (intrinsically safe)
•93.0% (explosion-proof)
• Antenna designs to +750 °F (+400 °C),
2320 psig (160 bar)
• IS, XP and Non-Incendive approvals
• Quick connect / disconnect antenna coupling
• Performance not process dependent (changing specific
gravity and dielectric have no effect).
Functional Saf ty Manual

58-651 Pulsar®Model R86 SIL Functional Safety Manual
Table of Co te ts
1.0 Introduction ...................................................................3
1.1 Product Description..................................................3
1.2 Theory of Operation.................................................3
1.3 Determining Safety Integrity Level............................3
2.0 Level Measuring Syste .................................................4
2.0.1 FOUNDATION fieldbus™..................................4
2.1 Applicable Models.....................................................4
2.2 Miscellaneous Electrical Considerations ....................4
2.2.1 Pollution Degree 2 .........................................4
2.2.2 Overvoltage ....................................................5
3.0 Mean Ti e To Repair (MTTR).....................................5
4.0 Supple entary Docu entation......................................5
5.0 Instructions ....................................................................5
5.1 Systematic Limitations ..............................................5
5.1.1 Application.....................................................5
5.1.2 Environmental................................................6
5.2 Skill Level of Personnel .............................................6
5.3 Necessary Tools .........................................................6
5.4 Storage ......................................................................6
5.5 Installation ................................................................7
5.6 Configuration ...........................................................7
5.6.1 General...........................................................7
5.6.2 Write Protecting / Locking.............................7
5.6.3 Write Enabling / Unlocking ...........................8
5.7 Site Acceptance Testing .............................................8
5.8 Recording results.......................................................8
5.9 Maintenance ..............................................................8
5.9.1 Diagnostics.....................................................8
5.9.2 Troubleshooting .............................................8
6.0 Recurrent Function Tests ...............................................9
6.1 Proof Testing.............................................................9
6.1.1 Introduction...................................................9
6.1.2 Interval...........................................................9
6.1.3 Recording Results...........................................9
6.1.4 Proof Test Procedure.....................................10
7.0 Appendices ................................................................... 12
7.1 FMEDA Report- Management Summary ..............12
7.2 SIL Declaration of Conformance ............................14
7.3 Specific Model R86 values ......................................14
7.4 Report- Lifetime of Critical Components ...............15
Pulsar®Model R86 Pulse Burst Radar Level Trans itter
SIL 2 Suitable

3
58-651 Pulsar®Model R86 SIL Functional Safety Manual
1.0 I troductio
1.1 Product Descriptio
The Pulsar®Model R86 Pulse Burst Radar Level
Transmitter is a loop-powered, 24 VDC level transmitter
based on Pulse Burst Radar technology. For Safety
Instrumented Systems usage, it is assumed that the 4–20 mA
output is used as the primary safety variable. The analog
output meets NAMUR NE 43 (3.8 mA to 20.5 mA
usable), and the transmitter contains self-diagnostics and
can be programmed to send its output to a user-selected
failure state, either low or high upon internal detection of
a failure. The device can be equipped with or without an
LCD display. Table 1 lists the versions of the PULSAR
Model R96 that have been considered for the hardware
assessment.
1.2 Theory of Operatio
PULSAR Model R86 is a top-mounted, downward-facing
pulse burst radar transmitter operating at 26 GHz. Unlike
true pulse devices that transmit a single, sharp (fast rise-
time) waveform of wide-band energy, the PULSAR Model
R86 emits short bursts of 26 GHz energy and measures the
transit time of the signal reflected off the liquid surface.
Distance is calculated utilizing the equation
Distance = C ×Transit time/2, then developing the Level
value by factoring in application-specific configuration.
The PULSAR Model R86 is classified as a Type B device
according to IEC 61508.
1.3 Determi i g Safety I tegrity Level (SIL)
Tables 2 & 3 define the criteria for the achievable SIL
against the target mode of operation in Demand Mode
Operation.
Table 2 shows the relationship between the Safety Integrity
Level (SIL) and the Probability of Failure on Demand
Average (PFDavg).
Table 3 can be used to determine the achievable SIL as a
function of the Hardware Fault Tolerance (HFT) and the
Safe Failure Fraction (SFF) for the complete safety system
(type B – complex components as per IEC 61508 Part 2) of
which the level transmitter is one component.
R86-51XX-aXX
(a=0, 1, A, C or D)
Intrinsically Saf
R86 is energy limited but
not isolated from current
loop.
R86-51XX-aXX
(a=3 or B)
Explosion Proof
R86 is galvanically isolated
from current loop.
Tabl 3
Minimum hardwar fault tol ranc
Typ B s nsors, final l m nts and non-PE logic solv rs
SFF
Hardwar Fault
Tol ranc (HFT)
012
None: <60% Not
Allowed SIL 1 SIL 2
Low: 60% to <90% SIL 1 SIL 2 SIL 3
Medium: 90% to <99% SIL 2 SIL 3
High: ≥99% SIL 3
Tabl 2
SIL vs. PFDavg
Tabl 1
Pulsar®Mod l Numb r
Saf ty
Int grity L v l
(SIL)
Targ t Av rag
probability of failur
on d mand (PFDavg)
≥10-5 to <10-
3≥10- to <10-3
2≥10-3 to <10-2
1≥10-2 to <10-1
The R86 is classified as a Type B2element according to
IEC 61508, having a hardware fault tolerance of 0)

458-651 Pulsar®Model R86 SIL Functional Safety Manual
2.0 Level Measuri g System
The diagram shows the structure of a typical measuring
system incorporating the MAGNETROL PULSAR Model
R86 Pulse Burst radar transmitter.
This SIL rated device is only available with an analog signal
(4–20 mA) with HART digital communication. (The meas-
urement signal used by the logic solver must be the analog
4– 20 mA signal proportional to the level generated).
For fault monitoring, the logic unit must recognize both
high alarms (21.5 mA) and low alarms (3.6 mA). If the
logic solver loop uses intrinsic safety barriers, caution must
be taken to ensure the loop continues to operate properly
under the low alarm condition.
The only unsafe mode is when the unit is reading an incor-
rect level within the 4–20mA range (> ±2% deviation).
MAGNETROL defines a safe failure as one in which the
4–20 mA current is driven out of range (i.e., less than
3.8 mA or greater than 20.5 mA).
2.0.1 FOUNDATION fi ldbus™
Although the PULSAR Model R86 is available with
FOUNDATION fieldbus™output, it does not presently meet
the FF-SIS standard.
2.1 Applicable Models
This manual is applicable to the following PULSAR Pulse
Burst Radar transmitters
R86-51XX-aXX (a=0, 1, 3, A, B, C or D)
2.2 Miscella eous Electrical Co sideratio s
Following are miscellaneous electrical issues to be considered.
2.2.1 Pollution D gr 3
The PULSAR system is designed for use in Category II,
Pollution Degree 3 installations.
The typical pollution degree used for equipment being eval-
uated to IEC/EN 61010 is a nonconductive pollution of
the sort where a temporary conductivity caused by conden-
sation might be expected.
Actuator
PACTware
HART Modem
Pulsar®Model R86
Logic
Unit
Figur 1
Typical Syst m

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58-651 Pulsar®Model R86 SIL Functional Safety Manual
2.2.2 Ov rvoltag
The MAGNETROL Model R86 has over-voltage protection
per CE requirements. When considering Hi-pot, Fast
Transients and Surge, this protection is to 1000 volts.
Therefore, there should be no unsafe failure modes up to 1 KV.
Overvoltage Category II is a local level, covering appliances,
portable equipment, etc., with smaller transient overvoltages
than those characteristic of Overvoltage Category III. This
category applies from the wall plug to the power-supply iso-
lation barrier (transformer). The typical plant environment
is Overvoltage Category II, so most equipment evaluated to
the requirements of IEC/EN 61010 are considered to
belong in that classification.
3.0 Mea Time To Repair (MTTR)
SIL determinations are based on a number of factors includ-
ing the Mean Time To Repair (MTTR). The analysis for
the PULSAR Model R86 is typically based on a MTTR of
24 hours.
4.0 Suppleme tary Docume tatio
The PULSAR Model R86 Installation and Operating
Manual Bulletin 58-603 must be available for installation of
the measuring system.
One of the following Electronic Device Description Files is
also required if HART is used
Manufacturer Code 0x0056
Model R86 1.x Device ID 0x56DD, device revision 1,
DD revision 1.
For device installations in a classified area, the relevant safety
instructions and electrical codes must be followed.
5.0 I structio s
5.1 Systematic Limitatio s
The following factors must be observed to avoid systematic
failures.
5.1.1 Application
Choosing the proper Pulse Burst Radar antenna is the most
important step in the application decision process. The
antenna configuration establishes fundamental performance
characteristics. Therefore, the horn antenna for use with the
PULSAR Model R86 should be selected as appropriate for
the application.

See Sections 2.3 & 2.4 of Installation and Operating
Manual 58-603 for more detailed application information
and limitations.
5.1.2 Environm ntal
See Section 3.7 of Installation and Operating Manual
58-603 for environmental limitations.
5.2 Skill Level of Perso el
Personnel following the procedures of this safety manual
should have technical expertise equal to or greater than that
of a qualified instrument technician.
5.3 Necessary Tools
Following are the necessary tools needed to carry out the
prescribed procedures
• Open-wrenches or adjustable wrench to fit the process con-
nection size and type.
•Antenna 2" (50 mm)
•Transmitter 11⁄2" (38 mm)
•Torque wrench is highly desirable
• Flat-blade screwdriver
• Digital multimeter
• 24 VDC power supply, 23 mA minimum
5.4 Storage
The device should be stored in its original shipping box
and not be subjected to temperatures outside the storage
temperature (-50 to +80 °C) shown in the PULSAR Model
R86 Installation and Operating Manual and associated
specifications.
658-651 Pulsar®Model R86 SIL Functional Safety Manual

5.5 I stallatio
Refer to the PULSAR Model R86 Installation and
Operating Manual Bulletin 58-603 for the proper installa-
tion instructions.
Section 2.6 of I/O Manual 58-603 contains information on
the use, changing and resetting of the password protection
function.
Section 2.6 of I/O Manual 58-603 provides menu selection
items for configuration of the transmitter as a level sensing
device and also contains configuration recommendations.
This SIL evaluation has assumed that the customer will be
able to acknowledge an over or under current condition via
the Logic Solver.
5.6 Co figuratio
5.6.1 G n ral
The MAGNETROL PULSAR Model R86 can be config-
ured via the local display, or via HART compatible hand-
held terminal or personal computer.
Ensure the parameters have been properly configured for
the application.
Special consideration should be given to the following con-
figuration parameters
DIELECTRIC RANGE: Enter the Dielectric Range for the
material to be measured
Above 10 (Water-based media)
3.0 to 10 (Mid-dielectric media)
1.7 to 3.0 (Most typical hydrocarbons)
Below 1.7 (Light Hydrocarbons like Propane and Butane) —
(stillwell only)
PV ALARM SELECTION: Do NOT choose HOLD for
this parameter as a Fault will not be annunciated on the
current loop.
LOOP CURRENT MODE: ensure this is set to ENABLED.
PASSWORD: should be changed to a specific value other
than Zero. See Section 5.6.2
5.6.2 Writ Prot cting / Locking
The PULSAR Model R86 is password protected with a
numerical password between 0 and 59999
(Default=0=Password disabled).
Refer to section 2.6 of the PULSAR Model R86 Installation
and Operating Manual Bulletin 58-603 for information on
password protection.
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58-651 Pulsar®Model R86 SIL Functional Safety Manual

5.6.3 Writ Enabling / Unlocking
Refer to section 2.6 of the PULSAR Model R86 Installation
and Operating Manual Bulletin 58-603 for information on
password protection.
When the alterations to the system are complete, ensure the
menu has been locked with the password to prevent inad-
vertent changes to the device.
5.7 Site Accepta ce Testi g
To ensure proper operation after installation and configura-
tion a site acceptance test should be completed. This proce-
dure is identical to the Proof Test Procedure described in
Section 6.1.4.
5.8 Recordi g Results
Results of Site Acceptance Testing must be recorded for
future reference.
5.9 Mai te a ce
5.9.1 Diagnostics
Internal diagnostic testing does a complete cycle approxi-
mately four times per minute. A message will appear and
the Output current will be driven to 3.6 or 22 mA (cus-
tomer selectable) upon detection of a Diagnostic Failure.
Worst-case internal fault detection time is one minute.
5.9.2 Troubl shooting
Report all failures to MAGNETROL.
Refer to Section 3.4 of the PULSAR Model R86
Installation and Operating Manual Bulletin 58-603 for
troubleshooting device errors.
• As there are no moving parts in this device, the only main-
tenance required is the proof test.
• Firmware can only be upgraded by factory personnel.
858-651 Pulsar®Model R86 SIL Functional Safety Manual

6.0 Recurre t Fu ctio Tests
6.1 Proof Testi g
6.1.1 Introduction
Following are the procedures utilized to detect
Dangerous Undetected (DU) failures. The procedure
will detect approximately 90% of possible DU failures
in the Model R86.
6.1.2 Int rval
To maintain the Safety Integrity Level of a Safety
Instrumented System, it is imperative that the entire system
be tested at regular time intervals (referred to as TI in the
appropriate standards). The onus is on the owner/operator to
select the type of inspection and the time period for these
tests.
The system check must be carried out to prove that the
functions meet the IEC specification and result in the
desired response of the safety system as a whole.
This system check can be guaranteed when the response
height is approached in the filling process; though, if this is
not practical, a suitable method of simulating the level of
the physical measurement must be used to make the level
sensor respond as if the fill fluid were above the alarm/set
point level. If the operability of the sensor/transmitter can
be determined by other means that exclude all fault condi-
tions that may impair the normal functions of the device,
the check may also be completed by simulating the corre-
sponding output signal of the device.
6.1.3 R cording r sults
Results of the Proof Test should be recorded for future
reference.
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58-651 Pulsar®Model R86 SIL Functional Safety Manual

6.1.4 Proof T st Proc dur
1. Bypass the PLC or take other action to avoid a false trip.
2. Inspect the Unit in detail outside and inside for physical
damage or evidence of environmental or process leaks.
a. Inspect the exterior of the Unit housing. If there is any
evidence of physical damage that may impact the integri-
ty of the housing and the environmental protection, the
unit should be repaired or replaced.
b. Inspect the interior of the Unit. Any evidence of mois-
ture, from process or environment, is an indication of
housing damage, and the unit should be repaired or
replaced.
3. Use the Unit’s DIAGNOSTICS menu to observe Present
Status, and review EVENT HISTORY in the Event Log.
Up to 20 events are stored. The events will be date and time
stamped if the internal clock is set and running. It is sug-
gested that the internal clock be set at the time of commis-
sioning of the unit. If the clock is set at the time of the
proof test, event times are calculated.
a. Choose the menu DIAGNOSTICS / Present Status.
i. Present Status should be OK.
b. Choose the menu DIAGNOSTICS / EVENT HISTORY /
Event Log
i. Any FAULT or WARNING messages must be investi-
gated and understood.
ii. Corrective actions should be taken for FAULT
messages.
4. Use the DIAGNOSTICS menu to perform a “CURRENT
LOOP TEST”. Choose the menu DIAGNOSTICS /
ADVANCED DIAGNOSTICS / TRANSMITTER TESTS /
Analog Output Test to change the output loop current and
confirm the actual current matches the value chosen.
a. Send a HART command to the transmitter (or use the
local interface) to go to the high alarm current output,
22mA, and verify that the analog current reaches that
value.
i. This step tests for compliance voltage problems such as
low supply voltage or increased wiring resistance.
ii. This also tests for current loop control circuitry and
adjustment problems.
b. Send a HART command to the transmitter (or use the
local interface) to go to the low alarm current output,
3.6mA, and verify that the analog current reaches that
value.
10 58-651 Pulsar®Model R86 SIL Functional Safety Manual

11
58-651 Pulsar®Model R86 SIL Functional Safety Manual
i. This step tests for high quiescent current and supply
voltage problems.
ii. This also tests for current loop control circuitry and
adjustment problems.
c. Exit the “Analog Output Test” and confirm that the out-
put returns to original state, with the proper loop current
as indicated and controlled by the unit.
5. Use the DIAGNOSTICS menu to observe the present Echo
Curve. Confirm that the ECHO Waveform is normal. The
echo curve is dependent on the type of antenna used, the
installation conditions and the level of process. Comparison
of the present Echo curve to one stored at the time of com-
missioning the unit gives additional confidence of the nor-
mal operation of the unit. Use of the DTM and digital
communications is necessary for comparison of echo curves.
a. Choose the menu DIAGNOSTICS / ECHO CURVES /
View Echo Curve
i. Observe the present Echo Curve, identify the character-
istic portions of the waveform related to the Initial
Launch, Process level, and other features.
ii. Confirm that the Initial Launch appears acceptable.
Confirm that Initial Launch is located where expected.
iii. Confirm that the signal from the process level appears
normal and is located as expected.
iv. Compare to Echo curve from commissioning in the
Initial Launch area.
6. Perform 2 point calibration check of the transmitter by
varying level to two points in the process and compare the
transmitter display reading and the current level value to a
known reference measurement.
7. If the calibration is correct the proof test is complete.
Proceed to step 9.
8. If the calibration is incorrect, remove the transmitter and
antenna from the process. Inspect the antenna for coating.
Clean the antenna, if necessary. Perform a bench calibration
check by placing a metal reflector at two points in front of
the antenna. Measure the distance of the two points and
compare to the transmitter display and current level read-
ings.
a. If the calibration is off by more than 2%, call the factory
for assistance.
b. Re-install the antenna and transmitter.
9. Restore loop to full operation.

12 58-651 Pulsar®Model R86 SIL Functional Safety Manual
7.0 Appe dices
7.1 FMEDA Report: Exida Ma ageme t Summary

13
58-651 Pulsar®Model R86 SIL Functional Safety Manual

14 58-651 Pulsar®Model R86 SIL Functional Safety Manual
7.3 Specific Model R86 Values
Product
PULSAR
R86-51XX-aXX
(a=1 or A)
PULSAR
R86-51XX-aXX
(a=3 or B)
SIL SIL 2
HFT 0
SFF 93.2% 93.0%
Sp cific Mod l R86
7.2 SIL Declaratio of Co formity
Hardware functional safety according to Section 2.4.4 of
IEC 61508-2 (Edition 2.0 2010).
Magnetrol International, Incorporated 705 Enterprise
Street, Aurora, Illinois 60504 declares as the manufacturer,
that the level transmitter
Pulse Burst Radar (4-20 mA) Model R86-511x-xxx
is suitable for use in safety-instrumented loops according
to IEC 61508 on condition that “the good practice of
engineering rules” as described in the IEC standards, the
appropriate parts of IEC 61508/61511, and the following
parameters of the instrument are applied.
Refer to Section 5 and Appendix D of the Model R86
FMEDA report for PFDavg information.
Product Mod l R96-51xx-axx
(a=1 or A)
Mod l R96-51xx-axx
(a=3 or B)
SIL 2 2
Proof Test Interval 1 Year 1 Year
Device Type B B
SFF 93.2% 93.0%
λSD 0 FIT 0 FIT
λSU 78 FIT 183 FIT
λDD 953 FIT 905 FIT
λDU 75 FIT 81 FIT

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58-651 Pulsar®Model R86 SIL Functional Safety Manual
7.4 Report: Lifetime of Critical Compo e ts
According to section 7.4.9.5 of IEC 61508-2, a useful life-
time, based on experience, should be assumed.
Although a constant failure rate is assumed by the proba-
bilistic estimation method, this only applies provided that
the useful lifetime* of components is not exceeded. Beyond
their useful lifetime the result of the probabilistic calcula-
tion method is therefore meaningless, as the probability of
failure significantly increases with time. The useful lifetime
is highly dependent on the subsystem itself and its operating
conditions.
This assumption of a constant failure rate is based on the
bathtub curve. Therefore, it is obvious that the PFDavg cal-
culation is only valid for components that have this con-
stant domain and that the validity of the calculation is lim-
ited to the useful lifetime of each component.
It is the responsibility of the end user to maintain and oper-
ate the R86 per manufacturer’s instructions. Furthermore,
regular inspection should show that all components are
clean and free from damage.
The R86 has an estimated useful lifetime of about 50 years.
When plant experience indicates a shorter useful lifetime
than indicated in this appendix, the number based on plant
experience should be used.
* Useful lifetime is a reliability engineering term that describes the operational
time interval where the failure rate of a device is relatively constant. It is not a
term which covers product obsolescence, warranty, or other commercial issues.

BULLETIN: 58-651.1
EFFECTIVE: July 2017
SUPERSEDES: April 2017
Service Policy
Owners of MAGNETROL controls may request the
return of a control or any part of a control for complete
rebuilding or replacement. They will be rebuilt or
replaced promptly. Controls returned under our service
policy must be returned by prepaid transportation.
MAGNETROL will repair or replace the control at no
cost to the purchaser (or owner) other than transportation
if
1. Returned within the warranty period; and
2. The factory inspection finds the cause of the claim to
be covered under the warranty.
If the trouble is the result of conditions beyond our con-
trol; or, is NOT covered by the warranty, there will be
charges for labor and the parts required to rebuild or
replace the equipment.
In some cases it may be expedient to ship replacement
parts; or, in extreme cases a complete new control, to
replace the original equipment before it is returned. If this
is desired, notify the factory of both the model and serial
numbers of the control to be replaced. In such cases, cred-
it for the materials returned will be determined on the
basis of the applicability of our warranty.
No claims for misapplication, labor, direct or consequen-
tial damage will be allowed.
Return Material Procedure
So that we may efficiently process any materials that are
returned, it is essential that a “Return Material
Authorization” (RMA) number be obtained from the
factory prior to the material’s return. This is available
through a MAGNETROL local representative or by con-
tacting the factory. Please supply the following information
1. Company Name
2. Description of Material
3. Serial Number
4. Reason for Return
5. Application
Any unit that was used in a process must be properly
cleaned in accordance with OSHA standards, before it is
returned to the factory.
A Material Safety Data Sheet (MSDS) must accompany
material that was used in any media.
All shipments returned to the factory must be by prepaid
transportation.
All replacements will be shipped F.O.B. factory.
ASSURED QUALITY & SERVICE COST LESS
• ANSI/ISA-84.00.01-2004 Part 3 (IEC 61511-3Mod)
“Functional Safety Safety Instrumented Systems for the
Process Industry Sector – Part 3 Guidance for the
Determination of the Required Safety Integrity Levels –
Informative”
• ANSI/ISA-TR84.00.04 Part 1 (IEC 61511 Mod)
“Guideline on the Implementation of ANSI/ISA-
84.00.01-2004”
Disclai er
The SIL values in this document are based on an FMEDA analysis using exida’s SILVER Tool. MAGNETROL accepts
no liability whatsoever for the use of these numbers of for the correctness of the standards on which the general
calculation methods are based.
References
• ANSI/ISA-84.00.01-2004 Part 1 (IEC 61511-1Mod)
“Functional Safety Safety Instrumented Systems for
the Process Industry Sector – Part 1 Hardware and
Software Requirements”
• ANSI/ISA-84.00.01-2004 Part 2 (IEC 61511-2Mod)
“Functional Safety Safety Instrumented Systems for
the Process Industry Sector – Part 2 Guidelines for the
Application of ANSI/ISA84.00.01-2004 Part 1 (IEC
61511-1 Mod) – Informative”
Magnetrol and Magnetrol logotype are registered trademarks of Magnetrol International.
705 Enterprise Street • Aurora, Illinois 60504-8149 USA
630.969.4000 • [e-mail] • magnetrol.com
Copyright © 2021 Magnetrol International, Incorporated