Milltronics 160 User manual

33455500
Rev. 3.1
IQ RADAR 160
Instruction Manual PL-550 January 2001
IQ RADAR I60

© Siemens Milltronics Process Instruments Inc. 2001
Safety Guidelines
Warning notices must be observed to ensure personal safety as well as that of others, and to
protect the product and the connected equipment. These warning notices are accompanied
by a clarification of the level of caution to be observed.
Qualified Personnel
This device/system may only be set up and operated in conjunction with this manual.
Qualified personnel are only authorized to install and operate this equipment in accordance
with established safety practices and standards.
Warning: This product can only function properly and safely if it iscorrectly transported,
stored, installed, set up, operated, and maintained.
Note: Always use product in accordance with specifications.
Copyright Siemens Milltronics Process
Instruments Inc. 2000. All Rights Reserved Disclaimer of Liability
This document is available in bound version and in
electronic version. We encourage users to
purchase authorized bound manuals, or to view
electronic versions as designed and authored by
Siemens Milltronics Process Instruments Inc.
Siemens Milltronics Process Instruments Inc. will
not be responsible for the contents of partial or
whole reproductions of either bound or electronic
versions.
While we have verified the contents of
this manual for agreement with the
instrumentation described, variations
remain possible. Thus we cannot
guarantee full agreement. The
contents of this manual are regularly
reviewed and corrections are included
in subsequent editions. We welcome
all suggestions for improvement.
Technicaldata subject to change.
MILLTRONICS®is a registered trademark of Siemens Milltronics Process Instruments Inc.
Contact SMPI Technical Publications at the following address:
Technical Publications
Siemens Milltronics Process Instruments Inc.
1954 Technology Drive, P.O. Box 4225
Peterborough, Ontario, Canada, K9J 7B1
Email: [e-mail]
For the library of SMPI instruction manuals, visit our Web site: www.milltronics.com

PL-550 IQ Radar 160/160 Ex Page 3
Table of Contents
General Information.........................................................................................5
About this Manual......................................................................................5
About IQ Radar 160/160 Ex......................................................................6
Specifications...................................................................................................7
IQ Radar 160/160 Ex................................................................................7
Installation.......................................................................................................11
Location ...................................................................................................11
Dimensions: Standard Unit with Rod Antenna.......................................12
Dimensions: Ex Unit with Rod Antenna.................................................13
Dimensions: Threaded Rod....................................................................14
Dimensions: Horn....................................................................................15
Dimensions: Waveguide Extension........................................................16
Dimensions: Sanitary Horn.....................................................................17
Dimensions: Sanitary Rod......................................................................18
Dimensions: Waveguide.........................................................................19
Dimensions: Flanges ..............................................................................20
Mounting..................................................................................................21
Rod Assembly.........................................................................................23
Mounting: Rod Assembly........................................................................24
Mounting: Manhole Covers.....................................................................25
Mounting: Horn Antennas.......................................................................25
Mounting: Waveguide Antenna..............................................................26
Mounting: Still pipe or Side pipe.............................................................27
Mounting: Horn with Waveguide Extensions.........................................28
Mounting: Sanitary Mounting..................................................................28
Mounting: Location/Beam Angle ............................................................29
Interconnection........................................................................................30
Start Up............................................................................................................33
Overview..................................................................................................33
Display.....................................................................................................35
Aiming the Hand Programmer................................................................35
Local Operation.......................................................................................36
Operation ........................................................................................................41
Overview..................................................................................................41
Transceiver..............................................................................................41
Loss of Echo............................................................................................42
Blanking...................................................................................................42
Analog Output..........................................................................................43
Run / Program.........................................................................................45
Application Example: Asphalt in Storage Tank......................................46
Application Example: Horizontal Tank with Volume..............................47

Page 4 IQ Radar 160/160 Ex PL-550
Application Example: Juice Batch Tank with Sanitary Horn Antenna ..48
Application Example: Sliding Waveguide on Anaerobic Digesters.......49
Application Example: Stand Pipe .........................................................50
Parameter Descriptions..............................................................................53
Troubleshooting
.........................................................................................63
Maintenance
...............................................................................................64
Appendix I....................................................................................................65
Alphabetical Parameter List .................................................................65
Appendix II...................................................................................................67
Appendix III..................................................................................................69
Temperature Derating ..........................................................................69
Rod Antenna ANSI Hole Pattern, 150# ................................................70
Rod Antenna DN Hole Pattern, PN16 ..................................................70
Rod Antenna Threaded Connection.....................................................71
Rod Antenna Sanitary Connection.......................................................71
Horn Antenna or Wave Guide Still Pipe – ANSI Hole Pattern, 150#....72
Horn Antenna or Wave Guide Still Pipe DN Hole Pattern, PN16 .........72
Horn Antenna Sanitary Connection......................................................73
Appendix IV .................................................................................................75
BZT Approval – English........................................................................75
BZT Approval – German Original Text.................................................76
Index.............................................................................................................77

PL-550 IQ Radar 160/160 Ex Page 5
General Information
General Information
About this Manual
Refer to this manual for proper installation and operation of your IQ Radar
160/160 Ex.
Installation gives you step-by-step direction for the installation and
interconnection of your IQ Radar 160/160 Ex.
Start-up instructs you in how to operate the keypad, program the
unit and read the display.
Operation describes the operation of the IQ Radar 160/160 Ex.
Applications looks at the IQ Radar 160/160 Ex from a practical point of
view, using a typical application example.
Parameters lists the parameters available to you, with a description of
their function and use. You are urged to read this section
to familiarize yourself with the parameters available to you
and get your IQ Radar 160/160 Ex working to its fullest.
Troubleshooting tabulates symptoms, causes and actions to common
installation and application problems that you might
encounter. Hopefully you will never have to read this
section, but know it’s there to help you.
Appendices An alphabetical cross-reference of the parameters and
their numbers, a record sheet for jotting down parameter
values, a Temperature Derating Chart, as well as a list of
approvals and certificates.

Page 6 IQ Radar 160/160 Ex PL-550
General Information
About IQ Radar 160/160 Ex
The IQ Radar 160/160 Ex is to be used only in the manner outlined in this
manual.
IQ Radar 160/160 Ex is a versatile process material level monitoring
instrument. Material level measurement is achieved using advanced pulse
radar techniques. The unit consists of an electronic component coupled to the
antenna and process connection.
IQ Radar 160/160 Ex Features:
{ANSI, DIN flange or sanitary tri-clamp mounting
{corrosion-resistant construction, epoxy coated aluminium enclosure with
stainless steel flange and Teflon®1antenna and process seal.
{local display
{infrared keypad
{Dolphin-compatible
IQ Radar 160/160 Ex Applications:
{liquids, slurries
{process temperatures up to 200°C
{vacuum and pressurized vessels
IQ Radar 160/160 Ex Approvals and Certificates
{safety and radio
{hazardous area
Note:
See Specifications on page 7 for an approvals listing and Appendix IV on
page 75 for approvals documentation.
1 Teflon is a registered trademark of Du Pont

PL-550 IQ Radar 160/160 Ex Page 7
Specifications
Specifications
Every attempt has been made to ensure the accuracy of these specifications,
however Milltronics reserves the right to change them at any time. Contact
your Milltronics representative for the most recent specifications.
IQ Radar 160/160 Ex
Power:
{AC version: {100/115/200/230 ±15% V ac2, 50/60 Hz, 15 VA
{DC version: {18 –36 V dc, 15W
Fuse:
{AC version: {FU1, 2AG type, slow blow, .25 Amp, 250V
{DC version: {F1, 2AG type, slow blow, 0.375A, 250V
Interface:
{analog output: {optically-isolated 0/4-20 mA into 750 Ωmax, 0.02
mA resolution
{Dolphin/RS-485 link: {refer to Dolphin Plus product specification
{programmer link: {infrared receiver (refer to Programmer
specification on page 9)
{display (local): {backlit, alphanumeric and multi-graphic liquid
crystal for readout and entry
Performance:
{frequency: {5.8 GHz (U.S.A. 6.3 GHz)
{accuracy at 20°C: {better than ±0.3% of range from 1 to 15 m
{temperature drift: {<±0.5% of range from –40 to 60°C (-40 to 392°F)
{measuring range: {0.4 to 15 m
{repeatability: {± 10 mm
{fail-safe: {mA programmable high, low or hold upon LOE
condition
Mechanical:
Process Connections: Refer to Appendix III for pressure / temperature
limitations.
{flat faced flanges: {316 stainless steel, 2”, 3”, 4”, 50mm, 80mm,
100mm. Bolt hole pattern to ANSI & DIN types.
{threaded connection: {316 stainless steel, 1-1/2”or 2”, NPT, BSP,G
{sanitary connection: {316 stainless steel, 2”, 3”, or 4”tri-clamp
2Factory set –see device nameplate

Page 8 IQ Radar 160/160 Ex PL-550
Specifications
Antennas:
{dielectric rod: {Teflon®3(PTFE)
{Ultra high molecular weight Polyethylene
(UHMW-PE4)
{Length 41cm (16.3”) including integral gasket
{horn: {316 stainless steel
{nominal diameters 100mm (4”), 150mm (6”),
200mm (8”)
{emitter cone PTFE or UHMW-PE4
{waveguide extensions optional
{waveguide: {316 stainless steel
{emitter cone PTFE or UHMW-PE4
Sanitary Antennas (FDA approved materials):
{dielectric rod: {one piece UHMW-PE4, optional PTFE
{2”, 3”, 4”tri-clamp connection
{horn: {304 stainless steel (316 special order)
{horn with integral 4”tri-clamp connection
{PTFE emitter
Enclosure (electronic):
{construction: {aluminium, epoxy coated
{conduit: {2 x 1/2" NPT or PG 16 entry
{ingress protection: {Type 6 / NEMA 6, IP-67
Weight:
{6.5 kg (14.3 lb) with 2"/150 psi flange
weight will vary with flange size and rating
Environmental:
{location: {indoor/outdoor
{altitude: {2000 m max
{ambient temperature: {-40 to 60°C (-40 to 140°F)5
{relative humidity: {suitable for outdoor
(Type 6/NEMA 6/IP 67 enclosure)
{installation category: {II for ac version; I for dc version
{pollution degree: {4
3Teflon is a registered trademark of Du Pont
4Not available for CENELEC EEx approval
5See Temperature Derating on page 69 and Approvals on page 9.

PL-550 IQ Radar 160/160 Ex Page 9
Specifications
Process:
{material dielectric: {εr> 1.8
(For εr< 3, you should use a wave guide antenna or
still pipe. See Mounting: Waveguide Antenna on page
26 or Mounting: Still pipe or Side pipe on page 27.)
{temperature: {UHMW-PE -40 to 80°C (-40 to 176°F)
{PTFE -40 to 200°C (-40 to 392°F)5
{pressure (vessel): {dependant on process connection type and
temperature. Refer to Appendix III on page 69 for
charts.
Approvals (refer to device nameplate):
{safety: {CSANRTL/C, CE, FM
{radio: {BAPT, Industry Canada, FCC
{hazardous areas:
{IQ Radar 160: {CSA Class I/II, Div.2, Group A, B, C, D, F
(standard) and G, Class III.
{CE, CSANRTL/C FM (non-hazardous)
{IQ Radar 160Ex6:{Cenelec/Sira7, EEx de IIB+H2 T6 (Note: antenna
may be used in Zone 0 environments).
{FM (USA) Class I, Div 1, Group A, B, C, D. Class
II/III, Div. 1, Group E, F, G (Class I, Zone 1 IIC
T6)
{CSA Class I/II, Div. 1, Group B, C, D, E, F, G.
{CE, CSANRTL/C FM (non-hazardous)
{Canadian Registration Number (CRN) for pressure fittings8:
Ontario, British Columbia, Alberta: OF6494.512
others pending
{3A Sanitary
Contact Milltronics for complete and up to date list of approvals.
Programmer (remote keypad):
{enclosure: {general purpose
67 mm w x 100 mm h x 25 mm d
(2.6" w x 4" h x 1" d)
{ambient temperature: {-20 to 50°C (-5 to 122°F)
{interface: {proprietary infrared pulse signal
{power: {9V battery (ANSI/NEDA 1604, PP3 or equivalent)
{weight: {150g (0.3 lb)
6Cenelec: -20 to 40°C (-4 to 104°F), CSA and FM: -20 to 60°C (-4 to 140°F) ambient
7Approved for PTFE material only
8All process connections except for the sliding waveguide

Page 10 IQ Radar 160/160 Ex PL-550
Specifications

PL-550 IQ Radar 160/160 Ex Page 11
Installation
Installation
Location
Notes:
•Installation shall only be performed by qualified personnel and in
accordance with local governing regulations.
•This product is susceptible to electrostatic shock. Follow proper
grounding procedures.
•Do not mount in direct sunlight without the use of a sun shield.
Warning:
For vessels with conical or parabolic tops, it is not advisable to
mount the unit at the centre. Otherwise, the concavity of the top can
focus echoes into the centre, giving false readings.
Conical
Flat
Parabolic

Page 12 IQ Radar 160/160 Ex PL-550
Installation
Dimensions: Standard Unit with Rod Antenna
* Flange thickness 25 mm (1") nominal.
** Standard length, 50 and 100 mm (2”and 4") extensions available.
For information on temperature and pressure ratings, see Appendix III on
page 69.
enclosure/
electronics
antenna
(rod)
antenna
(resonator)
flange
136 mm
(
5.4"
)
75 mm
(3.0")
50 mm
(
2.0"
)
211 mm
(
8.3"
)
41 mm(1.6")
183 mm
(7.2")
412 mm *
*
(16.3")
245 mm
(9.6")
100 mm
(4.0")

PL-550 IQ Radar 160/160 Ex Page 13
Installation
Dimensions: Ex Unit with Rod Antenna
* Flange thickness 25 mm (1") nominal.
** Standard length, 50 and 100 mm (2”and 4") extensions available.
For information on temperature and pressure ratings, see Appendix III on
page 69.
enclosure/
electronics
antenna
(
rod
)
antenna
(resonator)
flange
136 mm
(
5.4"
)
75 mm
(3.0")
64 mm
(
2.5"
)
239 mm
(
9.4"
)
41 mm (1.6")
183 mm
(7.2")
245 mm
(9.6")
100 mm (4.0")
earth
connection
412 mm *
*
(16.3")

Page 14 IQ Radar 160/160 Ex PL-550
Installation
Dimensions: Threaded Rod
50 mm
(2”)
100 mm
(
4”
)
optional
extension
standard antenna
Teflon paste
(supplied)
Note:
Ingress of water or process fluids into the connecting
threads can cause reflections at the connection,
appearing as false echoes.
Apply Teflon paste to threads and tighten slowly.
Ensure that the rod sections mate securely with no
gaps. Do not apply too much Teflon paste or parts
will not mate securely.
Do not use wrenches or pliers. Hand tight only.
Sealant must have εr< 3. We recommend a sealant
such as Teflon paste or silicone compound.

PL-550 IQ Radar 160/160 Ex Page 15
Installation
Dimensions: Horn
Nominal
Horn
Size
Horn
O.D. Horn Height
Beam
Angle
100 mm
(4”) 95.3 mm
(3.75”)
131.0
mm
(5.16”)
28
degrees
150 mm
(6”) 146.0 mm
(5.75”)
225.8
mm
(8.89”)
20
degrees
200 mm
(8”) 199.4 mm
(7.85”)
325.1
mm
(12.8”)
12
degrees
flange
horn 131 mm
(5.16”)225.8 mm
325.1 mm
(12.8”)
enclosure /
electronics
100 mm
(4”)
150 mm
(6”)
200 mm
(8”)
∅80 mm
(3”)
Note:
Signal amplitude increases with horn
diameter, so use the largest size
practical.

Page 16 IQ Radar 160/160 Ex PL-550
Installation
Dimensions: Waveguide Extension
Note:
1. Maximum pressure 0.5 bar at 60 deg. C (140 deg. F) for sliding flange
option.
Note:
Always clamp the instrument in the
same position for operation.
(see P006 on page 53).
1000 mm
(40.8”)
optional sliding flange
(see flange table)
131 mm
(5.16”)
225 mm
(8.89”)
325 mm
(12.8”)

PL-550 IQ Radar 160/160 Ex Page 17
Installation
Dimensions: Sanitary Horn
50 mm (2”) clamp
(supplied)
100 mm (4”) clamp (optional)
Materials: standard optional
horn SS 304 SS 316
ferrule SS 304 SS 316
clamp SS 304 SS 316
gasket PTFE
horn
ferrule (optional)
gasket (optional)
232 mm
(9.13”)

Page 18 IQ Radar 160/160 Ex PL-550
Installation
Dimensions: Sanitary Rod
50 mm (2”), 80 mm (3”) or 100 mm (4”)
with integral gasket
Materials: SS304 standard
SS316 optional.
ferrule (optional)
clamp (optional)
406 mm (16”)
nominal

PL-550 IQ Radar 160/160 Ex Page 19
Installation
Dimensions: Waveguide
Note: you can connect multiple waveguides together (maximum 2).
variable
waveguide
41.4 mm
(1.69”)
76.2 mm
(3.0”)
min: 100 mm (4.08”)
max: 6000 mm (244.90”)

Page 20 IQ Radar 160/160 Ex PL-550
Installation
Dimensions: Flanges
Pipe Size Flange
Size
Flange
O.D.
Bolt Hole
Circle Ø
Bolt
Hole Ø
Number
of Bolts
2”ANSI 150# 6.0”4.75”.7”4
3”ANSI 150# 7.5”6.0”.75”4
4”ANSI 150# 9.0”7.50”.75”8
6”ANSI 150# 11.0”9.50”.88”8
8”ANSI 150# 13.5”11.75”.88”8
50 mm DN PN 16 165 mm 125 mm 18 mm 4
80 mm DN PN 16 200 mm 160 mm 18 mm 8
100 mm DN PN 16 220 mm 180 mm 18 mm 8
150 mm DN PN 16 285 mm 240 mm 22 mm 8
200 mm DN PN 16 340 mm 295 mm 22 mm 12
bolt hole
bolt hole
circle
horn / waveguide
mounting holes
(threaded)
45°
O.D.
bolt hole
circle
bolt hole
process side
enclosure mounting
holes (threaded)
20 mm (0.8”), nominal