BULLETIN 353A Guided Wave Radar Continuous Level

“Setting The Standard For Supplier Excellence”
®
G u i d e d Wa v e R a d a r
Continuous Level
Measurement System
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Proven TDR Technology (Time Domain Reflectometry)
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Five Decades Of Application Expertise In Bulk Solids
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Unique Network-Ready PC-Based Inventory
Management Software
BULLETIN 353A
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Proven F l e x a r ® Technology Installed In
Thousands Of Bulk Solids Applications
®
Reliable TDR (a.k.a Reflex Radar)
Technology Used For Decades
“Smart” Transmitter Output For Use With
Industry-Leading SiloTrack™ Inventory
Management Software
G u i d e d Wa v e R a d a r
Continuous Level
Measurement System
When All The Pieces Fit Just Right!
®
The F l e x a r continuous level measurement system is a
smart guided wave radar device used for monitoring
the level of powders, granules and other bulk solids. It
is also suitable for use with a multiplicity of liquids. It
is used in a wide assortment of vessels and industries
for measuring levels up to 200ft (60m) in height.
SiloTrack Software Is Network-Ready –
Virtually Unlimited Users (Local & Remote)
Measuring Range Up To 100ft (30m)
In Solids And 200ft (60m) In Liquids
Unaffected By Airborne Dust, Bulk Density,
Temperature, And Other Properties – Ideal
For Powders And Pneumatically Filled Solids
Bringing the Pieces Together: We uniquely combine
this proven technology with five decades of expertise
and focus in powder and bulk solids applications,
along with our SiloTrack™ inventory management
software interface. Monitor Technologies uniquely
provides the best solutions in level measurement and
inventory management of powders and bulk solids.
Process Temperatures To +392˚F (200˚C)
No Field Calibration Required - Easy
To Install And Setup
Optional Analog Output For Easy
Connection To Existing Control Systems
Or Indicating Devices
The F l e x a r sensor requires no field calibration and can
be setup easily by customer personnel without the use
of any special tools or training. F l e x a r units are suited
for almost any application, can operate with process
temperatures up to 392˚ F (200˚C), can be provided
with a variety of process connections and can work
reliably with materials having a wide range of bulk densities and dielectric constants.
Hazardous Location Approvals Available
F l e x a r is available with a choice of two outputs. The
standard output is a “smart” interface for use with
SiloTrack™ Version 3.5 PC-based inventory management software. This network-ready software provides
a flexible graphical interface for up to 128 “smart” output sensors. In lieu of this “smart” output, an optional
analog output is also available.
®
SiloTrack™
F l e x a r technology
installed on grain bin
at Ethanol plant
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Level Reflection
Flange Reflection
In the application of TDR for process level measurement micro-pulses are continuously transmitted along
a probe or “wave guide” at the speed of light. As soon
as the pulses reach the material surface they reflect
back to the sensor electronics unit. The time-of-flight
of the pulses is calculated and directly related to the
distance from the point at which the sensor is mounted
on the top of the vessel to the material surface (level).
The output from the electronics is continuously updated as the level of the material surface changes.
Time = Distance
Direct measuring Mode
Probe End Reflection
Empty Vessel
Flange
Reflection
®
F l e x a r smart guided wave radar sensors operate
using TDR (time domain reflectometry) principles that
were first developed in the middle part of the 20th century for use in the geological field. Further
development of TDR led to its use in the telecommunication industry for detecting breaks in cables. F l e x a r
technology was pioneered in the mid-late 1990’s when
TDR was applied to level measuring applications within the process measurement industry.
Signal
Signal
P R I N C I P L E O F O P E R AT I O N
Probe End Reflection
Filled Vessel
F l e x a r smart guided wave radar sensors are equipped
with two different measuring modes. In the Direct
measuring mode the pulses directly reflect off the
material surface back to the electronics unit. This
mode is typically used in applications where the material being measured has a dielectric constant as low as
2.1 for single-cable/rod probes and 1.8 † for twin-cable
probes.
For materials with dielectric constant below the above
mentioned limits, down to as low as 1.4 † , the second
measurement mode is used. This is the TBF (tank bottom following) mode, which is used due to the inability
of the pulses to adequately reflect off of the surface of
very low dielectric materials. In this measuring mode
the F l e x a r sensor has a “short circuit” at the bottom of
the probe at a precisely known distance from the sensor’s mounting point.
Time = Distance
TBF (Tank Bottom Following) Measuring Mode
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Overall measuring range effects the minimum dielectric constant that
can be measured.
T YPIC AL APPLIC ATIONS INCLUDE,
BUT ARE NOT LIMITED TO:
In the TBF mode the pulses travel through air at the
speed of light and then pass through the material in
the vessel at a slower speed, dependent on the specific dielectric constant. The pulses are reflected at the
short circuit back up the probe. F l e x a r sensors in the
TBF mode measure the time between the emission and
reception of the pulses from the probe short circuit.
Because the return time of a pulse when no material is
present (through air) is known, we can determine the
difference in time between the time-of-flight when
empty and the time-of-flight when filled as being
directly proportional to the material level in the vessel.
Feeds
Cement
Coal Dust
Lime
Powders
Grains
Carbon Black
Silica
®
F l e x a r technology
measuring the level
of a powder mixture
for glass production
Bulk Chemicals
Plastic Pellets
Aggregates
Oils
Fly Ash
Flour
PVC Powder
The maximum range for solids applications is typically
limited to 100ft (30m) †† due to load limits possible from
heavy materials in long ranges. Liquid applications
can extend up to 200ft (60m) †† . Any application requiring a continuous level measurement update where the
process temperature does not exceed 392˚ F (200˚C)
and 580psig (40bar) is possible. The 316 stainless
steel probes and threaded or flanged process connections make the F l e x a r continuous level measuring
system ideal for almost any bulk solid and liquid application. To ensure a successful and reliable
application, consult with the Monitor Technologies
factory-based technical support group to see if F l e x a r
is right for your application.
REMOTE INVENTORY MONITORING
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If material levels need to be monitored at one or many
locations (i.e. your facility, a location down the street,
or a plant on the other side of the world) the F l e x a r
system can provide continuous, reliable and accurate
measurements. Using SiloTrack™ Version 3.5 software, inventory monitoring from remote locations has
never been easier.
A P P L I C AT I O N S
®
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The F l e x a r smart guided wave radar continuous level
measuring system can be used in a wide variety of
applications, including powders, coarse/fine granular
solids, liquids, foodstuffs and even some corrosive
substances. F l e x a r sensor technology is proven in
many difficult applications including those where dust
levels make it difficult for other technologies to perform reliably, especially at long ranges.
††
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Maximum measuring range is also limited by the dielectric constant
of the material being measured.
t Dual Compartment Enclosure.
The F l e x a r smart guided wave radar sensor uses an
enclosure with two compartments, each with its own
access cover. This allows separation of access for
wiring and setup/display. The setup/display compartment is provided with a cover window allowing local
viewing of the LCD display. In addition, every unit is
provided with either two 1/2” NPT conduit entrances
(NPT threaded and ANSI flanged process connections)
or M20 cable connectors (BSP threaded and DN
flanged process connections).
F E AT U R E S
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t Solid-State Performance, No Moving Parts.
Unlike weight and cable based systems of old,
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F l e x a r guided wave radar sensors are state-of-theart and use a time-proven electronic method for
continuous measurement of a material level. This
non-mechanical means of measurement helps ensure
low maintenance.
t Measure Materials With Dielectric > 1.4 (TBF
Mode). F l e x a r sensors are capable of sensing and
measuring the level of most any material. Materials
with dielectric constants below 1.8-2.1 † require the
use of our TBF (tank bottom following) measuring
mode.
t Local LCD Display And Setup.
Each sensor includes a built-in user interface consisting of a three-line backlit LCD display, three
pushbuttons and three magnetic sensors (used to perform setup and interact with the unit without having to
remove the display cover).
t Unaffected By Dust And Changes In Material
Properties. The technology employed in F l e x a r units
has been proven to be unaffected by airborne dust
even during pneumatic filling operations. Unlike
through-air technologies such as ultrasonic, throughair radar and laser, F l e x a r can reliably measure in
dusty environments without sacrificing performance
or reliability.
t Universal Power Supply.
Power supply choices include a universal high voltage
option 100-240 VAC and a low voltage 24 VAC/VDC
option.
t Choice of outputs.
The standard output for all F l e x a r guided wave radar
units is a “smart” RS-485 communications interface
for use with SiloTrack™ Version 3.5 inventory management software. In lieu of this “smart” interface an
analog 4-20mA output is available.
t Range Of Probes.
In order to handle the assortment of applications possible with F l e x a r , Monitor offers a range of probe
styles including single-cable, twin-cable and singlerod. All probes are constructed of 316 stainless steel,
have traction load handling capabilities suitable for
their respective applications and are easily field
replaceable. Consult with Monitor’s factory-based
technical support personnel to select the right probe
style for your application.
®
Flexar technology on
cement powder silo at
concrete batch plant
t Assortment Of Process Connections.
To meet the required bulk solids and liquid applications we have prepared a selection of process
connections that will ensure a smooth and simple
installation. F l e x a r sensors can be provided with 11/2” NPT, 1-1/2” BSP G, 2” ANSI or DIN DN50PN40
flange connections. Probe type will determine the
available process connections.
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Overall measuring range effects the minimum dielectric constant that
can be measured.
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t Hazardous location approvals available.
All units include the CE mark and are approved for use
in ordinary locations. When required, F l e x a r sensors
can be provided approved for use in hazardous areas
worldwide. F l e x a r is available with ATEX and CSA US/C
approvals for hazardous areas.
t Remote electronics available.
The standard unit includes the electronics integrally
mounted with the sensor. However, remote mounted
electronics is optionally available for applications
where the electronics are desired to be mounted away
from the probe due to extreme vibration, temperature
or for convenient access to the local operator interface. The remote electronics version includes a
pre-wired 16.4ft (5m) interconnecting cable.
PROBE STYLES
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Single Cable 0.16” (4mm)
Single Cable 0.31” (8mm)
Twin Cable 0.16” (4mm)
Single Rod 0.38” (10mm)
Single flexible 316 SS cable
with counterweight
Single Flexible 316 SS cable
with counterweight
Two flexible 316 SS cables
with spacers between them at
intervals, w/ counterweight
Single 316 SS rigid rod
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Vessel height < 200ft (60m) ;
Low dielectric liquids, some
granules (consult Monitor)
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Vessel height < 150ft (45m) ;
Liquids; Some solids
(consult Monitor)
††
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Vessel height < 100ft (30m) ;
Powders and other bulk solids
(consult Monitor)
Maximum measuring range is also limited by the dielectric constant of the material being measured.
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††
Vessel height < 10ft (3m) ;
Liquids; Some powders
(consult Monitor)
PC-BASED
I N V E N T O RY M A N A G E M E N T S O F T WA R E
SiloTrack™
Server Software
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SiloTrack™ Version 3.5 Inventory Management
Software provides users with an unsurpassed, flexible
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graphical interface for F l e x a r smart guided wave
radar sensors. Together, SiloTrack Server and Client
software can provide inventory monitoring and management to a virtually unlimited number of users, both
internal and external to your facility. This allows easy
implementation of remote monitoring and vendor
managed inventory programs.
SiloTrack™
Client Software
SiloTrack capabilities include:
t Monitor up to 128 sensors/with up to 5 sensors per vessel
t Easy to setup and use
t Network-ready
t Remote monitoring via LAN, Internet/WAN or dial-up
t Available in English/Spanish language
t Automatic and manual measurement initiation
t Curve-fit weight table
t Enhanced 3-D type silo graphics
t Export silo history and alarm data
t Automatic Reports and Scheduling
SiloTrack™ Client Software for Vendor Managed Inventory
t Set up four alarms per silo
t Alarm notification via e-mail, fax, and/or pager
Please refer to Bulletin 343B for additional information.
Remote and local monitoring of plastic storage at four facilities
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SENSOR MECHANICALS
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O R D E R I N G I N F O R M AT I O N
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F l e x a r ® Guided Wave Radar 1
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8 X X X
ELECTRONICS TYPE
1 = Integral Electronics
2 = Remote Electronics 5
X X X X
COUNTERWEIGHTS
1 = For 0.16” (4mm) single cable
2 = For 0.31” (8mm) single cable, large CW
3 = For 0.31” (8mm) single cable, small CW
4 = For 0.16” (4mm) twin cable
5 = None required (rods only)
OUTPUT
1 = “Smart” RS-485 2
2 = Analog 4-20mA
3 = “Smart” RS-485+
Passive Analog
4-20mA 8
PROBE CONNECTION
1 = 1-1/2” NPT Threaded 3
2 = G 1-1/2 (1-1/2” BSP) Threaded 3, 4
3 = 2” ANSI 150lb Flange, SS
4 = DN50PN40 DIN Flange, SS
OPERATING VOLTAGE
1 = Universal High Voltage (100-240VAC)
2 = Low Voltage (24VAC/VDC)
APPROVALS
1 = Ordinary Location
2 = Hazardous Location CSA US/C (North America) (see specifications for details) 5
3 = Hazardous Location ATEX (see specifications for details) 5
PROBE TYPE 7
1 = Single Cable, SS, 0.16” (4mm) Diameter
2 = Single Cable, SS, 0.31” (8mm) Diameter
3 = Twin Cable, SS, 0.16” (4mm) Diameter
4 = Single Rod, SS, 0.38” (10mm) Diameter
16-3060
16-3062
16-3064
16-3066
16-3070
16-3072
ACCESSORIES
FLANGE, 2” ANSI 150 LB, 1-1/2 NPT 6, Carbon Steel, Powder Coat
FLANGE, DN50 PN40, 1-1/2 NPT 6, Carbon Steel, Powder Coat
FLANGE, 4” ANSI 150 LB, 1- 1/2 NPT 6, Carbon Steel, Powder Coat
FLANGE, DN100 PN40, 1-1/2 NPT 6, Carbon Steel, Powder Coat
FLANGE, K-STYLE, FLAT, 1 1/2 NPT 6, Aluminum
FLANGE, K-STYLE, 10 DEG, 1 1/2 NPT 6, Aluminum
Note:
1
2
3
4
5
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Consult Monitor Technologies factory for all applications prior to pricing and issuing quotation.
For use with SiloTrack V3.5 and higher
Single Cable/Rod Probes Only
Availability of G 1-1/2 threaded process connection is “pending”. Consult factory.
Hazardous Location approval of Remote Electronics version is “pending”. Consult Factory.
®
Flange accessories include a 1-1/2” NPT center hole for attaching to Flexar units with 1-1/2” NPT threaded process connection.
Customer specified length is from the bottom of the process connection to the bottom of the counterweight
(end of rod on single rod probes).
Requires transmitter power supply on receiving end of passive 4-20A output.
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S P E C I F I C AT I O N S
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Power Requirements:
Altitude:
Installation Category:
Pollution Degree:
Process Temperature:
Ordinary Location Units
Hazardous Location Units
Ambient Temperature:
Operating Pressure:
1-1/2” NPT:
G 1-1/2 (1-1/2” BSP):
2” ANSI:
DN50PN40:
††
Measurement Range :
Single Cable 0.16” (4mm):
Single Cable 0.31” (8mm):
Twin Cable 0.16” (4mm):
Single Rod .38” (10mm):
Accuracy:
Direct Mode
Solids
Liquids
TBF Mode (All)
Repeatability:
Resolution:
†
Minimum Dielectric Constant :
Direct Mode
TBF Mode
Process Mounting Connection:
Single Cable/Rod Only
All probe Styles
Conduit/Cable Entry:
NPT/ANSI Process Connections
BSP/DN Process Connections
Probe Styles:
Single Cable
0.16” (4mm)
0.31” (8mm)
Single Rod
Twin Cable
Weight:
Enclosure
Single Cable
0.16” (4mm)
0.31” (8mm)
Single Rod
Twin Cable
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100-240VAC (+10%/- 15%); 9VA; 50/60Hz or
24VAC/VDC (+10%/- 15%); 9VA/W
6562ft (2000m) maximum
II
4 (reduced to 2 by enclosure) Suitable for indoor/outdoor use
-20˚F to +300˚F (-30˚C to +150˚C);
-20˚F to +392˚F (-30˚C to +200˚C)
-5˚F to +120˚F (-20˚C to +50˚C)
-14.5psig to +580psig (-1bar to +40bar)
-14.5psig to +580psig (-1bar to +40bar)
-14.5 psig to 150 psig (-1bar to 10bar)
-14.5psig to +580psig (-1bar to +40bar)
150ft (45m)
100ft (30m)
200ft (60m)
10ft (3m)
± 0.8” (20mm)
< 20ft (6m): ± 0.2” (5mm)
≥ 20ft (6m): ± 0.2” (5mm) + 0.02% of distance measured
± 0.8” (20mm) when Dielectric is constant
± 0.04” (1mm)
± 0.012” (0.3mm)
Twin Cable ≥ 1.8; Single Cable/Rod ≥ 2.1
All Probe Styles ≥ 1.4
1-1/2” NPT; G 1-1/2 (1-1/2” BSP)
2” ANSI 150lb. Flange; DN50PN40 Flange
(2) 1/2” NPT
(2) M20 x 1.5 cable connectors
316SS
316SS
316SS; 0.38” (10mm) diameter;
316SS; Two 0.16” (4mm) cables; FEP spacers
18lb (8kg) without probe for ordinary location;
20lb (9kg) without probe for hazardous location;
0.08lb/ft (0.12kg/m)
0.28lb/ft (0.41kg/m)
0.42lb/ft (0.62kg/m)
double weight of 4mm cables above for twin cable
††
Overall measuring range effects the minimum dielectric constant that
can be measured.
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Maximum measuring range is also limited by the dielectric constant
of the material being measured.
Maximum Traction Loading:
0.31” (8mm) Single Cable
0.16” (4mm) Single Cable
Minimum Separation From Objects:
Single Cable/Rod
Twin Cable
Output Signal:
“Smart”:
Analog:
Wiring Distance (“smart” output):
Local Display:
Materials of Construction:
Enclosure:
Threaded/Flange Connection:
Process Insulator:
O-Ring Seal:
Probes:
Remote Electronics:
Dead Zones:
Single Cable/Rod
Dielectric = 80 (water)
Dielectric = 2.4 (oil)
Twin Cable
Dielectric = 80 (water)
Dielectric = 2.4 (oil)
Enclosure Rating:
Approvals:
Integral Electronics Only
Ordinary Location
Hazardous Location
Remote Electronics
Ordinary Location
Hazardous Location
7,700lbs/3.9 tons (3.5 metric tons)
2,250lbs/1.1 tons (1.02 metric tons)
12” (300mm)
4” (100mm)
RS-485, half-duplex, isolated, proprietary protocol
4-20mA; 350ohms maximum load
4,000ft (1,220m)
3-line; Backlit LCD; 3 pushbuttons;
3 magnetic sensors for setup without cover removal
Aluminumm, powder coated
316 Stainless Steel
Teflon (PTFE)
Viton
316 Stainless Steel
16.4’ (5m) pre-wired interconnection cable
Top = 15.75” (400mm)
Bottom = 0.8” (20mm)
Top = 19.7” (500mm)
Bottom = 3.9” (100mm)
Top = 9.8” (250mm)
Bottom = 0.8” (20mm)
Top = 13.0” (330mm)
Bottom = 0.8” (20mm)
NEMA 4, IP66
CE Mark, CSA US/C (pending)
CSA US/C Class I, Div 1,2, Groups B, C, D;
Class II, Div 1,2, Groups E, F, G; Class III
ATEX II 1/2 GD T75...150C (pending)
CE Mark
ATEX II 1/2 GD T75...150C (pending)
WA R R A N T Y
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Monitor Technologies LLC warrants each F l e x a r guided wave radar continuous level measurement system it manufactures to be free from defects in material and workmanship under normal use and service within two (2) years from
the date of purchase. The purchaser must give notice of any defect to Monitor within the warranty period, return the
product intact and pre-paid transportation charges. The obligation of Monitor Technologies LLC under warranty is
limited to repair or replacement at its factory. This warranty shall not apply to any product which is repaired or altered
outside of the Monitor Technologies LLC factory, or which has been subject to misuse, negligence, accident, incorrect wiring by others or improper installation.
Monitor Technologies LLC reserves the right to change the design and/or specifications with our prior notice.
1100
44W320 Keslinger Road t P.O. Box 8048 t Elburn, IL 60119-8048 t 800-766-6486 t 630-365-9403 t Fax 630-365-5646
www.flexar.info
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www.monitortech.com
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www.typepad.monitortech.com
353A.4.0108
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monitor@monitortech.com
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