Magnetrol PULSAR RADAR R86 Gebrauchsanweisung

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

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

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.

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.

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

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