Operating Manual

Issue K
From WaveRadar serial Number 49318

RS Aqua Ltd.
Units 4 – 6, Hurst Barns Tel.: +44 (0)1730 828222
Privett Fax.: +44 (0)1730 828128
Alton, Hants. Email: [email protected]
GU34 3PL, UK Web: www.rsaqua.co.uk
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WaveRadar REX Operating Manual Issue K – 1st March 2014

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WaveRadar REX Operating Manual Issue K – 1st March 2014

Contents Section
1. INTRODUCTION 1-1
1.1 General 1-1
1.2 Features 1-2
1.3 Assumptions about the user 1-2

2. SPECIFICATION 2-1

3. GETTING STARTED 3-1

3.1 Unpacking 3-1
3.2 Assembly 3-2
3.3 Voltage supplies 3-8
3.4 System description 3-9
3.4.1 Sensor 3-9
3.4.2 Measurement method 3-11
3.4.3 Data communications 3-12
3.4.3.1 Serial link 3-14
3.4.3.2 Serial protocol 3-14
3.4.3.3 WaveRadar status indicator 3-14
3.5 Analogue output
3.6 Configuration 3-15
3.7 Testing 3-15

4. INSTALLATION 4-1
4.1 Mechanical 4-1
4.2 Electrical 4-3
4.2.1 Safety warning 4-3
4.2.2 Power supply 4-3
4.2.3 Cabling 4-3
4.2.3.1 General 4-3
4.2.3.2 Cables 4-3
4.2.3.3 Earthing 4-4
4.2.3.4 Integrated junction box 4-6
4.2.4 DC to DC converter module (Pre s/n 38587) 4-6
4.2.5 Field bus modem (FBM) 4-7
4.2.6 Remote Display Unit (RDU40) 4-8
4.2.7 Underwriters Laboratory (UL) standard 4-8

5. OPERATION 5-1
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WaveRadar REX Operating Manual Issue K – 1st March 2014

6. MAINTENANCE AND CALIBRATION 6-1

6.1 Routine maintenance 6-1
6.2 Calibration 6-1
6.3 Replacing fuses 6-2
6.4 Opening flameproof housing 6-2
6.5 Removal of electronics unit 6-2
6.6 Replacement of electronics unit 6-3

7. FAULT FINDING 7-1

7.1 WaveRadar - No initial response 7-2
7.1.1 Symptoms: Both digital and analogue outputs fail 7-2
7.1.2 Symptoms: No digital output, analogue output working 7-2
7.1.3 Symptoms: Digital message length reduced 7-2
7.2 WaveRadar - Failed during operation 7-2
7.2.1 Symptoms: Both digital and analogue outputs fail 7-2
7.2.2 Symptoms: No digital output, analogue output working 7-2
7.3 WaveRadar – Incorrect reading of level 7-3
7.3.1 Symptoms: Flat topping of data, gaps in data, static data
Incorrect level 7-3
7.4 Corrective actions 7-3
7.4.1 Corrective actions – Installation 7-3
7.4.2 Corrective actions – FBM / Host software 7-3
7.4.3 Corrective actions – WaveRadar status word 7-3

8. CRC GENERATION 8-1

9. GUARANTEE 9-1

10. DRAWINGS 10-1

Fig. 1 Assembly drawing
Fig. 2 Dimensions and mounting
Fig. 3A Frame installation (DS-1)
Fig. 3B Frame installation (GR-1)
Fig. 4A Wiring diagram
Fig. 4B Wiring diagram Underwriters Laboratory (UL) Standard

11. ANNEXES 11-1

11.1 Annex A – DC to DC converter module 11-3
11.2 Annex B – Power and data cabling 11-4
11.3 Annex C – Remote Display Unit (RDU40) 11-6
11.4 Annex D – Underwriters Laboratory (UL) Standard 11-9
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WaveRadar REX Operating Manual Issue K – 1st March 2014

Document Change Summary

Issue Issue date Reason for change

A 04/2000 Initial issue for WaveRadar REX.

B 09/2000 Specification change
C 06/2003 Introduction of RDU40 and 24vDC power supply
D 11/2003 Introduction of Baseefa03ATEX information and
Underwriters Laboratory (UL) standard
E 05/2006 Introduction of FBM 2180 and additional updates
F 12/2006 Introduction of WaveRadar REX (second generation)
with microwave module and other hardware
improvements
G 03/2007 Change of Saab name to Rosemount. Correction to text
H 04/2009 New installation and fault finding sections
J 09/2009 Change to maintenance instructions and minor
Correction to text
K 03/2014 Change to assembly instructions, access to electronics
Introduction of new mounting frame GR-1

Notes:

1. A vertical black line at the side of any text indicates either an amendment or the
introduction of new text, picture or sketch to this version of this manual.

2. RS Aqua Ltd. provides exclusive global sales and service support for WaveRadar
and WaveRadar REX systems.
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1. INTRODUCTION

1.1 General

WaveRadar REX is the latest version of the WaveRadar series first introduced in
1994. It is a non-invasive stable system for the measurement of waves, sea level and
air-gap in the offshore environment. The device is manufactured by Rosemount Tank
Radar AB of Gothenburg, Sweden, an Emerson Process Management company. It is
a derivative of their Rosemount TankRadar series, many thousands of which are
used throughout the world for monitoring levels in storage tanks.
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WaveRadar REX Operating Manual Issue K – 1st March 2014

1.2 Features

The downward looking sensor uses a microwave radar technique to measure the
distance to the sea surface. It continuously collects and processes information and
outputs distance measurement on to a data bus. Output values can be stored and
displayed to industry standards on a remote PC or may be interfaced to multi-
parameter environmental monitoring systems.

The microwave signals are very low in power and present no safety hazard.

WaveRadar REX is available in the following versions:

WaveRadar REX Type M Digital and analogue output, mains power

WaveRadar REX Type D Digital and analogue output, DC power

Both versions are hazardous zone BASEEFA03ATEX EEx certified.

The WaveRadar REX package comprises a radar electronics module enclosed in a

flameproof (explosion proof) housing, an integral antenna with parabolic reflector and
a field bus modem. The DC version operating range is from 20 to 28 volts.
WaveRadar REX D units with a s/n prior to 38587 require a 48 – 100 volt source. An
external module is used to convert a 24 volt source supply to 48 volts.

The WaveRadar REX is intended for external mounting on offshore or coastal

structures such that the antenna has a clear downward view of the sea surface within
at least a 10 angle conical beam.

The WaveRadar REX is shipped in a plywood pallet case. The wood packing used
meets the requirements of the International Standard for Phytosanitary Measures of
ISPM-15 and bears the International Plant Protection Convention (IPPC) mark on the
pallet case, showing that the material has been subjected to an approved measure.

1.3 Assumptions about the user

In writing this manual it has been assumed that the user has some prior knowledge
of computer operating systems and RS232/USB serial communications. It has also
been assumed that the user will have some experience with instrumentation and data
analysis.
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WaveRadar REX Operating Manual Issue K – 1st March 2014

2 SPECIFICATION

Performance Sensor measuring range 3 – 65 metres to surface

Accuracy Range <50m = +/-6mm
Range >50m = +/-12mm
Maximum deviation Range <50m = +/-1mm
Beam width 10 degrees included angle
Radar transmission Transmitter frequency 9.7 to 10.3GHz (linear sweep)
Effective radiated power <0.5mW
Antenna type Parant (parabolic) reflector
Radar measurement Measuring frequency 10Hz
Data output Data bus Digital two wire FSK field bus,
binary data output.
Connector cabling Eex ”e” (non intrinsically safe)
Output data rate 2 to 10Hz (4Hz default).
Factory selectable
Digital - from FBM RS232 at 4800 baud
Type 8 data bits, no parity, one stop bit
Protocol Half duplex
Analogue output 1 x Current loop
Range 4 – 20mA
Resolution 16 bits
Refreshing rate 4Hz (default)
Connector cabling Eex “e” (non intrinsically safe)
Power supply Mains voltage (type M) 100 to 240V AC (auto detects
110 and 220 VAC)
Radar power rating 50 – 60Hz
Current consumption 80 watts maximum
DC voltage (type D) 1.6A max: operating <1A
Radar power rating 20 to 28V DC +10% -15%
Current consumption 30 watts maximum
1.6A max: operating <550mA
Mechanical Overall dimensions 635(h) x 440(w) x 440(d)mm
Weight 26kg
Measurement datum Upper surface of TRL/2 adapter
Materials (external) Stainless steel 316 grade
Anodised aluminium alloy ss4253
PTFE (Teflon)
Environmental Operating and storage temp -40C to +70C
Environmental sealing IP67
CE Conformity Approval number 0575
BASEEFA03ATEX Radar unit type no. TH2015 – RTG3930
certification Certification no. Baseefa03ATEX0071X
Code Ex II 1/2G
EEx d IIB T6
(Tamb = -40C to +70C)
Shipping case Dimensions 600 x 800 x 600mm
Weight (gross) 45kg – standard supply
Materials Plywood to IPPC standard
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3. GETTING STARTED

3.1 Unpacking

WaveRadar REX (WRRex) is shipped in a plywood pallet case in modular form.

Please refer to WRRex Assembly Diagram, WP2001M001 to help identify
components. The primary task is to check the scope of supply which should be:

 Transmitter head (THE) with integrated junction box (fitted with cable glands) and
waveguide housing. (Note: UL version excludes junction box, see 4.2.7)
 Weather protection cover (fitted to transmitter head)
 Waveguide with 2 x grub screws (already fitted into waveguide housing)
 Spring sleeve seal (already fitted into waveguide housing)
 Mounting flange plate fitted with T30 flange ball (fitted with 2 x “O” rings on lower
face and large “O” ring under rim of flange ball), securing nut/locking ring with
locking hex head grub screw.
 Antenna feeder with washer ball, stop washer, finger nut, tab washer and lock nut
 TRL/2 adapter, 4 x M10 bolts and 4 x M10 washers
 Parabolic reflector with 5 x M5 socket cap screws and Allen key
 Field bus modem (FBM 2180) with 1 x 3m RS232 cable, ac/dc power supply
adapter with 4 x removable socket connectors and 2 x DIN rail mounting clips
 Documentation pack comprising:
 Operating manual and WaveRadar set-up report
 Manufacturer’s certificate of conformance
 Delivery test certificate
 IP67 certificate
 Radio Communications Agency (UK) exemption notice
 BASEEFA03ATEX certification
 EC declaration of conformity – EMC directive
 Special safety instruction
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WaveRadar REX Operating Manual Issue K – 1st March 2014

3.2 Assembly

Tools Required

Allen (hex) keys: 4mm, 5mm, 6mm,

Ring spanners: 10mm,17mm, 19mm
Adjustable spanner: 42mm opening
Flathead screwdriver: 8mm
Crosshead screwdriver: 6mm
Terminal screwdriver
“C” spanner (if required to fit flange ball into mounting plate)

The T30 flange ball will be fitted to the mounting flange plate. If not, follow the
instructions below:

Fit the large ‘O’ ring to the grove under the rim of the T30 flange ball and insert the
flange ball into the central hole of the mounting flange plate. Make sure that the
locating pin fits into the recess on the plate. Fit and tighten the securing nut and lock
in place with the Allen screw.
Fit the two “O” rings (black and red) into the grooves on the lower surface of the
flange ball.

Note that depending on your installation, it may be necessary at this point to fit the
mounting flange plate to the WaveRadar mounting frame (ensure the two ‘O’ rings on
the lower face of the flange ball are facing the water) and secure with M10 bolts,
insulation bushes, plain washer and nuts.

Fit the antenna feeder to the mounting plate, ensuring that the upper shoulder of the
antenna feeder meets the lower side of the flange ball that has the two “O” rings.
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WaveRadar REX Operating Manual Issue K – 1st March 2014

Fit in this order over the top of the antenna feeder: stop washer, washer ball
(ensuring the recessed section is lowermost) and finger nut.

Stop washer
fitted over
antenna
feeder

Washer Ball
fitted over
Stop Washer
(not shown)

Finger nut
screwed down
to retain
washer ball
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WaveRadar REX Operating Manual Issue K – 1st March 2014

Tab washer

Lock nut

TRL/2
Adapter fitted
to antenna
feeder
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WaveRadar REX Operating Manual Issue K – 1st March 2014

Lock nut
Tab washer
Finger nut
Washer ball
Stop washer
(not shown)

Check that the antenna and washer ball are central to the 3 x inscribed rings in the
top recess of the flange ball. Tighten the finger nut. Fit the tab washer and lock nut,
tighten the lock nut. Bend the tab of the tab washer against the flat of the lock nut to
lock the complete assembly.

Fit the parabolic reflector to the antenna feeder and secure using the five M5 socket
cap screws.

Place the TRL/2 adapter on top of the antenna feeder, engaging the locating key with
the key way of the antenna feeder and fully screw the adapter nut onto the antenna
feeder. Check that the antenna and adapter are vertical and fully tighten adapter nut.
There should be no movement of the TRL/2 adapter and the adapter should be fully
fitted to the antenna feeder.

Note. In the top recess of the flange ball, three rings are marked as an aid to
positioning the antenna and adapter in a vertical attitude.
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WaveRadar REX Operating Manual Issue K – 1st March 2014

Check that the two guide pins on the TRL/2 adapter are aligned (as shown by the
direction of the arrow) pointing outwards from the mounting frame or platform.

Note. The two guide pins on the TRL/2 adapter assist in positioning the antenna in
the correct orientation with regard to the microwave footprint on the sea surface. The
footprint is slightly elliptical and the guide pins alignment ensures that the smallest
axis is presented to the side of the platform.

The waveguide and stainless steel spring sleeve seal will be fitted to the waveguide
housing. If not, follow the instructions below:
Mount the waveguide unit into the waveguide housing at the base of the transmitter
head. The waveguide unit has two screws fitted at one end. This end goes into the
housing. Check that the side flutes engage the location pins fitted to the side of the
waveguide housing.

Fit the stainless steel spring sleeve seal with the tab located in the slot on the
transmitter head flange. Fit the two grub screws ensuring that they engage in the
dimples in the waveguide and tighten them.
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WaveRadar REX Operating Manual Issue K – 1st March 2014

Before fitting the waveguide housing to the TRL/2 adapter, lightly grease the flange
face then engage the guide pins into the holes on the base of the waveguide
housing. Fit 4 x M10 bolts and washers and tighten.

Remove the weather protection cover. Check that the gauge is vertical (by placing a
level on the flat plate that is fitted to the top of the transmitter housing). If not level,
loosen the finger nut, adjust the transmitter, and then tighten the finger nut.

Note. In the top recess of the flange ball, three rings are marked as an aid to
positioning the antenna and adapter in a vertical attitude.

Tighten the lock nut and secure by folding the tab washer over the nut. Replace the
weather cover.
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WaveRadar REX Operating Manual Issue K – 1st March 2014

3.3 Voltage supplies

Cautions

 Do not connect the power without first checking the supply voltage is
within the limits defined in Section 2 Specification

 Do not open the transmitter head without permission from RS Aqua Ltd. or
the warranty may be invalidated

 Do not connect power with the flameproof housing of the transmitter head
removed

The identification plate fitted to the transmitter head will display the power supply
required.
The mains version is auto sensing for a supply voltage between 100 to 240 volts AC.
Within this range the specifications are:
100 -120 VAC, 50 – 60 Hz, max. 80 W.
200 – 240 VAC, 50 – 60 Hz, max. 80 W.

The DC version operating range is from 20 to 28 volts.

WaveRadar REX D units with a s/n prior to 38587 require a 48 – 100 volt source. An
external module is used to convert a 24 volt source supply to 48 volts.
This module is described in Annex A.

For lightning protection, the power supply input and measurement signals are fully
galvanic separated from the field cabling. Additionally there are filters and internal
fuses for peaks and disturbances also multiple varistors to protect from over
voltages.
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WaveRadar REX Operating Manual Issue K – 1st March 2014

3.4 System description

3.4.1 Sensor

The transmitter head consists of a flameproof anodised cast aluminium alloy

enclosure with an integral junction box. A weather protection cover is fitted to protect
it from direct solar heating.
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WaveRadar REX Operating Manual Issue K – 1st March 2014

The enclosure contains the radar electronic unit (THE) that includes the microwave
module and cards for distributed power supplies, microprocessors, signal processing
and field bus communication. The electronics unit incorporates two high capacity
processors, each dedicated to a specific function within the overall operation of the
radar and a Dual Port Memory (DPM) module that acts as the interface between both
processors.

A digital reference ensures linearity of the radar sweep and internal temperature
control prevents signal drift. The dedicated measurement processor enables powerful
microwave signal processing, control of the measurement cycle and calculations of
range data. The communications processor, assembles the output data string,
controls the data bus and its output timing and all other internal and external
communications to the radar.

The internally generated radar signal is guided out of the base of the enclosure
through a PTFE plug pressed into the housing. The radar signals pass through a
waveguide in the base of the transmitter head to the antenna assembly which
consists of an antenna feeder and a parabolic reflector dish. Between the antenna
and the transmitter head is a TRL/2 adapter. The upper surface of the TRL/2 adapter,
where it bolts to the transmitter head, is the measurement datum. (See Section 4)

Electrical connections between the housing and the integral junction box are via
flameproof feedthroughs. The junction box, designed for safety EEx d[ia] B T6
classification, contains two separate chambers with DIN rail mounted terminal blocks.
X11 is for power supply, output data bus and analogue connections. X12 (when
fitted) is for intrinsically safe circuits.

Pre s/n 38587 WaveRadar REX type D units required a small external DC/DC
module intended to be located in a safe area.
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WaveRadar REX Operating Manual Issue K – 1st March 2014

3.4.2 Measurement method

The WaveRadar REX uses an optimum microwave frequency which keeps the radar
beam narrow to reduce influence from adjacent disturbing objects.

The transmitted frequency is a continuously varying signal (Frequency Modulated

Continuous Wave - FMCW). The transmitted signal changes frequency during the
time taken for the reflected signal to return. The reflected signal from the sea surface
is compared with the transmitted frequency value, the difference between
frequencies being proportional to the distance from the sensor to the sea surface.
This frequency difference is converted to a distance measurement. The radar
firmware also uses advanced digital filtering and FFT calculations to counter
disturbances and maintain measurement accuracy.

During the measurement cycle of 10 Hz, a number of measurements are collected

and at the end of the cycle an average distance value produced. At the end of a
measurement cycle the distance value is inserted into a serial data string and output
onto a data bus at intervals of 250ms (4Hz) as standard.
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WaveRadar REX Operating Manual Issue K – 1st March 2014

3.4.3 Data communications

3.4.3.1 Serial link

Digital communication with the sensor is over a two wire serial data field bus
developed by Rosemount. Frequency shift keying (FSK) is used and the bus
terminations are galvanically isolated and protected against noise transients and over
voltage. This ensures reliable communications over long distances even in
electrically noisy conditions.

A field bus modem (FBM 2171 or 2180) is provided to interface the FSK signals to
the PC end of the bus cable. The FBM is a small interface box that is intended to be
located in a safe area near the host computer. The FBM is connected to the PC via a
RS232 cable.
The FBM is supplied with an AC/DC converter to power it from any mains power
supply (115 – 240v) for use with RS232 configuration.

Field Bus Modem 2171

The FBM 2180 modem has five LEDs to indicate power on and communication
functions. There are front panel switches to set gain and termination if required.
The FBM is fitted with a USB output, this is not recommended for use with
software used for wave/metocean data functions.

Field Bus Modem 2180

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WaveRadar REX Operating Manual Issue K – 1st March 2014

The Termination switch is set to OFF by default. It should be set to ON when there
are extremely short cables between the WaveRadar and the FBM.
The Gain switch is set to low by default. The Hi Gain setting may be used if cable
dimensions (small conductor size) result in a reduced length message string
(communications signal).
A mechanical mounting kit is supplied with the modem to enable fitting of the FBM to
a DIN rail.

Serial port settings for all FBM types are:

Speed 4800 baud

Byte format 8 data bits
no parity
1 stop bit
Handshakes RTS is used for Tx/Rx control
On (+ve) to send commands
Off (-ve) to receive data

N.B. For RS232 a full 7 conductor cable is required (see 4.2.5)

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WaveRadar REX Operating Manual Issue K – 1st March 2014

3.4.3.2 Serial protocol

Messages from the WaveRadar REX consist of fixed length strings of binary values
which are sent over a half-duplex link. Output messages will utilise the data link for
approximately 20 ms every 250 ms and are repeated every 250 ms (4Hz). Any
message sent to the radar will be interpreted as a query and the continuous output of
data on the bus will cease. The communications processor will wait for a command
message. If no message is received within 60 seconds the data output string will
recommence. If within this period a further query is sent to the radar, the 60 second
period will then recommence from that query. A sample HEX message string of 17
bytes from the WaveRadar REX is shown below.

F6 04 0C 00 01 02 47 80 70 00 00 01 92 29 8F 17 B6
Where:-
Byte F6 is the RTG address (default)
Byte 04 is the command code (default)
Byte 0C is a byte counter. Number of data bytes in message excluding address,
command and check sum bytes.
Byte 00 01 02 47 comprise a measured range value in 1/10mm steps (MS byte to LS
byte). Where 00 01 02 47 Hex = 66119mm or 6.6119m
Byte 80 and 70 is the sensor status Ss1 and Ss2 (see description below)
Byte 00 and 00 are reserved – No value.
Byte 01 and 92 are signal strength value (for test use)
Byte 29 and 8F is (for test use)
Byte 17 is the check sum high byte
Byte B6 is the check sum low byte

The CRC checksum is a 2 byte sequence used at the end of each command and
data message. It is based on the CRC-16 sequence as defined by Modbus protocol.

Note
The digital output data message streamed from the 2180 FBM consists of 17
bytes, however, due to field bus loading and resonant frequency, occasionally
an 18 byte message (an extra null/space character) may be output.
It strongly recommended that host metocean software be capable of
recognising a mixed 17/18 byte message (using the address code of F604 as
the fixed length string identifier) to ensure that the host metocean software
does not hang up or treat the message as corrupt.

3.4.3.3 WaveRadar status indicator

The fields 'Ss1' and ‘Ss2’ provides information on both the operation of the sensor
and a quality assessment on the validity of the measurement produced. It is strongly
recommended that software used for metocean functions displays or store this status
word.

In the event of any permanent or regular change of the status word from
normal, please contact RS Aqua Ltd.
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WaveRadar REX Operating Manual Issue K – 1st March 2014

The sensor status 'Ss1' and ‘Ss2’ are bit fields where the normal status is 8000H or
8070H. When the most significant bit is set the measurement value is valid. As long
as the MSB is set the value is OK. If other bits of the status are set they have the
following meaning shown in the small example list below;

Bit no HEX Meaning: If the bit is set

1 0001 Running in Boot software
2 0002 Device warning: Radar detected something that should be
checked.
3 0004 Reserved
4 0008 Device error: Serious internal error detected. This bit may
only be cleared after a radar reset (this is a copy of bit 7)
5–7 0010 - 0070 Reserved
8 0080 Device error: Serious internal error detected. This may
only be cleared after a radar reset.
9 – 15 0100 - 4000 Reserved
16 8000 Valid level

3.5 Analogue Output

The WaveRadar Rex has a single 4-20mA analogue output that is directly
proportional to the range.

The output is internally powered with 16bit resolution and an update rate of 4 Hz.

3.5 Configuration

Every unit is configured by Rosemount Tank Radar AB to a set of default values

which are contained within the control registers of the electronic module and suit the
majority of applications. The principle variables are:

Item Factory setting

Range 65 metres
Measurement cycle 10 Hz
Output data rate 4 Hz
Operating mode Auto-start
Analogue output Enabled
Analogue refreshing rate 4 Hz

These items can be re-configured by RS Aqua Ltd. prior to delivery.

3.6 Testing

Every WaveRadar REX unit is thoroughly tested and calibrated by Rosemount Tank
Radar AB before shipment. A functional check is also carried out by RS Aqua Ltd.
before supply to the user.

It is difficult for the user to perform meaningful testing without installing the
WaveRadar REX in its correct working environment. This is a result of the difficulties
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WaveRadar REX Operating Manual Issue K – 1st March 2014

in obtaining a clear beam footprint at sufficient range and the possible introduction of
spurious echoes from surrounding workshop structures.
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WaveRadar REX Operating Manual Issue K – 1st March 2014

4. INSTALLATION

4.1 Mechanical

The microwave beam from the centre of the antenna is a 10 wide cone and the
installation must be selected to allow an unobstructed beam of at least 10. Greater
than 10 is preferable. As an example a unit installed 30 metres above the sea
surface will require an unobstructed footprint of at least 5.25 metres diameter.
The footprint is slightly elliptical and during assembly of the WaveRadar REX
the guide pins alignment ensures that the smallest axis is presented to the side
of the platform (see page 3-6).

Height of the sensor mounting should be chosen with regard to the maximum peak to
trough wave height (plus tidal excursion) expected under extreme conditions. This
must lie within the sensor’s measurement range of 3 to 65 metres (zero point is the
upper surface of the TRL/2 adapter, the measurement datum) to the sea surface. A
mounting height of 20 to 30 metres above mean sea level is normally ideal. A level
within this range identified as either the Mean Sea Level or the Lowest Astronomical
Tide Level is nominated as the DATUM LEVEL and the determined height from this
level to the radar TRL/2 adapter is known as the ‘Wave Sensor Elevation’.

Optional Mounting Frames

WaveRadar is normally installed by extending the sensor over the side of the
platform or structure. A mounting frame (DS-1), as illustrated in the following images
and in drawing figure 3A, is available from RS Aqua Ltd for this application.

Image courtesy of Fugro Structural Monitoring

It is designed to fit within a gap in the platform handrails, projecting outwards to offer
the WaveRadar an unobstructed beam to the sea surface. It can be vertically rotated
for ease of deployment and recovery. When in the deployment position it provides a
barrier across the gap in the handrails.
This application is particularly suitable for temporary/semi permanent installations.
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WaveRadar REX Operating Manual Issue K – 1st March 2014

Image courtesy of Areva T&D/Vestas Controls

Alternatively a WaveRadar mounting frame may be fitted to the platform guardrail,

removing the requirement to cut the rail or weld existing frames to the platform deck
and extending the sensor over the side of the platform or structure.
A mounting frame (GR-1), as illustrated in the following image and in drawing figure
3B, is available from RS Aqua Ltd for this application.

Image courtesy of Semco Maritime

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WaveRadar REX Operating Manual Issue K – 1st March 2014

Through Deck Mounting

An alternative method of mounting the WaveRadar is to install it through the decking
of the host platform/structure, aligned vertically to the water. The technique used is to
remove a section of the decking/grating, cut an opening to suit the mounting flange
plate and assemble the WaveRadar REX around the section. Details of the mounting
flange plate are shown in drawing figure 2. The flange is made from stainless steel
and it is recommended that insulating bushes are fitted to the mounting bolts to
prevent electrolytic corrosion of the carbon steel decking.

It is strongly recommended that a grill or grating is used with this method and
not a solid metal plate. Use of a solid metal plate may result in the introduction
of spurious echoes.

4.2 Electrical

4.2.1 Safety warning

 WaveRadar REX is BASEEFA03ATEX approved for use in hazardous areas.

Installation must be carried out in accordance with Special Safety
Instruction, Fourth Edition, Feb 2008 (see Documentation Pack).
 Do not open the flameproof housing while power is connected
 Do not replace any parts with non-approved spares

4.2.2 Power supply

Check WaveRadar REX for correct input voltage limits before connecting power.
Refer to 3.3 for details. Pre s/n 38587 WaveRadar REX type D units required a small
external DC/DC module intended to be located in a safe area.

4.2.3 Cabling

4.2.3.1 General
 Power and signals to be run in separate cables
 Cables and glands must be approved for use in hazardous areas as appropriate.

4.2.3.2 Cables

Cable conductor sizes must be selected to avoid excessive voltage drop over long
distances. The following table gives an indication of voltage drop resulting from
various combinations of cable length and conductor size at the maximum power
consumption of 80W (mains version). Combinations marked * should be avoided. For
the WaveRadar type D (DC version) the input voltage must be balanced against
conductor size and cable length to give a voltage within the range specified.
 RS Aqua Ltd.
WaveRadar REX Operating Manual Issue K – 1st March 2014

Cable length 110VAC 230VAC 24VDC

2 2 2 2
0.75mm 1.5mm 0.75m 1.5mm 1.5mm2 2.5mm2
(AWG18) (AWG16) (AWG18) (AWG16) (AWG16) (AWG14)
100m 4V 2V 1.6V 0.8V 4V 2V
200m 9V* 4V 3.2V* 1.6V 4V
400m 8.0V* 8.0V* 4.0V

The field bus cable is to be a single twisted preferably shielded pair of conductors,
polarity independent. The recommended cable length for specific conductor sizes
are:

Digital signal cable

Connection Max length No. of wires Type Min. core size
RS232 30m 7 Screened 0.25mm2
FSK bus 3000m 2 Screened 0.5 mm2
(AWG 20)
FSK bus 4000m 2 Screened 0.75mm2
twisted pair (AWG 18)

Analogue output cable

Connection Max length No. of wires Type Min. core size
Analogue output 1000 m 2 Screened 0.5mm2
(AWG 20)

4.2.3.3 Earthing

To be in accordance with local regulations. Ground connection terminals are fitted to

the transmitter head and the integral junction box.

To assist in preventing circulating earth paths it is recommended that insulating

bushes (Pt # WP2001-038-001C, available from RS Aqua Ltd) be fitted to the
securing bolts of the Mounting Flange Plate when installing the WaveRadar to its
Mounting Frame / grill etc. See drawing below.
 RS Aqua Ltd.
WaveRadar REX Operating Manual Issue K – 1st March 2014

4.2.3.4 Integrated junction box

The integrated junction box on WaveRadar REX has two separate chambers with
DIN rail mounted klippon terminal blocks. The right hand chamber X11 (non
intrinsically safe) is for power supply, data bus and analogue output connections. The
left hand chamber X12 is for the connection of intrinsically safe circuits. The junction
box has one M25 and two M20 cable gland inlets for intrinsic circuit cabling and for
the non-intrinsic cabling circuits, one M20 and two M25 inlets. Appropriate cable
glands are fitted to the junction box. Annex B gives further details on the glands and
cable inlets.

4.2.4 DC to DC Converter module (Pre s/n 38587)

Prior to s/n 38587, an external DC/DC module was supplied with D versions. This
was a small self contained module intended to be located in a safe area. The
converter was configured to produce a 48v DC output from a 24v DC input.

Fully enclosed in a black coated aluminium case, that acts as a heat sink and RFI
shield, the module corresponds to class 1 safety and installation specifications.
 RS Aqua Ltd.
WaveRadar REX Operating Manual Issue K – 1st March 2014

4.2.5 Field bus modem (FBM)

The FBM is not protected for use in hazardous areas or outdoor environments.
It is intended for indoor use in a safe area close to the host computer.

Version type changed from 2170 to 2171 in 2003 (see below) and then to type 2180
early in 2006. Carefully check to establish which version is being used.

The field bus modem has fitted connectors for the FSK bus (Klippon BL4/SL4) and
RS232 connection (9 way D type). A three metre long RS232 cable is provided for
connection to the host computer. The FBM 2180 is also fitted with a USB connector.

The FSK bus connections are not polarity sensitive and may be connected either way
round. Wiring connections for all types of FBM are shown in drawing figure 4.

FBM type 2170

Power for the FBM is supplied by the PC DTR line, provided the supply voltage is
sufficient. Some PCs, particularly small portables, do not provide sufficient voltage.
A miniature jack connector allows connection of an external DC power supply (6 to
12V, 150mA, polarity connections: outer +ve, inner -ve). It is recommended that if
this facility is required, a dedicated Rosemount power supply is used. Incorrect
voltage or polarity will damage the FBM.

FBM type 2171

Power for the FBM type 2171 is supplied by an external DC power supply (6 to 12V,
150mA, polarity connections: outer +ve, inner -ve). It is recommended that the
provided, dedicated Rosemount power supply be used. Incorrect voltage or polarity
will damage the FBM.

FBM type 2180

The FBM is fitted with a USB output. This is not recommended for use with
software used for wave/metocean data functions and, for this reason, no USB
cable is supplied with the FBM kit. Using a USB connection will produce an
unstable output and unwanted gaps in the data stream (due to the
USB/windows packet assembly transmissions).
The RS232 output is completely stable.

Front panel LEDs provide indications of power on, communication configuration and
Tx or Rx transmissions. Additional switches provide gain and termination selection.
Power for the RS232 configuration is supplied by an external DC power supply (7 to
12V, 50mA, polarity connections: outer +ve, inner -ve). It is recommended that the
supplied dedicated Rosemount power supply be used. Incorrect voltage or polarity
will damage the FBM. Additionally, connecting a USB cable and an external power
supply to the FBM at the same time will result in damage to the FBM.
 RS Aqua Ltd.
WaveRadar REX Operating Manual Issue K – 1st March 2014

The FBM type 2180 is designed to be mounted on a DIN-rail 35 EN50022.

Securing screws and 2 x DIN mounting clips are included with the FBM. There are 4
x pre-drilled holes on the base of the housing for securing the mounting clips.

4.2.6 Remote Display Unit (RDU40)

The RDU40 is a cable connected, remote display unit for use with the WaveRadar
REX. The display functions are software controlled and power for the display
operation is supplied by the connected WaveRadar REX. Only WaveRadar REX
units with firmware versions 1D2 and later are able to operate the RDU40.

When configured for a WaveRadar REX at the factory the RDU40 will show the
range measured by the WaveRadar. The four soft keys have limited functions and
the default setting is the View mode.

4.2.7 Underwriters Laboratory (UL) standard

Installation of a WaveRadar REX under the Underwriters Laboratory (UL)

configuration necessitates the replacement of the integrated junction box. The Non-
intrinsically (W11) and Intrinsically safe (W12) circuit outputs exit as single wires
through lead seals in the transmitter head. The wires are protected by conduit hoses
and must be terminated in two customer-supplied junction boxes. Annex D gives
further details on the wire identification and protective conduit hose kits.
 RS Aqua Ltd.
WaveRadar REX Operating Manual Issue K – 1st March 2014

5. OPERATION

WaveRadar REX produces distance measurements between the upper surface of

the TRL/2 adapter and the sea surface, over a range of 65 metres. The first 3 metres
from the TRL/2 adapter constitute an invalid zone where all measurements are
disregarded. The valid measurement range is therefore between 3 and 65 metres.
The measurement output to the data bus is a resultant average of several distance
measurements taken during the measurement cycle period and refers to the footprint
area covered by the microwave beam.

On first applying power to the WaveRadar REX, the unit carries out start up and
initialisation procedures where the control registers configure the radar to its
operating parameters. On completion it enters the first measuring cycle. On
completion of this cycle, all distance measurements that have been recorded in an
array are summed and the average distance measurement value is passed via the
Dual Port Memory to the communications processor and the analogue card. A
measuring cycle is carried out every 10 Hz as standard.

The communications processor assembles the output serial data string message that
contains the average distance measurement, status information on the radar unit and
other data gathered since the last output data string and this is transmitted on the
bus. Serial data messages are in binary form and are continuous while the
WaveRadar REX is powered.

The analogue output from the current loop card is continuously refreshed at the 4 Hz
rate until the WaveRadar REX is stopped.

The digital data output will continue until stopped by a message from the host
computer or when power is disconnected from the WaveRadar REX.

If any message is sent to the radar it will be interpreted as a query and the
continuous output of data on the bus will cease. The communications processor will
wait for a command message. If no message is received within 60 seconds the data
output string will recommence. If within this period a further query is sent to the radar,
the 60 second period will then recommence from that query.

The WaveRadar REX sensor does not perform any analysis of wave data. This must
be carried out by software in the host computer.

A suitable software package, WaveView, can be provided by RS Aqua Ltd. It has

functions for data acquisition, processing, display, logging and output to a remote
PC. Alternatives, some with emphasis towards specific applications e.g. Air-Gap
studies, are available from other sources.
 RS Aqua Ltd.
WaveRadar REX Operating Manual Issue K – 1st March 2014

6. MAINTENANCE AND CALIBRATION

6.1 Routine maintenance

WaveRadar REX is rugged and reliable with no moving parts. Therefore regular
maintenance is not required. However, due to the harsh offshore environment in
which the unit is normally used the following routine maintenance and inspection is
recommended.

Frequency Item
Monthly Hose / wipe down sensor unit with fresh water
(or whenever
reasonably Check the following items for damage, corrosion, and security
possible)
 Weather protection cover
 Flameproof housing, junction box and TRL/2 adapter
 Antenna feeder with washer ball, finger nut and lock nut
 Antenna dish
 Mountings
 Cable glands
 Cables
Annually (or Remove transmitter housing from TRL/2 adapter and check
biannually) waveguide for:
a) Corrosion to waveguide unit. Replace if corroded.

b) Ensure waveguide and the end of the antenna fitted to the

TRL/2 adapter are clear of foreign matter or crystal growth.
Remove as necessary.

Note – For WaveRadar units installed very close to the water

(less than 10m) there may be an increased likelihood that the
wave guide may be blocked by corrosion.

6.2 Calibration

Every WaveRadar REX is calibrated by Rosemount in a special calibration facility.

Due to the design and construction of the electronic and microwave unit, the
WaveRadar REX calibration is extremely stable and periodic re-calibration is not
required.
 RS Aqua Ltd.
WaveRadar REX Operating Manual Issue K – 1st March 2014

6.3 Replacing fuses

WaveRadar REX
There is one 1.6 Amp fuse in a fuse holder in the Transformer Rectifier Card (TRC)
module of the WaveRadar REX M electronics unit. There is one 3.15 Amp fuse in a
fuse holder in the TRC module of the WaveRadar REX D electronics unit.
To gain access to electronics unit the top half of the transmitter housing must be
removed as in 6.4 for access.

FBM 2170
There are two 0.05 Amp fuses on the circuit board of the field bus modem. Remove
the lid for access.
The FBM types 2171 and 2180 do not have any internal fuses.

6.4 Opening flameproof transmitter housing

Before opening the flameproof transmitter head housing, contact RS Aqua Ltd. to
obtain authority or the warranty may be invalidated.

Do not open the flameproof housing when power is connected. Danger from:
 Hazardous area
 Electrocution

Important - Only open the housing in a clean dry indoor environment

Unscrew (single captive M8 Allen screw) and remove the weather protection cover.
Remove the 10 x M8 Allen screws and lift off the top half of the transmitter housing.

6.5 Removal of “THE” electronics unit

If the electronics unit needs to be removed, it must be removed and replaced

as a complete module.

 Remove the top half of the transmitter housing as per 6.4.

 Note the orientation of the “THE” assembly. Loosen the two captive M6 bolts
on the bar of the electronics carriage assembly (between the circuit boards).
 RS Aqua Ltd.
WaveRadar REX Operating Manual Issue K – 1st March 2014

 Disconnect the two connectors to the TRC module.

 Lift the carriage assembly off the locating studs and disconnect the cable
connector underneath the assembly.
 Be especially careful not to damage the central PTFE plug.

6.6 Replacement of “THE” electronics unit

 Connect the cable connector underneath the assembly.

 Ensure that there is no foreign matter between the central PTFE plug and
connector.
 Lower the electronics carriage assembly onto the locating studs, carefully
ensuring that cables are not trapped and that the unit fits firmly on its base.

 Connect the two connectors to the TRC module

 Tighten the two captive M6 bolts
 When replacing the top half of the housing, ensure that the surfaces are clean,
the “O” ring is undamaged and seated correctly.
 Ensure all 10 x Allen screws are tightened evenly.
 RS Aqua Ltd.
WaveRadar REX Operating Manual Issue K – 1st March 2014

7. FAULT FINDING

This section on fault finding is divided into three subsections each of which
contains symptom identification and check actions. These are followed by a
corrective action section.

WaveRadar / installation fault

No initial response from

WaveRadar REX. See 7.1

WaveRadar REX Failed

during operation. See 7.2

Incorrect reading
of level. See 7.3

Distance values not displayed

on RDU.
See Section 11.3 Annex C

If a fault persists after following the fault finding checks and actions,
please contact RS Aqua Ltd for advice.
 RS Aqua Ltd.
WaveRadar REX Operating Manual Issue K – 1st March 2014

7.1 NO INITIAL RESPONSE FROM WAVERADAR REX

7.1.1 Symptoms: Both digital and analogue outputs fail to produce data
Check: 1) Power supply to Wave Radar
2) Cable wires to junction box.
3) Internal power fuse fitted to the “THE” of the radar unit.

7.1.2 Symptoms: No digital output but analogue output is working

Check: 1) That the RS232 cable has full standard wiring connections.
2) That the FBM is connected to correct comport on PC (2180 FBM RS232
LED).
3) The external power supply to FBM (2180 FBM power LED).
4) The data bus wiring. Use screened twisted pair for FSK bus and correct
wire core size for cable length.
5) The data bus wiring is connected to correct terminals (3 and 4) of Wave
Radar junction box and to terminal block (2 and 3) of FBM.
6) Ensure that the host software is not trying to communicate with the Wave
Radar or generate stray characters on the bus. This will stop data output on
the bus and activate the 60 second period before output recommences.

7.1.3 Symptoms: Digital message length is reduced (input data errors

reported by host software)
Check: 1) The data bus wiring. Only use screened twisted pair for FSK bus
and correct wire core size for cable length.
2) The 2180 FBM Terminal switch (TERM) is set to ON position (if
installation has a very short length of field bus cable).
3) The 2180 FBM Gain switch (GAIN), set to Hi (if communication signal is
heavily damped producing a serial output message of different lengths [byte
sizes] due to small or undersize cable core).
4) If using the 2170/2171 FBM, load the field bus by connecting a 100 ohm
resistor between the two bus wires at the FBM connector.

7.2 WAVERADAR REX FAILED DURING OPERATION

7.2.1 Symptoms: Both digital and analogue output failed
Check: 1) The power supply to WaveRadar
2) The cable wires to junction box
3) The internal power fuse fitted to the “THE” of the radar unit

7.2.2 Symptoms: Digital output has failed with analogue output still
working
Check: 1) The 2180 FBM, to confirm power and RS232 LEDs are illuminated
2) The 2180 FBM, to confirm the TX LED is flashing.
3) The data bus wiring is connected to correct terminals (3 and 4) of
WaveRadar junction box and to terminal block (2 and 3) of FBM.
4) That the RS232 cable between the FBM and the PC is connected.
5) The host software is operating correctly / has not frozen.
 RS Aqua Ltd.
WaveRadar REX Operating Manual Issue K – 1st March 2014

7.3 INCORRECT READING OF LEVEL

7.3.1 Symptoms: Flat topping of data, gaps in data, static data, incorrect
level
Possible causes:
 Intermittent or unusual measurements
 WaveRadar locked on a disturbing or spurious echo
 Corrupted data message or message length changed

Check: 1) The correct orientation of microwave footprint and whether the

WaveRadar is vertical.
2) The horizontal attitude of mounting frame.
3) Inspect the antenna and waveguide for correct fitting and no foreign
matter in waveguide.
4) The installation against instruction in the manual.
5) For objects in radar beam creating disturbing echoes and for a clear
downward view of surface.
6) For a change to WaveRadar STATUS word and note if distance
measurement values have static value.
7) The digital output message length for any changes.

7.4 CORRECTIVE ACTIONS

7.4.1 Corrective actions – Installation
1) Adjust mounting frame, attitude and orientation of WaveRadar.
2) Re-site WaveRadar (contact RS Aqua Ltd for advice).
3) Initiate new echo search by switching radar unit power off/on.

7.4.2 Corrective actions – FBM / Host software

1) For a short length message of less than 17 bytes:
a) 2180 FBM, set the terminal switch to GAIN.
b) 2170/2171 FBM, load the field bus by connecting a 100 ohm
resistor between the two bus wires at the FBM connector.
2) For a long message length of 18 bytes or more:
The 2180 FBM only, set the Terminal switch (TERM) to ON.
3) Amend host software to recognise a 17/18 byte message.
Note
The digital output data message streamed from the 2180 FBM consists of 17
bytes and is the same format as all earlier FBMs. However, due to field bus
loading and resonant frequency, occasionally an 18 byte message (an extra
null/space character) may be output.
It strongly recommended that host metocean software be capable of
recognising a mixed 17/18 byte message (perhaps using the address code of
F604 as the fixed length string identifier) to ensure that the host metocean
software does not hang up or treat the message as corrupt.

7.4.3 Corrective actions – WaveRadar status word

WaveRadar Status word change. Note changed value. Initiate restart procedure by
switching radar unit power off/on.

Note
If the status word remains at a non normal value, please contact RS Aqua Ltd..
 RS Aqua Ltd.
WaveRadar REX Operating Manual Issue K – 1st March 2014

8. CRC GENERATION

The CRC-16 error check sequence is implemented as follows:

The message (data bits only, disregarding start, stop and parity bits) is considered as
one continuous binary number, of which the MSB is transmitted first. The message is
pre-multiplied by x**16 (shifted left 16 steps), then divided by x**16+x**15+x**2+1
expressed as a binary number (11000000000000101). The integer quotient digits are
ignored and the 16 bit remainder (initialised to all ones at the start to avoid the case
of all zeroes being an accepted message), is appended to the message (MSB first)
as the two CRC check bytes. The resulting message including CRC, when divided by
the same polynomial at the receiver, will give a zero remainder if no errors have
occurred. The receiving unit re-calculates the CRC and compares it to the
transmitted CRC. All mathematics are performed using modulo 2 (no carry).

Example of a function:
Name of function: CRC_CALC

Input
BUF – Pointer to message buffer.
BYTE_NUM – Number of bytes in message (exclusive CRC bytes)

/*declarations*/
BUF_IDX word
IDX byte,
FLAG byte,
CRC word;

/*code*/

CRC=65535; /*Init*/
BUF_IDX=0; /*Pointer in message*/
do while BYTE_NUM>0;
CRC=CRC xor BUF(BUF IDX); /*Update CRC*/
Do IDX=0 to 7;
FLAG=CRC AND 1; /*Save shift flag*/
CRC=shr(CRC, 1); /*Shift one bit right*/
if FLAG then /*If flag is one*/
CRC=CRC xor 0A001H; /*Update CRC register*/
End;
BYTE_NUM=BYTE_NUM-1;
BUF_IDX=BUF_IDX+1;
end;
Return CRC;
 RS Aqua Ltd.
WaveRadar REX Operating Manual Issue K – 1st March 2014

Example of adding CRC-16 word to the message:

You have a message with the length LENGTH in your application

/*declarations*/
LENGTH BYTE; /*Length of message, inclusive of
CRC bytes*/
MESSAGE(LENGTH)BYTE; /*message buffer*/
CRC word;

/*code*/
CRC=CRC_CALC(MESSAGE. LENGTH-2);

MESSAGE(LENGTH-2)=LOBYTE(CRC); /*Intel l.o. to CRC h.o.*/

MESSAGE(LENGTH-1)=HIBYTE(CRC); /*Intel h.o. to CRC l.o.*/

Note: The CRC_CALC function can also swap l.o. and h.o. of CRC word before
returning but such code will be less efficient than the above example.
 RS Aqua Ltd.
WaveRadar REX Operating Manual Issue K – 1st March 2014

9. GUARANTEE

WaveRadar REX is guaranteed by Rosemount Tank Radar AB through RS Aqua Ltd.

against any defect resulting from faulty design, materials or workmanship for a period
of 18 months after ex-factory delivery.

Rosemount Tank Radar AB reserves the right to decide whether a guarantee repair
shall be carried out at the installation site or at Rosemount Tank Radar AB premises
or by RS Aqua Ltd. Travelling expenses and travelling time in connection with
guarantee visits are not included in the guarantee cover.

Further terms and conditions of this guarantee shall be in accordance with United
Nations Economic Commission for Europe, General Conditions for the supply of
Plant and Machinery for export 188/53.
 RS Aqua Ltd.
WaveRadar REX Operating Manual Issue K – 1st March 2014

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 RS Aqua Ltd.
WaveRadar REX Operating Manual Issue K – 1st March 2014

10. DRAWINGS

Fig 1. Assembly diagram

Drawing number: WP2001M001 Version: 2 – January 2012

Fig 2. Dimensions and mounting details

Drawing number: WP2001M002 Version: 3 – January 2012

Fig 3A. Frame installation (DS-1)

Drawing number: WP2001M003-1 Version: 3 – January 2012

Fig 3B. Frame installation (GR-1)

Drawing number: WP2001M003-2 Version: 1 – January 2012

Fig 4A. Wiring details

Drawing number: WP2001M006 Version: 2 – January 2009

Fig 4B. Wiring details

Drawing number WP2001M007 Version: 2- January 21012
 Waveguide grub screw

Earthing studd (fitted)

4 x M10 bolts & plain washers (TRL/2 Adapter)

Waveguide Weather protection cover

with securing bolt

Transmitter housing
with 10 x M8 screws
Lock nut
Integral junction box
with fitted glands
Stop washer

Flange ball and O ring Earthing clamp (fitted)

Spring sleeve seal
Flange ball locking ring
fitted with locking grub screw TRL/2 Adapter

Tab washer

Finger nut
Washer Ball

Mounting flange plate

2 x "O" rings fitted to concave face of Flange Ball

Antenna feeder

Parabolic reflector
with 5 x M5 screw
Drawing not to scale
Units 4 - 6, Hurst Barns, Equipment: WaveRadar REX
Privett, Alton,
Hampshire. GU34 3PL. UK. Assembly Diagram - Figure 1
Tel: +44 (0)1730 828222 Fax:+44 (0)1730 828128 Version : Drawing. No.
Email: [email protected] Web: www.rsaqua.co.uk 02 - January 2012 WP2001M001
 VIEW ON ARROW 'A' WITH WEATHER
A PROTECTION COVER REMOVED

Weather protection cover

Integral junction box

384 mm

Transmitter housing

Earth connection stud

635 mm

MEASUREMENT DATUM
10 mm
67 mm

TRL/2 Adapter
DIA 280mm
B B

Mounting flange plate PCD 241.5mm

184 mm

Parabolic reflector

Antenna feeder 50mm

PCD 225mm
440mm Hole dia 95mm

8 X Slots dia 22mm

VIEW ON SECTION B-B

Drawing not to scale MOUNTING FLANGE PLATE DETAIL

Units 4 - 6, Hurst Barns, Equipment: WaveRadar REX

Privett, Alton,
Hampshire. GU34 3PL. UK Dimensions / Mounting Details - Figure 2
Tel: +44 (0)1730 828222 Fax:+44 (0)1730 828128 Version : Drawing. No.
Email: [email protected] Web: www.rsaqua.co.uk
03 - January 2012 WP2001M002
 660

500
1050

A B
MEASUREMENT DATUM

Clamp bar
A B
Pivot

DECK
300
SECTION A - A VIEW ON B - B

1340 Dimensions are in millimeters (mm)

Drawing not to scale

Units 4 - 6, Hurst Barns, Equipment: WaveRadar REX
Privett, Alton,
Hampshire. GU34 3PL. UK Frame Installation (DS-1) - Figure 3A
Tel: +44 (0)1730 828222 Fax:+44 (0)1730 828128 Version : Drawing. No.
Email: [email protected] Web: www.rsaqua.co.uk
03 - January 2012 WP2001M003-1
 Safety rails - Standard 2" diameter rail
MEASUREMENT DATUM

350
Pivot
Service position lock

205
350
481 1120

MOUNTING U-BRACKETS (4 of)

Each bracket with 2 x M10 bolts, washers and nuts
and roll of insulating tape
Insulating tape

Guardrail

U-Bracket

393 Dimensions are in millimeters (mm)

Material: Stainless steel 316 - A4 , 3mm sheet
Drawing not to scale plate. Weight is 32 Kg.

Units 4 - 6, Hurst Barns, Equipment: WaveRadar REX

Privett, Alton,
Hampshire. GU34 3PL. UK Frame Installation (GR-1) - Figure 3B
Tel: +44 (0)1730 828222 Fax:+44 (0)1730 828128 Version : Drawing. No.
Email: [email protected] Web: www.rsaqua.co.uk
01 - January 2012 WP2001M003-2
Units 4 - 6, Hurst Barns,
Privett, Alton,
Hampshire. GU34 3PL. UK

Email: [email protected] Web: www.rsaqua.co.uk

Units 4 - 6, Hurst Barns,
Privett, Alton,
Hampshire. GU34 3PL. UK

Email: [email protected] Web: www.rsaqua.co.uk 03 - January 2012

 RS Aqua Ltd.
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 RS Aqua Ltd.
WaveRadar REX Operating Manual Issue K – 1st March 2014

11. ANNEXES

11.1 Annex A DC to DC Converter module

11.2 Annex B Power, data and RDU40 cabling

11.3 Annex C Remote Display Unit RDU40

11.4 Annex D Underwriters Laboratory (UL) standard

 RS Aqua Ltd.
WaveRadar REX Operating Manual Issue K – 1st March 2014

11.1 Annex A DC to DC Converter module

This text applies only in respect of WaveRadar REX D units with a s/n prior to 38587.

The DC/DC module supplied with WaveRadar REX type D is a small self contained
module that is intended to be located in a safe area. The converter module is
configured to produce a 48v DC output from a 24v DC input. The single output is
configured from a series output, with negative sense at the load and the inhibit
function disabled. This configuration is pre wired in the accompanying DIN H15
connector to the module.

Fully enclosed in a black coated aluminium case, that acts as a heat sink and RFI
shield, the module corresponds to class 1 safety and installation specifications and
meets EN60950, UL 1950, IEC 950 and EN 41003. It is recommended that the
output from the module shall be a SELV circuit, ( i.e. a circuit separated from mains
by at least basic insulation, that is so designed and protected that under normal and
single fault conditions, the voltage between any two conductors and between any
conductor and earth does not exceed 60 volts DC).

The module has a neon indicator to show when output is functional.

Specification

Input voltage 16 – 36 volts DC

24 volts nominal
Output voltage 48 volts DC nominal
Output current 2.2 Amps nominal
Max output power 105 Watt
Configuration Single output from series
connection
Connector DIN H15 female

Safety equipment EN 60950, VDE 0805, EN

specification for class 1 41003, UL 1950
Module installation IEC 950 SELV circuit
requirement regulation

Environmental Fully enclosed case that acts

as heat and RFI shield. With
connector fitted sealed to IP
30.
Temperature range (start -10 to 50 deg C
up and operational)
Temperature range -10 to 80 deg C
(operational)

Dimensions 164 x 111 x 20 mm

Weight 0.48 Kg
 RS Aqua Ltd.
WaveRadar REX Operating Manual Issue K – 1st March 2014

11.2 Annex B Power, data and RDU40 cabling

Cable specifications

The following are specifications for cables and gland components that may be
supplied by RS Aqua Ltd. that in most cases provide the optimum input voltage
balanced against conductor size and cable length to give a voltage within the range
specified for the different versions of the WaveRadar REX.

Power cable:
ESI two-core 1.5sq mm (Armoured). PVC / SWA / PVC BLACK
Or
BS 5467 2.5 sq mm (Armoured). PVC / SWA / PVC BLACK

Data cable:
BS 5308 part 2, type 1, one twisted pair 0.5 sq. mm. PVC / SCREEN / PVC / SWA
/PVC.

Remote Display Unit - RDU40:

BS5308 Part 2 three core 0.5 sq.mm. PVC / screened / PVC / SWA / PVC Blue
Or
BS5308 Part 2 four core 0.5 sq.mm. PVC / screened / PVC / SWA / PVC Blue
Or
IEC 228, IEC 227 core size 0.5 sq mm.

Gland and adapter specifications

The WaveRadar REX integrated junction box is supplied with fitted glands. These
glands are:
KEMA M20 x 1.5
KEMA M25 x 1.5.
Approval categories: 99ATEX 6971X II2G1D EEx e II /LDA20
IECEx – KEM 07.0014x
Temperature range 60deg C - + 105 deg C.

Glands available from RS Aqua Ltd. are:

Hawk JB gland - M20 501/453 size OS
Hawk reducer M25 to M20 Exd 25M-20F,1 with lock nut M25
Hawk washer M25 Hawk SLG WSH B 25M-1, FBR
Environmental IP66
Approval categories EEx dIIC, EEx e II

Plugs are also available from RS Aqua Ltd. These plugs replace unwanted/unused
glands.
Lapp Group - M20 and M25.
Approval categories: BExU03ATEX 1011
II2G1D EEx e II
Environmental IP66/IP68
 RS Aqua Ltd.
WaveRadar REX Operating Manual Issue K – 1st March 2014

Integrated Junction box - cable inlets

Connector X12 Connector X11

Cable inlet EEx i Cable inlet EEx e (power I/P, data O/P)

M20

M25

M25 M20

Remote Display Unit (RDU40) cable inlets – EEx-i

M25

M20
M20
 RS Aqua Ltd.
WaveRadar REX Operating Manual Issue K – 1st March 2014

11.3 Annex C Remote Display Unit RDU40

Technical data

Ambient temperature -40C to +70C

Ex Class Cenelec: Ex ib IIC T4
FM: Class 1, Group A, B, C, D
Division 1 Hazardous location.
ATEX Sira 00 ATEX 2062
To EN50 014 and EN50 020
CE CE0600 112G

Maximum cable length 100m (328 ft) – Total length if two units are
connected to the same WR Gauge.
Cable requirement 3 wire, shielded instrument cable
Min 0.5mm (AWG 20)
Max 2.5mm (AWG 14)
Max 14 mm (0.55 inch)
Min insulation thickness for each wire 0.25mm
(0.00985 inch)
Material housing Diecast aluminium
Dimensions 150 x 120 x 70 mm (6 x 4 x 3 inch)
Weight 1.2 kg (2.6 lbs)
Protection class IP67. NMEA 4.
 RS Aqua Ltd.
WaveRadar REX Operating Manual Issue K – 1st March 2014

Mount the RDU with the four M4 screws. Distances between the screws are 60mm
and 68mm and are shown on the diagram below.

If two RDU40 are to be connected to the same REX one of the RDU40 units must be
the “slave” while the other is the “master”. The slave unit will follow the master and
only the LCD contrast may be individually controlled at the slave unit.
To make the RDU40 work as a slave the jumper connection must be moved to
position 2.
 RS Aqua Ltd.
WaveRadar REX Operating Manual Issue K – 1st March 2014

Operation

The RDU40 is factory set to display the View mode presenting the default display.
The four soft keys have limited functions. The LCD contrast can be increased by
simultaneously pressing the two buttons on the right hand side to adjust from
minimum to maximum LCD contrast.

Approximately 30 seconds after power is applied to the WaveRadar REX the RDU40
display will show the measured range and status.

Fault finding

Symptom Cause Action

No display No power from the 1. Ensure WaveRadar is
WaveRadar operating.
2. Check wires are connected
correctly to the X12 JB on the
WaveRadar REX.
The RDU flashes 1. Wiring to RDU from Check
a checked pattern WaveRadar REX 1. Wiring connections to the RDU.
incorrect Wiring is the correct type and size.
2. The WaveRadar 2. Restart WaveRadar
REX is operating in
boot mode.
3. RDU has been 3. Restart WaveRadar
connected to the
WaveRadar while the
WaveRadar is running.

The RDU shows Incorrect slave/master 1. Ensure that jumper is fitted to

nothing but four mode the master position (position 1) on
black rectangles the back of the RDU PCB.
at the bottom of
the display
 RS Aqua Ltd.
WaveRadar REX Operating Manual Issue K – 1st March 2014

11.4 Annex D Underwriters Laboratory (UL) standard

Technical data

Hazardous Location Class 1, Division 1, Group C or D

Class 1, Zone 1, Group IIB. Ex d [ia] IIB T6
UL Listed 939U
FCC ID K8CREXX
Ambient temperature -40C to +70C
Environmental protection IP67

Reference Special Safety Instruction, Chapter 4.

System control drawing for hazardous location
installation, Number 9150072-966

Customer supplied items Flexible hose conduit to local regulations, 1m

length (two per REX unit) and hose
terminations/adapters to fit cable exit port of
electronic housing. The port threads are ¾”
NPT.
Junction boxes (two per REX unit) certified for
use in a hazardous area.

For the UL configured WaveRadar REX, the integrated junction box is removed and
the wires for the Non Intrinsically Safe (W11) and the Intrinsically Safe (W12) circuits
exit through a lead seal in the transmitter head. The permanently attached wires are
of 1.5m in length and flexible hose conduit is required for each outlet to provide
protection for the wires and fitting to a junction box. The permanently attached wires
must be suitably terminated in customer supplied junction boxes that must be
certified for use in a hazardous area.

The W12 output is optional and may contain up to 15 wires connected to six separate
intrinsically safe circuits. Wires are clearly numbered and identified both on the plate
attached to the outlet and on the System Control Drawing in chapter 4 of the Special
Safety Instruction.
 RS Aqua Ltd.
WaveRadar REX Operating Manual Issue K – 1st March 2014

W12 Intrinsically safe wire ID’s W11 Non Intrinsically Safe wire ID’s

Wire Circuit Identity Wire Circuit Identity

Number Number
1 AIN 1+: 1 MAINS L/L1 +
2 AIN 1 -: 2 MAINS L/L2 -
3 AIN +2: 3 BUS A
4 AIN –2: 4 BUS B
5 DS (RDU40) 5 K1 A
6 D + (RDU40) 6 K1 B
7 D GND (RDU40) 7 K2 A (Analogue o/p +)
8 T1 8 K2 B (Analogue o/p -)
9 T2 9 PROT EARTH
10 T3
11 T4
12 T5
13 T6
14 T7
15 T8

The wiring details for the WaveRadar REX are shown on drawing WP2001M007
attached to this annex.
 RS Aqua Ltd.
WaveRadar REX Operating Manual Issue K – 1st March 2014

11.4 Annex E ESAAASD standard

Technical data

Hazardous Location Class 1, Division 1, Group C or D

Class 1, Zone 1, Group IIB. Ex d [ia] IIB T6
UL Listed 939U
FCC ID K8CREXX
Ambient temperature -40C to +70C
Environmental protection IP67

Reference Special Safety Instruction, Chapter 4.

System control drawing for hazardous location
installation, Number 9150072-966

Customer supplied items Flexible hose conduit to local regulations, 1m

length (two per REX unit) and hose
terminations/adapters to fit cable exit port of
electronic housing. The port threads are ¾”
NPT.
Junction boxes (two per REX unit) certified for
use in a hazardous area.

For the UL configured WaveRadar REX, the integrated junction box is removed and
the wires for the Non Intrinsically Safe (W11) and the Intrinsically Safe (W12) circuits
exit through a lead seal in the transmitter head. The permanently attached wires are
of 1.5m in length and flexible hose conduit is required for each outlet to provide
protection for the wires and fitting to a junction box. The permanently attached wires
must be suitably terminated in customer supplied junction boxes that must be
certified for use in a hazardous area.

The W12 output is optional and may contain up to 15 wires connected to six separate
intrinsically safe circuits. Wires are clearly numbered and identified both on the plate
attached to the outlet and on the System Control Drawing in chapter 4 of the Special
Safety Instruction.