IOM027FVAE0804
7532 Radar Tank Gauge
Smart transmitter for continuous and non-contact precision
level measurement. For custody transfer and inventory-control
applications with NMI and PTB approval.
Installation and
Operations Manual
www.varec.com
Varec, Inc.
5834 Peachtree Corners East, Norcross (Atlanta), GA 30092 USA
Tel: +1 (770) 447-9202 Fax: +1 (770) 662-8939
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Radar Tank Gauge
Table of Contents
Table of Contents
Safety Instructions ....................................4
Commissioning .........................................45
Identification ................................................7
Maintenance ...............................................73
Accessories ................................................75
Troubleshooting .......................................77
Wiring ............................................................25
11.1 Operating menu HART (Display modul), ToF Tool
91
Operation .....................................................31
IOM027FVAE0804
3
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Safety Instructions
Radar Tank Gauge
1
Safety Instructions
1.1
Designated use
The Varec Model 7532 Radar Tank Gauge (RTG) is a compact radar level transmitter for
the continuous, contactless measurement of liquids, pastes and sludge in stilling wells.
The device can also be freely mounted outside closed metal vessels because of its
operating frequency of about 6 GHz and a maximum radiated pulsed energy of 1mW
(average power output 1 µW). Operation is completely harmless to humans and animals.
1.2
Installation, commissioning and operation
The 7532 RTG has been designed to operate safely in accordance with current technical,
safety and EU standards. If installed incorrectly or used for applications for which it is
not intended, however, it is possible that application-related dangers may arise, e.g.
product overflow due to incorrect installation or calibration. For this reason, the
instrument must be installed, connected, operated and maintained according to the
instructions in this manual: personnel must be authorised and suitably qualified. The
manual must have been read and understood, and the instructions followed.
Modifications and repairs to the device are permissible only when they are expressly
approved in the manual.
1.3
Operational safety
Hazardous areas
Measuring systems for use in hazardous environments are accompanied by separate “Ex
documentation”, which is an integral part of this Operating Manual. Strict compliance
with the installation instructions and ratings as stated in this supplementary
documentation is mandatory.
• Ensure that all personnel are suitably qualified.
• Observe the specifications in the certificate as well as national and local regulations.
FCC-approval
This device complies with part 15 of the FCC Rules. Operation is subject to the following
two conditions: (1) This device may not cause harmful interference, and (2) this device
must accept any interference received, including interference that may cause undesired
operation.
Caution!
Changes or modifications not expressly approved by the part responsible for
compliance could void the user’s authority to operate the equipment.
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7532
Safety Instructions
1.4
Return
The following procedures must be carried out before a transmitter is sent to Varec for
repair:
• Always enclose a duly completed “Declaration of contamination” form. Only then can
Varec transport, examine and repair a returned device.
• Enclose special handling instructions if necessary, for example a safety data sheet as
per EN 91/155/EEC.
• Remove all residue which may be present. Pay special attention to the gasket grooves
and crevices where fluid may be present. This is especially important if the fluid is
dangerous to health, e.g. corrosive, poisonous, carcinogenic, radioactive, etc.
Caution!
• No instrument should be sent back for repair without all dangerous material being
completely removed first, e.g. in scratches or diffused through plastic.
• Incomplete cleaning of the instrument may result in waste disposal or cause harm to
personnel (burns, etc.). Any costs arising from this will be charged to the operator of
the instrument.
5
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Safety Instructions
Radar Tank Gauge
1.5
Notes on safety conventions and symbols
In order to highlight safety-relevant or alternative operating procedures in the manual,
the following conventions have been used, each indicated by a corresponding symbol in
the margin.
Safety conventions
Symbol
Meaning
A warning highlights actions or procedures which, if not performed correctly,
will lead to personal injury, a safety hazard or destruction of the instrument
Warning!
Caution highlights actions or procedures which, if not performed correctly,
may lead to personal injury or incorrect functioning of the instrument
Caution!
Note!
A note highlights actions or procedures which, if not performed correctly, may
indirectly affect operation or may lead to an instrument response which is not
planned
Explosion protection
Device certified for use in explosion hazardous area
If the 7532 RTG has this symbol embossed on its name plate it can be
installed in an explosion hazardous area
0
-
Explosion hazardous area
Symbol used in drawings to indicate explosion hazardous areas.
– Devices located in and wiring entering areas with the designation
“explosion hazardous areas” must conform with the stated type of
protection
Safe area (non-explosion hazardous area)
Symbol used in drawings to indicate, if necessary, non-explosion
hazardous areas.
.
– Devices located in safe areas still require a certificate if their outputs run
into explosion hazardous areas.
Electrical symbols
Direct voltage
A terminal to which or from which a direct current or voltage may be
applied or supplied
%
&
Alternating voltage
A terminal to which or from which an alternating (sine-wave) current
or voltage may be applied or supplied
Grounded terminal
A grounded terminal, which as far as the operator is concerned, is
already grounded by means of an earth grounding system
)
*
Protective grounding (earth) terminal
A terminal which must be connected to earth ground prior to making
any other connection to the equipment
Equipotential connection (earth bonding)
A connection made to the plant grounding system which may be of
type e.g. neutral star or equipotential line according to national or
company practice
+
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7532
Identification
2
Identification
2.1
Device designation
2.1.1
Nameplate and Certification Plates
The following technical data are given on the instrument nameplate:
Figure 1: Information on the nameplate of the 7500 RTG (example)
Figure 2: Information on the NMi type plate for custody transfer applications of the
7500 RTG (example)
Figure 3: Information on the PTB type plate for custody transfer applications of the
7500 RTG (example)
7
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Identification
Radar Tank Gauge
2.1.2
Ordering structure
Ordering structure 7532 RTG
10
Certificates
Basic weight
6.5 kg
A
S
U
1
For non-hazardous areas
FM
CSA
IS - Class I, Division 1, Group A-D
IS - Class I, Division 1, Group A-D
ATEX II 1/2 G EEx ia IIC T6, note safety instruction (XA) for electrostatic charg-
ing!
Y
Special version
Antenna type
20
Additional
weight
Type
Size
Material
SS316L
SS316L
SS316L
SS316L
SS316L
SS316L
SS316L
SS316L
Sealing
A
B
E
Planar antenna DN150 / 6"
Planar antenna DN150 / 6"
Planar antenna DN250 / 10"
Planar antenna DN250 / 10"
Planar antenna DN200 / 8"
Planar antenna DN200 / 8"
Planar antenna DN300 / 12"
Planar antenna DN300 / 12"
Special version
FKM inside
HNBR inside
FKM inside
HNBR inside
FKM inside
HNBR inside
HNBR inside
FKM inside
F
2.1 kg
1.1 kg
2.5 kg
U
V
W
X
Y
30
Process connection
Flange Dia/Pressure
Standard
ANSI B16.5
ANSI B16.5
ANSI B16.5
ANSI B16.5
ANSI B16.5
ANSI B16.5
Material
316/316L
316/316L
316/316L
316/316L
316/316L
316/316L
316L
316L
316L
316L
316L
AVJ
A3J
A5J
AWJ
AXJ
A7J
CWJ
CXJ
CZJ
C1J
C6J
C8J
XXJ
XVU
6"/150 lbs / RF
8"/150 lbs / RF
10"/150 lbs / RF
6"/300 lbs / RF
8"/300 lbs / RF
12"/150 lbs / RF
DN150 PN10 / 16 C
DN200 PN16 C
DN200 PN25 C
DN150 PN25 C
DN250 PN16 C
DN300 PN16 C
with flange hub
11.4 kg
19.6 kg
28.8 kg
20.9 kg
34.3 kg
43.2 kg
10.6 kg
16.5 kg
22.7 kg
14.7 kg
25.6 kg
36.1 kg
EN 1092,1, B11)
EN 1092,1, B11)
EN 1092,1, B11)
EN 1092,1, B11)
EN 1092,1, B11)
EN 1092,1, B11)
316L
316L
304/1.4301
Varec UNI-Flange 6"/
3.5 kg
5.2 kg
7.5 kg
10.8 kg
DN150/150A,
max. 14.5LBS/PN1/1K,
compatible with:
- 6" 150LBS
- DN150 PN16
- 10K 150A
X3U
X5U
X7U
Varec UNI-Flange 8"/
DN200/200A,
304/1.4301
304/1.4301
304/1.4301
max. 14.5LBS/PN1/1K,
compatible with:
- 8" 150LBS
- DN200 PN16
- 10K 200A
Varec UNI-Flange 10"/
DN250/250A,
max. 14.5LBS/PN1/1K,
compatible with:
- 10" 150LBS
- DN250 PN16
- 10K 250A
Varec UNI-Flange 12"/
DN300/300A,
max. 14.5LBS/PN1/1K,
compatible with:
- 12" 150LBS
- DN300 PN16
- 10K 300A
1) agreeable to DIN2527 Form C
YY9
Special version
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7532
Identification
40
Output and operation
A
4…20 mA HART with VU 331, 4-line alphanumeric dis-
play
Y
Special version
Housing
50
60
C
Y
Aluminium T12-housing with separate connection compartment, coated, IP65
Special version
Gland / Entry
2
4
9
M20x1.5 cable gland
½ NPT cable entry
Special version
70
Custody transfer approvals
A
R
Y
NMi, PTB type and test rig approval,
weights&measures approved (< 1 mm)
Inventory Control Version,
not weights&measures approved (3 mm)
Special approval for custody transfer
80
Additional options
A
Y
Without additional options
Special version
7532-
Complete product designation
9
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Identification
Radar Tank Gauge
2.2
Scope of delivery
Caution!
It is essential to follow the instructions concerning the unpacking, transport and storage
of measuring instruments given in the section “Incoming acceptance, transport, storage”
The scope of delivery consists of:
• Assembled instrument
• ToF Tool (operating program)
Accompanying documentation:
• Short manual (basic equalization/troubleshooting): housed in the instrument
• Operating manual (this manual)
• Operating manual: Description of the instrument functions
• Approval documentation: if this is not included in the operating manual.
2.3
Certificates and approvals
CE mark, declaration of conformity
The instrument is designed to meet state-of-the-art safety requirements, has been
tested and left the factory in a condition in which it is safe to operate. The instrument
complies with the applicable standards and regulations in accordance with EN 61010
“Protection Measures for Electrical Equipment for Measurement, Control, Regulation and
Laboratory Procedures”. The instrument described in this manual thus complies with the
statutory requirements of the EG directives. Varec confirms the successful testing of the
instrument by affixing to it the CE mark.
2.4
Registered trademarks
KALREZ ®, VITON ®, TEFLON ®
Registered trademark of the company E.I. Du Pont de Nemours & Co., Wilmington, USA
TRI-CLAMP ®
Registered trademark of the company Ladish & Co., Inc., Kenosha, USA
HART ®
Registered trademark of HART Communication Foundation, Austin, USA
ToF ®
Registered trademark of the company Endress+Hauser GmbH+Co. KG, Maulburg, Ger-
many
PulseMaster ®
Registered trademark of the company Endress+Hauser GmbH+Co. KG, Maulburg, Ger-
many
PhaseMaster ®
Registered trademark of the company Endress+Hauser GmbH+Co. KG, Maulburg, Ger-
many
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7532
Mounting
3
Mounting
3.1
Quick installation guide
Installation only in stilling well:
Turn housing
The housing can be turned
in order to simplify access to the
display and the terminal compartment
T12 housing
2
90˚
3
1
Allen key
4 mm
tighten strongly
by hand
The performance of the 7532 RTG
.
planar antenna is not dependent on the
alignment or geometry of standard stilling
wells.
No special alignment is required.
However, make sure that the planar
antenna is installed vertically relative
to the stilling well axis.
.
Note!
The 7532 RTG with planar antenna is designed for use on stilling-wells only!
11
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Mounting
Radar Tank Gauge
3.2
Incoming acceptance, transport, storage
3.2.1
Incoming acceptance
Check the packing and contents for any signs of damage.
Check the shipment, make sure nothing is missing and that the scope of supply matches
your order.
3.2.2
Transport
Caution!
Follow the safety instructions and transport conditions for instruments of more than
18 kg. Do not lift the measuring instrument by its housing in order to transport it.
3.2.3
Storage
Pack the measuring instrument so that is protected against impacts for storage and
transport. The original packing material provides the optimum protection for this.
The permissible storage temperature is -40 °C…+80 °C.
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7532
Mounting
3.3
Installation Conditions
3.3.1
Dimensions
68 (2.68")
94 (3.7")
65 (2.56") 85 (3.35")
ENDRESS+HAUSER
Micropilot II
E+H UNI flange
(max. 1 bar)
DIN, ANSI,
JIS
detail A:
flange adapter
(see under)
Ø 150 (5.91")
DN150 / 6”
version without widening
DN200…300 / 8…12”
version with
antenna widening
detail A
flange hub for the connection
to flanges provided by the customer
mounting:
4 bolts M6 / 90°
e.g. DIN 912
Ø 78 (3.07")
Ø 62,5 (2.46")
Ø D
O-Ring 85.3 x 3.53,
included
(same material as
sensor seal)
flange hub
Ø 99,5 (3.92")
Figure 4: Dimensions 7532 RTG
Antenna version
L [mm]
DN150 / 6"
93
no horn
DN200 / 8"
337
DN250 / 10"
DN300 / 12"
490
240
517
290
Ø D [mm]
190
Note!
The inactive length of 60 mm prevents condensation effects to the antenna perfor-
mance. Special versions with longer construction are available.
13
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Mounting
Radar Tank Gauge
3.3.2
Engineering tips
Measuring conditions
• The measuring range starts at the bottom end of the stilling well.
• In case of media with a low dielectric constant (groups A and B), the pipe end can be
visible through the medium at low levels. In order to guarantee the required accuracy
in these cases, it is recommended to position the zero-point at a distance C above the
tank bottom (see Fig.).
• In applications with planar or parabolic antennas, especially for media with low
than 1 m (40”) to the flange.
• For overspill protection, it is possible to define a safety distance (SD) additionally to
the blocking distance (BD).
• This safety distance (SD) is set to 0.5 m (20") by default and generating an alarm in
case the level rises inside the safety distance.
• Distance B defined the smallest recommended measurement range.
• Depending on its consistence, foam can either absorb microwaves or reflect them off
the foam surface. Measurement is possible under certain conditions.
100%
BD
SD
A
max. level
B
C
0%
reference: flange / BD
(see picture)
reference: antenna tip
(see picture)
Blocking
distance
Safety
distance
recommended additional settings
BD [m / ft]
SD [m / ft]
A [mm / inch]
1000 / 40
B [m / ft]
C [mm / inch]
150…300 /
6…12
7532 RTG (planar)
1 / 3.28
0.5 / 1.6
0.5 / 1.64
Behaviour if measuring range is exceeded
The behaviour in case of the measuring range being exceeded can be freely set: the
default setting is a current of 22 mA and the generation of a digital warning (E681).
14
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7532
Mounting
Measuring range
The usable measuring range depends on the size of the antenna, the reflectivity of the
medium, the mounting location, and eventual interference reflections.
The following tables describe the groups of media as well as the achievable measuring
range as a function of application and media group. If the dielectric constant of a
medium is unknown, it is recommended to assume media group B to ensure a reliable
measurement.
Product class
DK (εr)
1.4 … 1.9
1.9 … 4
4 … 10
Examples
A
B
C
non-conducting liquids, e.g. liquefied gas 1)
non-conducting liquids, e.g. benzene, oil, toluene, …
e.g. concentrated acids, organic solvents, esters, aniline,
alcohol, acetone, …
D
> 10
conducting liquids, e.g. aqueous solutions, dilute acids and
alkalis
1)Treat Ammonia NH3 as a medium of group A, e.g. always use a stilling well.
Measuring range depending on product class for 7532 RTG:
Product class
Stilling well/ Bypass
Measuring range
7532 RTG
> DN150
A
B
DK(εr)=1,4…1,9
DK(εr)=1,9…4
DK(εr)=4…10
DK(εr)>10
38 m/124 ft
38 m/124 ft
38 m/124 ft
38 m/124 ft
C
D
max. measuring
range with custody
transfer approvals
20 m/65 ft
15
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Mounting
Radar Tank Gauge
Blocking distance
The blocking distance (= BD) is the minimum distance from the reference point of the
measurement (mounting flange) to the medium surface at maximum level.
referencepointof
measurement
BD
20mA
100%
Max.
Level
Stilling well / Bypass
7532 RTG
Blocking distance
(BD)
from Flange
1 m/40"
Note!
Inside the blocking distance a reliable measurement can not be guaranteed.
16
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7532
Mounting
3.4
Installation instructions
3.4.1
Mounting kit
In addition to the tool needed for flange mounting, you will require the following tool:
• 4 mm Allen wrench for turning the housing.
3.4.2
Installation in stilling well
Optimum mounting position for 7532 RTG
Standard installation
When mounting in the stilling well, please
observe engineering tips on page 14 and
the following points:
• After mounting, the housing can be
turned 350° in order to simplify access to
the display and the terminal
compartment.
• planar axis vertical to flange.
• Measurements can be performed
through an open ball valve without any
problems.
Recommendations for the stilling well
• Metal (no enamel coating, plastic on request).
• Constant diameter.
• Weld seam as smooth as possible and on the same axis as the slots.
• Slots offset 180° (not 90°).
• Slot width respectively diameter of holes max. 1/10 of pipe diameter, de-burred.
Length and number do not have any influence on the measurement.
• Select antenna extension as big as possible. For intermediate sizes (e.g. 180 mm)
select next larger antenna extension and adapt it mechanically. Maximum gap allowed
between the antenna/horn of 7532 RTG and the inside of the stilling well is 5 mm (3/
16").
• The antennna extension of the 7532 RTG is mounted with defined pressure.
It is strongly recommended not to dismantle this antenna.
• Dimensions of a nozzle for manual gauging must be adapted to the dimensions of
Stilling wells with pipe expansion
• When using a 7532 RTG, a gradual pipe expansion from DN150 to DN200 / DN200
to DN250 / DN250 to DN300 is acceptable. In such cases, the top end of the piping
must have a minimum length of 0.5 m in front of the expansion (see table on page 18).
Ideally, a dip socket is used for this.
• Greater expansion of the piping (e.g. DN150 to DN300) is possible if the top end of
• Avoid pipe expansions at right angles.
17
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7532
Mounting
3.4.3
Turn housing
After mounting, the housing can be turned 350° in order to simplify access to the display
and the terminal compartment. Proceed as follows to turn the housing to the required
position:
• Undo the fixing screws (1)
• Turn the housing (2) in the required direction
• Tighten up the fixing screws (1)
T12 housing
2
1
Allen key
4 mm
tighten strongly
by hand
19
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Mounting
Radar Tank Gauge
3.4.4
Installation with Varec UNI flange
Installation tips
Varec UNI flanges are designed for non-pressurized operation respectively max. 1 bar
absolute pressure. The number of bolts has sometimes been reduced. The bolt-holes
have been enlarged for adaption of dimensions, therefore, the flange needs to be
properly aligned to the counterflange before the bolts are tightened.
Version
Compatible with
D [mm]
K [mm]
Type plate no.
1000
DN150 PN16
ANSI 6" 150lbs
JIS 10K 150
280
240
942455-3001
2000
3000
4000
DN200 PN16
ANSI 8" 150lbs
JIS 10K 200
DN250 PN16
ANSI 10" 150lbs
JIS 10K 250
DN300 PN16
ANSI 12" 150lbs
JIS 10K 300
340
405
482
294.5
358
942455-3002
942455-3003
942455-3004
410 (for DIN), 431,8
(for ANSI), 400 (for
JIS),
404,5 (for DIN + JIS)
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7532
Mounting
Preparation for the installation of the Varec UNI flange
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Mounting
Radar Tank Gauge
pull off housing
16
mount Varec UNI flange
17
Varec UNI flange
(max. 1 bar)
detail A:
flange adapter
(see under)
detail A
flange hub for the connection
to flanges provided by the customer
mounting:
4 bolts M6 / 90˚
e.g. DIN 912
Ø 78
Ø 62.5
O-Ring 85.3 x 3.53,
included
(same material as
sensor seal)
flange hub
Ø 99.5
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7532
Mounting
3.4.5
Mounting with Sample hatch on stilling well
Installation tips
For control and cleaning purposes as well as for hand dipping (tape), a sample hatch
gauging is recommended. The sensor head can be easily checked in the area of the
opening. Manual gauging with gauge rod or tape is possible without removal of the
transmitter. The lower edge of the opening is the reference for the gauging. The
construction is only suitable for non-pressurized operation.
Note!
The nozzle for manual gauging is not part of the standard offering from Varec. Please
contact Varec for further information.
Flange
PN [lbs] 2)
A [mm]
L [mm}
DN150
16
110
—
DN200
16
140
300
DN250/300
16
Flange
ANSI 6"
150
110
ANSI 8"
150
140
ANSI 10"
150
170
2)
PN [lbs]
A [mm]
L [mm]
170
450
—
300
450
2)Only dimensions adapted to standard. Designed for non-pressurized operation only,
therefore thickness of flange can be reduced (e.g. 8mm).
23
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Mounting
Radar Tank Gauge
3.4.6
Mounting with Pivoting element
Installation tips
The Pivoting element serves to swivel the 7500 RTG from the measuring position, e.g.
to clean the antenna or dip the tank.
The pivoting element is not part of the standard offering from Varec, special offers
available under ref. number MVTFM0422.
3.5
Post-installation check
After the measuring instrument has been installed, perform the following checks:
• Is the measuring instrument damaged (visual check)?
• Does the measuring instrument correspond to the measuring point specifications
such as process temperature/pressure, ambient temperature, measuring range, etc.?
• Have the flange screws been tightened up with the respective tightening torque?
• Are the measuring point number and labeling correct (visual check)?
• Is the measuring instrument adequately protected against rain and direct sunlight
24
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Wiring
Radar Tank Gauge
Before connection please note the following:
"
●
The power supply must be identical to the data on the
nameplate (1).
Caution!
●
Switch off power supply before connecting up the device.
1
●
Connect Equipotential bonding to transmitter ground terminal
before connecting up the device.
●
Tighten the locking screw:
It forms the connection between the antenna and the housing
ground potential.
2
When you use the measuring system in hazardous areas, make sure you comply with
national standards and the specifications in the safety instructions (XA’s).
Make sure you use the specified cable gland.
Connect up the 7500 RTG as follows:
Before unscrew housing cover (2) at seperate connection room
turn off the power supply!
-
●
Insert cable through gland (3).
Use screened, twisted wire pair.
Only ground screening of the line (5) on sensor side.
-
●
Make connection (see pin assignment).
●
Tighten cable gland (4).
●
Screw off housing cover (2).
4
●
Switch on power supply.
3
power:
24 VDC
signal:
24 VDC
(16…30 V)
5
1
2
3
4
plant
ground
1 2 3 4 5
1 2 3
4 5
A 7500 RTG situated in a hazardous area is connected as a single
device to a power supply unit and transmitter situated outside of
the hazardous area. In this case, it is recommended that the screen
be connected directly to the 7500 RTG at the housing's earth,
whereby the 7500 RTG and the power supply unit are connected to
the same potential matching line (PML).
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7532
Wiring
Wiring with Tank Side Monitor 4590
Before connection please note the following:
"
●
The power supply must be identical to the data on the
nameplate (1).
Caution!
1
●
Switch off power supply before connecting up the device.
●
Connect Equipotential bonding to transmitter ground terminal
before connecting up the device.
2
●
Tighten the locking screw:
It forms the connection between the antenna and the housing
ground potential.
When you use the measuring system in hazardous areas, make sure you comply with
national standards and the specifications in the safety instructions (XA’s).
Make sure you use the specified cable gland.
Connect up the 7500 RTG as follows:
Before unscrew housing cover (2) at seperate connection room
turn off the power supply!
-
●
Insert cable through gland (3).
Use screened, twisted wire pair.
●
Make connection (see pin assignment).
●
Tighten cable gland (4).
●
Screw off housing cover (2).
Tank Side Monitor
4590 TSM
●
Switch on power supply.
4
3
intrinsicaly safe
terminal board
D+
16
S+
17
S-
D-
18
19
20
21
22
23
OPT1
OPT2
OPT3
OPT4
grounding not on
7500 RTG
grounding single sided
on Tank Side Monitor
4590 TSM
+
24
25
26
27
H
-
+
1
2
3
4
HART
sensor
H
-
+
+
plant
ground
28
29
30
31
4
3
H
-
+
-
+
1 2 3 4 5
2
1
P
-
-
1 2 3
4 5
only for
7500 RTG
The 7500 RTG is - possibly in combination with other devices - connected to a Tank
Side Monitor in a hazardous area. In this case, it is recommended that you ground
the cable screen centrally at the Tank Side Monitor and connect all devices to the
same potential matching line (PML). If, for functional reasons, a capacitive coupling is
required between local earth and screen (multiple grounding), ceramic condensers
with a dielectric strength of min. 1500 Veff must be used, whereby the total capacitance
of 10 nF must not be exceeded. Notes on grounding interconnected intrinsically safe
devices are provided by the FISCO model
27
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Wiring
Radar Tank Gauge
4.2
Connecting the measuring unit
Terminal compartment
The housing comes with a separate terminal compartment.
Load HART
Minimum load for Hart communication: 250 Ω
Cable entry
Cable gland: M20x1.5 or Pg13.5
Cable entry: G ½ or ½ NPT
Supply voltage
Direct current voltage: 16…36 VDC
.
Communication
Terminal voltage
U (20 mA) =
U (20 mA) =
U (4 mA) =
minimal
16 V
maximal
36 V
Power supply
Standard
Ex
16 V
30 V
Signal
11,5 V
11,5 V
30 V
Ex
U (20 mA) =
30 V
Power consumption
Max. 330 mW at 16 V, max. 500 mW at 24 V, max. 600 mW at 30 V.
Current consumption
Max. 21 mA (50 mA inrush current).
Power supply
For stand alone operation recommended via e.g. Varec RN 221N.
mm accuracy
For measurements with mm accuracy the measured variable must be transmitted
using HART protocol to ensure the necessary resolution.
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7532
Wiring
4.2.1
Connection to Tank Side Monitor 4590
4.2.2
HART connection with two Varec RN 221 N
- ToF Tool
FXA 193
RN 221N
power supply
signal
4...20 mA
df
d
d
a
s
f
d
m
a
a
a
.
DEL
ONLINE
QUICK SETUP
OPERATING MENU
PV
T
ABAR:
*
*
*
*
*
*
*
*
1
2
3
352 mbar
˚C
4
SV
0
HELP
SAVE
1
2
3
4
5
- COMMUWIN II
6
Page
Up
9
Bksp
Delete
Page
On
- ToF Tool
#
%
&
A
B
C
D
E
F
1
2
3
Copy
Paste
Hot Key
G
H
I
J
K
L
M
N
O
4
5
6
Insert
+
Hot Key
P
)
Q
R
S
T
U
V
W
X
Y
Z
7
8
9
,
(
‘
_
<
>
+
*
/
.
0
-
375
FIELD COMMUNICATOR
HART handheld
DXR 375
Commubox
FXA 191
4.2.3
HART connection with other supplies
- ToF Tool
DC voltage
FXA 193
or
PLC
power supply
signal
4...20 mA
≥ 250 Ω
a
as
df
a
dsdmdm
d
l
a
s
f
DEL
ONLINE
QUICK SETUP
OPERATING MENU
PV
T
ABAR:
*
*
*
*
*
*
*
*
1
2
3
352 mbar
°C
4
SV
0
HELP
SAVE
- COMMUWIN II
- ToF Tool
6
Page
Up
9
Bksp
Delete
Page
On
#
%
&
A
B
C
D
E
F
1
2
3
Copy
Paste
Hot Key
G
H
I
J
K
L
M
N
O
4
5
6
Insert
+
Hot Key
P
)
Q
R
S
T
U
V
W
X
Y
Z
7
8
9
,
(
‘
_
<
>
+
*
/
.
0
-
375
FIELD COMMUNICATOR
HART handheld
DXR 375
Commubox
FXA 191
Caution!
If the HART communication resistor is not built into the supply unit, it is necessary to
insert a communication resistor of 250 Ω into the 2-wire line.
29
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Wiring
Radar Tank Gauge
4.3
Equipotential bonding
Connect the Equipotential bonding to the external ground terminal of the transmitter.
Caution!
In Ex applications, the instrument must only be grounded on the sensor side. Further
safety instructions are given in the separate documentation for applications in explosion
hazardous areas.
4.4
Degree of protection
• housing: IP 65, NEMA 4X (open housing: IP20, NEMA 1)
• antenna: IP 68 (NEMA 6P)
4.5
Overvoltage protector
• The level transmitter 7500 RTG is equipped with an internal overvoltage protector
(600 Vrms electrode). Connect the metallic housing of the 7500 RTG to the tank wall
directly with an electrically conductive lead to ensure reliable potential matching.
• Installation with additional overvoltage protector HAW 262 Z (see XA 081F-A
"Safety instructions for electrical apparatus certified for use in explosion-hazardous
areas").
–Connect the external overvoltage protector and the 7500 RTG transmitter to the local
potential matching system.
–Potentials shall be equalised both inside and outside the explosion hazardous area.
–The cable connecting the overvoltage protector and the 7500 RTG transmitter shall
not exceed 1 m in length;
–The cable shall be protected e.g. routed in an armoured hose.
4.6
Post-connection check
After wiring the measuring instrument, perform the following checks:
• Is the cable gland tight?
• Is the housing cover screwed tight?
• If auxiliary power is available:
Is the instrument ready for operation and does the liquid crystal display show any
value?
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Operation
Radar Tank Gauge
–
+
E
X
F
2x
X
>3 s
X
F
X
...
F
O
S
O
S
O
S
...
...
Selection and configuration in Operation menu:
1.) Change from Measured Value Display to Group Selection by pressing F
2.) Press S or O to select the required Function Group (e.g.. "basic setup (00)") and confirm by pressing
F ➜ First function (e.g. "tank shape (002)") is selected.
Note!
The active selection is marked by a
3.) Activate Edit mode with O or S.
Selection menus:
in front of the menu text.
a) Select the required Parameter in selected function (e.g. "tank shape (002)") with S or O.
b) F confirms selection ➜ appears in front of the selected parameter
c) F confirms the edited value ➜ system quits Edit mode
d) O + S (= X) interrupts selection ➜ system quits Edit mode
Typing in numerals and text:
a) Press O or S to edit the first character of the numeral / text (e.g. "empty calibr. (005)")
b) F positions the cursor at the next character ➜ continue with (a) until you have completed your input
c) if a
symbol appears at the cursor, press F to accept the value entered
➜ system quits Edit mode
d) O + S (= X) interrupts the input, system quits Edit mode
4) Press F to select the next function (e.g. "medium property (003)")
5) Press O + S (= X) once ➜ return to previous function (e.g. "tank shape (002)")
Press O + S (= X) twice ➜ return to Group selection
6) Press O + S (= X) to return to Measured value display
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7532
Operation
5.1.1
General structure of the operating menu
The operating menu is made up of two levels:
• Function groups (00, 01, 03, …, 0C, 0D):
The individual operating options of the instrument are split up roughly into different
function groups. The function groups that are available include, e.g.: "basic setup",
"safety settings", "output", "display", etc.
• Functions (001, 002, 003, …, 0D8, 0D9):
Each function group consists of one or more functions. The functions perform the
actual operation or parameterization of the instrument. Numerical values can be
entered here and parameters can be selected and saved. The available functions of the
“basic setup (00)” function group include, e.g.: "tank shape (002)",
"medium property (003)", "process cond. (004)", "empty calibr. (005)", etc.
If, for example, the application of the instrument is to be changed, carry out the follow-
ing procedure:
1.Select the “basic setup (00)” function group.
2.Select the "tank shape (002)" function (where the existing tank shape is selected).
5.1.2
Identifying the functions
position is shown on the display.
The first two digits identify the function group:
•
basic setup
00
01
04
•
safety settings
linearization
•
…
The third digit numbers the individual functions within the function group:
•
basic setup
00
→
•
tank shape
002
003
004
•
medium property
process cond.
•
…
Here after the position is always given in brackets (e.g. "tank shape" (002)) after the
described function.
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Operation
Radar Tank Gauge
5.2
Display and operating elements
Figure 5: Layout of the display and operating elements
5.2.1
Display
Liquid crystal display (LCD):
Four lines with 20 characters each. Display contrast adjustable through key
combination.
Headline
Position indicator
Symbol
Main value Bargraph
Unit
–
+
E
Selection list
Help text
Envelope
curve
Figure 6: Display
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7532
Operation
5.2.2
Display symbols
The following table describes the symbols that appear on the liquid crystal display:
Symbols Meaning
ALARM_SYMBOL
This alarm symbol appears when the instrument is in an alarm state. If the symbol
flashes, this indicates a warning.
LOCK_SYMBOL
This lock symbol appears when the instrument is locked,i.e. if no input is possible.
COM_SYMBOL
This communication symbol appears when a data transmission via e.g. HART,
PFOFIBUS-PA or Foundation Fieldbus is in progress.
Calibration to regulatory standards disturbed
If the instrument is not locked or it cannot guarantee the calibration to regulatory
standards, the situation will be indicated on the display via the symbol.
Table 1: Meaning of the symbols
Light emitting diodes (LEDs):
There is a green and a red LED besides the Liquid Crystal Display.
LED
Meaning
red LED continuously on
red LED flashes
red LED off
Alarm
Warning
No alarm
green LED continuously on
Green LED flashes
Operation
Communication with external device
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Operation
Radar Tank Gauge
5.2.3
Key assignment
The operating elements are located inside the housing and are accessible for operation
by opening the lid of the housing.
Function of the keys
Key(s)
Meaning
Navigate upwards in the selection list
Edit numeric value within a function
O
S
or
or
V
W
Navigate downwards in the selection list
Edit numeric value within a function
X
F
or
or
Z
M
Navigate to the left within a function group
Navigate to the right within a function group, confirmation.
O
S
and
or
F
F
Contrast settings of the LCD
and
Hardware lock / unlock
After a hardware lock, an operation of the instrument via display or
communication is not possible!
The hardware can only be unlocked via the display. An unlock parameter must
be entered to do so.
O
and
S
and
F
Table 2: Function of the keys
Custody locking switch
Access to the electronics can be prevented by means of a custody locking switch that
The custody locking switch can be sealed for custody transfer applications.
Software reliability
The software used in the 7500 RTG fulfills the requirements of
OIML R85. This particularly includes:
• cyclical test of data consistency
• non-volatile memory
• segmented data storage
The 7500 RTG continuously monitor the compliance with accuracy requirements for
custody transfer measurements according to OIML R85. If the accuracy cannot be
maintained, a specific alarm is generated on the local display and via the digital
communication
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7532
Operation
5.3
Local operation
5.3.1
Locking of the configuration mode
The 7500 RTG can be protected in two ways against unauthorized changing of instru-
ment data, numerical values or factory settings:
"unlock parameter" (0A4):
A value <> 100 (e.g. 99) must be entered in "unlock parameter" (0A4) in the
"diagnostics" (0A) function group. The lock is shown on the display by the symbol and
can be released again either via the display or by communication.
Hardware lock:
The instrument is locked by pressing the O and S and F keys at the same time.
The lock is shown on the display by the
symbol and can only be unlocked again
via the display by pressing the O and S and F keys at the same time again. It is not
possible to unlock the hardware by communication.
All parameters can de displayed even if the instrument is locked.
⇒
–
+
E
O and S and F press simultaneous
⇓
⇓
The LOCK_SYMBOL appears on the LCD.
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Operation
Radar Tank Gauge
5.3.2
Unlocking of configuration mode
If an attempt is made to change parameters when the instrument is locked, the user is
automatically requested to unlock the instrument:
"unlock parameter" (0A4):
By entering the unlock parameter (on the display or via communication)
100 = for HART devices
the 7500 RTG is released for operation.
Hardware lock:
After pressing the O and S and F keys at the same time, the user is asked to enter the
unlock parameter
100 = for HART devices.
O and S and F press simultaneous
⇒
–
+
E
⇓
Please enter unlock code and confirm with F.
⇓
Caution!
Changing certain parameters such as all sensor characteristics, for example, influences
numerous functions of the entire measuring system, particularly measuring accuracy.
There is no need to change these parameters under normal circumstances and
consequently, they are protected by a special code known only to the Varec service
organization. Please contact Varec if you have any questions.
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7532
Operation
5.3.3
Factory settings (Reset)
Caution!
A reset sets the instrument back to the factory settings. This can lead to an impairment
of the measurement. Generally, you should perform a basic setup again following a
reset.
A reset is only necessary:
• if the instrument no longer functions
• if the instrument must be moved from one measuring point to another
• if the instrument is being de-installed /put into storage/installed
⇒
–
+
E
User input ("reset" (0A3)):
• 333 = customer parameters
• 555 = History
333 = reset customer parameters
This reset is recommended whenever an instrument with an unknown 'history' is to be
used in an application:
• The 7500 RTG is reset to the default values.
• The customer specific tank map is not deleted.
• A linearization is switched to "linear" although the table values are retained. The table
can be reactivated in the "linearization" (04) function group.
List of functions that are affected by a reset:
• tank shape (002)
• linearization (041)
• customer unit (042)
• diameter vessel (047)
• range of mapping (052)
• pres. Map dist (054)
• offset (057)
• low output limit (062)
• fixed current (063)
• fixed cur. value (064)
• simulation (065)
• empty calibr. (005)
• full calibr. (006)
• pipe diameter (007)
• output on alarm (010)
• output on alarm (011)
• outp. echo loss (012)
• ramp %span/min (013)
• delay time (014)
• safety distance (015)
• in safety dist. (016)
• Tank Gauging (030)
• auto correction (031)
• level/ullage (040)
• simulation value (066)
• format display (094)
• distance unit (0C5)
• download mode (0C8)
555 = History Reset
After mounting and aligning the equipment, carry out a history reset before switching
The tank map can also be reset in the "cust. tank map" (055) function of the
"extended calibr." (05) function group.
This reset is recommended whenever an instrument with an unknown 'history' is to be
used in an application or if a faulty mapping was started:
• The tank map is deleted. The mapping must be recommenced.
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Operation
Radar Tank Gauge
5.4
Display and acknowledging error messages
Type of error
Errors that occur during commissioning or measuring are displayed immediately on the
local display. If two or more system or process errors occur, the error with the highest
priority is the one shown on the display.
The measuring system distinguishes between two types of error:
• A (Alarm):
Instrument goes into a defined state (e.g. MAX 22 mA)
Indicated by a constant
symbol.
(For a description of the codes, see Table 9.2 on Page 79)
• W (Warning):
Instrument continue measuring, error message is displayed.
Indicated by a flashing
symbol.
(For a description of the codes, see Table 9.2 on Page 79)
• E (Alarm / Warning):
Configurable (e.g. loss of echo, level within the safety distance)
Indicated by a constant/flashing
symbol.
(For a description of the codes, see Table 9.2 on Page 79)
⇒
–
+
E
Error messages
Error messages appear as four lines of plain text on the display. In addition, a unique
error code is also output. A description of the error codes is given on page 79.
• The "diagnostics (0A)" function group can display current errors as well as the last
errors that occurred.
• If several current errors occur, use O or S to page through the error messages.
• The last occurring error can be deleted in the "diagnostics (0A)" function group
with the function "clear last error" (0A2).
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7532
Operation
5.5
HART communication
Apart from local operation, you can also parameterize the measuring instrument and
view measured values by means of a HART protocol. There are two options available for
operation:
• Operation via the universal handheld operating unit, the
HART Communicator DXR 375.
• Operation via the Personal Computer (PC) using the operating program
(e.g. ToF Tool or Commuwin II) (For connections, see page 29).
• Operation via the Tank Side Monitor 4590.
5.5.1
Handheld unit DXR 375
All device functions can be adjusted via menu operation with the handheld unit
DXR 375.
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asdas fa
asas la.
dsdmdm
df das.
asdas fa
asas la.
FMR531: LIC0001
ONLINE
FMR531: LIC0001
ONLINE
1
2
GROUP SELECTION
PV
1
2
GROUP SELECT
PV
Delete
8.7
m
8.7 m
HELP
SAVE
dsdmdm
df das.
asdas fa
asas la.
H
FMR531: LIC0001
HELP
SAVE
6
Page
Up
GROUP SELECTION
9
1
2
3
4
5
CALIBRATION
Bksp
Delete
Delete
LINEARISATION
EXT. CALIBRATION
SERVICE
Page
On
Bksp
OPERATING MODE
#
%
&
A
B
C
D
E
F
1
2
3
dsdmdm
df das.
asdas fa
asas la.
Copy
Paste
Hot Key
H
G
H
I
J
K
L
M
N
O
FMR531: LIC0001
4
5
6
SAVE
HOME
Insert
+
Hot Key
CALIBRATION
P
Q
R
S
T
_
U
V
W
X Y
Z
Page
Up
1
2
3
4
5
MEASURED VALUE
EMPTY CALIBRATION
FULL CALIBRATION
7
8
9
,
(
)
‘
<
>
+
*
/
.
0
-
APPLICATION PARAMETER
OUTPUT DAMPING
Bksp
Page
On
375
FIELD COMMUNICATOR
SAVE
HOME
Figure 7: Menu operation with the DXR 375 handheld instrument
Note!
• Further information on the HART handheld unit is given in the respective operating
manual included in the transport bag of the instrument.
5.5.2
ToF Tool operating program
The ToF Tool is a graphical operating software for instruments from Varec that operate
based on the time-of-flight principle. It is used to support commissioning, securing of
data, signal analysis and documentation of the instruments. It is compatible with the
following operating systems: Win95, Win98, WinNT4.0, Win2000 and
Windows XP.
The ToF Tool supports the following functions:
• Online configuration of transmitters
• Signal analysis via envelope curve
• Loading and saving of instrument data (Upload/Download)
• Documentation of measuring point
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Operation
Radar Tank Gauge
Note!
Further information you may find on the CD-ROM, which is enclosed to the instrument.
Menu-guided commissioning
Signal analysis via envelope curve
Connection options:
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7532
Operation
5.5.3
Commuwin II-Operating Program
Commuwin II is an operating software with graphical support for intelligent transmitters
with the communication protocols Rackbus, Rackbus RS 485, INTENSOR, HART or
PROFIBUS-PA. It is compatible with the operating systems Win 3.1/3.11, Win95, Win98
and WinNT4.0. All functions of Commuwin II are supported. The configuration is made
via operating matrix or graphic surface. A envelope curve can be displayed in ToF Tool.
Note!
Further information on Commuwin II is given in the following Varec documentation:
• System Information: SI 018F/00/en “Commuwin II”
• Operating Manual: BA 124F/00/en “Commuwin II” operating program
Connection
The table provides an overview of the Commuwin connections.
Interface
Hardware
Server
Device list
HART
Commubox FXA 191 to HART
HART
Connected instrument
Computer with RS-232C interface
Interface FXN 672
ZA 673 for
PROFIBUS
ZA 672 for
other
List of all rack bus modules:
the required FXN 672 must
be selected
Gateway for MODBUS, PROFIBUS,
FIP, INTERBUS, etc.
Computer with
RS-232C interface or
PROFIBUS card
Note!
The 7500 RTG can also be operated locally using the keys. If operation is prevented by
the keys being locked locally, parameter entry via communication is not possible either.
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Operation
Radar Tank Gauge
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7532
Commissioning
6
Commissioning
6.1
Function check
Make sure that all final checks have been completed before you start up your measuring
point:
6.2
Commissioning
6.2.1
Switching on the measuring device
When the instrument is switched on for the first time, the following messages appear on
the display:
⇒
–
+
E
After 5 s, the following message appears
⇓
After 5 s or after you have pressed F the follow-
ing message appears
⇓
Select the language
(this message appears the first time the instrument
is switched on)
⇓
Select the basic unit
(this message appears the first time the instrument
is switched on)
⇓
The current measured value is displayed
After F is pressed, you reach the group selection.
⇓
This selection enables you to perform the basic
setup
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7532
Commissioning
Commissioning
flange:
referencepointof
measurement
BD
SD
measuring cond.
measuring cond.
D
E
empty calibr.
full calibr.
F
L
pipe diameter
(for bypass/stilling well)
E
D
= empty calibr. (= zero)
settings in 005
F
L
= full calibr. (= span)
settings in 006
= level
display in 0A6
= distance (distance flange / product)
display in 0A5
mapping
SD = safety settings
settings in 015
BD = blocking dist.
settings in 059
Automatic
pipe diamter correction
(option)
first point corrects offset
further points correct linearity
safety settings
linearisation
extended calibr.
...
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Commissioning
Radar Tank Gauge
To successfully commission a precise measurement to the nearest mm, it is important
you carry out a history reset on first installation after mechanical installation and after
bration is carried out. Enter the measurement offset as the first point in the dip table for
the mounting calibration. When a value is dipped at a later date, make a second entry
into the dip table, again using the semi-automatic mode. This way, you can easily carry
out a linearization of the measurement.
When configuring the function in "basic setup" (00) please take into account the
following notes:
• Some functions can only be used depending on the parameterization of the
instrument. For example, the pipe diameter of a stilling well can only be entered if
"stilling well" was selected beforehand in the "tank shape" (002) function.
• Certain functions (e.g. starting an interference echo mapping (053)) prompt you to
confirm your data entries. Press O or S to select "YES" and press F to confirm. The
function is now started.
• If you do not press a key during a configurable time period (→ function group
"display (09)"), an automatic return is made to the home position (measured value
display).
Note!
• The instrument continues to measure while data entry is in progress, i.e. the current
measured values are output via the signal outputs in the normal way.
• If the envelope curve mode is active on the display, the measured values are updated
in a slower cycle time. Thus, it is advisable to leave the envelope curve mode after the
measuring point has been optimized.
• If the power supply fails, all preset and parameterized values remain safely stored in
the EEPROM.
Note!
All functions are described in detail, as is the overview of the operating menu itself, in
the 7500 RTG "Service manual and description of instrument functions".
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Commissioning
6.4
Basic Setup with the VU 331
Function "measured value" (000)
⇒
–
+
E
This function displays the current measured value in the selected unit
(see "customer unit" (042) function). The number of digits after decimal point can be
selected in the "no.of decimals" (095) function. The length of the bargraph corresponds
to the percentile value of the present measured value with regard to the span.
6.4.1
Function group "basic setup" (00)
⇒
⇒
–
+
E
Function "tank shape" (002)
–
+
E
This function is used to select the tank shape.
Note!
For the application of the 7532 RTG the selection "stilling well" has to be chosen in the
function "tank shape" (002).
Selection:
• dome ceiling
• horizontal cyl
• bypass
• stilling well
• flat ceiling (Typical ceiling of storage tanks: a slight slope of only a few degrees can
be neglected.)
• sphere
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Radar Tank Gauge
Function "medium property" (003)
⇒
–
+
E
This function is used to select the dielectric constant.
Selection:
• unknown
• < 1.9
• 1.9 ... 4
• 4 ... 10
• > 10
Product class
DK (er)
1,4 … 1,9
1,9 … 4
4 … 10
Examples
A
B
C
non-conducting liquids, e.g. liquefied gas 3)
non-conducting liquids, e.g. benzene, oil, toluene, …
e.g. concentrated acids, organic solvents, esters, aniline,
alcohol, acetone, …
D
> 10
conducting liquids, e.g. aqueous solutions, dilute acids and
alkalis
3)Treat Ammonia NH3 as a medium of group A, i.e. always use a stilling well.
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Function "process cond." (004)
⇒
–
+
E
This function is used to select the process conditions.
Selection:
• standard
• calm surface
• turb. surface
• agitator
• fast change
• test:no filter
standard
calm surface
For all applications that do
not fit into any of the
following groups.
Storage tanks with immersion
tube or bottom filling
The filter and output
damping are set to average
values.
The averaging filters and
output damping are set to
high values.
-> steady meas. value
-> precise measurement
-> slower reaction time
Note!
The phase evaluation of the 7500 RTG (see »Function "auto-correction" (031)« on
"calm surface". We strongly recommend that, in the case of rough product surfaces or
rapid filling, you activate the appropriate application parameters.
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Radar Tank Gauge
Function "empty calibr." (005)
⇒
–
+
E
This function is used to enter the distance from the flange (reference point of the
measurement) to the minimum level (=zero).
Caution!
For dish bottoms or conical outlets, the zero point should be no lower than the point at
which the radar beam hits the bottom of the tank.
Function "full calibr." (006)
⇒
–
+
E
This function is used to enter the distance from the minimum level to the maximum level
(=span).
In principle, it is possible to measure up to the tip of the antenna. However, due to
considerations regarding corrosion and build-up, the end of the measuring range
should not be chosen any closer than 50 mm (2”) to the tip of the antenna.
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Note!
If bypass or stilling well was selected in the "tank shape" (002) function, the pipe
diameter is requested in the following step.
Function "pipe diameter" (007)
⇒
–
+
E
This function is used to enter the pipe diameter of the stilling well or bypass pipe.
100%
100%
0%
0%
ø
d2
ø
Microwaves propagate slower in pipes than in free space. This effect depends on the
inside diameter of the pipe and is automatically taken into account by the 7500 RTG. It
is only necessary to enter the pipe diameter for applications in a bypass or stilling well.
If mounting the 7532 RTG on stilling wells with a widening of the pipe, the inner diam-
eter of the lower part of the pipe (d2 in the Fig.) must be entered. This is the part of the
stilling well, where the measurement is actually performed.
Function "dist./ meas. value (008)"
⇒
–
+
E
The distance measured from the reference point to the product surface and the level
calculated with the aid of the empty adjustment are displayed. Check whether the values
correspond to the actual level or the actual distance. The following cases can occur:
• Distance correct – level correct -> continue with the next function, "check
distance" (051)
• Distance correct – level incorrect -> Check "empty calibr." (005)
• Distance incorrect – level incorrect -> continue with the next function, "check
distance" (051)
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Radar Tank Gauge
Function "check distance" (051)
⇒
–
+
E
This function triggers the mapping of interference echoes. To do so, the measured
distance must be compared with the actual distance to the product surface. The
following options are available for selection:
Selection:
• distance = ok
• dist. too small
• dist. too big
• dist. unknown
• manual
distance = ok
• mapping is carried out up to the currently measured echo
• The range to be suppressed is suggested in the "range of mapping (052)" function
Anyway, it is wise to carry out a mapping even in this case.
dist. too small
• At the moment, an interference is being evaluated
• Therefore, a mapping is carried out including the presently measured echoes
• The range to be suppressed is suggested in the "range of mapping (052)" function
dist. too big
• This error cannot be remedied by interference echo mapping
• Check the application parameters (002), (003), (004) and "empty calibr." (005)
dist. unknown
If the actual distance is not known, no mapping can be carried out.
manual
A mapping is also possible by manual entry of the range to be suppressed. This entry is
made in the "range of mapping (052)" function.
Caution!
The range of mapping must end 0.5 m (20") before the echo of the actual level. For an
empty tank, do not enter E, but E – 0.5 m (20").
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Function "range of mapping" (052)
⇒
⇒
–
+
E
This function displays the suggested range of mapping. The reference point is always
operator.
For manual mapping, the default value is: 0 m.
Function "start mapping" (053)
–
+
E
This function is used to start the interference echo mapping up to the distance given in
"range of mapping" (052).
Selection:
• off: no mapping is carried out
• on: mapping is started
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Display "dist./meas.value (008)"
⇒
–
+
E
The distance measured from the reference point to the product surface and the level
calculated with the aid of the empty alignment are displayed again. Check whether the
values correspond to the actual level or the actual distance. The following cases can
occur:
• Distance correct – level correct -> basic setup completed
• Distance incorrect – level incorrect -> a further interference echo mapping must be
carried out "check distance" (051).
• Distance correct – level incorrect -> check "empty calibr." (005)
Function "history reset" (009)
⇒
⇒
–
+
E
By this function a history reset of the device is performed, i.e. the correspondence table
between level an index values is deleted. A new correspondence table will be filled and
stored after the history reset, see page 57.
Caution!
Perform only after first installation (see »Function "auto-correction" (031)« on page 57).
In this case also effect a reset of the dip table in function "dip table mode" (033).
–
+
E
After 3 s, the following message appears
⇓
Note!
After basic calibration, it is wise to evaluate the measurement using the envelope curve
(function group "display" (09)).
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Commissioning
6.5
Mounting calibration with VU 331
6.5.1
Function group "mounting calibr." (03)
⇒
⇒
–
+
E
Function "tank gauging" (030)
–
+
E
Using this function, you can either enter a dip table or carry out an auto-correction.
Function "auto-correction" (031)
⇒
–
+
E
When measuring levels with radar systems, so-called "multipath reflections" can affect
the level signal giving rise to serious measuring errors. "Multipath reflections" also
include radar beams which are received by the radar system, which have not been
reflected directly by the medium surface. They may reach the antenna via the basin wall
and the medium surface. This phenomenon is particularly noticeable with devices
mounted near to walls, as soon as the conical radar beam strikes the basin wall.
The 7500 RTG can automatically discover and correct measuring errors due to this
"multiple path" propagation. This is because it uses two independent sets of information
when evaluating reflection signals:
• Firstly, it evaluates the amplitude of the reflected energy using the so-called envelope
curve system.
• Secondly, it evaluates the phase of the reflected energy.
The decisive factor for a constant output signal is to assign the phase values to the
associated level values. This assignment is ensured using a correspondence table (index
correction table). The 7500 RTG learns this for the specific application after installation
(learning period).
Therefore, after mounting the device, and after completing the basic calibration, a
history reset must be performed (enter "yes" in the "history reset" (009) function in the
"basic setup " (00) function group).
Do not switch off the radar system during filling and emptying operations during the
teach-in phase. Switching off when there are only negligible level changes produces no
error.
Caution!
"
During the learning period, fast filling/emptying or turbulent surfaces can result in
switching off and on the phase evaluation. Subsequently observed measurement errors
will disappear as soon as tank levels come back to areas measured by 7500 RTG
previously with activated phase evaluation. If the observed measurement errors are
curetted by dip table entries, the 7500 RTG will take care of these corrections and
automatically adjust the index correction table. Do NOT correct any settings in the basic
calibration or the extended calibration.
Note!
Immediately after installation, the 7500 RTG measures with the specified mm-accuracy.
Until the level range has been completely covered by the medium (setting up the
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Radar Tank Gauge
correction table), the maximum permissible filling speed is 100 mm level
change / min. After this, the fill speed has no limitation.
Function "pipe diam. corr." (032)
⇒
–
+
E
For level measurement in stilling wells, radar systems require highly precise pipe inner
diameter data. An mm-exact level measurement cannot be guaranteed for deviations
from the actual stilling well inner diameter of more than ± 0.1mm to the value entered
in the function group "basic setup" (00). The errors which occur as a result are linear and
can be corrected with a dip table containing at least two entries.
The 7500 RTG also has an automatic pipe inner diameter correction. This adjusts the
entered stilling well inner diameter (input in the function group
"basic setup" (00)) to the actual values. However, this presupposes that the value entered
in the function group "basic setup" (00) matches the actual pipe inner diameter
accurately as possible. The user-defined value entered in the function group
"basic setup" (00) can be corrected with this value. In order to do this, switch on the "pipe
diam. corr." (032) function, after a level change of at least 5 m has occurred since start-
up. The pipe diameter, which the instrument determines automatically, will then be
transmitted to the "pipe diameter" (007) function.
Note!
Only if the "pipe diameter" (007) function has changed its value, it is necessary to per-
form a "history reset" (009) and to delete the dip table after activation of the "pipe diam.
corr." (032) function. Otherwise the level change of 5 m has not yet been exceeded. The
"pipe diam. corr." (032) function must be deactivated again and the procedure should be
repeated at a later point of time.
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Display "custody mode" (0A9)
⇒
–
+
E
This indicates the instrument calibration mode. The calibration mode (active) can be set
Selection:
• inactive
• active pos.
• active neg.
active pos.
The custody mode (instrument is lead-sealed and accurate to the nearest mm) is active
and is held.
active neg.
Custody mode (instrument is lead-sealed and accurate to the nearest mm) is activated
and not held, e.g. because the signal-to-noise ratio is less than 10 dB (refer to
function "echo quality" (056) in the function group "extended calibr." (05)).
Caution!
After entering all the values and completing mounting and aligning work, enter the
Reset Code "555" in the function "history reset" (009) of the "basic setup" (00) function
group to reset the instrument history for auto-correction.
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Radar Tank Gauge
Dip table
The dip table is used to correct the level readings of the 7500 RTG using independently
taken hand dips. The dip table is used in particular to adapt the level gauge to the
specific application conditions as mechanical offset and tank/stilling well design.
Depending on national regulations, national inspectors will dip the tank at one to three
levels during a calibration run and check the level readings.
Only one value pair must be entered into the dip table to correct the measurement
offset.
If a second value pair is entered into the dip table, the 7500 RTG accepts the corrected
measured values identically for both value pairs. All other measured values are
determined by linear extrapolation.
If you enter more than two value pairs, the system carries out a linear interpolation
between adjacent value pairs. Outside these value pairs, extrapolation is also linear.
basic setup
history reset
dip table
alternatives
preferred choice:
hand dip and
immediate
offset correction in
semi-automatic mode
collect hand dip and
measurement data over
full measurement range
collect further hand dip data;
evaluate collected data;
enter characteristic value
pairs into the dip table
using the manual mode
if deviation from measurements
> 4 mm and level change > 2 m:
enter a new dip value
into dip table using the
semi-automatic mode
Figure 8: Alternative procedures to fill the dip table.
To collect and enter data into the dip table, two alternative procedures may be carried
out. In order not to mix up measurement values corrected by the offset or linearization
of the dip table with uncorrected measurement values, it is recommended to use the
semi-automatic mode of the dip table to enter new data pairs. In this case, the first dip
value should be entered immediately after the basic calibration. Further linearization
preferred choice) and a deviation between the "uncorrected measurement value" and the
hand dip value of at least 4mm.
If this procedure can not be followed, then NO value pair should be entered into the dip
table after basic calibration. Measurement data and hand dip values should be collected
over the full measurement range and be evaluated with regard to a good linear fit. Only
then characteristic value pairs should be entered into the dip table using the "manual
values should be entered using only the "semi-automatic mode".
Note!
The offset should NOT be determined and entered within the close range of the antenna
(conf. definition of the safety distance) or immediately in the range of the tank bottom,
because within these ranges interferences of the radar signal may occur.
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Note!
The dip table can be printed out using the ToF-Tool. Before doing this, the ToF Tool
must be reconnected to the instrument in order to update the values within the ToF Tool.
Note!
Make your inputs into the dip table in semi-automatic mode. We advise you to leave
"auto correction" (031) activated ("on") while you enter your inputs.
Caution!
After entering one or more points into the dip table, make sure that the dip table is
activated and left in the "table on" dip table mode.
Function "dip table state" (037)
⇒
⇒
–
+
E
This function displays the dip table status.
Display:
• table on
• table off
table on
Indicates whether the dip table is active.
table off
Indicates whether the dip table is not active.
Function "dip table mode" (033)
–
+
E
The dip table can be switched on or off using this function.
Selection:
• manual
• semi-automatic
• table on
• table off
• clear table
• view
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manual
The value pairs in the dip table can be read and written. You can enter the measured
value and the dip value.
–uncorrected measured value:
This is the measured value supplied by the instrument, NOT corrected by the dip
table. The choice of measured value, level or remaining fill height is dependent on
the instrument setting.
–Dip value:
This is the level or distance to flange respectively, given by the hand dip. This value
should be used to correct the measured value.
The "manual mode" of the dip table can be used to enter collected data after a series
of data pairs taken at different tank levels.
Note!
The bigger the distance between the different levels while taking hand dips, the more
accurate the linearization of the dip table will be.
semi-automatic
The value pairs in the dip table can be read. You can enter the dip value only. When there
are new value pairs, the current level or distance is accepted as the measured value.
table on
The dip table is switched on.
table off
The dip table is switched off.
clear table
The complete dip table is deleted. The table is switched off. The number of free table
entries is set to the maximum value (= 32).
View
The value pairs in the dip table can only be read. You can still select this menu option,
even if there is no dip table available. In this case, the number of free table entries is at
maximum value (= 32).
Function "dip table" (034)
⇒
⇒
–
+
E
This function edits measured variable. The number behind the entry "remain" indicates
the current number of remaining free value pairs. The maximum number of value pairs
is 32; after each entry, the remaining number is decremented.
Note!
The uncorrected measured value is displayed in the "dip table" (034) function. This may
differ considerably from the measured values when a dip table is activated.
Function "dip table" (035)
–
+
E
This function edits the dip value.
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Function "dip table handl." (036)
⇒
–
+
E
Use this function to enter the dip value (level or distance) which will correct the mea-
surement values.
Selection:
• new point
• edit point
• store point
• delete point
• return
• next point
• previous point
General procedure:
To enter a new point into the dip table, use
"new point" to enter the value (pairs),
"store point" to sort the new value (pairs),
"return" to go to the dip table mode and
"table on" to activate the dip table.
new point
You can enter a new point. A suggested value is displayed for the measured variable, the
dip value of the current level or the distance. With semi-automatic inputs, the current
level or the current remaining fill height is displayed as proposed dip value. The new
value pair can be altered without selecting the
"edit point" parameter.
If the table is full, you can still select this parameter. In this case, the number of free
table entries stands at minimum value (= 0).
edit point
The displayed value pair can be changed. Only the dip value can be changed with semi-
automatic input mode.
Caution!
To accept the value pair in the table, confirm it with "store point".
store point
The displayed value pair is sorted in the table.
Note!
For sorting, the following criteria must be met:
• Measured variables may not be equal but have different dip values.
• A measured variable available in the table is recognized as equal when it is closer than
1 mm to the sorting value.
• After successful sorting, the setting remains at "edit point" and the number of free
table entries is decremented.
Caution!
If the value cannot be sorted, the setting remains at the previous menu option. No
warning or error message is generated. However, the number of remaining table entries
is not decremented.
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delete point
The currently displayed point is deleted from the table. After deletion, the previous point
is displayed. If the table only consisted of one point before deletion, then the current
measured variable is displayed as a value pair.
return
By selecting this point, you return to the function "dip table mode" (033).
next point
This scrolls down in the table. If the table is empty, you can still select this option.
However, the displayed value does not change.
previous point
This scrolls up in the table. If the table is empty, you can still select this option. However,
the displayed value does not change.
Caution!
After entering one or more points into the dip table, make sure that the dip table is
activated in the "table on" dip table mode.
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Commissioning
6.5.2
Envelope curve with VU 331
After the basic setup, an evaluation of the measurement with the aid of the envelope
curve ("display" (09) function group) is recommended.
Function "plot settings" (09A)
⇒
–
+
E
Here you can select which information is shown on the display:
• envelope curve
• env. curve+FAC (for FAC see 7500 RTG "Service manual and description of
instrument functions")
• env. curve+suppress. (i.e. the tank map is also displayed)
Function "recording curve" (09B)
This function determines whether the envelope curve is read as:
• single curve
or
• cyclic
⇒
–
+
E
Note!
If the envelope curve mode is active on the display, the measured values are updated in
a slower cycle time. Thus, it is advisable to leave the envelope curve mode after the
measuring point has been optimized.
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Radar Tank Gauge
6.6
Basic Setup with the ToF Tool
To carry out the basic setup with the ToF Tool operating program, proceed as follows:
• Start the ToF Tool operating program and establish a connection
• Select the "basic setup" function group in the navigation bar
The following display appears on the screen:
Basic Setup step 1/5:
• Status image
• Enter the measuring point description (TAG number).
Change to the next page
Note!
• Each parameter that is changed must be confirmed with the RETURN key!
• The "Next" button moves you to the next screen display:
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Commissioning
Basic Setup step 2/5:
• Enter the application parameters:
–medium property (for a description, see page 50)
–process cond. (for a description, see page 51)
Basic Setup step 3/5:
If "stilling well" or "bypass" is selected in the "tank shape" function, the following display
appears on the screen:
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Radar Tank Gauge
Note!
You can also specify the pipe diameter in this display.
Basic Setup step 4/5:
• This step starts the tank mapping
• The measured distance and the current measured value are always displayed in the
header
measured value
distance
Step 5/5:
After the first installation of the device, initialise the index correction table (compare
page 57) by activating the history reset 555.
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Commissioning
6.6.1
Envelope curve with the ToF Tool
After the basic setup, an evaluation of the measurement using the envelope curve is
recommended.
6.6.2
User-specific applications (operation)
To set the parameters of user-specific applications, see the 7500 RTG "Service manual
and description of instrument functions".
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Radar Tank Gauge
6.7
Mounting calibration with the ToF Tool
To carry out the basic setup with the ToF Tool operating program, proceed as follows:
• Start the ToF Tool operating program and establish a connection
• Select the "mounting calibr." function group in the navigation bar
The following display appears on the screen:
Mounting calibration step 1/2:
change to next page
Note!
• Each parameter that is changed must be confirmed with the RETURN key!
• the "Next" button moves you to the next screen display:
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Commissioning
Mounting calibration step 2/2:
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Maintenance
7
Maintenance
The 7500 RTG measuring instrument requires no special maintenance.
Exterior cleaning
When cleaning the exterior of measuring devices, always use cleaning agents that do not
attack the surface of the housing and the seals.
Replacement
After a complete 7500 RTG or electronic module has been replaced, the parameters can
be downloaded into the instrument again via the communication interface. Prerequisite
to this is that the data were uploaded to the PC beforehand using the ToF Tool /
Commuwin II.
Measurement can continue without having to carry out a new setup.
• You may have to activate linearization
• You may need to record the tank map again
After an antenna component has been replaced, a new calibration must be carried out.
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Maintenance
Radar Tank Gauge
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Accessories
8
Accessories
Various accessories, which can be ordered separately from Varec, are available for the
7500 RTG.
Weather protection cover
A Weather protection cover made of stainless steel is available for outdoor mounting
(order code: 543199-0001). The shipment includes the protective cover and tension
clamp.
Commubox FXA 191 HART
For intrinsically safe communication with ToF Tool or Commuwin II via the RS 232C-
interface.
Service adapter FXA 193
For communication with ToF Tool via the display connector. (Bestell-Nr.: 50095566).
Commuwin II
Operating software for intelligent instruments.
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Accessories
Radar Tank Gauge
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Troubleshooting
Radar Tank Gauge
7500 RTG - Troubleshooting
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Troubleshooting
9.2
System error messages
Code
Description
Possible cause
Remedy
A102
checksum error
general reset & new
calibr.required
device has been powered off
before data could be stored;
emc problem; E²PROM defect
reset;
avoid emc problem; if
alarm prevails after reset,
exchange electronics
W103
initialising - please
wait
E²PROM storage not yet
finished
wait some seconds; if
warning prevails, exchange
electronics
A106
A110
downloading please
wait
processing data download
wait until warning
disappears
checksum error
general reset & new
calibr.required
device has been powered off
before data could be stored;
emc problem; E²PROM defect
reset;
avoid emc problem; if
alarm prevails after reset,
exchange electronics
A111
A113
A114
A115
electronics defect
electronics defect
electronics defect
electronics defect
RAM defective
reset;
if alarm prevails after
reset, exchange electronics
ROM defective
reset;
if alarm prevails after
reset, exchange electronics
E2PROM defective
general hardware problem
reset;
if alarm prevails after
reset, exchange electronics
reset;
if alarm prevails after
reset, exchange electronics
A116
A121
W153
download error
repeat download
checksum of stored data not
correct
restart download of data
electronics defect
no factory calibration existant;
E²PROM defective
contact service
initialising - please
wait
initialisation of electronics
wait some seconds; if
warning prevails, power off
device and power on again
A155
A160
electronics defect
hardware problem
reset;
if alarm prevails after
reset, exchange electronics
checksum error
general reset & new
calibr.required
device has been powered off
before data could be stored;
emc problem; E²PROM defect
reset;
avoid emc problem; if
alarm prevails after reset,
exchange electronics
A164
A171
A231
electronics defect
electronics defect
hardware problem
hardware problem
reset;
if alarm prevails after
reset, exchange electronics
reset;
if alarm prevails after
reset, exchange electronics
sensor 1 defect
HF module or electronics
defective
exchange HF module or
electronics
check connection
Table 3: System error messages
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Radar Tank Gauge
Code
A270
Description
Possible cause
Remedy
custody switch
undef
switch for custody transfer
may be defective
check position of custody
switch
check position
exchange electronics
#
inconsistency between phase
and amplitude evaluation
inconsistent microfactor
inconsistent index mapping
check basic calibration
check mounting calibration
check echo quality
reset history "555"
check stilling pipe
diameter
switch off autocorrection
A272
W275
W511
A512
W601
W611
electronics defect
amplifier
inconsistency in amplification
offset drift of A/D commuter
exchange electronics
electronics defect
factory setting
exchange electronics
no factory
factory calibration has been
deleted
record new factory
calibration
calibration ch1
recording of
mapping active
wait some seconds until
alarm disappears
mapping please wait
linearization ch1
linearization not
correct linearization table
curve not monotone
monotonously increasing
less than 2
number of entered
correct linearization table
linearization points
for channel 1
linearization points < 2
W621
E641
simulation ch. 1 on
simulation mode is active
switch off simulation mode
no usable echo
channel 1
echo lost due to application
conditions of built up on
antenna
check installation;
optimize orientation of
antenna; clean antenna
check calibr.
E651
A671
W681
level in safety
distance - risk of
overspill
level in safety distance
alarm will disappear as
soon as level leaves safety
distance;
linearization ch1 not
complete, not
usable
linearization table is in edit
mode
activate linearization table
current ch1 out of
range
current out of range (3,8 mA
... 21,5 mA)
check calibration and
linearization
Table 3: System error messages
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Troubleshooting
9.3
Application errors
Error
Output
Possible cause
Remedy
Depending on the configuration
See table of
1. See table of error messages
A warning or
alarm has
occurred.
error messages
Measured distance yes → 1. Check empty calibr. (005) and
Measured
value (00) is
incorrect
(008) OK?
full calibr. (006).
20 mA/100%
expected
F m/ft
2. Check linearization:
→ level/ullage (040)
→ max. scale (046)
→ diameter vessel (047)
→ Check table
no ↓
actual
E m/ft
Measurement in
bypass or stilling
well?
yes → 1. Is bypass or stilling well
selected
4 mA/0%
t
→
in tank shape (002)?
2. Is the pipe diameter
(007) correct?
no
↓
Is an
yes → 1. offset (057)
FAR 10 antenna
extension
correctly set?
being used?
no
↓
An interference
echo
yes → 1. Carry out tank mapping
→ basic setup
may have been
evaluated.
Interference echo
from
1. Carry out tank mapping
No change off
measured
value on
→ basic setup
installations,
nozzle
20 mA/100%
2. If necessary, clean antenna
filling/empty-
ing
or extension on
the
3. If necessary, select better
mounting position
actual
antenna
expected
4 mA/0%
t
→
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Troubleshooting
Radar Tank Gauge
Error
Output
Possible cause
Remedy
Signal is weakened
by the rough
surface — the
interference
echoes
1. Carry out tank mapping
If the surface
is not calm
(e.g. filling,
emptying, agi-
tator run-
ning), the
measured
value
→ basic setup
20 mA/100%
actual
2. Set the process cond. (004) to
"turb. surface" or
"agitator"
are sometimes
stronger
3. Increase the output damping
(058)
expected
jumps sporad-
ically to a
higher
4. Optimize the orientation
4 mA/0%
t →
5. If necessary, select a better
mounting position
level
and/or larger antenna
20 mA/100%
actual
expected
4 mA/0%
t →
Multiple echoes
yes → 1. Check the tank shape (002),
e.g. "dome ceiling" or
During filling/
emptying
"horizontal cyl"
the measured
value jumps
downwards
20 mA/100%
actual
2. In the range of the blocking dist.
(059) there is no echo evalua-
tion
→ Adapt the value
expected
3. If possible, do not select
central installation position
4 mA/0%
t →
4. Perhaps use a stilling well
Level echo is too
weak.
yes → 1. Check application parameters
E 641 (loss of
echo)
(002), (003) and (004)
Possible causes:
• Rough surface
due to filling/
emptying
20 mA/100%
2. Optimize alignment
3. If necessary, select a better
installation position and/or
larger antenna
actual
• Agitator running
• Foam
E 641
expected
4 mA/0%
t →
noise level during
the initialisation
phase to high.
Repeat once more empty calibr.
(005).
E 641 (loss of
echo) after
If the instrument is configured to Hold
by loss of echo the output is set to any
value/current.
Caution!
turn on the
power supply
Before conformation change with
O or S to the edit mode.
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Troubleshooting
9.4
Spare parts
Note!
You can order spare parts directly from your Varec service organization by giving the
order code and the serial number which is printed on the measuring transducer
spare part. Installation instructions are given on the instruction card that is also
delivered.
Note!
If the calibration seal is broken, the national calibration authority should normally be
informed within 24 hours.
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Radar Tank Gauge
7532 RTG
The customer may exchange
modular assemblies in
accordance with Varec
instructions!
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Troubleshooting
Spare parts 7532 RTG
Process connection without antenna
Planar antenna
7532 RTG-
detailed order structure and variants
see spare parts price list
O-ring 49,21 x 3,53 EPDM
(Seal set 52005628)
O-ring 49,21 x 3,53 EPDM
(Seal set 52005628)
O-ring
85,32 x 3,53 FKM (green)
85,32 x 3,53 HNBR12-70
(black)
O-ring
85,32 x 3,53 FKM (green)
85,32 x 3,53 HNBR12-70
(black)
Antenna size
Seal
5200 6193
DN 150 ( 6")
DN 150 ( 6")
DN 200 ( 8")
DN 200 ( 8")
DN 250 (10")
DN 250 (10")
HNBR
FKM
HNBR
FKM
HNBR
FKM
5200 6332
5200 6194
5200 6333
5200 6195
5200 6334
Modification nameplate
be made as to whether the instrument description on the nameplate is still valid, e.g. for:
• an antenna component,
• an electronics module,
• an RF module,
• a VU 331 operating and display module,
• a housing cover with window.
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Troubleshooting
Radar Tank Gauge
Housing T12
The complete order code must be specified when ordering the replacement housing so
that the correct nameplate can be delivered, e.g.
• 7532 RTG-AACWJAC1AA
You must label the nameplate yourself.
Caution!
• It is not possible to convert a standard instrument into an Ex instrument by simply
exchanging parts.
• When repairing certified instruments, the relevant regulations must be followed.
• For FM approved instruments, it is forbidden to make any changes to the instrument
that are not expressly authorized in the operating manual. Contravening this
prohibition can invalidate the approval for operation of the instrument.
9.5
Return
If you need to send a 7500 RTG back to Varec for repair, please send a completed copy
of the form printed on the last page.
• An exact description of the application.
• The chemical and physical characteristics of the product.
• A short description of the error that occurred.
• If necessary, give the error code.
sending a 7500 RTG back for repair.
9.6
Disposal
In case of disposal please separate the different components according to their material
consistence.
9.7
Software history
Software version
/ Date
Software changes
Documentation changes
V 1.00.00 /
12.2000
Original software.
Operated via:
– ToF Tool
– Commuwin II (from version
2.05.03)
– HART communicator DXR 375
with Rev. 1, DD 1.
V 01.02.00 /
03.2002
simplified commissioning
history reset in basic calibration.
Operated via:
– ToF Tool (V3.0)
– Commuwin II (from version
2.05.03)
– HART communicator DXR 375
with Rev. 1, DD 1.
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Technical data
10 Technical data
10.1 Technical data at a glance
Application
Application
The 7500 RTG is used for highly accurate level measurement in
storage tanks and can be applied in custody transfer applications. It
meets the relevant requirements according to OIML R85 and API 3.1B.
• The 7532 RTG with planar antenna is specifically and only suited for
stilling well applications with ranges up to 38 m (124 ft).
Function and system design
Measuring principle
The 7500 RTG is a "downward-looking" measuring system, operating
based on the time-of-flight method. It measures the distance from
the reference point (process connection) to the product surface. Radar
impulses are emitted by an antenna, reflected off the product surface
and received again by the radar system.
Equipment architecture
The 7500 RTG can be used for measurement in a stilling well as well
as in free space. The different instrument versions are applied as
follows:
• The 7532 RTG with planar antenna is the preferred device in stilling
wells ≥ 150 mm.
• The instruments are equipped with a passive 4…20 mA output with
HART protocol.
Input
Measured variable
The measured variable is the distance between a reference point
(mounting flange) and a reflective surface (e.g. medium surface). The
measured value and all parameters are displayed using either metrical
SI-units or US/UK-units (inch, ft, …).
The level is calculated based on the tank height entered.
The level can be converted into other units (volume, mass) by means
of a linearization.
In order to compensate for non-linear effects like movement of the
tank roof, an additional correction table (diptable) can be entered.
Measuring range
Output signal
Output
4…20 mA with HART protocol:
this version can be operated via the PC operating software ToF Tool
and Commuwin II. The instrument supports both point-to-point and
multidrop operation.
Signal on alarm
Error information can be accessed via the following interfaces:
• Local display:
– Plain text display
– LED’s: red LED continuously on = alarm, red LED flashes = warn-
ing
• Current output
• Digital interface
Galvanic isolation
500 V towards ground.
500 V between power supply and signal
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Technical data
Radar Tank Gauge
Auxiliary energy
Electrical connection
Load HART
Housing T 12 with separate terminal compartment.
Minimum load for HART communication: 250 Ω
Cable entry
Cable gland: M20x1.5 or Pg13.5
Cable entry: G ½ or ½ NPT
Supply voltage
Power consumption
Current consumption
Power supply
Max. 330 mW at 16 V, max. 500 mW at 24 V, max. 600 mW at 30 V.
Max. 21 mA (50 mA inrush current).
For stand alone operation recommended via e.g. Varec RN 221N/Z.
Performance characteristics
Reference operating
conditions
According to OIML R85:
• Temperature = –25…+55 °C (-13…+131 °F)
• Atmospheric pressure
• Relative humidity (air) = 65 % ±15%
• Medium properties: e.g. medium with good reflectivity and calm
surface.
• Tank diameter: signal beam hits the tank wall only at one side.
Note!
No major interference reflections inside the signal beam.
Maximum measured
error
Absolute accuracy: 0.5 mm (2σ value)
Inventory Control Versios: ±3 mm
Proof of accuracy for
custody transfer ver-
sions
The accuracy of each 7500 RTG is established through a calibration
certificate that records the absolute and relative error at 10
equidistant points during the final test. For stilling well measurements
with 7532 RTG, a NMI / PTB calibrated tape with an absolute accuracy
of 0.25 mm is used.
Each 7500 RTG is delivered with the PTB and NMi type approval.
Additional initial factory verifications for custody applications are
available on demand for all 7500 RTG.
Maximum fill speed
By the first pass trough of measuring range: 100 mm/min., after it
unlimited.
Non-repeatability
Hysteresis
0,3 mm (1/64")
0.3 mm
Resolution
digital: 0.1 mm
analogue: 0.03 % of measuring range
Settling time
Typical 15 sec
Long-term drift
The long-term drift is within the specified accuracy.
Within the specified accuracy according to OIML R85.
Influence of ambient
temperature
Software reliability
The software used in the 7500 RTG fulfills the requirements of OIML
R85. This particularly includes:
• cyclical test of data consistency
• non-volatile memory
• segmented data storage
The 7500 RTG continuously monitor the compliance with accuracy
requirements for custody transfer measurements according to OIML
R85. If the accuracy cannot be maintained, a specific alarm is
generated on the local display and via the digital communication.
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Technical data
Inventory Control Ver-
sions
All device types can be delivered as "Inventory Control Versions" with a
reduced accuracy of ± 3mm (under reference conditions).
To these versions, the calibration certificate or custody transfer type
approval is NOT attached.
The "Inventory Control Versions" can be selected by choosing the
Operating conditions
Operating conditions
Engineering tips
Environment
Ambient temperature
range
Ambient temperature for the transmitter:
• Standard: -40 °C … +80 °C (-40 °F … +176 °F)
• For calibration to regulatory standards: -25 °C ... +60 °C (-30
°F…+140 °F)
With Tu<-20 °C and Tu>+60 °C the operability of the LC-display is
reduced.
A weather protection cover should be used for outdoor operation if
the instrument is exposed to direct sunlight.
Storage temperature
Climate class
-40 °C ... +80 °C (-40 °F … +176°F)
DIN EN 60068-2-38 (test Z/AD)
Degree of protection
• housing: IP 65, NEMA 4X (open housing: IP20, NEMA 1)
• antenna: IP 68 (NEMA 6P)
Vibration resistance
DIN EN 60068-2-64 / IEC 68-2-64: 20…2000 Hz, 5 (m/s²)²/Hz
See »Technical Information« TEC028
Cleaning of the antenna
Electromagnetic com-
patibility
• emissions according to EN 61326; equipment class B
• compatibility according to EN 61326; appendix A (industrial area,
10 V/m) and Namur recommendation EMC (NE 21).
Process conditions
Process temperature
range
See »Technical Information« TEC028
See »Technical Information« TEC028
See »Technical Information« TEC028
Process temperature
limits
Process pressure limits
Dielectric constant
• in a stilling well: εr ≥ 1.4
• in free space: εr ≥ 1.9
Wetted parts
• Planar, gas-tight
Wetted parts: 1.4435 / HNBR (Hydrated Nitrit Butadien Rubber,
resistent to NH3) or FKM / PTFE glas fiber laminat
Note!
The planar antenna is not resistant to hot vapor!
• Horn adapter for increase of diameter
Wetted parts: 1.4435
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Technical data
Radar Tank Gauge
Mechanical construction
Design, dimensions
Weight
Approx 6 kg + weight of flange
Material
Process connection
All process connections dispose of a gas-tight glass feed-through to
prevent any gas leakage to the inside of the housing.
Human interface
Operation concept
Display
Certificates and approvals
CE approval
The measuring system meets the legal requirements of the EC-
guidelines. Varec confirms the instrument passing the required tests
by attaching the CE-mark.
RF approvals
R&TTE 1999/5/EG, FCC CRF 47, part 15
Overspill protection
PTB , NMi and many other national approvals
External standards and
guidelines
EN 60529
Protection c3lass of housing (IP-code)
EN 61010
Safety regulations for electrical devices for measurement, control,
regulation and laboratory use.
EN 61326
Emissions (equipment class B), compatibility (appendix A – industrial
area)
NAMUR
Standards committee for measurement and control in the chemical
industry
API (American Petroleum Institute)
Particularly "Manual of Petroleum Measurement Standards".
OIML R85 (Organisation Internationale de Metrologie Legale)
Ex approval
XA 081F-A
Installation 7500 RTG (T12 / EEx ia IIC T6…T1)
PTB 00 ATEX 2067 X, Equipment marking: (II 1/2 G)
Ordering Information
The Varec service organisation can provide detailed ordering
information an information on the order codes on request.
Accessories
Supplementary Documentation
Supplementary
Documentation
• System Information
• Technical Information
• Operating Instructions
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Appendix
Radar Tank Gauge
basic setup
00
tank shape
002
010
030
medium property 003
process cond.
004
empty calibr.
enter value
005
full calibr.
006
dome ceiling
horizontal cyl.
bypass
stilling well
flat ceiling
sphere
unknown
DK: < 1.9
DK: 1.9 … 4
DK: 4 … 10
DK: > 10
standard
enter value
calm surface
turb. surface
add. agitator
fast change
test: no filter
pipe diameter
enter value
007
safety settings
01
output on alarm
outp. echo loss
012
delay time
014
MIN -10% 3.6mA
MAX 110% 22mA
hold
alarm
hold
in case of echo loss
max. 4000 sec.
default: 30 s
user specific
ramp %MB/min
ramp %/min
enter value
013
output on alarm
enter value
011
033
tank gauging
dip table
dip table mode
mounting calibr. 03
view
manual
semi-automatic
dip table state
dip table state
037
037
dip table
meas.v.
dip value
034
034
035
dip table handl.
036
next point
previous point
new point
edit point
store point
delete point
table on
table off
clear table
auto correct.
level/ullage
return
linearisation
04
040
040
linearisation
041
041
level CU
ullage CU
manual
semi-automatic
table on
customer unit
042
linearisation
table no.
input level
input volume
next point
yes
045
043
044
045
no
horizontal cyl
linear
customer unit
customer unit
042
042
reset table
level DU
ullage DU
040
050
extended calibr.
05
selection
mapping
dist./meas value
008
check distance
051
range of mapping 052
start mapping
053
D and L
are displayed
distance = ok
dist. too small
manual
input of
mapping range
off
on
dist. unknown
dist. too big
common
extended map..
pres. Map dist
is displayed
054
063
cust. Tank map
055
inactive
active
reset
output
06
commun. address 060
no. of preambels
061
low output limit
062
093
fixed current
off
on
off
on
fixed cur. value
064
095
display
09
0A
language
092
0A1
back to home
format display
094
no. of decimals
enter time
default: 100 s
decimal
1/16”
x
x.x
x.xx
x.xxx
diagnostics
present error
tag no.
0A0
0C0
previous error
clear last error
0A2
0C2
reset
0A3
0C3
unlock parameter 0A4
for reset code
see manual
for reset code
see manual
software no.
system parameter 0C
protocol+sw-no.
serial no.
0C4
custody transfer
Note! The default values of the parameters are typed in boldface.
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Appendix
dist./meas.value
008
check distance
051
range of mapping
052
start mapping
053
history reset
009
distance = ok
dist. too small
dist. too big
manual
input of
mapping range
off
on
no
yes
D and L
are displayed
dist. unknown
safety distance
015
in safety dist.
016
ackn. alarm
017
overspill protection 018
from blocking
distance
default: 0.1m
alarm
warning
self holding
no
yes
standard
german WHG
auto correction
031
pipe diam. corr.
032
047
off
on
off
on
max. scale
max. scale
046
046
diameter vessel
dist./meas.value
008
D and L
are displayed
echo quality
is displayed
056
offset
057
output damping
058
blocking dist.
is displayed
059
will be added to the
measured level
enter value
default: 5 s
simulation
065
output current
067
sim. off
sim. level
sim. volume
sim. current
simulation value
display test
066
097
sep. character
096
plot settings
09A
recording curve
09B
0A8
envelope curve
env.curve+FAC
env.curve+cust.map
single curve
cyclic
. point
, comma
off
on
measured dist.
distance unit
0A5
0C5
measured level
download mode
0A6
0C8
application par.
custody mode
0A9
not modified
modified
inaktiv
aktiv positiv
aktiv negativ
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Appendix
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Appendix
Radar Tank Gauge
11.3
Description of functions
Note!
A detailed description of the function groups, functions and parameters is given in the
the 7500 RTG "Service manual and description of instrument functions".
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Appendix
11.4
Function and system design
11.4.1 Measuring principle
The 7500 RTG is a "downward-looking" measuring system, operating based on the
time-of-flight method. It measures the distance from the reference point (process
connection) to the product surface. Radar impulses are emitted by an antenna, reflected
off the product surface and received again by the radar system.
Input
The reflected radar impulses are received by the antenna and transmitted into the
electronics. A microprocessor evaluates the signal and identifies the level echo caused
by the reflection of the radar impulse at the product surface. The unambiguous signal
identification is accomplished by the PulseMaster® software based on many years of
experience with time-of-flight technology. The mm-accuracy of the 7500 RTG is
achieved with the patented algorithms of the PhaseMaster® software.
The distance D to the product surface is proportional to the travel time t of the impulse:
D = c · t/2,
with c being the speed of light.
Based on the known empty distance E, the level L is calculated:
L = E – D
Reference point for "E" is the lower surface of the process connection.
The 7500 RTG is equipped with functions to suppress interference echoes. The user can
activate these functions. They ensure that interference echoes (e.g. from edges and weld
seams) are not interpreted as level echo.
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Appendix
Radar Tank Gauge
Output
The 7500 RTG is commissioned by entering an empty distance E (=zero), a full distance
F (=span), and an application parameter. The application parameter automatically
adapts the instrument to the measuring conditions. The data points “E” and “F”
correspond with 4mA and 20mA for instruments with current output. They correspond
with 0 % and 100% for digital outputs and the display module.
A linearization with max. 32 points, based on a table entered either manually or semi-
automatically, can be activated locally or remotely. This function provides a
measurement in engineering units and a linear output signal for spheres, horizontal
cylindrical tanks, and vessels with conical outlet.
11.4.2 Equipment architecture
Stand-alone
The 7500 RTG can be used for measurement in a stilling well as well as in free space.
The different instrument versions are applied as follows:
• The 7532 RTG with planar antenna is the preferred device in stilling wells ≥ 150 mm.
• The 7530 RTG with horn antenna can be used in stilling wells with a diameter
<150 mm. However, for these diameters no custody transfer approval is available.
• The 7533 RTG with parabolic antenna is preferred for free-space measurements. The
7530 RTG with horn antenna can be used as an alternative for small nozzle diameters.
• The 7531 RTG with rod antenna (PTFE) should be used for measurements of highly
aggressive media (e.g. sulphur).
• The instruments are equipped with a passive 4…20 mA output with HART protocol.
The complete measuring system consists of:
SPS
- COMMUWIN II
- ToF Tool
- ToF Tool
Service-Adapter
FXA 193
Commubox
FXA 191
HART
2x Messumformer-
speisegerät
RN 221 N
Anzeige- und
Bedienmodul
VU 331
ENDRESS
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HART-Handbediengerät
DXR 375
375
FIELD COMMUNICATOR
FXA 191
oder
DXR 375
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7532
Appendix
On-site operation:
• with display and operating module VU 331,
• with a Personal Computer, FXA 193 and the operating software ToF Tool.
The ToF Tool is a graphical operating software for instruments from Varec that operate
based on the time-of-flight principle (radar, ultrasonic, guided micro-impulse). It
assists with commissioning, securing data, troubleshooting, and documentation of the
measuring point.
Remote operation:
• with HART handheld DXR 35,
• with a Personal Computer, Commubox FXA 191 and the operating software
COMMUWIN II respectively ToF Tool.
• With a Personal Computer, TSM (Tank Side Monitor) and the operating software
FuelsManager.
System integration via Rackbus
Multiple 7500 RTG (or other instruments) can be connected to a higher-level bus system
via a Gateway ZA:
• Every HART transmitter via one interface module FXN 672 each.
• Gateways are available for MODBUS, FIP, PROFIBUS, INTERBUS etc.
• Both on-site as well as remote operation are possible.
Integration into the Asset Management System
The HART interface allows the integration into the AMS® (Asset Management System)
from Fisher-Rosemount.
99
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Appendix
Radar Tank Gauge
11.4.3 Custody transfer mode
7500 RTG is a weight and measure approved level transmitter. Either the innage or the
ullage can be selected as the custody transfer variable.
The selected variable is the basis for the subsequent calculation of the current amount
of product in a tank, along with other measured variables such as (average) temperature
and pressure.
This opens up numerous application options in custody transfer:
• Quantity calculation of mineral oils
• Quantity calculation of alcohols
11.4.4 Weight and measure approval, Standards Authorities ap-
proval, Compulsory reapproval
The type approvals for custody transfer issued by the PTB and NMi, a copy of which is
enclosed with every device, prove the fundamental suitability of the various types for
custody transfer.
In addition to this, the accuracy of every single device is documented using a calibration
certificate, which is issued in the factory after the device has been tested on a reference
test rig.
On request, a separate initial verification of the devices can be carried out with a
National Standards Authorities inspector present, who issues a preliminary test certifi-
cate for every device. In the initial verification, the device is tested to ensure that it com-
plies with the limit of error in legal metrology, which lies at +-2mm for radar measuring
devices in Germany.
Essentially, this proves that the devices are weight and measure approved. The devices
must not, however, be used in custody transfer mode straight away.
The measuring device is not approved until after the approval after installation by the
Standards Authorities. For this, the device's level measurement is compared with the
tank gauging by a National Standards Authorities inspector using manual dips (also "Ini-
tial verification"). As a rule, a quiescent tank gauging is dipped by hand three times in a
row and then compared with the value displayed by the level radar. Depending on
national regulations, the transfer error limit, calculated as the arithmetic mean of the
absolute deviations of all three measurements, must not exceed double the limit of error
in legal metrology (compare, for example, the German "Eichordnung" or the American
"API 3.1B", in which the necessary procedures are also defined).
Depending on national regulations, this test is repeated with various tank gaugings.
Using linearization tables to compensate any non-linearities that occur in measurement
is permitted. For this, the 7500 RTG level radar offers a special dip table, compare
After the measurement has been approved by an inspector, he seals the level radar at
the stamp position and thereby also secures the programming status of the device.
Those operating an approved level transmitter are obligated to obtain reapproval in
accordance with the applicable national regulations from the Standards Authorities.
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7532
Appendix
11.4.5 Particularities in "approved" operation
The 7500 RTG level radar is set to custody transfer mode after commissioning using a
secured and sealed using the sealing pin.
During custody transfer measurement, all custody transfer-relevant functions for
operation are automatically locked, so that the device software can not be used, either
via local operation or via digital communication settings. This locked status is displayed
by the key symbol ( ).
7500 RTG radar devices continuously monitor the compliance with accuracy
requirements for custody transfer measurements according to OIML R85. If, for
example, the accuracy cannot be maintained due to quick surface movements, this is
reported via a separate alarm in the local display (displays "#" symbol) and via digital
communication.
11.4.6 Definition of terms
For definitions and procedures please refer to the following documents:
• Manual of Petroleum Measurement Standards, Chapter 3 - Tank Gauging,
Section 1.B - Standard Practice for Level Measurement of Liquid Hydrocarbons in
Stationary Tanks by Automatic Tank Gauging, American Petroleum Institute, second
edition, 2001
• OIML R 85, Organisation Internationale de Métrologie Légale, International
Recommendation R 85, edition 1998 (E)
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Appendix
Radar Tank Gauge
11.4.7 Integrated on tank gauging system
The Varec Tank Side Monitor 4590 provides integrated communications for sites with
multiple tanks, each with one or more sensors on the tank, such as radar, spot or
average temperature, capacitive probe for water detection and/or pressure sensors.
Multiple protocols out of the Tank Side Monitor guarantee connectivity to nearly any of
the existing industry standard tank gauging protocols. Optional connectivity of analog
4...20 mA sensors, digital I/O and analog output simplify full tank sensor integration.
Use of the proven concept of the intrinsically safe HART bus for all on-tank sensors
yields extremely low wiring costs, while at the same time providing maximum safety,
reliability and data availability.
Fuels Manager
Software
7500 RTG
HART
4 wire
RTU 8130
(remote
terminal
unit)
Tank Side Monitor
Supply voltage:
16…253 VAC
Pressure
This product may be protected by at least one of the following patents.
i
• US 5,689,265
• US 5,387,918 i EP 0 535 196
EP 0 626 063
• US 5,659,321 i
• US 5,594,449
• US 6,047,598
• US 5,880,698
• US 5,926,152
• US 5,969,666
• US 5,948,979
• US 6,054,946
• US 6,087,978
• US 6,014,100
• US 5,614,911 i EP 0 670 048
EP 0 676 037
Further patents are pending.
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Radar Tank Gauge
P
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7532
Notes
IOM027FVAE0804
105
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Radar Tank Gauge
Your offical representative
www.varec.com
Varec, Inc.
5834 Peachtree Corners East, Norcross (Atlanta), GA 30092 USA
Tel: +1 (770) 447-9202 Fax: +1 (770) 662-8939
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