IOM019NVAE0208 4532 Average Temperature Sensor and Converter Installation and Operations Manual For software version V1.45 www.varec.com Varec, Inc.
4532 Copyright All rights reserved. Printed in the United States of America. Except as permitted under the United States Copyright Act of 1976, no part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means- electronic, mechanical, photocopying, recording or otherwise- without the prior written permission of the Publisher: Varec, Inc. 5834 Peachtree Corners East Norcross (Atlanta) GA 30096 USA Trademarks acknowledged Varec, Inc.
Average Temperature/Water Bottom Sensor and Converter Disclaimer of Warranties The contract between the Seller and the Buyer states the entire obligation of the Seller. The contents of this document shall not become part of or modify any prior or existing agreement, commitment or relationship between the Seller and Buyer. There are no express or implied warranties set out in this document. The only warranties that apply are those in the existing contract between the Seller and Buyer. Varec, Inc.
4532 Safety Precaution Definitions Caution! Damage to equipment may result if this precaution is disregarded. Warning! Direct injury to personnel or damage to equipment which can cause injury to personnel may result if this precaution is not followed. Safety Precautions Read and understand this instruction manual before installing, operating or performing maintenance on the Varec 4532 Average Temperature Sensor and Converter.
Average Temperature/Water Bottom Sensor and Converter 4 Installation and Operations Manual
4532 Contents Contents 1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.2 Installation and operation overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.3 Software history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.
Contents Average Temperature/Water Bottom Sensor and Converter 5.2.3 Anchor weight method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 5.3 Mounting on a floating roof tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.1 Top anchor method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.2 Thermo well method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.
4532 Contents 10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 10.1 System error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 10.2 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 11 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 11.1 Anchor weight (Tall profile) . . . . . . .
Contents 4 Average Temperature/Water Bottom Sensor and Converter Installation and Operations Manual
4532 1 Introduction Introduction 1.1 Introduction The 4532 Average Temperature Sensor and Converter (ATC) is a multi-element (Pt100) resistance device designed to measure the average product temperature in bulk liquid storage tanks. The measured value is converted into a HART® compatible output for use in temperature compensated volumetric calculations. The 4532 ATC contains up to 6 temperature elements, spaced at 2 or 3 meter intervals along the length of the probe.
Introduction 1.
4532 2 Safety instructions Safety instructions 2.1 2.2 Installation, commissioning and operation • Mounting, electrical installation, start-up and maintenance of the instrument may only be carried out by trained personnel authorized by the operator of the facility. • Personnel must absolutely and without fail read and understand this manual before carrying out its instructions. • The instrument may only be operated by personnel who are authorized and trained by the operator of the facility.
Safety instructions Average Temperature/Water Bottom Sensor and Converter 2.3.2 • Instruments mounted in explosion hazardous areas must not be opened when the power is on. Tighten the cable gland firmly. • The maintenance and repair of the instrument is limited to fulfill the explosion proof regulations. • Ensure that all personnel are suitably qualified. • Observe the specifications in the certificate as well as national and local regulations.
4532 Safety instructions 2.6 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 instructions 6 Average Temperature/Water Bottom Sensor and Converter Installation and Operations Manual
4532 3 Identification Identification 3.1 Device designation 3.1.1 Nameplate 4532 Series Temperature Device 4532 Series Temperature Device Ex ia IIB T ATEX II 1/2 G KEMA 08 ATEX 0012 X Ambient Temperature -40 °C to Ui<30V Ii<120mA Pi<1W Ci=7.9nF Li=48µH 0820 IS Cl. I, Div. 1, Gp. C,D Cl. I, Zone0, AEx ia IIBT NI Cl. I, Div. 2, Gp. C,D APPROVED Ambient Temperature -40 °C to °C Ui<30V Ci=6.6nF WARNING Do not modify parts and circuits of this instrument.
Identification 3.3 Average Temperature/Water Bottom Sensor and Converter CE marks, 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 50014 "Electrical apparatus for potentially explosive atmospheres-General requirements".
4532 4 Installation Installation 4.1 Design, dimensions 215 mm 142.5 mm Flexible tube depends on the tank height Bottom hook Ф10 Ф26 Figure 4-1: 4532 ATC dimensions Varec, Inc.
Installation 4.2 Average Temperature/Water Bottom Sensor and Converter Unpacking When unpacking, be careful not to bend, fold or twist the flexible tube. Please refer to the recommended procedure below. Recommended procedure 4.3 Incorrect procedure Flexible tube When attaching and bending the flexible tube, the radius of curvature must be at least 300 mm (11.8") at any bend portion. Flexible tube Min.1m (39.
4532 Installation 4.4 Installation Instructions Note! The level sensor circuit is connected to ground and is infallibly galvanically isolated from the supply and output circuit and from the temperature measurement circuit. All metal parts of the sensor and the transmitter shall be electrically conductive and securely be connected to the potential equalization system within the hazardous area. 4.
Installation 12 Average Temperature/Water Bottom Sensor and Converter Installation and Operations Manual
4532 5 Mounting Mounting 5.1 Mounting instruction Note! 1. The flexible tube length of the 4532 ATC is defined for the customer’s specifications. Before mounting, please check as follows: • The tag number (if available) on the body of the 4532 ATC • The length of the flexible tube • The number of measuring points • The intervals between measuring point 2. Mounting the 4532 ATC at a minimum of 500 mm (19.67") away from the tank shell.
Mounting 5.2 Average Temperature/Water Bottom Sensor and Converter Mounting on a fixed roof tank There are three methods for mounting the 4532 ATC on a fixed roof tank: • Top anchor method • Thermo well method • Anchor weight method If the tank bottom has a heating coil, the clearance from the flexible tube bottom hook to the tank bottom may increase depending on the heating coil type. 5.2.1 Top anchor method The flexible tube is stabilized by a wire hook and a top anchor.
4532 Mounting 4. Draw the tensioning wire through the wire hook on the tank bottom. 5. Wrap the tensioning wire twice around the hole on the bottom hook, tighten it and wrap the provided wire around it (see Figure 5-3). Tensioning wire Flexible tube Bottom hook Wire hook Provided wire Figure 5-3: Tensioning wire mounting 6. Fix the mounting flange of the 4532 ATC to the nozzle on the tank top using bolts. Note! Please keep the compression of the spring at 35 to 37 mm (1.38 to 1.47).
Mounting Average Temperature/Water Bottom Sensor and Converter 5.2.2 Thermo well method The flexible tube is inserted into a thermo well with a diameter of 2" or more. Electrical compartment Cable entry as specified Flange Flexible tube If the tank internal pressure exceeds 1bar, fix the thermo well in accordance with below figure. welding From tank bottom to element position #1 approx.500 mm(20") Ø26 mm(1.02") Clearance below bottom hook 400 mm (15.
4532 Mounting 5.2.3 Anchor weight method The flexible tube is stabilized by an anchor weight: Electrical compartment Cable entry as specified Flange Nozzle height 222 mm(8.74") Flexible tube Ø120 mm(4.72") 1000mm(39.37") Tank height 41mm(1.61") From tank bottom to element position #1 approx.500 mm (20") Ø26 mm(1.02") Clearance below bottom hook 400 mm (15.57") Tank bottom Figure 5-6: Anchor weight application Varec, Inc. Note! Make sure to put the anchor weight on the tank bottom.
Mounting Average Temperature/Water Bottom Sensor and Converter Flexible tube Flexible tube Bottom hook Bottom hook Provided wire Provided wire Figure 5-7: Anchor weight mounting 18 Installation and Operations Manual
4532 Mounting 5.3 Mounting on a floating roof tank There are three methods of mounting the 4532 ATC on a floating roof tank: • Top anchor method • Thermo well method • Guide wire ring method Note! 5.3.1 If the tank bottom has a heating coil, the clearance from the flexible tube or probe bottom hook to the tank bottom must increase according to the heating coil type. Top anchor method The flexible tube is installed in a fixed pipe and stabilized by a top anchor.
Mounting Average Temperature/Water Bottom Sensor and Converter 5.3.2 Thermo well method The flexible tube is inserted into a thermo well in the fixed pipe. Electrical compartment Cable entry as specified Flange Flexible tube Fixed pipe Gas hole Ø26mm (1.02") Element position #1 (Bottom element) Thermo well (Min.Ø2", depend on sch. ) 500mm (19.69") Clearance below bottom hook 400mm (15.
4532 Mounting 5.3.3 Guide ring and anchor weight method The flexible tube is stabilized by a guide ring and anchor weight. Electrical compartment Cable entry as specified Flange Flexible tube Guide ring Element position #1 (Bottom element) Ø26mm (1.02") Clearance below bottom hook 500mm (20") 400mm (15.75) Tank bottom Figure 5-10:Guide ring and anchor weight application Varec, Inc. Caution! Make sure to put the anchor weight on the tank bottom.
Mounting 22 Average Temperature/Water Bottom Sensor and Converter Installation and Operations Manual
4532 6 Wiring Wiring 6.1 Terminal Connection 6.1.1 4532 ATC terminal Note! The 4532 ATC allows an intrinsically safe HART connection only. Please refer to the i.s. regulation for establishing wiring and field device layout.
Wiring Average Temperature/Water Bottom Sensor and Converter 6.1.2 6000 Series Servo Tank Gauge terminal Since the 4532 ATC is an intrinsically safe instrument, the terminal connection to the Ex i side on HART connection is allowed on the 6000 Series Servo Tank Gauge terminal housing. 12 Digital output Rack bus RS485, Serial pulse, or R HART + 14 + 15 _ 18 STOP 19 25 20 + Alarm contact _ _ 4 ... 20 mA Channel 1 26 _ 4 ...
4532 Wiring 6.2 Note! The 4590 TSM has three sets of i.s. HART terminals. These three pairs are looped internally. Caution! Do not connect signal HART lines from the 4532 ATC to terminals 30 and 31. They are designed to supply drive power for the 7500 Series Radar Tank Gauge only. Grounding The 4532 ATC must be grounded to the tank potential before communication and power connections are made.
Wiring 26 Average Temperature/Water Bottom Sensor and Converter Installation and Operations Manual
4532 7 Operating Operating 7.1 Local HART connection 7.1.1 As a Varec tank gauging instrument The 4532 ATC has been developed and designated primarily to work with the Varec tank gauging host instruments 4590 TSM or 6000 Series Servo Tank Gauge. Temperature information is transmitted on a two wire i.s HART loop to the host instrument.
Operating Average Temperature/Water Bottom Sensor and Converter 7.2.2 The 4532 ATC specific parameter set up on the 4590 TSM Configuration of 4532 ATC parameters on the display of the 4590 TSM is dependent on the installed software and hardware version of the 4590 TSM. Please refer to the operating manual for the 4590 TSM to determine accessible parameters. All required initial setup and configuration can be performed by the ToF field service tool.
4532 Operating GVH447: Reference Zero Indication of the converted 100 Ohm reference resistor deviation value compared to the actual inserted element value in the temperature probe. The reading value of reference resistor and its deviation are continuously monitored during operation to prevent from performing an incorrect calculation. Indicated tolerance should be within ±0.15°C (±0.27°F) depending on element characteristics, e.g.
Operating 30 Average Temperature/Water Bottom Sensor and Converter Installation and Operations Manual
4532 8 Operation and Description of Instrument Function Operation and Description of Instrument Function 8.0.1 HART Device designation HART device code "190": Device code for temperature measurement function in 4532 ATC only. 8.0.2 Device Data Tag Number: read and write Default: HART A customer specific device identification and control number (or name). Tank name, site number, or any other ID can be entered.
Operation and Description of Instrument Function Average Temperature/Water Bottom Sensor and Converter VH07 Temperature 0 Item type: read only Display of converted 100 Ohm reference resistor deviation value compared to actual inserted element value in temperature probe. The reading value of reference resistor and its deviation are continuously monitored during operation to prevent an incorrect calculation.
4532 Operation and Description of Instrument Function Element #5: 4.5°C (T5) Element #4: 4.0°C (T4) Element #3: 2.0°C (T3) Element #2: 3.0°C (T2) Element #1: 3.5°C (T1) Formula: (T1 + T2 + T3) / # of element in liquid phase = Average temperature (3.5°C + 3.0°C + 2.0°C) / 3 = 2.83°C Advanced: Average temperature calculation with additional factor to compensate for unequal volume distribution (example: liquid temperature) Element #5: 4.5°C (T5) Element #4: 4.0°C (T4) Element #3: 2.0°C (T3) Element #2: 3.
Operation and Description of Instrument Function Average Temperature/Water Bottom Sensor and Converter Element #5: 4.5°C (T5) Element #4: 4.0°C (T4) 2.0°C 2.0°C 3.0°C 2.0°C 3.0°C 3.5°C 2.0°C 3.0°C 3.5°C Element #3: 2.0°C (T3) Element #2: 3.0°C (T2) Element #1: 3.5°C (T1) = V (volume factor) (3.5°C x 2 + 3.0°C x 3 + 2.0°C x 4) / (2 + 3 + 4) = 2.67°C Spot The same number of elements (resistance and material) are located in each input cable in the probe.
32 Operation and Description of Instrument Function VH29 Upper Limit Item type: read and write Default value: 245°C Range: -999.9°C ~ 999.9°C Hi limit temperature alarm setpoint. 8.1.4 Element Position 1: VH30 ~ VH35 (VH36~VH39 is used only in 4539 ATC) VH30 ~VH39 Position 1 ~ 6 (7~10 is used only in 4539 ATC) Item type: read and write Range: 0mm ~ 99999mm Individual element position from tank bottom. Calculation is automatically performed when element spacing "Even" is selected at VH85. 8.1.
Operation and Description of Instrument Function Average Temperature/Water Bottom Sensor and Converter VH48 Gas Offset Item type: read and write Default: 300mm Range: 0mm ~ 99999mm A function to exclude specific element(s) from the gas (vapor) phase average temperature calculation when the uncovered element(s) is (are) within the entered value from the liquid level. To 4532 ATC Electric housing Temperature Element Gas phase VH48 GAS Offset 300mm (default) Temp.
4532 Operation and Description of Instrument Function 8.1.6 WB primary and Advanced temp: VH50 ~ VH59 VH53 Element Point Item type: select Default: 0 Selection: 0 ~ 15 (element #1 = 0, element #6 = 5) Select element number for "Advanced" average calculation at VH26. Selected element position will be displayed on VH54 "Element Position" and allow modification of the volume factor at VH55 "Element Volume" for the specified element.
Operation and Description of Instrument Function Average Temperature/Water Bottom Sensor and Converter VH69 Ref Voltage Item type: read and write Default: 200 Range: 0 ~ 255 This parameter is the setpoint for the 4532 ATC power supply failure alarm. The 4532 ATC operates with a minimum 16 VDC supply voltage via the multi-drop HART loop under normal operating conditions. The 4532 ATC transmits an error message when the supply voltage drops below 16 VDC. The default value of 200 is equivalent to 16 VDC. 8.
4532 Operation and Description of Instrument Function VH73: "Temperature X" = raw element temperature x span (VH72) + zero offset (VH71) VH73 Temperature X Item type: read only Specified element temperature selected at VH70. The displayed value is also indicated at individual element temperature at VH10 ~ VH25. The value is calculated based on formula indicated on above VH72. VH74 Position X Item type: read and write Range: 0mm ~ 99999mm The position of the element specified at VH70.
Operation and Description of Instrument Function Average Temperature/Water Bottom Sensor and Converter VH79 Protect Code Item type: read and write Default: 0 Range: 0 ~ 999 Access code 530 required to modify parameters.
4532 Operation and Description of Instrument Function VH80: Present Error Item type: read only Display of current error message.
Operation and Description of Instrument Function Average Temperature/Water Bottom Sensor and Converter VH82 Element Number Item type: read and write Default: 2 Range: 1 ~ 6 Number of available temperature elements. Do not change the default parameter on the 4532 ATC. The number of elements on this version is pre-determined by the customer's choice. It may cause faulty calculation or an inappropriate error display. VH83 No.
4532 Operation and Description of Instrument Function VH87 Element Interval Item type: read and write Default: 1000mm Range: 0mm ~ 99999mm Applies only when Even Interval spacing is selected. Caution! Changing element interval, setting element position, these are only applied to reconfigure switching points for average temperature calculation. The physical element position will never be changed. VH88 Short Error Item type: read and write Default: -49.5 Range: -49.5 ~ 359.
Operation and Description of Instrument Function Average Temperature/Water Bottom Sensor and Converter VH92 Error Dis. Sel. Item type: select Default: 0_OFF Selection: 0_OFF, 1_ON Type of VH88 "Short Error Value" and VH89 "Open Error Value" display selection. 0_OFF: These 2 error messages will not be transmitted to the connected host gauge. This function automatically excludes defect element in average temperature calculation. 1_ON: Error message will be transmitted to the host gauge.
4532 9 Maintenance Maintenance The 4532 ATC Average temperature instrument requires no special maintenance. 9.1 Exterior cleaning When cleaning the 4532 ATC, always use cleaning agents that do not attack the surface of the housing and the seals. 9.2 Repairs The Varec repair concept assumes that the measuring devices have a modular design and that customers are able to undertake repairs themselves. Spare parts are contained in suitable kits. They contain the related replacement instructions.
Maintenance 9.4 Average Temperature/Water Bottom Sensor and Converter Replacement After a complete 4532 ATC electronic module has been replaced, the parameters must be manually re-entered to the replaced new module in order to maintain the proper operation. Measurement can continue without having to carry out a new setup. The following matrix parameters should be confirmed after replacement of the electronics. 46 GVH Contents 443 Level Data Selection 460-469 Element Position No.
4532 Troubleshooting 10 Troubleshooting 10.1 System error messages Code Description Possible cause Remedy 1 Common line open Ground (common) line has open circuit. All temperature element signals will be disabled or inaccurate.
Troubleshooting Average Temperature/Water Bottom Sensor and Converter 10.2 Spare parts Spare parts are contained in kits. Spare parts which you can order from Varec for the 4532 ATC are shown with their order numbers in the diagram below. For more information on service and spare parts, contact Varec. 70106024 017803-0043 70106026 58020200 017802-0008 017803-0044 70106024 017803-0043 70106026 58020200 Cover, El-housing M88 long type O-ring, EPDM 88-d3 Module assembly(Temp.
4532 Accessories 11 Accessories 11.1 Anchor weight (Tall profile) Caution! Installation of anchor weight will cause element position #1 (the lowest temperature measurement position) to be raised approximately 500 mm (20") from the tank floor. Material Weight: SS400 mild carbon steel Ring: SS400 mild carbon steel 180mm (7.09") 222mm (8.74") 42mm (1.65") Weight approx. 16kg 120mm (4.72") Figure 11-1:Anchor weight dimension Different dimension, weight, and material anchor are also available.
Accessories Average Temperature/Water Bottom Sensor and Converter 11.3 Wire hook, Top anchor Anchor weights are supplied with SUS316 standard 3 mm diameter tension wire for attaching anchor weight to temperature probe. Material Weight: SS400 mild carbon steel I-bolt: SS400 mild carbon steel 9mm (0.35") 21mm (0.83") Weight approx. 1.5kg 70 (2.76") 150 (5.91") 200 (7.
4532 Technical data 12 Technical data Technical data at a glance: Application Application The 4532 ATC performs precise liquid and gas phase average temperature measurement in bulk storage tank applications. • Standard 2" flange installation • Overall 18.5m temperature measurement range Function and system design Measuring principle Temperature measurement • Up to 6 elements spaced evenly over the length of the flexible tube.
Technical data 52 Average Temperature/Water Bottom Sensor and Converter Installation and Operations Manual
4532 A Order Structure Order Structure 10 20 30 40 50 4532 - Varec, Inc. Protection class 7 FM, IS class1, Div.1, Gr. A-D B ATEX, EEx [ia] IIB T4 -T6 Cable entry B Thread NPT 1/2 D Thread M20 Process connection (SUS304) 1 2" 150lbs RF, 304 flange ANSI B16.5 2 DN50 PN0 B1, 304 flange EN1092-1 (DIN2527 C) 9 Special version, to be specified Element #, Interval, Probe range (Below flange to end of probe) 022 ...mm; 2x Pt100; 2 m (min 2,500 mm, max 4,500 mm) 032 ...
Order Structure 54 Average Temperature/Water Bottom Sensor and Converter Installation and Operations Manual
4532 B Declaration of Contamination Form Declaration of Contamination Form 0 G 030 Declaration of Contamination For the safety of our employees and operating equipment, we require that you fill out this form and return it to Varec with your signature before we can fulfill your order. Please include the completed form with the device and shipping documents, along with safety sheets and/or specific handling instructions if appropriate. Type of device/sensor: Serial no.
Declaration of Contamination Form 56 Average Temperature/Water Bottom Sensor and Converter Installation and Operations Manual
4532 Index Index D Designated use 1 E explosion-proof type 3 G Grounding 4 H Hazardous Substance Datasheet 4 I installation & operation overview 1 M Maximum measured error 51 Measuring principle 51 O Overview, installation & operation 1 S Safety conventions and symbols 5 Safety instructions 3 Software history 1 Varec, Inc.
Index 58 Average Temperature/Water Bottom Sensor and Converter Installation and Operations Manual
4532 NOTES Varec, Inc.
Your official representative 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 © Varec, Inc. An SAIC Company. All Rights Reserved. This document is for information purposes only. Varec, Inc. makes no warranties, express or implied, in this summary. The names of actual companies and products mentioned herein may be the trademarks of their respective owners.
