Dispatch and Fuels Accounting IOM027FVAE1013 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 Software Version: 01.03.
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.
Disclaimer of Warranties The contract between the Seller and the Buyer states the entire obligation of the Seller. The contents of this instruction manual 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 instruction manual. The only warranties that apply are those in the existing contract between the Seller and Buyer.
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 this manual carefully and make sure you understand its contents before using this product. Follow all instructions and safety guidelines presented in this manual when using this product.
vi Installation and Operations Manual
532 Radar Tank Gauge Contents 1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.1 Brief Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.2 Custody Transfer Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1.3 Weight and Measure Approval, Standards Authorities Approval, and Compulsory Re-approval . . . . . . . . . . . . . . . . .
Contents 4.5 Post-installation Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 5 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 5.1 Quick Wiring Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 5.2 Connecting the Measuring Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 5.2.
7532 Radar Tank Gauge 7.2 Switching on the Measuring Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 7.3 Basic Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 7.4 Basic Setup with the VU331 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 7.5 Mounting Calibration with VU331 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 7.5.1 Envelope curve with VU331 . . .
Contents 11.5 Auxiliary Energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 11.6 Performance Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 11.7 Operating Conditions: Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 11.8 Operating Conditions: Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 11.9 Mechanical Construction. . . . . . . . . . . . . .
7532 Radar Tank Gauge 1 Overview 1.1 Brief Operating Instructions 000 measured value - + Contrast: + or 009 history reset Group selection - + 002 tank shape 003 medium property 004 process cond. 01 safety settings - flat ceiling - stilling well … - unknown - <1.9 - 1.9 … 4 - 4 … 10 - >10 input E input F - standard only for (see sketch) (see sketch) bypass + - calm surface stilling well - add. agitator … basic setup 03 mounting calibr.
Overview 1.2 Custody Transfer Mode The 7500 series 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.
7532 Radar Tank Gauge 1.4 Particularities in “Approved” Operation The 7500 series RTG is set to custody transfer mode after commissioning using a custody locking switch (see page 36). The position of the custody locking switch is 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.
Overview 1.6 Integrated Tank Gauging System The Varec 4590 Tank Side Monitor 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.
7232 Radar Tank Gauge 2 Safety Instructions 2.1 Designated Use The 7532 Radar Tank Gauge (7532 RTG) is a compact radar level transmitter for the continuous, contact less measurement of liquids. 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 W). Operation is completely harmless to humans and animals. 2.
Safety Instructions 2.4 Notes on Safety Conventions and Symbols 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.
7232 Radar Tank Gauge 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
Safety Instructions 8 Installation and Operations Manual
7232 Radar Tank Gauge 3 Identification 3.1 Nameplates The following is an example of technical data given on the device nameplate: Figure 3-1: Example Nameplate 3.2 Scope of Delivery Caution! It is essential to follow the instructions concerning the unpacking, transport, and storage of measuring devices given in the chapter “section 4.
Identification 10 Installation and Operations Manual
7532 Radar Tank Gauge 4 Mounting 4.1 Quick Installation Guide Installation only in a stilling well: . 90 ° 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. Figure 4-1: 4.2 . Installation Orientation Incoming Acceptance, Transport, and Storage 4.2.
Mounting Installation Conditions Dimensions 94 (3.7) 65 (2.56) 85 (3.35) L 30 (1.18) flange adapter (see under) 60 (2.36) detail A: 111 (4.37) E+H UNI flange (max. 1 bar) DIN, ANSI, JIS, JPI 8 (0.31) 238 (9.37) 68 (2.68) inactive length 4.3.1 Ø 129 (5.08") 4.3 Ø 150 (5.91) DN150 / 6” ver sion without widening DN200…300 / 8…12” ver sion with antenna widening detail A flange hub f or the connection to flanges pro vided by the customer Ø 78 (3.07) Ø 62,5 (2.
7532 Radar Tank Gauge 4.3.2 Engineering hints • The measuring range begins where the beam hits the tank bottom. Particularly with dish bottoms or conical outlets the level cannot be detected below this point. • For overspill protection, it is possible to define a safety distance (SD) additionally to the blocking distance (BD). • Depending on its consistence, foam can either absorb microwaves or reflect them off the foam surface. Measurement is possible under certain conditions.
Mounting Behavior if measuring range is exceeded The behavior 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). 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.
7532 Radar Tank Gauge The blocking distance (= BD) is the minimum distance from the reference point of the measurement (mounting flange) to the medium surface at maximum level. Figure 4-5: reference point of measurement Blocking Distance BD Max. Level Blocking distance (BD)1 Free space (Storage tank) from flange 1 m (40") (see page 12) 1. 1 mm accuracy under reference conditions Table 4-3: Note Varec, Inc.
Mounting 4.4 Installation Instructions 4.4.1 Mounting kit The following tools are required for mounting: • The tool for flange mounting • 4 mm (0.1") Allen wrench for turning the housing 4.4.2 Installation in tank (free space) Standard installation • Observe installation instructions, (see page 13). • After mounting, the housing can be turned 350° in order to simplify access to the display and the terminal compartment. Optimum Mounting Position 90 ° Figure 4-6: • Planar axis vertical to flange.
7532 Radar Tank Gauge • 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 and the inside of the stilling well is 5 mm (3/16”). • The antenna extension of the 7532 RTG is mounted with defined pressure. Dimensions of a nozzle for manual gauging must be adapted to the dimensions of the horn antenna used, to compare to. Varec, Inc.
Mounting 7532 RTG DIN, ANSI, JIS, JPI E+H UNI flange gap < 1 < 1/16” welding neck flange gap < 5 < 3/16” 100 % < 1/7 ø pipe 7532 RTG for retrofit of mechanical systems recommended increase of diameter: D1 150 / 6” D2 500 20” sample hatch for manual gauging DIN, ANSI, JIS, JPI L 200 / 8” 300 / 12” 150 / 6” 250 / 10” 300 / 12” D1 150 / 6” 300 / 12” 450 / 18” 200 / 8” 300 / 12” 450 / 18” increase of diameter for a stilling well 250 / 10” 300 / 12” 450 / 18” L 200 / 8” 250 / 10” 300 / 12
7532 Radar Tank Gauge 4.4.3 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: 1. Undo the fixing screws (1) 2. Turn the housing (2) in the required direction 3. Tighten up the fixing screws (1) Figure 4-8: T12 housing 2 1 Turn Housing Allen key 4 mm tighten strongly by hand Varec, Inc.
Mounting 4.4.4 Installation with Varec’s UNI flange Varec’s 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 counter flange before the bolts are tightened. A-A Ø 63.
7532 Radar Tank Gauge Version Compatible with D [mm] K [mm] Type plate 1000 DN150 PN16, ANSI 6" 150lbs, JIS 10K 150 280 240 942455-3001 2000 DN200 PN16, ANSI 8" 150lbs, JIS 10K 200 340 294,5 942455-3002 3000 DN250 PN16, ANSI 10" 150lbs, JIS 10K 250 405 358 942455-3003 4000 DN300 PN16, ANSI 12" 150lbs, JIS 10K 300 482 410 (for DIN), 942455-3004 431,8 (for ANSI), 400 (for JIS), 404,5 (for DIN + JIS) Table 4-4: Varec, Inc.
Mounting Varec’s Figure 4-10: Preparation for the Installation of the Varec UNi Flange 22 Installation and Operations Manual
7532 Radar Tank Gauge 16 pull off housing 17 mount Varec’s UNI flange Varec’s UNI flange (max. 1 bar) detail A: flange adapter (see under) detail A flange hub for the connection to flanges provided by the customer Ø 78 mounting: 4 bolts M6 / 90° e.g. DIN 912 Ø 62.5 9 O-Ring 85.3 x 3.53, included (same material as sensor seal) flange hub Ø 99.5 Figure 4-11: Preparation for the Installation of the Varec UNi Flange, cont’d 4.
Mounting 24 Installation and Operations Manual
7532 Radar Tank Gauge 5 Wiring 5.1 Quick Wiring Guide Varec, Inc. 7500 Series Radar Tank Gauges • The power supply must be identical to the data on the 1 Order Code: Ser.-No.: XXXXXXXXXXX nameplate (1). 1 II1/2 G EEx ia IIC T6...T3 terminal before connecting up the device. U: 16...30 VDC 4...20 mA / 16...30 VDC TA > 70°C: t >85°C Dat./Insp.: X X X X X X 0560 5 if modification see sep. label Messbereich max. Measuring range PN max. 3 TAntenne max.
Varec, Inc. 7500 Series Radar Tank Gauges The power supply must be identical to the data on the nameplate (1). 1 Order Code: Ser.-No.: XXXXXXXXXXX Switch off power supply before connecting up the device. 1 PTB 00 ATEX x= Messbereich max. Measuring range PN max. 3 TAntenne max. 4 8 II1/2 G EEx ia IIC T6...T3 D00676-F Connect Equipotential bonding to transmitter ground terminal before connecting up the device. U: 16...30 VDC 4...20 mA / 16...
7532 Radar Tank Gauge 5.2 Connecting the Measuring Unit 5.2.1 Terminal compartment The housing features a separate terminal compartment. 1 2 3 4 5 1 2 power supply Figure 5-3: 5.2.2 3 4 5 signal Housing with a Separate Terminal Compartment Load HART Minimum load for HART communication: 250 5.2.3 Cable entry • Cable gland: 2 x M20x1.5 • Cable entry: 2 x G½ or 2 x ½NPT 5.2.4 Supply voltage DC voltage: 16 to 36 V DC Communication Power supply Signal Table 5-1: 5.2.5 Varec, Inc.
Wiring 5.2.6 Current consumption Max. 21 mA (50 mA inrush current). 5.2.7 5.2.8 Overvoltage protector • The level transmitter 7500 series RTG is equipped with an internal overvoltage protector (600 Vrms surge arrester) according to EN/IEC 60079-14 or EN/IEC 60060-1 (impulse current test 8/20 μs, Î = 10 kA, 10 pulses). Additionally, the device is protected by a galvanic insulation of 500 Vrms between the power supply and the (HART) current output.
7532 Radar Tank Gauge Commubox FXA291 (USB) Field Xpert ToF Adapter FXA291 DC voltage FieldCare or PLC power supply ≥250Ω 4...20 mA signal dsdmdm df das. asdas fa asas la. DELTABAR: * * * * * * * * ONLINE 1 QUICK SETUP 2 OPERATING MENU 3 PV 4 SV HELP 1 2 3 4 352 mbar 0 °C SAVE 9 5 Page Up Bksp 6 Delete Page On 2 1 5 MNO 6 + Hot Key Insert W XY Z TUV 8 7 3 Hot Key Paste JKL 4 PQRS DEF ABC #%& Copy GHI 9 ,()‘ _<> +*/ .
Wiring 5.3 Recommended Connection 5.3.1 Equipotential bonding Connect the Equipotential bonding to the external ground terminal of the transmitter. 5.3.2 Wiring screened cable Caution! In Ex applications, the device must only be grounded on the sensor side. Further safety instructions are given in the separate documentation for applications in explosion hazardous areas. 5.4 5.
7532 Radar Tank Gauge 6 Operation 6.1 Quick Operation Guide Esc – + − E + E Esc 2x − Esc − + tank shape safety settings extended calibr. − --- >3 s + medium property E dome ceiling horizontal cyl bypass stilling well flat ceiling sphere + linearisation − Esc − + E basic setup + + − ... Return to Group Selection unknown DC: < 1.9 DC: 1.9 . . . 4 DC: 4 . . . 10 DC: > 10 --- Selection and configuration in Operation menu: 1.
Operation 6.1.1 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 device 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.
7532 Radar Tank Gauge 6.2 Display and Operating Elements LCD (liquid crystal display) symbols – + E snap-fit red LED sealing pin Figure 6-3: 3 keys green LED custody locking switch Display and Operating Elements Note To access the display, the cover of the electronic compartment may be removed even in hazardous areas. The LCD display is removable. Remove it for ease of operation by simply pressing the snap fit (see Figure 6-3), which is connected to the device by means of a 500 mm cable. 6.
Operation 6.2.2 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 device is in an alarm state. If the symbol flashes, this indicates a warning. LOCK_SYMBOL This lock symbol appears when the device is locked, i.e. if no input is possible. COM_SYMBOL This communication symbol appears when a data transmission via e.g. HART is in progress.
7532 Radar Tank Gauge 6.2.3 Key assignment The operating elements are located inside the housing and are accessible for operation by opening the lid of the housing. Key(s) Meaning -> + or + + -> - or + + Esc - or + E Navigate upwards in the selection list. Edit numeric value within a function. Navigate downwards in the selection list. Edit numeric value within a function. Navigate to the left within a function group. Navigate to the right within a function group confirmation.
Operation 6.2.3.1 Software reliability The software used in the 7500 series RTG, fulfills the requirements of OIML R85. This particularly includes: • cyclical test of data consistency • non-volatile memory • segmented data storage The 7500 series RTGs continuously monitor the compliance with accuracy requirements for custody transfer measurements according to OIML R85.
7532 Radar Tank Gauge 6.3.2 Unlocking configuration mode If an attempt is made to change parameters when the device is locked, the user is automatically requested to unlock the device: Function “unlock parameter” (0A4): By entering the unlock parameter (on the display or via communication) 100 = for HART devices the 7532 RTG is released for operation. Hardware unlock: After pressing the + and - and E the unlock parameter. keys at the same time, the user is asked to enter 100 = for HART devices.
Operation – + E Table 6-8: Factory Settings (Reset) User input (“reset” (0A3)): • 333 = customer parameters • 555 = History 333 = reset customer parameters This reset is recommended whenever a device with an unknown “history” is to be used in an application: • The 7532 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.
7532 Radar Tank Gauge 6.4 Display and Acknowledging Error Messages 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 shown on the display. The measuring system distinguishes between the following types of error: • A (Alarm): Device goes into a defined state (e.g. MIN, MAX, HOLD) Indicated by a constant symbol.
Operation 6.5 HART Communication Apart from local operation, parameterization of the measuring device and viewing of the measured values by means of a HART protocol can also be accomplished. There are two options available for operation: • Operation via the universal handheld operating unit, the Field Communicator 375, 475 • Operation via the Personal Computer (PC) using the operating program (e.g. FieldCare; see Figure 5-4 on page 29). • Operation via the 4590 Tank Side Monitor.
7532 Radar Tank Gauge FieldCare supports the following functions: • Configuration of transmitter in online operation • Signal analysis via envelope curve • Tank linearization • Loading and saving device data (upload / download) • Documentation of the measuring point Connection options: • HART via Commubox FXA195 and the USB port on a computer • Commubox FXA291 with ToF Adapter FXA291 (USB) via service interface Figure 6-5: Varec, Inc.
Operation 42 Figure 6-6: Signal Analysis via Envelope Curve Figure 6-7: Tank Linearization Installation and Operations Manual
7532 Radar Tank Gauge 7 Commissioning 7.1 Function Check Make sure that all final checks have been completed before you start up your measuring point:, 7.2 • Checklist “Post-installation Check” on page 23. • Checklist “Post-connection Check” on page 30. Switching on the Measuring Device When the device is switched on for the first time, the following messages appear in a sequence of 5s on the display: software version, communication protocol, and language selection.
Commissioning 7.3 Basic Setup flange: reference point of measurement Commissioning basic setup (standard) tank shape flat ceiling BD measuring cond. unknown SD D process cond. standard E F empty calibr. L full calibr. E = empty calibr. (= zero) settings in 005 D = distance (distance flange / product) display in 0A5 SD = safety settings settings in 015 pipe diameter (for bypass/stilling well) dist. / meas. value F = full calibr.
7532 Radar Tank Gauge Caution! 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 the basic setup of the device (see page 53). Only after a history reset the mounting calibration is carried out. Enter the measurement offset as the first point in the dip table for the mounting calibration.
Commissioning 7.4 Basic Setup with the VU331 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 bar graph corresponds to the percentile value of the present measured value with regard to the span.
7532 Radar Tank Gauge dome ceiling horizontal cyl bypass flat ceiling stilling well sphere Figure 7-2: Tank Shape Selections Function “medium property.” (003) – + E This function is used to select the dielectric constant. Selection: • unknown • DC: < 1.9 • DC: 1.9...4 • DC: 4...10 • DC: > 10 Media group Examples A 1.4 to 1.9 B 1.9 to 4 non-conducting liquids, e.g. benzene, oil, toluene, white products, black products, crudes, bitumen/asphalts, … C 4 to 10 e.g.
Commissioning Function “process cond.” (004) – + E This function is used to select the process conditions. Selection: • standard • calm surface • turb. surface • agitator • fast change • heavy conditions • 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.
7532 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). Figure 7-3: Distance from the Flange (Reference Point of the Measurement) 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.
Commissioning Figure 7-4: Full Calibration (= 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. Note If bypass or stilling well was selected in the “tank shape” (002) function, the pipe diameter is requested in the following step.
7532 Radar Tank Gauge 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 diameter of the lower part of the pipe (d2 as shown in Figure 7-5) must be entered. This is the part of the stilling well where the measurement is actually performed. Function “dist./ meas.
Commissioning Figure 7-6: Check Distance 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 Note 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.
7532 Radar Tank Gauge This function displays the suggested range of mapping. The reference point is always the reference point of the measurement (see page 44). This value can be edited by the 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).
Commissioning Caution! A history reset must be performed after: • first installation or • change of basic setup or • change of the installation situation. In this case, a reset of the dip table in function “dip table mode” (033). should also be performed.
7532 Radar Tank Gauge 7.5 Mounting Calibration with VU331 Function group “mounting calibr.” (03) – + E Function “tank gauging” (030) – + E Using this function, 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.
Commissioning 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 series RTG previously with activated phase evaluation. If the observed measurement errors are corrected by dip table entries, the 7500 series RTG will take care of these corrections and automatically adjust the index correction table.
7532 Radar Tank Gauge Function “custody mode” (0A9) – + E This indicates the device calibration mode. The calibration mode (active) can be set using the hardware security lock on the electronics (see page 36). Selection: • inactive • active pos. • active neg. active pos. The custody mode (device is lead-sealed and accurate to the nearest mm) is active and is held. active neg. Custody mode (device is lead-sealed and accurate to the nearest mm) is activated and not held, e.g.
Commissioning Dip table The dip table is used to correct the level readings of the 7500 series 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.
7532 Radar Tank Gauge Note • The offset should not be determined and entered within the close range of the antenna (confirm the 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. • The dip table can be printed out using FieldCare. Before doing this, FieldCare must be reconnected to the device in order to update the values within FieldCare.
Commissioning Manual 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. The parameter “manual” in the “dip table” (033) function can be used to enter data pairs, which have been recorded at different levels, into the dip table. The measured value and the dip value can be entered. • uncorrected measured value: This is the measured value supplied by the device, not corrected by the dip table.
7532 Radar Tank Gauge Function “dip table” (034) – + E This function edits the 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.
Commissioning New point One can enter a new point. Suggested values displayed for the measured value and dip value are the current uncorrected level or remaining fill height. 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.
7532 Radar Tank Gauge 7.5.1 Envelope curve with VU331 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 Select what information is shown on the display: • envelope curve • env. curve+FAC (for FAC see IOM117) • env. curve+cust.map (i.e.
Commissioning Function “envelope curve display” (09C) The envelope curve is displayed in this function and can be used to obtain the following information: quality of evaluated echo full calibr. evaluated echo is marked empty calibr.
32 Radar Tank Gauge 7.1 Basic Setup with the Varec Operating Program To carry out the basic setup with the operating program, proceed as follows: • Start the operating program and establish a connection. • Select the “basic setup” function group in the navigation window. The following display appears on the screen: Basic Setup step 1/5: • Status image • Enter the measuring point description (TAG number). Figure 7-10: 7500 Series Radar Tank Gauges - Basic Setup (Step 1/5) Note Varec, Inc.
Commissioning Basic Setup step 2/5: • Enter the application parameters: • Tank shape • Medium property • Process cond.
7532 Radar Tank Gauge Basic Setup step 3/5: If “dome ceiling” is selected in the “tank shape” function, the following display appears on the screen: • Empty calibr. • Full calibr. Figure 7-12: 7500 Series Radar Tank Gauges - Basic Setup (Step 3/5) If “horizontal cyl” or “sphere” is selected in the “tank shape” function, the following display appears on the screen: • Empty calibr. • Full calibr. Figure 7-13: 7500 Series Radar Tank Gauges - Basic Setup (Step 4/5) Varec, Inc.
Commissioning If “stilling well” or “bypass” is selected in the “tank shape” function, the following display appears on the screen: • Empty calibr. • Full calibr. • Diameter of bypass / stilling well Figure 7-14: 7500 Series Radar Tank Gauges - Basic Setup (Step 5/5) Note The pipe diameter must also be specified in this display. If “flat ceiling” is selected in the “tank shape” function, the following display appears on the screen: • Empty calibr. • Full calibr.
7532 Radar Tank Gauge 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 • A description is given, see »Function “check distance” (051)« on page 51. Figure 7-16: 7500 Series Radar Tank Gauges- Basic Setup (Step 7) Basic Setup step 5/5: After the first installation of the device, initialize the index correction table. To do so, set the history reset to “yes”. Varec, Inc.
Commissioning 7.2.1 Signal analysis via envelope curve After the basic setup, an evaluation of the measurement using the envelope curve is recommended. Figure 7-17: 7500 Series Radar Tank Gauges - Signal Analysis via Envelope Curve Note If the level of echo is very weak or there is a heavy interference echo, an orientation of the RTG can help optimize the measurement (increase of the useful echo/reduction of the interference echo). 7.3.
7532 Radar Tank Gauge 7.4 Mounting Calibration with the Varec Operating Program To carry out the mounting calibration with the operating program, proceed as follows: • Start the 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: • auto correction • pipe dam. corr.
Commissioning Mounting calibration step 2/2: • dip table mode • meas. v. • dip value • dip table handl. • dip table state • left dip t.entr.
7532 Radar Tank Gauge 8 Maintenance 8.1 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. 8.2 Replacing Seals The process seals of the sensors must be replaced periodically, particularly if molded seals (aseptic construction) are used. The period between changes depends on the frequency of cleaning cycles and on the temperature of the measured product and the cleaning temperature. 8.
Maintenance 74 Installation and Operations Manual
7532 Radar Tank Gauge 9 Accessories A variety of accessories are available for the 7500 series RTG. They can be ordered separately from Varec, Inc. 9.1 Weather Protection Cover A weather protective cover made of stainless steel is available for outdoor mounting (order code: 543199-0001). The shipment includes the protective cover and tension clamp. .45) (5.3 1) ° (3.7 45 95 F12 / T12 housing 135 70 (2.
Accessories 9.5 Mounting with Sample Hatch on Stilling Well 9.5.1 Installation hints For control and cleaning purposes for sample taking as well as for hand dipping (tape), a sample hatch 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.
7532 Radar Tank Gauge 10 Troubleshooting 10.1 Troubleshooting Instructions Check voltage and compare it with the specifications on the nameplate.. Instrument does not respond Not ok Connect the correct voltage Yes Instrument works? Ready No ok Check the polarity of the voltage.
Troubleshooting 10.2 System Error Messages Code A102 Description Possible cause Remedy Checksum error Device has been powered off before data could be stored Reset • EMC problem • EEPROM defect if alarm prevails after reset, exchange electronics General reset and new calibr.required.
7532 Radar Tank Gauge Code A270 # A272 Description Possible cause Remedy Custody switch undefined, check position Switch for custody transfer may be defective Check position of custody switch/ exchange electronics mm - accuracy not ensured Inconsistency between phase and amplitude evaluation Check basic calibration check mounting calibration check echo quality • Inconsistent micro factor > 10 dB history reset • Inconsistent index mapping Electronics defect Inconsistency in amplification
Troubleshooting 10.3 Application Errors Error Output Possible cause Remedy A warning or alarm has occurred Depending on the configuration See table of error messages (see page 78) 1. See table of error messages (see page 78) 1. Check empty calibr. (005) and full calibr (006). 2. Check linearization: Measured value (00) is incorrect D m/ft (008) Measured distance (008) OK? F m/ft yes 20 mA/100% • • • • expected actual E m/ft t→ 4 mA/0% level/ullage (040) max.
7532 Radar Tank Gauge Error During filling/ emptying the measured value jumps sporadically to a higher/lower level Output 20 mA/100% actual Possible cause Remedy During the definition of the auto correction table, the device has been switched off and the level has changed. 1. Reset “555” 2. If possible, do not switch off the device before the complete measuring range has been passed through. 1. Check the tank shape (002), e.g. “dome ceiling” or “horizontal cyl” 2.
Troubleshooting 10.4 Spare Parts When ordering spare parts, always quote the serial number indicated on the nameplate. As far as necessary, the spare parts also include replacement instructions. 10.5 Return The following procedures must be carried out before a transmitter is sent to Varec e.g.for repair or calibration: • Remove all residue which may be present. Pay special attention to the gasket grooves and crevices where fluid may be present.
7532 Radar Tank Gauge 10.7 Software History Date Software-version Software changes 12.2000 V 01.00.00 Original software. Documentation changes Operated via: ToF Tool from version 1.5 Commuwin II (from version 2.05.03) HART-Communicator DXR375 with Rev. 1, DD 1. 03.2002 V 01.02.00 simplified commissioning history reset in basic calibration Description of Instrument Functions Function group: envelope curve display Katakana (japanese) Operated via: ToF Tool (V 3.0) Commuwin II (from version 2.05.
7532 Radar Tank Gauge Varec, Inc.
7532 Radar Tank Gauge 11 Technical Data 11.1 11.2 11.3 Varec, Inc. General Manufacturer Varec Designation 7532 RTG Function and Design Application The 7500 series 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 suited for stilling well applications with ranges up to 38 m (124 ft).
Technical Data 11.4 Output Output signal 4 to 20 mA (invertible) with HART protocol (e.g. for multidrop connection to the 4590 Tank Side Monitor): This version can be operated via the PC operating software FieldCare. The device supports both point-to-point and multidrop operation. For measurements with mm accuracy, the measured value must be transmitted via the HART protocol in order to ensure the required accuracy.
7532 Radar Tank Gauge 11.6 Performance Characteristics Note Performance characteristics for devices that can be calibrated in compliance with OIML R85. Reference operating conditions • Temperature = -25°C to +55°C (-13°F to +131°F) • Atmospheric pressure • Relative humidity (air) = 65% ±15% • Medium properties: e.g.
Technical Data Software reliability The software used in the 7500 series RTG fulfills the requirements of OIML R85. This particularly includes: • cyclical test of data consistency • non-volatile memory • segmented data storage The 7500 series RTG continuously monitors the compliance with accuracy requirements for custody transfer measurements according to OIML R85.
7532 Radar Tank Gauge 11.8 Operating Conditions: Process Process temperature range -40°C to +200°C Process pressure limits 0 to 40 bar (Option 64 bar) Dielectric constant • • 11.9 In a stilling well: r 1.4 In free space: r 1.9 Mechanical Construction Weight Approx 6 kg + weight of flange Material Refer to TEC028, chapter “Material (not in contact with process)” and “Material (in contact with process). 11.
Technical Data 90 Installation and Operations Manual
7532 Radar Tank Gauge 12 Ordering Information 12.1 Order Codes for the 7532 RTG This overview does not mark options which are mutually exclusive. 10 20 30 Varec, Inc. Approval: A Non-hazardous area 1 ATEX II 1/2G EEx ia IIC T6 S FM - Instrinsically Safe - Class I, Division 1, Groups A, B, C, and D, Zones 0,1, and 2 U CSA - Instrinsically Safe - Class I, Division 1, Groups A, B, C, and D, Zones 0,1, and 2 Y Special version Antenna: A Planar ant. DN150/6", FKM-seal inside B Planar ant.
Ordering Information 40 50 60 70 80 90 N7532 Output and Operation: A 4-20mA HART; 4-line display VU331, envelope curve display on-site Y Special version Housing: C Alu T12-housing coated IP65 NEMA4X, separate connection with compartment Y Special version Cable entry: 2 Gland M20 4 Thread NPT1/2 9 Special version Custody transfer approvals: A NMi + PTB (<1mm) type approval R Not selected; Inventory control version (3mm) Y Special version Additional options: A Additional options not selected Y Special
7530 Radar Tank Gauge A Appendix A.1 Operating Menu HART (Display module) Note See Table A-1, "Operating Menu HART (Display module)", on page 94 page 95. Varec, Inc.
Appendix basic setup 00 tank shape 002 dome ceiling horizontal cyl. bypass stilling well flat ceiling sphere safety settings 01 output on alarm medium property 003 process cond. unknown DK: < 1.9 DK: 1.9 … 4 DK: 4 … 10 DK: > 10 standard calm surface turb. surface add. agitator fast change test: no filter 010 outp. echo loss MIN -10% 3.6mA MAX 110% 22mA hold 004 output on alarm 011 tank gauging 030 dip table mode 012 delay time 014 in case of echo loss max. 4000 sec.
7530 Radar Tank Gauge dist./meas.value 008 check distance 051 distance = ok dist. too small dist. too big manual D and L are displayed range of mapping 052 start mapping 053 off on input of mapping range history reset 009 no yes dist. unknown 015 from blocking distance default: 0.1m auto correction in safety dist. 016 alarm warning self holding 031 off on pipe diam. corr. . ackn. alarm 017 no yes overspill protection018 standard german WHG 032 off on max. scale 046 max.
Appendix 96 Installation and Operations Manual
7532 Index A Accessories 75 Alarm 34, 39 Alignment 70 Application errors 80 B Interference echo suppression 53, 69 Interference echoes 51 K Key assignment 35 L Basic setup 44, 46, 65 Bypass 50 Level 44 C Cable entry 27 Commissioning 43 Commubox 75 Current consumption 28 Custody locking switch 35 Maintenance 73 Mapping 51, 52, 53 Measuring conditions 13 Media group 14 Medium properties 47 Mounting 11 D N Declaration of contamination 82 Degree of protection 30 Designated use 5 Dielectric constant
Index Touble-shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Touble-shooting instructions . . . . . . . . . . . . . . . . . . . 77 Turn housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . 11, 19 U Unlock parameter . . . . . . . . . . . . . . . . . . . . . . . . 36, 37 V VU331. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46, 63 W Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Weather protection cover . . . . . . . . . . .
Document Code IOM027NVAE1013 Varec, Inc. • 5834 Peachtree Corners East, Norcross (Atlanta), GA 30092 USA Tel: +1 (770) 447-9202 • Fax: +1 (770) 662-8939 www.varec.com © 2006 Varec, Inc. 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.
