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Varec 4532 manual

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  • Page 1

    Varec, Inc. 5834 Peachtree Corners East, Norcross (Atlant a), GA 30092 USA Tel: +1 (770) 447 -9202 Fax: +1 ( 770) 662-8939 www.varec.com IOM019NVAE0208 4532 A v er a ge T emper a tur e Sensor and Con v er ter Installa tion and Oper a tions Manual For software version V1.45[...]

  • Page 2

    [...]

  • Page 3

    Varec, Inc. 1 4532 Copyright All rights rese rved. Printed in the United States of America. Except as p ermitted under the United States Copyright Act of 1976, no part of this publicati on may be reproduced, stored in a retrieval sy stem or transmitted in any form or by any means- electronic, mechanical, photocopying, recording or otherw ise- witho[...]

  • Page 4

    Average Temperature/Water Bottom Sensor and Converter 2 Installation and Operations Manual Disclaimer of W arranties The contract between the Seller and the Buyer states the entire obligation of the Seller. Th e co n t en ts o f t h i s d o cu m en t s ha l l n o t b e co m e p a rt o f o r mo d i fy a ny p ri o r or e xi s ti n g agreement, commit[...]

  • Page 5

    Varec, Inc. 3 4532 Safety Precaution Definitions Caution! Damage to equipment may result if this precaution is disregarded. Wa r n i n g ! Direct injury to personnel or damage to equipment whic h can ca use injury to personnel may result if this precaution is not followed. Safety Precautions Read and understand this instruction manual be fore insta[...]

  • Page 6

    Average Temperature/Water Bottom Sensor and Converter 4 Installation and Operations Manual[...]

  • Page 7

    Varec, Inc. 1 4532 Content s Contents 1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.2 Installation and operation overview . . . . . . . . . . . . . . . . . . . . [...]

  • Page 8

    Contents Average Temperature/Water Bottom Sensor and Converter 2 Installation and Operations Manual 5.2.3 Anchor weight method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 5.3 Mounting on a floating roof tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 5.3.1 Top anchor method . . . . . . . . [...]

  • Page 9

    Varec, Inc. 3 4532 Content s 10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 10.1 System error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 10.2 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 10

    Contents Average Temperature/Water Bottom Sensor and Converter 4 Installation and Operations Manual[...]

  • Page 11

    Varec, Inc. 1 4532 Introduction 1 Intro duction 1.1 Introductio n The 4532 Average Temperature Sensor and Co nverter (ATC) is a multi-element (Pt100) resistance de vice designed to measure the average p roduct temperature in bulk l iquid storage tanks. The measured value is conver ted into a HART® compatible output for use in temperature compensat[...]

  • Page 12

    Introduction Average Temperature/Water Bottom Sensor and Converter 2 Installation and Operations Manual 1.4 System functional diag r am Figure 1-1: Connection with 7500 Series Ra dar Tank Gauge and 6000 Series Servo Tank Gauge Pressure Power AC FuelsManager Software 8130 RTU or 8300 TGI +24V +5V +15V -15V CPU COMM I/O ERROR Level T emperature To F [...]

  • Page 13

    Varec, Inc. 3 4532 Safety instructions 2 Safety instr uctions 2.1 Installation, commissioning and operation • Mounting, electrical installation, start-up and maintenance of the instrument may only be carried out by tr ained personnel au thorized by the operator of the facility. • Personnel must absolutely and without fa il read and understand t[...]

  • Page 14

    Safety instructions Average Temperatur e/Water Bottom Sensor and Converter 4 Installation and Operations Manual • Instruments mounted in explosion hazardou s areas must not be opened when the power is on. Tighten the cable gland firmly. • The maintenance and repair of the ins tru ment is limited to fulfill the explosion proof regulations. • E[...]

  • Page 15

    Varec, Inc. 5 4532 Safety instructions 2.6 Notes on safety con v entions and symbols In order to highlight safety-relevant or alte rnative operating procedures in the manual, the following conventions have b een used, each indicated by a corresponding symbol in the margin. Safety conventions Wa r n i n g ! Warning! A warning highlights actions or p[...]

  • Page 16

    Safety instructions Average Temperatur e/Water Bottom Sensor and Converter 6 Installation and Operations Manual[...]

  • Page 17

    Varec, Inc. 7 4532 Identification 3 Identifica tion 3.1 De vice designation 3.1.1 Nameplate Figure 3-1: 4532 ATC labels Figure 3-2: Product label for 453x average tem perature devices 3.2 Scope of deliver y • Instrument according to the version ordered • ToF Tool (CD-ROM) • Accessorie s (as ordered) Varec, Inc. 5834 Peachtree Corners East Nor[...]

  • Page 18

    Identification Average Temperature/Water Bottom Sensor and Converter 8 Installation and Operations Manual 3.3 CE mar ks, declaration of conf ormity The instrument is de signed to meet state- of-the-art safety requir ements, has been tested and left the factor y in a condition in which i t is safe to operate. The instrume nt complies with the appl i[...]

  • Page 19

    Varec, Inc. 9 4532 Installation 4 Installation 4.1 Design, dimensions Figure 4-1: 4532 ATC dimensions Ф 10 Ф 26 Bottom hook 215 mm Flexible tube depends on the tank height 142.5 mm[...]

  • Page 20

    Installation Average Temperature/Wa ter Bottom Sensor and Converter 10 Installation and Operations Manual 4.2 Unpacking When unpacking, be careful not to bend, fold or twist the flexible tube. Please refer to the recommended procedure b elow. 4.3 Flexible tube When attaching and bending the flexible tube, the radius of cur vature must be a t least [...]

  • Page 21

    Varec, Inc. 11 4532 Installation 4.4 Installation Instructions Note! The level sensor circuit is connected to gr ound and is infallib ly galvanically isolated from the supply and output circuit and fr om the temperature measurement circu it. All metal parts of the sensor and the transm itter shall be electrically conductive and securely be connecte[...]

  • Page 22

    Installation Average Temperature/Wa ter Bottom Sensor and Converter 12 Installation and Operations Manual[...]

  • Page 23

    Varec, Inc. 13 4532 Mounting 5 Mounting 5.1 Mounting instr uction Note! 1. The flexible tube length of the 4532 ATC is defined for the customer ’s specifica- tions. Before mounting, pl ease 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[...]

  • Page 24

    Mounting Average Temperature/Water Bottom Sensor and Converter 14 Installation and Operations Manual 5.2 Mounting on a fixed roof tank There are three methods for mounting the 45 32 ATC on a fixed roof tank: • Top anchor method • Thermo well method • Anchor weight method If the tank bottom has a heating coil, the cl earance from the flexible [...]

  • Page 25

    Varec, Inc. 15 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). Figure 5-3: Tensioning wire mounting 6. Fix the mounting flange of the 4532 ATC to the nozzle on the tank top using[...]

  • Page 26

    Mounting Average Temperature/Water Bottom Sensor and Converter 16 Installation and Operations Manual 5.2.2 Thermo well method The flexible tube is inserted into a ther mo well with a diameter of 2" or more. Figure 5-5: Thermo well application Caution! The flexible tube must be lowered ca refu lly without bend ing too much or scratching at the [...]

  • Page 27

    Varec, Inc. 17 4532 Mounting 5.2.3 Anchor weight method The flexible tube is stabilized by an anchor weight: Figure 5-6: Anchor weight application Note! Make sure to put the anchor weight on th e tank bottom. When installing with the sus- pended anchor wei ght, please use the anchor weight at a maximum of 16 kg. More weight may cause internal break[...]

  • Page 28

    Mounting Average Temperature/Water Bottom Sensor and Converter 18 Installation and Operations Manual Figure 5-7: Anchor weight mounting Flexible tube Provided wire Bottom hook Flexible tube Provided wire Bottom hook[...]

  • Page 29

    Varec, Inc. 19 4532 Mounting 5.3 Mounting on a floating roof tank There are three methods of mounting th e 4532 ATC on a floating roof tank: • Top anchor method • Thermo well method • Guide wire ring method Note! If the tank bottom has a heating coil, the clearance from the flexible tube or probe bottom hook to the tank bottom must increase a[...]

  • Page 30

    Mounting Average Temperature/Water Bottom Sensor and Converter 20 Installation and Operations Manual 5.3.2 Thermo well method The flexible tube is inserted into a thermo well in the fixed pipe. Figure 5-9: Thermo well application The installation procedure i s the same as for mounting on a fixed roof tank using the thermo well. Flexible tube Elemen[...]

  • Page 31

    Varec, Inc. 21 4532 Mounting 5.3.3 Guide ring and anchor weight meth od The flexible tube is stabilized by a guide ring and anchor weight. Figure 5-10:Guide ring and anchor weight application Caution! Make sure to put the anchor weight on th e tank bottom. When installing with the sus- pended anchor weigh t, please use the ancho r wei ght at a maxi[...]

  • Page 32

    Mounting Average Temperature/Water Bottom Sensor and Converter 22 Installation and Operations Manual[...]

  • Page 33

    Varec, Inc. 23 4532 Wiring 6 W iring 6.1 T er minal Connection 6.1.1 4532 A TC terminal Note! The 4532 A TC allows an i ntrinsically safe HART connection only . Please refer to the i.s. regulation for establishing wiring and field device layo ut. Figure 6-1: 4532 ATC terminal The 4532 ATC has convenient daisy chain HA RT loop terminals that enable [...]

  • Page 34

    Wiring Average Temperature/Water Bottom Sensor and Converter 24 Installation and Operations Manual 6.1.2 6000 Series Servo T ank Gauge terminal Since the 4532 ATC is an intrinsicall y safe instrument, the terminal connection to the Ex i side on HART connection is allowed on the 6000 Series Servo Tank Gauge terminal housing. Figure 6-2: 6000 Series [...]

  • Page 35

    Varec, Inc. 25 4532 Wiring 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 A TC to terminals 30 a nd 31. They are designed to supply drive power for the 7500 Series Radar T ank Gauge only . 6.2 Grounding The 4532 ATC must be grounded to the t[...]

  • Page 36

    Wiring Average Temperature/Water Bottom Sensor and Converter 26 Installation and Operations Manual[...]

  • Page 37

    Varec, Inc. 27 4532 Operating 7 Operating 7.1 Local HART connection 7.1.1 As a V arec ta nk gauging instrument The 4532 ATC has been developed and d esignated primarily to wor k with the Varec tank gauging host instruments 4590 TSM or 60 00 Series Se rvo Tank Gauge. Temperature information is transmitted on a two wire i.s HART loop to the host inst[...]

  • Page 38

    Operating Average Temperature/Water Bottom Sensor and Converter 28 Installation and Operations Manual 7.2.2 The 4532 A TC specific parameter se t 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 versio n of the 4590 TSM. Please refer to the operating manual fo[...]

  • Page 39

    Varec, Inc. 29 4532 Operating GVH447: Refere nce Zero Indication of the converted 10 0 Ohm reference resis tor devi ation value compared to the actual inserted el ement value in the temperatur e probe. The rea ding value of referenc e resistor and its deviation are continuously monitored during operation to prevent from performing an incorrect calc[...]

  • Page 40

    Operating Average Temperature/Water Bottom Sensor and Converter 30 Installation and Operations Manual[...]

  • Page 41

    Varec, Inc. 31 4532 Operation and Description of Instrument Function 8 Operation and Description of Instr ument Function 8.0.1 HA RT Device d esignati on HART device code "190": Device code for te mperature measur ement function in 4532 ATC only. 8.0.2 Device Dat a Tag Number: read and write Default: HART A customer specific device identi[...]

  • Page 42

    Operation and Description of Instrument Function Aver age Temperature/Water Bottom Sensor and Converter 32 Installation and Operations Manual VH07 Temperature 0 Item type: read only Display of converted 100 Ohm reference resi stor deviation value compared to actual inserted element val ue in temperature pr obe. The reading value of reference resist[...]

  • Page 43

    Varec, Inc. 33 4532 Operation and Description of Instrument Function Formula: (T1 + T2 + T3) / # of element in liquid phase = Average temper ature (3.5 ° C + 3.0 ° C + 2.0 ° C) / 3 = 2.83 ° C Advanced: Average temperature calculation with additi onal factor to compensate f or unequal volume distribution (example: liquid temperature) Formula: (T[...]

  • Page 44

    Operation and Description of Instrument Function Aver age Temperature/Water Bottom Sensor and Converter 34 Installation and Operations Manual (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 (resis tance and material) are located in each input c able in the probe. Average calculation is pe rfor[...]

  • Page 45

    Varec, Inc. 35 4532 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 temperatur e alarm setpoint. 8.1.4 Element Position 1: VH30 ~ VH35 (VH36~VH39 is used only in 4539 A TC) VH30 ~VH39 Position 1 ~ 6 (7~10 is used only in 4539 ATC) Item type:[...]

  • Page 46

    Operation and Description of Instrument Function Aver age Temperature/Water Bottom Sensor and Converter 36 Installation and Operations Manual VH48 Gas Offset Item type: read and write Default: 300mm Range: 0mm ~ 99999mm A function to excl ude specific eleme nt(s) from the gas ( vapor) phase aver age temperature calculation when the uncovered el eme[...]

  • Page 47

    Varec, Inc. 37 4532 Operation and Description of Instrument Function 8.1.6 WB primary and Advanced te mp: VH50 ~ VH59 VH53 Element Point Item type: select Default: 0 Selection: 0 ~ 15 (element #1 = 0, element #6 = 5) Select element number for "Advanced" averag e calculation at VH26. Selected element position will be di splayed on VH54 &qu[...]

  • Page 48

    Operation and Description of Instrument Function Aver age Temperature/Water Bottom Sensor and Converter 38 Installation and Operations Manual VH69 Ref Voltage Item type: read and write Default: 200 Range: 0 ~ 255 This parameter is the setp oint for the 4532 ATC power supply failure alarm. The 4532 ATC operates with a minimum 16 VDC supply voltage v[...]

  • Page 49

    Varec, Inc. 39 4532 Operation and Description of Instrument Function VH73: "T emperatu re X" = raw elem ent temperat ure x span (VH72 ) + zero of fset (VH71) VH73 Temperature X Item type: read only Specified element tempe rature selected at VH70. The displayed value is also indicated at individual element temperature at VH10 ~ VH25. The v[...]

  • Page 50

    Operation and Description of Instrument Function Aver age Temperature/Water Bottom Sensor and Converter 40 Installation and Operations Manual VH79 Protect Code Item type: read and write Default: 0 Range: 0 ~ 999 Access code 530 required to modify parameters. Device setting 1: VH80 ~ VH89[...]

  • Page 51

    Varec, Inc. 41 4532 Operation and Description of Instrument Function VH80: Present Error Item type: read only Display of current error message. One of the following codes will be indicated: Error code • 0: No error presence • 1: Common line open • 2: undetermined • 3: #1 element open • 4: #1 element short • 5: #2 element open • 6: #2 [...]

  • Page 52

    Operation and Description of Instrument Function Aver age Temperature/Water Bottom Sensor and Converter 42 Installation and Operations Manual 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 p[...]

  • Page 53

    Varec, Inc. 43 4532 Operation and Description of Instrument Function VH87 Element Interval Item type: read and write Default: 1000mm Range: 0mm ~ 9 9999mm Applies only when Even Interval spacing is selected. Caution! Changing element interval, setting element pos ition, these are only applied to recon- figure switching points for average tem peratu[...]

  • Page 54

    Operation and Description of Instrument Function Aver age Temperature/Water Bottom Sensor and Converter 44 Installation and Operations Manual VH92 Error Dis. Sel . Item type: se lect Default: 0_OFF Selection: 0_ OFF, 1_ON Type of VH88 "Short Error Value " and VH 89 "Open Error Value" dis play selection. 0_OFF: These 2 error mes [...]

  • Page 55

    Varec, Inc. 45 4532 Maintenance 9 Maintenance The 4532 ATC Average te mperature instrument require s no special maintenance. 9.1 Exterior c leaning When cleaning the 4532 ATC, always use cleani ng 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 modula[...]

  • Page 56

    Maintenance Average Temperature/Wate r Bottom Sensor and Converter 46 Installation and Operations Manual 9.4 R eplacement After a complete 4532 ATC elec tronic module has been repl aced, the parameters must be manually re-entered to the replaced new module in order to maintain the proper operation. Measurement can continue wi thout having to carry [...]

  • Page 57

    Varec, Inc. 47 4532 Troubleshooting 10 T r oubleshooting 10.1 System er r or messages These error codes are displayed on the ToF t ool display when the ToF tool is properly connected. For details regarding the error disp lay on host i nstrument, please refer to documentation of 4590 TSM or 6000 Series Servo Tank Gauge. Code Description Possible cau[...]

  • Page 58

    Troubleshooting Average Temperature/Wa ter Bottom Sensor and Converter 48 Installation and Operations Manual 10.2 Spar e par ts Spare parts are contained in kits. Spare pa rts 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. Figur[...]

  • Page 59

    Varec, Inc. 49 4532 Accessories 11 Accessories 11.1 Anchor weight (T all profile) Caution! Installation of anchor weight will cause el ement position #1 (the lowest temperature measurement position) to be raised approxim ately 500 mm (20") fro m the tank floor . Figure 11-1:Anchor weight dimension Different dimension, weight, an d material anc[...]

  • Page 60

    Accessories Average Temperature/Wate r Bottom Sensor and Converter 50 Installation and Operations Manual 11.3 W ir e hook, T op anchor Anchor weights are supplied w ith SUS316 standard 3 mm diameter tensi on wire for attaching anchor weight to temperature probe. Figure 11-3:Wire hook di mension Actual tensioning can be completed with SUS316 strande[...]

  • Page 61

    Varec, Inc. 51 4532 Technical data 12 T ec hnical da ta Technical data at a glance: Application Application The 4532 ATC performs prec ise liquid and gas phase ave rage temperature measurement in bulk storage tank applications. • Standard 2" flange installa tion • Overall 18.5m temperature measurement range Function and system design Measu[...]

  • Page 62

    Technical data Average Temperature/Wa ter Bottom Sensor and Converter 52 Installation and Operations Manual[...]

  • Page 63

    Varec, Inc. 53 4532 Order Structure A Or der Str uctur e 10 Protection class 7 FM, IS class1, Div .1 , Gr . A-D B A TE X, EEx [ia] IIB T4 -T6 20 Cable entry B Thread NPT 1/ 2 D Thread M20 30 Process connection (SUS304) 1 2" 150lbs RF , 304 flange ANSI B16.5 2 DN50 PN0 B1, 304 flange EN1092-1 (DIN2527 C) 9 S p ecial version, to be specified 40 [...]

  • Page 64

    Order Structure Average Temperature/Water Bottom Sensor and Converter 54 Installation and Operations Manual[...]

  • Page 65

    Varec, Inc. 55 4532 Declaration of Contamination Form B Declaration of Contamina tion F or m Varec, Inc., an SAIC Company 5834 Peachtree Corners East, Norcross (Atlanta), GA 30092 USA Tel: +1 (770) 447-9202 Fax: +1 (770) 662-8939 0 G 030 For the safety of our employees and operating equipment, we require that you fill out this form and return it to[...]

  • Page 66

    Declaration of Contamination Form Average Temperature/Water Bottom Sensor and Converter 56 Installation and Operations Manual[...]

  • Page 67

    Varec, Inc. 57 4532 Index Index D Designated use 1 E explosion-proof typ e 3 G Grounding 4 H Hazardous Subst ance Data sheet 4 I installation & opera tion overview 1 M Maximum measured er ror 51 Measuring principle 51 O Overview , installation & operation 1 S Safety conventions and symbols 5 Safety instructions 3 Software history 1[...]

  • Page 68

    Index Average Temperature/Water Bottom Sensor and Converter 58 Installation and Operations Manual[...]

  • Page 69

    Varec, Inc. 59 4532 NOTES[...]

  • Page 70

    Your offical representative Varec, Inc. 5834 Peachtree Corners East, Norcross (Atlant a), GA 30092 USA Tel: +1 (770) 447-9202 Fax: +1 (770) 662-8939 © Varec, Inc. An SA IC Company. All Rights Reserve d. This document is for info rmation purposes on ly. Varec, Inc. makes no warran ties, express or im plied, in this su mmary. The na mes of actual co[...]